Volkswagen Phaeton 2003 Workshop Manual
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Volkswagen Phaeton 2003: The Volkswagen Phaeton 2003 is a high-performance, luxurious sedan that offers an unparalleled driving experience. It is equipped with a powerful 6-cylinder injection engine that delivers impressive acceleration and smooth handling. The Phaeton 2003 also features a spacious and comfortable interior, making it perfect for long journeys or special occasions. With its advanced technology and refined design, the Volkswagen Phaeton 2003 is the perfect choice for drivers who demand the best.
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Service rrectness of i t to the co nform spec at i h re o n wit in t his Workshop Manual Phaeton 2003 ➤ 6-cylinder injection engine Engine ID AYT BKL BRK Edition 02.2014 ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi Service Department. Technical Information do c um en es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s Service ility ab y li an pt ce 00 - Technical data 20 - Fuel supply system 24 - Mixture preparation - injection 26 - Exhaust system 28 - Ignition system AG. 19 - Cooling agen lksw Vo by 17 - Lubrication Prote cted by c o p yri gh t. C op yi 15 - Cylinder head, valve gear ht rig py Co t. 13 - Crankshaft group r fo ng 10 - Removing and installing engine rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en Repair Group urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p un le List of Workshop Manual Repair Groups 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 K0058950220 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Contents 00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 10 - Removing and installing engine . . . . . . . . . . . . .. V. o.lk.sw.a.ge. . . . . . . . . . . . . . . . . . . . 3 ility ab y li an pt ce 1 1.1 1.2 1.3 n AG gen AG Removing and installing engine . . . . . .V.ol.ks.w.a. . . . . . . . . . . . . . . .do. e.s.no. t. . . . . . . . . . . . . . . g y Removing engine . . . . . . . . . . . . .ise. d.b. . . . . . . . . . . . . . . . . . . . . . . . . . .u.ar.an. . . . . . . . . . . te r Securing engine on engine and ugearbox support VAS 6095 . . . . . . . . . . . . e. o.r . . . . . . . tho a a Installing engine . . . . . . . . . .ss. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c. . . . . . . es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng 1 1.1 1.2 1 . . . . 3 4 14 15 13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 19 20 23 25 26 28 30 30 31 33 34 35 37 40 40 41 41 43 44 44 45 46 rrectness of i t to the co nf o r m spec atio h re n in wit Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part I: assembly overview - chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part II: assembly overview - cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing engine bracket and engine mounting on left or right side . . . . . . Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sealing flange and dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing seal, flywheel end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing crankshaft oil seal, vibration damper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing crankshaft sealing flange -vibration damper side- . . . . . . . . . . . . . . . . . . . . . . . . Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking piston and cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fitting sender wheel to crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Allocation of crankshaft bearing shells (classification) . . . . . . . . . . . . . . . . . . . . . . . . . . . . thi sd o cu m en ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi 1 1.1 1.2 1.3 1.4 1.5 2 2.1 2.2 2.3 2.4 2.5 2.6 3 3.1 3.2 3.3 3.4 4 4.1 4.2 4.3 15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 2 2.1 2.2 2.3 2.4 2.5 2.6 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing timing chain for intermediate shaft drive and camshaft drive . . . . . . . . . . . . . . . . Installing camshaft adjuster with timing chain for camshaft drive . . . . . . . . . . . . . . . . . . . . Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - cover part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing camshaft control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contents 48 48 52 56 58 64 68 71 74 76 76 79 82 87 91 91 i Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 1 1.1 1.2 1.3 1.4 1.5 1.6 Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Assembly overview - dismantling and assembling oil filter housing . . . . . . . . . . . . . . . . . . 98 Assembly overview - dismantling and assembling oil pump . . . . . . . . . . . . . . . . . . . . . . . . 100 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 Parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - removing and installing fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 109 110 111 112 113 114 115 118 119 20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 1.10 1.11 2 2.1 2.2 3 rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 1.9 ility ab y li an pt ce 1.4 1.5 1.6 1.7 1.8 un le 1.3 Parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - fuel tank with attachments and fuel filter . . . . . . . . . . . . . . . . . . . . . . Dismantling and assembling right side fuel delivery unit, fuel gauge sender and suction-jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - fuel delivery unit, fuel gauge sender and suction jet pump on left side n AG. Volkswagen A . . . . . . . . . . . . . . . . . . . . . . . . . . .ol.ks.w.a.g.e . . . . . . . . . . . . .G.d.oe.s.n.o . . . . . . . . . . . . . . . . . . . . . . tg yV Schematic diagram of fuel lines d b and components in fuel tank . . .ua. r.a . . . . . . . . . . . . . . . . . e n s ri Safety precautions whenutworking on fuel supply system . . . . . . . . . t.ee. o. . . . . . . . . . . . . . . ho r Rules for cleanliness s.s a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ac. . . . . . . . . . . . . . Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel delivery unit, fuel gauge sender and suction-jet pump, right side ...................................................................... Removing and installing fuel delivery unit, fuel gauge sender and suction-jet pump, left side ...................................................................... Removing and installing fuel tank with attachments and fuel filter . . . . . . . . . . . . . . . . . . . . Checking fuel pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - parts of activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . Checking activated charcoal filter system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p 1 1.1 1.2 120 120 122 124 126 128 128 128 131 134 137 139 148 148 150 153 24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 r fo ng agen lksw Vo by AG. Prote cted by Contents c o p yri gh t. C op yi ii Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General notes on injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking fuel pressure regulator and holding pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . ht rig py Co t. 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2 2.1 2.2 155 155 155 157 158 158 159 159 161 161 163 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 . . . . 167 . . . . 167 . . . . 167 es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce 3 3.1 3.2 AG. Volkswagen AG d agen oes ksw no l o V y Engine control unit . . . . . . . . . . . . . . . .e.d .b . . . . . . . . . . . . . . . . . . . . . . . . . t. g.u.ar.a . . . . . nte ris Removing and installing engine control tho unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .e.or. . u a a Reading and erasing engine control ss unit fault memory . . . . . . . . . . . . . . . . . . . . . . . c. 26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 1.2 1.3 2 2.1 2.2 Parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - exhaust manifold with starter catalytic converters and attachments ........................................................................ Exhaust pipes with main catalytic converters and silencers with mountings . . . . . . . . . . . . Removing and installing exhaust manifolds and exhaust pipes with starter catalytic converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - parts of secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking combination valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 rrectness of i t to the co nform spec at i h re o n wit in t his 1 1.1 170 172 174 176 176 178 28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - parts of ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . do c um en ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi 1 1.1 1.2 1.3 1.4 Contents 180 180 182 182 184 iii Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi Contents do c um en iv rrectness of i t to the co nform spec at i h re o n wit in t his es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 00 – Technical data 1 Technical data es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng ility ab y li an pt ce (VRL006351; Edition 02.2014) AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s Engine number ⇒ page 1 1.1 rrectness of i t to the co nf o r m spec atio h re n in wit Engine data ⇒ page 1 Engine number The engine number (“engine code” and “serial number”) is located next to the vibration damper on the cylinder block. Additionally, a sticker with “engine code” and “serial number” is attached to the intake manifold. The engine code is also included on the vehicle data sticker. AYT BKL 05.02 ► VR2) 15.0° 3.2 177/6200 315/2400 84.0 95.9 11.25 4 98 unleaded3) 09.03 ► VR2) 15.0° 3.2 177/6200 315/2400 84.0 95.9 10.85 4 98 unleaded3) Prote cted by min. AG. l kW at rpm Nm at rpm ∅ mm mm agen lksw Vo by Manufactured Cylinder arrangement Cylinder angle Capacity Output Torque Bore Stroke Compression ratio Valves per cylinder RON c o p yri gh t. C op yi Engine code ht rig py Co t. Engine data thi sd o cu m en 1.2 BRK1) 05.04 ► VR2) 15.0° 3.2 177/6200 315/2400 84.0 95.9 10.85 4 98 unleaded3) 1) Emissions limit in accordance with EU2 norm, China only 2) VR = V-arrangement in compact in-line design 3) In exceptional circumstances min. 95 RON, however with reduced perform‐ ance. Engine code Injection, ignition Firing order Knock control Lambda control Catalytic converter Exhaust gas recirculation Turbocharging/supercharging Secondary air system Electronic power control AYT BKL BRK Motr. ME7.1.1 1-5-3-6-2-4 2 knock sensors 4 probes yes no no yes yes Motr. ME7.1.1 1-5-3-6-2-4 2 knock sensors 4 probes yes no no yes yes Motr. ME7.1.1 1-5-3-6-2-4 2 knock sensors 4 probes yes no no yes yes 1. Technical data 1 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Engine code AYT BKL BRK Variable intake manifold Camshaft timing control yes yes4) yes yes4) yes yes4) 4) Two independently variable camshafts ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi Rep. gr.00 - Technical data do c um en 2 rrectness of i t to the co nform spec at i h re o n wit in t his es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 10 – Removing and installing engine 1 Removing and installing engine Special tools and workshop equipment required ♦ Lifting tackle - 3033♦ Assembly tool - 3213♦ Engine and gearbox sup‐ port - VAS 6095♦ Drip tray - V.A.G 1306AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s agen lksw Vo by AG. Prote cted by ♦ Left engine support - VAS 6131/3-1- c o p yri gh t. C op yi Not illustrated: do c um en r te o iva r rp fo g n rrectness of i t to the co nform spec a t i h re o n in wit thi s es, in part or in w l purpos hole ercia , is n m ot com pe rm itte d ility ab y li an pt ce un le ♦ Scissor-type assembly platform - VAS 6131- ht rig py Co t. ♦ Workshop hoist VAS 6100- ♦ Right engine support - VAS 6131/3-2♦ Universal engine support - VAS 6131/1-1♦ Universal gearbox support - VAS 6131/1-2♦ Torque wrench (5…50 Nm) - V.A.G 1331- 1. Removing and installing engine 3 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 ♦ Stepladder - VAS 5085♦ Spring-type clip pliers VAS 5024 A♦ Guide rods - 3411♦ Torque wrench - V.A.G 1331- urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p ♦ Universal subframe support - VAS 6131/1-3- Prote cted by ♦ Cable ties Removing engine ⇒ page 4 . Securing engine to assembly stand ⇒ page 14 . Installing engine ⇒ page 15 . 1.1 Removing engine The engine is removed downwards with gearbox. – Read fault memories of all control units before removing ⇒ Ve‐ hicle diagnostic tester. 4 Rep. gr.10 - Removing and installing engine AG. ♦ Grease - G 000 100- agen lksw Vo by ♦ Container for removed parts - V.A.G 1698- c o p yri gh t . C op yi ♦ Securing pins - VAS 6131/1-6- ht rig py Co t. ♦ Securing pins - VAS 6131/1-5- r fo ng ♦ Universal gearbox console support - VAS 6131/1-4- rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en Not illustrated: n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss ility ab y li an pt ce un le ♦ Torque wrench - V.A.G 1332- Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Note ♦ To enable the propshaft to rotate freely, move selector lever to the “N” position. ♦ Leave key in ignition to prevent steering wheel lock from en‐ gaging. ♦ Some components cannot be removed, or removed only with difficulty, with the engine installed. Therefore, you should de‐ termine all defective components before removing engine and renew them while engine is removed. ♦ To prevent damage to removed components, place them in n AG. Volkswagen A G do ge waparts the container for removed - V.A.G 1698. es no olks t gu a V by ran is ed are opened or cut through when engine ♦ All cable ties which te ris position ⇒ Electrical system; Rep. gr. 92 ; Removing and installing windscreen wiper system The procedure must be strictly followed! – Switch off ignition and all electrical consumers. – First disconnect drive battery on right in luggage compartment ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and recon‐ necting batteries – Then disconnect second battery on left in luggage compart‐ ment ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and reconnecting batteries . Procedure All cable ties which are opened or cut through when engine is removed must be replaced in the same position when engine is installed. ht rig py Co t. – Pull engine compartment seal off bulkhead. rrectness of i t to the co nform spec at i h re o n wit in t his Disconnecting batteries do c um en es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ♦ Before disconnecting batteries, move wiper arms to service ility ab y li an pt ce eo tho be replaced in the same position when engine removed must ra au c s is installed. s Prote cted by c o py rig ht . C op yi – Remove plenum chamber covers. ⇒ General body repairs, exterior; Rep. gr. 64 ; Removing and installing plenum cham‐ ber cover . agen lksw Vo by AG. – Pull connector off air mass meter. – Remove intake hose and air filter housing ⇒ page 158 . – Separate “terminal 30 wire” -arrows- and remove bracket with positive terminal in engine compartment -1-. – Lay wiring harness on engine. – Remove right windscreen wiper motor. ⇒ Electrical system; Rep. gr. 92 ; Removing and installing windscreen wiper sys‐ tem – Pull smaller connector off engine control unit. – Separate remaining connectors and earth connections of this wiring harness. – Lay wiring harness on engine. – Pull connector off activated charcoal filter system solenoid valve 1 - N80- and pull down valve from bracket on intake manifold. 1. Removing and installing engine 5 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Pull breather hose off solenoid valve 1 and vacuum line off brake servo on intake manifold -arrows-. – Separate 4-pin connector -arrow- on lock carrier. – Pull connector off continued coolant circulation pump - V51⇒ page 114 . WARNING Fuel supply lines are under pressure! Wear eye protection and gloves to avoid injuries and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection. ility ab y li an pt ce pe rm itte d un le – AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o h Disconnect fuel usupply and fuel return lines and line to activa‐ e or t ac a ted charcoal filter. ss Press buttons on hose couplings to do this. – Seal lines with a clean cloth so that fuel system is not conta‐ minated by dirt. – Observe rules for cleanliness ⇒ page 128 . – Separate pressure hose -arrow- between combination valve and secondary air pump motor - V101– Pull cover upwards off protective housing for Lambda probe connectors. ht rig py Co t. Prote cted by c o p yri gh t. C op yi Note Connector for cylinders 1…3 = black, connector for cylinders 4… 6 = brown AG. Rep. gr.10 - Removing and installing engine agen lksw Vo by 6 do c um en r te o iva r rp fo g n – Separate connectors -1…4- for Lambda probes and lay wires on engine. rrectness of i t to the co nform spec a t i h re o n in wit thi s es, in part or in w l purpos hole ercia , is n m ot com Note – Remove poly V-belt ⇒ page 28 . – Extract air conditioning refrigerant ⇒ Heating, air conditioning; Rep. gr. 87 – Raise vehicle. – Remove insulation tray: ⇒ General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview - noise insula‐ tion . – Remove air conditioner compressor. – Observe additional notes and assembly work ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor brack‐ et . – Unbolt earth strap from left engine bracket. – Loosen double clamp between catalytic converter and centre silencer and slide clamp forward. c o p yri gh t. C op yi – Remove catalytic converters/front silencer ⇒ page 172 ; Re‐ moving and installing parts of exhaust system. ht rig py Co t. r fo ng – Support exhaust system on mounting at exhaust pipe junction -arrow- with guide pins - 3411- . rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p un le – To gain more working space, unscrew protective housing from bulkhead -arrows-. Phaeton 2003 ➤ engine - Edition 02.2014 ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise 6-cylinder injection r o eo h t u ra a c s s agen lksw Vo by AG. Prote cted by – Replace bolts with large washers on propshaft intermediate bearing one by one with bolts not having washers. – Remove propshaft heat shield from vehicle underbody. – Secure propshaft with assembly device - 3213- . – Remove propshaft ⇒ Transfer box and final drive; Rep. gr. 39 ; Removing and installing propshaft . – Push selector lever cable on gearbox off ball pin and pull out cable securing clip. – Remove front wheels. – Remove front wheel housing liners ⇒ General body repairs, exterior; Rep. gr. 66 ; Exterior equipment; Removing and in‐ stalling wheel housing liner; Rear wheel housing liner – Separate all connectors between body and front axle in wheel housings. – Separate front brake calipers and secure to body. ⇒ Brake system; Rep. gr. 46 ; Repairing front wheel brake – Remove front anti-roll bar. – Remove lower bolts -arrow- of suspension struts. 1. Removing and installing engine 7 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Unscrew securing nut -1- and remove bolt. – Now press upper suspension link -2- off wheel bearing hous‐ ing -3-. – Remove securing bolts -4- and press track rod ball joints off. – Unbolt power-assisted steering vane pump from compact bracket and place to one side; hoses remain connected: ⇒ Running gear, axles, steering; Rep. gr. 48 ; Assembly over‐ view: Vane pump, reservoir, hydraulic lines – Pull off/ disconnect electrical wiring from starter and place to one side. WARNING Steam may escape when expansion tank is opened. Wear eye protection and protective clothing to avoid eye injuries and scalding. Cover cap with cloth and open carefully. – Open and close expansion tank cap to release cooling system. – Pull off coolant hoses from continued coolant circulation pump - V51- . If engine is to be separated from gearbox: Note If engine and gearbox are to be separated following removal, the subframe must first be removed. – Disconnect drive shafts from gearbox ⇒ Running gear, axles, steering; Rep. gr. 40 ; Repairing drive shafts; Removing and installing drive shafts . – Remove subframe ⇒ Running gear, axles, steering - front and four-wheel drive; Rep. gr. 40 ; Removing and installing sub‐ frame, lower suspension links and anti-roll bar . Removing engine and gearbox without subframe ⇒ page 11 . r fo ng Prote cted by – Separate hydraulic line to hydraulic clutch slave cylinder ⇒ 6speed gearbox 01E/0A1; Rep. gr. 30 ; Repairing clutch mech‐ anism; Assembly overview - hydraulic system . – Seal line. Continuation for all vehicles 8 Rep. gr.10 - Removing and installing engine AG. Vehicles with manual gearbox agen lksw Vo by c o p yri gh t . C op yi Continuation if engine and gearbox are not separated following removal: ht rig py Co t. Separate engine and gearbox ⇒ Operating instructions for scis‐ sor-type assembly platform VAS 6131 . rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p un le ility ab y li an pt ce – Drain coolant ⇒ page 115 . n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran pressure ir se in tee o h t or u ac a ss Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Remove lower bolts -arrow- of suspension struts. – Loosen bolted connection -1- and pull upper suspension links -2- off wheel bearing housing -3-. – Separate track rod ends -4- of steering. Removing engine and gearbox with subframe Removing engine and gearbox without subframe ⇒ page 11 . n AG. Volkswagen AG do es n wage s k l ot g o yV Prepare scissor-type assembly platform - VAS 6131- for further ua b d ran e s i procedure tee r o h t or u ac a – Install engine supports -VAS 6131/3-1- -1- left and ss es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce VAS 6131/3-2- -2- right on scissor-type assembly platform VAS 6131- . – The arrows on the supports point in direction of travel. rrectness of i t to the co nform spec at i h re o n wit in t his – Secure the bolts in the following positions: left engine support -1-: C6 and D5; right engine support -2-: E6 and F5. – The universal supports - VAS 6131/1-3- for the subframe and the universal supports - VAS 6131/1-4- for the gearbox con‐ sole have a longitudinal hole in the diagonal direction and should be installed depending on the situation. do c um en ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t . C op yi – Remove both middle gearbox console bolts -arrows-. – Position assembly platform under power unit. The engine sup‐ ports must be guided into their respective mountings: A - Mounting on left of engine -arrow- 1. Removing and installing engine 9 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 B - Mounting on right of engine -arrow- rrectness of i t to the co nform spec at i h re o n wit in t his es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s – Guide universal supports for the subframe in the respective mountings -arrow-. AG. Prote cted by Rep. gr.10 - Removing and installing engine agen lksw Vo by c o p yri gh t. C op yi 10 ht rig py Co t. – Unscrew subframe bolts -1-, -2- and -3-. do c um en – Guide the universal supports in the gearbox console -arrows-. Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 n AG. Volkswagen AG – Remove both outer gearbox bracket wage bolts -arrows-. does not gu ara nte eo ra c rrectness of i t to the co nform spec at i h re o n wit in t his es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce ss olks yV db e ris tho au – Remove bolts -1- for engine carrier. ht rig py Co t. Prote cted by c o py rig ht . C op yi Removing engine and gearbox without subframe do c um en agen lksw Vo by AG. 1.1.1 – Disconnect drive shafts from gearbox ⇒ Running gear, axles, steering; Rep. gr. 40 ; Repairing drive shafts; Removing and installing drive shafts . – Remove subframe ⇒ Repairing front suspension; Rep. gr. 40 ; Removing and installing subframe, lower suspension link and anti-roll bar . Preparing scissor-type assembly platform - VAS 6131- for further procedure: – Install engine supports -VAS 6131/3-1- -1- left and VAS 6131/3-2- -2- right on scissor-type assembly platform VAS 6131- . – The arrows on the supports point in direction of travel. 1. Removing and installing engine 11 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Secure the bolts in the following positions: left engine support -1-: C6 and D5; right engine support -2-: E6 and F5. – Remove both middle gearbox console bolts -arrows-. – Position assembly platform under power unit. The engine sup‐ ports must be guided into their respective mountings: AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s r fo ng AG. Rep. gr.10 - Removing and installing engine agen lksw Vo by Prote cted by c o py rig ht . C op yi 12 ht rig py Co t. B - Mountings on right of engine -arrows- rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p ility ab y li an pt ce un le A - Mountings on left of engine -arrows- Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Guide the universal supports of the gearbox console in the mountings -arrows-. – Position the middle support as shown beneath the gearbox -arrow-. – Remove both outer gearbox bracket bolts -arrows-. rrectness of i t to the co nf o r m spec atio h re n in wit es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s thi sd o cu m en ht rig py Co t. agen lksw Vo by AG. 1. Removing and installing engine 13 Prote cted by c o py rig ht . C op yi Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Remove bolts -1- for engine carrier. Vehicles with manual gearbox – Lower assembly platform with engine and gearbox until se‐ lector mechanism can be unbolted: ⇒ 6-speed manual gear‐ box 01E/0A1; Rep. gr. 34 ; Repairing selector mechanism; Removing and installing selector mechanism . Vehicles with automatic gearbox wagen Volksgearbox – Lower assembly platform with engine only AG.and does agen of the selectorAG enough so as to facilitate unhooking lever cable. ksw not l o V y db Continuation for all vehicles ise or h ut – Remove engine and gearbox downwards. The engine has to be guided carefully when removing to prevent damage to the bodywork. 1.2 Securing engine on engine and gearbox support - VAS 6095- Secure engine to engine and gearbox support - VAS 6095- to carry out repairs. Procedure Note Separate engine and gearbox ⇒ Operating instructions for scis‐ sor-type assembly platform VAS 6131 . agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi Vehicles with automatic gearbox ht rig py Co t. – Unbolt gearbox. – Secure torque converter against “falling out” after separating engine from gearbox. Continuation for all vehicles – Connect lifting tackle - 3033- as shown: Vibration damper end: position 3. 14 Rep. gr.10 - Removing and installing engine rrectness of i t to the co nform spec at i h re o n wit in t his Note do c um en es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce a – Check that all connections between bulkhead and ss have been separated. gu ara nte eo ra c engine Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce un le Flywheel end: position 11. Installing engine r fo ng When doing any repair work, especially in the engine compart‐ ment, pay attention to the following due to the cramped condi‐ tions: agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi ♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐ vated charcoal filter system, coolant, refrigerant, brake fluid and vacuum) and electrical wiring in their original po‐ sitions. ht rig py Co t. Caution rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 1.3 urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p – Lift engine off with workshop hoist - VAS 6100- and secure on engine and gearbox support - VAS 6095- as shown. ♦ Ensure that there is sufficient clearance to all moving or hot components. 1. Removing and installing engine 15 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Note If a new engine is installed, the 3 bores on the face end -arrows- must be sealed by means of bolts. Procedure Install in reverse order. In the process, note the following: – Check whether dowel sleeves for centring engine and gearbox are in cylinder block and install if necessary. AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s Special tools and workshop equipment required ♦ Adapters M10 - VAS 6131/17-4- – Screw appropriate adapters -A- into threaded holes for secur‐ ing subframe to longitudinal member on left and right. – Screw dot lasers - VAS 6131/17-1- -B- into adapters -A-. – Insert securing bolts -C-, centred with bolt heads upwards in appropriate securing points of subframe. – Switch on dot lasers and align scissor-type assembly platform so that the laser beams on left and right strike the bolt heads. After completing alignment, remove dot lasers and adapters. – Screw in left and right securing pins as shown: A - For engine support, securing pin - VAS 6131/1-6- 16 Rep. gr.10 - Removing and installing engine AG. ♦ Adapters M12x1.5 - VAS 6131/17-3- agen lksw Vo by ♦ Adapters M14x1.5 - VAS 6131/17-2- Prote cted by c o py rig ht . C op yi ♦ Dot lasers - VAS 6131/17-1- ht rig py Co t. Individual parts of positioning tool: r fo ng ♦ Positioning tool - VAS 6131/17- rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p ility ab y li an pt ce un le Aligning scissor-type assembly platform Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 B - For gearbox bracket, securing pin - VAS 6131/1-5Vehicles with automatic gearbox – When installing engine, first raise assembly platform only enough to allow selector lever cable to be guided into position. Vehicles with manual gearbox – Check clutch release bearing for wear and renew if necessary ⇒ 6-speed manual gearbox 01E/0A1; Rep. gr. 30 ; Repairing clutch release mechanism . – Lightly grease input shaft splines with G 000 100 grease. – When installing engine, first raise scissor-type assembly plat‐ Volkswageninstallation form only far enough of the selector G.facilitate Ato AG do agen es n01E/0A1; Rep. gr. mechanism:Vo⇒lksw6-speed manual gearbox ot g ua and installing by 34 ; Repairing selector mechanism; Removing ran ed tee ris mechanism . selector o th o au ra Continuation for all vehicles rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p un le ility ab y li an pt ce c ss hydraulic line to hydraulic clutch slave cylinder and – Fit then bleed clutch system ⇒ 6-speed manual gearbox 01E/0A1; Rep. gr. 30 ; Repairing clutch control mechanism; Assembly overview - hydraulic system . – Install air conditioner compressor ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor bracket . – Install vane pump for power-assisted steering ⇒ Running gear, axles, steering; Rep. gr. 48 ; Vane pump . – Install poly V-belt ⇒ page 28 . – Reconnect all lines, hoses and connectors which were sepa‐ rated during removal. – Electrical connections and routing ⇒ Electrical system; Rep. gr. 97 . – Install catalytic converters/front silencer ⇒ page 172 ; Re‐ moving and installing parts of exhaust system. c o p yri gh t . C op yi Note ht rig py Co t. r fo ng – Replenish coolant ⇒ page 115 . agen lksw Vo by Perform wheel alignment after installing subframe ⇒ Running gear, axles, steering, front and four-wheel drive; Rep. gr. 44 ; wheel alignment AG. Prote cted by After completed engine fitting: – Connect Vehicle diagnosis, testing and information system VAS 5052- . – Carry out vehicle system test using ⇒ Vehicle diagnostic test‐ er; “Guided functions” . – Finish the vehicle system test so that any fault entries stored during assembly can be deleted automatically. – Generate the readiness code in combination with a road test. Observe applicable safety precautions during road test. – Carry out road test. – Then carry out vehicle system test again and rectify any faults which may have occurred. 