Removing and installing coolant pump belt pulley (Passat, Passat CC) — VW

🧭 Before you start

Fits: VW Passat CC (357, 2008–2012), VW Passat B7 saloon (362, 2010–2014), VW Passat B7 Variant (365, 2010–2014)

• Opens: coolant

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• Charge air hoses with screw-type clips are also installed .
• Housing with noise insulation remains in vehicle.
• As the poly V-belt is still tensioned, the pulley securing bolts must not yet be removed. — Remove poly V-belt .
• Note installation of charge air hoses.

🔧 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. ⚠ When the engine is warm, the cooling system is under pressure.Hot steam/hot coolant can escape - risk of scalding.Cover filler cap on expansion tank with a cloth and open carefully to dissipate pressure. — Remove noise insulation General body repairs, exterior50Body - front, noise insulation.
2. Pull retaining clip in direction of (arrow) and pull out charge air hose (1) from charge air pipe. [Note: Charge air hoses with screw-type clips are also installed .]
3. Unscrew securing bolt for charge air pipe (arrow).
4. Remove securing bolt (arrow) for charge air pipe (1).
5. Release and pull off connector (1) on oil level and oil temperature sender G266.

6. Unclip bracket (2) on subframe for electric wire to oil level and oil temperature sender G266.
7. Clamp off coolant hoses (1) with hose clips up to 40 mm3093.
8. Open clips (arrows).
9. Pull off coolant hoses (1) on charge air pipe (2).
10. Unclip wire (1) to engine preheater heater element Z97 on charge air pipe (2)(arrow).
11. Clamp off coolant hoses to auxiliary heaterZ using hose clips up to 40 mm3093.
12. Drain coolant .
13. Pull off coolant hoses for auxiliary heaterZ from coolant pipes (1).
14. Carefully press locking tabs on noise insulation housing for supercharger (arrows) outwards.
15. Pull off housing with noise insulation and place to one side. [Note: Housing with noise insulation remains in vehicle.]
16. Lift off engine cover panel at points (1) and pull it forwards in direction of (arrow).
17. Pull off fuel supply line (1) and line leading to activated charcoal filter (2) by pressing release tabs.
18. Pull off hose (1) from pressure pipe.
19. Unscrew securing bolts (2) from pressure pipe and remove pressure pipe.
20. Unscrew hose clip (1) on charge air pipe.
21. Open hose retainer (2) and pull out hose.
22. Unscrew securing bolt for charge air pipe (3) and pull off connector from charge air pressure sender G31 with intake air temperature sender 2G299.
23. Remove holder (4).
24. To do this, unscrew bolts (arrows).
25. Remove bracket (1).
26. Unscrew bolts (arrows) and remove charge pressure sender G31(1).
27. Remove charge air pipe downwards.
28. Loosen securing bolts (1) for coolant pump belt pulley.
29. ⚠ As the poly V-belt is still tensioned, the pulley securing bolts must not yet be removed. — Remove poly V-belt .
30. Unscrew securing bolts (1) and pull off belt pulley from coolant pump.
31. Position belt pulley on coolant pump and tighten securing bolts (1) by hand.
32. Install poly V-belt .
33. Tighten securing bolts (1). [Note: Note installation of charge air hoses.]
34. ⚠ The screw-type clips on the charge air pipes must be tightened to 5.5 Nm. If the torque is too low or too high, the charge air hose may slip off the charge air pipe during vehicle operation. — If oil seal is renewed, place seal in groove of charge air hose. Ensure that seal is correctly seated around groove and is not twisted. — 5.5 Nm (4.1 lb-ft)
35. Coat sealing surface and oil seal with oil.
36. Bring retaining clip to release position (1).
37. Push charge air hose into coupling as far as stop.
38. Bring retaining clip to locking position (2) and then press charge air hose again.
39. By pulling on hose, check whether plug-in connector seats correctly and is properly engaged.
40. Check coolant level and top up if necessary .
41. Replenish coolant .
42. Push down engine cover panel at points (1) in direction of (arrow) until engine cover panel engages.

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