Service
Workshop Manual
CC 2012 ➤
Passat 2011 ➤
Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V)
BWS CNN
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Edition 06.2019
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Engine ID
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Service Department. Technical Information
Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
24 - Mixture preparation - injection
26 - Exhaust system
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28 - Ignition system
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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.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2019 Volkswagen AG, Wolfsburg
D3E80345437
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1.1
2
2.1
3
3.1
3.2
3.3
3.4
4
4.1
4.2
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Numbering of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety precautions during work on fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety precautions when using testers and measuring instruments during a road test . . . .
Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
3
3
4
4
4
5
5
6
6
6
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1
1.1
1.2
1.3
1.4
2
2.1
2.2
2.3
2.4
Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Securing engine on engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking adjustment of assembly mountings (engine and gearbox mountings) . . . . . . . .
7
7
15
17
19
21
21
22
24
27
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1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
2
2.1
2.2
2.3
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
4
4.1
4.2
4.3
4.4
Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing sealing flange on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing crankshaft oil seal (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Allocation of main bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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Contents
28
28
30
31
32
32
33
34
36
36
36
37
40
40
42
44
44
44
45
49
51
51
52
55
56
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CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1
1.1
1.2
1.3
1.4
1.5
1.6
2
2.1
2.2
2.3
2.4
3
3.1
3.2
3.3
3.4
3.5
3.6
4
4.1
4.2
4.3
4.4
4.5
4.6
5
5.1
5.2
5.3
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover for timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - cover for timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing the camshaft control valve seal . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - valve timing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - camshaft timing chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing camshaft timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing chain drive sprocket for high-pressure pump . . . . . . . . . . . . . . . .
Removing and installing timing chain and chain drive for oil pump . . . . . . . . . . . . . . . . . .
Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing camshaft adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing camshaft control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58
58
60
68
69
70
71
75
75
76
78
79
81
81
83
86
87
91
93
98
98
100
101
105
112
116
119
119
119
121
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
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2.1
2.2
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Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing oil spray jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - oil filter housing, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.1
1.2
1.3
1.4
1.5
122
122
124
125
127
131
133
133
135
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
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Contents
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Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing continued coolant circulation pump V51 . . . . . . . . . . . . . . . . . .
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1
1.1
1.2
1.3
2
2.1
2.2
2.3
2.4
2.5
138
138
140
142
147
147
149
152
153
153
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
3
3.1
3.2
3.3
3.4
Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing radiator cowl with radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
154
154
155
157
159
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24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1
1.1
2
2.1
2.2
2.3
3
3.1
3.2
3.3
4
4.1
4.2
4.3
4.4
5
5.1
6
6.1
6.2
7
7.1
7.2
8
8.1
8.2
8.3
Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing seals on injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking intake air preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing lower part of intake manifold with fuel rail . . . . . . . . . . . . . . . . . .
Removing and installing intake manifold upper part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing engine (motor) control unit J623 . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing engine (motor) control unit J623 with protective housing . . . . . .
High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing lambda probe G39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing Lambda probe G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing lambda probe after catalytic converter G130 and lambda probe 2
after catalytic converter G131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
160
160
162
162
166
170
174
174
175
175
176
176
178
181
184
186
186
189
189
190
194
194
195
199
199
200
200
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
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Exhaust pipes and silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Separating exhaust pipes from silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation position of clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1
1.1
1.2
1.3
2
2.1
2.2
3
3.1
3.2
202
202
203
205
206
206
207
210
210
211
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
1
1.1
1.2
1.3
1.4
Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents
212
212
213
215
215
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CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
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Contents
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
00 –
Technical data
1
Identification
(VRL013139; Edition 06.2019)
⇒ “1.1 Engine number/engine data”, page 1
1.1
Engine number/engine data
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Engine number
The engine number (“engine code” and “serial number”) is located
next to the vibration damper -arrow- on the cylinder block.
There is also a sticker on the intake manifold showing the “engine
code” and “serial number”.
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The engine code is also included on the vehicle data sticker.
Vehicles with four digit engine codes
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Four-place engine codes are being introduced, starting with letter
“C”. The first 3 places show the mechanical design of engine and
are stamped on the engine as previously. The fourth digit shows
the engine output and torque and varies according to engine con‐
trol unit. The four-digit engine code can be found on the type plate,
the vehicle data label and on the engine control unit.
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Note
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Fitting locations of vehicle data sticker ⇒ Maintenance ; Booklet ;
Vehicle data sticker .
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Engine data
Codes
Manufactured
Exhaust emissions fulfil
Displacement
cm3
Power
Torque
Bore
kW at
rpm
Nm at
rpm
Diamete
r, mm
mm
Stroke
Cylinder angle
Compression ratio
Valves per cylinder
RON
min.
Injection, ignition
Knock control
Lambda regulation
Catalytic converter
Leakage diagnosis sys‐
tem
Exhaust gas recirculation
BWS
CNNA
12.10 ►
EU 5
3597
05.11 ►
ULEV 2
3580
220 / 6600
206 / 6200
350 / 2400
360 / 2800
89.0
89.0
96.4
10.6°
11.4
4
95.9
10.6°
11.4
4
98 unleaded1)
Motronic MED 9.1
2 knock sensors
4 probes
Yes
No
98 unleaded1)
Motronic MED 9.1
2 knock sensors
4 probes
Yes
Yes
internal
internal
1. Identification
1
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
1)
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In exceptional circumstances min. 95 RON, however with re‐
duced performance.
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2
Rep. gr.00 - Technical data
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
2
General information
⇒ “2.1 Numbering of cylinders”, page 3
2.1
Numbering of cylinders
Note
Cylinder 1 is opposite the power delivery side.
1-5-3-6-2-4
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Firing order
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2. General information
3
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CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
3
Safety information
⇒ “3.1 Safety precautions during work on fuel system”,
page 4
⇒ “3.2 Safety precautions when using testers and measuring in‐
struments during a road test”, page 4
⇒ “3.3 Safety precautions when working on the cooling system”,
page 5
⇒ “3.4 Safety precautions when working on ignition system”, page
5
3.1
Safety precautions during work on fuel
system
WARNING
The fuel line is under pressure.
Fuel poses danger of injury to eyes and skin.
Wear protective goggles and protective clothing to avoid injury
and contact with the skin. Wrap a cloth around the connection
before loosening hose connections. Then reduce pressure by
carefully opening the connection.
sn
For reasons of safety, the power supply to the fuel pump must
be interrupted before the fuel system is opened. The fuel pump
would otherwise be activated when the driver's door is opened
or the ignition is switched on. Use one of the following options
to interrupt the power supply:
♦ Disconnect battery
♦ Remove fuse for fuel pump - G6or
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♦ Pull connector off fuel delivery unit flange
Caution
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Observe the following during all assembly work, particularly in
the engine compartment due to the restricted space:
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♦ Route lines of any kind and cables so that original routing
is restored.
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3.2
Safety precautions when using testers
and measuring instruments during a
road test
Note the following if testers and measuring instruments have to
be used during a road test:
♦ Testers and measuring instruments must always be secured
to rear seat and operated by a second person from this loca‐
tion.
4
Rep. gr.00 - Technical data
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♦ Ensure that there is sufficient clearance to all moving or
hot components.
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
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.
Safety precautions when working on the
cooling system
3.3
WARNING
The cooling system is under pressure when the engine is hot!
Danger of scalding due to steam and hot coolant.
Cover filler cap on expansion tank with a cloth and open care‐
fully to release pressure.
sn
Caution
Observe the following during all assembly work, particularly in
the engine compartment due to the restricted space:
♦ Ensure that there is sufficient clearance to all moving or
hot components.
Note
♦ Cooling system is pressurised when engine is warm. If nec‐
essary, release pressure before carrying out repairs.
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♦ Secure all hose connections with hose clips. For allocation see
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⇒ Electronic Parts Catalogue (ETKA) .
♦ Hose clip pliers - VAS 6499- are recommended to install
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spring-type clips.
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♦ Renew gaskets and seals.
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♦ Route lines of any kind and cables so that original routing
is restored.
♦ The arrows on the coolant pipes and on the ends of the hoses
must be aligned with each other.
3.4
Safety precautions when working on ig‐
nition system
To prevent injuries to persons and/or damage to the injection and
ignition system, the following must be observed:
♦ Do not touch or disconnect ignition cables when the engine is
running or being turned at starter speed.
♦ Switch off ignition before connecting or disconnecting injection
and ignition system wiring as well as test instrument cables.
3. Safety information
5
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
4
Repair notes
⇒ “4.1 Rules for cleanliness”, page 6
⇒ “4.2 Foreign objects in engine”, page 6
4.1
Rules for cleanliness
When working on the fuel supply/injection system, carefully follow
the “5 rules” below:
♦ Thoroughly clean all joints and surrounding areas before dis‐
mantling.
♦ Place removed parts on a clean surface and cover them over.
Use lint-free cloths only!
♦ If repair work cannot be performed immediately, cover new
parts which have been removed from their packing.
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing. Do not use parts that
have been kept unpackaged (for example in toolboxes).
♦ If system is open, do not work with compressed air. Try not to
move the vehicle.
4.2
Foreign objects in engine
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♦ To prevent the ingress of foreign bodies during work on the
engine, seal open intake and exhaust ducts with suitable
bungs. The bungs from the engine bung set - VAS 6122- , for
example, can be used for this purpose.
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Rep. gr.00 - Technical data
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
10 –
Removing and installing engine
1
Removing and installing engine
⇒ “1.1 Removing engine”, page 7
⇒ “1.2 Separating engine and gearbox”, page 15
⇒ “1.3 Securing engine on engine and gearbox support”,
page 17
⇒ “1.4 Installing engine”, page 19
1.1
Removing engine
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Special tools and workshop
equipment required
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♦ Lifting tackle - 3033♦ Engine support - T40074♦ Torque wrench - V.A.G 1331♦ Torque wrench - V.A.G 1332♦ Engine and gearbox jack - V.A.G 1383 A♦ Stepladder - VAS 50851. Removing and installing engine
7
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CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
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♦ Hose clamp pliers - VAS 6340♦ Spring-type clip pliers - VAS 6499♦ Engine and gearbox support - VAS 6095♦ Workshop hoist - VAS 6100♦ Drip tray - VAS 6208♦ Engine plug set - VAS 6122Not illustrated:
♦ Container for removed parts - V.A.G 1698 A♦ Cable tie
♦ High-temperature grease - G 052 133 A2The engine is removed downwards with gearbox. Bringing the
lock carrier into the service position is not necessary.
8
Rep. gr.10 - Removing and installing engine
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Note
♦ Read the event memories of all control units ⇒ Vehicle diag‐
nostic tester.
♦ All cable ties that are opened or cut through when the engine
is removed must be renewed/replaced in the same position
when the engine is installed.
♦ Leave the ignition key in the ignition lock to prevent the steer‐
ing lock engaging.
sn
♦ Seal disconnected fuel and breather lines so that the system
is not contaminated with dirt.
♦ 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.
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♦ To prevent damage to removed components, place them in
the container for removed parts - V.A.G 1698- .
Caution
Observe the following during all assembly work, particularly in
the engine compartment due to the restricted space:
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♦ Route lines of any kind and cables so that original routing
is restored.
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♦ Ensure that there is sufficient clearance to all moving or
hot components.
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Disconnect earth strap at battery with ignition switched off ⇒
Electrical system; Rep. gr. 27 ; Battery; Disconnecting and con‐
necting battery .
– Completely remove air filter housing with connecting hose to
the throttle valve module - J338- ⇒ page 174 .
– Remove the bracket for the air-filter housing
⇒ Item 17 (page 174) .
– Remove wiper arms and plenum chamber cover ⇒ General
body repairs, exterior; Rep. gr. 50 ; Bulkhead; Removing and
installing plenum chamber cover .
Vehicles with anti-theft secured engine control unit:
– Remove the U-shaped striker from the engine control unit
⇒ page 190 .
Continued for all vehicles:
– Pull engine wiring harness connector off at engine control unit.
1. Removing and installing engine
9
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Release feed-through for engine wiring harness -arrow- and
pull off upwards.
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– Unscrew cable from alternator at fuse holder -arrow-.
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– Open cable duct latches on longitudinal member -arrows-.
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Rep. gr.10 - Removing and installing engine
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Detach connector -4-, open catch and place engine wiring
harness -3- on engine.
– Disconnect the earth cable -1- and starter motor connections
-2- and -5-.
– Disconnect Lambda probe cable from plenum chamber bulk‐
head.
– Pull off all the plug connectors from the gearbox.
– Pull off or disconnect all other electrical connections from the
engine and gearbox as necessary and lay open.
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– Remove selector lever cable from gearbox.
WARNING
The fuel line is under pressure.
Fuel poses danger of injury to eyes and skin.
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Wear protective goggles and protective clothing to avoid injury
and contact with the skin. Wrap a cloth around the connection
before loosening hose connections. Then reduce pressure by
carefully opening the connection.
– Disconnect fuel supply line -1- and breather line -2-.⇒ Rep.
gr. 20 ; Plug-in connectors; Disconnect plug-in connector .
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– Pull off vacuum line and intake manifold from brake servo.
– Seal lines so that no dirt is able to enter fuel system.
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– Observe rules for cleanliness ⇒ page 6 .
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WARNING
The cooling system is under pressure when the engine is hot!
Danger of scalding due to steam and hot coolant.
Cover filler cap on expansion tank with a cloth and open care‐
fully to release pressure.
– Open and close expansion tank cap to release pressure in
cooling system.
– Remove radiator cowl for radiator fan ⇒ page 157 .
– Removing wheel housing liners ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Wheel housing liner; Removing and
installing front wheel housing liner .
– Detach connector from oil level and oil temperature sender G266- .
– Pull off the cable bracket from the oil level and oil temperature
sender - G266- from the subframe and lay it down on the sub‐
frame.
1. Removing and installing engine
11
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Remove electrical wiring and retainer from gearbox cover at
front -arrows- (2 x M6 nuts).
– Raise and tie wiring in area of gearbox cover.
– Drain coolant ⇒ page 142 .
– Release coolant hoses and pull them off heat exchanger
-arrows-.
– Release retaining clip -arrow-.
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– Pull off coolant hose -1- from top of radiator.
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Rep. gr.10 - Removing and installing engine
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Unscrew bolt -2- and lay filler neck -1- for washer fluid reservoir
to front.
– Unplug connector -3-.
– Unscrew bolts -5- and lay coolant expansion tank -4- on en‐
gine with the hoses connected.
Note
Undo the bolts on the engine mounting and gearbox mounting by
one turn.
WARNING
Danger of injury due to coolant.
♦ Do not open the air conditioner refrigerant circuit.
So that engine can be removed even without opening refrigerant
circuit:
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– Remove air conditioner compressor from ancillary bracket ⇒
Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐
pressor; Removing and installing air conditioner compressor
from and to bracket .
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Caution
Danger of damage to coolant lines and hoses.
♦ Do NOT stretch, kink or bend refrigerant lines and hoses.
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– Secure air conditioner compressor, as shown, to bumper cov‐
er with fastening strap - T10038- and appropriate underlay
-A-. Slide fastening strap - T10038- as far as possible towards
securing bolt -arrow-.
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1. Removing and installing engine
13
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CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Remove heat shield above right drive shaft. Remove nuts -1to do so.
– Remove both drive shafts ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Unbolt flexible coupling of propshaft from gearbox ⇒ Rep. gr.
39 ; Propshaft; Removing and installing front flexible coupling .
Caution
Avoid damage to the flexible joint:
♦ Do not allow the flexible joint to kink by more than 20°.
♦ Install flexible joint so that it is not under tension.
♦ Do not damage wire mesh on decoupling element.
– Unbolt front exhaust pipes from exhaust manifolds -arrows-.
– Unbolt rear clamping sleeve and mounting for front exhaust
pipe. Remove front exhaust pipe with Lambda probes.
Note
Lambda probes can remain screwed in.
– Unscrew bolts -1 … 3- and remove pendulum support.
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– Insert engine bracket - T40074- in engine and gearbox jack V.A.G 1383 A- .
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– Remove adapter - T40074/1- from engine support - T40074and screw with nut -1- onto cylinder block.
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Rep. gr.10 - Removing and installing engine
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
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– Position engine support - T40074- on engine as shown and
retighten adapter - T40074/1- with engine support - T40074-2-.
– Fit engine support - T40074- with M10x25 bolts on exhaust
side as shown and tighten to approx. 20 Nm on cylinder block
-arrows-.
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– Lift engine and gearbox slightly using engine and gearbox jack
- V.A.G 1383 A- .
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– Unbolt engine side of assembly mounting from engine bracket
from above -arrows-.
– Unbolt gearbox side of assembly mounting from gearbox
bracket -arrows- from above.
Note
♦ To remove securing bolts use a stepladder - VAS 5085- .
♦ Engine with gearbox must be guided carefully when lowering
to prevent damage to bodywork.
– Carefully lower engine with gearbox.
1.2
Separating engine and gearbox
Condition
•
For vehicles with automatic gearbox the work procedure may
vary slightly.
•
Engine with gearbox removed and secured on engine bracket
- T10359- .
1. Removing and installing engine
15
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CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
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♦ Spring-type clip pliers - VAS 6499♦ Workshop hoist - VAS 6100♦ Multi-point bit - T10061♦ Insert tool, 18 mm - T10179♦ Hose clamps, up to 25 mm - 3094♦ Engine plug set - VAS 6122Disconnecting
– Clamp off coolant hoses using hose clamps - 3093- or -3094and remove hoses from gearbox oil cooler.
– Seal union of gear oil cooler using suitable bungs/plugs from
engine bung set - VAS 6122- .
16
Rep. gr.10 - Removing and installing engine
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Remove starter -A- ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .
It is advisable to remove the »lower« bolt first.
– Release rotary locking mechanism of connector -1- for me‐
chatronic unit by turning in »anti-clockwise direction« and pull
off connector.
Note
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– Undo all upper engine/gearbox connecting bolts. The insert
tool 18 mm - T10179- can be used for this.
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Figure shows the engine and gearbox installed.
One bolt is located in the starter motor hole -arrow-. This bolt can
be removed using multi-point bit - T10061- .
– Before unscrewing the last securing bolts, support gearbox
using workshop hoist .
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– Remove lower engine/gearbox securing bolts.
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– Press gearbox off from engine, guiding the gearbox
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– Remove remaining engine/gearbox connecting bolts.
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Connecting
Reassembly is carried out in the reverse order; note specified
torques:
♦ Specified torques ⇒ Rep. gr. 34 ; Removing and installing
gearbox; Specified torques for gearbox .
Securing engine on engine and gearbox
support
1.3
Note
The engine can be fastened to the engine and gearbox support VAS 6095- engine and gearbox support or the engine bracket 3269- according to choice. We recommend using the engine
bracket - 3269- for work on the chain drive.
1. Removing and installing engine
17
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
sn
Special tools and workshop
equipment required
♦ Lifting tackle - 3033♦ Workshop hoist - VAS 6100♦ Engine and gearbox support - VAS 6095ses
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♦ Engine support - 3269Procedure
– Separate engine and gearbox ⇒ page 15 .
– Attach lifting tackle - 3033- as follows and lift engine off engine
and gearbox jack - VAS 6100- using workshop hoist - V.A.G
1383 A- .
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Vibration damper end: position 3.
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Flywheel end: position 11.
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Rep. gr.10 - Removing and installing engine
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Secure engine on the engine and gearbox support - VAS 6095using universal mounting.
Secure engine on the engine and gearbox support - 3269- with
engine bracket - VAS 6095- .
1.4
Installing engine
Install in reverse order of removal, observing the following.
Caution
Observe the following during all assembly work, particularly in
the engine compartment due to the restricted space:
♦ Route lines of any kind and cables so that original routing
is restored.
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♦ Ensure that there is sufficient clearance to all moving or
hot components.
– When installing the engine and gearbox assembly, make sure
there is sufficient clearance to the subframe and radiator.
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– Align engine mountings as follows:
o
o
1. Removing and installing engine
19
yi
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
♦ There must be a distance -a- of at least 10 mm between engine
support and longitudinal member (right side).
♦ The side surface of the engine support -2- should be located
parallel to the support arm -1-.
– Tighten bolts for engine assembly mounting and engine brack‐
et. Specified torque ⇒ page 21 .
– Install pendulum support.
sn
– Bolt front exhaust pipe with catalytic converters to exhaust
manifold.
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Removing and installing drive shaft .
– Install the heat shield for the drive shaft.
ses
a purp
– Install air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air conditioner compressor; Removing and in‐
stalling air conditioner compressor from and to bracket .
– Install fan support with fans.
– Reconnect fuel supply line -1- and breather line -2-.
v
– Install poly V-belt ⇒ page 31 .
f
ng
p
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Assembly overview – noise insula‐
tion .
o
yi
– Add coolant ⇒ page 142 .
o
– Connect vehicle diagnostic tester.
– Read all the event memories and delete any entries that may
have been made during assembly.
– Conduct test drive and generate readiness code ⇒ Vehicle di‐
agnostic tester “Guided Function”.
– Then carry out vehicle system test again, rectify any event en‐
tries which may have occurred.
Note
If the event memory was cleared, the readiness code must be
generated ⇒ Vehicle diagnostic tester “Guided Functions”.
Bolted connection
Nuts and bolts
Torque setting
M6
M7
M8
M10
M12
10 Nm
15 Nm
25 Nm
40 Nm
60 Nm
Note
Specified torques for assembly mountings ⇒ page 21 .
20
Rep. gr.10 - Removing and installing engine
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
2
Assembly mountings
⇒ “2.1 Assembly overview - assembly mountings”, page 21
⇒ “2.2 Removing and installing engine mounting”, page 22
⇒ “2.3 Adjusting assembly mountings”, page 24
⇒ “2.4 Checking adjustment of assembly mountings (engine and
gearbox mountings)”, page 27
2.1
Assembly overview - assembly mountings
1 - Bolt
❑ Gearbox support to
gearbox
Specified torque ⇒ Rep. gr.
34 ; Removing and installing
gearbox; Specified torques for
gearbox .
sn
2 - Bolt
❑ Pendulum support to
gearbox
❑ Renew
❑ 50 Nm + 90° (1/4 turn)
further
3 - Bolt
❑ Pendulum support to
gearbox
❑ Renew
❑ 50 Nm + 90° (1/4 turn)
further
5 - Bolt
❑ Engine support to en‐
gine
❑ Renew
❑ 40 Nm + 180° (1/2 turn)
further
f
ng
p
v
6 - Engine mounting
❑ Removing and installing
⇒ page 22
7 - Bolt
❑ Engine mounting to body
❑ Renew
❑ 40 Nm + 90° (1/4 turn) further
o
yi
o
ses
a purp
4 - Engine support
8 - Connection
9 - Bolts
❑ Connecting plate to engine mounting
❑ Renew
❑ 20 Nm + 90° (1/4 turn) further
2. Assembly mountings
21
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
10 - Bolts
❑ Engine mounting to engine support
❑ Renew
❑ 60 Nm + 90° (1/4 turn) further
11 - Bolt
❑ Engine mounting to body
❑ Renew
❑ 40 Nm + 90° (1/4 turn) further
12 - Pendulum support
❑ Bolt pendulum support to gearbox and then to subframe.
sn
13 - Bolt
❑ Pendulum support to sub-frame
❑ Renew
❑ 100 Nm + 90° (1/4 turn) further
ses
a purp
14 - Bolts
❑ Gearbox mounting to body
❑ Renew
❑ 40 Nm + 90° (1/4 turn) further
15 - Gearbox mounting
16 - Bolts
❑ Gearbox support to gearbox
Specified torque ⇒ Rep. gr. 34 ; Removing and installing gearbox; Specified torques for gearbox .
v
17 - Gearbox support
f
ng
p
18 - Bolts
❑ Gearbox mounting to gearbox support
❑ Renew
❑ 60 Nm + 90° (1/4 turn) further
o
yi
o
2.2
Removing and installing engine mount‐
ing
Removing
Caution
Observe the following during all assembly work, particularly in
the engine compartment due to the restricted space:
♦ Route lines of any kind and cables so that original routing
is restored.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
22
Rep. gr.10 - Removing and installing engine
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
sn
– Detach exhaust system bracket from subframe -arrows-.
ses
a purp
– First unscrew bolt -1-.
– Then remove bolts -2- and -3-.
– Remove pendulum support.
Caution
f
ng
p
v
The racks - 10 - 222 A /1- must not be placed on the bolted on
sheet metal of the wings. These may otherwise be damaged.
yi
– Tighten shackle - 10 - 222 A /12- on right lifting eye.
o
– Fit support bracket - 10 - 222 A- with rack - 10 - 222 A /1- as
shown and take up weight of engine in installation position at
right lifting eye.
o
– Unscrew bolt -2- and lay filler neck -1- for washer fluid reservoir
to front.
– Unscrew bolts -5- and lay coolant expansion tank with hoses
connected on engine.
2. Assembly mountings
23
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Unscrew engine mount bolts -A-, -B- and -C- and remove en‐
gine mount upwards.
Installing
Installation is performed in the reverse order of removal. During
this step, observe the following:
Specified torques ⇒ page 21 .
2.3
Adjusting assembly mountings
ses
a purp
sn
Special tools and workshop
equipment required
♦ Support - 10 - 222 Av
♦ Rack - 10 - 222 A /1f
ng
p
♦ Hook - 10 - 222 A /10♦ Shackle - 10 - 222 A /12o
yi
♦ Adapter - 10 - 222 A /18o
24
Rep. gr.10 - Removing and installing engine
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
♦ Torque wrench - V.A.G 1332Procedure
Note
It is not necessary to remove the air filter if only the assembly
mounting at the engine end is to be adjusted.
– Remove air filter ⇒ page 174 .
– Remove air filter bracket ⇒ page 174 .
Caution
sn
The racks - 10 - 222 A /1- must not be placed on the bolted on
sheet metal of the wings. These may otherwise be damaged.
– Tighten shackle - 10 - 222 A /12- on right lifting eye.
f
ng
p
v
ses
a purp
– Fit support bracket - 10 - 222 A- with frame - 10 - 222 A /1- as
shown and take up weight of engine in installation position.
o
yi
o
Adjusting engine mountings:
– Unbolt engine side of assembly mounting from engine bracket
-arrows-.
2. Assembly mountings
25
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
ses
a purp
sn
– Renew assembly mounting bolts -arrows- in succession (if not
already carried out on installing engine) and screw in handtight.
Align engine bracket: There must be a distance -a- of at least
10 mm between engine support and right longitudinal member.
