Question about 1994 Volkswagen Passat

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Timing on 1.9 liter VW turbo diesel engine code AAZ

VW 1.9 liter turbo diesel engine code AAZ is out of vehicle. Cam shaft and injection pump are at top dead center, the mark on the pressure plate is not. To proceed do I lock the camshaft and injection pump, remove the timing belt and adjust the crankshaft to top dead center, then replace the timing belt? Also, the crankshaft pulley doesn't seem to want to come off (and will need to to get the lower timing belt cover off to get the timing belt off) does this require a special puller tool or will a generic puller work or do I just need to give it some muscle after the pulley retaining bolts are removed? Detailed instruction would be helpful. Thanks.

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  • serbo6 Jun 14, 2009

    This engine is not TDI. Will a generic puller work to get the crankshaft pulley off? Do I lock the camshaft and injection pump, remove the timing belt, then adjust the crankshaft to TDC, then replace the timing belt( with new one and new tensioner).

  • serbo6 Jun 14, 2009

    Will I be able to set camshaft and injection pump at TDC, lock them in place, loosen camshaft sprocketand tensioner,remove the timing belt, adjust the crankshaft to top dead center, then replace the timing beltand tensioner? At this point the mechanical should be timed,crankshaft and camshaft both a TDC, and since the pump sprocket wasn't moved the injection timing shouldn't be affected. What do you think? Also, what puller do I need for the crank pulley? Chiltons just says remove retaining bolts, remove pulley...

  • serbo6 Jun 15, 2009

    The link to the TDIclub pictorial on how to change a timing belt covered all the aspects of the question I posted. Thanks.



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Go to link for instructions and photo's of TDI timing belt change, coutesy of VW TDI club.

Posted on Jun 14, 2009

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From what I remember of manuals, usually a crankshaft pulley requires a special puller to prevent damage to said pully. usually, a second specialty tool is also required to reinstall it. be very carefull with a proceedure like this, as one minor misalignment may destroy the engine.

one of the best places to look for both detailed instructions and specialty tool numbers is a Chilton manual. these are sometimes available in a local library for access. make sure, with this kind of repair, that you follow instructions to the letter. also, have a pro doublecheck your work.

Posted on Jun 14, 2009

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Following are some speacial tools required:

Special Tools
Marking Plate
T 10008
Holds the hydraulic toothed belt tensioner
in place when installing and removing the
toothed belt.
Crankshaft Sealing Ring
Assembly Fixture
T 10053
Guide sleeve and compression sleeve for
installing the crankshaft sealing ring.
Camshaft Gear Puller
T 10052
Camshaft gear removal from the tapered
end of the camshaft.
Camshaft Gear Counter-Holder
T 10051
Camshaft gear installation.
Crankshaft Stop
T 10050
Holds the crankshaft in place at
the crankshaft gear when adjusting
the port timing.

There are some more but I would recomend you go through the article completely in the bellow mentioned article . Page number 56.

Thanks for contacting Fixya

Posted on Jun 14, 2009

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