VW Passat 1.

9 TDI
VW PASSAT 1.9 TDI
Engine

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 and
specific repair instructions for the individual
components.

GENERAL INSTRUCTIONS
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 surrounding
components if necessary
The engine may only turn on the crankshaft in the direction of rotation of
the engine (clockwise)

INSTRUCTIONS FOR CERTAIN COMPONENTS

ALL RUVILLE BELT DRIVE COMPONENTS FOR THE

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

Installation instructions for the specific vehicle:

55494711

Water pump + timing belt kit

Specific installation instructions must be heeded for all engine components of

the VW Passat 1.9 TDI. These are described in greater detail below.

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

PRACTICAL KNOW-HOW TRAINING

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 Schnsee directly by e-mail under rschoensee@ruville.de

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ENGINE PARTS FO

Know-how in detail

Page 1

VW PASSAT 1.9 TDI

ENGINE

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.

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.

Plug
Seal ring

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

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
belt tension damping unit:

Article: 65409
| Water pump

65432
| Water pump

55494711 | Water pump + timing belt kit

55739704 | Water pump + timing belt kit

Mechanical tension roller:

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 movements 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.

Removing friction rust:

In time, friction rust is caused in the timing belt drive as a result of micromovements 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 running-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.

The alternator constitutes the greatest mass inertia in the system and
therefore has a great impact on the whole accessory drive. If a faulty overrunning 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 T
RUVILLE No. 55470

Overrunning alternator pulley

for Valeo alternator:
OE No. 028 903 119 AC
RUVILLE No. 55451

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 tightening the vibration damper. It is
advisable to use new fastening
screws.

Know-how in detail

Page 2