Touareg 3.0L TDi 2010

2010 Volkswagen Touareg TDI
ENGINE 3.0 Liter - Crankshaft, Cylinder Block - Engine Code(s): CATA
ENGINE
3.0 Liter - Crankshaft, Cylinder Block - Engine Code(s): CATA
13 CRANKSHAFT, CYLINDER BLOCK

GENERAL INFORMATION
ENGINE
CAUTION: If large quantities of metal particles or other deposits such as those

caused by partial seizure of the crankshaft or connecting rod damage are
found in the engine oil, clean the oil passages thoroughly and replace the
oil cooler to prevent further damage.
The engine must not be set down on the oil pan, because the seal between
lower and upper oil pan is otherwise damaged.
NOTE: Secure the engine to the engine and transmission holder VAS 6095 with the
universal mounting VAS 6095/1 and the bracket for V6 TDI engine VAS 6095/1-4
when performing assembly work.
PISTON AND CONNECTING ROD
NOTE: Lubricate all bearing and contact surfaces before assembly work.
CRANKSHAFT
NOTE: Secure the engine on the engine and transmission holder VAS 6095 with the
universal mounting VAS 6095/1 and the bracket for V6 TDI engine VAS 6095/1-4
when performing assembly work.
Lubricate all bearing and contact surfaces before assembly work.
DESCRIPTION AND OPERATION
RIBBED BELT DRIVE OVERVIEW
lunes, 11 de enero de 2021 06:44:06

06:44:01 p. m. Page 1 © 2011 Mitchell Repair Information Company, LLC.
Fig. 1: Ribbed Belt Drive Overview

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
1. Ribbed Belt
Mark the running direction before removing. Reversing the running direction on a used belt can
destroy it.
Check for wear.
When installing, make sure it is seated correctly on the pulleys.
Removing and installing, refer to RIBBED BELT.
2. Bolt
20 Nm + 90° (1/4) additional turn
Always replace.
lunes, 11 de enero de 2021 06:44:01 p. m. Page 2 © 2011 Mitchell Repair Information Company, LLC.
Install with a shim, refer to RIBBED BELT DRIVE OVERVIEW.

3. Idler Pulley Cover
4. Generator
Removing and installing, refer to Removal and Installation .
To facilitate installing the generator, slightly push back the threaded bushings for the generator
bolts.
5. Bolt
22 Nm
6. Bolt
25 Nm
7. Idler Pulley
Note the installed position.
8. Bolt
40 Nm
9. Generator and Idler Pulley Bracket
Follow the tightening sequence, refer to Fig. 3.
10. Bolt
22 Nm
11. Idler Pulley
12. Bolt
22 Nm
13. Coolant Pump Pulley
Installed location: writing "front" indicates direction of travel.
Counter hold using the spanner wrench 3212 to remove.
14. Bolt
9 Nm
15. Coolant Pump
Removing and installing, refer to COOLANT PUMP .
16. Bolt
22 Nm
17. Bolt
22 Nm
18. Power Steering Pump
Installed position: writing "front" indicates direction of travel.
19. Power Steering Pump Pulley
Counter hold using the spanner wrench 3212 to remove.
20. Gasket
Always replace.
21. Accessory Bracket
22. Bolt
40 Nm
23. Bolt
25 Nm
Check for washers
24. A/C Compressor
Observe the alignment bushing -item 25- when installing.
25. Alignment Bushing
Ensure they are seated correctly in the bracket.
26. Bolt
25 Nm
27. Belt Tensioner
Pivot using a T60 TORX® socket.
28. Bolt
M10 bolt: 50 Nm +90° (1/4) additional turn.
M11 bolt: 60 Nm +90° (1/4) additional turn.
Always replace.
CAUTION: Differing threads in the cylinder block.
Before assembling, check whether the threads are M10 or M11.
Use the proper bolt size. The engine could be damaged.
29. Vibration Damper

Mark the vibration damper installed position.
Vibration Damper Threaded Connection
Fig. 2: Vibration Damper Connection

1 - 20 Nm + 90° (1/4) additional turn. Always replace.
2 - Shim, replace
3 - Vibration damper
Fig. 3: Generator Bracket Tightening Sequence

-- Install the generator bracket using the following steps:
1.: Install bolt -A- and tighten by hand.
2.: Install bolt -B- and tighten.
3.: Tighten bolt -A-.
4.: Install bolt -D- and tighten.
5.: Install bolt -C- and tighten.
DRIVE PLATE OVERVIEW
Fig. 4: Drive Plate Overview

1. Drive Plate
Removing and installing, refer to DRIVE PLATE.
2. Washer
Thickness: 3.4 mm
3. Bolt
30 Nm + 90° (1/4) additional turn.
Always replace.
5. Torque Converter Centering Bushing
6. Crankshaft Seal, Timing Chain Side

Removing and installing, refer to CRANKSHAFT SEAL, TIMING CHAIN SIDE.
7. Shim
Thickness: 1.5 mm
TIMING CHAIN COVERS OVERVIEW
Fig. 5: Timing Chain Covers Overview

1. Crankshaft Seal, Timing Chain Side

Removing and installing, refer to CRANKSHAFT SEAL, TIMING CHAIN SIDE.
Quantity: 2
3. Bolt
9 Nm
Note the tightening sequence, refer to TIMING CHAIN COVERS.
4. Left Timing Chain Cover
Removing and installing, refer to TIMING CHAIN COVERS.
5. Bolt
9 Nm
6. Gasket
Always replace.
7. Bolt
9 Nm
8. Bolt
9 Nm
9. Cap
10. O-ring
Always replace.
11. Right Timing Chain Cover
Removing and installing, refer to TIMING CHAIN COVERS.
12. Gasket
Always replace.
13. Bolt
9 Nm
Quantity: 2
15. Sealing Piece
Quantity: 2
16. Lower Timing Chain Cover
removing and installing, refer to TIMING CHAIN COVERS.
17. Bolt
M6 = 9 Nm
M8 = 22 Nm
BALANCE SHAFT OVERVIEW
Fig. 6: Balance Shaft Overview

1. Friction Bearing
2. Bolt
60 Nm
When loosening or tightening, use the diesel injection pump locking pin 3359 as a counter hold
tool.
3. Balance Weight (Timing Chain Side)
4. Bolt
9 Nm
5. Bearing End Bracket
6. Balance Weight (Belt Pulley Side)

7. Bolt
60 Nm
When loosening or tightening, use the diesel injection pump locking pin 3359 as a counter hold
tool.
8. Friction Bearing
9. Balance Shaft
Removing and installing, refer to BALANCE SHAFT.
TIMING MECHANISM DRIVE CHAIN OVERVIEW
Fig. 7: Timing Mechanism Drive Chain Overview
1. Drive Sprocket Pivot Pin

2. Bolt
45 Nm
3. Bolt
Always replace.
4. Bolt
Always replace.
5. Drive Sprocket Thrust Washer
6. Left Timing Chain Drive Sprocket
7. Timing Chain
Before removing, mark the direction of rotation using paint.
Removing and installing, refer to TIMING MECHANISM DRIVE CHAIN.
8. Guide Rail
9. Bolt
Always replace.
10. Bolt
Always replace.
11. Drive Sprocket Mounting Bracket
12. Thrust Washer
13. Right Timing Chain Drive Sprocket
14. Mounting Pin
12 Nm
15. O-ring
Always replace.
16. Chain Tensioner
17. Bolt
12 Nm
18. Tensioning Rail
19. Crankshaft
With sprockets.
20. Guide Rail
21. Mounting Pin

12 Nm
BALANCE SHAFT AND OIL PUMP CHAIN OVERVIEW
Fig. 8: Balance Shaft And Oil Pump Chain Overview

1. Drive Chain
Removing and installing, refer to BALANCE SHAFT AND OIL PUMP CHAIN.
2. Oil Pump Sprocket
Installed position: the side with the lettering on it faces the engine.
3. Bolt
62 Nm
If it is not possible to tighten the bolt to specification, remove the lower oil pan and the oil baffle
and counter hold the bolt with an open end wrench on the oil pump driveshaft.
4. Thrust Washer
5. Spring
6. Crankshaft
7. Bolt
23 Nm
8. Balance Shaft Sprocket
Installed position: the side with the lettering on it faces the transmission.
9. Bolt
9 Nm
10. Chain Tensioner
With guide rail.
11. Gasket
Always replace.
PISTONS AND CONNECTING ROD OVERVIEW
NOTE: Oil all bearing and contact surfaces before assembly work.
NOTE: Oil spray jet for piston cooling, refer to PISTONS AND CONNECTING ROD
OVERVIEW.
Fig. 9: Pistons And Connecting Rod Overview

1. Bolt
Always replace.
Lubricate the threads and contact surface.
Tighten to 30 Nm to measure radial play, do not tighten further.
Radial clearance, measuring. Refer to CONNECTING ROD RADIAL CLEARANCE,
CHECKING.
2. Connecting Rod Bearing Cap
Do not interchange.
Affiliation to the cylinder mark -B-, refer to PISTONS AND CONNECTING ROD
OVERVIEW.
Installed position: casting marks -A-.
3. Bearing Shells
Do not interchange used bearing shells (mark them).
Bearing shells that are worn down to the nickel layer must be replaced.
Radial clearance, measuring. Refer to CONNECTING ROD RADIAL CLEARANCE,
CHECKING.
When measuring radial clearance, tighten bolts -item 1- to 30 Nm but do not tighten further.
4. Connecting Rod
Only replace as set with the cap.
Affiliation to the cylinder mark -B-, refer to PISTONS AND CONNECTING ROD
OVERVIEW.
Installed position: casting marks -A-.
Axial play for each new connecting rod and cap pair: 0.20 to 0.44 mm
5. Circlip
6. Piston Pin
If tight, heat the piston to 60 °C (140 °F).
Remove and install using a pilot drift VW 222 A.
7. Piston
With the combustion chamber.
Mark the installed position and cylinder allocation, refer to PISTONS AND CONNECTING
ROD OVERVIEW.
Checking, refer to PISTONS AND CONNECTING ROD OVERVIEW.
Install with a piston ring compressor.
Replace if there are cracks on the piston shaft.
Piston and cylinder dimensions. Refer to PISTON AND CYLINDER DIMENSIONS.
Piston projection in Top Dead Center (TDC), checking. Refer to PISTON PROJECTION IN
TOP DEAD CENTER, CHECKING.
Cylinder bore, checking. Refer to PISTONS AND CONNECTING ROD OVERVIEW.
8. Piston Rings
Offset the gaps by 120°
Use piston ring pliers for removal and installation.
The mark "TOP" must face toward the piston head.
Checking ring gap, refer to PISTONS AND CONNECTING ROD OVERVIEW.
Checking piston ring groove clearance, refer to PISTONS AND CONNECTING ROD
OVERVIEW.
Oil Spray Jet for Piston Cooling
Fig. 10: Oil Spray Jet for Piston Cooling

1. Bolt - 9 Nm
2. Oil spray jet for cooling the piston and spray jet valve
Opening pressure: 1.3 bar.
Piston Ring Gap, Checking
Fig. 11: Checking Piston Ring Gap

-- Push the ring squarely from above down to approximately 15 mm from the bottom end of the cylinder. To do
this use a piston without rings.
Piston Ring
dimensions New Wear limit
in mm
1.
Compression 0.25 to 0.38 0.80
ring
2.
ring
Oil scraping
Max. 0.40 0.70
ring
Piston Ring Groove Clearance, Checking
Fig. 12: Piston Ring Groove Clearance, Checking

-- Clean the ring groove of piston before checking.
Piston Ring
dimensions New Wear limit
in mm
1.
ring
2.
0.020 to 0.090 0.115
Compression
ring
Oil scraping
0.020 to 0.090 0.115
ring
Piston, Checking
Fig. 13: Checking Piston

-- Measure approximately 10 mm from the lower edge at a 90° angle to the piston pin axis using an external
micrometer 75 to 100 mm.
Maximum deviation from nominal dimension: 0.05 mm.
Nominal dimension, refer to PISTON AND CYLINDER DIMENSIONS.
Cylinder Bore, Checking
Fig. 14: Checking Cylinder Bores

-- Using an internal dial gauge 50 to 100 mm, measure at 3 points in a diagonal sequence horizontally -A- and
vertically -B-.
Maximum deviation from nominal dimension: 0.08 mm.
Nominal dimension, refer to PISTON AND CYLINDER DIMENSIONS.
Piston Installed Position
Fig. 15: Piston, Installed Position

Installed position: arrow -1- on the piston head points toward the belt pulley side.
NOTE: Mark the installed position and assignment to the cylinder on the piston crown
of used pistons with chalk or a waterproof felt tip pen so they can be reinstalled
again.
Do not use a center punch or scribe, since the piston head coating will be
damaged.
Connecting Rod Marking
Fig. 16: Connecting Rod, Marking

-- Mark the connecting rod and connecting rod bearing cap in relation to each other before removing -arrow-.
NOTE: Only replace the connecting rod and cap as a set.
Do not interchange connecting rod bearings.
Fig. 17: Connecting Rod, Installed Position

The larger thrust flange on the connecting rod -arrow- faces the adjacent crankshaft bearing.
NOTE: The illustration shows the front connecting rod pair.
CRANKSHAFT OVERVIEW
CAUTION: If large quantities of metal particles or other deposits such as those

caused by partial seizure of the crankshaft or connecting rod damage are
found in the engine oil, clean the oil passages thoroughly and replace the
oil cooler to prevent further damage.
The engine must not be set down on the oil pan, because the seal between
the lower and upper oil pans is otherwise damaged.
NOTE: Secure the engine on the engine and transmission holder VAS 6095- using
the universal mounting VAS 6095/1- and the brackets VAS 6095/1-4- when
performing assembly work.
Oil all bearing and contact surfaces before assembly work.
Fig. 18: Crankshaft Overview

1. Crankshaft
Measuring axial play, refer to CRANKSHAFT AXIAL CLEARANCE, CHECKING.
Measuring radial clearance, refer to CRANKSHAFT RADIAL CLEARANCE, CHECKING.
Do not rotate the crankshaft when measuring radial play.
Crankshaft dimensions, refer to CRANKSHAFT DIMENSIONS.
Quantity: 2
Install into the cylinder block.

