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VW Parts & Tech Help for Aircooled Volkswagen Folks!

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We serve the VW parts and VW Tech needs of owners of aircooled VW Beetle, Volkswagen Bus, Karmann Ghia, Type 181 Thing, VW Type 3 Squareback / Fastback / Squareback, and Type 4 VW. Tech Tips, project advice, and quality parts for VW Restoration, VW Performance and Custom Aircooled VW projects.

2275cc “Mild” Engine Combo, L5 Heads; Requires 1 5/8″ Exhaust and at least (2) 44mm Carburetors

We have put together a parts list for our most popular engine combos to make shopping easier for you. This list will give you a long block that is proven and tested to delivery! This particular engine combo will deliver a 150hp with ease! It will need dual Weber 44 IDFs, or dual Dellorto 40 or 45 DRLAs. This version of 2275 is NOT a “full tilt street build”. This is one you can drive every day without issue! This “milder” 2275 will result in a longer lived and easier to drive engine which will last a long time. This engine will also work really well in a bus!

During the mock up stage, you’ll have to order cylinder base shims to get the engine’s deck height between .040-.060″; we target .050″, so if you are off +-.010″ it’s not a big deal.

Use this list as a
>>> Read Full Article

Aircooled VW Engine Long Block Parts Checklist!

One of the most common questions we get at Aircooled.Net from prospective builders is for a list of what they need to build an engine. So we’ve gone and detailed it down to every last part!

Click HERE if you want to see a list of all our engine combos to choose from!

You can print this out, or cut/paste it to keep yourself organized.

NOTES:

(Bal) – these items are sent to your balancer AFTER you have mocked up the engine, and are sure everything specs out properly, and it bolts together without any further machining or grinding. The last thing you want is to get it all balanced, then find out you have to change something because of a problem, AND GET TO PAY TO BALANCE IT A SECOND TIME!

(FF Only) – these items are only needed if you are full flowing the engine. This
>>> Read Full Article

1800cc Engine Parts List, no case machining needed, but heads must be bored!

We have put together a parts list for our most popular engine combos to make shopping easier for you. This list will give you a long block that is proven and tested to deliver! This particular engine combo is designed for a really broad torque curve, but does require case and head machine work.

This list is based on an 1800cc engine article we did a while ago, but we had a lot of repeated questions on the parts list, so that is what THIS article is for!

This 1800cc engine has stock to mild heads, a mini-stroker crank, and super reliable THICK WALL 88mm P&Cs. These slip into the stock 1300-1600cc engine case, and only require that your heads are bored to the 92mm register. If you are buying new heads, just have them bored to the 92mm size and they’ll go right on. If you are
>>> Read Full Article

2054cc Engine Parts List, for Convertible Beetles and Ghias, THINGs, Busses, and Type 3s!

We have put together a parts list for our most popular engine combos to make shopping easier for you. This list will give you a long block that is proven and tested to deliver! This particular engine combo is designed for a really broad torque curve, but does require case and head machine work.

This one has mild heads, a stroker crank, and super reliable THICK WALL 92mm P&Cs, which will hold up under the extra heat from Convertibles, THINGs, Busses, and Type 3s!

At the minimum you will need dual 1bbl carbs, but optimally it will have dual 2bbls (Dual 36 or 40mm DRLAs, or 40 IDFs). Also, know that the exhaust system you are going to use will determine the best heads to select! For example, if you are going to run 1 3/8″ exhaust, you are limited to stock dual port heads, or L3 dual
>>> Read Full Article

Master List of Engine Combos!

This is where we list all the engine combos that we have made up. You can simply click on the combo listed below to find the breakdown of all the components in the list.

If there is a combo you want to see, feel free to e-mail us and we’ll get on it ASAP!

1800cc “No Machining” Engine

2054cc for Convertibles, THINGs, Type 2s and Type 3s

2275cc “Milder” for Beetle, Karmann Ghia, Busses, and Type 3s

2275cc “Wilder” for Beetle, Karmann Ghia, and Buggies!

 

This parts list is also very helpful. Complete list of parts used in a VW long block!

