Power Take-Off Drive Chain, From 05.06

Power Take-Off Drive Chain, from 05.06

Special tools, testers and auxiliary items required

• Old oil collecting and extracting device (V.A.G 1782 )

• Wrench (T40049)

• Securing pin (T40071)Locking Pin (T40071)

• Drill bit 8 mm dia.

Removing

CAUTION!
To continue performing the repair procedure, ensure lock carrier is installed and torque support is tightened.

• Transmission removed.

- Manual Transmission Remove clutch pressure plate. Refer to => Manual Transmission/Transaxle 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 09L: Remove drive plate. Refer to => [ Drive Plate ] Drive Plate.

- Place Used Oil Collecting and Extracting Device ( V.A.G 1782) under engine and drain engine oil.

- Remove lower timing chain cover. Refer to => [ Lower Timing Chain Cover ] Lower Timing Chain Cover.

CAUTION!
If necessary, place a washer under the bolt heads, to prevent the chain from being pinched by the bolts.

- Install key (T40049) at rear on crankshaft using 2 old bolts for dual-mass flywheel.





- Remove locking bolt - arrow - for "TDC" marking from upper part of oil pan.





- Rotate crankshaft in direction of engine rotation to "TDC ".

- Install crankshaft holder (T40069) into the hole and tighten it to 20 Nm. If necessary rotate crankshaft very slightly back and forth to completely center holder.





- Mark running direction of power take-off chain with paint.





- Press chain tensioner guide rail in direction of - arrow - and secure chain tensioner using a Locking Pin ( T40071).

- Remove bolts - 3 - and balance shaft chain sprocket.

- Remove bolts - 1 - and - 2 - and chain tensioner with 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 using an 8 mm dia. drill bit - 2 - at "TDC".

• The slots in the 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 chain sprocket bolts - 1 - and - 3 -.

• It must still be possible to rotate the chain sprocket on balance shaft and it must not tip.

- Pull out Locking Pin (T40071) to release chain tensioner.

- Press against chain tensioner guide rail - arrow - using a screwdriver while tightening chain sprocket bolts - 1 - and - 3 -.

- Pull drill - 2 - out of balance shaft.

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

- Install timing chain lower cover. Refer to => [ Lower Timing Chain Cover ] Lower Timing Chain Cover.

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

- Install transmission-side crankshaft shaft seal. 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 Manual Transmission/Transaxle

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

- Vehicles with automatic transmission 09L: Install drive plate. Refer to => [ Drive Plate ] Drive Plate.

- Add engine oil and check oil level.

Tightening Specifications