1. Removing and installing engine 17 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Specified torques 10 Nm 15 Nm 25 Nm 40 Nm 60 Nm Deviations Engine bracket to engine mounting (bolt) M10 40 Nm + 1/4 turn (90°) Engine mounting to engine carrier (nut) M10 30 Nm + 1/4 turn (90°) Engine carrier to body (bolt) M12 rrectness of i t to the co nform spec at i h re o n wit in t his M6 M7 M8 M10 M12 ility ab y li an pt ce Bolts, nuts 90 Nm + 1/4 turn (90°) Drive shafts to gearbox: ⇒ Running gear, axles, steering; Rep. gr. 40 ; Repairing drive shafts; Removing and installing drive shafts . Additional information and assembly work for vehicles with air conditioner Prote cted by in workshops, which have trained personnel and the neces‐ sary range of tools and workshop equipment. ♦ To prevent damage to condenser and also to refrigerant lines/ hoses, ensure that the lines and hoses are not stretched, kinked or bent. To facilitate removing and installing engine without opening re‐ frigerant circuit: – Remove retaining clamp(s) for refrigerant lines. – Remove air conditioning compressor ⇒ Heating, air condi‐ tioning; Rep. gr. 87 ; Air conditioning compressor bracket . – Secure air conditioning compressor to body so that the refrig‐ erant lines are not under tension. 18 Rep. gr.10 - Removing and installing engine AG. ♦ The opening of the refrigerant circuit can only be carried out agen lksw Vo by c o p yri gh t . C op yi Note ht rig py Co t. 1.3.1 do c um en es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n Threaded connection n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a Specified torque ss Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 13 – Crankshaft group 1 Dismantling and assembling engine Overview rrectness of i t to the co nf o r m spec atio h re n in wit es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s thi sd o cu m en 1. Dismantling and assembling engine 19 ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Note ♦ Secure engine to engine and gearbox support - VAS 6095- to carry out assembly work ⇒ page 14 . ♦ Finding metal shavings or a large quantity of small metal par‐ ticles during engine repair could indicate that the crankshaft bearings or conrod bearings are damaged. To prevent this n AG. Volkswagen AG do from causing furtherlksdamage, perform the following repairs: es n wage o Vo by t gu ara nte eo ra c d ♦ Thoroughly rclean oil channels ise o h t au non-return valve ♦ Renew soil ♦ Renew oil cooler ♦ Renew oil filter Part I ⇒ page 20 Part II ⇒ page 23 Removing and installing poly V-belt ⇒ page 28 . Part I: assembly overview - chain drive 4 - Exhaust camshaft adjuster ❑ Identification: 32A. ❑ Rotate engine only with camshaft adjuster in‐ stalled. ❑ Installing ⇒ page 64 . 5 - Intermediate shaft 6 - Thrust washer ❑ Not installed on all en‐ gines. 20 Rep. gr.13 - Crankshaft group AG. 3 - Camshaft timing chain ❑ Before removing, mark running direction (instal‐ lation position) ⇒ page 22 ❑ Installing ⇒ page 64 . agen lksw Vo by Prote cted by c o p yri gh t. C op yi 2 - 8 Nm ❑ Renew thi sd o cu m en 1 - Valve timing housing ❑ Lightly lubricate contact surfaces of oil seals be‐ fore installing. ❑ Removing and installing ⇒ page 82 Removing and installing cam‐ shafts. ❑ Dismantling and assem‐ bling ⇒ page 78 . ❑ Check strainer of control housing for contamina‐ tion before installing ⇒ page 78 ht rig py Co t. 1.1 rrectness of i t to the co nf o r m spec atio h re n in wit es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng ility ab y li an pt ce s ♦ Renew oil spray jets Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 7 - 8 Nm ❑ Apply locking fluid “D 000 600 A2” when installing 8 - Tensioning rail ❑ For camshaft timing chain ⇒ Item 3 (page 20) 9 - Pivot pin, 18 Nm ❑ For tensioning rail ⇒ Item 8 (page 21) 10 - Chain tensioner, 40 Nm ❑ For camshaft timing chain ⇒ Item 3 (page 20) ❑ Only rotate engine when chain tensioner is installed. 11 - Seal ❑ Renew if damaged or leaking 12 - Sprocket ❑ For timing chain ⇒ Item 17 (page 21) . ❑ Installing ⇒ page 58 . 13 - Sprocket ❑ For camshaft timing chain ⇒ Item 3 (page 20) ❑ Installing ⇒ page 58 . 14 - 60 Nm + 1/4 turn (90°) further ❑ Renew ❑ Use counterhold - T10069- to loosen and tighten. 15 - Chain tensioner with tensioning rail ❑ For timing chain ⇒ Item 17 (page 21) . ❑ Before installing, release locking splines in chain tensioner using a small screwdriver and press tension‐ ing rail against chain tensioner. ❑ Only rotate engine when chain tensioner is installed. 16 - Drive sprocket AG. Volkswagen AG d agen oes ksw not l o ❑ Built into crankshaft. gu yV b ara d e nte isjoint = TDC No. 1 cyl. ⇒ page 58 ❑ Ground down tooth to bearing r o e h ut un le pe rm itte d rrectness of i t to the co nform spec a t i h re o n in wit thi s es, in part or in w l purpos hole ercia , is n m ot com 18 - Guide rail ❑ For timing chain ⇒ Item 17 (page 21) . ❑ Remove and install together with roller chain ⇒ page 58 or ac ility ab y li an pt ce a 17 - Timing chain ss ❑ Before removing, mark running direction (installation position) ⇒ page 22 ❑ Installing ⇒ page 58 . 19 - Locating pin without collar, 10 Nm ❑ For guide rail ⇒ Item 18 (page 21) . 20 - 18 Nm 21 - 23 Nm 23 - 60 Nm + 1/4 turn (90°) further do c um en r te o iva r rp fo g n 22 - Inlet camshaft adjuster ❑ Identification: 24E ❑ Rotate engine only with camshaft adjuster installed. ❑ Installing ⇒ page 64 . ❑ Renew ❑ Contact surface of sender wheel must be dry around bolt head when assembled. ht rig py Co t. agen lksw Vo by 1. Dismantling and assembling engine 21 AG. Prote cted by c o py rig ht . C op yi Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 ❑ To remove and install, counterhold using 32 mm open-end spanner on camshaft ⇒ page 82 Removing n AG. Volkswagen AG do and installing camshafts. e wage by 24 - Guide rail ed ris o ❑ For camshaft timing chain ⇒ Item 3 (page 20)uth s no t gu ara nte eo ra c ks Vol sa rrectness of i t to the co nform spec a t i h re o n in wit thi s es, in part or in w l purpos hole ercia , is n m ot com pe rm itte d un le ility ab y li an pt ce 25 - Exhaust camshaft control valve 1 - N318- s ❑ For exhaust camshaft. ❑ Before removing, mark connector belonging to component. ❑ Removing and installing ⇒ page 79 26 - Inlet camshaft control valve 1 - N205❑ For inlet camshaft. ❑ Before removing, mark connector belonging to component. ❑ Removing and installing ⇒ page 79 27 - Guide rail ❑ For camshaft timing chain ⇒ Item 3 (page 20) ❑ Clipped into valve timing housing – Mark roller chains before removing (e.g. with paint, arrow pointing in direction of rotation). Rep. gr.13 - Crankshaft group AG. 22 agen lksw Vo by Prote cted by c o py rig ht . C op yi Do not mark chain by way of centre punch, notch or the like. ht rig py Co t. Note do c um en r te o iva r rp fo g n Marking timing chains Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 1.2 Part II: assembly overview - cylinder block 1 - 8 Nm ❑ Secured to intake mani‐ fold. un le r fo ng urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p 8 - Oil pump drive cover 9 - O-ring ❑ Renew ❑ Lubricate before instal‐ ling. AG. 7 - 10 Nm agen lksw Vo by 6 - 20 Nm ❑ The torque setting influ‐ ences the function of the knock sensor. Prote cted by c o p yri gh t. C op yi 5 - Knock sensor 1 - G61❑ Fitting location: be‐ tween cylinder 1 and cylinder 3. rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 4 - Oil non-return valve ❑ Note installation posi‐ tion ❑ Clean if badly soiled or renew if necessary. ❑ See note ⇒ page 19 ility ab y li an pt ce 3 - Dipstick ❑ The oil level must not be above the max. mark! ❑ Markings ⇒ page 98 . AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ht rig py Co t. 2 - Guide tube ❑ For dipstick ❑ Secured with bolt to in‐ take manifold. 10 - Oil pump drive 11 - Cylinder block ❑ Removing and installing sealing flange and dual-mass flywheel ⇒ page 30 . ❑ Removing and installing crankshaft ⇒ page 44 . ❑ Dismantling and assembling pistons and conrods ⇒ page 40 . ❑ See note ⇒ page 25 12 - Intermediate shaft 13 - Thrust washer ❑ Not installed on all engines. 14 - 10 Nm ❑ Insert with “D6” locking fluid 15 - Drive shaft ❑ For oil pump drive. 16 - Engine speed sender - G2817 - Oil pump ❑ Dismantling and assembling ⇒ page 100 1. Dismantling and assembling engine 23 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 ❑ Observe note for installation of oil pump: ⇒ page 100 18 - 23 Nm 19 - 8 Nm ❑ Renew 20 - Oil drain plug, 30 Nm ❑ Renew if seal is attached 21 - Sump ❑ Removing and installing ⇒ page 101 es, in part or in w l purpos hole ercia , is n m ot com rrectness of i t to the co nform spec a t i h re o n in wit thi s 25 - Seal ❑ Renew pe rm itte d 24 - 12 Nm AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce 23 - Seal ❑ Renew ❑ Lubricate before installing. un le 22 - Oil level and oil temperature sender - G266- 26 - Oil filter housing / left engine bracket ❑ Dismantling and assembling ⇒ page 98 ❑ Coolant hose schematic diagram ⇒ page 114 . ❑ Right engine bracket and specified torque ⇒ page 25 ❑ Removing and installing engine bracket and engine mounting on left or right side ⇒ page 26 27 - 23 Nm 29 - 25 Nm 30 - Fitting bolt, 25 Nm 31 - Compact bracket ❑ For alternator, air conditioner compressor and power-assisted steering vane pump 35 - 100 Nm + 1/2 turn (180°) further ❑ Renew 24 Rep. gr.13 - Crankshaft group AG. 34 - Vibration damper ❑ Removing and installing ⇒ page 25 ❑ Removing and installing poly V-belt ⇒ page 28 . agen lksw Vo by Prote cted by c o py rig ht . C op yi 33 - Knock sensor 2 - G66❑ Fitting location: between cylinder 4 and cylinder 6. ht rig py Co t. 32 - Coolant pipe ❑ Removing and installing ⇒ page 113 , Parts of cooling system - engine side. do c um en r te o iva r rp fo g n 28 - To thermostat housing Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Note: If a new engine is installed, the 3 bores on the face end -arrows- must be sealed by means of bolts. es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng Right engine bracket ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s rrectness of i t to the co nf o r m spec atio h re n in wit Specified torque for securing bolt -1-: 40 Nm + 1/4 turn (90°) fur‐ ther. Specified torque for securing bolt -2-: 60 Nm. Removal of the engine bracket and the engine mounting ⇒ page 26 1.3 Removing and installing vibration damp‐ er ♦ Counterhold - T10069- thi sd o cu m en Special tools and workshop equipment required ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi ♦ Torque wrench - V.A.G 1601- Removing: – Remove poly V-belt ⇒ page 28 . 1. Dismantling and assembling engine 25 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Lock vibration damper using counterhold - T10069- . – Unscrew securing bolt for vibration damper and remove vi‐ bration damper. Installing: Caution Check rubber joint between inner and outer ring of vibration damper for cracks and separation. If rubber joint is damaged, . Volkswagen AG gen AG does renew vibration damper. a w ks n – Clean thread with a threaded chaser – Lock vibration damper using counterhold - T10069- . Specified torque: 100 Nm + 1/2 turn (180°). Note Turning further in several stages is permitted. – Install poly V-belt ⇒ page 28 . 1.4 Removing and installing engine bracket and engine mounting on left or right side Special tools and workshop equipment required Prote cted by c o py rig ht . C op yi ♦ Shackle - 10 - 222 A /12- AG. ♦ Adapter - 10 - 222 A /19- agen lksw Vo by ♦ Adapter - 10 - 222 A /16- ht rig py Co t. ♦ Support bracket - 10 - 222 A- Note The left engine bracket is one component together with the oil filter housing 26 Rep. gr.13 - Crankshaft group rrectness of i t to the co nform spec at i h re o n wit in t his – Tighten securing bolt using torque wrench - V.A.G 1601- . do c um en es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n – Renew securing bolt for vibration damper. ot g ua ran tee M18 x 1.5. or a c ility ab y li an pt ce ol yV db e ris tho inaucrankshaft ss Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Removing – Completely remove air filter with air mass meter ⇒ page 158 . – Unscrew securing bolts -1- on left and right engine bracket from above. – Fit adapter - 10 - 222 A- to support bracket - 10 - 222 A /16with the higher side for the spindle guide upwards, as illustra‐ ted. – Now fit adapter - 10 - 222 A /19- to support bracket - 10 - 222 A- on left and right. Set support bracket - 10 - 222 A- on lon‐ gitudinal members. – Hook engine with two shackles - 10 - 222 A /12- on adapter 10 - 222 A /16- and slightly take up weight of engine. – Remove the vacuum hose -1- from the right and left hand side of the engine mounting. – AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d e securing nuts -2- from the engine mounting nte isthe Remove below r o eo h t the engine carrier. u ra a c ss do c um en ht rig py Co t. r te o iva r rp fo g n rrectness of i t to the co nform spec a t i h re o n in wit thi s es, in part or in w l purpos hole ercia , is n m ot com pe rm itte d un le ility ab y li an pt ce – Note the space available between the cylinder head and the bulkhead and then carefully lift the engine using the adapter 10 - 222 A /16- . 1. Dismantling and assembling engine 27 agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 ility ab y li an pt ce pe rm itte d un le – n AG. Volkswagen AG do es n wage s k l ot g o yV ua b dbracket must ran To remove the engine mounting, also the engine ir se tee o be unscrewed from the cylinder block -2-, asuthe th engine cannot or ac a be raised high enough. ss Note rrectness of i t to the co nform spec a t i h re o n in wit thi s es, in part or in w l purpos hole ercia , is n m ot com The securing bolts of the left engine bracket/oil filter housing ⇒ Item 12 (page 99) may only be removed if there is not enough space available for disassembling the engine bracket. – Engine bracket can now be removed. Installing Installation is basically the reverse of the removal procedure. – When installing, ensure dowel pin of engine mounting is cor‐ rectly seated in engine bracket. – First insert all bolts by hand and then tighten all bolts to pre‐ scribed torque. r te o iva r rp fo g n Prote cted by 1.5 Removing and installing poly V-belt Special tools and workshop equipment required ♦ Hexagon bolt M8x50 Removing poly V-belt – Remove front noise insulation: ⇒ General body repairs, exte‐ rior; Rep. gr. 50 ; Body - front; Assembly overview - noise insulation – Mark direction of rotation of poly V-belt. 28 Rep. gr.13 - Crankshaft group AG. Specified torque for securing nuts -2- engine mounting to engine carrier: 30 Nm + 1/4 turn (90°) further. agen lksw Vo by c o p yri gh t . C op yi Specified torque for engine support with oil filter housing, left en‐ gine side ⇒ Item 12 (page 99) . ht rig py Co t. Specified torque for securing bolt -2-: 60 Nm. do c um en Specified torque for securing bolt -1-: 40 Nm + 1/4 turn (90°) fur‐ ther. Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Press tensioning arm in -direction of arrow- using a suitable screwdriver against tension in tensioning roller. – Screw M8×50 bolt into threaded hole -A- and thus secure ten‐ sioning roller. Screw in bolt sioning roller – Remove poly V-belt. Installing poly V-belt rrectness of i t to the co nf o r m spec atio h re n in wit Note ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d only far enough to remove poly V-belt because ten‐ nte ise r o eo h housing may otherwise be damaged. ut ra a c s s es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng Note ♦ Before installing poly V-belt, ensure that all ancillaries (alter‐ nator, air conditioner compressor, power-assisted steering vane pump) are secured tightly. ♦ When installing poly V-belt, check direction of belt rotation and proper seating of belt in pulleys. – Install poly V-belt and remove M8 bolt from tensioning roller. After completing repairs always: thi sd o cu m en – Start engine and check that belt runs properly. ht rig py Co t. agen lksw Vo by AG. 1. Dismantling and assembling engine 29 Prote cted by c o p yri gh t. C op yi Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 2 Sealing flange and dual-mass fly‐ wheel Note ♦ Repairing clutch: ⇒ 6-speed manual gearbox 01E/0A1; Rep. gr. 30 ; Repairing clutch mechanism; Assembly overview n AG. Volkswagen AG do es n wage s hydraulics k l ot Vo y db ise6095- to ♦ Secure engine to engine and gearbox support - VAS or ility ab y li an pt ce Assembly overview ⇒ page 30 th au ss es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng carry out repairs. gu ara nte eo ra c Removing and installing seal at flywheel end ⇒ page 31 rrectness of i t to the co nf o r m spec atio h re n in wit Removing and installing flywheel ⇒ page 33 Removing and installing drive plate ⇒ page 34 . Renewing crankshaft oil seal, vibration damper end ⇒ page 35 Assembly overview 6 - Cylinder block ❑ Removing and installing crankshaft ⇒ page 44 . ❑ Dismantling and assem‐ bling pistons and con‐ rods ⇒ page 40 . 7 - Sealing flange ❑ Coat sealing surfaces with sealant - D 176 501- . 30 Rep. gr.13 - Crankshaft group Prote cted by 5 - Sealing flange ❑ Coat sealing surfaces with sealant - D 176 501- . AG. 4 - Seal ❑ Renew ⇒ page 35 agen lksw Vo by 3 - 10 Nm c o p yri gh t . C op yi 2 - Vibration damper ❑ Removing and installing poly V-belt ⇒ page 28 . ❑ Removing and installing ⇒ page 25 thi sd o cu m en 1 - 100 Nm + 1/2 turn (180°) further ❑ Renew ❑ Use counterhold T10069- to loosen and tighten. ❑ Tighten using torque wrench - V.A.G 1601- . ht rig py Co t. 2.1 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 8 - Seal ❑ Remove using extractor hook - T20143/2❑ PTFE oil seal: ❑ Identification: Without garter spring ❑ Do not additionally oil or grease the oil seal sealing lip. ❑ Before installing,n Aremove ageresidue G. Volkswoil n AG d from crankshaft journal using a clean cloth. o wage ksand l ❑ Removing installing ⇒ page 31es not g o V by ed ua ran tee ris 9 - Spacer ho t au or a es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng 12 - 60 Nm + 1/2 turn (180°) further ❑ Renew ❑ Use counterhold - T10069- to loosen and tighten rrectness of i t to the co nf o r m spec atio h re n in wit 11 - Shim ❑ determining drive plate distance ⇒ page 34 ❑ Only use individually ility ab y li an pt ce c 10 -ssIntermediate plate ❑ For gearbox attachment ❑ When installing, bolt to cylinder block first and only then fit sump 13 - Dual-mass flywheel ❑ Removing and installing on vehicles with manual gearbox ⇒ page 33 ❑ The drive plate is fitted in vehicles with an automatic gearbox. Removing and installing ⇒ page 34 14 - M10 - 45 Nm, M12 - 65 Nm Removing and installing seal, flywheel end agen lksw Vo by Prote cted by c o py rig ht . C op yi Special tools and workshop equipment required AG. ♦ Fitting tool - T10122- ht rig py Co t. 2.2 thi sd o cu m en 15 - 25 Nm 2. Sealing flange and dual-mass flywheel 31 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 ♦ Puller hooks - T20143- Removing oil seal on flywheel end – Fit puller hooks - T20143/2- behind sealing lip of oil seal as shown in illustration. – Support puller hook - T20143/2- on sealing flange and lever seal out in direction of -arrow-. Installing oil seal at flywheel end – Pull oil seal -A- by the outside over the sleeve - T10122/1- onto pulling sleeve - T10122/2- . AG. Volkswagen AG d oes not V gu y b d Then set pulling sleeve - T10122/2- with dry oil seal ontoarante ise r eo crankshaft journal. tho ra au c s s agen – Separate the two fitting osleeves. lksw rrectness of i t to the co nf o r m spec atio h re n in wit es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng ility ab y li an pt ce agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi Rep. gr.13 - Crankshaft group thi sd o cu m en 32 ht rig py Co t. – Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Now drive it into sealing flange to stop using thrust piece T10122/3- . 2.3 Removing and installing flywheel Special tools and workshop equipment required ♦ Counterhold - T10044- es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng Note rrectness of i t to the co nf o r m spec atio h re n in wit Removing: ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s To avoid damaging the dual-mass flywheel during removal, the bolts -B- must not be removed using a pneumatic or impact driver. The bolts -B- must be unscrewed by hand without power tools. – Turn flywheel -A- so that bolts -B- are centred in holes -arrows-. thi sd o cu m en – When removing bolts -B-, make sure that screw heads do not jam on flywheel. ht rig py Co t. agen lksw Vo by 2. Sealing flange and dual-mass flywheel 33 AG. Prote cted by c o py rig ht . C op yi Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Tighten counterhold - T10044- on cylinder block with washer -arrow-. Bring counterhold - T10044- to -position A- to loosen flywheel. – Mark position of flywheel in relation to engine. – Unbolt flywheel. Installing: Installation is carried out in the reverse order. When installing, note the following: – Renew bolts. agen Bring counterhold - T10044- to -position B- to tighten flywheel. lksw Specified torque 1) 90° equals a quarter of a turn un le Removing and installing drive plate Special tools and workshop equipment required r fo ng Prote cted by Rep. gr.13 - Crankshaft group AG. 34 agen lksw Vo by c o p yri gh t. C op yi ♦ Torque wrench - V.A.G 1332- ht rig py Co t. ♦ Counterhold - T10069- rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 2.4 urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p Flywheel to crankshaft AG. Volkswagen AG d oes not gu ara nte eo ra c ility ab y li an pt ce Component o yV db e s ri ho ut a Nm ss 60 + 90°1) es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n Removing ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V Phaeton 2003 ➤ gu by ara d e nte 02.2014 6-cylinder injection engine Edition is r eo tho ra au c s s – Lock vibration damper using counterhold - T10069- . – Loosen drive plate securing bolts diagonally and remove. Installing Prerequisites • The intermediate plate, ⇒ Item 10 (page 31) , must be bolted securely to the cylinder block. • The spacer, ⇒ Item 9 (page 31) , must be fitted on the crank‐ shaft. rrectness of i t to the co nform spec at i h re o n wit in t his – Remove drive plate. – Attach drive plate to crankshaft using at least 3 old securing bolts and tighten to 30 Nm. – Measure dimension -a- using depth gauge. Specification: 18.0…20.0 mm do c um en ht rig py Co t. agen lksw Vo by AG. If specification is not attained: Prote cted by c o p yri gh t. C op yi – Remove drive plate again and fit appropriate shim -1-. Note Only one shim of the appropriate thickness may be used. When specification is attained: – Insert new securing bolts and tighten by hand. – Tighten securing bolts to 60 Nm +180° (1/2 turn) further. 2.5 Renewing crankshaft oil seal, vibration damper end 2. Sealing flange and dual-mass flywheel 35 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Special tools and workshop equipment required ♦ Puller hooks - T20143/1♦ Counterhold - T10069♦ Assembly tool - T10215♦ Torque wrench - V.A.G 1601♦ Torque wrench - V.A.G 1332- es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng rrectness of i t to the co nf o r m spec atio h re n in wit Prote cted by 36 Rep. gr.13 - Crankshaft group AG. – Fit puller hooks - T20143/1- behind sealing lip of oil seal as shown in illustration. agen lksw Vo by c o p yri gh t. C op yi – Remove vibration damper. To do this, lock vibration damper using counterhold - T10069- . ht rig py Co t. – Remove poly V-belt ⇒ page 28 . thi sd o cu m en Removing ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Support puller hook - T20143/1- on sealing flange and lever seal out in direction of -arrow-. Installing – Remove oil residue from crankshaft journal using clean cloth. – Slide guide sleeve - T10215/1- -1- onto front of crankshaft journal. – Now slide oil seal -2- carefully over guide sleeve as far as possible. – Press oil seal in to stop with fitting sleeve - T10215/2- -3-. To do this, use old vibration damper securing bolt -4-. Note ♦ Renew securing bolt for vibration damper. ♦ Tighten securing bolt using torque wrench - V.A.G 1601- . – Install vibration damper ⇒ page 25 . AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s do c um en ht rig py Co t. r te o iva r rp fo g n rrectness of i t to the co nform spec a t i h re o n in wit thi s es, in part or in w l purpos hole ercia , is n m ot com pe rm itte d Renewing crankshaft sealing flange -vibration damper side- ility ab y li an pt ce agen lksw Vo by 2. Sealing flange and dual-mass flywheel AG. Prote cted by c o p yri gh t. C op yi 2.6 un le – Install poly V-belt ⇒ page 28 . 37 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Special tools and workshop equipment required ♦ Counterhold - T10069♦ Assembly tool - T10215♦ Torque wrench - V.A.G 1601- agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi – Set lock carrier to service position ⇒ General body repairs, exterior; Rep. gr. 50 ; Service position . – Remove poly V-belt ⇒ page 28 . – Remove vibration damper. To do this, lock vibration damper using counterhold - T10069- . – Remove sump ⇒ page 101 . – Unbolt sealing flange. – Remove remaining sealant from sealing surfaces. Installing – Remove oil residue from crankshaft journal using clean cloth. 38 Rep. gr.13 - Crankshaft group do c um en r te o iva r rp fo g n rrectness of i t to the co nform spec a t i h re o n in wit thi s es, in part or in w l purpos hole ercia , is n m ot com pe rm itte d un le ility ab y li an pt ce Removing ht rig py Co t. ♦ Torque wrench 1332- AG. Volkswagen AG d agen oes ksw not l o V gu by ara V.A.G d e nte is r o eo h ut ra a c s s Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Cut off tube nozzle at forward marking (∅ of nozzle approx. 3 mm). – Apply sealant bead of about 2…3 mm as shown -arrows- to Volkswa gen AG . gen AG clean sealing surface of sealing flange. does swa ility ab y li an pt ce ss not gu ara nte eo ra c es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n Note olk yV db e ris tho au ♦ Before applying sealant bead, cover sealing ring with a clean cloth. ♦ The sealing compound bead must not be thicker that 2…3 mm. rrectness of i t to the co nform spec at i h re o n wit in t his Otherwise excessive sealing compound will enter the sump and may block the oil suction pipe strainer. ♦ Observe expiry date of sealing compound. ♦ The sealing flange must be installed within 5 minutes after ap‐ plying the silicone sealant. – Push guide sleeve - T10215/1- -1- at front onto crankshaft journal -3-. – Now slide sealing flange with oil seal -2- carefully over guide sleeve. – Bolt sealing flange to crankcase. – Install sump ⇒ page 101 . agen lksw Vo by Prote cted by c o py rig ht . C op yi AG. ♦ Tighten securing bolt using torque wrench - V.A.G 1601- . ht rig py Co t. ♦ Renew securing bolt for vibration damper. do c um en Note – Install vibration damper ⇒ page 25 . – Install poly V-belt ⇒ page 28 . 2. Sealing flange and dual-mass flywheel 39 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 3 Pistons and conrods Assembly overview ⇒ page 40 Checking pistons and cylinders ⇒ page 41 . 3.1 Assembly overview 1 - Piston rings ❑ Offset gaps by 120°. ❑ Use piston ring pliers to remove and install. ❑ “TOP” faces towards piston crown. ❑ Checking ring gap ⇒ page 41 . ❑ Checking ring-to-groove clearance ⇒ page 41 . es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n do c um en 4 - Conrod ❑ Renew as set only. ❑ Mark cylinder number -B-. ❑ Installation position: marks -A- must be above one another. ❑ Separate new conrod ⇒ page 41 . rrectness of i t to the co nform spec at i h re o n wit in t his 3 - Circlip ility ab y li an pt ce 2 - Piston ❑ Checking ⇒ page 41 ❑ Mark cylinder number and installation position relative to conrod. ❑ Low point of piston crown faces to centre of cylinder block. ❑ Installing piston ⇒ page 43 . AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s 5 - Bearing shell ❑ Note installation posi‐ tion ❑ Do not interchange used bearing shells. ❑ The lugs on bearing shells must fit tightly in the recesses. ❑ Axial clearance new: 0.05…0.31 mm, wear limit: 0.40 mm ❑ Check radial clearance with Plastigage: new: 0.02…0.07 mm, wear limit: 0.10 mm. Do not rotate crank‐ shaft when checking radial clearance. 40 Rep. gr.13 - Crankshaft group AG. ❑ Renew ❑ Oil threads and contact surface. ❑ To measure radial clearance, tighten to 30 Nm but not further. agen lksw Vo by Prote cted by c o py rig ht . C op yi 7 - 30 Nm + 1/4 turn (90°) further ht rig py Co t. 6 - Conrod bearing cap ❑ Mark cylinder number -B-. ❑ Installation position: marks -A- must be above one another. Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 8 - Cylinder block ❑ Checking cylinder bores ⇒ page 41 . ❑ Removing and installing crankshaft ⇒ page 44 . ❑ Piston and cylinder dimensions ⇒ page 43 . 9 - Piston pin ❑ If difficult to remove, heat piston to 60°C ❑ Remove and install using drift - VW 222 A- . 3.2 Separating new conrod On new conrods it is possible that the breaking point is not fully separated. Proceed as follows, when the conrod bearing cap cannot be removed by hand: – Mark cylinder allocation of conrod ⇒ Item 4 (page 40) – Lightly clamp the conrod in a vice using aluminium vice clamps, as shown in the illustration. Note ♦ To prevent damage to the conrod, only clamp conrod in lightly. ♦ Conrod is clamped below the dashed line. – Unscrew the two bolts -arrows- approx. 5 turns. ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit 3.3 es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng – AG. Volkswagen AG d agen oes ksw not l o gu Using a plastic hammer, carefully knock against conrod y V bear‐ b ara d e nte ing cap in -direction of arrow- until it is loose. oris eo h ut ra a c s s Checking piston and cylinder Installing piston ⇒ page 43 . Checking piston ring gap Special tools and workshop equipment required thi sd o cu m en agen lksw Vo by AG. Prote cted by c o py rig ht . C op yi Test procedure ht rig py Co t. ♦ Feeler gauges 3. Pistons and conrods 41 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Push ring at right angles from above down to approx. 15 mm from bottom end of cylinder. Push in using a piston without rings. Piston ring Rectangular-section ring Tapered stepped ring Oil scraper ring mm mm mm Ring gap New Wear limit 0.20...0.40 1.0 0.20...0.40 1.0 0.25...0.50 1.0 Checking ring-to-groove clearance Special tools and workshop equipment required ♦ Feeler gauges Clean annular groove before check. Piston ring Rectangular-section ring Tapered stepped ring Oil scraper ring mm mm mm Clearance New Wear limit 0.04...0.09 0.15 0.03...0.06 0.15 0.02...0.06 0.15 Checking piston Special tools and workshop equipment required ♦ Micrometre 75 - 100 mm - VAS 6071Measure approx. 