Cylinder Head: Installing

WARNING: This page is about a different car, the 2013 Volkswagen Beetle and 2012 Volkswagen Beetle. 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 is installed, only remove the plastic base right before the cylinder head is installed to protect open valves.

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

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

NOTE:

Replace the bolts which have been tightened to an additional torque angle.

Replace O-rings, seals and self-locking nuts.

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

Only use approved clamps for hose connections.

When installing a replacement cylinder head, rotate the camshaft to TDC and mark the new sprockets exactly the same as on the old sprockets (note the factory color codes on the sprockets).

When installing a replacement cylinder head, all of the contact surfaces between the hydraulic lash adjusters, roller rocker arms and cam running surfaces on the camshaft must be lubricated 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 - load cap - 700-1200 KG 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 tension and guide rails must not be damaged.

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

Fig 2: Locating Cylinder Block Centering Pins
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
Observe the cylinder head gasket location, identification: The 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 cylinder 1 piston TDC and rotate the crankshaft back again slightly.

-- Set the cylinder head in place.

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

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

-- Rotate the vibration damper into the TDC position -arrow- using the counter hold tool T10355:

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.

-- Mount 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.

-- Mount the timing chain on the exhaust camshaft.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Install the upper guide rail -3-.

Fig 6: Identifying 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 drive chain and guide rail -B arrows- do not align even though the engine is at TDC, the drive 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 repositioned again. Refer to CAMSHAFT TIMING CHAIN .

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Further installation is in the reverse order of removal. Note the following:

-- Fill the engine oil. Refer to Maintenance Procedures.

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

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

-- Check the Engine Control Module (ECM) Diagnostic Trouble Code (DTC) memory and erase all DTC entries which may have occurred during the assembly. Refer to "Guided Functions" in the vehicle diagnostic tester.

NOTE: Generate a readiness code if the DTC memory was erased. Refer to "Guided Functions" in the vehicle diagnostic tester.