Volkswagen Phaeton 2003 Workshop Manual

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Workshop Manual

Phaeton 2003 ➤

6-cylinder injection engine

Engine ID

AYT BKL BRK

Edition 02.2014

Service

Service Department. Technical Information

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List of Workshop Manual Repair Groups

Repair Group

00 - Technical data

10 - Removing and installing engine

13 - Crankshaft group

15 - Cylinder head, valve gear

17 - Lubrication

19 - Cooling

20 - Fuel supply system

24 - Mixture preparation - injection

26 - Exhaust system

28 - Ignition system

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.

Service

No reproduction without prior agreement from publisher.

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.2 Securing engine on engine and gearbox support VAS 6095 . . . . . . . . . . . . . . . . . . . . . . 14

1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.1 Part I: assembly overview - chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.2 Part II: assembly overview - cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1.3 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1.4 Removing and installing engine bracket and engine mounting on left or right side . . . . . . 26

1.5 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2 Sealing flange and dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2.2 Removing and installing seal, flywheel end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2.3 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2.4 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2.5 Renewing crankshaft oil seal, vibration damper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.6 Renewing crankshaft sealing flange -vibration damper side- . . . . . . . . . . . . . . . . . . . . . . . . 37

3 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3.2 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.3 Checking piston and cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.4 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4.2 Fitting sender wheel to crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.3 Allocation of crankshaft bearing shells (classification) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

1.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

1.3 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

1.4 Installing timing chain for intermediate shaft drive and camshaft drive . . . . . . . . . . . . . . . . 58

1.5 Installing camshaft adjuster with timing chain for camshaft drive . . . . . . . . . . . . . . . . . . . . 64

1.6 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

1.7 Assembly overview - cover part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

1.8 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

2.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

2.2 Removing and installing camshaft control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

2.3 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

2.4 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

2.5 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

2.6 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Phaeton 2003 ➤

6-cylinder injection engine - Edition 02.2014

Contents i

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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

1 Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

1.1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

1.2 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

1.3 Assembly overview - dismantling and assembling oil filter housing . . . . . . . . . . . . . . . . . . 98

1.4 Assembly overview - dismantling and assembling oil pump . . . . . . . . . . . . . . . . . . . . . . . . 100

1.5 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

1.6 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

1 Parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

1.1 Assembly overview - radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

1.2 Assembly overview - removing and installing fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

1.3 Assembly overview - parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . 111

1.4 Assembly overview - thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

1.5 Assembly overview - parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . 113

1.6 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

1.7 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

1.8 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

1.9 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

1 Parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

1.1 Assembly overview - fuel tank with attachments and fuel filter . . . . . . . . . . . . . . . . . . . . . . 120

1.2 Dismantling and assembling right side fuel delivery unit, fuel gauge sender and suction-jet

pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

1.3 Assembly overview - fuel delivery unit, fuel gauge sender and suction jet pump on left side

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

1.4 Schematic diagram of fuel lines and components in fuel tank . . . . . . . . . . . . . . . . . . . . . . 126

1.5 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 128

1.6 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

1.7 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

1.8 Removing and installing fuel delivery unit, fuel gauge sender and suction-jet pump, right side

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

1.9 Removing and installing fuel delivery unit, fuel gauge sender and suction-jet pump, left side

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

1.10 Removing and installing fuel tank with attachments and fuel filter . . . . . . . . . . . . . . . . . . . . 137

1.11 Checking fuel pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

2 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

2.1 Assembly overview - parts of activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . 148

2.2 Checking activated charcoal filter system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

3 Checking electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

1.1 General notes on injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

1.2 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

1.3 Assembly overview - fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

1.4 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

1.5 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

1.6 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

1.7 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

2 Checking components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

2.1 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

2.2 Checking fuel pressure regulator and holding pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Phaeton 2003 ➤

6-cylinder injection engine - Edition 02.2014

ii Contents

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3 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

