Volkswagen Touareg 2018 Workshop Manual
Service
Workshop Manual
Touareg 2018 ➤
6-cyl. direct injection (3.0 l, 4V, EA 839,
turbocharger)
Engine ID
Edition 11.2020
DCB
E
Service Department. Technical Information
List of Workshop Manual Repair Groups
Re pa ir G ro up
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
24 - Mixture preparation - injection
26 - Exhaust system
28 - Ignition system
93 - Electric drive systems
Service
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.
Touareg 2018 ➤
6-cyl. direct injection (3.0 l, 4V, EA 839, turbocharger) - Edition 11.2020
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety precautions when working in the vicinity of high-voltage components . . . . . . . . . . 2
1.3 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 3
1.5 Safety precautions when using testers and measuring instruments during a road test . . . . 3
1.6 Safety precautions when working on subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.7 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.8 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.9 Safety precautions when working on exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Numbering of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5 Fitting radiator and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.6 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Hazard classification of high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.3 Removing engine from scissor-type assembly platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.4 Securing engine on engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.5 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.1 Assembly overview – assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.2 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.3 Removing and installing engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.4 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.5 Removing and installing power unit mounting senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.6 Calibrating electrohydraulic engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3 Engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3.1 Removing and installing engine cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.1 Assembly overview - cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.2 Assembly overview - sealing flange, belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.3 Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.4 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.5 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.6 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.7 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.8 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.9 Removing and installing sealing flange on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Contents i
Touareg 2018 ➤
6-cyl. direct injection (3.0 l, 4V, EA 839, turbocharger) - Edition 11.2020
2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.2 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.3 Renewing crankshaft oil seal (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.3 Allocation of main bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.4 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3.5 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.6 Removing and installing sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.7 Checking sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.8 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4 Balancer shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4.1 Assembly overview - balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4.2 Removing and installing balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
5 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
5.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
5.2 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5.3 Removing and installing oil spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5.4 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
5.5 Checking radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.2 Assembly overview - camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.4 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
2 Cover for timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
2.1 Assembly overview - cover for timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
2.2 Removing and installing timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
3 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
3.1 Assembly overview - camshaft timing chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
3.2 Assembly overview - drive chain for oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3.3 Removing camshaft timing chain from camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3.4 Removing and installing camshaft timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
3.5 Removing and installing chain tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
4.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
4.2 Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
4.3 Measuring radial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
4.4 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
4.5 Removing and installing cam actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
4.6 Removing and installing camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . . . . . 243
4.7 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
5 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
5.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
5.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
5.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
1.2 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
ii Contents
Touareg 2018 ➤
6-cyl. direct injection (3.0 l, 4V, EA 839, turbocharger) - Edition 11.2020
1.3 Removing and installing lower part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
1.4 Removing and installing upper part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
1.5 Removing and installing oil baffle plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
1.6 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
1.7 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 280
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
2.1 Assembly overview - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
2.3 Removing and installing spray nozzle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
3 Crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
3.1 Assembly overview - crankcase breather system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
3.2 Removing and installing crankcase breather module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
4 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
4.1 Assembly overview - oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
4.2 Assembly overview - oil pressure switches/oil pressure control . . . . . . . . . . . . . . . . . . . . . . 291
4.3 Removing and installing oil pressure switch F22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
4.4 Removing and installingoil temperature sender G8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
4.5 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
4.6 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
4.7 Removing and installing oil pressure regulating valve N428 . . . . . . . . . . . . . . . . . . . . . . . . 297
4.8 Removing and installing oil pressure sender G10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
1.2 Overview of fitting locations – cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
1.3 Assembly overview – coolant expansion tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
1.4 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
1.5 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
1.6 Removing and installing coolant expansion tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
2.2 Assembly overview - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
2.3 Assembly overview - coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
2.4 Assembly overview – coolant valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
2.5 Removing and installing electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
2.6 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
