Everything you need to know about the 2004-2005 VW Passat timing belt replacement on the 2.0L TDI engine.
The 2.0 Liter TDI engine is driven by a timing belt system that links the cylinder head, camshaft, and crankshaft to run in sync. This VW Passat timing belt system consists of a wear-resistant, high strength, corded/molded rubber timing belt (a.k.a. VW Passat toothed belt). There's also an assortment of tensioners and idler rollers to guide and tension the BHW TDI timing belt.
It's very important to service your VW Passat TDI timing belt. The timing belt, tensioner, and idler components eventually reach the end of their recommended service life. The BHW engine code Passat TDI is an interference engine (a.k.a. non-clearance engine). If the VW Passat timing belt fails, the timing belt system that links the cylinder head, camshafts, and crankshaft no longer runs in sync. Close tolerance engine designs allow for the cylinder head valves to hit the top side of the pistons. VW Passat timing belt failure on these engines will result in catastrophic engine damage (i.e. bent valves and in some cases cracked pistons).
VW Passat Timing Belt Service Change Interval
What is the recommended VW Passat timing belt change interval on the 2.0L TDI engine? Has the recommended VW Passat timing belt interval for the 2.0L engines changed?
The most recent recommend interval is 80,000 miles.
What does Blauparts recommend? When dealing with crucial timing belt service, err on the side of caution and change your VW Passat timing belt every 80,000 miles. It is our recommendation to closely inspect all timing belt components before the recommended interval. Play it safe, changing your timing belt may seem expensive. However, choosing to exceed your timing belt service interval is risky and can lead to unknown repair costs that will far exceed typical timing belt replacement service costs.
Intended Life-Expectancy of Timing Belt Components
Various VW Passat timing belt component life spans. In our service facility, we've seen a few original timing belts last over the specified change interval and others ready to break well before it. In addition to mileage, other factors age the timing belt and related components. The following are some reasons why you see the difference in how long a VW Passat timing belt and related components last: (1) un-logged engine idle times and sitting in traffic; (2) warm-up time in cold weather; (3) environmental climate factors; (4) related engine maintenance that may have been overlooked.
Keys to the long life of your new timing belt components after timing belt replacement. Make your new parts last! You can expect your new BLAU INA OEM components to last the specified 80,000-mile interval if the following important steps were taken:
1) Timing belt service was performed using BLAU INA OEM components. The same timing belt and timing belt tensioner that was fitted on your VW Passat from the factory, that are engineered to meet the specified change interval requirements.
2) Timing belt service was performed by an experienced competent ASE-certified VW mechanic who is familiar with your specific engine 2.0 TDI engine.
3) Factory service procedures must be strictly followed. Even if installing the best parts, using improper procedures can shorten their life span. Incorrect installation or missteps during timing belt service are often done without intent and aren't noticed until further down the road. Fortunately, some common mishaps are noticed after re-assembly and during the final engine rotational timing sequences.
VW Passat Timing Belt Replacement Cost for 2.0L TDI Models
How much does it cost to replace the VW Passat timing belt on the 2.0 Turbo TDI? How long does it take to change the timing belt on a VW Passat 2.0 Turbo TDI? How much will the parts cost? How much will the labor cost? Thinking of buying a VW Passat 2.0L and wondering about timing belt replacement?
How Long Does It Take?
How long does it take to replace the VW Passat timing belt on the 2.0 Liter TDI? The average timing belt service labor time for this engine is around 6-8 hours depending on the technician's experience and the amount of timing belt parts being replaced.
How Much Does It Cost?
The average shop labor rate is $75 - $200 per hour. The lesser amount is often found in smaller cities and the more expensive labor rate seems to align itself with larger cities. Depending on shop rate, technician's experience, and the amount of timing belt parts being replaced it can cost approximately $600-$1,600. This is just the labor cost (not including parts).
How Much Do The Parts Cost?
It depends. Some choose to source the parts themselves, while others get the parts through their repair shop. Some repair shops prefer to supply the parts themselves. This allows for cost margins and potential profits on the parts. Also, they can control the type of parts used, reducing the potential problem of having customers come back with part issues.
You won't have to worry about this with our INA Gen II BLAU VW Passat Timing Belt Kits ranging from $180 - $320 and include the same INA OEM parts that came on your car, just without the genuine logo. This is a huge savings vs retail dealer cost. Have your mechanic call us!
Looking to Buy A Used VW Passat and Wondering About Timing Belt Replacement?
Many people who are looking to buy a used 2004-2005 VW Passat 2.0 TDI start researching the cost of replacing the timing belt. It's best to purchase a car that comes with service history records from the previous owner. Owners who value their car and took care of it will have a record of all service history, an indication of the vehicle's overall shape and reliability. The importance of service records is indisputable. A seller without any service records, is looking to take advantage of the "inexperienced" buyer, making more money at their expense.
Inspecting a timing belt that "seems fine" isn't enough. You'll also want to confirm when the last timing belt service was performed with the appropriate documentation. Don't just take the word of a seller saying "Oh, I think I changed it around 30,000 miles ago." Assumptions and no documents means RISK. Calculate the cost of timing belt replacement into your purchase price if they don't have the records.
Example of Negotiation:
2005 VW Passat TDI - 115,000 Miles - Asking Price: $8,900.00
Buyer: "When was the timing belt done last."
Seller: "Oh, I just did it. I think it was about 30,000 miles ago."
Buyer: "Do you have the paperwork?"
Seller: "No, I don't."
Buyer: "Well with no documentation, I'll have to get it replaced to establish a guarantee baseline. That will cost me around $890 - $1,920. Are you willing to take $890 - $1,920 off the purchase price?"