 

If there are items on this list that you would like more clarification on, please feel free to contact us (we’ll also update this article)!

Also, if there are other engine recipes you would like to see broken down, feel free to e-mail us,
>>> Read Full Article

2275cc Engine Combo, L6 Heads; Requires 1 3/4″ Exhaust and at least (2) 44mm Carburetors

We have put together a parts list for our most popular engine combos to make shopping easier for you. This list will give you a long block that is proven and tested to delivery! This particular engine combo will easily deliver 200hp with dual 48 IDFs, IDAs, or DRLAs, but we consider dual 44 IDFs or 45 DRLAs the minimum carbs needed for this engine. For example, to tune it down a notch, you simply can use L5 heads and a good 1 5/8″ exhaust along with a slightly milder camshaft. Or use a 1.1 rocker camshaft instead of shooting for almost .600″ of valve lift. This will result in a longer lived and easier to drive (Milder) engine.

During the mock up stage, you’ll have to order cylinder base shims to get the engine’s deck height between .040-.060″; we target .050″, so if you are off +-.010″
>>> Read Full Article

Making the Weber Progressive (32/36 DFEV) Work on the Aircooled VW Engine

DFEV Intake Preheat

Here at ACN we have gotten enough tech questions asking about the Weber Progressive Carburetor that we felt it was time to get a good article up on the subject. These are our OPINIONS on this subject. Hopefully this article will help some folks, who really have no idea what they are doing, to get their progressive running well.

If you have an EMPI progressive, understand that is a Chinese copy of a Weber DFAV/DFEV. We suggest that you get a real Weber DFAV/DFEV.

The DFAV and DFEV are the same basic carburetors, BUT the “A” stands for “Aqua”, or water. Put simply, the “A” is just a water choke version, and the “E” is the electric choke version. Because our cars are aircooled, we never ever deal with the DFAV. But if you pull one off of a Pinto or another car in the junkyard, you may
>>> Read Full Article

VW Super Beetle Shimmy – How to Find and Fix the Problem!

SB Suspension Diagram

VW SuperBeetle Shimmy (aka DEATH SHAKE): A Serious Problem — Not Just a Minor Annoyance!

In 1971, Volkswagen introduced the VW Super Beetle (aka: Model 1301), billing is as a nicer version of the tried and true Standard Beetle that had been used for over 50 years! The Super Beetle had a totally re-designed front suspension, which featured:

A Better Ride (quieter and smoother) A 50% Larger Fuel Tank Much Larger Trunk (almost 2x as large!) Tighter Turning Radius (because there is no axle beam in the way restricting the front tire turning angle!)

The Standard Beetle had a rigid axle beam, with torsion leaves (Springs) that were twisted inside each tube of the axle beam. These tubes and leaves ran across the front of the car. Unfortunately, this design cut right through the trunk and gas tank area, which is why the trunk and gas tank
>>> Read Full Article

Aircooled VW Ignition Tune Up Parts Chart

Find the Ignition tune up parts you need for your Aircooled VW with this handy chart. Locate your distributor model, and to the right will be the parts you need to get your ignition running it’s best! Distributor number(s) are stamped on the body of the distributor, below the distributor cap. We’ve included typical vehicle model and years to help you narrow it down, but you absolutely should NOT simply go by the model and year information! This is because these cars and engines are so old, and parts have been changed for years and decades, that the only way to know for sure is to look at the # on the actual distributor body!

We have done our best to ensure accuracy, but typos/errors are possible. Reference charts are provided for your convenience, and should not be relied upon exclusively.

 

Vehicle / Years Distributor Number Points  Condenser Distributor
>>> Read Full Article

VW Type 1 Mileage Master MPG Engine Combo

VW Tech Articles - Aircooled.Net Tech Talk

With fuel prices on the rise, we’ve been getting lots of inquiries about building a VW engine to improve and maximize. This article outlines Aircooled.Net’s recommendations for an MPG Long Block – we call it the “Mileage Master”. This article focuses on the components for a Mileage Master Engine. A lot of guys aren’t interested in improving mileage that much, but their ears perk up when they find out that if they build this engine as we have specified, they will have up to a 50% increase in power over the stock engine! Doing that and having a 40+ mpg power plant is nothing to sneeze at!

