Lower Timing Chain Cover

Lower Timing Chain Cover

Special tools, testers and auxiliary items required

• Oil Collecting and Extracting Device (V.A.G 1782)

• Hand drill with plastic brush attachment

• Protective goggles

• Sealant, refer to the Electronic Parts Catalog (ETKA)

Removing

• The transmission is removed.

- Place the (V.A.G 1782) under the engine and drain the engine oil.

- Remove the drive plate. Refer to => [ Drive Plate ] Drive Plate.

- Remove the timing chain covers. Refer to => [ Left Timing Chain Cover ] Left Timing Chain Cover, => [ Right Timing Chain Cover ] Right Timing Chain Cover.

- Remove intake manifold.






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

- Remove the bolts - 1 and 2 - and move the lower left coolant pipe to the side.






• Ignore - arrows -.

- Remove the bolts - arrows -.






- Remove the bolts in the following sequence: - 12 to 1 -.

- Carefully separate the timing chain guard lower section from the bond.

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

Installing






• For the correct tightening specifications, refer to => [ Lower Timing Chain Cover, Tightening Specifications and Sequence ] Timing Chain Covers Overview.

• Replace the M6 bolts.

- 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.


Risk of contaminating lubricating system.

• Cover open parts of the engine.


Danger of eye injury.

• Wear protective goggles.

- Remove the sealant residue on the lower timing chain cover and on the cylinder block and cylinder head, for example with a rotating plastic brush.






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

- Clean the threaded holes in the cylinder block for connecting the engine and transmission using a thread tap before installing the transmission.

- 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.


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 mm).






- 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.







The lubrication system could be plugged with excess sealant.

• Do not apply sealant bead thicker than indicated.

- Apply sealant beads - 1 through 9 - on the clean lower timing chain cover sealing surfaces as shown in the illustration.






• Thickness of sealant beads: 2.5 mm.

• The timing chains cover must be installed within 5 minutes after applying the sealant

- 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. Refer to => [ Lower Timing Chain Cover, Tightening Specifications and Sequence ] Timing Chain Covers Overview.

Install in reverse order of removal paying attention to the following:

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

- Installing the lower left coolant pipe. Refer to => [ Lower Left Coolant Pipe ] Lower Left Coolant Pipe.

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

- Install intake manifold.

- Install the timing chain covers. Refer to => [ Left Timing Chain Cover ] Left Timing Chain Cover, => [ Right Timing Chain Cover ] Right Timing Chain Cover.

- Installing drive plate. Refer to => [ Drive Plate ] Drive Plate.