The on loan winger was an unused substitute in Saturday’s 0-0 draw at Everton but is expected to feature in the third round clash with Emery ready to shake-up his team in an effort to kickstart their season.
Villa have taken just two points from their first four Premier League matches and are yet to score a goal, with Tuesday’s match giving the manager some scope to experiment.
At the same time, Emery is eager to retain some balance knowing any win can help boost confidence after a hugely disappointing start to the campaign.
Sancho, who joined on a season-long deal from Manchester United at the start of the month, has been building fitness on the training ground.
Another new signing, Harvey Elliott, is pushing to make his first start after coming off the bench in the second half on Saturday.
Emery said: "We have to try to add players who joined in the last two weeks, who are getting fit and knowing our style and idea. Also, maybe someone who didn’t play today will be good to play on Tuesday.
"It is a competition we will fight in and will try to get our best in. It is an opportunity for us, the club, and the player to get a title."
In previous seasons, Emery has always made clear the Carabao Cup ranks among the lowest of his priorities.
Last year’s third round win at League One Wycombe is Villa’s only victory in the competition under the Spaniard and they have exited the last three years to Premier League opposition.
All three defeats, to Manchester United, Everton and Crystal Palace, have featured radically changed line-ups, with Emery notably choosing not to bring senior players off the bench as his team chased an equaliser against the Eagles in last October’s 2-1 loss.
But the poor start to this term, with Villa now comfortably in their most difficult period since Emery first arrived in November 2022, places Tuesday’s tie with the Bees in a slightly different context.
Another defeat, particularly if it came without a goal, would further lower the mood. A win of any kind, by contrast, would provide some much-needed confidence heading toward a key fortnight which sees Villa face Sunderland, Fulham and Burnley in the league and also begin their Europa League campaign.
Emery is restricted in the changes he can make due to Villa’s injury worries in midfield with Youri Tielemans the latest player to be sidelined. Boubacar Kamara and Amadou Onana remain out, with Ross Barkley currently unavailable due to a personal issue.
The lack of numbers meant defender Victor Lindelof made his debut in midfield during the closing stages of Saturday’s draw. Pau Torres, whose only appearance of the season came in last month’s 1-0 league defeat at Brentford, is likely to replace Tyrone Mings with Ian Maatsen another expected to start.
Tuesday is just the second time the clubs have ever met in cup competition, with Villa winning an FA Cup fourth round replay 2-1 in 1953.