Timing chain lower cover, removing and installing

Special tools, testers and auxiliary items required 

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

Removing 

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• Remove rear sound insulation by loosening fasteners - 1 and 2  -.

• Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
• Remove automatic transmission → 37 - CONTROLS, HOUSING .
• Remove drive plate → Drive plate, removing and installing .
• Remove left and right timing chain covers → Left and right timing chain covers, removing and installing .

• Remove intake manifold → 24 - MULTIPORT FUEL INJECTION (MFI) .
• Remove oil filter housing → Oil filter housing, removing and installing .

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• Remove bolts - arrows  -.
• Remove bolts - 1 through 13  - and remove lower timing chain cover.
• Press transmission-side crankshaft sealing ring out of lower timing chain cover.

Installing 

• Tightening torques → Timing chain lower cover tightening sequence 

Installation is in reverse order of removal, note the following:

• Pull alignment bushing out of top right of cylinder block.

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• Chamfer alignment bushing with a file, as shown in the illustration.

• Dimension - x  - = 6.5 mm.
• Dimension - y  - = 8 mm.

• Install alignment bushing into cylinder block so that chamfered side faces upward.

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• Remove sealant residue on lower timing chain cover and on cylinder block and cylinder head, e.g. with a rotating plastic brush.
• Clean sealing surfaces so they are completely free of any oil or grease.

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• Clean old sealant from holes - arrow  - in the cylinder head gaskets.

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• Bend the ends of cylinder head gaskets very slightly downward - arrows  - until upper sealing surface of gasket and cylinder head can be cleaned.
• Clean both cylinder head gaskets, top and bottom, so they are completely free of any oil or grease.

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• Cut off nozzle on tube of sealant at front mark (dia. of nozzle approx. 2 mm).

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• Coat sealing surfaces of the cylinder head gaskets, top and bottom, to do this with a thin layer of sealant, slightly bending cylinder head gaskets downward again - arrows  -.
• To coat surface between cylinder head and gasket, use a flat object, e.g. a feeler gauge.

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• Apply sealant beads - 1 to 9  - on clean sealing surfaces of lower timing chain cover, as shown in illustration.

• Thickness of sealant beads: 2.5 mm.

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• Set lower timing chain cover in place, guiding cover at an angle from below onto sealing surface of the cylinder block and cylinder head.
• When installing, make sure that the cylinder head gaskets do not become damaged.

• Tighten bolts → Timing chain lower cover tightening sequence .

The rest of installation is in reverse order of removal, note the following:

• Install crankshaft seal, transmission side → Transmission-side crankshaft sealing ring, replacing .
• Install oil filter housing → Oil filter housing, removing and installing .
• Install intake manifold → 24 - MULTIPORT FUEL INJECTION (MFI) .
• Install left and right timing chain covers → Installing .

• Install drive plate → Drive plate, removing and installing .
• Install automatic transmission → 37 - CONTROLS, HOUSING .
• Add engine oil and check oil level → Oil level, checking .