Service

Workshop Manual
Touareg 2010 ➤
Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V)
Engine ID
CGR CMT
A A
Edition 12.2019

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Service Department. Technical Information

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00 - Technical data
10 - Removing and installing engine

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13 - Crankshaft group
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15 - Cylinder head, valve gear

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17 - Lubrication

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19 - Cooling
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20 - Fuel supply system

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24 - Mixture preparation - injection

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26 - Exhaust system
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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 © 2019 Volkswagen AG, Wolfsburg D3E802DF9E4

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 1
1.3 Safety precautions when using testers and measuring instruments during a road test . . . . 2
1.4 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . a.g.en. A. G. ..V.o.lk.sw. a.g.e.n .AG
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2.1 Engine number/engine data . . . . . . . . . . .by. V. . . . . . . . . . . . . . . . . . . . . . .no. t.g.ua. . . . . . . . . .
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2.2 Numbering of cylinders . . . . . . . . . . . o.ris.e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a.n.tee. . . . . . . 4
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3 Repair instructions . . . . . . . . . . . s.s .au. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .r a.c . . . . 5
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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3.2 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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3.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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3.4 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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3.5 Fitting radiator and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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1.3 Securing engine on engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1.5 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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2.2 Removing and installing engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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1.1 Part I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.2 Part II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.3 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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1.4 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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2 Sealing flanges and drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2.1 Assembly overview - sealing flanges and drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.2 Assembly overview - timing chain covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.3 Removing and installing seal on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.4 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.5 Renewing crankshaft sealing flange, vibration damper side . . . . . . . . . . . . . . . . . . . . . . . . 43
2.6 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.7 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.2 Fitting sender wheel to crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.3 Allocation of main bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.2 Checking piston and cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Contents i
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

1 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.1 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.2 Removing and installing camshaft adjuster age.n . . . . . . . . . . .AG
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1.3 Removing and installing camshaft timing by Vo chain . . . . . . . . . . . . . . .o.t g.u.a . . . . . . . . . . . . . . . . 71
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1.4 Removing and installing oil pump horis drive timing chain . . . . . . . . . . . . . . . n. te.e. . . . . . . . . . . . . 74
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1.5 Removing and installing chain au drive sprocket for high-pressure pump . . . . .r a.c . . . . . . . . . . 78
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2 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

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2.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
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2.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

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2.3 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

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2.4 Assembly overview - mechanical vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

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2.5 Removing and installing mechanical vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

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2.6 Installing cover oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

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2.7 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

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3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.2 Camshafts, checking axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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3.3 Assembly overview - timing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

3.4 Removing and installing camshaft control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

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3.5 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

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3.6 Camshaft identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
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4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

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4.1 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

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4.2 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
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4.3 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

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4.4 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
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1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.2 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1.3 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2.1 Removing and installing oil spray jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2.2 Assembly overview - oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2.3 Removing and installing oil filter housing, engine support . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2.4 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
2.5 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1 Cooling system (engine code CGRA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.1 Coolant hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.2 Vacuum hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1.3 Assembly overview - vacuum hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
1.4 Assembly overviews - cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2 Cooling system (engine code CMTA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
2.1 Coolant hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
2.2 Assembly overview - cooling system, engine side, front and rear . . . . . . . . . . . . . . . . . . . . 142
2.3 Assembly overview - cooling system, engine side, left . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3 Coolant pump and thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.1 Assembly overview - coolant pump and thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
3.2 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
3.3 Removing and installing coolant circulation pump 2 V178 . . . . . . . . . . . . . . . . . . . . . . . . 149
3.4 Removing and installing, checking thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

ii Contents
 AG. Volkswagen AG d Touareg 2010 ➤ , Touareg 2015 ➤
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3.5 utho Removing and installing temperature sender e o for engine temperature regulation G694 .
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4s Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

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4.1 Draining coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

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4.2 Draining cooling system (vehicles with one heat exchanger) . . . . . . . . . . . . . . . . . . . . . . . . 155

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4.3 Draining cooling system (vehicles with two heat exchangers) . . . . . . . . . . . . . . . . . . . . . . 156
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4.4 Filling with coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

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4.5 Checking filling quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
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4.6 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
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5 Radiator and radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
5.1 Assembly overview - radiator and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
5.2 Removing and installing radiator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

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5.3 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
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5.4 Dismantling cooler module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

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1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

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1.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

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2 Parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

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2.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
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2.2 Assembly overview - fuel tank with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
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2.3 Assembly overview - fuel delivery unit, fuel gauge sender and suction jet pumps . . . . . . . . 177
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2.4 Removing, installing and renewing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
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2.5 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
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2.6 Prote Removing and installing fuel gauge sender 2 G169 and suction-jet pump . . . . . . . . . . . .
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184
2.7 Removing and installing fuel delivery unit and fuel gauge sender G . . . . . . . . . . . . . . . . . . 188
2.8 Removing and installing fuel tank with attached components . . . . . . . . . . . . . . . . . . . . . . 191
3 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
3.1 Checking fuel pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
3.2 Checking holding pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
4 Electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4.1 Assembly overview - accelerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
5.1 Assembly overview - activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
5.2 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
6 Activated charcoal filter system (vehicles for USA and Canada) . . . . . . . . . . . . . . . . . . . . 206
6.1 Assembly overview - activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
6.2 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
1.1 General notes on the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
1.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
2 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
2.1 Assembly overview - fuel rail with high-pressure pump and injectors . . . . . . . . . . . . . . . . 217
2.2 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
2.3 Renewing seals on injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
3 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
3.1 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
3.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
3.3 Removing and installing air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
4.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
4.2 Checking vacuum unit for intake manifold flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

Contents iii
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

4.3 Removing and installing intake manifold upper part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

4.4 Removing and installing lower part of intake manifold with fuel rail . . . . . . . . . . . . . . . . . . 239
4.5 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
5 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
5.1 Checking fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
6 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
6.1 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
7 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
7.1 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
7.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

1 Exhaust manifold . . . . . . . . G. ..V.ol.ks. w. a.g.en. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
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1.1 Assembly overview o-lkexhaust
swa manifold . . . d.o.es. n.o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
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1.2 Removing andseinstalling
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exhaust manifold . . . . . . .ua.ra. n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
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Silencers aand
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2.1 Assemblyss overview - catalytic converter . . . . . . . . . . . . . . c. . . . . . . . . . . . . . . . . . . . . . . . 256

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2.2 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

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2.3 Separating centre and rear silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

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2.4 Replacing tail pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
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2.5 Removing and installing catalytic converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

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2.6 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
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2.7 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
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3 ...................................................................... 267

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269 rrectness of i

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
l purpos

1.1 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

1.2 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
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1.3 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

1.4 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
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1.5 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 272
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1.6 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

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iv Contents
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

00 – Technical data
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⇒ “1.5 Safety precautions when working on the cooling system”,
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1.1 Safety regulations for working on fuel supply

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Risk of injury from highly pressurised fuel.

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– To release pressure, wrap a clean cloth around the connection

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Danger of fire caused by escaping fuel

When the battery is connected and the driver door opens, the door
contact switch activates the fuel pump. Escaping fuel can ignite
and cause a fire.
– Disconnect voltage supply to fuel pump before opening the
fuel system.

1.2 Safety measures when working on vehicles with a start/stop system

Risk of injury due to unexpected motor start
If the vehicle’s start/stop system is activated, the engine can start
unexpectedly. A message in the dash panel insert indicates
whether the start/stop system is activated.
– Deactivate start/stop system by switching off the ignition.

1. Safety information 1
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

1.3 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury caused by unsecured testing and measuring instru‐
ments
When the front passenger airbag is triggered in an accident, in‐
sufficiently secured testing and measuring instruments become
dangerous projectiles.
– Secure testing and measuring instruments on the rear seat.
or
– Have a second person operate the test and measuring equip‐
ment on the rear seat.

1.4 Safety precautions when working on ignition system

Risk of injury due to electric shock
The ignition system is under high voltage when the engine is run‐
ning. Touching the ignition system may result in an electric shock.
– Do not touch or disconnect ignition cables when the engine is
running or being turned at starter speed.
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Risk of damage to components
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1.5 Safety precautions when working on the cooling system

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Danger of scalding by hot coolant

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On a warm engine, the cooling system is under high pressure.

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Danger of scalding by steam and hot coolant.

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2 Rep. gr.00 - Technical data

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

2 Identification
⇒ “2.1 Engine number/engine data”, page 3
⇒ “2.2 Numbering of cylinders”, page 4

2.1 Engine number/engine data

Engine number
The engine number (“engine code” and “serial number”) is located
next to the vibration damper -arrow- on the cylinder block.
There is also a sticker on the rear of the cylinder head cover
showing the “engine code” and “serial number”.
The first 3 digits denote the mechanical design of the engine and
are stamped on the engine. The fourth digit shows the engine
output and torque and varies according to engine gen AG
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Vehicle data sticker .

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Codes CGRA CMTA

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Manufactured 15.2010 ► 34.2010 ►

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Displacement cm³ 3597 3597
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Power kW at rpm 206 / 6200 183 / 5700
Torque Nm at 360 / 2900 to 4000 360 / 3000

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Bore ∅ mm 89.0 89.0
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Stroke mm 96.4 96.4

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Cylinder angle 10.6° 10.6°

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Compression ratio 11.4 11.4

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Valves per cylinder 4 4

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RON 98 unleaded1) 98 unleaded1)

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Injection, ignition Motronic MED 17 Motronic MED 17

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Catalytic converter Yes Yes
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Exhaust gas recirculation no no
Thermal management Yes no
1) At least 95 RON, though with reduced output

2. Identification 3
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

2.2 Numbering of cylinders

Note

Cylinder 1 is opposite the power delivery side.

Firing order 1-5-3-6-2-4

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4 Rep. gr.00 - Technical data

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

3 Repair instructions
⇒ “3.1 Rules for cleanliness”, page 5
⇒ “3.2 Foreign objects in engine”, page 5
⇒ “3.3 Contact corrosion”, page 5
⇒ “3.4 Routing and attachment of lines”, page 5
⇒ “3.5 Fitting radiator and condensers”, page 6

3.1 Rules for cleanliness

When working on fuel supply and injection system, pay careful
attention to the following “rules” for cleanliness:
♦ Thoroughly clean all joints and surrounding areas before dis‐
mantling.
♦ Place removed parts on a clean surface and cover them over.
Use lint-free cloths only.
♦ Carefully cover opened components or seal them if repairs
cannot be carried out immediately.
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing. Do not use parts that
have been kept unpackaged (for example in toolboxes).
♦ If system is open, do not work with compressed air. Do not
move the vehicle.
♦ Make sure that no fuel gets onto the fuel hoses. Should this
occur, the fuel hoses must be cleaned immediately.
♦ Protect disconnected electrical connectors from dirt and water,
and reconnect them only when dry.

3.2 Foreign objects in engine

To prevent the ingress of foreign bodies during work on the en‐
gine, seal open channels of the intake section and exhaust
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Contact corrosion can occur if non-approved fasteners are used

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For this reason, only connecting elements with a special surface

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If there is any doubt about the suitability of parts, a general rule

is to use new parts ⇒ Electronic Parts Catalogue .
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3.4 Routing and attachment of lines

♦ To prevent interchanging and to maintain the original installa‐
ss o

tion position, mark the fuel, hydraulic system, vacuum and

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ACF system pipes or any wiring for example prior to removal.

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 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

3.5 Fitting radiator and condensers

Even if installed correctly, the radiator, the condenser and the
charge air cooler may have small dents in their fins. This does not
mean that these components have been damaged. It is not per‐
missible to renew radiators, condensers or charge air coolers only
because of such minor dents.

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6 Rep. gr.00 - Technical data

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 7 .
⇒ “1.2 Separating engine and gearbox”, page 19
⇒ “1.3 Securing engine on engine support ”, page 21 .
⇒ “1.4 Installing engine”, page 22 .
⇒ “1.5 Supporting engine in installation position”, page 24
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1. Removing and installing engine 7

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine,
agen
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♦ Lifting tackle - 3033-

♦ Engine and gearbox support - VAS 6095-
♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Drip tray - V.A.G 1306-
♦ Workshop hoist - VAS 6100-
♦ Scissor-type assembly platform - VAS 6131-
♦ Pliers for spring-type clips - VAS 6340-

8 Rep. gr.10 - Removing and installing engine

 AG. Volkswagen AG d
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horis engine (3.6 l engine, 4V) - Edition nt12.2019
ee
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♦ Not illustrated:

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♦ Adapter - V.A.G 1318/20-

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♦ Adapter - V.A.G 1318/20-1-

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♦ Container for removed parts - V.A.G 1698-

, is n

h re
hole
♦ Left subframe mounting - VAS 6131/6-1-

spec
es, in part or in w
♦ Right subframe mounting - VAS 6131/6-2-

t to the co
♦ Left running gear support - VAS 6131/6-3-

rrectness of i
♦ Right running gear support - VAS 6131/6-4-
♦ Support - VAS 6131/6-5- (qty. 2) l purpos

♦ Support - VAS 6131/6-6- (qty. 2)

nform
ercia

♦ Gearbox support - VAS 6131/6-7-

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♦ Grease (vehicles with manual gearbox) - G 000 1000-

on in
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ted cables and wires to the engine/assembly (depending on by c lksw
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»origin«). Fit dummy plugs in all open connections. Prote AG.

♦ Move the selector lever to the “N” position so that the propshaft
can turn freely.
♦ To make sure you can still move the front wheels when the
battery has been disconnected, only disconnect the battery
with the ignition key inserted.

Procedure:
The engine is removed downwards with gearbox.
– Vehicles with air suspension: Activate jacking mode ⇒ Rep.
gr. 43 .
– Disconnect battery ⇒ Rep. gr. 27 ; Electrical system .
– Detach hoses -1- and -2- and remove air pipe -arrows-.
– Open clips and remove upper part of air filter.
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system .
– Remove plenum chamber cover ⇒ Body - front; Rep. gr. 50 ;
Plenum chamber cover .
– Remove protective housing from engine control unit
⇒ page 246 .
– Pull engine wiring harness off engine control unit.

1. Removing and installing engine 9

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Unscrew and disconnect earth wire -arrows-.

– Open cover -A- of central electrical system.

– Detach all connectors whose wires go to the engine.
– Remove engine wiring harness from plenum chamber and
place it on the engine.

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– Disconnect connectors by V-1 to 4- for lambda probes.
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The fuel line is under pressure.

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Fuel poses danger of injury to eyes and skin.

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Wear protective goggles and protective clothing to avoid injury

wit
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and contact with the skin. Wrap a cloth around the connection
h re
hole

before loosening hose connections. Then reduce pressure by

spec

carefully opening the connection.

es, in part or in w

t to the co

– Wrap a cloth around the joint to catch any escaping fuel.

rrectness of i

– Detach fuel supply line -arrow-.

l purpos

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Prote AG.

10 Rep. gr.10 - Removing and installing engine

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Disconnect vacuum lines -arrows-. Hose -1- can be disregar‐

ded.

– Open cover above terminal B+ distribution box -arrow-.

– Unscrew and disconnect positive wire:
1- To alternator
2- To starter
– Move electrical wiring clear.
– Siphon off refrigerant of the air-conditioning system ⇒ Rep.
gr. 87 . agen
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– Detach power-assisted steering hose together with clamps up

un

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to 25 mm - 3094- . Pull hose -A- off power-steering pump.

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t to the co
rrectness of i
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– Detach refrigerant lines -2 and 3- from air-conditioning com‐

nform
ercia

pressor.
m

a
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– Remove noise insulation ⇒ General body repairs, exterior;

tion in

Rep. gr. 50 ; Assembly overview - noise insulation .

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1. Removing and installing engine 11

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Unbolt bracket for noise insulation -arrows-.

– Drain coolant ⇒ page 154 . AG. Volkswagen AG d
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es, in part or in w

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– Open plug-in connector -A- under the coolant expansion tank
and pull off coolant hose.
– Unscrew connection of coolant hose at top of radiator.

rrectness of i
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nform
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– Open plug-in connector -A- at top of radiator and pull coolant

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– Detach coolant hose from lower radiator connection. copy Vo
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– Remove front wheels.
AG.

– Unscrew earth connection -A- on right longitudinal member.

12 Rep. gr.10 - Removing and installing engine

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Unscrew bolt -A- and pull connections off gear oil cooler. Catch
oil which runs out.

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– Disconnect hose of servo steering with hose
ss clips up to 25 mm
a ac
- 3094- , open clip -A- and pull off hose.

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t to the co
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– Open clips -A- and pull off coolant hoses of heat exchanger
for heating system.

nform
ercia

– Push propshaft off gearbox and tie at the top ⇒ Differential

m

a
and final drive; Rep. gr. 39 ; Removing and installing prop‐
com

tio
shafts .

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– Disconnect connector -arrows- at gearbox.

1. Removing and installing engine 13

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Unscrew and remove hangers -1- and -2-. Loosen clamps

-arrows- and push to rear.

– Separate selector lever cable at ball head -1- and unscrew

from gearbox -2-. Circlip -3- can remain fitted.

Caution

Danger of airbag coil connectors becoming twisted.

♦ Only disconnect universal joint from steering rack when
front wheels are in straight-ahead position.
♦ Secure steering wheel with adhesive tape so that position
of steering wheel and steering rack no longer change.

– Unscrew bolt -A- and remove universal joint from steering

rack.

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– Disconnect connector at steering rack.

rm

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t to the co
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mercia

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Cop py
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rig ht
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by lksw
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Prote AG.

14 Rep. gr.10 - Removing and installing engine

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Disconnect connectors on left and right from front speed sen‐

sors -arrow-. wage
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– Disconnect connector -arrow- for wear indicator.

rrectness of i
l purpos

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tion in
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– Remove bolts -arrows- for cable retainers.
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– Unscrew bolts -1- for brake caliper.
ht
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Note

Do not attempt to bend brake lines to a different shape.

– Suspend brake caliper in wheel housing with wire.

Caution

Avoid damage to brake pistons.

♦ Do not press brake pedal when brake caliper is removed.

– Unscrew nut for suspension link at top by several turns and

push off articulated joint together with ball joint puller -
T10187- .
– Completely unscrew nut and detach suspension link.

1. Removing and installing engine 15

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 lgengine,
en AG. V 4V)ag
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– Unscrew bolt -arrow- of couplingisrod
ed at bottom.
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– Unscrew nut -A- from lower swishbone,
au
t
leave bolt in hole. ra
c
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– Repeat work sequence of suspension on opposite side of ve‐

ce
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hicle.

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t to the co
rrectness of i
– Unscrew one of the rear securing bolts -2- on subframe.
l purpos

– Secure subframe to body using locating pins - T10300- ⇒

Running gear, axles, steering; Rep. gr. 40 ; l - Assembly over‐
view - subframe, anti-roll bar, lower suspension links .

nform
ercia

– Then proceed with other securing bolt -2- in the same way.
m

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– If the engine and gearbox are to be separated after being re‐

moved, undo lower bolts -arrows- of connection between en‐
gine and gearbox.
Prepare scissor-type assembly platform - VAS 6131- with basic
set for Touareg - VAS 6131/6- as follows:

16 Rep. gr.10 - Removing and installing engine

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

1 - VAS 6131/6-1
❑ Bolting point: A4; B3; B4
2 - VAS 6131/6-2
❑ Bolting point: H4; G3;
G4
3 - VAS 6131/6-3
❑ Bolting point: A5; B5
4 - VAS 6131/6-4
❑ Bolting point: G5; H5
5 - VAS 6131/6-5
❑ Bolting point: B7
6 - VAS 6131/6-5
❑ Bolting point: G7
7 - VAS 6131/6-6
❑ Bolting point: B14
8 - VAS 6131/6-6
❑ Bolting point: G14

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♦ All supports must only be tighten by hand so that their position

ility
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can still be adjusted.

wit
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♦ The basic set for Touareg - VAS 6131/6- consists of the sup‐
hole

spec

ports - VAS 6131/6-1- to -VAS 6131/6-7- . To make the fol‐

es, in part or in w

lowing procedure easier to understand, we designate them

t to the co

here as support 1 (for VAS 6131/6-1) to support 7 (for VAS

6131/6-7).
rrectness of i

– Place the scissor-type mounting platform in a horizontal posi‐

l purpos

tion.
• Check spirit level (bubble gauge) on scissor-type mounting
nf
ercia

platform.
orm
m

– Position scissor-type mounting platform - VAS 6131 A- under

atio
m

the vehicle.
o

n in
or c

thi
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sd
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t.
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17
AG.
1. Removing and installing engine
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– The supports -1- and -2- must be guided into corresponding

mountings on left and right -arrow-.

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– At the same time, guide the supports -6- for the left and right
erm

ab
sides of the gearbox transverse into corresponding holes

ility
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-arrows-.

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es, in part or in w

t to the co
rrectness of i
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When all four supports are in the receptacle holes without pres‐
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– Guide supports -5- into their respective receptacles in sub‐ Prote AG.
frame. If necessary, adjust support height with knurled nut.
– Screw all supports to scissor-lift table , tightening to 20 Nm.
– Bolt on the rotating plates of supports 3 and 4 under the wish‐
bones, applying a small amount of pretension.

18 Rep. gr.10 - Removing and installing engine

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Remove bolts -A- for right and left suspension struts.

– Remove bolts for gearbox transverse support -1- and for sub‐
frame -3 and 4-.

Caution

Be very careful when lowering. Make sure that all connections

to the body have been detached. Do this now if necessary.

– Now slowly lower engine/gearbox assembly, constantly ob‐

serving the clearance.

– On left and right sides, tighten one securing bolt with nut
-arrow- from subframe mounting. This n Aprevents
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1.2 Separating engine and gearbox

– Unscrew or detach all necessary pipes, hoses and lines from
rrectness of i

gearbox. Please also observe “Removing and installing gear‐

box” procedure ⇒ Automatic gearbox 0C8 - 8-speed; Rep. gr.
l purpos

37 ; Removing gearbox - vehicles with VR6 engine .

– Remove starter.
nf
ercia

orm
m

atio
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19
cted agen
Prote
1. Removing and installing engine
AG.
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Through opening of removed starter, unscrew 3 bolts

-arrows- for torque converter. To do this, turn the crankshaft
120° in the engine's direction of rotation.

– Tighten supports - VAS 6131/6-7- as shown on scissor-type

assembly and support gearbox stress free under sump.

Caution

Before separating engine and gearbox, use wooden wedges,

for example, to prevent engine from tipping over.
olkswagen AG
en AG. V
When separating the engine and gearbox, press off torque Volkswag does
not
converter from drive plate through opening of removed starter
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– Unscrew and remove all engine/gearbox connecting bolts.

pt
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hole

spec
es, in part or in w

t to the co
– Loosen clamping bolts -1- on side of scissor-type assembly
platform - VAS 6131 A- and pull rear section of platform to‐

rrectness of i
gether with gearbox towards rear -arrow-. Then press off
torque converter from drive plate through opening of removed
l purpos

starter.

nform
mercia

at
om

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c

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– Use the support bridge - 30-211 A- to secure the torque con‐
C py
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verter in the gearbox to prevent the converter falling out.
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Assembling:
agen
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For assembly, please observe “Removing and installing gearbox”

procedure ⇒ Automatic gearbox 0C8 - 8-speed; Rep. gr. 37 ;
Removing and installing gearbox - vehicles with VR6 engine .

20 Rep. gr.10 - Removing and installing engine

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

1.3 Securing engine on engine support

Secure engine to engine and gearbox support - VAS 6095- to
carry out repairs.
Secure engine on engine bracket - 3269- in order to do work on
chain drive.
Special tools and workshop equipment required
♦ Engine and gearbox support - VAS 6095-

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Procedure
– Separate engine and gearbox ⇒ page 19 .
nform
ercia

– Secure torque converter against “falling out” after separating

m

engine from gearbox.

com

tion in
r

– Attach lifting tackle - 3033- as follows and lift engine from scis‐
te o

thi

sor-type assembly platform - VAS 6100- using workshop hoist

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- 6131- .
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♦ Vibration damper end: position 3.

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♦ Flywheel end: position 11 ht. rig
rig ht
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Prote AG.
Note

Adjust length of threaded spindles according to need.

1. Removing and installing engine 21

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Secure engine on engine and gearbox support - VAS 6095- :

– Secure engine on engine and gearbox support - VAS 6095-
as shown.

Secure engine on engine support - 3269- :

– Unbolt right engine support.
– Secure engine on engine support - 3269- as shown.

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1.4 Installing engine
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Observe the following during all assembly work, particularly in

an
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the engine compartment due to the restricted space:

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♦ Route lines of any kind and cables so that original routing

ot p

wit

is restored.
, is n

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♦ Ensure that there is sufficient clearance to all moving or

spec

hot components.
es, in part or in w

t to the co
rrectness of i

Note
l purpos

When fitting engine and gearbox to body, it is essential to position

engine carrier against body with the aid of scissor-type assembly
nf
ercia

platform - VAS 6131- . »Pulling up« engine carrier with securing

rm

bolts will damage threads.

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Procedure:
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Install in reverse order of removal. During this procedure, observe

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– For assembly of engine and gearbox, observe “Installing gear‐ C py
ht. rig
box” instructions ⇒ Automatic gearbox 0C8 - 8-speed; Rep. rig ht
py by
gr. 37 .
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22 Rep. gr.10 - Removing and installing engine

 n AG. Volkswagen AG do
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ac
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Aligning scissor-type assembly platform

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es, in part or in w

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mercia

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or

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Special tools and workshop equipment required

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♦ Locating pins - VAS 6131/17-
t. rig
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Individual parts of positioning tool:
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♦ Dot laser - VAS 6131/17-1-
♦ Adapter M14x1.5 - VAS 6131/17-2-
♦ Adapter M12x1.5 - VAS 6131/17-3-
♦ Adapter 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.
Installing engine
– Raise engine until it contacts the body using scissor-type as‐
sembly platform - VAS 6131- . Observe the inserted locating
pins - T10300- in the process.
– Bolt subframe to vehicle ⇒ Running gear, axles, steering; Rep.
gr. 40
– Reassemble all electrical connections, lines, hoses and con‐
nectors that were disconnected during removal.
– Installing plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 64 ; Removing and installing plenum chamber
cover
– Unscrew left and right wiper arms ⇒ Electrical system; Rep.
gr. 29 ; Removing and installing windscreen wiper system .
– Replenish oil in power-assisted steering ⇒ Running gear,
axles, steering, front and four-wheel drive; Rep. gr. 48 ;
Checking power-assisted steering oil level .
– Add coolant ⇒ page 158 .
– Replenish engine oil if necessary.

1. Removing and installing engine 23

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

Disconnecting and connecting battery .
– Adjust selector lever cable ⇒ Automatic gearbox 0C8 - 8-
speed; Rep. gr. 37 ; Repairing gear selector mechanism .
– Top up ATF level ⇒ Automatic gearbox 0C8 - 8-speed; Rep.
gr. 37 ; Checking ATF level and topping-up .
– Connect the vehicle diagnostic tester .
– Perform vehicle system test ⇒ Vehicle diagnostic tester.
– Finish the vehicle system test so that any event entries stored
during assembly can be cleared automatically. gen AG
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Check wheel alignment if during the road test it is determined that
es, in part or in w

the steering wheel is not in the straight-ahead position when mov‐

t to the co
ing straight-ahead ⇒ Running gear, axles, steering, front and
four-wheel drive; Rep. gr. 44 ; Wheel alignment .

rrectness of i
Specified torques
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Bolted connection Specified torque

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Nuts and bolts M6 10 Nm

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M7 15 Nm

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drive; Rep. gr. 40 ; Repairing
drive shaft .
Gearbox carrier to body ⇒ Differential and final drive;
Rep. gr. 34 ; Installing gear‐
box carrier and console .
Drive shafts to gearbox ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Front wheel
suspension

1.5 Supporting engine in installation position

24 Rep. gr.10 - Removing and installing engine

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Special tools and workshop

equipment required

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♦ Adapter - 10 - 222 A /28-
AG.

♦ Square section tube - T40091/1- (qty. 2)

♦ Hook rail - T40091/2-
♦ 2 x articulated joints - T40091/3-
♦ Support bearing - T40093/5-
♦ 2 x articulated joints - T40093/4-
– Slide rotary joints - T40091/3- and hooks - 10 - 222 A /10- onto
square section tube of bracing device - 10 - 222 A- .
– Fit adapter - 10 - 222 A /29- onto square section tube.
– »Raise« plenum chamber cover on right and left.

1. Removing and installing engine 25

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Put on support bracket as shown.

Caution

Support bracket is not allowed to be placed on metal tabs

-arrow-!

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push square tube - T40091/1- into articulated joint -
urposes, in part or in wh

T40091/3- .

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– Repeat procedure on opposite side of vehicle.
– Push hook rail - T40091/2- on one side through articulated joint rrectne
- T40093/4- .
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– Push mounting - T40093/5- onto the hook rail - T40091/2- then

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– Insert hooks of spindles into the engine lifting eyes and brace C py
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26 Rep. gr.10 - Removing and installing engine

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

2 Assembly mountings
⇒ “2.1 Assembly overview - assembly mountings”, page 27 .
⇒ “2.2 Removing and installing engine mounting”, page 27

2.1 Assembly overview - assembly mountings

1 - Engine carrier bolts

❑ 120 Nm + turn 180° fur‐
ther
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6 - 75 Nm

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8 - Left engine support
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❑ With oil filter housing
9 - 25 Nm

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10 - Cable bracket
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11 - Cable bracket
12 - 25 Nm

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13 - 60 Nm
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14 - Left engine mounting n in

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2.2 Removing and installing engine mount‐

ing
Removing:
– Support engine in its installation position ⇒ page 24 .

2. Assembly mountings 27
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Unscrew nuts for engine mounting on left and right sides

-arrow-.
– Lift engine evenly with both spindles until threaded engine
mounting stud is »free«.
– Remove securing bolts for engine mounting. Remove engine
mounting.
Installing:
Assemble in reverse order of dismantling.
• Specified torques ⇒ page 27 .

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28 Rep. gr.10 - Removing and installing engine

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

13 – Crankshaft group
1 Dismantling and assembling engine
Overview
⇒ “1.1 Part I”, page 30 .
⇒ “1.2 Part II”, page 32 .
⇒ “1.3 Removing and installing poly-V belt”, page 34 .
⇒ “1.4 Removing and installing vibration damper”, page 35

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1. Dismantling and assembling engine 29

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Note

♦ Secure engine to engine and gearbox support - VAS 6095- to

carry out repairs.
♦ 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 spray jets.
♦ Renew engine oil cooler.
♦ Renewing oil filter.

1.1 Part I

1 - Valve timing housing

❑ Lightly lubricate contact
surface of oil seals be‐
fore installing.
❑ Removing and installing
⇒ page 105 Removing
and installing cam‐
shafts.
❑ Assembly overview
⇒ page 102
❑ Before installing valve
timing housing, check AG. Volkswagen AG d
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⇒ page 122
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4 - 8 Nm
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❑ Insert with locking fluid -

es, in part or in w

D 000 600 A2-

t to the co

5 - Chain tensioner, 50 Nm
❑ For camshaft timing
rrectness of i

chain
⇒ Item 10 (page 31)
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❑ Only rotate engine when

chain tensioner is instal‐
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7 - Tensioning rail
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❑ For camshaft timing chain ⇒ Item 10 (page 31)

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8 - Pivot pin, 10 Nm opyri
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❑ For tensioning rail ⇒ Item 7 (page 30) by c lksw

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30 Rep. gr.13 - Crankshaft group

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

9 - Sprocket
❑ For timing chains
❑ Install camshaft adjuster with camshaft timing chain ⇒ page 64 .
10 - Camshaft timing chain
❑ Before removing, mark direction of rotation (installation
agen
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❑ Install camshaft adjuster with camshaft
d b timing chain ⇒ page 64 .
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11 - 60 Nm + 1/4 turn (90°) further au
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12 - Exhaust camshaft adjuster itte

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❑ Identification: 32A.

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❑ Install camshaft adjuster with camshaft timing chain ⇒ page 64 .

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13 - 60 Nm + 1/4 turn (90°) further
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❑ Contact surface of sender wheel must be dry around bolt head when installed.
❑ To remove and install, counterhold using 27 mm open-end spanner on camshaft ⇒ page 105 , Removing

rrectness of i
and installing camshafts.
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14 - Inlet camshaft adjuster

❑ Identification: 24E

nf
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❑ Install camshaft adjuster with camshaft timing chain ⇒ page 64 .

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15 - 10 Nm
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16 - Chain tensioner with tensioning rail

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❑ For timing chain ⇒ Item 19 (page 31)

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❑ Only rotate engine when chain tensioner is installed.
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❑ Built into crankshaft.
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pump drive ⇒ page 74 .
AG.

18 - Locating pin without collar, 10 Nm

❑ For guide rail ⇒ Item 23 (page 31) .
19 - Timing chain
❑ Before removing, mark direction of rotation (installation position) ⇒ page 32 .
❑ Installing timing chain for oil pump drive ⇒ page 74 .
20 - Pivot pin, 10 Nm
❑ for guide rail
21 - 23 Nm
22 - Slide rail
❑ For camshaft timing chain ⇒ Item 10 (page 31)
23 - Slide rail
❑ For timing chain ⇒ Item 19 (page 31)
❑ Remove and install together with timing chain. Installing timing chain for oil pump drive ⇒ page 74 .
24 - Drive sprocket for high pressure pump
❑ With needle bearing
❑ Lubricate needle bearing before installing.

1. Dismantling and assembling engine 31

 AG. Volkswagen AG d
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Touareg 2010 ➤ , Touareg 2015 horis
➤ eo
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6-cylinder direct-injection engine
ss a (3.6 l engine, 4V) - Edition 12.2019 ra
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Marking timing chains

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– Mark timing chains before removing (e.g. with paint, arrow

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pointing in direction of rotation).

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Note es, in part or in w

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Do not mark chain by way of centre punch, notch or the like.

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1.2 Part II
Co
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1 - Vibration damper securing cted agen
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bolts
❑ Qty. 7
❑ 60 Nm + turn 180° fur‐
ther
2 - Vibration damper
❑ Removing and installing
⇒ page 35 .
❑ Removing and installing
poly V-belt ⇒ page 34
3 - Guide tube
❑ for oil dipstick
❑ Secured with bolt to in‐
take manifold.
4 - Cylinder block
❑ Sealing flanges and fly‐
wheel or drive plate
⇒ page 36
❑ Crankshaft
⇒ page 49 .
❑ Pistons and conrods
⇒ page 56 .
5 - Seal
❑ Renew
❑ Lubricate before as‐
sembling.
6 - Oil pump
❑ Removing and installing
⇒ page 122
7 - Sprocket
❑ Install camshaft adjust‐
er with camshaft timing
chain ⇒ page 64 .

32 Rep. gr.13 - Crankshaft group

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

8 - 60 Nm + turn 90° further

❑ Renew
9 - 8 Nm
❑ Insert with locking fluid - D 000 600 A2-
10 - 20 Nm
❑ The specified torque influences the function of the knock sensor.
11 - Knock sensor 1 - G61-
❑ Fitting location: between cylinder 1 and cylinder 3 below exhaust manifold.
12 - Seal
❑ Renew
13 - Oil intake tube
❑ For oil pump.
14 - O-ring
❑ Renew
15 - 8 Nm
❑ Insert with locking fluid - D 000 600 A2-
16 - Oil pressure pipe wage
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19 - Sump
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❑ Removing and installing ⇒ page 119

hole

spec

20 - Oil level and oil temperature sender - G266-

es, in part or in w

t to the co

21 - 12 Nm
22 - Securing bolt for oil sump
rrectness of i

❑ 10 Nm
l purpos

23 - Oil filter housing / left engine bracket

❑ Dismantling and assembling ⇒ page 128
nform
ercia

❑ Connection diagram for coolant hoses ⇒ page 135

m

❑ Removing left or right engine mountings ⇒ page 27

com

tion in
r

24 - 23 Nm
te o

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25 - Ancillary bracket
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❑ For alternator, air conditioner compressor and power-assisted steering vane pump
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26 - Engine speed sender - G28-
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28 - O-ring
❑ Renew
29 - 25 Nm
30 - 20 Nm
❑ The specified torque influences the function of the knock sensor.
31 - Knock sensor 2 - G66-
❑ Fitting location: between cylinder 4 and cylinder 6.

1. Dismantling and assembling engine 33

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

32 - 6 Nm
❑ Secured to intake manifold.

1.3 Removing and installing poly-V belt

Special tools and workshop equipment required
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– Press tensioning arm in -direction of arrow- using a suitable

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screwdriver.

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– Screw M8×50 bolt into threaded hole -A- and secure poly V-
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Screw in bolt only far enough to remove poly V-belt, as tensioning
roller housing may otherwise be damaged.

rrectness of i
– Remove poly V-belt.
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Installing poly V-belt:

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– Install poly V-belt and remove M8 bolt from tensioning roller.

After completing repairs always:
– Start engine and check belt running.

34 Rep. gr.13 - Crankshaft group

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

1.4 Removing and installing vibration damp‐

er
Special tools and workshop equipment required
♦ Counter-hold tool - T10172A-

♦ Screw-in bolts - T10172A/1-

Removing:
– Remove poly V-belt ⇒ page 34 .
– Remove radiator cowl ⇒ page 170 .
– Lock vibration damper using counterhold - T10172A- and
adapter - T10172A/1- .
– Unscrew securing bolts and remove vibration damper from
crankshaft journal.

Installing:
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Check rubber joint between inner and
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new vibration damper.

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– Renew securing bolt for vibration damper.

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– Fit vibration damper and tighten bolts by hand.

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– Lock vibration damper using counterhold - T10172A- .

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t to the co

– Tighten securing bolts.

– Install poly V-belt ⇒ page 34 .
rrectne

Specified torques ⇒ page 32

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1. Dismantling and assembling engine
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

2 Sealing flanges and drive plate

⇒ “2.1 Assembly overview - sealing flanges and drive plate”, page
36 .
⇒ “2.2 Assembly overview - timing chain covers”, page 37
⇒ “2.3 Removing and installing seal on gearbox side”,
page 38 .
⇒ “2.4 Removing and installing sealing flange on gearbox side”,
page 40 .
⇒ “2.5 Renewing crankshaft sealing flange, vibration damper
side”, page 43 . AG. Volkswagen gen AG d
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⇒ “2.6 Removing and installing
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⇒ “2.7 Removing and
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page 47 . sa
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2.1 Assembly overview - sealing flanges and drive plate
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36 Rep. gr.13 - Crankshaft group

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

1 - Vibration damper securing

bolts
❑ Qty. 7
❑ 60 Nm + turn 180° fur‐
ther
2 - Vibration damper
❑ Removing and installing
⇒ page 35
3 - 10 Nm
4 - Sealing flange
❑ With seal
❑ Renewing ⇒ page 43
5 - Cylinder block agen
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❑ Assembly overview - d by V gu
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⇒ page 49 . aut
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❑ Assembly overview -

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⇒ page 56 .
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6 - Sealing flange

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❑ Removing and installing
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⇒ page 40
hole

spec
7 - Seal
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❑ Remove using extractor
hook - T20143/2-
❑ Do not oil or grease the

rrectness of i
oil seal sealing lip
l purpos

❑ Before installing, re‐

move oil residue from
crankshaft journal using
nf
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a clean cloth.
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❑ Installing ⇒ page 38
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8 - Shim
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11 - Drive plate
AG.

