Timing Cover: Service and Repair

Timing Chain 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)


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.

- Remove the cover - 1 - for the E-box and remove the wire - 2 -.






- Remove the bolts - arrows - and remove the battery tray.


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 => [ Coolant, Draining and Filling ] Service and Repair.

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

- Remove the coolant pipe at the coolant thermostat housing and the bracket on the vacuum pump.

- Pull out the retaining clip - arrow - and remove the coolant pipe - A -.






- Disconnect the connectors - 1 and 3 -.






- Disconnect the connecting 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 lay aside the wiring harness with the pressure pipe.

- Press the bracket for the knock sensor wiring harness at the AIR valve slightly toward the rear.

- Remove the flange - 5 - and set it aside with the coolant hoses connected.

- Remove the timing chain cover bolts.

- Pry off the timing chain cover - 1 - from the cylinder head - 2 - uniformly at the top and bottom recesses.






• The sealing surfaces must not be damaged under any circumstances. If necessary, use the trim removal wedge (3409).

• After removing the timing chain cover, clean the trim removal wedge (3409) which is intended for the removal of interior equipment parts.

Installing


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

- Remove the remainder of sealant from the timing chain cover and from the cylinder head, using for example, a rotating plastic brush.


Make sure that no sealant residue enters the engine.

- Clean the coolant pipe connection on the cylinder head. If necessary, remove any coolant deposits with a copper wire brush or fine sandpaper (minimum 100 grit). If the pipe connection is worn, replace it using liquid locking fluid (D 000 600 A2).

- Replace the seal in the timing chain cover. Refer to => [ Timing Chain Cover Seal ] Service and Repair.

- Replace the seal in the coolant flange.

- Clean the sealing surfaces so they are completely free of any oil or grease.

- Cut the sealant tube nozzle at the front mark (nozzle diameter: approximately 1 mm).






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

- Apply the sealant bead - A - as shown onto the clean sealing surface of the timing chain cover.






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

- Coat the seal for the timing chain cover lightly with engine oil and slide the cover onto the coolant pipe connection.

- Install all the bolts and tighten them in a diagonal sequence.

The rest of the installation follows the reverse of the removal procedure. Note the following:

- Fill the coolant. Refer to => [ Coolant, Draining and Filling ] Service and Repair.

- Install the battery.

Tightening Specifications