Volkswagen Touareg 3.2 - Engine, disassembling and assembling
Engine, disassembling and assembling
Note:
„
Secure engine in engine and transmission holder
VAS 6095 when working on engine.
„
If large quantities of metal particles or abraded material are detected during engine repairs, it may be an indication for a damaged crankshaft or rod bearings. To prevent further damage, perform the following steps after the repair:
„
Thoroughly clean oil passages
„
Replace oil non-return valve
„
Replace oil spray jets
„
Replace oil cooler
„
Replace oil filter
Chain drive, assembly overview 13-1, Chain drive, assembly overview
Cylinder block, assembly overview 13-1, Cylinder block, assembly overview
Engine bracket and left/right engine mounts, removing and mounts, removing and installing
Removing and installing ribbed belt 13-1, Ribbed belt, removing and installing
Removing and installing sealing flange and dual-mass removing and installing
Removing and installing crankshaft 13-3, Crankshaft, removing and installing
Piston and connecting rod, disassembling and assembling
- assembly overview 13-4, Piston and connecting rod, disassembling and assembling
Page 1 / 16
13 - 1

Engine, disassembling and assembling
Chain drive, assembly overview
Page 2 / 16
„
Control housing
„
Lightly oil the contact surfaces of the camshaft and control housing seals before installing
„
Removing and installing
15-2, Camshafts, removing and installing , Camshafts, removing and installing
„
Disassembling and
Disassembling and assembling control housing
„
Before installing control housing strainer check for
Check the control housing

Engine, disassembling and assembling screen for contamination
„
8 Nm
„
Replace
„
Camshaft roller chain
„
Mark direction of rotation before removing (installation roller chains
„ timing, adjusting , Adjusting valve timing
„
Exhaust camshaft adjuster
„
Identification: 32A
„
Only rotate engine with camshaft adjuster installed
„ timing, adjusting , Adjusting valve timing
„
Intermediate shaft
„
Thrust washer
„
8 Nm
„
Insert with locking fluid D
000 600 A2
„
Tensioning rail
„
For camshaft roller chain
Item - 3 -
„
Pivot pin, 18 Nm
„
For tensioning rail Item - 8
-
„
Chain tensioner, 40 Nm
„
For camshaft roller chain
Page 3 / 16

Engine, disassembling and assembling
Item - 3 -
„
Only rotate engine with chain tensioner installed
„
Oil seal
„
Replace if damaged or leaking
„
Chain sprocket
„
For roller chain Item - 17 -
„ timing, adjusting , Adjusting valve timing
„
Chain sprocket
„
For camshaft roller chain
Item - 3 -
„ timing, adjusting , Adjusting valve timing
„
60 Nm +
1
/
4 turn (90 )
„
Replace
„
Use counter-holder tool
T10069 to tighten and and tighten securing bolt, hold harmonic balancer with
„
Chain tensioner with tensioning rail
„
For roller chain Item - 17 -
„
Before installation release the locking device in the chain tensioner with a small screwdriver and press the tensioning plate against the chain tensioner
„
Only rotate engine with chain
Page 4 / 16

Engine, disassembling and assembling tensioner installed
„
Drive gear
„
Integral part of crankshaft
„
Ground down tooth aligned with main bearing joint =
TDC cyl. 1 15-1, Valve timing, adjusting , Adjusting valve timing
„
Roller chain
„
Mark direction of rotation before removing (installation roller chains
„ timing, adjusting , Adjusting valve timing
„
Guide rail
„
For roller chain Item - 17 -
„
Remove and install together with roller chain 15-1,
Valve timing, adjusting ,
Adjusting valve timing
„
Locating pin without collar, 10
Nm
„
For guide rail Item - 18 -
„
18 Nm
„
23 Nm
„
Intake-camshaft adjuster
„
Identification: 24E
„
Only rotate engine with camshaft adjuster installed
„ timing, adjusting , Adjusting valve timing
Page 5 / 16

