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 V.A.G 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 V.A.G 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 approx. 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
