Note: Diesel cylinder heads cannot be resurfaced.
Cylinder head gasket: Identification/Installation
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.
After measuring piston height, select gasket from following table.
Piston Projection mm
Gasket thickness mm
Notches (1.5L)
Notches (1.6L)
0.43-.062
0.63-0.82
0.83-0.92
0.93-1.02
1.3
1.4
1.5
1.6
2
3
4
5
0
1
2
3
Piston height must be measured when installing new pistons or short block. Then select gasket according to measurement.
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:
- 50 Nm (35 ft.lbs.)
- 70 Nm (50 ft.lbs.)
- 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:
- 40 Nm (29 ft.lbs.)
- 60 Nm (43 ft.lbs.)
- 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.
