Okrasa Installation Instructions - PDF
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1. you get your hands on one They are worth every penny Not to belabor the point but if you have never disassembled a VW air cooled engine before you should consider hiring a competent mechanic to perform the job At bare minimum you should have the carburetion checked by an expert We will discuss this in detail later We estimate a full day and a half to complete the installation of this kit including the R and R of the engine The installation proce dures should not be done hastily so don t be in a rush Invariably and unexpected problem or glitch arises to cause a delay Expect it and consider yourself lucky if you move through the installation unhitched If you will be installing this kit on a Single cab Double cab Kar mann Ghia or convertible Beetle you will have issues with the air filters clearing the body At this point we do not have a solution that is aesthetically appealing Call if you need some ideas on what can be done 2 With that out of the way let s get started First remove the kit from the box and do a quick inventory to in sure everything is present Use the inventory checklist to the right to complete this step There are some items that will be necessary to complete the Wolfsburg West 2009 Orders 888 965 3937 Technical Support 951 549 0525 www wolfsburgwest com 2 YOUR VOLKSWAGEN RESTORATION PARTNER FOR OVER 20 YEARS Item ty Description Air Filter Balance tube assembly Carbu2. AZ WOLFSBURGW EST Parts For Volkswagen Restoration Dual Port Engine Kit Instructions Part number 111 198 700 and 111 198 700A A few notes before you begin the installation of this kit A reasonable amount of mechanical ability is necessary to success fully install this engine kit If there is any hesitation with regards to knowledge of engine tear down and engine tuning a competent professional should be hired Using the Wolfsburg West dual port 36hp engine kit will increase the horsepower a considerable amount This increase is very significant and therefore you must insure the engine is able to perform at this advanced level As a starting point we recommend replacing the rod bearings for engines with 50 000 or more miles If the engine has greater than 75 000 miles a complete tear down and inspection is necessary Consult your factory service manual for other technical specifications to ensure your engine is within tolerance Orders 888 965 3937 Technical Support 951 549 0525 www wolfsburgwest com Wolfsburg West 2009 le WOLFSBuRGWEST Parts For Volkswagen Restoration As noted previously these instructions assume that you have experience with the Volkswagen air cooled engine These instruc tions are not intended to provide a step by step process of install ing this engine kit We will cover the aspects not covered in the factory workshop manual Don t have one We highly suggest that
3. d to spec tape closed the intake ports on the cylinder heads Use the template found at the back page of this instruction manual to trim the engine tin Your cylinder head tin will need to be trimmed in order to properly clear the intake manifold We use spray glue to hold the pattern in place After trimming the tin you will need to slightly bend the tin Wolfsburg West 2009 Orders 888 965 3937 Technical Support 951 549 0525 www wolfsburgwest com 5 Ar WOLFSB RG WEST Parts For Volkswagen Restoration Trimming the cylinder tin in the areas shown to clear the manifold Installation of the manifolds requires both the engine tin and mani fold be installed as an assembly Before you do this inspect the inner surfaces of the manifolds to insure they are clean Io protect the paint finish of the manifolds during the installation process wrap masking tape around the manifolds as shown in the illustra tion Additionally apply tape to the top flange to fully cover the inlet as to prevent objects from entering the combustion chamber during the balance of the assembly On your first attempt you may find that you need to trim or adjust slightly the shape of the tin surrounding the manifold to al low it to properly seat against the engine Make the adjustments as necessary Now that the tin is fitting correctly remove the masking tape covering the intake ports and install the supplied manifold gaskets Use the supplied nuts a
4. e mounted near the inlet of the oil pump We found that heat from the muffler and engine case caused er roneous readings and therefore the location was moved to a dip stick sender y Pa 3 pA gt 4 Oil pressure sending unit Wolfsburg West 2009 Orders 888 965 3937 Technical Support 951 549 0525 www wolfsburgwest com 0 YOUR VOLKSWAGEN RESTORATION PARTNER FOR OVER 20 YEARS Oil pressure was measured by using VDO combo oil pressure sending unit mounted in the stock oil pressure switch outlet We tested our prototype engines in a 1957 single cab truck with stock gearing and reduction boxes All measurements shown be low were taken using a stock kit without any modifications Ambi ent air temperatures ranged from 80 100 degrees F Oil temperatures averaged between 70 200 degrees F in normal driving surfaces and increased to 220 degrees F in steep driving grades Cylinder head temperatures never exceeded 285 degrees F and averaged about 250 degrees F Please note that the 36hp Bus models have a top speed of 50mph at 3000 rpm s If you wish to increase this rate a gearing change should be considered The Volkswagen engineers had reason for for not exceeding 3000 rpm s for extended periods 6 Break In Our dual port 36hp engine kit is a reproduction of the original Gerhard Oettinger design Gerhard Oettinger founded the Oet tinger Company in 1951 A brilliant engineer he was a pionee