Engine, disassembling and assembling
„
60 Nm +
1
/
4 turn (90 )
„
Replace
„
Contact surface of sender wheel must be dry around bolt head when assembling
„
To remove and install, counter-hold with 32 mm open end wrench on
Camshafts, removing and installing , Removing and installing camshafts
„
Guide rail
„
For camshaft roller chain
Item - 3 -
„
Camshaft Adjustment Valve 1
(exhaust) N318
„
For exhaust camshaft
„
Before disconnecting, mark allocation of connector to component
„
Camshaft Adjustment Valve 1
N205
„
For intake camshaft
„
Before disconnecting, mark allocation of connector to component
„
Guide rail
„
For camshaft roller chain
Item - 3 -
„
Clipped in at control housing
Page 6 / 16

Engine, disassembling and assembling Page 7 / 16
Marking roller chains
- Mark roller chains before removing (e.g. with paint, arrow pointing in direction of rotation).
Note:
„
Do not mark chain with a center punch or similar means!
Cylinder block, assembly overview
Engine bracket and left/right engine mounts, removing and mounts, removing and installing

Engine, disassembling and assembling Page 8 / 16
„
8 Nm
„
Fastened to intake manifold
„
Guide tube
„
For dipstick
„
Secured by a bolt to intake manifold
„
Dipstick
„
Oil level must not be above the max. mark!
„ oil dipstick
„
Oil non-return valve

Engine, disassembling and assembling
„
Note installation position
„
Removing and installing
17-1, Oil non-return valve, removing and installing
„
Clean or replace if badly soiled
„
See note 13-1, Engine, disassembling and assembling
„
Knock Sensor 1 G61
„
Component location: between cyl. 1 and cyl. 3
„
20 Nm
„
Torque setting influences the function of knock sensor
„
10 Nm
„
Oil pump drive cover
„
O-ring
„
Replace
„
Oil before assembling
„
Oil pump drive
„
Cylinder block
„
Removing and installing sealing flange and dualmass flywheel 13-2,
Sealing flange and dualmass flywheel, removing and installing
„
Removing and installing
Crankshaft, removing and installing
„
Piston and connecting rod, disassembling and
Page 9 / 16

Engine, disassembling and assembling and connecting rod, disassembling and assembling
„
Intermediate shaft
„
Thrust washer
„
10 Nm
„
Insert with locking fluid D
000 600 A2
„
Input shaft
„
For oil pump drive
„
Engine Speed (RPM) Sensor
G28
„
Oil pump
„
Disassembling and pump, disassembling and assembling
„
23 Nm
„
8 Nm
„
Insert with locking fluid D
000 600 A2
„
Oil drain plug, 30 Nm
„
Replace
„
Oil pan
„
Removing and installing
17-1, Oil pan, removing and installing
„
Oil Level Thermal Sensor G266
„
Only for vehicles with engine code "AZZ"
Page 10 / 16

Engine, disassembling and assembling
„
Oil seal
„
Replace
„
Oil before assembling
„
20 Nm
„
Oil seal
„
Replace
„
Oil filter housing/left engine bracket
„
Disassembling and housing, disassembling and assembling
„
Coolant hose connection hose connection diagram
„
Engine bracket and left/right engine mounts, removing
13-1, Engine bracket and left/right engine mounts, removing and installing
„
23 Nm
„
To thermostat housing
„
25 Nm
„
Bolt, 25 Nm
„
Compact bracket
„
For alternator, air conditioning compressor, and power steering pump
„
Coolant line
„
Removing and installing
19-1, Cooling system components (engine side), assembly overview , components of cooling system - engine side
Page 11 / 16

