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 l  Engine removed and in position on scissor-type assembly platform -VAS 6131 A- with gearbox attached.   Note t  Fit all heat shields and heat insulation sleeves in the original positions when installing. t  All cable ties which are released or cut open when removing must be fitted in the same position when installing.

–  Remove bolts -2- and -3- and lift out guide tube for oil dipstick. –  Remove bolts -4- and -5-. –  Move heat insulating sleeve protecting coolant hose (left-side) clear to one side. –  Release hose clips -1- and -7-. –  Detach coolant pipe (left-side) from coolant hoses.   Note Disregard -item 6-.

–  Remove bolts -1- and -2-. –  Move air intake pipe going to combination valves for secondary air clear to one side.   Note Disregard -item 3-.

–  Remove bolts -3- and -4-. –  Move heat insulating sleeve protecting coolant hose (right-side) to the side. –  Slacken hose clip -1-. –  Detach coolant pipe (right-side) from coolant hose.   Note Disregard items marked -2- and -5-.

–  Unscrew nuts -2- and detach wiring harness bracket on coolant pipe (rear). –  Unplug electrical connector -3- at coolant temperature sender -G62-. –  Remove electrical connectors -1- and -4- from brackets on coolant pipe (rear).

–  Remove bolts -1 ... 4-. –  Detach coolant pipe (rear) and combination valves for secondary air.

–  Remove bolts -1 ... 8- and carefully release timing chain cover (left-side) from bonded joint.

–  Remove bolts -1 ... 8- and carefully release timing chain cover (right-side) from bonded joint. Installing   Note t  Renew O-rings. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. t  Fit all heat shields and heat insulation sleeves in the original positions when installing. t  Fit all cable ties in the original positions when installing.

WARNING Wear safety goggles. –  Remove remaining sealant on timing chain covers and 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.   Note

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

–  Use suitable drift to drive intermediate coolant pipe (left-side) -2- out of timing chain cover (left-side). –  Fit new O-rings -1- on intermediate coolant pipe. –  Fit intermediate coolant pipe in timing chain cover (left-side). –  Apply the bead of sealant -arrow- onto the clean sealing surfaces of the timing chain cover (left-side) as illustrated. l  Width of sealant bead: 2.5 mm.   Note The timing chain covers must be installed within 5 minutes after applying sealant.

–  Fit timing chain cover (left-side) and tighten bolts in sequence -1 ... 8-.

–  Use suitable drift to drive intermediate coolant pipe (right-side) -2- out of timing chain cover (right-side). –  Fit new O-rings -1- on intermediate coolant pipe. –  Fit intermediate coolant pipe in timing chain cover (right-side). –  Apply the bead of sealant -arrow- onto the clean sealing surfaces of the timing chain cover (right-side) as illustrated. l  Width of sealant bead: 2.5 mm.

–  Fit timing chain cover (right-side) and tighten bolts in sequence -1 ... 8-. Remaining installation steps are carried out in reverse sequence; note the following: –  Install combination valve for secondary air system: left-side → Chapter, right-side → Chapter. –  Install coolant pipe (rear) → Chapter. –  Install coolant pipe (left-side) → Chapter. –  Install coolant pipe (right-side) → Chapter. Tightening torque → Chapter