Cylinder Head, Installing
Cylinder Head, Installing
Procedure
• Tightening specifications. Refer to => [ Cylinder Head Assembly Overview ] Cylinder Head Assembly Overview.
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.
• There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.
Risk of 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 is installed, only remove plastic base right before cylinder head is installed to protect 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 2 full revolutions.
• Replace bolts which have been tightened to torque.
• Replace sealing rings, seals and self-locking nuts.
• Note different sealant for cylinder head sealing surfaces and bolts.
• If a replacement cylinder is installed, the contact surfaces between the hydraulic adjusting elements, roller rocker levers and cam running surfaces must be lubricated before installing the cylinder head cover.
• The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing.
• Secure all hose connections with hose clamps appropriate for the model.
• In order to be able to securely mount the air guide hoses on their connectors, spray the screws on the previously used clamps with a rust remover.
• The engine oil and coolant must be changed if the cylinder head or cylinder head seal are replaced.
• The procedure is primarily shown for the left cylinder head in the following illustration.
- Position camshafts at "TDC" before cylinder head is installed.
• Install the Camshaft Clamp (T40070) on the affected cylinder head and tighten it to 25 Nm.
• Crankshaft Holder (3242) must be screwed in.
- If there are no alignment bushings - arrows - for centering in the places shown in the cylinder block, insert them.
- Set cylinder head gasket in place.
• Pay attention to installation position of cylinder head gasket, marking " oben" (top) or part number must face toward cylinder head.
- Set cylinder head in place.
- Tighten cylinder head bolts. Refer to => [ Cylinder Head, Tightening Specifications and Sequence ] Cylinder Head Assembly Overview.
• Bolts must not be tightened after repairs.
- Tighten the locking bolt - arrow -.
- Check if the guide rail for the camshaft timing chain tensioner is secured with the Locking Pin (T40071).
• If the tensioning element was removed from the chain tensioner, note installation position: Hole in housing floor faces toward chain tensioner, piston faces toward tensioning rail.
• Disregard - arrow -.
- Clean the chain tensioner oil strainer - 2 -.
- Position a new seal - 3 - on the rear of the chain tensioner - 1 -.
- Insert the chain tensioner and position the camshaft timing chain as shown in the illustration.
- Fasten bolts - 1 - and - 2 -.
The rest of the installation is in reverse order of removal, note the following:
- Position the camshaft timing chain on the camshafts: Left => [ Installing ] Left Camshaft Timing Chain, Removing From the Camshaft, right => [ Installing ] Right Camshaft Timing Chain, Removing From Camshafts.
- Install the timing chain covers: left => [ Installing ] Left Timing Chain Cover, right => [ Installing ] Right Timing Chain Cover.
- Install the exhaust manifold. Refer to: left => [ Left Exhaust Manifold with Catalytic Converter ] Left Exhaust Manifold With Catalytic Converter, right => [ Right Exhaust Manifold with Catalytic Converter ] Right Exhaust Manifold With Catalytic Converter.
- Install the cylinder head cover. Refer to: left => [ Left Cylinder Head Cover ] Left Cylinder Head Cover, right => [ Right Cylinder Head Cover ] Right Cylinder Head Cover.
- Install the secondary air injection combination valve. Refer to: left => [ Secondary Air Injection Left Combination Valve ] Secondary Air Injection Left Combination Valve, right => [ Secondary Air Injection Right Combination Valve ] Secondary Air Injection Right Combination Valve.
- Install the rear coolant pipes. Refer to => [ Rear Coolant Pipe ] Rear Coolant Pipe.
- Install the engine compartment crossmember. Refer to => [ Engine Compartment Crossmember ] Engine Assembly.
- Use a Torque Wrench (V.A.G 1331) with 17 mm Socket (V.A.G 1331/6) to tighten the 17 mm union nut on the fuel rail.
- Install intake manifold.
- Install the refrigerant line on the cylinder head.
- Mount the rear wheels.
- Install the rear wheel housing liners.
- Install the engine compartment trim.
- Change engine oil.
- Replace coolant. Refer to => [ Cooling System, Draining and Filling ] Procedures.