Engine, disassembling and assembling
„
Knock Sensor 2 G66
„
Component location: between cyl. 4 and cyl. 6
„
Harmonic balancer
„
Removing and installing ribbed belt 13-1, Ribbed belt, removing and installing
„
100 Nm +
1
/
4 turn (90 )
„
Replace
„
Use counter-holder T10069 to loosen and tighten 13-
1, To loosen and tighten securing bolt, hold harmonic balancer with
„
Fasten with torque wrench
V.A.G 1601
To loosen and tighten securing bolt, hold harmonic balancer with counter-holder T10069
Note:
„
Harmonic balancer securing bolt must be replaced.
„
Tighten securing bolt with torque wrench V.A.G
1601 .
Page 12 / 16

Engine, disassembling and assembling
Engine bracket and left/right engine mounts, removing and installing
Special tools, testers and auxiliary items required
„
Engine support bridge 10 - 222 A
„
Shackle 10 - 222 A /12
„
Adapter 10 - 222 A /16
Page 13 / 16
„
Adapter 10 - 222 A /19
Removing
- Completely remove air filter with mass air flow (MAF) sensor.
- Remove nuts - 2 - on right and left engine bracket.
- Position adapter 10 - 222 A /16 on Engine and
Transmission Holder 10 - 222 A with high side of threaded spindle guide facing upward as shown in illustration.
- Place adapter 10 - 222 A /19 on left and right of Engine and Transmission Holder 10 - 222 A . Place Engine and

Engine, disassembling and assembling
Transmission Holder 10 - 222 A on longmembers.
Page 14 / 16
- Engage engine with two schackles 10 - 222 A /12 at adatper 10 - 222 A /16 and pretension engine slightly.
- Remove the bolts - 1 - from left and right engine mount / subframe.
- Be aware of available clearance between the cylinder head and the bulkhead.
- Carefully lift the engine with the adapter 10 - 222 A /16 .
- To remove the engine mount, the engine bracket must also be unbolted from the cylinder block, because the engine can not be lifted high enough.
Installing
Installation is performed in reverse order of removal.
- When installing, make sure the alignment pin of the engine mount is correctly positioned in the engine bracket.
- First install all bolts by hand, and then tighten them all to the specified torque.
Torque specification for bolt - 1 - : 60 Nm.

Engine, disassembling and assembling
Torque specification for nut - 2 - : 75 Nm.
Torque specification for oil filter housing/engine bracket bolts to cylinder block at left: 23 Nm.
Torque specification for engine bracket bolts to cylinder block at right: 40 Nm.
Ribbed belt, removing and installing
Special tools, testers and auxiliary items required
„
Hex bolt M8x50
Ribbed belt, removing
- Mark direction of rotation of ribbed belt.
- Press tensioning arm in direction of - arrow - using a suitable wrench.
- Install an M8×50 screw into threaded hole - A - , thereby securing ribbed belt tensioner.
Note:
„
Only screw bolt in so far until the ribbed belt can be removed, otherwise the housing of the tensioning
Page 15 / 16

Engine, disassembling and assembling roller can be damaged.
- Remove ribbed belt.
Ribbed belt, installing
Note:
„
Ensure, before installing ribbed belt, that all ancillaries (alternator, air conditioner compressor, power steering pump) are secured tightly.
„
Check that idler roller turns easily.
„
When installing the ribbed belt, be aware of the direction of rotation and ensure that the belt is seated correctly in the belt pulleys.
Page 16 / 16
- Route ribbed belt and remove M8 bolt from tensioning roller.
After completing repairs always:
- Start engine and check belt running.

Sealing flange and dual-mass flywheel, removing and installing
Sealing flange and dual-mass flywheel, removing and installing
Sealing flange, assembly overview 13-2, Sealing flange, assembly overview
Drive plate, removing and installing 13-2, Drive plate, removing and installing
Oil seal (flywheel side), removing and installing 13-2, Oil seal (flywheel side), removing and installing
Sealing ring for crankshaft - harmonic balancer side, side), replacing
Sealing flange, assembly overview
Page 1 / 14
13 - 2
„
100 Nm +
1
/
4 turn (90 )