3. Guide Frame
Installing, refer to CRANKSHAFT OVERVIEW.
4. Bolt
Always replace.
Tightening sequence, refer to CRANKSHAFT OVERVIEW.
5. Thrust Washer
Only on the 3rd crankshaft bearing.
Lubricating grooves face outward.
Observe the locating point.
Measuring crankshaft axial clearance, refer to CRANKSHAFT AXIAL CLEARANCE,
CHECKING.
6. Bearing Shell
For the guide frame.
Install new bearing shells for the guide frame with the proper colored mark. Refer to
CRANKSHAFT OVERVIEW.
7. Torque Converter Centering Bushing
Refer to CRANKSHAFT OVERVIEW.
8. Fitting Pin
Make sure the crankshaft fits correctly.
9. Thrust Washer
Only on the 3rd crankshaft bearing.
Lubricating grooves face outward.
Observe the locating point.
Measuring crankshaft axial clearance, refer to CRANKSHAFT AXIAL CLEARANCE,
CHECKING.
10. Bearing Shell
For the cylinder block with oil groove.
Install new bearing shells for the cylinder block with the proper colored mark. Refer to
CRANKSHAFT OVERVIEW.
Guide Frame, Installing
Fig. 19: Guide Frame, Installing

-- Replace the bolts -1 through 16-.
-- Install the alignment bushings in the guide frame.
-- Tighten the guide frame bolts in the following sequence:
-- Tighten the bolts -1 through 16- to 30 Nm.
-- Tighten the bolts -1 through 16- an additional 90° (1/4) turn.
Allocation of Crankshaft Bearing Shells for the Cylinder Block
Fig. 20: Application Of Crankshaft Bearing Shells For Cylinder Block

Bearing shells with the correct thickness are allocated to the cylinder block by the factory. Colored dots on the
bearing shells serve for identifying bearing shell thickness.
-Arrow- points to belt pulley side.
Allocation of bearing shells to the cylinder block is identified with a letter by each bearing.
Color
Letter on Cylinder Block of
Bearing
R= Red
G= Yellow
B= Blue
Allocation of Crankshaft Bearing Shells for the Guide Frame
Fig. 21: Allocation of Crankshaft Bearing Shells for the Guide Frame
Bearing shells with the correct thickness are allocated to the guide frame by the factory. Colored dots on
the bearing shells serve for identifying bearing shell thickness.
Allocation of bearing shells to crankshaft is identified with a sequence of letters on the crankshaft side.
The prefix "1" -arrow- indicates color code for bearing 1.
Color
Letter on Crankshaft of
Bearing
R= Red
G= Yellow
B= Blue
Torque Converter Bushing
Fig. 22: Torque Converter Centering Bushing

NOTE: Partial and replacement engines, new as well as replacement crankshafts are
delivered without the bushing -arrow-. The bushing must be installed before
installing the drive plate.
SPECIFICATIONS
CRANKSHAFT DIMENSIONS
Reconditioning Dimension
Crankshaft Journal Diameter Connecting Rod Journal Diameter
in mm
Basic dimension 65.00 - 0.022 - 0.042 60.00 - 0.022 - 0.042
PISTON AND CYLINDER DIMENSIONS
Cylinder Bore
Reconditioning Dimension in mm Piston Diameter
Diameter
82.939 to 82.951
Basic dimension (1) 83.006 to 83.014
82.979 to 82.991
Repair stage (1) 83.046 to 83.054
(1) Measurement does not include the graphite coating (thickness = 0.02 mm). The graphite coating
wears off.
FASTENER TIGHTENING SPECIFICATIONS
Component Fastener Size Nm
Air Conditioning Compressor Bolt - 25

Air Conditioning Compressor and Power Steering
- 40
Pump Bracket Bolt
Balance Shaft Bearing End Bracket to Cylinder
- 9
Block Bolt
Balance Shaft and Oil Pump Chain Tensioner Bolt - 9
Balance Shaft Sprocket Bolt - 23
Balance Weight to Balance Shaft Bolt - 60
Connecting Rod Bolt (1) - 30 + 90°
Coolant Pump Bolt - 9
Coolant Pump Pulley Bolt - 22
Drive Sprocket Mounting Bracket Bolt (1) - 5 + 90°
Drive Sprocket Pivot Pin Bolt - 45
Drive Sprocket Thrust Washer Bolt (1) - 5 + 90°
Drive Plate Bolt (1) - 30 + 90°
Generator to Generator and Idler Pulley Bracket
- 22
Bolt
Generator and Idler Pulley Bracket Bolt - 40
Guide Rail Bolt (1) - 5 + 90°
Guide Rail Mounting Pin (2) - 12
Idler Pulley to Generator and Idler Pulley Bracket
- 25
Bolt
Idler Pulley to Sealing Flange Bolt - 22
Oil Pump Drive Sprocket Bolt - 62
Oil Spray Jet (for piston cooling) Bolt - 9
Power Steering Pump Bolt - 22
Power Steering Pump Pulley Bolt - 22
Ribbed Belt Tensioner
-- Lower Bolt - 25
-- Upper Bolt - 40
Tensioning Rail Mounting Pin - 12
Timing Mechanism Drive Chain Tension Bolt - 12
Upper Timing Chain Cover Cap Bolt - 9
Vibration Damper Bolt (1) - 20 + 90°
(1) Always replace
(2) Insert using locking compound,
Guide Frame Bolt Tightening Sequence and Specification
Fig. 23: Guide Frame, Installing

-- Replace the bolts -1 through 16-.
-- Tighten the guide frame bolts in the following sequence:
-- Tighten the bolts -1 through 16- an additional 90° (1/4) turn.
Sealing Flange Bolt Tightening Sequence and Specification
Fig. 24: Identifying Sealing Flange -Arrow- Bolts -- Tighten Diagonally

-- Tighten the sealing flange -arrow- bolts in a diagonal sequence and in stages to 9 Nm.
Lower Timing Chain Cover Bolt Tightening Sequence and Specification
Fig. 25: Lower Timing Chain Cover Bolt Tightening Sequence and Specification
-- Tighten the bolts -1 through 9- from the inside toward the outside diagonally to 5 Nm.
-- Tighten the bolts -1 through 7- from the inside toward the outside diagonally to 9 Nm.
-- Tight the bolts -8 and 9- to 22 Nm.
Upper Left Timing Chain Cover Bolt Tightening Sequence and Specification
Fig. 26: Bolt Tightening Sequence

-- Tighten the bolts -1 through 3- in a diagonal sequence to 5 Nm.
-- Tighten the bolts -4- in a diagonal sequence to 9 Nm.
Upper Right Timing Chain Cover Bolt Tightening Sequence and Specification

-- Tighten the bolts -2 through 4- in a diagonal sequence to 5 Nm.
-- Tighten the bolts -1- in a diagonal sequence to 9 Nm.
DIAGNOSIS AND TESTING
PISTON PROJECTION IN TDC, CHECKING
Special tools and workshop equipment required
Measuring Bar VW 382/7

Magnetic Plate 50 mm Dia. VW 385/17
Dial Gauge 0-10 mm VAS 6079
Procedure
-- Install the dial gauge 0-10 mm VAS 6079 using the magnetic plate 50 mm dia. VW 382/7 and the measuring
bar VW 385/17.
Fig. 28: Identifying VW 382/7 And Measuring Bar VW 385/17

-- Measure the projection of each piston at two points -1-.
Piston Projection Above the Cylinder Block

Identification Holes
Upper Edge
0.39 to 0.49 mm 1
0.49 to 0.54 mm 2
0.54 to 0.65 mm 3
Cylinder Head Gasket Identification
Fig. 29: Cylinder Head Gasket Identification

-Arrow 1- : holes
-Arrow 2- : part number
NOTE: The cylinder head gaskets for the left and right cylinder head cannot be
interchanged because they each have a different shape.
CONNECTING ROD RADIAL CLEARANCE, CHECKING
Plastigage®
Procedure
-- Remove the connecting rod bearing cap. Clean the bearing cap and journal.
-- Place the Plastigage® over the entire width of the bearing journal or in the bearing shell.
-- Install the connecting rod bearing cap and tighten the bolts to 30 Nm. Do not rotate the crankshaft.
-- Remove the bearing cap again.
-- Compare the width of the Plastigage® with the measuring scale:
Radial clearance, new: 0.015 to 0.062 mm

Radial clearance wear limit: 0.12 mm
-- Replace the connecting rod cap bolts.
AXIAL CLEARANCE, CHECKING
Dial Gauge Holder VW 387

Procedure
Fig. 30: Attaching Dial Indicator VAS 6079 Together With Dial Gauge Holder VW 387 To Cylinder
Block And Setting Indicator Against Crankshaft Counterweight
-- Attach the dial gauge to the cylinder block using dial gauge holder VW 387 and position it against the
crankshaft counterweight.
-- Press the crankshaft against the dial indicator by hand, set the indicator to "0".
-- Press the crankshaft off the dial indicator and read the value:
Axial play new: 0.090 to 0.215 mm

Axial play wear limit: 0.280 mm
RADIAL CLEARANCE, CHECKING
Plastigage®
Procedure
NOTE: Do not interchange used bearing shells.
-- Remove the guide frame and clean the journals.
-- Place the Plastigage® over the entire width of the bearing journal or in the bearing shells.
The Plastigage® must rest in the center of the bearing shell.
-- Install the guide frame and tighten the bolts to 30 Nm. Do not rotate the crankshaft.
-- Remove the guide frame again.
-- Compare the width of the Plastigage® with the measuring scale:
Radial clearance, new: 0.018 to 0.045 mm

REMOVAL AND INSTALLATION
RIBBED BELT
Removing
NOTE: Before removing the ribbed belt, mark the running direction on it with chalk or a
felt tip pen. A reversed running direction can cause damage to the belt under
operating conditions.
-- Remove noise insulation panel. Refer to Description and Operation .
Remove the left charge air pipe. Refer to CHARGE AIR COOLER HOSES/PIPES
-- Rotate the belt tensioner in the -direction of the arrow- using a ratchet with a T60 TORX® socket to release
the tension from the ribbed belt.
Fig. 31: Rotating Belt Tensioner In -Direction Of Arrow-

-- Remove the ribbed belt from the tensioner.
Installing
NOTE: Ensure, before installing the ribbed belt, that all ancillaries (generator, Air
Conditioning (A/C) compressor, power steering pump) are secured tightly.
Check the idler pulleys for ease of movement
If reinstalling the old belt, note the previously marked direction of belt rotation
and be sure that it is seated correctly on the pulleys.
-- Rotate the tensioner in the -direction of the arrow- using a ratchet with a T60 TORX® socket.
Fig. 32: Rotating Belt Tensioner In -Direction Of Arrow-

-- Route the ribbed belt as shown.
Vehicles Without an Additional Idler Pulley
Fig. 33: Identifying Ribbed Belt Components

1. Generator
2. Idler roller
3. Idler roller
4. Coolant pump pulley

5. Power steering pump pulley
6. A/C compressor pulley
7. Ribbed belt tensioner
8. Vibration damper
with an Additional Idler Roller
Fig. 34: Identifying Ribbed Belt Components With An Additional Idler Pulley
1. Generator pulley
2. Idler roller
3. Idler roller
4. Coolant pump pulley
5. Idler roller
6. Power steering pump pulley
7. A/C compressor pulley
8. Ribbed belt tensioner
9. Vibration damper
Continuation for All
-- Install the left charge air pipe. Refer to CHARGE AIR COOLER HOSES/PIPES .
After completing the repairs always:
-- Start the engine and check the belt running direction.
CRANKSHAFT SEAL, BELT PULLEY SIDE
Oil Seal Extractor T40019

Assembly Device T40048
Removing
-- Remove the ribbed belt. Refer to RIBBED BELT.
-- Remove the vibration damper.
-- Install the inner part of the oil seal extractor T40019 flush with the outer part and secure using the knurled
thumb screw.
Fig. 35: Installing Inner Part Of Oil Seal Extractor T40019

-- Lubricate the threaded head of the seal remover, place against the seal, and with strong force screw into the
seal as far as possible.
-- Loosen the knurled thumb screw and turn the inner portion against the crankshaft until the seal is pulled out.
-- Secure the seal remover in a vice on the flat spots. Remove the seal using pliers
-- Clean the running and sealing surface.
Installing
-- Install the assembly device T40048/1 onto the pull sleeve T40048/2 and slide the seal -1- onto the pull sleeve
T40048/2.
Fig. 36: Inserting Assembly Device T40048/1 Onto Pull Sleeve T40048/2 And Slide Seal Onto Pull Sleeve
-- Remove the assembly device T40048/1.
-- Place the pull sleeve T40048/2 on the crankshaft and slide the seal -1- into the sealing surface on the engine.
Fig. 37: Placing Pull Sleeve T40048/2 On Crankshaft And Slide Seal -1- Into Sealing Surface On Engine
NOTE: The pull sleeve T40048/2 remains on the crankshaft for installation.
-- Position the assembly adapter T40048/4 (installation depth: 5 mm) on the crankshaft with 2 M8 x 55 mm
bolts -arrows-.
Fig. 38: Positioning Assembly Adapter T40048/4 On Crankshaft With 2 - M8 x 55 mm Bolts -Arrows-
-- Install the bolts by hand.
-- Tighten each bolt 1/2 rotation by alternating sides to press in the seal until it is seated.
-- Install the vibration damper.
-- Install the ribbed belt. Refer to RIBBED BELT.
SEALING FLANGE, BELT PULLEY SIDE
Spanner Wrench 3212

Hand Drill with Plastic Brush Attachment
Protective Eyewear
Silicone Sealant D 176 404 A2
Removing
-- Remove the ribbed belt. Refer to RIBBED BELT.
-- Remove the vibration damper.

