Timing belt replacement: Injection pumps with one-piece injection pump pulley — VW

🧭 Before you start

Fits: VW Passat B5 (3B)

• Timing position: the crankshaft or camshaft is set and locked during this job
• Special tools named: feeler gauge, pin wrench

Don't miss

• Use flared ring spanner3035 to loosen injector lines.
• Mark direction of rotation of toothed belt.
• To loosen and tighten camshaft pulley, never use adjustment bar2065 A as a counterhold! Use counterhold tool3036.
• Check whether TDC mark on flywheel and reference mark are aligned.
• Fit toothed belt on crankshaft toothed belt pulley, intermediate shaft sprocket, injection pump pulley and tensioning roller (note direction of rotation).

🔧 Engine codes this applies to

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Move lock carrier into its service position General body repairs, exterior50Lock carrier service position. [Note: Use flared ring spanner3035 to loosen injector lines.]
2. Unbolt all fuel lines from pump.
3. Cover openings with a clean cloth.
4. Using a straight ring spanner press poly V-belt tensioning roller (in direction of arrow) onto stop. Remove upper toothed belt guard.
5. Turn crankshaft to TDC No.1 cylinder (vehicles with manual gearbox).

6. Turn crankshaft to TDC No.1 cylinder (vehicles with automatic gearbox).
7. Lock camshaft using adjustment bar2065 A.
8. Align adjustment bar2065 A as follows: Turn locked camshaft until one end of the adjustment bar2065 A contacts cylinder head. Measure clearance which has arisen at other end of adjustment bar2065 A with a feeler gauge. Slide a feeler gauge with half of clearance dimension between adjustment bar2065 A and cylinder head. Now turn camshaft until adjustment bar2065 A contacts feeler gauge. Insert second feeler gauge with same dimension between adjustment bar2065 A and cylinder head at other end.
9. Lock injection pump sprocket with locking pin2064.
10. Mark direction of rotation of toothed belt.
11. Remove tensioning roller nut.
12. Release tension on toothed belt and remove from camshaft and injection pump toothed belt pulleys.
13. Remove idler roller.
14. Remove injection pump pulley securing nut.
15. Loosen puller3032 arms and position puller3032.
16. Align arms with bores on injection pump pulley and tighten.
17. Tension injection pump pulley with puller3032.
18. By tapping lightly on spindle of puller3032(arrow), loosen injection pump pulley from injection pump taper (hold sprocket to prevent it from falling down).
19. Separate fuel shut-off valve N109/commencement of injection valve N108 connector.
20. Separate connection for metering device and unclip connector from retainer.
21. Remove securing bolts from console (arrows).
22. Then remove securing bolt from rear support (arrow).
23. Remove injection pump.
24. Insert injection pump into bracket and tighten bolt on rear support with conical nut first.
25. Align injection pump to central position in console elongated holes and secure hand-tight.
26. Install injection pump pulley and lock with locking pin2064. When installing observe spring washer seating.
27. Tighten securing nut to 55 Nm. [Note: To loosen and tighten camshaft pulley, never use adjustment bar2065 A as a counterhold! Use counterhold tool3036.] — 55 Nm (41 lb-ft)
28. Loosen camshaft gear securing bolt a half turn.
29. Place a drift through hole in the rear of the toothed belt guard and release the camshaft pulley from camshaft taper with a blow from a hammer.
30. Remove camshaft pulley.
31. Check whether TDC mark on flywheel and reference mark are aligned.
32. Fit toothed belt on crankshaft toothed belt pulley, intermediate shaft sprocket, injection pump pulley and tensioning roller (note direction of rotation).
33. Fit camshaft pulley together with toothed belt and fix with securing bolt (camshaft pulley can still be turned).
34. Install idler roller.
35. Remove locking pin2064 from injection pump pulley.
36. Tension toothed belt. To do this, turn pin wrench (e.g. Matra pin wrenchV/159) clockwise on eccentric until notch and protrusion (arrows) are aligned. [Note: If eccentric has been turned too far, tensioning roller must be completely relieved of tension and retensioned. The eccentric should not be turned back just the amount it was turned too far.]
37. Tighten securing nut to 20 Nm. — 20 Nm (15 lb-ft)
38. Check TDC mark on flywheel again.
39. Tighten camshaft gear securing bolt to 45 Nm. — 45 Nm (33 lb-ft)
40. Remove adjustment bar2065 A.
41. Turn crankshaft two rotations in engine direction of rotation until crankshaft is set to TDC No. 1 cylinder again.
42. Check TDC marking on flywheel to determine whether adjustment bar2065 A fits in camshaft and adjustment of tensioning roller (notch/protrusion).
43. If notch and protrusion do not align, retension tensioning roller. To do this, hold tensioning roller with Matra pin wrenchV/159, loosen securing nut, continue turning eccentric clockwise until notch and protrusion align and tighten securing nut to 20 Nm. — 20 Nm (15 lb-ft)
44. Turn crankshaft two rotations in engine direction of rotation until crankshaft is set to TDC No. 1 cylinder again.
45. Repeat check.
46. Connect injector lines, fuel supply line and electrical wiring.
47. Fill injection pump, through return line union, with clean diesel.
48. Screw adapterV.A.G 1318/10-12 into return flow opening of injection pump.
49. Connect hand vacuum pumpV.A.G 1390/ with approx. 1 m transparent plastic hose to adapter.
50. Operate hand vacuum pump with accessoriesV.A.G 1390/ until fuel comes out of return aperture. Do not draw fuel into vacuum pump with accessoriesV.A.G 1390/.
51. Remove adapter and connect fuel return line.
52. Install toothed belt guard and cylinder head cover.
53. Dynamically check commencement of injection and adjust if necessary .

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