auto

London
299388 london

Date
17.Feb.2025

Timing belts/chains

Replacement intervals
Vehicle registered |09.2009-| (Longlife service)
Timing belt - Check/report Every 40000 km or 24 months (1)
Timing belt - Renew Every 120000 km or 60 months (2)
Timing belt tensioner - Renew Every 120000 km or 60 months (2)
Timing belt - Renew Every 210000 km or 60 months
Timing belt tensioner - Renew Every 210000 km or 60 months

Vehicle registered |-08.2009| (fixed interval service)

Timing belt - Check/report Every 40000 km or 24 months (1)
Timing belt - Renew Every 120000 km or 48 months (2)
Timing belt tensioner - Renew Every 120000 km or 48 months (2)
Timing belt - Renew Every 210000 km or 48 months
Timing belt tensioner - Renew Every 210000 km or 48 months

Vehicle registered |09.2009-| (fixed interval service)

Timing belt - Check/report Every 40000 km or 24 months (1)
Timing belt - Renew Every 120000 km or 60 months (2)
Timing belt tensioner - Renew Every 120000 km or 60 months (2)
Timing belt - Renew Every 210000 km or 60 months
Timing belt tensioner - Renew Every 210000 km or 60 months

Vehicle registered |-08.2009| (Longlife service)

Timing belt - Check/report Every 40000 km or 24 months (1)
Timing belt - Renew Every 120000 km or 48 months (2)
Timing belt tensioner - Renew Every 120000 km or 48 months (2)
Timing belt - Renew Every 210000 km or 48 months
Timing belt tensioner - Renew Every 210000 km or 48 months

Vehicle data:
Registration/licens Model: Volkswagen T5 Transporter [03-25] Engine code: CAAC
Model year:

1/7
(1) If normally used on dusty roads
(2) Dusty conditions only

General information

Check For Engine Damage

Warning :This engine has been identified as an
INTERFERENCE engine in which the possibility of
valve-to-piston damage in the event of a timing belt failure
is MOST LIKELY to occur. A compression check of all
cylinders should be performed before removing the
cylinder head(s).
Engine Damage
Warning :Although in the event of a timing belt failure
engine damage will NORMALLY occur, a compression
check of all cylinders should be performed before removing
the cylinder head.
Repair Times - hrs
Remove & install 1,60

Special Tools

Auxiliary drive belt tensioner locking pin - No.T10060A.

Camshaft sprocket/high-pressure fuel pump sprocket holding tool - Nos.T10172/4.
Camshaft/high-pressure fuel pump locking tool - No.3359 (x 2).
Crankshaft sprocket locking tool - No.T10050.
Tensioner pulley adjusting tool - No.T10264 or T10409.
Tensioner pulley locking tool - No.T10265.

Special Precautions
Vehicle data:
Registration/licens Model: Volkswagen T5 Transporter [03-25] Engine code: CAAC
Model year:

2/7
 Disconnect battery earth lead.
DO NOT turn crankshaft or camshaft when timing belt removed.
Remove glow plugs to ease turning engine.
Turn engine in normal direction of rotation (unless otherwise stated).
DO NOT turn engine via camshaft or other sprockets.
Observe all tightening torques.

Removal

Raise and support front of vehicle.

Remove:
Engine undershield (if necessary).
Engine upper cover (if necessary).
Air filter intake pipe.

Disconnect wiring harness from timing belt upper cover.

Remove:
Timing belt upper cover Fig. 1 [1] .
Auxiliary drive belt. Use tool No.T10060A.
Crankshaft pulley bolts Fig. 1 [2] .
Crankshaft pulley Fig. 1 [3] .
Intercooler air duct (if necessary).
Timing belt lower cover Fig. 1 [4] .

Turn crankshaft clockwise to TDC on No.1 cylinder.

