Workshop Manual
Touareg 2018 ➤
4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive)
Engine ID CYR B CYR C DMF A
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Service Service Department. Technical Information
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List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
24 - Mixture preparation - injection
26 - Exhaust system
28 - Ignition system
Technical information should always be available to the foremen and mechanics, because their carefulandconstantadherencetotheinstructionsisessentialtoensurevehicleroad-worthinessand safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.
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Service
rights reserved.
reproduction without prior agreement from publisher.
© 2018 Volkswagen AG, Wolfsburg D4B80844338
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thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG. Volkswagen AGdoesnotguaranteeoracceptanyliabilitywith respect t o t h e c o r r e c t n e ss o f niGAnegawskloVybthgirypoC.tnemucodsihtninoitamrof Contents 00 - Technical data 1 1 Safety information 1 1.1 Safety regulations for working on fuel supply 1 1.2 Safety measures when working on vehicles with a start/stop system 1 1.3 Safety precautions when using testers and measuring instruments during a road test 2 1.4 Safety precautions when working on ignition system 2 1.5 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 Identification 3 2.1 Engine number/engine data 3 3 Repair instructions 4 3.1 Rules for cleanliness 4 3.2 Foreign objects in engine 4 3.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3.4 Routing and attachment of lines 4 3.5 Fitting radiator and condensers 5 3.6 Checking vacuum system 5 10 - Removing and installing engine 6 1 Removing and installing engine 6 1.1 Removing engine 6 1.2 Securing engine on engine and gearbox support 21 1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2 Assembly mountings 27 2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 2.2 Supporting engine in installation position 29 2.3 Removing and installing engine mounting 30 2.4 Removing and installing support bearing 32 2.5 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 1.1 Assembly overview - cylinder block (pulley end) 34 1.2 Removing and installing poly-V belt 36 1.3 Removing and installing tensioner for poly V-belt 37 1.4 Removing and installing vibration damper 37 1.5 Removing and installing bracket for ancillaries 43 1.6 Removing and installing engine support 45 2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 2.1 Assembly overview - cylinder block, gearbox end 48 2.2 Removing and installing drive plate 49 2.3 Removing and installing sealing flange on gearbox side 50 3 Crankshaft 54 3.1 Assembly overview - crankshaft 54 3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 3.3 Allocation of main bearing shells 56 3.4 Measuring axial clearance of crankshaft 57 3.5 Measuring radial clearance of crankshaft 58 3.6 Removing and installing sender wheel 59 4 Balancer shaft 60 4.1 Assembly overview - balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 4.2 Removing and installing balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 4.3 Renewing oil seal for balance shaft (inlet side) 65 Touareg 2018 ➤ 4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018 Contents i
thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG Volkswagen AGdoesnotguaranteeoracceptanyliabilitywith respect t o t h e c o r r e c t n e ss o f niGAnegawskloVybthgirypoC.tnemucodsihtninoitamrof 5 Pistons and conrods 67 5.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 5.2 Removing and installing pistons 70 5.3 Checking pistons and cylinder bores 72 5.4 Separating new conrod 73 5.5 Checking radial clearance of conrods 74 5.6 Removing and installing oil spray jets 74 15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 1 Cylinder head 77 1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 1.2 Removing and installing cylinder head 79 1.3 Removing and installing vacuum pump 84 1.4 Checking compression 86 2 Cover for timing chain 88 2.1 Assembly overview - cover for timing chain 88 2.2 Removing and installing timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 2.3 Renewing seal for vibration damper 93 3 Chain drive 96 3.1 Assembly overview - camshaft timing chains 96 3.2 Assembly overview - drive chain for balance shaft 98 3.3 Removing and installing bearing saddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 3.4 Removing and installing camshaft timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 3.5 Checking timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 3.6 Checking valve timing 118 4 Valve gear 122 4.1 Assembly overview - valve gear 122 4.2 Removing and installing camshaft 125 4.3 Installing ball for sliding piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 4.4 Removing and installing actuators for camshaft adjustment . . . . . . . . . . . . . . . . . . . . . . . . 142 4.5 Removing and installing camshaft control valve 1 N205 143 4.6 Removing and installing valve stem seals 144 5 Inlet and exhaust valves 153 5.1 Checking valve guides 153 5.2 Checking valves 153 5.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155 1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 1.1 Assembly overview - sump/oil pump 155 1.2 Engine oil: 157 1.3 Check engine oil level with oil gauge tester T40178 157 1.4 Removing and installing lower part of sump 159 1.5 Removing and installing oil pump 160 1.6 Removing and installing upper part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 1.7 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 165 2 Engine oil cooler 166 2.1 Assembly overview - engine oil cooler 166 2.2 Removing and installing engine oil cooler 166 2.3 Removing and installing mechanical switching valve 167 3 Crankcase ventilation 168 3.1 Assembly overview - crankcase breather system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 3.2 Removing and installing oil separator 169 4 Oil filter, oil pressure switch 170 Touareg 2018 ➤ 4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018 ii Contents
thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG Volkswagen AGdoesnotguaranteeoracceptanyliabilitywith respect t o t h e c o r r e c t n e ss o f ni.GAnegawskloVybthgirypoC.tnemucodsihtninoitamrof 4.1 Assembly overview - oil filter 170 4.2 Assembly overview - oil pressure switches/oil pressure control . . . . . . . . . . . . . . . . . . . . . . 171 4.3 Removing and installing oil pressure switch F22 172 4.4 Removing and installing oil pressure switch for reduced oil pressure F378 172 4.5 Removing and installing stage 3 oil pressure switch F447 172 4.6 Removing and installing oil pressure regulating valve N428 173 4.7 Removing and installing piston cooling jet control valve N522 174 4.8 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 1.1 Connection diagram - coolant hoses 178 1.2 Fitting location overview - cooling system 180 1.3 Checking cooling system for leaks 182 1.4 Draining and adding coolant 186 2 Coolant pump, regulation of cooling system 192 2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 2.2 Assembly overview - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 2.3 Assembly overview - coolant temperature sender 196 2.4 Assembly overview - coolant valves 197 2.5 Removing and installing electric coolant pump 198 2.6 Removing and installing coolant pump 201 2.7 Removing and installing toothed belt for coolant pump 203 2.8 Removing and installing engine temperature regulation module GX33 . . . . . . . . . . . . . . 205 2.9 Removing and installing coolant temperature sender G62 207 2.10 Removing and installing radiator outlet coolant temperature sender G83 208 2.11 Removing and installing coolant valves 209 3 Coolant pipes 214 3.1 Assembly overview - coolant pipes 214 3.2 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 4 Radiator, radiator fan 221 4.1 Assembly overview - radiator/radiator fan 221 4.2 Removing and installing radiator module 223 4.3 Dismantling cooler module 226 4.4 Removing and installing radiator cowl 227 4.5 Removing and installing radiator fan 228 21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 1 Exhaust turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 1.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 1.2 Removing and installing turbocharger 231 2 Charge air system 236 2.1 Assembly overview - charge air system 236 2.2 Assembly overview - charge-air hose connections 237 2.3 Removing and installing charge air cooler 237 2.4 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239 2.5 Checking charge air system for leaks 239 24 - Mixture preparation - injection 242 1 Injection system 242 1.1 Overview of fitting locations - injection system 242 1.2 Checking fuel system for leaks 248 2 Injectors 249 2.1 Assembly overview - fuel rail with injectors 249 2.2 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251 Touareg 2018 ➤ 4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018 Contents iii
thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG Volkswagen AGdoesnotguaranteeoracceptanyliabilitywith respect t o t h e c o r r e c t n e ss o f niGAnegawskloVybthgirypoC.tnemucodsihtninoitamrof 2.3 Removing and installing injectors 251 2.4 Renewing seals on injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 2.5 Cleaning injectors 258 3 Air filter 260 3.1 Assembly overview - air filter housing 260 3.2 Removing and installing air filter housing 261 4 Intake manifold 264 4.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264 4.2 Removing and installing intake manifold 265 4.3 Removing and installing throttle valve module GX3 268 4.4 Cleaning throttle valve module GX3 269 4.5 Checking intake manifold change-over 270 5 Senders and sensors 272 5.1 Removing and installing intake manifold sender GX9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272 5.2 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272 5.3 Checking fuel pressure sender G247 273 5.4 Removing and installing fuel pressure sender for low-pressure G410 275 6 Engine (motor) control unit 276 6.1 Assembly overview - engine control unit 276 6.2 Removing and installing engine (motor) control unit J623 276 7 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 7.1 Assembly overview - high-pressure pump 278 7.2 Removing and installing high-pressure pump 279 7.3 Removing and installing high-pressure pipe 282 8 Lambda probe 285 8.1 Assembly overview - Lambda probe 285 8.2 Removing and installing Lambda probe 1 before catalytic converter GX10 . . . . . . . . . . . . 285 8.3 Removing and installing Lambda probe 1 after catalytic converter GX7 286 26 - Exhaust system 288 1 Exhaust pipes and silencers 288 1.1 Assembly overview - silencers 288 1.2 Separating exhaust pipes from silencers 289 1.3 Removing and installing front silencer 290 1.4 Removing and installing silencer 291 1.5 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293 1.6 Check exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294 2 Exhaust gas cleaning 295 2.1 Assembly overview - emission control 295 2.2 Removing and installing catalytic converter 295 3 Secondary air system 297 3.1 Assembly overview - secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297 3.2 Removing and installing secondary air pump motor V101 298 3.3 Removing and installing secondary air inlet valve N112 299 28 - Ignition system 301 1 Ignition system 301 1.1 Assembly overview - ignition system 301 1.2 Removing and installing ignition coils with output stage 302 1.3 Removing and installing knock sensor 1 G61 305 1.4 Removing and installing Hall sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306 1.5 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307 Touareg 2018 ➤ 4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018 iv Contents
00 –Technical data
1Safety information
(VRL012050; Edition 09.2018)
⇒ “1.1 Safety regulations for working on fuel supply”, page 1
⇒ “1.2 Safety measures when working on vehicles with a start/ stop system”, page 1
⇒ “1.3 Safety precautions when using testers and measuring in‐struments during a road test”, page 2
⇒“1.4Safetyprecautionswhenworkingonignitionsystem”,page 2
⇒ “1.5 Safety precautions when working on the cooling system”, page 2
1.1Safety regulations for working on fuel supply
Risk of injury from highly pressurised fuel.
The fuel system is pressurised. Injury from fuel spray possible. Before opening the fuel system:
–Wear protective goggles.
–Wear protective gloves.
– Toreleasepressure,wrapacleanclotharoundtheconnection and carefully loosen the connection.
Danger of fire caused by escaping fuel
Whenthebatteryisconnectedandthedriverdooropens,thedoor contact switch activates the fuel pump. Escaping fuel can ignite and cause a fire.
