Audi Workshop Service and Repair Manuals

Removing and installing timing chain cover (bottom) Special tools and workshop equipment required

t  Locking tool -T40098-

t  Counterhold tool -T10355-

t  Thrust piece -T10368- Removing –  Remove front noise insulation → Rep. gr.66. –  Remove bumper cover (front) and bumper → Rep. gr.63. –  Perform service position → Rep. gr.50.

Caution If a used belt runs in the opposite direction when it is refitted, this can cause breakage. Before removing, mark direction of rotation of poly V-belt with chalk or felt-tip pen for re-installation. –  To slacken poly V-belt turn tensioner in direction of -arrow-. –  Lock tensioner with locking tool -T40098-. –  Remove bolt -1- and take off tensioner for poly-V-belt from bracket for ancillaries. –  Take off poly V-belt.

–  Turn vibration damper to „TDC“ position -arrow- using counterhold tool -T10355-. l  Notch on vibration damper must align with arrow marking on cover for timing chains (bottom). –  Remove bolt for vibration damper using counterhold tool -T10355-. –  Remove vibration damper.   Note Always use thrust piece -T10368- when fitting bolt for vibration damper to avoid damaging splines.

–  Fit bolt for vibration damper and thrust piece -T10368- again.   Caution Risk of irreparable damage to engine. To avoid disturbing valve timing, do not turn crankshaft out of „TDC“ position when bolt for vibration damper is removed. –  Remove idler roller -1-.

–  Remove bolts -arrows- and detach guide tube for oil dipstick from timing chain cover.

–  Remove bolts -1 ... 15-.

–  Lever off timing chain cover (bottom) (start at points -1 and 2-).   Note To prevent damaging the timing chain cover, apply tool only at the bolt holes. Installing l  Tightening torques → Chapter „Timing chain covers - exploded view“ t  Silicone sealant → Electronic parts catalogue   Note t  Note the expiry date of the silicone sealant. t  The cover must be installed within 5 minutes after applying the silicone sealant. t  Renew the bolts tightened with specified tightening angle. t  Renew seals, gaskets and self-locking nuts. –  Spray sealing surface with sealant remover and wait for it to take effect. –  Remove sealant remaining on cylinder block with flat scraper.   WARNING Protect eyes against injuries. Wear safety goggles. –  Mask oil seal on both sides with adhesive tape to make sure the seal remains clean.

–  Remove remaining sealant from cover (e.g. with rotating plastic brush or similar). –  Clean surfaces; they must be free of oil and grease. –  Use old bolts when fitting cover and tighten to 8 Nm. –  Use feeler gauge to measure distance between cover and crankcase (max. distance is 0.2 mm).   Note t  Renew cover if distance exceeds 0.2 mm. t  It is not possible to measure distance between cover and sump (top section); check visually to ensure that sealing surface is even.

–  Check that both dowel pins are fitted in cover -arrows-.

–  Cut off nozzle of tube at front marking (Ø of nozzle approx. 3 mm).

–  Apply silicone sealant onto clean sealing surface of cover, as illustrated. t  Thickness of sealant bead: 2 ... 3 mm.   Note t  The cover must be installed within 5 minutes after applying the silicone sealant. t  The bead of sealant must not be thicker than specified, otherwise excess sealant can enter the sump and obstruct the strainer in the oil intake pipe. –  Immediately fit timing chain cover and tighten bolts; tightening sequence → Fig. „„Timing chain cover (bottom), tightening sequence““.   Note After fitting cover, let sealant dry for approx. 30 minutes. Then (and only then) fill the engine with engine oil. –  Install poly V-belt tensioner → Chapter. –  Install poly V-belt → Chapter. –  Reset service position → Rep. gr.50. –  Install front bumper and bumper cover → Rep. gr.63. –  Install front noise insulation → Rep. gr.66. –  Check oil level; A4 → Booklet812, A5 → Booklet811