SM 31

Service Volksw
agen
AG. Volkswagen AG d
oes
not
by gu
d 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
Workshop Manual
rrectness of i
Phaeton 2003 ➤
l purpos
6-cylinder diesel engine (3.0 l engine, common rail)
nform
ercia
BMK CAR CEX CEX

m
at
Engine ID
A A B
om
ion
c
in t
or
his
e
Edition 04.2016
at
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.
Service Department. Technical Information

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise
Service
r nte
tho eo
au ra
ss c
ce
e
nl
pt
du
List of Workshop Manual Repair Groups
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
Repair Group
00 - Technical data
rrectness of i
10 - Removing and installing engine
l purpos
13 - Crankshaft group
15 - Cylinder head, valve gear
nform
ercia
17 - Lubrication
m
at
om
io
19 - Cooling
n
c
in t
or
his
e
21 - Turbocharging/supercharging
at
do
priv
c
23 - Mixture preparation - injection
um
for
en
ng
t.
yi
26 - Exhaust system
Co
Cop py
t. rig
28 - Glow plug system
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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 © 2016 Volkswagen AG, Wolfsburg K0058952220

Phaeton 2003 ➤
6-cylinder diesel engine (3.0 l engine, common rail) - Edition 04.2016
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3 Specified torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4 Front engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.3 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.4 Removing and installing front sealing flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.5 Assembly overview - drive plate/dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.6 Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.7 Extracting and driving in needle roller bearing for dual-mass flywheel . . . . . . . . . . . . . . . . 31
1.8 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.9 Renewing crankshaft oil seal on timing chain end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.10 Assembly overview - timing chain covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.11 Removing and installing timing chain covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.12 Assembly overview - balancer shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.13 Removing and installing balancer n AG. Vshaft
olkswag.en. A
. G. .do. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
lkswage es n
2 Chain drive (enginebycode BMK) . . . . . . . . . . . . . . o.t .gu.a. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vo 47
ed ra
2.1 Assembly overview
ho
ris - drive chain for valve gear . . . . . . .nt.ee. . . . . . . . . . . . . . . . . . . . . . . . . . 47
t o
2.2 Removing and au installing drive chain for valve gear . . . . . . .r a.c . . . . . . . . . . . . . . . . . . . . . . 48
ss
2.3 Assembly overview - chain for balancer shaft and oil pump . . . . . . . . . . . . . . . . . . . . . . . . 49
ce
e
nl
pt
du
2.4 Removing and installing chain for balancer shaft and oil pump . . . . . . . . . . . . . . . . . . . . . . 51
an
itte
y li
erm
3 Chain drive (engine codes CARA, CEXA, CEXB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

ab
ility
ot p
3.1 Assembly overview - drive chain for valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

wit
, is n
3.2 Removing and installing drive chain for valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

h re
hole
3.3 Assembly overview - chain for balancer shaft and oil pump . . . . . . . . . . . . . . . . . . . . . . . . 57
spec
es, in part or in w
3.4 Removing and installing chain for balancer shaft and oil pump . . . . . . . . . . . . . . . . . . . . . . 59
t to the co
4 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

4.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
rrectness of i
4.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

4.3 Measuring axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
l purpos
4.4 Measuring radial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

5 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
nform
ercia
5.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

m
at
om
5.2 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

ion
c
in t
5.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

or
his
te
5.4 Checking radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

a
do
priv
cum
or
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

f
en
ng
t.
yi Co
op
1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
C py
t. rig
gh ht
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
yri
72
p by
co Vo
by lksw
1.2 Assembly overview - cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prote
cted AG.
agen
75
Contents i
Phaeton 2003 ➤
1.3 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

1.4 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.6 Assembly overview - vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.2 Checking axial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.3 Renewing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.4 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.5 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.6 Checking hydraulic valve compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
2.7 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2.8 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3 Chain drive for camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.1 Camshaft timing chains (engineacode gen AGBMK) . . n. A. G. d. o.e. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. Volkswage 112
ksw s no
3.2 Camshaft timing chains (engine
by
V o l codes CARA, CEXA, CEXB) t gu
a
...................... 131
ed ran
ris te
17 - Lubrication . . . . . . a.ut.ho. . . . . . . . . . . . . . . . . . . . . . . . . . . . .e o.r a. . . . . . . . . . . . . . . . 151
ss c
1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
ce
le
un
pt
1.1 Oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
an
d
itte
y li
1.2 Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
erm
ab
ility
2 Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
ot p
wit
is n
2.1 Assembly overview - oil pump, lower part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
h re
ole,
2.2 Removing and installing lower part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
spec
urposes, in part or in wh
2.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
t to the co
2.4 Assembly overview - upper part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
2.5 Removing and installing upper part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
rrectne
3 Oil cooler, pressure control valve and oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
3.1 Assembly overview - oil cooler, pressure control valve, and oil filter housing . . . . . . . . . . 161
s
3.2 Removing and installing oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

s o
cial p
3.3 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

inform
3.4 Removing and installing pressure control valve for crankcase breather system . . . . . . . . 164
mer
atio
3.5 Removing and installing mounting plate for oil cooler, pressure control valve and oil filter
om
housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
n
c
i
or
n thi
3.6 Removing and installing oil pressure switch F1 / oil pressure switch for reduced oil pressure
te
sd
a
F378 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
iv
o
pr
cum
3.7 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

r
fo
en
ng
t.
yi Co
op
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
C py
ht. rig
rig ht
1 Parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
py by
co Vo
by lksw
1.1 Assembly overview - radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
cted agen
Prote AG.
1.2 Removing and installing fan support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1.3 Assembly overview - fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
1.4 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
1.5 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
1.6 Assembly overview - coolant pump and thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1.7 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1.8 Removing and installing continued coolant circulation pump V51 . . . . . . . . . . . . . . . . . . 178
1.9 Removing and installing hose connection with thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.10 Assembly overview - pump for exhaust gas recirculation cooler V400 . . . . . . . . . . . . . . . . 180
1.11 Removing and installing pump for exhaust gas recirculation cooler V400 . . . . . . . . . . . . 181
1.12 Assembly overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.13 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
1.14 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 192
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
ii Contents
Phaeton 2003 ➤
. Volkswagen AG
gen AG d
1 Charge air system with turbocharger . . V. o.lk.s.w.a . . . . . . . . . . . . . . . .o.e.s n. o.t .g . . . . . . . . . . . . . . 194
y u
1.1 Rules for cleanliness . . . . . . . . . . .is.ed. b. . . . . . . . . . . . . . . . . . . . . . . . . . . .a.ra.nt. . . . . . . . . . . 194
r ee
1.2 Assembly overview - turbocharger aut (engine code BMK) . . . . . . . . . . . . . . . . . . .o.r a. . . . . . . .
ho 194
1.3 Removing and installing turbocharger
ss (engine code BMK) . . . . . . . . . . . . . . . . . c. . . . . . . 196
ce
le
1.4 Assembly overview - turbocharger (engine codes CARA, CEXA und CEXB) . . . . . . . . . . 198
un
pt
an
d
itte
1.5 Removing and installing turbocharger (engine codes CARA, CEXA und CEXB) . . . . . . . . 200
y li
erm
ab
1.6 Removing and installing turbocharger 1 control unit J724 . . . . . . . . . . . . . . . . . . . . . . . . 204
ility
ot p
1.7 Assembly overview - parts of charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
wit
is n
h re
1.8 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
ole,
spec
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
t to the co
1 Diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
rrectne
1.2 Rules for cleanliness and instructions for working on fuel system . . . . . . . . . . . . . . . . . . . . 218
1.3 Schematic overview of fuel system (engine code BMK) . . . . . . . . . . . . . . . . . . . . . . . . . . 219
ss
1.4 Schematic overview of fuel system (engine codes CARA, CEXA und CEXB) . . . . . . . . . . 221
o
cial p
f i
1.5 Assembly overview - fuel system (engine code BMK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
nform
mer
1.6 Assembly overview - fuel system (engine codes CARA, CEXA und CEXB) . . . . . . . . . . . . 225
atio
m
1.7 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

o
n
c
1.8 Removing and installing intake manifold upper part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
i
or
n thi
te
1.9 Removing and installing intake manifold flap motor V157 or intake manifold flap 2 motor V275
sd
iva
o
...................................................................... 236
pr
cum
r
fo
1.10 Removing and installing lower parts of intake manifold (engine code BMK) . . . . . . . . . . . . 243
en
ng
t.
yi Co
1.11 Removing and installing lower parts of intake manifold (engine codes CARA, CEXA und Cop py
t. rig
CEXB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
pyri
gh by
ht
249
1.12 Removing and installing injectors (piezo injectors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
co Vo
by lksw
cted agen
1.13 Checking fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Prote AG.
1.14 Removing and installing fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . 259
1.15 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
1.16 Checking return flow rate of injectors (piezo injectors) with engine running . . . . . . . . . . . . 262
1.17 Checking return flow rate of injectors (piezo injectors) at starting speed . . . . . . . . . . . . . . 265
1.18 Checking for injectors sticking open (piezo injectors). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
1.19 Installing high-pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
1.20 Checking pressure retention valve in fuel return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
1.21 Assembly overview - toothed belt for high-pressure pump (engine code BMK) . . . . . . . . . . 271
1.22 Removing and installing toothed belt for high-pressure pump (engine code BMK) . . . . . . 273
1.23 Assembly overview - high-pressure pump (engine code BMK) . . . . . . . . . . . . . . . . . . . . . . 277
1.24 Removing and installing high-pressure pump (engine code BMK) . . . . . . . . . . . . . . . . . . 280
1.25 Assembly overview - toothed belt for high-pressure pump (engine codes CARA, CEXA,
CEXB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
1.26 Removing and installing toothed belt for high-pressure pump (engine codes CARA, CEXA,
CEXB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
1.27 Assembly overview - high-pressure pump (engine codes CARA, CEXA und CEXB) . . . . 292
1.28 Removing and installing high-pressure pump (engine codes CARA, CEXA und CEXB) . . 293
1.29 Bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
1.30 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
2 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
2.1 Reading and clearing engine control unit fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
2.2 Adapting functions and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
2.3 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
2.4 Fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

1 Parts of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
1.1 Assembly overview - exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
1.2 Assembly overview - front exhaust pipe and catalytic converter . . . . . . . . . . . . . . . . . . . . 306
Contents iii
Phaeton 2003 ➤
n AG. Volkswagen AG
1.3 Assembly overview - exhaust ksmanifold
wage and intermediate
does pipes . . . . . . . . . . . . . . . . . . . . . .
not 307
y Vol gu
2 Exhaust gas recirculation
ise system, engine code BMK . . . . . .an. te. . . . . . . . . . . . . . . . . . . . .
d b ar 308
r
2.1 Assembly overview au
t - exhaust gas recirculation system . . . . . . .e.or. . . . . . . . . . . . . . . . . . . .
ho
a
308
2.2 Checking mechanical
ss
exhaust gas recirculation valve . . . . . . . . . .c . . . . . . . . . . . . . . . . . . 309
ce
le
2.3 Removing and installing mechanical exhaust gas recirculation valve . . . . . . . . . . . . . . . . 310
un
pt
an
d
itte
2.4 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 310
y li
erm
ab
3 Exhaust gas recirculation, engine codes CARA, CEXA, CEXB . . . . . . . . . . . . . . . . . . . . . . 312
ility
ot p
wit
3.1 Assembly overview - exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
is n
h re
3.2 Removing and installing exhaust gas recirculation control motor V338 . . . . . . . . . . . . . . 313
ole,
spec
3.3 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 314
t to the co
3.4 Removing and installing exhaust gas recirculation temperature sensor G98 . . . . . . . . . . 316
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
rrectne
1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
1.1 Glow plug characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
ss
1.2 Removing, installing and checking ceramic glow pin plugs . . . . . . . . . . . . . . . . . . . . . . . . 318
o
cial p
f in
1.3 Removing and installing metal glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
form
mer
1.4 Checking metal glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
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.
iv Contents
Phaeton 2003 ➤
00 – Technical data
1 Technical data
(VRL009107; Edition 04.2016)
Note
The term “common rail” means that all injectors on one cylinder
bank have the same high-pressure fuel accumulator (rail ele‐
ment). Pressure generation and fuel injection are separate in this
system: a separate high-pressure pump generates the high-pres‐
sure required for injection. This is stored in a high-pressure ac‐
cumulator (rail element) and is supplied to the injectors via short
injection lines.
Engine number ⇒ page 1

Engine data ⇒ page 1
1.1 Engine number

The engine number (“engine code” and “serial number”) can be
found at the front left below the toothed belt for the high-pressure
pump -arrow-.
There is also a sticker on the intake manifold showing the “engine
code” and “serial number”.
The engine code is also included on the vehicle data sticker.
Vehicles with four digit engine codes AG. Volkswagen AG d
agen oes
lksw not
Starting with the letter “C”, new four digit engine
byV
o codes have been gu
ara
introduced. The first 3 digits denote the ris mechanical design of the
ed
nte
o
engine and are stamped on the engine aut
h as before. The fourth digit eo
ra
denotes the performance and torque ss rating of the engine and de‐ c
pends on the engine control unit. The four digit engine code can
ce
e
nl
pt
du
be found on the identification plate, the vehicle data sticker and

an
itte
y li
on the engine control unit.

erm
ab
ility
ot p
wit
, is n
Note
h re
hole
spec
Vehicles for some countries do not have an identification plate.

es, in part or in w
t to the co
Locations of vehicle data plate and data sticker ⇒ Maintenance

manual .
rrectness of i
1.2 Engine data

l purpos
Engine code BMK CARA CEXA CEXB

nform
ercia
Manufactured 10.04 ► 05.07 ► 03.08 ► 11.13 ►

m
at
Emissions fulfil EU4 standard EU4 standard EU4 standard EU5 standard
om
ion
c
in t
Capacity l 3.0 3.0 3.0 3.0

or
his
te
Output kW at rpm
a
165/4000 175/4400 176/4400 180/4000

do
priv
cum
Torque Nm at rpm 450/1400 … 3250 500/1750 500/1750 500/1750

for
en
ng
t.
Bore ∅ mm 83.0 83.0 83.0 83.0
yi Co
Cop py
Stroke mm 91.4 91.4 91.4 91.4
ht. rig
rig ht
py by
Compression ratio 17.5 16.4 16.4 16.4
co Vo
by lksw
cted agen
Prote
Fuel according to DIN EN 590 DIN EN 590 DIN EN 590 DIN EN 590
AG.
Firing order 3–6–1–4–2–5 3–6–1–4–2–5 3–6–1–4–2–5 3–6–1–4–2–5
1. Technical data 1
Phaeton 2003 ➤
Engine code BMK CARA CEXA CEXB

Exhaust gas recirculation yes yes yes yes
Turbocharging/supercharging yes yes yes yes
Catalytic converter yes yes yes yes
Particulate filter yes yes yes yes
Charge air cooler yes yes yes yes
Lambda control yes yes yes yes
Cylinders are numbered beginning with the right side -A- (cylinder
bank 1) from the driver's perspective, not from the power output
end -C-. Cylinders are numbered sequentially
n AG. Volkson each
wagen AGside. -B-
= cylinder bank 2. wage does
olks not
yV gu
db ara
rise nte
tho eo
au ra
c
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
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.
2 Rep. gr.00 - Technical data

Phaeton 2003 ➤
10 – Removing and installing engine

1 Removing and installing engine
Removing engine ⇒ page 3 .
Notes on installing ⇒ page 15 .
Front engine mounting ⇒ page 16 .
AG. Volkswagen AG d
agen oes
lksw not
Special tools and workshop by
Vo gu
ara
equipment required rised
nte
ho eo
ut
♦ Hose clips up to 25 mm Ø - ss a ra
c
3094-
ce
e
nl
pt
du
an
♦ Adapter - T40058-
itte
y li
erm
ab
♦ Torque wrench - V.A.G
ility
ot p
1332-
wit
, is n
h re
♦ Spring-type clip pliers -
hole
spec
VAS 5024A-
es, in part or in w
t to the co
♦ Scissor-type assembly
platform - VAS 6131-
♦ Drip tray for workshop hoist
rrectness of i
- VAS 6208-
l purpos
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
o
by c lksw
cted agen
Prote AG.
Not illustrated:
♦ Base set for Phaeton - VAS 6131/1-
♦ Support set - VAS 6131/5-
♦ Container for removed parts - V.A.G 1698-
1.1 Removing engine

The engine is removed downwards with gearbox.
– Before removing the fault memory, scan all control units: ⇒ Ve‐
hicle diagnostic tester; or VAS 5052 “Guided functions” .
1. Removing and installing engine 3

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
Phaeton 2003 ➤ orise nte
eo
h
6-cylinder diesel engine (3.0 l engine, common
s aut
rail) - Edition 04.2016 ra
c
s
ce
le
un
pt
an
d
itte
y li
Note
rm
ab
pe
ility
ot
♦ To enable the propshaft to rotate freely, move selector lever
wit
, is n
to the “N” position.
h re
hole
spec
♦ Leave ignition key in ignition lock to prevent steering lock from
es, in part or in w
engaging.
t to the co
♦ Some components cannot be removed, or removed only with
difficulty, with the engine installed. Therefore, you should de‐
rrectness of i
termine all defective components before removing engine and
renew them while engine is removed. l purpos
♦ To prevent damage to removed components, place them in

the container for removed parts -V.A.G 1698- .
nform
ercia
♦ Before disconnecting batteries, move wiper arms to service

m
a
com
t
position ⇒ Electrical system; Rep. gr. 92 ; Removing and
ion in
installing windscreen wiper system .
r
te o
thi
s
iva
do
r
rp
cum
fo
Caution
en
ng
t.
yi Co
Cop py
The procedure for disconnecting batteries must be strictly fol‐
t. rig
gh ht
yri
lowed!
p by
co Vo
by lksw
cted agen
Prote AG.
– Switch off ignition and all electrical consumers.

– First disconnect drive battery on right in luggage compartment.
– Then disconnect second battery on left in luggage compart‐
ment ⇒ Repair group 27; Battery; Disconnecting and recon‐
necting batteries
– Remove noise insulation ⇒ General body repairs; Rep. gr.
50 ; Body - front; Assembly overview - noise insulation .
– Remove front wheels.
– Remove front wheel housing liners ⇒ General body repairs,
exterior; Rep. gr. 66 ; Exterior equipment; Removing and in‐
stalling wheel housing liner; Front wheel housing liner
– Remove the engine cover panel. To do this, pull sharply up‐
wards on the front of the cover panel, then on the rear of the
cover panel -arrows-.
Note
All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine is
installed.
– Extract air conditioning refrigerant ⇒ Heating, air conditioning;

Rep. gr. 87 .
– Loosen securing bolt for windscreen washer system reservoir
filler neck -1- and pull filler neck off in direction of -arrow-.
– Loosen clamp -2- for intake line, separate connector -3- from
air mass sensor and remove upper part of air filter -4-.
– Remove air duct -5-.
4 Rep. gr.10 - Removing and installing engine

AG. Volkswagen AG d
agen oes
o lksw not
V gu
d by ara
orise nte Phaeton 2003 ➤
h eo
6-cylinder
aut diesel engine (3.0 l engine, common rail) ra
c
- Edition 04.2016
ss
ce
e
nl
– Pull fuel hoses -6- off fuel filter.
pt
du
an
itte
y li
– Remove cover of plenum chamber.
erm
ab
ility
ot p
– Unscrew securing bolt for coolant expansion tank in plenum
wit
, is n
chamber.
h re
hole
spec
– Pull off bonnet seal in area of plenum chamber. es, in part or in w
t to the co
– Remove right-hand wiper motor: ⇒ Electrical system; Repair
group 92; Removing and installing wiper system
rrectness of i
l purpos
– Disconnect cable connections -1-, -2- and -3-, pull positive
nf
ercia
o
terminal -A- out of plenum chamber bulkhead and place on
rm
m
engine.
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
o
by c lksw
cted agen
Prote AG.
– Disconnect all connectors -A- for engine wiring harness and

pull small connector -B- off engine control unit.
– Lay engine wiring harness on engine.
– Separate connector for radiator fan at radiator fan mounting.
– Bring lock carrier into service position ⇒ General body repairs;
Rep. gr. 50 ; Body - front; Lock carrier service position .
– Remove charge air pipe -A-, separate connector -B-, loosen

fastening nuts on lock carrier and also remove charge air pipe
-C-.

Phaeton 2003 ➤
– Detach lines -A- from air conditioner compressor.
– Unclip coolant lines -1- from plenum chamber bulkhead.
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
– Open cover to rear of this and separate connectors -1-, -2-,
an
d
itte
-3- and -4-. Lay engine-side cable ends on engine.
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f in
– Separate vacuum line for brake servo at the points indicated

form
mer
-arrow-.
atio
om
– Place a cleaning cloth in area of servo pump.

n
c
i
or
n thi
e
– Clamp servo line off as shown using a hose clip - 3094- .

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.

Phaeton 2003 ➤
– Loosen banjo bolt -A- and then pull off the hose crimped with
the hose clip - 3094- . Collect escaping servo fluid in a suitable
container.
– Drain coolant ⇒ page 173 .
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
– Pull coolant hoses -arrows- from gearbox oil cooler -A-, loosen
ab
ility
its threaded connection and allow the cooler to hang free.
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
– Detach coolant hoses from connecting tube on lock carrier
om
io
-arrows-.
n
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.
– Detach coolant hoses -arrows- from engine.

Phaeton 2003 ➤
– Loosen nuts -arrow- and remove clamp from air conditioner

line.
– Unbolt earth wire from behind reservoir for windscreen washer
system.
– Remove propshaft heat shield from vehicle underbody.
– Secure propshaft with assembly device - 3213- .

– Remove propshaft ⇒ Transfer box and final drive; Rep. gr.
39 ; Removing and installing propshaft . AG. Volkswagen AG d
agen oes
ksw
– Push selector lever cable on gearbox off ball pin and pullbyout
Vol not
gu
cable securing clip. rised ara
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
– Replace outer bolts of engine carrier with locking pins - VAS
spec
6131/1-6- -arrow-.
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
– Replace outer bolts of gearbox console with locking pins - VAS

o
r
rp
cu
6131/1-5- -arrow-.
o
m
f
en
ng
t.
yi Co
– Separate all connectors between body and front axle in wheel Cop py
t. rig
housings. opyri
gh by
Vo
ht
by c
– Separate front brake calipers and secure to body. ⇒ Brake
lksw
cted agen
Prote
system; Rep. gr. 46 ; Repairing front wheel brake
AG.

Phaeton 2003 ➤
– Remove lower bolts -arrow- of suspension struts.

– Unscrew securing nut -1- and remove bolt.
– Now press upper suspension link -2- off wheel bearing hous‐
ing -3-.
– Remove securing bolts -4- and press track rod ball joints off.
Preparing scissor-type assembly platform - VAS 6131- for further
procedure:
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
– Loosen clamping bolt on universal engine support - VAS
ility
ot p
6131/1-1- with Allen key -1-, insert adapter -VAS 6131/5-3-
wit
is n
and tighten clamping bolt lightly against it.
h re
ole,
spec
– Screw knurled nut of universal engine support - VAS 6131/1-1-
as far down as possible.
t to the co
rrectness o
cial p
f inform
mer
atio
m
– Now screw modified universal engine supports - VAS

o
n
c
6131/1-1- -A- in position B3 and F3 on scissor-type assembly i

or
n thi
e
platform gently by hand.

t
sd
iva
o
pr
cum
r
fo
en
ng
Note
t.
yi Co
Cop py
t. rig
gh ht
The engine supports -B- and -C- have predetermined positions. pyri by
Vo
co
The other supports must be aligned and bolted in place in ac‐
by lksw
cted agen
cordance with the diagram.
Prote AG.
– Now attach mountings for left engine carrier - VAS 6131/5-1-

-B- to scissor-type assembly platform in position A5 and B6 as
well as mountings for right engine carrier - VAS 6131/5-2-
-C- in position H5 and G6. Arrows on the supports point
forwards.

Phaeton 2003 ➤
AG. Volkswagen
n AG do
wage es n
olks ot g
– Install supports -3- and -4- ed
byfrom basic set for
V
Phaeton - VAS ua
ran
6131/1- at the positions oris shown -E - and -F-. tee
th or
au ac
ss
ce
Note le
un
pt
an
d
itte
y li
erm
If, after removing, engine and gearbox are to be separated on
ab
ility
scissor-type assembly platform - VAS 6131- , note the additional
ot p
wit
steps required for this at this point. ⇒ page 11
is n
h re
ole,
spec
– Position horizontal scissor-type assembly platform under en‐

gine/gearbox assembly. Supports -B- and -C- must be guided
t to the co
into corresponding receptacles of engine carrier on left and
right.
rrectness o
cial p
f inform
mer
atio
om
n
c
– At the same time, guide right and left mountings for gearbox
i
or
n thi
bracket into corresponding holes -arrow-.
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.
– Now place the centre support under the traverse of the sub‐
frame -arrow-.
– Place the front supports in the engine bores as shown.

– Unscrew securing bolts for engine carrier and gearbox brack‐
et.

Phaeton 2003 ➤
– Unscrew subframe bolts -1-, -2- and -3-.
Note
After loosening subframe, wheel alignment on vehicle must be

checked.
– Check that all connections between power unit and body have
been separated.
Procedure for separating gearbox and engine:
Before positioning scissor-type assembly platform beneath vehi‐
cle:
AG. Volkswagen AG d
– Remove front anti-roll bar. lksw
agen oes
not
o
byV gu
– Detach lines to gearbox oilriscooler
ed on gearbox and on sump. ara
nte
Catch any escaping oil inut a container.
ho eo
ra
s a c
Continuation ⇒ page 10 s
ce
e
nl
pt
du
After removing the engine:
an
itte
y li
erm
ab
ility
– Support gearbox on scissor-type assembly platform with sup‐
ot p
wit
port - VAS 6131/1-2 - -D-.
, is n
h re
hole
– Separate all necessary lines and wiring harnesses between
spec
engine and gearbox.
es, in part or in w
t to the co
– Remove starter ⇒ Rep. gr. 27 ; Removing and installing start‐
er .
rrectness of i
– Unbolt retainer -arrow- for ATF line on upper part of sump.
l purpos
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
py by
– Unbolt retainer -arrow- for ATF line on bottom of gearbox.
co Vo
by lksw
cted agen
Prote AG.

Phaeton 2003 ➤
– Remove bolt -arrow-.

– Pull of ATF lines from gearbox. Catch any escaping oil in a
container. gen AG
. Volkswagen AG
a does
ksw not
Vol gu
d by ara
e nte
ris
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Unbolt engine speed sender - G28- from gearbox -arrow-.
es, in part or in w
t to the co
– Remove front exhaust pipe together with catalytic converter
⇒ page 306 .
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
– Insert guide pin of adapter - T40058- so that the large diameter

rp
cum
fo
-arrow 1- points towards the engine. The smaller diameter

en
ng
t.
yi
-arrow 2- faces the adapter.
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– When loosening torque converter bolts, counterhold crank‐

shaft using adapter - T40058- .
Note
Ignore -arrow-.

Phaeton 2003 ➤
– Unscrew 3 bolts -arrows- for torque converter, working

through opening of removed starter (turn crankshaft 1/3 turn
each time).
– Remove engine/gearbox securing bolts -3 … 10-.

– Loosen clamping bolts -1- on side of scissor-type assembly
platform - VAS 6131- .
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
– Pull rear section of platform together with gearbox to rear

wit
, is n
-arrow-; simultaneously separate torque converter from drive

h re
hole
plate through opening.

spec
es, in part or in w
– Secure the torque converter in the gearbox to prevent it falling

t to the co
out.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
1.1.1 Removing engine from scissor-type assembly platform - VAS 6131-

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.

Phaeton 2003 ➤
Special tools and workshop

equipment required
♦ Shackle - 10-222 A/12-
♦ Hook - 3004-
♦ Lifting tackle - 3033-
♦ Engine and gearbox sup‐
port - VAS 6095- with uni‐
versal support - VAS
6095/1- and support brack‐
et for V6 TDI engine - VAS
6095/1-4-
♦ Workshop hoist -
VAS 6100-
♦ Lift arm extension (work‐
shop crane) - VAS 6101- agen
AG. Volkswagen AG d
oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
Procedure
or
n thi
te
sd
a
• Engine separated from gearbox.

iv
o
pr
cum
r
fo
– Attach lifting tackle - 3033- to workshop crane - VAS 6100- as

en
ng
t.
yi
shown in the illustration.
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Phaeton 2003 ➤
– Screw a nut -arrow- about 4 turns onto stud on turbocharger.

– Attach lift arm extension - VAS 6101- to workshop crane -
VAS 6100- .
– Connect lift arm extension - VAS 6101- to shackle - 10-222 A/
12- and engage hook - 3004- on stud.
– Tension hook - 3004- so that engine is taken up horizontally.
– Loosen fastening nuts from left and right engine mounts

-arrow-.
– Lift engine off the support elements on scissor-type assembly
platform - VAS 6131- .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
– Using universal support - VAS 6095/1- and support bracket for
ce
le
un
pt
V6 TDI engine - VAS 6095/1-4- , secure engine to engine and
an
d
itte
gearbox support - VAS 6095- as shown in the illustration.
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
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
1.2 Notes on installing

en
ng
t.
yi Co
Cop py
Install in reverse order. In the process, note the following:
t. rig
gh ht
pyri by
Vo
co
– Specified tightening torques ⇒ page 16
by lksw
cted agen
Prote AG.
– Check whether dowel sleeves for centring engine/gearbox
have been fitted in cylinder block, insert if necessary.

Phaeton 2003 ➤
– Reconnect all lines, hoses and connectors which were sepa‐

rated during removal.
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Connect air conditioning lines ⇒ Repair group 87 .
– Fill with oil for power-assisted steering: ⇒ Repair group 48;
Checking oil level of power-assisted steering
– Replenish coolant ⇒ page 173 .
– Carry out a road test and read all fault memories: or ⇒ Vehicle
diagnostic tester; VAS 5052 “Guided functions”
1.3 Specified torques

Component to Specified torque
Subframe -1- and -2- Body 130 Nm + turn 90° further, renew bolts
Left and right support -3- Body 40 Nm + turn 90° further, renew bolts
Engine carrier Body 90 Nm + turn 90° further, renew bolts
. Volkswagen AG
Engine mounting kswage
n AG
Engine carrier does ⇒ page 16
l not
Vo
Gearbox carrier ed by Body gu
ara 50 Nm
ris nte
utho eo
ra
a c
ss
ce
e
Bolts for subframe

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
1.4 Front engine mounting

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.

Phaeton 2003 ➤
1 - 70 Nm
❑ Renew.
2 - Right engine support
3 - 70 Nm
❑ Renew.
4 - Left engine support
5 - Engine mounting
6 - Engine carrier agen
AG. Volkswagen AG d
oes
lksw not
❑ Secured to body with 90 d by Vo gu
ara
Nm + 90° further. orise nte
th eo
u ra
7 - 30 Nm + turn 90° further ss a c
ce
le
❑ Renew.
un
pt
an
d
itte
8 - 50 Nm
y li
rm
ab
pe
❑ Renew.
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
co lksw
by
cted agen
Prote AG.

Phaeton 2003 ➤
AG. Volkswagen AG d
agen oes
olksw not
13 – Crankshaft group
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
1 Dismantling and assembling engine
ce
e
nl
pt
du
an
itte
y li
erm
ab
Caution
ility
ot p
wit
, is n
If large quantities of swarf or metal particles (caused, for ex‐
h re
hole
ample, by partial seizure of the crankshaft or conrod bearings)
spec
are found in the engine oil when performing repairs, clean the
es, in part or in w
t to the co
oil passages thoroughly and renew the oil cooler in order to
prevent subsequent damage.
Engine must not be set down on oil sump, as this will damage
rrectness of i
the liquid gasket between the upper and lower sump.
l purpos
nf
ercia
or
Note
m
m
atio
om
n in
c
♦ To carry out assembly work, the engine should be mounted

or
thi
on the engine and gearbox support -VAS 6095- in conjunction
te
sd
a
with universal bracket - VAS 6095/1- and support bracket for

iv
o
r
rp
cu
V6 TDI engine - VAS 6095/1-4- .
o
m
f
en
ng
t.
yi
♦ Assembly overview - poly V-belt drive ⇒ page 20 .
Co
Cop py
t. rig
gh
♦ Removing and installing poly V-belt ⇒ page 23 .
ht
pyri by
Vo
o
by c lksw
♦ Renewing crankshaft oil seal on belt pulley end ⇒ page 24 .
cted agen
Prote AG.
♦ Removing and installing front sealing flange ⇒ page 26 .

♦ Assembly overview - drive plate ⇒ page 29 .
♦ Removing and installing drive plate ⇒ page 32 .
♦ Renewing crankshaft oil seal on timing chain end
⇒ page 33 .
♦ Assembly overview - timing chain covers ⇒ page 35 .
♦ Removing and installing timing chain covers ⇒ page 36 .
♦ Assembly overview - balancer shaft ⇒ page 43 .
♦ Removing and installing balancer shaft ⇒ page 44 .
18 Rep. gr.13 - Crankshaft group

Phaeton 2003 ➤
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
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.
Part I ⇒ page 20
Part II ⇒ page 29
Part III ⇒ page 35
Part IV ⇒ page 43
1. Dismantling and assembling engine 19

Phaeton 2003 ➤ agen
AG. Volkswagen AG d
oes
ksw
6-cylinder diesel engine (3.0 l engine, common rail) -byEdition
Vol 04.2016 not
gu
ara
ed nte
oris e
1.1 Assembly overview - poly V-belt drive th or
au ac
ss
ce
e
nl
pt
du
an
1 - Poly V-belt
itte
y li
erm
ab
❑ Mark direction of rota‐
ility
ot p
tion before removing.
wit
, is n
❑ Removing and installing
h re
hole
⇒ page 23
spec
es, in part or in w
❑ Check for wear.
t to the co
❑ When installing, make
sure it is properly seated
on pulleys.
rrectness of i
2 - 20 Nm + turn 90° further
l purpos
❑ Renew.
❑ Use shim ⇒ page 22 .
nf
ercia
orm
m
3 - Shim
atio
om
❑ Renew.
n in
or c
thi
e
❑ Also insert on vehicles

t
sd
iva
where no shim was pre‐
o
r
rp
cu
viously installed.
o
m
f
en
ng
t.
yi Co
4 - Cover for idler roller t. Cop py
rig
gh ht
5 - Alternator yri
p by
o Vo
by c lksw
❑ Removing and installing cted agen
Prote AG.
⇒ Electrical system;
Rep. gr. 27 .
❑ To facilitate attachment
of alternator, knock
back threaded bushes
for alternator securing
bolts slightly.
6 - 22 Nm
7 - Cover for idler roller
8 - 25 Nm
9 - Idler roller for poly V-belt
❑ Note installation position.
10 - 40 Nm
11 - Bracket for alternator and idler roller
❑ Observe tightening sequence ⇒ page 23 .
12 - 22 Nm
14 - Cover for idler roller
❑ On vehicles with additional idler roller.
15 - 22 Nm
16 - 22 Nm
17 - Poly V-belt pulley for coolant pump
❑ Counterhold with pin wrench - 3212- when loosening and tightening.
❑ Installation position: lettering “vorn” (front) faces in direction of travel (forwards).

Phaeton 2003 ➤
18 - 9 Nm
19 - Coolant pump
❑ Removing and installing ⇒ page 177
❑ Only from later production.
21 - 22 Nm
22 - Bracket for idler roller
23 - 22 Nm
24 - Power steering pump
❑ Removing and installing ⇒ Running gear, front-wheel drive and four-wheel drive; Rep. gr. 48 .
❑ Installation position: lettering “vorn”
gen(front)
AG. Volkfaces
swagenin
AGdirection
d
of travel (forwards).
wa oes
olks not
25 - Poly V-belt pulley for power
d b steering pump
yV gu
ara
e nte
ris
26 - 22 Nm tho eo
au ra
c
ss
27 - Gasket
ce
e
nl
pt
du
❑ Renew.
an
itte
y li
erm
ab
28 - Bracket for air conditioner compressor and power steering pump
ility
ot p
29 - 40 Nm
wit
, is n
h re
hole
30 - 25 Nm
spec
es, in part or in w
31 - Air conditioner compressor
t to the co
❑ Removing and installing ⇒ Air conditioning system; Rep. gr. 87 .
❑ When installing check dowel sleeves ⇒ Item 32 (page 21) .
rrectness of i
32 - Dowel sleeve
l purpos
❑ Qty. 2.
❑ Check for correct seating in bracket.
nf
ercia
or
33 - 25 Nm
m
m
atio
m
34 - Poly V-belt tensioning element

o
n in
or c
thi
te
sd
iva
Caution
o
r
rp
cu
o
m
f
Depending on the vehi‐

en
ng
t.
yi
cle version, the securing
Co
Cop py
thread in the cylinder
t. rig
gh ht
yri
crankcase for the ten‐
p by
o Vo
by c lksw
sioner can have an M10 Prote
cted agen
or M11 thread. It is abso‐
AG.
lutely necessary to cor‐

rectly assign bolt and
tensioner to the appro‐
priate cylinder crank‐
case.
❑ Swivel with Torx 60 insert.

Phaeton 2003 ➤
35 - Bolt
Caution
Different threads in
crankcase.
Before installation,
check whether the
thread is an M10 or M11.
Use corresponding bolt
size. Risk of engine dam‐
age.
It is absolutely necessa‐
ry to correctly assign bolt
and tensioner to the ap‐
propriate cylinder crank‐
case.
❑ M10: 50 Nm + 90° further

❑ M11: 60 Nm + 90° further
❑ Renew. agen
AG. Volkswagen AG d
oes
olksw not
36 - Vibration damper d by V gu
ara
ise nte
❑ With poly V-beltthopulley.
r eo
au ra
c
ss
ce
le
un
pt
Bolted connection for vibration damper

an
d
itte
y li
erm
ab
1 - 20 Nm + turn 90° further, renew

ility
ot p
wit
2 - Shim, renew
is n
h re
ole,
3 - Vibration damper
spec
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.

Phaeton 2003 ➤
Tightening sequence of bracket for alternator and idler roller

– Tighten bracket for alternator and idler roller in the following
steps:
1. Position bolt -A- and tighten by hand.
2. Position bolt -B- and tighten.
3. Tighten bolt -A-.
4. Position bolt -D- and tighten.
5. Position bolt -C- and tighten.
1.2 Removing and installing poly V-belt

Special tools and workshop equipment required
♦ Special wrench, long reach - T40087-
♦ Spring-type clip pliers - VAS 5024A-
Removing
olkswagen AG
en AG. V
– Carefully pull engine cover
olks
wagpanel off four retaining
does
npins
ot g one
after the other -arrows-.
ed
byV ua
ra
ris nte
– Remove noise thoinsulation ⇒ General body repairs, exterior;e or
au a
Rep. gr. 50
s ; Body - front; Assembly overview - noise insula‐ c
s
tion .
ce
le
un
pt
an
d
itte
– Remove lower charge air hoses ⇒ Item 2 (page 214) to Y-

y li
erm
ab
piece.
ility
ot p
– Remove securing bolts ⇒ Item 9 (page 214) from Y-piece.

wit
is n
h re
ole,
– Press Y-piece upwards and fix in this position e.g. using cable
spec
ties.
t to the co
rrectne
Note
s
Mark direction of rotation of poly V-belt before removing.

s o
cial p
f inform
– Slacken poly V-belt by swivelling tensioner in direction of

mer
-arrow-, using a lever and T60 Torx bit - T40087- .

atio
om
n
c
– Remove poly V-belt from tensioning roller.

i
or
n thi
te
sd
a
Installing
iv
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.

Phaeton 2003 ➤
Vehicles without additional idler roller:

Installation is carried out in the reverse order; note the following:
– Fit poly V-belt on pulleys.
1- Alternator
2- Idler roller
3- Idler roller
4- Coolant pump
5- Power steering pump
6- Air conditioner compressor
7- Tensioning element for poly V-belt
8- Crankshaft
Vehicles with additional idler roller:

1- Alternator
2- Idler roller
3- Idler roller
4- Coolant pump
5- Idler roller
AG. Volkswagen AG d
6- Power steering pump agen oes
olksw not
V gu
by ara
7- Air conditioner compressor ris ed
nte
ho eo
ut
8- Poly V-belt tensioning element
ss a ra
c
ce
le
9- Crankshaft
un
pt
an
d
itte
y li
All:
rm
ab
pe
ility
ot
wit
, is n
Note
h re
hole
spec
When installing poly V-belt, make sure it is properly seated on

es, in part or in w
t to the co
pulleys.
– Start engine and check that belt runs properly.

rrectness of i
l purpos
Loosening poly V-belt pulley for coolant pump

• Poly V-belt removed.
nform
ercia
– Counterhold using pin wrench - 3212- when loosening bolts

m
-arrows- on poly V-belt pulley for coolant pump.

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.
1.3 Renewing crankshaft oil seal - belt pul‐

ley end

Phaeton 2003 ➤
♦ Oil seal extractor - T40019-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
♦ Assembly appliance - T40048- with -T40048/4-
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
Procedure
s
iva
do
r
rp
cum
– Remove poly V-belt ⇒ page 23 .

fo
en
ng
t.
yi
– Mark position of vibration damper for re-installation.
Co
Cop py
t. rig
gh
– Loosen bolts -1- and remove vibration damper.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Adjust inner part of oil seal extractor - T40019- so that it is level

with the outer part and lock in position with knurled screw.
– Lubricate threaded head of oil seal extractor, place it in posi‐
tion and, exerting firm pressure, screw it into oil seal as far as
possible.
– Loosen knurled screw and turn inner part against crankshaft
until the oil seal is pulled out.
– Clamp flats of oil seal extractor in vice. Remove oil seal with
pliers.
– Clean contact surface and sealing surface.

Phaeton 2003 ➤
– Fit assembly aid - T40048/1- onto assembly sleeve -

T40048/2- and slide oil seal -1- onto assembly sleeve.
– Remove assembly aid.
– Fit assembly sleeve - T40048/2- on crankshaft and slide oil

seal -1- into sealing surface in engine.
Note
Leave assembly sleeve - T40048/2- in position on crankshaft for

pressing in seal.
– Apply press sleeve - T40048/4- (installation depth 5 mm) to

crankshaft using M8×55 mm bolts.
– Screw in bolts hand-tight to start with.
AG. Volkswagen AG d
– Tighten bolts alternately, 1/2 turn at a time, to press en
wagin oil seal oes
Volks not
onto stop. ed
by gu
ara
is nte
or eo
Further installation is carried out in the areverse
ut
h order. ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
1.4 Removing and installing front sealing

hole
spec
flange
es, in part or in w
t to the co

♦ 2-hole pin wrench - 3212-
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
o Vo
♦ Hand drill with plastic brush by c lksw
cted agen
Prote AG.
♦ Eye protection

Phaeton 2003 ➤
♦ Silicone sealant - D176 404 A2-

Removing
– Remove poly V-belt pulley for coolant pump. Counterhold us‐
ing pin wrench - 3212- when loosening bolts -arrows-.
– Mark position of vibration damper for re-installation.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
– Loosen bolts -1- and remove vibration damper.
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
ercia
– Pry off cover from idler roller for poly V-belt.

m
a
– Unscrew bolt -arrow- and detach idler roller from front sealing
com
tion in
flange.
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.
– Remove noise insulation from front sealing flange -arrows-.

– Remove coolant pipe securing nuts.
– Lever coolant pipe tab up.

Phaeton 2003 ➤
– Remove bolts.
– Pull off front sealing flange (right-side first -arrow 1-, then left-
side -arrow 2-.
– Drive out oil seal with flange removed.
Installing
Note
Renew seals and O-rings.
– Remove old sealant from grooves in sealing flange and from

sealing surfaces.
AG. Volkswagen AG d
agen oes
olksw not
V
WARNING ed by gu
ara
nte
ris
ho eo
ut
Wear eye protection. a ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Remove remaining sealant from sealing flange and cylinder
ility
ot p
block/upper part of sump with rotating plastic brush or similar.
wit
, is n
h re
– Clean sealing surfaces; they must be free of oil and grease.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
– Cut off tube nozzle at forward marking (approx. 2 mm nozzle

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
o
by c lksw
cted agen
Prote AG.

Phaeton 2003 ➤
– Install sealing elements -2- and -4- and O-rings -1- and -3-.
– Apply bead of sealant -arrow- onto clean sealing surface of
front sealing flange as illustrated.
• The bead of sealant must project 1.5…2.0 mm above the seal‐
ing surface.
Note
♦ The sealant bead must not be thicker. Otherwise, excess seal‐

ant will make its way into the sump and block the strainer or
sieve in the suction line of the oil pump. G. Volkswagen nA AG do
wage es n
♦ The front sealing flange must be installed within y5Vminutes
olks af‐ ot g
ter applying sealant. ed
b ua
ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Tighten bolts securing front sealing flange -arrow- in diagonal
wit
, is n
sequence and in stages. Specified torque: 9 Nm.
h re
hole
spec
– Install new oil seal ⇒ page 24 .
es, in part or in w
t to the co
Further installation is carried out in the reverse order.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
c
1.5 Assembly overview - drive plate/dual-

or
thi
te
sd
mass flywheel
iva
o
r
rp
cu
o
m
f
Removing and installing dual-mass flywheel ⇒ page 30 .

en
ng
t.
yi Co
op
Extracting and driving in needle bearing for dual-mass flywheel
C py
ht. rig
⇒ page 31 .
rig ht
py by
co Vo
by lksw
cted
Removing and installing drive plate ⇒ page 32 .
agen
Prote AG.
Renewing crankshaft oil seal on timing chain end ⇒ page 33 .

Phaeton 2003 ➤
1 - Drive plate
drive plate
⇒ page 32 .
2 - Washer
3 - Securing bolt
❑ Renew.
❑ 30 Nm + turn 90° further
4 - Washer
5 - Sender wheel
❑ For engine speed send‐
er - G28- .
❑ Location of engine
speed sender - G28-
⇒ page 302
6 - Crankshaft oil seal - timing
chain end
⇒ page 33
7 - Centring sleeve for torque
converter
Note AG. Volkswagen AG d

agen oes
olksw not
To drive into crankshaft, warm d by
V gu
ara
crankshaft with hot air blower and ise nte
or eo
h
cool centring sleeve with chilling aut ra
c
agent ss
ce
e
nl
pt
du
an
8 - Dowel sleeve
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
1.6 Removing and installing dual-mass fly‐

t to the co
wheel
rrectness of i

l purpos
♦ Counterhold tool - 10 - 201-

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
o
by c lksw
cted agen
Prote AG.

