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  • Examplepage for repair manual 6-cylinder diesel engine (3.0 l engine, common rail)
  • Examplepage for repair manual 2 6-cylinder diesel engine (3.0 l engine, common rail)
  • Examplepage for repair manual 3 6-cylinder diesel engine (3.0 l engine, common rail)

6-cylinder diesel engine (3.0 l engine, common rail)

For Touareg

Original Volkswagen repair manual


38,22 €7% VAT incl.

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Language: English

Digital PDF file

15.674 KB

548 Sites

Detailed technical data

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This repair manual contains: Removing and installing engine, Chain drive (engine codes BKS, BUN), Pistons and conrods, Cylinder head, Engine oil:, Oil cooler, pressure control valve and oil filter housing, Parts of fuel supply system and Charge air system with turbocharger. Show more
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Repair manual Touareg 6-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
    2
  • Removing and installing engine
    3
  • 1 Removing and installing engine
    3
  • 1.1 Removing engine
    5
  • 1.2 Removing engine from scissor-type assembly platform VAS 6131
    13
  • 1.3 Securing engine to assembly stand
    14
  • 1.4 Notes on installing
    15
  • 1.5 Assembly overview - engine mountings
    16
  • 1.6 Removing and installing engine mounting
    16
  • Crankshaft group
    22
  • 1 Dismantling and assembling engine
    22
  • 1.1 Assembly overview - poly V-belt drive
    23
  • 1.2 Removing and installing poly-V belt
    27
  • 1.3 Renewing crankshaft oil seal - pulley end
    29
  • 1.4 Removing and installing front sealing flange
    31
  • 1.5 Assembly overview - drive plate/dual-mass flywheel
    35
  • 1.6 Removing and installing drive plate
    36
  • 1.7 Removing and installing dual-mass flywheel
    37
  • 1.8 Extracting and driving in needle roller bearing for dual-mass flywheel
    39
  • 1.9 Renewing crankshaft oil seal (timing chain end)
    40
  • 1.10 Assembly overview - timing chain covers
    42
  • 1.11 Removing and installing timing chain covers
    43
  • 1.12 Assembly overview - balance shaft
    52
  • 1.13 Removing and installing balance shaft
    53
  • 2 Chain drive (engine codes BKS, BUN)
    57
  • 2.1 Assembly overview - drive chain for valve gear
    57
  • 2.2 Removing and installing drive chain for valve gear
    59
  • 2.3 Assembly overview - chain for balance shaft and oil pump
    60
  • 2.4 Removing and installing chain for balance shaft and oil pump
    61
  • 3 Chain drive (engine codes CASA, CASB, CASC, CATA)
    67
  • 3.1 Assembly overview - drive chain for valve gear
    67
  • 3.2 Removing and installing drive chain for valve gear
    69
  • 3.3 Assembly overview - chain for balance shaft and oil pump
    70
  • 3.4 Removing and installing chain for balance shaft and oil pump
    71
  • 4 Removing and installing crankshaft
    77
  • 4.1 Assembly overview - crankshaft
    77
  • 4.2 Crankshaft dimensions
    81
  • 4.3 Measuring axial clearance
    81
  • 4.4 Measuring radial clearance
    82
  • 5 Pistons and conrods
    83
  • 5.1 Assembly overview - pistons and conrods
    83
  • 5.2 Checking piston projection at TDC
    88
  • 5.3 Piston and cylinder dimensions
    90
  • 5.4 Checking radial clearance of conrods
    90
  • Cylinder head, valve gear
    91
  • 1 Cylinder head
    91
  • 1.1 Assembly overview - cylinder head
    91
  • 1.2 Assembly overview - cylinder head cover
    94
  • 1.3 Removing and installing cylinder head cover
    97
  • 1.4 Removing and installing cylinder head
    104
  • 1.5 Checking compression
    113
  • 1.6 Assembly overview - vacuum pump
    115
  • 2 Assembly overview - valve gear
    117
  • 2.1 Checking axial clearance of camshafts
    119
  • 2.2 Renewing camshaft oil seal
    120
  • 2.3 Removing and installing camshafts
    123
  • 2.4 Renewing valve stem seals
    136
  • 2.5 Checking hydraulic valve compensation elements
    141
  • 2.6 Valve dimensions
    143
  • 2.7 Checking valve guides
    143
  • 3 Chain drive for camshafts
    145
  • 3.1 Camshaft timing chain (engine codes BKS, BUN)
    145
  • 3.2 Camshaft timing chain (engine codes CASA, CASB, CASC, CATA)
