Removal and installation of parts and units of the lubrication system and balance shafts (Audi A4 B7)

Note: If, during repairs, an increased amount of metal shavings or wear products in the engine oil are found in the engine, then to avoid subsequent damage, the lubrication channels should be thoroughly cleaned and the oil cooler should be replaced.

1. The installation details of the lubrication system components are shown in the illustrations.

Emptying the oil filter housing

2. Unscrew the dust cap (arrow on the illustration) from the oil filter housing.



3. Direct the hose of the oil drain adapter #T40057 into the oil collection pan and screw the adapter into the oil filter housing (see illustration).

Note: When screwing in the oil drain adapter No. T40057, a valve opens in the oil filter housing, and when unscrewing the adapter, the valve automatically closes again.

4. Allow the oil to drain, unscrew the adapter and install the dust cap.

Removal and installation the oil cooler

5. Remove the top engine cover as shown in the illustration 17.10. Remove the cap from the engine cooling system expansion tank.



6. On models with independent/additional heating, remove the screw (1 in illustration 5.4) its exhaust pipe on a sound-insulating casing.

7. Unscrew the fasteners (1 and 2 in Illustration 5.5) and remove the front soundproofing screen. If present, unscrew the fasteners (3) and remove the rear soundproofing screen.

8. Drain the coolant (see Chapter 3), the exhaust pipe and the fuel distribution line (see Chapter 4).

9. Remove the connector holder fastener (arrows in the illustration) on the water pipe.



10. Disconnect the coolant supply hose (1 in the illustration) and unscrew the screw (2).



11. Disconnect the water hoses (arrows in the illustration) from the water pipe, unscrew the bolt (1) and remove the water pipe.





12. Remove the bolts (see illustration) and remove the oil cooler.



13. Installation is carried out in the reverse order of dismantling the components. Use new gaskets and sealing rings. Finally, fill the cooling systems (see Chapter 3).

Removal and installation the oil filter holder

14. Follow the steps described in paragraphs 5-7.

15. Drain the coolant (see Chapter 3).

16. Mark the alternator belt with chalk or a felt-tip pen to indicate the direction of rotation so that you can install the belt in the same way. Loosen the belt tension by turning the tensioner in the direction of the arrow (see illustration 17.18). Secure the tensioner clamps No. T40098 and remove the alternator belt.



17. Remove the bolts (see illustration 21.4) and remove the alternator belt tensioner with the engine lifting eye. Remove the alternator (see Chapter 5).

18. Remove the exhaust pipe and fuel rail (see Chapter 4).

19. Remove the holder fastener.

20. Remove the oil cooler as described in paragraphs 9-12.

21. Disconnect the tube (1 in the illustration) PCV and ground wire (2) D/V oil pressure. Loosen bolts (arrows) and remove oil filter holder.



22. Installation is carried out in the reverse order of dismantling the components. Use new gaskets and sealing rings. Finally, fill the cooling systems (see Chapter 3).

Removal and installation the oil pan

23. Remove the top engine cover as shown in the illustration 17.10.

24. Remove the engine compartment seal on the connecting edges of the wings. To avoid damaging the connecting edges of the wings, use the No.10-222-A hanging device to place the No. T40045 wing gaskets on both sides between the connecting edges of the wings and the vertical sheet below (see illustration 16.6).

25. Install crossmember No.10-222-A with adapters No.10-222/3 on the edge of the wing, hook the running bolts to the lifting eyes (see illustration) and slightly tighten the engine using the running bolts.





26. Remove the alternator drive belt (see Section 19).

27. On models with independent/additional heating, remove the screw (1 in illustration 5.4) its exhaust pipe on a sound-insulating casing.

28. Unscrew the fasteners (1 and 2 in Illustration 5.5) and remove the front soundproofing screen. If present, unscrew the fasteners (3) and remove the rear soundproofing screen.

29. Pump out the oil from the engine.

30. Remove the bolts (see illustration) and remove the torque support from the oil pan. Loosen the nuts (1) securing the turbocharger return oil line to the oil pan.