5. e until you are comfortable with the mixture setting Next is the adjustment of the idle speed screws Using a carbure tor synchronization tool such as a Uni Sync adjust the idle speed screws to an equal flow 800 900 rpm The linkage should be disconnected from the carburetors when establishing the idle speed Finish by adjusting the linkage ball joint fittings You should be able to snap the ball joint onto the bell crank ball joint without chang ing the idle speed or bell crank position Note A sure fire way to kill an air cooled Volkswagen engine is to run the mixture too lean If you are hesitant or unsure how to prop erly adjust the carburetors as outlined above hire an experienced mechanic to check and or adjust the air fuel ratio Wolfsburg West 2009 Orders 888 965 3937 Technical Support 951 549 0525 www wolfsburgwest com 9 Ar WOLFSB RG WEST Parts For Volkswagen Restoration 5 What To Expect We used a data logger to capture and log the engine performance data throughout our testing Many variables can cause your read ings to be different from our results Instrument quality sending unit locations and ambient air temperatures are just a few ex amples When measuring the cylinder head temperature we sampled the temperature from two locations Underneath the 3 spark plug and under the top of the inner 4 head stud When measuring the oil temperature we employed the use of a VDO sender which w
6. in our testing a more that expected oil vapor making its way out of the breather tube Installing this zig zag plate cleared the nagging drip on the garage floor We offer this plate separately under the part number III 115 450 Narrow end Location of baffle in generator stand Wolfsburg West 2009 Orders 888 965 3937 Technical Support 951 549 0525 www wolfsburgwest com 3 Air filter element 2 Ny lock nut 3 Rebuild kit 4 Hollow bolt 5 Air correction jet 6 Pilot air bleed jet 7 Main jet 8 Pilot jet 9 Pump jet Note All parts called out with black balloons are included in the rebuild kit D ation AR Bla cs Wolfsburg West 2009 Orders 888 965 3937 Technical Support 951 549 0525 www wolfsburgwest com 14 YOUR VOLKSWAGEN RESTORATION PARTNER FOR OVER 20 YEARS Align these two sloted holes and this edge to your original tin Cylinder head tin trim template Wolfsburg West 2009 Orders 888 965 3937 Technical Support 951 549 0525 www wolfsburgwest com 5 eo i WOLFSBuRGWEST Parts For Volkswagen Restoration Wolfsburg West 2009 Orders 888 965 3937 Technical Support 951 549 0525 www wolfsburgwest com l6
7. nd tighten each nut to 18 foot pounds Wolfsburg West 2009 Orders 888 965 3937 Technical Support 951 549 0525 www wolfsburgwest com 6 YOUR VOLKSWAGEN RESTORATION PARTNER FOR OVER 20 YEARS f PEN af 7 y as Bend cylinder head tin inward around the spark plug opening Shown with arrow With both manifolds and upper cylinder tin mounted install the black balance tube into the manifolds using the supplied red hose and band style clamps The package containing the red hoses and band clamps contains instructions for installing the clamps how ever for your convenience we have also noted the instructions below If you purchased a kit with the original style carburetor linkage system the balance tube should be routed underneath the gen erator If you purchased a kit with the updated CSP linkage the balance tube should be positioned behind the fan shroud The Wolfsburg West 2009 Orders 888 965 3937 Technical Support 951 549 0525 www wolfsburgwest com 7 DL a WOLFSB RG WEST LE De Parts For Volkswagen Restoration A N updated CSP linkage kit does not use the spark plug wire conduit At this point the engine is ready to be installed back into the vehi cle Carburetor fuel line and linkage installation will be performed with the engine installed in the vehicle We suggest that you test fit these components before the engine installation Install the carburetors onto the ma
