VW CGRA Workshop Manual

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Workshop Manual

Touareg 2010 ➤

Touareg 2015 ➤

6-cylinder direct-injection engine (3.6 l engine, 4V)

Engine ID CGR

ACMT

A

Edition 12.2019

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 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 1

1.3 Safety precautions when using testers and measuring instruments during a road test . . . . 2

1.4 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.5 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.2 Numbering of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.2 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.4 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.5 Fitting radiator and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.3 Securing engine on engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1.5 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2.2 Removing and installing engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.1 Part I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

1.2 Part II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1.3 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1.4 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2 Sealing flanges and drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2.1 Assembly overview - sealing flanges and drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2.2 Assembly overview - timing chain covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

2.3 Removing and installing seal on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2.4 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.5 Renewing crankshaft sealing flange, vibration damper side . . . . . . . . . . . . . . . . . . . . . . . . 43

2.6 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2.7 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

3.2 Fitting sender wheel to crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3.3 Allocation of main bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

4.2 Checking piston and cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

4.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Contents i

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1 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

1.1 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

1.2 Removing and installing camshaft adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

1.3 Removing and installing camshaft timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

1.4 Removing and installing oil pump drive timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

1.5 Removing and installing chain drive sprocket for high-pressure pump . . . . . . . . . . . . . . . . 78

2 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

2.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

2.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

2.3 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

2.4 Assembly overview - mechanical vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

2.5 Removing and installing mechanical vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

2.6 Installing cover oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

2.7 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

3.2 Camshafts, checking axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

3.3 Assembly overview - timing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

3.4 Removing and installing camshaft control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

3.5 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

3.6 Camshaft identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

4.1 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

4.2 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

4.3 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

4.4 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

1.2 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

1.3 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

2 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

2.1 Removing and installing oil spray jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

2.2 Assembly overview - oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

2.3 Removing and installing oil filter housing, engine support . . . . . . . . . . . . . . . . . . . . . . . . . . 130

2.4 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

2.5 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

1 Cooling system (engine code CGRA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

1.1 Coolant hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

1.2 Vacuum hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

1.3 Assembly overview - vacuum hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

1.4 Assembly overviews - cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

2 Cooling system (engine code CMTA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

2.1 Coolant hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

2.2 Assembly overview - cooling system, engine side, front and rear . . . . . . . . . . . . . . . . . . . . 142

2.3 Assembly overview - cooling system, engine side, left . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

3 Coolant pump and thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

3.1 Assembly overview - coolant pump and thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

3.2 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

3.3 Removing and installing coolant circulation pump 2 V178 . . . . . . . . . . . . . . . . . . . . . . . . 149

3.4 Removing and installing, checking thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

ii Contents

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3.5 Removing and installing temperature sender for engine temperature regulation G694 . . 151

4 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

4.1 Draining coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

4.2 Draining cooling system (vehicles with one heat exchanger) . . . . . . . . . . . . . . . . . . . . . . . . 155

4.3 Draining cooling system (vehicles with two heat exchangers) . . . . . . . . . . . . . . . . . . . . . . 156

4.4 Filling with coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

4.5 Checking filling quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

4.6 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

5 Radiator and radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

5.1 Assembly overview - radiator and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

5.2 Removing and installing radiator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

5.3 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

5.4 Dismantling cooler module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

1.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

2 Parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

2.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

2.2 Assembly overview - fuel tank with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

2.3 Assembly overview - fuel delivery unit, fuel gauge sender and suction jet pumps . . . . . . . . 177

2.4 Removing, installing and renewing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

2.5 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

2.6 Removing and installing fuel gauge sender 2 G169 and suction-jet pump . . . . . . . . . . . . 184

2.7 Removing and installing fuel delivery unit and fuel gauge sender G . . . . . . . . . . . . . . . . . . 188

2.8 Removing and installing fuel tank with attached components . . . . . . . . . . . . . . . . . . . . . . 191

3 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

3.1 Checking fuel pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

3.2 Checking holding pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

4 Electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

4.1 Assembly overview - accelerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

5 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

5.1 Assembly overview - activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

5.2 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

6 Activated charcoal filter system (vehicles for USA and Canada) . . . . . . . . . . . . . . . . . . . . 206

6.1 Assembly overview - activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

6.2 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

1.1 General notes on the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

1.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

2 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

2.1 Assembly overview - fuel rail with high-pressure pump and injectors . . . . . . . . . . . . . . . . 217

2.2 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

2.3 Renewing seals on injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

3 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

3.1 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

3.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

3.3 Removing and installing air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

4.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

4.2 Checking vacuum unit for intake manifold flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

Contents iii

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4.3 Removing and installing intake manifold upper part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

