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 t  Safety goggles t  Sealant → Electronic parts catalogue Removing l  Gearbox removed. –  Remove drive plate → Chapter. –  Remove intermediate pipe with intermediate flange: left-side → Chapter; right-side → Chapter. –  Remove timing chain covers: left-side → Chapter, right-side → Chapter.

–  Remove bolt -arrow- and detach bottom section of oil return line -1- from cylinder block.

–  Unplug electrical connector -2- for engine speed sender -G28-.   Note Disregard -item 1-.

–  Unscrew bolts -1 ... 9- and remove timing chain cover (bottom). –  Press crankshaft oil seal (gearbox end) out of timing chain cover (bottom). Installing –  Remove old sealant from grooves on timing chain cover and from sealing surfaces.   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 (bottom) and on cylinder block 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.   Note

Note the use-by date of the sealant. –  Cut off nozzle of tube at front marking (nozzle Ø approx. 1.5 mm).

–  Fit sealing elements -2- and -5-.   Caution Make sure lubrication system is not clogged by excess sealant. The sealant bead must not be thicker than specified. –  Apply sealant beads -1- and -4- onto clean sealing surface of timing chain cover (bottom) as illustrated. l  The grooves on the sealing surfaces must be completely filled with sealant. l  The bead of sealant must project 1.5 … 2.0 mm above the sealing surface. l  The beads of sealant around drillings -3- and -6- must be 1.5 … 2.0 mm thick.   Note The timing chain cover must be installed within 5 minutes after applying the sealant. –  Check whether the two dowel sleeves are fitted in the cylinder block; install if necessary.

–  Install timing chain cover (bottom) and tighten bolts → Fig.. Remaining installation steps are carried out in reverse sequence; note the following: –  Install timing chain covers: left-side → Chapter, right-side → Chapter. –  Install bottom section of oil return line → Chapter. –  Install intermediate pipe with intermediate flange: left-side → Chapter; right-side → Chapter. –  Install drive plate → Chapter. –  Before installing gearbox, remove residue from threaded holes for engine/gearbox bolts in cylinder block using a thread tap.