Removing and installing timing chain covers: VW Phaeton 3.0 TDI (BKS, BMK, BUN, CARA, …)

🧭 Before you start

Drain the oil, remove the engine, separate the gearbox and mark and remove the drive plate and shim. Remove the turbocharger, intermediate pipes, oil lines and vacuum pump, then the right, left and lower covers. Clean all old sealant, apply beads and sealing elements, fit the lower cover and tighten in stages to 5 Nm, 9 Nm and 22 Nm, then fit the side covers with new gaskets and the transition beads.

Fits: VW Phaeton (3D)

• Opens: engine oil
• Renewed: gaskets

Don't miss

• Mark the drive plate position before unbolting it and keep the shim behind it.
• Cut the sealant nozzle to about 2 mm; thicker beads can clog the oil pump strainer.
• Fit the covers within 5 minutes of applying sealant.
• Lower cover: bolts 1 to 9 at 5 Nm, 1 to 7 at 9 Nm, then 8 and 9 at 22 Nm.
• Renew bolts that are tightened through an additional angle.

Written for this job from the workshop steps below · TorqFix editorial.

🔧 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. Drain engine oil.
2. Remove engine .
3. Separate engine/gearbox unit.
4. Secure engine to engine stand , or leave engine on scissor-type assembly platformVAS 6131.
5. Mark installation position of drive plate on engine.

6. Attach counterhold10-201 in order to loosen bolts.
7. Unbolt drive plate.
8. Take out shim located behind.
9. Unscrew bolts (1) and (2) and disconnect air pipe from hoses (arrow).
10. Remove air intake hose together with crankcase breather hose (arrows).
11. Disconnect electrical connectors (1) and (2).
12. Unscrew banjo bolt (3) for oil supply line.
13. Disconnect electrical connector (4).
14. Remove bolts (2) and (3) and remove bracket.
15. Remove bolt (1).
16. Detach coolant pipe (rear) from coolant hose (arrow).
17. Unscrew bolts (1) and (2) and detach oil return line. [Note: Shown in illustration with intermediate pipe removed.]
18. Unscrew nuts and bolts (arrows) and detach left intermediate pipe.
19. Unscrew bolts and nuts (1 … 4) and detach right intermediate pipe.
20. Unscrew bolts (arrows) and remove turbocharger.
21. Unscrew bolt (arrow) and remove vacuum pump.
22. Unscrew bolts (1 … 4) and remove right timing chain cover.
23. Unscrew bolts (1 … 4) and remove left timing chain cover.
24. Unscrew bolts (1 … 9) and remove lower timing chain cover.
25. Press out crankshaft oil seal (rear) from timing chain cover. [Note: Renew gaskets, seals and O-rings. Secure all hose connections with hose clips (same as original equipment) Parts catalogue.Reinstall all cable ties in the same locations when assembling.]
26. Remove old sealant from grooves in timing chain covers and from sealing surfaces.
27. ⚠ Wear eye protection. — Remove remaining sealant on timing chain covers and cylinder block/cylinder head using rotating plastic brush or similar.
28. Clean sealing surfaces; they must be free of oil and grease.
29. Cut off nozzle on tube at front marking (∅ of nozzle approx. 2 mm). [Note: The sealant beads must not be thicker than specified, otherwise excess sealant could enter the sump and clog the strainer in the oil pump.The timing chain covers must be installed within 5 minutes after applying sealant.]
30. Insert sealing elements (2) and (5)
31. Apply sealant beads (1) and (4) onto the clean sealing surface of the timing chain cover (bottom) as illustrated.
32. Check whether the two dowel sleeves are fitted in the cylinder block; install if necessary.
33. Fit lower timing chain cover and tighten bolts as follows:
34. Tighten bolts (1 … 9) to 5 Nm in diagonal sequence starting from inside and working outwards. — 5 Nm (3.7 lb-ft)
35. Tighten bolts (1 … 7) to 9 Nm in diagonal sequence starting from inside and working outwards. — 9 Nm (6.6 lb-ft)
36. Tighten bolts (8) and (9) to 22 Nm. — 22 Nm (16 lb-ft)
37. Apply bead of sealant onto clean sealing surface of left timing chain cover as illustrated.
38. Fit gasket (2).
39. Apply a ∅ 3 mm bead of sealant to each transition between cylinder head and bottom timing chain cover (arrows), as shown in the illustration.
40. ⚠ Danger of blocking lubrication system with excess sealant.Do not apply a sealant bead that is thicker than prescribed. — Fit timing left chain cover and tighten bolts as follows: [Note: Renew bolts tightened through an additional specified angle.]
41. Tighten bolts in 4 stages in the sequence shown:
42. Apply bead of sealant onto clean sealing surfaces of right timing chain cover as illustrated.
43. Fit gasket (2).
44. Apply a ∅ 3 mm bead of sealant to each transition between cylinder head and bottom timing chain cover (arrows), as shown in the illustration.
45. ⚠ Danger of blocking lubrication system with excess sealant.Do not apply a sealant bead that is thicker than prescribed. — Fit timing chain cover (right) and tighten bolts as follows:

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