Intake Camshaft Balance Shaft

Intake Camshaft Balance Shaft

Special tools, testers and auxiliary items required

• Puller (T10394)

• Puller (T10055)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Always replace the balance shaft after removing it.

Removing

- Remove the balance shaft timing chain. Refer to => [ Balance Shaft Timing Chain ] Balance Shaft Timing Chain.

- Remove the coolant pump toothed belt. Refer to => [ Coolant Pump Toothed Belt ] Coolant Pump Toothed Belt.

- Remove the intermediate sprocket bolt - 1 - and sprocket.






- Remove the bolt - 2 - for the intake camshaft balance shaft and remove the balance shaft.






If the balance shaft cannot be removed by hand, use the puller (T10394) :

- Install the half shell (T10394/1) from the puller (T10394) and rotate it upward in the - direction of the arrow -.






- Install the puller (T10394) and push the sliding sleeve in the - direction of the arrow -.






- Install the puller (T10055) into the puller (T10394) and remove the balance shaft in the - direction of the arrow -.






Installing

• Because of the small clearance between the balance shaft and cylinder block, the balance shaft may need to be cooled in order to install it. Check if the balance shaft can be installed into the cylinder block without forcing it in. If it cannot, the balance shaft must be cooled before installing it.

• Tightening specifications, refer to => [ Balance Shaft Timing Chain Overview ] Balance Shaft Timing Chain Overview.

- Place the new balance shaft in a freezer for 30 minutes or spray it with commercially available cooling spray.

- Lubricate the balance shaft bearing with engine oil.

- Install the intake camshaft balance shaft.

- Replace the O-ring - 1 - and lubricate it with engine oil.






- Lubricate the bearing pin with engine oil and insert it. The alignment pin - arrow - for the bearing pin must engage in the hole in the cylinder block.


Always replace the intermediate shaft sprocket. Otherwise the backlash will not adjust itself and it could result in engine damage. The new intermediate shaft sprocket has an anti-friction coating that wears off after a short period of use, which automatically adjusts the backlash.

- Mark the tooth face on the intermediate sprocket - arrows -.






- Install the intermediate sprocket; the mark on the balance shaft must be between the marks on the tooth faces.

- Install and tighten the chain sprocket bolt - 1 -:






• Tightening specifications, refer to => [ Intermediate Shaft Sprocket Bolt Tightening Sequence and Specification ] Balance Shaft Timing Chain Overview.

- Check the marks on the intermediate shaft sprocket/balance shaft - arrow -.

• Due to the ratio, the marks align only after every 7th turn.

- Install the balance shaft timing chain. Refer to => [ Installing ] Balance Shaft Timing Chain.

The rest of the installation is basically a reverse of the removal sequence; when doing this, note the following:

- Replace the coolant pump drive gear seal. Refer to => [ Coolant Pump Drive Gear Seal, Replacing ] Coolant Pump Drive Gear Seal, Replacing.