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Repair Manual

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6-Cylinder Diesel Engine (3.0L Engine, Common Rail,

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Service Department. Technical Information

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List of Workshop Manual Repair Groups

Repair Group AG. Volkswag e nAG d

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00 - General, Technical Data by
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10 - Engine Assembly th o e or
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13 - Crankshaft, Cylinder Block ss

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15 - Cylinder Head, Valvetrain

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17 - Lubrication
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19 - Cooling System

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21 - Turbocharger, Supercharger
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23 - Diesel Fuel Injection

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26 - Exhaust System, Emission Controls
28 - Ignition/Glow Plug System

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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2017 Volkswagen AG, Wolfsburg D4B8028802A

 Touareg 2010 ➤ , Touareg 2015 ➤
6-Cylinder Diesel Engine (3.0L Engine, Common Rail, Generation II) - Edition 11.2017

Contents

00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine Number/Engine Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Safety Precautions when Working on Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Safety Precautions when Working on Vehicles with Start/Stop System . . . . . . . . . . . . . . 3
2.3 Safety Precautions during Road Test with Testing Equipment . . . . . . . . . . . . . . . . . . . . . . 4
2.4 Safety Precautions when Working on Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5 Safety Precautions when Working on SCR System . ..V.o.lk.sw. a. g.e. . . . . . . . . . . . . . . . . . . . . . 4
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2.6 Exhaust System Safety Precautions . . . . o . k. s.w.ag. e. . . . . . . . . . . . . . d. o.e.s n
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3 Repair Information . . . . . . . . . . . . . i.se. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ar.a.nt. . . . . . . . . .
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3.1 Clean Working Conditions . . . . a.u .th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . e.or.a. . . . . . . 6
3.2 Selective Catalytic Reduction (SCR)-ss
System Adaptation Value, Adapting . . . . . . c. . . . . . 6

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3.3 Engine Contaminants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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3.4 Contact Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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3.5 Wire Routing and Securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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3.6 Cooler and Condenser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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10 - Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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1 Engine, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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1.1 Engine, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Engine and Transmission, Separating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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1.3 Engine, Securing on Engine and Transmission Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.4 Engine, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2 Subframe Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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2.1 Overview - Subframe Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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2.2 Engine Mount, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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2.3 Engine Support, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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2.4 Engine, Supporting in Installed Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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3 Engine Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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3.1 Engine Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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13 - Crankshaft, Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 by cop Vo
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1 Cylinder Block, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Prote
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1.1 Overview - Ribbed Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

1.2 Overview - Belt Pulley Side Sealing Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.3 Ribbed Belt, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.4 Ribbed Belt Tensioner, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.5 Vibration Damper, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.6 Auxiliary Components Bracket, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.7 Crankshaft Seal, Replacing, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.8 Sealing Flange, Removing and Installing, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . 58
1.9 Belt Pulley Side Sealing Flange Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . 61
2 Cylinder Block, Transmission Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.1 Overview - Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.2 Drive Plate, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.3 Sensor Wheel, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.4 Sensor Wheel, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.5 Crankshaft Seal, Replacing, Transmission Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.1 Overview - Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

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6-Cylinder Diesel Engine (3.0L Engine, Common Rail, Generation II) - Edition 11.2017

3.2 Crankshaft Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

3.3 Main Bearing Shells Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.4 Crankshaft, Measuring Axial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.5 Crankshaft, Measuring Radial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4 Balance Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.1 Overview - Balance Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.2 Balance Shaft Roller Bearing, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.3 Balance Shaft, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5 Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.1 Overview - Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.2 Piston Projection, Measuring at “Top Dead Center (TDC)” . . . . . . . . . . . . . . . . . . . . . . . . 77
5.3 Pistons and Cylinder Bore, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.4 Connecting Rods, Checking Radial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

