Lower Timing Chain Cover

WARNING: This page is about a different car, the 2009 Volkswagen GTI and 2008 Volkswagen GTI. However, it is still accessible from the selected car via links, so may be relevant.

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
Frame 10-222 A/13 (GTI only)
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-
Bracket for Engine 10-222 A/1 (Eos only)

Removing

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

-- Remove the front part of the right wheel housing liner. Refer to FRONT WHEEL HOUSING LINER .

-- Drain the engine oil.

Fig 1: Identifying Air Guide Pipe And Bolts

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-- Remove the bolts -arrows-.

-- Lift the clamps -1 and 2- and remove the charge air pipe.

CAUTION:

Risk of destroying due to a reversed running direction on a used ribbed belt.

Before removing the ribbed belt, mark the running direction with chalk or a felt tip pen for reinstallation later.

-- Loosen the clamps -arrows- and remove the right charge air hose.

Fig 2: Identifying Right Charge Air Guide Hose -Arrows-

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-- To release the tension on the ribbed belt, rotate the tensioner in the -direction of the arrow- from underneath.

Fig 3: Identifying Wrench And Locking Pin -T10060 A-

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-- Secure the tensioner using the locking pin -T10060 A-.

-- Remove the ribbed belt from the vibration damper.

-- Rotate the vibration damper to the Top Dead Center (TDC) position -arrow- using the counter hold tool -T10355-.

Fig 4: 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 -arrow- on the lower timing chain cover.

CAUTION:

The engine could be destroyed.

In order not to change the valve timing, the crankshaft must not be moved out of the TDC position when the vibration damper bolt is removed.

-- Remove the vibration damper bolt using the counter hold tool -T10355-.

-- Remove the vibration damper.

CAUTION:

To avoid damaging the splines, only use the thrust piece -T10368- to install the vibration damper bolt.

-- Install the vibration damper bolt and the thrust piece -T10368- again.

Fig 5: Identifying Vibration Damper Bolt And Thrust Piece T10368

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Vehicles with a Noise Generator

-- Remove the charge air pipe from the noise generator. Refer to CHARGE AIR PIPE TO NOISE GENERATOR .

Continuation for all Vehicles

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

GTI

Fig 6: Identifying Engine Support Bridge -10-222 A- And Special Tools

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

Eos

Fig 7: Identifying Engine Support Bridge -10-222 A- And Special Tools

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Bracket for engine 10-222 A/1
Bracket with spindle and hook 10-222 A/10
Shackle 10-222 A/12

NOTE:

Do not place the bracket for engine 10-222 A/1 on the fender panels. The panels will be damaged.

The shackle 10-222 A/12 is needed to make sure the engine is lifted in the installed position and not tipped.

Continuation for all Vehicles

-- Secure the engine with the spindle.

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

Fig 8: Identifying Engine Mount To Engine Mount Bracket 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 wiring harness -arrow-.

Fig 9: 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 bolts for the engine mount bracket using the bits -T10099-.

-- Remove the engine mount bracket and the bolts.

-- Remove the bolts -arrows- and remove the oil dipstick guide tube from the timing chain cover.

Fig 10: Identifying Oil Dipstick Guide Tube And Bolts

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

Fig 11: Identifying Turbocharger And Supports

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-- Remove the turbocharger support -1-.

-- Remove the bolts -1 through 15-.

Fig 12: Identifying Lower Timing Chain Cover Bolts

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CAUTION:

The lower timing chain cover could be damaged. To avoid deformation, do not hold between the bolting points.

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

Fig 13: Identifying Lower Timing Chain Cover And Bolt Removal Start Sequence

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Installing

Tightening specifications, refer to TIMING CHAIN COVERS OVERVIEW .
Sealant: silicone sealant -D 174 003 A2-

NOTE:

Note the expiration date of the silicone sealant.

The cover must be installed within 5 minutes after application of silicone sealant.

Replace the bolts which have been tightened to a torque angle.

Replace O-rings, seals and self-locking nuts.

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

WARNING:

Wear safety glasses.

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

-- Use a rotating plastic brush to remove any remaining sealant on the cover.

Fig 14: 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 using the old bolts and tighten them to 8 Nm.

-- Check between the cover and housing using a feel gauge; the gap must not exceed 0.2 mm.

NOTE:

If the gap exceed 0.2 mm, replace the cover.

It is not possible to measure between the cover the upper oil pan, however check the sealing surface for evenness.

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

Fig 15: Identifying Centering Cover Alignment Bushings

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-- Cut the sealant tube nozzle at the front mark (nozzle diameter: approximately 3 mm).

Fig 16: Identifying Scissors To Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 3 Mm)

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-- Apply the silicone sealant -D 174 003 A2- on the clean sealing surface of the cover as shown in the illustration.

Fig 17: Identifying Silicone Sealant Application Area For Cover Sealing Surface

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Thickness of sealant bead: 2 to 3 mm.

NOTE:

The cover must be installed within 5 minutes after application of the silicone sealant.

The sealant bead may not be thicker than specified, otherwise the excess sealant could enter the oil pan and clog the oil intake pipe.

-- Install the cover immediately and all the bolts.

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

Fig 18: Identifying Lower Timing Chain Cover Bolts

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

NOTE:

After installing the cover, allow the sealant to dry for approximately 30 minutes. Only after then may the engine oil be added.

-- Fill the engine oil.

-- Check the oil level.

The rest of the installation is basically a reverse of the removal sequence.