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

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.

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