The cast edge on the engine support -2- must be aligned parallel
to the support arm -1- (distance -x- must be identical at front and
rear).
f
ng
p
v
– Tighten bolts for engine mounting. Specified torques
⇒ page 21 .
o
yi
o
Adjusting gearbox mountings:
– Renew gearbox mounting bolts -arrows- in succession (if not
already carried out when installing the engine) and screw in
hand-tight.
– On gearbox side, ensure that edges of support arm -1- and
gearbox mounting -2- are parallel.
•
Dimension -x- must be identical on both sides of mounting.
– Tighten bolts for gearbox mounting. Specified torques
⇒ page 21 .
Further installation is carried out in the reverse sequence.
26
Rep. gr.10 - Removing and installing engine
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
2.4
Checking adjustment of assembly
mountings (engine and gearbox mount‐
ings)
There must be a distance -a- of 10 … 13 mm between engine
support and right longitudinal member.
•
The cast edge on the engine support -2- must be aligned par‐
allel to the support arm -1- (distance -x- must be identical at
front and rear).
sn
•
f
ng
p
v
– Adjusting assembly mountings ⇒ page 24 .
o
o
yi
ses
a purp
Only when there is a complaint of noise (engine or gearbox con‐
tacts longitudinal member when travelling around bends) and
dimension -a- lies outside 10 … 13 mm:
2. Assembly mountings
27
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
13 –
Crankshaft group
1
Cylinder block (pulley end)
⇒ “1.1 Assembly overview - cylinder block (pulley end)”,
page 28
⇒ “1.2 Assembly overview - poly V-belt drive”, page 30
⇒ “1.3 Removing and installing poly-V belt”, page 31
⇒ “1.4 Removing and installing tensioner for poly V-belt”,
page 32
⇒ “1.5 Removing and installing vibration damper”, page 32
⇒ “1.6 Removing and installing bracket for ancillaries”,
page 33
⇒ “1.7 Removing and installing sealing flange on pulley end”,
page 34
Assembly overview - cylinder block (pulley end)
1 - Poly V-belt
❑ Removing and installing
⇒ page 31
sn
1.1
3 - Vibration damper securing
bolt
❑ Removing and installing
⇒ page 32
ses
a purp
2 - Vibration damper
❑ Removing and installing
⇒ page 32
❑ Removing and installing
poly V-belt ⇒ page 31
8 - Tensioning device for poly
V-belt
❑ Removing and installing
⇒ page 32
9 - Sealing flange
❑ Renewing ⇒ page 34
❑ Coat sealing surfaces
with sealant - D 176 501
A1- .
10 - Bolt
❑ 8 Nm
28
Rep. gr.13 - Crankshaft group
p
f
ng
o
7 - Bolt
❑ 50 Nm
yi
6 - Poly V-belt pulley for cool‐
ant pump
o
5 - Bolt
❑ 20 Nm
v
4 - Bolt
❑ 10 Nm
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
11 - Coolant pump
❑ Removing and installing ⇒ page 149
12 - Cylinder block
❑ Cover for timing chain ⇒ page 75
❑ Crankshaft ⇒ page 40 .
❑ Pistons and conrods ⇒ page 51 .
13 - Bolt
❑ 25 Nm
14 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
15 - Ancillary bracket
❑ For alternator and air conditioner compressor
❑ Removing and installing ⇒ page 33
16 - Bolt
❑ 25 Nm
17 - Bolt
❑ 25 Nm
18 - Air conditioner compressor
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Removing
and installing air conditioner compressor
19 - Bolt
❑ Specified torques ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Removing and
installing air conditioner compressor .
20 - Idler roller
f
ng
p
v
ses
a purp
sn
21 - Bolt
❑ 40 Nm
o
o
1. Cylinder block (pulley end)
29
yi
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
1.2
Assembly overview - poly V-belt drive
1 - Vibration damper bolts
❑ 60 Nm + 1/2 turn (180°)
2 - Vibration damper
❑ Removing and installing
⇒ page 32
❑ Removing and installing
poly V-belt ⇒ page 31
3 - Vibration damper securing
bolt
❑ Removing and installing
⇒ page 31
4 - Bolts, belt pulley on coolant
pump
❑ 20 Nm
5 - Coolant pump
❑ Removing and installing
⇒ page 149
6 - Bolts, alternator
❑ 25 Nm
7 - Bolt, tensioning element
❑ 50 Nm
9 - Fitted bolt, Bracket for an‐
cillaries
❑ 25 Nm
sn
8 - Clamp
❑ Removing and installing
⇒ page 32
10 - Securing bolt for bottom
ancillary bracket
❑ 25 Nm
ses
a purp
11 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
12 - Ancillary bracket
❑ Removing and installing ⇒ page 33
❑ 2 dowel sleeves
❑ Make sure that ancillary bracket and air conditioner compressor are properly seated
f
ng
p
v
13 - Securing bolt for bottom ancillary bracket
❑ 25 Nm
❑ lower left bolt is a fitted bolt
❑ 25 Nm
o
yi
14 - Air conditioner compressor
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Removing
and installing air conditioner compressor
o
15 - Hexagon bolt M8x100
❑ Qty. 3
❑ 23 Nm
30
Rep. gr.13 - Crankshaft group
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
16 - Deflection rollers
❑ 40 Nm
1.3
Removing and installing poly-V belt
Special tools and workshop equipment required
♦ Pin - T10027-
Removing poly V-belt:
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Remove front right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Removing
and installing front wheel housing liner .
Caution
Danger of destruction due to reverse running direction in the
case of a poly V-belt that has already run.
♦ Before removing the poly V-belt, use a piece of chalk or a
felt pen to mark the running direction.
sn
– Position spanner -1- onto tensioning roller securing bolt and
turn in -direction of arrow- until locking pin - T10027- can be
inserted on tensioning roller.
– Remove poly V-belt.
Installing poly V-belt:
ses
a purp
Note
♦ Before installing the poly V-belt, ensure that all units (alterna‐
tor, air conditioner compressor) are securely bolted on.
♦ Check deflection rollers for ease of movement.
♦ The poly V-belt must not be kinked.
v
♦ When fitting poly V-belt, check direction of belt rotation and
f
ng
p
make sure the belt is properly seated in the belt pulleys.
yi
– Fit poly V-belt as illustrated.
o
– Use spanner -1- to push tension roller slightly in direction of
-arrow- in order to engage locking pin - T10027- in tensioning
roller.
o
1. Cylinder block (pulley end)
31
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Pull out locking pin - T10027- from tensioning roller.
Always start engine and check belt running after completing work.
– Install front right wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liner; Removing and
installing front wheel housing liner .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Assembly overview – noise insula‐
tion .
1.4
Removing and installing tensioner for
poly V-belt
– Remove poly V-belt ⇒ page 31 .
– Unscrew bolt -2- and remove tensioning element -1-.
– Install in reverse order. During this step, observe the following:
Torque setting
Bolted connection
50 Nm
ses
a purp
sn
Tensioning element on bracket for ancillaries
1.5
Removing and installing vibration damp‐
er
f
ng
o
♦ Counter-hold tool - T10172-
p
v
Special tools and workshop equipment required
yi
o
32
Rep. gr.13 - Crankshaft group
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Removing:
– Remove poly V-belt ⇒ page 31 .
– Lock vibration damper using counterhold - T10172- .
– Unscrew securing bolts and remove vibration damper from
crankshaft journal.
Installing:
Caution
Check rubber joint between inner and outer ring of vibration
damper for cracks and separation. If rubber joint is damaged,
renew vibration damper.
– Renew securing bolt for vibration damper.
sn
– Fit vibration damper and tighten bolts by hand.
– Lock vibration damper using counterhold - T10172- .
– Tighten securing bolts. Specified torque: 60 Nm + 1/2 turn
(180°) further.
ses
a purp
– Install poly V-belt ⇒ page 31 .
p
v
Removing and installing bracket for an‐
cillaries
f
ng
1.6
o
– Remove poly V-belt ⇒ page 31 .
o
yi
Removing
– Remove alternator - C- ⇒ Electrical system; Rep. gr. 27 ;
Alternator; Removing and installing alternator .
– Remove air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Air conditioner compressor; Removing and
installing air conditioner compressor .
– Unbolt ancillary bracket.
Installing
– First hand-tighten locating bolts -2 and 4-.
– Then hand-tighten bolts -1, 3 and 5-.
– Now tighten all the bolts diagonally.
•
Specified torque ⇒ page 28
1. Cylinder block (pulley end)
33
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
1.7
Removing and installing sealing flange
on pulley end
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-
♦ Torque wrench - V.A.G 1332-
ses
a purp
sn
♦ Counter-hold tool - T10172-
♦ Sealant - D 176 501 A1-
p
f
ng
yi
– Remove poly V-belt ⇒ page 31 .
o
Removing:
v
♦ Cleaning solution - D 291 091 A1-
o
34
Rep. gr.13 - Crankshaft group
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Remove vibration damper. To do this, lock vibration damper
using counterhold - T10172- .
– Remove sump ⇒ page 125 .
– Unbolt sealing flange.
– Remove sealant residues from sealing surfaces.
Installing:
Note
The supplied guide sleeve must not be removed before installa‐
tion.
– Remove oil residues from crankshaft journal with a clean cloth.
– Clean sealing surfaces with cleaning solution - D 291 091 A1- .
– Cut off nozzle on tube at front marking (∅ of nozzle approx.
3 mm).
– Apply a bead of sealant - D 176 501 A1- of about 2 … 3 mm
as shown -arrows- to cleaned sealing surface of sealing
flange.
Note
♦ Before applying sealant bead, cover sealing ring with a clean
cloth.
♦ The sealing compound bead must not be thicker than 2 to
3 mm. Otherwise excessive sealing compound will enter the
sump and may block the oil suction pipe strainer.
♦ Observe use-by-date of sealant.
♦ The sealing flange must be installed within 5 minutes after ap‐
plying the silicone sealant.
– Fit sealing flange -1- with guide sleeve of seal -2- on the crank‐
shaft journal.
– Carefully slide sealing flange with sealing ring over guide
sleeve.
– Install sump ⇒ page 125 .
sn
– Bolt sealing flange to cylinder block. Specified torque: 10 Nm.
– Install vibration damper ⇒ page 32 .
f
ng
p
v
ses
a purp
– Install poly V-belt ⇒ page 31 .
o
1. Cylinder block (pulley end)
35
o
yi
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
2
Cylinder block, gearbox end
⇒ “2.1 Assembly overview - cylinder block, gearbox end”,
page 36
⇒ “2.2 Removing and installing flywheel”, page 36
⇒ “2.3 Renewing crankshaft oil seal (gearbox end)”, page 37
2.1
Assembly overview - cylinder block, gearbox end
1 - Cylinder block
❑ Crankshaft
⇒ page 40 .
❑ Dismantling and assem‐
bling pistons and con‐
rods ⇒ page 51
2 - Dowel pin
3 - Cover for timing chain
❑ Removing and installing
⇒ page 75
4 - Bolt
❑ 60 Nm + 1/4 turn (90°)
further
❑ Renew
❑ To loosen or tighten,
use counterhold T10044- (with 5 mm
spacers) or counterhold
- T10172- .
sn
5 - Flywheel
❑ Removing and installing
⇒ page 36
7 - Sealing ring
❑ Remove using extractor
hook - T20143/2❑ PTFE-type oil seal
ses
a purp
6 - Needle bearing
❑ Renew
❑ Removing and installing
⇒ page 42
Identification: Without
garter spring
f
ng
p
v
❑ Do not additionally oil or grease the oil seal sealing lip.
❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
❑ Removing and installing ⇒ page 37
Removing and installing flywheel
Special tools and workshop equipment required
36
Rep. gr.13 - Crankshaft group
o
yi
2.2
o
8 - Centring sleeve
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
sn
♦ Counter-hold tool - T10044-
ses
a purp
Removing:
Note
To prevent irreparable damage to the dual-mass flywheel, do not
unscrew the bolts -B- using a pneumatic/impact screwdriver. It is
only permissible to remove the bolts -B- by hand.
f
ng
p
v
– Rotate dual-mass flywheel -A- so that bolts -B- align centrally
with the holes -arrows-.
– When removing bolts -B-, make sure that screw heads do not
jam on flywheel.
o
yi
o
– Tighten counterhold - T10044- on cylinder block with washer
-arrow-. Bring counterhold - T10044- to -position A- to loosen
flywheel.
– Mark position of flywheel in relation to engine.
– Unscrew flywheel.
Installing:
Install in reverse order of removal, observing the following.
– Renew bolts.
Bring counterhold - T10044- to -position B- to tighten flywheel.
Bolted connection
Torque setting
Flywheel to crankshaft
60 Nm + turn
90° further
2.3
Renewing crankshaft oil seal (gearbox
end)
Special tools and workshop equipment required
2. Cylinder block, gearbox end
37
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
sn
♦ Fitting tool - T10122-
f
ng
p
v
ses
a purp
♦ Extractor hook - T20143-
o
o
yi
Removing:
– Removing gearbox ⇒ Rep. gr. 34 ; Removing and installing
gearbox .
– Remove flywheel ⇒ page 36 .
– Fit puller hook - T20143/2- behind sealing lip of oil seal as
shown in illustration.
– Support puller hook - T20143/2- on the cover for the timing
chain and lever sealing ring off in direction of -arrow-.
38
Rep. gr.13 - Crankshaft group
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Installing:
– Slide oil seal -A- by pressing on outside over sleeve T10122/1- onto pulling sleeve - T10122/2- .
– Separate assembly sleeves.
ses
a purp
sn
– Locate pulling sleeve - T10122/2- with dry oil seal on crank‐
shaft journal.
p
v
– Tap sealing ring into the timing chain cover as far as it will go,
using the thrust piece - T10122/3- .
f
ng
Further assembly is basically a reverse of the dismantling se‐
quence.
o
o
2. Cylinder block, gearbox end
39
yi
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
3
Crankshaft
⇒ “3.1 Assembly overview - crankshaft”, page 40
sn
⇒ “3.2 Renewing needle bearing in crankshaft”, page 42
⇒ “3.3 Crankshaft dimensions”, page 44
⇒ “3.4 Measuring axial clearance of crankshaft”, page 44
⇒ “3.5 Measuring radial clearance of crankshaft”, page 44
ses
a purp
⇒ “3.6 Allocation of main bearing shells”, page 45
⇒ “3.7 Removing and installing sender wheel”, page 49
3.1
Assembly overview - crankshaft
Note
f
ng
carry out repairs.
p
v
♦ Secure engine on engine and gearbox support - VAS 6095- to
♦ Before removing the crankshaft, prepare a suitable surface for
o
yi
storing the crankshaft so that it is not placed down on the
sender wheel ⇒ Item 6 (page 41) and the sender wheel is
not damaged.
o
♦ If large quantities of metal chips and abraded material are
found during engine repair, this may indicate that the crank‐
shaft bearings or conrod bearings are damaged. To avoid any
subsequent damage, the following work must be carried out
following the repair:
♦ Thoroughly clean oil channels.
♦ Renew oil non-return valve.
♦ Renew oil spray jets.
♦ Renew engine oil cooler.
♦ Renewing oil filter.
40
Rep. gr.13 - Crankshaft group
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
1 - Bearing cap
❑ Bearing cap 1: vibration
damper end
❑ Bearing cap 5 with re‐
cesses for thrust wash‐
ers
❑ Bearing shell retaining
lugs in cylinder block
and bearing caps must
align.
2 - 30 Nm + 1/2 turn (180°) fur‐
ther
❑ Renew
❑ 2 x 90° further is permit‐
ted.
ses
a purp
sn
3 - Bearing shells 1 to 7
❑ For bearing cap without
oil groove.
❑ for cylinder block with oil
groove
❑ Do not interchange
used bearing shells
(mark).
❑ Allocation of crankshaft
bearing shells
⇒ page 45 .
p
v
4 - Thrust washer
❑ For bearing cap 5
❑ Note fixing arrangement
f
ng
5 - Crankshaft
❑ If the crankshaft is re‐
newed, the crankshaft
bearing shells must be
reallocated ⇒ page 45 .
❑ Before removing, see notes ⇒ page 40 .
❑ Removing and installing needle bearing ⇒ page 42
❑ Axial clearance new: 0.07 to 0.23 mm; wear limit: 0.30 mm
❑ Measure radial clearance using Plastigage; new: 0.02 … 0.06 mm; wear limit: 0.10 mm
❑ Do not rotate crankshaft when checking radial clearance
❑ Crankshaft dimensions: crankshaft bearings 59.958 … 59.978 mm, conrod bearings
53.958 … 53.978 mm
❑ Reworking the crankshaft is not permitted.
o
yi
o
6 - Sender wheel
❑ For engine speed sender - G28❑ Renew
❑ Installing ⇒ page 49
7 - 10 Nm + 1/4 turn (90°) further
❑ Renew
8 - Oil spray jet
❑ For crankshaft bearings 2 to 7
❑ For piston cooling
❑ Opening pressure: 2.0 bar
❑ Removing and installing ⇒ page 124
3. Crankshaft
41
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
❑ Observe notes ⇒ page 40
3.2
Renewing needle bearing in crankshaft
Only vehicles with a dual clutch gearbox
Special tools and workshop equipment required
♦ Counter support, e.g. KUKKO 22-1 - VAS 251 621-
♦ Internal puller - VAS 251 635-
Condition:
ses
a purp
sn
♦ Pin - VW 207 C-
The front edges of the inner puller must be free of chips.
•
Gearbox has been removed.
f
ng
p
v
•
o
yi
o
42
Rep. gr.13 - Crankshaft group
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Pulling out needle roller bearing
– Pull out needle bearing -1- with internal puller - VAS 251 635-A- and counter support, e.g. KUKKO 22-1 - VAS 251 621-B- from crankshaft -2-.
– The internal puller must be positioned behind the needle-andcage assembly -arrow-.
Installing
– Clean bearing seat in crankshaft and apply as thin coating of
grease.
f
ng
p
v
ses
a purp
sn
– Drive needle bearing into crankshaft to installation depth using
drift - VW 207 C- .
Installation depth: dimension -a- = 1.5 mm
o
o
yi
Note
If the needle bearing is inadvertently driven in too far, it must be
renewed because it will be damaged when it is pulled out again.
3. Crankshaft
43
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
3.3
Crankshaft dimensions
Reworking the crankshaft is not permitted.
Main journal ∅
Conrod journal ∅
59.958 to 59.978 mm
53.958 to 53.978 mm
3.4
Measuring axial clearance of crankshaft
Special tools and workshop equipment required
sn
♦ Universal dial gauge holder - VW 387-
f
ng
p
v
ses
a purp
♦ Dial gauge - VAS 6079-
o
yi
o
Test sequence
– Screw dial gauge - VAS 6079- with universal dial gauge holder
- VW 387- onto cylinder block and set against crank web.
– Press crankshaft against dial gauge by hand and set gauge to
“0”.
– Push crankshaft away from dial gauge and read off value.
Axial clearance:
•
New: 0.07 … 0.23 mm
•
Wear limit: 0.30 mm
3.5
Measuring radial clearance of crank‐
shaft
Special tools and workshop equipment required
♦ Plastigage
Condition
•
Do not turn crankshaft when measuring radial clearance.
44
Rep. gr.13 - Crankshaft group
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Test sequence
Note
♦ Do not interchange used bearings.
♦ Bearing shells worn down to nickel layer must be renewed.
– Remove main bearing cap and clean bearing cap and bearing
journal.
sn
– Place a length of Plastigage corresponding to the width of the
bearing on the bearing journal or in the bearing shells.
•
The Plastigage must lie in the middle of the bearing shell.
– Fit main bearing caps and tighten without twisting the crank‐
shaft.
– Remove main bearing cap again.
Radial clearance:
•
New: 0.02 … 0.06 mm
•
Wear limit: 0.10 mm
3.6
Allocation of main bearing shells
p
v
Allocation of main bearing shells differs according to manufac‐
turing date of crankshaft.
f
ng
The manufacturing date is embossed on the outer crankshaft web
of No. 1 cylinder.
o
yi
1 - Manufacturing date of crankshaft (DDMMYY)
o
ses
a purp
– Compare width of Plastigage with the measurement scale.
2 - Letters for allocation of bearing shells
3 - Part number
– Check how main bearing shells are allocated, according to
manufacturing date.
Allocation of main bearing shells, up to and including manu‐
facturing date 230912 ⇒ page 45 .
Allocation of main bearing shells, from manufacturing date
240912 ⇒ page 47 .
3.6.1
Allocation of main bearing shells, up to
and including manufacturing date
23.09.12
Note
It is essential to observe the manufacturing date. The manufac‐
turing date is embossed on the crankshaft web. Establish manu‐
facturing date ⇒ page 45 .
Main bearing shells of the correct thickness are allocated to the
cylinder block and crankshaft at the factory. Coloured dots are
used to identify the thickness of the bearing shells.
If the cylinder block or crankshaft is changed, the crankshaft
bearing shells must be reallocated.
3. Crankshaft
45
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Establish the correct colour marking for the bearing shell using
the letters on the cylinder block and the crankshaft.
The first letter is allocated to crankshaft bearing 1, the second to
crankshaft bearing 2, etc.
Letters on cylinder block:
The letters for the allocation of the bearing shells are located on
the sealing surface of the sump.
Letters on crankshaft:
The letters for the allocation of the bearing shells are located on
the outer crankshaft web of No. 1 cylinder.
ses
a purp
sn
– Note letters and identify colour code to be installed based on
table.
Letter on crankshaft web
Colour marking of bearing Colour marking of bearing
shell for cylinder block (up‐ shell for bearing cap (low‐
per bearing shell)
er bearing shell)
A, B, C
A, B, C
A, B, C
A, B, C
D, E, G
D, E, G
D, E, G
D, E, G
H, I, K
H, I, K
H, I, K
H, I, K
L, M
L, M
L, M
R
G
B
V
R
G
B
V
R
G
B
V
R
G
B
red
yellow
yellow
blue
yellow
yellow
blue
blue
yellow
yellow
blue
blue
yellow
blue
blue
o
p
f
ng
yi
Rep. gr.13 - Crankshaft group
o
46
v
Letter on cylinder block
red
red
yellow
yellow
red
yellow
yellow
blue
red
yellow
yellow
blue
yellow
yellow
yellow
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Letter on cylinder block
Letter on crankshaft web
Colour marking of bearing Colour marking of bearing
shell for cylinder block (up‐ shell for bearing cap (low‐
er bearing shell)
per bearing shell)
L, M
V
violet
blue
Example:
1
2
3
4
5
6
7
Letters on cylinder block
Letters on crankshaft web
Colour marking of bearing shell
for cylinder block (upper bearing
shell)
Colour marking of bearing shell
for bearing cap (lower bearing
shell)
G
G
yellow
H
B
blue
K
R
yellow
H
V
blue
G
B
blue
E
B
blue
G
G
yellow
yellow
red
blue
yellow
yellow
yellow
Allocation of main bearing shells, from
manufacturing date 24.09.12
ses
a purp
3.6.2
yellow
sn
Crankshaft bearing
Note
f
ng
p
v
It is essential to observe the manufacturing date. The manufac‐
turing date is embossed on the crankshaft web. Establish manu‐
facturing date ⇒ page 45 .
Main bearing shells of the correct thickness are allocated to the
cylinder block and crankshaft at the factory. Coloured dots are
used to identify the thickness of the bearing shells.
o
yi
o
If the cylinder block or crankshaft is changed, the crankshaft
bearing shells must be reallocated.
Establish the correct colour marking for the bearing shell using
the letters on the cylinder block and the crankshaft.
The first letter is allocated to crankshaft bearing 1, the second to
crankshaft bearing 2, etc.
Letters on cylinder block:
The letters for the allocation of the bearing shells are located on
the sealing surface of the sump.
3. Crankshaft
47
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Letters on crankshaft:
The letters for the allocation of the bearing shells are located on
the outer crankshaft web of No. 1 cylinder.
sn
– Note letters and identify colour code to be installed based on
table.
Letter on crankshaft web
Colour marking of bearing Colour marking of bearing
shell for cylinder block (up‐ shell for bearing cap (low‐
per bearing shell)
er bearing shell)
A, B, C
A, B, C
A, B, C
A, B, C
A, B, C
A, B, C
D, E, G
D, E, G
D, E, G
D, E, G
D, E, G
D, E, G
H, I, K
H, I, K
H, I, K
H, I, K
H, I, K
H, I, K
L, M
L, M
L, M
L, M
L, M
L, M
F
E
D
C
B
A
F
E
D
C
B
A
F
E
D
C
B
A
F
E
D
C
B
A
red
yellow
yellow
blue
blue
violet
yellow
yellow
blue
blue
violet
violet
yellow
yellow
blue
blue
violet
violet
yellow
blue
blue
violet
violet
violet
f
ng
p
v
ses
a purp
Letter on cylinder block
red
red
yellow
yellow
blue
blue
red
yellow
yellow
blue
blue
violet
red
yellow
yellow
blue
blue
violet
yellow
yellow
yellow
blue
violet
violet
o
o
yi
Example:
Crankshaft bearing
1
2
3
4
5
6
7
Letters on cylinder block
G
H
H
H
G
E
G
48
Rep. gr.13 - Crankshaft group
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Crankshaft bearing
1
Letters on crankshaft web
A
Colour marking of bearing shell violet
for cylinder block (upper bearing
shell)
Colour marking of bearing shell violet
for bearing cap (lower bearing
shell)
3.7
2
3
4
5
6
7
B
violet
A
violet
C
blue
C
blue
A
violet
B
violet
blue
violet
blue
blue
violet
blue
Removing and installing sender wheel
⇒ “1.3 Removing and installing engine speed sender G28 ”, page
215
Special tools and workshop equipment required
ses
a purp
sn
♦ Torque wrench - V.A.G 1331-
♦ Locking fluid - D 154 100 A1Procedure
Note
f
ng
p
v
The contact surface of the crankshaft/sender wheel must be free
of oil and grease.
yi
♦ The second time the bolts are tightened, the contact points in
o
the sender wheel for the countersunk heads are deformed so
far that the bolt heads seat on the crankshaft -3-, -arrows- and
the sender wheel is »loose« under the bolts.
o
♦ The sender wheel can only be installed in one position, the
holes are offset.
– Apply thin coating of locking fluid - D 154 100 A1- to crankshaft/
sender contact surface for additional adhesion.
– Ensure during installation that marking »VR6« -arrow- is posi‐
tioned over single threaded bore.
– First, gently hand-tighten all new securing bolts.
