Audi Workshop Service and Repair Manuals

Removing and installing timing chain covers Special tools and workshop equipment required

t  Used oil collection and extraction unit -V.A.G 1782- t  Electric drill with plastic brush attachment t  Safety goggles t  Sealant → Electronic parts catalogue Removing l  Gearbox removed. –  Remove dual-mass flywheel (vehicles with manual gearbox) → Chapter. –  Remove flywheel (on a vehicle with multitronic gearbox → Chapter). –  Remove drive plate (vehicles with automatic gearbox) → Chapter. –  Place used oil collection and extraction unit -V.A.G 1782- under engine. –  Drain off engine oil. –  Remove starter catalytic converter: vehicles without particulate filter → Chapter; vehicles with particulate filter → Chapter. –  Remove vacuum pump → Chapter. –  Remove coolant pipe (rear) → Chapter. –  Remove turbocharger → Chapter. –  Remove intermediate pipe: left-side → Chapter, right-side → Chapter.

–  Unscrew bolts -1 ... 4- and remove heat shield.

–  Remove bolts -1 ... 4- and detach timing chain cover (left-side).

–  Remove bolts -1 ... 4- and detach timing chain cover (right-side).

–  Unscrew bolts -1 … 9- and remove timing chain cover (bottom). –  Press out crankshaft oil seal (rear) from timing chain cover (bottom). Installing   Note t  Renew gaskets, seals and O-rings. t  Fit all cable ties in the original positions when installing. –  Remove old sealant from grooves in timing chain covers and from sealing surfaces.

WARNING Wear safety goggles. –  Remove remaining sealant on timing chain covers and cylinder block / cylinder head using rotating plastic brush or similar. –  Clean sealing surfaces; they must be free of oil and grease.

–  Cut off tube nozzle at front marking (diameter of nozzle approx. 1.5 mm).   Note t  The sealant beads must not be thicker than specified, otherwise excess sealant could enter the sump and clog the strainer in the oil pump. t  The timing chain covers must be installed within 5 minutes after applying the sealant.

Timing chain cover (bottom) –  Insert sealing elements -2- and -5- –  Apply beads of sealant -1- and -4- onto clean sealing surfaces of timing chain cover (bottom) as illustrated. l  The grooves on the sealing surfaces must be completely filled with sealant. l  The bead of sealant must project 1.5 … 2.0 mm above the sealing surface. l  The beads of sealant around drillings -3- and -6- must be 1.5 … 2.0 mm thick. –  Check whether the two dowel sleeves are fitted in the cylinder block; install if necessary.

–  Fit timing chain cover (bottom) and tighten bolts as follows:

Stage	Tightening
I	–  Pre-tighten bolts -1 … 9- to 5 Nm in diagonal sequence starting from inside and working outwards.
II	–  Tighten bolts -1 … 7- to 9 Nm in diagonal sequence starting from inside and working outwards.
III	–  Tighten bolts -8- and -9- to 23 Nm.

Timing chain cover (left-side) –  Apply bead of sealant onto clean sealing surface of timing chain cover (left-side) as illustrated. l  The groove -1- on the sealing surface must be completely filled with sealant. l  The bead of sealant must project 1.5 … 2.0 mm above the sealing surface. –  Fit gasket -2-.

–  Apply a bead of sealant (Ø 3 mm) at each joint between cylinder head and timing chain cover (bottom) -arrow-, as shown in illustration.   Caution Make sure lubrication system is not clogged by excess sealant. The sealant bead must not be thicker than specified.

–  Fit timing chain cover (left-side) and tighten bolts as follows:

Stage	Bolts	Tightening torque
1.	-1-	3 Nm
2.	-2-	9 Nm
3.	-1-	9 Nm
4.	-3-	9 Nm in diagonal sequence

–  Secure heat shield with bolts -1 … 4-.

Timing chain cover (right-side) –  Apply bead of sealant onto clean sealing surfaces of timing chain cover (right-side) as illustrated. l  The groove -1- on the sealing surface must be completely filled with sealant. l  The bead of sealant must project 1.5 … 2.0 mm above the sealing surface. –  Fit gasket -2-.

–  Apply a bead of sealant (Ø 3 mm) at each joint between cylinder head and timing chain cover (bottom) -arrow-, as shown in illustration.   Caution Make sure lubrication system is not clogged by excess sealant. The sealant bead must not be thicker than specified.

–  Fit timing chain cover (right) and tighten bolts as follows:

Stage	Bolts	Tightening torque
1.	-1-	3 Nm
2.	-2-	9 Nm
3.	-1-	9 Nm
4.	-3-	9 Nm in diagonal sequence

Remaining installation steps are carried out in reverse sequence; note the following: –  Install intermediate pipe: left-side → Chapter, right-side → Chapter. –  Install turbocharger → Chapter. –  Install coolant pipe (rear) → Chapter. –  Install vacuum pump → Chapter. –  Install starter catalytic converter: vehicles without particulate filter → Chapter, vehicles with particulate filter → Chapter. –  Install crankshaft oil seal (gearbox end) → Chapter. –  Install dual-mass flywheel (vehicles with manual gearbox) → Chapter. –  Install flywheel (on a vehicle with multitronic gearbox → Chapter). –  Install drive plate (vehicles with automatic gearbox) → Chapter. –  Fill up with engine oil and check oil level → Booklet803 or → Booklet805. Tightening torques

Component		Nm
Timing chain cover (bottom) to engine	M6	9
	M8	23