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Oil pump to old 1.9 conversion

Discussion in 'Audi S4/A4/A4 Cab (B7 Chassis)' started by Darren198712, Jan 27, 2014.

  1. Darren198712
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    Darren198712 Member

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    Well I just did a conversion on my 2007 Audi a4 S-line Special Edition Quattro 2.0 TDi.

    Balancer shaft oil pump conversion using the old 1.9 oil pump.

    It was a night mare. Took my about 12 hours all in all on a ramp.

    With 91k miles the clock the balancer shaft was fine no unusual wear.

    Ran into some issues as the engine was in the car. Im a mechanic so it's not too bad as I had the tools.

    The gear on the crank was a pain to remove. In the end I had to use a angle grinder and cut the gear as close as I could without damaging the crank and shocked the gear with a punch so it just cracked and then it was free to remove

    The oil pick up pipe had to be modified and the Windsge tray. To drill the block to block up the other oil feed was a pain. I had to use a 90 degree drill and then tap it out and seal it off with a bolt.

    Any one else done this conversion?

    The car seems to have a bit more torque. I still got to see how much better it is on fuel.
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  2. tut_gareth
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    tut_gareth Member

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    Have thought about this mod rather than repair mine in the future but not found a lot of info about it so far.. Are there Any unwanted engine vibrations or judders apparent after the swap?
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  3. Darren198712
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    Darren198712 Member

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    The engine sounds Slightly different but apart from the extra torque it's all good. Vibrations wise I think it's about the same I can't comment because I get a bit of vibration as the dual mass would need replacing on mine. After that it should be good. I am selling my old balancer shaft/oil pump as well
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  4. Darren198712
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    Darren198712 Member

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    Well I used this guide:

    http://youtu.be/8oXIvSzIIak

    Please read all info before even thinking of doing this it's not a hour job it took me close to 13 hours on a ramp. Also use this information at your own risk as it is a guide. It worked on my car but I do not guarantee it will work on yours

    Well the parts list is what I used from the YouTube video.
    I got all the bits from TPS apart from the oil pump where I got else where for about half the price but the oil pump was still made in Germany and was good quality as you don't want to do this job again once you finished it.

    I will not name the tools listed as I virtually had all my tools out.

    Things you will defiantly need is

    90degree drill to drill the block
    A tap and die set to tap the block to block off one of the oil feeds
    A collections of nuts and bolts. M10 I think with a copper washer so once tapped the hole you can seal the the hole.

    Eye protection
    Angle grinder
    Thin steel
    High temp silicon for sump gasket
    Long 3/8 wobbly Allen keys to get to the sump bolts
    Drill bits to still the block

    Spline drive
    Allen keys
    And the usual
    Punches
    Chisels
    19mm 12 point socket half inch (impact if possible)
    Good impact gun And a big compressor


    As for the front gear it was a pain to remove. The sprocket that drives the oil pump/balancer shaft.

    I tried a mini ductor (heat coil or what ever you call it) which never entertained it

    I even tried oxyacetylene and that never entertained it so don't wast your time.

    With the front gear I ended up putting some thin steel against the block and the gear and used a angle grinder to cut the gear. I got as close as I could without damaging the crank. Make sure you put a few layers of masking tape on the crankshaft. Once you are as close as you can get (2-3mm ish) use a punch and hammer the edge of the gear where you cut and it should put a shatter and the gear should creating a hairline crack near where you hit. The gear should release it self and should be fairly free spinning by hand then I used a pry bar and pry it off. (pictures below)

    Also as for the oil pick up it needs to be modified. You need to get a angle grinder and cut the cup off as if you don't the sump won't go back on as the cup sits too low. I found this out and could not get the sump back on so it had to all come off again.

    Some pictures of when I was doing it. I am glad I had a ramp it would of been a nightmare doing it without. It was a nightmare with a ramp so good luck if your doing it without. A lot of people I have see had a blown oil pump do they had it on a bench but if it's in the car it's a right pain. As for oil you will require a oil and oil filter. When you put the new smaller sprocket on make sure it's on the right way as shown in the YouTube video.

    Also when you come to crack the front crankshaft bolt off make sure the timing belt is still fitted and that the timing tools are not in placed. Use a 19mm 12 point impact socket with a big compressor and a good impact gun. once it's cracked off tighten it back up a little bit and then do you timing pins and tool. The lower puller has a offset cut so it will only go on one way

    The bolt was a 19mm 12 sided on mine I can not guarantee its the same on others.

    I loosened the engine mounts and use 2 transmission jacks to lift the engine up to get the sump off. The other option is to drop the lower subframe but the engine mounts are on the subframe so you will need to secure the engine up with a hoist if your taking the frame off. Also be very careful if your using transmission jacks and don't jack it up too high.

    Some pictures anyway ImageUploadedByTapatalk1391112709.660195.jpg
    ImageUploadedByTapatalk1391112726.171839.jpg ImageUploadedByTapatalk1391112736.361562.jpg
    You will see I cut on the oil pick up cup but I had to cut it even more. Cut as close as you can without destroying the mesh. Once I had put the sump back On I got a inspection camera and looked though the sump plug hole and the oil pick up tube was virtually touching the bottom of the sump so this will restrict you oil pressure and put a lot of stress on the pump. So I had to take the sump off and cut it down even more
    ImageUploadedByTapatalk1391112751.146258.jpg
    old balancer shaft. No play and up for sale if you want to buy it
    ImageUploadedByTapatalk1391113000.178407.jpg

    The cut I had to make on the gear and shock it to create a hairline crack so I could pry it off
    ImageUploadedByTapatalk1391113028.302717.jpg

    Also I would recommend changing the front main crankshaft oil seal.

    I would also recommending doing 2 engine flushes.

    Engine flush in
    Run it up
    Drain the oil
    Put fresh oil in it
    Engine flush in
    Run it up
    Drain oil again.

    This will keep your engine a good clean and your oil should be golden for much longer then a day. We done a turbo once and this kept the engine oil golden for 4 weeks when it come back in for a final inspection.

    Good luck if your attempting this
    Last edited: Jan 30, 2014
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  5. tut_gareth
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    tut_gareth Member

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    Cheers for the info, appreciated. It's a job I'm a lot happier to tackle myself now, (ex vehicle tech) I have the tools, just need to acquire myself a ramp for a day or so.. As mine is still only on 50k miles I will probably tie this conversion in with the next timing belt change at 70k.
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  6. stevegrass777
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    stevegrass777 Member

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    I did this conversion Darren on a Passat,the gear gave me problems I tried to make a puller with no success so I ended up buying the dealer tool and it worked a treat.
    Although it is still attached to the gear and doesn't want to let go.
    I also had trouble undoing the crank bolt,I used a power bar with tube on and had the hit the end with a sledge hammer to undo it.I did replace the crank bolt as it was done in.I made a counter holder for holding the crank.
    I have got to do a a4sline blb now so was looking to see what pick up pipe you used.
    I also fitted a oil pressure gauge.
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  7. stevegrass777
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    stevegrass777 Member

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    I must admit you are braver than me cutting the gear with the grinder,lol
    Fair play to you it worked.
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  8. stevegrass777
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    stevegrass777 Member

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  9. Darren198712
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    Darren198712 Member

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    Never really had a choice as I was not going to put it all back together. And I never had the timing tool to time up the balancer shaft so I had to make do.
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