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

                      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

##END##

                                          Interference Engines

The AERA Technical Committee would like to offer the following information on engines that present the possibility of interference between pistons and valves. The interference or contact may bend valve(s) when the timing between the camshaft and crankshaft is interrupted. This is generally the result of a timing belt or chain breaking or slipping.

The following list are engines that AERA is currently aware of that have exhibited interference. There may be other engines that are not listed below that have the possibility of piston to valve contact. If the engine you are working on is not listed, do not assume that it is a freewheeling design. It is suggested to add to this listing as additional information is obtained.

ACURA
1986-89 1.6L Integra
1991-95 1.7L Integra
1990-95 1.8L Integra 
1986-89 2.5L Legend
1992-94 2.5L Vigor
1986-89 2.7L Legend
1990      2.7L Legend
1991-95 3.0L NSX
1991-95 3.2L Legend

AUDI
1970-93 All Except 1970-77 
1.9L & 1970-73 1.8L

BMW
1987-95 2.5L 325I 525I
1994-95 4.0L 740I

CHRYSLER
1993-95 1.5L Colt 
1987-88 1.5L Colt	
1992-95 1.5L Eagle Summit
1987-88 1.6L Colt	
1989-92 1.6L Eagle Summit
1994-98 2.0L Neon Stratus
1990-95 2.0L Eagle Talon

DAIHATSU
1988-92 1.0L Charade
1988-92 1.3L Charade
1990-92 1.6L Rocky

FIAT
1974-79 1.3L 128 Series
1979-82 1.5L Stranda
1974-78 1.6L 124 Series
1974-78 1.8L 124 Series
1974-78 1.8L 131 Series, Brava
1979-82 2.0L Brava, Spider 

FORD
1981-85 1.6L Escort, EXP
1981-83 1.6L LN7, Lynx
1984-85 2.0L Escort, Tempo
1993-95 2.0L Probe
1986-88 2.0L Ranger
1984-87 2.0L Lynx, Topaz Diesel
1985    2.2L Ranger
1989-92 2.2L Probe
1986-88 2.3L Ranger
1986-87 2.3L Diesel Ranger
1991-98 4.6L Crown Victoria

GM
1986-95 1.0L Geo Metro
1989-91 1.0L Firefly (CANADA)
1985-88 1.5L Sunburst (CANADA)
1985-89 1.5L Spectrum
1990-93 1.6L Prizm, Storm
1981-84 1.8L Diesel (CANADA)
1982-86 1.8L Buick Skyhawk
1990-98 1.9L Saturn
1987-88 2.0L Buick Skyhawk
1988-95 2.3L Quad Four
1985-87 3.0L Buick
1979-95 3.8L Buick

HONDA
1986-87 1.0L Prelude
1973-78 1.2L All
1973-78 1.3L All
1980-84 1.3L All
1973-78 1.5L All
1985-89 1.5L Civic
1988-95 1.5L Civic, CRX
1993-95 1.5L Civic Del Sol
1979-84 1.5L All
1985-87 1.5L CRX
1993-95 1.6L Civic Del Sol
1973-78 1.6L All
1980-82 1.6L All
1988-95 1.6L Civic, CRX
1984-87 1.8L Prelude, Accord
1979-83 1.8L All
1986-91 2.0L Prelude
1990-91 2.1L Prelude
1990-95 2.2L Prelude, Accord
1992-95 2.2L Prelude
1995      2.7L Accord

HYUNDAI
1984-95 1.5L Excel Scoupe
1995-98 1.5L Accent
1992-95 1.6L Elantra
1993-95 1.8L Elantra
1992-95 2.0L Sonata
1989-91 2.4L Sonata
1990-95 3.0L Sonata

INFINITI
1990-92 3.0L M30

ISUZU
1987-89 1.5L I-Mark
1990-93 1.6L Stylus Impulse
1987-89 2.0L Impulse
1981-87 2.2L Diesel Truck
1986-95 2.3L Truck Trooper
1988-95 2.6L Truck Rodeo Amigo
1991-96 3.2L Trooper Rodeo Amigo

KIA
1995      2.0L Sportage

MAZDA
1984-85 2.0L 626 
1988-92 2.2L 626 MX6
1989-93 2.2L Pickup
1988-95 3.0L 929 MPV

MITSUBISHI
1985-95 1.5L Mirage Precise
1990-92 1.6L Mirage
1989-95 2.0L Galant Eclipse
1983-86 2.3L Diesel Pickup
1994-95 2.4L Galant

NISSAN
1982      1.5L Centra
1983-88 1.6L Sentra Pulsar
1987-89 1.8L Pulsar
1982-89 2.0L Stanza 300ZX
1984-95 3.0L Maxima 300ZX Pathfinder

PORSCHE
1976-83 2.0L 924
1976-89 2.5L 944 Series
1989      2.7L 944 Series
1989-91 3.0L 944 Series
1976-83 4.5L 928
1984      4.7L 928
1985-91 5.0L 928
1992-95 5.4L 928

SUZUKI
1985-94 1.3L Samurai Sidekick
1989-94 1.3L Swift

TOYOTA
1986-95 1.5L Tercel
1981-83 2.2L Pickup
1984-87 2.4L Pickup
1982-88 2.8L Celica Cressida
1987-94 3.0L 4-Runner

VOLKSWAGEN
1976-91 All Except 1.9 2.1L Engine
1990-92 1.6L Golf (CANADA) Jetta
1990-95 2.0L GTI Jetta GLI Passat

VOLVO
1991      2.3L Coupe 940
1986-94 2.3L 240 740 940 

                                                                              The AERA Technical Committee