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

Courtesy of AUDI OF AMERICA, LLC

-- Remove any sealant residue still on the timing chain guard section -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

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 any oil and grease off the cylinder head seals.

NOTE:

Note the expiration date of the sealing compound.

Fig 5: Cutting 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).

-- 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 -1 Through 4-

Courtesy of AUDI OF AMERICA, LLC

-- 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.

Fig 9: Identifying Lower Timing Chain Cover Bolt, Tightening Sequence

Courtesy of AUDI OF AMERICA, LLC

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 left and right timing chain covers, refer to LEFT AND RIGHT TIMING CHAIN COVER, REMOVING AND INSTALLING .

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

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

-- Install the supercharger, refer to SUPERCHARGER, REMOVING AND INSTALLING .

-- Fill the engine oil and check the oil level, refer to appropriate FLUID CAPACITY information .