T4 2.5 TDI tightening torques?

[Pundit]

I'm in the process of replacing the cam & injection pump belts on my 2.5 TDI (ACV).
I know the main crank bolt is supposed to be 160nm plus 180 degrees but I'm having trouble finding the torque settings for the other bolts, cam pulleys, tensioners/idlers.

I also need the torque settings for the camshaft journal caps as I had to remove the camshaft in order to have the vacuum pump eccentric reground due to some wear. It was ground 11 thou so there should still be enough preload on the vacuum pump pushrod to avoid any rattling. - TIA

[gldgti]

I think pretty much any VW engine with OHC has a spec of around 13ft/lbs(20ish Nm) for camshaft cap nuts.

for camshaft pulley on an eccentric (one central bolt) 70Nm is plenty, and make sure you use a sprocket counter hold tool.

for idlers and tensioners with an 8mm stud, 30Nm is also plenty.

I think you'll need a lot of luck to go 180deg on the crank after your 160Nm, but as far as you can physically go is probably enough (thats what dad and I got when we did his caravelle about 12 months ago.

[jets]

For cambelt end, 4 bolts around main crank bolt, 20Nm + 90degrees.
Tensioner 20Nm
Cam pulley, if 8.8 strength bolt 85Nm
!0.9 " " !00Nm
Main crank bolt, Auto data says lightly oil thread & contact surfaces
Elsa Win doesn't mention whether dry or oiled.
Lower belt guard, Long bolt at top,20Nm, smaller bolts 10Nm.
Fuel pump end, cam pulley, 160Nm
Tensioner bolt 15Nm
Idler 20Nm.
Locking bolt for pump 30Nm [Elsa Win]
25Nm [Auto data] Take your pick.
Camshaft bearing caps, 20Nm
A few notes I made. Install belt starting from crankshaft,around water pump & finally over cam pulley. Belt is very tight fit so have entire belt just over edge of each pulley with edge of belt roughly in line. Gradually work work belt across pulleys until home. Naturally the tensioner is fully backed off while doing this.
Adjust tensioner. Loosely bolt harmonic balancer in place & turn crank two complete turns. Check tensioner adjustment again.
Remove harmonic balancer & install top belt cover before lower cover. Hook at bottom of top cover must slide into slot at rear of sheet metal cam cover. Install the three 6mm screws[10Nm]. Reinstall harmonic balance pulley[don't forget diamond coated washer] & tighten to correct torque

[Pundit]

Thanks for the info guys. Much appreciated.

[tooarbie]

And 11 years later ... I appreciate the info too!!

[ELK Audio]

When I did my 2.5 TDI (ACV) cam and injection pump belts, I followed a guide that recommended around 30-35 Nm for the cam pulleys and tensioners. For the camshaft journal caps, it's usually a lower torque, maybe in the range of 10-15 Nm, but definitely check your specific manual or guide for the exact specs.

[jets]

I think you'll need a lot of luck to go 180deg on the crank after your 160Nm, but as far as you can physically go is probably enough (thats what dad and I got when we did his caravelle about 12 months ago.

I should have mentioned this for the crank bolt. This is a stretch bolt [single use only]. I put a texta mark on the face of the hex. to show the final position & later on you can see if there has been any loosening. There is also a diamond coated washer that helps hold everything in the correct place for the long term.