5-Cylinder Diesel Engine BAC BLK BPD BPE VW Touar

5-Cylinder Diesel Engine
BAC BLK BPD BPE VW

Touareg
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Workshop Manual VW Touareg
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Engine ID
 Edition 11.2011
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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
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.2 Safety precautions for when using test and measuring equipment during a road test . . . . 3
2.3 Safety precautions when working on cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.2 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.2 Removing engine from scissor-type assembly platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4 Additional information and assembly work for vehicles with air conditioner . . . . . . . . . . . . 16
1.5 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Assembly overview - engine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.2 Specified torques - Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.1 Dismantling and assembling engine, parts I-III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.2 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.3 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.4 Crankshaft bearing cap identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.5 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.6 Renewing crankshaft oil seal - engine timing end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.7 Renewing alternator shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2.2 Separating new conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.3 Installation position and allocation of piston to cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.4 Checking piston ring gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.5 Checking ring-to-groove clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.6 Checking cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.7 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1.2 Renewing pipe connection for coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.3 Removing and installing camshaft drive gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.4 Setting engine to TDC No. 1 cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.5 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.6 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

2.2 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Contents i
Touareg 2003 ➤
2.3 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

2.4 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.5 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.1 Oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

1.2 Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.1 Assembly overview - oil pump, sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

2.2 Assembly overview - oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.3 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.4 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1.1 Parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

1.2 Assembly overview - radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.3 Removing and installing fan support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.4 Parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.5 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.6 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.7 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.8 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.9 Checking oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

1.2 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.3 Assembly overview - fuel tank with attachments (► model year 08) . . . . . . . . . . . . . . . . . . 87
1.4 Assembly overview - fuel tank with attachments (model year 08 ►) . . . . . . . . . . . . . . . . . . 88
1.5 Assembly overview - fuel filter with fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.6 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.7 Removing and installing fuel pump unit, fuel gauge sender and suction jet pumps (for vehicles
► model year 08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.8 Removing and installing fuel pump unit, fuel gauge sender and suction jet pumps (for vehicles
model year 08 ►) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.9 Removing and installing fuel tank with attached components . . . . . . . . . . . . . . . . . . . . . . 100
1.10 Checking fuel pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.11 Checking tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.12 Removing and installing tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.13 Assembly overview - accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

1.2 Turbocharger with attachments for engine codes BAC and BLK . . . . . . . . . . . . . . . . . . . . 110
1.3 Removing and installing turbocharger for engine codes BAC and BLK . . . . . . . . . . . . . . . . 112
1.4 Turbocharger with attachments (engine codes BPD and BPE) . . . . . . . . . . . . . . . . . . . . . . 114
1.5 Removing and installing turbocharger (engine codes BPD and BPE) . . . . . . . . . . . . . . . . 116
1.6 Removing and installing parts of charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.7 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.8 Hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.9 Vacuum hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
ii Contents
Touareg 2003 ➤
1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

1.3 Removing and installing unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.4 Assembly overview - unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
1.5 Removing and installing O-rings for unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
1.6 Assembly overview - intake manifold and fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.7 Repairing intake manifold flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1.8 Dismantling and assembling air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
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
2.1 Assembly overview - exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

2.2 Checking exhaust gas recirculation valve (mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.1 Characteristics of glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

1.2 Checking metal glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.3 Removing, installing and checking ceramic glow pin plugs . . . . . . . . . . . . . . . . . . . . . . . . 162
Contents iii
Touareg 2003 ➤
iv Contents
Touareg 2003 ➤
The engine number („engine code“ and „serial number“) can be

found on the joint between engine and gearbox.
Additionally there is a sticker on the front of the cylinder head with
„Engine code“ and „Serial number“.
The engine code is also included on the vehicle data sticker.
Edition 11.20011 Version 21.0
Manufactured 03.03 ► 08.03 ► 11.05 ► 11.05 ►

