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  • Examplepage for repair manual 10-cylinder diesel engine
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10-cylinder diesel engine

For Touareg

Original Volkswagen repair manual


16,77 €7% VAT incl.

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Language: English

Digital PDF file

4.594 KB

202 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Balancer shaft, Sealing flange, seals and vibration damper, Valve timing housing, Pistons and conrods, Engine oil:, Oil pan, Parts of fuel supply system, Additive tank (vehicles with engine code BLE) and Charge air system with turbocharger. Show more
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Repair manual Touareg 10-cylinder diesel engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Technical data
    1
  • 1.1 Engine number
    1
  • 1.2 Engine data
    1
  • Removing and installing engine
    3
  • 1 Removing and installing engine
    3
  • 1.1 Removing engine
    3
  • 1.2 Removing engine from scissor-type assembly platform VAS 6131
    14
  • 1.3 Securing engine on engine and gearbox support VAS 6095
    15
  • 1.4 Notes on installing
    16
  • Crankshaft group
    18
  • 1 Dismantling and assembling engine
    18
  • 1.1 Assembly overview - components in the V space
    18
  • 1.2 Assembly overview - gear train assembly
    20
  • 1.3 Removing and installing gear train assembly
    21
  • 1.4 Removing and installing engine mounting and engine support (left and right)
    24
  • 1.5 Removing and installing drive plate
    25
  • 2 Balancer shaft
    27
  • 2.1 Assembly overview - balance shaft
    27
  • 3 Crankshaft
    28
  • 3.1 Assembly overview - crankshaft
    28
  • 3.2 Removing and installing bearing saddle for crankshaft
    29
  • 3.3 Crankshaft dimensions
    31
  • 4 Sealing flange, seals and vibration damper
    32
  • 4.1 Assembly overview - front sealing flange and vibration damper
    32
  • 4.2 Renewing crankshaft oil seal, vibration damper end
    33
  • 4.3 Renewing crankshaft oil seal - engine timing end
    34
  • 4.4 Renewing alternator shaft oil seal
    36
  • 5 Valve timing housing
    39
  • 5.1 Assembly overview - timing housing
    39
  • 6 Pistons and conrods
    41
  • 6.1 Assembly overview - pistons and conrods
    41
  • 6.2 Checking piston projection at TDC
    42
  • 6.3 Piston and cylinder dimensions
    42
  • 6.4 Piston rings, cylinder bore and piston installation position
    43
  • Cylinder head, valve gear
    45
  • 1 Cylinder head
    45
  • 1.1 Assembly overview - cylinder head
    45
  • 1.2 Removing and installing camshaft compensating gear and drive gear wheel
    47
  • 1.3 Checking valve timing
    52
  • 1.4 Adjusting valve timing
    54
  • 1.5 Removing and installing cylinder heads
    56
  • 1.6 Checking compression
    58
  • 2 Valve gear
    62
  • 2.1 Assembly overview - valve gear
    62
  • 2.2 Reworking valve seats
    65
  • 2.3 Checking valve guides
    66
  • 2.4 Renewing valve stem seals
    67
  • 2.5 Removing and installing camshaft
    69
  • Lubrication
    71
  • 1 Engine oil:
    71
  • 1.1 Oil capacities
    71
  • 1.2 Checking engine oil level
    71
  • 2 Oil pan
    72
  • 2.1 Assembly overview - sump
    72
  • 2.2 Applying sealant
    75
  • 3 Assembly overview - oil supply lines
    76
  • 3.1 Oil supply line for turbocharger, cylinder bank 1
    76
  • 3.2 Oil supply line for turbocharger, cylinder bank 2
    77
  • 4 Oil pump, oil filter housing and oil pressure
    79
  • 4.1 Assembly overview - oil pump
    79
  • 4.2 Assembly overview - oil filter housing
    81
  • 4.3 Removing and installing oil filter housing
    82
  • 4.4 Checking oil pressure and oil pressure switch
    82
  • 4.5 Checking oil pressure at front of engine
    84
  • Cooling
    86
  • 1 Parts of cooling system
    86
  • 1.1 Assembly overview - radiator
    87
  • 1.2 Assembly overview - fans
    89
  • 1.3 Parts of cooling system, body side
    90
  • 1.4 Parts of cooling system engine side and top
    91
  • 1.5 Parts of alternator and fuel cooling
    92
  • 1.7 Assembly overview - thermostat housing