Phaeton 2003 ➤
Removing
• Gearbox removed. n AG. Volkswagen AG do
lkswage es n
– Remove clutch pressure plate ⇒ Rep. gr.d b30 yV .
o ot g
ua
ran
ir se tee
– Mark installation position of dual-mass uth flywheel on crankshaft.
o
or
a ac
ss
– Attach counterhold - 10 - 201- in order to loosen bolts.
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
Note
To prevent damage to the dual-mass flywheel when removing,
rrectness of i
the bolts -B- must not be removed with an impact wrench or sim‐
l purpos
ilar. The bolts may only be removed by hand.
nf
ercia
– Rotate the dual-mass flywheel -A- so that the bolts align with
or
the holes -arrows-.
m
m
atio
m
– When removing bolts, ensure that the bolt heads do not come
o
n in
or c
into contact with the dual-mass flywheel; the flywheel will oth‐
thi
e
erwise be damaged as the bolts are screwed out.

t
sd
iva
o
r
rp
cu
Installing
o
m
f
en
ng
t.
yi Co
Installation is carried out in the reverse order; note the following: t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
Note cted agen
Prote AG.
A needle bearing is fitted in the dual-mass flywheel; drive in the

needle bearing when fitting a new flywheel ⇒ page 31 .
– Use new bolts for securing.

– Reverse position of counterhold - 10 - 201- in order to tighten
bolts.
– Install clutch pressure plate ⇒ Rep. gr. 30 .
Specified torque
Component Nm
Dual-mass flywheel to crankshaft 30 Nm + turn
90° further 1)
• 1) Renew bolts.
1.7 Extracting and driving in needle roller

bearing for dual-mass flywheel

Phaeton 2003 ➤
♦ Punch - 3264-
♦ -1- Internal puller Kukko 21/1
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
♦ -4- Counterhold Kukko 22/1
hole
spec
Procedure
es, in part or in w
• Gearbox removed. t to the co
– Remove clutch pressure plate ⇒ Rep. gr. 30 .

rrectness of i
– Pull out needle roller bearing using puller Kukko 21/1 and
l purpos
counterhold Kukko 22/1.

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
– Drive needle bearing into dual-mass flywheel until stop using

o
m
f
en
ng
punch - 3264- .
t.
yi Co
Cop py
t. rig
– Install clutch pressure plate ⇒ Rep. gr. 30 . opyri
gh by
Vo
ht
by c lksw
cted agen
Prote AG.
1.8 Removing and installing drive plate


Phaeton 2003 ➤
♦ Counterhold tool - 10-201-
Removing
• Engine/gearbox removed.
– Mark installation position of drive plate on engine.
– Attach counterhold - 10-201- in order to loosen bolts.
– Unbolt drive plate.
– Take out shim located behind.
Installing
Installation is carried out in the reverse order. When installing,
note the following:
– Fit 1.5 mm shim onto crankshaft.
– Install drive plate with washer (1.5 mm).
– Use new bolts for securing.
AG. Volkswagen A
– Reverse position of counterhold ks-w10 - 201- in order to tighten
agen G do
es n
bolts. y Vol ot g
ua
db r e an
ris tee
Specified torque tho or
au ac
ss
Component Nm
ce
le
un
pt
an
d
Drive plate to crankshaft 30 Nm + turn

itte
y li
90° further 1)
rm
ab
pe
ility
• 1)
ot
Renew bolts.
wit
, is n
h re
hole
spec
es, in part or in w
1.9 Renewing crankshaft oil seal on timing

t to the co
chain end
rrectness of i

♦ Fitting tool - T10122-
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
by c lksw
cted agen
Prote AG.

Phaeton 2003 ➤
AG. Volkswagen AG d
agen oes
♦ Lever - T20143/2- olksw not
V gu
d by ara
ise nte
or eo
h
aut 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
Procedure
rrectness of i
• Engine/gearbox removed.
l purpos
– Remove drive plate ⇒ page 93 .
nform
ercia
– Lever oil seal out using lever - T20143/2- .

m
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
yri by
– Modify assembly sleeve - T10122/2- by drilling an 8 mm ∅ hole
op Vo
by c lksw
-arrow 2- for the dowel sleeve. cted agen
Prote AG.
– Use hole -arrow 1- in washer as a drilling template.
– Clean running surface and sealing surface.

– Fit assembly aid - T10122/1- onto assembly sleeve -
T10122/2- and slide oil seal -A- onto assembly sleeve.
– Remove assembly aid.

Phaeton 2003 ➤
– Fit assembly sleeve with oil seal onto crankshaft.

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
– Press in oil seal uniformly until flush all round using press
t to the co
sleeve - T10122/3- .
– Install drive plate ⇒ page 93 .
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
1.10 Assembly overview - timing chain covers m

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

Phaeton 2003 ➤
1 - Crankshaft oil seal on timing

chain end
⇒ page 33
2 - Dowel sleeve
❑ Qty. 2.
3 - 9 Nm
❑ Note sequence when
tightening ⇒ page 42 .
4 - Left timing chain cover
5 - 9 Nm
6 - Gasket
❑ Renew.
7 - 9 Nm agen
AG. Volkswagen AG d
oes
olksw not
❑ Note sequence d by V when gu
ara
tightening
oris ⇒ page 42 .
e nte
e
h
ut or
8 - 9 Nm ss a ac
ce
le
un
9 - Cap
pt
an
d
itte
y li
10 - O-ring
rm
ab
pe
ility
❑ Renew.
ot
wit
, is n
h re
11 - Right timing chain cover

hole
spec
12 - Gasket
es, in part or in w
t to the co
❑ Renew.
13 - 9 Nm
rrectness of i

l purpos
14 - Dowel sleeve
nform
ercia
❑ Qty. 2.
m
15 - Sealing element
a
com
tion in
❑ Qty. 2.
r
te o
thi
16 - Lower timing chain cover

s
iva
do
r
rp
cum
17 - M6 = 9 Nm; M8 = 22 Nm
fo
en
ng
t.
yi
❑ Note sequence when tightening ⇒ page 42 .
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
1.11 Removing and installing timing chain
Prote AG.
covers

AG. Volkswagen AG d
agen oes
ksw
gu Phaeton 2003 ➤
ol not
V
d by ara
6-cylinder diesel
orise engine (3.0 l engine, common rail) - nEdition
tee 04.2016
h
aut or
ac
♦ Counterhold tool - 10-201- ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
♦ Used oil collection and extraction unit - V.A.G 1782-
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
o
by c lksw
cted agen
Prote AG.
♦ Hand drill with plastic brush

♦ Eye protection
♦ Silicone sealant - D176 404 A2-
Removing
Note
All cable ties which are released or cut open when removing must
be fitted in the same position when installing.
– Drain engine oil.

– Remove engine ⇒ page 3 .
– Separate engine/gearbox unit.
– Secure engine to engine stand ⇒ page 13 , or leave engine on
scissor-type assembly platform - VAS 6131- .
– Mark installation position of drive plate on engine.
– Attach counterhold - 10-201- in order to loosen bolts.
– Unbolt drive plate.
– Take out shim located behind.

Phaeton 2003 ➤
– Unscrew bolts -1- and -2- and disconnect air pipe from hoses
-arrow-.
– Remove air intake hose together with crankcase breather

hose -arrows-.
. Volkswagen AG
wa oe gen AG d
– Disconnect electrical
yV
olks connectors -1- and -2-. s not g
u b ara
ed
– Unscrew banjo
ho
ris bolt -3- for oil supply line. nte
e
ut a
or
ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Disconnect electrical connector -4-.

rrectne
– Remove bolts -2- and -3- and remove bracket.

ss
– Remove bolt -1-.

o
cial p
f in
– Detach coolant pipe (rear) from coolant hose -arrow-.

form
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
o
by c lksw
cted agen
Prote AG.

Phaeton 2003 ➤
– Unscrew bolts -1- and -2- and detach oil return line.
Note
Shown in illustration with intermediate pipe removed.
– Unscrew nuts and bolts -arrows- and detach left intermediate

pipe.
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
– Unscrew bolts and nuts -1 … 4- and detach right intermediate

, is n
h re
pipe.
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
– Unscrew bolts -arrows- and remove turbocharger.

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.

AG. Volkswagen
Phaeton 2003 ➤ ksw
agen AG do
es n
Vol ot g
6-cylinder diesel engine (3.0 l engine, common
db
y rail) - Edition 04.2016 ua
ra
e nte
ris
tho eo
– Unscrew bolt -arrow- and remove vacuum aupump. ra
c
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
l purpos
– Unscrew bolts -1 … 4- and remove right timing chain cover.
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.
– Unscrew bolts -1 … 4- and remove left timing chain cover.
– Unscrew bolts -1 … 9- and remove lower timing chain cover.

– Press out crankshaft oil seal (rear) from timing chain cover.
Installing
Note
♦ Renew gaskets, seals and O-rings.

♦ Secure all hose connections with hose clips (same as original
equipment) ⇒ Parts catalogue .
♦ Reinstall all cable ties in the same locations when assembling.
– Remove old sealant from grooves in timing chain covers and

from sealing surfaces.
WARNING
Wear eye protection.

Phaeton 2003 ➤
– Remove remaining sealant on timing chain covers and cylin‐

der block/cylinder head using rotating plastic brush or similar.
– Cut off nozzle on tube at front marking (∅ of nozzle approx.

2 mm).
Note
♦ The sealant beads must not be thicker than specified, other‐

wise excess sealant could enter the sump and clog the strainer
in the oil pump.
♦ The timing chain covers must be installed within 5 minutes af‐
ter applying sealant.
– Insert sealing elements -2- and -5-

– Apply sealant beads -1- and -4- onto the clean sealing surface
of the timing chain cover (bottom) as illustrated.
• The grooves on the sealing surfaces must be completely filled
with sealant.
AG. Volkswagen AG d
ing surface. lkswagen oes
n
o ot g
yV u
• The beadris
edof sealant round drillings -3- and -6- must
b ara
nte be
1.5 …
utho2.0 mm thick. eo
r
sa ac
– Check
s
whether the two dowel sleeves are fitted in the cylinder
ce
e
nl
block; install if necessary.

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
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
o
by c lksw
cted agen
Prote AG.

Phaeton 2003 ➤
– Fit lower timing chain cover and tighten bolts as follows:

Stage Tightening
I – Tighten bolts -1 … 9- to 5 Nm in diagonal se‐
quence starting from inside and working out‐
wards.
II – Tighten bolts -1 … 7- to 9 Nm in diagonal se‐
quence starting from inside and working ageout‐
wards. Volksw es n
ot g
d by ua
III – Tighten bolts -8- and -9- too22
ri Nm.
se ran
tee
th or
s au ac
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
– Apply bead of sealant onto clean sealing surface of left timing
chain cover as illustrated.
rrectness of i
• The groove -1- on the sealing surface must be completely filled
l purpos
with sealant.
nform
ercia
ing surface.
m
– Fit gasket -2-.
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
– Apply a ∅ 3 mm bead of sealant to each transition between
C py
t. rig
gh
cylinder head and bottom timing chain cover -arrows-, as
ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.
Caution
Danger of blocking lubrication system with excess sealant.

♦ Do not apply a sealant bead that is thicker than prescribed.
– Fit timing left chain cover and tighten bolts as follows:

AG. Volkswagen AG d
agen oes
olksw not
yV ara Phaeton 2003 ➤
b gu
ed
6-cylinder horidiesel
s engine (3.0 l engine, common rail)n-te Edition 04.2016
eo
aut ra
ss c
Cover on left for timing chain - Tightening torque and sequence
ce
le
un
pt
an
d
itte
y li
erm
ab
Note
ility
ot p
wit
is n
Renew bolts tightened through an additional specified angle.
h re
ole,
spec
– Tighten bolts in 4 stages in the sequence shown:
t to the co
Stage Bolts Specified torque
1. -1- 3 Nm
rrectne
2. -2- 9 Nm
s
3. -1- 9 Nm
s o
cial p
f
4. -3- 9 Nm diagonally
inform
mer
Right timing chain cover
atio
om
n
c
i
or
n
– Apply bead of sealant onto clean sealing surfaces of right tim‐
thi
te
sd
a
ing chain cover as illustrated.

iv
o
pr
cum
r
fo
• The groove -1- on the sealing surface must be completely filled
en
ng
t.
with sealant.
yi Co
Cop py
ht. rig
• The bead of sealant must project 1.5…2.0 mm above the seal‐ rig ht
py by
ing surface.
co Vo
by lksw
cted agen
Prote AG.
– Fit gasket -2-.
– Apply a ∅ 3 mm bead of sealant to each transition between

cylinder head and bottom timing chain cover -arrows-, as
Caution
Danger of blocking lubrication system with excess sealant.

♦ Do not apply a sealant bead that is thicker than prescribed.
– Fit timing chain cover (right) and tighten bolts as follows:

Stage Bolts Specified torque
1. -1- 3 Nm
2. -2- 9 Nm
3. -1- 9 Nm
4. -3- 9 Nm diagonally
1.12 Assembly overview - balancer shaft

Removing and installing balancer shaft ⇒ page 44 .

Phaeton 2003 ➤
6-cylinder diesel engine (3.0 l engine, common rail) - Editiona04.2016
gen AG
. Volkswagen AG
do w es n
olks ot g
yV ua
1 - Sleeve bearing ris
ed
b ran
tee
tho or
2 - 60 Nm au ac
ss
❑ Counterhold with diesel
ce
le
un
pt
injection pump locking
an
d
itte
pin - 3359- when loos‐
y li
erm
ab
ening and tightening.
ility
ot p
wit
3 - Balance weight (timing
is n
h re
chain end)
ole,
spec
4 - 9 Nm
t to the co
5 - Bearing plate
6 - Balance weight (belt pulley
rrectne
end)
7 - 60 Nm
ss o
❑ Counterhold with diesel
cial p
f in
injection pump locking
form
mer
pin - 3359- when loos‐
atio
ening and tightening.
om
n
c
i
or
n
8 - Sleeve bearing
thi
te
sd
va
9 - Balancer shaft
i
o
pr
cum
r
fo
en
ng
t.
yi
⇒ page 44
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.13 Removing and installing balancer shaft

Removing
– Secure engine to engine stand ⇒ page 13 .

Phaeton 2003 ➤
– Remove front sealing flange ⇒ page 26 .

– Remove timing chain covers ⇒ page 36 .
– Attach adapter - T40049- at rear end of crankshaft using two
old securing bolts for drive plate.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
– Lay a cloth under upper part of sump to catch engine oil.
h re
hole
spec
– Unscrew plug from upper part of sump.
es, in part or in w
t to the co
WARNING
rrectness of i
To avoid any risk of injury, do not rotate crankshaft while feeling
for TDC hole with your finger.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
– Screw locking pin - 3242- into threaded hole (20 Nm); if nec‐
s
iva
do
essary, turn crankshaft -1- backwards and forwards slightly to
r
rp
cum
fo
fully centralise locking pin.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Lock balancer shaft at front of engine with diesel injection

pump locking pin - 3359-
– Unscrew bolt and remove balance weight from balancer shaft.

Phaeton 2003 ➤ agen
AG. Volkswagen AG d
oes
ksw n
6-cylinder diesel engine (3.0 l engine,bycommon
Vol
rail) - Edition 04.2016ot gua
ed ran
oris tee
– Lock balancer shaft at rear of engine awith
ut diesel injection pump
h or
ac
locking pin - 3359- ss
ce
le
un
pt
– Unscrew bolts -arrows- and detach chain sprocket from bal‐
an
d
itte
ancer shaft.
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
– Unscrew bolt -arrow- and remove balance weight from bal‐

ancer shaft.
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.
– Unscrew bolts -arrows- and remove bearing plate for balancer
shaft.
– Pull balancer shaft out of cylinder block.
Installing
• Crankshaft locked in TDC position with locking pin - 3242- .
Further assembly/installation is carried out in the reverse se‐
quence of removal.

Phaeton 2003 ➤
2 Chain drive (engine code BMK)
Note
Removing timing chains from camshafts only ⇒ page 122 .
Assembly overview - drive chain for valve gear ⇒ page 47 .

Removing and installing drive chain for valve gear ⇒ page 48 .
Assembly overview - chain for balancer shaft and oil pumpn AG. Volkswagen AG do
⇒ page 49 . wage es n
olks o V t gu
by ara
Removing and installing chain for balancer shaft
ris
ed and oil pump nte
o
⇒ page 51 . au
th eo
ra
ss c
2.1 Assembly overview - drive chain for valve gear
ce
e
nl
pt
du
an
itte
y li
erm
ab
1 - Bearing mounting for drive
ility
ot p
chain sprocket
wit
, is n
h re
2 - 45 Nm
hole
spec
es, in part or in w
3 - Mounting pin, 12 Nm
t to the co
❑ Heat with hot air blower
when removing.
rrectness of i
❑ Apply locking fluid when
inserting.
l purpos

❑ Renew.
nform
ercia
5 - Thrust washer for drive

m
at
om
chain sprocket
ion
c
in t
or
6 - Drive sprocket for left timing
his
ate
chain
do
priv
cum
or
f
en
ng
t.
yi Co
❑ Heat with hot air blower t. Cop py
when removing.
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
inserting. Prote AG.
8 - Drive chain for valve gear

❑ Before removing, mark
running direction with
paint.
9 - Guide rail
❑ Heat with hot air blower
when removing.
inserting.
11 - 9 Nm
12 - Bearing bracket for drive chain sprocket
13 - Thrust washer
14 - Drive sprocket for right timing chain
❑ Heat with hot air blower when removing.
2. Chain drive (engine code BMK) 47

Phaeton 2003 ➤
❑ Apply locking fluid when inserting.
16 - O-ring
❑ Renew.
17 - Chain tensioner
18 - 10 Nm
19 - Guide rail for chain tensioner
20 - Crankshaft
21 - Guide rail
❑ Heat with hot air blower when removing.
❑ Apply locking fluid when inserting.
2.2 Removing and installing drive chain for

valve gear
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
♦ Drill bit, ∅ 3.3 mm

ility
ot p
Removing
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
– Remove camshaft timing chain ⇒ page 134 .

m
atio
om
n in
c
– Remove chain for balancer shaft and oil pump ⇒ page 49 .

or
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.

Phaeton 2003 ➤
– Press guide rail of chain tensioner for drive chain in direction

of -arrow- and lock chain tensioner by inserting a 3.3 mm ∅
drill bit -item 4-.
– Mark direction of rotation of timing chain.
– Remove bolts -2- and -3- and detach chain sprockets together
with drive chain and guide rail -1-.
Installing
note the following:
• Crankshaft locked in TDC position with locking pin - 3242- .
– First install chain sprocket for left camshaft timing chain -2-.
– Install guide rail -1- with drive chain fitted.
– Now install chain sprocket for right camshaft timing chain -3-.
– Press guide rail of chain tensioner for drive chain in direction
of -arrow- and pull drill bit -4- out of chain tensioner.
– Install chain for balancer shaft and oil pump ⇒ page 49 .
AG. Volkswagen
gen AG do
swa es
– Install camshaft
by
Vol timing chain ⇒ page 114 . ot gu
k n
d ara
se nte
– Installthtiming
or
i
chain covers ⇒ page 35 . e or
au ac
– Install
ss drive plate ⇒ page 93 .
ce
le
un
pt
– Bolt gearbox to engine and install engine/gearbox assembly

an
d
itte
⇒ page 3 .
y li
rm
ab
pe
ility
– Fill with engine oil and check oil level ⇒ page 151 .
ot
wit
, is n
h re
hole
2.3 Assembly overview - chain for balancer shaft and oil pump
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
49
Prote AG.
2. Chain drive (engine code BMK)
Phaeton 2003 ➤
1 - 9 Nm
2 - Chain tensioner
❑ With guide rail.
3 - Thrust washer
4 - Spring
5 - 24 Nm
6 - Chain sprocket for balancer
shaft
❑ Side with inscription
faces towards gearbox.
7 - Chain for balancer shaft
and oil pump
paint.
❑ Removing and installing AG. Volkswagen AG d
agen oes
ksw
⇒ page 49 by
Vol not
gu
ara
ed
is nte
8 - Crankshaft hor eo
aut ra
c
9 - Chain sprocket for oil pump ss
ce
le
un
❑ Installation position:
pt
an
d
itte
side with inscription
y li
erm
ab
faces towards engine.
ility
ot p
10 - 62 Nm
wit
is n
h re
❑ If bolt cannot be tight‐
ole,
spec
ened to torque, remove
lower part of sump with
t to the co
baffle plate and counter‐
hold oil pump drive shaft
using an open-end
rrectne
spanner.
ss 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
o
by c lksw
cted agen
Prote AG.

Phaeton 2003 ➤
2.4 Removing and installing chain for balancer shaft and oil pump
AG. Volkswagen AG d
Special tools and workshop agen oes
olksw not
equipment required d by V gu
ara
rise nte
♦ Locking pin - 3242- utho eo
ra
s a c
s
♦ Diesel injection pump lock‐
ce
e
nl
ing pin - 3359-
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
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.

Removing
2. Chain drive (engine code BMK) 51

Phaeton 2003 ➤

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
– Unscrew plug from upper part of sump.
WARNING
rrectness of i
l purpos

nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
p
cum
or

f
en
ng
t.
yi
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Mark running direction of chain for oil pump and balancer

shaft.
– Lock balancer shaft with diesel injection pump locking pin -
3359- and loosen bolts -arrows- for balancer shaft chain
sprocket.

Phaeton 2003 ➤
– Press guide rail of chain tensioner in direction of -arrow- and

lock chain tensioner by inserting 3.3 mm ∅ drill bit -item 1-.
– Remove bolts -2-, -4- and -5- and take out chain tensioner,
balancer shaft chain sprocket -3- and chain.
Installing
• Crankshaft -1- locked in TDC position with locking pin - 3242- .
– Lock balancer shaft -arrow- with diesel injection pump locking

AG. Volkswagen AG d
pin - 3359- lksw
agen oes
n o ot g
yV ua
db ran
ir se tee
ho
aut or
ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
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
53
Prote AG.
2. Chain drive (engine code BMK)
Phaeton 2003 ➤
– Install chain tensioner with chain and balance shaft chain

sprocket.
• Elongated holes in chain sprocket -3- must be aligned centrally
over threaded holes in balancer shaft.
– Tighten bolts -2-, -4- and -5- for chain tensioner.
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
– Screw in bolts -arrows- for chain sprocket, but do not tighten.
ility
ot
wit
, is n
• It should just be possible to turn chain sprocket on balancer
h re
hole
shaft without axial movement.

spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tio
– Pull drill bit out of locating hole to release chain tensioner.

n in
r
te o
thi
– Press against guide rail of chain tensioner using a screwdriver,

s
iva
do
and at the same time tighten bolts securing chain sprocket.

r
rp
cum
fo
– Pull diesel injection pump locking pin - 3359- out of balancer

en
ng
t.
yi Co
shaft. t. Cop py
rig
gh ht
yri
p by
co Vo
by lksw
cted agen
Prote AG.

Phaeton 2003 ➤
3 Chain drive (engine codes CARA,

CEXA, CEXB)
Assembly overview - drive chain for valve gear ⇒ page 55 .
Removing and installing drive chain for valve gear ⇒ page 56 .
Assembly overview - chain for balancer shaft and oil pump
⇒ page 57 .
Removing and installing chain for balancer shaft and oil pump
⇒ page 59 . gen AG
. Volkswagen AG
wa does
olks not
3.1 Assembly overview - drive chain for valve gear ed
byV gu
ara
nte
ris
tho eo
au ra
c
ss
ce
le
chain sprocket
un
pt
an
d
itte
y li
2 - Bolt
erm
ab
ility
❑ 45 Nm
ot p
wit
is n
3 - Bolt
h re
ole,
spec
❑ Renew.
t to the co
4 - Bolt
❑ Renew.
rrectne
ss
o
cial p
f
chain sprocket
inform
mer
atio
m
chain
o
n
c
i
or
n
7 - Drive chain for valve gear
thi
te
sd
va

i
o
pr
running direction with cum

r
fo
en
ng
paint.
t.
yi Co
op py
❑ Removing and installing t. C rig
gh ht
⇒ page 56 yri
p by
co Vo
by lksw
cted
8 - Guide rail
agen
Prote AG.
❑ Note installation posi‐

tion.
9 - Bolt
❑ Renew.
10 - Bolt
❑ Renew.
11 - Bearing bracket for drive
chain sprocket
12 - Thrust washer
13 - Drive sprocket for right timing chain
14 - Bearing mounting
❑ Install using locking fluid; for locking fluid refer to ⇒ Parts catalogue .
❑ 12 Nm
3. Chain drive (engine codes CARA, CEXA, CEXB) 55

Phaeton 2003 ➤
15 - O-ring
❑ Renew.
17 - Bolt
❑ 12 Nm
18 - Tensioning plate
19 - Crankshaft
❑ With chain sprockets.
20 - Guide rail
21 - Bearing mounting
❑ Install using locking fluid; for locking fluid refer to ⇒ Parts catalogue .
❑ 12 Nm
3.2 Removing and installing drive chain for

valve gear
♦ Locking pin - T40071-
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
Removing
h re
hole
spec
• Gearbox removed.
es, in part or in w
t to the co

rrectness of i
– Remove camshaft timing chains ⇒ page 134 .

l purpos
– Remove chain for auxiliary drives ⇒ page 59 .

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.

Phaeton 2003 ➤
. Volkswagen AG
6-cylinder
sw adiesel
gen AG engine (3.0 l engine,
does
common rail) - Edition 04.2016
k not
Vol gu
d by ara
– Press guide rail of chain tensioner
oris
e for drive chain in direction nte
of -arrow- and lock chain auttensioner
h by inserting locking pin - eo
ra
T40071- . ss c
ce
e
nl
pt
du
an
itte
Caution
y li
erm
ab
ility
ot p
Drive chain may be destroyed if it runs in the opposite direction
wit
, is n
to the direction it ran before.
h re
hole
spec
♦ If chain is to be reinstalled: mark direction of rotation with
es, in part or in w
a coloured arrow.
t to the co
– Unscrew bolts -1- and remove guide rail.
rrectness of i
– Unscrew bolts -2- and -3- and remove chain sprockets with
l purpos
drive chain.
Installing
nf
ercia
orm
• Specified torques ⇒ page 55 .
m
atio
om
n in
or c
thi
te
– Install chain for auxiliary drives ⇒ page 59 .
sd
iva
o
r
rp
cu
– Install camshaft timing chains ⇒ page 134 .
o
m
f
en
ng
t.
yi Co
– Install timing chain covers ⇒ page 36 . t. Cop py
rig
gh ht
– Install drive plate ⇒ page 32 . pyri by
Vo
co lksw
by
cted agen
– Replenish engine oil and check oil level ⇒ Maintenance ; Prote AG.
Booklet 406 .
3.3 Assembly overview - chain for balancer shaft and oil pump

Phaeton 2003 ➤
1 - Drive chain for auxiliary

drives
⇒ page 59
2 - Drive chain sprocket for oil
pump
❑ Installation position: n AG. Volkswagen AG do
lkswage es n
side with lettering to‐ byV
o ot g
ua
wards engine. ir se
d ran
tee
tho
u or
3 - Bolt ss
a ac
❑ 62 Nm
ce
le
un
pt
an
d

itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
using an open-end
spec
es, in part or in w
spanner.
t to the co
4 - Thrust washer
5 - Spring
rrectness of i
6 - Crankshaft
l purpos
7 - Bolt
nform
ercia
❑ 23 Nm
m
8 - Chain sprocket for balancer
a
com
tio
shaft
n in
r
te o
thi
s
iva
side with lettering to‐

do
r
rp
wards gearbox.
um
fo
en
ng
t.
yi
9 - Bolt
Co
Cop py
.
❑ 9 Nm
t rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote AG.
❑ With guide rail.
11 - Gasket
❑ Renew.

Phaeton 2003 ➤
3.4 Removing and installing chain for balancer shaft and oil pump

equipment required
♦ Locking pin - 3242-
♦ Diesel injection pump lock‐
ing pin - 3359-
♦ Special wrench - T40049-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
Removing
c
i
or
n thi
e
t
sd
iva
o
pr
cum
r

fo
en
ng
t.
yi Co
– Remove timing chain covers ⇒ page 36 . t. Cop py
rig
gh ht
– Bolt special wrench - T40049- onto back of crankshaft. Use 2
yri
p by
o Vo
by c
old drive plate bolts -arrows- for this.
lksw
cted agen
Prote AG.

Phaeton 2003 ➤
– Unscrew plug -arrow- from upper part of sump.
WARNING
Risk of injury when feeling for “TDC” hole with finger.

♦ Do not turn crankshaft -1-.
– Screw locking pin - 3242- into hole (20 Nm); if necessary, turn
crankshaft backwards and forwards slightly to fully centralise
locking pin.
Caution
Chain for auxiliary drive may be destroyed if it runs in the op‐

posite direction to the direction it ran before.
♦ If chain for auxiliary drive is to be reinstalled: mark direc‐ n AG. Volkswagen AG do
tion of rotation with an arrow. Use paint for this. olkswage es n
ot g
byV ua
d ran
ir se tee
tho
– Lock balancer shaft on rear of engine with diesel injection au or
ac
pump locking pin - 3359- and loosen bolts -arrows- for bal‐ ss
ce
le
ancer shaft chain sprocket.

un
pt
an
d
itte
y li
rm
ab
– Wrap insulating tape around cutting end and cutting edges of
pe
3.3 mm ∅ drill to prevent flesh wounds. ility

ot
wit
, is n
h re
– Press guide rail of chain tensioner in direction of -arrow- and
hole
lock chain tensioner by inserting 3.3 mm ∅ drill bit -item 4-.

spec
es, in part or in w
t to the co
– Remove bolts -1- and -2- and take out chain tensioner, bal‐
ancer shaft chain sprocket -3- and chain.
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.

Phaeton 2003 ➤
Installing
• Crankshaft -1- locked at “TDC” with locking pin - 3242- .
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
– Lock balancer shaft -arrow- on rear of engine with diesel in‐
ot
wit
jection pump locking pin - 3359- .
, 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
tio
– Install chain tensioner with chain and balancer shaft chain
n in
r
te o
sprocket.
thi
s
iva
do
• Elongated holes in chain sprocket -3- must be aligned centrally
r
rp
cum
fo
over threaded holes in balancer shaft.

en
ng
t.
yi Co
op
– Tighten chain tensioner bolts -1- and -2-. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
Note
agen
Prote AG.
Disregard -item 4- and -arrows-.
– Screw in chain sprocket bolts -arrows- loosely.

• It should just be possible to turn chain sprocket on balancer
shaft without axial movement.

Phaeton 2003 ➤
– Pull drill bit out of locating hole, this releases the chain ten‐
sioner.
– Press against guide rail of chain tensioner with a screwdriver
in direction of -arrow- and simultaneously tighten bolts -1- for
chain sprocket.
– Pull diesel injection pump locking pin - 3359- out of balancer
shaft.
Remaining installation steps are carried out in reverse sequence;
note the following:
– Install timing chain covers ⇒ page 36 .
– Replenish engine oil and check oil level ⇒ Maintenance ;
Booklet 406 .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
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
yri by
62
op Vo
by c lksw
Rep. gr.13 - Crankshaft group Prote
cted AG.
agen
Phaeton 2003 ➤
4 Removing and installing crankshaft

Assembly overview - crankshaft ⇒ page 63 .
Crankshaft dimensions ⇒ page 65 .
Measuring axial clearance ⇒ page 65 .
Measuring radial clearance ⇒ page 66
4.1 Assembly overview - crankshaft
Vol
ksw
age es n
ot g
by ua
ed ran
oris tee
th or
Note ss
au ac
ce
e
nl
pt
When carrying out repairs, secure engine to engine stand - VAS 6095- ⇒ page 13 .
du
an
itte
y li
erm
ab
ility
ot p
wit
1 - Crankshaft
, is n
h re
❑ Measuring axial clear‐
hole
spec
ance ⇒ page 65 .
es, in part or in w
t to the co
❑ Measuring radial clear‐
ance ⇒ page 66
❑ Do not rotate crankshaft
rrectness of i
when checking radial
clearance.
l purpos
❑ Crankshaft dimensions
⇒ page 65 .
nform
ercia
2 - Dowel sleeve
m
at
om
i
❑ Qty. 2.
on
c
in t
or
❑ Insert in cylinder block.
his
ate
do
riv
3 - Retaining frame
p
cum
for
❑ Installing ⇒ page 64 .
en
ng
t.
yi Co
op
4 - Bolt
C py
ht. rig
rig ht
❑ Renew.
py by
co Vo
by lksw
cted
❑ Tightening sequence
agen
Prote AG.
⇒ page 64 .
5 - Thrust washer
❑ Only fitted on 3rd crank‐
shaft bearing.
❑ Lubrication groove
faces outwards.
❑ Note fixing arrange‐
ment.
❑ Measuring axial clear‐
ance of crankshaft
⇒ page 65 .
6 - Bearing shell
❑ For retaining frame.
❑ Do not interchange
used bearing shells (mark).
❑ Bearing shells worn down to nickel layer must be renewed.
❑ Install new bearing shells for retaining frame with correct coloured markings ⇒ page 65 .
7 - Centring sleeve for torque converter
❑ For vehicles with automatic gearbox ⇒ page 65 .
4. Removing and installing crankshaft 63

Phaeton 2003 ➤
8 - Dowel pin
❑ Check that pin is firmly seated in crankshaft.
9 - Thrust washer
❑ Only fitted on 3rd crankshaft bearing.
❑ Lubrication groove faces outwards.
❑ Note fixing arrangement.
❑ Measuring axial clearance of crankshaft ⇒ page 65 .
10 - Bearing shell
❑ For cylinder block with oil groove.
❑ Do not interchange used bearing shells (mark).
❑ Install new bearing shells for the cylinder block with the correct coloured markings ⇒ page 64 .
Installing retaining frame

– Renew bolts -1 … 16-.
– Fit both dowel sleeves into retaining frame.
– Tighten securing bolts for retaining frame in the following se‐
quence:
1. Tighten bolts -1 … 16- to 30 Nm with torque wrench.
2. Tighten bolts -1 … 16- to 50 Nm with torque wrench.
3. Turn bolts -1 … 16- 90° further using a fixed wrench.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
Allocation of crankshaft bearing shellsss for cylinder block
a ac
ce
le
Bearing shells of the correct thickness are allocated to the cylin‐

un
pt
an
d
der block at the factory. Coloured dots on bearing shell are used
itte
y li
erm
to identify bearing shell thickness.

ab
ility
ot p
• The -arrow- points to belt pulley end.

wit
is n
h re
ole,
The allocation of the bearing shells to the cylinder block is iden‐

spec
tified by a code letter next to the relevant bearing.

t to the co
Letter on cylinder block Bearing colour

R = Red
rrectne
G= Yellow
B= Blue
ss 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.

Phaeton 2003 ➤
Allocation of crankshaft bearing shells for retaining frame

♦ The bearing caps are assigned bearing shells of the correct
thickness at the factory. Coloured dots on bearing shell are
used to identify bearing shell thickness.
♦ The correct allocation of bearing shells to crankshaft is indi‐
cated by a sequence of letters on the crankshaft flank. The
number “1” -arrow- preceding the sequence of letters indicates
the colour code for No. 1 bearing.
Letter on crankshaft Bearing colour
R = n AG. VolksRed
wagen AG
lkswage does
not
o
yV gu
G= ed b Yellow ara
nte
oris
B= auth Blue eo
ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Bearing bush for torque converter
hole
spec
es, in part or in w
t to the co
Note
Short engines and reconditioned (exchange) engines, as well as
rrectness of i
new and reconditioned crankshafts, are supplied without centring
l purpos
sleeve -arrow-. The bush must therefore be knocked in before

fitting drive plate on vehicles with automatic gearbox. This cen‐
tring sleeve must not be fitted in vehicles with manual gearbox.
nform
mercia
at
om
ion
c
in t
or
his
ate
4.2 Crankshaft dimensions

do
priv
cum
for
en
g
Honing di‐ Crankshaft main jour‐ Crankshaft conrod jour‐

n
t.
yi Co
op
mension nal ∅ nal ∅ C py
t. rig
(in mm)
gh ht
pyri by
Vo
co lksw
by
Basic di‐ 65.00 – 0.022 Prote
cted 60.00 – 0.022
AG.
agen
mension – 0.042 – 0.042
4.3 Measuring axial clearance

♦ Universal dial gauge bracket - VW 387-
4. Removing and installing crankshaft 65

Phaeton 2003 ➤
♦ Dial gauge - VAS 6079-
Test procedure agen

AG. Volkswagen AG d
oes
olksw not
– Fit dial gauge onto universal dial gauge bracket -dVW by 387- ,
V gu
ara
install bracket on cylinder block and set gauge horagainst
ise
crank‐ nte
eo
shaft web. aut ra
c
ss
– Press crankshaft against dial gauge by hand and set gauge to
ce
le
un
pt
“0”.
an
d
itte
y li
rm
ab
– Push crankshaft away from dial gauge and read off value:
pe
ility
ot
• Axial clearance (new): 0.090…0.215 mm.
wit
, is n
h re
hole
• Axial clearance: wear limit: 0.280 mm
spec
es, in part or in w
t to the co
4.4 Measuring radial clearance
rrectness of i
l purpos
♦ Plastigage
Procedure
nform
mercia
a
com
tio
Note
n in
r
te o
thi
♦ Do not interchange used bearings.
s
iva
do
r
rp
cum
♦ Bearing shells worn down to nickel layer must be renewed.

fo
en
ng
t.
yi Co
Cop py
– Remove retaining frame and clean bearing journals. ht. rig
rig ht
py by
o Vo
– Place a length of Plastigage corresponding to the width of the by c lksw
cted agen
bearing on the bearing journal or in the bearing shell. Prote AG.
• The Plastigage must rest in the middle of the bearing shell.

– Fit retaining frame and tighten to 30 Nm. Do not rotate crank‐
shaft.
– Remove retaining frame again.
– Compare width of width of Plastigage with measurement
scale:
• Radial clearance (new): 0.018…0.045 mm
• Radial clearance: wear limit: 0.10 mm

Phaeton 2003 ➤
5 Pistons and conrods

Assembly overview - pistons and conrods ⇒ page 67 .
Checking piston projection at TDC ⇒ page 70 .
Piston and cylinder dimensions ⇒ page 71 .
Checking radial clearance of conrods ⇒ page 71 .
5.1 Assembly overview - pistons and con‐

rods
Note
Oil spray jet for piston cooling ⇒ page 68 .
1 - Conrod bolt, 30 Nm + 90°

further
❑ Renew.
❑ Oil threads and contact
surface.
❑ To measure radial clear‐
ance, tighten to 30 Nm
but not further.
2 - Conrod bearing cap
❑ Do not interchange.
❑ Mark cylinder number
-B- ⇒ page 69 . AG. Volkswagen AG d
agen
❑ Installation position: olksw
oes
not
yV gu
Note position of lugs on ed b ara
nte
is
casting -A-. hor eo
aut ra
3 - Bearing shells ss c ce
le
un

pt
an
d
tion.
itte
y li
erm
ab
❑ Do not interchange
ility
ot p
used bearing shells

wit
is n
(mark).
h re
ole,
❑ Bearing shells worn

spec
down to nickel layer

t to the co
must be renewed.
❑ Measuring radial clear‐
ance ⇒ page 71
rrectne
❑ To measure radial clear‐

ance, tighten bolts
ss
⇒ Item 1 (page 67) to 30

o
cial p
Nm but not further.

inform
mer
4 - Conrod
atio
m
❑ Renew as set only.

o
n
c
i
or
❑ Mark cylinder number

thi
te
sd
a
-B- ⇒ page 69 .
iv
o
pr
cum
r
❑ Installation position: Note position of lugs on casting -A-.

fo
en
ng
t.
yi
❑ Axial clearance for each conrod pair (when new): 0.20…0.44 mm
Co
Cop py
ht. rig
5 - Circlip rig ht
py by
co Vo
by lksw
6 - Piston pin cted agen
Prote AG.
❑ If difficult to move, heat piston to approx. 60 °C.
5. Pistons and conrods 67

Phaeton 2003 ➤
❑ Remove and install using drift - VW 222 A- . agen
AG. Volkswagen AG d
oes
olksw not
V
7 - Piston d by gu
ara
rise nte
❑ With combustion chamber. utho eo
ra
a
❑ Mark installation position and cylinder number ⇒ page 69 . ss c
ce
e
nl
❑ Check ⇒ page 69 .
pt
du
an
itte
y li
❑ Install using piston ring clamp.
erm
ab
❑ If cracking is visible on piston skirt, renew piston.
ility
ot p
wit
, is n
❑ Piston and cylinder dimensions ⇒ page 71 .
h re
hole
❑ Checking piston projection at TDC ⇒ page 70 .
spec
es, in part or in w
❑ Checking cylinder bores ⇒ page 69 .
t to the co
8 - Piston rings
❑ Offset gaps by 120°.
rrectness of i
❑ Use piston ring pliers to remove and install.
l purpos
❑ “TOP” must face towards piston crown.

❑ Checking ring gap ⇒ page 68 .
nf
ercia
o
❑ Checking ring-to-groove clearance ⇒ page 68 .
rm
m
atio
om
n in
or c
thi
Oil spray jet for piston cooling
te
sd
iva
o
r
1- Bolt, 9 Nm
rp
cu
o
m
f
en
ng
2- Oil spray jet with spray nozzle valve for piston cooling
t.
yi Co
Cop py
t. rig
• Opening pressure: 1.3 bar opyri
gh by
Vo
ht
c by lksw
cted agen
Prote AG.
Checking piston ring gap

– Push ring at right angles from above down to approx. 15 mm
from bottom end of cylinder. Push in using a piston without
rings.
Piston ring New Wear limit
dimensions in mm
1st compression ring 0.25 … 0.38 0.80
2nd compression ring 0.70 … 0.90 1.30
Oil scraper ring max. 0.40 0.70
Checking ring-to-groove clearance

– Clean ring groove of piston before checking.
Piston ring New Wear limit
dimensions in mm
1st compression ring 0.120 … 0.160 0.175
2nd compression ring 0.020 … 0.090 0.115
Oil scraper ring 0.020 … 0.090 0.115

Phaeton 2003 ➤
Checking piston
– Using a micrometer (75 … 100 mm), measure approx. 10 mm
from the lower edge, perpendicular to the piston pin axis.
• Maximum deviation from nominal dimension: 0.05 mm.
Nominal dimension ⇒ page 71
Checking cylinder bores

– Use 50…100 mm cylinder gauge to take measurements diag‐
onally at 3 points in transverse direction -A- and longitudinal
direction -B-.
• Maximum deviation from nominal dimension: 0.08 mm.
Nominal dimension ⇒ page 71
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
Installation position of pistons

spec
es, in part or in w
• Installation position: arrow -item 1- on piston crown points to

t to the co
belt pulley end.

rrectness of i
Note
l purpos
♦ To re-install used pistons, mark installation position and as‐

signment to cylinder on base of piston.
nform
ercia
♦ Do not use a centre punch or scriber, as this would damage

m
a
com
the coating of the piston crown.

ion in
r
te o
thi
s
iva
do
Marking conrods
r
rp
cum
fo
en
g
– Before removing, mark mating positions of conrods and con‐

n
t.
yi Co
rod bearing caps -arrow-. Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted
Note
agen
Prote AG.
♦ Only renew conrods as a complete set.

♦ Do not interchange conrod bearings.

Phaeton 2003 ➤
Conrod installation position

The larger contact shoulder on the conrod -arrows- faces towards
the adjacent main bearing.
Note
Illustration shows front pair of conrods.
5.2 Checking piston projection at TDC

equipment required
♦ -VW 382/7- from measuring
tool - VW 382-
♦ -VW 385/17- from universal
measuring tool - VW 385-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut 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
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Phaeton 2003 ➤
Test procedure
– Set up dial gauge - VAS 6079- with -VW 382/7- and -
VW 385/17- .
– Measure piston projection at 2 points -1- for each piston.
Piston projection above top sur‐ Identificationswagen AG. Volkswagen AG does
face of cylinder block (No. of bholes)
yV
olk not
gu
ara
ed
0.39 … 0.49 mm thoris 1 nte
e or
au
0.49 … 0.54 mm ss 2 ac
ce
le
0.54 … 0.65 mm 3
un
pt
an
d
itte
y li
erm
ab
Cylinder head gasket identification
ility
ot p
wit
is n
-Arrow 1-: holes
h re
ole,
spec
-Arrow 2-: part number
t to the co
Note
rrectne
The cylinder head gaskets for the left and right cylinder heads
have different shapes and cannot be interchanged.
ss o
cial p
f inform
mer
atio
m
5.3 Piston and cylinder dimensions

o
n
c
i
or
n thi
te
sd
a
Honing dimen‐ Piston ∅ Cylinder bore ∅

iv
o
pr
c
sion (in mm)
um
r
fo
en
ng
t.
Basic dimension 82.939 … 82.951 1) 83.006 … 83.014
yi Co
Cop py
t. rig
Repair oversize 82.979 … 82.991 1) 83.046 … 83.054
opyri
gh by
Vo
ht
by c lksw
1) Dimensions not including graphite coating (thickness 0.02 mm). The graphite Prote
cted AG.
agen
coating will wear down.
5.4 Checking radial clearance of conrods

♦ Plastigage
Test procedure
– Remove conrod bearing cap. Clean bearing cap and bearing
journal.
– Place a length of Plastigage corresponding to the width of the
bearing on the bearing journal or in the bearing shell.
– Fit conrod bearing cap and tighten to 30 Nm. Do not rotate
crankshaft.
– Remove conrod bearing cap again.
– Compare width of Plastigage with measurement scale:
• Radial clearance (new): 0.015…0.062 mm
• Radial clearance: wear limit: 0.12 mm
– Renew conrod bolts.