6 mm from lower edge of skirt, at 90° angle to piston pin axis. Volkswa gen AG n AG. wage max. 0.04 mm does n Deviation from nominal dimension ot olks yV db Checking cylinder bores ise or rrectness of i t to the co nform spec at i h re o n wit in t his es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce th au s s gu ara nte eo ra c Special tools and workshop equipment required ♦ Cylinder gauge - VAS 6078Test procedure ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi Rep. gr.13 - Crankshaft group do c um en 42 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 ♦ Take measurements at 3 positions in both lateral direction -A- and longitudinal direction -B-. ♦ Deviation from nominal dimension max. 0.08 mm Note The cylinder bores must not be measured when the cylinder block is mounted on assembly stand, as measurements may then be incorrect. 3.3.1 Installing piston Piston and cylinder dimensions ⇒ page 43 . ♦ Piston fitting tool - T10147Note If a new piston fitting tool is used to install the pistons, first pass piston with oiled piston rings twice through the tool and remove any resulting metal shavings, if necessary. Only then install piston with piston rings. Procedure – Push piston into oiled piston fitting tool - T10147- by hand. Low point of piston crown must face lug on the piston fitting tool -arrow-. – Hold piston fitting tool - T10147- (with piston inserted) on upper edge and press piston in with both thumbs. rrectness of i t to the co nf o r m spec atio h re n in wit Special tools and workshop equipment required thi sd o cu m en es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng ility ab y li an pt ce n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss ht rig py Co t. c o p yri gh t . C op yi – Push piston in until it protrudes approx. 15 mm from the lower edge of the piston fitting tool. agen lksw Vo by Prote cted by AG. – Place piston in respective cylinder bore. Lug on fitting tool -arrow- must face centre of cylinder block. – Hold fitting tool tightly against cylinder block and push piston in. 3.4 Piston and cylinder dimensions Honing dimen‐ sion Basic dimension mm Piston ∅ Cylinder bore ∅ 83.965 84.010 3. Pistons and conrods 43 . Volkswagen AG gen AG does not gu ara nte eo ra c wa Phaeton 2003 ➤ olks yV b d 6-cylinder injection engine - Edition 02.2014 ise es, in part or in w l purpos hole ercia , is n m ot com rrectness of i t to the co nform spec a t i h re o n in wit thi s Note pe rm itte d un le Crankshaft ility ab y li an pt ce 4 r ho ut a ss ♦ If the crankshaft or cylinder block is renewed, the crankshaft bearing shells must be reallocated ⇒ page 46 . ♦ Before removing crankshaft, ensure that a suitable surface for storing crankshaft is prepared to ensure that sender wheel ⇒ Item 6 (page 45) is not damaged or lies against any other item. ♦ Secure engine on engine and gearbox support - VAS 6095- to carry out repairs. Assembly overview ⇒ page 44 Assembly overview ht rig py Co t. agen lksw Vo by AG. 1 - Bearing cap ❑ Bearing cap 1: vibration damper end ❑ Bearing cap 5 with re‐ cesses for thrust wash‐ ers. ❑ Bearing shell retaining lugs in cylinder block and bearing caps must align. do c um en 4.1 r te o iva r rp fo g n Fitting sender wheel to crankshaft ⇒ page 45 Prote cted by c o p yri gh t. C op yi 2 - 30 Nm + 1/2 turn (180°) fur‐ ther ❑ Renew ❑ 2 x 90° further is permit‐ ted. 3 - Bearing shells 1…7 ❑ For bearing cap without oil groove. ❑ For cylinder block with oil groove. ❑ Do not interchange used bearing shells (mark). 4 - Thrust washer ❑ For bearing cap 5. ❑ Note fixing arrange‐ ment. 5 - Crankshaft ❑ If the crankshaft is re‐ newed, the crankshaft bearing shells must be reallocated ⇒ page 46 ❑ Before removing, see notes ⇒ page 44 . ❑ Axial clearance new: 0.07…0.23 mm, wear limit: 0.30 mm ❑ Check radial clearance with Plastigage new: 0.02…0.06 mm, wear limit: 0.10 mm 44 Rep. gr.13 - Crankshaft group Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 ❑ Do not rotate crankshaft when checking radial clearance. ❑ Crankshaft dimensions, main bearing: 59.958…59.978 mm, conrod bearing: 53.958…53.978 mm. Re‐ working is not permitted. 6 - Sender wheel ❑ For engine speed sender - G28❑ Renew ❑ Installing ⇒ page 45 . 7 - 10 Nm + 1/4 turn (90°) further ❑ Renew 8 - Oil spray jet ❑ For crankshaft bearings 2…7 ❑ For piston cooling. ❑ Opening pressure: 2.0 bar ❑ Removing and installing ⇒ page 97 ❑ See note ⇒ page 19 4.2 Fitting sender wheel to crankshaft Special tools and workshop equipment required ♦ Torque wrench - V.A.G 1331- rrectness of i t to the co nf o r m spec atio h re n in wit ♦ Locking fluid - D 000 6000 A2Procedure Ensure that contact surfaces of crankshaft and sender wheel are free of oil and grease. Note agen lksw Vo by c o p yri gh t. C op yi – Lightly coat contact surfaces of crankshaft and sender wheel with locking fluid “D 154 100 A1” for additional security. ht rig py Co t. The sender wheel must only be installed once, because after fas‐ tening for a second time, the attachment points -arrows- of coun‐ tersunk head bolts -1- in sender wheel -2- are deformed to such an extent that the bolt heads make contact with the crankshaft -3- and the sender wheel below the bolts is loose. thi sd o cu m en es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s 4. Crankshaft 45 AG. Prote cted by Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Ensure during installation that the marking -VR6- -arrow- is positioned over the single threaded hole. – First tighten all new securing bolts lightly by hand. – First tighten securing bolt -1- to 10 Nm + 1/4 turn (90°) further. – Then tighten securing bolt -2- to 10 Nm + 1/4 turn (90°) further. 4.3 Allocation of crankshaft bearing shells (classification) Main bearing shells of the correct thickness are allocated to the cylinder block and crankshaft at the factory. Coloured dots are . Volkswagen AG does used to identify the thickness of the bearing shells.kswagen AG ol yV b If the cylinder block or crankshaft is changed, ed the crankshaft ris o bearing shells must be reallocated. th u sa es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce Always insert bearing shell for cylinders block (upper bearing shell) with yellow colour marking. not gu ara nte eo ra c rrectness of i t to the co nform spec at i h re o n wit in t his Establish the correct colour marking for the bearing shell in bear‐ ing cap (lower bearing shell) with regard to the letters on the cylinder block and the crankshaft. The first letter is allocated to bearing cap one, the second to bear‐ ing cap two, etc. Cylinder block identification: The letters are located on the sealing surface of sump. ht rig py Co t. agen lksw Vo by AG. Prote cted by c o py rig ht . C op yi Rep. gr.13 - Crankshaft group do c um en 46 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Crankshaft identification: The letters are located on the outer crankshaft web of No. 1 cyl‐ inder. – Make a note of the letters and determine the colour marking for installation with regard to the table. Letter on crankshaft web A, B, C, D, E A, B, C, D, E A, B, C, D, E A, B, C, D, E G, H, I G, H, I G, H, I G, H, I K, L, M K, L, M K, L, M K, L, M R G B V R G B V R G B V Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow 2 3 4 5 6 G G Red H B Yellow H B Yellow H V Blue G B Yellow E B Yellow AG. Prote cted by r fo ng 1 agen lksw Vo by urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p Blue Red Red Yellow Blue Red Yellow Blue Purple ht rig py Co t. c o p yri gh t. C op yi Letters on cylinder block Letters on crankshaft web Colour marking of bearing shell for bearing cap AG. Volkswagen AG d agenRed oes Yellow ksw not l o V gu y b ara d e Red nYellow tee ris tho or u Yellow Yellow ac a ss rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en Bearing cap Colour marking of bearing Colour marking of bearing shell for bearing cap shell for cylinder block ility ab y li an pt ce Example: un le Letter on cylinder block 7 G G Red 4. Crankshaft 47 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 15 – Cylinder head, valve gear 1 Cylinder head Note ♦ ility ab y li an pt ce faces between the support elements, roller rocker fingers and the running surfaces of the cam shafts must be oiled before the cylinder head cover is installed. es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng ♦ AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte To remove cylinder head, engine must be removedor⇒ is page 3 eo h ut ra a If an exchange cylinder head is installed, all thess contact sur‐ c ♦ The plastic protectors fitted to protect the open valves must be rrectness of i t to the co nf o r m spec atio h re n in wit removed only immediately before the cylinder head is fitted. ♦ When replacing the cylinder head the complete coolant must be renewed. ♦ Disconnect the batteries before removing the cylinder head. ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and recon‐ necting batteries. ♦ Removing and installing intake manifold ⇒ page 68 , remov‐ ing and installing cylinder head cover. ♦ Dismantling and assembling intake manifold ⇒ page 155 . Assembly overview ⇒ page 48 Removing and installing cylinder head ⇒ page 52 . Checking compression ⇒ page 74 . 1.1 48 Assembly overview Rep. gr.15 - Cylinder head, valve gear AG. Install camshaft adjuster with timing chain for camshaft drive ⇒ page 64 agen lksw Vo by Prote cted by c o p yri gh t. C op yi Installing timing chains for intermediate shaft drive and camshaft drive ⇒ page 58 ht rig py Co t. Checking valve timing ⇒ page 56 . thi sd o cu m en Removing and installing camshaft control valves ⇒ page 79 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 1 - 10 Nm 2 - Bracket ❑ For wiring harness. 3 - 10 Nm ❑ With spacer sleeve and seal. ❑ Renew seal if damaged. 4 - Cap ❑ Renew seal if damaged 5 - Seal 6 - Cylinder head cover ❑ Removing and installing ⇒ page 68 ❑ Renew if damaged 7 - Lifting eye 8 - 23 Nm 9 - Camshaft timing chain ❑ Before removing, mark running direction (instal‐ lation position) ⇒ page 22 ❑ Installing ⇒ page 58 . 10 - Combination valve ❑ Removing and installing ⇒ page 176 Removing and installing parts of secondary air system. n AG. Volkswagen AG do ❑ Checking ⇒ page age178 es n ksw ol yV ot g ua ran tee or ac 12 - Hall sender 2 - G163❑ For exhaust camshaft. ❑ Before removing, mark connector belonging to component. 13 - Chain tensioner, 40 Nm ❑ For camshaft timing chain ⇒ Item 9 (page 49) ❑ Only rotate engine when chain tensioner is installed. 14 - Seal ❑ Renew if damaged or leaking rrectness of i t to the co nform spec a t i h re o n in wit thi s r te o iva r rp fo g n 15 - Inlet camshaft control valve 1 - N205❑ For inlet camshaft. ❑ Before removing, mark connector belonging to component. ❑ Removing and installing ⇒ page 79 do c um en 16 - Exhaust camshaft control valve 1 - N318❑ For exhaust camshaft. ❑ Before removing, mark connector belonging to component. ❑ Removing and installing ⇒ page 79 ht rig py Co t. es, in part or in w l purpos hole ercia , is n m ot com pe rm itte d un le ility ab y li an pt ce 11 - O-ring ised b r ho ❑ For ut sealing oil channel. a ss ❑ Renew ❑ Lubricate before installing. 1. Cylinder head 49 agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 un le 19 - Thermostat housing ❑ Dismantling and assembling ⇒ page 112 ❑ Coolant hose schematic diagram ⇒ page 114 . 20 - Seal ❑ Renew 21 - Hall sender - G40❑ For inlet camshaft. ❑ Before removing, mark connector belonging to component. ht rig py Co t. c o p yri gh t . C op yi 23 - 60 Nm + 1/4 turn (90°) further r fo ng 22 - Cover ❑ Removing and installing ⇒ page 71 ❑ If only cover has been removed, prepare cylinder head gasket for assembly ⇒ page 73 . ❑ With O-ring for sealing oil channel ⇒ Item 11 (page 49) . ❑ Renew ❑ Contact surface of sender wheel must be dry around bolt head when assembled. ❑ To remove and install, counterhold using 32 mm open-end spanner on camshaft ⇒ page 82 Removing and installing camshafts. 27 - Lifting eye 28 - Cylinder head gasket ❑ Metal gasket. ❑ Renew ❑ Preparing cylinder head gasket for assembly ⇒ page 73 . ❑ After renewing, renew entire coolant ⇒ page 115 29 - Cylinder head ❑ Check for distortion ⇒ page 51 . ❑ Removing and installing ⇒ page 52 ❑ After renewing, renew entire coolant ⇒ page 115 30 - Tensioning element ❑ For poly V-belt. ❑ Removing and installing poly V-belt ⇒ page 28 . 50 Rep. gr.15 - Cylinder head, valve gear Prote cted by 26 - Inlet camshaft adjuster ❑ Identification: 24E ❑ Rotate engine only with camshaft adjuster installed. ❑ Installing ⇒ page 58 . AG. 25 - Guide rail ❑ For camshaft timing chain ⇒ Item 9 (page 49) ❑ Clipped into valve timing housing agen lksw Vo by 24 - Exhaust camshaft adjuster ❑ Identification: 32A. ❑ Rotate engine only with camshaft adjuster installed. ❑ Installing ⇒ page 58 . rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p ⇒ Item 16 (page 49) . ❑ Renew if damaged or leaking ❑ Installing ⇒ page 73 . ility ab y li an pt ce n AG. Volkswagen AG do es n wage s k l ot g o 17 - 8 Nm yV ua b d ran ir se tee o 18 - Seal h t or u a a ❑ For camshaft control valve 1 - N205- ⇒ Item 15 (pagess49) and exhaust camshaft control valve 1 - N318- , c Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 31 - Cylinder head bolt ❑ Renew ❑ Refer to assembly instructions and sequence when loosening and tightening ⇒ page 52 Removing and installing cylinder head. 32 - Cylinder head cover gasket ❑ Renew if damaged or leaking ❑ Note installation position Checking cylinder head for distortion Special tools and workshop equipment required ♦ Straight edge ♦ Feeler gauges AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s ht rig py Co t. r fo ng rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p ility ab y li an pt ce un le Max. permissible distortion: 0.05 mm 1. Cylinder head 51 agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 1.2 Removing and installing cylinder head Special tools and workshop equipment required ♦ Camshaft bar - T10068 A♦ Drip tray - V.A.G 1306♦ Torque wrench (5…50 Nm) - V.A.G 1331♦ Torque wrench (40…200 Nm) - V.A.G 1332♦ Spring-type clip pliers VAS 5024A♦ Lifting tackle - 3033♦ Sealant - AMV 174 004 01♦ Sealant - D 176 501- es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n The engine must be no more than warm to touch. • Coolant has been drained ⇒ page 115 . Prote cted by c o p yri gh t. C op yi Caution When doing any repair work, especially in the engine compart‐ ment, pay attention to the following due to the cramped condi‐ tions: ♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐ vated charcoal filter system, coolant, refrigerant, brake fluid and vacuum) and electrical wiring in their original po‐ sitions. ♦ Ensure that there is sufficient clearance to all moving or hot components. 52 Rep. gr.15 - Cylinder head, valve gear AG. • agen lksw Vo by Engine has been removed ⇒ page 3 do c um en • ht rig py Co t. Prerequisites rrectness of i t to the co nform spec at i h re o n wit in t his Removing ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d Phaeton nte 2003 ➤ ise r o e o02.2014 h t 6-cylinder injection engine Edition u ra a c s s All cable ties which are opened or cut open when engine is re‐ moved must be replaced in the same position when engine is installed. rrectness of i t to the co nform spec at i h re o n wit in t his – Remove poly V-belt ⇒ page 28 . – Remove intake manifold and cylinder head cover ⇒ page 68 Removing and installing cylinder head cover. – Set crankshaft to TDC No. 1 cylinder marks -arrow- by turning crankshaft on the vibration damper securing bolt in direction of engine rotation: agen lksw Vo by AG. c o p yri gh t. C op yi Prote cted by – After checking, remove camshaft bar. ht rig py Co t. – If not, turn crankshaft another 360° in engine direction of ro‐ tation to TDC of cyl. 1. do c um en – The camshaft bar - T10068 A- must engage in both shaft grooves to allow the TDC position to be checked. – Unbolt exhaust manifold from cylinder head ⇒ page 169 Re‐ moving and installing parts of exhaust system. – Remove chain tensioner for camshaft timing chain -arrow-. – Now remove thermostat housing ⇒ page 113 Parts of cooling system - engine side. Note The cover has a “hidden bolt” ⇒ Item 14 (page 72) ! This cannot be removed until thermostat housing has been removed. – Now remove cover ⇒ page 71 . Note Before removing connectors, mark each connector and compo‐ nent to which it belongs. – Pull connectors off camshaft control valves -N205- and -N318on bracket. – After all securing bolts have been removed, cover can be pris‐ ed off carefully. 1. Cylinder head 53 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Mark timing chain before removing (e.g. with paint, arrow pointing in direction of rotation). Note Do not mark chain by way of centre punch, notch or the like. AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s – To do this, counterhold the relevant camshaft using an openend spanner on the hexagon drive -arrows-. – Now remove the camshaft adjuster together with the camshaft roller chain from the inlet camshaft. – Remove securing bolts -arrows- and remove guide rail -1-. AG. Rep. gr.15 - Cylinder head, valve gear agen lksw Vo by Prote cted by c o py rig ht . C op yi 54 ht rig py Co t. r fo ng – Lay camshaft timing chain aside. rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p ility ab y li an pt ce un le – First remove camshaft adjuster of exhaust camshaft. Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Loosen cylinder head bolts in the sequence given starting at the outside and working inwards and then remove completely. Note Use tool 3452 for polydrive cylinder head bolts. – Carefully remove cylinder head. – Place clean cloths in cylinders so that no dirt or emery cloth particles can get in between cylinder wall and piston. – Also prevent dirt and emery cloth particles from getting into coolant. AG. Volkswagen c – Carefully remove metal particles, emery residue and cloths. If the piston for No. 1 cylinder is not at TDC: – Turn crankshaft on the vibration damper securing bolt in di‐ rection of engine rotation to TDC No. 1 cylinder marking -arrow- while a second mechanic guides camshaft roller chain by hand. agen lksw Vo by Prote cted by c o py rig ht . C op yi Note ht rig py Co t. r fo ng – Ensure that the dowel sleeves are inserted in cylinder block holes 12 and 20 so that the cylinder head gasket is located. rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p ss ility ab y li an pt ce Installing un le AG do agen – Now carefully clean sealing surfaces of cylinder head and cyl‐ es n w ot g olks V y is not scored or scratched inder block. Ensure that the surface ua b d ran e in the process. If using abrasive tee ris paper, do not use a grade less o h t or than “100”. a au ♦ Do not remove new cylinder head gasket from its packing until AG. immediately before installing. ♦ Handle new gasket with extreme care. Damage will cause leakage. – Fit new cylinder head gasket. Inscription (Part No.) must be readable. – If necessary, position camshafts in cylinder head at TDC of cyl. 1. 1. Cylinder head 55 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 n AG. Volkswagen AG do es n wage ot g ua ran tee o h or ut bolts and tighten ac a Fit cylinder head, screw in new cylinder head ss ks – The camshaft bar - T10068 A- must engage in grooves Vol in both by d e shafts. ris Note ility ab y li an pt ce hand tight. rrectness of i t to the co nform spec at i h re o n wit in t his es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n – The longer cylinder head bolts must be inserted in the centre holes of cylinder head. – Tighten cylinder head bolts in tightening sequence shown working from inside to outside: – Pre-tighten all bolts to 30 Nm. – Then tighten all bolts to 50 Nm. – Then tighten all bolts 1/4 turn (90°) further using a rigid wrench. – Finally, tighten all bolts another 1/4 turn (90°) further. Prote cted by – Now prepare cylinder head gasket for fitting the cover ⇒ page 73 . – Install cylinder head cover and intake manifold ⇒ page 68 , Removing and installing cylinder head cover. Filling with new coolant ⇒ page 115 . Note It is not necessary to retighten cylinder head bolts after repairs. 1.3 Checking valve timing Special tools and workshop equipment required 56 Rep. gr.15 - Cylinder head, valve gear AG. Ensure that the O-ring ⇒ Item 11 (page 49) to seal the oil channel is inserted in the cover. agen lksw Vo by c o p yri gh t. C op yi Note ht rig py Co t. Installing timing chains for intermediate shaft drive and camshaft drive ⇒ page 58 do c um en Further assembly is basically the reverse of the dismantling se‐ quence. Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 ♦ Camshaft bar - T10068 A- es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng rrectness of i t to the co nf o r m spec atio h re n in wit Test procedure ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s – Remove intake manifold and cylinder head cover ⇒ page 68 Removing and installing cylinder head cover. – Remove front noise insulation: ⇒ General body repairs, exte‐ rior; Rep. gr. 50 ; Body - front; Assembly overview - noise insulation – Set crankshaft to TDC No. 1 cylinder marking -arrow- by turn‐ ing crankshaft on the vibration damper securing bolt in direc‐ tion of engine rotation. thi sd o cu m en ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi – Cams -A- of cylinder 1 must face each other. – Insert camshaft bar - T10068 A- in both shaft grooves. 1. Cylinder head 57 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h The grooves of the camshafts might not be exactly vertical due to ut ra a c the function of camshaft adjusters. Therefore, move the cam‐ s s Note un le urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p – Marks -A- and -B- on camshaft adjusters must align with notches -arrows- in valve timing housing -C-. Markings on valve timing housing ⇒ page 58 – The distance between tooth -1- and tooth -2- of the camshaft adjuster must be exactly 16 rollers of the camshaft roller chain. Note ♦ Figure shows view with cover removed. ♦ Depending on version, there may also be markings for FSI r fo ng If the markings align: AG. – Adjust valve timing ⇒ page 58 . agen lksw Vo by Prote cted by c o p yri gh t. C op yi If the markings do not align: ht rig py Co t. engines on the control housing. Observe only markings for MPI engines ⇒ page 58 . rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en Check setting marks of camshaft adjusters against marks on tim‐ ing housing: ility ab y li an pt ce shafts back and forth slightly if necessary when inserting the camshaft bar - T10068 A- using an open-end spanner. – Install cylinder head cover and intake manifold ⇒ page 68 , Removing and installing cylinder head cover. Markings on valve timing housing on MPI engines On the control housing can also be markings for FSI engines, depending on version. Observe only markings for MPI engines ⇒ page 58 . -A- View from flywheel end -B- View from vibration damper end The markings on camshaft adjusters must align with notches -arrows-. 1.4 58 Installing timing chain for intermediate shaft drive and camshaft drive Rep. gr.15 - Cylinder head, valve gear Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 do c um en pe rm itte d r te o iva r rp fo g n ♦ Sealant - D 176 501 A1- rrectness of i t to the co nform spec a t i h re o n in wit thi s ♦ Torque wrench V.A.G 1332- es, in part or in w l purpos hole ercia , is n m ot com ♦ Torque wrench V.A.G 1331- ility ab y li an pt ce ♦ Counterhold - T10069- un le ♦ Camshaft bar - T10068 A- AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s ht rig py Co t. Special tools and workshop equipment required agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi Procedure Caution When doing any repair work, especially in the engine compart‐ ment, pay attention to the following due to the cramped condi‐ tions: ♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐ vated charcoal filter system, coolant, refrigerant, brake fluid and vacuum) and electrical wiring in their original po‐ sitions. ♦ To avoid damage to lines/wiring, ensure sufficient clear‐ ance to all moving or hot components. Note The following procedure is only possible and described with en‐ gine removed. You can start with adjustments at the relevant point, depending on how far the engine has been dismantled. The sump is removed and may only be fitted after installing the sealing flange. 1. Cylinder head 59 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Install timing chain and chain tensioner with tensioning rail for in‐ termediate shaft drive: – First set crankshaft to TDC No. 1 cylinder. For this, the ground down tooth of drive sprocket -arrow- must align with main bearing joint. – Install both pins without collar for guide rail and tighten to 10 Nm. Fit guide rail on studs. AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e on crankshaft. nte is r o eo h ut ra a c s s – Turn intermediate shaft with flattened side upwards. ility ab y li an pt ce pe rm itte d un le – Insert timing chain into guide rail and place rrectness of i t to the co nform spec a t i h re o n in wit thi s es, in part or in w l purpos hole ercia , is n m ot com – Insert large sprocket into timing chain so that lug on sprocket aligns with marking behind on cylinder block -arrow B-. – Fit sprocket onto intermediate shaft. When installing, ensure that timing chain runs completely straight in guide rail from crankshaft to intermediate shaft. • Ground tooth of drive sprocket must align with main bearing joint -arrow A-. • Lug on sprocket of intermediate shaft must align with marking behind -arrow B-. – Now install chain tensioner. – To do this, release locking teeth of chain tensioner -A- with a small screwdriver and press tensioning rail against chain ten‐ sioner. 60 Rep. gr.15 - Cylinder head, valve gear AG. – Tighten bolt -arrow- hand-tight only as small sprocket has to be taken off again. agen lksw Vo by Prote cted by c o p yri gh t. C op yi – Fit small sprocket of intermediate shaft. Installation is only possible in one position. ht rig py Co t. If timing chain has already been used, note marking for direction of rotation ⇒ page 22 . do c um en Note r te o iva r rp fo g n – If large sprocket cannot be fitted, turn intermediate shaft slight‐ ly. Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Install chain tensioner in this position and tighten to 8 Nm -arrows-. Installing timing chain for camshaft drive: Prerequisite • The camshaft adjusters are installed Cams -A- of cylinder 1 must face each other. rrectness of i t to the co nf o r m spec atio h re n in wit • Crankshaft is positioned at TDC – Insert camshaft bar - T10068 A- in both shaft grooves. thi sd o cu m en es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng • ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ht rig py Co t. agen lksw Vo by AG. Prote cted by c o py rig ht . C op yi – Remove small sprocket on intermediate shaft. The large sprocket must not be pulled off. – Route chain between tensioning rail and guide rail in direction of valve timing housing. 1. Cylinder head 61 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Fit timing chain onto camshaft adjuster so that 2 individual copper coloured chain links -4- align with markings on the camshaft adjuster -3- and with markings on control housing -5-. Markings on valve timing housing ⇒ page 58 – Fit small sprocket of intermediate shaft into timing chain. lkswage . VoMark‐ gen AG link -1-. n AG doe achain ing -2- must align with middle copper coloured w sn s k l o yV b ed – Fit small sprocket with timing chain attached onto intermediate ris ho one position. shaft. Installation is only possibleutin rrectness of i t to the co nf o r m spec atio h re n in wit es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng ility ab y li an pt ce a ss ot g ua ran tee or ac – Lock vibration damper using counterhold - T10069- . AG. Prote cted by Rep. gr.15 - Cylinder head, valve gear agen lksw Vo by c o p yri gh t. C op yi 62 ht rig py Co t. – Check position of crankshaft to intermediate shaft once again. thi sd o cu m en – Tighten new securing bolt for intermediate shaft sprockets -arrow- to 60 Nm + 90° (1/4 turn further). (Further turning can be done in several steps.) Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 • ility ab y li an pt ce behind -arrow C-. ht rig py Co t. c o p yri gh t . C op yi Note do c um en r te o iva r rp fo g n – Check position of copper coloured chain links to adjustment markings. rrectness of i t to the co nform spec a t i h re o n in wit thi s es, in part or in w l purpos hole ercia , is n m ot com pe rm itte d un le • n AG. Volkswagen AG do es n wage s k l ot g bearing o Ground tooth of drive y V sprocket must align with main ua b ran joint -arrow B-.rised tee o h t or u ac a Lug on sprocket of intermediate shaft must align with marking ss The copper coloured chain links no longer align with the adjust‐ ment markings once the crankshaft has been turned. agen lksw Vo by AG. Prote cted by – Apply sealant - D 176 501 A1- onto clean sealing surface of sealing flange as shown. Note Observe dowel pins in cylinder block. – Immediately install sealing flange. – Insert all securing bolts by hand and tighten to 10 Nm. – Now install oil seal for crankshaft in sealing flange ⇒ page 31 . – Now install sump ⇒ page 101 . If seals in cover are to be renewed ⇒ page 73 . – Clean sealing surface on cover and cylinder head. 1. Cylinder head 63 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Lubricate O-ring for oil channel seal -1- and insert in cover. – Check that dowel sleeves -2- and -3- are inserted. – Insert O-ring -4- in cover. es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce – Remove old sealant from 3 mm holes in -arrows-. AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s cylinder head gasket s rrectness of i t to the co nform spec at i h re o n wit in t his – Fill 3 mm holes in cylinder head gasket with sealant - D 176 501 A1- . Coat sealing surfaces of cover with sealant - D 176 501 A1- and install cover without delay. – First insert all securing bolts -arrows- and tighten lightly. – Then tighten M8 securing bolts to 23 Nm and then tighten M6 securing bolts to 8 Nm. – Install cylinder head cover and intake manifold ⇒ page 68 . 1.5 • Installing camshaft adjuster with timing chain for camshaft drive Timing chain for oil pump drive and sealing flange are instal‐ led. 64 Rep. gr.15 - Cylinder head, valve gear AG. The copper coloured chain links no longer align with the adjust‐ ment markings once the crankshaft has been turned. agen lksw Vo by Prote cted by c o py rig ht . C op yi Note ht rig py Co t. – Turn crankshaft two full turns in direction of engine rotation and check valve timing again ⇒ page 56 . do c um en – Install chain tensioner for camshaft roller chain -arrow- and tighten to 40 Nm. Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Set crankshaft to TDC No. 1 cylinder marking -arrow- by turn‐ ing crankshaft on the vibration damper securing bolt in direc‐ tion of engine rotation. – Cams -A- of cylinder 1 must faceneach lkswagen AG AG. Voother. does not gu ara nte eo ra c ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi Note rrectness of i t to the co nf o r m spec atio h re n in wit – Insert camshaft bar - T10068 A- in both shaft grooves. If nec‐ essary, move the camshafts back and forth slightly with an open-end spanner. thi sd o cu m en es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng ility ab y li an pt ce age ksw Vol y b ed ris o h t au ss Both camshaft adjusters (marking: “24E” on inlet side and “32A” on exhaust side) can be screwed at camshaft mounting in one position only -arrows- due to a dowel pin. 1. Cylinder head 65 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Now turn sender wheel -1- on removed inlet camshaft adjuster to right stop in -direction of arrow- and hold adjuster in this position. Note If the inlet camshaft adjuster is bolted to the camshaft, turn ad‐ juster with sprocket to left accordingly and then fit camshaft roller chain. – rrectness of i t to the co nform spec a t i h re o n in wit thi s • es, in part or in w l purpos hole ercia , is n m ot com pe rm itte d un le It tight with camshaft roller chain positioned »tautly« on inlet cam‐ shaft. ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o g yV b Ensure the camshaft roller dchain is »tight« against guide rail uara e nte is r -1- and does not »slag«. eo ho ut ra a c s s must be possible to easily position adjuster and tighten it hand- “Arrow” -1- on the camshaft adjuster of the inlet camshaft must align with the left notch -2- on the control housing. Markings on valve timing housing ⇒ page 58 agen lksw Vo by AG. Prote cted by c o py rig ht . C op yi 66 Rep. gr.15 - Cylinder head, valve gear ht rig py Co t. – Turn sender wheel -1- of exhaust camshaft adjuster to right onto stop -arrow- and hold adjuster in this position. do c um en r te o iva r rp fo g n – Now, from the tooth that is aligned with the “24E” marking, count exactly 16 rollers on the timing chain to the right. Mark this roller with a coloured pen. Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Insert exhaust camshaft adjuster into camshaft roller chain with tooth on marking “32A” so that .the previously counted 16 AG Volkswagen AG d rollers lie precisely between marking “24E” and “32A”, agen oes and w s k not Vol gu markings align. y b a d ise ran un le – Remove camshaft bar - T10068 A- . Note So that the camshaft roller chain does not jump a tooth when the crankshaft is turned, the tensioning rail must be pressed against the camshaft roller chain by hand in place of the chain tensioner. – Turn crankshaft two full turns in direction of engine rotation and check valve timing ⇒ page 56 . r fo ng If the markings align: – Hold camshaft which is to be tightened using a 32 mm openend spanner -arrow-. ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi Note rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p – Check the position of both camshaft adjusters again to ensure the setting is correct. ility ab y li an pt ce tee r – It must be possible ho to easily position the exhaust camshaft o ut a adjuster ontossthe exhaust camshaft and tighten it hand-tight. r ac Camshaft bar - T10068 A- must be removed while this is done. – Tighten securing bolts of inlet and exhaust camshaft adjusters to 60 Nm + 90° (1/4 turn) further. If seals in cover are to be renewed ⇒ page 73 . – Clean sealing surface on cover and cylinder head. – Lubricate O-ring for oil channel seal -1- and insert in cover. – Check that dowel sleeves -2- and -3- are inserted. – Insert O-ring -4- in cover. 1. Cylinder head 67 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Remove old sealant from 3 mm holes in cylinder head gasket -arrows-. – Fill 3 mm holes in cylinder head gasket with sealant - D 176 501 A1- . Coat sealing surfaces of cover with sealant - D 176 501 A1- and install cover without delay. – First insert all securing bolts -arrows- and tighten lightly. – Then tighten M8 securing bolts to 23 Nm and then tighten M6 securing bolts to 8 Nm. – Install chain tensioner for camshaft roller chain and tighten to 40 Nm. – Turn crankshaft two full turns in direction of engine rotation and check valve timing again. – Install cylinder head cover and intake manifold ⇒ page 68 . 1.6 Removing and installing cylinder head cover Note To remove cylinder head, intake manifold must first be removed. ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi Rep. gr.15 - Cylinder head, valve gear thi sd o cu m en 68 rrectness of i t to the co nf o r m spec atio h re n in wit es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Special tools and workshop equipment required ♦ Spring-type clip pliers VAS 5024 A♦ Torque wrench - V.A.G 1331♦ Assembly tool - T10118♦ Puller - T10095 A- rrectness of i t to the co nform spec at i h re o n wit in t his es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s All cable ties which are opened or cut open when engine is re‐ moved must be replaced in the same position when engine is installed. ht rig py Co t. agen lksw Vo by Prote cted by c o py rig ht . C op yi – Remove engine covers. do c um en Removing AG. – Remove connectors from ignition coils using assembly tool T10118- . 1. Cylinder head 69 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Fit puller - T10095 A- from flat side of connector in direction of arrow and pull out ignition coil with output stage (cyl. 1…6). – Remove intake hose between air mass meter - G70- and throttle valve module - J338- . – Pull 6-pin connector off throttle valve module - J338- as well as 2-pin connector off activated charcoal filter system solenoid valve 1 - N80- and crankcase breather valve. – Now pull activated charcoal filter system solenoid valve 1 N80- with bracket off intake manifold support. – Pull all vacuum connections -arrow- off intake manifold and unscrew securing bolt -1- of intake manifold support. – Now unscrew intake manifold supports on left and right of in‐ take manifold. AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s agen lksw Vo by AG. Prote cted by c o py rig ht . C op yi Rep. gr.15 - Cylinder head, valve gear ht rig py Co t. 70 do c um en r te o iva r rp fo g n rrectness of i t to the co nform spec a t i h re o n in wit thi s es, in part or in w l purpos hole ercia , is n m ot com pe rm itte d ility ab y li an pt ce un le – Disconnect crankcase breather hose at cylinder head cover. Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Now remove securing bolts -1- and -2- on intake manifold. – Pull vacuum hose off intake manifold change-over vacuum actuator. – Pull vacuum canister out of mounting on intake manifold. – Unbolt coolant pipe on front of cylinder head. – Remove intake manifold and place it on a suitable surface so that the vacuum unit will not be damaged. Note Seal intake ports in intake manifold and in cylinder head with a clean cloth. – Unbolt retainer on front of cylinder head cover for wiring to knock sender and oil level/temperature sender. olkswagen AG en AG. V – Remove cylinder head cover. Installing s ag ksw Vol y b ed ris o h t au ♦ Bolt intake manifold first to cylinder head. Then tighten the two bolts for the heat shield and the bolts for the intake manifold support. ♦ Ensure that fuel hose connections are tight. Cylinder head cover to cylinder head Intake manifold to cylinder head Intake manifold to support Heat shield to exhaust manifold Dip stick guide tube to intake manifold 10 Nm 13 Nm 20 Nm 23 Nm 5 Nm Assembly overview - cover part Preparing cylinder head gasket for assembly of cover ⇒ page 73 AG. Installing cover seals ⇒ page 73 . agen lksw Vo by 1.7 Specified torque Prote cted by c o p yri gh t. C op yi Threaded connection ht rig py Co t. Specified torques do c um en es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n rrectness of i t to the co nform spec at i h re o n wit in t his Note ility ab y li an pt ce s When installing, Installation is carried out in the reverse order. note the following: does not gu ara nte eo ra c 1. Cylinder head 71 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 1 - Cable guide ❑ For coolant hose and wiring harness ❑ Coolant hose schematic diagram ⇒ page 114 . ❑ With retaining clip for pressure hose to combi‐ nation valve 3 - Return line connection r fo ng urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p 11 - Retainer ❑ For wiring harness and earth connection 12 - Thermostat housing ❑ Coolant hose schematic diagram ⇒ page 114 . 13 - Retainer ❑ For wiring harness. 14 - 8 Nm 15 - 23 Nm 16 - Seal ❑ Renew if damaged or leaking 17 - Cover ❑ Cannot be removed and installed with engine installed ❑ Preparing cylinder head gasket for assembly ⇒ page 73 . 18 - Hall sender - G40❑ For inlet camshaft. ❑ Before removing, mark connector belonging to component. 72 Rep. gr.15 - Cylinder head, valve gear Prote cted by 10 - Seal ❑ Renew if damaged or leaking ❑ Installing ⇒ page 73 . AG. 9 - 8 Nm agen lksw Vo by 8 - Seal ❑ Renew if damaged or leaking c o p yri gh t. C op yi 7 - Chain tensioner, 40 Nm ❑ For camshaft timing chain ⇒ Item 9 (page 49) ❑ Only rotate engine when chain tensioner is instal‐ led. rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 6 - Hall sender 2 - G163❑ For exhaust camshaft. ❑ Before removing, mark connector belonging to component. ility ab y li an pt ce 5 - 8 Nm un le 4 - Supply line connection AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s ht rig py Co t. 2 - Connecting pipes ❑ For fuel supply and re‐ turn hoses Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 19 - O-ring ❑ For sealing oil channel. ❑ Renew ❑ Lubricate before installing. n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng Installing cover seals rrectness of i t to the co nf o r m spec atio h re n in wit 1.7.1 ility ab y li an pt ce 20 - From expansion tank ❑ Coolant hose schematic diagram ⇒ page 114 . Special tools and workshop equipment required ♦ Fitting sleeve - 3378♦ Assembly tool - 3253Prerequisites • Engine has been removed ⇒ page 3 • Coolant has been drained ⇒ page 115 . Removing – Remove thermostat housing ⇒ page 113 Parts of cooling sys‐ tem, engine side. – Install oil seal with fitting sleeve - 3378- in cover -1- and pull in flush using thrust piece - 3253/6- of assembly tool - 3253- . AG. Prote cted by 1.7.2 agen lksw Vo by c o p yri gh t . C op yi – Do not lubricate seals. ht rig py Co t. Installing seals thi sd o cu m en – Now remove cover ⇒ page 71 . Preparing cylinder head gasket for fitting cover Special tools and workshop equipment required ♦ Sealant - D 176 501Procedure If only cover was removed: 1. Cylinder head 73 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Remove old sealant from 3 mm holes in cylinder head gasket -arrows-. – Fill 3 mm holes in cylinder head gasket -arrows- with sealant - D 176 501- and coat sealing surface on cover part and seal‐ ing flange with sealant - D 176 501- . – Install cover immediately! – First insert all securing bolts and tighten lightly. – Then tighten M8 securing bolts ⇒ Item 15 (page 72) to 23 Nm and M6 securing bolts to 8 Nm. – Install chain tensioner for camshaft roller chain ⇒ Item 7 (page 72) and tighten to 40 Nm. Checking compression Special tools and workshop equipment required ♦ Puller - T10095 A- r fo ng AG. Rep. gr.15 - Cylinder head, valve gear agen lksw Vo by Prote cted by c o p yri gh t. C op yi 74 rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en ♦ Compression tester V.A.G 1763- urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p ♦ Torque wrench (5…50 Nm) - V.A.G 1331- ility ab y li an pt ce ♦ Spark plug socket and ex‐ tension - 3122 B- un le ♦ Assembly tool - T10118- AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ht rig py Co t. 1.8 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Test prerequisite • Engine oil temperature must be at least 30 °C. • The battery voltage must be at least 11.5 V. • All electrical consumers, e.g. lights and rear window heating, must be switched off. • If the vehicle is equipped with an air conditioner, it must be switched off. • Fuel pump relays -1- and -2- must be removed from their sockets. Test procedure – Remove engine cover. – Remove ignition coils with output stages: ⇒ page 182 . – Remove spark plugs using spark plug socket and extension 3122 B- . – Check compression using compression tester - V.A.G 1763- . AG. Volkswagen AG do agen Note es n ot g ua ran tee or ac w olks yV b ed ris ho t au ss es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce Using compression tester ⇒ operating instructions . – Have a second mechanic fully depress accelerator and crank engine. rrectness of i t to the co nform spec at i h re o n wit in t his – Operate starter until tester shows no further pressure in‐ crease. Compression pressures: New: 10…13 bar, wear limit: 7.5 bar Maximum permissible difference between all cylinders: 3 bar – Insert spark plugs using spark plug socket and extension 3122 B- and tighten to 20 Nm. After the test has been completed: – Connect Vehicle diagnosis, testing and information system VAS 5052- . Prote cted by – Carry out road test. AG. Observe applicable safety precautions during road test. agen lksw Vo by c o p yri gh t . C op yi – Generate the readiness code in combination with a road test. ht rig py Co t. – Finish the vehicle system test so that any fault entries stored during assembly can be deleted automatically. do c um en – Carry out vehicle system test ⇒ Vehicle diagnostic tester “Gui‐ ded fault finding”. – Then carry out vehicle system test again and rectify any faults which may have occurred. 1. Cylinder head 75 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 2 Valve gear Assembly overview - valve gear ⇒ page 76 Removing and installing camshaft control valves ⇒ page 79 Removing and installing camshafts ⇒ page 82 . Renewing valve stem seals ⇒ page 87 . Checking valve guides ⇒ page 91 . 2.1 Assembly overview - valve gear 1 - 5 Nm + 1/8 turn (45°) further 2 - Exhaust camshaft bearing cap ❑ Installation position ⇒ page 85 ❑ Installation sequence ⇒ page 82 Removing and installing camshaft. pe rm itte d un le ility ab y li an pt ce 3 - Seal ❑ Renew if leaking. ❑ When installing valve AG. Volkswagen AG d timing housing, lightly agen oes not lubricate contact surfa‐y Volksw gu b ara d ces of seal. nte ise r o eo h t seals, ❑ When replacing u ra a c do not spreadss too wide‐ ly. rrectness of i t to the co nform spec a t i h re o n in wit thi s es, in part or in w l purpos hole ercia , is n m ot com 4 - Exhaust camshaft ❑ Check radial clearance with Plastigage; wear limit: 0.1 mm ❑ Runout: max. 0.01 mm ❑ Checking axial clear‐ ance ⇒ page 90 . ❑ Identification and valve timing ⇒ page 91 ❑ Removing and installing ⇒ page 82 ht rig py Co t. r te o iva r rp fo g n do c um en 5 - Valve timing housing ❑ Markings on valve tim‐ ing housing ⇒ page 58 ❑ Lightly lubricate contact surfaces of oil seals be‐ fore installing. ❑ Dismantling and assembling ⇒ page 78 ❑ Before installing valve timing housing, check strainer for soiling ⇒ page 78 ❑ Removing and installing ⇒ page 82 Removing and installing camshafts. ❑ Removing and installing camshaft control valves ⇒ page 79 agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi 6 - Camshaft timing chain ❑ Before removing, mark direction of rotation (installation position) ⇒ page 22 . ❑ Installing ⇒ page 64 . 76 Rep. gr.15 - Cylinder head, valve gear Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 7 - Exhaust camshaft adjuster ❑ Identification: 32A. ❑ Rotate engine only with camshaft adjuster installed. ❑ Installing ⇒ page 64 . 8 - 60 Nm + 1/4 turn (90°) further ❑ Renew ❑ Contact surface of sender wheel must be dry around bolt head when assembled. ❑ To remove and install, counterhold using 32 mm open-end spanner on camshaft ⇒ page 82 Removing and installing camshafts. 9 - Inlet camshaft adjuster ❑ Identification: 24E ❑ Rotate engine only with camshaft adjuster installed. ❑ Installing ⇒ page 64 . 10 - Cylinder head height ❑ Minimum height: a = 139.9 mm. 11 - Valves ❑ Do not rework, only lapping-in is permitted. AG. Volkswagen AG d ❑ Valve dimensions ⇒ page agen 94 oe w olks s no t gu ara nte eo ra c urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p un le ility ab y li an pt ce 12 - Cylinder headed by V ris ❑ Check for ho distortion ⇒ page 51 . ut a ss ❑ Removing and installing ⇒ page 52 ❑ Reworking valve seats ⇒ page 91 . ❑ After renewing, renew entire coolant. 14 - Valve stem seal ❑ Renew ⇒ page 87 15 - Securing clip ❑ Check for secure seating. rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 13 - Support element ❑ Before installing, check camshaft axial clearance ⇒ page 90 . ❑ Do not interchange ❑ With hydraulic valve clearance compensation. ht rig py Co t. r fo ng 16 - Roller rocker finger ❑ Before installing, check camshaft axial clearance ⇒ page 90 . ❑ Do not interchange ❑ Check roller bearing for ease of movement. ❑ Oil contact surface ❑ When installing, secure to supporting element using securing clip. Prote cted by c o p yri gh t. C op yi 17 - Valve spring ❑ Note installation position ❑ Removing and installing ⇒ page 87 , Renewing valve stem seals. agen lksw Vo by AG. 18 - Valve spring plate 19 - Valve cotters 20 - Inlet camshaft bearing cap ❑ Installation position ⇒ page 85 ❑ Installation sequence ⇒ page 82 Removing and installing camshaft. 21 - Inlet camshaft ❑ Check radial clearance with Plastigage; wear limit: 0.1 mm 2. Valve gear 77 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 ❑ ❑ ❑ ❑ Runout: max. 0.01 mm Checking axial clearance ⇒ page 90 . Identification and valve timing ⇒ page 91 Removing and installing ⇒ page 82 Dismantling and assembling valve timing housing 1 - Guide rail: clipped into timing housing 2 - Valve timing housing 3 - Removing and installing inlet camshaft control valve 1 - N205⇒ page 79 4 - Removing and installing exhaust camshaft control valve 1 N318- ⇒ page 79 5 - 8 Nm (renew bolts) Checking valve timing housing strainer for soiling – Unclip strainer -2- from back of valve timing housing -1- and remove any dirt. ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t . C op yi Rep. gr.15 - Cylinder head, valve gear do c um en 78 rrectness of i t to the co nform spec at i h re o n wit in t his es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 2.2 Removing and installing camshaft control valves Special tools and workshop equipment required ♦ Torque wrench - V.A.G 1783♦ Torx bit set - V.A.G 1766♦ 1/4" drive ratchet - VAS 6234- AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s rrectness of i t to the co nform spec a t i h re o n in wit thi s es, in part or in w l purpos hole ercia , is n m ot com pe rm itte d ility ab y li an pt ce un le ♦ Special wrench, long reach - T10072- Not illustrated: ♦ Sealant - AMV 174 004 01Removing: Prerequisites The engine must be removed. Prote cted by c o p yri gh t. C op yi – Remove cylinder head cover ⇒ page 68 . agen lksw Vo by AG. Note ht rig py Co t. • do c um en r te o iva r rp fo g n ♦ Sealant - AMV 176 501- Before removing connectors, mark each connector and compo‐ nent to which it belongs. – Disconnect connectors from following components of cover: ♦ Inlet camshaft control valve 1 - N205- 2. Valve gear 79 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 ♦ Exhaust camshaft control valve 1 - N318♦ Hall sender - G40♦ Hall sender 2 - G163– Move wiring harness clear. – Now remove thermostat housing ⇒ page 113 Parts of cooling system - engine side. Note The cover has a “hidden bolt”. This cannot be removed until ther‐ mostat housing has been removed. – Remove chain tensioner for camshaft roller chain -arrow-. – Remove securing bolts -arrows- from cover. AG. Volkswagen A n – Cover can be prised off carefully when all securing bolts have G does no wage olks t gu V y been removed. ar db es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ♦ Cover lower chain housing carefully so that no parts can fall into it. agen lksw Vo by AG. Prote cted by c o py rig ht . C op yi Rep. gr.15 - Cylinder head, valve gear do c um en 80 rrectness of i t to the co nform spec at i h re o n wit in t his ♦ Securing bolts for camshaft control valves must not be completely removed at first, so that the valve is not canted during removal. ht rig py Co t. ss ility ab y li an pt ce Caution an tee or ac e ris ho t au Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Unscrew securing bolts for camshaft control valves approx. 3 mm (5 turns) with socket - T10072- -arrows-. n AG. Volkswagen AG do es n ot g ua ran tee control or ac ge wahousing – Pull camshaft control valve out of seat in valve timing olks V y against loosened bolts. db e ris rrectness of i t to the co nform spec a t i h re o n in wit thi s Caution es, in part or in w l purpos hole ercia , is n m ot com Installing: pe rm itte d un le ility ab y li an pt ce – Completely remove securing bolts and upull tho camshaft a s valve out of valve timing housing. s ♦ The valve seat in the valve timing housing must not be scored or scratched. ♦ The camshaft control valves and the valve timing housing must be free of dirt and soiling. ♦ Ensure the camshaft control valves are protected from knocks and impacts. ♦ Only unpack the new camshaft control valves immediately prior to installation. – Moisten seals with clean engine oil. AG. – Clean sealing surface on cover and cylinder head. agen lksw Vo by Prote cted by c o p yri gh t. C op yi – Tighten securing bolts -arrows- to 3.8 Nm. ht rig py Co t. – Carefully insert camshaft control valve into housing and push vertically to valve axis to stop by hand. do c um en r te o iva r rp fo g n ♦ The camshaft control valves must not be pulled into their seat with the securing bolts. Only insertion by hand is per‐ mitted. – If seals in cover are to be renewed ⇒ page 73 . – Lubricate O-ring for oil channel seal ⇒ Item 11 (page 49) and insert in cover. – Insert O-ring ⇒ Item 20 (page 50) in cover. – Remove old sealant from 3 mm holes in cylinder head gasket -arrows-. – Fill 3 mm holes in cylinder head gasket with sealant - AMV 174 004 01- and coat sealing surfaces on cover and sealing flange with sealant - AMV 176 501- . Note With the cylinder head installed, the holes in the cylinder head gasket are only half visible. – Fit cover as quickly as possible. 2. Valve gear 81 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – First insert all securing bolts -arrows- and tighten lightly. – Then tighten M8 securing bolts ⇒ Item 8 (page 49) to 23 Nm and M6 securing bolts ⇒ Item 17 (page 50) to 8 Nm. – Install chain tensioner for camshaft roller chain ⇒ Item 13 (page 49) and tighten to 40 Nm. – Install cylinder head cover ⇒ page 68 and intake manifold. Further assembly is basically the reverse of the dismantling se‐ quence. 2.3 Removing and installing lkswagen AG . Vocamshafts gen AG d a ksw Vol y b ed ris Special tools and workshop o h equipment required s aut s pe rm itte d un le ility ab y li an pt ce ♦ oes not gu ara nte eo ra c ♦ Camshaft bar - T10068 A- rrectness of i t to the co nform spec a t i h re o n in wit thi s es, in part or in w l purpos hole ercia , is n m ot com ♦ Torque wrench (5…50 Nm) - V.A.G 1331♦ Torque wrench (40…200 Nm) - V.A.G 1332♦ Sealant - D 176 501- Prote cted by Camshafts, checking axial clearance ⇒ page 90 Camshaft identification ⇒ page 91 . 82 Rep. gr.15 - Cylinder head, valve gear AG. Renewing valve stem seals ⇒ page 87 . agen lksw Vo by c o p yri gh t. C op yi Installing camshafts ⇒ page 85 . ht rig py Co t. Removing camshafts ⇒ page 83 . do c um en r te o iva r rp fo g n ♦ Sealant - AMV 174 004 01- Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 2.3.1 Removing Prerequisite • Engine removed Caution When doing any repair work, especially in the engine compart‐ ment, pay attention to the following due to the cramped condi‐ tions: ♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐ vated charcoal filter system, coolant, refrigerant, brake fluid and vacuum) and electrical wiring in their original po‐ sitions. ♦ Ensure that there is sufficient clearance to all moving or hot components. – All cable ties which are opened or cut open when engine is removed must be replaced in the same position when engine is installed. – Remove intake manifold and cylinder head cover ⇒ page 68 . – Set crankshaft to TDC No. 1 cylinder marks -arrow- by turning crankshaft on the vibration damper securing bolt in direction of engine rotation: es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n – It must now be possible to insert camshaft bar - T10068 A- in groove in both shafts. ility ab y li an pt ce n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss rrectness of i t to the co nform spec at i h re o n wit in t his do c um en 2. Valve gear 83 ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t . C op yi Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Remove chain tensioner for camshaft timing chain -arrow-. Note Before removing connectors, mark each connector and compo‐ nent to which it belongs. . Volkswag ility ab y li an pt ce ♦ ♦ Exhaust camshaft control valve 1 - N318- , ♦ Hall sender - G40- , rrectness of i t to the co nform spec at i h re o n wit in t his ♦ Hall sender 2 - G163- . – Move wiring harness clear. – Now remove thermostat housing ⇒ page 113 Parts of cooling system - engine side. – Remove cover ⇒ page 71 . – Mark timing chain before removing (e.g. with paint, arrow pointing in direction of rotation). Note Do not mark chain by way of centre punch, notch or the like. – First remove exhaust camshaft adjuster. agen lksw Vo by AG. Prote cted by c o p yri gh t . C op yi Only counterhold camshaft with 32 mm open-end spanner -arrow-. The camshaft bar - T10068 A- must not be fitted when camshaft adjuster is loosened or tightened. – Remove camshaft adjuster together with camshaft roller chain from intake camshaft. – Lay camshaft timing chain aside. 84 Rep. gr.15 - Cylinder head, valve gear ht rig py Co t. Note do c um en es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n – en AG n AG does wage not olks V gu by Disconnect connectors from theedfollowing components of cov‐ ara nte ris er: o eo h t u ra a c Camshaft control valve 1ss- N205- , Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Unbolt control housing from cylinder head -arrows-. – Pull valve timing housing carefully off camshaft seals. Removing inlet camshaft -A– First remove bearing caps 1 and 13. – Remove bearing caps 3 and 11. – Remove bearing cap 7. – Loosen bearing caps 5 and 9 alternately and diagonally. Removing exhaust camshaft -B– First remove bearing caps 2 and 14. – Remove bearing caps 4 and 12. – Remove bearing cap 8. – – pe rm itte d un le – Remove roller rocker fingers together with support elements and lay aside on a clean surface. es, in part or in w l purpos hole ercia , is n m ot com 2.3.2 rrectness of i t to the co nform spec a t i h re o n in wit thi s – Ensure that roller rocker fingers and support elements are not interchanged. ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V gu y Loosen bearing caps 6 and 10 alternately and diagonally. b ara d nte ise r o eo h Carefully remove camshafts aand lay aside on clean surface. ut ra c s s Installing Lightly coat contact surfaces of bearing caps 7 and 8 with grease “G 052 723 A 2” before installing. Prerequisites • When installing camshafts, cams for no. 1 cylinder of inlet and exhaust camshaft must point upwards (bearing caps 13 and 14). do c um en ht rig py Co t. r te o iva r rp fo g n – Install supporting elements in cylinder head and fit respective roller rocker finger onto respective valve stem end or support‐ ing element. 2. Valve gear 85 agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Ensure that all roller rocker fingers -1- seat properly on valve stem ends and are clipped into their respective support ele‐ ments -2-. – Oil running surfaces of camshafts. – Carefully place each camshaft in its respective bearing in the cylinder head. When doing this, note camshaft identification ⇒ page 91 Note ♦ Observe fitting position of bearing caps: ♦ Point of bearing cap -arrow A- of inlet and outlet camshafts face outwards. es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s Installing inlet camshaft -A- – Tighten bearing caps 5 and 9 alternately and diagonally to 5 Nm + 1/8 turn (45°). rrectness of i t to the co nf o r m spec atio h re n in wit – Install bearing caps 1 and 13 and tighten to 5 Nm + 1/8 turn (45°). – Install bearing cap 7 and tighten to 5 Nm and turn 1/8 (45°) further. – Install bearing caps 3 and 11 and also tighten to 5 Nm + 1/8 turn (45°). Installing exhaust camshaft -B– Tighten bearing caps 6 and 10 alternately and diagonally to 5 Nm + 1/8 turn (45°). AG. Continuation for both camshafts – Position camshafts in cylinder head to TDC No. 1 cylinder. 86 Rep. gr.15 - Cylinder head, valve gear agen lksw Vo by Prote cted by c o p yri gh t. C op yi – Install bearing caps 4 and 12 and also tighten to 5 Nm + 1/8 turn (45°). ht rig py Co t. – Install bearing cap 8 and tighten to 5 Nm and turn 1/8 (45°) further. thi sd o cu m en – Install bearing caps 2 and 14 and tighten to 5 Nm + 1/8 turn (45°). Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – The camshaft bar - T10068 A- must engage in grooves in both shafts. – Before installing, check timing housing strainer for soiling ⇒ page 78 . – Before installing valve timing housing, lightly lubricate valve timing housing surfaces contacting camshaft seals. – Lightly lubricate contact surfaces of camshaft seals and slowly push valve timing housing over camshaft seals. n AG. Volkswagen A G o es n wage and tighten to 8 dNm. – Install control housing -arrowso olks t gu a V by a ss ac – Remove old sealant from 3 mm holes in cylinder head gasket -arrows-. – Fill 3 mm holes in cylinder head gasket with sealant - D 176 501- . Note – Lubricate O-ring for oil channel seal and insert in cover. – Coat sealing surface of cover with sealant - D 176 501- and immediately install. ht rig py Co t. agen lksw Vo by c o p yri gh t. C op yi – First insert all securing bolts and tighten lightly. do c um en r te o iva r rp fo g n Sealant - D 176 501- hardens quickly. rrectness of i t to the co nform spec a t i h re o n in wit thi s es, in part or in w l purpos hole ercia , is n m ot com pe rm itte d ility ab y li an pt ce un le ed roller chain with camshaft adjustersran – Now install camshaft tee ris o h ⇒ page 64 . ut or Prote cted by – Then tighten M8 securing bolts ⇒ Item 15 (page 72) to 23 Nm and M6 securing bolts to 8 Nm. AG. – Install chain tensioner for camshaft roller chain and tighten to 40 Nm. – Install cylinder head cover and intake manifold ⇒ page 68 , Removing and installing cylinder head cover. 