    171
  • Lubrication
    198
  • 1 Engine oil:
    198
  • 1.1 Oil capacities
    198
  • 1.2 Checking engine oil level
    198
  • 2 Parts of lubrication system
    200
  • 2.1 Assembly overview - oil pump, lower part of sump
    200
  • 2.2 Removing and installing lower part of sump
    203
  • 2.3 Removing and installing oil pump
    211
  • 2.4 Assembly overview - upper part of sump
    212
  • 2.5 Removing and installing oil pressure switch F1 (engine code CATA)
    217
  • 2.6 Removing and installing oil pressure control valve N428 (engine code CATA)
    217
  • 2.7 Removing and installing upper part of sump
    218
  • 3 Oil cooler, pressure control valve and oil filter housing
    222
  • 3.1 Assembly overview - oil cooler, pressure control valve, and oil filter housing
    222
  • 3.2 Removing and installing oil cooler
    224
  • 3.3 Removing and installing oil filter housing
    225
  • 3.4 Removing and installing pressure control valve for crankcase breather system
    227
  • 3.7 Checking oil pressure and oil pressure switch
    230
  • Cooling
    233
  • 1 Parts of cooling system
    233
  • 1.1 Assembly overview - radiator
    234
  • 1.2 Assembly overview - fan support
    235
  • 1.3 Assembly overview - thermostat and coolant pump
    236
  • 1.4 Coolant hose connection diagram
    238
  • 1.5 Removing and installing fan support
    241
  • 1.6 Draining and adding coolant
    241
  • 1.7 Removing and installing radiator
    245
  • 1.8 Removing and installing coolant pump
    246
  • 1.9 Removing and installing thermostat
    248
  • 1.10 Assembly overview - pump for exhaust gas recirculation cooler V400
    249
  • 1.11 Removing and installing pump for exhaust gas recirculation cooler V400
    250
  • 1.12 Assembly overview - coolant pipes
    250
  • 1.13 Removing and installing coolant pipes
    253
  • 1.14 Removing and installing coolant temperature sender G62
    266
  • 1.15 Checking cooling system for leaks
    267
  • 1.16 Checking coolant pump V36/fuel cooling pump V166
    269
  • Fuel supply system
    271
  • 1 Parts of fuel supply system
    271
  • 1.1 Safety regulations for working on fuel supply
    271
  • 1.2 Rules for cleanliness
    272
  • 1.3 Procedure in event of misfuelling
    272
  • 1.4 Assembly overview - fuel tank with attachments
    275
  • 1.5 Emptying fuel tank
    277
  • 1.6 Removing and installing fuel tank with attached components
    281
  • 1.8 Assembly overview - fuel filter with fuel cooler
    286
  • 1.9 Assembly overview - supplementary fuel pump V393
    288
  • 1.10 Checking fuel pump
    290
  • 1.11 Bleeding fuel system
    310
  • 1.12 Checking for leaks in the fuel system
    310
  • 1.13 Repairing accelerator mechanism
    311
  • Turbocharging/supercharging
    312
  • 1 Charge air system with turbocharger
    312
  • 1.1 Rules for cleanliness
    312
  • 1.2 Assembly overview - turbocharger (engine codes BKS, BUN)
    312
  • 1.3 Removing and installing turbocharger (engine codes BKS, BUN)
    314
  • 1.4 Assembly overview - turbocharger (engine codes CASA, CASB, CASC)
    317
  • 1.5 Removing and installing turbocharger (engine codes CASA, CASB, CASC)
    319
  • 1.6 Assembly overview - turbocharger (engine code CATA)
    324
  • 1.7 Removing and installing turbocharger (engine code CATA)
    326
  • 1.8 Removing and installing turbocharger 1 control unit J724
    333
  • 1.9 Removing and installing parts of charge air cooling
    346
  • 1.10 Assembly overview - parts of charge air cooling system, left side
    346
  • 1.11 Assembly overview - parts of right charge air cooling
    347
  • 1.12 Parts of charge air cooling (engine code CATA)
    348
  • Mixture preparation - injection
    351
  • 1 Repairing diesel direct injection system
    351
  • 1.1 Safety precautions
    353
  • 1.2 Rules for cleanliness and instructions for working on fuel system
    353
  • 1.3 Schematic overview of fuel system (engine codes BKS, BUN)
    354
  • 1.4 Assembly overview - fuel system (engine codes BKS, BUN)
    355
  • 1.5 Assembly overview - intake manifold (engine codes BKS, BUN)
    357
  • 1.6 Removing and installing upper part of intake manifold (engine codes BKS, BUN)
    359
  • 1.8 Removing and installing lower part of intake manifold (engine codes BKS, BUN)