Phaeton 2003 ➤
15 – Cylinder head, valve gear

1 Cylinder head
AG. Volkswagen AG d
Assembly overview - cylinder head ⇒ page 72 . agen oes
olksw not
y V gu
d b ara
Assembly overview - cylinder head cover ⇒ page 75 . orise nte
th eo
u ra
Removing and installing cylinder head cover ⇒ page 78 . ss a c
ce
le
Removing and installing cylinder head ⇒ page 84 .
un
pt
an
d
itte
y li
Checking compression ⇒ page 91 .
rm
ab
pe
ility
Assembly overview - vacuum pump ⇒ page 93 .
ot
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
♦ If an exchange cylinder head is installed, all the contact sur‐
faces between the supporting elements, roller rocker fingers
rrectness of i
and the running surfaces of the camshafts must be oiled be‐
fore the cylinder head cover is installed.
l purpos
♦ The plastic packing pieces for protecting the open valves must
not be removed until immediately before fitting cylinder head.
nform
ercia
♦ If the cylinder head is replaced, all the coolant in the system

m
a
must also be renewed.
com
tion in
♦ Reworking diesel cylinder heads is not permissible.
r
te o
thi
s
iva
do
r
rp
c
1.1 Assembly overview - cylinder head
um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
Note yri
p by
co Vo
by lksw
cted agen
Prote
Diagram shows cylinder head on cylinder bank 2 (left side).
AG.
72 Rep. gr.15 - Cylinder head, valve gear

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
orise nte
eo
Phaeton 2003 ➤
h
s aut
6-cylinder diesel engine (3.0 l engine, ra
c common rail) - Edition 04.2016
s
ce
e
nl
1 - Cylinder head
pt
du
an
itte
y li
erm
ab
⇒ page 84
ility
ot p
wit
, is n
h re
Caution
hole
spec
Vehicles
♦ with ceramic
es, in part or in w
t to the co
glow plugs: these glow
plugs are very easily
damaged, therefore do
NOT lay cylinder head
rrectness of i
down on the gasket side
l purpos
while the glow plugs are

still installed. The glow
plugs project slightly be‐
nf
ercia
yond the cylinder head
orm
gasket surface.
m
atio
om
n in
Handling
♦ ceramic glow
or c
thi
plugs ⇒ page 318 .
te
sd
iva
o
r
rp
cu
❑ Check for distortion
o
m
f
en
ng
⇒ page 75 .
t.
yi Co
Cop py
❑ Diesel cylinder heads
t. rig
gh ht
yri
must not be reworked. p by
co Vo
by lksw
cted
❑ If renewed, refill system
agen
Prote AG.
with fresh coolant.
2 - Toothed belt drive pulley
❑ Use counterhold - 3036-
when loosening and
tightening central bolt
⇒ page 74 .
❑ Use puller - 3032- or
puller - T10320- to re‐
move ⇒ page 74 .
3 - 75 Nm
to loosen and tighten ⇒ page 74 .
4 - Camshaft oil seal
❑ Renewing ⇒ page 97 .
5 - Bracket for oil dipstick
6 - 9 Nm
7 - Coolant line
8 - Banjo bolt, 12 Nm
9 - Oil seals
❑ Renew.
10 - Cylinder head bolt
❑ Renew.
❑ Note sequence when loosening ⇒ page 87 .
❑ Note sequence when tightening ⇒ page 91 .
11 - Oil retention valve
❑ Tighten to 25 Nm.
1. Cylinder head 73
Phaeton 2003 ➤
12 - Lifting eye
13 - M6 = 9 Nm; M8 = 22 Nm
14 - Left intermediate pipe
15 - 25 Nm
❑ Coat with high-temperature paste - G 052 112 A3- .
16 - Gasket
❑ Renew.
17 - Bolt
18 - Cylinder head gasket
❑ Identification ⇒ page 75 .
❑ Installation position: part number faces towards cylinder head
❑ If renewed, refill system with fresh coolant. agen
AG. Volkswagen AG d
oes
lksw n o ot g
yV ua
edb ran
ris tee
ho
Loosening and tightening central bolt for toothed belt drive
aut pulley or
ac
ss
– Use counterhold - 3036- when loosening and tightening cen‐
ce
e
nl
pt
tral bolt -1-.
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
Pull off toothed belt drive pulley to 02.2006

– Use puller - 3032- to pull off toothed belt drive pulley.
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.
Pull off toothed belt drive pulley from 02.2006
– Use puller - T10320- to pull off toothed belt drive pulley.

Phaeton 2003 ➤
Checking cylinder head for distortion

– Use straightedge and feeler gauge to check for distortion at
several points.
AG . Volkswagen AG
• Maximum permissible distortion: 0.1
ksw
mm.
agen does
not
ol
yV gu
edb ara
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
Cylinder head gasket identification
hole
spec
-Arrow 1-: holes
es, in part or in w
t to the co
-Arrow 2-: part number
rrectness of i
Note
l purpos
The cylinder head gaskets for the left and right cylinder heads
nform
mercia
at
om
ion
c
in t
or
his
te
1.2 Assembly overview - cylinder head cover

a
do
priv
cum
for
en
ng
t.
yi Co
op
Note C py
t. rig
gh ht
pyri by
Vo
o
Diagram shows cylinder head cover on cylinder bank 2 (left side).
c by lksw
cted agen
Prote AG.
1. Cylinder head 75
Phaeton 2003 ➤
1 - 9 Nm
2 - Bracket for intake connect‐
ing pipe
3 - 9 Nm
4 - O-ring
❑ Renew.
5 - Oil filler neck
❑ To remove: lift tab, turn
oil filler neck anti-clock‐
wise and take out.
6 - Seal
7 - Seal
❑ Renew if damaged or
leaking.
8 - Cap
9 - 5 Nm
10 - Fuel return line
❑ Observe rules for clean‐
liness ⇒ page 218 .
11 - High-pressure accumula‐
tor (rail element)
❑ With injection pipes.
❑ Observe rules for clean‐
liness ⇒ page 218 .
❑ Tightening injection AG. Volkswagen AG d
pipes at high-pressure agen oes
olksw not
V
accumulators d by gu
ara
⇒ page 77 . rise nte
tho eo
u ra
❑ Tightening injector line ss a c
connections at injectors
ce
e
nl
pt
⇒ page 77 .
du
an
itte
y li
❑ Do not attempt to bend injector pipes to a different shape.

erm
ab
ility
ot p
12 - 22 Nm
wit
, is n
h re
13 - O-ring
hole
spec
❑ Renew.
es, in part or in w
t to the co
14 - 9 Nm
❑ Tighten alternately in stages.
rrectness of i
15 - Clamping piece
l purpos
❑ Must be renewed if injector is renewed.

16 - Injector
nform
ercia
❑ Observe rules for cleanliness ⇒ page 218 .

m
at
❑ Removing and installing ⇒ “1.3 Removing and installing cylinder head cover”, page 78
om
ion
c
❑ When an injector is renewed, also renew the injector pipe and clamping piece at the same time.
in t
or
his
ate
17 - O-ring
do
priv
cum
or
❑ Renew.
f
en
ng
t.
yi Co
18 - Copper seal t. Cop py
rig
gh
❑ Renew.
ht
pyri by
Vo
co lksw
by
19 - Special bolt, 9 Nm
cted agen
Prote AG.
❑ Renew if damaged or leaking.

Phaeton 2003 ➤
❑ Tighten in stages and in diagonal sequence.
20 - Cylinder head cover
21 - Gasket for cylinder head cover
❑ Renew if damaged or leaking.
Tightening high-pressure lines at rail elements (14 mm)

– Tighten union nuts on high-pressure lines finger-tight initially.
– Ensure that high-pressure lines are not under tension.
– To tighten unions of high-pressure lines, use torque wrench -
V.A.G 1331- with ratchet - V.A.G 1331/1- and 14 mm socket -
3150- .
• Specified torque: 28 Nm.
Tightening high-pressure lines at rail elements (19 mm)

– Tighten union nuts on
waghigh-pressure
en AG. V linesdofinger-tight
olkswagen AG
e initially.
ks s no
Vol t
– Ensure that ehigh-pressure
db
y lines are not under tension.
gu
ara
n
is tee
or
– To tighten
au high-pressure lines, use torque wrench -
th or
ac
V.A.G 1331- and 19 mm socket - V.A.G 1331/5- .
ss
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
Tightening injection lines at injectors (17 mm)

t to the co
– Tighten union nuts on injector lines hand-tight to start with.

rrectness of i
– Ensure that injector lines are not under tension.

l purpos
– To tighten injector lines, use torque wrench - V.A.G 1331- with

ratchet - V.A.G 1331/1- and 17 mm socket - T40055- .
nform
ercia

m
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.
1. Cylinder head 77
Phaeton 2003 ➤
1.3 Removing and installing cylinder head cover

equipment required
♦ Torque wrench -
V.A.G 1331-
♦ Ratchet - V.A.G 1331/1-
♦ Tool insert 19 mm - V.A.G
1331/5-
♦ Puller - T10055- with adapt‐
er -T10055/1-
♦ Socket - T40055-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
Removing
erm
ab
ility
ot p
wit
is n
h re
Note
ole,
spec
The following description shows the removal and installation of

t to the co
the left cylinder head cover. The procedure for the other side is
the same, except that some steps are not required.
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
78
Prote AG.
Rep. gr.15 - Cylinder head, valve gear
lkswage es n
o ot g
byV ua
d ran
ir se
tho tee
or Phaeton 2003 ➤
u
ss
a
6-cylinder diesel engine (3.0 ac
l engine, common rail) - Edition 04.2016
ce
e
nl
pt
du
– Carefully pull engine cover panel off four retaining pins one
an
itte
y li
erm
ab
ility
ot p
On engine code BMK:
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Remove air intake hose -5- from throttle valve module - J338- .
m
at
– Separate electrical connection -6- from throttle valve module
om
ion
- J338- .
c
in t
or
his
te
– Unscrew bolts -1 … 4- and remove intake connecting pipe and

a
do
riv
throttle valve module - J338- .

p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove bolts -1, 2, 4- and remove bracket for intake connect‐

ing pipe from cylinder head.
For engine codes CARA, CEXA, CEXB:
– Remove cable tie -1-.
– Remove fuel high-pressure lines -2- and fuel return line -3-.
Only for removal of left cylinder head cover:
1. Cylinder head 79
Phaeton 2003 ➤
– Unscrew bracket for engine cover -1- and also securing bolts
-arrows- and remove upper part of intake manifold.
Continuation for all vehicles:
– Remove oil filler neck. To do so, lift tab -1- and turn oil filler
neck anti-clockwise -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
Vehicles to 09.2005:
wit
is n
h re
ole,
– Disconnect electrical connector -arrow- for Lambda probe -

spec
G39- and move wiring clear.

t to the co
Caution
rrectne
Rules for cleanliness when working on the injection system

⇒ page 218 .
ss o
cial p
f inform
mer
atio
om
n
c
i
or
– Pull release pins upwards -arrow- and pull return line connec‐
thi
e
tions off injectors.

t
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.

Phaeton 2003 ➤
– Separate electrical connectors at high-pressure accumulator

(rail element) -5- and at injectors.
– Loosen union nuts for injector pipes -1-, -6- and -7- using
socket, 17 mm - T40055- .
– Loosen union nuts for high-pressure line -3- at high-pressure
accumulator (rail element).
– Unscrew bolts -2- and -4- and remove high-pressure accumu‐
lator (rail element).
Vehicles from 09.2005:

– Remove wiring harness bracket -5- from cylinder head cover.
– Separate electrical connectors -1 … 4- at rail element and at
injectors.
– Move electrical wiring harness clear.
– Loosen union nuts of high-pressure lines -1 … 6- using socket

14 mm - 3150- and socket - T40055- .
– Remove high-pressure lines.
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
– Unbolt covers for injectors -arrows-.

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.
1. Cylinder head 81
Phaeton 2003 ➤
– Pull covers upwards and turn 1/4 turn (90°).
– Unbolt injectors -arrows-.

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
– Pull out injectors using puller - T10055- with adapter -
es, in part or in w
T10055/1- .
t to the co
Caution
rrectness of i
♦ Mark cylinder numbers on injectors.
l purpos
♦ Used injectors must always be re-installed on the same

cylinder.
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.

Phaeton 2003 ➤
– Loosen cylinder head cover bolts -arrows- in diagonal se‐

quence.
– Remove bolts and take off cylinder head cover.
Installing
note the following:
Note
♦ Renew cylinder head cover gaskets if damaged.

♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly.
♦ Secure all hose connections with hose clips which conform to
production standard.
– Tighten bolts for cylinder head cover in diagonal sequence and

in stages. agen
AG. Volkswagen AG d
o
w es n
olks ot g
Instructions for installing injectors: ed
byV ua
ran
ris tee
• ho surround‐
Before installation, make sure the injectors and their
t or
au ac
ings are clean. If necessary use a clean cloth to
ss wipe out the
injector slot in cylinder head, taking care not to cause damage
ce
le
un
pt
(do not use sharp-edged tools).
an
d
itte
y li
rm
ab
• Renew seals and gaskets. Lubricate all seals and gaskets
pe
ility
lightly with engine oil or assembly oil before installing.
ot
wit
, is n
h re
• The injectors must be completely undamaged. To remove the
hole
old copper seal, clamp the seal carefully in a vice such that it
spec
is just prevented from turning between the jaws. Then carefully
es, in part or in w
t to the co
pull and twist the injector out of the copper seal by hand.
• When an injector is renewed, also renew the injector pipe and
clamping piece at the same time.
rrectness of i
• Used injectors and injector pipes may only be re-installed on
l purpos
the same cylinder.
nform
ercia
– Install injectors ⇒ page 253 .

m
a
com
– Tighten union nuts on high-pressure lines and injector lines tion in

hand-tight to start with.
r
te o
thi
s
– Ensure that high-pressure lines and injector lines are not un‐
iva
do
r
der tension.
rp
cum
fo
en
ng

t.
yi Co
op
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Cylinder head 83
Phaeton 2003 ➤
– To tighten high-pressure lines at high-pressure accumulators

(rail elements), use torque wrench - V.A.G 1331- with ratchet
- V.A.G 1331/1- and socket, 14 mm - 3150- .
– Check fuel system for leaks ⇒ Fuel supply system - diesel
engines; Rep. gr. 20 .
Specified torques
Component Nm
Cylinder head cover to cylinder head 9
Injector to cylinder head 9
Cover for injector to cylinder head 5
High-pressure lines 28
AG. Volkswagen AG d
Wiring harness bracket to cylinder head agen 9 oes
olksw not
y V gu
Bracket for intake connectingispipeed b
to cylinder 9 ara
nte
head uthor eo
ra
a
Throttle valve Intakes manifold
s
9 c
ce
le
module - J338- Bracket

un
pt
with intake con‐
an
d
itte
y li
necting pipe to Connecting pipe for mechani‐ 9
rm
ab
cal exhaust gas recirculation
pe
ility
ot
valve
wit
, is n
h re
Hose clips (13 mm wide) 5.5
hole
spec
es, in part or in w
t to the co
1.4 Removing and installing cylinder head
rrectness of i
♦ Puller - T40064-
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
Removing
AG.

– Remove relevant intermediate pipe ⇒ page 307 .
Left cylinder head:
– Remove toothed belt for high-pressure pump:
Engine code BMK ⇒ page 273 .
Engine codes CARA, CEXA, CEXB ⇒ page 284 .

AG. Volkswagen AG d
agen oes
o lksw not Phaeton 2003 ➤
byV gu
ara
6-cylinder
rised
diesel engine (3.0 l engine, common nte rail) - Edition 04.2016
ho eo
aut ra
– Use puller - T40064- to pullsoff belt sprocket for high-pressure
s c
ce
le
pump.
un
pt
an
d
itte
– For engine codes CARA, CEXA und CEXB, take toothed belt
y li
rm
ab
drive pulley off camshaft.
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
– Unscrew bolts -arrows- and remove toothed belt cover (rear).
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.
Right cylinder head:

– Unscrew bolts -1- and -2-.
– Pull out right coolant pipe forwards from cylinder block and
remove right coolant pipe.
– Disconnect fuel supply line -2- and fuel return line -1- from
high-pressure pump and move lines clear to side.
Right cylinder head, to 10.05
1. Cylinder head 85
Phaeton 2003 ➤
Right cylinder head, from 11.05

Continuation for both sides:
– Remove upper part of intake manifold:
Engine codes CARA, CEXA, CEXB ⇒ page 234
– Remove lower part of cylinder head (left or right):
– Remove cylinder head cover (left or right) ⇒ page 78 .
– Remove relevant camshaft timing chain from camshaft
⇒ page 141 .
– Disconnect coolant line -arrow- (left or right).
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
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
o
by c lksw
cted agen
Prote AG.

Phaeton 2003 ➤

– Loosen cylinder head bolts in the sequence shown.
– Unscrew bolts completely and take off cylinder head carefully.
– Lay cylinder head aside on a clean surface with the combus‐
tion chamber side facing upwards.
Caution
♦ After removal, the cylinder head must not be placed on the

glow plug ends.
♦ Vehicles with ceramic glow plugs: these glow plugs are
very easily damaged, therefore do NOT lay cylinder head
down on the gasket side while the glow plugs are still in‐
stalled. The glow plugs project slightly beyond the cylinder
head gasket surface.
♦ Handling ceramic glow plugs ⇒ page 318 .
Installing
Note
♦ Reworking diesel cylinder heads is not permissible.

♦ Renew cylinder head bolts.
♦ Renew self-locking nuts and bolts when performing assembly
work.
♦ Renew bolts which are tightened to a specified angle asgewell
n AG. Volkswagen AG d
as oil seals and gaskets. olks
wa oes
not
byV gu
ara
♦ ed
In cases of repair carefully remove gasket remains from cyl‐ nte
ris
ho eo
inder head and cylinder block. Ensure that
au no long scores or
t ra
scratches are made on the surfaces. ss c
ce
e
nl
pt
♦ Carefully remove remains of emery and abrasives.
du
an
itte
y li
erm
♦ No oil or coolant must be allowed to remain in the blind holes

ab
ility
for the cylinder head bolts in the cylinder block.
ot p
wit
, is n
♦ Do not remove new cylinder head gasket from packaging until

h re
hole
it is ready to be fitted.
spec
es, in part or in w
♦ Handle gasket very carefully. Damage to the silicone coating

t to the co
or the indented area will lead to leaks.

♦ Position cylinder head gasket on dowel sleeves. The word
rrectness of i
»oben« (top) or the Part No. should face towards cylinder

head.
l purpos
♦ The plastic protectors fitted to protect the open valves should

not be removed until the cylinder head is ready to be fitted.
nf
ercia
orm
♦ When installing an exchange cylinder head with fitted cam‐

m
atio
m
shafts, oil contact surfaces between the roller rocker fingers

o
n in
c
and cams.
or
thi
te
sd
a
♦ After working on the valve gear, turn the engine carefully at

iv
o
r
rp
cu
least 2 rotations to ensure that none of the valves make con‐

o
m
f
tact when the starter is operated.

en
ng
t.
yi Co
op py
♦ Secure all hose connections with hose clips (same as original t. C rig
gh ht
equipment) ⇒ Parts catalogue . yri
p by
co Vo
by lksw
cted
♦ When fitting a new cylinder head or cylinder head gasket, drain
agen
Prote AG.
off all the old coolant and refill with new coolant.
1. Cylinder head 87
Phaeton 2003 ➤

note the following:
– Set crankshaft and camshafts to TDC before fitting cylinder

head:
• Locking pin - 3242- must be screwed in with crankshaft at TDC
position -1-.
• The camshafts on both cylinder heads must be locked with

locking pins - T40060- .
– Note identification markings on cylinder head gasket.

-Arrow 1-: holes
-Arrow 2-: part number n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
Note ir se tee
tho
u or
a ac
ss
♦ If the cylinder head gasket or cylinder head have been re‐
ce
e
nl
placed, select the new cylinder head gasket according to the

pt
du
an
number of holes on the old gasket.

itte
y li
erm
ab
♦ If parts of the crankshaft assembly have been renewed, the

ility
ot p
new cylinder head gasket must be selected by measuring the

wit
, is n
piston projection at TDC ⇒ page 70 .

h re
hole
spec
♦ The cylinder head gaskets for the left and right cylinder heads
es, in part or in w

t to the co
– Remove any oil and grease from sealing surfaces.

rrectness of i
l purpos
Note
nf
ercia
Observe expiry date of sealing compound.

rm
m
atio
om
n in
c

or
thi
5 mm).
te
sd
iva
o
r
Left cylinder head:

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.

Phaeton 2003 ➤
– Apply sealant beads -1- and -2- to the clean sealing surface
of the cylinder block and the timing chain cover (bottom) as
illustrated.
– Apply sealing compound in the sizes specified.

• a = 7mm
• b = 7mm
• c = 7mm
– Position cylinder head gasket. 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
t to the co
– Apply sealant beads -1- and -2- to the cylinder head gasket,
rrectne
as shown in the illustration.
ss 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
yri
– Apply sealant beads -1- and -2- to the clean sealing surface p by
co Vo
by lksw
of the cylinder block and the timing chain cover (bottom) as Prote
cted AG.
agen
illustrated.
1. Cylinder head 89
Phaeton 2003 ➤
– Apply sealing compound in the sizes specified.

• a = 7mm
• b = 7mm
• c = 7mm
– Position cylinder head gasket. lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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
– Apply sealant beads -1- and -2- to the cylinder head gasket,
as shown in the illustration.
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
– Fit cylinder head gasket.
c by lksw
cted agen
Prote AG.
• Pay attention to dowel sleeves -arrows- in cylinder block.
• Check installation position of cylinder head gasket: the word
“oben” (top) or the Part No. should face towards the cylinder
head.
– Fit cylinder head.
– Insert new cylinder head bolts and tighten hand-tight.

Phaeton 2003 ➤
– Tighten cylinder head bolts as follows in the sequence shown:

1. Tighten to 35 Nm using torque wrench.
2. Tighten to 60 Nm using torque wrench.
3. Use fixed wrench to turn 90° further.
4. Use fixed wrench to turn 90° further.
Note
After repair work it is not necessary to retighten the cylinder head

bolts.
– Install cylinder head cover (left and right) ⇒ page 78 .

– Install lower part of cylinder head (left or right):
– Install upper part of intake manifold:
Left cylinder head:
– Install toothed belt for high-pressure pump ⇒ page 273 .
– Install relevant intermediate pipe ⇒ page 307 .
– Install lock carrier with attachments ⇒ General body repairs,
exterior; Rep. gr. 50 .
– Install front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 .
n AG. Volkswagen A
– Deactivate jacking mode olks
w⇒ageRunning gear, front-wheel
G do
es n
o
drive
and four-wheel drive;
d by Rep. gr. 43 ; Operating the airt gsuspen‐
V ua
ran
sion . or
ise tee
h
ut or
– Fill coolingsssystem
a
with fresh coolant ⇒ page 173 . ac
ce
e
nl

pt
du
an

itte
y li
erm
ab
ility
ot p
1.5 Checking compression

wit
, is n
h re
hole

spec
es, in part or in w
♦ Compression tester - V.A.G 1763- with adapter - V.A.G

t to the co
1763/8-
rrectness of i
l purpos
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
91
by lksw
cted agen
Prote 1. Cylinder head
AG.
Phaeton 2003 ➤
Procedure
• Engine oil temperature approx. 80 °C.
• Battery voltage at least 12.5 V
after the other -arrows-
– Disconnect electrical connectors at glow plugs.
– Separate electrical connector at fuel pressure regulating valve

- N276- -item 1- on rail for cylinder bank 1 (right).
– Start engine briefly to reduce fuel pressure in rail.
– Remove all glow plugs ⇒ page 318 .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a 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
l purpos
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
92
Prote AG.
Phaeton 2003 ➤
– Screw in adapter - V.A.G 1763/8- in place of glow plugs and

connect compression tester - V.A.G 1763- .
Note
Using compression tester ⇒ operating instructions .
– Have starter operated by a 2nd mechanic until tester shows

no further pressure increase.
Compression pressures bar
New 28 … 33
Wear limit 21
Difference between cylinders max. 5
Assembly is carried out in the reverse order, note the following:
– Install glow plugs ⇒ page 318 .
– Finally read and clear the fault memory of engine control unit,
because faults have been stored when connectors were sep‐
arated ⇒ Vehicle diagnostic tester.
1.6 Assembly overview - vacuum pump

AG. Volkswagen AG d
agen oes
1 - 9 Nm Volksw not
gu
d by ara
2 - Vacuum pump orise nte
eo
h
ut ra
3 - Vacuum hose ss a c ce
e
nl
4 - 5 Nm
pt
du
an
itte
y li
5 - O-ring
erm
ab
ility
ot p
❑ Renew.
wit
, is n
h re
6 - Inlet camshaft
hole
spec
7 - O-ring
es, in part or in w
t to the co
❑ Renew.
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.
1. Cylinder head 93
Phaeton 2003 ➤
8 - O-ring
❑ Renew. agen
AG. Volkswagen AG d
oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
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
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
rised
nte Phaeton 2003 ➤
o e
aut
h
6-cylinder diesel engine (3.0 l engine,or acommon rail) - Edition 04.2016
ss c
ce
e
nl
pt
du
2 Valve gear
an
itte
y li
erm
ab
Assembly overview - valve gear ⇒ page 95 .
ility
ot p
wit
, is n
Checking axial clearance of camshafts ⇒ page 96 .
h re
hole
spec
Renewing camshaft oil seal ⇒ page 97 .
es, in part or in w
t to the co
Removing and installing camshafts ⇒ page 100 .
Renewing valve stem seals ⇒ page 104 .
rrectness of i
Checking hydraulic valve compensation elements ⇒ page 108 .
l purpos
Valve dimensions ⇒ page 110 .

Checking valve guides ⇒ page 110 .
nform
ercia
2.1 Assembly overview - valve gear

m
at
om
ion
c
in t
or
his
e
1 - Valve
at
do
priv
c
❑ Do not rework. Only lap‐
um
for
ping in is permitted.
en
ng
t.
yi Co
op
❑ Mark installation posi‐ C py
ht. rig
tion for re-installation. rig ht
py by
co Vo
❑ Valve dimensions
by lksw
cted agen
Prote
⇒ page 110 .
AG.
❑ Checking valve guides

⇒ page 110 .
2 - Cylinder head
❑ Checking valve guides
⇒ page 110 .
3 - Valve stem seal
4 - Valve spring
5 - Valve spring plate
6 - Valve cotters
7 - Camshaft oil seal
8 - 9 Nm
❑ Observe tightening se‐
quence ⇒ page 104 .
9 - 9 Nm
❑ Observe tightening se‐
quence ⇒ page 104 .
10 - Retaining frame
❑ With integrated cam‐
shaft bearings.
⇒ page 100
11 - Inlet camshaft
❑ Check axial clearance ⇒ page 96 .
❑ Check radial clearance with Plastigage (roller rocker fingers removed).
❑ Radial clearance (new): 0.035…0.085 mm.
❑ Radial clearance: wear limit: 0.1 mm.
2. Valve gear 95
Phaeton 2003 ➤
❑ Runout: max. 0.01 mm.
12 - Exhaust camshaft
❑ Check axial clearance ⇒ page 96 .
❑ Check radial clearance with Plastigage (roller rocker fingers removed).
❑ Radial clearance (new): 0.035…0.085 mm.
❑ Radial clearance: wear limit: 0.1 mm.
❑ Runout: max. 0.01 mm.
13 - Roller rocker finger
❑ Mark installation position.
❑ Do not interchange.
❑ Check roller bearing for ease of movement.
❑ Oil contact surface.
14 - Hydraulic compensation element
❑ Mark installation position.
❑ Check ⇒ page 108 . AG. Volkswagen AG d
agen oes
❑ Lubricate contact surfaces before installing.Volksw not
g by ua
ed ran
15 - Pressure limiting valve 1.0 bar, 25 Nmhoris tee
ut or
❑ For lubricating points in cylinder shead.
sa ac
ce
e
nl
pt
du
an
itte
y li
2.2 Checking axial clearance of camshafts
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
riv

p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ut
ho eo
ra
Phaeton 2003 ➤
a
ss 6-cylinder diesel engine (3.0 l engine,c common rail) - Edition 04.2016
ce
le
un
pt
Test procedure
an
d
itte
y li
rm
ab
– Perform measurement with retaining frame removed.
pe
ility
ot
wit
Inlet camshaft
, is n
h re
hole
• Specification: 0.03…0.08 mm.
spec
es, in part or in w
• Wear limit: 0.12 mm.
t to the co
rrectness of i
l purpos
nform
ercia
Exhaust camshaft
m
a
• Specification: 0.03…0.08 mm.
com
tion in
r
• Wear limit: 0.12 mm.

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.
2.3 Renewing camshaft oil seal
2. Valve gear 97
Phaeton 2003 ➤

equipment required
♦ Oil seal extractor - 2085-
♦ Puller - 3032-
♦ Counterhold tool - 3036-
♦ Assembly tool - T10053-
♦ Hexagon bolt
M10 x 1.25 x 40, (e.g. from
fitting sleeves - 3241- )
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
Procedure
ce
le
un
pt
an
d
– Loosen bolt -arrow- for tensioning roller approx. 2 turns.

itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
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.

Phaeton 2003 ➤
– Loosen central bolt -1- for toothed belt drive pulley approx.
2 turns using counterhold - 3036- .
lkswage es n
o ot g
byV ua
d ran
Vehicles to 02.2006: ir se tee
tho
u or
a ac
– Use puller - 3032- to pull offsstoothed belt drive pulley.
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
Vehicles from 02.2006:
l purpos
nf
ercia
orm
m
– Take off toothed belt drive pulley together with toothed belt.
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
– Unscrew inner section of oil seal extractor - 2085- 3 turns out Prote AG.
of outer section and lock with knurled screw.
– Lubricate threaded head of oil seal extractor, place it in posi‐
tion and, exerting firm pressure, screw it into oil seal as far as
possible.
– Loosen knurled screw and turn inner part against crankshaft
until the oil seal is pulled out.
– Clamp flats of oil seal extractor in vice and use pliers to remove
seal.
– Clean running surface and sealing surface.
2. Valve gear 99
Phaeton 2003 ➤
– Press in oil seal as far as stop using press sleeve - T10053-

and hexagon bolt M10 x 1.25 x 40 -arrow-, (e.g. from fitting
sleeves - 3241-
. Volkswagen AG
gen AGorder.
Installation is carried out in thekreverse does
swa ol not
yV gu
edb ara
ris nte
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
2.4 Removing and installing camshafts
spec
es, in part or in w
t to the co
♦ Camshaft fitting tool - T40094-
rrectness of i
♦ Bracket - T40095-
l purpos
♦ Clamping tool - T40096-

♦ Hand drill with plastic brush attachment
nform
ercia
♦ Eye protection
m
at
om
io
♦ Silicone sealant - D 176 001-
n
c
in t
or
his
e
Removing
at
do
priv
cum
– Remove relevant timing chain from camshafts:

for
en
ng
t.
yi Co
Engine code BMK ⇒ page 122 . t. Cop py
rig
gh ht
Engine codes CARA, CEXA, CEXB ⇒ page 141 yri
p by
o Vo
by c lksw
cted
Left cylinder head:
agen
Prote AG.
– Remove upper part of intake manifold .

– Remove toothed belt for high-pressure pump:

Phaeton 2003 ➤
All:
– Unscrew retaining frame bolts and nuts in. Vthe
n AG olkssequence
wagen AG
-18 … 1-. lkswage does
not
Vo g by ua
ed ran
oris tee
th or
Note ss
au ac
ce
le
un
pt
Make sure you do not damage roller rocker fingers and compen‐
an
d
itte
sation elements when removing camshafts.
y li
rm
ab
pe
ility
ot
– Carefully remove retaining frame and camshafts.
wit
, is n
h re
Installing
hole
spec
es, in part or in w
t to the co
Caution
The camshafts MUST only be installed using the camshaft fit‐
rrectness of i
ting tool - T40094- as described in the following, as the thrust
bearings in the retaining frame would otherwise be destroyed.
l purpos
The cylinder head would then have to be renewed.
nform
mercia
a
com
ti
WARNING
on in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
– Remove remaining sealant from cylinder head and bearing
Co
op py
frame using rotating plastic brush or similar.
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Caution Prote AG.
Make sure that no sealant residue gets into the cylinder head
or the bearings.

– Oil the camshaft running surfaces.
Set up camshaft fitting tool - T40094- as follows:

Left cylinder head:
– Insert support - T40094/2- in position -A-.
– Insert support - T40094/1- in position -D-.
– Insert support - T40094/2- in position -B-.
– Insert support - T40094/1- in position -C-.
2. Valve gear 101

Phaeton 2003 ➤
Note
♦ In the following the procedure is described for the left cylinder

head.
♦ The procedure for the right cylinder head is similar and is per‐
formed in the same sequence.
– Place exhaust camshaft -1- in support - T40094/1- and support

- T40094/2- .
– Turn camshaft in such a way that it can be locked in TDC po‐
sition using locking device -arrow-.
– Place clamping tool - T40096- on teeth of camshaft gear in
such a way that the two arms of the tool engage on the two
halves of the gear (one in each half, as shown in illustration).
– Tighten the clamping tool using the knurled wheel so that the
faces of the gear teeth are in alignment.
– Place inlet camshaft -2- in camshaft fitting tool - T40094- .

• The locating pin -3- must engage in the slot on the camshaft.
– Slide exhaust camshaft -1- towards inlet camshaft until gear
teeth engage.
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
– Fit retaining frame -1- onto camshafts.

y li
erm
ab
ility
• All camshaft bearings must be seated on the camshafts.

ot p
wit
, is n
– Attach retainer - T40095- to camshafts (align arms of retainer

h re
hole
as required and tighten knurled nuts).

spec
es, in part or in w
• Note the different shapes for inlet and exhaust camshaft.

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
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
102
cop Vo
by lksw
Rep. gr.15 - Cylinder head, valve gear Prote
cted AG.
agen
Phaeton 2003 ➤

1 mm).
Note
The retaining frame is shown without camshafts for illustration

purposes.
– Turn retaining frame upside down.

– Apply the beads of sealant -arrows- onto the clean sealing
surfaces of the retaining frame as illustrated.
• The grooves -arrows- on the sealing surface must be com‐
pletely filled with sealant.
• The beads of sealant must project 1.5 … 2.0 mm above the
sealing surface.
lkswage es n
o ot g
byV ua
d
Note o
ir se
ran
tee
th or
au ac
s
The sealant beads must not be thicker than specified, otherwise
s
ce
e
excess sealant could enter the camshaft bearings.

nl
pt
du
an
itte
y li
erm
ab
– Ensure that all roller rocker fingers contact the valve ends and
ility
ot p
compensation elements correctly.
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
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Valve gear 103

Phaeton 2003 ➤
– Fit retaining frame together with both camshafts and retainer

- T40095- onto cylinder head immediately.
Note
♦ The retaining frame should be fitted and secured without de‐

lay, as the sealant starts hardening immediately.
♦ After installing the retaining frame, wait about 30 minutes for
the sealant to dry.
– Tighten retaining frame bolts evenly in the sequence

-1 … 18-, initially only hand-tight.
AG. Volkswagen gen AG do
swa es
• The retaining framebyshould
Vol
k make contact with the cylinder
not
gu
head over the full
ris
esurface.
d ara
nt
o ee
th o
– Tighten retaining
s au frame bolts to final torque in the sequence r ac
-1 … 18-. Specified torque: 9 Nm
s
ce
e
nl
pt
du
– Detach retainer - T40095- and clamping tool - T40096- .
an
itte
y li
erm
ab
Perform further installation in reverse order, paying attention to
ility
ot p
the following:
wit
, is n
h re
hole
spec
Note
es, in part or in w
♦ After installing camshafts wait for approx. 30 minutes before t to the co

starting engine. Hydraulic compensation elements must settle rrectness of i
(otherwise valves will strike pistons).
♦ After working on valve gear, carefully crank engine at least 2
l purpos
revolutions by hand to ensure that no valves make contact on

starting.
nform
mercia
– Install cylinder head cover (left or right) ⇒ page 78 .

at
om
ion
c
Left cylinder head:

in t
or
his
ate
– Renew camshaft oil seal ⇒ page 97 .

do
priv
cum
or
– Install toothed belt for high-pressure pump:

f
en
ng
t.
yi Co
op
Engine code BMK ⇒ page 273 . C py
t. rig
gh ht
yri by
Engine codes CARA, CEXA, CEXB ⇒ page 284 cop Vo
by lksw
cted agen
Prote
– Install upper part of intake manifold:
AG.

– Renew sealing cap (front) on cylinder head.
– Using a suitable drift, knock in new sealing cap (core plug) until
flush.
All:
– Install camshaft timing chains:
2.5 Renewing valve stem seals

Phaeton 2003 ➤

equipment required
♦ Jointed wrench 10 mm -
3220-
♦ Valve stem seal puller -
3364-
♦ Valve stem seal fitting tool -
3365-
♦ Removal and installation
device for valve cotters -
VAS 5161- with guide plate
- VAS 5161/23- and knurled
spacer ring - VAS
5161/23-1-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
Procedure
spec
es, in part or in w
Vehicles with ceramic glow plugs:

t to the co
Caution
rrectness of i
♦ Due to the special properties of the material used, ceramic

l purpos
glow plugs are easily damaged and require extra care

when handling and removing/installing. Adherence to the
nform
ercia
prescribed procedures is vital on removal and installation

⇒ page 318 .
m
at
om
ion
c
in t
or
his
e
The metal glow plugs do not require any special handling proce‐
at
do
riv
dures.
p
cum
for
Vehicles with ceramic glow plugs:

en
ng
t.
yi Co
op py
– Remove all glow plugs using U/J extension and socket - t. C rig
gh ht
3220- . pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Valve gear 105

Phaeton 2003 ➤
AG. Volkswagen AG d
agen oes
lksw not
Continuation for all vehicles: byV
o gu
ara
ed
is nte
– Remove camshafts ⇒ page 100 . ut
hor eo
a ra
s c
– Fit guide plate - VAS 5161/23- onto cylinder head. s
ce
e
nl
pt
du
– Secure guide plate using the knurled screws - VAS 5161/12- .
an
itte
y li
erm
ab
– Insert drift - VAS 5161/3- into guide plate and knock valve cot‐
ility
ot p
ters loose using a plastic hammer.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Screw sealing pin - VAS 5161/10- into guide plate.
rrectness of i
– Screw adapter - VAS 5161/11- hand-tight into glow plug hole
l purpos
of relevant cylinder.
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
py by
– Screw toothed piece - VAS 5161/6- with hooking fork - co Vo
by lksw
VAS 5161/5- into guide plate . cted agen
Prote AG.
– Slide knurled spacer ring - VAS 5161/23-1- onto assembly

cartridge - VAS 5161/8- .
– Connect adapter to compressed air line using a commercially
available connection piece, and apply constant air pressure.
• Minimum pressure: 6 bar
– Attach pressure fork - VAS 5161/2- to snap-in device and push
assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters.
– Move knurled screw back and forth slightly; the valve cotters
are thus forced apart and taken up by the assembly cartridge.
– Release pressure fork.
– Take out assembly cartridge with knurled spacer ring, valve
plate and valve spring.
– Remove valve stem oil seals using valve stem seal puller -
3364- .

Phaeton 2003 ➤
If the valve shaft seal puller - 3364- cannot be used on some of

the valve stem oil seals due to the confined space, proceed as
follows:
– Knock out pin -arrow- of valve shaft seal puller - 3364- using
a punch and remove the extractor attachment.
– Apply lower part of valve shaft seal puller - 3364- to valve stem
oil seal.
– Secure valve shaft seal puller with a punch -1- or other suitable
tool, as illustrated.
– Apply a puller to valve shaft seal puller and pull out valve stem
oil seal -arrow-. wage
e ks s no
Vol t gu
d by ara
e nte
ris
utho eo
ra
a c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
Note
is n
h re
ole,
spec
A plastic sleeve -A- is included with the new valve stem oil seals.
– Fit plastic sleeve -A- onto valve stem to prevent damage to t to the co
new valve stem oil seal -B-. rrectne
– Lightly lubricate sealing lip of valve stem oil seal.

s
– Slip valve stem oil seal over plastic sleeve.

s o
cial p
f i
– Carefully press valve stem oil seal onto valve guide using
nform
valve stem seal fitting tool - 3365- .

mer
atio
m
– Remove plastic sleeve.

o
n
c
i
or
n thi
te
– If valve cotters have been removed from assembly cartridge ,

sd
iva
o
r
they need to be put into valve insertion device - VAS 5161/18-

p
cum
r
fo
first.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
Note p by
co Vo
by lksw
cted agen
Prote AG.
Larger diameter of valve cotters faces upwards.
– Press assembly cartridge onto insertion device from above

and take up valve cotters.
2. Valve gear 107

Phaeton 2003 ➤
– Re-insert assembly cartridge - VAS 5161/8- into guide plate .

– Push pressure fork down and pull knurled screw upwards,
while turning screw in both directions – this will insert the valve
cotters.
– Release pressure fork with knurled screw still in pulled posi‐
tion.
– Install glow plugs ⇒ TDI injection and glow plug system (6-cyl.
3.0 l, 4V common rail); Rep. gr. 28 . gen AG
. Volkswagen AG
wa does
olks not
– Install camshafts ⇒ page 100 . byV gu
ara
ed nte
ris
tho eo
au ra
Note ss c
ce
e
nl
pt
du
an
♦ Engine is not to be rotated for approx. 30 minutes after instal‐
itte
y li
ling camshafts. Hydraulic compensation elements must settle
erm
ab
ility
(otherwise valves will strike pistons).
ot p
wit
, is n
♦ After working on the valve gear, turn the engine carefully at
h re
hole
least 2 rotations to ensure that none of the valves make con‐
spec
tact when the starter is operated.
es, in part or in w
t to the co
2.6 Checking hydraulic valve compensation
rrectness of i
elements
l purpos
nform
ercia
♦ -Fühlerblattlehre-
m
at
om
Note ion
c
in t
or
his
ate
do
riv
♦ Hydraulic valve compensation elements cannot be serviced.

p
cum
for
♦ Irregular valve noise during starting is normal.

en
ng
t.
yi Co
Cop py
ht. rig
Procedure rig ht
py by
co Vo
by lksw
– Start engine and run until coolant temperature reaches ap‐ cted agen
Prote AG.
prox. 80 °C.
– Increase engine speed to about 2500 rpm for 2 minutes (per‐
form road test if necessary).

Phaeton 2003 ➤
lkswage es n
ot g
Note d byV
o
ua
ran
ir se tee
ho
If the irregular valve noises stop aubut recur repeatedly during short
t or
ac
ss
trips, the oil retention valve -arrow- at the rear end of the respec‐
ce
le
tive cylinder head must be renewed.
un
pt
an
d
itte
y li
rm
ab
If the hydraulic bucket tappets are still noisy, determine defective
pe
ility
tappet as follows:
ot
wit
, is n
h re
hole
spec
– Rotate crankshaft until cam of hydraulic compensation ele‐
es, in part or in w
t to the co
ment to be checked faces upwards. The procedure is:
♦ Vehicles with manual gearbox: push vehicle forwards with 4th
gear engaged and ignition switched off.
rrectness of i
♦ Vehicles with automatic gearbox: remove noise insulation and
l purpos
rotate crankshaft in clockwise direction via central bolt for vi‐

bration damper.
nform
ercia
– Determine clearance between cam and roller rocker finger.

m
a
com
tio
– Press roller rocker finger down -arrow- using a screwdriver.
n in
r
te o
thi
If it is possible to insert a feeler gauge of 0.20 mm between cam‐
s
iva
do
shaft and roller rocker finger:
r
rp
cum
fo
en
g
– Renew hydraulic compensation element ⇒ page 100 .

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Valve gear 109

Phaeton 2003 ➤
2.7 Valve dimensions

agen oes
olksw not
V
Inlet and exhaust valves must not be reworked. Onlysedlapping-in
by gu
ara
is permitted. thori nte
eo
au ra
ss c
ce
Dimension Inlet valve Exhaust valve
e
nl
pt
du
an
itte
∅a mm 28.60 … 28.80 26.70 … 26.90
y li
erm
ab
∅b mm 5.968 … 5.982 5.958 … 5.972
ility
ot p
wit
c mm 97.25 … 97.45 97.35 … 97.55
, is n
h re
hole
α ∠° 45 45
spec
es, in part or in w
t to the co
WARNING
rrectness of i
♦ Care must be taken when disposing of old sodium-cooled
exhaust valves.
l purpos
♦ The valves must be sawn in two with a metal saw between

the centre of the stem and valve plate. When doing this
nform
ercia
they must not come into contact with water. After prepar‐
ing the valves, throw a maximum of ten into a bucket of
m
at
om
water. Then step away immediately, since a chemical re‐
ion
c
action will occur in which the sodium filling burns.
in t
or
his
ate
♦ After performing these steps the valves can be disposed
do
priv
c
of in the normal way.
um
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
2.8 Checking valve guides
p by
co Vo
by lksw
cted agen
Prote AG.

