Volkswagen Touareg 2004-06

Timing Belt & Sprockets

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Removal & Installation



4.2L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the timing belt covers.
  4.  
  5. If reusing the timing belt, mark the running direction of the belt.
  6.  
  7. Set the crankshaft to Top Dead Center (TDC). The marking on the timing belt cover must be aligned with the notch on the belt pulley.
  8.  
  9. Check the position of the camshaft gears. The large holes on the securing plates must align on the inside.
    NOTE
    If the large holes are positioned on the outer side of the timing belt gears, the crankshaft must be turned one rotation further in the direction of engine rotation.



    Click image to see an enlarged view

    Fig. Align the marks on the crankshaft-4.2L engines



    Click image to see an enlarged view

    Fig. The large holes (arrows) must align on the inside-4.2L engines

  10.  
  11. Remove the sealing plug from the left side of the cylinder block. The TDC hole for the crankshaft must be visible or felt behind the hole of the sealing plug.
  12.  
  13. Carefully screw crankshaft holder 3242 or equivalent into the hole up to the stop to secure the crankshaft against turning.
  14.  
  15. Remove the center timing belt guard.
  16.  
  17. Remove the 8 bolts securing the vibration damper.
  18.  
  19. Remove the bolt from the oil filter housing and then remove the bolts for the timing belt tensioner cover. Remove the cover.
    NOTE
    The timing belt tensioner is oil-dampened. Therefore it can only be compressed slowly.



    Click image to see an enlarged view

    Fig. Remove the bolt (1) from the filter housing and the tensioner cover (2)-4.2L engines

  20.  
  21. Use locking pin T40011 or equivalent to secure the tensioner.
  22.  
  23. If necessary, align the holes in the housing and the tensioner piston using a pair of needle nose pliers or a thin piece of wire, before tensioning.
  24.  
  25. Turn the tensioning lever of the tensioning roller (1) in the direction of the arrow. When the lever pushes the tensioner together so that the holes in the housing and piston align, use locking pin T40011 or equivalent to lock the piston.

    Click image to see an enlarged view

    Fig. Turn the tensioning lever of the tensioning roller (1) in the direction of the arrow-4.2L engines

  26.  
  27. Place camshaft locking tool T40005 or equivalent into the securing plates of the camshafts and loosen the bolts about 5 turns.
  28.  
  29. Remove the camshaft locking tool.

    Click image to see an enlarged view

    Fig. Camshaft locking tool-4.2L engines

  30.  
  31. Remove the camshaft gears from the cone using puller T40001 and T40001/2 or equivalent.
  32.  
  33. Loosen the tensioning roller and remove the timing belt.
  34.  

To install:


NOTE
On used timing belts, observe the marking for the direction of rotation.

  1. Set the timing belt onto the timing belt crankshaft gear first, then onto the idler roller of the timing belt tensioner, then onto the tensioning roller. Now, set it onto the camshaft gears and the coolant pump belt pulley.
    NOTE
    The camshaft gears must just be able to be twisted on the camshaft cones.



    Click image to see an enlarged view

    Fig. Timing belt routing-4.2L engines

  2.  
  3. Install camshaft locking tool T40005 or equivalent onto the camshaft gears again.
  4.  
  5. Set a 5 mm drill bit between the tensioner lever and the piston of the tensioner.

    Click image to see an enlarged view

    Fig. Set a 5 mm drill as shown (arrow)-4.2L engines

  6.  
  7. Pretension the still loosened tensioning roller using a torque wrench. Rotate counter-clockwise to 35 inch lbs. (4 Nm). In this position, tighten the bolt to 16 ft. lbs. (22 Nm). Refer to the illustration.

    Click image to see an enlarged view

    Fig. Rotate the tensioning roller counter-clockwise-4.2L engines

  8.  
  9. Remove the 5 mm drill bit.
  10.  
  11. Turn the tensioning lever of the timing belt tensioning roller in the direction of the arrow. When the tensioning lever has compressed the piston in the tensioner, pull out the locking pin.

    Click image to see an enlarged view

    Fig. Rotate the tensioner lever as shown. Remove the locking pin when the piston is compressed

  12.  
  13. Turn the tensioning lever again and place a 7 mm drill between the housing and the tensioning lever.

    Click image to see an enlarged view

    Fig. Rotate the lever again and place a 7 mm drill as shown-4.2L engines

  14.  
  15. Tighten the camshaft gears to 41 ft. lbs. (55 Nm).
  16.  
  17. Remove the camshaft locking tool.
  18.  
  19. Remove the drill that was inserted between the housing and tensioner.
  20.  
  21. Remove the crankshaft holder tool and screw in the sealing plug. Tighten to 22 ft. lbs. (30 Nm).
  22.  
  23. Turn the crankshaft twice in the direction of engine rotation and check the gap of dimension (a). There should be a 5 mm gap.

    Click image to see an enlarged view

    Fig. Dimension (a) should be 5 mm-4.2L engines

  24.  
  25. The remaining installation is the reverse of removal.
  26.  

 
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