Lower Timing Chain Cover, Removing And Installing: Installing

Fig 1: Locating Alignment Sleeves

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• Replace seals, sealing rings and o-rings after removing.

-- Drive back the alignment sleeves -arrows- into the lower timing chain cover, until they no longer project over the sealing surface.

Fig 2: Cleaning Sealing Surfaces

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-- Clean the sealant residue on the lower timing chain cover -1-, cylinder block and oil pan upper section using a corresponding brush from the Cleaning Set for Sealing Surfaces :VAS 294 019  .

• Brush:VAS 294 019/1  for gray cast-iron surfaces
• Brush:VAS 294 019/2  for aluminum surfaces
• Brush:VAS 294 019/3  for painted surfaces

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

Fig 3: Identifying Cylinder Head Gasket Protrusion

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• A kinked cylinder head gasket must be replaced.

-- Bend the end of the cylinder head gasket downward slightly -arrows- only until the upper sealing surface of the gasket and cylinder head can also be cleaned.

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

• Be sure to check the expiration date of the sealant.
  Fig 4: 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 sealing surface of the upper and lower cylinder head gaskets. To do so, slightly bend the cylinder head gasket downward again -arrows-.

Fig 5: Identifying Cylinder Head Gasket Protrusion

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

-- Apply a thin sealant bead on the edge between the cylinder block and cylinder head gasket and cylinder head gasket -arrow-.

Fig 6: Identifying Cylinder Head Gasket Holes

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-- Insert the sealing sleeve -1- and O-ring -2-.

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-- Apply a sealant bead -arrow- to the clean sealing surface of the lower timing chain cover.

• Sealant bead thickness: 3.0 mm
• It is necessary to install the lower timing chain cover within five minutes after applying the sealant.

• The sealing sleeve must project the dimension -a- out of the contour of the lower timing chain cover.

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• Dimension -a- = minimum 0.6 mm.

-- Position the lower timing chain cover, guiding it at an angle from below to the sealing surface on the cylinder block and cylinder head.

-- When positioning, make sure that the cylinder head gasket is not damaged.

-- First insert the lower timing chain cover screws by hand all the way.

-- Drive the alignment sleeves from the respective lower timing chain cover all the way into the cylinder block.

-- Tighten the bolts for the lower timing chain cover.

-- After installing apply a sealant bead -arrow- from the top inward in the inner seam on the cylinder head gasket.

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Install in reverse order of removal. Note the following:

-- Install the Engine Speed Sensor -G28-.Refer to Engine Speed Sensor -G28-, REMOVING AND INSTALLING .

-- A3 2021: install the brake booster vacuum pump. Refer to Vacuum Pump, Removing and Installing .

-- All other models: install the brake booster vacuum pump. Refer to Vacuum Pump, Removing and Installing .

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

-- Bring the Engine Support Plate:T40299  into the installation position and tighten, and slightly tension the Engine Support Bridge - Spindle:10-222A/11  front left of the Extractor.

-- Install the crankshaft seal on the transmission side. Refer to UPPER TIMING CHAIN COVER SEAL, REPLACING .

-- Install the flywheel. Refer to FLYWHEEL, REMOVING AND INSTALLING .