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)
CAUTION!
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• Route all lines and wires in their original locations.
• Make sure there is enough clearance to moving or hot components to prevent damage to the lines.
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 battery tray bolts - arrows - and remove the battery holder from the vehicle.
CAUTION!
Hot steam may escape when opening expansion tank. 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 ] Draining and Filling.
- Remove the intake manifold. Refer to => [ Intake Manifold ] Intake Manifold.
- Remove the coolant pipe at the coolant distribution housing and the vacuum pump bracket.
- Pull out the retaining clip - arrow - and remove 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 -.
- Disconnect the vacuum hose - 6 - from the vacuum pump and disconnect the connector - 7 -.
- Remove 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 rear.
- Remove the coolant distribution housing - 5 - and set it aside with the coolant hoses connected.
- Remove all bolts for the 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 the (3409).
• After removing the chain compartment cover, clean the (3409 ) which is intended for the removal of interior 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 using a rotating plastic brush.
CAUTION!
Make sure that no sealant residue enters the engine.
- Clean the coolant connection - item 1 -=> [ Coolant Connection ] Cooling System Components, Engine Side on the cylinder head. If necessary, remove coolant deposits with a copper wire brush or fine sandpaper (minimum 100 grit). If the connection is worn, replace it using locking fluid (D 000600 A2).
- Replace the chain compartment cover seal. Refer to => [ Chain Compartment Cover Seal ] Chain Compartment Cover Seal.
- Replace the seal for 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 mark (nozzle diameter approximately 1 mm).
• The chain compartment cover must be installed within 5 minutes after application of sealant.
- Apply the sealant bead - A - as shown onto the clean sealing surface of chain compartment cover.
• The sealant bead must be 1.5 to 2.0 mm thick.
- Coat the chain compartment cover seal lightly with engine oil and slide the cover onto the coolant 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 with coolant. Refer to => [ Draining and Filling ] Draining and Filling.
- Install the battery.
Tightening Specification
