Скачать или смотреть VW Golf 4 1.9TDI How to Replace Timing Belt and Water Pump 1997-2004

Changing the timing belt (also known as the cambelt) on a VAG 1.9 TDI engine is a critical maintenance task. Since these are "interference engines," a belt failure results in the pistons hitting the valves, leading to a catastrophic engine breakdown.
​Here is the technical breakdown of the process in English.
​🛠️ Required Tools & Parts
​To do the job correctly and maintain "factory timing," you need specialized locking tools:
• ​Crankshaft Locking Tool: (e.g., T10050 or T10100 depending on whether your gear is round or oval).
• ​Camshaft Locking Pin/Plate: To keep the cam from rotating.
• ​Injection Pump Locking Pin: (Only for Non-PD engines like the ALH or ASV).
• ​Tensioner Spanner/Wrench: To adjust the tensioner pulley.
• ​Complete Kit: Timing belt, tensioner, idler pulleys, and a water pump.
​📝 Step-by-Step Procedure
​1. Access and Preparation
• ​Remove the engine cover and the acoustic tray (skid plate) underneath.
• ​Remove the serpentine (accessory) belt and the tensioner.
• ​Support the engine from below with a jack (use a wooden block to protect the oil pan) and remove the right-hand engine mount. This is necessary to access the belt covers.
​2. Setting to TDC (Top Dead Center)
• ​Rotate the engine by the crankshaft bolt clockwise only.
• ​Align the timing marks. On many 1.9 TDIs, you check the flywheel through a viewing hole in the transmission bell housing to find the "0" mark.
• ​Insert the crankshaft lock and the camshaft lock. If the tools don't fit perfectly, the timing is already slightly off.
​3. Belt Removal and Water Pump
• ​Loosen the nut on the tensioner pulley and turn the tensioner to release pressure.
• ​Slide the belt off.
• ​Pro Tip: Drain the coolant and replace the water pump now. It is driven by the timing belt, and if it fails later, you have to do the whole job again.
​4. Installation and Tensioning
• ​Install the new water pump and pulleys.
• ​Fit the new belt, starting from the crankshaft, then the water pump, then the camshaft.
• ​Tensioning: Turn the tensioner until the pointer aligns with the notch (the "window"). Tighten the nut to the specified torque.
​5. The "Two-Turn" Rule
• ​Remove all locking tools.
• ​Manually rotate the engine two full revolutions using a socket on the crankshaft bolt.
• ​Re-insert the locking tools. If they fit, your timing is perfect. If they don't, you must reset the timing. Never start the engine with the starter motor until you have done this manually.
​⚠️ Critical Specifications
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