Lower Timing Chain Cover
Lower Timing Chain Cover
Special tools, testers and auxiliary items required
• Engine Support Bridge (10-222 A)
• Bracket with Spindle and Hook (10-222 A/10)
• Shackle (10-222 A/12)
• Frame (10-222 A/13) (GTI only)
• Locking Pin (T10060 A)
• Bits (T10099)
• Counter Hold Tool (T10355)
• Thrust Piece (T10368)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Bracket for Engine (10-222 A/1) (Eos only)
Removing
- Remove the noise insulation.
- Remove the front part of the right wheel housing liner.
- Drain the engine oil.
- Remove the bolts - arrows -.
- Lift the clamps - 1 and 2 - and remove the charge air pipe.
Risk of destroying due to a reversed running direction on a used ribbed belt.
• Before removing the ribbed belt, mark the running direction with chalk or a felt tip pen for reinstallation later.
- Loosen the clamps - arrows - and remove the right charge air hose.
- To release the tension on the ribbed belt, rotate the tensioner in the - direction of the arrow - from underneath.
- Secure the tensioner using the locking pin (T10060 A).
- Remove the ribbed belt from the vibration damper.
- Rotate the vibration damper into the Top Dead Center (TDC) position - arrow - using the counter hold tool (T10355).
• The notch on the vibration damper must line up with the arrow mark - arrow - on the lower timing chain cover.
The engine could be destroyed.
• In order not to change the valve timing, the crankshaft must not be moved out of the TDC position when the vibration damper bolt is removed.
- Remove the vibration damper bolt using the counter hold tool (T10355).
- Remove the vibration damper.
To avoid damaging the splines, only use the thrust piece (T10368) to install the vibration damper bolt.
- Install the vibration damper bolt and the thrust piece (T10368) again.
Vehicles with a Noise Generator:
- Remove the charge air pipe from the noise generator. Refer to => [ Charge Air Pipe to Noise Generator ] Charge Air Pipe to Noise Generator.
Continuation for all Vehicles:
- Install the engine support bridge (10-222 A) using the following special tools:
GTI:
• Adapter (10-222 A/13) (Qty: 2)
• Bracket with spindle and hook (10-222 A/10)
• Shackle (10-222 A/12)
Eos:
• Bracket for engine (10-222 A/1)
• Bracket with spindle and hook (10-222 A/10)
• Shackle (10-222 A/12)
• Do not place the bracket for engine (10-222 A/1) on the fender panels. The panels will be damaged.
• The shackle (10-222 A/12) is needed to make sure the engine is lifted in the installed position and not tipped.
Continuation for all Vehicles:
- Secure the engine with the spindle.
- Remove the engine mount to engine mount bracket bolts - arrows -.
- Remove the engine mount. Refer to => [ Engine and Transmission Mount Overview ] Service and Repair.
- Lift the engine approximately 50 mm and loosen the upper bolt for the engine mount bracket.
- Now, lower the engine approximately 100 mm.
- Free up the wiring harness - arrow -.
- Remove the bolt - 1 - and remove the ribbed belt tensioner from the accessory bracket.
- Remove the lower bolts for the engine mount bracket using the bits (T10099).
- Remove the engine mount bracket and the bolts.
- Remove the bolts - arrows - and remove the oil dipstick guide tube from the timing chain cover.
- Remove the wastegate bypass regulator valve (N75) from the turbocharger- arrows -.
- Remove the turbocharger support - 1 -.
- Remove the bolts - 1 through 15 -.
The lower timing chain cover could be damaged. To avoid deformation, do not hold between the bolting points.
- Pry off the lower timing chain cover; when doing this, begin at - 1 and 2 -.
Installing
• Tightening specifications, refer to => [ Timing Chain Covers Overview ] Timing Chain Covers Overview.
• Sealant: silicone sealant (D 174 003 A2)
• Note the expiration date of the silicone sealant.
• The cover must be installed within 5 minutes after application of silicone sealant.
• Replace the bolts which have been tightened to a torque angle.
• Replace O-rings, seals and self-locking nuts.
- Remove any sealant residue on the cylinder block using a flat blade scraper.
Wear safety glasses.
- Seal off both sides of the seal with tape to prevent contamination.
- Use a rotating plastic brush to remove any remaining sealing on the cover.
- Clean sealing surfaces, must be free of oil and grease.
- Install the cover using the old bolts and tighten them to 8 Nm.
- Check between the cover and housing using a feel gauge; the gap must not exceed 0.2 mm.
• If the gap exceed 0.2 mm, replace the cover.
• It is not possible to measure between the cover the upper oil pan, however check the sealing surface for evenness.
- Make sure both alignment sleeves - arrows - for centering the cover are present.
- Cut the sealant tube nozzle at the front mark (nozzle diameter: approximately 3 mm).
- Apply the silicone sealant (D 174 003 A2) on the clean sealing surface of the cover as shown in the illustration.
• Thickness of sealant bead: 2 to 3 mm.
• The cover must be installed within 5 minutes after application of the silicone sealant.
• The sealant bead may not be thicker than specified, otherwise excess sealant could enter the oil pan and clog the oil intake pipe.
- Install the cover immediately and all the bolts.
- Tighten the bolts - 1 through 15 - in 2 passes in the sequence shown:
1 - Tighten the bolts to 8 Nm
2 - Tighten the bolts an additional 45° (1/8) turn
• After installing the cover, allow the sealant to dry for approximately 30 minutes. Only after then may the engine oil be added.
- Fill the engine oil.
- Check the oil level.
The rest of the installation is basically a reverse of the removal sequence.