Betty Work Done


Aim here is to list the work I have carried out on Betty.

20/4/13 - Accelerator Cable

Work completed today was the fitting of a 1 piece accelerator cable.

The kit was purchased from RJES. Cable kit costs £45 with £3 p&p.

Link here : http://www.rjes.com/html/throttle_cables.html

Great kit and instructions. Fitting was removing old RHD to LHD link cable. Removing old LHD cable and flex tubing from solid pipe to fan housing.

Route cable from RHD just under the pedal using Danbury bracket. to rear fan housing. Followed route of clutch cable. Cut cable housing with angle grinder and drilled out cable to fan housing adaptor. Then push new cable in the outer tubing all the way to the engine. Refitted bracket and attached cable ball joint to bracket. Attached new cable to engine with about 50mm extra. Checked and greased brackets etc.

Taken for test drive and its great. Best product for accelerator cable issues on the aircooled. Smooth acceleration and smooth action.

20/7/13 - Service 66000 Km

Decided on a service of Betty's engine. Purchased at 62000 Km and have covered 66000 so 4000Km she was due a service.

Following jobs to be done where:
  1. Gearbox Oil Change
  2. Engine Oil Change
  3. Spark Plugs
  4. Air filter
  5. Distributor Cap
  6. Distributor rotor arm
  7. HT Leads (Only Changed main cable)
  8. Fan Belt Change
  9. Tappets reset (+ Rocker cover gaskets)
All done in under 6 Hours. Full write up will be done in the service manual (WIP)

7/9/13 New Cylinder Heads

After discovering that the Exhaust Valve on Cylinder 4 was always tight and it was much higher the head was removed and found the valve seat had become detached from the head and was nearly on its way to dropping the valve. The following parts where ordered from VW heritage.

043-101-355/VW/C Cylinder head, complete ONLY FOR 22FIN CYLINDERS
113-129-717/A / **EX** Inlet Manifold Gasket, Twin-port (Manifold to he [20]
040-101-129/1 **EX** Washer for VWB Cylinder head nuts [50]
040-101-457 Nut, cyl.head, 8mm stud, Slimline (13mm across flats)
111-198-335 Pushrod Tube and Seal kit 1300-1600
111-251-261/B / **EX** Gasket, head to exhaust [20]

25/10/13 Battery Replacement & Tray Restoration

Replacement Battery required and also restoration of Battery tray.
  1. Removed Old Brazilian Battery
  2. Wire brushed battery tray - Rust around clamp and tray.
  3. Rust restored using Hamerite Rust Gel
  4. Primed Using Hamerite Paint
  5. Sprayed using Hamerite Smooth
  6. Replaced Battery with YUASA Silver 5000 50 A/h 440 A Battery
27/10/13 New Wing Mirrors

Fitted some chrome wing mirrors. Got rid of the original big black ears. Cheapest chrome late bay ones found on e-bay. Threaded attachments a little short but managed to tap a few turns on thread and fitted with new body seals. Cheap chrome mirrors only for £26 for the pair. Covered in WD40 and if they last 6 months it will be worth it.

27/10/13 Reset the Tappets

After the disaster of the valve and cylinder head replacements it was time to reset the tappets. Getting quick and doing them and a few loose and a few tight. Still a little noisy on passenger side (Nearside) but its an air-cooled flat 4 after all!

13/1/14 Leisure Battery Tray + New earth Straps

Another battery tray restoration. The main and leisure batteries removed and leisure battery tray was cleaned up and treated. Repainted with hamerite - This tray was not as bad. Hardly any rust.

New earth cables fitted to both batteries. Cleaned connection surfaces for good earth. Re crimped all connections. New +ve connector to leisure battery. Not much improvements in hot start issue but at least a good earth.

2/2/14 69278km Engine Oil Change

69278 Km Oil Change - Drained and replaced oil with Castrol GTX 15w40. While working underneath I noticed that the Earth Cable from Starter motor to chassis was disconnected. Cleaned both connections and earthed to Chassis under one of the rear gearbox mounting bolts. Seems much improved starting. Hopefully that is the end of the hot start issue.

22/2/14 Tappets reset

Thought it was about time to do the tappets again.Not much of adjustment just a little slack but all even. Reset.

6/3/14 Clutch Cable Change

Clutch cable went. Stripped out old cable - 2 strands of cable left! Purchased new cable from Custom & Commercial. removed all Danbury bodge extension bar. The LHD to RHD convertion by Danbury was quite shocking as the linkage assembly mounted on the front chassis rail was poorly aligned and self tapping bolt used. It rubs on the chassis rail unless it was loosened from the rail. Will need to sort out properly at a later date but back on the road.

19/4/14 Front Wheel Arches

Started to see some surface rust coming through on drivers side seat areas. Completely stripped off under seal back to bare metal metal. Found that water had ingresses along a strange plate edge seals. Treated with Jenolite and zinc 182 primer and white Hammerite. Replaced underseal in both arches.

10/5/14 71000km Front Beam Restoration

Completely cleaned and removed all paint & rust from front beam. Treated for surface rust and primed with Zinc 182 and matt black paint. Replaced anti roll bar clamps. Fully greased front beam. Much better looking and better suspension performance.

31/8/14 Waxoyl 

Completed a first pass Waxoyl. Managed to find many manufacture holes to inject into. Purchase a kit off the internet and a new compressor. Made short work of injecting the wax. Only areas hard to reach are the rear wheel wells and rear wheel arches as the cupboards get in the way. It will need a repeat coating before winter sets in but good enough for now. Major smell in the van!

6/3/15 MOT Failure :-(

Failed MOT and replaced Lambda Sensor. Universal one fitted

10/5/15 75700km Tune Up

Did the following:
  1. Vacuum Measurements
  2. Tappets Reset - 2 Loose & Adjusted. Most OK
  3. Rocker Gaskets replaced
  4. Air Box removed & Cleaned
  5. Carb Cleaner in Throttle Body
  6. Idle Pipes Cleaned
  7. Oil Pressure PRV cleaned (Ordered a new one)
  8. MAP & Fuel Pressure Vacuum hose ends replaced.
  9. Redex Injector cleaner in tank
01/07/15 Greased front Beam / Oil Changed / Tappets reset

Did the standard servicing as we where embarking on summer Holidays!

07/10/15 Fuel Filter Changed

Fitted new Fuel filter.

31/12/15 Fuel Pressure Tests & New FPR

Did static pressure tests and fitted a replacement Fuel Pressure Regulator (Bosch)

13/02/16 Exhaust investigation - Replacement CAT

Fitted Second hand replacement CAT.
Fitted new rear exhaust rubber hangers.

14/03/16 MOT Passed But still rich

Did the following before MOT.
  1. Remove, clean & check Throttle Body & Idle Valve
  2. Replace HT Leads
  3. Replace MAP Sensor
  4. Check and renew all Vacuum lines
  5. Re-set Mp9 ECU
  6. Attempt Basic Settings
04/06/16 Replacement ECU - Solved Running Rich

Replaced ECU for another Bosch MP9. Slightly earlier ECU model but solved rich running issue!

16/06/16 New Gearbox!

Broken Brazilian Gearbox. Replaced with AH Beetle (1302s 1600cc) Gearbox.

New Gearbox oil in new Gearbox.



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