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How to Replace timing belt on VW Golf 4 1.9 TDI and 4Motion

Published September 9, 2015

Replacement Interval Guide

  • Volkswagen recommend:
  • Fox:
  • →2007MY: Replacement every 60,000 miles.
  • 2008MY→: Replacement every 93,205 miles.
  • Lupo/Golf/Bora/Beetle:
  • →2003MY: Replacement every 60,000 miles (tensioner pulley must also be replaced).
  • 2004MY→: Replace timing belt every 80,000 miles.
  • Replace tensioner pulley every 160,000 miles.
  • Polo:
  • →2003MY: Replacement every 60,000 miles (tensioner pulley must also be replaced).
  • 2004-2006MY: Replace timing belt every 80,000 miles.
  • Replace tensioner pulley every 160,000 miles.
  • 2007MY→: Replace timing belt every 100,000 miles.
  • Replace tensioner pulley every 200,000 miles
  • Sharan – ANU/AUY engines:
  • →2003MY: Replacement every 40,000 miles (tensioner pulley must also be replaced).
  • 2004MY→: Replace timing belt every 60,000 miles.
  • Replace tensioner pulley every 120,000 miles.
  • Sharan – ASZ/BTB/BVK engines:
  • Replace timing belt every 60,000 miles.
  • Replace tensioner pulley every 120,000 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:
Lupo 2,20
Fox/Polo 2,50
Golf/Bora/Beetle/Sharan 2,90

Special Tools

  • Auxiliary drive belt tensioner locking pin – Volkswagen No.T10060.
  • Camshaft locking tool – Volkswagen No.3359.
  • Camshaft sprocket holding tool – Volkswagen No.T10172/4.
  • Crankshaft sprocket locking tool – Volkswagen No.T10050.
  • Tensioner pulley locking pin – Volkswagen No.T10115.
  • Two-pin wrench – Volkswagen No.3387 or T10004 or T10020.

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.
How to Replace timing belt on VW Golf 4 1.9 TDI and 4Motion
How to Replace timing belt on VW Golf 4 1.9 TDI and 4Motion

Removal

  1. Raise and support front of vehicle.
  2. Remove:
      • Engine undershield.
      • Engine top cover.
      • Golf/Bora: RH headlamp (if required).
      • Turbocharger/intercooler air hose(s) (as required).
      • Lupo: Mass air flow (MAF) sensor.
      • Lupo: Engine/gearbox steady bar.
      • Sharan: Air filter housing.
      • RH wheel arch liner (if required).
      • Auxiliary drive belt. Use tool No.T10060.
      • Auxiliary drive belt tensioner (if required).
      • Golf/Bora/Beetle: Coolant expansion tank. DO NOT disconnect hoses.
      • Golf/Bora: PAS reservoir. DO NOT disconnect hoses.
      • Beetle: Fuel filter bracket.
      • Timing belt upper cover [1] .
  3. Lupo/Golf/Bora: Detach fuel pipes from cylinder head cover.WARNING: Fuel may be under high pressure and very hot.
  4. Support engine.
  5. Remove:
      • Polo: RH engine mounting intermediate bracket.
      • All other models: RH engine mounting.
      • RH engine mounting bracket.
      • Crankshaft pulley bolts [2] .
      • Crankshaft pulley [3] .
      • Timing belt centre cover [4] .
      • Timing belt lower cover [5] .

    NOTE: Engine may need to be raised/lowered slightly.

  6. Turn crankshaft clockwise to TDC on No.1 cylinder.
  7. Ensure timing mark aligned with notch on camshaft sprocket hub:
      • 3 cylinder engines: 3Z [6] .
      • 4 cylinder engines: 4Z [7] .

    NOTE: Notch located behind camshaft sprocket teeth.

  8. Lock crankshaft sprocket. Use tool No.T10050 [8] .
  9. Ensure timing marks aligned [9] .
  10. Lock camshaft. Use tool No.3359 [10] .
  11. Slacken tensioner pulley nut [11] .
  12. Slacken camshaft sprocket bolts [12] .NOTE: Slacken bolts until sprocket can be moved within slotted holes.
  13. Turn tensioner pulley anti-clockwise until locking pin can be inserted [13] . Use tool No.3387 [14] .
  14. Insert locking pin in tensioner pulley [15] . Tool No.T10115.
  15. Turn tensioner pulley fully clockwise until it reaches stop [16] . Use tool No.3387 [14] .
  16. Lightly tighten tensioner pulley nut [11] .
  17. Remove timing belt, starting at water pump sprocket.NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

