Volkswagen Golf/Jetta 2 manual

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


1 Clean all traces of old gasket from the cylinder block and cylinder head faces, taking great care not to mark the gasket surfaces.

2 Using a new gasket, fit the inlet manifold (see illustrations).

11.2a Fitting a new inlet manifold gasket
11.2a Fitting a new inlet manifold gasket

11.2b Fitting inlet manifold complete with carburettor
11.2b Fitting inlet manifold complete with carburettor

3 If they have been removed, refit the oil pressure switches, using new copper sealing washers (see illustration).

11.3 Refitting oil pressure switch
11.3 Refitting oil pressure switch

4 Refit the thermostat housing, using a new O-ring (see illustration).

11.4 O-ring (arrowed) in thermostat housing
11.4 O-ring (arrowed) in thermostat housing

5 Refit the coolant hoses, ensuring that they are connected up in the correct position (see illustration).

11.5 Coolant hoses in position
11.5 Coolant hoses in position

6 Lubricate the fuel pump plunger with clean engine oil and slip it into its housing in the cylinder head (see illustration).

11.6 Fitting fuel pump plunger (arrowed)
11.6 Fitting fuel pump plunger (arrowed)

7 Refit the fuel pump and fit and tighten the bolts, not forgetting the engine lifting eye (see illustrations).

11.7a Fitting fuel pump
11.7a Fitting fuel pump

11.7b Location of engine lifting eye
11.7b Location of engine lifting eye

8 Slide the distributor into position and ensure that it goes fully home (see illustration). Hand-tighten the retaining bolts.

11.8 Refitting ignition distributor
11.8 Refitting ignition distributor

9 Fit the distributor rotor arm (see illustration).

11.9 Fitting rotor arm
11.9 Fitting rotor arm

10 Fit the distributor cap and connect up the earth lead (see illustration).

11.10 Fitting distributor cap and earth lead
11.10 Fitting distributor cap and earth lead

11 Check the timing marks on the cylinder head and camshaft sprocket are lined up.

12 Note that none of the pistons should be at TDC when refitting the cylinder head.

13 Position a new cylinder head gasket on the cylinder block (see illustration).

11.13 Cylinder head gasket in position
11.13 Cylinder head gasket in position

14 Lower the cylinder head gently into position. Special guides are used by the manufacturer both to line up the gasket and guide the cylinder head into position but this can be done using suitable sized rods inserted in two cylinder head bolt holes.

15 Install the cylinder head bolts. Refer to Part A of this Chapter for the tightening sequence but use the torque figures and stages given in the Specifications of this Chapter.

16 It is not necessary to retighten the bolts after a period of service, as is normally the case.

17 Refit the plastic oil shield (see illustration).

11.17 Plastic oil shield correctly located
11.17 Plastic oil shield correctly located

18 Using a new rubber sealing gasket properly located over the dowels, refit the valve cover (see illustration).

11.18 Locating dowel for valve cover gasket (arrowed)
11.18 Locating dowel for valve cover gasket (arrowed)

19 Fit a new gasket to the exhaust manifold (see illustration).

11.19 Fitting a new exhaust manifold gasket
11.19 Fitting a new exhaust manifold gasket

20 Fit the exhaust manifold, tightening its nuts securely, then fit the hot air shroud (see illustration).

11.20 Fitting hot air shroud
11.20 Fitting hot air shroud

21 Connect up the exhaust downpipe and any other exhaust brackets loosened during removal.

22 Refit all remaining hoses of the cooling system and fuel system, referring to the relevant Chapter where necessary.

23 Refit all electrical connections disturbed during dismantling (distributor, carburettor, oil pressure and coolant temperature switches, inlet manifold preheater, etc.) (see illustrations). Do not forget the earth lead under the inlet manifold nut.

11.23a Ignition distributor electrical connection
11.23a Ignition distributor electrical connection

11.23b Coolant temperature switch/sender electrical connection
11.23b Coolant temperature switch/sender electrical connection

11.23c Oil pressure switch electrical connection
11.23c Oil pressure switch electrical connection

11.23d Earth lead under inlet manifold bolt head
11.23d Earth lead under inlet manifold bolt head

24 Refit the distributor vacuum hose.

25 With reference to Part A of this Chapter, Section 37, refit the timing belt and covers.

26 Refit the throttle cable.

27 Refit the spark plugs, air cleaner and associated pipework and electrical leads.

28 Check oil and coolant levels, replenishing as necessary, then adjust the ignition timing.


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