timing_belt_replacement_interva1z_ahu_192.pdf

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Telephone:
Fax:
VAT Registration No.:
Name:
Manufacturer: Volkswagen
Address:
Model:
Year:
1996
Registration:
Tel - Private:
Mileage:
Tel - Business:
Job number:
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 Autodata CD.
http://www.autodata-cd.com
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: Sharan (95-00) 1,9D TDI
¨ Autodata Limited 2004
2005-11-01
Engine code: 1Z/AHU
Output: 66 (90) 4000
Tuned for:
Year: 1995-99
V5.373-
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Replacement Interval Guide
Volkswagen recommend:
Except AHH engine
2000MY: Check condition and width every 10,000 miles or 12 months, whichever occurs first (replacement width - 22 mm).
Replacement every 60,000 miles.
AHH engine
2000MY: Check condition and width every 10,000 miles or 12 months, whichever occurs first (replacement width - 22 mm).
2000MY : Check condition and tension every 20,000 miles.
Replacement every 60,000 miles.
The previous use and service history of the vehicle must always be taken into account.
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.
Repair Times - hrs
Sharan 1,9 TDI 1995-00
Remove and install 2,50
Special Tools
Support guides - No.3369.
Injection pump sprocket locking pin - No.2064.
Camshaft setting bar - No.2065A.
Two-pin wrench - Matra V.159.
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: Sharan (95-00) 1,9D TDI
¨ Autodata Limited 2004
2005-11-01
Engine code: 1Z/AHU
Output: 66 (90) 4000
Tuned for:
Year: 1995-99
V5.373-
116787701.016.png 116787701.001.png 116787701.002.png 116787701.003.png 116787701.004.png
Check diesel injection pump timing after belt replacement.
Removal
1.
Passat - remove:
Front bumper.
Air intake pipe between front panel and air filter.
Front panel bolts [13] & [14].
2.
Install support guides No.3369 in front panel [15].
3.
Slide front panel forward.
4.
Sharan:
Support engine.
Remove engine mounting.
5.
All models - remove:
Auxiliary drive belt.
Auxiliary drive belt tensioner.
Timing belt upper cover [1].
Cylinder head cover.
6.
Turn crankshaft to TDC on No.1 cylinder. Ensure flywheel timing marks aligned [2]- Passat or [16]- Sharan.
7.
Fit setting bar No.2065A to rear of camshaft [3]. Centralise camshaft using feeler gauges.
8.
Lock injection pump sprocket [4]. Use tool No.2064.
9.
Remove:
Crankshaft pulley bolts [5].
Crankshaft pulley [6].
Timing belt lower cover [7].
10.
Slacken tensioner nut [8]. Turn tensioner anti-clockwise away from belt. Lightly tighten nut.
11.
Remove:
Guide pulley [9].
Timing belt.
NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.
Installation
1.
Ensure flywheel timing marks aligned [2]- Passat or [16]- Sharan.
2.
Ensure camshaft setting bar fitted correctly [3].
3.
Ensure locking pin located correctly in injection pump sprocket [4].
4.
Slacken camshaft sprocket bolt 1/2 turn [10].
5.
Loosen sprocket from taper using a drift through hole in timing belt rear cover. Ensure sprocket can turn on taper.
6.
Fit timing belt in anti-clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets.
7.
Fit guide pulley [9]. Tighten bolt to 25 Nm.
8.
Remove locking pin from injection pump sprocket [4].
9.
Slacken tensioner nut [8].
10.
Turn automatic tensioner pulley clockwise until notch and raised mark on tensioner aligned [11]. Use wrench Matra V.159
[12].
11.
Tighten tensioner nut to 20 Nm [8].
12.
Ensure flywheel timing marks aligned [2]- Passat or [16]- Sharan.
13.
Tighten camshaft sprocket bolt to 45 Nm [10].
14.
Remove camshaft setting bar [3].
15.
Turn crankshaft two turns clockwise until timing marks aligned [2]- Passat or [16]- Sharan.
16.
Ensure camshaft setting bar can be fitted [3].
17.
Ensure locking pin can be inserted in injection pump sprocket [4].
18.
19.
Manufacturer: Volkswagen
Apply firm thumb pressure to belt. Tensioner marks should move out of alignment [11].
Model: Sharan (95-00) 1,9D TDI
¨ Autodata Limited 2004
2005-11-01
Engine code: 1Z/AHU
Output: 66 (90) 4000
Tuned for:
Year: 1995-99
V5.373-
116787701.005.png 116787701.006.png 116787701.007.png
19.
Release thumb pressure from belt. Tensioner marks should realign. If not: Repeat tensioning procedure.
20.
Install:
Timing belt lower cover [7].
Crankshaft pulley [6].
21.
Tighten crankshaft pulley bolts to 25 Nm [5].
22.
Install components in reverse order of removal.
Manufacturer: Volkswagen
Model: Sharan (95-00) 1,9D TDI
¨ Autodata Limited 2004
2005-11-01
Engine code: 1Z/AHU
Output: 66 (90) 4000
Tuned for:
Year: 1995-99
V5.373-
116787701.008.png 116787701.009.png
Manufacturer: Volkswagen
Model: Sharan (95-00) 1,9D TDI
¨ Autodata Limited 2004
2005-11-01
Engine code: 1Z/AHU
Output: 66 (90) 4000
Tuned for:
Year: 1995-99
V5.373-
116787701.010.png 116787701.011.png 116787701.012.png

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