Get Crankshaft group Guide for Volkswagen Touareg SUV First Generation (2002-2010)

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

13 – Crankshaft group

1

Dismantling and assembling engine

Assembly overview

Part I: toothed belt drive ⇒ page 15

Part II: cylinder block ⇒ page 17

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1. Dismantling and assembling engine

13

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

Caution

Warning, aluminium cylinder block! The crankshaft and pistons

must not be removed. Just loosening the main bearing caps

will cause deformation of the cylinder block bearing pedestals.

This deformation will cause a reduction of the bearing clear‐

ance. Even if the bearing shells are not renewed bearing

damage could occur due to a different bearing clearance. If the

bearing cap bolts are loosened, the cylinder block must be re‐

placed complete with the crankshaft and pistons. Measuring

the main bearing clearance is not possible with normal work‐

shop equipment.

Note

♦ Secure engine to engine and gearbox support -VAS 6095- to carry out repairs.

♦ Engine must not be set down on oil sump, as this will damage the liquid gasket between the upper and lower

sump.

♦ Finding metal shavings or a large quantity of small metal particles during engine repair could indicate that

the crankshaft bearings or conrod bearings are damaged. To prevent this from causing further damage,

perform the following repairs:

♦ Thoroughly clean oil passages,

♦ Renew oil return valve,

♦ Renew oil spray jets,

♦ Renew oil cooler,

♦ Renew oil filter.

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Rep. gr.13 - Crankshaft group

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

1.1

Assembly overview - part I, toothed belt drive

1 - 10 Nm

2 - Bearing sleeve

1

3 - 20 Nm + / turn (90°) fur‐

4

ther

❑ Renew.

4 - Washer

❑ For tensioning roller.

5 - 40 Nm

6 - Tensioning roller

7 - Tensioning lever

8 - 22 Nm

9 - 55 Nm

❑ Renew.

❑ Oil threads and bolt

head contact surface.

10 - Securing plate

❑ Renew.

❑ Observe installation po‐

sition: side with lettering

faces to rear.

11 - Right camshaft pulley

❑ Pull off camshaft with

two arm puller -T40001-

and claw -T40001/2- .

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❑ Removing and installing

⇒ page 34 Removing,

installing and tensioning

toothed belt.

12 - 10 Nm

❑ Insert with locking fluid -

D 000 600 A2- .

13 - Toothed belt guard, rear right

14 - Idler roller

15 - Pin, 6 Nm

16 - 15 Nm

17 - Coolant pump

❑ Removing and installing ⇒ page 89

18 - Gasket

❑ Renew.

19 - Toothed belt guard, rear left

20 - 10 Nm

❑ Insert with locking fluid -D 000 600 A2- .

21 - 10 Nm

22 - Left camshaft pulley

❑ Pull off camshaft with two arm puller -T40001- and claw -T40001/2- .

1. Dismantling and assembling engine

15

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

❑ Removing and installing ⇒ page 34 Removing, installing and tensioning toothed belt.

23 - Securing plate

❑ Renew.

❑ Observe installation position: side with lettering faces to rear.

24 - 55 Nm

❑ Renew.

❑ Oil threads and bolt head contact surface.

25 - Toothed belt

❑ Mark direction of rotation before removing.

❑ Check for wear.

❑ Do not kink.

❑ Removing, installing and tensioning ⇒ page 34 .

26 - Eccentric roller

27 - 45 Nm

28 - Crankshaft toothed belt pulley

❑ Fitting possible in one position only.

❑ For removal lock crankshaft using locking pin -3242- ⇒ page 22 ; Removing and installing drive plate.

1

29 - 200 Nm + / turn (180°) further

2

❑ Renew.

❑ Do not oil.

❑ Turning further can be done in several stages.

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30 - Washer

❑ For tensioning lever

31 - Tensioning element

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Rep. gr.13 - Crankshaft group

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

1.2

Assembly overview - part II, cylinder block

1 - 10 Nm

2 - Cover

❑ With connection for

crankcase breather

3 - Connecting hose

❑ For crankcase ventila‐

tion.

4 - Clip

5 - Baffle plate

❑ With seal.

❑ Renew.

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6 - Oil return supply valve

❑ For cylinder head, right

7 - O-ring

❑ Renew.

8 - 20 Nm

❑ The specified torque in‐

fluences the function of

the knock sensor.

9 - Knock sensor 1 (G61)

10 - Knock sensor 2 (G66)

11 - Plug, 35 Nm

12 - Seal

❑ Renew.

13 - Engine bracket

❑ Engine bracket and

specified torques

⇒ page 18

1

14 - 40 Nm + / turn (90°) fur‐

4

ther

❑ Renew.

