How to Replace timing belt on VW Passat 3C 1.9 TDI

Replacement Interval Guide

• Volkswagen recommend:
• Caddy/Caddy Maxi:
• Check every 20,000 miles or 24 months under adverse conditions.
• Replace timing belt every 80,000 miles.
• Replace tensioner pulley every 160,000 miles.
• Golf/Golf Estate/Golf Plus/Jetta/Passat/Eos/Touran:
• Replace timing belt every 80,000 miles.
• Replace tensioner pulley every 160,000 miles.

NOTE: Volkswagen UK recommend the timing belt is replaced every 4 years if the replacement mileage is not reached.

• 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 Estate/Golf Plus/Jetta/Passat/Eos/Touran	2,50
Caddy/Caddy Maxi: BJB	1,90
Caddy/Caddy Maxi: BLS/BSU with DPF	2,50
Caddy/Caddy Maxi: BLS/BSU without DPF →2007	1,60
Caddy/Caddy Maxi: BLS/BSU without DPF 2008→	2,50

Special Tools

• Auxiliary drive belt tensioner locking pin – Volkswagen No.T10060A.
• Camshaft sprocket locking tool – Volkswagen No.3359.
• Camshaft sprocket holding tool – Volkswagen No.T10172.
• Camshaft sprocket holding tool pins – Volkswagen No.T10172/4.
• Crankshaft sprocket locking tool – Volkswagen No.T10100.
• Tensioner pulley locking pin – Volkswagen No.T10265.
• Tensioning tool – Volkswagen No.T10264.

Special Precautions

• Disconnect battery earth lead.
• DO NOT turn crankshaft or camshaft when timing belt removed.
• Remove glow 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.
   • RH wheel arch liner.
   • Engine top cover.
3. Disconnect:
   • Fuel supply and return pipes.
   • Coolant expansion tank multi-plug.
4. Remove:
   • Turbocharger inlet hose.
   • Fuel filter. DO NOT disconnect pipes.
   • Fuel filter bracket.
   • Windscreen washer reservoir filler neck.
   • Coolant expansion tank. DO NOT disconnect hoses.
   • Auxiliary drive belt. Use tool No.T10060A.

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

   • Auxiliary drive belt tensioner.
   • Timing belt upper cover [1] .
   • Crankshaft pulley bolts [2] .
   • Crankshaft pulley [3] .
   • Timing belt centre cover [4] .
   • Timing belt lower cover [5] .
5. Turn crankshaft clockwise to TDC on No.1 cylinder.
6. Ensure timing mark aligned with notch on camshaft sprocket hub [6] .

   NOTE: Notch located behind camshaft sprocket teeth.

7. Lock camshaft. Use tool No.3359 [7] .
8. Lock crankshaft sprocket. Use tool No.T10100 [8] .
9. Ensure timing marks aligned [9] .
10. Slacken camshaft sprocket bolts [10] .

    NOTE: Slacken bolts until sprocket can be moved within slotted holes.

11. Slacken tensioner pulley nut [11] .
12. Turn tensioner pulley anti-clockwise until locking pin can be inserted [12] . Use tool No.T10264 [13] .
13. Insert locking pin in tensioner pulley [14] . Tool No.T10265.
14. Turn tensioner pulley fully clockwise until it reaches stop [15] . Use tool No.T10264 [13] .
15. Lightly tighten tensioner pulley nut [11] .
16. Remove timing belt, starting at water pump sprocket.

    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 locked with tool [7] .
2. Ensure crankshaft sprocket locking tool located correctly [8] .
3. Ensure timing marks aligned [9] .
4. Ensure tensioner pulley locking pin inserted [14] .
5. Ensure tensioner retaining lug is properly engaged [16] .
6. Turn camshaft sprocket until bolts in centre of slotted holes.

   NOTE: Sprocket should turn freely but not tilt.

7. Fit timing belt in following order:
   • Crankshaft sprocket.
   • Tensioner pulley.
   • Camshaft sprocket.
   • Guide pulley.
   • Water pump sprocket.

   NOTE: If reusing old belt, observe direction of rotation marks on belt. Ensure belt is taut between sprockets on non-tensioned side.

8. Remove locking pin from tensioner pulley [14] .
9. Slacken tensioner pulley nut [11] .
10. Turn tensioner pulley slowly clockwise until pointer aligned with notch [17] .

    NOTE: Ensure tensioner pulley nut does not turn [11] .

11. Hold tensioner pulley. Use tool No.T10264 [13] .
12. Tighten tensioner pulley nut [11] . Tightening torque: 20 Nm + 45°.
13. Hold camshaft sprocket. Use tool Nos.T10172/4.

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

14. Tighten camshaft sprocket bolts [10] . Tightening torque: 25 Nm.
15. Remove:
    • Camshaft sprocket holding tool.
    • Camshaft sprocket locking tool [7] .
    • Crankshaft sprocket locking tool [8] .
16. Turn crankshaft slowly two turns clockwise until just before TDC on No.1 cylinder.
17. Fit camshaft sprocket locking tool while slowly turning crankshaft to TDC [7] . Tool No.3359.
18. Ensure timing mark aligned with notch on camshaft sprocket hub [6] .

    NOTE: Notch located behind camshaft sprocket teeth.

19. Ensure crankshaft sprocket locking tool can be inserted easily [8] .
20. Ensure timing marks aligned [9] .
21. Ensure tensioner pulley pointer aligned with notch [17] .
22. If crankshaft sprocket locking tool cannot be inserted [8] :
    • Slacken camshaft sprocket bolts [10] .
    • Turn crankshaft anti-clockwise until lug of locking tool just passes hole in oil seal housing [18] .
    • Turn crankshaft clockwise until lug and hole aligned.
    • Lock crankshaft sprocket. Use tool No.T10100 [8] .
    • Hold camshaft sprocket. Use tool Nos.T10172/4.

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

    • Tighten camshaft sprocket bolts [10] . Tightening torque: 25 Nm.
    • Remove camshaft sprocket holding tool.
    • Remove locking tools [7] & [8] .
    • Turn crankshaft slowly two turns clockwise until just before TDC on No.1 cylinder.
    • Fit camshaft sprocket locking tool while slowly turning crankshaft to TDC [7] .
    • Ensure crankshaft sprocket locking tool can be inserted easily [8] .
    • Ensure timing marks aligned [9] .
    • Ensure tensioner pulley pointer aligned with notch [17] .
23. Install components in reverse order of removal.
24. Tighten crankshaft pulley bolts [2] . Tightening torque: 10 Nm + 90°.