Timing Chain Covers

Timing Chain Covers

Special tools, testers and auxiliary items required

• Old oil collecting and extracting device (V.A.G 1782 )

• Hand drill with plastic brush attachment

• Protective eyewear

• Sealant

Removing

• All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

- Place old oil collecting and extracting device ( V.A.G 1782) under engine and drain engine oil.

- Remove engine. Refer to: Vehicles with manual transmission => [ Engine, Manual Transmission, Removing ] Engine, Manual Transmission, Removing, vehicles with automatic transmission => [ Engine, Removing ] Engine, Automatic Transmission, Removing and Installing.

- Disconnect engine and transmission. Refer to: Vehicles with manual transmission => [ Engine and Transmission, Separating ] Engine, Manual Transmission, Removing, vehicles with automatic transmission => [ Engine and Transmission, Separating ] Engine, Automatic Transmission, Removing and Installing.

- Leave the engine on the Scissor Lift Table (VAS 6131 A) or secure the engine to the engine and transmission holder. Refer to: Vehicles with manual transmission => [ Engine, Securing to Engine and Transmission Holder ] Engine, Manual Transmission, Removing, vehicles with automatic transmission => [ Engine, Securing to Engine and Transmission Holder ] Engine, Automatic Transmission, Removing and Installing.

- Remove dual-mass flywheel. Refer to => [ Dual Mass Flywheel ] Dual Mass Flywheel, drive plate => [ Drive Plate ] Drive Plate.

- Disconnect electrical connection - 1 - at throttle valve control module (J338).

- Disconnect crankcase ventilation hose - 3 - at intake pipe.

• Ignore - 2 -.

- Remove electrical harness connectors - 1 -, - 2 -, - 5 - and - 6 - toward front from brackets on intake pipe.

- Disconnect connectors - 3 - and - 4 -.

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

- 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.

• Carefully protect the removed fuel injectors from contamination.

- Remove left rear engine lifting eye - arrows -.

- Remove intake manifold bolts - arrows - and remove it.

• Plug the intake ports of the cylinder head with clean rags.

- Remove cap - arrow - for oil filter housing.

- Remove oil filter element.

- Extract engine oil using old oil collecting and extracting device (V.A.G 1782) from oil filter housing.

• 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 old oil collecting and extracting device ( V.A.G 1782) underneath.

- Remove return pipe from power-steering pump - arrow -.

- Remove guide pipe bolt for oil dipstick at cylinder head - arrow -, pull up and remove.

- 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 connector - 2 - on the Engine Coolant Temperature (ECT) Gauge Sensor (G2)/ (G62).

- Remove nut - 1 - and remove electrical wiring harness at rear coolant pipe.

- Remove bolts - 2 to 5 -.

- Remove rear coolant pipe.

• Ignore - 1 - and - 6 -.

- Remove mounting bolts - 1 to 4 - of combination valves for Secondary Air Injection 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 -.

• Extractor (T40039) can be used for removal.

- Disconnect hose of crankshaft housing ventilation - arrow -.

- Remove left cylinder head cover bolts in sequence - 15 to 1 -.

- Remove cylinder head cover.

- Remove bolts - 5 - and - 6 - on right cylinder head.

- Remove right cylinder head cover bolts 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.

- Remove Ground (GND) cable on right cylinder head - arrow -.

- Set wiring harness aside.

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

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

- Remove bolts - 1 to 13 - and remove lower timing chain cover.

- Press sealing ring for crankshaft at rear out of cover.

Installing

• Replace gaskets, seals and O-rings.

• During installation, all cable ties must be re-installed at the same location.

- Using e.g. a rotating plastic brush, remove sealant residue on covers for timing chain and on cylinder block and head.

CAUTION!
Wear safety glasses.

- Clean sealing surfaces, they must be free of oil and grease.

- Cut tube nozzle at front marking (nozzle dia. approximately 1 mm).

