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Volkswagen Touareg 2003->

(7L)

Technical data

Engine identification

200 3 -> ( 7L ) Technical data Eng ine identification 00- 1, Engine identification E

00-1, Engine identification

Engine data

00- 1, Engine identification E n g i n e d a t a 00- 1,

00-1, Engine specifications

Engine identification

a t a 00- 1, Engine specifications Engine identification The engine number ( "engine code" and

The engine number ( "engine code" and "serial number" ) is located on cylinder block, below the cylinder head of cylinder bank 2.

The engine number consists of up to nine characters (alphanumeric). The first part (maximum 3 letters) represents the "engine code" , the second (six digit) is 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 acoustic cover of cylinder head at cylinder bank 1.

The engine code is also included on the vehicle data plate.

engine code is also inclu ded on the vehicl e data plate. Numbering of cylinders begins

Numbering of cylinders begins on right side - A - as seen in direction of travel (cylinder bank 1) opposite the power

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transfer side - C - . Cylinders are counted on each side in sequence.

Engine specifications

Engine code BKW BWF Production 12.03 10.04 02.06 Emission values in accordance with Tier 1
Engine code
BKW
BWF
Production
12.03
10.04
02.06
Emission values in accordance with
Tier 1
Displacement
ltr.
4.9
4.9
Output
kW at 1/rpm
230/3750
230/3750
Torque
Nm at rpm
750/2000
750/2000
Bore
Dia. mm
81.0
81.0
Stroke
mm
95.5
95.5
Compression ratio
18.5
18.5
CN
min.
51
51
Ignition sequence
1-6-5-10-2-7-3-8-4-9 1-6-5-10-2-7-3-8-4-9
Catalytic converter
yes
yes
Particle filter
no
yes
Exhaust gas recirculation
yes
yes
Charging
yes
yes
Charge air cooler
yes
yes

Engine, removing and installing

Page 1 / 21

Engine, removing and installing

Engine, removing

and installing E n g i n e , r e m o v i n

10-1, Engine, removing

Removing engine from Scissor Lift Table VAS 6131 10-1, Removing engine from Scissor Lift Table VAS 6131

10- 1, Removing engine from Scissor Lift Table VAS 6131 N o t e s o

Notes on installing

Engine, removing

s o n i n s t a l l i n g Eng ine, removin

10-1, Notes on installation

10 - 1

n g Eng ine, removin g 10- 1, Notes on installation 10 - 1 Special tools,
n g Eng ine, removin g 10- 1, Notes on installation 10 - 1 Special tools,

Special tools, testers and auxiliary items required

Scissor lift table VAS 6131

Drip tray V.A.G 1306

Frame support T10191

Engine, removing and installing

Page 2 / 21

Spring-type clip pliers VAS 5024

A

Torque wrench (40 to 200 Nm) V.A.G 1332

Tensioner Hooks (2) VW 552

Not illustrated:

Standard set for Touareg VAS 6131/6

Support F/Vas6131 For V6/V10/V8 VAS6131/8

Container for removed components V.A.G 1698

Engine bung set VAS 6122

Cable tie

The engine with transmission is removed downward.

- Before removing engine, check DTC memories of all

control modules

Information System VAS 5051 or VAS 5052 "Guided

functions"

System VAS 5051 or VAS 5052 "Guided functions" Vehicle Diagnosis, Testing and Note: To allow free

Vehicle Diagnosis, Testing and

Note:

To allow free rotation of the driveshaft, move the selector lever to 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 the disassembly. The vehicle can be lowered on the hoist until the cover plates of the brake discs are just above the floor. This ensures the greatest ability to perform work at body-level regarding accessibility of components in the engine compartment.

Engine, removing and installing

Page 3 / 21

When the engine is installed in the engine compartment some components cannot be removed or can only be removed with great difficulty. Determine which components are faulty before removing engine.

To prevent damage to removed components, use the container for removed components V.A.G 1698 for storage.

All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.

Caution!

Always observe the exact procedure for disconnecting the battery!

- Switch off ignition and all electrical consumers.

- First, disconnect batter under drivers seat.

- Then disconnect the auxiliary battery, in luggage compartment in spare wheel well.

Repair Manual, Electrical Equipment, Repair Group 27, Battery, disconnecting and connecting trical Equipment, Repair Group 27, Battery, disconnecting and connecting

- Remove left and right windshield wiper arms

Repair Manual, Electrical Equipment, Repair Group 92, Windshield wiper system trical Equipment, Repair Group 92, Windshield wiper system

- Remove engine compartment cover seal off bulkhead.

Elec trical Equipment, Repair Group 92, Windshield wiper system - Remove engine compartment cover seal off

Engine, removing and installing

Page 4 / 21

- Remove covers - A - , - B - (if equipped) and - C - in engine compartment and - D - for plenum chamber.

engine compartment and - D - for plenum chamber. - Disconnect smaller connector - A -

- Disconnect smaller connector - A - from Engine Control Modules (ECM) and remove Ground (GND) connection - arrow - for wiring harness.

connection - a r r o w - for wiring harness. - Open fuse box cover

- Open fuse box cover on left in plenum chamber and disconnect connectors - A - , - B - and -C- .

- Remove wiring harness from plenum chamber and place it on engine.

- Remove intake line on both sides between air filter and intake manifold.

Note:

With connector couplings, follow the installation

instructions closely

connector couplings, installing .

instructions closely connector couplings, installing . 21- 1, Hose connections with V ehicles with en g

21-1, Hose connections with

Vehicles with engine code BKW

Engine, removing and installing

Page 5 / 21

En g ine, removin g and installin g Page 5 / 21 - Disconnect vacuum lines

- Disconnect vacuum lines - arrows - for Exhaust Gas

Recirculation (EGR) valve and brake booster as well as harness connector - A - for Heated Oxygen Sensor (HO2S) G39 of cylinder bank 1.

for Heated O xygen Sensor (HO2S) G39 of cyl inder bank 1. - Disconnect vacuum line

- Disconnect vacuum line - arrow - for Exhaust Gas

Recirculation (EGR) valve as well as harness connector -

A - for Heated Oxygen Sensor (HO2S) 2 G108 of cylinder bank 2.

Vehicles with engine code BWF

2 G108 of cylinder bank 2. V ehicles with en g ine code BWF - Disconnect

- Disconnect vacuum lines - 1 - for the bypass flap

vacuum actuators (mark lines before separating) and brake booster - 2 - .

Engine, removing and installing

Page 6 / 21

En g ine, removin g and installin g Page 6 / 21 - Disconnect the foll

- Disconnect the following connections and free up wiring harness to components:

1 - 6-pin harness connector, black: For Heated Oxygen Sensor (HO2S) G39

2 - 6-pin harness connector, brown: For Heated Oxygen Sensor (HO2S) 2 G108

3 - 2-pin harness connector, black: For Turbocharger intake temperature sensor G507

4 - 2-pin harness connector, brown: For Turbocharger intake temperature sensor 2 G499

Continuation for all vehicles

temperature sensor 2 G499 Continuation for all vehicles - Disconnect harness connectors - a r r

- Disconnect harness connectors - arrows - for glow plugs in cylinder bank 1 and cylinder bank 2.

Engine, removing and installing

Page 7 / 21

En g ine, removin g and installin g Page 7 / 21 - Secure suspension struts

- Secure suspension struts using spring compressor VW 552. as shown.

- Remove upper suspension struts

Repair Manual, Suspension, Wheels, Steering, Repair Group 40, II - Assembly overview: Front suspension

Repair Group 40, II - Assembly ov erview: Front suspension . - Remove noise insulation Repair

.

-

Remove noise insulation

Repair Manual, Body Exterior, Repair Group 50, Noise insulation or, Repair Group 50, Noise insulation

.

