Timing belt replacement for Volkswagen Passat b5
Content
1996 was the start of production of the Volkswagen Passat B5 in Europe, two years later the car began to be produced in America. Thanks to the efforts of the concern's designers, the car has become more technologically advanced in production, the status of the car has become closer to "luxury" models. Volkswagen power units have a timing belt drive, so it will be useful for many owners of these cars to know how the Passat B5 timing is replaced.
About engines
The range of engines for this model has a rather impressive list, which includes power units that run on both gasoline and diesel. Its working volume ranges from 1600 cm 3 to 288 cm 3 for gasoline options, 1900 cm 3 for diesel engines. The number of working cylinders for engines up to 2 thousand cm 3 is four, the arrangement is in-line. Engines with a volume of more than 2 thousand cm 3 have 5 or 6 working cylinders, they are located at an angle. The piston diameter for gasoline engines is 81 mm, for diesel 79,5 mm.
Volkswagen Passat b5
The number of valves per cylinder can be 2 or 5, depending on the engine modification. The power of gasoline engines can range from 110 to 193 hp. Diesel engines develop from 90 to 110 hp. The valves are driven by a toothed belt, except for the TSI engine, which has a chain in the mechanism. The thermal clearance of the valve mechanism is regulated by hydraulic compensators.
Replacement procedure on AWT motor
Replacing the timing belt on the Passat B5 is a difficult operation, because to complete it you need to disassemble the front of the car. The compact design of the engine compartment will not allow you to replace the belt in the valve train drive without it.
The preparatory operation can be carried out in two ways, this is to transfer the front part with the “TV” to the service mode, or to completely remove this part with the bumper, headlights, radiator.
AVT Engine
Work begins by disconnecting the battery terminals to avoid accidental "mistakes" during operation. It will be enough to disconnect the negative terminal of the battery. Next, you need to dismantle the grille in front of the radiator, it is fastened with two screws, fixed with latches. And also at the same time you need to remove the hood opening handle, its lock. This will free up even more space in the engine compartment. The radiator grill is removed by pulling it up.
After that, access to the four screws that secure the bumper is opened, and 4 self-tapping screws are unscrewed under each wing. On the removed bumper, 5 more screws are visible that need to be unscrewed. The next step is to remove the headlights, each of them has 4 screws for fastening. The external screws are covered with rubber plugs, the connector with the headlight power cables is disconnected behind the left headlight. The air duct, held by three self-tapping screws, must be dismantled.
Temporary scheme
The bumper amplifiers are fastened with three bolts and a “TV” mounting nut on each side, we unscrew it. The next step is to disable the A/C sensor. To remove the radiator from the air conditioner, you need to get the studs to fix it. After that, the radiator is removed, it is better to disconnect the pipes from the engine block so as not to damage the radiator. Then disconnect the sensor and the power steering coolant pipe clamps. After that, part of the coolant is poured into an empty container.
A hose of suitable diameter is put on the drain pipe, the screw is unscrewed and the liquid is drained. After completing these works, you can move or completely remove the “TV” from the case, which prevents access to the timing mechanism. To reduce the hassle during assembly, marks are placed on the impeller housing and its shaft, after which it can be disassembled. Now you can remove the tensioner and the air conditioning belt. The tensioner is pushed back with an open-end wrench to “17”, fixed in a recessed state and the belt is removed.
In addition, the procedure would be something like this:
- The plastic protection of the timing is removed, for this the latches on the sides of the cover are broken.
- When the engine crankshaft rotates, the alignment marks are aligned. Marks are placed on the top and bottom of the belt, they are necessary to count the number of teeth on the belt for the correct installation of a new replacement part. There should be 68 of them.
TDC crankshaft
- The crankshaft pulley is disassembled, the twelve-sided bolt does not need to be removed, four screws are unscrewed.
Removing the crankshaft pulley
- Now remove the lower and then the middle protective covers from the timing drive.
- Gently, without sudden movements, the shock absorber rod is immersed, after which it is fixed in this state, the belt can be disassembled.
The service life of belts largely depends on the technical condition of the engine. Its performance is strongly affected by the ingress of technical fluids into the working area, especially engine oil. Passat engines in their "age" often have engine oil smudges from under the crankshaft, camshaft and countershaft oil seals. If traces of oil are visible on the cylinder block in the area of these shafts, the seals must be replaced.
Before installing a new spare part, once again check the position of the installation marks, the condition of the valve timing regulator. Install a new belt on the crankshaft, camshaft and pump pulleys. Make sure there are 68 teeth between the top and bottom alignment marks. If everything is done correctly, then tighten the timing belt. After that, you need to turn the crankshaft of the engine two turns, check the coincidence of the installation marks. Also, all previously dismantled components and assemblies are installed in their places.
Installation marks
They are necessary for the correct installation of the valve timing of the power unit to ensure its efficient operation. To do this, turn the head of the twelve-sided crankshaft screw until the marks of the camshaft pulley coincide with the marks of the timing cover. The crankshaft pulley also has risks that must be strictly opposite the mark on the cylinder block. This will correspond to the position when the piston of the first cylinder is at top dead center. After that, you can start replacing the timing belt.
Camshaft and crankshaft timing marks
Belt tension
Not only the service life of the drive belt, but also the performance of the entire transmission mechanism as a whole depends on the correct execution of this operation. Experts recommend changing the tensioner at the same time as the timing belt. The timing belt Passat B5, mounted on pulleys, is tensioned in this way:
- The tensioner eccentric is turned counterclockwise using a special wrench or round-nose pliers to remove the locking gauges until the stopper can be removed.
Tension roller
- Then turn the eccentric clockwise until a 8 mm drill bit is inserted between the body and the tensioner.
Weak belt tension
- The roller is fixed in this position, followed by tightening the fixing nut. The nut is processed with a thread stopper before installation.
Tension Adjustment Part 1
Tension Adjustment Part 2
Which kit to buy
Ideally, finding spare parts better than the original is almost impossible. The mileage of timing transmission parts is highly dependent on the quality of the parts. If for some reason it is impossible to install the original kit. You can do the following. The products of DAYCO, Gates, Contitech, Bosch have proven themselves. When choosing a suitable spare part, you need to be careful not to buy a fake.