-- Remove the coolant pump pulley. When loosening the bolts -arrows- use spanner wrench 3212 to counter
hold.
Fig. 39: Identifying Spanner Wrench 3212 And Bolts -Arrows-

-- Pry the cap off the idler pulley.
Fig. 40: Identifying Bolt -Arrow- And Idler Pulley

-- Remove the bolt -arrow- and remove the idler pulley from the sealing flange.
-- Remove the noise insulation retainers -arrows- on the front sealing flange.
Fig. 41: Noise Insulation Retainers

-- Loosen the nut on the coolant pipe.
-- Pry the tab upward out of the coolant pipe.
-- Remove the sealing flange bolts.
Fig. 42: Removing Front Sealing Flange First, At Right -Arrow 1-, Then At Left -Arrow 2-
-- Remove the front sealing flange first, at the right -arrow 1-, then at the left -arrow 2-.
-- Drive out the seal from the removed flange.
Installing
NOTE: Replace gaskets and O-rings.
-- Remove the sealant from the groves on the sealing flange and from the sealing surfaces.
WARNING: Wear safety glasses.
-- Remove sealant residue from the sealing flange and the cylinder block or upper oil pan with a rotating plastic
brush.
Fig. 43: Identifying Rotating Plastic Brush To Remove Sealant Residue From Sealing Flange, Cylinder
Block And Upper Part Of Oil Pan
-- Clean sealing surfaces so they are completely free of any oil or grease.
-- Cut the sealant tube nozzle at the front mark (nozzle diameter approximately 2 mm).
Fig. 44: Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 3 Mm)
-- Install the seals -2 and 4- and the O-rings -1 and 3-.
Fig. 45: Identifying Seals -2 & 4-, O-rings -1 & 3- And Sealant Bead
-- Apply a sealant bead -arrow- to the clean sealing surfaces on the sealing flange as illustrated.
The sealant bead must be 1.5 to 2.0 mm above the sealing surface.
NOTE: Sealant bead must not be thicker than specified, otherwise the sealant could get
into the oil pan and clog the oil pump strainer.
The front sealing flange must be installed within 5 minutes of being applied with
sealant.
-- Tighten the sealing flange bolts in a diagonal sequence and in stages. Tightening specification: 9 Nm.
Fig. 46: Identifying Sealing Flange -Arrow- Bolts -- Tighten Diagonally

-- Install the new seal. Refer to CRANKSHAFT SEAL, BELT PULLEY SIDE.
Further installation is performed in the reverse order of removal.
DRIVE PLATE
Counter Holder Tool 10-201
Removing
Fig. 47: Inserting Counter Hold Tool 10-201 To Loosen Bolts

Engine or transmission removed.
-- Mark the drive plate to the engine.
-- Install the counter holder tool 10-201 to loosen bolts.
-- Remove the drive plate.
-- Remove the shim behind it.
Installing
Installation is performed in the reverse order of removal, noting the following:
-- Place the 1.5 mm shim on the crankshaft.
-- Install the drive plate with 3.4 mm washer.
-- Secure with new bolts.
-- Reposition the counter holder tool 10-201 to tighten the bolts. Tightening specification: 30 Nm + 90° (1/4/)
additional turn.
CRANKSHAFT SEAL, TIMING CHAIN SIDE
Assembly Tool T10122
Pulling Hook T20143
Removing
Engine or transmission removed.
-- Remove the drive plate. Refer to DRIVE PLATE.
-- Pry out the seal using pulling hook T20143/2.
Fig. 48: Prying Out Sealing Ring Using Extractor Lever T20143/2
Installing
-- Drill an 8 mm hole -arrow 2- in the guide sleeve T10122/2 for the alignment sleeve.
Fig. 49: Drill An 8 Mm Hole -Arrow 2- In Guide Sleeve T10122/2 For Alignment Sleeve
-- Use the hole -arrow 1- in the washer as a template when drilling.
-- Clean the running and sealing surfaces.
Fig. 50: Identifying Seal, Sleeve T10122/1 And Assembly Tool T10122/2
-- Install the assembly device T10122/1 to the pull sleeve T10122/2 and slide the seal -A- onto the pull sleeve
T10122/2.
-- Remove the assembly device T10122/1.
-- Install the guide sleeve T10122/2 with the seal to the crankshaft.
Fig. 51: Installing Pull Sleeve T10122/2 With Sealing Ring Onto Crankshaft
-- Press in the seal all around evenly and flush using the pressure sleeve T10122/3.
Fig. 52: Pressing In Seal Evenly All Around Until It Reaches Stop Using T10122/3
-- Install the drive plate. Refer to DRIVE PLATE.
TIMING CHAIN COVERS

Used Oil Collecting and Extracting Device V.A.G 1782
Protective Eyewear
Silicone Sealant D 176 404 A2
Removing
NOTE: All cable ties opened or cut off during engine removal must be reinstalled at the
same locations during installation.
-- Drain the engine oil.
-- Remove the engine. Refer to ENGINE, REMOVING .
-- Separate the engine and transmission. Refer to ENGINE, REMOVING FROM SCISSOR LIFT TABLE .
-- Secure the engine to the assembly stand. Refer to ENGINE, SECURING TO ASSEMBLY STAND .
-- Remove the charge air pipe with the crankcase ventilation connecting hose.
-- Disconnect the connectors -1 and 2-.
Fig. 53: Disconnecting Connectors -1 And 2-

-- Remove the oil supply line banjo bolt -3-.
-- Disconnect the connector -4-.
Fig. 54: Removing Bolts -2 And 3- And Remove Bracket

-- Remove the bolts -2 and 3- and remove the bracket.
-- Remove the bolts -1-.
-- Disconnect the rear coolant pipe from the coolant hose -1-.
-- Remove the turbocharger oil return line -item 26- TURBOCHARGER OVERVIEW .
-- Remove the nuts and bolts -arrows- and the left intermediate pipe.
Fig. 55: Removing Intermediate Pipe Nuts -Arrows- And Pipe

-- Remove the bolts and nuts -1 through 4- and the right intermediate pipe.
Fig. 56: Identifying Bolts And Nuts -1 Through 4-

-- Remove the bolts -arrows- and the turbocharger.
Fig. 57: Removing Bolts -Arrows- And Turbocharger.

-- Remove the bolt -arrow- and the vacuum pump.
Fig. 58: Removing Bolt -Arrow- And Vacuum Pump

-- Remove the bolts -1 through 4- and remove the right timing chain cover.

-- Remove the bolts -1 through 4- and remove left timing chain cover.

-- Remove the bolts -1 through 9- and remove the lower timing chain cover.
-- Press the seal for the crankshaft out of the lower timing chain cover.
Installing
NOTE: Replace gaskets, seals and O-rings.
During installation, all cable ties must be reinstalled at the same location.
-- Remove the old sealant from the grooves in the timing chain covers and from the sealing surfaces.
-- Remove sealant residue on the timing chain covers and on the cylinder block or head with a rotating plastic
brush.
Fig. 62: Identifying Rotating Plastic Brush To Remove Sealant Residue From Sealing Flange, Cylinder
Block And Upper Part Of Oil Pan
-- Clean sealing surfaces so they are completely free of any oil or grease.
Fig. 63: Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 3 Mm)
NOTE: The sealant bead must not be thicker than specified or the sealant could enter
the oil pan and clog the oil pump strainer.
The timing chain covers must be installed within 5 minutes after applying
sealant.
-- Install the seals -2 and 5-.
Fig. 64: Installing Seals -2 And 5-

-- Apply the sealant beads -1 and 4- to the clean sealing surfaces on the lower timing chain cover as illustrated.
Completely fill the grooves on the sealing surfaces with sealant.

The bead of sealant around the holes -3 and 6- must be 1.5 to 2.0 mm thick.
-- Check whether the 2 alignment bushings are present in the cylinder block, install if necessary.
-- Position the lower timing chain cover and tighten the bolts as follows:
Step Tightening
-- Tighten
the bolts -1
through 9-
from the
I inside
toward the
outside
diagonally
to 5 Nm.
-- Tighten
the bolts -1
through 7-
II from the
inside
toward the
outside
diagonally
to 9 Nm.
-- Tight the
bolts -8
III
and 9- to
22 Nm.
-- Apply the sealant bead to the clean sealing surfaces on the left timing chain cover as illustrated.
Fig. 66: Applying Sealant Bead To Clean Sealing Surfaces

The groove -1- on the sealing surface must be completely filled with sealant.
-- Set the gasket -2- in place.
-- Apply a sealant bead with a 3 mm diameter to the transitions between the cylinder head and lower timing
chain cover -arrows- as illustrated.
Fig. 67: Applying Sealant Bead

CAUTION: The lubrication system could be plugged with excess sealant.
Do not apply the sealant bead thicker than specified.
-- Install the left timing chain cover and tighten the bolts as follows.
Fig. 68: Left Timing Chain Cover

NOTE: Replace the bolts that have been tightened to specification.
-- Tighten the bolts in 4 steps in the sequence shown:
Tightening
Step Bolts
Specifications
1. -1- 3 Nm
2. -2- 9 Nm
3. -1- 9 Nm
9 Nm in a
4. -3- diagonal
sequence
Right Timing Chain Cover
-- Apply the sealant bead to the clean sealing surfaces on the right timing chain cover as illustrated.
Fig. 69: Applying Sealant Bead To Clean Sealing Surfaces

The groove -1- on the sealing surface must be completely filled with sealant.
-- Set the gasket -2- in place.
-- Apply a sealant bead with a 3 mm diameter to the transitions between the cylinder head and lower timing
chain cover -arrows- as illustrated.
Fig. 70: Applying Sealant Bead

CAUTION: The lubrication system could be plugged with excess sealant.
Do not apply the sealant bead thicker than specified.
-- Position the right timing chain cover and tighten bolts as follows:

Tightening
Step Bolts
Specifications
1. -1- 3 Nm
2. -2- 9 Nm
3. -1- 9 Nm
9 Nm in a
4. -3- diagonal
sequence
Further installation is performed in reverse order.
BALANCE SHAFT
Used Oil Collecting and Extracting Device V.A.G 1782

Key T40049
3242
Removing
-- Drain the engine oil.
-- Remove the engine. Refer to ENGINE, REMOVING .
-- Separate the engine and transmission. Refer to ENGINE, REMOVING FROM SCISSOR LIFT TABLE .
-- Secure the engine to the assembly stand. Refer to ENGINE, SECURING TO ASSEMBLY STAND .
-- Remove the timing chain covers. Refer to TIMING CHAIN COVERS.
-- Remove the front sealing flange. Refer to SEALING FLANGE, BELT PULLEY SIDE.
-- Install the key T40049 to the crankshaft with two used bolts from the drive plate.
Fig. 72: Rotating Crankshaft To TDC Ignition Timing

-- Lay a cloth under the upper oil pan to collect any draining engine oil.
Fig. 73: Identifying Locking Bolt Of Upper Part Of Oil Pan

-- Remove the plug -arrow- from the upper oil pan.
WARNING: Do not turn the crankshaft while touching the Top Dead Center (TDC)
opening with a finger or injury could result.
-- Install the crankshaft holder 3242 in the hole (20 Nm). Rotate the crankshaft -1- back and forth slightly if
necessary to center the crankshaft holder 3242 completely.
Fig. 74: Installing Crankshaft Holder 3242 In Bore

-- Secure the balance shaft at the front of the engine using diesel injection pump locking pin 3359.
Fig. 75: Securing Balance Shaft Using Diesel Injection Pump Locking Pin 3359
-- Remove the bolt and the balance weight from the balance shaft.
-- Secure the balance shaft at the rear of the engine using diesel injection pump locking pin 3359.
Fig. 76: Securing Balance Shaft At Rear Of Engine Using Diesel Injection Pump Locking Pin 3359
-- Remove the bolts -arrows- and the n sprocket from the balance weight.
-- Remove the bolt -arrow- and the balance weight from the balance shaft.
Fig. 77: Identifying Rear Balance Shaft -Arrow- And Diesel Injection Pump Locking Pin 3359
-- Remove the bolts -arrows- and remove the balance shaft bearing end bracket.
Fig. 78: Identifying Bolts -Arrows- And Balance Shaft Bearing End Bracket
-- Remove the balance shaft from the cylinder block.
Installing

Secure the crankshaft in the TDC position using crankshaft holder 3242.
Installation is performed in reverse order.
TIMING MECHANISM DRIVE CHAIN
Locking Pin T40071

3.3 mm diameter drill bit
Removing
Transmission removed.
-- Remove the camshaft timing chains. Refer to CAMSHAFT TIMING CHAINS .
-- Remove the balance shaft and oil pump chain. Refer to BALANCE SHAFT AND OIL PUMP CHAIN.
-- Press the drive chain tensioner rail in the -direction of the arrow- and secure the chain tensioner using the
locking pin T40071.
Fig. 80: Pressing And Securing Drive Chain Tensioner Rail Using Locking Pin T40071
CAUTION: Risk of destroying due to reversed running direction of a used drive chain.
Mark the drive chain running direction with paint arrows for
reinstallation.
-- Remove the bolts -1- and the guide rail.
-- Remove the bolts -2 and 3- and remove the sprockets and drive chain.
Installing
Tightening specifications, refer to TIMING MECHANISM DRIVE CHAIN OVERVIEW.
Installation is performed in reverse order of removal, noting the following:
-- Install the balance shaft and oil pump chain. Refer to BALANCE SHAFT AND OIL PUMP CHAIN.
-- Install the camshaft timing chains. Refer to CAMSHAFT TIMING CHAINS .
-- Install the timing chain covers. Refer to TIMING CHAIN COVERS.
-- Fill the engine oil and check the oil level. Refer to Maintenance Procedures .
BALANCE SHAFT AND OIL PUMP CHAIN
Crankshaft Holder 3242

Diesel Injection Pump Locking Pin 3359
Key T40049
3.3 mm diameter drill bit
Removing
-- Install the key T40049 to the crankshaft using two used drive plate bolts -arrows-.
Fig. 81: Installing Key T40049 At Rear On Crankshaft Using 2 Old Bolts For Dual-Mass Flywheel

WARNING: Risk of injury when touching the Top Dead Center (TDC) hole with your
finger.
Do not rotate crankshaft -1-.

