Engine Timing Cover

Engine Timing Cover

Removing

- Disconnect the negative battery cable.

- Drain the engine cooling system. Refer to => [ Cooling System Draining and Filling ] Cooling System Draining and Filling.

- Remove the electric vacuum pump.

- Remove the upper radiator hose (2) and thermostat housing (1). Refer to => [ Thermostat ] Service and Repair.






- Remove the heater core return hose (1) from the water pump housing.






- Remove the lower radiator hose (2) from the water pump housing.

- Remove the heater core supply hose (1) from the coolant outlet housing (2).






- Remove the bolt (2) and reposition the heater core supply tube (1).






- Remove the accessory drive belt (4). Refer to => [ Accessory Drive Belt ] Accessory Drive Belt.






- Remove the accessory drive belt tensioner (7). Refer to => [ Accessory Drive Belt Tensioner ] Accessory Drive Belt Tensioner.

- Remove the accessory idler pulley (1). Refer to => [ Accessory Drive Belt Idler Pulley ] Accessory Drive Belt Idler Pulley.

- Remove the power steering pump pulley (5).

- Remove the crankshaft vibration damper (6). Refer to => [ Vibration Damper ] Service and Repair.

- Remove the right and left cylinder head covers. Refer to => [ Left Cylinder Head Cover ] Left Cylinder Head Cover and => [ Right Cylinder Head Cover ] Right Cylinder Head Cover.

- Remove the upper and lower oil pans. Refer to => [ Lower Oil Pan ] Lower Oil Pan or => [ Upper Oil Pan ] Upper Oil Pan.

- Remove the right engine mount bracket. Refer to => [ Right Engine Mount/Bracket ] Right Engine Mount/Bracket.






• It is not necessary to remove the water pump or the coolant outlet housing for engine timing cover removal.

- Remove the twenty-three M6 bolts (3) from the timing cover.

- Using the seven indicated pry points, carefully remove the timing cover.






- If required, remove the remaining four M6 bolts (2) and the coolant outlet housing (1) from the engine timing cover.






- If required, remove the remaining four M6 bolts (4) and the water pump (3) from the engine timing cover.







Do not use oil based liquids, wire brushes, abrasive wheels or metal scrapers to clean the engine gasket surfaces. Use only isopropyl (rubbing) alcohol, along with plastic or wooden scrapers. Improper gasket surface preparation may result in engine fluid leakage.

- Remove all residual sealant from the timing chain cover, cylinder head and engine block mating surfaces. Refer to => [ Engine Gasket Surface Preparation ] Engine Gasket Surface Preparation.

- Remove and discard the coolant outlet housing gasket (1) and the water pump gasket (2).






Installing

- If removed, install the coolant outlet housing (1) to the timing cover with a new gasket using only the four bolts (2) shown tightened to 12 Nm (106 in. lbs.).






- If removed, install the water pump (3) to the timing cover using only the four bolts (4) shown. Refer to => [ Water Pump ] Water Pump.

- Install the coolant outlet housing gasket (1) and the water pump gasket (2).











- Clean the engine timing cover, cylinder head and block mating surfaces with isopropyl alcohol in preparation for sealant application.


Engine assembly requires the use of a unique sealant that is compatible with engine oil. Using a sealant other than Volkswagen genuine Engine RTV Sealant may result in engine fluid leakage.


Following the application of Volkswagen genuine Engine RTV Sealant to the gasket surfaces, the components must be assembled within 20 minutes and the attaching fasteners must be tightened to specification within 45 minutes. Prolonged exposure to the air prior to assembly may result in engine fluid leakage.

- Apply a 2 to 3 mm wide bead of Volkswagen genuine Engine RTV Sealant to the front cover as shown in the following locations:

• Three cylinder head bosses (1)

• Right and left flanges (2)

• Four cylinder head to engine block T-joints (3)

• Cover to right cam chain tensioner gap (4)






- Align the locator pins (4) on the engine block to the engine timing cover and install the cover.

- Install and tighten the timing cover twenty-three M6 bolts (3) bolts to 12 Nm (106 in. lbs.).

- Install the right engine mount bracket. Refer to => [ Right Engine Mount/Bracket ] Right Engine Mount/Bracket.






- Install the upper and lower oil pans. Refer to => [ Lower Oil Pan ] Lower Oil Pan or => [ Upper Oil Pan ] Upper Oil Pan.

- Install the right and left cylinder head covers. Refer to => [ Left Cylinder Head Cover ] Left Cylinder Head Cover and => [ Right Cylinder Head Cover ] Right Cylinder Head Cover.

- Install the crankshaft vibration damper (6). Refer to => [ Vibration Damper ] Service and Repair.

- Install the power steering pump pulley (5).

- Install the accessory idler pulley (1). Refer to => [ Accessory Drive Belt Idler Pulley ] Accessory Drive Belt Idler Pulley.

- Install accessory drive belt tensioner (7). Refer to => [ Accessory Drive Belt Tensioner ] Accessory Drive Belt Tensioner.

- Install the accessory drive belt (4). Refer to => [ Accessory Drive Belt ] Accessory Drive Belt.

- Install the heater core supply tube (1) with one bolt (2) tightened to 12 Nm (106 in. lbs.).






- Install the heater core supply hose (1) to the coolant outlet housing (2).






- Install the lower radiator hose (2) to the water pump housing.






- Install the heater core return hose (1) to the water pump housing.



- Install the thermostat housing (1) and upper radiator hose (2). Refer to => [ Thermostat ] Service and Repair.






- Install the electric vacuum pump.

- If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to => [ Oil Filter ] Service and Repair.

- Connect the negative battery cable.

- Fill the cooling system. Refer to => [ Cooling System Draining and Filling ] Cooling System Draining and Filling.

- Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level.