Volkswagen Phaeton 2003 Workshop Manual
  1. Manuals
  2. Brands
  3. Volkswagen Manuals
  4. Automobile
  5. Phaeton 2003
  6. Workshop manual

Volkswagen Phaeton 2003 Workshop Manual

6-cylinder injection engine
Hide thumbs Also See for Phaeton 2003:
Table of Contents

Advertisement

Quick Links

Download this manual
Service
Workshop Manual
Phaeton 2003 ➤
6-cylinder injection engine
Engine ID
Edition 02.2014
Service Department. Technical Information
AYT
BKL
BRK

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Phaeton 2003 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Volkswagen Phaeton 2003

Summary of Contents for Volkswagen Phaeton 2003

  • Page 1 Service Workshop Manual Phaeton 2003 ➤ 6-cylinder injection engine Engine ID Edition 02.2014 Service Department. Technical Information...
  • Page 2 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...

  • Page 3: Table Of Contents

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Contents 00 - Technical data ........... .
  • Page 4 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 17 - Lubrication ............95 Parts of lubrication system .
  • Page 5 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Engine control unit ............167 Removing and installing engine control unit .
  • Page 6 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Contents...

  • Page 7: Technical Data

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 00 – Technical data Technical data (VRL006351; Edition 02.2014) Engine number ⇒ page 1 Engine data ⇒ page 1 Engine number The engine number (“engine code” and “serial number”) is located next to the vibration damper on the cylinder block.
  • Page 8 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Engine code Variable intake manifold Camshaft timing control 4) Two independently variable camshafts Rep. gr.00 - Technical data...

  • Page 9: Removing And Installing Engine

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 10 – Removing and installing engine Removing and installing engine Special tools and workshop equipment required ♦ Lifting tackle - 3033- ♦ Assembly tool - 3213- ♦ Engine and gearbox sup‐...

  • Page 10: Removing Engine

    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- ♦ Torque wrench - V.A.G 1332- Not illustrated: ♦...
  • Page 11 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 ♦...
  • Page 12 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 13 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – To gain more working space, unscrew protective housing from bulkhead -arrows-. – Remove poly V-belt ⇒ page 28 – Extract air conditioning refrigerant ⇒ Heating, air conditioning; Rep. gr. 87 –...
  • Page 14 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.
  • Page 15 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.
  • Page 16 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 B - Mounting on right of engine -arrow- – Guide universal supports for the subframe in the respective mountings -arrow-. – Guide the universal supports in the gearbox console -arrows-. – Unscrew subframe bolts -1-, -2- and -3-.
  • Page 17 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Remove both outer gearbox bracket bolts -arrows-. – Remove bolts -1- for engine carrier. 1.1.1 Removing engine and gearbox without subframe – Disconnect drive shafts from gearbox ⇒ Running gear, axles, steering;...
  • Page 18 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‐...
  • Page 19 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Guide the universal supports of the gearbox console in the mountings -arrows-. – Position the middle support as shown beneath the gearbox -arrow-. – Remove both outer gearbox bracket bolts -arrows-.

  • Page 20: Securing Engine On Engine And Gearbox Support Vas 6095

    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;...

  • Page 21: Installing Engine

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Flywheel end: position 11. – Lift engine off with workshop hoist - VAS 6100- and secure on engine and gearbox support - VAS 6095- as shown. Installing engine Caution When doing any repair work, especially in the engine compart‐...
  • Page 22 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: –...
  • Page 23 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 B - For gearbox bracket, securing pin - VAS 6131/1-5- Vehicles with automatic gearbox – When installing engine, first raise assembly platform only enough to allow selector lever cable to be guided into position.
  • Page 24 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Specified torques Threaded connection Specified torque Bolts, nuts 10 Nm 15 Nm 25 Nm 40 Nm 60 Nm Deviations Engine bracket to engine mounting 40 Nm + / 4 turn (bolt) (90°)

  • Page 25: Crankshaft Group

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 13 – Crankshaft group Dismantling and assembling engine Overview 1. Dismantling and assembling engine...

