Caution: When installing a new cylinder head, remove the plastic plugs designed to protect the exposed valves of the cylinder head.
1. The mating surfaces of the cylinder head and block must be completely clean. Use a hard plastic or wooden scraper to clean them. Be careful when cleaning, as the aluminum alloy is very easy to damage.
2. Check that carbon deposits have not entered the oil and water passages. This is especially important for the lubrication system, as carbon deposits can block the flow of oil to engine components. Clean the passages if necessary.
3. Using a metal ruler and feeler gauge, check the flatness of the mating surfaces.
4. Deviation from flatness should be no more than 0.1 mm.
5. Check the mating surfaces of the cylinder head and block for nicks, deep scratches and other damage. If the defects are small, they can be removed by mechanical treatment.
Measure the height (a) of the cylinder head at the specified location. The height of the cylinder head after machining should be for the 1.8L engine = 139.2 mm, and for the 1.6L engine = 132.6 mm.
(The information is available on the website vwmanual)
6. Clean the bolt holes in the cylinder block. Driving a bolt into an oil-filled hole can cause the block to burst due to hydraulic pressure.
Warning: When installing the cylinder head, it is necessary to use new cylinder head bolts and a new cylinder head gasket.
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