[This article does not address MPG TUNING issues — there is so much material to cover on that topic that we’ll instead do another article on MPG TUNING in the near future. ]

The primary goal of the Mileage Master MPG
>>> Read Full Article

VW Chassis Numbers

VW Chassis Numbers

What is a Chassis Number and why does it matter?

Fundamentally, a VW chassis number is your Vehicle’s Identification Number. But, more important to a VW enthusiast is that knowing the number(s) of your vehicle will enable you to correctly identify the production year (and sometimes month) of your car which, in turn, enables you to deduce what parts, options, features, and modifications are appropriate for it. VW used to introduce improvements into their cars when they were ready, and didn’t wait until the next “model year” to implement them. For example, early 1973 Beetles and Supers had a generator and fuel pump (and pushrod) that was DIFFERENT from the mid 73′ and newer cars (alternator equipped).

The chassis number is typically located in more than one place on VWs, and those locations may change depending on the production year. One of the ways that Type 1 VW’s
>>> Read Full Article

VW Carburetor Set Up Procedure

VW Technical Articles by Aircooled.Net VW Parts

Follow this procedure before you bolt any VW carburetor onto your engine, whether they are new or used! It will put you in the position to be able to tune your carbs without other factors getting in the way and creating a fuel system troubleshooting nightmare. If you haven’t set up your carbs yourself, you NEED to. Most people don’t realize that carbs as they are supplied from the factory are assembled, but NOT set up.


>>> Read Full Article

TMI VW Upholstery Fabrics – Tweed, Vinyl, Velour

TMI VW Swatches

TMI VW Upholstery Fabric Options: Choose from Vinyl, Tweed and Velour:

Due to differences in screen and monitor color presentation, the color swatches above are only APPROXIMATE. We recommend you consult a TMI swatch card for accurate color matching.

TMI VW Ragtop and Convertible Top & Boot Fabric Options

TMI VW Swatches

TMI VW Ragtop and Convertible Top & Boot Fabric options:

Due to differences in screen and monitor color presentation, the color swatches above are only APPROXIMATE. We recommend you consult a TMI swatch card for accurate color matching.

TMI VW Headliner Fabric and Color Options

TMI VW Swatches

TMI VW Headliner Fabric and Color options:

Due to differences in screen and monitor color presentation, the color swatches above are only APPROXIMATE. We recommend you consult a TMI swatch card for accurate color matching.

TMI VW Carpet Colors

TMI VW Swatches

TMI Carpet Colors and Styles

Due to differences in screen and monitor color presentation, the color swatches above are only APPROXIMATE. We recommend you consult a TMI swatch card for accurate color matching.

VW Part Numbers Explained

VW Part Number System

The VW Part Numbering System Explained

Do VW part numbers like this “133-201-075 AD” look like Greek to you?

Well it might surprise you to learn that VW actually had a “plan” when they created their part numbering system. With a little background information, you too will be able to dissect a VW part number and have a good idea what vehicle the part is for and what the part’s application is.


>>> Read Full Article

VW VIN Number Anatomy Lesson

VW VIN Number System

What is a Vehicle Identification Number (VIN)?

The VIN number on your VW can help you to identify the origin of your VW and it may also give you clues regarding the stock parts that were used in your vehicle when it was built. Early VINs were not standardized between manufacturers, nor were they called “VIN”s yet! VW used a combination of two numbers: The Chassis Number, and the Engine Code to convey information about their vehicles. A format for Vehicle Identification Numbers was “officially” outlined in February 1977, and shortly afterward, US National Highway Traffic Safety Administration began requiring that all road vehicles contain a 17-character VIN. VIN numbers are comprised of only numbers (1-0) and capital letters (A – Z), however, the letters I, O and Q are never used in order to avoid confusion in reading. There are no signs or spaces are allowed
>>> Read Full Article

