Intensive air-cooled Volkswagen maintenance, such as replacing head studs, is an involved procedure that requires several hours' time, tools and expertise. Head studs work in tension to hold both engine heads to the engine block and hold the engine head to the cylinder sleeves and block. Head stud mounting holes must be clear of debris or corrosion and only new studs should be used. Studs are installed using a torque wrench. Properly torqued head studs will improve the sound, longevity and performance of your air-cooled Volkswagen.
Park the car and set the emergency brake. Get underneath and locate both valve covers. Remove the baling wire with the screwdriver to release the valve covers. Place them in line with and underneath the cylinder heads to collect oil drops.
Use a 13 millimeter socket and ratchet to remove the rocker arm assembly. Work slowly to prevent losing any washers and nuts. Place the assembly in the valve cover and set it aside.
Use a socket and ratchet to loosen the nuts from the stud, one by one. Leave two studs hand-tightened to support the assembly temporarily during replacement. Unscrew the studs from the engine block using locking pliers on the unthreaded part, or lock two nuts tight against each other and rotate the stud with the ratchet.
Locate and clean the eight holes on each cylinder head. These holes align with castings in the finned cylinder sleeve, four per sleeve. Temporarily support the entire assembly from below during this step if the cylinder head, sleeve and pushrod tube assembly is loose.
Hand-tighten all studs into the case with vise-grip pliers. Do not damage the threaded ends of the studs with the pliers. Install one washer per stud. Hand-tighten the nut on the stud. Remove supports as the the studs are tightened.
Use the socket and torque wrench to torque the head nuts to 22 to 23 foot-pounds.
Place the rocker arm assembly on the mounting studs and hold it with one hand as you hand-tighten the nut and washer with the other. Tighten the rocker arm nuts with a ratchet. Reinstall the valve cover and baling wire with a screwdriver. Repeat for the opposite engine head.