3. Crankshaft
49
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Then tighten new securing bolt -1- to 10 Nm + 90° (1/4 turn)
further.
f
ng
p
v
ses
a purp
sn
– Then tighten new securing bolt -2- to 10 Nm + 90° (1/4 turn)
further.
o
yi
o
50
Rep. gr.13 - Crankshaft group
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
4
Pistons and conrods
⇒ “4.1 Assembly overview - pistons and conrods”, page 51
⇒ “4.2 Removing and installing pistons”, page 52
⇒ “4.3 Checking pistons and cylinder bores”, page 55
⇒ “4.4 Separating new conrod”, page 56
4.1
Assembly overview - pistons and conrods
1 - Piston rings
❑ Offset gaps by 120°
❑ Use piston ring pliers to
remove and install.
❑ “TOP” faces towards
piston crown.
❑ Checking ⇒ page 55
sn
2 - Piston
❑ Checking ⇒ page 55
❑ Mark cylinder number
and installation position
relative to conrod.
❑ The two deep valve
pockets in the piston
crown point to the centre
of the cylinder block.
❑ Installing piston
⇒ page 52 .
3 - Locking ring
❑ Ensure firm seating
p
f
ng
o
o
yi
5 - Bearing shell
❑ Observe installation po‐
sition
❑ Do not interchange
used bearing shells.
❑ The lugs on bearing
shells must fit tightly in
the recesses.
❑ Axial clearance:
v
ses
a purp
4 - Connecting rod
❑ Renew as set only.
❑ Mark allocation to cylin‐
der
❑ Mark installation posi‐
tion
New: 0.05 … 0.31 mm
Wear limit: 0.40 mm
❑ Checking radial clearance with Plastigage:
New: 0.02 … 0.07 mm
Wear limit: 0.10 mm
❑ Do not rotate crankshaft when checking radial clearance
4. Pistons and conrods
51
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
6 - Conrod bearing cap
❑ Mark allocation to cylinder
❑ Mark conrod number
7 - 40 Nm + 1/4 turn (90°) further
❑ Renew
❑ Oil threads and contact surface
❑ To measure radial clearance, tighten to 40 Nm but not further.
8 - Piston pin
❑ If difficult to remove, heat piston to 60°C.
❑ Remove and install using drift - VW 222 A- .
4.2
Removing and installing pistons
f
ng
p
v
ses
a purp
sn
Special tools and workshop
equipment required
o
yi
♦ Drip tray for workshop hoist - VAS 6208♦ Spring-type clip pliers - VAS 6499o
♦ Torque wrench - V.A.G 1331♦ Pin - VW 222 A-
52
Rep. gr.13 - Crankshaft group
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
♦ Special wrench, long reach - T10070♦ Piston fitting tool - T10333♦ Silicone sealant - D 174 003 A2Removing
– Remove sump ⇒ page 125 .
sn
– Remove cylinder head ⇒ page 60 .
– Mark piston installation position and corresponding cylinder
number. ⇒ Item 2 (page 51)
– Mark conrod installation position and corresponding cylinder
number ⇒ Item 4 (page 51) .
Note
ses
a purp
– Remove conrod bearing cap and withdraw piston and conrod
upwards.
v
If the piston pin is difficult to move, heat the piston to approx. 60°
C.
f
ng
p
– Remove retaining ring from piston pin eye.
– Drive out piston pin using drift - VW 222 A- .
o
yi
Installing
o
Note
To fit the pistons, the funnel - T10333- with inserted piston is
positioned on the cylinder block so that the straight edge of the
high funnel plate -arrow- points to the middle of the cylinder block.
Procedure
Note
♦ Renew bolts that are tightened with specified tightening angle.
♦ Offset piston ring gaps by 120°.
– Pull dowel sleeve -arrow- out of its bore before installing pis‐
tons.
4. Pistons and conrods
53
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
sn
– The pistons for cylinders 1, 3 and 5 must be installed so that
the deep valve pockets -1- point to the middle of the cylinder
block and the arrows -3- to the vibration damper.
f
ng
p
v
ses
a purp
– The pistons for cylinders 2, 4 and 6 must be installed so that
the deep valve pockets -2- point to the middle of the cylinder
block and the arrows -3- to the vibration damper.
o
yi
o
– Insert piston for relevant cylinder into funnel - T10333- from
above. Short piston side -arrow- must project approx. 15 mm
out of lower edge of funnel.
– Now place piston with piston fitting tool in respective cylinder
bore. The higher side of the piston fitting tool -arrow- must face
middle of cylinder block for this.
54
Rep. gr.13 - Crankshaft group
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Firmly position piston fitting tool on cylinder block and push
piston fully into cylinder bore.
– Once piston has been installed, relocate dowel sleeve
-arrow- in its bore.
– Oil running surfaces of bearing shells.
– Install conrod bearing cap, noting installation position and tor‐
que setting ⇒ page 51 .
– Install sump ⇒ page 125 .
– Install cylinder head ⇒ page 60 .
4.3
Checking pistons and cylinder bores
Checking piston ring gap:
Special tools and workshop equipment required
♦ Feeler gauge
Test sequence
– Push ring at right angles to cylinder wall from above down to
approx. 15 mm from bottom end of cylinder. Push in using a
piston without rings.
sn
Piston ring
Rectangular-section ring
Taper faced Napier ring
Oil scraper ring
Ring gap
New
Wear limit
mm 0.30 … 0.45
1.0
mm 0.30 … 0.50
1.0
mm 0.20 … 0.90
1.2
ses
a purp
Checking ring-to-groove clearance:
Special tools and workshop equipment required
f
ng
p
v
♦ Feeler gauge
o
o
4. Pistons and conrods
55
yi
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Test sequence
Clean annular groove before check.
Piston ring
Rectangular-section ring
Taper faced Napier ring
Oil scraper ring
Clearance
New
Wear limit
mm 0.04 … 0.06
0.12
mm 0.03 … 0.06
0.15
mm 0.02 … 0.06
0.15
Checking piston:
sn
Special tools and workshop equipment required
♦ Micrometre 75 - 100 mm - VAS 6071Test sequence
– Measure pistons approx. 15 mm from the lower edge of skirt,
at 90° to the piston pin axis.
ses
a purp
Deviation from nominal dimension: max. 0.06 mm
f
ng
p
v
Checking cylinder bores:
o
yi
Special tools and workshop equipment required
♦ Cylinder gauge - VAS 6078-
o
Test sequence
– Take measurements at 3 positions in both lateral direction
-A- and longitudinal direction -B-.
•
Deviations from nominal dimension: 0.08 mm
Basic dimension
mm
Piston ∅
Cylinder bore ∅
88.945
89.010
Note
Cylinder bores must not be measured when cylinder block is
mounted on engine and gearbox support - VAS 6095- , as meas‐
urements may be incorrect.
4.4
Separating new conrod
On a new conrod, it is possible that the breaking point has not
fully separated. Proceed as follows if the conrod bearing cap can‐
not be removed by hand:
56
Rep. gr.13 - Crankshaft group
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Mark allocation of conrod to cylinder.
– Lightly clamp the conrod in a vice using aluminium vice
clamps, as shown in the illustration.
Note
♦ Only clamp the conrod lightly in order to avoid damaging it.
sn
♦ Conrod is clamped below the dashed line.
– Unscrew both bolts -arrows- about 5 turns.
f
ng
p
v
ses
a purp
– Using a plastic hammer, carefully knock against conrod bear‐
ing cap in -direction of arrow- until it is loose.
o
o
4. Pistons and conrods
57
yi
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
15 –
Cylinder head, valve gear
1
Cylinder head
⇒ “1.1 Assembly overview - cylinder head”, page 58
⇒ “1.2 Removing and installing cylinder head”, page 60
⇒ “1.3 Removing and installing cylinder head cover”, page 68
⇒ “1.4 Assembly overview - vacuum pump”, page 69
⇒ “1.5 Removing and installing vacuum pump”, page 70
⇒ “1.6 Checking compression”, page 71
1.1
Assembly overview - cylinder head
⇒ Fig. ““Checking cylinder head for distortion”“ , page 60
1 - Holder
❑ For fuel hose
2 - 10 Nm
3 - Cap
❑ Renew seal if damaged.
4 - Cylinder head cover
❑ Removing and installing
⇒ page 68
5 - 10 Nm
❑ With spacer sleeve and
seal.
❑ Renew seal if damaged
6 - Gasket for cylinder head
cover
❑ Renew if damaged or
leaking
❑ Observe installation po‐
sition
sn
7 - Lifting eye
❑ With bolted on retaining
plate for knock sensor
connector.
8 - 23 Nm
9 - Intake manifold support
ses
a purp
10 - 23 Nm
11 - 10 Nm
12 - 10 Nm
13 - Union
❑ To heat exchanger
f
ng
p
v
14 - Gasket/seal
❑ Renew
❑ Observe installation position
o
yi
o
58
Rep. gr.15 - Cylinder head, valve gear
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
15 - Chain tensioner, 50 Nm
❑ for camshaft timing chain
❑ Only rotate engine when chain tensioner is installed.
16 - Cover
❑ Can be removed and installed with engine installed.
❑ Coat sealing surface with sealant - D 176 501 A1- .
sn
17 - Sealing ring
❑ For camshaft control valve 1 - N205- and exhaust camshaft control valve 1 - N318❑ Renew if damaged or leaking
❑ Installing ⇒ page 78
18 - 8 Nm
ses
a purp
19 - 8 Nm
20 - Coolant pipe
❑ With retaining clips for vacuum pipe
21 - 23 Nm
22 - Slide rail
❑ for camshaft timing chain
f
ng
p
v
23 - 23 Nm
❑ Insert with locking fluid - D 000 600 A2yi
24 - Union
❑ Bolt on before assembling cylinder head
o
o
25 - O-ring
❑ Renew
26 - Sealing ring
❑ Renew
27 - Cylinder head gasket
❑ Metal gasket.
❑ Renew
❑ Renew cylinder head gasket ⇒ page 60 .
❑ After renewing, renew entire coolant.
28 - Cylinder head
❑ Check for distortion ⇒ page 60 .
❑ Removing and installing ⇒ page 60
❑ After renewing, renew entire coolant.
29 - Cylinder head bolt
❑ Renew
❑ Coat bolt with locking fluid - D 197 300 A2- before installing ⇒ page 67 .
❑ Follow assembly instructions and note sequence when undoing ⇒ page 65
❑ Follow assembly instructions and note sequence when tightening ⇒ page 67
1. Cylinder head
59
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
sn
Checking cylinder head for distortion
Special tools and workshop equipment required
♦ Feeler gauge
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a purp
♦ Straight edge 500 mm - VAS 6075Max. permissible distortion: 0.05 mm
A cylinder head which is warped up to 0.1 mm may be reworked.
f
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Special tools and workshop
equipment required
v
Removing and installing cylinder head
p
1.2
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60
Rep. gr.15 - Cylinder head, valve gear
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
♦ Camshaft bar - T10068 A♦ Drip tray for workshop hoist - VAS 6208♦ Workshop hoist - VAS 6100♦ Lifting tackle - 3033♦ Pliers for spring-type clips - VAS 6499♦ Puller - T10095 A-
♦ Torque wrench - V.A.G 1331♦ Torque wrench - V.A.G 1332-
sn
Not illustrated:
♦ Sealant - D 176 501 A1♦ Locking fluid - D 197 300 A2Conditions
The engine must be no more than warm to touch.
ses
a purp
•
Removing:
Caution
v
Observe the following during all assembly work, particularly in
the engine compartment due to the restricted space:
f
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p
♦ Route lines of any kind and cables so that original routing
is restored.
yi
♦ Ensure that there is sufficient clearance to all moving or
hot components.
o
o
Note
♦ All cable ties which were opened or cut during removal must
be renewed at the same locations.
♦ To prevent damage to removed components, place them in
the container for removed parts - V.A.G 1698- .
– Disconnect earth strap at battery with ignition switched off ⇒
Electrical system; Rep. gr. 27 ; Battery; Disconnecting and
connecting battery .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Remove air filter ⇒ page 174 .
– Drain coolant ⇒ page 142 .
– Note safety precautions before starting further installation
work ⇒ page 4 .
– Observe rules for cleanliness ⇒ page 6 .
1. Cylinder head
61
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
WARNING
The fuel line is under pressure.
Fuel poses danger of injury to eyes and skin.
Wear protective goggles and protective clothing to avoid injury
and contact with the skin. Wrap a cloth around the connection
before loosening hose connections. Then reduce pressure by
carefully opening the connection.
– Disconnect fuel supply line -1- ⇒ Rep. gr. 20 ; Plug-in con‐
nectors; Separating plug-in connectors .
– Seal lines so that fuel system is not contaminated by dirt.
– Remove upper part of intake manifold ⇒ page 181 .
– Remove lower part of intake manifold and separate electrical
connectors ⇒ page 178 .
– Remove heat shield together with intake manifold support
from cylinder head.
– Unscrew front exhaust pipes from exhaust manifolds.
– Remove high-pressure pump ⇒ page 195 .
– Withdraw pump plunger ⇒ Item 17 (page 99) .
– Detach following connectors.
1-
Hall sender - G40-
2-
Inlet camshaft control valve 1 - N205-
3-
Hall sender 2 - G163-
4-
Exhaust camshaft control valve 1 - N318-
– Pull off/disconnect all further wiring necessary from cylinder
head and move clear.
– Detach coolant hose from connector nozzle to heat exchanger
⇒ Item 13 (page 58) .
– Remove vacuum pump ⇒ page 70 .
sn
– Unscrew coolant hoses at top and bottom of cover from cylin‐
der head.
– Unscrew mounting bolts -1- to -3- on the coolant connection
nozzles.
f
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– Remove cylinder head cover .
o
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62
Rep. gr.15 - Cylinder head, valve gear
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Turn crankshaft in engine direction of rotation to TDC No. 1
cylinder marking.
Cams -A- of cylinder 1 must face each other.
ses
a purp
sn
– Remove chain tensioner for camshaft timing chain -arrow-.
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– Undo the two bolts -1- from the lower cover and then undo all
the bolts -arrows- from the upper cover.
o
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1. Cylinder head
63
yi
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Note
sn
Only counterhold at camshaft with 27 mm open-end spanner
-arrow-. The camshaft bar - T10068 A- must not be fitted when
camshaft adjuster is loosened or tightened.
Note
ses
a purp
– Unscrew securing bolts -1- and -2- and then unscrew guide
rail -3-.
The timing chain must be held by its bottom cover in order to hold
it in position on the sprocket of the oil pump. The timing chain
cannot jump over.
– Remove camshaft adjusters from camshafts.
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– Remove timing chain from sprocket for high-pressure pump.
– Unscrew securing bolts -arrows- and pull valve timing housing
off camshafts.
o
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– Cover camshafts -arrows- with clean paper strips and wind
adhesive tape around ends.
64
Rep. gr.15 - Cylinder head, valve gear
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Loosen cylinder head bolts in the sequence given starting at
the outside and working inwards and then remove completely.
– Attach lifting tackle - 3033- as shown and carefully lift off cyl‐
inder head with workshop hoist - VAS 6100- .
Vibration damper end: position 3.
sn
Flywheel end: position 11
Note
♦ The positions marked 1 to 12 on the lifting tackle - 3033- face
the flywheel end.
– Carefully remove cylinder head.
– Place clean cloths in cylinders so that no dirt or emery cloth
particles can get in between cylinder wall and piston.
– Also prevent dirt and emery cloth particles from getting into
coolant.
f
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p
v
– Carefully clean sealing surfaces of cylinder head and cylinder
block. Ensure that surfaces are not scored or scratched (if
abrasive paper is used, grade must not be less than “100”).
yi
– Clean all tapped holes for cylinder head bolts.
o
– Check cylinder head for distortion ⇒ page 60 .
Installing:
o
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♦ Adjust length of threaded spindles according to need.
– Carefully remove metal particles, emery residue and cloths.
If the piston for No. 1 cylinder is not at TDC:
– Turn crankshaft in engine direction of rotation to TDC No. 1
cylinder marking -arrow- while a second mechanic guides
camshaft timing chain by hand.
1. Cylinder head
65
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
ses
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sn
– Ensure that dowel sleeves are inserted in the cylinder block in
bores 12 and 20.
p
Note
v
– Apply a 2 mm thick bead of sealant - D 176 501 A1- onto joint
between cylinder block and sealing flange as shown
-arrows-.
f
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♦ Do not remove new cylinder head gasket from packaging until
o
♦ Handle new gasket very carefully. Damage will cause leakage.
– Fit the new cylinder head gasket immediately. Inscription (Part
No.) must be readable.
– Additionally insert a little sealant - D 176 501 A1- into the two
3 mm bores which lie on the sealant bead.
– Set camshafts in cylinder head to TDC for No. 1 cylinder .
Cams -A- of cylinder 1 must face each other.
– Camshaft bar -T10068 A- must engage in grooves in both
shafts.
– Fit cylinder head.
66
Rep. gr.15 - Cylinder head, valve gear
o
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it is ready to be fitted.
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Apply locking fluid - D 197 300 A2- to each cylinder head bolt
in the area of the bearing surface -arrow- and insert bolts.
Note
♦ The locking fluid is used for sealing the cylinder head bolt.
♦ The longer cylinder head bolts must be inserted in the centre
holes of cylinder head.
– Tighten cylinder head bolts in tightening sequence shown
working from inside to outside:
Pre-tighten all bolts to 15 Nm.
2-
Then tighten all bolts to 30 Nm.
3-
Use fixed wrench to turn 90° further.
4-
Use fixed wrench to turn 90° further.
sn
1-
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– Oil seals of camshafts and install valve timing housing; when
doing so, the timing chain must be placed over the valves for
camshaft adjustment.
yi
– Secure position of high-pressure pump drive sprocket using
adjusting tool - T10363- . The marking -A- on the drive cam for
high-pressure pump must be on top.
o
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1. Cylinder head
67
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Place timing chain »tightly« onto sprocket of high-pressure
pump and then bolt on the guide rail -arrow-.
Further assembly is basically a reverse of the dismantling se‐
quence.
– Install camshaft adjuster with timing chain for camshaft drive
⇒ page 105 .
– Install cylinder head cover ⇒ page 68 .
– Install lower part of intake manifold ⇒ page 178 .
– Install upper part of intake manifold ⇒ page 181 .
– Fill with new coolant ⇒ page 142 .
Note
It is not necessary to retighten cylinder head bolts after repairs.
1.3
Removing and installing cylinder head
cover
Special tools and workshop equipment required
Removing:
sn
♦ Sealant - D 454 300 A2All cable ties which were opened or cut during removal must be
renewed at the same locations.
– Remove upper part of intake manifold ⇒ page 181 .
ses
a purp
Note
Seal the intake ports in the intake manifold and in the cylinder
head with a clean cloth.
– Pull off or disconnect all other electrical wiring from cylinder
head cover as necessary and lay to one side.
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– Loosen bolts for cylinder head cover, working from outside in
-17…1-.
– Unscrew bolts and remove cylinder head cover.
o
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68
Rep. gr.15 - Cylinder head, valve gear
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Installing:
– Apply a small amount of sealant - D 454 300 A2- to cover at
positions marked -arrows-.
sn
– Fit cylinder head cover and tighten the bolts equally from in‐
side out -1…17-.
– Install upper part of intake manifold ⇒ page 181 .
Note
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♦ Renew cylinder head cover if damaged or leaking.
♦ Ensure fuel hoses are seated correctly.
– If necessary fill with coolant ⇒ page 142 .
Torque settings
Torque setting
v
Bolted connection
10 Nm
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Cylinder head cover to cylinder head
yi
Assembly overview - vacuum pump
o
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1.4
1. Cylinder head
69
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
1 - Input shaft
❑ Only fits in one position
in drive sprocket.
2 - Cover
3 - Securing bolt
❑ Short
❑ 8 Nm
4 - Securing bolts
❑ Long
❑ 8 Nm
5 - Vacuum pump
❑ Removing and installing
⇒ page 70
6 - Seal
❑ Renew
sn
7 - Sealing ring
❑ Part of vacuum pump
1.5
Removing and installing vacuum pump
Removing:
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– Unclip air duct -2-.
ses
a purp
– Pull cover -1- off air duct, releasing clips on sides to do so.
o
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70
Rep. gr.15 - Cylinder head, valve gear
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
sn
– Remove air filter housing with connecting hose. To do this,
unscrew bolt -A-, pull off connector -B- and detach spring-type
clip -C-. Take note of marking -D- when refitting.
– Detach vacuum line -A-.
– Remove securing bolts -arrows-.
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Installing:
p
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a purp
– Carefully detach vacuum pump from cylinder head.
– Check sealing ring in vacuum pump -A- for damage. If the seal
is damaged, the vacuum pump must be renewed.
o
yi
– Turn the rotor in vacuum pump so that the flat sides of input
shaft fit into rotor.
o
– Push vacuum pump steadily as far as it will go into locating
bore of cover.
– Tighten the securing bolts -arrows- and refit the vacuum line
-A-.
Specified torques ⇒ page 69 .
1.6
Checking compression
1. Cylinder head
71
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
sn
Special tools and workshop
equipment required
♦ Puller - T10095 A♦ Assembly tool - T10118♦ Torque wrench - V.A.G 1331-
ses
a purp
♦ Spark plug socket - 3122 B-
♦ Compression tester - V.A.G 1763Prerequisites for check
Engine oil temperature at least 30°C
•
Battery voltage must be at least 11.5 V.
•
All electrical consumers, e.g. lights and rear window heating,
must be switched off.
•
If the vehicle is equipped with an air conditioner, it must be
switched off.
•
On vehicles with automatic gearbox the selector lever must be
in “P” or “N” position.
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v
•
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Test sequence
– Remove fuse for fuel pump control unit - J538- from fuse hold‐
er. Fuse assignment ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations
72
Rep. gr.15 - Cylinder head, valve gear
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Removing the fuse interrupts the voltage supply for fuel pump
activation.
– Unclip cover rail for ignition cable harness -arrows- and re‐
move forwards from retaining lugs -A-.
– Apply assembly tool - T10118- to the locking button -arrowand carefully pull the plug connector downwards.
– Push puller - T10095 A- on from flat side of connector in the
direction of the arrow and pull out ignition coil with output
stage.
f
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ses
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sn
– Unscrew spark plugs using spark plug socket and extension 3122 B- .
o
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1. Cylinder head
73
yi
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Check compression using compression tester - V.A.G 1763- ,
adapter - V.A.G 1381/1- and adapter - V.A.G 1381/5A- .
Note
Using compression tester ⇒ operating instructions .
– Have a second mechanic operate the starter until tester shows
no further pressure increase.
Compression pressures:
New
bar pressure
BWS, CNNA
11.0 … 13.0
Wear limit Difference be‐
bar pressure tween cylin‐
ders
bar pressure
sn
Engine code
8.0
max. 3.0
– Insert spark plugs using spark plug socket - 3122 B- and tight‐
en to 18 Nm.
– Install ignition coils with output stage ⇒ page 213 .
ses
a purp
After the test has been completed:
– Connect vehicle diagnostic tester .
– Perform vehicle system test vehicle diagnostic tester “Guided
Fault Finding”.
– Finish the vehicle system test so that any event entries stored
during assembly can be cleared automatically.
p
v
– Generate readiness code in connection with test drive.
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Note safety precautions applicable to a road test.
yi
– After the test drive, carry out vehicle system test again, rectify
any event which may have occurred.
o
o
74
Rep. gr.15 - Cylinder head, valve gear
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
2
Cover for timing chain
⇒ “2.1 Assembly overview - cover for timing chain”, page 75
⇒ “2.2 Removing and installing timing chain cover”, page 76
⇒ “2.3 Removing and installing the camshaft control valve seal”,
page 78
⇒ “2.4 Assembly overview - valve timing housing”, page 79
2.1
Assembly overview - cover for timing
chain
⇒ “4.5 Removing and installing camshaft control valve”,
page 112
1 - Sealing ring
❑ For crankshaft
❑ Renewing ⇒ page 37
2 - Lower cover for timing chain
❑ Gearbox side
❑ Removing and installing
⇒ page 76
3 - Bolt
❑ 23 Nm
sn
4 - Bolt
❑ Tighten in stages and in
diagonal sequence.
❑ 8 Nm
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a purp
5 - Sealing ring
❑ Qty. 2
❑ For camshaft control
valve 1 - N205- and ex‐
haust camshaft control
valve 1 - N318❑ Renew if leaking or
damaged.
❑ Renewing ⇒ page 78
v
6 - Bolt
❑ 8 Nm
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p
7 - Hall sender
❑ Hall sender - G40- and
Hall sender 2 - G163o
o
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8 - O-ring
❑ Qty. 2
❑ Renew
9 - Dowel pins
❑ Qty. 2
10 - Upper cover for timing chain
11 - Cylinder head gasket
❑ Clean drillings and fill with sealant ⇒ page 76 .
2. Cover for timing chain
75
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
12 - Dowel pins
13 - Bolt
❑ 10 Nm
2.2
Removing and installing timing chain
cover
Special tools and workshop equipment required
♦ Hand drill with plastic brush
♦ Safety glasses
♦ Sealant - D 176 501 A1Removing:
– Removing gearbox ⇒ Rep. gr. 34 ; Removing and installing
gearbox .
– Remove flywheel ⇒ page 36 .
– Remove sump ⇒ page 125 .
– Remove bolts -1 and 2- for cover.
Caution
Avoid damage to cylinder head gasket. If the cylinder head
gasket is bent excessively, it can be kinked. A kinked cylinder
head gasket must be renewed.
sn
– Pull off cover from cylinder block horizontally.
– Press crankshaft oil seal out of lower timing chain cover.
Installing:
Specified torques ⇒ page 78 .
Caution
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•
The lubrication system can be soiled by sealant residue. Care‐
fully cover open parts of engine so that no sealant residue can
fall into it.
f
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v
– Remove remaining sealant on the timing chain cover and cyl‐
inder head using rotating plastic brush etc. Wear safety gog‐
gles.
– Clean sealing surfaces; they must be free of oil and grease.
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76
Rep. gr.15 - Cylinder head, valve gear
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Remove old sealing compound from holes -arrow- of cylinder
head gasket.
Note
With the cylinder head installed, the holes in the cylinder head
gasket are only half visible.
Caution
Avoid damage to cylinder head gasket. If the cylinder head
gasket is bent excessively, it can be kinked. A kinked cylinder
head gasket must be renewed.
