Lower Timing Chain Cover, Removing And Installing: Installing

Fig 1: Chamfer Alignment Bushing With File

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

• Tightening specifications. Refer to Figure.

Install in reverse order of removal while noting the following:

-- 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.

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

Fig 2: Cleaning Remaining Sealant With Rotating Plastic Brush

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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

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-- Bend the end of the cylinder head gaskets down slightly in direction of -arrows- until the upper sealing surface of the gaskets and the cylinder head can be cleaned.

Fig 4: Bending Cylinder Head Gasket Ends Down

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

NOTE:

Be sure to check the expiration date of the sealant.

Fig 5: Cut Tube Nozzle At Front Marking

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-- Cut the tube nozzle at the front marking (nozzle diameter: about 2 mm).

-- Lightly the coat top and bottom cylinder head gasket sealing surfaces with sealant by bending the gaskets 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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-- Apply the sealant beads -1 through 4- on the clean lower timing chain cover sealing surfaces as shown in the illustration.

Fig 8: Applying Sealant Beads (Version 1)

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• 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.

-- 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 9: Identifying Lower Timing Chain Cover Bolt Loosening And Tightening Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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 starter. Refer to STARTER, VEHICLES WITH AUTOMATIC TRANSMISSION .

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

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

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