Lower Timing Chain Cover

Special Tools And Workshop Equipment Required 

• Engine Support Bridge 10-222 A
• Bracket with Spindle and Hook 10-222 A/10
• Shackle 10-222 A/12
• Adapter 10-222 A/13 (Qty: 2)
• Locking Pin T10060 A
• Bits T10099
• Counter Hold Tool T10355
• Thrust Piece T10368
• Torque Wrench (5-50 Nm) V.A.G 1331
• Torque Wrench (40-200 Nm) V.A.G 1332
• Silicone sealant D 174 003 A3
• Flat Scraper
• Hand Drill with Plastic Brush Attachment
• Protective Eyewear
• Feeler Gauge

Removing 

-- Remove the noise insulation. Refer to Description and Operation .

-- Remove the right front wheel.

-- Remove the right front wheel housing liner. Refer to Removal and Installation .

-- Drain the engine oil.

Fig 1: Identifying Air Guide Pipe And Bolts

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-- Remove the bolts -arrows-.

-- Remove the charge air pipe by lifting the clamps -1 and 2-.

-- Remove the ribbed belt. Refer to RIBBED BELT .

-- Use the counter hold Tool T10355 to rotate the vibration damper to Top Dead Center (TDC) -arrow- :

Fig 2: Identifying Vibration Damper Rotated Into "OT" Position Using Counter Hold Tool T10355

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• The notch on the vibration damper must line up with the arrow mark on the lower timing chain cover.

-- Use the counter hold Tool T10355 tool to remove the vibration damper bolt.

-- Remove the vibration damper.

-- Install the vibration damper bolt and the thrust Piece T10368.

Fig 3: Identifying Vibration Damper Bolt And Thrust Piece T10368

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-- Remove the charge air pipe from the noise generator, if equipped. Refer to CHARGE AIR PIPE FROM NOISE GENERATOR .

-- Install the engine support Bridge 10-222 A using the following tools:

Fig 4: Identifying Engine Support Bridge -10-222 A- And Special Tools

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• Bracket with spindle and Hook 10-222 A/10
• Shackle 10-222 A/12
• Adapter 10-222 A/13 (Qty: 2)

-- Tension the engine with the spindle.

-- Remove the engine mount to engine mount bracket bolts -arrows-.

Fig 5: Identifying Engine Mount Bolts

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-- Remove the engine mount. Refer to ENGINE AND TRANSMISSION MOUNT OVERVIEW .

-- Lift the engine approximately 50 mm and loosen the upper bolt for the engine mount bracket.

-- Now, lower the engine approximately 100 mm.

-- Free up the electrical harness -arrow-.

Fig 6: Identifying Ribbed Belt Tensioner Bolt And Locating Electrical Wiring Harness

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-- Remove the bolt -1- and remove the ribbed belt tensioner from the accessory bracket.

-- Remove the lower engine mount bracket bolts using the bits T10099.

-- Remove the engine mount bracket and bolts.

-- Remove the bolts -1- and pull the oil dipstick guide tube out.

Fig 7: Identifying Oil Dipstick Guide Tube Bolts

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-- Remove the wastegate bypass regulator valve -N75- bolts -arrows- and the valve from the turbocharger.

Fig 8: Identifying Turbocharger And Supports

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-- Remove the turbocharger support bolts -1-.

-- Remove the bolts -1 through 15-.

Fig 9: Identifying Lower Timing Chain Cover Bolts

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-- Pry off the lower timing chain cover; when doing this, begin at -1 and 2-.

Fig 10: Identifying Lower Timing Chain Cover

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Installing 

• Lower timing chain cover bolt tightening sequence and specification. Refer to Figure.
• Timing chain cover tightening specifications. Refer to TIMING CHAIN COVERS OVERVIEW .
• Turbocharger tightening specifications. Refer to TURBOCHARGER COMPONENT OVERVIEWS .
• Ribbed belt tightening specification. Refer to RIBBED BELT OVERVIEW .
• Engine/transmission tightening specifications. Refer to ENGINE AND TRANSMISSION MOUNT OVERVIEW .
• Use silicone sealant D 174 003 A3.

-- Remove any sealant residue on the cylinder block using a flat blade scraper.

-- Seal off both sides of the seal with tape to prevent contamination.

-- Remove any residual sealant from the cover with a rotating plastic brush.

Fig 11: Identifying Rotating Plastic Brush To Remove Sealant Residue From Sealing Flange, Cylinder Block And Upper Part Of Oil Pan

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

-- Install the cover with the old bolts and tighten:

• Tightening specification: 8 Nm.

-- Check the gap between the cover and the housing using a feel gauge.

• It may not exceed 0.2 mm.

-- Make sure both alignment bushings for centering the cover -arrows- are present.

Fig 12: Identifying Centering Cover Alignment Bushings

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-- Cut the sealant tube nozzle at the front mark (nozzle diameter: approximately 0.12 in).

Fig 13: Identifying Scissors To Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 3 Mm)

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-- Apply the silicone sealant to the clean sealing surface of the cover as shown.

Fig 14: Identifying Silicone Sealant Application Area For Cover Sealing Surface

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• Thickness of the sealant bead: 2 to 3 mm.

-- Install the cover immediately and tighten the new bolts:

-- Tighten the bolts -1 through 15- in 2 passes in the sequence shown:

Fig 15: Identifying Lower Timing Chain Cover Bolts

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1. Tighten the bolts to 8 Nm 
2. Tighten the bolts an additional 45° (1/8) turn. 

-- Fill the engine oil.

-- Check the oil level. Refer to OIL LEVEL, CHECKING .

Further installation is in the reverse order of removal.