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V10 Gear Train Replacement

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2006 diesel v10 v10
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53K views 305 replies 29 participants last post by  Professor Eggman  
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#1 ·
Round 2!…..ding, ding, ding
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So my New-To-Me 2006 v10 Touareg hit a huge snag, and things GROUND to a halt (see what I did there?). If you have seen my original post and read through all 6 pages, then you know the ups and downs.
Short story: PO told me Touareg had died on new batteries, had seen smoke from the engine and had a mechanic tell him it needs a new alternator. “Otherwise it was running great!” It had been sitting for 2 years. I get new batteries, get it to start….voltmeter says 14 volts but it just doesn’t sound right so shut it down. Did have white smoke from engine.
After removing engine and tearing it down, found it full of sludge and gelatinous old oil. Cleaned it all, new gaskets where appropriate, new oil and coolant, installed back into bay. Started it up, only to hear a horrible grinding noise. Figured out the drive gear for the generator was able to be turned by hand, meaning the gears for it in the gear train are shot.
Wife let me keep going (yay!) and (shout out to TRespect!) bought a used gear train from Germany for $300, plus $200 shipping. Brand new gear train would have been $6000!!
So now awaiting arrival of gear train while I tear down to prepare for it.
I will be mixing old and new pictures for a better flow of all the work I’ve done.
 
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#221 ·
So…..Glow Plug learning opportunity for me. Was about to reinstall the “new” glow plugs that I had bought last year. I had used them in the engine the few times I had run it. Noticed before putting them back in, that the ends were deformed. After plenty of research about all the different glow plugs…..5v, 7v, and 11v, found out I was using 7v plugs in an 11v system. Ordered and just installed Bosch 11v plugs. Picture is 3 of the worst of my 7v plugs, next to a new Bosch 11v.
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#230 ·
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I put the engine back in the car…..and starter would try to turn the engine but no joy. The engine was too hard to turn. I even tried 4 charged batteries, removed the valve covers and injector rockers, and loosened caps on the cams. Still no joy. After all the attempts the engine had turned over a full rotation, little by little with each turn of the key. So, engine is back out and in the process of disassembly. Going to pull each piston and check ring gaps. I had just thrown the new rings in without measuring (I know, I know). So back to that…..at least nothing is broken!
 
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#234 ·
This is an off topic but I think the audience here will enjoy it - Yesterday I was at a chevron gas station that sells Power Diesel, while I was waiting for my coffee I noticed a small fuel delivery truck pull in, the driver hops out and whips a one gallon can of Diesel Kleen from his storage and dumps it down into the ground tank and then proceeds to unload his diesel delivery. Being a "concerned citizen", I could not resist the temptation, so after pinching my self and picking my jaw up from the floor I walked over to the delivery guy and had a little heart to heart. So, it looks like Chevron with all the technical advancements in mixing, has a delivery guy winging the addition of the additive (in this case he was mixing one gallon to 1300 gal of diesel) - oooo how I love this old style!!! On the flip side, my previous doubts as to if the diesel at this particular gas station had any additive as advertised on the filling pipe have been alleviated.
 
#235 ·
In his defense, one gallon of diesel kleen is made for 1500 gallons of fuel...

Knowing somebody that tried to own and operate his own gas station, I'm sure the guy is doing any little thing that he can to prevent fuel issues with the subpar quality fuel we get in America coming back to bite his station in the butt
 
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#239 ·
Not sure about it, as it is a busy station and lots of diesel pickups and trucks do stop over. I think, and I might be "dreaming" here, they get small batches so as to always have fresh delivery or on the lighter side Chevron only gives the delivery company one gallon of Diesel Kleen per delivery so ..... ;)

Professori - Not trying to highjack your awesome thread, but we have to doodle while we wait for your updates. So sorry no hard feelings
 
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#240 ·
No worries about the thread hijack.
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So she’s all back together! But with some problems….
1. Barely starts….I did tweak the camshaft position sensor while removing one of the camshaft gear arms, so new one has been ordered. Will be replacing with engine in. Code keeps popping up for no signal from sensor.
2. Doesn’t move when put in gear…..Auto trans only shows code for implausible signal from Tiptronic. So move selector to D, hit gas and PRNDS goes to one solid yellow block, car doesn’t move at all. Only code is the tiptronic. Had to put in neutral and push out of the garage. Next time I get the started, I will double check my ATF level. I did check it when off, had ATF drip from the fill hole.
3. air compressor fitting is cracked, so only partially aired up. New fitting ordered. This is causing the “running gear fault” message, I assume.
4. Exhaust Gas Temp sensor short to ground….bank 1 sensor 2. This one did have wire issues so new one ordered. Blinking Glow plug light due to this.
5. No signal from Steering Angle Module. Pulled steering column apart and double checked all connections. Everything seems connected properly. Also, no communication to steering wheel controls. Stalks work, but not buttons on the airbag sides.
6. Small fuel leak from somewhere on left fuel rail. Will have to pull apart to see exactly where from.

