Covers For Timing Chain, Removing and Installing
Covers for timing chain, removing and installing
Special tools, testers and auxiliary items required
^ Oil collecting and extracting device V.A.G 1782
^ Drill with plastic brush attachment
^ Protective glasses
^ Sealant
Removing
Note: All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.
- Place oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
- Remove engine
- Disconnect engine and transmission
- Leave engine on scissor lift platform VAS 6131 or secure engine to assembly stand
- Remove dual-mass flywheel
- Disconnect electrical harness connector - 1 - at Throttle Valve Control Module -J338-.
- Disconnect crankcase ventilation hose - 3 - at intake pipe.
Note: Disregard - item 2 -.
- Remove electrical harness connectors - 1 -, - 2 -, - 5 - and - 6 - toward front from brackets on intake pipe.
- Disconnect electrical harness connectors - 3 - and - 4 -.
- Pull off vacuum hose - arrow - at T-connector.
- Disconnect connector strips - 1 - and - 5 - at fuel injectors.
- For vehicles with fuel return line, disconnect vacuum line - 4 - on fuel pressure regulator.
- Remove retaining bolts - 2 - and - 3 - for fuel rail pipe.
- Remove fuel rail pipe together with fuel injectors from intake manifold uniformly upward.
Note: Carefully protect removed fuel injectors from contamination.
- Remove bolts for left rear engine lifting eyelet - arrows -.
- Remove bolts from intake manifold - arrows - and remove.
Note: Plug intake channels in the cylinder heads with clean rags.
- Unscrew cap - arrow - for oil filter housing.
- Remove oil filter element.
- Extract engine oil using oil collecting and extracting device V.A.G 1782 from oil filter housing.
Note: Place a rag around oil filter housing to catch escaping engine oil.
- Remove bolts - arrows -.
- Remove oil filter housing.
- Remove bolts - 1 - and - 2 -.
- Place oil collecting and extracting device V.A.G 1782 underneath.
- Remove return pipe from power steering pump - arrow -.
- Remove bolt from oil dipstick guide tube at cylinder head - arrow -, pull up and remove guide tube.
- Remove bolts - 1 - and - 2 -.
- Loosen hose clamps - arrows - and remove left coolant pipe from coolant hoses.
- Remove bolts - 1 - and - 2 -.
- Loosen hose clamps - arrows - and remove right coolant pipe from coolant hoses.
- Disconnect electrical harness connector - 2 - at Engine Coolant Temperature (ECT) Sensor -G2-/-G62-.
- Remove nut - 1 - and remove electrical wiring harness at rear coolant pipe.
- Remove bolts - 2 to 5 -.
- Remove rear coolant pipe.
Note: Disregard - item 1 - and - item 6 -.
- Remove mounting bolts - 1 to 4 - of combination valves for Secondary Air Injection (AIR) system.
- Remove nuts - 1 to 12 - and remove left exhaust manifold.
- Remove left heat shield - arrows -.
- Remove nuts - 1 to 12 - and remove right exhaust manifold.
- Remove right heat shield - arrows -.
- Remove bolts - 5 - and - 6 - on left cylinder head.
- Disconnect electrical harness connectors - 1 to 4 -.
- Remove ignition coils - arrows -.
Note: Extractor T40039 can be used for removal.
- Disconnect hose of crankshaft housing ventilation - arrow -.
- Unscrew bolts for left cylinder head cover in sequence - 15 to 1 -
- Remove cylinder head cover.
- Remove bolts - 5 - and - 6 - on right cylinder head.
- Disconnect electrical harness connectors - 1 to 4 -.
- Remove ignition coils - arrows -.
Note: Extractor T40039 can be used for removal.
- Disconnect hose of crankshaft housing ventilation - arrow -.
- Unscrew bolts for right cylinder head cover in sequence - 15 to 1 -.
- Remove cylinder head cover.
- Disconnect electrical harness connector - arrow - for Camshaft Position (CMP) Sensor 2 -G163- on left cylinder head.
- Disconnect electrical harness connector - arrow - for Camshaft Position (CMP) Sensor -G40- on right cylinder head.
- Unscrew Ground (GND) cable on right cylinder head - arrow -.
- Set wiring harness aside.
- Remove bolts - 1 to 6 - and remove left cover for timing chain.
- Remove bolts - 1 to 6 - and remove right cover for timing chain.
- Unscrew bolts - 1 to 13 - and remove lower cover for timing chain.
- Press seal for crankshaft at rear out of cover.
Installing
Note:
^ Replace seals, sealing rings and O-rings.
^ During installation, reinstall all cable ties at the same locations.
- Using a rotating plastic brush, remove sealant residue on covers for timing chain and on cylinder block and head.
CAUTION: Wear protective glasses.
- Clean sealing surfaces so they are completely free of oil or grease.
- Cut tube nozzle at front marking (nozzle diameter approximately 1 mm).
Note: Covers for timing chain must be installed within 5 minutes of applying sealant.
- Apply sealant beads - 1 to 6 -, as shown in illustration, on clean sealing surfaces of lower cover for timing chain.
^ Thickness of sealant bead: 1.5 to 2.0 mm.
- Check whether 2 alignment bushings are present in cylinder block, install if necessary.
- Position lower cover for timing chain and tighten bolts as follows.
- Remove sealing flanges for camshaft adjuster on left and right covers for timing chain - arrows -.
- Apply sealant bead - arrow -, as shown in illustration, on clean sealing surfaces of left cover for timing chain.
^ Groove on lower sealing surface - arrow 1 - must be completely filled with sealant. Sealant bead must stand 1.5 to 2.0 mm above sealing surface.
^ Sealant bead on front sealing surface - arrows 2 - must be 1.5 to 2.0 mm thick.
- Screw new seal - 3 - on left cover for timing chain.
- Position left cover for timing chain and tighten bolts as follows.
- Apply sealant beads - arrow -, as shown in illustration, on clean sealing surfaces of right cover for timing chain.
^ Groove on lower sealing surface - arrow 1 - must be completely filled with sealant. Sealant bead must stand 1.5 to 2.0 mm above sealing surface.
^ Sealant bead on front sealing surface - arrows 2 - must be 1.5 to 2.0 mm thick.
- Screw new seal - 3 - on right cover for timing chain.
- Position right cover for timing chain and tighten bolts as follows.
- Install sealing flanges for camshaft adjuster with new sealing rings on left and right covers for timing chain - arrows -.
The rest of the installation is performed in reverse order of removal. Note the following:
- Install seal for crankshaft - timing belt side
- Install cylinder head cover
- Install exhaust manifold
- Install combination valve for Secondary Air Injection (AIR) system
- Install rear coolant pipe
- Install left and right coolant pipe
- Install oil filter housing
- Install intake manifold
- Install dual-mass flywheel
- Install engine
- Add engine oil and check oil level
Tightening torques