2.7 Removing and installing map-controlled engine cooling thermostat F265 . . . . . . . . . . . . . . 372
2.8 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 374
2.9 Removing and installing engine outlet coolant temperature sender G82 . . . . . . . . . . . . . . 375
2.10 Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . . . 377
2.11 Removing and installing temperature sender for engine temperature regulation G694 . . . . 380
2.12 Removing and installing coolant valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
2.13 Removing and installing coolant temperature sender for high-voltage system . . . . . . . . . . 387
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
3.1 Assembly overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
3.2 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
4 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
4.1 Assembly overview – radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
4.2 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
4.3 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
4.4 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
4.5 Removing and installing radiator for high-voltage system coolant circuit . . . . . . . . . . . . . . 422
4.6 Removing and installing air ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
Contents iii
Touareg 2018 ➤
6-cyl. direct injection (3.0 l, 4V, EA 839, turbocharger) - Edition 11.2020
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
1.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
1.3 Renewing vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
1.4 Removing and installing temperature sender for engine cover panel G765 . . . . . . . . . . . . 447
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
2.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
2.2 Assembly overview - charge-air hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
2.3 Removing and installing air pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
2.4 Removing and installing pressure pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
2.5 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
2.6 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
2.7 Removing and installing overrun air recirculation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
2.8 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
1.1 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
1.2 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479
2.1 Connection diagram - vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479
2.2 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479
3 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481
3.1 Assembly overview - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481
3.2 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
3.3 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485
3.4 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 491
4 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
4.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
4.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
5 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
5.1 Assembly overview – intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
5.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
5.3 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
5.4 Cleaning throttle valve module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
6 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
6.1 Assembly overview - actuator for structure-borne sound and control unit for structure-borne
sound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
6.2 Assembly overview - pressure differential sender, models with particulate filter . . . . . . . . 506
6.3 Removing and installing actuator for structure-borne sound R214 . . . . . . . . . . . . . . . . . . 507
6.4 Removing and installing control unit for structure-borne sound J869 . . . . . . . . . . . . . . . . 508
6.5 Removing and installing intake manifold sender GX9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
6.6 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
6.7 Removing and installing fuel pressure sender for low-pressure G410 . . . . . . . . . . . . . . . . 510
6.8 Removing and installing pressure differential sender for particulate filter G1037, models
with particulate filter (petrol) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
7 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
7.1 Assembly overview – motor control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
7.2 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
8 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
8.1 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
8.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520
8.3 Removing and installing high-pressure pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
iv Contents
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6-cyl. direct injection (3.0 l, 4V, EA 839, turbocharger) - Edition 11.2020
9 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
9.1 Assembly overview - Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
9.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
1 Exhaust pipes and silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
1.1 Assembly overview – silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
1.2 Removing and installing front silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540
1.3 Separating exhaust pipes from silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543
1.4 Removing and installing silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
1.5 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
1.6 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546
2 Emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547
2.1 Assembly overview – emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547
2.2 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
2.3 Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551
3 Exhaust gas temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554
3.1 Removing and installing exhaust gas temperature sender 3 G495 . . . . . . . . . . . . . . . . . . 554
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556
1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556
1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556
1.2 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 558
1.3 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562
1.4 Removing and installing Hall sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 563
1.5 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564
93 - Electric drive systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 566
1 High-voltage components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 566
1.1 Overview of fitting locations - high-voltage components . . . . . . . . . . . . . . . . . . . . . . . . . . 566
2 Warning stickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 569
2.1 Checking warning stickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 569
3 High-voltage battery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573
3.1 Assembly overview – high-voltage battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573
3.2 Visual inspection of high-voltage battery 1 AX2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575
3.3 Diagnosing high-voltage battery 1 AX2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 576
3.4 Searching for leaks from high-voltage battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 577
3.5 Removing and installing high-voltage battery 1 AX2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584
3.6 Removing and installing battery regulation control unit J840 . . . . . . . . . . . . . . . . . . . . . . . . 593
3.7 Removing and installing switching unit for high-voltage battery SX6 . . . . . . . . . . . . . . . . . . 594
4 High-voltage battery components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597
4.1 Assembly overview – high-voltage battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597
4.2 Overview of fitting locations - battery modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
4.3 Overview of fitting locations – battery connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
4.4 Marking battery modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
4.5 Removing battery module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
4.6 Installing battery module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619
