How to Rebuild VW Air-Cooled Engines: 1961-2003. Prescott Phillips
To take apart a serviceable engine, remove the spark plugs and spray penetrating oil or WD-40 down the holes. You will save yourself a lot of frustration by doing this well before you start the disassembly process. ■
Assembling a long-block will take about 10 to 12 hours, which is slightly longer than the tear-down process. It will take another 4 to 6 hours to get the engine to the point it can be started. This includes installing the cooling tin, fan shroud, charging system, ignition, and intake and exhaust systems.
A realistic time frame is three to four weeks total, which really isn’t too bad. In fact, that’s quicker than some shops that have a waiting list for complete engines.
Work Area
Most professional shops are divided into two areas: one to tear down engines and another for assembling engines. The reason for that is to keep the mess separate from the clean parts. This can be achieved by the home builder by doing the teardown in a different area from where the assembly is going to occur. The driveway or garage stall works just fine.
Disassembly can be quite messy and can occur just about anywhere, but a clean, dedicated area to assemble your engine is a must for a successful build. Most home workshops are small, but as long as the previous mess is cleaned up and you start fresh with a clear workbench and all the tools put away, you’re off on the right foot. An extra table close by helps as well to lay out parts and stay organized.
Lighting will also play a key role in how well your build turns out. There’s a reason the operating rooms are the best lit rooms in the hospital.
Your build may get put on hold for any amount of reasons. Be sure this area won’t be disturbed if that happens.
Cleaning Area
Cleaning parts is not the most popular aspect of engine building, but it is a very important one. Mineral spirits can be used as a solvent as well as some water-based parts cleaning solutions available at most tractor supply stores.
If you don’t have a parts washer but have access to one, by all means use that favor and clean your parts. If that’s not an option, a small bench top or floor model can be purchased for less than $100. Remember to place the cleaning tank in a well-ventilated area and add an exhaust fan if necessary. As an additional safety measure, keep a dry-chemical fire extinguisher handy.
To save some time and get a more thorough cleaning job, have the machine shop clean your engine components. For a fee, they will run your parts through an industrial parts washer or hot tank. Just be careful and keep track of what you bring there so you are certain to get it all back. Take a photo if necessary.
Tools
Volkswagen designed its engines early on with the idea that the average mechanic should be able to do most of the routine maintenance and even some of the more involved repairs right in his or her own garage. With this in mind, it limited the fastener sizes to just a few. VW mechanics joke they can take apart an entire Beetle with five wrenches: 8, 10, 13, 17, and 19 mm.
The internal components of the engine will add a couple more sizes to the mix, but if you own a decent set of metric tools you will be fine. You will also need combination wrenches; 1/4-, 3/8-, and 1/2-inch drive sockets; and ratchets to get the majority of the work done.
The majority of the fasteners that need to be torqued can be handled with a 3/8-inch drive torque wrench. Don’t rely on the cheap beam-type torque wrench lying in the bottom drawer of the toolbox. If you need to buy one, don’t get a cheap one. Buy a name-brand wrench that has a micrometer type adjustment and clicks when the set torque is reached. The latest electronic ones have LED lights that tell you when you are getting close to the correct torque then beep when the set torque is reached.
To torque the flywheel to the crankshaft, you will need a serious torque wrench that can measure at least 253 ft-lbs. The casual mechanic will find it hard to justify buying a torque wrench that can handle that much torque just to tighten one fastener. A 3/4-inch drive torque wrench can easily cost hundreds of dollars but can be rented inexpensively, and some major auto parts retailers will even lend you one for free with a deposit.
An air compressor or access to compressed air will be a must to clean components and blow out passages as well as operate air tools if you own some. Tearing down an engine will go much quicker with air tools or cordless impact tools if you have access to those.
Here is a list of tools you will need other than your basic hand tools.
• 3/8-inch drive torque wrench—10–75 ft-lbs range
• 3/4-inch drive torque wrench—50–300 ft-lbs range
You will need two torque wrenches to rebuild an entire VW engine. Most fasteners only require a 3/8-inch drive, such as the one shown. The “clicker” type is recommended over the beam type due to their increased accuracy. You will also need a larger one that can torque the flywheel to 253 ft-lbs.
A professional piston ring compressor is well worth the money. This ring compressor by K-D tools is made in the United States and built to last. The pliers (model 850H) and ring (model 850-BC) have a 3 ⅜ to 3 ⅝ -inch range.
In order to set and check the crankshaft end play, a dial indicator and magnetic base are a must. This Starrett indicator and Cullen magnetic base are examples of what you need but are, by no means, the caliber of tools necessary. An indicator and magnetic base from Harbor Freight Tools for around $29 will get the job done just the same.
• Piston ring compressor
• Dial indicator with magnetic base
• Digital calipers
• Professional lock ring pliers
• 1 ⁷⁄₁₆ -inch (36 mm) 3/4-inch drive socket
• 3/4-inch drive breaker bar
Removing the clip that holds the crankshaft gears on can be challenging, to say the least. A good pair of lock ring pliers are about the only way that clip is coming off. The Craftsman models (47386 and 46948) shown here work quite well. Wilde Tool lock ring pliers (model G409.B) are made in the United States and only cost $20.
If you have one of these, you already know what a joy it is when this fine device is in your hand. This particular Craftsman model (41588) is perfect for prying things apart or making sure that things you were thinking about replacing are now on the “need to replace” list.
In order to heat up the crankshaft gears to slide them onto the crank, you will need a source of heat. A single burner hot plate can be purchased for less than $20 and works quite well. It sure beats getting the kitchen all smoky heating up gears on the stove and taking heat from your better half.
• Screwdriver
• Hot plate or quick access to a stove
• Parts washer or access to one
• Air compressor and blow gun
Specialty Tools
As you can imagine, there will be some specialty tools needed