  • Page 26: Part I: Assembly Overview - Chain Drive

    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‐...
  • Page 27 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 ❑...
  • Page 28 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 and installing camshafts. 24 - Guide rail ❑ For camshaft timing chain ⇒ Item 3 (page 20) 25 - Exhaust camshaft control valve 1 - N318- ❑...

  • Page 29: Part Ii: Assembly Overview - Cylinder Block

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Part II: assembly overview - cylinder block 1 - 8 Nm ❑ Secured to intake mani‐ fold. 2 - Guide tube ❑ For dipstick ❑ Secured with bolt to in‐ take manifold.
  • Page 30 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 ❑...

  • Page 31: Removing And Installing Vibration Damper

    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. Right engine bracket Specified torque for securing bolt -1-: 40 Nm + / 4 turn (90°) fur‐...

  • Page 32: Removing And Installing Engine Bracket And Engine Mounting On Left Or Right Side

    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.
  • Page 33 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 /16- with the higher side for the spindle guide upwards, as illustra‐...

  • Page 34: Removing And Installing Poly V-Belt

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – To remove the engine mounting, also the engine bracket must be unscrewed from the cylinder block -2-, as the engine cannot be raised high enough. Note The securing bolts of the left engine bracket/oil filter housing ⇒...
  • Page 35 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.

  • Page 36: Sealing Flange And Dual-Mass Flywheel

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Sealing flange and dual-mass fly‐ wheel Note Repairing clutch: ⇒ 6-speed manual gearbox 01E/0A1; Rep. ♦ gr. 30 ; Repairing clutch mechanism; Assembly overview - hydraulics Secure engine to engine and gearbox support - VAS 6095- to ♦...

  • Page 37: Removing And Installing Seal, Flywheel End

    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.
  • Page 38 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-.

  • Page 39: Removing And Installing Flywheel

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Now drive it into sealing flange to stop using thrust piece - T10122/3- . Removing and installing flywheel Special tools and workshop equipment required ♦ Counterhold - T10044- Removing: Note To avoid damaging the dual-mass flywheel during removal, the bolts -B- must not be removed using a pneumatic or impact driver.

  • Page 40: Removing And Installing Drive Plate

    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.

  • Page 41: Renewing Crankshaft Oil Seal, Vibration Damper End

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Removing – Lock vibration damper using counterhold - T10069- . – Loosen drive plate securing bolts diagonally and remove. – Remove drive plate. Installing Prerequisites • The intermediate plate, ⇒ Item 10 (page 31) , must be bolted securely to the cylinder block.
  • Page 42 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Special tools and workshop equipment required ♦ Puller hooks - T20143/1- ♦ Counterhold - T10069- ♦ Assembly tool - T10215- ♦ Torque wrench - V.A.G 1601- ♦ Torque wrench - V.A.G...

  • Page 43: Renewing Crankshaft Sealing Flange -Vibration Damper Side

    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.
  • Page 44 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- ♦ Torque wrench - V.A.G 1332- Removing – Set lock carrier to service position ⇒ General body repairs, exterior;...
  • Page 45 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 clean sealing surface of sealing flange.

  • Page 46: Pistons And Conrods

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Pistons and conrods Assembly overview ⇒ page 40 Checking pistons and cylinders ⇒ page 41 Assembly overview 1 - Piston rings ❑ Offset gaps by 120°. ❑ Use piston ring pliers to remove and install.

  • Page 47: Separating New Conrod

    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 ❑...
  • Page 48 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 Ring gap Wear limit Rectangular-section ring 0.20...0.40...

  • Page 49: Piston And Cylinder Dimensions

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 ♦ Take measurements at 3 positions in both lateral direction -A- and longitudinal direction -B-. ♦ Deviation from nominal dimension max. 0.08 mm Note The cylinder bores must not be measured when the cylinder block is mounted on assembly stand, as measurements may then be incorrect.

