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 is disconnected from the flange.

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

- Remove the flywheel or drive plate and 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 vacuum pump - 2 -.






- Remove the bolts - 3 -.

- Pry off the control housing cover - 1 - from the cylinder block - 2 - and from the upper oil pan - 3 - at the positions designated at the top and bottom using a suitable screwdriver - A -.






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

• Make sure the sealing surfaces are not damaged.

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

Installing


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

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


Make sure that no sealant residue enters 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 - arrow -.

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

- Install all bolts hand tight.

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






- Finally, tighten the bolts to the cylinder block and the 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 crankshaft seal. Refer to => [ Crankshaft Seal, Transmission Side ] Crankshaft Seal, Transmission Side.

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 ] Cylinder Head.

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

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

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

Tightening Specifications