Passat AVB.pdf

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Volkswagen
Passat 1,9D TDI P
Engine code: AVB
Name:
Manufacturer:
Volkswagen
Address:
Model:
Year:
Important note
Important note
The intervals and procedures given are subject to alteration by the manufacturer at any time.
Check the regularly updated Timing Belts section on our website to ensure that you are kept
informed of any changes that may occur between issues of the data .
Timing belt replacement intervals
The information relating to timing belt replacement intervals is additional to the main purpose of this CD, but is included to
provide guidance to garages and for customer advice.
Where possible the recommended intervals have been compiled from vehicle manufacturers' information. In a few instances no
recommendation has been made by the manufacturer and the decision to replace the belt must be made from the evidence of a
thorough examination of the condition of the existing belt.
Apart from the visible condition of the belt, which is explained fully later in this section, there are several other factors which
must be considered when checking a timing belt:
1.
Is the belt an original or a replacement.
2.
When was the belt last replaced and was it at the correct mileage.
3.
Is the service history of the vehicle known.
4.
Has the vehicle been operated under arduous conditions which might warrant a shorter replacement interval.
5.
Is the general condition of other components in the camshaft drive, such as the tensioner, pulleys, and other ancillary
components driven by the timing belt, typically the water pump, sound enough to ensure that the life of the replacement
belt will not be affected.
6.
If the condition of the existing belt appears good, can you be satisfied that the belt will not fail before the next check or
service is due.
7.
If the belt does fail, have you considered the consequences. If the engine is an INTERFERENCE type then considerable
expensive damage may well be the result.
8.
The cost of replacing a belt as part of a routine service could be as little as 5 to 10% of the repair cost following a belt
failure. Make sure your customer is aware of the consequences.
9.
If in doubt about the condition of the belt - RENEW it.
Manufacturer: Volkswagen
Model: Passat (01-) 1,9D TDI PD
© Autodata Limited 2004
2005-07-04
Engine code: AVB
Output: 74 (100) 4000
915802145.039.png 915802145.040.png 915802145.041.png
Replacement Interval Guide
Replacement Interval Guide
Volkswagen recommend:
All engines:
2000MY: Check condition and width every 10,000 miles or 12 months, whichever occurs first (replacement width 27 mm).
AJM 2000MY: Replacement every 40,000 miles (tensioner pulley must also be replaced).
All other engines
2000MY: Replacement every 60,000 miles (tensioner pulley must also be replaced).
2001MY
: Replacement every 60,000 miles (tensioner pulley must also be replaced).
The previous use and service history of the vehicle must always be taken into account.
Check For Engine Damage
Check For Engine Damage
CAUTION: This engine has been identified as an INTERFERENCE engine in which the possibility of valve-to-piston
damage in the event of a timing belt failure is MOST LIKELY to occur. A compression check of all cylinders should be
performed before removing the cylinder head(s).
Repair Times - hrs
Repair Times - hrs
Passat 1,9 TDI PD 1998-03
Remove and install
2,50
Special Tools
Special Tools
Camshaft locking tool - Volkswagen No.3359.
Crankshaft sprocket locking tool - Volkswagen No.T10050.
Support guides ( 09/00) - Volkswagen No.3369.
Support guides (10/00 ) - Volkswagen No.3411.
Tensioner locking tool - Volkswagen No.T10008.
Two-pin wrench - Volkswagen No.3387.
4 mm drill bit.
Special Precautions
Special Precautions
Disconnect battery earth lead.
DO NOT turn crankshaft or camshaft when timing belt removed.
Remove glow plugs to ease turning engine.
Turn engine in normal direction of rotation (unless otherwise stated).
DO NOT turn engine via camshaft or other sprockets.
Observe all tightening torques.
Manufacturer: Volkswagen
Model: Passat (01-) 1,9D TDI PD
© Autodata Limited 2004
2005-07-04
Engine code: AVB
Output: 74 (100) 4000
915802145.042.png 915802145.001.png 915802145.002.png 915802145.003.png 915802145.004.png 915802145.005.png 915802145.006.png 915802145.007.png 915802145.008.png 915802145.009.png 915802145.010.png 915802145.011.png 915802145.012.png
Removal
Removal
1.
Raise and support front of vehicle.
2.
Remove engine undershield.
3.
Remove:
Front bumper.
Air intake pipe between front panel and air filter.
Front panel bolt [1].
Front panel bolts [2] (10/00 ).
Front bumper carrier - not shown (10/00
).
4.
Install support guides in front panel:
09/00 [3]. Tool No.3369.
10/00
[4] & [5]. Tool No.3411.
5.
Remove:
Front panel bolts [2] & [6](
09/00).
Front panel bolts [6] (10/00
).
6.
Slide front panel forward into service position.
7.
Remove:
Engine top cover.
Turbocharger air hoses.
Intercooler outlet hose.
Mass air flow (MAF) sensor.
Auxiliary drive belt.
Auxiliary drive belt tensioner.
Timing belt upper cover [7].
Cooling fan assembly.
Timing belt centre cover [8].
Crankshaft pulley bolts [9].
