Cylinder Head, Removing And Installing: Installing

WARNING: This page is about a different car, the 2014 Volkswagen Touareg, 2013 Volkswagen Touareg, 2012 Volkswagen Touareg, and 2011 Volkswagen Touareg. However, it is still accessible from the selected car via links, so may be relevant.

Tightening specifications. Refer to OVERVIEW - CYLINDER HEAD .

CAUTION:

There is a risk of damaging the sealing surfaces.

Carefully remove the sealant residue from cylinder head and cylinder block.
Make sure that no long grooves or scratches result.

Risk of damaging the cylinder block.

No oil or coolant must be in the cylinder head bolt blind holes in the cylinder block.

Risk of the cylinder head gasket leaking.

Carefully remove all lapping and sanding residue.
Only unpack the new cylinder head gasket immediately prior to installation.
To prevent cylinder head gasket silicone layer and recessed area from being damaged, always handle the gasket extremely carefully.

There is a 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 the 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.

NOTE:

Replace the bolts that were tightened with an additional turn.

Replace self-locking nuts, sealing rings, seals and O-rings.

Note the different sealants for the sealing surfaces and the cylinder head bolts. Refer to the Parts Information

If a replacement cylinder head is being installed, the contact surfaces between the hydraulic adjusters, the roller rocker levers and the cam running surfaces must be oiled before the cylinder head cover is installed.

Secure all hose connections with hose clamps that are specific to that model. Refer to the Parts Information.

Change the coolant and engine oil whenever replacing the cylinder head or cylinder head seal.

-- Secure the camshaft for cylinder bank 1 in "TDC" using the Camshaft Clamp:T40133/1 .

Fig 1: Camshaft Clamp -T40133/1

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Secure the camshaft for cylinder bank 2 in "TDC" using the Camshaft Clamp:T40133/2 .

Fig 2: Camshaft Clamp -T40133/2-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Secure the crankshaft -1- in "TDC" using the Crankshaft Locking Pin:T40069 .

Fig 3: Crankshaft Locking Pin T40069

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the new seals on the coolant pipe.

Fig 4: Alignment Bushings In Cylinder Block -Arrows-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Position the cylinder head gasket.

Installed position: the marking "oben" (top) or the part number must be legible.
Pay close attention to alignment bushings in cylinder block -arrows-.

-- Position the cylinder head.

-- Tighten the cylinder head bolts. Refer to Figure.

Fig 5: Cylinder Head Bolt Tightening Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tighten the bolts -arrows- for the lower timing chain cover. Refer to Figure.

Fig 6: Identifying Bolts At Rear Of Cylinder Head

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Left cylinder head: 3 bolts.
Right cylinder head: 4 bolts

NOTE:

It is not necessary to retighten the cylinder head bolts after repairs.

Install in reverse order of removal while Noting The Following:

-- Installing camshaft adjuster. Refer to CAMSHAFT ADJUSTER, REMOVING AND INSTALLING .

-- Install the upper coolant pipe. Refer to UPPER COOLANT PIPE, REMOVING AND INSTALLING .

-- Install oil dipstick guide tube. Refer to Figure.

-- Connections and wiring routing. Refer to Wiring Diagram.

-- Install the catalytic converter. Refer to left CATALYTIC CONVERTER, REMOVING AND INSTALLING, LEFT (BANK 2) and right CATALYTIC CONVERTER, REMOVING AND INSTALLING, RIGHT (BANK 1) .

-- Install the intake manifold lower section. Refer to INTAKE MANIFOLD LOWER SECTION WITH FUEL RAIL, REMOVING AND INSTALLING .

-- Install front coolant pipe. Refer to FRONT COOLANT PIPE, REMOVING AND INSTALLING .

-- Install the ribbed belt. Refer to RIBBED BELT, REMOVING AND INSTALLING .

-- Change the engine oil. Refer to appropriate service information

-- Fill with coolant.