Cylinder Head & Manifolds: Installation

WARNING: This page is about a different car, the 1983 Volkswagen Vanagon, 1983 Volkswagen Rabbit, 1983 Volkswagen Quantum, 1983 Volkswagen Pickup, and 1983 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Clean gasket surface and ensure that cylinder head and block are not warped. Maximum distortion of .004" (.010 mm) is allowed. If installing on original piston and block assembly select a new head gasket that has the same marks as the original.

To determine proper gasket, measure projection of piston above block when at TDC. Select proper gasket from following table. Gasket must be installed with word "OBEN" facing up.

AVAILABLE CYLINDER HEAD GASKETS

Piston Projection In. (mm)	Gasket Thickness In. (mm)	Ident. Notches
Quantum
.026-.031 (.67-.80)	*****	1
.032-.035 (.81-.90)	*****	2
.036-.040 (.91-1.02)	*****	3
All Others
.025-.032 (.63-.82)	.055 (1.40)	1
.033-.036 (.83-.92)	.059 (1.50)	2
.037-.040 (.93-1.02)	.063 (1.60)	3

NOTE: Due to the aluminum construction of the head, DO NOT use metal brushes or scrapers to clean gasket sealing surface or combustion chambers. Use solvent and wooden or plastic scrapers to remove foreign material. DO NOT mar piston tops when cleaning cylinder block. Ensure that all bolt holes and cylinder bores are absolutely free of debris prior to installation head or bolts.

Fig 1: Measuring Piston Projection

Lower head carefully onto gasket. Use guide pins (3070) or 2 of the outermost bolts and washers to keep gasket and head aligned with block. Diesel engines use either 6-point, head 11 mm bolts or 12-point, 12 mm head bolts. The 12-point bolts must be replaced with every engine repair.
On the 6-point bolts, tighten in 3 steps to specifications listed in table. After the third step, warm up engine until fan cycles on. Torque once again, without backing off, to third step specification. After 1000 miles of use, retorque by loosening bolts 30° at a time and then tighten again to third step specification.
On the 12-point bolts, tighten in 3 steps to specifications listed in table. After the second step, tighten the bolts an additional 1/2 turn. Warm up engine until fan cycles on. Tighten an additional 1/4 turn. After 1000 miles of use, retorque an additional 1/4 turn. To complete installation, reverse removal procedure.

CYLINDER HEAD BOLT TORQUE SPECIFICATIONS

Application

Ft. Lbs. (N.m)

6-Point Bolts

Step No. 1

35 (50)

Step No. 2

50 (70)

Step No. 3

65 (90)

12-Point Bolts

Step No. 1

29 (40)

Step No. 2

43 (60)

Step No. 3

⁽¹⁾

⁽¹⁾	For third step of procedure, see text of cylinder head installation.

Fig 2: Cylinder Head Tightening Sequence

NOTE: Loosen in reverse order.