Lower Timing Chain Cover
Lower Timing Chain Cover
Special tools, testers and auxiliary items required
• Used Oil Collecting and Extracting Device (V.A.G 1782)
• Hand drill with plastic brush attachment
• Protective eye-wear
• Sealant
Removing
• The transmission is removed.
• Engine oil drained.
• All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.
CAUTION!
To continue performing the repair procedure, ensure lock carrier is installed and torque support is tightened.
- Vehicles with multitronic transmission. Refer to: Remove damper unit => [ Damper Unit ] Damper Unit and flywheel => [ Flywheel, Multitronic Transmission ] Flywheel, Multitronic Transmission.
- Vehicles with automatic transmission 09L: Remove drive plate. Refer to => [ Drive Plate, Automatic Transmission 09L ] Drive Plate, Automatic Transmission 09L.
- Disconnect electrical harness connectors - 1 to 3 -.
- Remove nut - arrow -.
- Remove retainer for connection - 3 -.
- Remove the double-bolt lying beneath.
- Remove retainer for connections - 1 - and - 2 -.
- Remove the bolts - 1 through 8 - and then remove the left cover for the timing chain from the bond.
- Separate the electrical connector - 1 -.
- Remove bolt - arrow - and remove retainer for connection.
- Remove the bolts - 1 through 8 - and then remove the right cover for the timing chain from the bond.
- Remove cap - arrow - for oil filter housing.
- Remove oil filter element.
- Extract the oil from the oil filter housing using the Used Oil Collection and Extraction Device (V.A.G 1782).
• Place a rag under oil filter housing to catch escaping engine oil.
- Disconnect electrical harness connector from Oil Pressure Switch (F1) - arrow -.
- Remove oil pressure switch.
- Remove bolts - arrows -.
- Remove oil filter housing.
Vehicles through 04.2005:
- Remove bolts - arrows -.
- Remove bolts - 1 through 8 - and then remove the lower cover for the timing chain from the bond.
Vehicles from 05.2005:
- Remove bolts - arrows -.
- Remove bolts - 1 through 9 - and then remove the lower cover for the timing chain from the bond.
All:
- Press rear crankshaft seal out of lower timing chain cover.
Installing
• Replace gaskets, seals and O-rings.
• During installation, all cable ties must be re-installed at the same location.
- Pull alignment bushing out of top right of cylinder block.
- Chamfer the alignment bushing with a file, as shown in the illustration.
• Dimension - x - = 6.5 mm.
• Dimension - y - = 8 mm.
- Install the alignment bushing 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.
CAUTION!
Wear safety glasses.
- Using for example a rotating plastic brush, remove sealant residue on cover for timing chain and on cylinder block and head.
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.
• Note the expiration date of the sealing compound.
- Cut tube nozzle at front marking (jet dia. approximately 2 mm).
• The sealant must be applied to several places on the engine, as described in the following.
• Timing chain cover must be installed within 5 minutes of applying sealant.
CAUTION!
Cylinder head gasket must not be kinked. A kinked cylinder head gasket must be replaced.
- 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 to do this.
- Use a flat object, for example a feeler gauge, to coat surfaces between cylinder head and gasket.
- Fill the cleaned holes - arrow - in the cylinder head seal with sealant.
Vehicles through 04.2005:
- Apply sealant beads - 1 to 6 - on clean sealing surfaces of lower timing chain cover, as shown in illustration.
• The groove of sealing surface must be completely filled with sealant.
• The sealant beads must be 1.5 to 2.0 mm above the sealing surface.
• The sealant bead - 3 - must be pulled through as shown in the illustration even though the groove is intermittent.
- Lay O-ring - arrow - in lower timing chain cover groove.
- Secure O-ring with some sealant.
- Set the lower timing chain cover in place, guiding the cover at an angle from below onto the sealing surface of the cylinder block and cylinder head.
- When installing, make sure that the cylinder head gaskets do not become damaged. A damaged gasket must be replaced.
- Tighten bolts in 4 stages as follows:
- Then immediately install the oil filter housing. Refer to => [ Oil Filter Housing ] Oil Filter Housing.
Vehicles from 05.2005:
- Apply sealant beads - 1 to 5 - on clean sealing surfaces of lower timing chain cover, as shown in illustration.
• The groove of sealing surface must be completely filled with sealant.
• The sealant beads must be 1.5 to 2.0 mm above the sealing surface.
• The sealant bead - 2 - must be pulled through as shown in the illustration even though the groove is intermittent.
- Insert seals - arrows - in lower timing chain cover grooves.
- Set the lower timing chain cover in place, guiding the cover at an angle from below onto the sealing surface of the cylinder block and cylinder head.
- When installing, make sure that the cylinder head gaskets do not become damaged. A damaged gasket must be replaced.
- Tighten bolts in 5 stages as follows:
All:
Further installation is in reverse order of removal, note the following:
- Install left and right timing chain covers => [ Installing ] Left and Right Timing Chain Covers.
- Install oil filter housing. Refer to => [ Oil Filter Housing ] Oil Filter Housing.
- Install the crankshaft seal on the transmission side. Refer to => [ Crankshaft Seal, Transmission Side ] Service and Repair.
- Vehicles with multitronic transmission: Install flywheel. Refer to => [ Flywheel, Multitronic Transmission ] Flywheel, Multitronic Transmission and damper unit => [ Damper Unit ] Damper Unit.
- Vehicles with automatic transmission 09L: Install drive plate. Refer to => [ Drive Plate, Automatic Transmission 09L ] Drive Plate, Automatic Transmission 09L.
- Fill engine oil and check oil level.
Tightening Specifications