-- Install the crankshaft holder 3242 in the hole and tighten it to 20 Nm. Rotate the crankshaft back and forth
slightly to center the crankshaft holder 3242 completely, if necessary.
Fig. 84: Rotating Crankshaft Back And Forth Slightly To Center Crankshaft Holder 3242
CAUTION: Reversing the running direction on a used balance shaft and oil pump
chain can destroy it.
Paint arrows to mark the running direction of the chain so it can be

installed again.
-- Lock the rear balance shaft on the engine using the diesel injection pump locking pin 3359 and loosen the
bolts -arrows- for the balance shaft chain sprocket.
-- To protect against cuts, wrap the point and the cutting edges on an 3.3 mm diameter drill bit with insulating
tape.
Fig. 85: Identifying Chain Tensioner, Drive Chain, And Balance Shaft -3- Chain Sprocket
-- Push the chain tensioner guide rail in -direction of arrow- and lock the chain tensioner with the drill bit -4-.
-- Remove the bolts -1 and 2- and remove the chain tensioner, chain sprocket -3- for the balance shaft and the
chain.
Installing

Tightening specifications, refer to BALANCE SHAFT AND OIL PUMP CHAIN OVERVIEW.
Secure the crankshaft -1- in TDC position using crankshaft holder 3242.
-- Lock the rear balance shaft -arrow- to the engine using diesel injection pump locking pin 3359.
Fig. 87: Identifying Rear Balance Shaft -Arrow- And Diesel Injection Pump Locking Pin 3359
-- Install the chain tensioner with the chain and the drive chain and the balance shaft -3- chain sprocket.
Fig. 88: Identifying Chain Tensioner, Drive Chain, And Balance Shaft -3- Chain Sprocket
The slots in the chain sprocket -3- must be in the center position to the threaded holes in the balance shaft.
-- Tighten the chain tensioner bolts -1 and 2-.
NOTE: Ignore -item 4- and the -arrow-.
-- Install the chain sprocket bolts -arrows- loosely.
Fig. 89: Rotating Crankshaft Back And Forth Slightly To Center Crankshaft Holder 3242
It must still be possible to rotate the chain sprocket on the balance shaft and it must not tip.
-- Remove the drill bit from the alignment hole.
Fig. 90: Pushing Screwdriver In -Direction Of Arrow-

-- Push a screwdriver in the -direction of the arrow- against the chain tensioner guide rail while tightening the
chain sprocket bolts -1-.
-- Remove the diesel injection pump locking pin 3359 from the balance shaft.
The rest of the installation is performed in reverse order of removal, noting the following:
-- Install the timing chain covers. Refer to TIMING CHAIN COVERS.
-- Fill the engine oil and check the oil level. Refer to Maintenance Procedures .
SPECIAL TOOLS
Fig. 91: Dial Gauge Holder VW 387

Oil Seal Extractor T40019
Fig. 92: Oil Seal Extractor T40019

Assembly Device T40048
Fig. 93: Assembly Tool T40048

Spanner Wrench 3212
Fig. 94: Identifying Special Tool - Spanner Wrench 3212

Fig. 95: Counter-Holder Tool 10 - 201

Fig. 96: Identifying Installation Tool T10122

Pulling Hook T20143
Fig. 97: Extractor Hook T20143

Used oil Collecting and Extracting Device V.A.G 1782
Fig. 98: Identifying Oil Extractor V.A.G 1782

Locking Pin T40071
Fig. 99: Securing Pin T40071

Fig. 100: VW 382/7, VW 385/17 And VAS 6079

Measuring Bar VW 382/7

Magnetic Plate 50 mm Dia. VW 385/17
Fig. 101: Holder 3242, Pin 3359 And Key T40049


Diesel Injection Pump Locking Pin 3359
Key T40049
ENGINE 3.0 Liter - Cylinder Head, Valvetrain - Engine Code(s): CATA
ENGINE
3.0 Liter - Cylinder Head, Valvetrain - Engine Code(s): CATA
15 CYLINDER HEAD, VALVETRAIN

GENERAL INFORMATION
CYLINDER HEAD
NOTE: When installing a replacement cylinder head, all of the contact surfaces
between the supports, roller rocker levers and cam running surfaces on the
camshafts must be lubricated before installing the cylinder head cover.
The plastic protectors installed to protect the open valves must only be
removed immediately before installing the cylinder head.
When the cylinder head is replaced, all the coolant must also be replaced.
Remanufacturing diesel cylinder heads is not permitted.
DESCRIPTION AND OPERATION
CYLINDER HEAD COVER OVERVIEW
NOTE: The illustration shows the cylinder head cover for cylinder bank 2 (left side).
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06:44:41 p. m. Page 1 © 2011 Mitchell Repair Information Company, LLC.
Fig. 1: Identifying Cylinder Head Cover Overview

1. Bolt
9 Nm
2. Intake Tube Bracket
3. Bolt
9 Nm
4. O-ring
Always replace.
5. Oil Filler Neck
To remove, lift the tab, turn the oil filler neck to the left and remove it.
6. Seal
7. Seal
Replace if damaged or leaking.
8. Cap
9. Bolt
5 Nm
10. Fuel Return Line
Note the rules of cleanliness. Refer to CLEAN WORKING CONDITIONS .
11. High Pressure Line
Mark the assignment of the high pressure lines to the injector units.
Do not change the angles of the high pressure lines.
Tighten the high pressure line to the fuel rail, with a 19 mm wrench. Refer to TIGHTENING THE
HIGH PRESSURE LINE TO THE FUEL RAIL WITH A 19 MM WRENCH.
Tighten the high pressure line to the fuel rail, with a 14 mm wrench. Refer to TIGHTENING THE
HIGH PRESSURE LINE TO THE FUEL RAIL WITH A 14 MM WRENCH.
Tighten the high pressure line to the fuel injector. Refer to TIGHTENING THE HIGH
PRESSURE LINE TO THE FUEL INJECTOR WITH A 17 MM WRENCH.
12. O-ring
Always replace.
13. Nut
9 Nm
Tighten in an alternating sequence and in stages.
14. Tensioning Bracket
Replace when replacing the fuel injector.
15. Fuel Injector
Removing and installing, refer to CYLINDER HEAD COVER.
The high pressure line and tensioning bracket must be replaced to replace the injector.
16. O-ring
Always replace.
17. Copper Sealing Ring
Always replace.
18. Bolt
9 Nm
Replace if damaged or leaking
Tighten in a diagonal sequence and in steps.
19. Cylinder Head Cover
Removing and installing, refer to CYLINDER HEAD COVER.

20. Cylinder Head Cover Gasket
Replace if damaged or leaking.
TIGHTENING THE HIGH PRESSURE LINE TO THE FUEL RAIL WITH A 14 MM WRENCH
Fig. 2: Identifying High-Pressure Line (14 mm) At High Pressure Pump, Torque Wrench V.A.G 1331
With Ratchet V.A.G 1331/1 And Socket 14 mm 3150
-- Tighten the union nut for the high pressure line by hand.
-- Make sure the high pressure line is seated free of stress.
-- Tighten the high pressure line using torque wrench (5-50 Nm) V.A.G 1331 and socket 14 mm 3150.
Tightening specification: 25 Nm.
TIGHTENING THE HIGH PRESSURE LINE TO THE FUEL RAIL WITH A 19 MM WRENCH
Fig. 3: Identifying High Pressure Line To Fuel Rail And 19 mm Wrench

-- Tighten the high pressure line using torque wrench (5-50 Nm) V.A.G 1331 and tool insert AF 19 V.A.G
1331/5.
TIGHTENING THE HIGH PRESSURE LINE TO THE FUEL INJECTOR WITH A 17 MM WRENCH
Fig. 4: Identifying Torque Wrench V.A.G 1331T, Reversible V.A.G 1331/1 And Socket T40055
-- Tighten the high pressure line to the fuel injector using torque wrench (5-50 Nm) V.A.G 1331 with reversible
ratchet V.A.G 1331/1 and socket T40055.
CYLINDER HEAD OVERVIEW
NOTE: The illustration shows the cylinder head for cylinder bank 2 (left side).
Fig. 5: Identifying Cylinder Head Overview

1. Cylinder Head
Only set the removed cylinder head down on a foam pad. Otherwise the glow plugs can be
damaged.
Removing, refer to CYLINDER HEAD.
Check for distortion, refer to CHECKING CYLINDER HEAD FOR DISTORTION.
Do not rework diesel cylinder heads.
Installing, refer to INSTALLING
Replace the coolant after replacing.
2. Toothed Belt Drive Gear
Loosen and tighten the central bolt using Retainer 3036. Refer to LOOSENING AND
TIGHTENING THE CENTRAL BOLT FOR THE TOOTHED BELT DRIVE GEAR.
Remove using puller T10320. Refer to REMOVING THE TOOTHED BELT DRIVE GEAR.
3. Bolt
75 Nm
Loosen and tighten using Retainer 3036. Refer to LOOSENING AND TIGHTENING THE
CENTRAL BOLT FOR THE TOOTHED BELT DRIVE GEAR.
4. High Pressure Pump Toothed Belt Sprocket Seal
Replacing, refer to CAMSHAFT SEAL.
5. Bolt
9 Nm
6. Oil Dipstick Bracket
7. Coolant Ventilation Line
Illustration does not correspond to version in vehicle.
8. Banjo Bolt
15.5 Nm
9. Bolt
23 Nm
10. Fuel Rail
Do not change the angles of the high pressure lines.
Tighten the high pressure line to the fuel rail. Refer to one of the following:
Using a 14 mm wrench, refer to TIGHTENING THE HIGH PRESSURE LINE TO THE

FUEL RAIL WITH A 14 MM WRENCH.
Using a 19 mm wrench, refer to TIGHTENING THE HIGH PRESSURE LINE TO THE

FUEL RAIL WITH A 19 MM WRENCH.
11. Seals
Always replace.
12. Bolt
Always replace.
Observe the sequence for loosening, refer to LOOSEN THE CYLINDER HEAD BOLTS IN
THE SEQUENCE SHOWN.
Note the tightening sequence, refer to TIGHTEN THE CYLINDER HEAD BOLTS IN
SEQUENCE -1 THROUGH 8- AS FOLLOWS.
13. Oil Check Valve
Tighten to 25 Nm.
14. Lifting Eye
15. Bolt
M6 - 9 Nm
M8 - 23 Nm
16. Left Intermediate Pipe
Removing and installing, refer to LEFT INTERMEDIATE PIPE .
17. Bolt
Always replace.
Lubricate with hot bolt paste.
18. Gasket
Always replace.
19. Cylinder Head Gasket
Replacing, refer to CYLINDER HEAD.
Identification, refer to CYLINDER HEAD GASKET IDENTIFICATION.
Installed position: the part number points toward the cylinder head.
Replace the coolant after replacing.
LOOSENING AND TIGHTENING THE CENTRAL BOLT FOR THE TOOTHED BELT DRIVE GEAR
Fig. 6: Identifying Toothed Belt Drive Gear Bolt, Loosening and Tightening
-- Loosen and tighten the central bolt -1- using the Retainer 3036.
REMOVING THE TOOTHED BELT DRIVE GEAR
Fig. 7: Identifying Toothed Belt Drive Gear, Removing

-- Remove the toothed belt drive gear using the puller T10320.
CHECKING CYLINDER HEAD FOR DISTORTION
Fig. 8: Identifying Check Of Cylinder Head For Distortion

-- Check the cylinder head at multiple points for distortion, using a straightedge and feeler gauge.
Max. permissible distortion: 0.1 mm
CYLINDER HEAD GASKET IDENTIFICATION
Fig. 9: Identifying Cylinder Head Gasket Identification

1. Holes
2. Part number
NOTE: The cylinder head gaskets for the left and right cylinder head cannot be
VACUUM PUMP OVERVIEW
Fig. 10: Identifying Brake Booster Vacuum Pump Overview, Diesel Engine
1. Bolt
9 Nm
2. Vacuum Pump
3. Vacuum Hose
4. Bolt
5 Nm
5. O-ring
Always replace.
6. Intake Camshaft
7. O-ring
Always replace.
8. O-ring
Always replace.
VALVETRAIN OVERVIEW
Fig. 11: Identifying Valvetrain Overview

1. Valve
Replace if there are signs of wear on the stem and seating surface.
Do not grind, only lapping is permitted.
Mark the installed position for installation later.

Valve dimensions, refer to VALVE DIMENSIONS.
Valve guide checking, refer to VALVE GUIDE, CHECKING.
2. Cylinder Head
Removing and installing, refer to CYLINDER HEAD.
3. Valve Stem Seal
Replacing, refer to VALVE STEM SEALS.
4. Valve Spring
5. Valve Spring Plate
6. Valve Retainers
7. Camshaft Seal
Replacing, refer to CAMSHAFT SEAL.
8. Bolt
9 Nm
Observe the tightening sequence, refer to CAMSHAFTS.
9. Nut
9 Nm
Observe the tightening sequence, refer to CAMSHAFTS.
10. Guide Frame
With integrated camshaft bearings.
Removing and installing, refer to CAMSHAFTS.
11. Intake Camshaft
Checking axial play, refer to CAMSHAFT AXIAL CLEARANCE, CHECKING.
Check radial clearance using Plastigage® (roller rocker lever removed).
New radial clearance: 0.035 to 0.085 mm
Runout: maximum 0.01 mm
12. Exhaust Camshaft
Checking axial play CAMSHAFT AXIAL CLEARANCE, CHECKING.
Check radial clearance using Plastigage® (roller rocker lever removed).
New radial clearance: 0.035 to 0.085 mm
Runout: maximum 0.01 mm
13. Roller Rocker Lever
Mark the installed position.
Do not interchange.
Check the roller for ease of movement.