15 - Cylinder Head, Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

1 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.1 Overview - Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.2 Overview - Cylinder Head Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.3 Cylinder Head, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.4 Cylinder Head Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
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1.5 Compression Pressure, Checking . . . k.sw. a. g.e.n.AG . . . . . . . . .n.A.G.d.o.e s. n. . . . . . . . . . . . . . . . . . . . 101
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2 Timing Chain Cover . . . . . . . . .e d. b.y. . . . . . . . . . . . . . . . . . . . . . . . . . u.a.ra.n. . . . . . . . . . . . . . 103
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2.1 Overview - Timing Chain Cover ut
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2.2 Timing Chain Cover, Removing ss and Installing . . . . . . . . . . . . . . . . . . . . . . . .c . . . . . . . . . . 106

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3 Chain Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

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3.1 Overview - Camshaft Timing Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

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3.2 Overview - Oil Pump and High Pressure Pump Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . 114

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3.3 Camshaft Timing Chain, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

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3.4 Camshaft Timing Chain, Removing from Camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
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3.5 Oil Pump and High Pressure Pump Drive Chain, Removing and Installing . . . . . . . . . . . . 130
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4 Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.1 Overview - Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.2 Camshaft, Measuring Axial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rre c 135
4.3 Camshaft, Measuring Radial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4.4 Camshaft, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4.5 Hydraulic Adjusting Elements, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
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4.6 Valve Stem Seals, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

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5 Intake and Exhaust Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

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5.1 Valve Seats, Reworking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

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5.2 Valve Guides, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

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5.3 Valves, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

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5.4 Valve Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

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6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
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1 Oil Pan/Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
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1.1 Overview - Oil Pan/Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

1.2 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.3 Oil Pan Lower Section, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
1.4 Oil Pan Upper Section, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
1.5 Oil Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
1.6 Oil Level Thermal Sensor, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2 Oil Filter/Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

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6-Cylinder Diesel Engine (3.0L Engine, Common Rail, Generation II) - Edition 11.2017

2.1 Overview - Oil Filter Housing/Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

2.2 Oil Filter Housing, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2.3 Oil Pressure Regulation Valve N428 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 191
2.4 Oil Pressure and Oil Pressure Switch, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2.5 Oil Pressure Switch, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
3 Engine Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3.1 Overview - Engine Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3.2 Engine Oil Cooler, Removing and Installing nA.G.. V.o. lk. s.w.a.g e. n.A.G. d.o. . . . . . . . . . . . . . . . . . . . . . . 195
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3.4 Engine Oil Cooler Thermostat, o
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4 Special Tools . . . . . . . . s.au. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .r .ac. . . . . . . . . . . . 198
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19 - Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

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1 Coolant System/Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
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1.1 Connection Diagram - Coolant Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

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1.2 Cooling System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

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1.3 Coolant, Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

spe c
1.4 Cooling System, Emptying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
u rpose s, inpart or inwh

t toth e co tne ss of inform

1.5 Fill Quality, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
2 Coolant Pump/Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

rre c
2.1 Overview - Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
2.2 Overview - Coolant Shut-Off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
2.3 Overview - Engine Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
cial p

2.4 Coolant Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

2.5 Coolant Thermostat, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
me r

2.6 Engine Coolant Temperature Sensor G62 , Removing and Installing . . . . . . . . . . . . . . . . 213

a
m

tion
o

2.7 Engine Coolant Temperature Sensor on Radiator Outlet G83 , Removing and Installing . . 214
c

int
or

2.8 Engine Temperature Control Temperature Sensor G694 , Removing and Installing . . . . . . 215

h is
te
iva

do
2.9 Coolant Shut-Off Valve, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
pr

cum
r
fo

3 Coolant Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

en
ng

t.
yi Co
3.1 Overview - Coolant Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Cop py
ht. rig
3.2 Coolant Pipes, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
g h
yri t by
y cop Vo
lksw
4 Radiator/Coolant Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
b
cte d ag e n
Prote AG.
4.1 Overview - Radiator/Coolant Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
4.2 Fan Shroud with Coolant Fan, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 228
4.3 Radiator, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
4.4 Radiator, Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

