Control Housing Cover, Removing and Installing

Control housing cover, removing and installing

Special tools, testers and auxiliary items required





^ Torque wrench V.A.G 1331





^ Torque wrench V.A.G 1332
^ Hand drill with plastic brush attachment
^ Protective glasses

Removing
^ Engine removed, transmission disconnected from flange
- Remove chain case cover.
- Remove flywheel or drive plate and remove sensor wheel for Engine Speed (RPM) Sensor G28 from crankshaft.





- Remove upper bolts - arrows -.





- Disengage wiring harness - arrow - and remove Engine Speed (RPM) Sensor G28 - 1 - and vacuum pump - 2 -.
- Remove bolts - 3 -.





- Press off control housing cover - 1 - from cylinder block - 2 - or from upper section of oil pan - 3 - at the positions designated at top and bottom using a suitable screwdriver - A -.
- Start in area of alignment bushings - arrows -.

Note:
^ Make sure sealing surfaces are not damaged.

- Drive out sealing ring with control housing cover removed.
- Drive back alignment bushings (direction of transmission) far enough that they project approximately 4 mm on engine side. Do not damage sealing surfaces and contact surfaces of transmission when doing this.

Installing

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

- Remove remainder of sealant from cylinder block, upper section of oil pan and control housing cover e.g. using a rotating plastic brush.

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

- Clean sealing surfaces of cylinder block, upper section of oil pan and control housing cover, they must be free of oil and grease.

CAUTION: Cylinder head gasket must not be kinked. A kinked cylinder head gasket must be replaced.





- Slightly bend ends of cylinder head gasket - A - downward - arrows - only as far until upper sealing surface of cylinder head gasket and of cylinder head can be cleaned.
- Clean sealing surfaces of cylinder head and cylinder head gasket at top and bottom, they must be free of oil and grease.





- Replace sealing rings - 1 - and - 2 -.





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

CAUTION: Cylinder head gasket must not be kinked. A kinked cylinder head gasket must be replaced.





- Coat sealing surfaces of cylinder head gasket - A - at top and bottom thinly with sealant, to do so, slightly bend cylinder head gasket downward again.
- Use a flat object, e.g. a feeler gauge, to coat surfaces between cylinder head and gasket.

Note:The control housing cover must be installed within 5 minutes after application of sealant.





- Apply sealant bead - A - on to control housing cover as depicted.
^ The sealant bead must be 1.5 to 2.0 mm thick.
^ Pay special attention to course of sealant bead in area - arrow -.
- Attach control housing cover so that alignment bushings engage in bores in cylinder block. To do so, control housing cover must be pressed slightly upward.
- Install all bolts hand-tight.





- First tighten all bolts - 3 - in cylinder block and in upper section of oil pan to 10 Nm.





- Then tighten bolts in control housing cover - arrows - to 10 Nm.
- Finally tighten bolts in cylinder block and in upper section of oil pan to 25 Nm.
- Drive in alignment bushings until stop.
- Install a new sealing ring.

The rest of installation follows reverse of removal procedures. Note the following:
^ Installing drive plate.
^ Remove locking pin T40069 from cylinder block at rear and install screw plug.
^ Fill with coolant.

Tightening torques: