Cylinder Head

Cylinder Head, Installing

Work procedure

• Replace cylinder head bolts.

• During assembly, replace self-locking nuts and bolts.

• Always replace bolts that are tightened to torque as well as O-rings and gaskets.

• Carefully remove residual sealant from cylinder head and cylinder block. Make sure that no long scrapes or scratches result.

• Thoroughly remove all grinding and sanding residue.

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

• Only unpack new cylinder head gasket immediately prior to installation.

• Handle gasket carefully. Damage in silicon layer and recessed area lead to leakage.

• Install cylinder head gasket onto guide sleeves. Marking "oben " (top) or part number must face toward cylinder head.

• Cylinder heads with cracks between the valve seats, or between the valve seat and the spark plug threads, can continue to be used without reducing the service life, as long as the cracks have a width of max. 0.3 mm, or only the first 4 threads of the spark plug threads are cracked.

• If a cylinder head is replaced, a cap must be driven in on the front part of the respective head => [ Drive sealing cap into cylinder head ] Cylinder Head Assembly Overview.

• When installing a replacement cylinder head with camshafts installed, oil contact surfaces between valve lifters and cam running surfaces after installing cylinder head.

• Do not remove plastic bases protecting exposed valves until immediately before installing cylinder head.

• Secure all hose connections using hose clamps appropriate for the model type.

• Perform oil change if engine oil is contaminated.

• When replacing the cylinder head or cylinder head gasket, coolant must be completely replaced.

- Before positioning cylinder head, set crankshaft and camshafts on TDC:





• Camshaft Adjuster Gauge (T40030) must be inserted at both cylinder heads.

• Locking Pin (T40026) must be screwed into the crankshaft.





- Position cylinder head gasket.





• Pay close attention to centering pins - arrows - in cylinder block.

• Pay attention to installation position of cylinder head gasket, marking " oben" (top) or part number must face toward cylinder head.

- Install cylinder head.

- Insert new cylinder head bolts and tighten by hand.

- Tighten cylinder head bolts in 3 stages in the tightening sequence shown as follows:





- Using torque wrench, tighten to 40 Nm.

- With Torx key, 90° (1/4 turn) additional turn.

- With Torx key, 90° (1/4 turn) additional turn.

• There is no requirement to retighten the cylinder head bolts after repairs.

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

- Install toothed belt (adjust valve timing) => [ Installing (Adjusting valve timing) ] Service and Repair.

• After working on the valvetrain, carefully rotate engine by hand at least 2 full rotations to ensure that valves do not strike the pistons when starting.

- Install left front exhaust pipe with catalytic converter:

• Vehicles with manual transmission. Refer to => [ Left Front Exhaust Pipe with Catalytic Converter, Manual Transmission ] Left Front Exhaust Pipe With Catalytic Converter, Manual Transmission.

• Vehicles with 01J automatic transmission. Refer to => [ Left Front Exhaust Pipe with Catalytic Converter, Multitronic Transmission 01J ] Left Front Exhaust Pipe With Catalytic Converter, Multitronic Transmission 01J.

• Vehicles with 01V automatic transmission. Refer to => [ Left Front Exhaust Pipe with Catalytic Converter, Automatic Transmission 01V ] Left Front Exhaust Pipe With Catalytic Converter, Automatic Transmission 01V.

- Install right front exhaust pipe with catalytic converter:

• Vehicles with manual transmission. Refer to => [ Left Front Exhaust Pipe with Catalytic Converter, Manual Transmission ] Left Front Exhaust Pipe With Catalytic Converter, Manual Transmission.

• Vehicles with 01J automatic transmission. Refer to => [ Left Front Exhaust Pipe with Catalytic Converter, Multitronic Transmission 01J ] Left Front Exhaust Pipe With Catalytic Converter, Multitronic Transmission 01J.

• Vehicles with 01V automatic transmission. Refer to => [ Left Front Exhaust Pipe with Catalytic Converter, Automatic Transmission 01V ] Left Front Exhaust Pipe With Catalytic Converter, Automatic Transmission 01V.

- Align exhaust system free of tension:

• Vehicles with AWD. Refer to => [ Exhaust System, Aligning ] Procedures.

• Vehicles with FWD. Refer to => [ Exhaust System, Aligning ] Procedures.

All:

- Install intake manifold centering pins and install intake manifold. Refer to => [ Intake Manifold ] Intake Manifold.

- Observe safety precautions after connecting battery. Refer to => [ Before beginning repairs on the electrical
system: ] Testing and Inspection and.

- Replace coolant => [ Filling ] Procedures.

- Fill power-steering system oil and bleed steering system.

Tightening Specifications