Timing chain covers (All), removing and installing: Installing

Fig 1: Using Rotating Plastic Brush To Remove Any Sealant Residue From Sealing Flange, Cylinder Block And Upper Part Of Oil Pan

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Using e.g. a rotating plastic brush, remove sealant residue on covers for timing chain and on cylinder block and head.

• Clean sealing surfaces, they must be free of oil and grease.

Fig 2: Cutting Tube Nozzle At Front Marking

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Cut off nozzle on the tube of sealant at front mark (dia. of nozzle approx. 1 mm).

Fig 3: Applying Sealant Beads On Clean Sealing Surfaces Of Lower Cover For Timing Chain

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Apply sealant beads - 1 to 6  - , as shown in illustration, on clean sealing surfaces of lower cover for timing chain.

• Thickness of sealant bead: 1.5 to 2.0 mm.

• Check whether 2 alignment bushings are present in cylinder block, install if necessary.

Fig 4: Removing Bolts And Lower Timing Chain Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Position lower cover for timing chain and tighten bolts as follows.

1. Tighten bolts 11 , 12 , 13 to 10 Nm
2. Tighten bolts 1 , 3 , 4 , 5 , 6 , 7 , 8 , 9 , 10 to 10 Nm
3. Tighten bolts 4 , 8 , 9 , 10 to 22 Nm
4. Tighten bolts 2 for power-steering pump to 22 Nm

Fig 5: Removing/Installing Sealing Flanges For Camshaft Adjuster On Left/Right Covers For Timing Chain

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove sealing flanges for camshaft adjuster on left and right covers for timing chain - arrows  -.

Fig 6: Applying Sealant Bead On Clean Sealing Surfaces Of Left Cover For Timing Chain

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Apply sealant bead - arrow  - , as shown in illustration, on clean sealing surfaces of left cover for timing chain.

• Groove on lower sealing surface - arrow 1  - must be completely filled with sealant. Sealant bead must stand 1.5 to 2.0 mm above sealing surface.
• Sealant bead on front sealing surface - arrows 2  - must be 1.5 to 2.0 mm thick.

• Install new seal - 3  - on left cover for timing chain.

Fig 7: Removing/Installing Bolts And Left Timing Chain Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Position left cover for timing chain and tighten bolts as follows.

1. Tighten bolts to 1 to 4 to 5 Nm
2. Tighten bolts to 6 to 10 Nm
3. Tighten bolts to 5 to 10 Nm
4. Tighten bolts to 1 to 4 to 10 Nm

Fig 8: Applying Sealant Beads On Clean Sealing Surfaces Of Right Cover For Timing Chain

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Apply sealant beads - arrow  - , as shown in illustration, on clean sealing surfaces of right cover for timing chain.

• Groove on lower sealing surface - arrow 1  - must be completely filled with sealant. Sealant bead must stand 1.5 to 2.0 mm above sealing surface.
• Sealant bead on front sealing surface - arrows 2  - must be 1.5 to 2.0 mm thick.

• Install new seal - 3  - on right cover for timing chain.

Fig 9: Removing/Installing Bolts And Right Timing Chain Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Position right cover for timing chain and tighten bolts as follows.

1. Tighten bolts 2 , 3 , 5 , 6 to 5 Nm
2. Tighten bolts to 1 to 10 Nm
3. Tighten bolts to 4 to 10 Nm
4. Tighten bolts 2 , 3 , 5 , 6 to 10 Nm

Fig 10: Removing/Installing Sealing Flanges For Camshaft Adjuster On Left/Right Covers For Timing Chain

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Install sealing flanges for camshaft adjuster with new sealing rings on left and right covers for timing chain - arrows  -.

The rest of installation is in reverse order of removal, note the following:

• Install crankshaft seal, timing chain side → Crankshaft seal (timing chain side), replacing .
• Install cylinder head cover: → Left cylinder head cover, removing and installing  , → Right cylinder head cover, removing and installing .
• Install exhaust manifold: → Left exhaust manifold, removing and installing  , → Right exhaust manifold, removing and installing .
• Install combination valve for Secondary Air Injection (AIR) system: → Left combination valve for Secondary Air Injection, removing and installing  , → Right combination valve for Secondary Air Injection, removing and installing .

• Install rear coolant pipe → Rear coolant pipe, removing and installing .
• Install left and right coolant pipe → Right coolant pipe, removing and installing  and → Left coolant pipe, removing and installing .
• Install oil filter housing → Oil filter housing, removing and installing .
• Install intake manifold → Intake manifold, removing and installing .

• Install dual-mass flywheel → Dual-mass flywheel, removing and installing  , → Drive plate, removing and installing .
• Install engine: → Engine (vehicles with manual transmission), installing  , → Engine (vehicles with automatic transmission), installing .
• Add engine oil and check oil level → Oil level, checking .