Intake Camshaft Balance Shaft

WARNING: This page is about a different car, the 2009 Volkswagen GTI and 2008 Volkswagen GTI. 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-

NOTE:

Always replace the balance shaft after removing it.

Removing

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

-- Remove the upper timing chain cover. Refer to UPPER TIMING CHAIN COVER .

-- Remove the lower timing chain cover. Refer to one of the following:

Passat and CC, refer to .
GTI and Eos, refer to LOWER TIMING CHAIN COVER .
Tiguan, refer to .

-- Remove the camshaft timing chain. Refer to CAMSHAFT TIMING CHAIN .

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

-- Remove the intermediate sprocket bolt -1-.

Fig 1: Identifying Intermediate Shaft Sprocket

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- 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 turn 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 the 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 and tighten the bolt -2-.

Fig 6: Identifying Intake Camshaft Balance Shaft

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

Fig 7: Identifying Bearing Pins, Installation Position

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-- Lubricate the bearing pin with engine oil and install it; the pin -arrow- 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 8: 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.

-- Tighten the sprocket bolt -1-, refer to Figure.

Fig 9: Identifying Intermediate Shaft Sprocket

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

NOTE:

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

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

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

-- Replace the coolant pump drive seal. Refer to COOLANT PUMP DRIVESHAFT SEAL .