Volkswagen Air Cooled 1949-1969 Repair Guide

Cylinders

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Fig. Fig. 1 Prior to installing the cylinders and cylinder heads, make certain that the cylinder sealing surfaces (arrows) are perfectly clean and true



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Fig. Fig. 2 To remove the cylinders, slide the cooling air shield out from between the lower, middle two studs



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Fig. Fig. 3 Slide the cylinder jug off of the mounting studs and the piston


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

Before removing the cylinders, the cylinder head, valve pushrods, pushrod tubes, and deflector plate below the cylinders must be removed. The cylinders may then be pulled off.

Reinstall the cylinders as follows:

Cylinders should be checked for wear, and if necessary replaced with another matched cylinder and piston assembly of the same size. Also check the cylinder seating surface on the crankcase, cylinder shoulder, and gasket, for cleanliness. Foreign matter here could cause leaks due to distortion of the mating parts. When reinstalling the cylinders, a new gasket should be used between each cylinder and the crankcase.

The piston rings, and piston pin should be liberally oiled (a MoS 2 based lubricant is suitable). Compress the rings with a compression tool. Be sure that ring gaps are adequate and staggered on the piston with the oil ring inserted into the cylinder so that its gap is positioned UP when the pistons are in their horizontal position in the engine.

Lubricate the cylinder wall and slide the cylinder over the piston. Crankcase studs should not contact the cylinder cooling fins. Install the deflector plates under the cylinders, bending slightly if necessary to make them seat tightly on the cylinder head studs.

Install the pushrod tubes and pushrods, ensuring that the tubes are inserted with the seam facing upwards and are of the proper length.

 
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