How to Replace timing belt on Volkswagen Polo 1.6 TDi 2010

Volkswagen Polo 1.6 TDi 2010 cambelt change instructions and replacement inteval. Full guide!

Special tools

• Auxiliary drive belt tensioner locking pin – No.T10060A.
• Camshaft sprocket/high-pressure fuel pump sprocket holding tool – Nos.T10172/4.
• Camshaft/high-pressure fuel pump locking tool – No.3359.
• Crankshaft sprocket locking tool – No.T10050.
• Multi-spline socket – No.T10385.
• Tensioner pulley adjusting tool – No.T10264 or T10409.
• Tensioner pulley locking tool – No.T10265.

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.

Repair times – hrs

Camshaft drive belt/chain – R & I

2,50

Valve timing procedures

Removal

1. Raise and support front of vehicle.
2. Remove:
   • Engine upper cover.
   • Golf/Estate/Plus/Passat/Touran: Windscreen washer reservoir filler neck.
3. Disconnect diesel particulate filter (DPF) pressure sensor multi-plug.
4. Remove diesel particulate filter (DPF) pressure sensor bracket.
5. Disconnect:
   • Jetta/Polo: Fuel supply and return pipes.
   • Polo: Fuel pre-heater valve.
6. Remove:
   • Golf/Estate/Plus/Passat/Touran: Fuel filter housing. DO NOT disconnect hoses.
   • Jetta/Polo: Fuel filter housing.
   • Coolant expansion tank. DO NOT disconnect hoses.
7. Disconnect coolant level sensor multi-plug.
8. Disconnect engine coolant temperature (ECT) sensor multi-plug.
9. Jetta/Golf/Estate/Plus/Passat/Touran: Detach coolant pipe support bracket from engine mounting bracket. DO NOT disconnect hoses.
10. Remove timing belt upper cover [1] .
11. Support engine.
12. Remove:
    • RH engine mounting.
    • RH wheel arch liner.
    • Engine undershield.
    • Auxiliary drive belt. Use tool No.T10060A.
    • Crankshaft pulley bolts [2] .
    • Crankshaft pulley [3] .
    • Timing belt lower cover [4] .
13. Turn crankshaft clockwise to TDC on No.1 cylinder.
14. Ensure arrow on camshaft sprocket at approximately 12 o’clock position [5] .
15. If not: Turn crankshaft one turn clockwise.
16. Lock crankshaft sprocket [6] . Use tool No.T10050.
17. Ensure timing marks aligned [7] .
18. Ensure lug of crankshaft sprocket locking tool located in oil seal housing [8] .
19. Lock camshaft [9] . Use tool No.3359.
20. Slacken camshaft sprocket bolts [10] . Ensure sprocket can just be turned by hand.
21. Slacken high-pressure fuel pump sprocket bolts [11] . Ensure sprocket can just be turned by hand. Use tool No.T10385.
    NOTE: There are two types of tensioner pulley for timing belt.
22. Tensioner pulley type A:
    • Slacken tensioner pulley nut [12] .
    • Turn tensioner pulley anti-clockwise until locking tool can be inserted [13] . Use tool No.T10264 [14] .
    • Insert locking tool in tensioner pulley [15] . Tool No.T10265.
    • Turn tensioner pulley fully clockwise until it reaches stop [16] . Use tool No.T10264 [14] .
    • Tighten tensioner pulley nut finger tight [12] .
23. Tensioner pulley type B:
    • Slacken tensioner pulley nut [17] .
    • Turn tensioner pulley clockwise to release tension on belt. Use tool No.T10409 [18] .
    • Tighten tensioner pulley nut finger tight [17] .
24. Remove timing belt, starting at guide pulley (G2).
    NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

Installation

NOTE: Engine must be COLD.

1. Fit new camshaft sprocket bolts [10] . Tighten bolts finger tight.
2. Fit new high-pressure fuel pump sprocket bolts [11] . Tighten bolts finger tight.
   NOTE: Sprockets should turn freely but not tilt.
3. Ensure crankshaft sprocket locking tool located correctly [6] .
4. Ensure camshaft locked with tool [9] .
5. Lock high-pressure fuel pump [19] . Use tool No.3359.
6. Turn camshaft sprocket fully clockwise in slotted holes.
7. Turn high-pressure fuel pump sprocket fully clockwise in slotted holes.
8. Fit timing belt in following order:
   • Crankshaft sprocket.
   • Guide pulley (G1).
   • Tensioner pulley.
   • Camshaft sprocket.
   • Water pump sprocket.
   • Guide pulley (G3).
   • High-pressure fuel pump sprocket.
   • Guide pulley (G2).
9. Tensioner pulley type A:
   • Slacken tensioner pulley nut [12] .
   • Remove locking tool from tensioner pulley [15] .
     Ensure tensioner pulley retaining lug is properly engaged [20] .
   • Turn tensioner pulley slowly clockwise until pointer aligned with notch [21] . Use tool No.T10264 [14] .

