How to Replace timing belt on VW Polo 6N 1.9 D

Replacement Interval Guide

• Volkswagen recommend:
• Polo
• →1999MY: Check and adjust every 20,000 miles.
• 2000MY→: Check and adjust every 60,000 miles.
• The vehicle manufacturer has not recommended a timing belt replacement interval for this engine.
• Polo Classic/Caddy Pick-up
• Check and adjust every 60,000 miles.
• 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.

Repair Times – hrs

Check & adjust	0,90
Remove & install:
Polo/Polo Classic	2,20
Caddy Pick-up	1,90

Special Tools

• Injection pump locking pin – No.3359.
• 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:
   • Polo/Polo Classic: [3] .
   • Caddy Pick-up: [13] .
4. Fit setting bar No.2065A to rear of camshaft [4] . Centralise camshaft using feeler gauges.
5. Insert locking pin in injection pump [5] . Tool No.3359.
6. Slacken injection pump sprocket bolts [6] .

   NOTE: DO NOT slacken injection pump hub nut.

7. Slacken tensioner nut [7] . Turn tensioner anti-clockwise away from belt. Lightly tighten nut.
8. Lower engine slightly.
9. Remove:
   • Water pump pulley.
   • Crankshaft pulley bolts [8] .
   • Crankshaft pulley [9] .
   • Auxiliary drive belt tensioner.
   • Timing belt lower cover [10] .
   • Timing belt.

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

Installation

1. Ensure flywheel timing marks aligned:
   • Polo/Polo Classic: [3] .
   • Caddy Pick-up: [13] .
2. Ensure camshaft setting bar fitted correctly [4] .
3. Ensure locking pin located correctly in injection pump [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. Turn automatic tensioner pulley clockwise until notch and raised mark on tensioner aligned [12] . Use tool No.3387.
8. Tighten tensioner nut to 20 Nm [7] .
9. Tighten camshaft sprocket bolt to 45 Nm [11] .
10. Tighten injection pump sprocket bolts to 25 Nm [6] .
11. Remove:
    • Injection pump locking pin [5] .
    • Camshaft setting bar [4] .
12. Turn crankshaft two turns clockwise to TDC on No.1 cylinder.
13. Ensure flywheel timing marks aligned:
    • Polo/Polo Classic: [3] .
    • Caddy Pick-up: [13] .
14. Ensure camshaft setting bar can be fitted [4] .
15. Ensure locking pin can be inserted in injection pump [5] .
16. If not: Slacken injection pump sprocket bolts [6] . Turn sprocket hub until locking pin can be inserted. Tighten bolts to 25 Nm.
17. Install components in reverse order of removal.
18. Tighten crankshaft pulley bolts to 25 Nm [8] .