Replacment Intake Balance Shaft and Intermedite Gear Too Tight to Turn

[Big L LLC]

Hello-

2010 Audi A3 FWD Automatic 2.0T CCTA w/ 102k miles

Recently replaced balance shafts due to replacing water pump and bolt breaking off in balance shaft.

During this time I decided to refresh the timing components with new balance shafts, sprocket, chains, guides, and tensioners. In the process of reassembling the intake balance shaft and intermediate sprocket gear are meshing so tightly that I cannot spin the sprocket by hand. Both will spin independently of each other.

I have only tightened the intermediate sprocket to 10Nm as referenced in the repair manual. All components of this section of the system have been replaced with new OEM VW/Audi parts.

Balance Shaft kit: 06H198205N
Shaft bolt: WHT005227
Intermediate sprocket bolt: N10544904
Intermediate sprocket: 06K103319A
Intermediate Shaft: 06H103559B

In all the videos I have seen of this repair, the sprockets are able to be turned by hand. Mine are extremely tight where they will not turn by hand. I do not want to assemble the rest of the engine and "run it" as something is clearly wrong. In the service manual it states that sprocket has a coating that will wear to set the backlash however, I doubt this would "wear in"

HumbleMechanic showing gear moving easily in block https://youtu.be/B-nQ9nj-C0M?feature=shared&t=502



My videos below showing what I am experiencing

Balance shaft:

Intermediate Sprocket:

Installed together:


Appreciate everyone's help!

Here is the procedure I am following. I've never gotten past the 10 Nm torque due to the gears not spinning after torquing the bolt to the initial torque value.

[MovieCarTech]

Good Morning, I have just run into the exact same issue that you have. Based on what im finding, its an issue with the gear on the replacement balance shaft not meshing properly. I have tried the old and new intermediate sprokets with the same results and just like you they both spin nicely when installed alone. Where did you get your new balance shafts from, im going to be trying a set directly from VW/Audi. Hopefully we can figure this out *fingers crossed*
-Julian

[MovieCarTech]

UPDATE:
Purschased a set of Balance shafts directly from VW/AUDI. Anyone who runs into this issue and purchased shafts from Worldpac or an associated supplier.. be warned they seem to have a batch of knock off balance shafts. The gears on the intake shafts are different with a slightly different tooth profile and are visibly thicker on the "OEM" set from worldpac. will be installing this evening with confidence the dealer part will work nicely with no binding.

[Big L LLC]

Can you post a picture of the differences between the "real" OEM and the fakes?

[Big L LLC]

Wanted to give an update in case anyone else runs into this issue. The OEM balance shafts I purchased were counterfeit they were purchased through a local auto parts store that uses WORLDPAC. They were marked as OEM and appeared as such.

I purchased a set of Borsehung balance shafts and all went together as it should.