Volkswagen Touareg 2003-2017 (Typ 7L,7L6,7LA,7P,7P5,7P6) Workshop Manual - PDF DOWNLOAD

Workshop Manual

Touareg 2010 ➤

Touareg 2015 ➤

6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger)

Engine ID CMK A CMK B CJTA CYJA

Edition 02.2015

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List of Workshop Manual Repair Groups

Repair Group

00 - Technical data

10 - Removing and installing engine

13 - Crankshaft group

15 - Cylinder head, valve gear

17 - Lubrication

19 - Cooling

20 - Fuel supply system

21 - Turbocharging/supercharging

24 - Mixture preparation - injection

26 - Exhaust system

28 - Ignition system

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Technical information should always be available to the foremen and mechanics, because their carefulandconstantadherencetotheinstructionsisessentialtoensurevehicleroad-worthinessand safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.

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Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

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00 –Technical data

1Safety instructions

(VRL007791; Edition 02.2015)

⇒ “1.1 Safety precautions when working on fuel supply system”, page 1

⇒ “1.2 Safety precautions when working on vehicles with a Start/ Stop system”, page 1

⇒ “1.3 Safety precautions during road tests in which test and measuring equipment is used”, page 2

⇒“1.4Safetyprecautionswhenworkingonignitionsystem”,page 2

⇒“1.5Safetyprecautionswhenworkingoncoolingsystem”,page 2

1.1Safety precautions when working on fuel supply system

Risk of injury due to highly-pressurised fuel.

The fuel system is pressurised. Risk of injury due to fuel which may spurt out.

–Wear eye protection.

–Wear protective gloves.

–Release pressure: place clean cloth around connection and carefully open connection.

Risk of fire due to escaping fuel

If the battery is connected, the door contact switch will activate the fuel pump when the door is opened. Escaping fuel may ignite and cause a fire.

– Disconnect the fuel pump from the power supply before open‐ing the fuel system.

1.2Safety precautions when working on vehicles with a Start/Stop system

Risk of injury due to unexpected engine start-up

In the case of vehicles with activated Start/Stop system, the en‐gine may start up 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.

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

1.3 Safetyprecautionsduringroadtestsinwhichtestandmeasuringequipment is used

Risk of injury due to unsecured test and measuring equipment

If a front passenger airbag is triggered during an accident, unse‐cured test and measuring equipment can become dangerous projectiles.

–Secure test and measuring equipment with seat belts on the rear seat.

Or

– Haveasecondpersonoperatetestandmeasuringequipment on the rear seat.

1.4Safety 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.Touchingtheignitionsystemmayresultinanelectricshock.

– Do not touch or disconnect ignition cables when the engine is running or being turned at starter speed.

Risk of damage to components

If the engine is washed or if electric cables are connected or dis‐connectedwhiletheengineisrunning,componentsmaybedam‐aged.

– Switchofftheignitionbeforeconnectingordisconnectingelec‐tric cables.

–Switch off the ignition before washing the engine.

1.5Safety precautions when working on cooling system

Risk of scalding due to hot coolant

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Thecoolingsystemisunderpressurewhentheengineishot.Hot steam/hot coolant can escape - risk of scalding.

–Wear protective gloves.

–Wear eye protection.

–Release pressure by covering cap of coolant expansion tank with a cloth and opening it carefully.

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• You can download the complete manual from: www.heydownloads.com by clicking the link below

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Touareg 2010 ➤ , Touareg 2015 ➤ 6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

2Identification

⇒ “2.1 Engine number, engine data”, page 3

⇒ “2.2 Numbering of cylinders”, page 4

2.1Engine number, engine data

Engine number

Theenginenumbercanbeseenonlywhentheenginecoveris pulledoffatthefront.

The engine number (“Engine code” and “Serial number”) can be found on the top of the cylinder block at the front -arrow-.

In addition, there is a sticker on the right of the toothed belt guard with “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 denotes the perform‐ance and torque rating of the engine and depends on the engine control unit. The four-digit engine code can be found on the type plate and on the vehicle data sticker. It can also be read from the engine control unit.