Phaeton 2003 ➤
Test procedure
– Insert valve into valve guide.
• End of valve stem must be flush with valve guide.
Note
Only insert inlet valve into inlet guide and exhaust valve into ex‐
haust guide, as the stem diameters are different.
– Determine rock.
• Wear limit (sideways play) for inlet and exhaust valve guide:
1.0 mm.
Note
♦ If the wear limit is exceeded, repeat the measurement with

new valves. Renew cylinder head if wear limit is still exceeded.
Valve guides cannot be renewed.
♦ If the valve is to be renewed as part of a repair, use a new
valve for the calculation.
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
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
o
by c lksw
cted agen
Prote AG.
2. Valve gear 111

Phaeton 2003 ➤
3 Chain drive for camshafts

AG. Volkswagen AG d
agen oes
olksw not
3.1 Camshaft timing chains (engine code ised byV gu
ara
nte
BMK) or eo
h
aut ra
ss c
Assembly overview - left camshaft timing chain ⇒ page 112 .
ce
e
nl
pt
du
an
Assembly overview - right camshaft timing chain ⇒ page 113 .
itte
y li
erm
ab
Removing and installing camshaft timing chains ⇒ page 114 .
ility
ot p
wit
, is n
Removing camshaft timing chains from camshafts ⇒ page 122 .
h re
hole
spec
3.1.1 Assembly overview - left camshaft timing chain
es, in part or in w
t to the co
rrectness of i
❑ Renew.
l purpos

chain sprocket
nf
ercia
or
chain
m
m
atio
om
n in
or c
thi
❑ Renew.
te
sd
iva
o
r
rp
cu
5 - Chain tensioner for left tim‐
o
m
f
ing chain
en
ng
t.
yi Co
op
6 - Chain sprocket for inlet
C py
ht. rig
camshaft
rig ht
py by
co Vo
by lksw
❑ Side with inscription Prote
cted AG.
agen
7 - 24 Nm
8 - Left timing chain
⇒ page 114
❑ Removing timing chain
from camshafts
⇒ page 122 .
9 - Bearing bracket for drive
chain sprocket
10 - 9 Nm

Phaeton 2003 ➤
3.1.2 Assembly overview - right camshaft timing chain
1 - 45 Nm
chain sprocket
3 - Right timing chain
⇒ page 114
❑ Removing timing chain
from camshafts
⇒ page 122 .
4 - Chain sprocket for inlet
camshaft
❑ Side with inscription
5 - 24 Nm
6 - Chain tensioner for right
timing chain
❑ Renew.
chain sprocket
9 - Drive sprocket for right tim‐
ing chain
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. Chain drive for camshafts 113

Phaeton 2003 ➤
3.1.3 Removing and installing camshaft timing chains

equipment required
♦ Locking pin - T40060- (Qty.
2)
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a 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
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.
♦ Drill bit, 3.3 mm ∅ (Qty. 2)

Phaeton 2003 ➤
Removing
Note
The crankshaft and camshafts must only be turned with the chain
drive mechanism fully installed. Otherwise the valves may strike
the pistons, causing damage to valves and piston crowns.
AG. Volkswagen AG d
agen oes
olksw not
– Remove noise insulation tray ⇒ General d by Vbody repairs, exteri‐ gu
ara
or; Rep. gr. 50 ; Body - front; Assembly
orise
overview - noise nte
eo
insulation . aut
h
ra
ss c
ce
le
un
pt
an
d

itte
y li
rm
ab
pe
– Separate engine from gearbox ⇒ page 11 .
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
Note
Prote AG.
♦ Locking pin -T40060- has a flat -2- which makes it easier to

insert when the locating bores in the camshaft and cylinder
head are not exactly in line.
♦ The locking pin is inserted initially so that the side pin -1- is
perpendicular to the imaginary line between the locking pin
and the centre of the camshaft.
♦ To obtain the correct TDC position, the side pin -1- must then
be turned 90° -arrow- so it is in line with the imaginary line
between the locking pin and the centre of the camshaft.

Phaeton 2003 ➤
. Volkswage
AG n AG d
agen oes
olksw not
– Turn crankshaft in normal direction of rotation to TDC position:db
yV gu
ara
rise nte
• It should be possible to lock camshafts with lockingupinstho - eo
ra
T40060- . ss a c
ce
e
nl
• The side pin -arrow- in each locking pin - T40060- must be in
pt
du
an
line with the imaginary line between the locking pin and the
itte
y li
erm
centre of the camshaft.
ab
ility
ot p
Cylinder bank 1 (right side):
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Cylinder bank 2 (left side):
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
yri by
– Lay a cloth under upper part of sump to catch engine oil. cop Vo
by lksw
cted agen
Prote
AG.
WARNING


Phaeton 2003 ➤
– Press guide rail of chain tensioner for left timing chain in di‐
rection of -arrow- and lock chain tensioner by inserting a
3.3 mm ∅ drill bit -item 1-.
– Mark running direction of left timing chain.
– Remove locking pins - T40060- from both camshafts.
– Unscrew bolts -1- from chain tensioner and -2- from camshaft
chain sprocket.
– Take off camshaft chain sprocket, chain tensioner and left tim‐
ing chain.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
– Press guide rail of chain tensioner for right timing chain in di‐
ot p
rection of -arrow- and lock chain tensioner by inserting a
wit
is n
h re
3.3 mm ∅ drill bit -item 1-.
ole,
spec
– Mark running direction of right timing chain.
t to the co
rrectness o
cial p
f inform
mer
atio
m
o
n
c
chain sprocket.
or
n thi
te
sd
va
– Take off camshaft chain sprocket, chain tensioner and right

i
o
pr
cum
timing chain.
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Phaeton 2003 ➤
Installing
• Drive chain for valve gear installed ⇒ page 47
Note
♦ Renew seal.
♦ Renew the bolts tightened with specified tightening angle.
♦ The crankshaft must not be at TDC at any cylinder when the
camshafts are turned. Danger of damage to valves and piston
crowns.
– Check that camshafts on both cylinder heads are positioned

at TDC.
• It should be possible to lock camshafts with locking pins -
T40060- .
AG. Volkswagen AG d
agen oes
olksw not
yV gu
Cylinder bank 2 (left
ed side):
b ara
nte
ris
ho eo
– Remove alocking
ut pins - T40060- from both camshafts. ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Note
ss o
cial p
♦ If the locking pins cannot be inserted in the camshafts, the

inform
camshafts can be turned slightly using adapter - T40061- . To

mer
do so, screw securing bolts for camshaft chain sprocket into

atio
m
camshaft.
o
n
c
i
or

thi
te
sd
a
camshafts are turned. Otherwise there is a risk of damage to

iv
o
pr
valves and piston crowns.

um
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Phaeton 2003 ➤
– Install left timing chain with camshaft chain sprocket and chain
tensioner.
• The elongated holes in the chain sprocket must be aligned
centrally over the tapped holes in the camshaft.
– Tighten bolts -1- for chain tensioner.
– Screw in two bolts -2- for chain sprocket, but do not tighten
bolts.
• It should just be possible to turn the chain sprocket on the
camshaft without axial movement.
– Lock left camshaft with locking pin - T40060- .
• The side pin -arrow- on the locking pin - T40060- must be in
– Pull drill bit -3- from locating hole, this releases the left chain
tensioner.
. Volkswagen AG
a gen AG d
– Install right timing
Vol
ksw chain with camshaft chain
oes
not sprocket and
gu
chain tensioner.
ed by ara
n
is tee
or
• Theauelongated
th holes in the chain sprocket must be aligned
or
ac
centrally
ss over the tapped holes in the camshaft.
ce
le
un
pt

an
d
itte
y li
erm
ab
ility
bolts.
ot p
wit
is n

h re
ole,

spec
– Lock right camshaft with locking pin - T40060- .

t to the co

rrectne

– Pull drill bit -3- out of locating hole; this releases the right chain
ss
tensioner.
o
cial p
f inform
mer
– Using a torque wrench and adapter -T40062- , apply a torque

atio
of 30 Nm to right camshaft chain sprocket in direction indicated

om
(-arrow-). Maintain this torque for the following step.

c
i
or
n thi
te
– Tighten bolts -1- and -2-.

sd
iva
o
pr
cum
r
– Take off adapter - T40062- and pull out locking pin - T40060- .
fo
en
ng
t.
yi Co
– Tighten remaining bolts for right chain sprocket.
t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Phaeton 2003 ➤
– Using a torque wrench and adapter - T40062- , apply a torque

of 15 Nm to left chain sprocket in -direction of arrow- and
maintain pre-tension.
– Take off adapter - T40062- and pull out locking pin - T40060- .
– Tighten remaining bolts for left chain sprocket.
– Remove locking pin - 3242- .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
Checking valve timing

, is n
h re
hole
spec
Caution
es, in part or in w
t to the co
The crankshaft must only be turned in engine direction of ro‐

tation.
rrectness of i
l purpos
– Using adapter - T40049- , turn crankshaft two rotations in nor‐

mal direction of rotation -arrow- until crankshaft is just before
nform
ercia
TDC again.
m
a
com
tion in
r
te o
– While turning in this direction, lock crankshaft -1- with locking

thi
s
pin - 3242- . Tighten locking pin to 20 Nm.

iva
do
r
rp
cum
fo
en
ng
Caution
t.
yi Co
Cop py
ht. rig
rig ht
If the crankshaft has been rotated even only slightly beyond py by
o Vo
the TDC position, turn it back approx. 10° so you can then reset
by c lksw
cted agen
it to TDC by turning in the normal direction of rotation.
Prote AG.

Phaeton 2003 ➤
– Check that it is now possible to lock the camshafts with locking

pins - T40060- .
Adjusting valve timing

If the locking pin cannot be inserted in one of the camshafts:
AG. Volkswagen A
– Loosen all bolts -arrows- onolkthe
swarelevant chain sprocket
gen G do
es n ap‐
ot g
prox. 1 turn. d by V ua
r e an
ris tee
tho or
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Apply adapter - T40061- to the heads of the loosened bolts.

t to the co
– Turn camshaft slightly backwards and forwards with adapter -

T40061- until locking pin - T40060- can be inserted.
rrectne
ss o
– With adapter - T40061- and adjustment pin - T40060- still in

cial p
f in
position, tighten bolts on chain sprocket to approx: 5 Nm.

form
mer
– Remove adjustment pin - T40060- and adapter - T40061- .

atio
om
n
c
– Tighten bolts on chain sprocket to final torque.

i
or
n thi
te
sd
a
– Repeat this procedure on the other cylinder bank if necessary.

iv
o
pr
cum
r
fo

en
ng
t.
yi Co
op
– Check valve timing once again ⇒ page 120 . C py
ht. rig
rig ht
py by
Perform further installation in reverse order, paying attention to co Vo
by lksw
the following: cted agen
Prote AG.

Phaeton 2003 ➤
– Screw plug -arrow- for TDC mark into upper part of sump with
a new seal.
– Bolt gearbox to engine and install engine/gearbox assembly
⇒ page 3 .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
3.1.4 Removing camshaft timing chains from camshafts
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
equipment required
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Locking pin - T40060- (Qty.
2)
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.

Phaeton 2003 ➤
Note
♦ When working on one cylinder head only, it is not necessary

to remove the timing chain cover on the opposite cylinder head
as well. In this case it is only necessary to remove the ex‐
hauster pump or the sealing cap, because the timing chain on
this cylinder head stays in place.
♦ However, the valve timing for both cylinder heads must be ad‐
justed in all cases as described below.
Procedure
• Engine in vehicle.
Note
For illustration purposes, the following work on the timing chains

is shown from the rear with the engine removed

– Remove vacuum pump ⇒ page 93 .
– Remove air mass sensor/turbocharger connection hose.
– Unbolt engine lifting eye -arrow- from cylinder head.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
– Remove air intake hose together with crankcase breather

ility
ot p
hose -arrows-.
wit
is n
h re
ole,
spec
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
o
by c lksw
cted agen
Prote AG.

. Volkswage
Phaeton 2003 ➤ wage
n AG n AG d
oes
olks not
6-cylinder diesel engine (3.0 l engine,
d by common rail) - Edition 04.2016
V gu
ar
e an
ris tee
ho
– Separate connector -3- at intake smanifold
au
t
flap motor - V157- . or
ac
s
– Remove bolts -2- and -4- and move intake manifold flap motor
ce
e
nl
pt
du
- V157- clear to the side (with connecting rod installed).
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
In order to prevent damage to the intake manifold flap motor -
spec
V157- , the connecting rod is not removed.
es, in part or in w
t to the co
rrectness of i
l purpos
– Separate connector -1- at coolant temperature sender - G62- .

nform
ercia
– Disconnect coolant hoses -arrows- and take out coolant pipe

m
at
(rear).
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.
– Unscrew bolts -1 … 4- and remove left timing chain cover.

Phaeton 2003 ➤
– Insert guide pin of adapter - T40058- so that the large diameter

-arrow 2- faces the adapter.
– Using adapter - T40058- turn the crankshaft in the normal di‐

rection of rotation -arrow- to TDC.

agen oes
olksw not
y V gu
d b ara
♦ The locking
orise pin - T40060- has a flat -2- which makes
nte it easier
to insert when the locating bores in the camshaft and
eo
r a cylinder
th
au
head
ss are not exactly in line. c
ce
e
nl
pt
♦ The locking pin is inserted initially so that the side pin -1- is
du
an
itte
perpendicular to the imaginary line between the locking pin

y li
erm
ab
and the centre of the camshaft.

ility
ot p
wit
♦ To obtain the correct TDC position, the side pin -1- must then
, is n
h re
be turned 90° -arrow- so it is in line with the imaginary line

hole
between the locking pin and the centre of the camshaft.

spec
es, in part or in w
t to the co

at TDC.
rrectness of i

l purpos
T40060- .
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.

Phaeton 2003 ➤

AG. Volkswagen AG d
agen oes
o lksw not
WARNINGd by V gu
ara
ise nte
or e
h
To avoid any risk
s aut of injury, do not rotate crankshaft while feeling or a
c
for TDC hole swith your finger.
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
– Press guide rail of chain tensioner for left timing chain in di‐
um
fo
rection of arrow and lock chain tensioner by inserting a

en
ng
t.
yi Co
3.3 mm ∅ drill bit -Item 1-. t. Cop py
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
d by
V
Phaetongu 2003 ➤
ara
e nte
6-cylinder diesel engine
horis
(3.0 l engine, common rail) - Edition 04.2016
eo
aut ra
ss c
ce
e
nl
chain sprocket.
pt
du
an
itte
y li
– Remove camshaft chain sprocket and left chain tensioner.
erm
ab
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
Cover chain tensioner opening with a cloth or similar to stop small
t to the co
parts dropping in.
rrectness of i
l purpos
– Press guide rail of chain tensioner for right timing chain in di‐
rection of arrow and lock chain tensioner by inserting a
nform
ercia
3.3 mm ∅ drill bit -Item 1-.

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
o
by c lksw
cted agen
Prote AG.
chain sprocket.
– Remove camshaft chain sprocket and right chain tensioner.
Note
Cover chain tensioner opening with a cloth or similar to stop small

parts dropping in.
Installing
Note

camshaft is turned. Danger of damage to valves and piston
crowns.

Phaeton 2003 ➤

at TDC.
T40060- .

– Remove locking pins - T40060- from both camshafts.
Note
♦ If the locking pins cannot be inserted in the camshafts, the

camshafts can be turned slightly using adapter - T40061- . To
do so, screw securing bolts for camshaft chain sprocket into
camshaft.
camshaft is turned. Danger of damage to valves and piston
AG. Volkswagen AG d
crowns. lkswagen oes
n o ot g
yV ua
edb ran
ris tee
tho or
s au ac
– Install left timing
s
chain with camshaft chain sprocket and chain
ce
e
nl
tensioner.
pt
du
an
itte
y li

erm
ab

ility
ot p
wit
, is n

h re
hole
spec
es, in part or in w
bolts.
t to the co

rrectness of i
– Lock left camshaft with locking pin - T40060- .

l purpos

nform
ercia

m
– Pull drill bit -3- from locating hole, this releases the left chain
at
om
io
tensioner.
n
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
128
op Vo
by c lksw
Prote
cted AG.
agen
Phaeton 2003 ➤
– Install right timing chain with camshaft chain sprocket and

chain tensioner.
bolts.
– Lock right camshaft with locking pin - T40060- .
– Pull drill bit -3- out of locating hole; this releases the right chain
tensioner.
– Apply a torque of 30 Nm to right camshaft chain sprocket in

direction of arrow using a torque wrench and adapter -
T40062- . Maintain this torque for the following step.
– Take off adapter - T40062- and pull out locking pin -T40060- .
– Tighten remaining bolts for right chain sprocket.
– Using a torque wrench and adapter - T40062- , apply a torque

of 15 Nm to left chain sprocket in -direction of arrow- and
maintain pre-tension. wage
e s no ks
t gu Vol
– Tighten bolts -1- and
ed -2-.
by ara
nte
ris
o
t - T40062- and pull out locking pin - T40060-e.or
– Take off adapter
au
h
ac
ss
– Tighten remaining bolts for left chain sprocket.
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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
129
AG.
3. Chain drive for camshafts
Phaeton 2003 ➤
Checking valve timing lkswage es n
o ot g
byV ua
d ran
ir se tee
o
Caution auth or
ac
ss
ce
le
un
pt
an
d
tation.
itte
y li
erm
ab
ility
ot p
wit
– Turn crankshaft two rotations in normal direction of rotation
is n
h re
-arrow- until the crankshaft is just before TDC again.
ole,
spec
t to the co
rrectne
ss
Caution
o
cial p
f inform
If the crankshaft has been rotated even only slightly beyond
mer
the TDC position, turn it back approx. 10° so you can then reset
atio
m
it to TDC by turning in the normal direction of rotation.

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
– Check that it is now possible to lock the camshafts with locking pyri by
Vo
co
pins - T40060- .
by lksw
cted agen
Prote AG.

Phaeton 2003 ➤

If the locking pin cannot be inserted in one of the camshafts:
– Loosen all bolts -arrows- on the relevant chain sprocket ap‐
prox. 1 turn.
– Apply adapter - T40061- to the heads of the loosened bolts.

T40061- until locking pin - T40060- can be inserted.
– With adapter - T40061- and adjustment pin - T40060- still in
position, tighten bolts on chain sprocket to approx: 5 Nm.
– Tighten bolts on chain sprocket to final torque.
– Repeat this procedure on the other cylinder bank if necessary.
– Check valve timing once again ⇒ page 130 .
Perform further installation in reverse order, paying attention to
the following:
agen AG olksw
– Screw plug -arrow- for TDC mark ainto
gen Aupper
G. V part of sump
does with
ksw
a new seal. by Vol not
gu
d ara
se nte
– Install timing chain covers
tho
ri ⇒ page 35 . e or
au ac
– Install rear coolant
ss pipe.
ce
le
un
pt
– Install vacuum pump ⇒ page 93 .

an
d
itte
y li
rm
ab
– Fill coolant system with coolant ⇒ page 173 .

pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
3.2 Camshaft timing chains (engine codes

rrectness of i
CARA, CEXA, CEXB)

l purpos
Assembly overview - left camshaft timing chain ⇒ page 131 .

Assembly overview - right camshaft timing chain ⇒ page 133 .
nform
ercia
Removing and installing camshaft timing chain ⇒ page 134 .

m
a
com
tio
Removing camshaft timing chain from camshafts ⇒ page 141 .

n in
r
te o
thi
3.2.1 Assembly overview - left camshaft timing chain

s
iva
do
r
rp
cum
fo
Left camshaft timing chain

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

Phaeton 2003 ➤
1 - Thrust washer
❑ For drive chain sprock‐
lkswage es n
o ot g
et. ed
byV ua
ra
ris nte
2 - Bolt aut
ho eo
ra
ss c
❑ Specified torque
ce
le
⇒ Item 4 (page 55)

un
pt
an
d
itte
y li
3 - Bolt
erm
ab
ility
❑ Renew.
ot p
wit
is n
h re
ole,
spec
4 - Guide rail
t to the co
tion.
5 - Bolt
rrectne
❑ Renew.
ss o
cial p
f
6 - Chain tensioner
inform
❑ For left camshaft timing
mer
atio
chain.
om
n
c
i
7 - Bolt
or
n thi
te
sd
a
❑ 23 Nm
iv
o
pr
cum
r
fo
8 - Camshaft chain sprocket

en
ng
t.
yi Co
❑ For inlet camshaft. t. Cop py
rig
gh ht
pyri by
side with lettering for‐
co Vo
by lksw
cted
wards.
agen
Prote AG.
9 - Left camshaft timing chain

❑ Removing from cam‐
shafts ⇒ page 141 .
paint.
10 - Bolt
❑ With sleeve.
❑ Renew.
11 - Tensioning plate
12 - Bearing bracket
❑ For drive chain sprocket.
13 - Bolt
❑ Specified torque ⇒ Item 10 (page 55)
14 - Drive chain sprocket
❑ For left camshaft timing chain.

Phaeton 2003 ➤
3.2.2 Assembly overview - right camshaft timing chain

Right camshaft timing chain
1 - Bolt agen
AG. Volkswagen AG d
oes
olksw not
❑ Specified torque d by
V gu
ara
⇒ Item 2 (page 55) orise nte
eo
h
ut ra
2 - Bearing mounting ss a c
ce
e
nl
pt
du
an
et.
itte
y li
erm
ab
3 - Right camshaft timing chain
ility
ot p
❑ Removing from cam‐
wit
, is n
h re
shafts ⇒ page 141 .
hole
spec
es, in part or in w
t to the co
paint.
⇒ page 134
rrectness of i
4 - Camshaft chain sprocket
l purpos
❑ For inlet camshaft.
nform
ercia
side with lettering for‐
m
at
wards.
om
ion
c
in t
r
5 - Bolt
o
his
ate
❑ 23 Nm
do
priv
cum
or
6 - Chain tensioner
f
en
ng
t.
yi Co
❑ For right camshaft tim‐ t. Cop py
ing chain.
rig
gh ht
pyri by
Vo
o
by c
7 - Bolt
lksw
cted agen
Prote AG.
❑ Renew.
8 - Thrust washer
et.
9 - Drive chain sprocket
❑ For right camshaft timing chain.

Phaeton 2003 ➤
3.2.3 Removing and installing camshaft timing Achains

G. Volkswagen n AG do
wage es n
Volks ot g
by ua
Special tools and workshop ris
ed ran
tee
equipment required au
tho
or
ac
ss
ce
le
un
pt
an
d
♦ Special wrench - T40049-
itte
y li
erm
ab
♦ Adjustment pin - T40060-
ility
ot p
(Qty. 2)
wit
is n
h re
ole,
spec
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
Prote AG.
Removing
Caution
Avoid damage to valves and piston crowns.

♦ Crankshaft and camshafts may only be turned with chain
drive mechanism fully installed.


Phaeton 2003 ➤
– Install special wrench - T40049- on rear of crankshaft, use 2

old drive plate bolts -arrows- for this.
lkswage es n
o ot g
byV ua
d ran
ir se
Note tho tee
or
au ac
ss
♦ The adjustment pin - T40060- has a flat -2- which makes it
ce
e
nl
pt
easier to insert when the locating holes in the camshaft and
du
an
itte
cylinder head are not exactly in line.
y li
erm
ab
ility
♦ The adjustment pin is inserted initially so that the pin -1- so it
ot p
is transverse to the axis of the camshaft.
wit
, is n
h re
hole
♦ To obtain the correct “TDC” position, the pin -1- must then be
spec
turned 90° -arrow- so it is vertical to the axis of the camshaft.
es, in part or in w
t to the co
rrectness of i
Caution
l purpos
Risk of irreparable damage from camshaft timing chains jump‐
nf
ercia
ing.
orm
m
atio
♦ Only turn crankshaft in engine direction of rotation.
om
n in
or c
thi
te
sd
iva
– Turn crankshaft to “TDC”:

o
r
rp
cu
o
m
f
• It should be possible to lock camshafts with adjustment pin -

en
ng
t.
yi
T40060- .
Co
Cop py
t. rig
gh ht
• Pin -arrow- on adjustment pin - T40060- must be vertical to yri
p by
o Vo
centre axis of camshaft on cylinder bank 1 (right side).
c by lksw
cted agen
Prote AG.
• Pin -arrow- on adjustment pin - T40060- must be vertical to

centre axis of camshaft on cylinder bank 2 (left side).

Phaeton 2003 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
WARNING
spec
t to the co
rrectne
ss
o
cial p
f i
locking pin.
nform
mer
atio
om
n
c
i
or
n
thi
te
sd
a
3.3 mm ∅ drill to prevent flesh wounds.

iv
o
pr
cum
r
fo
– Press tensioning rail of chain tensioner for left camshaft timing
en
ng
t.
chain in direction of -arrow- and lock chain tensioner by in‐
yi Co
op
serting 3.3 mm ∅ drill bit -item 1-.
C py
ht. rig
rig ht
py by
co Vo
by lksw
Caution
cted agen
Prote AG.
Camshaft timing chain may be destroyed if it runs in the oppo‐

site direction to the direction it ran before.
♦ If camshaft timing chain is to be reinstalled: mark direction
of rotation with a coloured arrow.
– Remove adjustment pin - T40060- from both camshafts.
– Unscrew bolt -3- and remove tensioning rail.

– Unscrew bolts -1- for guide rail and -2- for camshaft chain
sprocket.
– Remove camshaft chain sprocket, guide rail and left camshaft
timing chain.

Phaeton 2003 ➤

3.3 mm ∅ drill to prevent
wage
n AGflesh
. Volkswounds.
wagen AG
does
ks not
Vol g
– Press guide d brail of chain tensioner for right camshaft
y ua
ran timing
se
chain inthodirection of -arrow- and lock chain tensioner
ri teeby in‐
or
serting
s au 3.3 mm ∅ drill bit -item 1-. ac
s
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
Caution
rrectness of i
Camshaft timing chain may be destroyed if it runs in the oppo‐
l purpos
site direction to the direction it ran before.

♦ If camshaft timing chain is to be reinstalled: mark direction
nf
ercia
o
of rotation with a coloured arrow.
rm
m
atio
om
n in
or c
– Unscrew bolts -1- for chain tensioner and -2- and -3- for cam‐
thi
te
shaft chain sprocket. sd

iva
o
r
rp
cu
– Remove camshaft chain sprocket, chain tensioner and right

o
m
f
en
ng
camshaft timing chain.

t.
yi Co
Cop py
t. rig
gh ht
yri
Installing p by
co Vo
by lksw
cted agen
• Specified torques ⇒ page 131 . Prote AG.

• Drive chain for valve gear installed ⇒ page 59
Note
♦ Renew seal for “TDC” mark sealing plug.

Caution

♦ When turning camshaft, crankshaft must be positioned so
that no piston is positioned at “TDC”.

Phaeton 2003 ➤

at “TDC”.
T40060- .
• Pin -arrow- on adjustment pin - T40060- must be vertical to agen

AG. Volkswagen AG d
oes
centre axis of camshaft on cylinder bank 2 (left side). Volksw not
gu
d by ara
– Remove adjustment pin - T40060- from both camshafts.horise nte
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
Caution
rrectness of i
l purpos

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
a
Note
iv
o
r
rp
cu
o
m
f
en
ng
If the camshaft cannot be locked, the camshafts can be turned

t.
yi Co
slightly using adapter - T40061- . To do so, screw securing bolts Cop py
t. rig
for camshaft chain sprocket into camshaft. gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Install left camshaft timing chain with camshaft chain sprocket,
guide rail and tensioning rail.
• Elongated holes in camshaft chain sprocket must be aligned
centrally with threaded holes in camshaft.
– Tighten bolts -1- and -3- for guide rail and tensioning rail.
– Screw both bolts -2- for camshaft chain sprocket in loosely.
• It should just be possible to turn camshaft chain sprocket on
– Lock left camshaft with adjustment pin - T40060- .
centre axis of camshaft.
– Pull drill -4- out of locating hole, this releases the left chain
tensioner.

Phaeton 2003 ➤
– Install right camshaft timing chain with camshaft chain sprock‐

et and chain tensioner.
– Lock right camshaft with adjustment pin - T40060- .
– Pull drill -3- out of locating hole, this releases the right chain
tensioner.
– Pretension right camshaft chain sprocket to 20 Nm in direction

of -arrow- using adapter - T40062- and torque wrench and hold
at this tension.
– Remove adapter - T40062- and adjustment pin - T40060- .
– Tighten remaining bolts for right camshaft chain sprocket.
– Pretension left camshaft chain sprocket to 15 Nm in direction

at this tension.
– Tighten bolts -1- and -2-.. Volkswage
n AG n AG d
wage oe
– Remove adapter
yV
olks - T40062- and adjustment
s no pin - T40060- .
tg
b ua
ed ra
– Tighten
ho remaining bolts for left camshaft chain sprocket.
ris nte
e
t or
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n

h re
ole,
spec
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
o
by c lksw
cted
139
agen
Prote AG.
3. Chain drive for camshafts
Phaeton 2003 ➤
Checking valve timing agen

AG. Volkswagen AG d
oes
olksw not
y V gu
d b ara
Caution horise nte
eo
ut ra
s a c
Risk of irreparable damage from camshaft timing chains jump‐ s
ce
e
nl
ing.
pt
du
an
itte
y li
♦ Only turn crankshaft in engine direction of rotation
erm
ab
-arrow-.
ility
ot p
wit
, is n
h re
hole
– Turn crankshaft 2 rotations until crankshaft is just before
spec
“TDC” again using special wrench - T40049- .
es, in part or in w
t to the co
rrectness of i
l purpos
Caution
nf
ercia
Adjustment fault through inexact “TDC” position.
orm
m
♦ If the crankshaft has been rotated even only slightly be‐
atio
m
yond the “TDC” position, first turn crankshaft back ap‐

o
n in
or c
prox. 10° then turn again in engine direction of rotation to
thi
te
“TDC”.
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t.
rig
gh ht
yri by
at “TDC”. cop Vo
by lksw
cted agen
Prote
AG.
T40060- .


Phaeton 2003 ➤

– If one of the camshafts cannot be locked, loosen all bolts
-arrows- of relevant camshaft chain sprocket approx. 1 turn.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
– Fit adapter - T40061- over bolt heads of loosened bolts.
y li
erm
ab
ility
ot p
wit
T40061- until adjustment pin - T40060- can be inserted. is n
h re
ole,
spec
t to the co
– Tighten bolts for camshaft chain sprocket to approx. 5 Nm with
adapter - T40061- and adjustment pin - T40060- still fitted.
rrectne
– Tighten bolts for camshaft chain sprocket to specified torque.
ss o
cial p
f
– If necessary, repeat procedure for other cylinder bank.
inform
mer
atio
m
– Check valve timing again ⇒ page 140 .

o
n
c
i
or
n thi
e

t
sd
va
note the following:

i
o
pr
cum
r
fo
en
ng
t.
yi
– Screw in sealing plug -arrow- for “TDC” mark in upper part of
Co
op py
oil sump ⇒ Item 21 (page 157) . t. C rig
gh ht
pyri by
o Vo
by c lksw
cted agen
Prote AG.
– Replenish engine oil and check oil level ⇒ Maintenance ;
Booklet .
3.2.4 Removing camshaft timing chains from camshafts

Phaeton 2003 ➤

equipment required
♦ Adjustment pin - T40060-
(Qty. 2)
♦ Adapter - T40062- agen
AG. Volkswagen AG d
oes
olksw not
♦ Drill bit, 3.3 mm ∅ (Qty. 2) ed by
V gu
ara
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
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
o
by c lksw
Removing cted agen
Prote AG.
• Engine and gearbox in vehicle
Note
If repairs have been undertaken on only one cylinder head, then

it is sufficient to check the valve timing on the cylinder head on
which the repairs were made.

– Remove starter catalytic converter ⇒ page 306 .
– Remove vacuum pump.
– Remove rear right coolant pipe ⇒ page 191 .
– Remove rear left coolant pipe ⇒ page 188 .
Note
For illustration purposes, the following work on the timing chains

is shown from the rear with the engine removed

Phaeton 2003 ➤
Volkswagen AG
n AG.common
6-cylinder diesel engine (3.0 klsengine,
wage rail) d-oEdition
es n 04.2016
ol ot g
yV ua
db ran
– Unscrew bolts -1 … 4- and remove left timing chain ris cover.
e
tee
ho
aut or
ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
ss 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
– Insert guide pin of adapter -T40058- as follows:
agen
Prote AG.
• The larger diameter -arrow 1- points towards the engine.

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

ing.
-arrow-.
– Turn crankshaft to “TDC” using adapter - T40058- .

Phaeton 2003 ➤
Note
♦ The adjustment pin - T40060- has a flat -2- which makes it

easier to insert when the locating holes in the camshaft and
cylinder head are not exactly in line.
♦ The adjustment pin is inserted initially so that the pin -1- so it
is transverse to the axis of the camshaft.
♦ To obtain the correct “TDC” position, the pin -1- must then be
turned 90° -arrow- so it is vertical to the axis of the camshaft.

at “TDC”:
T40060- .

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
Note
h re
ole,
spec
Place a cloth underneath upper part of sump to catch escaping

engine oil.
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.

Phaeton 2003 ➤
WARNING

locking pin.
AG. Volkswagen AG d
agen oes
– Wrap insulating tape around cutting end and cutting edges
Vol
ksw of not
gu
3.3 mm ∅ drill to prevent flesh wounds. se
d by ara
nte
i
or eo
– Press tensioning rail of chain tensioner for leftacamshaft
ut
h
timing ra
chain in direction of -arrow- and lock chain tensioner
ss
by in‐ 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
Caution
l purpos
Risk of damage to engine.
nform
ercia
♦ Block off opening in valve timing housing with a clean cloth

to prevent small items from dropping into engine.
m
a
com
tion in
r
te o
thi
– Unscrew bolt -3- and remove tensioning rail.
s
iva
do
r
rp
cum
– Unscrew bolts -1- for guide rail and -2- for camshaft chain
fo
en
g
sprocket.
n
t.
yi Co
Cop py
– Remove camshaft chain sprocket and guide rail.
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
agen
Prote AG.
3.3 mm ∅ drill to prevent flesh wounds.
– Press guide rail of chain tensioner for right camshaft timing
chain in direction of -arrow- and lock chain tensioner by in‐

Phaeton 2003 ➤
lkswage es n
o ot g
Caution byV ua
d ran
ir se tee
tho
or
Risk of damage sto
s au
engine. ac
ce
e
♦ Block off opening in valve timing housing with a clean cloth

nl
pt
du
an
to prevent small items from dropping into engine.
itte
y li
erm
ab
ility
ot p
wit
– Unscrew bolts -1- for chain tensioner and -2- and -3- for cam‐
, is n
h re
shaft chain sprocket.
hole
spec
– Remove camshaft chain sprocket and right chain tensioner.
es, in part or in w
t to the co
Installing
rrectness of i
l purpos
nf
ercia
Note
orm
m
atio
m

o
n in
or c
thi
e
♦ Renew seal for “TDC” mark sealing plug.

t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
Caution
Co
Cop py
t. rig
gh ht
yri
p by
co Vo
by lksw
cted agen
Prote AG.

at “TDC”.
T40060- .

– Remove adjustment pin - T40060- from both camshafts.

Phaeton 2003 ➤
Caution

AG. Volkswagen AG d
agen oes
olksw not
V gu
Note d by ara
ise nte
or eo
h
ut ra
If the camshaft cannot
ss a
be locked, the camshafts can be turned c
slightly using adapter - T40061- . To do so, screw securing bolts
ce
le
un
pt
for camshaft chain sprocket into camshaft.
an
d
itte
y li
rm
ab
pe
ility
– Install left camshaft timing chain with camshaft chain sprocket,
ot
wit
, is n
guide rail and tensioning rail.
h re
hole
spec
es, in part or in w
t to the co
– Tighten bolts -1- and -3- for guide rail and tensioning rail.
rrectness of i
l purpos

– Lock left camshaft with adjustment pin - T40060- .
nform
ercia

m
a
com
ti
on in
r
te o
thi
– Pull drill -4- out of locating hole, this releases the left chain
s
iva
tensioner.
do
r
rp
cum
fo
en
ng
– Install right camshaft timing chain with camshaft chain sprock‐

t.
yi Co
op
et and chain tensioner.
C py
t. rig
gh ht
yri by
op Vo
by c lksw
centrally with threaded holes in camshaft. cted agen
Prote AG.

– Lock right camshaft with adjustment pin - T40060- .
– Pull drill -3- out of locating hole, this releases the right chain
tensioner.

Phaeton 2003 ➤
– Pretension right camshaft chain sprocket to 20 Nm in direction

at this tension.
– Tighten remaining bolts for right camshaft chain sprocket.
– Pretension left camshaft chain sprocket to 15 Nm in direction

at this tension.
– Tighten remaining bolts for left camshaft chain sprocket.
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
Checking valve timing

ility
ot p
wit
, is n
h re
Caution
hole
spec
es, in part or in w

t to the co
ing.
rrectness of i
-arrow-.
l purpos
– Turn crankshaft 2 rotations until crankshaft is just before

nform
ercia
“TDC” again.
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.

Phaeton 2003 ➤

Caution
Adjustment fault through inexact “TDC” position. agen

AG. Volkswagen AG d
oes
olksw not
♦ If the crankshaft has been rotated even only slightly
d by V be‐ gu
ara
yond the “TDC” position, first turn crankshaft orisback
e
ap‐ nte
eo
prox. 10° then turn again in engine direction
aut of rotation to
h
ra
“TDC”. ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
at “TDC”.
, is n
h re
hole
spec
T40060- .
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
io
n
c
in t
r

o
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.

– If one of the camshafts cannot be locked, loosen all bolts
-arrows- of relevant camshaft chain sprocket approx. 1 turn.

Phaeton 2003 ➤
– Fit adapter - T40061- over bolt heads of loosened bolts.

T40061- until adjustment pin - T40060- can be inserted.
– Tighten bolts for camshaft chain sprocket to approx. 5 Nm with
adapter - T40061- and adjustment pin - T40060- still fitted.
Volkswagen AG
– Tighten bolts for camshaft chain sprocket to specified
swa
gtorque.
en AG. does
k not
Vol gu
– If necessary, repeat procedure for other cylinderd by bank. ara
e nte
ris
– Remove locking pin - 3242- . utho eo
ra
a c
ss
– Check valve timing again ⇒ page 148 .
ce
e
nl
pt
du
an
itte
y li
erm
ab
note the following:
ility
ot p
wit
, is n
h re
hole
oil sump ⇒ Item 21 (page 157) .
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.

Phaeton 2003 ➤
17 – Lubrication
1 Engine oil
Note
♦ If large quantities of metal shavings or particles are found in

the engine oil when repairing the engine, the oil passages
must be cleaned carefully, and the oil cooler must be renewed
in order to prevent further damage occurring later.
♦ The oil level must not be above max. mark on dipstick - danger
of damage to catalytic converter.
Engine oil specification ⇒ Maintenance ; Booklet 16.1

Oil capacities ⇒ page 151
Checking engine oil level ⇒ page 151
1.1 Oil capacities

With oil filter, 8.3 litres
1.2 Checking engine oil level

AG. Volkswagen AG d
agen
Test prerequisites Volksw
oes
not
gu
d by ara
• Engine oil temperature at least 60 °C. orise nte
eo
h
ut ra
• Vehicle must be level (horizontal). ss a c
ce
e
nl
• Wait a few minutes after switching engine off to allow oil to flow
pt
du
an
back into sump.
itte
y li
erm
ab
Test procedure
ility
ot p
wit
, is n
– Pull out dipstick, wipe off with a clean cloth and insert it again
h re
to stop.
hole
spec
es, in part or in w
– Pull out dipstick again and read oil level.
t to the co
Markings on dipstick:
a - Oil must be topped up. It is sufficient if the oil level is some‐
where in area -b- (grooved area on dipstick) after topping up. rrectness of i
l purpos
b - Oil can be topped up. The oil level may rise as far as area
-a- after topping up.
nf
ercia
c - Oil is not to be topped up.

rm
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
o
by c lksw
cted agen
Prote AG.
1. Engine oil 151

Phaeton 2003 ➤
2 Parts of lubrication system

Assembly overview - oil pump, lower part of sump ⇒ page 152 .
Removing and installing lower part of sump ⇒ page 153 .
Removing and installing oil pump ⇒ page 155 .
Assembly overview - upper part of sump ⇒ page 156 .
Removing and installing upper part of sump ⇒ page 157g.en AG. Volkswagen AG
a does
ksw not
Vol
2.1 Assembly overview - oil pump, lower part of sump ed
by gu
ara
nte
oris eo
th
au ra
c
ss
1 - 9 Nm
ce
le
un
pt
❑ Tighten in stages and in
an
d
itte
diagonal sequence.
y li
rm
ab
pe
ility
2 - 9 Nm
ot
wit
, is n
❑ Self-locking.
h re
hole
❑ Renew.
spec
es, in part or in w
3 - Baffle plate
t to the co
4 - Oil pump
❑ Do not dismantle.
rrectness of i
❑ With pressure relief
l purpos
valve for cold condition

(11 bar) and pressure
control valve (3.5 bar).
nform
ercia

m
a
com
t
⇒ page 155
ion in
r
te o
5 - 24 Nm
thi
s
iva
do
6 - Dowel sleeves
r
rp
cum
fo
en
g
7 - Drive shaft for oil pump

n
t.
yi Co
Cop py
8 - Follower
t. rig
gh ht
pyri by
Vo
o
9 - Spring
c by lksw
cted agen
Prote AG.
10 - Thrust washer
11 - 64 Nm
❑ To loosen, use 2-hole
pin wrench - 3212- to
counterhold chain
sprocket.
using an open-end spanner.
12 - Chain sprocket for oil pump
❑ Installation position: side with inscription faces engine.
13 - Lower part of sump
❑ With oil level and oil temperature sender - G266- .
❑ Removing and installing the oil level and oil temperature sender - G266- ⇒ page 153 .
14 - Seal
❑ Renew.
152 Rep. gr.17 - Lubrication

Phaeton 2003 ➤
15 - Oil drain plug

❑ M14 - 30 Nm
❑ M24 - 50 Nm AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
Oil spray jet for piston cooling aut ra
ss c
ce
e
1- Bolt, 9 Nm
nl
pt
du
an
itte
2- Oil spray jet with spray nozzle valve for piston cooling
y li
erm
ab
ility
• Opening pressure: 1.3 bar
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Oil retention valves

The oil retention valves are located at the rear end of the cylinder
nf
ercia
heads (left and right) -arrow-. They are accessible after removing
orm
the timing chains from the left or right camshaft, as applicable
m
atio
m
⇒ page 112 .
o
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
o
by c lksw
cted agen
Prote AG.
Removing and installing oil level/temperature sender - G266-

1- Nut -9 Nm-
2- Seal; renew
3- Electrical connector
4- Oil level and oil temperature sender - G266-
2.2 Removing and installing lower part of

sump
2. Parts of lubrication system 153

Phaeton 2003 ➤

♦ Eye protection
♦ Silicone adhesive sealant - D 176 501-
Removing
– Activate jacking mode ⇒ Running gear, front-wheel agedrive
n AG. Vand
olkswagen AG
does
four-wheel drive; Rep. gr. 43 ; Operating the o lkswsuspension .
air not
yV gu b ara
ed
– Remove noise insulation ⇒ General tbodyho
ris repairs, exterior; nte
e or
Rep. gr. 50 ; Body - front; Assemblyau overview - noise insula‐ ac
tion . ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Separate electrical connector at oil level/temperature sender
ility
ot p
- G266- -item 1-.
wit
, is n
h re
– Unbolt lower part of sump -arrow-.
hole
spec
Installing
es, in part or in w
t to the co
note the following:
rrectness of i
l purpos
Note
Renew seals.
nform
mercia
at
om
io
– Remove sealant residues from upper and lower parts of sump,

n
c
in t
r
e.g. with a rotating plastic brush.

o
his
ate
do
priv
cum
or
WARNING
f
en
ng
t.
yi Co
op
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
AG.

AG. Volkswagen AG d Phaeton 2003 ➤
agen
6-cylinder diesel engine (3.0
Volkslwengine, common rail) -esEdition
o
not 04.2016
y gu
db ara
ise nte
– Cut off nozzle on tube at front marking (∅ of unozzle
tho
r
approx. eo
2 mm). ss a ra
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
– Apply bead of sealant -arrow- onto clean sealing surface of
l purpos
lower part of sump as illustrated.

• Width of sealant bead: 2 mm.
nform
mercia
at
om
io
Note
n
c
in t
or
his
te
♦ The bead of sealant must not be thicker than specified, other‐

a
do
riv
wise excess sealant can enter the sump and obstruct the
p
cum
or
strainer in the oil intake pipe.

f
en
ng
t.
yi Co
op
♦ The lower part of sump must be installed within 5 minutes after
C py
t. rig
gh
applying sealant.
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Fit lower part of sump and tighten all bolts initially to 5 Nm in
diagonal sequence.
– Tighten bolts on lower part of sump in diagonal sequence.
– Deactivate jacking mode ⇒ Running gear, front-wheel drive
and four-wheel drive; Rep. gr. 43 ; Operating the air suspen‐
sion .
2.3 Removing and installing oil pump

♦ Long-nose grip pliers - VAS 6226-

Removing
– Activate jacking mode ⇒ Running gear, front-wheel drive and
four-wheel drive; Rep. gr. 43 ; Operating the air suspension .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Body - front; Assembly overview - noise insula‐
tion .

Phaeton 2003 ➤
– Drain engine oil. lkswage es n
o ot g
byV ua
ed ran
– Separate electrical
oris connector at oil level/temperature sender tee
- G266- -item au 1-.
th or
ac
ss
– Unbolt lower part of sump -arrow-.
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
– Detach baffle plate -arrows-.
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
– Unscrew bolts -1- and -2-. Prote AG.
– Hold oil pump drive shaft -3- firmly with long-nose grip pliers -
VAS 6226- and push shaft back against spring pressure.
– Take out oil pump.
Note
Oil pump drive shaft remains in position.
Installing
note the following:
Note
Replace oil seals and O-rings.
– Check that the two dowel sleeves are fitted in the oil pump;
install if necessary.
– Install lower part of sump ⇒ page 154 .
sion .
2.4 Assembly overview - upper part of sump

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
c
Phaeton 2003 ➤
s
s 6-cylinder diesel engine (3.0 l engine, common rail) - Edition 04.2016
ce
e
nl
pt
du
an
itte
1 - Upper part of sump
y li
erm
ab
ility
ot p
⇒ page 157
wit
, is n
h re
2 - Torque reaction support
hole
spec
es, in part or in w
3 - 40 Nm
t to the co
4 - 9 Nm
rrectness of i
diagonal sequence.
l purpos
5 - Crankshaft oil seal for belt

pulley end
nform
ercia
m
6 - Cover
at
om
ion
c
7 - 22 Nm
in t
or
his
ate
do
priv
cum
or

f
en
g
tion.
n
t.
yi Co
Cop py
t.
9 - Front sealing flange
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
⇒ page 26 Prote AG.
10 - O-ring
❑ Renew.
11 - Sealing element
❑ Qty. 2.
12 - O-rings
❑ Renew.
13 - 9 Nm
14 - 9 Nm
15 - Dipstick guide tube
16 - Gasket
❑ Renew.
17 - Gasket
❑ Renew.
18 - 14 Nm
❑ Tighten in stages and in diagonal sequence.
19 - 45 Nm
20 - Seal
❑ Renew.
21 - Plug for TDC drilling, 35 Nm
22 - Spring
23 - Follower
24 - Drive shaft for oil pump
2.5 Removing and installing upper part of

sump

Phaeton 2003 ➤
♦ Eye protection
♦ Silicone adhesive sealant - D 176 501-
Removing
tion .
– Secure engine to engine stand ⇒ page 13 .
olkswagen AG
en AG. V
– Remove timing chain covers
olks ⇒ page 36 .
wag does
not
y V gu
d b a
– Remove chain fororbalancer
ise shaft and oil pump ⇒ page 51 r.ante
th eo
– Remove au
frontsssealing flange ⇒ page 26 .
ra
c
ce
le
– Remove lower part of sump ⇒ page 153 .

un
pt
an
d
itte
y li
– Remove oil pump ⇒ page 155 .

erm
ab
ility
ot p
– Remove bolts -arrows- and take off left coolant pipe.

wit
is n
h re
ole,
spec
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.

