as PDF

REPLACEMENT OF VW POLO TIMING CHAIN
with
VW Polo 1.2 TSI models /2 00 9
11
production starting ID code CBZB
77 kW/110 PS with engine
As engine and chassis specialists, RUVILLE
naturally offers premium components in OE
quality for the VW Polo 1.2 TSI.
The percentage of registered vehicles with chaindrive is growing worldwide. In response, we are
constantly expanding and updating our chain-drive
kit portfolio with a close eye on the future. Naturally, we have an intelligent solution to make sure that
timing-chain replacement is just as smooth as the
operating attributes these drives offer.
THINGS TO WATCH OUT FOR
Basic installation tips:
If you repair an engine and find a lot of metal shavings and abrasion
(caused by scuffing, for example) you should clean the oil ducts and
replace the oil filter to prevent damage that this might cause.
Lubricate all bearing and running surfaces before you remount and
install new components.
Mount the engine to the engine and transmission holder (VAS 6095)
for carrying out replacement work.
Always adhere to specified torques.
Always use the specified special tools.
Never turn the engine using the camshaft.
Always use new bolts.
WITH CERTAIN COMPONENTS DO THE FOLLOWING
How do you know if the timing chain is damaged?
With the 1.2 TSI engines, the first sign of damage is chain rattle at cold
start. If the chain is elongated enough there can even be a loss of output
or a strong juddering of the vehicle. Possible errors recorded in the PCM
include “Signal crankshaft position sensor” or “Signal camshaft position
locator implausible.” Because the chain has become elongated, the timing is set incorrectly. That’s why an error code comes up that only indirectly indicates the problem as being the timing chain.
Recommended in cases like this is to always replace all peripheral components (like the timing chain, tensioner and guide rails,
sprockets) and the chain tensioner. The teeth of the individual
sprockets can have major damage if the chain is elongated and
they can cause a newly-installed chain to fail early if not replaced.
OUR TIMING-CHAIN KIT 3454036S
CONTAINS THE FOLLOWING ARTICLES:
Vehicle-specific replacement tips:
Article No.
Name
There are specific engine mounting instructions that apply to some engine components used in the VW Polo 1.2 TSI built starting in 11/2009.
The following describes these in detail.
3454036
Timing chain
3454037
Tensioner
3454036
Tensioner rail
3454037
Chain guiding rail
WE TEACH KNOWLEDGE YOU CAN USE DAILY
Only available as a kit.
A new model or model range means new specifications for installing chassis
parts. RUVILLE passes on the latest knowledge about this to garages. Learn
more about our training program at www.ruville.de or contact our Technical
Trainer, Remo Schönsee, directly by email at:
rschoensee@ruville.de.
OUT US AND
EXPERIENCE MORE AB
.ruville .de
OUR PRODUCTS AT www
Know-how in detail
Page 1
Replacing the timing chain of the VW Polo
Preparation:
Drain the coolant and remove the front right wheel-well liner. Then mark
the direction that the drive belt rotates and remove it.
Open the spring-band clamps and pull off the coolant hoses (1) and (2).
Push on the latching device (3) beneath the coolant hoses and pull the
hoses upwards and lay them towards the back.
1./2.
Spring-band
clamps
Unscrew and remove the mounting screws of the coolant pipe bracket.
Then unscrew and remove the screw plug (arrow) from the cylinder
block. This will enable you to turn the locking screw (T10340) into the
cylinder block until it stops. Now rotate the crankshaft in the running
direction of the engine until it stops.
Caution!
If the locking screw (T10340) cannot be turned until it stops, then the
crankshaft is not in the correct position!
Arrow:
Screw plug
3.
Latching
device
Pull both hoses (1) off the back-pressure valve, unscrew and remove the
mounting bolts (2). Pull the back-pressure valve out of the cylinder-head
cover.
T10340:
Locking screw
1.
Hoses
2.
Mounting bolts
Unscrew and remove all the mounting bolts of the timing-gear cover (1)
and take the timing-gear cover off.
Stick the camshaft lock (T10414) into the cylinder head cover until it
stops and is in the correct position, then tighten the mounting bolt (1)
with your hand. Now you can remove the oil pan.
1.
Mounting bolt
1.
Timing-gear
cover
Know-how in detail
Page 2
Remove the dust-protection cap from the deflection pulley and remove
the deflection pulley. After this, remove the water pump pulley while holding the water pump wrench (3415) against the direction you are turning.
After this is done, you can loosen the mounting bolts of the timing-gear
housing (1) and take the housing off.
1.
Timing-gear
housing
VW Polo 1.2 TSI models
production starting with
11
77 kW/110 PS with engine /2 00 9
ID code
CBZB
1.
Mounting bolt
Installing the new timing chain:
Place the timing chain (1) on the front-most sprocket (2) below and then
between the guiding rail and tensioner rail above. You can prevent the
timing chain from falling out by holding it in place with a screwdriver (3)
for example.
1.
Timing chain
2.
Sprocket
3.
Screwdriver
Place the timing chain (1) over the teeth of the upper sprocket (2) making
sure that the timing chain is fitted into the area of the guiding rail under
light tension.
Screw in the new mounting bolt, first by hand, then run the timing chain
through the middle of the tension rail. Put the chain tensioner (arrow)
back on and tighten it with 60 Nm.
Now unscrew and remove the timing-chain tensioner (arrow). Mark the
running direction of the chain with a felt-tip marker, if you want to use it
again. Loosen the mounting bolt (1) of the camshaft sprocket while holding the arrester (T10172) tightly. First remove the camshaft sprocket together with the mounting bolt, before you remove the timing chain in a
downward direction.
Arrow:
Timing-chain
tensioner
Know-how in detail
Tighten the camshaft sprocket with a new mounting bolt using 50 Nm
while holding the arrester (T10172).
1.
Timing chain
2.
Sprocket
3.
Guiding rail
Page 3
REPLACEMENT OF VW POLO TIMING CHAIN
Please note:
Do not turn the camshaft fastening bolt until the end of the replacement process and after checking the
valve timing. At that time it should be rotated a further ¼ turn (90º). Now mount the timing-chain housing
(tightening torque of the mounting bolts 4 Nm + 30º) and the crankshaft pulley and remove the locking pin
and bolts. Rotate the engine twice in the engine-running direction and check whether the locking pins for
the camshaft and crankshaft can be used again.
Install the remaining components in reverse order of that used when removing them.
For Vehicles with Production Dates starting in June 2011
Delete the variation learn-values stored in the PCM and adapt the PCM, if the timing chain was removed and
remounted, or if it was replaced.
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Commonly used Equipment
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Know-how in detail
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Page 4