Valve Cover: Service and Repair

Cylinder Head Cover

Special tools, testers and auxiliary items required

• Spring Type Clip Pliers (VAS 5024 A)

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

• Assembly Tool (T10118)

• Puller for Ignition Coil (T10095 A)

• Sealant (D 454 300 A2)

Removing

• To perform this procedure, the ground cable must be disconnected from the battery. If a coded radio is installed, obtain the anti-theft code beforehand.

• Replace the cylinder head cover if it is damaged or if there are leaks.

- Turn off the ignition and disconnect the ground cable from the battery.

- Any cable ties which are opened or cut off during the removal, must be replaced in the same position during the installation.

- Remove the upper intake manifold. Refer to => [ Upper Intake Manifold ] Upper Intake Manifold.

- Remove the ignition coil with power output stage using puller for ignition coil (T10095 A).






• Seal the intake passages in the intake manifold and in the cylinder head with clean cloths.

- Remove the fuel hose bracket bolts - arrows - and bracket - A - from the cylinder head cover.






- Disconnect all other electrical wires from the cylinder head cover and set them to the side.

- Loosen the cylinder head cover bolts - 1 through 17 - starting from the inside and working toward the outside.






- Remove the bolts and the cylinder head cover.

Installing






- Apply sealant (D 454 300 A2) to the locations marked - arrows - on the cover.

- Install the cylinder head cover and tighten the bolts - 1 through 17 - uniformly, starting from the inside and working toward the outside.






- Install the fuel hose bracket - A - and bolts - arrows -.






- Install the upper intake manifold. Refer to => [ Upper Intake Manifold ] Upper Intake Manifold.

Further installation is performed in the reverse order of removal, noting the following:

• Replace the cylinder head cover if it is damaged or if there are leaks.

• Make sure the fuel hoses are secure.

- Fill with coolant, if necessary. Refer to => [ Draining and Filling ] Procedures.

Tightening Specifications