Removing and installing toothed belt for high-pressure pump (engine codes CARA, CEXA, CEXB) — VW

🧭 Before you start

Fits: VW Phaeton (3D)

• Timing position: the crankshaft or camshaft is set and locked during this job
• Special tools named: T40135, T40058, locking pin

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• For illustration purposes, the procedure is shown with the toothed belt guard removed.
• To prevent any engine oil from escaping, place a cloth below the upper part of sump.
• Risk of injury when feeling for "“TDC”" hole with finger.Do not turn crankshaft (1). — Screw locking pin3242 into hole (20 Nm); if necessary, turn crankshaft backwards and forwards slightly to fully centralise locking pin.
• The toothed belt drive pulley remains on the camshaft.
• Risk of irreparable damage due to jumping of camshaft timing chain.Only turn crankshaft in engine direction of rotation (arrow). — Turn crankshaft to "“TDC”" using adapter T40058.

🔧 Engine codes this applies to

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Remove engine cover.
2. Pivot toothed belt guard forwards (arrows) and unhook retaining pin on underside of toothed belt guard. [Note: For illustration purposes, the procedure is shown with the toothed belt guard removed.]
3. ⚠ Risk of irreparable damage if direction of rotation is reversed on previously used toothed belt.Before removing toothed belt, mark direction of rotation with chalk or felt tipped pen for installation purposes. — Set engine to »Ignition TDC«: [Note: To prevent any engine oil from escaping, place a cloth below the upper part of sump.]
4. Unscrew plug (arrow) from upper part of sump.
5. ⚠ Risk of injury when feeling for "“TDC”" hole with finger.Do not turn crankshaft (1). — Screw locking pin3242 into hole (20 Nm); if necessary, turn crankshaft backwards and forwards slightly to fully centralise locking pin. — 20 Nm (15 lb-ft)

6. Lock toothed belt pulley for high-pressure pump using locking pin T40135.
7. Loosen bolt (1) for toothed belt tensioning roller about 1 full turn. Item (2) can be disregarded.
8. Loosen bolt (1) for toothed belt drive pulley approx. 2 turns using counterhold3036.
9. Pull off toothed belt drive pulley using puller T10320. [Note: The toothed belt drive pulley remains on the camshaft.]
10. First remove toothed belt from toothed belt pulley for high-pressure pump and then from toothed belt drive pulley.
11. Remove noise insulation.
12. Insert guide pin of adapter T40058 as follows:
13. ⚠ Risk of irreparable damage due to jumping of camshaft timing chain.Only turn crankshaft in engine direction of rotation (arrow). — Turn crankshaft to "“TDC”" using adapter T40058.
14. Unscrew plug (arrow) at rear of cylinder head on right. [Note: For reasons of clarity, the installation position as seen from the rear with the engine removed is shown.]
15. Check whether the groove (arrow) in the flange of the camshaft can be seen through the hole (1) for plug.
16. To do this, use a small torch to shine light into the plug hole. [Note: For reasons of clarity, the flange of the camshaft is shown without chain drive and without timing chain cover.]
17. If the groove is not beneath the hole, turn crankshaft 360 degrees in the engine's direction of rotation. [Note: Place a cloth underneath upper part of sump to catch escaping engine oil.]
18. Unscrew plug (arrow) from upper part of sump.
19. ⚠ Risk of injury when feeling for "“TDC”" hole with finger.Do not turn crankshaft (1). — Screw locking pin3242 into hole (20 Nm); if necessary, turn crankshaft backwards and forwards slightly to fully centralise locking pin. [Note: Before installing the toothed belt, the high-pressure pump and toothed belt sprocket for high-pressure pump must be properly secured in place.] — 20 Nm (15 lb-ft)
20. Check installation of toothed belt tensioning roller:
21. Fit toothed belt.
22. Screw in bolt (1) for toothed belt tensioning roller without applying pressure until eccentric of toothed belt tensioning roller can just be turned without tilting.
23. Screw in bolt (2) for toothed belt drive pulley until toothed belt drive pulley can just be turned without tilting.
24. Lock toothed belt pulley for high-pressure pump using locking tool T40135.
25. Pre-tension toothed belt tensioning roller with hexagon key by turning in direction of (arrow) until hexagon drive mounting is positioned at (1 o'clock)
26. ⚠ Never turn tensioning roller to "“12 o'clock position”" or beyond. — Now relieve tension of toothed belt tensioning roller (arrow) until hexagon drive mounting is positioned at (3 o'clock)
27. From the (3 o'clock) position, pre-tension toothed belt tensioning roller (arrow) until lug (1) and notch (2) align exactly.
28. Hold toothed belt tensioning roller in this position and tighten bolt (arrow).
29. Tighten bolt (1) for toothed belt drive pulley using counterhold3036.
30. Remove locking pin3242.
31. Screw in sealing plug (arrow) for "“TDC”" mark in upper part of oil sump 17.
32. Insert guide pin of adapter T40058 as follows:
33. ⚠ Risk of irreparable damage from camshaft timing chains jumping.Only turn crankshaft in engine direction of rotation (arrow). — Turn crankshaft 1 full turn using adapter T40058.
34. Check toothed belt tension:
35. If specification is not reached, adjust toothed belt tension again.

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