How to Rebuild VW Air-Cooled Engines 1961-2003 covers rebuilding the VW Type 1, 2, and 3 engines beginning in 1961, when a significant redesign improved the basic initial design.
Step-by-step color photos provide in-depth, hands-on rebuilding information, while engine model types, identification codes, specifications, and details help the user source a good candidate for rebuilding or retrofitting.
Contents: ● What Is a Workbench Book? ● Chapter 1: Before You Begin - A Brief History of the VW Flat 4 Engines - Engine Identification - Is This Engine Worth Rebuilding? - Planning - Work Area - Tools - Our Engine ● Chapter 2: Engine Disassembly - Spotting a Rebuilt Engine - Be Patient - Get Organized - Engine Disassembly - Parts to Keep and Parts to Replace ● Chapter 3: Parts Cleaning and Inspection - Cylinder Heads - Rocker Assemblies - Pushrods - Lifters - Camshaft - Connecting Rods - Crankshaft - Flywheel - Flywheel Gland Nut - Oil Pump - Oil Cooler - Engine Case ● Chapter 4: Machine Shop - Choosing a Machine Shop - Engine Case Machining Procedures - Head Rebuilding Procedures - Post-Machine Shop Procedures ● Chapter 5: Component Preparation - Engine Case - Head Studs - Internal Components - Long-Block Cooling Tin ● Chapter 6: Preassembly - Preset the Flywheel Endplay - Scribe the Main Bearings - Gap the Piston Rings - Install the Rings on the Pistons ● Chapter 7: Final Assembly - Crankshaft - Engine Case Preparation - Join the Two Halves - Flywheel - Piston - Barrel - Cylinder Heads - Oil Pressure Relief Valves - Full-Flow Filter Oil Pump Upgrade - Sump Plate - Valvetrain - Adjusting the Valves ● Chapter 8: Accessory Installation - Important Questions to Ask Yourself - Carburetor: Rebuild or Replace? - Installing Accessories - Exhaust System ● Chapter 9: Startup, Break-In, and Adjustments - Building a Test Stand - Installing an Engine on a Test Stand - Installing a 12V Starter in a 6V Transmission - Installing a 12V Engine in a 6V Transmission - Installing the Clutch and Pressure Plate - Vehicle Installation - Start the Engine ● Appendix ● Source Guide