-

Extract refrigerant from air conditioning system

. - Extract refrigerant fr om air conditioning system Repair Manual, He ating Air Conditio ning,

Repair Manual, Heating Air Conditioning, Repair Group

87,

- Drain coolant

filling .

Manual, He ating Air Conditio ning, Repair Group 87, - Drain coolant filling . 19- 1,

19-1, Cooling system, draining and

Engine, removing and installing

Page 8 / 21

En g ine, removin g and installin g Page 8 / 21 - Disconnect line -

- Disconnect line - arrow - from transmission oil cooler below on right. Catch fluid which runs out.

oil cooler below on right. Catch fluid which runs out. - Disconnect line - A -

- Disconnect line - A - from servo oil cooler at lower left. Catch fluid which runs out.

- Remove charge air connecting pipe - B - for cylinder bank 1 and cylinder bank 2.

- B - for cylinder bank 1 and cylinder bank 2. - Loosen clamp - a

- Loosen clamp - arrow - from connecting pipe to air filter for cylinder bank 1 and cylinder bank 2 and remove it.

Engine, removing and installing

Page 9 / 21

En g ine, removin g and installin g Page 9 / 21 - Disconnect coolant hoses

- Disconnect coolant hoses - arrows - and place them so

that they cannot be pinched when removing and installing engine.

cannot be pinched when removing and installing engine. - Disconnect starter wire - A - and

- Disconnect starter wire - A - and generator wire - B - and place them on engine.

generator wire - B - and place them on engine. - Unclip transmissi on ventilation line

Engine, removing and installing

Page 10 / 21

En g ine, removin g and installin g Page 10 / 21 - Disconnect connecto r

- Disconnect connector from Intake Air Temperature (IAT) sensor G42 - A - and from Mass Air Flow (MAF) sensor G70 - B - for cylinder bank 1.

Flow (MAF) sensor G70 - B - for cylinder bank 1. - Disconnect connecto r from

- Disconnect connector from Mass Air Flow (MAF) sensor 2 G246 - A - and from Intake Air Temperature (IAT) sensor 2 G299 - B - for cylinder bank 2.

(IAT) sensor 2 G299 - B - for cylinder bank 2. - Remove wire connection -

- Remove wire connection - arrow - of air suspension

compressor on air filter housing compressor for air suspension

on air filter housing compressor for air suspension 23- 1, Line connection to - Remove both

23-1, Line connection to

- Remove both top sections of air filter upward.

Engine, removing and installing

Page 11 / 21

En g ine, removin g and installin g Page 11 / 21 - Open clamp and

- Open clamp and pull off servo-line - A - . Catch fluid which runs out. Remove A/C lines - B - from A/C compressor.

Vehicles with engine code BKW

- from A/C compressor. V ehicles with en g ine code BKW - Disconnect fuel lines

- Disconnect fuel lines - arrows - from fuel filter.

- Separate connection of catalytic converter/center muffler

and remove exhaust system

mountings (vehicles with engine code BKW), assembly overview .

(vehicles with e ngine code BKW), assembly overview . 26-1, Muffler with V ehicles with en

26-1, Muffler with

Vehicles with engine code BWF

. 26-1, Muffler with V ehicles with en g ine code BWF - Disconnect fuel lines

- Disconnect fuel lines - arrows - from fuel filter.

Engine, removing and installing

Page 12 / 21

- Separate connection of particle filter/exhaust pipe and

remove exhaust system

26-1, Muffler with mountings

(vehicles with engine code BWF), assembly overview .

(vehicles with engine code BWF), assembly overview . Continuation for all vehicles - Remove heat shield

Continuation for all vehicles

- Remove heat shield on steering box and loosen universal joint

Repair Manual, Suspension, Wheels, Steering, Repair Group 48, Steering column

Wheels, Steering, Repair Group 48, Steer ing column . - Disconnect connectors on tr ansmission as

.

- Disconnect connectors on transmission as well as transfer case and loosen selector lever cable

Repair Manual, 6 Spd. Automatic Transmission 09D All Wheel Drive, Repair Group 37, Shift mechanism, servicing Spd. Automatic Transmission 09D All Wheel Drive, Repair Group 37, Shift mechanism, servicing

- Remove rear driveshaft

Repair Manual, Rear Final Drive, Repair Group 39, Driveshafts, removing and installing

Drive, Repair Group 39, Driveshafts, remo ving and installing - Remove transmission transverse support - A
Drive, Repair Group 39, Driveshafts, remo ving and installing - Remove transmission transverse support - A

- Remove transmission transverse support - A - .

Engine, removing and installing

Page 13 / 21

En g ine, removin g and installin g Page 13 / 21 - Disconnect brake lines

- Disconnect brake lines at points indicated - arrow - . Catch escaping brake fluid.

- Disconnect all harness connectors between chassis and front axle in wheel housings.

Preparing Scissor lift table VAS 6131 for further steps:

Note:

The basic set for Touareg VAS 6131/6 consists of supports supports VAS 6131/6-1 to VAS 6131/6-7 . To describe the following work sequence more clearly, they are called support 1 (for VAS 6131/6-1) to support 7 (for VAS 6131/6-7).

1 (for VAS 6131/6-1) to support 7 (for VAS 6131/6-7). - Install support - 1 -

- Install support - 1 - on left and support - 2 - on right

(arrows point in direction of travel) on the Scissor lift table VAS 6131 and secure bolts at the following positions:

Left support - 1 - : A5, B4 and B5

Engine, removing and installing

Page 14 / 21

Right support - 2 - : G4, H4 and H5

- Tighten support 3 and support 4 on Scissor lift table VAS 6131 in the following positions:

Left support - 3 - : A6 and C6

Right support - 4 - : F6 and H6

- Screw down turntables of supports -3- and -4- .

- Place supports - 5 - for subframe and - 6 - for

transmission console in corresponding positions on lift

table.

Engine and transmission are separated after removal:

- Remove insulation mat under lower section of oil pan.

- Loosen clamp for starter cable.

lower se ction of oil pan. - Loosen clamp for starter cable. - Loosen and remove

- Loosen and remove transmission bolts - A - .

- Remove six bolts for torque converter through hole in

upper section of oil pan - arrow - . To do so, rotate engine at vibration damper using Counterhold Tool Touareg V10

T10172 and associated pin T10172/2 .

Engine, removing and installing

Page 15 / 21

En g ine, removin g and installin g Page 15 / 21 - Install support -

- Install support - 7 - for transmission support in

corresponding positions on Scissor lift table VAS 6131 and tighten down turntables completely.

lift table VAS 6131 and tighten down turntables completely. - Before moving up Scissor li ft

- Before moving up Scissor lift table VAS 6131 , always

engage Support F/Vas6131 For V6/V10/V8 VAS6131/8 , which was completely tightened down earlier, into hole of transmission flange - arrow - as shown.

Continued:

Engine, removing and installing

Page 16 / 21

En g ine, removin g and installin g Page 16 / 21 - Position horizontally adjust

- Position horizontally adjusted Scissor lift table VAS

6131 under engine/transmission assembly. The supports -

1 - and - 2 - must be guided into corresponding mount -

arrows - at right and left.

mount - a r r o w s - at right and left. - At the

- At the same time, guide support - 6 - for transmission

cross bar into corresponding holes - arrows - at right and left.

When all four supports are in the appropriate receptacle holes without pressure:

- If installed, check support height of support for V10, V8 and V6 assembly, Touareg VAS 6131/8 at knurled nut and secure support in position D7 on Scissor lift table VAS

Engine, removing and installing

Page 17 / 21

- Using light pressure beneath control arm, screw both

turning knobs of supports 3 and 4 until securing device can

be removed using Tensioner Hooks (2) VW 552 .

device can be removed using Tensioner Hooks (2) VW 552 . - Guide support - 5

- Guide support - 5 - into corresponding mount in

subframe, if necessary check support height on knurled nut.

