DIY: V10 Teardown and Rebuild - Repair of the distribution of a Touareg V10 [Frex]

Frex · Apr 19, 2012

I go back the piston Poles used,

A quick compressor segment and is threaded into the piston
tapping and by greasing the room beforehand,
is monitored at the same time that the connecting rod which is set up on the landing,
then the connecting rod cap is based in the tightening torque.

Once set up you spin the motor to check that there is no hard point.

Frex · Apr 19, 2012

Okay now I can rest the bottom of the engine,
the two oil sumps, oil pump last and plastic covers

Replacing the two guides of oil "Orange" and clips,

Finally based hule main sump,

We can now return the engine to read ....

Frex · Apr 19, 2012

I think we should also emphasize the expertise of our specialized companies
in the [rebuild] rehabilitation of our engines,

I deplore the systematic change today by a motor exchange standard,
I'm glad we asked for this work,

The few residual marks that you can see in the picture have no impact on the operation,

here in detail after the front of my head ...

Frex · Apr 19, 2012

Centering of the distribution module for the alignment of the axis of the alternator,
and tightening torque 60Nm then terminal 150 nm, for the installation of the seal spie.

Surface

cleaning for the rest of the gaskets,

Frex · Apr 19, 2012

Hello,

Meanwhile my pieces that are slow to arrive, I reinstall those available.

Thus replacing the seal of the alternator,

Then clean the parting of the bolt free,

And then out of curiosity I removed the piston rod from my hs,
given the outcome I was right to change the connecting rod + piston!

It is bent and twisted on itself!

Frex · Apr 19, 2012

Reassembly of the injector pump,

And

glow plugs,

Cleaning and reassembly of the intake ports with their EGR valves

Frex · Apr 19, 2012

My pieces have finally arrived!

Reassembly of the water pump with change of the two gaskets,
do not forget the introduction of the central shaft.

Fit the new oil seal on the housing front,

Then replacing the two housings of the front side pump

Changing the gearbox oil seal side,

Considering the difficulty to stand beside the sump box,
here's a little trick to avoid damaging the oil seal lips during reinstallation.
I use a plastic bottle slightly conical gift I cut a thin strip

more tomorrow ....

Frex · Apr 19, 2012

Now wind the pulley damper and hydraulic coupler

I finished all fasteners rest of the housing with torque tightening

I based the trident of hydraulic coupling and resting
compared to white + marker already torquing.

Replacing the coupler, ditto from mark removal,
6 screws are fixed through the hatch and is tightened to the torque by raising the motor to move the key.

Based temporary damper pulley, I must control the mounting screws.

Frex · Apr 19, 2012

Replacing the cylinder heads, head gaskets poses,

Poses two cylinder heads, and then tightening the wrench
the couple have broken down as:

1st pass to 30Nm
2 nd goes to 60Nm
3 rd pass with a simple ratchet tightening to 180 °
4 th pass with a simple ratchet tightening to 180 °

it is essential to change at this stage reassembling all the original cylinder head bolts with new ones.
Do not take the risk of reusing the old ones, especially given the stress that one has when attacking the 4 th pass,
you are always afraid of breaking a screw!

Here is the tightening sequence:

Finally based pinion bearing cylinder heads:

Then the gears camshafts:

Frex · Apr 19, 2012

Reassembling the alternator, and it does not surprise when the heads are amazing places right?
Ben then VW engineers?

no question of re-depositing them!

So little trick, it seems that a small ridge on the admission without real interest is the cause of the problem,
So cut it with the usual precautions and hop it goes!

Then

presents common rail fuel changed after all O-rings,

Frex · Apr 19, 2012

Finalizing the installation of ramps, fuel pipe cooling
Fuel filter and oil filter.

Frex · Apr 19, 2012

Preparation of the valve timing,

Ask the camshafts without putting the bearing caps for now,
Position the crankshaft position TDC (top up)
Spotted the cylinder 1 and 7 of the bank No. 1 and 2
Bench No. 1 Left front of engine
Bench No. 2 to the right front engine
Turn the camshafts for the cams up the cylinder 7
and the cams down the cylinder 1 to the pre injection
Ask the two timing tools from two camshafts
Position the sprocket's Bench # 1 of the white mark on the horizontal cylinder head
After a while the games instead of reducing gears in reverse the engine running.
Fixed gears to tighten the central screw 150 nm
Remove the hardware and maintains two laps in the driving direction to check, you must be able to rest holds camshaft in position without forcing happened TDC.

Frex · Apr 19, 2012

Frex · Apr 19, 2012

the ignition sequence

Frex · Apr 19, 2012

I just received my key capital and the crankshaft timing,

I will continue my timing.

dragline1570 · Apr 19, 2012

Hey Frex
Not only do some salute you i bow to you.
The documentation of this repair /rebuild is fantastic.
I will study this posting foe a long time.
Hopefully you have some more photos / info of this incredible
posting you havent shown us.
Over what time frame did you do this?
Hopefully you will remain active on this site as im sure others will marvel in your pictorial and probably have questions.
You have shown me things that no one else here has shown or even shown or described in most of info available from VW or others.

regards
Mark

Frex · Apr 19, 2012

Well today I go on calibration,
tightening the two screws to 150 nm after preparing a flange maintains,
Indeed € 230 for a clamp that I use once it is a bit expensive.

Thus making two plates fixed to maintain
the cylinder head cover fasteners.

There soda two threaded rods

On

a plate is welded half a gear compatible with that of the cylinder head,
I had those of the old module distribution so it was perfect!

With

two holes at the ends is fixed all,

Here

we get the sets of gears as indicated by the instructions, and you tighten the two screws at 150nm.

Then you place the material we make two turns in the direction of clockwise and it is verified that it holds little rest without forcing me good I got back to twice anyway.

Another little trick, I marked the pinion with an extension of a white line
it is better to extend the line by a saw for accuracy.

Tests of motor rotation, now that everything is in place the compression when the engine is running,
well mean the breath of compression that escapes through the valves, it is impressive compression of this engine!

Frex · Apr 19, 2012

Little analysis of the destruction of this engine,

Looking more closely at the landing gear of the distribution module that has broken
we find that a little wear on it is probably the cause of the overheated pinion finally caved.

One little note that the oil hole ended up closing!
therefore more lubrication, wear, overheating and breaking ...

Frex · Apr 19, 2012

I had never seen an engine with a couple like that and such compression, and it's right that my mistake from the beginning! it is far from a standard 4-cylinder diesel!

Frex · Apr 19, 2012

So I chose my timing depending on the operating logic:

Mark on the shaft head down

Admission, Injection, Exhaust.

I think this is the one I need is the most logical in my opinion,

Then I moved up the two ramps of the control unit injectors

I then based the cylinder head and Coveralls Coveralls plastic anti-noise

DIY: V10 Teardown and Rebuild - Repair of the distribution of a Touareg V10 [Frex]

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