How to Replace timing belt on VW Golf 4 1.8 T

Replacement Interval Guide

• Volkswagen recommend:
• Check at the first 60,000 miles and then every 20,000 miles (replace if necessary).
• Replacement every 120,000 miles (tensioner pulley must also be replaced).

NOTE: Volkswagen UK recommend the timing belt is replaced every 4 years if the replacement mileage is not reached.

• The previous use and service history of the vehicle must always be taken into account.

Check For Engine Damage

CAUTION: This engine has been identified as an INTERFERENCE engine in which the possibility of valve-to-piston damage in the event of a timing belt failure is MOST LIKELY to occur. A compression check of all cylinders should be performed before removing the cylinder head.

Repair Times – hrs

Remove & install

2,20

Special Tools

• 1 x M5 x 55 mm stud and nut.

Special Precautions

• Disconnect battery earth lead.
• DO NOT turn crankshaft or camshaft when timing belt removed.
• Remove spark plugs to ease turning engine.
• Turn engine in normal direction of rotation (unless otherwise stated).
• DO NOT turn engine via camshaft or other sprockets.
• Observe all tightening torques.

Removal

1. Raise and support front of vehicle.
2. Remove:
   • Engine upper cover.
   • RH engine undershield.
   • Golf/Bora: RH headlamp.
   • Intercooler to turbocharger hose.
   • Auxiliary drive belt.
   • Auxiliary drive belt tensioner [1] .
3. Turn crankshaft to TDC on No.1 cylinder.
4. Ensure timing marks aligned [2] or [3] .
5. Remove:
   • Coolant expansion tank. DO NOT disconnect hoses.
   • PAS reservoir. DO NOT disconnect hoses.
   • Fuel vapour hose from charcoal canister to throttle body.
   • Timing belt upper cover [5] .
6. Ensure camshaft sprocket timing marks aligned [4] .
7. Support engine.
8. Remove:
   • RH engine mounting bolts [6] , [7] & [8] .
   • RH engine mounting.
   • Engine mounting bracket bolts [9] .
   • Engine mounting bracket.
   • Crankshaft pulley bolts [10] .
   • Crankshaft pulley [11] .
   • Timing belt centre cover [12] .
   • Timing belt lower cover [13] .
9. Insert M5 stud into tensioner [14] .
10. Fit nut and washer to stud [15] . Tighten nut sufficiently to allow a suitable locking pin to be inserted [16] .

    NOTE: DO NOT overtighten nut.

11. Remove timing belt.

    NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

Installation

1. Ensure timing marks aligned [3] & [4] .
2. Fit timing belt in following order:
   • Crankshaft sprocket.
   • Water pump sprocket.
   • Tensioner pulley.
   • Camshaft sprocket.

   NOTE: Ensure belt is taut between sprockets on non-tensioned side.

3. Remove locking pin [16] .
4. Remove nut and stud [14] & [15] .
5. Turn crankshaft two turns clockwise. Ensure timing marks aligned [3] & [4] .
6. Fit engine mounting bracket.
7. Tighten engine mounting bracket bolts to 45 Nm [9] .
8. Install:
   • Timing belt lower cover [13] .
   • Crankshaft pulley [11] .
   • Crankshaft pulley bolts [10] .
9. Tighten crankshaft pulley bolts [10] . Tightening torque: 25 Nm.
10. Fit engine mounting.
11. Tighten:
    • Engine mounting bolts [8] . Tightening torque: 40 Nm + 90°. Use new bolts.
    • Engine mounting bolts [7] . Tightening torque: 25 Nm.
    • Engine mounting bolts [6] . Tightening torque: 60 Nm + 90°. Use new bolts.
12. Check engine mounting alignment:
    • Engine mounting clearance: 14 mm [17] .
    • Engine mounting clearance: 10 mm minimum [18] .
    • Ensure engine mounting bolts [6] aligned with edge of mounting [19] .
13. Install components in reverse order of removal.