Chain Case Cover, Removing and Installing

Chain case cover, removing and installing

Special tools, testers and auxiliary items required





^ Trim removal wedge 3409





^ Torque wrench V.A.G 1331
^ Hand drill with plastic brush attachment Protective glasses

CAUTION: When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
^ Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.
^ To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.

Removing
- Remove engine cover with air filter.
- Remove battery.





- Open cover - 1 - of E-box and remove wire - 2 -.
- Remove bolts - arrows - and remove battery holder from vehicle.

CAUTION: Hot steam may escape when opening expansion tank. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover the cap with a rag and open very carefully.

- Drain coolant.
- Remove intake manifold.
- Remove coolant pipe at coolant distribution housing and at bracket at vacuum pump.





- Remove retaining clip - arrow - and remove coolant pipe - A -.





- Separate connectors - 1 - and - 3 -.
- Disconnect pressure pipe - 2 - at Secondary Air Injection (AIR) valve.
- Remove rear coolant pipe - 4 -.
- Disconnect vacuum hose - 6 - from vacuum pump and connector - 7 -.
- Remove brackets - 8 - and - 9 - and set wiring harness with pressure pipe aside.
- Press bracket for knock sensor wiring harness at Secondary Air Injection (AIR) valve slightly toward rear.
- Remove coolant distribution housing - 5 - and set it aside with coolant hoses connected.
- Remove all bolts for chain case cover.





- Press off chain case cover - 1 - uniformly from cylinder head - 2 - at top and bottom recesses.

Note:
^ Sealing surfaces must not be damaged under any circumstances. If necessary, use trim removal wedge 3409.
^ After removing chain case cover, clean trim removal wedge 3409 which is intended for the removal of interior equipment parts.

Installing

CAUTION: To prevent injuries from shavings, wear protective goggles and protective clothing.

- Remove remainder of sealant from chain case cover and from cylinder head e.g. using a rotating plastic brush.

CAUTION: Make sure that no sealant residue enters the engine.

- Clean pipe connection on cylinder head. If necessary, remove coolant deposits using a copper wire brush or using fine sandpaper (minimum 100 grit).
- Replace sealing ring in chain case cover.
- Replace sealing ring in coolant distribution housing.
- Clean sealing surfaces so they are completely free of any oil or grease.





- Cut tube nozzle at front marking (jet dia. approximately 1 mm).

Note:
^ The chain case cover must be installed within 5 minutes after application of sealant.





- Apply sealant bead - A - as depicted on to clean sealing surface of chain case cover.

^ The sealant bead must be 1.5 to 2.0 mm thick.

- Coat sealing ring of chain case cover lightly with engine oil and slide chain case cover on to pipe connection.
- Install all bolts and tighten them in diagonal sequence.

The rest of installation follows reverse of removal procedures. Note the following:
- Fill with coolant.
- Install battery.

Tightening torques: