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  • Examplepage for repair manual 8-cylinder injection engine (direct injection)
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  • Examplepage for repair manual 3 8-cylinder injection engine (direct injection)

8-cylinder injection engine (direct injection)

For Touareg

Original Volkswagen repair manual


25,44 €7% VAT incl.

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Immediately available for download

Language: English

Digital PDF file

8.758 KB

326 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Cylinder block - belt pulley end, Crankshaft, Pistons and conrods, Valve gear, Safety precautions, Activated charcoal filter system, Injection system (vehicles with aluminium intake manifold), Assembly overview - air filter and Engine control unit J623. Show more
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Repair manual Touareg 8-cylinder injection engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Technical data
    1
  • 1.1 Engine data
    1
  • 1.2 Numbering of cylinders
    2
  • Removing and installing engine
    3
  • 1 Removing and installing engine
    3
  • 1.1 Removing engine
    4
  • Crankshaft group
    22
  • 1 Cylinder block - belt pulley end
    22
  • 1.1 Assembly overview - poly V-belt drive for alternator
    22
  • 1.2 Removing and installing poly V-belt
    23
  • 1.3 Removing and installing vibration damper
    24
  • 1.4 Renewing crankshaft oil seal - belt pulley end
    25
  • 2 Cylinder block - gearbox end
    28
  • 2.1 Assembly overview - drive plate
    28
  • 2.2 Removing and installing drive plate
    28
  • 2.3 Renewing crankshaft oil seal on timing chain end
    29
  • 2.4 Assembly overview - timing chain covers
    31
  • 2.5 Removing and installing left and right timing chain covers
    32
  • 2.6 Removing and installing lower timing chain cover
    35
  • 2.7 Assembly overview - camshafts timing chains
    39
  • 2.8 Removing camshaft timing chains from camshafts
    42
  • 2.9 Removing and installing camshaft timing chains
    49
  • 2.10 Assembly overview - drive chain for valve gear
    52
  • 2.11 Removing and installing drive chain for valve gear
    54
  • 2.12 Assembly overview - drive chain for auxiliary drives
    56
  • 2.13 Removing and installing drive chain for auxiliary drives
    56
  • 2.14 Assembly overview - auxiliary drives
    58
  • 2.15 Renewing oil seals for auxiliary drives
    59
  • 2.16 Removing and installing spur gear drive
    61
  • 3 Crankshaft
    66
  • 3.1 Assembly overview - crankshaft
    66
  • 3.2 Allocation of main bearing shells for new crankshafts
    69
  • 3.3 Allocation of main bearing shells for used and re-machined crankshafts
    71
  • 3.4 Bearing bush for torque converter
    71
  • 3.5 Crankshaft dimensions
    72
  • 3.6 Measuring axial clearance
    72
  • 3.7 Measuring radial clearance
    72
  • 4 Pistons and conrods
    74
  • 4.1 Assembly overview - pistons and conrods
    74
  • 4.2 Piston and cylinder dimensions
    77
  • 4.3 Measuring radial clearance of conrods
    77
  • Cylinder head, valve gear
    79
  • 1 Cylinder head
    79
  • 1.1 Assembly overview - cylinder head
    79
  • 1.2 Removing and installing left cylinder head cover
    80
  • 1.3 Removing and installing cylinder head cover (right side)
    82
  • 1.4 Removing and installing cylinder head
    84
  • 1.5 Checking compression
    91
  • 2 Valve gear
    94
  • 2.1 Assembly overview - valve gear
    94
  • 2.2 Checking axial clearance of camshafts
    96
  • 2.3 Removing and installing camshafts
    97
  • 2.4 Renewing valve stem seals
    105
  • 2.5 Checking supporting elements with hydraulic clearance compensation
    109
  • 2.6 Valve dimensions
    111
  • 2.7 Checking valve guides
    111
  • 2.8 Checking valves
    112
  • Lubrication
    113
  • 1 Parts of lubrication system
    113
  • 1.1 Assembly overview - oil pump, lower part of sump
    113
  • 1.2 Removing and installing lower part of sump
    116
  • 1.3 Removing and installing oil pump
    120
  • 1.4 Assembly overview - upper part of sump
    123
  • 1.5 Removing and installing upper part of sump
    124
  • 1.6 Assembly overview - oil retention valve and spray nozzle valve
    129
  • 1.7 Removing and installing oil retention valve and spray nozzle valve
    130
  • 1.8 Assembly overview - oil filter housing
    132
  • 1.9 Removing and installing oil filter housing
    133
  • 1.10 Removing and installing oil cooler
    133
  • 1.11 Checking oil pressure and oil pressure switch F1
    134
  • 1.12 Checking oil level
    137
  • Cooling
    138
  • 1 Parts of cooling system
    138
  • 1.1 Assembly overview - radiator
    139
  • 1.2 Assembly overview - radiator fan
    140
  • 1.3 Removing and installing radiator fan mounting with fans
    141
  • 1.4 Assembly overview - parts of cooling system, body side
    141
  • 1.5 Coolant hose schematic diagram
    143
  • 1.6 Draining and filling coolant
    144
  • 1.7 Removing and installing radiator
    150
  • 1.8 Assembly overview - coolant pipes
    151
  • 1.9 Assembly overview - coolant pump and thermostat
    168
  • 1.10 Removing and installing coolant pump
    169
  • 1.11 Removing and installing recirculation pump V55
