Lower Timing Chain Cover, Removing And Installing: Installing

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.

-- 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.

Fig 2: Cleaning Remaining Sealant With Rotating Plastic Brush

Courtesy of AUDI OF AMERICA, LLC

-- 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

Fig 4: Bending Cylinder Head Gasket Ends Down

Courtesy of AUDI OF AMERICA, LLC

-- 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.

NOTE:

Note The Expiration Date Of The Sealing Compound.

Fig 5: Cut Tube Nozzle At Front Marking

Courtesy of AUDI OF AMERICA, LLC

-- Cut The Tube Nozzle At The Front Marking (Nozzle Diameter: About 2 mm).

-- 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: Identifying Sealant Beads -1 Through 9- On Clean Lower Timing Chain Cover Sealing Surface

Courtesy of AUDI OF AMERICA, LLC

-- 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.

-- 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 .

-- Install The Oil Filter Housing. Refer To OIL FILTER HOUSING, REMOVING AND INSTALLING .

-- Install The Timing Chain Covers. Refer To LEFT TIMING CHAIN COVER, REMOVING AND INSTALLING , RIGHT TIMING CHAIN COVER, REMOVING AND INSTALLING .

-- Install The Drive Plate. Refer To DRIVE PLATE, REMOVING AND INSTALLING .