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How to Rebuild VW Air-Cooled: 1961-2003 Paperback – August 7, 2019

by Prescott Phillips (Author)
4.8 4.8 out of 5 stars 237 ratings
See all formats and editions
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Rebuild your Volkswagen’s air-cooled engine with confidence and get your beloved boxer back on the road.

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.

This resource focuses on the VW Type 1, 2, and 3 engines beginning in the year 1961, when a significant redesign improved the reliability, durability, and horsepower of the basic initial design. For more than 70 years, automotive enthusiasts and the public in general has embraced the VW air-cooled engine for its simplicity, its capacity to be modified, and its bulletproof reliability.

One of the most widely used and versatile internal combustion engines in the world, this engine has powered VW Beetles, Buses, Porsche 914s, off-road buggies and rails, formula race cars, and many other machines both on and off-road. From 1938 until 2003, more than 21 million Beetles equipped with an air-cooled rear-mounted engine were produced.

If you have any interest in reviving your old VW, or perhaps are researching the purchase of one, this handy guide will cover all the bases in bringing that old air-cooled powerplant back to life.

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  1. Print length
    144 pages
  2. Language
    English
  3. Publisher
    CarTech
  4. Publication date
    August 7, 2019
  5. Dimensions
    8.5 x 0.33 x 11 inches
  6. ISBN-10
    1613254334
  7. ISBN-13
    978-1613254332
  8. See all details
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From the Publisher

VW Air-Cooled Engines: How to Rebuild will focus its coverage on the VW Type 1, 2 and 3 engines beginning in the year 1961, when a significant re-design improved the reliability, durability and horsepower of the basic initial design. This book will offer insightful step-by-step captions and color photos for expertly rebuilding an air-cooled engine and will provide in-depth hands-on information for disassembly, inspection, machining, parts selection, pre-assembly, final assembly, installation, and tuning.

Not only will all the procedures for rebuilding be covered in depth, but engine model types, Identification codes, specifications and details will be covered in a manner that will allow the user to source a good later model candidate for rebuilding and help retrofit the modern engine designs into earlier chassis.

Disassembly

This is what it should look like with all the cooling tin removed. All the sheet metal is attached with 6-mm flathead screws. Depending on how complete the engine you have is or what type of vehicle it was previously installed in will determine what sheet metal it has and what it will need when reassembling.

Cleaning & Inspection

To prep an engine case for initial inspection, remove all cam bearings, center main bearings, and six main stud seals. Next, scrape both halves with a razor blade to remove sealer that’s usually baked on.

Machining

Before clamping the head to the Bridgeport mill, it is always a good idea to make sure the valve cover surface is free of burrs and dents. People tend to get a little overzealous when removing the valve covers. The rocker studs should clear the bottom of the T-slot in the table, but double-check to be sure.

Preassembly

Apply a thin coat of silicone sealer to the pushrod tube seals. Note the dark line that runs the length of the tube. That is the seam that is welded together. Make sure that seam faces up when the engine is installed in the car. Periodically, that seam splits and if it faces down you will have a pesky oil leak.

Final Assembly

Here are the necessary components installed in the 1-2 case half: one bearing dowel pin under one center main bearing, three cam bearings, and four lifters with plenty of assembly lube.

Accessories

Install the fuel pump with a 13-mm wrench. Don’t forget the wave washers under the nuts. If the fuel pump seems too high off the base, don’t force it on with the nuts. This indicates that two things may be wrong: either the distributor drive isn’t seated all the way down in the bore or the fuel pump pushrod is the wrong length.

Editorial Reviews

Review

"From disassembly, to inspection, and on to the machining processes, Prescott tames the process like no other book available on the market. Engine books can be a little overwhelming at times, but all bases are covered in a simple and matter-of-fact way that's very appealing. DIYers will feel empowered to test themselves in the garage." ― VolksAmerica Published On: 2019-11-12

About the Author

Prescott Phillips has been building stock and high-performance Volkswagen engines and transmissions since 1981. A semiretired Journeyman Tool and Die Maker, he always strives for perfection and has the reputation for building strong, reliable powerplants. His love for drag racing and Volkswagens led him to build some of the fastest Beetles in the Midwest.

