Lower Timing Chain Cover, Removing And Installing: Installing

Fig 1: Chamfer Alignment Bushing With File

Courtesy of AUDI OF AMERICA, LLC

-- 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 Sealing Surfaces

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-- 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

-- 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.

Fig 4: Bending Cylinder Head Gasket Ends Down

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NOTE:

Note the expiration date of the sealing compound.

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

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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 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: Applying Sealant Beads (Version 1)

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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.

• 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 -2- 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.

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

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

Installation is performed in reverse order of removal, while noting the following:

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

-- Install the starter and the generator, refer to STARTER, REMOVING AND INSTALLING, VEHICLES WITH 3.0L TFSI AND 3.2L FSI ENGINE and 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 upper coolant pipe, refer to UPPER COOLANT PIPE, REMOVING AND INSTALLING .

-- 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 .

-- Fill the engine oil and check the oil level, refer to => 817.