Phaeton 2003 ➤
– Remove bolts -2- and -3- and take off coolant pipe (bottom
right).
Note
-Item 1- and -item 4- should be disregarded.
– Unscrew bolts -1 … 4- for upper part of sump.

– Press sump - upper part from cylinder block spring pins.
Installing
NoteAG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
Renew ogaskets,
ris
e seals and O-rings. nte
eo
h
aut ra
s c
– Remove old sealant from grooves in upper part of sump and
s
ce
e
nl
from sealing surfaces.

pt
du
an
itte
y li
erm
ab
WARNING
ility
ot p
wit
, is n
h re

hole
spec
es, in part or in w
t to the co
– Remove sealant residue from upper part of sump and cylinder

block with a rotating plastic brush or similar.
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
op
C py
t. rig
gh
2 mm).
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Phaeton 2003 ➤
– Install seals -1- and -2- in upper part of sump.

– Apply beads of sealant -arrows- onto clean sealing surface of
upper part of sump as illustrated.
• The grooves -arrows- on the sealing surfaces must be com‐
pletely filled with sealant.
• Sealant beads must project 1.5…2.0 mm above sealing sur‐
face.
Note
♦ The sealant beads must not be thicker than specified, other‐

wise excess sealant could enter the sump and clog the strainer
in the oil pump.
♦ The upper part of the sump must be installed within 5 minutes
after applying sealant.
– Fit upper part of sump and tighten bolts -1…4- in diagonal se‐
quence to 5 Nm.
– Tighten bolts -1…4- in diagonal sequence.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
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
Prote AG.

agen
AG. Volkswagen AG d
oes
Phaeton 2003 ➤
olksw 6-cylinder diesel engine
not (3.0 l engine, common rail) - Edition 04.2016
byV gu
ara
ed
ris nte
ho eo
ut ra
3 sOil cooler, pressure control valve and
s a c
ce
le oil filter housing
un
pt
an
d
itte
y li
erm
Assembly overview - oil cooler, pressure control valve, and oil
ab
ility
filter housing ⇒ page 161 .
ot p
wit
is n
Removing and installing oil cooler ⇒ page 162 .
h re
ole,
spec
Removing and installing oil filter housing ⇒ page 163 .
t to the co
Removing and installing pressure control valve for crankcase
breather system ⇒ page 164 .
rrectne
Removing and installing mounting plate for oil cooler, pressure
control valve and oil filter housing ⇒ page 164 .
ss
Removing and installing oil pressure switch - F1- ⇒ page 166 .
o
cial p
f in
Checking oil pressure ⇒ page 167 .
form
mer
atio
3.1 Assembly overview - oil cooler, pressure control valve, and oil filter housing
om
n
c
i
or
n thi
te
sd
a
1 - Mounting plate
iv
o
pr
cum
r
❑ For oil cooler, pressure

fo
en
ng
control valve of crank‐

t.
yi Co
op
case breather system,
C py
ht. rig
oil filter housing. rig ht
py by
co Vo
lksw
by
cted agen
Prote
⇒ page 165
AG.
2 - 9 Nm
3 - Seal
❑ Renew.
4 - Oil pressure switch -
F1- , 0.9 bar
❑ Grey insulation.
⇒ page 166
5 - O-rings
❑ Renew.
6 - Gasket
❑ Renew.
7 - O-ring
❑ Renew.
8 - 9 Nm
9 - Oil supply line
❑ To turbocharger.
10 - O-ring
❑ Renew.
11 - Oil filter element
❑ When removing, pull out
of sealing cap ⇒ Item 13 (page 162) .
❑ When installing, fit connection at bottom of oil filter element in bore in oil filter housing.
12 - Gasket
❑ Renew.
3. Oil cooler, pressure control valve and oil filter housing 161
Phaeton 2003 ➤
13 - Sealing cap, 35 Nm
❑ Use 32 mm socket to loosen and tighten.
14 - 9 Nm
AG. Volkswagen AG d
agen oes
15 - Retaining clip olksw not
byV gu
ara
ed
16 - Oil filter housing horis nte
eo
ut
❑ Removing and installing ⇒ page
ss a 163 ra
c
❑ With oil filter bypass valve, 2.0…3.0 bar (pressure differential upstream/downstream of filter).
ce
le
un
pt
an
d
itte
17 - Pressure control valve for crankcase breather.
y li
rm
ab
pe
ility
ot
wit
, is n
18 - 9 Nm
h re
hole
spec
19 - Crankcase breather pipe
es, in part or in w
t to the co
20 - O-ring
❑ Renew.
rrectness of i
21 - O-ring
❑ Renew.
l purpos
22 - 9 Nm
nform
ercia
23 - Oil cooler
m
a
❑ See note ⇒ page 152 .
com
tion in
r
te o
thi
❑ With oil cooler bypass valve, 2.0…3.0 bar (pressure differential upstream/downstream of oil cooler).
s
iva
do
r
rp
cum
24 - 9 Nm
fo
en
ng
t.
yi Co
25 - Gaskets . Cop py
rig
ht
❑ Renew. rig ht
py by
co Vo
by lksw
26 - Coolant hose cted agen
Prote AG.
27 - Coolant pipe
28 - O-ring
❑ Renew.
29 - Gasket
❑ Renew.
3.2 Removing and installing oil cooler

Removing
– Remove exhaust gas recirculation cooler:
– Spread out rags round oil cooler to catch escaping oil.

Phaeton 2003 ➤
– Remove bolts -1 … 5- and take out oil cooler.

Installing
note the following:
– Renew seals/gaskets and O-ring for upper coolant pipe.
3.3 Removing and installing oil filter housing

Removing
– For engine code BMK, remove mechanical exhaust gas recir‐
culation valve ⇒ page 310 .
– Loosen sealing cap -arrow- using 32 mm socket. Take off
sealing cap together with oil filter element.
– Pull oil filter element off sealing cap.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
ut ra
– Detach exhaust gas recirculation
s valve - N18- -arrow- from
s a c
retainer.
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
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
co Vo
by lksw
cted agen
Prote AG.
Phaeton 2003 ➤
– Disconnect oil supply pipe -arrow- from mounting plate.
– Unbolt retaining clip -arrows-.

– Spread out rags round oil filter housing to catch escaping oil.
– Pull out oil filter housing.
AG. Volkswagen AG d
Installing agen oes
olksw not
byV gu
ara
Install in reverse order. orised
nte
h eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
3.4 Removing and installing pressure con‐
h re
hole
spec
trol valve for crankcase breather system
es, in part or in w
t to the co
Removing
rrectness of i
l purpos

tion .
nf
ercia
or
m
m
atio
om
n in
or c
thi
e

t
sd
iva
o
r
rp
cu

o
m
f
en
ng
t.
yi
– Remove lower part of cylinder head (left or right):
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted
agen
Prote AG.


Phaeton 2003 ➤
– Detach hose -arrow- from pressure control valve for crankcase

breather system.
– Unscrew bolts -1- and -2-.
– Take out pressure control valve for crankcase breather sys‐
tem.
Installing
note the following:
Note
♦ Renew O-rings.
3.5 Removing and installing mounting plate

for oil cooler, pressure control valve and
oil filter housing
Removing
four-wheel drive; Rep. gr. 43 ; Operating the air suspension
agen
AG. Volks.wagen AG d
w oes
olks not
– Remove noise insulation ⇒ General body d brepairs, exterior;
yV gu
ara
Rep. gr. 50 ; Body - front; Assembly overview
rise - noise insula‐ nte
tion . tho eo
au ra
c
ss
ce
le
un
pt
an
d

itte
y li
rm
ab
pe

ility
ot
wit
, is n

h re
hole
– Remove lower part of left and right intake manifolds: 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.
Phaeton 2003 ➤
– Unscrew bolts -1 … 8-.

– Take out mounting plate with oil cooler, pressure control valve
and oil filter housing
Installing
note the following:
Note

– Tighten bolts securing mounting plate from the inside out‐

wards. Specified torque: 9 Nm
AG. Volkswagen AG d
agen
3.6 Removing and Voinstalling oil pressurees not gua
o
lksw
by
switch - F1- ris / oil pressure switch for re‐
ed ran
tee
tho or
duced soil
s au
pressure - F378- ac
ce
le
un

pt
an
d
itte
y li
♦ Jointed wrench 24 mm - T40175-
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
Removing
com
tion in
r
te o
thi

s
iva
do
r
rp
cum
Vehicles with engine code BMK

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

Phaeton 2003 ➤
– Detach exhaust gas recirculation valve - N18- -arrow- from

retainer.
Vehicles with engine codes CARA, CEXA und CEXB
– Remove pump for exhaust gas recirculation cooler - V400-
⇒ page 181 .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
– Remove coolant hose and push to side, loosen clip -2- for this.
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
Disregard -items 1, 3, 4-.
h re
hole
spec
es, in part or in w
Continuation for all vehicles
t to the co
rrectness of i
l purpos
– Disconnect electrical connector -arrow-.
nf
ercia
o
– Remove oil pressure switch - F1- using jointed wrench 24 mm
rm
m
- T40175- . atio
om
n in
c
Installing
or
thi
te
sd
a

iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Note Cop py
t. rig
gh ht
pyri by
Renew seal.
co Vo
by lksw
cted agen
Prote AG.
Specified torque
Component Nm
Oil pressure switch - F1- to engine 20
3.7 Checking oil pressure and oil pressure switch
Phaeton 2003 ➤
AG. Volkswagen AG d
Special tools and workshop ksw
agen oes
not
l
equipment required by Vo gu
ara
d
ise nte
♦ Oil pressure tester - V.A.G uthor eo
1342- ss a ra
c
ce
le
♦ Voltage tester -
un
pt
an
d
V.A.G 1527 B-
itte
y li
rm
ab
♦ Auxiliary measuring set -
pe
ility
V.A.G 1594 C-
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
co lksw
by
cted agen
Prote AG.
Test prerequisites
• Oil level OK.
• Engine oil temperature approx. 80 °C.
Preparation for test
– Remove oil pressure switch ⇒ page 166 .

Phaeton 2003 ➤
– Connect oil pressure tester - V.A.G 1342- to threaded hole for

oil pressure switch.
– Screw oil pressure switch -2- into oil pressure tester -
V.A.G 1342- .
Checking oil pressure switch
– Connect brown wire -1- of oil pressure tester to earth (-).
– Connect voltage tester - V.A.G 1527 B- with test cables from
adapter set - V.A.G 1594 C- to oil pressure switch and battery
positive (+).
• LED should not light up.
If the LED is lit:
– Renew oil pressure switch.
– Start engine.
Note
Observe tester and LED while starting, as switching point of oil

pressure switch may already be exceeded when starting.
• LED should light up at 0.7…1.1 bar.

If the LED does not light up:
– Renew oil pressure switch. AG. Volkswagen AG d
agen oes
lksw not
Checking oil pressure by
Vo gu
ara
ed
is nte
– Start engine. ut
hor eo
a ra
s c
• Oil pressure at idling speed: at least 0.8 bar s ce
le
un
pt
• Oil pressure 2,000 rpm: min. 1.5 bar
an
d
itte
y li
rm
ab
The pressure relief valve or oil pump is defective if the specifica‐
pe
ility
tions are not attained.

ot
wit
, is n
h re
– Renew oil pump ⇒ page 155 .

hole
spec
Reassembly
es, in part or in w
t to the co
– Install oil pressure switch ⇒ page 166 .

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
by c lksw
cted agen
Prote AG.
Phaeton 2003 ➤
19 – Cooling
1 Parts of cooling system
Caution
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ To avoid damage to lines, ensure sufficient clearance to
all moving or hot components.
Note
♦ When the engine is warm, the cooling system is under pres‐

sure. If necessary, release pressure before beginning repair
work.
♦ Hoses are secured with spring-type clips. In case of repair,
only use spring-type clips.
♦ Spring-type clip pliers - VAS 5024- are recommended for in‐
stallation of spring-type clips.
n AG. Volkswagen A ge G do
swa es
♦ When installing coolant
by
Vol hoses, route stress-free so
k not
gthat
u they
do not come into
ris contact with other components (observe
ed
ara
nte
markings on
ut coolant connection and hose).
ho eo
r
sa ac
♦ Test for leaks
s
in cooling system using cooling system tester -
ce
le
V.A.G 1274- with adapter - V.A.G 1274/1A- and adapter -

un
pt
an
d
V.A.G 1274/7- .
itte
y li
rm
ab
pe
ility
Assembly overview - radiator ⇒ page 170 .

ot
wit
, is n
h re
Removing and installing fan support ⇒ page 171 .

hole
spec
Assembly overview - fans ⇒ page 172 .

es, in part or in w
t to the co
Checking cooling system for leaks ⇒ page 173 .

Draining and filling with coolant ⇒ page 173 .
rrectness of i
Assembly overview - coolant pump and thermostat

l purpos
⇒ page 177 .
Removing and installing coolant pump ⇒ page 177 .
nform
ercia
Removing and installing continued coolant circulation pump -

m
V51- ⇒ page 178

com
tion in
r
Removing and installing connection with thermostat

te o
thi
s
⇒ page 179 .
iva
do
r
rp
cum
Removing and installing coolant temperature sender - G62-

fo
en
ng
⇒ page 192 .
t.
yi Co
Cop py
ht. rig
1.1 Assembly overview - radiator
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
170 Rep. gr.19 - Cooling

Phaeton 2003 ➤
1 - Securing bolt
2 - 10 Nm
❑ Bolt for lid lock.
3 - Lock carrier
4 - 10 Nm
5 - Radiator
❑ After renewing, renew
entire coolant
6 - Retaining clip n AG. Volkswagen AG do
wage
❑ Check for secure seat‐
olks es n
ot g
yV
ing. se
d b ua
ran
ri tee
ho
7 - Coolant temperature
ut send‐ or
ac
sa
er - radiator outlet - G83-
s
ce
le
un
❑ Before removing, re‐
pt
an
d
itte
lease pressure in cool‐
y li
erm
ab
ing system if necessary.
ility
ot p
8 - To thermostat housing.
wit
is n
h re
ole,
9 - To oil cooler.
spec
❑ For gear oil
t to the co
10 - Coolant pipe
11 - From continued coolant
rrectne
circulation pump - V51- .
❑ Fitting location
⇒ page 178 ss o
cial p
f in
12 - To continued coolant cir‐

form
mer
culation pump - V51- .

atio
m
❑ Fitting location
o
n
c
i
or
⇒ page 178
thi
te
sd
va
13 - Rubber mounting
i
o
pr
cum
r
fo
14 - Rubber bush
en
ng
t.
yi Co
op py
15 - From engine coolant pipe t. C rig
gh ht
pyri by
16 - From thermostat housing
co Vo
by lksw
cted agen
Prote AG.
17 - 10 Nm
1.2 Removing and installing fan support

Removing
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front; Lock carrier - service po‐
sition .
– Pull out retaining clamp for upper coolant hose and remove
bolt -1-.
1. Parts of cooling system 171

Phaeton 2003 ➤
– Pull upper coolant hose off radiator.

– Separate fan connectors.
– Disconnect fastenings -arrows- and remove fan support up‐
wards.
Installing
note the following:
– Fan support must engage in its intended fastenings.
1.3 Assembly overview - fans
Note
Removing fan support ⇒ page 171
1 - Fan support
2 - 10 Nm
3 - Radiator fan control unit -
J293-
4 - 10 Nm agen
AG. Volkswagen AG d
oes
olksw not
V
5 - Radiator fan - V7- d by gu
ara
rise nte
o
6 - 10 Nm auth eo
ra
ss c
7 - Radiator fan control unit 2 -
ce
e
nl
pt
J671-
du
an
itte
y li
8 - Radiator fan 2 - V177-

erm
ab
ility
ot p
9 - Bracket
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.

Phaeton 2003 ➤
1.4 Checking cooling system for leaks

♦ Cooling system tester - V.A.G 1274-
♦ Adapter for cooling system tester - V.A.G 1274/1A-
♦ Adapter for cooling system tester - V.A.G 1274/7-
– Screw cooling system tester - V.A.G 1274- with adapter -
V.A.G 1274/7- onto expansion tank.
– Operate pump and create a pressure of between 1.4…1.6 bar.
– Check system for leaks.
Also check sealing cap:
– Connect adapter - V.A.G 1274/1A- and adapter - V.A.G olks
wage es n
ot g
1274/7- as shown to cooling system tester - V.A.G
d b 1274- .
y V ua
ran
e
ris tee
– Screw cap onto adapter - V.A.G 1274/1A- . utho or
ac
a
ss
– Operate pump and create a pressure of between 1.4…1.6 bar. ce
le
un
pt
an
d
The pressure relief valve in the cap should not open yet.
itte
y li
rm
ab
If the pressure relief valve opens prematurely:
pe
ility
ot
wit
, is n
– Renew sealing cap.

h re
hole
spec
es, in part or in w
t to the co
1.5 Draining and filling coolant

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.

Phaeton 2003 ➤

equipment required
♦ Refractometer - T10007-
♦ Drip tray - V.A.G 1306-
1331-
♦ Spring-type clip pliers -
VAS 5024A-
♦ Adapter for cooling system
tester - V.A.G 1274/7-
♦ Cooling system charge unit
- VAS 6096-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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
Draining
t to the co
Note
rrectness of i
Collect drained coolant in a clean container for re-use or disposal.

l purpos

nform
ercia

m
a
com
tion in
WARNING
r
te o
thi
s
iva
do
Hot steam or coolant may escape when expansion tank is

r
rp
cum
opened. Place a cloth over cap and open with caution.

fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
– Open cap for coolant expansion tank. yri
p by
co Vo
by lksw
cted
agen
Prote AG.
tion .
– Place drip tray - V.A.G 1306- or -VAS 6208- under engine.

Phaeton 2003 ➤
– Disconnect coolant hoses -1- from lock carrier and quick-re‐

lease coupling -2- from lower right of radiator and drain off
coolant.
– Disconnect coolant hoses -1- and -2- from lower left of engine
and drain off remaining coolant at engine.
Filling
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
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
yri by
175
op Vo
by c lksw
Prote
cted AG.
agen 1. Parts of cooling system
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
Phaeton 2003 ➤ ut ho eo
ra
a
ss (3.0 l engine, common rail) - Edition 04.2016c
ce
le
un
pt
an
d
itte
y li
rm
ab
Note
pe
ility
ot
wit
, is n
♦ The amount of water used in the coolant mixture has a great
h re
influence on its effectiveness. Because the water quality dif‐
hole
spec
fers from country to country and even region to region, the
es, in part or in w
quality of the water to be used has been defined. Distilled wa‐
t to the co
ter fulfils all requirements. For this reason, we recommend
using distilled water when mixing coolant for topping up or re‐
placing coolant.
rrectness of i
♦ Use only coolant additives which conform with the ⇒ Elec‐
l purpos
tronic Parts Catalogue (ETKA) . Other coolant additives may

reduce corrosion protection substantially. The resulting dam‐
nform
ercia
age could lead to loss of coolant and subsequent severe

damage to the engine.
m
a
com
tio
♦ The correct coolant solution ratio helps prevent damage due
n in
to freezing and corrosion as well as scaling. Moreover, the
r
te o
thi
boiling temperature is raised. Therefore, the cooling system
s
iva
do
must be filled all year round with coolant additive.
r
rp
cum
fo
en
g
♦ Because of its higher boiling point, the coolant improves en‐

n
t.
yi Co
op
gine reliability under heavy loads, particularly in countries with C py
t. rig
tropical climates. gh ht
pyri by
Vo
o
by c lksw
♦ ONLY refractometer - T10007A- may be used for determining Prote
cted AG.
agen
current anti-freeze value.
♦ The normal frost protection must be to at least -25°C, in coun‐
tries with arctic conditions to -36°C. When climatic conditions
require a stronger frost protection, only then may the frost pro‐
tection be increased. But only to -48°C. Otherwise, the cooling
effect of the coolant will be impaired.
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. The frost
protection must be at least -25°C.
♦ Read off anti-freeze figures for respective replenished anti-
freeze.
♦ The temperature read off the refractometer - T10007A- equa‐
tes to the »ice flocculation point«. Ice crystals can start forming
in the coolant below this temperature.
♦ Do not reuse old coolant.
♦ Use only a water/anti-freeze mixture as a slip agent for coolant
hoses.
Recommended mixing ratios (use only distilled water for mixing):

Frost protection Anti-freeze Coolant ad‐ Distilled wa‐
to quantity ditive 1) ter
-25 °C 40 % 5.0 l 8.0 l
-36 °C 50 % 6.5 l 6.5 l
1)The quantity of coolant can vary depending on the vehicle
equipment.
– Install coolant hoses and secure.
– Screw adapter for cooling system tester - V.A.G 1274/7- onto
expansion tank.
– Fill coolant circuit using cooling system charge unit - VAS
6096- ⇒ Operating instructions for cooling system charge unit
VAS 6096

Phaeton 2003 ➤
1.6 Assembly overview - coolant pump and thermostat
1 - 22 Nm
2 - 9 Nm
3 - Coolant hose
❑ To top right on radiator.
4 - Hose flange with thermostat
AG. Volkswagen AG d
❑ Removing and installing agen oes
olksw not
V
⇒ page 179 ed by gu
ara
ris nte
o
5 - Seal aut
h eo
ra
s c
❑ Renew. s
ce
le
un
pt
6 - Coolant pump
an
d
itte
y li
rm
ab
pe
ility
⇒ page 177
ot
wit
, is n
7 - 9 Nm
h re
hole
spec
8 - Poly V-belt pulley for cool‐
es, in part or in w
ant pump
t to the co
❑ Installation position: let‐
tering “vorn” (front)
rrectness of i
faces in direction of trav‐
el (forwards).
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
by c lksw
cted agen
Prote AG.
1.7 Removing and installing coolant pump

♦ 2-hole pin wrench - 3212-
Removing
– Remove coolant pipe (top) ⇒ page 213 .

Phaeton 2003 ➤

– Remove poly V-belt pulley from coolant pump using pin
wrench - 3212- to counterhold when loosening bolts
-arrows-.
– Unscrew bolts and take out

wage
n Acoolant
G. Volkswpump
agen AG-arrow-.
doe
olks s no
yV t gu
Installing edb ara
ris nte
Installation is ho eo
autcarried out in the reverse order. When installing, ra
note the following:
ss c
ce
e
nl
pt
– Clean sealing surface.
du
an
itte
y li
erm
Specified torques ab
ility
ot p
Component Nm
wit
, is n
h re
hole
Coolant pump to cylinder block 9

spec
es, in part or in w
Poly V-belt pulley to coolant pump 23

t to the co
Hose clips 9 mm wide 3

13 mm wide 5.5
rrectness of i
l purpos
1.8 Removing and installing continued cool‐

ant circulation pump - V51-
nform
ercia

m
at
om
io
♦ Hose clip pliers - VAS 6362-

n
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.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by Phaeton 2003
ara ➤
ise nte
r
ut
ho (3.0 l engine, common rail) - Edition 04.2016 eo
ra
s a c
s
♦ Hose clamps up to 40 mm - 3093-
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
Removing l purpos
nform
ercia
– Pinch off coolant hoses at the coolant circulation pump -1 -
m
at
om
i
with hose clamps, up to 40 mm dia. - 3093- .
on
c
in t
or
– Open clamps -2- and pull off coolant hoses from the coolant
his
ate
circulation pump.
do
priv
cum
or
– Remove connector -6- and remove from the bracket -3-. Move
f
en
ng
t.
yi
wiring clear.
Co
Cop py
t. rig
gh
– Unscrew bolts -4- and remove coolant circulation pump.
ht
pyri by
Vo
o
by c lksw
Installing cted agen
Prote AG.

note the following:
– Tightening torque for bracket coolant circulation pump to gear‐
box: 20 Nm.
1.9 Removing and installing hose connec‐

tion with thermostat
♦ Spring-type clip pliers - VAS 5024A-
Removing

Phaeton 2003 ➤
sition .
– Remove charge air pipe -A-, separate connector -B-, loosen

fastening nuts on lock carrier and also remove charge air pipe
-C-.
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
– Disconnect coolant hose -1-.
– Unscrew bolts -arrows- and take out hose connection with
rrectness of i
thermostat.
l purpos
Installing
nform
ercia
note the following:

m
at
om
ion
Note
c
in t
or
his
ate
do
riv
Renew O-ring.
p
cum
for
en
ng
t.
yi
– Clean sealing surface.
Co
Cop py
t. rig
gh
– Thermostat housing to engine, specified torque: 9 Nm
ht
pyri by
Vo
co lksw
by
– Fill with coolant ⇒ page 175 . cted agen
Prote AG.
1.10 Assembly overview - pump for exhaust gas recirculation cooler - V400-

Phaeton 2003 ➤
1 - Coolant hose
❑ To thermostat.
2 - Pump for exhaust gas re‐
circulation cooler - V400-
⇒ page 181
3 - 23 Nm
4 - 3 Nm
5 - Engine lifting eye
6 - Coolant hose
❑ To exhaust gas recircu‐
lation cooler.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a 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
l purpos
1.11 Removing and installing pump for ex‐

nf
ercia
or
haust gas recirculation cooler - V400-

m
m
atio
om
n in
c
Removing
or
thi
te
sd
a

iv
o
r
rp
cu
o

f
en
ng
t.
yi Co
op
– Unscrew bolts -1-. C py
t. rig
gh ht
yri by
– Remove coolant hoses, loosen hose clips -arrows- for this. cop Vo
by lksw
cted agen
Prote
– Remove pump for exhaust gas recirculation cooler - V400-
AG.
with engine lifting eye.

Phaeton 2003 ➤
– Remove bolts -arrows- and take pump for exhaust gas recir‐
culation cooler - V400- off engine lifting eye.
Installing
Note
Secure all hose connections with hose clips which conform to

1.12 Assembly overview - coolant pipes

Removing and installing coolant pipes ⇒ page 185 .
swage es n
Part 1 byV
olk ot g
ua
d ran
ir se tee
tho
u or
1 - O-ring ss
a ac
ce
❑ Renew.
e
nl
pt
du
an
itte
2 - 9 Nm
y li
erm
ab
ility
3 - Right coolant pipe
ot p
wit
, is n
4 - 23 Nm
h re
hole
spec
5 - Seal
es, in part or in w
t to the co
❑ Renew.
6 - Breather bolt, 9 Nm
rrectness of i
7 - Engine lifting eye
l purpos
8 - 9 Nm
9 - 9 Nm
nform
ercia
10 - Connection
m
at
om
io
11 - O-ring
n
c
in t
or
❑ Renew.
his
ate
do
riv
12 - Upper right coolant pipe

p
cum
for
en
g

n
t.
yi Co
⇒ page 190 Cop py
t. rig
gh ht
yri
13 - Bolt p by
co Vo
by lksw
cted agen
14 - Mounting pin for engine Prote AG.
cover
15 - O-ring
❑ Renew.
16 - Connection
17 - 9 Nm
18 - Coolant temperature
sender - G62- , 2 Nm
19 - O-rings
❑ Renew.
❑ Note various diameters.

Phaeton 2003 ➤
20 - Rear coolant pipe

21 - 9 Nm
22 - O-ring
❑ Renew.
23 - 9 Nm
24 - Rear left coolant pipe on exhaust gas recirculation cooler
25 - 9 Nm
26 - O-ring
❑ Renew.
AG. Volkswagen AG d
agen oes
27 - Rear left coolant pipe on gearbox olksw not
y V gu
d b ara
❑ Removing and installing ⇒ page 188 orise nte
th eo
u ra
28 - 9 Nm ss a c
ce
le
29 - 9 Nm
un
pt
an
d
itte
y li
30 - Upper coolant pipe
rm
ab
pe
ility
ot
wit
, is n
31 - 9 Nm
h re
hole
spec
32 - O-ring
es, in part or in w
t to the co
❑ Renew.
rrectness of i
Part 2
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.

Phaeton 2003 ➤
1 - Oil seals
❑ Renew.
3 - 9 Nm
4 - Coolant line
❑ To cylinder heads.
5 - Coolant hose
❑ From exhaust gas recir‐
culation valve.
6 - Seal
❑ Renew. n AG. Volkswagen AG do
lkswage es n
o ot g
7 - Breather bolt, 9 Nm d byV ua
ran
ir se tee
8 - Mounting pinau for engine
tho
or
ac
cover ss
ce
e
nl
9 - Upper left coolant pipe
pt
du
an
itte
y li
erm
ab
⇒ page 190
ility
ot p
wit
, is n
10 - 9 Nm
h re
hole
11 - Rear left coolant pipe

spec
es, in part or in w
❑ Removing and installing t to the co

⇒ page 188
12 - 9 Nm
rrectness of i
13 - 9 Nm
l purpos
14 - 9 Nm
nform
ercia
15 - Left coolant pipe

m
at
om
⇒ page 185
ion
c
in t
or
16 - 9 Nm
his
ate
do
riv
17 - O-ring
p
cum
for
en
g
❑ Renew.
n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Phaeton 2003 ➤
1.13 Removing and installing coolant pipes

Removing and installing upper coolant pipe ⇒ page 185 .
Removing and installing left coolant pipe ⇒ page 185 .
Removing and installing rear left coolant pipe on gearbox
⇒ page 188 .
Removing and installing rear left coolant pipe ⇒ page 188 .
Removing and installing rear left coolant pipe on supplementary
cooler for exhaust gas recirculation ⇒ page 189 .
Removing and installing upper left coolant pipe ⇒ page 190ag.en AG. Volkswagen AG do
w es n
olks ot g
Removing and installing upper right coolant pipe ⇒edpage
by
V
190 . ua
ran
ris tee
Removing and installing rear coolant pipe ⇒ page
au
tho 191 . or
ac
ss
1.13.1 Removing and installing upper coolant
ce
e
nl
pt
du
pipe
an
itte
y li
erm
ab
Removing
ility
ot p
wit
, is n
h re
hole
spec
– Remove oil cooler ⇒ page 162 .
es, in part or in w
t to the co
– Remove coolant hose, loosen hose clip -2- for this.
rrectness of i
Note
l purpos
Ignore -item 1- and -arrow-.
nform
ercia
– Pull front coolant pipe out of cylinder block.

m
at
om
Installing
ion
c
in t
or
his
ate
do
priv
cum
for
Note en
ng
t.
yi Co
Cop py
t. rig
♦ Renew O-ring.
gh ht
pyri by
Vo
co lksw
by
♦ Secure all hose connections with the correct type of hose clips Prote
cted AG.
agen
(same as original equipment) ⇒ Electronic parts catalogue .
– Clean or smoothen sealing surface for O-ring.

– Moisten new O-ring with coolant and slide onto coolant pipe.
– Install oil cooler ⇒ page 162 .
1.13.2 Removing and installing left coolant pipe


Phaeton 2003 ➤
AG. Volkswagen n AG do
wage es n
olks ot g
♦ 2-hole pin wrench - 3212- ed
by
V ua
ran
oris tee
th or
au ac
ss
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
♦ Hose clip pliers - V.A.G 1921-
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
Removing
cted agen
Prote AG.
– Remove air conditioner compressor ⇒ Rep. gr. 87 .

– Remove bolts -1- and -2-, take throttle valve module - J338-
off intake union.
– Remove bolts -arrows-, use 2-hole pin wrench - 3212- to coun‐

terhold, remove poly V-belt pulley for servo pump.

Phaeton 2003 ➤
– Remove bolts -1- and -2-.

– Remove servo pump and tie up upwards.
– Remove bolt -2- for dipstick guide tube. AG. Volkswagen AG d

agen oes
olksw not
– Remove bolt -1- for poly V-belt tensioning
d by V element. gu
ara
rise nte
– Drain coolant ⇒ page 173 .utho eo
ra
s a c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Remove coolant hose from left coolant pipe, loosen hose clip
-1- for this.
rrectne
– Unscrew bolts -4- and -arrows- and remove bracket for ancil‐
laries.
ss o
cial p
– Remove coolant hose from left coolant pipe, loosen hose clip
f in
-3- for this.
form
mer
atio
– Remove bolt -2- and pull left coolant pipe off retainer.
om
n
c
Installing
or
n thi
te
sd
va

i
o
pr
cum
r
fo
Specified torque ⇒ page 182 .

en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
Note cop Vo
by lksw
cted agen
Prote AG.
♦ Renew seal and O-ring.
– Clean or smoothen sealing surface for seal and O-ring.

– Moisten new seal and O-ring with coolant and slide onto cool‐
ant pipe.
– Install bracket for ancillaries and tensioning element for poly
V-belt.
– Install dipstick guide tube ⇒ page 156 .
– Install power steering pump ⇒ Rep. gr. 48 .
– Install throttle valve module - J338- ⇒ Item 23 (page 230) .
– Install air conditioner compressor ⇒ Rep. gr. 87 .

Phaeton 2003 ➤
1.13.3 Removing and installing rear left coolant

pipe on gearbox
Removing
– Remove catalytic converter ⇒ page 306 .
– Release coolant hoses -arrows-.
– Remove coolant hoses, loosen hose clip -2- and lift retainer
-4- for this.
– Release breather hose -arrow- for gearbox.
– Remove bolts -1- and -3-, take left coolant pipe on rear of
gearbox off along with coolant hoses.
Installing
Specified torque ⇒ page 182 . AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
Note rise nte
tho eo
au ra
s c
Secure all hose connections with hose clips which conform to s
ce
le
un
pt
an
d
itte
y li
rm
ab
– Install catalytic converter ⇒ page 306 .

pe
ility
ot
wit

, is n
h re
hole
spec
1.13.4 Removing and installing rear left coolant

es, in part or in w
t to the co
pipe
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.

Phaeton 2003 ➤
Removing
– Remove left intermediate pipe ⇒ page 307 .
– Remove bolts -arrows-.
– Remove rear left coolant pipe from coolant hoses, loosen hose
clips -1- and -2- for this.
Installing
Volkswa
AG. gen AG
agen does
olksw not
yV gu
db ara
Note
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Install left intermediate pipe ⇒ page 307 .
ility
ot p
wit
, is n
h re
hole
1.13.5 Removing and installing rear left coolant spec

es, in part or in w
t to the co
pipe on supplementary cooler for ex‐
haust gas recirculation
rrectness of i

l purpos

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.
Removing

Phaeton 2003 ➤

– Pull rear left coolant pipe off supplementary cooler for exhaust
gas recirculation.
– Remove coolant hose, loosen hose clip -arrow- for this.
Installing

agen oes
olksw not
y V gu
Secure all hose connections with hose clips which conform to ise d b ara
nte
production standard. uthor eo
ra
s a c
s
ce
– Clean or smoothen sealing surface for O-ring.
e
nl
pt
du
an
itte
– Moisten new O-ring with coolant and slide onto coolant pipe.
y li
erm
ab
ility
ot p
wit
, is n
h re
1.13.6 Removing and installing upper left cool‐
hole
spec
ant pipe
es, in part or in w
t to the co
Removing
rrectness of i
l purpos
– Unscrew bolt -4- and mounting pin for engine cover -2-.
– Release wiring harness -3- from upper left coolant pipe.
nform
ercia
– Remove upper left coolant pipe, loosen hose clips -arrows- for
m
this.
at
om
ion
c
Installing
in t
or
his
ate
do
priv
cum
or

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
Note p by
co Vo
by lksw
cted agen
Prote AG.
1.13.7 Removing and installing upper right

coolant pipe
Removing
– Remove intake manifold upper part ⇒ page 232 .
– Disconnect electrical connectors for glow plugs for cylinders
“1” and “2”.
– Release wiring harness from upper right coolant pipe.

Phaeton 2003 ➤
– Disconnect electrical connector -1- on radiator outlet coolant

temperature sender - G83- .
– Remove coolant hoses, loosen hose clips -arrows- for this.
– Remove upper right coolant pipe.
Installing AG. Volkswagen AG d
agen oes
olksw not
yV gu
Installation is carried ed out in the reverse order; note the following:
b ara
nte
ris
ho eo
aut ra
ss c
Note
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
– Install upper part of intake manifold ⇒ page 232 .
hole
spec
es, in part or in w
t to the co
rrectness of i
1.13.8 Removing and installing rear coolant
pipe
l purpos
nform
ercia

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.
Removing
– Remove turbocharger:
– Remove catalytic converter ⇒ page 306 .
– Remove bolts -1- and -3-, push left coolant pipe on rear of
gearbox to rear.
Note
♦ For reasons of clarity, diagram shows installation position with

removed engine.
♦ Ignore -items 2, 4- and -arrow-.

Phaeton 2003 ➤
– Disconnect electrical connector -4- at coolant temperature

sender - G62- .
– Remove bolts -1- and -2-, pull rear coolant pipe off cooler for
exhaust gas recirculation.
– Remove rear coolant pipe, loosen hose clip -3- for this.
Installing
Note
♦ Renew O-ring.
♦ Hose unions and air intake pipes/hoses must be free of oil and
grease when installing.
1.14 Removing and installing coolant temper‐

ature sender - G62-
Removing
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
– Remove air pipe between turbocharger and air mass meter -

ility
ot p
G70- -arrows-.
wit
is n
h re
ole,
spec
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
Prote AG.

Phaeton 2003 ➤
– Disconnect electrical connector -1- at coolant temperature

sender - G62- .
– Pull off retaining clip -2- and detach coolant temperature send‐
er - G62- .
Installing
Install in reverse order.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut 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
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Phaeton 2003 ➤
21 – Turbocharging/supercharging
1 Charge air system with turbocharger
Rules for cleanliness ⇒ page 194 .
Assembly overview - turbocharger (engine code BMK)
⇒ page 194 .
Removing and installing turbocharger (engine code BMK)
⇒ page 196 .
Assembly overview - turbocharger (engine codes CARA, CEXA
und CEXB) ⇒ page 198
Removing and installing turbocharger (engine codes CARA,
CEXA und CEXB) ⇒ page 200
Removing and installing turbocharger g1encontrol
AG. Volkunit
swag-en
J724-
AG do
⇒ page 204 . Volkswa es n
ot
y gu
db ara
Assembly overview - partsoriof
se charge air cooling ⇒ page 213 . nte
h eo
ut ra
Removing and installing
ss charge air cooler ⇒ page 214
a c
ce
e
nl
1.1 Rules for cleanliness
pt
du
an
itte
y li
erm
ab
When working on the turbocharger, pay careful attention to the
ility
ot p
following “5 rules” for cleanliness:
wit
, is n
h re
♦ Thoroughly clean all unions and surrounding areas before dis‐
hole
connecting.
spec
es, in part or in w
♦ Place removed parts on a clean surface and cover. Use only

t to the co
lint-free cloths.
♦ Carefully cover opened components or seal if repairs cannot
rrectness of i
be carried out immediately.

l purpos
♦ 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
nform
ercia
tool boxes etc.).

m
at
om
♦ When the system is open: Do not work with compressed air.

on
c
Do not move vehicle.

in t
or
his
ate
1.2 Assembly overview - turbocharger (engine code BMK)

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.
194 Rep. gr.21 - Turbocharging/supercharging

Phaeton 2003 ➤
6-cylinder diesel
wage engine
n AG. Volk(3.0
swagel nengine,
AG doe common rail) - Edition 04.2016
ks s no
Vol t gu
by ara
1 - 27 Nm ris
ed
nte
ho eo
❑ Coat with high-tempera‐ aut ra
c
ture paste - G 052 112 ss
ce
le
A3- .
un
pt
an
d
itte
y li
2 - Gasket
rm
ab
pe
❑ Renew.
ility
ot
wit
, is n
3 - Intermediate flange
h re
hole
spec
4 - Seal
es, in part or in w
t to the co
❑ Renew.
5 - Gasket
rrectness of i
❑ Renew.
l purpos
6 - Bolt
nform
ercia
❑ Renew.
m
7 - Connecting pipe to change-
a
com
tio
over flap for exhaust gas recir‐
n in
r
culation cooler
te o
thi
s
iva
❑ Assembly overview
do
r
rp
c
⇒ page 308 .
um
fo
en
ng
t.
yi
8 - 9 Nm
Co
Cop py
t. rig
gh
9 - O-ring
ht
pyri by
Vo
o
by c lksw
❑ Renew. Prote
cted AG.
agen
10 - Exhaust gas temperature

sender 1 - G235-
❑ Coat with high-tempera‐
ture paste - G 052 112
A3- .
❑ Tighten union nut to
25 Nm.
❑ Renew.
12 - Gasket
❑ Renew.
13 - Catalytic converter
14 - 27 Nm
15 - Heat shield for turbocharger
16 - 9 Nm
17 - Oil seals
❑ Renew.
19 - Oil supply line
❑ From cylinder block.
20 - 9 Nm
21 - O-ring
❑ Renew.
1. Charge air system with turbocharger 195

Phaeton 2003 ➤
22 - Turbocharger
❑ With turbocharger 1 control unit - J724- .
❑ Removing and installing turbocharger 1 control unit - J724- ⇒ page 204 .
23 - Air intake hose
❑ From air mass meter - G70- to turbocharger.
❑ Must be free of oil and grease prior to installation.
24 - Retaining clip, 5.5 Nm
❑ Reinforced.
❑ From turbocharger to right air pipe.
❑ Must be free of oil and grease prior to installation.
❑ Reinforced.
27 - 9 Nm
28 - Air pipe
29 - Bracket for turbocharger
30 - 20 Nm n AG. Volkswagen AG do
wage es n
❑ Coat with high-temperature pastey-VoGlks052 112 A3- . ot g
u b ara
ed
31 - 22 Nm horis nte
e
t or
au ac
32 - Oil return line ss
ce
e
nl
❑ To cylinder block. pt
du
an
itte
y li
33 - Gasket
erm
ab
ility
❑ Renew.
ot p
wit
, is n
34 - 22 Nm
h re
hole
spec

es, in part or in w
t to the co
35 - Intermediate pipe
❑ Assembly overview - exhaust manifold with intermediate pipe ⇒ page 307 .
rrectness of i
l purpos

(engine code BMK)
nform
ercia
Removing
m
at
om
ion

c
in t
or
his
ate

do
priv
cum
or
– Remove upper part of air filter together with intake hose

f
en
ng
t.
yi
⇒ page 295 .
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
Volksw not
gu
Phaeton 2003 ➤
y
ise6-cylinder diesel engine (3.0 l engine, common rail) - Edition 04.2016
d b ara
r nte
tho eo
au ra
– Unscrew securing bolts
ss -arrows- of charge air pipe, open c
clamp -1- and pull charge air pipe off turbocharger.
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
– Remove heat shield from turbocharger -arrows-.
nform
ercia
– Open cover of wiring connections on plenum chamber bulk‐

head by pulling cover upwards.
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.
– Disconnect electrical connectors -1- and -2-, unscrew banjo

bolt -3- and remove oil supply line.
– Unbolt catalytic converter from turbocharger.
Note
For illustration purposes the following procedure is shown with

the intermediate pipe removed.
– Cover opening -arrow- in gearbox to prevent small parts from

dropping in.
– Remove bolt for oil return line-2-.

Phaeton 2003 ➤
– Unscrew securing bolts of coolant line -arrows-, open clamp

-1- and pull hose off. Seal ends of hoses and pipes with plugs.
lkswage es n
Vo ot g
– Loosen lower securing bolt -arrow- of turbocharger
ed
by approx. ua
ran
2 turns. thoris tee
or
au ac
– Remove rear part of noise insulation ⇒ss General body repairs;
ce
e

nl
pt
du
tion .
an
itte
y li
erm
ab
– Remove bracket between catalytic converter and gearbox
ility
ot p
⇒ page 306 .
wit
, is n
h re
– Remove guard plate above left drive shaft from gearbox.
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove lower securing bolt of oil return line -1- from below
and remove line.
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
– Unscrew bolts -arrows- and detach turbocharger from inter‐
c by lksw
cted agen
mediate flange.
Prote AG.
Installing
note the following:
Note
♦ Renew gaskets and seals.

♦ Fill turbocharger with engine oil at oil supply line connection.
♦ After installing turbocharger, run engine for about 1 minute at
idling and do not rev up immediately, this ensures that the tur‐
bocharger is fully primed with oil
1.4 Assembly overview - turbocharger (engine codes CARA, CEXA und CEXB)

Phaeton 2003 ➤
1 - Starter catalytic converter

2 - 27 Nm
❑ Coat with high-tempera‐
ture paste; for high-tem‐
perature paste refer to
⇒ Parts catalogue .
3 - Heat shield for turbocharger
4 - 9 Nm
5 - Seal
❑ Renew.
7 - Oil supply line
❑ From cylinder block.
8 - Seal
❑ Renew. AG. Volkswagen AG d
agen oes
lksw not
9 - Hose clip, 5.5 Nm by Vo gu
ara
d
❑ Reinforced. rise nte
tho eo
au ra
10 - Connecting piece for air ss c
intake hose
ce
e
nl
pt
du
an
❑ From air mass meter -
itte
y li
G70- to turbocharger.
erm
ab
ility
ot p
wit
, is n
h re
❑ From turbocharger to
hole
spec
right air pipe.
es, in part or in w
❑ Must be free of oil and
t to the co
grease when installing.
12 - Air pipe
rrectness of i
13 - Upper part of oil return line
l purpos
From turbocharger
nform
ercia
14 - Lower part of oil return line

m
❑ To cylinder block.
at
om
ion
c
15 - Bolt
in t
or
his
te

a
do
priv
❑ Renew.
um
for
en
ng
t.
yi
16 - Gasket
Co
Cop py
t. rig
❑ Renew.
gh ht
pyri by
Vo
co lksw
by
17 - Bolt/nut Prote
cted AG.
agen
❑ Renew.
❑ Coat with high-temperature paste; for high-temperature paste refer to ⇒ Parts catalogue .
❑ Turbocharger to intermediate flange: 30 Nm + turn 90° further.
❑ Intermediate pipe to intermediate flange and exhaust manifold: 25 Nm
19 - 25 Nm
20 - Intermediate flange
21 - Connecting pipe to change-over flap for exhaust gas recirculation cooler
22 - Turbocharger

Phaeton 2003 ➤
❑ With turbocharger 1 control unit - J724- .