3.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

3.2 Reading and erasing engine control unit fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

1 Parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

1.1 Assembly overview - exhaust manifold with starter catalytic converters and attachments

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

1.2 Exhaust pipes with main catalytic converters and silencers with mountings . . . . . . . . . . . . 172

1.3 Removing and installing exhaust manifolds and exhaust pipes with starter catalytic

converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

2 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

2.1 Assembly overview - parts of secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

2.2 Checking combination valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

1.1 Assembly overview - parts of ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

1.3 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 182

1.4 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Phaeton 2003 ➤

6-cylinder injection engine - Edition 02.2014

Contents iii

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Phaeton 2003 ➤

6-cylinder injection engine - Edition 02.2014

iv Contents

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00 – Technical data

1 Technical data

(VRL006351; Edition 02.2014)

Engine number ⇒ page 1

Engine data ⇒ page 1

1.1 Engine number

The engine number (“engine code” and “serial number”) is located

next to the vibration damper on the cylinder block.

Additionally, a sticker with “engine code” and “serial number” is

attached to the intake manifold.

The engine code is also included on the vehicle data sticker.

1.2 Engine data

Engine code AYT BKL

BRK

1)

Manufactured 05.02 ► 09.03 ► 05.04 ►

Cylinder arrangement

VR

2)

VR

2)

VR

2)

Cylinder angle 15.0° 15.0° 15.0°

Capacity l 3.2 3.2 3.2

Output kW at rpm 177/6200 177/6200 177/6200

Torque Nm at rpm 315/2400 315/2400 315/2400

Bore ∅ mm 84.0 84.0 84.0

Stroke mm 95.9 95.9 95.9

Compression ratio 11.25 10.85 10.85

Valves per cylinder 4 4 4

RON min.

98 unleaded

3)

98 unleaded

3)

98 unleaded

3)

1) Emissions limit in accordance with EU2 norm, China only

2) VR = V-arrangement in compact in-line design

3) In exceptional circumstances min. 95 RON, however with reduced perform‐

ance.

Engine code AYT BKL BRK

Injection, ignition Motr. ME7.1.1 Motr. ME7.1.1 Motr. ME7.1.1

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

Knock control 2 knock sensors 2 knock sensors 2 knock sensors

Lambda control 4 probes 4 probes 4 probes

Catalytic converter yes yes yes

Exhaust gas recirculation no no no

Turbocharging/supercharging no no no

Secondary air system yes yes yes

Electronic power control yes yes yes

Phaeton 2003 ➤

6-cylinder injection engine - Edition 02.2014

1. Technical data 1

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Engine code AYT BKL BRK

Variable intake manifold yes yes yes

Camshaft timing control

yes

4)

yes

4)

yes

4)

4) Two independently variable camshafts

Phaeton 2003 ➤

6-cylinder injection engine - Edition 02.2014

2 Rep. gr.00 - Technical data

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.

10 – Removing and installing engine

1 Removing and installing engine

Special tools and workshop

equipment required

♦ Lifting tackle - 3033-

♦ Assembly tool - 3213-

♦ Engine and gearbox sup‐

port - VAS 6095-

♦ Drip tray - V.A.G 1306-

♦ Workshop hoist -

VAS 6100-

♦ Scissor-type assembly

platform - VAS 6131-

Not illustrated:

♦ Left engine support - VAS 6131/3-1-

♦ Right engine support - VAS 6131/3-2-

♦ Universal engine support - VAS 6131/1-1-

♦ Universal gearbox support - VAS 6131/1-2-

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

Phaeton 2003 ➤

6-cylinder injection engine - Edition 02.2014

1. Removing and installing engine 3

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♦ Stepladder - VAS 5085-

♦ Spring-type clip pliers -

VAS 5024 A-

♦ Guide rods - 3411-

♦ Torque wrench - V.A.G

1331-

♦ Torque wrench - V.A.G

1332-

Not illustrated:

♦ Universal subframe support - VAS 6131/1-3-

♦ Universal gearbox console support - VAS 6131/1-4-

♦ Securing pins - VAS 6131/1-5-

♦ Securing pins - VAS 6131/1-6-

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

♦ Grease - G 000 100-

♦ Cable ties

Removing engine ⇒ page 4 .