❑ Removing and installing drive plate ⇒ page 45

12 - 23 Nm

2.2 Assembly overview - timing chain cov‐

ers
Mechanical vacuum pump ⇒ page 92

2. Sealing flanges and drive plate 37

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

1 - Seal
❑ For crankshaft
❑ Renewing ⇒ page 38
2 - Sealing flange
❑ Gearbox side
❑ Removing and installing
⇒ page 40
3 - Bolt
❑ 23 Nm
4 - Bolt
❑ Tighten in stages and in
diagonal sequence.
❑ 8 Nm
5 - Seal
❑ Qty. 2 agen
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❑ Renew if leaking or

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❑ Renewing ⇒ page 94

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6 - Bolt
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❑ 8 Nm

spec
urposes, in part or in wh

7 - Hall sender

t to the co
❑ Hall sender - G40- and
Hall sender 2 - G163-

rrectne
8 - O-ring
❑ Qty. 2

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❑ Renew
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9 - Dowel pins
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❑ Qty. 2 atio
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10 - Cover for timing chain

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11 - Cylinder head gasket

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❑ Clean drillings and fill with sealant ⇒ page 41 .

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12 - Dowel pins
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❑ 10 Nm Prote AG.

2.3 Removing and installing seal on gear‐

box side
Special tools and workshop equipment required

38 Rep. gr.13 - Crankshaft group

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

♦ Fitting tool - T10122-

♦ Extractor hook - T20143-

AG. Volkswagen AG d
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Remove seal: auth
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Proceed as follows:

ce
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pt
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– Remove gearbox ⇒ Automatic gearbox 0C8 - 8-speed; Rep.

itte

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gr. 37 .

ab
pe

ility
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– Remove drive plate ⇒ page 45 .

wit
, is n

h re
– Fit puller hooks - T20143/2- behind sealing lip of oil seal as
hole

spec
shown in illustration.
es, in part or in w

t to the co
– Support puller hook - T20143/2- on sealing flange and lever
seal out in direction of -arrow-.

rrectness of i
l purpos

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2. Sealing flanges and drive plate 39

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Install seal:
– Pull seal -A- with the outer side over the sleeve - T10122/1- of
fitting tool - T10122- onto pulling sleeve - T10122/2- .
– Separate the two fitting sleeves.
– Then set pulling sleeve - T10122/2- with dry oil seal onto
crankshaft journal.

– Tap sealing ring into sealing flange as far as it will go, using
the thrust piece - T10122/3- to do so.
Further assembly is basically a reverse of the dismantling se‐
quence.

2.4 Removing and installing sealing flangelksw

agen
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on gearbox side Vo gu
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se n i tee
or
Special tools and workshop equipment required
au
th or
ac
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♦ Hand drill with plastic brush
ce
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nl

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du

an

♦ Safety glasses
itte

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♦ Sealant - D 176 501 A1-

ility
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Removing:
h re
hole

spec

Proceed as follows:
es, in part or in w

t to the co

– Remove engine ⇒ page 7 .

– Separate engine and gearbox.
rrectness of i

– Secure engine on engine and gearbox support - VAS 6095-

⇒ page 21 .
l purpos

– Remove drive plate ⇒ page 45 .

nform
ercia

– Remove sump ⇒ page 119 .

m

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ion
c

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or

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ate

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priv

cum
for

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t.
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Cop py
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gh ht
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Vo
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by
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Prote AG.

40 Rep. gr.13 - Crankshaft group

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Remove bolts for sealing flange -1 and 2-.

Caution

Avoid damage to cylinder head gasket. If the cylinder head

gasket is bent excessively, it can be kinked. A kinked cylinder
head gasket must be renewed.

– Pull sealing flange from cylinder block horizontally.

– Press crankshaft oil seal out of lower timing chain cover.
Installing:
• Specified torques ⇒ page 37 .

Caution

The lubrication system can be soiled by sealant residue. Care‐

fully cover open parts ofn Aengine
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wagthat no sealant residue can
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fall into it. olkswage does
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– Remove
ss remainingsealant from sealing cyl‐ flange and from c
ce
e

inder block, e.g. using a rotating plastic brush. Wear protective

nl

pt
du

goggles.
an
itte

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erm

ab

– Clean sealing surfaces; they must be free of oil and grease.

ility
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wit
, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Remove old sealing compound from holes -arrow- of cylinder

head gasket.
nform
mercia

at
om

Note
ion
c

in t
or

his
e

With the cylinder head installed, the holes in the cylinder head
at

do
riv

gasket are only half visible.

p

cum
for

en
ng

t.
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Cop py
Caution
t. rig
gh ht
pyri by
Vo
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by
Avoid damage to cylinder head gasket. If the cylinder head
cted agen
Prote AG.
gasket is bent excessively, it can be kinked. A kinked cylinder
head gasket must be renewed.

2. Sealing flanges and drive plate 41

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Bend end of cylinder head gasket down very slightly

-arrows-, just far enough to be able to clean upper sealing
surface on cylinder head gasket and cylinder head.
– Clean top and bottom of cylinder head gasket; both faces must
be free of oil and grease.

– Cut off nozzle on tube at front marking (∅ of nozzle approx. 2

mm).

– Apply thin coating of sealant to upper and lower sealing sur‐

faces of cylinder head gaskets; to do this, bend cylinder head
gasket downwards very slightly -arrows-.
– To coat the surface between cylinder head and gasket use a
flat object, e.g. a feeler gauge.
AG. Volkswagen AG d
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– Apply thin bead of sealant -arrows- from below into both cor‐
ility
ot p

ners between cylinder head gasket and cylinder block, so that

wit
is n

holes in cylinder head gasket are filled.

h re
ole,

spec

– Check if dowel sleeves for sealing flange are inserted in cyl‐

urposes, in part or in wh

inder block.
t to the co
rrectness o
cial p

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mer

atio
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n
c

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t.
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by c lksw
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Prote AG.

42 Rep. gr.13 - Crankshaft group

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Apply sealant - D 176 501 A1- on sealing flange as shown and

install.

Note

The sealing flange must be installed within 5 minutes after sealant

application.

– Tighten bolts in 3 stages as follows:

A - Pre-tighten bolts -1- to 5 Nm.
B - Tighten bolts -2- to 23 Nm. AG. Volkswagen AG d
agen oes
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C - Tighten bolts -1- to 10 Nm. by Vol not
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Continue installation in the reverse order of removal,
thor observing eo
the following: s au ra
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s

ce
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– Install crankshaft oil seal ⇒ page 38 .

nl

pt
du

an
itte

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– Install sump ⇒ page 119 .
erm

ab
ility
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– Install drive plate ⇒ page 45 .

wit
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– Install engine with gearbox.

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

2.5 Renewing crankshaft sealing flange, vi‐

bration damper side

nform
ercia

Special tools and workshop equipment required

m

at
om

ion
♦ Torque wrench - V.A.G 1331-
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. Sealing flanges and drive plate 43

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

♦ Torque wrench - V.A.G 1332-

♦ Counter-hold tool - T10172- with adapter - T10172/1-

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is n

h re
ole,

♦ Cleaning solution - D 291 091 A1-

spec
urposes, in part or in wh

♦ Sealant - D 176 501 A1-

t to the co
Removing:

rrectne
– Remove poly V-belt ⇒ page 34 .
– Remove vibration damper ⇒ page 35 .

ss o
– Unscrew bolts -1- and -2-.
cial p

f inform
– Carefully prise off sealing flange.
mer

atio
m

– Remove sealant residue from sealing surfaces.

o

n
c

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Installing:
te

sd
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o
r

– Clean sealing surfaces with cleaning solution - D 291 091 A1- .

p

cum
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fo

en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Thinly coat lower sealing surface »shaded area« on sealing

flange with sealant.

44 Rep. gr.13 - Crankshaft group

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Apply sealant bead of about 2 to 3 mm as shown -arrow- to

clean sealing surface of sealing flange.

– Apply a thin bead of sealant at the edge of the joint between

the cylinder block and the sump -arrows-.

Note

♦ Before applying sealant bead, cover sealing ring with a clean

cloth.
♦ The sealing compound bead must not be thicker than 2 to
3 mm. Otherwise excessive sealing compound will enter the
sump and may block the oil suction pipe strainer.
♦ Observe use-by-date of sealant.
♦ The sealing flange must be installed within 5 minutes after ap‐
plying the silicone sealant.

– Slide sealing flange -1- over guide sleeve -2- provided and
carefully onto crankshaft journal.

AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
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au ra
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nl

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ab
ility

– Insert bolts for sealing flange with locking fluid - D 154 100 A1-
ot p

wit

and tighten as follows:

, is n

h re
hole

spec

Stage Bolts Specified torque

es, in part or in w

t to the co

1. -1- hand-tight
2. -2- hand-tight
3. -1- 10 Nm
rrectness of i

4. -2- 10 Nm
l purpos

– Install vibration damper and tighten securing bolts

⇒ page 35 .
nf
ercia

orm

– Install poly V-belt ⇒ page 34 .

m

atio
om

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2.6 Removing and installing drive plate

thi
te

sd
iva

o
r
rp

cu

Special tools and workshop equipment required

o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
yri by

45
cop Vo
by lksw
Prote
cted AG. 2. Sealing flanges and drive plate
agen
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

♦ Counter-hold tool - T10172- with adapter - T10172/1-

♦ Torque wrench - V.A.G 1332-

Removing:
Proceed as follows:
– Remove gearbox ⇒ Automatic gearbox 0C8 - 8-speed; Rep.
gr. 37 .
AG. Volkswagen AG d
– Lock vibration damper using counterhold - T10172- . agen oes
olksw not
V gu
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– Loosen drive plate securing bolts diagonally and remove.
orised
nte
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– Remove drive plate. ss a c
ce
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Installing:
un

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d
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– Fit drive plate on crankshaft.

rm

ab
pe

ility

– Insert at least 3 old securing bolts and tighten to 30 Nm.

ot

wit
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h re
hole

spec
es, in part or in w

t to the co

– Measure dimension -a- using depth gauge . Specification:

rrectness of i

21.0 to 23.0 mm.

l purpos

If specification is not attained:

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
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rp

cum
fo

en
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t.
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Cop py
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by c lksw
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Prote AG.

46 Rep. gr.13 - Crankshaft group

 AG. Volkswagen AG d
agen oes
olksw not Touareg 2010 ➤ , Touareg 2015 ➤
byV gu
a
rised
6-cylinder direct-injectionraengine
nte (3.6 l engine, 4V) - Edition 12.2019
ho eo
aut ra
– Removessdrive plate again and fit appropriate shim -1-. c

ce
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pt
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Note
erm

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wit
Only one shim of the appropriate thickness may be used for com‐
is n

h re
pensation.
ole,

spec
urposes, in part or in wh

When specification is attained:

t to the co
– Insert new securing bolts and tighten by hand.

rrectne
– Tighten securing bolt to 60 Nm + turn 90° further.

ss
2.7 Removing and installing bracket for an‐

o
cial p

f in
cillaries

form
mer

atio
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Removing:
o

n
c

i
or

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Proceed as follows:

thi
te

sd
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– Remove poly V-belt ⇒ page 34 .

i

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cum
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fo

en
ng

– Remove alternator ⇒ Rep. gr. 27 .

t.
yi Co
Cop py
– Remove power-assisted steering pump ⇒ Rep. gr. 48 . ht. rig
rig ht
py by
o Vo
– Remove air conditioner compressor ⇒ Rep. gr. 87 . by c lksw
cted agen
Prote AG.
– Unscrew bolts -1 to 5- and remove ancillary bracket.

2. Sealing flanges and drive plate 47

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Installing:
Install in reverse order of removal, observing the following.
– Tighten bolts in sequence -1 to 5- in 2 stages as follows:
1. Tighten bolts by hand.

2. Tighten bolts to 25 Nm.

Note

Bolts -1- and -2- are fitted bolts.

– Install A/C compressor ⇒ Rep. gr. 87 .

– Install power-assisted steering pump ⇒ Rep. gr. 48 .
– Install alternator ⇒ Rep. gr. 27 .
– Install poly V-belt ⇒ page 34 .

n AG. Volkswagen AG do
lkswage es n
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erm

ab
ility
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wit
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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

48 Rep. gr.13 - Crankshaft group

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

3 Crankshaft ksw
agen
AG. Volkswagen AG d
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⇒ “3.1 Assembly overview - crankshaft”, page 49 . ed b ara
nte
ris
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⇒ “3.2 Fitting sender wheel to crankshaft”, page 50 .aut ra
c
ss
⇒ “3.3 Allocation of main bearing shells”, page 51 .

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Note

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♦ If the crankshaft or cylinder block is renewed, the crankshaft

h re
hole
bearing shells must be reallocated ⇒ page 51 .

spec
es, in part or in w
♦ Before removing crankshaft, make provision for a suitable sur‐

t to the co
face for storing crankshaft to ensure that sender wheel
⇒ Item 6 (page 50) is not damaged or lies against any other
item.

rrectness of i
♦ Secure engine on engine and gearbox support - VAS 6095- to
l purpos

carry out repairs.

nform
ercia

3.1 Assembly overview - crankshaft

m

a
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tion in
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te o

1 - Bearing cap

thi
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do
❑ Bearing cap 1: vibration
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❑ Bearing cap 5 with re‐
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cesses for thrust wash‐
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❑ Bearing shell retaining Prote
cted AG.
agen
lugs in cylinder block
and bearing caps must
align.
2 - 30 Nm + 1/2 turn (180°) fur‐
ther
❑ Renew
❑ 2 x 90° further is permit‐
ted.
3 - Bearing shells 1 to 7
❑ For bearing cap without
oil groove.
❑ for cylinder block with oil
groove
❑ Do not interchange
used bearing shells
(mark).
❑ Allocation of crankshaft
bearing shells
⇒ page 51 .
4 - Thrust washer
❑ For bearing cap 5
❑ Note fixing arrangement
5 - Crankshaft
❑ If the crankshaft is re‐
newed, the crankshaft
bearing shells must be
reallocated ⇒ page 51 .
❑ Before removing, see notes ⇒ page 49 .

3. Crankshaft 49
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019
❑ Axial clearance new: 0.07 to 0.23 mm; wear limit: 0.30 mm
❑ Measure radial clearance using Plastigage; new: 0.02 to 0.06 mm; wear limit: 0.10 mm
❑ Do not rotate crankshaft when checking radial clearance
❑ Crankshaft dimensions: crankshaft bearings: 59.958 to 59.978 mm, conrod bearings: 53.958 to
53.978 mm
❑ Reworking the crankshaft is not permitted.
6 - Sender wheel
❑ For engine speed sender - G28-
❑ Renew
❑ Installing ⇒ page 50
7 - 10 Nm + 1/4 turn (90°) further
❑ Renew
8 - Oil spray jet
❑ For crankshaft bearings 2 to 7
❑ For piston cooling
❑ Opening pressure: 2.0 bar
❑ Removing and installing ⇒ page 128

3.2 Fitting sender wheel to crankshaft

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
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♦ Locking fluid D 154 100 A1

erm

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Procedure
wit
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Ensure that contact surfaces of crankshaft and sender wheel are

ole,

free of oil and grease.

spec
urposes, in part or in wh

t to the co

Note
rrectne

The sender wheel must only be installed once, because after fas‐
tening for a second time, the attachment points -arrows- of coun‐
s

tersunk head bolts -1- in sender wheel -2- are deformed to such
s o

an extent that the bolt heads make contact with the crankshaft
cial p

f in

-3- and the sender wheel below the bolts is loose.

form
mer

atio
m

– Lightly coat contact surfaces of crankshaft and sender wheel

o

n
c

with locking fluid “D 154 100 A1” for additional security.

or

n thi
te

sd
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– Ensure during installation that »VR6« marking -arrow- is posi‐

iv

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tioned over single threaded hole.

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ng

t.
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– First tighten all new securing bolts lightly by hand.
Co
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50
Prote AG.
Rep. gr.13 - Crankshaft group
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Then tighten securing bolt -1- to 10 Nm + 90° (1/4 turn) further.

– Then tighten securing bolts -2- to 10 Nm + 90° (1/4 turn) fur‐

ther.

3.3 Allocation of main bearing shells

Allocation of main bearing shells differs according to manufac‐
turing date of crankshaft.
The manufacturing date is embossed on the outer crankshaft web
of No. 1 cylinder.
1 - Manufacturing date of crankshaft (DDMMYY)
2 - Letters for allocation of bearing shells
3 - Part number
– Check how main bearing shells are allocated, according to
manufacturing date.
Allocation of main bearing shells, up to and including manu‐
facturing date 230912 ⇒ page 51 .
Allocation of main bearing shells, from manufacturing date
240912 ⇒ page 53 . . Volkswag n AG en AG
wage does
Volks not
3.3.1 Allocation of main bearing shells, up to
by gu
ara
ed nte
ris
and including manufacturing date
tho eo
au ra
c
ss
23.09.12
ce
le
un

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itte

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ab

Note
pe

ility
ot

wit
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It is essential to observe the manufacturing date. The manufac‐

h re
hole

turing date is embossed on the crankshaft web. Establish manu‐

spec

facturing date ⇒ page 51 .

es, in part or in w

t to the co

Main bearing shells of the correct thickness are allocated to the

cylinder block and crankshaft at the factory. Coloured dots are
rrectness of i

used to identify the thickness of the bearing shells.

l purpos

If the cylinder block or crankshaft is changed, the crankshaft

bearing shells must be reallocated.
nform
ercia

Establish the correct colour marking for the bearing shell using
the letters on the cylinder block and the crankshaft.
m

a
com

tion in

The first letter is allocated to crankshaft bearing 1, the second to

r
te o

crankshaft bearing 2, etc.

thi
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fo

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Cop py
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Prote AG.

3. Crankshaft 51
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Letters on cylinder block:

The letters for the allocation of the bearing shells are located on
the sealing surface of the sump.

Letters on crankshaft:
The letters for the allocation of the bearing shells are located on
the outer crankshaft web of No. 1 cylinder.
– Note letters and identify colour code to be installed based on
table.

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Letter on cylinder block Letter on crankshaft web Colour marking of bearing Colour marking of bearing
ce
le
un

pt

shell for cylinder block (up‐ shell for bearing cap (low‐
an
d
itte

per bearing shell) er bearing shell)

y li
erm

ab
ility

A, B, C R red red
ot p

wit
is n

A, B, C G yellow red
h re
ole,

A, B, C B yellow yellow
spec
urposes, in part or in wh

A, B, C V blue yellow
t to the co

D, E, G R yellow red
D, E, G G yellow yellow
rrectne

D, E, G B blue yellow
s

D, E, G V blue blue
s o
cial p

H, I, K R yellow red
inform
mer

H, I, K G yellow yellow
atio
m

H, I, K B blue yellow
o

n
c

i
or

H, I, K V blue blue
thi
te

sd
va

L, M R yellow yellow
i

o
pr

cum
r
fo

L, M G blue yellow
en
ng

t.
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op
L, M B blue yellow
C py
t. rig
gh ht
L, M V violet blue
pyri by
Vo
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cted agen
Prote AG.

52 Rep. gr.13 - Crankshaft group

 AG. Volkswagen AG d
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Touareg 2010 ➤ , Touareg 2015 ➤
ris
ut
ho 6-cylinder direct-injection
eo
ra
engine (3.6 l engine, 4V) - Edition 12.2019
s a c
s
Example:

ce
e
nl

pt
du

an
itte

Crankshaft bearing 1 2 3 4 5 6 7

y li
erm

ab
ility
Letters on cylinder block G H K H G E G
ot p

wit
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Letters on crankshaft web G B R V B B G

h re
hole

Colour marking of bearing shell yellow blue yellow blue blue blue yellow

spec
es, in part or in w

for cylinder block (upper bearing

t to the co
shell)
Colour marking of bearing shell yellow yellow red blue yellow yellow yellow
for bearing cap (lower bearing

rrectness of i
shell)
l purpos

nf
ercia

3.3.2 Allocation of main bearing shells, from

orm
m

manufacturing date 24.09.12

atio
om

n in
or c

thi
te

sd
iva

Note

o
r
rp

cu
o

m
f

en
ng

It is essential to observe the manufacturing date. The manufac‐

t.
yi Co
op
turing date is embossed on the crankshaft web. Establish manu‐
C py
ht. rig
facturing date ⇒ page 51 . rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Main bearing shells of the correct thickness are allocated to the
cylinder block and crankshaft at the factory. Coloured dots are
used to identify the thickness of the bearing shells.
If the cylinder block or crankshaft is changed, the crankshaft
bearing shells must be reallocated.
Establish the correct colour marking for the bearing shell using
the letters on the cylinder block and the crankshaft.
The first letter is allocated to crankshaft bearing 1, the second to
crankshaft bearing 2, etc.
Letters on cylinder block:
The letters for the allocation of the bearing shells are located on
the sealing surface of the sump.

3. Crankshaft 53
 AG. Volkswagen AG d
agen oes
olksw not
y V gu
Touareg 2010 ➤ , Touareg 2015 ➤rise d b ara
nte
6-cylinder direct-injection engineau(3.6
tho
l engine, 4V) - Edition 12.2019 eo
ra
ss c

ce
e
Letters on crankshaft:

nl

pt
du

an
itte
The letters for the allocation of the bearing shells are located on

y li
erm

ab
the outer crankshaft web of No. 1 cylinder.

ility
ot p

wit
– Note letters and identify colour code to be installed based on

, is n

h re
table.

hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
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ion
c

in t
or

his
ate

do
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cum
for

en
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Letter on cylinder block Letter on crankshaft web Colour marking of bearing Colour marking of bearing
n

t.
yi Co
op
shell for cylinder block (up‐ shell for bearing cap (low‐
C py
t. rig
per bearing shell) er bearing shell)
gh ht
pyri by
Vo
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A, B, C F Prote red
cted AG. red
agen

A, B, C E yellow red
A, B, C D yellow yellow
A, B, C C blue yellow
A, B, C B blue blue
A, B, C A violet blue
D, E, G F yellow red
D, E, G E yellow yellow
D, E, G D blue yellow
D, E, G C blue blue
D, E, G B violet blue
D, E, G A violet violet
H, I, K F yellow red
H, I, K E yellow yellow
H, I, K D blue yellow
H, I, K C blue blue
H, I, K B violet blue
H, I, K A violet violet
L, M F yellow yellow
L, M E blue yellow
L, M D blue yellow
L, M C violet blue
L, M B violet violet
L, M A violet violet

Example:
Crankshaft bearing 1 2 3 4 5 6 7
Letters on cylinder block G H H H G E G

54 Rep. gr.13 - Crankshaft group

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Crankshaft bearing 1 2 3 4 5 6 7
Letters on crankshaft web A B A C C A B
Colour marking of bearing shell violet violet violet blue blue violet violet
for cylinder block (upper bearing
shell)
Colour marking of bearing shell violet blue violet blue blue violet blue
for bearing cap (lower bearing
shell)

n AG. Volkswagen AG do
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ab
pe

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ot

wit
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hole

spec
es, in part or in w

t to the co
rrectness of i
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mercia

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tion in
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thi
s
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cum
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t.
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Cop py
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cted agen
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3. Crankshaft 55
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019
AG. Volkswagen AG d
agen oes
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4 Pistons and conrods d by Vol not
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⇒ “4.1 Assembly overview
autho
- pistons and conrods”, page 56 . eo
ra
ss c
⇒ “4.2 Checking piston and cylinder”, page 57 .

ce
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nl

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an
⇒ “4.3 Piston and cylinder dimensions”, page 61
itte

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ab
4.1 Assembly overview - pistons and conrods

ility
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wit
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h re
hole

1 - Piston rings

spec
es, in part or in w

❑ Offset gaps by 120°

t to the co
❑ Use piston ring pliers to
remove and install.

rrectness of i
❑ “TOP” faces towards
piston crown.
l purpos

❑ Checking ring gap

⇒ page 57 .

nf
ercia

o
❑ Checking ring-to-groove

rm
m

clearance ⇒ page 57 .

atio
om

n in
c

2 - Piston
or

thi
te

sd
❑ Checking ⇒ page 58
iva

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cu
❑ Mark cylinder number
o

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f

en
ng

and installation position

t.
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relative to conrod. Cop py
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❑ The two deep valve
ht
pyri by
Vo
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pockets in the piston
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crown point to the centre Prote AG.
of the cylinder block.
❑ Installing piston
⇒ page 58 .
3 - Retaining ring
❑ Ensure firm seating
4 - Connecting rod
❑ Renew as set only.
❑ Mark cylinder number
-B-
❑ Installation position:
marks -A- must be
above one another.
5 - Bearing shell
❑ Observe installation po‐
sition
❑ Do not interchange used bearing shells.
❑ The lugs on bearing shells must fit tightly in the recesses.
❑ Axial clearance new: 0.05 to 0.31 mm; wear limit: 0.40 mm
❑ Measure radial clearance using Plastigage; new: 0.02 to 0.07 mm; wear limit: 0.10 mm. Do not rotate
crankshaft when checking radial clearance.
6 - Conrod bearing cap
❑ Mark cylinder number -B-
❑ Installation position: marks -A- must be above one another.
7 - 40 Nm + 1/4 turn (90°) further
❑ Renew
❑ Oil threads and contact surface

56 Rep. gr.13 - Crankshaft group

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019
❑ To measure radial clearance, tighten to 40 Nm but not further.
8 - Cylinder block
❑ Checking cylinder bores ⇒ page 58 .
❑ Removing and installing crankshaft ⇒ page 49 .
❑ Piston and cylinder dimensions ⇒ page 61 .
9 - Piston pin
❑ If difficult to remove, heat piston to 60°C.
❑ Remove and install using drift - VW 222 A- .

4.2 Checking piston and cylinder

Checking piston ring gap ⇒ page 57 .
Checking ring-to-groove clearance ⇒ page 57 .
Checking piston ⇒ page 58 .
Checking cylinder bore ⇒ page 58 .
en A. G . Volkswagen AG
Installing piston ⇒ page
ksw
ag58 does
not
Vol gu
Piston and cylinder by dimensions ⇒ page 61 ara
ed nte
oris eo
th
4.2.1 ss
au Checking piston ring gap ra
c
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nl

Special tools and workshop equipment required

pt
du

an
itte

y li

♦ Feeler gauge
erm

ab
ility
ot p

Test sequence
wit
, is n

h re

– Push ring at right angles to cylinder wall from above down to

hole

spec

approx. 15 mm from bottom end of cylinder. Push in using a

es, in part or in w

piston without rings.

t to the co

Piston ring Ring gap

New Wear limit
rrectness of i

Rectangular-section ring mm 0.20 … 0.40 1.0

l purpos

Tapered stepped ring mm 0.20 … 0.40 1.0

Oil scraper ring mm 0.25 … 0.50 1.0
nf
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thi
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4.2.2 Checking ring-to-groove clearance

iva

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f

Special tools and workshop equipment required

en
ng

t.
yi Co
op py
♦ Feeler gauge t. C rig
gh ht
pyri by
Clean annular groove before check.
co Vo
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Prote AG.
Piston ring Clearance
New Wear limit
Rectangular-section ring mm 0.04 … 0.09 0.15
Tapered stepped ring mm 0.03 … 0.06 0.15
Oil scraper ring mm 0.02 … 0.06 0.15

4. Pistons and conrods 57

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

4.2.3 Checking piston

Special tools and workshop equipment required
♦ External micrometre 75 - 100 mm - VAS 6071-
Measure pistons approx 15 mm from the lower edge of skirt, at
90° to the piston pin axis.
Deviation from nominal dimension: max. 0.06 mm

4.2.4 Checking cylinder bores

Special tools and workshop equipment required
♦ Cylinder gauge - VAS 6078-
Test sequence
♦ 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. wage
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tho eo
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erm

ab
ility
ot p

wit
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h re
hole

spec

4.2.5 Installing piston

es, in part or in w

t to the co

Special tools and workshop equipment required

♦ Piston fitting tool - T10333-
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

58 Rep. gr.13 - Crankshaft group

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Note

To fit the pistons, the piston fitting tool - T10333- with inserted
piston is positioned on the cylinder block so that the straight edge
of the higher side of the piston fitting tool -arrow- points to the
middle of the cylinder block.

Procedure

– Pull dowel sleeve -arrow- out of its hole before installing piston.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c ce
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nl

– The pistons for cylinders 1, 3 and 5 must be installed so that

pt
du

an

the deep valve pockets -1- point to the middle of the cylinder
itte

y li
erm

block and the arrows -3- to the vibration damper.

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4. Pistons and conrods 59

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– The pistons for cylinders 2, 4 and 6 must be installed so that

the deep valve pockets -2- point to the middle of the cylinder
block and the arrows -3- to the vibration damper.

n AG. Volkswagen AG do
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d ran
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– Push the correct piston for the correct
utho cylinder into piston fitting or
tool until the shorter side of thesspiston -arrow- emerges approx.
a ac
15 mm from lower edge of piston fitting tool.

ce
e
nl

pt
du

an
– Now place piston with piston fitting tool in respective cylinder
itte

y li
bore. The higher side of the piston fitting tool -arrow- must face
erm

ab
ility
middle of cylinder block for this.
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
– Firmly position piston fitting tool on cylinder block and push rrectness of i
l purpos

piston fully into cylinder bore.

nf
ercia

orm
m

atio
om

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or c

thi
te

sd
iva

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o

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f

en
ng

t.
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Cop py
t. rig
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pyri by
Vo
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by
cted agen
Prote AG.
– Insert dowel sleeve -arrow- in its hole again once piston is in‐
stalled.

60 Rep. gr.13 - Crankshaft group

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

4.3 Piston and cylinder dimensions

Honing dimen‐ Piston ∅ Cylinder bore ∅
sion
Basic dimension mm 88.945 89.010

AG. Volkswagen AG d
agen oes
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V gu
d by ara
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pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

4. Pistons and conrods 61

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

15 – Cylinder head, valve gear

1 Chain drive
⇒ “1.1 Checking valve timing”, page 62 .
⇒ “1.2 Removing and installing camshaft adjuster”, page 64 .
⇒ “1.3 Removing and installing camshaft timing chain”,
page 71 .
⇒ “1.4 Removing and installing oil pump drive timing chain”, page
74 .
⇒ “1.5 Removing and installing chain drive sprocket for high-
pressure pump”, page 78

1.1 Checking valve timing

Special tools and workshop equipment required
♦ Camshaft bar - T10068 A-

Test sequence
– Remove noise insulation ⇒ General body repairs, .exterior;
Volkswagen AG
gen AG
Rep. gr. 50 ; Assembly overview - noise
olkinsulation
swa . does
not
V gu
d by ara
– Remove upper part of intake manifold
or
ise ⇒ page 236 . nte
h eo
ut ra
– Remove cylinder head coverss a⇒ page 90 . c
ce
le

– Turn crankshaft in engine direction of rotation to TDC No. 1

un

pt
an
d

cylinder marking.
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o

62
c by lksw
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Rep. gr.15 - Cylinder head, valve gear Prote AG.
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Cams -A- of cylinder 1 must face each other.

– Insert camshaft bar - T10068 A- in both shaft grooves.

Note
AG. Volkswagen AG d
agen oes
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The grooves of thedcamshafts might not be exactly vertical ara due to
Vo gu
by
the function of camshaft
orise adjusters. Therefore, move the cam‐
nte
e
shafts back and
aut forth slightly if necessary when inserting the or a
h
camshaft bar
s - T10068 A- using an open-end spanner -arrows-.
s c
ce
le
un

pt
an
d

Check setting marks of camshaft adjusters against marks on tim‐

itte

y li
rm

ing housing:
ab
pe

ility
ot

wit
, is n

h re
hole

spec

• Arrows on camshaft adjusters must align with right notches on

es, in part or in w

t to the co

timing housing. Markings on timing housing ⇒ page 64 .

rrectness of i

Note
l purpos

♦ A slight offset between marking »32A« and notch is permissi‐

ble.
nform
ercia

♦ Position of copper-coloured chain links can be disregarded.

m

a
com

tion in
r
te o

thi
s
iva

do
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rp

cum
fo

en
ng

t.
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Prote AG.

1. Chain drive 63
 AG. Volkswagen AG d
agen oes
olksw not
Touareg 2010 ➤ , Touareg 2015 ➤ d by
V gu
ara
e nte
6-cylinder direct-injection engine (3.6 l engine, 4V) horis
- Edition 12.2019 eo
aut ra
ss c
– The gap between markings of camshaft adjuster must be ex‐

ce
e
nl
actly 16 rollers of camshaft timing chain.

pt
du

an
itte

y li
If the markings do not align:

erm

ab
ility
ot p
– Adjust valve timing ⇒ page 74 .

wit
, is n

h re
If the markings align:

hole

spec
es, in part or in w
– Install cylinder head cover ⇒ page 90 .

t to the co
– Install upper part of intake manifold ⇒ page 236 .

rrectness of i
l purpos
Markings on timing housing on FSI engines

nform
ercia

-A- View from flywheel end

m

at
om

-B- View from vibration damper end

ion
c

in t
or

The markings on camshaft adjusters must align with notches

his
ate

-arrows-.

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

1.2 Removing and installing camshaft adjuster

64 Rep. gr.15 - Cylinder head, valve gear

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Special tools and workshop

equipment required

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c

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un

pt
an
d
itte

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ility
ot

wit
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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

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mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.

♦ Camshaft bar - T10068 A-

♦ Counterhold - T10172- with pins - T10172/1-
♦ Torque wrench - V.A.G 1331-
♦ Torque wrench - V.A.G 1332-
♦ Adjusting tool - T10363-
Not illustrated:

♦ Sealant - D 176 501 A1-

Removing camshaft adjuster
– Remove upper part of intake manifold ⇒ page 236 .
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing wiper arms .
– Removing plenum chamber cover ⇒ General body repairs,
exterior; Rep. gr. 64 ; Removing and installing plenum cham‐
ber cover
– Remove centre plenum chamber bulkhead ⇒ General body
repairs, exterior; Rep. gr. 50 ; Plenum chamber bulkhead .
– Remove cylinder head cover ⇒ page 90 .

1. Chain drive 65
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Unclip wiring harness -1-, undo bolt -2- and -3- remove engine
lifting eye.

– Separate the following connectors:

1- Hall sender - G40-
2- Inlet camshaft control valve 1 - N205-
3- Hall sender 2 - G163-
4- Exhaust camshaft control valve 1 - N318-
– Remove mechanical vacuum pump ⇒ page 93 .
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– Unscrew nut -A- and remove bolts -arrows-.
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– Remove cover securing bolts -arrows- and lever off cover.

nform
ercia

– Remove noise insulation ⇒ General body repairs, exterior;

m

Rep. gr. 50 ; Assembly overview - noise insulation .

a
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66 Rep. gr.15 - Cylinder head, valve gear

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Turn crankshaft from below using counterhold - T10172- in

engine direction of rotation to TDC no. 1 cylinder marking.

Cams -A- of cylinder 1 mustwface

agen each other. AG doe
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– Unscrew bolt for camshaft adjuster approx. 1 turn at outlet end,
using an open-ended spanner to counterhold on flat side of
camshaft. rrectness of i
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– Unscrew bolt for camshaft adjuster approx. 1 turn at inlet end,
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camshaft.
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Prote AG.

1. Chain drive 67
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Insert camshaft bar - T10068 A- in both shaft grooves. If nec‐

essary, move the camshafts back and forth slightly with an
open-end spanner.

– Secure position of high-pressure pump chain drive sprocket

using adjusting tool - T10363- . The marking -A- on the drive
cam for high-pressure pump must be on top.

Note

If the journal for vacuum pump drive is not vertical: remove cam‐
shaft bar - T10068 A- . Turn crankshaft further in direction of
rotation until the journal is vertical and the camshaft bar - T10068
A- can be inserted.
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– Remove chain tensioner for camshaft timing chain
hor -arrow-. eo
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nl

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c

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or

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ate

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Prote AG.

68 Rep. gr.15 - Cylinder head, valve gear

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Mark chain links that are opposite the markings on the cam‐
shaft adjusters. Installation is facilitated by marking the cam‐
shaft timing chain.
– Undo and remove camshaft adjuster bolts and remove cam‐
shaft adjuster.

Note

The camshaft timing chain is held on the sprocket of the oil pump
by the bottom timing chain cover. The timing chain cannot jump
over.

Installing camshaft adjuster

Condition:
• Crankshaft is at »TDC« position
• Chain drive sprocket for high-pressure pump is fixed in place
with adjusting tool - T10363- AG. Volkswagen AG d
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• Camshafts have been fixed in place with camshaft bar - d by Vo gu
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T10068 A- orise nte
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First install inlet camshaft adjuster as follows: ss a c

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Note

ab
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♦ The camshaft adjusters are locked when »at rest«. This pre‐

h re
ole,

vents the sender wheel from turning when adjusting the valve

spec
timing. If the locking mechanism is not engaged (locked) when
urposes, in part or in wh

»at rest«, turn the adjuster in both directions by hand until it is

t to the co
locked. If this is not possible, renew camshaft adjuster.
♦ Due to a fitted key, camshaft adjusters can only be bolted on

rrectne
in one position -arrows- at camshaft mounting.

s
– Fit inlet camshaft adjuster with fitted timing chain on camshaft.

s o
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f
Observe the following when doing this:

inform
mer

• The timing chain to high-pressure pump drive sprocket must

atio
m

not »sag«.
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• It must be possible to easily position the camshaft adjuster with

t

sd
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»tight« timing chain and to tighten hand-tight.

i

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• The arrow -1- on camshaft adjuster »24E« must align with right
en
ng

t.
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notch -2- of timing housing. Markings on timing housing Cop py
⇒ page 64 .
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– Tighten camshaft adjuster bolt hand-tight.
by lksw
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– From the tooth which aligns with the arrow -1- and the notch
-2-, now count exactly 16 rollers to the right on the camshaft
timing chain. Mark this roller with a coloured pen.

1. Chain drive 69
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Place exhaust camshaft adjuster »32A« into camshaft timing

chain. Previously counted 16 rollers must lie between teeth at
arrow markings »24E« and »32A«.
. Volkswagen AG
– Connect camshaft adjuster »32A« with camshaft timing chain kswagen AG does
not
onto exhaust camshaft. Observe the following when doingby Vol gu
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• The arrow -1- on camshaft adjuster »32A« must align with right

spec
notch -2- of timing housing. Markings on timing housing
es, in part or in w

t to the co
⇒ page 64 .

rrectness of i
Note
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It must be possible to easily position the exhaust camshaft ad‐

juster onto the exhaust camshaft. Move camshaft back and forth

nform
slightly if necessary.
mercia

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– Remove setting tool - T10363- from bearing shaft.

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– Remove camshaft bar - T10068 A- .

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– Install chain tensioner for camshaft timing chain -arrow-.

Specified torque: 50 Nm.

70 Rep. gr.15 - Cylinder head, valve gear

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Turn engine two revolutions in direction of engine rotation and

check valve timing.

