Balance shaft, removing and installing

Special tools, testers and auxiliary items required 

Fig 1: Identifying Old Oil Collecting And Extracting Device V.A.G 1782

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• Old oil collecting and extracting device V.A.G 1782
• 8 mm dia. drill bit

Removing 

Fig 2: Locating Fasteners Exhaust Pipe

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• For vehicles with auxiliary heater, remove bolts - arrows  - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

Fig 3: Identifying Quick-Release Fasteners And Noise Insulation

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• Loosen quick-release fasteners - 1 through 3  - and remove front and rear noise insulation.
• Place old oil collecting and extracting device V.A.G 1782 under engine.
• Drain engine oil.
• Remove engine: Vehicles with manual transmission → Engine, removing  , vehicles with automatic transmission → Engine, removing .

• Separate engine/transmission assembly: Vehicles with manual transmission → Engine and manual transmission, separating  , vehicles with automatic transmission → Engine and automatic transmission 09L, separating .
• Secure engine to assembly stand: Vehicles with manual transmission → Engine, securing to assembly stand  , Vehicles with automatic transmission → Engine, securing to assembly stand  or lower engine on scissor lift platform VAS 6131.
• Vehicles with manual transmission: Remove clutch pressure plate →
  • 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE
  • 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE
  • 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE
  • 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE
  • 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE
  • 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE
  and dual mass flywheel → Dual mass flywheel (vehicles with manual transmission), removing and installing .
• Vehicles with automatic transmission: Remove drive plate → Drive plate (vehicles with automatic transmission), removing and installing .

• Remove front sealing flange → Front sealing flange with crankshaft seal, removing and installing .
• Remove left and right timing chain covers → Left and right timing chain covers, removing and installing .
• Remove lower timing chain cover → Lower timing chain cover, removing and installing .
• Remove drive chain for oil pump and balance shaft → Drive chain for oil pump and balance shaft, removing and installing .

Fig 4: Securing Balance Weight At Rear Of Engine With Drill Bit

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• To protect against cuts, wrap point and cutting edges of 8 mm dia. drill bit with insulating tape.
• Secure balance weight - 2  - at rear of engine with 8 mm dia. drill bit - 1  -.
• Remove bolt - 3  - and remove balance weight from balance shaft.

Fig 5: Removing Bolt, Counter-Holding Balance Weight With Drift And Removing Balance Weight From Balance Shaft At Front Of Engine

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• Remove bolt - 2  - , thereby counter-hold balance weight with drift and remove balance weight - 1  - from balance shaft at front of engine.

Fig 6: Removing Bolts And Bearing End Bracket From Balance Shaft At Rear Of Engine

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• Remove bolts - arrows  - and remove bearing end bracket from balance shaft at rear of engine.
• Pull balance shaft rearward and out from cylinder block.

Installing 

Fig 7: Installing Crankshaft Holder T40069 Into Hole

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• Secure crankshaft - 1  - in TDC position using crankshaft holder T40069.

Installation is in reverse order of removal, note the following:

• Install oil pump drive chain and balance shaft → Drive chain for oil pump and balance shaft, removing and installing .
• Install lower timing chain cover → Lower timing chain cover, removing and installing .
• Install oil filter housing → Oil filter housing, removing and installing .
• Install left and right timing chain covers → Left and right timing chain covers, removing and installing .

• Install crankshaft seal, timing chain side → Crankshaft seal, timing chain side, replacing .
• Install front sealing flange → Front sealing flange with crankshaft seal, removing and installing .
• Vehicles with manual transmission: Install dual mass flywheel → Dual mass flywheel (vehicles with manual transmission), removing and installing  and clutch pressure plate →
  • 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE
  • 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE
  • 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE
  • 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE
  • 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE
  • 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE
  .
• Vehicles with automatic transmission: Install drive plate → Drive plate (vehicles with automatic transmission), removing and installing .

• Attach transmission to engine and install engine/transmission assembly: Vehicles with manual transmission → Engine, installing  , vehicles with automatic transmission → Engine, installing .
• Add engine oil and check oil level → Oil level, checking .

Torque specifications