Audi Workshop Service and Repair Manuals

Removing and installing sump and balance shaft assembly

Special tools and workshop equipment required

t	Support bracket -10-222 A-

t	Shackle -10 - 222 A/12-

t	Used oil collection and extraction unit -V.A.G 1782-

t	Workshop hoist -VAS 6100- or workshop hoist -V.A.G 1202-

t	Locking pin -T10060 A- or -T10060-

t	Mud wing compensation plate -T40045-

t	Electric drill with plastic brush attachment

t	Safety goggles

t	Sealant → Parts catalogue

Removing   Note t  The balance shaft assembly must be removed and the intermediate plate → Item renewed if the sump is removed. t  All cable ties which are released or cut open when removing must be fitted in the same position when installing.

–  If fitted, detach cover -1- on right of engine compartment.

–  Disengage solenoid valve 1 for activated charcoal filter system -N80--item 1- at air duct. –  Remove bolts -arrows-. –  Remove air duct -2-.   Note

Before removing, mark direction of rotation of poly V-belt with chalk or felt-tipped pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage. –  Turn the tensioner in the direction of the -arrow- to slacken the poly V-belt.

–  Lock tensioner for poly V-belt in position with locking pin -T10060 A- or -T10060-. –  Remove poly V-belt.

–  Pull off engine cover panel -arrows-.

–  Detach air intake pipe from throttle valve module -J338--arrow-.

–  Move electrical wiring clear of air pipe (rear). –  Detach air pipe from air cleaner housing -1- and from retaining stud -2-.

–  Pull off bonnet seal at wing mounting flanges. –  Place compensation plates -T40045- between the wing mounting flange and the body panel underneath, so that the support bracket -10-222 A- does not damage the wing mounting flanges.

–  Position support bracket -10-222 A- on wing mounting flanges (spindle faces to rear). –  Engage shackle -10-222 A/12- into rear engine lifting eye. –  Attach hook on spindle -10-222 A/11- to shackle. –  Take up weight of engine using spindle of support bracket.

–  Vehicles with auxiliary heater: remove bolts -arrows- securing exhaust pipe for auxiliary/additional heater to noise insulation.

–  Release fasteners -1 … 3- and take off front noise insulation and rear noise insulation (if fitted).

–  Unbolt bracket for noise insulation -arrows-.

–  Place used oil collection and extraction unit -V.A.G 1782- under engine and drain engine oil. –  Unplug electrical connector -arrow- at oil level/oil temperature sender -G266-.

–  Unbolt refrigerant pipe bracket from sump -arrow-.

–  Unplug electrical connector -1- for magnetic clutch on air conditioner compressor.   WARNING The air conditioner refrigerant circuit must not be opened. –  Unscrew air conditioner compressor from bracket -arrows-.   Note To prevent damage to the refrigerant lines, ensure that the pipes and hoses are not stretched, kinked or bent. –  Tie up air conditioner compressor to vehicle, with lines attached.

–  Remove bolts -arrows-. –  Remove torque reaction support.

Vehicles up to 10.2004: –  If fitted, unclip actuator rod for vehicle level sender at bottom transverse link -arrow-.

Vehicles from 11.2004 onwards: –  If fitted, unplug electrical connector -arrow- at front left vehicle level sender -G78-.

All models: –  Remove bolts -1- and -2- from anti-roll bar mounting.

–  Cut open the cable ties -arrows-, open bracket for starter wire and take out the electrical wire.

–  Support subframe using workshop hoist -VAS 6100- or -V.A.G 1202 A-.   Note

To avoid having to check and adjust wheel alignment, only loosen the front subframe mountings and lower the subframe at the front. –  Unscrew nut -3- at bottom of engine mounting. –  Unscrew bolts -4- and -5- on console for engine mounting. –  Unscrew bolt -1- (front) for subframe and remove console for engine mounting -2-. –  Repeat procedure on other side of vehicle.

–  Carefully lower subframe using workshop hoist -VAS 6100- or -V.A.G 1202 A-.

–  Lift engine up slightly using spindle -10-222 A/11- of support bracket -10-222 A-; make sure the selector linkage and exhaust system do not become trapped.

–  Unscrew gearbox/sump bolts -arrows-.   Note

On vehicles with manual gearbox, the two rear sump bolts -1- and -2- are accessible via the recess -arrow- on the dual-mass flywheel -3- (turn the flywheel as required). –  Take off sump; if necessary loosen it by striking lightly with a rubber hammer.   Note Detach bolts which cannot be removed together with the sump.

