Volkswagen Phaeton 2003 Workshop Manual

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Workshop Manual
Phaeton 2003 ➤
6-cylinder injection engine
Engine ID
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Service Department. Technical Information
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Service
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00 - Technical data
20 - Fuel supply system
24 - Mixture preparation - injection
26 - Exhaust system
28 - Ignition system
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19 - Cooling
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15 - Cylinder head, valve gear
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13 - Crankshaft group
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Repair Group
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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. . . . . . . . . . . . . . . . . . . .
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1.1
1.2
1.3
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Removing and installing engine . . . . . .V.ol.ks.w.a. . . . . . . . . . . . . . . .do. e.s.no. t. . . . . . . . . . . . . . . .
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Removing engine . . . . . . . . . . . . .ise. d.b. . . . . . . . . . . . . . . . . . . . . . . . . . .u.ar.an. . . . . . . . . . . .
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Securing engine on engine and ugearbox
support VAS 6095 . . . . . . . . . . . . e. o.r . . . . . . . .
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Installing engine . . . . . . . . . .ss. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c. . . . . . . .
un
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1
1.1
1.2
1
3
4
14
15
19
20
23
25
26
28
30
30
31
33
34
35
37
40
40
41
41
43
44
44
45
46
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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) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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
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4.2
4.3
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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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
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48
52
56
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64
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71
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76
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79
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Assembly overview - radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Assembly overview - removing and installing fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Assembly overview - parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Assembly overview - thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Assembly overview - parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . 113
Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.10
1.11
2
2.1
2.2
3
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1.5
1.6
1.7
1.8
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1.3
Parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Assembly overview - fuel tank with attachments and fuel filter . . . . . . . . . . . . . . . . . . . . . . 120
Dismantling and assembling right side fuel delivery unit, fuel gauge sender and suction-jet
pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Assembly overview - fuel delivery unit, fuel
gauge sender and suction jet pump on left side
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Schematic diagram of fuel lines
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Safety precautions whenutworking
on fuel supply system . . . . . . . . . t.ee. o. . . . . . . . . . . . . . . 128
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Rules for cleanliness s.s a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ac. . . . . . . . . . . . . . 128
Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Removing and installing fuel delivery unit, fuel gauge sender and suction-jet pump, right side
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Removing and installing fuel delivery unit, fuel gauge sender and suction-jet pump, left side
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Removing and installing fuel tank with attachments and fuel filter . . . . . . . . . . . . . . . . . . . . 137
Checking fuel pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Assembly overview - parts of activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . 148
Checking activated charcoal filter system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Checking electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
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24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
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ii Contents
Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
General notes on injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Assembly overview - fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Checking components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Checking fuel pressure regulator and holding pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
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1.2
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1.4
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1.6
1.7
2
2.1
2.2
Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
167
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Engine control unit . . . . . . . . . . . . . . . .e.d .b . . . . . . . . . . . . . . . . . . . . . . . . . t. g.u.ar.a . . . . . . . . .
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Removing and installing engine control
tho unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .e.or. . . . . .
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Reading and erasing engine control
ss unit fault memory . . . . . . . . . . . . . . . . . . . . . . . c. . . . .
1.2
1.3
2
2.1
2.2
Parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Assembly overview - exhaust manifold with starter catalytic converters and attachments
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Exhaust pipes with main catalytic converters and silencers with mountings . . . . . . . . . . . . 172
Removing and installing exhaust manifolds and exhaust pipes with starter catalytic
converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Assembly overview - parts of secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Checking combination valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
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26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
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Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Assembly overview - parts of ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
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1
1.1
1.2
1.3
1.4
Contents
iii
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iv Contents
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Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
Technical data
1
Technical data
1.1
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Engine data ⇒ page 1
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Engine number ⇒ page 1
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(VRL006351; Edition 02.2014)
un
le
00 –
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.
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)
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l
kW at rpm
Nm at rpm
∅ mm
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Manufactured
Cylinder arrangement
Cylinder angle
Capacity
Output
Torque
Bore
Stroke
Compression ratio
Valves per cylinder
RON
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Engine data
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The engine code is also included on the vehicle data sticker.
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)
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2 Rep. gr.00 - Technical data
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4) Two independently variable camshafts
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
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♦ Left engine support - VAS 6131/3-1-
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♦ Scissor-type assembly
platform - VAS 6131-
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♦ 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-
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♦ Universal subframe support - VAS 6131/1-3-
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♦ 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-
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♦ Container for removed parts - V.A.G 1698-
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♦ Securing pins - VAS 6131/1-6-
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♦ Securing pins - VAS 6131/1-5-
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♦ Universal gearbox console support - VAS 6131/1-4-
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♦ 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
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- V.A.G 1698. es no
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ed are opened or cut through when engine
♦ All cable ties which
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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
– Pull engine compartment seal off bulkhead.
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All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine is
installed.
rrectness of i
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spec
at
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Disconnecting batteries
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♦ Before disconnecting batteries, move wiper arms to service
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– Remove plenum chamber covers. ⇒ General body repairs,
exterior; Rep. gr. 64 ; Removing and installing plenum cham‐
ber cover .
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– 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.
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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.
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Note
Connector for cylinders 1…3 = black, connector for cylinders 4…
6 = brown
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6 Rep. gr.10 - Removing and installing engine
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– Separate connectors -1…4- for Lambda probes and lay wires
on engine.
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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.
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– Remove catalytic converters/front silencer ⇒ page 172 ; Re‐
moving and installing parts of exhaust system.
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– Support exhaust system on mounting at exhaust pipe junction
-arrow- with guide pins - 3411- .
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– To gain more working space, unscrew protective housing from
bulkhead -arrows-.
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Phaeton 2003 ➤
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6-cylinder
injection
engine
Edition 02.2014
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Prote
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– 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.
–
– 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
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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
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Continuation if engine and gearbox are not separated following
removal:
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Separate engine and gearbox ⇒ Operating instructions for scis‐
sor-type assembly platform VAS 6131 .
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– Drain coolant ⇒ page 115 .
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Open and close expansion tank cap to release pressure
ir se in
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or
cooling system.
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 .
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Prepare scissor-type assembly platform - VAS 6131- for further
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– Install engine supports -VAS 6131/3-1- -1- left and
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VAS 6131/3-2- -2- right on scissor-type assembly platform VAS 6131- .
– The arrows on the supports point in direction of travel.
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– Secure the bolts in the following positions: left engine support
-1-: C6 and D5; right engine support -2-: E6 and F5.
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– Remove both middle gearbox console bolts -arrows-.
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– 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.
– 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
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B - Mounting on right of engine -arrow-
AG.
Prote
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10 Rep. gr.10 - Removing and installing engine
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– Unscrew subframe bolts -1-, -2- and -3-.
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– Guide the universal supports in the gearbox console
-arrows-.
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– Guide universal supports for the subframe in the respective
mountings -arrow-.
Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
not
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– Remove both outer gearbox bracket
wage bolts -arrows-. does
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Removing engine and gearbox without
subframe
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1.1.1
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– Remove bolts -1- for engine carrier.
– 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:
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12 Rep. gr.10 - Removing and installing engine
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B - Mountings on right of engine -arrows-
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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-.
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– Remove both outer gearbox bracket bolts -arrows-.
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1. Removing and installing engine
13
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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
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enough so as to facilitate unhooking
lever
cable.
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Check that all connections
between
bulkhead
and
engine
s
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db
Continuation for all vehicles
ise
or
have been separated.
– 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
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Note
Separate engine and gearbox ⇒ Operating instructions for scis‐
sor-type assembly platform VAS 6131 .
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Vehicles with automatic gearbox
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– 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
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–
Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
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Flywheel end: position 11.
Installing engine
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When doing any repair work, especially in the engine compart‐
ment, pay attention to the following due to the cramped condi‐
tions:
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♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant, refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
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– 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.
