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2006 V10 Engine out for Exhaust manifolds

51K views 85 replies 15 participants last post by  noobytoogy 
#1 ·
Hello people,
Just thought would share my experience of my 2006 Touareg V10 TDi exhaust manifold leakage.
Not long after buying the car i noticed smoke coming from around the O/S headlight only in the dark and headlight on, further checking found what looked like the exhaust manifold gasket leaking around the front of the manifold and small amount of soot on things like the air filter housing.
I am a mechanic by trade so looking at the job and having a ring around some pals who specialise in VW's it was more than apparent the engine would have to come out.
Not relishing that idea i set a week aside and started positive thinking!!
Anyway job complete and to be honest it was not hard at all.
I heard about this 'fixture' that was required to hold the engine and gearbox but to be honest the subframe was substantial so decided to use axle stands!.
Well if the pics upload you can see they worked fine.
Turns out a 2 post lift and 4 axle stands was the extent of the special tools required, load of money on parts and some positive thinking :)

Both my exhaust manifolds turned out to be cracked and leaking which i welded back up by Tig and stainless rods, one rocker cover was leaking in the rear corner which was dropping down onto the turbo and catalytic converter causing some smoke but apart from that all was good.
Was not prepared to spend £700 x 2 on new manifolds so taking my chances on repairing them.

It started first try and sounds very sweet again.

If you asked me to do another then i would, its not hard, i spent a lot more time than i should making sure all was clean and tidy, replacing manifold studs and nuts etc. My total labour time has been 36hrs.

Love the car.....
 

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#2 ·
Well done!

There may be one or two V10 owners on the UK site who would like to know about this . . . and your location too!

www.mytreg.com
 
#3 ·
To add think the most frustrating thing was the lack of rocker cover gaskets, the right hand side showed signs of leaking and did not want to just try sealing them up, bought a new rocker cover as the rubber is impregnated into the cover and not replaceable, at nearly £300 it was a bitter pill to swallow.
Oh and the locking devices VW use to protect the ECU plugs as they need to be disconnected, were a real pain to get off!! but hey now the ECU can be re-mapped ;-)
 
#4 ·
As it turns out i got to drop the motor again :-((, manifolds are good but the oil leak from the rocker cover, or so i thought, must be from the turbo seals on the O/S instead.

Gutted, but then no seized bolts.......
 
#5 ·
Crap, that sucks. Check the tandem pump seals and consider replacing. That was that cause of my smoke issues since they were directly over the turbos. Right side was bad and actively dripping, left side was starting to weep.
 
#6 ·
Cheers air-cooled, not 100% sure what you mean by tandem pump? you mean the fuel pumps on the end above the turbos?
 
#7 ·
Yes, cam driven fuel and vacuum pumps. Common source of oil leakage.
 
#8 ·
Magic thanks for heads up, doing it next week so will be ordering parts tomorrow. There a seal between the pump and head? or you mean to strip the units and replace seals?
 
#9 ·
Just the seal between the pump assy and the head unless you suspect more. The pump itself id very costly. The seal is around US$40. I think the part number for the seal is 070145215 but I will need to check my invoice to confirm. Remember, one for each pump. It may or may not be the cause of your smoke but I have seen a large proportion of V10 owner have to go thru this replacement.
 
#10 ·
Brilliant many thanks for heads up. I dropped the engine out to replace / repair the manifolds and found why i thought was the rocker cover leaking. But the oil is dripping down onto the CAT bracket and then onto the Catalytic converter making the bad oil smell.

I will replace those seals anyway just to be sure.
Need to complete this job asap as 'borrowing' a friends ramp in his busy workshop and don't want to inconvenience him longer than needed. Now i have done it once will be interesting to see how long it takes second time round :)

Turbo feed and return seals also while i am at it?
 
#12 ·
Brilliant many thanks for heads up. I dropped the engine out to replace / repair the manifolds and found why i thought was the rocker cover leaking. But the oil is dripping down onto the CAT bracket and then onto the Catalytic converter making the bad oil smell.

I will replace those seals anyway just to be sure.
Need to complete this job asap as 'borrowing' a friends ramp in his busy workshop and don't want to inconvenience him longer than needed. Now i have done it once will be interesting to see how long it takes second time round :)

Turbo feed and return seals also while i am at it?
TUNINGBYAMG had his tandem pump leak from the joint between the vacuum and fuel sections so have a look at that before you just replace the mounting gasket. LH should just need a new mounting gasket.
Would pay to do the seals on the oil feed/return pipe while you are there.

