DIY - Removing Engine Cover

[JJ-R32]

Credit goes to syntrix for the write-up and all pics. :clap:
________________________________________________

I had a little issue today that I had to troubleshoot, so I took some pics. I think there's some general directions, but here's details with pics:


1. Unclip the two metal clips.
2. Unclip the MAF sensor and pull out of the way.
3. Undo the air intake or undo the clip right behind the box area.
X. Pull. Cuss. Repeat. After a few attempts, pull harder and wiggle cover out.

http://www.swankmonkey.com/vw/jetta/2006/images/engine_cover/cover_map.jpg



These are the mount points (4 of them) on the engine. If there are any rubber pieces on the posts, pull them off and put them in the cover before re-assy.

http://www.swankmonkey.com/vw/jetta/2006/images/engine_cover/engine_mountpoints.jpg



And here's the underside of the cover showing the mount points:

http://www.swankmonkey.com/vw/jetta/2006/images/engine_cover/cover_underside.jpg


Right after the cover comes off, locate all 4 rubber pieces. I lost the front passenger side, and it went under the intake. That was so much fun trying to find it!!!!
Anyway, hope that helps everyone that needs to get under that fancy plastic cover.

[TeknoGroover]

Damn, I was gonna do it. But the thing I learned when putting it back on is to have the rubber pieces on the cover first, then replace it.

[Plyngntrffc]

Can you repost the pictures? they aren't showing up on my computer...at all, and i really dont think its on my end...

[HotLanta MKfizzle]

Can you repost the pictures? they aren't showing up on my computer...at all, and i really dont think its on my end...

Try this:

http://www.swankmonkey.com/vw/jetta/2006/remove_engine_cover/

:headbang:

[Plyngntrffc]

Keep it on!!! lol not pretty with it off...

[taekwondo_kevin]

the carbon fiber one looks HAWT!
http://homepage.mac.com/risowu/OSIR/GTI_enginecover.htm


I guess it assembles onto the engine just like the regular cover...?
Does anyone know?

[Plyngntrffc]

its not the entire engine cover...just the lil part in the middle of it...

[cmdrfire]

the carbon fiber one looks HAWT!
http://homepage.mac.com/risowu/OSIR/GTI_enginecover.htm


I guess it assembles onto the engine just like the regular cover...?
Does anyone know?

You need to remove the silver bit and replace with the Carbon bit. Hopefully I will have this done by the end of the month.

[JeepNGLI]

I'm trying to take off just the center grey piece, but I can't seem to do it. Will those little grey things in the center(there's two of them) break? Will I be able to reuse it? Thanks.

[SoCalComatose]

Damn, I was gonna do it. But the thing I learned when putting it back on is to have the rubber pieces on the cover first, then replace it.

A tip: A bit of soapy water on the inside/outside of the grommets can make putting them in the cover and reinstalling it easier.

[DaleMeetsWall]

out of curiosity does the silver part of the cover come off by itself?

[c1rcausa]

Another Tip

Dont yank on it, just pull up with some force and the mounts will release.

Remeber dont yank

[AndorGLI]

ya i got the front of the center gray piece of but i cant seem to get it back on. your saying soap and water will help?

[Jax$MkV]

Can someone tell me how to remove the intake (#3) part out? Do I have to unscrew the two silver screw things on the sides of the box/funnel? Or...? I might have to look at it again, but when I tried today it wouldn't pop off? :iono:

[primus2211]

Can someone tell me how to remove the intake (#3) part out? Do I have to unscrew the two silver screw things on the sides of the box/funnel? Or...? I might have to look at it again, but when I tried today it wouldn't pop off? :iono:

2 options:

1) As u mentioned, remove the 2 torx screw and the front end of the intake.

2) 2nd option is to use a plier and loosen the metal clamp on the hose midway along intake.

Option #1 is easier if you have the right screwdriver. Do be careful about the 2 metal sleeves there because if that falls off, you're gonna have hard time retrieving them from the undertray.

In the event that happens, I find that the easiest to remove any screws or component that falls off on the front undertray is to give it a couple of good smack. The piece will inadvertantly fall off one of the holes onto the ground. :biggrin:

[Jax$MkV]

Thanks man. What do most of you guys do or prefer? Removing the screws or the clip? :iono: Can't the screws be removed with an allen wrench or something?

