Cylinder Head: Installing

WARNING: This page is about a different car, the 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.

Install in reverse order of removal. Note the following:

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 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 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 head is installed, only remove the accompanying plastic base immediately before installing to protect the open valves.

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

To ensure valves do not strike pistons when starting, carefully rotate engine at least two full revolutions.
Before installing, make sure the decoupling element for the oil return pipe is bent and therefore stretched. If that is the case, tiny cracks can form that can lead to leaks. Replace the oil return pipe before installing the cylinder head if necessary.

-- Before mounting the cylinder head, remove the Crankshaft Stop T10050 and rotate the crankshaft back opposite the direction of engine rotation until all of the pistons are nearly even under "TDC".

-- Place the cylinder head seal with the identification -arrows- upward.

Fig 1: Identifying Cylinder Head Gasket Identification

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Slide the Guide Pins 3070 into the outer bores on the intake side to center.

Fig 2: Identifying Installed Guide Pins

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NOTE: The tensioning roller must be placed on the stud bolt when positioning the cylinder head.

-- Install the cylinder head, insert the eight cylinder head bolts and tighten them by hand.

-- Remove the guide pins using the guide pin handle from 3070 by removing the bolts, and then install the remaining cylinder head bolts.

-- Install the 2 remaining cylinder head bolts hand-tight in the outer opening on the intake side.

-- Tighten cylinder head in sequence indicated, in four stages as follows:

Fig 3: Cylinder Head Bolt Tightening Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Pretighten using torque wrench
Step I = 30 Nm

Step II = 50 Nm
Tighten further using a solid wrench
Step III = 90°

Step IV = 90°

-- Attach the rear toothed belt guard to the cylinder head.

Fig 4: Identifying Nut To Toothed Belt Tension

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the camshaft sprocket and the hub. Refer to Installing .

-- Lock the camshaft and the high pressure pump with the Diesel Injection Pump Locking Pin 3359. Refer to TOOTHED BELT .

-- Rotate the crankshaft in the direction of engine rotation on the upper TDC and lock it with the Crankshaft Stop T10050. Refer to TOOTHED BELT .

Fig 5: Identifying Crankshaft Stop T10050

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install toothed belt. Refer to Installing .

NOTE:

Replace the seals, self-locking nuts and the clamp for the particulate filter.

When installing, bring all cable ties back to same positions.

-- Install the particulate filter. Refer to PARTICULATE FILTER WITH NOX ABSORPTION CATALYTIC CONVERTER .

-- Install the exhaust system free of tension. Refer to EXHAUST SYSTEM, INSTALLING WITHOUT TENSION .

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

-- Perform a road test and then check all the DTC memories. Refer to Vehicle Diagnostic Tester.