Lower Timing Chain Cover, Removing And Installing: Installing

Fig 1: Chamfer Alignment Bushing With File

Courtesy of AUDI OF AMERICA, LLC

Tightening Specifications. Refer to Figure.

NOTE:

Replace The M6 Bolts.

-- Remove the right upper alignment bushing from the cylinder block.

-- Grind the alignment bushing down at an angle as shown in the illustration.

Dimension -x- = 6.5 mm.
Dimension -y- = 8 mm.

-- Insert the alignment bushing in the cylinder block so the angled side faces up.

NOTE:

Because Of The Chamfer, The Lower Timing Chain Cover Can Be Positioned More Easily When The Cylinder Head Is Installed.

CAUTION:

Risk Of Contaminating The Lubricating System.

Cover open parts of engine.

WARNING:

Danger Of Eye Injury.

Wear protective eyewear.

-- Remove The Sealant Residue On The Lower Timing Chain Cover And On The Cylinder Block And Cylinder Head, For Example With A Rotating Plastic Brush.

Fig 2: Cleaning Remaining Sealant With Rotating Plastic Brush

Courtesy of AUDI OF AMERICA, LLC

-- Clean the sealing surfaces. They must be free of oil and grease.

-- Clean the threaded holes in the cylinder block for connecting the engine and transmission using a thread tap before installing the transmission.

-- Clean old sealant out of the holes -arrow- in the cylinder head seals.

Fig 3: Cleaning Old Sealant From Holes In Cylinder Head Gaskets

Courtesy of AUDI OF AMERICA, LLC

NOTE:

With Cylinder Head Installed, Holes In Cylinder Head Seal Are Only Half Visible.

CAUTION:

The Cylinder Head Seal Could Be Damaged.

Only bend ends of cylinder head seals slightly, do not kink.

NOTE:

A Kinked Cylinder Head Seal Must Be Replaced.

-- Bend the end of the cylinder head seals down slightly in direction of -arrows- until the upper sealing surface of the seals and the cylinder head can be cleaned.

Fig 4: Bending Cylinder Head Gasket Ends Down

Courtesy of AUDI OF AMERICA, LLC

-- Clean the top and bottom of the cylinder head seals so they are free of oil and grease.

NOTE:

Note The Expiration Date Of The Sealing Compound.

-- Cut the tube nozzle at the front marking (nozzle diameter: about 2 mm).

Fig 5: Cut Tube Nozzle At Front Marking

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-- Lightly the coat top and bottom cylinder head seal sealing surfaces with lubricant by bending the seals down slightly again in direction of -arrows-.

Fig 6: Bending Cylinder Head Gasket Ends Down

Courtesy of AUDI OF AMERICA, LLC

-- Use a flat object such as a feeler gauge to coat the surface between the cylinder head and seal.

-- Fill the cleaned cylinder head seal holes -arrow- with sealant.

Fig 7: Cleaning Old Sealant From Holes In Cylinder Head Gaskets

Courtesy of AUDI OF AMERICA, LLC

Fig 8: Applying Sealant Beads On Clean Sealing Surfaces Of Lower Timing Chain Cover

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

The Lubrication System Could Be Plugged With Excess Sealant.

Do not apply sealant bead thicker than indicated.

-- Apply sealant beads -1 through 9- on the clean lower timing chain cover sealing surfaces as shown in the illustration.

Thickness of sealant beads: 2.5 mm.

NOTE:

The Timing Chains Cover Must Be Installed Within 5 Minutes After Applying The Sealant

-- Position the lower timing chain cover, guiding it diagonally from below to the sealing surface on the cylinder block and cylinder head.

Fig 9: Identifying Lower Timing Chain Cover Bolts

Courtesy of AUDI OF AMERICA, LLC

-- When positioning, ensure the cylinder head seals are not damaged.

-- Tighten the bolts. Refer to Figure.

Install in reverse order of removal. Note The Following:

-- Install the crankshaft seal on the transmission side. Refer to CRANKSHAFT SEAL, REPLACING, TRANSMISSION SIDE .

-- Installing the lower left coolant pipe. Refer to LOWER LEFT COOLANT PIPE, REMOVING AND INSTALLING .

-- Install the oil filter housing. Refer to OIL FILTER HOUSING, REMOVING AND INSTALLING .

-- Install the intake manifold. Refer to INTAKE MANIFOLD, REMOVING AND INSTALLING .

-- Install the timing chain covers. Refer to LEFT TIMING CHAIN COVER, REMOVING AND INSTALLING . Refer to RIGHT TIMING CHAIN COVER, REMOVING AND INSTALLING .

-- Install the drive plate. Refer to DRIVE PLATE, REMOVING AND INSTALLING .