Intake Camshaft Balance Shaft

WARNING: This page is about a different car, the 2010 Volkswagen Jetta, 2009 Volkswagen Jetta, 2009 Volkswagen GLI, 2008 Volkswagen Jetta, and 2008 Volkswagen GLI. However, it is still accessible from the selected car via links, so may be relevant.

Special Tools And Workshop Equipment Required

Puller T10394
Puller T10055
Torque Wrench (5-50 Nm) V.A.G 1331

NOTE:

Always replace the balance shaft after removing it.

Removing

-- Remove the balance shaft timing chain. Refer to BALANCE SHAFT TIMING CHAIN .

-- Remove the coolant pump toothed belt. Refer to COOLANT PUMP TOOTHED BELT .

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

Fig 1: Identifying Intermediate Shaft Sprocket

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

Fig 2: Identifying Intake Camshaft Balance Shaft

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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-.

Fig 3: Identifying Half Shell -T10394/1-

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

Fig 4: Identifying Installation Of Puller Pieces -T10394- And -T10394/1-

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

Fig 5: Identifying Installation And Operation Of Puller -T10055-

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Installing

NOTE:

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 .

-- 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.

Fig 6: Identifying Bearing Pins - Installation Position

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-- 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.

CAUTION:

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-.

Fig 7: Identifying Tooth Face On Intermediate Shaft Sprocket Marked With Paint

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-- 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- :

Fig 8: Identifying Intermediate Shaft Sprocket

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Tightening specifications, refer to Figure.

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

NOTE:

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

-- Install the balance shaft timing chain. Refer to 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 .