–Disconnect voltage supply to fuel pump before opening the fuel system.
1.2Safety measures when working on vehicles with a start/stop system
Risk of injury due to unexpected motor start
If the vehicle’s start/stop system is activated, the engine can start unexpectedly. A message in the dash panel insert indicates whether the start/stop system is activated.
–Deactivate start/stop system by switching off the ignition.
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Touareg 2018 ➤ 4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018 1. Safety information 1
Touareg 2018 ➤
4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018
1.3Safety precautions when using testers and measuring instruments during a road test
Risk of injury caused by unsecured testing and measuring instru‐ments
When the front passenger airbag is triggered in an accident, in‐sufficiently secured testing and measuring instruments become dangerous projectiles.
–Secure testing and measuring instruments on the rear seat. or
– Have a second person operate the test and measuring equip‐ment on the rear seat.
1.4Safety precautions when working on ignition system
Risk of injury due to electric shock
The ignition system is under high voltage when the engine is run‐ning.Touchingtheignitionsystemmayresultinanelectricshock.
– Do not touch or disconnect ignition cables when the engine is running or being turned at starter speed.
Risk of damage to components
Connecting or disconnecting electric cables or washing the en‐gine while it is running may damage components.
– Switchofftheignitionbeforeconnectingordisconnectingelec‐tric cables.
–Switch off the ignition before washing the engine.
1.5Safety precautions when working on the cooling system
Danger of scalding by hot coolant
On a warm engine, the cooling system is under high pressure. Danger of scalding by steam and hot coolant.
–Wear protective gloves.
–Wear protective goggles.
–Reduce excess pressure by covering cap of coolant expan‐sion tank with cloths and opening it carefully.
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thgirypocybdetcetorP
2 Rep. gr.00 - Technical data
2Identification
⇒ “2.1 Engine number/engine data”, page 3
2.1Engine number/engine data
Engine number
The engine number (“code letters” and “serial number”) can be found at the joint between the engine and gearbox.
Theenginecodeisalsostampedonthecylinderblockbehindthe oil filter.
In addition, there is a sticker on the right of the timing chain cover with “engine code” and “serial number”.
The first 3 digits denote the mechanical design of the engine and are stamped on the engine. The fourth digit shows the engine outputandtorqueandvariesaccordingtoenginecontrolunit.The four-digitenginecodecanbefoundontheidentificationplateand on the vehicle data sticker. It can also be read from the engine control unit.
Note
Fittinglocationsofvehicledatasticker⇒Maintenance;Booklet; Vehicledatasticker.
Engine data
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Codes CYRB CYRC DMFA Manufactured from 04.2018 ► 04.2018 ► 07.2018 ► Exhaust emission standard EU 6 EU 6 C6b without RDE Displacement l 2.0 2.0 2.0 Power kW at rpm 185at5000…6000 183at5000…6000 180at5000…6000 Torque Nm at rpm 370at1600…4500 370at1600…4500 370at1600…4500 Bore Diameter, mm 82.5 82.5 82.5 Stroke mm 92.8 92.8 92.8 Compression ratio 9.6:1 9.6:1 9.6:1 RON 95 95 95 Injection system Direct injection and intake manifold in‐jection Direct injection and intake manifold in‐jection Direct injection Firing order 1-3-4-2 1-3-4-2 1-3-4-2 Charging Exhaust turbo‐charger Exhaust turbo‐charger Exhaust turbo‐charger Camshaft timing adjustment Yes Yes Yes Valvelift system Yes Yes Yes Secondary air injection No No Yes Valves per cylinder 4 4 4 Oil pressure control Yes Yes Yes Touareg 2018 ➤ 4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018 2. Identification 3
3Repair instructions
⇒ “3.1 Rules for cleanliness”, page 4
⇒ “3.2 Foreign objects in engine”, page 4
⇒ “3.3 Contact corrosion”, page 4
⇒ “3.4 Routing and attachment of lines”, page 4
⇒ “3.5 Fitting radiator and condensers”, page 5
⇒ “3.6 Checking vacuum system”, page 5
3.1Rules for cleanliness
Even small amounts of contamination/soiling can lead to defects. Youmustthereforecomplywiththefollowingrulesforcleanliness when working on the fuel supply system, injection system and turbocharger:
♦ Carefully clean connection points and the surrounding area withenginecleanerorbrakecleaneranddrythoroughlybefore opening.
♦ Seal open pipes and connections immediately with clean plugs for example from the engine bung set - VAS 6122- .
♦ Place removed parts on a clean surface. Cover with lint-free cloths only.
♦ If repair work cannot be performed immediately, carefully cov‐er or seal components.
♦ Install clean components only. Do not remove replacement parts from packing until immediately before installing. Do not use parts that have been stored outside their packaging (e.g. in tool boxes).
♦ When the system is open, avoid working with compressed air and moving vehicle.
♦ Make sure that no fuel gets onto the fuel hoses. Should this occur, the fuel hoses must be cleaned immediately.
♦ Protectdisconnectedelectricalconnectorsfromdirtandwater, and reconnect them only when dry.
3.2Foreign objects in engine
♦ To prevent the ingress of foreign bodies during work on the engine,sealopenchannelsoftheintakeandexhaustsections with suitable bungs, for example from the engine bung setVAS 6122- .
3.3Contact corrosion
Contact corrosion can occur if non-approved fasteners are used on the vehicle (bolts, nuts, washers etc.).
For this reason, only connecting elements with a special surface coating have been fitted.
