Removing and installing lower timing chain cover: VW Touareg I 4.2 (BAR, CGEA, CGFA)

🧭 Before you start

Fits: VW Touareg I (7L, 2002–2010)

• Opens: engine oil
• Special tools named: feeler gauge, torque wrench

Don't miss

• The bevelling makes it easier to fit the lower timing chain cover with the cylinder head installed.
• Make sure that no sealant residue gets into the engine. — Clean sealing surfaces; they must be free of oil and grease.
• With the cylinder head installed, the holes in the cylinder head gasket are only half visible.
• Clean both cylinder head gaskets (top and bottom); they must be free of oil and grease.
• Cut off tube nozzle at forward marking (∅ of nozzle approx. 2 mm).

🔧 Engine codes this applies to

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Remove screws and remove front (1) and rear (2) noise insulation.
2. Place used oil collection and extraction unitV.A.G 1782 under engine and drain engine oil.
3. Remove engine .
4. Separate engine and gearbox .
5. Secure engine to engine and gearbox supportVAS 6095.

6. Remove drive plate .
7. Remove left and right timing chain covers .
8. Remove intake manifold .
9. Remove oil filter housing .
10. Unscrew bolts (arrows).
11. Remove bolts (1 … 13) and remove lower timing chain cover.
12. Press rear crankshaft oil seal out from lower timing chain cover.
13. Pull upper right dowel sleeve out of cylinder block.
14. Bevel the dowel sleeve with a file, as illustrated.
15. Fit dowel sleeve on cylinder block in such a way that the bevelled side points upwards. [Note: The bevelling makes it easier to fit the lower timing chain cover with the cylinder head installed.]
16. Remove remaining sealant on timing chain cover and cylinder block using, for example, a rotating plastic brush.
17. ⚠ Make sure that no sealant residue gets into the engine. — Clean sealing surfaces; they must be free of oil and grease.
18. Clean any old sealing compound from the bores (arrow) in the cylinder head gaskets. [Note: With the cylinder head installed, the holes in the cylinder head gasket are only half visible.]
19. ⚠ The cylinder head gasket must not to be bent more than a small amount. If the cylinder head gasket has been bent and kinked it must be renewed. — Carefully bend the ends of the cylinder head gaskets down very slightly (arrows), just far enough to be able to clean the upper sealing surface on the gasket and cylinder head.
20. Clean both cylinder head gaskets (top and bottom); they must be free of oil and grease.
21. Cut off tube nozzle at forward marking (∅ of nozzle approx. 2 mm).
22. Apply a thin coating of sealant to upper and lower sealing surfaces of cylinder head gaskets, bend cylinder head gaskets downwards very slightly (arrows) for this.
23. Use a flat object (e.g. a feeler gauge) to apply sealant to the area between cylinder head and gasket.
24. Apply beads of sealant (1 … 9) onto clean sealing surfaces of lower timing chain cover as illustrated. [Note: The timing chain cover must be installed within 5 minutes after applying sealant.]
25. Fit lower timing chain cover, guiding it towards the sealing surface on cylinder block and cylinder head at an angle and from below.
26. Take care not to damage the cylinder head gaskets when fitting the cover. A damaged cylinder head gasket must be renewed.
27. Tighten bolts as follows.
28. Apply locking fluid to bolts (arrows) and tighten to 5 Nm with torque wrench. — 5 Nm (3.7 lb-ft)
29. Tighten bolts (1 … 13) in diagonal sequence to 8 Nm with torque wrench. — 8 Nm (5.9 lb-ft)
30. Tighten bolts (arrows) to 8 Nm with torque wrench. — 8 Nm (5.9 lb-ft)
31. Tighten bolts (2, 4, 8, 9, 10) to 22 Nm with torque wrench. — 22 Nm (16 lb-ft)
32. Tighten bolts (1, 3, 5, 6, 7, 11, 12, 13) in diagonal sequence 90° further (1/4 turn) using a rigid wrench.
33. Tighten bolts (arrows) 90° further (1/4 turn) using a rigid wrench.
34. Install crankshaft oil seal on timing chain side .
35. Install oil filter housing .
36. Install intake manifold .
37. Install left and right timing chain covers .
38. Install drive plate .
39. Install engine .
40. Fill with engine oil and check oil level .

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