Last one to work on the car
both jobs timing belt had to be removed
TIMING BELT REPLACEMENT - 2.8L -2002 Volkswagen Passat GLS
REMOVAL & INSTALLATION
CAUTION:This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur.
CAUTION:Obtain the radio anti-theft code before disconnecting the battery.
NOTE: Lock carrier is slid forward onto alignment tools. This will allow servicing of front engine components. Lock carrier can be removed at technicians discretion.
1. Disconnect negative battery cable. Remove engine top cover. Remove noise insulation panel from under front of vehicle. 2. For vehicles manufactured up to September, 2000, disconnect front turn signal light assembly wiring harnesses. Separate hood release lever from bumper cover. Remove front bumper cover. See Fig. 1. Remove bumper beam. Remove air intake duct from air cleaner housing. Remove support bolts from lock carrier assembly. See Fig. 2. Install Support Tool (3369) through lock carrier to body. Remove oil cooler from lock carrier assembly. Move lock carrier forward on support tools. 3. For vehicles manufactured from October, 2000, remove bumper cover from bumper carrier. See Fig. 3. Remove noise insulation panel from under engine compartment. Remove air intake duct at lock carrier. Remove bolts from front of bumper carrier. See Fig. 4. Install guide rods on right and left sides. Pull lock carrier forward about 4" (10 cm) on guide rods into service position. 4. Hold cooling fan pulley with spanner wrench (3312). See Fig. 5. Unscrew and remove viscous cooling fan clutch from pulley. Viscous cooling fan is LEFT-HAND threaded. 5. Use a long 17-mm box wrench to turn serpentine belt tensioner clockwise and relieve belt tension. Secure tensioning roller with pin 3204 when both holes are positioned over one another. Remove serpentine belt. If reusing belt, mark belt rotation direction with arrow for reassembly reference. 6. Unclip timing belt guard on front of both camshafts and remove. Position crankshaft to top dead center No. 3 cylinder. Mark on toothed belt guard must align with notch on belt pulley. See Fig. 6. 7. Note securing plate on front end of each camshaft sprocket. If large hole in each plate does not face inward, toward center of engine, rotate crankshaft one revolution. See Fig. 7. Ensure crankshaft timing marks are still aligned. See Fig. 6. 8. Remove sealing plug from left side of engine block. See Fig. 8. TDC mark on crankshaft must be visible or be felt through sealing hole. Install Crankshaft Holding Tool (Audi 3242) into sealing plug hole. 9. Remove serpentine belt tensioner. Remove center and left timing belt covers. 10. Using an 8-mm hex wrench, SLOWLY turn timing belt tensioner pulley clockwise to compress
timing belt tensioner. See Fig. 9. Compress timing belt tensioner just enough so a 2-mm pin can be inserted through the holes in top of tensioner body and push rod. This will hold the tensioner in the compressed position.
CAUTION:If reusing old timing belt, mark an arrow indicating direction of rotation on accessory drive belt or timing belt. Damage may result if belts are installed in opposite direction of rotation.
11. Remove crankshaft vibration damper from crankshaft. It is NOT necessary to remove center bolt. If center bolt is removed, manufacturer recommends using NEW bolt on reassembly. Remove serpentine belt idler pulley. 12. Remove fan retainer and belt pulley toothed belt protection. Remove timing belt.
1. Install Camshaft Locator Bar (3391) into locking plates of camshafts. See Fig. 10. Loosen camshaft sprocket bolts about 5 turns. Remove locator bar. 2. Leaving camshaft sprocket bolts in place, use gear puller to loosen camshaft sprockets on camshaft taper.
NOTE: Camshaft sprockets must be loose enough to rotate on camshaft, but not loose enough to tilt.
3. Ensure all timing marks are still aligned. Install timing belt on engine. Ensure belt routing is correct and there is no slack in belt. See Fig. 11. Install Camshaft Locator Bar (3391) into locking plates of camshafts. 4. Using an 8-mm hex wrench, SLOWLY compress timing belt tensioner so that 2-mm pin can be removed from tensioner. 5. Pre-load timing belt tension, using 8-mm hex socket and torque wrench on timing belt tensioner pulley, apply 11 ft. Lbs. (15 N.M) to tensioner in direction of tension (clockwise). 6. Tighten camshaft sprocket bolts to specification. See TORQUE SPECIFICATIONS. Remove camshaft locator bar. Remove crankshaft holder. Install sealing plug. 7. Install timing belt cover. Install crankshaft pulley. Install serpentine drive belt. 8. To complete installation, reverse remaining removal procedure. When installing crankshaft pulley, ensure notches in pulley are aligned with locating lugs in crankshaft. Tighten all fasteners to specification.
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Monday, December 1st, 2008 AT 7:19 PM