Volkswagen Golf/Jetta 2 manual

Cylinder head - refitting
Engine repair procedures - 1.05 and 1.3 litre pre August 1985 / Cylinder head - refitting


1 Position Nos 1 and 4 pistons at TDC then turn the crankshaft a quarter of a turn anti-clockwise so that neither of the pistons is at TDC.

2 Ensure that the faces of the cylinder head and block are perfectly clean then locate the new gasket on the block, making sure that all oil and coolant holes are visible. The gasket part number should be uppermost (see illustration).

36.2 Correct fitting of cylinder head gasket
36.2 Correct fitting of cylinder head gasket

3 Lower the cylinder head onto the gasket then insert the bolts together with the engine lifting hooks.

4 Using a splined key, tighten the bolts in the stages given in Specifications, using the sequence shown (see illustration).

36.4 Cylinder head bolt tightening sequence
36.4 Cylinder head bolt tightening sequence

5 Refit the coolant pump, if applicable.

6 Fit the timing cover plate and insert the coolant pump bolts loosely.

7 If required, refit the camshaft.

8 Refit and tighten the timing cover plate upper retaining bolt.

9 If applicable, refit the crankshaft sprocket and timing belt to the crankshaft (see illustration).

36.9 Fitting crankshaft sprocket and timing belt
36.9 Fitting crankshaft sprocket and timing belt

10 Turn the camshaft so that the indentation in the sprocket is aligned with the pointer on the timing cover plate.

11 Turn the crankshaft a quarter of a turn clockwise so that the notch in the crankshaft pulley (temporarily refit if necessary) is aligned with the TDC pointer on the front of the oil pump.

12 Fit the timing belt to the camshaft sprocket and coolant pump.

13 Using a screwdriver in the coolant pump, turn the pump anti-clockwise and tension the timing belt until it can just be turned through 90° with the thumb and forefinger midway between the camshaft sprocket and coolant pump (see illustration).

36.13 Tensioning timing belt
36.13 Tensioning timing belt

14 Tighten the coolant pump bolts when the tension is correct and check that the timing marks are still aligned.

15 Fit the dipstick tube to the cylinder block.

16 Fit the timing cover, insert the bolts with the earth lead and dipstick tube bracket and tighten the bolts.

17 Refit the valve cover with a new gasket, locate the reinforcement strips and tighten the nuts and bolts.

18 If the engine is in the vehicle, reverse the preliminary procedures given in Section 9.


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