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Important note
Important note

The intervals and procedures given are subject to alteration by the manufacturer at any time.
Check the regularly updated Timing Belts section on our website to ensure that you are kept
informed of any changes that may occur between issues of the Autodata CD.
http://www.autodata-cd.com

Timing belt replacement intervals

Where possible the recommended intervals have been compiled from vehicle manufacturers' information. In a few instances no
recommendation has been made by the manufacturer and the decision to replace the belt must be made from the evidence of a
thorough examination of the condition of the existing belt.

Apart from the visible condition of the belt, which is explained fully in the General Instructions/Toothed Timing Belts section,
there are several other factors which must be considered when checking a timing belt:

1. Is the belt an original or a replacement.

2. When was the belt last replaced and was it at the correct mileage.
3. Is the service history of the vehicle known.
4. Has the vehicle been operated under arduous conditions which might warrant a shorter replacement interval.
5. Is the general condition of other components in the camshaft drive, such as the tensioner, pulleys, and other ancillary
components driven by the timing belt, typically the water pump, sound enough to ensure that the life of the replacement
belt will not be affected.
6. If the condition of the existing belt appears good, can you be satisfied that the belt will not fail before the next check or
service is due.
7. If the belt does fail, have you considered the consequences. If the engine is an INTERFERENCE type then considerable
expensive damage may well be the result.
8. The cost of replacing a belt as part of a routine service could be as little as 5 to 10% of the repair cost following a belt
failure. Make sure your customer is aware of the consequences.
9. If in doubt about the condition of the belt - RENEW it.
10. Refer to the Toothed Timing Belts/Service Replacement section for further information relating to arduous or adverse
operating conditions, inspection and service replacement.

Replacement Interval Guide

Replacement Interval Guide

Volkswagen recommend:
All models 2000MY: Check condition and width every 10,000 miles or 12 months, whichever occurs first.
Polo/Classic/Caddy ALH, AT: Check timing belt and tensioner pulley every 20,000 miles.
Replacement every 60,000 miles.
Golf/Bora 2001MY: Replacement every 60,000 miles.
2002MY : Replacement every 80,000 miles (guide pulley must also be replaced - part No.038109244H).

Manufacturer: Volkswagen Model: Golf (98-06) 1,9D TDI © Autodata Limited 2007
Engine code: AHF Output: 81 (110) 4150 2009-07-17
Tuned for: Year: 1997-05 V6.410-
 Beetle 1999MY Replacement at the first 40,000 miles using:
Part No.038 109 119 - replacement then every 40,000 miles.
Part No.038 109 119D - replacement then every 60,000 miles.
ALH, AT: Check every 20,000 miles and replacement every 40,000 miles.
Beetle 2000MY Models on longlife servicing: Check condition and width every 20,000 miles or 24 months, whichever occurs
first.
Part No.038 109 119D - replacement every 60,000 miles.
ALH, AT: Replacement every 40,000 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

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

Repair Times - hrs

Golf/Bora 1,9 TDI 1998-05

Remove and install 3,30

Golf/Bora 1,9 TDI 4x4 1998-05

Remove and install 3,30

Special Tools
Special Tools

Camshaft setting bar - No.3418/T10098.

Injection pump locking pin - No.3359.
Sprocket holding tool - No.3036.
Two-pin wrench - Matra V.159 - TDI.
Puller - No.T40001.

Special Precautions
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.
Check diesel injection pump timing after belt replacement.

Removal

Manufacturer: Volkswagen Model: Golf (98-06) 1,9D TDI © Autodata Limited 2007
Engine code: AHF Output: 81 (110) 4150 2009-07-17
Tuned for: Year: 1997-05 V6.410-
 Removal

1. Raise and support front of vehicle.

2. Remove:
RH headlamp (Golf/Bora).
Coolant expansion tank. DO NOT disconnect hoses (Golf/Bora).
PAS reservoir. DO NOT disconnect hoses (Golf/Bora).
RH engine undershield (Golf/Bora).
Fuel filter and bracket (Beetle).
Engine undershield (Beetle).
Intercooler to intake manifold hose.
Timing belt upper cover [1] .
Vacuum pump.
Engine undershield (if fitted).
Auxiliary drive belt.

3. Remove - if using camshaft setting bar No.3418:

Polo Classic/Caddy SDI: Inlet manifold upper chamber.
Cylinder head cover.

4. Turn crankshaft to TDC on No.1 cylinder.

5. Ensure timing marks aligned. MT: [2] . AT: [3] .
6. Fit setting bar to rear of camshaft:
Tool No.3418 [4] . Centralise camshaft using feeler gauges.
Or tool No.T10098 [20] .

7. Lock injection pump. Use tool No.3359 [5] .

8. Slacken injection pump sprocket bolts [6] .
NOTE: DO NOT slacken injection pump hub nut.
9. Golf/Bora/Beetle: Support engine.
10. Golf/Bora/Beetle: Remove:
RH engine mounting bolts [7], [8] & [9] .
RH engine mounting.
Engine mounting bracket bolts [10] .
Engine mounting bracket.

11. Remove:
Crankshaft pulley bolts [11] .
Crankshaft pulley [12] .
Timing belt centre cover [13] .
Timing belt lower cover [14] .

12. Slacken tensioner nut [15] .

13. SDI: Turn tensioner anti-clockwise away from belt. Use Allen key.
14. TDI: Turn tensioner anti-clockwise away from belt. Use wrench Matra V.159.
15. Lightly tighten tensioner nut [15] .
16. Remove timing belt.
NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

Installation
Installation

IMPORTANT: DO NOT reuse old belt if width is less than 22 mm.

