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How to Replace timing gears on VW Passat 3C 1.6 TDI

Special tools

  • Camshaft alignment tool – No.T40094.
  • Camshaft holding tool – No.T40095.
  • Camshaft sprocket hub holding tool – No.T10051.
  • Camshaft sprocket hub puller – No.T10052.
  • Camshaft/high-pressure fuel pump locking tool – No.3359.
  • Crankshaft sprocket locking tool – No.T10050.
  • Two-piece exhaust camshaft gear alignment tool – No.T40096/1.

General precautions

  • Disconnect battery earth lead.
  • Remove glow plugs to ease turning engine.
  • Turn engine in normal direction of rotation (unless otherwise stated).
  • Observe tightening torques.
  • If fitted: Mark position of crankshaft position (CKP) sensor before removal.
  • Do NOT turn crankshaft via camshaft or other gears.
  • Do NOT turn crankshaft or camshaft with timing gear(s) removed.

Valve timing procedures

How to Replace timing gears on VW Passat 3C 1.6 TDI
How to Replace timing gears on VW Passat 3C 1.6 TDI
  • Removal/installation of timing gears requires:
      • Timing belt removal.
      • Removal of camshafts.
  • Engine at TDC on No.1 cylinder.
  • Fit crankshaft sprocket locking tool [1] .
  • Ensure timing marks aligned [2] .
  • Install camshaft sprocket locking tool [3] .
  • Fit inlet camshaft on camshaft alignment tool [4] .
  • Ensure camshaft alignment tool engages in end of camshaft [5] .
  • Insert 0,5 mm feeler gauge between camshaft alignment tool and inner edge of camshaft slot [6] .
  • Fit exhaust camshaft on camshaft alignment tool [7] .
  • Ensure camshaft alignment tool engages in end of camshaft [8] .
  • Ensure indents on camshafts are facing outwards [9] .
  • If fitted: Align gear teeth of two-piece exhaust camshaft gear with camshaft gear alignment tool [10] .
  • Move inlet camshaft in direction of arrow to engage teeth of camshaft gears [11] .
  • Fit camshaft housing on camshafts [12] .
  • Retain camshafts in position with camshaft holding tool [13] .
  • Disengage camshaft alignment tool from end of camshafts [5] & [8] .
  • Remove camshaft housing and camshafts held in position with special tools from camshaft alignment tool.
  • Place camshaft housing with camshafts and special tools on cylinder head [12] .
  • Ensure crankshaft sprocket locking tool located correctly [1] .
  • Ensure timing marks aligned [2] .
  • Refit camshaft housing [12] .
  • Remove special tools [10] & [13] .

WARNING: Allow 30 minutes after installing camshafts before starting engine to prevent engine damage.

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