Upgrading TDi balance shaft

[34stuey]

Planning the upgrade of the balance shaft and oil pump this weekend on my A3 2009 2.0 TDI, parts from KMB arrived today, and looking to follow the procedure as described in this post below:

Worn oil pump hex drive shaft on MY09 2.0 TDI

did this balancer shaft / drive swap to my old 09 plate a4 3 years ago . i went and collected the kit direct from kmb ,at that time it cost me £150 exchange . most of the 170 engines have the balancer shaft setup . the parts from KMB Parts Direct are far far better than audi's own design. the...

www.audi-sport.net

One query - The method recommends turning the engine by hand to check that the gears have sufficient tolerance and are meshing correctly once new parts installed. How is the compression of the engine overcome when turning by hand as no reference is made to removing the glow plugs, for example, or in practice is this not an issue?

Thanks

 

[aqibi2000]

Planning the upgrade of the balance shaft and oil pump this weekend on my A3 2009 2.0 TDI, parts from KMB arrived today, and looking to follow the procedure as described in this post below:

Worn oil pump hex drive shaft on MY09 2.0 TDI

did this balancer shaft / drive swap to my old 09 plate a4 3 years ago . i went and collected the kit direct from kmb ,at that time it cost me £150 exchange . most of the 170 engines have the balancer shaft setup . the parts from KMB Parts Direct are far far better than audi's own design. the...

www.audi-sport.net

One query - The method recommends turning the engine by hand to check that the gears have sufficient tolerance and are meshing correctly once new parts installed. How is the compression of the engine overcome when turning by hand as no reference is made to removing the glow plugs, for example, or in practice is this not an issue?

Thanks

when doing the timing belt we turn the engine over as part of the installation to test it.

it’s done by using the 19 point socket on the crankshaft. Just need an 18 inch breaker bar to rotate in a controlled manner…

 

[34stuey]

Thanks @aqibi2000 for the tip much appreciated

 

[aqibi2000]

I meant 19mm 12 point socket

clockwise direction only

 

[34stuey]

Reached the half way point swapping the balance shat with the upgrade, a few curve balls en route, camshaft lock pin stuck and the replacement oil pump circlip is still in ‘the post’.
Installed the balance shaft and ready to torque the two halves of the housing together but can’t figure out what torque value for the bolts. Extract from Haynes manual attached doesn’t make it that clear.
Please can anyone provide some clarity on this?
Thanks

 

[34stuey]

Hi Folks - Does anyone have the part numbers for a) the stretch bolts that hold the two halves of the balance shaft assembly together and b) the stretch bolts to mount the housing to the crankcase?
The diagram below shows items 17 as a m8 x 40 (2off) for the housing but in addition i have removed M8x60 (9off ). Also to mount the housing to the crankcase i have 1off m8X50 in addition to item 15 (5off). Spoke to Audi parts and they couldn't offer any other part numbers or advice.
Thanks

 

[34stuey]

For anyone following this thread the answers to my two previous posts are:
- 20nm + 90degrees turn for housing bolts and mounting bolts.
- The housing bolts aren’t available new and haven’t been as Audi only supply the whole balance shaft assembly. If that is the case then what have others done on this forum that have recommended and appear to have used new bolts?

 

[34stuey]

Upgraded balance shaft and hex key now fitted. Thought it would be worth sharing the existing shaft and key to show the condition. It appears that the shaft has a hex slot rather than the more minimal ‘star’ type drive that others have described.
There is wear on the original 77mm hex drive but not as much as expected for 134k miles.
No evidence of oil sludge in the sump despite the long life oil changes that were recorded.