On a positive note, when the engine does start, it is an absolute monster! Able to rev like crazy, sounds amazing. Can’t wait for this to hit the road!

I did have to grind all of the piston rings, all were very very tight. Then engine turned beautifully.
 
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#241 ·
Professor Eggman said:
No worries about the thread hijack.
View attachment 251913
View attachment 251915
View attachment 251916
View attachment 251914
So she’s all back together! But with some problems….
1. Barely starts….I did tweak the camshaft position sensor while removing one of the camshaft gear arms, so new one has been ordered. Will be replacing with engine in. Code keeps popping up for no signal from sensor.
2. Doesn’t move when put in gear…..Auto trans only shows code for implausible signal from Tiptronic. So move selector to D, hit gas and PRNDS goes to one solid yellow block, car doesn’t move at all. Only code is the tiptronic. Had to put in neutral and push out of the garage. Next time I get the started, I will double check my ATF level. I did check it when off, had ATF drip from the fill hole.
3. air compressor fitting is cracked, so only partially aired up. New fitting ordered. This is causing the “running gear fault” message, I assume.
4. Exhaust Gas Temp sensor short to ground….bank 1 sensor 2. This one did have wire issues so new one ordered. Blinking Glow plug light due to this.
5. No signal from Steering Angle Module. Pulled steering column apart and double checked all connections. Everything seems connected properly. Also, no communication to steering wheel controls. Stalks work, but not buttons on the airbag sides.
6. Small fuel leak from somewhere on left fuel rail. Will have to pull apart to see exactly where from.

On a positive note, when the engine does start, it is an absolute monster! Able to rev like crazy, sounds amazing. Can’t wait for this to hit the road!

I did have to grind all of the piston rings, all were very very tight. Then engine turned beautifully.
Click to expand...
Professor Eggman, you get the golden screw driver award for determination and uncommon persistence! I have a thought about your trans not going into gear. With the tranny dry it will take 10 liters or so to be near full. Just my thoughts. You a WAY overdue for so good luck , it will arrive soon,YES
 
#242 ·
Wow thing looks great. Any video of it running?
 
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#246 ·
I replaced the camshaft position sensor with a new one, and now have a no-start condition. Wiring all has continuity between sensor and ECM harness, and showing 5v at sensor plug. Timing can’t be off since it was correct and is gear driven. Next step is to pull the new sensor out and bench test it. Maybe I got a dud. I don’t understand what “signal out of range” really means.


012296 - Camshaft Position Sensor (G40)
P3008 - 000 - Signal Out of Range
Freeze Frame:
Fault Status: 01110000
Fault Priority: 0
Fault Frequency: 1
Reset counter: 255
Mileage: 297522 km
Time Indication: 0

Freeze Frame:
RPM: 147 /min
Speed: 0.0 km/h
Load: 6.7 %
Voltage: 10.11 V
Bin. Bits: 00001011
Idle Stabilization: 0.0°KW
(no units): 35.0
 
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#248 ·
Turns out the cam position sensor I had received is defective. With the sensor plugged in and the key on, 5v to the positive and signal wire. Move any metal near or right on the sensor and no change in signal voltage. I tired a variety of different metal tools all with no change of the sensor signal voltage. Replacement ordered.
 
#249 ·
Where did get from? OEM?
 
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#251 ·
Front suspension wasn’t holding air, would drop within minutes. Soapy bubble test showed from within dust cover area. Pulled both out and disassembled. Boots all appear intact. New O-ring seals, upper strut mounts, valves, and bump stops ordered. Left spring was full of broken rubber from the strut mount. Right spring had orange rubber from worn bump stop.
Inside left air spring:
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Left strut mount came off in pieces:
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Left strut mount:
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Bump stops:
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#252 ·
Had a medium leak of fluid under left suspension, looked to be power steering fluid, coming from the steering rack boot cover. Pulled the cover off and had a rush of fluid from the rack….left seal major leak. Personally, I like to fix parts rather than just replace, so I ordered a seal kit specific to T1 Touareg/Q7/Cayenne. Can’t find any videos specific to disassembling this rack, only other brands. I will be attempting this next week.
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