1999 VW Passat 1 8L Turbo Timing Belt and Water Pump Replacement
Our Journey replacing the water pump and timing belt on a 1999 Volkswagen VW Passat. 1.8L, Turbo. Basic Step-by-Step below:
1999 VW Passat GLS 1.8L L4 Water Pump Replacement. V-Belt driven water pump vs. timing belt driven.
YouTube limits prevented me from including the Disassembly steps, but the Assembly Steps are more valuable. Sorry
See: • 1999 VW Passat 1.8L Turbo Timing Belt and ... for the Disassembly Steps. Comments Section.
Step Assembly Tasks
101 Glue new gasket to new water pump and apply a light coat of Permatex gasket maker to the block side of gasket
102 Slip water pump over the one stud and install the 8 water pump bolts (My stud was missing)
103 Install the Oil Pump gear and Snug the bolt. Tighten in later step or use a screw driver to jam the gear and tighten now
104 This gear is keyed, but has no timing concerns, it just turns the oil pump
105 Install the new Relay Roller / tensioner wheel
106 To gain slack. Remove the arm from the Relay Roller. Insert an allen wrench to pull on while removing the 10mm bolt
107 Install the new timing belt tensioner. Do not pull pin yet!
108 Turn the cam gear to align the mark on the housing with the mark on the gear
109 Slip the lower timing belt cover on (no bolts). Install the crankshaft/balancer pulley with two finger tight bolts.
110 Use a 19mm (12-point) socket and ratchet to turn the crank and align the mark on the balancer with the arrow on the cover
111 Without moving the crankshaft, remove the two finger tight bolts and balancer, and remove the lower timing belt cover
112 Put the timing belt over the cam gear, over the Relay Roller, past the tensioner idler, and pull tight around the crank gear
113 and then push the timing belt over the Oil Pump gear. Any slack should be between the oil pump gear and cam gear
114 Put an allen wrench in the Relay Roller and move enough to reinstall the arm piece removed earlier (10mm bolt)
115 Note: The crankshaft/balancer pulley is "keyed" with a 5th hole for an alignment pin in the crankshaft
116 Install the lower timing belt cover ( 3 bolts + 1 pin?).
117 Install the crankshaft/balancer pulley and Snug all four bolts. Tighten in a later step
118 Note: In the next two steps holding the cam gear bolt steady while tightening bolts will keep things from moving
119 Have an assistant use a 16mm socket/ratchet to hold cam gear bolt while Tightening the large oil pump pulley bolt (65ft-lbs)
120 Have an assistant use a 16mm socket/ratchet to hold cam gear bolt while Tightening the four crankshaft pulley bolts (20ft-lbs)
121 With timing belt tensioner pin still in place turn the engine over at least twice and make sure the marks still line up
122 If the marks are not lined up (e.g. more than 1/4"off) you are likely one cog off and will need to correct & redo do steps
123 Don't pull the timing belt tensioner pin yet!
124 Note: If the timing belt is off by a cog you can correct it WITHOUT removing the crankshaft pulley and lower timing cover -
125 -This can be done by again relieving tension by removing the arm on the relay roller, slipping the belt off the cam gear, -
126 -moving the cam gear and then slipping the timing belt back over the cam gear. Reinstall arm and recheck mark alignment
127 - Once you have the marks on the Cam gear and crankshaft/balancer pulley lined up you can move to the next step
128 Release the timing belt tensioner spring. "Pull the pin". Note the slack is already gone, so nothing exciting happens
129 Install the upper timing belt cover and snap the two clips holding it in place. May take some fiddling.
130 Pull coolant crossover hose back into place in front of the timing belt cover, along with the other small hose
131 Install the Serpentine belt tensioner (3 bolts). May need to remove top bolt of the A/C tensioner to slip it by
132 Place the serpentine belt into position around the various items. Check routing diagram
133 Install the serpentine belt over the drive pulley and on the inside piece of the water pump pulley
134 Install the inner piece of the 2-part water pump pulley
135 Install the outer piece of the 2-part water pump pulley and start the three bolts
136 Slip the water pump belt over the water pump pulley and then work it onto the drive pulley
137 Tighten the three allen bolts holding on the water pump pulley. Squeeze belt while tightening bolts
138 The water pump belt has no tensioner. If fits loose, but that's OK
139 Optional: lnstall new A/C belt tensioner
140 Install the A/C belt and adjust tension while tightening both bolts. Approx. 1/2" of slack in the belt at mid span
141 Install 4 bolts holding the fan onto the fan clutch
142 Push the radiator back into place. [connect horns & A/C switch]
143 Fill the system with Antifreeze. Fill surge/overflow tank and wait a bit. It will take about 1.5 gallons
144 Start the engine and check for leaks, etc. Bleed air from the cooling system.
Sorry, I had to cut some steps (145+) to fit under the 5000 character limit......