TECHNICAL VOLKSWAGEN MAGAZINE

Our webshop is full of technical information, with each part you get additional information about the applications, assembly instructions and so on. With this online publication we go a bit further, this will be your technical manual to work on your air-cooled Volkswagen. We discuss the technology of the VW Beetle, Karmann Ghia, VW Bus, the VW type 3 and type 4 and the VW Golf. You can read this magazine online, download it in PDF format and view it offline, or print it out.

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The latest technical articles for your classic VW

The technology of your Volkswagen by topic

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VW part numbering

VW part numbering

All Volkswagen parts are identified by a unique reference number. This VW reference is made up of 9 digits, to which sometimes a letter is added. Before 1956 Volkswagen used only 6 digits to number the parts, from 1956 on 9 digits are used.

adjust type 1 carburetor

adjust type 1 carburetor

The adjustment of the carburetor will determine the behavior of the engine. There are two types of carburetors for the type 1 engine when it comes to adjustment. The old generation (up to SOLEX 30 PICT-2) with two adjusting screws and the young generation with three adjusting screws (from SOLEX 30 PICT-3), recognizable by the large screw in the carburetor housing.

battery diagnosis

battery diagnosis

The battery supplies the entire electrical installation of your Volkswagen with power. Without the battery, the car could not be started. In this article we will talk about the diagnosis of the battery, we will estimate if your battery needs to be replaced.

engine types and codes

engine types and codes

The engine number indicates which type of engine is involved and with which engine capacity. The first letter(s) determine the capacity and type of engine and the following figures determine the year of manufacture. The engines up to and including July 31, 1965 had no letters for the engine number, which is why up to and including this year of manufacture only numbers are given.

basic electrical circuit diagram

basic electrical circuit diagram

An electrical problem is difficult to detect when you cannot distinguish the basic components. After a restoration, you will have to reconnect the electricity, step by step is the message. Let's try in this article to make the electrical circuit of our VW simple, all cars eventually use the same basic circuit diagram.

crankshaft types

crankshaft types

The heart of the engine is the crankshaft. Literally, everything revolves around this piece, we can compare it to the human backbone. The robustness and optimal performance of this component is therefore essential for a reliable engine, especially when the engine has to push a heavier VW Bus or when the engine has more horsepower than standard.

the lifting jack

the lifting jack

A lot of technical work on your classic Volkswagen can only be done when the car comes up from the ground. The jack that came with your VW, is mainly meant for an occasional job, for example changing a wheel.

mixture preheating

mixture preheating

The engine is stopped as a result of poor combustion. This bad combustion is often caused by a, at that moment, wrong composition of the fuel in the cylinders. Because of this bad combustion, the engine does not deliver the desired power and you can feel this in the form of stuttering of the engine.

6 volts and 12 volts

6 volts and 12 volts

Until the early 1970s, the VW Beetles were equipped with 6 volts in their 1200 cc version. The 1300 cc Beetle was first equipped with a 12 volt system in 1968. The VW Bus and type 3 VWs were increased to 12 volts in 1967. Types 4 are in 12 volts, as they were only introduced to the market in the late 1960s.

HPMX carburetors

HPMX carburetors

The most famous double carburettors are the Weber IDF and the Dellorto DRLA. Since a few years there is a new player on the market, namely the HPMX carburettor. This is marketed by EMPI and is also sold as a complete set, including manifolds, air filters, linkage and mounting material.

radio interference

radio interference

Have you ever driven a classic Volkswagen with an original radio or a classic radio, then you have probably ever known the phenomenon "interference". That annoying noise, buzzing, crackling that comes out of your speakers. These disturbances can have different causes, but they can also be remedied.

the valve clearance explained

the valve clearance explained

The valves of the VW boxer engine ensure that the petrol air mixture can be fed into the cylinders (through the inlet valves), and that after compression this mixture can be discharged through the exhaust (exhaust valves). An accurate adjustment of the valves is of utmost importance for the proper functioning of your engine.