Installation

  1. Ensure camshaft locked with tool [10] .
  2. Ensure crankshaft sprocket locking tool located correctly [8] .
  3. Ensure timing marks aligned [9] .
  4. Ensure tensioner pulley locking pin inserted [15] . Tool No.T10115.
  5. Ensure tensioner retaining lug is properly engaged [17] .
  6. Turn camshaft sprocket fully anti-clockwise in slotted holes.NOTE: Sprocket should turn freely without tilting.
  7. Fit timing belt in clockwise direction, starting at crankshaft sprocket.NOTE: If reusing old belt, observe direction of rotation marks on belt. Ensure belt is taut between sprockets on non-tensioned side.
  8. Slacken tensioner nut [11] .
  9. Turn tensioner pulley anti-clockwise [13] until locking pin can be removed. Use tool No.3387 [14] .
  10. Remove locking pin from tensioner pulley [15] . Tool No.T10115.
  11. Turn tensioner pulley slowly clockwise until pointer aligned with notch [18] . Use tool No.3387 [14] .NOTE: Belt adjustment must be carried out when engine is cold.
  12. Tighten tensioner nut [11] . Tightening torque: 20 Nm + 45°.
  13. Hold camshaft sprocket. Tool No. T10172/4.
  14. Tighten camshaft sprocket bolts [12] . Tightening torque: 25 Nm.
  15. Remove:
      • Camshaft locking tool [10] .
      • Crankshaft sprocket locking tool [8] .
  16. Turn crankshaft slowly two turns clockwise until just before TDC on No.1 cylinder.
  17. Fit crankshaft sprocket locking tool while slowly turning crankshaft to TDC [8] . Tool No.T10050.NOTE: If turned past TDC, turn crankshaft 1/4 turn anti-clockwise and repeat above procedure to fit crankshaft sprocket locking tool.
  18. Ensure timing marks aligned [9] .
  19. Ensure tensioner pulley pointer aligned with notch [18] .
  20. Ensure camshaft locking tool can be inserted easily [10] . Tool No.3359.
  21. If not:
      • Remove lug of crankshaft sprocket locking tool from hole in oil seal housing.
      • Turn crankshaft until camshaft locking tool can be inserted [10] . Tool No.3359.
      • Slacken camshaft sprocket bolts [12] .
      • Turn crankshaft anti-clockwise until lug of locking tool just passes hole in oil seal housing [19] .
      • Turn crankshaft clockwise until lug and hole aligned.
      • Lock crankshaft sprocket. Use tool No.T10050 [8] .
      • Tighten camshaft sprocket bolts [12] . Tightening torque: 25 Nm.
      • Remove locking tools [8] & [10] .
      • Turn crankshaft slowly two turns clockwise until just before TDC on No.1 cylinder.
      • Fit crankshaft sprocket locking tool while slowly turning crankshaft to TDC [8] . Tool No.T10050.NOTE: If turned past TDC, turn crankshaft ¼ turn anti-clockwise and repeat above procedure to fit crankshaft sprocket locking tool.
      • Ensure camshaft locking tool can be inserted easily [10] . Tool No.3359.
  22. Remove:
      • Camshaft locking tool [10] .
      • Crankshaft sprocket locking tool [8] .
  23. Install components in reverse order of removal.
  24. Tighten crankshaft pulley bolts [2] . Tightening torque: 10 Nm + 90°.
  25. Tighten bolts securing engine mounting bracket to engine:
      • Lupo/Polo/Golf/Bora/Beetle: 45 Nm.
      • Sharan: M8 bolts – 30 Nm. M10 bolts – 45 Nm.
  26. Lupo: Tighten RH engine mounting:
      • Bolts securing engine mounting to body – 20 Nm + 90°. Use new bolts.
      • Bolts securing engine mounting to engine bracket – 40 Nm + 90°. Use new bolts.
  27. Lupo: Tighten engine/gearbox steady bar.
      • Bolts securing steady bar bracket to gearbox – 40 Nm + 90°. Use new bolts.
      • Bolt securing steady bar to bracket – 90 Nm + 90°. Use new bolt.
      • Bolt securing steady bar to subframe – 90 Nm + 90°. Use new bolt.
  28. Polo: Tighten RH engine mounting intermediate bracket:
      • Bolts securing intermediate bracket to engine bracket – 30 Nm + 90°. Use new bolts.
      • Nut securing intermediate bracket to engine mounting – 40 Nm + 90°. Use new nut.
  29. Golf/Bora/Beetle: Fit and align RH engine mounting:
      • Engine mounting clearance [20] : 14 mm.
      • Engine mounting clearance [21] : 10 mm minimum.
      • Ensure bolts [22] aligned with edge of engine mounting [23] .
  30. Golf/Bora/Beetle: Tighten RH 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 bracket – 100 Nm.
  31. Sharan: Tighten RH engine mounting:
      • Bolts – 60 Nm. Lubricate bolts.
      • Nuts – 55 Nm. Lubricate nuts.
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Published in Golf 4