Removing and installing timing chain cover: VW 1.4 (CAVD, CBTA, CBUA, CCCA, …)

🧭 Before you start

Fits: platform codes 5C7, 5C1

• Renewed: gasket onto dowel pins

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• Risk of engine damage.To prevent the chain sprocket slipping out of the drive on the crankshaft , do not turn the crankshaft when the poly V-belt pulley is loose/removed. — Remove coolant pump .
• Danger of damage to refrigerant lines and hoses.Do NOT stretch, kink or bend refrigerant lines and hoses. — Secure air conditioner compressor to longitudinal member.
• Note that pulley contact surfaces, securing bolt, bearing bush and crankshaft chain sprocket must be free of oil and grease.

🔧 Engine codes this applies to

📋 Procedure

1. Observe safety instructions .
2. Observe repair instructions .
3. Remove engine cover .
4. Remove crankshaft pulley .
5. ⚠ Risk of engine damage.To prevent the chain sprocket slipping out of the drive on the crankshaft , do not turn the crankshaft when the poly V-belt pulley is loose/removed. — Remove coolant pump .

6. ⚠ Risk of injury caused by refrigerant.The air conditioner refrigerant circuit must not be opened. — Remove air conditioner compressor from ancillary bracket Heating, air conditioning87Air conditioner compressor; Removing and installing air conditioner compressor from and to bracket.
7. ⚠ Danger of damage to refrigerant lines and hoses.Do NOT stretch, kink or bend refrigerant lines and hoses. — Secure air conditioner compressor to longitudinal member.
8. Remove bracket for tensioning element and air conditioner compressor.
9. Remove alternator Electrical system27Alternator; Removing and installing alternator.
10. Unscrew banjo bolt (2) of oil supply line (1) for turbocharger from valve timing housing (3).
11. Remove sump .
12. Remove bolts (1).
13. Detach spring-type clip and pull off hose (2) on activated charcoal filter system solenoid valve 1N80 off at pressure pipe (3).
14. Unscrew securing bolts for pressure pipe (3) at turbocharger and valve timing housing and pull pressure pipe (3) off.
15. ⚠ The fuel system is pressurised!Wear eye protection and protective clothing to avoid possible injury and skin contact.Before loosening line connections, wrap a cloth around the connection. Then release pressure by carefully pulling off line. — Disconnect fuel supply line (1) and breather line (2).20Plug-in connectors; Disconnect plug-in connector.
16. Pull line (2) off activated charcoal filter.
17. Seal lines so that fuel system is not contaminated by dirt.
18. Pull line (1) off activated charcoal filter.
19. Undo securing bolts (2) and pull activated charcoal filter upwards.
20. Disconnect electrical connector on expansion tank coolant shortage indicator sender G32 and lay wiring harness to side.
21. Remove coolant expansion tank and move it inwards with hoses still connected.
22. Bracing the engine in its installation position .
23. Undo bolts (1) and (2) and remove connecting bracket.
24. Unscrew bolts (3 … 6) and remove engine mounting.
25. Unscrew Allen bolts for valve timing housing and hexagon bolts indicated by (arrows).
26. Remove cover for timing chain.
27. Drive crankshaft oil seal (belt pulley end) out of timing chain cover.
28. Clean sealing surfaces carefully. They must be free of oil and grease. [Note: Note that pulley contact surfaces, securing bolt, bearing bush and crankshaft chain sprocket must be free of oil and grease.]
29. Insert new seals (arrows) into timing chain cover on rear side. [Note: The timing chain cover is still sealed to the engine with a seal and also sealant D 176 501 A1.The sealant D 176 501 A1 is used to prevent leaks between the timing chain cover and the joints (1) and (2).Sealant spots must have a diameter of 10 mm and a thickness of approx. 1 mm.Do not apply sealant until directly before the timing chain cover is fitted.]
30. Apply sealant D 176 501 A1 to the joints camshaft housing/cylinder head (1) and cylinder head/cylinder block (2).
31. Fit new gasket onto dowel pins.
32. When fitting, install two studs M6x80 into cylinder head and cylinder block as a guide.
33. Place timing chain cover onto studs and dowel pins.
34. Tighten timing chain cover securing bolts evenly and diagonally.
35. Align engine mountings as follows:
36. Tighten new assembly mounting bolts .
37. Renew crankshaft oil seal (belt pulley end) .
38. Connect oil supply line for turbocharger to valve timing housing .

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