Fitting locations of vehicle data sticker ⇒ Maintenance ; Booklet ; Vehicle data sticker .

Engine data

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

2.2Numbering of cylinders

Cylindersarenumberedbeginningwiththerightside-A-(cylinder bank 1) from the driver's perspective, not from the power output end -C-. Cylinders are numbered sequentially on each side. -B= cylinder bank 2.

Touareg 2010 ➤ , Touareg 2015 ➤ 6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

3Repair 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 securing lines”, page 5

⇒ “3.5 Installing coolers, condensers and radiators”, page 6

3.1Rules for cleanliness

When working on fuel supply and injection system, pay careful attention to the following “rules” for cleanliness:

♦ Thoroughlycleanallunionsandsurroundingareasbeforedis‐connecting.

♦ Place removed parts on a clean surface and cover. Use only lint-free cloths.

♦ Carefully cover opened components or seal if repairs cannot be carried out immediately.

♦ Install clean components only. Do not remove replacement parts from packing until immediately before installing. Do not use parts that have not been stored in their packing (e.g. in tool boxes etc.).

♦ When the system is open: Do not work with compressed air. Do not move vehicle.

♦ Make sure that no fuel gets onto the fuel hoses. Should this occur, the fuel hoses must be cleaned immediately.

♦ Protect detached electrical connections against dirt and mois‐ture and only connect when they are dry.

3.2Foreign 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 sec‐tion with suitable bungs, for example from the engine bung setVAS 6122- .

3.3Contact corrosion

Contact corrosion can occur if unsuitable connecting elements (screws, bolts, nuts, washers, etc.) are used.

For this reason, only connecting elements with a special surface coating are fitted in the vehicle.

Moreover, certain rubber or plastic parts as well as adhesives made of electrically non-conductive materials.

If there is any doubt about the suitability of parts, a general rule is to use new parts ⇒ Electronic Parts Catalogue .

3.4Routing and securing lines

♦ Inordertoruleoutmix-upsandensurethatlines/wires/cables/ hoses/pipe are all installed in their original position, the lines for the fuel, hydraulic systems, vacuum systems and the acti‐vated charcoal filter, for example, as well as electrical wires/ cables must be marked appropriately before they are re‐moved. If necessary, take a photo or make a sketch.

♦ Becauseofthelackofspaceintheenginecompartment,make sure that all lines are sufficiently far away from all moving or hot components.

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

3.5Installing coolers, condensers and radi‐ators

Even if installed correctly, the radiator, the condenser and the chargeaircoolermayhavesmalldentsintheirfins.Thisdoesnot mean that these components have been damaged. It is not per‐missibletorenewradiators,condensersorchargeaircoolersonly because of such minor dents.

10 –Removing and installing engine

1Removing and installing engine

⇒ “1.1 Removing engine”, page 7

⇒“1.2SecuringengineonengineandgearboxsupportVAS6095

”, page 19

⇒ “1.3 Installing engine”, page 23

⇒ “1.4 Detaching gearbox from engine”, page 25

1.1Removing engine

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

Special tools and workshop equipment required

♦Used oil collection and ex‐traction unit - VAS 6622Aor -V.A.G 1782-

♦Stepladder

♦Engine bung set - VAS 6122-

♦ Drip tray for workshop hoist - VAS 6208-

♦Hose clip pliers - VAS 6362-

♦ Balljointremover-T10187-

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Not illustrated:

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♦ Basic kit for Touareg - VAS 6131/6-

♦ Support - VAS 6131/8-

♦ Stepladder

♦ Torque wrench (5 … 50 Nm) - V.A.G 1331-

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Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

The engine is removed downwards with gearbox. Do not open air conditioning system.

Note

♦ Usesuitablematerials,e.g.cableties,toattachalldisconnec‐tedcablesandwirestotheengine/assembly(dependingon »origin«).Fitdummyplugsinallopenconnections.

