Lower Timing Chain Cover

Lower Timing Chain Cover

Special tools, testers and auxiliary items required

• Hand drill with plastic brush attachment

• Protective eyewear

• Sealant

Removing

• Engine and transmission separated, refer to => [ Engine and Transmission, Separating ] Engine and Transmission, Separating, engine on the Scissor Lift Platform (VAS 6131 A) or secured by the engine/transmission holder, refer to => [ Engine, Securing to Engine and Transmission Holder ] Engine, Securing to Engine and Transmission Holder.

• Engine oil drained.

- Remove clutch pressure plate.

- Remove dual-mass flywheel. Refer to => [ Dual Mass Flywheel ] Dual Mass Flywheel.

- Remove left and right timing chain covers. Refer to => [ Left and Right Timing Chain Covers ] Left and Right Timing Chain Covers.

- Remove intake manifold.

- Remove oil filter housing. Refer to => [ Oil Filter Housing ] Oil Filter Housing.

- Remove the bolts - arrows -.





- Remove the bolts - 1 through 13 - and then remove the lower cover for the timing chain from the bond.

- Press the transmission side of the crankshaft shaft seal out of the lower timing chain cover.

Installing

Installation is in reverse order of removal, note the following:

- 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 e.g. 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 (nozzle dia. approximately 2 mm).





- Fill the cleaned cylinder head seal holes - arrow - with sealant.





CAUTION!
Cylinder head gasket must not be kinked. A kinked cylinder head gasket must be replaced.

- Lightly coat the sealing surfaces of the cylinder head gaskets, top and bottom, with sealant. While doing this slightly bend the cylinder head gaskets downward - arrows -.





- Use a flat object, e.g. a feeler gauge, to coat surfaces between cylinder head and gasket.

- Apply sealant beads - 1 to 9 - on clean sealing surfaces of lower timing chain cover, as shown in illustration.





• Thickness of sealant beads: 2.5 mm.

• Covers for timing chain must be installed within 5 minutes after applying sealant.

• Replace the M6 bolts - 1, 3, 5, 6, 7, 11, 12 and 13 -.





• Replace the bolts - arrows - that connect the timing chain lower cover to the cylinder head.

- Set the timing chain lower cover in place, guiding it at an angle from below onto cylinder block sealing surface and cylinder head.

CAUTION!
When installing, make sure that the cylinder head gaskets do not become damaged. A damaged cylinder head seal must be replaced.

- Tighten the bolts in 6 steps as follows:





The rest of the installation is in reverse order of removal, note the following:

- Install the transmission-side crankshaft shaft seal. Refer to => [ Crankshaft Seal, Transmission Side ] Service and Repair.

- Install oil filter housing => [ Oil Filter Housing ] Oil Filter Housing.

- Install intake manifold.

- Install left and right timing chain covers => [ Installing ] Left and Right Timing Chain Covers.

- Install dual-mass flywheel. Refer to => [ Dual Mass Flywheel ] Dual Mass Flywheel.

- Install clutch pressure plate.

- After installing the engine, fill with oil and check the oil level.