Aircooled Renovation – 6 volt to 12 volt Engine Upgrade
As the previous post mentioned, I combined two major projects into one – mainly because i was pulling the engine apart anyway.
- Replacing the wiring harness
- Upgrading from a 6 volt system to a 12 volt system
I spent most of the time in the past few days dismantling the engine. I quickly realized that simply removing the hood would make life much easier.
I have two manuals: The original shop manual for the VW Beetle, 1960-1965, and
How to Keep Your Volkswagen Alive: A Manual of Step-By-Step Procedures for the Complete Idiot
. The difference between these two books is shattering. On one hand, the direct no-nonsense German engineering text, on the other: “Dude, like remove the carburetor, but you’ll want to rest first . . .” OK, it’s not that extreme, but it is fascinating.
My biggest complaint on the shop manual is that it isn’t cross-referenced. Step one of removing the alternator/generator is that I had to remove the carburetor. So, i had to flip through all 500 pages to find the carburetor removal instructions. Hardly efficient. The two manuals do make an interesting compliment each other. The Complete Idiot Manual lets me know when something will be especially difficult and where I can expect to skin a knuckle.
On the technical side, I was surprised at the amount that i needed a ratchet extension, though in thinking about it – it made sense. The process went fairly smooth. Removal of fuel line, air line, electrical connectors, carburetor, clutch assembly, and then the alternator. I kept all of the parts in marked plastic bags so that i know where they go later.
The fan shroud came out very easily. remembering to feed the clutch line back through it was important, as I realized. but after so many years – this stuff was dirty!
When I moved into our current house, the owner left behind a couple of galvanized steel tubs. I often wondered what to do with them, and couldn’t bring myself to throw them out, but now they have come in very handy as a safe place to wash down all of these parts with de-greaser.
April 29th, 2009 at 9:40 am
Really interesting reading on this web site. I need help fitting a solenoid to the boot lid release please.