- Locate subframe to body

Repair Manual, Suspension, Wheels, Steering, Repair Group 40, I - Assembly overview: Subframe, stabilizer bar, lower control arms

overview: S ubframe, stabilizer bar, lower control arms - Loosen subframe bolts - 2 - and
overview: S ubframe, stabilizer bar, lower control arms - Loosen subframe bolts - 2 - and

- Loosen subframe bolts - 2 - and - 3 - , as well as transmission transverse support - 4 - .

If subframe was not located:

Engine, removing and installing

Page 18 / 21

Note:

If the subframe was not located, it is necessary to perform a vehicle alignment

Repair Manual, Suspension, Wheels, Steering, Repair Group 44, Vehicle alignment

Wheels, Steering, Repair Group 44, Vehicle alignment . - Slowly lower assembly, cons tantly observing clearances.

.

- Slowly lower assembly, constantly observing clearances.

Removing engine from Scissor Lift Table VAS 6131

Special tools, testers and auxiliary items required

Shop crane VAS 6100

Transportation plate T10126

Transportation plate T10126/1

Frame support T10191

Work procedure

- Disconnect transmission from engine

Repair Manual, 6 Spd. Automatic Transmission 09D All Wheel Drive, Repair Group 37, Transmission, removing and installing

Repai r Group 37, Transmi ssion, removing and installing - Loosen threaded connection - A -
Repai r Group 37, Transmi ssion, removing and installing - Loosen threaded connection - A -

- Loosen threaded connection - A - of engine mount on

Engine, removing and installing

Page 19 / 21

both sides of engine.

- Loosen support for V10, V8 and V6 assembly, Touareg

VAS 6131/8 from scissor lift platform and remove it.

VAS 6131/8 from scissor lift platform and remove it. - Install transportation plat es T10126 and

- Install transportation plates T10126 and transportation

plates T10126/1 on cylinder heads as shown - arrows - .

- Hook lifting tackle 3033 into workshop crane VAS 6100 and into transportation plate .

- Lift engine from Scissor Lift Table VAS 6131 .

- Set engine in frame support T10191 .

Notes on installation

Caution!

When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

Route lines of all types (e.g. for fuel, hydraulic, additive, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.

To prevent damages to the lines, make sure there is sufficient clearance to all moving or hot components.

Installation is performed in reverse order. When doing this note the following:

Engine, removing and installing

Page 20 / 21

- Make sure centering sleeves for engine to transmission

are installed in cylinder block. Install if necessary.

- Reconnect all lines, hoses and connections that were disconnected for removal sequence.

- Electrical connections and routing

Diagrams, Troubleshooting and Component Locations

binder .

Diagrams, Troubleshooting and Component Locations binder . Electrical Wiring - Connect air conditioning lines Repair

Electrical Wiring

- Connect air conditioning lines

binder . Electrical Wiring - Connect air conditioning lines Repair Manual, He ating Air Conditio ning,

Repair Manual, Heating Air Conditioning, Repair Group

 

87,

.

-

Top off oil level for power steering system

Repair Manual, Maintenance , Maintenance

.

- Fill with coolant filling .

Manual , Maintenance . - Fill with coolant filling . 19- 1, Cooling system , draining

19-1, Cooling system, draining and

- Check headlight adjustment, correct if necessary

and - Check headlight adjustmen t, correct if necessary Repair Manual , Maintenance : - Perform

Repair Manual, Maintenance

:

-

Perform test drive and check all DTC memories

- Perform test drive and check all DTC memories Vehicle

Vehicle

Diagnosis, Testing and Information System VAS 5051 or VAS 5052 "Guided Fault Finding" .

Torque specifications

Bolted connections Torque specifications Engine to transmission M10 45 Nm (except starter) M12 80 Nm
Bolted connections
Torque specifications
Engine to transmission
M10
45 Nm
(except starter)
M12
80 Nm
Engine support to cylinder block
50 Nm
Engine support to engine mount
75 Nm
Engine mount to engine carrier
60 Nm
Engine carrier to body
100 Nm plus an additional 1 / 2 turn (180
)
Transmission carrier to body
50 Nm plus an additional 1 / 4 turn (90
)
Subframe to body

Engine, removing and installing

Page 21 / 21

Repair Manual, Suspension, Wheels, Steering, Repair Group 40, I - Assembly overview: Subframe, stabilizer bar,
Repair Manual, Suspension, Wheels, Steering, Repair Group 40, I - Assembly overview:
Subframe, stabilizer bar, lower control arms

Engine, disassembling and assembling

Page 1 / 17

Engine, disassembling and assembling

Caution!

13 - 1

1 / 17 En gine, disassembling and assembling Caution! 13 - 1 Upper section of be

Upper section of bearing bracket is bolted to the cylinder with two multi-point socket bolts M8, which are found in the valley between the cylinder heads. These bolts must not be loosened under any circumstances, because it causes a deformation of the cylinder block which is no longer reparable.

Crankshaft, piston, and connecting rods must not be replaced! Only removal and installation of these components is permitted.

Note:

If large quantities of metal particles or other deposits (caused, for example, by partial seizure of the crankshaft or connecting rod damage) are found in the engine oil, the oil passages must be cleaned thoroughly and the oil cooler replaced in order to prevent further damage from re-occurring.

The engine must not be set down on the oil pan otherwise the liquid gasket between the upper and lower oil pan will be damaged. To set down the engine, use frame T10191 .

Secure engine using engine and transmission holder VAS 6095 when working on the engine.

Components in engine valley, assembly overview 13-1, Components in engine valley, assembly overview

13- 1, Components in engine valley, assembly overview Engine timing module , assembly overview Engine timing

Engine timing module, assembly overview Engine timing module, assembly overview

assembly overview Engine timing module , assembly overview 13-1, Engine timing module (whe el cassette), removing

13-1,

Engine timing module (wheel cassette), removing and

installing

removing and installing

and i n s t a l l i n g removing and installing 13- 1,

13-1, Engine timing module (wheel cassette),

Engine mounts and engine supports (right and left),

removing and installing

engine supports (right and left), removing and installing

engine supports (right and left ), removing and installing 13- 1, Engine mounts and Drive plate,

13-1, Engine mounts and

Drive plate, removing and installing

and left ), removing and installing 13- 1, Engine mounts and Drive plate, removing and installin

13-1, Drive plate,

Engine, disassembling and assembling

Page 2 / 17

Volkswagen Technical Site:

http://volkswagen.msk.ru

http://vwts.info

http://vwts.ru

огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi

removing and installing

Components in engine valley, assembly overview

installing Components in eng ine valle y, assembly overview Input hub 8 Nm Clutch Phased in

Input hub

8 Nm

Clutch

Phased in introduction of a torsion elastic clutch

Repair Manual, Electrical Equipment, Repair Group 27, Generator

clutch Repair Manual, Elec trical Equipment, Repair Group 27, Generator 50 Nm plus an additional 1

50 Nm plus an additional 1 / 4

turn (90

clutch Repair Manual, Elec trical Equipment, Repair Group 27, Generator 50 Nm plus an additional 1

)

Engine, disassembling and assembling

Page 3 / 17

Replace

20 Nm

Generator

Removing and installing

Repair Manual, Electrical Equipment, Repair Group 27, Generator trical Equipment, Repair Group 27, Generator

Oil filter housing, upper section

Coolant connection

With Engine Coolant Temperature (ECT) Sensor

G62

Removing and installing 19-1, Coolant connection, removing and installing

19- 1, Coolant connection, removing and installing Gasket Replace Seal Replace 20 Nm plus an additional

