Removing and installing chain guard cover: VW Jetta VI / Golf V / Jetta (BGP, BGQ, BPR, BPS, …)

🧭 Before you start

Fits: VW Jetta VI (16, 2010–2018), VW Golf V / Jetta (1K, 2003–2009)

• Opens: coolant, brake fluid
• Renewed: pipe connection, seal in chain guard cover

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• Under no circumstances should the sealing surfaces be damaged. Use removal wedge3409 if necessary.Once chain guard cover has been removed, clean removal wedge3409 which is designed for removing interior equipment components.
• Clean sealing surfaces; they must be free of oil and grease.
• The chain guard cover must be installed within 5 minutes of the sealant being applied.

🔧 Engine codes this applies to

📋 Procedure

1. ⚠ When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions:Route all the various lines (e.g. for fuel, hydraulics, activated charcoal filter system, coolant and refrigerant, brake fluid and vacuum) and electrical wiring in their original positions. To avoid damage to lines, ensure sufficient clearance from all moving or hot components. — Remove engine cover with air filter (see the separate procedure).
2. Remove battery and battery tray Electrical system 27. Removing and installing battery; models with a petrol engine.
3. ⚠ Steam may escape when expansion tank is opened. Wear eye protection and protective clothing to avoid eye injuries and scalding. Cover cap with cloth and open carefully. — Drain coolant.
4. Remove intake manifold (see the separate procedure).
5. Unscrew coolant pipe from coolant distribution housing and from bracket on vacuum pump.

6. Pull out retaining clip (arrow) and remove coolant pipe (A).
7. Separate connectors (1) and (3).
8. Pull off pressure pipe (2) on secondary air inlet valve.
9. Remove rear coolant pipe (4).
10. Pull off vacuum hose (6) from vacuum pump and connector (7).
11. Unscrew brackets (8) and (9) and place wiring harness with pressure pipe to one side.
12. Push back bracket for wiring harness knock sensors slightly on secondary air inlet valve.
13. Unbolt coolant distribution housing (5) and place it to one side with coolant hoses connected.
14. Remove all bolts of chain guard cover.
15. Press off chain guard cover (1) at top and bottom recesses equally from cylinder head (2). [Note: Under no circumstances should the sealing surfaces be damaged. Use removal wedge 3409 if necessary. Once chain guard cover has been removed, clean removal wedge 3409 which is designed for removing interior equipment components.]
16. ⚠ To avoid injury from swarf, wear eye protection and protective clothing. — Remove sealant residue from chain guard cover and cylinder head using a rotating plastic brush, for example.
17. ⚠ Be sure that no sealant residue gets into the engine. — Clean pipe connection on cylinder head. If necessary, remove coolant deposits using a brass wire brush or fine sandpaper (at least 100 grade). If the pipe connection is worn, renew pipe connection and insert with locking fluidD 000600 A2.
18. Renew seal in chain guard cover (see the separate procedure).
19. Renew seal in coolant distribution housing.
20. Clean sealing surfaces; they must be free of oil and grease.
21. Cut off nozzle on tube at front marking (∅ of nozzle approx. 1 mm). [Note: The chain guard cover must be installed within 5 minutes of the sealant being applied.]
22. Apply sealant bead (A), as shown, on clean surface of chain guard cover.
23. Coat chain guard cover seal lightly with engine oil and push chain guard cover onto pipe connection.
24. Insert all bolts and tighten in diagonal sequence.
25. Fill with coolant.
26. Install battery Electrical system 27. Removing and installing battery; models with a petrol engine.

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