Passat Wagon L4-1.9L DSL Turbo (AAZ) (1996)
Timing Belt: Service and Repair
Special tools
2065A setting bar
3359 locating pin (engine code AAZ)
2064 lock pin (engine codes 1Z, AHU)
Matra V159 pin wrench or equivalent; e.g. Hazet 2587, US4493
Removing
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Remove ribbed belt.
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Remove ribbed belt tensioning roller (if installed).
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Remove upper toothed bell guard and valve cover.
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Set crankshaft to TDC for cylinder 1 and lock camshaft using 2065A setting bar.
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Center the 2065A setting bar as follows:
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Turn locked camshaft, with setting bar in place, until one end of setting bar touches cylinder head.
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Measure gap at other end of setting bar using feeler gauge.
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Select feeler gauge that is one half of measured gap, and temporarily install between setting bar and cylinder head.
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Turn camshaft so that setting bar is resting against feeler gauge then insert second feeler gauge of same thickness at other end between setting
bar and cylinder head.
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Lock injection pump sprocket using lock pin.
Engine code AAZ: 3359 rig pin
Engine codes 1Z, AHU. 2064 lock pin
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Loosen injection pump sprocket mounting bolts -1- (AAZ) or center bolt (1Z, AHU).
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Loosen tensioner roller.
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Remove vibration damper and belt pulley.
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Remove lower toothed belt guard.
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Clearly identify toothed belt running direction using felt marker.