VW 1.9 TDI Timing Belt Replacement

Want to learn how to change the timing belt on a 1.9 TDI engine?
In this video I try to go in to as much detail as possible regarding how to do it. It is a straight forward job, though you will need a special tool kit in order to lock the camshaft primarily. But also the injection pump.
Fear not, I got you covered with my affiliate link to the required tools below.
Hope you enjoy!
Support me on Patreon: / cactusapesgarage
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Important! Read below the Gates link!
Gates GAT4740 Tool Kit on Amazon:
geni.us/GAT4740
^ This tool kit seems to be out of stock alot on Amazon, so I have sourced another one if the one above is out-of-stock for you. The replacement kit has just about everything my Gates kit has:
Replacement Tool Kit:
geni.us/gRbcqJA .
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**Disclaimer: This guide is for a 1.9 TDI with a Bosch VE injection pump ONLY. If you have a PD engine or an earlier variant with a purely mechanical pump, then this guide will probably not help you.**
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Interested in starting your own KZbin channel or something similar?
Here's some affiliate links to my camera setup.
GoPro Hero 7 Black on Amazon:
geni.us/hQbVv
Rode SmartLav + Lavalier Mic on Amazon:
geni.us/qkqe
Boya BY-MM1 on Amazon:
geni.us/yfypU7
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[@babelonchabalala1690]

Thanks..... I have the AHF engine and it look exactly the same..... Did my timing belt 2 years ago and its almost time again to do so..... Just came to refresh my memory lol..... I have the OEM Cam sprocket with the locking hole so i dont think i need to remove the vacuum pump then.... My torque wrench was stolen when they broke into my car so i will just mark the bolts and nuts when installing back

[@KD0CAC]

Good video , hope to see the injection timing soon . Just picked up a 2003 1.9 TDI wagon .

[@cactusapesgarage6580]

It's been delayed for too long but it's out now. I imagine you might already have found how to do it elsewhere but I am terribly sorry for the long wait!

[@howtofrank502]

@@cactusapesgarage6580 I will be checking out, timing belt has 80k on my newly owned ALH golf. One owner car, got it for $1700 just before the fuel crisis! Been a great 10,000 miles so far

[@shanehoward8579]

I should have been listening harder during the first 15 seconds of the video when you mentioned this was an ALH. I was gearing up to do my AHU belt and noticed this had two timing belt idler pulleys vs the one pulley in my AHU kit. Had a mini panic attack and after searching around realized I indeed had all of my required parts.

[@rotaecho]

Curious, you had the cam lock in place, but you loosened the camshaft bolt without a counter-sink like you would with an AHU or some tension by leaving belt on could this cause damage having your camlock as your countersink? Unless I'm missing something. Thanks!

[@philippebartz8922]

i hope u will be uploading more content, greetings from germany and happy new year mate

[@cactusapesgarage6580]

Greetings! New video is out now. :) Happy New Year!

[@alanzarycki2621]

Is there a way to set the tension IF the metal square on the inner timing belt cover is missing? It’s as if it broke off.

[@conorjoelwagner5051]

Hey guys.....do u also have the 1.9 TDI PD 131hp engine over there in North America?

[@oddsock7100]

Excellent video, do you have the Gates part number for the belt and water pump kit please

[@rodrigozelaya5021]

Hey brother hope all is well, quick question where did you get the blue air hose? Thank you

[@DavinaTTV]

AWESOME VIDEO BRO, BRO MOMENT

[@benyounesmikanik4897]

Merci pour votre vidéo

[@ReparandomiAutocaravana]

Thank you so mucho! Very healpfull !!

[@noelconroy3647]

Hi I subbed your Awesome channel keep the good work up ✨👍🍺🍀

[@TheRetro161]

does the camshaft wheel not be wedged?

[@binagarten4667]

It is easy out of the engine the fung and games comes in situ!

[@roberthammond43]

Hi, this is an excellent video. I too replaced the flywheel with a single mass flywheel. So, I don’t think I have the flywheel timing mark either. What procedure did you use to get the crankshaft to TDC?

[@cactusapesgarage6580]

Hi! Thank you! I removed the injector for cylinder nr 1, stuck a welding rod in there ( but you can use a long screwdriver etc.), and rotated the crank till the rod stopped at its highest. Then you need to split the difference because it will stay at TDC for a few degrees of rotation on the crank. So find where it stops moving higher and starts moving down, adjust the crank to be in the middle of those two positions and you have TDC.

[@familyman831]

@@cactusapesgarage6580 clever

[@technocris1]

@@cactusapesgarage6580 Typical for any type of engine ! but even old flywheel had a sign of TDC !