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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-
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♦ Dot lasers - VAS 6131/17-1-
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♦ Positioning tool - VAS 6131/17-
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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
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34 ; Repairing
selector mechanism; Removing
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Continuation for all vehicles
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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.
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– Replenish coolant ⇒ page 115 .
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Perform wheel alignment after installing subframe ⇒ Running
gear, axles, steering, front and four-wheel drive; Rep. gr. 44 ;
wheel alignment
AG.
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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
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M6
M7
M8
M10
M12
Additional information and assembly
work for vehicles with air conditioner
Prote
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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
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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 .
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Specified
torque
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Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
13 –
Crankshaft group
1
Dismantling and assembling engine
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Overview
1. Dismantling and assembling engine
19
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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
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perform the following
repairs:
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♦ Thoroughly rclean
oil channels
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♦ Renew soil
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♦ Renew oil spray jets
♦ Renew oil cooler
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Part I ⇒ page 20
Part II ⇒ page 23
Removing and installing poly V-belt ⇒ page 28 .
Part I: assembly overview - chain drive
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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 .
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2 - 8 Nm
❑ Renew
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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
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♦ Renew oil filter
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
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❑ Built into crankshaft.
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❑ Ground down tooth to bearing
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18 - Guide rail
❑ For timing chain ⇒ Item 17 (page 21) .
❑ Remove and install together with roller chain ⇒ page 58
or
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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
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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.
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1. Dismantling and assembling engine
21
AG.
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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
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24 - Guide rail
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❑ For camshaft timing chain ⇒ Item 3 (page 20)uth
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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).
AG.
22 Rep. gr.13 - Crankshaft group
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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.
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8 - Oil pump drive cover
9 - O-ring
❑ Renew
❑ Lubricate before instal‐
ling.
AG.
7 - 10 Nm
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6 - 20 Nm
❑ The torque setting influ‐
ences the function of the
knock sensor.
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5 - Knock sensor 1 - G61❑ Fitting location: be‐
tween cylinder 1 and
cylinder 3.
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4 - Oil non-return valve
❑ Note installation posi‐
tion
❑ Clean if badly soiled or
renew if necessary.
❑ See note ⇒ page 19
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3 - Dipstick
❑ The oil level must not be
above the max. mark!
❑ Markings ⇒ page 98 .
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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
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25 - Seal
❑ Renew
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24 - 12 Nm
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23 - Seal
❑ Renew
❑ Lubricate before installing.
un
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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 .
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33 - Knock sensor 2 - G66❑ Fitting location: between cylinder 4 and cylinder 6.
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32 - Coolant pipe
❑ Removing and installing ⇒ page 113 , Parts of cooling system - engine side.
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28 - To thermostat housing
Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
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Right engine bracket
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Note: If a new engine is installed, the 3 bores on the face end
-arrows- must be sealed by means of bolts.
rrectness
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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
Special tools and workshop equipment required
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♦ Counterhold - T10069-
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Removing and installing vibration damp‐
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♦ 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,
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Clean thread inaucrankshaft with a threaded chaser M18 x 1.5. or a
c
ss
– 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
♦ Support bracket - 10 - 222 A-
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♦ Shackle - 10 - 222 A /12-
AG.
♦ Adapter - 10 - 222 A /19-
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♦ Adapter - 10 - 222 A /16-
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Special tools and workshop equipment required
Note
The left engine bracket is one component together with the oil
filter housing
26 Rep. gr.13 - Crankshaft group
rrectness of i
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– Tighten securing bolt using torque wrench - V.A.G 1601- .
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– Renew securing bolt for vibration damper.
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.
–
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– 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
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Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
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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.
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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.
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Specified torque for engine support with oil filter housing, left en‐
gine side ⇒ Item 12 (page 99) .
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Specified torque for securing bolt -2-: 60 Nm.
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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.
Note
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rrectness
o
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spec
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Note
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Installing poly V-belt
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– Remove poly V-belt.
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Screw in bolt only far enough to remove poly V-belt because
ten‐
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sioning roller housing may otherwise be damaged. ut
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♦ 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:
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– Start engine and check that belt runs properly.
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AG.
1. Dismantling and assembling engine
29
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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
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♦ Secure engine to engine and gearbox support - VAS
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Assembly overview ⇒ page 30
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carry out repairs.
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Removing and installing seal at flywheel end ⇒ page 31
rrectness
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Removing and installing flywheel ⇒ page 33
Removing and installing drive plate ⇒ page 34 .
Renewing crankshaft oil seal, vibration damper end
⇒ page 35
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
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5 - Sealing flange
❑ Coat sealing surfaces
with sealant - D 176
501- .
AG.
4 - Seal
❑ Renew ⇒ page 35
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3 - 10 Nm
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2 - Vibration damper
❑ Removing and installing
poly V-belt ⇒ page 28 .
❑ Removing and installing
⇒ page 25
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1 - 100 Nm + 1/2 turn (180°)
further
❑ Renew
❑ Use counterhold T10069- to loosen and
tighten.
❑ Tighten using torque
wrench - V.A.G 1601- .
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Assembly overview
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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
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⇒
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❑ Renew
❑ Use counterhold - T10069- to loosen and tighten
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
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2.2
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Special tools and workshop equipment required
AG.
♦ Fitting tool - T10122-
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15 - 25 Nm
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12 - 60 Nm + 1/2 turn (180°) further
rrectness
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spec
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11 - Shim
❑ determining drive plate distance ⇒ page 34
❑ Only use individually
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10 -ssIntermediate plate
❑ For gearbox attachment
❑ When installing, bolt to cylinder block first and only then fit sump
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- .
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Then set pulling sleeve
- T10122/2- with dry oil seal ontoarante
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crankshaft journal.
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– Separate the two fitting osleeves.
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32 Rep. gr.13 - Crankshaft group
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–
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
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Removing:
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♦ Counterhold - T10044-
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.
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– When removing bolts -B-, make sure that screw heads do not
jam on flywheel.
in t
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– Turn flywheel -A- so that bolts -B- are centred in holes
-arrows-.
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2. Sealing flange and dual-mass flywheel
33
AG.
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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
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Removing and installing drive plate
Special tools and workshop equipment required
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AG.
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34 Rep. gr.13 - Crankshaft group
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♦ Torque wrench - V.A.G 1332-
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♦ Counterhold - T10069-
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2.4
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Flywheel to crankshaft
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Removing
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Phaeton
2003 ➤
gu
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d
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6-cylinder
injection
engine
Edition
is
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– 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.
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If specification is not attained:
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– Measure dimension -a- using depth gauge. Specification:
18.0…20.0 mm
Prote
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– 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-
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36 Rep. gr.13 - Crankshaft group
AG.
– Fit puller hooks - T20143/1- behind sealing lip of oil seal as
shown in illustration.
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– Remove vibration damper. To do this, lock vibration damper
using counterhold - T10069- .
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– Remove poly V-belt ⇒ page 28 .
in t
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Removing
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♦ Torque wrench - V.A.G
1332-
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 .
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Renewing crankshaft sealing flange -vibration damper side-
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2. Sealing flange and dual-mass flywheel
AG.
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2.6
un
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– 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-
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– 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
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a
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Removing
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Torque wrench - V.A.G
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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.
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♦ Before applying sealant bead, cover sealing ring with a clean
♦ 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.
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♦ Tighten securing bolt using torque wrench - V.A.G 1601- .
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♦ Renew securing bolt for vibration damper.
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Note
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– Install sump ⇒ page 101 .
– 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
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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
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spec
at
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3 - Circlip
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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 .
un
le
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 .
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.
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7 - 30 Nm + 1/4 turn (90°) further
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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.
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–
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Using a plastic hammer, carefully knock against conrod
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ing cap in -direction of arrow- until it is loose. oris
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Checking piston and cylinder
Installing piston ⇒ page 43 .
