Cylinder Head, Removing And Installing: Installing

• Do not use any sanding materials (sandpaper, sand stone sanding pads, sanding strips, or abrasive cloths etc.).
• May not be applied on sealing surfaces.
• The dark discoloration does not need to be removed.

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• When removing the sealant residue pay attention that no loosened sealant residue gets into the channel to the engine.
• Pay attention to the neighboring work stations cleanliness and that no there is no sanding from above.
• The use of unpermitted sanding materials can cause subsequent damage, such as turbocharger damage, connecting rod bearing, etc.

-- Remove the sealing lip from the cylinder head and cylinder block using only a commercially available blade scraper (blade width minimum 40 mm).

-- Remove any loose residue with a lint-free cloth.

• Replace bolts that were tightened with an additional turn after removing them.
• Replace the self-locking nuts, gaskets, seals and O-rings after removal.
• Check the O-ring in the crankcase ventilation hose for damage. Refer to OVERVIEW - CRANKCASE VENTILATION .
• Secure all hose connections with hose clamps that match the ones used in series production. Refer to the Parts Information.
• Only unpack the new cylinder head gasket immediately before installing.
• To prevent the cylinder head gasket silicone layer and recessed area from being damaged, always handle the gasket extremely carefully.
• If a replacement cylinder is installed, only remove the plastic base right before cylinder head is installed to protect open valves.
• When installing a replacement cylinder head, the contact surfaces between the roller rocker lever and cam running surface need to be oiled before the cylinder head cover can be installed.
• When replacing the cylinder head or cylinder head gasket, replace all of the coolant and engine oil.

-- Clean oil and coolant residue out of the blind holes for the cylinder head bolts in the cylinder block

-- Position the cylinder head gasket.

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• Pay attention to alignment pins in cylinder block -arrows-.
• Pay attention to the cylinder head gasket installation position: the part number must be readable from the intake side.

-- If the crankshaft was turned in the meantime: bring the piston for cylinder 1 to TDC and then turn the crankshaft another 90° counter-clockwise out of "TDC".

-- Position the cylinder head with a second technician.

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

-- Cylinder head tightening sequence. Refer to Figure.

TIP:

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

-- Install the intake manifold. Refer to INTAKE MANIFOLD, REMOVING AND INSTALLING .

-- Install the spark plugs. Refer to OVERVIEW - IGNITION SYSTEM .

-- Install the front air duct pipe. Refer to FRONT AIR DUCT PIPE, REMOVING AND INSTALLING .

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

-- Install the catalytic converter. Refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING .

-- Install the Oxygen Sensor 1 Before Catalytic Converter -GX10-. Refer to HEATED OXYGEN SENSOR, REMOVING AND INSTALLING .

-- Install the camshafts. Refer to CAMSHAFT, REMOVING AND INSTALLING .

-- Change the engine oil. Refer to ENGINE OIL .

-- Connect the coolant hoses with the connector coupling. Refer to Fig 1.

Fig 1: Connect the Connector Coupling

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-- Change the coolant. Refer to COOLANT, FILLING USING Cooling System Charge Kit:VAS 6096 [DNNA, DNNB, DNND, DNVB] .