Installation

GENERAL:
- When replacing the cylinder head or the cylinder head gasket, it is recommended that the old coolant be flushed out and new coolant added. This will help ensure that any metal shavings and contaminants are removed from the engine and the cooling system. Note that the cylinder head bolts are stretch-type fasteners and should not be reused.
- If installing a VW replacement cylinder head (complete with camshaft), check to see it protective plastic liners are installed for protection of the open valves. If installed, be sure to remove these liners prior to installing the head.
- If the camshaft was removed or if installing a new or remanufactured cylinder head, lubricate the contact surfaces between the cam lobes and the hydraulic cam followers prior to start-up.

TO INSTALL CYLINDER HEAD:
1. Clean the cylinder head and the gasket surface of the cylinder block. Clean the bolt holes with thread chasers and remove all foreign matter and liquid from the holes.

CAUTION: Do not use a metal scraper or wire brush to clean the aluminum cylinder head. Instead, use a solvent to soften carbon deposits and old sealing materials. If necessary use a wooden or plastic scraper.

2. Check the gasket surfaces of the cylinder head and the cylinder block for warpage.
3. Place a new cylinder head gasket on the surface of the cylinder block. The word "OBEN", found imprinted on the gasket near the part number, should face up.
4. Place the cylinder head in position on the cylinder block. Loosely install all the head bolts.

NOTE: To ensure proper cylinder head alignment during installation, place two 200 mm long by 11 mm diameter wooden dowels into two of the outermost head bolt holes to hold the gasket and serve as guides as the cylinder head is installed. Install the head and thread in several bolts, then remove the dowels and install the remaining bolts.

Cylinder Head Tightening Sequence:

4. Tighten the new head bolts in stages using the sequence shown.

CAUTION: Always replace the cylinder head mounting bolts. They are stretch bolts designed to be used only once.

Tightening Torques:
Cylinder Head Bolts [1]:
Stage I: 40 Nm (30 ft lb)
Stage II: 60 Nm (44 ft lb)
Stage III: additional 1/4 turn (90°)
Stage IV: additional 1/4 turn (9O°)

5. Install the cylinder head cover.
6. Install the spark plugs and attach the spark plug connectors.
7. Reconnect all coolant hoses to the outlets on the cylinder head.
8. Reconnect the exhaust pipe to the exhaust manifold.
9. Reconnect all hoses and wire connected to the throttle body, the intake manifold and cylinder head.
10. Reconnect the fuel injector harness connectors. Reconnect the throttle cable and harness connectors to the throttle body.
11. Install the camshaft drive belt.
12. Refill the cooling system.
13. Reconnect the intake air duct to the throttle body on the intake manifold.
14. Reconnect the battery negative (-) terminal to the battery.



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[1]: Stretch bolts, always replace.