Lower timing chain cover, removing and installing

WARNING: This page is about a different car, the 2009 Audi A4, 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Identifying Old Oil Collecting And Extracting Device V.A.G 1782

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Removing

Remove transmission →
- 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE
- 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE
- 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE
- 34 - CONTROLS, HOUSING for 6 SPD. MANUAL TRANSMISSION 0A3 ALL WHEEL DRIVE, INTERNAL COMPONENT SERVICING
- 34 CONTROLS, HOUSING for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE
- 34 CONTROLS, HOUSING for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE
- 34 CONTROLS, HOUSING for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE
or →
- 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V
- 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING
- 37 CONTROLS, HOUSING for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE
.
Vehicles with manual transmission: Remove clutch pressure plate →
- 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE
- 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE
- 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE
- 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE
- 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE
- 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE
and dual mass flywheel → Dual mass flywheel (vehicles with manual transmission), removing and installing .
Vehicles with automatic transmission: Remove drive plate → Drive plate (vehicles with automatic transmission), removing and installing .

NOTE:

After removing transmission, the engine is supported by engine support bridge 10-222 A and the torque support stop is loosened.

CAUTION: For the further sequence of work, it must be made sure that the lock carrier is installed.

To remove transmission, remove attached engine support bridge 10-222 A from engine.

Fig 2: Removing/Installing Bolts At Torque Support Stop

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten torque support stop to 28 Nm - arrows -.
Remove left and right timing chain covers → Left and right timing chain covers, removing and installing .

Fig 3: Disconnecting Electrical Harness Connector From Oil Pressure Switch F1

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Place a rag under oil filter housing to catch escaping engine oil.

Disconnect electrical harness connector from Oil Pressure Switch F1 - arrow -.
Remove oil pressure switch.
Extract engine oil using old oil collecting and extracting device V.A.G 1782 from oil filter housing.

Fig 4: Removing Oil Filter Housing Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows -.
Remove oil filter housing.
Place old oil collecting and extracting device V.A.G 1782 under engine.
Drain engine oil.

Fig 5: Removing/Installing Bolts And Lower Timing Chain Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows -.
Remove bolts - 1 to 8 - and remove lower timing chain cover.
Press rear crankshaft seal out of lower timing chain cover.

Installing

NOTE:

Replace gaskets, seals and O-rings.

Fig 6: Pulling Alignment Bushing Out Of Top Right Of Cylinder Block

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull alignment bushing out of top right of cylinder block.
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 the chamfered side faces upward.

NOTE:

The chamfer simplifies installation of the lower timing chain cover with cylinder head installed.

CAUTION: Wear safety glasses.

Fig 7: Using Rotating Plastic Brush To Remove Any Sealant Residue From Sealing Flange, Cylinder Block And Upper Part Of Oil Pan

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Using e.g. a rotating plastic brush, remove sealant residue on timing chain cover, cylinder block and head.

CAUTION: Make sure that no sealant residue enters the engine.

Clean sealing surfaces so they are completely free of any oil or grease.

Fig 8: Cleaning Old Sealant From Holes In Cylinder Head Gaskets

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

NOTE:

With the cylinder head installed only half of the holes in the cylinder head gasket are visible.

CAUTION: Cylinder head gasket must not be kinked. A kinked cylinder head gasket must be replaced.

Fig 9: Bending Ends Of Cylinder Head Gaskets Very Slightly Downward Until Upper Sealing Surface Of Gasket And Cylinder Head Can Be Cleaned

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Bend 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.

Fig 10: Cutting Tube Nozzle At Front Marking

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Cut tube nozzle at front marking (jet dia. approx. 2 mm).

NOTE:

The sealant must be applied to several places on the engine, as described in the following.
The curing time for the sealant after application is only approx. 5 minutes.

CAUTION: Cylinder head gasket must not be kinked. A kinked cylinder head gasket must be replaced.