Checking piston ring gap
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Test procedure
in t
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♦ Feeler gauges
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Special tools and workshop equipment required
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
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Checking cylinder bores
ise
or
Special tools and workshop equipment required
♦ Cylinder gauge - VAS 6078-
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42 Rep. gr.13 - Crankshaft group
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Test procedure
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
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3.3.1
un
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The cylinder bores must not be measured when the cylinder block
is mounted on assembly stand, as measurements may then be
incorrect.
Installing piston
♦ 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
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– 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
o
f
i
t to the co
n
f
orm
spec
atio
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Special tools and workshop equipment required
in t
his
d
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Piston and cylinder dimensions ⇒ page 43 .
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– Push piston in until it protrudes approx. 15 mm from the lower
edge of the piston fitting tool.
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– 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
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Phaeton 2003 ➤
olks
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6-cylinder injection engine
- Edition 02.2014
ise
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hole
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, is n
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spec
a
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Note
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Crankshaft
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4
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♦ 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
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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
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4.1
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Fitting sender wheel to crankshaft ⇒ page 45
Prote
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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
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spec
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♦ Locking fluid - D 000 6000 A2Procedure
Ensure that contact surfaces of crankshaft and sender wheel are
free of oil and grease.
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.
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– Lightly coat contact surfaces of crankshaft and sender wheel
with locking fluid “D 154 100 A1” for additional security.
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Note
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♦ Torque wrench - V.A.G 1331-
4. Crankshaft
45
AG.
Prote
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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
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used to identify the thickness of the bearing shells.kswagen AG
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If the cylinder block or crankshaft is changed,
ed the crankshaft
ris
o
bearing shells must be reallocated.
th
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Always insert bearing shell for cylinders block (upper bearing shell)
with yellow colour marking.
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nform
spec
at
i
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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:
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46 Rep. gr.13 - Crankshaft group
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The letters are located on the sealing surface of sump.
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
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ole,
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Blue
Red
Red
Yellow
Blue
Red
Yellow
Blue
Purple
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Letters on cylinder block
Letters on crankshaft web
Colour marking of bearing shell
for bearing cap
AG. Volkswagen AG d
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Red
nYellow
tee
ris
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or
u
Yellow
Yellow
ac
a
ss
rrectne
s
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t to the co
n
form
spec
atio
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i
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thi
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en
Bearing cap
Colour marking of bearing Colour marking of bearing
shell for bearing cap
shell for cylinder block
ility
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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
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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.
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♦
AG. Volkswagen AG d
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To remove cylinder head, engine must be removedor⇒
is page 3
eo
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ut
ra
a
If an exchange cylinder head is installed, all thess contact sur‐
c
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
♦ The plastic protectors fitted to protect the open valves must be
rrectness
o
f
i
t to the co
n
f
orm
spec
atio
h re
n
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
r
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iva
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fo
ng
Removing and installing cylinder head ⇒ page 52 .
Checking compression ⇒ page 74 .
1.1
Assembly overview
48 Rep. gr.15 - Cylinder head, valve gear
AG.
Install camshaft adjuster with timing chain for camshaft drive
⇒ page 64
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Installing timing chains for intermediate shaft drive and camshaft
drive ⇒ page 58
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Checking valve timing ⇒ page 56 .
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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.
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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
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15 - Inlet camshaft control valve 1 - N205❑ For inlet camshaft.
❑ Before removing, mark connector belonging to component.
❑ Removing and installing ⇒ page 79
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16 - Exhaust camshaft control valve 1 - N318❑ For exhaust camshaft.
❑ Before removing, mark connector belonging to component.
❑ Removing and installing ⇒ page 79
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11 - O-ring ised b
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❑ For
ut sealing oil channel.
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❑ Renew
❑ Lubricate before installing.
1. Cylinder head
49
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Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
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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.
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23 - 60 Nm + 1/4 turn (90°) further
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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
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24 - Exhaust camshaft adjuster
❑ Identification: 32A.
❑ Rotate engine only with camshaft adjuster installed.
❑ Installing ⇒ page 58 .
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⇒ Item 16 (page 49) .
❑ Renew if damaged or leaking
❑ Installing ⇒ page 73 .
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❑ 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
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Max. permissible distortion: 0.05 mm
1. Cylinder head
51
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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-
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•
The engine must be no more than warm to touch.
•
Coolant has been drained ⇒ page 115 .
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Engine has been removed ⇒ page 3
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♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant, refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
52 Rep. gr.15 - Cylinder head, valve gear
AG.
When doing any repair work, especially in the engine compart‐
ment, pay attention to the following due to the cramped condi‐
tions:
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Prerequisites
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Removing
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♦ Sealant - D 176 501-
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injection
engine
Edition
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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
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spec
at
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– Remove poly V-belt ⇒ page 28 .
– Remove intake manifold and cylinder head cover
⇒ page 68 Removing and installing cylinder head cover.
AG.
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– After checking, remove camshaft bar.
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– If not, turn crankshaft another 360° in engine direction of ro‐
tation to TDC of cyl. 1.
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– The camshaft bar - T10068 A- must engage in both shaft
grooves to allow the TDC position to be checked.
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– Set crankshaft to TDC No. 1 cylinder marks -arrow- by turning
crankshaft on the vibration damper securing bolt in direction
of engine rotation:
– 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.
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– 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-.
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54 Rep. gr.15 - Cylinder head, valve gear
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– Lay camshaft timing chain aside.
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– 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
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– 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.
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– Ensure that the dowel sleeves are inserted in cylinder block
holes 12 and 20 so that the cylinder head gasket is located.
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– Now carefully clean sealing surfaces of
cylinder
head and cyl‐
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inder block. Ensure that the surface
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or
than “100”.
a
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♦ 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
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– The camshaft bar - T10068 A- must engage in grooves
Vol in both
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–
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.
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– 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.
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Installing timing chains for intermediate shaft drive and camshaft
drive ⇒ page 58
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Further assembly is basically the reverse of the dismantling se‐
quence.
Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
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♦ Camshaft bar - T10068 A-
– 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
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– 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.
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– 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
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The grooves of the camshafts
might not be exactly vertical due to
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the function of camshaft
adjusters.
Therefore,
move
the
cam‐
s
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– 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
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If the markings align:
AG.
– Adjust valve timing ⇒ page 58 .
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If the markings do not align:
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engines on the control housing. Observe only markings for
MPI engines ⇒ page 58 .
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Check setting marks of camshaft adjusters against marks on tim‐
ing housing:
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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
Installing timing chain for intermediate shaft drive and camshaft drive
58 Rep. gr.15 - Cylinder head, valve gear
Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
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♦ Sealant - D 176 501 A1-
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♦ Torque wrench V.A.G 1331-
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♦ Counterhold - T10069-
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♦ Camshaft bar - T10068 A-
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Special tools and workshop
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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.
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Insert timing chain into guide rail and place on crankshaft.
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– Turn intermediate shaft with flattened side upwards.
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– 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.
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– Fit small sprocket of intermediate shaft. Installation is only
possible in one position.
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If timing chain has already been used, note marking for direction
of rotation ⇒ page 22 .
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– 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:
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The camshaft adjusters are installed
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Cams -A- of cylinder 1 must face each other.
Crankshaft is positioned at TDC
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– Insert camshaft bar - T10068 A- in both shaft grooves.
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– 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
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achain
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– Fit small sprocket with timing chain attached
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– Check position of crankshaft to intermediate shaft once again.
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– 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.)
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– Lock vibration damper using counterhold - T10069- .
Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
•
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behind -arrow C-.
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– Check position of copper coloured chain links to adjustment
markings.
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Lug on sprocket
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shaft
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marking
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The copper coloured chain links no longer align with the adjust‐
ment markings once the crankshaft has been turned.
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– 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.
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-arrows-.
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Remove old sealant from 3 mm holes in cylinder
head gasket
s
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spec
at
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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.
The copper coloured chain links no longer align with the adjust‐
ment markings once the crankshaft has been turned.
