I'm pretty annoyed with my workshop manual for the kombi at the moment. I'm not sure which one it is - it's white with a blue kombi on the front.
I've been putting my motor back together for the last few days. It came back from the builder as a short block with oil pump, cooler and filter installed.
Simple, I thought. I'll just read the manual and put it back together, nothin to it....
Wrong!!! I can't find anywhere in the manual where it tells me to put the lower cylinder cooling tin on before the pushrod tubes. 😠
I also couldn't find where it says to fit the cooling tin on the oil cooler before fitting the fan shroud 😠😠, nor where it tells me to put the cooling tin on the back of #2 cylinder before fitting the alternator 😠😠😠
As a result, my pushrod tubes have been installed twice, as has my fan shroud.
Just to add insult to injury, I've just discovered that I have to remove one heater box, because I didn't install the rear engine support bar!!! :jesus
I have 9 different workshop manuals for My 68 Auto Beetle, as they are all different and ALL seem to leave little bits out here and there.... or they tell You what to do and don't show any diagrams or photos.... I still have to get a Bentley VW of America Workshop Manual... the most expensive of them all... I bought most of these books thru Amazon.com in the USA. I Don't have an Idiots book as I don't like it.. I have read it... My Son has a copy of it... I believe You NEED more than one manual.... Maybe 10 is the Answer..... :bounce:bounce:bounce:bounce:bounce:bounce
Good old workshop manuals, Im sure the people that write them do this on purpose, just to catch DIY people like us out, at least the things that happened to you will be remembered next time, we have all fallen victim to this at least once before. how the Kombi comming along Col.
Rob....
Boxer Power
Member of DMLRK.....Die Mittler Lebuns Resto Komeradschaft
BizarreModeratorThe artist formerly known as blue74l
KruizinKombi wrote:I can't find anywhere in the manual where it tells me to put the lower cylinder cooling tin on before the pushrod tubes. 😠
As a result, my pushrod tubes have been installed twice, as has my fan shroud.
:jesus
BLOODY LUXURY
Hey try owning a Type 1 and forgetting the tin. The bloody heads have to come off!!!
Be grateful Col - this will make great drinking stories at Valla. You will sit there and laugh your head off and say "Thats nothing - i did the old T4........"
68AutoBug wrote:I have 9 different workshop manuals for My 68 Auto Beetle, as they are all different and ALL seem to leave little bits out here and there.... or they tell You what to do and don't show any diagrams or photos.... I still have to get a Bentley VW of America Workshop Manual... the most expensive of them all... I bought most of these books thru Amazon.com in the USA. I Don't have an Idiots book as I don't like it.. I have read it... My Son has a copy of it... I believe You NEED more than one manual.... Maybe 10 is the Answer..... :bounce:bounce:bounce:bounce:bounce:bounce
[Edited on 15-7-2003 by 68AutoBug]
Do you have bad eyesight or is this a form of A.D.D.? 😉
I haven't tried the Idiot's Guide, purely because I don't like it. I also found that it was geared more towards the upright motors than a type IV engine.
Lee, I have two manuals, including the Bentley. Although I have read both, I choose to keep the greasy fingerprints to one.
Hopefully tonight's effort will go smoother, I've nearly finished the reassembly. I'll post again later tonight to let you know how its going.
Yes blue, I have no doubt that it will all make for great VW stories down the track, but at the time it is more than a little bit frustrating - I hate doing things twice, especially when it could have been done once.
Kruizin Kol
BizarreModeratorThe artist formerly known as blue74l
Walt, the text size is for Lee's benefit; He keeps shouting at us, so I just assume he's deaf and shout back to make sure he can hear me! 😉😀
Ben, you seem to be implying that I should be paying a 'professional' such as yourself to do the job 'the right way'. No thanks. Unlike many people, I do not call a carpenter to build me a set of bookshelves. I'd rather learn how to do it myself. Sure I call an electrician, but only because it is required by law. I know perfectly well how to wire power points and lights. 🙂
These mistakes will only happen once. Sure, maybe next time I'll make different mistakes, or maybe I'll make more mistakes before I've finished this motor, but I rarely make the same mistake twice. I took the 'safe' option of having my short motor built by a trusted pro, but I see no reason why qualifications should be necessary to complete the rest, and it is saving me a CONSIDERABLE amount of money - money that I'd rather have in my pocket than someone else's. 🙂
Graham, no, it doesn't make me feel any better, but reading Blue's post does!!! 😀
Dunno Dave, but I'm sure you'd be able to tell me!:P
I Dont call tradespeople because I dont trust them. One of the bastards almost had me electocuted when I went to change the light bulb. Threw me off the bed. I fixed it. My extension roof leaked. Other roof plumbers I called in to fix it didnt fix it. I fixed it. Wired up the 8 flouros in my garage, installed the ceiling fans and security lights. Installed most of the airconditioning. The only things I havent done are inside the fuse box. Getting the 15 amp supply for the air con, and installing the safety switch. (There are other lights I havent fitted, need to be sure I dont get zapped) Now dont get me started on telstra technicians! That will need its own thread. Wish I knew how to fix phone lines. The amount I would pay per day for a tradesman pays the mortgage for a month.
I've done all those things you mention Col. Its all learning. And doing it wrong the first time means you dont need to memorise it for the second time. As you put the first tube in next time you will remember how many times you did it this time.
