Removing

Preliminary work for bearing cover for intermediate shaft

Note: Note the work instructions for disconnecting and reconnecting the battery.

1. Disconnect the battery.
2. Drain engine oil.
3. Remove air cleaner housing.

Tiptronic transmission:
4. Remove engine.
5. Remove Tiptronic transmission.
6. Remove drive plate for converter.

Manual transmission:
7. Remove manual transmission.
8. Remove clutch.
9. Remove double-mass flywheel.

Removing bearing cover for intermediate shaft

ATTENTION: Risk of engine damage if timing belt jumps over.
^ Following removal of the chain tensioner, the crankshaft must not be turned under any circumstances.

Note:
^ It is only possible to remove the bearing cover with the engine installed in vehicles with manual transmission.
^ In Tiptronic vehicles, the complete engine/transmission unit must be removed.

Bearing cover





1. Lever out two green closure caps on pulley side of cylinder bank 1 - 3.





2. Turn the engine at the hexagon-head bolt (a/f 24) of the crankshaft belt pulley (or vibration damper) clockwise to overlapping TDC of cylinder bank 1-3 and fix it with special tool fixing pins 9595/1.

Note: For checking with the adjusting gauge, the timing adjustment must be correct.

3. To check the camshaft adjustment, insert adjusting gauge 9686 for camshaft into the camshaft slots (pulley side) (inscription on gauge pointing towards cylinder head cover). If the gauge cannot be inserted, rotate the crankshaft a further 360° and secure it again.
4. Unscrew two M6 x 12 hexagon-head bolts on the coolant pipe (heating) at cylinder side 4 - 6.





5. Remove primary chain tensioner (hexagon socket a/f 32).





6. Remove chain tensioner, cylinder bank 1 - 3 (hexagon socket a/f 32).





Note: To make it easier to remove the bearing cover spray the sealing surface with anti-rust agent.

7. Unscrew M8 hexagon collar nut on the bearing cover of the intermediate shaft with special tool socket wrench 9110, while at the same time countering the slotted threaded pin on the intermediate shaft with a screwdriver.
8. Unscrew the three M6 x 20 hexagon-head bolts (coated) on the intermediate-shaft flange. Replace screws during installation and clean thread.





Note:
^ Remove bearing cover using special tool puller 9673. If this is not available, lever the bearing cover out carefully with two screwdrivers so as not to damage the sealing surfaces. Turning several times to the left and right loosens the bearing cover.
^ After removing the bearing cover, do not press the threaded bolts of the intermediate shaft.

9. Position special tool puller 9673 at the bearing cover grooves and secure by turning the locking lever anti-clockwise.





10. Pull the slide hammer on the puller a number of times against the stop nuts while countering the tool at the same time with the other hand.





11. If the puller is not available, lever the bearing cover out carefully using two screwdrivers (or angle screwdrivers), for example. Move the bearing cover frequently to the left and right to make the levering easier. Do not damage the sealing surfaces.