    171
  • 1.12 Removing and installing map-controlled engine cooling thermostat F265
    171
  • 1.13 Removing and installing coolant temperature sender G62
    172
  • 1.14 Checking cooling system for leaks
    174
  • Fuel supply system
    176
  • 1 Safety precautions
    176
  • 1.1 Safety precautions when working on fuel supply system
    176
  • 1.2 Releasing pressure in high-pressure area
    177
  • 2 Parts of fuel supply system
    179
  • 2.1 Rules for cleanliness
    180
  • 2.2 Assembly overview - fuel tank with attachments
    181
  • 2.3 Assembly overview - fuel filter
    183
  • 2.4 Renewing fuel filter
    183
  • 2.5 Emptying fuel tank
    185
  • 2.6 Removing and installing fuel gauge sender and suction-jet pumps
    188
  • 2.7 Removing and installing fuel delivery unit and fuel gauge sender
    190
  • 2.8 Removing and installing fuel tank with attached components
    193
  • 2.9 Checking fuel pump
    197
  • 3 Electronic power control (EPC)
    206
  • 3.1 Function of EPC system
    206
  • 3.2 Assembly overview - accelerator
    206
  • 4 Activated charcoal filter system
    208
  • 4.1 Assembly overview - activated charcoal filter system
    208
  • 4.2 Checking fuel system for leaks
    208
  • 5.1 Assembly overview - activated charcoal filter system
    213
  • 5.2 Checking fuel system for leaks
    215
  • 6 Activated charcoal filter system (vehicles for USA and Canada from 08.2006)
    222
  • 6.1 Assembly overview - activated charcoal filter system
    223
  • 6.2 Checking fuel system for leaks
    224
  • Mixture preparation - injection
    232
  • 1 Injection system (vehicles with aluminium intake manifold)
    232
  • 1.1 Assembly overview - intake manifold
    232
  • 1.2 Removing and installing intake manifold
    234
  • 1.3 Assembly overview - injectors and fuel rail
    242
  • 1.4 Removing and installing injectors
    244
  • 1.5 Assembly overview - high-pressure pump
    249
  • 1.6 Removing and installing high-pressure pump
    250
  • 1.7 Rules for cleanliness
    252
  • 1.8 Technical data
    252
  • 2 Injection system (vehicles with plastic intake manifold)
    254
  • 2.1 Assembly overview - intake manifold
    254
  • 2.2 Removing and installing intake manifold
    255
  • 2.3 Assembly overview - injectors and fuel rail
    258
  • 2.4 Removing and installing injectors
    260
  • 2.5 Assembly overview - high-pressure pump
    264
  • 2.6 Removing and installing high-pressure pump
    266
  • 2.7 Vacuum hose schematic diagram
    268
  • 2.8 Assembly overview - fuel pipes and fuel rail
    269
  • 2.9 Rules for cleanliness
    269
  • 2.10 Technical data
    270
  • 3 Assembly overview - air filter
    271
  • 3.1 Removing and installing lower part of air filter
    271
  • 3.2 Removing and installing air intake pipe
    273
  • 3.3 Disconnecting connecting line to air suspension compressor
    274
  • 4 Engine control unit J623
    276
  • 4.1 Removing and installing anti-theft engine control unit J623
    276
  • 4.2 Removing and installing engine control unit J623
    278
  • Exhaust system
    279
  • 1 Parts of exhaust system
    279
  • 1.1 Assembly overview - exhaust manifold
    279
  • 1.2 Removing and installing left exhaust manifold
    280
  • 1.3 Removing and installing right exhaust manifold
    281
  • 1.4 Assembly overview - catalytic converters, Lambda probes and attachments
    282
  • 1.5 Removing and installing left main catalytic converter
    286
  • 1.6 Removing and installing left starter catalytic converter
    287
  • 1.7 Removing and installing right main catalytic converter
    290
  • 1.8 Removing and installing right starter catalytic converter
    291
  • 1.9 Assembly overview - silencers with mountings
    294
  • 1.10 Separating front and rear silencers
    296
  • 1.11 Aligning exhaust system free of stress
    297
  • 1.12 Renewing tailpipes
    298
  • 2 Secondary air system
    300
  • 2.1 Assembly overview - secondary air system
    300
  • 2.2 Removing and installing secondary air pump
    302
  • 2.3 Checking combination valve for secondary air system
    302
  • 2.4 Removing and installing combination valve for secondary air system
    303
  • 3 Secondary air system (vehicles for USA and Canada from 06.2007)
    304
  • 3.1 Assembly overview - secondary air system
    304
  • 3.2 Removing and installing secondary air pump
    306
  • 3.3 Checking combination valve for secondary air system
    307
  • 3.4 Removing and installing combination valve for secondary air system
    308
  • Ignition system
    310
  • 1 Ignition system
    310
  • 1.1 Assembly overview - cylinder bank 1
    310
  • 1.2 Assembly overview - cylinder bank 2
    313
  • 1.3 Safety precautions
    316
  • 1.4 Removing and installing ignition coils with output stage
    316
  • 1.5 Removing and installing engine speed sender G28
    318
  • 1.6 Removing and installing knock sensors
    319
  • 1.7 Test data, spark plugs
    320
Manufacturer's designation 8-cylinder injection engine (direct injection)
Manufacturer Volkswagen
Suitable for Touareg (2003 - 2007)
Suitable car types 7L
Engine code BAR
Category Reparaturanleitung

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