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Hi,

I don't know the service history of my 120,000 mile 2004 Passat TDI wagon. I have stopped driving the car because I think I hear the balance shaft chain noise as compared to the sound on other internet video. The Lock Carrier is removed in preparation for timing belt and balance shaft work but I have not purchase parts yet. From reading it appears that one could either replace the chain tensioner or the entire balance shaft module. I am a little concerned about shelling out $1200 for a part that I may not need.

From this point of disassembly is it possible to inspect the balance shaft drive chain without removing the oil pan. I am wondering if an inspection could be done by removing the crankshaft seal housing before dropping the sub frame and oil pan.

Thanks again.
 

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Premium Member
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You can inspect the top of the chain by removing the front seal. Note that you should use a seal install tool to prevent the seal lip from folding over, otherwise it could leak. I do rent all the balance shaft kit tools and the TB tools, send me a PM if interested, it can go out right away. The crankshaft sprocket bolt is also a single use only bolt so you need a new one if you loosen it.

To inspect the tensioner which requires oil pan removal which requires subframe lowering.

You could replace just the tensioner, the part number is VW# 03g115124 but I wouldn't because you're doing 90% of the effort without fixing all the problems. Before the tensioners were having problems, the oil pump driveshaft was wearing out. The gear motion is smoother and should fix it. Read this FAQ for a magazine article on it: http://www.myturbodiesel.com/1000q/b5/oil-pump-failure-passat-tdi.htm
 
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