Lubricate the contact surface.
14. Hydraulic Lash Adjuster
Mark the installed position.
Checking, refer to HYDRAULIC LASH ADJUSTER, CHECKING.
Lubricate the running surfaces before installing.
15. Pressure Relief Valve
25 Nm
For lubricating points in the cylinder head.
LEFT CAMSHAFT TIMING CHAIN OVERVIEW
Fig. 12: Identifying Left Camshaft Timing Chain Overview

1. Thrust Washer
For the drive sprocket.
2. Bolt
Tightening specification -item 4- under TIMING MECHANISM DRIVE CHAIN
OVERVIEW .
3. Bolt
Always replace.
4. Guide Rail
5. Bolt
Always replace.
6. Chain Tensioner
For the left camshaft timing chain.
7. Bolt
23 Nm
8. Camshaft Chain Sprocket
For the intake camshaft.
Installed position: the side with the writing on it faces forward.
9. Left Camshaft Timing Chain
Removing from the camshafts, refer to CAMSHAFT TIMING CHAINS, REMOVING FROM
CAMSHAFTS.
Before removing, mark the direction of rotation with paint.
Removing and installing, refer to CAMSHAFT TIMING CHAINS.
10. Bolt
Always replace.
With a sleeve.
11. Tensioning Rail
12. Bracket
13. Bolt
Tightening specification -item 10- under TIMING MECHANISM DRIVE CHAIN
OVERVIEW .
14. Drive Sprocket
For the left camshaft timing chain.
RIGHT CAMSHAFT TIMING CHAIN OVERVIEW
Fig. 13: Identifying Right Camshaft Timing Chain Overview

1. Bolt
Tightening specification TIMING MECHANISM DRIVE CHAIN OVERVIEW => Bolt .
2. Mounting Pin
3. Right Camshaft Timing Chain
Removing from the camshafts, refer to CAMSHAFT TIMING CHAINS, REMOVING FROM
CAMSHAFTS.
Before removing, mark the direction of rotation with paint.
Removing and installing, refer to CAMSHAFT TIMING CHAINS.
4. Camshaft Chain Sprocket
For the intake camshaft.
Installed position: the side with the writing on it faces forward.
5. Bolt
23 Nm
6. Chain Tensioner
For the right camshaft timing chain.
7. Bolt
Always replace.
8. Thrust Washer
9. Drive Sprocket
For the right camshaft timing chain.
SPECIFICATIONS
VALVE DIMENSIONS
Fig. 14: Identifying Valve Dimensions

NOTE: Intake and exhaust valves must not be refaced by grinding. Only hand lapping
is permitted.
Dimension Intake Valve Exhaust Valve

Diameter a mm 28.60 to 28.80 26.70 to 26.90
Diameter b mm 5.968 to 5.982 5.958 to 5.972
c mm 97.25 to 97.45 97.35 to 97.55
a Angle° 45 45
WARNING: Worn sodium filled exhaust valves must not be scrapped without
first being properly treated.
Using a metal saw, the valves must be cut into two pieces between
the shaft center and valve head. While doing this, do not come into
contact with water. At the very most, throw 10 of the prepared valves
into a bucket filled with water. Then, move quickly away, because a
sudden chemical reaction will occur during which the sodium is
burnt away.
The treated parts may then be discarded through conventional
disposal channels.
FASTENER TIGHTENING SPECIFICATIONS
Component Fastener Size Nm

Camshaft Chain Sprocket to Camshaft Bolt - 23
Camshaft Timing Chain Tensioner Bolt (1) - 5 + 90°
Coolant Ventilation Line to Cylinder Head Banjo Bolt - 15.5
Cylinder Head Cover Bolt (2) - 9
Fuel Injector Cover Bolt - 5
Fuel Injector Tensioning Bracket Nut - 10
Fuel Rail to Cylinder Head Bolt - 23
Fuel Return Line to High Pressure Pump Banjo Bolt - 25
Fuel Supply Line to High Pressure Pump Banjo Bolt - 25
High Pressure Fuel Line to Fuel Injector Union Nut - 25
High Pressure Fuel Line to Fuel Rail Union Nut - 25
Hose Clamp, 13 mm Wide - 5.5
Intermediate Exhaust Pipe to Exhaust Manifold Bolt (1) - 30 + 90°
Intake Tube Bracket to Cylinder Head Bolt - 9
Left Timing Chain Guide Rail Bolt (1) - 5 + 90°
Left Timing Chain Tensioning Rail Bolt (1) - 5 + 90°
Lifting Eye Bolt
M6 9
M8 23
Oil Check Valve to Cylinder Head - 25
Oil Dipstick Tube Bracket Bolt - 9
Pressure Relief Valve to Cylinder Head - 25

Rear Toothed Belt Guard to Engine Bolt - 9
Right Coolant Pipe to Cylinder Head Bolt - 9
Throttle Valve Control Module with Intake Tube to Bracket Bolt - 9
Throttle Valve Control Module with Intake Tube to Connecting - 9
Pipe for Exhaust Gas Recirculation Valve Bolt
Throttle Valve Control Module with Intake Tube to Intake - 9
Manifold Bolt
Toothed Belt Drive Gear Bolt - 75
Vacuum Hose to Vacuum Pump Bolt - 5
Vacuum Pump to Cylinder Head Bolt - 9
Wiring Harness Bracket to Cylinder Head Bolt - 9
(1) Always replace
(2) Tighten in a diagonal sequence and in stages
Cylinder Head Bolt Tightening Sequence and Specifications
Fig. 15: Identifying Cylinder Head, Tightening Specifications and Sequence

-- Tighten the cylinder head bolts in the sequence -1 through 8- as follows:
-- Tighten the bolts to 35 Nm.
-- Tighten the bolts an additional 90° (1/4 turn).
-- Tighten the bolts an additional 90° (1/4 turn).
Guide Frame Bolt Tightening Sequence and Specification
Fig. 16: Identifying Left Cylinder Head Guide Frame, Tightening Specifications and Sequence
-- Tighten the guide frame bolts by hand evenly in the sequence -1 through 18- shown.
-- Tighten the guide frame bolts/nuts in the sequence -1 through 18- shown to 9 Nm.
DIAGNOSIS AND TESTING
COMPRESSION, CHECKING
Compression Tester V.A.G 1763
Procedure
Engine oil temperature approximately 80 °C (176 °F).

Battery voltage min. 12.5 volts.
-- Carefully pull the engine cover off the 4 studs one after the other -arrows-.
Fig. 17: Identifying Removal Of Engine Cover From 4 Ball Studs -Arrow-
-- Disconnect the connectors from the glow plugs.
-- Disconnect the connector from the fuel pressure regulator valve -N276- -1- on the cylinder bank 1 (right) rail.
Fig. 18: Identifying Connector From Fuel Pressure Regulator Valve -1-
-- In order to reduce the fuel pressure in the rail, start the engine briefly.
Fig. 19: Identifying Socket 3320 To Remove Glow Plugs

-- Remove the glow plugs. Refer to one of the following:
CERAMIC GLOW PLUGS .
METAL GLOW PLUGS .
-- Install the adapter V.A.G 1763/8 instead of the glow plugs and connect the compression tester V.A.G 1763.
Fig. 20: Identifying Adapter V.A.G 1763/8 And Compression Tester V.A.G 1763
NOTE: Using tester, refer to the operating instructions.
-- Have a second technician operate the starter until the tester does not show the pressure increasing any further.
Compression
Bar Pressure
Pressure
New 28 to 33
Wear limit 21
Difference
between Max. 5
cylinders
Assembly is performed in the reverse order of removal, noting the following:
-- Install the glow plugs. Refer to one of the following:
METAL GLOW PLUGS .
-- Check the Engine Control Module (ECM) Diagnostic Trouble Code (DTC) memory and erase it to clear any
faults stored from disconnecting the connectors. Refer to the vehicle diagnostic tester.
CAMSHAFT AXIAL CLEARANCE, CHECKING

Dial Gauge (0-10 mm) VAS 6079
Intake Camshaft
Fig. 21: Identifying Dial Gauge Holder VW387 And Dial Gauge (0-10 mm) VAS6079, Intake Camshaft
Check
-- Take the measurement when the guide frame is removed.
Target value: 0.03 to 0.08 mm

Wear limit 0.12 mm
Exhaust Camshaft
Fig. 22: Identifying Dial Gauge Holder VW387 And Dial Gauge (0-10 mm) VAS6079, Exhaust Camshaft
Check
-- Take the measurement when the guide frame is removed.
Target value: 0.03 to 0.08 mm

Wear limit 0.12 mm
HYDRAULIC LASH ADJUSTER, CHECKING
Feeler Gauge
NOTE: Hydraulic lash adjusters cannot be repaired.
Irregular valve noises are normal while starting the engine.
Procedure
-- Start the engine and let it run until the coolant temperature is at least 80 °C (176 °F).
-- Increase the engine speed for about 2 minutes to approximately 2500 RPM, perform a road test if necessary.
NOTE: If the irregular valve noises disappear but always appear when driving short
differences, replace the oil check valve -arrow- on the rear face side in the
affected cylinder head.
Fig. 23: Identifying Oil Check Valve

If the hydraulic lash adjusters are still noisy, determine which adjuster is defective as follows:
-- Remove the left or right cylinder head cover. Refer to CYLINDER HEAD COVER.
-- Rotate the crankshaft until the cams on the hydraulic lash adjuster to be checked is at the top. To do this:
Remove the noise insulation and rotate the crankshaft clockwise at the vibration damper central bolt.
-- Determine the play between the cams and the roller rocker lever.
Fig. 24: Identifying Play Between Cams With Screwdriver -Arrow- And 0.20 mm Feeler Gauge
-- Press the roller rocker lever down with a screwdriver -arrow-.
If a 0.20 mm feeler gauge can be inserted between the camshaft and roller rocker lever:
-- Replace the hydraulic lash adjuster.
VALVE GUIDE, CHECKING

Sequence
Fig. 25: Identifying Determining Valve Rock (Wear Limit)

-- Insert valve into the valve guide.
Valve stem tip must seal with valve guide.
NOTE: Due to differences in valve stem diameter, make sure that only intake valves are
used to check intake valve guides, and only exhaust valves are used to check
exhaust valve guides.
-- Determine tilt clearance.
Tilt clearance wear limit: intake and exhaust valve guide 1.0 mm
NOTE: If wear limit is exceeded, measure again using new valves. If wear limit is still
exceeded, replace cylinder head. The valve guides cannot be replaced.
If the valve is to be replaced as part of a repair, use a new valve for the
calculation.
REMOVAL AND INSTALLATION
CYLINDER HEAD COVER
Torque Wrench (5-50 Nm) V.A.G 1331

Ratchet, Reversible V.A.G 1331/1
Tool Insert AF 19 V.A.G 1331/5
Puller T10055
Socket T40055
Removing
NOTE: The following removal and installation procedure is for the left cylinder head
cover. The procedure for the right side is identical except for a few steps.
-- Disconnect the vacuum hose -2- from the vacuum reservoir.
Fig. 26: Identifying Vacuum Hose -2-

NOTE: Ignore -1-.
-- Place a clean cloth under the separating location to catch any fuel that may leak out.
Fig. 27: Identifying Bolts -1 & 2-, Fuel Hose -3 & 5-, Fuel Supply Hose -6- And Nut -4-
CAUTION: Always observe the rules for cleanliness when working on the injection
system. Refer to CLEAN WORKING CONDITIONS .
-- Remove the fuel supply hose -6- from the fuel filter.
-- Remove the fuel hose -3 and 5- to the fuel cooler.
-- Remove the bolts -1 and 2- and the nut -4-.
-- Free up the fuel lines at the plenum chamber bulkhead and lay the fuel filter aside with the fuel hoses
connected.
-- Remove the wiring connector -1-.
-- Remove the high pressure fuel lines -2- and the overflow oil line -3-.
Fig. 28: Identifying Wiring Connector -1-, High Pressure Fuel Lines -2- And The Overflow Oil Line -3-
For the Left Cylinder Head Cover
-- Remove the engine cover bracket -1-, the bolts -arrows- and the upper intake manifold.
Fig. 29: Identifying Engine Cover Bracket -1-, Bolts -Arrows- And Upper Intake Manifold
-- Lift the tab -1-, turn the oil filler tube counterclockwise -arrow- and remove the tube.
Fig. 30: Identifying Tab -1- And Position To Turn Oil Filler Tube (Counterclockwise -Arrow-)
-- Remove the wiring harness bracket bolt -5- from the cylinder head cover.
Fig. 31: Identifying Connectors -1 Through 4- To Fuel Injectors

-- Disconnect the connectors -1 through 4- from the fuel injectors.
-- Free up the wiring harness.
Fig. 32: Identifying Release Pins Upward -Arrow-

CAUTION: Always observe the rules for cleanliness when working on the injection
system. Refer to CLEAN WORKING CONDITIONS .
-- Pull the release pins upward -arrow- and remove the return line connections from the injectors.
-- Mark the assignment of the high pressure lines to the injectors.
-- Loosen the high pressure line union nuts -1 through 6- using the tool insert AF 19 V.A.G 1331/5 or socket 14
mm 3150 and the socket T40055.
Fig. 33: Identifying High Pressure Line Union Nuts -1 Through 6-

-- Remove the high pressure lines.
-- Remove the injector covers bolts -arrows-.
Fig. 34: Identifying Injector Cover Bolts -Arrows-

-- Pull the covers upward and rotate them 90° (1/4 turn).
Fig. 35: Identifying Injector Tensioning Bracket Nuts -Arrows-

-- Remove the injector tensioning plate nuts -arrows-.
-- Remove the injectors using puller T10055 and adapter T10055/1.
Fig. 36: Identifying Puller T10055 With Adapter T10055/1

CAUTION: Mark the allocation of the injectors to the cylinder.

