Timing Cover: Service and Repair
Chain Compartment Cover
Special tools, testers and auxiliary items required
• Trim removal wedge (3409)
• Torque wrench 5-50 Nm (VAG 1331)
• Hand drill with plastic brush attachment
• Protective eyewear
• Silicone sealant (D 174 003 A2)
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. fuel, hydraulic, Evaporative Emission (EVAP) , coolant, refrigerant, brake or vacuum) and electrical wires 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 the engine cover with air filter. Refer to --> [ Engine Cover with Air Filter ] Engine Cover with Air Filter.
- Remove the battery..
- Open the cover - 1 - for the E-box and remove the wire - 2 -.
- Remove the bolts - arrows - and remove the battery holder from the vehicle.
CAUTION!
Hot steam may escape when opening the expansion tank cap. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover the cap with a cloth and open very carefully.
- Drain the cooling system. Refer to --> [ Draining and Filling ] [1][2]Cooling System, Draining and Filling.
- Remove the intake manifold. Refer to --> [ Intake Manifold ] Intake Manifold.
- Remove the coolant pipe from the coolant distribution housing and the bracket for the vacuum pump.
- Remove the retaining clip - arrow - and remove the coolant pipe - A -.
- Disconnect the electrical connectors - 1 - and - 3 -.
- Disconnect the pressure pipe - 2 - from the Secondary Air Injection (AIR) valve.
- Remove the rear coolant pipe - 4 -.
- Disconnect the vacuum hose - 6 - from the vacuum pump and disconnect electrical connector - 7 -.
- Remove the bolts for brackets - 8 - and - 9 - and set the wiring harness with pressure pipe aside.
- Press the bracket for the knock sensor wiring harness at the AIR valve slightly toward the rear.
- Remove the coolant distribution housing - 5 - and set it aside with the coolant hoses connected.
- Remove all the bolts for chain compartment cover.
- Pry off the chain compartment cover - 1 - uniformly from the cylinder head - 2 - at the top and bottom recesses.
• Sealing surfaces must not be damaged under any circumstances. If necessary, use (3409).
• After removing the chain compartment cover, clean the (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 the remainder of sealant from the chain compartment cover and from the cylinder head e.g. using a rotating plastic brush.
CAUTION!
Make sure that no sealant residue enters the engine.
- Clean the pipe connection on the cylinder head. If necessary, remove coolant deposits with a copper wire brush or fine sandpaper (minimum 100 grit). If the pipe connection is worn, replace it using locking fluid (D 000600 A2).
- Replace the seal in the chain compartment cover. Refer to --> [ Chain Compartment Cover Seal ] Service and Repair.
- Replace the seal in the coolant distribution housing.
- Clean the sealing surfaces so they are completely free of any oil or grease.
- Cut the tube nozzle at the front marking (diameter of nozzle approximately 1 mm).
• The chain compartment cover must be installed within 5 minutes after application of sealant.
- Apply the sealant bead - A - as shown on to a clean sealing surface on the chain compartment cover.
• The sealant bead must be 1.5 to 2.0 mm thick.
- Coat the seal in the chain compartment cover lightly with engine oil and slide the chain compartment cover onto the pipe connection.
- Install all bolts and tighten them in a diagonal sequence.
The rest of the installation follows the reverse of the removal procedures. When doing this note the following:
- Fill the cooling system. Refer to --> [ Draining and Filling ] [1][2]Cooling System, Draining and Filling.
- Install the battery..
Tightening Specifications