If the markings align:

– Hold camshaft which is to be tightened using a 27 mm open-
end spanner -arrow-.
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♦ Camshaft bar - T10068 A- must be removed whilessthis is done.

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♦ Note that all sprocket securing bolts must be renewed.

an
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– Tighten securing bolts of inlet and exhaust camshaft adjusters

ility
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to 60 Nm + 1/4 turn (90°) further.

wit
is n

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ole,

– Clean sealing surfaces for rear cover. Coat sealing surface

spec
urposes, in part or in wh

with sealant - D 176 501 A1- .

t to the co
– Fit cover and tighten securing bolts -arrows- in diagonal se‐
quence to 8 Nm.

rrectne
Further assembly is carried out in the reverse order of removal.

ss o
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f inform
mer

atio
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Cop py
1.3 Removing and installing camshaft tim‐
t. rig
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ing chain
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Conditions:
• Engine removed
• Drive plate removed
• Sump removed
• Sealing flange removed - gearbox side
• Cylinder head cover removed

1. Chain drive 71
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Removing:
– Turn engine -at vibration damper- to setting marks.
• Ground tooth of drive sprocket -arrow A- must align with bear‐
ing joint.
• The marked hole -arrow- must be in line with the mark on the
oil pump.

Note

This position is reached only after every 4th full rotation.

Cams -A- of cylinder 1 must face each other.

– Removing camshaft adjuster ⇒ page 64 .

– Unscrew securing bolts -1- and -2-. Remove guidearail

gen A-A-.
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– Remove camshaft timing chain out upwards.
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Installing: tho or
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Condition:
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• Crankshaft is at »TDC« position

itte

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ab

• Chain drive sprocket for high-pressure pump is fixed in place

ility
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with adjusting tool - T10363-

wit
is n

h re

• Camshafts have been fixed in place with camshaft bar -

ole,

spec

T10068 A-
urposes, in part or in wh

t to the co

– Guide camshaft timing chain in through hole in cylinder head

from above.
rrectness o
cial p

f inform
mer

atio
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c

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Cop py
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py by

72
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Rep. gr.15 - Cylinder head, valve gear
agen
Prote AG.
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Fit guide rail -A- and, initially, only tighten bolt -2-.

Note

Some of the camshaft timing chain links are copper coloured.

These chain links are to be used as an aid to installation. The 3
copper-coloured chain links next to each other must be placed on
the oil pump sprocket. gen AG
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– First, fit camshaft timing chain onto oil pump sprocket. Marking

an
itte

y li
must align with middle copper coloured chain link -A-.
erm

ab
ility
ot p

– Fit camshaft timing chain onto chain drive sprocket of high-

wit
pressure pump. Marking must align with copper-coloured
, is n

h re
chain link.
hole

spec
es, in part or in w

t to the co
rrectness of i
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nf
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– Tighten bolt -1- for guide rail.

orm
m

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or c

thi
te

sd
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cu
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f

en
ng

t.
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Cop py
ht. rig
rig ht
py by
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by lksw
cted agen
Prote AG.

– Insert inlet camshaft adjuster »24E« into camshaft timing

chain in such a way that the copper-coloured chain link is
aligned with the marking on the camshaft adjuster. Bolt cam‐
shaft adjuster onto camshaft and tighten bolt hand-tight.
– Insert exhaust camshaft adjuster »32A« into camshaft timing
chain in such a way that copper-coloured chain link is aligned
with marking on camshaft adjuster. Bolt camshaft adjuster on‐
to camshaft and tighten bolt hand-tight.

1. Chain drive 73
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Check position of copper coloured chain links to adjustment

markings.

Note

The copper coloured chain links no longer align with the adjust‐
ment markings once the crankshaft has been turned.

– Install chain tensioner for camshaft timing chain -arrow-.

Specified torque: 50 Nm.
– Remove camshaft bar - T10068 A- and tighten bolt of camshaft
adjuster. Specified torque: 60 Nm + 1/4 turn (90°)

AG. Volkswagen AG d
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Note
erm

ab
ility
ot p

Only counterhold at camshaft with 27 mm open-end spanner

wit
, is n

-arrow-. The camshaft bar - T10068 A- must not be fitted when

h re
hole

camshaft adjuster is loosened or tightened.

spec
es, in part or in w

t to the co

Further assembly is carried out in the reverse order of removal.

rrectness of i
l purpos

1.4 Removing and installing oil pump drive

nf
ercia

orm

timing chain
m

atio
om

n in
or c

thi
te

sd
a

Note
iv

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cu
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en

Procedure is only possible with engine removed.

ng

t.
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Prote AG.

74 Rep. gr.15 - Cylinder head, valve gear

 Touareg 2010 ➤ , Touareg 2015 ➤
. Volkswagen AG
6-cylinder direct-injection engine
kswa(3.6
gen AlGengine, 4V) - Edition
does
n
12.2019
ol ot g
yV ua
db ran
Special tools and workshop ris
e
tee
equipment required tho or
au ac
ss

ce
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ility
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spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

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tion in
r
te o

thi
s
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cum
fo

en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.

♦ Camshaft bar - T10068 A-

♦ Counter-hold tool - T10172-
♦ Torque wrench - V.A.G 1331-
♦ Torque wrench - V.A.G 1332-
♦ Adjusting tool - T10363-
Not illustrated:

♦ Sealant - D 176 501 A1-

Removing:
Conditions:
• Engine removed
• Engine and gearbox separated
• Drive plate removed
• Sump removed
• Sealing flange removed

1. Chain drive 75
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Loosen bolt -arrow- for sprockets wabout

agen 1 full turn. To
AG. Volkswagen AGdo
doethis,
counterhold vibration dampery Vusing
olks counterhold - T10172-s n.ot gu
b ara
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th or
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ce
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nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
– Turn engine by vibration damper to adjustment markings.

rrectness of i
• Ground tooth of drive sprocket -arrow A- must align with bear‐
ing joint.
l purpos

• The marked hole -arrow B- must be in line with the mark on

the oil pump.

nform
mercia

at
om

i
Note

on
c

in t
or

his
te

This position is reached only after every 4th full rotation.

a

do
priv

cum
for

en
g

– If the camshaft timing chain is to be replaced, remove cam‐

n

t.
yi Co
shaft timing chain ⇒ page 71 . Cop py
t. rig
gh ht
yri
– If the camshaft timing chain is not to be replaced, mark position p by
co Vo
of timing chains to sprockets of oil pump using a permanent
by lksw
cted agen
Prote
marker.
AG.

– Remove chain tensioner for camshaft timing chain -arrow-.

– Fix chain tensioner spring using 3 mm Allan key -A-.

– Remove chain tensioner for oil pump drive chain -arrows-.

76 Rep. gr.15 - Cylinder head, valve gear

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Unscrew securing bolt for sprockets completely and remove

sprockets with timing chain from oil pump.

Installing:
– Set crankshaft to TDC position.
. Volkswage
• Ground tooth of drive sprocket
ksw
agen -arrow- must A
AG align
n Gd
oewith
s no bearing
joint. by Vol t gu
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oris tee
th or
au ac
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ab
pe

ility
ot

wit
, is n

h re
hole

spec
– Now turn oil pump shaft -1- with flat side -arrow- horizontal to
es, in part or in w

mark -2- on oil pump.

t to the co
– First, only fit the rear chain onto the large sprocket. When do‐
ing this, observe the previously made markings.
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r

– Fit chain onto crankshaft and fit sprocket onto oil pump shaft.
rp

cum
fo

The marked hole -arrow B- must be in line with the mark on

en
ng

t.
yi
the oil pump.
Co
Cop py
t. rig
– If sprocket cannot be fitted, turn oil pump shaft slightly.
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1. Chain drive 77
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– If the camshaft timing chain has not been removed, carefully

pull sprocket off oil pump and swing upwards a little. In this
position, fit the camshaft timing chain. The marking made dur‐
ing removal must align.
– Fit sprocket onto oil pump shaft again and tighten hand-tight.

– Install chain tensioner for camshaft timing chain -arrow-.

n AG. Volkswagen AG do
lkswage es n
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d ran
ir se tee
tho
u or
a ac
ss
ce
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pt
an
d

– Install lower chain tensioner and tighten to 8 Nm -arrows-.

itte

y li
rm

ab

– Remove Allan key -A-.

pe

ility
ot

wit
, is n

– Tighten sprockets to 60 Nm + 90° (1/4 turn) further. To do this,

h re
hole

counterhold vibration damper using counterhold - T10172- .

spec
es, in part or in w

– Install sealing flange ⇒ page 41 .

t to the co

Further assembly is carried out in the reverse order of removal.

rrectness of i

– If the camshaft timing chain has been removed, Install cam‐

shaft timing chain ⇒ page 72 .
l purpos

nform
ercia

1.5 Removing and installing chain drive

m

a
com

sprocket for high-pressure pump

ion in
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thi

Removing:
s
iva

do
r
rp

– Remove high-pressure pump ⇒ page 249 .

um
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

78 Rep. gr.15 - Cylinder head, valve gear

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Remove camshaft adjuster for inlet camshaft -1- ⇒ page 64 .

– Undo and remove bolt -3- for guide rail.
– Remove camshaft timing chain from chain drive sprocket.
Volkswa
– Pull out bearing shaft -4- and removeschain
agen drive sprocket
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Installing: oris tee
th or
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pt
Note
du

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itte

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erm

ab
Coat faces of chain drive sprocket and bearing shaft with lubri‐

ility
ot p

cating paste - G 052 723 A2- .

wit
, is n

h re
hole

spec
– Insert drive sprocket. The notch -arrow- must be on top.
es, in part or in w

t to the co
– Coat bearing shaft with lubricating paste - G 052 723 A2- and
push it in. The bearing shaft fits in only one position.

rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
– Secure position of high-pressure pump chain drive sprocket
for

en
g

using adjusting tool - T10363- . The marking -A- on the drive

n

t.
yi Co
op
cam for high-pressure pump must be on top. C py
t. rig
gh ht
yri
– Fit camshaft timing chain onto chain drive sprocket. Ensure
p by
co Vo
by lksw
the chain runs »tautly« against the guide rail. Prote
cted AG.
agen

– Tighten bolt -arrow- for guide rail.

– Install camshaft adjuster ⇒ page 69 .
– Installing high-pressure pump ⇒ page 249 .

1. Chain drive 79
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

2 Cylinder head
⇒ “2.1 Assembly overview - cylinder head”, page 80 .
⇒ “2.2 Removing and installing cylinder head”, page 82 .
⇒ “2.3 Removing and installing cylinder head cover”, page 90 .
⇒ “2.4 Assembly overview - mechanical vacuum pump”,
page 92 .
⇒ “2.5 Removing and installing mechanical vacuum pump”, page
93
⇒ “2.6 Installing cover oil seals”, page 94 .
⇒ “2.7 Checking compression”, page 95 .

Note

♦ To remove cylinder head, engine must first be removed

⇒ page 7 .
♦ If an exchange cylinder head is installed, all the contact sur‐
faces between the supporting elements, roller rocker fingers
and the running surfaces of the camshafts must be oiled be‐
fore the cylinder head cover is installed.
♦ The plastic protectors fitted to protect the open valves must
only be removed immediately before fitting the cylinder head.
♦ When renewing the cylinder head or cylinder head gasket,
drain all the old coolant andwarefill
gen Awith
G. Volnew
kswagcoolant.
en AG
doe
ks s no
Vol t gu
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2.1 Assembly overview - cylinder head
e nte
ris
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ab
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ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

80 Rep. gr.15 - Cylinder head, valve gear

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

1 - Cap
❑ Renew seal if damaged.
2 - Cylinder head cover
❑ Removing and installing
⇒ page 90
3 - 10 Nm
❑ With spacer sleeve and
seal.
❑ Renew seal if damaged
4 - Lifting eye
5 - 23 Nm
6 - Intake manifold support
7 - 23 Nm
8 - 10 Nm
9 - Union
10 - Seal
❑ Renew
❑ Observe installation po‐
sition
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11 - Chain tensioner, 50 Nm olksw not
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❑ for camshaft timing orise nte
chain aut
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❑ Only rotate engine when s

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nl

chain tensioner is instal‐

pt
du

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led.
itte

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ab
12 - Seal
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wit
❑ Renew
, is n

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hole

13 - Seal spec
es, in part or in w

❑ For camshaft control

t to the co

valve 1 - N205- and exhaust camshaft control valve 1 - N318-

❑ Renew if damaged or leaking
rrectness of i

❑ Installing ⇒ page 94
l purpos

14 - Cover
❑ Can be removed and installed with engine installed.
nform
ercia

❑ Coat sealing surface with sealant - D 176 501 A1- .

m

at

15 - Holder
om

ion
c

in t
r

16 - 8 Nm
o

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ate

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17 - 23 Nm
p

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for

18 - Slide rail
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❑ for camshaft timing chain C py
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19 - 23 Nm op Vo
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❑ Insert with locking fluid - D 000 600 A2- Prote AG.

20 - Union
❑ Bolt on before assembling cylinder head
❑ Can be renewed only with gearbox removed
21 - O-ring
❑ Renew

2. Cylinder head 81
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

22 - Seal
❑ Renew
23 - Cylinder head gasket
❑ Metal gasket.
❑ Renew
❑ Renew cylinder head gasket ⇒ page 82 .
❑ After renewing, renew entire coolant.
n AG. Volkswagen AG do
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24 - Cylinder head Vol ot g
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❑ Check for distortion ⇒ page 82 . ris
e
tee
tho or
❑ Removing and installing ⇒ page s82
sa
u ac
❑ After renewing, renew entire coolant.

ce
e
nl

pt
du

an
itte

25 - Tensioning element

y li
erm

ab
❑ for poly V-belt

ility
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wit
❑ Removing and installing poly V-belt ⇒ page 34
, is n

h re
hole

26 - Cylinder head bolt

spec
es, in part or in w

❑ Renew

t to the co
❑ Coat bolt with locking fluid - D 197 300 A2- before installing ⇒ page 89 .
❑ Refer to assembly instructions and sequence when loosening and tightening ⇒ page 82 Removing and

rrectness of i
installing cylinder head.
l purpos

27 - Gasket for cylinder head cover

❑ Renew if damaged or leaking

nform
ercia

❑ Observe installation position

m

at
om

ion
c

in t
r

Checking cylinder head for distortion

o

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ate

do
priv

cum
for

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Special tools and workshop equipment required

♦ Straight edge 500 mm - VAS 6075-
♦ Feeler gauge
Max. permissible distortion: 0.05 mm
A cylinder head which is warped up to 0.1 mm may be reworked.

2.2 Removing and installing cylinder head

Note

The cylinder head can only be removed with engine removed

⇒ page 7 .

82 Rep. gr.15 - Cylinder head, valve gear

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Special tools and workshop

equipment required

n AG. Volkswagen AG do
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spec
es, in part or in w

t to the co
rrectness of i
♦ Camshaft bar - T10068 A-
l purpos

♦ Drip tray for workshop hoist - VAS 6208-

nform
ercia

♦ Workshop hoist - VAS 6100-

m

at

♦ Lifting tackle - 3033-

om

ion
c

in t
r

♦ Pliers for spring-type clips - VAS 6499-

o

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ate

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♦ Puller - T10095 A-
p

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for

en

Not illustrated:
ng

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♦ Torque wrench - V.A.G 1331-
gh ht
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♦ Torque wrench - V.A.G 1332- cted agen
Prote AG.

♦ Sealant - D 176 501 A1-

♦ Locking fluid - D 197 300 A2-
Conditions
• The engine must be removed.

2. Cylinder head 83
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Removing:

Caution

Observe the following during all assembly work, particularly in

the engine compartment due to the restricted space:
♦ Route lines of any kind and cables so that original routing
is restored.
♦ Ensure that there is sufficient clearance to all moving or
hot components.

Note
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♦ All cable ties which bwere
y V opened or cut during removal
ol not
gu must
ara
be renewed andoriinstalled
sed
in the same position during installa‐ nte
tion. aut
h eo
ra
ss c
♦ Some components cannot be removed, or removed only with

ce
le
un

difficulty, with the engine installed. Therefore, you should de‐

pt
an
d

termine all defective components before removing engine and

itte

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renew them while engine is removed.

ab
ility
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♦ To prevent damage to removed components, place them in

wit
is n

the container for removed parts - V.A.G 1698- . h re

ole,

spec
urposes, in part or in wh

– Remove upper part of intake manifold ⇒ page 236 .

t to the co

– Remove high-pressure pump ⇒ page 249 .

– Pull out pump plunger ⇒ Item 17 (page 100) .
rrectne

– Remove heat shield together with intake manifold support

s

from cylinder head.

s o
cial p

f i

– Detach following connectors.

nform
mer

1- Hall sender - G40-

atio
om

n
c

2- Inlet camshaft control valve 1 - N205-

i
or

n thi
te

sd
a

3- Hall sender 2 - G163-

iv

o
pr

cum
r
fo

4- Exhaust camshaft control valve 1 - N318-

en
ng

t.
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op
– Pull off/disconnect all further wiring necessary from cylinder C py
t. rig
head and move clear. gh ht
pyri by
Vo
o
by c lksw
– Unbolt retainer from camshaft timing chain cover. Prote
cted AG.
agen

– Unscrew three bolts -1 to 3- at coolant union.

– Remove cylinder head cover.

84 Rep. gr.15 - Cylinder head, valve gear

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Turn crankshaft in engine direction of rotation to TDC marking

-arrow-, using counterhold - T10172- .

Cams -A- of cylinder 1 must face each other.

– Remove vacuum pump ⇒ page 93 .
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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aut ra
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ab
ility
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– Undo the two bolts -1- from sealing flange and then undo and
hole

spec
remove all bolts -arrows- from the cover.
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

– Remove chain tensioner for camshaft timing chain -arrow-. o

r
rp

cu
o

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f

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

2. Cylinder head 85
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

AG. Volkswagen AG d
agen oes
ksw
Note by
Vol not
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Only counterhold at camshaft with 27 mm open-end spanner aut
h
ra
-arrow-. The camshaft bar - T10068 A- must not be fitteds when
s c

ce
le
camshaft adjuster is loosened or tightened.

un

pt
an
d
itte

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erm

ab
ility
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wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
– Unscrew securing bolts -1- and -2- and then unscrew guide
rail -3-.

rrectne
Note

ss o
cial p

f in
The camshaft timing chain is held on the sprocket of the oil pump

form
mer

by the bottom timing chain cover. The timing chain cannot jump

atio
over.
om

n
c

i
or

n thi
e

– Remove camshaft adjusters from camshafts.

t

sd
iva

o
pr

c
– Remove camshaft timing chain from sprocket for high-pres‐

um
r
fo

en
ng

sure pump.
t.
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Cop py
t. rig
gh
– Unscrew four securing bolts -arrows- from valve timing hous‐
ht
pyri by
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ing and pull valve timing housing down from camshafts. by c lksw
cted agen
Prote AG.

– Cover camshafts -arrows- with clean paper strips and wrap the
ends with adhesive tape.

86 Rep. gr.15 - Cylinder head, valve gear

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder
olksw
direct-injection engine (3.6 l engine, 4V) - Edition 12.2019
AG. V agen AG
agen does
lksw n t
– Loosen cylinderdb
y V head bolts in the sequenceogiven
o gu
ar starting at
the outsideris and working inwards and then removeancompletely.
e
tee
ho
aut or
ac
ss

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le
un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
– Attach lifting tackle - 3033- as shown and carefully lift off cyl‐

rrectne
inder head with workshop hoist - VAS 6100- or -
V.A.G 1202 A- :

ss o
Vibration damper end: position 3.
cial p

f inform
Flywheel end: position 11
mer

atio
om

n
c

i
or

n
Note

thi
te

sd
iva

o
pr

♦ The positions marked 1 to 12 on the lifting tackle - 3033- face cum

r
fo

the flywheel end.

en
ng

t.
yi Co
op
♦ Adjust length of threaded spindles according to need.
C py
t. rig
gh ht
pyri by
Vo
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by c lksw
– Carefully remove cylinder head.cted agen
Prote AG.

– 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.
– Now carefully clean sealing surfaces of cylinder head and cyl‐
inder block. When doing this, ensure that surfaces are not
scored or scratched (if abrasive paper is used, grade must not
be less than “100”).
– Clean all tapped holes for cylinder head bolts.
– Check cylinder head for distortion ⇒ page 82 .
Installing:
– Carefully remove metal particles, emery residue and cloths.
If the piston for No. 1 cylinder is not at TDC:

– Turn crankshaft in engine direction of rotation to TDC No. 1

cylinder marking -arrow- while a second mechanic guides
camshaft timing chain by hand.

2. Cylinder head 87
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Ensure that dowel sleeves are inserted in the cylinder block in

holes 12 and 20.

– Apply a 2 mm thick bead of sealant - D 176 501 A1- onto joint

between cylinder block and sealing flange as shown
-arrows-.

Note

♦ Do not remove new cylinder head gasket from its packing until
immediately before installing.
♦ Handle new gasket with extreme care. Damage will cause
leakage.
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gen AG does
– Immediately fit new cylinder head gasket. Inscription
Vol
ksw (Part
a
not
No.) must be readable. ed
by gu
ara
is nte
or eo
– Additionally insert a little sealant - D 176au 501 A1- into
th the two ra
3 mm holes which lie on the sealant bead.ss c

ce
e
nl

pt
– Position camshafts in cylinder head to TDC No. 1 cylinder.
du

an
itte

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ab
Cams -A- of cylinder 1 must face each other.

ility
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wit
, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

– Camshaft bar - T10068 A- must engage in grooves in both

on
c

in t

shafts.
or

his
ate

– Cylinder head can now be positioned.

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

88 Rep. gr.15 - Cylinder head, valve gear

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Apply locking fluid - D 197 300 A2- to each cylinder head bolt
in bolt head contact surface -arrow-, insert bolts.

Note

♦ The locking fluid is used for sealing the cylinder head bolt.
♦ The longer cylinder head bolts must be inserted in the centre
holes of cylinder head.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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ut
– Tighten cylinder
ss a head bolts in tightening sequence shown ra
c
working from inside to outside:

ce
le
un

pt
an
d

1- Pre-tighten all bolts to 15 Nm.

itte

y li
rm

ab
2- Then tighten all bolts to 30 Nm.
pe

ility
ot

wit
, is n

3- Use fixed wrench to turn 90° further.

h re
hole

4- Use fixed wrench to turn 90° further.

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Oil sealing rings of camshafts and install valve timing housing;

when doing so, the camshaft timing chain must be placed over
the valves for camshaft adjustment.
nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Secure position of high-pressure pump drive sprocket using

adjusting tool - T10363- . The marking -A- on the drive cam for
high-pressure pump must be on top.

2. Cylinder head 89
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Place camshaft timing chain »tightly« onto sprocket of high-

pressure pump and then bolt-on the guide rail -arrow-.
Further assembly is basically a reverse of the dismantling se‐
quence.
– Install camshaft adjuster with camshaft timing chain
⇒ page 69 .
– Install cylinder head cover and intake manifold ⇒ page 236 .

Note

It is not necessary to retighten cylinder head bolts after repairs.

2.3 Removing and installing cylinder head cover

Special tools and workshop

equipment required

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

♦ Pliers for spring-type clips - VAS 5024 A-

♦ Torque wrench - V.A.G 1331-
♦ Assembly tool - T10118-
♦ Puller - T10095 A-

90 Rep. gr.15 - Cylinder head, valve gear

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine
agen A(3.6
G. Vollkengine, 4V)
swagen AG
do - Edition 12.2019w es n
olks ot g
yV ua
Removing: ris
ed
b ran
tee
tho or
– Remove ignition coils with output stages ⇒s apage
u 272 . ac
s

ce
le
– Remove upper part of intake manifold ⇒ page 236 .

un

pt
an
d
itte

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rm

ab
pe
Note

ility
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wit
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Seal intake ports in intake manifold and in cylinder head with a

hole

spec
clean cloth.

es, in part or in w

t to the co
– Unscrew securing bolts -1- and -2- and remove bracket -A-.

rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
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– Expose electric cables at rear of cylinder head and unscrew Cop py
. rig
cable retainer -A- from cover.
ht ht
rig by
copy Vo
– Pull off crankcase breather hose from cylinder head cover.
by lksw
cted agen
Prote AG.

– Loosen bolts for cylinder head cover from outside in

-17 to 1-.
– Unscrew bolts and remove cylinder head cover.

2. Cylinder head 91
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Installing:
– Apply a small amount of sealant - D 454 300 A2- to cover at
marked positions -arrows-.

– Fit cylinder head cover and tighten equally from inside out
-1 to 17-.
Perform further installation in reverse order, paying attention to
the following:

Note

♦ Renew cylinder head cover if damaged or leaking.

♦ Bolt intake manifold first to cylinder head. Then tighten the two
bolts of intake manifold support.
♦ Ensure fuel hoses are seated correctly.

– If necessary fill with coolant ⇒ page 158 .

Specified torques
Bolted connection Specified torque
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Cylinder head cover to cylinder head yV
olks 10 Nm es n
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d b ua
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Upper part of intake manifold to lower o
ir separt of 10 Nm tee
intake manifold auth or
ac
ss
Further specified torques ⇒ “4.1 Assembly
ce
le
un

overview - in‐
pt
an
d

take manifold”,
itte

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rm

page 233
ab
pe

ility
ot

wit
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2.4 Assembly overview - mechanical vacuum pump

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

92 Rep. gr.15 - Cylinder head, valve gear

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

1 - Bearing shaft
❑ The splines fit in only Volkswa
one position into athe
gen AG
. gen AG
does
ksw
drive sprocket.
b y Vol not
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2 - Cover thori tee
or
au ac
❑ Can
ss be renewed with
engine removed

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un

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an
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itte

3 - Securing bolt

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rm

ab
❑ Short
pe

ility
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wit
❑ 8 Nm
, is n

h re
hole

4 - Securing bolts

spec
es, in part or in w

❑ Long

t to the co
❑ 8 Nm
5 - Vacuum pump

rrectness of i
❑ Removing and installing
l purpos

⇒ page 93
6 - Seal

nform
ercia

❑ Renew
m

a
7 - Seal
com

tion in
❑ Part of vacuum pump
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2.5 Removing and installing mechanical

vacuum pump
Removing:
– Place wiring to one side and unscrew cable retainer -A- from
cover.

2. Cylinder head 93
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Pull off vacuum line -A-.

– Remove securing bolts -arrows-.
– Carefully pull vacuum pump from cylinder head.

AG. Volkswagen AG d
agen oes
olksw not
yV gu
Installing: ised b ara
nte
or eo
h
– Check sealing ring
s auin
t
vacuum pump -A- for damage. If the seal ra
c
is damaged, thesvacuum pump must be renewed.

ce
le
un

pt
– Turn rotor in vacuum pump so that the flat sides of input shaft

an
d
itte

y li
fit into rotor.
rm

ab
pe

ility
– Push vacuum pump evenly into fitting hole of cover to stop.
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
– Tighten securing bolts -arrows- and reconnect vacuum line
-A-.
l purpos

Specified torques ⇒ page 92 .

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c
2.6 Installing cover oil seals
lksw
cted agen
Prote AG.

Special tools and workshop equipment required

♦ Fitting sleeve - 3378-

94 Rep. gr.15 - Cylinder head, valve gear

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

♦ Fitting sleeve - 3253/6- from assembly tool - 3253- .

Installing:
– Do not lubricate seals.
– Install seal with fitting sleeve - 3378- in cover -1- and pull in
flush using fitting sleeve - 3253/6- from assembly tool - 3253- .

n AG. Volkswagen AG do
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ir se tee
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nl

pt
du

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itte

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erm

ab
ility
ot p

wit
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h re
hole

spec
es, in part or in w

t to the co
rrectness of i
2.7 Checking compression
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. Cylinder head 95
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Special tools and workshop

equipment required

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
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un

pt
an
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ab
ility
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wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness
♦ Spark plug socket - 3122 B-
o
cial p

f inform

♦ Puller - T10095 A-
mer

atio

♦ Assembly tool - T10118-

om

n
c

i
or

♦ Torque wrench - V.A.G 1331-

thi
te

sd
va

♦ Compression tester - V.A.G 1763-

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en

Check condition
ng

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• Engine oil temperature at least 30°C
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• Battery voltage must be at least 11.5 V.
co Vo
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Prote AG.
• 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.
• On vehicles with automatic gearbox the selector lever must be
in “P” or “N” position.
Test sequence
– Remove fuse for fuel pump from fuse holder ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.

96 Rep. gr.15 - Cylinder head, valve gear

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Removing the fuse interrupts the voltage supply for fuel pump
activation.
– Apply assembly tool - T10118- to locking mechanism button
-arrow- and carefully pull connector off.

AG. Volkswagen AG d
agen oes
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un

pt
– Push on puller - T10095 A- on from flat side of connector in

an
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direction of arrow and pull out ignition coil with output stage.
rm

ab
pe

ility
– Unscrew spark plugs using spark plug socket and extension -
ot

wit
, is n

3122 B- .

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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia

– Check compression using compression tester - V.A.G 1763- ,

m

adapter - V.A.G 1381/1- and adapter - V.A.G 1381/5A- .

a
com

tion in
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te o

thi

Note
s
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fo

Using compression tester ⇒ operating instructions .

en
ng

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– Have a second mechanic operate starter until tester shows no
gh ht
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further pressure increase.
op Vo
by c lksw
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Prote AG.
Compression pressures:
Engine code New Wear limit Difference be‐
bar pressure bar pressure tween cylin‐
ders
bar pressure
CGRA, CMTA 11.0 … 13.0 8.0 max. 3.0
– Insert spark plugs using spark plug socket - 3122 B- and tight‐
en to 18 Nm.
– Now install ignition coils with output stage.

2. Cylinder head 97
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019
agen
AG. Volkswagen AG d
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– To install, insert ignition coil with output stage into respective
ris
ed
b ran
tee
spark plug hole so that the flat sides of connectors fit with thoeach or
other -arrows-. au ac
ss

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e
nl
After the test has been completed:

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– Connect vehicle diagnostic tester .

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ility
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– Carry out vehicle system test using ⇒ Vehicle diagnostic test‐

wit
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er .

h re
hole

spec
– End the vehicle system test so that any entries stored in the

es, in part or in w
event memory during assembly can be deleted automatically.

t to the co
– Generate the readiness code in combination with a road test.
Observe applicable safety precautions during road test.

rrectness of i
– Then carry out vehicle system test again and rectify any faults
l purpos

which may have occurred.

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

98 Rep. gr.15 - Cylinder head, valve gear

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

3 Valve gear
⇒ “3.1 Assembly overview - valve gear”, page 99 .
⇒ “3.2 Camshafts, checking axial clearance”, page 101 .
⇒ “3.3 Assembly overview - timing housing”, page 102 .
n AG. Volkswagen AG do
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⇒ “3.4 Removing and installing camshaft controlVovalves”,
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page 103 . d b ua
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⇒ “3.5 Removing and installing camshaft”,
au page 105 .
t or
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ss
⇒ “3.6 Camshaft identification”, page 110 .

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3.1 Assembly overview - valve gear

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erm

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ility
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wit
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1 - Inlet camshaft

h re
hole

❑ Check radial clearance

spec
es, in part or in w

with Plastigage, wear

t to the co
limit: 0.1 mm
❑ Runout: max. 0.01 mm

rrectness of i
❑ Checking axial clear‐
ance ⇒ page 101 .
l purpos

❑ Identification
⇒ page 110

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ercia

❑ Removing and installing

orm
⇒ page 105
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2 - Camshaft bearing caps
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❑ Installation position
t

sd
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⇒ page 108

o
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❑ Installation sequence
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t.
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⇒ page 105 Removing
Co
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and installing camshaft.
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3 - Exhaust camshaft
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❑ Check radial clearance
AG.

with Plastigage, wear

limit: 0.1 mm
❑ Runout: max. 0.01 mm
❑ Checking axial clear‐
ance ⇒ page 101 .
❑ Identification
⇒ page 110
❑ Removing and installing
⇒ page 105
4 - 5 Nm + turn 45° further
5 - Seal
❑ Renew if leaking.
❑ When installing timing
housing, lubricate con‐
tact surfaces of seals.
❑ When replacing seals, do not spread too widely.
6 - Valve timing housing
❑ Lightly lubricate contact surface of oil seals before installing.
❑ Removing and installing camshaft control valves ⇒ page 103
❑ Marks for valve timing ⇒ page 64 .
❑ Assembly overview - timing housing ⇒ page 102

3. Valve gear 99
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019
❑ Before installing valve timing housing, check strainer for soiling ⇒ page 102
❑ Removing and installing ⇒ page 105 Removing and installing camshafts.
7 - Bolts of valve timing housing.
❑ Specified torque ⇒ page 102
8 - Exhaust camshaft adjuster
❑ Identification: 32A.
❑ Only rotate engine when camshaft adjuster is installed and chain is fitted
❑ Install camshaft adjuster with camshaft timing chain ⇒ Apage 64 .
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❑ Identification: 24E orise nte
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❑ Only rotate engine when camshaftsadjuster
s a is installed and chain is fitted ra
c
❑ Install camshaft adjuster with camshaft timing chain ⇒ page 64 .

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nl

pt
du

an
itte

10 - 60 Nm + turn 90° further

y li
erm

ab
❑ Renew

ility
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wit
❑ Contact surface of sender wheel must be dry around bolt head when installed.
, is n

h re
❑ To remove and install, counterhold using 27 mm open-end spanner on camshaft ⇒ page 105 Removing
hole

spec
and installing camshafts.
es, in part or in w

t to the co
11 - Cylinder head height
❑ Minimum height: a = 139.9 mm.

rrectness of i
12 - Drive sprocket for high pressure pump
l purpos

❑ With inner splines

❑ Bearing shaft fits in only one position

nf
ercia

13 - Bearing shaft

orm
m

atio
❑ Bearing shaft fits in only one position into chain drive sprocket.
om

n in
c

❑ Oil bearing shaft before installing

or

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❑ Vacuum pump drive shaft

t

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14 - Valves cu
o

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❑ Do not rework; only lapping-in is permitted.
Co
Cop py
.
❑ Valve dimensions ⇒ page 113
ht rig
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15 - Dowel sleeve
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16 - Cylinder head
❑ Check for distortion ⇒ page 82 .
❑ Removing and installing ⇒ page 82
❑ Reworking valve seats ⇒ page 114 .
❑ After renewing, renew entire coolant.
17 - Pump plunger
❑ Observe installation position
18 - Support element
❑ Before installing, check camshaft axial clearance ⇒ page 101 .
❑ Do not interchange
❑ With hydraulic valve clearance compensation.
19 - Valve stem seal
❑ Renewing ⇒ page 111
20 - Camshaft timing chain
❑ Before removing, mark direction of rotation (installation position) ⇒ page 32 .
❑ Install camshaft adjuster with camshaft timing chain ⇒ page 64 .

100 Rep. gr.15 - Cylinder head, valve gear

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

21 - Retaining clip
❑ Check for firm seating
22 - Roller rocker fingers
❑ Before installing, check camshaft axial clearance ⇒ page 101 .
❑ Do not interchange
❑ Check roller bearing for ease of movement.
❑ Oil contact surface
❑ When installing, secure to supporting element using securing clip.
23 - Valve springs
❑ Observe installation position
❑ Removing and installing ⇒ page 111 , Renewing valve stem seals.
24 - Valve spring plate
25 - Valve cotters

3.2 Camshafts, checking axial clearance

Special tools and workshop equipment required
♦ Universal dial gauge holder - VW 387-

n AG. Volkswagen AG do
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d ran
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u or
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♦ Dial gauge
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Test sequence
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erm

ab

Perform measurements with support elements and roller rocker

ility
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fingers removed.
wit
, is n

h re
hole

Middle bearing cap of respective camshaft installed.

spec
es, in part or in w

Wear limit: max. 0.40 mm

t to the co
rrectness of i
l purpos

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orm
m

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Cop py
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co lksw
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Prote AG.

3. Valve gear 101

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

3.3 Assembly overview - timing housing

1 - Seal
❑ Renew
2 - Guide rail: is clipped into
valve timing housing
3 - Valve timing housing
4 - Inlet camshaft control valve
1 - N205-
❑ Removing and installing
⇒ page 103
5 - Bolt
❑ 3.8 Nm
6 - Exhaust camshaft control
valve 1 - N318-
❑ Removing and installing n AG. Volkswagen AG do
⇒ page 103 olkswage es n
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7 - 8 Nm + turn 180° furtherrised ran
tee
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❑ Renew aut or
ac
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pt
an
d
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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in

Checking valve timing housing strainer for soiling

r
te o

thi

– Unclip strainer -2- from back of valve timing housing -1- and
s
iva

do
r

remove any dirt.

rp

cum
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

102 Rep. gr.15 - Cylinder head, valve gear

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

3.4 Removing and installing camshaft control valves

Special tools and workshop

equipment required

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

♦ Torque wrench - V.A.G 1783-

nform
ercia

♦ TORX bit set - V.A.G 1766-

m

at
om

♦ Ratchet insert 1/4" - VAS 6234-

ion
c

in t
or

♦ Socket wrench - T10072-

his
ate

do
riv

Not illustrated:
p

cum
for

en
ng

t.
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♦ Sealant - D 176 501 A1- t. Cop py
rig
gh ht
♦ Sealant - D 454 300 A2- pyri by
Vo
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Removing: Prote AG.

– Remove upper part of intake manifold ⇒ page 236 .

– Remove cylinder head cover ⇒ page 90 .

3. Valve gear 103

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Note

Before removing connectors, mark each connector and compo‐

nent to which it belongs.

– Disconnect connectors from the following componentsGof cov‐

A . Volkswagen AG d
er: lkswagen oes
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♦ Inlet camshaft control valve 1 - N205- ised b ran
r tee
tho
♦ Exhaust camshaft control valve 1s a-u N318- or
ac
s

ce
♦ Hall sender - G40-
e
nl

pt
du

an
itte

♦ Hall sender 2 - G163-

y li
erm

ab
ility
– Move wiring harness clear.
ot p

wit
, is n

– Unscrew nut -A- and remove bolts -arrows-.

h re
hole

spec
– Remove vacuum pump ⇒ page 93 .
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
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– Remove cover securing bolts -arrows- and lever off cover.

t

sd
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cu
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f

en
Caution
ng

t.
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Cop py
t. rig
♦ Cover lower chain housing carefully so that no parts can
gh ht
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fall into it.
op Vo
by c lksw
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Prote AG.
♦ Securing bolts for camshaft timing control valves must not
be completely removed at first, so that the valve is not
canted during removal.

104 Rep. gr.15 - Cylinder head, valve gear

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– 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.
– Completely remove securing bolts and pull camshaft control
valve out of valve timing housing.
Installing:

Caution

♦ 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.
♦ The camshaft control valves must not be pulled into their
seat with the securing bolts. Only insertion by hand is per‐
mitted.

– Moisten seal with clean engine oil.

– Carefully insert camshaft control valve into housing and push
vertically to valve axis to stop by hand.

– Tighten bolts -arrows- to 3.8 Nm.