    375
  • 1.9 Schematic overview of fuel system (engine codes CASA, CASB, CASC, CATA)
    381
  • 1.10 Assembly overview - fuel system (engine codes CASA, CASB, CASC, CATA)
    384
  • 1.11 Assembly overview - intake manifold (engine codes CASA, CASB, CASC, CATA)
    387
  • 1.14 Removing and installing injectors (piezo injectors)
    396
  • 1.15 Checking return flow rate of injectors (piezo injectors) with engine running
    402
  • 1.16 Checking return flow rate of injectors (piezo injectors) at cranking speed
    404
  • 1.17 Checking for injectors sticking open (piezo injectors)
    407
  • 1.18 Installing high-pressure lines
    408
  • 1.19 Checking pressure retention valve in fuel return line
    411
  • 1.24 Assembly overview - high-pressure pump (engine codes BKS, BUN)
    431
  • 1.25 Removing and installing high-pressure pump (engine codes BKS, BUN)
    436
  • 1.28 Removing and installing fuel pressure regulating valve N276
    444
  • 1.29 Removing and installing fuel pressure sender G247
    446
  • 1.30 Assembly overview - air filter
    447
  • 1.31 Removing and installing exhaust gas pressure sensor 1 G450
    449
  • 2 Engine control unit
    451
  • 2.1 Removing and installing engine control unit
    451
  • 2.2 Removing and installing anti-theft engine control unit
    451
  • Exhaust system
    455
  • 1 Parts of the exhaust system
    455
  • 1.3 Removing and installing starter catalytic converter
    460
  • 1.4 Removing and installing particulate filter
    464
  • 1.5 Removing and installing reduction catalytic converter
    467
  • 1.6 Assembly overview - exhaust gas temperature regulator (engine code CATA)
    468
  • 1.7 Silencer with mountings
    469
  • 1.8 Replacing tail pipes
    470
  • 1.9 Aligning exhaust system free of stress
    471
  • 1.10 SCR system (selective catalytic reduction)
    472
  • 1.11 Assembly overview - exhaust manifold with intermediate pipe
    494
  • 1.12 Removing and installing left exhaust manifold
    495
  • 1.13 Removing and installing right exhaust manifold
    498
  • 1.14 Removing and installing intermediate pipe (left side)
    501
  • 1.15 Removing and installing intermediate pipe (right side)
    502
  • 2 Exhaust gas recirculation system (engine codes BKS, BUN)
    506
  • 2.1 Assembly overview - exhaust gas recirculation system
    506
  • 2.2 Checking mechanical exhaust gas recirculation valve
    508
  • 2.3 Removing and installing mechanical exhaust gas recirculation valve
    508
  • 2.4 Removing and installing exhaust gas recirculation cooler
    509
  • 3 Exhaust gas recirculation (engine codes CASA, CASB, CASC)
    512
  • 3.1 Assembly overview - exhaust gas recirculation system
    512
  • 3.2 Removing and installing exhaust gas recirculation control motor V338
    514
  • 3.3 Removing and installing exhaust gas recirculation cooler
    516
  • 3.4 Removing and installing exhaust gas recirculation temperature sensor G98
    518
  • 4 Exhaust gas recirculation (engine code CATA)
    520
  • 4.1 Assembly overview - exhaust gas recirculation system
    520
  • 4.2 Assembly overview - supplementary cooler for exhaust gas recirculation system
    522
  • 4.3 Removing and installing exhaust gas recirculation control motor V338
    522
  • 4.4 Removing and installing exhaust gas recirculation cooler
    524
  • 4.6 Removing and installing exhaust gas recirculation temperature sensor G98
    530
  • Glow plug system
    532
  • 1 Checking glow plug system
    532
  • 1.1 Assembly overview - Glow plugs, Hall sender, engine speed sender
    532
  • 1.2 Characteristics of ceramic glow plugs
    533
  • 1.3 Removing, installing and checking ceramic glow plugs
    533
  • 1.4 Removing and installing glow plugs, engine code CATA
    535
  • 1.5 Removing and installing metal glow plugs
    537
  • 1.6 Checking metal glow plugs
    538
  • 1.7 Removing and installing engine speed sender G28
    539
  • 1.8 Removing and installing Hall sender G40
    540
Manufacturer's designation 6-cylinder diesel engine (3.0 l engine, common rail)
Manufacturer Volkswagen
Suitable for Touareg (2003 - 2007)
Suitable car types 7L
Engine code CASB, BUN, CASC, CATA, BKS
Category Reparaturanleitung

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