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
- Raise and support front of vehicle.
- Remove:
- Engine top cover.
- Engine undershield.
- Intercooler to turbocharger hose.
- Auxiliary drive belt. Use tool No.T10060A.
- Auxiliary drive belt tensioner.
- Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure timing marks aligned [1] .
- Remove coolant expansion tank. DO NOT disconnect hoses.
- Support engine.
- Remove timing belt upper cover [2] .
- Ensure camshaft sprocket timing marks aligned [3] .
- 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] .
- Fully insert Allen key into tensioner pulley [8] .
- Turn tensioner pulley slowly anti-clockwise until locking tool [9] can be inserted. Tool No.T10008.
- Slacken tensioner pulley nut [10] .
- 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.
- Ensure camshaft sprocket timing marks aligned [3] .
- Ensure automatic tensioner unit locked with tool [9] .
- Fit timing belt to crankshaft sprocket.NOTE: If reusing old belt: Observe direction of rotation marks on belt.
- 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] .
- Lightly tighten crankshaft pulley bolts [4] .
- Ensure timing marks aligned [1] .
- Turn tensioner pulley clockwise [12] until just before it touches stop. Use tool No.3387 [13] .
- Fit timing belt in following order:
- Guide pulley.
- Tensioner pulley.
- Camshaft sprocket.
- Water pump sprocket.
- Install automatic tensioner unit [11] .
- Turn tensioner pulley slowly anti-clockwise [14] until locking tool [9] can be removed. Use tool No.3387 [13] .
- Ensure dimension [15] is less than 4 mm.
- Turn tensioner pulley slowly clockwise [12] until dimension [15] is 4±1 mm. Use drill bit [16] .
- Hold tensioner pulley in position. Use tool No.3387 [13] .
- Tighten tensioner pulley nut [10] . Tightening torque: 20 Nm + 45°.
- Turn crankshaft slowly two turns clockwise to TDC on No.1 cylinder.
- Ensure timing marks aligned [1] & [3] . Check dimension [15] is 4±1 mm.
- 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] .
- Install components in reverse order of removal.
- 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.