– 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.
Note
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– Turn crankshaft two full turns in direction of engine rotation
and check valve timing again ⇒ page 56 .
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– Install chain tensioner for camshaft roller chain -arrow- and
tighten to 40 Nm.
do
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– Then tighten M8 securing bolts to 23 Nm and then tighten M6
securing bolts to 8 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.
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Note
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spec
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– Insert camshaft bar - T10068 A- in both shaft grooves. If nec‐
essary, move the camshafts back and forth slightly with an
open-end spanner.
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– Cams -A- of cylinder 1 must faceneach
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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
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spec
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tight with camshaft roller chain positioned »tautly« on inlet cam‐
shaft.
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– Ensure the camshaft roller
dchain is »tight« against guide rail uara
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-1- and does not »slag«.
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It 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
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66 Rep. gr.15 - Cylinder head, valve gear
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– Turn sender wheel -1- of exhaust camshaft adjuster to right
onto stop -arrow- and hold adjuster in this position.
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– 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”,
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– 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
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If the markings align:
– Hold camshaft which is to be tightened using a 32 mm openend spanner -arrow-.
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– Check the position of both camshaft adjusters again to ensure
the setting is correct.
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– It must be possible
ho to easily position the exhaust camshaft
o
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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
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68 Rep. gr.15 - Cylinder head, valve gear
in t
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spec
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To remove cylinder head, intake manifold must first be removed.
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-
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♦ Puller - T10095 A-
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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.
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– Remove engine covers.
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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.
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70 Rep. gr.15 - Cylinder head, valve gear
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– 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
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– Remove cylinder head cover.
Installing
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Note
♦ 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.
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 .
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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
Specified torque
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Threaded connection
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s When installing,
Installation is carried out in the reverse order.
note the following:
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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
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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
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by
10 - Seal
❑ Renew if damaged or leaking
❑ Installing ⇒ page 73 .
AG.
9 - 8 Nm
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8 - Seal
❑ Renew if damaged or
leaking
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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
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thi
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6 - Hall sender 2 - G163❑ For exhaust camshaft.
❑ Before removing, mark
connector belonging to
component.
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5 - 8 Nm
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4 - Supply line connection
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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.
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Installing cover seals
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1.7.1
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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
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– Install oil seal with fitting sleeve - 3378- in cover -1- and pull
in flush using thrust piece - 3253/6- of assembly tool - 3253- .
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– Do not lubricate seals.
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Installing seals
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– Now remove cover ⇒ page 71 .
in t
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– Remove thermostat housing ⇒ page 113 Parts of cooling sys‐
tem, engine side.
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-
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74 Rep. gr.15 - Cylinder head, valve gear
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♦ Torque wrench (5…50 Nm)
- V.A.G 1331-
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♦ Spark plug socket and ex‐
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♦ Assembly tool - T10118-
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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
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Using compression tester ⇒ operating instructions .
– Have a second mechanic fully depress accelerator and crank
engine.
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– 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- .
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– Carry out road test.
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Observe applicable safety precautions during road test.
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– Generate the readiness code in combination with a road test.
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– Finish the vehicle system test so that any fault entries stored
during assembly can be deleted automatically.
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– 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.
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3 - Seal
❑ Renew if leaking.
❑ When installing valve
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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
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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
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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
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12 - Cylinder headed by V
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❑ Check for
ho distortion ⇒ page 51 .
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❑ 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.
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13 - Support element
❑ Before installing, check camshaft axial clearance ⇒ page 90 .
❑ Do not interchange
❑ With hydraulic valve clearance compensation.
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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.
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17 - Valve spring
❑ Note installation position
❑ Removing and installing ⇒ page 87 , Renewing valve stem seals.
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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
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78 Rep. gr.15 - Cylinder head, valve gear
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– Unclip strainer -2- from back of valve timing housing -1- and
remove any dirt.
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-
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♦ Special wrench, long reach
- T10072-
Not illustrated:
♦ Sealant - AMV 174 004 01Removing:
Prerequisites
The engine must be removed.
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– Remove cylinder head cover ⇒ page 68 .
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♦ 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.
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♦ Cover lower chain housing carefully so that no parts can
fall into it.
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80 Rep. gr.15 - Cylinder head, valve gear
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♦ Securing bolts for camshaft control valves must not be
completely removed at first, so that the valve is not canted
during removal.
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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-.
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Installing:
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–
♦ 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.
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– Tighten securing bolts -arrows- to 3.8 Nm.
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– Carefully insert camshaft control valve into housing and push
vertically to valve axis to stop by hand.
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♦ 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
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♦ Camshaft bar - T10068 A-
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♦ Torque wrench (5…50 Nm)
- V.A.G 1331♦ Torque wrench (40…200
Nm) - V.A.G 1332♦ Sealant - D 176 501-
Prote
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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 .
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Installing camshafts ⇒ page 85 .
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♦ 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 .
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– It must now be possible to insert camshaft bar - T10068 A- in
groove in both shafts.
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– Set crankshaft to TDC No. 1 cylinder marks -arrow- by turning
crankshaft on the vibration damper securing bolt in direction
of engine rotation:
2. Valve gear
83
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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.
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Disconnect connectors from theedfollowing
components of cov‐
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Camshaft control valve 1ss- N205- ,
♦ Hall sender - G40- ,
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spec
at
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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.
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Note
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
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– First remove exhaust camshaft adjuster.
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♦ Exhaust camshaft control valve 1 - N318- ,
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.
–
–
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– Remove roller rocker fingers together with support elements
and lay aside on a clean surface.
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2.3.2
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– Ensure that roller rocker fingers and support elements are not
interchanged.
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Loosen bearing caps 6 and 10 alternately
and
diagonally.
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Carefully remove camshafts aand
lay aside on clean surface.
ut
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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).
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– 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
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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
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Installing inlet camshaft -A-
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– Tighten bearing caps 5 and 9 alternately and diagonally to
5 Nm + 1/8 turn (45°).
– Install bearing caps 1 and 13 and tighten to 5 Nm + 1/8 turn
(45°).
– Install bearing cap 7 and tighten to 5 Nm and turn 1/8 (45°)
further.
– Install bearing caps 3 and 11 and also tighten to 5 Nm + 1/8
turn (45°).
Installing exhaust camshaft -B-
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– Install bearing caps 2 and 14 and tighten 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
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– Install bearing caps 4 and 12 and also tighten to 5 Nm + 1/8
turn (45°).
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– Install bearing cap 8 and tighten to 5 Nm and turn 1/8 (45°)
further.
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– Tighten bearing caps 6 and 10 alternately and diagonally 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.
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– Install control housing -arrowso
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– 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.
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ed roller chain with camshaft adjustersran
– Now install camshaft
tee
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⇒ page 64 . ut
or
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– 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
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88 Rep. gr.15 - Cylinder head, valve gear
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♦ Adapter - T40012/1-
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♦ Valve stem seal fitting tool 3365-
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♦ Valve stem seal puller 3364-
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♦ Valve assembly device 2036-
Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
♦ Torque wrench (5…50 Nm)
- V.A.G 1331-
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– Remove camshafts ⇒ page 82 .
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– 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
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– Remove valve springs using valve lever - VW 541/1A- and
press tool - VW 541/6- .
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Tight cotters can be loosened by tapping lightly on lever.
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– Pull off valve stem seals using valve stem seal puller - 3364- .
AG.
Installing
2. Valve gear
89
– 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
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– 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
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2.4.1
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– To prevent damage to new valve stem seals, place plastic
sleeve -A- on valve stem.
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Phaeton 2003 ➤
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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
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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
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– Renew cylinder head.
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If rock tolerance is exceeded:
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– Determine rock. Wear limit: 0.8 mm
rrectne
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form
spec
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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 .
