How to Rebuild a VW Air-Cooled Engine "PART 4" Case Prep & Test Fitting | JW Classic VW

**JW Classic VW** brings you the 4th video in a series that covers how to rebuild your stock 40 HP Volkswagen Engine. This video will cover the joining of the case to confirm clearances. Also going to cover a bunch of other tricks and great details... check out the timeline below.
Watch the Entire Playlist for Rebuilding your Air-Cooled Engine here!!
• How to Rebuild a VW Ai...
📽📽📽 Video Time Line Break Down 📽📽📽
2:55 Video Intro
4:36 Crankshaft Top Assembly
7:10 Case Thread Clean up
7:35 Cylinder Head Stud Clean Up
10:23 Center Bearing Install
11:10 Lifter Install "Hoover Mods"
12:15 Crankshaft Install
14:50 VW Darrin TRICK!
15:45 Camshaft Install
17:05 Camshaft lobe to lifter Face Spec
19:46 Oil Pump Fitment
21:57 Other Case Half Prep
22:25 Joining the Case
24:07 Case Torque Specs
30:25 End
👀👀Reference Material👀👀
*Lifter to Cam lobe spec: .060 -.100
**Case Stud Tourque M8 - 14 ft lbs | M12 - 24 - 26 ft lbs
***Cam Shaft Thrust Setting: Endplay: .002-.004"
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
Lifter Clips: amzn.to/3fnj7As
Dremel 3000: amzn.to/32LiA63
Red Loctite: amzn.to/398e59H
Blue Loctite: amzn.to/3fqE1hV
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.
🎶Audio Thanks🎶
Twenties by Peyruis / peyruis
Creative Commons - Attribution 3.0 Unported - CC BY 3.0
Free Download / Stream: bit.ly/twenties-peyruis
Music promoted by Audio Library | • Twenties - Peyruis (No...

[@JWClassicVW]

Be Sure to LIKE, SHARE, & SUBSCRIBE Thank you for all the support!!!

[@robbyrodriguez7813]

Great stuff. The trivial stuff you don’t show, you’d be surprised how many of us want to see it. (Ie, cleaning out lifter bores, punching connecting rod washers, etc , ). Thanks for this stuff. I’ll be rebuilding my 1500 6v 64’ notch engine soon. This really helps.

[@JWClassicVW]

Thanks for the comment Robby!! glad you liked the video! I'm looking forward to finishing this video series up in Jan!!

[@johanhelberglongbowsknifes1185]

You are awesome teacher brother.

[@TimsWorkshopTJY]

Interesting as I read up on this stuff. When checking the lifters I found they were all flat don't rock against each other. Well, there is a reason they don't. Older engines have a flat cam and it takes lifters that are also flat when put them face to face with each other. So, mine are all good and will be reused. My crank gear removal tool will be here tomorrow. yippie.

[@GoodOldMike]

What, no Crème brûlée? I feel robbed! LOL. Seriously, great vid.. enjoyed the musical jams too!

[@JWClassicVW]

Lol... thanks Mike that would be funny huh! A little BBQ and fancy dessert.

[@OACSOME]

Awesome video series, getting my first garage soon, gonna be searching for a bug motor for my first project and see what’s needed for it. Thank you so much

[@JWClassicVW]

Glad you enjoyed it man! I'll be finishing it up after I get my turbo going!! Definitely looking forward to it!

[@Jayvans_Super]

Awesome video! So awesome that it makes me feel I can do this lol

[@JWClassicVW]

Thanks brother... glad you enjoyed it. Oh, and I bet you can!

[@philbrookman3126]

no gasket cement between the halves .. great vids well explained

[@JWClassicVW]

Gasket silicone was added... believe I used Curil T but I'd have to give back and watch... probably the following video.

[@LuisPerez-gl6xp]

Great job man thanks!

