Operation CHARM: Car repair manuals for everyone.

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.