Removing and installing sump and balance shaft assembly — AUDI

🧭 Before you start

Fits: Audi A4 Cabriolet B6/B7 (8H), Audi A4 B6/B7 (8E)

• Opens: engine oil
• Timing position: the crankshaft or camshaft is set and locked during this job
• Special tools named: T10060, V.A.G 1202, torque wrench
• Renewed: intermediate plate, o-ring

Don't miss

• 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.
• To prevent damage to the refrigerant lines, ensure that the pipes and hoses are not stretched, kinked or bent.
• To avoid having to check and adjust wheel alignment, only loosen the front subframe mountings and lower the subframe at the front.
• Lift engine up slightly using spindle10-222 A/11 of support bracket10-222 A; make sure the selector linkage and exhaust system do not become trapped.
• 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).

🔧 Engine codes this applies to

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. If fitted, detach cover (1) on right of engine compartment.
2. Disengage solenoid valve 1 for activated charcoal filter system N80(item 1) at air duct.
3. Remove bolts (arrows).
4. 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.]
5. Turn the tensioner in the direction of the (arrow) to slacken the poly V-belt.

6. Lock tensioner for poly V-belt in position with locking pin T10060 A or T10060.
7. Remove poly V-belt.
8. Pull off engine cover panel (arrows).
9. Detach air intake pipe from throttle valve module J338(arrow).
10. Move electrical wiring clear of air pipe (rear).
11. Detach air pipe from air cleaner housing (1) and from retaining stud (2).
12. Pull off bonnet seal at wing mounting flanges.
13. Place compensation plates T40045 between the wing mounting flange and the body panel underneath, so that the support bracket10-222 A does not damage the wing mounting flanges.
14. Position support bracket10-222 A on wing mounting flanges (spindle faces to rear).
15. Engage shackle10-222 A/12 into rear engine lifting eye.
16. Attach hook on spindle10-222 A/11 to shackle.
17. Take up weight of engine using spindle of support bracket.
18. Vehicles with auxiliary heater: remove bolts (arrows) securing exhaust pipe for auxiliary/additional heater to noise insulation.
19. Release fasteners (1 … 3) and take off front noise insulation and rear noise insulation (if fitted).
20. Unbolt bracket for noise insulation (arrows).
21. Place used oil collection and extraction unitV.A.G 1782 under engine and drain engine oil.
22. Unplug electrical connector (arrow) at oil level/oil temperature sender G266.
23. Unbolt refrigerant pipe bracket from sump (arrow).
24. Unplug electrical connector (1) for magnetic clutch on air conditioner compressor.
25. ⚠ 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.]
26. Tie up air conditioner compressor to vehicle, with lines attached.
27. Remove bolts (arrows).
28. Remove torque reaction support.
29. If fitted, unclip actuator rod for vehicle level sender at bottom transverse link (arrow).
30. If fitted, unplug electrical connector (arrow) at front left vehicle level sender G78.
31. Remove bolts (1) and (2) from anti-roll bar mounting.
32. Cut open the cable ties (arrows), open bracket for starter wire and take out the electrical wire.
33. Support subframe using workshop hoistVAS 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.]
34. Unscrew nut (3) at bottom of engine mounting.
35. Unscrew bolts (4) and (5) on console for engine mounting.
36. Unscrew bolt (1) (front) for subframe and remove console for engine mounting (2).
37. Repeat procedure on other side of vehicle.
38. Carefully lower subframe using workshop hoistVAS 6100 or V.A.G 1202 A.
39. Lift engine up slightly using spindle10-222 A/11 of support bracket10-222 A; make sure the selector linkage and exhaust system do not become trapped.
40. 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).]
41. 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.]
42. Unscrew M10 bolts (arrows).
43. Slacken bolts (1 ... 18) in diagonal sequence.
44. Remove all bolts and take off sump; if necessary loosen it by striking lightly with a rubber hammer.
45. Remove oil pipe (arrows).
46. Detach chain sprocket cover by using screwdriver to carefully lever out clips in openings (arrows).
47. Loosen bolt for oil pump chain sprocket approx. 1 turn.
48. Press guide rail down (arrow) using a screwdriver.
49. Lock guide rail by inserting 3 mm Allen key (item 1).
50. Detach oil pump chain sprocket and disengage chain at balance shaft assembly.
51. Working from outside inwards, slacken off bolts (arrows) of balance shaft assembly.
52. Detach balance shaft assembly with intermediate plate. [Note: Renew the intermediate plate.Renew bolts which are tightened to a specified angle as well as oil seals, gaskets and O-rings.]
53. Remove sealant residue from sump and cylinder block with rotating plastic brush or similar.
54. ⚠ Wear safety goggles. — Clean all sealing surfaces; they must be free of oil and grease.
55. Cut off tube nozzle at front marking (nozzle approx. 2 mm ∅).
56. Apply bead of sealant to intermediate plate on clean sealing surface for cylinder block as shown in illustration (arrows). [Note: The sealant bead must not be thicker than specified, otherwise excess sealant could enter the sump and clog the strainer in the oil pump.Apply sealant round inside of bolt holes, as shown in illustration.Take particular care when applying sealant bead in area of rear sealing flange (arrows).Also take particular care when applying sealant bead in area around oil return passages on right of cylinder block.Balance shaft assembly and sump must be installed within 5 minutes after applying sealant.]
57. Fit intermediate plate onto dowel sleeves on balance shaft assembly as shown in illustration (arrows).
58. Renew all balance shaft assembly bolts.
59. Renew O-ring on balance shaft assembly bolt .
60. Install balance shaft assembly with oil pump. [Note: Note the centring sleeves (arrows).]

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