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Customer statement / workshop findings Customer statement / workshop findings Customer statement / workshop findings Customer statement / workshop findings
Customer statement: Customer statement: Customer statement: Customer statement:
Workshop findings: Workshop findings: Workshop findings: Workshop findings:
Technical background Technical background Technical background Technical background
Because of component-related deviations the cylinder head cover with the part number 03L 103 469 H 03L 103 469 H 03L 103 469 H 03L 103 469 H can leak
around the oil filler neck.
Production change Production change Production change Production change

Measure Measure Measure Measure

Assess the damage according to the following instructions and, if necessary, replace the cylinder head cover. Assess the damage according to the following instructions and, if necessary, replace the cylinder head cover. Assess the damage according to the following instructions and, if necessary, replace the cylinder head cover. Assess the damage according to the following instructions and, if necessary, replace the cylinder head cover.
Repair the cylinder head cover according to the following instructions. Repair the cylinder head cover according to the following instructions. Repair the cylinder head cover according to the following instructions. Repair the cylinder head cover according to the following instructions.
With the following check the crankcase ventilation must not be closed for more than 30 seconds when the engine With the following check the crankcase ventilation must not be closed for more than 30 seconds when the engine With the following check the crankcase ventilation must not be closed for more than 30 seconds when the engine With the following check the crankcase ventilation must not be closed for more than 30 seconds when the engine
is running. If the check takes longer, the pressure must be released. is running. If the check takes longer, the pressure must be released. is running. If the check takes longer, the pressure must be released. is running. If the check takes longer, the pressure must be released.
1. 1. 1. 1.
Technical product information Technical product information Technical product information Technical product information Transaction No.: 2030685/5 2030685/5 2030685/5 2030685/5
Oil loss in cylinder head area/cylinder head cover Release date:13-Dec-2013
Oil leaks in the engine compartment.
Oil marks under the vehicle.
Engine oil loss in cylinder head/cylinder head cover.
Unlock the crankcase ventilation hose on the cylinder head cover and lay it aside (illustration 1, red arrows).
Illustration 1 Illustration 1 Illustration 1 Illustration 1
Illustration 2 Illustration 2 Illustration 2 Illustration 2
Close the adapter on the cylinder head cover (illustration 1).
Run the engine at idle speed.
Spray the marked area (illustration 2 and 3) with commercially available glass cleaner or a leak-searching
spray. Check sprayed area between oil filler neck and cylinder head cover for bubbles.
If a leak is found in the marked area (illustrations 2 and 3) and a cylinder head cover with part number: 03L 03L 03L 03L
103 469 H 103 469 H 103 469 H 103 469 H is fitted (illustration 3), repair the cylinder head cover according to point 2 point 2 point 2 point 2 of the instructions.
Illustration 3 Illustration 3 Illustration 3 Illustration 3
2. 2. 2. 2.
The cylinder head cover must be dried several times with compressed air, as liquid settles in the beadings and The cylinder head cover must be dried several times with compressed air, as liquid settles in the beadings and The cylinder head cover must be dried several times with compressed air, as liquid settles in the beadings and The cylinder head cover must be dried several times with compressed air, as liquid settles in the beadings and
indents. indents. indents. indents.
Illustration 4 Illustration 4 Illustration 4 Illustration 4
Wash the engine and carefully dry the engine and the engine compartment with compressed air.
Clean the bonding surface in the oil filler neck (with cloth). Thoroughly clean the bonding surface with
applicator (part number D 009 500 25 D 009 500 25 D 009 500 25 D 009 500 25) and cleaner (part number D 009 401 04 D 009 401 04 D 009 401 04 D 009 401 04). Dry the complete area with
compressed air (illustration 4-6). Repair the cleaning process several times till the bonding surface is
completely dry and liquid does not come out any more.
Illustration 5 Illustration 5 Illustration 5 Illustration 5
Illustration 6 Illustration 6 Illustration 6 Illustration 6
Warm up the bonder (part number D 176 501 A1 D 176 501 A1 D 176 501 A1 D 176 501 A1) in the cartridge heater -V.A.G 1939- for at least 15 minutes.
The tip of the bonder cartridge must be extended with a 10 cm long protective sleeve (part number N 018 007 N 018 007 N 018 007 N 018 007
5 55 5, illustration 7).
Illustration 7 Illustration 7 Illustration 7 Illustration 7
With the following work make sure that bonder does not get into the valve drive. With the following work make sure that bonder does not get into the valve drive. With the following work make sure that bonder does not get into the valve drive. With the following work make sure that bonder does not get into the valve drive.
Illustration 8 Illustration 8 Illustration 8 Illustration 8
Brush the bonder on the bonding surface and in the beading (illustration 8 and 9).