– Bend end of cylinder head gasket down very slightly
-arrows-, just far enough to be able to clean upper sealing
surface on cylinder head gasket and cylinder head.
sn
– Clean top and bottom of cylinder head gasket; both faces must
be free of oil and grease.
f
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p
v
ses
a purp
– Cut off nozzle on tube at front marking (∅ of nozzle approx.
2 mm).
yi
– Apply thin coating of sealant to upper and lower sealing sur‐
faces of cylinder head gaskets; to do this, bend cylinder head
gasket downwards very slightly -arrows-.
o
o
– To coat the surface between cylinder head and gasket use a
flat object, e.g. a feeler gauge.
2. Cover for timing chain
77
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Apply thin bead of sealant -arrows- from below into both cor‐
ners between cylinder head gasket and cylinder block, so that
holes in cylinder head gasket are filled.
ses
a purp
sn
– Check if dowel sleeves for cover are inserted in the cylinder
block.
– Apply sealant - D 176 501 A1- as shown and fit the cover.
Note
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Install the timing chain cover within 5 minutes after sealant has
been applied.
o
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o
– Tighten bolts in 3 stages as follows:
A - Pre-tighten bolts -1- to 5 Nm.
B - Tighten bolts -2- to 23 Nm.
C - Tighten bolts -1- to 10 Nm.
– Install crankshaft oil seal ⇒ page 37 .
– Install sump ⇒ page 125 .
– Install flywheel ⇒ page 36 .
– Install gearbox ⇒ Rep. gr. 34 ; Removing and installing gear‐
box .
2.3
Removing and installing the camshaft
control valve seal
Special tools and workshop equipment required
78
Rep. gr.15 - Cylinder head, valve gear
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
ses
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sn
♦ Fitting sleeve - 3378-
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♦ Fitting sleeve - 3253/6- from assembly tool - 3253- .
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o
Removing:
– Using a suitable tool, press out the old seal without damaging
the cover.
Installing:
– Do not lubricate seals.
– Install seal with fitting sleeve - 3378- in cover -1- and pull in
flush using fitting sleeve - 3253/6- from assembly tool - 3253- .
2.4
Assembly overview - valve timing housing
2. Cover for timing chain
79
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
1 - Seal
❑ Renew
2 - Guide rail: is clipped into
valve timing housing
3 - Valve timing housing
4 - Inlet camshaft control valve
1 - N205❑ Removing and installing
⇒ page 112
5 - Bolt
❑ 3.8 Nm
6 - Exhaust camshaft control
valve 1 - N318❑ Removing and installing
⇒ page 112
ses
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sn
7 - 8 Nm + turn 180° further
❑ Renew
Checking valve timing housing strainer for soiling
f
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v
– Unclip the strainer -2- from rear of valve timing housing -1- and
remove any dirt.
o
yi
o
80
Rep. gr.15 - Cylinder head, valve gear
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
3
Chain drive
⇒ “3.1 Assembly overview - camshaft timing chains”, page 81
⇒ “3.2 Removing and installing camshaft timing chain”,
page 83
⇒ “3.3 Removing and installing chain drive sprocket for highpressure pump”, page 86
⇒ “3.4 Removing and installing timing chain and chain drive for
oil pump”, page 87
⇒ “3.5 Checking valve timing”, page 91
⇒ “3.6 Adjusting valve timing”, page 93
3.1
Assembly overview - camshaft timing chains
ses
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sn
1 - Valve timing housing
❑ Lightly lubricate contact
surface of oil seals be‐
fore installing.
❑ removing and installing
⇒ page 76 Removing
and installing camshafts
⇒ page 101
❑ Assembly overview
⇒ page 79 .
❑ Before installing valve
timing housing, check
strainer for soiling
⇒ page 79
2 - Sealing ring
❑ Renew
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ng
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3 - Oil pump
❑ Removing and installing
⇒ page 127
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4 - 8 Nm
❑ Insert with locking fluid D 000 600 A2o
5 - Chain tensioner, 50 Nm
❑ For camshaft timing
chain
⇒ Item 10 (page 82)
❑ Only rotate engine when
chain tensioner is instal‐
led.
6 - Sealing ring
❑ Renew if damaged or
leaking
7 - Tensioning rail
❑ For camshaft timing chain ⇒ Item 10 (page 82)
8 - Pivot pin, 10 Nm
❑ For tensioning rail ⇒ Item 7 (page 81)
9 - Sprocket
❑ For timing chains
❑ Install camshaft adjuster with timing chain for camshaft drive ⇒ page 105
3. Chain drive
81
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
10 - Camshaft timing chain
❑ Before removing, mark direction of rotation (installation position) ⇒ page 83 .
❑ Install camshaft adjuster with timing chain for camshaft drive ⇒ page 83
11 - 60 Nm + 1/4 turn (90°) further
❑ Renew
12 - Exhaust camshaft adjuster
❑ Identification: 32A.
❑ Install camshaft adjuster with timing chain for camshaft drive ⇒ page 83
13 - 60 Nm + 1/4 turn (90°) further
sn
❑ Renew
❑ Contact surface of sender wheel must be dry around bolt head when installed.
❑ To remove and install, counterhold using 27 mm open-end spanner on camshaft ⇒ page 101 , Removing
and installing camshafts.
ses
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14 - Inlet camshaft adjuster
❑ Identification: 24E
❑ Install camshaft adjuster with timing chain for camshaft drive ⇒ page 83
15 - 10 Nm
16 - Chain tensioner with tensioning rail
❑ For timing chain ⇒ Item 19 (page 82)
❑ Only rotate engine when chain tensioner is installed.
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17 - Drive gear
❑ Built into crankshaft.
❑ Ground down tooth aligned with main bearing joint = TDC No. 1 cylinder, Adjusting timing chain for oil
pump drive ⇒ page 87 .
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18 - Locating pin without collar, 10 Nm
❑ For guide rail ⇒ Item 23 (page 82) .
19 - Timing chain
❑ Before removing, mark direction of rotation (installation position) ⇒ page 83 .
❑ Installing timing chain for oil pump drive ⇒ page 87 .
20 - Pivot pin, 10 Nm
❑ for guide rail
21 - 23 Nm
22 - Slide rail
❑ For camshaft timing chain ⇒ Item 10 (page 82)
23 - Slide rail
❑ For timing chain ⇒ Item 19 (page 82)
❑ Remove and install together with timing chain. Installing timing chain for oil pump drive ⇒ page 87 .
24 - Drive sprocket for high pressure pump
❑ With needle bearing
❑ Lubricate needle bearing before installing.
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Rep. gr.15 - Cylinder head, valve gear
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Marking timing chains
– Mark timing chains before removing (e.g. with paint, arrow
pointing in direction of rotation).
Note
Do not mark chain by way of centre punch, notch or the like.
3.2
Removing and installing camshaft tim‐
ing chain
⇒ “4.4 Removing and installing camshaft adjuster”, page 105
sn
Conditions:
Gearbox removed
•
Flywheel removed
•
Sump removed
•
Cover for timing chain removed
•
Cylinder head cover removed
ses
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•
Removing:
– Turn engine by vibration damper to adjustment markings.
Ground tooth of drive sprocket -arrow A- must align with bear‐
ing joint.
•
The marked hole -arrow- must be in line with the mark on the
oil pump.
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•
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Note
This position is reached only after every 4th full rotation.
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3. Chain drive
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CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
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Cams -A- of cylinder 1 must face each other.
– Removing camshaft adjuster ⇒ page 105 .
– Unscrew securing bolts -1- and -2-. Remove guide rail -A-.
– Take timing chain out upwards.
Installing:
Condition:
Crankshaft is at »TDC« position
•
Chain drive sprocket for high-pressure pump is fixed in place
with adjusting tool - T10363-
•
Camshafts have been fixed in place with camshaft bar T10068 A-
sn
•
– Insert timing chain through hole in cylinder head from above.
Note
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– Fit guide rail -A- and, initially, only tighten bolt -2-.
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Some of the timing chain links are copper coloured. These chain
links are to be used as an aid to installation. The 3 copper-col‐
oured chain links next to each other must be placed on the oil
pump sprocket.
o
– Fit timing chain onto chain drive sprocket of high-pressure
pump. Marking must align with copper-coloured chain link.
84
Rep. gr.15 - Cylinder head, valve gear
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– First, fit timing chain onto oil pump sprocket. Marking must
align with middle copper coloured chain link -A-.
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
sn
– Tighten bolt -1- for guide rail.
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– Insert inlet camshaft adjuster »24E« into timing chain in such
a way that the copper-coloured chain link is aligned with the
marking on the camshaft adjuster. Bolt camshaft adjuster onto
camshaft and tighten bolt hand-tight.
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– Insert exhaust camshaft adjuster »32A« into timing chain in
such a way that copper-coloured chain link is aligned with
marking on camshaft adjuster. Bolt camshaft adjuster onto
camshaft and tighten bolt hand-tight.
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o
– Check position of copper coloured chain links to adjustment
markings.
Note
The copper coloured chain links no longer align with the adjust‐
ment markings once the crankshaft has been turned.
3. Chain drive
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– Install tensioner for timing chain -arrow-. Specified torque:
50 Nm.
Note
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sn
– Remove camshaft bar - T10068 A- and tighten bolt of camshaft
adjuster. Specified torque: 60 Nm + 1/4 turn (90°) further.
Only counterhold at camshaft with 27 mm open-end spanner
-arrow-. The camshaft bar - T10068 A- must not be fitted when
camshaft adjuster is loosened or tightened.
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Further assembly is carried out in the reverse order of removal.
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3.3
Removing and installing chain drive
sprocket for high-pressure pump
o
Removing:
– Remove high-pressure pump ⇒ page 195 .
– Remove camshaft adjuster for inlet camshaft -1⇒ page 108 .
– Undo and remove bolt -3- for guide rail.
– Remove timing chain from chain drive sprocket.
– Pull out bearing shaft -4- and remove chain drive sprocket
-6-.
Installing:
Note
Coat faces of chain drive sprocket and bearing shaft with lubri‐
cating paste - G 052 723 A2- .
86
Rep. gr.15 - Cylinder head, valve gear
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Insert drive sprocket. The notch -arrow- must be on top.
– Coat bearing shaft with lubricating paste - G 052 723 A2- and
push it in. The bearing shaft fits in only one position.
sn
– Secure position of high-pressure pump chain drive sprocket
using adjusting tool - T10363- . The marking -A- on the drive
cam for high-pressure pump must be on top.
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– Place timing chain onto chain drive sprocket. Ensure that
chain runs »tautly« against guide rail.
– Tighten bolt -arrow- for guide rail.
– Install camshaft adjuster ⇒ page 109 .
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– Installing high-pressure pump ⇒ page 195 .
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3.4
Removing and installing timing chain
and chain drive for oil pump
Note
Procedure is possible only with gearbox removed.
3. Chain drive
87
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sn
Special tools and workshop
equipment required
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♦ Camshaft bar - T10068 A♦ Counter-hold tool - T10172♦ Torque wrench - V.A.G 1331♦ Torque wrench - V.A.G 1332♦ Adjusting tool - T10363v
Not illustrated:
o
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Conditions:
o
Removing:
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♦ Sealant - D 176 501 A1-
•
Gearbox removed
•
Flywheel removed
•
Sump removed
•
Cover for timing chain removed
•
Cylinder head cover removed
– Removing timing chain for camshaft drive ⇒ page 83 .
88
Rep. gr.15 - Cylinder head, valve gear
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sn
– Loosen bolt -arrow- for sprockets about 1 full turn. To do this,
counterhold vibration damper using counterhold - T10172- .
– Fix chain tensioner spring using 3 mm Allan key -A-.
– Remove chain tensioner for oil pump drive chain -arrows-.
o
•
yi
– Set crankshaft to TDC position.
o
Installing:
f
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– Remove sprockets together with timing chain from oil pump.
Ground tooth of drive sprocket -arrow- must align with bearing
joint.
– Now turn oil pump shaft -1- with flat side -arrow- horizontal to
mark -2- on oil pump.
– Insert timing chain into guide rail and place on crankshaft.
3. Chain drive
89
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– Insert large sprocket into timing chain in such a way that the
hole with marking -arrow B- is aligned with marking on oil
pump.
– Fit sprocket onto oil pump shaft and tighten hand-tight.
Note
♦ If sprocket cannot be fitted, turn oil pump shaft slightly.
♦ If timing chain has already been used, note marking for direc‐
sn
tion of rotation ⇒ page 83 .
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– Install tensioner for timing chain -arrows-. Specified torque
⇒ Item 15 (page 82) .
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– Remove Allan key -A-.
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– Check setting markings.
•
Ground tooth of drive sprocket -arrow A- must align with bear‐
ing joint.
•
The marked hole -arrow- must be in line with the mark on the
oil pump.
90
Rep. gr.15 - Cylinder head, valve gear
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Tighten new bolt -arrow- for sprockets. Specified torque
⇒ Item 7 (page 123) . To do this, counterhold vibration damper
using counterhold - T10172- .
Note
New sprocket bolt.
– Install timing chain for camshaft drive ⇒ page 84 .
3.5
Checking valve timing
Special tools and workshop equipment required
Test sequence
ses
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sn
♦ Camshaft bar - T10068 A-
v
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
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– Remove upper part of intake manifold ⇒ page 181 .
– Remove cylinder head cover ⇒ page 68 .
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– Position crankshaft in engine direction of rotation to TDC No.
1 cylinder marking.
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3. Chain drive
91
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
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Cams -A- of cylinder 1 must face each other.
sn
– Insert camshaft bar - T10068 A- in both shaft grooves.
Note
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The grooves of the camshafts might not be exactly vertical due to
the function of camshaft adjusters. Therefore, move the cam‐
shafts back and forth slightly if necessary when inserting the
camshaft bar - T10068 A- using an open-end spanner -arrows-.
p
Arrows on camshaft adjusters must align with right notches on
timing housing. Markings on timing housing ⇒ page 93 .
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Check adjustment markings of camshaft adjusters against mark‐
ings on valve timing housing:
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Note
♦ A slight offset between marking »32A« and notch is permissi‐
ble.
♦ Position of copper-coloured chain links can be disregarded.
92
Rep. gr.15 - Cylinder head, valve gear
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– The gap between markings of camshaft adjuster must be ex‐
actly 16 rollers of camshaft timing chain.
If the markings do not align:
– Adjust valve timing ⇒ page 93 .
If the markings align:
– Install cylinder head cover ⇒ page 68 .
– Install upper part of intake manifold ⇒ page 181 .
Markings on timing housing on FSI engines
-A- View from flywheel end
-B- View from vibration damper end
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The markings on camshaft adjusters must align with notches
-arrows-.
Adjusting valve timing
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3.6
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Note
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Procedure is possible only with gearbox removed.
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3. Chain drive
93
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ses
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sn
Special tools and workshop
equipment required
v
♦ Camshaft bar - T10068 Af
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♦ Counter-hold tool - T10172♦ Torque wrench - V.A.G 1331o
yi
♦ Torque wrench - V.A.G 1332♦ Adjusting tool - T10363o
Not illustrated:
♦ Sealant - D 176 501 A1Conditions:
•
Gearbox removed
•
Flywheel removed
•
Sump removed
•
Cover for timing chain removed
•
Cylinder head cover removed
– Removing timing chain for camshaft drive ⇒ page 83 .
94
Rep. gr.15 - Cylinder head, valve gear
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Loosen bolt -arrow- for sprockets about 1 full turn. To do this,
counterhold vibration damper using counterhold - T10172- .
– Fix chain tensioner spring using 3 mm Allan key -A-.
– Remove chain tensioner for oil pump drive chain -arrows-.
Installing:
sn
– Remove sprockets together with timing chain from oil pump.
– Set crankshaft to TDC position.
Ground tooth of drive sprocket -arrow- must align with bearing
joint.
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•
v
– Now turn oil pump shaft -1- with flat side -arrow- horizontal to
mark -2- on oil pump.
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– Insert timing chain into guide rail and place on crankshaft.
o
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3. Chain drive
95
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– Insert large sprocket into timing chain in such a way that the
hole with marking -arrow B- is aligned with marking on oil
pump.
– Fit sprocket onto oil pump shaft and tighten hand-tight.
Note
sn
♦ If sprocket cannot be fitted, turn oil pump shaft slightly.
♦ If timing chain has already been used, note marking for direc‐
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tion of rotation ⇒ page 83 .
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– Remove Allan key -A-.
v
– Install tensioner for timing chain -arrows-. Specified torque
⇒ Item 15 (page 82) .
o
yi
o
– Check setting markings.
•
Ground tooth of drive sprocket -arrow A- must align with bear‐
ing joint.
•
The marked hole -arrow- must be in line with the mark on the
oil pump.
96
Rep. gr.15 - Cylinder head, valve gear
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Tighten new bolt -arrow- for sprockets. Specified torque
⇒ Item 11 (page 82) . To do this, counterhold vibration damper
using counterhold - T10172- .
Note
New sprocket bolt.
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sn
– Install timing chain for camshaft drive ⇒ page 84 .
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3. Chain drive
97
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4
Valve gear
⇒ “4.1 Assembly overview - valve gear”, page 98
⇒ “4.2 Measuring axial play of camshaft”, page 100
⇒ “4.3 Removing and installing camshaft”, page 101
⇒ “4.4 Removing and installing camshaft adjuster”, page 105
⇒ “4.5 Removing and installing camshaft control valve”,
page 112
⇒ “4.6 Removing and installing valve stem seals”, page 116
4.1
Assembly overview - valve gear
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sn
1 - Inlet camshaft
❑ Check radial clearance
with Plastigage, wear
limit: 0.1 mm
❑ Runout: max. 0.01 mm
❑ Checking axial clear‐
ance ⇒ page 100 .
❑ Identification
⇒ page 100
❑ Removing and installing
⇒ page 101
2 - Camshaft bearing caps
❑ Installation position
⇒ page 104
❑ Installation sequence
⇒ page 104 Removing
and installing camshaft.
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3 - Exhaust camshaft
❑ Check radial clearance
with Plastigage, wear
limit: 0.1 mm
❑ Runout: max. 0.01 mm
❑ Checking axial clear‐
ance ⇒ page 100 .
❑ Identification
⇒ page 100
❑ Removing and installing
⇒ page 101
o
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4 - 5 Nm + 1/8 turn (45°) further
5 - Sealing ring
❑ Renew if leaking.
❑ When installing timing
housing, lubricate con‐
tact surfaces of seals.
❑ When replacing seals, do not spread too widely.
6 - Valve timing housing
❑ Lightly lubricate contact surface of oil seals before installing.
❑ Removing and installing camshaft control valves ⇒ page 112
❑ Marks for valve timing ⇒ page 93 .
❑ Assembly overview ⇒ page 79 .
98
Rep. gr.15 - Cylinder head, valve gear
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6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
❑ Before installing valve timing housing, check strainer for soiling ⇒ page 80
❑ Removing and installing ⇒ page 101
7 - 8 Nm + turn 180° further
❑ Renew
8 - Exhaust camshaft adjuster
❑ Identification: 32A.
❑ Only rotate engine when camshaft adjuster is installed and chain is fitted
❑ Installing ⇒ page 105
9 - Inlet camshaft adjuster
❑ Identification: 24E
❑ Only rotate engine when camshaft adjuster is installed and chain is fitted
❑ Installing ⇒ page 105
10 - 60 Nm + 1/4 turn (90°) further
sn
❑ Renew
❑ Contact surface of sender wheel must be dry around bolt head when installed.
❑ To remove and install, counterhold using 27 mm open-end spanner on camshaft ⇒ page 101 , Removing
and installing camshafts.
11 - Cylinder head height
❑ Minimum height: a = 139.9 mm.
ses
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12 - Drive sprocket for high pressure pump
❑ With inner splines
❑ Bearing shaft fits in only one position
13 - Bearing shaft
❑ Bearing shaft fits in only one position
❑ Coat bearing shaft with grease - G 052 723 A2❑ Vacuum pump drive shaft
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14 - Valves
❑ Exhaust valve with sodium filling
❑ Do not rework; only lapping-in is permitted.
❑ Valve dimensions ⇒ page 121
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15 - Dowel sleeve
16 - Cylinder head
❑ Check for distortion ⇒ page 60 .
❑ Removing and installing ⇒ page 60
❑ Reworking valve seats
❑ After renewing, renew entire coolant.
o
17 - Pump plunger
❑ Note installation position ⇒ page 197
18 - Support element
❑ Before installing, check camshaft axial clearance ⇒ page 100 .
❑ Do not interchange
❑ With hydraulic valve clearance compensation.
19 - Valve stem seal
❑ Renewing ⇒ page 116
20 - Camshaft timing chain
❑ Before removing, mark direction of rotation (installation position).
❑ Removing and installing ⇒ page 83
4. Valve gear
99
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21 - Retaining clip
❑ Check for firm seating
sn
22 - Roller rocker fingers
❑ Before installing, check camshaft axial clearance ⇒ page 100 .
❑ Do not interchange
❑ Check roller bearing for ease of movement.
❑ Oil contact surfaces.
❑ When installing, secure to supporting element using securing clip.
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23 - Valve springs
❑ Observe installation position
❑ Removing and installing ⇒ page 116 , Renewing valve stem seals.
24 - Valve spring plate
25 - Valve cotters
v
Camshaft identification:
f
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Identification between cam pair for cylinders 4 and 5 of respective
camshaft.
o
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Camshaft
Identification
A - exhaust camshaft
B - inlet camshaft
o
4.2
03H 101 index
03H 102 index
Measuring axial play of camshaft
Special tools and workshop equipment required
♦ Universal dial gauge holder - VW 387-
♦ Dial gauge
Test sequence
Perform measurements with support elements and roller rocker
fingers removed.
Install middle bearing cap of respective camshaft.
100
Rep. gr.15 - Cylinder head, valve gear
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
sn
Wear limit: max. 0.40 mm
4.3
Removing and installing camshaft
f
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v
ses
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Special tools and workshop
equipment required
o
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o
♦ Torque wrench - V.A.G 1331♦ Torque wrench - V.A.G 1332♦ Camshaft bar - T10068 A♦ Adjusting tool - T10363♦ Counterhold - T10172- with pins - T10172/1-
4. Valve gear
101
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Not illustrated:
♦ Sealant - D 176 501 A1Removing:
– Remove air filter housing ⇒ page 174 .
– Remove upper part of intake manifold ⇒ page 181 .
– Remove cylinder head cover ⇒ page 68 .
– Removing the two camshaft adjusters ⇒ page 105 .
– Undo bolts -arrows- from valve timing housing and pull valve
timing housing off cylinder head.
sn
– Lay camshaft timing chain aside.
A - Inlet camshaft
– First remove bearing caps 1 and 13.
– Remove bearing caps 3 and 11.
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– Remove bearing cap 7.
v
– Loosen bearing caps 5 and 9 alternately and diagonally.
f
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B - Exhaust camshaft
– First remove bearing caps 2 and 14.
o
yi
– Remove bearing caps 4 and 12.
o
– Remove bearing cap 8.
– Loosen bearing caps 6 and 10 alternately and diagonally.
Continuation for both camshafts
– Carefully remove camshafts and lay aside on clean surface.
– Remove roller rocker fingers together with supporting ele‐
ments and place them on a clean surface.
– Ensure that roller rocker fingers and supporting elements are
not interchanged.
Installing:
Conditions:
102
Rep. gr.15 - Cylinder head, valve gear
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
When installing camshafts, No. 1 cylinder cams -A- must point
upwards.
Procedure:
ses
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sn
•
f
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– Position crankshaft with counterhold - T10172- in engine di‐
rection of rotation to TDC No. 1 cylinder marking.
o
yi
o
– Lightly coat contact surfaces of bearing caps 7 and 8 with
grease - G 052 735 A2- before installing.
– Install supporting elements in cylinder head and fit respective
roller rocker finger onto respective valve stem end or support‐
ing element.
– Ensure that all roller rocker fingers contact valve stem ends
-1- correctly and that they are clipped into their respective
support elements -2-.
– Oil running surfaces of camshafts.
– Carefully place camshaft into the corresponding camshaft
bearing of the cylinder head. Take note of camshaft marking
⇒ page 100 .
– Note installation position of bearing caps.
4. Valve gear
103
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Fitting position of camshaft bearing caps
sn
Points of bearing caps -arrow A- of inlet and exhaust camshafts
face outwards.
A - Inlet camshaft
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– Tighten bearing caps 5 and 9 alternately and diagonally to
5 Nm + 1/8 turn (45°) further.
– Install bearing caps 1 and 13 and tighten to 5 Nm + 1/8 (45°)
turn further.
– Install bearing cap 7 and tighten to 5 Nm + 1/8 (45°) turn fur‐
ther.
o
– Tighten bearing caps 6 and 10 alternately and diagonally to
5 Nm + 1/8 turn (45°) further.
– Install bearing caps 2 and 14 and tighten to 5 Nm + 1/8 (45°)
turn further.
– Install bearing cap 8 and tighten to 5 Nm + 1/8 (45°) turn fur‐
ther.
– Install bearing caps 4 and 12, tighten to 5 Nm + 1/8 (45°) turn
further.
Continuation for both camshafts
– Insert camshaft bar - T10068 A- in both shaft grooves.
– Before installing, check valve timing housing strainer for con‐
tamination ⇒ page 80 .
– Before installing timing housing, lubricate camshaft seals.
– Lubricate contact surfaces of seals in timing housing and then
slowly push timing housing over camshaft seals.
104
Rep. gr.15 - Cylinder head, valve gear
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B - Exhaust camshaft
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– Install bearing caps 3 and 11 and also tighten to 5 Nm + 1/8
(45°) turn further.
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Install timing housing and tighten bolts -arrows-. Specified tor‐
que ⇒ page 79 .
– Install camshaft adjuster with timing chain for camshaft drive
⇒ page 105 .
– Clean sealing surface on cover.
– If damaged, renew the seal in the cover ⇒ page 78 .
– Apply a thin bead of sealant - D 176 501 A1- to clean sealing
surface of cover.
– Install cover, start all securing bolts -arrows- and tighten light‐
ly.
– Then tighten all securing bolts. Specified torque ⇒ page 58 .
– Install vacuum pump ⇒ page 70 .
– Install cylinder head cover ⇒ page 68 .
– Install upper part of intake manifold ⇒ page 181 .
Further assembly is basically a reverse of the dismantling se‐
quence.
