Cylinder Head: Installing

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

NOTE:

Always replace cylinder head bolts.

Carefully remove residual sealant from cylinder head and cylinder block. Make sure that no long scrapes or scratches result. When using sand paper, grit must not be below 100.

Carefully remove all grinding and sanding residue.

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.

-- Before installing cylinder head, position crankshaft to TDC marking.

-- Turn the crankshaft in opposite direction of engine rotation until all pistons are positioned almost evenly below TDC.

-- Position cylinder head gasket.

NOTE:

Observe cylinder head gasket identification Figure

-- Set cylinder head in place and tighten all cylinder head bolts hand tight.

-- Fasten the cylinder head in four steps according to the indicated tightening sequence, as follows:

Fig 1: Identifying Cylinder Head Bolt Tightening Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Tighten using torque wrench
Step 1 = 35 Nm

Step 2 = 60 Nm
Tighten further using a ratchet
Step 3 = ¹ /₄ turn (90°)

Step 4 = ¹ /₄ turn (90°)

NOTE:

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

Further installation is performed in reverse order. When doing this note the following:

-- After fastening the cylinder head turn the camshaft sprocket so that the lobes -arrows- for cylinder 1 point upward equally. Before installing the toothed belt, turn the crankshaft in engine rotation direction to TDC TOOTHED BELT .

Fig 2: Identifying Cam Lobes For Cylinder 1 Pointing Upward

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install hub for camshaft sprocket CAMSHAFT .

-- Install toothed belt TOOTHED BELT .

-- Install ribbed belt RIBBED DRIVE BELT .

-- Install oil supply line OIL SUPPLY LINE .

-- Install noise insulation Removal and Installation .

-- Install plenum chamber bulkhead Description and Operation .

-- Fill with coolant COOLING SYSTEM, DRAINING AND FILLING .

-- Perform a test drive and afterwards check the fault memory ENGINE CONTROL MODULE DTC MEMORY, CHECKING AND ERASING .