AG. Volkswagen AG d
agen
– Clean sealing surface on cover and cylinder head. o lksw
oes
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– If seals in cover are to be renewed ⇒ page 94 .orise nte
eo
h
ut ra
– Apply a thin bead of sealant - D 176 501 A1-
ss a
on clean sealing c
surface of cover.
ce
le
un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

– Install cover, start all securing bolts -arrows- and tighten light‐
ly.
rrectness of i

– Then tighten all securing bolts. Specified torque ⇒ page 80 .

l purpos

– Install vacuum pump ⇒ page 93 .

– Fitting the cylinder head cover ⇒ page 90
nform
ercia

Further assembly is basically a reverse of the dismantling se‐

m

quence.
com

tion in
r
te o

thi
s
iva

do
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rp

cum
fo

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ng

t.
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3.5 Removing and installing camshaft Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

3. Valve gear 105

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Special tools and workshop

equipment required

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
m

♦ Torque wrench - V.A.G 1331-

o

n in
or c

thi
e

♦ Torque wrench - V.A.G 1332-

t

sd
iva

o
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rp

cu

♦ Camshaft bar - T10068 A-

o

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f

en
ng

t.
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♦ Adjusting tool - T10363-
Co
Cop py
t. rig
♦ Counterhold - T10172- with pins - T10172/1-
gh ht
pyri by
Vo
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by c lksw
Not illustrated: cted agen
Prote AG.

♦ Sealant - D 176 501 A1-

Removing:
– Removing the two camshaft adjusters ⇒ page 64 .

106 Rep. gr.15 - Cylinder head, valve gear

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Undo bolts -arrows- from valve timing housing and pull valve
timing housing off cylinder head.
– Lay camshaft timing chain aside.

A - Inlet camshaft
– 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.

B - Exhaust camshaft
– First remove bearing caps 2 and 14. AG. Volkswagen AG d
agen oes
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– Remove bearing caps 4 and 12. byV
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– Remove bearing cap 8. ut
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– Loosen bearing caps 6 and 10 alternately and diagonally. s

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pt
Continuation for both camshafts

an
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ab
– Carefully remove camshafts and lay aside on clean surface.
pe

ility
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wit
– Remove roller rocker fingers together with support elements
, is n

h re
and lay aside on a clean surface.
hole

spec
– Ensure that roller rocker fingers and support elements are not
es, in part or in w

t to the co
interchanged.
Installing:
Conditions: rrectness of i
l purpos

• When installing camshafts, No. 1 cylinder cams -A- must point

upwards.
nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
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rp

cum
fo

en
ng

t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

3. Valve gear 107

 Touareg 2010 ➤ , Touareg 2015 ➤ gen AG
. Volkswagen AG
does
swa
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition
yV
olk 12.2019 not
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Procedure: au
tho e or
ac
ss
– Turn crankshaft using counterhold - T10172- in engine direc‐

ce
le
un
tion of rotation to TDC No. 1 cylinder.

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
– Lightly coat contact surfaces of bearing caps 7 and 8 with uni‐
l purpos
versal grease - G 052 735 A2- .

nform
ercia

– Install supporting elements in cylinder head and fit respective

roller rocker finger onto respective valve stem end or support‐
m

a
ing element.
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– 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, observe camshaft identifica‐
tion ⇒ page 110 .
– Observe fitting position of bearing caps.

Fitting position of camshaft bearing caps

Points of bearing caps -arrow A- of inlet and exhaust camshafts
face outwards.

108 Rep. gr.15 - Cylinder head, valve gear

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

A - Inlet camshaft
– Tighten bearing caps 5 and 9 alternately and diagonally to 5
Nm + 1/8 turn (45°) further.
– Install bearing caps 1 and 13 and tighten to 5 Nm and turn 1/
8 (45°) further.
– Install bearing cap 7 and tighten to 5 Nm and turn 1/8 (45°)
further.
– Install bearing caps 3 and 11, tighten to 5 Nm and turn 1/8 (45°)
further.

B - Exhaust camshaft
– Tighten bearing caps 6 and 10 alternately and diagonally to 5
Nm + 1/8 turn (45°) further.
– Install bearing caps 2 and 14 and tighten to 5 Nm and turn 1/
8 (45°) further.
– Install bearing cap 8 and tighten to 5 Nm and turn 1/8 (45°)
further.
– Install bearing caps 4 and 12, tighten to 5 Nm and turn 1/8 (45°)
further.
Continuation for both camshafts

– Insert camshaft bar - T10068 A- in both shaft grooves.

– Before installing, check valve timing housing strainer for soil‐
ing ⇒ page 102 .
– Before installing timing housing, lubricate camshaft seals.
– Lubricate contact surfaces of seals in timing housing and then
slowly push timing housing overncamshaft
AG. Volkswaseals.
gen AG
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c
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pt
du

an
itte

y li

– Install timing housing and tighten bolts -arrows-. Specified tor‐

erm

ab

que ⇒ page 102 .

ility
ot p

wit
, is n

– Install camshaft adjuster with camshaft timing chain

h re

⇒ page 64 .
hole

spec
es, in part or in w

– Clean sealing surface on cover.

t to the co

– If seals in cover are to be renewed ⇒ page 94 .

– Apply a thin bead of sealant - D 176 501 A1- on clean sealing
rrectness of i

surface of cover.
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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f

en
ng

t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw

109
cted agen
Prote AG.
3. Valve gear
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Install cover, start all securing bolts -arrows- and tighten light‐
ly.
– Then tighten all securing bolts. Specified torque ⇒ page 80 .
– Install vacuum pump ⇒ page 93 .
– Fitting the cylinder head cover ⇒npage
AG. Vo90
lkswagen A
ge G do
swa es
Further assembly is basically
y V a reverse of the dismantling se‐
olk not
gu
quence. edb ara
ris nte
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c
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3.6 Camshaft identification

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Identification between cam pair for cylinders 4 and 5 of respective

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camshaft.

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Camshaft Identification
A - exhaust camshaft 03H 101 index

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B - inlet camshaft 03H 102 index
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110 Rep. gr.15 - Cylinder head, valve gear

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

4 Inlet and exhaust valves

⇒ “4.1 Renewing valve stem seals”, page 111 .
⇒ “4.2 Valve dimensions”, page 113 .
⇒ “4.3 Checking valve guides”, page 113 .
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4.1 Renewing valve stem seals utho tee
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Special tools and workshop

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equipment required

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♦ Valve lever - VW 541/1 A- with press tool - VW 541/6-

♦ Valve assembly device - 2036- with adapter plates - 2036/1-
♦ Spark plug socket - 3122 B-
♦ Valve stem seal puller - 3364-
♦ Valve stem seal fitting tool - 3365-
♦ Adapter - T40012/1-

4. Inlet and exhaust valves 111

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

♦ Torque wrench - V.A.G 1331-

Removing:
– Remove camshafts ⇒ page 105 .
– Remove roller rocker fingers together with support elements
and lay aside on a clean surface.

Note

Ensure that roller rocker fingers and support elements are not
interchanged.

– Unscrew spark plugs using spark plug socket and extension -

3122 B- .
olkswagen AG
en AG. V
– Set piston of respective cylinder oto
lks“bottom
wag dead centre”.does no
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– Set-up valve assembly device
ris
ed - 2036- with adapter plates - nte
2036/1- and adjust mounting.
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– Screw adapter - T40012/1- into spark plug thread, connect to
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compressed air line with commercially available adapter and

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apply constant pressure. At least 6 bar.

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– Remove valve springs using valve lever - VW 541/1 A- and

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press tool VW 541/6 .

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Note
t to the co

Tight valve cotters can be loosened by tapping lightly on assem‐

bly lever.
rrectness of i
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– Pull off valve stem seals using valve stem seal puller - 3364- .
Installing:
nform
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for

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Cop py
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Prote AG.

112 Rep. gr.15 - Cylinder head, valve gear

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– To prevent damage to new valve stem seals, place plastic

sleeve -A- on valve stem.
– Lubricate sealing lip of valve stem oil seal -B-, place it in the
valve stem oil seal fitting tool - 3365- and push carefully onto
valve guide.
– Install camshafts ⇒ page 105 .
Install camshaft adjuster with camshaft timing chain ⇒ page 64 .

4.2 Valve dimensions

Valve dimensions

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Do not rework valves. Only lapping-in is permitted. tho ris nte
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Valve dimensions for inlet valves

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Dimension Short inlet valve Long inlet valve

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∅a mm 33.20 33.20
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∅b mm 5.98 5.98

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c mm 102.46 136.36

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α ∠° 44° 40' 44° 40'

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Valve dimensions for exhaust valves

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Dimension Short exhaust valve Long exhaust valve
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∅a mm 30.20 30.20
∅b mm 5.97 5.97 nform
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c mm 102.20 136.20
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α ∠° 44° 40' 44° 40'

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4.3 Checking valve guides

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Special tools and workshop equipment required

en
ng

t.
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Cop py
ht. rig
rig ht
py by
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by lksw
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Prote AG.

4. Inlet and exhaust valves 113

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

♦ Universal dial gauge holder - VW 387-

♦ Dial gauge
Test sequence
– Insert new valve into guide. The end of the valve stem must
be flush with the guide. On account of differing stem diame‐
ters, only use inlet valve in inlet guide and exhaust valve in
exhaust guide.
– Determine rock. Wear limit: 0.8 mm
If the amount of sideways play is exceeded:
– Renew cylinder head.
AG. Volkswagen AG d
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4.4 Reworking valve seats ss aut ra
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Special tools and workshop equipment required

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♦ Depth gauge
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♦ Valve seat refacing tool
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Procedure
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Note

♦ When repairing engines with leaking valves, it is not sufficient

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to rework or renew valve seats and valves. Particularly on high
mileage engines, it is necessary also to check valve guides for
l purpos

wear ⇒ page 113 .

nform
ercia

♦ Valve seats are only to be reworked to the extent required to

yield a proper surface appearance. Before beginning to rework
m

valve seats, calculate the maximum permissible reworking di‐

com

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mensions. If the reworking dimension is exceeded, the hy‐

n in
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draulic valve clearance compensation can no longer be

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guaranteed and the cylinder head must be renewed.

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– Remove camshafts ⇒ page 105 .

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– Insert valve and press firmly against seat.
AG.

Note

If the valve is to be renewed as part of a repair, use a new valve

for the calculation.

114 Rep. gr.15 - Cylinder head, valve gear

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– 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
Minimum dimension: AG. Volkswagen AG d
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Short inlet valve mm d 31.8
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Long inlet valve mmutho 10.2 eo
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Short exhaust valve mm
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31.8

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Long exhaust valve mm 10.2

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Measured distance minus minimum dimension = max. permissi‐
pe

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Example:

spec
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Measured distance 10.6 mm

t to the co
- Minimum dimension 10.2 mm
= Max. permissible reworking dimension 0.4 mm

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Reworking inlet valve seat.

nform
ercia

a = 32.8 mm diameter
m

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b = max. permissible reworking dimension

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α = 45° valve seat angle

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β = 30° upper correction angle
γ = 60° lower correction angle
2) Calculating max. permissible reworking dimension ⇒ page 114 .

Reworking exhaust valve seat.

a = 29.8mm diameter
b = max. permissible reworking dimension
3)

c = 1.2 to 1.7 mm
d = max. ∅ 35.0 mm
r2 = radius 2.0 mm
Z = bottom surface of cylinder head
α = 45° valve seat angle
β = 30° upper correction angle
γ = 60° lower correction angle
3) Calculating max. permissible reworking dimension ⇒ page 114 .

4. Inlet and exhaust valves 115

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

17 – Lubrication
1 Sump, oil pump
⇒ “1.1 Assembly overview - sump/oil pump”, page 116 AG. Volkswagen AG d
agen oes
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⇒ “1.2 Engine oil:”, page 118 d by ara
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⇒ “1.3 Removing and installing oil pan”, page 119aut ra
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⇒ “1.4 Removing and installing oil pump”, page 122

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1.1 Assembly overview - sump/oil pump

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Note

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spec
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♦ Finding metal shavings or a large quantity of small metal par‐

t to the co
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:

rrectness of i
♦ Thoroughly clean oil channels.
l purpos

♦ Renew oil spray jets.

nf
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♦ Renew engine oil cooler.

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m

♦ Renewing oil filter.

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c

♦ The oil level must remain below the max. mark - danger of
or

thi
damage to catalytic converter!
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Cop py
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Prote AG.

116 Rep. gr.17 - Lubrication

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

1 - 6 Nm
❑ Secured to intake mani‐
fold.
2 - Guide tube
❑ for oil dipstick
❑ Secured with bolt to in‐
take manifold.
3 - Cylinder block
❑ Removing and installing
sealing flanges and fly‐
wheel/drive plate
⇒ page 36
❑ Removing and installing
crankshaft ⇒ page 49 .
❑ Pistons and conrods
⇒ page 56 .
4 - O-ring
❑ Renew
❑ Lubricate before as‐
sembling.
5 - Oil pump
❑ To remove oil pump, en‐
gine must be removed.
❑ Removing and installing AG. Volkswagen AG d
oil pump ⇒ page 122 . agen oes
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6 - Sprockets orise nte
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❑ For timing chain s au ra
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❑ Removing and installing
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⇒ page 30 pt
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❑ Install camshaft adjust‐ y li

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er with camshaft timing ility

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chain ⇒ page 64 .
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7 - 60 Nm + 1/4 turn (90°) further

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❑ Renew
t to the co

8 - 8 Nm
❑ Install with locking fluid
rrectness of i

9 - Seal
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❑ Renew
❑ Lubricate before assembling.
nform
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10 - Oil spray jet

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❑ For crankshaft bearings 2 to 7

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❑ For piston cooling

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❑ Opening pressure: 2.0 bar

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❑ Removing and installing ⇒ page 128

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11 - Seal
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❑ Renew if damaged
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❑ Lubricate before assembling.
agen
Prote AG.

12 - Oil intake tube

❑ Clean strainer if soiled
13 - 8 Nm
❑ Install with locking fluid

1. Sump, oil pump 117

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

14 - Oil pipe
15 - 8 Nm
❑ Install with locking fluid
16 - Baffle plate
17 - Oil drain plug, 30 Nm
❑ With captive seal
❑ Renew
18 - Sump
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant - D 176 501 A1- .
❑ Removing and installing ⇒ page 119
19 - Oil level and oil temperature sender - G266-
❑ Checking ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
20 - 10 Nm
21 - Securing bolts for oil sump
❑ Sump/cylinder block 12 Nm
❑ Sump/gearbox 45 Nm
22 - 10 Nm
23 - Oil filter housing/left engine support
❑ Assembly overview - oil filter housing ⇒ page 128
olkswagen AG
❑ Connection diagram for coolant en AG. V⇒ page
ghoses 135 does
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24 - 23 Nm d by ara
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25 - Oil pressure switchaut ra
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❑ Checking ⇒ page 131
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26 - Seal
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❑ Renew
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❑ Lubricate before assembling.

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27 - Seal
hole

spec

❑ Renew
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❑ Lubricate before assembling.

rrectness of i

1.2 Engine oil:

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Oil capacities
nform
ercia

♦ without oil filter 5.8 l.

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♦ With oil filter 6.7 l

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Engine oil specifications:

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⇒ Maintenance ; Booklet ; Service tables

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Check engine oil level with oil gauge tester - T40178-

n

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⇒ page 118 . Cop py
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1.2.1 Check engine oil level with oil gauge
p by
co Vo
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cted agen
tester - T40178-
Prote AG.

Checking engine oil level in infotainment display ⇒ Maintenance ;

Booklet ; Engine oil level: check .

118 Rep. gr.17 - Lubrication

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Test conditions
olkswagen AG
en AG. V
• Engine oil temperature min.
olks60 °C.
wag does
not
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• Vehicle is level. rised
nte
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• Wait a few minutes
ss a after switching engine off to allow oil to flow ra
c
back into sump.

ce
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Special tools and workshop equipment required
itte

y li
erm

ab
♦ Oil level test tool - T40178-

ility
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wit
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es, in part or in w

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Test sequence

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– Loosen knurled screw -arrow- on setting ring. Set lower edge

at

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of adjustment ring to 16 mm.

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– Push tester into dipstick tube as far as it will go (setting ring),

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then pull it out again and read off the oil level. Cop py
ht. rig
rig ht
py by
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by lksw
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Prote AG.

– Read off the value on the lower scale.

Engine Setting value at top setting Minimum oil level on lower Maximum oil level on lower
ring scale scale
3.6 l FSI engine 16 mm 0 mm 21 mm

1.3 Removing and installing oil pan

Special tools and workshop equipment required

1. Sump, oil pump 119

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

♦ Used oil collector and extractor - VAS 6622-

♦ Bit XZN 8 - T40159-

AG. Volkswagen AG d
agen oes
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♦ Sealant - D 176 501 A1-

spec
es, in part or in w

♦ Hand drill with plastic brush

t to the co

♦ Scraper
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♦ Safety glasses
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Removing:
– Drain engine oil.
nform
mercia

at
om

Note
ion
c

in t
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Please observe disposal instructions!

at

do
priv

cum
for

– Support engine in its installation position ⇒ page 24 .

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ng

t.
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op
– Remove subframe ⇒ Running gear, axles, steering; Rep. gr.
C py
t. rig
gh
40 ; Removing and installing subframe .
ht
pyri by
Vo
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– Remove engine carrier. The engine carrier can remain bolted
cted agen
Prote AG.
to the engine carrier.
– Drain engine oil.

120 Rep. gr.17 - Lubrication

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Unscrew bolt -arrow- on retainer for ATF lines.

AG. Volkswagen AG d
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– Disconnectd by V electrical connector -2- on oil olevel
o gu and oil temper‐
ara
atureorisender
se - G266- . nte
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– Lay
ss a wiring harness on sump to one side. c

ce
le

– Unscrew gearbox/sump securing bolts -arrows-.

un

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– Loosen bolts for sump -1- diagonally, and unscrew them.
erm

ab
ility
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wit
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spec
urposes, in part or in wh

t to the co

– Remove sump bolts on the gearbox side -arrows- using bit

rrectne

XZN 8 - T40159- through holes in gearbox.

s

– Carefully lever sump off cylinder block.

s o
cial p

f i

– Remove sealant residue from cylinder block with a flat scraper.

nform
mer

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Cop py
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– Remove sealant residue on sump with a rotating brush, e.g.
cop Vo
by lksw
cted
an electric drill with plastic brush attachment (wear eye pro‐
agen
Prote AG.
tection).
– Clean sealing surfaces; they must be free of oil and grease.

1. Sump, oil pump 121

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Touareghor2010 ➤ , Touareg 2015 ➤
is tee
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6-cylinder
au direct-injection engine (3.6 l engine, 4V) - Edition
ac 12.2019
ss

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Installing: un

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Note
ot

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♦ Check the expiry date of the sealant.
hole

spec
es, in part or in w

♦ The sump must be installed within 5 minutes of applying sili‐

t to the co
cone sealing compound.

– Cut off tube nozzle at forward marking (approx. 3 mm ∅ of

rrectness of i
nozzle).
l purpos

– Apply silicone sealant to clean sealing surface of sump as

nform
ercia

shown.
m

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com

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• Thickness of sealant bead: 2…3 mm.

on in
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The sealant bead must not be thicker, otherwise excessive seal‐
Co
op py
ant enters the sump and may block the oil suction pipe strainer.
t. C rig
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pyri by
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– Fit sump immediately, and tighten all sump bolts only lightly.
cted agen
Prote AG.

– Tighten bolts in 3 stages as follows:

1. Tighten bolts securing sump -1- to cylinder block in diagonal
sequence to initially 5 Nm.
2. Tighten bolts securing sump to gearbox -arrows- to 45 Nm.
3. Tighten bolts securing sump -1- to cylinder block in diagonal
sequence to 12 Nm.

Note

Let sealing compound dry for approx. 30 minutes after installing

oil sump. Only then fill with engine oil.

Further assembly is basically a reverse of the dismantling se‐

quence.

1.4 Removing and installing oil pump

Note

To remove oil pump, engine must be removed ⇒ page 7 .

Removing:
– Remove gearbox.
– Remove flywheel.
– Remove sealing flange on gearbox side ⇒ page 40 .

122 Rep. gr.17 - Lubrication

 AG. Volkswagen AG d
agen oes
olksw not
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ed
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aut
h
Touareg 2010 ➤ , Touareg
2015 ➤ ra
s c
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019
s

ce
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nl

pt
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an
– Loosen bolt -arrow- for sprockets about 1 full turn. To do this,

itte

y li
erm
counterhold vibration damper using counterhold - T10172- .

ab
ility
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hole

spec
es, in part or in w

t to the co
rrectness of i
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nf
ercia

or
– Turn engine by vibration damper to adjustment markings.

m
m

atio
m

• Ground tooth of drive sprocket -arrow A- must align with bear‐

o

n in
or c

ing joint.

thi
te

sd
iva

• The marked hole -arrow B- must be in line with the mark on

o
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rp

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the oil pump.
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Cop py
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Note rig ht
py by
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cted agen
This position is reached only after every 4th full rotation.
Prote AG.

– Mark position of timing chains to sprockets of oil pump using

a permanent marker.

– Remove chain tensioner for camshaft timing chain -arrow-.

– Fix chain tensioner spring using 3 mm Allan key -A-.

– Remove chain tensioner for oil pump drive chain -arrows-.

1. Sump, oil pump 123

 n AG. Volkswagen AG do
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Touareg 2010 ➤ , Touareg hor 2015 ➤
is tee
t
u engine (3.6 l engine, 4V) - Edition 12.2019 or a
6-cylinder direct-injection
a c
ss

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– Unscrew securing bolt for sprockets completely and remove

pt
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d
itte
sprockets with timing chains from oil pump.

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pe

ility
ot

wit
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h re
hole

spec
es, in part or in w

t to the co
rrectness of i
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nform
ercia

– Unscrew oil pump securing bolts -arrows-.

m

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com

tion in
r
te o

thi
s
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fo

en
ng

t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Lever oil pump out evenly at lugs -arrows-.

Installing:

Note

♦ Do not tilt oil pump when installing.

♦ Renew O-ring and securing bolt for the sprockets.
♦ Insert securing bolts for oil pump with locking fluid.

– Install oil pump, coat securing bolts -arrows- with locking

agent, then tighten bolts. Specified torque
⇒ Item 8 (page 117) .

124 Rep. gr.17 - Lubrication

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Set crankshaft to TDC position.

• Ground tooth of drive sprocket -arrow- must align with bearing
joint.

– Now turn oil pump shaft -1- with flat side -arrow- horizontal to
mark -2- on oil pump.
– First, only fit the rear chain onto the large sprocket. When do‐
ing this, observe the previously made markings.

– Fit chain onto crankshaft and fitasprocket

n AG. Volonto
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en Apump
G do shaft.
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The marked hole -arrow B- y Vomust be in line with the mark
lks es n
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the oil pump. ise
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– If sprocket cannot
sa
ube
t
fitted, turn oil pump shaft slightly. or
ac
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nl

pt
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itte

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ility
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Prote AG.

1. Sump, oil pump 125

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Carefully pull sprocket off oil pump and swing upwards a little.
In this position, fit the camshaft timing chain. The marking
made during removal must align.
– Fit sprocket onto oil pump shaft again and tighten hand-tight.

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– Install lower chain tensioner and tighten to 8 Nm -arrows-.
es, in part or in w

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– Remove Allan key -A-.

rrectness of i
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– Install chain tensioner for camshaft timing chain -arrow-.

cum
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rig ht
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Prote AG.

126 Rep. gr.17 - Lubrication

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Recheck adjustment markings. wagen AG. Volkswagen AG doe

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• Ground tooth of drive sprocket
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• The marked holess-arrow B- must be in line with the mark on
the oil pump.

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– Tighten sprockets to 60 Nm + 90° (1/4 turn) further. To do this,

y li
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ab
counterhold vibration damper using counterhold - T10172- .
pe

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wit
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– Install sealing flange ⇒ page 41 .

h re
hole

spec
Further assembly is carried out in the reverse order of removal.
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
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Prote AG.

1. Sump, oil pump 127

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

2 Oil filter, oil pressure switch

⇒ “2.1 Removing and installing oil spray jet”, page 128
⇒ “2.2 Assembly overview - oil filter housing”, page 128
⇒ “2.3 Removing and installing oil filter housing, engine support”,
page 130
⇒ “2.4 Removing and installing oil pressure switch F1 ”,
page 131
⇒ “2.5 Checking oil pressure and oil pressure switch”,
page 131

2.1 Removing and installing oil spray jet

Special tools and workshop equipment required
♦ Drift ∅ 4 mm
♦ Drift ∅ 6 mm

Note

Oil spray jets are installed in crankshaft bearings 2 to 7.

Removing:
– Press out oil spray jet towards engine mounting -arrow-, using
a 4 mm ∅ punch .
Installing:
– To install, press in oil spray jet by hand using a 6 mm ∅ punch .
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2.2 Assembly overview - oil filter housing wit

is n

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spec
urposes, in part or in wh

t to the co
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cial p

f inform
mer

atio
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Prote AG.

128 Rep. gr.17 - Lubrication

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

1 - Oil drain plug, 10 Nm

❑ Use flexible funnel -
VAS 6675- to catch oil.
2 - Seal
❑ Renew
❑ Lubricate before as‐
sembling.
3 - Oil filter lower part, 25 Nm
❑ Drain before removing.
❑ With bypass valve,
opening pressure: 2.50
bar
4 - Seal
❑ Renew
❑ Lubricate before as‐
sembling.
5 - Oil filter element
❑ Observe change inter‐
vals.
6 - 23 Nm
7 - Left engine support with oil
filter housing
❑ Removing and installing
n AG. Volkswagen AG do
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⇒ page V130
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8 - Sealhoris tee
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❑ss a Renew ac

❑ Lubricate before as‐

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9 - Oil cooler seal

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❑ Renew
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❑ Lubricate before as‐

hole

spec

sembling.
es, in part or in w

t to the co

10 - Engine oil cooler

❑ Ensure clearance to adjacent components
❑ Connection diagram for coolant hoses ⇒ page 135
rrectness of i

11 - Bolt
l purpos

❑ 8 Nm
nf
ercia

12 - Oil pressure switch - F1- , 20 Nm

orm
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❑ black
atio
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❑ Switch point 1.4 bar.

n in
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❑ If seal is leaking, nip open and renew.

t

sd
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❑ Checking ⇒ page 131

rp

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❑ Removing and installing ⇒ page 131 yi

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13 - Seal
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Prote AG.

2. Oil filter, oil pressure switch 129

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

2.3 Removing and installing oil filter hous‐

ing, engine support
Used oil collector and extractor - VAS 6622 A-
Removing
– Support engine in its installation position ⇒ page 24 .
– Unbolt power-assisted steering reservoir, and lay it to one
side.

– Remove connector -arrow- for engine speed sender - G28-

from dipstick guide tube, and disconnect it.

– Separate electrical connector -2- on oil pressure switch - F1- .

– Unscrew nut -1- and the bolts -upper arrows- which can be
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– Clamp off coolant hoses on engine oil cooler, andsedpull
by them ara
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off. thori eo
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wit
is n

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spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

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c

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or

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rig ht
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Prote AG.

130 Rep. gr.17 - Lubrication

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Remove noise insulation at front -1- and rear -2-.

– Place used oil collection and extraction unit - VAS 6622 A-

under engine.
– Unscrew cap -4- for oil filter housing.
– Unscrew bolts -lower arrows-, and remove left engine support
with oil filter housing. Do not damage wire for engine speed gen AG
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does
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• Specified torque ⇒ page 128 . ss

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Install in reverse order of removal, observing the following.
du

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Note

wit
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Renew the seals and gaskets.

spec
es, in part or in w

t to the co
– Check oil level ⇒ page 118 .

rrectness of i
2.4 Removing and installing oil pressure
l purpos

switch - F1-
nf
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Removing
orm
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Proceed as follows:
atio
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– Separate electrical connector -2- on oil pressure switch - F1- .

or

thi
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– Unscrew oil pressure switch - F1- -item 1-.

iv

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• Specified torque ⇒ page 128 . C py
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Installation is carried out in the reverse order; note the following. copy Vo
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Note

Renew the seal.

2.5 Checking oil pressure and oil pressure switch

2. Oil filter, oil pressure switch 131

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Special tools and workshop

equipment required

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♦ Oil pressure tester - V.A.G 1342-

rrectne

♦ Adapter - V.A.G 1342/14-

ss

♦ Voltage tester - V.A.G 1527 B-

o
cial p

f inform

♦ Adapter set - V.A.G 1594C-

mer

atio
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♦ Current flow diagram

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Functional check and repair of the optical and acoustic oil pres‐
t.
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sure warning ⇒ Current flow diagrams, Electrical fault finding and
C py
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Fitting locations.
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Test conditions
• Engine oil level OK, checking ⇒ page 118 .
• Engine oil temperature at least 80°C (radiator fan must have
run once)
• On vehicles with automatic gearbox the selector lever must be
in “P” or “N” position.

132 Rep. gr.17 - Lubrication

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Checking oil pressure switch:

– Remove oil pressure switch - F1- ⇒ Item 12 (page 129) and
screw into tester.
– Screw oil pressure tester - V.A.G 1342- into oil filter housing
in place of oil pressure switch using adapter - V.A.G 1342/14- .

Note

Observe installation position of adapter - V.A.G 1342/14- : the

conical connecting piece of the adapter must be screwed into the
pressure hose of the oil pressure tester - V.A.G 1342- .

– Connect brown wire of oil pressure tester - V.A.G 1342- to

earth (-).
– Connect voltage tester - V.A.G 1527B- to battery positive (+)
and oil pressure switch - V.A.G 1594C- using cables from
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If the LED lights up: ir se
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– Renew oil pressureaut switch - F1- ⇒ Item 12 (page 129) . or
ac
ss

ce
If LED does not light up:
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pt
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ab
Note

ility
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Observe tester and LED while starting, as switching point of oil
ole,

pressure switch may already be exceeded when starting.

spec
urposes, in part or in wh

– Start engine and run at idling speed. t to the co

At 1.2 to 1.6 bar the LED must light up; otherwise renew oil pres‐
rrectne

sure switch - F1- ⇒ Item 12 (page 129) .

Checking oil pressure:
ss o
cial p

– Check oil pressure at different revolutions:

inform
mer

♦ 1,500 rpm: at least 1.7 bar

atio
m

♦ 2000 rpm: 3.0 to 5.5 bar

o

n
c

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♦ Over 2000 rpm: maximum 7.0 bar

t

sd
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If the specifications are not attained:

um
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en
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t.
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♦ Check strainer in oil suction pipe ⇒ Item 12 (page 117) for dirt.
Co
Cop py
t. rig
♦ Check control piston of oil pressure safety valve in oil pump
gh ht
pyri by
for dirt.
co Vo
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♦ Check oil pipe at bottom of cylinder block
⇒ Item 14 (page 118) for leaks.

Note

♦ Mechanical damage, e.g. to bearings, could also be the cause

for oil pressure being too low.
♦ The oil pressure safety valve control piston is spring-loaded.
Great care is therefore required when screwing the plug in/out.
♦ The plug is tightened to 35 Nm in oil pump.

If no fault is found:

2. Oil filter, oil pressure switch 133

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Renew oil pump ⇒ page 122 .

If the specification is exceeded:
– Check oil channels.
– If necessary, renew oil pump ⇒ page 122 .

AG. Volkswagen AG d
agen oes
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Cop py
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by lksw
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Prote AG.

134 Rep. gr.17 - Lubrication

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

19 – Cooling
AG. Volkswagen AG d
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The cooling system is under pressure when the engine is hot!

an
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Danger of scalding by steam and hot coolant.

pe

ility
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wit
Cover filler cap on expansion tank with a cloth and open care‐ , is n

h re
fully to release pressure.
hole

spec
es, in part or in w

t to the co
Note

rrectness of i
♦ Secure all hose connections with hose clips corresponding to
l purpos

the series equipment ⇒ ETKA (electronic parts catalogue) .

♦ The arrow markings on coolant pipes and on ends of hoses

nform
ercia

must align.
m

a
com

tio
⇒ “1.1 Coolant hose connection diagram”, page 135

n in
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⇒ “1.2 Vacuum hose connection diagram”, page 137

s
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⇒ “1.3 Assembly overview - vacuum hoses”, page 138
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1.1 Coolant hose connection diagram py by
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1. Cooling system (engine code CGRA) 135

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019
olkswagen AG
en AG. V
1 - Coolant expansion otank
lksw
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2 - Coolant circulation
ris
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- V178- aut
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❑ Removing and installing

ce
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⇒ page 149
un

pt
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itte

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3 - Shut-off valve for ATF pre‐
rm

ab
heater
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❑ Actuated by valve for
, is n

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coolant oil - N471-
hole

spec
4 - ATF preheater
es, in part or in w

t to the co
5 - Coolant shut-off valve -
N82-

rrectness of i
❑ Inclusion of auxiliary
heater in coolant circuit
l purpos

⇒ Rep. gr. 87
6 - Heat exchanger for heater

nform
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❑ Removing and installing

m

⇒ Rep. gr. 87

a
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tion in
❑ Inclusion of auxiliary
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heater in coolant circuit

thi
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⇒ Rep. gr. 87 do
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❑ Renew coolant after re‐

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7 - Engine oil cooler
rig
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8 - Cylinder block
lksw
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Prote AG.
9 - Coolant pump
❑ Actuated by coolant
thermostat valve -
N515-
❑ Check diaphragm in
coolant pump for leaks
using hand vacuum
pump - VAS 6213- .
10 - Radiator for engine coolant
❑ With ATF cooler and condenser
❑ Renew coolant after replacing
11 - Thermostat
❑ Removing and installing, checking ⇒ page 150
12 - Cylinder head
13 - Cylinder block shut-off valve
❑ Actuated by coolant valve for cylinder block - N545-

136 Rep. gr.19 - Cooling

 AG. Volkswagen AG d
agen
Volksw
oes
not Touareg 2010 ➤ , Touareg 2015 ➤
by gu
ed 6-cylinder direct-injection engine
ara
nte (3.6 l engine, 4V) - Edition 12.2019
ris
tho eo
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1.2 Vacuum hose connection diagram
ss c

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1 - Fuel system diagnostic
rm

ab
pe

pump - V144-

ility
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❑ Vehicles for USA/Cana‐
, is n

h re
da only
hole

spec
2 - Valve for cooling oil - N471-
es, in part or in w

t to the co
3 - Shut-off valve for ATF pre‐
heater

rrectness of i
4 - Coolant valve for cylinder
block - N545-
l purpos

5 - Cylinder block shut-off

valve

nform
ercia

6 - Intake manifold flap air flow

m

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com

ti
control valve - N316-

on in
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7 - Vacuum actuator for intake

s
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manifold flap

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8 - Non-return valve

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9 - Intake manifold
C py
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10 - Non-return valve
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11 - Brake servo
AG.

12 - Non-return valve
13 - Mechanical vacuum pump
14 - Coolant pump
15 - Coolant regulation valve -
N515-

1. Cooling system (engine code CGRA) 137

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

1.3 Assembly overview - vacuum hoses

1 - Coolant regulation valve -

N515-
2 - Coolant pump
❑ Check diaphragm in
coolant pump for leaks
using hand vacuum
pump - VAS 6213- .
3 - Cylinder block shut-off
valve
4 - Coolant valve for cylinder
block - N545-
❑ Installation location: at
rear of engine
5 - Shut-off valve for ATF pre‐
heater
6 - Valve for cooling oil - N471-
❑ Installation location: on
top of gearbox
7 - Vacuum connection on me‐
chanical vacuum pump
8 - To fuel system diagnostic
pump - V144-
❑ Vehicles for USA/Cana‐
da only
9 - Intake manifold flap air flow
control valve - N316-
10 - To intake manifold flap
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1.4 Assembly overviews - cooling system

rm

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⇒ “1.4.1 Cooling system - assembly overview part 1”, page 138

, is n

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hole

⇒ “1.4.2 Cooling system - assembly overview part 2”, page 139

spec
es, in part or in w

⇒ “1.4.3 Cooling system - assembly overview part 3”, page 140

t to the co

1.4.1 Cooling system - assembly overview

rrectness of i

part 1
l purpos

Renew O-rings and seals.

Pull plug-in connector to make sure they are securely connected.
nform
ercia

Specified torques:
m

a
com

tio

Bolts, M6: 10 Nm
n in
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thi

Bolts, M8: 20 Nm
s
iva

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en
ng

t.
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Cop py
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pyri by
Vo
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cted agen

138
Prote AG.
Rep. gr.19 - Cooling
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

1 - Coolant expansion tank

2 - Coolant circulation pump 2
- V178-
❑ Removing and installing
⇒ page 149
3 - ATF preheater
❑ Removing and installing
⇒ Rep. gr. 37
4 - Radiator outlet coolant -
G62-
Volkswagen AG
5 - Temperature senderswfor ageen‐
n AG. does
gine temperature bregulation
yV
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❑ Removing tho and installing
eo
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⇒ page
ss
151

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6 - Coolant pump

an
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7 - Coolant regulation valve -

ility
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N515-

wit
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urposes, in part or in wh

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1.4.2 Cooling system - assembly overview
C py
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gh ht
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part 2
p by
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Prote AG.
Renew O-rings and seals.
Pull plug-in connector to make sure they are securely connected.
Specified torques:
Bolts, M6: 10 Nm
Bolts, M8: 20 Nm

1. Cooling system (engine code CGRA) 139

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

1 - ATF preheater
❑ Removing and installing
⇒ Rep. gr. 37
2 - Cylinder block shut-off AG. Volkswagen AG d
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4 - Coolant circulation pump 2

h re
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⇒ page 149
5 - Shut-off valve for ATF pre‐
heater

rrectness of i
❑ To remove, remove
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centre plenum chamber

bulkhead ⇒ General
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1.4.3 Cooling system - assembly overview

part 3
Renew O-rings and seals.
Pull plug-in connector to make sure they are securely connected.
Specified torques:
Bolts, M6: 10 Nm
Bolts, M8: 20 Nm

140 Rep. gr.19 - Cooling

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

1 - Coolant expansion tank

2 - Coolant circulation pump 2
- V178-
❑ Removing and installing
⇒ page 149
3 - Cylinder block shut-off
valve
❑ To remove, remove
centre plenum chamber
bulkhead ⇒ General
body repairs, exterior;
Rep. gr. 50 ; Plenum
chamber bulkhead .
4 - Hoses of heat exchanger
for heating system
5 - Engine oil cooler
6 - Thermostat housing
❑ Removing and installing
⇒ page 150
7 - Union
❑ For top of radiator. AG. Volkswagen AG d
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1. Cooling system (engine code CGRA) 141

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

2 Cooling system (engine code CMTA)

⇒ “2.1 Coolant hose connection diagram”, page 142
⇒ “2.2 Assembly overview - cooling system, engine side, front and
rear”, page 142
⇒ “2.3 Assembly overview - cooling system, engine side, left”,
page 143

2.1 Coolant hose connection diagram

1 - Expansion tank
2 - Electric coolant pump
3 - Heat exchanger for heater
4 - Engine oil cooler
❑ For engine oil
5 - Coolant pipe
❑ Bolted to underside of
intake manifold.
6 - Alternator
7 - Front coolant pipe
8 - Upper coolant hose
9 - Radiator/cooler
10 - Lower coolant hose AG. Volkswagen AG d
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12 - Thermostat hor eo
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❑ Removing and instal‐
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ling, checking
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⇒ page 150
an
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13 - Cylinder block
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2.2 Assembly overview - cooling system,

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Coolant hose schematic diagram ⇒ page 142 rig ht
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142 Rep. gr.19 - Cooling

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

1 - To top of expansion tank

2 - To connection on cylinder
head.
3 - Electric coolant pump
4 - From heat exchanger
5 - To heat exchanger
6 - To top of radiator
7 - Front coolant pipe
8 - 8 Nm
9 - From bottom of radiator.
10 - Radiator outlet coolant
temperature sender - G83-
❑ Before removing, re‐
lease pressure in cool‐
ing system if necessary.
11 - To top of expansion tank AG. Volkswagen AG d
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2.3 Assembly overview - cooling system,

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2. Cooling system (engine code CMTA) 143

 Touareg 2010 ➤ , Touareg 2015 ➤
. Volkswage
6-cylinder direct-injection engine (3.6 l engine, 4V) gen AG 12.2019 n AG doe
- aEdition
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1 - Coolant pipe ris tee
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2 - Coolant pipe

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❑ With thermostat hous‐

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❑ For engine oil
5 - To heat exchanger

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6 - From heat exchanger
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7 - From bottom of radiator.