Sealing flange and dual-mass flywheel, removing and installing
„
Replace
„
Use counter-holder T10069 to loosen and tighten 13-
1, To loosen and tighten securing bolt, hold harmonic balancer with
„
Fasten with torque wrench
V.A.G 1601
„
Harmonic balancer
„
Removing and installing ribbed belt 13-1, Ribbed belt, removing and installing
„
10 Nm
„
Oil seal
„ seal (harmonic balancer side), replacing
„
Sealing flange
„
Coat sealing surfaces with sealant AMV 176 501
„
Cylinder block
„
Removing and installing
Crankshaft, removing and installing
„
Piston and connecting rod, disassembling and and connecting rod, disassembling and assembling
„
Sealing flange
„
Coat sealing surfaces with sealant AMV 176 501
„
Oil seal
Page 2 / 14

Sealing flange and dual-mass flywheel, removing and installing
„
Use extractor hook
T20143/2 for removal
„
PTFE version of oil seal
„
Identification: no inner coil spring
„
Do not additionally oil or grease sealing lip of sealing ring
„
Before installing, remove oil remains from crankshaft journal with a clean cloth
„
(flywheel side), removing and installing
„
Dual mass flywheel
„
60 Nm +
1
/
4 turn (90 )
„
Replace
„
To loosen or tighten, use counter-hold T10044 (with 5 mm spacers), or counterhold T10069 .
„
25 Nm
Drive plate, removing and installing
Special tools, testers and auxiliary items required
Page 3 / 14
„
Counter-holder tool T10069

Sealing flange and dual-mass flywheel, removing and installing Page 4 / 14
„
Torque wrench (40 to 200 Nm) V.A.G 1332
„
Depth gauge
Removing
- Remove drive plate. To do this, lock harmonic balancer with counter-holder T10069 .
- Loosen drive plate securing bolts diagonally and remove.
- Remove drive plate.
Installing
- Tighten drive plate on crankshaft with at least 3 old securing bolts to 30 Nm.

Sealing flange and dual-mass flywheel, removing and installing Page 5 / 14
- Measure dimension - a - using depth gauge :
Specification: 21.0 to 23.0 mm
If the specification is not attained:
- Remove drive plate again and install appropriate shim -
1 - .
Note:
„
Only one shim of the appropriate thickness may be used.
If the specification is attained:
- Insert new securing bolts and tighten by hand.
- Tighten securing bolts to 60 Nm + 90 (
1
/
4
turn) (90
) further (additional rotation can occur in several stages).
Oil seal (flywheel side), removing and installing
Special tools, testers and auxiliary items required

Sealing flange and dual-mass flywheel, removing and installing Page 6 / 14
„
Pulling fixture T10122
„
Extractor hook T20143
Oil seal (flywheel side), removing
- Place removal hook T20143/2 behind the sealing lip of the oil seal as shown in the illustration.
- Support removal hook T20143/2 on the sealing flange and pry out the oil seal in direction of - arrow .
Oil seal (flywheel side), installing

Sealing flange and dual-mass flywheel, removing and installing Page 7 / 14
- Pull seal - A - with the outer side over the sleeve
T10122/1 onto the assembly tool T10122/2 .
- Separate both assembly sleeves.
- Place the assembly tool T10122/2 with the dry seal onto the crankshaft flange.
- Drive the seal into the sealing flange until the stop using the thrust piece T10122/3 .
Crankshaft seal (harmonic balancer side), replacing

Sealing flange and dual-mass flywheel, removing and installing Page 8 / 14
Special tools, testers and auxiliary items required
„
Extractor hook T20143/1
„
Counter-holder tool T10069
„
Assembly tool T10215
„
Torque wrench V.A.G 1601
„
Torque wrench V.A.G 1332
Note:
„
If a plastic sealing flange is installed, sealing ring cannot be replaced separately and sealing flange

