Volkswagen Workshop Service and Repair Manuals

Removing and installing lower timing chain cover (Golf, Eos, Scirocco)

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Hook -10 - 222 A /10-

t	Shackle -10 - 222 A /12-

t	Locking pin -T10060 A-

t	Bits -T10099-

t	Counterhold tool -T10355-

t	Thrust piece -T10368-

t	Torque wrench -V.A.G 1331-

t	Torque wrench -V.A.G 1332-

t	Golf: Rack -10 - 222 A /13-

t	Eos, Scirocco: Rack -10 - 222 A /1-

Removing Proceed as follows: –  Remove noise insulation → General body repairs, exterior; Rep. gr.50. –  Remove front part of right wheel housing liner → General body repairs, exterior; Rep. gr.66. –  Drain off engine oil.

Vehicles with auxiliary heater: –  Slacken clip -1- and remove bolt -2-. –  Detach exhaust silencer for auxiliary heater.

All: –  Remove bolts -arrows-. –  Remove air pipe (lift clips -items 1 and 2-).   Caution If a used belt runs in the opposite direction when it is refitted, this can cause breakage. Before removing, mark direction of rotation of poly V-belt with chalk or felt-tipped pen for re-installation.

–  Remove right air hose -arrows-.

–  To slacken poly V-belt turn tensioner from below in direction of -arrow-. –  Lock tensioner with locking pin -T10060 A-. –  Remove poly V-belt from pulley on vibration damper.

–  Turn vibration damper to »TDC« position -arrow- using counterhold -T10355-. l  Notch on vibration damper must align with arrow marking on cover for timing chains (bottom).   Caution Risk of damage to engine. To avoid disturbing valve timing, do not turn crankshaft out of »TDC« position when bolt for vibration damper is removed. –  Remove bolt for vibration damper using counterhold -T10355-. –  Remove vibration damper.   Caution Always use sleeve -T10368- when fitting bolt for vibration damper to avoid damaging splines.

–  Fit bolt for vibration damper and sleeve -T10368- again. Vehicles with sound generator: –  Remove charge air duct to sound generator → Chapter. All: –  Fit support bracket -10 - 222 A- with the following tool parts:

Golf: t  2x Adapter -10 - 222 A /13- t  Hook -10 - 222 A /10- t  Shackle -10 - 222 A /12-

Eos, Scirocco: t  Rack -10 - 222 A /1- t  Hook -10 - 222 A /10- t  Shackle -10 - 222 A /12-   Note t  The racks -10 - 222 A /1- must not be located on the screw plates of the wings, as this will otherwise cause damage to them. t  The shackle -10 - 222 A /12- is needed so the engine is raised in its installation position and does not »fall back«. All: –  Take up weight of engine with spindle.

–  Remove bolts -arrows- of assembly mounting at engine. –  Removing engine mounting → Chapter. –  Raise engine approx. 50 mm and slacken upper engine support bolt. –  Now lower engine by approx. 100 mm.

–  Place wiring harness to one side -arrow-. –  Remove bolt -1- and take off tensioner for poly V-belt from bracket for ancillaries. –  Unscrew lower bolts for engine support using bits -T10099-. –  Remove engine support with bolts.

–  Remove bolts -arrows- and pull guide tube for oil dipstick out of timing chain cover.

–  Unbolt charge pressure solenoid valve -N75- from turbocharger -arrows-. –  Remove turbocharger connection -1-.

–  Remove bolts -1 … 15-.   Note Depending on model, the cover may be secured with only 8 bolts.   Caution Risk of damaging lower timing chain cover. To prevent damaging the timing chain cover, apply tool only at the bolt holes.

–  Lever off timing chain cover (bottom) (start at points -1 and 2-). Installing t  Specified torques → Chapter. t  Sealant: Silicone sealant -D 174 003 A2-   Note t  Note expiry date of silicone sealant. t  The cover must be installed within 5 minutes after applying the silicone sealant. t  Renew bolts tightened with specified tightening angle. t  Renew seals, gaskets and self-locking nuts. –  Remove sealant residues from cylinder block with a flat scraper.   WARNING Wear eye protection. –  Mask oil seal on both sides with adhesive tape to make sure the seal remains clean.

–  Remove remaining sealant from cover, e.g. using rotating plastic brush. –  Clean sealing surfaces. They must be oil and grease free. –  Use old bolts when fitting cover and tighten to 8 Nm. –  Use feeler gauge to measure distance between cover and housing (max. distance is 0.2 mm).   Note t  Renew cover if distance exceeds 0.2 mm. t  It is not possible to measure distance between cover and sump (top section); check visually to ensure that sealing surface is even.

–  Check that both dowel pins are fitted in cover -arrows-.

–  Cut off nozzle on tube at front marking (Ø of nozzle approx. 3 mm).

Cover with 15 bolts –  Apply silicone sealant -D 174 003 A2- onto clean sealing surface of new cover, as shown in illustration. t  Thickness of sealant bead: 2 ... 3 mm

Cover with 8 bolts –  Apply silicone sealant -D 174 003 A2- onto clean sealing surface of new cover, as shown in illustration. t  Thickness of sealant bead: 2 ... 3 mm   Note t  The cover must be installed within 5 minutes after applying the silicone sealant. t  The bead of sealant must not be thicker than specified, otherwise excess sealant can enter the sump and obstruct the strainer in the oil intake pipe. –  Install cover immediately and tighten bolts: t  Cover with 15 bolts → Fig.. t  Cover with 8 bolts → Fig..   Note After fitting cover, let sealant dry for approx. 30 minutes. Only then fill with engine oil. –  Fill up with engine oil. –  Check oil level. Further assembly is basically the reverse of the dismantling sequence.