Lower Timing Chain Cover, Removing And Installing

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

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-- 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

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-- 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.

Fig 4: Cleaning Remaining Sealant With Rotating Plastic Brush

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-- 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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-- 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.

-- 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.