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How to Replace timing belt on VW Golf 4 1.6 FSI

Replacement Interval Guide

  • Volkswagen recommend check at the first 60,000 miles and then every 20,000 miles (replace if necessary).
  • The vehicle manufacturer has not recommended a timing belt replacement interval for this engine.

NOTE: Volkswagen UK recommend the timing belt is replaced every 4 years.

  • 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(s).

Repair Times – hrs

Remove & install 2,20

Special Tools

  • Camshaft locking tools – No.T10074.
  • Crankshaft pulley holding tool – No.3415.

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.

Timing Belt

How to Replace timing belt on VW Golf 4 1.6 FSI
How to Replace timing belt on VW Golf 4 1.6 FSI

Removal

  1. Raise and support front of vehicle.
  2. Remove:
      • Engine upper cover.
      • Timing belt upper cover [1] .
      • RH engine undershield.
      • Auxiliary drive belt.NOTE: Mark direction of rotation on belt with chalk if belt is to be replaced.
  3. Support engine.
  4. Remove:
      • Coolant expansion tank. DO NOT disconnect hoses.
      • PAS reservoir. DO NOT disconnect hoses.
      • Upper bolt from timing belt lower cover.
      • RH engine mounting.
      • RH engine mounting bracket.
  5. Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure timing marks on crankshaft pulley aligned [2] .
  6. Ensure camshaft sprocket locating holes aligned [3] .
  7. If locating holes not aligned: Turn crankshaft one turn clockwise.
  8. Fit crankshaft pulley holding tool. Tool No.3415.
  9. Slacken crankshaft pulley bolt [4] .
  10. Remove:
      • Holding tool. Tool No.3415.
      • Crankshaft pulley bolt [4] .
      • Crankshaft pulley [5] .
  11. Fit two washers to crankshaft pulley bolt [4] .
  12. Fit crankshaft pulley bolt [4] . Lightly tighten bolt.
  13. Remove:
      • Auxiliary drive belt tensioner pulley (models with AC).
      • Timing belt lower cover [6] .
  14. Ensure timing mark aligned [7] .NOTE: Align ground tooth on crankshaft sprocket.
  15. Install locking tools to camshaft sprockets [8] . Tool No.T10074.NOTE: Ensure locking tools located correctly in cylinder head.
  16. Slacken tensioner pulley bolt [9] .
  17. Turn tensioner pulley anti-clockwise to release tension on belt.
  18. Remove timing belt.NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

Installation

  1. Ensure locking tools fitted to camshaft sprockets [8] .
  2. Ensure timing mark aligned [7] .NOTE: Align ground tooth on crankshaft sprocket.
  3. Remove:
      • Guide pulley bolt [10] .
      • Guide pulley [11] .
  4. Tighten tensioner pulley bolt finger tight [9] . Ensure baseplate is supported by bolt [12] .
  5. Fit timing belt in anti-clockwise direction, starting at water pump sprocket.
  6. Fit:
      • Guide pulley [11] .
      • Guide pulley bolt [10] .
  7. Tighten guide pulley bolt [10] . Tightening torque: 50 Nm.
  8. Turn tensioner pulley clockwise [13] until pointer [14] aligned with notch [15] in baseplate.
  9. Tighten tensioner pulley bolt to 20 Nm [9] .
  10. Remove locking tools from camshaft sprockets [8] .
  11. Turn crankshaft two turns clockwise to TDC on No.1 cylinder. Ensure timing mark aligned [7] .
  12. Ensure locking tools can be inserted into camshaft sprockets [8] .
  13. Ensure pointer [14] aligned with notch [15] in baseplate.
  14. If not: Repeat tensioning procedure.
  15. Apply firm thumb pressure to belt at warning. Pointer [14] and notch [15] in baseplate must move apart.
  16. Release thumb pressure from belt at warning.
  17. Turn crankshaft two turns clockwise to TDC on No.1 cylinder. Ensure timing mark aligned [7] .
  18. Ensure pointer [14] aligned with notch [15] in baseplate.
  19. Remove crankshaft pulley bolt [4] .
  20. Install:
      • Timing belt lower cover [6] .
      • Crankshaft pulley [5] .
      • New oiled crankshaft pulley bolt [4] .
  21. Fit crankshaft pulley holding tool. Tool No.3415.
  22. Tighten crankshaft pulley bolt [4] . Tightening torque: 90 Nm + 90°.
  23. Remove holding tool. Tool No.3415.
  24. Install components in reverse order of removal.
  25. Tighten bolts securing engine mounting bracket to engine. Tightening torque: 50 Nm.
  26. Tighten engine mounting:
      • Long bolts securing engine mounting to body – 40 Nm + 90°. Use new bolts.
      • Short bolts securing engine mounting to body – 25 Nm.
      • Bolts securing engine mounting to engine mounting bracket – 100 Nm.

Exhaust Camshaft Drive Belt

Removal

  1. Remove timing belt as described previously.
  2. Slacken tensioner pulley bolt [16] .
  3. Turn tensioner pulley clockwise to release tension on belt.
  4. Remove:
      • Tensioner pulley bolt [16] .
      • Tensioner pulley [17] .
      • Drive belt.NOTE: Mark direction of rotation on belt with chalk if belt is to be replaced.

Installation

  1. Ensure locking tools fitted to camshaft sprockets [8] . Tool No.T10074.
  2. Fit drive belt in clockwise direction, starting at top of inlet camshaft sprocket.
  3. Ensure belt is taut between sprockets on non-tensioned side.
  4. Turn tensioner pulley clockwise until pointer in position as shown [18] .
  5. Install:
      • Tensioner pulley [17] .
      • Tensioner pulley bolt [16] .
  6. Tighten tensioner pulley bolt finger tight [16] .NOTE: Ensure lug [19] in baseplate is located in cylinder head hole.
  7. Turn tensioner anti-clockwise [20] until pointer [21] aligned with lug [19] in baseplate.
  8. Tighten tensioner pulley bolt to 20 Nm [16] .
  9. Fit timing belt as described previously.
  10. Remove locking tools from camshaft sprockets [8] .
  11. Turn crankshaft two turns clockwise to TDC on No.1 cylinder. Ensure timing mark aligned [7] .
  12. Ensure locking tools can be inserted into camshaft sprockets [8] .
  13. Ensure pointer [21] aligned with lug [19] in baseplate.
  14. If not: Repeat tensioning procedure.
  15. Apply firm thumb pressure to belt at warning. Pointer [21] and lug [19] in baseplate must move apart.
  16. Release thumb pressure from belt at warning.
  17. Turn crankshaft two turns clockwise to TDC on No.1 cylinder.
  18. Ensure pointer [21] aligned with lug [19] in baseplate.
  19. Install components in reverse order of removal.

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