Lower Timing Chain Cover, Removing And Installing

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Hand drill with plastic brush attachment
Protective eyewear
Sealant.

Removal

The transmission is removed.
Engine oil is drained. Refer to Maintenance Booklet 406.

-- Remove the drive plate. Refer to DRIVE PLATE, REMOVING AND INSTALLING .

-- Remove the intermediate pipe and intermediate flange: left, refer to LEFT INTERMEDIATE PIPE, REMOVING AND INSTALLING , right, refer to RIGHT INTERMEDIATE PIPE, REMOVING AND INSTALLING and INTERMEDIATE FLANGE, REMOVING AND INSTALLING .

-- Remove the timing chain covers: left, refer to LEFT TIMING CHAIN COVER, REMOVING AND INSTALLING , right RIGHT TIMING CHAIN COVER, REMOVING AND INSTALLING .

-- If equipped, remove the nuts -arrows- and the connector bracket from the left engine support.

Fig 1: Identifying Bolts -Arrows- And Connector Bracket From Left Engine Mount Bracket

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts -arrows- and remove the oil return pipe -1- from the cylinder block.

Fig 2: Identifying Bolts -Arrows- And Remove Oil Return Pipe -1-

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NOTE:

Lay a cloth below to catch the draining engine oil.

Fig 3: Lower Timing Chain Cover Bolts

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts -1 through 9- and remove the lower timing chain cover.

-- Press the transmission side of the crankshaft shaft seal out of the lower timing chain cover.

Installation

Tightening specifications, refer to SUBFRAME OVERVIEW , TURBOCHARGER OVERVIEW .

-- Remove old sealant form the grooves in the timing chain cover as well as from the sealing surfaces.

CAUTION:

Risk of contaminating lubricating system.

Cover open parts of engine.

Fig 4: Cleaning Remaining Sealant With Rotating Plastic Brush

Courtesy of AUDI OF AMERICA, LLC

WARNING:

Danger of eye injury.

Wear protective eyewear.

-- Remove any sealant residue on the lower timing chain cover and cylinder block with a rotating plastic brush.

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

NOTE:

Note the expiration date of the sealing compound.

Fig 5: Cut Tube Nozzle At Front Marking

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-- Cut the tube nozzle at the front marking (nozzle diameter: approximately 1.5 mm).

-- Install the seals -2- and -5-.

Fig 6: Identifying Seals -2- And -5-

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CAUTION:

The lubrication system could be plugged with excess sealant.

Do not apply sealant bead thicker than specified.

-- Apply a bead of sealant -1- and -4- on the clean sealing surfaces on the lower timing chain cover as illustrated.

Completely fill the grooves on the sealing surfaces with sealant.
The sealant bead must be 1.5 to 2.0 mm above the sealing surface.
The bead of sealant around the holes -3- and -6- must be 1.5 to 2.0 mm thick.

NOTE:

The timing chains cover must be installed within 5 minutes after applying the sealant

-- Make sure the dowel sleeves are inside the cylinder block; it not install them.

-- Install the lower timing chain cover and tighten the screws, refer to Figure.

Fig 7: Lower Timing Chain Cover Bolts

Courtesy of AUDI OF AMERICA, LLC

Install in reverse order of removal. Note the following:

-- Install the lower part of the oil return line, refer to TURBOCHARGER OVERVIEW .

-- Install the timing chain covers. Refer to LEFT TIMING CHAIN COVER, REMOVING AND INSTALLING for the left and RIGHT TIMING CHAIN COVER, REMOVING AND INSTALLING for the right.

-- Install the intermediate pipe and intermediate flange: left LEFT INTERMEDIATE PIPE, REMOVING AND INSTALLING , right RIGHT INTERMEDIATE PIPE, REMOVING AND INSTALLING and INTERMEDIATE FLANGE, REMOVING AND INSTALLING .

-- Install the drive plate. Refer to DRIVE PLATE, REMOVING AND INSTALLING .

-- Fill engine oil and check the oil level. Refer to Maintenance Booklet 406.