Gasket

Replace

Seal

Replace

20 Nm plus an additional 1 / 4

turn (90

Seal Replace 20 Nm plus an additional 1 / 4 turn (90 ) Replace Oil filter

)

Replace

Oil filter housing, lower section

Oil filter housing, assembly

overview

housing, assembly

overview

hous ing, assembly overview housing, assembly overview 17- 3, Oil filter With coolant thermostat housing:

17-3, Oil filter

With coolant thermostat housing: Assembly overview

19-1, Coolant thermostat housing, assembly 1, Coolant thermostat housing, assembly

Engine, disassembling and assembling

Page 4 / 17

overview

Cover

Noise insulation

Installation not necessary

Bypass flap with cooler for Exhaust Gas Recirculation (EGR)

On vehicles with engine code BWF

Assembly overview

26-2,(EGR) On vehicles with engine code BWF Assembly overview Bypass flap with cooler for Exhaust Gas

Bypass flap with cooler for Exhaust Gas Recirculation (EGR) (vehicles with engine code BWF), assembly overview

Fuel filter

For vehicles with engine code BKW

Assembly overview

20-1,filter For vehicles with engine code BKW Assembly overview Fuel filter (vehicles with engine code BKW),

Fuel filter (vehicles with engine code BKW), assembly overview

Alignment bushing

Secure with commercially available grease, if necessary, before installation

Engine timing module, assembly overview

Engine, disassembling and assembling

Page 5 / 17

En g ine, disassemblin g and assemblin g Page 5 / 17 Sleeve For linkage mounting

Sleeve

For linkage mounting components

Replace with compensation linkage in case of noticeable formation of deposits

Compensation linkage

Camshaft gear

For cylinder bank 1: with sensor wheel for camshaft position

Removing and installing 15-1, Camshaft compensation wheel and input gear, removing and installing

camshaft position Removing and installing 15- 1, Camshaft compensation wheel and input gear, removing and installing

Engine, disassembling and assembling

Page 6 / 17

Compensation wheel

Removing and installing 15-1, Camshaft compensation wheel and input gear, removing and installing

wheel and input gear, removing and installing 150 Nm plus an additional 1 / 4 turn

150 Nm plus an additional 1 / 4

turn (90

installing 150 Nm plus an additional 1 / 4 turn (90 ) Full-floating axle Compensating piston

)

Full-floating axle

Compensating piston

Replace

20 Nm

Observe tightening

Seal

sequence

Tightening sequence of bolts

for control housing

sequence Tightening sequen ce of bolts for control housing 13-5, Do not oil or grease sealing

13-5,

Do not oil or grease sealing lip of sealing ring

Before installing, remove oil residue from crankshaft journal with a clean cloth

Replace

residue from crankshaft journal with a clean cloth Replace 13- 4, Crankshaft seal (engine ti ming

13-4, Crankshaft

seal (engine timing side), replacing

Control housing

Assembly overview

ti ming side), replacing Control housing Assembly overview 13-5, Control housing, assembly overview Cylinder bolt

13-5,

Control housing, assembly overview

Cylinder bolt

Tighten to 60 Nm, then to 150 Nm plus an additional 1 /

4 turn (90

housing, assembly overview Cylinder bolt Tighten to 60 Nm, then to 150 Nm plus an additional

)

Engine, disassembling and assembling

Page 7 / 17

Oil pan, upper section

Assembly overview

g Page 7 / 17 Oil pan, upper section Assembly overview 17-2, Oil pan (upper section),

17-2,

Oil pan (upper section),

assembly overview

Hex bolt

Tighten to 60 Nm, then to 150 Nm plus an additional 1 /

4 turn (90

then to 150 Nm plus an additional 1 / 4 turn (90 ) Engine timing module

)

Engine timing module

Removing and installing 13-1, Engine timing module (wheel cassette), removing and installing

timing module (wheel cassette), removing and installing Engine timing module (wheel cassette), removing and

Engine timing module (wheel cassette), removing and installing

Engine, disassembling and assembling

Page 8 / 17

En g ine, disassemblin g and assemblin g Page 8 / 17 Special tools, tester s

Special tools, testers and auxiliary items required

Engine and transmission holder VAS 6095

Guide pins T10200

Assembly tool T10208/3

Not illustrated:

Torque wrench (40 to 200 Nm) V.A.G 1332

Requirements:

Engine and transmission removed

Engine, disassembling and assembling

Page 9 / 17

Engine secured to engine and transmission holder VAS 6095

Removing

- Drain engine oil

Repair Manual, Maintenance , Maintenance

.

- Set crankshaft to TDC Cylinder 1 checking , check valve timing.

to TDC Cylinder 1 checking , check valve timing. 15- 1, Valve timing, - Remove cylinder

15-1, Valve timing,

- Remove cylinder heads

valve timing. 15- 1, Valve timing, - Remove cylinder heads 15- 1, Cylinder head . -

15-1, Cylinder head .

- Disconnect transmission from engine

Repair Manual, 6 Spd. Automatic Transmission 09D All Wheel Drive, Repai r Group 37, Transmi ssion, removing and Spd. Automatic Transmission 09D All Wheel Drive, Repair Group 37, Transmission, removing and installing

.

- Remove all required hoses, lines and pipes from the engine management side.

- Remove lower and upper sections of oil pan pan, assembly overview .

and upper sections of oil pan pan, assembly overview . 17- 2, Oil - Loosen bolts

17-2, Oil

- Loosen bolts for engine timing module.

Caution!

Make sure that the input shafts for oil- and coolant pumps do not fall off cylinder block.

- Carefully pull engine timing module off inclined splines.

Installing

Engine, disassembling and assembling

Page 10 / 17

En g ine, disassemblin g and assemblin g Page 10 / 17 - Screw guide pins

- Screw guide pins T10200 into threaded holes of upper section of bearing bracket as shown.

- Place engine timing module on guide pins.

Note:

as shown. - Place engine timing module on guide pins. Note: Observe the following adjustment marks

Observe the following adjustment marks and requirements and note the inclined splines while doing so (wheels turn slightly when sliding on the module):

Engine, disassembling and assembling

Page 11 / 17

En g ine, disassemblin g and assemblin g Page 11 / 17 - Holes on splines

- Holes on splines of crankshaft gear and input gear for oil pump must align as shown.

t gear and input gear for oil pump must align as shown. - Input shaft fits

- Input shaft fits only in one position. Rotate shaft so that

the wide cut-out in the hole aligns to the broad tooth on the pin.

cut-out in the hole al igns to the broad tooth on the pin. - The hole

- The hole on the drive wheel of cylinder bank 1 must align with cast tab on inside of engine timing module as shown.

- Carefully slide engine timing module on guide pins in its seat, note the mentioned adjustment markings while doing so.

Engine, disassembling and assembling

Page 12 / 17

En g ine, disassemblin g and assemblin g Page 12 / 17 - Center engine timi

- Center engine timing module by placing pressure piece

of assembly tool T10208/3 on generator shaft end - A - .

Pressure piece must be able to be set into countersink without force.

- Replace individual guide pins with bolts and tighten bolts to 60 Nm.

- Tighten bolts to 150 Nm plus an additional 1 / 4 turn. (90

bolts to 150 Nm plus an additional 1 / 4 turn. (90 ) turn. Engine mounts

) turn.

