5-Cylinder Diesel Engine BAC BLK BPD BPE VW Touar
5-Cylinder Diesel Engine BAC BLK BPD BPE VW Touar
5-Cylinder Diesel Engine BAC BLK BPD BPE VW Touar
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Workshop Manual VW Touareg
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5-cylinder diesel engine BAC BLK BPD BPE VW Touareg
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Engine ID
Edition 11.2011
Эл. почта
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system
21 - Turbocharging/supercharging
23 - Mixture preparation - injection
26 - Exhaust system
28 - Glow plug 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.
Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011
Contents i
Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011
ii Contents
Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011
2.1 Reading and deleting engine control unit event memory . . . . . . . . . . . . . . . . . . . . . . . . . . 139
2.2 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
2.3 Removing and installing anti-theft engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . 140
1.1 Assembly overview - front exhaust pipe with catalytic converters . . . . . . . . . . . . . . . . . . . . 145
1.2 Assembly overview - front exhaust pipe with particulate filter . . . . . . . . . . . . . . . . . . . . . . 146
1.3 Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.4 Assembly overview - exhaust manifold (engine codes BPD, BPE) . . . . . . . . . . . . . . . . . . 148
1.5 Removing and installing exhaust manifold (engine codes BPD, BPE) . . . . . . . . . . . . . . . . 150
1.6 Silencer with mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Contents iii
Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011
iv Contents
Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011
1. Technical data 1
Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011
Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011
2. Safety instructions 3
Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011
Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011
♦ Scissor-type assembly
platform -VAS 6131-
♦ Drip tray -V.A.G 1306- or
drip tray for workshop hoist
-VAS 6208-
♦ Spring-type clip pliers -VAS
5024 A-
♦ Torque wrench -V.A.G
1332- (40...200 Nm)
♦ spring compressor -VW
552-
– All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.
– Disconnect batteries ⇒ Electrical system; Rep. gr. 27 ; Bat‐
tery; Disconnecting and connecting battery .
Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011
– Disconnect starter cable -1- and alternator cable -2-, and place
on engine.
Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011
– Pull fuel supply hose -1- and fuel return hose -2- off fuel filter.
– Remove brake servo vacuum supply hose from tandem pump.
Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011
Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011
– Unscrew universal joint bolt -B- from steering box, and pull
universal joint off steering box.
– Remove bracket for catalytic converter on underbody.
– Disconnect connectors -A- from gearbox.
Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011
– Clamp off power steering oil line to cooler with hose clips up
to 40 mm Ø -3093- , loosen clip and pull hose off cooler. Collect
escaping oil.
Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011
Support 2: G 4, H 4 and H 5
– Bolt support 3 and support 4 to scissor-type assembly platform
at following positions:
Support 3: A 6 and B 5
Support 4: F 6 and H 6
– Screw turntables of supports 3 and 4 downwards.
– Place support 5 for subframe and support 6 for gearbox trans‐
verse support in appropriate positions on scissor-type assem‐
bly platform.
– Fix subframe in position ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Fixing subframe in position .
– At the same time, guide the supports -6- for the left and right
sides of the gearbox transverse into corresponding hole
-arrow-.
When all 4 supports are located in the mountings without pres‐
sure:
– Screw both turntables of axle supports under wishbones (with
slight pretension), until the spring compressor -VW 552- can
be removed.
Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011
Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011
♦ Hooks -10-222A/2-
♦ Lifting eye -2024A/2-
♦ Lifting tackle -2024 A-
♦ Lifting tackle -3033-
♦ Workshop crane -V.A.G
1202A- or workshop crane
-VAS 6100- with lifting tack‐
le -3033-
♦ Drip tray -V.A.G 1306- or
drip tray for workshop hoist
-VAS 6208-
♦ Torque wrench -V.A.G
1331- (5...50 Nm)
Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011
Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011
Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011
Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011
Bolts, nuts M6 10 Nm
M7 15 Nm
M8 25 Nm
M10 40 Nm
M12 60 Nm
Specified torques gearbox carrier to body ⇒ Rep. gr. 34 ; Instal‐
ling transfer box, gearbox carrier and console .
Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011
Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011
Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011
❑ Renew.
❑ Renew if damaged.
Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011
❑ Remove to remove
coolant pump.
❑ Remove to remove
coolant pump.
❑ Renew.
❑ Tighten on cylinder
block to 10 Nm.
❑ Renew.
❑ Renew.
Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011
❑ Renew.
❑ Tighten to 75 Nm.
❑ Renew.
❑ Renew.
❑ Renew if damaged.
❑ Specified torque ⇒ Heating, air conditioning system; Rep. gr. 87 ; Air conditioning compressor; Re‐
moving and installing air conditioning compressor from and to bracket
❑ Removing and installing ⇒ Heating, air conditioning system; Rep. gr. 87 ; Air conditioning compressor;
Removing and installing air conditioning compressor from and to bracket
Touareg 2003 ➤
5-cylinder diesel engine - Edition 11.2011
❑ Renew.
❑ Renew.
❑ If the tie bolts are to be
loosened then the cylin‐
der head bolts must be
removed and the cylin‐
der head removed from
the block first
⇒ page 34 .
❑ For bearing 4.
❑ If the crankshaft is to be
removed, first remove
cylinder head bolts and
cylinder head before
loosening crankshaft
bearings.
❑ Axial clearance new:
0.07…0.231 mm, wear
limit: 0.250 mm.
❑ Check radial clearance
using Plastigage:
0.026…0.040 mm, wear
limit: 0.16 mm
❑ Do not rotate crankshaft
when checking radial clearance.
❑ Crankshaft dimensions ⇒ page 27 .
От Everand
VW Transporter T4 Workshop
Manual Diesel 2000-2004
Greg Hudock
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От Everand
VW Transporter T4 ( Diesel -
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