Basic Tool Requirements

The basic hand tools described below can be used to accomplish most of the simple maintenance and repair tasks.

Screwdrivers. Two types, the common flat-blade type and the Phillips type, will handle 99% of all screws used on Volkswagens. Two or three different sizes of each type will be best, since a screwdriver of the wrong size will damage the screw head. Screwdrivers are for screws. Do not use them for anything else, such as prying or chiseling. A complete set of screwdrivers can often be purchased for about the same money as the four or six individual ones that are really necessary. See Fig. 4-1.

For the more complete tool box, include "stubby" screwdrivers or offset screwdrivers for use in tight spots where a normal length screwdriver will not easily fit.

Fig. 4-1.

Common flat-blade (top) and Phillips (bottom) screwdrivers. Offset screwdriver (inset) is used for screws with limited access.

Wrenches. Wrenches come in different styles for different uses. Fig. 4-2 shows several. The basic open-end wrench is most widely useful, but grips on only two sides. It can spread apart and slip off more easily. The box wrench has better grip, on all six sides of a nut or bolt, and is much less prone to slip. A 12-point box end can loosen a nut or bolt with less movement, while a 6-point box end provides greater grip for tight fasteners. For hex fasteners on fluid lines, like brake lines and fuel lines, a flare-nut wrench offers better grip and less chance of fastener damage, but will still fit over the line.

Fig. 4-2.

Types of wrench heads. From left, open-end, 12-point box, 6-point box, flare nut.

Most universal is the combination wrench, shown in Fig. 4-3, with one open-end and one 12-point box end. For Volkswagens, 10mm and 13mm wrenches are the most common sizes needed. A 19mm wrench is needed to loosen and tighten the engine oil drain plug. A complete set should also include 6mm, 7mm, 8mm, 9mm, 11mm, 12mm, 14mm, 15mm, and 17mm.

Fig. 4-3.

Combination wrenches with one open-end and one 12-point box end. 12-point box end is more universal than 6-point.

Sockets. Sockets perform the same job as box wrenches, but offer greater flexibility. Normally used with a ratchet handle for speed and convenience, they can be combined with extensions to reach fasteners more easily. Standard sockets come in 6-point and 12-point styles. For use with a ratchet, the universal nature of the 12-point is unnecessary, and the 6-point type offers better grip on tight nuts and bolts. Sockets are also characterized by their drive size, the size of the connection to a handle or extension. To start, choose 6-point sockets with a 3/8 in. square drive, two or three extensions of different lengths, and a 3/8 in. drive ratchet handle. As with wrenches, 6mm to 15mm, 17mm, and 19mm are the most needed sizes. See Fig. 4-4.

For the more complete tool box, add deep sockets and a greater variety of handles and extensions. A universal joint extension can allow access from an angle where a straight extension will not quite fit.

Fig. 4-4.

Sockets, handles, and extensions.

Spark Plug Socket. A special socket for spark plugs is the correct size, is deep enough to accomodate a spark plug's length, and contains a rubber insert to both protect the spark plug from damage and grip it for easy removal. This gripping feature is especially necessary on 16-valve engines. A spark plug socket is shown in Fig. 4-5.

The spark plugs used in all Volkswagen engines except 16-valve require a 13/16 in. socket. The spark plugs used in 16-valve engines require a 5/8 in. socket. Get one with a drive size to match the socket handle and extensions.

Fig. 4-5.

Spark plug socket.

Pliers. A few of the many types of pliers are shown in Fig. 4-6. Most all are used for holding irregular objects, bending, or crimping. Some have special applications. A needlenose plier is used for gripping small and poorly accessible objects, and is useful for wiring and other electrical work. A locking plier, such as the famous Vise-Grip is useful because it can grip tightly all by itself. Snap-ring pliers with special tipped jaws are used to remove and install snap-rings or circlips. A channel lock or water pump plier has adjustable jaws which can be quickly changed to match the size of the object being held to give greater leverage. There are many different types and sizes of pliers. Start with a small selection of different types of medium size.

Fig. 4-6.

Pliers. From left, channel lock, common, snap-ring, needlenose, locking.

Adjustable wrench. An adjustable wrench, shown in Fig. 4-7, can be a useful addition to a small tool kit. It can substitute in a pinch if, for example, two wrenches of the same size are needed to remove a nut and bolt. Use extra care with adjustable wrenches, as they especially tend to loosen, slip, and damage fasteners if not used carefully. Compared to a wrench of the correct size, an adjustable wrench is always second best. Choose one of average size range, about 6 to 8 inches in length.

Fig. 4-7.

Adjustable wrench is useful if used with care. Adjust for best possible fit. Use only when correct size wrench is not available.