Lower Timing Chain Cover, Removing And Installing: Installing

WARNING: This page is about a different variant/trim than selected.

Fig 1: Chamfer Alignment Bushing With File

Courtesy of AUDI OF AMERICA, LLC

Install in reverse order of removal. Note the following:

Tightening specifications. Refer to Figure.

NOTE:

Replace any bolts that were tightened with an additional turn.

-- 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.

Fig 2: Cleaning Remaining Sealant With Rotating Plastic Brush

Courtesy of AUDI OF AMERICA, LLC

WARNING:

Danger of eye injury.

Wear protective eyewear.

-- Remove any sealant residue still on the timing chain guard lower section, cylinder block and cylinder head with a rotating plastic brush.

-- 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.

-- Clean the upper and lower cylinder head gaskets; they must free from oil and grease.

Fig 4: Bending Cylinder Head Gasket Ends Down

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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

NOTE:

Refer to Installing .

Fig 8: Identifying Second Sleeve

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CAUTION:

There is a risk of sealant entering the hole for connecting the transmission.

Before positioning the lower timing chain cover, a sleeve -1- must be installed.
The sleeve should extend -a- = 3 mm above the sealing surface.

NOTE:

Do not replace the sleeve -1- with sleeve -2-. The diameter of the sleeves is different.

CAUTION:

The lubrication system could be plugged with excess sealant.

Do not apply sealant beads thicker than indicated.

-- Apply sealant beads -1 through 4- on the clean lower timing chain cover sealing surfaces as shown in the illustration.

Fig 9: Applying Sealant Beads (Version 2)

Courtesy of AUDI OF AMERICA, LLC

The groove of sealing surface must be completely filled with sealant.
The sealant beads must be 1.5 to 2.0 mm above the sealing surface.
Draw through the sealant bead -3- as illustrated, even though the groove is intermittent.

NOTE:

The timing chains cover must be installed within 5 minutes after applying the sealant

-- Insert the seals -arrows- in the grooves on the lower timing chain cover.

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

Fig 10: Identifying Lower Timing Chain Cover Bolt Loosening And Tightening Sequence

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, REMOVING AND INSTALLING, TRANSMISSION SIDE .

-- Install the left and right timing chain guards. Refer to LEFT AND RIGHT TIMING CHAIN COVER, REMOVING AND INSTALLING .

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

-- Install the upper coolant pipe. Refer to UPPER COOLANT PIPE, REMOVING AND INSTALLING .

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

-- Install the compressor. Refer to SUPERCHARGER, REMOVING AND INSTALLING .

-- Fill the engine oil and check the oil level. Refer to Maintenance, Diagnosis .