5 Power and control electronics for electric drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635
5.1 Overview of fitting locations - power and control electronics for electric drive . . . . . . . . . . 635
5.2 Removing and installing power and control electronics for electric drive . . . . . . . . . . . . . . 638
5.3 Removing and installing bracket for power and control electronics for electric drive JX1 . . 642
6 Electric drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644
6.1 Assembly overview – electric drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644
6.2 Removing and installing three-phase current drive VX54 . . . . . . . . . . . . . . . . . . . . . . . . . . 648
Contents v
Touareg 2018 ➤
6-cyl. direct injection (3.0 l, 4V, EA 839, turbocharger) - Edition 11.2020
6.3 Removing and installing centring sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 648
6.4 Removing and installing drive motor temperature sender G712 . . . . . . . . . . . . . . . . . . . . 650
6.5 Removing and installing drive motor rotor position sender 1 G713 . . . . . . . . . . . . . . . . . . 651
6.6 Removing and installing torsion damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 652
6.7 Removing and installing actuator for disengagement clutch V606 . . . . . . . . . . . . . . . . . . . . 654
6.8 Removing and installing coolant connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 657
6.9 Transporting three-phase current drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 658
6.10 Checking ease of movement of disengagement clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 659
7 High-voltage cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661
7.1 Overview of fitting locations - high-voltage cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661
7.2 Removing and installing high-voltage wiring harness for high-voltage battery . . . . . . . . . . 668
7.3 Removing and installing high-voltage wiring harness for drive motor . . . . . . . . . . . . . . . . 673
7.4 Removing and installing high-voltage cable for electrical air conditioner compressor . . . . 678
7.5 Removing and installing high-voltage cable for high-voltage heater (PTC) . . . . . . . . . . . . 681
8 De-energising high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 689
9 Re-energising high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 691
10 Potential equalisation lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 692
10.1 General notes - potential equalisation lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 692
10.2 Overview of fitting locations - potential equalisation lines . . . . . . . . . . . . . . . . . . . . . . . . . . 692
10.3 Removing and installing potential equalisation line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 694
11 Charging socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 698
11.1 Assembly overview – charging socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 698
11.2 Removing and installing high-voltage battery charging socket 1 UX4 . . . . . . . . . . . . . . . . 699
11.3 Removing and installing module for battery charge selector buttons EX32 . . . . . . . . . . . . 704
12 Charging unit for high-voltage battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 705
12.1 Assembly overview – charging unit for high-voltage battery . . . . . . . . . . . . . . . . . . . . . . . . 705
12.2 Removing and installing charging unit 1 for high-voltage battery AX4 . . . . . . . . . . . . . . . . 705
12.3 Removing and installing bracket for charging unit 1 for high-voltage battery AX4 . . . . . . . . 710
vi Contents
6-cyl. direct injection (3.0 l, 4V, EA 839, turbocharger) - Edition 11.2020
00 – Technical data
1 Safety information
(VRL014943; Edition 11.2020)
⇒ p1.1 recautions when working on high-voltage system”, page
1
⇒ p1.2 recautions when working in the vicinity of high-voltage
components”, page 2
⇒ r1.3 egulations for working on fuel supply”, page 2
⇒ m1.4 easures when working on vehicles with a start/stop
system”, page 3
⇒ p1.5 recautions when using testers and measuring instru‐
ments during a road test”, page 3
⇒ p1.6 recautions when working on subframe”, page 3
⇒ p1.7 recautions when working on ignition system”, page 3
⇒ p1.8 recautions when working on the cooling system”, page
4
⇒ p1.9 recautions when working on exhaust system”, page 4
Touareg 2018 ➤
1.1 Safety precautions when working on high-voltage system
Danger to life from high voltage
The high-voltage system is under high voltage. Severe or fatal
injury from electric shock.
– Persons with life-preserving or other electronic medical devi‐
ces in or on their body must not perform any work on the
high-voltage system. Such medical devices include internal
analgesic pumps, implanted defibrillators, pacemakers, insu‐
lin pumps and hearing aids.
– The high-voltage system must be de-energised by a suitably
qualified technician.
Risk of injury from engine starting unexpectedly
On electric and hybrid vehicles, the operational readiness of the
vehicle is difficult to detect. There is a risk of parts of the body
becoming trapped or drawn in.
– Switch off ignition.
– Always store the ignition key outside the vehicle.
Risk of damage to high-voltage cables
Improper handling of high-voltage cables or high-voltage con‐
nectors may result in damage to their insulation.
– Never support body weight on high-voltage cables or high-
voltage connectors.
– Never support any tools on high-voltage cables or high-volt‐
age connectors.
1. Safety information 1
Touareg 2018 ➤
6-cyl. direct injection (3.0 l, 4V, EA 839, turbocharger) - Edition 11.2020
– Never kink or severely bend high-voltage cables.
– Always observe the coding when connecting high-voltage
connectors.
Risk of injury from activated stationary air conditioning
On electric and hybrid vehicles with activated stationary air con‐
ditioning, the stationary air conditioning could switch on uninten‐
tionally. Risk of limbs becoming trapped or drawn in by the
radiator fan starting automatically.
– Deactivate the stationary air conditioning.
1.2 Safety precautions when working in the vicinity of high-voltage compo‐
nents
Danger to life from high voltage
The high-voltage system is under high voltage. Damage to highvoltage components or high-voltage cables can result in severe
or fatal injury from electric shock.
– Perform visual check of high-voltage components and high-
voltage cables.
– Never use cutting or forming tools, or any other sharp-edged
tools.
– Never use heat sources such as welding, brazing, soldering,
hot air or thermal bonding equipment.
1.3 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 connec‐
tion 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.
2 Rep. gr.00 - Technical data
Touareg 2018 ➤
6-cyl. direct injection (3.0 l, 4V, EA 839, turbocharger) - Edition 11.2020
1.4 Safety measures when working on vehicles with a start/stop system
Risk of injury due to unexpected engine start
If the vehicle’s start/stop system is activated, the engine can
start unexpectedly. A message in the dash panel insert indi‐
cates whether the start/stop system is activated.
– Deactivate start/stop system by switching off the ignition.
1.5 Safety precautions when using testers and measuring instruments during a road test
Risk of injury caused by unsecured testing and measuring in‐
struments
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
equipment on the rear seat.
1.6 Safety precautions when working on subframe
Risk of damage to components
If the assembly mountings, steering rack or subframe cross
brace are not installed correctly, components can become dam‐
aged when the vehicle is settled on its wheels.
– Never settle the vehicle on its wheels if running gear compo‐
nents are loose.
– Never support the vehicle if running gear components on the
subframe or subframe cross brace are loose.
1.7 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
running. 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.
1. Safety information 3
Touareg 2018 ➤
6-cyl. direct injection (3.0 l, 4V, EA 839, turbocharger) - Edition 11.2020
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
electric cables.
– Switch off the ignition before washing the engine.
1.8 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.
1.9 Safety precautions when working on exhaust system
Risk of poisoning due to chemical substances
Exhaust gas temperature senders may contain chemical sub‐
stances. There is a risk of poisoning or injuries to respiratory
system.