   NOTE: Ensure tensioner pulley nut does not turn [12] .

   • Hold tensioner pulley. Use tool No.T10264 [14] .
   • Tighten tensioner pulley nut [12] . Tightening torque: 20 Nm + 45°.
10. Tensioner pulley type B:
    • Ensure tensioner pulley at position shown [22] .
    • Slacken tensioner pulley nut [17] .
    • Turn tensioner pulley anti-clockwise until pointer aligned with notch [23] & [24] . Use tool No.T10409 [18] .

    NOTE: Ensure tensioner pulley nut does not turn [17] .

    • Ensure tensioner pulley marks aligned [25] .
    • Hold tensioner pulley. Use tool No.T10409 [18] .
    • Tighten tensioner pulley nut [17] . Tightening torque: 20 Nm + 45°.
11. Turn camshaft sprocket anti-clockwise to remove slack from belt between camshaft sprocket and high-pressure fuel pump sprocket. Use tool Nos.T10172/4.
12. Hold camshaft sprocket. Use tool Nos.T10172/4.
13. Tighten camshaft sprocket and high-pressure fuel pump sprocket bolts [10] & [11] . Tightening torque: 20 Nm.
14. Remove:
    • Camshaft locking tool [9] .
    • High-pressure fuel pump locking tool [19] .
    • Crankshaft sprocket locking tool [6] .
15. Turn crankshaft slowly two turns clockwise until just before TDC on No.1 cylinder.
16. Fit crankshaft sprocket locking tool while slowly turning crankshaft to TDC [6] .
17. Ensure lug of crankshaft sprocket locking tool located in oil seal housing [8] .
18. Ensure timing marks aligned [7] .
19. Ensure camshaft locking tool can be inserted easily [9] .
    NOTE: DO NOT insert high-pressure fuel pump locking tool as alignment hole may be slightly misaligned. No adjustment required.
20. Ensure tensioner pulley pointer aligned with notch or 5 mm maximum to the right of notch [21] or [23] . If not: Repeat tensioning procedure.
21. If camshaft locking tool cannot be inserted easily [9] :
    • Remove lug of crankshaft sprocket locking tool from hole in oil seal housing.
    • Turn crankshaft anti-clockwise until lug of locking tool just passes hole in oil seal housing [26] .
    • Turn crankshaft clockwise until camshaft locking tool can be inserted [9] .
    • Slacken camshaft sprocket bolts [10] .

    NOTE: Lug of crankshaft sprocket locking tool will be positioned to the left or right of hole in oil seal housing.

22. If lug of crankshaft sprocket locking tool is positioned to the left of hole in oil seal housing:
    • Turn crankshaft clockwise until lug and hole aligned [8] .
    • Lock crankshaft sprocket [6] .
    • Ensure timing marks aligned [7] .
    • Hold camshaft sprocket. Use tool Nos.T10172/4.
    • Tighten camshaft sprocket bolts [10] . Tightening torque: 20 Nm.
23. If lug of crankshaft sprocket locking tool is positioned to the right of hole in oil seal housing:
    • Turn crankshaft anti-clockwise until lug of locking tool just passes hole in oil seal housing [26] .
    • Turn crankshaft clockwise until lug and hole aligned [8] .
    • Lock crankshaft sprocket [6] .
    • Ensure timing marks aligned [7] .
    • Hold camshaft sprocket. Use tool Nos.T10172/4.
    • Tighten camshaft sprocket bolts [10] . Tightening torque: 20 Nm.
24. Remove locking tools [6] & [9] .
25. Turn crankshaft slowly two turns clockwise until just before TDC on No.1 cylinder.
26. Lock crankshaft sprocket [6] .
27. Ensure timing marks aligned [7] .
28. Ensure lug of crankshaft sprocket locking tool located in oil seal housing [8] .
29. Ensure camshaft locking tool can be inserted easily [9] .
30. Hold camshaft sprocket. Use tool Nos.T10172/4.
31. Tighten camshaft sprocket bolts [10] . Tightening torque: 20 Nm + 45°.
32. Hold high-pressure fuel pump sprocket. Use tool Nos.T10172/4.
33. Tighten high-pressure fuel pump sprocket bolts [11] . Tightening torque: 20 Nm + 90°.
34. Remove locking tools [6] & [9] .
35. Install components in reverse order of removal.
36. Tighten crankshaft pulley bolts [2] . Tightening torque: 10 Nm + 90°. Use new bolts.