What, if any special tools would I need to tear down a 1500 type 1 engine, clean and put back together?
Never done this kind of thing, have an old engine and just thought I'd give it a go for the leaning experience and hopefully end up with a clean spare engine at the end.
Yeah you do need a couple of things
-A good manual such as "how to rebuild your volkswagen air-cooled engine" By Tom Wilson, the muir book also is good although the wilson book goes into much more detail and has photos and diagrams. I thoroughly reccomend this book.
-Torque wrench for assembly, range from 5ft/lbs to 80ft/lbs (essential)
-End play tool, there are lots of types, like the dial gauge, another one that uses a bolt and a locknut which u use feeler gauges to measure. (essential)
-Pair of soft hammers/mallots to split the case halves(essential)
-Angle iron or flywheel lock to hold the flywheel still when u are tightening it(essential)
-Harmonic dampener puller to remove crankshaft pulley(sometimes it will come off by hand)
-Deck height tool, you can make your own if you are willing to or just use a straightedge to substitute.
-Clutch alignment tool, not really necessary as you can align it by eye or make your own out of a broomstick
-Clips to hold lifters, not really necessary if u grease the lifter bores
-other basic tools which you probably already have i.e. 36mm socket w/ cheater, socket set etc.
cant think of anything else...
have fun, rebuilding is definitely a great learning experience, take your time, triple check everything and take care
[Edited on 23-9-2002 by Che Castro]
Jon
probably a good idea to hone the barrels and fit some new rings and bearings while youre at it so buy or borrow a cylinder hone and depending on the condition of the heads you can just lap the valves in for which you'll needa valve spring compressor and some valve grinding paste and a valve holder but if they look sus have them checked out for wear good luck its great fun pulling engines to bits and putting them back together just make sure you keep everythinbg together john muir says put everything into bags and label them so when you put it back together it will be heaps easier to remember
marcel:thumb
and if want a clean engine make sure you use a quality degreaser maybe abit more expensive but you will use alot less ( we made out parts washer out of a deep sink and welded up a basic frame which has 2 "H's" on each end and a piece joining them together very basic and cheap and does the job well!)
cheers
rhys
p.s. you could just use 1/2 of a 44 gallon drum and some diesel in it?
don't bother honing your cylinders, just buy a new set of pistons & cylinders , last time i checked a new set was under $300, not only do u get parts that haven't gone through thousands of heating and cooling cycles you also get a nice clean sealing surface on the cylinder/head.
If you are going to rebuild the heads yourself get the bits marcel said, however it is hard work and there is a lot of stuff to do. Probably a lot easier to get new heads, they aren't cracked, not stressed from heat cycles etc. All you need to do is lap the valves.
Last time i checked new complete Dual Port heads were about 500 or so for a pair. only a bit more than getting someone to rebuild your old ones, you also get to upgrade to a Dual port, however you will need to run a doghouse fan and shroud, cooler, tinware and distributor without the #3 retard.
Jon
Thankyou all.
Let the games begin.🙂
So can I just add 1600 cylinders and heads to the 1500 case without any machining?
[Edited on 24-9-2002 by Kafer Lover]
Yes you can replace the 1500 with 1600 barrels n pistons.
Also an engine stand helps .