8 - Front coolant pipe

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9 - Alternator
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144 Rep. gr.19 - Cooling

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

3 Coolant pump and thermostat

Caution

Observe the following during all assembly work, particularly in

the engine compartment due to the restricted space:
♦ Route lines of any kind and cables so that original routing
is restored.
♦ Ensure that there is sufficient clearance to all moving or
hot components.

WARNING

The cooling system is under pressure when the engine is hot!

Danger of scalding by steam and hot coolant.
Cover filler cap on expansion tank with a cloth and open care‐
fully to release pressure.

AG. Volkswagen AG d
agen oes
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3. Coolant pump and thermostat 145

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Touareg 2010 ➤ , aTouareg
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ac
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019
ss

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Note

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♦ Cooling system is pressurized when engine is warm. If nec‐

h re
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essary, release pressure before carrying out repairs.

spec
es, in part or in w

♦ Hose connections are secured with spring-type clips. In case

t to the co
of repair, only use spring-type clips.
♦ Spring-type clip pliers - VAS 6340- are recommended for in‐

rrectness of i
stallation of spring-type clips.
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♦ Space saving hose clip pliers - VAS 6362- are recommended

for installation of space saving hose clips.

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♦ When installing coolant hoses, position them so they are free

of stress and do not come into contact with other components.
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♦ The arrows on the coolant pipes and on the ends of the hoses

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Test for leaks in cooling system using cooling system tester - Cop py
V.A.G 1274- and adapters - V.A.G 1274/8- and - V.A.G 1274/9- .
t. rig
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⇒ “3.1 Assembly overview - coolant pump and thermostat”, page
by lksw
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⇒ “3.2 Removing and installing coolant pump”, page 148 .

⇒ “3.3 Removing and installing coolant circulation pump 2 V178
”, page 149
⇒ “3.4 Removing and installing, checking thermostat”,
page 150
⇒ “3.5 Removing and installing temperature sender for engine
temperature regulation G694 ”, page 151 .

3.1 Assembly overview - coolant pump and

thermostat

Note

♦ Coolant hose schematic diagram ⇒ page 135

♦ Removing and installing temperature sender for engine tem‐
perature regulation - G694- ⇒ page 151 .

146 Rep. gr.19 - Cooling

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

1 - 10 Nm
2 - To connecting piece be‐
tween recirculation pump -
V55- and expansion tank
3 - Union
4 - Seal
❑ Renew
5 - Coolant pipe
6 - From bottom of expansion
tank
7 - 6 Nm
8 - From alternator
9 - Seal
❑ Renew
10 - Radiator outlet coolant -
G62-
❑ Before removing, re‐
lease pressure in cool‐
ing system if necessary.
11 - O-ring
❑ Renew
12 - Retaining clip
❑ Check for firm seating
13 - 10 Nm
14 - Retaining clip
❑ Check for firm seating
15 - To top of radiator agen
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21 - Thermostat
spec
urposes, in part or in wh

❑ Removing and installing, checking ⇒ page 150

t to the co

22 - Coolant pipe
❑ With thermostat housing
rrectne

23 - Coolant pump
s

❑ Check for ease of movement.

s o
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❑ Check spray applied seal of coolant pump

inform

❑ Removing and installing ⇒ page 148

mer

atio
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24 - 8 Nm
o

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25 - Belt pulley
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❑ For coolant pump

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147
Prote AG.
3. Coolant pump and thermostat
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

3.2 Removing and installing coolant pump

AG. Volkswagen AG d
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♦ Torque wrench - V.A.Gris
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♦ Drip tray - V.A.G 1306- or drip tray - VAS 6208-

ss o
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Removing:
AG.

– Remove noise insulation ⇒ General body repairs, exterior;

Rep. gr. 50 ; Assembly overview - noise insulation .
– Drain coolant ⇒ page 154 .
– Remove poly V-belt ⇒ page 34 .

Note

The pulley can remain installed when the coolant pump is re‐
moved.

148 Rep. gr.19 - Cooling

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Remove coolant pump securing bolts through holes in belt

pulley -arrows- and remove coolant pump.
If coolant pump must be renewed:
– Remove coolant pump belt pulley. To do this, counterhold belt
pulley with a drift (commercially available).
Installing:
Installation is carried out in the reverse order. When installing,
note the following:
– Check spray applied seal of coolant pump. If the gasket is
damaged, the coolant pump must be renewed.
– Fit coolant pump.
– Tighten securing bolts for coolant pump. Specified torque: 8
Nm
– Install belt pulley for coolant pump. Specified torque: 20 Nm
– Install poly V-belt ⇒ page 34 .
– Fill with new coolant ⇒ page 158 .

3.3 Removing and installing coolant circula‐

tion pump 2 - V178-
Removing
– Remove throttle valve module - J338- ⇒ page 242 .
– Remove wiper arms ⇒ Electrical system;
wage
Rep.
n AG. Volksgr.
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screen wiper system; Removing
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– Removing plenum chamber ho
ris cover ⇒ General body repairs, nte
e
exterior; Rep. gr. 64 s; aRemoving
ut and installing plenum cham‐ or
ac
ber cover s
ce
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nl

pt
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– Remove centre plenum chamber bulkhead ⇒ General body

an
itte

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repairs, exterior; Rep. gr. 50 ; Plenum chamber bulkhead .

erm

ab
ility
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– Detach electrical connector from pump.

wit
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h re

– Unscrew nut -A- and unscrew bracket for pump -arrows- from
hole

cover.
spec
es, in part or in w

t to the co

– Clamp off and remove coolant hoses from pump.

– Unscrew pump from bracket.
rrectness of i

Installing
l purpos

Installation is carried out in the reverse order. When installing,

note the following:
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Prote AG.

3. Coolant pump and thermostat 149

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Check coolant level in expansion tank. Replenish if necessary.

– Check coolant for air bubbles ⇒ page 161

3.4 Removing and installing, checking ther‐

mostat
Special tools and workshop equipment required
♦ Hose clamp pliers - VAS 6340-

AG. Volkswagen AG d
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Removing: rise
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– Remove noise insulation ⇒ s aGeneral body repairs, exterior;
u ra
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Rep. gr. 50 ; Noise insulation . s
ce
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pt

– Drain coolant ⇒ page 154 .

an
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– Remove coolant hoses -1- and -2- from intake manifold.

ility
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wit
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t to the co
rrectness o
cial p

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150 Rep. gr.19 - Cooling

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Unscrew bolts -arrows- and remove coolant connection with

coolant hose.
– Remove thermostat from coolant pipe.

Installing:

Note
olkswagen AG
en AG. V
There should be a metal sleeve -arrow- in the coolant
Vol
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– Clean sealing surface for O-ring. ss
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– Insert thermostat into coolant pipe.

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• Installation position: the edges on thermostat and on housing

h re
must align -arrows-.
hole

spec
es, in part or in w

– Moisten new seal with coolant and fit on coolant connection.

t to the co
– Fit coolant connection with seal and tighten bolts alternately
and diagonally.

rrectness of i
Specified torque: 5 Nm.
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– Secure coolant hoses to intake manifold.

– Add coolant ⇒ page 158 .
nf
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m

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gr. 50 ; Noise insulation .

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Checking:
thi
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3.5 Removing and installing temperature
AG.

sender for engine temperature regula‐

tion - G694-

Note

The temperature sender for engine temperature regulation -

G694- is located between intake manifold and alternator in cylin‐
der head.

Special tools and workshop equipment required

♦ Insert tool - T10058-

3. Coolant pump and thermostat 151

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

♦ M8x50 bolt
Removing:
– Press tensioning pulley in -direction of arrow- using a suitable
screwdriver. AG. Volkswagen n AG do
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– In the non-tensioned position,
Vol screw a M8×50 bolt into the
not
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– Remove tensioning pulley for poly V-belt -arrows-.

t to the co
– Disconnect connector of temperature sender - G694- and
move wire clear.

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n

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– Pull temperature sender - G694- out of cylinder head and re‐
p by
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agen

Caution

The O-ring and support washer can remain in cylinder head.

Check whether the temperature sender for engine temperature
regulation - G694- is »complete«.

152 Rep. gr.19 - Cooling

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– There must be the following components on the temperature

sender - G694- .
1- Support washer
2- O-ring

Note

If the O-ring and support washer have been left in the cylinder
head, they must be pulled out with a wire. To do this, obtain a wire
which is slightly crooked at the end and bend it ∅ approx. 1.5 mm.

Installing:
– Moisten O-ring with coolant additive.
– Place temperature sender - G694- in its installation position
and use a suitable tool to press iteninto cylinder
AG. Volkswagenhead.
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ss for temperature sender - G694- : 5 Nm.
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Prote AG.

3. Coolant pump and thermostat 153

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

4 Coolant

WARNING

The cooling system is under pressure when the engine is hot!

Danger of scalding by steam and hot coolant.
Cover filler cap on expansion tank with a cloth and open care‐
fully to release pressure.

⇒ “4.1 Draining coolant”, page 154 .

⇒ “4.2 Draining cooling system (vehicles with one heat exchang‐
er)”, page 155 .
⇒ “4.3 Draining cooling system (vehicles with two heat exchang‐
ers)”, page 156 .
⇒ “4.4 Filling with coolant”, page 158 .
⇒ “4.5 Checking filling quality”, page 161 .
⇒ “4.6 Checking cooling system for leaks”, page 162 .

4.1 Draining coolant

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moved/installed, it is absolutely necessary to drain the cooling
ce
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system ⇒ page 155 . Otherwise, hidden air bubbles can result

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in incorrect filling. This results in temperature problems in the

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cooling system and heating circuit.

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spec

Rep. gr. 50 ; Assembly overview - noise insulation .

es, in part or in w

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– Place drip tray - VAS 6208- beneath engine.

rrectness of i

WARNING
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The cooling system is under pressure when the engine is hot!

Danger of scalding by steam and hot coolant.
nform
ercia

Cover filler cap on expansion tank with a cloth and open care‐
m

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om

fully to release pressure.

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do
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– Open filler cap on coolant expansion tank.

p

cum
for

en
ng

t.
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Cop py
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pyri by
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by
cted agen
Prote AG.

154 Rep. gr.19 - Cooling

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Pull off plug-in connector -arrow- on lower right of cooler.

AG. Volkswagen AG d
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spec
urposes, in part or in wh

4.2 Draining cooling system (vehicles with

t to the co
one heat exchanger)

rrectne
Note

ss o
Draining cooling system (vehicles with two heat exchangers)
cial p

f in
⇒ page 156

form
mer

atio
m

Special tools and workshop equipment required

o

n
c

i
or

n thi
♦ Spring-type clip pliers - VAS 6499-
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

♦ Drip tray for workshop hoist - VAS 6208-

♦ Hose extension ∅ 20 mm
♦ Compressed air gun
– Drain coolant ⇒ page 154 .
– Close coolant expansion tank.
– Remove front left wheel ⇒ Rep. gr. 44 .
– Remove front left wheel housing liner ⇒ Rep. gr. 66 .

4. Coolant 155
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Drain off engine coolant pipes:

– Open clamps and pull off coolant hoses -A- and -B-.

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– Extend the line -B- with a suitable hose -2- so that it ends in itte

y li
drip tray for workshop hoist - VAS 6208- .
erm

ab
ility
ot p

– Apply maximum air pressure of 1 bar in line -A- by means of

wit
is n

pneumatic cartridge gun -1- until circuit is completely drained.

h re
ole,

spec
Drain off heating coolant pipes:
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
– Extend the line -A- with a suitable hose -1- so that it ends in
mer

drip tray for workshop hoist - VAS 6208- .

atio
om

n
c

– Apply maximum air pressure of 1 bar in line -B- by means of

i
or

n thi
pneumatic cartridge gun -2- until circuit is completely drained.
te

sd
iva

o
pr

c
– Re-attach coolant hoses and secure with clips.

um
r
fo

en
ng

t.
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Cop py
t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.

4.3 Draining cooling system (vehicles with

two heat exchangers)
Special tools and workshop equipment required
♦ Spring-type clip pliers - VAS 6499-

156 Rep. gr.19 - Cooling

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

♦ Drip tray for workshop hoist - VAS 6208-

AG. Volkswagen AG d
agen oes
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h re
♦ Hose extension ∅ 20 mm
ole,

spec
urposes, in part or in wh

♦ 2 x dummy plugs ∅ 20 mm

t to the co
♦ Compressed air gun
– Drain coolant ⇒ page 154 .

rrectne
– Remove front left wheel ⇒ Rep. gr. 44 .

s
– Remove front left wheel housing liner ⇒ Rep. gr. 66 .

s o
cial p

f in
– Open clips -A ... D- and pull off coolant hoses.

form
mer

– Extend the line -C- with a suitable hose -1- so that it ends in

atio
m

drip tray for workshop hoist - VAS 6208- .

o

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Apply maximum air pressure of 1 bar in line -D- by means of

pneumatic cartridge gun-2- until circuit is completely drained.

– Fit dummy plugs -3- as shown and extend line -B- with a suit‐
able hose -1- so that it ends in drip tray for workshop hoist -
VAS 6208- .
– Apply maximum air pressure of 1 bar in line -A- by means of
pneumatic cartridge gun -2- until circuit is completely drained.
– Re-attach coolant hoses and secure with clips.

4. Coolant 157
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

4.4 Filling with coolant

Caution

If large components (e.g. engine, radiator etc.) are to be re‐

moved/installed, it is absolutely necessary to drain the cooling
system ⇒ page 155 . Otherwise, hidden air bubbles can result
in incorrect filling. This results in temperature problems in the
cooling system and heating circuit.

Special tools and workshop equipment required

♦ Coolant system charge unit - VAS 6096-

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ab
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wit
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♦ Adapter for cooling system tester - V.A.G 1274/8-

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
e

♦ Refractometer - T10007 A-
t

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caution

Use only distilled water for mixing coolant additives. The use
of distilled water ensures optimum protection against corro‐
sion.

158 Rep. gr.19 - Cooling

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Note

♦ The water used for mixing has a major influence on the effec‐
tiveness of the coolant. Because the water quality differs from
country to country and even from region to region, the quality
of the water to be used in the cooling system has been speci‐
fied by Volkswagen. Distilled water fulfils all requirements.
Therefore, only ever use distilled water when mixing coolant
for topping up or renewing 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.
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐
rosion damage as well as scaling. Such additives also raise
the boiling point of the coolant. For this reason, the cooling
system must be filled all-year-round with coolant additives.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ The refractometer - T10007A- or refractometer - T10007B-
must be used to determine the current anti-freeze value.
♦ Scale -1- of the refractometer is calibrated for the coolant ad‐
ditives G12++ and G12evo.
♦ Scale -2- of the refractometer is calibrated for the coolant ad‐
ditive G13.
♦ If it is not possible to ensure that the same type of coolant
additive is filled: always determine anti-freeze protection using
the scale for G13.
♦ Frost protection must be guaranteed down to -25°C as a min‐
imum and, in countries with arctic conditions, swa
gen down
AG. Volkto approx.does
swagen AG
-36°C. Increasing the frost protection y V is permissible only if cli‐
o lk not
gu
matic conditions require stronger risedfrost
b
protection. It may, how‐ ara
nte
ever, be increased only to autmaximum of -48°C. Otherwise,
ho eo
ra
the cooling effect will be impaired.
ss a c
ce
e

♦ Do not reduce the coolant concentration by adding water even

nl

pt
du

an

in warmer seasons and in warmer countries. Frost protection

itte

y li

must be guaranteed down to at least -25°C.

erm

ab
ility
ot p

♦ The temperature reading on the refractometer corresponds to

wit
, is n

the »ice flocculation point«. Flakes of ice may start forming in

h re
hole

the coolant below this temperature.

spec
es, in part or in w

♦ Never reuse old coolant.

t to the co

♦ Use only a water/coolant additive mixture as a slip agent for

coolant hoses.
rrectness of i
l purpos

– Fill coolant expansion tank of -VAS 6096- with at least 15 litres

of pre-mixed coolant in correct mixture ratio:
nform
ercia

• Coolant additive (40 %) and distilled water (60 %) for frost

protection to -25 °C
m

at
om

io

• Coolant additive (50%) and distilled water (50%) for frost pro‐
n
c

in t
r

tection to -36 °C
o

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
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Prote
159
AG.
4. Coolant
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Screw adapter for cooling system tester - V.A.G 1274/8- onto

coolant expansion tank.
– Attach cooling system charge unit - VAS 6096- to adapter -
V.A.G 1274/8- .
AG. Volkswagen AG d
– Close valves -A- and -B- (turn lever transverse to direction
ksw
agen of oes
not
flow to do this). y Vol gu
db e
ara
ris nte
– Feed vent hose -1- into a small container u-2-.
tho eo
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a c
ss

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le
un

pt
Note

an
d
itte

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erm

ab
Exhaust air takes a slight quantity of coolant along with it; this

ility
ot p

should be collected.

wit
is n

h re
ole,

spec
– Connect hose -3- to compressed air.
urposes, in part or in wh

t to the co
• Pressure: 6 to 10 bar.

rrectne
– Open valve -B-; turn lever in direction of flow to do this.

s
• A vacuum of at least 0.7 bar must be generated.

s o
cial p

f in
– Also briefly open valve -A- (turn lever in direction of flow to do

form
mer

this) so that hose on -VAS 6096- coolant reservoir fills with

atio
coolant.
om

n
c

i
or

n
– Close valve -A- again.

thi
te

sd
va

– Leave valve -B- open for a further 2 minutes.

i

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pr

cum
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en
• The suction-jet pump still generates a vacuum in the cooling
ng

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system. t. Cop py
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– Close valve -B-.
agen
Prote AG.

– Pull off compressed air hose.

– Observe pressure gauge. Vacuum must drop to min. 0.4 bar.
If vacuum drops further, cooling system must be checked for
leaks.

Note

♦ If vacuum drops, but stabilises at about 0.4 bar, the cooling

system is leak tight.
♦ The subsequent filling must be performed »slowly«.

– Open valve -A- slowly.

• Vacuum in cooling system causes coolant to be extracted from
-VAS 6096- coolant reservoir and coolant system to be filled.
– Remove cooling system charge unit - VAS 6096- from adapter
-V.A.G 1274/8- on coolant expansion tank.

160 Rep. gr.19 - Cooling

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Check coolant level in expansion tank. Top up or extract as

necessary.
– Check coolant for air bubbles ⇒ page 161

4.5 Checking filling quality

Note

It is necessary to make sure that there is no air in the cooling

system.

Special tools and workshop equipment required

♦ Cooling system tester - V.A.G 1274 B-

AG. Volkswagen AG d
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♦ Adapter for cooling system tester - V.A.G 1274/8-
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio

– Open filler cap on expansion tank.

om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
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fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4. Coolant 161
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Fit cooling system tester - V.A.G 1274 B- with adapter -

V.A.G 1274/8- to coolant expansion tank.
– Build up pressure of approx. 1.0 bar using hand pump of cool‐
ing system tester.
– Observe coolant level in expansion tank.

Caution

If there are no leaks in the cooling system, it is only permissible

for the coolant level to fall by a maximum of 25 mm. A consid‐
erably larger drop in the coolant level or evaporation of the
coolant from the expansion tank suggests that there is an air
bubble in the cooling system.

Coolant level OK:

– Perform road test until operating temperature of engine is
reached.
– Check coolant level again.
Coolant level drops considerably:
– Drain cooling system ⇒ page 155 .
– Repeat cooling system filling process ⇒ page 158
– Check coolant for air bubbles ⇒ page 161

AG. Volkswagen AG d
4.6 Checking cooling system for leaks Volksw
agen oes
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d
Special tools and workshop equipment required orise nte
eo
th
u ra
♦ Cooling system tester - V.A.G 1274 B- ss a c

ce
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un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

♦ Adapter for cooling system tester - V.A.G 1274/8-

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

162 Rep. gr.19 - Cooling

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

♦ Adapter for cooling system tester - V.A.G 1274/9-

Procedure:
• Engine at operating temperature.

WARNING

The cooling system is under pressure when the engine is hot!

Danger of scalding by steam and hot coolant.
Cover filler cap on expansion tank with a cloth and open care‐
fully to release pressure.

– Open filler cap on expansion tank.

– Fit cooling system tester - V.A.G 1274 B- with adapter -
V.A.G 1274/8- to coolant expansionatank.
gen AG
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do w es n
olks o
– Build up pressure of approx.d b1.0
y V bar using hand pump of cool‐ t gua
ran
ing system tester. or
ise
tee
h
ut or
– If this pressure is notss amaintained, locate and rectify leaks. ac
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia

Check pressure relief valve in cap.

m

at

– Fit cooling system tester - V.A.G 1274 B- with adapter -

om

ion

V.A.G 1274/9- onto coolant filler cap.

c

in t
or

his
te

– Build up pressure using hand pump of cooling system tester.

a

do
priv

cum
or

• The pressure relief valve must open at a pressure of 1.4 to

f

en
ng

1.6 bar.
t.
yi Co
Cop py
t.
– Renew filler cap, if pressure relief valve does not open as de‐
rig
gh ht
yri by
scribed. cop Vo
by lksw
cted agen
Prote AG.

4. Coolant 163
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

5 Radiator and radiator fans

⇒ “5.1 Assembly overview - radiator and radiator fan”,
page 164
⇒ “5.2 Removing and installing radiator module”, page 165
⇒ “5.3 Removing and installing radiator cowl”, page 170
⇒ “5.4 Dismantling cooler module”, page 171

WARNING

Danger of injury; the radiator fans can run at any time.

♦ Disconnect electrical connectors before starting work in
the area of the radiator cowl.

AG. Volkswagen AG d
agen oes
5.1 Assembly overview - radiator and radiator fan d byV
olksw not
gu
ara
ise nte
or eo
h
aut ra
1 - Cooler module ss c

ce
e

❑ With condenser and

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an
ATF cooler
itte

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erm

ab
2 - Radiator cowl

ility
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❑ Removing and installing

wit
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h re
⇒ page 170
hole

spec
3 - Radiator fan - V7-
es, in part or in w

t to the co
❑ Remove together with
radiator cowl
4 - Rubber mounting rrectness of i
❑ For radiator mounting
l purpos

5 - Lower radiator mounting

nf
ercia

6 - Bolts
orm
m

❑ 25 Nm
atio
om

n in
c

7 - Upper radiator mounting

or

thi
te

sd
a

8 - Rubber mounting
iv

o
r
rp

cu

❑ For radiator mounting

o

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f

en
ng

t.
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9 - Bolt Cop py
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❑ 5 Nm
rig ht
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by lksw
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10 - Locking pin
agen
Prote AG.

164 Rep. gr.19 - Cooling

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au
6-cylinder
ss direct-injection engine (3.6 l engine, 4V) - Edition
ac
12.2019

ce
le
un

pt
Connecting coolant hose with plug-in connector

an
d
itte

y li
erm

ab
– Remove old O-ring -2- in coolant hose -3-.

ility
ot p

wit
– Moisten new O-ring with coolant and insert into coolant hose.

is n

h re
ole,
– Push coolant hose into connection -1- until it audibly engages.

spec
urposes, in part or in wh
– Press again on coolant hose and check plug-in connector is

t to the co
engaged correctly by pulling hose back.

rrectness o
cial p

f inform
5.2 Removing and installing radiator module
mer

atio
m

Special tools and workshop equipment required

o

n
c

i
or

n thi
e

♦ Used oil collector and extractor - VAS 6622-

t

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Engine plug set - VAS 6122-

♦ Drip tray for workshop hoist - VAS 6208-

5. Radiator and radiator fans 165

 n AG. Volkswagen AG do
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Touareg 2010 ➤ , Touareg 2015 ➤ auth or
ac
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019
ss

ce
le
un

pt
an
d
♦ Spring-type clip pliers - VAS 6362-

itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer
♦ Hose clamps to 25 mm - 3094-

atio
om

Removing:

n
c

i
or

n thi
te

sd
iva

o
pr

c
Note

um
r
fo

en
ng

t.
yi Co
♦ The radiator module consists of a radiator for coolant, a cooler Cop py
t. rig
for power steering, a condenser and a gearbox oil cooler. gh ht
pyri by
Vo
co lksw
by
♦ Even when correctly installed, radiator and condenser may Prote
cted AG.
agen
show slight marks on plates. This does not mean that these
components have been damaged. Minor indentations such as
these are not a reason to renew either the radiator or con‐
denser.

– Remove radiator cowl ⇒ page 170 .

– Extract refrigerant from air conditioning system ⇒ Heating, air
conditioning system; Rep. gr. 87 .
– Drain coolant ⇒ page 154 .
– Position used oil collection and extraction unit - VAS 6622-
under separation point on gearbox oil cooler.
– Unscrew bolt -A- and pull connections off gear oil cooler. Catch
oil which runs out.
– Seal gear oil cooler and pipes with plugs.

– Unscrew refrigerant lines -arrow- from radiator module.

– Seal condenser and pipes with plugs.

166 Rep. gr.19 - Cooling

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Disconnect coolant hose at bottom of radiator (pull out retain‐

ing clip).
– Clamp off hoses for power-assisted steering and pull off.

– Disconnect upper coolant hose from radiator; to do this, lift

retaining clip -1-.

n AG. Volkswagen AG do
swage es n
– Remove radiator by Vgrille -1- ⇒ Rep. gr. 66 .
olk ot g
ua
d ran
ir se
– Remove number
tho plate bracket -2- and centre air grille t-3-
ee ⇒
or
Rep. gr.s au63 . ac
s
ce
e
nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

– Lift up air guide on both sides of the air grille opening -arrow-
rrectness of i

and unscrew the bolts -A- behind it in each case.

l purpos

– Pull the two radiator mountings sideways out of the radiator

module over the longitudinal members.
nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

5. Radiator and radiator fans 167

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection
AG. Vengine
olkswage(3.6
n A l engine, 4V) - Edition 12.2019
n G do
wage es n
Volks ot g
– Reach in through ed the lowest
by air grill to unscrew bolts ua -arrow-
ran
(3 bolts) ofhair
oris guide. tee
t or
au ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
– Unscrew bolt -arrow- next to headlights on left and right.
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
o Vo
– Push radiator module in direction of engine and release clips by c lksw
cted agen
-arrows- of air guide on top of radiator and remove. Prote AG.

– Release locking pins -B- of both upper radiator mountings

-A- by pressing in direction of -arrow- and pulling out upwards.
– Remove the two radiator mountings at top -A-.
– Take radiator module out upwards.
Installing:
• Specified torques ⇒ page 164 .
– Install radiator module from above.
– Fit radiator mountings on top at front end and bolt them on.

168 Rep. gr.19 - Cooling

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Insert radiator module into the radiator mountings at top -A-

and push in locking bolt -B-.

– Insert lower side radiator mounting into radiator module and

tighten.
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– Press in clips -arrows- for upper air duct on radiator and lock.
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5. Radiator and radiator fans 169

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Fit radiator grille -1- ⇒ Rep. gr. 66 .

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– Install number plate carrier -2- and centre air intake grille -3- ksw
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⇒ Rep. gr. 63 . yV
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ut
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the series equipment ⇒ ETKA (electronic parts catalogue) .

h re
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spec
♦ If radiator has been renewed, change the entire coolant.
urposes, in part or in wh

t to the co
– Connect coolant hoses with plug-in connector ⇒ page 165 .
– Install ATF lines ⇒ Rep. gr. 37 .

rrectne
– Drain cooling system completely before filling it ⇒ page 155 .

ss
– Add coolant ⇒ page 158 .

o
cial p

f in
– Check ATF level ⇒ Rep. gr. 37

form
mer

atio
– Install noise insulation ⇒ General body repairs, exterior; Rep.
om

gr. 50 ; Assembly overview - noise insulation .

n
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5.3 Removing and installing radiator cowl

i

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Removing:
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– Unscrew securing bolts -1- for coolant pipes from radiator yri
gh by
ht
cowl. Pull off connectors -arrows- and unclip cable.
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Prote AG.

– Unscrew coolant pipe from radiator cowl -arrows-.

170 Rep. gr.19 - Cooling

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Press in clips -arrows- on both sides of cowl and take cowl out
upwards.
Installing:
Install in reverse order of removal.

5.4 Dismantling cooler module

Note

The radiator module consists of a radiator for coolant, a condens‐

er, a cooler for power-assisted
agen
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ss
a module removed ⇒ page 165 . ac
ce
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– Unscrew securing bolts -1- and -2-.

nl

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es, in part or in w

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– Turn radiator module over. Press locking mechanism -1- and

nf
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swing out gear oil cooler.

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5. Radiator and radiator fans 171

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Unscrew bolts -arrows- and remove bracket -1- and then

swing out power-assisted steering oil cooler.

– Remove clamps -A-, lift condenser a little and remove from

radiator in direction of arrow.

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172 Rep. gr.19 - Cooling

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

20 – Fuel supply system

1 Safety precautions
⇒ “1.1 Safety regulations for working on fuel supply”, page 173

1.1 Safety regulations for working on fuel

supply

Caution n AG. Volkswagen AG do

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For safety reasons, when the battery is not disconnected, d b the ua
ran
ir se
fuse for the fuel pump must be removed before topening
ho the tee
or
fuel system, otherwise the fuel pump could be activated
au by the ac
ss
driver door contact switch. Fuse assignment ⇒ Current flow

ce
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nl
diagrams, Electrical fault finding and Fitting locations

pt
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itte

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Observe the following points during all installation work, in par‐
erm

ab
ticular in the engine compartment, due to the space limitations:

ility
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wit
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♦ Route all the various lines, e.g. for fuel, hydraulics, acti‐

h re
vated charcoal filter system, coolant and refrigerant, brake
hole

spec
fluid and vacuum and electrical wiring in their original po‐
es, in part or in w

sitions.

t to the co
♦ To avoid damage to lines, ensure sufficient clearance to
all moving or hot components.

rrectness of i
l purpos

When removing and installing fuel gauge sender or fuel pump

(fuel delivery unit) from a full or partly full fuel tank, observe the

nform
ercia

following:
m

at
♦ Before starting work, the extraction hose of a switched-on ex‐
om

io
haust gas extraction system must be laid near to the assembly

n
c

in t
r

opening of the fuel tank. The escaping fuel fumes can only be
o

his
te

extracted this way. If no exhaust gas extraction system is

a

do
riv

available, a radial fan with a displacement greater than

p

cum
or

15 m3/h can be used providing that motor is not in air flow.

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♦ Prevent skin contact with fuel! Wear fuel-resistant gloves! t. C rig
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♦ If the engine is to be turned at starter speed without starting:
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Pull off connectors for output stages.
agen
Prote AG.

1. Safety precautions 173

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

2 Parts of fuel supply system

Caution
G. Volkswage
Observe the following during all assembly wawork,
gen A particularly in oes n
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the engine compartment due to the Volks
restricted space: ot g
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♦ Route lines of any kind and ho cables so that original routing
r tee
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is restored. ss
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ce
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♦ Ensure that there is sufficient clearance to all moving or

un

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an
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hot components.
itte

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♦ Hose connections are secured with either spring-type or

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♦ Fuel hoses on engine must be secured with spring-type clips co Vo
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only. The use of crimp-type or screw-type clips is not permis‐
cted agen
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sible.
♦ Spring-type clip pliers - VAS 6340- or spring-type clip pliers -
VAS 5024 A- are recommended for installation of spring-type
clips.
♦ Space saving hose clip pliers - VAS 6362- are recommended
for installation of space saving hose clips.

⇒ “1 Safety precautions”, page 173 .

⇒ “2.1 Rules for cleanliness”, page 175 .
⇒ “2.2 Assembly overview - fuel tank with attachments”,
page 175 .
⇒ “2.3 Assembly overview - fuel delivery unit, fuel gauge sender
and suction jet pumps”, page 177 .
⇒ “2.4 Removing, installing and renewing fuel filter”, page 179 .
⇒ “2.5 Emptying fuel tank”, page 181 .
⇒ “2.6 Removing and installing fuel gauge sender 2 G169 and
suction-jet pump”, page 184 .
⇒ “2.7 Removing and installing fuel delivery unit and fuel gauge
sender G ”, page 188 .
⇒ “2.8 Removing and installing fuel tank with attached compo‐
nents”, page 191 .

174 Rep. gr.20 - Fuel supply system

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

2.1 Rules for cleanliness

When working on the fuel supply/injection system, pay careful at‐
tention to the following “5 rules”:
♦ Thoroughly clean all joints and surrounding areas before dis‐
mantling.
♦ Place removed parts on a clean surface and cover them over.
Use lint-free cloths only.
♦ Carefully cover opened components or seal them if repairs
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♦ Install only clean
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b ara
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tee
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tho before installing. Do not use parts othat
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have beenss a kept unpackaged (for example in toolboxes). c

ce
le

♦ If system is open, do not work with compressed air. Do not

un

pt
an
d

move the vehicle.

itte

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2.2 Assembly overview - fuel tank with at‐
pe

ility
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tachments

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spec
Assembly overview - fuel delivery unit, fuel gauge sender and
es, in part or in w

suction jet pumps ⇒ page 177

t to the co
Caution

rrectness of i
Observe the following for all removal and installation work on
l purpos

fuel tank:
♦ Route all the various lines, e.g. for fuel, hydraulics, acti‐
nform
ercia

vated charcoal filter system, coolant and refrigerant, brake

m

fluid and vacuum and electrical wiring in their original po‐

a
com

tio

sitions.
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♦ Ensure earth cable is correctly installed and tight between

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fuel filler neck and body to prevent build-up of an electro‐

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static charge.
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♦ Ensure that there is sufficient clearance to all moving or
Cop py
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2. Parts of fuel supply system 175

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

1 - Fuel tank filler neck

❑ With connection for
earth cable to body.
❑ Ensure firm seating
❑ Screw onto body to 10
Nm.
2 - Breather line
❑ From fuel tank
❑ To activated charcoal fil‐
ter
3 - Breather line
❑ From activated charcoal
filter system solenoid
valve 1 - N80-
❑ To activated charcoal fil‐
ter
4 - Fuel pump control unit -
J538-
5 - Fuel
❑ When removing, sup‐
port using engine and
gearbox jack - n AG. Volkswagen AG do
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V.A.G 1383 A- . byV
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❑ Removing and installing ir se tee
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⇒ page 191 aut or
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❑ Drain fuel tank using

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fuel extractor -

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VAS 5190- ⇒ page 181

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6 - Locking ring 145 Nm

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❑ Remove and install us‐

h re
ing wrench - T10202- .
hole

spec
❑ Ensure firm seating
es, in part or in w

t to the co
7 - Fuel filter
❑ Installation position of flange ⇒ page 177

rrectness of i
❑ Always renew flange seal.
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❑ Fuel filter: Renew ⇒ page 179

8 - Heat shield
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9 - Securing strap
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❑ Observe installation position

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❑ Ensure firm seating

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10 - 33 Nm
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11 - Protective cover
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❑ For bottom of fuel tank C py
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12 - Line coupling
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❑ Release by pressing button on line coupling
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13 - Fuel delivery unit

❑ Individual flange parts, right side ⇒ page 177
❑ Installation position of flange ⇒ page 177
❑ Removing and installing ⇒ page 188

176 Rep. gr.20 - Fuel supply system

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Individual flange parts, right side

1 - Earth cable
2 - Connector for fuel pump
3 - Connector for fuel gauge sender - G-
4 - From fuel filter.
5 - Pressure limiting valve

Installation position of flange on fuel tank

– Insert flange in direction of travel -arrow-.
Lug -2- must stay between tabs -1- and -3- of fuel tank.

2.3 Assembly overview - fuel delivery unit, fuel gauge sender and suction jet
pumps

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ility
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es, in part or in w

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c

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or

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for

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Cop py
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177
op Vo
by c lksw
Prote
cted AG. 2. Parts of fuel supply system
agen
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

1 - Breather line
❑ blue
❑ Ensure firm seating
2 - Fuel supply line
❑ black
❑ Ensure firm seating
3 - Connector
❑ For fuel gauge sender 2
- G169-
4 - Locking ring 145 Nm
❑ Remove and install us‐
ing wrench - T10202- .
❑ Ensure firm seating
5 - Seal
❑ Renew
6 - Fuel filter
❑ Left side
❑ Fuel filter: Renew
⇒ page 179
7 - Fuel gauge sender 2 -
G169-
❑ Left side
❑ Flat, square float
❑ Clipped on bottom of
tank into retaining ring
⇒ Item 8 (page 178)
❑ Removing and installing
⇒ page 184
8 - Retaining ring wage
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❑ Welded to fuel tank d byV ua
ran
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❑ For fuel gauge sender 2 - G169- and retainer tfor
h suction jet pump
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9 - Suction-jet pump ss
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❑ Clipped into retaining ring ⇒ Item 8 (page 178) .

pt
du

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itte

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❑ Removing and installing ⇒ page 184

erm

ab
ility
ot p

10 - Suction-jet pump
wit
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❑ Removing and installing ⇒ page 184

h re
hole

spec

11 - Retaining ring
es, in part or in w

t to the co

❑ Welded to fuel tank

❑ For fuel gauge sender - G-
rrectness of i

12 - Fuel gauge sender - G-

❑ Right side
l purpos

❑ Round, ball float

❑ Clipped on bottom of tank into retaining ring ⇒ Item 11 (page 178)
nf
ercia

orm

❑ Removing and installing ⇒ page 188

m

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om

13 - Fuel delivery unit

n in
or c

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❑ Removing and installing ⇒ page 188

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14 - Flange
o

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❑ Right side
t.
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❑ With pressure limiting valve
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178
Prote AG.
Rep. gr.20 - Fuel supply system
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019
❑ For fuel delivery unit.
❑ For fuel gauge sender - G-
❑ Always renew flange seal.
❑ Individual parts ⇒ page 177
❑ Note installation position on fuel tank ⇒ page 177
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15 - Connector olks
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❑ For fuel pump.
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16 - Connectorau ra
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❑ For fuel gauge sender - G-

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2.4 Removing, installing and renewing fuel
ot p

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is n

filter

h re
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urposes, in part or in wh

Special tools and workshop equipment required

t to the co
♦ Special wrench - T10202-

rrectness o
cial p

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mer

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om

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c

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♦ Torque wrench - V.A.G 1332-
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
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Note

The fuel filter is located in the left opening of fuel tank, as seen
from direction of travel.

