Audi Workshop Service and Repair Manuals

Removing and installing timing chain cover (bottom) 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. –  Vehicles with manual gearbox: remove clutch pressure plate → Rep. Gr.30 and dual-mass flywheel → Chapter. –  Vehicles with multitronic gearbox: Remove damper unit → Chapter and flywheel → Chapter. –  Vehicles with automatic gearbox: remove drive plate → Chapter.   Note After the gearbox has been removed the engine is supported with support bracket -10-222 A- and the stop for the torque reaction support is detached.   WARNING Make sure that the lock carrier is installed on the vehicle before performing the following steps. –  Detach support bracket -10-222 A- from engine (attached previously in order to remove gearbox).

–  Secure stop for torque reaction support -arrows- (tighten bolts to 28 Nm). –  Remove timing chain covers (left and right) → Chapter.   Note

Place a cloth below the oil filter housing to catch escaping oil. –  Unplug electrical connector at oil pressure switch -F1--arrow-. –  Unscrew oil pressure switch. –  Extract engine oil from oil filter housing using used oil collection and extraction unit -V.A.G 1782-.

–  Remove bolts -arrows-. –  Remove oil filter housing. –  Place used oil collection and extraction unit -V.A.G 1782- under engine. –  Drain off engine oil.

Vehicles up to 04.2005: –  Remove bolts -arrows-. –  Unscrew bolts -1 … 9- and remove timing chain cover (bottom).

Vehicles from 05.2005: –  Unscrew bolts -1 … 9- and remove timing chain cover (bottom). All vehicles: –  Press out crankshaft oil seal (rear) from timing chain cover (bottom). Installing   Note Renew gaskets, seals and O-rings.

–  Pull dowel sleeve (top right) out of cylinder block. –  Bevel the dowel sleeve with a file, as illustrated. l  Dimension -x- = 6.5 mm. l  Dimension -y- = 8 mm. –  Fit dowel sleeve on cylinder block in such a way that the bevelled side points upwards.   Note Bevelling the dowel sleeve makes it easier to fit the timing chain cover (bottom) with the cylinder head installed.

WARNING Wear safety goggles. –  Remove remaining sealant on timing chain cover 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.

–  Clean any old sealing compound from the bores -arrow- in the cylinder head gaskets.   Note With the cylinder head installed the holes in the cylinder head gasket are only half visible.   Caution The cylinder head gasket must not to be bent more than a small amount. If the cylinder head gasket has been bent and kinked it must be renewed.

–  Carefully bend the ends of the cylinder head gaskets down very slightly -arrows-, just far enough to be able to clean the upper sealing surface on the gasket and cylinder head. –  Clean both cylinder head gaskets (top and bottom); they must be free of oil and grease.

–  Cut off nozzle of tube at front marking (Ø of nozzle approx. 2 mm).   Note t  The sealant must be applied at several points on the engine as described below. t  The sealant hardens within approx. 5 minutes after being applied.   Caution The cylinder head gasket must not to be bent more than a small amount. If the cylinder head gasket has been bent and kinked it must be renewed.

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

–  Fill cleaned holes -arrow- in cylinder head gasket with sealant.

Vehicles up to 04.2005: –  Apply the beads of sealant -1 ... 6- onto the clean sealing surfaces of the timing chain cover (bottom) as illustrated. l  The groove on the sealing surface must be completely filled with sealant. l  The beads of sealant must project 1.5 … 2.0 mm above the sealing surface. l  The sealant -item 3- must be applied in a continuous bead as shown in the illustration (although the groove is not continuous). –  Insert the O-ring -arrow- in the groove in the bottom timing chain cover. –  Apply a small amount of sealant to hold O-ring in position.

–  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 gaskets when fitting the cover. Renew gaskets if damaged. –  Tighten bolts as follows.

1.  Apply locking fluid to bolts -arrows- and tighten to 5 Nm. 2.  Tighten bolts -1 ... 8- in diagonal sequence to 9 Nm. 3.  Tighten bolts -arrows- to 9 Nm. 4.  Tighten bolts -6-, -7- and -8- to 20 Nm.

–  Install oil filter housing immediately → Chapter.

Vehicles from 05.2005: –  Apply the beads of sealant -1 ... 5- onto the clean sealing surfaces of the timing chain cover (bottom) as illustrated. l  The groove on the sealing surface must be completely filled with sealant. l  The beads of sealant must project 1.5 … 2.0 mm above the sealing surface. l  The sealant -item 2- must be applied in a continuous bead as shown in the illustration (although the groove is not continuous). –  Insert seals -arrows- in grooves on timing chain cover (bottom).

–  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 gaskets when fitting the cover. Renew gaskets if damaged. –  Tighten bolts as follows.

1.  Apply locking fluid to bolts -arrows- and tighten to 5 Nm. 2.  Tighten bolts -1 ... 9- in diagonal sequence to 9 Nm. 3.  Tighten bolts -arrows- to 9 Nm. 4.  Tighten bolts -7-, -8- and -9- to 20 Nm. 5.  Tighten stud -3- to 16 Nm.

All vehicles: Perform further installation in reverse order, paying attention to the following: –  Install oil filter housing → Chapter. –  Install timing chain covers (left and right) → Anchor. –  Install crankshaft oil seal (timing chain end) → Chapter. –  Vehicles with manual gearbox: Install dual-mass flywheel → Chapter and pressure plate → Rep. Gr.30. –  Vehicles with multitronic gearbox: Install flywheel → Chapter and damper unit → Chapter. –  Vehicles with automatic gearbox: install drive plate → 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 1)
	M7	16
	M8	20
Timing chain covers (left and right) to engine		5 + 90° 2)3)
Bracket for electrical connectors to cylinder head		9
l  1) Install securing bolts between cylinder head and timing chain cover (bottom) using locking fluid; locking fluid → Electronic parts catalogue. l  2) Renew bolts. l  3) 90° = one quarter turn.