♦ Movetheselectorlevertothe“N”positionsothatthepropshaft canturnfreely.

♦ Tomakesureyoucanstillmovethefrontwheelswhenthe batteryhasbeendisconnected,onlydisconnectthebattery withtheignitionkeyinserted.

♦ Somecomponentscannotberemoved,orremovedonlywith difficulty,withtheengineinstalled.Therefore,youshouldde‐terminealldefectivecomponentsbeforeremovingengineand renewthemwhileengineisremoved.

♦ Topreventdamagetoremovedcomponents,placethemin thecontainerforremovedparts-V.A.G1698-.

♦ Allcabletiesthatareopenedorcutthroughwhentheengine isremovedmustberenewed/replacedinthesameposition whentheengineisinstalled.

Procedure:

–Connect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐necting and reconnecting batteries

–Remove front wheels.

–Remove air pipe. To do this, remove hose -1- and hose clips -arrows-.

–Disconnect connectors -1 ... 4- for lambda probes.

– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐screen wiper system; Removing and installing wiper arms .

– Remove plenum chamber cover ⇒ General body repairs, ex‐terior; Rep. gr. 50 ; Plenum chamber cover .

–Remove anti-theft alarm from engine control unit ⇒ page 292 .

–Pull engine wiring harness off engine control unit.

1. Removing and installing engine 9

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

–Unscrew earth wire and connector -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.

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

–Unscrew positive cable -2- to starter and alternator and place cable to one side.

WARNING

Thefuellineisunderpressure.

Riskofinjurytoeyesandskinfromfuel.

Weareyeprotectionandprotectiveclothingtoavoideyeinju‐riesandskincontact.Beforelooseninghoseconnections, wrapaclotharoundtheconnection.Thenreleasepressureby carefullyopeningtheconnectionpoint.

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

–Detach fuel supply line -arrow-.

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Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

–Remove noise insulation -1- and -2- ⇒ Rep. gr. 50 .

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–Disconnect connector at steering rack.

–Remove heat shield -1- for universal joint -2-.

–Unscrew earth wire -A- at right longitudinal member.

1. Removing and installing engine

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• You can download the complete manual from: www.heydownloads.com by clicking the link below

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Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

– Unscrewbolt-A-andpullconnectionsoffgearoilcooler.Catch leaking oil with used oil collection and extraction unit - VAS 6622A- .

– Detachpowersteeringhosetogetherwithclampsupto25mm - 3094- . Open clip -A- and pull off hose. Catch leaking oil with used oil collection and extraction unit - VAS 6622A- .

Disconnect connectors on left and right from front speed sen‐sors -arrow-.

–Disconnect connector -arrow- for wear indicator.

–Remove bolts -arrows- for cable retainers.

–Unscrew bolts -1- for brake caliper.

Note

Donotattempttobendbrakelinestoadifferentshape.

–Suspend brake caliper in wheel housing with wire.

Caution

Avoiddamagetobrakepistons.

♦ Donotpressbrakepedalwhenbrakecaliperisremoved.

–Unscrew bolt -arrow- of coupling rod at bottom.

– Unscrew nut -A- from lower transverse link, leave bolt in hole.

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–Unscrew nut for suspension link at top by several turns and push off articulated joint together with ball joint pullerT10187- .

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–Completely unscrew nut and detach suspension link.

– Repeat work sequence of suspension on opposite side of ve‐hicle.

–Disconnect connector -arrows- at gearbox.

Touareg 2010 ➤ , Touareg 2015 ➤ 6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

–Release clamps -1 and 2- from front and centre silencers.

– Support exhaust system between centre silencer and front si‐lencerwithengineandgearboxjack-V.A.G1383A-.Unscrew front and centre mountings of exhaust system and lower ex‐haust system by approx. 20 cm. After removing propshaft, secure exhaust system again.

–Remove propshaft ⇒ Transfer box and final drive; Rep. gr. 39 ; Removing and installing propshaft .

– Separateselectorlevercableatballhead-1-andremovelock washer -3-.

Note

♦ Item-2-canbedisregarded.

