Volkswagen Golf Variant / Jetta. Manual - part 395

 

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Volkswagen Golf Variant / Jetta. Manual - part 395

 

 

tional 90° (1/4) turn using a ratchet.

• The locking tool pins must engage in the groove on the bal‐

ance shaft.

– Carefully position the balance shaft spur gear on the balance

shaft while pressing the intermediate sprocket to the side

slightly.

Note

Make sure the threaded holes on the balance shaft are cen‐

tered as much as possible in the oblong holes on the balance

shaft spur gear.

If the oblong holes in the balance shaft spur gear cannot be

aligned with the threaded holes in the cover, rotate the balance

shaft spur gear the corresponding number of teeth and posi‐

tion it again.

– Tighten the bolts for the balance shaft spur gear -arrows-.
– Remove the Locking Tool - T10255- .

2. Lubrication System Components, Engine Code CBEA    

163

second technician is required):
– Press the intermediate gear -3- forcefully in the direction of

-arrow- into the splines of the crankshaft spur gear -2- and the

balance shaft spur gear -1- using a wooden block if necessary.

– Rotate the balance shaft spur gear counter-clockwise slightly.
– Tighten the new intermediate sprocket bolt:
• Tightening specification -item 12- 

⇒ Item 12 (page 154)

 .

– Remove the Crankshaft Stop - T10100- or the Crankshaft Stop

- T10050- .

Note

The intermediate sprocket must not have any backlash after in‐

stallation. This can be checked by pressing slightly by hand.

The rest of the installation is performed in reverse order of re‐

moval, while doing so pay attention to the following:
– Install the oil pan. Refer to

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

 .

– Install the toothed belt guard lower section:
• Tightening specification -item 27- 

⇒ Item 27 (page 44)

 .

– Install the belt pulley/vibration damper.
• Tightening specification -item 28- 

⇒ Item 28 (page 44)

 .

– Install the ribbed belt. Refer to

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

 .

164

Used Balance Shaft Assembly, Instal‐

ling

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

the Crankshaft Stop - T10050- .

Caution

♦ If the intermediate sprocket bolt was loosened, the crank‐

shaft spur gear was replaced, or the crankshaft was re‐

moved, then a new intermediate sprocket with coating

must be installed and the hub -item 11-

⇒ Item 11 (page 154)

 including the bolt -item 12-

⇒ Item 12 (page 154)

 and axial bearing disc -item 13-

⇒ Item 13 (page 154)

 must be replaced. Otherwise the

backlash will not be correct.

♦ Installation procedure. Refer to

⇒ “2.4.2 New Balance Shaft Assembly, Installing”,

page 161

 , New Balance Shaft Assembly, Installing

Note

Proceed as follows if the used balance shaft assembly will be

installed again and neither the crankshaft spur gear was re‐

placed nor the crankshaft was removed. Never loosen the

intermediate sprocket.

Replace the bolts which have been tightened to torque.

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

Rotate the balance shaft if necessary.

• The locking tool pins must engage in the groove on the bal‐

ance shaft.

– Check that the alignment sleeves for centering the balance

shaft assembly on the cylinder block are present.

– Position the balance shaft assembly on the cylinder block.
• The intermediate sprocket must engage in the spur gear on

the crankshaft when the balance shaft is locked.

• The intermediate sprocket must have slight noticeable back‐

lash.

2. Lubrication System Components, Engine Code CBEA    

165

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.

Tightening Sequence - Balance Shaft Module with Six Attach‐

ment Points

– Install the new bolts in 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.
– 4. Tighten the bolts in sequence -1 through 6- turn an addi‐

tional 90° (1/4) turn using a ratchet.

– Remove the Crankshaft Stop - T10100- or the Crankshaft Stop

- T10050- .

The rest of the installation is performed in reverse order of re‐

moval, while doing so pay attention to the following:
– Install the oil pan. Refer to

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

 .

– Install the toothed belt guard lower section:
• Tightening specification -item 27- 

⇒ Item 27 (page 44)

 .

– Install the belt pulley/vibration damper.
• Tightening specification -item 28- 

⇒ Item 28 (page 44)

 .

– Install the ribbed belt. Refer to

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

 .

2.5

Spur Gear, Removing from Crankshaft

and Shrink-Fitting New Spur Gear

⇒ “2.5.1 Spur Gear, Removing from Crankshaft”, page 166

 .

⇒ “2.5.2 New Spur Gear, Shrink-Fitting”, page 168

 .

2.5.1

Spur Gear, Removing from Crankshaft

Special tools and workshop equipment required
♦ Seal Installer - Crankshaft/Camshaft - 10-203-
♦ Commercially available hotplate
♦ Puller - Spur Gear - T10392- with

166

 

 

 

 

 

 

 

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