Used injectors may only be installed in the same cylinder.
-- Loosen the cylinder head cover bolts -arrows- in a diagonal sequence.
Fig. 37: Identifying Cylinder Head Cover, Tightening Specifications and Sequence
-- Remove the bolts and the cylinder head cover.
Installing
NOTE: Replace the cylinder head cover gaskets if damaged.
Replace gaskets, seals and O-rings.
Hose connections and charge air system hoses must be free of oil and grease
before installing.
Secure all hose connections using hose clamps appropriate for the model type.
-- Tighten the cylinder head cover bolts in a diagonal sequence and in stages.
Injector Installation Information
Make sure the injectors and their installed locations are clean before installing. Clean the injector shaft in
the cylinder head with a clean cloth if necessary. Do not use any sharp tools and be careful not to damage
it.
Always use new seals. Lubricate all the seals with installation oil or assembly oil before installing.
The fuel injectors must not be damaged. To remove the used copper sealing ring from the fuel injector,
clamp the sealing ring carefully in a vise until the clamping jaws on the vise prevent the ring from
turning. Pull the fuel injector out of the copper sealing ring by hand with a slight twisting and pulling
motion.
The high pressure line and tensioning bracket must be replaced when replacing the injector.
When installing, the fuel injectors and injection lines may only be installed on the same cylinder as
before.
-- Install the fuel injectors.
-- Tighten the high pressure line union nuts by hand.
-- Make sure the high pressure lines are seated free of stress.
-- Tighten the high pressure lines, refer to one of the following:
Using a 14 mm wrench, refer to TIGHTENING THE HIGH PRESSURE LINE TO THE FUEL RAIL
WITH A 14 MM WRENCH.
Using a 17 mm wrench, refer to TIGHTENING THE HIGH PRESSURE LINE TO THE FUEL
INJECTOR WITH A 17 MM WRENCH.
Using a 19 mm wrench, refer to TIGHTENING THE HIGH PRESSURE LINE TO THE FUEL RAIL
WITH A 19 MM WRENCH.
-- Inspect the fuel system for leaks. Refer to FUEL SYSTEM, PERFORMING LEAK TEST .
Tightening Specifications
Component Nm
Cylinder head cover to cylinder head 9
Injector to cylinder head 9
Injector cover to cylinder head 5
High pressure lines 25
Wiring harness bracket to cylinder head 9
Intake tube bracket to cylinder head 9
Intake
9
manifold
Bracket 9
Connecting
Throttle valve control module with intake tube to pipe for
mechanical
9
Exhaust Gas
Recirculation
(EGR) valve
Hose clamps 13 mm wide 5.5
CYLINDER HEAD
Retainer 3036 for the left cylinder head

Puller T10320 for the left cylinder head
Puller T40064 for the left cylinder head
REMOVING
-- Drain the coolant. Refer to DRAINING AND FILLING .
Left Cylinder Head
-- Remove the high pressure pump toothed belt. Refer to HIGH PRESSURE FUEL PUMP TOOTHED
BELT .
-- Remove the high pressure pump toothed belt using puller T40064.
Fig. 38: Identifying High Pressure Pump Toothed Belt Sprocket, Removing
-- Using Retainer 3036, loosen the central bolt -1- for the toothed belt drive sprocket approximately two turns.
-- Remove the toothed belt drive gear using puller T10320.
Fig. 40: Identifying Toothed Belt Drive Gear, Removing

-- Remove the toothed belt drive sprocket with the toothed belt.
-- Remove the bolts -arrows- and the rear toothed belt guard.
Fig. 41: Identifying Bolts -Arrows- And Rear Toothed Belt Guard
Right Cylinder Head through 10.05
-- Remove the fuel supply line banjo bolt -2- and fuel return line banjo bolt -1- from the high pressure pump and
lay it aside.
Fig. 42: Identifying Fuel Supply Line Banjo Bolt -2- And Fuel Return Line Banjo Bolt -1-
Right Cylinder Head from 11.05
-- Remove the fuel supply line banjo bolt -2- and fuel return line banjo bolt -1- from the high pressure pump and
lay it aside.
Fig. 43: Identifying Fuel Supply Line Banjo Bolt -2- And Fuel Return Line Banjo Bolt -1-
Continuation for Both Sides
-- Remove the upper intake manifold. Refer to UPPER INTAKE MANIFOLD .
-- Remove the left or right lower intake manifold. Refer to one of the following:
LOWER LEFT INTAKE MANIFOLD
LOWER RIGHT INTAKE MANIFOLD
-- Remove the affected camshaft timing chain from the camshafts. Refer to CAMSHAFTS.
-- Remove the coolant ventilation line banjo bolt and the coolant ventilation line, refer to -item 8- under
CYLINDER HEAD OVERVIEW.
-- Remove the intermediate exhaust pipes. Refer to:
LEFT INTERMEDIATE PIPE
RIGHT INTERMEDIATE PIPE
Right Cylinder Head
Fig. 44: Identifying Right Coolant Pipe Bolt -Arrow- From Cylinder Head
-- Remove the right coolant pipe bolt -arrow- from the cylinder head.
LOOSEN THE CYLINDER HEAD BOLTS IN THE SEQUENCE SHOWN.
-- Remove the bolts and carefully remove cylinder head.
Fig. 45: Identifying Bolt Removal Sequence

CAUTION: Do not set the cylinder head down on the ends of the glow plug elements.
INSTALLING
NOTE: Remanufacturing diesel cylinder heads is not permitted.
Replace the cylinder head bolts.
During assembly, replace self locking nuts and bolts.
Always replace bolts that have been tightened to an angle specification as well
as O-rings and gaskets.
Carefully remove sealant residue from the cylinder head and cylinder block.
Make sure that no long scrapes or scratches result.
Carefully remove all grinding and sanding residue.
There must be no oil or coolant in the blind holes for the cylinder head bolts in
the cylinder block.
Only unpack the new cylinder head gasket immediately prior to installation.
Handle the gasket carefully. Damages to the silicone layer and in areas of
recesses may result in leaks.
Do not remove plastic sleeves protecting the valves until immediately before
installing the cylinder head.
When installing a replacement cylinder head with the camshafts installed,

lubricate the contact surfaces between the roller rocker levers and the cam
running surfaces.
After working on the valvetrain and lifters, carefully rotate the crankshaft by
hand at least 2 full revolutions before starting to be sure that the valves do not
strike the pistons.
Secure all hose connections using hose clamps appropriate for the model type.
Hose connections and charge air system hoses must be free of oil and grease
before installing.
Replace all of the coolant and engine oil when replacing the cylinder head or
cylinder head gasket.
Fig. 46: Identifying Crankshaft Holder 3242 In Bore

-- Rotate the crankshaft and the camshafts to the Top Dead Center (TDC) position before installing the cylinder
head:
The crankshaft Holder 3242 must be installed in the crankshaft -1- TDC opening.
The camshafts in the cylinder head must be secured using the adjustment pin T40060.
Fig. 47: Identifying Check Of Camshafts For Both Cylinder Heads In TDC Position And
Adjustment Pin T40060
-- Note the cylinder head gasket identification:
Fig. 48: Identifying Cylinder Head Gasket Identification

1. Holes
2. Part number
NOTE: If the cylinder head gasket or the cylinder head were replaced, select a new
cylinder head gasket with the same number of holes as the old gasket.
If the crankshaft drive is replaced, measure the piston projection in TDC to

determine the new cylinder head. Refer to PISTON PROJECTION IN TOP DEAD
CENTER, CHECKING .
The cylinder head gaskets for the left and right cylinder head cannot be
-- Clean any oil or grease from the sealing surfaces.
NOTE: Note the expiration date of the sealant.
Fig. 49: Identifying Scissors To Cut Tube Nozzle At Front Marking (Nozzle
Diameter Approx. 3 mm)
Left Cylinder Head
-- Apply a bead of sealant -1 and 2- on the clean sealing surfaces of the cylinder block and the lower timing
chain cover as illustrated.
Fig. 50: Identifying Areas -1 And 2- To Apply Bead Of Sealant

-- Apply the sealant in the amounts specified.
Fig. 51: Identifying Dimensions -a to c-

a = 7 mm
b = 7 mm
c = 7 mm
-- Set the cylinder head gasket in place.
-- Apply sealant beads -1 and 2- to the clean sealing surfaces as illustrated.

Right Cylinder Head
-- Apply a bead of sealant -1 and 2- on the clean sealing surfaces of the cylinder block and the lower timing
chain cover as illustrated.

-- Apply the sealant in the amounts specified.
Fig. 54: Identifying Dimensions -a to c-

a = 7 mm
b = 7 mm
c = 7 mm
-- Set the cylinder head gasket in place.
-- Apply sealant beads -1 and 2- to the clean sealing surfaces as illustrated.
Fig. 55: Identifying Sealant Beads -1 And 2-

-- Install the cylinder head gasket.
Fig. 56: Identifying Cylinder Head Gasket

Pay close attention to the alignment bushings in the cylinder block -arrows-.
Pay attention to the installed position of the cylinder head gasket, the mark "oben" (top) or part number
must face toward the cylinder head.
-- Install the cylinder head.
-- Install new cylinder head bolts and tighten them by hand.
TIGHTEN THE CYLINDER HEAD BOLTS IN SEQUENCE -1 THROUGH 8- AS FOLLOWS:
Fig. 57: Identifying Cylinder Head, Tightening Specifications and Sequence

-- Tighten the bolts an additional 90° (1/4) turn.
-- Tighten the bolts an additional 90° (1/4) turn.
NOTE: There is no requirement to tighten the cylinder head bolts after repairs.
-- Install the left or right cylinder head cover. Refer to CYLINDER HEAD COVER.
-- Install the camshaft timing chains. Refer to CAMSHAFTS.
-- Install the intermediate exhaust pipe. Refer to:
LEFT INTERMEDIATE PIPE
RIGHT INTERMEDIATE PIPE
-- Install the left or right lower intake manifold. Refer to one of the following:
LOWER LEFT INTAKE MANIFOLD
LOWER RIGHT INTAKE MANIFOLD
-- Install the upper intake manifold. Refer to UPPER INTAKE MANIFOLD .
Left Cylinder Head
-- Install the high pressure pump toothed belt. Refer to HIGH PRESSURE FUEL PUMP TOOTHED BELT .
-- Change the engine oil. Refer to Maintenance Procedures .
-- Replace the coolant. Refer to DRAINING AND FILLING .
-- Inspect the fuel system for leaks. Refer to FUEL SYSTEM, PERFORMING LEAK TEST .
Component Nm
Coolant line to cylinder head 15.5
Right coolant pipe to cylinder head 9
Toothed belt drive sprocket to camshaft 75
Rear toothed belt guard to engine 9
Fuel supply and return line to high pressure pump 25
CAMSHAFT SEAL
Seal Puller - General Usage 2085

Retainer 3036
M10 x 1.25 x 40 Bolt from Seal Installer 3241
Puller T10320
Removing
Fig. 58: Identifying Removal Of Engine Cover From 4 Ball Studs -Arrow-
-- Carefully remove the engine cover from the 4 studs -arrows- one after the other.
-- Disengage the clamps -arrows-.
Fig. 59: Identifying Clamps -Arrows-

-- Tilt the toothed belt guard forward and disengage the pins on the bottom side of it.
-- Loosen the tensioner bolt -arrow- approximately two turns.
Fig. 60: Identifying Tensioner Bolt -Arrow-

-- Using the Retainer 3036, loosen the central bolt -1- for the toothed belt drive sprocket approximately two
turns.
Fig. 62: Identifying Toothed Belt Drive Gear, Removal

-- Remove the toothed belt drive sprocket with the toothed belt.
-- Move the inner section of the 2085 three turns out of the outer section and secure the inner section with the
knurled bolt.
Fig. 63: Identifying Seal Puller 2085

-- Lubricate the threaded head of the seal puller - general usage 2085, place it against the seal, and with strong
force screw into the seal as far as possible.
-- Loosen the knurled bolt and turn the inner part against the camshaft until the seal is removed.
-- Secure the seal puller - general usage 2085 in a vice at the mounting points and remove the seal with pliers.
Installing
-- Clean the running and sealing surfaces.
-- Press the new seal in until it stops using the thrust sleeve from the assembly tool T10053 and the M10 x 1.25
x 40 bolt -arrow- from the seal installer 3241.
Fig. 64: Identifying Assembly Tool T10053 And M10 x 1.25 x 40 Bolt -Arrow- From Seal Installer 3241
CAMSHAFTS
Retainer 3036
Puller T10320
Camshaft Insertion Tool T40094
Protective Eyewear
Sealant
Removing
-- Remove the affected camshaft timing chain from the camshafts. Refer to CAMSHAFT TIMING CHAINS,
REMOVING FROM CAMSHAFTS.
Left Cylinder Head
-- Remove the upper intake manifold. Refer to UPPER INTAKE MANIFOLD .
-- Remove the high pressure pump toothed belt. Refer to HIGH PRESSURE FUEL PUMP TOOTHED
BELT .
-- Using the Retainer 3036, loosen the central bolt -1- for the toothed belt drive sprocket approximately two
turns.
Fig. 66: Identifying Toothed Belt Drive Gear, Removal

-- Loosen the guide frame bolts and nuts in sequence -18 through 1-.
NOTE: Be careful of the roller rocker levers and the adjusters when removing the
camshafts.
-- Carefully remove the guide frame and the camshafts.
Installing
CAUTION: Only install the camshafts with the camshaft insertion tool T40094 as
described below. Otherwise the axial bearing in the guide frame will be
destroyed and the cylinder head will have to be replaced.
-- Remove any sealant residue from the cylinder head and guide frame with a rotating plastic brush.
CAUTION: Make sure that no sealant residue enters the cylinder head and bearings.
-- Clean the sealing surfaces, they must be free of oil and grease.
-- Oil the journal surfaces of the camshafts.
Assemble the camshaft insertion tool T40094 as follows:
Fig. 68: Identifying Bracket T40094/1 And Bracket T40094/2

Left Cylinder Head
-- Insert the bracket T40094/2 in location -A-.
-- Insert the bracket T40094/1 in location -D-.
Right Cylinder Head
-- Insert the bracket T40094/2 in location -B-.
-- Insert the bracket T40094/1 in location -C-.
Fig. 69: Identifying Camshaft Insertion Tools T40094 And T40096

NOTE: The following procedure describes the left cylinder head. The procedure is
performed in the same order for the right cylinder head.
-- Install the exhaust camshaft -1- in the brackets T40094/1 and T40094/2.
-- Rotate the camshaft so it can be secured in the Top Dead Center (TDC) position with the straight edge -
arrow-.
-- Install the camshaft insertion tool T40096 on the camshaft splines so each of the arms on the camshaft
insertion tool T40096l engages in half of the sprocket.
-- Tighten the camshaft insertion tool T40096 with the knurled bolt until the tooth faces align.
-- Install the intake camshaft -2- in the camshaft insertion tool T40094.
Fig. 70: Identifying Intake Camshaft -2- In Camshaft Insertion Tool T40094
The pin -3- must engage in the groove on the camshaft.
-- Slide the exhaust camshaft -1- toward the intake camshaft until the splines mesh.
-- Place the guide frame -1- on the camshafts.
Fig. 71: Identifying Guide Frame -1- On Camshafts