In addition, rubber, plastic and adhesives are made of non-con‐ductive materials.
If there is any doubt about the suitability of parts, a general rule is to use new parts ⇒ Electronic parts catalogue (ETKA) .
3.4Routing and attachment of lines
♦ Mark fuel lines, vacuum lines, pipes/hoses for activated char‐coal filter system and electrical wiring etc. before removal so
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Touareg 2018 ➤ 4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III,
drive) - Edition 09.2018 4 Rep. gr.00 - Technical data
turbocharger, chain
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
Touareg 2018 ➤ 4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018
they can be re-installed in the original positions and correctly connected. Make sketches or take photographs if necessary.
♦ To avoid damaging pipes and wires, ensure adequate clear‐ance from all moving or hot components in the engine com‐partment on account of the confined space.
3.5Fitting radiator and condensers
Even if installed correctly, the radiator, the condenser and the chargeaircoolermayhavesmalldentsintheirfins.Thisdoesnot mean that these components have been damaged. It is not per‐missibletorenewradiators,condensersorchargeaircoolersonly because of such minor dents.
AG. Volkswagen
3.6Checking vacuum system
Special tools and workshop equipment required
♦ Hand operated vacuum pump - VAS 6213-
Procedure
– Check all vacuum lines throughout entire vacuum system for:
♦ Cracks
♦ Marten bites
♦ Crushing
♦ Porous areas and other leaks
– Check vacuum line to solenoid valve and from solenoid valve to relevant component.
– If a fault has been entered in the event memory, make sure to check not only all vacuum lines leading to the specified com‐ponent, but also those leading to other components.
– Ifpressurecannotbebuilt-upusinghandvacuumpump-VAS 6213- or pressure immediately drops again, check hand vac‐uum pump and connecting hoses for leaks.
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3. Repair instructions 5
10 –Removing and installing engine
1Removing and installing engine
⇒ “1.1 Removing engine”, page 6
⇒ “1.2 Securing engine on engine and gearbox support”, page 21
⇒ “1.3 Installing engine”, page 23
1.1Removing engine
Special tools and workshop equipment required
♦ Support - 10-222A-
♦
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♦ Lifting tackle - 2024A-
Touareg 2018 ➤ 4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018 6 Rep. gr.10 - Removing and installing engine
Gearbox support - 3147-
♦ Lambda probe open ring spanner set - 3337-
♦ Flared ring attachment AF 16 - V.A.G 1332/14-
♦ Workshop hoist - VAS 6100-
♦ Engine bung set - VAS 6122-
Touareg 2018 ➤ 4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018 1. Removing and installing engine
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Touareg 2018 ➤
4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018
♦ Coolant collection system - VAS 5014- or drip tray for work‐shop hoists - VAS 6208-
♦ Spring-type clip pliers - VAS 6362-
♦ Adapter - VAS 6948-
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♦ Locking pin - T10060A-
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8 Rep. gr.10 - Removing and installing engine
Touareg 2018
4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018
♦ -T40093/6- from engine support supplement set - T40093-
♦ Wrench, 21 mm - T40263-
♦ Adapter - T40314-
♦ Safety glasses
♦ Safety gloves
Procedure
• The engine is removed upwards without gearbox.
–Move front wheels to straight-ahead position.
–Disconnect earth wire from battery terminal ⇒ Electrical sys‐tem; Rep. gr. 27 ; Battery, Disconnecting and connecting battery .
–Remove air filter housing ⇒ page 261
–Remove upper cross piece ⇒ General body repairs, exterior; Rep. gr. 50 ; Lock carrier, Assembly overview - lock carrier .
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1. Removing and installing engine 9
Touareg 2018 ➤
4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018
–Release fastener -arrow- and open electronics box.
–Unscrew nut -2- and expose B+ wire.
–Free off electric wire -1- from wiring duct.
–Unscrew nut -2- and free off earth wire.
–Remove bolt -3- and nut -4- and free off wiring duct.
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–Unscrew nut (accessible from above) -2- for front silencer. (-Items 1, 3, 4- will be unscrewed later).
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10 Rep. gr.10 - Removing and installing engine
4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018
CAUTION
On a warm engine, the cooling system is under high pressure. Danger of scalding by steam and hot coolant.
There is a risk of injury to the skin and parts of the body due to scalding.
– Wear protective gloves.
– Wear protective goggles.
– Reduce excess pressure by covering cap of coolant expan‐sion tank with cloths and opening it carefully.
–Open cap -1- on coolant expansion tank. To do this, release fastener -arrow-.
–Remove front wheels ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels, tyres .
–Detach front left wheel housing liner on longitudinal member, remove right wheel housing liner ⇒ General body repairs, ex‐terior; Rep. gr. 66 ; Wheel housing liner; Removing and installing front wheel housing liner .
–Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insulation; Removing and installing noise insulation .
– Placecollectorofcoolantcollectionsystem-VAS5014-ordrip tray for workshop hoists - VAS 6208- underneath.
–Lift retaining clip -arrow-, remove coolant hose from radiator and drain off coolant.
– Detachhoseclip-arrow-,removecoolanthosefromATFcool‐er and drain off coolant.
1. Removing and installing engine
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Touareg 2018
11
–Separate electrical connectors -1, 2- for radiator fan.
–Press locking tabs on left and right sides of radiator cowl si‐multaneously-arrow-,liftradiatorcowloffradiatorandremove from below.
–Unscrew bolt -arrow-, pull off wiring duct -1- from sump (top section) forwards and push downwards.