  • Page 50: Crankshaft

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Crankshaft Note 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 ♦...

  • Page 51: Fitting Sender Wheel To Crankshaft

    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- ❑...

  • Page 52: Allocation Of Crankshaft Bearing Shells (Classification)

    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 + / 4 turn (90°) further.
  • Page 53 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.

  • Page 54: Cylinder Head, Valve Gear

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 15 – Cylinder head, valve gear Cylinder head Note To remove cylinder head, engine must be removed ⇒ page 3 ♦ If an exchange cylinder head is installed, all the contact sur‐...
  • Page 55 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...
  • Page 56 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 17 - 8 Nm 18 - Seal ❑ For camshaft control valve 1 - N205- ⇒ Item 15 (page 49) and exhaust camshaft control valve 1 - N318- , ⇒ Item 16 (page 49) ❑...
  • Page 57 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 ❑...

  • Page 58: Removing And Installing Cylinder Head

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 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- ♦...
  • Page 59 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 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. – Remove poly V-belt ⇒ page 28 –...
  • Page 60 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. – First remove camshaft adjuster of exhaust camshaft.
  • Page 61 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.

  • Page 62: Checking Valve Timing

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – The camshaft bar - T10068 A- must engage in grooves in both shafts. – Fit cylinder head, screw in new cylinder head bolts and tighten hand tight. Note The longer cylinder head bolts must be inserted in the centre holes of cylinder head.
  • Page 63 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 ♦ Camshaft bar - T10068 A- Test procedure – Remove intake manifold and cylinder head cover ⇒ page 68 Removing and installing cylinder head cover. – Remove front noise insulation: ⇒ General body repairs, exte‐...

  • Page 64: Installing Timing Chain For Intermediate Shaft Drive And Camshaft Drive

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Note The grooves of the camshafts might not be exactly vertical due to the function of camshaft adjusters. Therefore, move the cam‐ shafts back and forth slightly if necessary when inserting the camshaft bar - T10068 A- using an open-end spanner.
  • Page 65 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Special tools and workshop equipment required ♦ Camshaft bar - T10068 A- ♦ Counterhold - T10069- ♦ Torque wrench - V.A.G 1331- ♦ Torque wrench - V.A.G 1332- ♦ Sealant - D 176 501 A1-...
  • Page 66 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.
  • Page 67 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Install chain tensioner in this position and tighten to 8 Nm -arrows-. Installing timing chain for camshaft drive: Prerequisite • The camshaft adjusters are installed • Cams -A- of cylinder 1 must face each other.
  • Page 68 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 69 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 • Ground tooth of drive sprocket must align with main bearing joint -arrow B-. • Lug on sprocket of intermediate shaft must align with marking behind -arrow C-. – Check position of copper coloured chain links to adjustment markings.

  • Page 70: Installing Camshaft Adjuster With Timing Chain For Camshaft Drive

    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. – Remove old sealant from 3 mm holes in cylinder head gasket -arrows-.
  • Page 71 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Set crankshaft to TDC No. 1 cylinder marking -arrow- by turn‐ ing crankshaft on the vibration damper securing bolt in direc‐ tion of engine rotation. – Cams -A- of cylinder 1 must face each other.
  • Page 72 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‐...
  • Page 73 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 rollers lie precisely between marking “24E” and “32A”, and markings align.

  • Page 74: Removing And Installing Cylinder Head Cover

    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.
  • Page 75 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Special tools and workshop equipment required ♦ Spring-type clip pliers - VAS 5024 A- ♦ Torque wrench - V.A.G 1331- ♦ Assembly tool - T10118- ♦ Puller - T10095 A- Removing All cable ties which are opened or cut open when engine is re‐...
  • Page 76 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- .

  • Page 77: Assembly Overview - Cover Part

    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.
  • Page 78 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 2 - Connecting pipes ❑...
  • Page 79 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 19 - O-ring ❑ For sealing oil channel. ❑ Renew ❑ Lubricate before installing. 20 - From expansion tank ❑ Coolant hose schematic diagram ⇒ page 114 1.7.1 Installing cover seals Special tools and workshop equipment required ♦...