(engine codes CARA, CEXA und CEXB)
Caution
If a mechanical fault is discovered on the turbocharger (e.g. a

destroyed compressor impeller), it is not sufficient to just renew
the turbocharger. To avoid any subsequent damage, the fol‐
lowing work must be carried out:
♦ Check air filter housing, air filter element and air inlet ho‐
ses for contamination.
♦ Check the whole charge air path and charge air cooler for
foreign objects.
♦ If foreign objects are discovered in the charge air system,
clean the charge air path and, if necessary, renew the
charge air cooler.

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
– Remove heat shield for turbocharger -arrows-.

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
co lksw
by
cted agen
Prote AG.

Phaeton 2003 ➤
– Cover opening -arrow- in gearbox to prevent small parts from

dropping in.
lkswage es n
o ot g
byV ua
Note ir se
d ran
tee
tho
u or
a ac
♦ Shown in illustration
ss with intermediate pipe removed.
ce
le
un
pt
♦ -Item 1- and -item 2- should be disregarded.
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Unscrew nuts -arrows- securing starter catalytic converter to
t to the co
turbocharger and move starter catalytic converter to one side.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
– Remove air hose -arrows-.

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Unscrew air intake connecting piece -arrows left- and place to

one side with air intake hose attached -arrow right-.

Phaeton 2003 ➤
– Separate electrical connector -1- at turbocharger 1 control

motor - V280- .
– Unscrew oil supply line -2- from turbocharger.
– Loosen hose clips -arrows- for connecting hose between tur‐

bocharger and air intake pipe and push to one side.
– Push connecting hose onto turbocharger flange. agen

AG. Volkswagen AG d
oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
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
Prote AG.

Phaeton 2003 ➤
– Unscrew bolts -arrows-.

1- O-ring
2- Intermediate flange
AG. Volkswagen AG d
agen oes
ksw
by Vol Caution not
gu
d ara
rise nte
o
♦ The upper partauof
t oil return line -3- secured to the turbo‐
h eo
ra
charger musts be carefully pulled off the lower part of oil
s c
return line -5-.
ce
e
nl
pt
du
an
itte
♦ To avoid bending the two pipes of the oil return line, move
y li
erm
ab
the turbocharger -4- slightly backwards and forwards
ility
ot p
while pulling it off upwards and towards one side.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
Do not place removed turbocharger on upper part of oil return line.
rrectness of i
l purpos
Installing
nf
ercia
o
Note
rm
m
atio
om
n in
or c
thi
e

t
sd
iva

o
r
rp
cu
o
m
f
en
ng

t.
yi Co
equipment) ⇒ Parts catalogue . Cop py
t. rig
gh ht
yri
♦ In order to be in a position to securely attach the charge air p by
co Vo
hoses on their connections, the worm screws of the used hose
by lksw
cted agen
Prote
clips have to the sprayed with penetrating spray before instal‐
AG.
ling.
♦ Fit all heat insulation sleeves in the original position when in‐
stalling.
♦ Fill turbocharger with engine oil at oil supply line connection.
♦ After installing turbocharger, run engine for about 1 minute at
idling and do not rev up immediately, this ensures that the tur‐
bocharger is fully primed with oil
– Prepare turbocharger for installation. To do this, push on con‐

necting hose -1- and both hose clips -2- onto turbocharger
flange.

Phaeton 2003 ➤
– Fit the new O-ring -1- on lower part -5- of oil return line.
– Lightly lubricate O-ring and inner sealing surface on upper part
-3- of oil return line.
– When fitting turbocharger in place -4-, guide upper part -3- of
oil return line through intermediate flange -2- to lower part
-5- of oil return line.
– Place upper part of oil return line carefully on lower part of oil
return line.
Caution
The O-ring must not be damaged.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
– Tighten turbocharger bolts -arrows-. ss c
ce
le
un
pt
an
d
itte
note the following:
y li
erm
ab
ility
– Install starter catalytic converter.
ot p
wit
is n
Specified torques
h re
ole,
spec
Component Nm
t to the co
Turbocharger to intermediate flange 30 Nm + turn
90° further 1)2)
rrectne
Oil supply line to turbocharger 15
Hose clips 9 mm wide 3
ss
13 mm wide 5.5
o
cial p
f in
• 1) Renew bolts.
form
mer
atio
• 2)
Coat with high temperature paste; hot temperature paste
om
n
⇒ Parts catalogue .
c
i
or
n thi
te
sd
iva
o
pr
cum
r
1.6 Removing and installing turbocharger 1

fo
en
ng
t.
yi Co
control unit - J724- Cop py
t. rig
gh ht
yri by
Special tools and workshop equipment required cop Vo
by lksw
cted agen
Prote
♦ Electronics box - VAS 6395/1-
AG.
♦ Connector cable - VAS 6395/4-2-

♦ 10 mm open-end spanner, 90 mm long - VAS 6395/4-3-

Phaeton 2003 ➤
Removing
– Unscrew bolts -arrows- and remove heat shield for turbo‐

charger.
Note
The lower bolt -right arrow- need not be turned out fully.
– Open red cover over positive terminal on plenum chamber

bulkhead.
– Connect electronics box - VAS 6395/1- with connector . Volkscable
wagen AG
- VAS 6395/4-2- to positive terminal gripolk“+” gen AG
swaand to earth. does
no
yV t gu
db ara
rise nte
Checking software version of electronics
tho box - VAS 6395/1- : eo
s au ra
c
s
ce
e
nl
Caution
pt
du
an
itte
y li
erm
ab
The turbocharger 1 control unit - J724- could be damaged.
ility
ot p
♦ For further procedure first check for correct software

wit
, is n
h re
download in the electronics box - VAS 6395/1- , to do this
hole
proceed as follows: spec

es, in part or in w
t to the co
Indicated on display of -VAS 6395/1- (2 seconds after connecting

voltage supply) with correct software download:
rrectness of i
1- >TEST
l purpos
2- LEARN
nf
ercia
orm
Note
m
atio
om
n in
or c
♦ The following appears on display with incorrect software

thi
e
download:
t
sd
iva
o
r
rp
cu
♦ 1. START
o
m
f
en
ng
t.
yi Co
♦ 2. NEXT t. Cop py
rig
gh ht
♦ In this case the correct software must be downloaded via pyri by
Vo
co
“Volkswagen ServiceNet”, “Workshop Equipment”.
by lksw
cted agen
Prote AG.

Phaeton 2003 ➤
Continuation of procedure:
– Separate electrical connector for turbocharger 1 control unit -
J724- .
– Connect connector cable - VAS 6395/4-2- to turbocharger 1
control unit - J724- and to electronics box - VAS 6395/1- .
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
Indicated on display of -VAS 6395/1- :
ot p
wit
, is n
1- >TEST
h re
hole
spec
2- LEARN
es, in part or in w
t to the co
– To continue, press v button -item 4-.
rrectness of i
l purpos
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
py by
Indicated on display of -VAS 6395/1- : co Vo
by lksw
cted agen
Prote AG.
1- CHECK
2- S: XX % I: XX %
• The electronics box - VAS 6395/1- checks the adjustment
range of turbocharger 1 control unit - J724- in stages and
checks the feedback of positions.

Phaeton 2003 ➤
Indicated on display of -VAS 6395/1- if turbocharger 1 control unit

- J724- is OK:
1- ACTUATOR O.K.
• The check is completed.
– Separate electrical connectors for electronics box - VAS
6395/1- .
Installation is carried out in the reverse order.
Indicated on display of -VAS 6395/1- if turbocharger 1 control unit

- J724- is not OK: gen AG. Volkswagen AG d
a oes
o lksw not
1- PROBLEM
db
yV gu
ara
e nte
ris
• The
ut turbocharger 1 control unit -
ho J724- must be renewed.
eo
ra
a c
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
l purpos
nf
ercia
– To do this, perform the following procedure:

orm
m
atio

om
n in
or c

thi
te
sd
iva
1- >TEST
o
r
rp
cu
o
m
f
en
ng
2- LEARN
t.
yi Co
op py
– Press ↓ button -item 6-.
t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Phaeton 2003 ➤

1- TEST
2- >LEARN
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
1- STEP 1
, is n
h re
hole
– Using buttons ↑ -item 5- and ↓ -item 6-, adjust turbocharger
spec
1 control unit - J724- so that the coupling rod is accessible for
es, in part or in w
t to the co
removing.
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
– Unclip coupling rod -arrows- and dispose of. py by
co Vo
by lksw
cted agen
Prote AG.

Phaeton 2003 ➤

1- STEP 2
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
– Separate connector cable - VAS 6395/4-2- from turbocharger
erm
ab
1 control unit - J724- .
ility
ot p
wit
, is n
h re
Caution
hole
spec
es, in part or in w
t to the co
The voltage supply for electronics box - VAS 6395/1- must re‐
main connected.
rrectness of i
l purpos
nform
mercia
– Unclip retaining clip -1- for electrical wire.

at
om
ion
c
– Unscrew bolts -arrows-, use 10 mm open-end spanner, 90 mm

in t
or
his
long - VAS 6395/4-3- for central and lower bolts.

ate
do
priv
– Remove old turbocharger 1 control unit - J724- and dispose

um
for
of.
en
ng
t.
yi Co
op py
– Install new turbocharger 1 control unit - J724- in the reverse t. C rig
gh ht
sequence, but only tighten bolts -arrows- by hand. yri
p by
o Vo
by c lksw
cted
• The turbocharger 1 control unit - J724- must contact the re‐
agen
Prote AG.
taining plate without play, but should even be moved by hand.
– Clip new coupling rod in position -arrows-.

AG. Volkswagen AG d
agen oes
olksw not
Phaeton 2003 d➤ by
V gu
ara
e
6-cylinder thdiesel
oris
engine (3.0 l engine, common rail) - nEditiontee
or
04.2016
au ac
ss
– Connect connector cable - VAS 6395/4-2- to turbocharger 1
ce
e
nl
control unit - J724- .
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

m
at
om
i
1- STEP 3
on
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.
– Press turbocharger 1 control unit - J724- down to rear using

light force -arrow A-, at the same time tighten bolts
-arrows B- to 10 Nm, for central and lower bolts use 10 mm
open-end spanner, 90 mm long - VAS 6395/4-3- .

Phaeton 2003 ➤

1- WARNING
2- LEARNING
Caution
♦ Now check that turbocharger 1 control unit - J724- is in‐

stalled correctly because from the next program step -
confirmed by the v button -item 4- - the turbocharger 1
control unit - J724- programs the end positions of the ad‐
justment path only once. If the adjustment path is pro‐
grammed incorrectly due to a wrong installation position,
the turbocharger 1 control unit - J724- can no longer be
programmed and will need renewing.
♦ If there is any doubt about proper installation, the process
can be cancelled by pressing the x button -item 3- and
then repeated.
– To confirm that the new turbocharger 1 control unit - J724- was

installed correctly, press the v button -item 4-.
1- TEST 1
2- S: 80.0 % I: XX %
• Specification: I = 80 %, programming is confirmed by the
“LEARNING” display in display zone -1-.
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
– At the same time, check the position of the control lever on

spec
turbocharger 1 control unit - J724- :

es, in part or in w
t to the co
• The edge of control lever -2- must be within marking -1-.

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.

Phaeton 2003 ➤

1- TEST 2
2- S: 16.0 % I: XX %
• Specification: I = 16 %, programming is confirmed by the
“LEARNING” display in display zone -1-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
– At the same time, check the position of the control lever on

un
turbocharger 1 control unit - J724- : pt

an
d
itte
y li
rm
ab
• The edge of adjusting lever -1- must be within marking -2-.
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
ercia

m
a
com
tion in
1- TEST 3
r
te o
thi
2- S: 55.0 % I: XX %
s
iva
do
r
rp
cum
• The centre position is being checked.

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

Phaeton 2003 ➤

1- OK
– To confirm, press v button -item 4-.
• The setting is complete.
6395/1- .
1.7 Assembly overview - parts of charge air

cooling
Note
♦ All hose connections of charge air system are secured by

spring-type clips or by connector couplings. Always check the
following points with push-on connectors:
♦ Release connection by pulling the locking clip -arrow-.
♦ Pull hose/pipe off without the use of tools.
n AG. Volkswagen AG
♦ When installing, ensureolthe
ksw locking lugs -A- engage
age does correctly.
no
yV t gu
db ara
rise nte
tho eo
s au ra
c
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
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.

Phaeton 2003 ➤
1 - Charge air cooler (right)

⇒ page 214
2 - Air intake hose
grease prior to installa‐
tion.
3 - Retaining clip, 5.5 Nm gen AG. Volkswagen AG d
swa oes
❑ Reinforced. by Volk not
gu
a
d ran
se
4 - Air pipe thori tee
or
au ac
❑ Mustss be free of oil and
ce
le
un
pt
tion.
an
d
itte
y li
rm
ab
5 - From turbocharger
pe
ility
ot
6 - To throttle valve module -
wit
, is n
h re
J338- .
hole
spec
7 - Air pipe
es, in part or in w
t to the co
tion.
rrectness of i
8 - Spring-type clip
l purpos
9 - 9 Nm
10 - Y-piece
nform
mercia
11 - Charge air pressure send‐

a
com
ti
er - G31-
on in
r
te o
thi
12 - Charge air cooler (left)

s
iva
do

r
rp
cum
fo
⇒ page 214
en
ng
t.
yi Co
op
13 - 9 Nm C py
t. rig
gh ht
yri
14 - Bracket
p by
o Vo
by c lksw
cted agen
15 - Air duct
Prote AG.
1.8 Removing and installing charge air cool‐

er
– Remove engine cover.
– Remove front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 .

Phaeton 2003 ➤
Remove right charge air cooler

– Unscrew bolts -arrows- and remove air duct -A-.
– Remove air duct ⇒ Item 15 (page 214) (15) from charge air
cooler
– Release securing clips and pull out charge air hoses -A- and
-B-.
– Unclip hoses for headlight washer system -C- and place to one
side.
– Unscrew securing bolts -arrows- and remove charge air cool‐
er.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
Remove left charge air cooler oris .
e nte
eo
h
ut ra
– Unscrew bolts -arrow-
ss a
for the charge air pipe -A-. c
ce
le
un
– Remove air duct ⇒ Item 15 (page 214) (15) from charge air
pt
an
d
cooler
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
– Release securing clips and pull out charge air hoses -A- and
l purpos
-B-.
– Unhook-C- pipe from the body.
nform
ercia
– Unscrew securing bolts -arrows- and remove charge air cool‐

m
er.
com
tion in
r
Install charge air cooler

te o
thi
s
iva
do
– Install in reverse order of removal.

r
rp
cum
fo
en
g
♦ Specified torques
n
t.
yi Co
⇒ “1.7 Assembly overview - parts of charge air cooling”, page Cop py
t.
213 .
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen A
Phaeton 2003 ➤ agen G do
es n
ksw
Vol ot g
ed by common rail) - Edition 04.2016 ua
ra
ris nte
utho eo
ra
a c
23 – Mixture preparation - injection
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
l purpos
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.
216 Rep. gr.23 - Mixture preparation - injection

Phaeton 2003 ➤
1 Diesel direct injection system

Safety precautions ⇒ page 218 .
Rules for cleanliness and instructions for working on fuel system
⇒ page 218 .
Schematic overview of fuel system (engine code BMK)
⇒ page 219 .
Schematic overview of fuel system (engine codes CARA, CEXA
Assembly overview - fuel system (engine code BMK)
⇒ page 223 .
Assembly overview - fuel system (engine codes CARA, CEXA
Assembly overview - intake manifold (engine code BMK)
⇒ page 228 . wage es n
olks o V t gu
by ara
Assembly overview - intake manifold (engine
ris
ed codes CARA, CEXA nte
und CEXB) ⇒ page 230 au
tho eo
ra
ss c
Removing and installing upper part of intake manifold (engine
ce
e
nl
code BMK) ⇒ page 232 .
pt
du
an
itte
y li
Removing and installing intake manifold (engine codes CARA,
erm
ab
ility
ot p
wit
, is n
Removing and installing lower parts of intake manifold (engine
h re
hole
spec
es, in part or in w
Removing and installing lower parts of intake manifold (engine
t to the co
codes CARA, CEXA und CEXB) ⇒ page 249
Removing and installing injectors (piezo injectors) ⇒ page 253 .
rrectness of i
Removing and installing fuel pressure regulating valve - N276-
l purpos
⇒ page 259 .
Removing and installing fuel pressure sender - G247-
nf
ercia
⇒ page 261 .
orm
m
atio
Checking return flow rate of injectors (piezo injectors) with engine
om
running ⇒ page 262 .

n in
or c
thi
e
Checking return flow rate of injectors (piezo injectors) at starter

t
sd
iva
motor speed ⇒ page 265 .

o
r
rp
cu
o
m
f
en
ng
Checking for injectors sticking open (piezo injectors)

t.
yi Co
⇒ page 266 . Cop py
ht. rig
rig ht
Checking pressure retention valve in fuel return line py by
co Vo
lksw
⇒ page 270 .
by
cted agen
Prote AG.
Assembly overview - toothed belt for high-pressure pump (engine
Removing and installing toothed belt for high-pressure pump (en‐
gine code BMK) ⇒ page 273 .
Assembly overview - high-pressure pump (engine code BMK)
⇒ page 277 .
Removing and installing high-pressure pump (engine code BMK)
⇒ page 280 .
Assembly overview - toothed belt for high-pressure pump (engine
codes CARA, CEXA, CEXB) ⇒ page 283
Removing and installing toothed belt for high-pressure pump (en‐
gine codes CARA, CEXA, CEXB) ⇒ page 284
Assembly overview - high-pressure pump (engine codes CARA,
1. Diesel direct injection system 217

Phaeton 2003 ➤
Removing and installing high-pressure pump (engine codes

CARA, CEXA und CEXB) ⇒ page 293
Bleeding fuel system ⇒ page 294 .
Assembly overview - air filter ⇒ page 295 .
1.1 Safety precautions

Note the following if testers and measuring instruments nhave tolkswagen A
AG. Vo
be used during a road test: olkswage
G do
es n
o
yV t gu
db ara
ir se nte
WARNING ut
ho eo
ra
a c
ss
♦ Test equipment must always be secured on the rear seat
ce
le
un
pt
and operated from that position by a second person.
an
d
itte
y li
erm
ab
♦ If test and measuring instruments are operated from front
ility
ot p
passenger seat and the vehicle is involved in an accident,
wit
is n
there is a possibility that the person sitting in this seat may
h re
receive serious injuries when the airbag is triggered.
ole,
spec
t to the co
♦ Persons wearing a pacemaker should not lean over the engine
compartment while the engine is running, as the injectors use
high voltage pulses.
rrectne
♦ Do not open any fuel line connections while the engine is run‐
s
ning.
s o
cial p
f i
♦ Always switch off the ignition before connecting or discon‐
nform
necting injection and glow plug system wiring or tester cables.
mer
atio
m
♦ Always switch off ignition before cleaning engine.

o
n
c
i
or
n thi
♦ Disconnecting and connecting the battery must only be done
te
sd
a
with the ignition switched off, otherwise the engine control unit
iv
o
pr
could be damaged. cum

r
fo
en
ng
t.
yi
♦ Certain tests may lead to a fault being detected by the control
Co
op py
unit and stored. Therefore after completing all checks and re‐ t. C rig
gh ht
pairs the fault memory must be read and if necessary cleared. pyri by
Vo
co lksw
by
cted agen
1.2 Rules for cleanliness and instructions
Prote AG.
for working on fuel system

♦ Clean tools and workbench etc. before working on injection
system.
♦ Thoroughly clean all unions and surrounding areas before dis‐
connecting.
♦ When removing components, plug all open connections im‐
mediately with suitable clean sealing caps.
♦ Do not remove sealing caps from components until immedi‐
ately prior to installation. After removal, components should
be kept in new, sealable packaging (plastic bags or wooden
boxes; not in cartons). If available, use the original new part
packaging).
♦ 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.).

Phaeton 2003 ➤
♦ When the system is open: Do not work with compressed air.

Do not move vehicle.
♦ Before installation, check injectors and their surroundings n Avis‐
G. Volkswagen AG d
ually; they must be undamaged and free of lint.VInjector wage bore oes
olks not
cleanliness must be ensured. If necessary, eclean db
y injector gu
ara
bores using a clean cloth, taking care not horto cause damage
is nte
eo
(do not use any sharp tools!). s aut ra
c s
♦ When renewing a component, also renew all high-pressure
ce
e
nl
pt
du
fuel lines leading from the relevant component.
an
itte
y li
erm
ab
♦ If components are not being renewed, always mark the high-
ility
pressure fuel lines on removal. High-pressure fuel lines must ot p
wit
, is n
always be re-installed in their original positions (i.e. on the
h re
same cylinder).
hole
spec
es, in part or in w
♦ The following components and seals/O-rings must always be
t to the co
renewed when the injectors are removed and installed: “cop‐
per seal”, “O-ring for injector bore”, “O-ring for injector return
connection”.
rrectness of i
♦ The following components and seals/O-rings must always be
l purpos
renewed when an injector is renewed: “clamping piece”, “in‐

jector pipe”, “copper seal”, “O-ring for injector bore”, “O-ring
for injector return connection”.
nf
ercia
or
♦ Always fit new copper seals for the injectors. Check all new O-
m
m
atio
rings for damage before installing. Lubricate O-rings lightly
om
n in
with assembly oil or clean engine oil before installing.
or c
thi
te
sd
♦ Take care not to damage the injectors when removing the old
iva
o
r
copper seals.
rp
cu
o
m
f
en
ng
♦ Align the high-pressure fuel lines so they are free of tension.

t.
yi Co
op
First tighten all unions hand-tight before tightening to final tor‐
C py
t. rig
gh
que.
ht
pyri by
Vo
o
by c lksw
♦ Never attempt to reshape high-pressure fuel lines.
cted agen
Prote AG.
♦ When working on any parts of the high-pressure fuel system,

tools may only be used for loosening and tightening pipe un‐
ions. All other components must always be removed and
installed by hand without using tools or other equipment.
♦ Press the return lines onto the injectors by hand from above
so that they engage audibly on each injector (do not press in
the release pins when doing this). Then press down the re‐
lease pin after connecting the return line. Check that the return
lines are seated securely by pulling them by hand from above.
Also check that they seal properly (fuel pressure in return line
as far as pressure retention valve: between 8 and 10 bar).
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
1.3 Schematic overview of fuel system (en‐

gine code BMK)
Caution
Always read rules for cleanliness and instructions for working

on fuel system ⇒ page 218 .
Follow these instructions before starting work and while work‐
ing on the fuel system.

Phaeton 2003 ➤
Caution
To prevent the high-pressure fuel pump from running while it

is empty and to ensure that the engine starts quickly after parts
have been renewed, it is important to observe the following:
If components of the fuel system between the tank and the
high-pressure fuel pump are removed or renewed, the basic
setting “Checking fuel system pressurisation pump” must be
performed to bleed the fuel system.
If supplementary fuel pump, fuel line (between fuel tank and gen AG
. Volkswagen AG
does
high-pressure fuel pump) or the fuel filter are removedy Vorolkre‐swa not
gu
newed, perform basic setting “first fuel filling” »once«
ise
d b before ara
nte
first starting engine. thor eo
u ra
sa c
If the high-pressure fuel pump is removed or renewed,
s the ba‐
ce
e
sic setting channel 35 “first fuel filling” must be performed

nl
pt
du
an
»three times« before the engine is started for the first time.
itte
y li
erm
ab
Performing first fuel filling after installing high-pressure pump
ility
ot p
⇒ Fuel supply system - diesel engines; Rep. gr. 20 .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1 - Fuel metering valve - N290-
❑ Do not unscrew.
rrectness of i
2 - High-pressure fuel pump
❑ With gear-type pre-sup‐
l purpos
ply pump.
❑ High-pressure pump
nform
ercia
generates fuel pressure

m
up to 1600 bar.
at
om
ion
❑ Gear-type pre-supply
c
in t
or
pump generates fuel
his
ate
pressure between 4 and
do
priv
c
5 bar.
um
for
en
ng
t.
3 - High-pressure accumulator
yi Co
op py
(rail element) t. C rig
gh ht
yri by
❑ Cylinder bank 1. cop Vo
by lksw
cted agen
Prote
4 - Fuel pressure regulating
AG.
valve - N276-
❑ On cylinder bank 1.
⇒ page 259 .
5 - Fuel pressure sender -
G247-
❑ On cylinder bank 2.
⇒ page 261 .
6 - High-pressure accumulator
(rail element)
❑ For cylinder bank 2.
7 - Injectors (piezo injectors)
❑ Injectors 1 … 6

Phaeton 2003 ➤
⇒ page 253 .
8 - Fuel return lines (from injectors)
❑ The fuel return lines must not be dismantled. They can only be renewed together with the pressure
retention valve as one unit.
❑ After replacement, engine must be run at idling speed for approx. 2 minutes to bleed fuel system. Then
check fuel return lines for leaks.
9 - Pressure retention valve
❑ The pressure retention valve maintains a residual pressure (for control purposes) of approx. 10 bar in
the return lines.
❑ This residual pressure is required for the control function of the piezo injectors.
❑ The pressure retention valve may only be renewed together with the fuel return lines.
❑ After replacement, engine must be run at idling speed for approx. 2 minutes to bleed fuel system.
10 - Fuel system pressurisation pump - G6-
❑ Pressurisation pressure approx. 1 bar.
11 - Fuel filter
❑ Fuel filter - assembly overview ⇒ Fuel supply - diesel engines; Rep. gr. 20
1.4 Schematic overview of fuel system (en‐

gine codes CARA, CEXA und CEXB)
WARNING
AG. Volkswagen AG d
agen oes
♦ Always read rules for cleanliness and instructions yfor
Vol
ksw not
gu
working on fuel system ⇒ page 218 . ise
d b ara
nte
r
ho eo
♦ Always follow these rules for cleanliness sand
au instructions
t ra
c
before starting work and while working ons the fuel system.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
Caution
ot
wit
, is n
h re
To prevent the high-pressure fuel pump from running while it
hole
spec
is empty and to ensure that the engine starts quickly after parts
es, in part or in w
have been renewed, it is important to observe the following:

If components of the fuel system between the tank and the t to the co
high-pressure fuel pump are removed or renewed, the basic rrectness of i
setting “Checking fuel system pressurisation pump” must be
performed to bleed the fuel system.
l purpos
If supplementary fuel pump, fuel line (between fuel tank and

high-pressure fuel pump) or the fuel filter are removed or re‐
nform
ercia
newed, perform basic setting “first fuel filling” »once« before

first starting engine.
m
a
com
tion in
If the high-pressure fuel pump is removed or renewed, the ba‐

r
te o
thi
sic setting channel 35 “first fuel filling” must be performed

s
iva
»three times« before the engine is started for the first time.
do
r
rp
cum
fo
Performing first fuel filling after installing high-pressure pump

en
ng
t.
yi
⇒ Fuel supply system - diesel engines; Rep. gr. 20 .
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Phaeton 2003 ➤
1 - Fuel metering valve - N290-

❑ Do not unscrew.
❑ After renewing, a first
fuel filling must be per‐
formed (it is important
not to allow the pump to
run while it is still empty)
⇒ Fuel supply system -
diesel engines; Rep. gr.
20 .
❑ Assembly overview -
high-pressure pump
⇒ page 292 .
⇒ page 293
3 - Common rail (high-pres‐
sure accumulator)
❑ Cylinder bank 1.
valve - N276-
❑ On cylinder bank 1. AG. Volkswagen AG d
agen oes
❑ Cannot be re-installed. olksw not
V gu
d by ara
❑ Removing and installing orise nte
eo
⇒ page 259 . aut
h
ra
ss c
5 - Fuel pressure sender -
ce
le
un
pt
G247-
an
d
itte
y li
❑ Screwed into rail ele‐
rm
ab
pe
ment on cylinder bank 2.
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
by c lksw
cted agen
Prote AG.

Phaeton 2003 ➤
⇒ page 261 .
6 - Common rail (high-pressure accumulator)
7 - Injectors (piezo injectors)
❑ Injectors 1 … 6
❑ Removing and installing ⇒ page 253 .
❑ The pressure retention valve maintains a residual pressure (for control purposes) of approx. 10 bar in
the return lines.
10 - Fuel tank
❑ With fuel system pressurisation pump - G6- .
11 - Fuel filter
❑ Fuel filter - assembly overview ⇒ Fuel supply - diesel engines; Rep. gr. 20
❑ Renewing fuel filter ⇒ Fuel supply - diesel engines; Rep. gr. 20 .
12 - Supplementary fuel pump - V393-
❑ Assembly overview ⇒ Fuel supply - diesel engines; Rep. gr. 20
AG. Volkswagen AG d
agen oes
ksw
1.5 Assembly overview - fuel system (en‐
ol not
V gu
d by ara
e
gine code BMK) ris nte
ho eo
aut ra
ss c
ce
le
Caution
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
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Phaeton 2003 ➤

❑ To fuel filter
2 - To fuel filter
❑ From fuel filter.
3 - Clip agen
AG. Volkswagen AG d
oes
olksw not
V
4 - Fuel temperature sender - ed by gu
ara
G81- horis nte
eo
aut ra
5 - Banjo bolt for fuel return line ss c
ce
e
nl
❑ 25 Nm
pt
du
an
itte
y li
erm
ab
valve - N276-
ility
ot p
wit
❑ Located on cylinder
, is n
h re
bank 1.
hole
spec
es, in part or in w
⇒ page 259 .
t to the co
7 - Banjo bolt for fuel return
line, 25 Nm
rrectness of i
8 - Banjo bolt for fuel return
l purpos
line, 25 Nm
9 - High-pressure fuel line, 28
nform
ercia
Nm
m
❑ Between high-pressure
at
om
io
pump and high-pres‐
n
c
in t
r
sure accumulator (rail

o
his
te
element) for cylinder

a
do
riv
bank 1.
p
cum
for
en
g
10 - High-pressure fuel line, 28

n
t.
yi Co
op
Nm C py
t. rig
gh ht
yri
❑ Between high-pressure p by
o Vo
by c
accumulator (rail ele‐
lksw
cted agen
Prote
ment) for cylinder bank
AG.
1 and high-pressure ac‐

cumulator (rail element) for cylinder bank 2.
❑ With gear-type pre-supply pump.
❑ High-pressure pump generates fuel pressure up to 1600 bar.
❑ Gear-type pre-supply pump generates fuel pressure between 4 and 5 bar.
13 - 5.5 Nm
14 - Injector cover
15 - Seal
16 - Clamping piece
❑ If they are to be re-installed, the injector units and clamping pieces must always be re-installed on the
cylinder they were removed from.
❑ When an injector is renewed, the corresponding clamping piece must be renewed at the same time.
17 - Hexagon collar nut, 10 Nm
❑ For clamping piece.

Phaeton 2003 ➤
18 - Injector (piezo injectors)

❑ When removing and installing or replacing an injector, always renew the following components and seals/
O-rings: “clamping piece”, “copper seal”, “O-ring for injector bore” and “O-ring for injector return connec‐
tion”.
❑ If they are to be re-installed, the injectors, high-pressure fuel pipes and clamping pieces must always be
re-fitted in their original positions (i.e. on the same cylinder).
19 - 22 Nm
20 - High-pressure lines, 28 Nm
21 - Fuel pressure sender - G247-
❑ Located on cylinder bank 2.
❑ Check for damage before reinstalling.
❑ Removing and installing ⇒ page 261 .
❑ 30 Nm
22 - High-pressure accumulator (rail element)
23 - High-pressure lines
24 - High-pressure accumulator (rail element)
26 - Retainer
❑ For fuel return lines (from injectors)
AG. Volkswagen
27 - Pressure retention valve wage
n AG do
es n
Volks ot g
❑ In return lines from cylinderedbanks 1 and 2.
by ua
ran
ris tee
❑ The pressure retentionuthvalve maintains a residual pressure of approx.
o
or10 bar in the return lines.
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p

wit
, is n
❑ Common return line to fuel tank

h re
hole
spec
es, in part or in w
t to the co
1.6 Assembly overview - fuel system (en‐

gine codes CARA, CEXA und CEXB)
rrectness of i
l purpos
WARNING
nf
ercia
♦ Always read rules for cleanliness and instructions for

or
working on fuel system ⇒ page 218 .

m
m
atio
m
♦ Always follow these rules for cleanliness and instructions

o
n in
or c
before starting work and while working on the fuel system.

thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
225
co Vo
by lksw
cted
1. Diesel direct injection system
agen
Prote AG.
Phaeton 2003 ➤

❑ To fuel tank.
❑ The fuel return line must
not be kinked, damaged
or blocked.
2 - Fuel supply line
❑ From fuel filter.
3 - Banjo bolt for fuel return line
4 - Fuel temperature sender -
G81-
5 - Bolt
6 - Bracket
valve - N276-
❑ Located on cylinder
bank 1.
❑ Cannot be re-installed.
⇒ page 259 .
8 - Bolt
9 - Bracket
10 - High-pressure fuel line
❑ Between high-pressure
pump and rail element.
❑ 28 Nm
❑ Between rail element for
cylinder bank 1 and rail
element for cylinder 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
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
226
cted agen
Prote AG.
Rep. gr.23 - Mixture preparation - injection
Phaeton 2003 ➤
bank 2.
❑ 28 Nm
❑ Before re-using “high-pressure fuel line”, perform visual check of taper seats for damage such as trans‐
verse scores or corrosion; always renew if damaged.
❑ If high-pressure line is not O.K., always renew high-pressure line.
AG. Volkswagen
12 - High-pressure fuel pump lksw
agen AG do
es n
Vo ot g
❑ With fuel metering valve - N290- ed b.y ua
ran
ris tee
❑ After renewing high-pressure ut pump, a first fuel filling must be performed (never
ho
or allow pump to run while
it is still empty) ⇒ Fuel supply
ss
a
system - diesel engines; Rep. gr. 20 . ac
ce
le
❑ Assembly overview - high-pressure pump ⇒ page 292 .
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
14 - Bolt
rrectne
❑ Cover for injector on cylinder head cover.
❑ 5.5 Nm
ss
15 - Injector cover
o
cial p
f inform
16 - Clamping piece
mer
❑ If they are to be re-installed, the injector units and clamping pieces must always be re-installed on the
atio
m
cylinder they were removed from.

o
n
c
i
or
n thi
❑ When an injector is renewed, the corresponding clamping piece must be renewed at the same time.
te
sd
iva
o
r
17 - Hexagon collared nut

p
cum
r
fo
en
ng

t.
yi Co
op
❑ 10 Nm
C py
t. rig
gh ht
yri by
18 - Bolt cop Vo
by lksw
cted agen
❑ For rail element (high-pressure accumulator) for cylinder bank 2.
Prote AG.
❑ 22 Nm
19 - Fuel pressure sender - G247-
❑ Screwed into rail element on cylinder bank 2.
❑ Check for damage before reinstalling.
❑ 30 Nm
20 - Seal
❑ Renew.
❑ 28 Nm
22 - Common rail (high-pressure accumulator)
23 - Oil seals
❑ Renew.
24 - Hexagon collared nut
❑ 10 Nm

Phaeton 2003 ➤
6-cylinder diesel engine (3.0 l engine, common rail) - Edition
gen AG
. V04.2016
olkswagen AG
d
wa oes
olks not
yV gu
25 - Injector (piezo injectors) ed b ara
nte
oris
❑ When removing and installing or replacingauan injector, always renew the following components
th eo
r a and seals/
O-rings: “clamping piece”, “copper seal”,ss“O-ring for injector bore” and “O-ring for injector return c connec‐
tion”.
ce
e
nl
pt
du
an
❑ Before re-using “high-pressure injector line”, perform visual check of taper seats for damage such as
itte
y li
transverse scores or corrosion; always renew if damaged.
erm
ab
ility
ot p
❑ If they are to be re-installed, the injectors, high-pressure fuel lines and clamping pieces must always be
wit
, is n
re-fitted in their original positions (i.e. on the same cylinder).
h re
hole
spec
es, in part or in w
26 - Bolt
t to the co
❑ Cover for injector on cylinder head cover.
❑ 5.5 Nm
rrectness of i
27 - Injector cover
l purpos
28 - Seal
❑ Renew.
nform
mercia
at
om
io
n
c
in t
or
his
e
❑ 28 Nm
at
do
priv
c
30 - Bolt
um
for
en
g
❑ For rail element (high-pressure accumulator) for cylinder bank 1.

n
t.
yi Co
op py
❑ 22 Nm
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
AG.

❑ In return lines from cylinder banks 1 and 2.
❑ The pressure retention valve maintains a residual pressure of approx. 10 bar in the return lines.
1.7 Assembly overview - intake manifold

1.7.1 Engine code BMK
Note
The illustration shows the left upper and lower intake manifold.

Phaeton 2003 ➤
1 - Connecting pipe for exhaust

gas recirculation
2 - Intake connecting pipe
3 - Gasket
❑ Renew.
4 - 9 Nm
diagonal sequence.
5 - 9 Nm
6 - 9 Nm
7 - Upper part of intake mani‐
fold
⇒ page 232
8 - 9 Nm
9 - Gasket
❑ Renew.
10 - Intake manifold flap motor
❑ Cylinder bank 1 (right AG. Volkswagen AG d
agen oes
ksw
side): intake manifold by Vol not
gu
ara
flap motor - V157- . rise
d
nte
ho eo
❑ Cylinder bank 2 (left aut ra
c
side): intake manifold ss
ce
le
flap motor - V275- .

un
pt
an
d
itte
y li
rm
ab
⇒ page 236
pe
ility
ot
11 - Bolt
wit
, is n
h re
❑ 10 Nm
hole
spec
es, in part or in w
12 - Securing clip
t to the co
13 - Connecting rod
14 - Follower
rrectness of i
15 - Lower part of intake manifold, left

l purpos

nform
ercia
16 - Gasket
❑ Renew if damaged.
m
a
com
tion in
17 - 9 Nm
r
te o
thi
18 - Plug, 25 Nm
s
iva
do
r
rp
cum
19 - Seal
fo
en
ng
t.
yi
❑ Renew.
Co
Cop py
t. rig
gh
20 - Gasket
ht
pyri by
Vo
co lksw
❑ Renew.
by
cted agen
Prote AG.
❑ Reinforced.
❑ Must be free of oil and grease when installing.

Phaeton 2003 ➤
23 - Throttle valve module - J338-

24 - 9 Nm
25 - Gasket
❑ Renew.
1.7.2 Engine codes CARA, CEXA, CEXB
Note
The illustration shows the left upper and lower intake manifold.
1 - Retaining clamp
❑ 5.5 Nm
❑ Reinforced.
2 - Throttle valve module -
J338-
❑ 9 Nm
3 - O-ring
❑ Renew.
4 - Bolt
❑ 9 Nm
AG. Volkswagen AG d
❑ Tighten in stages and in agen oes
olksw not
diagonal sequence. d byV gu
ara
ise nte
r
5 - Bolt ut
ho eo
ra
s a c
❑ 9 Nm s
ce
e
nl
pt
du
6 - Gasket
an
itte
y li
❑ Renew.
erm
ab
ility
ot p

wit
, is n
gas recirculation h re
hole
spec
8 - Upper part of intake mani‐
es, in part or in w
fold
t to the co

⇒ page 232
rrectness of i
9 - Seal
l purpos
❑ Renew.
10 - Plug
nform
ercia
❑ 10 Nm
m
at
om
11 - Bolt
ion
c
in t
r
❑ 9 Nm
o
his
ate
do
riv
12 - Mounting pin for engine

p
cum
or
cover
f
en
ng
t.
yi
❑ 5 Nm
Co
Cop py
ht. rig
13 - Bolt rig ht
py by
co Vo
lksw
❑ 9 Nm
by
cted agen
Prote AG.
14 - Gasket
❑ Renew.

Phaeton 2003 ➤
15 - Intake manifold flap motor

❑ Cylinder bank 1 (right side): intake manifold flap motor - V157- .
❑ Cylinder bank 2 (left side): intake manifold flap motor - V275- .
16 - Bolt
❑ 10 Nm
17 - Securing clip
18 - Connecting rod
19 - Follower
20 - Intake manifold lower part
21 - Gasket
❑ Renew.
❑ Must be free of oil and grease when installing.
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
231
Prote AG.
1. Diesel direct injection system
Phaeton 2003 ➤
1.8 Removing and installing intake manifold

upper part
1.8.1 Engine code BMK

equipment required
♦ Socket, 14 mm - 3150-
1331-
♦ Open ring tool insert -
V.A.G 1331/8-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
Removing
atio
om
– Remove engine cover panel ⇒ page 4 .

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.

Phaeton 2003 ➤
– Pull off vacuum hoses -1- and -2-.
Note
Plug open connections with suitable sealing caps immediately.
Caution

– Unscrew union nuts -arrows- and remove high-pressure lines.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
– Unscrew connections for fuel supply line -2- and fuel return
wit
is n
line -1- at high-pressure pump and move fuel lines aside.

h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
– Disconnect air intake hose -5-.

or
n thi
te
sd
a

iv
o
pr
cum
r
fo

en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
Note
p by
o Vo
by c lksw
cted agen
Prote AG.
Disregard -item 1-.

Phaeton 2003 ➤
– Unscrew bolts -arrows- and remove upper part of intake mani‐

fold.
Installing
Note
♦ Renew all seals and gaskets.

free of oil and grease before assembly. agen
AG. Volkswagen AG d
oes
olksw not
yV
♦ Check for dirt or leaves in intake passages; clean if snecessary.
ed b gu
ara
nte
ri
o eo
♦ Secure all hose connections with hose clips (same aut
h
as original ra
equipment) ⇒ Parts catalogue . ss c
ce
le
un
pt
an
d

itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
– To tighten unions of high-pressure line at high-pressure pump,
hole
spec
use torque wrench - V.A.G 1331- with open ring tool insert -
es, in part or in w
V.A.G 1331/8- .
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
– To tighten high-pressure lines at high-pressure accumulators
do
r
rp
c
um
fo
- V.A.G 1331/1- and socket, 14 mm - 3150- .

en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.8.2 Engine codes CARA, CEXA, CEXB

Removing
Caution


Phaeton 2003 ➤
– Pull oil dipstick -1- out off guide tube.

– Remove air intake hose. To do this, loosen hose clip -3-.
– Unscrew bolt -2- and separate electrical connector -4-.
– Remove throttle valve module - J338- -item 5-.
– Unscrew bolts -arrows- and remove engine lifting eye -1- on

front left.
– Unscrew bolts -arrows- and remove retaining clamps.

– Unscrew union nuts -1- and -4- and remove high-pressure line.
Note
-Items 2, 3- should be disregarded. agen

AG. Volkswagen AG d
oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut 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
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Phaeton 2003 ➤
– Unscrew mounting pin for engine cover -1- and -2-.

– Unscrew bolts -arrows- and remove upper part of intake mani‐
fold.
Installing
• For specified torques, see assembly overview for intake mani‐
fold ⇒ page 228
Note
♦ Renew seals and gaskets.

♦ In order to be in a position to securely attach the charge air
hoses on their connections, the worm screws ofgethe
swa
used
n AG. Volkshose
wagen AG
does
clips have to the sprayed with penetrating
y V spray before instal‐
olk not
gu
ling. ris
edb ara
nt ee
tho or
au ac
– Install high-pressure lines ⇒ page
ss 225 .
ce
e
nl
pt
du
an
1.9 Removing and installing intake manifold
itte
y li
erm
ab
flap motor - V157- or intake manifold flap
ility
ot p
wit
2 motor - V275-
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Electronics box - VAS 6395/1-
♦ Connector cable - VAS 6395/4-2- rrectness of i
Removing
l purpos
Note
nf
ercia
orm
The procedure for removal and installation of the intake manifold

m
atio
m
flap motor - V157- for cylinder bank 1 (right) is described as an

o
n in
c
example. The same approach should be applied as appropriate

or
thi
e
for intake manifold flap 2 motor - V275- .

t
sd
iva
o
r
rp
cu
o
m
f
Proceed as follows:
en
ng
t.
yi Co
op
C py
t. rig
gh
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Phaeton 2003 ➤
– Disconnect electrical connector -3- at air mass meter - G70- .

– Remove air hose -4- between air filter and turbocharger.
– Open red cover over positive terminal on plenum chamber
bulkhead.
– Connect electronics box - VAS 6395/1- with connector cable
- VAS 6395/4-2- to positive terminal grip “+” and to earth.
Checking software version of electronics box - VAS 6395/1- :
Caution
lkswage es n
Vo ot g
Risk of damage to intake manifold flap d bymotors . ua
ran
ir se tee
♦ For further procedure first check
utho
for correct software or
download in the electronics
ss box - VAS 6395/1- , to do this
a ac
proceed as follows:
ce
le
un
pt
an
d
itte
y li
rm
ab
Indicated on display of -VAS 6395/1- (2 seconds after connecting
pe
ility
voltage supply) with correct software download:
ot
wit
, is n
h re
1- >TEST
hole
spec
es, in part or in w
2- LEARN
t to the co
Note
rrectness of i
♦ The following appears on display with incorrect software
l purpos
download:
♦ 1. START nform
mercia
♦ 2. NEXT
a
com
tion in
♦ In this case the correct software must be downloaded via

r
te o
thi
“Volkswagen ServiceNet”, “Workshop Equipment”.

s
iva
do
r
rp
cum
fo
en
g
Continuation of procedure:
n
t.
yi Co
Cop py
– Separate electrical connection for intake manifold flap motor -
t. rig
gh ht
yri by
V157- . cop Vo
by lksw
cted agen
Prote
– Connect connector cable - VAS 6395/4-2- to intake manifold
AG.
flap motor - V157- and to electronics box - VAS 6395/1- .

Phaeton 2003 ➤

1- >TEST
2- LEARN
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
1- CHECK
itte
y li
erm
ab
2- S: XX % I: XX %
ility
ot p
wit
is n
• The electronics box - VAS 6395/1- checks the adjustment
h re
range of intake manifold flap motor - V157- in stages and
ole,
spec
checks the feedback of the positions.
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
Indicated on display of -VAS 6395/1- if intake manifold flap motor

fo
en
ng
- V157- is OK:
t.
yi Co
Cop py
. rig
1- ACTUATOR O.K.
t
gh ht
pyri by
Vo
co
• The check is completed.
by lksw
cted agen
Prote AG.
6395/1- .