–  Unscrew M10 bolts -arrows-. –  Slacken bolts -1 ... 18- in diagonal sequence. –  Remove all bolts and take off sump; if necessary loosen it by striking lightly with a rubber hammer.

–  Remove oil pipe -arrows-.

–  Detach chain sprocket cover by using screwdriver to carefully lever out clips in openings -arrows-.

–  Loosen bolt for oil pump chain sprocket approx. 1 turn.

–  Press guide rail down -arrow- using a screwdriver. –  Lock guide rail by inserting 3 mm Allen key -item 1-.

–  Detach oil pump chain sprocket and disengage chain at balance shaft assembly.

–  Working from outside inwards, slacken off bolts -arrows- of balance shaft assembly. –  Detach balance shaft assembly with intermediate plate.

Installing   Note t  Renew the intermediate plate. t  Renew bolts which are tightened to a specified angle as well as oil seals, gaskets and O-rings. –  Remove sealant residue from sump and cylinder block with rotating plastic brush or similar.   WARNING Wear safety goggles. –  Clean all sealing surfaces; they must be free of oil and grease.

–  Cut off tube nozzle at front marking (nozzle approx. 2 mm Ø). –  Apply bead of sealant to intermediate plate on clean sealing surface for cylinder block as shown in illustration -arrows-. l  Thickness of sealant bead: 2 ... 3 mm   Note t  The sealant bead must not be thicker than specified, otherwise excess sealant could enter the sump and clog the strainer in the oil pump. t  Apply sealant round inside of bolt holes, as shown in illustration. t  Take particular care when applying sealant bead in area of rear sealing flange -arrows-. t  Also take particular care when applying sealant bead in area around oil return passages on right of cylinder block. t  Balance shaft assembly and sump must be installed within 5 minutes after applying sealant. –  Fit intermediate plate onto dowel sleeves on balance shaft assembly as shown in illustration -arrows-. l  Sealant bead faces cylinder block. –  Renew all balance shaft assembly bolts. –  Renew O-ring on balance shaft assembly bolt → Item.

–  Install balance shaft assembly with oil pump.   Note Note the centring sleeves -arrows-.

–  Renew bolts (note different bolt lengths). –  Tighten bolts -arrows- in the specified sequence, working from inside outwards: 1.  Screw in bolts finger-tight. 2.  Tighten bolts to 15 Nm using torque wrench. 3.  Turn bolts 90° (1/4 turn) further using a rigid wrench.

–  Turn the crankshaft to TDC -arrows-.   Caution The engine must only be turned at the crankshaft, in the direction of normal engine rotation (clockwise).

–  Marking -arrow- on chain sprocket of balance shaft must be positioned opposite the locating hole. –  Use locking pin -T10060 A- or -T10060- to lock chain sprocket in this position. –  Place chain on chain sprocket of balance shaft. –  Install oil pump chain sprocket and hand-tighten the bolt.   Note t  The oil pump chain sprocket can only be installed correctly in one position. t  When installing, you may ONLY turn the oil pump.

–  Remove locking pin -T10060 A- or -T10060- and Allen key -1-. –  Tighten bolt on oil pump sprocket. l  Tightening torque: 22 Nm.

–  Fit chain sprocket cover -arrows-.

–  Install oil pipe -arrows-.

–  Install sump and tighten bolts in the following sequence:

1.  Pre-tighten bolts -1 ... 18- in diagonal sequence to 5 Nm. 2.  Tighten bolts securing sump to gearbox to 45 Nm. 3.  Tighten bolts M10 -arrows- to 40 Nm. 4.  Tighten bolts -1 ... 18- in diagonal sequence to 15 Nm.

Note

t  When installing the sump -3- with the engine removed from the vehicle, make sure that it is positioned flush with the intermediate plate -1- at the flywheel end. In other words, the sump should protrude by 0.8 mm (distance -a-) from cylinder block -2-. t  After installing, allow sealant to dry for approx. 30 minutes Then (and only then) fill the engine with engine oil. –  Install subframe → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40. –  Install anti-roll bar → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40. –  Install air conditioner compressor → Air conditioning system; Rep. Gr.87. –  Install poly V-belt → Chapter. –  Fill up with engine oil and check oil level → Chapter. Tightening torques

Component		Nm
Balance shaft assembly		15 + 90° 1)2)
Oil pump chain sprocket		20 + 90° 1)2)
Oil pipe to balance shaft assembly		10
Sump to cylinder block	M7	15
	M10	40
Sump to gearbox		45
Intake manifold support to sump		23
Torque reaction support to sump		23
Oil drain plug		30
Engine mounting to console for engine mounting		23
l  1) Renew bolts. l  2) 90° = one quarter turn.