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

CAUTION!
Risk of injury.

• The lock carrier must be installed and the torque support must be securely attached.

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

• The transmission is removed.

• Engine oil drained.

- Remove the flywheel. Refer to => [ Flywheel ] Flywheel.

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

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

- Remove bolts - arrows -.





- Remove bolts - 1 through 9 - and remove the lower timing chain cover.

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

Installing

• Replace seals, gaskets and O-rings.

- Remove the right upper alignment bushing from the cylinder block.

- Grind the alignment bushing down at an angle as shown in the illustration.





• Dimension - x - = 6.5 mm.

• Dimension - y - = 8 mm.

- Insert the alignment bushing in the cylinder block so the angled side faces up.

• 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 the sealant residue on the cover for the timing chain, cylinder block and cylinder head, for example using a rotating plastic brush.





- Clean the sealing surfaces so that they are free of oil and grease on both the top and bottom.

- Clean old sealant out of the holes - arrow - in the cylinder head seals.





• With cylinder head installed, holes in cylinder head seal are only half visible.

CAUTION!
The cylinder head seal could be damaged.

• Only bend ends of cylinder head seals slightly, do not kink.

• A kinked cylinder head seal must be replaced.

- Bend the end of the cylinder head seals down slightly - arrows - until the upper sealing surface of the seals and the cylinder head can be cleaned.





- Clean the top and bottom of the cylinder head seals so they are free of oil and grease.

• Note the expiration date of the sealing compound.

- Cut the tube nozzle at the front marking (nozzle diameter approximately 2.0 mm).





• The sealant must be applied to several places on the engine, as described in the following.

- Lightly coat the top and bottom cylinder head seal sealing surfaces with lubricant by bending the seals down slightly again - arrows -.





- Use a flat object such as a feeler gauge to coat the surface between the cylinder head and seal.

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





CAUTION!
The lubrication system could be plugged with excess sealant.

• Do not apply sealant bead thicker than indicated.

- Apply sealant beads - 1 through 4 - on the clean lower timing chain cover sealing surfaces as shown in the 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 drawn through as shown in the illustration even though the groove is intermittent.

• The sealant only needs to cure for approximately 5 minutes after applying.

- Insert the seals - arrows - in the grooves on the lower timing chain cover.

- Position the lower timing chain cover, guiding it diagonally from below to the sealing surface on the cylinder block and cylinder head.





- When positioning, ensure the cylinder head seals are not damaged.

- Tighten the bolts for the lower timing chain cover. Refer to => [ Lower Timing Chain Cover, Tightening Specifications
and Sequence ] Timing Chain Covers Assembly Overview.

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

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

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

- Install the oil filter element.

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

- Install the flywheel. Refer to => [ Flywheel ] Flywheel.