Get Crankshaft group -> 2 Removing and installing sealing flange and drive plate Guide for Volkswagen Touareg SUV First Generation (2002-2010)

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

2

Removing and installing sealing

flange and drive plate

Note

lk

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

lk

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.

lk

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.

lk

– 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-

24

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.

lk

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.

lk

– 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

lk

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 -> 2 Removing and installing sealing flange and drive plate for Your Volkswagen Touareg SUV First Generation (2002-2010)

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