V10 TDI Cam Replacement

[@jimkillen1065]

Thanks for the videos. Great information..When the Touareg came out i thought i might want one . Interesting watch

[@donniet525]

Great vids Josh! Just bought myself a v10 touareg. Wow are they a wild engine but a pain to work on. Great vids brother!

[@JoshsJettas]

Thanks David, they are pretty sweet engines. Definitely looking forward to getting this back together and putting some miles on it.

[@danielfl.9347]

You can tune the engine to 350hp/850 NM. In Europe they made an R50 edition. Same engine!

[@donniet525]

@@danielfl.9347 Pretty ridiculous numbers.

[@danielfl.9347]

David Termure Yes, but you need to change the oil every 10.000 km and not 30.000km as VW says.

[@gerardmccarthy2432]

@@danielfl.9347 I run 15w40 Rotella T4 in all my diesels with oil and filter changes every 5000miles.

[@jamesprimus5291]

Excellent video. 2 questions. 1) there seems to be a lot of time spent getting the cam gears back in. Is it possible to lay the cam in without tightening, set the gears and then tighten the gears and adjust the cam at same time, would that make the process easier? 2) I expect there are journal bearings on the brackets that hold the cam in place. I did notice in the video that the ones on the block were changed should the upper journals not be changed as well (maybe it was done and I missed it) ?

[@JoshsJettas]

Biggest trouble is getting the gears held against the cam without loosing the diamond washer and lining up the compensator arms. Just a lot of stuff that has to be lined up in a tight area. Yes theres 2 halves, both get changed although the bottom wears the most from the injector rockers pushing down so hard on the cam (also an oiling issue)

[@jamesprimus5291]

Thanks. Good info. I did come across some information that the diamond washers should be changed every time removed. $17. Probably good policy.@@JoshsJettas

[@jamesprimus5291]

Thanks. Good info. I did come across some information that the diamond washers should be changed every time removed. $17. Probably good policy.@@JoshsJettas

[@JoshsJettas]

Considering it’s a friction fit I wouldn’t risk it, end up with a big mess if it slips.

[@mikesimpson3565]

Hello Josh, this video is still helping people such as myself. Question, is there a way to assess the compensator piston? mine appear stuck, I would think they should be able to be compressed? Cheers

[@JoshsJettas]

They get stuck in pretty bad, I was able to thread a flange head bolt in then pry off that head to walk it out. I’ve also heard of using a bushing and bolt/washer combo abd pulling it that way. Assuming your doing it out of frame a slide hammer would be easiest

[@EddieHsu82]

About to get my 04 engine hauled out and over. Can you list where you got the cams and followers and any other parts you replaced?

[@JoshsJettas]

-Cams were stage 2 colt cams I had ordered from Mec Evo in Quebec -Ina nitride follower set X2 for V10 from idparts -Kolbenschmidt bearings for PD engines from idparts. Bought 4 cylinder sets as needed with some to spare, V10 has a specific bearing on the front of bank 1 so that’ll need to be ordered as well X2 -diamond disc washers X2 from idparts -non stretch 12.9 bolts for cam caps and injector rockers

[@EddieHsu82]

@@JoshsJettas a gentleman and a coal rolling scholar

[@JoshsJettas]

Haah I try

[@Shane55113]

Josh, is it feasible to do this repair in car?

[@JoshsJettas]

Shane lampi I think it’s possible but would be tricky and awkward. The compensator piston can be stuck pretty good and need a puller which you won’t have room for (I cut that part out of the video). That and you’ll be hunched over in the back of the bay with the timing components.

[@Italmind]

@@JoshsJettas FYI. I just wrapped this job up. In Situ. Pull the false firewall. Use a pulley remover/installer. It fits in the space between the head and the actual firewall with plenty of room to spare....

[@JoshsJettas]

@Italmind I’ve wanted to try doing one inframe, I know of a few people that have done it this way now

[@Italmind]

@@JoshsJettas Thanks again for the content. Your videos are super helpfull.

[@AirlineF0od]

Josh, what direction do you do you pull the cam gear to remove the slack from the gear train? It looked like the slack was being pulled clockwise (facing engine) on bank two and counterclockwise on bank one.

[@JoshsJettas]

Yes looking from the front backwards yes, both sides away from the Center of the engine. If you send an email to me at [e-mail] I can send a repair PDF that outlines direction/torque etc.

[@a9n8d7r6e5a4s3]

Any chance you can post some links to the parts you purchased? I saw the cams, the bearings, and the lifters. Anything else? Would love to order parts but am concerned about compatibility. Love your videos, and thanks for doing this. Hoping to drop my engine sometime this month!

