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R/R Timing Belt 1.8T VW Passat

Customer Question
How and what do you...
How and what do you need to remove on the Passat to R/R Timing Belt?
I'am an ASE Master Tech with 46 Years Experience,And not too much scares me,But looking at the Overengineered Vehicle challenges my Mental Resources,If at all possible some detailed Pictures would work!
Submitted: 9 years ago.Category: VW
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Answered in 9 minutes by:
4/1/2009
VW Mechanic: Jim Barlogio, ASE Certified Technician replied 9 years ago
Jim Barlogio
Jim Barlogio, ASE Certified Technician
Category: VW
Satisfied Customers: 1,257
Experience: 38 Years Import Domestic AAA Aproved Auto Repair Shop Owner
Verified

Toothed belt, removing, installing and tensioning

Special tools and equipment

  • V.A.G 1331 torque wrench (5...50 Nm)
  • V.A.G 1332 torque wrench (40...200 Nm)
Tensioning roller up to 07.00 (not adjustable)
  • T10092 tensioning bolt
  • T40011 pin
Tensioning roller from 08.00 (must be adjusted)
  • 3387 pin wrench
  • T10008 locking plate

Removing

  • Adjust camshaft to TDC cylinder 1.

  • Remove harmonic balancer/belt pulley.
  • Remove lower and center toothed belt guard.

Tensioning roller up to 07.00 (not adjustable)

  • Thread T10092 tensioning bolt into tensioning device for toothed belt.
  • If necessary, align pressure piston before tensioning, using needle nose pliers or thin wire (hole in pressure piston and hole in housing must overlap.
  • Tighten pressure piston only far enough so that the pressure piston can be secured using T40001 pin.

Tensioning roller from 08.00 (must be adjusted)

  • Insert an hex wrench into hex socket up to stop and press tensioning roller in counter clockwise direction (in direction of arrow) with uniform non-excessive force until the tensioning device of the toothed belt can be aligned using T10008 locking plate.
Note: Toothed belt tensioning device is an oil damper device and can only be compressed slowly and with equal force. Excessive force during compression can damage tensioning roller.

  • To loosen toothed belt, loosen nut -1 of tensioning roller and turn pin wrench in direction of arrow using 3387 pin wrench.
Note: Impact tab -A- of pin wrench must not be bent.

Continuation for all

  • Remove toothed belt.
  • Then turn crankshaft back slightly.

Installing

Requirement

  • Pistons must not be positioned in TDC.

Work sequence

  • Align mark on camshaft gear and mark at cylinder head cover.
  • Install toothed belt on crankshaft gear (note direction of rotation)
  • Install toothed belt guard, lower.

  • Install harmonic balancer/belt pulley using new bolts. Tightening torque: 10 Nm + 1/4 turn (90°) additional

  • Adjust crankshaft to TDC cylinder 1.
  • Install toothed belt in the order coolant pump, tensioning roller, camshaft gear.
  • Tighen toothed belt.

Tensioning toothed belt

Requirements

  • Engine must not be more than hand warm.
  • Engine is at TDC cylinder 1.

Work sequence

Tensioning roller up to 07.00 (not adjustable)

  • Tension toothed belt by pulling out T40001 pin and unbolting T10092 tensioning bolt.
Tensioning roller from 08.00 (must be adjusted)

Note: If the toothed belt tensioning device is completely extended, it must be pressed back in installed position with the tensioning roller. This procedure can take up to 5 minutes. Excessive force during compression can damage tensioning roller.

  • Turn pin wrench counterclockwise (tab -A- of pin wrench must not be bent) using 3387 pin wrench until T10008 locking plate can be removed without tension.

  • Turn pin wrench to the right in clockwise direction (direction of arrow) until a drill bit -2- with dimension -a- can be pulled through tensioning lever and housing of tensioning device.

Specified value dimension -a- 8 mm.

  • Hold tensioning roller in this position and tighten securing nut of tensioning roller as follows: Specified value: 27 Nm

Continuation for all

  • Turn crankshaft two rotations and check whether the camshaft and crankshaft marks align with their reference points.

Tensioning roller from 08.00 (must be adjusted)

  • Check dimension -a- using a drill bit -2 between tensioning lever and housing of tensioning device. Specified value: 6...10 mm

If dimension -a- is not being reached

  • Repeat procedure

If dimension -a- is being reached

Continuation for all

  • Toothed belt guard, install center and upper part.
  • Install tensioning device for ribbed belt. Tightening torque: 25 Nm
  • Install ribbed belt

This is what you need.. Jim

 

Jim Barlogio
Jim Barlogio, ASE Certified Technician
Category: VW
Satisfied Customers: 1,257
Experience: 38 Years Import Domestic AAA Aproved Auto Repair Shop Owner
Verified
Jim Barlogio and 87 other VW Specialists are ready to help you
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Customer reply replied 9 years ago
Thanks for the Time Jim! The Mechanical End I understand,as far as the Engine,Cam and Crank alignment,But my problem is the whole front of the Vehicle has to come off the access the Timing Belt ,Thats where the Problem is,Not knowing what to take off and how.
VW Mechanic: Jim Barlogio, ASE Certified Technician replied 9 years ago

How and what do you need to remove on the Passat to R/R Timing Belt? That is what I saw on your question. Are you talkng about mounts. etc. ? Drive belt?

Ask Your Own VW Question
VW Mechanic: Jim Barlogio, ASE Certified Technician replied 9 years ago
Special tools, testers and auxiliary items required



  • Torque wrench V.A.G 1331

Note: Before removing ribbed belt, note direction of rotation with chalk or felt-tip marker. When installing the ribbed belt, make sure it is seated correctly on the pulleys.

Removing

  • Bring the lock carrier into service position.

  • Loosen bolts of the air conditioning compressor ribbed belt tensioner and take off ribbed belt.

Installing

  • Set ribbed belt onto A/C compressor.

  • Place torque wrench in 7 o'clock position (30° from vertical) and tighten belt tensioner to 30 Nm. Hold torque wrench securely and tighten bolts - A - to 20 Nm.

 

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