VW Touareg repair


+ 1. Operation and car maintenance
+ 2. Engine
- 3. Transmission
   + 6-step automatic transmission 09D
   - Hydrotransformer check
      Liquid pumping from the hydrotransformer
      Hydrotransformer installation
      Repair of a drive of gear shifting
      Removal and installation of the handle of the selector
      Check and adjustment of draft of the selector
      Removal and installation of draft of the selector
      Removal and slip installation
      Removal and frame installation
      Removal and installation of an electromagnet of blocking of the N110 selector
      Removal and installation of the switch of the selector (the lever is blocked in the situation "P") F319
      Removal and installation of a drive of gear shifting
      Removal and transmission installation, cars with the diesel R5 engine
      Removal and transmission installation, cars with petrol V6 and V8 engines, turbodiesel engines V6 TDI, V10 TDI and the petrol W12 engine
      Inhaling moments
      Removal and installation of highways and ATF radiator
      Removal and installation of the control unit of an automatic transmission of J217
      Replacement of a sealing ring of a secondary shaft
      Removal and installation of the oil pallet
      Removal and installation of the mesh oil filter
      Removal and installation of the sensor of pressure for hydrosystem 1 in AKP G193 and the pressure sensor for hydrosystem 2 in AKP G194
      Removal and installation of a zolotnikovy box
      Removal, installation and adjustment of the multipurpose F125 switch
   + Mechanical transmission 08D and transfer case Е473
   + Driveshaft
   + Driving mechanism
   + Tables
+ 4. Running gear
+ 5. Steering mechanism
+ 6. Brake system
+ 7. Onboard electric equipment
+ 8. Body
+ electric equipment Schemes


Volkswagen Touareg / Touareg repair>> Transmission>> Hydrotransformer check>> Removal and transmission installation, cars with the diesel R5 engine
Short description
At these cars it is possible to remove a transmission separately down. The engine remains established in the car.
At the Touareg car with any options of the engine the engine / transmission is recommended to dismantle before removal of the power unit the bottom bolts of connection. At possibility in advance establish hydrotransformer fastening. Given advice operates both at removal, and at transmission installation.

Removal
Remove an engine casing.

NOTE
In drawing 3.28 the pump of tandemny type is represented from below at the removed engine.


Fig. 3.28 . Fixing of a wooden slip


Fix wooden laying in thickness of 20 mm 1 by means of a sticky tape 2, as shown, on the pump of tandemny type (fig. 3.28) .
If too thin wooden laying or wooden laying is used not used, at further dismantle the transmission can lay down on a stretcher, thus a transmission it will be impossible to remove.

Fig. 3.29 . Hoses of system of cooling


Remove hoses of system of cooling 1–4 from a noise isolation from the engine face (fig. 3.29) .
Turn off a noise isolation (3 bolts).
Unscrew bolts of A and remove the holder of a noise isolation.

Fig. 3.30 . Bolts of fastening of a sealing cover


Remove a sealing cover of B by means of a stripper 10-221 from a sealing flange (fig. 3.30) .

Fig. 3.31 . Key installation


Fasten a key of T10225 to the crankshaft (fig. 3.31) .
It is necessary to observe sequence of shutdown of joint stock bank surely.
Disconnect the mass plug from joint stock bank. at the switched-off ignition.
Completely remove an engine / transmission noise isolation.

Fig. 3.32 . Holders of a noise isolation


Remove holders of a noise isolation 1 and 2 (fig. 3.32) .

Fig. 3.33 . Bolts of the holder of hoses of system of cooling


Unscrew bolts of the holder of hoses of system of cooling on the right pillow of the engine (fig. 3.33) .

Fig. 3.34 . Fixing of hoses


Pull hoses of system of cooling, as shown, up and fix, for example, by means of a welding wire on the right pillow of the engine (fig. 3.34) .
Turn off hydrotransformer bolts / a conducted disk (6 pieces).
Turn gidrotransformator/a conducted disk via the engine crankshaft by means of T10225 nozzle on 1–3
turn (120 °) in the direction of rotation of a shaft of the engine (fig. 3.31) .

Fig. 3.11 . Draft of the selector


Remove a lock washer 1 and draft of the selector 2 a hand from the switching lever (fig. 3.11) .

