Cylinder Head and Gasket

Note: Diesel cylinder heads cannot be resurfaced.

Cylinder head gasket: Identification/Installation

[ezcol_1half]1.108[/ezcol_1half] [ezcol_1half_end]Gasket identified by part no. and number of notches (arrows).

Marking oben on gasket must face cylinder head.

Cylinder head gasket selection

  • Always select gasket thickness
    according to piston height above top of cylinder block.

Measuring piston height

  • Measure piston height with US1026 (1027), VW 382/7 and VW 385/17.
  • Piston must be at TDC. Determine piston TDC by reading highest point on dial indicator before measuring piston height.[/ezcol_1half_end]

 

After measuring piston height, select gasket from following table.

[ezcol_1quarter]Piston Projection mm[/ezcol_1quarter] [ezcol_1quarter]Gasket thickness mm[/ezcol_1quarter] [ezcol_1quarter]Notches (1.5L)[/ezcol_1quarter] [ezcol_1quarter_end]Notches (1.6L)[/ezcol_1quarter_end]

[ezcol_1quarter]0.43-.062

0.63-0.82

0.83-0.92

0.93-1.02[/ezcol_1quarter] [ezcol_1quarter]1.3

1.4

1.5

1.6[/ezcol_1quarter] [ezcol_1quarter]2

3

4

5[/ezcol_1quarter] [ezcol_1quarter_end]0

1

2

3[/ezcol_1quarter_end]

Piston height must be measured when installing new pistons or short block. Then select gasket according to measurement.

[ezcol_1half]Loosening/tightening sequence

  • Tighten in numerical order (1,2,3, etc.).
  • Loosen in reverse order (10, 9, 8, etc.).
  • When installing head, first install bolts 8 and 10 to center head.
  • Note: Do not remove a cylinder head from a hot engine.

Tightening Procedure — 6 point bolts

  • Torque in three steps:
    1. 50 Nm (35 ft.lbs.)
    2. 70 Nm (50 ft.lbs.)
    3. 90 Nm (65 ft.lbs.)
  • After step 3, warm up engine until radiator fan cycles or until oil temperature reaches 50° C (122° F).
  • Torque head bolts again, without backing off to 90 Nm (65 ft.lbs.).
  • Engine may be cold or warm.
  • Bolts may be reused.

 

Tightening Procedure — 12 point bolts

  • Torque in three steps:
    1. 40 Nm (29 ft.lbs.)
    2. 60 Nm (43 ft.lbs.)
    3. 75 Nm (54 ft.lbs.)
  • After step 3, tighten bolts 1/2 turn (180°)(two 1/4 turns are OK) further without backing off.
  • Warm up engine until radiator fan cycles or until oil temperature reaches 50° C (122° F).
  • Tighten bolts an additional 1/4 turn (90°).
  • Retorque at 1000-mile service an additional 1/4 turn (90°) without backing off.
  • Engine may be cold or warm.
  • The 12 point bolts must be replaced if they are removed.[/ezcol_1half] [ezcol_1half_end]1.109

 

 

 

 

 

 

 

 

 

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