Power Take-Off Drive Chain, Through 04.06, Removing and Installing

Power Take-Off Drive Chain, through 04.06, Removing and Installing





Special tools, testers and auxiliary items required

^ Old oil collecting and extracting device V.A.G 1782
^ Wrench T40049
^ Locking pin T40069
^ Securing pin T40071
^ Drill bit 8 mm dia.

Removing

^ Transmission removed.

- Manual Transmission Remove clutch pressure plate.
- Vehicles with multitronic transmission: Remove damper unit.
- Vehicles with automatic transmission: Remove drive plate.

Note:
^ After removing transmission, the engine is supported by engine support bridge 10-222 A and the torque support stop is loosened.

CAUTION: For the further sequence of work, it must be made sure that the lock carrier is installed. Service and Repair

- To remove transmission, remove attached engine support bridge 10-222 A from engine.





- Tighten torque support stop to 28 Nm - arrows -.
- Remove left and right timing chain covers.
- Place old oil collecting and extracting device V.A.G 1782 under engine.
- Drain engine oil.
- Remove lower timing chain cover.

CAUTION: Place a washer under bolt heads, to prevent the chain from being pinched by the bolts.





- Install key T40049 at rear of the crankshaft using 2 old bolts - arrows - for dual mass flywheel.

Manual Transmission





- Unfasten left and right stabilizer bar mountings -1- and -2-.
- Pivot stabilizer bar downward.





- Remove sealing plug - arrow - from cylinder block.

CAUTION: Do not turn the crankshaft while touching the TDC opening with a finger or personal injury could result.

- Rotate crankshaft in direction of engine rotation to TDC of ignition timing.





- Install crankshaft holder T40069 into hole to 20 Nm, if necessary rotate crankshaft very slightly back and forth to completely center the holder.





- Mark running direction of power take-off chain with paint.
- Press chain tensioner guide rail in direction of - arrow - and secure chain tensioner with securing pin T40071.
- Remove bolts - 1 through 3 - and remove chain tensioner, balance shaft sprocket and chain.

Installing





^ Secure crankshaft -1- in TDC position using crankshaft holder T40069.





- Mount chain tensioner with chain and balance shaft sprocket.
- To protect against cuts, wrap point and cutting edges of 8 mm dia. drill bit with insulating tape.
- Secure balance shaft with drill bit 8 mm dia. -1- in TDC position.

^ The slots in balance shaft sprocket must be at the middle position in relation to the threaded holes of the balance shaft. If necessary, adjust chain by one tooth.

- Tighten chain tensioner bolts.
- Loosely install bolts -2- for sprocket.

^ Chain sprocket must still be able to be rotated on balance shaft and must not tip.

- Pull out securing pin T40071 to release chain tensioner.
- Press against chain tensioner guide rail - arrow - with screwdriver and simultaneously fasten bolts -2- for sprocket.
- Pull drill -1- out of balance shaft.

Further installation is in reverse order of removal, noting the following:

- Install lower timing chain cover.
- Install oil filter housing.
- Install left and right timing chain covers.
- Install crankshaft seal, timing chain side.
- Manual Transmission Install dual mass flywheel.
- Vehicles with multitronic transmission: Install flywheel.
- Vehicles with automatic transmission: Install drive plate.
- Install stabilizer bar.
- Add engine oil and check oil level.

Tightening Specifications