Lower Timing Chain Cover
Lower Timing Chain Cover
Special tools, testers and auxiliary items required
• Old oil collecting and extracting device (VAG 1782)
• Hand drill with plastic brush attachment
• Protective eyewear
• Sealant.
Removing
- Remove bolts and remove front - 1 - and rear - 2 - noise insulation.
- Place the old oil collecting and extracting device (VAG 1782) under the engine and drain engine oil.
- Remove engine. Refer to --> [ Engine, Removing ] Engine Removing.
- Separate engine and transmission. Refer to --> [ Separating transmission from engine ] Engine Removing.
- Secure engine on engine and transmission holder (VAS 6095). Refer to --> [ Engine, Securing on Engine and Transmission Holder ] Engine, Securing on Engine and Transmission Holder.
- Remove drive plate. Refer to --> [ Drive Plate ] Drive Plate.
- Remove left and right timing chain covers. Refer to --> [ Left and Right Timing Chain Covers ] Left and Right Timing Chain Covers.
- Remove intake manifold. Refer to --> [ Intake Manifold ] Intake Manifold.
- Remove oil filter housing. Refer to --> [ Oil Filter Housing ] Oil Filter Housing.
- Remove the bolts - arrows -.
- Remove bolts - 1 through 13 - and remove lower timing chain cover.
- Press rear crankshaft seal out of the lower timing chain cover.
Installing
Installation is performed in reverse order of removal, noting the following:
- Pull alignment pin out of top right of cylinder block.
- Chamfer the alignment pin with a file, as shown in the illustration.
• Dimension - x - = 6.5 mm.
• Dimension - y - = 8 mm.
- Install the alignment pin into the cylinder block so that the chamfered side faces upward.
• The chamfer simplifies installation of the lower timing chain cover with cylinder head installed.
- Remove sealant residue in timing chain cover and cylinder block, e.g. with a rotating plastic brush.
CAUTION!
Wear safety glasses.
CAUTION!
Make sure that no sealant residue enters the engine.
- Clean sealing surfaces so they are completely free of any oil or grease.
- Clean the old sealant from the holes - arrow - in the cylinder head gaskets.
• With the cylinder head installed only half of the holes in the cylinder head gasket are visible.
CAUTION!
Cylinder head gasket must not be kinked. A kinked cylinder head gasket must be replaced.
- Bend the ends of the cylinder head gaskets very slightly downward - arrows - until the upper sealing surface of the gasket and cylinder head can be cleaned.
- Clean both cylinder head gaskets, top and bottom, so they are completely free of any oil or grease.
- Cut tube nozzle at front marking (nozzle dia.approximately 2 mm).
- Coat the sealing surfaces of the cylinder head gaskets, top and bottom, with a thin layer of sealant, slightly bending the cylinder head gaskets downward again - arrows - to do this.
- To coat the surface between the cylinder head and gasket, use a flat object, e.g. a feeler gauge.
- Apply sealant beads - 1 through 9 - on clean sealing surfaces of the lower timing chain cover, as shown in illustration.
• Thickness of sealant beads: 2.5 mm.
• Timing chain cover must be installed within 5 minutes of applying sealant.
- Set lower timing chain cover in place, guiding cover at an angle from below onto cylinder block sealing surface and cylinder head.
- When installing, make sure that the cylinder head gaskets do not become damaged. A damaged cylinder head seal must be replaced.
- Tighten bolts as follows:
- Insert bolts - arrows - with locking compound and tighten to 5 Nm with torque wrench.
- Tighten the bolts - 1 through 13 - in a diagonal sequence to 8 Nm using a torque wrench.
- Tighten the bolts - arrows - to 8 Nm using a torque wrench.
- Tighten the bolts - 2, 4, 8, 9 and 10 - to 22 Nm using a torque wrench.
- Tighten bolts - 1, 3, 5, 6, 7, 11, 12, 13 - an additional 90° (1/4 turn) in a diagonal sequence using a wrench.
- Tighten bolts - arrows - 90° (1/4 additional turn) using a wrench.
The rest of the installation is performed in reverse order of removal, noting the following:
- Install crankshaft seal, timing chain side. Refer to --> [ Crankshaft Seal, Timing Chain Side ] Service and Repair.
- Install oil filter housing. Refer to --> [ Oil Filter Housing ] Oil Filter Housing.
- Install intake manifold. Refer to --> [ Intake Manifold ] Intake Manifold.
- Install left and right timing chain covers. Refer to --> [ Installing ] Left and Right Timing Chain Covers.
- Install drive plate. Refer to --> [ Drive Plate ] Drive Plate.
- Install engine. Refer to --> [ Engine, Installing ] Engine Installing.
- Add engine oil and check oil level. Refer to --> [ Oil Level, Inspection ] Testing and Inspection.
Tightening Specifications