Phaeton 2003 ➤
Indicated on display of -VAS 6395/1- if intake manifold flap motor

- V157- is not OK:
1- PROBLEM
• Intake manifold flap motor - V157- must be renewed.
. Volkswagen AG
gen AG does
– To do this, perform the following procedure:Volkswa not
y gu
db ara
– To continue, press v button -item 4-. orise nte
eo
th
au ra
Indicated on display of -VAS 6395/1-ss: c
ce
le
un
1- >TEST
pt
an
d
itte
y li
2- LEARN
rm
ab
pe
ility
– Press ↓ button -item 6-.
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

ion in
r
te o
1- TEST
thi
s
iva
do
2- >LEARN
r
rp
cum
fo
en
g

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

Phaeton 2003 ➤

1- STEP 1
– Using buttons ↑ -item 5- and ↓ -item 6-, adjust intake manifold
flap motor - V157- so that the coupling rod is accessible for
removing.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a 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
– Unclip coupling rod -1- off intake manifold flap motor - V157- .
rrectness of i
Note
l purpos
Disregard items -2, 3 and 4-.
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
– To continue, press v button -item 4-. t. Cop py
rig
gh ht
yri
Indicated on display of -VAS 6395/1- : p by
co Vo
by lksw
cted agen
1- STEP 2 Prote AG.

Phaeton 2003 ➤
– If fitted, remove electrical connector -arrow- for exhaust gas

temperature sender 1 - G235- from bracket.
– Separate connector cable - VAS 6395/4-2- -item 3- from intake

manifold flap motor - V157- .
Caution AG. Volkswagen AG d

agen oes
olksw not
The voltage supply for electronics box - VAS 6395/1- mustedre‐by V gu
ara
main connected. horis nte
eo
ut ra
s a c
s
ce
e
nl
pt
du
an
itte
y li
– Remove and dispose of old intake manifold flap motor - V157- .
erm
ab
ility
ot p
wit
, is n
h re
– Install new intake manifold flap motor - V157- in reverse order
hole
and clip on coupling rod.
spec
es, in part or in w
t to the co
Note
rrectness of i
Proceed as follows on version with self-locking bolt: Start bolt by
hand and screw in so that it can pick up the old threads. Then
l purpos
tighten bolts to prescribed torque.
nform
ercia
– Connect connector cable - VAS 6395/4-2- to intake manifold

flap motor - V157- .
m
at
om
ion
c
in t
or
his
te
– To confirm that the new intake manifold flap motor - V157- was
a
do
riv
installed, press the v button -item 4-.

p
cum
for
en
ng
t.
Indicated on display of -VAS 6395/1- : Cop
yi Co
py
t. rig
1- STEP 3 gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Phaeton 2003 ➤

1- WARNING
2- LEARNING

1- TEST 1
2- S: 84.0 % I: XX %
• Specification: I = 84 %.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– To continue, press v button -item 4-. t to the co

1- TEST 2
rrectne
2- S: 16.0 % I: XX %
ss
• Specification: I = 16 %.
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
Prote AG.

Phaeton 2003 ➤

1- TEST 3
2- S: XX % I: XX %
• The adjustment range of intake manifold flap motor - V157- is
run through.
1- OK
– To confirm, press v button -item 4-.
• The setting is complete.
6395/1- .
1.10 Removing and installing lower parts of

intake manifold (engine code BMK)
olkswagen AG
en AG. V
Removing and installing
olkslower part of left intake manifold
wag does
not
⇒ page 243 . ed byV gu
ara
ris nte
Removing and ho
ut installing lower part of right intake manifold or a
e
a
⇒ page 246ss . c
ce
le
un
pt
1.10.1 Removing and installing lower part of left

an
d
itte
y li
intake manifold (engine code BMK)

erm
ab
ility
ot p

wit
is n
h re
ole,
♦ Torque wrench - V.A.G 1331-

spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
r

p
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Phaeton 2003 ➤
♦ Tool insert 19 mm - V.A.G 1331/5-
♦ Socket - T40055-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
Removing
ility
ot p
wit
, is n
h re
Caution
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
o
rm
m
atio
m
– Unscrew union nuts -1…4- and remove high-pressure lines.

o
n in
or c
– Remove upper part of intake manifold ⇒ page 232 .

thi
te
sd
iva
– Remove mechanical exhaust gas recirculation valve

r
rp
cu
o
⇒ page 310 .
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Phaeton 2003 ➤
– Unscrew retaining pin -2- for engine cover on lower part of

intake manifold.
– Unclip changeover valve for exhaust gas recirculation cooler
- N345- -1- from bracket.
– Remove bracket for changeover valve for exhaust gas recir‐
culation cooler - N345- . gen AG. Volkswagen AG
a does
lksw n
– Loosen banjo boltd for
by coolant bleed line through one gturn,
Vo ot
ua use
counterhold asorishown
se in illustration for this. ran
te
th eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Bend the coolant line carefully to one side to gain access to
ility
ot p
the retaining tab.
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.

Phaeton 2003 ➤
– Disconnect electrical connector -1- at intake manifold flap mo‐

tor 2 - V275- .
– Push banjo bolt for coolant bleed line aside and remove lower
part of intake manifold along with intake manifold flap motor.
Note
Seal intake ports in cylinder head with a clean cloth.

G. Volkswagen nA AG do
wage es n
Volks ot g
Installing ed
by ua
ran
oris te
Installation is carried
au
th out in the reverse order; note the following:e or a
⇒ page 228 ss c
ce
e
nl
pt
• Specified torques: assembly overview - intake manifold
du
an
itte
⇒ page 228
y li
erm
ab
ility
ot p
wit
, is n
Note
h re
hole
spec
Renew gaskets and seals.
es, in part or in w
t to the co
– Before installing lower part of left intake manifold, fit banjo bolt
for coolant bleed line with a new seal and screw bolt in 2…3
rrectness of i
turns.
l purpos
– Install mechanical exhaust gas recirculation valve

⇒ page 310 .
nf
ercia

orm
m
atio
– Installing high-pressure lines ⇒ page 75 .

om
n in
or c
– Fill with coolant ⇒ page 173 .

thi
te
sd
iva

o
r
rp
cu

o
m
f
en
ng
t.
yi Co
op py
1.10.2 Removing and installing lower part of
. C rig
ht ht
rig by
py
right intake manifold (engine code BMK)
co Vo
by lksw
cted agen
Prote AG.

Phaeton 2003 ➤
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
or
♦ Socket - T40055-
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing
WARNING


Phaeton 2003 ➤
– Unscrew union nuts -1…4- and remove high-pressure lines.

– Remove air pipe -arrows-.
– Remove electrical connector -arrow- for exhaust gas temper‐

agen
AG. Volkswagen AG d
oes
ature sender 1 - G235- from retainer. V olksw not
g y ua
db ran
rise tee
tho or
s au ac
s
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
– Disconnect electrical connector -3- at intake manifold flap mo‐

tor - V157- .
rrectness of i

l purpos
Note
nf
ercia
orm
m
atio
-Item 1- and -item 4- should be disregarded.

om
n in
or c
thi
e
– Disconnect electrical connectors at glow plugs for right cylin‐

t
sd
iva
der bank.
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.

Phaeton 2003 ➤
– Remove bolts -arrows- and take off lower part of right intake
manifold.
Note
♦ Disregard -item 1-.

♦ Cover/seal intake ports in cylinder head with clean cloths.
Installing
⇒ page 228
Note
Renew seals and gaskets.

– Install high-pressure lines ⇒ page 75 .
AG. Volkswagen AG d
agen oes
ksw
1.11 Removing and installing lower parts of
d byV
ol not
gu
ara
intake manifold (engine codes CARA,
ise nte
or eo
h
ut ra
ss a
CEXA und CEXB) c
ce
le
un
pt
Removing and installing lower part of left intake manifold

an
d
itte
⇒ page 249 .
y li
erm
ab
ility
Removing and installing lower part of right intake manifold

ot p
wit
⇒ page 251 .
is n
h re
ole,
1.11.1 Removing and installing lower part of left

spec
intake manifold
t to the co
Removing
rrectne
WARNING
ss o

cial p
f in

form
mer
atio

om

n
c
i
or
n thi
te
sd
iva
o
pr

um
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Phaeton 2003 ➤
– Carefully press connecting rod -arrow- off intake manifold flap

motor - V275- .
– Unscrew bolts -3- and remove intake manifold flap motor -
V275- -item 4-.
4, 5, 6.
– Take exhaust gas recirculation cooler changeover valve -

N345- -1- out of retainer.
– Remove bolt -4-. n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a 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
l purpos
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.

Phaeton 2003 ➤
– Release clip -arrow- and remove pipe -1- for exhaust gas re‐
circulation.
– Carefully remove lower part of intake manifold.
Note
Seal intake ports in cylinder head with a clean cloth.
Installing
⇒ page 230 .
Note

AG. Volkswagen AG d
agen oes
– Install upper part of intake manifold ⇒ page 234 .y Volksw not
gu
b ara
ed
– Install high-pressure lines ⇒ page 75 . horis nte
eo
t
au ra
– Check fuel system for leaks ⇒ Fuel supply
ss system - diesel c
ce
le
un
pt
an
d
itte
y li
1.11.2 Removing and installing lower part of
erm
ab
ility
ot p
right intake manifold
wit
is n
h re
ole,
Removing
spec
t to the co
WARNING
rrectne
s
s o
cial p
f inform
mer
atio
m

o
n
c
i
or

thi
te
sd
iva
– Unscrew bolts -arrows- and detach guard for high-pressure

pr
cum
r
fo
line.
en
ng
t.
yi Co
op
– Unscrew union nuts -1- and -4- and remove high-pressure line. C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
Note
agen
Prote AG.
-Items 2, 3- should be disregarded.

Phaeton 2003 ➤
– Disconnect electrical connector -2- from pump for exhaust gas

recirculation cooler - V400- .
– Unscrew bolts -1-.
– Remove electrical connectors -1 and 2- from retainer.

olksw AG. V agen AG
agen does
olksw not
yV gu
db ara
rise nte
tho eo
au ra
c
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
– Disconnect electrical connector -3- on intake manifold flap
motor - V157- .
rrectness of i
– Unscrew bolts -4-.
l purpos
Note
nform
ercia
Disregard -item 2-.

m
at
om
ion
c
in t
r

o
his
te
1, 2, 3.
a
do
priv
cum
or
– Move wiring harness aside.

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

Phaeton 2003 ➤

– Push coolant pipe aside and remove lower part of right intake
manifold.
AG. Volkswagen AG d
Note lksw
agen oes
not
Vo gu
d by ara
e
♦ -Item 1- should be disregarded. horis nte
eo
aut ra
♦ Seal intake ports in cylinder head with
ss a clean cloth. c
ce
le
un
pt
an
d
Installing
itte
y li
rm
ab
pe
ility
ot
⇒ page 228
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
Renew seals
l purpos

nform
ercia

m
a
com
t
ion in
r
te o
thi
s
1.12 Removing and installing injectors (piezo injectors)
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.

Phaeton 2003 ➤

equipment required
♦ Socket, 14 mm - 3150-
♦ Torque wrench -
V.A.G 1331-
♦ Puller - T10055- with adapt‐
er - T10055/1-
♦ Socket, 17 mm - T40055-
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
nf
ercia
orm
m
atio
om
n in
or c
Vehicles from 11.2005

thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
Removing
t.
yi Co
Cop py
t. rig
gh ht
yri by
Caution cop Vo
by lksw
cted agen
Prote AG.
When a new injector is installed, the adaptation value for the
new injector must be written to the engine control unit.
⇒ page 299
Note
The following description shows the removal and installation of

the injectors on cylinder bank 2 (left side). The procedure for cyl‐
inder bank 1 is the same, except that some steps are not required.

Phaeton 2003 ➤
WARNING
Mark cylinder numbers on injectors.

Observe rules for cleanliness when working on the injection
system.
Plug open connections with suitable sealing caps immediately.
– Step required only for cylinder bank 2: Open cable tie securing
electrical connector -arrow- for Lambda probe - G39- .
Note
Step required only for cylinder bank 1: Remove upper part of air
filter with air mass meter ⇒ page 295 .
– Pull release pins upwards -arrow- and pull return line connec‐
tions off injectors. en AG. V
olkswagen AG
ag does
l ksw not
– Disconnect electrical connectorsbyat
Voinjectors which are to be gu
ara
removed. ris
ed
nte
tho eo
s au ra
c
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
– Loosen union nuts for injector lines -1-, -6- and -7- at injectors
using socket, 17 mm - T40055- .
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
by c lksw
cted agen
Prote AG.

Phaeton 2003 ➤
– Loosen union nuts for injector lines -1-, -6- and -7- at high-
pressure accumulator (rail element) using 14 mm socket -
3150- or 19 mm tool insert - V.A.G 1331/5- .
– Unbolt covers for injectors -arrows-.

– Pull covers upwards and turn 1/4 turn (90°).
– Unbolt clamping pieces for injectors -arrows-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a 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
l purpos
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.

Phaeton 2003 ➤
– Pull out injectors using puller - T10055- with adapter -

T10055/1- . gen AG
. Volkswagen AG
a does
lksw not
– After removal, lay injectors on a clean cloth.d by Vo gu
ara
e nte
ris
Important instructions for installing injectors
ut
ho eo
ra
sa c
• When removing and installing or replacing
s
an injector, always
ce
le
renew the following components and seals/O-rings: “clamping
un
pt
an
d
piece”, “copper seal”, “O-ring for injector bore” and “O-ring for
itte
y li
injector return connection”.
erm
ab
ility
ot p
• Used injectors and injector pipes may only be re-installed on
wit
the same cylinder. is n
h re
ole,
spec
• Make sure that the injectors and the installation area are clean
before installing.
t to the co
• The injectors must be completely undamaged.
rrectne
• Lubricate all O-rings with engine oil or assembly oil before in‐
stalling.
s
If a used injector is being re-installed:
s o
cial p
f in
– Spray tip of injector nozzle with rust-releasing spray. Wait ap‐
form
mer
prox. 5 minutes and wipe off soot particles and oil with a cloth.
atio
m
– If an injector is very dirty, the tip of the nozzle should also be

o
n
c
i
or
n
cleaned with a soft brass wire brush to make it easier to re‐
thi
e
move the copper seal. Do not apply the wire brush to the bores
t
sd
iva
o
in the nozzle.
pr
cum
r
fo
en
ng
– To remove the old copper seal from the injector, clamp the seal
t.
yi Co
op
carefully in a vice so that it is just held between the jaws without C py
t. rig
turning. Then carefully pull and twist the injector out of the
gh ht
yri by
copper seal by hand. cop Vo
by lksw
cted agen
Prote AG.
– Clean off deposits under the copper seal using a suitable scra‐
per.
– Use a plastic bush to fit the new copper seal.
– Check O-ring for fuel return connection on injector for damage
and deformation.
If there is any damage or deformation on the O-ring:
– Renew O-ring for fuel return connection. Lubricate O-ring with
assembly oil before installing.
– Lubricate O-ring for fuel return connection as well as fuel re‐
turn connection with assembly oil or clean engine oil.
– Roll new O-ring with great care on fuel return connection.
Check that it is seated correctly.
Continuation
Caution
Danger of damage to sealing surface of injector.

♦ To remove carbon deposits from the injector sealing sur‐
face, clean the injector shaft in the cylinder head with
cleaning set - VAS 6811- . Refer to ⇒ operating manual
(with the device) for information on how to use it.
– Install injectors.
– Tighten union nuts on high-pressure lines and injector lines
hand-tight to start with.

Phaeton 2003 ➤
– Ensure that high-pressure lines and injector lines are not un‐
der tension.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut
– To tighten high-pressure lines
ss aat high-pressure accumulators ra
c
ce
e
nl
- V.A.G 1331/1- and socket, 14 mm - 3150- .
pt
du
an
itte
y li
– Press return line connections carefully over seals and onto in‐
erm
ab
jectors (check seal for damage before connecting return line).
ility
ot p
The catch should engage audibly. Then press release pin
wit
, is n
down carefully.
h re
hole
spec
After replacement of one or more injectors, the “injector delivery
es, in part or in w
calibration values (IDC)” and “injector voltage calibration values
t to the co
(IVC)” for the new injectors must be written into the engine control
unit ⇒ page 299 .
rrectness of i
Bleed fuel system and check for leaks.
l purpos
– Run engine at idling speed for several minutes and then switch
off.
nf
ercia
– Switch off ignition.
orm
m
atio
– Check the complete fuel system including all 6 return line con‐
om
nections for leaks. n in

or c
thi
te
sd
Renew the affected component if leakage still occurs after tight‐

iva
o
r
ening to the correct torque.

rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
Note
t. rig
gh ht
pyri by
Vo
o
by c lksw
The return lines can only be renewed together with the pressure cted agen
Prote AG.
– After completing the repair, road-test the vehicle over a dis‐

tance of at least 20 km. Accelerate with full throttle at least
once. Then inspect the high-pressure section of the fuel sys‐
tem again for leaks.
Note
If there is any air left in the fuel system, the engine may switch to
the backup mode ('emergency running' mode) during the road
test. Switch off the engine and erase the fault memory
⇒ page 298 . Then continue road test.

Phaeton 2003 ➤
1.13 Checking fuel pressure regulating valve

- N276-
WARNING


– Pull off fuel return line -1-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Seal open fuel return line connection with a blanking plug
es, in part or in w
-1-.
t to the co
– Connect open fuel return line connection to suitable hose -2-.
rrectness of i
– Hold end of this hose -2- in suitable container to measure re‐
turn flow rate.
l purpos
– Carry out test at starting speed.

nform
ercia
• Specification: the return flow is 0 ml while the starter turns over

m
If the specification is not attained, the fuel pressure regulating

a
com
tio
valve - N276- is defective.

n in
r
te o
thi
s
iva
do
r
rp
cum
1.14 Removing and installing fuel pressure

fo
en
ng
t.
yi
regulating valve - N276-
Co
Cop py
t. rig
gh ht
yri
The fuel pressure regulating valve is located in the right high- p by
co Vo
by lksw
pressure accumulator (cylinder bank 1). It maintains a constant Prote
cted AG.
agen
pressure in the high-pressure accumulator and the injection lines
(high-pressure fuel circuit).
If the pressure in the high-pressure fuel circuit is too high, the
regulating valve opens to allow some of the fuel to flow back from
the high-pressure accumulator to the fuel tank via a return line.
If the pressure in the high-pressure fuel circuit is too low, the valve
closes and seals off the high-pressure section of the system from
the low-pressure section.
The fuel pressure regulating valve - N276- ⇒ Item 6 (page 224)
cannot be re-used.

Phaeton 2003 ➤
Caution


– Clean threaded area around fuel pressure regulating valve
(e.g. with standard cleaning solution) before removing. Under
no circumstances may dirt enter the hole of the high pressure
accumulator (rail element).
Note
Clean carefully; cleaning solvent must not enter the electrical

connector.
– Dry off fuel pressure regulating valve - N276- .

– Disconnect electrical connector from fuel pressure regulating
valve - N276- .
– Slacken union nut (counterhold at hexagonal flats on housing).
Then unscrew and remove by hand.
– Extract dirt from high-pressure accumulator bore (threads and
sealing surface). Do not use tools or other instruments for this
purpose.
AG. Volkswagen AG d
agen oes
olksw not
V
Note ed by gu
ara
ris nte
ho eo
ut
Seal off high-pressure accumulator hole immediatelysswith a suit‐
a ra
c
able plug to prevent dirt from entering.
ce
e
nl
pt
du
an
itte
y li
Installing
erm
ab
ility
ot p
wit
, is n
Note h re
hole
spec
♦ The fuel pressure regulating valve - N276- has a deformable
es, in part or in w
t to the co
sealing lip and no separate seal; it can therefore be used only

once.
♦ Check that sealing surfaces (deformable sealing lip) and
rrectness of i
threads on new fuel pressure regulating valve - N276- are not

l purpos
damaged.
♦ Also check sealing surface at high-pressure accumulator bore.
nf
ercia
♦ Thread on fuel pressure regulating valve - N276- must be free

rm
m
atio
of oil and grease.

om
n in
or c
thi
– Screw on union nut by hand.

te
sd
iva
o
r
rp
cu
– Align fuel pressure regulating valve - N276- so that connecting

o
m
f
wire is free of mechanical tension after electrical connector is

en
ng
t.
yi
attached.
Co
Cop py
t. rig
gh
Tighten union nut in 2 stages.
ht
pyri by
Vo
o
by c lksw
cted
1. Stage 1: 60 Nm (counterhold hexagonal flats on housing)
agen
Prote AG.

Phaeton 2003 ➤
Then back off union nut 1/ 4 turn (90°); counterhold hexagonal

flats on housing.
2. Stage 1: 85 Nm (counterhold hexagonal flats on housing)
– After installation, run engine at moderate speed for several
minutes and then switch off.
– Check fuel system for leaks.
Note
If the fuel pressure regulating valve - N276- or the high-pressure

pump have been changed, the learnt values for the regulating
valve must be reset using the vehicle diagnosis tester in guided
functions; Resetting learnt values for fuel pressure regulating
valve.
AG. Volkswagen AG d
agen
– Read fault memory. Volksw
oes
not
by gu
d ara
– After completing the repair, road-test theorvehicle.
ise Accelerate nte
eo
with full throttle at least once. Then check
auth the high-pressure ra
section of the fuel system again for leaks.
ss c
ce
le
un
pt
– Read fault memory again.
an
d
itte
y li
rm
1.15 Removing and installing fuel pressure
ab
pe
ility
sender - G247-
ot
wit
, is n
h re
hole
The fuel pressure sender - G247- (rail pressure sensor) is located
spec
in the left high-pressure accumulator (cylinder bank 2) and con‐
es, in part or in w
t to the co
tinuously measures the current fuel pressure in the high-pressure
system. It transmits a corresponding voltage signal to the diesel
direct injection system control unit - J248- .
rrectness of i
Should the sender fail, the engine control unit will control the fuel
pressure via a mapped open-loop backup function, allowing a
l purpos
maximum of approx. 3000 rpm.
nform
ercia
Removing
m
a
com
Caution tion in
r
te o
thi
s

iva
do
r

rp
cum
fo
en
ng

t.
yi Co
op
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
AG.
– Clean threaded area around fuel pressure sender (e.g. with

standard cleaning solution) before removing. Under no cir‐
cumstances may dirt enter the hole of the high pressure
accumulator.
Note
Clean carefully; cleaning solvent must not enter the electrical

connector.
– Dry off fuel pressure sender - G247- .

– Disconnect electrical connector at fuel pressure sender -
G247- .

Phaeton 2003 ➤
– Unscrew and remove fuel pressure sender - G247- .

– Extract dirt from high-pressure accumulator bore (threads and
sealing surface). Do not use tools or other instruments for this
purpose.
Note
Seal off high-pressure accumulator bore immediately with a suit‐

able plug to prevent dirt from entering.
Installing
Note
♦ The fuel pressure sender - G247- has a deformable sealing lip

and no separate seal; it can therefore be used only once.
♦ Check that sealing surfaces (sealing lip) and threads on new
fuel pressure sender - G247- are undamaged.
♦ Also check sealing surface at high-pressure accumulator bore.
♦ The thread on the fuel pressure sender - G247- has a special
lubricating coating and must therefore be kept free of oil and
grease.
– Screw in fuel pressure sender - G247- by hand.

– Tighten sender to specified torque.
Engine code BMK ⇒ page 223 . lkswage es n
o ot g
byV ua
ed ran
Engine codes CARA, CEXA, CEXB ⇒ page 225or is tee
th or
u
– After installation, run engine at moderate speed
ss
a
for several ac
minutes and then switch off.
ce
le
un
pt
an
d

itte
y li
erm
– Read fault memory. ab

ility
ot p
wit
is n
– After completing the repair, road-test the vehicle. Accelerate h re

ole,
with full throttle at least once. Then check the high-pressure

spec
section of the fuel system again for leaks.

t to the co
– Read fault memory.
1.16 Checking return flow rate of injectors

rrectne
(piezo injectors) with engine running

ss
Checking return flow rate of all injectors

o
cial p
f inform
mer
WARNING
atio
om
n
c

i
or
n thi

te
sd
iva
o
pr

um
r
fo

en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
– Remove engine cover panel ⇒ page 4 . cop Vo
by lksw
cted agen
Prote
– Disconnect hose connection behind pressure retention valve
AG.
of fuel return lines ⇒ Item 28 (page 225) .

– Hold the end of this hose in a suitable container to measure
the total return flow rate.

Phaeton 2003 ➤
6-cylinder
agen Adiesel
G . Volksengine
wagen AG(3.0 l engine, common rail) - Edition 04.2016
do
w es n
olks ot g
yV
d run at idling speed for 2 minutes. uara
– Start engine and allow ritisetob
nte
tho eo
Specification for 2 minutes:
s au 25 ml to 50 ml (1000 ml = 1 litre). ra
c
s
ce
e
A return flow rate in excess of 250 ml indicates that one or more
nl
pt
du
injectors are defective. Check return flow rate from each injector
an
itte
y li
individually.
erm
ab
ility
ot p
Checking return flow rate of individual injectors
wit
, is n
h re
hole
spec
♦ Injection rate comparison meter - V.A.G 1348/2 B-
es, in part or in w
t to the co
♦ 6 lengths of hose (made up in the workshop) to fit return line
connections on injectors
rrectness of i
Each injector normally has a relatively low return flow rate. If the
return flow rate at one injector is relatively high compared to the
l purpos
other injectors, that injector is probably defective.

– Clean all return line connections (with commercial cleaning
nf
ercia
o
solution etc.) before removing.
rm
m
atio
m
– Dry all components after cleaning.

o
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
co Vo
by lksw
cted agen
Prote AG.

Phaeton 2003 ➤
– Pull off return line connections to injector units of relevant cyl‐

inder bank. To do this, push connector downwards at tabs and
pull up centre piece to release -arrow-.
Note
♦ Illustration shows cylinder bank 2.

♦ On cylinder bank 2 the coolant expansion tank must be de‐
tached; coolant hoses remain connected.
♦ Adhere strictly to rules of cleanliness. No dirt must be allowed
to get into the disconnected fuel return lines or the open con‐
nections on the injectors.
– Connect hoses onto return line connections of all 6 injectors.

– Run the 6 hoses into injection rate comparison meter - V.A.G
1348/2 B- .
– Start engine and let it idle for several minutes.
Caution
Do NOT press the accelerator during this test; the engine must
only run at idling speed.
Running the engine at higher speeds
wage
n AGwith
. Volkthe
swagreturn
en AG lines dis‐
does
connected will cause damage
yV
olksto the injectors. not
gu b ara
ed nte
oris e
th or
au
– When the enginess is warm and running at idling speed the re‐
ac
turn flow rates at each of the 6 return lines must not differ by
ce
e
nl
pt
more than a small amount.

du
an
itte
y li
erm
– If one injector has a significantly higher return flow rate than

ab
ility
the others it must be renewed ⇒ page 253 .

ot p
wit
, is n
Installing fuel return lines

h re
hole
spec
– Check O-ring for fuel return connection on injector for damage

es, in part or in w
and deformation.
t to the co
If there is any damage or deformation on the O-ring:

rrectness of i
– Renew O-ring for fuel return connection. Lubricate O-ring with

assembly oil before installing.
l purpos
– Lubricate O-ring for fuel return connection as well as fuel re‐

turn connection with assembly oil or clean engine oil.
nf
ercia
or
– Roll new O-ring with great care on fuel return connection.

m
m
atio
Check that it is seated correctly.

om
n in
or c
Continuation
thi
te
sd
iva
Lubricate all seals with engine oil or assembly oil before installing.
o
r
rp
cu
o
m
f
en
– Push the return line connections carefully over the new seals
ng
t.
yi Co
and onto the injectors. The catch should engage audibly. Then . Cop py
press release pin down carefully.
ht rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
AG.

Phaeton 2003 ➤
1.17 Checking return flow rate of injectors

(piezo injectors) at starting speed
If the engine cannot be started, the return flow rate of the injectors
can also be checked at starter motor speed. wage
e
olks s no
yV t gu
Special tools and workshop equipment required edb ara
ris nte
♦ Two injection rate comparison meters - V.A.G ho
ut 1348/2 B- are eo
a ra
required. ss c
ce
le
un
pt
♦ 6 lengths of hose (made up in the workshop) to fit return line
an
d
itte
connections on injectors
y li
rm
ab
pe
ility
ot
WARNING
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Each injector normally has a relatively low return flow rate. If the
return flow rate at one injector is relatively high compared to the
nform
ercia
other injectors, that injector is probably defective.

m
a
com
tion in
– Clean all return line connections (with commercial cleaning
r
te o
thi
solution etc.) before removing.
s
iva
do
r
rp
c
um
fo
en
ng
t.
– Pull off return line connections to 6 injector units of both cyl‐
yi Co
op py
inder banks. To do this, push connector downwards at tabs
. C rig
ht ht
and pull up centre piece to release -arrow-.
rig by
copy Vo
by lksw
cted agen
Prote AG.
Note
♦ Illustration shows cylinder bank 2.

♦ On cylinder bank 2 the coolant expansion tank must be de‐
tached; coolant hoses remain connected.
♦ Adhere strictly to rules of cleanliness. No dirt must be allowed
to get into the disconnected fuel return lines or the open con‐
nections on the injectors.

Phaeton 2003 ➤
– Disconnect electrical connector -1- from fuel pressure regu‐

lating valve - N276- .
Note
This prevents the fuel from being injected during the attempt at
starting.
– Connect hoses onto the 6 return line connections of all 6 in‐

jectors.
– Run the 6 hoses into injection rate comparison meter - V.A.G
1348/2 B- .
– Actuate the starter 3 times. Wait approx. 20 seconds each time
after operating starter to prevent it from overheating.
♦ Return flow rate specification: 0 ml
– If fuel escapes from an injector, that injector has to be re‐
newed.
– Re-attach electrical connector from fuel pressure regulating
valve - N276- .
– Erase fault memory entry using diagnosis equipment.
1.18 Checking for injectors sticking open

(piezo injectors).
If one of the injectors is sticking open, this means that the injector
needle is not closing fully and fuel escapes into the cylinder.
lkswage es n
o ot g
WARNING d byV ua
ran
ir se tee
tho
♦ Always read rules for cleanliness and instructionss for
au
or
ac
working on fuel system ⇒ page 218 . s
ce
e
nl
pt
du

an
itte
before starting work and while working on the fuel system. y li

erm
ab
ility
ot p
wit
, is n
h re
hole
spec
♦ Hand vacuum pump - VAS 6213-

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.

Phaeton 2003 ➤
. Volkswagen AG
gen AG does
♦ Make an -adapter- from a return
Vol
ksw line.
a
not
y gu
db ara
rise nte
tho eo
s au ra
c
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
– Erase fault memory entry with vehicle diagnosis tester.
rrectness of i
l purpos
– Clean all connections (e.g. with commercial cleaning solution)

before removing.
nform
mercia
a
com
tio
Note
n in
r
te o
thi
s
♦ Make sure all parts are clean; no dirt must be allowed to enter
iva
do
r
the fuel system.

rp
cum
fo
en
ng
t.
♦ Check all cylinders in turn.
yi Co
Cop py
t. rig
gh ht
yri
p by
co Vo
by lksw
cted agen
Start with cylinder 1.
Prote AG.
– Pull fuel return hoses off the injectors by pressing the two tabs
downwards and simultaneously pulling the centre piece up‐
wards in order to release them -arrow-.
– Connect clean, blown-out adapter to return-flow connection
piece of injector to be tested.
– Use hand-operated vacuum pump - VAS 6213- to generate
vacuum of approx. -500 mbar.
If injector is OK, pressure remains constant for 30 s.
If injectors are defective, the pressure drops within 2 ... 3 s to 0
bar
Repeat check is necessary, observe pressure loss at hand-oper‐
ated vacuum pump - VAS 6213- .
– Renew defective injectors ⇒ page 253
1.19 Installing high-pressure lines


Phaeton 2003 ➤
♦ Socket, 14 mm - 3150-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
♦ Tool insert 19 mm - V.A.G 1331/5- 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
o
by c lksw
cted agen
Prote AG.

Phaeton 2003 ➤
♦ Socket - T40055-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Procedure
rrectne
Note
ss
♦ Observe cylinder specific markings when reusing high-pres‐
o
cial p
f i
sure lines.
nform
mer
♦ The high-pressure lines may be re-used after the following
atio
m
checks:
o
n
c
i
or
n thi
♦ Check taper seat of respective high-pressure line for defor‐
te
sd
a
mation and cracks.

iv
o
pr
cum
r
fo
♦ The line hole must not be deformed, constricted or damaged.
en
ng
t.
yi Co
op
♦ Corroded lines should no longer be used.
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
– Extract soiling from taper seat on rail. Prote
cted AG.
agen
– Clean fuel line and head of line using cold cleaning solvent
and dry using compressed air.
– Moisten union nut thread with fuel.
– Tighten high-pressure union nuts hand-tight, check lines are
free of stress when doing this.
• Specified torque: 28 Nm
– To tighten high-pressure lines, use torque wrench - V.A.G
1331- with ratchet - V.A.G 1331/1- and 17 mm socket -
T40055- .

Phaeton 2003 ➤
– To tighten high-pressure lines, use torque wrench -

V.A.G 1331- with 17 mm socket - V.A.G 1331/6- 19 mm socket
- V.A.G 1331/5- as applicable.
– Checking fuel system for leaks ⇒ Fuel supply system - diesel
1.20 Checking pressure retention valve in

fuel return agen
AG. Volkswagen AG d
oes
olksw not
The pressure retention valve maintains a residual pressure of ap‐ d byV gu
ara
prox. 10 bar in the return lines. orise nte
eo
h
aut ra
This residual pressure is required for the control function
s of the
s c
piezo injectors.
ce
e
nl
pt
du
an
itte
y li
erm
ab
♦ Fuel return system tester - VAS 6330-
ility
ot p
wit
, is n
h re
WARNING
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
– Clean return line connection of cylinder no. 1 (e.g. with com‐
m
atio
m
mercial cleaning solution) before removing.

o
n in
or c
– Dry return line connection of No. 1 cylinder.
thi
te
sd
iva
– Cover return line connection on No. 1 cylinder with a cloth. o

r
rp
cu
o
m
f
en
ng
– Pull off return line connection on 1st cylinder bank. To do this,

t.
yi Co
op
push connector downwards at tabs and pull up centre piece to C py
ht. rig
release. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
Adhere strictly to rules of cleanliness. No dirt must be allowed to

get into the disconnected fuel return lines or the open connections
on the injectors.

Phaeton 2003 ➤
– Install fuel return system tester - VAS 6330- between return

line connection on injector and return line.
– Start engine.
– Check pressure on pressure gauge.
♦ Specification: approx. 10 bar
If the specification is not reached, replace the pressure retention
valve.
1.21 Assembly overview - toothed belt for high-pressure pump (engine code
BMK) agen
AG. Volkswagen AG d
o w es n
olks ot g
byV ua
ed ran
1 - Front toothed belt guard tho
ris tee
or
au
❑ Engage in position at ss
ac
the bottom at clip on at
ce
le
un
pt
the side.
an
d
itte
y li
erm
2 - 70 Nm
ab
ility
ot p
wit
is n
to loosen and tighten
h re
ole,
⇒ page 272 .
spec
3 - Damper weight
t to the co
when loosening and
tightening central nut
rrectne
⇒ page 272 .
s
4 - 23 Nm
s o
cial p
5 - Toothed belt pulley for high- f inform

pressure pump
mer
atio
m
❑ Remove using puller -

o
T40064- ⇒ page 272 .

c
i
or
n thi
te
sd
6 - Toothed belt tensioning roll‐

iva
o
r
er
p
cum
r
fo
en
ng
7 - 9 Nm
t.
yi Co
Cop py
t. rig
8 - Rear toothed belt guard opyri
gh by
Vo
ht
c lksw
by
cted agen
Prote AG.
when loosening and
tightening central bolt
⇒ page 272 .
❑ Use puller - 3032- or
puller - T10320- to re‐
move ⇒ page 74 .
10 - 75 Nm
❑ With washer.

Phaeton 2003 ➤
❑ Use counterhold - 3036- to loosen and tighten ⇒ page 272 .
11 - Toothed belt for high-pressure pump
❑ Before removing, mark direction of rotation with chalk or felt-tipped pen. If the belt runs in the opposite
direction when it is refitted, this can cause breakage.
AG. Volkswagen AG d
❑ Check for wear. ksw
agen oes
n ol ot g
yV ua
edb ran
ris tee
tho or
Loosening and tightening central nut for high-pressure
ss
pump au ac
shaft
ce
le
un
pt
an
d
itte
y li
tral nut -1-.
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
Pulling off toothed belt pulley for high-pressure pump

– Use puller - T40064- to pull off belt sprocket for high-pressure
nform
ercia
pump.
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.
Loosening and tightening central bolt for toothed belt drive pulley
tral bolt -1-.
Pull off toothed belt drive pulley to 02.2006

– Use puller - 3032- to pull off toothed belt drive pulley.

Phaeton 2003 ➤
Pull off toothed belt drive pulley from 02.2006

1.22 Removing and installingolktoothed

gen AG belt for high-pressure pump (engine code
n AG d . Volkswage
swa oes
not
BMK) y V gu
d b ara
e nt
ris ee
tho or
s au ac
s
ce
le
un
equipment required
pt
an
d
itte
y li
♦ Puller - 3032-
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
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.

Phaeton 2003 ➤
Removing
sition . agen
AG. Volkswagen AG d
o
es n w
ot g olks
– Loosen clamps -arrows-.
ed
by
V ua
ran
ris tee
– Pivot toothed belt
autho
guard forward and disengage retaining pegs or
ac
on lower sidesof
s toothed belt guard.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
– Loosen bolt -arrow- for toothed belt tensioning roller approx.
hole
spec
2 turns.
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
– Loosen central nut -1- for high-pressure pump shaft using

do
r
rp
counterhold - 3036- .
um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Phaeton 2003 ➤
– Use puller - 3032- or puller - T10320- to pull off toothed belt

drive pulley ⇒ page 74 .
Installing agen
AG. Volkswagen AG d
oes
olksw not
V g
Installation is carried out in theedreverse order; note the following: uaran
by
ris tee
ho
aut or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Check installation of toothed belt tensioning roller:
hole
spec
• Retaining lug -arrow 2- must engage in slot on front bracket
es, in part or in w
for high-pressure pump.
t to the co
• Tensioning roller must be relieved, hexagon drive mounting
-arrow 1- faces downwards.
rrectness of i
– Fit toothed belt together with toothed belt drive pulley.
l purpos
– Fit toothed belt tensioning roller, screw in bolt for toothed belt
tensioning roller without applying pressure until eccentric of
nform
ercia
toothed belt tensioning roller can just be turned without tilting.

m
at
om
– Screw in bolt for toothed belt drive pulley until toothed belt
ion
c
drive pulley can just be turned without tilting.
in t
or
his
ate
do
riv
– Pre-tension toothed belt tensioning roller with hexagon key by

p
cum
or
turning in direction of -arrow- until hexagon drive mounting is

f
en
ng
t.
positioned at -1 o'clock- Cop
yi Co
py
ht. rig
rig ht
py by
Caution co Vo
by lksw
cted agen
Prote AG.
Never turn tensioning roller to “12 o'clock position” or beyond.
– Now relieve tension of toothed belt tensioning roller -arrow-

until hexagon drive mounting is positioned at -3 o'clock-

Phaeton 2003 ➤
– From the -3 o'clock- position, pre-tension toothed belt tension‐

ing roller -arrow- until lug -1- and notch -2- align exactly.
– Hold toothed belt tensioning roller in this position and tighten

bolt -arrow- ⇒ Item 4 (page 271) .
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
– Tighten bolt -1- for toothed belt drive pulley using counterhold
- 3036- ⇒ Item 10 (page 271) .

t to the co
The crankshaft must be turned 1 turn in order to check the tension
of the toothed belt.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
– Insert guide pin of adapter -T40058- so that the large diameter

um
r
fo

en
ng
t.
yi Co
-arrow 2- faces the adapter. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Phaeton 2003 ➤
– Turn crankshaft at least one complete revolution in normal

running direction -arrow-.
Caution

tation.
– Check toothed belt tension.

• Lug -1- should align with notch -2-.
If the specification is not attained:
swa
gen AG
. Volkswagen AG
does
k not
Vol gu
– Adjust the toothed
se
dbelt
by tension again. ara
nte
i
or e
♦ Assembly overview
au
th - specified torques for toothed belt for or a
high-pressure
ss pump ⇒ page 271 c
ce
e
nl
pt
du
Further assembly is carried out in the reverse order, note the fol‐
an
itte
lowing:
y li
erm
ab
ility
– Install lock carrier with attachments ⇒ General body repairs,
ot p
wit
exterior; Rep. gr. 50 .
, is n
h re
hole

spec
es, in part or in w
sion . t to the co
– Check headlight adjustment ⇒ Maintenance ; Booklet 4E .

rrectness of i
1.23 Assembly overview - high-pressure pump (engine code BMK)

l purpos
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
py by
co Vo
by lksw
cted agen
Prote AG.

Phaeton 2003 ➤
1 - Damper weight
when loosening and AG. Volkswagen AG d
agen
tightening central nut Volksw
oes
not
gu
⇒ page 279 . ed by ara
nte
ris
o eo
2 - 70 Nm aut
h
ra
ss c
ce
le
un
pt
an
d
⇒ page 279 .
itte
y li
rm
ab
pe
3 - Toothed belt pulley for high-
ility
pressure pump ot
wit
, is n
h re
❑ Remove using puller -
hole
spec
T40064- ⇒ page 279 .
es, in part or in w
t to the co
4 - 22 Nm
5 - High-pressure pump
rrectness of i
Caution
l purpos
Observe
♦ rules for cleanli‐
ness when working on
nform
ercia
the injection system

m
⇒ page 218 .
a
com
tion in
The
♦ high-pressure pump
r
te o
thi
must first be filled with
s
iva
do
fuel before the engine is
r
rp
c
started. The high-pres‐
um
fo
en
g
sure pump must not be

n
t.
yi Co
allowed to run while still Cop py
t. rig
empty. gh ht
pyri by
Vo
o
by c lksw
cted agen
❑ Removing and installing Prote AG.
⇒ page 280
❑ The fuel system must be
bled after installing high-
pressure pump ⇒ Fuel
supply system - diesel
6 - Oil seals
❑ Renew.
7 - Fuel supply line
10 - Oil seals
❑ Renew.
12 - Union nut for injector line
❑ Tighten using open ring tool insert - V.A.G 1331/8- ⇒ page 279 .

Phaeton 2003 ➤
13 - 22 Nm
14 - 22 Nm
15 - Bracket for high-pressure pump
16 - 22 Nm
17 - Bracket for high-pressure pump
18 - 9 Nm
Loosening and tightening central nut for high-pressure pump

AG. Volkswagen AG d
shaft lksw
agen oes
no ot g
yV u
– Use counterholdris
ed - 3036- when loosening and tightening
b ara
nte cen‐
tral nut -1-.
utho eo
r
a ac
ss
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
Pulling off toothed belt pulley for high-pressure pump
– Use puller - T40064- to pull off toothed belt pulley.
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
op
Tightening union nut for injector line at high-pressure pump C py
ht. rig
rig ht
by
– Tighten using open ring tool insert - V.A.G 1331/8-copy Vo
by lksw
cted agen
Prote AG.

Phaeton 2003 ➤
1.24 Removing and installing high-pressure pump (engine code BMK)
Special tools and workshop en AG. Volkswagen AG

equipment required olks
wag does
no
V t gu
by ara
♦ Puller - 3032-rised nte
ho eo
ut
♦ Counterhold
ss
a tool - 3036- ra
c
ce
e
♦ Puller - T40064-
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
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
o
by c lksw
cted agen
Prote AG.
Removing
Caution
Rules for cleanliness when working on the injection system

⇒ page 218 .

sition .
– Remove lower part of left intake manifold ⇒ page 243 .

Phaeton 2003 ➤
– Unscrew bolt -3- for toothed belt tensioning roller and remove
toothed belt tensioning roller.
– Loosen central nut -1- for high-pressure pump shaft using

counterhold - 3036- .
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
– Use puller - 3032- or puller - T10320- to pull off toothed belt
es, in part or in w
drive pulley ⇒ page 74 .
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
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Phaeton 2003 ➤
– Use puller - T40064- to pull off belt sprocket for high-pressure

pump.
– Remove bolts -arrows- and detach toothed belt cover (rear).
– Remove bolts -arrows- and take off connecting pipe for ex‐
haust gas recirculation.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
– Disconnect fuel supply line -2- and fuel return line -1- from
an
itte
y li
high-pressure pump and move lines clear to side.

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
282
cted agen
Prote AG.
Phaeton 2003 ➤
swage es n
– Disconnect electrical
byV
o connector -1-.
lk ot g
ua
d ran
ir se
– Unscrew tbolts
ho -arrows-. tee
or
au ac
– Take off high-pressure pump together with front bracket.
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
– Detach front bracket from high-pressure pump.
l purpos
Installing
nform
ercia

note the following:
m
at
om
ion
c
in t
or
his
e
Note
at
do
priv
cum
or

f
en
ng
t.
pump have been changed, the learnt values for the regulating
yi Co
op
valve must be reset using the vehicle diagnosis tester in guided
C py
t. rig
gh
functions; Resetting learnt values for fuel pressure regulating
ht
pyri by
Vo
o
valve.
c by lksw
cted agen
Prote AG.
Caution
The high-pressure pump must first be filled with fuel before the
engine is started. The high-pressure pump must not be allowed
to run while still empty.
Note
♦ Renew gaskets and seals.


