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How to Replace timing belt on VW Polo 6N 1.6

Published September 15, 2015

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:
Golf/Bora/Beetle 2,50
Lupo 1,4/Polo →2002 1,60
Polo 2002→ 2,20
Lupo 1,6 1,90
Polo Classic 1,30
Caddy →2004 1,60
Caddy 2004→ 2,20

Special Tools

  • Camshaft locking tool (except ARC/ARR/AVY) – Volkswagen No.T10016.
  • Camshaft locking tools (ARC/ARR/AVY) – Volkswagen No.T10074.
  • Crankshaft pulley holding tool (except ARC/ATN/AUS/AVY/AZD/BCB) – Volkswagen No.3415.
  • Crankshaft pulley holding tool (ARC/ATN/AUS/AVY/AZD/BCB) – Volkswagen No.T10028.

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 Polo 6N 1.6
How to Replace timing belt on VW Polo 6N 1.6

Removal

  1. Raise and support front of vehicle.
  2. Remove:
      • Engine upper cover.
      • Air filter assembly.
      • Timing belt upper cover [1] .
  3. Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure timing marks on crankshaft pulley aligned [2] .
  4. Ensure camshaft sprocket locating holes aligned:
      • Except ARC/ARR/AVY: [3]
      • ARC/ARR/AVY: [4]
  5. If locating holes not aligned: Turn crankshaft one turn clockwise.
  6. Fit locking tool(s) to camshaft sprockets:
      • Except ARC/ARR/AVY: [5] . Tool No.T10016.
      • ARC/ARR/AVY: [21] . Tool No.T10074.

    NOTE: Ensure locking tool(s) located correctly in cylinder head.

  7. Remove:
      • PAS reservoir. DO NOT disconnect hoses.
      • RH engine undershield.
  8. Except Polo Classic: Support engine.
  9. Except Polo Classic: Remove:
      • RH engine mounting.
      • RH engine mounting bracket.
  10. Except Polo Classic: Lower engine until crankshaft pulley bolt accessible.
  11. Remove auxiliary drive belt.

    NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

  12. Fit crankshaft pulley holding tool:
      • Except ARC/ATN/AUS/AVY/AZD/BCB – tool No.3415.
      • ARC/ATN/AUS/AVY/AZD/BCB – tool No.T10028.
  13. Slacken crankshaft pulley bolt [6] .
  14. Remove:
      • Holding tool. Tool No.3415/T10028.
      • Crankshaft pulley bolt [6] .
      • Crankshaft pulley [7] .
  15. Fit two washers to crankshaft pulley bolt [6] .
  16. Fit crankshaft pulley bolt [6] . Lightly tighten bolt.
  17. Remove:
      • Auxiliary drive belt guide pulley (models with AC).
      • Auxiliary drive belt tensioner.
      • Timing belt lower cover [8] .
  18. Slacken tensioner pulley bolt [9] .
  19. Turn tensioner pulley anti-clockwise to release tension on belt.
  20. Remove timing belt.

    NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

Installation

  1. Ensure locking tool(s) fitted to camshaft sprockets:
      • Except ARC/ARR/AVY: [5] . Tool No.T10016.
      • ARC/ARR/AVY: [21] . Tool No.T10074.
  2. Ensure timing mark on crankshaft sprocket aligned [10] .

    NOTE: Align ground tooth on crankshaft sprocket.