31. Perform the actions described in paragraphs 47-49 Section 5.



32. Disconnect the connector (1 in the illustration) front left ride height sensor.



33. Perform the actions described in the paragraphs 15-17 Section 16.

34. Slowly lower the subframe on the transmission jack. Pull the engine up slightly using the lead screws of the #10-222A engine jack, making sure there is free play in the shift linkage/lever system and the exhaust system (see illustration 27.25).

35. Remove the bolts (see illustration 5.52) fastening the transmission to the oil pan.

36. Unscrew the M10 bolts (arrows in illustration 16.21), loosen the bolts (1-18) crosswise, unscrew all the bolts and remove the oil pan, lightly tapping it with a rubber-faced hammer if necessary.

37. Installation is performed in the reverse order of component dismantling. Please note the following features.

38. Prepare the following new parts: oil pan gasket, lip seals, sealing rings and bolts/screws tightened to a certain angle. Remove any remaining sealant from the mating surfaces of the oil pan and cylinder block, clean all seating surfaces from oil and grease.

39. Apply a 2-3 mm diameter bead of sealant to the clean surface of the oil pan as shown in the illustration.

Note: In the area of the threaded holes, the bead of sealant should run along the inside; in the area of the rear sealing flange (arrows), apply the sealant with particular care. The balance shaft module and oil pan must be installed within 5 minutes after applying the sealant.

40. Immediately after applying the sealant, install the oil pan and tighten its mounting bolts as shown in the illustration 16.21 sequence in several stages: first bolts 1-18 - crosswise with a force of 5 Nm, then - bolts fastening the pan to the transmission with a force of 45 Nm, then - bolts M10 (arrows) with a force of 40 Nm, and finally - bolts 1-18 crosswise with a force of 15 Nm.

41. When installing the oil pan (3 in the illustration 16.36) on the removed engine, pay attention to the fact that the pallet should be flush with the intermediate shield (1), i.e. the pallet should protrude beyond the cylinder block (2) by the size (a) - 0.8 mm. After installation, the sealant should dry for about 30 minutes. Only then can you fill in the engine oil.

42. Install the subframe and stabilizer (see Chapter 10).

Removal and installation the balance shaft module with oil pump

43. Remove the engine oil pan (see subsection above).

44. Set the piston of the first cylinder to the TDC position of the end of the compression stroke (see illustration 22.9).

45. Remove the sprocket cover by carefully pressing the clips in the holes with a screwdriver (see illustration 16.23).

46. Loosen the bolt (18 in illustration 27.1a) fastening the oil pump sprocket by one turn. Loosen the tensioner bar with a screwdriver (arrow in illustration 16.24) and secure the damper bar with a 3 mm rod wrench (1).

47. Remove the oil pump sprocket and remove the chain from the balance shaft drive.

48. Remove the bolts (1 and 2 in the illustration) fastenings of the oil separator and remove it.



49. Loosen the balance shaft module mounting bolts and remove it (see illustration). The installation process is described below.



50. Tighten the tensioner piston by hand (see illustration).



51. Press the tensioner bar in the direction of the arrow (see illustration) and secure it with a 3 mm rod wrench (1).



52. Prepare new balance shaft module mounting bolts and a new sealing ring for the module mounting bolt. Place the spacer (4 in illustration 27.1b) on the centering bushings of the balance shaft module and install the module with the oil pump and spacer. Tighten the new bolts (they have different lengths) fastening the module in sequence from the inside out (see illustration 27.49) in several stages: first by hand, then with a force of 15 Nm, and finally, pull them to an angle of 90°.

53. Install the oil separator into the grooves (arrows in illustration 27.48), tighten bolt (1) to 21 Nm and bolts (2) to 9 Nm.

54. Screw the central bolt into the crankshaft and turn the shaft so that the piston of the first cylinder is in the TDC position (see illustration 22.9).

55. Put a mark (arrow on the illustration) on the balance shaft sprocket opposite the locking hole, lock the sprocket in this position using the No. T10027 rod wrench and put the chain on the balance shaft sprocket. Install the oil pump sprocket and tighten its mounting bolt by hand.

Note: The oil pump sprocket can only be installed in one position; during installation, only the oil pump can be turned.

56. Remove key No. T10027 and rod key (1 in illustration 16.24). Tighten the oil pump sprocket bolt to the required torque and install the engine oil pan.