  • Page 80: Checking Compression

    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‐...
  • Page 81 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.

  • Page 82: Valve Gear

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 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 83 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 + / 4 turn (90°) further ❑...
  • Page 84 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...

  • Page 85: Removing And Installing Camshaft Control Valves

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 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- ♦...
  • Page 86 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.
  • Page 87 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-. – Pull camshaft control valve out of seat in valve timing housing against loosened bolts.

  • Page 88: Removing And Installing Camshafts

    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.
  • Page 89 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‐...
  • Page 90 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. – Disconnect connectors from the following components of cov‐...
  • Page 91 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.
  • Page 92 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.

  • Page 93: Renewing Valve Stem Seals

    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.
  • Page 94 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Special tools and workshop equipment required ♦ Valve lever - VW 541/1 A- ♦ Valve assembly device - 2036- ♦ Spark plug socket and ex‐ tension - 3122 B- ♦ Valve stem seal puller - 3364- ♦...
  • Page 95 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 ♦ Torque wrench (5…50 Nm) - V.A.G 1331- Removing – Remove camshafts ⇒ page 82 – Remove roller rocker fingers together with support elements and lay aside on a clean surface.
  • Page 96 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – To prevent damage to new valve stem seals, place plastic sleeve -A- on valve stem. – 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.

  • Page 97: Checking Valve Guides

    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 101 Index B - Inlet camshaft 102 Index Valve timing at 1 mm valve lift...
  • Page 98 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 99 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 2.6.1 Reworking inlet valve seat ∅ 32.8 mm Max. permissible re‐ working dimension 0.9…1.5 mm max. ∅ 38.0 mm radius 2.0 mm Lower edge of cylin‐ der head α 45° valve seat angle β...
  • Page 100 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 2.6.3 Valve dimensions Note Valves must not be reworked. Only lapping-in is permitted. Inlet valves Dimension Short Long inlet valve inlet valve ∅ a 33.20 33.20 ∅ b 5.98 5.98 102.46 136.36...

  • Page 101: Lubrication

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 17 – Lubrication Parts of lubrication system Note 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...
  • Page 102 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 ❑...
  • Page 103 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 - G266-...

  • Page 104: Assembly Overview - Dismantling And Assembling Oil Filter Housing

    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.
  • Page 105 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 1 - Oil filter housing/engine bracket 2 - Seal ❑ Renew 3 - Oil cooler seal ❑ Insert in oil cooler before installing ⇒ page 99 ❑ Renew ❑ Lubricate before instal‐...

  • Page 106: Assembly Overview - Dismantling And Assembling Oil Pump

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Assembly overview - dismantling and assembling oil pump Note When installing oil pump, note the following: First tighten all se‐ curing bolts by hand. Then tighten oil pressure pipe ⇒ Item 7 (page 100) to cylinder block and then to oil pump ⇒...

  • Page 107: Removing And Installing Sump

    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 Checking oil pump axial clearance Special tools and workshop equipment required ♦ Straight edge ♦...
  • Page 108 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 ♦ Support - T10151- Removing – 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 –...
  • Page 109 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.

  • Page 110: Checking Oil Pressure And Oil Pressure Switch

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Apply silicone sealing compound bead as shown to the clean sealing surface of the sump. – Install sump immediately and tighten all sump bolts lightly. – Tighten oil sump bolts to 12 Nm.
  • Page 111 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Special tools and workshop equipment required ♦ Oil pressure tester - V.A.G 1342- ♦ Adapter - V.A.G 1342/14- ♦ Voltage tester - V.A.G 1527B- ♦ Auxiliary measuring set - V.A.G 1594C-...
  • Page 112 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.
  • Page 113 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: –...

  • Page 114: Cooling

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 19 – Cooling 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.

