How to Replace timing belt on VW Polo 9N4 1.4i 2006-2009

Replacement Interval Guide

• Volkswagen recommend check at the first 60,000 miles and then every 20,000 miles (replace if necessary).
• 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

Remove & install

2,20

Special Tools

• None required.

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:
   • Air filter housing.
   • RH front wheel.
   • RH front inner wing panel.
   • Engine top cover (if fitted).
   • Auxiliary drive belt cover (if fitted).
   • Auxiliary drive belt.

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

3. Remove:
   • Exhaust manifold heat shield.
   • Auxiliary drive belt tensioner (models with AC).
   • Timing belt upper cover [1] .
   • Crankshaft pulley bolts (4 bolts) [2] .
   • Crankshaft pulley [3] .
   • Timing belt lower cover [4] .
4. Support engine.
5. Remove coolant expansion tank. DO NOT disconnect hoses.
6. Remove:
   • RH engine mounting intermediate bracket bolts [5] .
   • RH engine mounting bolts [6] .
   • RH engine mounting.
   • RH engine mounting bracket bolts [7] .
   • RH engine mounting bracket.
7. Lower engine slightly.
8. Turn crankshaft clockwise to TDC on No.1 cylinder.
9. Ensure timing mark aligned [8] .NOTE: Align ground tooth on crankshaft sprocket with ‘2V’ mark on sealing flange.
10. Ensure camshaft sprocket timing marks aligned [9] .
11. Slacken tensioner bolt [10] .
12. Remove 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 timing marks aligned [8] & [9] .
2. Fit timing belt in anti-clockwise direction. Ensure belt is taut between sprockets on non-tensioned side.
3. Tighten tensioner bolt finger tight [10] . Ensure baseplate is supported by bolt [11] .
4. Turn tensioner clockwise [12] until pointer [13] aligned with notch [14] in baseplate.
5. Tighten tensioner bolt to 20 Nm [10] .
6. Turn crankshaft two turns clockwise to TDC on No.1 cylinder. Ensure timing marks aligned [8] & [9] .
7. Ensure pointer [13] aligned with notch [14] in baseplate.
8. Apply firm thumb pressure to belt at . Pointer [13] and notch [14] must move apart.
9. Release thumb pressure from belt at .
10. Turn crankshaft two turns clockwise to TDC on No.1 cylinder.
11. Ensure pointer [13] aligned with notch [14] in baseplate. If not: Replace tensioner pulley [12] .
12. Fit timing belt lower cover [4] .
13. Install:
    • Crankshaft pulley [3] .
    • Crankshaft pulley bolts [2] .
14. Tighten crankshaft pulley bolts to 20 Nm [2] .
15. Install components in reverse order of removal.
16. Fit RH engine mounting bracket.
17. Tighten RH engine mounting bracket bolts [7] . Tightening torque: 50 Nm.
18. Fit RH engine mounting and intermediate bracket. Use new bolts.
19. Tighten RH engine mounting and intermediate bracket:
    • Bolts [5] . Tightening torque: 30 Nm + 90°.
    • Bolts [6] . Tightening torque: 20 Nm + 90°.