Fig. 3.35 . Bolts of fastening of a support


Unscrew bolts 2 and remove a support 1 (fig. 3.35) .

Fig. 3.36 . ATF tubes


Remove ATF tubes from a transmission (fig. 3.36) .
Close tubes of ATF and a transmission opening by means of pure caps.

Fig. 3.37 . Bolt of the holder of tubes of ATF


Unscrew a bolt of the holder of tubes of ATF on a transmission (fig. 3.37) .

Fig. 3.38 . Fixing bolt


Unscrew a fixing bolt of an engine/transmission before lowering the power unit (fig. 3.38) .
Bolt dismantle at the lowered box is impossible because of lack of a place.
Remove a transfer case.
Remove a reception pipe with the catalyst.

Fig. 3.39 . Screen fastening


Remove the screen (fig. 3.39) .

Fig. 3.40 . Shtekernye of connection


Remove the screen 1, unblock and disconnect shtekerny connections 2–4 (fig. 3.40) .
Lower a transmission a little more as follows.

Fig. 3.41 . Installation of wooden laying


Establish a tip of a podkatny jack With in a rack for the engine and a transmission of V. A. G 1383 A also put from above wooden laying In (fig. 3.41) .
Establish a rack for the engine and a transmission of V. A. G 1383 A under a transmission.
Lift a transmission so that it was possible remove holding VW device of 785/1 B (is used for removal and installation of a transfer case) from a transmission.
Then put wooden laying And thickness about 50 mm between a transmission and a stretcher.
Watch that wooden laying was not under ATF tubes.
Lower and set aside aside a rack for the engine and V.A.G 1383 A transmission.

Fig. 3.42 . Bolt of fastening of the holder of the right reception pipe


Turn off nuts 1 and remove the holder of the right reception pipe 2 from fixing bolts of a starter (fig. 3.42) .
It is possible to leave a cable of a starter established.
Unscrew bolts 1 and remove a starter from an engine/transmission.

Fig. 3.43 . Bolts of fastening of a starter and fixing bolt of an engine/transmission


Unscrew a fixing bolt of an engine/transmission 2 (fig. 3.43) .

Fig. 3.44 . Nut and bolt of the holder of a tube of system of cooling


Turn off a nut 2 holders of a tube of system of cooling from a bolt 3 (fig. 3.44) .
Unscrew connection bolts an engine / transmission 1 and 3.
Adjust the provision of an emphasis of a transmission 3282 for dismantle of an automatic box «09D» by means of an adjusting plate 3282/49.
Establish an emphasis of a transmission 3282 in a rack for the engine and V.A.G 1383 A transmission.
Shoulders of levers of an emphasis of a transmission соориентируйте according to openings in an adjusting plate.
Symbols on an adjusting plate show necessary basic details, the arrow specifies the movement direction.
Establish a rack for the engine and V.A.G 1383 A transmission with an emphasis of a transmission 3282 under the car.

Fig. 3.45 . Installation of the special adaptation


Fix behind a transmission an emphasis 3282/52 by means of M10 x 30 bolt (fig. 3.45) .

Fig. 3.46 . Emphasis installation


Fix at the left and on the right on a transmission an emphasis 3282/52 under the oil pallet (fig. 3.46) .
Then raise a transmission so that it was possible take wooden laying between a transmission and a stretcher.
When lowering watch that tubes of ATF were not clamped between a transmission and a stretcher.
Carefully lower a transmission, thus the engine will adjoin to wooden laying on the pump of tandemny type and will adjoin to a partition.
Review of connecting bolts of an engine / transmission.

Fig. 3.47 . Bolts of fastening of a transmission to the engine


Unscrew two connecting bolts of an engine/transmission at the upper left (fig. 3.47) .

Fig. 3.48 . Bottom connecting bolts


Remove the bottom connecting bolts of an engine/transmission (fig. 3.48) .
Wring out a transmission from the engine (adjusting plugs). Thus squeeze out the hydrotransformer from a conducted disk from the pump ATF, do not turn the hydrotransformer.
Mark position of the hydrotransformer in relation to a transmission.
These labels are necessary at installation in order that openings of fixing bolts in the hydrotransformer and a conducted disk coincided.
Then alternately pull a transmission down and lower.
Fix the hydrotransformer from loss.

