Sprockets not alligned properly

The alignment of the sprockets themselves keeps the belt true. If the belt moves out of alignment then one or all the sprockets is worn.Examine and replace.

1999 Volkswagen Passat 1.9 Tdi are of two types. Two piece injection pump sprocket type and single piece injection sprocket type. First diagram is of two piece sprocket and the other one is single piece sprocket type. Tightening torque for the important nuts and bolts are also shown in the diagram.
Two piece injection pump sprocket timing setting:


Single piece injection pump sprocket timing setting:

Hope that works.

Refer to Figures 1,2,3,4 when performing 17-step timing procedure for 1981-1985 Diesel Engines.

Fig 1. Injection pump and camshaft alignment marks - Diesel engine.




Fig 2. Removing the timing belt holder - Diesel engine.



Fig 3. Injection pump alignment marks - Diesel engine.



Fig 4. Tensioiner Pulley Bolt Sequence - Diesel engine.



Procedure - Timing Belt replacement.

1. Disconnect the negative battery cable. Drain the cooling system.

CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

2. Remove the timing belt cover. Remove the injection pump sprocket flange.

3. Using a prybar, remove the tension spring from the timing belt tensioner.

When removing the tension spring, avoid using excessive force for the spring may become distorted.

4. Remove the tensioner pulley bolt and the pulley.

5. Remove the timing belt and discard it.

To install:

6. Rotate the crankshaft to bring the No. 1 piston to TDC of the compression stroke.

7. Align the timing marks on the injection pump sprocket with the camshaft sprocket; the marks must be facing each other.

8. Using a new timing belt, install it in the following sequence: crankshaft sprocket, camshaft sprocket and the injection pump sprocket; the slack must be between the injection pump and camshaft sprockets.

9. Install the tension center and the tension pulley so the end of the tension center is fitted against both pins on the timing pulley housing.

10. Hand tighten the nut so the tension pulley can be rotated freely.

11. Install the tension spring and semi-tighten the pulley nut to 22-36 ft. lbs. (30-48 Nm).

12. Rotate the crankshaft 2 full turns clockwise to seat the belt and further turn the crankshaft 90° beyond TDC to settle the injection pump.

13. Loosen the tension pulley nut to take up the timing belt slack. Tighten the tension pulley nut to 79-94 ft. lbs. (108-128 Nm).

14. Install the injection pump sprocket flange; the hole in the outer circumference of the flange should be aligned with the triangular timing mark on the injection pump sprocket.

15. Rotate the crankshaft 2 full turns clockwise to bring the No. 1 piston to TDC of the compression stroke. Make sure the triangular timing mark on the timing sprocket is aligned with the hole in the flange, then, measure the timing belt tension; it should be 33-55 lbs.

16. Install the timing belt cover.

17. Connect the negative battery cable.

Here are instructions from autozone.com: Please be sure the belt is tight on the right side with the gears aligned before releasing tensioner onto belt.

To install:

1. If necessary, install the timing belt inside cover.
2. Slide the timing belt guide on the crankshaft so that the concave side faces the oil pump, then install the sprocket key in the groove in the crankshaft.
3. Slide the pulley onto the crankshaft, and install the center retaining bolt. Tighten the center bolt to 48-54 ft. lbs. (65-75 Nm) for 1986-88 1.3L engines, to 76-83 ft. lbs. (105-115 Nm) for 1989-95 1.3L engines, or to 58-65 ft. lbs. (80-90 Nm) for 1.6L engines. To hold the crankshaft from turning, you can use Suzuki Tool 09927-56010 (or equivalent), or a large prybar inserted in the transmission housing slot and the flywheel teeth.
4. Install the timing belt camshaft sprocket, ensuring that the slot in the sprocket engages the camshaft (pulley) pin; this ensures that the sprocket is properly positioned on the end of the camshaft. Secure the camshaft with the metal rod used during removal, then tighten the sprocket bolt to 41-46 ft. lbs. (56-64 Nm).
5. Assemble the timing belt tensioner plate and the tensioner, making sure that the lug of the tensioner plate engages the tensioner.

Fig. 14: Assemble the tensioner (2) and the plate (1) so that the lug (3) engages the hole (4) in the tensioner

1. Install the timing belt tensioner, tensioner plate and spring on the engine. Tighten the mounting bolt and stud only finger-tight at this time. Ensure that when the tensioner is moved in a counterclockwise direction, the tensioner moves in the same direction. If the tensioner does not move, remove it and the tensioner plate to reassemble them properly.
2. Loosen all rocker arm valve lash locknuts and adjusting screws. This will permit movement of the camshaft without any rocker arm associated drag, which is essential for proper timing belt tensioning. If the camshaft does not rotate freely (free of rocker arm drag), the belt will not be properly tensioned.
3. Rotate the camshaft sprocket clockwise until the timing mark on the sprocket and the V mark on the timing belt inside cover are aligned.
4. Using a 17mm wrench, or socket and breaker bar, on the crankshaft sprocket center bolt, turn the crankshaft clockwise until the punch mark on the sprocket is aligned with the arrow mark on the oil pump.

