Replacement Interval Guide
- Volkswagen recommend replacement every 140,000 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(s).
Repair Times – hrs
Remove & install: | |
---|---|
Polo | 2,50 |
Jetta/Golf/Golf Estate | 2,20 |
Golf Plus | 3,00 |
Passat/Touran | 1,90 |
Special Tools
- Camshaft sprocket/high-pressure fuel pump sprocket holding tool – Nos.T10172/4.
- Camshaft/high-pressure fuel pump locking tool – No.3359.
- Crankshaft sprocket locking tool – No.T10050.
- Multi-spline socket – No.T10385.
- Tensioner pulley adjusting tool – No.T10264.
- Tensioner pulley locking tool – No.T10265.
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.
Removal
- Raise and support front of vehicle.
- Remove:
- Engine upper cover.
- Golf/Estate/Plus/Passat/Touran: Windscreen washer reservoir filler neck.
- Disconnect diesel particulate filter (DPF) pressure sensor multi-plug.
- Remove diesel particulate filter (DPF) pressure sensor bracket.
- Disconnect:
- Jetta/Polo: Fuel supply and return pipes.
- Polo: Fuel pre-heater valve.
- Remove:
- Golf/Estate/Plus/Passat/Touran: Fuel filter housing. DO NOT disconnect hoses.
- Jetta/Polo: Fuel filter housing.
- Coolant expansion tank. DO NOT disconnect hoses.
- Disconnect coolant level sensor multi-plug.
- Disconnect engine coolant temperature (ECT) sensor multi-plug.
- Golf/Estate/Plus/Passat/Touran: Detach coolant pipe support bracket from engine mounting bracket. DO NOT disconnect hoses.
- Remove timing belt upper cover [1] .
- Support engine.
- Remove:
- RH engine mounting.
- RH wheel arch liner.
- Engine undershield.
- Auxiliary drive belt.
- Crankshaft pulley bolts [2] .
- Crankshaft pulley [3] .
- Remove:
- Timing belt lower cover [4] .
- Timing belt centre cover [5] .
- Turn crankshaft clockwise to TDC on No.1 cylinder.
- Ensure arrow on camshaft sprocket at approximately 12 o’clock position [6] .
- If not: Turn crankshaft one turn clockwise.
- Lock crankshaft sprocket [7] . Use tool No.T10050.
- Ensure timing marks aligned [8] .
- Ensure lug of crankshaft sprocket locking tool located in oil seal housing [9] .
- Lock camshaft [10] . Use tool No.3359.
- Slacken camshaft sprocket bolts [11] .
- Slacken high-pressure fuel pump sprocket bolts [12] . Use tool No.T10385.
NOTE: Slacken bolts until sprockets can be moved within slotted holes.
- Slacken tensioner pulley nut [13] .
- Turn tensioner pulley anti-clockwise until locking tool can be inserted [14] . Use tool No.T10264 [15] .
- Insert locking tool in tensioner pulley [16] . Tool No.T10265.
- Turn tensioner pulley fully clockwise until it reaches stop [17] . Use tool No.T10264 [15] .
- Tighten tensioner pulley nut finger tight [13] .
- Remove timing belt, starting at guide pulley (G3).
- Slacken tensioner pulley nut [13] . Remove tensioner pulley.
NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.
Installation
NOTE: Engine must be COLD.
- Fit new tensioner pulley.
- Turn tensioner pulley anti-clockwise until locking tool can be inserted [14] . Use tool No.T10264 [15] .
- Insert locking tool in tensioner pulley [16] . Tool No.T10265.
- Turn tensioner pulley fully clockwise until it reaches stop [17] . Use tool No.T10264 [15] .
- Tighten tensioner pulley nut finger tight [13] .
- Fit new camshaft sprocket bolts [11] . Tighten bolts finger tight.
- Fit new high-pressure fuel pump sprocket bolts [12] . Tighten bolts finger tight.
NOTE: Sprockets should turn freely but not tilt.
- Ensure crankshaft sprocket locking tool located correctly [7] .
- Ensure camshaft locked with tool [10] .
- Lock high-pressure fuel pump [18] . Use tool No.3359.
- Turn camshaft sprocket fully clockwise in slotted holes.
