JBugs - 1971 VW Super Beetle - Engine Build Series - Top End Assembly

The top end of our 1800cc stroker engine is ready to be completed so we’re going to prep the pistons and cylinders before installing them on the short block. Then the pushrod tubes, the heads will be set in place and torqued down before the pushrods and rocker assemblies are set in place to complete our long block.

Intro 0:00
Pistons & Heads Preparation: 0:58
Piston Reassembly: 1:07
Piston and Head Installation: 2:54
Cylinder Deflect Tin Installation: 3:40
Push Rod Tube Preparation: 4:00
Push Rod Tube Installation: 4:23
Cylinder Head Installation: 4:34
Cylinder Head Nuts Installation: 4:53
Cylinder Head Nut Torque Sequence: 5:15
Rocker Assembly Installation: 5:30
Valve Cover Replacement: 6:30

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Tools used in this video:

Piston Ring Compressor
Linesman Pliers
Snap Ring Pliers
Torque Wrench
15mm Socket
6'' Extension
Clutch Alignment Tool
Flathead Screwdriver

Chemicals Used:

Aviation Sealant
Parts Cleaner
Assembly Lube

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The parts used in this video are:

AA 88mm Piston & Cylinder Kit (31119806988TWAA)

85.5mm VW Cylinder Shims (21-6040)

90.5mm VW Cylinder Shims(16-9529)

VW Cylinder Deflector Tins (311119317A)

EMPI GTV-2 Dual Port Cylinder Head (98-1334-B)

EMPI Stainless (8531)

VW Pushrod Tube Seal (113109345A)

Hardened Valve Lash Caps (4006)

VW Chromoly Push Rods(4034)

Rocker Stand Shim Kit (21-2310)

High Ratio Rocker Arms (21-2164)

NGK D8EA Spark Plug (D8EA)

EMPI Stainless Steel Valve Covers (16-9470)

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Videos are intended for entertainment purposes. Factory specifications should be followed when performing any task on your vehicle.

[jorgeborrego]

Great set of videos, thanks. One note, if you install steel shims on the bottom of the cylinder plus copper shims on the top of the cylinder you will end up with much lower than the 8.25:1 you are looking for.

[advance]

This series has brought back many great memories, as I have rebuilt many of these back in the 70's. Thank you for doing such a great job!!!

[daos]

polished rocker covers are a great way to reflect heat back into the heads.

[SkaBob]

I saw that normally heads go on with no gasket or seal, is the copper seal you are using to adjust compression ? And if you are reusing heads are they normally resurfaced or just bolted back on ?

[farukmulaku]

Hi,
Thank you for a such great videos, explaining how to put together the air-cooled engine. My question is, is it OK instead cooper rings between engine heads and cylinders to put aluminum rings?
Thank You,

[HondaRidea]

I have (4) single exhaust on my 1600 and the 3rd cylinder has white smoke puffing from it, is that worn piston rings? Im going to purchase a compression checker soon to test them

[cadincaldwell]

Can you guys make a vid on how to do a front disk brake conversion install?

[chesterumana]

What torque size you recommend 3/8 or 1/2 torque wrench?

[robharris]

I love the information in these videos Really well done. only suggestion is your host should learn to speak normally instead of speaking like hes reading a script (which Im sure he is lol) it just doesnt sound natural

[luzbelemhafley]

How do I cut out the space to install a vintage radio for a 71 bug?