Note
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
r
fo
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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
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- Measured distance
Minimum dimension
= max. perm. rework dimension 5)
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Example:
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Minimum dimension:
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The max. permissible reworking dimension is calculated
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– Insert valve and press firmly against seat. s
Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
AG. Volkswagen AG d
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=
=
=
Z
=
α
β
=
=
g
=
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
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∅ 29.8 mm
Max. permissible re‐
working dimension6)
1.2…1.7 mm
max. ∅ 35.0 mm
radius 2.0 mm
AG.
=
=
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Reworking exhaust valve seat
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2.6.2
working dimension6)
0.9…1.5 mm
max. ∅ 38.0 mm
radius 2.0 mm
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mm
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Reworking inlet valve seat by Volksw
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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
2.6.3
Valve dimensions
Note
mm
mm
mm
∠°
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Long
exhaust valve
30.20
5.97
102.20
44° 40´
30.20
5.97
136.20
44° 40´
Prote
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94 Rep. gr.15 - Cylinder head, valve gear
in t
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∅b
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Short
exhaust valve
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Dimension
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Exhaust valves
33.20
5.98
136.36
44° 40´
AG.
33.20
5.98
102.46
44° 40´
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mm
mm
∠°
Long
inlet valve
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Short
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Valves must not be reworked. Only lapping-in is permitted.by V
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Inlet valves
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Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
Lubrication
1
Parts of lubrication system
rrectness of i
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nform
spec
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♦ 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
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Assembly overview ⇒ page 95
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Engine oil (oil capacities and engine oil specification)
⇒ page 95
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♦ 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
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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.
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10 - Intermediate shaft
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9 - Oil pump drive
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8 - O-ring
❑ Renew
❑ Lubricate before installing.
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spec
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4 - Cylinder block
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❑ Removing and installing
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sealing flange and dual- by V
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mass flywheel
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⇒ page 30 .
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❑ 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
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Oil spray jets are installed in main bearings
2…7.
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Note
– Press oil spray jet out towards bearing using a 4 mm ∅ drift.
Installing
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– To install, press oil spray jet in to correct installation position
by hand using a 6 mm ∅ drift -arrow-.
rrectne
s
s
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f
i
t to the co
n
form
spec
atio
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Removing
1. Parts of lubrication system
97
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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
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b - Oil level within hatched zone:sengine
can be added
does
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98 Rep. gr.17 - Lubrication
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Assembly overview - dismantling and assembling oil filter housing
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c - Area from min. mark up
ed to hatched field: Must be topped up, ran
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max. 0.5 l of engine oil!
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Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
1 - Oil filter housing/engine
bracket
2 - Seal
❑ Renew
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3 - Oil cooler seal
❑ Insert in oil cooler before
installing ⇒ page 99
❑ Renew
❑ Lubricate before instal‐
ling.
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spec
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5 - Securing ring
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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
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9 - Oil filter element
❑ Observe change inter‐
vals.
❑ See note ⇒ page 95
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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
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First tighten
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⇒ Item 7 (page 100) to cylinder
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and
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⇒ Item 2 (page 100) . aFinally
tighten oil pump with securing bolts
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⇒ Item 3 (page 100) s.s
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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 .
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100 Rep. gr.17 - Lubrication
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9 - Seal
❑ Renew if damaged
AG.
8 - 8 Nm
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7 - Oil pressure pipe
❑ Secure only with new
“microencapsulated”
bolts
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6 - 10 Nm
❑ Renew
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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
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Checking oil pump axial clearance
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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
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♦ Engine and gearbox jack - V.A.G 1383 A-
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♦ 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
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– 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.
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fo
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– 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 .
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– Fit support - T10151- in place of retainer -arrows-.
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– Now unbolt retainer for cable guide.
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– Pull 3-pin connector off oil level and oil temperature sender G266- .
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Removing
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♦ 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
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– Clean sealing surfaces. They mustrisebe
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Intermediate plate must be bolted firmly to cylinder block
⇒ Item 10 (page 31) .
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Prerequisite
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Installing
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♦ 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-.
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The sealant bead must not be thicker, otherwise excess sealing
compound will enter the oil sump and may block the oil suction
line strainer.
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– 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
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– Apply silicone sealing compound
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– Install sump uimmediately
and tighten all sump bolts lightly.tee o
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– Tighten sump/intermediate plate securing bolt -arrow- to
45 Nm.
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Let sealing compound dry for approx. 30 minutes after installing
sump. Only then fill with engine oil.
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Further assembly is basically the reverse of the dismantling se‐
quence.
AG.
1.6
Checking oil pressure and oil pressure
switch
Checking oil pressure switch ⇒ page 106 .
Checking oil pressure ⇒ page 107 .
104 Rep. gr.17 - Lubrication
rrectne
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form
spec
atio
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– 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
♦
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♦ Auxiliary measuring set V.A.G 1594C-
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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
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agen
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•
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)
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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 (-).
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Observe installation position of adapter: the conical connecting
piece of the adapter must be screwed into the pressure hose of
the tester.
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– 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.
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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
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form
spec
atio
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Test prerequisites utho
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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.
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– Check pressure pipe between oil pump and cylinder
wage block for
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leaks.
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– Rectify mechanical damage, e.g. bearing
damage.
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At higher engine speeds, the oil pressure
must not exceed 7.0
bar.
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spec
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– Check oil channels.
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If the specification is exceeded:
Pressure relief valve in oil pump may be stuck.
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– Renew oil pump ⇒ page 100 , Dismantling and assembling oil
pump.
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1. Parts of lubrication system
107
AG.
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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
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♦
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Spring-type
clip pliers - VAS 5024A- are recommended for in‐
ss
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♦ When installing coolant hoses, route stress-free so that they
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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 .
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Thermostat housing ⇒ page 112
Coolant mixture ratios ⇒ page 115 , draining and filling with cool‐
ant.
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108 Rep. gr.19 - Cooling
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Removing and installing coolant pump ⇒ page 119 .
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a
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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
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3 - 10 Nm
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4 - Radiator
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2 - Condenser
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❑ Removing and installing
⇒ page 118
❑ After renewing, renew
entire coolant.
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.
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10 - Front coolant pipe, bottom
❑ With coolant pipe for
gear oil cooler
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9 - Lower coolant hose
❑ Secured to radiator and
thermostat housing with
a retaining clip.
❑ Ensure secure seating
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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
7 - Radiator fan control unit 2 J6718 - Radiator fan 2 - V177-
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110 Rep. gr.19 - Cooling
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5 - Radiator fan - V7-
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4 - 10 Nm
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2 - 10 Nm
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1.2
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Phaeton 2003 ➤
e
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6-cylinder injection engine - Edition 02.2014
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Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
Assembly overview - parts of cooling system, body side
4 - Plug
5 - Coolant hose
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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
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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.
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10 - To upper coolant hose
❑ ⇒ Item 15 (page 109)
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9 - To heat exchanger for aux‐
iliary heater
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8 - To heat exchanger for heat‐
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7 - Y-piece
❑ Note installation posi‐
tion
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6 - Cable guide
❑ For coolant hose and
wiring harness
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
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Assembly overview - thermostat hous‐
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Phaeton 2003 ➤ aut
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6-cylinder injections engine - Edition 02.2014
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
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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.
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4 - 8 Nm
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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 .
11 - Y-piece
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10 - Bracket
12 - From continued coolant
circulation pump - V51- .
❑ Installation location of
pump ⇒ page 114
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9 - To heat exchanger for heat‐
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8 - Connection
❑ ⇒ Item 4 (page 99)
AG.
7 - To cylinder block
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5 - Coolant pipe
❑ Between coolant pump
and thermostat housing
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4 - Lower coolant hose
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3 - To upper coolant hose
❑ Secured to radiator with
quick-release coupling.
❑ Ensure secure seating
❑ Coolant hose schematic
diagram ⇒ page 114 .
