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How to change water pump & timing belt kit on VW Passat B3/B4 Saloon (3A2, 35i) – replacement guide

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Recommended replacement interval for the part category Water pump and timing belt kit : 70000 km

Important!

This replacement procedure can be used for:
VW PASSAT (3A2, 35I) 1.9 TD, VW PASSAT (3A2, 35I) 1.9 D … View more

The steps may slightly vary depending on the car design.

This video shows the replacement procedure of a similar car part on another vehicle

All the parts you need to replace – Water Pump + Timing Belt Kit for PASSAT (3A2, 35I) and other VW models

Alternative products

Water pump and timing belt kit

Replacement: water pump & timing belt kit – VW PASSAT (3A2, 35I). Tools you need:

                      Wire brush
                    
                      WD-40 spray
                    
                      All-purpose cleaning spray
                    
                      Brake cleaner
                    
                      Copper grease
                    
                      Sealant
                    
                      Torque wrench
                    
                      Combination spanner #15
                    
                      HEX bit No.H6.
                    
                      Drive socket # 7
                    
                      Drive socket # 10
                    
                      12-point socket # 19
                    
                      Drive socket # 13
                    
                      Drive socket # 15
                    
                      Drive socket # 16
                    
                      Drive socket # 19
                    
                      Ratchet wrench
                    
                      Universal pulley holder
                    
                      Engine timing tool set
                    
                      Circlip pliers
                    
                      Phillips screwdriver
                    
                      Seal scraper
                    
                      Funnel
                    
                      Fluid container
                    
                      Crow bar
                    
                      Microfibre towel
                    
                      Fender cover
                    
                      Wheel chock

Buy tools

Replacement: water pump & timing belt kit – VW PASSAT (3A2, 35I). AUTODOC experts recommend:

Follow the terms, recommendations and requirements of the part operation provided by the manufacturer.
All work should be done with the engine stopped.

Replacement: water pump & timing belt kit – VW PASSAT (3A2, 35I). Use the following procedure:

Step 1

Open the bonnet.

Step 2

Use a fender protection cover to prevent damaging paintwork and plastic parts of the car.

Step 3

Unscrew the fasteners of the car battery terminals. Use a drive socket #10. Use a ratchet wrench.
Step 4

Remove the battery terminals.
Step 5

Unscrew the coolant reservoir cap.
Step 6

Release the air filter cover clips.
Step 7

Slightly raise the cover of the air filter housing.
Step 8

Unscrew the fasteners of the air distribution housing assembly. Use a drive socket #7. Use a ratchet wrench.
Step 9

Remove the air distribution housing assembly.
Step 10

Cover the throttle body with a microfibre towel to prevent dust and dirt from getting into the system.
Step 11

Release the air filter housing retainers. Remove the air filter housing.
Step 12

Undo the fasteners of the upper timing cover.
Step 13

Unscrew the fasteners of the upper timing cover. Use a drive socket #13. Use a ratchet wrench.
Step 14

Remove the upper timing cover.
Step 15

Secure the wheels with chocks.
Step 16

Loosen the wheel mounting bolts. Use wheel impact socket #17.
Step 17

Raise the front of the car and secure on supports.

Step 18

Unscrew the wheel bolts.

Replacement: water pump & timing belt kit – VW PASSAT (3A2, 35I). AUTODOC recommends:
To avoid injury, hold up the wheel when unscrewing the bolts.
Step 19

Remove the wheel.
Step 20

Unscrew the wheel arch cover fasteners. Use a Phillips screwdriver.
Step 21

Remove the wheel arch cover.
Step 22

Clean the fasteners of the hydraulic power steering pump. Use a wire brush. Use WD-40 spray.
Step 23

Unscrew the fasteners of the hydraulic power steering pump. Use a drive socket #13. Use a drive socket #16. Use a ratchet wrench.
Step 24

Loosen the V belt.
Step 25

Remove the V belt.
Step 26

Clean the alternator fasteners. Use a wire brush. Use WD-40 spray.
Step 27

Loosen the alternator fasteners. Use a drive socket #13. Use a drive socket #16. Use a ratchet wrench.
Step 28

Remove the V-ribbed belt.
Step 29

Clean the fastener of the crankshaft pulleys. Use a wire brush. Use WD-40 spray.
Step 30

Unscrew the fastener of the crankshaft pulleys. Use HEX No.H6. Use a ratchet wrench.
Step 31

Remove the crankshaft pulleys.
Step 32

Clean the water pump pulley fastener. Use a wire brush. Use all-purpose cleaning spray.
Step 33

Unscrew the water pump pulley fastener. Use HEX No.H6. Use a ratchet wrench.
Step 34

Remove the water pump pulley.
Step 35

Unscrew the fasteners of the lower timing cover. Use a drive socket #10. Use a ratchet wrench.
Step 36

Remove the lower timing cover.
Step 37

Turn the crankshaft gear. Use 12-point socket No.19. Use a ratchet wrench.

