Control Housing Cover

Control Housing Cover

Special tools, testers and auxiliary items required

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

• Torque Wrench (40-200 Nm) (V.A.G 1332)

• Hand Drill with Plastic Brush Attachment

• Protective Eyewear

• Silicone Sealant (D 174 003 A2)

When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

• Route lines of all types (for example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and 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

• The engine is removed, and the transmission is separated from the flange.

- Remove the timing chain cover. Refer to => [ Chain Compartment Cover ] Service and Repair.

- Remove the flywheel or drive plate and then remove the sensor wheel for the engine speed sensor (G28) from the crankshaft.

- Remove the cylinder head. Refer to => [ Cylinder Head ] Cylinder Head.

- Disengage the wiring harness - arrow - and remove the engine speed sensor - 1 - and the vacuum pump - 2 -.






- Remove the bolt - 3 -.

- Remove the control housing cover - 1 - from the cylinder block - 2 - and from the lower oil pan - 3 - at the upper and lower marked locations using a screwdriver - A -.






Start near the alignment sleeves - arrows -.

• Be careful not to damage the sealing surfaces.

- Remove the seal from the removed control housing cover.

Installing

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

- Remove the sealant residue from the cylinder block, upper oil pan and control housing cover using a rotating plastic brush.

Make sure that no sealant residue gets into the engine.

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

- Replace the seals - 1 and 2 -.






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






• The control housing cover must be installed within 5 minutes after application of the sealant.

- Apply the sealant bead - A - onto the control housing cover as shown.






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

• Pay special attention to the course of the sealant bead in the area of the - arrow -.

- Install the control housing cover so that the alignment sleeve fit into the holes in the cylinder block.

- Install the bolts hand tight.

- Install the bolts - 3 - to the cylinder block and the upper oil pan and tighten them to 10 Nm.






- Tighten the bolts to the cylinder block and upper oil pan to 25 Nm.

- Wipe off any sealant that leaks out.

- Install the alignment sleeves all the way in.

- Install a new seal. Refer to => [ Crankshaft Seal, Transmission Side ] Service and Repair.

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

• Install the brake booster vacuum pump. Refer to => [ Vacuum Pump ] Service and Repair.

• Install the cylinder head. Refer to => [ Cylinder Head ] Cylinder Head.

• Install the drive plate or flywheel.

• Remove the locking pin (T40069) from the cylinder block and install the plug.

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

Tightening Specifications