[@bearvw1966]

Thanks dude cools👍

[@vintage76vipergreenBeetle]

Great info on timing marks. 👍

[@JWClassicVW]

Glad you liked the video brother!! Appreciate the support as always!!

[@Ruffner61]

Your doing a great job ! Videos are 😎

[@JWClassicVW]

Thanks brother I appreciate the support!! Glad your enjoying the channel!

[@backyardkombi5466]

Terrific series of videos.

[@JWClassicVW]

Thanks... I'm glad you liked it, I plan on finishing it after my turbo build.

[@bearkamakana8487]

Awesome .🤙Thank you🤙

[@JWClassicVW]

You bet! Glad you liked it!

[@MrGarcon98]

i must say i have not did a vw yet but built american engines i did ,,,,never with only this thin oil ,,,,? cant wait to see the outcome LOL ,,,,,i am sure you know it works i just never did it with that ,,,,having fun watching ,,thank you very much

[@JWClassicVW]

Glad you are enjoying the show... the thin oil is for test fitting... final assembly will include a good priming of the system with a good break in oil with zinc.

[@mcristinarobles4110]

Estå encantado de haberse conocido.

[@davyboscart1089]

That's just car porn! Keep juggling those rod's Jason!! 😂😂

[@JWClassicVW]

Lol... thats stupid funny. Never learned how to juggle but man I tried.

[@philbrookman3126]

great vids no gasket cement between the halves ???

[@JWClassicVW]

I did... 😉

[@roberttaylor7732]

Rubber bands from broccoli would be good to keep the connecting rods from tapping on the case.

[@JWClassicVW]

Very true, I need some of those!

[@TimsWorkshopTJY]

Hi Jason, just took all the Crank measurements today and hitting 2.164 on all the main and connecting rod journals on the crankshaft. What has me scratching my head is the OD of the Con rods without the bushings? 2.275. Aren't these suppose to be 2.175?

[@JWClassicVW]

The measurements can be misleading, this is why measurements must be taken with the case torqued down with bearings in place. Bushings and bearing qualities will very greatly based off manufacturers. The most important measurements will be the oil clearance when torqued down. .003 to .005 is what I shoot for.

[@TimsWorkshopTJY]

Got it figured out. Jbugs put the wrong inch number down for the con rod mm 57.75 @ 2.175 and sb 2.275 to 2.276 which gives the oil clearance once torqued down on the crank. Just waiting on the tool to remove the gears and last main bearing to check the measurement on it. The crank will need to be polished and will do that myself.

[@JWClassicVW]

Sounds great!

[@bubot17]

i'm also in the process of fixing up my 1200 motor, man the price for the parts are pricier than the 1300,1500 and 1600 and you have to look for them 1200 parts

[@JWClassicVW]

Very cool brother!! Join the Facebook group and post some pic... would love to see it.

[@mexicanist2601]

What book is the one ur referring to in the beginning? Great video btw

[@JWClassicVW]

Hey man glad your enjoying the videos, all the tech books are listed in the video description.

[@TimsWorkshopTJY]

Hi Jason, since the connecting rods are all balanced for this engine and changing the bushings anyway does it matter which one goes where on the crank?

[@JWClassicVW]

Nope... it doesn't

[@TimsWorkshopTJY]

That's what I thought. just for fun will weigh the old ones and check for any flaws before installing them. Thanks

[@TJ-ik3gn]

How did you check clearance on the main bearings and what numbers did you get?

[@JWClassicVW]

Crap... not sure on the numbers, that was awhile ago. But I installed the main bearing into the case and torqued it, then measured with a bore gauge. I just compared that to my journal sizes to ensure I had at least 3 to 5 thousands.

[@daveshipman2677]

Hi bud,may i ask where you get the blue vw manual from,as i have a manual,but it's not very informative with regards to pictures and descriptions,i may have to take out my crank shaft again as looking at how freely your con rods rotate is different from mine,maybe it's the engine oil i'm using but now need to recheck to see if this is the case,love watching your video's dude.