– Never open an exhaust gas temperature sender by cutting,
sawing or any other means.
Risk of injury due to hot condensate and particles in the ex‐
haust system.
The exhaust system could contain hot condensate and/or parti‐
cles. There is a risk of injury to the eyes, skin and respiratory
system, as well as poisoning.
– Always wear protective gloves and eye protection when cut‐
ting the exhaust system.
– When cutting, use an extraction system or otherwise ensure
sufficient ventilation.
4 Rep. gr.00 - Technical data
6-cyl. direct injection (3.0 l, 4V, EA 839, turbocharger) - Edition 11.2020
2 Identification
⇒ n2.1 umber/engine data”, page 5
⇒ o2.2 f cylinders”, page 6
2.1 Engine number/engine data
Engine number
♦ Engine number is visible once air filter housing has been
removed.
Touareg 2018 ➤
♦ Engine number is located on rear of cylinder block at top.
1 - Serial number engine code
♦ There is also a sticker on the timing chain cover (top) show‐
ing the “engine code” and the “serial number”.
♦ The engine code is also indicated on the vehicle data stick‐
ers.
Engine data
Code DCBE
Displace‐
ment
Power kW at rpm 250/5300
Torque Nm at rpm 450/1500 to 5300
Bore Diameter, mm 84.5
Stroke mm 89.0
Compression ratio 11.2
RON min.
Ignition and injection sys‐
tems
Exhaust
emissions
fulfil
Firing order 1-4-3-6-2-5
Exhaust gas recirculation No
Charging Turbocharger
Knock control Yes
Lambda regulation Yes
Charge air cooling Yes
Camshaft timing adjustment Yes
Variable intake manifold No
Secondary air system No
Valves per cylinder 4
l 2.99
98
FSI direct injection
EU 6
1)
2. Identification 5
Touareg 2018 ➤
6-cyl. direct injection (3.0 l, 4V, EA 839, turbocharger) - Edition 11.2020
1)
92 RON also permitted
but with reduced power
2.2 Numbering of cylinders
Cylinders are numbered beginning with the right side -A- (cylin‐
der bank 1) from the driver's perspective, not from the power
output end -C-. The cylinders are counted on each side in suc‐
cession. -B- = cylinder bank 2.
6 Rep. gr.00 - Technical data
6-cyl. direct injection (3.0 l, 4V, EA 839, turbocharger) - Edition 11.2020
3 Repair instructions
⇒ f3.1 or cleanliness”, page 7
⇒ o3.2 bjects in engine”, page 7
⇒ c3.3 orrosion”, page 7
⇒ a3.4 nd attachment of lines”, page 8
⇒ r3.5 adiator and condensers”, page 8
⇒ f3.6 uel system for leaks”, page 8
3.1 Rules for cleanliness
Even slight soiling can cause faults. For this reason, observe
the following rules for cleanliness when working on the fuel
supply system, the charge air system and the injection system:
♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly
before opening.
♦ Seal open pipes and connections immediately with clean
plugs for example from the engine bung set -VAS 6122-.
♦ Place removed parts on a clean surface. Cover with lint-free
cloths only.
♦ If repair work cannot be performed immediately, carefully
cover or seal components.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have been stored outside their packaging (e.g.
in tool boxes).
♦ When the system is open, do not work with compressed air
or 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 wa‐
ter, and reconnect them only when dry.
Touareg 2018 ➤
3.2 Foreign objects in engine
♦ To prevent the ingress of foreign bodies during work on
the engine, seal open channels of the intake and exhaust
sections with suitable bungs, for example from the engine
bung set -VAS 6122-.
♦ To prevent subsequent damage when a cylinder bank is
damaged mechanically, check the intake and exhaust sec‐
tions as well as the combustion chambers of the opposite
cylinder bank for foreign bodies.
♦ In the event of mechanical damage on turbocharger refer to
⇒ page 435 .
3.3 Contact corrosion
Contact corrosion can occur if unsuitable connecting elements
(screws, bolts, nuts, washers, etc.) are used.
For this reason, only connecting elements with a special surface
coating have been fitted.
In addition, rubber, plastic and adhesives are made of non-con‐
ductive materials.
3. Repair instructions 7
Touareg 2018 ➤
6-cyl. direct injection (3.0 l, 4V, EA 839, turbocharger) - Edition 11.2020
If there is any doubt about the suitability of parts, a general rule
is to use new parts ⇒ Electronic parts catalogue.
Observe the following:
♦ Use only genuine parts which are tested and compatible with
aluminium.
♦ Damage resulting from contact corrosion is not covered by
the warranty.
3.4 Routing and attachment of lines
♦ To prevent interchanging and to maintain the original instal‐
lation position, mark the fuel, hydraulic system, vacuum and
ACF system pipes or any wiring for example prior to remov‐
al. 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.
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 permissible to renew radiators, condensers or charge air
coolers only because of such minor dents.
3.6 Checking fuel system for leaks
– Allow engine to run at average revs for a few minutes.
– Switch off ignition.
– Check entire fuel system for leaks.
– If leaks are found although the connections have been tight‐
ened to the correct torque, the relevant component must be
renewed.
