Lower timing chain cover, removing and installing

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 

Fig 2: Removing Quick-Release Fasteners, Screws And Noise Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove quick-release fasteners - 1  - , remove screws - 2  - and remove noise insulation.
• Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
• Remove engine → Engine, removing .
• Separate engine and transmission → Engine and transmission, separating .

• Leave engine on Scissor Lift Table VAS 6131 or secure engine to assembly stand → Engine, securing to assembly stand .
• 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
  .
• Remove dual-mass flywheel → Dual-mass flywheel, removing and installing .
• Remove left and right timing chain covers → Left and right timing chain covers, removing and installing .

• Remove intake manifold → 24 - MULTIPORT FUEL INJECTION (MFI) .
• Remove oil filter housing → Oil filter housing, removing and installing .

Fig 3: Removing Bolts And Lower Timing Chain Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove bolts - arrows  -.
• Remove bolts - 1 to 13  - and remove lower timing chain cover.
• Press rear crankshaft seal out of lower timing chain cover.

Installing 

Installation is in reverse order of removal, note the following:

• Pull alignment bushing out of top right of cylinder block.

Fig 4: Chamfer Alignment Bushing With File

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• 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.

Fig 5: 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.

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

Fig 6: 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.

Fig 7: 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 8: Cutting Tube Nozzle At Front Marking

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Cut off nozzle on tube of sealant at front mark (dia. of nozzle approx. 2 mm).

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.

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

Fig 10: Applying Sealant Beads On Clean Sealing Surfaces Of Lower Timing Chain Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Apply sealant beads - 1 to 9  - on clean sealing surfaces of lower timing chain cover, as shown in illustration.

• Thickness of sealant beads: 2.5 mm.

Fig 11: 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 cylinder block sealing surface 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:

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

• Install crankshaft seal, timing chain side → Crankshaft seal (timing chain side), replacing .
• Install oil filter housing → Oil filter housing, removing and installing .
• Install intake manifold → 24 - MULTIPORT FUEL INJECTION (MFI) .
• Install left and right timing chain covers Installing .

• Install dual-mass flywheel → Dual-mass flywheel, removing and installing .
• Install 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
  .
• Install engine → Engine, installing .
• Add engine oil and check oil level → Oil level, checking .

Torque specifications