Cylinder head, removing and installing: Installing

WARNING: This page does not describe the selected car, but rather 15 other vehicles, including the 2006 Volkswagen GTI, 2005 Volkswagen Jetta, 2005 Volkswagen GTI, 2004 Volkswagen Jetta, and 2004 Volkswagen GTI. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.
Only remove the new cylinder head gasket from its packing immediately before installing.
Handle the new gasket with extreme care. Damaging will lead to leaks.

Stuff clean cloths into cylinder so that no dirt or abrasive powder can get between cylinder wall and piston.
Do not allow dirt or abrasive powder to get into coolant either.
Carefully clean cylinder head and cylinder block sealing surfaces. Avoid introducing scratches or scoring (do not use sandpaper with grit below 100).
Carefully remove metal particles, emery remains and cloths.

Fig 1: Identifying Vibration Damper At TDC No. 1 Cylinder

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Turn crankshaft to set cylinder 1 at TDC.
Turn crankshaft back slightly.

Fig 2: Cylinder Head Bolt Position Numbers

Courtesy of VOLKSWAGEN UNITED STATES, INC.

To center, install Guide Pins 3070 in cylinder head bolts 8 and 10.
Install new cylinder head gasket. Text (replacement part number) must be visible.
Install cylinder head, insert remaining 8 cylinder head bolts and hand tighten.
Remove Guide Pins 3070 through bolt holes with guide pin handle. Do this by turning pin handle toward left until pins are free.

Insert both remaining cylinder head bolts and then fasten them hand-tight.

Fig 3: Cylinder Head Bolt Position Numbers

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten cylinder head in tightening sequence as follows:
Pre-tighten all bolts to 40 Nm.
Then tighten all bolts a ¹ / ₄ turn (90 ° ) further using a rigid wrench.
Then tighten all bolts again a ¹ / ₄ turn (90 ° ) further.

The rest of the assembly is basically a reverse of disassembling sequence.

Install toothed belt and adjust valve timing, refer to Toothed belt, removing, installing and tensioning

Fill with new coolant, refer to Cooling system, draining and filling .

Perform "Procedure after interrupting voltage supply", refer to PROCEDURE AFTER VOLTAGE SUPPLY OPEN CIRCUIT .