Audi Workshop Service and Repair Manuals

Removing and installing timing chain cover

Special tools and workshop equipment required

t	Support bracket -10-222 A-

t	Allen key (long reach) -T10058-

t	Counterhold tool -T10172-

Removing –  Unclip air intake hose from air duct -arrows-.

–  Unplug electrical connector at intake air temperature sender 2 -G299--item 2-. –  Detach vacuum hose -1- from actuator for intake air preheater.

–  Pull dipstick -1- out of guide tube. –  Remove the engine cover together with air cleaner housing -arrows-. –  Re-insert dipstick in guide tube.

–  Remove cover -1- over battery. To do so, press release tab -arrow-.

Caution Observe notes on procedure for disconnecting the battery → Rep. Gr.27. –  With ignition switched off, disconnect battery earth cable -arrow-.

–  Detach rubber bellows -1- from air duct -2-. –  Release both retainers -arrows- and detach air duct.

–  Unbolt hot air collector plate -arrows-.

–  Unbolt front exhaust pipe from exhaust manifold -arrows-.

–  Remove centre noise insulation -fasteners 1 ... 3-.

–  Remove noise insulation (right-side) -fasteners 1 ... 3-. –  Place used oil collection and extraction unit -V.A.G 1782- under engine. –  Drain off engine oil.   Note

Before removing, mark direction of rotation of poly V-belt with chalk or felt-tipped pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage. –  Turn the tensioner in the direction of the -arrow- to slacken the poly V-belt. –  Lock the belt tensioner with a 4 mm Allen key -item 1-. –  Remove poly V-belt.   WARNING The air conditioner refrigerant circuit must not be opened.

–  Unplug electrical connector -1- for magnetic clutch of air conditioner compressor. –  Remove bolts -arrows- for air conditioner compressor.   Note To prevent damage to the air conditioner compressor and refrigerant pipes/hoses, ensure that the pipes and hoses are not stretched, kinked or bent. –  Tie air conditioner compressor up to lock carrier.

–  Unscrew bolts -1 ... 3- and remove pendulum support.

–  Remove nuts -2- and -3- at exhaust pipe flange. –  Separate exhaust system at flange. –  Remove bolts -1- and -5-. –  Pull off bracket -4- for exhaust system from pins on front exhaust pipe.

Vehicles with manual gearbox: –  Unplug electrical connector -2- for Lambda probe -G39-. –  Unplug electrical connector -1- for exhaust gas temperature sender 1 -G235- (if fitted). –  Remove all electrical connectors from the bracket.   Note Disregard items marked -3- and -4-.

Vehicles with automatic gearbox: –  Unplug electrical connector -2- for Lambda probe -G39-. –  Unplug electrical connector -1- for exhaust gas temperature sender 1 -G235- (if fitted). –  Remove all electrical connectors from the bracket.

All models:   Note To avoid damage, the flexible joints in the front exhaust pipe must not be bent more than 30°. Vehicles with engine code letters BAG: –  Unscrew bolts -arrows-. –  Swing front exhaust pipe forwards and remove.   Note Disregard -item 1-.

Vehicles with engine code letters BLF, BLP: –  Unscrew bolts -arrows- and remove bracket for front exhaust pipe. –  Swing front exhaust pipe forwards and remove.   Note Disregard -item 1-.

All models: –  Detach electrical connector -2-. –  Unscrew wire -1- at alternator. –  Unbolt wire clamp -3- at alternator and move wiring harness clear.

–  Unscrew idler roller -2-. –  Unscrew bolts -1- and -3- and remove alternator.   Note t  If alternator sticks in its bracket, screw bolt back in again down to the last 2 turns. t  Tap carefully on bolt heads with flat side of hammer to release bushes of alternator mountings.

–  Unbolt crankshaft pulley; use tool -T10172- with -T10172/2- to counterhold.

–  File down the 3 round corners on the water pump wrench -V.A.G 1590- to dimension -a-. l  Dimension -a- = 1 mm.

–  Unbolt coolant pump pulley; use water pump wrench -V.A.G 1590- to counterhold.

–  Unplug electrical connector -1- at oil level and oil temperature sender -G266-. –  Unclip bracket -2- for wire to oil level and oil temperature sender -G266- at subframe.

–  Unscrew sump/gearbox bolts -arrows-. –  Unscrew bolts for sump -1- in diagonal sequence and remove. –  Take off sump; if necessary loosen it by striking lightly with a rubber hammer.

–  Disconnect fuel supply pipe -3- by pulling release ring. Vehicles with engine code letters BAG: –  Disconnect fuel return pipe -2- by pulling release ring. All models:   Note Disregard -item 1-.

–  Disconnect vacuum pipe -1- from activated charcoal filter. –  Pull the activated charcoal filter upwards out of the retainer -arrow-.

–  Unscrew bracket -3- for activated charcoal filter. –  Unscrew bolt at filler neck -2- for washer fluid reservoir. –  Disconnect the electrical connector at coolant shortage indicator switch -F66- (on coolant expansion tank) and move electrical wire clear. –  Unscrew coolant expansion tank -1- and place on top of engine with the hoses attached (secure if necessary).

–  Loosen bolts -arrows- of assembly mounting for engine approx. 2 turns.

–  Attach the shackle -10-222 A/12- to the right-side engine lifting eye. –  Set up support bracket -10-222 A- on wing panel flanges. l  The spindle is located at rear. –  Attach spindle hook to shackle. –  Pretension the spindle slightly.

–  Unscrew bolts -1- and -2- and detach connecting bracket. –  Remove bolts -3 ... 6- and detach engine mounting.

–  Unbolt pressure control valve for crankcase breather system -arrows-.

–  Unscrew bolts -arrows-. –  Remove engine lifting eye.

–  Unscrew hexagon socket head bolts -1 ... 6- for timing chain cover and hexagon bolts -arrows-. –  Raise engine slightly and remove timing chain cover. –  Use drift to drive out oil seal.

Installing –  Clean sealing surfaces carefully; they must be free of oil and grease. –  Insert new seals -arrows- onto rear of timing chain cover. –  Fit new gasket onto cylinder block dowel pins. –  Screw in 2 studs M6x80 into cylinder head and cylinder block to help guide. –  Carefully fit timing chain cover onto studs and dowel pins. –  Tighten securing bolts for timing chain cover evenly in a diagonal sequence. Installation is carried out in the reverse order. Note the following: –  Renew crankshaft oil seal → Chapter. –  Install crankshaft pulley → Chapter. –  Install sump → Anchor. –  Install exhaust system and align free of stress → Chapter. –  Install alternator → Rep. Gr.27. –  Adjust engine mountings → Chapter. –  Install poly V-belt → Chapter. Tightening torques

Component		Nm
Timing chain cover to	M6	10
cylinder block and cylinder head	M10	50
Engine lifting eye to timing chain cover		20
Pressure control valve for crankcase breather system to timing chain cover		10
Engine mounting to body		50
Connecting bracket to engine mounting/body		20 + 90° 1)2)
Coolant pump pulley to coolant pump		20
Idler roller to engine		40
Hot air collector plate to exhaust manifold		10
l  1) Renew bolts. l  2) 90° = one quarter turn.