Replacement: water pump & timing belt kit – VW PASSAT (3A2, 35I). Tip:
The piston should be at its top dead centre (TDC).
Step 38

Lock the high pressure fuel pump pulley. Use an engine timing tool set.
Step 39

Detach the crankcase ventilation hose clamp. Use a drive socket #7. Use a ratchet wrench.
Step 40

Remove the crankcase ventilation hose.
Step 41

Detach the crankcase ventilation hose clamp. Use a drive socket #7. Use a ratchet wrench.
Step 42

Remove the crankcase ventilation hose.
Step 43

Cover the PCV valve hole with a microfibre cloth to prevent dirt and foreign objects from getting into the system.
Step 44

Unscrew the engine valve cover fasteners. Use a drive socket #10. Use a ratchet wrench.
Step 45

Remove the engine valve cover.

AUTODOC recommends:
Replacement: water pump & timing belt kit – VW PASSAT (3A2, 35I). To avoid damaging the part during installation, do not use excessive force.
Step 46

Install the camshaft locking tool according to the factory marks. Use an engine timing tool set.
Step 47

Make a mark on the camshaft gear.
Step 48

Make a mark on the timing belt.
Step 49

Make a mark on the high pressure fuel pump.

Step 50

Make a mark on the crankshaft gear.
Step 51

Loosen the fastener of the timing belt tensioner pulley. Use a drive socket #15. Use a ratchet wrench.
Step 52

Remove the timing belt tensioner pulley.
Step 53

Remove the timing belt.
Step 54

Loosen the vacuum pump pulley fastener. Use a universal pulley holder. Use a drive socket #19. Use a ratchet wrench.
Step 55

Remove the vacuum pump pulley.
Step 56

Unscrew the fasteners of the hydraulic power steering pump. Use a drive socket #13. Use a drive socket #16. Use a ratchet wrench.
Step 57

Remove the hydraulic power steering pump.
Step 58

Prepare a container for fluids.
Step 59

Detach the clip of the lower coolant hose. Use a crowbar.
Step 60

Detach the lower coolant pipe.
Step 61

Drain the coolant from the engine.

Replacement: water pump & timing belt kit – VW PASSAT (3A2, 35I). Tip from AUTODOC experts:
Caution! The coolant can be very hot.Wear gloves to prevent contact with hot liquid.All work should be done with the engine stopped.
Step 62

Unscrew the water pump fasteners. Use a drive socket #10. Use a ratchet wrench.
Step 63

Remove the water pump. Use a crowbar.

Replacement: water pump & timing belt kit – VW PASSAT (3A2, 35I). Tip from AUTODOC:
Caution! Coolant may come out from the water pump channels and body.
Step 64

Clean the water pump mounting seat. Use a seal scraper. Use all-purpose cleaning spray.
Step 65

Treat the water pump mounting seat. Use a sealant.
Step 66

Install the water pump gasket.
Step 67

Install the new water pump.
Step 68

Tighten the water pump fasteners. Use a drive socket #10. Use a torque wrench. Observe the recommended tightening torque.
Step 69

Treat the mounting seat of the vacuum pump pulley. Use all-purpose cleaning spray.
Step 70

Install the vacuum pump pulley.
Step 71

Tighten the vacuum pump pulley fastener. Use a universal pulley holder. Use a drive socket #19. Use a torque wrench. Observe the recommended tightening torque.
Step 72

Attach the lower coolant pipe.
Step 73

Attach the clip of the lower coolant hose.
Step 74

Install the hydraulic power steering pump.
Step 75

Tighten the fasteners of the hydraulic power steering pump. Use a drive socket #13. Use a drive socket #16. Use a torque wrench. Observe the recommended tightening torque.
Step 76

Clean the mounting seat of the timing belt tensioner pulley. Use a wire brush. Use all-purpose cleaning spray.
Step 77

Treat the mounting seat of the timing belt tensioner pulley. Use a sealant.
Step 78

Install the timing belt tensioner pulley.
Step 79

Install the new timing belt according to the factory marks.

Replacement: water pump & timing belt kit – VW PASSAT (3A2, 35I). AUTODOC recommends:
Be careful not to damage the timing belt.
Step 80

Adjust the timing belt tension by moving the tensioner pulley. Use circlip pliers. Use a combination spanner #15.
Step 81

Remove the locking tool from the high pressure fuel pump pulley.
Step 82

Remove the camshaft locking tool.
Step 83

Turn the crankshaft gear. Use 12-point socket No.19. Use a ratchet wrench.