– Then test drive the vehicle, accelerating to full throttle at
least once.
– Then, check the high-pressure system for leaks again.
8 Rep. gr.00 - Technical data
6-cyl. direct injection (3.0 l, 4V, EA 839, turbocharger) - Edition 11.2020
4 Hazard classification of high-voltage
system
DANGER
The vehicle’s high-voltage system and the high-voltage bat‐
tery are dangerous and can cause burns or other injuries and
even lead to a fatal electric shock.
– Any work on the high-voltage system, or on systems which
could be indirectly affected by it, may only be carried out
by properly trained and qualified expert personnel.
– In the event of queries or uncertainties regarding the terms
"high-voltage technician" or "high-voltage expert", or those
concerning the high-voltage system, the responsible im‐
porter must be contacted prior to the commencement of
any work.
– Any repair work must be performed in accordance with ap‐
plicable laws and regulations, the recognised engineering
practices, any relevant accident prevention regulations (in
Germany, including but not limited to the Information of
the German Social Accident Insurance (DGUV) 200-005 –
Qualification training for work on vehicles with high-voltage
systems), as well as this workshop manual.
Touareg 2018 ➤
Before work on the high-voltage system is started, a high-volt‐
age technician must de-energise the high-voltage system ⇒
h8 igh-voltage system”, page 689 .
The types of work for which the high-voltage system has to
be de-energised are indicated in the list entitled “Work on the
high-voltage system” ⇒ page 11 .
Work for which the high-voltage system has to be de-energised:
♦ Only the HVT is authorised to certify that the high-voltage
system has been de-energised.
♦ All work on an e-Golf must be carried out only by those who
are at least qualified as electrically instructed persons (EIP).
♦ Regardless of the work to be performed, visually inspect
high-voltage components in the work area.
♦ High-voltage cables must not be overly bent or kinked.
♦ In the event of conspicuous findings or uncertainties, the
high-voltage technician (HVT) or the high-voltage expert
(HVE) must be consulted.
♦ Any work involving metal-removing, deforming and sharp-
edged tools or heat sources such as welding, soldering, hot
air, thermal bonding and infrared drying in the vicinity of
high-voltage components and cables is prohibited. In this
case the high-voltage system must be de-energised and the
respective component removed or sufficiently protected.
♦ All listed work refers to the removal and installation or the
renewal of the individual components.
♦ For regular maintenance work, the high-voltage system does
not have to be de-energised.
For reasons of safety, the following activities must not be car‐
ried out during charging.
♦ Activities that prolong the charging process.
♦ Activities for which the vehicle must be de-energised and
made safe in accordance with the ensuing hazard rating.
4. Hazard classification of high-voltage system 9
Touareg 2018 ➤
6-cyl. direct injection (3.0 l, 4V, EA 839, turbocharger) - Edition 11.2020
♦ Activities during which the vehicle is moved and cables and
connectors could be placed under strain (pulled).
♦ Activities during which the connected charging cable could
present a danger of tripping and injury.
♦ Activities during which the charging cable could block work
paths and emergency exit routes.
♦ Activities on the 12V battery.
The following activities may be carried out with the vehicle diag‐
nostic tester during charging.
♦ Interrogation of event memory and measured values permit‐
ted
♦ The vehicle and control units may be identified.
Explanation of qualifications
Qualification Volks‐
wagen
EIP (person with
electrical training)
HVT (high-voltage
technician)
HVE level 1 (highvoltage expert)
DGUV-I 200-005 Scenario
Chapter 2 Induction training
for non-electrical
work (< 60 VDC)
Chapter 3.1 b Working on inher‐
ently safe HV pro‐
duction vehicles
♦ Vehicles are de-
energised exclu‐
sively with certif‐
ication.
♦ Complete con‐
tact protection in
place.
Chapter 3.2 b Working on not in‐
herently safe HV
production vehicles
♦ Vehicles are al‐
so de-energised
without certifica‐
tion or there is
no complete
contact protec‐
tion in place,
e.g. in the event
of an accident.
HVE level 2 (highvoltage expert)
Chapter 3.3 Working on live ac‐
10 Rep. gr.00 - Technical data
cumulators
♦ Working on
parts supplied
with voltage, in‐
evitably with no
contact protec‐
tion, for fault
finding, compo‐
nent replace‐
ment, etc.
Work on high-voltage system
Touareg 2018 ➤
6-cyl. direct injection (3.0 l, 4V, EA 839, turbocharger) - Edition 11.2020
When working on the
Minimum qualification
following components:
De-energise high-volt‐
age system
Work on power unit
When working on the following
components:
three-phase current drive -VX54-
Electric drive motor -V141Mechatronic unit for dual clutch
gearbox -J743Drive motor temperature sender/ro‐
tor position sender -G712-/-G713Lambda probe 1 ahead of catalytic
converter -GX10Lambda probe 1 after catalytic con‐
verter -GX7Coolant pumps -V467-, -V468-, -
V508-, -V590Valves in coolant circuit
Oil level and oil temperature sender
-G266Combustion engine
HVT
Must the HVT de-energise high-voltage sys‐
tem before work is started?
yes (manual
de-energisa‐
tion)
yes (only di‐
agnostic de-
energisation)
X
X
X
X
X
no
X EIP
X EIP
X EIP
X EIP
X EIP
Minimum qualifica‐
tion: ⇒ page 10
EIP
EIP
EIP
EIP
EIP
Work on power and control electronics for electric drive
When working on the following
components:
Must the HVT de-energise high-voltage sys‐
tem before work is started?