Removing:
– Note safety precautions before starting installation work
⇒ page 173 .
– Observe rules for cleanliness ⇒ page 175 .
– Remove rear bench seat ⇒ General body repairs, interior;
Rep. gr. 72 ; Removing and installing bench seat .

2. Parts of fuel supply system 179

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Fold right-hand carpet cut-out to the side.

– Remove securing nuts -1 to 4- of flange cover.
– Remove flange cover.

– Release connector -arrow- from flange of fuel filter.

– Use special socket - T10202- to unscrew locking ring from

flange.

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agen oes
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d by ara
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pt
du

an

– Slightly lift flange of fuel filter and disconnect connector -1-

itte

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from fuel gauge sender.

erm

ab
ility
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wit
, is n

h re

Note
hole

spec
es, in part or in w

♦ Draw off fuel, if necessary ⇒ page 181

t to the co

♦ Earth wire -2- can remain connected.

rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

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cum
for

en
ng

t.
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Cop py
t. rig
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Vo
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cted agen
Prote
180
AG.
Rep. gr.20 - Fuel supply system
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Pull fuel lines -1- and -2- off fuel filter housing.

Note

To do this, press buttons on line couplings.

– Remove fuel filter out of opening in fuel tank.

– Empty fuel filter housing.
Installing:
Installation is carried out in the reverse order. When installing,
note the following:
– Renew flange seal.
– Ensure that connector for fuel gauge sender, earth wire and
fuel lines on fuel filter are properly seated.

– Insert flange of fuel filter in direction of travel -arrow-.

Lug -2- must stay between tabs -1- and -3- of fuel tank.

– Use special socket - T10202- to tighten locking ring to 145 Nm.

n AG. Volkswagen AG do
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ility
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wit
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hole

spec
es, in part or in w

t to the co

2.5 Emptying fuel tank

Special tools and workshop equipment required
rrectness of i

♦ Fuel extractor - VAS 5190-

l purpos

nf
ercia

orm
m

atio
om

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t.
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by
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Prote AG.

2. Parts of fuel supply system 181

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

♦ Special wrench - T10202-

Caution

Risk of damage to the flaps in fuel filler neck by suction hose

of fuel extractor! The fuel tank may only be drained via the
flanges.

Procedure:
– Note safety precautions before starting installation work
⇒ page 173 .
– Observe rules for cleanliness ⇒ page 175 .
– Remove rear bench seat ⇒ General body repairs, interior;
Rep. gr. 72 ; Removing and installing bench seat ..Volkswag
AG en AG
agen does
– Fold right-hand carpet cut-out to the side.
yV
olks
w not
gu
b ara
ed
– Remove securing nuts -1 to 4- of
ho
risflange cover. nte
eo
t
au ra
– Remove flange cover. ss c
ce
e
nl

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itte

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erm

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ility
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es, in part or in w

t to the co
rrectness of i
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nf
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t.
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Cop py
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by
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Prote AG.

182 Rep. gr.20 - Fuel supply system

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Detach breather line -1-.

Note

Release connection by pressing button on line coupling.

WARNING

The fuel line is under pressure.

Fuel poses danger of injury to eyes and skin.
Wear protective goggles and protective clothing to avoid injury
and contact with the skin. Wrap a cloth around the connection
before loosening hose connections. Then reduce pressure by
carefully opening the connection.

– Hold a cleaning cloth on connection of fuel supply line -2- and

pull off hose coupling.

AG. Volkswagen AG d
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ara
ed
Release connection hoby
ris
pressing button on line coupling. nte
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aut ra
ss c
– Disconnect connector -3- from fuel gauge sender and con‐
ce
le
un

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nector -4- for fuel pump.

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d
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pe

– Use special socket - T10202- to unscrew locking ring from

ility
ot

sender flange.
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h re

– Carefully raise the sender flange.

hole

spec
es, in part or in w

– Insert suction hose of fuel extractor - VAS 5190- as far as

t to the co

possible into fuel tank and extract fuel.

– To extract fuel and perform work on left-hand side of fuel tank,
rrectness of i

remove fuel filter ⇒ page 179 .

l purpos

– Then, insert suction hose of fuel extractor - VAS 5190- as far

as possible into fuel tank and extract fuel.
nform
ercia

For further work on inside of fuel tank, sender flanges may remain
removed.
m

a
com

tio

If fuel tank only needs to be drained, install sender flange again.

n in
r
te o

thi

– First renew seals of sender flanges.

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iva

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rp

cum
fo

– Insert flange in direction of travel -arrow-.

en
ng

t.
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op
Lug of flange -2- must stay between tabs -1- and -3- of fuel tank.
C py
ht. rig
rig ht
py by
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by lksw
cted agen
Prote AG.

2. Parts of fuel supply system 183

 Touareg 2010 ➤ , Touareg 2015 ➤
AG. Volkswagen AG d
swagen
6-cylinder direct-injection engine (3.6 loengine,
es n 4V) - Edition 12.2019
olk o
t gu
yV
edb ara
– Use specialhosocket
ris - T10202- to tighten locking ring to 145
nte
e oNm.
ut ra
a c
ss

ce
le

Note
un

pt
an
d
itte

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rm

ab
Ensure that connectors and fuel hose connections are fitted se‐
pe

ility
curely.
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
2.6 Removing and installing fuel gauge
l purpos

sender 2 - G169- and suction-jet pump

nform
ercia

Special tools and workshop equipment required

m

a
♦ Special wrench - T10202-
com

tion in
r
te o

thi
s
iva

do
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rp

cum
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
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by
cted agen
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♦ Torque wrench - V.A.G 1332-

Removing:

Note

Attach cable ties in all the same places when installing.

– Note safety precautions before starting installation work

⇒ page 173 .
– Observe rules for cleanliness ⇒ page 175 .
– Remove rear bench seat ⇒ General body repairs, interior;
Rep. gr. 72 ; Removing and installing bench seat .
– Remove flange with fuel filter on left side of fuel tank
⇒ page 179 .
– Draw off fuel, if necessary ⇒ page 181

184 Rep. gr.20 - Fuel supply system

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Unclip fuel gauge sender 2 - G169- -1- and pull out of fuel tank.

– To do this, press locking lug -1-.

Proceed as follows if the suction-jet pumps are to be removed:

– Fold right-hand carpet cut-out to the side.

– Remove securing nuts -1 to 4- of flange cover.
– Remove flange cover.

AG. Volkswagen AG d
agen oes
olksw not
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or eo
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ility
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wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw

185
cted agen
Prote
2. Parts of fuel supply system
AG.
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Detach breather line -1-.

Note

Release connection by pressing button on line coupling.

WARNING

The fuel line is under pressure.

Fuel poses danger of injury to eyes and skin.
Wear protective goggles and protective clothing to avoid injury
and contact with the skin. Wrap a cloth around the connection
before loosening hose connections. Then reduce pressure by
carefully opening the connection.agen AG. Volkswagen AG do
w es n
olks ot g
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– Hold a cleaning cloththo on connection of fuel supply line -2- and ee or
au
pull off hose coupling. ac
ss

ce
e
nl

pt
du

an
itte

Note

y li
erm

ab
ility
ot p

Release connection by pressing button on line coupling.

wit
, is n

h re
hole

spec
– Disconnect connector -3- from fuel gauge sender and con‐
es, in part or in w

nector -4- for fuel pump. t to the co

– Use special socket - T10202- to unscrew locking ring from

sender flange.
rrectness of i

– Carefully raise the sender flange.

l purpos

– Draw off fuel, if necessary ⇒ page 181

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
.
– Pull connector -1- of fuel pump off flange.
t rig
gh ht
pyri by
Vo
co
– Pull connector -2- for fuel gauge sender off flange.
by lksw
cted agen
Prote AG.
– Remove sender flange.
– To do this, pull out sender flange together with fuel line of fuel
filter out of right opening of fuel tank.

186 Rep. gr.20 - Fuel supply system

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Unclip black supply/filler hose -1- and -2- from fuel delivery unit
housing.
– Detach fuel supply line -3- from suction-jet pumps.

Note

Press in securing ring to release fuel line.

– On the left side of the fuel tank, unclip bracket -2- of suction-
jet pumps -3-.

Note

The rear suction jet pump ⇒ Item 10 (page 178) is not visible in
the illustration.

– To remove suction-jet pump, press locking lug -1-.

Pull suction-jet pumps together with supply/filler hoses and fuel
lines out of left opening of fuel tank.
Installing:
Installation is carried out in the reverse order. When installing,
note the following:
n AG. Volkswagen AG do
– First renew seals of sender flanges.
olks
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rise tee
tho or
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nl

pt
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an

– Insert flange in direction of travel -arrow-.

itte

y li
erm

ab

Lug of flanges -2- must stay between tabs -1- and -3- of fuel tank.
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

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f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
187
AG.
2. Parts of fuel supply system
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Use special socket - T10202- to tighten locking ring to 145 Nm.

Note

Ensure that connectors and fuel hose connections are fitted se‐
curely.

2.7 Removing and installing fuel delivery

unit and fuel gauge sender - G-
Special tools and workshop equipment required
♦ Special wrench - T10202-

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un

pt
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ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

♦ Torque wrench - V.A.G 1332-

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
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cum
fo

en
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♦ Not illustrated:
t.
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Cop py
t. rig
♦ Assembly tool - T10118- opyri
gh by
Vo
ht
c
Procedure:
by lksw
cted agen
Prote AG.

Note

Attach cable ties in all the same places when installing.

– Note safety precautions before starting installation work

⇒ page 173 .
– Observe rules for cleanliness ⇒ page 175 .
– Remove rear bench seat ⇒ General body repairs, interior;
Rep. gr. 72 ; Removing and installing bench seat .

188 Rep. gr.20 - Fuel supply system

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– On left side, remove flange with fuel filter ⇒ page 179 .

– Then, fold right-hand carpet cut-out to the side.
– Remove securing nuts -1 to 4- of flange cover.
– Remove flange cover.

– Detach breather line -1-.

Note
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gen AG does
swa
Release connection
by
Vol by pressing button on line coupling.
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ed ran
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ss WARNING
ce
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nl

pt
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an

The fuel line is under pressure.

itte

y li
erm

ab

Fuel poses danger of injury to eyes and skin.

ility
ot p

wit
, is n

Wear protective goggles and protective clothing to avoid injury

h re

and contact with the skin. Wrap a cloth around the connection
hole

spec

before loosening hose connections. Then reduce pressure by

es, in part or in w

carefully opening the connection.

t to the co

– Hold a cleaning cloth on connection of fuel supply line -2- and

rrectness of i

pull off hose coupling.

l purpos

Note
nf
ercia

orm
m

Release connection by pressing button on line coupling.

atio
om

n in
or c

thi

– Disconnect connector -3- from fuel gauge sender and con‐

te

sd
a

nector -4- for fuel pump.

iv

o
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rp

cu
o

m
f

en
ng

t.
– Use special socket - T10202- to unscrew locking ring from
yi Co
op
sender flange.
C py
t. rig
gh ht
yri by
– Carefully raise the sender flange. cop Vo
by lksw
cted agen
Prote AG.
– Draw off fuel, if necessary ⇒ page 181

2. Parts of fuel supply system 189

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Pull connector -1- of fuel pump off flange.

– Pull connector -2- for fuel gauge sender off flange.
– Remove sender flange.
– To do this, pull out sender flange together with fuel line of fuel
filter out of right opening of fuel tank.

– Unclip black supply/filler hose -1- and -2- from fuel delivery unit
housing.
– Detach fuel supply line -3- for suction-jet pumps.

Note
AG. Volkswagen AG d
Press in securing ring to release fuel line. agen oes
olksw not
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– Pull fuel return line -4- off fuel filter
thor
/ fuel pump. eo
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le
un

pt
Note

an
d
itte

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erm

ab
♦ Press red button on coupling together for this.

ility
ot p

wit
is n

♦ Use assembly tool - T10118- for this.

h re
ole,

spec
urposes, in part or in wh

– Unscrew fuel delivery unit in bottom of fuel tank by turning ap‐

t to the co
prox. 15° to left.
rrectne

Note

The fuel pump housing is filled with fuel. Fuel may run out if hous‐
ss

ing is tipped or canted.

o
cial p

f inform
mer

– Unclip and pull out fuel gauge sender.

atio
om

Installing:
n
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or

n thi
e

Installation is carried out in the reverse order. When installing,

t

sd
iva

note the following:

pr

cum
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fo

en
ng

– First renew seals of sender flanges.

t.
yi Co
Cop py
t. rig
gh ht
– Insert flange in direction of travel -arrow-. yri
p by
co Vo
by lksw
cted
Lug of flange -2- must stay between tabs -1- and -3- of fuel tank.
agen
Prote AG.

190 Rep. gr.20 - Fuel supply system

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Use special socket - T10202- to tighten locking ring to 145 Nm.

Note

Ensure that connectors and fuel hose connections are fitted se‐
curely.

2.8 Removing and installing fuel tank with

attached components

Caution

Observe the following for all removal and installation work on

fuel tank:
♦ Route all the various lines, e.g. for fuel, activated charcoal
filter system and vacuum and electrical wiring in their orig‐
inal positions.
♦ Ensure earth cable is correctly installed and tight between
fuel filler neck and body to prevent build-up of an electro‐
static charge.
♦ Ensure that there is sufficient clearance to all moving or
hot components.

AG. Volkswagen AG d
agen oes
olksw not
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un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen

191
Prote AG.
2. Parts of fuel supply system
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Special tools and workshop

equipment required

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un

pt
an
d
itte

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♦ Fuel extractor - VAS 5190-

ab
ility
ot p

♦ Special wrench - T10202-

wit
is n

h re
ole,

♦ Torque wrench - V.A.G 1331-

spec
urposes, in part or in wh

♦ Torque wrench - V.A.G 1332-

t to the co

♦ Engine and gearbox jack - V.A.G 1383 A-

Conditions
rrectne

• Fuel tank must be empty

s

⇒ “2.5 Emptying fuel tank”, page 181 .

s o
cial p

f i

Removing:
nform
mer

– Note safety precautions before starting installation work

atio
m

⇒ page 173 .
o

n
c

i
or

n thi

– Observe rules for cleanliness ⇒ page 175 .

te

sd
iva

o
r

– Remove rear axle ⇒ Body assembly work, exterior; Rep. gr.

p

cum
r
fo

55 ; Repairing rear axle .

en
ng

t.
yi Co
op
– Open fuel filler flap and unscrew cap. C py
t. rig
gh ht
yri by
– Remove tank flap ⇒ Body assembly work, exterior; Rep. gr. cop Vo
by lksw
55 . cted agen
Prote AG.

– Pull rubber seal of fuel filler neck downwards.

192 Rep. gr.20 - Fuel supply system

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Undo fastening bolts -1- of filler neck and pull off earth wire
-2-.
– Remove rear bench seat ⇒ General body repairs, interior;
Rep. gr. 72 ; Removing and installing bench seat .

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
– Fold right-hand carpet cut-out to the side.

ot

wit
, is n
– Remove securing nuts -1 to 4- of flange cover.

h re
hole

spec
– Remove flange cover.
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tio
– Detach breather line -1-.

n in
r
te o

thi
s
iva

do
r

Note
rp

cum
fo

en
ng

t.
yi Co
Release connection by pressing button on line coupling. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
WARNING Prote AG.

The fuel line is under pressure.

Fuel poses danger of injury to eyes and skin.
Wear protective goggles and protective clothing to avoid injury
and contact with the skin. Wrap a cloth around the connection
before loosening hose connections. Then reduce pressure by
carefully opening the connection.

– Hold a cleaning cloth on connection of fuel supply line -2- and

pull off hose coupling.

Note

Release connection by pressing button on line coupling.

– Disconnect connector -3- from fuel gauge sender and con‐

nector -4- for fuel pump.

2. Parts of fuel supply system 193

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019
AG. Volkswagen AG d
agen oes
– Fold left-hand carpet cut-out to the side.Volksw not
gu
by ara
ed
– Remove securing nuts -1 to 4- ofhflange
oris cover. nte
eo
t
au ra
– Remove flange cover. ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
– Pull connector -arrow- off sender flange.

rrectness of i
– Remove rear right wheel housing liner ⇒ General body re‐
l purpos

pairs, exterior; Rep. gr. 66 ; Removing and installing wheel

housing liner .

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
– Unscrew stone guard -arrows-. py by
co Vo
by lksw
cted agen
Prote AG.

– Unclip fuel tank breather lines attached to longitudinal mem‐

ber.

194 Rep. gr.20 - Fuel supply system

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Remove securing bolt for filler neck -arrow- in wheel housing.

– Pull off breather pipes on activated charcoal filter
⇒ page 207 .
– Now remove securing straps together with covers on right and
left under fuel tank.
G . Volkswage
– Use engine and gearbox jack - V.A.G 1383 A-
ageto
n Asupport fueln AG does n
lksw
tank and then remove securing strapbin
y middle of fuel tank.
Vo ot g
ua d ran
ise
– Carefully lower fuel tank slightly.
ut
ho
r tee
or
sa ac
– Disconnect connector from fuel
s pump control unit - J538-

ce
le
⇒ Item 4 (page 176) .
un

pt
an
d
itte

y li
– Detach breather pipe on pipe coupling ⇒ Item 12 (page 176) .
erm

ab
ility
ot p

wit
is n

Note

h re
ole,

spec
urposes, in part or in wh

Release connection by pressing button on line coupling.

t to the co
– Lower fuel tank.

rrectne
Installing:
Installation is carried out in the reverse order. When installing,

ss
note the following:

o
cial p

f in
♦ Connections for breather and fuel lines must engage audibly

form
mer

when joined.

atio
om

♦ Install breather and fuel hoses free of kinks.

n
c

i
or

n thi
e

♦ When opening always renew flange seal.

t

sd
iva

o
pr

cum
r

♦ Secure fuel hoses with spring-type clips.

fo

en
ng

t.
yi Co
♦ Ensure that connectors and fuel hose connections are fitted Cop py
securely.
t. rig
gh ht
pyri by
Vo
co
♦ Ensure that earth wire on fuel filler neck is secured tight to
by lksw
cted agen
body.
Prote AG.

Note

Before bolting on fuel tank, check that supply and breather lines
are still clipped onto fuel tank.

2. Parts of fuel supply system 195

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

3 Checking fuel pump

⇒ “3.1 Checking fuel pressure”, page 196 .
⇒ “3.2 Checking holding pressure”, page 200 .
Special tools and workshop equipment required
♦ Pressure gauge - VAS 6550-
♦ Hose - VAS 6550/2-
♦ Connecting nipple - VAS 6550/3-1-
♦ Connector cable - VAS 6550/3-2-
♦ Connector cable - VAS 6550/3-3-
♦ Connector cable - VAS 6550/3-4-
♦ Vehicle diagnostic tester
♦ Measuring container
♦ Current flow diagram
AG. Volkswagen AG d
Test conditions: agen oes
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ara
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• The event memory of theoengineris
e control unit contains no event nte
entry relating to the voltage
aut
h supply to the fuel pump. eo
ra
ss c
• Fuel pump control unit - J538- OK.
ce
e
nl

pt
du

• Battery charger connected ⇒ Electrical system; Rep. gr. 27 ; an

itte

Charging battery . y li
erm

ab
ility
ot p

• Fuse for fuel pump OK. Fuse assignment ⇒ Current flow dia‐ wit
, is n

grams, Electrical fault finding and Fitting locations

h re
hole

spec

• Fuel filter OK.

es, in part or in w

t to the co

• Fuel tank filled at least to more than reserve quantity.

• Ignition off
rrectness of i

3.1 Checking fuel pressure

l purpos

– Note safety precautions before starting installation work

⇒ page 173 .
nf
ercia

or

– Observe rules for cleanliness ⇒ page 175 .

m
m

atio
om

n in
or c

WARNING
thi
te

sd
iva

o
r
rp

cu

The fuel line is under pressure.

o

m
f

en
ng

t.
yi
Fuel poses danger of injury to eyes and skin.
Co
Cop py
ht. rig
Wear protective goggles and protective clothing to avoid injury rig ht
py by
and contact with the skin. Wrap a cloth around the connection
co Vo
by lksw
cted
before loosening hose connections. Then reduce pressure by
agen
Prote AG.
carefully opening the connection.

196 Rep. gr.20 - Fuel supply system

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Pull fuel supply hose -arrow- off fuel supply line.

– Connect pressure tester - VAS 6550- with hose - VAS 6550/2-

to connecting nipple - VAS 6550/3-1- and hose - VAS
6550/3-2- as shown.

Note

♦ Secure hoses with supplied clips.

♦ Ensure that hose clips are attached firmly.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

3. Checking fuel pump 197

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Open shut-off taps “A” and “B” of pressure tester - VAS 6550-
and open in flow direction.
– Close shut-off valve “C”.
– Switch on pressure tester - VAS 6550- by pressing On/Off
button.
– Connect the vehicle diagnostic tester .
– Switch on ignition.
– Press one after the other in the display the buttons for Vehicle
self-diagnosis , Engine electronics and Final con-
trol diagnosis .

– Press right arrow button ► on display to Final control di-

agnosis for fuel pump electronics .

The fuel pump must now run slowly up to maximum speed.

– Read pressure shown by pressure tester - VAS 6550- .
• Specification: 5.0 … 7.0 bar
– Switch off ignition.
If reading matches specification:
– Checking holding pressure ⇒ page 200 .
If specification is not obtained
n AG. Volkswagen AG do
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Note d by ua
ran
ir se tee
tho
or
When the pressure tester - VAS 6550- is tossbe
au removed, open the ac
shut-off tap “C” and release remaining pressure. To do this, hold

ce
le
un

the hose of the shut-off tap “C” in a measuring container.

pt
an
d
itte

y li
erm

ab
– Remove pressure tester - VAS 6550- and re-connect the fuel
ility
ot p

supply line.
wit
is n

– Ensure that hose clip is securely fitted. h re

ole,

spec
urposes, in part or in wh

– Remove rear bench seat ⇒ General body repairs, interior;

t to the co

Rep. gr. 72 ; Removing and installing bench seat .

– Fold right-hand carpet section to the side.

rrectne

– Remove securing nuts -1 to 4- of flange cover.

ss

– Remove flange cover.

o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

198 Rep. gr.20 - Fuel supply system

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Pull off fuel supply line -2-.

Note

Release connection by pressing button on hose coupling.

– Connect pressure tester - VAS 6550- to connecting line - VAS

6550/3-4- and connecting line - VAS 6550/3-3- as shown.

AG. Volkswagen AG d
agen oes
olksw not
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– b of pressure tester - VAS 6550- guar
Open shut-off taps “A” andsed“B”y
an
and open in flow direction.
tho
ri tee
or
au ac
– Close shut-off tap “C”.
ss
ce
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un

pt

– Connect the vehicle diagnostic tester .

an
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itte

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rm

– Switch on ignition.
ab
pe

ility
ot

– Press one after the other in the display the buttons for Vehicle
wit
, is n

h re

self-diagnosis , Engine electronics and Final con-

hole

spec

trol diagnosis .
es, in part or in w

t to the co

– Press right arrow button ► on display to Final control di-

agnosis for fuel pump electronics .
rrectness of i

The fuel pump must now run slowly up to maximum speed.

– Read pressure shown by pressure tester - VAS 6550- .
l purpos

• Specification: 5.0 … 7.0 bar

nform
ercia

– Switch off ignition.

m

a
com

If the specifications are now attained:

ion in
r
te o

– Check fuel supply line from fuel tank to engine for possible
thi
s
iva

damage.
do
r
rp

cum
fo

If the specifications are again not attained:

en
ng

t.
yi Co
op
– Check all couplings and fuel lines in fuel tank and fuel delivery C py
t. rig
unit to make sure they are firmly seated and are not leaking.
gh ht
pyri by
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by
If no fault is found: cted agen
Prote AG.

– Renew fuel delivery unit ⇒ page 188 .

3. Checking fuel pump 199

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Note

When the pressure tester - VAS 6550- is to be removed, open the

shut-off tap “C” and release remaining pressure. To do this, hold
the hose of the shut-off tap “C” in a measuring container.

3.2 Checking holding pressure

Check condition
• The pressure tester - VAS 6550- has been connected
⇒ page 196 .
• Fuel pressure: approx. 5.0 bar
Test sequence
– Observe pressure drop on pressure gauge. After 10 minutes,
pressure must not drop below 4.3agbar.
en AG. V
olkswagen AG
do w es n
olks ot g
If pressure drops below 4.3 dbar:
by
V ua
ran
e
ris tee
– Switch on ignition. utho or
ac
a
ss
– Press one after the other in the display the buttons for Vehicle
ce
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nl

pt

self-diagnosis , Engine electronics and Final con-

du

an
itte

trol diagnosis .
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erm

ab
ility
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– Press right arrow button ► on display to Final control di-

wit
, is n

agnosis for fuel pump electronics .

h re
hole

spec

The fuel pump must now run slowly up to maximum speed.

es, in part or in w

t to the co

– Read pressure shown by pressure tester - VAS 6550- .

• Specification: 5.0 … 7.0 bar
rrectness of i

– Switch off ignition and immediately close shut-off tap “B” of

pressure tester. The shut-off tap “B” is then at right angles to
l purpos

direction of flow.
– Observe pressure drop on pressure gauge. After 10 minutes,
nform
ercia

pressure must not drop below 4.3 bar.

m

at
om

If the pressure does not drop now (leak on engine side):

ion
c

in t
or

Leak must be sought on engine side; proceed as follows

his
ate

⇒ page 201 .
do
priv

cum
or

If the pressure drops again (leak on fuel tank side):

f

en
ng

t.
yi Co
op
Leak must be sought on fuel tank side; proceed as follows: C py
t. rig
gh ht
yri by
– Check connections at fuel tank for leaks . cop Vo
by lksw
cted agen
Prote
If no fault is found:
AG.

– Check fuel line to sender flange ⇒ Item 14 (page 178) for leaks.
– Check all other fuel lines in fuel tank for leaks.
If no fault is found on the fuel line:
– Renew fuel delivery unit ⇒ page 188 .

200 Rep. gr.20 - Fuel supply system

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Note

When the pressure tester - VAS 6550- is to be removed, open the

shut-off tap “C” and release remaining pressure. To do this, hold
the hose of the shut-off tap “C” in a measuring container.

If the pressure does not drop now (leak on engine side):

Note

Search for leak on engine side. To do this, repeat the holding-

pressure test. This time, close shut-off tap -A- to check whether
leak actually is on engine side.

– If there is a leak on the engine side, carry out »external« check

of the fuel pipes and high-pressure pump for leaks.
If no fault can be determined, check the injectors for leaks:
– Remove spark plugs. Open shut-off valves -A- and -B-. Ac‐
tuate fuel pump with final control diagnosis.
– Check through spark plug holes whether fuel has collected on
the piston crown due to a leaking injector.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
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nf
ercia

orm
m

atio
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n in
or c

thi
te

sd
iva

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m
f

en
ng

t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

3. Checking fuel pump 201

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

4 Electronic power control (EPC)

⇒ “4.1 Assembly overview - accelerator”, page 202

4.1 Assembly overview - accelerator

1 - Mounting bracket
2 - Connector
❑ Black, 6-pin.
3 - 10 Nm
4 - Accelerator position sender
- G79- and accelerator position
sender 2 - G185-
❑ Not adjustable.
❑ Remove footwell cover
to remove sender.

AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
h
aut ra
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nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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rp

cu
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m
f

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

202 Rep. gr.20 - Fuel supply system

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

5 Activated charcoal filter system

⇒ “5.1 Assembly overview - activated charcoal filter system”, page
203 .
⇒ “5.2 Checking fuel system for leaks”, page 203 .

5.1 Assembly overview - activated charcoal filter system

1 - Breather line
❑ From fuel tank
❑ Ensure firm seating
2 - Breather line
❑ To activated charcoal fil‐
ter solenoid valve 1 -
N80-
❑ Ensure firm seating
3 - Breather connection
4 - Activated charcoal filter
❑ Location: in rear right
wheel housing.
5 - 9 Nm
6 - Spacer sleeve
7 - Rubber mounting

AG. Volkswagen AG d
agen oes
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ab
ility
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wit
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spec
es, in part or in w

t to the co
rrectness of i

5.2 Checking fuel system for leaks

l purpos

Special tools and workshop equipment required

nf
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orm
m

atio
om

n in
or c

thi
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sd
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f

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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

5. Activated charcoal filter system 203

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

♦ Tester - V.A.G 1371-

Procedure:
– Remove wheel and rear right wheel housing liner.
– Disconnect breather line -arrow- to solenoid valve in engine
compartment.

AG. Vo wagen line lks

– Connect tester - V.A.Gsw1371-
agen to breather A G doas shown
es n
-arrow-. by
Volk ot g
u d ara
se n
– Connect valve
tho adapter of tester - V.A.G 1371- to tyre valve.
ri tee
o
au ra
c
ss
ce
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un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co

– Remove cap -arrow- from breather connection of activated

charcoal filter and seal opening with a plug.
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
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pr

cum
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fo

en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

204 Rep. gr.20 - Fuel supply system

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Regulate the pressure to 35 mbar with valve -A-. When the

pressure has stabilised, it must not drop below 30 mbar after
5 minutes.
If no pressure builds up or the pressure is not held for at least 5
minutes, localise leak as follows:
– Perform visual check on all components and hoses of the fuel
system.

Note

Also check fuel tank cap for leaks.

Only if no fault has yet been detected:

– Check breather line and activated charcoal filter for leaks. To

do this, remove breather line -1- from activated charcoal filter
and seal connection with a plug.
– Repeat pressure test.
If pressure still drops, the leakage can be found on the activated
charcoal filter or breather line:

– When valve -A- is open, check the following lines and compo‐
nents for leaks by listening, touching, with commercially avail‐
able leak detector spray or ultrasonic tester - V.A.G 1842- .
♦ Line from engine compartment to activated charcoal filter.
♦ Activated charcoal filter n AG. Volkswagen AG do
lkswage es n
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If the pressure does not drop again, the leakage can berisfound
ed
b
on ran
tee
fuel tank: utho
or
s a ac
– To do this, reconnect breather line on activated charcoal filter.
s
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nl

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itte

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ab
ility
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wit
– When valve -A- is open, check fuel tank for leaks by listening,
, is n

h re

touching, with commercially available leak detector spray or

hole

spec

ultrasonic tester - V.A.G 1842- .

es, in part or in w

t to the co

Caution
rrectness of i

After completing work check tyre pressure!

l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

5. Activated charcoal filter system 205

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

6 Activated charcoal filter system (ve‐

hicles for USA and Canada)
⇒ “6.1 Assembly overview - activated charcoal filter system”, page
207 .
⇒ “6.2 Checking fuel system for leaks”, page 208 .
Function
Fuel vapour forms above the surface of the fuel in the tank; the
quantity depends upon the air pressure and ambient temperature.
The activated charcoal filter system prevents these HC emissions
escaping to the atmosphere.
Fuel vapours pass from the highest point in the tank (on filler neck)
through the expansion tank and into the activated charcoal filter.
The activated charcoal stores these vapours like a sponge.
When the vehicle is being operated and the Lambda control is
active (engine warm), the activated charcoal filter system sole‐
noid valve 1 - N80- is activated (pulsed) by the engine control unit
- J623- 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 system solenoid valve 1 - N80- is
closed when it is not supplied with current (e.g. open circuit). The
activated charcoal filter will not be purged.
AG. Volkswagen AG d
Description of leakage diagnosis agen oes
olksw not
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ara
The activated charcoal filter system
rised (including fuel tank) is equip‐ nte
ped with leakage diagnosis ut which can detect if there is a leak in
ho eo
ra
the system. ss a c
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nl

The diagnosis is based on a pressure method and indicates leaks

pt
du

an

with a diameter greater than 0.5 mm.

itte

y li
erm

ab

During the diagnosis, the fuel system diagnostic pump - V144-

ility
ot p

develops pressure in the activated charcoal filter system. Once

wit
, is n

the pressure is attained, the pump switches off. If the pressure

h re
hole

drops below a certain value, the pump switches on again. Self-

spec

diagnosis monitors the intervals at which the pump is switched on

es, in part or in w

t to the co

or off and, if the intervals are too short, writes an entry to the event
memory.
rrectness of i
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orm
m

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n in
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thi
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

206 Rep. gr.20 - Fuel supply system

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Note

♦ Hose connections are secured with either spring-type or

clamp-type clips.
♦ Use spring-type clip pliers - VAS 6340- for installation of
spring-type clips
AG. Volkswagen AG d
agen
♦ or space-saving hose clip pliers - VAS 6362-
Vol .
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oes
not
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by ara
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⇒ “1 Safety precautions”, page 173 . utho eo
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⇒ “2.1 Rules for cleanliness”, page 175 .

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6.1 Assembly overview - activated charcoal filter system
erm

ab
ility
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wit
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1 - Vacuum line
hole

spec
❑ For vacuum supply of
es, in part or in w

fuel system diagnostic

t to the co
pump - V144-
❑ To vacuum connection
on intake manifold

rrectness of i
❑ Ensure firm seating
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2 - 9 Nm

nform
ercia

3 - Breather line
m

❑ From fuel tank

at
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ion
❑ Ensure firm seating
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4 - Fuel tank filler neck

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❑ With expansion tank

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for

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t.
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5 - 5 Nm
Co
Cop py
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6 - 9 Nm rig ht
py by
co Vo
by lksw
7 - Breather line
cted agen
Prote AG.

❑ To activated charcoal fil‐

ter solenoid valve 1 -
N80-
❑ Ensure firm seating
8 - 5 Nm
9 - 9 Nm
10 - Activated charcoal filter
❑ Location: in rear right
wheel housing.
11 - Rubber bush
❑ Observe installation po‐
sition
❑ Renew if damaged
12 - Connection hose
❑ Between air filter and fuel system diagnostic pump - V144-
❑ Ensure firm seating
13 - Fuel system diagnostic pump - V144-
❑ Checking fuel system for leaks ⇒ page 208
❑ Black 3-pin connector

6. Activated charcoal filter system (vehicles for USA and Canada) 207
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

6.2 Checking fuel system for leaks

Special tools and workshop equipment required
♦ Fuel system tester (so-called smoke tester) - KLI 9210-
♦ Adapter hose - KLI 9210/57-
♦ Vehicle diagnostic tester
♦ Hose clamps to 25 mm - 3094-

AG. Volkswagen AG d
agen oes
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Test specification: ss c

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• A leak has been detected by the fuel system diagnostic pump

an
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- V144- .

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pe

ility
• Guided fault finding has been performed with the vehicle di‐
ot

wit
agnostic tester .
, is n

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hole

Preparation of fuel system tester - KLI 9210- :

spec
es, in part or in w

t to the co

Note
rrectness of i

The fuel system tester - KLI 9210- may differ in appearance de‐
pending on the version.
l purpos

– Check on fuel system tester - KLI 9210- if there is enough fluid

nform
ercia

in smoke generator.
m

– Set valve -D- to “Hold”.

com

tion in
r

– Open nitrogen bottle -H-.

te o

thi
s
iva

do

– Connect test hose -G- to self-test connection -B-.

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rp

cum
fo

en

– Set valve -D- to “Test”.

ng

t.
yi Co
op py
– Regulate pressure to 10 in. H2O (25 mbar) with pressure re‐
. C rig
ht ht
rig
ducer -J-. py by
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by lksw
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– Set valve -D- to “Hold”. Prote AG.

– Now pressure must be maintained for at least 2 minutes.

Check tester if pressure is not maintained.
Checking fuel system for leaks:

208 Rep. gr.20 - Fuel supply system

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– In engine compartment, disconnect breather line -arrow- to

activated charcoal filter solenoid valve 1 - N80- .

– Connect adapter hose - KLI 9210/57- between activated char‐

coal filter solenoid valve 1 - N80- and breather line as illustra‐
ted.
AG. Volkswagen AG d
agen oes
olksw not
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pt
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ility
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wit
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h re
hole

– Connect measuring hose -G- from fuel system tester - KLI

spec
9210- to adapter hose - KLI 9210/57- .
es, in part or in w

t to the co
– Set valve -D- to “Hold”.

rrectness of i
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nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
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co lksw
by
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Prote AG.

6. Activated charcoal filter system (vehicles for USA and Canada) 209
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Connect vehicle diagnostic tester to vehicle.

– Start engine and run at idling speed.
– On vehicle diagnostic tester, select operating mode Guided
functions .

– Select guided function “Checking tank ventilation system for

leaks”.
– Initiate test.
– Observe pressure gauge - KLI 9210- while test is running.
• Fuel system diagnostic pump - V144- must pump up pressure
in fuel system to at least 7 in. H2O (17 mbar).
The minimum pressure was not reached, but the available pres‐
sure does not drop.
– Switch off ignition and perform a pressure retention test
⇒ page 210 . If no pressure drop can be detected: Check
vacuum supply of fuel system diagnostic pump - V144-
⇒ page 213 .
The minimum pressure was not reached and the available pres‐
sure drops immediately:

– Clamp off hose to activated charcoal filter solenoid valve 1 -

N80- using a hose clip -arrow-.
– Repeat check. If the minimum pressure is reached now, renew
activated charcoal filter solenoid valve 1 - N80- .
If the minimum pressure was again not reached and the available
pressure drops immediately:
AG. Volkswagen AG d
– Leak in fuel system. Perform “leak detection in fuel system” wage
n oes
olks not
⇒ page 211 . db
y V gu
ara
e nte
ris
Switch off ignition if the minimum pressure is reached. utho eo
ra
a c
ss
The valve in the fuel system diagnostic pump - V144- closes and

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nl

the pressure is retained.

pt
du

an
itte

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– Observe pressure gauge:
erm

ab
ility
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If the pressure does not drop at first, perform a pressure retention

wit
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test to localise any potential small leaks ⇒ page 210 .

h re
hole

If the pressure drops, clamp off hose to activated charcoal filter spec
es, in part or in w

t to the co
solenoid valve 1 - N80- using a hose clip -arrow-.
– If the pressure does not drop again, renew activated charcoal
filter solenoid valve 1 - N80- .
rrectness of i

If the pressure still drops, perform “leak detection in fuel system”

l purpos

⇒ page 211 .
Pressure retention test
nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

210 Rep. gr.20 - Fuel supply system

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Set valve -D- to “Test”. Set the available pressure to 10 in. H2O
(25 mbar).
– Observe pressure gauge -C- and flow meter -E-. When the
throughput quantity decreases and the pressure increases to
10 in. H2O (25 mbar), the fuel system is filled.

Note

Depending on the filling level of the fuel tank, this process can
take up to 3 minutes.

– Once pressure has stabilised, set valve -D- to “Hold”.

