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How to Replace timing belt on VW Golf 4 1.9 SDI

Published September 9, 2015

Replacement Interval Guide

  • Volkswagen recommend:
  • All models
  • →2000MY: Check condition and width every 10,000 miles or 12 months, whichever occurs first.
  • Polo/Classic/Caddy
  • ALH, AT: Check timing belt and tensioner pulley every 20,000 miles.
  • Replacement every 60,000 miles.
  • Golf/Bora
  • →2001MY: Replacement every 60,000 miles.
  • 2002MY: Replacement every 80,000 miles (guide pulley must also be replaced – part No.038109244H with part No.038109244M).
  • 2003MY→: Replacement every 90,000 miles.
  • Beetle
  • →2001MY: Replacement every 60,000 miles.
  • 2002MY: Replacement every 80,000 miles (guide pulley must also be replaced – part No.038109244H with part No.038109244M).
  • 2003MY→: Replacement every 100,000 miles.

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(s).

Repair Times – hrs

Remove & install:
Polo/Classic 2,50
Golf/Bora SDI 2,50
Golf/Bora TDI/Beetle 3,30
Caddy SDI 1,90
Caddy TDI 2,50

Special Tools

  • Camshaft setting bar – No.3418/T10098.
  • Injection pump locking pin – No.3359.
  • Sprocket holding tool – No.3036.
  • Two-pin wrench – Matra V.159 – TDI.
  • Puller – No.T40001.

Special Precautions

  • Disconnect battery earth lead.
  • DO NOT turn crankshaft or camshaft when timing belt removed.
  • Remove glow 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.
  • Check diesel injection pump timing after belt replacement.
How to Replace timing belt on VW Golf 4 1.9 SDI
How to Replace timing belt on VW Golf 4 1.9 SDI

Removal

  1. Raise and support front of vehicle.
  2. Remove:
      • RH headlamp (Golf/Bora).
      • Coolant expansion tank. DO NOT disconnect hoses (Golf/Bora).
      • PAS reservoir. DO NOT disconnect hoses (Golf/Bora).
      • RH engine undershield (Golf/Bora).
      • Fuel filter and bracket (Beetle).
      • Engine undershield (Beetle).
      • Intercooler to intake manifold hose.
      • Timing belt upper cover [1] .
      • Vacuum pump.
      • Engine undershield (if fitted).
      • Auxiliary drive belt.
  3. Remove – if using camshaft setting bar No.3418:
      • Polo Classic/Caddy SDI: Inlet manifold upper chamber.
      • Cylinder head cover.
  4. Turn crankshaft to TDC on No.1 cylinder.
  5. Ensure timing marks aligned. MT: [2] . AT: [3] .
  6. Fit setting bar to rear of camshaft:
      • Tool No.3418 [4] . Centralise camshaft using feeler gauges.
      • Or tool No.T10098 [20] .
  7. Lock injection pump. Use tool No.3359 [5] .
  8. Slacken injection pump sprocket bolts [6] .NOTE: DO NOT slacken injection pump hub nut.
  9. Golf/Bora/Beetle: Support engine.
  10. Golf/Bora/Beetle: Remove:
      • RH engine mounting bolts [7] , [8] & [9] .
      • RH engine mounting.
      • Engine mounting bracket bolts [10] .
      • Engine mounting bracket.
  11. Remove:
      • Crankshaft pulley bolts [11] .
      • Crankshaft pulley [12] .
      • Timing belt centre cover [13] .
      • Timing belt lower cover [14] .
  12. Slacken tensioner nut [15] .
  13. SDI: Turn tensioner anti-clockwise away from belt. Use Allen key.
  14. TDI: Turn tensioner anti-clockwise away from belt. Use wrench Matra V.159.
  15. Lightly tighten tensioner nut [15] .
  16. Remove timing belt.NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

Installation

IMPORTANT: DO NOT reuse old belt if width is less than 22 mm.

