Installing

WARNING: This page is about a different car, the 2012 Volkswagen Touareg and 2011 Volkswagen Touareg. However, it is still accessible from the selected car via links, so may be relevant.

Install in reverse order of removal. Note The Following:

-- Remove noise insulation.

-- Insert the Crankshaft Socket:T40058 guide pins as follows:

Fig 1: Guide Pin And Adapter T40058

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The large diameter -arrow 1- faces the engine.
The small diameter -arrow 2- faces the adapter.

Fig 2: Identifying TDC With Special Tool Adapter T140058

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CAUTION:

Components could be destroyed by the camshaft timing chains jump off.

Turn crankshaft only in direction of engine rotation -arrow- .

-- Turn the crankshaft to "TDC" using the Crankshaft Socket: T40058 .

As shown in the illustration, the marking -arrow- must be vertical on the center of the crankshaft.

Fig 3: Identifying Vertical Mark -Arrow- On Center Of Crankshaft
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-- Remove the plug -arrow- behind the right cylinder head.

Fig 4: Identifying Plug -Arrow- Behind Right Cylinder Head

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NOTE:

To provide a better illustration, installed position is shown with engine removed from behind.

-- Check to see if the groove -arrow- in the camshaft flange can be seen through the sealing plug hole -1- .

-- Shine a small flashlight in the sealing plug hole to see.

Fig 5: Identifying Groove -Arrow- In Camshaft Flange And Plug Hole -1-

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NOTE:

The camshaft flange is shown without chain drive and without timing chain guard to make the illustration better.

-- Turn the crankshaft 360 degrees in the direction of engine rotation if the groove is not under the hole.

NOTE:

To collect escaping engine oil, place a clean cloth under the upper part of the oil pan.

Fig 6: Identifying Locking Bolt Of Upper Part Of Oil Pan

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-- Remove the sealing plug -arrow- from the upper section of the oil pan.

Fig 7: Identifying Crankshaft Holder 3242

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WARNING:

Risk of injury when touching "TDC" hole with finger.

Do not rotate crankshaft -1- .

-- Install the Crankshaft Key:3242 in the hole and tighten to 20 Nm. Rotate the crankshaft back and forth slightly to center the pin completely, if necessary.

NOTE:

The high pressure pump and its toothed belt gear must be installed securely before installing the toothed belt.

-- Check the installation position of the toothed belt tensioning roller:

Fig 8: Identifying Hex Mount -Arrow 1- And Claw -Arrow 2-

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The claw -arrow 2- must fit into the recess in the high pressure pump bracket.

The tension roller must be relieved of tension and the hex mount -arrow 1- faces downward.

-- Install the toothed belt.

Fig 9: Identifying Toothed Belt Tensioner Bolt -1-, Toothed Belt Sprocket Bolt -2- And Locking Tool T40135

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-- Install the toothed belt tension roller bolt -1- without using force until the eccentric pulley for the tensioning roller can be turned without tipping.

-- Install the toothed belt drive sprocket bolt -2- far enough until sprocket can be turned without tilting.

-- Stop the high pressure pump toothed belt wheel with the High Pressure Pump Sprocket Locking Tool:T40135 .

-- Continue to pretension the toothed belt tensioning roller in the direction of the -arrow- with the hex socket wrench until the hex mount is in the -1-'o' clock-position- .

Fig 10: Identifying Hex Socket And Toothed Belt Tensioning Roller

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CAUTION:

Never remove while in the "12-'o'clock-position" or above.

-- Release -arrow- the toothed belt tensioning roller to the point where the hex mount is in the -3-'o' clock position- .

Fig 11: Identifying Toothed Belt Tensioning Roller Aligned With Hex Mount

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-- Pretension the toothed belt tensioning roller from the -3 o'clock position- in direction of -arrow- to the point where the tab -1- and the notch -2- are exactly opposite each other.

Fig 12: Identifying Toothed Belt Tensioning Roller With Tab -1- And Notch -2- Held In Position

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-- Hold the toothed belt tensioning roller in this position and tighten the bolt -arrow- . Refer to -item ) OVERVIEW - HIGH PRESSURE PUMP TOOTHED BELT - BOLT.

Fig 13: Identifying Toothed Belt Tensioning Roller And Bolt -Arrow-

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-- Tighten the toothed belt drive wheel bolt -1- using the Wrench - Pin Type:3036 or Counterhold - Multiple Use:T10172A -item ) OVERVIEW - HIGH PRESSURE PUMP TOOTHED BELT - BOLT.

Fig 14: Identifying Toothed Belt Drive Sprocket Bolt -1- And 3036

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-- Remove the Crankshaft Holder:3242 .

Fig 15: Identifying Crankshaft Holder 3242

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-- Install the bolt -arrow- for the "TDC" marking into the upper section of the oil pan. Refer to Lubrication .

Fig 16: Identifying Locking Bolt Of Upper Part Of Oil Pan

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-- Insert the Crankshaft Socket:T40058 guide pins as follows:

Fig 17: Guide Pin And Adapter T40058

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The large diameter -arrow 1- faces the engine.
The small diameter -arrow 2- faces the adapter.

Fig 18: Identifying TDC With Special Tool Adapter T140058

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CAUTION:

Components could be damaged by the camshaft timing chain jump off.

Turn crankshaft only in direction of engine rotation -arrow- .

-- Turn the crankshaft one turn using the Crankshaft Socket:T40058 .

-- Check the toothed belt tension:

Fig 19: Identifying Tab -1- Aligned With Notch -2-

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The tab -1- must align with the notch -2- .

-- If the specified value is not reached, adjust the toothed belt tension one more time.

Assembly is performed in reverse order.

Tightening specifications High Pressure Pump Toothed Belt Assembly Overview. Refer to OVERVIEW - HIGH PRESSURE PUMP TOOTHED BELT .