10-cylinder diesel engine Volkswagen R GmbH

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
  12
• 1.3 Securing engine on engine and gearbox support VAS 6095
  13
• 1.4 Notes on installing
  14
• Crankshaft group
  16
• 1 Dismantling and assembling engine
  16
• 1.1 Assembly overview - components in the V space
  16
• 1.2 Assembly overview - gear train assembly
  18
• 1.3 Removing and installing gear train assembly
  19
• 1.4 Removing and installing engine mounting and engine support (left and right)
  22
• 1.5 Removing and installing drive plate
  23
• 2 Balancer shaft
  25
• 2.1 Assembly overview - balancer shaft
  25
• 3 Crankshaft
  26
• 3.1 Assembly overview - crankshaft
  26
• 3.2 Removing and installing bearing saddle for crankshaft
  27
• 3.3 Crankshaft dimensions
  29
• 4 Sealing flange, seals and vibration damper
  30
• 4.1 Assembly overview - front sealing flange and vibration damper
  30
• 4.2 Renewing crankshaft oil seal, vibration damper end
  31
• 4.3 Renewing crankshaft oil seal - engine timing end
  32
• 4.4 Renewing alternator shaft oil seal
  34
• 5 Timing housing
  37
• 5.1 Assembly overview - timing housing
  37
• 6 Pistons and conrods
  39
• 6.1 Assembly overview - pistons and conrods
  39
• 6.2 Checking piston projection at TDC
  40
• 6.3 Piston and cylinder dimensions
  40
• 6.4 Piston rings, cylinder bore and piston installation position
  41
• Cylinder head, valve gear
  43
• 1 Cylinder head
  43
• 1.1 Assembly overview - cylinder head
  43
• 1.2 Removing and installing camshaft compensating gear and drive gear wheel
  45
• 1.3 Checking valve timing
  49
• 1.4 Adjusting valve timing
  51
• 1.5 Removing and installing cylinder heads
  53
• 1.6 Checking compression
  55
• 2 Valve gear
  58
• 2.1 Assembly overview - valve gear
  58
• 2.2 Reworking valve seats
  61
• 2.3 Checking valve guides
  62
• 2.4 Renewing valve stem seals
  63
• 2.5 Removing and installing camshaft
  65
• Lubrication
  67
• 1 Engine oil
  67
• 1.1 Oil capacities
  67
• 1.2 Checking engine oil level
  67
• 2 Oil sump
  68
• 2.1 Assembly overview - sump
  68
• 2.2 Applying sealant
  71
• 3 Oil pump, oil filter housing and oil pressure
  72
• 3.1 Assembly overview - oil pump
  72
• 3.2 Assembly overview - oil filter housing
  74
• 3.3 Removing and installing oil filter housing
  75
• 3.4 Checking oil pressure and oil pressure switch
  75
• 3.5 Checking oil pressure at front of engine
  77
• Cooling
  79
• 1 Parts of cooling system
  79
• 1.1 Assembly overview - radiator
  80
• 1.2 Assembly overview - fans
  81
• 1.3 Parts of cooling system - body side
  82
• 1.4 Parts of cooling system - engine side and at top
  83
• 1.5 Parts of alternator and fuel cooling system
  84
• 1.6 Fitting location of continued coolant circulation pump and fuel cooling pump
  85
• 1.7 Assembly overview - thermostat housing
  85
• 1.8 Assembly overview - coolant pump
  87
• 1.9 Coolant hose schematic diagram
  88
• 1.10 Draining and filling coolant
  89
• 1.11 Removing and installing fan support
  92
• 1.12 Removing and installing radiator
  92
• 1.13 Removing and installing coolant connection
  93
• 1.14 Removing and installing coolant pump
  94
• Fuel supply system
  97
• 1 Parts of fuel supply system
  97
• 1.1 Safety precautions when working on fuel supply system
  98
• 1.2 Rules for cleanliness
  98
• 1.3 Assembly overview - fuel tank with attachments
  99
• 1.4 Assembly overview - fuel filter
  101
• 1.5 Schematic diagram of fuel lines and components in fuel tank
  103
• 1.6 Schematic diagram of fuel hoses in engine compartment
  104
• 1.7 Emptying fuel tank
  105
• 1.9 Removing and installing fuel tank with attached components
  109
• 1.10 Checking fuel pumps
  113
• 1.11 Checking tandem pump and fuel pump
  114
• 1.12 Removing and installing tandem pump and fuel pump
  116
• 1.13 Assembly overview - accelerator mechanism
  118
• 2 Additive tank
  120
• 2.1 Safety precautions when working on additive tank
  120
• 2.2 Assembly overview - additive tank
  120
• 2.3 Removing and installing additive tank
  122
• Turbocharging/supercharging
  125
• 1 Charge air system with turbocharger
  125
• 1.1 Safety precautions
  125
• 1.2 Rules for cleanliness
  125
• 1.3 Installing hose connections with connector couplings
  126
• 1.4 Assembly overview - turbocharger
  127
• 1.5 Assembly overview - parts of charge air cooling
  129
• 1.6 Checking charge air system for leaks
  130
• Mixture preparation - injection
  132
• 1 Repairing diesel direct injection system
  132
• 1.1 Safety precautions
  132
• 1.2 Rules for cleanliness
  133
• 1.3 Removing and installing intake manifold
  133
• 1.4 Assembly overview - intake connecting pipe
  134
• 1.5 Assembly overview - air filter
  136
• 1.6 Assembly overview - unit injector
  138
• 1.7 Removing and installing unit injector
  139
• 1.8 Checking and adjusting position of pump plungers in unit injectors
  141
• 1.9 Renewing O-rings for unit injectors
  143
• 2 Engine control units
  145
• 2.1 Reading and clearing fault memory of engine control units
  145
• 2.2 Adapting functions and components
  146
• 2.3 Removing and installing engine control units
  147
• Exhaust system
  148
• 1 Removing and installing parts of exhaust system
  148
• 1.1 Assembly overview - exhaust manifold
  149
• 1.3 Assembly overview - silencers with mountings
  152
• 2 Exhaust gas recirculation system
  154
• 2.1 Safety precautions
  154
• 2.2 Rules for cleanliness
  154
• 2.3 Assembly overview - exhaust gas recirculation
  155
• 2.4 Assembly overview - bypass flap with exhaust gas recirculation cooler
  156
• 2.5 Removing and installing bypass flap with exhaust gas recirculation cooler
  158
• 2.6 Vacuum hose schematic diagram
  160
• Glow plug system
  162
• 1 Glow plugs
  162
• 1.1 Removing, installing and checking glow plugs
  162