How to Replace timing chains on VW Polo 1.6i 9N4 2006-2010

Special tools

• Camshaft alignment tool – No.T10171.
• Crankshaft pulley/camshaft sprocket holding tool – No.T10172.
• Crankshaft pulley locking tool – No.3415.
• Dial gauge – No.VAS 6079.
• Dial gauge holder – No.T10170.
• Tensioner locking tool – No.T40011.

General precautions

• Disconnect battery earth lead.
• Remove spark plugs to ease turning engine.
• Turn engine in normal direction of rotation (unless otherwise stated).
• Observe tightening torques.
• If fitted: Mark position of crankshaft position (CKP) sensor before removal.
• Do NOT turn crankshaft via camshaft or other sprockets.
• Do NOT turn crankshaft or camshaft with timing chain removed.

Valve timing procedures

NOTE: If reusing timing chains: Mark direction of rotation on chains.

• Removal/installation of timing chain requires:
  • Timing chain cover removal.
  • Sump removal.
• Install dial gauge and holder in No.1 cylinder plug hole. Ensure engine at TDC on No.1 cylinder [1] .
• Ensure timing marks on camshafts aligned as shown. If not, turn crankshaft 360° [2] .
• Fit camshaft alignment tool [3] .
• If camshaft alignment tool cannot be inserted valve timing is incorrect. Adjust camshafts as follows:
  • Turn crankshaft anti-clockwise 45°.
  • Carefully press tensioner rail against tensioner piston.
  • Fit tensioner locking tool [4] .
  • Remove camshaft sprockets and chain.

  NOTE: Inlet camshaft sprocket bolt has LH thread.

  • Align camshafts. Use special tool [3] .
  • Install camshaft sprockets and timing chain.
  • Ensure camshaft sprockets turn freely but do not tilt.
  • Remove tensioner locking tool [4] .
  • Turn crankshaft slowly to TDC on No.1 cylinder.
  • Tighten camshaft sprocket bolt, as follows:
  • Tighten inlet camshaft sprocket bolt to stage 1. Tightening torque: 40 Nm.
  • Tighten exhaust camshaft sprocket bolt to stage 1. Tightening torque: 50 Nm.

  NOTE: Hold camshaft sprockets with holding tool.

  • Remove special tool [3] .
  • Turn the crankshaft two turns clockwise to No.1 cylinder at TDC [1] .
  • Ensure camshaft alignment tool can be fitted [3] .
  • Remove special tool [3] .
  • Tighten inlet camshaft sprocket bolt to stage 2. Tightening torque: + 90°.
  • Tighten exhaust camshaft sprocket bolt to stage 2. Tightening torque: + 90°.
  • Turn the crankshaft two turns clockwise to No.1 cylinder at TDC [1] .
  • Ensure camshaft alignment tool can be fitted [3] .
  • If not, repeat adjustment procedure of camshafts.
• Tighten crankshaft pulley bolt.
• Type A: Tightening torque: 90 Nm + 90°.
• Type B: Tightening torque: 150 Nm + 180°.

NOTE: Crankshaft pulley bolt and bolt on each camshaft sprocket MUST only be used once.