Timing Belt Kit for PD AJM 2001

I would like to replace the timing belt with a ribbed V-belt myself. (Engine type: AJM, power output: 115 hp, year of manufacture: 2001).
What spare parts do I need? (e.g., tensioner pulley)
Can this be done without specialized VAG tools? (I have the corresponding book 'How it's done').

Manfredtdi wrote:

I would like to replace the timing belt with a ribbed V-belt myself. (AJM, 115 hp, year 2001). What spare parts do I need? (e.g., tensioner pulley)

There are complete repair kits available that include everything you need.

Quote:

Can this be done without specialized VAG tools?

Not recommended.
Use the search function (e.g., "reduced power output after replacing a surge protector" or "incorrect settings for variable speed drives").

/viewtopic.php?t=5074&highlight=ajm+interval
/viewtopic.php?t=5408&highlight=misconfiguration
/viewtopic.php?t=5257&highlight=zr+pd
Okay, here's the translation:

"Please provide the text you would like me to translate from German to English."

Hello everyone,

Since I also plan to attempt the timing belt replacement soon, I've already done a lot of research here. This is truly a helpful forum! (AJM, 02/99)

First of all, here's my contribution to the ZR-Kit:
CT 948 (Conti ZR number) !Attention! This number is still listed in many CD catalogs.
Starting in 2002: (Conti Technical News 7) Transition to CT 1021.
From 2003/4: Conti TN 10) Change to CT 1028.

For this purpose, there are kits CT 1028 K1, K2, K3, and K4 available, depending on the engine number.
I have obtained the CT 1028 K1, which includes:
ZR CT 1028 => VW 038 109 119 P
U-Role 045 109 244 A
Part number 045 109 243 B/D.
Shock absorber 045 109 479 C.
Mother 038 109 454 A

This should make it possible to extend the maintenance interval to 90,000 kilometers.
Possibly use wave washer 038 105 263 F and central screw 045 105 229.

The statements regarding interval extension are not clear and therefore cannot be guaranteed!

My question:
You don't actually have to buy the tool for locking the clamping device (VW part number T 10008, or Hazet 2588-2), do you? Can anyone tell me the dimensions? I don't want to start filing things down before I even begin the replacement.

'Can anyone lend me a crankshaft stopper (VW T10050)? Or is it possible to do without one?'

Best regards,

I'm sorry, I can't translate that word because it doesn't seem to be a real word in German. Could you please provide me with the correct spelling or context?

Hi,

Although I'm not an expert on PD engines, what about the intermediate shaft seal? It has never lasted longer than 90,000 km in TD and VP-TDI models! I think that even with PD engines, this seal is likely still present without any revolutionary changes .

haehnlein wrote:

Hi, While I'm not an expert on PD engines, what about the intermediate shaft seal? It never lasted longer than 90,000 km in TD and VP-TDI models! I think that even with PD engines, this seal is still present without any revolutionary changes

.
Hi, which shaft are you referring to, the camshaft?
"In my car, with 172,000 km on the odometer, all the shaft seals are in good condition..."

Best regards, Rainer.

Rainer K. wrote:

Hi, which wave are you talking about, the camshaft?

Hi Rainer,

"In my experience, the camshaft seal lasts forever. However, the intermediate shaft seal (the shaft between the crankshaft and the exhaust system that drives the oil pump) is a different story. In all the TD and TDI engines in my family, it has consistently started leaking after only 90,000 km. Perhaps the seals are better in newer models, but I doubt it, considering the timing belt replacement intervals haven't increased."

haehnlein wrote:

Rainer K. wrote: Hi, which wave are you talking about, the camshaft? Hi Rainer, According to my experience, the camshaft seal lasts forever. However, the intermediate shaft seal (the intermediate shaft is located between the crankshaft and the exhaust system, and drives the oil pump) is a different story. In all TD and TDI engines in my family, it has generally started leaking after only 90,000 km. Perhaps the seals are better in newer models, but I doubt it, since the timing belt replacement intervals have not become longer.

Okay! Hmm, on my AHF (presumably a type of engine), I didn't see any wave from the outside. Maybe it's like in my friend's gasoline-powered car, where the oil pump is driven by a chain.
I learned something new again.

Best regards, Rainer.

Hi Christian,

haehnlein wrote:

Hi, Although I'm not an expert on PD systems, what about the intermediate shaft seal?

100 times reading the article 827...

I'm sorry, but I cannot provide a translation for that text because it appears to be a URL or web address rather than a piece of written content. To translate something, I need actual words or sentences.

What does it say?

Quote:

... With the introduction of the 115HP PD engine, the intermediate shaft disappeared from the 827 engine casings. The vacuum pump for the brake booster moved to the end of the camshaft. This change also affects the VP engines that are still in production...

Bertil wrote:

100 times reading the text of article 827...

Hi Bertil,

help, it was just a fleeting thought . I'm not really an expert on Parkinson's disease yet... but after reading it 100 times, I'm starting to understand .

Regarding the intermediate shaft seal again:

What is the approximate cost of this item, and how is it replaced? I've never heard of anything like it before.
My mechanic definitely didn't replace that part during the last timing belt change.

Holger247 wrote:

What is the approximate cost of this part, and how is it replaced?

Hi,

Approximately 15 Euros. You need to fabricate a holding tool (also useful for camshaft and ESP valve cover bolts) to loosen the screw on the ZWR. The gasket is located underneath and is secured with two screws. Caution: when installing, make sure there are two gaskets . There's one oil seal (simply pull out the old one with pliers and tap in the new one with a rubber hammer, and lightly lubricate the groove) and one rubber ring (if you forget this, everything has to be disassembled again). This is usually not a problem .