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2 - From expansion tank
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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)
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2 - Non-return valve, observe
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Coolant hose schematic diagram
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3 - Hose (pump inlet)
ed from lower coolant hose
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⇒ 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
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9 - Continued coolant circula‐
tion pump - V51-
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8 - Oil cooler
❑ For engine oil.
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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-
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Draining
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♦ Cooling system charge unit
- VAS 6096-
WARNING
– Open cap on coolant expansion tank.
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– Remove insulation tray: ⇒ General body repairs, exterior;
Rep. gr. 50 ; Body - front; Assembly overview - noise insulation
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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.
1. Parts of cooling system
115
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Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
– Unscrew plug -arrow- from coolant pipe
⇒ Item 16 (page 113) .
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Follow disposal regulations for coolant!
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– 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) .
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116 Rep. gr.19 - Cooling
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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
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♦ Read off anti-freeze figures for
ed respective replenished anti-
freeze.
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in the coolant below this temperature.
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♦ 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.
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Procedure
40 %
50 %
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-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.
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– Screw adapter - V.A.G 1274/7- onto expansion tank.
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Frost protection Anti-freeze
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♦ Do not reuse old coolant.
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♦
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The temperature read soff
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1. Parts of cooling system
117
AG.
Prote
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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-
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– Drain coolant ⇒ page 115 .
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Removing
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♦ Torque wrench - V.A.G 1331- (5…50 Nm)
– 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 .
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Installation is carried out in the reverse order. When installing,
note the following:
– 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.
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– Replenish coolant ⇒ page 115 .
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– Remove radiator upper securing pins and remove radiator to
rear.
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-
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nform
spec
at
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– 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.
– Tighten securing bolts. Specified torque: 20 Nm
AG.
Prote
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– Fill with new coolant ⇒ page 115 .
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– Install poly V-belt ⇒ page 28 .
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– Fit coolant pump.
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Removing
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♦ Torque wrench - V.A.G 1331- (5…50 Nm)
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.
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Observe rules for cleanliness ⇒ page 128 .
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Assembly overview - fuel tank with attachments
and
fuel
filter
s
Observe safety precautions ⇒ page 128 .
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⇒ page 120 .
Removing and installing fuel tank with its attachments and fuel
filter ⇒ page 137 .
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spec
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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
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Assembly overview - fuel tank with attachments and fuel filter
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120 Rep. gr.20 - Fuel supply system
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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
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12 - 20 Nm + /4 turn (90°) fur‐ tho
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14 - Cross member
❑ For fuel tank
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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
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23 - To connection on supply and return flange
❑ ⇒ Item 8 (page 123)
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22 - Supply line
❑ Black
❑ Ensure secure seating
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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
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The fuel hoses between the right and left side of fuel tank are
secured with cable binder.
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122 Rep. gr.20 - Fuel supply system
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fuel delivery unit, fuel gauge sender and
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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)
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4 - Connector
❑ Coded connector to
flange
⇒ Item 25 (page 124) .
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3 - Supply line for suction-jet
pumps
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8 - Connection
❑ For fuel return line ⇒ Item 23 (page 121) .
❑ Arrow points towards connection.
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7 - Seal
❑ Renew
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6 - Connection
❑ Fuel supply line
⇒ Item 24 (page 122) .
❑ Arrow points away from
connection.
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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 .
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.
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18 - Supply line
ss
❑ Suction-jet pump, right side
19 - Return line
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20 - Supply line
21 - Non-return valve
22 - To return line of fuel delivery unit, left side
❑ ⇒ Item 20 (page 126)
23 - From supply line of fuel delivery unit, left side
❑ ⇒ Item 19 (page 126)
24 - Locking ring, 110 Nm
❑ Ensure secure seating
❑ Remove and install using wrench - 3087-
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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
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27 - To fuel delivery unit on left side.
❑ Clipped onto right of fuel delivery unit.
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26 - Seal
❑ Renew
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25 - Flange
❑ Note installation position on fuel tank ⇒ page 126
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‐
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4 - Seal rised b
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6 - Flange
❑ Note installation posi‐
tion on fuel tank
⇒ page 126
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7 - Fuel gauge sender 2 G169❑ Plunger-type sender.
❑ Checking: ⇒ Vehicle di‐
agnostic tester.
8 - Locking lug
❑ Clipped onto left of fuel
delivery unit
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9 - Connector
❑ Coded connector to
flange
⇒ Item 6 (page 125) .
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5 - Supply line
❑ For auxiliary heater.
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10 - To supply line for suction-jet pump, right side
❑ ⇒ Item 28 (page 124)
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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.
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The pressure retention valve is open from breathers valve (on ex‐
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pansion tank) for flow in both directions (-arrow 1-, side to expan‐
sion tank).
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spec
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Schematic diagram of fuel lines and
components in fuel tank
Note
The fuel hoses between the right and left side of fuel tank are
secured with cable binder.
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126 Rep. gr.20 - Fuel supply system
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-B- Right side of tank
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-A- left side of fuel tank
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On the other side, flow is possible in only direction -arrow 2- (side
to activated charcoal filter).
11 - Flange
❑ Left side
un
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12 - Fuel delivery unit
❑ Left side
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10 - Supply line for auxiliary
heater
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9 - Y-piece
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8 - Non-return valve
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7 - Y-piece
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6 - Connecting hose
❑ From filler neck.
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❑ Right side
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❑ Right side
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3 - Return line
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2 - Supply line
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1 - Supply and return flange
❑ With connections for
quick-release couplings
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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.
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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.
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♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
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♦ 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
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When working on the fuel supply and injection system, observe
the following “5 rules” for cleanliness:
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♦ 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.
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♦ Fuel supply lines are under pressure! Before
swagen AG
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points,
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opening the fuel line. oris
Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
♦ Fuel extractor - VAS 5190-
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.
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When no more fuel can be extracted
do
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– Push suction hose -arrow- of fuel extractor - VAS 5190- about
160…170 cm into fuel filler neck and extract fuel.
rrectness of i
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♦ Wrench - 3087-
– Unclip both covers for sender flanges in luggage compartment
floor.
1. Parts of fuel supply system
129
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Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
AG. Volkswagen AG d
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– Pull connector -arrows- off right sender flange.
– 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.
– When breather lines are pulled off, buttons of hose couplings
sometimes cannot be pressed in. Use assembly tool - T10118-arrow- to press in button.
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.
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– For work on left side of fuel tank, proceed as described above.
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– Insert suction hose of fuel extractor - VAS 5190- as deeply as
possible into right and then left side of fuel tank and extract
fuel.
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– Carefully lever out flange and raise it slightly.
do
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– 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
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Removing and installing fuel delivery
unit, fuel gauge sender and suction-jet
pump, right side
Special tools and workshop equipment required
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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
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♦ Wrench - 3087-
rrectne
s
s
o
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i
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spec
atio
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i
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thi
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1.8
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– 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
AG. Volkswagen AG d
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– Pull off three connectors -arrows- underneath right sender
flange.
rrectness
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orm
spec
atio
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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-.
AG.
132 Rep. gr.20 - Fuel supply system
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– Pull off three connectors -arrows- underneath left sender
flange.
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– Pull off return line -1- and supply line -2- on right side.
in t
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– On right side, -B-, unclip return hose of left-hand suction-jet
pump -2- out of fuel delivery unit -1- -arrows-.
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
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– Now unclip black return hose -2- from fuel delivery unit housing
-1- on left side -A- -arrows-
rrectness of i
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The fuel delivery unit housing is filled with fuel. Fuel may run out
if housing is tipped or canted.
1. Parts of fuel supply system
133
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Prote
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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.
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1.9
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– Now unclip fuel gauge sender -2- and it pull out.
rrectness of i
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at
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his
Removing and installing fuel delivery
unit, fuel gauge sender and suction-jet
pump, left side
Special tools and workshop equipment required
r
fo
ng
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
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•
AG.
Fuel tank must be drained ⇒ page 128 , Draining fuel tank.
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•
do
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Test prerequisites
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♦ 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.