15 - Banjo bolt, 30 Nm

16 - 10 Nm

17 - Coolant drain pipe

18 - Cylinder block

19 - Thermostat

❑ Removing and installing ⇒ page 89

20 - Thermostat housing

21 - Oil return supply valve

❑ For cylinder head, left

1. Dismantling and assembling engine

17

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

Specified torque for engine bracket

Specified torque for securing bolt -1-: 60 Nm.

Specified torque for securing nut -2-: 75 Nm.

1.3

Removing and installing poly V-belt

Special tools and workshop equipment required

♦ Locking pin -T10060 A-

Removing poly V-belt

– Remove noise insulation tray.

– Mark direction of rotation of poly V-belt.

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– Turn spanner clockwise until tensioning element can be

locked using locking pin -T10060 A- .

– Remove poly V-belt.

Installing poly V-belt

Note

♦ Before installing poly V-belt, ensure that all ancillary assem‐

blies (alternator, air conditioner compressor, vane pump) are

secured tightly.

♦ Check that idler roller turns easily.

♦ When installing poly V-belt, check direction of belt rotation and

proper seating of belt in pulleys.

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Rep. gr.13 - Crankshaft group

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Fit poly V-belt as illustrated.

After completing repairs always:

– Start engine and check that belt runs properly.

1.4

Checking alignment of poly V-belt

Note

Alignment of poly V-belt must always be checked to prevent dam‐

age if power-assisted steering vane pump, air conditioning sys‐

tem compressor or the respective brackets for power-assisted

steering or air conditioning system compressor have been re‐

newed.

Special tools and workshop equipment required

♦ Aligning gauge -3201-

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♦ Torque wrench (5…50 Nm) -V.A.G 1331-

Procedure

– Remove power-assisted steering vane pump pulley.

– Remove poly V-belt ⇒ page 18 .

1. Dismantling and assembling engine

19

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Remove idler roller -1-.

– Position aligning gauge -3201- on air conditioning system

compressor belt pulley.

Note

The air conditioning system compressor pulley must align with the

power-assisted steering vane pump pulley.

If belt pulleys do not align

– Compensate misalignment of pulleys using shims with thick‐

nesses of 0.6, 0.8, 1.0, 1.2, and 1.4 mm.

– Check alignment of belt pulleys again with aligning gauge

-3201-

– Install idler roller. Specified torque: 25 Nm

– Install poly V-belt ⇒ page 18 .

– Tighten power-assisted steering belt pulley securing bolts to

22 Nm.

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20

Rep. gr.13 - Crankshaft group

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

2

Removing and installing sealing

flange and drive plate

Note

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Secure engine to engine and gearbox support -VAS 6095- to car‐

ry out repairs.

Assembly overview ⇒ page 21 .

Removing and installing drive plate ⇒ page 22 .

Removing and installing sealing flange at drive plate end

⇒ page 24

Renewing crankshaft oil seal, vibration damper end

⇒ page 26

2.1

Assembly overview

1 - Gasket

❑ Renew.

2 - Sealing flange

❑ With seal.

❑ Remove sump in order

to remove and install

⇒ page 70 .

❑ Must seat on dowel

sleeves.

❑ Before installing, re‐

move oil residue from

crankshaft journal using

a clean cloth.

❑ Do not additionally oil or

grease the oil seal seal‐

ing lip.

❑ Use support sleeve sup‐

plied when installing.

❑ Only remove supporting

sleeve after sealing

flange has been slid on‐

to crankshaft journal.

❑ If the sealing flange has

not been renewed use

fitting tool -T10122- for

installing ⇒ page 26 ,

Removing and installing

sealing flange at drive

plate end.

❑ Removing and installing

⇒ page 24 .

3 - Shim

❑ 2 mm thick

4 - Drive plate

❑ Use locking pin -3242- to loosen and tighten ⇒ page 22 ; Removing and installing drive plate.

5 - Washer

❑ 3.4 mm thick

2. Removing and installing sealing flange and drive plate

21

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

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1

6 - 30 Nm + / turn (90°) further

4

❑ Renew.

7 - 10 Nm

8 - 15 Nm

9 - Cylinder block

10 - Oil sump

❑ Removing and installing ⇒ page 70

11 - Securing bolt

❑ M7 = 15 Nm

❑ M8 = 22 Nm

12 - Timing chain

❑ Mark with arrow pointing in direction of rotation before removing (e.g. using paint).

❑ Do not mark with a centre punch mark, notch or anything similar!

13 - Chain sprocket

❑ For crankshaft.

14 - Thrust washer

❑ In case of signs of abnormal wear remove and reverse or renew.

15 - Gasket

❑ Renew.

16 - Sealing flange at belt pulley end

❑ Remove sump in order to remove and install ⇒ page 70 .

❑ Must seat on dowel sleeves.

❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.

17 - O-ring

❑ Renew.

18 - Spray nozzle valve, 35 Nm

19 - Seal

❑ Renew. ⇒ page 26 .