Rebuilding Weber 48 IDA VW Carburetors

How to Rebuild Weber 48 IDA VW Carburetors

The Weber 48 IDA has been used for decades by VW enthusiasts whose goal it is to squeeze every ounce of performance out of their engine. Problem is, production of these coveted Webers was halted many years ago. These excellent VW carburetors in decent condition have become rather scarce! Typically VW performance engine fanatics have to resort to scrounging the swap meets to find a pair of 48’s and even then, they may not be lucky enough to find a pair but have to acquire them one at a time. But if you are lucky enough to acquire a set in usable condition, and you are willing put the time, money and energy into rebuilding and tuning them, you WILL be rewarded. The Weber IDA’s sheer size will likely result in gasps of awe and astonishment from those that have never seen them before!


>>> Read Full Article

1800cc VW Engine Combo: How to Build a Big VW Engine on a Budget

VW Tech Articles - Aircooled.Net Tech Talk

Some folks with aircooled VWs are looking to move up to an 1800cc VW engine from their stock 1600cc VW engine, but don’t want to break the bank in the process. The advice below is intended to help you build an economical 1800cc Aircooled VW Engine Combo.

Know you can see all of our engine combos broken down at this Master List of Engine Combinations! You can see our 1800cc parts list if you find this article confusing.

On THIS one, the first way we recommend to keep costs reasonable is to stay away from machine work – sometimes called a “no machine” VW engine. This is the first article written for our “VW Engine Combo” series. We are outlining a bare bones build that assumes you do NOT have an unlimited funds. You can add to or change components in this engine combo, of course, but if
>>> Read Full Article

VW Type What? The VW Type Designation Systems Explained

Aircooled VW General Information Index

What’s Your Aircooled VW “TYPE”?

Start hanging around the VW scene and you will shortly be confused by all the references to “Type this” and “Type that”. In written form, you will become even more boggled by a variety of VW Type System abbreviations including terms like “T4″, “Type 4″, or “TIV”. A general understanding the VW Type System will both assist you in communicating with your fellow Aircooled VW enthusiasts, and in deciphering many of the numbers (including part numbers) associated with classic Volkswagens. (After reading this, be sure to read our article on the VW Part Numbering System and also on Chassis Numbers).


>>> Read Full Article

VW Engine Removal and Replacement – World Record Speed Video

VW Bug Engine Removal in World Record time

How fast can YOU remove and reinstall your Volkswagen engine? The engineers at VW designed it so that engine removal was easy, but I bet they never dreamed that it could be done THIS fast!

The Shape of Quality – A Documentary Video

vw-documentary

A Documentary highlighting the quality control and process of assembling a VW Beetle at the factory – by Volkswagen Australasia Limited

Watch this VW Beetle Factory Assembly documentary in three parts.

A Brief Video History of VWs

Aircooled VW History Video

Some interesting old footage of early VWs on the road and in the factory. Approx 3 min.

VW Distributor Options

Choosing the Right Distributor for your VW

Aircooled VW owners have an assortment of options when choosing a distributor for their engine. If you only look on the surface it seems simple: The “obvious” choice is the Bosch 009, right? Not necessarily. Once you do a little research, you’ll find a variety of stock units (including the SVDA unit), as well as the Bosch 009, 010, and 050 series, and finally the Mallory, MSD, and the age old Magneto. So which one is “best”?

Each of these units is excellent – for the right application. In this article, I will clarify the right time and application for each option available. You can read the entire straight through, or skip directly to your area of interest using the quick links below:

Before we rush ahead, we are going to use some terminology, we may as well define
>>> Read Full Article

How to Install a 009 (or any) VW Distributor

How to Install a VW Distributor

VW Distributor Installation How To


>>> Read Full Article

Stock VW Ignition Timing Vintage Training Videos

VW Ignition Timing Vintage Training Video

Stock VW Ignition Timing Vintage Training Videos

How to Adjust Stock VW Valves

Stock VW Valve Adjustment - Vintage Training Video

VW Valves Adjustment Part 1

How to Adjust VW Valves Part 2

VW Carburetors 101: Carb Selection Options

VW Carburetor Options - VW Technical Article

Aircooled Volkswagen enthusiasts have quite a few carburetor options. Performance increases that can be gained by going with aftermarket carburetion are a common consideration, but without a little guidance, you can end up with nightmares associated with poor carburetor selection or poor tuning. In the aircooled VW hobby world, it is easy to get confused by the volume of available, and often times conflicting information. There are a number of aspects to consider when upgrading your fuel system and selecting the best set of VW carburetors for your engine and driving needs.