♦ Donotbendorkinkselectorlevercable.

♦ Alwaysrenewsecuringclip.

–Drain coolant for high-temperature cooling system

⇒ page 167

–Drain coolant for low-temperature cooling system

⇒ page 177 .

–Remove universal joint -1- from steering rack and push up‐wards. Place drip tray for workshop hoist - VAS 6208- under engine and pull off hoses from coolant pipes -2-.

Caution

♦ Disconnectuniversaljointfromsteeringrackonlywhen wheelsareinstraight-aheadposition.

♦ Donotchangepositionofsteeringwheelandsteering rack,securesteeringwheelwithadhesivetapeifneces‐sary.

–Detach coolant hoses -arrows- and remove upper coolant hose -1- from brackets.

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

–Pull off coolant hose -1- and disconnect breather pipes -arrows-.

–Pull off secondary air pipe -1- and bottom coolant hose -arrow-.

–Pull off coolant hoses -arrows-.

–Remove poly V-belt from air conditioning compressor.

Useclothtocatchescapinghydraulicfluid.

– Detach power steering hose together with clamp up to 25 mm - 3094- . Detach hose clip -arrow- and pull off hose.

–Remove hydraulic pipe from vane pump. To do this, unscrew bolts -A-.

Touareg 2010 ➤ , Touareg 2015 ➤ 6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

–Unscrew one of the rear securing bolts -2- on subframe. –Secure subframe to body using locating pins - T10300- ⇒ Runninggear,axles,steering;Rep.gr. 40;l-Assemblyover‐view - subframe, anti-roll bar, lower suspension links .

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

–Unscrew bolts -arrows- and remove bracket for noise insula‐tion.

–Remove bolt -1- at bottom of engine. The mounting - VAS 6131/8-1- will be placed in this hole later.

–If engine and gearbox are to be separated after removal, un‐screw bolts -arrows-.

Preparing scissor-type assembly platform - VAS 6131- for further procedure:

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

1 - VAS 6131/6-1

❑ Boltingpoint:A4;B3;B4

2 - VAS 6131/6-2

❑Bolting point: H4; G3; G4

3 - VAS 6131/6-3

❑Bolting point: A5; C5

❑Use rotating plate with short spindle

4 - VAS 6131/6-4

❑Bolting point: F5; H5

❑Use rotating plate with short spindle

5 - VAS 6131/6-5

❑Bolting point: B7

6 - VAS 6131/8-1

❑Bolting point: D7

7 - VAS 6131/6-5

❑Bolting point: G7

8 - VAS 6131/6-6

❑Bolting point: B14

9 - VAS 6131/6-6

❑Bolting point: G14

♦ Allsupportsmustonlybetightenbyhandsothattheirposition canstillbeadjusted.

♦ ForrunninggearsupportsVAS6131/6-3andVAS6131/6-4, userotatingplatewithshortspindle.Rotatingplateswithlong spindleareusedtosupportthegearbox.

–Position horizontal scissor-type assembly platform under en‐gine/gearbox assembly. Supports -1- must be guided into corresponding receptacles on left and right -arrow-.

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

–At the same time, guide right and left mountings for gearbox bracket into corresponding holes -arrow-.

When all 4 mountings are in the receptacle holes without pres‐sure:

–Turn turntables of running gear supports with a slight preload under the suspension link.

–Guide supports -2- into their respective receptacles in sub‐frame, correcting support height as necessary with knurled nuts.

–Tighten all supports on scissor-type assembly platform.

–Support also engine with mounting - VAS 6131/8-1- . To do this, insert hook from below into free bolt hole on engine. Ad‐just height with spindle and tighten mounting on scissor-type assembly platform.

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

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

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

Caution

Beverycarefulwhenlowering.Makesurethatallconnections tothebodyhavebeendetached.Wherenecessary,dothis now.

– Lower engine/gearbox assembly using scissor-type assembly platform - VAS 6131 A- initially only as far as distance -a-.

• Dimension -a- = maximum 180 mm.