20 - Crankshaft toothed belt pulley

❑ Fitting possible in one position only.

❑ For removal lock crankshaft using locking pin -3242- ⇒ page 22 ; Removing and installing drive plate.

1

21 - 200 Nm + / turn (180°) further

2

❑ Renew.

❑ Do not oil.

❑ Turning further can be done in several stages.

22 - Vibration damper/belt pulley

❑ For poly V-belt.

❑ For removal lock crankshaft using locking pin -3242- ⇒ page 22 ; Removing and installing drive plate.

23 - 22 Nm

24 - 25 Nm

25 - Cover

2.2

Removing and installing drive plate

Special tools and workshop equipment required

22

Rep. gr.13 - Crankshaft group

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

♦ Locking pin -3242-

♦ Torque wrench (5…50 Nm) -V.A.G 1331-

Removing

– Remove engine ⇒ page 3 .

– Separate engine from gearbox.

– Set engine to TDC. For this, notches -A- and -B- must align.

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Note

♦ The engine is cranked by turning crankshaft centre bolt.

♦ The engine must only be cranked in clockwise direction.

– Remove screw plug -arrow-.

Note

There is a TDC drilling in the crankshaft directly behind the plug

(it is possible to feel the hole).

2. Removing and installing sealing flange and drive plate

23

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Screw locking pin -3242- into crankshaft.

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– Loosen drive plate securing bolts diagonally and remove.

– Remove drive plate together with washer and shim.

Installing

Installation is carried out in the reverse order. When installing,

note the following:

– Fit shim -1- of „2.0 mm thickness“ onto crankshaft journal.

– Then, install drive plate and washer -2- of „3.4 mm thickness“.

– Insert new securing bolts and tighten by hand.

1

–

Tighten securing bolt to 30 Nm + / turn (The additional turn

4

may be performed in several steps.)

– Unscrew locking pin -3242- .

– Install sealing plug with a new seal. Specified torque: 35 Nm

2.3

Removing and installing sealing flange

at drive plate end

Removing ⇒ page 25 .

Installing ⇒ page 25 .

Special tools and workshop equipment required

♦ Fitting tool -T10122-

♦ Torque wrench (5…50 Nm) -V.A.G 1331-

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Rep. gr.13 - Crankshaft group

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

2.3.1

Removing

– Remove engine ⇒ page 3 .

– Separate engine from gearbox.

– Remove drive plate ⇒ page 22 .

– Remove sump ⇒ page 70 .

– Remove sealing flange -arrow- from cylinder block.

– Remove existing gasket.

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2.3.2

Installing

Note

♦ In the following work procedure the seal is illustrated without

sealing flange.

♦ If repair is required, sealing flange and seal must be renewed

completely. Use protective sleeve supplied when installing.

– Clean sealing surfaces on sealing flange and cylinder block.

They must be free of oil and grease.

– Remove oil residue from crankshaft journal using clean cloth.

– Fit new gasket -1- onto dowel sleeves on cylinder block.

2. Removing and installing sealing flange and drive plate

25

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Pull oil seal with sealing flange -A- by the outside over sleeve

-T10122/1- onto pulling sleeve -T10122/2- .

– Separate the two fitting sleeves.

– Then set pulling sleeve -T10122/2- with dry seal and sealing

flange onto crankshaft journal.

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– Bolt sealing flange to cylinder block. Specified torque: 10 Nm

– Install sump ⇒ page 70 .

– Install drive plate ⇒ page 22 .

– Install engine ⇒ page 3 .

2.4

Renewing crankshaft oil seal, vibration

damper end

Special tools and workshop equipment required

♦ Thrust piece -T40007-

♦ Torque wrench (150…800 Nm) -V.A.G 1601-

Removing

– Remove noise insulation tray.

– Remove toothed belt ⇒ page 34 .

– Unscrew centre bolt -2- from crankshaft toothed belt pulley

-1- and remove crankshaft toothed belt pulley from crankshaft

journal.

– Then remove seal using extractor hook -T20143/1- .

26

Rep. gr.13 - Crankshaft group

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Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Remove thrust washer from crankshaft journal and mark thrust

washer front face -arrow- using a waterproof felt-tip marker.

Installing

– Remove oil residue from crankshaft journal and thrust washer

using a clean cloth.

– Press new seal in to stop using thrust piece -T40007- .

– Reverse thrust washer and fit it on crankshaft journal with

marked front face towards engine.

– Install crankshaft toothed belt pulley using a new centre bolt.

1

Specified torque: 200 Nm + / turn (180°) further.

2

– Install toothed belt. ⇒ page 34

– Install poly V-belt ⇒ page 18 .

– Install noise insulation tray.

2. Removing and installing sealing flange and drive plate

27

Crankshaft group for Your Volkswagen Touareg SUV First Generation (2002-2010)

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