21 - Turbocharger, Supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
1.1 Overview - Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
1.2 Turbocharger, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
1.3 Turbocharger Control Module 1 J724 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 243
2 Charge Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
2.1 Overview - Charge Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
2.2 Overview - Charge Air Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
2.3 Charge Air Cooler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
2.4 Charge Air Pressure Sensor G31 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 259
2.5 Air Duct Pipe, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
2.6 Charge Air System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

23 - Diesel Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

Contents iii
 Touareg 2010 ➤ , Touareg 2015 ➤
6-Cylinder Diesel Engine (3.0L Engine, Common Rail, Generation II) - Edition 11.2017

1 Fuel Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

1.1 Schematic Overview - Fuel System . . . . . . . .ks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
AG. Vol wag e n d
1.2 Component Location Overview - Injection ag e n System . . A. G . . o.e.s .n. . . . . . . . . . . . . . . . . . . . . . . . 273
o lksw o
1.3 Fuel System, Filling/Bleeding by .V . . . . . . . . . . . . . . . . . . . . . . . . t .g u. a. . . . . . . . . . . . . . . . . . . . . 277
e d ran
s
1.4 Fuel System Leak Test th o.ri. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .te.e .o . . . . . . . . . . . . . . . . 277
au ra
2 Vacuum System . . s.s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .c. . . . . . . . . . . . . . . 278

ce
le
2.1 Connection Diagram - Vacuum System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

un

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an
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3 Fuel Injectors/High Pressure Reservoir (Rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

y li
rm

ab
3.1 Overview - Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
pe

ility
ot

3.2 Fuel Injectors, Adapting Correction Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

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, is n

h re
3.3 Fuel Injectors, Checking Return Quantity with Engine Running . . . . . . . . . . . . . . . . . . . . . . 282
h ole

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3.4 Fuel Injectors, Checking Return Quantity at Starting Speed . . . . . . . . . . . . . . . . . . . . . . . . 284
e s, inpart or inw

3.5 Open Fuel Injectors, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

t toth e co tne ss of infor

3.6 Fuel Return Line Restrictor, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
3.7 Fuel Injectors, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288

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3.8 High Pressure Lines, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
l pu rpos

4 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

4.1 Overview - Air Filter Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
e rcia

4.2 Air Filter Housing, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

m
m

5 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

a
com

tion
5.1 Overview - Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

int
r
te o

5.2 Intake Manifold, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

h is
iva

d
5.3 Intake Flap Motor V157 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304

o
r
rp

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m
5.4 Throttle Valve Control Module J338 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 306

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ng

i t.
py Co
6 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
t. Co py
rig 307
6.1 Fuel Pressure Regulator Valve N276 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 307
h g h
yri t by
op Vo
6.2 Fuel Pressure Sensor G247 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
by c lksw
cte d ag e n
Prote
6.3 Mass Airflow Sensor G70 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
AG.

6.4 Differential Pressure Sensor G505 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 313

6.5 NOx Sensor G295 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
6.6 NOx Sensor 2 G687 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
6.7 Particulate Sensor G784 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
7 Engine Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
7.1 Engine Control Module J623 with Protective Housing, Removing and Installing . . . . . . . . 317
8 High Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
8.1 Overview - High Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
8.2 High Pressure Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
9 Heated Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
9.1 Overview - Heated Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
9.2 Oxygen Sensor 1 before Catalytic Converter GX10 , Removing and Installing . . . . . . . . . . 327
10 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329

26 - Exhaust System, Emission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333

1 Exhaust Pipes/Mufflers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
1.1 Overview - Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
1.2 Tail Pipes, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
1.3 Exhaust System, Installing without Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
1.4 Exhaust System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
2 Emissions Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
2.1 Overview - Emissions Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
2.2 Catalytic Converter, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
2.3 Particulate Filter, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
2.4 Reducing Agent Catalytic Converter, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 344
3 Selective Catalytic Reduction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

iv Contents
 Touareg 2010 ➤ , Touareg 2015 ➤
6-Cylinder Diesel Engine (3.0L Engine, Common Rail, Generation II) - Edition 11.2017
AG. Volkswag e nAG d
ag e n o
3.1 Overview - Reducing Vol
ksw Agent Tank . . . . e. s.n.ot.g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
by ua
3.2 Overview ris
e - Reducing Agent Delivery Module . r.an
d . t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
o e
3.3 Overview
au th - Reducing Agent Delivery Line . . . . . . e. o.r a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
s c
3.4 Overview
s - Reducing Agent Injector N474 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350

