2.0TFSI engine cover removal?

[Gti Dave]

I had a quick read on this link I found prior to attempting to remove the engine cover to change the air filter but got stuck and don't want to go tugging it any harder in case I crack the darn thing. I've got a Skoda octavia RS but it has the same engine and drive train as the mkV gti so thought I might be able to get some pointers from here.

Removing cover 2.0T FSI - VW GTI GLI JETTA AUDI A3 - 2006 VW Jetta GLI 2.0T FSI

How hard do you need to pull exactly and is there any specific technique or extra screws that I don't know about that is not outlined int he guide from the link above?

It should be as easy as undoing one or two things and then a tug but its stuck on or something? Won't budge. Any experiences?

[HOTHATCH]

Looking at the "X" on the RH side of the picture in the link you've provided you will feel a "V" depression in the cover. If you take the cover off your battery you can then use the wooden handle end of a hammer to lever off the cover using the edge of the battery as a fulcrum. That's how I do it and it works every time. Pulling up will only ruin your back and give your Chiropractor your hard earned $$$. Hope this helps.

David.

[TomC]

I used this DIY - DIY: removing stock engine cover (2.0T) | Volkswagen Rabbit/GTI/Jetta/GLI MkV DIY & FAQ - I found the photos more helpful to see exactely where you should pull on the cover so you don't break it.

Also, best advice I was given was to let the engine run for a few minutes to warm the cover up. This helped to soften the rubber grommits, which are basically what holds the cover on. After doing this, it came off with only moderate force (but it will "pop" off when you reach the threshold of the rubber grommits, be ready for that!).

[Jmac]

Always go from the rear. And yes be ready for the pop. Dont be surprised if you break a balljoint, they go brittle and crack. I keepthem along with grommets in the Mobile rig at all times now. now bit of advice as ive seen this heaps, if you have had it removed before or someone else has, then check it and make sure its secure. Reason i stress this is ive had a customer buy a second hand Gti, it was serviced and the rear balljoint were snapped off and not replaced. Now the air box was flopping around. The Mk5 gti engine does have a fair bit of movement on a good day, now with this said , my customers car presented running very rough, engine light on the worx. Turned out the air box moved and knocked the top off the oil filler cap. So what you say?? the engine then draws in secondary air and runs like a pork chop, send the ecu haywire. Now that was an easy fix, new ball joint and grommets and filler cap. Next was a bit worse. Passat with the same BWA engine. Running very poor. Loose air cleaner snapped the top off the high pressure fuel pump. VW quoted mega price to fix. I soldered 2 new terminals into the pump and rewired so all good, but could have got ugly at the dealer and all stemmed from a loose air cleaner. treat them with upmost respect. Break the joints or loose/tear the grommets change them for the win
Cheers
Jmac

[Corey_R]

Hey Jmac - where do you get the balljoints from and how much do they cost approx?

[Jmac]

Hey Jmac - where do you get the balljoints from and how much do they cost approx?

Straight from VW, weird part number i can post it up if you like. Well worth havin spares along with grommets
Cheers
Jmac

[Corey_R]

The reason I asked is I'm going to get a new intake for my R. Whilst it doesn't have this exact cover, it has the MK6 TFSI version and the air filter is integrated. So I was going to get an Audi TT-S engine cover, but it needs different ball joints - two WHT000731A and one 06E103164. ECS Tuning have them for US$10.97 each. I was just wondering if that is "out there" for these types of parts, or around what you'd expect.

[whiteVR6]

Always go from the rear. And yes be ready for the pop. Dont be surprised if you break a balljoint, they go brittle and crack. I keepthem along with grommets in the Mobile rig at all times now. now bit of advice as ive seen this heaps, if you have had it removed before or someone else has, then check it and make sure its secure. Reason i stress this is ive had a customer buy a second hand Gti, it was serviced and the rear balljoint were snapped off and not replaced. Now the air box was flopping around. The Mk5 gti engine does have a fair bit of movement on a good day, now with this said , my customers car presented running very rough, engine light on the worx. Turned out the air box moved and knocked the top off the oil filler cap. So what you say?? the engine then draws in secondary air and runs like a pork chop, send the ecu haywire. Now that was an easy fix, new ball joint and grommets and filler cap. Next was a bit worse. Passat with the same BWA engine. Running very poor. Loose air cleaner snapped the top off the high pressure fuel pump. VW quoted mega price to fix. I soldered 2 new terminals into the pump and rewired so all good, but could have got ugly at the dealer and all stemmed from a loose air cleaner. treat them with upmost respect. Break the joints or loose/tear the grommets change them for the win
Cheers
Jmac

As above with pictures : Engine cover issues - VW GTI Forum / VW Rabbit Forum / VW R32 Forum / VW Golf Forum - Golfmkv.com

[99_FGT]

So how does one remove the ball joints when fitting an intake??
Can't work that out, and already spent 30 minutes getting the hose off the turbo, so no going back now.
Al..

[Corey_R]

If you're talking the engine cover ball joints, then from what I've seen from the link I pasted about people changing the MKV GTI to the Audi TT-S engine cover, they're just bolts and should unscrew...

[Transporter]

I always put a bit of ATE Plasti Lube on these ball joints, it makes removing them next time a bit easier.

[99_FGT]

Figured it out - was looking at the front ones and going on the same basis to do the rears. The rears, however, have a 10mm nut underneath the fairing that the mounts are fastened too. The fronts are much easier to get at. Needless to say, I now need two new ball joints (one was already broken) if I want to refit the std cover.
I do like the look of the TT-S cover, maybe down the track though.
Al..