Emissions fulfil EU3 standard EU3 standard EU4 standard EU4 standard
Capacity l 2.5 2.5 2.5 2.5
Output kW at rpm 128/3500 120/3500 120/3500 128/3500
Torque Nm at rpm 400/2000… 400/2000… 400/2000 400/2000
2300 2300
Bore ∅ mm 81.0 81.0 81.0 81.0
Stroke mm 95.5 95.5 95.5 95.5
Compression ratio 18.0 18.0 19.5 19.5
Fuel according to DIN EN 590 DIN EN 590 DIN EN 590 DIN EN 590
Firing order 1-2-4-5-3 1-2-4-5-3 1-2-4-5-3 1-2-4-5-3
Catalytic converter yes yes yes yes
Exhaust gas recirculation yes yes yes yes
Turbocharging/supercharging yes yes yes yes
Particulate filter no no yes yes
Charge air cooling yes yes yes yes
Volkswagen Technical Site: http://vwts.ru http://vwts.info
1. Technical data 1
Touareg 2003 ➤
♦ Always switch off the ignition before connecting or discon‐

necting electrical wiring of injection and glow plug system or
connecting/disconnecting tester cables.
♦ Wash the engine only with the ignition switched off.
♦ Entries have been stored in the event memory of the engine
control unit if the engine was started after electrical connectors
had been disconnected: Read event memor y in vehi c l e
s el f - di agnos i s ⇒ Vehicle diagnosis tester .
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 .
2 Rep. gr.00 - Technical data
Touareg 2003 ➤
♦ Test and measuring instruments must always be secured to

the rear seat and operated by a second person from this lo‐
cation.
♦ If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there
is a possibility that the person sitting in this seat may receive
serious injuries when the airbag is triggered.
2. Safety instructions 3
Touareg 2003 ➤
When working on fuel supply and injection system, pay careful

attention to the following rules for cleanliness:
♦ Before disconnecting, thoroughly clean all connections and
adjacent areas e.g. with brake cleaner.
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
♦ Carefully cover opened components and connections or seal
if repairs cannot be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
♦ When the system is open: Do not work with compressed air.
Do not move vehicle.
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
If large quantities of swarf or metal particles (caused, for example,

by partial seizure of the crankshaft or conrod bearings) are found
in the engine oil when performing repairs, clean the oil passages
thoroughly and renew the engine oil cooler in order to prevent
subsequent damage.
4 Rep. gr.00 - Technical data
Touareg 2003 ➤
The engine is removed downwards with gearbox.
♦ 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-
♦ Basic set for Touareg -VAS 6131/6-
1. Removing and installing engine 5

Touareg 2003 ➤
♦ Engine and gearbox support -T10220- or engine and gearbox

support -T10342-
♦ Engine bracket -T10224-
♦ Container for removed parts -V.A.G 1698-
♦ Cable ties
– First check whether a coded radio is fitted. If so, obtain anti-

theft coding.
♦ Leave ignition key in ignition lock to prevent steering lock from

engaging.
♦ It is advisable to remove the front wheels before beginning
engine removal. The vehicle can then be lowered on hoist until
the brake disc splash plates are just above the floor. This pro‐
vides a more ergonomic working position regarding accessi‐
bility of engine compartment components.
♦ Some components cannot be removed, or removed only with
difficulty, with the engine installed. Therefore, you should de‐
termine all defective components before removing engine and
renew them while engine is removed.
♦ To prevent damage to removed components, place them in
the container for removed parts -V.A.G 1698- .
– All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.
– Disconnect batteries ⇒ Electrical system; Rep. gr. 27 ; Bat‐
tery; Disconnecting and connecting battery .
– Remove selector mechanism from centre console ⇒ Rep. gr.

34 ; Selector mechanism; Assembly overview - selector mech‐
anism .
– Then place selector mechanism on gearbox.
6 Rep. gr.10 - Removing and installing engine
Touareg 2003 ➤
– Remove engine cover -A- and engine compartment covers

-B-, -C- and -D-, if fitted.
– Remove intake hose -A-.

– Pull vacuum hoses off exhaust gas recirculation valve, intake
manifold changeover vacuum actuator and turbocharger.
– Remove crankcase breather hose from cylinder head cover.
– Release clip of air filter connecting hose on engine, then dis‐
connect hose.
– Extract air conditioning system refrigerant ⇒ Heating, air con‐
ditioning system; Rep. gr. 87 .
– Unscrew refrigerant lines from air conditioner compressor.
– Remove noise insulation: ⇒ General body repairs, exterior;
Rep. gr. 50 ; Body - front; Assembly overview - noise insulation
– Drain off coolant: ⇒ page 72 .
– Disconnect starter cable -1- and alternator cable -2-, and place
on engine.
Touareg 2003 ➤
– Pull fuel supply hose -1- and fuel return hose -2- off fuel filter.
– Remove brake servo vacuum supply hose from tandem pump.
– Disconnect glow plugs connector -1-.

