Audi Workshop Service and Repair Manuals

Removing and installing timing chain covers (left and right) Special tools and workshop equipment required t  Electric drill with plastic brush attachment t  Safety goggles t  Sealant → Electronic parts catalogue

Removing   Note All cable ties which are released or cut open when removing must be refitted in the same position when installing. –  Pull off engine cover panel (rear) -arrows-.

–  Pull off engine cover panel (front) -arrows-.

Timing chain cover (left-side): –  Unbolt coolant expansion tank -arrow-. –  Unplug electrical connector for coolant shortage indicator switch -F66- at bottom of expansion tank and move expansion tank to one side with coolant hoses -1- and -2- attached.

–  Remove electrical connectors -1- and -2- from bracket. –  Move wiring harness clear. –  Unscrew nuts and detach bracket (left-side) for connectors from bulkhead.   Note

Place a cloth below the oil filter housing to catch escaping oil. –  Unscrew sealing cap -arrow- for oil filter housing. –  Remove oil filter element.

Rest-of-world vehicles: –  Disconnect crankcase breather hose -arrow- from cylinder head cover (left-side). USA models:   Caution Do not disconnect crankcase breather hose on USA models. –  Detach cylinder head cover (left-side) and move clear to one side (crankcase breather hose remains connected) → Chapter.

All vehicles: –  Unplug electrical connectors. 1 -  Hall sender 2 -G163- 2 -  Inlet camshaft control valve 2 -N208- 3 -  Exhaust camshaft control valve 2 -N319- 4 -  Hall sender 4 -G301- –  Unscrew bolts -arrows- and unplug electrical connectors at ignition coils. –  Move wiring harness clear.

–  Unplug electrical connectors -1 ... 3-. –  Unscrew nut -arrow-. –  Remove bracket for electrical connector -3-. –  Unscrew centre hex stud located beneath the bracket. –  Remove bracket for electrical connectors -1- and -2-.

–  Remove bolts -1 ... 8- and detach timing chain cover (left-side).

Timing chain cover (right-side): –  Pull non-return valve -1- off connection at air intake hose. –  Remove air intake hose. To do so, release hose clip -2- and clamps -arrows-.

–  Pull pin out of fastener -arrow-. –  Detach air cleaner housing.

–  Unscrew nuts and detach bracket (right-side) for connectors -1- and -2- from bulkhead.

–  Unplug electrical connectors. 1 -  Exhaust camshaft control valve 1 -N318- 2 -  Hall sender -G40- 3 -  Intake manifold flap potentiometer -G336- 4 -  Hall sender 3 -G300- –  Unscrew bolts -arrows- and unplug electrical connectors at ignition coils. –  Move wiring harness clear.

–  Unplug electrical connector -1-. –  Remove bolt -arrow- and detach bracket for electrical connector.

–  Remove bolts -1 ... 8- and detach timing chain cover (right-side). Installing   Note t  Fit all cable ties in the original positions when installing. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue.

WARNING Wear safety goggles. –  Remove remaining sealant on timing chain covers and cylinder block / cylinder head using rotating plastic brush or similar.   Caution Make sure that no sealant residue gets into the engine. –  Clean sealing surfaces; they must be free of oil and grease.

–  Cut off nozzle of tube at front marking (Ø of nozzle approx. 1 mm).   Note

The timing chain covers must be installed within 5 minutes after applying sealant. –  Apply sealant bead -arrow- onto the clean sealing surface of the timing chain cover (left-side) as illustrated. l  The groove 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 timing chain cover (left-side) and tighten bolts in sequence -1 ... 8-.

–  Apply sealant bead -arrow- onto the clean sealing surface of the timing chain cover (right-side) as illustrated. l  The groove 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 timing chain cover (right-side) and tighten bolts in sequence -1 ... 8-. Perform further installation in reverse order, paying attention to the following: –  Check oil level → Booklet803 or → Booklet805. Tightening torques

Component	Nm
Timing chain covers (left and right) to engine	5 + 90° 1)2)
Bracket for electrical connectors to cylinder head	9
Sealing cap on oil filter housing	25
Hose clips (9 mm wide)	3
l  1) Renew bolts. l  2) 90° = one quarter turn.