Question about 2009 Volkswagen Passat 2.0T

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2009 Passat 2.0 T - Cam cover removal

Do you need to remove the Exhaust manifold when removing the cam cover to gain access to the timing chain?

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6ya6ya
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Posted on Jan 02, 2017

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SOURCE: vw passat brake light

3 clips total. 2 on outside of light unit, to get to these you have to remove central trim from over boot latch, side trims and carpets, toolkit out, seats folded down, luggage blind removed, small trim piece inside wheel well removed (2 bolts 1 nut), then you can get up behind the light unit, gently clip the 2 outside (red) clips out till the light unit becomes free. to get to the third there is a black plastic trim piece clipped to the light unit where the boot comes down and meets it, this covers the third clip, gently pop it off and you will reveal the third clip and the nut needed to be removed to release it.


Posted on Oct 22, 2008

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gordoncla
  • 3 Answers

SOURCE: 2007 Passat wagon. I need to reset the air bag warning light.

the air bag light will only show if the ignition was turned on while it was disconnected.

it will defo need to be pluged into the computer to be put out but some smaller garages will have the software to do this and will be a little cheaper.here in ireland VW wanted 50euro to do mine but a small garage done it for 30euro.

you can buy code finders/reset gadgets on ebay but might not be worth it for one job compared to $130.

my suggestion would be to get the main dealer to do it if a normal automotive shop cannot access it.

Posted on Mar 01, 2009

  • 316 Answers

SOURCE: Interior trim panel removal instruction

Normal 0 . Disconnect your negative battery cable. Locate and remove the screws that hold your interior door handles in place (they may be hidden by snap in, or snap on clips). Remove the interior door handles, then disconnect the wire clips to the switches. Your panel is held in place by snap in clips; use a small pry bar to pull them from the door (try to get as close to, or directly under the clips to prevent them from tearing out of the door panel). Once the clips are pulled, pull the panel upward to remove it from the door.
Install in reverse.


If you don't have power windows you will have to remove the manual window crank. It is held in place by a clip on the back side of the base. To remove the clip, you will need a small hook (kind of like a knitting needle). Put the hook in behind the base, and grab the clip and pull it off. To replace it, slide the clip back on the window crank, and snap it back on the door.

Posted on May 31, 2009

audi vw love
  • 18 Answers

SOURCE: how to remove the alternator on a 02 passat 2.8L

You have to remove the entire front bumper and radiator

Posted on Dec 05, 2009

drsinister69
  • 2317 Answers

SOURCE: changing out spark plugs on a 1994 vw jetta. i can

You have to remove the upper intake manifold. You'll need to unbolt it and disconnect the hoses and connectors and move it enough out of your way. It would also be suggestable to get a new gasket for the upper intake manifold, increase the old on breaks or comes a part, during removal.

Posted on May 12, 2010

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How to replace timing chain on 2001 dodge intrepid 2.7


It's a BIG job. It requires removing everything from the top of the engine (intake manifold, throttle body, all plumbing, valve covers) then removing the harmonic damper, most of the accessories, and then the timing cover. That's just to get to the timing chain. You have to remove the chain guides and tensioner, then cam gears and crank gear. If you're going this route, also replace the two chains (intake cam to exhaust cam) on top of the heads, the water pump, and the tensioners. Be very precise in reinstalling the three timing chains so that everything is in time.
The link shows the details of the chain itself, but be aware that your engine is packed into your Intrepid with limited work space in some areas.
Chrysler Sebring Concorde 300 2 7L timing replacement Cloyes kit 9 0397SA

Aug 20, 2017 | Dodge Cars & Trucks

2 Answers

Need timing gear marks for 2004 Kia Sadona 3.5L engine



Removal & Installation

3.5L Engine

  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2. Record the radio anti theft code data.
  3. Remove or disconnect the following:

    Negative battery cable Engine cover Accessory drive belts Idler pulley Crankshaft pulley Power steering pump pulley Belt tensioner pulley Upper and lower timing belt covers
  4. Support the engine with a floor jack and remove the engine mount.
  5. Rotate the engine to align the camshaft sprocket timing marks with the cylinder head cover timing marks.