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– On left side, -A-, unclip return hose of right suction-jet pump
-2- out of fuel delivery unit -1-.
do
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– Pull off three connectors -arrows- underneath right sender
flange.
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1. Parts of fuel supply system
135
AG.
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– 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.
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– 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
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Note
r
fo
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– 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
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spec
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Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
– Now unclip suction-jet pump -3- on left side -A- and remove
by turning slightly.
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– Now unclip fuel gauge sender -2-geand
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1.10
Removing and installing fuel tank with attachments and fuel filter
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Special tools and workshop
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♦ Fuel extractor - VAS 5190-
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♦ Engine and gearbox jack V.A.G 1383 A-
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♦ Torque wrench V.A.G 1332-
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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.
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♦ 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
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– Remove propshaft ⇒ Transfer
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– Remove rear axle
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– Disconnect breather line -1-.
– Remove securing bolt -3- for breather tank -2- and pull it out
of mounting in inner wheel housing -arrows-.
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– Unclip both covers for sender flanges in luggage compartment
floor.
– Pull connector -arrows- off right sender flange.
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138 Rep. gr.20 - Fuel supply system
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– Remove filler neck securing bolts ⇒ Item 32 (page 122) .
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– Unscrew securing bolt and remove tank flap unit with rubber
cup.
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– 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.
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– Hold cloth around fuel line connectors -1- and -2- and pull them
apart.
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– Then separate connector -3- of breather line.
– Support fuel tank with engine and gearbox jack - V.A.G 1383
A- and loosen securing straps -2-.
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– Now unscrew cross member -1-.
Installation is carried out in the reverse order. When installing,
note the following:
AG.
Prote
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♦ 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-
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140 Rep. gr.20 - Fuel supply system
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♦ 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-
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1.11.1
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♦ Multimeter - V.A.G 1715-
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♦ Auxiliary measuring set V.A.G 1594C-
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♦ Voltage tester - V.A.G
1527B-
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♦ 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
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Push in button on hose coupling to do this.
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– 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.
Prote
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– Empty measuring container.
– 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.
– 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.
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– Connect positive terminal -1- of remote control to positive pole
in engine compartment.
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– 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-.
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– Open pressure tester shut-off tap. The lever then points in the
direction of flow.
Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
– Compare quantity of fuel delivered with specification.
7) Delivery rate cm3/30 seconds
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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.
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– Renew fuel filter.
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– Repeat delivery rate check.
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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
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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.
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– 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
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– Operate remote control for 30 seconds while measuring bat‐
tery voltage.
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– Compare quantity of fuel delivered withsspecification.
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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
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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
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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
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– Separate supply line on right side -2-.
– 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.
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146 Rep. gr.20 - Fuel supply system
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– Disable activation of left pump:
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
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– Right fuel pump is defective.
Renew
fuel
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⇒ page 131 .
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Checking non-return valve of left pump
– Reconnect supply line on right side -2-.
– On right side, separate supply line -4- to left pump.
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– 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.
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1.11.7
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If pressure drops
⇒ page 147
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– 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
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The activated charcoal filter system
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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.
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♦ Spring-type clip pliers - VAS 5024A- or hose clip pliers -
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clips.
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clamp-type clips.
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The activated charcoal stores these vapours like a sponge.
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hothe highest point in the tank (on filler neck)
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activated
charcoal
filter.
ss
AG.
Prote
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Assembly overview - parts of activated charcoal filter system
⇒ page 148
Observe safety precautions ⇒ page 128 .
Observe rules for cleanliness ⇒ page 128 .
2.1
Assembly overview - parts of activated charcoal filter system
148 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
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❑ On intake amanifold.
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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
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10 - Breather line
❑ To pressure retention
valve on expansion tank
⇒ Item 28 (page 122)
2. Activated charcoal filter system
149
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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-
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– Pull breather hose -1- (to solenoid valve) off breather line -2(from activated charcoal filter).
AG.
Prote
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150 Rep. gr.20 - Fuel supply system
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Test procedure
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♦ Adapter set - V.A.G
1318/17-
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.
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– Connect adapter - V.A.G 1318/17- to line leading to solenoid
valve and seal it.
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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.
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– Operate hand vacuum pump - V.A.G 1390- several times.
Vacuum must not build up.
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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
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152 Rep. gr.20 - Fuel supply system
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– Renew activated charcoal filter.
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
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4 - Accelerator position sender
- G79- and accelerator position
sender 2 - G185❑ Not adjustable.
❑ Remove footwell cover
to remove sender.
Function of EPC system
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.
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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.
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The position of the accelerator (driver's requirement) is a main
input value for the engine control unit.
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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.
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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
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Observe rules for cleanliness ⇒ page 128 .
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154 Rep. gr.20 - Fuel supply system
or
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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
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Assembly overview - dismantling and assembling fuel rail
⇒ page 157
Assembly overview - air filter ⇒ page 158
rrectness of i
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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.
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Assembly overview - intake manifold
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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
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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
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156 Rep. gr.24 - Mixture preparation - injection
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20 - Dowel sleeve
❑ To secure intake manifold.
❑ To locate seal.
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13 - Vacuum actuator
❑ For intake manifold change-over.
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12 - 10 Nms au
AG.
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
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4 - Injector - N30...N33, N83,ise
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❑ Checking ⇒ pages 161
3 - Fuel rail
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5 - Seal
❑ Renew
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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
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12 - Connector
❑ Black, 2-pin
❑ Check for secure seating.
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11 - Retaining clip
❑ Check for secure seat‐
ing.
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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
1 - Intake hose
un
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9 - Air duct
❑ Secured to lock carrier
10 - Connecting piece
❑ For air filter lower part
with air pipe
r
fo
ng
8 - 8 Nm
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
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7 - 6 Nm
AG.
6 - Upper part of air filter
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5 - Seal
❑ Renew if damaged
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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
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wit
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his
3 - To throttle valve module J338- .
❑ ⇒ Item 11 (page 156)
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2 - Spring-type clip
❑ Check for secure seat‐
ing.
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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.
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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.
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♦ 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.).
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♦ Carefully cover opened components or seal if repairs cannot
be carried out immediately.
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form
spec
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thi
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1.6
urposes, in part or in wh
ole,
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Apply assembly tool - T10118- to locking mechanism button
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-arrow- and carefully pull connector off.
ir se
tee
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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
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160 Rep. gr.24 - Mixture preparation - injection
rrectne
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o
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form
spec
atio
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13) Not adjustable.
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Checking components
Checking injectors ⇒ page 161 .
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2.1
rrectness of i
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wit
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s
Checking fuel pressure regulator and holding pressure
⇒ page 163 .
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2
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Phaeton 2003 ➤
ksw
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6-cylinder
injection
engine
Edition 02.2014
e
nte
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ss
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-
do
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♦ Injection rate tester - V.A.G
1602-
2. Checking components
161
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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
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– Operate remote control.
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– 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
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If fuel pump runs:
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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.
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162 Rep. gr.24 - Mixture preparation - injection
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– Insert injector to be checked into measuring glass from injec‐
tion rate tester - V.A.G 1602- .
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– 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- .
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Checking quantity injected
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♦ Fit fuel rail with injectors installed and secured onto lower part
of intake manifold and press in evenly.
– 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:
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♦ Renew O-rings on all injectors and lightly moisten with clean
engine oil.
rrectness of i
t to the co
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spec
at
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his
– Connect crocodile clip to positive battery pole in engine com‐
partment.
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– Connect second injector contact to remote control V.A.G 1348/3A- using adapter cable - V.A.G 1348/3-2- .
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Phaeton 2003 ➤
AG. Volkswagen AG d
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Connect a contact
of
injector
to
be
tested
to
engine
earth
using
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auxiliary cables
from
auxiliary
measuring
set
V.A.G
1594C.
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♦ Insert injectors vertically and in the correct position into the fuel
rail and secure with retaining clips.
