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My Beetle's Maintenance Schedule - Help Please!



 
 
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Old October 18th 04, 01:53 AM
Sleepy Joe
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Default My Beetle's Maintenance Schedule - Help Please!

Hi All!
I am formulating a maintenance achedule for my aircooled VW Beetle.
Special thanks to Howard Rose and Rob Bordman (Aussibug) for the
excerps I took from their data or website.

------------ ---------------- ----------

Maintenance Schedule Complete

Index
Key Checks
Weekly
Front End Inspection
Tune-Up
Brakes
Electrical
Cables, Belt, Hoses
30,000 Mile Check
Other
Parts Replaced Routinely
Part In Car


Key Checks
Valve Adjustment

Oil Change
-Oil
-Filter
-Strainer

V-belt
-adjusted
-replaced

Spark Plugs

Fuel Filter
Fuel Pump Tested
Carb Adjustment

Brake Inspection-Adjustment




Weekly

Check v-belt tension

Check oil level
Check brake fluid level
Check windshield reservoir level

Check fuel line grommet

Check intake manifold boots

Check dash indicator lights

Check tire pressure

Check condition of tires

Clean windows

Clean interior


















Front End Inspection

Lube front axle

Check front bearings free play
Check dust seals on tie-rod ends and ball joints
Check tie rod ends for looseness
Check operation of steering gear box
Check torque of axle bolts
Check torque of steering gear box

Check horn connections
Horn replaced last

Inspect fuel hose
Check steering coupler disc

Adjust front wheel bearings

Adjust front brakes

Check torque of lug nuts or lug bolts

Rotate the tires

Remove flints, nails, etc.

Remove grease, oil, and dirt from tires

Front-wheel alignment checked by garage









Tune-Up

Transaxle gear oil, check level
Transaxle gear oil replace

Air cleaner, inspect filter or sludge level
Air cleaner, replace filter or oil
Note: rinse top with gas. Turn it over. Fill big center hole until it
comes out the small holes. Rinse with kerosene. Fill lower part up to
the baffle shelf with 10 w30 oil.

v-belt adjust
v-belt replace

Lubricate distributor cam lobes
Drop of oil on distributor wick

Inspect dist. cap contacts
Inspect dist. cap center spring tension

Valve adjustment

Replace points
Replace condensor
Adjust points to .016 inch gap
Adjust dwell to 49 to 53 degrees
Note: this does not apply to you since you have an electronic
ignition.

Practice replacing the distributor
Practice setting the timing with a static timing light

Inspect tightness of carb nuts
Inspect carb drain plug tightness
Inspect carb idle cut off valve tightness
Inspect carb fuel inlet tightness
Lube all moving parts on the carburetor

Inspect fuel filter
Replace fuel filter

Check fuel pump pressure

Check thermostat, cold
Check distributor vac advance
Check distributor centrifugal advance

Carb choke setting adjustment
Turn the choke element clockwise (viewed from the right) until the
butterfly is standing straight up, then turn the choke
counterclockwise (viewed from the right) until the choke butterfly
fully closes (barely -- not too tightly), then tighten the three
screws that hold the choke in place.
Note: This is important; the automatic choke may be assembled wrong
and not catching the hook on the coil spring at all.
Start the engine with the air cleaner off. As the engine warms up,
make sure that the butterfly opens until it is standing straight up
(full open) when the engine is fully warm. If it doesn't, readjust the
choke until you get it right.
(Aussiebug)
Battery
-Clean battery top
-Clean terminal posts
-Inspect electrolyte level
-Electrolyte 4 ball test with hydrometer
-Charge battery
-Test starter cranking voltage at coil, should be 9 volts
-Replace battery

Coil
-test spark
-blue ok
-orange, replace coil

Check spark plug air seals

Compression test

Spark plugs -replace and inspect electrode deposits
Note: If you drive only 6,000 miles or less a year, change the plugs
every two years. Note: Use Marvel Mystery Oil in the fuel tank a
month before changing the plugs.

