The step-by-step photo procedures also contain many additional photos that show how to install high-performance components, modify stock components for special applications, or even call attention to assembly steps that are critical to proper operation or safety. These are labeled with unique icons. These symbols represent an idea, and photos marked with the icons contain important, specialized information.
Here are some of the icons found in Workbench® books:
Important!
Calls special attention to a step or procedure, so that the procedure is correctly performed. This prevents damage to a vehicle, system, or component.
Save Money
Illustrates a method or alternate method of performing a rebuild step that will save money but still give acceptable results.
Torque Fasteners
Illustrates a fastener that must be properly tightened with a torque wrench at this point in the rebuild. The torque specs are usually provided in the step.
Special Tool
Illustrates the use of a special tool that may be required or can make the job easier (caption with photo explains further).
Performance Tip
Indicates a procedure or modification that can improve performance. The step most often applies to high-performance or racing engines.
Critical Inspection
Indicates that a component must be inspected to ensure proper operation of the engine.
Precision Measurement
Illustrates a precision measurement or adjustment that is required at this point in the rebuild.
Professional Mechanic Tip
Illustrates a step in the rebuild that non-professionals may not know. It may illustrate a shortcut or a trick to improve reliability, prevent component damage, etc.
Documentation Required
Illustrates a point in the rebuild where the reader should write down a particular measurement, size, part number, etc. for later reference or photograph a part, area, or system of the vehicle for future reference.
Tech Tip
Tech Tips provide brief coverage of important subject matter that doesn’t naturally fall into the text or step-by-step procedures of a chapter. Tech Tips contain valuable hints, important info, or outstanding products that professionals have discovered after years of work. These will add to your understanding of the process, and help you get the most power, economy, and reliability from your engine.
CHAPTER 1
BEFORE YOU BEGIN
The iconic air-cooled VW engine is shown here in its long-block form.
The early Volkswagen power-plants were a marvel of engineering, which is why they have endured for more than 80 years. Developed by Ferdinand Porsche and his team in the late 1930s, the final design was rolled out in 1938. The engine was a 25-hp air-cooled engine that had a top speed of 100 km per hour (62 mph) and was capable of 32 mpg while traveling with two adults and three children.
A Brief History of the VW Flat 4
Very few Volkswagens were produced during World War II. Most of the assembly plants were in shambles, and none of the Allies wanted to take over producing the Beetle. They said they didn’t see a market for such an ugly little car. The English decided they would take on the task of producing the car in Germany to give the German economy a boost.
Though not a hit when first introduced to the United States in 1949, Volkswagen knew it could sell the car to the automobile-thirsty American public. When Volkswagen started to gain popularity, a setback almost spelled disaster for the manufacturer. Early imports had mechanical issues, mainly with crankshafts and connecting rods breaking. Germany wasn’t about to let some bad publicity about the reliability of their little car stop them, so in typical German fashion, the engineers overengineered the components in question. Throughout their production, components were continuously refined and upgraded.
Horsepower numbers continuously increased over the years. In 1954, the displacement was 1,192 cc and produced 36 hp. In 1961, the horsepower increased to 40 hp. Five years later, the horsepower jumped from 40 to 50 with the introduction of a new cylinder head design and displacement of 1,300 cc. In 1967, the displacement grew to 1,500 cc.
In 1968, Volkswagen had its best annual US sales year ever when it sold nearly 400,000 units at a base price of $1,699. In 1970, the final displacement increased from 1,500 to 1,600 cc, which increased horsepower to 57. The dual-port head was introduced in the Type 1 in 1971, and the horsepower topped out at 60. Finally, electronic fuel injection was introduced in 1975. After that, the engine remained relatively unchanged until the final VW Beetle was imported into the United States in 1979. There were more than 21 million air-cooled Volkswagens total built as late as 2003.
Engine or Motor? The Great Debate
You may have seen discussions on the internet regarding what people like to call the device that motivates their vehicle. Notice how I avoided saying “motor vehicle”?
According to Merriam-Webster:
engine: a machine for converting any of various forms of energy into mechanical force and motion; also : a mechanism or object that serves as an energy source.
motor: one that imparts motion; specifically : prime mover
2: any of various power units that develop energy or impart motion: as
a: a small compact engine
b: internal combustion engine; especially : a gasoline engine
Many people get caught up in the notion that engines use a fuel of some sort to