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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

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

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