Recommended to be replaced at 12000 miles or once a year.

Tools and Parts;

• Spark plug spanner or socket and ratchet.
• Torque wrench.
• Feeler gauge set / plug gap tool.
• Optional3" piece of 3/8" ID rubber hose.
• 4 x new spark plugs.
• Anti-seize compound.

Instructions;

• Carefully remove the spark plug wire from the spark plug and position it out of the way.
• Remove the old spark plug, make a note of which position it came from.
• Check the gap on your new replacement spark plug, between the electrode and the grounding post with a .024" (0.60mm) feeler gauge or gapping tool adjust as required.
• Coat the threads with anti-seize compound, as well as preventing corrosion, it makes it easier for installation and removal.
• Now place the spark plug back in the hole in the head, if you have the hose, wet the plug wire-end of the spark plug and push the 3" piece of rubber hose onto the plug.  . 
• Carefully engage the threads by hand only once the spark plug is threaded as far as it will go by hand you may now use spark plug spanner or socket and ratchet to gently tighten it up.
• Torque the spark plug up to 22ft lbs.
  
• Replace the spark wire plug on the new spark plug and repeat the process for the remaining three spark plugs.​

This should be carried out every 12000 miles or at least once a year.  
(It is recommended your points and condenser should be replaced as a set, I must admit I never have done and never had a problem in 15 years of driving air-cooled VW's but I always carry spares.)

Tools and Parts required;

• Flat blade screwdriver
• Feeler Gauges
• Point set, condenser and rotor arm for your distributor set.
  

Instructions;

• Remove the distributor cap and rotor from distributor body. 
• Disconnect the electrical spade connectors for both the points (inside the distributor) as well as the condenser on the negative ( marked "-" / "1") side of the coil the green wire.
• Unscrew the set screw for the points being careful not to loose the screw into the distributor.
  
• Remove the old points and inspect. (If they are in good condition clean them up as use them as your spares).
• Undo the screw on the side of the distributor that holds the condenser in place. Replace the condenser and replace it.  (again if its good save it for your spares)
• Position the points into place ensuring the pivot peg fits into the recess in the base plate. Replace the screw so it begins to squeeze the points down to the base plate but not tight.
• Hand turn the engine so that the points are in the open position, centre on one of the lobes, checking the gap with your feeler gauge. 
  
• Once the correct gap is achieved between .016" - .020" (0.40mm - 0.50mmtighten the screw and recheck the gap to ensure it is correct.
• Reconnect the spade connectors from the points to the condenser as well as the condenser to the negative (marked "-" / "1") side of the coil using the GREEN wire.
  
• Now replace the rotor arm and reposition the cap on the distributor body and clip the retaining clips in place.

​

 
Tools and Parts required

• 17mm Allen key/plug.
• 80W90  gear oil
• Optional manual oil pump 

​
Instructions

• Park your vehicle onto a flat surface.
• Take out the oil plug on the left hand side half way down the gearbox using the 17mm Allen key.

(If you are carrying out a total oil replacement of the gearbox make sure you take out the side oil plug before removing the bottom one so you can fill it back up again)

• Place the end of the pump filling tube into the service hole and slowly pump the oil until it starts to flow out over the lip
  
• Wait a minute for the oil to settle then repeat.
  
• Replace the oil plug.

​Guide to set your timing to TDC. 

Tools Required;

• Spanner for your dynomo pulley (19mm)
• Spanner for your distributor bolt (10mm)
• a flat bed screwdriver
• a timing light (Simply a wire with a 12v bulb in the middle and crocodile clips either end).

Instructions

• Unclip the distributor cap from the main body of the distributor with the flat blade screwdriver and locate the notch on the rim which should be your number 1 cylinder mark.
• Using the the appropriate spanner rotate the generator pulley clockwise until the crank pulley notch/mark is lined up with the crack between the two halves of the crankcase and the rotor arm is pointing towards the notch on the distributor body.
• Place the distributor cap back on the distributor body ensuring its clipped down properly and place your static timing light to same connector as the thin green wire on the coil, (or negative side of coil) the other end should connect to a good earth.
• Loosen the 10mm nut on the distributor just enough so the distributor will turn, now turn on the ignition (Don't start the engine!).
• Rotate the distributor until the timing light turns on, now turn it clockwise until it turns off and then slowly counter clockwise until is just turns on, keep doing this till you get it just right i.e the light just comes on, then tighten up the 10mm nut on the distributor and check the light comes on at the right place just to ensure you haven't moved it while tightening the 10mm nut.
• Turn off the ignition, you have now completed statically timing your engine. 
• You should now finely adjust your timing with a timing gun if you haven't got one then you can measure 11mm from TDC that will give you 7.5 degrees and 46.5 mm gives you 30 degrees. Mark them with tipex and you have your rough timing marks.

Guides are exactly that so use at your own risk.

If doing this as part of your service interval worth doing the valve adjustment check first.
​
Recommended Tools;

• 19mm socket or spanner
• 10mm socket or spanner
• Oil Tray
• Torque wrench

Parts Required;

• Oil change gasket set
• 2.5 litres of Mineral Motor Oil

Optional*

• Sump screen
• Gloves (Dirty oil is hazardous to your health)
• Rags, Cloth for clean up
• Sealant (non hardening)

Instructions;

• Warm-up your engine and place your oil tray under the engine.
• Undo and remove 19mm oil drain plug in the centre of sump plate and allow the oil to drain.
• Undo and remove the 6 x 10mm sump plate nuts and remove the sump plate and screen.
• Clean off the old gasket and any sealant from the sump, screen and plate.
• Clean up the sump, screen and plate.
• Now re-fit using new sump gaskets apply light sealant to gaskets if required (personal choice some do some don't)
• Order is gasket, sump screen, gasket, sump plate.
• Fit the sump plate back on 10mm nut using new copper sealing washers.
• Fit sump plug with new copper sealing washer.
• Add oil slowly checking the dip stick till it reaches the level
• Start engine and check for leaks, let things cool down and recheck oil level.

​
Your done

​Tools Required;

• 13mm spanner
• Straight-tipped screwdriver
• Feeler gauge .006" or 0.15mm

Instructions;

1. The engine should be stone cold before the procedure is carried out.
2. Remove the valve covers flat bladed screwdriver.
3. Pull off the distributor cap and turn the main pulley until it is at top dead centre and the rotor arm is pointing at number 1 (the intake valve on the cylinder head at number 1 should close).
4. Press on the bottom of the rocker arm while inserting the feeler gauge between the tappet and valve stem. If it doesn't go in it's tight, if it goes in loosely it is too loose you should feel slight resistance as it is drawn through if it is set correctly.
5. To adjust the valve loosen the 13mm nut with your spanner, now while holding the nut, turn the adjustment screw until the feeler gauge is as per previous step. Then while holding the screw tighten up the nut, takes practice.
6. Now re-check with the feeler gauge and repeat until it is correct.
7. Turn the main pulley 180 degrees counter clockwise again rotor arm now pointing to position number 2 on the distributor and repeat the procedure 4 - 6 for intake a& exhaust valves number 2.
8. Turn the main pulley 180 degrees counter clockwise again rotor arm now pointing to position number 3 on the distributor and repeat the procedure 4 - 6 for intake a& exhaust valves number 3.
9. Turn the main pulley 180 degrees counter clockwise again rotor arm now pointing to position number 4 on the distributor and repeat the procedure 4 - 6 for intake a& exhaust valves number 4.
10. Replace your rocker covers with new cork gaskets ensuring they are seated correctly.​