Cylinder head, removing and installing: Installing

WARNING: This page is about a different car, the 2004 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

Carefully remove metal particles, emery remains and cloths.

If piston for No. 1 cylinder is not at TDC:

Fig 1: Identifying Crankshaft At Vibration Damper Securing Bolt In Engine At TDC Cyl. 1

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Set crankshaft to TDC No. 1 Cyl. marks - arrow - by turning crankshaft on vibration damper securing bolt in engine direction of rotation. When doing this, guide camshaft roller chain by hand with aid of a 2nd technician.

NOTE:

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.

Install new cylinder head gasket. Install new cylinder head gasket. Inscription (Part No.) must be legible.

Fig 2: Cylinder Head Tightening Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Ensure that alignment bushings are inserted into cylinder block holes 12 and 20 and that cylinder head gasket is seated.
Position camshafts in cylinder head to TDC No. 1 cylinder.

Fig 3: Identifying Camshaft Bar T10068 Engage In Both Shaft Grooves

Courtesy of VOLKSWAGEN UNITED STATES, INC.

The camshaft bar T10068 A must engage in both shaft grooves.
Prepare cylinder head gasket for installation Preparing cylinder head gasket for installation , under Preparing cylinder head gasket for installation
Install cylinder head, insert new cylinder head bolts and hand tighten.

NOTE:

The longer cylinder head bolts must be inserted in the middle holes of cylinder head.

Fig 4: Cylinder Head Tightening Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten cylinder head in tightening sequence as follows from inside to outside:
Pretighten all bolts to 30 Nm.
Then tighten all bolts to 50 Nm.
Tighten all bolts ( ¹ / ₄ turn) (90 ° ) further using a rigid wrench.

Afterwards, tighten all bolts again ¹ / ₄ turn (90 ° ) further

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

NOTE:

Make sure that the O-ring for sealing the oil channel and the seal in the cover are installed.

How to adjust valve timing, refer to Valve timing, adjusting .

Install cylinder head cover and intake manifold, refer to Cylinder head cover, removing and installing .

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

NOTE:

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