"How To....."

Maintenance Routine

(December 30, 2010)

“How to… Maintain your Bus?”

So how many owners use their buses for their daily driver duties? Even if they’re not used as daily transport, how many owners are too used to their modern daily driver maintenance periods of many thousand miles between service intervals?

And how many have bought that shiny new engine, gearbox or suspension and not given the OG initial recommended service routine another thought?

After changing major components or as part of a post restoration routine, these are the Volkswagen recommended initial checklist items & following service intervals.

 

Lubrication Periods:

Initial 300 mile Lubrication Service:

(1)               Engine: Drain when hot and renew oil. (Replace external oil filter if fitted, check external oil hoses)

(2)               Remove & clean OG oil strainer

(3)               Lubricate torsion arms

(4)               Lubricate king pins & torsion arm link pins

(5)               Lubricate track rod ends

(6)               Oil door hinges

(7)               Steering gear: Check oil level, top up if necessary

(8)               Lubricate brake cables

(9)               Lubricate pedal linkage

(10)             Oil carb’ linkage

(11)             Lubricate door & lid locks

(12)             Transmission case: Change oil, clean magnetic oil drain plug(s)

(13)             Reduction gear cases: Change oil

 

First 1,200 mile Lubrication Service:

(1)               Engine: Drain when hot and renew oil. (Replace external oil filter if fitted, check external oil hoses)

(2)               Remove & clean OG oil strainer

(3)               Lubricate torsion arms

(4)               Lubricate king pins & torsion arm link pins

(5)               Lubricate track rod ends

(6)               Oil door hinges

(7)               Transmission case: Check oil level, top up as necessary

(8)               Reduction gear cases: Change oil

 

First 2,400 mile Lubrication Service:

(1)               Engine: Drain when hot and renew oil. (Replace external oil filter if fitted, check external oil hoses)

(2)               Remove & clean OG oil strainer

(3)               Clean carb’ air cleaner. If aftermarket twin carb’s / throttle bodies, clean & re-oil filters

(4)               Lubricate torsion arms

(5)               Lubricate king pins & torsion arm link pins

(6)               Lubricate track rod ends

(7)               Oil door hinges

(8)               Steering gear: Check oil level, top up as necessary

(9)               Lubricate brake cables

(10)             Lubricate pedal linkages

(11)             Oil carb’ linkage

(12)             Lubricate door & lid locks

(13)             Transmission case: Check oil level, top up if necessary

 

Every 1,200 mile Lubrication Service:

(1)               Engine: Check oil level, top up as necessary

(2)               Lubricate torsion arms

(3)               Lubricate king pins & torsion arm link pins

(4)               Lubricate track rod ends

(5)               Oil door hinges

(6)               Transmission case: Check oil level, top up as necessary

 

Every 2,400 mile Lubrication Service:

(1)               Carry out 1,200 mile interval service 

(2)               Engine: Drain when hot, clean OG strainer and renew oil. (Replace external oil filter if fitted, check external oil hoses)

(3)               Clean OG carb’ air cleaner. If aftermarket twin carb’s / throttle bodies, clean & re-oil filters

(4)               Steering gear: Check oil level, top up as necessary

(5)               Lubricate brake cables

(6)               Lubricate pedal linkage

(7)               Oil carb’ linkage

(8)               Lubricate door & lid locks

 

Every 7,200 mile Lubrication Service:

(1)               Carry out 2,400 mile interval service 

(2)               Transmission case: Change oil, clean magnetic drain plug(s)

(3)               Reduction gear cases: Change oil

(4)               Lubricate felt in ignition distributor cam

 

Every 14,400 mile Lubrication Service:

(1)                Lubricate front wheel bearings

 

Maintenance Periods:

Initial 300 mile Maintenance Service:

(1)               Check adjustment of automatic air intake control, correct as necessary. If twin carb’s / throttle bodies check linkage operation

(2)               Check nuts & bolts on engine, exhaust & inlet manifold, carburettor & fuel pump. Tighten as necessary

