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 TorxKiwi
A.k.a.: Dean Newell
Officially Full-On Dubber
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 posted on November 26th, 2011 at 08:19 PM |
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The List
OK, so 'Sonny' went in for a roadworthy, not that I was expecting him to pass on the first attempt but it was the easiest way to create a priority
list, even if it was a bit expensive. So here's the list-
1. 3 Tyres - No surprises, I expected this.
2. Brake hoses on the front- I'll order a set of the stainless braided ones and replace the lot.
3. Sway bar mount rubbers need replacing - Looks like a quick fix, will order and fit.
4. Wheel cylinders - both leaking in the back, have replacements on the way, will fit when they get here.
5. Horn to work - works most of the time, assume it's just a contact issue, will clean.
6. Secure back of drivers seat - Previous owner had a well placed self tapping screw to keep frame secured. Will need to have a good look at this,
have no idea what it should look like but sure I can figure it out. Replaced the plastic slides on the rear rails today so at least I don't end up on
the other side of the car when cornering any more!
7. Reverse lights - Not working and can't figure out where the switch is located, probably under the inch of scum that is on the underside; to be
cleaned tomorrow. Tail light assemblies need replacing, not sure how these got through anyway!
8. Secure air filter - Done
9. Secure L/H door trim - Done
10. Clear engine oil leaks - Where to start?
11. Stop engine smoke - The guys a comedian. 'Sonny' gives one big puff of smoke on starting then bugger all? Recommendations?
12. Tune to idle - I think 'Sonny' is an asthmatic. I replaced a couple of missing hoses today and it's almost like he is running out of air. If I
open the oil filler cap he is happy; bit of a puffing billy out of the oil filler though. The air filter element is a bit cruddy so I've just taken
that out until I can get a replacement. He needs a tune up, just need to read up on the process and get onto it.
13. There is a small rust hole in the left right floor pan, under the seat. Bit unusual in that it's the opposite side to the battery. Do I buy a
replacement panel or just get a panel beater to patch it?
'Sonny' didn't get a great deal of love from his previous owner. Last nights oil change was a dead giveaway. Have adjusted valves today also. I
have a mystery 'loose bit' on the carb, about to read up to try and figure out where it should be attached. I'll try and put up photos. I'm also
not thrilled that the fuel filter is in the engine bay, is this normal? Finally, for now, and I thought this was THE rule, oil light out of action,
bulb is fine, switch looks dodgy so I'll change this anyway and will hopefully resolve. Hopefully VW karma will be in force and I will be rewarded
for showing the love.
Now to get to work on this list.
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"Ownership of a Beetle is not a destination it is a journey." |
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68AutoBug
A.k.a.: Lee Noonan
Aircooled Master
Beetle Restorer - Experience over 138% - YIKES --
Posts: 11654
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 posted on November 27th, 2011 at 12:10 AM |
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YIKES...
when I take My cars to get tested...
I am quite upset if anything is NOT as it should be...
What model car is it ???
tyres...??
before taking Your car to be tested again... spray all the engine top and bottom with spray can of foaming degreaser
about $3 at the cheap shops... wait 3 minutes and hose all the degreaser and oil off... it should look like new...
if it doesn't... do it again....
I do mine every few weeks if I have an oil leak...
that piece in the pic looks like a linkage off the carburetor...
on that side of the carby it could only be the accelerator pump lever... [from memory]
Reverse lamps.. beetles didn't have them until 1972 but most modern mechanics will think all cars had them...
OIL SENDER - Very cheap part.. replace.. even replace if it leaks..
the engine needs to breath... as You say when the cap is off it can breath...
there should be a pipe and hose near the cap...
pipe goes under the car... hose goes to oil filter...
if either of those is blocked.... oil will be pumped out of around the crankshaft pulley... or even dipstick... hole..
sounds like Your engine needs a bit of work..
smoke when starting means oil is leaking past the piston rings
or down the valve stems... when the engine is sitting...