4.4 Removing and installing lower part of intake manifold with fuel rail . . . . . . . . . . . . . . . . . . 239

4.5 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

5 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

5.1 Checking fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

6 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

6.1 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

7 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

7.1 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

7.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

1 Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

1.1 Assembly overview - exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

1.2 Removing and installing exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

2 Silencers and catalytic converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

2.1 Assembly overview - catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

2.2 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

2.3 Separating centre and rear silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

2.4 Replacing tail pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

2.5 Removing and installing catalytic converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

2.6 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

2.7 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

1.1 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

1.2 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

1.3 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

1.4 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

1.5 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 272

1.6 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

iv Contents

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00 – Technical data

1 Safety information

(VRL013732; Edition 12.2019)

⇒ “1.1 Safety regulations for working on fuel supply”, page 1

⇒ “1.2 Safety measures when working on vehicles with a start/

stop system”, page 1

⇒ “1.3 Safety precautions when using testers and measuring in‐

struments during a road test”, page 2

⇒ “1.4 Safety precautions when working on ignition system”, page

2

⇒ “1.5 Safety precautions when working on the cooling system”,

page 2

1.1 Safety regulations for working on fuel supply

Risk of injury from highly pressurised fuel.

The fuel system is pressurised. Injury from fuel spray possible.

Before opening the fuel system:

– Wear protective goggles.

– Wear protective gloves.

– To release pressure, wrap a clean cloth around the connection

and carefully loosen the connection.

Danger of fire caused by escaping fuel

When the battery is connected and the driver door opens, the door

contact switch activates the fuel pump. Escaping fuel can ignite

and cause a fire.

– Disconnect voltage supply to fuel pump before opening the

fuel system.

1.2 Safety measures when working on vehicles with a start/stop system

Risk of injury due to unexpected motor start

If the vehicle’s start/stop system is activated, the engine can start

unexpectedly. A message in the dash panel insert indicates

whether the start/stop system is activated.

– Deactivate start/stop system by switching off the ignition.

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

1. Safety information 1

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1.3 Safety precautions when using testers and measuring instruments during

a road test

Risk of injury caused by unsecured testing and measuring instru‐

ments

When the front passenger airbag is triggered in an accident, in‐

sufficiently secured testing and measuring instruments become

dangerous projectiles.

– Secure testing and measuring instruments on the rear seat.

or

– Have a second person operate the test and measuring equip‐

ment on the rear seat.

1.4 Safety precautions when working on ignition system

Risk of injury due to electric shock

The ignition system is under high voltage when the engine is run‐

ning. Touching the ignition system may result in an electric shock.

– Do not touch or disconnect ignition cables when the engine is

running or being turned at starter speed.

Risk of damage to components

Connecting or disconnecting electric cables or washing the en‐

gine while it is running may damage components.

– Switch off the ignition before connecting or disconnecting elec‐

tric cables.

– Switch off the ignition before washing the engine.

1.5 Safety precautions when working on the cooling system

Danger of scalding by hot coolant

On a warm engine, the cooling system is under high pressure.

Danger of scalding by steam and hot coolant.

– Wear protective gloves.

– Wear protective goggles.

– Reduce excess pressure by covering cap of coolant expan‐

sion tank with cloths and opening it carefully.

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

2 Rep. gr.00 - Technical data

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2 Identification

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

⇒ “2.2 Numbering of cylinders”, page 4

2.1 Engine number/engine data

Engine number

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

next to the vibration damper -arrow- on the cylinder block.

There is also a sticker on the rear of the cylinder head cover

showing the “engine code” and “serial number”.

The first 3 digits denote the mechanical design of the engine and

are stamped on the engine. The fourth digit shows the engine

output and torque and varies according to engine control unit. The

four-digit engine code can be found on the identification plate and

on the vehicle data sticker. It can also be read from the engine

control unit.

Fitting locations of vehicle data sticker ⇒ Maintenance ; Booklet ;

Vehicle data sticker .

