Cylinder Head: Installing

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

NOTE:

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

Only remove the new cylinder head gasket from its packing immediately before installing.

Handle the new gasket with extreme care. Damaging will lead to leaks.

Replace the cylinder head bolts.

-- Stuff clean cloths into cylinders and chain compartment so that no dirt or abrasive powder can penetrate between cylinder wall and piston and into chain compartment.

-- Do not allow dirt or abrasive powder to get into coolant either.

-- Carefully clean the cylinder head and cylinder block sealing surfaces. Avoid introducing scratches or scoring (do not use sandpaper with grit below 100).

-- Carefully remove metal particles, emery remains and cloths.

-- Cut the tube nozzle at the front marking (nozzle diameter: approximately 1 mm).

Fig 1: Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 1 Mm)

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Note shelf-life date.

-- Apply a bead of sealant -1- (front and rear) on the clean sealing surfaces as shown.

Fig 2: Identifying Sealant Bead Locations

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The bead of sealant must be 2.0 to 2.5 mm thick.

-- Install the new cylinder head gasket -2-.

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

Fig 3: Identifying Centering Pins In Cylinder Block

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-- Apply a bead of sealant -3- (rear only), as shown, on the cylinder head seal.

Fig 4: Identifying Sealant Bead Locations

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The bead of sealant must be 2.0 to 2.5 mm thick.

NOTE: The cylinder head must be installed within 5 minutes of being applied with sealant.

-- Install cylinder head.

-- Guide the timing chain over the pipe connection.

-- Insert cylinder head bolts and tighten them hand-tight.

-- Tighten the cylinder head bolts -1 through 12- in the following:

Fig 5: Identifying Cylinder Head Bolts Tightening Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Stage	Tighten
1	-- Using torque wrench, tighten to 40 Nm.
2	-- Tighten further 90° using a rigid wrench.
3	-- Tighten further 90° using a rigid wrench.

-- Tighten the bolt -13- to 10 Nm.

-- Wipe off any sealant, which has leaked out.

The rest of the installation follows the reverse of the removal procedures. Note the following:

Remove the Crankshaft Locking Pin T40069 from the back of the cylinder block and install the bolt.
Install the battery tray. Refer to REMOVAL AND INSTALLATION .
Install the battery. Refer to REMOVAL AND INSTALLATION .
Drain and fill the coolant. Refer to COOLANT, DRAINING AND FILLING .