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How to Replace timing belt on VW Polo 9N 1.8 GTI

Replacement Interval Guide

  • Volkswagen recommend replacement every 120,000 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(s).

Repair Times – hrs

Remove & install 2,20

Special Tools

  • Auxiliary drive belt tensioner locking pin – No.T10060A.
  • Tensioner locking tool – No.T10008.
  • Two-pin wrench – No.3387.
  • 4 mm drill bit.

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.
How to Replace timing belt on VW Polo 9N 1.8 GTI
How to Replace timing belt on VW Polo 9N 1.8 GTI

Removal

  1. Raise and support front of vehicle.
  2. Remove:
      • Engine top cover.
      • Engine undershield.
      • Intercooler to turbocharger hose.
      • Auxiliary drive belt. Use tool No.T10060A.
      • Auxiliary drive belt tensioner.
  3. Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure timing marks aligned [1] .
  4. Remove coolant expansion tank. DO NOT disconnect hoses.
  5. Support engine.
  6. Remove timing belt upper cover [2] .
  7. Ensure camshaft sprocket timing marks aligned [3] .
  8. Remove:
      • RH engine mounting and intermediate bracket.
      • Crankshaft pulley bolts [4] .
      • Crankshaft pulley [5] .
      • RH engine mounting bracket.
      • Timing belt centre cover [6] .
      • Timing belt lower cover [7] .
  9. Fully insert Allen key into tensioner pulley [8] .
  10. Turn tensioner pulley slowly anti-clockwise until locking tool [9] can be inserted. Tool No.T10008.
  11. Slacken tensioner pulley nut [10] .
  12. Remove:
      • Automatic tensioner unit [11] .
      • Timing belt.

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

Installation

NOTE: Engine must be COLD.

  1. Ensure camshaft sprocket timing marks aligned [3] .
  2. Ensure automatic tensioner unit locked with tool [9] .
  3. Fit timing belt to crankshaft sprocket.

    NOTE: If reusing old belt: Observe direction of rotation marks on belt.

  4. Install:
      • Timing belt lower cover [7] . Coat bolt threads with ‘D 000 600 A2’ or similar thread locking compound.
      • Crankshaft pulley [5] .
      • Crankshaft pulley bolts [4] .
  5. Lightly tighten crankshaft pulley bolts [4] .
  6. Ensure timing marks aligned [1] .
  7. Turn tensioner pulley clockwise [12] until just before it touches stop. Use tool No.3387 [13] .
  8. Fit timing belt in following order:
      • Guide pulley.
      • Tensioner pulley.
      • Camshaft sprocket.
      • Water pump sprocket.
  9. Install automatic tensioner unit [11] .
  10. Turn tensioner pulley slowly anti-clockwise [14] until locking tool [9] can be removed. Use tool No.3387 [13] .
  11. Ensure dimension [15] is less than 4 mm.
  12. Turn tensioner pulley slowly clockwise [12] until dimension [15] is 4±1 mm. Use drill bit [16] .
  13. Hold tensioner pulley in position. Use tool No.3387 [13] .
  14. Tighten tensioner pulley nut [10] . Tightening torque: 20 Nm + 45°.
  15. Turn crankshaft slowly two turns clockwise to TDC on No.1 cylinder.
  16. Ensure timing marks aligned [1] & [3] . Check dimension [15] is 4±1 mm.
  17. If not:
      • Hold tensioner pulley in position. Use tool No.3387 [13] .
      • Slacken tensioner pulley nut [10] .
      • Adjust position of tensioner pulley until dimension [15] is 4±1 mm. Use drill bit [16] .
      • Tighten tensioner pulley nut [10] . Tightening torque: 20 Nm + 45°.
      • Turn crankshaft slowly two turns clockwise to TDC on No.1 cylinder.
      • Ensure dimension [15] is 4±1 mm. Use drill bit [16] .
  18. Install components in reverse order of removal.
  19. Tighten crankshaft pulley bolts to 25 Nm [4] .

    NOTE: When installing timing belt centre cover, coat threads of bolts with ‘D 000 600 A2’ or similar thread locking compound.

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