Yes (manual
power discon‐
nect)
Power and control electronics for
electric drive -JX1- with
♦ Electric drive control unit -J841-
♦ Intermediate circuit capacitor 1
-C25-
♦ Voltage converter -A19-
♦ DC/AC converter for drive motor
-A37-
High-voltage system fuse 3 -S353-
yes (only di‐
agnostic de-
energisation)
X
X
no
Minimum qualifica‐
tion: ⇒ page 10
EIP
EIP
4. Hazard classification of high-voltage system 11
Touareg 2018 ➤
6-cyl. direct injection (3.0 l, 4V, EA 839, turbocharger) - Edition 11.2020
Work on high-voltage system
When working on the following
components:
Potential equalisation lines (earth)
with connection to HV components
Measure insulation resistance
Maintenance connector for high-
voltage system (service connector,
service disconnector)
PX – high-voltage cables (orange)
in vehicle
Work on heating and air conditioning system
When working on the following
components:
Electrical air conditioner compres‐
sor -V470-
High-voltage heater (PTC) -Z115Work on heating and air condition‐
ing system in vehicle interior
Refrigerant lines in vehicle periph‐
ery. Work which is not directly on
the AC compressor and can be car‐
ried out without opening the refrig‐
erant circuit, e.g. loosening and se‐
curing refrigerant lines.
Air conditioning performance test.
For checking the pressure levels in
the refrigerant circuit by means of
air conditioning service equipment.
Refrigerant lines directly on the AC
compressor
Extract, evacuate or fill refrigerant
Heat exchanger for high-voltage
battery -VX63-
Must the HVT de-energise high-voltage sys‐
tem before work is started?
Yes (manual
power discon‐
nect)
Must the HVT de-energise high-voltage sys‐
tem before work is started?
Yes (manual
power discon‐
nect)
yes (only di‐
agnostic de-
energisation)
yes (only di‐
agnostic de-
energisation)
Minimum qualifica‐
tion: ⇒ page 10
no
X
X
X
X
X
X
X EIP
Minimum qualifica‐
tion: ⇒ page 10
no
X EIP
X EIP
X EIP
X EIP
X EIP
HVT
HVT
HVT
EIP
EIP
EIP
Work on charging connection
When working on the following
components:
High-voltage battery charging sock‐
et 1 -UX4- with
♦ Temperature sender for charg‐
ing socket 1 -G853-
♦ Actuator for locking
12 Rep. gr.00 - Technical data
Must the HVT de-energise high-voltage sys‐
tem before work is started?
Yes (manual
power discon‐
nect)
yes (only di‐
agnostic de-
energisation)
X
no
Minimum qualifica‐
tion: ⇒ page 10
EIP
Touareg 2018 ➤
6-cyl. direct injection (3.0 l, 4V, EA 839, turbocharger) - Edition 11.2020
When working on the following
components:
Module for battery charge selector
buttons -EX32♦ LED module for charging socket
1 -L263-
Manual release mechanism for
charging connector
Charge high-voltage battery in
workshop area
Work on charging unit
When working on the following
components:
Charging unit 1 for high-voltage
battery -AX4With control unit for high-voltage
battery charging unit -J1050-
Must the HVT de-energise high-voltage sys‐
tem before work is started?
Yes (manual
power discon‐
nect)
yes (only di‐
agnostic de-
energisation)
X
no
X
X EIP
Must the HVT de-energise high-voltage sys‐
tem before work is started?
Yes (manual
power discon‐
nect)
yes (only di‐
agnostic de-
energisation)
X
no
Minimum qualifica‐
tion: ⇒ page 10
EIP
EIP
Minimum qualifica‐
tion: ⇒ page 10
EIP
Work on high-voltage battery
When working on the following
components:
Removing and installing underbody
cladding
Removing and installing high-volt‐
age battery 1 -AX2-, de-energised,
high voltage system connection and
DC charging connection disconnec‐
ted. Approval by technician quali‐
fied at least as HVT.
Disconnect high voltage system
connection
Disconnect low-voltage connection
of high-voltage battery
Battery regulation control unit J840-
Switching unit for high-voltage bat‐
tery -SX6- (battery removed)
Module monitor control unit for bat‐
teries -J497- (battery removed)
Open high-voltage battery 1 -AX2(battery removed)
Bond/screw high-voltage battery 1
-AX2- (battery removed)
Must the HVT de-energise high-voltage sys‐
tem before work is started?
