How to Rebuild Your Volkswagon Air-Cooled

Complete details for rebuilding air-cooled engines in all chassis from 1961 to 1983: Beetle, Ghia, Bus, Squareback, 411/412 and Porsche 914. The text includes chapters on how to remove, disassemble, inspect and assemble engines, and recondition cylinder heads and crankcase internals.

Introduction

4

(5)

Time To Rebuild?

5

(13)

Accumulated Mileage

5

(1)

Oil Consumption

5

(2)

Poor Performance

7

(6)

Diagnostic Tests

13

(5)

Engine Removal

18

(13)

Preparation

18

(1)

Beetles & Karmann Ghias (Type 1)

19

(4)

Bus & Transporters (Types 2 & 4)

23

(3)

Fastback, Squareback, Notchback (Type 3)

26

(1)

411/412

26

(1)

Porsche/VW 914

27

(4)

Parts Identification & Interchange

31

(26)

Indentification

32

(2)

Engine Descriptions

34

(1)

Cases

35

(3)

Crankshafts

38

(5)

Flywheels

43

(1)

Connecting Rods

44

(1)

Pistons & Cylinders

45

(1)

Cylinder Heads

46

(7)

Oil Pumps & Camshafts

53

(2)

Oil Coolers & Sheet Metal

55

(2)

Teardown

57

(18)

Accessory Removal---Uprights

58

(4)

Accessory Removal---Flat

62

(4)

Basic Engine

66

(1)

Valve Train

66

(2)

Cylinder Heads

68

(1)

Oil Pump

68

(2)

Splitting Cases

70

(2)

Crankshaft Teardown

72

(3)

Crankcase & Cylinder Reconditioning

75

(25)

Clean & Inspect Crankcase Parts

75

(7)

Crankshaft

82

(6)

Pistons & Connecting Rods

88

(6)

Oil Pump

94

(2)

Camshaft

96

(4)

Cylinder Head Reconditioning

100

(16)

Disassembly

101

(4)

Valve Guides & Stems

105

(2)

Inspecting & Reconditioning Valves

107

(3)

Valve-Seat Reconditioning

110

(1)

Rocker-Arm Service

111

(1)

Valve-Spring Inspection & Installation

112

(2)

Cylinder Head Assembly

114

(1)

Intake & Exhaust Manifolds

115

(1)

Engine Assembly

116

(40)

Crankcase Assembly

119

(2)

Install Crankshaft

121

(1)

Install Camshaft

122

(10)

Prep Cylinders

132

(2)

Valve Train

134

(4)

External Accessories

138

(18)

Type 1 & Pre-'72 Bus

138

(5)

Type 3

143

(5)

411/412, Post-'72 Bus, 914

148

(8)

Engine Installation, Break-in, Tuneup

156

(17)

Transaxle Prep

156

(1)

Engine Installation

157

(3)

Type 1

160

(1)

Type 2

161

(1)

Type 3

162

(1)

Type 4

163

(3)

914

166

(3)

First Start!

169

(1)

Break-in & Tuneup

170

(3)

Index

173

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How to Rebuild Your Volkswagon Air-Cooled Engine

Summary

Table of Contents

Supplemental Materials