Engine mounts and engine supports (right and left), removing and installing

Special tools, testers and auxiliary items required

removin g and installing Sp ecial tools, testers and auxiliar y items re q uired Torque

Torque wrench (40 to 200 Nm) V.A.G 1332

Engine, disassembling and assembling

Page 13 / 17

En g ine, disassemblin g and assemblin g Page 13 / 17 Engine/transmission jack V.A.G 1383

Engine/transmission jack V.A.G 1383 A

Assembly support T10296

Removing

- Remove front sound insulation

Repair Manual, Body Exterior, Repair Group 50, Sound insulation or, Repair Group 50, Sound insulation

- Remove front wheelhousing liners

Repair Manual, Body Exterior, Repair Group 66, Wheelhousing liners terior, Repair Group 66, Wheelhousing liners

- Remove lower part of air filter for cylinder bank 1 and 2

23-1, Air filter, assembly overview , Air filter - Assembly overview.

assembly overview , Air filter - Assembly overview. - Remove nut - 2 - on engine
assembly overview , Air filter - Assembly overview. - Remove nut - 2 - on engine

- Remove nut - 2 - on engine mount at left and right engine supports.

Engine, disassembling and assembling

Page 14 / 17

En g ine, disassemblin g and assemblin g Page 14 / 17 - Align mounting pins

- Align mounting pins of assembly support T10296

centrally at the mountings of the cylinder block - arrows - to assembly support . Tighten mounting pins.

- Insert assembly support T10296 into

engine/transmission jack V.A.G 1383 A and support assembly (engine and transmission) at mountings of cylinder block - arrows - with slight pretension.

block - a r r o w s - with slight pretension. - Remove right and

- Remove right and left bolts - 1 - for engine mount.

right and left bolts - 1 - for engine mount. - Carefully lift assembly wi th

- Carefully lift assembly with assembly support T10296 and remove engine mount.

Caution!

Engine, disassembling and assembling

Page 15 / 17

Be aware of the available clearance between the cylinder heads and the bulkhead.

- If necessary, unfasten engine supports at cylinder block and remove engine mounts together with engine supports.

Installing

- Make sure the alignment pin of engine mount is correctly positioned in engine carrier.

- Start all bolts and nuts by hand and then tighten to torque specification.

and nuts by hand and then tighten to torque specification. Torque specifications Bolted connections Torque
Torque specifications Bolted connections Torque specifications Engine support to cylinder block 50 Nm Engine mount
Torque specifications
Bolted connections
Torque specifications
Engine support to cylinder block
50 Nm
Engine mount to engine carrier - 1 -
60 Nm
Engine support to engine mount - 2 -
75 Nm

The rest of assembly is basically a reverse of the disassembling sequence.

Drive plate, removing and installing

Special tools, testers and auxiliary items required

Engine, disassembling and assembling

Page 16 / 17

En g ine, disassemblin g and assemblin g Page 16 / 17 Flywheel lock adapter VW

Flywheel lock adapter VW 558

and assemblin g Page 16 / 17 Flywheel lock adapter VW 558 Torque wrench (40 to

Torque wrench (40 to 200 Nm) V.A.G 1332

Not illustrated:

Caliper gauge

Hex bolt M8×50 and three M12-hex nuts

Drive plate, loosening and tightening

and three M12-hex nuts Drive p late, loosenin g and tig htenin g - Secure flywheel

- Secure flywheel lock adapter VW 558 with hex bolt

Engine, disassembling and assembling

Page 17 / 17

M8x50 to drive plate. Insert three M12 hex nuts between flywheel lock adapter and drive plate. Installed location of flywheel retainer: - A - to loosen; - B - to tighten

Installing drive plate.

- Install drive plate using a washer

g drive p late. - Install drive plat e using a washer Item - 8 -

Item - 8 - .

- Install new bolts and tighten to 30 Nm.

Item - 8 - . - Install new bolts and tighten to 30 Nm. - Using

- Using caliper gauge, check distance between drive plate

and cylinder block. Specified dimension - a - : 19.0 to 20.6

mm.

If specification is not obtained:

- Remove drive plate again and insert shim between

crankshaft and drive plate. Tighten bolts again to 30 Nm.

- Tighten bolts to 50 Nm and turn an additional 1 / 4 turn

(90

bolts to 50 Nm and turn an additional 1 / 4 turn (90 ), (additional rotation

), (additional rotation may occur in several stages).

Differential shaft

Page 1 / 2

Differential shaft

Note:

13 - 2

shaft Page 1 / 2 Differential shaft Note: 13 - 2 Secure engine in engine and

Secure engine in engine and transmission holder VAS 6095 when working on engine.

Balance shaft, assembly overview shaft, assembly overview

Balance shaft, assembly overview shaft, assembly overview 13- 2, Balance Balance shaft, assembly overview Note: It

13-2, Balance

Balance shaft, assembly overview

Note:

It is only possible to remove the balancing shaft when the engine timing module has been removed

beforehand

cassette), removing and installing .

timing module has been removed beforehand cassette), removi ng and installing . 13- 1, Engine timi

13-1, Engine timing module (wheel

timing module has been removed beforehand cassette), removi ng and installing . 13- 1, Engine timi

Differential shaft

Page 2 / 2

Thrust washer

Main bearing bolt

Note tightening sequence

and torque

Main bearing bolts, tightening.

sequence and torque Main bearing bolts, tightening. Topic 13 -3 , Bearing cap bolt For differential

Topic 13-3 ,

Bearing cap bolt

For differential shaft bearing

Note tightening sequence

and torque

Main bearing bolts, tightening.

sequence and torque Main bearing bolts, tightening. Topic 13 -3 , Bearing cap With eye for

Topic 13-3 ,

Bearing cap

With eye for securing oil pump

Bearing shell

Balancing shaft

Positioning

Bearing shell

Thrust washer

Bearing cap

shaft Positioning Bearing shell Thrust washer Bearing cap Topic 13 -1 Bearing cap with grooves for

Topic 13-1

Bearing cap with grooves for thrust washers

Crankshaft

Page 1 / 6

Crankshaft

Caution!

13 - 3

Crankshaft Page 1 / 6 Crankshaft Caution! 13 - 3 Upper section of bearing bracket is

Upper section of bearing bracket is bolted to cylinder with two multi-point socket bolts M8, which are found in the valley between the cylinder heads. These bolts must not be loosened under any circumstances, because it causes a deformation of the cylinder block which is no longer reparable.

Crankshaft, piston, and connecting rods must not be replaced! Only removal and installation of these components is permitted.

Note:

Secure engine on engine and transmission holder VAS 6095 when working on engine.

Crankshaft, assembly overview assembly overview

on engine. Crankshaft, assembly overview assembly overview 13- 3, Crankshaft, Bearing bracket for crankshaft, removing

13-3, Crankshaft,

Bearing bracket for crankshaft, removing and

installing

removing and installing

and i n s t a l l i n g removing and installing 13- 3,

13-3, Bearing bracket for crankshaft,

Crankshaft dimensions

C r a n k s h a f t d i m e n s

13-3, Crankshaft dimensions

Crankshaft, assembly overview

Crankshaft

Page 2 / 6

Volkswagen Technical Site:

http://volkswagen.msk.ru

http://vwts.info

http://vwts.ru

огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi

по автомобилям Volkswagen, Skoda, Seat, Audi Bearing bracket Installed in tensioned state Removing and

Bearing bracket

Installed in tensioned state

Removing and installing 13-3, Bearing bracket for crankshaft, removing and installing

3, Bearing bracket for crankshaft, removing and installing Thrust washer For lower section of bearing bracket

Thrust washer

For lower section of bearing bracket

Main bearing bolt

Note tightening sequence

and torque

Main bearing bolts, tightening.

of bearing bracket Main bearing bolt Note tightening sequence and torque Main bearing bolts, tightening. Topic

Topic 13-3 ,

Crankshaft

Page 3 / 6

Bearing shell

Crankshaft

Axial play new: 0.07 to 00.17 mm, Wear limit: 0.37 mm

Check radial clearance with Plastigage 0.03 to 00.08 mm, Wear limit: 0.17 mm

Do not turn crankshaft when measuring radial play

Crankshaft dimensions 13-3, Crankshaft dimensions

8 Nm

Oil spray jet

dimensions 13- 3, Crankshaft dimensions 8 Nm Oil spray jet For piston cooling Bearing shell Cylinder

For piston cooling

Bearing shell

Cylinder block

With upper section of bearing bracket

Cylinder bore, checking 13-6, Checking cylinder bores

Cylinder bore, checking 13-6, Checking cylinder bores Piston and cylinder dimensions and cylinder dimensions 13-

Piston and cylinder

dimensions

and cylinder dimensions

bores Piston and cylinder dimensions and cylinder dimensions 13- 6, Piston Engine Speed (RPM) Sensor G28

13-6, Piston

Engine Speed (RPM) Sensor

G28

10 Nm

Thrust washer

For upper section of bearing bracket

Bearing bracket for crankshaft, removing and installing

Crankshaft

Page 4 / 6

Caution!

