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

 

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.

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.