1. Seal (part number: 03L 103121) Seal (part number: 03L 103121) Seal (part number: 03L 103121) Seal (part number: 03L 103121)
2. Bonder (part number: D 176501 A1) Bonder (part number: D 176501 A1) Bonder (part number: D 176501 A1) Bonder (part number: D 176501 A1)
3. Damage area Damage area Damage area Damage area
Illustration 9 Illustration 9 Illustration 9 Illustration 9
When positioning the seal observe its shape and the "top" label. Remove any escaped bonder straight away with a When positioning the seal observe its shape and the "top" label. Remove any escaped bonder straight away with a When positioning the seal observe its shape and the "top" label. Remove any escaped bonder straight away with a When positioning the seal observe its shape and the "top" label. Remove any escaped bonder straight away with a
screwdriver (illustration 11, arrow). screwdriver (illustration 11, arrow). screwdriver (illustration 11, arrow). screwdriver (illustration 11, arrow).
Illustration 10 Illustration 10 Illustration 10 Illustration 10
Feed the seal with part number 03L 103 121 03L 103 121 03L 103 121 03L 103 121 (illustration 10) through the opening of the oil filler neck, position
and press it down (illustration 11).
Illustration 11 Illustration 11 Illustration 11 Illustration 11
Warranty accounting instructions Warranty accounting instructions Warranty accounting instructions Warranty accounting instructions
Service number/damage code/manufacturer: S444/0050/WWO
The labour times are correct at the time of publication. The time units may differ, if the repair operations catalogue The labour times are correct at the time of publication. The time units may differ, if the repair operations catalogue The labour times are correct at the time of publication. The time units may differ, if the repair operations catalogue The labour times are correct at the time of publication. The time units may differ, if the repair operations catalogue
has been updated. The information in the repair operations catalogue applies, except for the open time items (... has been updated. The information in the repair operations catalogue applies, except for the open time items (... has been updated. The information in the repair operations catalogue applies, except for the open time items (... has been updated. The information in the repair operations catalogue applies, except for the open time items (...
99). 99). 99). 99).
Accounting with APOS: Accounting with APOS: Accounting with APOS: Accounting with APOS:
Determining the specified time
Use the specified times only for this TPI.
Variant 1: Establish damage
Variant 2: Repair cylinder head cover
Remove bonder residues (illustration 11) with a screwdriver.
Do not yet start the engine. Let the bonder harden for at least 8 hours at room temperature.
The The The The necessary time for using the diagnostic tester is not included. it must be accounted separately with the necessary time for using the diagnostic tester is not included. it must be accounted separately with the necessary time for using the diagnostic tester is not included. it must be accounted separately with the necessary time for using the diagnostic tester is not included. it must be accounted separately with the
print print print print- -- -out of the tester. out of the tester. out of the tester. out of the tester.
Variants Variants Variants Variants
Main Main Main Main
operation /Associated operation /Associated operation /Associated operation /Associated
operation operation operation operation
AP AP AP AP Designation Designation Designation Designation TU TU TU TU
Variant 1 Variant 1 Variant 1 Variant 1 Main operation Main operation Main operation Main operation 15820199 15820199 15820199 15820199 Check cylinder head cover Check cylinder head cover Check cylinder head cover Check cylinder head cover 30 30 30 30
Variant 2 Variant 2 Variant 2 Variant 2 Associated operation Associated operation Associated operation Associated operation 15825199 15825199 15825199 15825199 Seal off cylinder head cover Seal off cylinder head cover Seal off cylinder head cover Seal off cylinder head cover 50 50 50 50
Includes Includes Includes Includes
Clean engine
Accounting with APOS/2: Accounting with APOS/2: Accounting with APOS/2: Accounting with APOS/2:
Parts information Parts information Parts information Parts information
The part numbers and indexes of this TPI are correct at the time of publication. If the parts catalogue has been The part numbers and indexes of this TPI are correct at the time of publication. If the parts catalogue has been The part numbers and indexes of this TPI are correct at the time of publication. If the parts catalogue has been The part numbers and indexes of this TPI are correct at the time of publication. If the parts catalogue has been
updated, use the current part numbers and indexes. updated, use the current part numbers and indexes. updated, use the current part numbers and indexes. updated, use the current part numbers and indexes.
Associated operation Associated operation Associated operation Associated operation 01500099 01500099 01500099 01500099 GFF/guided function .
*according to
self-diagnosis
protocol
The repair operations include all the work of this TPI. The repair operations include all the work of this TPI. The repair operations include all the work of this TPI. The repair operations include all the work of this TPI.
Model Model Model Model Illustration Illustration Illustration Illustration Position Position Position Position Designation Designation Designation Designation Activity Activity Activity Activity TU TU TU TU
2C T10-00 03 Check cylinder head cover 98 30
2C T10-00 05 Seal off cylinder head cover 98 50
2C STA-02 01 GFF/guided function . 00 *according to
self-diagnosis
protocol
The repair operations include all the work of this TPI. The repair operations include all the work of this TPI. The repair operations include all the work of this TPI. The repair operations include all the work of this TPI.
Part number Part number Part number Part number Designation Designation Designation Designation
03L 103 121 Moulded seal
D 176 501 A1 Bonder
N 018 007 5 Insulation hose
D 009 401 04 Cleaner
D 009 500 25 Applicator