2.4 Renewing valve stem seals 2. Valve gear 87 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Special tools and workshop equipment required ♦ Valve lever - VW 541/1 A- ♦ Spark plug socket and ex‐ tension - 3122 Bun le pe rm itte d AG. Rep. gr.15 - Cylinder head, valve gear agen lksw Vo by Prote cted by c o py rig ht . C op yi 88 do c um en r te o iva r rp fo g n rrectness of i t to the co nform spec a t i h re o n in wit thi s ♦ Adapter - T40012/1- es, in part or in w l purpos hole ercia , is n m ot com ♦ Valve stem seal fitting tool 3365- ility ab y li an pt ce ♦ Valve stem seal puller 3364- AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ht rig py Co t. ♦ Valve assembly device 2036- Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 ♦ Torque wrench (5…50 Nm) - V.A.G 1331- un le ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra c Removing ss a urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p – Remove camshafts ⇒ page 82 . rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en – Remove roller rocker fingers together with support elements and lay aside on a clean surface. – Ensure that roller rocker fingers and support elements are not interchanged. – Remove spark plugs using spark plug socket and extension 3122 B- . – Set piston of respective cylinder to “bottom dead centre”. – Set up valve assembly device - 2036- with adapter plates -2036/1- and adjust mounting. – Screw adapter - T40012/1- into spark plug thread, connect to compressed air line with commercially available adapter and apply continual pressure of at least 6 bar. Note ht rig py Co t. r fo ng – Remove valve springs using valve lever - VW 541/1A- and press tool - VW 541/6- . c o p yri gh t. C op yi Tight cotters can be loosened by tapping lightly on lever. agen lksw Vo by Prote cted by – Pull off valve stem seals using valve stem seal puller - 3364- . AG. Installing 2. Valve gear 89 AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s un le – Lubricate sealing lip of valve stem seal -B-, place it in the valve stem oil seal fitting tool - 3365- and push carefully onto valve guide. r fo ng – Install camshafts ⇒ page 82 . Camshafts, checking axial clearance Prote cted by ♦ Universal dial gauge bracket - VW 387♦ Dial gauge Perform measurements only with support elements and roller rocker fingers removed. Middle bearing cap of respective camshaft installed. – With dial gauge inserted, screw universal dial gauge bracket - VW 387- to cylinder head, as shown, and measure axial clearance. Wear limit: max. 0.10 mm 90 Rep. gr.15 - Cylinder head, valve gear AG. Special tools and workshop equipment required agen lksw Vo by c o p yri gh t. C op yi 2.4.1 ht rig py Co t. – To prevent damage to new valve stem seals, place plastic sleeve -A- on valve stem. rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p ility ab y li an pt ce Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 2.4.2 Camshaft identification Identification between cam pair for cylinders 4 and 5 of respective camshaft. Camshaft Identification A - Exhaust camshaft 022 101 Index 022 102 Index B - Inlet camshaft Valve timing at 1 mm valve lift Opens BTDC Closes BTDC Opens ATDC Closes ATDC Exhaust valve ----18.50° 223.5° 211.5° 6.5° ----- Checking valve guides AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce un le 2.5 Inlet valve ♦ Universal dial gauge bracket - VW 387♦ Dial gauge Test procedure – Insert new valve into guide. The end of the valve stem must be flush with the guide. Due to slight differences in stem di‐ ameters, use only an inlet valve in inlet guide and an exhaust valve in exhaust guide. Reworking valve seats Special tools and workshop equipment required ♦ Valve seat refacing tool AG. ♦ Depth gauge agen lksw Vo by 2.6 Prote cted by c o py rig ht . C op yi – Renew cylinder head. ht rig py Co t. If rock tolerance is exceeded: r fo ng – Determine rock. Wear limit: 0.8 mm rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p Special tools and workshop equipment required 2. Valve gear 91 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Procedure Note ♦ When repairing engines with leaking valves, it is not sufficient to rework or renew valve seats and valves. Particularly on high mileage engines, it is necessary also to check valve guides for wear ⇒ page 91 . ♦ Valve seats should be reworked only enough to produce a perfect seating pattern. Before beginning to rework valve seats, calculate the maximum permissible reworking dimen‐ sions. If the reworking dimension is exceeded, hydraulic valve compensation can no longer be guaranteed and the cylinder head should be renewed. – Remove camshafts, ⇒ page 82 . The max. permissible reworking dimension is lows: rrectness of i t to the co nform spec at i h re o n wit in t his If the valve is to be renewed as part of a repair, use a new valve for the calculation. – Measure distance -a- between end of valve stem and upper edge of cylinder head. – Calculate maximum permissible reworking dimension from measured distance -a- and minimum dimension. Short inlet valve Long inlet valve Short exhaust valve Long exhaust valve mm mm mm mm 31.8 10.2 31.8 10.2 Measured distance minus minimum dimension = max. permissi‐ ble reworking dimension. 5) The max. permissible reworking dimension is shown as dimension “b” in the illustrations for reworking valve seats. 92 Rep. gr.15 - Cylinder head, valve gear AG. 10.6 mm 10.2 mm 0.4 mm agen lksw Vo by - Measured distance Minimum dimension = max. perm. rework dimension 5) Prote cted by c o p yri gh t. C op yi Example: ht rig py Co t. Minimum dimension: do c um en es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n Note ility ab y li an pt ce – Insert valve and press firmly against seat. AG. Volkswagen AG d agen oes ksw not l o V gu byas fol‐ ara calculated d e nte is r o eo h ut ra a c s s Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Z = α β = = g = un le = = = urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p c d r2 working dimension6) 0.9…1.5 mm max. ∅ 38.0 mm radius 2.0 mm Lower edge of cylin‐ der head 45° valve seat angle 30° upper correction angle 60° lower correction angle Z = α β = = g = Lower edge of cylin‐ der head 45° valve seat angle 30° upper correction angle 60° lower correction angle Prote cted by = = = AG. c d r2 ∅ 29.8 mm Max. permissible re‐ working dimension6) 1.2…1.7 mm max. ∅ 35.0 mm radius 2.0 mm agen lksw Vo by = = c o p yri gh t. C op yi a b r fo ng Reworking exhaust valve seat rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en = = ility ab y li an pt ce a b 2.6.2 AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h ∅ 32.8 mm t u ra a c s s Max. permissible re‐ Reworking inlet valve seat ht rig py Co t. 2.6.1 6) The max. permissible reworking dimension is shown as dimension “b” in the illustrations for reworking valve seats. 2. Valve gear 93 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Valve dimensions Note Valves must not be reworked. Only lapping-in is 33.20 5.98 102.46 44° 40´ 33.20 5.98 136.36 44° 40´ Exhaust valves Dimension ∅a ∅b c α mm mm mm ∠° Short exhaust valve Long exhaust valve 30.20 5.97 102.20 44° 40´ 30.20 5.97 136.20 44° 40´ Prote cted by c o py rig ht . C op yi Rep. gr.15 - Cylinder head, valve gear thi sd o cu m en 94 AG. Long inlet valve agen lksw Vo by mm mm mm ∠° Short inlet valve rrectness of i t to the co nf o r m spec atio h re n in wit ∅a ∅b c α ility ab y li an pt ce Dimension es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng Inlet valves AG. Volkswagen AG d agen oes ksw not l o permitted.by V gu ara d e nte is r o eo h ut ra a c s s ht rig py Co t. 2.6.3 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Lubrication 1 Parts of lubrication system rrectness of i t to the co nform spec a t i h re o n in wit thi s es, in part or in w l purpos hole ercia , is n m ot com Note pe rm itte d un le 17 – ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ♦ Finding metal shavings or a large quantity of small metal par‐ ticles during engine repair could indicate that the crankshaft bearings or conrod bearings are damaged. To prevent this from causing further damage, perform the following repairs: ♦ Thoroughly clean oil channels ♦ Renew oil non-return valve. ♦ Renew oil spray jets. ♦ Renew oil cooler ♦ Renew oil filter damage to catalytic converter! AG. Markings on oil dipstick ⇒ page 98 Checking oil pressure and oil pressure switch ⇒ page 104 agen lksw Vo by Prote cted by c o p yri gh t. C op yi Assembly overview ⇒ page 95 ht rig py Co t. Engine oil (oil capacities and engine oil specification) ⇒ page 95 do c um en r te o iva r rp fo g n ♦ The oil level must not be above the max. mark - danger of Renew oil non-return valve ⇒ page 98 . Removing and installing oil spray jet ⇒ page 97 Removing and installing sump ⇒ page 101 . 1.1 Engine oil Oil capacities: With oil filter 6.0 l Engine oil specifications: Long-life engine oil New VW standard (specially developed, ageing resistant). Initial filling: VW standard 503 00 Note ♦ The engine is filled at the factory with engine oil conforming to VW standard 503 00. This engine oil is designed for long serv‐ ice intervals. ♦ Engine oils conforming to VW standard 500 00, 501 01 or 502 00 can be used furthermore. These oils must be changed every 12 months or 15,000 kilometres. The service interval display must be programmed accordingly. Procedure: ⇒ Main‐ tenance ; Booklet 16.1 1.2 Assembly overview 1. Parts of lubrication system 95 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 1 - 8 Nm ❑ Secured to intake mani‐ fold. 2 - Dipstick ❑ The oil level must not be above the max. mark! ❑ Markings ⇒ page 98 . 3 - Guide tube ❑ For dipstick ❑ Secured with bolt to in‐ take manifold. 5 - Oil non-return valve ❑ Note installation posi‐ tion ❑ Removing and installing ⇒ page 98 ❑ Renew if badly soiled. ❑ See note ⇒ page 95 6 - 8 Nm 7 - Oil pump drive cover r te o iva r rp fo g n 12 - 10 Nm ❑ Insert with “D6” locking fluid 13 - Oil spray jet ❑ For crankshaft bearings 2…7 ❑ For piston cooling. ❑ Opening pressure: 2.0 bar ❑ Removing and installing ⇒ page 97 ❑ See note ⇒ page 95 14 - Drive shaft ❑ For oil pump drive. 15 - Oil pump ❑ Dismantling and assembling ⇒ page 100 96 Rep. gr.17 - Lubrication AG. 11 - Thrust washer ❑ Not installed on all engines. agen lksw Vo by Prote cted by c o py rig ht . C op yi 10 - Intermediate shaft ht rig py Co t. 9 - Oil pump drive do c um en 8 - O-ring ❑ Renew ❑ Lubricate before installing. rrectness of i t to the co nform spec a t i h re o n in wit thi s es, in part or in w l purpos hole ercia , is n m ot com pe rm itte d un le ility ab y li an pt ce 4 - Cylinder block AG. Volkswagen AG d ❑ Removing and installing agen oes ksw not l o sealing flange and dual- by V gu ara d e mass flywheel nte is r o eo h ⇒ page 30 . ut ra a c s s ❑ Removing and installing crankshaft ⇒ page 44 . ❑ Dismantling and assem‐ bling pistons and con‐ rods ⇒ page 40 . Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 16 - 23 Nm 17 - Oil drain plug, 30 Nm ❑ Renew bolt if it has a captive seal 18 - Sump ❑ Removing and installing ⇒ page 101 19 - Oil level and oil temperature sender - G26620 - 12 Nm 21 - Baffle plate 22 - 8 Nm ❑ Apply locking fluid “D 000 600 A2” when installing 23 - Seal ❑ Renew ❑ Lubricate before installing. 24 - Oil filter housing / left engine bracket ❑ Dismantling and assembling ⇒ page 98 ❑ Coolant hose schematic diagram ⇒ page 114 . ❑ Right engine bracket and specified torque ⇒ page 25 25 - 23 Nm 1.2.1 Removing and installing oil spray jet Special tools and workshop equipment required ♦ 4 mm ∅ drift ♦ 6 mm ∅ drift Note ility ab y li an pt ce – Press oil spray jet out towards bearing using a 4 mm ∅ drift. Installing ht rig py Co t. r fo ng – To install, press oil spray jet in to correct installation position by hand using a 6 mm ∅ drift -arrow-. rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p Removing un le Oil spray jets are installed in AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r main bearings 2…7. o eo h ut ra a c s s 1. Parts of lubrication system 97 agen lksw Vo by AG. Prote cted by c o py rig ht . C op yi Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 1.2.2 Removing and installing oil non-return valve Removing – Screw commercially available M8x1.5 bolt about 4 full turns into valve -arrow- and withdraw it from bore. Installing – Before installing, moisten O-ring with oil. Press valve into oil channel by hand. 1.2.3 Markings on oil dipstick 1 - Max. mark 2 - Min. mark a - Area above hatched field up to max. mark: do not add engine oil . Volkswagen AG n AGoil b - Oil level within hatched zone:sengine can be added does wage k Vol not g ra c urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p AG. Prote cted by Rep. gr.17 - Lubrication agen lksw Vo by c o p yri gh t . C op yi 98 rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en r fo ng Assembly overview - dismantling and assembling oil filter housing ht rig py Co t. 1.3 au ss ility ab y li an pt ce un le ua by c - Area from min. mark up ed to hatched field: Must be topped up, ran tee ris o max. 0.5 l of engine oil! th o Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 1 - Oil filter housing/engine bracket 2 - Seal ❑ Renew AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce 3 - Oil cooler seal ❑ Insert in oil cooler before installing ⇒ page 99 ❑ Renew ❑ Lubricate before instal‐ ling. 5 - Securing ring rrectness of i t to the co nform spec at i h re o n wit in t his 4 - Oil cooler ❑ Ensure clearance to ad‐ jacent components. ❑ See note ⇒ page 95 ❑ Coolant hose schematic diagram ⇒ page 114 . 6 - Seal ❑ Renew ❑ Lubricate before instal‐ ling. 7 - Oil cooler cover, 25 Nm ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi 9 - Oil filter element ❑ Observe change inter‐ vals. ❑ See note ⇒ page 95 do c um en 8 - Oil pressure switch - F1- , 20 Nm ❑ Black ❑ If seal is leaking, nip open and renew ❑ Checking ⇒ page 104 10 - Oil filter lower part, 25 Nm ❑ Before removing, drain via oil drain plug ⇒ Item 11 (page 99) ❑ With by-pass valve, opening pressure: 2.50 bar 11 - Oil drain plug, 10 Nm 12 - 23 Nm Installing oil cooler seal – Insert seal moistened with oil into oil cooler as illustrated. When doing this note installation position -arrow-. 1. Parts of lubrication system 99 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 1.4 Assembly overview - dismantling and assembling oil pump Note AG. Volkswagen A es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce n G do es n wage When installing oil pump, note the First tighten all se‐ ksfollowing: ot g Vol oil pressure pipe y ua curing bolts by hand. Then tighten b d ran e s i ⇒ Item 7 (page 100) to cylinder block and then to oil pump tee r o h or ut ⇒ Item 2 (page 100) . aFinally tighten oil pump with securing bolts ac ⇒ Item 3 (page 100) s.s rrectness of i t to the co nform spec at i h re o n wit in t his 1 - Drive shaft ❑ For oil pump drive. 2 - Oil pump housing 3 - 23 Nm 4 - Gears ❑ Checking backlash ⇒ page 101 . ❑ Checking axial clear‐ ance ⇒ page 101 . 100 Rep. gr.17 - Lubrication Prote cted by 9 - Seal ❑ Renew if damaged AG. 8 - 8 Nm agen lksw Vo by c o p yri gh t. C op yi 7 - Oil pressure pipe ❑ Secure only with new “microencapsulated” bolts ht rig py Co t. 6 - 10 Nm ❑ Renew do c um en 5 - Oil pump cover with pres‐ sure relief valve ❑ Opening pressure: 5.3…5.7 bar ❑ Clean strainer if soiled Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Checking oil pump backlash Special tools and workshop equipment required ♦ Feeler gauges Wear limit: 0.20 mm n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss pe rm itte d ility ab y li an pt ce un le Checking oil pump axial clearance es, in part or in w l purpos hole ercia , is n m ot com rrectness of i t to the co nform spec a t i h re o n in wit thi s Special tools and workshop equipment required ♦ Straight edge ♦ Feeler gauges Wear limit: 0.10 mm 1.5 Removing and installing sump Special tools and workshop equipment required do c um en ht rig py Co t. r te o iva r rp fo g n ♦ Engine and gearbox jack - V.A.G 1383 A- agen lksw Vo by AG. Prote cted by c o p yri gh t . C op yi ♦ Torque wrench (5…50 Nm) - V.A.G 1331♦ Silicone sealant - D 176 404 A2♦ Flat scraper ♦ Hand drill with plastic brush attachment 1. Parts of lubrication system 101 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p – With the ignition switched off, disconnect earth straps of bat‐ teries. – Remove insulation tray: ⇒ General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview - noise insulation – Drain engine oil. Note Observe environmental regulations for disposal. r fo ng – On right side of engine carrier, now unscrew bracket for 4-pin connector and signal horn. – On left and right side, pull vacuum hose -1- out of engine mounting and unscrew securing nut -2- from engine mounting. – Position gearbox jack at bolted-on support and raise engine slightly. – Now remove engine carrier by loosening bolts equally in stages. – Unscrew both front securing bolts out of subframe, pull sub‐ frame downwards and wedge a block of wood, approx. 7cm thick, between subframe and longitudinal member. 102 Rep. gr.17 - Lubrication AG. – Remove anti-roll bar: ⇒ Running gear, axles, steering - front and four-wheel drive; Rep. gr. 40 ; Removing and installing subframe, lower suspension links and anti-roll bar . agen lksw Vo by – Fit support - T10151- in place of retainer -arrows-. Prote cted by c o p yri gh t. C op yi – Now unbolt retainer for cable guide. ht rig py Co t. – Pull 3-pin connector off oil level and oil temperature sender G266- . rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en Removing AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce un le ♦ Support - T10151- Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – First unscrew securing bolt -arrow- that is screwed through the intermediate plate from the gearbox side. Note Working space in vehicles with automatic gearboxes is restricted. Therefore, unscrew retainer for connectors and wiring. – Now unscrew sump. – Loosen sump with light blows of a rubber headed hammer if necessary. – Remove sealant residue from cylinder block with a flat scraper. WARNING When removing sealant residue, wear eye protection to pre‐ vent eye injuries. – Remove sealant residue on sump with a rotating Abrush, e.g. a G. Volkswagen AG d agen oes hand drill with a plastic brush. n lksw o yV d b free of oil and grease. – Clean sealing surfaces. They mustrisebe pe rm itte d Intermediate plate must be bolted firmly to cylinder block ⇒ Item 10 (page 31) . rrectness of i t to the co nform spec a t i h re o n in wit thi s Note es, in part or in w l purpos hole ercia , is n m ot com • tho au s s ility ab y li an pt ce Prerequisite un le Installing ot g ua ran tee or ac ♦ Observe expiry date of sealing compound. ♦ The oil sump must be installed within 5 minutes of applying silicone sealing compound. – Cut off tube nozzle at forward marking (∅ of nozzle approx. 3 mm). ♦ 2…3 mm thick. ♦ Run bead along inner side of bolt holes -arrows-. agen lksw Vo by Prote cted by c o py rig ht . C op yi The sealant bead must not be thicker, otherwise excess sealing compound will enter the oil sump and may block the oil suction line strainer. ht rig py Co t. Note do c um en r te o iva r rp fo g n – Apply silicone sealing compound, as shown, to clean sealing surface on sump. Sealing compound bead must be: 1. Parts of lubrication system 103 AG. Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 . Volkswage AG AG do to the clean – Apply silicone sealing compound bead as nshown agen es n ksw l ot g o V sealing surface of the ua by sump. d ise ran r – Install sump uimmediately and tighten all sump bolts lightly.tee o tho ra c sa – Tighten sump/intermediate plate securing bolt -arrow- to 45 Nm. ht rig py Co t. r fo ng Note c o p yri gh t. C op yi Let sealing compound dry for approx. 30 minutes after installing sump. Only then fill with engine oil. agen lksw Vo by Prote cted by Further assembly is basically the reverse of the dismantling se‐ quence. Checking oil pressure and oil pressure switch Checking oil pressure switch ⇒ page 106 . Checking oil pressure ⇒ page 107 . 104 AG. 1.6 Rep. gr.17 - Lubrication rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p un le ility ab y li an pt ce – Tighten oils sump bolts to 12 Nm. Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Special tools and workshop equipment required ♦ Oil pressure tester V.A.G 1342agen ♦ Adapter - V.A.G 1342/14lksw ♦ Voltage 1527B- do c um en ht rig py Co t. r te o iva r rp fo g n rrectness of i t to the co nform spec a t i h re o n in wit thi s es, in part or in w l purpos hole ercia , is n m ot com pe rm itte d un le ♦ Auxiliary measuring set V.A.G 1594C- AG. Volkswagen AG d oes not gu ara nte eo ra c ility ab y li an pt ce o yV db e tester - rV.A.G is ho ut a ss agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi Function of dynamic oil pressure warning indicator When not under pressure, the oil pressure switch is open and will close when the operating pressure is attained. The oil pressure warning will be activated approx. 10 seconds after switching the ignition on. Switch-in delay of oil pressure warning approx. 3 seconds. Switch-off delay of oil pressure warning approx. 5 seconds. Note Functional check and repair of the optical and acoustic oil pres‐ sure warning: ⇒ Current flow diagrams, Electrical fault finding and Fitting locations Checking warning lamp When ignition is switched on and engine is stopped, oil pressure warning lamp in dash panel insert must light up for approx. 3 sec‐ onds and then go out. The test will be terminated if the engine is running. 1. Parts of lubrication system 105 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Criteria for warning The visual oil pressure warning switches on (oil pressure warning lamp lights up continuously) and the acoustical warning buzzer sounds three times under any one of the following conditions. • “Ignition on”, engine not running, oil pressure switch closed • Engine revolutions above 1500 rpm, oil pressure switch open Note ♦ At an engine speed above 5000 rpm, the warning lamp will still remain on when the oil pressure switch is closed. The warning lamp will be switched off again if the engine revolutions are below 5000 rpm. ♦ If the oil pressure switch is only open for 0.3…3.0 seconds at an engine speed above 1500 rpm, this will be stored in the combination processor of the dash panel insert. If this condi‐ tion occurs three times while the engine is running, the oil pressure warning will be activated immediately and will not be cancelled even below 1500 rpm. The oil pressure warning will be cancelled when the oil pressure switch is closed for longer agen Arpm than 5 seconds at an engine speed above . Volksw1500 AG G do or when agen es n the ignition is switched off. ksw l ot o V Test gu ara nte eo ra c • Oil pressure warning lamp - K3- must light up for approx. 3 seconds when ignition is switched on • Engine oil temperature at least 80 °C (radiator fan must have run once) urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p un le Engine oil level OK, checking ⇒ page 98 . 1.6.1 Checking oil pressure switch – Remove oil pressure switch - F1- and screw it into oil pressure tester - V.A.G 1342- . – Screw oil pressure tester - V.A.G 1342- into oil filter bracket in place of oil pressure switch using adapter - V.A.G 1342/14- . Note – Connect brown wire of tester to earth (-). ht rig py Co t. r fo ng Observe installation position of adapter: the conical connecting piece of the adapter must be screwed into the pressure hose of the tester. c o p yri gh t. C op yi – Connect voltage tester - V.A.G 1527B- to battery positive (+) and oil pressure switch using cables from auxiliary measuring set - V.A.G 1594C- . LED must not light up. agen lksw Vo by AG. Prote cted by If the LED lights up: – Renew oil pressure switch - F1- ⇒ Item 8 (page 99) . If LED does not light up: – Start engine and run at idling speed. At 1.2…1.6 bar, the LED must light up; otherwise renew oil pressure switch - F1⇒ Item 8 (page 99) . 106 Rep. gr.17 - Lubrication rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en • ility ab y li an pt ce y db ise r prerequisites utho a ss Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 1.6.2 Checking oil pressure – Check oil pressure at different revolutions: ♦ 1,500 rpm: at least 1.7 bar ♦ 2000 rpm: 3.0…5.5 bar ♦ Over 2000 rpm: maximum 7.0 bar If the specifications are not attained: – Check strainer in suction line for dirt. AG. Volkswagen AG d oes not gu ara nte eo ra c n – Check pressure pipe between oil pump and cylinder wage block for olks V leaks. y db e ris ho – Rectify mechanical damage, e.g. bearing damage. ut sa pe rm itte d un le ility ab y li an pt ce s At higher engine speeds, the oil pressure must not exceed 7.0 bar. rrectness of i t to the co nform spec a t i h re o n in wit thi s – Check oil channels. es, in part or in w l purpos hole ercia , is n m ot com If the specification is exceeded: Pressure relief valve in oil pump may be stuck. do c um en ht rig py Co t. r te o iva r rp fo g n – Renew oil pump ⇒ page 100 , Dismantling and assembling oil pump. agen lksw Vo by 1. Parts of lubrication system 107 AG. Prote cted by c o p yri gh t . C op yi Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 19 – Cooling 1 Parts of cooling system WARNING Steam may escape when expansion tank is opened. Wear eye protection and protective clothing to avoid eye injuries and scalding. Cover cap with cloth and open carefully. Caution When doing any repair work, especially in the engine compart‐ ment, pay attention to the following due to the cramped condi‐ tions: ♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐ vated charcoal filter system, coolant, refrigerant, brake fluid and vacuum) and electrical wiring in their original po‐ sitions. ♦ Ensure that there is sufficient clearance to all moving or hot components. Note ♦ When the engine is warm, the cooling system is under pres‐ sure. If necessary, release pressure before beginning repair . Volkswagen AG work. gen AG d a lksw oes no o gu repair, y V with spring-type clips. In case tof ♦ Hoses are secured ar db ise only use spring-type clips. or th au pe rm itte d un le stallation of spring-type clips. ility ab y li an pt ce ♦ Spring-type clip pliers - VAS 5024A- are ss an tee or ac recommended for in‐ ♦ When installing coolant hoses, route stress-free so that they es, in part or in w l purpos hole ercia , is n m ot com Test for leaks in cooling system using cooling system tester V.A.G 1274- and adapters -V.A.G 1274/1A- and -V.A.G 1274/7- . Assembly overview - dismantling and assembling radiator ⇒ page 109 . Radiator ⇒ page 118 Removing and installing fans ⇒ page 110 . Parts of cooling system - body side ⇒ page 111 . Parts of cooling system - engine side ⇒ page 113 . Coolant hose schematic diagram ⇒ page 114 . Draining and filling with coolant ⇒ page 115 . do c um en r te o iva r rp fo g n Thermostat housing ⇒ page 112 Coolant mixture ratios ⇒ page 115 , draining and filling with cool‐ ant. agen lksw Vo by Prote cted by c o py rig ht . C op yi Rep. gr.19 - Cooling AG. 108 ht rig py Co t. Removing and installing coolant pump ⇒ page 119 . rrectness of i t to the co nform spec a t i h re o n in wit thi s do not come into contact with other components (observe markings on coolant connection and hose). Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 1.1 Assembly overview - radiator 1 - Lock carrier AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte 10 Nm ise r o eo h t u ra a Radiator c s s 2 - Condenser 3- ility ab y li an pt ce ❑ Removing and installing ⇒ page 118 ❑ After renewing, renew entire coolant. rrectness of i t to the co nform spec a t i h re o n in wit thi s es, in part or in w l purpos hole ercia , is n m ot com pe rm itte d un le 4- 5 - To oil cooler. ❑ For gear oil 6 - Radiator outlet coolant tem‐ perature sender - G83❑ Before removing, re‐ lease pressure in cool‐ ing system if necessary. 7 - Retaining clip ❑ Check for secure seat‐ ing. r te o iva r rp fo g n agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi 10 - Front coolant pipe, bottom ❑ With coolant pipe for gear oil cooler ht rig py Co t. 9 - Lower coolant hose ❑ Secured to radiator and thermostat housing with a retaining clip. ❑ Ensure secure seating do c um en 8 - O-ring ❑ Renew 11 - Rubber mounting 12 - Rubber bush 13 - To thermostat housing 14 - From thermostat housing 15 - Upper coolant hose ❑ Secured to radiator with retaining clip. ❑ Ensure secure seating ❑ With distributor piece for coolant hose from expansion tank 16 - From expansion tank 17 - 10 Nm 18 - Securing bolt 19 - 10 Nm ❑ Bolt for bonnet catch. 1. Parts of cooling system 109 Assembly overview - removing and installing fan 5 - Radiator fan - V76 - 10 Nm 7 - Radiator fan control unit 2 J6718 - Radiator fan 2 - V177- Prote cted by c o py rig ht . C op yi 110 Rep. gr.19 - Cooling thi sd o cu m en 9 - Bracket es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng 4 - 10 Nm AG. 3 - Radiator fan control unit J293- agen lksw Vo by 2 - 10 Nm rrectness of i t to the co nf o r m spec atio h re n in wit 1 - Fan support ility ab y li an pt ce 1.2 ht rig py Co t. Phaeton 2003 ➤ 6-cylinder injection engine - AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h Edition 02.2014 ut ra a c s s Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 1.3 Assembly overview - parts of cooling system, body side n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce 1 - Expansion tank ❑ Carry out leak test of cooling system with cooling system tester V.A.G 1274- and adapt‐ er -V.A.G 1274/7- . ❑ Depending on equip‐ ment, connection may be sealed with a blank‐ ing plug. 3 - 10 Nm 4 - Plug 5 - Coolant hose rrectness of i t to the co nform spec at i h re o n wit in t his 2 - Cap ❑ Check using cooling system tester V.A.G 1274- and adapt‐ er - V.A.G 1274/1A❑ Test pressure: 1.4…1.6 bar 6 - Cable guide ❑ For coolant hose and wiring harness AG. Prote cted by 10 - To upper coolant hose ❑ ⇒ Item 15 (page 109) agen lksw Vo by c o p yri gh t . C op yi 9 - To heat exchanger for aux‐ iliary heater ht rig py Co t. 8 - To heat exchanger for heat‐ er unit do c um en 7 - Y-piece ❑ Note installation posi‐ tion 11 - To heat exchanger for heater unit 12 - To thermostat housing 13 - Bracket 14 - Coolant pipe 15 - From cylinder head 16 - Spring-type clip 17 - From oil cooler ❑ For gear oil 18 - Protective tube 1. Parts of cooling system 111 pe rm itte d un le Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Note rrectness of i t to the co nform spec a t i h re o n in wit thi s Assembly overview - thermostat hous‐ ing es, in part or in w l purpos hole ercia , is n m ot com 1.4 ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s Routing of coolant hoses on thermostat housing ⇒ page 113 , parts of cooling system - engine side. 1 - O-ring ❑ Renew if damaged 3 - Thermostat housing Prote cted by 7 - Seal ❑ Renew 8 - Coolant temperature send‐ er - G62❑ With coolant tempera‐ ture display sender G2❑ For engine control unit. ❑ Before removing, re‐ lease pressure in cool‐ ing system if necessary. 9 - Plug ❑ Before removing, re‐ lease pressure in cooling system if necessary. 112 Rep. gr.19 - Cooling AG. 6 - Connection agen lksw Vo by c o p yri gh t. C op yi 5 - Thermostat ❑ Note installation posi‐ tion ❑ Checking: heat thermo‐ stat in water. ❑ Begins to open at ap‐ prox. 80°C ❑ Ends at approx. 105°C ❑ Opening lift at least 7 mm. ht rig py Co t. 4 - 8 Nm do c um en r te o iva r rp fo g n 2 - Retaining clip ❑ Check for secure seat‐ ing. Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Assembly overview - parts of cooling system, engine side 1 - To top of radiator ❑ Coolant hose schematic diagram ⇒ page 114 . 8 - Connection ❑ ⇒ Item 4 (page 99) 10 - Bracket 11 - Y-piece 12 - From continued coolant circulation pump - V51- . ❑ Installation location of pump ⇒ page 114 do c um en 9 - To heat exchanger for heat‐ er unit AG. 7 - To cylinder block agen lksw Vo by 6 - Thermostat housing Prote cted by c o py rig ht . C op yi 5 - Coolant pipe ❑ Between coolant pump and thermostat housing rrectness of i t to the co nform spec at i h re o n wit in t his 4 - Lower coolant hose ility ab y li an pt ce 3 - To upper coolant hose ❑ Secured to radiator with quick-release coupling. ❑ Ensure secure seating ❑ Coolant hose schematic diagram ⇒ page 114 . es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n 2 - From expansion tank AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ht rig py Co t. 1.5 13 - To continued coolant cir‐ culation pump - V51- . ❑ From lower coolant hose 14 - From alternator 15 - To alternator 16 - Plug, 3 Nm ❑ Draining and filling with coolant ⇒ page 115 . 