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The following technical bulletins were published by AERA.


                                       Revised Cylinder Head Gasket On
                                   1995-2000 Volkswagen 2.0L ABA Engines

The AERA Technical Committee offers the following information regarding a revised cylinder head gasket on 1995-2000 Volkswagen 2.0L ABA engines. This information applies to the Jetta, Golf, & GTI during those years. 

Volkswagen has come out with a metal type cylinder head gasket. Along with the different cylinder head gasket, there are also different head bolts that need to be used with the revised gasket. The head of the bolt can identify cylinder head bolts. If the head of the bolt is smooth, it was used for previous head gaskets. A head bolt with raised markings on the head is used for metal head gaskets as shown in Figure 1.

When the cylinder head is removed, distortion on the cylinder head should not be more than .004" or the cylinder head needs to be resurfaced. Minimum cylinder head thickness is 5.2204". Going below that thickness on the cylinder head could cause engine damage. 

During installation of the cylinder head gasket, be careful not to damage the gasket around the beeding or the silicone coating. If damaged, there could be leakage around the damaged area. To align the cylinder head onto the cylinder block, install guide pins into the cylinder head bolt holes #8 & #10 as shown in Figure 2. These guide pins can be purchased from Volkswagen under Kit 3070. Install the cylinder head gasket with the lettering or part number facing up. 

After the gasket has been installed, install the cylinder head and the 8 remaining head bolts and tighten them by hand. Remove the guide pins using removal tool from Kit 3070 and then install the remaining two head bolts. Tighten the cylinder head in sequence as shown in Figure 3. Use the torque values provided below for correct installation. 

1. 30 ft/lbs.
2. 44 ft/lbs.
3. Turn additional 90°
4. Turn additional 90°

                                                                               The AERA Technical Committe


                                  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


                      Hydraulic Lifters On
         1986 Volkswagen 1.6L (96.9 CID) Diesel Engines

Volkswagen 1.6L (96.9 CID) diesel engines used on the 1986 Jetta
and Golf are now equipped with hydraulic lifters.

In comparison to mechanical lifters, these hydraulic lifters do
not require valve adjustment as part of routine maintenance
service or after engine disassembly.

According to VW, intermittent valve noise is normal during
startup and does not require replacement of the lifter assembly.
Use the following procedure to determine when the hydraulic
lifter needs to be replaced.

Start the engine and allow it to reach operating temperature. The
cooling fan should come on at least once.

Increase engine speed to 3500 RPM, maintain this speed for 2
minutes. Allow the engine to return to idle. If lifters are still
noisy they should be replaced.

Remove the rocker cover and rotate the camshaft so that the lobe
above the lifter to be tested is at base circle (lobe facing away
from head). Using a wood stick or other suitable tool press down
on the lifter (see illustration). If the lifter can be depressed
by more than .004 replace the lifter.

                      (insert illustration)

                                     The AERA Technical Committee

October 1987 - TB 462



                                      Revised Torque Specifications On
                                  1992-98 Volkswagen 2.8L VR6 Engines

The AERA Technical Committee offers the following information on revised torque specifications on 1992-98 Volkswagen 2.8L VR6 engines. Failure to use the revised specifications may cause engine failure after assembly. 

With the revised torque procedures on the vibration damper and flywheel mounting bolts, replacement of the bolts is required. It should also be noted that 
the cylinder head and the connecting rod bolts require replacement during re-assembly of the engine. To correctly torque those bolts, Volkswagen offers 
the following specifications.

Engine Part                   Torque Spec      Use New Bolts
Vibration Damper          74 ft/lbs + 90°                 Yes
Flywheel                         44 ft/lbs +90°                  Yes
*Cylinder Head           30, 40 ft/lbs +180°             Yes
*Connecting Rod           22 ft/lbs +90°                  Yes

*The cylinder head and the connecting rod torque did not change from the original specifications provided by Volkswagen. Those components have been added to this technical bulletin to remind rebuilders that those bolts need to be replaced when rebuilding the engine. Some AERA members? report that they also replace the main bearing cap bolts during rebuilding procedures.

                                                                         The AERA Technical Committee


                                        Cylinder Head Gasket Selection On
                             1981-86 Volkswagen 1.6L (96.9 CID) Diesel Engines

The cylinder head gasket used in the 1981-86 Volkswagen 1.6L (96.9 CID) diesel engines is available in three thicknesses distinguished by notches on the side of the gasket.  The correct gasket is selected by measuring piston protrusion on all four cylinders and basing the selection on the highest piston height.

Protrusin should be measured as indicated in the illustration below by using Volkswagen tools VW382/7 and VW385/17 or equivalents.  It is important that your depth gauge/dial indicator set-up not rest directly on the piston itself to
prevent possible distorted readings.  Parallels placed on the deck surface next to each cylinder will provide a good base for measuring.

Use the following table for determining gasket usage: 

Piston Height               Identification Notches

.0260-.0339                       1 (1.4mm thick)

.0343-.0665                       2  (1.5mm thick)

.0358-.0402                       3 (1.6mm thick)

Additionally, be sure to install the cylinder head gasket with the side marked TOP or OBEN (on OE gaskets) facing up.  

