DIY engine cover removal/air filter change

Cayjack · Feb 10, 2010

So I have taken my engine cover off so many times in that past few days that I decided I would post this for anyone who has never done it or even those who have and not had a good time doing this horrible task.

Some of the steps are very obvious and but I figured I would be as detailed as possible. And hopefully this makes for easier removal.

Step 1.
Unhook air intake.
a. remove cap (this is very simple, just lift up on tabs on either side)

b. push in the tabs on sides of the lower part(in the center of pic) and just lift up and it will come free

c. release clamp and remove plastic hose from cover inlet

Don't know how to add any more pics to this post so I will continue with seperate posts. Sorry. If anyone can tell me how to put all pics in one, let me know.

Cayjack · Feb 10, 2010

Continued

Step 2. Undo clips near MAF sensor and disconnect.

Then unhook MAF plug connection. Insert screwdriver and GENTLY pull back while pulling plug towards you with your other hand. You really don't have to pry hard at all to release tab.

Cayjack · Feb 10, 2010

Continued

Step 3 is the fun part! Pulling cover off.:fighting0030:
I have heard many horror stories about this and several different methods to get these stupid things off. This is the way I found worked best for me.

a. Grab front right side first.

You can pull up rather hard while wiggling it side to side a bit. Then just when you feel like you are pulling as hard as you can with a steady pull, give it a quick jerk to pop the rubber grommet off of the post.

b. grab front left side here and repeat

c. grab right rear here and repeat

d. now with the left rear I used both places to pull, you dedcide which one works best for you.

Note: if you place your fingers in the hole to pull be careful not to go in to far and damage MAF sensor.

Cayjack · Feb 10, 2010

Continued

DO NOT PULL HERE!!!! THIS IS WHAT HAPPENS!!!!

Cayjack · Feb 10, 2010

Continued

Now that your cover is off. Hopefully in one piece. Check the posts to make sure that the rubber grommets are not stuck on them. If one is, just pop it off and put it back in the hole on the cover.
It should look like this.

Not this.

Next, flip cover over on your workbench, cardboard, etc. and you will see all eight of the screws that need to be loosened. They don't come all the way out. You will know when they are loose.

Then just lift up on front like you are opening your laptop. It is hinged at the back. Then just pull apart.

Cayjack · Feb 10, 2010

Continued

Now replace filter and put it all back together. I found it easier to re-attach the two pieces of the cover if you flip it back over the other way and get all the tabs in the slots. Don't force it closed. If it doesn't close easily then all the tabs are probably not set right in the slots. Take your time.
Then obviously tighten screws down. When they stop they are tight. Don't over tighten.

To place cover back on engine you need to start frome the front again. Place it on, lining up the oil fill hole then look under cover on both sides to make sure grommets are lined up with posts. Then give a good push down till it seats. The back ones should be lined up now so just push down in back and you're done.

Reverse all other steps, making sure everything is reconnected properly.

Hope this helps. Anybody have anything to add feel free.:thumbsup:

victim2009 · Feb 13, 2010

Bro,

great detail job, by the way how much the air filter? how many mileage need to change?

Look forward to hear from you

Thank

Cheers

tmoult · Feb 13, 2010

Good guide, anyway you could sort of highlight with a red line or something what screws you are taking off? Sorry Im such a noob!

Cayjack · Feb 13, 2010

victim2009 said:
Bro,

great detail job, by the way how much the air filter? how many mileage need to change?

Look forward to hear from you

Thank

Cheers

The AFE filter was $38, the OEM was $21.50 @ dealership, but you can order them cheaper(like 15 or 16 bucks). I just didn't want to wait. VW recommends to change every 20k I believe. Check owners manual to be sure.:thumbsup:

Cayjack · Feb 13, 2010

tmoult said:
Good guide, anyway you could sort of highlight with a red line or something what screws you are taking off? Sorry Im such a noob!

I wanted to hightlight and circle things when I posted this thread, but I don't know how yet.
But there are 8 screws on the underside of the cover, 2 in upper left hand corner, 3 across the center section and 3 across the bottom. You need to loosen all of them, but not remove them. There is a built in retainer to hold them in, you will know when they are loose enough.
Hope that helps.

Marionettenspieler · Aug 14, 2011

Well Done!

Thank you for this very helpful and detailed DIY.

bigbadvoodooguru · Aug 14, 2011

The Rabbit is essentially the same thing except all the intake hardware stuff is in the front. My 09 does not have a MAF plug either, but earlier Rabbits do.

Nataraki · Sep 8, 2011

this is the DIY i'm looking for, great job and thanks!

darbs · Nov 19, 2011

is there a trick to removing the turbo inlet pipe from the MAF? after removing the two clips and pulling the pipe away a little bit, it doesn't really budge from the MAF housing. there's a little bit of give to it, but it appears to return back to it's original position after I let go of it, any tips? thanks.

chimchim · Jul 22, 2012

Thanks Cayjack! This saved me so much time and money. One little thing I learned: the rubber gaiter around the oil fill neck goes on before the engine cover does. I learned this the hard way and had to remove and reinstall the cover again.

DIY engine cover removal/air filter change

Cayjack

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tmoult

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Cayjack

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