Procedure:
1. Disconnect battery2. Remove rear carpet, mattress (where applicable) and engine cover.
3. Remove air cleaner assembly.
4. Remove air conditioning compressor from bracket and place on ledge next to engine. It is not necessary to drain Freon.
5. Remove left and right fuel rails, injectors, ground wires and manifolds.
WARNING Fire hazard do not smoke or have anything in
area that can ignite fuel.
6. Remove left and right splash shields, push rod tube shields, and disconnect oxygen sensor wire.
7. Drain all coolant, oil and remove oil filter.
Do not reinstall oil drain plug at this time.
To drain coolant from engine remove drain plugs between cylinders.
Remove spare tire cover under front of vehicle and disconnect coolant hoses from radiator. Reconnect coolant hoses to radiator and close spare tire cover.
Remove coolant pump.
9. Remove exhaust system, including cross-over pipes, muffler with converter and exhaust heat-shield.
10. Remove crankshaft pulley.
Depending on the model year use retaining tool 3149 for 1986 and above or tool 3120 for pre-1986 vehicles. Refer to Vanagon workshop microfiche Group 13, pages 13.35 for 1986 and above or 13.42 for pre-1986 vehicles.
11. Remove power steering pump.
12. Remove coolant cross-over pipes at front and rear of cylinder head.
13. Remove valve covers, rocker arms, push rods and oil filler pipe.
NOTE: Mark push rods to be certain they are re-installed in the same position.
14. Remove cylinder head cap nuts. Remove push rod tubes and both cylinder heads.
In cases where the cylinder sleeves are stuck to the head, lightly tap the sleeve with a small solid rubber mallet.
15. Clean old gasket material from cylinder heads, engine block and covers.
16. Inspect sealing surface of cylinder head. Replace cylinder head if cavitation or pitting is visible.
17. Remove cylinder sleeves, with tool # 3092, until piston circlip is visible. Refer to Repair Microfiche, Group 13, page 13.44. Before removing, mark matching numbers on pistons and cylinder sleeve.
18. Remove piston circlip and remove wrist pin using tool # 3091 and # 3159. Refer to Repair Microfiche, Group 13, page 13.44 and 13.47.
19. Inspect cylinder head studs. Replace studs that show any sign of corrosion on the stud shank.
20. Clean wrist pins, cylinder sleeves and pistons.
21. Replace both cylinder sleeve "O" rings. Install pistons into sleeves.
22. Install piston and sleeve onto corresponding connecting rod. With tool # 3091 and # 3090 install wrist pin to connecting rod. Refer to Repair Microfiche, Group 13, page 13.46 and 13.47.
23. Clean push rod tubes, rocker arms, valve covers and cylinder head cap nuts. Measure and adjust push-rod tubes to the required length. "A" Approximately 194 mm (7.638 in.). See figure 1
24. Install NEW cylinder head gasket to engine block.
Note: The next 3 steps are for one cylinder head installation at a time.
CAUTION Do not use too much sealant. Excessive
sealant could plug cylinder head coolant passages or hydrolock cap nuts.
25. Apply cylinder head sealant material, P/N D 000 400 01, in a 1 mm to 2 mm bead on the side facing cylinder head in center of gasket. See figure 2.
26. Install cap nut sealant, P/N AKD 456 000 02, into cap nut location on cylinder head in a 1 mm bead.
27. Install cylinder head onto studs, install push-rod tubes, with seam up, into position.
Tighten cylinder at stud # 1 with cap nut just enough so that all 7 remaining nuts can be installed. See figure 3.
CAUTION Use only a beam or dial type torque
wrench. DO NOT USE A CLICK TYPE TORQUE WRENCH.
28. Tighten cap nuts in designated sequence to 10 N-m (7 ft.lb.).
29. Tighten cap nuts in designated sequence to 40 N-m (30 ft.lb.).
30. Tighten cap nuts in designated sequence to 50 N-m (37 ft.lb.).
Double check final torque of 50 N-m (37 ft.lb.) in Cylinder hood. Installing designated sequence.
31. Reinstall push rods and rocker arms. Be sure that push rods are properly seated before tightening rocker arm.
Torque rocker arm nuts to 25 N-m (18 ft.lb.).
32. Adjust hydraulic valves as follows:
- Back out adjusting screws in rocker arms so that the ball shaped end is flush with surface of arm.
- Rotate crankshaft until cylinder # 1 is at TDC. (mark on rotor in line with mark on distributor housing)
- Turn adjusting screws in so that they just touch valve stems.
- Turn adjusting screws 2 turns clockwise and tighten locknuts.
- Rotate crankshaft 1800 clockwise and adjust next cylinder.
- Repeat until all cylinders are adjusted.
33. Reinstall remaining components in reverse sequence of disassembly.
34. With tool VAG 1274/99 check cap for correct pressure bleed release. Refill with fresh coolant in specified concentration.
CAUTION Coolant/antifreeze must not be reused when
performing this procedure. When replacing coolant/antifreeze solution in all Volkswagen models, all model years, use phosphate-free coolant/antifreeze ZVW 237 104
35. Reinstall engine oil drain plug and fill with oil.
36. Reconnect battery.
37. Remove radiator grill and bleed air from coolant system. Reinstall grill.
36. With tool VAG 1274/99 pressure check coolant system for leaks.
37. Remove CO tap plug and install 120-239 tool for checking CO%. Install VAG 1367 and other necessary equipment to check and adjust engine specifications.
Operation Description Time/Units
- 1310 14 8 R&R all pistons/cylinders 220 T.U. with engine in vehicle.
- 1570 22 4 R&R both cylinder heads 840 T.U. engine in vehicle.