Ensure arrow on camshaft sprocket at approximately 12 o'clock position Fig. 1 [5] . If not:
Turn crankshaft one turn clockwise.
Lock crankshaft sprocket Fig. 1 [6] . Use tool No.T10050.
Ensure timing marks aligned Fig. 1 [7] .
Ensure lug of crankshaft sprocket locking tool located in oil seal housing Fig. 1 [8] .
Lock camshaft Fig. 1 [9] . Use tool No.3359.
Slacken camshaft sprocket bolts Fig. 1 [10] . Ensure sprocket can just be turned by hand.
Slacken high-pressure fuel pump sprocket bolts Fig. 1 [11] . Ensure sprocket can just be
turned by hand. There are two types of tensioner pulley for timing belt.
Tensioner pulley type A:
Slacken tensioner pulley nut Fig. 1 [12] .
Turn tensioner pulley anti-clockwise until locking tool can be inserted Fig. 1 [13] . Use tool
No.T10264 Fig. 1 [14] .
Insert locking tool in tensioner pulley Fig. 1 [15] . Tool No.T10265.
Turn tensioner pulley fully clockwise until it reaches stop Fig. 1 [16] . Use tool No.T10264

Vehicle data:
Registration/licens Model: Volkswagen T5 Transporter [03-25] Engine code: CAAC
Model year:

3/7
 Fig. 1 [14] .
Tighten tensioner pulley nut finger tight Fig. 1 [12] .

Tensioner pulley type B:

Slacken tensioner pulley nut Fig. 1 [17] .
Turn tensioner pulley clockwise to release tension on belt. Use tool No.T10409 Fig. 1 [18] .
Tighten tensioner pulley nut finger tight Fig. 1 [17] .

Remove timing belt, starting at camshaft sprocket. Mark direction of rotation on belt with
chalk if belt is to be reused.

Installation
Note :Engine must be COLD.
Fit new camshaft sprocket bolts Fig. 1 [10] . Tighten bolts finger tight.
Fit new high-pressure fuel pump sprocket bolts Fig. 1 [11] . Tighten bolts finger tight.
Sprockets should turn freely but not tilt.
Ensure crankshaft sprocket locking tool located correctly Fig. 1 [6] .
Ensure camshaft locked with tool Fig. 1 [9] .
Lock high-pressure fuel pump Fig. 1 [19] . Use tool No.3359.
Turn camshaft sprocket fully clockwise in slotted holes.
Turn high-pressure fuel pump sprocket fully clockwise in slotted holes.
Fit timing belt in following order:
Crankshaft sprocket.
Guide pulley (G1).
Tensioner pulley.
Camshaft sprocket.
Water pump sprocket.
Guide pulley (G3).
High-pressure fuel pump sprocket.
Guide pulley (G2).

Tensioner pulley type A:

Slacken tensioner pulley nut Fig. 1 [12] .
Remove locking tool from tensioner pulley Fig. 1 [15] .
Ensure tensioner pulley retaining lug is properly engaged Fig. 1 [20] .
Turn tensioner pulley slowly clockwise until pointer aligned with notch Fig. 1 [21] . Use tool
No.T10264 Fig. 1 [14] . Ensure tensioner pulley nut does not turn Fig. 1 [12] .
Hold tensioner pulley. Use tool No.T10264 Fig. 1 [14] .
Tighten tensioner pulley nut Fig. 1 [12] . Tightening torque: 20 Nm + 45°.

Tensioner pulley type B:

Vehicle data:
Registration/licens Model: Volkswagen T5 Transporter [03-25] Engine code: CAAC
Model year:

4/7
 Ensure tensioner pulley at position shown Fig. 1 [22] .
Slacken tensioner pulley nut Fig. 1 [17] .
Turn tensioner pulley anti-clockwise until pointer aligned with notch Fig. 1 [23] & Fig. 1
[24] . Use tool No.T10409 Fig. 1 [18] . Ensure tensioner pulley nut does not turn Fig. 1
[17] .
Ensure tensioner pulley marks aligned Fig. 1 [25] .
Hold tensioner pulley. Use tool No.T10409 Fig. 1 [18] .
Tighten tensioner pulley nut Fig. 1 [17] . Tightening torque: 20 Nm + 45°.

Turn camshaft sprocket anti-clockwise to remove slack from belt between camshaft sprocket
and high-pressure fuel pump sprocket. Use tool Nos.T10172/4.
Hold camshaft sprocket. Use tool Nos.T10172/4.
Tighten camshaft sprocket bolts Fig. 1 [10] . Tightening torque: 20 Nm.
Hold high-pressure fuel pump sprocket. Use tool Nos.T10172/4.
Tighten high-pressure fuel pump sprocket bolts Fig. 1 [11] . Tightening torque: 20 Nm.
Remove:
Camshaft locking tool Fig. 1 [9] .
High-pressure fuel pump locking tool Fig. 1 [19] .
Crankshaft sprocket locking tool Fig. 1 [6] .

