Lower Timing Chain Cover: Installing

WARNING: This page is about a different car, the 2010 Audi Q7, 2009 Audi Q7, 2008 Audi Q7, and 2007 Audi Q7. However, it is still accessible from the selected car via links, so may be relevant.

Tightening specifications, refer to Figure.

Installation is in reverse order of removal, note the following:

-- Pull alignment bushing out of top right of cylinder block.

-- Chamfer the alignment bushing with a file, as shown in the illustration.

Fig 1: Chamfer Alignment Bushing With File

Courtesy of AUDI OF AMERICA, LLC

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

-- Install the alignment bushing into the cylinder block so that the chamfered side faces upward.

NOTE:

The chamfer simplifies installation of the lower timing chain cover with cylinder head installed.

CAUTION:

Risk of contaminating lubricating system.

Cover open parts of engine.

WARNING:

Risk of eye injury.

Wear safety glasses.

-- Remove sealant residue in timing chain cover and cylinder block, for example with a rotating plastic brush.

Fig 2: Cleaning Remaining Sealant With Rotating Plastic Brush

Courtesy of AUDI OF AMERICA, LLC

-- Clean sealing surfaces so they are completely free of any oil or grease.

-- Clean the old sealant from the holes -arrow- in the cylinder head gaskets.

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

Courtesy of AUDI OF AMERICA, LLC

NOTE:

With the cylinder head installed only half of the holes in the cylinder head gasket are 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 gasket must be replaced.

-- Bend the ends of the cylinder head gaskets very slightly downward -arrows- until the upper sealing surface of the gasket and cylinder head can be cleaned.

Fig 4: Bending Cylinder Head Gasket Ends Down

Courtesy of AUDI OF AMERICA, LLC

-- Clean both cylinder head gaskets, top and bottom, so they are completely free of any oil or grease.

NOTE:

Note the expiration date of the sealing compound.

-- Cut tube nozzle at front marking (nozzle diameter approximately 2 mm).

Fig 5: Cut Tube Nozzle At Front Marking

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

The cylinder head seal could be damaged.

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

NOTE:

A kinked cylinder head gasket must be replaced.

-- Coat the sealing surfaces of the cylinder head gaskets, top and bottom, with a thin layer of sealant, slightly bending the cylinder head gaskets downward again -arrows- to do this.

Fig 6: Bending Cylinder Head Gasket Ends Down

Courtesy of AUDI OF AMERICA, LLC

-- To coat the surface between the cylinder head and gasket, use a flat object, for example a feeler gauge.

-- 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

CAUTION:

The lubrication system could be plugged with excess sealant.

Do not apply sealant beads thicker than indicated.

-- Apply sealant beads -1 to 9- on the clean sealing surfaces on the lower timing chain cover as illustrated.

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

Courtesy of AUDI OF AMERICA, LLC

Thickness of sealant beads: 2.5 mm.

NOTE:

Timing chain cover must be installed within 5 minutes of applying sealant.

-- Set the lower timing chain cover in place, guiding the cover at an angle from below onto the sealing surface of the cylinder block and cylinder head.

Fig 9: Identifying Bolts And Lower Timing Chain Cover

Courtesy of AUDI OF AMERICA, LLC

-- When installing, make sure that the cylinder head gaskets do not become damaged.

NOTE:

A damaged cylinder head seal must be replaced.

-- Tighten bolts. Refer to Figure.

The rest of the installation is in reverse order of removal, note the following:

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

-- Install oil filter housing. Refer to OIL FILTER HOUSING .

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

-- Install left and right timing chain covers Installing .

-- Install drive plate. Refer to DRIVE PLATE .