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  Engine separated from gearbox → Chapter, engine attached to scissor-type assembly platform -VAS 6131 A- or secured to engine and gearbox support → Chapter. l  Engine oil drained → Booklet803 or → Booklet805. –  Remove clutch pressure plate → Rep. Gr.30. –  Remove dual-mass flywheel → Chapter. –  Remove timing chain covers (left and right) → Chapter. –  Remove intake manifold → Rep. Gr.24. –  Remove oil filter housing → Chapter.

–  Remove bolts -arrows-. –  Remove bolts -1 ... 13- and release timing chain cover (bottom) from bonded joint. –  Press crankshaft oil seal (gearbox end) out of timing chain cover (bottom).

Installing Installation is carried out in the reverse order; note the following: –  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.   Note

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

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

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, bend cylinder head gaskets down slightly -arrows-. –  Use a flat object (e.g. a feeler gauge) to apply sealant to area between cylinder head and gasket.

–  Apply the beads of sealant -1 ... 9- onto the clean sealing surfaces of the timing chain cover (bottom) as illustrated. l  Width of sealant beads: 2.5 mm.   Note t  The timing chain covers must be installed within 5 minutes after applying sealant.

t  Renew M6 bolts -1, 3, 5, 6, 7, 11, 12, 13-. t  Renew bolts -arrows- securing timing chain cover (bottom) to cylinder head. –  Position timing chain cover (bottom), guiding it towards sealing surface on cylinder block and cylinder head at an angle and from below.   Caution Take care not to damage the cylinder head gaskets when fitting the cover. If the cylinder head gasket has been damaged it must be renewed. –  Tighten bolts in 6 stages as follows:

Stage	Bolts	Tightening torque/tightening angle
1.	-arrows-	5 Nm
2.	-1 … 13-	8 Nm in diagonal sequence
3.	-arrows-	11 Nm
4.	-2, 4, 8, 9, 10-	22 Nm
5.	-1, 3, 5, 6, 7, 11, 12, 13-	Turn 90° further in diagonal sequence
6.	-arrows-	turn 90° further

Remaining installation steps are carried out in reverse sequence; note the following: –  Install crankshaft oil seal (gearbox end) → Chapter. –  Install oil filter housing → Chapter. –  Install intake manifold → Rep. Gr.24. –  Install timing chain covers (left and right) → Anchor. –  Install dual-mass flywheel → Chapter. –  Install clutch pressure plate → Rep. Gr.30. –  After installing engine, fill up with engine oil and check oil level → Booklet803 or → Booklet805.