setting valve clearance

setting valve clearance

The first technical work I ever did on my first Volkswagen Beetle was to set the valves. I didn't know much about the technology of the VW Beetle at the time, but I dared to do it, valve setting is easy to do yourself, you don't need many tools, and it's essential for the proper functioning of your classic.

fuses

fuses

Our oldest classic Volkswagen had a fuse box with four fuses, after that this was extended to eight. The most recent VW T25/T3 (Vanagon) Bus has more than twenty fuses. But what is the purpose of these fuses?

hydraulic brakes

hydraulic brakes

Hydraulic braking systems are available in single and double braking systems. Below we show a double braking system, the master cylinder operates two separate brake lines, fed by two separate lines coming from the brake fluid reservoir.

the clutch: basic concept

the clutch: basic concept

For a long time I wondered how the clutch in our Volkswagen Fastback worked, I was only six years old. I didn't understand very well that by releasing a pedal our VW started to drive spontaneously. Well, if you understand how disc brakes work, then the step to understanding how the clutch mechanism works is not far.

finding the top dead center

finding the top dead center

What does Top Dead Center (TDC) actually mean? If you study the theory of the operation of an internal combustion engine - or the "petrol engine" - it will become clear. Without going into too much detail about the theory, we have to talk about the otto cycle, better known as the four stroke cycle.

mesuring the compression

mesuring the compression

How can you determine very objectively how much wear the engine has? An indication of the wear level can be obtained by performing a compression measurement, the engine compression determines the power of your VW. Anyone can perform a compression measurement on an air-cooled or water-cooled VW.

oil leakage

oil leakage

If you are planning to buy a classic Volkswagen, you will certainly take a look under the engine lid and under the car. If it's dirty both at the bottom and under the bonnet, it doesn't offer much trust. The engine will need a lot of attention in the coming weeks, but how bad is it?

(dis)assembly of the spark plugs

(dis)assembly of the spark plugs

It seems like a simple job, replacing or checking the spark plugs of your VW. Yet we see that it is not always done according to the rules. Spark plugs that are not properly assembled or have been disassembled carelessly can cause a lot of problems with the engine.

cylinder head specifications

cylinder head specifications

One of the most heavily loaded parts in the air-cooled VW engine is undoubtedly the cylinder head. Especially the valves, valve guides and valve seats have to endure a lot because of the high temperatures, the temperature differences and the mechanical load in an air-cooled engine.

testing the coil

testing the coil

You can easily check if the electrical voltage in the primary circuit of the coil is correct by using a multimeter. High voltage measurement at the secondary circuit cannot be performed with a standard multimeter.

oil consumption

oil consumption

Oil leaks are easy to rectify, sometimes even without having to remove the motor. We have saved the more difficult cases for this article, so we did not call this "oil leaks part 2" but "oil consumption". The distinction between the two is sometimes difficult to make, hopefully the information that follows will bring clarity.

the VW suspension

the VW suspension

Ferdinand Porsche came up with an ingenious concept at the beginning of the last century. A car that was built on the basis of a steel chassis plate with an independent and self-supporting body. Most of the cars from that period were built around a tubular chassis, so the Volkswagen Beetle (then still a Kdf-car) was revolutionary.

exhaust: principle and types

exhaust: principle and types

At first glance, a car's exhaust system may not appear to be a component that uses high technology. Yet the final design is the result of many years of scientific research. The exhaust system performs various functions.

replace a thread

replace a thread

When you are working on your VW, you will encounter this problem at some point; a bolt of the crankcase cover doesn't really turn in the thread in the crankcase anymore. The more you try, the worse it gets. There is too little tension between the crankcase cover and crankcase, with oil leakage as a result.

