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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

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

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