LEE
My engine has a different carburetor and has many other bits and hoses for the semi automatic transmission.. LEE
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- [size=4]Helping keep Air Cooled VWs on the road - location: SCONE in the Upper Hunter Valley - Northern NSW 320 kms NNW of SYDNEY--- [/size]
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TorxKiwi
A.k.a.: Dean Newell
Officially Full-On Dubber
Posts: 231
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Registered: June 12th, 2011
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Location: Torquay, Victoria
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| posted on November 27th, 2011 at 05:35 AM |
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Cheers Lee
Car is a 1975 L. I've been in possession for a little over a week so trying to get on top of some serious neglect. The car is generally tidy just
neglected mechanically. I think the rings are essentially shot so anticipate a rebuild at some point in the not too distant future but want to get it
running as well as it can while I figure out what approach I take ....... Buy a second hand motor, buy a reconditioned motor, buy a temporary motor
and then work on mine with a rebuild kit or buy a new motor out of the US.
1. I wasn't sure if I could unleash a pressure washer in the engine bay.
2. Given the age of the car I expect it will have reverse lights, just not sure of the approach to take in tracking the problem.
3. Hose from air cleaner to under car is there and it's new; I put it on yesterday.
4.Tyres, just old, cracks appearing on walls.
Is it worth sending him in for a major tune up if the rings are shot or should I just keep plugging away at it myself? I don't have a major
mechanical background but am quite capable and have the trusty How to Keep My VW Alive and Bentley manuals as trusty assistants.
Dean
"Ownership of a Beetle is not a destination it is a journey." |
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TorxKiwi
A.k.a.: Dean Newell
Officially Full-On Dubber
Posts: 231
Threads: 38
Registered: June 12th, 2011
Member Is Offline
Location: Torquay, Victoria
Theme: UltimaBB Pro Blue ( Default )
Mood: "It's not easy being green"
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| posted on November 27th, 2011 at 05:52 AM |
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I'm pretty sure my 'mystery bit' is the connecting rod ..... Just can't figure out what exactly it connects to. It does have a handy bit of wire
wrapped around it; I assume replacing the retaining clip. That clearly worked.
"Ownership of a Beetle is not a destination it is a journey." |
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Aussie Dubbin
Fahrvergnugen
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| posted on November 27th, 2011 at 06:53 AM |
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The reverse switch is positively fed. It is located at the top front drivers side of the gear box. You would want to replace gear box oil too. I would
just clean the switch while it is out and might not have to do anything else. I think that ATM in the pic is meant to head up the back side of the
carb near the generator.
Oil leaks are probably. Rear main have to take engine out to do this. Pushrods seals have to take heads off. Gearbox input shaft do while engine is
out and lastly probably oil dean plate. If you are not taking engine out use the degreasing spray I find it works better when engine is a little hot
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beetleboyjeff
A.k.a.: Jeff Walsh
Custom Title Time!
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| posted on November 27th, 2011 at 10:11 AM |
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The reversing lights are powered by a wire from the coil, across the engine (where there is a ceramic fuse in a holder) and through the tinware behind
the engine on the drivers side and to the front of the gearbox.
Check the connection of the wires, and the fuse would be a good start.
From your ole' mate Jeff
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68AutoBug
A.k.a.: Lee Noonan
Aircooled Master
Beetle Restorer - Experience over 138% - YIKES --
Posts: 11654
Threads: 449
Registered: August 31st, 2002
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Location: SCONE in UPPER HUNTER VALLEY NSW
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Mood: Really Mentally Ill - all of the time -
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 posted on November 27th, 2011 at 10:25 AM |
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on some carburetors the end of the wire linkage is crimped a certain way, so You have to insert the wire into the hole in the carby lever.. while You
have the carby apart... and once its assembled, it cannot come off the lever...
some used very small e type circlips...
after spraying FOAMING degreaser on any grease and oil and let it settle for 3 minutes... then hit it with high pressure water hose.. any really
thick hard stuff will need to be scraped off first
When spraying degreaser in the engine bay..
I don't spray the carburetor , disrtibutor or air cleaner...
all over below the distributor...
I wouldn't pay good money for a tune up if the engine is badly worn... it doesn't take much to tune a Beetle engine if You follow the
manuals...
Fuel filter shouldn't be in the engine compartment..
that is why so many VWs burn...
below fuel tank or above LH side rear wheel where the pipe comes out of the chassis...
any more pics of the engine appreciated... distributor etc..
LEE
- [size=4]Helping keep Air Cooled VWs on the road - location: SCONE in the Upper Hunter Valley - Northern NSW 320 kms NNW of SYDNEY--- [/size]
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 helbus
A.k.a.: Pete S
Super Administrator
Mad fabricator, paint and body
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| posted on November 27th, 2011 at 06:52 PM |
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First thing is to get any fuel filters out of your engine bay.