  3. Remove – ARC/ARR/AVY:
      • Guide pulley bolt [22] .
      • Guide pulley [23] .
  4. Tighten tensioner pulley bolt finger tight [9] . Ensure baseplate is supported by bolt [11] .
  5. Fit timing belt in anti-clockwise direction, starting at water pump sprocket.
  6. Fit – ARC/ARR/AVY:
      • Guide pulley [23] .
      • Guide pulley bolt [22] .
  7. Tighten guide pulley bolt [22] . Tightening torque: 50 Nm.
  8. Turn tensioner pulley clockwise [12] until pointer [13] aligned with notch [14] in baseplate.
  9. Tighten tensioner pulley bolt to 20 Nm [9] .
  10. Remove locking tool(s) from camshaft sprockets:
      • Except ARC/ARR/AVY: [5] . Tool No.T10016.
      • ARC/ARR/AVY: [21] . Tool No.T10074.
  11. Turn crankshaft two turns clockwise to TDC on No.1 cylinder. Ensure timing marks on crankshaft sprocket aligned [10] .
  12. Ensure locking tool(s) can be inserted into camshaft sprockets:
      • Except ARC/ARR/AVY: [5] . Tool No.T10016.
      • ARC/ARR/AVY: [21] . Tool No.T10074.
  13. Ensure pointer [13] aligned with notch [14] in baseplate.
  14. If not: Repeat tensioning procedure.
  15. Apply firm thumb pressure to belt at warning. Pointer [13] and notch [14] 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 [13] aligned with notch [14] in baseplate.
  19. Remove crankshaft pulley bolt [6] .
  20. Install:
      • Timing belt lower cover [8] .
      • Crankshaft pulley [7] .
      • New oiled crankshaft pulley bolt [6] .
  21. Fit crankshaft pulley holding tool:
      • Except ARC/ATN/AUS/AVY/AZD/BCB – tool No.3415.
      • ARC/ATN/AUS/AVY/AZD/BCB – tool No.T10028.
  22. Tighten crankshaft pulley bolt [6] . Tightening torque: 90 Nm + 90°.
  23. Remove holding tool. Tool No.3415/T10028.
  24. Install components in reverse order of removal.
  25. Except Polo Classic: Tighten bolts securing engine mounting bracket to engine. Tightening torque: 50 Nm.
  26. Lupo/Polo →2002: Tighten engine mounting:
      • Bolts securing engine mounting to body – 20 Nm + 45°. Use new bolts.
      • Bolts securing intermediate bracket to engine mounting bracket – 40 Nm + 90°. Use new bolts.
      • Bolt securing intermediate bracket to engine mounting – 50 Nm.
  27. Polo 2002→: Tighten engine mounting:
      • Bolts securing engine mounting to body – 20 Nm + 90°. Use new bolts.
      • Bolts securing intermediate bracket to engine mounting bracket – 30 Nm + 90°. Use new bolts.
  28. Golf/Bora: 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 – 60 Nm + 90°. Use new bolts.

Exhaust Camshaft Drive Belt

Removal

  1. Remove timing belt as described previously.
  2. Slacken tensioner pulley bolt [15] .
  3. Turn tensioner pulley clockwise to release tension on belt.
  4. Remove:
      • Tensioner pulley bolt [15] .
      • Tensioner pulley [16] .
      • Drive belt.

    NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

Installation

  1. Ensure locking tool(s) fitted to camshaft sprockets:
      • Except ARC/ARR/AVY: [5] . Tool No.T10016.
      • ARC/ARR/AVY: [21] . 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 [17] .
  5. Install:
      • Tensioner pulley [16] .
      • Tensioner pulley bolt [15] .
  6. Tighten tensioner pulley bolt finger tight [15] .

    NOTE: Ensure lug [18] in baseplate is located in cylinder head hole.

  7. Turn tensioner anti-clockwise [19] until pointer [20] aligned with lug [18] in baseplate.
  8. Tighten tensioner pulley bolt to 20 Nm [15] .
  9. Fit timing belt as described previously.
  10. Remove locking tool(s) from camshaft sprockets:
      • Except ARC/ARR/AVY: [5] . Tool No.T10016.
      • ARC/ARR/AVY: [21] . Tool No.T10074.
  11. Turn crankshaft two turns clockwise to TDC on No.1 cylinder. Ensure timing mark on crankshaft sprocket aligned [10] .
  12. Ensure locking tool(s) can be inserted into camshaft sprockets:
      • Except ARC/ARR/AVY: [5] . Tool No.T10016.
      • ARC/ARR/AVY: [21] . Tool No.T10074.
  13. Ensure pointer [20] aligned with lug [18] in baseplate.
  14. If not: Repeat tensioning procedure.
  15. Apply firm thumb pressure to belt at warning. Pointer [20] and lug [18] 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 [20] aligned with lug [18] in baseplate.
  19. Install components in reverse order of removal.
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Published in Polo 6N