One thing you dont find in the manual under torque settings is 'tighten it up, add 10% GST, then tighten it some more, till it starts to go loose then back it off half a turn. I'm a BHP fitter by trade. I'll see you through it 😀
Chris.... kombi pilot, oval dreamer... finisher #26971 2005 city to surf
If it is your first rebiuld it is not easy. I rebuilt the Helbus motor August last year, but not case split or bottom end, and that took so many hours.
I laid all tinware in like a blown up way on the floor and cleaned each piece one by one. then I epoxy black painted each one by one to keep the order.
then I assembled in order. It was the only way as I had both the Gregory's manual you described and the Idiots guide and I still needed some genuine skill. I must have done ok as the motor has done 15000 k's with no ill effects.
I did add some extra work, like putting back in the thermostat and cable to operate the flaps. Works well.
Thank you to Boris at VVDS who provided a part and posted free of charge. To help me out with the job. I do recommend VVDS in Sydney anyday.
Col I think you made the same mistakes everyone makes the first time you build a VW Type 4 motor!
If I remember right, a white manual with a blue Kombi on the cover was the Gregory's manual, an Australian-produced effort. I found it pretty good, but yes olnly a guide. It did have some good exploded view photos of the tinware. I also have the Bentley manual, and I also borrowed the Haynes and InerEurope manuals from the local library when I built my engine.
Here's some things I found when I built my first Type 4 motor:
* The rods don't have casting marks on them like Type 1 rods do, so there's no 'right' way to install them. All manuals for Type 4 engines still use a photo of a Type 1 crank and rods, with casting marks! I installed mine with the rod numbers all facing up.
* I nearly forgot the finned plastic shanks that fit over the case through-bolts. The manuals only mention them in passing, but they are vital to locate the bolts correctly.
* I didn't forget the tinware under the cylinders, having built many Type 1 engines over the years. The Type 4 bits are much bigger. I had all the tinware pieces laid out on the garage floor so I wouldn't miss any!
* I remember fitting and unfitting the alloy fan shroud several times before I got all the tinware on correctly. There was always a piece left over. Eventually I gort it right, but even now I can't remember the exact order.
* Leaving out the rear engine bar is mandatory for a first Type 4 rebuild. I finished my engine, took photos of it on the stand and was ready to install it before I saw the bar still lying in the garage floor! And yes the exhaust and one heater box has to come off again to reinstall it.
We've all made these kind of mistakes. It's all part of learning about our cars. And in spite of our errors, you can't pay anyone to show as much care and patience as you would yourself.
Craig Torrens6 times Australian, 7 times State Hillclimb Class Champion
lol i always laugh at the complete idiots guid cause no where in there do they say stuff a complete idot would knned to know like "get a 13mm ring spanner, thats the 1 with a lil 13 written on it and has a circley looking bit on the end" LOL
Ben Durie wrote:Hi,
the manual is just a guide , it asumes a skilled trades person is used for the job.
If I need a powerpoint or light fitting replaced i call an Electrician, or a plumber if the dunny is blocked , builder for my house etc, sure I could do em all my-self but usually best and quicker to pay the right person for the job.
regards
Ben..
[Edited on 10-12-2002 by Ben Durie]
This has got to be a stir yeah ? You can't seriously be suggesting that you should take the tinware to a mechanic to assemble ? Next you will be saying we need to get an air technician to check my tire pressure :repuke
Good work COL !
even the pros stuffed up when they started in the trade following there workshop manual !
wish i had the time and patience to do it at the moment. o yeah and some space would be good too 🙂
68AutoBugBeetle Restorer - Experience over 138\% - YIKES --
Well Folks, I will never touch a type 4 engine... Well! maybe touch it, but I'll never pull one apart and try to put it back again.... Some Owners workshop manuals show all the easy things and leave All the hard bits out.... and Yes I am a bit DEAF.... and a bit Blind (wear glasses) BUT, I still Love air cooled VWs ... (Especially type 1s)... and NO , I'm Not shouting, I just like large text.." THIS IS SHOUTING..." "this is not"
I rest My Ear Drums.... 😀😀:o:thumb:bounce:bounce:bounce:bounce:bounce
Well guys, I'm making progress, albeit slowly. I've come down with a bug (pun not intended) and everytime I bend over or move my head I see stars. 🙁
At last, I think I have everything on where it's supposed to be. :thumb I'm still missing a few non-crucial bolts (isn't it always the way?) because it never had them to begin with. I have shuffled them around though so that the ones that are still missing are the easiest ones to get to with the engine installed. 😉
I still need a thermostat and cable, but I've fitted the flaps. This motor didn't have them installed before. :o
There is now a light at the end of the tunnel. If everything goes to plan, I'll have it running tomorrow afternoon. I have an unplanned trip to the movies in the morning - I won tickets at Karaoke last night, right before the virus hit me - maybe I won because my voice was starting to go husky!😀
Anyway, I've got the engine mated up to the gearbox with the top two bolts in, so (hopefully) not too much can go wrong from here.....
Not trying to be a smart so and so, but dont forget the oil! Its been done before too. not by me I promise 🙂 although I have filled a car without the sump plug. Oh and I have been doing some plumbing, removed the S bend and poured the water down the sink. Best shut up before too much more embarrassment.
Chris.... kombi pilot, oval dreamer... finisher #26971 2005 city to surf
Craig Torrens6 times Australian, 7 times State Hillclimb Class Champion