Yes (manual
power discon‐
nect)
yes (only di‐
agnostic de-
energisation)
X
X
no
X
X EIP
X EIP
Minimum qualifica‐
tion: ⇒ page 10
EIP
EIP
HVT
HVE
HVE
HVE
HVE
4. Hazard classification of high-voltage system 13
Touareg 2018 ➤
6-cyl. direct injection (3.0 l, 4V, EA 839, turbocharger) - Edition 11.2020
When working on the following
components:
Battery module 1 -J991- and other
battery modules (battery removed)
Work on accident vehicles
When working on the following
components:
Status assessment / initial assess‐
ment of risk status
Body work (with straightening jig)
Paint vehicle – observe instructions
in paint manual
Work in vicinity of high-voltage components
Must the HVT de-energise high-voltage sys‐
tem before work is started?
Yes (manual
power discon‐
Must the HVT de-energise high-voltage sys‐
tem before work is started?
Yes (manual
power discon‐
yes (only di‐
agnostic de-
nect)
nect)
energisation)
yes (only di‐
agnostic de-
energisation)
X
Minimum qualifica‐
tion: ⇒ page 10
no
HVE
Minimum qualifica‐
tion: ⇒ page 10
no
HVT
X EIP
EIP
When working on the following
components or for following work:
Body work (assembly work as well
as glass and dent repairs)
Gearbox with electric drive motor
Steering rack
Subframe, front
Exhaust system, in front area of ve‐
hicle
Exhaust system, in rear area of ve‐
hicle
Front brakes
Rear brakes
Brake servo
Brake pressure accumulator for en‐
ergy recovery
Rear axle and running gear
Underbody cladding
When welding, cover high-voltage
components and visually inspect af‐
terwards
Work involving metal-removing, de‐
forming and sharp-edged tools or
heat sources such as welding, sol‐
dering, hot air, thermal bonding
and infrared drying in the vicinity
of high-voltage components and ca‐
bles
Must the HVT de-energise high-voltage sys‐
tem before work is started?
yes (diagnos‐
tic and man‐
ual power dis‐
connection)
Yes (only di‐
agnostic pow‐
er disconnec‐
tion)
X
X
X
no
X
X EIP
X EIP
X EIP
X EIP
X EIP
X EIP
X EIP
X EIP
X EIP
X EIP
Minimum qualifica‐
tion: ⇒ page 10
EIP
EIP
EIP
EIP
14 Rep. gr.00 - Technical data
Touareg 2018 ➤
6-cyl. direct injection (3.0 l, 4V, EA 839, turbocharger) - Edition 11.2020
When working on the following
components or for following work:
Work for which the engine is lifted,
on right side (e.g. engine mounting)
Work for which the engine is lifted,
on left side (e.g. gearbox mounting)
Control units and electric compo‐
nents of 12-V system (excluding
airbag)
Battery -AFront left headlight -MX1Front right headlight -MX2Change bulb in headlight
General work
When working on the following
components:
Drain and fill fluids (coolant and
oils)
Coolant circuit and coolant expan‐
sion tank
Change tyres
Miscellaneous work on 12 V system
(excluding airbag)
Work on earth points of 12 V sys‐
tem (without potential equalisation
lines)
Tail lights
Renew/repair windows
Repairs in vehicle interior
Repairs in roof area
Repairs on rear lid
Repairs on bumpers
Move lock carrier to service position
Removing and installing lock carrier
Repair work on lock carrier
Must the HVT de-energise high-voltage sys‐
tem before work is started?
yes (diagnos‐
tic and man‐
ual power dis‐
connection)
Yes (only di‐
agnostic pow‐
er disconnec‐
tion)
no
X
X EIP
X EIP
X EIP
X EIP
X EIP
X EIP
De-energise high-voltage system before work
is started?
yes (diagnos‐
tic and man‐
ual power dis‐
connection)
Yes (only di‐
agnostic pow‐
er disconnec‐
tion)
no
X
X EIP
X EIP
X EIP
X EIP
X EIP
X EIP
X EIP
X EIP
X EIP
X EIP
X EIP
X EIP
X EIP
Minimum qualifica‐
tion: ⇒ page 10
EIP
Minimum qualifica‐
tion: ⇒ page 10
EIP
4. Hazard classification of high-voltage system 15
Touareg 2018 ➤
6-cyl. direct injection (3.0 l, 4V, EA 839, turbocharger) - Edition 11.2020
10 – Removing and installing engine
1 Removing and installing engine
⇒ e1.1 ngine”, page 16
⇒ e1.2 ngine and gearbox”, page 49
⇒ e1.3 ngine from scissor-type assembly platform”, page 57
⇒ e1.4 ngine on engine and gearbox support”, page 58
⇒ e1.5 ngine”, page 61
1.1 Removing engine
⇒ e1.1.1 ngine – vehicles without high-voltage system”, page
16
⇒ e1.1.2 ngine – vehicles with high-voltage system”, page 30
1.1.1 Removing engine – vehicles without high-voltage system
Special tools and workshop equipment required
♦ Hook -10-222A/20-
♦ Engine bung set -VAS 6122-
16 Rep. gr.10 - Removing and installing engine
6-cyl. direct injection (3.0 l, 4V, EA 839, turbocharger) - Edition 11.2020
♦ Scissor-type assembly platform -VAS 6131 B-
♦ Set of mountings for Audi -VAS 6131/10-
Touareg 2018 ➤
♦ Supplement set, Audi A8 >2002 -VAS 6131/11-, not shown
♦ Supplement set, Audi Q7 > 2005 -VAS 6131/13-
♦ Coolant collection system -VAS 5014- or drip tray for work‐
shop hoists -VAS 6208-
1. Removing and installing engine 17
Touareg 2018 ➤
6-cyl. direct injection (3.0 l, 4V, EA 839, turbocharger) - Edition 11.2020
♦ Hose clamp pliers -VAS 6340-
♦ Spring-type clip pliers -VAS 6362-
♦ Engine and gearbox jack -VAS 6931-
♦ Ball joint splitter -VAS 251 805-
18 Rep. gr.10 - Removing and installing engine
6-cyl. direct injection (3.0 l, 4V, EA 839, turbocharger) - Edition 11.2020
♦ Tensioning strap -T10038-
♦ Stepladder, commercially available
♦ Safety goggles
♦ Safety gloves
Procedure
♦ The engine is removed from underneath together with the
gearbox and subframe (with lock carrier installed).