Removing and installing camshaft adjuster
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sn
4.4
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4. Valve gear
105
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CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
sn
Special tools and workshop
equipment required
ses
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♦ Camshaft bar - T10068 A♦ Counterhold - T10172- with pins - T10172/1♦ Torque wrench - V.A.G 1331♦ Torque wrench - V.A.G 1332-
p
Not illustrated:
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♦ Adjusting tool - T10363-
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♦ Sealant - D 176 501 A1-
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Removing camshaft adjuster
– Remove upper part of intake manifold ⇒ page 181 .
o
– Remove cylinder head cover ⇒ page 68 .
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Rep. gr.15 - Cylinder head, valve gear
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Disconnect the following plug connectors:
1-
Hall sender - G40-
2-
Inlet camshaft control valve 1 - N205-
3-
Hall sender 2 - G163-
4-
Exhaust camshaft control valve 1 - N318-
– Remove vacuum pump ⇒ page 70 .
– Remove coolant pipes from cover.
– Remove the securing bolts for the cover -arrows- and remove
the cover.
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sn
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
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– Turn crankshaft in direction of engine rotation to TDC No. 1
cylinder marking from below using counterhold - T10172- .
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Cams -A- of cylinder 1 must face each other.
4. Valve gear
107
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Unscrew bolt for camshaft adjuster approx. 1 turn at outlet end,
using an open-ended spanner to counterhold on flat side of
camshaft.
– Unscrew bolt for camshaft adjuster approx. 1 turn at inlet end,
using an open-ended spanner to counterhold on flat side of
camshaft.
– Insert camshaft bar - T10068 A- in both shaft grooves. If nec‐
essary, move the camshafts back and forth slightly with an
open-end spanner.
sn
– Secure position of high-pressure pump chain drive sprocket
using adjusting tool - T10363- . The marking -A- on the drive
cam for high-pressure pump must be on top.
Note
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If the journal for vacuum pump drive is not vertical: remove the
camshaft bar - T10068 A- . Turn the crankshaft further in the di‐
rection of rotation until the journal is vertical and the camshaft bar
- T10068 A- can be inserted.
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108
Rep. gr.15 - Cylinder head, valve gear
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Remove tensioner for timing chain -arrow-.
– Mark chain links that are opposite the markings on the cam‐
shaft adjusters. Installation is facilitated by marking the timing
chain.
sn
– Undo and remove camshaft adjuster bolts and remove cam‐
shaft adjuster.
The timing chain must be held by its bottom cover in order to hold
it in position on the sprocket of the oil pump. The timing chain
cannot jump over.
Installing camshaft adjuster
Condition:
Crankshaft is at »TDC« position
•
Chain drive sprocket for high-pressure pump is fixed in place
with adjusting tool - T10363p
Camshafts have been fixed in place with camshaft bar T10068 Af
ng
•
v
•
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First install camshaft adjuster for inlet camshaft as follows:
o
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Note
Note
Due to a fitted key, camshaft adjusters can only be bolted on in
one position -arrows- at camshaft mounting.
– Put on inlet camshaft adjuster with fitted timing chain onto
camshaft. Observe the following:
4. Valve gear
109
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
•
The timing chain to high-pressure pump drive sprocket must
not »sag«.
•
It must be possible to easily position the camshaft adjuster with
»tight« timing chain and to tighten hand-tight.
•
The arrow -1- on camshaft adjuster »24E« must align with right
notch -2- of timing housing. Markings on timing housing
⇒ page 93 .
– Tighten camshaft adjuster bolt hand-tight.
sn
– From the tooth which aligns with the arrow -1- and the notch
-2-, now count exactly 16 rollers to the right on the timing chain.
Mark this roller with a coloured pen.
– Insert the exhaust camshaft adjuster »32A« into camshaft tim‐
ing chain. Previously counted 16 rollers must lie between teeth
at arrow markings »24E« and »32A«.
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– Connect camshaft adjuster »32A« with camshaft timing chain
onto exhaust camshaft. Observe the following:
v
The arrow -1- on camshaft adjuster »32A« must align with right
notch -2- of timing housing. Markings on timing housing
⇒ page 93 .
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•
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Note
It must be possible to easily position the exhaust camshaft ad‐
juster onto the exhaust camshaft. Move camshaft back and forth
slightly if necessary.
– Remove setting tool - T10363- from bearing shaft.
– Remove camshaft bar - T10068 A- .
110
Rep. gr.15 - Cylinder head, valve gear
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Install tensioner for timing chain -arrow-. Specified torque:
50 Nm.
If the markings align:
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sn
– Turn engine two revolutions in direction of engine rotation and
check if markings align.
– Hold camshaft which is to be tightened using a 27 mm openend spanner -arrow-.
Note
v
♦ Camshaft bar - T10068 A- must be removed while this is done.
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newed.
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♦ Note that all the securing bolts for the sprockets must be re‐
– Tighten securing bolts of inlet and exhaust camshaft adjusters
to 60 Nm + 1/4 turn (90°) further.
o
– Clean sealing surfaces for rear cover. Coat sealing surface
with sealant - D 176 501 A1- .
4. Valve gear
111
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Fit cover and tighten securing bolts -arrows- in diagonal se‐
quence to 8 Nm.
Removing and installing camshaft control valve
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Special tools and workshop
equipment required
v
4.5
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sn
Further assembly is carried out in the reverse order of removal.
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♦ Torque wrench - V.A.G 1783♦ TORX bit set - V.A.G 1766♦ Ratchet insert 1/4" - VAS 6234♦ Torx screwdriver - T10072Not illustrated:
112
Rep. gr.15 - Cylinder head, valve gear
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
♦ Sealant - D 176 501 A1♦ Sealant - D 454 300 A2Removing:
– Pull cover -1- off air duct, releasing clips on sides to do so.
sn
– Unclip air duct -2-.
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– Remove air filter housing with connecting hose. To do this,
unscrew bolt -A-, pull off connector -B- and detach spring-type
clip -C-. Take note of marking -D- when refitting.
Note
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Before removing connectors, mark each connector and compo‐
nent to which it belongs.
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– Detach following connectors.
o
1-
Hall sender - G40-
2-
Valve 1 for - N205-
3-
Hall sender 2 - G163-
4-
Exhaust camshaft control valve 1 - N318-
– Lay wiring harness to side.
– Unscrew coolant pipes from cover.
– Remove vacuum pump ⇒ page 70 .
– Unscrew the three cylinder head cover bolts -arrows-.
– Unscrew coolant hoses at top and bottom of cover.
4. Valve gear
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– Unscrew cover -arrows- from cylinder head.
Caution
♦ Cover lower chain housing carefully so that no parts can
fall into it.
♦ Securing bolts for camshaft timing control valves must not
be completely removed at first, so that the valve is not
canted during removal.
– Unscrew securing bolts for camshaft control valves approx.
3 mm (5 turns) with socket - T10072- -arrows-.
– Pull camshaft control valve out of seat in valve timing housing
and slide it along loosened bolts.
– Unscrew securing bolts and pull the valve for cam adjustment
out of valve timing housing.
Installing:
Caution
sn
♦ The valve seat in the valve timing housing must not be
scored or scratched.
♦ The camshaft control valves and the valve timing housing
must be free of dirt and soiling.
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♦ Ensure the camshaft control valves are protected from
knocks and impacts.
♦ Only unpack the new camshaft control valves immediately
prior to installation.
♦ The camshaft control valves must not be pulled into their
seat with the securing bolts. Only insertion by hand is per‐
mitted.
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– Moisten oil seal with clean engine oil.
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– Carefully insert camshaft adjustment valve into housing and
press in perpendicularly to the valve axis by hand until stop is
reached.
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– Tighten securing bolts -arrows- to 3.8 Nm.
-1- Camshaft control valve 1 - N205- .
-2- Exhaust camshaft control valve 1 - N318- .
– Clean sealing surface on cover and on cylinder head.
– Check seals for camshaft control valves and renew if neces‐
sary ⇒ page 78 .
114
Rep. gr.15 - Cylinder head, valve gear
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Check if gasket -arrows- is correctly seated in cylinder head
cover.
– Remove sealant residue from positions -A-, if necessary.
– Apply a thin bead of sealant - D 176 501 A1- to clean sealing
surface of cover.
– In addition, apply a small amount of sealant - D 454 300 A2to cover at positions marked.
Note
Sealant - D 176 501 A1- hardens quickly.
1-
Push cover upwards under gasket for cylinder head cover.
2-
Push cover against cylinder head onto dowel pins.
– Check that gasket -arrows- is correctly seated. It must not
have been pushed back.
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– Slide cover - slightly diagonally - onto camshaft adjustment
valves. Ensure that cylinder head cover gasket is not pushed
back.
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4. Valve gear
115
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CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– First insert all securing bolts -arrows- and tighten lightly.
sn
– Then tighten all securing bolts. Specified torque:
⇒ Item 18 (page 59) .
– Install vacuum pump ⇒ page 70 .
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– Then tighten the three securing bolts -arrows- of cylinder head
cover to specified torque. Specified torque:
⇒ Item 5 (page 58) .
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Further assembly is basically a reverse of the dismantling se‐
quence.
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Removing and installing valve stem seals
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116
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4.6
Rep. gr.15 - Cylinder head, valve gear
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
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sn
Special tools and workshop
equipment required
o
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♦ Valve lever - VW 541/1 A- with press tool - VW 541/6♦ Valve assembly device - 2036- with adapter plates - 2036/1♦ Spark plug socket - 3122 B♦ Valve stem seal puller - 3364♦ Valve stem seal fitting tool - 3365♦ Adapter - T40012/1♦ Torque wrench - V.A.G 1331-
4. Valve gear
117
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Removing:
sn
When removed, the cylinder head can be mounted on the Cylin‐
der head tensioning device - VAS 6419- for assembly work.
– Remove camshafts ⇒ page 101 .
Note
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– Remove roller rocker fingers together with supporting ele‐
ments and place them on a clean surface.
Ensure that roller rocker fingers and supporting elements are not
interchanged.
– Unscrew spark plugs using spark plug socket and extension 3122 B- .
v
– Set piston of respective cylinder to “bottom dead centre”.
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– Set-up valve assembly device - 2036- with adapter plates 2036/1- and adjust mounting.
yi
– Screw adapter - T40012/1- into spark plug thread, connect to
compressed air line with commercially available adapter and
apply constant pressure. At least 6 bar.
o
o
– Remove valve springs using valve lever - VW 541/1 A- and
press tool VW 541/6 .
Note
Tight valve cotters can be loosened by tapping lightly on assem‐
bly lever.
– Pull off valve stem seals using valve stem seal puller - 3364- .
Installing:
– To prevent damage to new valve stem seals, place plastic
sleeve -A- on valve stem.
– Lubricate sealing lip of valve stem oil seal -B-, place it in the
valve stem oil seal fitting tool - 3365- and push carefully onto
valve guide.
– Install camshafts ⇒ page 101 .
Adjust valve timing ⇒ page 93 .
118
Rep. gr.15 - Cylinder head, valve gear
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
5
Inlet and exhaust valves
⇒ “5.1 Checking valve guides”, page 119
⇒ “5.2 Reworking valve seats”, page 119
⇒ “5.3 Valve dimensions”, page 121
5.1
Checking valve guides
Special tools and workshop equipment required
♦ Universal dial gauge holder - VW 387-
♦ Dial gauge
Test sequence
– Insert new valve in guide. The end of the valve stem must be
flush with the guide. On account of differing stem diameters,
only use inlet valve in inlet guide and exhaust valve in exhaust
guide.
– Determine rock. Wear limit: 0.8 mm
If the amount of sideways play is exceeded:
– Renew cylinder head.
5.2
Reworking valve seats
sn
Special tools and workshop equipment required
♦ Depth gauge
♦ Valve seat refacing tool
Note
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Procedure
♦ When repairing engines with leaking valves, it is not sufficient
to rework or renew valve seats and valves. Particularly on high
mileage engines, it is necessary also to check valve guides for
wear ⇒ page 119 .
♦ Valve seats are only to be reworked to the extent required to
f
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yield a proper surface appearance. Before beginning to rework
valve seats, calculate the maximum permissible reworking di‐
mensions. If the reworking dimension is exceeded, the hy‐
draulic valve clearance compensation can no longer be
guaranteed and the cylinder head must be renewed.
o
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5. Inlet and exhaust valves
119
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CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Remove camshafts ⇒ page 101 .
Calculate the max. permissible reworking dimension as follows:
– Insert valve and press firmly against seat.
Note
sn
If the valve is to be renewed as part of a repair, use a new valve
for the calculation.
– Measure distance -a- between end of valve stem and upper
edge of cylinder head.
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– Calculate maximum permissible reworking dimension from
measured distance -a- and minimum dimension
Minimum dimension:
mm
mm
mm
mm
31.8
10.2
31.8
10.2
v
Short inlet valve
Long inlet valve
Short exhaust valve
Long exhaust valve
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Measured distance minus minimum dimension = max. permissi‐
ble reworking dimension.
o
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Example:
o
=
Measured distance
Minimum dimension
Max. permissible reworking dimension
Reworking inlet valve seat:
a
b
= 32.8 mm diameter
= max. permissible reworking dimension
c
d
r2
= 0.9 to 1.5 mm
= max. ∅ 38.0 mm
= radius 2.0 mm
Z
α
β
γ
= bottom surface of cylinder head
= 45° valve seat angle
= 30° upper correction angle
= 60° lower correction angle
1)
1) Calculating max. permissible reworking dimension ⇒
120
Rep. gr.15 - Cylinder head, valve gear
page 119 .
10.6 mm
10.2 mm
0.4 mm
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Reworking exhaust valve seat:
a
b
= 29.8 mm diameter
= max. permissible reworking dimension
c
d
r2
= 1.2 to 1.7 mm
= max. ∅ 35.0 mm
= radius 2.0 mm
Z
α
β
γ
= bottom surface of cylinder head
= 45° valve seat angle
= 30° upper correction angle
= 60° lower correction angle
2)
2) Calculating max. permissible reworking dimension ⇒
5.3
page 119 .
Valve dimensions
Valve dimensions
Note
sn
Do not rework valves. Only lapping-in is permitted.
Valve dimensions for inlet valves
∅a
∅b
c
α
mm
mm
mm
∠°
Short inlet valve
Long inlet valve
33.20
5.98
102.46
44° 40’
33.20
5.98
136.36
44° 40’
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Dimension
Valve dimensions for exhaust valves
30.20
5.97
136.20
44° 40’
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30.20
5.97
102.20
44° 40’
o
mm
mm
mm
∠°
yi
∅a
∅b
c
α
Short exhaust valve Long exhaust valve
o
Dimension
5. Inlet and exhaust valves
121
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
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17 –
Lubrication
1
Sump, oil pump
⇒ “1.1 Assembly overview - sump/oil pump”, page 122
⇒ “1.2 Removing and installing oil spray jet”, page 124
⇒ “1.3 Removing and installing sump”, page 125
⇒ “1.5 Engine oil:”, page 131
1.1
sn
⇒ “1.4 Removing and installing oil pump”, page 127
Assembly overview - sump/oil pump
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Note
♦ If large quantities of metal chips and abraded material are
found during engine repair, this may indicate that the crank‐
shaft bearings or conrod bearings are damaged. To avoid any
subsequent damage, the following work must be carried out
following the repair:
♦ Renewing oil filter.
p
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♦ Renew engine oil cooler.
o
♦ Renew oil spray jets.
v
♦ Thoroughly clean oil channels.
♦ The oil level must not be above the max. marking on the dip‐
stick - danger of damage to the catalytic converter! Markings
⇒ page 131 , Checking engine oil level.
o
122
Rep. gr.17 - Lubrication
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
1 - Bolt
❑ 6 Nm
❑ Secured to intake mani‐
fold.
2 - Guide tube
❑ for oil dipstick
❑ Secured with bolt to in‐
take manifold.
3 - Cylinder block
❑ Crankshaft ⇒ page 40 .
❑ Pistons and conrods
⇒ page 51 .
4 - O-ring
❑ Renew
❑ Lubricate before as‐
sembling.
5 - Oil pump
❑ with pressure relief
valve
❑ Remove gearbox to re‐
move oil pump.
❑ Removing and installing
oil pump ⇒ page 127 .
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sn
6 - Sprockets
❑ For timing chain
❑ Removing and installing
⇒ page 105
❑ Install camshaft adjust‐
er with timing chain for
camshaft drive
⇒ page 105
7 - Bolt
❑ 60 Nm + 1/4 turn (90°) further
❑ Renew
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8 - Bolt
❑ 8 Nm
❑ Install with locking fluid
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9 - Sealing ring
❑ Renew
❑ Lubricate before assembling.
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10 - Oil spray jet
❑ For crankshaft bearings 2 to 7
❑ For piston cooling
❑ Opening pressure: 2.0 bar
❑ Removing and installing ⇒ page 124
11 - Sealing ring
❑ Renew if damaged
❑ Lubricate before assembling.
12 - Oil intake tube
❑ Clean strainer if soiled
1. Sump, oil pump
123
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
13 - Bolt
❑ 8 Nm
❑ Install with locking fluid
14 - Oil pipe
15 - Bolt
❑ 8 Nm
❑ Install with locking fluid
16 - Baffle plate
17 - Oil drain plug
❑ 30 Nm
❑ With captive seal
❑ Renew
18 - Sump
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant - D 176 501 A1- .
❑ Removing and installing ⇒ page 125
20 - Bolt
❑ 10 Nm
21 - Securing bolts for oil sump
❑ 12 Nm
sn
19 - Oil level and oil temperature sender - G266❑ Checking: ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
22 - Bolt
❑ 10 Nm
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27 - Sealing ring
❑ Renew
❑ Lubricate before assembling.
1.2
Removing and installing oil spray jet
Special tools and workshop equipment required
♦ Drift ∅ 4 mm
♦ Drift ∅ 6 mm
124
o
26 - Sealing ring
❑ Renew
❑ Lubricate before assembling.
yi
25 - Oil pressure switch
❑ Checking ⇒ page 135
o
24 - Bolt
❑ 23 Nm
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23 - Oil filter housing
❑ With engine oil cooler.
❑ Assembly overview ⇒ page 133 .
Rep. gr.17 - Lubrication
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Note
Oil spray jets are installed in crankshaft bearings 2 to 7.
Removing:
– Press out oil spray jet -arrow- using 4 mm ∅ punch towards
engine mounting.
Installing:
sn
– To install, press in oil spray jet by hand using a 6 mm ∅ punch .
1.3
Removing and installing sump
Special tools and workshop equipment required
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♦ Torque wrench - V.A.G 1331-
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♦ Socket XZN 8 - T40159o
Not illustrated:
♦ Used oil collector and extractor - V.A.G 1782♦ Sealant - D 176 501 A1♦ Hand drill with plastic brush
♦ Scraper
♦ Safety glasses
1. Sump, oil pump
125
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Removing:
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Detach connector from oil level and temperature sender G266- .
sn
– Drain engine oil.
– Unbolt heat shield above right drive shaft from sump.
– Remove poly V-belt ⇒ page 31 .
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Note
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– Unscrew gearbox/sump securing bolts.
yi
♦ Follow disposal regulations for engine oil!
o
♦ On vehicles with DSG® gearbox, the flywheel has an inden‐
tation -A- to fit the sump bolts. Turn the flywheel so that the
bolt head is accessible.
o
– Remove sump bolts on the gearbox side -arrows- using bit
XZN 8 - T40159- .
– Remove remaining sump bolts and remove sump.
– Loosen sump with light blows of a rubber headed hammer if
necessary.
– Remove sealant residues from cylinder block with a flat scra‐
per.
– Remove sealant residues on sump with a rotating brush, e.g.
an electric drill with plastic brush attachment (wear eye pro‐
tection).
– Clean sealing surfaces. They must be free of oil and grease.
Installing:
Note
♦ Observe use-by-date of sealant.
♦ The sump must be installed within 5 minutes of applying sili‐
cone sealing compound.
126
Rep. gr.17 - Lubrication
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Cut off nozzle on tube at front marking (∅ of nozzle approx.
3 mm).
– Apply sealant - D 176 501 A1- to clean sealing surface of sump
as shown. Sealant bead must be:
♦ 2 to 3 mm thick
♦ Run bead along inner side of bolt holes -arrows-.
Note
The sealant bead must not be thicker, otherwise excessive seal‐
ant enters the sump and may block the oil suction pipe strainer.
– Apply sealant - D 176 501 A1- as shown in figure to clean
sealing surface of sump.
– Immediately position sump and tighten all sump bolts slightly.
– Tighten sump bolts to 11 Nm.
– Tighten bolts securing sump to gearbox to 45 Nm.
Note
Let sealing compound dry for approx. 30 minutes after installing
oil sump. Only then fill with engine oil.
sn
Further assembly is basically a reverse of the dismantling se‐
quence.
1.4
Removing and installing oil pump
Note
Procedure:
– Remove gearbox.
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To remove the oil pump, the gearbox must be removed.
– Remove flywheel.
– Remove timing chain cover ⇒ page 76 .
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– Loosen bolt -arrow- for sprockets about 1 full turn. To do this,
counterhold vibration damper using counterhold - T10172- .
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1. Sump, oil pump
127
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CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Turn engine by vibration damper to adjustment markings.
•
Ground tooth of drive sprocket -arrow A- must align with bear‐
ing joint.
•
The marked hole -arrow B- must be in line with the mark on
the oil pump.
Note
This position is reached only after every 4th full rotation.
– Mark position of timing chains to sprockets of oil pump using
a permanent marker.
sn
– Remove chain tensioner for camshaft timing chain -arrow-.
– Fix chain tensioner spring using 3 mm Allan key -A-.
f
ng
p
v
ses
a purp
– Remove chain tensioner for oil pump drive chain -arrows-.
yi
– Unscrew securing bolt for sprockets completely and remove
sprockets with timing chains from oil pump.
o
o
128
Rep. gr.17 - Lubrication
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Unscrew oil pump securing bolts -arrows-.
– Lever oil pump out evenly at lugs -arrows-.
Installing:
Note
♦ Do not tilt oil pump when installing.
♦ Renew O-ring and securing bolt for the sprockets.
♦ Insert securing bolts for oil pump with locking fluid.
ses
a purp
sn
– Install oil pump, coat securing bolts -arrows- with locking
agent, then tighten bolts. Specified torque
⇒ Item 8 (page 123) .
– Set crankshaft to TDC position.
f
ng
p
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Ground tooth of drive sprocket -arrow- must align with bearing
joint.
o
o
yi
•
1. Sump, oil pump
129
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– Now turn oil pump shaft -1- with flat side -arrow- horizontal to
mark -2- on oil pump.
– First, only fit the rear chain onto the large sprocket. When do‐
ing this, observe the previously made markings.
– Fit sprocket onto oil pump shaft. The marked hole -arrow- must
be in line with the mark on the oil pump.
f
ng
p
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ses
a purp
sn
– If sprocket cannot be fitted, turn oil pump shaft slightly.
– Carefully pull sprocket off oil pump and swing upwards a little.
In this position, fit the camshaft timing chain. The marking
made during removal must align.
o
yi
o
– Fit sprocket onto oil pump shaft again and tighten hand-tight.
130
Rep. gr.17 - Lubrication
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Install lower chain tensioner and tighten to 8 Nm -arrows-.
– Remove Allan key -A-.
– Install chain tensioner for camshaft timing chain -arrow-.
– Recheck adjustment markings.
•
Ground tooth of drive sprocket -arrow A- must align with bear‐
ing joint.
•
The marked hole -arrow B- must be in line with the mark on
the oil pump.
– Tighten sprockets to 60 Nm + 1/4 turn (90°) further. To do this,
counterhold vibration damper using counterhold - T10172- .
– Install timing chain cover ⇒ page 76 .
1.5
Engine oil:
Oil capacities:
♦ Without oil filter: 5.0 l
p
v
♦ With oil filter: 5.5 l
f
ng
Engine oil specifications:
yi
⇒ Maintenance ; Booklet ; Service tables
o
Checking engine oil level:
Test conditions
•
o
ses
a purp
sn
Further assembly is carried out in the reverse order of removal.
Engine oil temperature min. 60 °C.
1. Sump, oil pump
131
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6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
•
Vehicle in horizontal position.
•
Wait a few minutes after switching engine off to allow oil to flow
back into sump.
Test sequence
– Pull out dipstick, wipe off with a clean cloth and insert it again
to stop.
– Pull out dipstick again and read oil level.
Markings on oil dipstick
1 - Max. mark
2 - Min. mark
a - Area above hatched field up to max. mark: Do not top up with
engine oil!
b - Oil level within hatched field: engine oil can be topped-up.
f
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ses
a purp
sn
c - Area from min. mark up to hatched field: top up, max. 0.5 l of
engine oil!
o
yi
o
132
Rep. gr.17 - Lubrication
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
2
Oil filter, oil pressure switch
sn
⇒ “2.1 Assembly overview - oil filter housing, oil pressure switch”,
page 133
⇒ “2.2 Checking oil pressure and oil pressure switch”,
page 135
ses
a purp
2.1
Assembly overview - oil filter housing, oil
pressure switch
Note
♦ If large quantities of metal chips and abraded material are
v
found during engine repair, this may indicate that the crank‐
shaft bearings or conrod bearings are damaged. To avoid any
subsequent damage, the following work must be carried out
following the repair:
f
ng
p
♦ Thoroughly clean oil channels.
♦ Renew oil spray jets.
o
yi
♦ Renew engine oil cooler.
o
♦ Renewing oil filter.
♦ The oil level must not be above the max. marking on the dip‐
stick - danger of damage to the catalytic converter! Markings
⇒ page 131 , Checking engine oil level.
2. Oil filter, oil pressure switch
133
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
1 - Sealing ring
❑ Renew
❑ Lubricate before as‐
sembling.
2 - Oil filter housing
3 - Oil seals
❑ Renew
❑ Lubricate before as‐
sembling.
v
f
ng
7 - Coolant hose
❑ Ensure firm seating
❑ Connection diagram for
coolant hoses
⇒ page 138
p
6 - Bolt
❑ 8 Nm
ses
a purp
5 - Engine oil cooler
❑ Remove with oil filter
housing
❑ Ensure clearance to ad‐
jacent components
❑ Observe notes
⇒ page 133
❑ Connection diagram for
coolant hoses
⇒ page 138
sn
4 - Connection plate
❑ Component of the en‐
gine oil cooler
11 - Oil pressure switch - F1- , 20 Nm
❑ 0.9 bar switch
❑ If seal is leaking, nip open and renew.
❑ Checking ⇒ page 135
12 - Oil drain plug
❑ 10 Nm
13 - O-ring
❑ Renew
❑ Lubricate before assembling.
14 - Threaded cover
❑ 25 Nm
15 - O-ring
❑ Renew
❑ Lubricate before assembling.