- Turn high-pressure fuel pump sprocket fully clockwise in slotted holes.
- Fit timing belt in following order:
- Crankshaft sprocket.
- Guide pulley (G1).
- Tensioner pulley.
- Camshaft sprocket.
- Water pump sprocket.
- Guide pulley (G3).
- High-pressure fuel pump sprocket.
- Guide pulley (G2).
- Slacken tensioner pulley nut [13] .
- Remove locking tool from tensioner pulley [16] .
- Ensure tensioner pulley retaining lug is properly engaged [19] .
- Turn tensioner pulley slowly clockwise until pointer aligned with notch [20] .
- Ensure tensioner pulley nut does not turn [13] .
- Hold tensioner pulley. Use tool No.T10264 [15] .
- Tighten tensioner pulley nut [13] . Tightening torque: 20 Nm + 45°.
- Turn camshaft sprocket anti-clockwise to remove slack from belt between camshaft sprocket and high-pressure fuel pump sprocket. Use tool Nos.T10172/4.
- Hold camshaft sprocket.
- Tighten camshaft sprocket and high-pressure fuel pump sprocket bolts [11] & [12] . Tightening torque: 20 Nm.
- Remove:
- Camshaft locking tool [10] .
- High-pressure fuel pump locking tool [18] .
- Crankshaft sprocket locking tool [7] .
- 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 [7] .
- Ensure lug of crankshaft sprocket locking tool located in oil seal housing [9] .
- Ensure timing marks aligned [8] .
- Ensure camshaft locking tool can be inserted easily [10] .
NOTE: DO NOT insert high-pressure fuel pump locking tool as alignment hole may be slightly misaligned. No adjustment required.
- Ensure tensioner pulley pointer aligned with notch or 5 mm maximum to the right of notch [20] . If not: Repeat tensioning procedure.
- If camshaft locking tool cannot be inserted easily [10] :
- Remove lug of crankshaft sprocket locking tool from hole in oil seal housing.
- Turn crankshaft anti-clockwise until lug of locking tool just passes hole in oil seal housing [21] .
- Turn crankshaft clockwise until camshaft locking tool can be inserted [10] .
- Slacken camshaft sprocket bolts [11] .
NOTE: Lug of crankshaft sprocket locking tool will be positioned to the left or right of hole in oil seal housing.
- If lug of crankshaft sprocket locking tool is positioned to the left of hole in oil seal housing:
- Turn crankshaft clockwise until lug and hole aligned [9] .
- Lock crankshaft sprocket [7] .
- Ensure timing marks aligned [8] .
- Hold camshaft sprocket. Use tool Nos.T10172/4.
- Tighten camshaft sprocket bolts [11] . Tightening torque: 20 Nm.
- If lug of crankshaft sprocket locking tool is positioned to the right of hole in oil seal housing:
- Turn crankshaft anti-clockwise until lug of locking tool just passes hole in oil seal housing [21] .
- Turn crankshaft clockwise until lug and hole aligned [9] .
- Lock crankshaft sprocket [7] .
- Ensure timing marks aligned [8] .
- Hold camshaft sprocket. Use tool Nos.T10172/4.
- Tighten camshaft sprocket bolts [11] . Tightening torque: 20 Nm.
- Remove locking tools [7] & [10] .
- Turn crankshaft slowly two turns clockwise until just before TDC on No.1 cylinder.
- Lock crankshaft sprocket [7] .
- Ensure timing marks aligned [8] .
- Ensure lug of crankshaft sprocket locking tool located in oil seal housing [9] .
- Ensure camshaft locking tool can be inserted easily [10] .
- Hold camshaft sprocket. Use tool Nos.T10172/4.
- Tighten camshaft sprocket bolts [11] . Tightening torque: 20 Nm + 45°.
- Hold high-pressure fuel pump sprocket. Use tool Nos.T10172/4.
- Tighten high-pressure fuel pump sprocket bolts [12] . Tightening torque: 20 Nm + 90°.
- Remove locking tools [7] & [10] .
- Install components in reverse order of removal.
- Tighten crankshaft pulley bolts [2] . Tightening torque: 10 Nm + 90°. Use new bolts.