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When its 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 andspeci c repair instructions
for the individualcomponents.
Installation instructions for the speci c vehicle:
Speci c installation instructions must be heeded for all engine
components ofthe 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 speci ed by the manufacturer Use
speci ed special tools Comply with the recommended change intervals
When replacing a defective part, check and replace surrounding
components 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 speci cations
for the engine.RUVILLE passes on all the latest know-how to
garages: to nd out more about
ur training courses, go to www.ruville.de, or contact our
technical instructorRemo Schnsee directly by e-mail under
[email protected]
PRACTICAL KNOW-HOW TRAINING
GENERAL INSTRUCTIONS ALL RUVILLE BELT DRIVE COMPONENTS FOR THE
VW PASSAT 1.9 TDI
K N O W - H O W IN D E T A IL C A N A LS O B E D O W
N LO A D E D
F R O M T H E IN T E R N E T:
W W W .R U V IL L E .D E S E R V IC E D O W N L
O A D S
T E C H N IC A L IN F O F L Y E R
E N G IN E P A R T S F O R T H E V W P A S S A T 1 . 9 T D I
NSTRUCTIONS 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 De ection/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 De ection/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 De ection/guide pulley, V-ribbed belt
56343 Belt tensioner, V-ribbed belt
65409 Water pump
65432 Water pump
V W P A S S A T 1 . 9 T D I
E N G IN E
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Article: 55465 | De ection/guide pulley, timing belt55494 |
Tensioner pulley, timing belt5549450 | Tensioner pulley, timing
belt5549451 | Tensioner pulley, timing belt5549470 | Timing belt
kit
5549471 | Timing belt kit55494711 | Water pump + timing belt
kit55739704 | Water pump + timing belt kit55495 | Vibration damper,
timing belt55735 | De ection/guide pulley, timing belt55739 |
Tensioner pulley, timing belt5573950 | Pulley kit, timing belt
When replacing the timing belt, it is advisable to replace all
timing gearcomponents: all rollers and also the water pump.
Used timing belts shouldnot be used again.
For engines with the engine
code ATJ, the fastening nutsand the set screw of thetension
roller must bereplaced. Ensure that thebelt is taut in the pulling
strand.Caution, the engine mustbe 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 TDImodels:
either with a hydraulic belt tension damping unit or with a
mechanicaltension 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 super cial and does not jeopardise the service
life of any ofthe affected parts. Even so, this friction rust in
the timing belt drive shouldbe removed with compressed air.
Note : The high forces transmitted by the timing belt can
occasionally result innoises in the event of unfavourable
tolerances of timing belt and belt wheels.
This can apply particularly to new vehicles. However, in this
case the noiseswill disappear again within approx. the rst 5,000 km
as a result of the run-ning-in effects. The noises are not
detrimental to the expected service life ofthe timing belt. When
such noises occur, do not carry out any repairs anddo not change
the tension of the timing belt! The nut of the tension rollermay
only be loosened when changing the timing belt.
V W P A S S A T 1 . 9 T D I
E N G IN E
Article: 515408 | Crankshaft damper 55451 or 55470 | Overrunning
alternator pulley
55464 | Tensioner pulley, V-ribbed belt55480 | Belt tensioner,
V-ribbed belt5548080 | V-ribbed belt set56342 | De ection/guide
pulley, V-ribbed belt
56343 | Belt tensioner, V-ribbed beltRotational irregularity of
the crankshaft generates strong dynamic move-ments in the accessory
drive. These are normally minimised by overrunningalternator
pulleys. If a rigid pulley or blocked overrunning pulley is tted,
inthe worst case it is possible for noises to occur with subsequent
breakageof the belt tensioner v-ribbed belt.
The alternator constitutes the greatest mass inertia in the
system andtherefore 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 theother peripheral parts as
well (de ection pulleys, belt tension damping unit,crankshaft
dampers). Two versions of the overrunning alternator pulleyare
available for the different makes of alternator:
Overrunning alternator pulleyfor Bosch alternator:OE No. 028 903
119 T RUVILLE No. 55470
The washer must be tted between overrunning alternator pulley
andalternator.
Article: 515408 | Crankshaft damper
Hold the central screw with a ringspanner when loosening and
tight-ening the vibration damper. It isadvisable to use new
fasteningscrews.
Article: 65409 | Water pump 65432 | Water pump
55494711 | Water pump + timing belt kit55739704 | Water pump +
timing belt kit
When replacing the water pump, ush and clean the whole cooling
systembefore tting the new pump. This prevents any dirt or
corrosion particlesfrom destroying the scraper ring sealing and/or
impeller of the new waterpump.
Under certain conditions, the coolant may change colour. The
violet colourparticles of the coolant additive can settle on
various engine components.Discolouring of the coolant is harmless.
However, the mixture ratio inthe coolant circuit should be
supplemented with 40 ccm undiluted G12.
Installation instructions: Always replace gaskets and sealrings.
Clean respectively smoothenthe sealing surface for O-ringsand coat
new O-rings with G12(do not use lubricant or sealant)and insert
coolant pump. Fill withcoolant and vent the system.
Installation position:Housing plug points downwards(as
illustrated).
Plug
Seal ring
Overrunning alternator pulley for Valeo alternator:OE No. 028
903 119 ACRUVILLE No. 55451
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