134
Rep. gr.17 - Lubrication
o
10 - Bolt
❑ 23 Nm
yi
9 - Hose clamp
o
8 - Coolant hose
❑ Ensure firm seating
❑ Connection diagram for coolant hoses ⇒ page 138
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
16 - Oil filter element
❑ Observe change intervals.
❑ Observe notes ⇒ page 133
17 - O-ring
❑ Renew
❑ Lubricate before assembling.
2.2
Checking oil pressure and oil pressure switch
f
ng
p
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ses
a purp
sn
Special tools and workshop
equipment required
o
yi
o
♦ Oil pressure tester - V.A.G 1342♦ Adapter - V.A.G 1342/14♦ Voltage tester - V.A.G 1527 B♦ Adapter set - V.A.G 1594C-
2. Oil filter, oil pressure switch
135
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Jointed wrench 24 mm - T40175Note
Functional check and repair of the optical and acoustic oil pres‐
sure warning ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
Test conditions:
•
Oil level OK, checking ⇒ page 131
•
Engine oil temperature at least 80°C (radiator fan must have
run once)
•
On vehicles with automatic gearbox the selector lever must be
in “P” or “N” position.
Checking oil pressure switch:
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Remove oil pressure switch - F1- and screw into tester.
– Screw tester into oil filter bracket in place of oil pressure
switch.
Note
Note the installation position of the adapter: the conical union of
the adapter must be screwed to the pressure hose of the tester.
f
ng
p
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ses
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sn
– Connect brown wire of tester to earth (-).
o
yi
o
136
Rep. gr.17 - Lubrication
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Connect voltage tester - V.A.G 1527B- with cables from aux‐
iliary measuring set - V.A.G 1594C- to battery positive (+)
(connection in engine compartment -arrow-) and oil pressure
switch. LED must not light up.
If the LED lights up:
– Replace oil pressure switch - F1If LED does not light up:
Note
Observe the tester and LED while starting because the switching
point of the oil pressure switch may already be exceeded when
starting.
– Start engine and run at idling speed. At 0.7…1.1 bar the LED
must light up; otherwise renew oil pressure switch - F1- .
Checking oil pressure:
– Check oil pressure at various speeds:
♦ 1500 rpm: at least 1.7 bar
♦ 2000 rpm: 3.0 … 5.5 bar
♦ Over 2,000 rpm: maximum 7.0 bar
If the specifications are not attained:
– Check strainer in oil suction pipe ⇒ Item 12 (page 123) for dirt.
– Check control piston of oil pressure safety valve in oil pump
for dirt.
– Check oil pipe at bottom of cylinder block
⇒ Item 14 (page 124) for leaks.
Note
♦ Mechanical damage, e.g. to bearings, could also be the cause
for oil pressure being too low.
♦ The oil pressure safety valve control piston is spring-loaded.
Great care is therefore required when screwing the plug in/out.
If no fault is found:
sn
♦ The plug is tightened to 35 Nm in oil pump.
– Renew oil pump ⇒ page 127 .
If the specification is exceeded:
– Check oil channels.
f
ng
p
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ses
a purp
– Renew oil pump, if necessary ⇒ page 127 .
o
2. Oil filter, oil pressure switch
137
o
yi
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
19 –
Cooling
1
Cooling system/coolant
⇒ “1.1 Connection diagram - coolant hoses”, page 138
⇒ “1.2 Checking cooling system for leaks”, page 140
⇒ “1.3 Draining and adding coolant”, page 142
Connection diagram - coolant hoses
sn
1.1
Note
♦ Incorporation of auxiliary heater in ⇒ auxiliary heater; Rep. gr.
ses
a purp
82 coolant circuit.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue .
♦ Hose clip pliers - VAS 6340- or hose clip pliers - VAS 6362-
are recommended for installation of spring-type clips.
♦ The arrow markings on coolant pipes and on ends of hoses
f
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p
v
must align when installing.
o
yi
o
138
Rep. gr.19 - Cooling
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
1 - Expansion tank
2 - Heat exchanger for heater
❑ If renewed, refill system
with fresh coolant.
3 - Upper side coolant pipe
4 - Gear oil cooler
5 - Non-return valve
❑ Observe installation po‐
sition
❑ Arrow on non-return
valve points in direction
of flow
6 - Auxiliary radiator
❑ Not installed
7 - Upper coolant hose
8 - Lower coolant hose
9 - Radiator/cooler
10 - Lower side coolant pipe
11 - Non-return valve
❑ Observe installation po‐
sition
❑ Arrow on non-return
valve points in direction
of flow
12 - Engine oil cooler
13 - Continued coolant circula‐
tion pump - V51sn
14 - Coolant pipe
❑ With thermostat hous‐
ing
15 - Coolant pump
v
p
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o
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18 - Rear coolant pipe
o
17 - Cylinder block
ses
a purp
16 - Thermostat
1. Cooling system/coolant
139
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
1.2
Checking cooling system for leaks
ses
a purp
sn
Special tools and workshop
equipment required
p
v
♦ Adapter for cooling system tester - V.A.G 1274/8f
ng
♦ Adapter for cooling system tester - V.A.G 1274/9o
yi
♦ Cooling system tester - V.A.G 1274 B-
o
Note
To perform the leakage test correctly, first run a self-test on the
cooling system tester - V.A.G 1274 B- .
140
Rep. gr.19 - Cooling
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Self-test of cooling system tester - V.A.G 1274 B– Operate cooling system tester - V.A.G 1274 B- several times.
– Build up a pressure of 3.0 bar on cooling system tester .
– Observe pressure on pressure gauge of cooling system tester
for 30 seconds.
If no pressure builds up or if the pressure drops again:
The cooling system tester - V.A.G 1274 B- is leaking and should
not be used.
•
Engine at operating temperature.
sn
Checking cooling system for leaks
WARNING
The cooling system is under pressure when the engine is hot!
ses
a purp
Danger of scalding due to steam and hot coolant.
Cover filler cap on expansion tank with a cloth and open care‐
fully to release pressure.
f
ng
p
v
– Open cap -1- on coolant expansion tank.
o
o
1. Cooling system/coolant
141
yi
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Fit cooling system tester - V.A.G 1274 B- with adapter V.A.G 1274/8- to coolant expansion tank.
– Build up pressure of approx. 1.5 bar using hand pump of cool‐
ing system tester.
•
The pressure must not drop by more than 0.2 bar within 10 mi‐
nutes.
– If the pressure drops by more than 0.2 bar, locate and rectify
leaks.
Note
sn
The pressure drop of 0.2 bar within 10 minutes depends on the
how far the coolant can cool down. The colder the engine, the
lower the pressure drop. If necessary, repeat the check while the
engine is cold.
DANGER!
ses
a purp
Risk of scalding! Before the cooling system tester - V.A.G 1274
B- is disconnected from the connecting hose or the connector
- V.A.G 1274 B/1- , it is essential that the pressure is relieved.
To do this, press pressure relief valve on cooling system tester
- V.A.G 1274 B- until pressure gauge displays value of »0«.
Check pressure relief valve in cap.
f
ng
p
v
– Fit cooling system tester - V.A.G 1274 B- with adapter V.A.G 1274/9- onto coolant filler cap.
– Build up pressure using hand pump of cooling system tester.
o
yi
•
The pressure relief valve must open at a pressure of 1.4 to
1.6 bar.
o
– Renew filler cap, if pressure relief valve does not open as de‐
scribed.
1.3
142
Draining and adding coolant
Rep. gr.19 - Cooling
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
f
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p
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ses
a purp
sn
Special tools and workshop
equipment required
o
yi
o
♦ Adapter for cooling system tester - V.A.G 1274/8♦ Drip tray - VAS 6208♦ Spring-type clip pliers - VAS 6340♦ Coolant system charge unit - VAS 6096♦ Refractometer - T10007 ADrain coolant:
WARNING
The cooling system is under pressure when the engine is hot!
Danger of scalding due to steam and hot coolant.
Cover filler cap on expansion tank with a cloth and open care‐
fully to release pressure.
– Carefully open filler cap on coolant expansion tank.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
1. Cooling system/coolant
143
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
sn
– Open quick-release coupling -arrow- and pull off coolant hose
downwards from radiator.
ses
a purp
– Remove additional bottom coolant hose to continued coolant
circulation pump - V51- -arrow- and allow remaining coolant
to drain out.
Note
Follow disposal regulations for coolant!
Caution
f
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p
v
Filling with coolant:
yi
Only distilled water may be used for mixing coolant additives.
The use of distilled water ensures optimum protection against
corrosion.
o
o
144
Rep. gr.19 - Cooling
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Note
♦ The water used for mixing has a major influence on the effec‐
tiveness of the coolant. Because the water quality differs from
country to country and even from region to region, the quality
of the water to be used in the cooling system has been speci‐
fied by Volkswagen. Distilled water fulfils all requirements.
Therefore, only ever use distilled water when mixing coolant
for topping up or renewing coolant.
♦ Use only coolant additives which conform with the ⇒ Elec‐
tronic parts catalogue (ETKA) . Other coolant additives may
reduce corrosion protection substantially. The resulting dam‐
age could lead to loss of coolant and subsequent severe
damage to the engine.
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐
rosion damage as well as scaling. Such additives also raise
the boiling point of the coolant. For this reason, the cooling
system must be filled all-year-round with coolant additives.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ The refractometer - T10007A- or refractometer - T10007B-
must be used to determine the current anti-freeze value.
sn
♦ The scale -1- of the refractometer is calibrated for the coolant
additives G12++ and G12evo.
♦ The scale -2- of the refractometer is calibrated for the coolant
additive G13.
♦ If it is not possible to ensure that the same type of coolant
ses
a purp
additive is filled: always determine anti-freeze protection using
the scale for G13.
♦ Frost protection must be guaranteed down to -25°C as a min‐
imum and, in countries with arctic conditions, down to approx.
-36°C. Increasing the frost protection is permissible only if cli‐
matic conditions require stronger frost protection. It may, how‐
ever, be increased only to a maximum of -48°C. Otherwise,
the cooling effect will be impaired.
♦ Do not reduce the coolant concentration by adding water even
f
ng
p
v
in warmer seasons and in warmer countries. Frost protection
must be guaranteed down to at least -25°C.
yi
♦ The temperature reading on the refractometer corresponds to
o
the »ice flocculation point«. Flakes of ice may start forming in
the coolant below this temperature.
o
♦ Never reuse old coolant.
♦ Use only a water/coolant additive mixture as a slip agent for
coolant hoses.
Recommended mixture ratios:
Frost protection Amount of antito:
freeze
-25°C
-36°C
40%
50%
Coolant ad‐ Distilled wa‐
ditive 3)
ter 3)
3.6 l
4.5 l
5.4 l
4.5 l
3) The quantity of coolant can vary depending upon vehicle equipment.
Procedure:
1. Cooling system/coolant
145
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
ses
a purp
sn
– Reconnect coolant hose to continued circulation coolant pump
- V51- -arrow-.
– Push lower coolant hose onto radiator union and secure.
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Assembly overview – noise insula‐
tion .
v
– Screw adapter for cooling system tester - V.A.G 1274/8- onto
expansion tank.
f
ng
p
– Fill coolant circuit using cooling system charge unit VAS 6096- ⇒ Operating instructions for cooling system charge
unit VAS 6096 .
o
o
yi
WARNING
The cooling system is under pressure when the engine is hot!
Danger of scalding due to steam and hot coolant.
Cover filler cap on expansion tank with a cloth and open care‐
fully to release pressure.
– Check coolant level and top up as needed. When engine is at
normal operating temperature, the coolant level must be at the
upper mark; when engine is cold, in the middle of the shaded
field.
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Assembly overview – noise insula‐
tion .
146
Rep. gr.19 - Cooling
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
2
Coolant pump, regulation of cooling
system
⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 147
⇒ “2.2 Removing and installing coolant pump”, page 149
⇒ “2.3 Removing and installing thermostat”, page 152
⇒ “2.4 Checking thermostat”, page 153
⇒ “2.5 Removing and installing continued coolant circulation
pump V51 ”, page 153
2.1
Assembly overview - coolant pump,
thermostat
Note
♦ Coolant hose schematic diagram ⇒ page 138
♦ Hose connections are secured with spring-type clips. In case
of repair, only use spring-type clips.
sn
♦ Hose clip pliers - VAS 6340- or hose clip pliers - VAS 6362-
are recommended for installation of spring-type clips.
♦ When installing coolant hoses, position them so they are free
of stress and do not come into contact with other components.
♦ The arrows on the coolant pipes and on the ends of the hoses
ses
a purp
must be aligned with each other.
f
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p
v
♦ Renew gaskets and seals.
o
o
2. Coolant pump, regulation of cooling system
147
yi
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
1 - To top of expansion tank
2 - Rear coolant pipe
3 - 20 Nm
4 - From heat exchanger
5 - To heat exchanger
6 - Coolant pipe
7 - 10 Nm
8 - From gear oil cooler
9 - Upper side coolant pipe
10 - 10 Nm
11 - Radiator outlet coolant G62❑ Before removing, re‐
lease pressure in cool‐
ing system if necessary.
12 - O-ring
❑ Renew
13 - Retaining clip
❑ Check for firm seating
sn
14 - 10 Nm
15 - To top of radiator
17 - To additional cooler
❑ If installed.
18 - From bottom of radiator.
ses
a purp
16 - From additional cooler
❑ If installed.
19 - Non-return valve
❑ Observe installation position
❑ Arrow on non-return valve points in direction of flow
24 - 8 Nm
25 - Thermostat
❑ Checking ⇒ page 153
❑ Removing and installing ⇒ page 152
26 - Coolant pipe
❑ With thermostat housing
27 - Sealing ring
❑ Renew
148
Rep. gr.19 - Cooling
p
f
ng
o
23 - Continued coolant circulation pump - V51❑ Removing and installing ⇒ page 153
yi
22 - To gear oil cooler
❑ If installed.
o
21 - 25 Nm
v
20 - Lower side coolant pipe
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
28 - 8 Nm
29 - Pulley
❑ For coolant pump
❑ Removing and installing ⇒ page 149
30 - 20 Nm
31 - Coolant pump
❑ Check for ease of movement.
❑ Removing and installing ⇒ page 149
32 - Seal
❑ Renew
33 - Union
34 - 10 Nm
sn
35 - From bottom of expansion tank
2.2
Removing and installing coolant pump
f
ng
p
v
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a purp
Special tools and workshop
equipment required
o
yi
o
♦ Support bracket - 10 - 222 A- with rack - 10 - 222 A /12. Coolant pump, regulation of cooling system
149
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
♦ Refractometer - T10007 A♦ Drip tray - VAS 6208♦ Torque wrench - V.A.G 1331♦ Spring-type clip pliers - VAS 6362♦ Shackle - 10 - 222 A /12Removing:
– Remove front right wheel.
– Remove front right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Removing
and installing front wheel housing liner .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Unbolt bracket for exhaust system -arrows-.
– Remove pendulum support.
– Drain coolant ⇒ page 142 .
– Remove poly V-belt ⇒ page 31 .
Caution
The racks - 10 - 222 A /1- must not be placed on the bolted on
sheet metal of the wings. These may otherwise be damaged.
sn
– Tighten shackle - 10 - 222 A /12- on right lifting eye.
f
ng
p
v
ses
a purp
– Fit support bracket - 10 - 222 A- with rack - 10 - 222 A /1- as
shown and take up weight of engine in installation position at
right lifting eye.
o
yi
o
150
Rep. gr.19 - Cooling
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Unbolt engine side of assembly mounting from engine bracket
-arrows-.
– Lower engine on support bracket - 10 - 222 A- until coolant
pump can be removed.
– Remove coolant pump belt pulley. To do this, counterhold belt
pulley with a drift (commercially available).
– Unscrew coolant pump securing bolts -1- and remove coolant
pump -2- forwards and downwards.
Installing:
Install in reverse order of removal, observing the following.
– Moisten new O-ring with coolant.
– Fit coolant pump.
– Tighten securing bolts for coolant pump. Specified torque:
8 Nm
– Install belt pulley for coolant pump. Specified torque: 20 Nm
– Raise engine with support device - 10 - 222 A- again and
mount with new securing bolts, hand-tightened.
sn
– Align engine mountings as follows:
♦ There must be a distance -a- of at least 10 mm between engine
support and longitudinal member (right side).
♦ The side surface of the engine support -2- should be located
parallel to the support arm -1-.
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– Tighten new bolts for engine assembly mounting and engine
bracket. Specified torque ⇒ page 21 .
– Install pendulum support.
– Install poly V-belt ⇒ page 31 .
– Add coolant ⇒ page 142 .
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– Install front right wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liner; Removing and
installing front wheel housing liner .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Assembly overview – noise insula‐
tion .
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– Install right front wheel.
1-
When fitting the wheel, tighten all the wheel bolts by hand
uniformly.
2-
Tighten wheel bolts to approx. 30 Nm in diagonal sequence.
3-
Lower the vehicle to the floor and use a torque spanner to
tighten all the wheel bolts diagonally to the specified tor‐
ques.
2. Coolant pump, regulation of cooling system
151
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
2.3
Removing and installing thermostat
Special tools and workshop equipment required
♦ Hose clamp pliers - VAS 6340-
Removing:
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Drain coolant ⇒ page 142 .
– Unscrew bolts -arrows- and remove coolant connection with
coolant hose.
sn
– Remove thermostat from coolant pipe.
Installing:
Note
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There should be a metal sleeve -arrow- in the coolant connection.
If this is missing, the coolant connection must be replaced.
– Clean sealing surface for O-ring.
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– Insert thermostat into coolant pipe.
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152
Rep. gr.19 - Cooling
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
•
Installation position: the edges on thermostat and on housing
must align -arrows-.
– Moisten new seal with coolant and fit on coolant connection.
– Fit coolant connection with seal and tighten bolts alternately
and diagonally.
Specified torque: 5 Nm.
– Add coolant ⇒ page 142 .
sn
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Assembly overview – noise insula‐
tion .
Checking thermostat
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2.4
Note
The thermostat can be tested with the “Guided Fault Finding” un‐
der “Selection of functions and components”.
– Remove thermostat ⇒ page 152 .
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– Heat thermostat in water.
•
Starts to open at 80 °C
•
Opening at 94°C: 9 mm
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Removing and installing continued cool‐
ant circulation pump - V51o
2.5
Location of continued coolant circulation pump - V51The continued coolant circulation pump - V51- is secured to an‐
cillary unit bracket -arrow-.
– To remove, ancillary bracket must be removed from cylinder
block ⇒ page 33 .
The continued coolant circulation pump - V51- is bolted to ancil‐
lary bracket to specified torque of 8 Nm.
2. Coolant pump, regulation of cooling system
153
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
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3
Radiator, radiator fan
⇒ “3.1 Assembly overview - radiator/radiator fan”, page 154
⇒ “3.2 Removing and installing radiator”, page 155
⇒ “3.3 Removing and installing radiator cowl with radiator fan”,
page 157
⇒ “3.4 Removing and installing radiator fan”, page 159
3.1
Assembly overview - radiator/radiator
fan
Note
Coolant hose schematic diagram ⇒ page 138
1 - Upper coolant hose
❑ To connection on cylin‐
der head.
2 - O-ring
❑ Renew if damaged
sn
3 - Radiator/cooler
❑ Removing and installing
⇒ page 155
❑ After renewing, renew
entire coolant.
4 - Seal
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8 - Expansion tank
❑ Check cooling system
for leaks using cooling
system tester - V.A.G
1274- and adapter for
cooling system tester V.A.G 1274/8-
yi
7 - 5 Nm
o
6 - Connector
v
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5 - Cap
❑ Check using cooling
system tester - V.A.G
1274- and adapter for
cooling system tester V.A.G 1274/9❑ Pressure relief valve
must open at between
1.4 and 1.6 bar
9 - Holder
❑ For radiator
10 - 5 Nm
11 - Support
12 - 10 Nm
13 - Radiator cowl
❑ Removing and installing radiator cowl with fans ⇒ page 157 .
154
Rep. gr.19 - Cooling
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
14 - 5 Nm
15 - Radiator fan 2 - V177❑ Removing and installing radiator cowl with fans ⇒ page 157 .
16 - Connector
17 - Radiator fan - V7❑ With radiator fan control unit - J293❑ Removing and installing radiator cowl with fans ⇒ page 157 .
18 - Lower coolant hose
❑ To connection for thermostat.
19 - Retaining clip
20 - Radiator outlet coolant temperature sender - G8321 - O-ring
❑ Renew
3.2
Removing and installing radiator
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Special tools and workshop
equipment required
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♦ Adapter for cooling system tester - V.A.G 1274/83. Radiator, radiator fan
155
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
♦ Drip tray - VAS 6208♦ Spring-type clip pliers - VAS 6340♦ Coolant system charge unit - VAS 6096♦ Refractometer - T10007 ARemoving:
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Remove front bumper ⇒ General body repairs, exterior; Rep.
gr. 63 ; Front bumper; Removing and installing bumper cover .
– Remove radiator cowl with fans ⇒ page 157 .
– Drain coolant ⇒ page 142 .
– Pull all coolant hoses off radiator.
Note
For illustration purposes the air deflector elements are not shown.
– Unscrew bolts -1- from radiator mounting.
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– Swing radiator and condenser back slightly and lift out of lower
supports. When doing this, pull lock carrier on left support
-1- down slightly.
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156
Rep. gr.19 - Cooling
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Move radiator and condenser to the left side, so that the right
securing bolts are accessible. Remove securing bolts
-arrows-.
sn
– Remove mounting bolt at the side -arrow- from the condenser
on the radiator.
– Move radiator and condenser to the right side, so that the left
securing bolts are accessible. Remove securing bolts
-arrows-.
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– Secure condenser to lock carrier with cable ties.
– Remove radiator downwards.
Installing:
– Install radiator from below and bolt to condenser.
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– Insert radiator and condenser into lower supports.
– Swing radiator and condenser forwards and tighten radiator
mounting -1-.
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Perform further installation in reverse order, paying attention to
the following:
o
♦ If a new radiator is fitted, the old coolant must not be reused.
– Add coolant ⇒ page 142 .
Bolted connection
Condenser to radiator
Radiator cowl to radiator
Radiator mounting to lock carrier
3.3
Torque setting
5 Nm
5 Nm
5 Nm
Removing and installing radiator cowl
with radiator fan
Special tools and workshop equipment required
3. Radiator, radiator fan
157
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
♦ Torque wrench - V.A.G 1331-
Removing:
– Remove the intake air duct -1- and -2- from the air filter
⇒ page 174 .
– Unscrew the upper securing bolts for radiator cowl -arrows-.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Unclip coolant hose from the radiator cowl.
sn
– Disconnect connector -1- and unscrew lower securing bolts for
radiator cowl -arrows-.
– Remove radiator cowl together with fans downwards.
Installing:
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Install in reverse order of removal, observing the following.
Bolted connection
Torque setting
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Radiator cowl to radiator
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158
Rep. gr.19 - Cooling
5 Nm
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
3.4
Removing and installing radiator fan
Removing:
– Remove radiator cowl ⇒ page 157 .
– Disconnect connector -1-.
– Move electrical wiring clear.
– Unscrew nuts -arrows- and remove radiator fans.
Installing:
Bolted connection
sn
Install in reverse order.
Torque setting
10 Nm
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Radiator fan to radiator cowl
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3. Radiator, radiator fan
159
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CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
24 –
Mixture preparation - injection
1
Injection system
⇒ “1.1 Overview of fitting locations - injection system”,
page 160
1.1
Overview of fitting locations - injection system
Part 1
1 - Activated charcoal filter sol‐
enoid valve 1 - N802 - Fuel pressure sender for
low-pressure - G410 3 - Ignition coil with output
stage - N70, N127, N291,
N292, N323, N3244 - Engine control unit - J623 ❑ Fitting location: in ple‐
num chamber
❑ Removing and installing
⇒ page 189
5 - Air mass meter - G706 - Connection for gearbox me‐
chatronic unit
7 - Radiator outlet coolant tem‐
perature sender - G838 - Fuel pressure regulating
valve - N276❑ in the high pressure
pump
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10 - Engine speed sender G28❑ Removing and installing
⇒ page 215
sn
9 - Fuel pressure sender G247❑ in the fuel rail for Cylin‐
ders 2, 4 and 6
❑ Checking ⇒ page 186
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13 - Continued coolant circulation pump - V51❑ Removing and installing ⇒ page 153
o
12 - Oil pressure switch - F1❑ 0.9 bar switch
❑ Checking ⇒ page 135
v
11 - Knock sensor 2 - G66❑ Fitting location: be‐
tween cylinder 4 and cylinder 6
14 - Injector, cylinder 2 - N31- , injector, cylinder 4 - N33- , injector, cylinder 6 - N84- .
❑ Removing and installing ⇒ page 166
160
Rep. gr.24 - Mixture preparation - injection
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
sn
15 - Injector, cylinder 1 - N30- , injector, cylinder 3 - N32- , injector, cylinder 5 - N83❑ Removing and installing ⇒ page 166
16 - Knock sensor 1 - G61❑ Fitting location: between Cylinder 1 and Cylinder 3 in the cylinder block.
1 - Radiator outlet coolant tem‐
perature sender - G832 - Hall sender - G40❑ For inlet camshaft
3 - Inlet camshaft control valve
1 - N205 ❑ Removing and installing
⇒ page 112
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4 - Exhaust camshaft control
valve 1 - N318❑ Removing and installing
⇒ page 112
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5 - Hall sender 2 - G163❑ For exhaust camshaft
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Part 2
6 - Heater element for crank‐
case breather - N79❑ in the connection noz‐
zles for crankcase
breather
7 - Throttle valve module J338❑ with throttle valve drive G186- , angle sensor 1
for throttle valve drive G187- and angle sensor
2 for throttle valve drive
- G188❑ Removing and installing
⇒ page 184
1. Injection system
161
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
2
Injectors
⇒ “2.1 Assembly overview - fuel rail with injectors”, page 162
⇒ “2.2 Removing and installing injectors”, page 166
⇒ “2.3 Renewing seals on injectors”, page 170
2.1
Assembly overview - fuel rail with injec‐
tors
Note
♦ Never dismantle the high-pressure pump.
sn
♦ If the fuel rail is removed, the injector O-ring, support washer,
spring element and combustion chamber seal must always be
renewed ⇒ page 170 .
♦ Vehicles from June 2013 onwards: After installing the injec‐
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tors, the adaption values must be deleted ⇒ Vehicle diagnostic
tester, Guided Functions ; Delete injector’s adaption
values .
