Toothed Belt

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Special tools and workshop equipment required

Locking Pin 3359
Crankshaft Stop T10050
Counterhold T10172
Special Wrench, Long Reach T10264 for tensioning roller A
Locking Tool T10265
Allan Head 8mm T10409 for tensioning roller B
Torque Wrench 5-50 Nm V.A.G 1331
Torque Wrench 40-200 Nm V.A.G 1332

Removing:

NOTE:

The toothed belt may be adjusted only when the engine is cold because the position of the pointer on the tensioner will change due to the temperature of the engine.

CAUTION:

A used toothed belt could be destroyed if the running direction is reversed.

Before removing the ribbed belt, mark the running direction with chalk or a felt-tip pen for installation later.

-- Remove the engine cover. Refer to ENGINE COVER .

-- Remove the noise insulation. Refer to REMOVAL AND INSTALLATION .

-- Remove the bolts -3- and the coolant reservoir -2-.

Fig 1: Identifying Coolant Reservoir, Bolts And Connector

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-- Disconnect and remove the connector for the coolant reservoir -2-.

-- Set the coolant reservoir -2- aside.

WARNING:

Very hot fuel can burn your skin.

The temperature of the fuel lines and may reach 100° C (212° F) after stopping the engine. Let the fuel cool down before opening any line connections otherwise there is a danger of scalding.
Wear safety gloves
Wear protective eyewear.

-- Open the couplings -A- and -B- and remove the fuel lines. Disconnect the couplings. Refer to DESCRIPTION AND OPERATION .

Fig 2: Identifying Fuel Line Couplers

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-- Remove the fuel filter and set it aside. Refer to DESCRIPTION AND OPERATION .

-- Disconnect the connector -2-.

Fig 3: Disconnecting Connector -2- On Exhaust Pressure Sensor 1 -G450

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-- Remove the screw -3- and then remove the Differential Pressure Sensor -G505- from the bracket -arrow-.

-- Remove the screw -1- at the top of the particulate filter mount.

-- Lay the Differential Pressure Sensor -G505- and mount on the particulate filter.

-- Open the clips -arrows- and remove the toothed belt guard.

Fig 4: Removing Upper Toothed Belt Guard

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-- Remove right front wheel housing liner. Refer to REMOVAL AND INSTALLATION .

-- Remove the ribbed belt. Refer to RIBBED BELT WITH TENSIONER AND A/C COMPRESSOR .

-- Remove the vibration damper. Refer to :Belt Pulley/Vibration Damper.

-- Remove the lower and center toothed belt guard -arrows-.

Fig 5: Identifying Lower And Center Toothed Belt Guard Bolts

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-- Rotate the engine to TDC and secure the crankshaft toothed belt gear with the Crankshaft Stop T10050.

Fig 6: Identifying Crankshaft Toothed Belt Pulley And Crankshaft Stop T10050

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-- The crankshaft stop can be pushed from the front side of the toothed belt sprocket onto the crankshaft toothed belt gear splines -2-. The toothed segment must be at 12 o'clock.

NOTE:

The markings on the crankshaft toothed belt sprocket -2- and the Crankshaft Stop T10050 -1- must align.

-- The pins for the Crankshaft Stop T10050 must attach in the openings -arrow - for the sealing flange.

Fig 7: Identifying Crankshaft Stop T10050

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-- Mark direction of rotation of toothed belt.

-- Loosen the camshaft sprocket bolts -1-.

Fig 8: Identifying Camshaft Pulley Securing Bolts

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-- Loosen the high pressure pump toothed belt sprocket bolts -2-.

Fig 9: Identifying Coolant Pipe Bolt -1- And High Pressure Fuel Pump Toothed Belt Gear -2-

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-- Loosen the tensioning roller nut -1-.

Fig 10: Identifying Long Reach T10264 And Locking Tool T10265

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-- Turn the tensioning roller eccentric pulley with the Socket T10264 counter-clockwise -arrow- until the tensioning roller can be locked with the Locking Pin T10265.

-- Turn the tensioning roller eccentric pulley clockwise -arrow- all the way and tighten the nut -1- by hand.

Fig 11: Identifying Long Reach T10264 And Locking Tool T10265

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-- Remove the toothed belt from the idler roller and then from the remaining toothed belt gears.

Installing:

NOTE:

The toothed belt may be adjusted only when the engine is cold because the position of the pointer on the tensioner will change due to the temperature of the engine.

The engine bracket must be removed in order to replace the tensioning roller. Refer to ENGINE BRACKET .

Replace the bolts for the camshaft- and high pressure pump gear.

There are two versions of tension roller installed. It is possible to exchange them for one another. When adjusting, first check which tension roller is installed.

The Locking Tool T10265 must be inserted in the tensioning roller and the roller must be secured on the right stop.
Secure the crankshaft with the Crankshaft Stop T10050.

NOTE:

Turn the camshaft hub with the Counterhold Tool T10172 and the Adapters T10172/4 until they can be secured in place. Use at least one bolt -1- tightened by hand to do that.

-- Lock the camshaft hub with the Locking Pin 3359. To do this, push the rig pin through the empty outer slot and into the cylinder head bore.

Fig 12: Identifying Camshaft Hub And Counterhold Tool T10172

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-- Loosen the bolts, which were tightened hand-tight.

