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  Gearbox removed.   Note Fit all cable ties in the original positions when installing.

Caution Electronic components are susceptible to damage. Observe notes on procedure for disconnecting the battery. –  Switch off ignition and take out ignition key. –  Disconnect earth wire -2- from battery terminal → Rep. Gr.27. –  Remove drive plate → Chapter. –  Remove timing chain covers (left and right) → Chapter. –  Remove oil filter housing → Chapter. –  Remove alternator → Rep. Gr.27.

–  Remove bolts -arrows- (left and right) and detach bracket for electrical connectors.   Note Disregard items marked -1 ... 4-.

–  Unplug electrical connector -3- at starter (push retainer to the rear and press down release catch). –  Remove nut -2- for electrical wiring and detach starter.   Note Disregard -items 1, 4-.

–  Remove bolts -arrows-. –  Unscrew bolts -1 ... 10- and remove timing chain cover (bottom). –  Press crankshaft oil seal (gearbox end) out of timing chain cover (bottom).

Installing l  Tightening torques → Fig.   Note Renew gaskets, seals and O-rings. –  Pull dowel sleeve at 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.

Caution Protect lubrication system against contamination. Cover exposed parts of the engine.   WARNING Protect eyes against injuries. Wear safety goggles. –  Remove remaining sealant on timing chain cover, cylinder block and cylinder head using rotating plastic brush or similar. –  Clean sealing surfaces; they must be free of oil and grease. –  Before installing gearbox, remove residue from threaded holes for engine/gearbox bolts in cylinder block using a thread tap.

–  Clean old sealant from holes -arrow- in cylinder head gaskets.   Note With the cylinder head installed the holes in the cylinder head gasket are only half visible.

Caution Avoid damage to cylinder head gasket. Only bend the ends of the cylinder head gaskets slightly and do not kink.   Note 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 cylinder head gasket and cylinder head. –  Clean 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 nozzle of tube at front marking (nozzle Ø approx. 2 mm).   Note The sealant must be applied at several points on the engine as described below.

–  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 -arrows-. –  Use a flat object (e.g. a feeler gauge) to apply sealant to the area between cylinder head and gasket.

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

Caution Make sure lubrication system is not clogged by excess sealant. The bead of sealant must not be thicker than specified. –  Apply sealant beads -1 ... 4- 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 -2- must be applied in a continuous bead as shown in the illustration (although the groove is not continuous).   Note The sealant hardens within approx. 5 minutes after being applied. –  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.

–  Tighten bolts for timing chain cover (bottom) → Fig.. Remaining installation steps are carried out in reverse sequence; note the following: –  Install starter → Rep. Gr.27 –  Install alternator → Rep. Gr.27. –  Install oil filter housing → Chapter. –  Install timing chain covers (left and right) → Anchor. –  Install crankshaft oil seal (gearbox end) → Chapter. –  Install drive plate → Chapter. –  Fill up with engine oil and check engine oil level → Chapter.