Aircooled VW South Africa

Original early baywindow Westfalia owner's manual with SO67R layout:
http://www.thesamba.com/vw/archives/man ... rm_eng.php

Full manul in pdf:
http://www.thesamba.com/vw/archives/man ... rm_eng.pdf

Thank you Christian,
Found those yesterday and downloaded them as well thanks.
Also looked a bit more closely under the seats and you are correct about the 1/3; 2/3 seats. There is a molding for a spare although I have not figured out how to get the spare in there.
I think I will try fit two single seats up front and keep the space between for packing and camera storage etc.
But time will tell.

Got my tank cap and ignition switch back working like a charm.
I replaced the contact switch and that gave it the proper spring return again. Two things crossed off my list.

Next I must find the cubby liner and seats. and after that the rubber mats.

Did you fix the original ignition switch or is it one that is built into the dash. If its the original, where did you get it from, I also need to repair mine?

Try Henry at Berg Motors, I lent him a cubby hole box, he was making glass-fibre options, they looked good 071828201four (he is in Belville, Western Cape)

Hi Jolas, it is the original. It was very notchy and that probably why they installed the button on the dash. the locksmith made a new key, which I must say looks quite different to the original but now the key is solid in the lock and turns like new. The start action was still marginal but after fitting the replacement electrical part everything works like new. Have not yet reconnected but it will work.
Will give Henry a call, thanks for that heads up.

Can you perhaps take a pic of the replacement electrical part, where did you source it from ? Thanks man

Hi Jolas, sorry for the late reply.
The switch is already installed, but here is a picture as it appears on the Volksspares website.

http://www.volkspares.co.za/shop/item/i ... -metal_840

Today I removed all the extra gauges and more wiring. Removed the instruments and just cleaned them and tested the globes. What a difference already.

So after the electrics are sorted I had to tackle the brakes. Battled a bit to get the 46 Axle nuts loose but with proper tools it's sorted.
On the one wheel I found that oil was leaking from the axle tube. The seal was a bit bulged which was suspect. After I removed the seal I could see that the plastic cage from the bearing was damaged and the rollers all on one side. This explains why the wheel was locked when I bought the vehicle. I somehow got it moving but am now glad I found the cause.
Anyone have the numbers for the bearings and seals?
I will also need new brake pads and possibly drums. Apparently I have to take the brakes to Norbrake for repair?

So now I am looking for:
1. two single seats
2. Fuse holder (yellow or equivalent)
3. bearings and seals for rear axle


And I need some advice.
Currently a Toyota 2l 3Y motor is installed. I would like to go aircooled again. The 3Y has 46kW and 156Nm torque.
The original motor was a 1600 but judging from what I have read it will be quite a task to get a good complete unit. I have been offered a 2l type 4 motor complete. Now that motor has 52kW not sure about torque.
My questions,
Will a type 4 fit without too many changes?
Will the heater pipes fit (original was 1600 remember)
Will the gearbox handle the 2l?

Hi Alan. Getting hold of a complete 1600 type 1 shouldn't be a problem at all, they come up very regularly for sale. The sub assembly may need a recondition, but then you got a good motor with the accessories you will need.

Fitting a type 4 motor will not be easy at all. It will involve hacking the engine bay, valance, rear engine support, the whole lot. The engine bay was not designed for it. I wouldn't consider this.

Single port would be the original motor, but you can install a twin port for a little more liveliness.

With regard to brakes, you can just go buy new ones at a spares shop, but rather just have your old ones rebonded.

I don't have the numbers for the rear bearings or seals, but just take your sample old ones to a bearing shop and they can match it.

Thanks for that info Sean.
Will then keep my eyes open for a 1600 TP. I was mainly concerned with the case which might be out of spec already and thus not last even when reconditioned.
My Westy's engine bay was already hacked as well as the valence and rear engine support.

Should you still wish to utilise the 2.0L motor, you will need to find a 2.0l bellhousing, input shaft and starter motor. You can leave the 1600 box but can also change to the 2.0l box.

Today I removed the rear wheel bearings.
Inner is a FAG 6207 (C3)

Here the specs of a SKF 6207
Bore Diameter: 35 mmSee Diagram Image
Outside Diameter: 72 mmSee Diagram Image
Overall Width: 17 mmSee Diagram Image
Bore Type: Round
Closure Type: Open
Row Type & Fill Slot: Single Row Non-Fill Slot
Snap Ring Included: Without Snap Ring
Internal Clearance: C3
Dynamic Load Capacity: 27 kN
Static Load Capacity: 15.3 kN
Precision Rating: ABEC 3 (ISO Class 6)
Finish/Coating: Uncoated
Cage Material: Steel
Outer Ring Width: 17 mm
Maximum RPM: 13000 RPM
Fillet Radius: 1 mm
Series: 62

The outer bearing is a taper roller bearing RKW N207E C3NA

This seems to be a more specialised bearing and thus also quite a bit more expensive.

OD(Outer diameter) : 72
ID(Inner diameter): 35
B(Thickness) : 17

I will go to a bearing supplier and report on what is available.

I will also get New Viton double lip seals.

I was going to buy a kit but was a bit skeptical of the quality. Make was Pegasus which I have not heard of before.

BMG usually has all the bearings you need for ACVWs. The N207E bearing is also used in the split bus nad, as you note, is a lot pricier that the ball bearings. It can sometimes be hard to source, but is still available. BMG had stock last time I needed, as did FAG.

I was able to find these kits for rear wheel bearings. It comes complete with both inner and outer bearings, both inner and outer seals with circlip and split pin.

@ Christan Thanks. Am busy finding out from suppliers.

@Sean Wow, R10, where and when was that? Exactly what I am looking for.