Timing Chain Covers
Timing Chain Covers
Special tools, testers and auxiliary items required
• Counter Hold Tool (10-201)
• Used Oil Collecting and Extracting Device (V.A.G 1782)
• Hand Drill with Plastic Brush Attachment
• Protective Eyewear
• Sealant, refer to the Parts Catalog
Removing
• All cable ties opened or cut off during the engine removal must be reinstalled at the same locations during installation.
- Drain the engine oil.
- Remove the engine. Refer to => [ Engine, Removing ] Engine, Removing.
- Separate the engine from the transmission. Refer to => [ Engine, Removing from the ] Engine, Removing from the Scissor Lift Table (VAS 6131).
- Secure the engine to the assembly stand. Refer to => [ Engine, Securing to the ] Engine, Securing to the Engine and Transmission Holder (VAS 6095).
- Remove the drive plate. Refer to => [ Drive Plate ] Drive Plate.
- Remove the shim behind it.
- Remove the charge air pipe with the crankcase ventilation connecting hose.
- Disconnect the connectors - 1 and 2 -.
- Remove the oil supply pipe banjo bolt - 3 -.
- Disconnect the connector - 4 -.
- Remove the bolts - 2 and 3 - and the bracket.
- Remove the bolt - 1 -.
- Disconnect the rear coolant pipe from the coolant hose - 1 -.
- Remove the turbocharger oil return pipe, - item 26 - in the => [ Turbocharger and Components Overview ] Turbocharger and Components Overview.
- Remove the nuts and bolts - arrows - and the left intermediate pipe.
- Remove the bolts and nuts - 1 through 4 - and the right intermediate pipe.
- Remove the bolts - arrows - and the turbocharger.
- Remove the bolt - arrows - and the vacuum pump.
• The vacuum pump shown in the illustration on cylinder bank 2 (left side) is on a vehicle with either engine codes CASA or CASD which are not available in the US/Canadian market.
• On vehicles with engine code CATA, then the vacuum pump is installed on cylinder bank 1 (right side).
- Remove the Exhaust Gas Recirculation (EGR) auxiliary cooler. Refer to => [ Exhaust Gas Recirculation System Auxiliary Cooler ] Exhaust Gas Recirculation System Auxiliary Cooler.
• The sealing cap shown in the illustration on cylinder bank 1 (right side) is on a vehicle with either engine codes CASA or CASD which are not available in the US/Canadian market.
• On vehicles with engine code CATA, then the sealing cap is installed on cylinder bank 2 (left side).
- Remove the bolts - 1 through 4 - and the right timing chain cover.
- Remove the bolts - 1 through 4 - and the left timing chain cover.
- Remove the bolts - 1 through 9 - and the lower timing chain cover.
- Press the seal for the crankshaft out of the cover.
Installing
• Replace the gaskets, seals and O-rings.
• During installation, all cable ties must be installed again at the same location.
- Remove the old sealant from the grooves in the timing chain covers and from the sealing surfaces.
Wear protective eyewear.
- Remove any sealant residue on the timing chain covers and on the cylinder block or head using a rotating plastic brush.
- Clean the sealing surfaces so they are completely free of any oil or grease.
- Cut the sealant tube nozzle at the front mark (nozzle diameter: approximately 2 mm).
• The sealant bead must not be thicker than specified otherwise excess sealant could enter the oil pan and clog the oil pump strainer.
• The timing chain covers must be installed within 5 minutes after applying the sealant.
- Install the seals - 2 and 5 -.
- Apply the sealant beads - 1 and 4 - to the clean sealing surfaces of the lower timing chain cover as illustrated.
• Completely fill the grooves on the sealing surfaces with sealant.
• The sealant bead must be 1.5 to 2.0 mm above the sealing surface.
• The sealant bead around the holes - 3 and 6 - must be 1.5 to 2.0 mm thick.
- Check whether the 2 alignment sleeves are present in the cylinder block, install them if necessary.
- Position the lower timing chain cover and tighten the bolts as follows.
Lower Timing Chain Cover Bolt, Tightening Sequence and Specification
- Tighten the bolts in 3 steps and in the sequence shown:
- Apply the sealant bead to the clean sealing surfaces on the left timing chain cover as illustrated.
• The groove - 1 - in the sealing surface must be completely filled with sealant.
• The sealant bead must be 1.5 to 2.0 mm above the sealing surface.
- Install the gasket - 2 -.
- Apply a sealant bead with a 3 mm diameter to the transitions between the cylinder head and lower timing chain cover - arrows - as illustrated.
The lubrication system could be plugged with excess sealant.
• Do not apply the sealant bead thicker than specified.
- Install the left timing chain cover and tighten the bolts as follows:
Left Timing Chain Cover Bolt Tightening Sequence and Specification
• Replace any bolts that were tightened to an additional torque angle.
- Tighten the bolts in 4 steps and in the sequence shown:
- Apply the sealant bead to the clean sealing surfaces of the right timing chain cover as illustrated.
• The groove - 1 - on the sealing surface must be completely filled with sealant.
• The sealant bead must be 1.5 to 2.0 mm above the sealing surface.
- Install the gasket - 2 -.
- Apply a sealant bead with a 3 mm diameter to the transitions between the cylinder head and lower timing chain cover - arrows - as illustrated.
The lubrication system could be plugged with excess sealant.
• Do not apply sealant the bead thicker than specified.
- Install the right timing chain cover and tighten the bolts as follows:
Right Timing Chain Cover Bolt Tightening Sequence and Specification
• Replace any bolts that were tightened to an additional torque angle.
- Tighten the bolts in 4 steps and in the sequence shown:
Further installation is in the reverse order of removal.