Get Crankshaft group -> 1 Dismantling and assembling engine 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

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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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Rep. gr.13 - Crankshaft group

Crankshaft group -> 1 Dismantling and assembling engine for Your Volkswagen Touareg SUV First Generation (2002-2010)

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