• After 5 minutes the pressure must remain at or above 8 in.
H2O (20 mbar).
If the pressure is not held for at least 5 minutes, localise leak as
follows:

– First check activated charcoal filter solenoid valve 1 - N80- for

leaks. To do this, clamp off hose to activated charcoal filter
solenoid valve 1 - N80- using a hose clip -arrow-.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
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nl

pt
du

an

– Repeat pressure test by setting valve -D- again to “Test”.

itte

y li
erm

ab

– Observe pressure gauge and flow meter. When the through‐

ility
ot p

put quantity decreases and the pressure increases to 10 in.

wit
, is n

H2O (25 mbar), the fuel system is filled.

h re
hole

spec

– Once pressure has stabilised, set valve -D- to “Hold”.

es, in part or in w

t to the co

– If the pressure does not drop again, renew activated charcoal

filter solenoid valve 1 - N80- .
If the pressure still drops, perform “leak detection in fuel system”
rrectness of i

⇒ page 211 .
l purpos

After completing work, perform guided function “Checking fuel

tank breather system for leaks” using ⇒ Vehicle diagnostic tester.
nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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6.2.1 Leak detection in fuel system
C py
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Test specification:
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cted agen
Prote AG.
• Procedure for “checking fuel system for leaks” has been com‐
pleted ⇒ page 208 .
• Fuel system tester - KLI 9210- is connected to vehicle via
adapter hose - KLI 9210/57- .

6. Activated charcoal filter system (vehicles for USA and Canada) 211
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Connect fuel system tester - KLI 9210- to vehicle battery.

– Remove rear right wheel housing liner.
– Clamp off hose between fuel system diagnostic pump - V144-
⇒ Item 8 (page 213) and air filter ⇒ Item 7 (page 213) to
-arrow-.

AG. Volkswagen AG d
agen oes
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byV gu
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ed
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aut ra
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nl

pt
du

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– Set valve -D- to “Test”.
erm

ab
ility
ot p

– Observe pressure gauge -C- and flow meter -E-. When the

wit
throughput quantity decreases and the pressure increases to
, is n

h re
10 in. H2O (25 mbar), the fuel system is filled.
hole

spec
– Once pressure has stabilised, set valve -D- to “Hold”.
es, in part or in w

t to the co
• After 5 minutes the pressure must remain at or above 8 in.
H2O (20 mbar).

rrectness of i
– If the pressure no longer drops, renew fuel system diagnostic
pump - V144- .
l purpos

If the pressure is not held for at least 5 minutes or does not build
up, localise leak as follows:
nf
ercia

– Fill fuel system with smoke, set valve -D- again to “Test” for orm
m

atio
m

this.
o

n in
or c

thi

– While fuel system is being filled, press button -I- for smoke
te

sd
a

generator for approx. one minute.

iv

o
r
rp

cu
o

The fuel system is now pressurised and filled with smoke.

f

en
ng

t.
yi Co
op
– Check whether smoke escapes from any fuel system line or C py
ht. rig
hose. Also check fuel tank cap. rig ht
py by
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by lksw
cted agen
Prote AG.
Note

♦ Light up the components and hoses with a strong floodlight. In

the floodlight, smoke is more visible.
♦ For leak detection in accessible areas, also use ultrasonic de‐
tector or commercially available leak detecting spray.
♦ Depending on how long the fault finding takes, it may be nec‐
essary to press the smoke generator button from time to time.
This ensures that sufficient smoke is present in the fuel sys‐
tem.
♦ To inspect flanges for fuel pump and fuel filter, open assembly
opening in vehicle interior.

– Renew leaking hoses or components.

After completing work, perform guided function “Checking fuel
tank breather system for leaks” using ⇒ Vehicle diagnostic tester.

6.2.2 Schematic overview of activated charcoal filter system

212 Rep. gr.20 - Fuel supply system

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

1 - Activated charcoal filter

2 - Location of adapter hose -
KLI 9210/57-
❑ For leak detection in fuel
system
3 - Activated charcoal filter sol‐
enoid valve 1 - N80-
4 - Breather line
❑ To intake manifold
5 - Solenoid valve
❑ For fuel system diagno‐
sis pump - V144- .
6 - Vacuum line n AG. Volkswagen AG do
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❑ To intake manifold byV
o ot g
ua
d ran
ir se
7 - Air filter utho tee
or
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❑ For fuel system diagno‐ ss
sis pump - V144- .

ce
le
un

pt
an
d
itte

8 - Fuel system diagnostic

y li
rm

ab
pump - V144-
pe

ility
ot

wit
9 - Fuel
, is n

h re
hole

10 - Cap

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

6.2.3 Checking vacuum supply of fuel system

do
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rp

cum

diagnostic pump - V144-

fo

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t.
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op
Special tools and workshop equipment required
C py
t. rig
gh ht
yri by
♦ Turbocharger tester - V.A.G 1397A- cop Vo
by lksw
cted agen
Prote AG.

♦ T-piece - 251 201 346-

♦ Hose ∅ 6mm

6. Activated charcoal filter system (vehicles for USA and Canada) 213
 AG. Volkswagen AG d
agen oes
Touareg 2010 ➤ , Touareg 2015 ➤ Vol
ksw not
gu
by
6-cylinder direct-injection engine (3.6 l engine,
ris
e 4V) - Edition 12.2019
d ara
nte
tho eo
s au ra
c
s

ce
e
Note

nl

pt
du

an
itte

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erm
The fuel system diagnostic pump - V144- is fitted in the rear right

ab
ility
wheel housing behind the wheel housing liner.

ot p

wit
, is n

h re
hole
– Remove rear right wheel and wheel housing liner.

spec
es, in part or in w
– Pull off vacuum line -1- from fuel system diagnostic pump -

t to the co
V144- .
– Connect turbocharger tester - V.A.G 1397A- with T-piece and

rrectness of i
hose ∅ 6 mm, between vacuum line -1- and fuel system di‐
agnostic pump - V144- -2-.
l purpos

– Switch on measuring range I (absolute pressure measure‐

ment).

nf
ercia

orm
– Connect vehicle diagnostic tester and start engine.
m

atio
om

n in
– On vehicle diagnostic tester, select operating mode Guided
or c

functions .

thi
te

sd
iva

o
r

– Select guided function “Checking tank ventilation system for

rp

cu
o

m
leaks”.
f

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ng

t.
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op
– Initiate test.
C py
t. rig
gh ht
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– Observe display on turbocharger tester - V.A.G 1397A- while cop Vo
by lksw
test is running.
cted agen
Prote AG.

• Pressure must pulsate and must remain at or below 0.7 bar

(absolute pressure) during test.
– If pressure exceeds 0.7 bar during test, vacuum supply is too
low. Check vacuum line to intake manifold for possible kinks
or blockages.

214 Rep. gr.20 - Fuel supply system

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019
. Volkswage AG n AG d
agen oes
olksw not
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db
24 – Mixture preparation - injection
ara
rise nte
tho eo
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s

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1 Injection system

nl

pt
du

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itte

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erm
⇒ “1.1 General notes on the injection system”, page 215

ab
ility
ot p
⇒ “1.2 Rules for cleanliness”, page 215

wit
, is n

h re
⇒ “1.3 Technical data”, page 216
hole

spec
es, in part or in w
⇒ “1.2 Vacuum hose connection diagram”, page 137

t to the co
⇒ “1.3 Assembly overview - vacuum hoses”, page 138

1.1 General notes on the injection system

rrectness of i
l purpos

♦ Fuel hoses in engine compartment must be secured only with

spring-type clips which conform to production standard. The
use of crimp-type or screw-type clips is not permissible.

nf
ercia

orm
♦ Spring-type clip pliers - VAS 6340- or space saving hose clip
m

atio
m

pliers - VAS 6362- are recommended for installing and remov‐

o

n in
c

ing spring-type clips.

or

thi
te

sd
a

♦ Note safety precautions before beginning work ⇒ page 1 .

iv

o
r
rp

cu
o

m
♦ The battery must be disconnected only with ignition switched
f

en
ng

t.
off. If a coded radio is installed, ascertain code before discon‐
yi Co
op
necting battery.
C py
t. rig
gh ht
yri by
♦ Observe required procedures after connecting battery ⇒ Elec‐ cop Vo
by lksw
cted
trical system; Rep. gr. 27 ; Disconnecting and reconnecting
agen
Prote AG.
battery.
♦ For trouble-free operation of electrical components, a voltage
of at least 11.5 V is necessary.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not be burnt in the engine and dam‐
age the Lambda probe.
♦ If, after fault finding, repairs or component tests, the engine
starts, runs for a short period and then stops, then the fault
may be that the immobilizer is blocking the engine control unit.
In this case, the control unit must be adapted.
♦ Certain tests may lead to an event being detected by the con‐
trol unit and stored. Therefore, after completing all the checks
and repairs, read the event memory and clear it if necessary
⇒ Vehicle diagnostic tester.
♦ Vehicles with an airbag are fitted with a crash fuel shut-off. It
reduces the danger of a fire following a crash as the fuel pump
is switched off via the fuel pump control unit - J538- .
♦ When driver door is opened, fuel pump is activated for 2 sec‐
onds to generate pressure in fuel system. This improves the
quality of the start behaviour.

1.2 Rules for cleanliness

When working on the fuel supply/injection system, pay careful at‐
tention to the following “5 rules”:
♦ Thoroughly clean all joints and surrounding areas before dis‐
mantling.
♦ Place removed parts on a clean surface and cover them over.
Use lint-free cloths only.
♦ Carefully cover opened components or seal them if repairs
cannot be carried out immediately.

1. Injection system 215

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing. Do not use parts that
have been kept unpackaged (for example in toolboxes).
♦ If system is open: do not use compressed air if possible. Try
not to move the vehicle.

1.3 Technical data n AG. Volkswagen AG do

lkswage es n
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Engine code d byV CGRA, CMTA ua
ran
ir se tee
Idling check utho
or
a ac
Idling speed ss rpm 600 … 800

ce
le
un

pt
Engine control unit

an
d
itte

y li
System designation Motronic MED 17

rm

ab
pe

ility
Part number ot ⇒ ETKA (Electronic parts catalogue)

wit
, is n

Governed speed rpm approx. 6200

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
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rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

216 Rep. gr.24 - Mixture preparation - injection

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

2 Injectors
⇒ “2.1 Assembly overview - fuel rail with high-pressure pump and
injectors”, page 217
⇒ “2.2 Removing and installing injectors”, page 221 .
⇒ “2.3 Renewing seals on injectors”, page 225

2.1 Assembly overview - fuel rail with high-

pressure pump and injectors

Note

♦ Never dismantle the high-pressure

agen
AG. Volkswapump.
gen AG
d w oes
olks no
♦ If the fuel rail disbyremoved,
V the injector O-ring, support
t gu
ar washer,
spring element
ris and combustion chamber seal must always
e an
tee be
ho
renewedau ⇒ page 225 .
t or
a
ss c
♦ Note safety precautions before starting installation work

ce
le
un

pt
⇒ page 173 .

an
d
itte

y li
rm

♦ Observe rules for cleanliness ⇒ page 215 .

ab
pe

ility
ot

wit
, is n

h re
WARNING
hole

spec
es, in part or in w

t to the co
For safety reasons, when the battery is not disconnected, the
fuse for the fuel pump must be removed before opening the
fuel system, otherwise the fuel pump could be activated by the
driver door contact switch. Fuse assignment ⇒ Current flow
rrectness of i

diagrams, Electrical fault finding and Fitting locations

l purpos

The fuel pressure in the high-pressure pipe can reach 120 bar!
Wear protective goggles and protective clothing to avoid injury
nform
ercia

and contact with the skin. Before loosening fuel pipes, wrap a
cloth around the connection. Then release pressure by care‐
m

a
com

fully loosening the union nuts.

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2. Injectors 217
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

1 - 30 Nm
❑ Observe assembly
markings
2 - Fuel pressure sender for
low-pressure - G410-
❑ 15 Nm
AG. Volkswagen AG d
3 - Fuel supply hose ksw
agen oes
not
ol
❑ From fuel tank byV gu
ara
ed
ris nte
❑ If fuel hose is pulled off ut
ho eo
ra
fuel rail it must be re‐ ss a c
newed. When pulling

ce
le
un

pt
off, it will be damaged by

an
d
itte
the corrugated pipe con‐

y li
rm

ab
nection.
pe

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ot

wit
4 - Spring-type clip
, is n

h re
❑ Only use standard fitted
hole

spec
clips
es, in part or in w

t to the co
5 - Fuel low-pressure hose
❑ Between high-pressure
pump and fuel rail

rrectness of i
❑ Always renew fuel hose
l purpos

because when pulling

off, it will be damaged by
the corrugated pipe con‐

nform
ercia

nection.
m

a
❑ Observe assembly
com

tion in
markings ⇒ page 251
r
te o

thi
6 - Plunger

s
iva

do
r
rp

c
❑ Before installing, coat

um
fo

en
g

with clean engine oil.

n

t.
yi Co
op
❑ Observe installation po‐
C py
ht. rig
sition rig ht
py by
co Vo
by lksw
7 - Seal
cted agen
Prote AG.
❑ Renew
❑ Before installing, moisten lightly with clean engine oil.
8 - High-pressure pump
❑ With fuel pressure regulating valve - N276- .
❑ To loosen and tighten fuel lines, counterhold with a wrench at connection.
❑ Removing and installing ⇒ page 249
❑ Before installing fuel lines first tighten connections for fuel lines.
High-pressure line connection: 40 Nm

Low-pressure line connection: 28 Nm.

9 - 8 Nm
10 - O-ring
❑ Before installing lightly moisten O-rings with clean engine oil.
11 - Pressure limiting valve
❑ Before installing lightly moisten O-rings with clean engine oil.
❑ Renew removed valve.
❑ Press in by hand using an 8 mm hexagon key.

218 Rep. gr.24 - Mixture preparation - injection

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

12 - 22 Nm
13 - Fuel pressure sender - G247-
❑ 22 Nm
❑ Checking ⇒ page 243
❑ Before installing, coat front sealing taper and threads with clean engine oil.
14 - Fuel distributor
❑ For cylinders 2, 4 and 6
❑ Tighten evenly from inside to outside.
❑ If the fuel rail is removed, the injector O-ring, support washer, spring element and combustion chamber
seal must always be renewed ⇒ page 225 .
❑ Removing and installing ⇒ page 239
15 - 30 Nm + turn 90° further
❑ Renew
❑ Tighten fuel rails evenly from inside to outside.
16 - O-ring
❑ Before installing lightly moisten O-rings with clean engine oil.
17 - Support washer
❑ Renew if damaged ⇒ page 225 .
18 - Spring element
❑ Renew each time fuel rail is removed.
❑ Ensure firm seating
19 - Injector, cylinder 2 - N31-
❑ Injector, cylinder 4 - N33- AG. Volkswagen AG d
agen oes
olksw not
❑ Injector, cylinder 6 - N84- ed byV gu
ara
is nte
❑ Removing and installing ⇒ page ut
h 221
or eo
a ra
❑ Assembly overview ⇒ pages 221s c
ce
e
nl

pt

20 - Fuel distributor
du

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itte

y li

❑ For cylinders 1, 3 and 5

erm

ab
ility

❑ If the fuel rail is removed, the injector O-ring, support washer, spring element and combustion chamber
ot p

wit

seal must always be renewed ⇒ page 225 .

, is n

h re

❑ Tighten evenly from inside to outside.

hole

spec
es, in part or in w

21 - Injector, cylinder 1 - N30-

t to the co

❑ Injector, cylinder 3 - N32-

❑ Injector, cylinder 5 - N83-
rrectness of i

❑ Removing and installing ⇒ page 221

l purpos

❑ Assembly overview ⇒ page 220

❑ The »long« No. 1, 3 and 5 cylinder injectors must not be separated.
nform
ercia

22 - Seal
m

at
om

23 - Fuel high-pressure pipe

ion
c

in t
r

❑ 28 Nm
o

his
ate

❑ Make sure that fuel pipe does not touch other components!
do
priv

cum
or

❑ To install, first tighten union nuts hand tight.

f

en
ng

t.
yi
❑ The fuel pressure in the high-pressure line can reach 120 bar! Wear protective goggles and protective
Co
Cop py
clothing to avoid injury and contact with the skin. Before loosening fuel lines, wrap cleaning cloths around ht. rig
rig ht
the connection. Then release pressure by carefully loosening the union nuts. py by
co Vo
by lksw
cted
❑ To loosen and tighten the union nut, counterhold with a wrench at high-pressure pump connection.
agen
Prote AG.

❑ Before installing: first tighten connection at high-pressure pump to 40 Nm.

2. Injectors 219
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

24 - Connecting pipe
❑ 28 Nm n AG. Volkswagen AG do
lkswage es n
o ot g
❑ Make sure that fuel d b pipe
yV does not touch other components!
ua
ran
ir se
❑ To install, first
uth tighten union nuts hand tight.
o tee
or
a ac
❑ Loosen and ss tighten with socket - T10456-

ce
e
nl

pt
du

an
itte

y li
erm

ab
2.1.1 Assembly overview - injectors for cylinders 1, 3 and 5

ility
ot p

wit
, is n

h re
hole

1 - O-ring

spec
es, in part or in w

❑ Renew

t to the co
❑ Before installing, mois‐
ten lightly with clean en‐
gine oil.

rrectness of i
2 - Support washer
l purpos

❑ Renewing ⇒ page 225

nform
ercia

3 - Spring element
❑ Renew
m

at
om

io
❑ Ensure firm seating

n
c

in t
or

his
e

4 - Seal
at

do
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❑ Renew
p

cum
for

en
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❑ Before installing, mois‐

n

t.
yi Co
ten lightly with clean en‐ Cop py
. rig
gine oil.
t
gh ht
pyri by
Vo
co lksw
5 - Combustion chamber seal
by
cted agen
Prote AG.
❑ Renewing ⇒ page 225
6 - Injection valve
❑ Removing and installing
⇒ page 221

220 Rep. gr.24 - Mixture preparation - injection

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

2.1.2 Assembly overview - injectors for cylinders 2, 4 and 6

1 - O-ring
❑ Renew
❑ Before installing, mois‐
ten lightly with clean en‐
gine oil.
2 - Support washer
❑ Renewing ⇒ page 225
3 - Spring element
❑ Renew
❑ Ensure firm seating
4 - Combustion chamber seal
❑ Renewing ⇒ page 225
5 - Injection valve
❑ Removing and installing
⇒ page 221

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
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ss
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nl

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

2.2 Removing and installing injectors

Note safety precautions before beginning work ⇒ page 173 .
rrectness of i
l purpos

Note
nf
ercia

♦ If an injector is removed, the injector O-ring, support washer,

or

spring element and combustion chamber seal must always be

m
m

atio

renewed ⇒ page 225 .

om

n in
or c

♦ The »long« injectors for cylinders No. 1, 3 and 5 must not be

thi
e

separated.
t

sd
iva

o
r
rp

cu
o

m
f

en
ng

Special tools and workshop equipment required yi

t.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. Injectors 221
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

♦ Torque wrench - V.A.G 1331-

AG. Volkswagen AG d
agen oes
ksw
♦ Tool set - T10133- by
Vol not
gu
d ara
ise nte
or eo
h
aut ra
ss c

ce
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nl

pt
du

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itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
Removing:
– Remove upper part of intake manifold ⇒ page 236 .
l purpos

Injectors for cylinders 1, 3 and 5

nform
ercia

– Remove lower part of intake manifold with fuel rail

m

⇒ page 239 .
at
om

ion
c

Injectors for cylinders 2, 4 and 6

in t
or

his
ate

– Removing fuel rail ⇒ page 239 .

do
priv

cum
or

Continuation for all cylinders

f

en
ng

t.
yi Co
op
– Manually press the O-ring upwards as shown and remove it C py
t. rig
from the injector.
gh ht
pyri by
Vo
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by c lksw
– Screw slide hammer - T10133/3- to puller - T10133/15- . cted agen
Prote AG.

222 Rep. gr.24 - Mixture preparation - injection

 AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
ut
ho Touareg 2010 e o ➤ , Touareg 2015 ➤
ra
a
ss 6-cylinder direct-injection engine (3.6 l engine, c4V) - Edition 12.2019

ce
e
nl

pt
du

an
– Then insert puller - T10133/15- into groove -arrow- on injector.

itte

y li
erm

ab
ility
ot p

wit
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hole

spec
es, in part or in w

t to the co
rrectness of i
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nf
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orm
m

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n in
or c

thi
te

sd
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f

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t.
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Cop py
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Note yri
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The spring element -arrow- must not be removed before removing
AG.

the injectors.

– Pull injector out by tapping carefully.

2. Injectors 223
 AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
Touaregor2010
ise ➤ , Touareg 2015 ➤ nte
eo
h
6-cylinder
s aut
direct-injection engine (3.6 l engine, 4V) - Edition ra
c 12.2019
s

ce
le
Installing: un

pt
an
d
itte

y li
– Clean injector bores in cylinder head thoroughly with a nylon
rm

ab
pe

brush - T10133/4- .

ility
ot

wit
, is n

– Renew injector O-ring, support washer, spring element and

h re
combustion chamber seal ⇒ page 225 .
hole

spec
es, in part or in w

– Renew O-rings between injector and fuel rail and moisten

t to the co
slightly with clean engine oil.

rrectness of i
Note
l purpos

♦ The seal ⇒ Item 22 (page 219) must also be renewed for the
injectors for cylinders 1, 3 and 5.

nform
ercia

♦ The combustion chamber seal (Teflon) on the injector must

m

a
not be oiled or greased.
com

tion in
r
te o

thi
– Push injector into cylinder head bore as far as it will go by

s
iva

do
hand. Do not press on spring element when doing this.
r
rp

cum
fo

en
ng

t.
yi Co
Caution t. Cop py
rig
gh ht
yri by
The injectors must not be pulled into their seat with the fuel rail
cop Vo
by lksw
cted
bolts. Otherwise the spring element will be damaged.
agen
Prote AG.

– Ensure injectors are correctly seated and positioned in cylin‐

der head.
Injectors for cylinders 1, 3 and 5
– Install lower part of intake manifold with fuel rail
⇒ page 239 .
Injectors for cylinders 2, 4 and 6
– Installing fuel rail ⇒ page 239 .
Continuation for all cylinders

– Check spring elements, they must not be pushed »flat«

-arrows-.
– Install upper part of intake manifold ⇒ page 236 .

224 Rep. gr.24 - Mixture preparation - injection

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

2.3 Renewing seals on injectors

Note

♦ The »long« injectors for cylinders No. 1, 3 and 5 must not be

separated.
♦ The combustion chamber seal (Teflon) on the injector must
not be oiled or greased.

Special tools and workshop equipment required

♦ Tool set - T10133-

Procedure
Renewing combustion chamber seal (Teflon):
– Remove lower part
wageof intake manifoldd⇒
n AG. Volkswagen AG o page 239 .
e
ks s no
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– Removeedinjectors
by ⇒ page 221 . ara
nte
is
or eo
– Clean
au injector carefully.
th ra
ss c
– Carefully cut open seal with a knife. Avoid contact between
ce
le
un

pt

knife blade and valve body under all circumstances.

an
d
itte

y li
rm

– Remove old seal and clean seal groove in area of seal

ab
pe

ility

-arrow-. Remove coking deposits using a brass wire brush.

ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

– Fit new oil seal -1- onto assembly cone - T10133/5- . Using
com

tio

assembly sleeve - T10133/6- (knurled end faces seal -1-),

n in
r

gently slide seal onto assembly cone - T10133/5- as far as

te o

thi

possible.
s
iva

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rp

cum
fo

en
ng

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Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. Injectors 225
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Turn assembly sleeve - T10133/6- around (knurl no longer

points to seal), and push seal -1- to end of assembly cone -
T10133/5- .
– Now place assembly cone - T10133/5- with seal onto injector
from front. Slide seal further onto injector using assembly
sleeve - T10133/6- .

AG. Volkswagen AG d
agen oes
olksw not
byV gu
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aut ra
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ce
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un

pt
an
d
itte

The seal is not yet seated in its groove.

y li
rm

ab
pe

ility
– Remove assembly sleeve - T10133/6- and assembly cone -
ot

T10133/5- .

wit
, is n

h re
hole

– Slide seal into annular groove by hand.

spec
es, in part or in w

– Position spacer sleeve - T10133/11- onto valve body.

t to the co
– Now push calibrating sleeve - T10133/7- over seal to stop onto
spacer sleeve - T10133/11- .

rrectness of i
l purpos

nform
ercia

– Pull off calibrating sleeve - T10133/7- again.

m

a
com

tio
– Now push calibrating sleeve - T10133/8- over seal to stop onto

n in
r

spacer sleeve - T10133/11- .

te o

thi
s
iva

do
– Pull off calibrating sleeve - T10133/8- again.
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Combustion chamber seal now has correct installation dimen‐

sions.
Renewing support washer:
– Remove O-ring -3-.
– Cut support washer -2- open with a small pair of side cutters
and remove it.

226 Rep. gr.24 - Mixture preparation - injection

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Pull spring element -1- off injector and replace with retaining
plate - T10133/12- .
– Place new support washer -1- onto assembly cone -
T10133/13- and position onto injector as shown.

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ce
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un

pt
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itte

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erm

ab
– Slide support washer -1- into first groove -arrow- on injector

ility
ot p

using calibration sleeve - T10133/14- (knurled side points to

wit
is n

injector).

h re
ole,

spec
– Now turn calibration sleeve - T10133/14- around (knurled side
urposes, in part or in wh

no longer points to injector). Slide calibration sleeve over sup‐

t to the co
port washer -1- in direction of -arrow- to stop on retaining plate
- T10133/12- .

rrectne
– Pull calibrating sleeve - T10133/14- down again.

ss o
cial p

f inform
mer

atio
m

The support washer now has correct installation dimensions.

o

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
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cted agen
Prote AG.

– Now position a new spring element -1- for retaining plate -

T10133/12- and position a new O-ring -3- in front of support
washer -2-.

2. Injectors 227
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Note

♦ The combustion chamber seal (Teflon) -arrow- must not be

oiled to install the injector.
♦ Also renew the seal ⇒ Item 22 (page 219) with the injectors for
cylinders 1, 3 and 5.

– Install injectors ⇒ page 221 .

n AG. Volkswagen AG do
lkswage es n
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ce
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nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

228 Rep. gr.24 - Mixture preparation - injection

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

3 Air filter
⇒ “3.1 Assembly overview - air filter”, page 229
⇒ “3.2 Removing and installing air filter housing”, page 229
⇒ “3.3 Removing and installing air filter element”, page 231

3.1 Assembly overview - air filter

1 - Air duct
❑ Secured to lock carrier.
2 - Protective sleeve
3 - Air filter lower part
4 - 10 Nm
5 - Air filter element
Removing and installing
⇒ page 231
6 - Air filter upper part
7 - Seal n AG. Volkswagen AG do
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❑ Renew if damaged yV
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8 - Air mass meter - G70- ir se tee
tho
u or
❑ Gold-plated contacts on ss
a ac
sensor and connector.

ce
e
nl

pt
du

an
❑ Black 5-pin connector
itte

y li
erm

ab
9 - 6 Nm

ility
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wit
10 - Spring-type clip
, is n

h re
hole

❑ Check for firm seating

spec
es, in part or in w

11 - Connection hose
12 - Retainer for vacuum line t to the co
13 - To throttle valve module -
rrectness of i

J338- .
l purpos

14 - To compressor for air sus‐

pension
nf
ercia

❑ Depending on equip‐
rm
m

ment, connection may

atio
m

be sealed with a blank‐

o

n in
c

ing plug
or

thi
te

sd
iva

15 - Heat insulation
o
r
rp

cu
o

❑ For upper part of air filter.

f

en
ng

t.
yi Co
op
16 - 6 Nm C py
t. rig
gh ht
pyri by
Vo
co lksw
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Prote AG.
3.2 Removing and installing air filter hous‐
ing
Special tools and workshop equipment required

3. Air filter 229

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

♦ Release lever - 80 - 200-

Removing:
– Remove air filter element ⇒ page 231 . AG. Volkswagen AG d
agen oes
ksw not
– Remove front right wheel housing liner ⇒ Rep. gr. by V 66 .
ol
gu
ara
ed
is nte
– Remove air duct -1- from lower part of air filter,
hor
working from eo
ut
the wheel housing side. ss a ra
c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
– Unscrew bolt -1-. Pull air filter housing upwards out of the rub‐
l purpos

ber bushes.
Installing:

nform
ercia

Installation is carried out in the reverse order. When installing,

m

a
com

note the following: tion in

r
te o

♦ A clean air filter housing is essential.

thi
s
iva

do

♦ Water drainage hose must be installed correctly.

r
rp

cum
fo

en
g

♦ When using compressed air to blow out the air filter housing,
n

t.
yi Co
op
observe the following: in order to avoid functional impairments, C py
ht. rig
cover the critical air-carrying components such as air pipes, rig ht
py by
etc. with a clean cloth.
co Vo
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cted agen
Prote AG.
♦ Install front right wheel housing liner ⇒ Rep. gr. 66 .
♦ Install air filter element ⇒ page 231 ; to do this, observe all
notes concerning installation of air filter element.

230 Rep. gr.24 - Mixture preparation - injection

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

3.3 Removing and installing air filter ele‐

ment
Removing:
– Remove air hose -2-, loosen hose clip -1- for this.
AG. Volkswagen AG d
agen oes
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au ra
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nl

pt
du

an
itte

y li
erm

ab
ility
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wit
, is n

h re
hole

spec
es, in part or in w

t to the co
– Open retaining clips -arrows-.

rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi
– Press air filter upper part -1- off lower part -2- and pull upwards
Co
op py
out of openings for retaining lugs -arrows-.
t. C rig
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pyri by
Vo
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cted agen
Prote AG.

3. Air filter 231

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Remove air filter element -arrow-.

Installing:

Note

♦ Always use Genuine part for air filter element.

♦ A clean air filter housing is essential.
♦ Secure all hose connections with hose clips corresponding to
the series equipment ⇒ ETKA (electronic parts catalogue) .
♦ When using compressed air to blow out the air filter housing,
observe the following: in order to avoid functional impairments,
cover the critical air-carrying components such as air pipes,
etc. with a clean cloth.
AG. Volkswagen AG d
agen
♦ Observe relevant disposal regulations. olksw
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– Remove salt residues, dirt and leaves fromuthtop and bottom part
o eo
ra
of air filter housing using a vacuum cleaner.
ss a c

ce
le
un

pt
an
– Blow out water drain -arrow- at bottom of air filter housing with
d
itte

y li
compressed air.
erm

ab
ility
ot p

– Check air duct leading from lock carrier to air filter housing for

wit
is n

dirt and leaves.

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
– Insert air filter element -arrow-.
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Working carefully and without exerting great force, place air

filter upper part-1- on air filter lower part -2-.
Continue installation in reverse order of removal.

232 Rep. gr.24 - Mixture preparation - injection

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

4 Intake manifold
⇒ “4.1 Assembly overview - intake manifold”, page 233
⇒ “4.2 Checking vacuum unit for intake manifold flap”,
page 234
⇒ “4.3 Removing and installing intake manifold upper part”, page
236
⇒ “4.4 Removing and installing lower part of intake manifold with
fuel rail”, page 239
⇒ “4.5 Removing and installing throttle valve module J338 ”, page
242

4.1 Assembly overview - intake manifold

1 - Intake manifold support

2 - 20 Nm
3 - 10 Nm
4 - Seal
❑ Renew
❑ Ensure correct seating
in intake manifold.
5 - Throttle valve module - n AG. Volkswagen AG do
wage
J338- olks es n
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❑ Including throttle valve ir se
d ran
tee
drive (electric throttle
autho
or
ac
operation) - G186-ss , an‐
gle sender 1 for throttle
ce
le
un

pt

valve drive (electric

an
d
itte

y li

throttle operation) -
erm

ab

G187- and angle sender

ility
ot p

2 for throttle valve drive

wit
is n

(electric throttle opera‐

h re
ole,

tion) - G188- .
spec
urposes, in part or in wh

❑ If renewed, adapt en‐

t to the co

gine control unit to throt‐

tle valve module ⇒ Ve‐
hicle diagnostic tester
rrectne

“Guided functions”
❑ Removing and installing
s

⇒ page 242
s o
cial p

f i

6 - 7 Nm
nform
mer

7 - Seal
atio
om

❑ Renew
n
c

i
or

n thi

❑ Ensure correct seating

te

sd
va

in intake manifold.
i

o
pr

cum
r
fo

8 - Connection
en
ng

t.
yi Co
op
❑ For crankcase ventila‐ C py
t. rig
tion.
gh ht
pyri by
Vo
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❑ With heater element for crankcase breather - N79-
c by lksw
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Prote AG.
❑ From cylinder head cover
9 - 3.5 Nm
10 - Upper part of intake manifold
❑ With vacuum unit and intake manifold flap

4. Intake manifold 233

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019
❑ Checking vacuum unit for intake manifold flap ⇒ page 234
❑ Removing and installing ⇒ page 236
11 - 10 Nm
12 - Vacuum line
⇒ “1.2 Vacuum hose connection diagram”, page 137 CGRA only

⇒ “1.3 Assembly overview - vacuum hoses”, page 138 CGRA only

13 - Intake manifold flap air flow control valve - N316-

⇒ “1.2 Vacuum hose connection diagram”, page 137 CGRA only
AG. Volkswagen AG d
agen oes
⇒ “1.3 Assembly overview - vacuum hoses”, page 138 CGRAVoonly
lksw not
gu
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14 - Fuel distributor tho
r eo
au ra
❑ For cylinders 2, 4 and 6 ss c

ce
le

❑ Injector spring elements must be renewed prior to installation ⇒ Item 18 (page 219)
un

pt
an
d
itte

❑ Tighten evenly from inside to outside.

y li
erm

ab
❑ Assembly overview - fuel rail with high-pressure pump and injectors ⇒ page 217 .

ility
ot p

wit
is n

15 - 30 Nm + 90° (1/4 turn) further

h re
ole,

spec
❑ Renew
urposes, in part or in wh

❑ Tighten fuel rails evenly from inside to outside.

t to the co
16 - 3.5 Nm

rrectne
17 - Retaining plate
❑ For coolant hoses

ss
18 - 3.5 Nm

o
cial p

f inform
19 - Coolant pipe
mer

atio
m

20 - 8 Nm
o

n
c

i
❑ Qty. 4
or

n thi
te

sd
va

21 - Intake manifold lower part

i

o
pr

cum
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fo

22 - Seal en
ng

t.
yi Co
op
❑ Renew if damaged C py
t. rig
gh ht
❑ Before installing, lightly moisten with clean engine oil and insert into upper part of intake manifold. pyri by
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23 - Seal Prote AG.

❑ Ensure correct seating in lower part of intake manifold.

24 - Intake manifold support

4.2 Checking vacuum unit for intake mani‐

fold flap
Special tools and workshop equipment required

234 Rep. gr.24 - Mixture preparation - injection

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

♦ Hand operated vacuum pump - VAS 6213-

⇒ “1.2 Vacuum hose connection diagram”, page 137

⇒ “1.3 Assembly overview - vacuum hoses”, page 138
Condition
• The intake manifold flap valve - N316- has been checked with
⇒ Vehicle diagnostic tester. AG. Volkswagen AG d
agen oes
olksw not
Test sequence d by
V gu
ara
ise nte
r
If the intake manifold flap valve - N316- is OK: ut
ho eo
ra
s a c
– Detach coolant hoses -A- and lever out cover -arrow-. s

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Move slide ring -1- on hand-operated vacuum pump - VAS

6213- to position -A- for “vacuum”.

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

4. Intake manifold 235

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Editionw12.2019
agen
AG. Volkswagen AG d
oe
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by ara
– Connect hand operated vacuum pump to vacuum unit rised
nte
-arrow-. au
tho eo
ra
ss c
– Operate hand vacuum pump several times. The operating rod

ce
le
un
must move in -direction of arrow-.

pt
an
d
itte

y li
– Pull hand-operated vacuum unit off vacuum unit . The oper‐

rm

ab
pe
ating rod must move back to its original position.

ility
ot

wit
, is n
– If operating rod does not move as described, renew actuator.

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
4.3 Removing and installing intake manifold
l purpos

upper part

nform
ercia

Special tools and workshop equipment required

m

♦ Torque wrench - V.A.G 1331-

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Assembly tool - T10118-

Removing:

Note

♦ Note safety precautions before beginning work ⇒ page 173 .

♦ Observe rules for cleanliness ⇒ page 215 .
♦ Assembly overview - intake manifold ⇒ page 233 .

236 Rep. gr.24 - Mixture preparation - injection

 n AG. Volkswagen AG do
lkswage es n
d byV
o ot g
ua Touareg 2010 ➤ , Touareg 2015 ➤
ran
ho
ir se 6-cylinder direct-injection engine
tee (3.6 l engine, 4V) - Edition 12.2019
aut or
a
ss c
– Unclip cover rail for ignition cable harness -arrows- and re‐

ce
e
nl
move forwards from retaining lugs -A-.

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Position assembly tool - T10118- on locking button -arrow- and

carefully pull off all connectors of ignition coils with output

nform
ercia

stage .
m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Push cable duct upwards with a screwdriver and lay connec‐

tors to one side.

– Remove intake hose, disconnect electrical connectors and pull

off hoses.

4. Intake manifold 237

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Detach coolant hoses, unscrew bolts, remove bracket and pull

vacuum hose off.

– Unscrew bolts and remove intake manifold.

Note

Block off intake ports in lower part of cylinder head with a clean
cloth.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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Installing: aut ra
ss c
ce
e
nl

pt
du

Caution
an
itte

y li
erm

ab

Seals must always be fitted to upper part of intake manifold. If

ility
ot p

seals remain in lower part in intake manifold then the system

wit
, is n

will leak.
h re
hole

spec
es, in part or in w

t to the co

– Insert seals into upper part of intake manifold and lightly mois‐
ten with clean engine oil.
rrectness of i

-1- »Large« O-rings

l purpos

-2- »Small« O-rings

– Position upper part of intake manifold onto lower part of intake
nf
ercia

manifold.
orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by

238
co Vo
by lksw
cted
Rep. gr.24 - Mixture preparation - injection
agen
Prote AG.
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– First tighten bolts connecting upper and lower parts of intake

manifold uniformly from inside out -1 to 5-. Specified torque:
10 Nm
– Then tighten the intake manifold support securing bolts.
Further assembly is basically a reverse of the dismantling se‐
quence.
Specified torques ⇒ page 233

4.4 Removing and installing lower part of in‐

take manifold with fuel rail
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

AG. Volkswagen AG d
agen oes
olksw not
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tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

♦ Assembly tool - T10118-

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
g

♦ Insert tool - T10347-

n

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4. Intake manifold 239

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Removing:

Note

♦ Note safety precautions before beginning work ⇒ page 173 .

♦ Observe rules for cleanliness ⇒ page 215 .
♦ If the fuel rail is removed, the injector O-ring, support washer,
spring element and combustion chamber seal must always be
renewed ⇒ page 225 .
♦ The seal ⇒ Item 22 (page 219) must also be renewed for the
injectors for cylinders 1, 3 and 5.
♦ If the fuel rail is removed the injector spring elements -arrow-
must be renewed.
♦ Assembly overview - fuel rail with high-pressure pump and in‐
jectors ⇒ page 217 .
♦ Assembly overview - intake manifold ⇒ page 233 .