Securing engine to assembly stand ⇒ page 14 .

Installing engine ⇒ page 15 .

1.1 Removing engine

The engine is removed downwards with gearbox.

– Read fault memories of all control units before removing ⇒ Ve‐

hicle diagnostic tester.

Phaeton 2003 ➤

6-cylinder injection engine - Edition 02.2014

4 Rep. gr.10 - Removing and installing engine

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Note

♦

To enable the propshaft to rotate freely, move selector lever

to the “N” position.

♦

Leave key in ignition to prevent steering wheel lock from en‐

gaging.

♦

Some components cannot be removed, or removed only with

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

termine all defective components before removing engine and

renew them while engine is removed.

♦

To prevent damage to removed components, place them in

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

♦

All cable ties which are opened or cut through when engine is

removed must be replaced in the same position when engine

is installed.

♦

Before disconnecting batteries, move wiper arms to service

position ⇒ Electrical system; Rep. gr. 92 ; Removing and

installing windscreen wiper system

Disconnecting batteries

The procedure must be strictly followed!

– Switch off ignition and all electrical consumers.

– First disconnect drive battery on right in luggage compartment

⇒ Electrical system; Rep. gr. 27 ; Disconnecting and recon‐

necting batteries

– Then disconnect second battery on left in luggage compart‐

ment ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and

reconnecting batteries .

Procedure

All cable ties which are opened or cut through when engine is

removed must be replaced in the same position when engine is

installed.

– Pull engine compartment seal off bulkhead.

– Remove plenum chamber covers. ⇒ General body repairs,

exterior; Rep. gr. 64 ; Removing and installing plenum cham‐

ber cover .

– Pull connector off air mass meter.

– Remove intake hose and air filter housing ⇒ page 158 .

– Separate “terminal 30 wire” -arrows- and remove bracket with

positive terminal in engine compartment -1-.

– Lay wiring harness on engine.

– Remove right windscreen wiper motor. ⇒ Electrical system;

Rep. gr. 92 ; Removing and installing windscreen wiper sys‐

tem

– Pull smaller connector off engine control unit.

– Separate remaining connectors and earth connections of this

wiring harness.

– Lay wiring harness on engine.

– Pull connector off activated charcoal filter system solenoid

valve 1 - N80- and pull down valve from bracket on intake

manifold.

Phaeton 2003 ➤

6-cylinder injection engine - Edition 02.2014

1. Removing and installing engine 5

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– Pull breather hose off solenoid valve 1 and vacuum line off

brake servo on intake manifold -arrows-.

– Separate 4-pin connector -arrow- on lock carrier.

– Pull connector off continued coolant circulation pump - V51-

⇒ page 114 .

WARNING

Fuel supply lines are under pressure! Wear eye protection and

gloves to avoid injuries and skin contact. Before loosening

hose connections, wrap a cloth around the connection. Then

release pressure by carefully pulling hose off connection.

– Disconnect fuel supply and fuel return lines and line to activa‐

ted charcoal filter.

Note

Press buttons on hose couplings to do this.

– Seal lines with a clean cloth so that fuel system is not conta‐

minated by dirt.

– Observe rules for cleanliness ⇒ page 128 .

– Separate pressure hose -arrow- between combination valve

and secondary air pump motor - V101-

– Pull cover upwards off protective housing for Lambda probe

connectors.

– Separate connectors -1…4- for Lambda probes and lay wires

on engine.

Note

Connector for cylinders 1…3 = black, connector for cylinders 4…

6 = brown

Phaeton 2003 ➤

6-cylinder injection engine - Edition 02.2014

6 Rep. gr.10 - Removing and installing engine

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– To gain more working space, unscrew protective housing from

bulkhead -arrows-.

– Remove poly V-belt ⇒ page 28 .

– Extract air conditioning refrigerant ⇒ Heating, air conditioning;

Rep. gr. 87

– Raise vehicle.

