Timing Cover: Service and Repair

Chain Compartment Cover

Special tools, testers and auxiliary items required

• Trim Removal Wedge (3409)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Hand Drill with Plastic Brush Attachment

• Protective Eyewear

• Silicone Sealant (D 174 003 A2)

Note the following whenever working inside the engine compartment due to limited space:

• Route all lines and wires in their original locations.

• Ensure sufficient clearance to all moving or hot components.

Removing

- Remove the air filter with engine cover. Refer to => [ Air Filter and Engine Cover ] Air Filter and Engine Cover.

- Remove the intake hose - 4 - between the throttle valve control module (J338) and air filter. To do so, disconnect the hose - 1 -, if present, and the hose - 2 - (compress the securing ring) and remove the spring clamp - 3 -.






- Remove the battery and the battery tray.

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 coolant. Refer to => [ Draining and Filling ] Procedures.

- Remove the intake manifold. Refer to => [ Intake Manifold ] Intake Manifold.

- Remove the coolant pipe from the coolant thermostat housing and the bracket on the vacuum pump.

- Remove the clamp - arrow - and the coolant pipe - A -.






- Disconnect the connectors - 1 and 3 -.






- Disconnect the pressure pipe - 2 - from the Secondary Air Injection (AIR) valve.

- Remove the rear coolant pipe - 4 -.

- Remove the vacuum hose - 6 - from the vacuum pump and disconnect the connector - 7 -.

- Remove the brackets - 8 and 9 - and then move the wiring harness and pressure pipe to the side.

- Push the knock sensor wiring harness bracket on the AIR solenoid valve slightly to the rear.

- Disconnect the flange with seal - 5 - and move it to the side with the coolant hoses still connected.

- Remove the chain compartment cover bolts.

- Remove the chain compartment cover - 1 - from the cylinder head at the upper and lower holes - 2 -.






• The sealing surfaces must not be damaged under any circumstances. Use the trim removal wedge (3409).

• Clean the trim removal wedge (3409) after removing the chain compartment cover because it is meant to be used for removing parts from the interior of the vehicle.

Installing

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

- Remove any remaining sealant from the chain compartment cover and cylinder head with a plastic bush.

Make sure that no sealant residue gets into the engine.

- Clean the adapter (pipe connection) on the cylinder head. If necessary, remove any coolant deposits using a copper wire brush or fine sandpaper (minimum 100 grit). If the adapter (pipe connection) is worn, replace it using liquid locking fluid (D 000 600 A2).

- Replace the seal in the chain compartment cover. Refer to => [ Chain Compartment Cover Seal ] Service and Repair.

- Clean the sealing surfaces, they must be free of oil and grease.

- Cut the sealant tube nozzle at the front mark (nozzle diameter: approximately 1 mm).






• The chain compartment cover must be installed within 5 minutes of applying the sealant.

- Apply the sealant bead - A - onto the clean sealing surface of the chain compartment cover as shown.






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

- Coat the seal for the chain compartment cover lightly with engine oil and push the cover onto the adapter (pipe connection).

- Install and tighten all the bolts in a diagonal sequence.

The rest of the installation follows the reverse of the removal procedures. When doing this note the following:

- Fill the coolant. Refer to => [ Draining and Filling ] Procedures.

- Install the battery.

Tightening Specifications