replacing the clutch

replacing the clutch

The clutch is an important mechanical part of your classic Volkswagen. The complete system with clutch plate, pressure group, thrust bearing, flywheel, pilot shaft and clutch pedal must be in good condition and properly adjusted. In Paruzzi Magazine edition 06 we have explained the principle and parts of the clutch system.

the distributor

the distributor

The intention is that we can adjust the ignition of our classic Volkswagen ourselves. First you have to know which parts have an influence on the operation of the ignition and you have to understand how the ignition circuit works, this is very important to be able to make a good diagnosis and to be able to adjust the ignition later on.

air filter preheating

air filter preheating

It seems to be a natural part of your air-cooled engine, but the air filter plays a crucial role, it's like breathing in a human being. The carburettor is tasked with mixing petrol with air to deliver a flammable mixture. Petrol alone is not a good fuel. That requires oxygen and not just a little bit of it.

crankshaft end play

crankshaft end play

Whether an oil leak is caused by a defective crankshaft seal or O-ring/packaging is not always easy to determine. At the bottom of the engine, near the flywheel, where the gearbox and the engine are connected to each other, you will see traces of engine oil.

measure crankshaft end play

measure crankshaft end play

The play is caused by wear of the engine, this is actually very normal, and will occur faster with performance engines. With normal use of standard VW engines in combination with a good maintenance of the engine, wear will not occur quickly.

vacuum advance

vacuum advance

Both the vacuum advance and the mechanical advance were used for the VW Beetle, Karmann Ghia, VW Bus, VW Thing, type 3 and type 4. You can't stick a year of manufacture or type of engine on it, both systems do the same thing in the end, they bring forward the ignition time depending on the engine speed.

air filter thermostat

air filter thermostat

The preheating of the fresh air supplied via the air filter to the carburettor is a part of our VW engine that gets too little attention. This system will ensure that in all weather conditions the carburettor is supplied with air at the right temperature. With these younger air filter models you don't have to adjust anything in contrast to the older models.

drum brakes

drum brakes

Almost all classic VWs are equipped with drum brakes at the rear and front, a number of models such as Type 3, Type 4, Beetle 1300S, 1302 and 1303 and Bay Window Bus were first fitted as an option and then standard with disc brakes at the front. Of course, you can convert any drum brake into a disc brake if you wish.

oil seals

oil seals

All rotating parts fitted with bearings lubricated by oil or grease, such as crankshafts, transmission shafts, drive shafts, steering rods, etc., must be sealed. In our classic VW's we find two types of oil seals, namely the static and the dynamic (lip seal) oil seals.

replacing ignition points

replacing ignition points

We will discuss how to adjust the gap between the contact points, also known as the contact angle or Dwell angle. Instead of just discussing the adjustment of the contact points, we will replace them with new ones.

checking the Dwell angle

checking the Dwell angle

There are several devices available to dynamically measure the Dwell Angle. These are usually combined devices that measure battery voltage, Dwell Angle and advance. Others can also be used to measure the CO content of exhaust gases.

Type 1 engine mount

Type 1 engine mount

In this article we show how to mount the engine of a VW Beetle or Karmann Ghia, so it becomes clear what to look out for when you mount the engine and build it back in.

crankshaft seal replacement

crankshaft seal replacement

If you find that the crankshaft clearance is outside the factory specifications, replacing the crankshaft seal will not be a solution for the oil leak you have identified. If the crankshaft clearance is less than 0.30 mm, it makes sense to replace the oil seal, otherwise a total engine overhaul is the only worthwhile option.

underneath the VW 1200

underneath the VW 1200

When I bought my first Volkswagen Beetle convertible, I had a lot of problems starting. On a hotel parking lot the starter motor failed, I had heard that you had to knock on the starter motor to release it, but I had no idea where it was. Is this a familiar situation for you? Then this article is exactly what you need.

remove a threaded stud

remove a threaded stud

While working on old-timers, you may come across a situation where you think "how can I solve that?". In my case, I was looking for a solution to loosen a stuck threaded rod, without damaging it.

