Well, I replaced the pistons and heads in my bug, and now when I> adjust the valves, I find I'm running out of screw and on one valve in> particular, it is the rocker arm that is pressing against the valve> spring with a gap 0.004.> My engine is a Mexican engine> I bought Mahle forged pistons, stock size.> I bought new stock size heads which turned out to be made in Brazil (> seemed kind of cheap as compared to the Mex heads with 3/4 inch deep> plug holes, and seemingly more solid casting)> I replaced the pushrods with EMPI steel rods which when I compared> to my "stock" pushrods they looked to be the same length.> I put the rubber gasket on the rocker arm studs, and re-used the Mex> rocker arms.> Everything was torqued properly> Now when I go to adjust the valves @ 0.006, I find that the> adjusting screws for each valve are just about backed out all the way,> just litte threads are noticed through the rocker arm. One of the> adjusting screws is all the way out and the rocker arm itself is giving> about 0.004 gap to the valve cap.> Ok, so I put the engine in the car and ran it with the hope that this> would somehow give me some more play, but the valves just got tighter.> SO I learned that lesson - car ran great though.>

It seems for things to give no or very little valve lash - it would> have to be,,> 1) pushrods are too long - don't think this is the case - they are> seem exact by eye compared to the original ones.> 2) The distance between the block and the outside of the head is> shorter - but why would this be?> Could it be cheap quality heads? - not having the correct flycut> depth? ( into the piston too far?).> I would think the pistons are the correct length.>

Are the rocker arms now of an improper size with this combination?>

How can I solve this? What would be the consequence of putting a thin> shim under the rocker arms - where it bolts to the head? That should> afford me clearance -> argh.. but something is not right?> Am I missing something?>

Thanks so very much!>

Matt S>