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Powerunit>4cylinderTDIunitinjectorengine(2.0ltr.4valve),mechanics>Enginelubrication>Servicingsump,oilpumpandbalanceshaftassemblywithspurgeardrive>Sump,oilpump,balanceshaft

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assemblywithspurgeardriveexplodedview

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Manual Used In
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1 Sump
WithoillevelandoiltemperaturesenderG266
12.99. Buy
RemovingandinstallingsumpChapter
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manualsfreelyavailable. 2 23Nm

3 Torquereactionsupport

4 10Nm

5 Intakeconnectingpipe
OtherAudiWorkshopManuals Cleanstrainerifdirty
OtherMakes
6 10Nm
Runninggear
Body 7 Oring
Powerunit
Motronicinjectionandignitionsystem(8cyl.) Renew
Motronicinjectionandignitionsystem(4cylinder)
Motronicinjectionandignitionsystem(4cyl.turbo)
Motronicinjectionandignitionsystem(6cyl.)
8 Oilpump
6cylinderengine,mechanics
Simosinjectionandignitionsystem(4cyl.) RemovingandinstallingChapter
MotronicDirectInjectionandIgnitionSystem(4Cyl.)
4cylinderengine(5valveturbo),mechanics Beforeinstalling,checkthatthetwodowelsleevesforcentringoil
Fuelsupplysystem,dieselengines pumparefittedontobalanceshaftassembly.
Fuelsupplysystem,petrolengines
Simosdirectpetrolinjectionandignitionsystem(6cyl.3.2ltr.4valve)
9 Oilpumpdriveshaft
6cylinderdirectpetrolinjectionengine(3.2ltr.4valve),mechanics
Directpetrolinjectionandignitionsystem(4cyl.2.0ltr.4valveturbo)
10 Circlip
4cylinderdirectpetrolinjectionengine(2.0ltr.4valveturbo),mechanics
6cylinderTDIengine(2.7ltr.3.0ltr.4valvecommonrail),mechanics
Mustfitsecurelyingroove
4cylinderTDIinjectionandglowplugsystem(1.9ltr.2.0ltr.unitinjector,2valve)
6cylinderdieseldirectinjectionengine(TDI),mechanics
TDIinjectionandglowplugsystem(6cyl.) Renewcirclipifdamagedorstretched
4cylinderdirectpetrolinjectionengine(2.0ltr.4valve),mechanics
TDIinjectionandglowplugsystem(4cyl.2.0ltr.unitinjector,4valve)
Removingandinstallingairmassmeter 11 Spurgearforbalanceshaft
4cylinderTDIunitinjectorengine(2.0ltr.4valve),mechanics
Technicaldata 12 20Nm+turn90further
Engineassy,cylinderblock,crankcase
Enginecrankshaftgroup,pistons Renew
Enginecylinderhead,valvegear
Enginelubrication
Removingandinstallingpartsoflubricationsystem 13 Hub
Servicingsump,oilpumpandbalanceshaftassemblywithchaindrive
Foridlergear
Servicingsump,oilpumpandbalanceshaftassemblywithspurgeardrive
>>Sump,oilpump,balanceshaftassemblywithspurgeardriveexplodedview<<
Removingandinstallingsump 14 90Nm+turn90further
Removingandinstallingoilpump
Removingbalanceshaftassembly Renew
Installinganewbalanceshaftassembly
Reinstallingthe"old"balanceshaftassembly
Servicingoilfilterbracketwithoilcooler 15 Thrustwasher
Enginecooling
Exhaustturbocharger,Gcharger Foridlergear
Exhaustsystem
6cylinderengine(3.0ltr.5V),mechanics Renew
4cylinderTDIunitinjectorengine(1.9ltr.2.0ltr.2valve),mechanics
8cylinderengine(4.2ltr.5valvewithtimingchains),mechanics InstallationpositionFig.
4cylinderengine(2.0ltr.5valve),mechanics
16 Idlergear
TDIinjectionandglowplugsystem(6cyl.2.7ltr.,3.0ltr.4valvecommonrail)
8cylinderdirectpetrolinjectionengine(4.2ltr.4valveRS4),mechanics
Renew
Directpetrolinjectionandignitionsystem(8cyl.4.2ltr.4valve),RS4
Powertransmission
Vehicleelectrics Toachievethecorrectbacklashasuitablythickcoatingisalreadyappliedtothenewidlergear
Heating,ventilation,airconditioningsystem
InstallingChapter

17 Thrustwasher
Foridlergear

18 Spurgear

19 Balanceshaftassembly
RemovingChapter
InstallingnewbalanceshaftassemblyChapter
Reinstalling"old"balanceshaftassemblyChapter
Beforeinstalling,checkthatthetwodowelsleevesforcentringbalanceshaftassemblyarefittedontocylinderblock.

20 Bolt
Renew
TighteningtorqueandsequencewitheightattachmentpointsFig.
TighteningtorqueandsequencewithsixattachmentpointsFig.

21 Oilintakepipe

22 10Nm

23 40Nm
ObservecorrecttighteningsequenceAnchor

24 45Nm
ObservecorrecttighteningsequenceAnchor

25 15Nm
Tighteninstagesandindiagonalsequence
ObservecorrecttighteningsequenceAnchor

26 Seal
Renew

27 Oildrainplug,30Nm

Balanceshaftassemblywitheightattachmentpointstighteningtorqueandsequence

Tightenboltsin8stagesinthesequenceshown:
 Stage Bolts Tighteningtorque/anglespecification
1. 18 handtighten
2. 18 6Nm
3. 14 20Nm
4. 5 13Nm
5. 6 20Nm
6. 7 13Nm
7. 8 20Nm
8. 18 turn90further

Balanceshaftassemblywithsixattachmentpointstighteningtorqueandsequence

Tightenboltsin8stagesinthesequenceshown:

Stage Bolts Tighteningtorque/anglespecification

1. 16 handtighten
2. 16 6Nm
3. 14 20Nm
4. 5,6 13Nm
5. 16 turn90further

Installationpositionofthrustwasher

Caution

MakesurethatthethrustwasherAdoesnotslipoutoftherecessesinthebalanceshaft
assemblyarrowswhenfittingtheidlergear.Ifthisisneglected,thethrustwashercan
becomestuck.Ifnecessary,applygreasetothethrustwasherandattachittothebalance
shaftassembly.

Powerunit>4cylinderTDIunitinjectorengine(2.0ltr.4valve),mechanics>Enginelubrication>Servicingsump,oilpumpandbalanceshaftassemblywithspurgeardrive>Sump,oilpump,balanceshaft
assemblywithspurgeardriveexplodedview

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