How to Install a GTI 1.8T Timing Belt


1. Jack up the car and place it securely on jack stands. Remove the passenger side wheel as well as the plastic liner inside the wheel arch.
2. Remove both engine covers, the upper timing belt cover and the belly pan. These are held on with spring clips.
3. Remove the lower charge pipe by removing the hose clamps with a flathead screwdriver.
4. Remove the sound-dampening shield that is located behind the lower intercooler tube. There are two tabs that are bent back with a screwdriver, allowing the shield to be pulled down and out.
5. Pull out the timing plug on the gearbox so that you can see the TDC (Top Dead Center) mark located on the flywheel.
6. Loosen the tensioner on the accessory belt with a 16 mm wrench. Lock the tensioner in the loose position with a small allen wrench or similar tool. Remove the accessory belt.
7. Remove the intake pipe from the throttle body hose. Finish removing the tensioner with a 13 mm wrench and set aside.
8. Remove the pulley located on the harmonic balancer. Turn the engine to TDC by placing a 19 mm socket on the crank bolt.
9. Place a jack under the motor with a piece of wood between the jack and the engine, and jack up the motor until the weight is supported by the jack.
10. Unscrew the two screws holding the coolant reservoir in place. Using a 10 mm deep socket, loosen the power steering reservoir so it can be pushed out of the way.
11. Remove the six bolts that hold the engine mount to the chassis and bracket. Slide the mount out of the top of the motor.
12. Jack the motor up a two or three inches. This will allow you to remove the rest of the engine mount.
13. Remove the five bolts that hold the middle and lower timing belt covers on with a 10 mm socket.
14. Make a mark on the timing belt and a corresponding mark on the crank gear and cam gear with paint or something similar.
15. Remove the small timing belt tensioner pulley ad the entire tensioner. Remove the timing belt.
16. Unbolt pump by removing the three 10 mm bolts if you are replacing the water pump (recommended). Pull and wiggle the pump to remove it.
17. Install new pump with a new O-ring. Wet the O-ring with coolant.
18. Transfer the marks from the old timing belt to the new timing belt. Install the new tensioner idle pulley.
19. Align the marks on the cam gear with the new belt. Place the belt on the crank gear with the marks in the right spot. This may take several attempts to get lined up correctly.
20. Install the new tensioner. Use a small allen wrench to keep the top bolt hole in alignment by sliding it through the bolt hole. Install the lower bolt, then the top bolt. Check to ensure that the marks on the belt, crank and cam have not shifted.
21. Turn the engine over with the crank bolt to ensure that the flwheel and cam gear line up with their TDC marks. The cam gear has a corresponding mark on the valve cover.
22. Reinstall all other components in the reverse of removal and top up the coolant.