>>> Read Full Article

Running Nitrous Oxide in a VW

Nitrous oxide can be used in your VW engine to create more horsepower. All engines operate under the same principles: better breathing, plus more fuel in a denser vapor equals more power. Using nitrous is not a whole lot different from using a bigger carburetor, a better manifold, a supercharger, or a turbocharger — all are methods to increase the amount of oxygen available for combustion. The air you and your engine breathe is made up, at sea level, of 78% gaseous nitrogen, 21% gaseous oxygen, and just 1% other gases. Nitrous oxide (N2O) is a liquid created by chemically bonding 2 molecules of nitrogen and 1 molecule of oxygen. When the nitrous oxide goes into your engine, the heat of combustion breaks the chemical bond which releases the oxygen and makes it available in a relatively high gaseous concentration compared to the concentration found in normal air,
>>> Read Full Article

Synthetic Oil Explained

7/13/14 IMPORTANT UPDATE! Since this article was written, there have been a lot of changes with oils which we use in our beloved vintage aircooled engines. For a long time, one “insider trick” was to use a good diesel oil, like Delo 15-40, which had great anti-scuff properties, even for our gasoline engines. But as things progress, things change! You have to keep up with these changes, or you can pay a serious price. A couple years ago the formulation of diesel oils CHANGED, and they no longer offered the advantages they had previously for us!

At ACN we try to keep abreast of what people at the ground level (that’s you) are experiencing, with all sorts of products. We have been hearing reports of people running diesel oils running oil temperatures that were ~20F elevated from their “normal” temperatures for some time, and finally put 2 and
>>> Read Full Article

VW Engine Piston & Cylinder Operation

VW Piston and Cylinder Operation

Increase your VW Engine Power with Proper Piston, Cylinder, and Ring Operation The way that pistons, cylinders, and rings work together to support engine power is often misunderstood or mysterious to enthusiasts. But anyone who wants to get the most fun and drivability out of their VW engine should take the time to understand how pistons and cylinders operate in relation to the air flow through their engine system. Oxygen availability is a well known limiting factor in the combustive process. Maximize the volume of air and exhaust that can be moved through your VW engine, and you increase the potential for more power. Performance engine builders and do-it-yourself VW engine enthusiasts tend to focus on modifications designed increase airflow volume, or overall air capacity of their engine system. These modifications include cylinder head work, increasing camshaft size, improving carburetor intake/exhaust, running the engine at higher RPMs,
>>> Read Full Article

Type 1 VW Transmission Conversion to Porsche 5 Speed

VW Tech Articles - Aircooled.Net Tech Talk

A Porsche 5 speed conversion is a nifty modification that makes your Type 1 VW really nice to drive! The Porsche transaxle is strong from the start because it is engineered for the power of a flat six engine. The close ratio gears of the Porsche tranny are able to keep your high performance engine in its power band, while the 5th gear ratio allows for easy highway cruising. However, this is not a “weekend mod” for newbies! The work involved in converting to a Porsche 5 speed tranny includes welding and custom fitment and should only be undertaken if you you have fabricating experience. You will also need to be prepared to do some fine tuning in order to achieve perfectly smooth shifting.


>>> Read Full Article

VW Carburetors 102: VW Carburetor Jetting

VW Tech Article - Basic Jetting Theory and Procedure

After springing for a set of carburetors, some people bolt them on, and are “pleased” with the results. Others are upset by a backfiring, or smoke belching monster. In either case, spending the time to properly jet a set of dual (or single) carburetors is a worthwhile task, since receiving “perfect out-of-the-box” carburetors is one of the biggest myths in the VW industry!