  • Page 115: Assembly Overview - Radiator

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Assembly overview - radiator 1 - Lock carrier 2 - Condenser 3 - 10 Nm 4 - Radiator ❑ Removing and installing ⇒ page 118 ❑ After renewing, renew entire coolant.

  • Page 116: Assembly Overview - Removing And Installing Fan

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Assembly overview - removing and installing fan 1 - Fan support 2 - 10 Nm 3 - Radiator fan control unit - J293- 4 - 10 Nm 5 - Radiator fan - V7-...

  • Page 117: Assembly Overview - Parts Of Cooling System, Body Side

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Assembly overview - parts of cooling system, body side 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- .

  • Page 118: Assembly Overview - Thermostat Housing

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Assembly overview - thermostat hous‐ Note Routing of coolant hoses on thermostat housing ⇒ page 113 parts of cooling system - engine side. 1 - O-ring ❑ Renew if damaged 2 - Retaining clip ❑...

  • Page 119: Assembly Overview - Parts Of Cooling System, Engine Side

    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 2 - From expansion tank 3 - To upper coolant hose ❑...

  • Page 120: Coolant Hose Schematic Diagram

    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 - V51- Continued coolant circulation pump - V51- is located on left in engine bay, next to longitudinal member.

  • Page 121: Draining And Filling Coolant

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 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- ♦...
  • Page 122 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Unscrew plug -arrow- from coolant pipe ⇒ Item 16 (page 113) Note Follow disposal regulations for coolant! – To drain coolant from engine, also remove coolant hose from oil cooler -arrow-.
  • Page 123 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.

  • Page 124: Removing And Installing Radiator

    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 Removing and installing radiator Special tools and workshop equipment required ♦...

  • Page 125: Removing And Installing Coolant Pump

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Check headlight adjustment and correct if necessary ⇒ Main‐ tenance ; Booklet 16.1 . Removing and installing coolant pump Special tools and workshop equipment required ♦ Drip tray - V.A.G 1306- ♦...

  • Page 126: Fuel Supply System

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 20 – Fuel supply system 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. ♦...
  • Page 127 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 ❑...

  • Page 128: Dismantling And Assembling Right Side Fuel Delivery Unit, Fuel Gauge Sender And Suction-Jet

    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 + / 4 turn (90°) further 28 - Pressure retention valve ❑...
  • Page 129 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 ❑...

  • Page 130: Assembly Overview - Fuel Delivery Unit, Fuel Gauge Sender And Suction Jet Pump On Left Side

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 15 - Suction-jet pump 16 - Locking lug ❑ Clipped onto support for fuel delivery unit. 17 - Supply line ❑ Suction-jet pump, right side 18 - Supply line ❑ Suction-jet pump, right side...
  • Page 131 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 1 - Fuel delivery unit ❑ Activated by the electric fuel pump2 relay - J49- 2 - Connector ❑ For fuel pump. ❑ Coded connector to flange ⇒ Item 6 (page 125) 3 - Locking ring, 110 Nm ❑...

  • Page 132: Schematic Diagram Of Fuel Lines And Components In Fuel Tank

    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 ❑...
  • Page 133 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 1 - Supply and return flange ❑ With connections for quick-release couplings 2 - Supply line 3 - Return line 4 - Suction-jet pump ❑ Right side 5 - Fuel delivery unit ❑...

  • Page 134: Safety Precautions When Working On Fuel Supply System

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 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: ♦...
  • Page 135 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 ♦ Fuel extractor - VAS 5190- ♦ Wrench - 3087- WARNING Fuel system is under pressure! Wear eye protection and pro‐ tective clothing to avoid possible injury and skin contact. Before loosening hose connections, wrap a cloth around the connec‐...
  • Page 136 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – 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.

  • Page 137: Removing And Installing Fuel Delivery Unit, Fuel Gauge Sender And Suction-Jet Pump, Right Side

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Insert flange with locating tab facing forwards -arrow-. – Tighten locking rings on left and right to specified torque. Removing and installing fuel delivery unit, fuel gauge sender and suction-jet...
  • Page 138 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Pull off three connectors -arrows- underneath right sender flange. – On right side -B-, unclip plunger-type sender -3- from fuel de‐ livery unit -1- -arrows- and carefully pull it out.
  • Page 139 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.

