VWTypeI

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Contents

[edit] Type I - Beetle

[edit] History

In the 1930s automobile production was a low priority for the German People. The nation was in the middle of a depression of sorts, with high unemployment and rising currency inflation. During this time, Ferdinand Porsche had decided to leave 30 years of corporate work and strike out on his own (at 55), and run a company his way. They housed the new company in Stuttgart at 24 Kronenstrasse, and entered the official register on April 25th, 1931. The new company was called "Dr. Ing. h.c.F. Prosche G.m.b.H, Konstruktionsburo fur Motoren-, Fahrzeug-Luftfahrzeug- und Wasserfahrzeugbau" or "Doctor Engineer honoris causa F.Porsche, Incorporated, Design Office for Motors, Motor Vehicles, Aircraft and Ships".

The chief designer was Karl Rabe (who came from Austrian automaker Steyr). The body designer was Erwin Komenda, and 10 other engineers joined Prosche at this time.

Early on, Wanderer, a German auto-maker commissioned Porsche to design a small sedan... The Type 7. This became the Porsche Wanderer, named the W17/W20 series in 1932. Porsche stayed busy working on other designs for Wanderer and the like. Through it all, Porsche and Rabe nurtured the idea of designing an efficient small car that would put the common man on wheels. Design work began in September 1931.

A motorcycle company, Zundapp, was looking to get into automobiles, so they commissioned a design by Porsche. On the road by mid 1932, this Type 12 was the true forerunner of the Beetle, and it was dubbed the Volksauto - people's car.

Through several other commissions, Porsche was able to bring in some of his more original design ideas and flesh out his efficiency plans. (NSU Type 32) Through Jacob Werlin, Porsche's ideas were pitched to the new chancellor, Adolf Hitler. Hitler's schemes included huge public works, such as an unprecedented highway system, thus creating the autobahns. Corollary to this was Hitler's vision of a mass-produced, German-built, low-priced "people's car". Hitler was sold on Porsche's confidence in his designs, and awarded a state subsidy.

Porsche's goals for the Beetle were as follows:

  • It must be designed to be space-efficient and very durable, even if that meant developing new materials and production methods
  • It must be capable of 100kph (62mph), have the ability to climb hills, and average seven liters of fuel per 100km (~ 40mpg)
  • It should have an air-cooled engine for reliability in all climates, and be very cheap to repair
  • It must accommodate a family of two adults and three children and their luggage
  • Its basic platform should accommodate several uses, including transport vehicles

In 1934, Hitler addressed the Berlin Motor Show: "So long as the motorcar remains only a means of transportation for especially privileged circles, itis with bitter feelings that we see millions of honest, hard-working, and capable fellow men... cut off from the use of a vehicle which would be a special source of yet-unknown happiness to them..." Hitler saw the design for the Type 60 and decided to back it.

The Type 60 was a linear development of the NSU Type 32 project and except for some detail changes, the original Type 60 design was retained in the pre-production car. The Type 60 had a 98.5 inch wheelbase, a 47.3 inch track, and a dry weight of 1,435 punds. An air-cooled 985cc flat-four engine was mounted in the tail.

By 1935, using little more than rudimentary hand tools, the team had turned out two cars: The V1, a sedan, and the V2, a convertible. V was for "Versuch" - experimental.

In 1936, three V3 models were put through rigorous testing on the autobahns, the Black Forest, and the Alps, completing more than 465 miles each day. Problems aside, each car completed its mileage by the end of the year.

In 1937, the company moved producing the VW30 series. These still had no rear windows and suicide doors, until the VW38 series (of which 44 more prototypes were built).

It was time to name the new car. "Volkswagen" had actually been applied formally or informally to several earlier German small cars. The state felt something new was in order. The project was being managed by the recreational and leisure section of the DAF, whose motto was "Kraft durch Freude" (Strength through Joy). So KdF-Wagen it became. Those who scoffed at the odd name scoffed in private. Nobody was willing to tell Hitler it sounded silly. Most civilians simply continued to use Volkswagen, and especially its diminutive VW.

