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 How to Rebuild Volkswagen Air-Cooled Engines: 1961 - 2003
How to Rebuild Volkswagen Air-Cooled Engines: 1961 - 2003

How to Rebuild Volkswagen Air-Cooled Engines: 1961 - 2003

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How to Rebuild Volkswagen Air-Cooled Engines: 1961 - 2003
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How to Rebuild VW Air-Cooled Engines: 1961-2003 offers beautiful color photos with insightful step-by-step captions for expertly rebuilding Volkswagen air-cooled engines and provides in-depth, hands-on information for disassembly, inspection, machining, parts selection, preassembly, final assembly, installation, and tuning.

Not only are the procedures for rebuilding covered in depth but engine model types, identification codes, specifications, and details are also covered in a manner that allows the user to source a good later-model candidate for rebuilding and helps retrofit the modern engine designs into earlier chassis.


TABLE OF CONTENTS:


About the Author 
Acknowledgments 
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 
Barrell
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
Specifications
Publisher: CarTech, Inc.
Softcover: Approx: 140 pages
Dimensions: 11.0 x 8.5 x 0.5 inches
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