Lower Timing Chain Cover, Removing And Installing: Installing

WARNING: This page is about a different car, the 2012 Audi S5, 2011 Audi S5, 2010 Audi S5, 2009 Audi S5, and 2008 Audi S5. 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 The M6 Bolts.

-- 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.

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 Lower Timing Chain Cover And On The Cylinder Block And Cylinder Head, For Example With A Rotating Plastic Brush.

Fig 2: Cleaning Remaining Sealant With Rotating Plastic Brush

Courtesy of AUDI OF AMERICA, LLC

-- 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.

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.

Fig 4: Bending Cylinder Head Gasket Ends Down

Courtesy of AUDI OF AMERICA, LLC

-- 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.

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

Fig 5: Cut Tube Nozzle At Front Marking

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 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 On Clean Sealing Surfaces Of Lower Timing Chain Cover

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

Thickness of sealant beads: 2.5 mm.

NOTE:

The Timing Chains Cover Must Be Installed Within 5 Minutes After Applying The Sealant

-- 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 Bolts

Courtesy of AUDI OF AMERICA, LLC

-- 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 .

-- Installing the lower left coolant pipe. Refer to LOWER LEFT COOLANT PIPE, REMOVING AND INSTALLING .

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

-- Install the intake manifold. Refer to INTAKE MANIFOLD, REMOVING AND INSTALLING .

-- Install the timing chain covers. Refer to LEFT TIMING CHAIN COVER, REMOVING AND INSTALLING . Refer to RIGHT TIMING CHAIN COVER, REMOVING AND INSTALLING .

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