Engine data

Codes CGRA CMTA

Manufactured 15.2010 ► 34.2010 ►

Displacement cm³ 3597 3597

Power kW at rpm 206 / 6200 183 / 5700

Torque Nm at

rpm

360 / 2900 to 4000 360 / 3000

Bore ∅ mm 89.0 89.0

Stroke mm 96.4 96.4

Cylinder angle 10.6° 10.6°

Compression ratio 11.4 11.4

Valves per cylinder 4 4

RON 98 unleaded1) 98 unleaded1)

Injection, ignition Motronic MED 17 Motronic MED 17

Knock control 2 knock sensors 2 knock sensors

Lambda regulation 4 lambda probes 4 lambda probes

Catalytic converter Yes Yes

Leakage diagnosis sys‐

tem Vehicles for USA/Canada only no

Exhaust gas recirculation no no

Thermal management Yes no

1) At least 95 RON, though with reduced output

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

2. Identification 3

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2.2 Numbering of cylinders

Note

Cylinder 1 is opposite the power delivery side.

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

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

4 Rep. gr.00 - Technical data

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3 Repair instructions

⇒ “3.1 Rules for cleanliness”, page 5

⇒ “3.2 Foreign objects in engine”, page 5

⇒ “3.3 Contact corrosion”, page 5

⇒ “3.4 Routing and attachment of lines”, page 5

⇒ “3.5 Fitting radiator and condensers”, page 6

3.1 Rules for cleanliness

When working on fuel supply and injection system, pay careful

attention to the following “rules” for cleanliness:

♦ Thoroughly clean all joints and surrounding areas before dis‐

mantling.

♦ Place removed parts on a clean surface and cover them over.

Use lint-free cloths only.

♦ Carefully cover opened components or seal them if repairs

cannot be carried out immediately.

♦ Install only clean parts; do not remove new parts from pack‐

aging until immediately before installing. Do not use parts that

have been kept unpackaged (for example in toolboxes).

♦ If system is open, do not work with compressed air. Do not

move the vehicle.

♦ Make sure that no fuel gets onto the fuel hoses. Should this

occur, the fuel hoses must be cleaned immediately.

♦ Protect disconnected electrical connectors from dirt and water,

and reconnect them only when dry.

3.2 Foreign objects in engine

To prevent the ingress of foreign bodies during work on the en‐

gine, seal open channels of the intake section and exhaust sec‐

tion with suitable bungs, for example from the engine bung set -

VAS 6122- .

3.3 Contact corrosion

Contact corrosion can occur if non-approved fasteners are used

on the vehicle (bolts, nuts, washers etc.).

For this reason, only connecting elements with a special surface

coating have been fitted.

Furthermore, rubber and plastic components as well as adhe‐

sives are made of non-conductive materials.

If there is any doubt about the suitability of parts, a general rule

is to use new parts ⇒ Electronic Parts Catalogue .

3.4 Routing and attachment of lines

♦ To prevent interchanging and to maintain the original installa‐

tion position, mark the fuel, hydraulic system, vacuum and

ACF system pipes or any wiring for example prior to removal.

Make sketches or take photographs if necessary.

♦ To avoid damaging pipes and wires, ensure adequate clear‐

ance from all moving or hot components in the engine com‐

partment on account of the confined space.

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

3. Repair instructions 5

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3.5 Fitting radiator and condensers

Even if installed correctly, the radiator, the condenser and the

charge air cooler may have small dents in their fins. This does not

mean that these components have been damaged. It is not per‐

missible to renew radiators, condensers or charge air coolers only

because of such minor dents.

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

6 Rep. gr.00 - Technical data

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10 – Removing and installing engine

1 Removing and installing engine

⇒ “1.1 Removing engine”, page 7 .

⇒ “1.2 Separating engine and gearbox”, page 19

⇒ “1.3 Securing engine on engine support ”, page 21 .

⇒ “1.4 Installing engine”, page 22 .

⇒ “1.5 Supporting engine in installation position”, page 24

1.1 Removing engine

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

1. Removing and installing engine 7

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Special tools and workshop

equipment required

♦ Lifting tackle - 3033-

♦ Engine and gearbox support - VAS 6095-

♦ Engine and gearbox jack - V.A.G 1383 A-

♦ Drip tray - V.A.G 1306-

♦ Workshop hoist - VAS 6100-

♦ Scissor-type assembly platform - VAS 6131-

♦ Pliers for spring-type clips - VAS 6340-

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

8 Rep. gr.10 - Removing and installing engine

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♦ Not illustrated:

♦ Adapter - V.A.G 1318/20-

♦ Adapter - V.A.G 1318/20-1-

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

♦ Left subframe mounting - VAS 6131/6-1-

♦ Right subframe mounting - VAS 6131/6-2-

♦ Left running gear support - VAS 6131/6-3-

♦ Right running gear support - VAS 6131/6-4-

♦ Support - VAS 6131/6-5- (qty. 2)

♦ Support - VAS 6131/6-6- (qty. 2)

♦ Gearbox support - VAS 6131/6-7-

♦ Grease (vehicles with manual gearbox) - G 000 1000-

♦ Cable tie

Note

♦

Use suitable materials, e.g. cable ties, to attach all disconnec‐

ted cables and wires to the engine/assembly (depending on

»origin«). Fit dummy plugs in all open connections.

