New Balance Shaft, Installing

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

Conditions

Fig 1: Locking Crankshaft Toothed Belt Pulley Using Crankshaft Stop T10050

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Secure the crankshaft using the crankshaft stop T10100.

NOTE:

The balance shaft module spur gear must be installed with the correct backlash.

A coating is applied to the new intermediate sprocket to achieve the correct backlash.

If the intermediate sprocket has a white dot, the coating covers only parts of the circumference. If there is no white dot, the entire circumference of the intermediate sprocket is coated.

The coating wears off in a short period of time and ensure the correct backlash.

For this reason, a new balance shaft module must always be installed in conjunction with a new intermediate sprocket with coating.

Only intermediate sprockets with a partial coating have a white dot to indicate the correct installed position.

There is no installed position to follow for intermediate sprockets with coating on the entire circumference.

Replace bolts which have been tightened to a torque angle.

CAUTION:

The intermediate shaft threaded connection must be loosened to position the balance shaft module. When doing so, make sure the bolt is not loosened too much. Otherwise the bearing disc could slip behind the intermediate sprocket.
Axial bearing disc installed position, refer to Figure.

-- Before positioning the balance shaft module on the cylinder block, loosen the intermediate sprocket bolt -1- approximately 45° (1/8) turn.

Fig 2: View Of Intermediate Sprocket Bolt

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-- Make sure both alignment sleeves for centering the balance shaft module on the cylinder block are present.

-- Position the balance shaft module on the cylinder block. Make sure the partially coated intermediate sprocket is positioned correctly:

Fig 3: Identifying Correctly Positioned Intermediate Sprocket

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The white dot -arrow- on the intermediate sprocket must be centered with the crankshaft.

NOTE:

Make sure the coating on the intermediate sprocket is not damaged.

Due to the gear ratio, the white dot -arrow- will not be in the original location after rotating the engine.

-- Install the new bolts in the sequence -1 to 8- and tighten them by hand.

Fig 4: View Of Balance Shaft Module Bolt Tightening Sequence

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-- Tighten the balance shaft module bolts as follows:

-- Tighten the nuts in sequence -1 through 8- to 6 Nm.

-- Tight the bolts -5 and 7- to 13 Nm.

-- Tighten the bolts -5 and 7- an additional 90° (1/4) turn using a ratchet.

-- Tighten the bolts -1 through 4, 6 and 8- to 20 Nm.

-- Tighten the bolts -1 through 4, 6 and 8- an additional 90° (1/4) turn using a ratchet.

-- Secure the balance shaft using the locking tool T10255. Rotate the balance shaft if necessary.

Fig 5: View Of Locking Tool T10255

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The locking tool pins must engage in the groove on the balance shaft.

-- Carefully position the balance shaft spur gear on the balance shaft while pressing the intermediate sprocket to the side slightly.

Fig 6: View Of Balance Shaft Spur Gear

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NOTE:

Make sure the threaded holes on the balance shaft align and are centered as much as possible in the slots on the balance shaft spur gear.

If the slots on the balance shaft spur gear cannot be aligned with the threaded holes in the cover, rotate the spur gear the corresponding number of teeth and position it again.

-- Tighten the balance shaft spur gear bolts -arrows-.

-- Remove the locking tool T10255.

The following three steps must be performed at the same time (a second technician is required):

Fig 7: Identifying Crankshaft Spur Gear

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-- Using a wooden block to assist if necessary, press the intermediate shaft -3- forcefully in the -direction of the arrow- into the splines on the crankshaft spur gear -2- and balance shaft spur gear -1-.

-- Rotate the balance shaft spur gear counterclockwise slightly when doing so.

-- Tighten the new bolt for the intermediate sprocket:

Tightening specification, see -item 12- in the OIL PUMP, PAN AND BALANCE SHAFT MODULE OVERVIEW .

-- Remove the crankshaft stop T10100.

NOTE:

The intermediate sprocket must not have any angular clearance after installation. This can be checked by pressing slightly with the hand.

The rest of the installation is performed in reverse order of removal, noting the following:

-- Install the oil pan. Refer to OIL PAN .

-- Install the lower toothed belt guard:

Tightening specification, see -item 27- in the TOOTHED BELT OVERVIEW .

-- Install the vibration damper.

Tightening specification, see -item 28- in the TOOTHED BELT OVERVIEW .

-- Install the ribbed belt. Refer to RIBBED BELT .