How to Replace timing belt on VW Polo 6N 1.7 SDI

Replacement Interval Guide

• Volkswagen recommend:
• All models
• →2000MY: Check condition and width every 10,000 miles or 12 months, whichever occurs first.
• Lupo
• →2000MY: Replacement every 40,000 miles.
• 2001MY→: Replacement every 60,000 miles.
• Polo–AHG/AKU engines
• →2000MY: Replacement every 40,000 miles.
• 2001MY→: Replacement every 60,000 miles.
• Polo–AGD/ASX engines
• Replacement every 60,000 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.

Repair Times – hrs

Remove & install

2,50

Special Tools

• Injection pump sprocket locking pin – No.2064.
• Camshaft setting bar – No.2065A.
• Two-pin wrench – No.3387.

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.

Removal

1. Support engine.
2. Remove:
   • Insulation shield.
   • Air filter.
   • Auxiliary drive belt.
   • Lower engine steady bar.
   • Timing belt upper cover [1] .
   • Cylinder head cover.
   • Engine mounting.
   • Bracket [2] .
3. Turn crankshaft to TDC on No.1 cylinder. Ensure flywheel timing marks aligned [3] .
4. Fit setting bar No.2065A to rear of camshaft [4] . Centralise camshaft using feeler gauges.
5. Lock injection pump sprocket [5] . Use tool No.2064.
6. Slacken tensioner nut [6] . Turn tensioner anti-clockwise away from belt. Lightly tighten nut.
7. Lower engine slightly.
8. Remove:
   • Water pump pulley.
   • Crankshaft pulley bolts [7] .
   • Crankshaft pulley [8] .
   • Auxiliary drive belt tensioner.
   • Timing belt lower cover [9] .
   • Guide pulley [10] .
   • Timing belt.

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

Installation

IMPORTANT: Timing belt width must not be less than 21 mm.

1. Ensure flywheel timing marks aligned [3] .
2. Ensure camshaft setting bar fitted correctly [4] .
3. Ensure locking pin located correctly in injection pump sprocket [5] .
4. Slacken camshaft sprocket bolt 1/2 turn [11] .
5. Loosen sprocket from taper using a drift through hole in timing belt rear cover. Sprocket should turn freely without tilting.
6. Fit timing belt in anti-clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets.
7. Remove locking pin from injection pump sprocket [5] .
8. Fit guide pulley [10] . Tighten bolt to 25 Nm.
9. Slacken tensioner nut [6] .
10. Turn automatic tensioner pulley clockwise until notch and raised mark on tensioner aligned [13] . Use tool No.3387 [12] .
11. Tighten tensioner nut to 20 Nm [6] .
12. Ensure flywheel timing marks aligned [3] .
13. Tighten camshaft sprocket bolt to 45 Nm [11] .
14. Remove camshaft setting bar [4] .
15. Turn crankshaft two turns clockwise until timing marks aligned [3] .
16. Ensure camshaft setting bar can be fitted [4] .
17. Ensure locking pin can be inserted in injection pump sprocket [5] .
18. Apply firm thumb pressure to belt. Tensioner marks should move out of alignment [13] .
19. Release thumb pressure from belt. Tensioner marks should realign [13] . If not: Repeat tensioning procedure.
20. Install:
    • Timing belt lower cover [9] .
    • Crankshaft pulley [8] .
21. Tighten crankshaft pulley bolts [7] :
    • (A) Except Lupo – 25 Nm.
    • (B) Lupo – 10 Nm + 90°.
22. Install components in reverse order of removal.