Cylinder Head: Installing

WARNING: This page is about a different car, the 2016 Volkswagen Beetle, 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, and 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION:

The sealing surfaces could be damaged.

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

Risk of damaging cylinder block.

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

Risk of cylinder head seal leaking.

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

Risk of damaging open valves.

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

Risk of damaging valves and piston heads after working on valve train.

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

NOTE:

Replace the bolts were tightened with an additional turn.

Replace the gaskets, seals and self-locking nuts.

Pay attention to the different sealants for sealing surfaces and bolts for the cylinder head.

When installing a replacement cylinder head, the contact surfaces between hydraulic adjusters, roller rocker levers and cam lubricating surfaces needs to be oiled before the camshafts can be installed.

The hose supports, air guide pipes and hoses must be free of oil and grease before installing.

Secure all hose connections with hose clamps.

To safely secure the charge air hoses to their connections, spray the screws on the previously used screw-type clamps with rust remover.

After the cylinder head or cylinder head gasket has been replaced, change the engine oil and coolant.

-- Set cylinder head gasket in place.

Fig 1: Identifying Centering Pins

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Pay attention to centering pins -arrows- in cylinder block.
Observe cylinder head seal location, identification: The part number must be visible from the intake side.

WARNING:

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: Place the piston of the 1st cylinder on the top dead center and turn the crankshaft back a little bit.

-- Set cylinder head in place.

-- Insert cylinder head bolts and tighten by hand.

-- Cylinder head tightening sequence, refer to Figure.

NOTE:

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

-- Rotate the vibration damper using the Counterhold - Vibration Damper T10355 into the "TDC" position.

Fig 2: Locating TDC

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The notch on the vibration damper and the marking on the lower cover for timing chain must be opposite one another -arrow-.

The rest of the installation is performed in reverse order of removal, noting the following:

-- Install the camshafts, refer to CAMSHAFT .

-- Change the engine oil.

-- Replace the coolant, refer to COOLANT, DRAINING AND FILLING .

-- Install the front exhaust pipe with the catalytic converter, refer to CATALYTIC CONVERTER WITH FRONT EXHAUST PIPE .

WARNING:

Do not use a charger as a starting aid. There is the risk that the vehicle control modules could be damaged.