• Covers for timing chain must be installed within 5 minutes after 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 the 2 alignment bushings are present in cylinder block, install if necessary.

- Position lower cover for timing chain and tighten bolts as follows.

1. Tighten bolts - 11 -, - 12 -, - 13 - to 10 Nm.

2. Tighten bolts - 1 -, - 3 -, - 4 -, - 5 -, - 6 -, - 7 -, - 8 -, - 9 -, - 10 - to 10 Nm.

3. Tighten bolts - 4 -, - 8 -, - 9 -, - 10 - to 22 Nm.

4. Tighten bolts - 2 - for power-steering pump to 22 Nm

- 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. The sealant bead must be 1.5 to 2.0 mm above the sealing surface.

• Sealant bead on front sealing surface - arrows 2 - must be 1.5 to 2.0 mm thick.

- Install new seal - 3 - on left cover for timing chain.

- Position left cover for timing chain and tighten bolts as follows:

1. Tighten bolts - 1 to 4 - to 5 Nm

2. Tighten bolts - 6 - to 10 Nm

3. Tighten bolts - 5 - to 10 Nm

4. Tighten bolts - 1 to 4 - to 10 Nm

- 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. The sealant bead must be 1.5 to 2.0 mm above the sealing surface.

• Sealant bead on front sealing surface - arrows 2 - must be 1.5 to 2.0 mm thick.

- Install new seal - 3 - on right cover for timing chain.

- Position right cover for timing chain and tighten bolts as follows:

1. Tighten bolts - 1 to 4 - to 5 Nm

2. Tighten bolts - 6 - to 10 Nm

3. Tighten bolts - 5 - to 10 Nm

4. Tighten bolts - 1 to 4 - to 10 Nm

1. Tighten bolts - 2 -, - 3 -, - 5 -, - 6 - to 5 Nm.

2. Tighten bolts - 1 - to 10 Nm

3. Tighten bolts - 4 - to 10 Nm

4. Tighten bolts - 2 -, - 3 -, - 5 -, - 6 - to 10 Nm.

- Install sealing flanges for camshaft adjuster with new sealing rings on left and right covers for timing chain - arrows -.

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

- Install crankshaft seal, timing chain side. Refer to => [ Crankshaft Seal, Timing Chain Side, Replacing ] Service and Repair.

- Install cylinder head cover. Refer to: Left => [ Left Cylinder Head Cover ] Left Cylinder Head Cover, right => [ Right Cylinder Head Cover ] Right Cylinder Head Cover.

- Install exhaust manifold. Refer to: Left => [ Left Exhaust Manifold ] Left Exhaust Manifold, right => [ Right Exhaust Manifold ] Right Exhaust Manifold.

- Install combination valve for Secondary Air Injection (AIR) system. Refer to: Left => [ Secondary Air Injection Left Combination Valve ] Secondary Air Injection Left Combination Valve, right => [ Secondary Air Injection Right Combination Valve ] Secondary Air Injection Right Combination Valve.

- Install rear coolant pipe. Refer to => [ Rear Coolant Pipe ] Rear Coolant Pipe.

- Install left and right coolant pipe. Refer to => [ Right Coolant Pipe ] Right Coolant Pipe and => [ Left Coolant Pipe ] Left Coolant Pipe.

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

- Install intake manifold. Refer to => [ Intake Manifold ] Intake Manifold.

- Install dual-mass flywheel. Refer to => [ Dual Mass Flywheel ] Dual Mass Flywheel, drive plate => [ Drive Plate ] Drive Plate.

- Install engine. Refer to: Vehicles with manual transmission => [ Engine, Installing ] Engine, Manual Transmission, Removing, vehicles with automatic transmission => [ Engine, Installing ] Engine, Automatic Transmission, Removing and Installing.

- Add engine oil and check oil level. Refer to => [ Oil Level, Checking ] Testing and Inspection.

Tightening Specifications

* Insert using locking compound