Volkswagen Workshop Service and Repair Manuals

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

• ◆ T10060 Retaining pin
• ◆ T10061 Socket
• ◆ V.A.G 1331 Torque wrench (5...50 Nm)
• ◆ V.A.G 1332 Torque wrench (40...200 Nm)
• ◆ Spanner (24/27 mm AF)

Removing

• ‒ Remove ribbed belt .
• ‒ Remove toothed belt => Page15-10.
• ‒ Remove sump => Page 17-17.
• ‒ Remove sealing flange, pulley side => Page 13-22.
• ‒ Remove securing bolts from cover.
• ‒ Unclip cover from retaining frame.

• ‒ → Lock chain tensioner with retaining pin T10060 -arrow-.
• ‒ Unbolt sprocket/idler roller -1- from retaining frame.
• ‒ Remove securing bolts -2- from chain tensioner and remove it.
• ‒ Remove chain from sprockets and lay it aside on a clean surface.

• ‒ → Block the counterbalance shaft as shown with a spanner (24/27 mm AF) -1-.

Note:

When blocking the counterbalance shaft, make sure that the spanner is centred on the counterbalance weight and at right angles to counterbalance shaft.

• ‒ Loosen securing bolt -2- of counterbalance weight.

Note:

Only loosen counterbalance weight securing bolt -2-; do not remove it.

• ‒ Unbolt retaining frame -3- from cylinder block and remove retaining frame with counterbalance shaft.
• ‒ Lay retaining frame aside on a clean surface.
• ‒ Remove securing bolt from counterbalance shaft.
• ‒ Remove counterbalance weight and sprocket from counterbalance shaft.
• ‒ Turn the counterbalance shaft so that it can be removed from the bearing.

Installing

• ‒ Oil bearing's running surfaces.
• ‒ Set counterbalance shaft in bearing.
• ‒ Fit sprocket and counterbalance weight on counterbalance shaft.

Note:

The assembly of the sprocket and the counterbalance weight is possible in one position only.

• ‒ Hand tighten securing bolt for counterbalance weight and sprocket.
• ‒ Tighten retaining frame to cylinder block by hand so that there is no play.

Notes:

• ◆ When fitting retaining frame, ensure that the dowel sleeve is inserted in the cylinder block and the O ring is fitted in the retaining frame.
• ◆ Align the retaining frame so that it fits flush with the outer edge of the cylinder block on the pulley end.

• ‒ Bolt retaining frame with counterbalance shaft to cylinder block
      Tightening torque: 20 Nm.
• ‒ Check that retaining frame aligns flush with outer edge of cylinder block on the pulley end.

• ‒ → Block counterbalance shaft as shown with spanner (24/27 mm AF) -1-.

Note:

When blocking the counterbalance shaft, make sure that the spanner is centred on the counterbalance weight and at right angles to counterbalance shaft.

• ‒ Tighten counterbalance weight securing bolt -2-
      Tightening torque: 100 Nm + 1/4 turn (90 °) further.

Note:

The securing bolt is a stretch bolt am must always be replaced.

• ‒ Install chain tensioner
      Tightening torque: 8 Nm + 1/4 turn (90°) further.

Note:

The chain tensioner securing bolts are stretch bolts and must be renewed without exception.

• ‒ Clean chain with a lint-free cloth.

• ‒ → Ensure that mark on crankshaft sprocket -arrow- is at top.

• ‒ → Lay chain over crankshaft sprocket, oil pump sprocket and counterbalance shaft sprocket. Ensure that the marks on the crankshaft sprocket and counterbalance sprocket align with the colour-coded chain links -arrows-.

Note:

The colour-coded chain links are marked with a notch.

• ‒ Engage idler sprocket in chain and tighten idler sprocket to retaining frame
      Tightening torque: 20 Nm.
• ‒ Remove retaining pin T10060 from chain tensioner.

• ‒ → Check that marks on crankshaft sprocket and counterbalance shaft sprocket align with the colour-coded chain links -arrows-.

Note:

The colour-coded chain links are marked with a notch.

• ‒ Install pulley end sealing flange => Page 13-22.
• ‒ Install counterbalance shaft cover
      Tightening torque: 5 Nm.

Notes:

• ◆ Before installing cover, oil O ring of oil pump as well as shaft on inside of cover.
• ◆ Ensure proper seating of sealing strip in cover.
• ◆ When installing cover, ensure that cover engages in retaining frame.

• ‒ Install sump => Page 17-17.
• ‒ Install and tension toothed belt => Page 15-10.
• ‒ Install ribbed belt => Page 13-16.