1. Ensure timing marks aligned. MT: [2] . AT: [3] .

2. Ensure camshaft setting bar fitted correctly [4] or [20] .
3. Ensure locking pin located correctly in injection pump [5] .
4. Hold camshaft sprocket. Use tool No.3036.
5. Slacken camshaft sprocket bolt one turn [16] .
NOTE: DO NOT use setting bar to hold camshaft when slackening sprocket bolt.
6. Loosen sprocket from taper.
Method 1: Use drift through hole in timing belt rear cover.

Manufacturer: Volkswagen Model: Golf (98-06) 1,9D TDI © Autodata Limited 2007
Engine code: AHF Output: 81 (110) 4150 2009-07-17
Tuned for: Year: 1997-05 V6.410-
 Method 2: Use puller. Tool No.T40001.

7. Remove:
Camshaft sprocket bolt [16] .
Camshaft sprocket.

8. Remove bolts from injection pump sprocket [6] . Proceed as follows:

Injection pump sprocket 038 130 111A: Bolts with pointed ends - type A. Fit new bolts.
Injection pump sprocket 038 130 111B: Bolts with flat ends - type B. Bolts can be re-used.

9. Align injection pump sprocket with bolts in centre of slotted holes.

10. Fit timing belt in following order:
Crankshaft sprocket.
Guide pulley G1.
Water pump sprocket.
Injection pump sprocket.
Guide pulley G2 - TDI.
Tensioner pulley.
Guide pulley G3.

NOTE: Turn injection pump sprocket slightly to engage timing belt teeth.
11. Ensure belt is taut between sprockets.
12. Fit camshaft sprocket to belt, then install camshaft sprocket with belt onto end of camshaft.
13. Fit camshaft sprocket bolt [16] .
14. Lightly tighten camshaft sprocket bolt [16] . Sprocket should turn freely without tilting.
15. Slacken tensioner nut [15] .
16. SDI: Turn tensioner pulley clockwise until pointer and notch in baseplate aligned [17] . Use Allen key.
17. TDI: Turn tensioner pulley clockwise as follows:
ALH, AT: Pointer and raised section of tensioner baseplate aligned [18] . Use Allen key.
Except ALH, AT: Notch and raised mark on tensioner aligned [19] . Use wrench Matra V.159.

18. If tensioner pulley turned too far: Turn fully anti-clockwise and repeat tensioning procedure.
19. Tighten tensioner nut to 20 Nm [15] .
NOTE: Ensure tensioner retaining lug is properly engaged.
20. Ensure timing marks aligned. MT: [2] . AT: [3] .
21. Hold camshaft sprocket. Use tool No.3036.
22. Tighten camshaft sprocket bolt to 45 Nm [16] .
23. Tighten injection pump sprocket bolts [6] .
Type A: Temporarily tighten to 20 Nm.

NOTE: Tighten bolts a further 90° after checking pu mp timing using diagnostic equipment.
Type B: Tighten to 25 Nm.

24. Remove:
Camshaft setting bar [4] or [20] . Tool No.3418/T10098.
Injection pump locking pin [5] . Tool No.3359.

25. Turn crankshaft two turns clockwise until timing marks aligned. MT: [2] . AT: [3] .
26. Ensure camshaft setting bar can be fitted [4] or [20] .
27. Ensure locking pin can be inserted in injection pump [5] .
28. SDI: Ensure pointer aligned with notch [17] in baseplate.
29. TDI: ALH, AT: Pointer and raised section of tensioner baseplate aligned [18] . Except ALH, AT: Ensure notch and raised
mark on tensioner aligned [19] .
30. If not: Repeat tensioning procedure.
31. Apply firm thumb pressure to belt. Tensioner marks should move out of alignment [17], [18] or [19] .
32. Release thumb pressure from belt. Tensioner marks should follow movement of belt.
33. Install components in reverse order of removal.
34. Tighten crankshaft pulley bolts [11] . Tightening torque: 10 Nm + 90°.
35. Golf/Bora/Beetle: Tighten RH engine mounting bracket bolts to 45 Nm [10] .
36. Golf/Bora/Beetle: Fit and align RH engine mounting:
Engine mounting clearance: 14 mm [21] .
Engine mounting clearance: 10 mm [22] .
Ensure engine mounting bolts [7] aligned with edge of mounting [23] .

37. Golf/Bora/Beetle: Tighten:

Manufacturer: Volkswagen Model: Golf (98-06) 1,9D TDI © Autodata Limited 2007
Engine code: AHF Output: 81 (110) 4150 2009-07-17
Tuned for: Year: 1997-05 V6.410-
 Engine mounting bolts [9] . Tightening torque: 40 Nm + 90°. Use new bolts.
Engine mounting bolts [8] . Tightening torque: 25 Nm.
Engine mounting bolts [7] . Tightening torque: 100 Nm.

Manufacturer: Volkswagen Model: Golf (98-06) 1,9D TDI © Autodata Limited 2007
Engine code: AHF Output: 81 (110) 4150 2009-07-17
Tuned for: Year: 1997-05 V6.410-
Manufacturer: Volkswagen Model: Golf (98-06) 1,9D TDI © Autodata Limited 2007
Engine code: AHF Output: 81 (110) 4150 2009-07-17
Tuned for: Year: 1997-05 V6.410-