Cylinder Head: Installing

WARNING: This page is about a different car, the 2013 Volkswagen Jetta and 2012 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Tightening specifications, refer to CYLINDER HEAD OVERVIEW .

CAUTION:

The sealing surfaces could be damaged:

Carefully remove any sealant residue from the cylinder head and cylinder block.
Make sure that no long scrapes or scratches result.

Risk of damaging the cylinder block:

There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.

Risk of the cylinder head gasket leaking:

Carefully remove all grinding and sanding residue.
Only unpack the new cylinder head gasket immediately prior to installation.
To prevent the cylinder head gasket silicone layer and recessed area from being damaged, always handle the gasket extremely carefully.

Risk of damaging open valves:

If a replacement cylinder head is installed, only remove the plastic base right before the cylinder head is installed to protect the open valves.

Risk of damaging valves and piston heads after working on the valvetrain:

To ensure the valves do not strike the pistons when starting, carefully rotate the engine at least 2 full revolutions.

NOTE:

Replace the bolts which are being tightened to a torque angle.

Replace sealing rings, seals and self-locking nuts.

Note the different sealant for cylinder head sealing surfaces and bolts.

Install only approved clamps for securing hose connections.

When installing a replacement cylinder head, rotate he camshaft to OT and mark the new sprockets exactly the same as on the old sprockets -arrows- (note the factory colored marks on the sprockets).

If an exchange cylinder head is installed, all contact surfaces between the bearing elements, roller rocker arms and cam running surfaces of camshafts must be oiled before installing the cylinder head cover.

The engine oil and coolant must be changed if the cylinder head or cylinder head gasket are replaced.

-- Lift the cylinder head using the shop crane and position it above the cylinder block.

Fig 1: Identifying Installation Of Engine Sling -2024 A- And Engine Support -T10014-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

CAUTION:

Carefully lower the cylinder head.
The tensioning and guide rails must not be damaged.

Pay attention to the centering pins -arrows- in cylinder block.

Fig 2: Cylinder Block Centering Pins
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
Observe the cylinder head gasket location, identification: Replacement part number must be visible from the intake side.

CAUTION:

When rotating the crankshaft, make sure the timing chain cannot damage any other components.

-- In the event the crankshaft has been rotated in the meantime: Set the piston for cylinder 1 to TDC and rotate the crankshaft back again slightly.

-- Set the cylinder head in place.

-- Install the cylinder head bolts and tighten them hand tight.

NOTE:

In order to be able to tighten the cylinder head bolts, the intake camshaft must be turned with a wrench.

Cylinder head bolt, tightening sequence and specification. Refer to Figure.

NOTE:

It is not necessary to tighten the cylinder head bolts again after performing the repair.

CAUTION:

When rotating the crankshaft, make sure the timing chain cannot damage any other components.

-- Using the counter hold tool T10355, rotate the vibration damper to TDC -arrow- :

Fig 3: Identifying Vibration Damper "TDC" Position With Special Tool T10355

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The notch on the vibration damper must line up with the arrow mark on the lower timing chain cover.

-- Install the timing chain on the intake camshaft.

Fig 4: Identifying Drive Chain/Chain Sprocket Markings And Turning Intake Camshaft Using Wrench

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The marks must align.

-- Rotate the intake camshaft in the -direction of the arrow- with a wrench until the timing chain is >>taut<<. Hold the intake camshaft secure in this position.

-- Install the timing chain on the exhaust camshaft.

Fig 5: Identifying Position Marks: Drive Chain To Sprockets -A- And Drive Chain To Guide Rail -B-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The marks on the drive chain and sprocket -A arrows- and the chain and guide rail -B arrows- must line up with each other.

-- Install the upper guide rail -3-.

Fig 6: Guide Tensioning Rail, Upper Guide Rai And Bolt

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Move the tensioning rail -2- up and tighten the guide pin -1-.

NOTE:

If the marks on the chain and guide rail -B arrows- do not align even though the engine is at TDC, the chain has skipped on the crankshaft sprocket. Check the valve timing. Refer to VALVE TIMING, CHECKING . If the timing does not agree, the camshaft timing chain must be positioned again. Refer to CAMSHAFT TIMING CHAIN .

Fig 7: Identifying Position Marks: Drive Chain To Sprockets -A- And Drive Chain To Guide Rail -B-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Install in reverse order of removal. When doing this note the following:

-- Fill the engine oil. Refer to [[Editorial:Pick one xref]]Maintenance Procedures .

-- Check the oil level. Refer to OIL LEVEL, CHECKING .

-- Replace the coolant. Refer to DRAINING AND FILLING .

-- Check the Engine Control Module (ECM) Diagnostic Trouble Code (DTC) memory and erase any entries. Refer to "Guided Function" in the vehicle diagnostic tester.

NOTE:

If the DTC memory was erased, the readiness code must be generated again. Refer to "Guided Fault Finding" in the vehicle diagnostic tester.