How to Replace timing belt on VW Golf 4 2.0 and 2.0 4Motion

Replacement Interval Guide

• Volkswagen recommend check at the first 60,000 miles and then every 20,000 miles (replace if necessary).
• No manufacturer’s recommended replacement interval.

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

1,90

Special Tools

• Engine support – No.10-222A.
• Engine support adaptor (Beetle) – No.10-222A/8.
• Engine support adaptor (Golf/Bora) – No.10-222A/1.
• Two-pin wrench – No.T10020.

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:
   • RH splash guard.
   • Engine cover.
   • Auxiliary drive belt.
   • Auxiliary drive belt tensioner.
   • Coolant expansion tank. DO NOT disconnect hoses.
   • Golf/Bora: PAS reservoir. DO NOT disconnect hoses.
   • Timing belt upper cover [1] .
3. Turn crankshaft clockwise to TDC on No.1 cylinder.
4. Ensure timing marks aligned [2] or [3] .
5. Ensure camshaft sprocket timing marks aligned [4] .
6. Install engine support and adaptor. Tool Nos.10-222A/A1/A8.
7. Remove:
   • RH engine mounting [5] .
   • Crankshaft pulley bolts [6] .
   • Crankshaft pulley [7] .
   • Timing belt centre cover [8] .
   • Timing belt lower cover [9] .
8. Raise engine slightly.
9. Remove:
   • RH engine mounting bracket bolts [10] .
   • RH engine mounting bracket [11] .
10. Slacken tensioner nut [12] . Turn tensioner clockwise away from belt. Use tool No.T10020 [13] . Lightly tighten nut [12] .
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.
   • Guide pulley.
   • Tensioner pulley.
   • Camshaft sprocket.

   NOTE: If belt is to be reused: Observe direction of rotation marks on belt. Ensure belt is taut between sprockets on non-tensioned side.

3. Slacken tensioner nut [12] .
4. Ensure tensioner retaining lug [14] is properly engaged.
5. Turn tensioner 5 times fully anti-clockwise and clockwise from stop to stop. Use tool No.T10020 [13] .
6. Turn tensioner fully anti-clockwise then slowly clockwise until pointer [15] aligned with notch [16] in baseplate. Use tool No.T10020 [13] .NOTE: Engine must be COLD.
7. Tighten tensioner nut [12] . Tightening torque: 20 Nm.
8. Turn crankshaft slowly two turns clockwise until timing marks aligned [3] & [4] .NOTE: Turn crankshaft last 45° smoothly without stopping.
9. Ensure pointer [15] aligned with notch [16] in baseplate.
10. If not: Repeat tensioning procedure.
11. Apply firm thumb pressure to belt at . Pointer [15] and notch [16] must move apart.
12. Release thumb pressure from belt at .
13. Turn crankshaft slowly two turns clockwise until timing marks aligned [3] & [4] .NOTE: Turn crankshaft last 45° smoothly without stopping.
14. Ensure pointer [15] aligned with notch [16] in baseplate.
15. Install:
    • Timing belt lower cover [9] .
    • Timing belt centre cover [8] .
    • Crankshaft pulley [7] .
    • Crankshaft pulley bolts [6] .
16. Tighten crankshaft pulley bolts [6] . Tightening torque: 25 Nm.
17. Install:
    • RH engine mounting bracket [11] .
    • RH engine mounting bracket bolts [10] .
18. Tighten RH engine mounting bolts [10] . Tightening torque: 45 Nm.
19. Fit and align RH engine mounting [5] .
    • Engine mounting clearance: 14 mm [17] .
    • Engine mounting clearance: 10 mm [18] .
    • Ensure engine mounting bolts [20] aligned with edge of mounting [19] .
20. Tighten:
    • Engine mounting bolts [21] . Tightening torque: 40 Nm + 90°. Use new bolts.
    • Engine mounting bolts [22] . Tightening torque: 25 Nm.
    • Engine mounting bolts [20] . Tightening torque: 100 Nm.
21. Remove engine support and adaptor.
22. Install components in reverse order of removal.