–To slacken poly V-belt turn tensioning device in direction of -arrow-.
–Lock tensioning device in place with locking pin - T10060A- .
–Remove poly V-belt.
–Remove air conditioner compressor from bracket, raise and tie on left-hand side ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Removing air conditioner com‐pressor from and installing to bracket .
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Touareg 2018 ➤ 4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018 12 Rep. gr.10 - Removing and installing engine
Touareg 2018 ➤
4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018
–Remove left connector -2- from retainer.
–Remove left and right bolt -1- on support bearing.
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–Release hose clip -arrow- and detach right air hose from tur‐bocharger.
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–Unscrew bolt -arrow- and push retainer with cable -1- to one side.
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–Unscrew nut -4- and release earth wire.
–Unscrew bolt -2-.
–Disconnect connectors -1, 3- and free off wires.
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Removing
installing engine
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
Touareg 2018 ➤ 4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018
–Unscrew bolts -arrows- and remove heat shield for right drive shaft.
–Unbolt left and right drive shaft from flange shaft ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
–Unscrew nuts -1, 3- and bolt -4- for front silencer.
NOTICE
Danger of damage to flexible joint from improper handling.
– Do not bend flexible joint more than 10°.
– Ensure flexible joint is not placed under tension.
–Unscrew bolts -arrows-.
–Loosen threaded connections -arrows- and push clamp to rear.
–Remove front silencer.
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14 Rep. gr.10 - Removing and installing engine
4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive)
–Unscrew nut -2- for catalytic converter. (Do not remove nuts -1- yet.)
–Remove cross struts for subframe ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe; Removing and installing cross struts for subframe .
–Unscrew bolts -arrows- and push ATF cooler with hoses still attached -1, 2, 4- to one side.
–Pull off cover -1- downwards from gearbox -arrow-.
–Unscrew 3 bolts -arrow- for torque converter -1-.
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15
Touareg 2018 ➤
- Edition 09.2018 1. Removing and installing engine
Touareg 2018 ➤ 4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018
–Counterhold crankshaft to release bolts for torque converter using wrench AF 21 - T40263- and adapter -T40314- .
NOTICE
Risk of damage to engine when the drive chain slips.
– Only turn engine in engine direction of rotation.
–Then turn crankshaft further by 120° respectively in direction of engine rotation -arrow-.
–Unscrew bolt -1- using flared ring attachment, AF 16 - V.A.G 1332/14- and adapter - VAS 6948- .
–Remove engine/gearbox securing bolts -6 … 11-.
–Unscrew bolt -arrow- on left and right for engine mounting.
–Disconnect electrical connector -2-.
–Release fasteners -arrow-, detach engine control unit - J623-item 3- and place to one side.
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16 Rep. gr.10 - Removing and installing engine
Touareg 2018
4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018
–Disconnect electrical connector -1-.
–Pull off electrical connector to one side. To do this, release fastener -arrow-.
–Expose engine wiring harness and place it on engine.
–Remove body brace ⇒ Running gear, axles, steering; Rep. gr. 40 ; Suspension strut, upper suspension link; Removing and installing body brace .
–Remove connector -1- for Lambda probe after catalytic con‐verter-G130--item2-fromretainer,disconnectitandlaywire to one side.
– Remove electrical connector -1- from bracket and disconnect.
–Unscrew nuts -1- and remove catalytic converter upwards.
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1. Removing and installing engine
Touareg 2018 ➤
4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018
– Disconnect fuel hose -1- ⇒ Fuel supply; Rep. gr. 20 ; Plug-in connectors; Disconnecting plug-in connectors .
–Detach hose clip -2- and pull off hose for activated charcoal filter system.
–Pull off resonator -3- from air pipe.
–Pull back heat guard very slightly.
–Lift retaining clip -arrow- and disconnect coolant hose.
–Release screw-type clip -arrow- and pull off air hose from throttle valve module - J338- .
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–Lift retaining clip -1- and disconnect coolant hose.
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18 Rep. gr.10 - Removing and installing engine
4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018
– Pulloffvacuumhose-arrow-forbrakeservoonplenumcham‐ber bulkhead.
–Lift retaining clips -1, 3-, and remove coolant hoses.
–Lift retaining clip -1- and disconnect coolant hose.
–Release hose clip -2-, and disconnect coolant hose.
–Release hose clip -1- and detach coolant hose.
–Disconnect electrical connector -2-.
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–Unscrew bolts -arrows-, push Climatronic coolant shut-off valve - N422- -item 3- towards rear.
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1. Removing and installing engine 19
–Separate electrical connector -1- for radiator outlet coolant temperature sender - G83- .
Remove bolts -2 … 5- securing gearbox to engine (accessible from above).
–Pull off starter from gearbox but leave in installation position.
–Remove spacer sleeve -arrow-.
– Remove rear cover for wing on left and right ⇒ General body repairs,exterior;Rep.gr. 50;Wings;Removingandinstalling rear cover for wing.
–To protect against damage, mask off bonnet struts in bottom area.
– Assemblesupportbracket-10-222A-withadapters-10-222A/ 22- on left and right of wing threaded connection edges as shown.
–Join gearbox and spindle - 10-222A/11- to gearbox support3147- . (Shown with engine removed.)
–Lightly take up weight of gearbox using spindle.
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Touareg 2018 ➤ 4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018 20 Rep. gr.10 - Removing and installing engine
4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition
– Secure lifting tackle - 2024A- on engine, and attach it to work‐shop hoist - VAS 6100- as shown in illustration.