[@JWClassicVW]

Glad your enjoying the videos and you find them helpful. If you look in the video description you'll find a link to the books I use.

[@daveshipman2677]

@@JWClassicVW Thanks bud,i'll make a note of it..👍

[@TimsWorkshopTJY]

where did you get your 4 leg engine support from to load into your engine stand? I see the 2 leg ones online.

[@JWClassicVW]

I picked mine up off of the FB market groups, just got lucky. You used to be able to find them on the Samba but it looks like that guy is no longer making them. This is the Samba link: www.thesamba.com/vw/classifieds/detail.php?id=606308

[@TimsWorkshopTJY]

Just going to get a two leg from aapreformance to put into my stand. So far no sign of this motor being oversized so untouched as far as that goes👍 very oily which is good for removing screws and bolts

[@TimsWorkshopTJY]

Hi Jason, Here's one for the books. I have a flywheel with small dowel pin holes? This will not fit my 40hp crank with the 5/16 pins on the crank? They look like 3/16? it's a 6V flywheel so is the crank with the 5/16 dowel pins for the 12V flywheel or is it for either one?

[@JWClassicVW]

That's a new one on me brother, maybe take some photos and drop the question in the FB group.

[@TimsWorkshopTJY]

I actually later found out that the 36hp has the smaller dowel pins on the flywheel and you can buy them which are german made but refurbishing. going to ask the group though if I can drill this one up to the 8mm 5/16 size so it will fit my 40hp crank pins?

[@JWClassicVW]

Sounds good... someone may know or may have done it. I've drilled my 40hp crank for 8 dowels using the jig that's available out there and that worked well. I'm not sure on the hole alignment for the 36hp.

[@TimsWorkshopTJY]

That's what I'm thinking too. I will do some measurements on that and the fit on the crank and depth to make sure once it's on it won't fall off. I just posted this question on the Samba forum page for early year VW's

[@gotenz90640]

Hey I have a question, so my bug recently just took a crap on me. It's a crank no start issue. The car has fuel, but no spark, I have the magnaspark 2 by cb performance I checked the coil no spark is coming out of the coil, so I replaced it and replaced the ignition module as well and still no spark. I checked the black wire going to the coil and it has power but still no spark? Do you have any idea on what it can be I'm lost here

[@JWClassicVW]

Did you check the actual voltage at the coil, or did you use a test light. I would be curious as to what the voltage was. It is also very easy to mix up the wires at the coil... might want to double check... that would for sure cause an issue by smoking the module. Also leaving the ignition on for a prolonged period can damage the module. From there I would double check spark using a screw driver at the plug wires, all plug wires.

[@gotenz90640]

@@JWClassicVW i didn't check the voltage i only used a test light. I made sure to take a picture of the wires a couple months ago when I dropped my engine i used the picture as a reference.

[@gordonmack9948]

Hi can you please help me, when I turn the fly wheel there is a slight delay before the distributor arm movies, I have to turn the fly wheel about 10mm before the distributor arm movies. Is that ok thanks

[@JWClassicVW]

There is going to be a bit of play... thats normal as the gear engagement needs to be considered. As long as when it does move it is consistent with the crank movement. Like it shouldn't be stopping while your moving the crank.

[@bearvw1966]

😍😍😍 UR funny Jason😁

[@juanvaca8627]

Who do you use for any machine shop work thanks

[@JWClassicVW]

Local shop in Pasadena, Texas... Bugoholics.

[@juanvaca8627]

Ok thanks for the information

[@kafkaskartal3194]

add subtitle please

[@JWClassicVW]

Sorry brother, not as simple as pushing a button.

[@kafkaskartal3194]

@@JWClassicVW thanks

[@VolksStokes]

But when I was installing engine case studs on mine... they kept going. I read somewhere they just keep going in and so I used Permatex High Tack sealant and just stopped at a level. Did i do that i incorrect? 🙄🥲🫢