(3)               Check tyre pressures & wheel mounting bolts

(4)               Check fan belt for tension, adjust as necessary

(5)               Clean OG fuel pump filter. Check aftermarket filter if fitted. Check fuel pipe & connections

(6)               Clean contact breaker points, check breaker arm fibre block for lubrication

(7)               Check contact breaker points gap & check ignition timing. Adjust as necessary with engine cold

(8)               Check valve clearances. Adjust as necessary with engine cold

(9)               Check engine & transmission for leaks

(10)             Check clutch pedal free play. Adjust as necessary

(11)             Check steering adjustment, correct as necessary

(12)             Check torsion arm link pins, front wheel bearing play, track rod ends, steering damper mounting & tracking. Tighten or adjust as necessary

(13)             Check brake system for leaks. Check fluid level. Check foot and handbrake operation, adjust as necessary

(14)             Check shock absorber mounts.

(15)             Check battery condition, (fluid level if not ‘maintenance free’), grease terminals

(16)             Check lights, horn, windscreen wipers & flashers. Correct as necessary

(17)             Check adjustment of door striker plates, adjust as necessary

(18)             Road test vehicle. Check idle speed, adjust as necessary

(19)             Check nuts & bolts on chassis, body, rear axle, front axle & steering, tighten as necessary

 

Every 3,000 mile Maintenance Service:

(1)               Check fan belt tension, adjust as necessary

(2)               Check throttle ring for proper contact to fan housing

(3)               Clean OG fuel pump filter. Check aftermarket filter if fitted. Check fuel pipe & connections

(4)               Lubricate felt ring in contact breaker base plate

(5)               Clean contact breaker points, check breaker arm fibre block for lubrication

(6)               Check contact breaker points gap & check ignition timing. Adjust as necessary with engine cold

(7)               Check valve clearances. Adjust as necessary with engine cold

(8)               Clean & check spark plugs, adjust as necessary. Check compression

(9)               Check engine & rear axle for leaks

(10)             Check intake & exhaust system for damage / leaks

(11)             Check clutch pedal free play, adjust as necessary

(12)             Check steering adjustment, correct as necessary

(13)             Check torsion arm link pins, front wheel bearing play, track rod ends, steering damper mounting & tracking. Tighten & adjust as necessary

(14)             Rotate wheels. Check for abnormal wear or damage. Check tyre pressures.

(15)             Check brake system for leaks. Check fluid level. Check foot & handbrake operation, adjust as necessary

(16)             Check thickness of brake linings

(17)             Check shock absorber mounts

(18)             Check battery condition, (fluid level if not ‘maintenance free’), grease terminals

(19)             Check lights, horn, windscreen wipers & flashers. Correct as necessary

(20)             Check adjustment of door striker plates, adjust as necessary

(21)             Road test vehicle. Check idle speed, adjust as necessary

 

Every 30,000 mile Maintenance Service:

(1)                     Carry out 3,000 mile maintenance service

(2)                     Clean, grease & adjust front wheel bearings

 

Every 2 Year Maintenance Service:

(1)               Replace brake fluid

 

Lubrication Chart.

Lubrication

Lubrication Point

Temperature Celsius (F)

SAE No.

Engine oil

Engine, Oil bath cleaner, Carb’ controls, door hinges & felt ring in distributor.

above +30C (+86 F)

zero C (+32) to +30C (+86 F)

below zero C (+32 F)

below –25 C (-13 F)

30

20 or 20W

10W

5W

Modern oil / modified engines

15w/40

Gear oil

Transmission case

above zero C (+32)

below zero C (+32)

90

80

Steering gear

 

90

Universal grease

Torsion arms, king pins, torsion arm link pins, tie rod ends, brake cables, pedal cluster bearing, gearshift lever, distributor fibre block, door & hood locks.

Low freezing and water repellent.

Lithium grease

Front wheel bearings.

Multi-purpose grease

 

Capacities.

 

Crankcase

3.12 litres

Oil bath oil cleaner

0.24 litre

Transmission

before chassis no. 218000001 

3.12 litres

after chassis no. 218000001

3.5 litres

Reduction gears

0.24 litre

Steering gear

0.24 litre

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