Audi Workshop Service and Repair Manuals

Removing and installing all timing chain covers 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 → Parts catalogue Removing   Note All cable ties which are released or cut open when removing must be fitted in the same position when installing. –  Place used oil collection and extraction unit -V.A.G 1782- under engine and drain engine oil. –  Remove engine: Vehicles with manual gearbox → Chapter; vehicles with automatic gearbox → Chapter. –  Separate engine and gearbox: vehicles with manual gearbox → Chapter; vehicles with automatic gearbox → Chapter. –  Leave engine on scissor-type assembly platform -VAS 6131 A- or secure it to engine and gearbox support: vehicles with manual gearbox → Chapter; vehicles with automatic gearbox → Chapter. –  Remove the dual-mass flywheel → Chapter or the drive plate → Chapter.

–  Unplug electrical connector -1- at throttle valve module -J338-. –  Disconnect hose -3- for crankcase breather system at intake manifold.   Note Disregard -item 2-.

–  Detach electrical connectors -1-, -2-, -5- and -6- forwards from brackets on intake manifold. –  Unplug electrical connectors -3- and -4-.

–  Detach vacuum hose -arrow- from T-piece.

–  Unplug connector rail -1- and -5- at injectors. –  On vehicles with fuel return line, disconnect vacuum line -4- at fuel pressure regulator. –  Unscrew securing bolts -2- and -3- for fuel rail. –  Pull fuel rail together with injectors from intake manifold evenly upwards.   Note Make sure the removed injectors do not become soiled.

–  Unscrew engine lifting eye (rear left) -arrows-.

–  Unscrew and remove intake manifold -arrows-.   Note Seal intake ports on cylinder heads with clean cloths.

–  Unscrew sealing cap -arrow- for oil filter housing. –  Remove oil filter element. –  Extract engine oil from oil filter housing using used oil collection and extraction unit -V.A.G 1782-.   Note Place a cloth around the oil filter housing to catch any escaping oil.

–  Remove bolts -arrows-. –  Remove oil filter housing.

–  Remove bolts -1- and -2-. –  Place used oil collection and extraction unit -V.A.G 1782- underneath. –  Detach return pipe from power steering pump -arrow-.

–  Unbolt dipstick guide tube on cylinder head -arrow- and lift out upwards.

–  Remove bolts -1- and -2-. –  Loosen hose clips -arrows- and detach coolant pipe (left-side) from coolant hoses.

–  Remove bolts -1- and -2-. –  Loosen hose clips -arrows- and detach coolant pipe (right-side) from coolant hoses.

–  Unplug electrical connector -2- at coolant temperature sender -G2-/-G62-. –  Unscrew nut -1- and detach electrical wiring harness at coolant pipe (rear).

–  Remove bolts -2 ... 5-. –  Detach coolant pipe (rear).   Note Disregard items marked -1- and -6-.

–  Unscrew securing bolts -1 ... 4- for combination valves for secondary air system.

–  Unscrew nuts -1 ... 12- and remove exhaust manifold (left-side).

–  Detach heat shield (left-side) -arrows-.

–  Unscrew nuts -1 ... 12- and remove exhaust manifold (right-side).

–  Detach heat shield (right-side) -arrows-.

–  Remove bolts -5- and -6- at cylinder head (left-side). –  Unplug electrical connectors -1 ... 4-. –  Pull out ignition coils -arrows-.   Note Use puller -T40039- to remove.

–  Detach crankcase breather hose -arrow-. –  Remove cylinder head cover bolts (left-side) in the sequence -15 ... 1-. –  Remove cylinder head cover.

–  Unscrew bolts -5- and -6- at cylinder head (right-side). –  Unplug electrical connectors -1 ... 4-. –  Pull out ignition coils -arrows-.   Note Use puller -T40039- to remove.

–  Detach crankcase breather hose -arrow-. –  Remove cylinder head cover bolts (right-side) in the sequence -15 ... 1-. –  Remove cylinder head cover.

–  Unplug electrical connector -arrow- for Hall sender 2 -G163- at cylinder head (left-side). –  Unplug electrical connector -arrow- for Hall sender -G40- at cylinder head (right-side).

–  Unscrew earth cable at cylinder head (right-side) -arrow-. –  Move wiring harness clear.

–  Remove bolts -1 ... 6- and detach timing chain cover (left-side).

–  Remove bolts -1 ... 6- and detach timing chain cover (right-side).

–  Remove bolts -1 … 13- and detach timing chain cover (bottom).

