Balance shaft update complete.
Timing belt and balance shaft update complete on my '05 Passat wagon. Thanks to this forum the job went smoothly and the tools I rented worked perfectly. Nothing much to add to the posted instructions, pretty much went as described. I was able to replace my timing belt without having to loosen the three bolts on the camshaft sprocket and the timing marks lined up perfectly with the new belt installed. While I was in there I installed new motor mounts, performed a mufflerectomy with 2.5" straight pipe and installed a Diesel Power Digi PD module from Pareys diesel performance.
Do I notice a difference? Yes, the engine revs much smoother and that annoying chain noise is gone. My TDI no longer sounds like a Singer sewing machine. The PD module is well worth the money. I commute daily about 75 miles on the highway and the upper end performance is much improved. Passing from 50 mph to 75 mph is where I notice the biggest difference. I've got it set at the "B" setting and have seem some reduction in MPG.
I am most pleased with the mufflerectomy. I left the cat in place and I don't think there is much difference in sound from stock. Put it this way, my wife hasn't noticed. When you get on it, that's when you hear the difference and it might be my imagination but the throttle respones seems much improved even before I installed the PD module. I highly recommend this modification. Check out
Mandrel Bending Solutions on eBay for a nice exhaust kit package.
Thanks again for the great site and I'd be happy to discuss my experience with anyone contemplating the same.
