Volkswagen Air-Cooled 1970-1981 Repair Guide

Cylinder Heads

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REMOVAL & INSTALLATION



See Figures 1 through 13

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Fig. Fig. 1: To remove the cylinder head, first pry the rocker arm cover retaining wire down and off of the cover . . .



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Fig. Fig. 2: . . . then remove the rocker arm cover from the cylinder head



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Fig. Fig. 3: Make sure to discard the old gasket-a new gasket will be needed upon assembly



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Fig. Fig. 4: Slowly and alternately remove the rocker arm shaft mounting nuts . . .



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Fig. Fig. 5: . . . then remove the shaft from the cylinder head



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Fig. Fig. 6: Once the rocker arm shaft is removed, the pushrods can be pulled out of their tubes



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Fig. Fig. 7: Loosen the cylinder head nuts . . .



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Fig. Fig. 8: . . . and slowly slide the cylinder head off of the mounting studs



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Fig. Fig. 9: Remove the pushrod tubes from either the cylinder head or the crankcase



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Fig. Fig. 10: Remove the lower air shield from between the lower, middle two studs



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Fig. Fig. 11: Make certain to tighten the cylinder heads to the proper torque value and in the proper sequence to ensure adequate cylinder sealing



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Fig. Fig. 12: To install the cylinder heads, first tighten the cylinder head nuts to 7 ft. lbs. following sequence I, then tighten the nuts to 23 ft. lbs. following sequence II - 1600cc engines



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Fig. Fig. 13: Make certain to tighten the cylinder head nuts in the sequence shown to ensure proper cylinder sealing-1700cc, 1800cc and 2000cc engines

In order to remove the cylinder head from either pair of cylinders, it is necessary to remove the engine.

  1. Remove the valve cover and gasket. Remove the rocker arm assembly. Unbolt the intake manifold from the cylinder head. The cylinder head is held in place by eight studs. Since the cylinder head also holds the cylinders in place in the VW engine, and the cylinders are not going to be removed, it will be necessary to hold the cylinders in place after the head is removed.
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  3. After the rocker arm cover, rocker arm retaining nuts, and rocker arm assembly have been removed, the cylinder head nuts can be removed and the cylinder head lifted off.
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To install:
  1. When reinstalling the cylinder head, the head should be checked for cracks both in the combustion chamber and in the intake and exhaust ports. Cracked heads must be replaced.
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  3. Spark plug threads should be checked. New seals should be used on the pushrod tube ends and they should be checked for proper seating.
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  5. The pushrod tubes should be turned so that the seam faces upward. In order to ensure perfect sealing, used tubes should be stretched slightly before they are reinstalled.
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  7. Install the cylinder head. Using new rocker shaft stud seals, install the pushrods and rocker shaft assembly.
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Pay careful attention to the orientation of the shaft as described in the "Rocker Shafts" portion of this section.

  1. Tighten the cylinder head in three stages. Adjust the valve clearance. Using a new gasket, install the rocker cover. It may be necessary to re-adjust the valves after the engine has been run a few minutes and allowed to cool.
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VALVE SEAT SF



On all air-cooled VW engines, the valve seats are shrunk-fit into the cylinder head. This usually involves freezing the seat with a liquid nitrogen or some other refrigerant to about 200 below zero, and heating up the cylinder head to approximately 400F. Due to the extreme temperatures required to shrink-fit these items, and because of the extra care needed when working with metals at these extreme temperatures, it is advised that this operation be referred to an experienced repair shop.

OVERHAUL & VALVE GUIDE REPLACEMENT



See Engine Rebuilding'' at the end of this section.

 
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