Upper section of bearing bracket is bolted to cylinder with two multi-point socket bolts M8, which are found in valley between the cylinder heads. These bolts must not be loosened under any circumstances, because it causes a deformation of the cylinder block which is no longer reparable.

Note:

Secure engine in engine and transmission holder VAS 6095 when working on engine.

Special tools, testers and auxiliary items required

Sp ecial tools, testers and auxiliar y items re q uired Tensioning element T10201 Torque wrench

Tensioning element T10201

and auxiliar y items re q uired Tensioning element T10201 Torque wrench (5 to 50 Nm)

Torque wrench (5 to 50 Nm) V.A.G 1331

Not illustrated:

Torque wrench (40 to 200 Nm) V.A.G 1332

Removing

Crankshaft

Page 5 / 6

- Remove bolts for lower section of bearing bracket.

5 / 6 - Remove bolts for lower section of bearing bracket. - Install engine support

- Install engine support bridge T10201 on lower section of bearing bracket as shown.

- Tighten bolts of tensioning device T10201 to 20 Nm.

- Remove lower section of bearing bracket.

Installing

- Place tensioning device T10201 on lower section of bearing bracket and tighten bolts to 20 Nm.

- Check whether all bearing shells are lying properly in

bearing supports

washers

sh ells are lying properly in bearing supports washers Item - 4 - . Pay attention

Item - 4 - . Pay attention to thrust

supports washers Item - 4 - . Pay attention to thrust Item - 2 - .

Item - 2 - .

- Carefully place lower section of bearing bracket into cylinder block.

Tightening main bearing bolts

bracket into cylinder block. Tightening main bearing bolts Topic 13 -3 . Ti ghtening main bearin

Topic 13-3 .

Tightening main bearing bolts

bolts Topic 13 -3 . Ti ghtening main bearin g bolts - Tighten main bearing bolts

- Tighten main bearing bolts in three stages in the

tightening sequence shown as follows ( - arrow - points in

driving direction).

Tighten using torque wrench:

Crankshaft

Page 6 / 6

Step I = 35 Nm

Step II = 65 Nm

Tighten further using a solid wrench:

Stage III = 1 / 2 additional turn (180

Crankshaft dimensions

(Dimensions in mm)

turn (180 Crankshaft dimensions (Dimensions in mm) ) Reconditioning dimension, dimensions in mm Crankshaft

)

Reconditioning dimension, dimensions in mm Crankshaft bearing pins-diameter Connecting rod bearing pins-diameter
Reconditioning
dimension, dimensions in mm
Crankshaft bearing
pins-diameter
Connecting rod bearing
pins-diameter
-0.032
-0.022
Basic dimension
65.00
58.00
-0.047
-0.042
-0.032
-0.022
1st oversize
64.75
57.75
-0.047
-0.042
-0.032
-0.022
2nd oversize
64.50
57.50
-0.047
-0.042

Sealing flanges, seals and vibration damper

Page 1 / 11

Sealing flanges, seals and vibration damper

Note:

13 - 4

Sealing flan ges, seals and vibration damper Note: 13 - 4 Secure engine on engine and

Secure engine on engine and transmission holder VAS 6095 when working on engine.

Front sealing flange and vibration damper, assembly

overview

damper, assembly overview

13-4, Front sealing flange and vibration 4, Front sealing flange and vibration

Sealing ring for crankshaft, vibration damper side,

replacing

r e p l a c i n g 13- 4, Crankshaft seal (v ibration damper

13-4, Crankshaft seal (vibration damper side),

replacing

Crankshaft seal (engine timing side), replacing Crankshaft seal (engine timing side), replacing

replacing Crankshaft seal (engine ti ming side), replacing 13-4, Generator shaft seal, replacing seal, replacing

13-4,

Generator shaft seal, replacing seal, replacing

Front sealing flange and vibration damper, assembly overview

seal, replacing seal, replacing Front sealing flange and vibration damper, assembly overview 13- 4, Generator shaft

13-4, Generator shaft

Sealing flanges, seals and vibration damper

Page 2 / 11

Sealing flan ges, seals and vibration damper Page 2 / 11 Sealing flange, front Must be

Sealing flange, front

Must be located on dowel sleeves

8 Nm

Observe tightening

sequence

Tightening sequence of bolts

for front sealing flange and coolant pump cover

ce of bolts for front sealing flange and coolant pump cover 13-4, Coolant pump cover Vibration

13-4,

Coolant pump cover

Vibration damper

50 Nm plus an additional 1 / 4

turn (90

flange and coolant pump cover 13-4, Coolant pump cover Vibration damper 50 Nm plus an additional

)

Sealing flanges, seals and vibration damper

Page 3 / 11

Washer

Seal

Do not additionally oil or grease sealing lip of sealing ring

Before installing, remove oil remains from crankshaft journal with a clean cloth

Replace

13-4, Crankshaft

seal (vibration damper side), replacing

13- 4, Crankshaft seal (vibration damper side), replacing 13 Nm Tightening sequence of bolts for front

13 Nm

4, Crankshaft seal (vibration damper side), replacing 13 Nm Tightening sequence of bolts for front sealing

Tightening sequence of bolts for front sealing flange and coolant pump cover

- Tighten bolts in the shown tightening sequence to 8 Nm.

Crankshaft seal (vibration damper side), replacing

Special tools, testers and auxiliary items required

Sealing flanges, seals and vibration damper

Page 4 / 11

Sealing flan ges, seals and vibration damper Page 4 / 11 Counter-holder tool T10172 Extractor hook

Counter-holder tool T10172

vibration damper Page 4 / 11 Counter-holder tool T10172 Extractor hook T20143/2 Not illustrated: Assembly tool

Extractor hook T20143/2

Not illustrated:

Assembly tool T10196

Work procedure

- Bring lock carrier into service position

Repair Manual, Body Exterior, Repair Group 50, Lock carrier

Manual, Body Exte rior, Repair Group 50, Lock carrier . - Remove vibration damper Item -

.

-

Remove vibration damper

- Remove vibration damper Item - 4 - .

Item - 4 - .

Note:

Be careful not to damage sealing surface when removing sealing ring.

Sealing flanges, seals and vibration damper

Page 5 / 11

Sealing flan ges, seals and vibration damper Page 5 / 11 - Carefully remove old sealing

- Carefully remove old sealing ring from its seat using hook T20143/2 .

- Before installing, remove oil remains from end of crankshaft with a clean cloth.

Note:

Only remove protective ring from seal immediately prior to assembly.

protective ri ng from seal immediately prior to assembly. - Join assembly sleeve T 10196/1 and

- Join assembly sleeve T10196/1 and assembly sleeve

T10196/2 . Slide sealing ring - A - to stop on assembly sleeve T10196/2 .

