Volkswagen Golf Variant / Jetta. Manual - part 394

 

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Volkswagen Golf Variant / Jetta. Manual - part 394

 

 

pump in direction of -arrow-.

– Remove the screw -4- and remove the intake tube from the oil

pump.

– Remove the bolts -3 and 5- and the oil pump.

Caution

Do not loosen the bolt on the intermediate sprocket.

Installing:
Install in reverse order of removal. Note the following:
• Replace the O-ring.
• Replace damaged or stretched circlips.
• The circlip must lie in the base of the groove.
• Tightening specifications. Refer to

⇒ “2.1 Overview - Oil Pump, Oil Pan and Balance Shaft As‐

sembly”, page 153

 , Overview - Oil Pump, Oil Pan and Balance

Shaft Assembly

– Check that the alignment sleeves to center the oil pump on the

balance shaft assembly are present before installing the oil

pump.

– Install the oil pan. Refer to

⇒ “2.2 Oil Pan, Removing and Installing”, page 156

 .

2.4

Balance Shaft Assembly, Removing and

Installing

⇒ “2.4.1 Balance Shaft Assembly, Removing”, page 159

 .

⇒ “2.4.2 New Balance Shaft Assembly, Installing”, page 161
⇒ “2.4.3 Used Balance Shaft Assembly, Installing”, page 165

2.4.1

Balance Shaft Assembly, Removing

Special tools and workshop equipment required
♦ Crankshaft Stop - T10100- or the Crankshaft Stop - T10050-

for engines with a round crankshaft toothed belt sprocket

♦ Locking Tool - T10255-
– Remove the ribbed belt. Refer to

⇒ “1.4 Ribbed Belt, Removing and Installing”, page 47

 .

– Remove the belt pulley/vibration damper -item 29-

⇒ Item 29 (page 45)

 .

– Remove the toothed belt guard lower section -item 25-

⇒ Item 25 (page 44)

 .

– Remove the oil pan. Refer to

⇒ “2.2 Oil Pan, Removing and Installing”, page 156

 .

2. Lubrication System Components, Engine Code CBEA    

159

belt sprocket with the Crankshaft Stop - T10050- . Push the

crankshaft stop from the front side of the toothed belt sprocket

into the splines. The camshaft toothed segment must be in the

»12 o'clock« position.

Note

The markings on the crankshaft toothed belt sprocket -2- and the

Crankshaft Stop - T10050- -1- must align. The pin on the Crank‐

shaft Stop - T10050- must engage in the hole on the sealing

flange.

– Remove the bolts in the sequence -8 to 1- and remove the

balance shaft assembly with the oil pump.

Loosening Sequence - Balance Shaft Module with Six Attachment

Points

– Remove the bolts in the sequence -6 through 1- and remove

the balance shaft module with the oil pump.

Refer to

⇒ “2.4.2 New Balance Shaft Assembly, Installing”, page 161

Refer to

⇒ “2.4.3 Used Balance Shaft Assembly, Installing”, page 165

160

New Balance Shaft Assembly, Installing

Conditions
• Crankshaft secured using the Crankshaft Stop - T10100- or

the Crankshaft Stop - T10050- .

Note

The balance shaft assembly spur gear drive must be installed

with the correct backlash.

A coating is applied to the new intermediate sprocket to ach‐

ieve the correct backlash.

When the intermediate sprocket has a white dot, only sections

of the circumference are coated. When there is not a white dot,

then the entire circumference of the intermediate sprocket is

coated.

The coating wears off in a short period of time and this ensures

the correct backlash.

For this reason, a new balance shaft assembly 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 installation position.

No installation position must be observed for intermediate

sprockets with coating on the entire circumference.

Replace the bolts which have been tightened to torque.

Caution

♦ The intermediate sprocket threaded connection must be

loosened to position the balance shaft assembly. When

doing so, make sure the bolt is not loosened too much.

Otherwise the bearing disc could slip behind the inter‐

mediate sprocket.

♦ Axial bearing disc installation position. Refer to

⇒ Fig. ““Axial Bearing Disc Installation Position”“ ,

page 156

 .

– Loosen the bolt -1- for the intermediate sprocket approximate‐

ly 45° (

1

/8 turn) before mounting the balance shaft assembly

on the cylinder block.

– Check that the alignment sleeves for centering the balance

shaft assembly on the cylinder block are present.

2. Lubrication System Components, Engine Code CBEA    

161

make sure the partially-coated intermediate sprocket is in the

correct position:

• The white dot -arrow- on the intermediate sprocket must be

centered to the crankshaft.

Note

Make sure the coating on the intermediate sprocket is not

damaged.

Due to the gear ratio, the white dot -arrow- does not go back

to its original position after the engine is turned over.

– Also install the new bolts in the sequence -1 to 8- hand-tight.
– Tighten the balance shaft assembly bolts as follows:
1.

Pretighten the bolts in sequence -1 to 8- to 6 Nm.

2.

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

3.

Turn the bolts -5 and 7- an additional 90° (

1

/4 turn) using a

rigid wrench.

4.

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

5.

Turn the bolts -1 to 4, 6 and 8- an additional 90° (

1

/4 addi‐

tional turn) using a rigid wrench.

– Secure the balance shaft with the Locking Tool - T10255- .

Rotate the balance shaft if necessary.

Tightening Sequence - Balance Shaft Module with Six Attach‐

ment Points

– Install the new bolts in the sequence -1 through 6- and tighten

them by hand.

– Tighten the balance shaft module bolts in four stages as fol‐

lows:

– 1. Tight the bolts -1 through 6- to 6 Nm.
– 2. Tighten the bolts -1 through 4- to 20 Nm.
– 3. Tighten the bolts in sequence -5 and 6- to 13 Nm.

162

 

 

 

 

 

 

 

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