Timing cover removal

Hi,

Here are the directions for removal and replacement of the engine timing chain cover. The attached pics correlate with the directions.

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2011 Volkswagen Routan (7B1) V6-3.6L (CJRA)
Engine Timing Cover
Vehicle Engine, Cooling and Exhaust Engine Cylinder Head Assembly Service and Repair Removal and Replacement Engine Timing Cover
ENGINE TIMING COVER
Engine Timing Cover

Removing

- Disconnect the negative battery cable.

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

- Remove the electric vacuum pump.

- Remove the upper radiator hose (2) and thermostat housing (1). Refer to => [ Thermostat ] See: Thermostat, Engine Cooling > Removal and Replacement > Thermostat.

Pic 1

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

Pic 2

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

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

Pic 3

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

Pic 4

- Remove the accessory drive belt (4). Refer to => [ Accessory Drive Belt ] See: Drive Belt > Removal and Replacement > Accessory Drive Belt.

Pic 5

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

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

- Remove the power steering pump pulley (5).

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

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

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

- Remove the right engine mount bracket. Refer to => [ Right Engine Mount/Bracket ] See: Engine Mount > Removal and Replacement > Right Engine Mount/Bracket.

- Temporarily reinstall the front fore and aft crossmember (4).

Pic 6

- Remove the right engine mount isolator and bracket (1). Refer to => [ Right Engine Mount/Bracket ] See: Engine Mount > Removal and Replacement > Right Engine Mount/Bracket.

Pic 7

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.

Pic 8

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

Pic 9

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

Pic 10

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

Pic 11

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 ] See: Engine > Procedures > Engine Gasket Surface Preparation.

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

Pic 12

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.).

Pic 13

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

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

Pic 14

pic 15

- 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)

pic 16

- 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 and isolator. Refer to => [ Right Engine Mount/Bracket ] See: Engine Mount > Removal and Replacement > Right Engine Mount/Bracket

pic 17

- Remove the temporarily installed front fore and aft crossmember (4).

Pic 18

- Install the right engine mount bracket. Refer to => [ Right Engine Mount/Bracket ] See: Engine Mount > Removal and Replacement > Right Engine Mount/Bracket.

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

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

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

Pic 19

- Install the power steering pump pulley (5).

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

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

- Install the accessory drive belt (4). Refer to => [ Accessory Drive Belt ] See: Drive Belt > Removal and Replacement > Accessory Drive Belt.

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

Pic 20

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

Pic 21

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

Pic 22

- 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 ] See: Thermostat, Engine Cooling > Removal and Replacement > Thermostat.

Pic 23

- 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 ] See: Oil Filter, Engine > Removal and Replacement > Oil Filter.

- Connect the negative battery cable.

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

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

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Let me know if this helps.

Joe