–Disconnect electrical connector -1- to air conditioning com‐pressor regulating valve - N280- .

–Remove bolts -arrows- for air conditioner compressor.

–Now slowly lower engine/gearbox assembly, constantly ob‐serving the clearance. The compressor must be guided by a second mechanic.

–On left and right sides, insert one securing bolt with nut -arrow-andtighten.Thispreventsenginecarrierfromslipping.

Note

Todothis,usetheboltsfromthesubframemountings.

1.2Securing

engine on engine and gearbox support - VAS 6095-

1. Removing and installing engine

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

Special tools and workshop equipment required

♦Lifting tackle - 2024 A-

♦Engine and gearbox sup‐port - VAS 6095- with sup‐port bracket for V6 FSI engine -VAS 6095/1-5-

♦Workshop hoistVAS 6100-

♦Lift arm extension (work‐shop crane) - VAS 6101-

Prerequisites:

• Gearbox is separated from engine.

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Procedure:

direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

– Attach lifting tackle - 2024 A- to engine lifting eye and to work‐shop crane as shown in the illustration.

Note

Toadjusttothecentreofgravityoftheassembly,theperforated railsofthesupporthooksmustbepositionedasshown.

WARNING

Riskofaccidents.

♦ Theenginemustonlybetransportedwithoutgearboxas described.

♦ Thesupporthooksandretainingpinsontheliftingtackle mustbesecuredwithlockingpins-arrows-.

–Take up some of the weight of the engine with the workshop crane, but do not raise the engine.

–Unscrew nuts for engine mounting on left and right sides -arrow-.

–Remove support -VAS 6131/13-7- from engine. –Lift engine from engine carrier.

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

–Unscrew bolts -arrows- and remove engine support on right.

–Unscrew bolts -arrows- and remove engine support on left.

–Secure engine with support bracket for V6 FSI engine -VAS 6095/1-5- to engine and gearbox support - VAS 6095- as shown and tighten to 40 Nm.

Touareg 2010 ➤ , Touareg 2015 ➤ 6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

1.3Installing engine

Caution

Whendoinganyrepairwork,especiallyintheenginecompart‐ment,payattentiontothefollowingduetothecrampedcondi‐tions:

♦ Routeallthevariouslines(e.g.forfuel,hydraulics,acti‐vatedcharcoalfiltersystem,coolantandrefrigerant,brake fluidandvacuum)andelectricalwiringintheiroriginalpo‐sitions.

♦ Toavoiddamagetolines,ensuresufficientclearanceto allmovingorhotcomponents.

Note

♦ Whenfittingengineandgearboxtobody,itisessentialtopo‐sitionenginecarrieragainstbodywiththeaidofscissor-type assemblyplatform-VAS6131-.»Pullingup«enginecarrier withsecuringboltswilldamagethreads.

♦ Thecompressormustbeguidedbyasecondmechanic.

Procedure:

–Before installing assembly, fit exhaust manifold with catalytic converter.

Aligning scissor-type assembly platform

Special tools and workshop equipment required

♦ Positioning tool - VAS 6131/17-

Individual parts of positioning tool:

♦ Dot lasers - VAS 6131/17-1-

♦ Adapters M14x1.5 - VAS 6131/17-2-

♦ Adapters M12x1.5 - VAS 6131/17-3-

♦ Adapters M10 - VAS 6131/17-4-

1. Removing and installing engine

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

Note

Theillustrationshowsanexample.Othercontactpointsofthe subframemayalsobeused.

– 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.

– Boltsubframetovehicle⇒ Runninggear,axles,steering;Rep. gr. 40

–Reconnect all electrical connections, lines, hoses and con‐nectors which were separated during removal.

–Install plenum chamber cover ⇒ General body repairs, exte‐rior; Rep. gr. 50 ; Plenum chamber cover .

–Install wiper arms on left and right ⇒ Electrical system; Rep. gr. 92 ; Windscreen wiper system; Removing and installing wiper arms .

