How to Maintain an Air Cooled Vw (Volkswagen)

Step-by-Step Guide

1. 1

   Step 1: Remove large chunks of dirt and dry mud from underside of car body and chassis and check for rust.

   Fix rusted area and coat with top grade primer or lead-based primer and paint, or coat with fiberglass resin.
   
   Mud is usually trapped under the fender wells on the upper light domes, fender ends, and on the Super Beetle, the top area of the front coil shock springs.
2. 2

   Step 2: Pull tar-paper rug off floor to expose the sheet metal floor pan.

   Clean and coat rusted area of floor pan with top grade primer or lead-base paint.
   
   This is very important especially the rear floors and battery area.
   
   Replace tar paper rug with rubber mats (spike side of mat down.) Note: 72 VW Beetles and later models had no tar paper rugs. , Coat body attachment area and metal part of running boards with fiberglass resin, and use a thin layer of fiberglass with resin at rust damaged areas.
   
   File and sand smooth all resin/fiberglass work. , Use new original VW hoses or 3/16 diameter braided fuel hoses for replacement. ,,,,,, Disassemble and pack all four c v joints with molybdenum disulphide lithium grease.
   
   Rotate the c v joints by installing the previous wheel c v joint to the inside transmission flanges, and installing the previous transmission c v joints to the outside wheel flanges. , Coat brake line in this area with Rustoleum or lead-base primer and paint. , Apply the brakes and have an assistant outside try to rotate the front left and right wheels.
   
   If one (or both) front wheel still rotates when the brakes are applied, check for faulty brake hose, brake cylinder or caliper, master cylinder, rubber grommet on Master cylinder where brake fluid enters for cracking or leakage, or brake shoes and linings.
   
   Apply (with force) and release brake and then check again for free rotation of front wheels.
   
   If one (or both) front wheels do not rotate freely, check for faulty brake hose, brake cylinder of caliper.
   
   NOTE: brake hose deteriorates from the inside and may look perfectly good on the outside. ,, It assures the engine is not overstressed (lugged down,) and will not overheat due to faulty brakes.
   
   The engine will last longer and the car will get better gas mileage. , Therefore, the brake procedure should also be performed when: the gas mileage drops; the car does not roll freely (coast) on the road, especially after releasing brakes; a wheel drum overheats, or smelling of burning brake shoes.
3. 3

   Step 3: On VW Beetle

4. 4

   Step 4: remove running boards (both L and R side) and clean/repair body attachment area and running boards.

5. 5

   Step 5: Change fuel hose just under fuel tank

6. 6

   Step 6: and forward of engine firewall

7. 7

   Step 7: and at fuel pump area.

8. 8

   Step 8: Check fuel tank at lower area for fuel leaks.

9. 9

   Step 9: Change transmission oil

10. 10

    Step 10: and change engine oil.

11. 11

    Step 11: Adjust engine valves

12. 12

    Step 12: points

13. 13

    Step 13: and timing.

14. 14

    Step 14: Grease front wheel bearings

15. 15

    Step 15: and grease front chassis.

16. 16

    Step 16: Remove front wheel bearings

17. 17

    Step 17: and grease front chassis.

18. 18

    Step 18: Remove dirt from all four c v joints (constant velocity joints) at rear wheels (on '68 automatic and '69 and later VWs.)

19. 19

    Step 19: Check brake line at foot pedal area for rust and fluid leaks.

20. 20

    Step 20: Jack front of car to free front wheel rotation.

21. 21

    Step 21: Repeat above brake procedure to rear wheels.

22. 22

    Step 22: Checking the brakes in this manner is the most important thing to do before driving the car.

23. 23

    Step 23: A driver can not always detect when the car brakes are dragging.

Detailed Guide

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