Lower Timing Chain Cover, Removing And Installing: Installing

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Fig 1: Grinding Alignment Bushing Down At An Angle

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Replace seals, gaskets and O-rings.

-- 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 Sealing Surfaces

Courtesy of AUDI OF AMERICA, LLC

WARNING:

Danger of eye injury.

Wear protective eyewear.

-- Remove the sealant residue on the cover for the timing chain, cylinder block and cylinder head, for example using a rotating plastic brush.

-- Clean any oil or grease off the sealing surfaces.

-- 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.

Fig 4: Bending Cylinder Head Gasket Ends Down

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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 any oil and grease off the cylinder head seals.

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 (Nozzle Diameter Approx. 1 Mm)

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NOTE:

The sealant must be applied to several places on the engine, as described in the following.

-- Lightly coat the 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

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-- 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

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NOTE:

Depending on the version, there may be a second sleeve -2- between the sealing flange and cylinder block on the left side of the engine .

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.

Lower Timing Chain Cover Version 1

Fig 9: Applying Sealant Beads (Version 1)

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 the sealant beads -1 through 4- on the clean lower timing chain cover sealing surfaces as shown in the illustration (See Fig 9).

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:

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

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

Lower Timing Chain Cover Version 2:

Fig 10: Applying Sealant Beads (Version 2)

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 the sealant beads -1 through 4- on the clean lower timing chain cover sealing surfaces as shown in the illustration (See Fig 10).

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.

Continuation for All Versions

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

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

-- Tighten the bolts for the lower timing chain cover. Refer to Figure.

Fig 11: Lower Timing Chain Cover Bolts

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Install in reverse order of removal. Note the following:

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

-- Install the generator. Refer to GENERATOR, REMOVING AND INSTALLING, Vehicles with 3.0L TFSI and 3.2L FSI Engine .

-- Install the starter. Refer to STARTER, REMOVING AND INSTALLING, Vehicles with 3.0L TFSI and 3.2L FSI Engine .

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

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

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

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

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

-- Fill with engine oil and check the level. Refer to the appropriate "FLUID CAPACITY TABLES" information.