♦ Note safety precautions before starting installation work
⇒ “3.1 Safety precautions during work on fuel system”,
page 4 .
♦ Observe rules for cleanliness
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WARNING
v
⇒ “4.1 Rules for cleanliness”, page 6 .
♦ If the battery is not disconnected, the fuel pump fuse must
be removed. The fuel pump may otherwise be activated
by the driver door contact switch. Fuse assignment ⇒ Cur‐
rent flow diagrams, Electrical fault finding and Fitting lo‐
cations
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♦ The fuel pressure in the high-pressure pipe can reach
120 bar! Wear eye protection and protective clothing to
avoid possible injury and skin contact. Before loosening
fuel pipes, wrap a cloth around the connection. Then re‐
lease pressure by carefully loosening the union nuts.
162
Rep. gr.24 - Mixture preparation - injection
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
1 - Fuel pressure sender for
low-pressure - G410❑ 15 Nm
2 - Fuel supply hose
❑ From fuel tank
❑ With mounting bracket
for fuel pressure sender
for low-pressure - G410❑ Always renew fuel hose
because when pulling
off, it will be damaged by
the corrugated pipe con‐
nection.
3 - Bolt
❑ 8 Nm
4 - Holder
❑ For fuel hose
5 - Bolt
❑ 8 Nm
sn
6 - O-ring
❑ Renew
❑ Before installing, mois‐
ten lightly with clean en‐
gine oil.
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7 - Sealing ring
❑ Renew
❑ Before installing, mois‐
ten lightly with clean en‐
gine oil.
8 - Spring element
❑ Renew each time fuel
rail is removed.
❑ Ensure firm seating
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9 - Injector, cylinder 1 - N30❑ Injector, cylinder 3 - N32❑ Injector, cylinder 5 - N83❑ Removing and installing ⇒ page 166
❑ The »long« No. 1, 3 and 5 cylinder injectors must not be separated.
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10 - Fuel low-pressure hose
❑ Between high-pressure pump and fuel rail
❑ Always renew fuel hose because when pulling off, it will be damaged by the corrugated pipe connection.
11 - Spring-type clip
12 - Fuel high-pressure pipe
❑ 28 Nm
❑ Make sure that fuel pipe does not touch other components!
❑ To install, first tighten union nuts hand tight.
❑ Loosen and tighten with socket - T10456❑ Before removing, wrap a cloth around the connection. Then release pressure by carefully loosening the
union nuts.
❑ To loosen and tighten the union nut, counterhold with a wrench at high-pressure pump connection.
❑ Before installing: first tighten connection at high-pressure pump to 40 Nm.
2. Injectors
163
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6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
13 - Union
❑ To loosen and tighten union nut, counterhold with a wrench on connection.
❑ Before installing high-pressure pipe, first tighten connection to 40 Nm.
14 - Fuel distributor
❑ the lower part of the intake manifold must be removed to remove the fuel rail
❑ For cylinders 1, 3 and 5
❑ If the fuel rail is removed, the injector O-ring, support washer, spring element and combustion chamber
seal must always be renewed ⇒ page 170 .
❑ Tighten evenly from inside to outside.
15 - Union
❑ To loosen and tighten union nut, counterhold with a wrench on connection.
❑ Before installing high-pressure pipe, first tighten connection to 40 Nm.
16 - Connecting pipe
❑ 28 Nm
❑ Make sure that fuel pipe does not touch other components!
❑ Install free of tension.
❑ To install, first tighten union nuts hand tight.
❑ To loosen and tighten the union nut, counterhold with a wrench at high-pressure pump connection.
❑ Before installing: first tighten connection at high-pressure pump to 40 Nm.
17 - Union
❑ To loosen and tighten union nut, counterhold with a wrench on connection.
❑ Before installing high-pressure pipe, first tighten connection to 40 Nm.
sn
18 - Fuel distributor
❑ For cylinders 2, 4 and 6
❑ If the fuel rail is removed, the injector O-ring, support washer, spring element and combustion chamber
seal must always be renewed ⇒ page 170 .
❑ Tighten evenly from inside to outside.
❑ Removing and installing ⇒ page 178
20 - 22 Nm
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19 - Fuel pressure sender - G247❑ Before installing, coat front sealing taper and threads with clean engine oil.
❑ 22 Nm
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21 - Pressure limiting valve
❑ Before installing lightly moisten O-rings with clean engine oil.
❑ Renew removed valve.
❑ Press in by hand using an 8 mm hexagon key.
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22 - Bolt
❑ 30 Nm + 90° (1/4 turn) further
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❑ Renew
❑ Tighten fuel rails evenly from inside to outside.
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23 - Injector, cylinder 2 - N31❑ Injector, cylinder 4 - N33❑ Injector, cylinder 6 - N84❑ Removing and installing ⇒ page 166
24 - Support washer
❑ Renewing ⇒ page 170
164
Rep. gr.24 - Mixture preparation - injection
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
25 - Spring element
❑ Renew each time fuel rail is removed.
❑ Ensure firm seating
sn
26 - Bolt
❑ 30 Nm + 90° (1/4 turn) further
❑ Renew
❑ Tighten fuel rails evenly from inside to outside.
27 - Spring-type clip
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Assembly overview - injectors for cylinders 1, 3 and 5
v
1 - O-ring
❑ Renew
❑ Before installing, mois‐
ten lightly with clean en‐
gine oil.
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2 - Support washer
❑ Renewing ⇒ page 170
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3 - Spring element
❑ Renew
❑ Ensure firm seating
4 - Sealing ring
❑ Renew
❑ Before installing, mois‐
ten lightly with clean en‐
gine oil.
5 - Combustion chamber seal
❑ Renewing ⇒ page 170
6 - Injection valve
❑ Removing and installing
⇒ page 166
Assembly overview - injectors for cylinders 2, 4 and 6
2. Injectors
165
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
1 - O-ring
❑ Renew
❑ Before installing, mois‐
ten lightly with clean en‐
gine oil.
2 - Support washer
❑ Renewing ⇒ page 170
3 - Spring element
❑ Renew
❑ Ensure firm seating
sn
4 - Combustion chamber seal
❑ Renewing ⇒ page 170
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5 - Injection valve
❑ Removing and installing
⇒ page 166
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2.2
Removing and installing injectors
Note
♦ Never dismantle the high-pressure pump.
♦ If an injector is removed, the injector O-ring, support washer,
spring element and combustion chamber seal must always be
renewed ⇒ page 170 .
♦ Vehicles from June 2013 onwards: After installing the injec‐
tors, the adaption values must be deleted ⇒ Vehicle diagnostic
tester, Guided Functions ; Delete injector’s adaption
values .
♦ Note safety precautions before starting installation work
⇒ “3.1 Safety precautions during work on fuel system”,
page 4 .
♦ Observe rules for cleanliness
⇒ “4.1 Rules for cleanliness”, page 6 .
Special tools and workshop equipment required
166
Rep. gr.24 - Mixture preparation - injection
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
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♦ Torque wrench - V.A.G 1331-
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♦ Tool set - T10133-
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Removing:
– Remove upper part of intake manifold ⇒ page 181 .
Injectors for cylinders 1, 3 and 5
– Remove lower part of intake manifold with fuel rail
⇒ page 178 .
Injectors for cylinders 2, 4 and 6
– Removing fuel rail ⇒ page 178 .
Continuation for all cylinders
– Manually press the O-ring upwards as shown and remove it
from the injector.
– Bolt hammer - T10133/3- and puller - T10133/15- to each oth‐
er.
2. Injectors
167
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– Then insert puller - T10133/15- into groove -arrow- on injector.
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Note
The spring element -arrow- must not be pulled off before the in‐
jector is pulled out.
– Tap injector carefully to remove it.
168
Rep. gr.24 - Mixture preparation - injection
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Installing:
– Clean injector bores in cylinder head thoroughly with a nylon
brush - T10133/4- .
– Renew injector O-ring, support washer, spring element and
combustion chamber seal ⇒ page 170 .
– Lightly moisten O-rings between injector and fuel rail with
clean engine oil.
Note
♦ Also renew the seal ⇒ Item 4 (page 165) with the injectors for
cylinders 1, 3 and 5.
sn
♦ The combustion chamber seal (Teflon) on the injector must
not be oiled or greased.
Caution
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– Push injector into cylinder head bore as far as it will go by
hand. Do not press on spring element when doing this.
The injectors must not be pulled into their seat with the fuel rail
bolts. Otherwise the spring element will be damaged.
– Ensure injectors are correctly seated and positioned in cylin‐
der head.
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Injectors for cylinders 1, 3 and 5
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– Install lower part of intake manifold with fuel rail
⇒ page 178 .
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– Installing fuel rail ⇒ page 178 .
o
Injectors for cylinders 2, 4 and 6
Continuation for all cylinders
– Check spring elements, they must not be pushed »flat«
-arrows- and caught on shoulder.
– Install upper part of intake manifold ⇒ page 181 .
– Vehicles from June 2013 onwards: Deleting injector’s adap‐
tation values ⇒ Vehicle diagnostic tester, Guided functions ; Delete injectors’ adaptation values .
2. Injectors
169
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
2.3
Renewing seals on injectors
Note
♦ The »long« injectors for cylinders No. 1, 3 and 5 must not be
separated.
♦ The combustion chamber seal (Teflon) on the injector must
not be oiled or greased.
Special tools and workshop equipment required
sn
♦ Tool set - T10133-
Procedure
Renewing combustion chamber seal (Teflon):
– Remove injectors ⇒ page 166 .
– Clean injector carefully.
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– Remove upper part of intake manifold ⇒ page 181 .
– Carefully cut oil seal open with a knife -arrow- as shown. Avoid
contact between knife blade and valve body under all circum‐
stances.
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– Remove old seal and clean seal groove in area of seal
-arrow-. Remove any deposits (coking) with a brass wire
brush.
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170
Rep. gr.24 - Mixture preparation - injection
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Put new seal -1- on assembly cone - T10133/5- . Using as‐
sembly sleeve - T10133/6- (knurled end faces seal -1-), gently
slide the seal onto the assembly cone - T10133/5- as far as
possible.
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– Turn the assembly sleeve - T10133/6- around (knurling no
longer points to seal) and thus push seal -1- to the end of the
assembly cone - T10133/5- .
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– Place the assembly cone - T10133/5- with seal onto the injec‐
tor from front. Slide the seal with assembly sleeve - T10133/6further onto the injector.
The seal is not yet seated in its groove.
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– Remove assembly sleeve - T10133/6- and assembly cone T10133/5- .
o
– Push seal into annular groove by hand.
– Fit spacer sleeve - T10133/11- onto valve body.
– Now push calibration sleeve - T10133/7- over seal as far as it
will go until it is touching the spacer sleeve - T10133/11- .
– Pull the calibration sleeve - T10133/7- off.
2. Injectors
171
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– Then push calibration sleeve - T10133/8- over seal as far as
it will go until it is touching spacer sleeve - T10133/11- .
– Pull the calibration sleeve - T10133/8- off.
Combustion chamber seal now has correct installation dimen‐
sions.
Renewing support washer:
– Remove O-ring -3-.
ses
a purp
sn
– Cut open support washer -2- with small side-cutting pliers and
remove.
– Withdraw spring element on the injector -1- and slide on the
retaining plate - T10133/12- for it.
v
– Push a new support washer -1- onto the assembly cone T10133/13- and push the latter onto the injector as shown.
f
ng
p
– Slide support washer -1- into first groove -arrow- on injector
using calibration sleeve - T10133/14- (knurled side faces to‐
wards injector).
o
yi
o
– Turn the calibrating sleeve - T10133/14- round (knurled side
no longer faces towards injector). Slide calibration sleeve over
support washer -1- in -direction of arrow- as far as it will go
onto retaining plate - T10133/12- .
– Pull calibration sleeve - T10133/14- off again.
The support washer now has correct installation dimensions.
172
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Note
sn
– Now position a new spring element -1- for retaining plate T10133/12- and position a new O-ring -3- in front of support
washer -2-.
♦ The combustion chamber seal (Teflon) -arrow- must not be
oiled to install the injector.
♦ Also renew the seal ⇒ Item 3 (page 165) with the injectors for
v
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– Installing injectors
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cylinders 1, 3 and 5.
2. Injectors
173
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3
Air filter
sn
⇒ “3.1 Assembly overview - air filter housing”, page 174
⇒ “3.2 Removing and installing air filter housing”, page 175
⇒ “3.3 Checking intake air preheating”, page 175
4 - Filter element
5 - Air mass meter - G706 - Sealing ring
❑ Renew if damaged
7 - Air filter upper part
8 - Bolt
❑ 2 Nm
9 - Connection
❑ Clipped into upper part
of air filter
10 - 8 Nm
11 - Cover
12 - Air duct
❑ Secured to lock carrier.
13 - Bolt
❑ 5 Nm
14 - Seal
❑ Renew if damaged
15 - Rubber mounting
16 - Bolt
❑ 10 Nm
17 - Holder
❑ For air filter
18 - Connection
❑ Not fitted in all vehicles.
❑ For hot air intake.
19 - Air filter lower part
174
Rep. gr.24 - Mixture preparation - injection
v
p
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3 - Connection hose
❑ To throttle valve module
- J338- .
o
2 - Bolt
❑ 2 Nm
yi
1 - Regulating flap
❑ Only on vehicles for cold
climate zones
❑ With thermal element
❑ Checking intake air pre‐
heating ⇒ page 175
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Assembly overview - air filter housing
o
3.1
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
3.2
Removing and installing air filter hous‐
ing
Removing:
– Pull cover -1- off air duct, releasing clips on sides to do so.
– Unclip air duct -2-.
sn
– Remove air filter housing with connecting hose. To do this,
unscrew bolt -A-, pull off connector -B- and detach spring-type
clip -C-.
– Take note of marking -D- when refitting.
Installing:
Specified torques ⇒ page 174 .
f
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p
v
•
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Install in reverse order of removal, observing the following.
Checking intake air preheating
o
3.3
yi
Special tools and workshop equipment required
o
♦ Chilling spray (commercially available)
Note
Only installed on vehicles for cold climate zones.
Checking regulating flap:
– Remove air filter upper section and filter insert ⇒ page 174 .
– Check position of control flap -1-.
– Spray thermocouple -arrow- with cold spray.
♦ At above +14°C, the regulating flap must have completely
closed the hot air connection.
♦ At below + 0°C, the regulating flap must have completely
opened the hot air connection.
3. Air filter
175
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4
Intake manifold
⇒ “4.1 Assembly overview - intake manifold”, page 176
⇒ “4.2 Removing and installing lower part of intake manifold with
fuel rail”, page 178
⇒ “4.3 Removing and installing intake manifold upper part”, page
181
⇒ “4.4 Removing and installing throttle valve module J338 ”, page
184
4.1
Assembly overview - intake manifold
Note
♦ If an injector is removed, the injector O-ring, support washer,
spring element and combustion chamber seal must always be
renewed ⇒ page 170 .
♦ Note safety precautions before starting installation work
⇒ “3.1 Safety precautions during work on fuel system”,
page 4 .
♦ Observe rules for cleanliness
f
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p
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sn
⇒ “4.1 Rules for cleanliness”, page 6 .
o
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176
Rep. gr.24 - Mixture preparation - injection
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
1 - Bolt
❑ 10 Nm
2 - Upper part of intake mani‐
fold
❑ Removing and installing
⇒ page 181
3 - Bolt
❑ 10 Nm
4 - Sealing grommet
❑ Renew if damaged
5 - To brake servo
6 - From activated charcoal fil‐
ter system solenoid valve 1 N807 - Rear intake manifold sup‐
port
8 - Bolt
❑ 20 Nm
9 - Bolt
❑ 7 Nm
p
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12 - Bolt
❑ 3.5 Nm
o
11 - Sealing ring
❑ Renew
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sn
10 - Throttle valve module J338❑ Including throttle valve
drive (electric throttle
operation) - G186- , an‐
gle sender 1 for throttle
valve drive (electric
throttle operation) G187- and angle sender
2 for throttle valve drive
(electric throttle opera‐
tion) - G188- .
❑ If renewed, adapt engine control unit to throttle valve module ⇒ Vehicle diagnostic tester “Guided Func‐
tions”.
❑ Removing and installing ⇒ page 184
13 - Connection
❑ For crankcase ventilation.
❑ With heater element for crankcase breather - N79❑ From cylinder head cover
o
14 - Sealing ring
❑ Renew
15 - Front intake manifold support
16 - Seal
❑ Renew if damaged
❑ Before installing, lightly moisten with clean engine oil and insert into upper part of intake manifold.
17 - Seal
❑ Renew
4. Intake manifold
177
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❑ Ensure correct seating in lower part of intake manifold.
18 - Intake manifold lower part
❑ Removing and installing ⇒ page 178
sn
19 - Fuel distributor
❑ For cylinders 2, 4 and 6
❑ If the fuel rail is removed, the injector O-ring, support washer, spring element and combustion chamber
seal must always be renewed ⇒ page 170 .
❑ Tighten evenly from inside to outside.
❑ Assembly overview ⇒ page 162 .
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20 - Bolt
❑ 30 Nm + 90° (1/4 turn) further
❑ Renew
❑ Tighten fuel rails evenly from inside to outside.
v
21 - Bolt
❑ 8 Nm
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p
22 - Seal
❑ Renew if damaged
❑ Before installing, lightly moisten with clean engine oil and insert into upper part of intake manifold.
o
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4.2
Removing and installing lower part of in‐
take manifold with fuel rail
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-
♦ Assembly tool - T10118-
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Rep. gr.24 - Mixture preparation - injection
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Removing:
Note
♦ Note safety precautions before starting installation work
⇒ page 4 .
♦ Observe rules for cleanliness ⇒ page 6 .
♦ If the fuel rail is removed, the injector O-ring, support washer,
spring element and combustion chamber seal must always be
renewed ⇒ page 170 .
♦ With the injectors for cylinders 1, 3 and 5, also renew the seal
⇒ Item 4 (page 165) .
♦ Assembly overview - fuel rail with high-pressure pump and in‐
jectors ⇒ page 162 .
sn
♦ Assembly overview - intake manifold ⇒ page 176 .
Caution
Observe the following during all assembly work, particularly in
the engine compartment due to the restricted space:
ses
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♦ Route lines of any kind and cables so that original routing
is restored.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
p
v
– Disconnect earth strap at battery with ignition switched off ⇒
Electrical system; Rep. gr. 27 ; Battery; Disconnecting and
connecting battery .
f
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– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
o
yi
– Remove upper part of intake manifold ⇒ page 181 .
o
– Remove high-pressure pump ⇒ page 195 .
– Remove connecting pipe of fuel rail -arrows-.
4. Intake manifold
179
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sn
– Unscrew securing bolts for lower part of intake manifold/cyl‐
inder head -arrows-.
– Unscrew securing bolt from oil dipstick guide tube -1-.
– Remove bracket -2- from lower part of intake manifold.
– Unscrew bolt -3-.
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– Undo bolts of fuel rail for cylinders 2, 4, and 6 -arrows-.
– Carefully pull fuel rail off injectors.
– Remove lower part of intake manifold.
Note
p
v
Block off intake ports in cylinder head with a clean cloth.
f
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Installing:
yi
Install in reverse order of removal, observing the following.
o
– Before installing fuel rail, always renew injector O-ring, support
washer, spring element and combustion chamber seal
⇒ page 170 .
o
– Lightly moisten O-rings between injector and fuel rail with
clean engine oil.
– Fit lower part of intake manifold with a new gasket.
– Set fuel rail and evenly press onto injectors.
Caution
The injectors must not be pulled into their seat with the fuel rail
bolts. Otherwise the spring element will be damaged.
– Fit all intake manifold and fuel rail securing bolts by hand.
Note
♦ Tighten fuel rail securing bolts on cylinder head evenly from
inside to outside.
♦ Then tighten securing bolts for lower part of intake manifold/
cylinder head.
180
Rep. gr.24 - Mixture preparation - injection
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6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Install connecting pipe of fuel rail.
Note
♦ First tighten union nuts for connection pipe hand tight, then
tighten to specified torque.
♦ Make sure that the connecting pipe does not touch any other
components.
– Installing high-pressure pump ⇒ page 195 .
– Install upper part of intake manifold ⇒ page 181 .
Bolted connection
Torque setting
Intake manifold lower part to
cylinder head
Fuel rail to cylinder head 4)
30 Nm + 90° (1/4 turn) further
10 Nm
28 Nm
28 Nm
sn
High-pressure pump to cylinder
head
Union nuts for high-pressure
fuel line
Union nuts for fuel rail connect‐
ing line
8 Nm
4) Renew
4.3
Removing and installing intake manifold
upper part
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Special tools and workshop equipment required
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p
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♦ Torque wrench - V.A.G 1331-
o
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♦ Assembly tool - T10118-
4. Intake manifold
181
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6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Removing:
Note
♦ Note safety precautions before starting installation work
⇒ page 4 .
♦ Observe rules for cleanliness ⇒ page 6 .
♦ If the fuel rail is removed, the injector O-ring, support washer,
spring element and combustion chamber seal must always be
renewed ⇒ page 170 .
♦ With the injectors for cylinders 1, 3 and 5, also renew the seal
⇒ Item 4 (page 165) .
Caution
Observe the following during all assembly work, particularly in
the engine compartment due to the restricted space:
sn
♦ Route lines of any kind and cables so that original routing
is restored.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
f
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p
v
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– Unclip cover rail for ignition cable harness -arrows- and re‐
move forwards from retaining lugs -A-.
o
yi
– Position assembly tool - T10118- on locking button -arrow- and
carefully pull off all connectors of ignition coils with output
stage .
o
182
Rep. gr.24 - Mixture preparation - injection
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– Push cable duct upwards with a screwdriver and lay connec‐
tors to one side.
– Separate electrical connections -1-, remove intake manifold
hose -2- and pull off connecting hose -3- for crankcase breath‐
er from cylinder head cover.
– Disconnect lines -arrows- from upper part of intake manifold.
– Unscrew securing bolt for rear intake manifold support -1-.
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sn
– Unscrew securing bolts for front of intake manifold support
-2-.
– Unscrew securing bolts from the intake manifold upper and
lower parts.
p
f
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Note
v
– Remove upper part of intake manifold and place on suitable
surface.
Block off intake ports in lower part of cylinder head with a clean
cloth.
o
o
4. Intake manifold
183
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Installing:
Note
Remove the seal from the lower part of intake manifold and place
it back in the upper part of the intake manifold before installation
to prevent leaks.
– Insert seals into upper part of intake manifold and lightly mois‐
ten with clean engine oil.
-1- »Large« O-rings
sn
-2- »Small« O-rings
– Position upper part of intake manifold onto lower part of intake
manifold.
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– First tighten securing bolts for upper part of intake manifold/
lower part evenly from inside out -1…5-. Specified torque:
10 Nm
– Then tighten the intake manifold support securing bolts.
Further assembly is basically a reverse of the dismantling se‐
quence.
f
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p
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Specified torques ⇒ page 176 .
yi
Removing and installing throttle valve
module - J338o
4.4
o
Removing:
– Open hose clamps -arrow- and remove breather pipe -A-.
184
Rep. gr.24 - Mixture preparation - injection
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Separate electrical connector -1- on throttle valve module J338- .
– Remove bolts -arrows- and detach throttle valve module J338- .
Installing:
Install in reverse order of removal, observing the following.
sn
– Specified torques ⇒ page 176 .
– Make sure that gasket is correctly seated in intake manifold.
f
ng
p
v
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– If throttle valve module - J338- is renewed, adapt engine con‐
trol unit to throttle valve module - J338- ⇒ Vehicle diagnostic
tester “Guided Functions”.
o
o
4. Intake manifold
185
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5
Senders and sensors
⇒ “5.1 Checking fuel pressure sender G247 ”, page 186
5.1
Checking fuel pressure sender - G247Note
sn
Observe rules for cleanliness
⇒ “4.1 Rules for cleanliness”, page 6 .
Special tools and workshop equipment required
p
v
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♦ Assembly tool - T10118-
f
ng
♦ Open ring spanner with 3/8" drive, width across flats 27 mm
(flared spanner)
o
yi
o
♦ Pressure sensor tester - VAS 6394/1-
♦ Adapter - VAS 6394/3♦ Test adapter - VAS 5570♦ Vehicle diagnostic tester
186
Rep. gr.24 - Mixture preparation - injection
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Procedure:
WARNING
The fuel line is under pressure.
Fuel poses danger of injury to eyes and skin.
sn
Wear protective goggles and protective clothing to avoid injury
and contact with the skin. Wrap a cloth around the connection
before loosening hose connections. Then reduce pressure by
carefully opening the connection.
v
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– Pull connector off fuel pressure sender - G247- -A- and re‐
move fuel pressure sender using open ring spanner.
f
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p
– Unscrew plug -2- and screw fuel pressure sender - G247- into
tester - VAS 6394/1- . Specified torque: 22 Nm.
o
yi
o
– Moisten tapered seal of adapter - VAS 6394/3- using clean
engine oil and screw into fuel rail -arrow-. Specified torque:
22 Nm.
5. Senders and sensors
187
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– Connect pressure line of tester - VAS 6394/1- to adapter - VAS
6394/3- -arrow-.
sn
– Connect fuel pressure sender and electrical connector of fuel
pressure sender using test instrument adapter - VAS 5570- .
– Switch on tester - VAS 6394/1- by briefly pressing the -A- but‐
ton once.
Note
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a purp
♦ When button -A- is pressed for 2 seconds, the illumination will
be switched on for 20 seconds.
♦ If the digital pressure gauge - VAS 6394/1- reading is not 0
bar, carry out a zero calibration procedure ⇒ Operating in‐
structions .
p
– Switch on ignition.
v
– Connect vehicle diagnostic tester to diagnostic connection.
f
ng
– On vehicle diagnostic tester select “guided function” Test
fuel pressure sender G247 .
o
yi
– Start engine.
o
– Compare pressure displayed on tester - VAS 6394/1- with ac‐
tual value displayed on vehicle diagnostic tester .
•
A maximum pressure deviation of 5 bar is permissible.
– If the deviation is greater than 5 bar, renew fuel pressure
sender - G247- .
WARNING
The tester - VAS 6394- is under extreme fuel pressure! With
engine running, detach connector from fuel pressure sender G247- . This reduces fuel pressure to approx. 6 bar. Switch off
ignition and wrap a cloth around fuel pressure sender - G247- .
Then release residual pressure by carefully loosening the fuel
pressure sender - G247- .
– Repeat the test with the new fuel pressure sender - G247- and
compare the two measured values.