  • Page 140: Removing And Installing Fuel Delivery Unit, Fuel Gauge Sender And Suction-Jet Pump, Left Side

    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.
  • Page 141 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.
  • Page 142 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Pull off return line -3- and supply line -4- on right side. – Pull both hose ends out through left sender hole. – Push both retaining clips -1- from right fuel delivery unit -A- to side slightly and carefully remove fuel delivery unit with sender flange attached.

  • Page 143: Removing And Installing Fuel Tank With Attachments And Fuel Filter

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Now unclip suction-jet pump -3- on left side -A- and remove by turning slightly. – Now unclip fuel gauge sender -2- and it pull out. Note Only two fuel lines (supply ⇒...
  • Page 144 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 145: Checking Fuel Pumps

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Pull connectors and supply hose -arrows- off left-hand sender flange. When doing this, hold a rag over the supply hose. – Hold cloth around fuel line connectors -1- and -2- and pull them apart.
  • Page 146 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- ♦...
  • Page 147 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Special tools and workshop equipment required ♦ Torque wrench - V.A.G 1332- ♦ Remote control - V.A.G 1348/3A- with adapt‐ er cable - V.A.G 1348/3-3- ♦ Voltage tester - V.A.G 1527B- ♦...
  • Page 148 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 Push in button on hose coupling to do this. – Connect pressure gauge - V.A.G 1318- with adapter - V.A.G 1318/23- and -V.A.G 1318/17- to fuel supply line.
  • Page 149 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Compare quantity of fuel delivered with specification. 7) Delivery rate cm 3 /30 seconds 8) Voltage at fuel pumps with engine not running and pump running (approx. 2 volts less than battery voltage).
  • Page 150 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Compare quantity of fuel delivered with specification. 9) Delivery rate cm 3 /30 seconds 10) Voltage at fuel pumps with engine not running and pump running (approx. 2 volts less than battery voltage).
  • Page 151 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.
  • Page 152 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.
  • Page 153 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: – Right fuel pump is defective. Renew fuel delivery unit ⇒...

  • Page 154: Activated Charcoal Filter System

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 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. The activated charcoal filter system prevents these HC emissions escaping to the atmosphere.
  • Page 155 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‐ enoid valve 1 - N80- 5 - To connection ❑...

  • Page 156: Checking Activated Charcoal Filter System For Leaks

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Checking activated charcoal filter system for leaks Special tools and workshop equipment required ♦ Vacuum tester - V.A.G 1368- ♦ Hand vacuum pump - V.A.G 1390- ♦ Adapter set - V.A.G...
  • Page 157 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-.
  • Page 158 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.

  • Page 159: Checking Electronic Power Control (Epc)

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Checking electronic power control (EPC) 1 - Mounting bracket ❑ Removing and instal‐ ling: ⇒ Brake systems; Rep. gr. 46 ; Assembly overview - brake pedal (LHD) . 2 - Connector ❑...
  • Page 160 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‐...

  • Page 161: Mixture Preparation - Injection

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 24 – Mixture preparation - injection 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 162 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 ❑...

  • Page 163: Assembly Overview - Fuel Rail

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 21 - 15 Nm 22 - To cylinder head cover Assembly overview - fuel rail 1 - Wiring harness ❑ With connectors for in‐ jectors ❑ Clipped into cable chan‐ 2 - 10 Nm 3 - Fuel rail 4 - Injector - N30...N33, N83,...

  • Page 164: Assembly Overview - Air Filter

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Assembly overview - air filter 1 - Intake hose 2 - Spring-type clip ❑ Check for secure seat‐ ing. 3 - To throttle valve module - J338- . ❑ ⇒ Item 11 (page 156)

  • Page 165: Rules For Cleanliness

    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.
  • Page 166 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 13) Not adjustable. Rep. gr.24 - Mixture preparation - injection...

