The 1970-1981 Volkswagen Air-Cooled Repair Manual by Chilton, covers U.S. and Canadian models, including:
ABOUT THE VOLKSWAGEN ENGINE
- Volkswagen Beetle
- Volkswagen Karmann Ghia
- Volkswagen Transporter
- Volkswagen Vanagon
- Volkswagen Fastback
- Volkswagen Squareback
- Volkswagen 411
- Volkswagen 412
The VW engine is a flat four-cylinder design. This 4-cycle, overhead valve engine has two pairs of horizontally-opposed cylinders. All rear-engined VW models are air cooled. The fan is mounted vertically on top of the engine and is driven by the generator shaft.
The Type 1 and 2/1600 engine is known as an upright fan engine. Type 2/1700, Type 2/1800, Type 2/2000, Type 3 and 4 engines, although of the same basic design, have a cooling fan driven by the crankshaft, and the fan is mounted on the front of the engine. These engines are known as "suitcase" engines.
This Chilton manual provides complete engine rebuilding procedures. Perfect for the DIY VW owner or restorer.
Book Excerpt: 1970-1981 Volkswagen Air-Cooled Repair Manual
ENGINE AND ENGINE REBUILDING
ROCKER SHAFTS | REMOVAL AND INSTALLATION
Before the valve rocker assembly can be reached, it is necessary to lever off the clip that retains the valve cover and remove the valve cover. Remove the rocker arm retaining nuts, the rocker arm shaft, and the rocker arms. Remove the stud seals.
Before installing the rocker arm mechanism, be sure that the parts are as clean as possible. Install new stud seals. On Types 1, 2/1600 and 3, install the rocker shaft assembly with the chamfered edges of the rocker shaft supports pointing outward and the slots pointing upward.
On Type 4 and Type 2/1700, 2/1800 and 2/2000 models, the chamfered edges must point outward and the slots must face downward. The pushrod tube retaining wire must engage the slots in the rocker arm shaft supports as well as the grooves in the pushrod tubes.
Tighten the retaining nuts to the proper torque. Use only the copper colored nuts that were supplied with the engine. Make sure that the ball ends of the pushrods are centered in the sockets of the rocker arms.
Adjust the valve clearance on models without hydraulic lifters. Install the valve cover using a new gasket.
Carburetors are used on 1970-1974 Type 1 and 2 models. A single downdraft unit is used on all Type 1 models and on 1970-1971 Type 2 models. Beginning with the 1972 model year, the Type 2 utilizes twin carburetion. The type of carburetor used (34 PICT-3, etc.) is stamped on the float bowl and should be clearly visible.
REMOVAL AND INSTALLATION | TYPES 1 AND 2/1600
- Remove the air cleaner.
- Disconnect the fuel hose. Plug it to prevent leakage.
- Disconnect the vacuum hoses.
- Remove the automatic choke cable and remove the wire for the electromagnetic pilot jet.
- Disconnect the accelerator cable at the throttle valve lever.
- Remove the two nuts securing the carburetor on the intake manifold and then remove the carburetor from the engine.
- Using a new gasket, install the carburetor on the manifold.
- Reconnect the fuel and vacuum hoses, the automatic choke cable, and the wiring for the pilot jet.
- Reconnect the throttle cable and adjust it so that a full throttle there is a gap of 0.04 in. between the throttle lever and its stop on the lower position of the carburetor body.
Subject: 1970, 1971, 1972, 1973, 1974, 1975, 1976, 1977, 1978, 1979, 1980, 1981 Volkswagen Beetle, Karmann Ghia, Transporter, Vanagon, Fastback, Squareback service, maintenance, repair. ISBN-10: 0801989752 | ISBN-13: 9780801989759 | Chilton 70202