Fig. 15: When installing the crankshaft sprocket (pulley), ensure that the concave side of the timing belt guide is facing the engine Fig. 16: Before installing the timing belt, position the camshaft sprocket (1) so that the timing mark on the sprocket (2) is aligned with the notch (3) on the inside timing belt cover (4)

Fig. 17: ... and ensure that the crankshaft sprocket (1) timing mark (2) is aligned with the mark on the oil pump (3)

Fig. 18: Install the timing belt on the sprockets so that there is no slack in the drive side of the belt (1), then install the tensioning assembly

Fig. 19: To properly tension the timing belt, rotate the crankshaft through two full revolutions

1. With the camshaft and crankshaft marks properly aligned, push the tensioner up with your finger and install the timing belt on the two sprockets, ensuring that the drive side of the belt is free of all slack. Release your finger from the tensioner. Be sure to install the timing belt so that the directional arrow is pointing in the appropriate direction.

In this position, the No. 4 cylinder is at Top Dead Center (TDC) on the compression stroke.

1. Rotate the crankshaft clockwise two full revolutions, then tighten the tensioner stud to 18-21 ft. lbs. (24-30 Nm) for 1986-88 models, or to 80-106 inch lbs. (9-12 Nm) for 1989-95 models. Then, tighten the tensioner bolt to 18-21 ft. lbs. (24-30 Nm).
2. Ensure that all four timing marks are still aligned as before; if they are not, remove the timing belt, and install and tension it again.
3. Install the timing belt cover and all related components.

Timing Belt and Sprockets REMOVAL & INSTALLATION Fig. 1: If you plan on reusing the timing belt, make sure you note the direction of the rotation before removal Fig. 2: If the special tool is unavailable, a suitable length and width straight edge can be used to align the camshafts Fig. 3: Camshaft alignment using the special service tool Fig. 4: Insert the crankshaft damper bolt to turn the crankshaft and . . . Fig. 5: . . . align the camshafts and the . . . Fig. 6: . . . crankshaft before removing the old belt Fig. 7: Loosen the timing belt tensioner pulley bolt, slide the tensioner back and . . . Fig. 8: . . . tighten the bolt to the farthest right hand side as possible to hold the release the tensioner pulley so that the belt can be removed Fig. 9: . . . remove the belt starting from around the camshaft pulleys Fig. 10: Installation of the tensioner spring and retaining bolt For information on timing belt recommended replacement interval, refer to Section 1. CAUTION
The 2.0L engine is an interference motor. Extending the replacement interval could lead to the belt breaking and severe and costly engine damage. Care must be taken if rotating the crankshaft or camshafts with the belt off, if resistance is felt, do not force them to turn.

1. Disconnect the negative battery cable.
2. Remove the timing belt covers as outlined in this Section.
3. Remove the valve cover.
4. Place Camshaft Alignment Timing Tool T94P-6256-CH or equivalent, into the slots of both camshafts at the rear of the cylinder head to lock the camshafts into position. NOTE: If the special tool is unavailable, a suitable length and width straight edge can be used to align the camshafts.
   
5. Loosen the camshaft timing belt tensioner pulley retaining bolt and move the tensioner pulley to relieve the tension on the timing belt.
6. Temporarily tighten the tensioner in this position. NOTE: If the timing belt is to be reused, mark the belt for the direction of rotation before removing to prevent premature wear or failure.
   
7. Remove the timing belt.
8. If required, remove the sprockets as follows:
   1. Hold the camshaft with an appropriate camshaft sprocket holding tool.
   2. Loosen and remove the camshaft sprocket retaining bolt.
   3. Remove the sprocket from the camshaft.
   4. Repeat the procedure for the 2nd camshaft sprocket.
   5. Remove the crankshaft sprocket.
9. Slide the crankshaft sprocket onto the crankshaft aligning the key-way.
10. Align the camshafts using the Camshaft Alignment Timing Tool T94P-6256-CH. NOTE: If the special tool is unavailable, a suitable length and width straight edge can be used to align the camshafts.
    