Installation
Installation is carried out in return sequence. Thus it is necessary to consider the following.
At pollution of ATF oil or before installation of a new transmission clear ATF and ATF line radiator.
Carving of the bolts which have been earlier greased with a carving varnish, clear a wire brush. Then establish bolts with use of a carving varnish of AMV 185 101 A1.
All carving openings in which are twisted самоконтрящиеся bolts/screws, should be cleared by a tap of the remains of a carving varnish. Otherwise at the following dismantle their carving can be broken.
Самоконтрящиеся bolts and nuts replace always.
Before installation of a new transmission it is necessary to clear a radiator and ATF tubes.
Before installation of a transmission it is necessary to watch that the hydrotransformer was correctly established in a transmission.
Before installation check correctness of landing of adjusting plugs.
Watch the correct position of the driven plugs between the engine and a transmission. Lack of the driven plugs conducts to violation of centering of the engine and a transmission, therefore, to destruction of the bearing of sliding and a hydrotransformer nave.
Combine the put labels on a transmission and the hydrotransformer.
If labels are not present, turn the hydrotransformer and a conducted disk to each other so that the carving opening of the hydrotransformer and an opening of a conducted disk stood on the center of fastening of a starter.
At the lowered transmission tighten two connecting bolts of an engine/transmission at the upper left and a connecting bolt under a starter (fig. 3.47) .
Tighten the bottom connecting bolts of an engine/transmission.
Then raise a transmission so that it was possible to insert wooden laying in thickness about 50 mm between a transmission and a stretcher (fig. 3.48) .
Watch that wooden laying was not under ATF tubes.
Lower a transmission and remove an emphasis for a transmission 3282.
Tighten bolts of connection of an engine/transmission 1 and 3.
Fasten a nut 2 holders of a tube of system of cooling on a bolt 3 (fig. 3.44) .
Establish a reception the pipe/catalyst with fastening.
Establish a transfer case.
Fasten hydrotransformer bolts / a conducted disk (6 pieces)
Turn gidrotransformator/a conducted disk via the engine crankshaft by means of T10225 nozzle on 1–3 turns (120 °) in the direction of rotation of a shaft of the engine (fig. 3.31) .
Establish a starter.
Tighten other connecting bolts of an engine/transmission.
Establish the screen and tighten bolts with the moment of 10 N · m (fig. 3.39) .
Establish the screen 1 and tighten bolts with the moment of 10 N · m.
Connect shtekerny connections 2–4 (fig. 3.40) .
Tighten a bolt of the holder of tubes of ATF on a transmission (fig. 3.37) .
Remove caps and insert ATF tubes against the stop into a transmission (fig. 3.36) .
Tighten a bolt.
Establish a support 1.
Establish bolts 2, having greased with a carving varnish, and tighten (fig. 3.35) .
Press draft of the selector 2 a hand to a rod of a choice of transfers (fig. 3.11) .
At installation it is impossible bend the lever of a shaft of management of gear shifting, otherwise it will be impossible to make exact adjustment of gear shifting.
Establish a new lock washer 1.
Tighten bolts of the holder of hoses of system of cooling on the right pillow of the engine (fig. 3.33) .
Establish holders of a noise isolation 1 and 2 (fig. 3.32) .
Turn off T10225 key from the crankshaft.
Replace a sealing cover.
Tighten bolts of the holder of a noise isolation (fig. 3.30) .
Tighten bolts (3 pieces) noise isolations.
Establish hoses of system of cooling 1–4 on a noise isolation (fig. 3.29) .
Remove from the pump of tandemny type wooden laying 1 and a sticky tape 2 (fig. 3.28) .
It is necessary to observe sequence of shutdown of joint stock bank surely.
To carry out working operations after joint stock bank connection.
Check adjustment of draft of the selector, if necessary, adjust.
Check level of ATF and add oil.
At control of level of ATF check conclusions of tubes of ATF to tightness (fig. 3.36) .

Inhaling moments

Fig. 3.49 . The moments of an inhaling of bolts of fastening of KP to the engine: And – adjusting plugs


Look tab. 3.3.


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