–  Press out crankshaft oil seal (rear) from timing chain cover. Installing   Note t  Renew gaskets, seals and O-rings. t  Fit all cable ties in the original positions when installing.

–  Remove remaining sealant on timing chain covers and cylinder block / cylinder head using rotating plastic brush or similar.   WARNING Wear safety goggles. –  Clean sealing surfaces; they must be free of oil and grease.

–  Cut off tube nozzle at front marking (nozzle approx. 1 mm Ø).   Note The timing chain covers must be installed within 5 minutes after applying sealant.

–  Apply sealant beads -1 ... 6- onto the clean sealing surfaces of the timing chain cover (bottom) as illustrated. l  Thickness of sealant bead: 1.5 ... 2.0 mm –  Check whether the two dowel sleeves are fitted in the cylinder block; install if necessary.

–  Fit timing chain cover (bottom) and tighten bolts as follows: 1 -  Tighten bolts -11-, -12- and -13- to 10 Nm. 2 -  Tighten bolts -1-, -3-, -4-, -5-, -6-, -7-, -8-, -9-, -10- to 10 Nm. 3 -  Tighten bolts -4-, -8-, -9-, -10- to 22 Nm. 4 -  Tighten bolts -2- for power steering pump to 22 Nm.

–  Unbolt sealing flanges for camshaft adjuster at timing chain covers (left and right) -arrows-.

–  Apply sealant bead -arrow- onto the clean sealing surface of the timing chain cover (left-side) as illustrated. l  The groove on the bottom sealing surface -arrow 1- must be completely filled with sealant. The bead of sealant must project 1.5 … 2.0 mm above the sealing surface. l  The bead of sealant on the front sealing surface -arrow 2- must be 1.5 ... 2.0 mm wide. –  Secure new gasket -3- with bolt on timing chain cover (left-side).

–  Fit timing chain cover (left-side) and tighten bolts as follows: 1 -  Tighten bolts -1 ... 4- to 5 Nm. 2 -  Tighten bolts -6- to 10 Nm. 3 -  Tighten bolts -5- to 10 Nm. 4 -  Tighten bolts -1 ... 4- to 10 Nm.

–  Apply sealant beads -arrow- onto the clean sealing surface of the timing chain cover (right-side) as illustrated. l  The groove on the bottom sealing surface -arrow 1- must be completely filled with sealant. The bead of sealant must project 1.5 … 2.0 mm above the sealing surface. l  The bead of sealant on the front sealing surface -arrow 2- must be 1.5 ... 2.0 mm wide. –  Secure new gasket -3- on timing chain cover (right-side).

–  Fit timing chain cover (right) and tighten bolts as follows: 1 -  Tighten bolts -1 ... 4- to 5 Nm. 2 -  Tighten bolts -6- to 10 Nm. 3 -  Tighten bolts -5- to 10 Nm. 4 -  Tighten bolts -1 ... 4- to 10 Nm. 1 -  Tighten bolts -2-, -3-, -5-, -6- to 5 Nm. 2 -  Tighten bolts -1- to 10 Nm. 3 -  Tighten bolts -4- to 10 Nm. 4 -  Tighten bolts -2-, -3-, -5-, -6- to 10 Nm.

–  Install sealing flanges for camshaft adjuster with new seals at timing chain covers (left and right) -arrows-. Remaining installation steps are carried out in reverse sequence; note the following: –  Install crankshaft oil seal (timing chain end) → Chapter. –  Install cylinder head cover: left-side → Chapter, right-side → Chapter. –  Install exhaust manifold: left-side → Chapter, right-side → Chapter. –  Install combination valve for secondary air system: left-side → Chapter, right-side → Chapter. –  Install coolant pipe (rear) → Chapter. –  Install coolant pipe (left and right) → Chapter and → Chapter. –  Install oil filter housing → Chapter. –  Install intake manifold → Chapter. –  Install the dual-mass flywheel → Chapter or the drive plate → Chapter. –  Install engine: vehicles with manual gearbox → Chapter; vehicles with automatic gearbox → Chapter. –  Fill up with engine oil and check oil level → Chapter. Tightening torques

Component			Nm
Cover (bottom)	Power steering pump		22
For timing chain	Engine	M6	10
to:		M8	22
Gasket to timing chain cover			4 → Note
Timing chain covers (left and right) to engine			10
Sealing flange to timing chain cover			10
Hall sender to timing chain cover			10
Earth cable to cylinder head			10
Heat shield to engine			10
Oil drain plug			50

1)  Install using locking fluid; locking fluid → Parts catalogue.