SEAT Workshop Service and Repair Manuals

Fitting a new balance shaft assembly Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter. Special tools and workshop equipment required

t  Wrench XZN -T10099-, see equivalent → Anchor

t  Hose clamp -T10255-, see equivalent → Anchor Operation process l  Crankshaft is locked using crankshaft stop -T10050-. l  Tightening torques → Chapter   Note t  The spur gear drive of the balance shaft assembly must be installed with a backlash of 0.038 ... 0.072 mm. t  To achieve the correct backlash, a suitably thick coating is already applied to the new idler gear. The coating is applied to the teeth on parts of the circumference. t  The coating is worn down rapidly and the backlash is then correct. t  A new balance shaft assembly must always be installed in conjunction with a new idler gear which has the correct coating. t  A white dot on the idler gear indicates the correct installation position. t  Idler gears not marked with a white dot are coated all round. They can be installed in any position. t  Renew the bolts tightened with specified tightening angle.   Caution Thrust washer can slip out of position behind idler gear. Before positioning balance shaft assembly, slacken off bolt for idler gear as specified below, but not further. Installation position of thrust washer → Fig.

–  Unscrew the bolt -1- for the intermediate wheel by approx. 45° (1/8 turn). –  If not already fitted, fit dowel sleeves into cylinder block for centring balance shaft assembly.

–  Attach balance shaft assembly to cylinder block. When the idle drive has a partial coating, check that it is mounted correctly: l  White dot -arrow- on idler gear must be aligned centrally with crankshaft. l  Idler gears not marked with a white dot can be installed in any position. l  Take care not to damage the coating of the idler gear.   Note Due to the gear ratio, the white dot -arrow- will not return to its original position after the crankshaft has been rotated.

–  Tighten the screws in the sequence -1 … 8- by hand. –  Tighten the bolts of the balance shaft assembly as follows: 1.  Tighten to 6 Nm in the sequence -1 ... 8-. 2.  Tighten the bolts -5- and -7- to 13 Nm. 3.  Continue turning bolts -5- and -7- a further 90° (1/4 turn) using a rigid wrench. 4.  Tighten the bolts -1 -4-, -6- and -8- to 20 Nm. 5.  Continue turning bolts -1 ... -4-, -6- and -8- a further 90° (1/4 turn) using a rigid wrench.

–  Lock the balance shaft using the pinning tool -T10255-; If necessary, turn the balance shaft. l  The lug of the locking tool must engage in the groove of the balance shaft.

–  Carefully fit balance shaft gear onto balance shaft; to do so, push idler gear slightly to one side. l  Take care not to damage the coating of the idler gear. l  The threaded holes in the balance shaft should be aligned as centrally as possible with the elongated holes in the balance shaft gear.   Note If it is not possible to align the elongated holes in the balance shaft gear with the threaded holes, you must turn the gear some teeth further as required and then fit it again. –  Tighten bolts -arrows- for balance shaft gear. –  Extract the counterhold -T10255-.   Note The following three steps have to be performed simultaneously (a second mechanic is therefore required):

–  Push idler gear -3- firmly in direction of -arrow- into teeth on drive gear -2- and balance shaft gear -1-. If necessary use a suitable wooden tool. –  At the same time, turn balance shaft gear slightly anti-clockwise. –  Tighten the idle drive bolt using the wrench XZN -T10099- → Item. –  Extract the counterhold -T10050-.   Note After installation the idler gear must have no backlash. This can be checked by exerting light pressure by hand. The remaining installation steps are carried out in reverse sequence - note the following points: –  Fit the oil sump → Chapter. –  Install vibration damper → Chapter. –  Replenish engine oil and check oil level → Booklet601.