  • Page 167: Checking Components

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Checking components Checking injectors ⇒ page 161 Checking fuel pressure regulator and holding pressure ⇒ page 163 Checking injectors Checking injectors for leaks and quantity injected ⇒ page 162 Special tools and workshop equipment required ♦...
  • Page 168 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. •...

  • Page 169: Checking Fuel Pressure Regulator And Holding Pressure

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Connect a contact of injector to be tested to engine earth using auxiliary cables from auxiliary measuring set - V.A.G 1594C- . – Connect second injector contact to remote control - V.A.G 1348/3A- using adapter cable - V.A.G 1348/3-2- .
  • Page 170 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- ♦ Adapter - V.A.G 1318/23- The fuel pressure regulator regulates the fuel pressure depending on intake manifold pressure.
  • Page 171 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Separate coupling -1- from fuel supply line (black) -2- and col‐ lect escaping fuel in a cloth. Note Push in button on hose coupling to do this. – Connect pressure tester - V.A.G 1318- with adapter - V.A.G 1318/17- on hose coupling -1- fuel rail.
  • Page 172 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Switch ignition off after the pressure has built up. At the same time, shut-off valve of pressure tester - V.A.G 1318- -arrow- should be closed (lever perpendicular to direction of flow).

  • Page 173: Engine Control Unit

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Engine control unit Removing and installing engine control unit ⇒ page 167 Reading and clearing engine control unit fault memory ⇒ page 167 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”.
  • Page 174 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.

  • Page 175: Exhaust System

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 26 – Exhaust system 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 176: Assembly Overview - Exhaust Manifold With Starter Catalytic Converters And Attachments

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 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.
  • Page 177 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 ❑...

  • Page 178: Exhaust Pipes With Main Catalytic Converters And Silencers With Mountings

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 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 ❑...
  • Page 179 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 –...

  • Page 180: Removing And Installing Exhaust Manifolds And Exhaust Pipes With Starter Catalytic

    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‐...
  • Page 181 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- .

  • Page 182: Secondary Air System

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Secondary air system Function The secondary air system blows air in behind the exhaust valve for max. 65 seconds after a cold start (+15 °C … +35 °C coolant temperature). This produces an oxygen rich exhaust gas, causing afterburning and reducing the heat-up phase of the catalytic con‐...
  • Page 183 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 1 - Intake manifold 2 - Vacuum actuator for intake manifold change-over 3 - To intake manifold 4 - To fuel pressure regulator. 5 - Combination valve ❑ Checking ⇒ page 178 6 - Gasket ❑...

  • Page 184: Checking Combination Valve

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 Secondary air pump relay - J299- Note The relay for secondary air pump is inserted in socket 7. ♦ If tools are necessary to pull relays or control units out of the ♦...
  • Page 185 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 – Connect hand vacuum pump - V.A.G 1390- to vacuum con‐ nection on combination valve -arrow-. – Detach pressure hose to combination valve at connection -arrow- and blow in softly. Combination valve must be closed.

  • Page 186: Ignition System

    Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 28 – Ignition system Ignition system General notes on ignition system ♦ Only the components which specifically relate to the ignition system are dealt with here. For other components of the in‐...
  • Page 187 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 1 - Ignition coil with output stage - N70, N127, N291, N292, N323, N324- ❑ Removing and installing ⇒ page 182 2 - Connector ❑ 4-pin. ❑ Use assembly tool - T10118- to pull off.

  • Page 188: Safety Precautions

    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 ❑...
  • Page 189 Phaeton 2003 ➤ 6-cylinder injection engine - Edition 02.2014 ♦ Puller - T10095A- ♦ Lubricating paste - G 052 141 A2- Removing – Apply assembly tool - T10118- to locking mechanism button -arrow- and carefully pull connector off each ignition coil with output stage .

  • Page 190: Test Data, Spark Plugs

    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. – 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-.

Table of Contents

Save PDF