Lower Timing Chain Cover, Removing And Installing: Installing

WARNING: This page is about a different car, the 2009 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Chamfer Alignment Bushing With File

Courtesy of AUDI OF AMERICA, LLC

Tightening specifications. Refer to Figure.

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.

Fig 2: Cleaning Sealing Surfaces

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

Risk of contaminating the lubricating system.

Cover open parts of engine.

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 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.

Fig 4: Bending Cylinder Head Gasket Ends Down

Courtesy of AUDI OF AMERICA, LLC

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 -arrows- until the upper sealing surface of the seals and the cylinder head can be cleaned.

-- Clean the top and bottom of the cylinder head seals so they are free of oil and grease.

NOTE:

Note the expiration date of the sealing compound.

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

Courtesy of AUDI OF AMERICA, LLC

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

NOTE:

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

-- 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

Fig 8: 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.

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.
The sealant bead -2- must be drawn through as shown in the illustration even though the groove is intermittent.

NOTE:

The sealant only needs to cure for approximately 5 minutes after applying.

-- 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.

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

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

Fig 9: Identifying Lower Timing Chain Cover Bolt Loosening Sequence

Courtesy of AUDI OF AMERICA, LLC

Install in reverse order of removal. Note the following:

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

-- Install the generator. Refer to GENERATOR, 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 left and right timing chain covers. Refer to INSTALLING .

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

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

-- Fill the engine oil and check the oil level. Refer to ENGINE OIL, CHECKING LEVEL .