Check rubber valve for crankcase ventilation
Check c.v. boots
Drive shafts, check for looseness
Check big engine compartment seal

Oil Change
-Oil
-Oil filter
-Strainer replace

Check timing

Carburetor adjustment
-Unscrew the Fast Idle Adjuster (sits on the stepped cam), until it is
clear of the stepped cam. Now screw it in until it JUST touches the
very bottom of the stepped cam - NOT on any of the steps themselves.
Now screw it in another 1/4 turn - no more

-set idle speed to 900 rpm
-set air: fuel mixture screw to 3 turns out. Then turn it very slowly
IN until the revs drop by about 30rpm. It might be about 2.5 turns out
now. Now turn it ¼ turn out.
(Aussiebug)

-reset idle speed
-recheck timing 7.5 btdc

Check thermostat, warm













Brakes

Inspect front brake shoes
Replace front brake shoes
Adjust front brakes

Replace front wheel cylinders

Replace front wheel bearings

Repack front wheel bearings

Adjust front wheel bearings

Replace e-brake cables

Inspect rear brakes
-Remove drum inspection. Sometimes a spring will come loose.

Replace rear wheel cylinders

Replace rear brake shoes

Adjust rear brakes

Adjust e-brake

Replace master cylinder

Replace brake light switches

Inspect brake lines

Replace center brake line

Inspect brake hoses

Bleed brakes
-pressurize power bleeder to not more than 10 to 15 psi.
Electrical

Battery
-Clean terminal posts
-Inspect electrolyte level
-Electrolyte 4 ball test with hydrometer
-charge battery
-test starter cranking voltage at coil, should be 9 volts
-Replace battery

Clean electrical ground connections

Clean charging circuit connection

Clean fuse box connections
Inspect fuses
Replace fuses

Inspect horn connections

Check starter connections

Check hard start relay connections

Check firewall grommets














Cables, Belt, Hoses
Check cables:

Check throttle cable

Check clutch cable

Check emergency brake cables

Inspect heater cables

Replace heater cables

Lube trunk latch and cable

Replace trunk latch cable

Inspect battery cables

Replace battery cables

Check v-belt

Adjust v-belt

Replace v-belt













Every 30,000 miles or 50,000 kilometres
As 6,000 mile or 10,000 kilometre service, plus the following:

Clean out front-hub bearings and repack with grease.

Clean out rear -hub bearings and repack with grease

Clean out c.v. joints and repack with grease
Replace c.v. joint boots

Change transmission case oil.

Replace brake light switches

Replace brake fluid
Note: pressurize Power Bleeder to only 15psi

Adjust brakes and e-brake





















Other
Lube all moving parts on the carburetor

Apply petroleum jelly to the door catches

Apply LockEase or graphite powder inside the key slots

Lube door hinges

Lube the hood latch and cable

Fill wiper washer reservoir

Adjust choke in Spring

Adjust choke for cold weather

Remove deck lid louver covers in Spring
Install 3 deck lid louver covers for late Fall weather

Clean windows and interior

Check for water after it rains or after washing

Wash

Wax

Check for body rust
Note: cut, fiberglass cloth, POR15, and primer









Parts replaced routinely:
Battery - replace at half life or carry a portable jump start kit with
you

Fuel hoses and tank outlet and finger shaped filter strainer
Note: get the fuel hoses from C.B. Performance

Horn

Lights:
Note: use bulb grease, silicone grease, or dialectric tune up
grease
Headlights

All turn signal lights

Front side marker lights

Stop/tail lights

Liscense tag light

Back Up Lights

Indicator warning lights

Courtesy light

Courtesy light door jam switches

Wiper blades










Parts In Car:
Dist cap
Rotor
Accelerator cable
Bulbs
Fuses
v-belt

Distributor
Static timing light
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