8. ne kit With the old cylinder heads removed inspect the cylinders for wear Inspect the deck height and measure accordingly A stock engine will most likely fall in the 040 045 range The cylinder head combustion chambers contained in this kit will measure 43 cc s cc You will find many compression ratio calculators on the Internet We like the version found at http www race cars net calculators compression_calculator html Wolfsburg West 2009 Orders 888 965 3937 Technical Support 951 549 0525 www wolfsburgwest com 4 YOUR VOLKSWAGEN RESTORATION PARTNER FOR OVER 20 YEARS Next remove the upper two 2 inner cylinder head studs from your engine and replace these with the shorter version studs supplied with the kit If you don t have one of those handy dandy stud removal tools use the double nut trick for removal Install the new short studs accordingly leaving a thread at most showing from the point in which it enters the engine case Install the new cylinder heads refer to your workshop manual for the tightening sequence and torque setting Use the Allen head nuts and washers supplied with the kit to secure the cylinder head onto the short studs Do not use your original hex nuts and wash ers for these studs Use the standard 006 valve backlash for both exhaust and intake valve settings JAF T h S Po OE lumen Double nut the head studs for replacement With the heads installed and torque
9. nifolds using the supplied bolts nuts and gaskets The carburetors will work on either side e A few important notes before finishing up the installation e The air filters are supplied with a foam element We offer a K amp N filter to replace this under the part number III 129 511 If you disassemble the air filter you must pay attention to the integrity of the ny lock nut that holds the two halves together during re assembly e Do not exceed the recommended 2 5 psi fuel pump pressure Doing so can override the float valves Please refer to the instructions for the carburetor linkage included with your kit to finish installation Wolfsburg West 2009 Orders 888 965 3937 Technical Support 951 549 0525 www wolfsburgwest com 8 YOUR VOLKSWAGEN RESTORATION PARTNER FOR OVER 20 YEARS 4 Carburetor Adjustments Before starting engine adjust the static timing Adjust the mixture screw of the carburetor to a base setting of 2 turns and the idle speed screws to to 5 turns Start the engine and don t worry if the engine idles too slowly as long as it will stay running Check the fittings and fuel lines for possible leaks The first step in adjusting the carburetors is to establish the mixture Turn each mixture screw inward until the engine runs worse then back it out 4 turn at a time Continue turning the screw outward until you hear no change in idle speed or smooth ness Perform this for each carburetor as least twic
10. r of early Volkswagen performance products Mr Oettinger made the following recommendations for engine break in for which we agree The first 2000 miles do not exceed 3000 rpm s or 62 miles per hour Wolfsburg West 2009 Orders 888 965 3937 Technical Support 951 549 0525 www wolfsburgwest com PP pami e a eS Jam 5 A SN gt Do not exceed the shift points marked on your original speedom eter Do not exceed 194 degrees F oil temperature after 2000 miles do not exceed 240 degrees F If you are not looking to solely rely on the seat of your pants method to gauge the health of your engine we recommend using an oil temperature gauge The reason being is that even in our desert testing we found the cylinder head temperature to be low Although oil temperature never reached a point of concern the gauges did provide for us a better indication Of course a good head temperature is also nice The Gene Berg oil temperature dipstick is a great product and is accurate in providing oil tem perature This device is simple to install and will illuminate your oil pressure light in the event your oil reaches the 220 225 degrees F range Better yet this device is not voltage dependent and will run at 6 of 2 volts Wolfsburg West 2009 Orders 888 965 3937 Technical Support 951 549 0525 www wolfsburgwest com 2 Engine crankcase ventilation is a common problem with early engines We found
11. retors e Fuel line assembly Left intake manifold Right intake manifold Complete cylinder head with valves Head studs with washers and nuts Misc hardware kit Manifold gaskets Preheat block off plates O0 J O U1 R U N AN N NO Wolfsburg West 2009 AP ey Sy Orders 888 965 3937 Technical Support 951 549 0525 3 www wolfsburgwest com tie WOLFSBuRGWEST Parts For Volkswagen Restoration installation of this kit please find the listing below e Engine gasket kit Wolfsburg West part 111198003 e Flywheel seal not necessary but a good idea Wolfsburg West part I 11105245 e Sealing compounds available at any auto part store e You will also need a centrifugal advance distributor such as the Bosch 010 019 or 009 version A vacuum takeoff is not provided on the carburetors Note Something that may throw the backyard mechanic a curve You will need a 10mm Allen head socket wrench that can be at tached to your torque wrench With all of this in check remove the engine from the vehicle 3 Engine disassembly We like working with a clean engine so now is a good time to em ploy the use of your favorite toxic chemical concoction to remove the road grime Remove all necessary components including the cylinder heads If your car still has the thermostat and fan hous ing ring remove this as it will not be used in conjunction with this engi
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