1. Preparation:
- Park your car on a flat surface and apply the parking brake.
- Allow the engine to cool down completely.
- Disconnect the battery's negative terminal.
2. Remove Bottom Plate:
- Position a drain pan under the car, directly beneath the bottom crankcase plate.
- Remove the bolts holding the bottom crankcase plate and slowly lower the plate to drain any remaining oil.
- Remove the bottom crankcase plate gasket.
3. Remove Clutch Plate:
- Shift the gearbox to neutral and rotate the engine's flywheel until you see a small access cover on the clutch housing.
- Remove the access cover and insert an 8mm hex key into the flywheel until you feel it engage the pressure plate.
- Hold the hex key in place to prevent the engine from turning and remove the bolts securing the clutch plate to the flywheel using a 17mm socket.
- Once all bolts are removed, gently pry the clutch plate off the flywheel.
4. Remove Engine Case:
- Remove the bolts holding the engine case together. They can be found along the upper part of the crankcase, both on the engine side and the transaxle side.
- Use a long screwdriver or pry bar to carefully pry the engine case apart, starting from the flywheel end and working your way towards the front.
- Be mindful of the gasket material between the engine case halves and clean off any remnants.
5. Replace Gaskets:
- Clean both surfaces of the engine case halves where the gasket sits, removing any old gasket material or debris.
- Apply a thin, even bead of high-temperature gasket sealant to both surfaces, ensuring a complete seal.
- Place a new engine case gasket in place, making sure it aligns correctly with the bolt holes.
6. Reassemble Engine Case:
- Carefully reattach the engine case halves, starting from the flywheel end and ensuring the gasket is properly seated.
- Tighten the bolts evenly, following the specified torque sequence for your engine.
7. Reinstall Clutch Plate:
- Position the clutch plate back onto the flywheel, making sure to align it correctly.
- Secure the clutch plate with the bolts you previously removed, tightening them evenly in a star pattern.
8. Reattach Bottom Plate:
- Place a new bottom crankcase plate gasket in place.
- Reattach the bottom crankcase plate and tighten the bolts securely.
- Refill the engine with oil to the recommended level.
9. Reattach Access Cover and Reconnect Battery:
- Reinstall the access cover on the clutch housing and reconnect the battery's negative terminal.
10. Start the Engine and Test:
- Recheck all the bolts and connections to ensure they are tight.
- Start the engine and let it run for a few minutes.
- Check for any oil leaks or unusual noises.
Once you're satisfied that the crankcase has been split and reassembled correctly, you can move on to any necessary repairs or replacements within the engine.
Remember to follow specific guidance for your particular VW Bug model and consult a repair manual or seek professional help if you're unsure about any step.