What to Replace While Changing the VW Passat Timing Belt on the 2.0L TDI Engine
System Setup Apart from the timing belt the 2.0L BHW Passat TDI engine's timing belt system consists of 5 serviceable timing belt components. One is the water pump that is driven by the timing belt. Second is the two small fixed idler bearings, one is located in the mid to lower area of the timing belt system and the other is on the top side of the timing belt system. Fourth is the timing belt tensioner which provides variable spring-loaded tension to the timing belt. Fifth is the large idler bearing located closest to the injector pump on the timing belt system. All of these components work in sync with each other to guide and tension the timing belt.
Before going through the significant work of taking your car apart for timing belt replacement, please consider the following:
Looking To Save Money... "Can I Just Replace the Timing Belt?" Simply changing the VW Passat timing belt isn't enough. Why? Around the timing belt service interval (80,000 miles), due to age, the integrity of the tensioner, idlers, water pump, and other seals and o-rings are at the end or very near the end of their service life. Some individuals make the mistake of only replacing the timing belt. Then, 10,000-20,000 miles later, their new timing belt fails due to tensioner, idler bearing, or water pump failure.
Why replace your VW Passat timing belt tensioner during timing belt service? Just as the timing belt has a designated service life and subsequent change interval, so do the tensioner and idler bearings. Timing belts can indeed get old, begin to crack, and eventually fail. However, it is just as common for the timing belt tensioner and/or idler bearings to fail, thus causing timing belt failure.
How can the tensioner cause a timing belt to fail? Most tensioner bearings contain a set amount of grease behind the seal. This grease provides ample lubrication and ensures tensioner reliability for the designated life span (80,000 miles). During engine operation, constant thermal temperature fluctuations eventually cause the bearing's grease to break down and lose its lubricating properties. Over time, this results in unwanted bearing play and the eventual seizure. If a timing belt tensioner has too much play or seizes, the timing belt can become misaligned, or begin to 'burn up' and shred, causing engine failure. Thermal temperatures also affect the timing belt causing the material composition of the belt to change and accelerate its life span, often resulting in premature failure.
Why replace your VW Passat water pump during timing belt service? It makes sense from a labor standpoint since timing belt disassembly is required for the water pump replacement. The water pump is driven by the timing belt and contains an internal sealed bearing that has a life span similar to the timing belt, tensioner, and idler bearings. The internal bearing and seals of a VW water pump can weaken and is the primary reason why a water pump eventually fails.
Why replace your VW Passat thermostat during timing belt service? The engine temperature is controlled by the thermostat. Near the end of its designated service life the thermostat spring temper changes. This causes the thermostat to open too much allowing the engine to run cooler, resulting in poor fuel optimization, decreased fuel economy, and less horsepower.
Special Tools for VW Passat Timing Belt Replacement 2.0L TDI Models
Please Note: Our timing belt tool rental kits are no longer available for rental. All tool rental kits are available for sale in good used condition in our online catalog.
Do I need special tools? Can I do it without the tools?
When replacing the VW Passat timing belt on my 2.0 TDI model, do I need the special tools? On older single-cam VW engines it is possible to achieve general timing without the special tools. However, on the BHW VW Passat TDI engine, special tools were designed for a reason. Slight variations in timing or orientation can result in catastrophic engine damage (e.g. bent valves).
This isn't the area of vehicle maintenance to cut corners or try to save time. On these VW models, to achieve 100% proper cam to crankshaft timing and injector pump timing, special tools are necessary. When the timing is off several degrees the check engine light could appear and a lack of performance is noticed (i.e. - poor fuel economy, excessive black smoke, soot, hard starting). Remember, you're performing a crucial maintenance repair. If done incorrectly, catastrophic engine damage will result.
Basic Descriptions of Essential VW Passat Timing Belt Tools:
3099/3415 - Crankshaft Counter Holding Torque Holder
T10172 - Camshaft Sprocket Counter Holding Tool
T10051 - Camshaft Hub Counter Holding Tool
T10052 - Camshaft Sprocket Puller
3359 - Camshaft and Fuel pump Hub Lock Pin Tool
T10100 - Crankshaft Sprocket Holder
3387 - Eccentric Tensioner Pulley Pin Wrench
3369/3411 - Radiator valance tools used for bumper removal and putting the vehicle in timing belt service position.
NOTE: The following tools are used depending on the depth of the VW Passat timing belt service that you're performing and if you've chosen to change the cam or crank seals.
3389 - Cam Seal Installer
3265 - Crankshaft Oil Seal Installer Press Sleeve
3240 - Camshaft Seal Remover
3203 - Crankshaft Oil Seal Puller
SPECIAL NOTE: Engine and Transmission Support Tools for Mk V B5 VW Passat 2.0 TDI models
VW Passat B5 platform features a transversely mounted engine. The transversely mounted engine has a timing belt that runs through the center of the passenger side motor mount bracket. This motor mount bracket must be removed to perform the timing belt service. To remove the motor mount bracket the engine and transmission need to be properly supported. If they are not properly supported, damage can occur to the engine, transmission, fenders, and body of the car. It is necessary to use the specified and specifically designed VW B5 chassis special tools listed below. Due to their size and complexity, these tools are not available through us and are not included in our tool rental kits.
10-222 A - Engine and transmission support bar set.
10-222 A/13 - Engine support bar to fender brackets.
10-222 A/18 - Engine to bar lateral bracket.
10-222 A/3 - Engine support rod spindle.
Diagnostic Software - Diagnostic software (e.g. Ross-Tech) is also needed to properly tune the injector timing. The timing belt tools will only get the injector pump timing to a window where the engine will start and run. The Ross-Tech diagnostic software is designed to fine-tune the injection timing for optimal efficiency and performance.