If measured values again fail to correspond:
– Perform line test ⇒ Vehicle diagnostic tester.
188
Rep. gr.24 - Mixture preparation - injection
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
6
Engine control unit
⇒ “6.1 Removing and installing engine (motor) control unit J623
”, page 189
⇒ “6.2 Removing and installing engine (motor) control unit J623
with protective housing”, page 190
6.1
Removing and installing engine (motor)
control unit - J623Note
If the engine control unit is to be replaced, connect vehicle diag‐
nostic tester and carry out the guided function “Replacing engine
control unit”.
Removing:
– Switch off ignition.
sn
– Remove wiper arms and plenum chamber cover ⇒ General
body repairs, exterior; Rep. gr. 50 ; Bulkhead; Removing and
installing plenum chamber cover .
ses
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– Push retaining frame down in -direction of arrow- and remove
engine control unit.
f
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– Push locking devices of connectors in -direction of arrow- and
pull off connectors.
o
o
6. Engine control unit
189
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CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Installing:
– Fit connectors to engine control unit and slide locking devices
onto stop in -direction of arrow-.
– Install engine control unit into retaining frame and push up‐
wards in the direction of the -arrow-.
– Install wiper arms and plenum chamber cover ⇒ General body
repairs, exterior; Rep. gr. 50 ; Bulkhead; Removing and in‐
stalling plenum chamber cover .
6.2
Removing and installing engine (motor)
control unit - J623- with protective hous‐
ing
Note
♦ If the engine control unit is to be replaced, connect vehicle
diagnostic tester and carry out the guided function “Replacing
engine control unit”.
♦ The shear-head bolt threads may coated with locking com‐
Removing:
sn
pound. To simplify removal, the shear-head bolts can be heat‐
ed using hot air blower - VAS 1978/14- . When doing this,
ensure that no adjacent cables, connectors or components are
damaged!
– Switch off ignition.
f
ng
p
v
ses
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– Remove wiper arms and plenum chamber cover ⇒ General
body repairs, exterior; Rep. gr. 50 ; Bulkhead; Removing and
installing plenum chamber cover .
o
yi
o
190
Rep. gr.24 - Mixture preparation - injection
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Push retaining frame down in -direction of arrow- and remove
engine control unit.
– Unscrew shear-head bolts -arrows- using a pair of pliers.
– Insert screwdriver between both locking plates -arrow-.
sn
– Carefully press screwdriver in -direction of arrow- and bend
retaining bar -1- upwards at the same time.
f
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– Bend retaining bar -1- in direction of -arrow- until it can be
pulled off connector.
o
o
6. Engine control unit
191
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CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Push locking devices of connectors in -direction of arrow- and
pull off connectors.
Installing:
– Fit connectors to engine control unit and slide locking devices
onto stop in -direction of arrow-.
– Fit retaining bar -1- onto connectors and press it in direction
of -arrow-.
– Push guide pin -2- to stop into hole on valve timing housing.
f
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p
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sn
– Bolt retaining bar with new shear-head bolts onto the engine
control unit -arrows- until the bolt heads shear off.
o
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o
192
Rep. gr.24 - Mixture preparation - injection
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Install engine control unit into retaining frame and push up‐
wards in the direction of the -arrow-.
f
ng
p
v
ses
a purp
sn
– Install wiper arms and plenum chamber cover ⇒ General body
repairs, exterior; Rep. gr. 50 ; Bulkhead; Removing and in‐
stalling plenum chamber cover .
o
o
6. Engine control unit
193
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7
High-pressure pump
⇒ “7.1 Assembly overview - high-pressure pump”, page 194
⇒ “7.2 Removing and installing high-pressure pump”, page 195
7.1
Assembly overview - high-pressure
pump
Note
sn
♦ Never dismantle the high-pressure pump.
♦ If an injector is removed, the combustion chamber seal (Tef‐
lon) and O-ring must be renewed ⇒ page 170 .
♦ Note safety precautions before starting installation work
ses
a purp
⇒ “3.1 Safety precautions during work on fuel system”,
page 4 .
♦ Observe rules for cleanliness
p
f
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4 - Plunger
❑ Check for damage
❑ oiled and insert in the
cylinder head with its
guide in the correct po‐
sition ⇒ page 195
5 - O-ring
❑ From high-pressure
pump
❑ Renew
❑ Lubricate lightly with
clean engine oil
194
Rep. gr.24 - Mixture preparation - injection
o
3 - Spring-type clip
❑ Note the position of the
spring clips
yi
2 - Low-pressure hose
❑ Note installation marks
❑ Renew when removed
⇒ page 195
o
1 - High-pressure pipe
❑ 28 Nm
❑ Make sure that fuel pipe
does not touch other
components!
❑ Install free of tension.
❑ To install, first tighten
union nuts hand tight.
❑ Loosen and tighten with
socket - T10456❑ Before installing: first
tighten connection at
high-pressure pump to
40 Nm.
v
⇒ “4.1 Rules for cleanliness”, page 6 .
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
6 - High-pressure pump
❑ Removing and installing ⇒ page 195
7 - Bolt
❑ 10 Nm
Removing and installing high-pressure
pump
sn
7.2
Special tools and workshop equipment required
f
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p
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♦ Socket - T10456-
o
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Removing:
Note
♦ Never dismantle the high-pressure pump.
♦ Note safety precautions before starting installation work
⇒ “3.1 Safety precautions during work on fuel system”,
page 4 .
♦ Observe rules for cleanliness
⇒ “4.1 Rules for cleanliness”, page 6 .
– Pull cover -1- off air duct, releasing clips on sides to do so.
– Unclip air duct -2-.
7. High-pressure pump
195
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Remove air filter housing with connecting hose. To do this,
unscrew bolt -A-, pull off connector -B- and detach spring-type
clip -C-. Take note of marking -D- when refitting.
ses
a purp
sn
– Unscrew the air duct on lock carrier -arrows- and remove the
air duct.
p
WARNING
v
– Remove lifting eye -A- -arrows-.
f
ng
The fuel line is under pressure.
yi
Fuel poses danger of injury to eyes and skin.
o
Wear protective goggles and protective clothing to avoid injury
and contact with the skin. Wrap a cloth around the connection
before loosening hose connections. Then reduce pressure by
carefully opening the connection.
o
– Remove low-pressure hose -1-. Remove high-pressure line
-2- using socket - T10456- . To do this, counterhold at highpressure pump connections with a wrench.
Note
The low-pressure hose must always be renewed because when
pulling off, it will be damaged by the corrugated pipe connection.
196
Rep. gr.24 - Mixture preparation - injection
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Pull off connector -A-, undo and remove bolts -arrow- and re‐
move high-pressure pump -B- from engine.
Installing:
– Check plunger -1- for damage, renew if necessary. Insert oiled
plunger along guide -2- correctly into cylinder head.
– Slowly turn engine by vibration damper in engine's direction of
rotation. When doing this, press plunger in
-direction of arrow- until it has reached lowest point in cylinder
head.
– Renew high-pressure pump O-ring and coat slightly with clean
engine oil.
sn
– Install high-pressure pump and tighten securing bolts
-arrows- ⇒ Item 7 (page 195) .
– Tighten union for high-pressure pipe and low-pressure pipe at
high-pressure pump.
Low-pressure line union: 28 Nm.
Caution
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High-pressure pipe union: 40 Nm
♦ The low-pressure hose must always be renewed because
when pulling off, it will be damaged by the corrugated pipe
connection.
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♦ Make sure low-pressure hose and high-pressure hose do
not touch each other after bolts have been tightened. En‐
sure there is sufficient »clearance« between them.
o
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7. High-pressure pump
197
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CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Install new low-pressure hose -A-. When doing this, take in‐
stallation markings and position of spring clamps -arrows- into
consideration.
– Install high-pressure pipe but only tighten bolts hand-tight.
– Tighten high-pressure pipe -A- using socket - T10456- uni‐
formly, while counterholding the high-pressure pipe in
-direction of arrow-. Make sure high-pressure hose -A- and
low-pressure hose -B- do not touch each other after bolts have
been tightened.
•
Specified torque: 28 Nm
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Install engine lifting eye.
o
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o
198
Rep. gr.24 - Mixture preparation - injection
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
8
Lambda probe
⇒ “8.1 Removing and installing lambda probe G39 ”, page 199
⇒ “8.2 Removing and installing Lambda probe G108 ”,
page 200
⇒ “8.3 Removing and installing lambda probe after catalytic con‐
verter G130 and lambda probe 2 after catalytic converter G131 ”,
page 200
8.1
Removing and installing lambda probe G39-
Special tools and workshop equipment required
♦ Lambda probe open ring spanner set - 3337-
♦ High-temperature paste - G 052 112 A3Removing:
– Remove air filter housing with connection hose.
– Separate electrical connector -1- »black connector« for lamb‐
da probe - G39- .
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sn
– Move lambda probe wiring aside.
– Undo bolts of Lambda probe - G39- -1- and remove it.
Installing:
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– When reusing Lambda probe, lubricate threads with high tem‐
perature paste - G 052 112 A3- . Paste may not come into
contact with slots on probe body.
– Screw Lambda probe - G39- -1- into exhaust pipe of bank 1.
Identifying feature: Black connector.
o
o
yi
Specified torque: 50 Nm
– Restore the original cable routing.
Continue installation in reverse order of removal.
8. Lambda probe
199
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
8.2
Removing and installing Lambda probe
- G108-
Special tools and workshop equipment required
♦ Lambda probe open ring spanner set - 3337-
♦ High-temperature paste - G 052 112 A3Removing:
– Remove air filter housing with connection hose.
– Separate electrical connector -2- »brown connector« for lamb‐
da probe 2 - G108- .
ses
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sn
– Move lambda probe wiring aside.
– Unscrew lambda probe 2 - G108- -2-.
Installing:
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– When reusing Lambda probe, lubricate threads with high tem‐
perature paste - G 052 112 A3- . Paste may not come into
contact with slots on probe body.
– Screw lambda probe 2 - G108- -2- into exhaust pipe of bank
2. Identifying feature: brown connector.
o
o
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Specified torque: 50 Nm
– Restore the original cable routing.
Continue installation in reverse order of removal.
8.3
Removing and installing lambda probe
after catalytic converter - G130- and
lambda probe 2 after catalytic converter
- G131-
Special tools and workshop equipment required
200
Rep. gr.24 - Mixture preparation - injection
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
♦ Lambda probe open ring spanner set - 3337-
♦ High-temperature paste - G 052 112 A3Removing:
– Remove 3 bolts of underbody cover on right -arrows-.
– Disconnect plug connectors for the Lambda probe after the
catalytic converter - G130- -1- and the Lambda probe 2 after
catalytic converter - G131- -2- on vehicle underbody.
– Undo bolts of Lambda probes -1- and -2-.
Installing:
sn
– When reusing Lambda probe, lubricate threads with high tem‐
perature paste - G 052 112 A3- . Paste may not come into
contact with slots on probe body.
– Screw Lambda probe after catalytic converter - G130- into ex‐
haust pipe of bank 1. Identifying feature: Black connector.
– Screw Lambda probe 2 after catalytic converter - G131- into
exhaust pipe of bank 2. Identifying feature: brown connector.
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Specified torque: 50 Nm
– Restore the original cable routing.
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Continue installation in reverse order of removal.
o
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8. Lambda probe
201
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CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
26 –
Exhaust system
1
Exhaust pipes and silencers
⇒ “1.1 Assembly overview - silencers”, page 202
⇒ “1.2 Separating exhaust pipes from silencers”, page 203
⇒ “1.3 Installation position of clamp”, page 205
1.1
Assembly overview - silencers
5 - Retainer
❑ Renew if damaged
6 - Centre silencer
❑ Combined in one unit
with rear silencer as
original equipment. Can
be renewed individually
for repair purposes.
❑ Separate exhaust sys‐
tem ⇒ page 203
7 - Mounting
❑ For centre silencer
❑ Renew if damaged
❑ Secure to underbody
⇒ page 203 .
8 - Nuts
❑ M8: 25 Nm
❑ M10: 40 Nm
❑ Tighten bolted connections evenly.
9 - Clamping sleeve
❑ Fitting position ⇒ page 205
❑ Tighten bolted connections evenly.
202
Rep. gr.26 - Exhaust system
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4 - Rear left silencer
❑ In initial equipment,
component with centre
silencer. Can be re‐
newed individually for
repair purposes.
❑ Separate exhaust sys‐
tem ⇒ page 203
o
3 - 25 Nm
yi
2 - Mounting
❑ For rear silencer
o
1 - Rear right silencer
❑ In initial equipment,
component with centre
silencer. Can be re‐
newed individually for
repair purposes.
❑ Separate exhaust sys‐
tem ⇒ page 203
sn
Separating centre and rear silencers ⇒ page 203 .
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
10 - Bolt
11 - Retainer
❑ Renew if damaged
sn
12 - to front silencer ⇒ page 206
Support for centre silencer to body
The mounting -2- is bolted to the underbody in conjunction with
the heat shield -3- and the fuel tank securing strap -4-.
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Separating exhaust pipes from silencers
yi
Note
o
1.2
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Specified torque for securing bolts -1-: 25 Nm.
o
♦ The connecting pipe can be cut through at the cutting location
in order to remove and install or renew the centre and rear
silencers separately.
♦ Cutting location is marked by an indentation on the circumfer‐
ence of exhaust pipe.
Special tools and workshop equipment required
♦ Pneumatic sabre saw - V.A.G 1523 A-
or
1. Exhaust pipes and silencers
203
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
♦ Chain-type pipe cutter - VAS 6254♦ Safety glasses
Procedure
WARNING
To avoid injury from metal shavings, wear eye protection and
protective clothing.
sn
– Cut through exhaust pipe at separation point using e.g. pneu‐
matic sabre saw - V.A.G 1523 A- perpendicular to pipe.
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♦ Separating point on exhaust pipe -arrows 1- for rear right si‐
lencer.
♦ Marking -arrow 2- is necessary for the installation position of
the clamp ⇒ page 205 .
♦ Separating point on exhaust pipe -arrows 1- for rear left si‐
lencer.
♦ Marking -arrow 2- is necessary for the installation position of
the clamp ⇒ page 205 .
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– Install rear silencer and connect it to the middle silencer with
a clamp. Installation position and specified torque of clamp
⇒ page 205 .
o
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– Adjust the exhaust system so that distance -a- on left and right
is the same.
o
204
Rep. gr.26 - Exhaust system
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
1.3
Installation position of clamp
Installation position of front clamp
– Align clamp -1- to marking on exhaust pipe -2- -Arrow- points
in direction of travel.
•
Dimension -a- = 5 mm.
•
Specified torque: 25 Nm
•
Bolted connection faces to right.
– Install clamp so that end of bolt -arrow- does not extend be‐
yond lower edge of clamp.
Installation position of clamp rear (for repair)
– Align the clamp with the mark on the exhaust pipe.
•
Specified torque: 25 Nm
– Install clamp so that end of bolt -arrow- does not extend be‐
yond lower edge of clamp.
Bolted connection faces rear.
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•
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1. Exhaust pipes and silencers
205
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CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
2
Emission control
⇒ “2.1 Assembly overview - emission control”, page 206
⇒ “2.2 Removing and installing catalytic converter”, page 207
2.1
Assembly overview - emission control
Note
♦ After working on the exhaust system, ensure that the system
has sufficient clearance to the bodywork. If necessary, loosen
double clamp on front exhaust pipe and realign silencer and
exhaust pipes.
♦ Do not use sealants containing silicone. Silicone particles
drawn into the engine will not be burnt in the engine and will
damage the Lambda probes.
♦ Renew self-locking nuts.
sn
1 - Securing nuts
❑ Renew
❑ Coat studs with high
temperature paste - G
052 112 A3- .
❑ M8: 25 Nm
❑ M10: 40 Nm
2 - Front exhaust pipes
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3 - Lambda probe 2 - G108- ,
50 Nm
❑ Bank 2, probe 1
❑ Brown connector, 6-pin
❑ Installed in exhaust gas
stream of cylinders 4, 5
and 6
❑ Grease only thread with
-G 052 112 A3- . -G 052
112 A3- must not get in‐
to slots in probe body.
❑ Removing and installing
⇒ page 199
o
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4 - Lambda probe 2 after cata‐
lytic converter - G131- , 50 Nm
❑ Bank 2, probe 2
❑ Brown connector, 4-pin
❑ Installed in exhaust gas
stream of cylinders 4, 5
and 6
❑ Grease only thread with
-G 052 112 A3- . -G 052
112 A3- must not get in‐
to slots in probe body.
❑ Removing and installing
⇒ page 200
5 - Flexible joints
❑ Do not bend flexible joints more than 20° - otherwise they can be damaged.
206
Rep. gr.26 - Exhaust system
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
sn
6 - Lambda probe after catalytic converter - G130- , 50 Nm
❑ Bank 1, probe 2
❑ Black 4-pin connector
❑ Installed in exhaust gas stream of cylinders 1, 2 and 3
❑ Grease only thread with -G 052 112 A3- . -G 052 112 A3- must not get into slots in probe body.
❑ Removing and installing ⇒ page 200
7 - Front silencer
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8 - to the centre silencer ⇒ page 202
9 - Catalytic converters
❑ Observe notes ⇒ page 206
❑ Installed in exhaust gas stream of cylinders 1, 2, 3 right and 4, 5 and 6 left
10 - Mounting
❑ For front exhaust pipe, left and right
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11 - 20 Nm
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12 - Lambda probe - G39- , 50 Nm
❑ Bank 1, probe 1
❑ Black 6-pin connector
❑ Installed in exhaust gas stream of cylinders 1, 2 and 3
❑ Grease only thread with -G 052 112 A3- . -G 052 112 A3- must not get into slots in probe body.
❑ Removing and installing ⇒ page 199
o
yi
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2.2
Removing and installing catalytic con‐
verter
Removing:
– Pull cover -1- off air duct, releasing clips on sides to do so.
– Remove air duct -2-.
– Remove air filter housing with connection hose. To do this,
unscrew bolt -A-, pull off connector -B- and loosen spring-type
clip -C-. Take note of marking -D- when refitting.
– Remove throttle valve module ⇒ page 184 .
2. Emission control
207
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Disconnect electrical connectors -1- and -2- for Lambda probe
- G39- and Lambda probe 2 - G108- .
sn
– Expose electric cables to Lambda probes.
ses
a purp
– Unscrew nuts for the exhaust pipe - accessible from above -arrow- from the exhaust manifolds.
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– Remove centre noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Noise insulation; Assembly overview noise insulation .
o
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– Remove drive shaft protection for right drive shaft.
208
Rep. gr.26 - Exhaust system
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
– Unscrew nuts for front exhaust pipe - accessible from below from exhaust manifolds -arrows-.
Note
♦ The flexible joint in the front exhaust pipe must not be bent by
more than 20° - risk of damage. To remove, ask for the assis‐
tance of a second mechanic.
♦ An approx. 600 mm long extension is required to unscrew nuts
which are accessible from below.
– Remove 3 bolts of underbody cover on right -arrows-.
– Disconnect plug connectors for the Lambda probe after the
catalytic converter - G130- -1- and the Lambda probe 2 after
catalytic converter - G131- -2- on vehicle underbody.
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– Expose electric cables to Lambda probes.
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– Unbolt bracket for exhaust system -arrows-.
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– Remove cross members -A- and -B- for underbody (if present).
– Disconnect exhaust system at clamping sleeve -1-.
– Remove front exhaust pipe with catalytic converters and front
silencers from exhaust manifold.
Installing:
Install in reverse order, noting the following:
♦ Renew seals, gaskets and self-locking nuts.
♦ Coat studs with high-temperature paste - G 052 112 A3- .
Bolted connection
Front exhaust pipe to exhaust mani‐
fold
Cross member to body
Mounting to subframe
Clamping sleeve
Torque setting
40 Nm
25 Nm
25 Nm
25 Nm
2. Emission control
209
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
3
Exhaust manifold
⇒ “3.1 Assembly overview - exhaust manifold”, page 210
⇒ “3.2 Removing and installing exhaust manifold”, page 211
Assembly overview - exhaust manifold
sn
3.1
Note
♦ After working on the exhaust system, ensure that the system
ses
a purp
has sufficient clearance to the bodywork. If necessary, loosen
double clamp on front exhaust pipe and realign silencer and
exhaust pipes.
♦ Do not use sealants containing silicone. Silicone particles
drawn into the engine will not be burnt in the engine and will
damage the Lambda probes.
4 - Seal
❑ Bank 1
❑ Cylinders 1, 2, and 3
❑ Renew
5 - Exhaust manifold
❑ Bank 1
❑ Cylinders 1, 2, and 3
❑ Coat studs with high
temperature paste - G
052 112 A3- .
❑ Removing and installing
⇒ page 211
6 - Nut
❑ Renew
❑ 25 Nm
7 - Heat shield
8 - Bolt
❑ 20 Nm
9 - Intake manifold support
10 - Exhaust manifold
❑ Bank 2
❑ Cylinders 4, 5, and 6
❑ Removing and installing
⇒ page 211
11 - Seal
❑ Bank 2
210
Rep. gr.26 - Exhaust system
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3 - Bolt
❑ 20 Nm
yi
2 - Bolt
❑ 20 Nm
o
1 - Heat shield bracket on the
cylinder head
v
♦ Renew self-locking nuts.
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
❑ Cylinders 4, 5, and 6
❑ Renew
3.2
Removing and installing exhaust mani‐
fold
Removing:
sn
– Remove upper part of intake manifold ⇒ page 181 .
ses
a purp
– Unscrew coolant pipe from heat shield -arrows-. Unscrew se‐
curing bolts -1- and remove heat shield with intake manifold
support.
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– Unbolt exhaust pipe at exhaust manifolds -arrows- and push
back slightly.
o
yi
Note
The lambda probes remain in situ.
o
– Remove securing nuts at top and bottom -arrows- of both ex‐
haust manifolds.
– Remove exhaust manifold to rear.
Installing:
Install in reverse order, noting the following:
Note
♦ Renew seals, gaskets and self-locking nuts.
♦ Coat studs with high-temperature paste - G 052 112 A3- .
Bolted connection
Exhaust manifold on cylinder head
Front exhaust pipe to exhaust manifold
Heat shield for exhaust manifold to cylinder
head
Torque setting
25 Nm (re‐
new)
40 Nm (re‐
new)
20 Nm
3. Exhaust manifold
211
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
28 –
Ignition system
1
Ignition system
⇒ “1.1 Assembly overview - ignition system”, page 212
sn
⇒ “1.2 Removing and installing ignition coils with output stage”,
page 213
⇒ “1.3 Removing and installing engine speed sender G28 ”, page
215
⇒ “1.4 Test data, spark plugs”, page 215
Assembly overview - ignition system
Note
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1.1
4 - 20 Nm
5 - Connector
❑ Black, 3-pin.
❑ Gold-plated contacts on
sensor and connector.
6 - Knock sensor 1 - G61❑ Location: cylinder block
exhaust side
7 - 20 Nm
❑ The specified torque in‐
fluences the function of
the knock sensor.
8 - Exhaust camshaft adjuster
❑ Identification: 32A.
❑ With sender wheel for
Hall sender 2 - G163❑ Removing and installing
⇒ page 105
9 - Cover
10 - Connector
❑ Black, 3-pin.
212
Rep. gr.28 - Ignition system
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3 - Holder
❑ For connector for knock
sensor 1 - G61- .
yi
2 - Connector
❑ black
❑ Use assembly tool T10118- to pull off.
o
1 - Ignition coil with output
stage - N70, N127, N291,
N292, N323, N324❑ Removing and installing
⇒ page 213
v
The engine speed sender - G28- can be found on the cylinder
block ⇒ Item 10 (page 160) .
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
❑ Gold-plated contacts on sensor and connector.
❑ Mark connector before removing.
11 - 10 Nm
sn
12 - Hall sender 2 - G163❑ For exhaust camshaft
❑ Gold-plated contacts on sensor and connector.
13 - Sealing ring
❑ Renew
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14 - Hall sender - G40❑ For inlet camshaft
❑ Gold-plated contacts on sensor and connector.
15 - Knock sensor 2 - G66❑ Fitting location: cylinder block intake side
❑ Gold-plated contacts on sensor and connector.
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16 - Connector
❑ Black, 2-pin.
❑ Gold-plated contacts on sensor and connector.
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17 - Inlet camshaft adjuster
❑ Identification: 24E
❑ With sender wheel for Hall sender - G40❑ Removing and installing ⇒ page 105
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18 - Spark plug, 18 Nm
❑ Remove and install with spark plug socket and extension - 3122B❑ Type and electrode gap ⇒ page 215 .
19 - Valve timing housing
❑ For camshaft adjustment.
1.2
Removing and installing ignition coils
with output stage
Special tools and workshop equipment required
♦ Puller - T10095 A-
1. Ignition system
213
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
♦ Assembly tool - T10118-
Removing:
– Unclip cover rail for ignition cable harness -arrows- and re‐
move forwards from retaining lugs -A-.
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– Apply assembly tool - T10118- to the locking button -arrowand carefully pull the plug connector downwards.
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– Push puller - T10095 A- on from flat side of connector in
-direction of arrow- and pull out ignition coil with output stage .
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214
Rep. gr.28 - Ignition system
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Installing:
– To install, insert ignition coil with output stage into respective
spark plug hole so that the flat sides of connectors fit with each
other -arrows-.
– Push puller - T10095 A- on from flat side of connector in di‐
rection of -arrow- and push ignition coil with output stage onto
spark plug.
1.3
Removing and installing engine speed
sender - G28-
Fitting location ⇒ Item 10 (page 160)
Removing:
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Disconnect connector for engine speed sender and lay cable
to side.
sn
– Unscrew bolt -2- and ease out the engine speed sender -1with slight turning movements.
Installing:
Install in reverse order of removal, observing the following.
Fit gasket.
•
Moisten oil seal lightly with clean engine oil.
•
Specified torque for bolt -2- 8 Nm.
•
Do not tilt engine speed sender -1- when fitting it so that the
seal is not damaged.
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•
Firing order
Spark plugs 5)
Part number
BWS, CNNA
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Engine code
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Test data, spark plugs
o
1.4
p
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– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
1-5-3-6-2-4
101 905 622 A
1. Ignition system
215
CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤
6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019
Engine code
BWS, CNNA
Electrode gap
Torque setting
Change interval
0.7 to 0.8 mm
18 Nm
⇒ Maintenance ; Booklet ; Service tables
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5) Current spark plugs ⇒ Electronic parts catalogue (ETKA)
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216
Rep. gr.28 - Ignition system