This is not a step by step instruction on replacing head gaskets. This is a set of tips that can make the job easier, or better.

1.
HEAD BOLTS:

When changing a head gasket on any car, a very important thing to know is whether or not you can re-use the head bolts. There is a very good chance the answer is "NO". The reason? A lot of head bolts are 'torque to yield' or 'stretch bolts'. These bolts are torqued down to a specified setting, then and additional 1/4 or 1/2 turn, resulting in the bolt stretching in length. Once this happens, the bolt can no longer be re-used, or the second stretch would leave the bolt to week to do its job reliably.

Since you HAVE to replace the bolts anyway, I recommend getting ARP HEAD STUDS for two main reasons. They are reusable! If you ever have to take the head off again, you do not need to buy new studs! The clamp tighter: because they are studs, the threads are not twisting in the block as the nut is tightened. This allows a higher clamping force on the head to the block for a better seal, making the head gasket last longer.

ARP HEAD STUDS are available for any VW engine.

Rather then a bolt screwing into the block, you screw in a stud, threaded on both ends, finger tight into the block. Slip on the gasket, the head, and install the nuts and torque. The head now glides on, in perfect alignment compared to the old bolts.


2.
THE MATING SURFACES

The deck of the block and the flat of the head need to be extremely flat and clean before re-assembly. If the water jackets have caused any corrosion on either the block or head's mating surface, it must be smoothed out. All of the old head gasket material and sealant must be scraped off, without damaging the head. A straight edge razor blade can easily leave heavy gouges on an aluminum block or head. So be careful!

3.
PISTONS AND VALVES

Take the time to clean the pistons and valves while the head is off. Carbon buildup and coking can get out of hand on an older engine. If you can take the valves out for a soak, they will clean much easier. The piston tops can be soaked by putting all pistons below the deck of the block and pour a little gas or cleaner on them. Do not do anything that would scratch the cylinder walls, or valve seats!

4.
GASKET MATERIAL
If it is available, a metal type gasket is almost always better then a fiber type gasket. They may cost more, but will last much longer!