ignition timing - static

ignition timing - static

In air-cooled Volkswagens from August 1970, the notch in the crankshaft pulley is used to dynamically adjust the ignition timing. The static adjustment with the test lamp is then only suitable for temporary adjustment on younger models.

underneath the VW 1303

underneath the VW 1303

We are going to study the "more modern" VW that in the early seventies had to compete with brands like Opel and Ford but also with the Japanese brands like Datsun and Toyota. VW introduced new technologies to revitalise the obsolete Beetle concept before the water-cooled VW Golf was ready for production.

fuel circuit - concept

fuel circuit - concept

The combustion engine of our air-cooled Volkswagen uses a mixture of petrol and air. It is extremely important that both the amount of air and the purity of the air are regulated, this also applies to the petrol. Unfortunately, the petrol circuit is not very well known to enthusiasts and it is not always well maintained.

ignition timing - dynamic

ignition timing - dynamic

In this edition, we will adjust the ignition with the engine running, this is called a dynamic measurement. VW advises in its workshop manuals this way of adjusting all air-cooled VWs from August 1970 onwards. The static adjustment with a test bulb is then only suitable for a temporary engine adjustment on these young Volkswagens.

removing the engine

removing the engine

The air-cooled Volkswagen is an ingenious design, but not all work can be done with built-in engine, unfortunately. Sometimes it is also much more comfortable to work with the engine on the workbench hanging from an engine mount.

spark plug heat range

spark plug heat range

The construction of the part of the spark plug that is screwed into the cylinder head determines the degree of heat. The spark plugs are screwed into the cylinder head, which is the warmest spot of the engine. Temperatures can be as high as 1000°C. The electrode part of the spark plug extends into the combustion chamber of the cylinder head.

independent suspension

independent suspension

Fixed one-piece front axles with leaf springs or torsion springs as on the VW Beetle, were widely used until the end of the sixties. Due to the demand for more comfort, better steering and by driving longer distances, the independent front suspension became more and more popular on luxury cars.

spark plug codes

spark plug codes

Spark plug manufacturers use different codes to identify their spark plugs. It can be very confusing if you are not familiar with their own brand names. At the end of this article, we summarize again the coding structure, so that everything becomes crystal clear.

DC versus AC

DC versus AC

A car needs a direct voltage of 12 V or 6 V to operate, a battery can only be charged by direct current. The alternator and dynamo generate alternating current. But what is the difference between AC and DC?

removing the MacPherson

removing the MacPherson

Sometimes it will be necessary to disassemble the MacPherson. It is located at the front on younger Volkswagen models such as the VW Beetles 1302 and 1303 and the VW Vanagon and at the front and rear on the VW Golf and VW 411/412. We will show how it works on a VW 1303, repair the bearings and install.

wheel play adjustment

wheel play adjustment

The front and rear axles of your VW are mechanical parts that have to withstand a lot of forces. They are designed to withstand the full weight of the car, but they are also designed to absorb the forces that occur during acceleration and braking, which are several times greater than the weight of the car.

the condenser explained

the condenser explained

The condenser is the most misunderstood part of the motor. What is inside that metal cylindrical part? So, what does this part actually do? Is it really necessary for the proper functioning of the engine? In this article we will limit ourselves to explaining what a capacitor is and what it does, and to measuring and testing the condenser.

installing the engine

installing the engine

In edition 16 we explained how to remove the engine of a VW Beetle, two techniques were discussed. The most important points of attention for the installation of the engine are indicated in this article. During the installation of the engine you will have to position the pilot shaft of the gearbox perfectly opposite the centre of the clutch.

axle play with dial gauge

axle play with dial gauge

The wheel play of the front wheel axles must be accurately adjusted. It can be done by feeling, but what if you don't have that experience. If you don't trust your gut feeling, or you are more of the type that wants to measure everything accurately, then adjusting the wheel play with a dial gauge is something you will appreciate.