– Pull all necessary coolant hoses off engine.
– Clamp off power-assisted steering oil hose -arrow- with hose

clips up to 40 mm Ø -3093- , loosen clip and disconnect hose
from power steering pump.
– Pull engine compartment seal off plenum chamber bulkhead.
– Remove plenum chamber cover.
– Unclip engine control unit from mountings (on right in plenum
chamber) and pull connector off engine control unit.
– Disconnect earth connection -1- from engine control unit wir‐

ing harness.
Touareg 2003 ➤
– Open fuse holder cover in plenum chamber on left and sepa‐

rate connectors -1-, -2- and -3-.
– Remove wiring harness (smaller connection on engine control
unit) from plenum chamber and lay aside on engine.
– Unclip line for gearbox breather -arrows-.
– Secure suspension strut, as shown, with spring compressor -

VW 552- .
– Remove upper bolts of suspension strut: ⇒ Running gear;
Rep. gr. 40 ; Front suspension .
– Disconnect engine earth connection -1-.
Touareg 2003 ➤
– Pull coolant hose -arrow- off continued coolant circulation

pump.
– Remove connecting hose between turbocharger and charge
air pipe.
– Pull additional heater coolant hoses -arrows- off and place to

the side so that they are not torn off when removing the engine.
– Remove heat shield -A- (if fitted) from steering box (2 bolts).
– 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.
– Release exhaust system clip -B- and push to rear.

– Remove propshaft tube ⇒ Transfer box and final drive; Rep.
gr. 39 ; Removing and installing propshaft .
Touareg 2003 ➤
– 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.
– Disconnect connectors on gearbox and transfer box ⇒ Auto‐

matic gearbox 09C; Rep. gr. 37 .
– Remove selector cable from gearbox ⇒ Automatic gearbox
09C; Rep. gr. 37 .
– Disconnect lines on lower right of radiator -arrow- for gearbox

oil. Collect escaping oil.
– Remove clutch slave cylinder ⇒ Rep. gr. 30 ; Clutch mecha‐

nism; Removing and installing clutch slave cylinder .
– Remove gearbox transverse support -A-.
– Disconnect brake line at point shown -arrow-. Collect brake

fluid which runs out.
The vehicle specific mounting set VAS 6131/6 consists of sup‐

ports VAS 6131/6-1 to VAS 6131/6-7. Support 1 (for VAS
6131/6-1) to support 7 (for VAS 6131/6-7) are mentioned to pro‐
vide a better overview of the following procedures.
– Assemble support 1 left and support 2 right (arrows point for‐

wards) on assembly platform -VAS 6131- and secure bolts at
following positions:
Support 1: A 5, B 4 and B 5
Touareg 2003 ➤
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 .
– Position horizontal scissor-type assembly platform under en‐

gine/gearbox assembly. The supports -1- and -2- must be
guided into corresponding mountings on left and right
-arrow-.
– 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 ➤
– Guide supports 5 into their respective mountings in subframe

-arrow-, correcting support height as necessary with knurled
nuts.
– Loosen subframe bolts -1-, -2- and -3- as well as gearbox

transverse support -4-.
Specified torque gearbox carrier -4- to body ⇒ Rep. gr. 34 ; In‐
stalling transfer box, gearbox carrier and console
♦ Engine and gearbox must be guided carefully when lowering

to prevent damage to the bodywork.
♦ If the subframe is not fixed on body, after reinstalling it is nec‐
essary to perform wheel alignment on the vehicle.
– Now slowly lower engine/gearbox assembly, constantly ob‐

serving the clearance.
Touareg 2003 ➤
♦ 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)
– Unbolt gearbox from engine: ⇒ Manual gearbox; Rep. gr. 34 ;

Removing and installing gearbox .
– Unbolt gearbox from engine: ⇒ Automatic gearbox 09D; Rep.

