Renewing balancer shaft for inlet camshaft — VW

Renewing balancer shaft for inlet camshaft
Special tools and workshop equipment required
Puller
T10394
Puller
T10055
Removing
Note
The balancer shaft for the inlet camshaft must always be renewed after removing.
Remove drive sprocket and toothed belt for coolant pump
Chapter
.
Remove camshaft timing chain
Chapter
.
Remove balance shaft timing chain
Chapter
.
Lower engine with
support bracket
10 - 222 A
slightly until balance shaft is accessible.
Remove intermediate shaft sprocket
1
.
Unscrew bolt
2
for balance shaft of inlet camshaft.
Insert
shell half
T10394/1
from
puller
T10394
and turns upwards in direction of arrow.
Insert
puller
T10394
and push locking collar in
direction of arrow
.
Screw
puller
T10055
into
puller
T10394
and force out balancer shaft in
direction of arrow
.
Installing
Installation is carried out in the reverse order; note the following:
Note
Due to the small amount of play between the balancer shaft and cylinder block, the balancer shaft may need to be installed chilled. Check whether the balancer shaft can be fitted into the cylinder block without exerting force. If this is not the case, the balancer shaft must be chilled before installing.
Place new balancer shaft in freezer compartment for 30 minutes, if necessary, or spray with commercially available cooling spray.
Lubricate balance shaft bearing with engine oil.
Install new balance shaft for inlet camshaft and tighten bolt
2
.
Renew O-ring
1
and lubricate with engine oil.
Note
Dowel pin
arrow
for bearing mounting must engage in bore in cylinder block.
Coat bearing mounting with engine oil and insert.
Note
The intermediate shaft sprocket must be replaced. Otherwise no tooth backlash is set, engine damage.
The new intermediate shaft sprocket is coated with a solid film lubricant that wears off after a short period and thus automatically sets the tooth backlash.
Mark faces of gear teeth of intermediate shaft sprocket with paint
arrows
.
Insert intermediate shaft sprocket; marking on balancer shaft must be positioned between markings on faces of gear teeth.
Tighten bolt
1
for intermediate shaft sprocket: tightening sequence
Fig.
.
Check markings on intermediate shaft sprocket/balance shaft
arrow
.
Install balancer shaft module
Chapter
.
Install camshaft timing chain
Chapter
.
Install lower timing chain cover
Chapter
.
Install timing chain cover (top)
Chapter
.
Install engine mounting
Chapter
.
Install plenum chamber bulkhead on left and right
General body repairs, exterior
Rep. gr.
50
Plenum chamber bulkhead; Removing and installing plenum chamber bulkhead
.
Install tensioner for poly V-belt
Chapter
.
Install poly V-belt
Chapter
.
Renew oil seal for coolant pump drive
Chapter
.
Install drive sprocket and toothed belt for coolant pump
Chapter
.
If present, install noise insulation
General body repairs, exterior
Rep. gr.
66
Noise insulation; Removing and installing noise insulation
.
Specified torques
Chapter
“
Assembly overview - assembly mountings
”
Chapter
“
Assembly overview - drive chain for balance shaft
”
Chapter
“
Assembly overview - poly V-belt drive
”
Chapter
“
Assembly overview - coolant pump, thermostat
”
Chapter
“
Assembly overview - cover for timing chain
”