Volkswagen Workshop Service and Repair Manuals

Removing and installing top valve timing housing   Note In this engine, the valve timing housing is split. This procedure describes removal and installation of the top valve timing housing. Special tools and workshop equipment required

t  Hose clip pliers -VAS 6340-

t  Torque wrench -VAS 6583- t  Sealant D 176 501 A1 t  2 studs M6x70 (e.g. bolts with sawn-off head) Removing –  Drain coolant → Chapter.

–  Open spring-type clips and pull coolant hoses -1- and -2- off. –  Push catch -3- underneath coolant hoses and pull hoses upwards. –  Put down coolant hoses to rear.

–  Remove all securing bolts from valve timing housing cover -1-. –  Remove valve timing housing cover. Installing

–  To improve guidance of valve timing housing cover, screw 2 studs M6x70 -1- into cylinder head cover.   Note t  The installation procedure must not be allowed to exceed 6 minutes from the moment when the sealant is applied to the point when the securing bolts are tightened to 8 Nm. t  The sealant starts to harden after 6 minutes. t  Note that the securing bolts are tightened in 2 stages. –  Clean sealing surfaces carefully. They must be free of oil and grease. –  Apply sealant D 176 501 A1 -1- to sealing surface.

Bead of sealant must be 2 … 3 mm thick and must run closer to inside edge in area of bolt holes. –  Apply slightly more sealant in area of -arrows-.

–  Place valve timing housing cover -1- onto studs -2-. Push valve timing housing cover -1- onto cylinder head cover as far as stop. Take care to keep valve timing housing cover straight. –  Unscrew studs and screw in securing bolts until finger-tight. Tightening procedure stage I

–  Tighten securing bolts to 5 Nm in sequence as specified -A- to -E-. Tightening procedure stage II

–  Tighten securing bolts to 8 Nm in sequence as specified -A- to -G-.

–  Push clamp -3- into bracket from top to stop. –  Push on coolant hoses and secure spring-type clips -1- and -2- with hose clip pliers -VAS 6340-. –  Fill coolant system with coolant → Chapter.