Timing Cover: Service and Repair

Timing Chain Covers

Special tools, testers and auxiliary items required

• Counter Holder Tool (10-201)

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

• Hand Drill with Plastic Brush Attachment

• Protective Eyewear

• Silicone Sealant (D176 404 A2)

Removing

• All cable ties opened or cut off during engine removal must be reinstalled at the same locations during installation.

- Drain the engine oil.

- Remove the engine. Refer to => [ Engine, Removing ] Engine, Removing.

- Separate the engine and transmission. Refer to => [ Engine, Removing from Scissor Lift Table ] Engine, Removing from Scissor Lift Table.

- Secure the engine to the assembly stand. Refer to => [ Engine, Securing to Assembly Stand ] Engine, Securing to Assembly Stand.

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

- Remove the shim behind it.

- Remove the charge air pipe with the crankcase ventilation connecting hose.

- Disconnect the connectors - 1 and 2 -.





- Remove the oil supply line banjo bolt - 3 -.

- Disconnect the connector - 4 -.





- Remove the bolts - 2 and 3 - and remove the bracket.

- Remove the bolts - 1 -.

- Disconnect the rear coolant pipe from the coolant hose - 1 -.

- Remove the turbocharger oil return line - item 26 -=> [ Upper Oil Return Line ] Turbocharger Overview.

- Remove the nuts and bolts - arrows - and the left intermediate pipe.





- Remove the bolts and nuts - 1 through 4 - and the right intermediate pipe.





- Remove the bolts - arrows - and the turbocharger.





- Remove the bolt - arrow - and the vacuum pump.





- Remove the bolts - 1 through 4 - and remove the right timing chain cover.





- Remove the bolts - 1 through 4 - and remove left timing chain cover.





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





- Press the seal for the crankshaft out of the lower timing chain cover.

Installing

• Replace gaskets, seals and O-rings.

• During installation, all cable ties must be reinstalled at the same location.

- Remove the old sealant from the grooves in the timing chain covers and from the sealing surfaces.

CAUTION!
Wear safety glasses.

- Remove sealant residue on the timing chain covers and on the cylinder block or head with a rotating plastic brush.





- Clean sealing surfaces so they are completely free of any oil or grease.

- Cut the tube nozzle at the front mark (nozzle diameter approximately 2 mm).





• The sealant bead must not be thicker than specified or the sealant could enter the oil pan and clog the oil pump strainer.

• The timing chain covers must be installed within 5 minutes after applying sealant.

- Install the seals - 2 and 5 -.





- Apply the sealant beads - 1 and 4 - to the clean sealing surfaces on the lower timing chain cover as illustrated.

• Completely fill the grooves on the sealing surfaces with sealant.

• The sealant bead must be 1.5 to 2.0 mm above the sealing surface.

• The bead of sealant around the holes - 3 and 6 - must be 1.5 to 2.0 mm thick.

- Check whether the 2 alignment bushings are present in the cylinder block, install if necessary.

- Position the lower timing chain cover and tighten the bolts as follows:









- Apply the sealant bead to the clean sealing surfaces on the left timing chain cover as illustrated.





• The groove - 1 - on the sealing surface must be completely filled with sealant.

• The sealant bead must be 1.5 to 2.0 mm above the sealing surface.

- Set the gasket - 2 - in place.

- Position the left timing chain cover and tighten the bolts as follows.









- Apply the sealant bead to the clean sealing surfaces on the right timing chain cover as illustrated.





• The groove - 1 - on the sealing surface must be completely filled with sealant.

• The sealant bead must be 1.5 to 2.0 mm above the sealing surface.

- Set the gasket - 2 - in place.

- Position the right timing chain cover and tighten bolts as follows:









Further installation is performed in reverse order.