Proper jetting varies depending on engine size, elevation, cam overlap, etc. Jetting is so specific to an individual engine that two identical engine combos with the SAME carbs can even require different jets! The moral of the story is: With your engine combo, carb information and driving elevation, we can advise and get you CLOSE, but to know that your carbs are jetted optimally, you will need to spend the time necessary to dial it in. It IS worth doing for drivability, engine life, and
>>> Read Full Article

VW Carburetors 103: How to Synchronize Dual Carburetors

VW Tech Article - How to Synchronize Dual VW Carburetors

This article contains the step by step, detailed procedure for synchronizing dual carburetors on an aircooled VW engine. But before you actually tackle the syncronization, remove the air cleaners, and make sure there are no vacuum leaks (spray starting fluid around the carburetor bases and intake manifolds while the engine is idling). Make sure the engine’s ignition timing, valve adjustments, and other items are all correct also. You do this to ensure that you are adjusting the carburetors to a TUNED engine, not one that has problems.


>>> Read Full Article

Stock VW Carburetor Adjustment Vintage How To Video

Vintage VW Carburetor How To Video

How to Adjust your Stock VW Carburetor Part 1

Stock VW Carb Adjustment Part 2

VW Engine Break In Procedure

VW Engine Break In Procedure - VW Tech Articles by Aircooled.Net

Many people do not understand the importance of the following the appropriate steps to prepare an engine to run for the first time. Following proper VW Engine Break In Procedure can mean a long life or fast death for a high VW performance engine. The information in this article can also be a useful guide to starting a VW engine that has been sitting for a long period of time, since it ensures proper oiling before the engine fires up.


>>> Read Full Article

VW Performance Engine Building Considerations

Building a ‘Big’ Aircooled VW Engine (Type 1)

This article is a guide to the theory and choices involved in building performance engines for Aircooled VWs (Type 1). There are careful decisions to be made with regard to the engine size and components that are “right” for what you have in mind. The Beetle (and other Type 1 VWs) are fairly light cars. Relatively speaking, it doesn’t take a lot of power for you to really get moving! 140 HP will keep even the Mustang GT’s in your rear view mirror on the street, and 180 HP will eat Corvette’s and Vipers for lunch all day.


>>> Read Full Article

VW Drag Racing Suspension

VW Racing - VW Drag Racing Suspension Tech Article

Drag Racing Suspension & Setup for Type 1 Aircooled VWs

In this article we cover some basic car setup for VW Drag Racing. The information in this article, properly applied, may be able to keep you from breaking and/or crashing your car, or at the very least keep you from scaring the living daylights out of yourself (and/or your spouse, track personnel, or spectators at the track!) This article is NOT a safety article intended to keep you from getting hurt IF you crash — For that we recommend you consult the NHRA rulebook. Many of the principles discussed apply to other cars, but since our specialty is rear engined VWs, that is the focus of the article.


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VW Handling & Suspension Tuning

Suspension Tuning Tips for Type 1 Swingaxle Beetles, IRS Beetles and Buggies (Street and Auto-X)

My name is Greg Ward, I am a guest writer for Aircooled.Net, and I have a 69’ Std Beetle with IRS rear that I run in the Hillclimb circuits in Australia. Some of you may know of me from my posts in several of the Volkswagen related forums on the Internet. I have been racing these terrific cars for the last 12 years and hope to relay some of my knowledge on how to make these cars handle, corner, and stop well. I have broken it down into the 2 combinations I’m familiar with; Ball Joint Front with either a Swing Axle or IRS Rear. Let’s get started!


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Aircooled VW Performance ‘Easy’ Bolt-On Modifications

“Bolt-On” VW Performance Improvements for your Stock VW

This article is for the aircooled VW owner who ask “What relatively straightforward modifications can I do to make my aircooled VW faster and even more fun to drive — without breaking the bank?”

The following modification recommendations will give you the biggest grin per dollar you invest in your car! Most of the modifications in this article are easily reversible, and do no damage to your stock VW. To help you stay in your budget, this guide attempts to present modifications in the order that will maximize the performance boost or drivability benefit per dollar you spend. Of course there are more involved VW performance and drivability modifications you could do, but this article focuses on mods that you can make to your stock VW in a course of a few hours or a
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