Timing Chain Cover

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

Removing 

-- Remove the engine cover with air filter. Refer to ENGINE COVER WITH AIR FILTER .

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

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

Fig 1: Identifying Battery Holder & Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Drain the coolant. Refer to COOLANT, DRAINING AND FILLING .

-- Remove the intake manifold. Refer to 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-.

Fig 2: Pulling Out Retaining Clip And Removing Coolant Pipe

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connectors -1 and 3-.

Fig 3: Identifying Connectors, Pressure Pipe, Rear Coolant Pipe, Vacuum Hose, Vacuum Pump And Connector

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-- 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.

Fig 4: Pressing Off Chain Case Cover Uniformly From Cylinder Head At Top And Bottom Recesses

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Installing 

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

-- 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 .

-- 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).

Fig 5: Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 3 Mm)

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

Fig 6: Applying sealant bead

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• 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 .

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

Tightening Specifications