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un
3.5 Reducing Agent Tank, Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

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3.6 Reducing Agent Tank, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354

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3.7 Reducing Agent Delivery Line, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 356
e

ility
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3.8 Reducing Agent Injector N474 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 358

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is n

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3.9 Reducing Agent Pump V437 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
ole ,

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3.10 Heating Element, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
u rpose s, inpart or inwh

t toth e co tne ss of inform

4 Reducing Agent Delivery Line, Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
5 Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
5.1 Overview - Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370

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5.2 Exhaust Manifold, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
6 Exhaust Temperature Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
cial p

6.1 Overview - Exhaust Temperature Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376

6.2 Exhaust Temperature Regulation Components, Removing and Installing . . . . . . . . . . . . . . 380
me r

a
7 Exhaust Gas Recirculation (EGR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
m

tion
co

7.1 Overview - Exhaust Gas Recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386

int
or

h is
te

7.2 EGR Motor V338 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388

iva

d o
pr

7.3 EGR Cooler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389

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m
7.4 EGR Temperature Sensor G98 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 390

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t.
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op
8 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
C py
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rig
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28 - Ignition/Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
by lksw
cte d ag e n
Prote AG.
1 Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
1.1 Overview - Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
1.2 Glow Plug, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
1.3 Engine Speed Sensor G28 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
1.4 Camshaft Position Sensor G40 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 395
2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
3 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397

Contents v
 Touareg 2010 ➤ , Touareg 2015 ➤
6-Cylinder Diesel Engine (3.0L Engine, Common Rail, Generation II) - Edition 11.2017

AG. Volkswag e nAG d

ag e n oe s
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vi Contents
 nAG. Volkswag e nAG d o
wag e es n
Volks ot g
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or Touareg 2010 ➤ , Touareg 2015 ➤
au ac
ss 6-Cylinder Diesel Engine (3.0L Engine, Common Rail, Generation II) - Edition 11.2017

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00 – General, Technical Data
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1 Identification
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(Edition 11.2017)

t toth e co tne ss of inform

⇒ “1.1 Engine Number/Engine Characteristics”, page 1

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1.1 Engine Number/Engine Characteristics
The engine number (“engine code” and “serial number”) is located
on the left side in the front under the high pressure pump toothed
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belt -arrow-.
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In addition, a sticker with “engine code” and “serial number” is

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tion
affixed to the intake manifold.
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The engine code is also included on the vehicle data plate.

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c
Four-digit engine codes beginning with “C” are used. The first

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three digits describe the mechanical structure of the engine and

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are still stamped on the engine, as before. The fourth digit de‐
Co
Cop py
scribes the engine output and torque and depends on the Engine ht. rig
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Control Module (ECM). The four-digit engine code is on the type cop by
Vo
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label, the vehicle data sticker and the ECM. Prote
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AG.

Note

Vehicles for some countries do not have a type label. Installed

locations for the vehicle data sticker and the type label. Refer to
⇒ Maintenance ; Booklet 29.1 .