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–Replenish oil in power-assisted steering ⇒ Running gear, axles, steering, front and four-wheel drive; Rep. gr. 48 ; Checking power-assisted steering oil level .

–Replenish coolant for high-temperature cooling circuit

⇒ page 169 .

–Replenish coolant for low-temperature cooling circuit

⇒ page 177 .

–Replenish engine oil if necessary.

–Connect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐necting and reconnecting batteries .

–Adjust selector lever cable ⇒ Automatic gearbox 0C8 - 8speed; Rep. gr. 37 ; Selector mechanism .

–Top up ATF level ⇒ Automatic gearbox 0C8 - 8-speed; Rep. gr. 37 ; Checking ATF level and topping-up

–Connect vehicle diagnostic tester .

–Perform vehicle system test ⇒ Vehicle diagnostic tester “Gui‐ded fault finding”.

– Finish the vehicle system test so that any event entries stored during assembly can be cleared automatically.

–Generate the readiness code in combination with a road test. Observe applicable safety measures when carrying out a road test.

– Then carry out vehicle system test again and rectify any faults which may have occurred.

Note

Touareg 2010 ➤ , Touareg 2015 ➤ 6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

Checkwheelalignmentifduringtheroadtestitisdeterminedthat thesteeringwheelisnotinthestraight-aheadpositionwhenmov‐ingstraight-ahead⇒ Runninggear,axles,steering,frontand four-wheeldrive;Rep.gr. 44;Wheelalignment.

Specified torques

Threaded connection Specified torque

Deviations

Assembly mountings ⇒ page 31

Drive shafts to gearbox ⇒ Runninggear,axles,steer‐ing, front and four-wheel drive; Rep. gr. 40 ; Repairing drive shaft .

Gearbox carrier to body ⇒ Differential and final drive; Rep. gr. 34 ; Installing gear‐box carrier and console .

1.4Detaching gearbox from engine

• Engine/gearbox assembly removed and placed on scissortype assembly platform - VAS 6131 A- .

Note

Duringinstallation,attachallcabletiesandprotectivesleeves againinsameplace.

Special tools and workshop equipment required

♦ Support bridge - 30 - 211 A-

♦ Support - VAS 6131/13-7-

1. Removing and installing engine

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

Separating engine and gearbox:

–Unscrew bolt -1- and nuts -arrows- for left catalytic converter.

– Unscrewbolt-1-andnuts-arrows-forrightcatalyticconverter.

–Remove bolts -1- and -3-. Remove catalytic converters with front silencers.

– Unscrew front right earth wire on engine and tighten supportVAS 6131/13-7- in threaded hole.

–Secure support -VAS 6131/13-7- to scissor-type assembly platform and tighten to 20 Nm.

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Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

– Removenut-1-andbolts-arrows-fromrightenginemounting.

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– Raise engine with pivot mounting -VAS 6131/13-7- enough so that right engine mounting can be removed.

–Undo and remove bolts -arrows- and remove engine support on right -1-.

–Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter, vehicles with automatic gearbox

–Reinstall engine support and engine mounting to continue work procedure ⇒ page 32 .

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–Insert guide pin of adapter -T40058- as follows:

• The larger diameter -arrow 1- points towards the engine.

• The smaller diameter -arrow 2- faces the adapter.

1. Removing and installing engine

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

–Counterhold crankshaft with adapter - T40058- and offset head ring spanner to loosen torque converter bolts.

Note

Onlyturncrankshaftinenginedirectionofrotation-arrow-for subsequentturns.

–Remove cover -1- towards the front.

– Unscrew6bolts-arrows-fortorqueconverterthroughopening of removed starter. To do this, turn crankshaft 120° in engine direction of rotation for each instance.

–Place breather hose -1- to one side.

– Remove bolts-arrows-. Open hose clip-2- and pull off coolant pipe from engine.

–Unscrew securing bolt -1- for coolant pipe and ATF pipes.

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

–Unscrew bolts -1 and 2-, pull off ATF lines from gearbox.