NOTE:

Rotate the high pressure pump hub with a screwdriver at the bolt heads until it can be secured.

Fig 13: Camshaft Hub Rotated With Screwdriver

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-- Secure the high pressure pump hub with the Locking Pin 3359. To do that, slide the rig pin into the hole outside the toothed belt sprocket.

Fig 14: Identifying Diesel Injection Pump Locking Pin 3359

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-- Rotate the camshaft sprocket and high pressure toothed belt sprocket clockwise in their slots as far as the stop.

-- Install the toothed belt on the crankshaft sprocket, the tensioning roller, the camshaft sprocket, coolant pump toothed belt sprocket and the high pressure toothed belt sprocket.

-- Lay the toothed belt on the tensioning roller last.

-- Loosen the tensioning roller nut and remove the Locking Tool T10265.

NOTE:

Make sure the tensioning roller is properly positioned in the rear toothed belt guard -arrow-.

Fig 15: Identifying Tensioner Positioned In Rear Toothed Belt Guard

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-- Carefully turn the tensioning roller eccentric pulley with the Long Reach Special Wrench T10264 clockwise. The pointer -2- must be somewhat above the center of the gap in the base plate. This will be corrected when pretensioning.

Fig 16: Identifying Long Reach T10264 And Nut

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Make sure that the nut -1- does not turn with it.

-- Hold the tensioning roller in this position and tighten the tensioning roller nut.

-- Attach the Counterhold Tool T10172 as shown in the figure. Push the Counterhold Tool T10172 in the direction of arrow and hold the camshaft sprocket pretensioned.

Fig 17: Identifying Camshaft Hub And Counterhold Tool T10172

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-- Tighten the bolts for the camshaft sprocket and for the high pressure pump belt sprocket hand-tight.

-- Tighten bolts to 20 Nm.

-- Remove the Locking Pin 3359 and the Crankshaft Stop T10050.

-- Turn the crankshaft two turns further in direction of engine rotation and just up to "TDC" for cylinder 1.

-- Insert the Crankshaft Stop T10050 back into the crankshaft toothed belt gear.

-- Turn the crankshaft in direction of engine rotation, until the pins on the crankshaft stop -arrow- fit into the sealing flange.

Fig 18: Identifying Crankshaft Stop T10050

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NOTE:

In the following check, only the camshaft and crankshaft are secured. The peg position for the high pressure pump hub is very difficult to find again. A small deviation -arrow- does not affect engine operation.

Fig 19: Identifying Small Deviation -Arrow- On High Pressure Fuel Pump Hub

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-- Check if :

The camshaft hub can be secured with the Locking Pin 3359.
The pointer on the tension roller point to the center or maximum 5 mm to the right of the gap in the base plate.

If the camshaft hub cannot be secured:

-- Pull the Crankshaft Stop T10050 toward the back until the pin opens the hole.

-- Turn the crankshaft opposite the direction of engine rotation just past TDC.

-- Slowing turn the crankshaft in the direction of engine rotation until the camshaft hub is secured.

-- After securing, loosen the bolts on the camshaft toothed belt sprocket.

If the Crankshaft Stop T10050 tab is to the left of the hole:

-- Turn the crankshaft in direction of engine rotation, until the tip on the crankshaft stop fits into the sealing flange.

Fig 20: Identifying Crankshaft Stop T10050

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-- Tighten the bolts for the camshaft toothed belt gear hand-tight.

-- Then tighten them to 20 Nm.

If the Crankshaft Stop T10050 tab is to the right of the hole:

-- Turn the crankshaft just a little opposite the direction of engine rotation.

-- Turn the crankshaft in direction of engine rotation, until the tip on the crankshaft stop fits into the sealing flange.

-- Tighten the bolts for the camshaft toothed belt gear hand-tight.

-- Then tighten them to 20 Nm.

Continuation

-- Remove the Locking Pin 3359 and the Crankshaft Stop T10050.

-- Turn the crankshaft two turns further in direction of engine rotation and just up to "TDC" for cylinder 1.

-- Check again.

-- Now it is possible to install the camshaft hub. Tighten the bolts as follows:

Counter-hold with the Counterholder T10172 and Adapters T10172/4.
Tighten bolts to 20 Nm.
Turn the camshaft sprocket 45° further.
Turn the high pressure pump gear 90°.

Fig 21: Identifying Counterhold Tool Touareg V10 T10172
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-- Install the lower and center toothed belt guard.

-- Install the vibration damper/belt pulley.

-- Install the ribbed belt. Refer to RIBBED BELT WITH TENSIONER AND A/C COMPRESSOR .

-- Install the upper toothed belt guard.

Assemble in reverse order of disassembly. Note the following:

Make sure the fuel hoses are secure.
Do not interchange supply and return lines (return line blue or with blue markings, supply line white).

-- Install the right front wheel housing liner. Refer to REMOVAL AND INSTALLATION .

-- Install the noise insulation. Refer to DESCRIPTION AND OPERATION .

Tightening Specifications

Component	Tightening specification
Tensioning roller	20 Nm +45°
Camshaft sprocket	20 Nm +45°
High pressure pump	20 Nm
Turn the vibration damper/belt pulley further	10 Nm +90°