Codes CNRB
Manufactured From 05/2012
Emission values in accordance with BIN5/ULEV2
Displacement liter 3.0
Output kW at RPM 176/4000
Torque Nm at RPM 550/2100
Bore diameter in mm 83.0
Stroke mm 91.4
Compression ratio 16.8
Fuel conforms to
Ignition sequence 1-4-3-6-2-5
Exhaust Gas Recirculation (EGR) yes
Turbocharger yes
Catalytic Converter yes
Particulate Filter yes
Charge air cooler yes
Oxygen sensor regulation yes
Valves per cylinder 4
Selective Catalytic Reduction (SCR system) yes

1. Identification 1
 Touareg 2010 ➤ , Touareg 2015 ➤
6-Cylinder Diesel Engine G. VolkEngine,
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Common
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Numbering begins on right side -A- as seen in direc‐ ac sa
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-C-. Cylinders are counted on each side in sequence. -B- = cyl‐
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2 Rep. Gr.00 - General, Technical Data

 Touareg 2010 ➤ , Touareg 2015 ➤
6-Cylinder Diesel Engine (3.0L Engine, Common Rail, Generation II) - Edition 11.2017
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⇒ “2.1 Safety Precautions when Working on au Fuel System”, ac
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⇒ “2.4 Safety Precautions when Working on Cooling System”,

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page 4

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⇒ “2.5 Safety Precautions when Working on SCR System”, page
4

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⇒ “2.6 Exhaust System Safety Precautions”, page 5

2.1 Safety Precautions when Working on

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WARNING

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Very hot fuel can burn your skin.

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♦ The temperature of the fuel lines may reach 100 °C (212

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°F) after stopping the engine. Let the fuel cool down before
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opening any line connections otherwise there is a danger
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♦ Wear safety gloves.
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♦ Wear protective eyewear.

There is a risk of injury due to the fuel being under pressure.

The fuel system is under pressure. Injuries are possible from fuel
spraying out.
Before opening the fuel system:
– Wear protective eyewear.
– Wear safety gloves.
– Reduce the pressure: place clean cloths around the connec‐
tion point and carefully open the connection point.

Risk of a fire due to leaking fuel.

When the battery is connected, the door contact switch activates
the fuel pump when opening the driver door. Leaking fuel can
ignite and start a fire.
– Before opening the fuel system, interrupt the power supply to
the fuel pump.

2.2 Safety Precautions when Working on

Vehicles with Start/Stop System
There is a risk of injury due to the engine starting unexpectedly.
The engine can start unexpectedly on vehicles with an activated
Start/Stop System. A message in the instrument cluster indicates
whether the Start/Stop System is activated.
– Deactivate the Start/Stop System: switch off the ignition.

2. Safety Precautions 3
 Touareg 2010 ➤ , Touareg 2015 ➤
6-Cylinder Diesel Engine (3.0L Engine, Common Rail, Generation II) - Edition 11.2017

2.3 Safety Precautions during Road Test

with Testing Equipment
There Is A Risk of Injury Due to Unsecured Testing Equipment.
If the front passenger airbag activates during an accident unse‐
cured testing equipment becomes a dangerous projectile.
– Secure testing equipment on the rear seat.
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2.4 Safety Precautions when Working on

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Cooling System

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There Is A Risk of Burns from Hot Coolant.

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The coolant system is under pressure when the engine is warm. is n

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Risk of scalding due to hot steam and hot coolant.
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– Wear safety gloves.

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– Wear protective eyewear.
– Reduce the pressure: cover the coolant reservoir cap with a

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cloth and carefully open.

2.5 Safety Precautions when Working on

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SCR System
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WARNING
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The reducing agent can cause skin irritation:

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♦ Avoid contact with skin and eyes! Wear protective gloves!

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♦ If reducing agent should get on your skin, wash it off im‐ . Co py
mediately with soap and water.
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♦ If reducing agent gets in your eye, rinse the eye for several
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minutes with water.
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♦ Never inhale or swallow the reducing agent!

♦ Should you swallow any reducing agent, rinse your mouth,
drink plenty of water and contact a doctor immediately.
♦ Make sure the reducing agent does not come into contact
with clothing or the vehicle body.
♦ If this occurs, wash immediately with clean water and then
dry with a lint-free cotton cloth.
♦ If the reducing agent has already crystallized, use warm
water and a sponge.
♦ Reducing agent that is not removed will crystallize and can
damage the affected surface.
♦ For information on storage and disposal. Ask the importer
about storage and disposal information that is specific to