Covers For Timing Chains, Removing and Installing

Covers for timing chains, removing and installing





Special tools and equipment
^ V.A.G. 1358 A or V.A.G. 1782
^ Hand drill with plastic brush insert
^ Safety glasses
^ Silicone sealant
^ Refer to Part Supplier

Removing
- Drain engine oil.
- Remove engine.
- Separate engine/transmission assembly.
- Place engine on workbench or a firm surface and secure in position with wooden blocks.

WARNING:
^ Engine must be secure to avoid risk of accident.
^ Do not set down engine on oil pan.

- Remove drive plate.
- Detach lifting tackle 3033 from engine.





- Disconnect connector -1- at throttle valve control module -J338-.
- Detach crankcase breather hose -3- at intake manifold.

Note: Ignore item -2-.





- Pull connectors -1 -, -2-, -5- and -6- forward off holders at intake manifold.
- Disconnect connectors -3- and -4-.





- Disconnect vacuum hose (arrow) at T-piece.





- Disconnect connector consoles -1- and -5- at injectors.
- Detach vacuum pipe -4- at fuel pressure regulator.
- Remove fuel rail retaining bolts -2- and -3-.
- Lift fuel rail together with injectors off intake manifold.

Note: Make sure injectors removed are properly protected against contamination.





- Remove left rear engine lifting eye bolts (arrows).





- Remove bolts (arrows) and take out intake manifold.

Note: Seal intake ducts in cylinder heads with clean cloths.





- Unscrew cap (arrow) for oil filter housing.
- Take out oil filter element.
- Use VAG 1358 A or VAG 1782 to extract engine oil from oil filter housing.

Note: Place cloth around oil filter housing to catch engine oil emerging.





- Remove bolts (arrows).
- Detach oil filter housing.





- Disconnect connector -1- at left engine mount.
- Remove nut -2- and detach engine mount.





- Remove bolts -1 -and -2-.
- Detach return line from power steering pump (arrow).





- Unscrew guide tube bolt for dipstick at cylinder head (arrow) and lift off.





- Remove bolts -1 -and -2-.
- Unfasten hose clamps (arrows) and detach left coolant pipe from coolant hoses.





- Remove bolts -1 -and -2-.
- Unfasten hose clamps (arrows) and detach right coolant pipe from coolant hoses.





- Disconnect connector -2- at Engine Coolant Temperature (ECT) Sensor -G2-/-G62-.
- Remove nut -1- and detach wiring harness at rear coolant pipe.





- Screw out bolts -2- to -5,
- Detach rear coolant pipe.

Note: Ignore items -I- and -6-.





- Remove bolts -1- to -4- of combination valves for secondary air system.





- Remove nuts -1- to -12- and detach left exhaust manifold.





- Remove bolts (arrows) and detach left heat shield.





- Remove nuts -1- to -12- and detach right exhaust manifold.





- Remove bolts (arrows) and detach right heat shield.





- Remove bolts -5- and -6- at left cylinder head.
- Unplug connectors -1 -to -4-. - Pull out ignition coils (arrows).

Note: Special tool T10094 can be used for removal.





- Detach crankcase breather hose (arrow).
- Remove bolts for left cylinder head cover in sequence -15- to -1 -.
- Detach cylinder head cover.





- Remove bolts -5- and -6- at right cylinder head.
- Disconnect connectors -1 -to -4-.
- Pull out ignition coils (arrows).

Note: Special tool T10094 can be used for removal.





- Detach crankcase breather hose (arrow).
- Remove bolts for right cylinder head cover in sequence -15- to -1 -.
- Detach cylinder head cover.





- Disconnect connector (arrow) for camshaft position (CMP) sensor 2 G163- at left cylinder head.





- Disconnect connector (arrow) for Camshaft Position (CMP) Sensor -G40- at right cylinder head.





- Remove ground (GND) cable at right cylinder head (arrow).
- Move aside wiring harness.





- Remove bolts -1- to -6- and detach left timing chain cover.





- Remove bolts -1- to -6- and detach right timing chain cover.





- Detach shim (arrow) from crankshaft.





- Remove bolts -1- to -13- and detach timing chain lower cover.
- Press crankshaft oil seal to rear out of cover.

Installing

Note: Replace gaskets, oil seals and O-rings.





- Use rotating plastic brush to remove remnants of sealant at covers for timing chains and at cylinder block/head.

WARNING: Use same glasses.

- Clean sealing surfaces; they must be free from oil and grease.





- Cut off nozzle of tube at front mark (diameter of nozzle approximately 1 mm).

Note: Covers for timing chains must be installed within 5 minutes after applying silicone sealant





- Apply silicone sealant beads -1- to -6- as shown to clean sealing surfaces of timing chain lower cover.
^ Thickness of sealant bead: 1.5 to 2.0 mm
- Check whether the 2 dowel sleeves have been installed in the cylinder block and insert if necessary.





- Install timing chain lower cover and tighten bolts as follows.
1. Bolts 11, 12, 13
^ To 10 Nm
2. Bolts 1, 3, 4, 5, 6, 7, 8, 9, 10
^ To 10 Nm
3. Bolts 4, 8, 9, 10
^ To 22 Nm
4. Bolts 2 for power steering pump
^ To 22 Nm





- Detach sealing flanges for camshaft adjusters at left and right for timing chain covers (arrows).





- Apply silicone sealant bead (arrow) as shown to clean sealing surfaces of left timing chain cover.
^ Groove at lower sealing surface (arrow -1-) must be completely filled with sealant; sealant bead must project 1.5 to 2.0 mm over sealing surface
^ Sealant bead at front sealing surface (arrows -2-) must be 1.5 to 2.0 mm thick
- New gasket -3- screw on left timing chain cover.





- Install left timing chain cover and tighten bolts as follows.
1. Bolts 1, 4
^ To 5 Nm
2. Bolts 6
^ To 10 Nm
3. Bolts 5
^ To 10 Nm
4. Bolts 1, 2, 3, 4
^ To 10 Nm





- Apply silicone sealant beads (arrow) as shown to clean sealing surfaces of right timing chain cover.
^ Groove at lower sealing surface (arrow -1 -) must be completely filled with sealant; sealant bead must project 1.5 to 2.0 mm over sealing surface
^ Sealant bead at front sealing surface (arrows -2-) must be 1.5 to 2.0 mm thick
- New gasket -3- Screw on right timing chain cover.





- Install right timing chain cover and tighten bolts as follows.
1. Bolts 2, 6
^ To 5 Nm
2. Bolts 1
^ To 10 Nm
3. Bolts 4
^ To 10 Nm
4. Bolts 2, 3, 5, 6
^ To 10 Nm





- Attach sealing flange bolts (arrows) for camshaft adjusters with new oil seals to left and right timing chain covers.
Perform further installation in reverse order, note the following:
- Install crankshaft oil seal on timing chain end.
- Install left and right cylinder head cover.
- Install left and right exhaust manifold.
- Install left and right secondary air system combination valves.
- Install rear coolant pipe.
- Install left and right coolant pipe.
- Install oil filter housing.
- Install intake manifold.
- Install drive plate.
- Bolt transmission to engine and install engine/transmission assembly.
- Pour in engine oil and check oil level.





Tightening torques