Cylinder Head, Removing And Installing: Installing
Install in reverse order of removal. Note the following:
Tightening specifications:
- Refer to OVERVIEW - CYLINDER HEAD .
- Cylinder head - tightening specification and sequence. Refer to OVERVIEW - CYLINDER HEAD .
The sealing surfaces could be damaged.
- Carefully remove sealant residue from cylinder head and cylinder block.
- Make sure that no long scrapes or scratches result.
Risk of damaging cylinder block.
- No oil or coolant must be in the cylinder head bolt blind holes in the cylinder block.
Risk of leaks in cylinder head seal.
- Carefully remove all grinding and sanding residue.
- Only unpack new cylinder head gasket immediately prior to installation.
- To prevent cylinder head gasket silicone layer and recessed area from being damaged, always handle seal extremely carefully.
Risk of damaging open valves.
- If a replacement cylinder is installed, only remove plastic base right before cylinder head is installed to protect open valves.
Risk of damaging valves and piston heads after working on valve train.
- To ensure valves do not strike pistons when starting, carefully rotate engine at least two full revolutions.
Replace the bolts that were tightened with an additional turn.
Replace self-locking nuts, gaskets, seals and O-rings.
It is not permitted to re-work the cylinder heads on TDI engines
If a replacement cylinder is installed, contact surfaces between the roller rocker lever and the cam lubricating surface must be lubricated before installing cylinder head cover.
Secure all hose connections with standard production hose clamps.
When replacing the cylinder head or cylinder head seal, all of the coolant and engine oil must be replaced.
-- Before installing the cylinder head, adjust the crankshaft and camshafts to "Top Dead Center (TDC)" :
- Secure crankshaft -1- in "TDC" position using Crankshaft Holder3242.
- The camshafts are stopped with the Camshaft Adjustment PinsT40060.
- The bolt -arrow- in the Camshaft Adjustment PinsT40060 must be perpendicular to the center line of the camshaft on cylinder bank 1 (right).
- The bolt -arrow- in the Camshaft Adjustment PinsT40060 must be perpendicular to the center line of the camshaft on cylinder bank 2 (left).
-- Note the marking on the cylinder head gasket:
- Part number
- Holes
If the cylinder head gasket or the cylinder head were replaced, select a new cylinder head gasket with the same number of holes as the old gasket.
If parts of the crank drive were replaced, then the new cylinder head gasket must be determined by measuring the piston projection in "TDC". Refer to PISTON PROJECTION, MEASURING AT "Top Dead Center (TDC)" .
The cylinder head gaskets for the left and right cylinder head cannot be interchanged because they each have a different shape.
-- Position the cylinder head gasket.
- Pay close attention to alignment bushings in cylinder block -arrows-.
- Cylinder head gasket installation position: "oben" (top) marking or part number toward cylinder head.
-- Set the cylinder head in place.
-- Tighten the cylinder head bolts. Refer to OVERVIEW - CYLINDER HEAD .
It is not necessary to retighten the cylinder head bolts after repairs.
-- Install front coolant pipe. Refer to FRONT COOLANT PIPE ON ENGINE, REMOVING AND INSTALLING .
-- Install the high pressure lines. Refer to FUEL RAIL, HIGH PRESSURE LINES, FUEL INJECTORS OVERVIEW .
-- Install the EGR pipe. Refer to OVERVIEW - EXHAUST GAS RECIRCULATION .
-- Install the camshafts. Refer to CAMSHAFTS, REMOVING, USED CAMSHAFTS FOR CYLINDER BANK 1 (RIGHT), REINSTALLING .
-- Install the intake manifold. Refer to INTAKE MANIFOLD .
-- Install the air guide hoses and screw-type clamps. Refer to Fig 7.
-- Install the turbocharger. Refer to TURBOCHARGER, REMOVING AND INSTALLING .
-- Change the engine oil.
-- Connect the coolant hose to the coupling. Refer to Fig 8.
-- Change the coolant. Refer to COOLANT, DRAINING AND FILLING .