17 - O-ring ❑ Renew 18 - From coolant pump 19 - 20 Nm ❑ To loosen and tighten, counterhold belt pulley with drift through bores 20 - Belt pulley ❑ For coolant pump. 21 - 8 Nm 22 - Coolant pump ❑ Check for ease of movement. ❑ Removing and installing ⇒ page 119 1. Parts of cooling system 113 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 23 - To front coolant pipe, bottom ❑ ⇒ Item 10 (page 109) Location of continued coolant circulation pump - V51Continued coolant circulation pump - V51- is located on left in engine bay, next to longitudinal member. 1 - Hose (pump outlet) to cylinder block ⇒ Item 12 (page 113) . Volkswage n AG d en AG for direction 2 - Non-return valve, observe ofoeflow. agarrow sn ksw y Vol pe rm itte d es, in part or in w l purpos hole ercia , is n m ot com Coolant hose schematic diagram rrectness of i t to the co nform spec a t i h re o n in wit thi s 1.6 a ss ot g ua ran tee or ac ility ab y li an pt ce un le b 3 - Hose (pump inlet) ed from lower coolant hose ris o ⇒ Item 13 (pageuth113) 1 - Radiator 2 - Oil cooler ❑ For gear oil 3 - Cylinder head 4 - Expansion tank 5 - Thermostat housing 7 - Coolant pump for auxiliary heater Prote cted by 11 - Cylinder block 12 - Alternator 13 - Coolant pump 114 Rep. gr.19 - Cooling AG. 10 - Non-return valve agen lksw Vo by c o p yri gh t . C op yi 9 - Continued coolant circula‐ tion pump - V51- ht rig py Co t. 8 - Oil cooler ❑ For engine oil. do c um en r te o iva r rp fo g n 6 - Heat exchanger for heater unit Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 1.7 Draining and filling coolant Special tools and workshop equipment required ♦ Refractometer - T10007 A♦ Drip tray - VAS 6208♦ Torque wrench - V.A.G 1331♦ Hose clip pliers - VAS 6499♦ Adapter - V.A.G 1274/7♦ Cooling system charge unit - VAS 6096- es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng rrectness of i t to the co nf o r m spec atio h re n in wit Draining ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s WARNING Steam may escape when expansion tank is opened. Wear eye protection and protective clothing to avoid eye injuries and scalding. Cover cap with cloth and open carefully. ht rig py Co t. – Remove insulation tray: ⇒ General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview - noise insulation thi sd o cu m en – Open cap on coolant expansion tank. 1. Parts of cooling system 115 agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Unscrew plug -arrow- from coolant pipe ⇒ Item 16 (page 113) . Note rrectness of i t to the co nform spec at i h re o n wit in t his es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce Follow disposal regulations for coolant! AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s – To drain coolant from engine, also remove coolant hose from oil cooler -arrow-. – Then pull off hose from lower coolant pipe ⇒ Item 10 (page 109) . agen lksw Vo by AG. Prote cted by c o py rig ht . C op yi Rep. gr.19 - Cooling do c um en 116 ht rig py Co t. Filling Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Note ♦ The water used in the coolant mixture has a great influence on its effectiveness. Because the water quality differs from country to country and even region to region, the quality of the water to be used has been defined. Distilled water fulfils all requirements. For this reason, we recommend using distilled water when mixing coolant for topping up or replacing coolant. ♦ Use only coolant additives which conform with the ⇒ Elec‐ tronic Parts Catalogue (ETKA) . Other coolant additives may reduce corrosion protection substantially. The resulting dam‐ age could lead to loss of coolant and subsequent severe damage to the engine. ♦ The correct coolant solution ratio helps prevent damage due to freezing and corrosion as well as scaling. Moreover, the boiling temperature is raised. Therefore, the cooling system must be filled all year round with coolant additive. ♦ Because of its higher boiling point, the coolant improves en‐ gine reliability under heavy loads, particularly in countries with tropical climates. ♦ ONLY refractometer - T10007A- may be used for determining current anti-freeze value. ♦ The normal frost protection must be for -25°C, in countries with arctic conditions to -36°C. When climatic conditions require a stronger frost protection, only then may the frost protection be increased. But only to -48°C. Otherwise, the cooling effect of the coolant will be impaired. ♦ 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. swagen AG. Volkswagen AG does k Vol by ♦ Read off anti-freeze figures for ed respective replenished anti- freeze. ♦ Do not reuse old coolant. rrectness of i t to the co nf o r m spec atio h re n in wit ♦ Use only a water/anti-freeze mixture as a slip agent for coolant hoses. Recommended mixture ratios: Note The quantity of coolant can vary depending upon vehicle equip‐ ment. Procedure 40 % 50 % c o p yri gh t . C op yi -25 °C -36 °C Coolant ad‐ Distilled wa‐ ditive ter 4.0 l 4.5 l 5.0 l 4.5 l – Install coolant hoses and secure. agen lksw Vo by – Screw adapter - V.A.G 1274/7- onto expansion tank. ht rig py Co t. Frost protection Anti-freeze to quantity thi sd o cu m en es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng refractometer - T10007A- equa‐ tes to the »ice flocculation point«. Ice crystals can start forming in the coolant below this temperature. ility ab y li an pt ce ♦ The temperature ris tho u s a the read soff not gu ara nte eo ra c 1. Parts of cooling system 117 AG. Prote cted by Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Fill coolant circuit using cooling system charge unit VAS 6096- ⇒ Operating instructions for cooling system charge unit VAS 6096 1.8 Removing and installing radiator Special tools and workshop equipment required ♦ Drip tray - V.A.G 1306- ♦ Torque wrench - V.A.G 1331- (5…50 Nm) rrectness of i t to the co nf o r m spec atio h re n in wit – Drain coolant ⇒ page 115 . es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng Removing ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s – Pull off upper coolant hose retaining clip and remove coolant hose from radiator. – Pull off lower coolant hose on radiator. – Remove front bumper ⇒ General body repairs, exterior; Rep. gr. 63 ; Assembly overview - front bumper – Bring lock carrier into service position ⇒ General body repairs, exterior; Rep. gr. 50 ; Lock carrier - service position . – Remove radiator fan with radiator fan mounting ⇒ page 110 . – Remove radiator upper securing pins and remove radiator to rear. – Install front bumper: ⇒ General body repairs, exterior; Rep. gr. 63 ; Assembly overview - front bumper 118 Rep. gr.19 - Cooling AG. – Electrical connections and routing ⇒ Current flow diagrams, Electrical fault finding and Fitting locations. agen lksw Vo by Prote cted by c o py rig ht . C op yi – Replenish coolant ⇒ page 115 . ht rig py Co t. Installation is carried out in the reverse order. When installing, note the following: thi sd o cu m en Installing Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Check headlight adjustment and correct if necessary ⇒ Main‐ tenance ; Booklet 16.1 . 1.9 Removing and installing coolant pump Special tools and workshop equipment required ♦ Drip tray - V.A.G 1306- ♦ Torque wrench - V.A.G 1331- (5…50 Nm) rrectness of i t to the co nform spec at i h re o n wit in t his – Remove front bumper ⇒ General body repairs, exterior; Rep. gr. 63 ; Assembly overview - front bumper – Bring lock carrier into service position ⇒ General body repairs, exterior; Rep. gr. 50 ; Lock carrier - service position . – Remove poly V-belt ⇒ page 28 . – Drain coolant ⇒ page 115 . – Unscrew coolant pump securing bolts and remove coolant pump. Installing Installation is carried out in the reverse order. When installing, note the following: – Moisten new O-ring with coolant. – Fit coolant pump. AG. Prote cted by – Fill with new coolant ⇒ page 115 . agen lksw Vo by c o p yri gh t. C op yi – Install poly V-belt ⇒ page 28 . ht rig py Co t. – Tighten securing bolts. Specified torque: 20 Nm do c um en es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n Removing ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s 1. Parts of cooling system 119 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 20 – Fuel supply system 1 Parts of fuel supply system Note ♦ Hose connections are secured with couplings or spring-type or clamp-type clips. ♦ Always renew crimp-type clips with spring-type clips. ♦ Fuel hoses on engine must be secured with spring-type clips only. The use of crimp-type or screw-type clips is not permis‐ sible. ♦ Spring-type clip pliers - VAS 5024A- or hose clip pliers - V.A.G 1921- are recommended for installation of spring-type clips. AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is Observe rules for cleanliness ⇒ page 128 . r o eo h ut ra a c s Assembly overview - fuel tank with attachments and fuel filter s Observe safety precautions ⇒ page 128 . es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce ⇒ page 120 . Removing and installing fuel tank with its attachments and fuel filter ⇒ page 137 . rrectness of i t to the co nform spec at i h re o n wit in t his Assembly overview - fuel delivery unit, fuel gauge sender and suction-jet pump on right ⇒ page 122 . Removing and installing fuel delivery unit, fuel gauge sender and suction-jet pump on right ⇒ page 131 . Assembly overview - fuel delivery unit, fuel gauge sender and suction-jet pump on left side ⇒ page 124 . Removing and installing fuel delivery unit, fuel gauge sender and suction-jet pump on left side ⇒ page 134 . Draining fuel tank ⇒ page 128 Schematic diagram of fuel lines and components in fuel tank ⇒ page 126 . Checking fuel pumps ⇒ page 139 AG. Rep. gr.20 - Fuel supply system agen lksw Vo by Prote cted by c o p yri gh t. C op yi 120 Assembly overview - fuel tank with attachments and fuel filter ht rig py Co t. 1.1 do c um en Parts of activated charcoal filter system ⇒ page 148 . Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 1 - Cap 2 - Securing bolt 3 - Tank flap unit ❑ With rubber cup 4 - Fuel filler neck 5 - Breather line ❑ Ensure secure seating 6 - Fuel tank ❑ When removing, sup‐ port using engine and gearbox jack V.A.G 1383 A- . ❑ Removing and installing ⇒ page 137 7 - Connecting hose ❑ From filler neck. 8 - Aperture for left sender ❑ Removing and installing ⇒ page 134 9 - Aperture for right sender ❑ Removing and installing ⇒ page 131 10 - Sender aperture for supply and return flange 11 - Heat shield ❑ For fuel tank un le ility ab y li an pt ce 12 - 20 Nm + 1/4 turn (90°) ther AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r eo fur‐ tho u ra a c s s rrectness of i t to the co nform spec a t i h re o n in wit thi s es, in part or in w l purpos hole ercia , is n m ot com 14 - Cross member ❑ For fuel tank pe rm itte d 13 - Securing strap ❑ Note installation position 15 - Securing clip ❑ Ensure secure seating 16 - Cover 17 - Screw-type clip 18 - To fuel rail 19 - Fuel filter 20 - From fuel rail r te o iva r rp fo g n agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi 23 - To connection on supply and return flange ❑ ⇒ Item 8 (page 123) ht rig py Co t. 22 - Supply line ❑ Black ❑ Ensure secure seating do c um en 21 - Return line ❑ Blue ❑ Ensure secure seating 1. Parts of fuel supply system 121 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 24 - To connection on supply and return flange ❑ ⇒ Item 6 (page 123) 25 - Expansion tank 26 - Breather valve 27 - 8 Nm + 1/4 turn (90°) further 28 - Pressure retention valve ❑ Checking ⇒ page 126 29 - Breather line ❑ Ensure secure seating 30 - To activated charcoal filter 31 - Breather line 32 - 8 Nm + 1/4 turn (90°) further . Volkswagen AG gen AG does not gu ara nte eo ra c Note r fo ng The fuel hoses between the right and left side of fuel tank are secured with cable binder. AG. Prote cted by Rep. gr.20 - Fuel supply system agen lksw Vo by c o p yri gh t . C op yi 122 rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p un le ility ab y li an pt ce Dismantling and assembling right side y Volkswa b ed fuel delivery unit, fuel gauge sender and ris o th au suction-jet pump ss ht rig py Co t. 1.2 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 1 - Fuel delivery unit ❑ Activated by the fuel pump relay - J17❑ Checking fuel pump ⇒ page 139 ❑ Removing and installing ⇒ page 131 2 - To Y-piece on supply line for left suction-jet pump ❑ ⇒ Item 11 (page 125) es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng ility ab y li an pt ce 3 - Supply line for suction-jet pumps AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s rrectness of i t to the co nf o r m spec atio h re n in wit 4 - Connector ❑ Coded connector to flange ⇒ Item 25 (page 124) . 5 - Fuel gauge sender 3 G237❑ Lever-type sender. ❑ Clipped onto support for fuel delivery unit. ❑ Checking ⇒ Current flow diagrams; Fault finding program; Check‐ ing fuel gauge sender . agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi 8 - Connection ❑ For fuel return line ⇒ Item 23 (page 121) . ❑ Arrow points towards connection. ht rig py Co t. 7 - Seal ❑ Renew thi sd o cu m en 6 - Connection ❑ Fuel supply line ⇒ Item 24 (page 122) . ❑ Arrow points away from connection. 9 - Supply and return flange 10 - Locking ring, 60 Nm ❑ Ensure secure seating ❑ Remove and install using wrench - 308711 - Connector ❑ For fuel pump. 12 - Connector ❑ Coded connector to flange ⇒ Item 25 (page 124) . 13 - Locking lug ❑ Clipped onto right of fuel delivery unit. 14 - Fuel gauge sender - G❑ Plunger-type sender. ❑ Checking: ⇒ Vehicle diagnostic tester. 1. Parts of fuel supply system 123 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 15 - Suction-jet pump 16 - Locking lug ❑ Clipped onto support for fuel delivery unit. n AG. Volkswagen A G do es n ot g ua ran tee or ac ge swa k Vol 17 - Supply line by d e ris ❑ Suction-jet pump, right side ho t au es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce 18 - Supply line ss ❑ Suction-jet pump, right side 19 - Return line rrectness of i t to the co nform spec at i h re o n wit in t his 20 - Supply line 21 - Non-return valve 22 - To return line of fuel delivery unit, left side ❑ ⇒ Item 20 (page 126) 23 - From supply line of fuel delivery unit, left side ❑ ⇒ Item 19 (page 126) 24 - Locking ring, 110 Nm ❑ Ensure secure seating ❑ Remove and install using wrench - 308725 - Flange ❑ Note installation position on fuel tank ⇒ page 126 agen lksw Vo by c o p yri gh t . C op yi Prote cted by 28 - From supply line for suction-jet pump on fuel delivery unit, right side ❑ ⇒ Item 10 (page 125) AG. 29 - Filler hose connection 1.3 Assembly overview - fuel delivery unit, fuel gauge sender and suction jet pump on left side Note The fuel hoses between the right and left side of fuel tank are secured with cable binder. 124 Rep. gr.20 - Fuel supply system ht rig py Co t. 27 - To fuel delivery unit on left side. ❑ Clipped onto right of fuel delivery unit. do c um en 26 - Seal ❑ Renew Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 1 - Fuel delivery unit ❑ Activated by the electric fuel pump2 relay - J492 - Connector ❑ For fuel pump. ❑ Coded connector to flange ⇒ Item 6 (page 125) . 3 - Locking ring, 110 Nm ❑ Ensure secure seating ❑ Remove and install us‐ AG. Volkswagen AG d agen oes ing wrench - 3087n lksw ot g ua ran tee or ac o yV 4 - Seal rised b tho ❑ auRenew ss un le 6 - Flange ❑ Note installation posi‐ tion on fuel tank ⇒ page 126 rrectness of i t to the co nform spec a t i h re o n in wit thi s 7 - Fuel gauge sender 2 G169❑ Plunger-type sender. ❑ Checking: ⇒ Vehicle di‐ agnostic tester. 8 - Locking lug ❑ Clipped onto left of fuel delivery unit r te o iva r rp fo g n do c um en 9 - Connector ❑ Coded connector to flange ⇒ Item 6 (page 125) . ht rig py Co t. es, in part or in w l purpos hole ercia , is n m ot com pe rm itte d ility ab y li an pt ce 5 - Supply line ❑ For auxiliary heater. c o p yri gh t . C op yi 10 - To supply line for suction-jet pump, right side ❑ ⇒ Item 28 (page 124) agen lksw Vo by Prote cted by 11 - From supply line for suction-jet pump on fuel delivery unit, right side ❑ ⇒ Item 2 (page 123) AG. 12 - Supply line ❑ Suction-jet pump, left side 13 - Locking lug ❑ Clipped onto support for fuel delivery unit. 14 - Suction-jet pump 15 - Supply line ❑ Suction-jet pump, left side 16 - Fuel gauge sender 4 - G393❑ Lever-type sender. ❑ Clipped onto support for fuel delivery unit. ❑ Checking: ⇒ Vehicle diagnostic tester. 17 - Connector ❑ Coded connector to flange ⇒ Item 6 (page 125) . 1. Parts of fuel supply system 125 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 18 - To fuel delivery unit on right side ❑ ⇒ Item 1 (page 123) ❑ Clipped onto upper left of fuel delivery unit. 19 - To supply line ❑ ⇒ Item 23 (page 124) 20 - From return line ❑ ⇒ Item 22 (page 124) 21 - Return line 22 - Supply line Installation position of fuel delivery unit flange Insert sender flange with marking -arrow- in direction of travel. AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte s i r Checking pressure retention valve on expansion tank.ho eo ut ra a c s The pressure retention valve is open from breathers valve (on ex‐ es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng ility ab y li an pt ce pansion tank) for flow in both directions (-arrow 1-, side to expan‐ sion tank). 1.4 rrectness of i t to the co nf o r m spec atio h re n in wit On the other side, flow is possible in only direction -arrow 2- (side to activated charcoal filter). Schematic diagram of fuel lines and components in fuel tank Note AG. Rep. gr.20 - Fuel supply system agen lksw Vo by 126 Prote cted by c o py rig ht . C op yi -B- Right side of tank ht rig py Co t. -A- left side of fuel tank thi sd o cu m en The fuel hoses between the right and left side of fuel tank are secured with cable binder. 4 - Suction-jet pump ❑ Right side 5 - Fuel delivery unit ❑ Right side 6 - Connecting hose ❑ From filler neck. 7 - Y-piece 8 - Non-return valve 9 - Y-piece rrectness of i t to the co nform spec at i h re o n wit in t his 3 - Return line es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n 2 - Supply line ility ab y li an pt ce 1 - Supply and return flange ❑ With connections for quick-release couplings AG. Volkswagen AG d Phaeton 2003 ➤ agen oes ksw not l o V 6-cylinder injection engine Edition 02.2014 g y u ara db nte ise r eo tho u ra a c s s agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi 12 - Fuel delivery unit ❑ Left side ht rig py Co t. 11 - Flange ❑ Left side do c um en 10 - Supply line for auxiliary heater 13 - Suction-jet pump ❑ Left side 14 - Supply line ❑ To fuel delivery unit on right side 15 - Y-piece 16 - Supply line for suction-jet pumps 17 - Supply line ❑ To fuel delivery unit on left side. 1. Parts of fuel supply system 127 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 1.5 Safety precautions when working on fuel supply system Caution When doing any repair work, especially in the engine compart‐ ment, pay attention to the following due to the cramped condi‐ tions: ♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐ vated charcoal filter system, coolant, refrigerant, brake fluid and vacuum) and electrical wiring in their original po‐ sitions. ♦ Ensure that there is sufficient clearance to all moving or hot components. eo ra c th au ss urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p When removing and installing fuel gauge sender or fuel pump (fuel delivery unit) from a full or partly full fuel tank, observe the following: ♦ Before beginning work, place an extraction hose close to sender opening in fuel tank to extract escaping fuel fumes and switch on exhaust extraction system. If no exhaust gas ex‐ traction system is available, a radial fan with a displacement greater than 15 m3/h can be used providing that motor is not in air flow. ♦ Prevent skin contact with fuel! Wear fuel-resistant gloves! 1.6 Rules for cleanliness ♦ Thoroughly clean all unions and surrounding areas before dis‐ connecting. Prote cted by c o py rig ht . C op yi ♦ Place removed parts on a clean surface and cover. Use only lint-free cloths. agen lksw Vo by AG. ♦ Carefully cover opened components or seal if repairs cannot be carried out immediately. ♦ Install clean components only. Do not remove replacement parts from packing until immediately before installing. Do not use parts that have not been stored in their packing (e.g. in tool boxes etc.). ♦ When system is open: do not work with compressed air if this can be avoided. Do not move vehicle unless absolutely nec‐ essary. 1.7 Emptying fuel tank Special tools and workshop equipment required 128 Rep. gr.20 - Fuel supply system ht rig py Co t. r fo ng When working on the fuel supply and injection system, observe the following “5 rules” for cleanliness: rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en ♦ For safety reasons, fuel pump relays -1- (right) and -2- (left) have to be removed from the fuse box before the fuel system is opened because the fuel pump can be activated when the driver door is opened. ility ab y li an pt ce un le ♦ Fuel supply lines are under pressure! Before swagen AG . Volkloosening gen AGwrap a cloth does a hose connections and separating points, w ks not l o V gu around the connection. Then pressure by carefully yrelease b ara d e nte opening the fuel line. oris Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 ♦ Fuel extractor - VAS 5190- ♦ Wrench - 3087- WARNING Fuel system is under pressure! Wear eye protection and pro‐ tective clothing to avoid possible injury and skin contact. Before loosening hose connections, wrap a cloth around the connec‐ tion. Then release pressure by carefully pulling hose off con‐ nection. Procedure – Note safety precautions before beginning work ⇒ page 128 . – Open fuel tank filler flap. When no more fuel can be extracted do c um en – Push suction hose -arrow- of fuel extractor - VAS 5190- about 160…170 cm into fuel filler neck and extract fuel. rrectness of i t to the co nform spec at i h re o n wit in t his es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss ht rig py Co t. – Unclip both covers for sender flanges in luggage compartment floor. 1. Parts of fuel supply system 129 agen lksw Vo by AG. Prote cted by c o p yri gh t . C op yi Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Pull connector -arrows- off right sender flange. rrectness of i t to the co nform spec at i h re o n wit in t his es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s – Pull connector and supply hose -arrows- off left sender flange. – Hold cloth around fuel hose for auxiliary heater on left sender flange and pull off fuel hose. – Carefully lever out flange and raise it slightly. For further work on inside of fuel tank, flanges may remain re‐ moved. If fuel tank needed only to be emptied, install flanges again. – First check that flange seals are properly seated. Note Always renew seals if the fuel has caused them to swell. 130 Rep. gr.20 - Fuel supply system AG. – When breather lines are pulled off, buttons of hose couplings sometimes cannot be pressed in. Use assembly tool - T10118-arrow- to press in button. agen lksw Vo by Prote cted by c o p yri gh t. C op yi – For work on left side of fuel tank, proceed as described above. ht rig py Co t. – Insert suction hose of fuel extractor - VAS 5190- as deeply as possible into right and then left side of fuel tank and extract fuel. do c um en – Now remove locking ring from flange using wrench - 3087- . Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Insert flange with locating tab facing forwards -arrow-. urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p Removing and installing fuel delivery unit, fuel gauge sender and suction-jet pump, right side Special tools and workshop equipment required agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi Test prerequisites • Fuel tank must be drained ⇒ page 128 , Draining fuel tank. • Connectors and wires for left and right-hand sender flanges have been removed. • Locking rings for left and right sender flanges have been re‐ moved. • Fuel pump relays have been removed from fuse box. ht rig py Co t. r fo ng ♦ Wrench - 3087- rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 1.8 AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s ility ab y li an pt ce un le – Tighten locking rings on left and right to specified torque. Note The fuel hoses between the right and left side of fuel tank are secured with cable binder. Procedure – Note safety precautions before starting work ⇒ page 128 . 1. Parts of fuel supply system 131 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Pull off three connectors -arrows- underneath right sender flange. es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s rrectness of i t to the co nf o r m spec atio h re n in wit – On right side -B-, unclip plunger-type sender -3- from fuel de‐ livery unit -1- -arrows- and carefully pull it out. – Now pull black filler hose out of hole -4- in fuel delivery unit housing -1-. – On right side, -B-, unclip return hose of left-hand suction-jet pump -2- out of fuel delivery unit -1- -arrows-. AG. Rep. gr.20 - Fuel supply system agen lksw Vo by Prote cted by c o p yri gh t. C op yi 132 ht rig py Co t. – Pull off three connectors -arrows- underneath left sender flange. thi sd o cu m en – Pull off return line -1- and supply line -2- on right side. Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Pull supply hose -1- on left side off Y-piece -2- and pull it out of right sender hole. – Push both retaining clips -1- from right fuel delivery unit -B- to side slightly and carefully remove fuel delivery unit. Note The fuel delivery unit housing is filled with fuel. Fuel may run out if housing is tipped or canted. – Now unclip black return hose -2- from fuel delivery unit housing -1- on left side -A- -arrows- rrectness of i t to the co nform spec at i h re o n wit in t his es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s do c um en 1. Parts of fuel supply system 133 ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Pull supply hose -3- off Y-piece -2-. Then pull out both hoses of suction-jet pump through right-hand sender opening. – Now unclip suction-jet pump -3- on right side -B- and remove by turning slightly. – Now unclip fuel gauge sender -2- and it pull out. es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n 1.9 ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s rrectness of i t to the co nform spec at i h re o n wit in t his Removing and installing fuel delivery unit, fuel gauge sender and suction-jet pump, left side Special tools and workshop equipment required Connectors and wires for left and right-hand sender flanges have been removed. • Locking rings for left and right sender flanges have been re‐ moved. • Fuel pump relays have been removed from fuse box. 134 Rep. gr.20 - Fuel supply system Prote cted by • AG. Fuel tank must be drained ⇒ page 128 , Draining fuel tank. agen lksw Vo by c o p yri gh t. C op yi • do c um en Test prerequisites ht rig py Co t. ♦ Wrench - 3087- Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Note The fuel hoses between the right and left side of fuel tank are secured with cable binder. Procedure – Note safety precautions before beginning work ⇒ page 128 . – Pull off three connectors -arrows- underneath left sender flange. – On left side -A-, unclip plunger-type sender -3- from fuel de‐ livery unit -1- -arrows- and carefully pull it out. – On left side, -A-, unclip return hose of right suction-jet pump -2- out of fuel delivery unit -1-. rrectness of i t to the co nform spec at i h re o n wit in t his es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s – Pull off three connectors -arrows- underneath right sender flange. do c um en ht rig py Co t. agen lksw Vo by 1. Parts of fuel supply system 135 AG. Prote cted by c o py rig ht . C op yi un le – Pull both hose ends out through left sender hole. The fuel delivery unit housing is filled with fuel. Fuel may run out if housing is tipped or canted. agen lksw Vo by AG. Prote cted by c o py rig ht . C op yi – Now unclip black return hose -2- from fuel delivery unit housing -1- on right side -B- -arrows– Now pull black filler hose of suction-jet pump out through left sender hole. 136 Rep. gr.20 - Fuel supply system ht rig py Co t. Note r fo ng – Push both retaining clips -1- from right fuel delivery unit -A- to side slightly and carefully remove fuel delivery unit with sender flange attached. rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p – Pull off return line -3- and supply line -4- on right side. ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h Phaeton 2003ut➤ ra a c s 6-cylinder injection engine - Edition 02.2014 s Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Now unclip suction-jet pump -3- on left side -A- and remove by turning slightly. olkswout. agen AG – Now unclip fuel gauge sender -2-geand n AG.itVpull Note does not gu ara nte eo ra c rrectness of i t to the co nf o r m spec atio h re n in wit 1.10 es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng Only two fuel lines (supply ⇒ Item 19 (page 124) and return ⇒ Item 20 (page 124) ) can be seen through the right sender hole. These can only be removed via the supply and return flange ⇒ Item 9 (page 123) with fuel tank removed. ility ab y li an pt ce ss a ksw Vol by d e ris ho t au Removing and installing fuel tank with attachments and fuel filter ♦ Fuel extractor - VAS 5190- AG. ♦ Engine and gearbox jack V.A.G 1383 A- agen lksw Vo by Prote cted by c o p yri gh t. C op yi ♦ Torque wrench V.A.G 1332- ht rig py Co t. ♦ Torque wrench V.A.G 1331- thi sd o cu m en Special tools and workshop equipment required ♦ Wrench - 3087- 1. Parts of fuel supply system 137 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Test prerequisites • Fuel tank must be drained ⇒ page 128 , Draining fuel tank. • Fuel pump relays -1- and -2- must be removed from their sockets. Removing – Note safety precautions before beginning work ⇒ page 128 . – Remove rear bumper: ⇒ General body repairs, exterior; Rep. gr. 63 ; Removing and installing rear bumper – Remove rear right wheel housing liner: ⇒ General body re‐ pairs, exterior; Rep. gr. 66 ; Removing and installing wheel housing liner – Remove centre and rear silencers ⇒ page 172 olksw agendrives; AG. V – Remove propshaft ⇒ Transfer box and final AG do Rep. gr. agen es n ksw propshaft . l 39 ; Removing and installing ot g o V by ed ua ra nte ris⇒ Running gear; Rep. gr. 42 ; Removing – Remove rear axle eo ho t u ra and installing arear axle . c – Disconnect breather line -1-. – Remove securing bolt -3- for breather tank -2- and pull it out of mounting in inner wheel housing -arrows-. – Unclip both covers for sender flanges in luggage compartment floor. – Pull connector -arrows- off right sender flange. agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi Rep. gr.20 - Fuel supply system ht rig py Co t. 138 rrectness of i t to the co nf o r m spec atio h re n in wit – Remove filler neck securing bolts ⇒ Item 32 (page 122) . thi sd o cu m en es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng – Unscrew securing bolt and remove tank flap unit with rubber cup. ility ab y li an pt ce ss – Open fuel tank filler flap. Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Pull connectors and supply hose -arrows- off left-hand sender flange. When doing this, hold a rag over the supply hose. – Hold cloth around fuel line connectors -1- and -2- and pull them apart. . Volkswage n AG wage olks V by ed ris o th au ss n AG d oes not gu ara nte eo ra c rrectness of i t to the co nf o r m spec atio h re n in wit es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng ility ab y li an pt ce – Then separate connector -3- of breather line. – Now unscrew cross member -1-. agen lksw Vo by c o p yri gh t . C op yi Installing ht rig py Co t. – Lower fuel tank. thi sd o cu m en – Support fuel tank with engine and gearbox jack - V.A.G 1383 A- and loosen securing straps -2-. Installation is carried out in the reverse order. When installing, note the following: AG. Prote cted by ♦ Connections for breather and fuel lines must engage audibly when joined. ♦ Do not interchange supply and return hose (return hose blue or blue markings, supply hose black). ♦ Install breather and fuel hoses free of kinks. ♦ Secure fuel hoses with spring-type clips. ♦ Ensure that fuel hose connections are tight. Note Before raising fuel tank, check that the supply, return and breather lines are still clipped onto the fuel tank. 1.11 Checking fuel pumps Checking delivery rate of both fuel pumps ⇒ page 141 Checking delivery rate of right pump ⇒ page 143 Checking delivery rate of left pump ⇒ page 144 Checking current draw of pumps ⇒ page 144 . Checking non-return valves of fuel pump ⇒ page 145 . Checking non-return valve of right pump ⇒ page 146 1. Parts of fuel supply system 139 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Checking non-return valve of left pump ⇒ page 147 Special tools and workshop equipment required ♦ Pressure gauge V.A.G 1318♦ Adapter - V.A.G 1318/11♦ Adapter - V.A.G 1318/16♦ Adapter - V.A.G 1318/17♦ Adapter - V.A.G 1318/23- AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s r fo ng agen lksw Vo by AG. Prote cted by c o py rig ht . C op yi Rep. gr.20 - Fuel supply system ht rig py Co t. 140 rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p ility ab y li an pt ce un le ♦ Spring-type clip pliers VAS 5024A- Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Special tools and workshop equipment required ♦ Torque wrench V.A.G 1332- pe rm itte d agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi 1.11.1 do c um en r te o iva r rp fo g n ♦ Current flow diagram rrectness of i t to the co nform spec a t i h re o n in wit thi s ♦ Measuring container es, in part or in w l purpos hole ercia , is n m ot com ♦ Multimeter - V.A.G 1715- ility ab y li an pt ce ♦ Auxiliary measuring set V.A.G 1594C- un le ♦ Voltage tester - V.A.G 1527B- AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ht rig py Co t. ♦ Remote control V.A.G 1348/3A- with adapt‐ er cable - V.A.G 1348/3-3- Checking delivery rate of both fuel pumps Test prerequisites • Voltage supply for both batteries OK. • Fuel pump relays -1- and -2- must be removed from their sockets. Test procedure – Remove filler cap from fuel tank filler neck. – Remove intake hose between air mass meter - G70- and throttle valve module - J338- ⇒ page 158 . WARNING Fuel supply lines are under pressure! Wear eye protection and gloves to avoid injuries and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection. 1. Parts of fuel supply system 141 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Pull off supply hose -1- from supply line -2- and collect fuel that leaks out with a cloth. Note ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n Push in button on hose coupling to do this. AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s – Connect pressure gauge - V.A.G 1318- with adapter V.A.G 1318/23- and -V.A.G 1318/17- to fuel supply line. – Push hose -V.A.G 1318/16- onto adapter -V.A.G 1318/11- of pressure gauge and hold hose in a measuring container. – Open pressure tester shut-off tap. The lever then points in the direction of flow. Prote cted by – The delivery rate of the fuel pumps depends on the battery voltage. Therefore connect the multimeter with auxiliary ca‐ bles from auxiliary measuring set - V.A.G 1594C- to the left vehicle battery. – Operate remote control for 30 seconds while measuring bat‐ tery voltage. 142 Rep. gr.20 - Fuel supply system AG. – Empty measuring container. agen lksw Vo by c o p yri gh t. C op yi – Operate remote control - V.A.G 1348/3A- . Then slowly close shut-off tap until a pressure of 4 bar is displayed on pressure gauge. From this point on do not move position of shut-off tap. ht rig py Co t. – Connect positive terminal -1- of remote control to positive pole in engine compartment. do c um en – Connect remote control - V.A.G 1348/3 A- using adapter V.A.G 1348/3-3- to connections of fuel pump relay -2- and -3-. Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Compare quantity of fuel delivered with specification. 7) Delivery rate cm3/30 seconds . Volkswagen AG gen AG does swa k not l o 8) Voltage at fuel pumps with engine not running and pump running (approx. V2 gu y ara db volts less than battery voltage). e nte is r o eo h ut ra Example: a c s s rrectness of i t to the co nform spec a t i h re o n in wit thi s es, in part or in w l purpos hole ercia , is n m ot com pe rm itte d un le ility ab y li an pt ce During the test a voltage of 13.0 volts is measured at the battery. As the voltage at the pumps is approx. 2 volts less than the battery voltage, this will equate to a minimum delivery rate of 1,200 cm3/30 s. If delivery rate has been attained, but nevertheless you suspect a fuel supply system fault (e.g. intermittent failure of fuel supply system): – Check current draw of fuel pumps ⇒ page 144 . If the minimum delivery rate is not attained: – Check fuel lines for possible restrictions (kinks) or blockages. – Pull supply line -1- off inlet to fuel filter. Press buttons on hose couplings to do this. AG. – Renew fuel filter. agen lksw Vo by If the minimum delivery rate is now attained: Prote cted by c o p yri gh t. C op yi – Repeat delivery rate check. ht rig py Co t. – Connect pressure gauge - V.A.G 1318- with adapter set V.A.G 1318/17- to hose. do c um en r te o iva r rp fo g n Note If the minimum delivery rate is still not reached: ⇒ page 143 1.11.2 Checking delivery quantity of right pump – Disable activation of left pump: – To do this, pull connector -2- for remote control out of relay socket for left pump. – Empty measuring container. – Operate remote control for 30 seconds while measuring bat‐ tery voltage. 1. Parts of fuel supply system 143 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Volkswagen AG does k not l o V gu y ara db 9) Delivery rate cm3/30 seconds e nte is r o eo h t running and pump running (approx. 2 10) Voltage at fuel pumps with engineaunot ra c s volts less than battery voltage). s – Remove fuel delivery unit and check for dirt in filter strainer. Only if still no fault has been detected: – Right fuel pump is defective. Renew fuel delivery unit ⇒ page 131 . If the minimum delivery rate is not reached: ⇒ page 144 1.11.3 Checking delivery quantity of left pump – Reconnect remote control connector -2-. – Disable activation of right pump: – To do this, pull connector -1- for remote control out of relay socket for right pump. – Empty measuring container. agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi – Compare quantity of fuel delivered with specification. 11) Delivery rate cm3/30 seconds 12) Voltage at fuel pumps with engine not running and pump running (approx. 2 volts less than battery voltage). If the minimum delivery rate is again not attained – Remove fuel delivery unit and check for dirt in filter strainer. Only if still no fault has been detected: – Left fuel pump defective; renew fuel delivery unit ⇒ page 134 . 1.11.4 Checking current draw of pumps – Check current draw of each fuel pump separately as follows: – Install intake hose between air mass meter - G70- and throttle valve module - J338- . – Reconnect all disconnected fuel lines. 144 Rep. gr.20 - Fuel supply system ht rig py Co t. r fo ng – Operate remote control for 30 seconds while measuring bat‐ tery voltage. rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p If the minimum delivery rate is again not attained ility ab y li an pt ce un le n AG. – Compare quantity of fuel delivered withsspecification. wage Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Connect multimeter - V.A.G 1715- pick-up clamp to wire for contact -1- -arrow- of 4-pin connector of wiring harness to right fuel delivery unit. – Start engine and run at idling speed. – Measure current draw of fuel pump. Specification: max. 11 amps. – Repeat test on left fuel delivery unit. Note The left fuel pump will be switched off at idle a few seconds after the engine has been started. If current draw is exceeded: – Right fuel pump is defective. Renew fuel delivery unit ⇒ page 131 . – Left fuel pump defective; renew fuel delivery unit ⇒ page 134 . Note If the fuel system malfunction is intermittent, you can perform the check during a road test, but a 2nd person is necessary. 1.11.5 Checking fuel pump non-return valves AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d Remote control - V.A.G 1348/3Ante ise is still connected. r o eo h t u ra The pressure tester - V.A.G a 1318- is still connected. c s s Test prerequisites rrectness of i t to the co nform spec a t i h re o n in wit thi s Note un le ility ab y li an pt ce Test procedure pe rm itte d • es, in part or in w l purpos hole ercia , is n m ot com • do c um en ht rig py Co t. r te o iva r rp fo g n At the same time, this test checks for leaks in the fuel supply line connections from the fuel delivery unit to the point at which the pressure tester - V.A.G 1318- is connected. 1. Parts of fuel supply system 145 agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Close shut-off valve of pressure gauge - V.A.G 1318-arrow- (lever perpendicular to direction of flow). – Operate remote control at short intervals until a pressure of approx. 4 bar has built up. – If pressure builds up too high, relieve excess pressure by carefully opening shut-off tap. WARNING Danger of spray when opening shut-off tap. Hold container over free connection of pressure tester. – Watch pressure drop on pressure gauge. After 10 minutes, pressure must not drop below 3.0 bar. If the pressure drops further: – Check fuel lines and connections to fuel tank for leaks. If no fault in lines is detected: ⇒ page 146 1.11.6 Checking non-return valve of right pump – Separate supply line on right side -2-. rrectness of i t to the co nf o r m spec atio h re n in wit es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng ility ab y li an pt ce n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss – Connect pressure gauge - V.A.G 1318- (lever perpendicular to direction of flow) with adapter -V.A.G 1318/23- and V.A.G 1318/17- on hose -1- to pump. – Disable activation of left pump: ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t . C op yi Rep. gr.20 - Fuel supply system thi sd o cu m en 146 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – To do this, pull connector -2- for remote control out of relay socket for left pump. – Repeat check. If the pressure drops further: agendelivery G. Volksw A – Right fuel pump is defective. Renew fuel AG do unit agen es n ksw l ⇒ page 131 . ot g o V by ed ua ran tee urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p or ac Checking non-return valve of left pump – Reconnect supply line on right side -2-. – On right side, separate supply line -4- to left pump. ht rig py Co t. r fo ng – Connect pressure gauge - V.A.G 1318- (lever perpendicular to direction of flow) with adapter -V.A.G 1318/23- and V.A.G 1318/17- on hose -1- to pump. rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 1.11.7 t au ss ility ab y li an pt ce un le is rfurther: If pressure drops ⇒ page 147 ho agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi – Reconnect remote control connector -2-. – Disable activation of right fuel pump. – To do this, pull connector -1- for remote control out of relay socket for right pump. – Repeat check. If the pressure drops further: – Left fuel pump defective; renew fuel delivery unit ⇒ page 134 . 1. Parts of fuel supply system 147 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 2 Activated charcoal filter system Function Depending upon the air pressure and ambient temperature, fuel vapour will form above the level of fuel in the tank. Volkswa gen AG . gen AG The activated charcoal filter system these HC emissions does waprevents not olks V escaping to the atmosphere. gu by a d r un le When the car is being driven and the Lambda control is active (engine warm), the activated charcoal filter system solenoid valve 1 - N80- is activated (pulsed) by the engine control unit depending on load and engine speed. The opening period depends on the input signals. During the purging procedure (regeneration of activated char‐ coal), the intake manifold vacuum draws fresh air through the vent of the activated charcoal filter. The fuel vapours stored in the ac‐ tivated charcoal and fresh air are fed to combustion in metered quantities. The activated charcoal filter solenoid valve 1 - N80- is closed when it is not supplied with current (e.g. open circuit). The acti‐ vated charcoal filter will not be purged. Note ♦ Hose connections are secured with either spring-type or ♦ Always renew crimp-type clips with spring-type clips. c o p yri gh t . C op yi ♦ Spring-type clip pliers - VAS 5024A- or hose clip pliers - agen lksw Vo by V.A.G 1921- are recommended for installation of spring-type clips. ht rig py Co t. r fo ng clamp-type clips. rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p The activated charcoal stores these vapours like a sponge. ility ab y li an pt ce an e tee ris Fuel vapours pass from hothe highest point in the tank (on filler neck) t or u ac a through the expansion tank and into the activated charcoal filter. ss AG. Prote cted by Assembly overview - parts of activated charcoal filter system ⇒ page 148 Observe safety precautions ⇒ page 128 . Observe rules for cleanliness ⇒ page 128 . 2.1 148 Assembly overview - parts of activated charcoal filter system Rep. gr.20 - Fuel supply system Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 1 - Activated charcoal filter ❑ In spare wheel well on vehicle floor. 2 - 9 Nm 3 - Breather line 4 - Activated charcoal filter sol‐ n AG. Volkswagen A G do es n wage enoid valve 1 - N80o olks t gu ara nte eo ra c V by 5 - To connection rised ho ut ❑ On intake amanifold. ss es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce 6 - Connecting hose rrectness of i t to the co nform spec at i h re o n wit in t his 7 - Connector ❑ For breather line. ❑ On front right wheel housing 8 - Connector ❑ For breather line. ❑ Next to fuel filter 9 - Connector ❑ In area of rear axle 10 - Breather line ❑ To pressure retention valve on expansion tank ⇒ Item 28 (page 122) do c um en 2. Activated charcoal filter system 149 ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t . C op yi Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 2.2 Checking activated charcoal filter system for leaks Special tools and workshop equipment required ♦ Vacuum tester V.A.G 1368♦ Hand vacuum pump V.A.G 1390♦ Adapter set - V.A.G 1318/17- agen lksw Vo by c o p yri gh t. C op yi Prote cted by Rep. gr.20 - Fuel supply system AG. 150 ht rig py Co t. – Pull breather hose -1- (to solenoid valve) off breather line -2(from activated charcoal filter). thi sd o cu m en Test procedure rrectness of i t to the co nf o r m spec atio h re n in wit es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Connect vacuum tester - V.A.G 1368- at connection -A- to breather line of activated charcoal filter using adapters V.A.G 1318/12- , -V.A.G 1318/13- and -V.A.G 1318/17- . – Connect hand vacuum pump - V.A.G 1390- to connection -B-. – Set vacuum tester to position “A/B”. – Operate hand vacuum pump - V.A.G 1390- several times. Vacuum must not build up. n AG. Volkswagen A G do e agfault es n wa If no vacuum builds up, but nevertheless in the activated ot g olks V y ua charcoal filter system is suspected b d r e ris ho t au rrectness of i t to the co nform spec a t i h re o n in wit thi s un le pe rm itte d es, in part or in w l purpos hole ercia , is n m ot com – Connect adapter - V.A.G 1318/17- to line leading to solenoid valve and seal it. ility ab y li an pt ce ss -1- (to solenoid valve in engine com‐ – Disconnect breather line partment) on activated charcoal filter. an tee or ac – Operate hand vacuum pump - V.A.G 1390- several times. A vacuum must build up. If vacuum does not build up: – Check breather lines and couplings for interruptions or sepa‐ rated couplings ⇒ page 148 . If vacuum builds up, the breather lines are OK. If there is still rea‐ son to believe that there is a fault in the activated charcoal system – Check breather line to wheel housing. – Check pressure retention valve ⇒ page 126 . – Disconnect breather line -3- (to solenoid valve in engine com‐ partment) on fuel filter. AG. – Check breather line for blockage. agen lksw Vo by Prote cted by c o py rig ht . C op yi If vacuum builds up: ht rig py Co t. – Operate hand vacuum pump - V.A.G 1390- several times. Vacuum must not build up. do c um en r te o iva r rp fo g n If vacuum builds up: If vacuum does not build up: – Reconnect breather line on fuel filter. – Disconnect breather line -1- (to solenoid valve in engine com‐ partment) on activated charcoal filter. – Operate hand vacuum pump - V.A.G 1390- several times. Vacuum must not build up. If vacuum builds up: – Check breather line for blockage. If vacuum does not build up: 2. Activated charcoal filter system 151 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Reconnect breather line -1- (to solenoid valve in engine com‐ partment) on activated charcoal filter. – Separate breather line -2- (to expansion tank in wheel hous‐ ing) at activated charcoal filter. – Connect adapter - V.A.G 1318/17- to line from activated char‐ coal filter and seal it. – Operate hand vacuum pump - V.A.G 1390- several times. Vacuum must not build up. If vacuum builds up: – Check breather -arrow- on activated charcoal filter -1- for dam‐ age or soiling. If no damage or soiling can be detected – Renew activated charcoal filter. ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi Rep. gr.20 - Fuel supply system thi sd o cu m en 152 rrectness of i t to the co nf o r m spec atio h re n in wit es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 3 Checking electronic power control (EPC) 1 - Mounting bracket ❑ Removing and instal‐ ling: ⇒ Brake systems; Rep. gr. 46 ; Assembly overview - brake pedal (LHD) . 2 - Connector ❑ Black, 6-pin. 3 - 10 Nm 4 - Accelerator position sender - G79- and accelerator position sender 2 - G185❑ Not adjustable. ❑ Remove footwell cover to remove sender. rrectness of i t to the co nf o r m spec atio h re n in wit es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s Function of EPC system With the EPC system, the throttle valve is not operated by a cable from the accelerator There is no mechanical connection between the accelerator and the throttle valve. Prote cted by c o py rig ht . C op yi The throttle valve is operated over the complete engine speed and load range by an electric motor (throttle valve positioner) in the throttle valve module. ht rig py Co t. The position of the accelerator (driver's requirement) is a main input value for the engine control unit. thi sd o cu m en The position of the accelerator is transmitted to the engine control unit by two accelerator position senders (variable resistors to‐ gether in one housing) connected to the accelerator. agen lksw Vo by AG. The throttle valve is operated by the throttle valve positioner which is controlled by the engine control unit. When the engine is not running and the ignition is switched on, the engine control unit moves the throttle valve exactly as pre‐ scribed by the accelerator position sender. That is, when the accelerator is depressed halfway, the throttle valve positioner 3. Checking electronic power control (EPC) 153 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 opens the throttle valve by the same amount. The throttle is then approximately half open. When the engine is running (under load), the engine control unit can open or close the throttle valve independently of the accel‐ erator position sender. This means that the throttle valve can already be completely open even though the accelerator is depressed half way. This has the advantage of preventing throttling losses at the throttle valve. This also results in significantly improved consumption and ex‐ haust emission values under certain load conditions. The torque required by the engine can be produced by the engine control unit by optimising the combination of throttle valve crosssection and charge pressure. After evaluating the torque requirements of various components n AG. Volkswagen AG do es n wageand s (e.g. air conditioning system, automatic gearbox, ABS/ESP k l ot g Vo y ua b so on), the engine control unit calculates the optimal ran ed throttle valve s i tee opening angle for the respective situation. hor t au es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n Observe rules for cleanliness ⇒ page 128 . rrectness of i t to the co nform spec at i h re o n wit in t his ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t . C op yi Rep. gr.20 - Fuel supply system do c um en 154 or ac ility ab y li an pt ce Observe safety precautions ⇒ page 128 . ss Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 24 – Mixture preparation - injection 1 Injection system General notes on injection ⇒ page 155 . Observe safety precautions when working on fuel supply system ⇒ page 128 . Safety precautions ⇒ page 158 . Observe rules for cleanliness ⇒ page 128 . Technical data ⇒ page 159 . Assembly overview - intake manifold ⇒ page 155 AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce Assembly overview - dismantling and assembling fuel rail ⇒ page 157 Assembly overview - air filter ⇒ page 158 rrectness of i t to the co nform spec at i h re o n wit in t his 1.1 General notes on injection ♦ Fuel hoses in engine compartment must be secured only with spring-type clips. The use of crimp-type or screw-type clips is not permissible. ♦ For trouble-free operation of electrical components, a voltage of at least 11.5 V is necessary. ♦ Do not use sealants containing silicone. Silicone particles drawn into the engine will not be burnt in the engine and will damage the Lambda probes. Assembly overview - intake manifold agen lksw Vo by 1. Injection system do c um en ht rig py Co t. AG. Prote cted by c o p yri gh t. C op yi 1.2 155 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 1 - Intake manifold ❑ Removing and installing ⇒ page 68 2 - Crankcase breather valve ❑ With heater element for crankcase breather N79- . 3 - 10 Nm 4 - Bearing cap ❑ For intake manifold change-over barrel 5 - Seal ❑ Renew 6 - 25 Nm 7 - Vacuum connection ❑ For brake servo or vac‐ uum pump for brakes V192- for vehicles with automatic gearbox 8 - Vacuum connection 9 - Vacuum connection 10 - 25 Nm 11 - Throttle valve module J338❑ Gold-plated connector contacts ❑ If renewed, adapt en‐ gine control unit to throt‐ tle valve module ⇒ Ve‐ hicle diagnostic wagen AG. Volkswagen AG does not olks tester; ;“Guided gu y V func‐ ara tions” rised b nt ee or ac tho s 14 - To intake manifold changeover valve - N15615 - 10 Nm 16 - Positioning lever ❑ For change-over barrel. ❑ Ensure secure seating 17 - Change-over barrel 18 - Gasket ❑ Note installation position ❑ Renew if damaged 19 - Vacuum reservoir ❑ For intake manifold change-over. ❑ For secondary air system r fo ng AG. Rep. gr.24 - Mixture preparation - injection agen lksw Vo by Prote cted by c o py rig ht . C op yi 156 ht rig py Co t. 20 - Dowel sleeve ❑ To secure intake manifold. ❑ To locate seal. rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p 13 - Vacuum actuator ❑ For intake manifold change-over. ility ab y li an pt ce un le 12 - 10 Nms au Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 21 - 15 Nm 22 - To cylinder head cover 1.3 Assembly overview - fuel rail 1 - Wiring harness ❑ With connectors for in‐ jectors ❑ Clipped into cable chan‐ nel 2 - 10 Nm AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d 4 - Injector - N30...N33, N83,ise nte r o eo N84h ut ra a c s ❑ Checking ⇒ pages 161 3 - Fuel rail pe rm itte d un le ility ab y li an pt ce 5 - Seal ❑ Renew rrectness of i t to the co nform spec a t i h re o n in wit thi s es, in part or in w l purpos hole ercia , is n m ot com 6 - Retaining clip ❑ Check for secure seat‐ ing. 7 - Return line connection 8 - Supply line connection 9 - Fuel pressure regulator ❑ Checking ⇒ page 163 , checking fuel pressure regulator and holding pressure r te o iva r rp fo g n agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi 12 - Connector ❑ Black, 2-pin ❑ Check for secure seating. ht rig py Co t. 11 - Retaining clip ❑ Check for secure seat‐ ing. do c um en 10 - Vacuum connection ❑ To non-return valve/in‐ take manifold junction piece 1. Injection system 157 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Assembly overview - air filter 8 - 8 Nm 9 - Air duct ❑ Secured to lock carrier 10 - Connecting piece ❑ For air filter lower part with air pipe 11 - Heat shield ❑ For lower part of air filter 12 - Lower part of air filter 13 - 10 Nm 14 - Filter element 15 - 6 Nm 1.5 Safety precautions ♦ For safety reasons, fuse No. 28 must be removed from the fuse holder before opening the fuel system. Otherwise, the fuel pump could be activated by the driver's door contact switch. WARNING Fuel supply lines are under pressure! Wear eye protection and gloves to avoid injuries and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection. To prevent injuries to persons and/or damage to the injection and ignition system, the following must be observed: 158 Rep. gr.24 - Mixture preparation - injection do c um en 7 - 6 Nm AG. 6 - Upper part of air filter agen lksw Vo by 5 - Seal ❑ Renew if damaged Prote cted by c o p yri gh t. C op yi 4 - Air mass meter - G70- with intake air temperature sender G42❑ Gold-plated contacts on sensor and connector. ❑ Black connector, 5-pin. ❑ Gold-plated contacts on sensor and connector. rrectness of i t to the co nform spec at i h re o n wit in t his 3 - To throttle valve module J338- . ❑ ⇒ Item 11 (page 156) ility ab y li an pt ce 2 - Spring-type clip ❑ Check for secure seat‐ ing. AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n 1 - Intake hose ht rig py Co t. 1.4 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 ♦ Do not touch or pull off ignition wiring when engine is running or turning at starter speed. ♦ Switch off ignition before connecting or disconnecting injection and ignition system wiring as well as test instrument cables. Observe following if test and measuring instruments are required during a road test: ♦ Test and measuring instruments must be secured to rear seat and operated by a second person from this location. If test and measuring instruments are operated from front pas‐ senger seat and the vehicle is involved in an accident, there is a possibility that the person sitting in this seat may receive serious injuries when the airbag is triggered. ♦ If the engine is to be turned at starter speed without starting: – Pull connectors off ignition coils 1…6. Assembly tool - T10118can be used to release locking mechanism. ility ab y li an pt ce Rules for cleanliness When working on the fuel supply and injection system, observe the following “5 rules” for cleanliness: ♦ Thoroughly clean all unions and surrounding areas before dis‐ connecting. ♦ Place removed parts on a clean surface and cover. Use only lint-free cloths. Prote cted by 1.7 AG. ♦ When system is open: do not work with compressed air if this can be avoided. Do not move vehicle unless absolutely nec‐ essary. agen lksw Vo by c o p yri gh t . C op yi ♦ Install clean components only. Do not remove replacement parts from packing until immediately before installing. Do not use parts that have not been stored in their packing (e.g. in tool boxes etc.). ht rig py Co t. r fo ng ♦ Carefully cover opened components or seal if repairs cannot be carried out immediately. rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 1.6 urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p un le – Apply assembly tool - T10118- to locking -arrow- and carefully pull connector off. n AG. Volkswagen AG do es n wage s k l ot g o mechanism button yV ua b d ran ir se tee o h t or u ac a ss Technical data Engine codes Idling check Idling speed13) Engine control unit System designation Part number Governed speed AYT, BKL, BRK rpm 650...750 rpm Motronic ME71.1 ⇒ EKTA (Electronic Parts Catalogue) from approx. 6500 1. Injection system 159 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s r fo ng agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi Rep. gr.24 - Mixture preparation - injection ht rig py Co t. 160 rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p ility ab y li an pt ce un le 13) Not adjustable. pe rm itte d un le Checking components Checking injectors ⇒ page 161 . es, in part or in w l purpos hole ercia , is n m ot com 2.1 rrectness of i t to the co nform spec a t i h re o n in wit thi s Checking fuel pressure regulator and holding pressure ⇒ page 163 . Checking injectors Checking injectors for leaks and quantity injected ⇒ page 162 Special tools and workshop equipment required ♦ Remote control V.A.G 1348/3♦ Adapter - V.A.G 1348/3-2♦ Injection rate tester - V.A.G 1602- do c um en ht rig py Co t. r te o iva r rp fo g n Phaeton 2003 ➤ engine - Edition 02.2014 ility ab y li an pt ce 2 AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d 6-cylinder injection e nte is r o eo h t ra au c ss 2. Checking components 161 agen lksw Vo by AG. Prote cted by c o py rig ht . C op yi Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 2.1.1 Checking injectors for leaks and quanti‐ ty injected Test prerequisite • The fuel pressure must be in order. Checking ⇒ page 163 , Checking fuel pressure regulator and holding pressure. • Fuel pump relays -1- and -2- must be removed from their sockets. Test procedure – Remove intake manifold ⇒ page 68 Removing and installing cylinder head; Removing and installing cylinder head cover – Then remove fuel rail complete (fuel lines remains connected) ⇒ page 157 , dismantling and assembling fuel rail. Checking for leaks – Remove fuse holder cover. – Connect remote control of V.A.G 1348 - V.A.G 1348/3A- with Phaeton adapter cable - V.A.G 1348/3-3- to connections -1- wagen AG. Volkswagen AG does not olks and -2-. gu yV – Operate remote control. un le ara nte e rrectness of i t to the co nform spec a t i h re o n in wit thi s – Renew defective injector. es, in part or in w l purpos hole ercia , is n m ot com pe rm itte d – Check injectors for leaks (visual check). No more than 1 to 2 drops per minute must escape from each valve when fuel pump is running. If the fuel loss is greater: or ac ility ab y li an pt ce If fuel pump runs: b ed ris o h t au ss Pay attention to the following when installing the injectors: ♦ Renew O-rings on all injectors and lightly moisten with clean engine oil. ♦ Insert injectors vertically and in the correct position into the fuel rail and secure with retaining clips. • Fuel pump relays are fitted. Prote cted by Rep. gr.24 - Mixture preparation - injection AG. 162 agen lksw Vo by c o p yri gh t. C op yi – Insert injector to be checked into measuring glass from injec‐ tion rate tester - V.A.G 1602- . do c um en – Connect test box, 121-pin - V.A.G 1598/31- and bridge test box sockets 1 and 65 using auxiliary cables from auxiliary measuring set - V.A.G 1594C- . ht rig py Co t. Checking quantity injected r te o iva r rp fo g n ♦ Fit fuel rail with injectors installed and secured onto lower part of intake manifold and press in evenly. – Connect second injector contact to remote control V.A.G 1348/3A- using adapter cable - V.A.G 1348/3-2- . – Operate remote control for V.A.G 1348 - V.A.G 1348/3A- for 30 seconds. – Repeat check on other injectors. Use new measuring beakers. – After all injectors have been activated, place measuring beak‐ ers on a horizontal surface and compare the injected quantity. Specification: 128…140 ml per injector. If the measured values of one or more injectors are above or be‐ low the prescribed specifications: – Renew defective injector. Install injectors in reverse order. When doing this, note the fol‐ lowing: do c um en ♦ Renew O-rings on all injectors and lightly moisten with clean engine oil. rrectness of i t to the co nform spec at i h re o n wit in t his – Connect crocodile clip to positive battery pole in engine com‐ partment. Phaeton 2003 ➤ engine - Edition 02.2014 ility ab y li an pt ce es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n – AG. Volkswagen AG d agen oes 6-cylinder injection ksw not l o gu yV b ara d e nte is r o Connect a contact of injector to be tested to engine earth using eo h ut ra a auxiliary cables from auxiliary measuring set V.A.G 1594C. c s s ht rig py Co t. Prote cted by c o py rig ht . C op yi ♦ Insert injectors vertically and in the correct position into the fuel rail and secure with retaining clips. agen lksw Vo by ♦ Fit fuel rail with secured injectors onto intake manifold and press in evenly. AG. 2.2 Checking fuel pressure regulator and holding pressure 2. Checking components 163 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Special tools and workshop equipment required ♦ Pressure gauge V.A.G 1318♦ Adapter - V.A.G 1318/9♦ Adapter - V.A.G 1318/17- AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s r fo ng Prote cted by c o py rig ht . C op yi The specification for the check is dependent upon the working pressure of the fuel pump. This is approx. 