1.25 Assembly overview - toothed belt for high-pressure pump (engine codes
CARA, CEXA, CEXB)

Phaeton 2003 ➤
1 - Front toothed belt guard

❑ Engage in position at
the bottom at clip on at
the side.
2 - Nut, 70 Nm agen
AG. Volkswagen AG d
oes
olksw not
V
3 - Bolt, 23 Nm ed by gu
ara
ris nte
o
4 - Toothed abelt
ut pulley for high-
h eo
ra
pressure pump
ss c
ce
e
nl
pt
5 - Idler roller
du
an
itte
y li
6 - Toothed belt for high-pres‐
erm
ab
ility
sure pump
ot p
wit
, is n
h re
direction of rotation with
hole
spec
chalk or felt-tipped pen.
es, in part or in w
If the toothed belt runs in
t to the co
the opposite direction
when it is refitted, this
can cause breakage.
rrectness of i
❑ Check for wear.
l purpos

⇒ page 284
nf
ercia
7 - Bolt, 9 Nm orm
m
atio
m
8 - Rear toothed belt guard

o
n in
or c
9 - Toothed belt tensioning roll‐

thi
te
sd
a
er
iv
o
r
rp
cu
o

f
en
ng
t.
yi Co
op
11 - Bolt, 75 Nm C py
ht. rig
rig ht
❑ With washer. py by
co Vo
by lksw
cted agen
Prote AG.
⇒ page 272 .
12 - Bolt, 23 Nm
1.26 Removing and installing toothed belt for

high-pressure pump (engine codes
CARA, CEXA, CEXB)

Phaeton 2003 ➤
♦ Puller - T10320- 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
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
♦ Mandrel -T40135- rig ht
py by
co Vo
by lksw
Removing Prote
cted AG.
agen

Phaeton 2003 ➤
– Pivot toothed belt guard forwards -arrows- and unhook retain‐

ing pin on underside of toothed belt guard.
Note n AG. Volkswagen AG do

lkswage es n
o ot g
yV
For illustration purposes, the procedure ir seis shown with the toothed
d b ua
ran
belt guard removed. utho tee
or
a ac
ss
ce
le
un
pt
Caution
an
d
itte
y li
rm
ab
pe
Risk of irreparable damage if direction of rotation is reversed
ility
ot
on previously used toothed belt.
wit
, is n
h re
Before removing toothed belt, mark direction of rotation with
hole
spec
chalk or felt tipped pen for installation purposes.
es, in part or in w
t to the co
– Set engine to »Ignition TDC«:
rrectness of i
l purpos
Note
nform
ercia
To prevent any engine oil from escaping, place a cloth below the
m
upper part of sump.
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.
WARNING

locking pin.
– Lock toothed belt pulley for high-pressure pump using locking
pin -T40135- .
– Loosen bolt -1- for toothed belt tensioning roller about 1 full
turn. Item -2- can be disregarded.

Phaeton 2003 ➤
– Loosen bolt -1- for toothed belt drive pulley approx. 2 turns
using counterhold - 3036- .
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
– Pull off toothed belt drive pulley using puller - T10320- .
t to the co
Note
rrectne
The toothed belt drive pulley remains on the camshaft.
ss o
cial p
f
– First remove toothed belt from toothed belt pulley for high-
inform
pressure pump and then from toothed belt drive pulley.
mer
atio
Installing
om
n
c
i
or
n
thi
te
sd
va
– Remove noise insulation.

i
o
pr
cum
r
fo
en
ng
t.
yi
Co
Cop py
t. rig
gh
ht
pyri by
Vo
co lksw
by
• The smaller diameter -arrow 2- faces the adapter. cted agen
Prote AG.
Caution
Risk of irreparable damage due to jumping of camshaft timing

chain.
-arrow-.
– Turn crankshaft to “TDC” using adapter - T40058- .

Phaeton 2003 ➤
• The marking -arrow- must be perpendicular to the middle of

the crankshaft as shown in illustration.
– Unscrew plug -arrow- at rear of cylinder head on right.
Note
For reasons of clarity, the installation position as seen from the

rear with the engine removed is shown.
– Check whether the groove -arrow- in the flange of the cam‐

shaft can be seen through the hole -1- for plug.
– To do this, use a small torch to shine light into the plug hole.
Note
AG. Volkswagen AG d
agen oes
lksw not
For reasons of clarity, the flange of the d by camshaft
Vo
is shown without gu
ara
chain drive and without timing chain orise cover. nte
eo
th
au ra
s c
– If the groove is not beneath the hole, turn crankshaft 360 de‐
s
ce
le
grees in the engine's direction of rotation.

un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Note
t to the co
Place a cloth underneath upper part of sump to catch escaping

engine oil.
rrectne

ss 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.

Phaeton 2003 ➤
WARNING

swa
gen AG
. Volkswagen AG
does
olk not
yV gu
edb ara
ris nte
o
– Screw lockingaupin
th - 3242- into hole (20 Nm); if necessary, turn eo
ra
crankshaft backwards
ss and forwards slightly to fully centralise c
locking pin.
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
h re
Before installing the toothed belt, the high-pressure pump and
hole
toothed belt sprocket for high-pressure pump must be properly
spec
secured in place.
es, in part or in w
t to the co
– Check installation of toothed belt tensioning roller:
rrectness of i
• Retaining lug -arrow 2- must engage in slot on front bracket
l purpos
for high-pressure pump.

• Tensioning roller must be relieved, hexagon drive mounting
nform
ercia
-arrow 1- faces downwards.

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
– Fit toothed belt. py by
co Vo
by lksw
cted agen
– Screw in bolt -1- for toothed belt tensioning roller without ap‐ Prote AG.
plying pressure until eccentric of toothed belt tensioning roller
can just be turned without tilting.
– Screw in bolt -2- for toothed belt drive pulley until toothed belt
drive pulley can just be turned without tilting.
– Lock toothed belt pulley for high-pressure pump using locking
tool - T40135- .
– Pre-tension toothed belt tensioning roller with hexagon key by

turning in direction of -arrow- until hexagon drive mounting is
positioned at -1 o'clock-
Caution
Never turn tensioning roller to “12 o'clock position” or beyond.

Phaeton 2003 ➤
– Now relieve tension of toothed belt tensioning roller -arrow-

until hexagon drive mounting is positioned
gen AG
. Volkswageat -3 o'clock-
n AG
a does
ksw not
y Vol gu
b ara
ed nte
oris eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– From the -3 o'clock- position, pre-tension toothed belt tension‐
ing roller -arrow- until lug -1- and notch -2- align exactly.
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
– Hold toothed belt tensioning roller in this position and tighten
Co
op py
bolt -arrow- ⇒ Item 3 (page 284) . t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Tighten bolt -1- for toothed belt drive pulley using counterhold
- 3036- ⇒ Item 11 (page 284) .

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
rised
Phaetonnte 2003 ➤
o e
6-cylinder diesel
aut
h
engine (3.0 l engine, common rail) - Editionor04.2016ac
ss
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
ercia
oil sump ⇒ Rep. gr. 17 .

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.

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

ing.
-arrow-.
– Turn crankshaft 1 full turn using adapter - T40058- .

Phaeton 2003 ➤
– Check toothed belt tension:

• Lug -1- should align with notch -2-.
– If specification is not reached, adjust toothed belt tension
again.
Further assembly is carried out in the reverse order of removal. AG. Volkswagen AG d
agen oes
ksw
• Assembly overview - specified torques for toothed belt for by
Vol not
gu
ara
high-pressure pump ⇒ page 283 rised
nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
1.27 Assembly overview - high-pressure pump (engine codes CARA, CEXA und
ility
ot p
wit
CEXB) , is n
h re
hole
spec
es, in part or in w
1 - Bolt
t to the co
❑ M6: 9 Nm.
❑ M8: 23 Nm.
rrectness of i
2 - Bracket for high-pressure
l purpos
pump
3 - Bolt, 9 Nm
nf
ercia
orm
4 - Protective plate
m
atio
om
5 - Union nut for high-pressure
n in
or c
line, 28 Nm
thi
te
sd
iva
6 - High-pressure pump
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Caution Cop py
t. rig
gh ht
Observe
♦ rules for cleanli‐ pyri by
Vo
o
by c
ness when working on
lksw
cted agen
Prote
the injection system
AG.
⇒ page 218 .
The
♦ high-pressure pump
must first be filled with
fuel before the engine is
started. The high-pres‐
sure pump must not be
allowed to run while still
empty.

⇒ page 293
❑ The fuel system must be
bled after installing high-
pressure pump ⇒ Fuel
supply system - diesel
7 - Hose clip
❑ Use only hose clips that
are of the equivalent standard used in series production ⇒ Parts catalogue .
8 - Fuel supply hose
9 - Fuel return hose
❑ The fuel return line must not be kinked, damaged or blocked.

Phaeton 2003 ➤
10 - Hose clip
❑ Use only hose clips that are of the equivalent standard used in series production ⇒ Parts catalogue .
11 - Union nut for high-pressure line, 28 Nm
12 - Bolt, 23 Nm
1.28 Removing and installing high-pressure

pump (engine codes CARA, CEXA und
CEXB)
Removing
– Removing toothed belt for high-pressure pump ⇒ page 284 .
– Unscrew bolts -arrows- and detach guard for high-pressure
line.
– Unscrew union nuts -1 … 4- and place high-pressure lines to
one side. gen AG
. Volkswagen AG
d a oes
ksw not
– Disconnect electrical connector -3-. Vol gu
d by ara
e nte
ris
– Remove fuel supply hose -1- and fuel return hose
tho -2-. eo
au ra
c
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
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.

Phaeton 2003 ➤
– Unscrew bolts -arrows- and remove high-pressure pump.
WARNING

Installing
Note

pump have been changed, thegelearnt n AG. Vvalues
olkswagefor
n AGthe regulating
valve must be reset using olkthe
swavehicle diagnosis tester
does
noin guided
t gu
functions; Resetting elearnt
db
y V
values for fuel pressure regulating ara
valve. tho
ris nte
e or
au ac
ss
ce
le
un
pt
Caution
an
d
itte
y li
erm
ab
Risk of irreparable damage to high-pressure pump if allowed

ility
ot p
to run dry.
wit
is n
h re
♦ The high-pressure pump must first be filled with fuel before

ole,
spec
the engine is started.

t to the co
rrectne
Note
♦ Renew seals and gaskets.

ss o
cial p
♦ The fuel return line must not be kinked, damaged or blocked.

inform
mer
atio
– Install toothed belt for high-pressure pump ⇒ page 284 .

om
n
c
i
or
– Install high-pressure lines.

thi
te
sd
va

i
o
pr
cum
r
fo
en
– Bleed fuel system after installing high-pressure pump ⇒ Fuel

ng
t.
yi Co
supply system - diesel engines; Rep. gr. 20 . t. Cop py
rig
gh ht
pyri by
Vo
1.29 Bleeding fuel system
co lksw
by
cted agen
Prote AG.
After installation, the high-pressure pump must first be filled with

fuel before the engine is started (the pump must not be allowed
to run while still empty).

Phaeton 2003 ➤
Note
♦ When installing the high-pressure pump, it is essential to en‐

sure that no dirt enters the fuel system.
♦ Only remove sealing plugs immediately prior to installation of
fuel lines.
♦ There must be sufficient fuel in the tank.
AG. Volkswagen AG d
agen oes
Bleeding fuel system olksw not
y V gu
d b ara
Proceed as follows to fill high-pressure pump with rise
fuel. nte
tho eo
au ra
– Connect battery charger if necessary ⇒ Electrical
ss system; c
ce
Rep. gr. 27 ; Charging battery .
le
un
pt
an
d
itte
– Disconnect connector from fuel pressure regulating valve -
y li
erm
ab
N276- so that engine does not start when starter motor is
ility
ot p
operated.
wit
is n
h re
– Operate starter for 3 x 13 seconds. (Wait approx. 20 seconds
ole,
each time after operating starter to prevent it from overheat‐
spec
ing.)
t to the co
– Re-attach connector of fuel pressure regulating valve - N276- .
– Erase event memory ⇒ Vehicle diagnostic tester.
rrectne
– Start engine.
ss
– After bleeding the fuel system, leave engine running at mod‐
o
cial p
f
erate speed for a few minutes and then switch off again.
inform
mer
atio
om
– Observe applicable safety precautions during road test
n
c
i
or
n
⇒ page 218 .
thi
te
sd
iva
o
– After completing the repair, road-test the vehicle over a dis‐
pr
cum
r
fo
tance of at least 20 km. Accelerate with full throttle at least
en
ng
t.
once. Then inspect the high-pressure section of the fuel sys‐
yi Co
op
tem again for leaks.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
Note
AG.
If there is any air left in the fuel system, the engine may switch to
the backup mode ('emergency running' mode) during the road
test. Switch off the engine and erase event memory ⇒ Vehicle
diagnostic tester. Then continue road test.
1.30 Assembly overview - air filter

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
Phaeton 2003 ➤ horis
eo
ut
ss a (3.0 l engine, common rail) - Edition 04.2016 ra
c
ce
e
nl
pt
1 - Intake hose
du
an
itte
y li
erm
2 - Spring-type clip
ab
ility
ot p
3 - Seal
wit
, is n
h re
❑ Renew if damaged.
hole
spec
4 - Air duct
es, in part or in w
t to the co
❑ Secured to lock carrier.
5 - Connecting piece
rrectness of i
6 - Air filter lower part
l purpos
❑ See note.
7 - Heat reflective film
nform
ercia
8 - Rubber bush
m
at
om
io
❑ Clipped to longitudinal
n
c
in t
r
member.
o
his
ate
do
riv
9 - Filter element
p
cum
for
10 - 10 Nm
en
ng
t.
yi Co
op py
11 - Air filter upper part t. C rig
gh ht
pyri by
12 - Air mass meter - G70-
o Vo
by c lksw
cted agen
Prote AG.
13 - 6 Nm
1.30.1 Removing and installing air filter lower

part
Removing
– Remove air filter upper part and air duct
⇒ Item 4 (page 296) .
– Remove filter element ⇒ Item 9 (page 296) .
– Remove securing bolt of air filter lower part
⇒ Item 10 (page 296) .
– Loosen fuel filter from bracket, remove quick release fasteners
and lay fuel filter to side.
– Pull lower part of air filter out of bracket and for new version of
air filter, release water drain hose on bottom of air filter by
pressing retaining lugs.
Installing
Reinstalling used air filter:
– Installation is carried out in the reverse sequence of removal.
Installing new air filter:

Phaeton 2003 ➤
Note
♦ The hole for the gearbox breather is discontinued on new low‐

er parts of air filter. If the lower part is to be renewed and the
vehicle is fitted with a gearbox breather, the drilling must be
made subsequently ⇒ page 297 .
♦ New air filter housings have a modified drainage. Before in‐
stalling new drain hose turn horn in bracket through 90°.
Drilling hole for gearbox breather

Bohrung ∅ - 10.3 mm
Maß a - 40 mm
Maß b - 70 mm
– Loosen front right wheel housing liner near bumper.
– Install lower part of air filter.
– Route water drain hose from below over washer fluid reservoir
and towards charge air cooler.
– Push water drain hose from below through hole in longitudinal
member and onto connection on lower part of air filter and en‐
AG. Volkswagen AG d
gage. lksw
agen oes
n o ot g
yV ua
– Fix lower end of water drain hose to a suitable point iusing
ed
b
ca‐ ran
rs
ble ties. utho tee
or
sa ac
– Further installation is carried out in the reverses order.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
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.

Phaeton 2003 ➤
2 Engine control unit

Reading and clearing engine control unit fault memory
⇒ page 298 .
Adapting functions and components ⇒ page 299 .
Removing and installing engine control unit ⇒ page 300 . AG. Volkswagen AG d
agen oes
lksw not
Installation positions ⇒ page 300 d by Vo gu
ara
rise nte
2.1 Reading and clearing engine control unit tho eo
au ra
s c
fault memory s
ce
e
nl
pt
du
an
itte
y li
erm
ab
♦ Vehicle diagnostic, testing and information system - VAS
ility
ot p
5051A-
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
io
♦ Diagnosis cable - VAS 5051/1- or diagnosis cable - VAS
n
c
in t
r
5051/3-
o
his
ate
do
riv
Procedure
p
cum
for
en
g
– Connect vehicle diagnostic, testing and information system -

n
t.
yi Co
VAS 5051A- as follows: Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Phaeton 2003 ➤
– Connect diagnosis cable - VAS 5051/1- or diagnosis cable -

VAS 5051/3- to diagnosis connector.
– Start engine and run at idling speed.
Only when engine does not start:
– Switch on ignition.
Selecting operating mode:
– Press button on display for “Vehicle self-diagnosis”.
Selecting vehicle system:
– Press button “01 - Engine electronics” on display to read con‐
trol unit for cylinder bank 1 or button “21 - Engine electronics
2” to read control unit for cylinder bank 2.
The display indicates the control unit identification and the coding
of the engine control unit.
Select diagnostic function:
. Volkswagen AG
a gen AG does
– Press button “02 - Read fault memory”
Vol
ksw on display. not
gu
y
db ara
– If no fault is stored in the engine
orise
control unit “0 faults detected” nte
eo
is displayed. aut
h
ra
ss c
– If faults are stored in the engine control unit, these are shown
ce
e
nl
pt
one below the other on the display.
du
an
itte
y li
erm
– Press the ← button.
ab
ility
ot p
– Press button “05 - Clear fault memory” on display.
wit
, is n
h re
hole
– Press function “06-End output”.
spec
es, in part or in w
t to the co
2.2 Adapting functions and components
rrectness of i
♦ Vehicle diagnostic, testing and information system - VAS
l purpos
5051A-
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.
♦ Diagnosis cable - VAS 5051/1- or diagnosis cable - VAS
5051/3-
Select “guided fault finding” in the vehicle diagnostic, testing and
information system - VAS 5051A- .
When all control units have been read:
– Press “GoTo” button.
– Select “Function/component selection”.
– Select “Drive”.
– Select “Engine code”.
– Select “01 - Systems capable of self-diagnosis”.
2. Engine control unit 299

Phaeton 2003 ➤
– Select “engine control”.

– Select “Functions”.
– Select “Function or component”.
2.3 Removing and installing engine control

unit
– Before removing engine control unit, read control unit identifi‐
cation and, with it, coding of current control unit as well
⇒ page 298 .
– Remove plenum chamber cover.
– Remove right wiper motor: ⇒ Electrical system; Repair group
92; Removing and installing wiper system
– Remove coolant expansion tank in plenum chamber.
– Remove control unit, release connectors and pull them off.
– Renew defective control unit and reinstall.
– Check the previous coding and code the new control unit
⇒ page 299 ; Adapting functions and components.
2.4 Fitting locations

Fuel pressure sender - G247- -1- on cylinder bank 2
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
Hall sender - G40- -1- on cylinder bank 1 thor eo
au 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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
300
Prote AG.
Phaeton 2003 ➤
Fuel pressure regulating valve - N276- -1- on cylinder bank 1
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
Fuel temperature sender
s - G81- -1- and pressure retention valve
s c
-2-
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
Fitting locations
nf
ercia
1 - Electrical connector for exhaust gas recirculation temperature
or
sensor - G98-
m
m
atio
m
2 - Exhaust gas recirculation control motor - V338-

o
n in
or c
thi
e
3 - Exhaust gas recirculation cooler changeover valve - N345-

t
sd
iva
o
r
rp
cu
4 - Exhaust gas recirculation temperature sensor - G98-

o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Exhaust gas temperature sender 1 G235
Note
Shown from rear with engine removed for illustration purposes.
2. Engine control unit 301

lkswage es n
Phaeton 2003 ➤ byV
o ot g
ua
ed ran
horis common rail) - Edition 04.2016 tee
ut or
a ac
ss
Pump for exhaust gas recirculation cooler - V400- -1-
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
Oil pressure switch - F1- -arrow-
nform
ercia
♦
m
a
com
t
Installed in gearbox housing:
ion 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.
Engine speed sender - G28- -2-

Phaeton 2003 ➤
26 – Exhaust system
1 Parts of the exhaust system
Note
♦ Renew seals, gaskets and self-locking nuts.

♦ After working on the exhaust system, ensure that the system
is not under stress and that there is sufficient clearance to the
bodywork. If necessary, loosen clamps and align silencers and
exhaust pipes so that sufficient clearance is maintained to the
body at all points and the mountings are evenly loaded.
♦ To avoid damage, the flexible joints in the front exhaust pipes
must not be bent more than 10°.
♦ After renewing particulate filter perform adaption in “Guided
Fault Finding” ⇒ Vehicle diagnostic tester.
Assembly overview - exhaust system ⇒ page 303 .

Assembly overview - front exhaust pipe and catalytic converter
⇒ page 306 .
Assembly overview - exhaust manifold and intermediate pipes
⇒ page 307 .
1.1 Assembly overview - exhaust system
Note
AG. Volkswagen AG d
agen oes
ksw
If the particulate filter Vor the exhaust gas pressure sensor
not
ar 1 -
ol
by gu
G450- is changed, rise the exhaust gas pressure sensor 1 - aG450-
d
nte
must alwaysaubetho adapted using diagnostic tester : Guided e or
functions; adapting exhaust pressure sensor 1 - G450- .
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
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. Parts of the exhaust system 303

lkswage es n
o ot g
byV ua
ed ran
Phaeton 2003 ➤ horis tee
t
u (3.0 l engine, common rail) - Edition 04.2016 or a
6-cylinder diesel enginea c
ss
ce
e
nl
pt
du
an
itte
y li
2 - Lambda probe - G39-
erm
ab
ility
ot p
❑ Remove with Lambda
wit
probe open ring span‐ , is n
h re
ner set - 3337- .
hole
spec
es, in part or in w
3 - Exhaust gas temperature
t to the co
sender 2 for bank 1 - G448-
rrectness of i
4 - Front exhaust pipe
l purpos
5 - 25 Nm
6 - Gasket
nform
ercia
❑ Renew.
m
at
om
7 - Temperature sender before
ion
c
particulate filter - G506-
in t
or
his
te
a
do
priv
c
❑ Lower the gearbox
um
for
en
g
slightly if necessary to
n
t.
yi Co
loosen and remove the . Cop py
connector cable
t rig
gh ht
pyri by
Vo
co
8 - Pressure pipes
by lksw
cted agen
Prote AG.
❑ To exhaust gas pres‐
sure sensor 1 - G450- ,
location ⇒ page 305 .
9 - Diesel particulate filter
10 - Double clamp
❑ Installation position
⇒ page 305 .
11 - 25 Nm
12 - Mounting
13 - 25 Nm
14 - Rear silencer
❑ Left side.
15 - Rear silencer
❑ Right side.
16 - Separating point
❑ Centre and rear silencers are installed as a single component during production. In cases of repair, the
Y pipe and rear silencer are supplied separately, including a double clamp for purposes of connection.
❑ The notches to the left and right of the separating points must be visible following the installation of the
double clamp.
❑ Installation position ⇒ page 305 .
17 - Y-pipe
18 - 27 Nm
304 Rep. gr.26 - Exhaust system

Phaeton 2003 ➤
Fitting location exhaust gas pressure sensor 1 - G450-

1 - Exhaust gas pressure sensor 1 - G450-
2 - Pressure line, see note ⇒ page 305 .
A - Securing bolt, specified torque: 4 Nm
B - Securing bolt, specified torque: 20 Nm
C - Securing bolt, specified torque: 8 Nm
Note
♦ The pressure lines from the particulate filter to the pressure

sensor G450 are checked for leaks, for this reason they must
be renewed only as unit. To remove and install bolt -C-, slightly
lower gearbox at rear if necessary.
♦ If the particulate filter or the exhaust gas pressure sensor 1 -
G450- is changed, the exhaust gas pressure sensor 1 - G450-
must always be adapted using diagnosis tester : Guided
functions; adapting exhaust pressure sensor 1 - G450- .
Aligning exhaust system

Prerequisite:
• Exhaust system cold
– Push exhaust system in direction of travel -1- and tighten dou‐
ble clamps until dimension -a- is attained at the mountings. Y
pipe: dimension a = 10 mm, rear silencer: dimension a = 15
mm
AG. Volkswagen AG d
agen oes
Installation position of double
Vol clamp
ksw not
gu
by ara
ed
1- From diesel particulate
oris filter nte
eo
h
ut ra
2- To Y-pipe ss a c
ce
e
nl
3 - Three markings along circumference

pt
du
an
itte
y li
4 - Dimension = 5 mm
erm
ab
ility
ot p
5 - Angle 5°
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Installation position, repair double clamp in direction of travel

rrectness of i
1 - The end of the bolt must not project beyond lower edge of
l purpos
clamp.
2 - Angle between 10° and 15°
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
305
cted agen
Prote AG.
1. Parts of the exhaust system
Phaeton 2003 ➤
1.2 Assembly overview - front exhaust pipe and catalytic converter
2 - Lambda probe - G39-
3 - Decoupling element AG. Volkswagen AG d
agen oes
olksw not
yV gu
4 - Gasket ed b ara
nte
ris
❑ Renew. autho eo
ra
ss c
5 - Front mounting
ce
e
nl
pt
du
an
itte
y li
erm
ab
6 - Mounting
ility
ot p
❑ Joint to subframe.
wit
, is n
h re
7 - 25 Nm
hole
spec
es, in part or in w
8 - Turbocharger
t to the co
9 - 25 Nm
❑ Renew.
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.

Phaeton 2003 ➤
1.3 Assembly overview - exhaust manifold and intermediate pipes
1 - Turbocharger
2 - 25 Nm
3 - Seal
❑ Renew.
4 - Y-piece
5 - Gasket
❑ Renew.
❑ Left cylinder bank.
AG. Volkswagen AG d
7 - 22 Nm ksw
agen oes
not
ol
yV gu
8 - Exhaust manifold ised b ara
nte
or
❑ Left cylinder
aut bank.
h eo
ra
ss c
9 - Exhaust manifold
ce
e
nl
pt
du
❑ Right cylinder bank.
an
itte
y li
erm
ab
ility
ot p
❑ Right cylinder bank.
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.
1. Parts of the exhaust system 307

Phaeton 2003 ➤
2 Exhaust gas recirculation system,

engine code BMK
Assembly overview - exhaust gas recirculation system
⇒ page 308 .
Check mechanical exhaust gas recirculation valve ⇒ page 309 .
Removing and installing mechanical exhaust gas recirculation
valve ⇒ page 310 .
Removing and installing exhaust gas recirculation cooler
⇒ page 310 .
2.1 Assembly overview - exhaust gas recirculation system

gas recirculation
2 - Gasket agen
AG. Volkswagen AG d
oes
lksw not
❑ Renew. by
Vo gu
ara
ed
is nte
3 - 25 Nm ut
hor eo
a ra
s c
4 - Vacuum hose s
ce
le
un
pt
5 - Bracket for exhaust gas re‐
an
d
itte
y li
circulation cooler
erm
ab
ility
❑ With connection for
ot p
wit
coolant hose.
is n
h re
ole,
6 - O-ring
spec
❑ Renew.
t to the co
7 - 9 Nm
8 - Coolant hose
rrectne
9 - 9 Nm
ss
10 - Exhaust gas recirculation

o
cial p
cooler
inform
mer

atio
⇒ page 310
om
n
c
i
or
11 - Coolant hose
thi
te
sd
va
12 - Coolant hose
i
o
pr
cum
r
fo
en
ng
13 - Gasket yi
t.
Co
op
❑ Renew.
C py
t. rig
gh ht
yri by
14 - Vacuum hose
op Vo
by c lksw
cted agen
❑ From changeover valve Prote AG.
for exhaust gas recircu‐
lation cooler - N345- .
15 - Vacuum unit for exhaust
gas recirculation changeover
function
16 - 4 Nm
17 - Gasket
❑ Renew.

Phaeton 2003 ➤
18 - 25 Nm
19 - Connecting pipe for exhaust gas recirculation
wage es n
20 - Changeover flap for exhaust gas recirculation cooler yV
olks ot g
ua
d b ran
21 - Coolant hose ir se tee
tho
u or
a ac
22 - 9 Nm ss
ce
le
un
pt
23 - Connection for coolant hose
an
d
itte
y li
24 - O-ring
erm
ab
ility
ot p
❑ Renew.
wit
is n
h re
25 - 9 Nm ole,
spec
26 - 9 Nm
t to the co
27 - Bracket for change-over flap for exhaust gas recirculation cooler
28 - 9 Nm
rrectne
29 - Gasket
s
❑ Renew.
s o
cial p
f i
30 - Mechanical exhaust gas recirculation valve
nform
mer
atio
om
31 - 9 Nm
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
2.2 Checking mechanical exhaust gas recir‐

fo
en
ng
t.
yi
culation valve
Co
Cop py
t. rig
gh ht
yri by
Special tools and workshop equipment required cop Vo
by lksw
cted agen
Prote
♦ Hand vacuum pump with accessories - V.A.G 1390-
AG.
Test procedure
– Pull vacuum hose off exhaust gas recirculation valve.
– Connect hand vacuum pump with accessories - V.A.G 1390-
to valve.
– Operate hand vacuum pump a few times.
– Pull hand vacuum pump hose off exhaust gas recirculation
valve. The diaphragm rod must audibly return to its original
position.
2. Exhaust gas recirculation system, engine code BMK 309

Phaeton 2003 ➤
2.3 Removing and installing mechanical ex‐

haust gas recirculation valve
Removing
– Remove bolts -arrows- and remove mechanical exhaust gas
recirculation valve with connecting pipe.
Installing
note the following:
Note
2.4 Removing and installing exhaust gas re‐

circulation cooler
Removing
AG. Volkswagen AG d
agen
– Drain coolant ⇒ page
Vol 173 .
ksw not
gu
oes
d by ar
– Remove upper orisepart of intake manifold ⇒ page 232 . ante
eo
th
au ra
– Removesslower part of left and right intake manifolds c
⇒ page 243 .
ce
e
nl
pt
du
an
– Remove bolts -arrows- and remove mechanical exhaust gas

itte
y li
erm
recirculation valve with connecting pipe.

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.

Phaeton 2003 ➤
– Disconnect hose -arrow-.

– Unscrew bolts -1 … 6-.
Note
To remove exhaust gas recirculation cooler, the retainer for the

cooler, along with the unions for the coolant, must be pulled up‐
wards out of the cylinder head ⇒ Item 5 (page 308) or pulled out
using puller - T10055- and a suitable adapter..
– Lift off left cooler for exhaust gas recirculation from cylinder
block.
Installing
note the following:
AG. Volkswagen AG d
Note lksw
agen oes
not
o
byV gu
ara
d
♦ Renew seals and O-rings. ise nte
or eo
h
ut ra
♦ Secure all hose connections with shose clips which conform to
s a 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.
2. Exhaust gas recirculation system, engine code BMK 311

Phaeton 2003 ➤
3 Exhaust gas recirculation, engine co‐

des CARA, CEXA, CEXB
Assembly overview - exhaust gas recirculation system
⇒ page 312 .
Removing and installing exhaust gas recirculation control motor
- V338- ⇒ page 313 .
Removing and installing exhaust gas recirculation cooler
⇒ page 314 . AG. Volkswagen n AG do
ks wage es
Removing and installing exhaust Vol gas recirculation temperature
not
gu
by
sensor - G98- ⇒ page 316ris
e.d ara
nt ee
ho
ut or
3.1 Assembly overview - exhaust gas recirculation system
ss
a ac
ce
le
un
pt
an
d
itte
1 - Bolt
y li
erm
ab
❑ 9 Nm
ility
ot p
wit
is n
2 - Bracket
h re
ole,
❑ For exhaust gas recircu‐
spec
lation system.
t to the co
gas recirculation
rrectne
4 - Bolt
❑ 25 Nm
5 - Bolt ss o
cial p
f inform
❑ 9 Nm
mer
atio
m
6 - Gasket
o
n
c
i
or
❑ Renew.
thi
te
sd
va

i
o
pr
cum
temperature sensor - G98-

r
fo
en
ng
t.
yi
❑ 45 Nm
Co
Cop py
.
t rig
gh ht
yri by
⇒ page 316 cop Vo
by lksw
cted agen
Prote
8 - Coolant hose
AG.
9 - Connection with thermostat

for exhaust gas recirculation
10 - Retaining clip
11 - O-ring
❑ Renew.
cooler
⇒ page 314
13 - Coolant hose
14 - Coolant hose
15 - Bolt
❑ 9 Nm
16 - Gasket
❑ Renew.

Phaeton 2003 ➤
17 - Vacuum hose
❑ From exhaust gas recirculation cooler changeover valve - N345- .
18 - Vacuum unit for exhaust gas recirculation changeover function
19 - Bolt
❑ 4 Nm
20 - Connecting pipe for exhaust gas recirculation n AG. Volkswagen AG do
lkswage es n
o ot g
21 - Bolt d byV ua
ran
ir se
❑ 25 Nm utho tee
or
a ac
22 - Gasket ss
ce
e
nl
pt
❑ Renew.
du
an
itte
y li
23 - Changeover flap for exhaust gas recirculation cooler
erm
ab
ility
ot p
24 - Coolant hose
wit
, is n
h re
25 - Gasket
hole
spec
❑ Renew.
es, in part or in w
t to the co
26 - Exhaust gas recirculation control motor - V338-
❑ With exhaust gas recirculation potentiometer - G212- .
rrectness of i
l purpos
27 - Coolant hose
28 - Bolt
nf
ercia
o
❑ 9 Nm
rm
m
atio
om
n in
or c
thi
e

t
sd
iva
o
r
rp
cu
circulation control motor - V338-
o
m
f
en
ng
t.
yi Co
Removing t. Cop py
rig
gh ht
yri
– Drain coolant ⇒ page 173 . p by
co Vo
by lksw
cted agen
– Carefully pull engine cover panel off four retaining pins one Prote AG.
– Unscrew bolt -left arrow- and remove retaining clip.

– Unscrew union nuts -1 … 4- and remove high-pressure lines.
Note
Disregard -right arrow-.
3. Exhaust gas recirculation, engine codes CARA, CEXA, CEXB 313

Phaeton 2003 ➤

– Remove oil filter housing ⇒ page 163 .
– Remove connection -arrow- with thermostat for exhaust gas
recirculation. Pull off retaining clip to do this.
– Remove electrical connection -2- for exhaust gas recirculation

temperature sensor - G98- from bracket and separate.
Note
Disregard -item 1-.
– Separate electrical connection -arrow- for exhaust gas recir‐

culation control motor - V338- .
wage es n
– Unscrew bolts -1, 2, 3-, remove exhaust gas recirculation con‐ Vol
ks ot g
by ua
trol motor - V338- and remove from coolant hose -4-. ise d ran
tee
r
ho
Installing aut or
ac
ss
ce
• Specified torque ⇒ page 312 .
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
Note
h re
ole,
spec

t to the co
– Install oil filter housing ⇒ page 163 . rrectne

ss o

cial p
f inform
mer

atio
om
circulation cooler
n
c
i
or
n thi
te
sd
a
Removing
iv
o
pr
cum
r
fo

en
ng
t.
yi Co
op
– Remove upper and lower parts of right intake manifold C py
t. rig
gh
⇒ page 234 .
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Phaeton 2003 ➤
– Remove banjo bolt -3- and disconnect oil supply pipe from
turbocharger.
Note
Disregard -item 1, 2-.

AG. Volkswagen AG d
agen oes
lksw not
– Remove rear left coolant by V pipe.
o gu
ara
ed
is nte
– Remove exhaustuthgas recirculation control motor - V338-
or eo
⇒ page 313 . ss a ra
c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
– Carefully press of linkage -2- from ball head -arrow-.
wit
is n
h re
– Unscrew bolts -3- and remove intake manifold flap 2 motor -
ole,
spec
V275- -item 4-.
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
– Remove bolts -arrows- and -1-. ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Pull off vacuum hose -arrow- from control motor for exhaust
gas recirculation flap.
– Remove bolts -1 … 5-.

Phaeton 2003 ➤
– Remove coolant hose -top right arrow-.

– Unscrew bolt -2- and push rear coolant pipe to slightly to one
side.
Note
To remove exhaust gas recirculation cooler, the retainer for the

cooler, along with the unions for the coolant, must be pulled up‐
wards out of the cylinder head ⇒ Item 2 (page 312) or pulled out
using puller - T10055- and a suitable adapter..
– Lift off left cooler for exhaust gas recirculation from cylinder
block.
Installing
• Specified torque ⇒ page 312 . AG. Volkswagen AG d
agen oes
olksw not
y V gu
Installation is carried out in the reverse order; noteisethe
d b following: ara
nte
or eo
th
au ra
ss c
Note
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Install intake manifold flap 2 motor - V275- ⇒ page 236 .
es, in part or in w
t to the co
– Install control motor for exhaust gas recirculation - V338-
⇒ page 313 .
rrectness of i
– Install rear right coolant pipe.
l purpos
– Install rear left coolant pipe.

– Install upper and lower parts of right intake manifold
nform
ercia
⇒ page 234 .
m
at
om
ion
c
in t
or
his

ate
do
riv
circulation temperature sensor - G98-

p
cum
for
en
ng
t.
yi
Co
Cop py
t. rig
gh
♦ Socket - T40055-
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Phaeton 2003 ➤
Removing
– Remove electrical connection -2- for exhaust gas recirculation
temperature sensor - G98- from bracket and separate.
– Unscrew exhaust gas recirculation temperature sensor - G98-
-item 1- using socket insert - T40055- .
Installing
• Specified torque ⇒ page 312 .
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
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
co lksw
by
cted agen
Prote AG.

Phaeton 2003 ➤
28 – Glow plug system

AG. Volkswagen AG d
1 Glow plug system y Volksw
agen oes
not
gu
d b ara
rise nte
ho eo
Caution s aut ra
c
s
ce
e
nl
The ceramic glow plugs ⇒ page 318 are sensitive to jolts and
pt
du
an
bending. For this reason a glow plug which has dropped from
itte
y li
erm
a small height (approx. 2 cm) must not be used, even if there
ab
ility
is no obvious damage. It is absolutely essential to follow the
ot p
wit
installation instructions, otherwise the heater pin of the glow
, is n
h re
plug can break and cause engine damage.
hole
spec
es, in part or in w
t to the co
Glow plug characteristics ⇒ page 318
Removing, installing and checking ceramic glow pin plugs
rrectness of i
⇒ page 318
l purpos
Removing and installing metal glow plugs ⇒ page 320

Checking metal glow plugs ⇒ page 321
nf
ercia
or
1.1 Glow plug characteristics
m
m
atio
om
n in
Visual features of ceramic glow pin plugs
or c
thi
te
sd
iva
o
r
WARNING
rp
cu
o
m
f
en
ng
t.
yi Co
Ceramic glow plugs are sensitive to knocks and bending. For Cop py
this reason a glow plug which has dropped from a small height
t. rig
gh ht
yri
(approx. 2 cm) must not be used, even if there is no obvious
p by
co Vo
by lksw
damage. It is absolutely essential to follow the installation in‐ Prote
cted AG.
agen
structions, otherwise the heater pin of the glow plug can break
and cause engine damage.
-A- = Ceramic glow plug, phase step on top (see enlargement),

colour-coded white -arrow-.
-B- = Metal glow plug, colour-coded red -arrow-.
Remove, install or check ceramic glow pin plugs ⇒ page 318 .
Removing, installing and checking metal glow plugs
⇒ page 320
1.2 Removing, installing and checking ceramic glow pin plugs
318 Rep. gr.28 - Glow plug system

Phaeton 2003 ➤

equipment required
♦ Jointed spanner - 3220-
♦ Torque wrench (5…50 Nm)
- V.A.G 1331-
♦ Hand-held multimeter -
V.A.G 1526 A-
♦ Auxiliary measuring set -
V.A.G 1594 C-
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
Test prerequisites
y li
erm
ab
ility
• Engine is cold
ot p
wit
, is n
• Ignition switched off h re

hole
spec
Removing
es, in part or in w
t to the co
Note
rrectness of i
Do not cant ceramic glow plugs when removing and installing.

l purpos
Remove any components hindering assembly.

nf
ercia
– Before removal, the ceramic glow plugs must be burnt clean

or
using the final control diagnosis function in the diagnostic test‐

m
m
atio
er.
om
n in
or c
– Before removing the ceramic glow plugs, always detach any

thi
te
ancillary components which restrict access (e.g. upper and

sd
iva
o
r
lower parts of intake manifold).

rp
cu
o
m
f
en
ng
– Disconnect the connector from the glow plug to be removed.

t.
yi Co
Cop py
. rig
– To loosen the glow plugs use U/J extension and socket, 10 mm
ht ht
rig by
py
- 3220- . co Vo
by lksw
cted agen
Prote
– Then unscrew the ceramic glow plug carefully by hand or using
AG.
a suitable length of hose (approx. 25 cm; Part No.
1. Glow plug system 319

Phaeton 2003 ➤
N 0201 5005, sold by the metre). Keep the glow plug straight
while unscrewing.
– Carefully pull ceramic glow pin plugs out from above using a
suitable tool (such as a length of hose). Prevent glow plugs
from contacting other parts.
Installing
– Screw in ceramic glow plugs hand-tight.
WARNING AG. Volkswagen AG d

agen oes
olksw not
V
It is important to keep to the specified d btorque for glow pin plugs:
y gu
ara
12 Nm (threads dry and free of oil ise grease). The heater pins
and
r nte
tho eo
of the glow plugs can break sifa this specified torque is not ob‐
u ra
c
served, which would invariably s cause engine damage.
ce
e
nl
pt
du
After installing and before the engine is started, perform a re‐
an
itte
y li
sistance test on all ceramic glow plugs when engine is cold.
erm
ab
ility
ot p
wit
, is n
h re
After installation, check electrical resistance directly at glow pin
hole
plug. Specification: max. 1 Ω.
spec
es, in part or in w
– If the specification is exceeded, renew the defective ceramic
t to the co
glow plug.
rrectness of i
Note
l purpos
If the defective ceramic glow plug is broken, remove all fragments

from the engine, otherwise these can cause damage to the en‐
nform
ercia
gine.
m
at
om
ion
– Reconnect electrical connectors on ceramic glow plugs. Make
c
in t
or
sure that connector engages properly.

his
ate
do
riv
Additionally check ceramic glow pin plugs via self-diagnosis.

p
cum
for
en
ng
– Clear fault memory of engine control unit. Do not start engine

t.
yi Co
op
at this stage.
C py
t. rig
gh ht
yri by
– Perform final control diagnosis ( automatic glow period control cop Vo
by lksw
unit - J179- ). cted agen
Prote AG.
– Read the fault memory again. Do not start the engine when
doing this.
– The engine must not be started if the fault memory has regis‐
tered a fault relating to the ceramic glow plugs. Check electri‐
cal connectors and renew relevant ceramic glow plug if
necessary.
1.3 Removing and installing metal glow

plugs

Phaeton 2003 ➤
♦ Jointed wrench 10 mm - 3220-
♦ Torque wrench (5…50 Nm) - V.A.G 1331-
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
Procedure
ility
ot p
wit
, is n
h re
hole
– Pull glow plug connectors off glow plugs.
spec
es, in part or in w
– Before removal, always detach any ancillary components
t to the co
which restrict access (e.g. upper and lower parts of intake
manifold).
rrectness of i
– To loosen the glow plugs use U/J extension and socket, 10 mm
- 3220- .
l purpos

note the following:
nform
ercia
– Screw glow plugs into cylinder head manually using U/J ex‐
m
at
om
tension and socket, 10 mm - 3220- .

ion
c
in t
or
– Tighten glow plugs to 15 Nm.

his
ate
do
riv
1.4 Checking metal glow plugs

p
cum
for
en
ng
t.
yi
Co
Cop py
ht. rig
♦ Jointed spanner - 3320- rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Glow plug system 321

Phaeton 2003 ➤
♦ Auxiliary measuring set - V.A.G 1594 A-
♦ Diode test lamp - V.A.G 1527-

Test prerequisites
• Battery voltage at least 11.5 V
• Ignition switched off
Test procedure
– Pull glow plug connectors off glow plugs.
– Connect diode test lamp cable to battery positive using adapt‐
er clips from auxiliary measuring set.
n AG. Volkswagen AG age does
ksw n
– Place diode test lamp probe y V on each glow plug one after t the
ol o g
ua
db
other. Diode lights up:
ris
eglow plug OK., diode does not light up:rante
renew glow plug.aut ho eo
ra
ss c
– Remove and install glow plugs with U/J extension and 10 mm
ce
le
un
socket - 3220- . Specified torque: 15 Nm.

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

SM 31

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SM 31

Uploaded by

Copyright:

Available Formats

Service Volksw

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

BMK CAR CEX CEX

Service Department. Technical Information

All rights reserved.

Copyright © 2016 Volkswagen AG, Wolfsburg K0058952220

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3 Chain drive (engine codes CARA, CEXA, CEXB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

3.1 Assembly overview - drive chain for valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

3.2 Removing and installing drive chain for valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

4 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

4.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

4.4 Measuring radial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

5.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

5.2 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

5.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

5.4 Checking radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

1.3 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

2.1 Assembly overview - oil pump, lower part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

2.2 Removing and installing lower part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

2.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

3.2 Removing and installing oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

3.3 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

3.7 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

1.7 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

1.8 Removing and installing intake manifold upper part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

1.4 Checking metal glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

Engine number ⇒ page 1

1.1 Engine number

be found on the identification plate, the vehicle data sticker and

on the engine control unit.

Vehicles for some countries do not have an identification plate.

Locations of vehicle data plate and data sticker ⇒ Maintenance

1.2 Engine data

Engine code BMK CARA CEXA CEXB

Manufactured 10.04 ► 05.07 ► 03.08 ► 11.13 ►

Capacity l 3.0 3.0 3.0 3.0

165/4000 175/4400 176/4400 180/4000

Torque Nm at rpm 450/1400 … 3250 500/1750 500/1750 500/1750

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

Engine code BMK CARA CEXA CEXB

2 Rep. gr.00 - Technical data

10 – Removing and installing engine

1.1 Removing engine

1. Removing and installing engine 3

♦ To prevent damage to removed components, place them in

♦ Before disconnecting batteries, move wiper arms to service

– Switch off ignition and all electrical consumers.

– Extract air conditioning refrigerant ⇒ Heating, air conditioning;

4 Rep. gr.10 - Removing and installing engine

– Disconnect cable connections -1-, -2- and -3-, pull positive

– Disconnect all connectors -A- for engine wiring harness and

– Remove charge air pipe -A-, separate connector -B-, loosen

1. Removing and installing engine 5

– Detach lines -A- from air conditioner compressor.

– Unclip coolant lines -1- from plenum chamber bulkhead.

-3- and -4-. Lay engine-side cable ends on engine.

– Separate vacuum line for brake servo at the points indicated

– Place a cleaning cloth in area of servo pump.

– Clamp servo line off as shown using a hose clip - 3094- .