Camshaft Sprocket Timing Tool Kit for VW Touareg / T5 / Phaeton 2.5 & 4.9 TDI

This comprehensive tool kit is designed for precise installation, adjustment, and locking of camshaft sprockets on VW 5- and 10-cylinder TDI engines. It is essential for timing-related service operations such as timing belt replacement and engine repair.

The tools ensure correct synchronization between crankshaft and camshaft, minimizing the risk of engine damage and ensuring factory-specified timing accuracy.

Vehicle Compatibility

Compatible with the following Volkswagen models:

• VW Touareg (from 2003)
• VW T5 Transporter (from 2004)
• VW Phaeton (from 2003)

Engine codes:
AXD, AXE, BAC, BLJ, BLK, BNZ, BPC, BPD, BPE

Function

The tool kit enables:

• Accurate installation and adjustment of camshaft sprockets
• Secure locking of camshaft and crankshaft during service
• Controlled tensioning and adjustment of timing components
• Safe handling and preloading of intermediate gears (where applicable)
• Precise torque-controlled assembly according to manufacturer specifications

Usage Guidelines (Simplified Procedure Overview)

(Always follow the official manufacturer repair instructions when working on the engine.)

1. Install the TDC setting tool on the crankshaft together with the camshaft locking tool.
2. If an intermediate gear is present (gearbox side), preload it with 0.5 Nm counterclockwise.
3. Install the camshaft sprocket and hand-tighten the center bolt.
4. Mount the clamping tool and tighten to 70 Nm.
5. Remove the TDC tool and install the crankshaft locking tool to prevent rotation.
6. Apply preload of 80 Nm via the clamping tool while tightening the camshaft sprocket to 50 Nm.
7. Important: Always use a new center bolt.
8. Remove the clamping tool and install tool (T10199), tighten to 40 Nm.
9. Ensure the tool is seated correctly, then tighten the new center bolt to 150 Nm + 90°.
10. Remove all tools, rotate the engine manually, and verify correct timing alignment.

OEM Reference Tools

• Camshaft locking tool (T10193)
• Camshaft locking tool (T10194)
• Camshaft sprocket tensioning tool (T10199)
• Camshaft sprocket clamping tool (T10199/1)
• Crankshaft adjustment tool (T10225)
• Crankshaft locking tool (T10226)
• Eccentric bolt adjustment tool (T10234)

OEM numbers are for reference purposes only and do not imply original manufacturer tools.

 Usage – 5-Cylinder

1. Remove camshaft seal (A).
2. Turn the crankshaft in the engine’s direction of rotation until the markings on the rotary insert (5) align with marking (B) on the radial shaft seal carrier.
3. Remove rotary insert (5).
4. Install crankshaft locking tool (8) and lock the crankshaft.

Note: The locking angle of the crankshaft locking tool (8) must engage in the engine mount bracket (C) on the cylinder block.

5. The crankshaft locking tool (8) can only be tightened in one position.
6. If tightening is not possible, rotate the crankshaft one full turn in the engine’s direction of rotation until the markings of the rotary insert (5) are opposite marking (B) on the radial shaft seal carrier.
7. Install camshaft locking tool (4).
8. See application for 10-cylinder engine from step 3.

Diagram Labels

• A – Camshaft seal
• B – Alignment marking
• 5 – Rotary insert
• 4 – Camshaft locking tool
• 8 – Crankshaft locking tool
• C – Engine mount bracket 

Usage – 10-Cylinder Engine

Rotate the engine until at least one camshaft locking tool (4 or 7) can be installed, then follow the instructions below.

If only one camshaft locking tool can be installed:

1. Install the clamping tool (2) onto the camshaft sprocket of the locked camshaft and loosen the bolt (A) of the camshaft sprocket.
   The sprocket can now rotate freely on the camshaft.
2. Rotate the engine until the camshaft locking tool for the other cylinder bank can be installed.
3. Install the clamping tool (2) onto the camshaft sprocket and loosen its fastening.
   The sprocket is now also free to rotate on the camshaft.
4. Remove the vibration damper.
5. Install the crankshaft locking tool (9) (not included in delivery) onto the crankshaft end.
6. Carefully rotate the crankshaft until the locating pin of the crankshaft locking tool (6) can be inserted into the locating bore.
7. Install the clamping tool (2) and tighten to 70 Nm.
8. Insert a torque wrench (40–200 Nm) into the square drive of the clamping tool and apply torque against the engine rotation direction.
   This removes play from the gear train.

NOTE:
Cylinder bank 1 → rotate in arrow direction
Cylinder bank 2 → rotate opposite to arrow direction

9. Maintain the torque and tighten the camshaft sprocket bolt to the specified torque.
10. Remove the clamping tool (2).
11. Install the clamping device (3) onto the camshaft sprocket.
12. Tighten the bolts of the clamping device (3) to 40 Nm.
13. Then tighten the camshaft sprocket to the specified torque.
14. Remove the clamping device (3).
15. Remove camshaft and crankshaft locking tools.
16. Rotate the crankshaft 2 full turns in the engine’s direction of rotation until cylinder 1 is again at TDC.
17. Check whether the camshaft and crankshaft locking tools can be installed simultaneously.