Lower Timing Chain Cover
Lower Timing Chain Cover
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
- Remove rear noise insulation by loosening fasteners - 1 and 2 -.
• Ignore items - 3 and 4 -.
- Place Old Oil Collecting and Extracting Device (V.A.G 1782) under engine and drain engine oil.
- Remove automatic transmission.
- 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.
- Remove oil filter housing. Refer to => [ Oil Filter Housing ] Oil Filter Housing.
- Remove bolts - arrows -.
- Remove bolts - 1 through 13 - and remove lower timing chain cover.
- Press transmission-side crankshaft sealing ring out of lower timing chain cover.
Installing
• Tightening specifications => [ Lower timing chain cover, tightening specifications
and sequence ] Timing Chain Covers Assembly Overview
Installation is performed in reverse order of removal, note the following:
- Pull alignment bushing out of top right of cylinder block.
- Chamfer 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.
• Because of the chamfer, the lower timing chain cover can be positioned more easily when the cylinder head is installed.
CAUTION!
Risk of contaminating lubricating system.
• Cover open parts of engine.
CAUTION!
Risk of eye injury.
• Wear safety glasses.
- Remove sealant residue on lower timing chain cover and on cylinder block and cylinder head, e.g. with a rotating plastic brush.
- Clean sealing surfaces so they are completely free of any oil or grease.
- Clean 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!
The cylinder head seal could be damaged.
• Only bend ends of cylinder head seals slightly, do not kink.
• 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).
CAUTION!
The cylinder head seal could be damaged.
• Only bend ends of cylinder head seals slightly, do not kink.
• 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 - arrows - to do this.
- To coat the surface between the cylinder head and gasket, use a flat object, e.g. a feeler gauge.
CAUTION!
The lubrication system could be plugged with excess sealant.
• Do not apply sealant beads thicker than indicated.
- 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.
• Lower timing chain cover must be installed within 5 minutes of applying 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 cylinder head seal must be replaced.
- Tighten bolts => [ Lower timing chain cover, tightening specifications
and sequence ] Timing Chain Covers Assembly Overview.
The rest of installation is in reverse order of removal, note the following:
- Install crankshaft seal, transmission side. Refer to => [ Transmission-Side Crankshaft Sealing Ring, Replacing ] Service and Repair.
- Install oil filter housing. Refer to => [ Oil Filter Housing ] Oil Filter Housing.
- Install intake manifold.
- Install left and right timing chain covers => [ ] Left and Right Timing Chain Covers.
- Install drive plate. Refer to => [ Drive Plate ] Drive Plate.
- Install automatic transmission.
- Add engine oil and check oil level. Refer to => [ Oil Level, Checking ] Component Tests and General Diagnostics.