11. Reinstall the sprockets onto the camshafts and loosely install the camshaft retaining bolts.
12. Tighten the camshaft sprocket retaining bolts to 47–53 ft. lbs. (64–72 Nm) .
13. Loosely install the crankshaft pulley to verify that the engine is at TDC. Realign the marks if they have moved.
14. Verify that the camshafts are aligned. NOTE: It is recommended to purchase a tensioner spring and retaining bolt through the dealer parts to apply the proper tension for used or new belt installations. The spring is bolted to the tensioner assembly and becomes a part of the engine. Ignore this notice if the tensioner spring is already installed.
    
15. Reinstall the retaining bolt (W700001-S309) into the hole provided in the cylinder block and place the tensioner spring (6L277) between the bolt and the camshaft timing belt tensioner pulley.
16. Tighten the retainer bolt to 71–97 inch lbs. (8–11 Nm) .
17. Remove the crankshaft pulley and install the timing belt onto the crankshaft sprocket, then onto the camshaft sprockets working in a counterclockwise direction.
18. Tighten the camshaft sprocket retaining bolts to 47–53 ft. lbs. (64–72 Nm) .
19. Be sure that the span of the camshaft timing belt between the crankshaft sprocket and the exhaust camshaft sprocket is not loose.
20. Be sure that the camshaft timing belt is securely aligned on all sprockets.
21. Reinstall the lower timing belt cover and tighten the retaining bolts to 53–71 inch lbs. (6–8 Nm) .
22. Apply silicone sealer to the key-way of the crankshaft pulley and install. Tighten the retaining bolt to 81–89 ft. lbs. (110–120 Nm) .
23. Inspect the timing mark on the crankshaft pulley to verify that the engine is still at TDC.
24. Loosen the camshaft timing belt tensioner pulley retaining bolt and allow the tensioner spring attached to the pulley to draw the tensioner pulley against the camshaft timing belt.
25. Remove the camshaft alignment timing tool from the camshafts at the rear of the engine.
26. Turn the crankshaft two revolutions in a clockwise direction.
27. Tighten the camshaft timing belt tensioner pulley retaining bolt to 26–30 ft. lbs. (35–40 Nm) .
28. Recheck that the crankshaft timing mark is at TDC for the No. 1 piston, and that both camshafts are in alignment using the camshaft alignment timing tool. NOTE: A slight adjustment of the camshafts to allow the insertion of the camshaft alignment timing tool is permissible as long as the crankshaft stays at the TDC location.
    
29. An appropriate camshaft sprocket holding tool can be used to move the camshaft sprocket (s) if a slight adjustment is required.
30. If a camshaft is not properly aligned, perform the following procedure:
    1. Loosen the retaining bolt securing the sprocket to the camshaft while holding the camshaft sprocket from turning with the sprocket holding tool.
    2. Turn the camshaft until the camshaft alignment timing tool can be installed.
    3. Verify that the crankshaft timing mark is at TDC for the No. 1 cylinder.
    4. While holding the camshaft sprocket with the camshaft sprocket holding tool, tighten the retaining bolt to 47–53 ft. lbs. (64–72 Nm) .
    5. Remove the tool and rotate the crankshaft two revolutions (clockwise) .
    6. Verify that the camshafts are aligned and that the crankshaft is at TDC for the No. 1 cylinder.
31. Install the valve cover.
32. Install the timing belt covers.
33. Connect the negative battery cable.

TIMING BELT CHANGE You should have some mechanical skills before attempting any engine maintenance! These are basic instructions, and you must knoe what you removed, when, and what order so you can reinstall them in order. First, you have to remove everything in the way! You need to remove the Fan, clutch, and shroud, pump pully & drive belts. Next, you need to remove the Crank Pully:

1. Crank Pully Bolt 2. Crank Pully 3. Center Bolt 4. 5mm Hex drive (used to remove pully bolts) Once the fan stuff, and pully(s) are removed, then you need to remove the Timing Belt cover:

