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Home >> Volkswagen >> 1984 >> Vanagon Base, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 6 (1.6L 4-CYL Diesel/Turbo Diesel) >> Engine, Cylinder Head & Manifolds >> Cylinder Head & Manifolds >> Removal (All Except Quantum & Vanagon)

Removal (All Except Quantum & Vanagon)

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.
  1. Remove air cleaner and ducting, then drain cooling system (engine cool). Remove camshaft drive belt. Unbolt thermostat housing from water pump. Disconnect battery ground strap.
    NOTE: Never drain coolant while engine is hot. Doing so could cause engine block or cylinder head to warp.
  2. Disconnect accelerator cable from injection pump. Detach fuel lines at injectors by unscrewing unions. Disconnect wire from glow plug bus, temperature sending wire and any other wires which could interfere with removal of cylinder head.
  3. Remove spring clips holding exhaust pipe to manifold using clip remover tool (3059 or equivalent). Unbolt exhaust pipe support from engine and transaxle assembly (if equipped). From underneath vehicle, remove bolts and nuts holding exhaust manifold to cylinder head. Remove manifold from head.
  4. Disconnect coolant hoses from head and remove any other hoses which may interfere with head removal. Remove cylinder head cover bolts and retaining plate. Carefully lift off cover and gasket. Loosen head bolts in reverse order of tightening sequence. See Figure. Lift off head. Remove injectors and glow plugs to prevent damage while working on head.
  5. Remove combustion chamber inserts by placing drift through injector hole and tapping out with hammer. Prior to installation, pre-chamber inserts must be reinstalled. When installing injectors, new heat shields must be installed between each injector and cylinder head. Place new shield in position with recess upward, toward injector. Tighten injector.
NOTE: Combustion chamber inserts are NOT supplied as spare parts on latest models. If inserts are damaged it will be necessary to replace cylinder head.
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