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.

NOTE:

Remanufacturing diesel cylinder heads is not permitted.

Replace the cylinder head bolts.

During assembly, replace self-locking nuts and bolts.

Always replace bolts that are tightened to torque as well as O-rings and gaskets.

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

Carefully remove all grinding and sanding residue.

There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.

Only unpack new cylinder head gasket immediately prior to installation.

Handle gasket carefully. Damages to the silicone layer and in areas of recesses may result in leaks.

Do not remove plastic bases protecting free up valves until immediately before installing cylinder head.

When installing a replacement cylinder head with camshafts installed, lubricate the contact surfaces between the roller rocker lever and the cam running surfaces.

After working on the valvetrain and lifters, carefully rotate the crankshaft by hand at least two full revolutions before starting to be sure that valves do not strike the pistons.

Secure all hose connections using hose clamps appropriate for the model type. Refer to the Parts Information.

Hose connections and charge air system hoses must be free of oil and grease before installing.

Replace all of the coolant and engine oil when replacing the cylinder head or cylinder head gasket.

Use the sealant provided. Refer to the Parts Information.

Install in reverse order of removal. Note the following:

Fig 1: Identifying Crankshaft Holder 3242

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-- Move the crankshaft and the camshafts to the "TDC" position before positioning the cylinder head:

The Crankshaft Holder:3242 must be installed in the "TDC" position on the crankshaft -1-.

The camshafts on both cylinder head must be secured with the Camshaft Adjustment Pins:T40060 .

Fig 2: Identifying Check Of Camshafts For Both Cylinder Heads In TDC Position And Adjustment Pin T40060
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-- Note the cylinder head gasket identification:

Fig 3: Cylinder Head Gasket Identification

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Holes
Part Number

NOTE:

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 the crankshaft drive is replaced, measure the piston projection in "TDC" to determine the new cylinder head. Refer to PISTON PROJECTION IN TDC, CHECKING .

The cylinder head gaskets for the left and right cylinder head cannot be interchanged because they each have a different shape.

-- Clean any oil or grease off the sealing surfaces.

NOTE:

Note the expiration date of the sealing compound.

Fig 4: Cut Tube Nozzle At Front Marking

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-- Cut the tube nozzle at the front marking (nozzle diameter: about 5 mm).

Left Cylinder Head:

-- Apply a bead of sealant -1 and 2- on the clean sealing surfaces on the cylinder block and the lower timing chain cover as illustrated.

Fig 5: Identifying Areas -1 And 2- To Apply Bead Of Sealant

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-- Apply the sealant in the amounts specified.

Fig 6: Identifying Dimensions -A To C-

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a = 7mm
b = 7 mm
c = 7 mm

-- Set cylinder head gasket in place.

-- Apply sealant beads -1- and -2- to the clean sealing surfaces as illustrated.

Fig 7: Identifying Areas -1 And 2- To Apply Bead Of Sealant

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Right Cylinder Head:

-- Apply a bead of sealant -1 and 2- on the clean sealing surfaces on the cylinder block and the lower timing chain cover as illustrated.

Fig 8: Identifying Areas -1 And 2- To Apply Bead Of Sealant

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-- Apply the sealant in the amounts specified.

Fig 9: Identifying Dimensions -A To C-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

a = 7mm
b = 7 mm
c = 7 mm

-- Set cylinder head gasket in place.

-- Apply sealant beads -1 and 2- to the clean sealing surfaces as illustrated.

Fig 10: Identifying Sealant Beads -1 And 2-

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Continued for Both Sides:

Fig 11: Identifying Cylinder Head Gasket

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Pay close attention to alignment bushings in cylinder block -arrows-.
Pay attention to installation position of cylinder head gasket, marking "upper" (top) or part number must face toward cylinder head.

-- Install cylinder head.

-- Insert new cylinder head bolts and tighten by hand.

-- Tighten the cylinder head bolts in the sequence -1 through 8- as follows:

Fig 12: Cylinder Head, Tightening Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Using torque wrench, tighten to 35 Nm.

-- Using torque wrench, tighten to 60 Nm.

-- Turn another 90° using a rigid wrench.

NOTE:

There is no requirement to tighten the cylinder head bolts after repairs.

-- Install the left or right cylinder head cover. Refer to CYLINDER HEAD COVER, REMOVING AND INSTALLING .

-- Install the camshaft timing chains. Refer to CAMSHAFTS, REMOVING AND INSTALLING .

-- Install the connecting pipe. Refer to LEFT INTERMEDIATE PIPE, REMOVING AND INSTALLING for the left and. Refer to RIGHT INTERMEDIATE PIPE, REMOVING AND INSTALLING for the right.

-- Install the left or right intake manifold lower section. Refer to INTAKE MANIFOLD LOWER SECTIONS, REMOVING AND INSTALLING .

-- Install the intake manifold upper section. Refer to INTAKE MANIFOLD UPPER SECTION, REMOVING AND INSTALLING .

Left Cylinder Head:

-- Install the high pressure pump toothed belt. Refer to HIGH PRESSURE PUMP TOOTHED BELT, REMOVING AND INSTALLING .

Continued for Both Sides:

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

-- Replace coolant. Refer to COOLANT, FILLING .

-- Inspect the fuel system for leaks. Refer to FUEL SYSTEM, CHECKING FOR LEAKS .