Variable Valve Timing Cover / Housing: Service and Repair

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)

Removing

• Engine removed, transmission separated from flange

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

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

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

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





- Remove the bolts - 3 -.

- Pry the control housing cover - 1 - from the cylinder block - 2 - or upper oil pan - 3 - at the locations indicated on the top and bottom using a suitable screwdriver - A -.





Start in the area of the alignment bushings - arrows -.

• Make sure the sealing surfaces are not damaged.

- Drive out the seal with the control housing cover removed.

Installing

CAUTION!
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.

CAUTION!
Make sure that no sealant residue enters the engine.

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

- Replace the seal - 1 and 2 -.





- Cut the tube nozzle at the front marking (nozzle diameter approximately 1 mm).





• The control housing cover must be installed within 5 minutes after application of 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 - arrow -.

- Install the control housing cover so that the alignment bushings engage in the bores in the cylinder block.

- Install all bolts hand tight.

- First tighten all the bolts - 3 - in the cylinder block and in the upper oil pan to 10 Nm.





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

- Wipe off any sealant, which has leaked out.

- Drive the alignment sleeves in until seated, if necessary.

- Install a new seal. Refer to => [ Control Housing Cover Seal ] 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 => [ Brake Booster Vacuum Pump ] Brake Booster Vacuum Pump.

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

• Install the flywheel/drive plate. Refer to => [ Drive Plate ] Drive Plate.

• Remove the (T40069) from the rear of the cylinder block and install the locking bolt.

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

Tightening Specification