Upper Engine Cover, Removing And Installing

2.0L TSI 

Removing 

-- Disengage engine cover at the retaining points -arrows- and remove engine cover upward.

Fig 1: Identifying Engine Cover Attachment Points

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Installing 

-- Set engine cover onto retaining points -arrows- and press it on, until it is engages.

2.0L TFSI 

Fig 2: Identifying Air Intake Components

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Removing 

-- Remove bolts from air intake -arrows A-.

Fig 3: Identifying Fastening Clips

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-- Disconnect connector -1- from Mass Air Flow (MAF) sensor and set connector aside.

-- Release both fastening clips -A arrows-.

Fig 4: Identifying Engine Cover Remove/Install Components -- 2.0L TFSI Vehicles From Model Year 2006

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- First release engine cover at -arrow 3-, then -arrow 4- and raise.

Installing 

Installation is the reverse of removal.

2.0L FSI 

Removing 

Fig 5: Identifying Engine Cover Mounting Points

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-- Unclip engine cover at mounting points -arrows- and remove upward.

Installing 

Installation is the reverse of removal.

2.5L 

Special tools and workshop equipment required 

• Spring Type Clip Pliers VAS 5024A
  Fig 6: Identifying Spring Clamps VAS 5024A

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Fig 7: Identifying Air Intake Components

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Removing 

-- Remove bolts from air intake -arrows A-.

-- Release the clamp from the Mass Air Flow (MAF) sensor -arrow B- with the VAS 5024A and push it back.

-- Disconnect the air intake hose -1- from the Mass Air Flow (MAF) sensor -2-.

-- Disconnect connector -arrow C- from Mass Air Flow (MAF) sensor and lay connector aside.

Fig 8: Identifying Engine Cover Mounting Points

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- First, pull the engine cover at the fastening points -arrows A- carefully out from the retainer.

-- Lift the front of the engine cover slightly.

-- Then, pull engine cover carefully at mounting points -arrows B- out of retainer.

-- Carefully lift the engine cover upward and out -movement - arrows-.

Fig 9: Identifying Engine Cover Mounting Points

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Installing 

-- First place engine cover on to rear mounting points -arrows B-, then on to front mounting points -arrows A-.

Carefully press by hand on to mounting points until engine cover engages audibly.

1.9L TDI PD 

Removing 

Fig 10: Identifying Engine Cover Components & Fastening Points

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

• 1. the outer part, shown shaded in illustration

• 2. the center part, shown not shaded here in illustration

Fig 11: Identifying Engine Cover Components & Fastening Points

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Carefully disengage engine cover in the following sequence at the individual fastening points and raise up.

• -1-, -3-, -2-, -4-.

-- Remove outer part -1-.

-- Carefully release center part -2- and raise slightly.

Fig 12: Identifying Engine Cover Fastening Points

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Installing 

Fig 13: Identifying Center Engine Cover Fastening Points

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-- Position engine cover on fastening points -arrows- and press on.

-- Then position outer part -1- on attachment points -arrows- and press on.

Fig 14: Identifying Engine Cover Fastening Points

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2.0L TDI PD Diesel, 103 KW 

Fig 15: Identifying Oil Dipstick -1- And Direction To Lift Engine Cover -Arrow 2-

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Removing 

-- Pull out oil dipstick -1-.

-- Disengage and lift engine cover -arrow 2-.

-- Then remove forward -upper arrow-

Fig 16: Identifying Engine Cover -A- On Fastening Points -Arrows 1 To 4-

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Installing 

-- Slide engine cover -A- in at fastening point first -upper arrow-.

-- Then position engine cover -A- on other fastening points -arrows 1 to 4- and press on until you feel it engage.

2.0L TDI CR Diesel 

Removing 

-- Disconnect the lift the engine cover on the mounting points -arrow-.

Fig 17: Locating Engine Cover On Mounting Points

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Installing 

-- If necessary push the ball sockets on the engine cover into the correct position.

Fig 18: Identifying Correct Position Of Ball Sockets

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-- Position the engine cover on the mounting points and press on the corners.