Product details

  • Publisher ‏ : ‎ CarTech (August 7, 2019)
  • Language ‏ : ‎ English
  • Paperback ‏ : ‎ 144 pages
  • ISBN-10 ‏ : ‎ 1613254334
  • ISBN-13 ‏ : ‎ 978-1613254332
  • Item Weight ‏ : ‎ 1.1 pounds
  • Dimensions ‏ : ‎ 8.5 x 0.33 x 11 inches
  • Customer Reviews:
    4.8 4.8 out of 5 stars 237 ratings

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Prescott Phillips

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Customer reviews

4.8 out of 5 stars
237 global ratings

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Customers find the instructions clear and easy to follow. They appreciate the detailed explanations and good photos, compared to older manuals.

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11 customers mention "Instructions"11 positive0 negative

Customers find the instructions in the book clear and concise. They appreciate the detailed explanations of most steps, making it easy to follow along. The guide provides helpful hints on how to complete projects. Overall, customers find the instructions informative and well-thought-out.

"I found this guide easy to read and follow along. Much better color pics than some older manuals...." Read more

"...The walkthrough process is very straight-forward and most steps are explained in detail...." Read more

"Great and heavily detailed book, both visually and verbally. One concern I have is this torn-out insert on page 49 about machining...." Read more

"...you’ll need, the specifications for the motors, and helpful hints on how to complete any project. For the price, you can’t beat this one!..." Read more

5 customers mention "Photo quality"5 positive0 negative

Customers appreciate the book's photo quality. They find the photos detailed and better than older manuals. The book is detailed both visually and verbally.

"I found this guide easy to read and follow along. Much better color pics than some older manuals...." Read more

"Great and heavily detailed book, both visually and verbally. One concern I have is this torn-out insert on page 49 about machining...." Read more

"...This guy does perfect for novices an expert the lake. The nice, detailed photographs, and precise instructions make any job seem doable...." Read more

"Great photos well written ! Thanks !" Read more

Fantastic.
5 out of 5 stars
Fantastic.
Clear. Concise. Everything you need, nothing you don’t. There are lots of other books, this one is modern—loads of clear color photos and well-written text. FYI, not for early engines, it’s focused on 1600cc
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Top reviews from the United States

  • Democracy
    5.0 out of 5 stars Fantastic.
    Reviewed in the United States on August 4, 2024
    Verified Purchase
    Clear. Concise. Everything you need, nothing you don’t. There are lots of other books, this one is modern—loads of clear color photos and well-written text. FYI, not for early engines, it’s focused on 1600cc
    Customer image
    Democracy
    5.0 out of 5 stars
    Fantastic.

    Reviewed in the United States on August 4, 2024
    Clear. Concise. Everything you need, nothing you don’t. There are lots of other books, this one is modern—loads of clear color photos and well-written text. FYI, not for early engines, it’s focused on 1600cc
    Images in this review
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    2 people found this helpful
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  • L. Ashimine
    5.0 out of 5 stars Lots of pics and detailed descriptions
    Reviewed in the United States on October 8, 2021
    Verified Purchase
    I found this guide easy to read and follow along. Much better color pics than some older manuals.

    While I like that it referred to many current parts (with their part#s) available to engine builders today, unlike older manuals that often refer to parts (stock or aftermarket) that used to be plentiful but today are harder to find. But many of the parts were Empi brand parts which are not always the highest quality. This means the end result may not be the highest quality. One such example is the engine tin which looks brand new but may not fit together or fit the engine compartment well.

    While the process was not "by the book" in some cases (eg. distributor install) the intructions were easier to follow.

    Unlike some other build manuals, this one focused on the build and not on compatible parts or considerations outside the build itself. A good book to add to your shelf if you maintain ACVW engines.
    2 people found this helpful
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  • N. Lee
    5.0 out of 5 stars A must-have
    Reviewed in the United States on September 14, 2023
    Verified Purchase
    It cannot be understated how beneficial color pictures are. The walkthrough process is very straight-forward and most steps are explained in detail. The corresponding images really help to guide you in your work. This book and How To Keep Your Volkswagen Alive are my go-to manuals for my VW.
    One person found this helpful
    Helpful
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  • T Munoz
    5.0 out of 5 stars Very helpful
    Reviewed in the United States on August 7, 2024
    Verified Purchase
    My first review here on Amazon… very review worthy. Helped me much better than reading a guide with barely any photos. This has clear high def photos and instructions and part #s for replacing parts. Recommend
    One person found this helpful
    Helpful
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  • Kyle C. Anderson
    4.0 out of 5 stars Great overall
    Reviewed in the United States on November 8, 2022
    Verified Purchase
    Great and heavily detailed book, both visually and verbally. One concern I have is this torn-out insert on page 49 about machining. I want to know what it is and if I’m supposed to have it, because I surely didn’t tear it out. Would love to hear from the author about this issue, but otherwise it really is a helpful book.
    Customer image
    Kyle C. Anderson
    4.0 out of 5 stars
    Great overall

