Audi Workshop Service and Repair Manuals

Renewing balance shaft for inlet camshaft Special tools and workshop equipment required

t  Puller -T10394-

t  Puller -T10055- Removing   Note Always renew balance shaft for inlet camshaft after removal. –  Remove toothed belt for coolant pump → Chapter. –  Remove timing chain cover (top) → Chapter. –  Remove timing chain cover (bottom) → Chapter. –  Remove camshaft timing chain → Chapter. –  Remove balance shaft timing chain → Chapter.

–  Remove idler gear -1-.

–  Remove bolt -2- securing balance shaft for inlet camshaft.

–  Insert half shell -T10394/1- of puller -T10394- and turn upwards in direction of arrow.

–  Insert puller -T10394- and press locking collar in direction of -arrow-.

–  Screw puller -T10055- into puller -T10394- and knock out balance shaft in direction of -arrow-. Installing   Note It might be necessary to cool the balance shaft before installing due to the minimal clearance between balance shaft and cylinder block. Check if it is possible to insert the balance shaft into the cylinder block without applying force. If this is not the case, the balance shaft must be cooled before installing. l  Tightening torque → Chapter „Balance shaft timing chain - exploded view“ –  Put new balance shaft for 30 minutes into freezer compartment or spray with chilling agent (commercially available) if necessary. –  Lubricate balance shaft bearing with engine oil.

–  Install new balance shaft for inlet camshaft and tighten bolt -2-.

–  Renew O-ring -1- and lubricate with engine oil. –  Lubricate bearing mounting with engine oil and install; dowel pin -arrow- for bearing mounting must engage in bore in cylinder block.   Caution Always renew idler gear. If this is not done, there is no backlash, which causes engine damage. The new idler gear has a special lubricant coating, which wears off after a short running period and thus automatically creates the specified backlash.

–  Mark faces of gear teeth of idler gear with paint marker -arrows-. –  Insert idler gear; marking on balance shaft must be positioned between markings on faces of gear teeth.

–  Tighten bolt -1- for idler gear: tightening sequence → Fig.. –  Check markings on idler gear/balance shaft -arrow-. Further assembly is basically carried out in reverse order of dismantling. Note the following: –  Install balance shaft timing chain → Chapter. –  Install camshaft timing chain → Chapter. –  Install timing chain cover (bottom) → Chapter. –  Install timing chain cover (top) → Chapter. –  Install poly V-belt tensioner → Chapter. –  Install poly V-belt → Chapter. –  Renew oil seal for coolant pump drive → Chapter. –  Install toothed belt for coolant pump → Chapter.