  1. Ensure timing marks aligned. MT: [2] . AT: [3] .
  2. Ensure camshaft setting bar fitted correctly [4] or [20] .
  3. Ensure locking pin located correctly in injection pump [5] .
  4. Hold camshaft sprocket. Use tool No.3036.
  5. Slacken camshaft sprocket bolt one turn [16] .NOTE: DO NOT use setting bar to hold camshaft when slackening sprocket bolt.
  6. Loosen sprocket from taper.
      • Method 1: Use drift through hole in timing belt rear cover.
      • Method 2: Use puller. Tool No.T40001.
  7. Remove:
      • Camshaft sprocket bolt [16] .
      • Camshaft sprocket.
  8. Remove bolts from injection pump sprocket [6] . Proceed as follows:
      • Injection pump sprocket 038 130 111A: Bolts with pointed ends – type A. Fit new bolts.
      • Injection pump sprocket 038 130 111B: Bolts with flat ends – type B. Bolts can be re-used.
  9. Align injection pump sprocket with bolts in centre of slotted holes.
  10. Fit timing belt in following order:
      • Crankshaft sprocket.
      • Guide pulley G1.
      • Water pump sprocket.
      • Injection pump sprocket.
      • Guide pulley G2 – TDI.
      • Tensioner pulley.
      • Guide pulley G3.

    NOTE: Turn injection pump sprocket slightly to engage timing belt teeth.

  11. Ensure belt is taut between sprockets.
  12. Fit camshaft sprocket to belt, then install camshaft sprocket with belt onto end of camshaft.
  13. Fit camshaft sprocket bolt [16] .
  14. Lightly tighten camshaft sprocket bolt [16] . Sprocket should turn freely without tilting.
  15. Slacken tensioner nut [15] .
  16. SDI: Turn tensioner pulley clockwise until pointer and notch in baseplate aligned [17] . Use Allen key.
  17. TDI: Turn tensioner pulley clockwise as follows:
      • ALH, AT: Pointer and raised section of tensioner baseplate aligned [18] . Use Allen key.
      • Except ALH, AT: Notch and raised mark on tensioner aligned [19] . Use wrench Matra V.159.
  18. If tensioner pulley turned too far: Turn fully anti-clockwise and repeat tensioning procedure.
  19. Tighten tensioner nut to 20 Nm [15] .NOTE: Ensure tensioner retaining lug is properly engaged.
  20. Ensure timing marks aligned. MT: [2] . AT: [3] .
  21. Hold camshaft sprocket. Use tool No.3036.
  22. Tighten camshaft sprocket bolt to 45 Nm [16] .
  23. Tighten injection pump sprocket bolts [6] .
      • Type A: Temporarily tighten to 20 Nm.NOTE: Tighten bolts a further 90° after checking pump timing using diagnostic equipment.
      • Type B: Tighten to 25 Nm.
  24. Remove:
      • Camshaft setting bar [4] or [20] . Tool No.3418/T10098.
      • Injection pump locking pin [5] . Tool No.3359.
  25. Turn crankshaft two turns clockwise until timing marks aligned. MT: [2] . AT: [3] .
  26. Ensure camshaft setting bar can be fitted [4] or [20] .
  27. Ensure locking pin can be inserted in injection pump [5] .
  28. SDI: Ensure pointer aligned with notch [17] in baseplate.
  29. TDI: ALH, AT: Pointer and raised section of tensioner baseplate aligned [18] . Except ALH, AT: Ensure notch and raised mark on tensioner aligned [19] .
  30. If not: Repeat tensioning procedure.
  31. Apply firm thumb pressure to belt. Tensioner marks should move out of alignment [17] , [18] or [19] .
  32. Release thumb pressure from belt. Tensioner marks should follow movement of belt.
  33. Install components in reverse order of removal.
  34. Tighten crankshaft pulley bolts [11] . Tightening torque: 10 Nm + 90°.
  35. Golf/Bora/Beetle: Tighten RH engine mounting bracket bolts to 45 Nm [10] .
  36. Golf/Bora/Beetle: Fit and align RH engine mounting:
      • Engine mounting clearance: 14 mm [21] .
      • Engine mounting clearance: 10 mm [22] .
      • Ensure engine mounting bolts [7] aligned with edge of mounting [23] .
  37. Golf/Bora/Beetle: Tighten:
      • Engine mounting bolts [9] . Tightening torque: 40 Nm + 90°. Use new bolts.
      • Engine mounting bolts [8] . Tightening torque: 25 Nm.
      • Engine mounting bolts [7] . Tightening torque: 100 Nm.
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Published in Golf 4