                                                                                 The AERA Technical Committee


                                            Cylinder Head Thickness On
                            Water Cooled Volkswagen 4 Cylinder Engines

The minimum cylinder head thickness for Volkswagen 1.5L, 1.6L, 1.7L and 1.8L gasoline engines is 5.215 as measured from the deck surface to the valve cover rail.  See illustration below.  Although AERA members report following the above specification for 1.5L and 1.6L diesel cylinder heads as well, Volkswagen's official position is that the diesel cylinder heads are not to be
resurfaced.  Heads warped more than .003 are to be replaced.

AERA members are reminded that the diesel engines have 5 different thicknesses of cylinder head gaskets identified by the number of notches located on a tab on the side of the gasket.  The proper gasket is selected based on piston protrusion and size of engine, not cylinder head thickness.  The table below indicates the proper gasket selection.

Piston                            Gasket                             Notches
Projection                   Thickness                            1500cc    1600cc
.025-.032                        .055                                     3         1
.033-.036                        .059                                     4         2
.037-.040                        .063                                     5         3
                                                                       The AERA Technical Committee


                                     Cylinder Head Gasket Caution On
                                  1992-98 Volkswagen 2.8L V-6 Engines

The AERA Technical Committee offers the following information on a cylinder head gasket caution on 1992-98 Volkswagen 2.8L engines, when replacing the 
single head gasket on this narrow 18-degree V-6 engine.

Before installing the head gasket, engine clean all gasket-mating surfaces and check the cylinder head for warpage and minimum cylinder head height. The 
maximum head warpage is .004 (.10mm) and the minimum cylinder head height is 5.4920 (139.497 mm). Replace the head if necessary. The head bolts for this engine should be replaced with new ones, anytime the head gasket is replaced. 


1. Make sure that the head gasket says Top or Oben. Remove sealer from the two 3-mm holes and replace with new sealer. See Figure 1 to install the gasket with top up onto the guide pins.                                                                  2. Install head onto cylinder block, do not use any type of sealer, and install NEW head bolts finger tight.
3. Torque all bolts in the sequence shown in Figure 2 to 30 ft/lbs.
4. Torque all bolts in the sequence shown in Figure 2 to 40 ft/lbs.
5. Rotate all bolts in the sequence shown in Figure an additional 180°.

Note: Do Not Reuse antifreeze if the engine had any failures of the cylinder head gasket, cylinder head casting, cylinder block casting, heater core and/or 
the radiator.

                                                                      The AERA Technical Committee


                               Valve Retainer & Lock Changes On
                            Volkswagen 1500 & 1600 Diesel Engine

Perfect Circle engineers report that Volkswagen is using two different combinations of valve retainers and locks on its 1500cc and 1600cc diesel engines.  Both combinations have been found on the same head at times with all the exhaust one type and the intakes the other type.

The single groove lock is used with the retainer that has an overall height of .375 while the three groove lock is used with the retainer having an overall height of .325.  

Care must be taken to insure that the correct locks are used with each retainer to avoid costly damage to the engine.  Valve breakage will occur if you intermix the retainers and locks. 
                                                                          The AERA Technical Committee


                        Torque Valves On
               Two Volkswagen Drive Belt Sprockets

The illustrations below show the two different versions of a
drive belt sprocket used on all water-cooled Volkswagen 4-
cylinder in-line engines (except the Vanagon Waterboxer).  Note
that the newer design eliminates the slip-in keyway as well as
other differences.

It is important to use the correct tightening torque
specifications when installing the respective sprockets.

Always check the drive belt sprocket bolt torque after repairs
that may require turning the engine counterclockwise using the
sprocket bolt head.

                     (insert illustrations)

                                     The AERA Technical Committee

October 1985 - TB 363



                                        Head Gasket Caution On
                        1992-97 Volkswagen 1.9L VIN Z Diesel Engines

The AERA Technical Committee offers the following information on head gasket caution on 1992-97 Volkswagen 1.9L VIN Z diesel engines. These turbocharged engines use one of the three different thickness gaskets available for each of the engines, TD or TDI. The correct gasket to be used depends upon the amount of piston protrusion measured before installation.

Measuring piston protrusion requires mounting a dial indicator to the block top and bringing each piston to TDC (top dead center). This measurement should be made directly above the piston pin. Observe and record the amount each piston extends above the top of the block deck. Use the highest value measured to select the correct cylinder head gasket to be used. The three different gaskets can be identified by the number of notches located on the 
head gasket next to the part number.

Engine        Part Number        Notches              Piston Protrusion

TD              028 103 383 BH            1                  .036-.039 (.914-.990 mm)
TD              028 103 383 BJ             2                  .040-.043  (1.106-1.092 mm)
TD              028 103 383 BK             3                  .044-.047  (1.117-1.193 mm)

TDI             028 103 383 BL              1                  .036-.039  (.914-.990 mm)
TDI             028 103 383 BM             2                  .040-.043  (1.106-1.092 mm)
TDI             028 103 383 BN             3                   .044-.047  (1.117-1.193 mm)

AERA is currently unaware of an aftermarket supplier for the above mentioned head gaskets.

                                                                               The AERA Technical Committee

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