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FOREWORD. |
STEP 1 - DISASSEMBLY
PROCESS. |
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Here is my DIY article contribution for the many
out there that I have used in the past.
- This covers replacing the valve cover gaskets
for a 2000 1.8T (AWD).
- Should work for any 99-04 engine.
- Perform at your own risk, I take no
responsibility for you following this.
Torque specs according to Bentley:
- Cylinder head cover to cylinder head.....10Nm
(7ft-lb)
- Ignition coil to cylinder head
cover.........10Nm(7ft-lb)
- Ground wire to cylinder head
cover.........10Nm(7ft-lb)
Tools:
- Flat Head Screwdriver
- 10MM Wrench & any other large sized wrench
- Ratchet & small extension
- 10MM deep socket
- 5MM Allen Key w/ ball end
- Vice grips
- Telescoping magnet
- Gloves (optional of course)
Why are we doing this?
See all that oil seepage along the cover edge?
Not good.
VW TECH BY: Stewart (Stewz-GTI) |
- Remove the engine cover
- Using 10MM wrench remove the 2 bolts holding
this down
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STEP 2. |
STEP 3. |
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Remove the bracket and all the bolts holding
the coil packs in place using 5MM Allen Key.
Ball end will come in handy if you have it.
Remove the remaining bolts for each coil pack.
(2 each) |
Remove each coil pack by releasing the clip with
your flat head. Push the square hole in the
center and it will click. Pull out lifting
straight up (which is really at a 15deg angle). |
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STEP 4. |
STEP 5. |
I don't know if it is important to keep the same
order during re-install, so I made sure to place
them in the order I took them out. |
Using your 10mm wrench disconnect the ground
wire. |
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STEP 6. |
STEP 7. |
Next release the coil
pack
wire harness. Use your flat head to pry up each
of these plastic anchor pins. (the push back in
during the re-assemble). |
Using your 10MM ratchet w/
extension remove this bolt in the top right
corner of the cover. |
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STEP 8. |
STEP 9. |
Get your vice grip locked
on this spring clip connecting the hose to the
cover. Make sure the clip can move freely. |
Take your large wrench
and use it to pry the hose off the cover. It may
take some force but should pop off. |
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STEP 9. |
STEP 10. |
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Disconnect the cover
using the clips at the front and back with your
flat head or fingers. |
Using your 10MM ratchet
w/ extension equally loosen the 9 nuts
holding the cover in place. (3-back 3-mid
3-front) Get your telescoping magnet and lock
onto the nut and remove. |
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STEP 10. |
SEALANT AND GASKET. |
Get your flat head and
gently pry up on all 4 corners of the cover.
Slide the cover up (15 deg) and off the studs.
Remove and inspect old gaskets. There are two. |
Get your gasket
sealant and new gaskets ready. Make sure the
sealer you choose will not interfere with oil
and can handle some heat.
PART# 058198025A - VC Gasket Kit.
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STEP 11. |
STEP 12. |
Apply the sealant as
instructed by product. Make sure to apply to
both sides to get a proper seal. |
Now is a good time to
clean or polish that cover. Make sure it is 100%
dry before re-installing. |
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STEP 13. |
Reverse your process
making sure to take your time and take
her for a test run. After 1 week of performing
this I had no more leaks. |
