How to Rebuild a VW Air-Cooled Engine "PART 6" Piston Prep | JW Classic VW
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- Опубліковано 30 січ 2021
- **JW Classic VW** brings you the 6th video in a series that covers how to rebuild your stock 40 HP Volkswagen Engine. This video will cover how to install the engine sump cover, engine oil cooler, and prepping the pistons and cylinders for install.
Watch the Entire Playlist for Rebuilding your Air-Cooled Engine here!!
• How to Rebuild a VW Ai...
📽📽📽 Video Time Line Break Down 📽📽📽
1:35 Video Overview
2:34 Engine Rebuild Kit
3:29 Oil Cooler Install
6:50 Oil Strainer & Sump Cover Install
11:00 Oil Relief Valve Install
12:15 Piston & Cylinder Tear Down
14:00 Checking Piston Ring Gap
22:45 Piston Ring Clocking
24:13 Let' Talk Ring Specifics
26:55 Building the Piston & Cylinders
28:22 Final Thoughts
👀👀Reference Material👀👀
Volkswagen 1200 Workshop Manual: 1961-1965: amzn.to/3fyA36V
VW Beetle & Karmann Ghia 1954 - 1979 (Haynes Manual): amzn.to/3fwFROl
How to Rebuild Your Volkswagen Air-Cooled Engine: amzn.to/34T4PUE
How to Hot Rod Volkswagen Engines: amzn.to/2I3UkoA
How to Keep Your Volkswagen Alive "Rick Steves": amzn.to/32baGTl
🛠* Parts List & Tools *🛠
Tools
Proform 66785 Piston Ring Filer Manual - amzn.to/3ctauoj
Stainless Steel Feeler Gauge - amzn.to/36tdNrY
Lucas Assembly Lube: amzn.to/397mk67
Marvel Mystery Oil: amzn.to/3lWtMVi
Curil T: amzn.to/2UWHrzu
** Parts List for the 40 HP rebuild- / files
- just look for the excel doc but check out the other resource docs there.
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🛑Disclaimer🛑
JW Classic VW is a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for sites to earn advertising fees by advertising and linking to Amazon.com.
Any information on performing maintenance or modifying your vehicle viewed on this channel is intended for general guidance only and must never be considered a substitute for the advice provided by a Certified Professional. - Авто та транспорт
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Watched part 3 today because I remembered to check between cam and lifter. I'm using the same cam but put new lifters in so just want to check it before closing the short block up. Got your info on here so good to go👍
Really good stuff!
I am in the process of doing a rebuild in my engine.
Thank you
My late father was a Volkswagen mechanic at a Volkswagen dealership and service manager just used freash oil on those oil cool seals the same with the push rod tubes he said that what the Germans did at at vw school .
I've heard that too, some times I do just the oil, but other times, I use some sort of sealer.
Super awesome video and info!! Im about to install pistons n cylinders, now that you warned me.... ima gonna install that oil cooler first lol! Thanks again!
Glad I could help
Great video, short, sweet and without BS, thank you Sir.
Glad you liked it! Thanks for the support!
I usually do the pistons and cylinders then the oil cooler. Just so I dont drop a nut into that opening. still pretty accessible. and dont put the tin on that makes it much harder.
Yup having the tin in place would make it a bit of a pain.... As for engine assembly I probably do it in a little different order each time. If I were building engines all the time I'm sure I would have a strict method to my assembly but I don't build them that often.
Hi Jason, I got the VW 1200 book which has info for my 1965 engine. Great to have now that I measured everything and know the tolerances. After cleaning everything to where it's ready for rebuild will check the measurements again. From what I'm reading it shows wear at the low end of the tolerance in some locations. For a first time build not worried about an old stock engine but for my next build will spend the time and money to make it last and have more power. I'll be watching your videos on these for sure. Learning so much in a short amount of time. I'm starting to look at what years this engine will fit the early bugs other than the 65 it came out of?
LOL .....A little chilly . We are in the middle of a snow blizzard .
Lol... yeah spoiled down here!
Nice tip on the math ,for ring gap.👍
Yes sir! Glad you liked it!
When you break in/bed the rings the gap will be inclined to increase, so I’d say leaning to the minimum gap is advisable.