♦

Move the selector lever to the “N” position so that the propshaft

can turn freely.

♦

To make sure you can still move the front wheels when the

battery has been disconnected, only disconnect the battery

with the ignition key inserted.

Procedure:

The engine is removed downwards with gearbox.

– Vehicles with air suspension: Activate jacking mode ⇒ Rep.

gr. 43 .

– Disconnect battery ⇒ Rep. gr. 27 ; Electrical system .

– Detach hoses -1- and -2- and remove air pipe -arrows-.

– Open clips and remove upper part of air filter.

– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐

screen wiper system .

– Remove plenum chamber cover ⇒ Body - front; Rep. gr. 50 ;

Plenum chamber cover .

– Remove protective housing from engine control unit

⇒ page 246 .

– Pull engine wiring harness off engine control unit.

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

1. Removing and installing engine 9

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– Unscrew and disconnect earth wire -arrows-.

– Open cover -A- of central electrical system.

– Detach all connectors whose wires go to the engine.

– Remove engine wiring harness from plenum chamber and

place it on the engine.

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

WARNING

The fuel line is under pressure.

Fuel poses danger of injury to eyes and skin.

Wear protective goggles and protective clothing to avoid injury

and contact with the skin. Wrap a cloth around the connection

before loosening hose connections. Then reduce pressure by

carefully opening the connection.

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

– Detach fuel supply line -arrow-.

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

10 Rep. gr.10 - Removing and installing engine

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– Disconnect vacuum lines -arrows-. Hose -1- can be disregar‐

ded.

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

– Unscrew and disconnect positive wire:

1 - To alternator

2 - To starter

– Move electrical wiring clear.

– Siphon off refrigerant of the air-conditioning system ⇒ Rep.

gr. 87 .

– Detach power-assisted steering hose together with clamps up

to 25 mm - 3094- . Pull hose -A- off power-steering pump.

– Detach refrigerant lines -2 and 3- from air-conditioning com‐

pressor.

– Remove noise insulation ⇒ General body repairs, exterior;

Rep. gr. 50 ; Assembly overview - noise insulation .

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

1. Removing and installing engine 11

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– Unbolt bracket for noise insulation -arrows-.

– Drain coolant ⇒ page 154 .

– Open plug-in connector -A- under the coolant expansion tank

and pull off coolant hose.

– Unscrew connection of coolant hose at top of radiator.

– Open plug-in connector -A- at top of radiator and pull coolant

hose off.

– Detach coolant hose from lower radiator connection.

– Remove front wheels.

– Unscrew earth connection -A- on right longitudinal member.

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

12 Rep. gr.10 - Removing and installing engine

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– Unscrew bolt -A- and pull connections off gear oil cooler. Catch

oil which runs out.

– Disconnect hose of servo steering with hose clips up to 25 mm

- 3094- , open clip -A- and pull off hose.

– Open clips -A- and pull off coolant hoses of heat exchanger

for heating system.

– Push propshaft off gearbox and tie at the top ⇒ Differential

and final drive; Rep. gr. 39 ; Removing and installing prop‐

shafts .

– Disconnect connector -arrows- at gearbox.

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

1. Removing and installing engine 13

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– Unscrew and remove hangers -1- and -2-. Loosen clamps

-arrows- and push to rear.

– Separate selector lever cable at ball head -1- and unscrew

from gearbox -2-. Circlip -3- can remain fitted.

Caution

Danger of airbag coil connectors becoming twisted.

♦ Only disconnect universal joint from steering rack when

front wheels are in straight-ahead position.

♦ Secure steering wheel with adhesive tape so that position

of steering wheel and steering rack no longer change.

– Unscrew bolt -A- and remove universal joint from steering

rack.

– Disconnect connector at steering rack.

Touareg 2010 ➤ , Touareg 2015 ➤

6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 12.2019

14 Rep. gr.10 - Removing and installing engine

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