Lower Timing Chain Cover, Removing And Installing: Installing

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Install in the reverse order of removal while noting the following:

• Replace bolts that were tightened with an additional turn after removing them.
• Both alignment sleeves must be present.

-- Remove the right upper alignment sleeve from the cylinder block.

-- Grind the alignment sleeve as shown using a file.

• Dimension -x- = 6.5 mm.
• Dimension -y- = 8 mm.

-- Insert the alignment sleeve in the cylinder block so that the angled side faces upward. (Because of the chamfer, it is easier to position the lower timing chain cover when the cylinder head is installed.)

• To prevent contamination of the lubricating system with sealant residue, place a clean cloth over the open part of the oil pan.
  Fig 1: Cleaning Sealing Surfaces

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-- Remove any sealant residue still on the lower timing chain cover -1-, cylinder block and cylinder head with a rotating plastic brush.

-- Clean any oil or grease off the sealing surfaces.

-- The old sealant cannot be removed from the groove -arrow- in the cylinder head gaskets. (In the cylinder head the groove is only halfway visible.)

Courtesy of AUDI OF AMERICA, LLC

Courtesy of AUDI OF AMERICA, LLC

• Replace the cylinder head gasket if kinked.

-- Bend the left and right cylinder head gasket -1- downward slightly -arrows- only until the upper sealing surface between the gasket and cylinder head can also be cleaned.

-- Clean any oil and grease off the upper and lower cylinder head seals.

• Be sure to check the expiration date of the sealant.
  Fig 2: Cut Tube Nozzle At Front Marking

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-- Cut the tube nozzle at the front marking (nozzle diameter: about 2.5 mm).

-- Apply a thin coat of sealant on the left and right sealing surfaces of the upper and lower cylinder head gaskets -1-. To do so, slightly bend the cylinder head gaskets downward again in direction of -arrows-.

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-- Use a flat object such as a feeler gauge to coat the surface between the cylinder head and gasket.

Courtesy of AUDI OF AMERICA, LLC

-- Apply sealant beads -1 and 2- on the clean sealing surfaces of the lower timing chain covers.

• Sealant bead thickness: 3.0 mm
• Install the timing chain cover within five minutes after applying the sealant.
• When positioning the lower timing chain cover pay attention that the cylinder head gasket is not damaged.

-- Place the lower timing chain cover at the same time guide the cover at an angle from below to the sealing surface on the cylinder block and cylinder head but do not press on with the sealant bead.

• The sealant must not get into the threaded holes.

-- Next install all bolts by hand and then tighten.

-- Remove the excess sealant from the transmission threaded connections.

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 rear coolant pipe 5. Refer to COOLANT PIPES, REMOVING AND INSTALLING .

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

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