Sam,
after doing this a few times due to thinking it was a blown seal and
not a cracked head, I got it down to the point where I did the
disassembly and reassembly with a new head in one night.

For the right side
 - disconnect battery
 - drain coolant and oil
 - air cleaner, auxiliary air regulator, alternator
 - remove exhaust for cylinders 1 and 3
 - loosen exhaust on cylinder 4 and remove nuts on cylinder 2
 - remove crossover coolant pipe, spark plug wires
 - remove remaining coolant connections from the head
 - remove valve cover and that main rocker arm assembly
 - I then removed the head with most of the exhaust still on

Don't take out the sleeves.  It is really hard to get the pistons back
in the sleeves.  I did not change the rear o-rings, but it appears
to be holding together.

Note that the first time I did it, I took off everything and actually
I'm glad I did.  However, if you're in a rush, you can probably leave
some pieces on.

-- Craig

On Fri, 12 Jul 2002, Sam Scholten wrote:

> Deciding that I don't have the cash to have someone
> else replace the right-side head on my '87 GL, I am
> undertaking this myself. This is my first time on a
> 2.1. Bentley offers the concept but not a procedure
> sequence, i.e. what surrounding parts to take off in
> what order, besides the valve cover, splash guard,
> manifolds and fuel rail.
>
> I understand that this sounds banal, but the labor
> estimate indicated a time-consuming procedure. I have
> too much going on in my life right now to be able to
> fumble through the process willy-nilly, so I need to
> be able to organize the time I have in the most
> efficient way to avoid rushing through the job. The
> archives search came up dry, as did a search for
> personal pages with the procedure on them (although
> I've come close several times).
>
> Please help if you can.
>
> Thanks,
> Sam
>
> P.S. If anyone has a way to bend the laws of physics
> in order to get the exhaust header studs out, please
> let me know. This is beyond the powers of Liquid
> Wrench. :)
>
>
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--
Craig Oda   craigoda@communitybuilders.info
VW Info: 1983 VW Westfalia, water-cooled, automatic