How to Rebuild VW Air-Cooled Engines 1961-2003

By Prescott Phillips
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Front Cover
Stock image only. Actual cover art may differ.
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
Publisher
Cartech, Inc.
ISBN
1613254334
ISBN-13
9781613254332
Format
Paperback: 144 pages
Published
2019

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