[@Sensei948]

@@cactusapesgarage6580 Hello, why does the timing synchronization change from 1.2 on a cold engine to 0.4 on a warm 90 C? Is the timing correctly installed? 1.6 tdi cayc engine ....

[@bomark2002]

Is this a close procedure to a 2001 VW New Beetle 1.9tdi ALH engine?

[@todayintheshopbanksy5904]

My ARL 1.9 had a hole in the Cam Sprocket to lock it, no need to remove that one. Also I had a crankshaft locking tool on that crank too.

[@cactusapesgarage6580]

Ah true, since the ARL is a PD engine the procedure is a bit different. The kit i'm using and the procedure is for the older VE TDI engines.

[@todayintheshopbanksy5904]

@@cactusapesgarage6580 I'd love an ARL in a MK I caddy

[@cactusapesgarage6580]

@WhitwellMike B Yea that would be sweet. It is the VNT-17 turbo from an ARL that will be slapped onto my engine, resulting in more power and spooling up faster.

[@ashtonflowers9951]

I didnt quite catch how you adjust the timing if it was to be off...maybe someone can help with a link..great video!

[@cactusapesgarage6580]

You mean the timing of the pump with VCDS? (Because that is a clip i'm working on at the moment). Or do you mean that after rotating the crankshaft 2 revolutions the locking holes doesn't line up?

[@tonykollar6870]

In your opinion is this 1z most bullet proof vag engine? If you were to pick up one of 1.9 engines as far as reliability is concerned . Which one would you pick?

[@cactusapesgarage6580]

Personally I would choose any one of 1Z/AHU or ALH. The ALH is completely different to the other two (which are more or less the same) but they all are equally as sturdy and reliable. But I bet the ALH is easier to find on most markets as it's newer and i think they made more of those units. Sorry for the late reply!

[@joseirva3159]

Hello the code motor is ASV?

[@hritcucosmin9794]

Yesterday i changed my injection pump on a 99 1.9 tdi alh, and now it dosen't start, any reason why? Maybe the timing is not properli set?

[@hectorbernaldo8076]

Did you get rid of the power steering pump? Did you run a new serpentine belt? Shorter?

[@cactusapesgarage6580]

Originally I removed it and was going to find a shorter serpentine belt, but plans have changed and this is going to keep it's power steering :)

[@petruadrianpatrascu6239]

Hello,for converting to a single flywheel should I make any modifications?

[@cactusapesgarage6580]

Hi, I can't speak for all 1.9 TDI variations but on my ALH I did not have to do anything except for changing the flywheel. If you are going to chase more power from the engine I would suggest upgrading the clutch while you are there though.

[@petruadrianpatrascu6239]

@@cactusapesgarage6580 thanks. I have an ALH also.

[@mihaiilisei3971]

La cât se schimba distribuția la alh vw bora din 2000?

[@ibuildbikesOML]

What’s the link for the gates timing tool kit I can’t seem to find it that link in the description doesn’t work

[@cactusapesgarage6580]

I've found this kit that has everything my Gates kit has: geni.us/gRbcqJA . I imagine you might have already solved the issue though. Amazon doesn't seem to re-stock the Gates tool kit very often i've noticed. It is still available from Gates so they have not stopped making it at least.

[@raunosuhhinin16]

this should be basically the same as 1.9tdi 81kw afn from audia6? the toolkit will fit? thinking to buy

[@cactusapesgarage6580]

Yes, the gates toolkit I used is for all 1.9 TDi models. However, if you buy something other than the Gates toolkit I can't be certain of it. Good luck!

[@MsMad555]

Wich side is to remove nikt from crankshaft clock vise or opisie on timming bełt engine side nie to remove IT???

[@martinpoole1451]

Great video, but why remove the cam sprocket and injection pump sprocket?

[@cactusapesgarage6580]

Oh sorry, this TDI is being swapped into my Caddy mk1. I had to remove those sprockets because of the engine mount that appears under the tensioner. The inner plastic cover had to be bent out in order to cut a section of it. This is ofc nothing you would have to do on just a timing belt change! I'll look into it if I can add a bit of text explaining that part.

[@martinpoole1451]

@@cactusapesgarage6580 Ok thanks for the reply.

[@estewarrior1]

Why did you take out the two big sprockets?

[@cactusapesgarage6580]

I had to remove them in order to trim the inner plastic cover for the new engine mount that appears in the video at the time stamp: 6:12. It is NOT something that you need to do when replacing the timing belt. Sorry I thought I had mentioned that in the video but I see now that I haven't. I will pin a comment to make sure that other people can see the reason in the future. Thank you for bringing it to my attention!

