Installing the cylinder head (VW Golf 2)

When ordering a cylinder head gasket, you should correctly specify the engine identification data in order to purchase a gasket designed specifically for a diesel engine or a turbocharged diesel engine. Moreover, engines with hydraulic tappets have a special design gasket, it is equipped with a 16 mm diameter hole between the windows of the 1st and 2nd cylinders. Cylinder head gaskets are manufactured in various thicknesses, which depend on the height to which the pistons protrude above the upper mating plane of the cylinder block. To determine the thickness of the gasket, one of the pistons must be installed at TDC, and then use a ruler and a depth gauge to measure the height of the piston protrusion above the upper mating plane of the cylinder block (figure 195). Based on the obtained result and the dependence given below, the thickness of the gasket is determined, indicated by the number of marks on the gasket protrusion (figure 196). The top black arrow indicates where the catalog number for ordering the gasket is stamped.


Data for engine without hydraulic tappets:

protrusion height	number of risks
0.67-0.80 mm	1
0.81-0.90 mm	2
0.91-1.02 mm	3

Data for engine with hydraulic valve lifters:

protrusion height	number of risks
0.66-0.86 mm	1
0.87-0.90 mm	2
0.91-1.02 mm	3

To install the cylinder head correctly, it is necessary to use special installation pins that are screwed into the cylinder block from the intake manifold side in the area shown in Figure 197, for which: Clean the mating surfaces of the head and cylinder block.



Tighten all bolts in the specified sequence to a torque of 60 Nm (second stage of tightening).



Replace the torque wrench with a regular one and tighten each bolt exactly half a turn in the order specified. Tightening twice by a quarter turn (2x90°) is possible.


Start the engine and let it warm up. Tighten the bolts in the order shown exactly 1/4 turn with a smooth, continuous motion.

After a run of about 1000 km, the bolts should be tightened in the specified order with a smooth, continuous movement by another 1/4 turn. The engine can be cold or warm.

All other actions are performed in the reverse order of disassembly.