Volkswagen Workshop Service and Repair Manuals

Removing and installing balancer shaft

Special tools and workshop equipment required

t	Mandrel -T10060 A-

t	Special wrench, long reach -T10061-

t	Torque wrench -V.A.G 1331-

t	Torque wrench -V.A.G 1332-

t	24/27 mm spanner

Removing –  Remove poly V-belt → Chapter. –  Remove toothed belt → Chapter. –  Remove sump → Chapter. –  Remove sealing flange at belt pulley end → Chapter. –  Unscrew securing bolts for cover. –  Unclip cover from retaining frame.

–  Lock chain tensioner using locking pin -T10060 A--arrow-. –  Remove idler chain sprocket -1- from retaining frame. –  Remove securing bolts -2- from chain tensioner and remove chain tensioner. –  Remove chain from sprockets and place chain on a clean surface.

–  Lock balancer shaft using a 24/27 mm spanner -1-.   Note The spanner must be positioned centrally to the balance weight and at right-angles to the balancer shaft. –  Loosen securing bolt -2- for balance weight.   Note Only loosen securing bolt -2- for balance weight, do not remove. –  Unscrew retaining frame -3- from cylinder block and remove retaining frame together with balancer shaft. –  Place retaining frame on a clean surface. –  Remove securing bolt from balance weight. –  Remove balance weight and sprocket from balancer shaft. –  Turn balancer shaft so that the shaft can be taken out of the bearings. Installing –  Lubricate running surfaces of bearings. –  Insert balancer shaft into the bearings. –  Fit sprocket and balance weight on balancer shaft.   Note The sprocket and the balance weight can only be fitted in one position. –  Tighten securing bolt for balance weight and sprocket hand-tight. –  Bolt retaining frame hand-tight to cylinder block so that there is no play.   Note t  Ensure when installing the retaining frame that the dowel sleeves are fitted in the cylinder block and the O-ring is fitted in the retaining frame. t  Align the retaining frame so that the belt pulley end is flush with the outer edge of the cylinder block. –  Bolt retaining frame with balancer shaft to cylinder block. Torque setting: 20 Nm. –  Check that the belt pulley end of the retaining frame is aligned flush with the outer edge of the cylinder block

–  Lock balancer shaft using a 24/27 mm spanner -1-.   Note The spanner must be positioned centrally to the balance weight and at right-angles to the balancer shaft. –  Tighten securing bolt -2- for balance weight. Torque setting: 100 Nm + 1/4 turn (90°) further.   Note Securing bolt is a stretch bolt and must always be renewed. –  Install chain tensioner, torque setting: 8 Nm + 1/4 turn (90°) further.   Note Securing bolts for chain tensioner are stretch bolts and must always be renewed. –  Clean chain using a lint-free cloth.

–  Check marking -arrow- on crankshaft sprocket is at top.

–  Place chain on sprockets of crankshaft, oil pump and balancer shaft. Ensure the marks on the sprockets for the crankshaft and balancer shaft align with the coloured chain links -arrows- as shown.   Note The coloured chain links also have an additional raised portion. –  Fit the idler chain sprocket into the chain and bolt the idler chain sprocket to the retaining frame. Torque setting: 20 Nm. –  Remove locking pin -T10060 A- from chain tensioner.

–  Check that the marks on the sprockets for the crankshaft and balancer shaft align with the coloured chain links -arrows-.   Note The coloured chain links also have an additional raised portion. –  Install sealing flange at belt pulley end → Chapter. –  Install cover for balancer shaft. Torque setting: 5 Nm.   Note t  Before installing cover, oil O-ring for oil pump and seat on inside of cover. t  Ensure the sealing strip is seated correctly in the cover. t  When installing, ensure the cover engages in the retaining frame –  Install sump → Chapter. –  Install and tension toothed belt → Chapter. –  Install poly V-belt → Chapter.