2002-2006 Volkswagen Touareg Service & Repair Manual

ENGINE 3.2L V6 4V Engine Mechanical, Fuel Injection Ignition, Engine Codes: BAA, BMX 00 - GENERAL, TECHNICAL DATA TECHNICAL DATA Technical data Engine specifications --> Engine data Engine number Fig. 1: Identifying Engine Number Located On Vibration Damper Courtesy of VOLKSWAGEN UNITED STATES, INC. The engine number "engine code" and "serial number" is located next to vibration damper on cylinder block under the coolant pump. The engine number consists of up to nine characters (alphanumeric). The first part (maximal 3 characters) makes up the engine code, and the second part (6 characters), the serial number. If more than 999,999 engines with the same engine code are produced, the first of the six characters is replaced with a letter. In addition, a sticker with "engine code" and "serial number" is affixed to intake manifold. The engine code is also included on vehicle data plate. Engine data Engine code BAA BMX Manufactured 03.03 --> 04.04 --> Cylinder arrangement VR * See note VR * See note Cylinder angle 15.0° 15.0° 2004 Volkswagen Touareg ENGINE 3.2L V6 4V Engine Mechanical, Fuel Injection Ignition, Engine Codes: BAA, BMX 2004 Volkswagen Touareg ENGINE 3.2L V6 4V Engine Mechanical, Fuel Injection Ignition, Engine Codes: BAA, BMX

*VR = V-Arrangment in compact in-line design *In exceptional circumstances min. 95 RON, however with reduced performance *Two independently variable camshafts. 10 - ENGINE - ASSEMBLY ENGINE, REMOVING AND INSTALLING Engine, removing and installing Engine, removing --> Engine, removing Securing engine to engine stand --> Engine, securing to assembly stand Installing engine --> Engine, installing Displacement ltr. 3.2 3.2 Output kW at RPM 162/6000 177/6000 Torque Nm at RPM 300/4000 310/3200 Bore dia. mm 84.0 84.0 Stroke mm 95.9 95.9 Compression ratio 11.25 10.85 Valves per cylinder 4 4 RON min. 98 unleaded * See note 98 unleaded * See note System designation Motronic ME7.1.1 Motronic ME7.1.1 Ignition sequence 1-5-3-6-2-4 1-5-3-6-2-4 Knock control 2 knock sensors 2 knock sensors Oxygen sensor regulation 4 sensors 4 sensors On Board Diagnostic (OBD) OBD II yes Catalytic converter yes yes Exhaust gas recirculation no no Charging no no Secondary air injection (AIR) system yes yes Electronic Power Control (EPC) yes yes Variable intake manifold yes yes Variable valve timing Yes * See note Yes * See note Leak diagnostic system yes yes 2004 Volkswagen Touareg ENGINE 3.2L V6 4V Engine Mechanical, Fuel Injection Ignition, Engine Codes: BAA, BMX

Fig. 2: Identifying Special Tools - Engine, Removing And Installing (1 Of 2) Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required  Lifting tackle 3033  Tensioner Hooks (2) VW 552  Engine and transmission holder VAS 6095  Drip tray V.A.G 1306  Torque wrench (5 to 50 Nm) V.A.G 1331  Torque wrench (40 to 200 Nm) V.A.G 1332 2004 Volkswagen Touareg ENGINE 3.2L V6 4V Engine Mechanical, Fuel Injection Ignition, Engine Codes: BAA, BMX

Fig. 3: Identifying Special Tools - Engine, Removing And Installing (2 Of 2) Courtesy of VOLKSWAGEN UNITED STATES, INC. Special tools, testers and auxiliary items required  Engine/transmission jack V.A.G 1383 A  Spring-type clip pliers VAS 5024A  Step ladder VAS 5085  Diesel Extractor VAS 5226  Shop crane VAS 6100  Scissor lift table VAS 6131  Not illustrated:  Adapter V.A.G 1318/20 2004 Volkswagen Touareg ENGINE 3.2L V6 4V Engine Mechanical, Fuel Injection Ignition, Engine Codes: BAA, BMX

 Adapter V.A.G 1318/20-1  Container for removed components V.A.G 1698  Left subframe mounting VAS 6131/6-1  Right subframe mounting VAS 6131/6-2  Left suspension support VAS 6131/6-3  Right suspension support VAS 6131/6-4  Supports VAS 6131/6-5 (Qty. 2)  Supports VAS 6131/6-6 (Qty. 2)  Transmission support VAS 6131/6-7  V6 engine support VAS 6131/7  Grease (Vehicles with manual transmission) G 000 1000  Cable tie Engine, removing Work procedure The engine with transmission is removed downward.  When the engine is installed in the engine compartment some components cannot be removed or can only be removed with great difficulty. Therefore determine which components are faulty before removing engine.  Check DTC memories of all control modules, before removing engine: CAUTION: Fuel supply lines are under pressure! Wear protective goggles and protective gloves to avoid damage and contact with skin. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection. NOTE:  To allow free rotation of the drive axle, move the selector lever in the "N" position.  Leave the key in the ignition lock to prevent the steering wheel lock from engaging.  It is advisable to remove the front wheels before removing the engine/transmission assembly. The vehicle can be lowered on the hoist until the cover plates of the brake discs are just above the floor. This enables the most ergonomic work position possible regarding accessibility of components in the engine compartment.  To prevent damage to the removed components, use parts trolley V.A.G 1698 for storage. 2004 Volkswagen Touareg ENGINE 3.2L V6 4V Engine Mechanical, Fuel Injection Ignition, Engine Codes: BAA, BMX