    0996b43f8022cb71.jpg enlarge_icon.gifenlarge_tooltip.gif

    Fig. Timing belt routing and timing marks-3.5L Engine

  6. Remove or disconnect the following:

    Auto tensioner Timing belt

    0996b43f8022cb72.jpg enlarge_icon.gifenlarge_tooltip.gif

    Fig. Timing belt and related components-3.5L Engine


To install:
  1. Ensure that the engine is set to Top Dead Center (TDC).
  2. Prepare the auto tensioner for installation by compressing it in a vise and installing a retaining pin.
  3. Install the timing belt in the following order:
    1. Crankshaft sprocket
    2. Idler pulley
    3. Left bank exhaust camshaft sprocket
    4. Left bank intake camshaft sprocket
    5. Water pump pulley
    6. Right bank intake camshaft sprocket
    7. Right bank exhaust camshaft sprocket
    8. Tensioner pulley

  4. Install the auto tensioner. Do not remove the retaining pin at this time.
  5. Check that the crankshaft and camshaft timing marks are aligned correctly.
  6. Rotate the crankshaft 1 / 4 turn Counterclockwise .
  7. Rotate the crankshaft 1 / 4 turn Clockwise to return the engine to TDC.
  8. Loosen the tensioner pulley center bolt.
  9. Apply 44 inch lbs. (5 Nm) torque to the tensioner pulley as shown and tighten the center bolt to 32-41 ft. lbs. (43-55 Nm).

    0996b43f8022cb73.jpg enlarge_icon.gifenlarge_tooltip.gif

    Fig. Adjusting the tensioner pulley-3.5L Engine

  10. Remove the auto tensioner retaining pin.
  11. Rotate the crankshaft 2 revolutions Clockwise , then wait 5 minutes for the auto tensioner to adjust.
  12. Measure the auto tensioner rod as shown. If the measurement is not 3.8-4.5 mm, then repeat the belt tensioning procedure.

    0996b43f8022cb74.jpg enlarge_icon.gifenlarge_tooltip.gif

    Fig. Measuring the auto tensioner rod-3.5L Engine

  13. When the auto tensioner measurement is correct, install or connect the following:

    Engine mount Upper and lower timing belt covers Belt tensioner pulley Power steering pump pulley Crankshaft pulley Idler pulley Accessory drive belts Engine cover Negative battery cable
  14. Reprogram the radio anti theft codes.

    Kia_Sedona_2002-2006
    Timing Chain, Sprockets, Front Cover & Seal

    Print


    Removal & Installation

    3.8L Engine

    1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
    2. Record the radio anti theft code data.
    3. Remove the engine from the vehicle.
    4. Remove the drive belt. Remove the power steering pump. Remove the air conditioning compressor.
    5. Remove the alternator. Remove the drive belt idler. Remove the drive belt tensioner. Remove the water pump pulley. Remove the intake manifold.
    6. Remove the connector bracket from the left cylinder head cover. Disconnect the right ignition coil connector, condenser connector and remove the bracket.
    7. Remove the left cylinder head cover retaining bolts. Remove the cylinder head cover from the engine.
    8. Remove the right cylinder head cover retaining bolts. Remove the cylinder head cover from the engine.
    9. Set the No. 1 cylinder to TDC on the compression stroke. Turn the crankshaft pulley and align its groove with the timing mark T of the lower timing chain cover.
    10. Check that the mark of the camshaft timing sprockets are in straight line positioning on the cylinder head surface. If not rotate the crankshaft 360 degrees. Do not rotate the engine counterclockwise.
    11. Remove the oil pan. Remove the crankshaft damper pulley. Remove the timing chain cover.
      NOTE Be careful not to damage the contact surfaces of the cylinder block, cylinder head and timing chain cover. Before removing the timing chain, mark the right and left timing chains with an identification mark based on the location of the sprocket because the identification mark on the chain for TDC can be erased.
    12. After compressing the timing chain tensioner, install a set pin. Remove the right cam to cam guide. Remove the right timing chain auto tensioner and timing chain tensioner arm.
    13. Remove the oil pump chain cover. Remove the oil pump chain tensioner assembly. Remove the oil pump chain guide. Remove the right timing chain.
    14. Remove the right timing chain guide. Remove the oil pump chain sprocket and oil pump chain. Remove the crankshaft sprocket, oil pump and camshaft drive gear.
    15. Remove the left cam to cam guide. Remove the left timing chain auto tensioner and timing chain tensioner arm. Remove the left timing chain.
    16. Remove the left timing chain guide. Remove the crankshaft sprocket and left camshaft drive. Remove the tensioner adapter assembly.