gr. 37 ; Removing and installing gearbox .
– Remove assembly mounting nut/bolt -A- on both sides of en‐

gine.
Touareg 2003 ➤
– Fit lifting tackle -2024 A- on cylinder block as shown.
– Attach lifting tackle -3033- together with hooks -10-222 A/2- to

crane and transportation plates, and lift engine off scissor-type
assembly platform, as shown.
Before carrying out repair work, secure engine on assembly stand

with engine and gearbox support -T10220- .
– Unbolt gearbox from engine ⇒ Manual gearbox; Rep. gr. 34 ;

Removing and installing gearbox ⇒ Automatic gearbox 09C;
Rep. gr. 37 .
– Remove engine bracket from cylinder head.
Touareg 2003 ➤
– Fit lifting eye -2024A/2- to cylinder block and tighten to 40 Nm

– Fit engine and gearbox support -T10220- as shown and tight‐
en to 40 Nm.
– Secure engine to assembly stand with engine and gearbox
support -T10220- .
Before carrying out repair work, secure engine on assembly stand

with engine and gearbox support -T10342- .
– Unbolt gearbox from engine ⇒ Manual gearbox; Rep. gr. 34 ;

Removing and installing gearbox ⇒ Automatic gearbox 09C;
Rep. gr. 37 .
– Remove engine bracket from cylinder head.
– Fit lifting eye -2024A/2- to cylinder block and tighten to 40 Nm

– Fit engine and gearbox support -T10342- as shown and tight‐
en to 40 Nm.
– Secure engine to assembly stand with engine and gearbox
support -T10342- .
♦ Always observe the notes on installing air conditioner com‐

pressor ⇒ Heating, air conditioning system; Rep. gr. 87 .
♦ To prevent damage to condenser or to refrigerant lines/hoses,
ensure that the lines and hoses are not stretched, kinked or
bent.
– Remove air conditioner compressor ⇒ Heating, air condition‐

ing system; Rep. gr. 87 .
Touareg 2003 ➤
When moving engine/gearbox into body it is essential to position

the subframe relative to the body with aid of scissor-type assem‐
bly platform. „Pulling up“ the subframe with the securing bolts will
damage thread inserts.
Installation is carried out in the reverse order. When installing,

note the following:
Specified torques ⇒ page 18 , assembly mounting.
– Install hydraulic clutch slave cylinder ⇒ 6-speed manual gear‐
box 0A5; Rep. gr. 30 ; Repairing clutch mechanism .
– Install selector mechanism and adjust cables if necessary ⇒
6-speed manual gearbox 0A5; Rep. gr. 34 ; Repairing selector
mechanism; Removing and installing selector cables .
– Install selector lever cable on gearbox ⇒ Rep. gr. 37 ; Selector

mechanism; Assembly overview - selector lever cable .
– Top up ATF level ⇒ Automatic gearbox 09D; Rep. gr. 37 ;
Checking ATF level and topping-up.
– Electrical connections and routing: ⇒ Electrical system; Rep.

gr. 97 .
– Install subframe: ⇒ Running gear, axles, steering; Rep. gr.
40 ; Removing and installing subframe
– Reconnect air conditioning lines: ⇒ Heating, air conditioning
system; Rep. gr. 87 ; Repairing components of refrigerant cir‐
cuit .
– Replenish coolant ⇒ page 72 .
– Replenish oil in power-assisted steering: ⇒ Running gear,
axles, steering; Rep. gr. 48 ; Checking power-assisted steer‐
ing system oil level.
– Install noise insulation.
– Carry out a road test and read event memory ⇒ page 139
Reading and clearing event memory of engine control unit.
Touareg 2003 ➤
Engine assembly mountings

A- Bracket for additional 20 Nm
water pump
B- Engine bracket to cylin‐ 55 Nm
der block
C- Engine mounting 60 Nm
D- Engine bracket to en‐ 75 Nm
gine mounting
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 ➤
♦ If large quantities of swarf or metal particles (caused, for ex‐

ample, by partial seizure of the crankshaft or conrod bearings)
are found in the engine oil when performing repairs, clean the
oil galleries thoroughly and renew the engine oil cooler in order
to prevent subsequent damage.
♦ Engine must not be set down on oil sump, as this will damage
the oil sump liquid gasket.
♦ Secure engine to engine and gearbox support -VAS 6095- to
carry out repairs.
1. Dismantling and assembling engine 19
Touareg 2003 ➤
20 Rep. gr.13 - Crankshaft group
Touareg 2003 ➤
❑ Must seat on dowel

sleeves.
❑ Must be removed to al‐
low for removal of sump
and cylinder head.
❑ Insert with sealant ac‐
cording to ⇒ Electronic
parts catalogue (ETKA)
⇒ page 22 .
❑ Renew.
❑ With gear train.
❑ Removing and installing

⇒ page 34
❑ For coolant pump.

coolant pump
⇒ page 77 .
❑ Clean sealing surface

before fitting.
❑ Install with sealant ac‐
⇒ page 62 .
❑ Renew if damaged.
❑ Do not additionally oil or grease the oil seal sealing lip.

❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
❑ Renew. ⇒ page 27 .
❑ For coolant pump.

❑ Renew seal if damaged.
1. Dismantling and assembling engine 21
Touareg 2003 ➤
❑ Remove to remove
coolant pump.
❑ Remove to remove
coolant pump.
❑ Renew.
❑ Tighten on cylinder
block to 10 Nm.
❑ With engine oil cooler.

❑ Dismantling and assem‐
bling ⇒ page 58 .
❑ Renew.
❑ For oil sump.
❑ Clean sealing surface

before fitting.
❑ Install with sealant ac‐
⇒ page 62 .
❑ Renew seal if damaged.
❑ Renew.
Touareg 2003 ➤
❑ Renew.
❑ The bolts between alter‐

nator and alternator
bracket must not be
loosened.
⇒ Electrical system;
Rep. gr. 27 ; Alternator;
Removing and installing
alternator .
❑ Tighten to 75 Nm.
❑ Renew.

⇒ Running gear, axles,
steering; Rep. gr. 48 ;
Vane pump, hydraulic
lines, storage tank with
suction hoses; Remov‐
ing and installing vane
pump .
❑ 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
❑ For air conditioner compressor.

❑ Note dowel sleeves between bracket/cylinder block and bracket/air conditioner compressor.
❑ For alternator shaft.
Volkswagen Technical Site: http://vwts.ru http://vwts.info 1. Dismantling and assembling engine 23
Touareg 2003 ➤
❑ Renew.
Repairing clutch ⇒ 6-speed manual gearbox 0A5; Rep. gr. 30 ;

Repairing clutch
❑ 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 .
❑ Bearing cap 4 with re‐

cesses for thrust wash‐
ers.
❑ Bearing shell retaining
lugs in cylinder block
and bearing caps must
align.
❑ 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 .
❑ Insert with sealant according to ⇒ Electronic parts catalogue (ETKA) ⇒ page 22 .

❑ With seal.
❑ Use fitting tool -T10122- to pretension seal before installing.
❑ Do not additionally oil or grease the oil seal sealing lip.
❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
❑ Renewing seal ⇒ page 27 .
Engine code: BAC.
Only vehicles with manual gearbox up to engine number 05984.













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5-Cylinder Diesel Engine BAC BLK BPD BPE VW Touar

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1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.1 Assembly overview - engine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.1 Dismantling and assembling engine, parts I-III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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2.3 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

1.1 Oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

2.1 Assembly overview - oil pump, sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

1.1 Parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

1.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

1.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

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1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

2.1 Assembly overview - exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

1.1 Characteristics of glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

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The engine number („engine code“ and „serial number“) can be

Edition 11.20011 Version 21.0

Manufactured 03.03 ► 08.03 ► 11.05 ► 11.05 ►

Volkswagen Technical Site: http://vwts.ru http://vwts.info

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♦ Always switch off the ignition before connecting or discon‐

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

2 Rep. gr.00 - Technical data

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♦ Test and measuring instruments must always be secured to

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When working on fuel supply and injection system, pay careful

If large quantities of swarf or metal particles (caused, for example,

4 Rep. gr.00 - Technical data

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The engine is removed downwards with gearbox.

♦ Basic set for Touareg -VAS 6131/6-

1. Removing and installing engine 5

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♦ Engine and gearbox support -T10220- or engine and gearbox

– First check whether a coded radio is fitted. If so, obtain anti-

♦ Leave ignition key in ignition lock to prevent steering lock from

– Remove selector mechanism from centre console ⇒ Rep. gr.

6 Rep. gr.10 - Removing and installing engine

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– Remove engine cover -A- and engine compartment covers

– Remove intake hose -A-.

– Drain off coolant: ⇒ page 72 .

1. Removing and installing engine 7