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Hi, I have pasted instructions below from autozone.com. The instructions call for the use of special tools. You can improvise with alternate tools, but please make sure your timing is right before closing the cover. Please let me know if you have questions, and thanks for using FixYa.
1.9L Diesel Engine Some special tools are required to
perform this procedure properly. A flat bar, VW tool 2065A is used to
secure the camshaft in position. A pin, VW tool 2064 is used to fix the
pump position while the timing belt is removed. The camshaft and pump
work against spring pressure and will move out of position when the
timing belt is removed. It is not difficult to find substitutes but do
not remove the timing belt without these tools.
Do not turn the engine or camshaft with the timing belt removed.
The pistons will contact the valves and cause internal engine damage.
Disconnect the negative battery cable and remove the accessory
drive belts, crankshaft pulley and the timing belt cover(s). Remove the
camshaft cover and rubber plug at the back end of the camshaft.
Temporarily reinstall the crankshaft pulley bolt and turn the
crankshaft to Top Dead Center (TDC) of No. 1 piston. The mark on the
camshaft sprocket should be aligned with the mark on the inner timing
belt cover or the edge of the cylinder head.
With the engine at TDC, insert the bar into the slot at the back
of the camshaft. The bar rests on the cylinder head to will hold the
camshaft in position.
Insert the pin into the injection pump drive sprocket to hold the pump in position.
Loosen the locknut on the tensioner pulley and turn the tensioner
counterclockwise to relieve the tension on the timing belt. Slide the
timing belt from the sprockets.
Fig. Use the VW tool to lock the camshaft at TDC for timing belt replacement-Volkswagen 1.9L Diesel engines
Fig. Locking the injection pump with the VW tool as shown-Volkswagen 1.9L Diesel engines
Install the new timing belt and adjust the tension so the belt can
be twisted 45 degrees at the halfway point between the camshaft and
pump sprockets. Tighten the tensioner nut to 33 ft. lbs. (45 Nm).
Remove the holding tools.
Turn the engine 2 full revolutions to return to TDC for the No. 1
cylinder. Recheck belt tension and timing mark alignment, readjust as
Install the belt cover and accessory drive belts.
If the belt is too tight, there will be a growling noise that rises and falls with engine speed.
The water pump is driven by the timing belt, so the front of the engine must come off, including radiator, fans, belts, pulleys, timing belt cover, etc. the timing belt removed (making sure cams do not rotate, water pump can then be changed. 4 bolts on it to be removed.The water pump is driven by the backside of the timing belt. The pump is buried deep in the front of the engine. ------------Thanks.
keep updated for any more query.you can rate this solution and show your
Rotate the engine so that No. 1 cylinder is at TDC on the
compression stroke. Check that the timing marks are aligned on the
camshaft and crankshaft pulleys. An access plug is provided in the cam
belt cover so that the camshaft timing can be checked without removal
of the cover or any other parts. Set the crankshaft to TDC by aligning
the timing mark on the crank pulley with the TDC mark on the belt
cover. Look through the access hole in the belt cover to make sure that
the timing mark on the cam drive sprocket is lined up with the pointer
on the inner belt cover.
Loosen the alternator retaining bolts and remove the drive belt from the pulleys. Remove the water pump pulley.
Loosen and position the power steering pump mounting bracket and position it aside.
Remove the four timing belt outer cover retaining bolts and remove the cover. Remove the crankshaft pulley and belt guide.
Loosen the belt tensioner pulley assembly, then position a
camshaft belt adjuster tool (T74P-6254-A or equivalent) on the tension
spring rollpin and retract the belt tensioner away from the timing
belt. Tighten the adjustment bolt to lock the tensioner in the
Remove the timing belt.
Install the new belt over the crankshaft sprocket and then
counterclockwise over the auxiliary and camshaft sprockets, making sure
the lugs on the belt properly engage the sprocket teeth on the pulleys.
Be careful not to rotate the pulleys when installing the belt.
Release the timing belt tensioner pulley, allowing the tensioner
to take up the belt slack. If the spring does not have enough tension
to move the roller against the belt (belt hangs loose), it might be
necessary to manually push the roller against the belt and tighten the
The spring cannot be used to set belt tension; a wrench must be used on the tensioner assembly.
Rotate the crankshaft two complete turns by hand (in the normal
direction of rotation) to remove the slack from the belt, then tighten
the tensioner adjustment and pivot bolts to specifications. Refer to
the necessary illustrations. Make sure the belt is seated properly on
the pulleys and that the timing marks are still in alignment when No. 1
cylinder is again at TDC/compression.
Install the crankshaft pulley and belt guide.
Install the timing belt cover.
Install the water pump pulley and fan blades. Install upper radiator hose if necessary. Refill the cooling system.
Position the alternator and drive belts, then adjust and tighten it to specifications.
Start the engine and check the ignition timing. Adjust the timing, if necessary.
timing belt or chain and or timing gears have failed... please rate my help thanks, if you can and if the vehicle has a accessible distributor cap, remove the cap and note if the rotor spins, no spin when you crank over engine then this will confirm timing gear issue. also you can confirm it sometimes by removing oil filler cap on engine valve cover and looking to see any valve train movement...please rate my help, thanks
these bend valves if belt breaks while running
Align the timing marks on the camshaft gears to the notches on the camshaft cover, using the intake gear mark for the intake gear and the exhaust gear mark for the exhaust gear.
Align the mark on the crankshaft gear with the
notch at the bottom of the rear timing belt cover.
Yes, As long as the Timing Belt is not Damaged. Just remove the Cover and Replace it. You will need to remove the Belt again and the Bottom Pulley that Covers the Timing Belt Cover. Please Rate my Solution, I need all the Help that I can Get! Thanks!
TAKE FRONT COVER OFF(AFTER REMOVING FAN, BELT S, PULLEY AND FAN SHROUD).THEN REMOVE CRANK SHAFT PULLEY. WHEN COVER IS REMOVED YOU'LL SEE 3 SPROKETS, SUGGEST TO BRING CRANK TO TOP DEAD CENTER UNTIL YOU SEE ALL 3 MARKS FOR THE TIMING BELT. REMOVE BELT/INSTALL NEW AND REVERSE PROCEDURE.