Lower Timing Chain Cove

Special tools and workshop equipment required

Hand drill with plastic brush attachment
Protective goggles
Sealant

Removing

The transmission is removed. Refer to Removal and Installation .

NOTE:

When installing, bring all cable ties back to the same positions.

-- Remove dual mass flywheel. Refer to DUAL MASS FLYWHEEL .

-- Remove timing chain guard upper section. Refer to UPPER TIMING CHAIN COVER .

-- Remove the brake booster vacuum pump. Refer to Removal and Installation .

-- Remove Engine Speed (RPM) sensor -G28-. Refer to Removal and Installation .

-- Remove bolts -arrows- first, then remove bolts -1 through 6-.

Fig 1: Identifying Lower Timing Chain Cover, Tightening Sequence

Courtesy of AUDI OF AMERICA, LLC

-- Carefully loosen the timing chain guard lower section -1- from the bonding in order to position a screwdriver -A- on the upper and lower marked locations:

Fig 2: Identifying Screwdriver And Removal Positions For Control Housing Cover From Cylinder Block Or From Upper Section Of Oil Pan

Courtesy of AUDI OF AMERICA, LLC

2 - Cylinder block

3 - Oil pan (upper section)

-- Meanwhile, begin loosening in the area of the alignment sleeve -arrows-.

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

Installing

Fig 3: Locating Alignment Sleeves

Courtesy of AUDI OF AMERICA, LLC

-- Drive the alignment sleeve -arrows- back into the timing chain guard lower section so far that it no longer protrudes out from the sealing surface.

NOTE:

Replace seals, gaskets and O-rings.

CAUTION:

Risk of contaminating lubricating system.

Cover open parts of engine.

WARNING:

Danger of eye injury.

Wear protective goggles.

-- Remove any sealant residue still on the timing chain guard lower section, cylinder block and oil pan upper section with a rotating plastic brush.

Fig 4: Identifying Rotating Plastic Brush To Remove Sealant Residue From Sealing Flange, Cylinder Block And Upper Part Of Oil Pan

Courtesy of AUDI OF AMERICA, LLC

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

-- Clean the old sealant off the holes -arrow- in the cylinder head gasket.

Fig 5: Identifying Cylinder Head Gasket Holes

Courtesy of AUDI OF AMERICA, LLC

NOTE:

With cylinder head installed, holes in cylinder head seal are only half visible.

Fig 6: Identifying Cylinder Head Gasket Protrusion

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

The cylinder head seal could be damaged.

Only bend ends of cylinder head seals slightly, do not kink.

NOTE:

A kinked cylinder head seal must be replaced.

-- Bend the end of the cylinder head seal down slightly -arrows- until the upper sealing surface of the seals and the cylinder head can be cleaned.

-- Clean the upper and lower cylinder head gasket; they must free from oil and grease.

NOTE:

Note the expiration date of the sealing compound.

-- Cut the tube nozzle at the front marking (nozzle diameter approximately 2 mm).

Fig 7: Cutting Tube Nozzle At Front Marking (Nozzle Diameter Approx. 2 mm)

Courtesy of AUDI OF AMERICA, LLC

-- Lightly coat the top and bottom cylinder head seal sealing surface with lubricant by bending seal down slightly again -arrows-.

Fig 8: Identifying Cylinder Head Gasket Protrusion

Courtesy of AUDI OF AMERICA, LLC

-- Use a flat object such as a feeler gauge to coat the surface between the cylinder head and seal.

-- Fill the cleaned cylinder head seal holes -arrow- with sealant.

Fig 9: Identifying Cylinder Head Gasket Holes

Courtesy of AUDI OF AMERICA, LLC

Fig 10: Applying Sealant Bead

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

The lubrication system could be plugged with excess sealant.

Do not apply sealant bead thicker than indicated.

-- Apply a sealant bead -arrow- to the clean sealing surface of the timing chain guard lower section as shown in the illustration.

Thickness of sealant bead: 1.5 to 2.0 mm.

NOTE:

The timing chain guard lower section must be installed within 5 minutes after applying the sealant.

-- Install the sealing sleeve -1- and O-ring -2-.

-- Position the lower timing chain cover, guiding it diagonally from below to the sealing surface on the cylinder block and cylinder head.

-- When positioning, ensure the cylinder head seal is not damaged.

-- Install the timing chain guard lower section bolts all the way by hand.

Fig 11: Identifying Lower Timing Chain Cover, Tightening Sequence

Courtesy of AUDI OF AMERICA, LLC

-- Drive in the alignment sleeve on the timing chain guard lower section all the way into the cylinder block.

-- Tighten the bolts for the lower timing chain cover. Refer to Figure.

Install in reverse order of removal paying attention to the following:

-- Install the Engine Speed (RPM) sensor -G28-. Refer to Removal and Installation .

-- Install the brake booster vacuum pump. Refer to Removal and Installation .

-- Install timing chain guard upper section. Refer to UPPER TIMING CHAIN COVER .

-- Install the transmission-side crankshaft shaft seal. Refer to CRANKSHAFT SEAL, TRANSMISSION SIDE .

-- Install the dual mass flywheel. Refer to DUAL MASS FLYWHEEL .