Adapted from Volkswagen Chronicle

[edit] Tuning Procedures

[edit] Useful Tools

  • Hydraulic Jack
  • Lug wrench
  • Flashlight
  • Large screwdriver
  • Screwdriver set
  • 3/8" metric socket set
  • Wrenches (7,9,10,11,13 (short and long), 14,17,19, and 21mm)
  • Pocket knife
  • Hammer
  • Test light
  • Fire Extinguisher
  • Dwell meter
  • Metric allen-head wrenches
  • Files
  • Vice Grips
  • Feeler gagues
  • Compression Tester
  • Wire Brush
  • Pliers
  • Tire Gague
  • Tie Wire (Baling Wire)
  • Small Mirror
  • 3ft of 14ga wire
  • Torque Wrench
  • Ratchet and Adapter
  • Magnet

Adapted from How To Keep Your Volkswagen Alive

[edit] Check List

(Click headings for in-depth procedures)

[edit] Valve Adjustment

  • Remove distributor cap, rotate engine to No. 1.
  • Remove the right valve cover making note of any leaks
  • Rotat engine to Top Dead Center
  • Adjust right front valves
  • Rotate engine 180 degrees counterclockwise
  • Adjust right rear valves, clean and replace valve cover and gasket if needed
  • Rotate engine 180 degrees counter clockwise, remove left valve cover, note leaks
  • Adjust left front valves.
  • Rotate engine 180 degrees counterclockwise
  • Adjust rear valves, clean and replace valve cover. Gasket?

[edit] Adjust Points

  • Remove rotor
  • Make sure the nylon rider is on top of the distribvutor lobe
  • Check with feeler gauge for proper gap
  • Check condition of points and other connections in the distributor
  • Loosen hold down screw, put feeler gauge between the contacts and adjust until the proper clearance is reached.
  • Tighten hold down screw
  • Connect Tach-Dwell meter. Red (+) lead to No 1 terminal of coil. Black to ground. Switch meter to 4 cylinder position. Start engine, note dwell. (approx 50 degrees). If the reading is too high, the points are too far closed

[edit] Timing

  • Check timing with static or strobe light
  • To change timing, loosen 10mm nut under distributor and...
  • Hook up static or strobe light. Set timing to proper mark

[edit] Check Vacuum Advance

  • Take off distributor cap, pull rotor
  • Pull hose from distributor to carburetor
  • Suck on the hose and watch the points plate - the whole plate should move

[edit] Change Oil

  • Remove 21mm drain plug or entire sump plate on newer models
  • Remove and clean screen and replace. Remember oil filter
  • Put in oil

[edit] Compression Check

  • Have engine at operating temperature
  • Remove spark plug connections then the spark plugs. Check spark plug color
  • Place tester in each hole while a friend turns the engine over six times with the key
  • They should all be over 100 and within 5lbs of each other

[edit] Spark Plugs

  • Gap .025" (.6mm)
  • Replate

[edit] Coil

  • Pull center wire from distributor cap and hold it 1/8" to 1/4" from a ground: bright blue to white, good. Yellow, OK. Orange, bad.


Adapted from How To Keep Your Volkswagen Alive

[edit] Maintenance Schedules

Every 250 miles (weekly) Every 3000 miles (3 months)
Every 6000 miles (6 months) Every 12000 miles (12 months)
Every 18000 miles (18 months) Every 24000 miles (24 months)
Every 30000 miles (30 months)

Adapted from VW Air-cooled engines Tune-Up and Maintenance Guide

[edit] Identification

[edit] VIN and Engine Numbers

Model YearStarting Chassis Serial No. (VIN)Starting Engine Serial No.
194872 7431-100 788
194991 9211-122 649
1950138 5541-169 913
1951220 1331-265 600
1952313 8291-379 470
1953428 1561-519 136
1954575 4151-0695282
1955781 8851-0945527
19561 020 7461-1120615
19571 394 1191-4595946
19581 600 4401-937450
19592 226 2062-721-313
19602 528 6683-072-320
19613 192 5075-000-001
19624 010 9955-958-948
19634 846 8366-935-204
19645 677 1197-893-119
1965115 000 0018-796-623
1966116 000 001F-0-000-001
1967117 000 001H-0-204-001
1968118 000 001H-0-204-001
1969119 000 001H-5-414-586
1970110 2000 001B-6-000-001
1971111 2000 001AE-0-005-901
1972112 2000 000AE-0-558-001 (USA) AE-0-000-001 (Calif.)
1973113 2000 001 113 2000 001 113 2212 117AH-0-005-901 (Calif.) AE-0-917-264 (USA) AK-0-000-001 (USA)
1974114 2000 001AK-0-239-365 (USA) AH-0-101-889 (Calif.)
1975115 2000 001AJ-0-000-001
1976116 2000 001AJ-0-012-406
1977117 2000 001AJ-0-095-936
1978118 2000 001AJ-0-119-688
1979159 2000 001AJ-0-200-000

From Y.B.D.B.

