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How to Replace the Timing Belt in a 2004 Volkswagen Passat 1 8T

The new generation of the Volkswagen Passat was first introduced in 1998 on the North American market. The vehicle shares the same platform as the Audi A4 and features a 1.8L Turbo engine that has an output of 168-brake horsepower and 225 foot-pounds of torque. The timing belt is a crucial part in every engine and requires service and replacement if it fails.

Instructions

Removal

1

Bring the lock carrier into service position. Remove the tensioning element for the ribbed belt and the upper timing-belt guard. Mark the direction of rotation of the toothed belt.

2

Adjust the camshaft to top dead center (TDC) at the first cylinder. Remove the harmonic balancer/belt pulley. Take out the lower- and center-toothed belt guard.

3

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

4

Insert a V.A.G 1331 hex torque wrench into the hex socket, and torque the tensioning roller nut in counter-clockwise direction with uniform non-excessive force until the toothed belt can be aligned with the mark on the cylinder block. Use the T10008 locking plate to lock in place the roller. To loosen toothed belt, loosen the nut of the tensioning roller by turning the wrench in the clockwise direction. Remove the timing belt and then turn crankshaft back slightly.

Installation

5

Align marks on the camshaft gear and the cylinder head cover. Pistons must not be positioned in top dead center (TDC) position. Install the timing belt on the crankshaft gear (note the direction of rotation). Install the lower timing belt guard.

6

Install harmonic balancer/belt pulley using new bolts. Tighten the bolts applying 7 foot-pounds of torque, plus an additional 1/4 turn. Rotate the crankshaft until the first cylinder is in the top dead center (TDC) position. Install the timing belt in the specific order. First, position the belt on the coolant pump, and then on the tensioning roller and, finally, on the camshaft gear.

7

Tension the timing belt by pulling out the T40001 pin and unbolting the T10092 tensioning bolt. The engine shouldnt be more than hand warm. If the timing belt tensioning device is completely extended, it must be pressed back in the installed position with the tensioning roller. This procedure can take up to five minutes. Excessive force during compression can damage the tensioning roller.

8

Turn the 3387-pin wrench in counter-clockwise direction until the T10008 locking plate can be removed without tension. Turn the pin wrench clockwise until a drill bit can be pulled through the tensioning lever and the housing of the tensioning device. Hold the tensioning roller in this position and tighten the securing nut of the tensioning roller, as you apply 20 foot-pounds of torque. Turn the crankshaft two rotations and check whether the camshaft and crankshaft marks align with their erence points.

9

Install the timing belt guard, the center and upper part. Install the tensioning device for the ribbed belt. Tighten it to 19 foot-pounds. Install the ribbed belt.