How to Replace timing belt on VW Passat 3C 1.6

Replacement Interval Guide

• Volkswagen recommend check at the first 60,000 miles and then every 20,000 miles (replace if necessary).
• No manufacturer’s recommended replacement interval.

NOTE: Volkswagen UK recommend the timing belt is replaced every 4 years.

• The previous use and service history of the vehicle must always be taken into account.

Check For Engine Damage

CAUTION: This engine has been identified as an INTERFERENCE engine in which the possibility of valve-to-piston damage in the event of a timing belt failure is MOST LIKELY to occur. A compression check of all cylinders should be performed before removing the cylinder head(s).

Repair Times – hrs

Remove & install:
Golf/Golf Plus/Jetta/Passat/Touran	2,20
Caddy	1,90

Special Tools

• Auxiliary drive belt tensioner locking pin – Volkswagen No.T10060A.
• Two-pin wrench – Volkswagen No.T10020.

Special Precautions

• Disconnect battery earth lead.
• DO NOT turn crankshaft or camshaft when timing belt removed.
• Remove spark plugs to ease turning engine.
• Turn engine in normal direction of rotation (unless otherwise stated).
• DO NOT turn engine via camshaft or other sprockets.
• Observe all tightening torques.

Removal

1. Raise and support front of vehicle.
2. Remove:
   • Engine undershield.
   • Engine upper cover.
   • Auxiliary drive belt. Use tool No.T10060A.

   NOTE: Remove auxiliary drive belt tensioner locking pin No.T10060A before removing RH engine mounting.

3. Drain coolant (if necessary).
4. Disconnect coolant expansion tank top hose.
5. Remove:
   • Coolant expansion tank. DO NOT disconnect hoses.
   • Timing belt upper cover [1] .
6. Turn crankshaft to TDC on No.1 cylinder.
7. Ensure crankshaft pulley timing marks aligned [2] .
8. Ensure camshaft sprocket timing marks aligned [3] .
9. Support engine.
10. Remove:
    • Crankshaft pulley bolts [4] .
    • Crankshaft pulley [5] .
    • Timing belt centre cover [6] .
    • Timing belt lower cover [7] .
    • RH engine mounting.
    • RH engine mounting bracket.
11. Slacken tensioner pulley nut [8] . Turn tensioner clockwise away from belt. Use tool No.T10020 [9] . Lightly tighten nut [8] .
12. Remove timing belt.

    NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

Installation

NOTE: Engine must be COLD.

1. Ensure camshaft sprocket timing marks aligned [3] .
2. Fit timing belt to crankshaft sprocket and water pump sprocket.
3. Install:
   • Timing belt lower cover [7] .
   • Timing belt centre cover [6] .
   • Crankshaft pulley [5] .
   • Crankshaft pulley bolts [4] .
4. Tighten crankshaft pulley bolts [4] . Tightening torque: 10 Nm + 90°. Use new bolts.
5. Ensure crankshaft pulley timing marks aligned [2] .
6. Fit timing belt to tensioner pulley and camshaft sprocket.

   NOTE: Ensure belt is taut between sprockets on non-tensioned side.

7. Ensure tensioner retaining lug is properly engaged [10] .
8. Slacken tensioner pulley nut [8] .
9. Turn tensioner 5 times fully anti-clockwise and clockwise from stop to stop. Use tool No.T10020 [9] .
10. Turn tensioner fully anti-clockwise then slowly clockwise until pointer [11] aligned with notch [12] in baseplate. Use tool No.T10020 [9] .
11. Tighten tensioner pulley nut [8] . Tightening torque: 20 Nm.
12. Turn crankshaft two turns clockwise to TDC on No.1 cylinder.

    NOTE: Turn crankshaft last 45° smoothly without stopping.

13. Ensure camshaft sprocket timing marks aligned [3] .
14. Ensure crankshaft pulley timing marks aligned [2] .
15. Ensure pointer [11] aligned with notch [12] in baseplate.
16. If not: Repeat tensioning procedure.
17. Install components in reverse order of removal.
18. Refill coolant (if necessary).