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

• 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.