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Home >> Audi >> 2007 >> S4 Quattro Wagon (8ED) V8-4.2L (BHF) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Timing Components >> Timing Cover >> Service and Repair >> Timing Chain Covers (All), Removing and Installing

Timing Chain Covers (All), Removing and Installing



Timing chain covers (All), removing and installing

Special tools, testers and auxiliary items required





^ Old oil collecting and extracting device V.A.G 1782
^ Hand drill with plastic brush attachment
^ Protective glasses
^ Sealant

Removing

Note:
^ All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

- Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
- Remove engine.
- Disconnect engine and transmission.
- Leave engine on Scissor Lift Table VAS 6131 A or secure engine to engine and transmission holder.
- Remove dual-mass flywheel.





- Disconnect electrical connection - 1 - at throttle valve control module J338
- Disconnect crankcase ventilation hose - 3 - at intake pipe.

Note:
^ Ignore - 2 -.





- Remove electrical harness connectors - 1 -, - 2 -, - 5 - and - 6 - toward front from brackets on intake line.
- Separate the electrical connectors - 3 - and - 4 -.





- Disconnect vacuum hose - arrow - at T-piece.





- Disconnect connector strips - 1 - and - 5 - at fuel injectors.
- For vehicles with fuel return line, disconnect vacuum line - 4 - on fuel pressure regulator.
- Remove retaining bolts - 2 - and - 3 - for fuel rail line.
- Remove fuel rail line together with fuel injectors from intake manifold uniformly upward.

Note:
^ Carefully protect the removed fuel injectors from contamination.





- Remove left rear engine lifting eye - arrows -.





- Remove intake manifold bolts - arrows - and remove it.

Note:
^ Plug the intake ports of the cylinder head with clean rags.





- Remove cap - arrow - for oil filter housing.
- Remove oil filter element.
- Extract engine oil using old oil collecting and extracting device VAG 1782 from oil filter housing.

Note:
^ Place a rag around oil filter housing to catch escaping engine oil.





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





- Remove bolts - 1 - and - 2 -.
- Place old oil collecting and extracting device VAG 1782 underneath.
- Remove return line from power-steering pump - arrow -.





- Remove bolt - arrow - from oil dipstick guide tube at cylinder head, pull up and remove guide tube.





- Remove bolts - 1 - and - 2 -.
- Loosen hose clamps - arrows - and remove left coolant pipe from coolant hoses.





- Remove bolts - 1 - and - 2 -.
- Loosen hose clamps - arrows - and remove right coolant pipe from coolant hoses.





- Disconnect electrical harness connector - 2 - on Engine Coolant Temperature (ECT) Gauge Sensor G2 / G62.
- Remove nut - 1 - and remove electrical wiring harness at rear of coolant pipe.





- Remove bolts - 2 to 5 -.
- Remove rear coolant pipe.

Note:
^ Ignore - 1 - and - 6 -.





- Remove mounting bolts - 1 to 4 - of combination valves for Secondary Air Injection (AIR) system.





- Remove nuts - 1 to 12 - and remove left exhaust manifold.





- Remove left heat shield - arrows -.





- Remove nuts - 1 to 12 - and remove right exhaust manifold.





- Remove right heat shield - arrows -.





- Remove bolts - 5 - and - 6 - on left cylinder head.
- Disconnect electrical harness connectors - 1 to 4 -. Remove ignition coils - arrows -.

Note:
^ Extractor T40039 can be used for removal.





- Disconnect hose of crankshaft housing ventilation - arrow -.
- Remove left cylinder head cover bolts in sequence - 15 to 1 -
- Remove cylinder head cover.





- Remove bolts - 5 - and - 6 - on right cylinder head.
- Disconnect electrical harness connectors - 1 to 4 -.
- Remove ignition coils - arrows -.

Note:
^ Extractor T40039 can be used for removal.





- Disconnect hose of crankshaft housing ventilation - arrow -.
- Remove right cylinder head cover screws in sequence - 15 to 1 -
- Remove cylinder head cover.





- Disconnect electrical harness connector - arrow - for Camshaft Position (CMP) Sensor 2 G163 on left cylinder head.
- Disconnect electrical harness connector - arrow - for Camshaft Position (CMP) Sensor G40 on right cylinder head.





- Remove Ground (GND) cable on right cylinder head - arrow -.
- Set wiring harness aside.





- Remove bolts - 1 to 6 - and remove left timing chain cover.





- Remove bolts - 1 to 6 - and remove right timing chain cover.





- Remove bolts - 1 to 13 - and remove lower timing chain cover.





- Press sealing ring for crankshaft at rear out of cover.

Installing

Note:
^ Replace gaskets, seals and O-rings.
^ During installation, all cable ties must be re-installed at the same location.





- Using e.g. a rotating plastic brush, remove sealant residue on covers for timing chain and on cylinder block and head.

CAUTION! Wear safety glasses.

- Clean sealing surfaces, they must be free of oil and grease.





- Cut off nozzle on the tube of sealant at front mark (dia. of nozzle approximately 1 mm).

Note:
^ Covers for timing chain must be installed within 5 minutes after applying sealant.





- Apply sealant beads - 1 to 6 -, as shown in illustration, on clean sealing surfaces of lower cover for timing chain.

^ Thickness of sealant bead: 1.5 to 2.0 mm.

- Check whether 2 alignment bushings are present in cylinder block, install if necessary.





- Position lower cover for timing chain and tighten bolts as follows.
1. Tighten bolts 11, 12 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





- Remove sealing flanges for camshaft adjuster on left and right covers for timing chain arrows





- Apply sealant bead - arrow -, as shown in illustration, on clean sealing surfaces of left cover for timing chain.

^ Groove on lower sealing surface - arrow 1 - must be completely filled with sealant. Sealant bead must stand 1.5 to 2.0 mm above sealing surface.
^ Sealant bead on front sealing surface - arrows 2 - must be 1.5 to 2.0 mm thick.

- Install new seal - 3 - on left cover for timing chain.





- Position left cover for timing chain and tighten bolts as follows.

1. Tighten bolts to 1 to 4 to 5 Nm
2. Tighten bolts to 6 to 10 Nm
3. Tighten bolts to 5 to 10 Nm
4. Tighten bolts to 1 to 4 to 10 Nm





- Apply sealant beads - arrow -, as shown in illustration, on clean sealing surfaces of right cover for timing chain.

^ Groove on lower sealing surface - arrow 1 - must be completely filled with sealant. Sealant bead must stand 1.5 to 2.0 mm above sealing surface.
^ Sealant bead on front sealing surface - arrows 2 - must be 1.5 to 2.0 mm thick.

- Install new seal - 3 - on right cover for timing chain.





- Position right cover for timing chain and tighten bolts as follows.

1. Tighten bolts 2, 3, 5, 6 to 5 Nm
2. Tighten bolts to 1 to 10 Nm
3. Tighten bolts to 4 to 10 Nm
4. Tighten bolts 2 3,5 6 to 10 Nm





- Install sealing flanges for camshaft adjuster with new sealing rings on left and right covers for timing chain - arrows

The rest of installation is in reverse order of removal, note the following:
- Install crankshaft seal, timing chain side.
- Install cylinder head cover.
- Install exhaust manifold.
- Install combination valve for Secondary Air Injection (AIR) system.
- Install rear coolant pipe.
- Install left and right coolant pipe.
- Install oil filter housing.
- Install intake manifold.
- Install dual-mass flywheel.
- Install engine.
- Add engine oil and check oil level.

Torque specifications




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