Repairing diesel direct injection system — VW
Repairing diesel direct injection system on VW: factory workshop procedure for engines AFN, AGD, AHG, AHH. Full factory text, tools and checks.
Workshop procedure for VW — the factory write-up, straight from real workshop data.
📋 Procedure
VW
Touareg
2003
Power unit
6-cylinder diesel engine (3.0 l engine, common rail)
Edition
05.2015
Repairing diesel direct injection system
Note
The diesel direct injection system control unit is equipped with an event memory. The event memory must be read before and after repairs or adjustments
Vehicle diagnostic tester
; Read and clear event memory of engine control unit.
Chapter
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Safety precautions
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Chapter
“
Rules for cleanliness and instructions for working on fuel system
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Chapter
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Schematic overview of fuel system (engine codes BKS, BUN)
”
Chapter
“
Assembly overview - fuel system (engine codes BKS, BUN)
”
Chapter
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Assembly overview - intake manifold (engine codes BKS, BUN)
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Chapter
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Removing and installing upper part of intake manifold (engine codes BKS, BUN)
”
Chapter
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Removing and installing
intake manifold flap motor
V157
or
intake manifold flap motor 2
V275
(engine codes BKS, BUN)
”
Chapter
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Removing and installing lower part of intake manifold (engine codes BKS, BUN)
”
Chapter
“
Schematic overview of fuel system (engine codes CASA, CASB, CASC, CATA)
”
Chapter
“
Assembly overview - fuel system (engine codes CASA, CASB, CASC, CATA)
”
Chapter
“
Assembly overview - intake manifold (engine codes CASA, CASB, CASC, CATA)
”
Chapter
“
Removing and installing upper part of intake manifold (engine codes CASA, CASB, CASC, CATA)
”
Chapter
“
Removing and installing lower part of intake manifold (engine codes CASA, CASB, CASC, CATA)
”
Chapter
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Removing and installing injectors (piezo injectors)
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Chapter
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Checking return flow rate of injectors (piezo injectors) with engine running.
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Chapter
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Checking return flow rate of injectors (piezo injectors) at starting speed
”
Chapter
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Checking for injectors sticking open (piezo injectors).
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Chapter
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Installing high-pressure lines
”
Chapter
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Checking pressure retention valve in fuel return line
”
Chapter
“
Assembly overview - toothed belt for high-pressure pump (engine codes BKS, BUN)
”
Chapter
“
Removing and installing toothed belt for high-pressure pump (engine codes BKS, BUN)
”
Chapter
“
Assembly overview - toothed belt for high-pressure pump (engine codes CASA, CASB, CASC, CATA)
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Chapter
“
Removing and installing toothed belt for high-pressure pump (engine codes CASA, CASB, CASC, CATA)
”
Chapter
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Assembly overview - high-pressure pump (engine codes BKS, BUN)
”
Chapter
“
Removing and installing high-pressure pump (engine codes BKS, BUN)
”
Chapter
“
Assembly overview - high-pressure pump (engine codes CASA, CASB, CASC, CATA)
”
Chapter
“
Removing and installing high-pressure pump (engine codes CASA, CASB, CASC, CATA)
”
Chapter
“
Removing and installing
fuel pressure regulating valve
N276
”
Chapter
“
Removing and installing
fuel pressure sender
G247
”
Chapter
“
Assembly overview - air filter
”
TorqFix answers live for your specific car — tell it the engine code and it serves the matching sequence, torque figures and wiring for that exact variant.
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Who makes these pages, and how
TorqFix was built by a mechanic — after a 2,700 km drive with five roadside repairs that no diagnostic tool could explain.
The figures on this page come from manufacturer workshop documentation and are shown as they are. The page is assembled automatically from that data — it is not written by an AI. The AI works in the chat, where it answers for your specific car. It writes nothing here.
Variants of the same model differ. Cross-check torque against the factory manual for your engine before final tightening.
Seen a figure that does not match your manual? Write to us — we correct it and note when. support@torqfix.com
The story behind TorqFix →Workshop data on this page last updated 20 Sep 2026.