Crankshaft pulley [10].
Timing belt lower cover [11].
8.
Release coolant pipes for fuel cooler from engine.
9.
Turn crankshaft clockwise to TDC on No.1 cylinder.
10.
Ensure timing mark aligned with notch on camshaft sprocket hub (4Z) [12].
NOTE: Notch located behind camshaft sprocket teeth.
11.
Lock crankshaft sprocket [13]. Use tool No.T10050.
12.
Ensure timing marks aligned [14].
13.
Lock camshaft [15]. Use tool No.3359.
14.
Fully insert Allen key [16]into tensioner pulley [17]18151.
15.
Turn tensioner pulley slowly anti-clockwise until locking tool can be inserted [18]18151. Tool No.T10008.
16.
Slacken tensioner nut [19].
17.
Remove:
Automatic tensioner unit [20].
Timing belt.
Installation
Installation
1.
Ensure camshaft locked with tool [15].
2.
Ensure crankshaft sprocket locking tool located correctly [13].
3.
Ensure timing marks aligned [14].
4.
Ensure automatic tensioner unit locked with tool [18]. Tool No.T10008.
5.
Slacken camshaft sprocket bolts [21].
6.
7.
Manufacturer: Volkswagen
Turn camshaft sprocket fully clockwise in slotted holes. Tighten bolts finger tight [21].
Model: Passat (01-) 1,9D TDI PD
© Autodata Limited 2004
2005-07-04
Engine code: AVB
Output: 74 (100) 4000
915802145.013.png 915802145.014.png 915802145.015.png 915802145.016.png 915802145.017.png 915802145.018.png 915802145.019.png 915802145.020.png 915802145.021.png 915802145.022.png 915802145.023.png 915802145.024.png 915802145.025.png 915802145.026.png 915802145.027.png 915802145.028.png
7.
Turn tensioner pulley slowly clockwise [22]until lug [23]just reaches stop [24]. Use tool No.3387 [25].
8.
Fit timing belt in following order:
Camshaft sprocket.
Tensioner pulley.
Crankshaft sprocket.
Water pump sprocket.
9.
Install:
Automatic tensioner unit [20].
NOTE: Ensure belt is taut between sprockets on non-tensioned side.
10.
Turn tensioner pulley slowly anti-clockwise [26] (lug [23]moves towards stop [27]). Use tool No.3387 [25].
11.
Remove locking tool without force [18].
NOTE: Ensure two-pin wrench remains in position.
12.
Allow tensioner pulley to turn back slowly [22](lug [23]moves towards stop [24]) until dimension [28]is 4±1 mm. Use drill bit
[29].
NOTE: Engine must be COLD.
13.
Tighten tensioner nut [19]. Tightening torque: 20 Nm + 45°.
14.
Tighten camshaft sprocket bolts [21]. Tightening torque: 25 Nm.
15.
Remove:
Camshaft locking tool [15].
Crankshaft sprocket locking tool [13].
Drill bit [29].
16.
Turn crankshaft slowly two turns clockwise to TDC on No.1 cylinder.
17.
Ensure dimension [28]is 4±1 mm. Use drill bit [29].
18.
If not: Slacken tensioner nut [19]. Turn tensioner pulley until dimension as specified [28]. Tighten tensioner nut [19].
Tightening torque: 20 Nm + 45°.
19.
Lock crankshaft sprocket [13]. Use tool No.T10050.
20.
Ensure timing marks aligned [14].
21.
Ensure camshaft locking tool can be inserted easily [15]. Tool No.3359.
22.
If not:
Remove lug of crankshaft sprocket locking tool from hole in oil seal housing.
Turn crankshaft until camshaft locking tool can be inserted [15]. Tool No.3359.
Slacken camshaft sprocket bolts [21].
Turn crankshaft anti-clockwise until lug of locking tool just passes hole in oil seal housing [30].
Turn crankshaft clockwise until lug and hole aligned.
Lock crankshaft sprocket [13]. Use tool No.T10050.
Tighten camshaft sprocket bolts [21]. Tightening torque: 25 Nm.
Remove locking tools [13] & [15]18151.
Turn crankshaft slowly two turns clockwise to TDC on No.1 cylinder.
Ensure locking tools can be fitted correctly [13] & [15].
23.
Remove:
Camshaft locking tool [15].
Crankshaft sprocket locking tool [13].
Drill bit [29].
24.
Install components in reverse order of removal.
25.
Tighten crankshaft pulley bolts [9]. Tightening torque: 10 Nm + 90°.
Manufacturer: Volkswagen
Model: Passat (01-) 1,9D TDI PD
© Autodata Limited 2004
2005-07-04
Engine code: AVB
Output: 74 (100) 4000
915802145.029.png 915802145.030.png 915802145.031.png 915802145.032.png 915802145.033.png 915802145.034.png 915802145.035.png
Manufacturer: Volkswagen
Model: Passat (01-) 1,9D TDI PD
© Autodata Limited 2004
2005-07-04
Engine code: AVB
Output: 74 (100) 4000
915802145.036.png 915802145.037.png 915802145.038.png

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