Once the cover is removed, you will need to loosen the adjusting nut and pully bolt on the Belt Tensioner:
A. Adjust Nut B. Pully Bolt C. TENSIONER PULLY Once the the Adjust Nut, and Pully bolt are loose, move the pully as far towards the water pump as possible.
Then, you can slip the timing belt from the sprockets. Check the tensioner for roughness and excess play! DO NOT MOVE THE CAM OR CRANK SPROCKETS! IF you do, then you will have to line up the Crank and Cam for piston number one at Top Dead Center before placing the new timing belt on! Note the timing marks on the crank and camshaft sprockets. IF YOU MUST! Allign the Cam and Crank at piston#1, Top Dead Center before removing the belt. Each sprocket has a small hole, with a line through it, and there is a small groove or "V" it alligns with on the engine. Now, once the timing belt is off, look at your new timing belt. Older belts use the Squared off teeth, while new ones have the rounded teeth. Make sure you have the correct belt for your sprockets! Never reinstall a belt that is in questionable condition. BELT WEAR CONDITIONS
If there are Arrows on the belt, they must be pointing to the RIGHT when you put the new belt on the sprockets. If there isn't one, then paint one on, and place the belt back on the sprockets. The arrow will indicate to a mechanic, this is the way the belt must be put back on (if they replace any cam or crank oil seals). Slip the new belt onto the Crank sprocket. While maintaining tension on the side of the belt opposite the tensioner, slip the belt onto the Camshaft sprocket. Releace the Tensioner adjusting nut to allow spring tension against the belt. Temporarily reinstall the crank pully, taking care to align the notch in the pully with the raised area on the sprocket. Rotate the crank clockwise two complete revolutions. Recheck the alignment of the of the valve timing marks. If they do not align properly, loosen the tensioner, slip the belt off the crank pully, align the timing marks, reinstall the belt, and check alignment again. Tighten the tensioner nut, then the bolt. Reinstall all parts removed, in the opposite order, of course. Start the engine and allow to reach normal operating temp, then road test. THEORETICALLY, you should simply be able to replace the belt with the new one, and go, as long as you did not move any of the sprockets when removing or installing the belt. Most people do it this way, and do not test for alignment before replacing everything. When the belt wears, timing will be off, very little, and this is why you check alignment. The belt may have slipped a tooth, making the timing off. This is why the Cam and Crank sprockets must both align properly. An experienced person will do just that: Replace the belt, and go. It really isn't all that hard. It helps to have a second person around with some experience also.

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 ratation unless otherwise stated, Support engine. Remove, engine mounting, auxilliaty drive belts. Water pump pulley 1. Crankshaft pulley bolts 21. crankshaft pully 2. timing belt covers 3. Turn crankshaft to TDC on No 1 cyclinder. Ensure crankshaft sprocket, camshaft sprocket, oil pump sprocket and balancer shaft sprocket timing marks aligned. Timing marks on camshaft sprockets should align with cylinder head upper face. Dowel pins on camshaft sprockets should face upwards. Slacken tensioner bolt. Move tensioner away from belt and lightly tighten bolt. Remove, automatic tensioner unit bolts. Automatic tensioner unit. Timing belt, crankshaft centre bolt, crankshaft sprocket. Crankshaft sprocket guide washer. Slacken blancer shaft belt tensioner bolt. Move tensioner away from belt and lightly tighten bolt. Remove balancer shaft belt.

Installation
Ensuring timing marks arligned. Note timing marks on camshaft sprockets should align with cylinder head upper face. Exhaust sprocket mark is on recess, but inlet sprocket mark is on tooth. Note: to check oil pump sprocket positioned correctly, removing blanking plug from cylinder block. Insert 8mm diameter Phillips srcrewdriver in hole. Ensure screwdriver is inserted 60mm from face of cylinder block. if screwdriver can only be inserted 20mm: turn oil pump sprocket 360°. Insert screwdriver again. Fit balancer shaft belt in anti-clockwise direction, starting at crankshaft sprocket. Slacken balancer shaft belt tensioner bolt. Turn tensioner clockwise to tension belt. Tighten bolt to 15-22Nm. Apply thumb pressure to belt. Belt should deflect 5-7 mm. If not repeat tensioning procedure. Install crankshaft sprocket guide washer, crnakshaft sprocket. Tighten crankshaft cente bolt. Tighten torque:110-130 Nm. Note ensure crankshaft sprocket guide washer is fitted correclty. Oil treads and contact face of crankshaft body before fitting. Check tensioner body for leakage or damage replace if necessary. Check pushrod protrusion is 12mm. If not replace automatic tensioner unit. Slowly compress pushrod into tensioner body until holes aligned. Resistance should be felt. Place flat washer under tnesioner body to avoid damage to body end plugs. Retain pushrod with suitable pin through hole in tensioner body. install automatic tensioner unit to cylinder block. Tighten bolts to 22-27Nm. Fit timing belt in anti-clockwise direction, starting at the tensioner pulley. Slacken tensioner pulley bolt. Turn tensioner pully clockwise to temporarily tension belt. Tighten bolts to 43-45Nm. Turn crankshaft slowly 1/4 turn anti-cockwise. Turn crankshaft clockwise until timing marks alligned. Slacken tensioner pully bolt. Fit tool to tensioner pulley. Tool No 09244 28100. Apply clockwise torque of 2,6-2,8 Nm to tensioner pulley. Tighten bolt to 43-45Nm. Insert special tool in timing belt rear casing. Tool no 09244-28000. Screw in tool until pin can be removed from automatic tensioner unit. Remove special tool. Tool nr 09244-28000. turn crankshaft two turns clockwise. Wait 15 minutes. Ensure timing marks aligned. Check extended length of pushrod is 3,8-4,5mm. Install components in reverse order of removal. Tighten crankshaft pulley bolts, Tighten torque 20-30Nm