3.5 bar. agen lksw Vo by AG. Test prerequisite Fuel pump delivery rate OK, checking: ⇒ page 139 Test procedure WARNING Fuel supply lines are under pressure! Wear eye protection and gloves to avoid injuries and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection. 164 Rep. gr.24 - Mixture preparation - injection ht rig py Co t. The fuel pressure regulator regulates the fuel pressure depending on intake manifold pressure. rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p ility ab y li an pt ce un le ♦ Adapter - V.A.G 1318/23- Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 ility ab y li an pt ce Note Push in button on hose coupling to do this. – Now screw pressure tester - V.A.G 1318- to adapter V.A.G 1318/9- and adapter - V.A.G 1318/17- and connect this assembly to supply line -2-. – Open pressure tester shut-off tap. The handle points in direc‐ tion of flow. – Start engine and run at idling speed. – Measure fuel pressure. Specification: approx. 3.5 bar. rrectness of i t to the co nform spec at i h re o n wit in t his – Connect pressure tester - V.A.G 1318- with adapter V.A.G 1318/17- on hose coupling -1- fuel rail. do c um en es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n – AG. Volkswagen AG d agen oes ksw not l o V gu col‐ y Separate coupling -1from fuel supply line (black) -2- and b ara d e nte isin lect escaping fuel a cloth. r o eo h t u ra a c s s ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi – Pull vacuum hose off fuel pressure regulator -arrow-. The fuel pressure must increase to approx. 4.0 bar. If the specification is not attained: – Check delivery rate of fuel pumps ⇒ page 139 Checking fuel pumps. If specification is attained: – Switch off ignition. – Now check for leaks and holding pressure. Do this by observ‐ ing pressure drop on gauge. After 10 minutes, there must be a residual pressure of at least 3.0 bar. If the holding pressure drops below 3 bar: – Start engine and run at idling speed. When the fuel pump has built-up the pressure again: 2. Checking components 165 AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c Atss the same Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Observe pressure drop on gauge again. If the pressure does not drop: – Check non-return valves of fuel pumps ⇒ page 145 . If the pressure drops again: – Check pressure tester - V.A.G 1318- for leaks. – Check line connections, O-rings on fuel rail and injectors for leaks. If no leaks can be found: – Switch off ignition. – Renew fuel pressure regulator ⇒ Item 9 (page 157) . r fo ng Fuel supply lines are under pressure! Wear eye protection and gloves to avoid injuries and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection. 166 Rep. gr.24 - Mixture preparation - injection AG. – Hold a cloth over the adapter to be loosened and remove pressure tester - V.A.G 1318- . agen lksw Vo by Prote cted by c o py rig ht . C op yi When removing the pressure tester - V.A.G 1318- after the test has been completed, ht rig py Co t. WARNING rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p un le ility ab y li an pt ce – Switch ignition off after the pressure has built up. time, shut-off valve of pressure tester - V.A.G 1318- -arrowshould be closed (lever perpendicular to direction of flow). Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 3 Engine control unit Removing and installing engine control unit ⇒ page 167 . Reading and clearing engine control unit fault memory ⇒ page 167 . 3.1 Removing and installing engine control unit If you wish to replace the engine control unit, connect the vehicle diagnosis, testing and information system - VAS 5051B- and carry out the guided function “Renew control unit”. Removing – Switch off ignition. ility ab y li an pt ce es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n – n AG. Volkswagen AG do es n wage s k l ot g Vo y ua b Remove windscreen wiper motor on right side: ⇒ Electrical ran ed s i tee r system; Rep. gr. 92 ; Removing and installing windscreen o h t or u ac a wiper system . ss – Release both connectors from control unit and pull off. – Control unit can now be removed. rrectness of i t to the co nform spec at i h re o n wit in t his Installing – Place control unit into retaining frame. – Fit connector and lock in position. – Install windscreen wiper motor on right side: ⇒ Electrical sys‐ tem; Rep. gr. 92 ; Windscreen wiper system . – Install plenum chamber cover. – Adapt new engine control unit: ⇒ Vehicle diagnostic tester; “Guided functions” . 3.2 Reading and erasing engine control unit fault memory Special tools and workshop equipment required ht rig py Co t. ♦ Diagnosis cable - VAS 5051/1- or -VAS 5051/3- do c um en ♦ Vehicle diagnosis, testing and information system - VAS 5051- agen lksw Vo by AG. Prote cted by c o p yri gh t . C op yi Procedure – Connect vehicle diagnosis, testing and information system VAS 5051- as follows: 3. Engine control unit 167 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Connect connector of diagnostic cable - VAS 5051/1- or VAS 5051/3- to diagnostic connection. – Start engine and run at idling speed. Only when engine does not start: – Switch on ignition. Selecting operating mode: – Press button on display for “Vehicle self-diagnosis”. Selecting vehicle system: – Press “01 - Engine electronics” button on display. The control unit identification with code as well as chassis number and immobilizer identification number will be indicated on the dis‐ . Volkswagen AG gen AG does play. a w ks n ss ot g ua ran tee or ac – Press → button. Selecting diagnostic function: – Press button “02 - Read fault memory” on display. – If no fault is stored in engine control unit “0 fault detected” is displayed. – If faults are stored in the engine control unit, these are shown one below the other on the display. – Press ← button. – Press button “05 - Clear fault memory” on display. AG. Rep. gr.24 - Mixture preparation - injection agen lksw Vo by Prote cted by c o py rig ht . C op yi 168 ht rig py Co t. r fo ng – Press function “06-End output”. rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p A print-out can be made if required. Press the Print button. ility ab y li an pt ce un le Note ol yV db e ris tho au Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 26 – Exhaust system 1 Parts of exhaust system Assembly overview - exhaust manifold with starter catalytic con‐ verters and attachments ⇒ page 170 Exhaust pipes with main catalytic converters and silencers with mountings ⇒ page 172 Removing and installing exhaust manifolds and exhaust pipes with starter catalytic converters ⇒ page 174 Note AG. Volkswagen AG d agen oes ksw ♦ To support the exhaust system when removing, use Vol engine and gearbox jack - V.A.G 1383 A- . not gu ara nte eo ra c ility ab y li an pt ce un le ♦ y db ise r tho that the system After working on the exhaust system, ensure au s s If necessary, loosen has sufficient clearance to the bodywork. pe rm itte d flange on catalytic converter and realign silencers and exhaust pipes ⇒ page 174 . rrectness of i t to the co nform spec a t i h re o n in wit thi s es, in part or in w l purpos hole ercia , is n m ot com Special tools and workshop equipment required ♦ Lambda probe open ring spanner set - 3337- do c um en r te o iva r rp fo g n ♦ Torque wrench (40…200 Nm) - V.A.G 1332- ht rig py Co t. agen lksw Vo by 1. Parts of exhaust system 169 AG. Prote cted by c o p yri gh t. C op yi Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 1.1 Assembly overview - exhaust manifold with starter catalytic converters and at‐ tachments Note ♦ Disconnect batteries before removing front exhaust pipes with catalytic converter. First disconnect drive battery on right in luggage compartment. Then disconnect second battery on left in luggage compartment ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and reconnecting batteries . . Volkswagen AG ♦ When installing exhaustwapipes, the gen AG ensure that doeflange connec‐ es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce s no ks tion after the catalytic t in Vol converter seals tightly. Leaks gu this area by arareach d cause pulsation in exhaust. This allows ambient air to e nte ris o eo the Lambda probe after the catalytic converter, thereby dis‐ h ut ra a turbing Lambda regulation. c s s ♦ Renew self-locking nuts. rrectness of i t to the co nform spec at i h re o n wit in t his 1 - Cylinder head 2 - Gasket ❑ Renew 3 - M8 - 25 Nm, M10 - 40 Nm 4 - Exhaust manifold 5 - Gasket ❑ Renew ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi 7 - Lambda probe 2 - G108- 50 Nm ❑ Installed in exhaust gas stream of cylinders 4, 5 and 6 ❑ Grease only the threads with “G 052 112 A3”; “G 052 112 A3” must not get into the slots on the probe body. ❑ Remove and install with Lambda probe open ring spanner set 3337- . 8 - Starter catalytic converter ❑ Installed in exhaust gas stream of cylinders 4, 5 and 6 170 Rep. gr.26 - Exhaust system do c um en 6 - Lambda probe - G39- 50 Nm ❑ Installed in exhaust gas stream of cylinders 1, 2 and 3 ❑ Grease only the threads with “G 052 112 A3”; “G 052 112 A3” must not get into the slots on the probe body. ❑ Remove and install with Lambda probe open ring spanner set 3337- . Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 9 - Starter catalytic converter ❑ Installed in exhaust gas stream of cylinders 1, 2 and 3 10 - Lambda probe after catalytic converter - G130- 50 Nm ❑ Installed in exhaust gas stream of cylinders 1, 2 and 3 ❑ Grease only the threads with “G 052 112 A3”; “G 052 112 A3” must not get into the slots on the probe body. ❑ Remove and install with Lambda probe open ring spanner set - 3337- . 11 - Lambda probe 2 after catalytic converter - G131- , 50 Nm ❑ Installed in exhaust gas stream of cylinders 4, 5 and 6 ❑ Grease only the threads with “G 052 112 A3”; “G 052 112 A3” must not get into the slots on the probe body. ❑ Remove and install with Lambda probe open ring spanner set - 3337- . 12 - 20 Nm 13 - Heat shield 15 - 20 Nm ility ab y li an pt ce r fo ng urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi 17 - 23 Nm un le 16 - Bracket ❑ For Lambda probe wiring and AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a activated charcoal filter system solenoid valve 1 N80c s s ht rig py Co t. 14 - Clip ❑ For Lambda probe wiring 1. Parts of exhaust system 171 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 1.2 Exhaust pipes with main catalytic converters and silencers with mountings 1 - Securing bolt, 25 Nm 2 - Mounting ❑ Individual parts ⇒ page 173 . 3 - 40 Nm 4 - Front exhaust pipe ❑ For exhaust gas stream of cylinders 4, 5 and 6 5 - Front exhaust pipe ❑ For exhaust gas stream of cylinders 1, 2 and 3 6 - Catalytic converter with front silencer ❑ For cylinders 4, 5 and 6 7 - Gasket 8 - Catalytic converter with front silencer ❑ For cylinders 1, 2 and 3 AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c positionss rrectness of i t to the co nf o r m spec atio h re n in wit es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng 10 - 25 Nm ility ab y li an pt ce 9 - Mounting ❑ Installation ⇒ page 174 ❑ Renew if damaged 11 - Centre silencer AG. Prote cted by c o p yri gh t. C op yi 15 - Rear silencer ❑ Align rear silencer free of stress. agen lksw Vo by 14 - Mounting ❑ Installation position ⇒ page 174 ❑ Renew if damaged ht rig py Co t. 13 - 25 Nm thi sd o cu m en 12 - Separating point ❑ For repair cases ❑ Marked by impressions on exhaust pipe. ❑ Centre and rear silenc‐ ers are installed as a single component during production. In repair cases, the centre and rear silencers are supplied individ‐ ually with a repair double clamp for connecting them. Installing ⇒ page 173 ❑ Cut through connecting pipe at right angles at separating point using pneumatic sabre saw - V.A.G 1523A- ⇒ page 173 ❑ The notches to the left and right of the separating points must be visible following the installation of the double clamp. 16 - Double clamp ❑ Installation position ⇒ page 173 ❑ Must be slid to its middle onto front exhaust pipe. ❑ Observe installation position: threaded end of securing bolts must not protrude beyond lower edge of clamping sleeve. 172 Rep. gr.26 - Exhaust system Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 17 - 25 Nm Individual parts of mounting 1 - Washer 2 - Bracket with buffer 3 - Bracket 4 - Spring 5 - Spacer sleeve 6 - Hexagon bolt, 25 Nm Separating point between centre silencer and rear silencer – Separate connecting pipe between centre silencer and rear silencer at the point marked with a groove. ♦ Pneumatic sabre saw - V.A.G 1523AInstallation position of double clamp 1 - From main catalytic converter 2 - To centre silencer 3 - Three markings along circumference 4 - Dimension = 5 mm 5 - Angle 5° Installation position, repair double clamp in direction of travel 2 - Angle between 10° and 15° thi sd o cu m en 1 - The end of the bolt must not project beyond lower edge of clamp. rrectness of i t to the co nf o r m spec atio h re n in wit es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng Special tools and workshop equipment required ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s 1. Parts of exhaust system 173 ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Aligning exhaust system • Exhaust system cold – Push exhaust system in direction of normal travel -1- and tighten double clamps until dimension -a- is attained at the mountings. Centre silencer: dimension a = 10 mm, rear si‐ lencer: dimension a = 15 mm 1.3 Removing and installing exhaust mani‐ folds and exhaust pipes with starter cat‐ alytic converters Disconnecting batteries The procedure must be strictly followed! – Switch off ignition and all electrical consumers and remove key. – First disconnect drive battery on right in luggage compartment. – Then disconnect second battery on left in luggage compart‐ ment ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and reconnecting batteries Removing – Pull all coolant hoses off intake manifold. – Remove air filter housing complete with intake hose ⇒ page 158 . – Unscrew throttle valve module from intake manifold ⇒ Item 11 (page 156) . n AG. Volkswagen AG does wage air system on combination – Pull off pressure hose of secondary not olks V gu y valve ⇒ Item 11 (page d177) . b ar an tee or ac e ris – Now separate fuel supply and return line as well as line from activated charcoal filter to activated charcoal filter system sol‐ enoid valve 1 - N80- . agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi Rep. gr.26 - Exhaust system ht rig py Co t. 174 rrectness of i t to the co nf o r m spec atio h re n in wit – Hold cloth beneath separation point of fuel lines. thi sd o cu m en es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng – Then unscrew heat shield with intake manifold support from cylinder head. ility ab y li an pt ce tho activated charcoal filter system solenoid – Remove bracket for au s valve 1 - N80- from heat shield. s Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Separate wiring connections to Lambda probes -arrows- and unclip wires from cable guides. – Unscrew Lambda probes before catalytic converter using Lambda probe open ring spanner set - 3337- . – Raise vehicle and remove front right wheel housing liner. – Unscrew heat shield above right drive shaft -arrows- to gain access to threaded connections of catalytic converter / ex‐ haust pipe. – Now unscrew securing bolt ⇒ Item 1 (page 172) so that ex‐ haust pipes can be removed individually. – Now remove catalytic converter for cylinders 1, 2 and 3 from exhaust manifold. – Unscrew Lambda probe after catalytic converter using Lamb‐ da probe open ring spanner set - 3337- . – Remove catalytic converter for cylinders 4, 5 and 6 and Lamb‐ da probe after catalytic converter in the same way. – Now remove exhaust manifold.wagen AG. Volkswagen AG doe s no ks t gu Vol by ara d e nte s ri o eo h t u The assembly is basically a reverse of the dismantling sequence. ra a c s s Installing un le pe rm itte d es, in part or in w l purpos hole ercia , is n m ot com rrectness of i t to the co nform spec a t i h re o n in wit thi s – Then install the catalytic converter for cylinders 1, 2 and 3 with Lambda probe after catalytic converter screwed in. ility ab y li an pt ce – First install the catalytic converter for cylinders 4, 5 and 6 to exhaust manifold with Lambda probe after catalytic converter screwed in. – Now tighten bracket for front exhaust pipes ⇒ Item 2 (page 172) to gearbox and fit exhaust pipes to brack‐ et. Note ♦ When installing exhaust pipes, ensure that the flange connec‐ tion after the catalytic converter seals tightly. Leaks in this area cause pulsation in exhaust. This allows ambient air to reach the Lambda probe after the catalytic converter, thereby dis‐ turbing Lambda regulation. gearbox and subframe. ht rig py Co t. Further assembly is basically the reverse of the dismantling se‐ quence. do c um en r te o iva r rp fo g n ♦ Adjust exhaust system so that there is sufficient clearance to 1. Parts of exhaust system 175 agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 2 Secondary air system AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e The secondary air system blows air in behind therisexhaust valve nte o eo h for max. 65 seconds after a cold start (+15 °C u… t +35 °C coolant ra a c temperature). This produces an oxygen rich exhaust gas, causing s s Function rrectness of i t to the co nf o r m spec atio h re n in wit es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng ility ab y li an pt ce afterburning and reducing the heat-up phase of the catalytic con‐ verter. Actuation is performed by the engine control unit via the secondary air pump relay - J299- to secondary air inlet valve N112- and combination valve. Additionally, after each subse‐ quent engine start (up to max. 85 C engine temperature), the secondary air system will, after a 20 second delay, switch in for 5 seconds during idling and will be checked by the self-diagnosis. Assembly overview - parts of secondary air system ⇒ page 176 Checking combination valve ⇒ page 178 2.1 Assembly overview - parts of secondary air system Note Location of secondary air pump relay - J299- ⇒ page 178 ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi Rep. gr.26 - Exhaust system thi sd o cu m en 176 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 1 - Intake manifold 3 - To intake manifold 11 - Pressure hose ❑ Ensure secure seating 13 - Connection 14 - Secondary air pump motor - V10115 - Rubber bush 16 - Bracket ❑ For secondary air pump motor - V101- do c um en 12 - O-ring ❑ Renew if damaged Prote cted by 10 - 5 Nm AG. 9 - Connection ❑ For combination valve. agen lksw Vo by 8 - 10 Nm c o p yri gh t . C op yi 7 - Air duct ❑ In cylinder head rrectness of i t to the co nform spec at i h re o n wit in t his 6 - Gasket ❑ Renew ility ab y li an pt ce 5 - Combination valve ❑ Checking ⇒ page 178 es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n 4 - To fuel pressure regulator. n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss ht rig py Co t. 2 - Vacuum actuator for intake manifold change-over 17 - Connector ❑ For secondary air pump motor - V10118 - 20 Nm 19 - Retaining clamp 20 - Air filter ❑ With non-return valve. ❑ Clean if soiled. 21 - Intake hose ❑ Ensure secure seating 22 - Non-return valve ❑ White connection points towards secondary air inlet valve - N112- or variable intake manifold changeover valve - N15623 - Connector ❑ Black, 2-pin 24 - Variable intake manifold changeover valve - N15625 - Secondary air inlet valve - N11226 - Vacuum reservoir 2. Secondary air system 177 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Secondary air pump relay - J299Note ♦ The relay for secondary air pump is inserted in socket 7. ♦ If tools are necessary to pull relays or control units out of the relay plate, first disconnect battery earth strap ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and reconnecting batter‐ ies. 2.2 Checking combination valve Special tools and workshop equipment required ♦ Hand vacuum pump - V.A.G 1390- Vacuum pipes and hose connections free of leaks. Vacuum pipes not blocked or kinked. rrectness of i t to the co nform spec at i h re o n wit in t his Test procedure – Detach vacuum hose from secondary air inlet valve - N112from combination valve -arrow-. Note Do not use compressed air during the following check! agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi Rep. gr.26 - Exhaust system ht rig py Co t. 178 do c um en es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce Test prerequisites AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Connect hand vacuum pump - V.A.G 1390- to vacuum con‐ nection on combination valve n-arrow-. AG. Volkswagen A – Operate hand vacuum pump - V.A.G 1390- . Combination valve must open. If combination valve does not open: Renew combination valve ⇒ Item 5 (page 177) . rrectness of i t to the co nform spec at i h re o n wit in t his – Detach pressure hose to combination valve at connection -arrow- and blow in softly. Combination valve must be closed. do c um en es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n ility ab y li an pt ce ss G do es n ot g ua ran tee or ac wage olks V by ed ris o th au 2. Secondary air system 179 ht rig py Co t. agen lksw Vo by AG. Prote cted by c o py rig ht . C op yi Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 1 Ignition system pe rm itte d rrectness of i t to the co nform spec a t i h re o n in wit thi s es, in part or in w l purpos hole ercia , is n m ot com General notes on ignition system un le Ignition system ility ab y li an pt ce 28 – AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ♦ Only the components which specifically relate to the ignition system are dealt with here. For other components of the in‐ jection and ignition system, ⇒ page 155 . ♦ For trouble-free operation of electrical components, a voltage of at least 11.5 V is necessary. ♦ During some checks, it is possible that the control unit will de‐ tect and store a fault. Therefore after completing all checks and repairs the fault memory must be read and if necessary cleared. Safety precautions ⇒ page 182 . Test data, spark plugs ⇒ page 184 Removing and installing ignition coils with output stage ⇒ page 182 . Prote cted by c o p yri gh t. C op yi AG. Rep. gr.28 - Ignition system agen lksw Vo by 180 Assembly overview - parts of ignition system ht rig py Co t. 1.1 do c um en r te o iva r rp fo g n Assembly overview - parts of ignition system ⇒ page 180 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n AG. Prote cted by 7 - 20 Nm ❑ The torque setting influ‐ ences the function of the knock sensor. do c um en 6 - Knock sensor 1 - G61❑ Gold-plated contacts on sensor and connector. ❑ Location: cylinder block exhaust side agen lksw Vo by 5 - Connector ❑ Black, 3-pin ❑ Gold-plated contacts on sensor and connector. c o p yri gh t. C op yi 4 - 10 Nm ht rig py Co t. 3 - Bracket ❑ For connector for knock sensor 1 - G61- . rrectness of i t to the co nform spec at i h re o n wit in t his 2 - Connector ❑ 4-pin. ❑ Use assembly tool T10118- to pull off. AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s ility ab y li an pt ce 1 - Ignition coil with output stage - N70, N127, N291, N292, N323, N324❑ Removing and installing ⇒ page 182 8 - Exhaust camshaft adjuster ❑ With sender wheel for Hall sender 2 - G163❑ Installing ⇒ page 64 . 9 - Cover ❑ Removing and installing ⇒ page 71 10 - Seal ❑ Renew 11 - Hall sender 2 - G163❑ For exhaust camshaft. ❑ Gold-plated contacts on sensor and connector. 12 - 10 Nm 13 - Connector ❑ Black, 3-pin ❑ Gold-plated contacts on sensor and connector. ❑ Mark connector before removing. 14 - Hall sender - G40❑ For inlet camshaft. ❑ Gold-plated contacts on sensor and connector. 15 - Knock sensor 2 - G66❑ Gold-plated contacts on sensor and connector. ❑ Fitting location: cylinder block intake side 16 - Connector ❑ Black, 2-pin 1. Ignition system 181 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 ❑ Gold-plated contacts on sensor and connector. 17 - Inlet camshaft adjuster ❑ With sender wheel for Hall sender - G40❑ Installing ⇒ page 64 . 18 - Spark plug, 20 Nm ❑ Removing and installing ⇒ page 182 ❑ Type and electrode gap ⇒ page 184 , test data, spark plugs 19 - Valve timing housing ❑ For camshaft adjustment. ❑ Removing and installing ⇒ page 82 Removing and installing camshafts. 1.2 Safety precautions To prevent injuries to persons and/or damage to the injection and ignition system, the following must be observed: olkswagen AG en AG. V ag ksw Vol ♦ Switch off ignition before connecting by or disconnecting injection d e and ignition system wiring as well ris as test instrument cables. ho ut rrectness of i t to the co nform spec at i h re o n wit in t his ♦ Test and measuring instruments must be secured to rear seat and operated by a second person from this location. If test and measuring instruments are operated from front pas‐ senger seat and the vehicle is involved in an accident, there is a possibility that the person sitting in this seat may receive serious injuries when the airbag is triggered. 1.3 Removing and installing ignition coils with output stage Special tools and workshop equipment required ♦ Assembly tool - T10118- agen lksw Vo by AG. Prote cted by c o p yri gh t . C op yi Rep. gr.28 - Ignition system ht rig py Co t. 182 do c um en es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n Observe following if test and measuring instruments are required during a road test: ility ab y li an pt ce a ♦ If the engine is to be turned ss at starter speed without starting: does not gu ara nte eo ra c Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 ♦ Puller - T10095A- ♦ Lubricating paste - G 052 141 A2Removing – Apply assembly tool - T10118- to locking mechanism button -arrow- and carefully pull connector off each ignition coil with output stage . rrectness of i t to the co nf o r m spec atio h re n in wit es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng ility ab y li an pt ce n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss thi sd o cu m en – Push puller - T10095A- on from flat side of connector in -direction of arrow- and pull out ignition coil with output stage . c o p yri gh t . C op yi agen lksw Vo by AG. Prote cted by Note ht rig py Co t. Installing ♦ When fitting new spark plugs, the ignition coil must be re‐ greased using lubricating paste - G 052 141 A2- This will stop the ignition coil sealing hose from »sticking« to the spark plug. The lubricating paste must be distributed on the spark plug when inserting on the ignition coil. ♦ New ignition coils with output stage are lubricated when de‐ livered. 1. Ignition system 183 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Apply a thin line of lubricating paste - G 052 141 A2- around the ignition coil sealing hose -arrow-. The bead must be 1…2 mm thick. rrectness of i t to the co nf o r m spec atio h re n in wit – Push puller - T10095A- on from flat side of connector in -direction of arrow- and push ignition coil with output stage onto spark plug. ht rig py Co t. agen lksw Vo by AG. Prote cted by c o p yri gh t. C op yi 1.4 thi sd o cu m en es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng – To install, insert ignition coil with output stage into respective spark plug recess so that the flat sides of connectors fit with each other -arrows-. ility ab y li an pt ce AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s Test data, spark plugs Engine code AYT / BKL BRK14) Firing order Spark plugs VW/Audi Electrode gap Specified torque 1-5-3-6-2-4 1-5-3-6-2-4 101 905 606 max. 1.1 mm 20 Nm 101 905 624 max. 1.1 mm 20 Nm 14) Emissions limit in accordance with EU2 norm, China only 184 Rep. gr.28 - Ignition system
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Key Features
- 6-cylinder injection engine for powerful performance
- Spacious and comfortable interior for a luxurious driving experience
- Advanced technology features for enhanced safety and convenience
- Exceptional handling and stability for a smooth and controlled ride
- High-quality craftsmanship and materials for durability and style
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Frequently Answers and Questions
What type of engine does the Volkswagen Phaeton 2003 have?
The Volkswagen Phaeton 2003 has a powerful 6-cylinder injection engine.
Is the Volkswagen Phaeton 2003 fuel-efficient?
The fuel efficiency of the Volkswagen Phaeton 2003 depends on various factors such as driving conditions and driving style. However, it is generally known for its efficient fuel consumption.
What are the safety features of the Volkswagen Phaeton 2003?
The Volkswagen Phaeton 2003 is equipped with advanced safety features such as airbags, anti-lock brakes, and electronic stability control to ensure the safety of passengers.
Is the Volkswagen Phaeton 2003 comfortable for long journeys?
Yes, the Volkswagen Phaeton 2003 has a spacious and comfortable interior, making it suitable for long journeys.
What is the seating capacity of the Volkswagen Phaeton 2003?
The Volkswagen Phaeton 2003 has a seating capacity of five.
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