Audi Workshop Service and Repair Manuals

Removing and installing balance shaft assembly

Special tools and workshop equipment required

t	Diesel injection pump locking pin -3359-

t	Locking pin -T10115-

t	Counter-hold tool -T10172- with -T10172/1-

t	Locking tool -T10255-

Removing –  Remove sump → Chapter. –  Lever off cover cap from vibration damper. –  Turn the crankshaft to TDC. l  The space between the two lugs -1- on sender wheel of camshaft must align with marking “4Z”-item 2- on toothed belt cover (rear).   Note For illustration purposes, the camshaft sprocket is shown with the toothed belt removed. –  Lock hub with locking pin -3359-.   Note

The following procedure is shown with the front sealing flange removed. –  Unscrew bolts -arrows- and detach chain sprocket cover.

–  Press guide rail for chain tensioner in -direction of arrow- using a screwdriver and lock chain tensioner with locking pin -T10115-. –  Remove bolts -1- and -3-.   Note Disregard -item 2-.

–  Unscrew bolts -arrows- and detach chain sprocket from balance shaft.

–  Unscrew bolts in the sequence -8 ... 1- and remove balance shaft assembly with oil pump. Installing   Note Renew the bolts tightened with specified tightening angle and the chain sprocket for balance shaft assembly. l  Toothed belt fitted. l  Camshaft locked with locking pin -3359-. –  Tighten bolts securing balance shaft assembly as follows: 1.  Pre-tighten bolts in the sequence -1 ... 8- to 6 Nm. 2.  Tighten bolts -5- and -7- to 13 Nm. 3.  Turn bolts -5- and -7- 90° further using a rigid wrench. 4.  Tighten bolts -1 … 4-, -6- and -8- to 20 Nm. 5.  Turn bolts -1 ... 4-, -6- and -8- 90° further using a rigid wrench.

–  Insert new sprocket -1- into chain – do not screw in securing bolts. –  Initially screw in bolts -2- and -3- finger-tight, but do not tighten. –  Remove locking pin -T10115- from chain tensioner.   Note

t  Before tightening the chain sprocket for the balance shaft assembly turn the de-coupling element in the drive chain sprocket to its central position. To do so, you must align the arrows marked on the drive chain sprocket and its de-coupling element. t  However, these arrows are not visible with the sealing flange fitted. The following description explains how to achieve the central position without the aid of these arrows. –  Turn chain sprocket -1- as far as right stop using counterhold -T10172--arrows-. l  De-coupling element -2- of drive chain sprocket will be turned to right stop at the same time.

–  In this position mark drive chain position -1- to hole -2- in balance shaft assembly.

–  Use counterhold tool -T10172- to turn chain sprocket -1- back as far as left stop -arrows-. l  De-coupling element -2- of drive chain sprocket will be turned to left stop at the same time.

–  In this position mark present drive chain position -3- opposite hole -2- in balance shaft assembly.

–  Then turn chain sprocket -1- back again, until de-coupling element -2- of drive chain sprocket is located in central position.   Note As the de-coupling element of the drive chain sprocket is not visible with the front sealing flange fitted, the central position is determined at the bottom of the drive chain.

Determining central position of de-coupling element of drive chain sprocket with front sealing flange fitted. –  The chain sprocket has to be turned back, until it reaches the central position exactly between the markings -1- and -3- on the drive chain. l  Reference mark is again hole -2- on balance shaft assembly.

–  Lock balance shaft with locking tool -T10255-. l  The lug of the locking device must engage in the groove of the balance shaft, if necessary, turn the balance shaft.

–  Check whether elongated holes of chain sprocket align with tapped holes of balance shaft. If holes do not align: –  Secure tensioner with locking pin -T10115- and unscrew bolts -2- and -3-. –  Turn chain sprocket -1- in drive chain one tooth further. –  Tighten bolts. –  Remove locking pin -T10115-.

–  Use new bolts to secure chain sprocket -arrows-. –  Lock balance shaft with locking tool -T10255- and tighten bolts for chain sprocket initially to 10 Nm. l  When doing this, make sure not to change position of chain sprocket and balance shaft, otherwise slacken bolts and once again move chain sprocket to its central position. –  Turn bolts -arrows- for chain sprocket 90° further.

–  Fit chain tensioner cover -arrows-.

–  Remove locking pin -3359-.   Note Disregard -arrows-. Remaining installation steps are carried out in reverse sequence; note the following: –  Install sump → Chapter. –  Fill up with engine oil and check oil level → Booklet803 or → Booklet805. Tightening torques

Component			Nm
Balance shaft assembly		M7	13 + 90° 1)
to cylinder block		M8	20 + 90° 1)
Chain tensioner to balance shaft assembly			9
Chain sprocket to balance shaft			10 + 90° 1)
Cover for	Chain tensioner		5 2)
chain sprocket to:	Oil pump		5 2)
l  1) Renew bolts. l  2) Apply locking fluid when installing; refer to → Electronic parts catalogue for locking fluid.