    93
  • 1.8 Assembly overview - coolant pump
    95
  • 1.9 Coolant hose schematic diagram (vehicles with engine codes AYH, BKW)
    96
  • 1.10 Coolant hose schematic diagram (vehicles with engine codes BLE and BWF)
    97
  • 1.11 Draining and adding coolant
    98
  • 1.12 Removing and installing fan support
    100
  • 1.13 Removing and installing radiator
    101
  • 1.14 Removing and installing coolant connection
    102
  • 1.15 Removing and installing coolant pump
    103
  • Fuel supply system
    106
  • 1 Parts of fuel supply system
    106
  • 1.1 Safety regulations for working on fuel supply
    107
  • 1.2 Rules for cleanliness
    107
  • 1.3 Assembly overview - fuel tank with attachments
    107
  • 1.4 Assembly overview - fuel filter (vehicles with engine codes AYH, BKW)
    110
  • 1.5 Assembly overview - fuel filter (vehicles with engine codes BLE and BWF)
    111
  • 1.6 Schematic diagram of fuel lines and components in fuel tank
    113
  • 1.9 Emptying fuel tank
    116
  • 1.11 Removing and installing fuel tank with attached components
    121
  • 1.12 Removing and installing fuel filter (vehicles with engine codes AYH, BKW)
    125
  • 1.13 Checking fuel pumps
    127
  • 1.14 Checking tandem pump and fuel pump
    129
  • 1.15 Removing and installing tandem pump and fuel pump
    131
  • 1.16 Assembly overview - accelerator mechanism
    133
  • 2 Additive tank (vehicles with engine code BLE)
    135
  • 2.1 Safety precautions when working on additive tank
    135
  • 2.2 Assembly overview - additive tank
    135
  • 2.3 Removing and installing additive tank
    137
  • Turbocharging/supercharging
    140
  • 1 Charge air system with turbocharger
    140
  • 1.1 Safety precautions
    140
  • 1.2 Rules for cleanliness
    140
  • 1.3 Installing hose connections with plug-in connectors
    141
  • 1.4 Assembly overview - turbocharger
    142
  • 1.5 Assembly overview - parts of charge air cooling
    144
  • 1.6 Checking charge air system for leaks
    145
  • Mixture preparation - injection
    148
  • 1 Repairing diesel direct injection system
    148
  • 1.1 Safety precautions
    148
  • 1.2 Rules for cleanliness
    149
  • 1.3 Removing and installing intake manifold
    149
  • 1.6 Assembly overview - air filter
    153
  • 1.7 Assembly overview - unit injector
    155
  • 1.8 Removing and installing unit injector
    156
  • 1.9 Checking and adjusting position of pump plungers in unit injectors
    158
  • 1.10 Renewing O-rings for unit injectors
    160
  • 2 Engine control units
    163
  • 2.1 Reading and clearing fault memory of engine control units
    163
  • 2.2 Adapting functions and components
    164
  • 2.3 Engine control units
    165
  • Exhaust system
    169
  • 1 Removing and installing parts of exhaust system
    169
  • 1.1 Assembly overview - exhaust manifold
    170
  • 1.4 Metering pumps for post-injection (engine code BWF)
    174
  • 1.5 Assembly overview - silencer with mountings (vehicles with engine codes AYH and BKW)
    175
  • 1.6 Assembly overview - silencer with mountings (vehicles with engine codes BLE and BWF)
    177
  • 2 Exhaust gas recirculation system
    180
  • 2.1 Safety precautions
    180
  • 2.2 Rules for cleanliness
    180
  • 2.3 Assembly overview - exhaust gas recirculation (vehicles with engine codes AYH, BKW)
    181
  • 2.4 Assembly overview - exhaust gas recirculation (vehicles with engine codes BLE and BWF)
    182
  • 2.6 Removing and installing bypass flap with exhaust gas recirculation cooler
    186
  • 2.7 Vacuum hose schematic diagram (vehicles with engine codes AYH, BKW)
    187
  • 2.9 Checking exhaust gas recirculation valve (vehicles with engine codes AYH, BKW)
    189
  • Glow plug system
    191
  • 1 Glow plugs
    191
  • 1.1 Removing, installing and checking glow plugs (vehicles with engine code AYH)
    191
Manufacturer's designation 10-cylinder diesel engine
Manufacturer Volkswagen
Suitable for Touareg (2003 - 2007)
Suitable car types 7L
Engine code AYH, BKW, BLE
Category Reparaturanleitung

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