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Manufacturer: Volkswagen
Model: Passat 1.8, RP
Year: 1988
Timing belt replacement intervals
The information relating to timing belt replacement intervals is additional to the main purpose of this CD, but is included to provide guidance to garages and for customer advice.
Where possible the recommended intervals have been compiled from vehicle manufacturers’ information. In a few instances no recommendation has been made by the manufacturer and the decision to replace the belt must be made from the evidence of a thorough examination of the condition of the existing belt.
Apart from the visible condition of the belt, which is explained fully later in this section, there are several other factors which must be considered when checking a timing belt:
1. Is the belt an original or a replacement.
2. When was the belt last replaced and was it at the correct mileage.
3. Is the service history of the vehicle known.
4. Has the vehicle been operated under arduous conditions which might warrant a shorter replacement interval.
5. Is the general condition of other components in the camshaft drive, such as the tensioner, pulleys, and other ancillary components driven by the timing belt, typically the water pump, sound enough to ensure that the life of the replacement belt will not be affected.
6. If the condition of the existing belt appears good, can you be satisfied that the belt will not fail before the next check or service is due.
7. If the belt does fail, have you considered the consequences. If the engine is an INTERFERENCE type then considerable expensive damage may well be the result.
8. The cost of replacing a belt as part of a routine service could be as little as 5 to 10% of the repair cost following a belt failure. Make sure your customer is aware of the consequences.
9. If in doubt about the condition of the belt - RENEW it.
Replacement Interval Guide
Volkswagen recommend:
--> 1995: Check & adjust every 20,000 miles (replace if necessary).
1996 --> Check at first 60,000 miles and then every 20,000 miles (replace if necessary).
No manufacturers recommended replacement interval.
The previous use and service history of the vehicle must always be taken into account.
Check For Engine Damage
CAUTION: This engine has been identified as an INTERFERENCE engine in which the possibility of valve-to-piston damage in the event of a timing belt failure is MOST LIKELY to occur.
A compression check of all cylinders should be performed before removing the cylinder head.
Special Precautions
• Disconnect battery earth lead.
• DO NOT turn crankshaft or camshaft when timing belt removed.
• Remove spark plugs to ease turning engine.
• Turn engine in normal direction of rotation (unless otherwise stated).
• DO NOT turn engine via camshaft or other sprockets.
• Observe all tightening torques.
Removal
1. Raise and support front of vehicle.
2. Remove:
- Auxiliary drive belt(s).
- Auxiliary drive belt tensioner (if fitted).
- Crankshaft pulley bolts [3].
- Crankshaft pulley [4].
- Water pump pulley (if required).
- Timing belt upper cover [6].
- Timing belt lower cover [5].
3. Temporarily fit crankshaft pulley. Lightly tighten one bolt.
4. Turn crankshaft until timing marks aligned [1] & [2].
5. Ensure distributor rotor arm aligned with mark on distributor body [8].
6. Remove:
- Crankshaft pulley bolt [3].
- Crankshaft pulley [4].
7. Slacken tensioner bolt [7]. Turn tensioner anti-clockwise away from belt. Lightly tighten bolt.
8. Remove timing belt.
Installation
1. Ensure timing mark on camshaft sprocket aligned [1].
2. Fit timing belt to crankshaft sprocket and auxiliary shaft sprocket.
3. Temporarily fit crankshaft pulley. Lightly tighten one bolt.
4. Ensure timing mark on crankshaft pulley aligned with mark on auxiliary shaft sprocket [2].
5. Ensure distributor rotor arm aligned with mark on distributor body [8].
6. Fit timing belt to camshaft sprocket and tensioner pulley.
7. Ensure timing marks aligned [1] & [2].
8. Turn tensioner clockwise until belt can just be twisted with finger and thumb through 90^ at V.
9. Tighten tensioner bolt to 45 Nm [7].
10. Turn crankshaft two turns clockwise.
11. Ensure timing marks aligned [1] & [2].
12. Ensure distributor rotor arm aligned with mark on distributor body [8].
13. Check belt tension.
14. Install components in reverse order of removal.
15. Tighten crankshaft pulley bolts [3]. Tightening torque: 20-25 Nm.
16. Tighten auxiliary drive belt tensioner bolt to 20-25 Nm (if fitted).
17. Tighten water pump pulley bolts to 20 Nm (if removed).
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