Lower Timing Chain Cover
Lower Timing Chain Cover
Special tools, testers and auxiliary items required
• Engine support bridge (10-222A)
• Bracket with spindle and hook (10-222A/10)
• Shackle (10-222A/12)
• Adapter (10-222A/13) (quantity 2)
• Locking pin (T10060A)
• Bits (T10099)
• Counter holder tool (T10355)
• Thrust piece (T10368)
• Torque wrench 5-50 Nm (VAG 1331)
• Torque wrench 40-200 Nm (VAG 1332)
• Silicone sealant (D 174 003 A3)
• Flat scraper
• Hand drill with plastic brush attachment
• Protective eyewear
• Feeler gauge
Removing
- Remove the noise insulation..
- Remove the right front wheel.
- Remove the right front wheel housing liner.
- Drain the engine oil.
- Remove the charge air pipe bolts - arrows -.
- Remove the charge air pipe by lifting the clamps - 1 and 2 -.
- Remove the ribbed belt. Refer to --> [ Ribbed Belt ] Ribbed Belt.
- Rotate the vibration damper to the "OT" position - arrow - using the (T10355):
• The notch on the vibration damper must line up with the arrow on the lower timing chain cover.
CAUTION!
The engine could be destroyed:
• In order not to change the valve timing, the crankshaft must not be moved out of the "OT" position when the vibration damper bolt is removed.
- Remove the vibration damper bolt using the (T10355).
- Remove the vibration damper.
CAUTION!
To avoid damaging the splines, only use the (T10368) to install the vibration damper bolt.
- Install the vibration damper bolt again with the (T10368).
- Remove the charge air pipe leading to the noise generator. Refer to --> [ Charge Air Pipe to Noise Generator ] Service and Repair.
- Install the (10-222A) using the following tools:
• (10-222A/10)
• (10-222A/12)
• (10-222A/13) (quantity 2)
- Tension the engine with the (10-222A/10).
- Remove the engine mount to engine mount bracket bolts - arrows -.
- Remove the engine mount. Refer to --> [ Engine and Transmission Mount Assembly 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 electrical wiring harness - arrow -.
- Remove the bolt - 1 - and remove the ribbed belt tensioner from the accessory bracket.
- Remove the lower engine mount bracket bolts using the (T10099).
- Remove the engine mount bracket and the bolts.
- Remove the bolts - 1 - and remove the oil dipstick guide tube out of the lower timing chain cover.
- Remove the wastegate bypass regulator valve bolts - arrows - and valve from the turbocharger.
- Remove the turbocharger connection bolts - 1 - and connection.
- Remove the lower timing chain cover bolts - 15 through 1 -.
CAUTION!
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, begin at locations - 1 and 2 -.
Installing
• Lower timing chain cover, tightening sequence and specification, refer to --> [ Lower Timing Chain Cover Bolt Tightening Sequence and Specification ] Timing Chain Covers Assembly Overview.
• Tightening specifications, refer to --> [ Timing Chain Covers Assembly Overview ] Timing Chain Covers Assembly Overview.
• Tightening specifications, refer to --> [ Description and Operation ].
• Tightening specification, refer to --> [ Ribbed Belt Assembly Overview ] Ribbed Belt Assembly Overview.
• Tightening specifications, refer to --> [ Engine and Transmission Mount Assembly Overview ] Service and Repair.
• Use silicone sealant (D 174 003 A3).
• Sealing surfaces must be completely free of oil and grease.
• Note the expiration date of the silicone sealant (D 174 003 A3).
• The cover must be installed within 5 minutes after applying the silicone sealant (D 174 003 A3).
• Replace bolts which have been tightened to specifications.
• Replace sealing rings, seals and self locking nuts.
- Remove any sealant residue on the cylinder block using a flat blade scraper.
CAUTION!
Wear safety glasses.
- Seal off both sides of the sealing ring with tape to prevent contamination.
- Remove the residual sealant on the cover for example, with a rotating plastic brush.
- Clean the sealing surfaces, they must be free of oil and grease.
- Install the cover with the old bolts and tighten:
• Tightening specification: 8 Nm.
- Check the gap between the cover and the housing using a feel gauge.
• It may not exceed 0.2 mm.
• If the gap exceeds 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 pins for centering the cover - arrows - are present.
- Cut the tube nozzle at the front marking (diameter of nozzle approximately 3 mm).
- Apply the silicone sealant (D 174 003 A3) on the clean sealing surface of the cover as shown.
• Thickness of sealant bead: 2 to 3 mm.
• The cover must be installed within 5 minutes after applying the silicone sealant (D 174 003 A3).
• The sealant bead must not be thicker than specified, otherwise excess sealant could get into the oil pan and clog the strainer in the intake line of the oil pump.
• Note the expiration date of the sealing compound.
- Install the cover immediately and tighten the bolts:
• Tightening sequence and specification, refer to --> [ Lower Timing Chain Cover Bolt Tightening Sequence and Specification ] Timing Chain Covers Assembly Overview.
• After installing the cover, allow the sealant to dry for approximately 30 minutes. Only after, may the engine oil be added.
Install in reverse order of removal. When doing this note the following:
- Adjust the engine and transmission mounts. Refer to --> [ Engine and Transmission Mount, Adjusting ] Engine and Transmission Mount, Adjusting.
- Fill the engine with oil.
- Check the oil level. Refer to --> [ Oil Level, Checking ] Testing and Inspection.