Jason . Your top rings are made of a different material than the 2 ring . You CANNOT swap them around . Love the music.
Thanks for the info, I knew that was true with forged sets didn't know about that with the Hypereutectic sets... thought they were both mild steel or iron.
I find that bearing grease works better than oil on the oil strainer gaskets.
Yup... grease works great to. Used it as well.
I'm building a 1641 today to replace a aging 1600 in my 1969 beetle
Awesome!! Hows it going?
@@JWClassicVW great i have the short block all done and and getting ready to put the pistons in the jugs.
Hello, your videos are very good. I love the engineering of those engines. Do you have manuals and bibliography to send me?
Sorry I don't but The Samba is a great source.
Nice video, you were talking about AA pistons, but if i look on your pistons is see a Mahle logo? Is that correct?
Maybe... I buy both so I'll check that.
Could you recommend a parts supplier for a top end rebuild. Pistons-heads-pushrod tubes I dont need performance parts Just stock stuff. dual port 1972 motor. Im in NY and on a budget. great site thanks joe
Two companies to check Joe... I've used them both and have no complaints.
aapistons.com/
www2.cip1.com/
I have some new kb 2323 pistons and rings. The pistons do not have an arrow on the top. How do i know which way they go in?
If they are forged pistons, the direction normally doesn't matter. I'd reach out to the manufacturer to check.
I| also put " lube " on EVERYTHING !
👍😎👍
The rop two rins appear to be of different material?
They are... ended up getting new rings.
Jason, Q, if the ring gap is too tight how do you file/grind the rings to get in spec. ?
All kinds of tools out there just for this. The key is that a 90 degree profile must be maintained. No tapering or burrs. This can also be achieved with a Dremel or file but care must be considered.
@@JWClassicVW Amazon has a very simple ring grinder. A hand turned grinding wheel on a flat surface so that ring ends stay 90 degrees from one another and flat .
@@1fastbuggy502 yes sir, they do have a simple one that can get the job done. I'll link it in the video discretion.
Here ya go Mike, Proform 66785 Piston Ring Filer Manual - amzn.to/3ctauoj
Where did you Get your yolk for your Engine stand?
They can be found on the Samba. The bad thing is when I checked this morning the Samba was down.
or those rubber stops where your engine mounts to the stand arm?
What about them... I just used them to take up some of the threads. It's just something I had lying around.
@@JWClassicVW I wondered what they were. Nothing more than that. Nothing sinister going on.
I installed that higher pressure oil relief valve... and oh boy... that spring would not go in without a fight. If someone tries to open that jn future... they r gonna lose their eye balls 😅. I wonder if that will have any adverse effects of having too much pressure 😢
LOLOL... Yes those buggers can be scary for real... but the spring will relax as it heats up. You may want to install a oil pressure gauge though... always best to know.
@@JWClassicVW Great idea! Its better to know psi instead of just low pressure warning light. Do you have any videos on that? Do I install that at the same spot where the oil pressure switch goes on engine case below carb area?
do you cross hatch or not and why ? thank you
I do... when installing new rings or if new cylinders don't have them.
Why didn't weight balance the pistons,rods and rings?
Just a stock 1600... normally not something I do with a stocker. Definitely done with my higher performance builds. Thanks for the comment!
@@JWClassicVW
I thought it would be better, never knew how to balance before , learned from u.
Thanks for sharing ur knowledge.
Never hurts to run through a weights of pistons and rods. You can use a simple food scale to compare the weights. Same with the rods.... thanks for being here!
If your taking an engine apart. Never re-use rings once they’ve been used and broken in. Replace them . Their cheap
Yup... I agree definitely a good idea. I like Grant rings.
but 3.364 x .0045 is .015 O_o
Correct that's what I came up with... I just rounded up a little... better to be a lil more vs a little less. Not much of a difference... Definitely not enough to cause any issues. Thanks for the comment brother, can't wait to get this build finished up after I get the Turbo done.
Why do those piston say 85.45 mm on them? I thought this was a 40 hp build? The 40 hp engines used 77 mm cylinders, and the pistons would have been 76.95 mm.
Because I went with a bigger piston.. so probably more like a 45hp.. lol
@@JWClassicVW LOL! Yep!
i
Thanks for the letter... lol