      0996b43f8020193b.jpg enlarge_icon.gifenlarge_tooltip.gif

      Fig. Timing chain and related components-3.8L Engine


    To install:
    1. Check the camshaft and crankshaft sprockets for wear and damage, replace as required.
    2. Inspect the tensioner arm and chain guide for wear and damage, replace as required.
    3. Check that the tensioner pin moves smoothly when the ratchet pawl is released with a thin rod.
    4. The key of the crankshaft should be aligned with the timing mark of the timing chain cover. This indicates that the piston is at TDC on the compression stroke.
    5. Install the tensioner adapter assembly. Install the crankshaft sprocket and left camshaft drive.
    6. Install the left timing chain guide and torque the retaining bolts 14-18 ft. lbs.
    7. Install the left timing chain. Be sure to install the chain with no slack between the camshaft and the crankshaft (crankshaft sprocket, timing chain guide, exhaust camshaft sprocket, intake camshaft sprocket). The timing mark of each sprocket should be matched with the timing mark (color ink) of the timing chain at installation of the timing chain.

      0996b43f80201924.jpg enlarge_icon.gifenlarge_tooltip.gif

      Fig. Left timing chain markings and installation: (D) exhaust camshaft sprocket (C) intake camshaft sprocket-3.8L Engine

    8. Install the left timing chain tensioner arm and torque the retaining bolts 14-16 ft. lbs.
    9. Install the left timing chain tensioner and torque the retaining bolts 7-9 ft. lbs.
    10. Install the left cam to cam guide and torque the retaining bolts 7-9 ft. lbs.
    11. Install the crankshaft sprocket, oil pump and right camshaft drive.
    12. Install the oil pump chain and oil pump sprocket. Torque the retaining bolt to 14-16 ft. lbs.
    13. Install the right timing chain guide. Torque the retaining bolts to 14-18 ft. lbs.
    14. Install the right timing chain. Be sure to install the chain with no slack between the camshaft and the crankshaft (crankshaft sprocket, intake camshaft sprocket, exhaust camshaft sprocket). The timing mark of each sprocket should be matched with the timing mark (color ink) of the timing chain at installation of the timing chain.

      0996b43f80201925.jpg enlarge_icon.gifenlarge_tooltip.gif

      Fig. Right timing chain markings and installation: (C) exhaust camshaft sprocket (B) intake camshaft sprocket-3.8L Engine

    15. Install the right timing chain tensioner arm. Torque the retaining bolts to 14-17 ft. lbs.
    16. Install the right timing chain auto tensioner. Torque the retaining bolts to 7-9 ft. lbs.
    17. Install the right cam to cam guide and torque the retaining bolts to 7-9 ft. lbs.
    18. Install the oil pump chain guide. Torque the retaining bolts to 7-9 ft. lbs.
    19. Install the oil pump tensioner assembly. Torque the retaining bolts to 7-9 ft. lbs.
    20. Pull out the pins on both the left and right hydraulic tensioners. Install the oil pump chain cover.
    21. Rotate the crankshaft two revolutions in the clockwise direction. Confirm the timing mark. Be sure to rotate the crankshaft in the clockwise direction.
    22. Apply sealant on the chain cover and on the cylinder head, cylinder block, and lower oil pan. Be sure these parts are free of engine oil and dirt.
      NOTE Before assembling the timing chain cover, the liquid sealant TB1217H should be applied on the gap between the cylinder head and block. The part must be assembled with five minutes after the sealant is applied.


      0996b43f80201926.jpg enlarge_icon.gifenlarge_tooltip.gif

      Fig. Sealant application (1 inch bead width)-3.8L Engine

    23. Apply sealant on the chain cover.
      NOTE The liquid sealant TB1217H should be applied on the gap between the cylinder head and block. The part must be assembled with five minutes after the sealant is applied.


      0996b43f80201927.jpg enlarge_icon.gifenlarge_tooltip.gif

      Fig. Timing cover sealant application-3.8L Engine

    24. Install a new gasket to the timing case cover.
      NOTE It is important that the dowel pins on the cylinder block and holes on the timing chain cover should be used as a reference in order to assemble the timing chain cover in the correct position.


      0996b43f80201928.jpg enlarge_icon.gifenlarge_tooltip.gif

      Fig. Timing cover gasket installation (A) gaskets-3.8L Engine

    25. Install the timing chain cover. Torque the retaining bolts in the proper sequence and to specification. The engine should not be started for at least thirty minutes after timing chain cover assembly.

      0996b43f80201929.jpg enlarge_icon.gifenlarge_tooltip.gif

      Fig. Timing cover bolt torque sequence and specification-3.8L Engine

    26. Install the timing case cover oil seal.
    27. Continue the installation in the reverse order of the removal procedure.