All the camshaft bearings must lie on the camshafts.
-- Align the grips and tighten with the knurled nuts to install the camshaft insertion tool T40095 on the
camshafts.
Note that the intake and exhaust camshafts have different shapes.
-- Cut the tube nozzle at the front mark (nozzle diameter approximately 1.5 mm).
Fig. 72: Identifying Scissors To Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 3 mm)
NOTE: The illustration shows the guide frame without the camshafts.
Fig. 73: Identifying Sealant Beads -Arrows- On Clean Sealing Surfaces Of Guide
Frame
-- Turn the guide frame over.
-- Apply sealant beads -arrows- on the clean sealing surfaces of the guide frame as shown in the illustration.
The grooves -arrows- of the sealing surface must be completely filled with sealant.
The sealant beads must be 1.5 to 2.0 mm above the sealing surface.
NOTE: Sealant beads must not be thicker than specified, otherwise extra sealant can
enter the camshaft bearings.
The guide frame must be installed within 5 minutes after application of sealant.
-- Make sure all the roller rocker levers are seated correctly on the valve stem ends and the adjusters.
-- Place the guide frame on the cylinder head immediately with both camshafts and the camshaft insertion tool
T40095.
NOTE: After installing the guide frame, sealant must dry for approximately 30 minutes.
TIGHTEN THE GUIDE FRAME BOLTS BY HAND EVENLY IN SEQUENCE -1 THROUGH 18-
The guide frame must be in contact with the entire contact surface of the cylinder head.
-- Tighten the guide frame bolts in sequence -1 through 18- until they are seated.
-- Remove the camshaft insertion tool T40095 and the camshaft insertion tool T40096.
NOTE: After installing the camshafts, the engine may not be started for approximately
30 minutes. The hydraulic adjusting elements must seat themselves (otherwise
the valves will seat themselves on the pistons).
After working on the valvetrain, carefully rotate engine by hand at least 2 full
revolutions to ensure that valves do not strike the pistons when starting.
Left Cylinder Head
-- Replace the camshaft seal. Refer to CAMSHAFT SEAL.
-- Install the upper intake manifold. Refer to UPPER INTAKE MANIFOLD .
Right Cylinder Head
-- Replace the front cover on the cylinder head.
-- Drive the new cover in with a suitable drift until it is flush.
-- Install the left or right cylinder head cover. Refer to CYLINDER HEAD COVER.
-- Install the camshaft timing chain. Refer to CAMSHAFT TIMING CHAINS.
Component Nm
Guide frame to cylinder head 9
Toothed belt drive sprocket to camshaft 75
VALVE STEM SEALS
Hinged Socket 3220

Valve Seal Removal Tool 3364
Valve Stem Seal Driver 3365
Valve Cotters Asm/Disasm Device VAS 5161
Guide Plate for 3.0 Liter TDI Engine VAS 5161/23
Removing
With Ceramic Glow Plugs
CAUTION: Ceramic glow plugs are very sensitive because of the materials they
are made with. They require special handling when assembling and
disassembling. Always follow the procedures described when
removing and installing. Refer to one of the following:
CERAMIC GLOW PLUGS
METAL GLOW PLUGS
With Metal Glow Plugs
-- Remove the glow plugs using the hinged Socket 3220.
Fig. 75: Identifying Punch VAS 5161/3, Knurled Thumb Screws VAS 5161/12 And Guide Plate For 3.0
Liter TDI Engine VAS 5161/23
-- Remove the camshafts. Refer to CAMSHAFTS.
-- Install the guide plate for 3.0 liter TDI engine VAS 5161/23 to the cylinder head.
-- Secure the guide plate using knurled thumb screws VAS 5161/12.
-- Insert the punch VAS 5161/3 into the guide plate and loosen any stuck valve retainers using a plastic mallet.
-- Install the compression stud VAS 5161/10 in the guide plate.
Fig. 76: Identifying Compression Stud VAS 5161/10 And Compressed Air Connection VAS 5161/11
-- Install the adapter for compressed air connection VAS 5161/11 in the glow plug threads and tighten by hand.
-- Install the retainer VAS 5161/6 with the guide forks M6/M8 with threaded studs VAS 5161/5 into the guide
plate for 3.0 liter TDI engine VAS 5161/23.
Fig. 77: Identifying Valve Insertion Device VAS 5161/8 Inserted In Guide Plate For 3.0 Liter TDI Engine
VAS 5161/23
-- Push the sleeve VAS 5161/23-1 onto the assemble cartridge VAS 5161/8.
-- Connect compressed air to the adapter for compressed air connection VAS 5161/11 with a commercially
available connector and apply constant pressure.
Minimum pressure: 6 bar
-- Engage the pressure fork with lever for assembly cartridge VAS 5161/2 at sleeve VAS 5161/23-1 and press
down the assembly cartridge VAS 5161/8.
-- At the same time, turn the knurled bolt on the assembly cartridge VAS 5161/8 to the right, until the points
engage in the valve retainers.
-- Lightly move the knurled bolt back and forth, causing the valve retainers to be pressed apart and be captured
in the assembly cartridge VAS 5161/8.
-- Release the pressure fork.
-- Remove the assembly cartridge VAS 5161/8 with the spacer ring, the valve plate and the valve spring.
-- Pull off valve stem seals using the valve seal removal tool 3364.
Fig. 78: Identifying Valve Seal Removal Tool 3364

If the valve seal removal Tool 3364 cannot be used on some valve stem seals due to restricted clearance,
proceed as follows:
Fig. 79: Identifying Spring Dowel Sleeve

-- Drive the roll pin -arrow- in the valve seal removal Tool 3364 out with a drift and remove the impact puller
attachment.
-- Place the lower section of the valve seal removal Tool 3364 on the valve stem seal.
Fig. 80: Identifying Lower Section Of Valve Seal Removal Tool 3364 On Valve Stem Seal
-- Using a drift or punch -1- insert it into the valve seal removal Tool 3364 as illustrated.
-- Using the drift or punch -1- and the valve seal removal Tool 3364, remove the seal -arrow-.
NOTE: A plastic sleeve -A- is supplied with the new valve shaft seals.
Fig. 81: Identifying Plastic Sleeve, New Valve Stem Oil Seals & Valve Stem Seal
Driver 3365
-- Place the plastic sleeve -A- on the valve stem to prevent damage to new valve stem seals -B-.
-- Lightly lubricate the sealing lips of the valve stem seal with oil.
-- Push the valve stem seal onto plastic sleeve.
-- Carefully press the valve stem oil seal onto valve guide using Valve Stem Seal Driver 3365.
-- Remove the plastic sleeve again.
-- If the valve retainers were removed from the valve insertion device VAS 5161/18, they must then be inserted
into the valve insertion device VAS 5161/18.
Fig. 82: Identifying Installation Cartridge VAS 5161/8

NOTE: The large diameter of the valve retainers point upward.
-- Press the valve insertion device VAS 5161/18 onto the insertion tool from above and install the valve
retainers.
-- Insert the valve insertion device VAS 5161/8 in the guide plate for 3.0 liter TDI engine VAS 5161/23.
Fig. 83: Identifying Valve Insertion Device VAS 5161/8 Inserted In Guide Plate For 3.0 Liter TDI Engine
VAS 5161/23
-- Press the pressure fork down and pull the knurled bolt upward while turning it left and right to insert the
valve retainers.
-- Release pressure fork with the knurled bolt still pulled.
-- Install the glow plugs. Refer to one of the following:
METAL GLOW PLUGS .
-- Install the camshafts. Refer to CAMSHAFTS.
NOTE: After installing the camshafts, do not crank the engine for at least 30 minutes.
The hydraulic adjusting elements must seat themselves (otherwise the valves
will seat themselves on the pistons).
After working on the valvetrain and lifters, carefully rotate the crankshaft by
hand at least 2 full revolutions before starting to be sure that valves do not
strike the pistons.
CAMSHAFT TIMING CHAINS

Key T40049
Adjustment Pin T40060 (Quantity: 2)
Adapter T40061
Adapter T40062
3.3 mm Diameter Drill Bit (Quantity: 2)
REMOVING
CAUTION: Risk of damaging valves and piston crowns.
Turn the crankshaft and camshafts only with the chain drive
completely installed.
-- Remove the drive plate. Refer to DRIVE PLATE .
-- Remove the timing chain covers. Refer to TIMING CHAIN COVERS .

-- Install the key T40049 at the rear of the crankshaft using two used drive plate bolts -arrows-.
Fig. 84: Identifying Key T40049 At Rear On Crankshaft And 2 Old Bolts For Dual-Mass Flywheel
NOTE: The adjustment pin T40060 has a flat part -2- which makes it easier to insert if
the camshaft and the cylinder head are slightly offset.
Fig. 85: Identifying Adjustment Pin T40060

Install the adjustment pin T40060 so that the pin -1- is perpendicular to the
camshaft axis.
Rotate the adjustment pin T40060 using the pin -1- 90° -arrow- so that it is
perpendicular to the camshaft axis and it is possible to attain the correct Top
Dead Center (TDC) position.
Fig. 86: Identifying TDC Position Of Camshafts

CAUTION: Components could be destroyed by the camshaft timing chain jump off.
Only rotate the crankshaft in engine rotation direction.
-- Rotate the crankshaft to TDC:
It must be possible to secure the camshafts using the adjustment pin T40060.
The pin -arrow- on the adjustment pin T40060 must be perpendicular to the center axis of the cylinder
bank 1 (right) camshaft.
bank 2 (left) camshaft.
Fig. 87: Identifying Perpendicular Pin -Arrow- On Adjustment Pin T40060



WARNING: Risk of injury when inserting your finger in the TDC hole.
Do not rotate crankshaft -1-.
-- Install the crankshaft Holder 3242 into the hole and tighten it to 20 Nm. Rotate the crankshaft back and forth
slightly to center the crankshaft Holder 3242 completely, if necessary.
-- To protect against cuts, wrap the point and the cutting edges of a 3.3 mm diameter drill bit with insulating
tape.
Fig. 90: Identifying Chain Tensioner Secured Using 3.3 Mm Diameter Drill Bit
-- Push the chain tensioner tensioning rail for the left camshaft timing chain in the -direction of the arrow- and
secure the chain tensioner using the 3.3 mm diameter drill bit -1-.
CAUTION: If the running direction is reversed on a used camshaft timing chain, it

could be destroyed.
Paint arrows to mark the timing chain running direction so it can be

installed again.
-- Remove the adjustment pin T40060 from both camshafts.
-- Remove the bolt -3- and remove the tensioning rail.
Fig. 91: Identifying Bolts -1- For Guide Rail And Bolts -2- For Camshaft Chain Sprocket
-- Remove the bolts -1- for the guide rail and the bolts -2- for the camshaft chain sprocket.
-- Remove the camshaft chain sprocket, guide rail and left camshaft timing chain.
tape.
Fig. 92: Identifying 3.3 mm Diameter Drill Bit -1- To Install Chain Tensioner Guide Rail On Right
Camshaft Timing Chain
-- Push the chain tensioner guide rail for the right camshaft timing chain in the -direction of the arrow- and
Fig. 93: Identifying Chain Tensioner Guide Rail Installed On Right Camshaft Timing Chain
CAUTION: If the running direction is reversed on a used camshaft timing chain, it

could be destroyed.
Paint arrows to mark the timing chain running direction so it can be
installed again.
-- Remove the chain tensioner bolts -1- and camshaft chain sprocket bolts -2 and 3-.
-- Remove the camshaft chain sprocket, chain tensioning and right camshaft timing chain.
INSTALLING

Tightening specifications, refer to LEFT CAMSHAFT TIMING CHAIN OVERVIEW.

Secure the crankshaft -1- in TDC position using the crankshaft Holder 3242.
Install the balance shaft and oil pump chain. Refer to BALANCE SHAFT AND OIL PUMP CHAIN .
NOTE: Replace the plug in the upper oil pan for the TDC mark.
Replace bolts which have been tightened to a angle specification.
If camshafts are rotated, crankshaft may not rest with any piston at
TDC.
-- Check whether the camshafts for both cylinder heads are in the TDC position.
Fig. 95: Identifying Check Of Camshafts For Both Cylinder Heads In TDC Position And Adjustment Pin
T40060
It must be possible to secure the camshafts using adjustment pin T40060.

The pin -arrow- on adjustment pin T40060 must be perpendicular to the center axis of the cylinder bank 1
(right) camshaft.
(left) camshaft.

Fig. 97: Identifying Adapter T40061 And Adjustment Pin T40060

If camshafts are rotated, the crankshaft may not rest with any piston
at TDC.
NOTE: If the camshafts are not secured, it is possible to correct them slightly using
adapter T40061 by installing the camshaft chain sprocket on the camshaft.
-- Install the left camshaft timing chain with the camshaft chain sprocket, the guide rail and the tensioning rail.
Fig. 98: Identifying Left Camshaft Timing Chain, Camshaft Chain Sprocket, Guide Rail And Tensioning
Rail
The slots in the camshaft chain sprocket must be at the middle position in relation to the threaded holes in
the camshaft.
-- Tighten the bolts -1 and 3- for the guide rail and the tensioning rail.
-- Install both camshaft chain sprocket bolts -2- loosely.
It must still be possible to rotate the camshaft chain sprocket on the camshaft and it must not tip.
-- Secure the left camshaft using adjustment pin T40060.
The pin -arrow- on adjustment pin T40060 must be perpendicular to the center axis of the camshaft.
-- Remove the drill bit -4- out of the alignment hole, thereby releasing the chain tensioner.
-- Install the right camshaft timing chain with the chain sprocket and chain tensioner.
Fig. 99: Identifying Drill Bit -4- And Alignment Hole

the camshaft.
-- Tighten the chain tensioner bolts -1-.
-- Secure the right camshaft using adjustment pin T40060.
-- Remove the drill bit -3- out of the alignment hole, thereby releasing the right chain tensioner.
-- Pre-tighten the right camshaft chain sprocket using the adapter T40062 and a torque wrench to 20 Nm in the -
direction of the arrow- and hold it.
Fig. 100: Identifying Bolts -1 And 2-, Torque Wrench, Adapter T40062 And Adjustment Pin T40060
-- Tighten the bolts -1 and 2-.
-- Remove the adapter T40062 and the adjustment pin T40060.
-- Install and tighten the remaining bolts for the right camshaft chain sprocket.
-- Tighten the left camshaft chain sprocket using the adapter T40062 and a torque wrench to 15 Nm in the -
direction of the arrow- and hold it.
Fig. 101: Identifying Adapter T40062 On Left Camshaft Chain Sprocket

-- Remove the adapter T40062 and adjustment pin T40060.
-- Install and tighten the remaining bolts for the left camshaft chain sprocket.
-- Remove the crankshaft Holder 3242.