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♦ 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-
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The specification for the check is dependent upon the working
pressure of the fuel pump. This is approx. 3.5 bar.
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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
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The fuel pressure regulator regulates the fuel pressure depending
on intake manifold pressure.
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spec
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♦ Adapter - V.A.G 1318/23-
Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
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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.
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– Measure fuel pressure. Specification: approx. 3.5 bar.
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at
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– Connect pressure tester - V.A.G 1318- with adapter V.A.G 1318/17- on hose coupling -1- fuel rail.
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Separate coupling -1from
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supply
line
(black)
-2- and
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lect escaping fuel
a
cloth.
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– 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
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Switch ignition off after the pressure has built up. Atss the same
Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
time, shut-off valve of pressure tester - V.A.G 1318- -arrowshould be closed (lever perpendicular to direction of flow).
– 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- .
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When removing the pressure tester - V.A.G 1318- after the test
has been completed,
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WARNING
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–
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.
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Remove windscreen wiper motor on right side: ⇒ Electrical
ran
ed
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system; Rep. gr. 92 ; Removing and installing windscreen
o
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wiper system .
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– 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
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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
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♦ Diagnosis cable - VAS 5051/1- or -VAS 5051/3-
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♦ Vehicle diagnosis, testing and information system - VAS 5051-
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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‐
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– 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.
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168 Rep. gr.24 - Mixture preparation - injection
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– Press function “06-End output”.
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A print-out can be made if required. Press the Print button.
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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
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♦ To support the exhaust system when removing, use
Vol engine
and gearbox jack - V.A.G 1383 A- .
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After working on the exhaust system, ensure
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has sufficient clearance to the bodywork.
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flange on catalytic converter and realign silencers and exhaust
pipes ⇒ page 174 .
rrectness of i
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spec
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Special tools and workshop equipment required
♦ Lambda probe open ring spanner set - 3337-
do
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♦ Torque wrench (40…200 Nm) - V.A.G 1332-
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1. Parts of exhaust system
169
AG.
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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
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s no
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Vol converter seals tightly. Leaks
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by
arareach
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cause pulsation
in
exhaust.
This
allows
ambient
air
to
e
nte
ris
o
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the Lambda
probe
after
the
catalytic
converter,
thereby
dis‐
h
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ra
a
turbing Lambda
regulation.
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l purpos
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♦ Renew self-locking nuts.
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spec
at
i
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1 - Cylinder head
2 - Gasket
❑ Renew
3 - M8 - 25 Nm, M10 - 40 Nm
4 - Exhaust manifold
5 - Gasket
❑ Renew
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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
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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
14 - Clip
❑ For Lambda probe wiring
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16 - Bracket
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❑ For Lambda probe wiring and activated
charcoal
filter
system
solenoid
valve
1
N80c
s
s
15 - 20 Nm
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17 - 23 Nm
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
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9 - Mounting
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❑ Installation positionss
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spec
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10 - 25 Nm
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⇒ page 174
❑ Renew if damaged
11 - Centre silencer
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15 - Rear silencer
❑ Align rear silencer free of stress.
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14 - Mounting
❑ Installation position ⇒ page 174
❑ Renew if damaged
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13 - 25 Nm
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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
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Installation 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
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1 - The end of the bolt must not project beyond lower edge of
clamp.
2 - Angle between 10° and 15°
rrectness
o
f
i
t to the co
n
f
orm
spec
atio
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♦ Pneumatic sabre saw - V.A.G 1523A-
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Special tools and workshop equipment required
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– Separate connecting pipe between centre silencer and rear
silencer at the point marked with a groove.
1. Parts of exhaust system
173
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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) .
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– Pull off pressure hose of secondary
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valve ⇒ Item 11 (page d177)
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– Then unscrew heat shield with intake manifold support from
cylinder head.
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174 Rep. gr.26 - Exhaust system
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– 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- .
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spec
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– Hold cloth beneath separation point of fuel lines.
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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
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The assembly is basically
a
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sequence.
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– Then install the catalytic converter for cylinders 1, 2 and 3 with
Lambda probe after catalytic converter screwed in.
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– 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.
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Further assembly is basically the reverse of the dismantling se‐
quence.
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♦ Adjust exhaust system so that there is sufficient clearance to
1. Parts of exhaust system
175
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Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
2
Secondary air system
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The secondary air system blows air in behind therisexhaust
valve
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for max. 65 seconds after a cold start (+15 °C u…
t +35 °C coolant
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temperature). This produces an oxygen rich exhaust
gas,
causing
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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
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176 Rep. gr.26 - Exhaust system
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Location of secondary air pump relay - J299- ⇒ page 178
Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
1 - Intake manifold
3 - To intake manifold
14 - Secondary air pump motor
- V101-
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13 - Connection
15 - Rubber bush
16 - Bracket
❑ For secondary air pump
motor - V101-
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12 - O-ring
❑ Renew if damaged
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11 - Pressure hose
❑ Ensure secure seating
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10 - 5 Nm
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9 - Connection
❑ For combination valve.
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8 - 10 Nm
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7 - Air duct
❑ In cylinder head
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6 - Gasket
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5 - Combination valve
❑ Checking ⇒ page 178
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4 - To fuel pressure regulator.
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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-
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Test prerequisites
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Vacuum pipes not blocked or kinked.
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Test procedure
– Detach vacuum hose from secondary air inlet valve - N112from combination valve -arrow-.
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178 Rep. gr.26 - Exhaust system
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Do not use compressed air during the following check!
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Vacuum pipes and hose connections free of leaks.
Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
– Operate hand vacuum pump - V.A.G 1390- . Combination
valve must open.
If combination valve does not open:
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Renew combination valve ⇒ Item 5 (page 177) .
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in t
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– Detach pressure hose to combination valve at connection
-arrow- and blow in softly. Combination valve must be closed.
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– Connect hand vacuum pump - V.A.G 1390- to vacuum con‐
nection on combination valve n-arrow-.
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2. Secondary air system
179
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Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
1
Ignition system
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General notes on ignition system
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Ignition system
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28 –
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♦ 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 .
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Assembly overview - parts of ignition system
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180 Rep. gr.28 - Ignition system
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1.1
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Assembly overview - parts of ignition system ⇒ page 180
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7 - 20 Nm
❑ The torque setting influ‐
ences the function of the
knock sensor.
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6 - Knock sensor 1 - G61❑ Gold-plated contacts on
sensor and connector.
❑ Location: cylinder block
exhaust side
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5 - Connector
❑ Black, 3-pin
❑ Gold-plated contacts on
sensor and connector.
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4 - 10 Nm
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3 - Bracket
❑ For connector for knock
sensor 1 - G61- .
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2 - Connector
❑ 4-pin.
❑ Use assembly tool T10118- to pull off.
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1 - Ignition coil with output
stage - N70, N127, N291,
N292, N323, N324❑ Removing and installing
⇒ page 182
un
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Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
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
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If the engine is to be turned
c
ss at starter speed without starting:
Vol
♦ Switch off ignition before connecting
by or disconnecting injection
d
e
and ignition system wiring as well
ris as test instrument cables.
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at
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♦ 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
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182 Rep. gr.28 - Ignition system
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♦ Assembly tool - T10118-
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Observe following if test and measuring instruments are required
during a road test:
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♦
Phaeton 2003 ➤
6-cylinder injection engine - Edition 02.2014
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♦ Lubricating paste - G 052 141 A2-
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– Apply assembly tool - T10118- to locking mechanism button
-arrow- and carefully pull connector off each ignition coil with
output stage .
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spec
atio
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Removing
in t
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– Push puller - T10095A- on from flat side of connector in
-direction of arrow- and pull out ignition coil with output stage .
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Installing
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♦ Puller - T10095A-
♦ 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
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f
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spec
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1.4
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– Push puller - T10095A- on from flat side of connector in
-direction of arrow- and push ignition coil with output stage
onto spark plug.
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– 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-.
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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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