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  Shackle -10 - 222 A /12-

Removing –  Remove alternator → Electrical system; Rep. Gr.27. –  Remove poly V-belt pulley for crankshaft → Chapter. –  Remove poly V-belt pulley for coolant pump → Chapter. –  Removing idler roller for poly V-belt → Chapter.

–  Disengage coolant hose -1- at engine cover panel. –  Pull oil dipstick -2- out of guide tube. –  Unscrew bolts -arrows- and remove engine cover panel.

–  Remove bolt -1- for coolant pipe. –  Disconnect crankcase breather hose -2- from timing chain cover (press release tabs). –  Remove sump → Chapter.

–  Unplug electrical connector -1- for air conditioner compressor regulating valve -N280- at air conditioner compressor.   WARNING Risk of injury caused by refrigerant. The air conditioner refrigerant circuit must not be opened. –  Remove bolts -arrows- for air conditioner compressor.   Caution Danger of damage to refrigerant lines and hoses. Do NOT stretch, kink or bend refrigerant lines and hoses. –  Tie up air conditioner compressor together with refrigerant hoses to longitudinal member (refrigerant hoses remain connected). –  Remove bracket for air conditioner compressor → Rep. Gr.87.

–  Disconnect line -1- going to activated charcoal filter (press release tab).   Note Disregard -item 2-.

–  Release activated charcoal filter -arrow B-, lift off -arrow A- and move clear to one side with line -1- connected.

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

–  Vehicles from approx. 04.2008 onwards: remove banjo bolt -arrow- for oil supply pipe at timing chain cover.

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

–  Secure shackle -10 - 222 A /12- to engine lifting eye (right-side). –  Position support bracket -10 - 222 A- on bolted flanges of wing panels (vehicles up to 05.2008) or body flanges (vehicles from 06.2008 onwards). l  The spindle is located at rear. –  Engage hook on spindle in shackle. –  Apply light tension to spindle.

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

–  Remove bolts -1 ... 6- and -arrows- for timing chain cover. –  Raise engine slightly and remove timing chain cover. –  Use drift to drive out crankshaft oil seal.

Installing l  Tightening torques → Chapter, → Fig..   Note Renew gasket and O-rings. –  Clean sealing surfaces; they must be free of oil and grease. –  Insert O-rings -arrows- on reverse side of timing chain cover. –  Fit gasket onto dowel pins in cylinder block. –  Screw 2 threaded pins M6x80 into cylinder head and cylinder block to help guide cover. –  Carefully fit timing chain cover onto threaded pins and dowel pins, then tighten bolts. The remaining installation steps are carried out in the reverse sequence. Note the following: –  Install engine mounting and adjust assembly mountings → Chapter. –  Renew crankshaft oil seal → Chapter. –  Install air conditioner compressor → Rep. Gr.87. –  Install sump → Anchor. –  Install engine cover panel → Fig.. –  Install idler roller for poly V-belt → Chapter. –  Install poly V-belt pulley for coolant pump → Chapter. –  Install poly V-belt pulley for crankshaft → Chapter. –  Install alternator → Electrical system; Rep. Gr.27.