Timing chain covers (All), removing and installing: Removing

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2009 Audi S4, 2008 Audi S4, 2007 Audi S4, 2006 Audi S4, and 2005 Audi S4. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
Remove engine: → Engine (vehicles with manual transmission) , → Engine (vehicles with automatic transmission), removing .
Disconnect engine and transmission: → Engine (vehicles with manual transmission), separating , → Engine and transmission (vehicles with automatic transmission), separating .
Leave engine on Scissor Lift Table VAS 6131 A or secure engine to engine and transmission holder: → Engine (vehicles with manual transmission), securing to engine and transmission holder , → Engine (vehicles with automatic transmission), securing to assembly stand .

Remove dual-mass flywheel → Dual-mass flywheel, removing and installing , drive plate → Drive plate, removing and installing .

Fig 1: Disconnecting Electrical Connection At Throttle Valve Control Module J338 & Crankcase Ventilation Hose At Intake Pipe

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical connection - 1 - at throttle valve control module J338.
Disconnect crankcase ventilation hose - 3 - at intake pipe.

NOTE:

Ignore - 2 -.

Fig 2: Remove Electrical Harness Connectors Toward Front From Brackets On Intake Line

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove electrical harness connectors - 1 - , - 2 - , - 5 - and - 6 - toward front from brackets on intake line.
Separate the electrical connectors - 3 - and - 4 -.

Fig 3: Disconnecting Vacuum Hose At T-Piece

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect vacuum hose - arrow - at T-piece.

Fig 4: Identifying Connector Strips At Fuel Injectors, Vacuum Line On Fuel Pressure Regulator & Retaining Bolts For Fuel Rail Line

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect connector strips - 1 - and - 5 - at fuel injectors.
For vehicles with fuel return line, disconnect vacuum line - 4 - on fuel pressure regulator.
Remove retaining bolts - 2 - and - 3 - for fuel rail line.
Remove fuel rail line together with fuel injectors from intake manifold uniformly upward.

NOTE:

Carefully protect the removed fuel injectors from contamination.

Fig 5: Removing Left/Rear Engine Lifting Eye

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove left rear engine lifting eye - arrows -.

Fig 6: Removing Intake Manifold Bolts

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove intake manifold bolts - arrows - and remove it.

NOTE:

Plug the intake ports of the cylinder head with clean rags.

Fig 7: Removing Cap For Oil Filter Housing

GW00018154

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove cap - arrow - for oil filter housing.
Remove oil filter element.
Extract engine oil using old oil collecting and extracting device V.A.G 1782 from oil filter housing.

NOTE:

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

Fig 8: Removing Bolts & Oil Filter Housing

GW00018155

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows -.
Remove oil filter housing.

Fig 9: Removing Bolts & Return Line From Power-Steering Pump

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - 1 - and - 2 -.
Place old oil collecting and extracting device V.A.G 1782 underneath.
Remove return line from power-steering pump - arrow -.

Fig 10: Removing Bolt From Oil Dipstick Guide Tube At Cylinder Head

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolt - arrow - from oil dipstick guide tube at cylinder head, pull up and remove guide tube.

Fig 11: Removing Bolts, Loosening Hose Clamps And Removing Left Coolant Pipe From Coolant Hoses

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - 1 - and - 2 -.
Loosen hose clamps - arrows - and remove left coolant pipe from coolant hoses.

Fig 12: Removing Bolts, Locating Hose Clamps And Removing Right Coolant Pipe From Coolant Hoses

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - 1 - and - 2 -.
Loosen hose clamps - arrows - and remove right coolant pipe from coolant hoses.

Fig 13: Disconnecting Electrical Harness Connector On Engine Coolant Temperature (ECT) Gauge Sensor G2/G62

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connector - 2 - on Engine Coolant Temperature (ECT) Gauge Sensor G2/G62.
Remove nut - 1 - and remove electrical wiring harness at rear of coolant pipe.

Fig 14: Removing Bolts & Rear Coolant Pipe

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - 2 to 5 -.
Remove rear coolant pipe.

NOTE:

Ignore - 1 - and - 6 -.

Fig 15: Removing Mounting Bolts Of Combination Valves For Secondary Air Injection (AIR) System

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove mounting bolts - 1 to 4 - of combination valves for Secondary Air Injection (AIR) system.

Fig 16: Removing Nuts And Left Exhaust Manifold

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove nuts - 1 to 12 - and remove left exhaust manifold.

Fig 17: Removing Left Heat Shield

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove left heat shield - arrows -.

Fig 18: Removing Nuts And Right Exhaust Manifold

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove nuts - 1 to 12 - and remove right exhaust manifold.

Fig 19: Removing Right Heat Shield

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove right heat shield - arrows -.

Fig 20: Removing Bolts On Left Cylinder Head, Disconnecting Electrical Harness Connectors & Removing Ignition Coils

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - 5 - and - 6 - on left cylinder head.
Disconnect electrical harness connectors - 1 to 4 -.
Remove ignition coils - arrows -.

NOTE:

Extractor T40039 can be used for removal.

Fig 21: Disconnecting Hose Of Crankshaft Housing Ventilation & Removing Left Cylinder Head Cover Bolts In Sequence

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect hose of crankshaft housing ventilation - arrow -.
Remove left cylinder head cover bolts in sequence - 15 to 1 -.
Remove cylinder head cover.

Fig 22: Removing Bolts On Right Cylinder Head, Disconnecting Electrical Harness Connectors & Removing Ignition Coils

GW00018169

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - 5 - and - 6 - on right cylinder head.
Disconnect electrical harness connectors - 1 to 4 -.
Remove ignition coils - arrows -.

NOTE:

Extractor T40039 can be used for removal.

Fig 23: Disconnecting Hose Of Crankshaft Housing Ventilation & Removing Right Cylinder Head Cover Screws In Sequence

GW00018170

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect hose of crankshaft housing ventilation - arrow -.
Remove right cylinder head cover screws in sequence - 15 to 1 -.
Remove cylinder head cover.

Fig 24: Disconnecting Electrical Harness Connector For Camshaft Position (CMP) Sensor 2 G163 On Left Cylinder Head

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connector - arrow - for Camshaft Position (CMP) Sensor 2 G163 on left cylinder head.
Disconnect electrical harness connector - arrow - for Camshaft Position (CMP) Sensor G40 on right cylinder head.

Fig 25: Removing Ground (GND) Cable On Right Cylinder Head

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove Ground (GND) cable on right cylinder head - arrow -.
Set wiring harness aside.

Fig 26: Removing/Installing Bolts And Left Timing Chain Cover

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - 1 to 6 - and remove left timing chain cover.

Fig 27: Removing Bolts And Right Timing Chain Cover

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - 1 to 6 - and remove right timing chain cover.

Fig 28: Removing Bolts And Lower Timing Chain Cover

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - 1 to 13 - and remove lower timing chain cover.

Fig 29: Pressing Sealing Ring For Crankshaft At Rear Out Of Cover

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press sealing ring for crankshaft at rear out of cover.