Sealing flange and dual-mass flywheel, removing and installing must be replaced 13-2, Sealing flange for crankshaft - harmonic balancer side, replacing .
Removing
- Bring lock carrier into service position
Repair Manual, Body Exterior, Repair Group 50,
Perform service position
.
- Remove ribbed belt 13-1, Ribbed belt, removing and installing .
Page 9 / 14
- Remove harmonic balancer. To do this, lock harmonic balancer with counter-holder T10069 .
- Place removal hook T20143/1 behind the sealing lip of the oil seal as shown in the illustration.
- Support removal hook T20143/1 on the sealing flange and pry out the oil seal in direction of - arrow .
Installing

Sealing flange and dual-mass flywheel, removing and installing
- Before installing, remove oil remains from end of crankshaft with a clean cloth.
- Install guide sleeve T10215/1 - 1 - onto front of crankshaft journal.
- Carefully slide oil seal - 2 - onto guide sleeve as far as possible.
Page 10 / 14
- Press in oil seal until stop using thrust sleeve T10215/2 -
3 - . To do this use an old harmonic balancer securing bolt
- 4 - .
Note:
„
Harmonic balancer securing bolt must be replaced.
„
Tighten securing bolt with torque wrench V.A.G
1601 .
- Install harmonic balancer and lock with counter-holder
T10069 .
- Fasten new bolt to 100 Nm +
1
/
4
turn (90 ) further.
- Install ribbed belt 13-1, Ribbed belt, removing and installing .

Sealing flange and dual-mass flywheel, removing and installing
Sealing flange for crankshaft - harmonic balancer side, replacing
Page 11 / 14
Special tools, testers and auxiliary items required
„
Counter-holder tool T10069
„
Assembly tool T10215
„
Torque wrench V.A.G 1601
„
Torque wrench V.A.G 1332
Removing
- Bring lock carrier into service position

Sealing flange and dual-mass flywheel, removing and installing
Repair Manual, Body Exterior, Repair Group 50,
Perform service position
.
- Remove ribbed belt 13-1, Ribbed belt, removing and installing .
Page 12 / 14
- Remove harmonic balancer. To do so, lock harmonic balancer using counter-holder tool T10069 .
- Remove oil pan 17-1, Oil pan, removing and installing .
- Remove sealing flange.
- Remove sealant residue on sealing surfaces.
Installing
- Before installing, remove oil remains from end of crankshaft with a clean cloth.
- Cut off nozzle on tube of sealant at front mark (diameter of nozzle approx. 3 mm).
- Apply a sealant bead of approx. 2 to 3 mm as shown - arrows - on to clean sealing surface of sealing flange.

Sealing flange and dual-mass flywheel, removing and installing
Note:
„
Cover sealing ring with a clean cloth before applying sealing bead.
„
Sealant bead must not be thicker than 2 to 3 mm, otherwise excess sealant could get into oil pan and clog oil intake pipe strainer.
„
Note expiration date of the sealing compound.
„
The sealing flange must be installed within 5 minutes after application of silicon sealant.
- Insert guide sleeve T10215/1 - 1 - at front on to crankshaft pin - 3 - .
- Slide sealing flange with sealing ring - 2 - carefully over guide sleeve.
Page 13 / 14
- Tighten bolt sealing flange on cylinder crankshaft housing.
- Install oil pan 17-1, Oil pan, removing and installing .
Note:
„
Harmonic balancer securing bolt must be replaced.
„
Tighten securing bolt using torque wrench V.A.G
1601 .

Sealing flange and dual-mass flywheel, removing and installing Page 14 / 14
- Install harmonic balancer and secure using counterholder tool T10069 .
- Tighten new mounting bolt to 100 Nm plus
1
/
4
(90 ) rotation.
- Install ribbed belt 13-1, Ribbed belt, removing and installing .