- Separate both assembly sleeves.

Sealing flanges, seals and vibration damper

Page 6 / 11

Sealing flan ges, seals and vibration damper Page 6 / 11 - Place assembly sleeve T1019

- Place assembly sleeve T10196/2 together with sealing

ring on crankshaft flange and tighten knurled bolts - A - hand-tight.

- Press in seal up to stop using pressure sleeve T1096/3 .

The rest of the assembly is a reverse of the disassembling sequence.

Crankshaft seal (engine timing side), replacing

Special tools, testers and auxiliary items required

Sp ecial tools, testers and auxiliar y items re q uired Pulling hook T20143/2 Not illustrated:

Pulling hook T20143/2

Not illustrated:

Assembly tool T10207

Requirement:

Sealing flanges, seals and vibration damper

Page 7 / 11

Engine removed

Transmission separated from engine

Work procedure

Note:

Make sure the sealing surface is not damaged when removing the seal.

the sealing su rface is not damaged when removing the seal. - Carefully remove old sealing

- Carefully remove old sealing ring from its seat using hook T20143/2 .

- Before installing, remove oil remains from end of crankshaft with a clean cloth.

oil remains from end of crankshaft with a clean cloth. - Join assembly sleeve T 10207/1

- Join assembly sleeve T10207/1 and assembly sleeve

T10207/2 . Slide sealing ring - A - to stop on assembly sleeve T10207/2 .

Sealing flanges, seals and vibration damper

Page 8 / 11

- Separate both assembly sleeves.

damper Page 8 / 11 - Separate both assembly sleeves. - Place assembly sleeve T1020 7/2

- Place assembly sleeve T10207/2 together with sealing

ring on crankshaft flange and tighten knurled bolts - A -

hand-tight.

- Press in seal up to stop using pressure sleeve T1207/3 .

The rest of the installation follows the reverse of the removal procedures.

Generator shaft seal, replacing

Special tools, testers and auxiliary items required

Sp ecial tools, testers and auxiliar y items re q uired Pulling hook T20143/1 Not illustrated:

Pulling hook T20143/1

Not illustrated:

Assembly tool T10208

Sealing flanges, seals and vibration damper

Page 9 / 11

Work procedure

Vehicles with engine code BKW

- Remove fuel filter

code BKW), removing and installing .

- Remove fuel filter code BKW), removing and installing . 20- 1, Fuel filter (vehicles with

20-1, Fuel filter (vehicles with engine

Vehicles with engine codes BWF

- Remove bypass flap with cooler for Exhaust Gas

Recirculation (EGR)

Exhaust Gas Recirculation (EGR) (vehicles with engine

code BWF), assembly overview .

(EGR) (vehicles with engine code BWF), assembly overview . 26- 2, Bypass flap with cooler for

26-2, Bypass flap with cooler for

Continuation for all vehicles

- Remove generator

Repair Manual, Electrical Equipment, Repair Group 27, Generator

Manual, Elec trical Equipment, Repair Group 27, Generator . Note: Make sure the sealing su rface

.

Note:

Make sure the sealing surface is not damaged when removing the seal.

the sealing su rface is not damaged when removing the seal. - Carefully remove old sealing

- Carefully remove old sealing ring from its seat using hook T20143/1 .

- Remove oil residue on input shaft for generator using a clean cloth.

Sealing flanges, seals and vibration damper

Page 10 / 11

Sealing flan ges, seals and vibration damper Page 10 / 11 - Press inner part of

- Press inner part of sealing ring toward outside as shown.

Press inner part of sealing ring toward outside as shown. - Screw guide sleeve T10208/1 hand-tight

- Screw guide sleeve T10208/1 hand-tight onto input shaft

for generator and carefully slide sealing ring - A - on up to stop.

Sealing flanges, seals and vibration damper

Page 11 / 11

Sealing flan ges, seals and vibration damper Page 11 / 11 - Position pressure piece T1020

- Position pressure piece T10208/2 and press in inner part of sealing ring up to stop.

- Position pressure piece T10208/3 and press in outer part of sealing ring up to stop.

The rest of the assembly is basically a reverse of the disassembling sequence.

Control housing

Page 1 / 3

Control housing

Note:

13 - 5

Control housin g Page 1 / 3 Control housing Note: 13 - 5 Secure engine on

Secure engine on engine and transmission holder VAS 6095 when working on engine.

Control housing, assembly overview housing, assembly overview

housing, ass embly overview housing, assembly overview 13- 5, Control Control housing, assembly overview Engine

13-5, Control

Control housing, assembly overview

overview 13- 5, Control Control housing, assembly overview Engine timing module Removing and installing 13- 1,

Engine timing module

Removing and installing 13-1, Engine timing module (wheel cassette), removing and installing

Engine timing module Removing and installing 13- 1, Engine timing module (wheel cassette), removing and installing

Control housing

Page 2 / 3

Control housing

Insert with silicone sealant D

13-5, Sealant

176 501 A1

Insert with silicone sealant D 13- 5, Sealant 176 501 A1 bead on control housing 20

bead on control housing

20 Nm

Observe tightening

sequence

sequence 13-5,

13-5,

Tightening sequence of bolts

for control housing

20 Nm

Seal

Do not additionally oil or grease sealing lip of sealing ring

Before installing, remove oil remains from crankshaft journal with a clean cloth

Replace

remains from crankshaft journal with a clean cloth Replace 13- 4, Crankshaft seal (engine ti ming

13-4, Crankshaft

seal (engine timing side), replacing

Drive plate

Removing and installing 13-1, Drive plate, removing and installing

and installing 13- 1, Drive plate, removing and installing 50 Nm plus an additional 1 /

50 Nm plus an additional 1 / 4

turn (90

13- 1, Drive plate, removing and installing 50 Nm plus an additional 1 / 4 turn

)

Replace

Washer

13 Nm

Control housing

Page 3 / 3

Control housin g Page 3 / 3 Sealant bead on control housin g - Apply sealant

Sealant bead on control housing

- Apply sealant bead onto clean sealing surface of the control housing as shown.

clean sealin g surface of the control housing as shown. Tightening se q uence of bolts

Tightening sequence of bolts for control housing

- Tighten bolts in the illustrated tightening sequence to 20 Nm.

Piston and connecting rod

Page 1 / 7

Piston and connecting rod

Caution!

13 - 6

g rod Page 1 / 7 Piston and connecting rod Caution! 13 - 6 Crankshaft, piston,

Crankshaft, piston, and connecting rods must not be replaced! Only removal and installation of these components is permitted.

Note:

Secure engine on engine and transmission holder VAS 6095 when working on engine.

