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 (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

- Remove the engine cover.

- Remove the battery.

- Remove the battery holder 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 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 thermostat housing and vacuum pump bracket.

- Remove the retaining clip - arrow - and remove the coolant pipe - A -.





- Disconnect 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 the 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 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 on the cylinder head, see - item 1 - in => [ Coolant Connection ] Cooling System Components, Engine Side. 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 seal in the chain compartment cover. Refer to => [ Chain Compartment Cover Seal ] Service and Repair.

- Replace the seal in the coolant thermostat 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 millimeter (mm)).





• The chain compartment cover must be installed within 5 minutes after application of sealant.

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





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

- Coat the seal of the chain compartment cover lightly with engine oil and slide the chain compartment cover onto the coolant 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:

• Install the battery.

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

Tightening Specifications