Cylinder Head: Installation
- Make sure push rod tube is correct length. Tube should be about 7.64" (194 mm) between inside edges of tube sealing "O" rings. See Fig 1. Seam of tube faces up and small end is toward cylinder head. Always use new sealing rings. Sand any damaged sealing substance on cylinder head until smooth.
NOTE: Install small end to cylinder head with seam up.
- Clean cylinder head sealing surface with solvent. Install new thin Green "O" ring and metal gasket on cylinder sleeves. Install new water jacket gasket on crankcase surface. Apply l-2 mm wide bead of sealing compound (VW No. D 000 400) in center of new water jacket gasket. DO NOT
use excessive sealant as cylinder head cooling passages may become plugged.NOTE: Manufacturer specifies only VW No. D 000 400 sealing compound and G-11 coolant. Cylinder head must be installed within 45 minutes of application of sealing compound.
- Coat sealing face of cap nuts with waterproof compound. Install and snug cap nut at No. 1 stud enough to install remaining cap nuts. Tighten cap nuts to first stage of 7 ft. lbs. (9.5 N.m) in sequence shown. See Figure. Make sure push rod tubes are correctly seated.
- Tighten cap nuts to final setting of 33 ft. lbs. (45 N.m). Install push rods, making sure that push rods fit into cups of lifters. Install rocker assembly with slots facing upward on shaft supports. Adjust hydraulic lifters after nuts attaching rocker assembly to head are tight. Install rocker cover with new gasket.
- Reassemble remaining parts in reverse order of removal. Use new exhaust flange gaskets with metal surface toward head. Always use new locking nuts. Use new gaskets on drain plugs. Fill and bleed cooling system. See WATER PUMP Installation. Make sure engine develops oil pressure after starting.