Lower Timing Chain Cover, Removing and Installing, Passat and Passat CC
Lower Timing Chain Cover, Removing and Installing, Passat and Passat CC
Special tools, testers and auxiliary items required
• Engine support bridge (10 - 222 A)
• Shackle (10 - 222 A /12)
• Drift (T10060 A)
• Counter-holder tool (T10355)
• Pressure piece (T10368)
• Bits (T10099)
• Passat: Frame (10 - 222 A /1)
Special tools, testers and auxiliary items required
• Passat CC: Adapter (10 - 222 A /8)
Removing
Proceed as follows:
- Remove the noise insulation => Body Exterior 50 Noise Insulation.
- Remove the front part of the right wheel housing liner => Body, Exterior 66 Wheel Housing Liner.
- Drain engine oil.
Vehicles with auxiliary heater:
- Loosen the clamp - 1 - and remove the bolt - 2 -.
- Remove the auxiliary heater muffler.
All:
- Remove bolts - arrows -.
- Remove the air guide pipe by lifting the clamps - items 1 and 2 -.
CAUTION!
Risk of destroying due to reversed running direction on a used ribbed belt.
• Before removing ribbed belt, marking running direction with chalk or felt-tip pen for reinstallation later.
- Remove the right air guide hose - arrows -.
- To release the tension on the ribbed belt, turn the tensioner in - direction of arrow - from underneath.
- Secure tensioner with Drift (T10060 A).
- Remove ribbed belt from vibration damper ribbed belt pulley.
- Rotate the vibration damper using the Counter Hold Tool (T10355) into the "OT" position - arrow -.
• The notch on the vibration damper must line up with the arrow marking on the timing chain lower cover.
CAUTION!
The engine could be destroyed.
• In order not to change the valve timing, the crankshaft must not be moved out of the "OT" position when the vibration damper bolt is removed.
- Remove vibration damper bolt using Counterhold (T10355).
- Remove the vibration damper.
CAUTION!
To avoid damaging the splines, only use Thrust Piece (T10368) to install the vibration damper bolt.
- Install the vibration damper bolt and thrust piece (T10368) again.
- Mount the Engine Support Bridge (10 - 222 A) using the following tools:
Passat:
• Frame (10 - 222 A /1)
• Hook (10 - 222 A /10)
• Shackle (10 - 222 A /12)
Passat CC:
• Adapter (10 - 222 A /8)
• Hook (10 - 222 A /10)
• Shackle (10 - 222 A /12)
• Do not place the adapter (10 - 222 A /8) on the fender panels. They will be damaged.
• The shackle (10 - 222 A /12) is needed to make sure the engine is lifted in the installation position and not tipped away.
All:
- Tension the engine with the spindle.
- Remove the subframe bolts - arrows - on the engine.
- Remove the engine bracket => [ Subframe Mount, Rabbit, Eos, Passat and Scirocco, Assembly Overview ] Subframe Mount, Rabbit, Eos, Passat and Scirocco, Assembly Overview.
- Lift the engine approx. 50 mm and loosen the upper bolt for the engine support.
- Now lower the engine approx. 100 mm.
- Free up electrical wiring harness - arrow -.
- Remove the bolt - 1 - and remove the ribbed belt tensioner from the accessory assembly bracket.
- Remove the lower bolts for the engine support using Bits (T10099).
- Remove the engine support and the bolts.
- Remove the bolts - 1 - and pull the oil dipstick guide tube out of the lower timing chain cover.
- Disconnect the Wastegate Bypass Regulator Valve (N75) from the turbocharger- arrows -.
- Remove the turbocharger support - 1 -.
- Remove the bolts - 1 through 15 -.
CAUTION!
The lower timing chain cover could be damaged. To avoid deformation, do not hold between the bolting points.
- Pry off the lower timing chain cover; when doing this, begin at - 1 and 2 -.
Installing
• Tightening specifications => [ Timing Chain Covers, Assembly Overview ] Timing Chain Covers, Assembly Overview
• Sealant: Silicone sealant (D 174 003 A3)
• Note the expiration date of the silicone sealant.
• The cover must be installed within 5 minutes after application of silicone sealant.
• Replace bolts which have been tightened to torque.
• Replace sealing rings, seals and self-locking nuts.
- Remove any sealant residue on the engine block using the flat blade scraper.
CAUTION!
Wear safety glasses.
- Seal off both side of the seal with tape to prevent soiling
- Remove residual sealant on the cover e.g. with a rotating plastic brush.
- Clean sealing surfaces, must be free of oil and grease.
- Install the cover using the old bolts and tighten to 8 Nm.
- Check between the cover and housing using a feel gauge; the gap must not exceed 0.2 mm.
• If the gap exceed 0.2 mm, replace the cover.
• It is not possible to measure between the cover the upper part of the oil pan, however check the sealing surface for evenness.
- Make sure both alignment bushings for centering the cover - arrows - are present.
- Cut tube nozzle at front marking (dia. of nozzle approximately 3 mm).
- Apply the silicone sealant (D 174 003 A3) on the clean sealing surface of the cover as shown in the illustration.
• Thickness of sealant bead: 2 to 3 mm.
• The cover must be installed within 5 minutes after application of silicone sealant.
• The sealant bead may not be thicker than specified, otherwise excess sealant could enter the oil pan and clog the oil intake tube.
- Install the lid immediately and all the bolts.
- Tighten the bolts - 1 through 15 - in 2 stages in the sequence shown:
- 1. Tighten the bolts to 8 Nm
- 2. Tighten the bolts an additional 90°.
• After installing cover, allow sealant to dry for approximately 30 minutes. Only after then may the engine oil be replenished.
- Fill the engine oil.
- Check oil level.
The rest of the assembly is basically a reverse of the disassembling sequence.