♦ Fit cable tie in same place when installing.
♦ Observe rules for cleanliness ⇒ f3.1 or cleanliness”, page 7 .
♦ All bolts on running gear components with bonded rubber
bushes may be tightened only when the component is in the
unladen position (normal position).
♦ Bonded rubber bushes can be twisted only to a limited
extent. Axle components with bonded rubber bushes must
therefore be brought to a position equivalent to the unla‐
den (normal) position before being tightened. Otherwise, the
bonded rubber bush would be subject to torsion loading,
shortening its service life.
– Before starting work, determine unladen position ⇒ Running
gear, axles, steering; Rep. gr. 00; Repair instructions; Rais‐
ing vehicles with coil springs, wheel bearing in unladen posi‐
tion.
• To be able to turn the propshaft during removal, the electro‐
mechanical parking brake must be released before discon‐
necting the battery.
– Move front wheels to straight-ahead position.
– Switch off ignition.
– Disconnect earth wire from battery terminal ⇒ Electrical sys‐
tem; Rep. gr. 27; Battery, Disconnecting and connecting bat‐
tery.
Touareg 2018 ➤
– Remove air filter housing ⇒ a4.2 nd installing air filter hous‐
ing”, page 495 .
– Remove lock carrier cover ⇒ General body repairs, exterior;
Rep. gr. 63; Body - front; Removing and installing attach‐
ments.
– Remove front wheels ⇒ Running gear, axles, steering; Rep.
gr. 44; Wheels, tyres.
– Remove front wheel housing liner on left and right as well as
wheel spoiler ⇒ General body repairs, exterior; Rep. gr. 66;
Wheel housing liner; Assembly overview - front wheel hous‐
ing liner.
1. Removing and installing engine 19
Touareg 2018 ➤
6-cyl. direct injection (3.0 l, 4V, EA 839, turbocharger) - Edition 11.2020
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66; Noise insulation; Removing and installing noise
insulation.
– Remove front lower longitudinal member ⇒ General body
repairs, exterior; Rep. gr. 50; Lock carrier; Removing and
installing lower longitudinal member.
– Remove cross strut for subframe ⇒ Running gear, axles,
steering; Rep. gr. 40; Subframe; Removing and installing
cross struts for subframe.
– Remove propshaft ⇒ Propshaft and rear final drive; Rep.
gr. 39; Propshaft; Removing and installing propshaft.
– Unscrew bolts -arrows- on left and right, and detach upper
part -1- of subframe shield.
– Remove front silencers on left and right ⇒ a1.2 nd installing
front silencer”, page 540 .
– Drain coolant ⇒ a1.5 nd adding coolant”, page 323 .
– Release hose clips -1 and 3-, remove air hose from air pipe.
– Disconnect fuel hose -2- ⇒ Fuel supply; Rep. gr. 20; Plug-in
connectors; Disconnecting plug-in connectors.
20 Rep. gr.10 - Removing and installing engine
6-cyl. direct injection (3.0 l, 4V, EA 839, turbocharger) - Edition 11.2020
– Release hose clip -1- and disconnect hose for activated
charcoal filter system.
– Seal open pipes and connections with thoroughly cleaned
plugs from engine bung set -VAS 6122-.
– Release hose clip -1-, pull off air pipe, push towards left and
tie in place.
Touareg 2018 ➤
– Release fastener -arrow- and open electronics box -1-.
– Unscrew nut -2- and expose B+ wire.
– Free off electric wire -1- from wiring duct.
1. Removing and installing engine 21
Touareg 2018 ➤
6-cyl. direct injection (3.0 l, 4V, EA 839, turbocharger) - Edition 11.2020
– Unscrew nut -2- and free off earth wire.
– Remove bolt -3- and nut -4- and free off wiring duct.
– Lift retaining clip -1- and disconnect coolant hose.
– Equipment version without auxiliary heater: release fastener
-arrow- and push coolant circulation pump -V50- to one side.
– Release hose clip -1- and detach coolant hose.
– Lift retaining clip -2-, remove upper left coolant hose from
radiator.
– Release fastener -arrow-, detach vacuum hose -1-, ensuring
when doing so that it is not damaged.
22 Rep. gr.10 - Removing and installing engine
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