They are a cause of fires that burn Beetles to the ground, so if you dont have one in the engine bay, then it cannot happen.
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TorxKiwi
A.k.a.: Dean Newell
Officially Full-On Dubber
Posts: 231
Threads: 38
Registered: June 12th, 2011
Member Is Offline
Location: Torquay, Victoria
Theme: UltimaBB Pro Blue ( Default )
Mood: "It's not easy being green"
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| posted on November 27th, 2011 at 07:07 PM |
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Thanks guys, it's great having such easy access to the collective mind of the 'VW Nation' in Australia.
Two cans of degreaser later and I can see a hell of a lot more hardware than I could before! Engine bay wasn't too bad but under the car is a work in
progress, beats me how you get half an inch of scum there and do nothing to clear it.
In amongst it I found the switch for the reversing lights on the front of the gearbox, removed cleaned and replaced the connections, getting them back
on was fun with fat fingers, but still no success. I'll trace the wiring and see what other delights previous owners have left for me.
Got a bit on this week with work, but I'll keep you updated on progress.
Heading up to Melbourne for work tomorrow, any recommended parts suppliers up there? Aside from the shopping list I already had I now need a new tail
light assembly ... knocked it when washing the engine bay and discovered that the single screw that was holding it wasn't up to the job 
"Ownership of a Beetle is not a destination it is a journey." |
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TorxKiwi
A.k.a.: Dean Newell
Officially Full-On Dubber
Posts: 231
Threads: 38
Registered: June 12th, 2011
Member Is Offline
Location: Torquay, Victoria
Theme: UltimaBB Pro Blue ( Default )
Mood: "It's not easy being green"
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| posted on November 30th, 2011 at 08:55 PM |
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Progress
Have been shopping and rapidly collecting parts, just need time to hide away in the garage ......
New brake hoses are here, not yet on.
Sway bar mount rubbers replaced.
New brake wheel cylinders are here, not yet on.
Horn fixed, crap on the contacts, all good.
Reverse lights still not resolved, I have a horrible feeling that these and the oil pressure light are going to be a related issue and require me
rapidly progressing my automotive electrical skills. I replaced the oil pressure sender and this didn't magically fix my problem. I've since found a
couple of 'terminated' (read cut) wires under the back seat, that judging by the colours are the cause of both issues. A mate is bringing a meter
around to try and confirm my fears. God knows what my next step will be. What guage wire should I be using to run replacements?
New distributor and cables here, not yet on.
Tail light assemblies, carb rebuild kit, fuel line and filter, new air filter, generator brushes all either here or in transit.
Work space much cleaner now, degreaser is my friend!,
Rust hole and tyres yet to do, I'll get 'Sonny' ticking over happily before I move on to the on road issues.
Moving house this weekend so I'm banned from the garage for anything other than placing or removing a carton. Might pull a couple of late nights next
week to get on top of 'The List'.
Compliments to the team at Vollks, have had two orders arrive in amazingly quick time and prices are great. I'd like to support local businesses but
it's hard to justify when online prices offer savings of anywhere up to or exceeding 50%.
"Ownership of a Beetle is not a destination it is a journey." |
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TorxKiwi
A.k.a.: Dean Newell
Officially Full-On Dubber
Posts: 231
Threads: 38
Registered: June 12th, 2011
Member Is Offline
Location: Torquay, Victoria
Theme: UltimaBB Pro Blue ( Default )
Mood: "It's not easy being green"
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| posted on April 23rd, 2012 at 10:20 PM |
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Done.
'Sonny' is officially roadworthy, almost five months, a top end rebuild and hours of frustration sweat and a few tears and tantrums later and it's
done. Been a great experience to date, wouldn't swap it for quids. my wife reckons I won't have to spend every spare minute in the shed or on the
forum now ....... Gotta love a comedian.
With the essentials taken care of I think I'm going to lower him a bit now, make him sleeker and more manly, rather than like a rearing praying
mantis!!! All I need now is for George at Classic Veedub to answer the phone, been trying to get him since last Monday ..... Could be another five
months.
"Ownership of a Beetle is not a destination it is a journey." |
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