Turn crankshaft slowly two turns clockwise until just before TDC on No.1 cylinder.
Fit crankshaft sprocket locking tool while slowly turning crankshaft to TDC Fig. 1 [6] .
Ensure lug of crankshaft sprocket locking tool located in oil seal housing Fig. 1 [8] .
Ensure timing marks aligned Fig. 1 [7] .
Ensure camshaft locking tool can be inserted easily Fig. 1 [9] . DO NOT insert high-pressure
fuel pump locking tool as alignment hole may be slightly misaligned. No adjustment required.
Ensure tensioner pulley pointer aligned with notch or 5 mm maximum to the right of notch
Fig. 1 [21] or Fig. 1 [23] . If not: Repeat tensioning procedure.
If camshaft locking tool cannot be inserted easily Fig. 1 [9] :
Remove lug of crankshaft sprocket locking tool from hole in oil seal housing.
Turn crankshaft anti-clockwise until lug of locking tool just passes hole in oil seal housing Fig.
1 [26] .
Turn crankshaft clockwise until camshaft locking tool can be inserted Fig. 1 [9] .
Slacken camshaft sprocket bolts Fig. 1 [10] . Lug of crankshaft sprocket locking tool will
be positioned to the left or right of hole in oil seal housing.

If lug of crankshaft sprocket locking tool is positioned to the left of hole in oil seal housing:
Turn crankshaft clockwise until lug and hole aligned Fig. 1 [8] .
Lock crankshaft sprocket Fig. 1 [6] .
Ensure timing marks aligned Fig. 1 [7] .
Hold camshaft sprocket. Use tool Nos.T10172/4.
Tighten camshaft sprocket bolts Fig. 1 [10] . Tightening torque: 20 Nm.

Vehicle data:
Registration/licens Model: Volkswagen T5 Transporter [03-25] Engine code: CAAC
Model year:

5/7
 If lug of crankshaft sprocket locking tool is positioned to the right of hole in oil seal housing:
Turn crankshaft anti-clockwise until lug of locking tool just passes hole in oil seal housing Fig.
1 [26] .
Turn crankshaft clockwise until lug and hole aligned Fig. 1 [8] .
Lock crankshaft sprocket Fig. 1 [6] .
Ensure timing marks aligned Fig. 1 [7] .
Hold camshaft sprocket. Use tool Nos.T10172/4.
Tighten camshaft sprocket bolts Fig. 1 [10] . Tightening torque: 20 Nm.

Remove locking tools Fig. 1 [6] & Fig. 1 [9] .

Turn crankshaft slowly two turns clockwise until just before TDC on No.1 cylinder.
Lock crankshaft sprocket Fig. 1 [6] .
Ensure timing marks aligned Fig. 1 [7] .
Ensure lug of crankshaft sprocket locking tool located in oil seal housing Fig. 1 [8] .
Ensure camshaft locking tool can be inserted easily Fig. 1 [9] .
Hold camshaft sprocket. Use tool Nos.T10172/4.
Tighten camshaft sprocket bolts Fig. 1 [10] . Tightening torque: 20 Nm + 45°.
Hold high-pressure fuel pump sprocket. Use tool Nos.T10172/4.
Tighten high-pressure fuel pump sprocket bolts Fig. 1 [11] . Tightening torque: 20 Nm + 90°.
Remove locking tools Fig. 1 [6] & Fig. 1 [9] .
Install components in reverse order of removal.
Tighten crankshaft pulley bolts Fig. 1 [2] . Tightening torque: 10 Nm + 90°. Use new bolts.

Fig. 1

Fig. 1

Vehicle data:
Registration/licens Model: Volkswagen T5 Transporter [03-25] Engine code: CAAC
Model year:

6/7
Vehicle data:
Registration/licens Model: Volkswagen T5 Transporter [03-25] Engine code: CAAC
Model year:

7/7