[primus2211]

Thanks man. What do most of you guys do or prefer? Removing the screws or the clip? :iono: Can't the screws be removed with an allen wrench or something?

Both ways are OK. Screws, you may be able to get away with an allen key of the right size as the screws are not that tight. Once you get that out, for easy removal in the future, change em to normal screws.

[Prince GTI]

Thank for a great write up! It helped me install my EVOMS intake

:thumbup:

[LasVegas]

I read somewhere that it's easier to do one side at a time. Pull up on the right side first and the left side comes out easier. Pull at the places marked by the "X"s. You can pull like hell on the right side but be careful on the left side because it's not as rigid.

Thanks for the write-up! :clap:

[blackgti06]

anyone wanna sell their engine cover to me?

[-mission-]

I read somewhere that it's easier to do one side at a time. Pull up on the right side first and the left side comes out easier. Pull at the places marked by the "X"s. You can pull like hell on the right side but be careful on the left side because it's not as rigid.
Thanks for the write-up! :clap:Is that right side you facing the car or right side (medical right) - as if from the perspective of the car.

- M -

[-mission-]

A tip: A bit of soapy water on the inside/outside of the grommets can make putting them in the cover and reinstalling it easier.Proper rubber grease OK ..

Not THAT kinda "rubber" grease ... hahaha

This kind.
http://www.pbr.com.au/products/replacement/ancillary.shtml

http://www.pbr.com.au/products/replacement/images/RubberGrease_000.jpg

[Jax$MkV]

How the hell do you remove the center gray piece to paint? I cut myself trying and it wouldn't budge... stupid tabs. :mad:

[Whafrodamus]

I've had the hardest time removing it. It won't detach from the TI hose >_<

[Jax$MkV]

Nevermind, I used a cardboard cutter and sliced the tabs off from the back. It still snaps on fine. :smile:

[ewoo]

I read somewhere that it's easier to do one side at a time. Pull up on the right side first and the left side comes out easier. Pull at the places marked by the "X"s. You can pull like hell on the right side but be careful on the left side because it's not as rigid....

He's totally right. I'd do the lower right first (nearest to the intake opening), then the lower left. Finally, do the two upper ones at the same time. Once you look at the rubber mounts, you'll know how strong you need to pull (but steady without yanking).

Wear some mechanics gloves because your finger can get torn-up the metal parts beneath the cover.

Also, it's pretty damn hard to get it back on--so, use some rubber grease or lubricant. It will help. Install the top (rear) portion of the cover first then do the lower left and finally the lower right side. Make sure you get the rubber gasket around the oil cap right before you put the cover back too!

BTW, if you don't need to swap out the air filter, DON'T. It's not worth the trouble. Mine was pretty damn clean after 22,000 miles (I live in the midwest). Also, IMHO, aftermarket intakes have no significant improvement on performance because the stock is designed so well---and also because this is a turbo charged engine. Your money is better spent on an ECU upgrade and/or new exhaust system.

[eROCK]

^^^^ Instead of starting a new thread, I thought I'd resurrect this old DIY with my experience. This above comment was more helpful than any of the others. I spent about an hour following the other DIY for this...everyone says grab the sides and just pull...don't yank. Well that didn't work for me. Once I took a break to research more online, I saw the above comment, so I decided to attack this differently. I first removed the clamp that holds on the intake hose/tube so I could take that off - more room for my hands to pull on the cover. I started on the lower right corner by where the intake hose would have been. After pulling on it steady for about 15 seconds...it popped off! I spent an hour before just pulling on both sides at the same time. My back and fingers are killing me! Once the front popped off, the rear right corner just popped off too. I then started on the front left, and it came off on the second try of pulling. The rear left side was super easy after that. So now that I had it off, I swapped out the filter with a new K&N. I followed the above suggestion to put soapy water on the rubber grommets, and this worked perfectly! No struggle at all to get the cover back on...it just snapped on with little effort.
I was very close to giving up on this...but the persistence paid off. I'm sure I could have it off in 20 minutes tops next time.
So just to recap...take in all the information at the beginning of this thread...know where the connection points are under the cover. My useful tips are:
* remove the clamp and intake hose/tube first to make room for your hands/fingers.
* start pulling with both hands on the bottom right side next to where the intake tube would be. Once it pops off, try the rear right side. Then start on the bottom left side with both hands. Last is the rear left side.
Once you get the first corner off, the rest are easy.
* get a cup of soapy water and a rag. Put the soap on the inside of the rubber grommets before trying to put the cover back on the engine. It'll just snap on after that.
Hope this helps anyone that's close to the point of quitting...Like I was.
Cheers...
:thumbsup:

[wilytech]

I found that pulling from the bottom left first is best but that's me. Maybe the right is the same but I could reach right under and feel the grommet thing and exactly where to pull

[PyRo H4cKeR]

Just grab it and pull really hard, doesnt matter if you break it. Cause it looks gay anyway. get an intake so you don't need that engine cover.

engine covers FTL

[Orotaro]

off-topic, but does anyone know the part number to the four rubber piece attached to the ball joint and engine cover??? i tried looking at the oem VW part number thread.no luck.

[Orotaro]

nvm.found it!! =)

[sh00k0nes pt. 2]

man **** these engine covers lol
i was pulling on the damn thing so hard i almost got an hernia

[N8_DUB]

I had a bolt come loose on one of the mounts that holds the grommet...

I have the pics located here:

http://www.golfmkv.com/forums/showthread.php?t=73774

Any Ideas how to get that bolt back in without removing the intake?

[N8_DUB]

Just grab it and pull really hard, doesnt matter if you break it. Cause it looks gay anyway. get an intake so you don't need that engine cover.

engine covers FTL

YES! if you want to void the warranty... If your warranty is up, GO FOR IT!

[N8_DUB]

^^^^ Instead of starting a new thread, I thought I'd resurrect this old DIY with my experience. This above comment was more helpful than any of the others. I spent about an hour following the other DIY for this...everyone says grab the sides and just pull...don't yank. Well that didn't work for me. Once I took a break to research more online, I saw the above comment, so I decided to attack this differently. I first removed the clamp that holds on the intake hose/tube so I could take that off - more room for my hands to pull on the cover. I started on the lower right corner by where the intake hose would have been. After pulling on it steady for about 15 seconds...it popped off! I spent an hour before just pulling on both sides at the same time. My back and fingers are killing me! Once the front popped off, the rear right corner just popped off too. I then started on the front left, and it came off on the second try of pulling. The rear left side was super easy after that. So now that I had it off, I swapped out the filter with a new K&N. I followed the above suggestion to put soapy water on the rubber grommets, and this worked perfectly! No struggle at all to get the cover back on...it just snapped on with little effort.
I was very close to giving up on this...but the persistence paid off. I'm sure I could have it off in 20 minutes tops next time.
So just to recap...take in all the information at the beginning of this thread...know where the connection points are under the cover. My useful tips are:
* remove the clamp and intake hose/tube first to make room for your hands/fingers.
* start pulling with both hands on the bottom right side next to where the intake tube would be. Once it pops off, try the rear right side. Then start on the bottom left side with both hands. Last is the rear left side.
Once you get the first corner off, the rest are easy.
* get a cup of soapy water and a rag. Put the soap on the inside of the rubber grommets before trying to put the cover back on the engine. It'll just snap on after that.
Hope this helps anyone that's close to the point of quitting...Like I was.
Cheers...
:thumbsup:

If that is not an option, I found that keeping the grommets in the engine cover helps... The posts go into the grommets easier than the grommets go into the cover....

:wink:

[Edgar]

Thanks to the OP for putting this DIY for us, it make changing my air filter so much easy!!!!

Thanks again.

[kithng]

does removing the engine cover help releasing heat from the engine??

[cmdrfire]

Probably not much is my guess. In any case, the stock intake filter is in the (FSI) engine cover, so you can't remove it unless you get an aftermarket intake/filter.

[N8_DUB]

Probably not much is my guess. In any case, the stock intake filter is in the (FSI) engine cover, so you can't remove it unless you get an aftermarket intake/filter.


Only other option (I don't recommend if you are still under warranty) is cutting the middle part of the engine cover off, leaving the air intake peice of it on the car... Only thing is, you would need to mount the intake half to the engine where an aftermarket CAI would bolt on... And there are not any mounts built into the engine cover to do this (you would have to not only cut and fit this yourself, but you would have to come up with a way to mount that intake housing)...

Summary:

NOT WORTH IT!!! It most likely won't even reduce the heat on your engine enough to be worth the effort.... :thumbsup:

[hpdevildog]

Yea i ended up cracking mine today while putting a new intake on. Those 4 little rubber pieces are really on there.