[edit] Engine ID Codes

Code Year Engine Size Remarks
4 60 1200 40 HP
5 61 1200 40 HP
6 62 1200 40 HP
7 63 1200 40 HP
8 64 1200 40 HP
9 65 1200 40 HP
FO 66 1300 8mm oil pump studs
HO/TO 67 1500 8mm oil pump studs
H5 68-69 1500 8mm oil pump studs
B6 70 1600 Dual Relief - single port
AE 71-72 1600 Dual Relief - Dual Port
AH 73-74 1600 8mm Head studs w/case savers
AJ 75 1600 Fuel injected, no fuel pump mount.

From Chirco Automotive

[edit] Year Approximation By Rear Window

Split Window

Split rear window. 2 triangular pieces of glass with a section of the roof dividing them vertically in the middle.

1938-1953

Oval Window

The center divider was removed and the triangular glass pieces were replaced by a single, oval shaped piece of glass to improve visibility

1953-1957

Small Window "earlies"

These years had a smaller rear window than later models but it was larger than oval windows and shaped more like a curved-cornered rectangle

1958-1964

Big Window

Same as small window, but the glass diameter was about an inch and a half larger all around.

1965-1972(?)

[edit] Troubleshooting

[edit] Dashboard Lights

[edit] Fuel System

[edit] Mechanical Engine Parts

[edit] Oil Consumption

[edit] Engine Noises

[edit] Fuel System

[edit] Carburetor

[edit] Overhauling a Solex Carburetor

[edit] Electrical

[edit] Chassis Wiring Diagrams

[edit] Battery

[edit] Cranking

[edit] Charging

[edit] Ignition

[edit] Clutch

[edit] Transmission

[edit] Rear Axle

[edit] Brakes

[edit] Suspension and Wheel Alignment

[edit] Specifications

[edit] General Engine Specifications

[edit] Valve Specifications

[edit] Engine Torque Specifications

[edit] Battery Specifications

[edit] Starter Specifications

[edit] Distributor Specifications

[edit] Wiring Diagrams

Vintage Bus' Very complete list of diagrams

[edit] Paint Color Codes

[edit] Modification

[edit] Looks

[edit] California Look

[edit] Resto-Cal

[edit] German Look

[edit] 6v to 12v Conversion

[edit] Bolt-on Horsepower

[edit] Ignition

[edit] Carburetion

[edit] Exhaust

[edit] Heads

[edit] Pistons and Cylinders

[edit] Crankshafts

[edit] Lubrication and Cooling

[edit] Valve Train

[edit] Blueprinting

[edit] Supercharging

[edit] Porsche Engines

[edit] Suspension

[edit] Wheels and Tires

[edit] Engine Recipes

[edit] Restoration

[edit] Body Work

[edit] Headliners

[edit] Engine Rebuilding

[edit] Is it Time to Rebuild?

[edit] Engine Removal

[edit] Teardown

[edit] Case Reconditioning

[edit] Head Reconditioning

[edit] Engine Assembly

[edit] Engine Installation

[edit] Engine Break-In

[edit] Manufacturers and Parts Suppliers

Note: These links are provided as a courtesy, no recommendation of any of these vendors is implied. Do your homework BEFORE you purchase.

[edit] Parts Suppliers, Transmission

[edit] Online Resources

[edit] Community Groups

[edit] Clubs

[edit] Message Boards / Forums

Note: Many online forums have excellent technical resources as well!!

[edit] Annual Shows

[edit] United States

[edit] Southwest

[edit] Arizona
  • Bugtoberfest. Tucson, AZ. Mid October annually archives from previous shows
  • Phoenix Bug-o-Rama, Phoenix, AZ. Late march or early April annually show information
  • Copperstate, Phoenix, AZ. Mid February annually
  • Karl's Custom Show and Shine, Mesa, AZ. Early November Annually
  • Volkswagens on the River, Yuma, AZ. Early November annually

[edit] Publications

[edit] Popular Books

[edit] Magazines

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