Fig 11: Bending Ends Of Cylinder Head Gaskets Very Slightly Downward Until Upper Sealing Surface Of Gasket And Cylinder Head Can Be Cleaned

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Fig 12: Cleaning Old Sealant From Holes In Cylinder Head Gaskets

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Vehicles through 04.2005:

Fig 13: Applying Sealant Beads On Clean Sealing Surfaces Of Lower Timing Chain Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Apply sealant beads - 1 to 6 - on clean sealing surfaces of lower timing chain cover, as shown in illustration.

The groove of sealing surface must be completely filled with sealant.
Sealant beads must stand 1.5 to 2.0 mm above sealing surface.
The sealant bead - 3 - must be pulled through as shown in the illustration even though groove is intermittent.

Lay O-ring - arrow - in lower timing chain cover groove.
Secure O-ring with some sealant.

Fig 14: Removing/Installing Bolts And Lower Timing Chain Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Set lower timing chain cover in place, guiding cover at an angle from below onto sealing surface of cylinder block and cylinder head.
When installing, make sure that the cylinder head gaskets do not become damaged. A damaged gasket must be replaced.
Tighten bolts as follows:

Insert bolts - arrows - with locking compound and tighten to 5 Nm.
Tighten bolts - 1 to 8 - in diagonal sequence to 10 Nm.

Tighten bolts - arrows - to 10 Nm.
Tighten bolts - 6 - , - 7 - and - 8 - to 22 Nm.

Vehicles from 05.2005:

Fig 15: Applying Sealant Beads On Clean Sealing Surfaces Of Lower Timing Chain Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Apply sealant beads - 1 to 5 - on clean sealing surfaces of lower timing chain cover, as shown in illustration.

The groove of sealing surface must be completely filled with sealant.
Sealant beads must stand 1.5 to 2.0 mm above sealing surface.
The sealant bead - 2 - must be pulled through as shown in the illustration even though groove is intermittent.

Insert seals - arrows - in lower timing chain cover grooves.

Fig 16: Setting Lower Timing Chain Cover In Place, Guiding Cover At An Angle From Below Onto Sealing Surface Of Cylinder Block And Cylinder Head

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Set lower timing chain cover in place, guiding cover at an angle from below onto sealing surface of cylinder block and cylinder head.
When installing, make sure that the cylinder head gaskets do not become damaged. A damaged gasket must be replaced.
Tighten bolts as follows:

Insert bolts - arrows - with locking compound and tighten to 5 Nm.
Tighten bolts - 1 to 9 - in diagonal sequence to 10 Nm.

Tighten bolts - arrows - to 10 Nm.
Tighten bolts - 7 - , - 8 - and - 9 - to 22 Nm.

Tighten stud bolt - 3 - to 16 Nm.

All:

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

Install oil filter housing → Oil filter housing, removing and installing .
Install left and right timing chain covers Installing .
Install crankshaft seal, timing chain side → Crankshaft seal, timing chain side, replacing .
Vehicles with manual transmission: Install dual mass flywheel → Dual mass flywheel (vehicles with manual transmission), removing and installing and clutch pressure plate →
- 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE
- 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE
- 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE
- 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE
- 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE
- 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE
.

Vehicles with automatic transmission: Install drive plate → Drive plate (vehicles with automatic transmission), removing and installing .
Install transmission →
- 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE
- 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE
- 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE
- 34 - CONTROLS, HOUSING for 6 SPD. MANUAL TRANSMISSION 0A3 ALL WHEEL DRIVE, INTERNAL COMPONENT SERVICING
- 34 CONTROLS, HOUSING for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE
- 34 CONTROLS, HOUSING for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE
- 34 CONTROLS, HOUSING for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE
or →
- 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V
- 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING
- 37 CONTROLS, HOUSING for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE
.
Add engine oil and check oil level → Oil level, checking .

Torque specifications

Component		Nm
Lower timing chain cover to engine	M6	9 ¹⁾
M7	16
M8	20
Left and right cover for timing chain on engine		5 + 90 ° ²⁾³⁾
Retainer for connections to cylinder head		9
¹⁾ Install threaded fasteners between cylinder head and lower timing chain cover with locking compound; Locking compound . ²⁾ Replace bolts. ³⁾ 90 ° corresponds to a quarter turn.