May 19, 2012 | 2004 Kia Sedona

1 Answer

How to replace a waterpump on a 2001 olds alero 2.4 cam


Water pump is driven by timing chain idler and is mounted on the rear of the timing chain housing. Disconnect the neg. battery cable. Drain cooling system. Disconnect oxygen sensor connector.
Remove upper exhaust manifould heat sheild. Remove exhaust manifold brace. Remove lower exhaust manifold heat sheild. Loosen manifold to exhaust manifold spring loaded nuts. Remove radiator outlet pipe to water pump coverbolts. Disconnect exhaust pipe from manifold.
Pull down on the exhaust pipe to disconnect it from exhaust manifold bolts. Disconnect outlet pipe from oil pan and transaxle. If equipped with manual tranaxle, remove exhaust maifold brace. Leave lower radiator hose attached and pull down on radiator out look pipe to disengauge from water pump. Leave outlet pipe hanging.
Lower vehicle. Remove exhaustmanifold to cylinder head nuts. Remove exhaust manifold to cylinder head nuts. Remove manifould. Remove timing chain front cover. Remove timing chain tensioner. Remove bolts bolts securing water pump cover to cylinder block. Remove water pump to timing chain housing nuts. Remove water pump attaching nuts. Remove water pump and cover assembly. Separate componets as necessary.
WHEN INSTALLING WATER PUMP MAKE SURE YOU FOLLOW THE TIGHTENING SEQUENCES THAT AFFECT SEALING. My frist one I messed up and broke the pump so becarful.
Installation
If cover was separated from body during removal, join this componets with a new gasket and hand tighten bolts. Apply bearing grease to splines of water pump drive. Set body and assemble into position.
Install and hand tighten bolts securing cover to cylinder block. Install and hand tighten bolts securing cover to cylinder block. Installand hand tighten nuts securing body to timing chain housing. Lubracate outlet pipe "O" ring with antifreeze. (I use RTV) Connect outlet pipe. Install and hand tighten bolts. Tighten bolts and nuts to specification in the following sequence. I'll ad the torque spec. at the end but this is where if you tighten out of order something will break.
pump assembly to timing chain housing nuts.
pump cover to pump body bolts
pump cover to cylinder block bolts (Bottom Bolt First)
outlet pipe to cover bolts
To complete installation reverse removel procedure.
Torque specs are 19 in. or 26mm all except water pump cover bolts which are 124 in or 14Nm
I never torque the bolts just make sure there done in the right order.

Oct 19, 2010 | Oldsmobile Alero Cars & Trucks

2 Answers

2002 Passat, 30 valve V6 has oil leaking on exhaust manifold. VW dealer says its the cam adjuster seals. It looks to me like its just the valve cover gaskets but I can't get an engine schematic to see the...


I have a 2000 Passat V6. They told me that same thing. To replace the gaskets is easy. You just remove the covers and the air filter box and unscrew the 6 bolts holding the valve cover on it and there you go. You want to clean around the gasket service and add a little bit of sealant to the edges. Replace the old gaskets and put everything back together, be careful not to overtighten the bolts, can flatten out the gasket and cause oil leak again. On the right side of the engine, you have to remove the coolant box to get to it. Same procedure....

Oct 18, 2010 | 2002 Volkswagen Passat

1 Answer

How do i take the heads off of the motor and whats the specks to put a new one back on


I don't recommend that unless you have a full set of tools and a lot pf patience and organizational skills. But here goes. Remove the coolant, drain the oil, disconnect the battery cable. remove the spark plug wires. Remove all cables and wires going to the intake. Remove the air cleaner and hoses connected to it. Remove all heater hoses and raciator hoses. Remove all the vacuum lines, remove the fuel lines,caution they are pressurized and may spray gas into the engine compartment. Remove the serpintene belt and alternator, air pump, and ac compressor. Remove timeing chain cover. Remove timing chain. Note where the timing marks are on the crankshaft and on the cam or cams if you have more than one cam. Remove the intake manifold, remove valve covers. If you have have push rods for the valves remove them. You will have to back off the pressure on the valve lifters to remove most of them. Remove the head bolts and lift the head free of the engine. Keep everything in perfect order. The water pump and timing chain often uses different length bolts that must be put back in the same holes. Also the push rods are supposed to be put back in the exact order as some may have worn more than others. To reinstall just clean all gasket surfaces on the head, engine block, intake and exhaust manifolds, valve covers, timing chain cover, thermostat cover, etc. I would go ahead and replace the timing belt or chain, depending on which engine you have. I would also go ahead and replace the spark plugs and wires too. Once everything is cleaned up, just reverse the order

Sep 24, 2010 | Ford F-350 Cars & Trucks

1 Answer

Whats the proper order and torque specs for a 99 32v northstar head?


