Audi Workshop Service and Repair Manuals

Removing and installing timing chain cover (bottom) Special tools and workshop equipment required t  Electric drill with plastic brush attachment t  Safety goggles t  Sealant → Electronic parts catalogue Removing l  Gearbox removed → Rep. gr.34.   Note Fit all cable ties in the original positions when installing. –  Remove dual-mass flywheel → Chapter. –  Remove timing chain cover (top) → Chapter. –  Remove vacuum pump → Rep. gr.47. –  Remove engine speed sender -G28- → Rep. gr.28.

–  First remove bolts -arrows-, then -1 ... 6-.

–  Carefully release timing chain cover (bottom) -1- from bonded joint; to do so, apply screwdriver -A- at the correct positions at top and bottom. 2 -  Cylinder block 3 -  Sump (top section) –  Always start to release cover in area of dowel sleeves -arrows-. –  Press crankshaft oil seal (gearbox end) out of timing chain cover (bottom).

Installing l  Tightening torques → Fig. „„Timing chain cover (bottom) - tightening torque and tightening sequence““ –  Drive back dowel sleeves -arrows- in timing chain cover (bottom) that they do not protrude beyond sealing surface.

Note Renew gaskets, seals and O-rings.   Caution Protect lubrication system against contamination. Cover exposed parts of the engine.   WARNING Protect eyes against injuries. Wear safety goggles. –  Remove remaining sealant on timing chain cover (bottom), cylinder block and sump (top section) using rotating plastic brush or similar. –  Clean sealing surfaces; they must be free of oil and grease.

–  Clean old sealant from holes -arrow- in cylinder head gasket.   Note With the cylinder head installed the holes in the cylinder head gasket are only half visible.

Caution Avoid damage to cylinder head gasket. Only bend the end of the cylinder head gasket slightly and do not kink.   Note If the cylinder head gasket has been bent and kinked it must be renewed. –  Carefully bend the end of the cylinder head gasket down very slightly -arrows-, just far enough to be able to clean the upper sealing surface on the cylinder head gasket and cylinder head. –  Clean cylinder head gasket (top and bottom); it must be free of oil and grease.   Note

Note the use-by date of the sealant. –  Cut off nozzle of tube at front marking (nozzle Ø approx. 2 mm).

–  Apply a small amount of sealant to sealing surface of cylinder head gasket (top and bottom). To do so, you again have to bend cylinder head gasket down very slightly -arrows-. –  Use a flat object (e.g. a feeler gauge) to apply sealant to the area between cylinder head and gasket.

–  Clean holes -arrow- in cylinder head gasket and fill them with sealant.

Caution Make sure lubrication system is not clogged by excess sealant. The bead of sealant must not be thicker than specified. –  Apply sealant bead -arrow- onto the clean sealing surface of the timing chain cover (bottom) as illustrated. l  Thickness of sealant bead: 1.5 ... 2.0 mm   Note The timing chain cover (bottom) must be installed within 5 minutes after applying the sealant. –  Fit dowel sleeve -1- and O-ring -2-. –  Fit timing chain cover (bottom), guiding it towards the sealing surface on cylinder block and cylinder head at an angle and from below. –  Take care not to damage the cylinder head gasket when fitting the cover.

–  Initially screw in bolts for timing chain cover (bottom) by hand until they make contact. –  Drive in dowel sleeves from timing chain cover (bottom) into cylinder block in each case until they make contact. –  Tighten bolts for timing chain cover (bottom) → Fig.. Remaining installation steps are carried out in reverse sequence; note the following: –  Install engine speed sender -G28- → Rep. gr.28. –  Install vacuum pump → Rep. gr.47. –  Install timing chain cover (top) → Chapter. –  Install crankshaft oil seal (gearbox end) → Chapter. –  Install dual-mass flywheel → Chapter.