Audi Workshop Service and Repair Manuals

Converting balance shaft assembly to spur gear drive   Note If the chain drive of the balance shaft assembly is worn or defective, the chain drive must be converted to spur gear drive. The balance shaft assembly with chain drive is no longer supplied. Special tools and workshop equipment required

t  Two-arm puller -T40001- with claw -T40001/5- and claw -T40001/3-

t  Thrust plate -30 - 11-

t  Locking tool -T10255-

t  Hotplate (commercially available) t  Temperature gauge -VAS 6519- Procedure –  Remove noise insulation tray → General body repairs, exterior; Rep. Gr.50. –  Remove balance shaft assembly → Chapter. –  Remove front sealing flange → Chapter. –  Apply two-arm puller -T40001- with thrust plate -30 - 11- to chain sprocket on end of crankshaft as illustrated.   Caution Make sure that the puller is applied correctly. Otherwise the crankshaft can be irreparably damaged if the sprocket is not pulled off straight.

–  Pull chain sprocket off crankshaft.   Note t  While heating up the new spur gear, monitor the temperature with the temperature gauge -VAS 6519-. t  When the temperature reaches 200°C, you have approx. 4 seconds to fit the spur gear on the crankshaft. t  A higher temperature increases the amount of time available (220°C = approx. 6 seconds). t  Make sure the end of the crankshaft is clean.   Caution Do not exceed a maximum temperature of 240°C; otherwise the spur gear can become discoloured and distorted.

–  Place the new spur gear flat on a commercially available hotplate and heat it up to at least 200°C, but not more than 240°C. The lettering must face upwards. –  Set temperature gauge -VAS 6519- to measuring range 2. –  Position temperature sensor -VAS 6519/1- on collar of spur gear (as shown) and read off temperature at temperature gauge.   WARNING Risk of burns. Use suitable protective gloves for the following steps. –  When the required temperature has been reached, take up the new spur gear with pliers. Take care not to damage the gear teeth.

–  Slide the gear without delay onto the end of the crankshaft as far as the stop, taking care to keep it straight. Use fitting tool -10 - 203-. –  Allow the spur gear to cool for a few minutes and then install the new balance shaft assembly → Chapter.