CHECKING THE VALVE TIMING
Fig. 103: Identifying Key T40049 At Rear On Crankshaft And 2 Old Bolts For Dual-Mass Flywheel
Turn crankshaft only in direction of engine rotation -arrow-.
-- Turn the crankshaft 2 turns using key T40049 until it is just in front of TDC.
-- Lock the crankshaft -1- from turning using the crankshaft Holder 3242 and tighten it to 20 Nm.

CAUTION: An inaccurate TDC setting will cause an inaccurate setting.
If the crankshaft was only rotated slightly past TDC, first rotate it
back approximately 10° and then rotate it in engine rotation direction
again to TDC.
-- Check whether the camshafts for both cylinder heads are in TDC position.


(right) camshaft.
(left) camshaft.

CORRECTING THE VALVE TIMING
Fig. 107: Identifying Bolts -Arrows-

-- If one of the camshafts does not lock, loosen all the bolts -arrows- for that particular camshaft chain sprocket
about 1 turn.
-- Install the adapter T40061 over the bolt heads.

-- Turn the camshaft using the adapter T40061 just a little back and forth until it is possible to install the
T40060.
-- Tighten the bolts for the camshaft chain sprocket using adapter T40061 with the adjustment pin T40060 still
attached to approximately 5 Nm.
-- Remove the adjustment pin T40060 and adapter T40061.
-- Tighten the camshaft chain sprocket bolts to the final specification.
-- Repeat the procedure on the other cylinder bank if necessary.
-- Check the valve timing once again, refer to CHECKING THE VALVE TIMING.
-- Install the plug -arrow- in the upper oil pan.

-- Install the timing chain covers. Refer to TIMING CHAIN COVERS .
-- Install the drive plate. Refer to DRIVE PLATE .
-- Fill the engine oil and check the oil level. Refer to Maintenance Procedures
CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS

Socket T40058
Adjustment Pin T40060 (Quantity: 2)
Adapter T40061
Adapter T40062
3.3 mm Diameter Drill Bit (Quantity: 2)
REMOVING
Engine and transmission installed.
NOTE: If work will only be done on one cylinder head, it is only necessary to adjust the
valve timing on the cylinder bank that was repaired.
-- Drain the coolant. Refer to DRAINING AND FILLING .
-- Remove the primary catalytic converter. Refer to EXHAUST SYSTEM COMPONENTS .
-- Remove the vacuum pump. Refer to VACUUM PUMP OVERVIEW.
-- Remove the rear right coolant pipe. Refer to REAR COOLANT PIPE .
-- Remove the left rear coolant pipe. Refer to LEFT REAR COOLANT PIPE .
NOTE: The following illustrations shows the steps on the drive chains from behind
with the engine removed.
-- Remove bolts -1 through 4- and remove the left timing chain cover.
Fig. 110: Identifying Bolt Tightening Sequence

-- Remove the bolts -1 through 4- and remove the right timing chain cover.
Fig. 111: Identifying Bolts -1 Through 4-

-- Assemble the socket T40058 as follows:
Fig. 112: Identifying Guide Pin Of Adapter T40058

The large diameter -arrow 1- faces the engine.

The small diameter -arrow 2- points to the adapter.
Fig. 113: Identifying Torque Converter Bolts Using Adapter T40058

Turn the crankshaft only in engine rotation direction -arrow-.
-- Using the socket T40058, rotate the crankshaft to Top Dead Center (TDC).
NOTE: The adjustment pin T40060 has a flat part -2- which makes it easier to insert if
the camshaft and the cylinder head are slightly offset.
Fig. 114: Identifying Adjustment Pin T40060

Install the adjustment pin T40060 so that the pin -1- is perpendicular to the
camshaft axis.
Rotate the adjustment pin T40060 using the pin -1- 90° -arrow- so that it is
perpendicular to the camshaft axis and it is possible to attain the correct TDC
position.


(right) camshaft.
(left) camshaft.

NOTE: To collect any leaking engine oil, place a clean cloth under the upper oil pan.


WARNING: Risk of injury when inserting your finger in the TDC hole.
Do not rotate the crankshaft -1-.
-- Install the crankshaft Holder 3242 into the hole and tighten it to 20 Nm. Rotate the crankshaft back and forth
slightly to center the crankshaft Holder 3242 completely, if necessary.
tape.
Fig. 119: Identifying Chain Tensioner Secured Using 3.3 Mm Diameter Drill Bit
-- Push the chain tensioner tensioning rail for the left camshaft timing chain in the -direction of the arrow- and
Fig. 120: Identifying Bolts -1- For Guide Rail And Bolts -2- For Camshaft Chain Sprocket
CAUTION: The engine could be destroyed.
To prevent small parts from accidentally entering the engine through

the opening in the timing chain compartment, cover the opening with
a clean cloth.
-- Remove the bolt -3- and remove the tensioning rail.
-- Remove the bolts -1- for the guide rail and the bolts -2- for the camshaft chain sprocket.
-- Remove the camshaft chain sprocket and guide rail.
tape.
Fig. 121: Identifying 3.3 mm Diameter Drill Bit -1- To Install Chain Tensioner Guide Rail On Right
Camshaft Timing Chain
-- Push the chain tensioner guide rail for the right camshaft timing chain in the -direction of the arrow- and
Fig. 122: Identifying Chain Tensioner Guide Rail Installed On Right Camshaft Timing Chain
CAUTION: The engine could be destroyed.
To prevent small parts from accidentally entering the engine through

the opening in the timing chain compartment, cover the opening with
a clean cloth.
-- Remove the chain tensioner bolts -1- and camshaft chain sprocket bolts -2 and 3-.
-- Remove the camshaft chain sprocket and chain tensioner.
INSTALLING

Tightening specifications, refer to LEFT CAMSHAFT TIMING CHAIN OVERVIEW.

Secure the crankshaft -1- in TDC position using the crankshaft 3242.
NOTE: Replace bolts which have been tightened to an angle specification.
Replace the plug in the upper oil pan.
If the camshafts are rotated, crankshaft may not rest with any piston
at TDC.
Fig. 124: Identifying Check Of Camshafts For Both Cylinder Heads In TDC Position And Adjustment
Pin T40060

(right) camshaft.
(left) camshaft.


If the camshafts are rotated, crankshaft may not rest with any piston
at TDC.
NOTE: If the camshafts are not secured, it is possible to correct them slightly using
adapter T40061 by installing the camshaft chain sprocket on the camshaft.
-- Install the left camshaft timing chain with the camshaft chain sprocket, the guide rail and the tensioning rail.
Fig. 127: Identifying Left Camshaft Timing Chain, Camshaft Chain Sprocket, Guide Rail And
Tensioning Rail
the camshaft.
-- Tighten the bolts -1 and 3- for the guide rail and the tensioning rail.
-- Secure the left camshaft using adjustment pin T40060.
-- Remove the drill bit -4- out of the alignment hole, thereby releasing the chain tensioner.
-- Install the right camshaft timing chain with the chain sprocket and chain tensioner.
Fig. 128: Identifying Drill Bit -4- And Alignment Hole

the camshaft.
-- Tighten the chain tensioner bolts -1-.
-- Secure the right camshaft using adjustment pin T40060.
-- Remove the drill -3- out of the alignment hole, thereby releasing the right chain tensioner.
-- Pre-tighten the right camshaft chain sprocket using the adapter T40062 and a torque wrench and tighten to 20
Nm in the -direction of the arrow- and hold it.
Fig. 129: Identifying Bolts -1 And 2-, Torque Wrench, Adapter T40062 And Adjustment Pin T40060
-- Install and tighten the remaining bolts for the right camshaft chain sprocket.
-- Pre-tighten the left camshaft chain sprocket using the adapter T40062 and a torque wrench and tighten to 15
Nm in the -direction of the arrow- and hold it.
Fig. 130: Identifying Adapter T40062 On Left Camshaft Chain Sprocket

-- Install and tighten the remaining bolts for the left camshaft chain sprocket.

CHECKING THE VALVE TIMING
Fig. 132: Identifying Torque Converter Bolts Using Adapter T40058
Turn the crankshaft only in engine rotation direction -arrow-.
-- Turn the crankshaft two turns until the crankshaft is just in front of TDC.
-- Lock the crankshaft -1- from turning using the crankshaft Holder 3242 and tighten it to 20 Nm.

CAUTION: An inaccurate TDC setting will cause an inaccurate setting.
If the crankshaft was only rotated slightly past TDC, first rotate it
back approximately 10° and then rotate it in engine rotation direction
again to TDC.

It must be possible to secure the camshafts using the adjustment pin T40060.
bank 1 (right) camshaft.
bank 2 (left) camshaft.

CORRECTING THE VALVE TIMING
Fig. 136: Identifying Bolts -Arrows-

-- If one of the camshafts does not lock, loosen all the bolts -arrows- for that particular camshaft chain sprocket
about 1 turn.
-- Install the adapter T40061 over the bolt heads.

-- Turn the camshaft by the adapter T40061 just a little back and forth until it is possible to install the
adjustment pin T40060.
The pin -arrow- on the adjustment pin T40060 must be perpendicular to the center axis of the camshaft.
-- Tighten the bolts for the camshaft chain sprocket using the adapter T40061 with the adjustment pin T40060
still attached to approximately 5 Nm.
-- Remove the adjustment pin T40060 and the adapter T40061.
-- Tighten the camshaft chain sprocket bolts to the final specification.
-- Repeat the procedure on the other cylinder bank if necessary.
-- Check the valve timing once again. Refer to CHECKING THE VALVE TIMING.
-- Install the plug -arrow- to the upper oil pan.

-- Install the timing chain covers. Refer to TIMING CHAIN COVERS .
SPECIAL TOOLS
Seal Puller - General Usage 2085

M10 x 1.25 x 40 Bolt from Seal Installer 3241

Socket T40058
Compression Tester V.A.G 1763
Fig. 139: Identifying Compression Tester V.A.G 1763

Fig. 140: Identifying Dial Gauge Holder VW 387
Fig. 141: Identifying Dial Gauge VAS 6079

Fig. 142: Identifying Special Tools - Torque Wrench, Ratchet And Puller
Torque Wrench (5-50 Nm) V.A.G 1331

Ratchet, Reversible V.A.G 1331/1
Tool Insert AF 19 V.A.G 1331/5
Puller T10055
Socket T40055
Fig. 143: Identifying Special Tools - Retainer And Pullers

Retainer 3036
Puller T10320
Puller T40064
Fig. 144: Identifying Special Tools - 3220, 3364, 3365 And VAS 5161
Hinged Socket 3220

Valve Seal Removal Tool 3364
Valve Stem Seal Driver 3365
Valve Cotters Asm/Disasm Device VAS 5161 with
Guide Plate for 3.0 Liter TDI Engine VAS 5161/23
Fig. 145: Identifying Special Tools - Crankshaft Holder And Accessories


Key T40049
Adjustment Pin T40060
Adapter T40061
Adapter T40062

Touareg 3.0L TDi 2010

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2010 Volkswagen Touareg TDI

ENGINE 3.0 Liter - Crankshaft, Cylinder Block - Engine Code(s): CATA

3.0 Liter - Crankshaft, Cylinder Block - Engine Code(s): CATA

13 CRANKSHAFT, CYLINDER BLOCK

CAUTION: If large quantities of metal particles or other deposits such as those

PISTON AND CONNECTING ROD

Lubricate all bearing and contact surfaces before assembly work.

DESCRIPTION AND OPERATION

RIBBED BELT DRIVE OVERVIEW

lunes, 11 de enero de 2021 06:44:06

Fig. 1: Ribbed Belt Drive Overview

Install with a shim, refer to RIBBED BELT DRIVE OVERVIEW.

CAUTION: Differing threads in the cylinder block.

Before assembling, check whether the threads are M10 or M11.

Use the proper bolt size. The engine could be damaged.

29. Vibration Damper

Vibration Damper Threaded Connection

Fig. 2: Vibration Damper Connection

1 - 20 Nm + 90° (1/4) additional turn. Always replace.

Fig. 3: Generator Bracket Tightening Sequence

-- Install the generator bracket using the following steps:

1.: Install bolt -A- and tighten by hand.

2.: Install bolt -B- and tighten.

3.: Tighten bolt -A-.

4.: Install bolt -D- and tighten.

5.: Install bolt -C- and tighten.

DRIVE PLATE OVERVIEW

Fig. 4: Drive Plate Overview

6. Crankshaft Seal, Timing Chain Side

TIMING CHAIN COVERS OVERVIEW

Fig. 5: Timing Chain Covers Overview

1. Crankshaft Seal, Timing Chain Side

BALANCE SHAFT OVERVIEW

Fig. 6: Balance Shaft Overview

6. Balance Weight (Belt Pulley Side)

TIMING MECHANISM DRIVE CHAIN OVERVIEW

Fig. 7: Timing Mechanism Drive Chain Overview

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Drive Sprocket Pivot Pin

21. Mounting Pin

BALANCE SHAFT AND OIL PUMP CHAIN OVERVIEW

Fig. 8: Balance Shaft And Oil Pump Chain Overview

PISTONS AND CONNECTING ROD OVERVIEW

Fig. 9: Pistons And Connecting Rod Overview

Oil Spray Jet for Piston Cooling

Fig. 10: Oil Spray Jet for Piston Cooling

Opening pressure: 1.3 bar.

Piston Ring Gap, Checking

Fig. 11: Checking Piston Ring Gap

Piston Ring Groove Clearance, Checking

Fig. 12: Piston Ring Groove Clearance, Checking

-- Clean the ring groove of piston before checking.

Fig. 13: Checking Piston

Maximum deviation from nominal dimension: 0.05 mm.

Nominal dimension, refer to PISTON AND CYLINDER DIMENSIONS.

Cylinder Bore, Checking

Fig. 14: Checking Cylinder Bores

Maximum deviation from nominal dimension: 0.08 mm.

Nominal dimension, refer to PISTON AND CYLINDER DIMENSIONS.