– Seal open lines and unions with clean plugs from engine seal‐ing plug set - VAS 6122- .

–Unscrew coolant pipe -arrows- and lay to side.

– Pressofffrontpropshaftfromtransferbox⇒ Transferboxand final drive; Rep. gr. 39 ; Removing and installing front prop‐shaft .

–Tighten supports - VAS 6131/6-7- as shown on scissor-type assembly and support gearbox stress free under sump. For this, use turntables with long spindle.

–Unscrew bolts -3 … 11- from engine/gearbox connection.

Caution

Whenseparatingtheengineandgearbox,pressofftorque converterfromdriveplatethroughopeningofremovedstarter motor.

GAneg

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Touareg 2010 ➤ , Touareg 2015 ➤ 6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

–Loosen clamping bolts -1- on sides of scissor-type assembly platform - VAS 6131 A- and pull rear section of platform to‐gether with the gearbox towards rear -arrow- slightly.

–Press torque converter off drive plate through opening of re‐moved starter.

– Use the support bridge - 30 - 211 A- to secure the torque con‐verter in the gearbox to prevent the converter falling out.

Assembling:

–For assembly, observe work steps for “installing gearbox” ⇒ Automatic gearbox 0C8 - 8-speed; Rep. gr. 37 ; Removing gearbox - vehicles with V6 TFSI engine .

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

2Assembly mountings

⇒ “2.1 Assembly mountings - exploded view”, page 31

⇒ “2.2 Removing engine mounting (left-side)”, page 32

⇒ “2.3 Remove engine mounting (right-side)”, page 34

AG. Volkswagen

2.1Assembly mountings - exploded view

1 - Bolt

❑Renew.

❑120 Nm +180°

2 - Right engine mounting

❑ Removing and installing

⇒ page 34

3 - Bolt

❑60 Nm

4 - Bolt

❑40 Nm

5 - Nut

❑75 Nm

6 - Right engine support

7 - Left engine support

8 - Bolt

❑40 Nm

9 - Bolt

❑60 Nm

10 - Left engine mounting

❑ Removing and installing

⇒ page 32

11 - Engine carrier

AGdoesnotguaranteeor

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

2.2Removing engine mounting (left-side)

Special tools and workshop equipment required

♦ Bracingdevice-10-222Awith adapter - 10 - 222 A / 29-

♦Hook - 10 - 222 A /10-

♦Adapter - 10 - 222 A /3-

♦Adapter - 10 - 222 A /28-

♦ 2xsquarepipe-T40091/1-

♦Perforated rail - T40091/2-

♦ 2 x turning joint - T40091/3-

♦Mounting - T40093/5-

♦ 2 x turning joint - T40093/4-

Removing:

–Remove power assisted steering reservoir and lay to side.

–Remove engine mounting nut -arrow-.

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

–Push turning joints - T40091/3- and adapters - 10 - 222 A /3onto square pipe of bracing device - 10 - 222 A- .

–»Raise« plenum chamber cover on right and left.

–Fit adapter - 10 - 222 A /29- onto square pipe.

–Fit bracing device as shown.

Caution

Itmustbeensuredthatthebracingdeviceisnotplacedonthe metallugs-arrows-!

–Slide turning joint - T40093/4- and adapter - 10 - 222 A /28onto square pipe - T40091/1- .

– Place adapter - 10 - 222 A /28- onto vehicle longitudinal mem‐ber and insert square tube - T40091/1- into rotary jointT40091/3- .

–Repeat procedure on opposite side of vehicle.

– Push perforated rail - T40091/2- through one side of the turn‐ing joint - T40093/4- .

–Push mounting - T40093/5- onto the perforated railT40091/2- then slide perforated rail onto other side of turning joint.

–Fit locking bolts and secure with splints.

–Hand-tighten all bolted connections of the bracing device.

–Secure both threaded spindles on the left lifting eyes as shown.

–Lift engine evenly with both spindles until threaded engine mounting stud is »free«.

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

– Remove securing bolts of engine mounting -arrows-. Remove engine mounting.

