Volkswagen New Beetle. Manual - part 67

 

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Volkswagen New Beetle. Manual - part 67

 

 

CYLINDER HEAD DISASSEMBLY 

Mark valves for location. Using valve spring compressor, compress valve springs. Remove valve locks. 
Carefully release spring compressor. Remove retainer or rotator, valve spring, spring seat and valve. See Fig. 2 

Fig. 2: Exploded View of Valve Assemblies 

CYLINDER HEAD CLEANING & INSPECTION 

Clean cylinder head and valve components using approved cleaning methods. Inspect cylinder head for cracks, 
damage or warped gasket surface. Place straightedge across gasket surface. Determine clearance at center of 
straightedge. Measure across both diagonals, longitudinal center line and across cylinder head at several points. 
See Fig. 3 .  

On cast iron cylinder heads, if warpage exceeds .003" (.08 mm) in a 6" span, or .006" (.15 mm) over total 
length, cylinder head must be resurfaced. On most aluminum cylinder heads, if warpage exceeds .002" (.05 
mm) in any area, cylinder head must be resurfaced. Warpage specification may vary by manufacturer. If 
warpage exceeds specification on some cylinder heads, cylinder head must be replaced.  

Cylinder head thickness should be measured to determine amount of material which can be removed before 
replacement is required. Cylinder head thickness must not be less than the manufacturer's specification.  

If cylinder head required resurfacing, it may not align properly with intake manifold. On "V" type engines, 
misalignment is corrected by machining intake manifold surface that contacts cylinder head. Cylinder head may 
be machined on surface that contacts intake manifold. Using oil stone, remove burrs or scratches from all 
sealing surfaces.  

 

1998 Chevrolet Pickup C1500 

GENERAL INFORMATION Engine Overhaul Procedures

  

Fig. 3: Checking Cylinder Head for Warpage 

VALVE SPRINGS 

Inspect valve springs for corroded or pitted valve spring surfaces which may lead to breakage. Polished spring 
ends caused by a rotating spring indicate that spring surge has occurred. Replace springs showing evidence of 
these conditions.  

Inspect valve springs for squareness using a 90-degree straightedge. See Fig. 4 . Replace valve spring if out-of-
square exceeds manufacturer's specification. 

 

1998 Chevrolet Pickup C1500 

GENERAL INFORMATION Engine Overhaul Procedures

  

Fig. 4: Checking Valve Spring Squareness 

Using vernier caliper, measure free length of all valve springs. Replace springs if not within specification. 
Using valve spring tester, test valve spring pressure at installed and compressed heights. See Fig. 5 .  

Usually compressed height is installed height minus valve lift. Replace valve spring if not within specification. 
It is recommended to replace all valve springs when overhauling cylinder head. Valve springs may need to be 
installed with color coded end or small coils at specified area according to manufacturer.  

 

1998 Chevrolet Pickup C1500 

GENERAL INFORMATION Engine Overhaul Procedures

  

Fig. 5: Checking Valve Spring Pressure 

VALVE GUIDE 

Measuring Valve Guide Clearance 

Check valve stem-to-guide clearance. Ensure valve stem diameter is within specification. Install valve in valve 
guide. Install dial indicator assembly on cylinder head with tip resting against valve stem just above valve 
guide. See Fig. 6 .  

 

1998 Chevrolet Pickup C1500 

GENERAL INFORMATION Engine Overhaul Procedures

  

 

 

 

 

 

 

 

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