How to Rebuild a Volkswagen Air-Cooled Engine

The Volkswagen air-cooled engine is one of the most popular combustion engines used around the world today. The production of the air-cooled engine ended on December 27, 2005. Production ended due to a change in emissions regulations that went into effect in 2006. A commemorative edition is available with the old air-cooled engine installed. Currently, there are only 30 special editions available worldwide.

Things You'll Need

• Air tools
• Air compressor
• Engine cleaning fluid
• Long-arm hoist
• Valve cleaning rods
• Rags

Instructions

1. Check for attachment parts on the engine. Remove these parts first. Parts will include mounting brackets, hoses and belts.

2. Purchase an engine hoist because you will need to lift the air-cooled engine out of the car and place it where you will rebuild it. Make sure you buy a long arm engine hoist.

3. Install new engine mounts in the Volkswagen and remove the transmission shifter tab. You don't have to lift the car for this step-it can be done at ground level.

4. Take the engine and transmission apart labeling each piece as you go. You may not want to have a lot of distraction at this point. Remember you will have to put the engine back together at some point.

5. Spray engine cleaner on all the parts and rub them with a clean cloth. It is at this stage you will look for cracks and gouges in the metal. You will need to replace these parts with new or used ones before you put the air-cooled engine back together.

6. Stick cleaner rods into the valves of the engine. Check for areas where friction occurs. In order to rebuild the engine you need to replace all worn parts.

7. Slide the splined end of the drive shaft into the rear of the transmission and bolt the opposite end to the differential.

Tips & Warnings

• It is important to label each engine part correctly and to organize them in the order you took them apart.

• When lifting the engine, make sure you are in view of another person as accidents do occur.