When it’s time to change the timing belt:Put your trust in the top-quality, precise components from RUVILLE, your system specialist also for the VW Passat 1.9 TDI engine.

Please comply with the general and specific repair instructions for the individual components.

Installation instructions for the specific vehicle:

Specific installation instructions must be heeded for all engine components of the VW Passat 1.9 TDI. These are described in greater detail below.

Basic installation instructions:

Use or replace self-locking nuts It is advisable to replace the screws Comply with the torques specified by the manufacturer Use specified special tools Comply with the recommended change intervals When replacing a defective part, check and replace surroundingcomponents if necessary

The engine may only turn on the crankshaft in the direction of rotation of the engine (clockwise)

Every new model or series entails new installation specifications for the engine. RUVILLE passes on all the latest know-how to garages: to find out more about our training courses, go to www.ruville.de, or contact our technical instructor Remo Schönsee directly by e-mail under rschoensee@ruville.de

PRACTICAL KNOW-HOW TRAINING

GENERAL INSTRUCTIONS ALL RUVILLE BELT DRIVE COMPONENTS FOR THE VW PASSAT 1.9 TDI

KNOW-HOW IN DETAIL CAN ALSO BE DOWNLOADED

FROM THE INTERNET:

WWW.RUVILLE.DE ➜ SERVICE ➜ DOWNLOADS

➜ TECHNICAL INFO FLYER

➜ ENGINE PARTS FOR THE VW PASSAT 1.9 TDI

INSTRUCTIONS FOR CERTAIN COMPONENTS

VW Passat 1.9 TDI

Article No.: Description

515408 Crankshaft damper

55451 o. 55470 Overrunning alternator pulley

55464 Tensioner pulley, V-ribbed belt

55465 Deflection/guide pulley, timing belt

55480 Belt tensioner, V-ribbed belt

5548080 V-ribbed belt set

55494 Tensioner pulley, timing belt

5549450 Pulley kit, timing belt

5549451 Pulley kit, timing belt

5549470 Timing belt kit

5549471 Timing belt kit

55494711 Water pump + timing belt kit

55495 Vibration damper, timing belt

55735 Deflection/guide pulley, timing belt

55739 Tensioner pulley, timing belt

5573950 Pulley kit, timing belt

5573970 Timing belt kit

55739704 Water pump + timing belt kit

56342 Deflection/guide pulley, V-ribbed belt

56343 Belt tensioner, V-ribbed belt

65409 Water pump

65432 Water pump

VW PASSAT 1.9 TDI

ENGINE

KNOW-HOW IN DETAIL PAGE 1

Article: 55465 | Deflection/guide pulley, timing belt 55494 | Tensioner pulley, timing belt 5549450 | Tensioner pulley, timing belt 5549451 | Tensioner pulley, timing belt 5549470 | Timing belt kit 5549471 | Timing belt kit 55494711 | Water pump + timing belt kit 55739704 | Water pump + timing belt kit 55495 | Vibration damper, timing belt 55735 | Deflection/guide pulley, timing belt 55739 | Tensioner pulley, timing belt 5573950 | Pulley kit, timing belt

When replacing the timing belt, it is advisable to replace all timing gear components: all rollers and also the water pump.

Used timing belts should not be used again.

For engines with the engine code ATJ, the fastening nuts and the set screw of the tension roller must be replaced. Ensure that the belt is taut in the pulling strand. Caution, the engine must be cold during installation.

One build year, two timing drive versions: In 2002 there were two different versions for the timing drive in the 1.9 TDI models: either with a hydraulic belt tension damping unit or with a mechanical tension roller. These are distinguished according to model year.

Tension roller with hydraulic Mechanical tension roller: belt tension damping unit:

Removing friction rust: In time, friction rust is caused in the timing belt drive as a result of micro-movements in the trigger wheel, generated by acceleration of the camshaft. This is purely superficial and does not jeopardise the service life of any of the affected parts. Even so, this friction rust in the timing belt drive should be removed with compressed air.

Note:The high forces transmitted by the timing belt can occasionally result in noises in the event of unfavourable tolerances of timing belt and belt wheels. This can apply particularly to new vehicles. However, in this case the noises will disappear again within approx. the first 5,000 km as a result of the run-ning-in effects. The noises are not detrimental to the expected service life of the timing belt. When such noises occur, do not carry out any repairs and do not change the tension of the timing belt! The nut of the tension roller may only be loosened when changing the timing belt.

VW PASSAT 1.9 TDI

ENGINE

Article: 515408 | Crankshaft damper 55451 or 55470 | Overrunning alternator pulley 55464 | Tensioner pulley, V-ribbed belt 55480 | Belt tensioner, V-ribbed belt 5548080 | V-ribbed belt set 56342 | Deflection/guide pulley, V-ribbed belt 56343 | Belt tensioner, V-ribbed belt

Rotational irregularity of the crankshaft generates strong dynamic move-ments in the accessory drive. These are normally minimised by overrunning alternator pulleys. If a rigid pulley or blocked overrunning pulley is fitted, in the worst case it is possible for noises to occur with subsequent breakage of the belt tensioner v-ribbed belt.

The alternator constitutes the greatest mass inertia in the system and therefore has a great impact on the whole accessory drive. If a faulty over-running alternator pulley has to be replaced, it is advisable to replace the other peripheral parts as well (deflection pulleys, belt tension damping unit, crankshaft dampers). Two versions of the overrunning alternator pulley are available for the different makes of alternator:

Overrunning alternator pulley for Bosch alternator:OE No. 028 903 119 TRUVILLE No. 55470 The washer must be fitted between overrunning alternator pulley and alternator.

Article: 515408 | Crankshaft damper

Hold the central screw with a ring spanner when loosening and tight-ening the vibration damper. It is advisable to use new fastening screws.

Article: 65409 | Water pump 65432 | Water pump 55494711 | Water pump + timing belt kit 55739704 | Water pump + timing belt kit

When replacing the water pump, flush and clean the whole cooling system before fitting the new pump. This prevents any dirt or corrosion particles from destroying the scraper ring sealing and/or impeller of the new water pump.

Under certain conditions, the coolant may change colour. The violet colour particles of the coolant additive can settle on various engine components. Discolouring of the coolant is harmless. However, the mixture ratio in the coolant circuit should be supplemented with 40 ccm undiluted G12.

Installation instructions: Always replace gaskets and seal rings. Clean respectively smoothen the sealing surface for O-rings and coat new O-rings with G12 (do not use lubricant or sealant) and insert coolant pump. Fill with coolant and vent the system.

Installation position: Housing plug points downwards (as illustrated).

Plug

Seal ring

Overrunning alternator pulleyfor Valeo alternator:OE No. 028 903 119 ACRUVILLE No. 55451

KNOW-HOW IN DETAIL PAGE 2