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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
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg K0058950220
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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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