REMOVAL & INSTALLATION NOTE: The manufacturer recommends that the entire powertrain be removed from the vehicle before removing the cylinder heads.
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Drain the cooling system.
  3. Properly relieve the fuel system pressure.
  4. Remove or disconnect the following:
    • Negative battery cable
    • Powertrain assembly
    • Intake manifold
    • Cam covers
    • Harmonic balancer
    • Timing chain front cover
    • Oil pump
    WARNING
    Align all timing marks before performing the next step.
    • Chain tensioner from the timing chain
    • Cam sprockets
    NOTE: The timing chain remains in the chain case.
    • Timing chain guides, access for the retaining screws is through the plugs at the front of the cylinder head
    • Water crossover
    • Exhaust manifold
    • Cylinder head bolts by reversing the torque sequence
    • Cylinder head and discard the gasket
    WARNING
    With the camshafts remaining in the cylinder head some valves will be open at all times. Do not rest the cylinder head on a flat service with the cylinder face down, or valve damage will result. NOTE: Clean all gasket mating surfaces. Clean the head bolt holes in the crankcase. WARNING
    Be careful when cleaning aluminum gasket surfaces to prevent damage to the sealing surfaces.
  5. Check the cylinder head for warpage; it must be less than 0.002 in. (0.05mm). If the cylinder head was resurfaced, the dimension between the combustion chamber gauge pad and the deck surface must be at least 10.5mm. To install: NOTE: Refer to Section 1 of this manual for the cylinder head torque sequence illustration. The illustration is located after the Torque Specification Chart.
  6. Install or connect the following:
    • New cylinder head gasket
    • Cylinder head, lubricate the bolts with engine oil
  7. Torque the M11 bolts, in sequence, as follows:
    1. Step 1: 22 ft. lbs. (30 Nm).
    2. Step 2: Turn an additional 60 degrees.
    3. Step 3: Turn an additional 60 degrees (total 180 degrees).
  8. Torque the M6 bolts to 106 inch lbs. (12 Nm).
  9. Set the camshaft timing
  10. Camshaft guide bolt access hole plugs in the cylinder heads. The plugs should be seated and snug
  11. Install or connect the following:
    • Intake cam covers
    • Oil pump
    • Timing chain front cover
    • Harmonic balancer
    • Cam sprockets
    • Chain tensioner to the timing chain
    • Timing chain guides
    • Intake manifold
    • Water crossover
    • Exhaust manifold. Torque the nuts to 22 ft. lbs. (30 Nm) or the bolts to 18 ft. lbs. (25 Nm).
    • Powertrain assembly
    • Negative battery cable Fig. 1: Minimum head resurface dimension 7922vg04.gif

  12. Fill the cooling system.
  13. Evacuate and charge the air conditioning system.
  14. Run the engine and check for leaks.
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Aug 19, 2010 | 1999 Cadillac DeVille

1 Answer

Blown head gasket


please read all before starting not to bad to change did you check compression if your sure that's what it is its about 4hr job.start by putting #1 tdc intake side.note where vacuum hoses are can mark with gray or yellow perm marker remove breather all plug wires exhaust manifold then intake manifold remember what bolts in and whats nutted on.remove break booster cross vacuum hose and egr control valve on left rear of intake side remove vale cover ((you'll have to get something to hold tension on timing chain so not to let tentioner come out inside timing chain cover when removing came gear)) remove head bolts only in off order so not to put tension in one area. do not remove cam shaft bolts and do not turn cam shaft at all after timing gear is removed take off head and check piston walls for wear replace gasket and put back in GOOD LUCK

Jun 30, 2010 | 1985 Nissan Pickup

1 Answer

Rapping noice, sounds like a lifter...how hard is it to fix without going to garage


do to the complexity of the 4.2 dohc engine i am pretty sure you will find that you have a worn lobe on the cam shaft you will need to remove the intake and exhaust manifolds and remove the cam gears supporting the cam chain make sure the engine is on number on compression before removeing it once the manifolds are removed you can remove the valve cover to inspect the cam lobes and valve height

Jan 08, 2010 | 2002 Chevrolet TrailBlazer

1 Answer

I have a 1995 maxima 6 cylinder dual overhead cam engine,with a blown head gasket on tne number 1 piston.now ive got it torn down up to the front timing chain cover,and ive removed the main timing...


HI you need to remove all the bolts that attach rear cover to block and remove the oil pan to gain access to bolt that hold rear timing cover to upper pan hope thie helps.4163b8c.jpg

Sep 26, 2009 | 1995 Nissan Maxima

1 Answer

How do I change a 1999 chevy cavalier water pump?


if it's a 2.4 twin cam, not gonna be fun 6 hrs min, remove timinig chain cover, timing chain, and housing, next remove exhaust manifold, the you can get to it, sorry gotthe same car

Jun 20, 2009 | 2001 Chevrolet Cavalier

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