LEMON Manuals: Even more car manuals for everyone
Home >> Volkswagen >> 2018 >> Beetle S, 2D Hatchback >> Repair and Diagnosis >> External Pages >> Different car >> Section 47 (2.0L - Cylinder Head & VALVETRAIN - Engine Code: CVCA (Convertible)) >> 15 Cylinder Head, VALVETRAIN >> Removal And Installation >> Cylinder Head >> Installing

Cylinder Head: Installing

WARNING: This page is about a different car, the 2015 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.

  • No oil or coolant must be in the cylinder head bolt blind holes in the cylinder block.

Risk of leaks in cylinder head seal.

  • Carefully remove sealant residue from cylinder head and cylinder block. Make sure that no long scrapes or scratches result.
  • 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 valves and piston heads after working on valve train.

  • To ensure valves do not strike pistons when starting, carefully rotate the crankshaft at least 2 turns.
NOTE:

It is not permitted to re-work the cylinder heads on TDI engines

Replace the bolts that were tightened with an additional turn after removing them.

Replace the self-locking nuts, sealing rings, seals and O-rings after removal.

Grease the contact surfaces between the roller rocker lever and the cam lubricating surface.

Secure all hose connections with hose clamps.

When replacing the cylinder head or cylinder head seal, all of the coolant and engine oil must be replaced.

-- Before mounting the cylinder head, remove the Crankshaft Lock T10490 and rotate the crankshaft back opposite the direction of engine rotation until all of the pistons are nearly even under "TDC".

-- Install alignment bushings for centering the cylinder block and cylinder head if they are missing.

-- Note the marking on the cylinder head gasket:

Fig 1: Identifying Cylinder Head Seal Identification
GWWA15-11309Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
  1. Part Number
  2. Ignore
  3. Holes
NOTE:

If the cylinder head gasket or the cylinder head were replaced, select a new cylinder head gasket with the same number of holes as the old gasket.

If parts of the crank drive were replaced, then determine the new cylinder head gasket by measuring the piston projection in "TDC", refer to PISTON PROJECTION, MEASURING AT TDC .

-- Install the cylinder head gasket on the alignment bushings -arrows- in the cylinder block.

Fig 2: Identifying Cylinder Head Gasket With Alignment Bushings
GWWA15-11421Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
NOTE: A second technician is needed to install the cylinder head.

-- Set cylinder head in place.

-- Install and tighten the bolts for the cylinder head, refer to Figure.

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

-- Turn the crankshaft in direction of engine rotation, until the tip -arrow- on the Crankshaft Lock T10490 fits into the sealing flange.

Fig 3: Identifying Crankshaft Lock T10490
GWWA15-11465Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the toothed belt (adjust timing), refer to Installing (Adjusting Valve Timing) .

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

-- Install the emissions control module, refer to EMISSIONS CONTROL MODULE .

-- Install the front exhaust pipe, refer to FRONT EXHAUST PIPE .

-- Install the left coolant pipes LEFT COOLANT PIPES .

-- Install the rear coolant pipes, refer to REAR COOLANT PIPE .

-- Install the front upper coolant pipes, refer to FRONT UPPER COOLANT PIPE .

-- For the electrical connections and wiring routing, refer to Release Tool Set VAS1978/35

-- Install the engine cover, refer to ENGINE COVER .

-- Change the engine oil.

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

NOTE: After installing new parts (engine/partial engine, cylinder head, camshaft housing or turbocharger) limit the oil pressure regulation for approximately 1000 km to the higher pressure stage. From this, the higher friction is taken into account when breaking in new components, and the optimum removal of particles from the initial wear in is ensured. To do this connect the vehicle diagnostic tester, switch on the ignition and select the following menu items:

01 - Engine electronics 

Guided functions 

Adaptations 

Oil pressure regulation/retraction activating 

scientia non olet · About LEMON Manuals