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  • Examplepage for repair manual 5-cylinder diesel engine
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  • Examplepage for repair manual 3 5-cylinder diesel engine
  • Examplepage for repair manual 5-cylinder diesel engine
  • Examplepage for repair manual 2 5-cylinder diesel engine
  • Examplepage for repair manual 3 5-cylinder diesel engine

5-cylinder diesel engine

For Touareg

Original Volkswagen repair manual


14,43 €7% VAT incl.

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  • English

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Language: English

Digital PDF file

8.029 KB

170 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Assembly mountings, Overview - cylinder head, Engine oil and Parts of lubrication system. Show more
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Repair manual Touareg 5-cylinder diesel engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Technical data
    1
  • 1.1 Engine number
    1
  • 1.2 Engine data
    1
  • 2 Safety instructions
    2
  • 2.1 Safety precautions when working on fuel supply system
    2
  • 2.3 Safety precautions when working on cooling system
    3
  • 3 General repair notes
    4
  • 3.1 Rules for cleanliness
    4
  • 3.2 Foreign objects in engine
    4
  • Removing and installing engine
    5
  • 1 Removing and installing engine
    5
  • 1.1 Removing engine
    5
  • 1.2 Removing engine from scissor-type assembly platform
    13
  • 1.3 Securing engine to assembly stand
    15
  • 1.4 Additional information and assembly work for vehicles with air conditioner
    16
  • 1.5 Installing engine
    17
  • 2 Assembly mountings
    18
  • 2.1 Assembly overview - engine mountings
    18
  • 2.2 Specified torques - Assembly mountings
    18
  • Crankshaft group
    19
  • 1 Dismantling and assembling engine
    19
  • 1.1 Dismantling and assembling engine, parts I-III
    19
  • 1.2 Removing and installing crankshaft
    24
  • 1.3 Removing and installing drive plate
    25
  • 1.4 Crankshaft bearing cap identification
    26
  • 1.5 Crankshaft dimensions
    27
  • 1.6 Renewing crankshaft oil seal - engine timing end
    27
  • 1.7 Renewing alternator shaft oil seal
    28
  • 2 Dismantling and assembling pistons and conrods
    30
  • 2.1 Assembly overview - pistons and conrods
    30
  • 2.2 Separating new conrods
    31
  • 2.3 Installation position and allocation of piston to cylinder
    32
  • 2.4 Checking piston ring gap
    32
  • 2.5 Checking ring-to-groove clearance
    32
  • 2.6 Checking cylinder bores
    33
  • 2.7 Piston and cylinder dimensions
    33
  • Cylinder head, valve gear
    34
  • 1 Overview - cylinder head
    34
  • 1.1 Assembly overview - cylinder head
    34
  • 1.2 Renewing pipe connection for coolant
    36
  • 1.3 Removing and installing camshaft drive gear
    37
  • 1.4 Setting engine to TDC No. 1 cylinder
    41
  • 1.5 Removing and installing cylinder head
    42
  • 1.6 Checking compression
    44
  • 2 Repairing valve gear
    47
  • 2.1 Assembly overview - valve gear
    47
  • 2.2 Reworking valve seats
    51
  • 2.3 Checking valve guides
    53
  • 2.4 Renewing valve stem seals
    53
  • 2.5 Removing and installing camshaft
    55
  • Lubrication
    57
  • 1 Engine oil
    57
  • 1.1 Oil capacities
    57
  • 1.2 Checking engine oil level
    57
  • 2 Parts of lubrication system
    58
  • 2.1 Assembly overview - oil pump, sump
    58
  • 2.2 Assembly overview - oil filter housing
    59
  • 2.3 Removing and installing oil sump
    62
  • 2.4 Checking oil pressure and oil pressure switch
    64
  • Cooling
    67
  • 1 Removing and installing parts of cooling system
    67