1995 Volkswagen Passat 2.0L SFI 4cyl

1. With the distributor cap removed, the rotor should be pointing toward the No. 1 mark on the rim of the distributor housing. On 8 valve engines, the notch on the crankshaft pulley should align with the dot on the intermediate shaft sprocket.
2. Loosen the locknut on the tensioner pulley and turn the tensioner counterclockwise to relieve the tension on the timing belt.
3. Slide the timing belt from the sprockets.

Fig. Adjusting the belt tension on a 2.0L


Fig. Locate the tensioner


Good luck (remember rated this help).

Align the mark on the crank sprocket with the edge of the intermediate pulley, and the cam sprocket mark with the top right edge of the valve cover. Be aware that as you tension the belt that the cam sprocket will move a few degrees, so allow for this when setting them up! It's tricky so be sure they are aligned properly by rotating the engine through 2 complete revolutions by hand and recheck the alignment. More than 1 sprocket tooth off and engine will run poorly and have little power... Hope this helps...;-)

See Figures 1, 2 and 3

1. If possible, position the engine so the No. 1 piston is at TDC.
2. Disconnect the negative battery cable.
3. Remove the timing belt covers.
4. Remove the timing (outer) belt tensioner and remove the outer timing belt.
5. Remove the outer crankshaft sprocket and flange.
6. Remove the silent shaft (inner) belt tensioner and remove the belt.

Fig. 1: Silent shaft belt timing marks-1.8L engine Fig. 2: Checking the silent shafts for proper positioning Fig. 3: Timing belt timing mark alignment-1.8L engineTo install:

1. Align the timing marks of the silent shaft sprockets and the crankshaft sprocket with the timing marks on the front case. Wrap the timing belt around the sprockets so there is no slack in the upper span of the belt and the timing marks are still aligned.
2. Install the tensioner pulley and move the pulley by hand so the long side of the belt deflects about 1/4in.
3. Hold the pulley tightly so the pulley cannot rotate when the bolt is tigthened. Tighten the bolt to 15 ft. lbs. (20 Nm) and recheck the deflection amount.
4. Install the timing belt tensioner fully toward the water pump and tighten the bolts. Place the upper end of the spring against the water pump body.
5. Align the timing marks of the camshaft, crankshaft and oil pump sprockets with their corresponding marks on the front case or rear cover.

There is a possibility to align all timing marks and have the oil pump sprocket and silent shaft out of time, causing an engine vibration during operation. If the following step is not followed exactly, there is a 50 percent chance that the silent shaft alignment will be 180 degrees off.

1. Before installing the timing belt, ensure that the left side (rear) silent shaft (oil pump sprocket) is in the correct position as follows:
   1. Remove the plug from the rear side of the block and insert a tool with shaft diameter of 0.31 in. (8mm) into the hole.
   2. With the timing marks still aligned, the shaft of the tool must be able to go in at least 2 1/2 in. If the tool can only go in about 1 in., the shaft is not in the correct orientation and will cause a vibration during engine operation. Remove the tool from the hole and turn the oil pump sprocket 1 complete revolution. Realign the timing marks and insert the tool. The shaft of the tool must go in at least 2 1/3 in.
   3. Recheck and realign the timing mark.
   4. Leave the tool in place to hold the silent shaft while continuing.
2. Install the belt to the crankshaft sprocket, oil pump sprocket, then camshaft sprocket, in that order. While doing so, make sure there is no slack between the sprocket except where the tensioner is installed.
3. Recheck the timing marks' alignment. If all are aligned, loosen the tensioner mounting bolt and allow the tensioner to apply tension to the belt.
4. Remove the tool that is holding the silent shaft and rotate the crankshaft a distance equal to 2 teeth on the camshaft sprocket. This will allow the tensioner to automatically apply the proper tension on the belt. Do not manually overtigthen the belt or it will howl.
5. Tigthen the lower mounting bolt first, then the upper spacer bolt.
6. To verify correct belt tension, check that the deflection at the longest span of the belt is about 1/2in.
7. Install the timing belt covers and all related items.
8. Connect the negative battery cable.