Caution

Observe the following during all assembly work, particularly in

the engine compartment due to the restricted space:
♦ Route lines of any kind and cables so that original routing
is restored. wage
n AG. Volkswagen AG do
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olks s no
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♦ Ensure that there is sufficient
ed
by
V
clearance to all moving or ara
hot components. hor is nte
eo
t
au ra
c
ss
ce
le

– Disconnect earth strap at battery with ignition switched off ⇒

un

pt
an
d

Electrical system; Rep. gr. 27 ; Disconnecting and connecting

itte

y li
rm

battery.
ab
pe

ility
ot

– Remove upper part of intake manifold ⇒ page 236 .

wit
, is n

h re

– Remove high-pressure pump ⇒ page 249 .

hole

spec
es, in part or in w

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– Remove connecting pipe of fuel rail -arrows-.

rrectness of i
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240 Rep. gr.24 - Mixture preparation - injection

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Undo bolts of fuel rail for cylinders 2, 4, and 6 -arrows-.

– Carefully pull fuel rail off injectors.

– Unscrew securing bolts for lower part of intake manifold/cyl‐

inder head -arrows- using socket Torx T30 - T10347- .
– Remove lower part of intake manifold.

Note

Block off intake ports in cylinder head with a clean cloth.

Installing:
Installation is carried out in the reverse order. When installing,
note the following: en AG. V
olkswagen AG
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– Before installing fuel rail, always renew injectordO-ring,
by
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⇒ page 225 . tho eo
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c
ss
– Renew O-rings between injector and fuel rail and moisten

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slightly with clean engine oil.
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– Fit lower part of intake manifold with a new gasket.
erm

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– Fit all intake manifold and fuel rail securing bolts by hand.
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p

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or

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4. Intake manifold 241

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Install connecting pipe of fuel rail.

Note

♦ First tighten union nuts for connection pipe hand tight, then
tighten to specified torque.
♦ Make sure that the connecting pipe does not touch any other
components.

– Installing high-pressure pump ⇒ page 249 .

– Install upper part of intake manifold ⇒ page 236 .
Specified torque Nm
Intake manifold lower part to 8
cylinder head
Fuel rail to cylinder head 4) 30 Nm + 90° (1/4 turn) further
High-pressure pump to cylinder 10
head
Union nuts for high-pressure 28 agen
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Union nuts for fuel rail connect‐ 28 orised
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4.5 Removing and installing throttle valve
erm

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module - J338-

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– Detach hoses -1- and -2- and remove air pipe -arrows-.

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– Separate electrical connector -1- on throttle valve module -

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Installing
Installation is carried out in the reverse order. When installing,
note the following:
– Specified torques ⇒ page 233 .
– Make sure that gasket is correctly seated in intake manifold.
– If throttle valve module - J338- is renewed, adapt engine con‐
trol unit to throttle valve module - J338- ⇒ Vehicle diagnostic
tester “Guided Functions”.

242 Rep. gr.24 - Mixture preparation - injection

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tho engine (3.6 l engine, 4V) - Edition 12.2019 tee
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⇒ “5.1 Checking fuel pressure sender G247 ”, page 243

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5.1 Checking fuel pressure sender - G247-

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Special tools and workshop equipment required

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♦ Assembly tool - T10118-

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♦ Pressure sensor tester - VAS 6394-

♦ Test instrument adapter/DSO (3-pin) - VAS 5570-

Procedure:

WARNING

♦ The fuel pressure sender is under pressure! Wear protec‐

tive goggles and protective clothing to avoid injury and
contact with the skin. Before loosening fuel pressure send‐
er, wrap a cloth around the connection. Then release
pressure by carefully loosening the connection.

5. Senders and sensors 243

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Pull connector off fuel pressure sender -A- and remove fuel
pressure sender using open ring spanner.

– Unscrew plug -2- and screw fuel pressure sender - G247- into
tester - VAS 6394/1- . Specified torque: 22 Nm.

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– Moisten tapered seal of adapter - VAS 6394/3- with clean en‐
itte

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gine oil and screw into fuel rail. Specified torque: 22 Nm.
erm

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– Connect pressure line of tester - VAS 6394/1- to adapter - VAS

rm
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6394/3- -arrow-.
atio
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– Connect fuel pressure sender and electrical connector of fuel

or

thi
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pressure sender with the aid of test adapter - VAS 5570- .

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244 Rep. gr.24 - Mixture preparation - injection

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Switch on tester - VAS 6394/1- to do this, press button -A- once

briefly.

Note

♦ When button -A- is pressed for 2 seconds, the illumination will

be switched on for 20 seconds.
♦ If the digital pressure gauge - VAS 6394/1- reading is not 0
bar, perform zero calibration procedure ⇒ operating instruc‐
tions .

– Connect vehicle diagnostic tester to diagnostic connection.

– Switch ignition on.
– Press following buttons on display of diagnostic tester one af‐
ter the other:
Vehicle self-diagnosis

Self-diagnosis ►

01 - Engine electronics ►

011 - Measured values ►

– Select measured value block 1 4 0 and confirm with Q .

The actual fuel pressure value is shown in display zone 3, meas‐
ured by the fuel pressure sender - G247- .
– Start engine.
– Compare the displayed pressure of pressure tester - VAS n AG. Volkswagen AG do
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– If the deviation is greater than 5 bar, renew fuel pressure
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sender - G247- .
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– Repeat the test with the new fuel pressure sender - G247- and
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compare both measured values.

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– Check wiring ⇒ Vehicle diagnostic tester.
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5. Senders and sensors 245

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

6 Engine control unit

⇒ “6.1 Removing and installing engine control unit J623 ”, AG. Volkswagen AG d
page 246 agen oes
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6.1 Removing and installing engine control ed
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unit - J623- ss a ra
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If engine control unit is to be renewed, connect ⇒ Vehicle diag‐

wit
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nostic tester and carry out the guided function “Renew engine

h re
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control unit”.

spec
es, in part or in w

t to the co
Special tools and workshop equipment required
♦ Hot air blower from wiring harness repair set - VAS 1978-

rrectness of i
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♦ Nozzle attachment from wiring harness repair set - VAS 1978- op Vo
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♦ Grip pliers
AG.

Removing:
– Switch off ignition.
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing wiper arms .
– Removing plenum chamber cover ⇒ General body repairs,
exterior; Rep. gr. 64 ; Removing and installing plenum cham‐
ber cover
– Cover engine compartment in the area of the engine control
unit in order to prevent paintwork from being scratched.

246 Rep. gr.24 - Mixture preparation - injection

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Unscrew bolts and remove engine control unit upwards.

Note

The shear-head bolt threads are coated with locking compound.

Heating the shear-head bolt with a hot air blower releases the
locking effect of the locking compound.

Caution

Make sure that no components are damaged due to burning.

When shear-head bolts are heated up, parts of the protective
housing will be subjected to a large amount of heat. Wear pro‐
tective gloves to avoid injury.

– Heat shear-head bolt -arrow- with the help of a hot-air blower.

– Fit clamping pliers to end of bolt -1- and loosen bolt.
– Bend down metal edges of protective housing and unscrew
bolts.
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– Install new protective housing
s a with new shear-head bolts.
ut ra
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– Tighten shear-head bolts evenly until bolt head breaks off.
ce
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itte

– Insert engine control unit into plenum chamber.

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ab
ility
– Installing plenum chamber cover ⇒ General body repairs, ex‐
ot p

terior; Rep. gr. 64 ; Removing and installing plenum chamber

wit
is n

cover h re
ole,

spec
urposes, in part or in wh

– Install wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐

t to the co

screen wiper system; Removing and installing wiper arms .

rrectness o
cial p

f inform
mer

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6. Engine control unit 247

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

7 High-pressure pump
⇒ “7.1 Assembly overview - high-pressure pump”, page 248
⇒ “7.2 Removing and installing high-pressure pump”, page 249

7.1 Assembly overview - high-pressure

pump

Note

♦ Never dismantle the high-pressure pump.

wage
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♦ If an injector is removed, the combustion
ed
by chamber seal (Tef‐ ara
lon) and O-ring must be renewed
tho
ris ⇒ page 225 . nte
eo
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♦ Note safety precautionsssbefore starting installation work c
⇒ page 1 .

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♦ Observe rules for cleanliness ⇒ page 215 .

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1 - High-pressure pipe
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❑ 28 Nm
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❑ Make sure that fuel pipe
does not touch other
components!

rrectness of i
❑ Install free of tension.
l purpos

❑ To install, first tighten

union nuts hand tight.
❑ Loosen and tighten with nf
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socket - T10456-
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❑ Note the position of the

spring clips
4 - Plunger
❑ Check for damage
❑ Oil it, and insert it in cyl‐
inder head with its guide
in the correct position
5 - O-ring
❑ From high-pressure
pump
❑ Renew
❑ Lubricate lightly with
clean engine oil
6 - High-pressure pump
❑ Removing and installing ⇒ page 249

248 Rep. gr.24 - Mixture preparation - injection

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

7 - Bolt
❑ 10 Nm

7.2 Removing and installing high-pressure

pump
Special tools and workshop equipment required
♦ Insert tool - T10347-

AG. Volkswagen AG d
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♦ Socket - T10456-

spec
es, in part or in w

Removing:

t to the co
– Remove coolant hoses -1- and -2- from intake manifold.

rrectness of i
WARNING
l purpos

♦ The fuel system is pressurised! Wear protective goggles

and protective clothing to avoid injury and contact with the

nf
ercia

o
skin. Before loosening fuel pipes, wrap a cloth around the

rm
m

atio
connection. Then release pressure by carefully loosening
om

the connection.

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– Disconnect electrical connectors -arrows- and remove intake
. C rig
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7. High-pressure pump 249

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Unscrew coolant pipe from intake manifold -arrows-.

– Unclip wiring harness -1-, undo bolt -2- and -3- remove engine
lifting eye.

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– Remove low-pressure hose -1-. Remove high-pressure line
, is n

h re
-2- using socket - T10456- . To do this, counterhold at high-
hole

spec
pressure pump connections with a wrench.
es, in part or in w

t to the co
rrectness of i
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nf
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– Pull off connector -A-, undo and remove bolts -arrow- and re‐
thi
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sd

move high-pressure pump -B- from engine.

iva

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pyri by
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Prote AG.

250 Rep. gr.24 - Mixture preparation - injection

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Installing:
– Check plunger -1- for damage, renew if necessary. Insert oiled
plunger along guide -2- correctly into cylinder head.
– Slowly turn engine by vibration damper in engine's direction of
rotation. When doing this, press plunger in
-direction of arrow- until it has reached lowest point in cylinder
head.
– Renew high-pressure pump O-ring and coat slightly with clean
engine oil.

– Install high-pressure pump and tighten securing bolts

-arrows-. wage
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– Tighten union for high-pressure
db
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ara
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High-pressure pipe
ss union: 40 Nm c

ce
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Low-pressure line union: 28 Nm.
du

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ab
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Caution
ot p

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♦ The low-pressure hose must always be renewed because
hole

spec
when pulling off, it will be damaged by the corrugated pipe
es, in part or in w

connection.

t to the co
♦ Make sure low-pressure hose and high-pressure hose do
not touch each other after bolts have been tightened. En‐

rrectness of i
sure there is sufficient »clearance« between them.
l purpos

– Install new low-pressure hose -A-. When doing this, take in‐
nform
ercia

stallation markings and position of spring clamps -arrows- into

m

consideration.
at
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ion
c

– Install high-pressure pipe but only tighten bolts hand-tight.

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7. High-pressure pump 251

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Tighten high-pressure pipe -A- using socket - T10456- uni‐

formly, while counterholding the high-pressure pipe in
-direction of arrow-. Make sure high-pressure hose -A- and
low-pressure hose -B- do not touch each other after bolts have
been tightened.
• Specified torque: 28 Nm
Install engine lifting eye.
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Prote AG.

252 Rep. gr.24 - Mixture preparation - injection

 Touareg 2010 ➤ , Touareg 2015 ➤
AG. Volkswagen AG d
ksw
agen 6-cylinderodirect-injection
es n engine (3.6 l engine, 4V) - Edition 12.2019
ol ot g
byV ua
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26 – Exhaust system
tho
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1 Exhaust manifold
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⇒ “1.1 Assembly overview - exhaust manifold”, page 253 .
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⇒ “1.2 Removing and installing exhaust manifold”, page 253 .

h re
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1.1 Assembly overview - exhaust manifold
es, in part or in w

t to the co
1 - Seal

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❑ Renew
l purpos

2 - Heat shield
3 - Bolt

nform
ercia

❑ 20 Nm
m

at
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i
4 - Holder

on
c

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or

5 - Bolt

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❑ 20 Nm
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6 - Holder
n

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8 - Seal
❑ With heat shield
❑ Renew
9 - Nut
❑ Coat studs with high
temperature paste - G
052 112 A3- .
❑ Renew
❑ 23 Nm
10 - Exhaust manifold
❑ Removing and installing
⇒ page 253

1.2 Removing and installing exhaust mani‐

fold
Special tools and workshop equipment required
♦ High-temperature paste - G 052 112 A3-
Removing:
Proceed as follows:

1. Exhaust manifold 253

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Note

Attach cable ties in all the same places when installing.

– Detach hoses -1- and -2- and remove air pipe -arrows-.

AG. Volkswagen AG d
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– Separate electrical
aut connector -1- on throttle valve module - or ac
J338- . ss

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– Remove bolts -arrows- and detach throttle valve module -

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es, in part or in w

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– Remove vacuum lines at intake manifold as follows:

1 - For activated charcoal filter, press release buttons
nf
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or

3 - For brake servo -arrow-

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– Remove air filter upper part.
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– Undo bolts -arrow- and remove bracket.

– Undo bolts -1 and 2- and remove heat shield.

254 Rep. gr.26 - Exhaust system

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Undo bolt for catalytic converter of exhaust bank 2 -arrow-

from below.

– Undo bolts for catalytic converter of exhaust bank 1 -arrow-

from below.

– Undo nuts -arrows- and pull primary catalytic converters off

exhaust manifolds. agen
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– Undo 6 nuts on each of the two exhaust manifolds -arrows-
and remove exhaust manifolds.
rrectness of i

Installing:
l purpos

• Specified torques ⇒ page 253 .

Install in reverse order of removal, observing the following:
nf
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atio
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Note
o

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♦ Renew seals, gaskets and self-locking nuts.

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♦ Coat studs with high temperature paste - G 052 112 A3- .

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f

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ng

t.
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op
– Install catalytic converter ⇒ page 260 .
C py
t. rig
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cted agen
Prote AG.

1. Exhaust manifold 255

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

2 Silencers and catalytic converters

⇒ “2.1 Assembly overview - catalytic converter”, page 256 .
⇒ “2.2 Assembly overview - silencers”, page 258
. Volkswagen AG
a gen AG d
⇒ “2.3 Separating centre
Vol and rear silencers”, page o259
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⇒ “2.4 Replacing
or tail pipes”, page 260 .
ise tee
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⇒ “2.5 Removing
ss
a
and installing catalytic converters”, page 260
ac
.

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nl

⇒ “2.6 Aligning exhaust system free of stress”, page 265 .

pt
du

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⇒ “2.7 Checking exhaust system for leaks”, page 266 .
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2.1 Assembly overview - catalytic converter

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1 - Exhaust manifold
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❑ For exhaust bank 1
❑ Removing and installing
⇒ page 253

rrectness of i
2 - Seal
l purpos

❑ Renew
nf
ercia

3 - Lambda probe - G39- orm

m

❑ The screw thread on

atio
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new Lambda probes is

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coated with assembly

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paste.
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Lambda probe, grease

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thread with high-tem‐ Cop py
perature paste - G 052
t. rig
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112 A3- ; the paste must
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not get into the slots of Prote
cted AG.
agen
the probe body.
❑ Removing and installing
⇒ page 267
❑ 50 Nm
4 - Catalytic converter
❑ For exhaust bank 1
❑ Remove together with
catalytic converter for
exhaust bank 2
❑ Protect from damage by
knocks and impact.
❑ Removing and installing
⇒ page 260
5 - Nuts
❑ Renew
❑ Coat studs with high
temperature paste - G 052 112 A3- .
❑ 23 Nm
6 - Bolts
❑ 23 Nm
7 - Lambda probe after catalytic converter - G130-
❑ The threads on the new Lambda probes are coated with a special assembly paste.

256 Rep. gr.26 - Exhaust system

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019
❑ When re-using the old Lambda probe, grease thread with high-temperature paste - G 052 112 A3- ; the
paste must not get into the slots of the probe body.
❑ Removing and installing ⇒ page 267
❑ 50 Nm
8 - Mounting
❑ Renew if damaged
9 - Bolts
AG. Volkswagen AG d
❑ 23 Nm ksw
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10 - Mounting ise d b ara
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❑ Renewauift damaged
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11 - Bolts

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❑ 23 Nm

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12 - Lambda probe 2 after catalytic converter - G131-

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❑ The threads on the new Lambda probes are coated with a special assembly paste.

wit
, is n

h re
❑ When re-using the old Lambda probe, grease thread with high-temperature paste - G 052 112 A3- ; the
hole

spec
paste must not get into the slots of the probe body.
es, in part or in w

❑ Removing and installing ⇒ page 267

t to the co
❑ 50 Nm
13 - Bolt

rrectness of i
❑ 23 Nm
l purpos

14 - Catalytic converter
nf
ercia

❑ For exhaust bank 2 orm

❑ Can be removed individually
m

atio
m

❑ Protect from damage by knocks and impact.

o

n in
or c

thi

❑ Removing and installing ⇒ page 260

te

sd
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15 - Holder
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❑ For catalytic converter

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Cop py
16 - Seal
t. rig
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❑ Renew
op Vo
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cted agen
Prote AG.
17 - Nuts
❑ Renew
❑ Coat studs with high temperature paste - G 052 112 A3- .
❑ 23 Nm
18 - Lambda probe 2 - G108- (before catalytic converter)
❑ The threads on the new Lambda probes are coated with a special assembly paste.
❑ When re-using the old Lambda probe, grease thread with high-temperature paste - G 052 112 A3- ; the
paste must not get into the slots of the probe body.
❑ Removing and installing ⇒ page 267
❑ 50 Nm
19 - Exhaust manifold
❑ For exhaust bank 2
❑ Removing and installing ⇒ page 253
20 - Holder
❑ For catalytic converter

2. Silencers and catalytic converters 257

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Position of double clamp

AG. Volkswagen AG d
– Fit double clamp as shown and tighten to 20 Nm. ksw
agen oes
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Vol
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2.2 Assembly overview - silencers

rrectness of i
1 - Bolts
l purpos

❑ 23 Nm
2 - Mounting

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❑ Renew if damaged

orm
m

atio
3 - Mounting
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c

❑ Renew if damaged
or

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4 - Bolts
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❑ 23 Nm
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5 - Mounting C py
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❑ Renew if damaged yri
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6 - Nuts
agen
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❑ For clamp.
❑ 35 Nm
7 - Clamping sleeve
❑ Renew
❑ Align exhaust system
free of tension before
tightening ⇒ page 265 .
❑ Tighten threaded con‐
nections evenly.
8 - Nuts
❑ For clamp.
❑ 35 Nm
9 - Clamping sleeve
❑ Renew
❑ Align exhaust system
free of tension before
tightening ⇒ page 265 .
❑ Tighten threaded con‐
nections evenly.
10 - Centre silencer
❑ Combined in one unit with rear silencer as original equipment. Can be renewed individually for repair
purposes.
❑ Separating centre and rear silencers ⇒ page 259
❑ Aligning exhaust system free of tension ⇒ page 265 .

258 Rep. gr.26 - Exhaust system

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

11 - Mounting
❑ Renew if damaged
12 - Bolts
❑ 23 Nm
13 - Tailpipe
❑ Renewing ⇒ page 260
. Volkswagen AG
does gen AG
14 - Rear silencer Vol
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❑ In initial equipment, component
risedb with centre silencer. Can be renewed
ara
nte individually for repair purposes.
o eo
❑ Separating centre andau rear silencers ⇒ page 259
th
ra
ss c
❑ Aligning exhaust system free of tension ⇒ page 265 .

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15 - Tailpipe
itte

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❑ Renewing ⇒ page 260

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2.3 Separating centre and rear silencers

spec
es, in part or in w

t to the co
♦ The connecting pipe can be cut through at the cutting location
in order to renew the centre and rear silencers separately.
♦ Cutting location is marked by an indentation on the circumfer‐

rrectness of i
ence of exhaust pipe.
l purpos

Special tools and workshop equipment required

♦ Chain-type pipe cutter - VAS 6254-

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Procedure:
– Cut through exhaust pipes at right angles at the position
marked -arrows- using chain pipe cutter - VAS 6254- .

2. Silencers and catalytic converters 259

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– When installing, position clamps -arrows- in centre of cutting

location.
– Install clamps so that the bolt ends do not protrude beyond
bottom of clamp. Even when the exhaust system moves much,
the clamp must not contact any other component.
• Specified torque: 35 Nm
– Align exhaust system free of stress ⇒ page 265 .

2.4 Replacing tail pipes

Procedure:
– Unbolt exhaust tailpipe -arrows-.

AG. Volkswagen AG d
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– Fit exhaust tailpipe onto rear silencer and align. hor eo
aut ra
– Check distance between left and right exhaust tailpipes and ss c

ce
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bumper:
nl

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itte

• Distance -a- = min. 20 mm

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ab
ility
• Distance -b- = align uniformly
ot p

wit
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• Specified torque: 60 Nm

h re
hole

spec
– Centre exhaust tailpipe in bumper cut-out.
es, in part or in w

t to the co
rrectness of i

2.5 Removing and installing catalytic con‐

l purpos

verters
nform
mercia

at

Note
om

ion
c

in t
or

♦ The catalytic converters must be removed »downwards«. To

his
ate

do this, the gearbox carrier and propshaft must be removed.

do
priv

cum
or

♦ The catalytic converter for the exhaust bank 2 can be removed

f

en
ng

t.
yi
individually.
Co
Cop py
t. rig
gh ht
yri by
Special tools and workshop equipment required
op Vo
by c lksw
cted agen
Prote AG.

260 Rep. gr.26 - Exhaust system

 AG. Volkswagen AG d
agen oes
olksw not
d byV Touareg
gu
ar 2010 ➤ , Touareg 2015 ➤
ris 6-cylinder direct-injection engine (3.6 l aengine,
e nte 4V) - Edition 12.2019
tho e or
s au ac
s
♦ Engine and gearbox jack - V.A.G 1383 A-

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ility
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spec
urposes, in part or in wh

t to the co
rrectness o
cial p

♦ Gearbox support - T10337-

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

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pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

Removing:
Proceed as follows:
– Vehicles with air suspension: Activate jacking mode ⇒ Rep.
gr. 43 .
– Remove air pipe -arrows-.
– Remove air filter upper part.

– Separate electrical connector -1- on throttle valve module -

J338- .
– Remove bolts -arrows- and detach throttle valve module -
J338- .

2. Silencers and catalytic converters 261

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Remove vacuum lines at intake manifold as follows:

1 - For activated charcoal filter, press release buttons
3 - For brake servo

Note

-Item 2- and -arrow- can be disregarded.

– Unscrew securing bolt -arrow- from intake manifold.

– Undo bolts -1 and 2- and remove heat shield.
– Remove Lambda probes ⇒ page 267 .

– Undo nuts at connection between catalytic converters and ex‐

agen
AG. Volkswagen AG d
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haust manifolds -arrows-. Volksw not
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ed ran
oris tee
th or
Note ss
au ac

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nl

pt
If only the catalytic converter for the exhaust bank 2 needs to be
du

an
itte

removed, the nuts and securing bolts of the catalytic converter for
y li
erm

the exhaust bank 1 do not need to be unscrewed. ab

ility
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wit
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es, in part or in w

t to the co

– Undo bolts for catalytic converter of exhaust bank 1 -arrow-.

rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

262 Rep. gr.26 - Exhaust system

 AG. Volkswagen AG d
agen
olksw Touareg
oes
not 2010 ➤ , Touareg 2015 ➤
yV gu
6-cylinder
ed b direct-injection engine (3.6 l engine,
ara
nte 4V) - Edition 12.2019
ris
tho eo
au ra
– Remove noise insulationss ⇒ General body repairs, exterior; c
Rep. gr. 50 ; Assembly overview - noise insulation .

ce
e
nl

pt
du

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itte

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erm

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ility
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wit
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hole

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es, in part or in w

t to the co
rrectness of i
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orm
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or c

thi
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– Unbolt bracket for noise insulation -arrows-.

rp

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f

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t.
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Cop py
t. rig
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by c lksw
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Prote AG.

– Unbolt bracket -A-.

– Remove clips -arrows-. Unscrew and remove hangers -1- and

-2-.

2. Silencers and catalytic converters 263

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Support gearbox with engine and gearbox jack - V.A.G 1383

A- and attached gearbox support - T10337- as shown in dia‐
gram.

– Remove bolts -1 and 2- for gearbox carrier.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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aut ra
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nl

pt
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– Undo bolts -arrows- and remove gearbox carrier.
erm

ab
ility
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wit
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Note
hole

spec
es, in part or in w

-Items 1 and 2- can be disregarded.

t to the co
– Remove front propshaft ⇒ Rep. gr. 39 .

rrectness of i
l purpos

nform
mercia

– Undo bolt for catalytic converter of exhaust bank 2 -arrow-.

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

264 Rep. gr.26 - Exhaust system

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Right-hand drive:
– Unscrew bolts -arrows- and remove bracket -A-. agen
AG. Volkswagen AG d
oes
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V
All vehicles: d by gu
ara
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au ra
Caution ss c

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Risk of damage to flexible joint.

d
itte

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♦ Do not allow the flexible joint to kink by more than 10°.

ility
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wit
♦ Install flexible joint so that it is not under tension. is n

h re
ole,

♦ Do not damage wire mesh on decoupling element.

spec
urposes, in part or in wh

t to the co
– First, remove »upper« catalytic converter for exhaust bank 2
downwards. Then remove catalytic converter for exhaust bank

rrectne
1.
Installing:

ss o
cial p

f
• Specified torques ⇒ page 258 and ⇒ page 253 .

inform
mer

atio
m

Note
o

n
c

i
or

n thi
e

♦ Renew seals, gaskets and self-locking nuts.

t

sd
iva

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pr

cum
r

♦ Coat studs with high-temperature paste - G 052 112 A3- .

fo

en
ng

t.
yi Co
♦ Attach cable ties in all the same places when installing. t. Cop py
rig
gh ht
pyri by
Vo
– First place »bottom« catalytic converter for exhaust bank 1 in
co lksw
by
cted agen
its installation position. Then, install catalytic converter for ex‐ Prote AG.
haust bank 2.
Further installation is carried out in reverse order of removal, ob‐
serving the following:
– Bolt propshaft to final drive at front securely ⇒ Rep. gr. 39 .
– Install gearbox carrier ⇒ Differential and final drive; Rep. gr.
34 ; Installing gearbox carrier and console .
– Install Lambda probes ⇒ page 267 .
– Install throttle valve module - J338- .
– Align exhaust system free of stress ⇒ page 265 .
– For vehicles with air suspension, deactivate jacking mode ⇒
Rep. gr. 43 .

2.6 Aligning exhaust system free of stress

• The exhaust system must be aligned when cold.
• Specified torques ⇒ page 258 .
– Loosen threaded connections of front clamps.
– Loosen threaded connections of rear repair clamps if there are
any.
– Push exhaust system forwards -arrow- until preload at mount‐
ings is as follows:

2. Silencers and catalytic converters 265

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

• Front mounting: dimension -a- = 2 mm

• Centre mounting: dimension -a- = 15 mm

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
• Rear mounting: dimension -a- = 12 mm hor eo
aut ra
s c
– Hold exhaust system in this position and tighten threaded con‐ s

ce
e

nections of clamps uniformly to 35 Nm.

nl

pt
du

an
itte

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erm

ab
ility
Note
ot p

wit
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h re
♦ A second mechanic is required when aligning an exhaust sys‐
hole

spec
tem with repair clamps between front and rear silencers
es, in part or in w

t to the co
♦ If all adjustment dimensions are impossible to achieve, loosen
respective bracket at body and move bracket.
rrectness of i

2.7 Checking exhaust system for leaks

l purpos

– Start engine and allow to idle.

nform
ercia

– Seal exhaust tailpipes with cloths for the duration of the leak‐
m

age test.
at
om

ion
c

in t

– Listen for noise at connection points (cylinder head/exhaust

or

his
e

manifold, exhaust manifold/front exhaust pipe, etc.) to locate

at

do
riv

any leaks.
p

cum
for

en
g

– Repair any leaks found.

n

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

266 Rep. gr.26 - Exhaust system

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

3 Lambda probes
Lambda probe connectors
Connector Lambda probe Heating
4-pin, Lambda probe 2 after Lambda probe 2 heater
brown catalytic converter - after catalytic converter -
G131- Z30-
6-pin, Lambda probe 2 - G108- Lambda probe 2 heater -
brown Z28-
4-pin, Lambda probe after cat‐ Lambda probe 1 heater
black alytic converter - G130- after catalytic converter -
Z29- AG. Volkswagen AG d
agen oes
6-pin, Lambda probe - G39- yLambda o lksw probe heater - not
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black ise
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Removing Lambda probes: ss au ac

ce
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un

pt
Special tools and workshop equipment required

an
d
itte

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rm

ab
♦ Lambda probe open ring spanner set - 3337-
pe

ility
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wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r

Note
te o

thi
s
iva

do
r
rp

Attach cable ties in all the same places when installing.

um
fo

en
ng

t.
yi Co
op
– Detach hoses -1- and -2- and remove air pipe -arrows-. C py
t. rig
gh ht
yri by
– Remove air filter upper part. cop Vo
by lksw
cted agen
Prote
– Disconnect connector of Lambda probe to be removed and
AG.

move wire clear.

3. 267
 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– Remove Lambda probes with Lambda probe open ring span‐

ner set - 3337- .
1- Lambda probe - G39- (exhaust bank 1, probe 1)
2- Lambda probe after catalytic converter - G130- (exhaust
bank 1, probe 2)
3- Lambda probe 2 - G108- (exhaust bank 2, probe 1)
4- Lambda probe 2 after catalytic converter - G131- (exhaust
bank 2, probe 2):
Install Lambda probes:
Install in the reverse order of removal, observing the following:
♦ When re-using the old Lambda probe, grease thread with high-
temperature paste - G 052 112 A3- ; the paste must not get
into the slots of the probe body.
♦ Specified torque ⇒ page 256

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

268 Rep. gr.26 - Exhaust system

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

28 – Ignition system
1 Ignition system
⇒ “1.1 General notes on ignition system”, page 269
. Volkswagen AG
⇒ “1.2 Assembly overview - ignition system”, page 269 kswagen AG does
not
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⇒ “1.3 Safety precautions”, page 271 isedb ara
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⇒ “1.4 Test data, spark plugs”, page 272 aut ra
c
ss
⇒ “1.5 Removing and installing ignition coils with output stage”,

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e
nl

pt
du
page 272

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itte

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⇒ “1.6 Removing and installing engine speed sender G28 ”, page

ility
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274

wit
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1.1 General notes on ignition system
hole

spec
es, in part or in w

♦ For trouble-free operation of electrical components, a voltage

t to the co
of at least 11.5 V is necessary.
♦ Certain tests may lead to an event being detected by the con‐

rrectness of i
trol unit and stored. Then after completing all checks and
repairs, read event memory and erase if necessary ⇒ vehicle
l purpos

diagnostic tester “Guided functions”.

♦ If, after fault finding, repairs or component tests, the engine

nf
ercia

starts, runs for a short period and then stops, then the fault

orm
may be that the immobilizer is blocking the engine control unit.
m

atio
m

In this case, the control unit must be adapted using ⇒ vehicle

o

n in
c

diagnostic tester under “Guided functions”.

or

thi
te

sd
a

1.2 Assembly overview - ignition system

iv

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rp

cu
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f

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t.
yi Co
op py
Note t. C rig
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pyri by
Vo
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by c
The engine speed sender - G28- can be found on the cylinder
lksw
cted agen
Prote
block ⇒ Item 26 (page 33) .
AG.

1. Ignition system 269

 Touareg 2010 ➤ , Touareg 2015 ➤
n AG. Volkswagen AG do
6-cylinder direct-injection engine (3.6olkl sengine,
wage 4V) - Edition 12.2019
es n
o
yV t gu
db ara
1 - Ignition coil with output rise nte
tho eo
stage - N70, N127, N291, s au ra
c
N292, N323, N324- s

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le
un

pt
❑ Remove and install with

an
d
itte
puller - T10095 A- .

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rm

ab
pe

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2 - Connector
ot

wit
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❑ black

h re
hole

❑ Use assembly tool -

spec
T10118- to pull off.
es, in part or in w

t to the co
3 - Holder
❑ For connector for knock

rrectness of i
sensor 1 - G61- .
l purpos

4 - 20 Nm
5 - Connector

nform
ercia

❑ Black, 3-pin.
m

a
❑ Gold-plated contacts on
com

tio
sensor and connector.

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thi
6 - Knock sensor 1 - G61-

s
iva

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c
❑ Location: cylinder block

um
fo

exhaust side

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ng

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op
7 - 20 Nm
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❑ The specified torque in‐
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fluences the function of Prote
cted AG.
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the knock sensor.
8 - Exhaust camshaft adjuster
❑ Identification: 32A.
❑ With sender wheel for
Hall sender 2 - G163-
❑ Install camshaft adjust‐
er with camshaft timing
chain ⇒ page 64 .
9 - Cover
10 - Connector
❑ Black, 3-pin.
❑ Gold-plated contacts on sensor and connector.
11 - 10 Nm
12 - Hall sender 2 - G163-
❑ For exhaust camshaft
❑ Gold-plated contacts on sensor and connector.
13 - Seal
❑ Renew
14 - Hall sender - G40-
❑ For inlet camshaft
❑ Gold-plated contacts on sensor and connector.
15 - Knock sensor 2 - G66-
❑ Fitting location: cylinder block intake side
❑ Gold-plated contacts on sensor and connector.
16 - Connector
❑ Black, 2-pin.
❑ Gold-plated contacts on sensor and connector.

270 Rep. gr.28 - Ignition system

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

17 - Inlet camshaft adjuster

❑ Identification: 24E
❑ With sender wheel for Hall sender - G40-
❑ Install camshaft adjuster with camshaft timing chain ⇒ page 64 .
18 - Spark plug, 18 Nm
❑ Remove and install with spark plug socket and extension - 3122B-
❑ Type and electrode gap ⇒ page 272 .
19 - Valve timing housing
❑ For camshaft adjustment.
❑ Removing and installing ⇒ page 105

1.3 Safety precautions

To prevent injuries to persons and/or damage to the injection and
ignition system, the following must be observed:
♦ Switch off ignition before connecting or disconnecting injection
and ignition system wiring as well as test instrument cables.
♦ Do not touch or disconnect ignition cables when the engine is
running or being turned at starter speed.
Note the following if testers and measuring instruments have to
be used during a road test: AG. Volkswagen n AG do
wage es
olks
♦ Test and measuring instruments must always be secured
not
gu to
yV
rear seat and operated
ris
ed b by a second person from this location.
ara
nt
o ee
th or
If test and measuringau instruments are operated from front pas‐ ac
ss
senger seat and the vehicle is involved in an accident, there is a
ce
e
nl

possibility that the person sitting in this seat may receive serious
pt
du

an

injuries when the airbag is triggered.

itte

y li
erm

ab

♦ If the engine is to be turned at starter speed without starting:

ility
ot p

wit
, is n

– Unclip cover rail for ignition cable harness -arrows- and re‐
h re

move forwards from retaining lugs -A-.

hole

spec
es, in part or in w

– Pull connectors off ignition coils 1 to 6 using assembly tool -

t to the co

T10118- .
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

– To do this, apply assembly tool - T10118- to locking button

his
ate

-arrow- and carefully pull connector off.

do
priv

cum
or

– Pull fuse for fuel pump out of fuse holder ⇒ Current flow dia‐
f

en
ng

t.
yi
grams, Electrical fault finding and Fitting locations.
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1. Ignition system 271

 AG. Volkswagen AG d
agen oes
Touareg 2010 ➤ , Touareg 2015 ➤ Vol
ksw not
gu
by
6-cylinder direct-injection engine (3.6 l engine, 4V) r-iseEdition 12.2019
d ara
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1.4 Test data, spark plugs ss c

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le
un

pt
an
d
Engine code CGRA, CMTA

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Firing order 1-5-3-6-2-4

pe

ility
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wit
Spark plugs 5)

, is n

h re
VW/Audi 101 905 622

hole

spec
Electrode gap 0.8 to 0.9 mm

es, in part or in w

t to the co
Specified torque 18 Nm
Change interval ⇒ Maintenance ; Booklet 17.1 ; Service

rrectness of i
tables

l purpos
5) Current spark plugs ⇒ Electronic parts catalogue (ETKA)

nform
ercia

1.5 Removing and installing ignition coils

m

a
com

tio
with output stage

n in
r
te o

thi
Special tools and workshop equipment required

s
iva

do
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rp

cum
♦ Puller - T10095 A-
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Assembly tool - T10118-

Removing:
– Unclip cover rail for ignition cable harness -arrows- and re‐
move forwards from retaining lugs -A-.

272 Rep. gr.28 - Ignition system

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

– To do this, apply assembly tool - T10118- to locking button

-arrow- and carefully pull connector off.

– Slide puller - T10095 A- from flat side of connector in direction

of -arrow- and pull out ignition coil with final output stage .
Installing:

– To install, insert ignition coil with output stage into respective

spark plug hole so that the flat sides of connectors fit with each
other -arrows-.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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au ra
ss c
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nl

pt
du

an
itte

y li
erm

ab
ility
ot p

– Push puller - T10095 A- on from flat side of connector in

wit
, is n

-direction of arrow- and push ignition coil with output stage

h re

onto spark plug.

hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Ignition system 273

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

1.6 Removing and installing engine speed

sender - G28-

Note

The engine speed sensor - G28- is located behind oil filter hous‐
ing. There is an opening in sthe
wagoil
en Afilter
G. Vohousing sodthat
lkswagen AG
oes the engine
speed sender - G28- can
by
Volbe
k removed. not
gu
ara
ed nte
oris e
Installation location
aut
h
of connector for engine speed sender - G28-or :a
on pipe for dipstick
ss -arrow-. c

ce
le
un

pt
Removing:

an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Detach connector for engine speed sender - G28- -arrow-.

– Remove noise insulation ⇒ General body repairs, exterior; nform
ercia

Rep. gr. 50 ; Assembly overview - noise insulation .

m

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Move aside cable for engine speed sender - G28- .
– Undo bolt -A-.
– Remove engine speed sender - G28- downwards.

274 Rep. gr.28 - Ignition system

 Touareg 2010 ➤ , Touareg 2015 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Installing:
– Insert engine speed sender - G28- from below and screw on
firmly. AG. Volkswagen AG d
agen oes
lksw not
– Carefully route cable for engine speed sender - G28- . by V o gu
ara
ed
is nte
– Further assembly is carried out in the reverse orderut
hof removal.
or eo
a ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1. Ignition system 275