How to Replace timing belt on Volkswagen Passat 2.0 FSI 2007

Volkswagen Passat 2.0 FSI turbo 2007 cambelt change instructions and replacement inteval. Full guide!

Special tools

• Auxiliary drive belt tensioner locking pin – Volkswagen No.T10060A.

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.

Repair times – hrs

Camshaft drive belt/chain – R & I	2,20
Camshaft drive belt/chain (rear) – R & I	2,20

Valve timing procedures

Removal

1. Raise and support front of vehicle.
2. Remove:
   • Engine undershield.
   • RH front wheel.
   • RH front inner wing panel.
   • Engine top cover (if necessary).
   • Air filter and housing (if necessary).
3. Partially drain coolant (if necessary).
4. Disconnect fuel vapour hose(s) from evaporative emission (EVAP) canister.
5. Remove fuel pump fuse from fascia fuse box.
   NOTE: If fuse is left in position fuel pump will be activated by driver’s door switch.
6. Disconnect fuel supply pipe(s).
7. Move evaporative emission (EVAP) canister to one side (if necessary).
8. Remove:
   • Coolant expansion tank multi-plug (if necessary).
   • Coolant expansion tank.
   • Auxiliary drive belt. Use tool No.T10060A.
   • Auxiliary drive belt tensioner.
9. Support engine.
10. Remove:
    • Timing belt upper cover [1] .
    • Intercooler to turbocharger hose (if necessary).
11. Turn crankshaft clockwise to TDC on No.1 cylinder.
12. Ensure timing marks aligned [2] & [3] .
13. Remove:
    • Crankshaft pulley bolts [4] .
    • Crankshaft pulley [5] .
    • Timing belt lower cover bolts.
    • RH engine mounting bracket bolt [6] .
14. Ensure timing marks aligned [3] .
15. Mark crankshaft sprocket and backplate with paint [7] .
16. Remove engine steady bar bolts [8] .
17. Raise engine.
18. Remove:
    • RH engine mounting [9] .
    • RH engine mounting bracket bolts [10] .
    • Timing belt lower cover [11] .
    • RH engine mounting bracket [12] .
19. Slacken tensioner nut [13] .
20. Turn tensioner away from belt. Use Allen key [14] . Lightly tighten nut [13] .
21. Remove timing belt.NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

Installation

1. NOTE: Engine must be COLD.
   1. Ensure camshaft sprocket timing marks aligned [3] .
   2. Ensure crankshaft sprocket timing mark aligned [7] .
   3. Fit timing belt in following order:
      • Crankshaft pulley.
      • Guide pulley (G1).
      • Tensioner pulley.
      • Camshaft sprocket.
      • Water pump sprocket.
      • Guide pulley (G2).

      NOTE: If reusing old belt, observe direction of rotation marks on belt.

   4. Ensure tensioner retaining lug located in slot in cylinder head [15] .
      NOTE: Ensure belt is taut between sprockets on non-tensioned side.
   5. Slacken tensioner pulley nut [13] .
   6. Turn tensioner clockwise until notch [16] is above lug [17] in baseplate. Use Allen key [14] .
   7. Release tension on belt.
   8. Turn tensioner slowly clockwise until notch aligned with lug in baseplate [17] & [18] . Use Allen key [14] .
   9. Tighten tensioner pulley nut [13] . Tightening torque: 25 Nm.
   10. Turn crankshaft slowly two turns clockwise until timing marks aligned [3] & [7] .
       NOTE: Turn crankshaft last 45° smoothly without stopping.
   11. Ensure timing marks aligned [3] & [7] .
   12. Ensure notch [18] aligned with lug [17] in baseplate.
   13. If not: Repeat tensioning procedure.
   14. Install:
       • Timing belt lower cover [11] .
       • RH engine mounting bracket [12] .
   15. Tighten RH engine mounting bracket bolts [10] . Tightening torque: 45 Nm.
   16. Lower engine.
   17. Tighten RH engine mounting bracket bolt [6] . Tightening torque: 45 Nm.
       NOTE: RH engine mounting bracket bolt [6] is 25 mm shorter than the other bolts [10] .
   18. Install:
       • Crankshaft pulley [5] .
       • Crankshaft pulley bolts [4] . Use new bolts.
   19. Tighten crankshaft pulley bolts [4] . Tightening torque:
       Except AXX/BPY/BWA – A: 10 Nm + 90°.
       AXX/BPY/BWA – B: 20 Nm + 90°.
   20. Ensure timing marks aligned [2] & [3] .
   21. Fit and align RH engine mounting [9] :
       • Engine mounting clearance: 10 mm minimum [19] .
       • Ensure engine mounting aligned parallel with engine mounting bracket [20] .
   22. Tighten:
       • Engine mounting bolts [21] . Tightening torque: 40 Nm + 90°. Use new bolts.
       • Engine mounting bolts [22] . Tightening torque: 20 Nm + 90°. Use new bolts.
       • Engine mounting bolts [23] . Tightening torque: 60 Nm + 90°. Use new bolts.
   23. Install components in reverse order of removal.
   24. Tighten engine steady bar bolts [8] . Tightening torque: 40 Nm + 90°. Use new bolts.
   25. Refill cooling system.