Crankshaft, removing and installing
Crankshaft, removing and installing
Sensor wheel to crankshaft, installing 13-3, Installing sensor wheel to crankshaft
Note:
„
Before removing crankshaft, prepare for appropriate storage, so that sensor wheel Item - 6 - does not make contact or become damaged.
„
Secure engine to engine and transmission holder
VAS 6095 when working on engine.
„
When changing bearing shells ensure that bearing shells with the same color code are used.
Page 1 / 4
13 - 3

Crankshaft, removing and installing
„
Bearing cap
„
Bearing cap 1: harmonic balancer side
„
Bearing cap 5 with notches for thrust washers
„
Retaining tabs of bearing shells and cylinder block/bearing caps must lie above one another
„
30 Nm +
1
/
2 turn (180 )
„
Replace
„
2 x 90 turns further is permissible
„
Bearing shells 1 to 7
„
For bearing cap without oil groove
„
For cylinder block with oil groove
„
Do not interchange used bearings (mark)
„
Thrust washer
„
For bearing cap 5
„
Observe locating point
„
Crankshaft
„
Observe note before
Crankshaft, removing and installing
„
Axial play new: 0.07 to 0.23 mm, Wear limit: 0.30 mm
„
Check radial clearance with
Plastigage 0.02 to 00.06 mm, Wear limit: 0.10 mm
Page 2 / 4

Crankshaft, removing and installing
„
Do not turn crankshaft when measuring radial play
„
Crankshaft dimensions: Main bearing: 59.958 to 59.978 mm, Connecting rod bearing:
53.958 to 53.978 mm reworking is not permitted
„
Sensor wheel
„
For Engine Speed (RPM)
Sensor G28
„
Replace
„ sensor wheel to crankshaft
„
10 Nm +
1
/
4 turn (90 )
„
Replace
„
Oil spray jet
„
For crankshaft bearing 2 to 7
„
For piston cooling
„
Opening pressure 2.0 bar pressure
„
Removing and installing
17-1, Oil spray jet, removing and installing
„
See note 13-1, Engine, disassembling and assembling
Page 3 / 4

Crankshaft, removing and installing
Installing sensor wheel to crankshaft
Special tools, testers and auxiliary items required
„
Torque wrench (5 to 50 Nm) V.A.G 1331
„
Locking fluid D 000 600 A2
Work procedure
Make sure crankshaft/sensor wheel contact surfaces are free of oil and grease.
- Apply a thin coat of locking compound D 000 600 A2 to contact surfaces of crankshaft and sensor wheel for additional security.
- Check that when installing "VR6" - arrow - is marked at individual threaded holes.
- Tighten all new securing bolts lightly by hand.
- Tighten securing bolt - 1 - to 10 Nm +
1
/
4
turn. (90 ) further
- Tighten securing bolts - 2 - to 10 Nm +
1
/
4
turn. (90 ) further
Page 4 / 4

Piston and connecting rod, disassembling and assembling Page 1 / 9
13 - 4
Piston and connecting rod, disassembling and assembling
Pistons and connecting rods - assembly overview 13-4,
Piston and connecting rod, assembly overview
Checking pistons, piston rings and cylinder bore 13-4,
Pistons, piston rings and cylinder bore, checking
Piston and connecting rod, assembly overview
Piston ring gap, checking 13-4, Checking piston ring gap
Piston ring groove clearance, checking 13-4, Checking ring to groove clearance
Piston, checking 13-4, Checking piston
Installing piston with piston insertion funnel T10147 13-
4, Installing piston with

Piston and connecting rod, disassembling and assembling Page 2 / 9
„
Piston rings
„
Offset gaps by 120
„
Use piston ring pliers for removal and installation
„
"TOP" faces toward piston crown
„
Checking ring gap 13-4,
Pistons, piston rings and cylinder bore, checking
„
Check piston ring groove piston rings and cylinder bore, checking
„
Piston
„

