Toothed Belt: Installing

• 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.

-- 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 1: Identifying Camshaft Hub And Counterhold Tool T10172

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 2: 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 3: Identifying Diesel Injection Pump Locking Pin 3359

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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.

Fig 4: 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 5: Identifying Long Reach T10264 And Nut

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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. Push the Counterhold Tool T10172 in the direction of arrow and hold the camshaft sprocket pretensioned.

Fig 6: Identifying Camshaft Hub And Counterhold Tool T10172

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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 7: 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 8: Identifying Small Deviation 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 9: 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 10: Identifying Counterhold Tool Touareg V10 T10172

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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 .