– Remove insulation tray: ⇒ General body repairs, exterior;

Rep. gr. 50 ; Body - front; Assembly overview - noise insula‐

tion .

– Remove air conditioner compressor.

– Observe additional notes and assembly work ⇒ Heating, air

conditioning; Rep. gr. 87 ; Air conditioner compressor brack‐

et .

– Unbolt earth strap from left engine bracket.

– Support exhaust system on mounting at exhaust pipe junction

-arrow- with guide pins - 3411- .

– Loosen double clamp between catalytic converter and centre

silencer and slide clamp forward.

– Remove catalytic converters/front silencer ⇒ page 172 ; Re‐

moving and installing parts of exhaust system.

– Replace bolts with large washers on propshaft intermediate

bearing one by one with bolts not having washers.

– 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 .

– Push selector lever cable on gearbox off ball pin and pull out

cable securing clip.

– Remove front wheels.

– Remove front wheel housing liners ⇒ General body repairs,

exterior; Rep. gr. 66 ; Exterior equipment; Removing and in‐

stalling wheel housing liner; Rear wheel housing liner

– Separate all connectors between body and front axle in wheel

housings.

– Separate front brake calipers and secure to body. ⇒ Brake

system; Rep. gr. 46 ; Repairing front wheel brake

– Remove front anti-roll bar.

– Remove lower bolts -arrow- of suspension struts.

Phaeton 2003 ➤

6-cylinder injection engine - Edition 02.2014

1. Removing and installing engine 7

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– 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.

– Unbolt power-assisted steering vane pump from compact

bracket and place to one side; hoses remain connected: ⇒

Running gear, axles, steering; Rep. gr. 48 ; Assembly over‐

view: Vane pump, reservoir, hydraulic lines

– Pull off/ disconnect electrical wiring from starter and place to

one side.

WARNING

Steam may escape when expansion tank is opened. Wear eye

protection and protective clothing to avoid eye injuries and

scalding. Cover cap with cloth and open carefully.

– Open and close expansion tank cap to release pressure in

cooling system.

– Drain coolant ⇒ page 115 .

– Pull off coolant hoses from continued coolant circulation pump

- V51- .

If engine is to be separated from gearbox:

Note

If engine and gearbox are to be separated following removal, the

subframe must first be removed.

– Disconnect drive shafts from gearbox ⇒ Running gear, axles,

steering; Rep. gr. 40 ; Repairing drive shafts; Removing and

installing drive shafts .

– Remove subframe ⇒ Running gear, axles, steering - front and

four-wheel drive; Rep. gr. 40 ; Removing and installing sub‐

frame, lower suspension links and anti-roll bar .

Removing engine and gearbox without subframe ⇒ page 11 .

Separate engine and gearbox ⇒ Operating instructions for scis‐

sor-type assembly platform VAS 6131 .

Continuation if engine and gearbox are not separated following

removal:

Vehicles with manual gearbox

– Separate hydraulic line to hydraulic clutch slave cylinder ⇒ 6-

speed gearbox 01E/0A1; Rep. gr. 30 ; Repairing clutch mech‐

anism; Assembly overview - hydraulic system .

– Seal line.

Continuation for all vehicles

Phaeton 2003 ➤

6-cylinder injection engine - Edition 02.2014

8 Rep. gr.10 - Removing and installing engine

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– Remove lower bolts -arrow- of suspension struts.

– Loosen bolted connection -1- and pull upper suspension links

-2- off wheel bearing housing -3-.

– Separate track rod ends -4- of steering.

Removing engine and gearbox with subframe

Removing engine and gearbox without subframe ⇒ page 11 .

Prepare scissor-type assembly platform - VAS 6131- for further

procedure

– Install engine supports -VAS 6131/3-1- -1- left and -

VAS 6131/3-2- -2- right on scissor-type assembly platform -

VAS 6131- .

– The arrows on the supports point in direction of travel.