CAUTION
Danger of injury caused by falling of the raised engine. Crushing of body parts possible.
The support hooks and pins on the lifting tackle must be se‐cured with locking pins.
–Lift engine until engine mountings are free.
–Turn back spindle - 10-222A/11- .
NOTICE
Danger of damage to lines and hoses as well as engine com‐partment as engine/gearbox assembly is lowered.
– Check that all connections between engine, gearbox, sub‐frame and body have been disconnected.
– When lowering, carefully guide engine/gearbox assembly with assembly carrier out of engine compartment.
– Pull off engine from gearbox and lift out upwards from engine compartment.
1.2Securing engine on engine and gearbox support
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–
Touareg 2018 ➤
Removing and installing
21
09.2018 1.
engine
Touareg 2018 ➤ 4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018
Special tools and workshop equipment required
♦ Lifting tackle - 2024 A-
♦ Workshop hoist - VAS 6100-
♦ Engine and gearbox support - VAS 6095-
Procedure
• Gearbox detached from engine.
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22 Rep. gr.10 - Removing and installing engine
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
Touareg 2018 ➤ 4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018
–Attach lifting tackle - 2024 A- to engine on workshop hoistVAS 6100- .
– Inordertomatchtheliftingtackletothecentreofgravityofthe engine, the holes in the hook rail must be allocated as shown in the illustration.
–The support hooks and pins on the lifting tackle must be se‐cured with locking pins -arrows-.
–Using workshop hoist - VAS 6100- , lift engine off engine and gearbox jack - VAS 6931- .
– Removedowelsleevesforgearbox,and,ongearboxside,bolt engine to engine and gearbox support - VAS 6095- .
1.3Installing engine
Special tools and workshop equipment required
♦ All special tools listed for engine removal
Torque settings
• The specified torques are only valid for nuts and bolts which havebeenslightlygreased,oiled,phosphate-treatedorblackoxided.
• Additionallubricantsuchasengineoilorgearoilmaybeused, but do not use lubricant containing graphite.
• Do not use degreased parts.
• Tolerance for specified torques ± 15%.
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 27
♦ Engine to gearbox ⇒ 8-speed automatic gearbox; Rep. gr. 37 ; Removing and installing gearbox; Tightening torques for gearbox
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Component Nm Bolts and nuts M6 9 M7 15 M8 20 M10 40 M12 65
23
1. Removing and installing engine
Touareg 2018 ➤
4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018
Procedure
• Renew bolts that are tightened with turning further angle after each removal.
• Renew self-locking nuts and bolts as well as gaskets, seals and O-rings after each removal.
• Hoseconnectionsaswellashosesforchargeairsystemmust be free of oil and grease when installing.
• Secureallhoseconnectionswiththecorrecttypeofhoseclips (same as original equipment) ⇒ Electronic parts catalogue .
• To properly secure the charge air hoses on their connections, spray rust remover onto the worm thread of used hose clips before installing.
• Fit all cable ties in the original position when installing.
• Fit thermal sleeves in same place when installing turbocharg‐er.
– Mountgearboxonengine⇒ 8-speedautomaticgearbox;Rep. gr. 37 ; Removing and installing gearbox; Installing gearbox .
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24 Rep. gr.10 - Removing and installing engine
Touareg 2018 ➤
4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018
–Relieve spindle - 10-222A/11- tension.
– Lower workshop hoist and allow engine with gearbox to settle on engine mountings.
–Install engine mountings and support bearing ⇒ page 27
–Remove workshop hoist - VAS 6100- and lifting tackle2024A- .
Further installation is carried out in reverse order of removal. Ob‐serve the following:
–Install rear cover for wing ⇒ General body repairs, exterior; Rep. gr. 50 ; Wings ; Removing and installing rear cover for wing.
–Install Climatronic coolant shut-off valve - N422⇒ page 209
–Attach fuel hoses ⇒ Fuel supply system; Rep. gr. 20 ; Plugin connectors; Disconnecting plug-in connectors .
–Install body brace ⇒ Running gear, axles, steering; Rep. gr. 40 ; Suspension strut, upper suspension link; Assembly over‐view - suspension strut, upper suspension link .
– InstallATFcooler⇒ 8-speedautomaticgearbox;Rep.gr. 37; ATF circuit; Removing and installing ATF cooler .
– Install subframe cross brace ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe; Assembly overview - subframe .
– Tightendriveshaftbolts⇒ Runninggear,axles,steering;Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
AG. Volkswagen
– Installheatshieldfordriveshaft⇒ Runninggear,axles,steer‐ing; Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft heat shield .
– Install air conditioner compressor ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Removing and in‐stalling air conditioner compressor from and to bracket .
–Install poly V-belt ⇒ page 36 .
–Install radiator cowl ⇒ page 227
–Electrical connections and routing ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.
–Install catalytic converter ⇒ page 295
–Align exhaust system free of stress ⇒ page 293
–Remove upper cross piece ⇒ General body repairs, exterior; Rep. gr. 50 ; Lock carrier, Assembly overview - lock carrier .
–Install air filter housing ⇒ page 261
–Replenish engine oil and check oil level ⇒ page 157 .
–Observe measures required after connecting battery ⇒ Elec‐trical system; Rep. gr. 27 ; Battery; Disconnecting and con‐necting battery .
–Connect coolant hose with plug-in connector ⇒ page 222
• Never reuse old coolant.
