Timing belt replacement: VW Passat5 2.0 TDi (BKP, BMA, BMR, BUZ, …)

🧭 Before you start

Fits: platform codes 2.0, TDI, |, DPF

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

Don't miss

• Always fit a new timing belt after removal
• Never turn the engine in the direction opposite to that of normal operation
• Remove the coolant reservoir, but do not disconnect
• Loosen the camshaft gearwheels. Ensure the gearwheels rotate without play

🔧 Engine codes this applies to

📐 32 workshop diagrams for BKP

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

Preparation and removal

1. Crankshaft locking tool:
2. Unless otherwise advised by the manufacturer, the following procedures are recommended:
3. Always fit a new timing belt after removal
4. Locking pin:
5. Engine support tool:

6. Never turn the engine in the direction opposite to that of normal operation
7. Stage 2:
8. Use new bolts
9. Remove the ancillary drive belt
10. Remove the ancillary drive belt tensioner
11. Use new bolts
12. Remove the timing belt upper cover
13. Stage 2:
14. Remove the front right wheel
15. Stage 1:
16. Stage 2:
17. Remove the wheel arch cover lining
18. Engine support bracket:
19. Stage 1:
20. Stage 2:
21. Stage 1:
22. Stage 2:
23. Stage 1:
24. Stage 2:
25. Guide pulley:
26. Camshaft gearwheel
27. Remove the crankshaft pulley
28. Remove the timing belt centre cover
29. Remove the timing belt lower cover
30. Turn the crankshaft to TDC for cylinder 1
31. Fit the crankshaft TDC locking pin
32. Align the crankshaft timing marks
33. Type 1:
34. Check the blocking tools
35. Lock the crankshaft
36. Check the camshaft timing marks
37. Disconnect the fuel feed and return lines
38. Move the fuel filter aside
39. Remove the coolant reservoir, but do not disconnect
40. Remove the intercooler/turbocharger air hose(s)
41. Plug the holes

Installation and checks

42. Note: Fit the bolt(s) finger-tight only
43. Raise the engine slightly
44. Loosen the tensioner pulley bolt
45. Check for correct fitting
46. Turn the tensioner anti-clockwise until the locking tool can be removed easily
47. Remove the locking pin
48. Turn the tensioner clockwise to align both marks
49. Hold the tensioner pulley in this position
50. Tighten the tensioner pulley mounting bolt
51. Turn the special tool anti-clockwise
52. Note: Keep the camshaft gearwheel under tension
53. Tighten the camshaft gearwheels
54. Remove all the locking tools
55. Turn the engine 2 rotations until just before TDC
56. Turn the engine clockwise
57. Until the special tool engages
58. Loosen the tensioner pulley bolt
59. Check that the special tools fit
60. Check that the tensioner indicator is centered or no more than 5 mm to the right of the notch on the backplate
61. Lift the engine slightly
62. Lower the engine slightly
63. Remove the lower engine support bracket bolt
64. Remove the engine support bracket
65. Loosen the camshaft gearwheels. Ensure the gearwheels rotate without play
66. Use the special tool
67. Turn the crankshaft slightly anti-clockwise
68. Turn the crankshaft clockwise
69. Turn the tensioner anti-clockwise until the locking pin fits
70. Tighten the camshaft gearwheels
71. Remove all the locking tools
72. Turn the engine 2 rotations until just before TDC
73. Remove the timing belt, starting at the coolant pump
74. Refit the locking tools to check the timing
75. Note: Repeat the procedure if the special tool does not fit
76. Lower the engine slightly
77. Refit the engine support bracket
78. Refit the timing belt lower cover
79. Refit the timing belt centre cover
80. Fit the crankshaft pulley
81. Refit the engine mount
82. Remove the engine support bar
83. Refit the air hose between the turbo and the intercooler
84. Refit the fuel filter
85. Refit the coolant reservoir
86. Refit the wheel arch cover lining
87. Refit the front right wheel
88. Refit the timing belt upper cover
89. Fit the ancillary drive belt tensioner
90. Fit the ancillary drive belt
91. Refit the noise insulation cover
92. Refit the engine cover

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• Removing and installing engine support – VW · 3 torque figures
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• Installing a previously used balancer shaft module again – VW · 5 torque figures
• Removing and installing accelerator module · 5 torque figures
• Removing engine · 41 torque figures
• Removing and installing camshaft – VW Golf Cabriolet · 47 torque figures
• Adjusting valve timing – VW Passat B5 · 83 torque figures
• Removing and installing camshafts – VW Passat B6 · 39 torque figures
• Removing and installing coolant pump · 53 torque figures