[@JoshsJettas]

Glad you found them helpful. -I ordered the stage 2 colt cams from MecEvo.com -(X20) M8 1.25X90mm 12.9 grade bolts for injector rocker from fastenal -(X36) M6 1.00X55mm 12.9 grade bolts for cam caps from fastenal Everything else was ordered from Idparts -Ina nitride followers for V10 038109309COE -V10 specific cam bearing (X2) 070103673AGLB -BEW cam bearing (X2 sets) KOLBENSCHMIDT 77913600 (the issue with using 4 cyl. sets is youll be short 2 bearing halves when doing bank 2) -Diamond disk washers (X2) 070109421A -Tandem pump gasket 070145215 -Fuel pump gasket 07Z145215 Then obviously oil and filters as preferred

[@a9n8d7r6e5a4s3]

@@JoshsJettas Another question! Are you going to replace the cylinder head gaskets on each bank? I don't know if I need to do that on my V10, but I have lots of oil buildup on the engine. Have you taken off the heads despite the VW documentation saying don't unscrew those bolts because it might warp the block??

[@JoshsJettas]

I didn’t as I didn’t have any known head gasket issues. I’d make sure that the valve cover gaskets and tandem pump gaskets aren’t leaking and running down the cylinder head. I’d also make sure the exhaust manifolds and flex pipes before the turbos aren’t leaking/cracked causing soot to stick to everything.

[@a9n8d7r6e5a4s3]

Hey! Any chance you have the SKUs for the M6 and M8 bolts? I want to make sure I order the right heads, but Fastenal has a ton of fasteners to choose from, with various bolt head configurations. Do you recommend a finish of Black Oxide or Zinc? Or something else?

[@cammmy]

HI Mate, thanks for the vid. I'm doing this on a Phaeton V10 at the moment and have what is probably the same timing kit. How did you lock the crank in the end? I didn't see that in the vid?

[@JoshsJettas]

I wasn’t real proud of my method so I left that out of the video. I set the engine to tdc so cam locks would go in with the gears preloaded and marked a spot on the front dampener and the front cover. When I preloaded the gears with the new cams the crank never moved so I wasn’t to concerned of it being out of time. After re assembly I checked torsion value (cam timing) which was -1.5 so slightly retarded. It doesnt take much to change that number so I’m not sure how close it would be with the correct crank lock.

[@cammmy]

@@JoshsJettas okay cool, thanks. Is there any reason to take the damper off if you aren't going to use the crank lock? Also, for anyone else reading this. The cam locks have little seals over them that appear to be one time use

[@JoshsJettas]

I’d just leave it on, if the front main isn’t leaking then there’s no use taking it off. As far as the front cam seals/caps they are one time use, if you loosen the front cam caps slightly the seal/cap will fall out

[@cammmy]

@@JoshsJettas cool, thanks. I've got some fairly uncommon car's but I've never had anything as hard to find information on as this. Especially given how common this issue is.

[@JoshsJettas]

Yeah that’s why I had made some of these videos as there isn’t a whole lot for DIY. If your looking for a service manual for the engine strictly send an email to [e-mail], I can send a PDF over.

[@petigyorok9424]

Hello. The video is very good, I'm getting ready to replace it now, but I'm not taking out the engine. The firewall can be completely dismantled. Was there no washer behind the lower gears? It's as shown in the exploded view.

[@JoshsJettas]

On the compensator link? no washers down there, only washer is the diamond disc. Do you have the V10 service manual? If not send an email to [e-mail] and i can send it over, the manual lays it out nicely and has quite good pictures

[@petigyorok9424]

@@JoshsJettas Thanks. It has already been disassembled. There is no washer. An exhaust hydraulic lifter broke through the shocking waves.

[@segull635]

hey josh could you explain how you put the engine into top dead center , like what tools you used thanks also nice job

[@JoshsJettas]

As far as getting it rotated to tdc I just threaded some of the bolts out on the harmonic balancer and used a pry bar to bar it over. As far as tools I just ordered the 2.5L/5L timing tool kit but the downside is that kit doesn’t have the crank lock so I just used the marks on the balancer and front cover

[@snapforth]

Josh, I'm getting into this work now on my 2006. I'm stuck right now trying to get the elbow out of the valve cover so I can remove the plastic valve cover cover. Does this just pull out?

[@JoshsJettas]

Yup should just pop up, it can take a good pull. A flat screwdriver helps pop it up as well.

[@snapforth]

@@JoshsJettas Yep I gave it a good pull and it broke. Yay. Can I put you on a flight to come down here and do this for me

[@JoshsJettas]

@@snapforth the plastics can be brittle, same with the connectors. It’d be a good time to do it I imagine flights are cheap

[@DedoMrazii]

Hey Josh where can i buy cams like that?

[@JoshsJettas]

I bought them from Mec Evo in Quebec Canada, stage 2 colt cams. Colt is located on the west coast and Quebec’s a lot closer to me. Remainder of the stuff from IDParts.

[@karleon38]

Thanks Josh for this video, great job. I'm looking for the workshop manual for this engine, that i'm rebuilding now. Do you know where can i get it ?

[@JoshsJettas]

Thanks, send me an email, [e-mail], I’ll send it over tonight or tomorrow morning.

[@benjaminking1735]

cant find these cams anywhere

[@JoshsJettas]

Mecevo.com is where I got mine. I believe you can contact colt cams directly as well but they don’t advertise their tdi products on their website.