Andy depending on how long it takes before you to get the engine out I would like you ask you to have a look at a part number for me while it is out. I have a coolant pipe that is corroded and weeping that I need the part number for. The dealer tells me its 7L6 121 065 P but looking at the photos it is not the same.
From the very limited view I can get with a mirror and a endoscope camera I think it is 7L6 121 065 Q but this number is not recognized by VW. You should be able to have a clear look with the engine out.
Please view the photos and get back to me.
Some photos showing the upper end of the pipe on your engine would be great also so i can see the arrangement as there seem to be a few different styles.

Regards
Drag
 

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#11 ·
Ordered parts today, ramped booked for next week will post some more pics and time taken etc later on :)
 
#13 ·
Yep will do Drag, and let you know.
The area you have highlighted on my picture, is two hoses that connect to alloy pipes going under wheel arch.
 
#15 ·
Andy
Yea the 2 hoses connect to the webasto heater and also run heat to the rear aircon unit.
You will have a dual steel pipe attached to your block very similar to the unit in my photo. The part number will be on the top mounting bracket but the number will be on the back (block side) of the bracket and when you look at them they will be upside down.

Thanks for your help

Regards
Drag
 
#14 ·
Asked the dealer if there was a seal repair kit for the tandem pump but he said no, the only parts available are the seal to head. The pump complete is £570.......
 
#17 ·
Hi Jo, First time dropping engine and box took me just over day, maybe 10 hours as the size was daunting and i have read so much about this 'frame' that was needed. I did take far too much stuff off the engine and engine bay that was not required to drop engine (header tank, diesel filter, diesel cooler, bulkhead plate....) these were to get to suspension top mounts.
I am fairly sure this time i could have the engine out, gaskets replaced, and pretty much back in in a 10 hour shift :) but time will tell......
Planning on doing the job Saturday / Sunday to avoid using my pals ramp space during his working week.
 
#18 ·
Started :)

Hi All,
Job didn't happen saturday as ramp not free but started this evening.
From pulling onto ramp to having engine and box on floor 3.5 hrs, two post ramp and working alone :)
Engine Auto part Automotive engine part Motor vehicle Vehicle


Engine Auto part Motor vehicle Automotive engine part Vehicle


Vehicle Automobile repair shop Motor vehicle Car Tire

Drag, the picture of the pipe is attached, if this is not the number then let me know as fixing oil leak in the morning and re-installing.
Auto part Automotive engine part Engine

And yes you were all correct it looks like the tandem pipe is to blame and running around the shield and onto cat, rocker cover good and turbo feed and return look dry too.
Auto part Fuel line Engine Vehicle Automotive engine part

Auto part Fuel line Clutch

Auto part Fuel line

Auto part Tire Automotive tire Automotive wheel system Automotive lighting
 
#19 ·
Drag, will drop a couple more pics of the shape of the pipe tomorrow, sorry just read your post again and the part number on mine is quite some difference!!
 
#20 ·
One thing for sure, if anyone got a V10 in Newcastle NSW area then i wouldn't have a problem working on it for you!!! post august....
 
#21 ·
3.5 hours??!!

**** me -THAT is IMPRESSIVE!!!!

I wish you had set up a camera to record yourself and then put it on one of the fast forward play things before posting on U tube.
 
#22 ·
No doubt. You have my respect! I'm glad the problem appears to be only the tandem pump seals. Is it one, or both sides?
 
#23 ·
just the one side at the moment from what i can see aircooled, as you look from the front its the left hand side bank of cylinders. Having a closer look today and will report back if interested??

Pulled in the workshop 16.00pm and was driving home 19.26pm, but you have to remember just done the job so all bolts were free, pipes seals good, no security on the ECU's etc etc
 
#25 ·
Hey that's very nice work ;-)
3.5h of work is very nice.I pulled my engine (half V10, R5 ;-) ) out through the bonnet in 4h but that was without ramp.
I like those "home" workshops, you see with limited special tools the job can always be done with some proper Thinking.

Enjoy your V10 ;-)
 
#26 ·
Finished!!

Hello all,
Well she's finished, running sweet and no oil leaks :D
The dealer told me that no gaskets are available for the fuel pumps but while off had to strip, clean and reseal the covers :)
Spent total of 8 hrs and 45 mins today, about hour half spent removing and resealing the tandem pump and opposite fuel pump but them installation, fluids, bleeding brakes etc etc

Just finished full steam clean underside with wheel arch liners removed to make sure all muck off.

Bodyshop next week for painting bumpers and repairs to 'car park' dents, then to detailing company for a full inside and outside including paint treatment then.....

Karman shipping for its journey to Sydney..........
 

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#27 ·
Few more pics of car.....
 

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#28 ·
Sydney . . . ??!!

And I hope you cleaned out all the crud in the bulkhead drains whilst you had the front wheel arch covers out . . . ?
 
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