Cylinder head, removing and installing: Installing

WARNING: This page is about a different car, the 2006 Volkswagen Golf, 2005 Volkswagen Jetta, 2005 Volkswagen Golf, 2004 Volkswagen Jetta, and 2004 Volkswagen Golf. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Always replace cylinder head bolts.
For repairs, carefully remove gasket remains from the cylinder head and cylinder block. Make sure that no long scores or scratches are made on the surfaces. When using abrasive paper do not use a grade less than 100.
Carefully remove emery and abrasive remains.
Thoroughly blow out threaded holes for cylinder head bolts. Place a cloth over the respective hole as a protection against oil etc which may be sprayed out of the hole.
Remove the new cylinder head gasket from the packaging just before installation.
Handle the gasket extremely carefully. Damaging the silicone layer or the indented area will lead to leaks.

Check before installing the cylinder head that new cylinder head gasket is identical to old cylinder head gasket (3 possible thicknesses)
Turn crankshaft to TDC marking before installing cylinder head.
Turn crankshaft against engine direction of rotation until all pistons are approximately equally placed below TDC.
Position cylinder head gasket.
Install cylinder head and hand tighten all 10 new cylinder head bolts.

Fig 1: Identifying Cylinder Head Tightening Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten cylinder head in four stages in sequence shown as follows:

Stage I = 40 Nm

Stage II = 60 Nm

Stage III = 14 turn (90 ° )

Stage IV = 14 turn (90 ° )

NOTE:

Re-torquing the cylinder head after repairs is no longer necessary.

Fig 2: Identifying Cam Lobes Pointing Equally Upward

Courtesy of VOLKSWAGEN UNITED STATES, INC.

After tightening cylinder head, turn camshaft so that cam lobes for No. 1 cylinder point equally upward. Before installing toothed belt, turn crankshaft in direction of engine rotation to TDC. Refer to Toothed belts, removing, installing and tensioning .
Install camshaft pulley hub. Refer to Camshaft, removing and installing .

The remainder of the installation is performed in the reverse sequence of removal.

Road test vehicle and read fault memory. Refer to Engine control module fault memory, reading and erasing .