[@AlesJezek-xw7po]

Super Labombastic Fantastic Školastic!!!👍👏🤘👃👂🦵💪🤝👀🫁🫀🧠💓😍🌹🏖️🏝️🌌🌍🪐🌠🐢🐒🦍🦧🐪🐫🦜🐠🐟🐳🐬🦀🦞🦐🐡🐙🦑🦪🍻🏍️⚓🧭🛢️⛽🚦🚀✈️🚜🚚🚢

[@cactusapesgarage6580]

**Regarding the Cam Sprocket and Injection Pump Sprocket being removed in the video, that is NOT something that you need to do for a regular timing belt replacement.** I did that in order to trim the inner plastic cover so it would clear the new engine mount at the time stamp: 6:12. So again, it is NOT something that you need to do when replacing the timing belt. I just want to make a correction of what I say at 00:05:00. I meant a Bosch VP37 Injection Pump, not the VP44 as that one is for a cummins engine.

[@damann2925]

the vp44 is also in the v6 tdi's. this 1.9 tdi engine is known as a VE, the pre PD.

[@RGV2300]

Thanks for clarifying this.

[@MrEdwinhardesty]

If you are just changing the injection pump, do you need to remove the cam shaft pulley? Obviously you must remove the injection pump pulley to get the pump out.

[@hchelfman]

I'm so glad you clarified this

[@HalfassDIY]

So much easier with engine out !

[@lonewolf031]

Good to know about the inspection cover, don't want to have the timing belt wear out then cause problems.

[@StrongFreeLovin]

What's the torque for harmonic balancer bolts?

[@cactusapesgarage6580]

18 ft lb or 24 Nm (24.4 Nm to be exact) for the harmonic balancer.

[@zaza-io1xm]

ტურბოძრავების 1,9 .1999წლის გასა

[@zaza-io1xm]

0

[@stephanegarnier7002]

perfect

[@cactusapesgarage6580]

Thank you!

[@Golfmk3tutorial]

Sonho 💝

[@benyounesmikanik4897]

Merci

[@cactusapesgarage6580]

Glad I could be of help!

[@atoutmeca4076]

Bonjour j’adore ce que tu fait j’ai aussi une chaîne KZbin français . À bientôt

[@cactusapesgarage6580]

Hello! Sry I can't reply in French, but google translate for the rescue. Thank you! Good luck with your own channel!

[@gagansidhugagana2590]

Where you from bro and happy new year 🇮🇳🇮🇳🇮🇳

[@cactusapesgarage6580]

Hello! I'm from Sweden. A little late reply perhaps but, Happy New Year and a good continuation! (The last part is a saying we have in Sweden)

[@petergabrielbloodofeden4025]

How to check TDI1.9 timing

[@walintondario6606]

This is a BEW or ALH engine?

[@cactusapesgarage6580]

It's an ALH engine :)

[@Dislxud_kid]

Where is the vibration dampener

[@jasonelliott9762]

Does the engine have to come out?

[@adivarso8175]

No, but you'll need to support the engine when you remove the engine mount to carry out the swap, also i'd advise you don't mess with the belt tensioner stud especially if its been in there a while they are notorious for bringing out some of the alloy threads from the block when you back it out, I've had 3 cambelts on mine and never changed that one tensioner stud if it strips the threads its a whole world of hurt having it heli coiled and then the anxiety of wondering if it'll hold. You can change the cambelt without removing the engine mount but i'd leave that to be used only in emergency.

[@cactusapesgarage6580]

As Adi Varso said, no the engine does not have to come out. Mine was out because of a different reason and while I had it out I thought that perhaps someone would benefit from a video like this. Plus it's easier to showcase everything with it out anyway. I agree with Adi Varso on the tensioner stud aswell, That thing is a nightmare, I am probably going to have to helicoil it and i'm NOT looking forward to it.

[@dieselmats]

The injection pump is a VP37 not a VP44.

[@cactusapesgarage6580]

You are absolutely correct! I have written that in my pinned comment on that video already though. :)

[@guilhermemarques101]

I was find it easier to put the upper roller after I put on the timing belt

[@cactusapesgarage6580]

True, thats probably a better way of doing it!

[@charleshealy341]

This is much different then the 2004 model BEW PD engine that I have in my Volkswagen Golf. My main problem has been that the motor mount bracket that bolts to the front of the block with three long bolts, will simply not remove from the engine compartment. It's plenty loose but the thing is more than 4 inches wide, and it will not remove. Every indication is that I am going to have to pull the engine out of the car, simply to be able to remove the motor mount bracket. The new belt will not install, because the inner finger of the bracket is inside the loop of the timing belt. It is simply impossible to change, without lifting the engine out of the car. Does anyone have any suggestions?

[@cactusapesgarage6580]

You might have already solved this issue, but to anyone else; It might be possible to un-bolt the engine mount(s) on the timing belt side of the engine and then raise or lower the engine to be able to remove the mount in question here.

