Lower Timing Chain Cover, Removing And Installing: Installing

Install in reverse order of removal. Note the following:

NOTE: Replace any bolts that were tightened with an additional turn.

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

Fig 1: Chamfer Alignment Bushing With File

Courtesy of AUDI OF AMERICA, LLC

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

Dimension -x- = 6.5 mm (0.256 in.)
Dimension -y- = 8 mm. (0.314 in.)

-- 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 any sealant residue still on the lower timing chain cover -1-, cylinder block and cylinder head with 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.

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 upper and lower cylinder head seals.

Fig 4: Bending Cylinder Head Gasket Ends Down

Courtesy of AUDI OF AMERICA, LLC

NOTE: Note the expiration date of the sealing compound.

-- Cut the tube nozzle at the front marking (nozzle diameter: about 2.5 mm 0.098 in.)).

Fig 5: Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 1 Mm)

Courtesy of AUDI OF AMERICA, LLC

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

CAUTION:

The lubrication system could be plugged with excess sealant.

Do not apply sealant bead thicker than indicated.

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

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

Sealant bead thickness: 2.0 mm (0.078 in.)

Fig 8: Identifying Lower Timing Chain Cover Sealing Surfaces
Courtesy of AUDI OF AMERICA, LLC

-- 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, refer to Figure.

The rest of the installation is performed in reverse order of removal, noting 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 OVERVIEW - COOLANT PIPES .

-- Install the timing chain cover, refer to TIMING CHAIN COVER, REMOVING AND INSTALLING .

-- Install the Engine Coolant Circulation Pump 2 -V178-, refer to ENGINE COOLANT CIRCULATION PUMP 2 -V178-, REMOVING AND INSTALLING .

-- Install the upper rear coolant pipe, refer to UPPER REAR COOLANT PIPE, REMOVING AND INSTALLING .

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