Volkswagen Engine >> REVISED CYLINDER HEAD INSTALLATION

Volkswagen Engine >> REVISED CYLINDER HEAD INSTALLATION

Revised Cylinder Head Installation For
1993-2000 Volkswagen 1.9L Diesel Engines

The AERA Technical Committee offers the following information regarding a revised cylinder head installation procedure on 1993-2000 Volkswagen 1.9L diesel engines. Beginning in November of 1993, these engines started using a metal head gasket with a silicone coating. Using that gasket required a reduction in applied torque to the gasket. All engines built previous to the above date may be fitted with the revised gasket during service.

When making head gasket repairs with the above-mentioned gasket do not rotate the head bolts an additional 90° after the engine is hot. That final procedure is no longer required with the revised gasket. To install the cylinder head, obtain a set of NEW head bolts and follow the procedure listed below.

Step 1. Rotate the crankshaft so all pistons are below top dead center.
Step 2. Align head over locating dowels and place head on block, remove dowels.
Step 3. Install NEW head bolts and tighten bolts by hand.
Step 4. Torque all bolts in sequence to 30 ft/lbs.
Step 5. Torque all bolts in sequence to 44 ft/lbs.
Step 6. Rotate all bolts in sequence an additional 90° turn.
Step 7. Rotate all bolts in sequence an additional 90° turn.

Note: Leave the head gasket in its packaging until just prior to installation as scratching the gasket surface is unacceptable. Handle the gasket with extreme care as damage to the silicone coating may allow leakage.

The AERA Technical Committe

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