How to install PD Engine Cover Attachments on an MK4 Cover Part 1

[tothemax]

These PD Engine Cover Attachments literally makes it a snap to take the engine cover on and off. Saves getting my 10mm socket and ratchet every time.

I am making a short "how to" so that the next nub (like me) can understand which part to file off. Everyone was explaining me which part I needed to file off but for the life of me, I could not visualize it. So for all those of us that cannot visualize without photos, here it goes:

First I needed these:

I bought them here:

http://www.tdiparts.com/catalog/product_info.php?products_id=770

Then I pulled off the engine cover, and turned it upside down on a stable work area. (better not to use the recycling bin for this) I pulled off the 3 rubber sleeves shown here

Now it looks like this:

I get my Dremel tool and widen the inside of the plastic posts off the engine cover. I shave off about 1/8 " to increase the ID of the hole about 1/4". I make sure I wear safety glasses so as not to get molten plastic and other debris in my eyes.

Now the hole looks about like this and I can stop widening it.

Then I stick the sleeve in from the bottom and try to stick is all it in there. it's not easy. A lot harder to stick in than some other things I stuck into when I was 15. It helps to use a flat head screw driver and push down on the horizontal groove shown below to get in all in there. It helps to fold it over onto itself and push it down into the hole with the flat head to get it engaged.

It ends up looking like this when it's in all the way in:

This engine cover is ready to go back on. Except I need to replace the studs. Let's go to part 2

 

[tothemax]

How to install PD Engine Cover Attachments on an MK4 Cover Part 2

Now I am removing the three OEM MK4 engine cover studs. One may want to lube them up ahead of time w/ loose nut or wd40 b/c I ended up breaking one stud.

After pulling them off, I installed the snap on new PD engine cover studs. I put a little lithium grease on them so they will not break if/when I remove them in the future.

It makes it a lot easier to pull the cover on and off. Now I put the engine cover back on. WHAT A SNAP!

The female part looks like this from above

In my opinion, this is a well worth upgrade for those who like to tinker and check a lot under the engine cover.

I am very happy with this upgrade. the whole thing took less than one hour but I had to deal w/ the broken stud. Good luck!

 

[rocketeer928]

Very nice. Maybe I'll give this mod a try.

 

[cattlerepairman]

That looks like a mod that makes sense. I like having the cover on during the winter up here. It seems to trap warm air.

I need to check how much the parts are at the stealership....

 

[whitedog]

Is that the same thing that Matthew_S posted here a couple years back?

 

[Occams_Razor]

Is that the same thing that Matthew_S posted here a couple years back?

Yup.

 

[agdtec]

Thanks for the post I never saw it before but I like this upgrade I'll have to do it myself.
It looks easy enought that even I could manage,.....
but being the chicken sh!7 I am I'll probably ask a freind to look over my shoulder cause I always seem to screw up easy stuff.
Not so much the big stuff since I am usually smart enought not to tackle those jobs, except I did try to do my own brakes.

Not my best thinking
add tow cost to mechanics fee and lets just say.. I did not save money.

But this looks like something even I could handle... maybe

 

[tothemax]

I just searched back and found Matthew_S's post on this subject. It is exactly the same topic, I wish I had seen his post before I made this one. His provides an excellent description of how to do this job.

Is that the same thing that Matthew_S posted here a couple years back?

 

[Farfromovin]

Nice. I would probably use my engine cover with this mod if I could get it to fit over the darn 2 slow oil cap I'm using... LOL. Good writeup though.

 

[brotha bran]

Reviving this thread so hopefully someone can offer some input. I shot an email to Peter at tdiparts as well but this might be quicker being Sunday and all.

I am trying to install the PD engine cover attachments on my '03 Golf. Everything sets up fine but for some reason the rear most bolt (closest to the windshield) doesn't engage into the hole. It appears the hole isn't threaded except for the very bottom, so maybe the bolt isn't long enough to hit the threads? Anyone else run into this or have any idea why it may be like this on my Golf? The other two screwed in perfectly and I have the rubber grommets in, just can't get the top bolt on.

 

[whitedog]

It sounds like the hole in the intake manifold is stripped out. You will need to install a thread repair in the hole. The proper way to do it would be to install a helicoil or some such, but since the stud won't be removed again (theoretically) there are other, liquid thread repair options. See your local auto parts store for details.

 

[brotha bran]

Figured that's what it was. Should some JB Weld do the trick or should I try to hunt down a helicoil like you mention?

 

[whitedog]

I'm not sure if JD weld would work, though it might.

 

[burpod]

if anyone wants some of the brackets/bolts for PD engine cover stuff, i removed them from my two BEW tdi's. PM me

edit -- turns out i only have a few of the bolts and brackets that mount to the engine, but no grommets. sorry. back to your regularly scheduled program

 

[fnord]

Just did this on the car today. Works like a charm. Cheap, easy convenience mod.

I found that the new rubber sleeves went in easier if you warm 'em up in a glass of hot water (it was a cold day today), and you put a little oil on em before you go trying to shoe-horn em into the holes.

 

[SFHGolfTDI]

It sounds like the hole in the intake manifold is stripped out. You will need to install a thread repair in the hole. The proper way to do it would be to install a helicoil or some such, but since the stud won't be removed again (theoretically) there are other, liquid thread repair options. See your local auto parts store for details.

Whitedog, I have the same issue and want to install a helicoil. My only concern is that it appears that the angle of the rear hole makes drill access difficult. I need to doublecheck whether I will be able to drill the hole at the proper angle (car body is in the way by a hair). Have you done this? Or anyone who has, can you confirm that you are able to get in there with a drill? If not, what other options are there?

Thanks.

 

[whitedog]

I have only done it off the enigne, so I can't give you any help there other than use a small drill or an angle drill.

Edit:

Here is a thought. It may be possible that the stripped hole is the same size as the helicoil drill, or at least very close. If so, you may just be able to run the helicoil tap down the hole.