Installing:

• Specified torques ⇒ page 31

–Insert and tighten engine mounting.

–Slowly lower engine and guide stud into engine support. Further assembly is carried out in the reverse order of removal.

2.3Remove engine mounting (right-side)

Special tools and workshop equipment required

♦ Bracingdevice-10-222Awith adapter - 10 - 222 A / 29-

♦Hook - 10 - 222 A /10-

♦Adapter - 10 - 222 A /3-

♦Adapter - 10 - 222 A /28-

♦ 2xsquarepipe-T40091/1-

♦Perforated rail - T40091/2-

♦ 2 x turning joint - T40091/3-

♦Mounting - T40093/5-

♦ 2 x turning joint - T40093/4-

Removing:

–Remove air filter housing completely ⇒ page 280

GAnegawskloVybthgirypoC.tnem

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

–Remove engine mounting nut -arrow-.

–Push turning joints - T40091/3- and adapters - 10 - 222 A /3onto square pipe of bracing device - 10 - 222 A- .

–»Raise« plenum chamber cover on right and left.

–Fit adapter - 10 - 222 A /29- onto square pipe.

–Fit bracing device as shown.

Caution

Itmustbeensuredthatthebracingdeviceisnotplacedonthe metallugs-arrow-!

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–Slide turning joint - T40093/4- and adapter - 10 - 222 A /28onto square pipe - T40091/1- .

– Place adapter - 10 - 222 A /28- onto vehicle longitudinal mem‐ber and insert square tube - T40091/1- into rotary jointT40091/3- .

–Repeat procedure on opposite side of vehicle.

Push perforated rail - T40091/2- through one side of the turn‐ing joint - T40093/4- .

–Push mounting - T40093/5- onto the perforated railT40091/2- then slide perforated rail onto other side of turning joint.

–Fit locking bolts and secure with splints.

–Hand-tighten all bolted connections of the bracing device.

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

–Secure both threaded spindles on the right lifting eyes as shown.

–Lift engine evenly with both spindles until threaded engine mounting stud is »free«.

–Remove securing bolts of engine mounting -arrows-.

Installing:

• Specified torques ⇒ page 31

–Insert and tighten engine mounting.

–Slowly lower engine and guide stud into engine support. Further assembly is carried out in the reverse order of removal.

13 –Crankshaft group

1Cylinder block (pulley end)

⇒“1.1Assemblyoverview-superchargerpolyV-beltdrive”,page 37

⇒ “1.2 Removing and installing supercharger poly V-belt”, page 38

⇒ “1.3 Removing and installing tensioning element for super‐charger poly V-belt”, page 39

⇒ “1.4 Assembly overview - poly-V-belt drive for ancillary units”, page 39

⇒ “1.5 Removing and installing poly V-belt”, page 42

⇒ “1.6 Removing and installing tensioning element for poly Vbelt”, page 44

⇒ “1.7 Removing and installing vibration damper”, page 45

⇒ “1.8 Renewing sealing flange with oil seal for crankshaft”, page 46

1.1Assembly overview - supercharger poly V-belt drive

1 - Supercharger poly V-belt.

❑Check for wear.

❑ Removing and installing

⇒ page 42

❑When installing, make sureitisproperlyseated on poly V-belt pulleys.

2 - Bolt

❑42 Nm

3 - Washer

4 - Cover

5 - Supercharger

❑ Removing and installing

⇒ page 253

6 - Idler pulley for poly V-belt

7 - Vibration damper

❑With poly V-belt pulley

❑ Assemblythroughoffset holes only possible in one position

❑ Removing and installing

⇒ page 45

8 - Bolt

❑Renew.

❑20 Nm + 90°

9 - Poly V-belt tensioning ele‐ment

❑ Removing and installing

⇒ page 39

AG Volkswagen

Touareg 2010 ➤ , Touareg 2015 ➤ 6-cylinder direct-injection engine (3.0 l engine, 4V, supercharger) - Edition 02.2015

1. Cylinder block (pulley end)

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.