[@jonbuh1440]

You can also place a scissor jack behind the egr valve against the bulkhead and jack the engine forward away from the bulkhead, this gives you room to remove the bracket. No need to remove the engine entirely.

[@witoldgruzowty]

Look here kzbin.info/www/bejne/ooDRYZeAidOXaMk around 29

[@mountaindewFTW45]

Could of explained the timing of the camshaft with the fuel pump and crank shatft

[@cactusapesgarage6580]

That is on my to do-list as soon as the engine is fired up again. I wasn't expecting it to be delayed as much as it has, then I would have waited with releasing this video. But you are right and i'm sorry for the inconvenience.

[@johnsilvernale6472]

It's a lot easier with the engine sitting on the floor...a bit more difficult with the motor installed in a vehicle

[@cactusapesgarage6580]

You are absolutely correct! However I would not have been able to angle the camera as well if it had done this video with the engine installed, atleast this way people who are looking to do this by themselves know what to look for despite it being tighter in the engine bay. The procedure is still exactly the same and (at least on the vehicle this came from) the only thing needing to be removed prior to this is the intake pipes (one by the vacuum pump and the other in front of the timing belt cover. Some other models might have the air filter housing in the way too.

[@johnsilvernale6472]

@@cactusapesgarage6580 right on Also motor mount can be a bitch

[@adivarso8175]

@@johnsilvernale6472 you can do it without removing motor mount but i'd only advise that if it was an emergency such as the mount wont come off.

[@familyman831]

Can you send me a link to the 1.9tdi tool set to lock the engine up please.

[@cactusapesgarage6580]

This kit that has everything my Gates kit has: geni.us/gRbcqJA . The Gates kit i'm using is out of stock more often than in stock on Amazon. Hope this helps if you haven't already solved it!

[@halilkorudjiiski5091]

I did the change in the same way, but the belt now whistles

[@cactusapesgarage6580]

Did you rotate the tensioner so that the pin was by the slot? After rotating the engine twice when you were done, did you re-check that the tensioner pin hadn't moved away from the slot? If there is enough slack in the belt between just two of the gears that could affect the tension after it has rotated a few turns.

[@hylndrfan]

Any reason not to lock the crankshaft sprocket?

[@cactusapesgarage6580]

None at all! If your kit has the locking tool, use it to make sure your crank doesn't turn.

[@laszapasde_sergio7739]

Asv engine?

[@cactusapesgarage6580]

This is an ALH engine, but the ASV is very similar to this from what I've read.

[@adivarso8175]

@@cactusapesgarage6580 ASV similar apart from some little things but there is a major difference....ASV has oil jets for cooling the pistons.. :)

[@dieterdoedel]

Motor unbedingt zweimal durchdrehen und alle Markierungen nochmal überprüfen. Zahnriemen eventuell nochmal nachspannen.

[@StrongFreeLovin]

5:44 >Says not to remove the screws >Doesn't elaborate why >Removes them anyway

[@cactusapesgarage6580]

Yes sorry about that, forgot to mention why I removed them in the actual video. But I did however pin a comment as to why. The reason is that I needed to remove the rear timing cover to trim it, since this engine is going in a caddy mk1. The making of this timing belt video was an afterthought and not the original purpose of the raw clips, hence why it isn't really as coherent as I would like it to be.

[@sunnytabone6200]

sdi engen

[@bwalsh6992]

Why did they make it so complicated..

[@cactusapesgarage6580]

You know, german engineering. For ex. Thats why I have marked my crankshaft sprocket at tdc, who wants to look at the flywheel in order to set it up.

[@dalescott6409]

you absolutely don't have to remove the cam sprocket or injection pump and you absolutely don't have to adjust the IQ after doing a tb

[@cactusapesgarage6580]

Technically, you should. Sure, the engine will run even if you skip those steps, but potentially not as good as it could. The engine is designed to allow for the cam and injection pump sprocket to be rotated when tensioning the belt. If you don't allow it to do that, by loosening said sprockets, then what do you think will happen when you remove the locking pins? The tensioned belt will pull the camshaft and pump counter-clockwise by some degree. Thus potentially making the engine run worse, you may not notice it, but that will most likely happen. It takes a maximum of 5 more minutes of doing it the correct way. You can be lazy and do shoddy mechanics all you want, but imo you shouldn't teach it to others.. especially not potential beginners. Regarding the IQ, I think I mentioned that it is a good idea to check it IF it needs an adjustment. However it was years ago that I made this clip so I'll have to watch it to make sure.

[@MrKarthik18]

Much complicated. Like a open heart by pass surgery 😭

[@bomark2002]

😅😅😅