Chain Compartment Cover

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment 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

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 with air filter. Refer to ENGINE COVER WITH AIR FILTER .

-- Remove the battery and the battery tray. Refer to Removal and Installation .

WARNING:

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 one of the following:

Jetta from MY 05 through 10, Jetta SportWagen (US)/Jetta Wagon (Canada) for MY 09 and Jetta SportWagen (US)/Golf Wagon (Canada) from MY 10, refer to DRAINING AND FILLING .

-- Remove the intake manifold. Refer to INTAKE MANIFOLD .

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

-- Pull out the circlip -arrow- and remove the coolant line -A-.

Fig 1: Identifying Retaining Clip And Coolant Pipe

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connectors -1 and 3-.

Fig 2: Identifying Vacuum Hose Disconnected From Vacuum Pump And Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the pressure tube -2- from the Secondary Air Injection (AIR) valve.

-- Remove 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 vent hose aside.

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

-- Remove the coolant thermostat 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.

Fig 3: Identifying Chain Case Cover Pressed Off Uniformly From Cylinder Head At Top And Bottom Recesses

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

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

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

Installing

WARNING:

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

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

CAUTION:

Make sure that no sealant residue enters the engine.

-- Clean the adapter on the cylinder head. If necessary, remove coolant deposits using a copper wire brush or using 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 chain compartment cover. Refer to CHAIN COMPARTMENT COVER SEAL .

-- Replace the seal in the coolant thermostat housing.

-- 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).

Fig 4: Identifying Scissors To Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 3 Mm)

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

The chain compartment 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 chain compartment cover.

Fig 5: Identifying Sealant Bead Applied As Depicted To Clean Sealing Surface Of Chain Case Cover

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The sealant bead must be 1.5 to 2.0 mm thick.

-- Lubricate the seal for the chain compartment cover lightly with engine oil and slide the chain compartment cover onto the pipe connection.

-- Install all the 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:

-- Fill with coolant, refer to one of the following:

Jetta from MY 05 through 10, Jetta SportWagen (US)/Jetta Wagon (Canada) for MY 09 and Jetta SportWagen (US)/Golf Wagon (Canada) from MY 10, refer to DRAINING AND FILLING .

-- Install the battery tray and battery. Refer to Removal and Installation .

Tightening Specifications

Component		Nm
Chain compartment cover to cylinder head		10
Coolant thermostat housing to chain compartment cover		10