Piston and connecting rod, assembly overview Piston and connecting rod, assembly overview

overview Piston and conne cting rod, assembly overview 13-6, Checking piston position at TDC at TDC,

13-6,

Checking piston position at TDC at TDC, checking

13-6, Checking piston position at TDC at TDC, checking 13- 6, Piston position Piston and cylinder

13-6, Piston position

Piston and cylinder dimensions cylinder dimensions

position Piston and cylinder dimensions cylinder dimensions 13- 6, Piston and Piston rings, cylinder bore s

13-6, Piston and

Piston rings, cylinder bores and piston positioning 13-6, Piston rings, cylinder bores and piston positioning

positioning 13- 6, Piston rings, cylinder bo res and piston positioning Piston and connecting rod, assembly

Piston and connecting rod, assembly overview

Piston and connecting rod

Page 2 / 7

Piston and connectin g rod Page 2 / 7 Connecting rod bol t, 30 Nm plus

Connecting rod bolt, 30 Nm plus

an additional 1 / 4 turn (90

Replace

t, 30 Nm plus an additional 1 / 4 turn (90 Replace ) Lubricate threads and

)

Lubricate threads and contact surface

Use old bolt to measure radial play

Connecting rod bearing cap

Note installation position

Bearing shell

Note installation position

Note version: Upper bearing shell (to piston) made of

Piston and connecting rod

Page 3 / 7

wear-resistant material, identification: Black line on contact surface in area of separating point

Do not interchange used bearing shells

Insert bearing shells in

center

Check for secure seating

Axial play wear limit: 0.37

mm

Measure radial clearance with Plastigage: Wear limit:

0.08 mm. Do not turn crankshaft when checking radial clearance

Connecting rod

Mark matching cylinder - arrow A -

Location: Markings - arrows

B - point to vibration damper

side

Circlip

Piston

With combustion chamber

Mark installed position and cylinder allocation

Installed position and allocation, piston/cylinder Topic 13-6

position and allocation, piston/cylinder Topic 13 -6 Directional arrow on piston head points to intake side

Directional arrow on piston head points to intake side

Install with piston ring

compressor

Checking piston position at

TDC

at TDC, checking

with piston ring compressor Checking piston position at TDC at TDC, checking 13- 6, Piston position

13-6, Piston position

Piston and cylinder

Piston and connecting rod

Page 4 / 7

dimensions

and cylinder dimensions

g rod Page 4 / 7 dimensions and cylinder dimensions 13- 6, Piston Cylinder bore, checking

13-6, Piston

Cylinder bore, checking 13-6, Checking cylinder bores

Cylinder bore, checking 13-6, Checking cylinder bores Piston pin If difficult to move, heat piston to

Piston pin

If difficult to move, heat

piston to 60

bores Piston pin If difficult to move, heat piston to 60 C Removing and installing using

C

Removing and installing using a drift VW 222 A

Piston rings

Offset gaps by 120

using a drift VW 222 A Piston rings Offset gaps by 120 Use piston ring pliers

Use piston ring pliers for removal and installation

"TOP" faces toward piston crown

Checking ring gap

13-6,"TOP" faces toward piston crown Checking ring gap Checking piston ring gap Check piston ring groove

Checking piston ring gap

Check piston ring groove

clearance

ring to groove clearance

Check piston ring groove clearance ring to groove clearance 13- 6, Checking Piston position at TDC,

13-6, Checking

Piston position at TDC, checking

It is not possible to measure piston projection position

using workshop equipment. Due to the connecting rod principle for cylinder head bolts in conjunction with the aluminum cylinder block results in a compression of the cylinder block which cannot be reproduced when cylinder head is removed. For this reason, a new cylinder head

gasket with the same index number (

sequence of bolts for cylinder head cover ) must be installed when replacing the cylinder head gasket.

must be installed when replacing the cylinder head gasket. 15- 1, Tightening Piston and cylinder dimensions

15-1, Tightening

Piston and cylinder dimensions

Note:

No repair sizes are provided!

Piston and connecting rod

Page 5 / 7

Honing dimension Piston diameter Cylinder bore diameter Basic dimension mm 80.97 81.01 Piston rings, cylinder
Honing dimension
Piston diameter
Cylinder bore diameter
Basic dimension
mm
80.97
81.01
Piston rings, cylinder bores and piston positioning
81.01 Piston rings, cylinder bores and piston positioning Checkin g p iston rin g gap Sp

Checking piston ring gap

Special tools, testers and auxiliary items required

Feeler gauge

Test sequence

- Push piston ring squarely from above down to approx. 15 mm from bottom end
- Push piston ring squarely from above down to approx. 15
mm from bottom end of cylinder.
Piston ring
dimensions in mm
New
Wear limit
1. Compression ring
0.20 to 0.40
1.0
2. Compression ring
0.30 to 0.50
1.0
Oil scraping ring
0.25 to 0.50
1.0
1.0 2. Compression ring 0.30 to 0.50 1.0 Oil scraping ring 0.25 to 0.50 1.0 Checkin

Checking ring to groove clearance

Piston and connecting rod

Page 6 / 7

Special tools, testers and auxiliary items required

Feeler gauge

Test sequence

- Clean ring groove before checking. Piston ring dimensions in mm New Wear limit 1.
- Clean ring groove before checking.
Piston ring
dimensions in mm
New
Wear limit
1. Compression ring
0.08 to 0.10
0.25
2. Compression ring
0.03 to 0.05
0.25
Oil scraping ring
0.02 to 0.05
0.15
0.03 to 0.05 0.25 Oil scraping ring 0.02 to 0.05 0.15 Checkin g cy linder bores

Checking cylinder bores

Special tools, testers and auxiliary items required

Internal dial gauge 50 - 100 mm

Test sequence

- Measure bores at 3 locations in both directions - A - across engine and - B - in line with crankshaft.

Deviations from nominal dimension: max. 0.05 mm.

Piston: Installed position and allocation, piston/cylinder

Piston and connecting rod

Page 7 / 7

Pistons are identified on piston head:

Pistons 1 through 5: for cylinder bank 1

Pistons 6 through 10: for cylinder bank 2

Positioning:

Directional arrow on piston head points to intake side

Cylinder head

Page 1 / 28

Cylinder head

Caution!

15 - 1

Cy linder hea d Page 1 / 28 Cylinder head Caution! 15 - 1 Because of

Because of the threaded connection of cylinder head through the aluminum cylinder block into crankshaft bearing bracket (connecting rod), both cylinder heads must always be removed. If cylinder head bolts are loosened or tightened on one side, cylinder block is warped.

Note:

Secure engine on engine and transmission holder VAS 6095 when working on engine.

When installing a replacement cylinder head with camshaft installed, the contact surfaces between the lifters and cam lobes must be lubricated before installing the cylinder head cover.

The plastic protectors installed to protect the open valves must only be removed immediately before fitting the cylinder head.

When cylinder heads are replaced, all coolant must also be replaced.

Cylinder head, assembly overview head, assembly overview

15-1, CylinderCylinder head, assembly overview head, assembly overview Removing input gear for camshaft compensation wheel and i

Removing input gear for camshaft

compensation wheel and input gear, removing and

installing

15-1, Camshaft 1, Camshaft

Valve timing, checking

Valve timing, adjusting

15-1, Valve timing, checking 1, Valve timing, checking

15-1, Valve timing, adjusting 1, Valve timing, adjusting

Cylinder heads, removing and installing Cylinder heads, removing and installing

and installing Cylinder heads, removi ng and installing 15-1, Checking compression pressure pressures, checking 15-

15-1,

Checking compression pressure pressures, checking

15-1, Checking compression pressure pressures, checking 15- 1, Compression Cylinder head, assembly overview Note:

15-1, Compression

Cylinder head, assembly overview

Note:

Cylinder head

Page 2 / 28

Volkswagen Technical Site:

http://volkswagen.msk.ru

http://vwts.info

http://vwts.ru

огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi

Components depicted here correspond to cylinder bank 1. They are different only as a mirror image of components for cylinder bank 2.

only as a mirror image of components for cylinder bank 2. Connecting hose On vehicles with

Connecting hose

On vehicles with engine code BWF

To crankcase ventilation valve

Ensure seated tightly

Sealing sleeve

On vehicles with engine code BWF

Replace if damaged

Cylinder head

Page 3 / 28

Ensure seated tightly

Bracket

On vehicles with engine code BWF

For intake hose between air filter and intake manifold flap

Acoustic cover

For vehicles with engine code BWF

Cylinder head cover

On vehicles with engine code BWF

Always clean sealing surfaces of cylinder head cover with a clean cloth before setting in place

Replace seal together with cylinder head cover if damaged or leaking

Observe tightening sequence of bolts

if damaged or leaking Observe tightening sequence of bolts 15-1, Tightening sequen ce of bolts for

15-1,