    Reviewed in the United States on November 8, 2022
    Great and heavily detailed book, both visually and verbally. One concern I have is this torn-out insert on page 49 about machining. I want to know what it is and if I’m supposed to have it, because I surely didn’t tear it out. Would love to hear from the author about this issue, but otherwise it really is a helpful book.
    Images in this review
    Customer image
    Helpful
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  • Sleepless in Oregon
    5.0 out of 5 stars Nice detailed photos and instructions
    Reviewed in the United States on May 29, 2020
    Verified Purchase
    There are no shortage of books about how to repair your air cooled Volkswagen. Unfortunately, many of them are designed for automotive experts. If you go with the standard manual like a Haynes or a Chiltons, a lot of information can be difficult to decipher for your shade tree mechanic. This guy does perfect for novices an expert the lake. The nice, detailed photographs, and precise instructions make any job seem doable. It spells out the types of tools you’ll need, the specifications for the motors, and helpful hints on how to complete any project. For the price, you can’t beat this one! The only way this would be better is if it were in a binder form.
    Customer image
    Sleepless in Oregon
    5.0 out of 5 stars
    Nice detailed photos and instructions

    Reviewed in the United States on May 29, 2020
    There are no shortage of books about how to repair your air cooled Volkswagen. Unfortunately, many of them are designed for automotive experts. If you go with the standard manual like a Haynes or a Chiltons, a lot of information can be difficult to decipher for your shade tree mechanic. This guy does perfect for novices an expert the lake. The nice, detailed photographs, and precise instructions make any job seem doable. It spells out the types of tools you’ll need, the specifications for the motors, and helpful hints on how to complete any project. For the price, you can’t beat this one! The only way this would be better is if it were in a binder form.
    Images in this review
    Customer imageCustomer imageCustomer imageCustomer image
    12 people found this helpful
    Helpful
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  • R. Young
    5.0 out of 5 stars A worthy new contender for the best book on the subject
    Reviewed in the United States on October 22, 2023
    Verified Purchase
    Tom Wilson's similarly titled book has long been the standard on the subject. The color pictures in this new work are in improvement, as is the treatment of typical modern day mods like full flowing the oil system.
    One person found this helpful
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  • Shawn Mielke
    5.0 out of 5 stars Amazing book with tons of great information!
    Reviewed in the United States on May 26, 2022
    Verified Purchase
    Pretty much a step by step book on rebuilding your air-cooled VW engine. Clear and concise instructions and tips for building. This is a 2nd copy I own. Also great reference material.
    Customer image
    Shawn Mielke
    5.0 out of 5 stars
    Amazing book with tons of great information!

    Reviewed in the United States on May 26, 2022
    Pretty much a step by step book on rebuilding your air-cooled VW engine. Clear and concise instructions and tips for building. This is a 2nd copy I own. Also great reference material.
    Images in this review
    Customer image
    3 people found this helpful
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Top reviews from other countries

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  • Eduardo Salas Avila
    5.0 out of 5 stars Buen producto
    Reviewed in Mexico on January 3, 2024
    Verified Purchase
    Detallado manual, recomendable.
    Report
  • fabiano da silva bonfim
    5.0 out of 5 stars how to rebuild vw air-cooled
    Reviewed in Brazil on May 18, 2023
    Verified Purchase
    muito bom chegou tudo certo excelente recomendo
    Report
  • Josef
    5.0 out of 5 stars Perfect book for rebuilding VW engines
    Reviewed in Sweden on June 30, 2024
    Verified Purchase
    Detailed description with plenty photos. Great guide.
    Report
  • Joost Last
    5.0 out of 5 stars Quick delivery. Clear and efficient instructions
    Reviewed in Spain on November 3, 2023
    Verified Purchase
    Clear instructions
    On how to rebuild your VW aircooled engine. Color pictures help greatly.
    Report
  • JPust
    5.0 out of 5 stars Great VW Air-cooled Engine Rebuilding Book!
    Reviewed in Canada on December 28, 2020
    Verified Purchase
    This has to be best VW air-cooled engine rebuilding book there is. It has tons of color photos of how to perform most of the tasks, and its well written. I have a few VW engine rebuilding books, and this one is the best one that I have read!
    Report