  • 1.1 Parts of cooling system, body side
    68
  • 1.2 Assembly overview - radiator fan
    69
  • 1.3 Removing and installing fan support
    69
  • 1.4 Parts of cooling system, engine side
    70
  • 1.5 Coolant hose schematic diagram
    72
  • 1.6 Draining and filling coolant
    72
  • 1.7 Removing and installing radiator
    75
  • 1.8 Removing and installing coolant pump
    77
  • 1.9 Checking oil cooler for leaks
    82
  • Fuel supply system
    85
  • 1 Removing and installing parts of fuel supply system
    85
  • 1.1 Rules for cleanliness
    85
  • 1.2 Safety precautions when working on fuel supply system
    86
  • 1.3 Assembly overview - fuel tank with attachments (► model year 08)
    86
  • 1.4 Assembly overview - fuel tank with attachments (model year 08 ►)
    88
  • 1.5 Assembly overview - fuel filter with fuel cooler
    90
  • 1.6 Emptying fuel tank
    91
  • 1.9 Removing and installing fuel tank with attached components
    99
  • 1.10 Checking fuel pumps
    102
  • 1.11 Checking tandem pump
    104
  • 1.12 Removing and installing tandem pump
    107
  • 1.13 Assembly overview - accelerator mechanism
    109
  • Turbocharging/supercharging
    110
  • 1 Charge air system with turbocharger
    110
  • 1.1 Rules for cleanliness
    110
  • 1.2 Turbocharger with attachments for engine codes BAC and BLK
    110
  • 1.3 Removing and installing turbocharger for engine codes BAC and BLK
    111
  • 1.4 Turbocharger with attachments (engine codes BPD and BPE)
    114
  • 1.5 Removing and installing turbocharger (engine codes BPD and BPE)
    116
  • 1.6 Removing and installing parts of charge air cooling
    119
  • 1.7 Checking charge air system for leaks
    120
  • 1.8 Hose connections
    122
  • 1.9 Vacuum hose schematic diagram
    123
  • Mixture preparation - injection
    126
  • 1 Repairing diesel direct injection system
    126
  • 1.1 Safety precautions
    126
  • 1.2 Rules for cleanliness
    127
  • 1.3 Removing and installing wiring harness for unit injectors
    127
  • 1.4 Removing and installing unit injector
    130
  • 1.5 Assembly overview - unit injector
    133
  • 1.6 Removing and installing O-rings for unit injector
    134
  • 1.7 Assembly overview - intake manifold and fuel rail
    135
  • 1.8 Repairing intake manifold flap
    137
  • 1.9 Dismantling and assembling air filter
    139
  • 2 Engine control unit
    140
  • 2.1 Reading and deleting engine control unit event memory
    140
  • 2.2 Removing and installing engine control unit J623
    141
  • 2.3 Removing and installing anti-theft engine control unit J623
    141
  • Exhaust system
    145
  • 1 Exhaust system
    145
  • 1.1 Assembly overview - front exhaust pipe with catalytic converters
    145
  • 1.2 Assembly overview - front exhaust pipe with particulate filter
    146
  • 1.3 Removing and installing particulate filter
    148
  • 1.4 Assembly overview - exhaust manifold (engine codes BPD, BPE)
    149
  • 1.5 Removing and installing exhaust manifold (engine codes BPD, BPE)
    151
  • 1.6 Silencer with mountings
    153
  • 2 Exhaust gas recirculation system
    155
  • 2.1 Assembly overview - exhaust gas recirculation
    155
  • 2.2 Checking exhaust gas recirculation valve (mechanical)
    159
  • Glow plug system
    161
  • 1 Glow plug system
    161
  • 1.1 Characteristics of glow plugs
    161
  • 1.2 Checking metal glow plugs
    161
  • 1.3 Removing, installing and checking ceramic glow pin plugs
    162
Manufacturer's designation 5-cylinder diesel engine
Manufacturer Volkswagen
Suitable for Touareg (2003 - 2007)
Suitable car types 7L
Engine code BPE, BAC, BLK
Category Reparaturanleitung

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