Note: Replace the intermediate plate.
Note: Observe the expiration date of the sealant.
Note: The oil pan and balance shaft drive with intermediate plate must be installed and bolted down within 5 minutes after applying the silicone sealant.
Remove any remaining sealant from the cylinder block using a flat scraper.
Cut off the tube tip along the front mark (The hole diameter is about 3 mm).
Apply silicone sealant as shown to the clean seating surface of the new spacer plate.
Please follow the instructions below.
The sealant bead should be 2–3 mm thick.
Apply sealant to the inside of the mounting bolt holes
The bead of sealant should face the cylinder block. No sealant is needed for the oil pan.
Fig. 2.179. Sealant application diagram
Note: The thickness of the sealant bead should not exceed the above specified value, since excess sealant may enter the oil pan and clog the mesh filter of the oil pump oil inlet pipe (fig. 2.179).
Fig. 2.180. Balance shaft drive mounting bushings
Place the intermediate plate on the balance shaft drive mounting bushings as shown in Figure 2.180.
Install the oil pump with balance shaft drive and intermediate plate. Tighten the mounting bolts, starting from the middle to the edges, with a tightening torque of 15 N·m + 1/4 turn (90°).
Note: Please note the different bolt lengths.
Bring the crankshaft to the TDC position of the first cylinder.
Fig. 2.181. Alignment of marks when bringing the crankshaft to the TDC position of the first cylinder
Align the mark on the balance shaft chain sprocket with the locking hole (fig. 2.181).
Lock the sprocket in this position with the locking pin. Place the chain on the balance shaft sprocket.
Install the oil pump sprocket and tighten the mounting bolt by hand.
Note: The oil pump chain sprocket can only be installed in one position. Only the oil pump may be rotated for installation.
Remove the locking pin and Allen key 1. Secure the oil pump sprocket. Tightening torque 20 Nm + 1/4 turn. (90°). You can hold it by the central bolt of the vibration damper.
Install the oil pan.
Further assembly is carried out, accordingly, in the reverse order of dismantling.
Matching balance shaft drive mounting bolts:
- A - Hexagon bolt M7x40;
- B - Hexagonal bolt M7x55;
- C - Hexagonal bolt M7x90;
- D - Hexagonal bolt M7x115;
- E - Threaded plug with O-ring seal.
Pre-tensioning the chain tensioner
Fig. 2.182. Tensioner piston
Pull the piston by hand (fig. 2.182).
Fig. 2.183. Tensioner bar
Press the tensioner bar in the direction of the arrow and lock it with a hex key 1, spanner size 3 mm (fig. 2.183).
(The original text is available on the website: «www.vwmanual.ru»)
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