–Add coolant ⇒ page 186
– Install wheel housing liners ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; Assembly overview - front wheel housing liner .
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25
1. Removing and installing engine
Touareg 2018 ➤
4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018
– Installnoiseinsulations⇒ Generalbodyrepairs,exterior;Rep. gr. 66 ; Noise insulation; Assembly overview - noise insula‐tion .
– Mount front wheels ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels, tyres .
If a new base engine or short engine was installed, additional adaptations must be carried out in the engine control unit. Pro‐ceed as follows to do this:
– Connect⇒Vehiclediagnostictester,andselectfollowingfunc‐tions.
♦ Engine control unit functions
♦ 0001 - Activate engine run-in and
♦ Engine control unit functions
♦ 0001 - Basic setting
♦ 0001 - Adaption of chain drive after repairs
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26 Rep. gr.10 - Removing and installing engine
4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018
2Assembly mountings
⇒ “2.1 Assembly overview - assembly mountings”, page 27
⇒ “2.2 Supporting engine in installation position”, page 29
⇒ “2.3 Removing and installing engine mounting”, page 30
⇒ “2.4 Removing and installing support bearing”, page 32
⇒ “2.5 Removing and installing gearbox mounting”, page 33
2.1Assembly overview - assembly mountings
Engine mounting
1 - Subframe
2 - Assembly mounting sender
❑Not fitted
3 - Bolt
❑Not fitted
4 - Bolt
❑55 Nm
5 - Bolt
❑20 Nm
6 - Bolt
❑10 Nm
7 - Support bearing
❑ Removing and installing
⇒ page 32
❑Fitting position
⇒ page 28
8 - Engine support
❑ Removing and installing
⇒ page 45
9 - Bolt
❑55 Nm
10 - Bolt
❑10 Nm
11 - Heat shield
12 - Engine mounting
❑ Left electrohydraulic en‐gine mounting solenoid valve - N144-
❑Right electrohydraulic engine mounting solenoid valve - N145-
❑Removing and installing ⇒ page 30
13 - Bolt
❑Renew after removal
❑90 Nm +90°
14 - Bolt
❑30 Nm
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Touareg 2018 ➤
27
2. Assembly mountings
Touareg 2018 ➤
4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018
Support bearing - installation position
• Protrusion-2-onenginesupportmustengageinrecess-1-on support bearing.
Gearbox mountings for automatic gearbox
1 - Bolt
❑55 Nm
2 - Tunnel cross member
❑ Removing and installing
⇒ 8-speed automatic gearbox; Rep. gr. 37 ; Assembly mountings; Assemblyoverview-as‐sembly mountings
3 - Stop
❑For gearbox mounting
4 - Rear gearbox mounting
❑ Removing and installing
⇒ page 33
5 - Nut
❑ Only unscrew if gearbox mounting has to be sep‐arated from gearbox support
❑20 Nm
6 - Bolt
❑ Only unscrew if gearbox mounting has to be sep‐arated from gearbox support
❑20 Nm +90°
❑Renew after removal
7 - Gearbox support
❑ Removing and installing
⇒ page 33
8 - Bolt
❑40 Nm
9 - Bolt
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❑Only unscrew if gearbox mounting has to be separated from gearbox support
❑20 Nm +90°
❑Renew after removal
10 - Nut
❑20 Nm
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28 Rep. gr.10 - Removing and installing engine
Touareg 2018
4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018
2.2Supporting engine in installation posi‐tion
Special tools and workshop equipment required
♦ Support - 10-222A-
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Preparing tools
–Unless already done, drill a hole centrally in both frames -10-222A/1- measuring ∅ 11 mm, as shown in diagram.
• Dimension -a- = 30 mm.
Procedure
–Remove air filter housing ⇒ page 261
–Remove headlight cover on both sides ⇒ General body re‐pairs, exterior; Rep. gr. 63 ; Front bumper .
– Place support bracket - 10-222A- on left and right longitudinal members.
– Tightenadapter-10-222A/34-onframes-10-222A/1-withnut -2-. When doing this, adapter must engage as shown in lon‐gitudinal member -1-.
–Engage spindles -10-222A/11- in engine lifting eyes.
–Tighten spindles to take up weight of engine; do not lift.
Installing
Assembly is carried out in reverse sequence; note the following:
– Installheadlightcovers⇒ Generalbodyrepairs,exterior;Rep. gr. 63 ; Front bumper .
–Install air filter housing ⇒ page 261
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29
2. Assembly mountings
Touareg 2018 ➤
4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018
2.3Removing and installing engine mount‐ing
⇒ “2.3.1 Removing and installing right engine mounting”, page 30
⇒ “2.3.2 Removing and installing left engine mounting”, page 31
2.3.1Removing and installing right engine mounting
–Support engine in installation position ⇒ page 29 and tension withspindles-10-222A/11-enoughtoensureenginemounting is relieved of load.
–Remove front noise insulation ⇒ General body repairs, exte‐rior; Rep. gr. 66 ; Noise insulation; Removing and installing noise insulation .
Vehicles with secondary air system:
–Remove secondary air pump motor - V101- ⇒ page 298
Continued for all vehicles:
–Detach front right wheel housing liner front section on longi‐tudinal member ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; Removing and installing front wheel housing liner .
–Release hose clip -arrow- and detach right air hose from tur‐bocharger.
–Remove right-hand support bearing ⇒ page 32
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–Remove nut -arrow- and move earth wire clear.
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AG Volkswagen
30 Rep. gr.10 - Removing and installing engine
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
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4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018
–Unscrew bolt -1-.
