Stock 1600 DP rebuild, step by step

maboyce · Posted: Wed Jan 16, 2013 1:24 pm Post subject:

I rechecked the valves, and found that the #1 and #4 exhaust valves were slightly tight. I readjusted them to 0.15 mm.

Image may have been reduced in size. Click image to view fullscreen.

I ran the engine again to see if it made any difference to the chirping, and it didn't. I think it may be down to using a non-VW muffler, and as I said before, it's much less noticeable in person than in the video.

PatterBon · Posted: Wed Jan 16, 2013 4:32 pm Post subject:

What brand of muffler are you using?
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maboyce · Posted: Wed Jan 16, 2013 6:00 pm Post subject:

sinful · Posted: Wed Jan 16, 2013 6:55 pm Post subject:

woho great job !

flyboat · Posted: Wed Jan 16, 2013 8:11 pm Post subject:

There is another chirp that is related to the timing and carb adjustment. sometimes it takes a bit of fiddling to get it out. It usually is the carb more than the timing.. get it warm. Set the timeing, adjust the carb according to Bentley then set teh timiong again.

Great job and great persistance.

Loctite 518 is my gasket sealer/maker of choice, especially with aluminum. Thick enought to do teh job, thin enough to not cause problems.
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thebornotaku · Posted: Thu Jan 17, 2013 12:48 am Post subject:

This thread is awesome and aside from the disassembling/reassembling it's shown me just how easy VW engines really are and definitely giving me encouragement to go set up my workbench and start tearing in to my AE case...
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1974 Super: "Diego"

ach60 · Posted: Thu Jan 17, 2013 2:22 am Post subject:

Why are the spark plugs so deep in the holes?
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Good Luck
Al

maboyce · Posted: Thu Jan 17, 2013 8:57 am Post subject:

fred69vert · Posted: Fri Jan 18, 2013 6:03 am Post subject:

I took this thread, copied and pasted, resized the pictures and ended up with a 68MB, 182 page Word document to go into my tech library.

Thanks for the informative thread........
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I'm not losing my hair, it's just retired and relocating further south.

1969 VW convertible, "Heidi"

kcman · Posted: Sat Mar 30, 2013 1:24 pm Post subject:

Awesome job and thanks for sharing.
I have worked on my own bus and have had a blast so far, but I have not build my own engine yet. I think this post will help me a lot in getting that goal accomplished. Love the vw community and thanks again for the sharing and all the info on how to do this right!
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garfish · Posted: Sat Mar 30, 2013 9:53 pm Post subject:

I think I'll have to buy a couple of new ink cartridges but
I'm definitely printing this out and putting it in a binder. Kudos for your meticulousness!!

hethen57 · Posted: Thu Apr 11, 2013 10:21 am Post subject:

Thanks so much for your detailed description of the process....after all the takedowns and rebuilds is there a happy ending to this story? ie, How does it run? Did you get the oil leaks solved? Shocked

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69 Baja Bug
77 Bus

johnnypan · Posted: Thu Apr 11, 2013 8:48 pm Post subject:

hethen57 · Posted: Fri Apr 12, 2013 3:46 pm Post subject:

That's too bad....it didn't sound like it was going well with multiple teardowns and rebuilds. However, the cleanliness of the worksite, the meticulousness, and the detail of the photos was still pretty darn good.
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69 Baja Bug
77 Bus

maboyce · Posted: Fri Apr 12, 2013 5:04 pm Post subject:

I didn't notice that I hadn't quite finished this thread.

I had to reseal the strainer plate with Hylomar one last time, and then replace the oil and zinc additive yet again.

I ran the engine again. It didn't leak, but when I checked the acorn nuts, they weren't as tight as they had been. So I tightened them, and that seemed to kill the leak permanently.

Since I don't have a Beetle myself any more, I sold the engine within a few days of the last post here. With my parts cost covered, I feel I got a good deal on a very valuable learning experience.

I think the biggest thing I learned is not to use aftermarket parts, or even parts from multiple years if at all possible. The other engine hasn't given me nearly as much aggravation as this one did, and it's because all the pieces were made to fit together. I thought that this would be the easy engine, that I would build and sell 'really quick', and the other one would give more trouble, but it's the opposite.

Thanks to everyone who posted encouraging things, and who enjoyed reading along over the past several years.

AustinVonZweigart · Posted: Sat Jun 08, 2013 3:51 pm Post subject:

Such a great help thanks!

Johnnybgoood · Posted: Fri Jun 21, 2013 3:01 pm Post subject:

is the cam plug on the back installed wrong? on my engine it is dished in, cup side facing out.

ghi66

Briiliant reference and build Smile

Busdriver79 · Posted: Sun Sep 22, 2013 7:08 am Post subject:

The exhaust "chirping" in the video can be adjusted by moving the tailpipes either a bit inward or by pulling them out a little...Awesome thread ! Very Happy

1970VWGUY · Posted: Mon Sep 23, 2013 6:20 pm Post subject:

I have a question that's been bugging me...no pun intended...with all the crap you put on all the joints from those tubes of stuff....why and how could any oil be leaking unless that stuff is worthless...

And I thought that's what gaskets were for ...to seal the mating surfaces...some gaskets do not require any type of stuff on them...

Not being smart just trying to understand what's going wrong with all the leakage..


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Stock 1600 DP rebuild, step by step
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