using the dial gauge

using the dial gauge

A dial indicator is part of the basic equipment of the professional mechanic. As an enthusiast of automotive technology, you will soon need such a precision measuring tool. For example, to measure the axial crankshaft play, to measure the straightness of the disc brakes, the front wheel play, or during the overhaul of the engine. We explain how to use a dial indicator.

measuring the coil

measuring the coil

Everyone knows that the capacitor will protect the contact points from burn-in. But what few people know is that the capacitor also plays a very important role in transforming the low voltage of the battery (6V or 12V) into a high voltage (more than 10,000V) needed to create a spark between the electrodes of the spark plug.

type 1 sump plate

type 1 sump plate

Replacing the crankcase oil of a Type 1 engine is a job every VW enthusiast has done once in a while. It involves loosening a few nuts, replacing gaskets and tightening everything again, right? It seems a simple operation, but nothing could be further from the truth.

bearings replacement

bearings replacement

When you like to repair and replace everything on your classic Volkswagen yourself, there will come a time when you will have to replace damaged bearings? Bearings are used in the steering unit, suspension, wheel axles, dynamo or alternator, among other things.

testing the condenser

testing the condenser

Without the condenser, the ignition will really not work properly and the contacts will burn in quickly. So it is important to measure at regular intervals if the condenser in your VW motor is still working.

crimp terminals

crimp terminals

Replacing the complete wiring loom seems the most obvious solution. We have them all in stock for every type of VW. But this is a very drastic job that you will probably only do when a total restoration is at hand. And, is it really always necessary?

front wheel bearing replacement

front wheel bearing replacement

If the wheel bearings are worn or damaged, there is no point in adjusting the wheel play. You will first have to replace the wheel bearings to get a good result. In edition 18 we tuned the wheel play of the front wheels to the feel, in edition 19 we fine-tuned the wheel play by using a measuring clock. In edition 21, we are replacing the front wheel bearings.

sump plate stud length

sump plate stud length

How many VW enthusiasts are surprised that the engine leaks after an oil change? Read all about the type 1 sump plate in edition 20, what to look out for, how to attach it and with which tools. In this edition we will determine the maximum length of the sump plate studs, to prevent oil leaks.

replacing the sump plate studs

replacing the sump plate studs

If the studs are not tightened properly, it is practically impossible to tighten the crankcase sump plate to compress the paper gaskets. The infamous engine oil leak is the result, and no, it is not normal for an air-cooled VW to leak! A leaking engine will be rejected at the mandatory technical inspection.

replacing spade connectors

replacing spade connectors

A messy electrical connection will soon lead to the failure of electrical accessories or, in the worst case, the engine. Incorrect connections can also result in short-circuits, causing the wiring harness to burn out. Enough reasons to master a good technique to make the electrical connections of your VW neat and tidy.

replacing brake drums

replacing brake drums

Not all brake parts have to be replaced every time you change the brake shoe. But usually we have to deal with under-maintained oldtimers, cars that have been stationary for too long or classic cars with no service history. It is then advisable to replace all mechanical parts.

voltage drops

voltage drops

The electric consumers of your classic Volkswagen expect the full 6 volts or 12 volts (or more) to function properly, which is unfortunately not always the case. Especially the 6 volt version sometimes complains about slow running windscreen wipers, weak headlights and direction indicators that pinch too slowly.

brake disassembly

brake disassembly

We will replace the drum brakes at the rear of a Volkswagen 1303 convertible. If you want to do this for another type of VW, the procedure is quite similar. We replaced the brake backing plate, the wheel brake cylinder, the brake shoes and the springs.

swing axle and IRS

swing axle and IRS

In edition 08 we gave a short introduction about the suspension of our old Volkswagens. We made an abstraction of the two types of drive shafts that Volkswagen used on all air-cooled models, especially the old swing axle and the modern IRS (independent rear suspension).