– Secure the bolts in the following positions: left engine support

-1-: C6 and D5; right engine support -2-: E6 and F5.

– The universal supports - VAS 6131/1-3- for the subframe and

the universal supports - VAS 6131/1-4- for the gearbox con‐

sole have a longitudinal hole in the diagonal direction and

should be installed depending on the situation.

– Remove both middle gearbox console bolts -arrows-.

– Position assembly platform under power unit. The engine sup‐

ports must be guided into their respective mountings:

A - Mounting on left of engine -arrow-

Phaeton 2003 ➤

6-cylinder injection engine - Edition 02.2014

1. Removing and installing engine 9

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B - Mounting on right of engine -arrow-

– Guide universal supports for the subframe in the respective

mountings -arrow-.

– Guide the universal supports in the gearbox console

-arrows-.

– Unscrew subframe bolts -1-, -2- and -3-.

Phaeton 2003 ➤

6-cylinder injection engine - Edition 02.2014

10 Rep. gr.10 - Removing and installing engine

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.

– Remove both outer gearbox bracket bolts -arrows-.

– Remove bolts -1- for engine carrier.

1.1.1 Removing engine and gearbox without

subframe

– Disconnect drive shafts from gearbox ⇒ Running gear, axles,

steering; Rep. gr. 40 ; Repairing drive shafts; Removing and

installing drive shafts .

– Remove subframe ⇒ Repairing front suspension; Rep. gr.

40 ; Removing and installing subframe, lower suspension link

and anti-roll bar .

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

procedure:

– Install engine supports -VAS 6131/3-1- -1- left and -

VAS 6131/3-2- -2- right on scissor-type assembly platform -

VAS 6131- .

– The arrows on the supports point in direction of travel.

Phaeton 2003 ➤

6-cylinder injection engine - Edition 02.2014

1. Removing and installing engine 11

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– Secure the bolts in the following positions: left engine support

-1-: C6 and D5; right engine support -2-: E6 and F5.

– Remove both middle gearbox console bolts -arrows-.

– Position assembly platform under power unit. The engine sup‐

ports must be guided into their respective mountings:

A - Mountings on left of engine -arrows-

B - Mountings on right of engine -arrows-

Phaeton 2003 ➤

6-cylinder injection engine - Edition 02.2014

12 Rep. gr.10 - Removing and installing engine

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– Guide the universal supports of the gearbox console in the

mountings -arrows-.

– Position the middle support as shown beneath the gearbox

-arrow-.

– Remove both outer gearbox bracket bolts -arrows-.

Phaeton 2003 ➤

6-cylinder injection engine - Edition 02.2014

1. Removing and installing engine 13

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– Remove bolts -1- for engine carrier.

Vehicles with manual gearbox

– Lower assembly platform with engine and gearbox until se‐

lector mechanism can be unbolted: ⇒ 6-speed manual gear‐

box 01E/0A1; Rep. gr. 34 ; Repairing selector mechanism;

Removing and installing selector mechanism .

Vehicles with automatic gearbox

– Lower assembly platform with engine and gearbox only

enough so as to facilitate unhooking of the selector lever cable.

Continuation for all vehicles

– Check that all connections between bulkhead and engine

have been separated.

– Remove engine and gearbox downwards.

Note

The engine has to be guided carefully when removing to prevent

damage to the bodywork.

1.2 Securing engine on engine and gearbox

support - VAS 6095-

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

carry out repairs.

Procedure

Note

Separate engine and gearbox ⇒ Operating instructions for scis‐

sor-type assembly platform VAS 6131 .

– Unbolt gearbox.

Vehicles with automatic gearbox

– Secure torque converter against “falling out” after separating

engine from gearbox.

Continuation for all vehicles

– Connect lifting tackle - 3033- as shown:

Vibration damper end: position 3.

Phaeton 2003 ➤

6-cylinder injection engine - Edition 02.2014

14 Rep. gr.10 - Removing and installing engine

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Volkswagen Phaeton 2003 Workshop Manual

Volkswagen Phaeton 2003 Workshop Manual

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