Cylinder Head, Removing And Installing: Installing
There is a risk of damaging the sealing surfaces.
- Carefully remove the sealant residue from the cylinder head and cylinder block.
- Make sure that no long grooves or scratches result.
Risk of damaging the 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 gasket.
- Carefully remove the sealant residue from cylinder head and cylinder block. Make sure that no long grooves or scratches result.
- Carefully remove all lapping and sanding residue.
- Only unpack the new cylinder head gasket immediately before installing.
- To prevent the cylinder head gasket silicone layer and recessed area from being damaged, always handle the gasket extremely carefully.
Risk of damaging the valves and piston crowns after working on valvetrain.
- To ensure valves do not strike pistons when starting, carefully rotate the crankshaft at least two turns.
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 self-locking nuts, gaskets, seals and O-rings after removing.
Grease the contact surfaces between the roller rocker lever and the cam running surface.
Secure all hose connections with standard production hose clamps.
It is necessary to replace all the coolant and engine oil whenever the cylinder head or the cylinder head gasket are replaced.
-- Before mounting the cylinder head, remove the :T10490 and rotate the crankshaft back opposite the direction of engine rotation until all of the pistons are nearly even under "TDC".
-- Install the alignment sleeves for centering the cylinder block and cylinder head if they are missing.
-- Note the marking on the cylinder head gasket:
- Part Number
- Ignore
- Holes
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 cylinder head 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.
- Cylinder head gasket installation position: "oben" (top) marking or part number toward the cylinder head.
A second technician is needed to install the cylinder head.
-- Position the cylinder head.
-- Install and tighten the cylinder head bolts. Refer to Figure.
It is not required to retighten the cylinder head bolts after repairs.
-- Turn the crankshaft in the direction of engine rotation, until the pin -arrow- on the :T10490 engages into the sealing flange.
-- Install the toothed belt (adjust valve timing). Refer to Installing (Adjusting Valve Timing)
Further installation is performed in reverse order of removal, while noting the following:
-- Install the emissions control module. Refer to EMISSIONS CONTROL MODULE, REMOVING AND INSTALLING .
-- Install the front exhaust pipe. Refer to FRONT EXHAUST PIPE, REMOVING AND INSTALLING .
-- Install the left coolant pipes. Refer to LEFT COOLANT PIPES, REMOVING AND INSTALLING .
-- Install the rear coolant pipe. Refer to REAR COOLANT PIPE, REMOVING AND INSTALLING .
-- Install the upper front coolant pipes. Refer to UPPER FRONT COOLANT PIPES, REMOVING AND INSTALLING .
-- Electrical connections and routing. Refer to RELAY CARRIERS, FUSE PANELS AND E-BOXES and the Appropriate Wiring Diagram.
-- Install the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .
-- Change the engine oil.
-- Fill with coolant. Refer to COOLANT, FILLING .
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. Connect the Vehicle Diagnostic Tester for this.