installing rear brakes

installing rear brakes

In issue 23, we removed the rear brakes from our VW 1303. All classic Volkswagens were equipped with drum brakes in the rear, the procedure for other models is quite similar. If you used the previous edition to replace the rear brakes on your VW, you should be able to continue your work with this article.

determine cable diameter

determine cable diameter

The older your Volkswagen the more likely it is that the electrical consumers no longer get the full 6 volts or 12 volts due to voltage losses between the battery and the consumer. A voltage drop across the electrical conductor is inevitable, we are dealing with copper and we cannot make the cross section of the cable infinitely large.

metric bolts

metric bolts

According to Wikipedia, a bolt is a round rod of metal or other material to which threads have been applied and which has a head. When combined with a nut, it is a means of connecting two or more objects. When the head has a slot, a cross, an Allen ... then one speaks of a screw.

brake fluid replacement

brake fluid replacement

After you have disconnected the brake hoses of a hydraulic brake system, to replace the wheel brake cylinders, master cylinder or calipers, for example, you will need to bleed the brake circuit, that goes without saying.

crankshaft pulley removal

crankshaft pulley removal

Removing the crankshaft pulley on an engine that has run 100,000 km and more is best not done with just a hammer and brute force. You would prefer to reuse the original crankshaft pulley on your engine, were it not for the budget, also for the factory originality.

camber and King Pin

camber and King Pin

The most visually striking of all wheel geometry settings, is wheel camber. We also discuss the King Pin Inclination and the Scrub radius in this article.

Caster and Toe

Caster and Toe

In the previous edition, we explained what Camber and King Pin Inclination (KPI) are. An important consequence of KPI is the Scrub Radius, which is the friction radius of the front wheels. In addition to Camber and KPI, there are other important parameters, such as Caster angle and Toe.

brake circuit bleeding

brake circuit bleeding

Of course, flushing the brake fluid is not always necessary. If you have disconnected a brake hose or line, or you have disassembled a brake cylinder or caliper, then bleeding part of the brake circuit is sufficient. This saves brake fluid and it's done faster than complete flushing.

dynamo operating principal

dynamo operating principal

Wouldn`t it be nice to know what DF means, for example? And what does D+ mean? If you know what`s behind these letters and numbers, then connecting the dynamo will be a breeze. In this article, we will explain the working principle of the dynamo, also known as a direct current generator.

alternator operating principle

alternator operating principle

The direct current dynamo greatest asset turned out to be its greatest limitation, the collector. Supplying more current would shorten the life of the carbon brushes; something had to be found for that. So the dynamo no longer sufficed for the new situation of the mid-sixties.

measuring electric current

measuring electric current

To measure current, you must interrupt the circuit through which the current flows. The ammeter must be connected in series. Therefore, that a current clamp is a better solution. This type of ammeter does not affect the circuit to be measured, it measures the magnetic field around the conductor (induction principle, see edition 26).

measuring front wheel geometry

measuring front wheel geometry

In this edition, we will explain how to measure front axle wheel geometry, and what the values are for each type of classic VW. Camber Angle, Toe and Caster are discussed in this edition. Measuring the rear axle is covered in edition 28, and in edition 29 we will show how to adjust front and rear axle wheel geometry.

measuring rear wheel geometry

measuring rear wheel geometry

In the previous edition of this series, we measured the wheel geometry of the front axle. In this edition, we will measure the wheel geometry of the rear axle. The adjustment of both front and rear axles will follow in the next edition.

oil pressure gauge

oil pressure gauge

After an engine rebuild, when you start the engine for the first time, and when you start driving, you need to keep a close eye on a number of engine parameters. The most important are oil pressure, engine oil temperature and cylinder head temperature.

replace dynamo bearings

replace dynamo bearings

Dynamo bearings last a very long time, but they are wear parts. Wear will be promoted by an over-tightened dynamo pulley. A dynamo has two sealed ball bearings. These are bearings that do not require grease, but are factory ready to mount