Replacement: water pump & timing belt kit – VW PASSAT (3A2, 35I). Tip:
Make sure all the timing belt components are mounted correctly.
Step 84

Tighten the fastener of the timing belt tensioner pulley. Use a drive socket #15. Use a torque wrench. Observe the recommended tightening torque.
Step 85

Clean the engine valve cover mounting seat. Use all-purpose cleaning spray.
Step 86

Treat the engine valve cover mounting seat. Use a sealant.
Step 87

Install the engine valve cover gasket.
Step 88

Install the engine valve cover.
Step 89

Tighten the engine valve cover fasteners. Use a drive socket #10. Use a torque wrench. Observe the recommended tightening torque.
Step 90

Remove the microfibre cloth from the PCV valve hole.
Step 91

Install the PCV pipe.
Step 92

Remove the microfibre cloth from the PCV valve hole.
Step 93

Install the PCV pipe.
Step 94

Fasten the clamp on the crankcase ventilation hose. Use a drive socket #7. Use a ratchet wrench.
Step 95

Install the lower timing cover.
Step 96

Tighten the fasteners of the lower timing cover. Use a drive socket #10. Use a torque wrench. Observe the recommended tightening torque.
Step 97

Install the water pump pulley.
Step 98

Tighten the water pump pulley fastener. Use HEX No.H6. Use a torque wrench. Observe the recommended tightening torque.
Step 99

Install the crankshaft pulleys according to the factory marks.
Step 100

Tighten the fastener of the crankshaft pulleys. Use HEX No.H6. Use a torque wrench. Observe the recommended tightening torque.
Step 101

Install the V-ribbed belt.

Replacement: water pump & timing belt kit – VW PASSAT (3A2, 35I). Professionals recommend:
Make sure that the V-ribbed belt fits all pulleys snugly.
Step 102

Place the V-ribbed belt on the alternator. Use a crowbar.

AUTODOC recommends:
Make sure that the V-ribbed belt is properly tensioned.
Step 103

Install the V belt.
Step 104

Tighten the fasteners of the hydraulic power steering pump. Use a drive socket #13. Use a drive socket #16. Use a torque wrench. Observe the recommended tightening torque.
Step 105

Install the upper timing cover. Make sure you hear a click indicating that it is locked in place.
Step 106

Tighten the fasteners of the upper timing cover. Use a drive socket #13. Use a torque wrench. Observe the recommended tightening torque.
Step 107

Tighten the alternator fasteners. Use a drive socket #13. Use a drive socket #16. Use a torque wrench. Observe the recommended tightening torque.
Step 108

Install the air filter housing.
Step 109

Lock the air filter housing retainers.
Step 110

Remove the microfibre towel from the throttle body.
Step 111

Reinstall the air distribution housing assembly.
Step 112

Reinstall the air filter cover. Fasten it.

Replacement: water pump & timing belt kit – VW PASSAT (3A2, 35I). AUTODOC experts recommend:
When installing, do not use excessive force to avoid damage to the part.
Step 113

Press the air filter cover clips into place.
Step 114

Screw in the fasteners of the air distribution housing assembly. Use a drive socket #7. Use a ratchet wrench.
Step 115

Remove the coolant reservoir cap.
Step 116

Insert the funnel.
Step 117

Pour coolant in the coolant reservoir.

Replacement: water pump & timing belt kit – VW PASSAT (3A2, 35I). Tip from AUTODOC:
Only use the coolant recommended by the manufacturer.The coolant level should be at the MAX mark.Wait until the air goes out of the system.
Step 118

Install the wheel arch cover to its mounting seat. Screw in the fasteners. Use a Phillips screwdriver.
Step 119

Clean the wheel rim mounting seat. Use a wire brush.
Step 120

Treat the surface where the brake disc contacts the wheel rim. Use copper grease.
Step 121

Clean the brake disk surface. Use a brake cleaner.

AUTODOC recommends:
Replacement: water pump & timing belt kit – VW PASSAT (3A2, 35I). After applying the spray, wait a few minutes.
Step 122

Install the wheel.

AUTODOC recommends:
Warning! To avoid injury, hold the wheel while screwing in the fastening bolts on the car. VW PASSAT (3A2, 35I)
Step 123

Screw in the wheel bolts. Use wheel impact socket #17.
Step 124

Lower the car and working in a cross order, tighten the wheel bolts. Use wheel impact socket #17. Use a torque wrench. Tighten it to 110 Nm torque.
Step 125

Remove the jacks and chocks.
Step 126

Attach the terminals to the battery.

Replacement: water pump & timing belt kit – VW PASSAT (3A2, 35I). Tip:
Be careful! Do not mix up the positive and the negative terminals of the car battery.
Step 127

Screw in the fasteners of the battery terminals. Use a drive socket #10. Use a ratchet wrench.
Step 128

Run the engine for a few minutes. This should be done in order to remove residual air from the cooling system and to check if the components are operating correctly.

Step 129

Shut off the engine.

Step 130

Check the coolant level. If necessary, top up to the required level.

Please note!
The coolant level should be at the MAX mark.
Step 131

Install the coolant reservoir cap.

Step 132

Screw on the coolant reservoir cap.

Step 133

Remove the fender protection cover.

Step 134

Close the hood.

Replacement: water pump & timing belt kit – VW PASSAT (3A2, 35I). Professionals recommend:
Be sure to record the mileage at which you replaced the timing belt and water pump kits.

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