Piston and connecting rod, disassembling and assembling piston rings and cylinder bore, checking
„
Mark installed location to connecting rod and affiliation to cylinder
„
Flatter side of piston crown faces toward center of cylinder block
„
Install using funnel T10147
13-4, Installing piston with
„
Circlip
„
Connecting rod
„
Only replace as set
„
Affiliation to the cylinder mark - B -
„
Installed location: Markings -
A - must lie above one another
„
Bearing shell
„
Note installation position
„
Do not interchange used bearing shells
„
Bearing shell retaining tabs must be firmly seated in the notches
„
Axial play new: 0.05 to 00.31 mm, Wear limit: 0.40 mm
„
Measure radial clearance with Plastigage: New: 0.02 to
00.07 mm, Wear limit: 0.10 mm. Do not turn crankshaft when checking radial clearance
„
Connecting rod bearing cap
„
Affiliation to the cylinder mark - B -
Page 3 / 9

Piston and connecting rod, disassembling and assembling
„
Installed location: Markings -
A - must lie above one another
„
30 Nm +
1
/
4 turn (90 )
„
Replace
„
Lubricate threads and contact surface
„
Tighten to 30 Nm to measure radial play, do not turn further
„
Cylinder block
„
Cylinder bore, checking
13-4, Pistons, piston rings and cylinder bore, checking
„
Removing and installing
Crankshaft, removing and installing
„
Piston and cylinder piston rings and cylinder bore, checking
„
Piston pin
„
If difficult to move, heat piston to 60 C
„
Removing and installing using a drift VW 222 A
Pistons, piston rings and cylinder bore, checking
Page 4 / 9

Piston and connecting rod, disassembling and assembling Page 5 / 9
Checking piston ring gap
Special tools, testers and auxiliary items required
„
Feeler gauge
Test sequence
- Push ring squarely from above down to approx. 15 mm from bottom end of cylinder. To do this use a piston without rings.
Piston ring
Compression ring
Tapered ring
Oil scraping ring mm mm mm
New
0.20 to 0.40
0.20 to 0.40
0.25 to 0.50
Gap
1.0
1.0
1.0
Checking ring to groove clearance
Special tools, testers and auxiliary items required

Piston and connecting rod, disassembling and assembling
„
Feeler gauge
- Clean ring groove before checking.
Piston ring
Compression ring
Tapered ring
Oil scraping ring mm mm mm
Ring to groove clearance
New
0.04 to 0.09
0.03 to 0.06
0.02 to 0.06
0.15
0.15
0.15
Checking piston
Special tools, testers and auxiliary items required
„
External micrometer 75 to 100 mm
Take measurement approx. 6 mm from lower edge of piston skirt and offset 90 to piston axis.
Deviation from nominal dimension: max. 0.04 mm
Page 6 / 9

Piston and connecting rod, disassembling and assembling Page 7 / 9
Checking cylinder bores
Special tools, testers and auxiliary items required
„
Internal dial gauge 50 to 100 mm
Test sequence
Measure bores at 3 locations in both directions - A - across engine and - B in line with crankshaft.
Deviation from nominal dimension: max. 0.08 mm
Note:
„
Measurement of cylinder bore may not be performed when the cylinder block is mounted on engine and transmission holder VAS 6095 , false measurements are possible.
Piston and cylinder dimensions
Honing dimension
Basic dimension mm
Piston
83.965
Cylinder bore
84.010

Piston and connecting rod, disassembling and assembling Page 8 / 9
Installing piston with funnel T10147
Special tools, testers and auxiliary items required
„
Piston installation tool T10147
Work procedure
Note:
„
If a new piston installation tool T10147 is used to install the pistons, first pass piston with oiled piston rings through the funnel twice and remove the resulting metal shavings if necessary. Only then install piston with piston rings.
- Push piston by hand into oiled piston installation tool
T10147 . Flat side of piston crown must face toward tab on piston installation tool - arrow - .
- Hold piston installation tool (with piston inserted) on upper edge and press piston in with both thumbs.
- Push piston in until it protrudes approx. 15 mm from lower edge of piston installation tool .

Piston and connecting rod, disassembling and assembling
- Insert piston into appropriate cylinder bore. Tab on piston installation tool - arrow - must face center of cylinder block.
- Press piston installation tool tightly against cylinder block and push piston in.
Page 9 / 9