–Release fasteners -arrows-, free off retainer -2- for electrical wiring on subframe.
–Unscrew bolts -arrows- and remove engine mounting -1-. Installing
Install in reverse order of removal, observing the following:
• Renew bolts that are tightened with turning further angle after each removal.
Torque settings
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 27
♦ ⇒ Generalbodyrepairs,exterior;Rep.gr. 66;Wheelhousing liner; Assembly overview- front wheel housing liner
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐tion; Assembly overview - noise insulation
2.3.2Removing and installing left engine mounting
–Support engine in installation position ⇒ page 29 and tension withspindles-10-222A/11-enoughtoensureenginemounting is relieved of load.
–Remove front noise insulation ⇒ General body repairs, exte‐rior; Rep. gr. 66 ; Noise insulation; Removing and installing noise insulation .
–Detach front left wheel housing liner front section on longitu‐dinal member ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; Removing and installing front wheel housing liner .
–Separate connector -3- for solenoid valve.
–Remove connector -2- from retainer.
–Unscrew bolt -1- for support bearing.
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Touareg 2018 ➤
31
2. Assembly mountings
Touareg 2018 ➤ 4-cyl. direct injection engine
–Unscrew bolts -arrows- and remove engine mounting.
Installing
Install in reverse order of removal, observing the following:
• Renew bolts that are tightened with turning further angle after each removal.
Torque settings
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 27
♦ ⇒ Generalbodyrepairs,exterior;Rep.gr. 66;Wheelhousing liner; Assembly overview- front wheel housing liner
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐tion; Assembly overview - noise insulation
2.4Removing and installing support bear‐ing
⇒ “2.4.1 Removing and installing support bearing, right”, page 32
⇒ “2.4.2 Removing and installing support bearing, left”, page 32
2.4.1Removing and installing support bear‐ing, right
Removing
–Remove front noise insulation ⇒ General body repairs, exte‐rior; Rep. gr. 66 ; Noise insulation; Removing and installing noise insulation .
Vehicles with secondary air system:
–Remove secondary air pump motor - V101- ⇒ page 298 .
Continued for all vehicles:
–Unscrew bolts -1- and -2-, remove support bearing -3-.
Installing
Install in reverse order of removal, observing the following:
• Installation position ⇒ page 28 .
Torque settings
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 27
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐tion; Assembly overview - noise insulation
2.4.2Removing and installing support bear‐ing, left
Removing
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–Remove front noise insulation ⇒ General body repairs, exte‐rior; Rep. gr. 66 ; Noise insulation; Removing and installing noise insulation . (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018 32 Rep. gr.10 - Removing and installing engine
4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive)
–Remove connector -4- from retainer.
–Unscrew bolts -1- and -3-, remove support bearing -2-.
Installing
Install in reverse order of removal, observing the following:
• Installation position ⇒ page 28 .
Torque settings
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 27
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐tion; Assembly overview - noise insulation
2.5Removing and installing gearbox mounting
Removing
– Remove tunnel cross member ⇒ 8-speed automatic gearbox; Rep. gr. 37 ; Assembly mountings; Assembly overview - as‐sembly mountings .
–Unscrew bolts -arrows- and remove gearbox support with gearbox mounting -1- from gearbox.
–Unscrew bolts -1-, remove stop -2- for gearbox mounting.
–Unscrew nut -5- and bolt -6-, remove gearbox mounting -3from gearbox support -4-.
Installing
Install in reverse order of removal, observing the following:
–Tighten nut -5- and bolt -6- by hand first.
–Tighten bolts and nuts in the sequence -1, 5, 6-.
–Install gearbox support and gearbox mounting.
Torque settings
♦ ⇒ 8-speedautomaticgearbox;Rep.gr. 37;Assemblymount‐ings; Assembly overview - assembly mountings
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Touareg 2018 ➤
2.
33
- Edition 09.2018
Assembly mountings
13 –Crankshaft group
1Cylinder block (pulley end)
⇒ “1.1 Assembly overview - cylinder block (pulley end)”, page 34
⇒ “1.2 Removing and installing poly-V belt”, page 36
⇒ “1.3 Removing and installing tensioner for poly V-belt”, page 37
⇒ “1.4 Removing and installing vibration damper”, page 37
⇒ “1.5 Removing and installing bracket for ancillaries”, page 43
⇒ “1.6 Removing and installing engine support”, page 45
1.1Assembly overview - cylinder block (pulley end)
1 - Poly V-belt
❑Check for wear
❑Do not kink
❑Before removing, mark direction of rotation with chalk or felt-tipped pen
❑ Removing and installing
⇒ page 36
❑When installing, make sureitisproperlyseated on pulleys.
2 - Tensioning device for poly V-belt
❑Swing with spanner to slacken poly V-belt.
❑Lock with locking pinT10060A- .
❑ Specified torque for ten‐sioning roller to tension‐er: 60 Nm
❑ Removing and installing
⇒ page 37
3 - Bolt
❑Renew after removal
❑8 Nm +45°
4 - Bolt
❑Renew after removal
❑Use counter-hold toolT10355- to loosen and tighten
❑Lubricate O-ring with engine oil.
❑150 Nm +90°
5 - O-ring
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❑Not a replacement part. Included in items supplied with bolt ⇒ Item 4 (page 34)
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.
AG Volkswa
Touareg 2018 ➤ 4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive) - Edition 09.2018 34 Rep. gr.13 - Crankshaft group
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