Disconnecting batteries The procedure must be strictly followed!  Switch off ignition and all electrical consumers.  Disconnect battery under drivers seat. --> 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL Work procedure  Remove left and right wiper arms: --> 92 - WINDSHIELD WIPER AND WASHER SYSTEM  Remove engine compartment cover seal off bulkhead. Fig. 4: Identifying Covers In Engine Compartment And For Plenum Chamber Courtesy of VOLKSWAGEN UNITED STATES, INC.  Remove covers - A - , - B - and - C - in engine compartment and - D - for plenum chamber. Fig. 5: Identifying V.A.G 1318/20 - 1 & V.A.G 1318/20 Courtesy of VOLKSWAGEN UNITED STATES, INC.  Install adapter V.A.G 1318/20-1 on to adapter V.A.G 1318/20.  Turn valve (on T-piece) counter-clockwise until completely open. 2004 Volkswagen Touareg ENGINE 3.2L V6 4V Engine Mechanical, Fuel Injection Ignition, Engine Codes: BAA, BMX

 Remove breather valve. Fig. 6: Connecting Adapter V.A.G 1318/20 With Adapter V.A.G 1318/20 - 1 And Diesel Extractor VAS 5226 To Bleed Valve Courtesy of VOLKSWAGEN UNITED STATES, INC.  Connect Adapter V.A.G 1318/20 with Adapter V.A.G 1318/20-1 and Diesel Extractor VAS 5226 to bleed valve - 1 -.  Turn valve (on T-piece) clockwise into bleed valve to stop.  When fuel pressure has been released, fuel system may be opened. Fig. 7: Identifying Fuel Supply Line Courtesy of VOLKSWAGEN UNITED STATES, INC.  In addition, wrap a cloth around connection to catch fuel which runs out.  Disconnect fuel supply line - arrow -.  All cable ties which are opened or cut open when removing engine, must be replaced in same position when installing engine. CAUTION: Fuel supply lines are under pressure! Before opening fuel system, connect Diesel Extractor VAS 5226 and release pressure. 2004 Volkswagen Touareg ENGINE 3.2L V6 4V Engine Mechanical, Fuel Injection Ignition, Engine Codes: BAA, BMX

Fig. 8: Identifying Breather Line To Solenoid Valve Courtesy of VOLKSWAGEN UNITED STATES, INC.  Disconnect breather line - arrow - to evaporative emission (EVAP) canister purge regulator valve N80 in engine compartment. Fig. 9: Identifying Small Connector, Engine Control Module (ECM) J623, And Wiring Harness Ground Connection Courtesy of VOLKSWAGEN UNITED STATES, INC.  Disconnect small connector - A - off engine control module and disconnect Ground (GND) connection - arrow - of wiring harness. 2004 Volkswagen Touareg ENGINE 3.2L V6 4V Engine Mechanical, Fuel Injection Ignition, Engine Codes: BAA, BMX

Fig. 10: Identifying Connectors In Fuse Box Courtesy of VOLKSWAGEN UNITED STATES, INC.  Open fuse box cover on left in plenum chamber and separate connectors - A - , - B - and - C -.  Remove wiring harness from plenum chamber and place it on engine. Fig. 11: Identifying Starter Wire And Generator Wire Courtesy of VOLKSWAGEN UNITED STATES, INC.  Disconnect starter wire - A - and generator wire - B - and place them on engine. Fig. 12: Identifying Vacuum Hoses Of Intake Manifold 2004 Volkswagen Touareg ENGINE 3.2L V6 4V Engine Mechanical, Fuel Injection Ignition, Engine Codes: BAA, BMX

Courtesy of VOLKSWAGEN UNITED STATES, INC.  Pull vacuum hoses - 1 - from intake manifold. Vehicles with engine code BAA  Pull vacuum hose - 4 - from intake manifold. Continuation for all vehicles Fig. 13: Identifying Pressure Hose And Secondary Air Injection Pump Courtesy of VOLKSWAGEN UNITED STATES, INC.  Pull pressure hose off secondary air injection pump - arrow -. Fig. 14: Identifying Connectors For Oxygen Sensors Courtesy of VOLKSWAGEN UNITED STATES, INC.  Disconnect connectors - 1 to 4 - for oxygen sensors and place connectors on engine.  Cylinders 1 to 3 = black  Cylinders 4 to 6 = brown 2004 Volkswagen Touareg ENGINE 3.2L V6 4V Engine Mechanical, Fuel Injection Ignition, Engine Codes: BAA, BMX

2002-2006 Volkswagen Touareg Service & Repair Manual

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