Power Take-Off Drive Chain, Through 04.06

Power Take-Off Drive Chain, through 04.06

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. Refer to => Manual Transmission/Transaxle [1][2]Manual Transmission/Transaxle and dual mass flywheel => [ Dual Mass Flywheel ] Dual Mass Flywheel.

- Vehicles with multitronic transmission: Remove damper unit. Refer to => [ Damper Unit ] Damper Unit and flywheel => [ Flywheel ] Flywheel.

- Vehicles with automatic transmission. Remove drive plate. Refer to => [ Dual Mass Flywheel ] Dual Mass Flywheel.

• 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.

- 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. Refer to => [ Left and Right Timing Chain Covers ] 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. Refer to => [ Lower Timing Chain Cover ] 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. Refer to => [ Lower Timing Chain Cover ] Lower Timing Chain Cover.

- Install oil filter housing. Refer to => [ Oil Filter Housing ] Oil Filter Housing.

- Install left and right timing chain covers. Refer to => [ Left and Right Timing Chain Covers ] Left and Right Timing Chain Covers.

- Install crankshaft seal, timing chain side. Refer to => [ Crankshaft Seal, Timing Chain Side, Replacing ] Crankshaft Seal, Timing Chain Side, Replacing.

- Manual Transmission Install dual mass flywheel. Refer to => [ Dual Mass Flywheel ] Dual Mass Flywheel and clutch pressure plate => Manual Transmission/Transaxle [1][2]Manual Transmission/Transaxle

- Vehicles with multitronic transmission: Install flywheel. Refer to => [ Flywheel ] Flywheel and damper unit => [ Damper Unit ] Damper Unit.

- Vehicles with automatic transmission: Install drive plate. Refer to => [ Drive Plate ] Drive Plate.

- Install stabilizer bar.

- Add engine oil and check oil level.

Tightening Specifications