NOTE: Cylinder head may be removed with engine installed.

Removal

1. Remove rocker arm cover. Loosen rocker arm retaining nuts so tension is relieved evenly. Remove intake manifold assembly.
2. Remove expansion tank cap and drain plugs under cylinder heads. Drain cooling system. Disconnect coolant hoses at cylinder head. Remove front and rear exhaust pipes from cylinder head. Remove push rods and keep in order for reassembly.
3. Remove 8 cap nuts holding cylinder head to block. Gradually loosen nuts in reverse order of tightening sequence. See Fig. 4. Remove cylinder head and gasket. Remove push rod tubes. Remove metal sealing ring and thin Green "O" ring from cylinder sleeve.

Installation

1. Ensure push rod tube is about 7.64" (194.0 mm) long between inside edges of tube sealing "O" rings. Seam of tube faces upward and small end of tube faces cylinder head. Always use new sealing rings and thoroughly clean mating surfaces.
2. Clean cylinder head sealing surface. Install new thin Green "O" ring and metal gasket on cylinder sleeves. Apply a 1-2 mm bead of Sealing Compound (VW No. D 000 400) to center of new water jacket gasket.
3. Coat sealing face of cap nuts with waterproof sealant. Install and snug cap nut at No. 1 stud to hold cylinder head in place. Install remaining cap nuts. Tighten cap nuts (in sequence) to 84 INCH lbs. (10 N.m). Make sure push rod tubes are correctly seated.
4. Tighten cap nuts in 2 steps (in sequence) to final torque of 37 ft. lbs. (50 N.m). Install push rods, ensuring push rods fit into cups of lifters. Install rocker assembly with slots facing upward on shaft supports. Adjust hydraulic lifters after tightening rocker arm assembly nuts. Install rocker cover with new gasket.
5. Install remaining parts in reverse order of removal. Use new exhaust flange gaskets with metal surface toward head. Always use new locking nuts. Fill and bleed cooling system.

Tightening Sequence

TORQUE SPECIFICATIONS