Owners Workshop Manual
VW Transporter1600OwnersWorkshopManualby J H HaynesMember of the.Guild of Motoring Writersand DH SteadModels covered:All Volkswagen Transporter 1600 models with 1584 cc(96.7 cu in) engineDoes not cover the alternative bodies and conversions produced by specialistmanufacturersISBN 0 85696 660 6 Haynes Publishing Group 1990All rights reserved. No part of this book may be reproduced or transmitted inany form or by any means, electronic or mechanical, including photocopying,recording or by any information storage or retrieval system, without permissionin writing from the copyright holder.Printed in the USA(082 - 2S6)MEMBERHaynes Publishing GroupSparkford Nr YeovilSomerset BA22 7JJ EnglandHaynes Publications, Inc861 Lawrence DriveNewbury ParkCalifornia 91320 USAABCDEFGHUKLM
AcknowledgementsThanks are due to the VW organisation for the supply oftechnical information and certain illustrations. Castrol Limitedprovided lubrication details and the Champion Sparking PlugCompany supplied the illustrations showing the various sparkplug conditions., Lastly, thanks are due to all those people at Sparkford whohelped in the production of this manual.About this manualIts aimThe aim of this manual is to help you get the best value fromyour vehicle. It can do so in several ways. It can help you decidewhat work must be done (even should you choose to get itdone by a garage), provide information on routine maintenanceand servicing, and give a logical course of action and diagnosiswhen random faults occur. However, it is hoped that you willuse the manual by tackling the work yourself. On simpler jobs itmay even be quicker than booking the car into a garage andgoing there twice, to leave and collect it. Perhaps mostimportant, a lot of money can be saved by avoiding the costs agarage must charge to cover its labour and overheads.The manual has drawings and descriptions to show thefunction of the various components so that their layout can beunderstood. Then the tasks are described and photographed in astep-by-step sequence so that even a novice can do the work.Its arrangementThe manual is divided into twelve Chapters, each covering alogical sub-division of the vehicle. The Chapters are eachdivided into Sections, numbered with single figures, eg 5; andthe Sections into paragraphs (or sub-sections), with decimalnumbers following on from the Section they are in, eg 5.1, 5.2,5.3 etc.It is freely illustrated, especially in those parts where there isa detailed sequence of operations to be carried out. There aretwo forms of illustration: figures and photographs. The figuresare numbered in sequence with decimal numbers, according totheir position in the Chapter - eg Fig. 6.4 is the fourthdrawing/illustration in Chapter 6. Photographs carry the samenumber (either individually or in related groups) as the Sectionor sub-section to which they relate.There is an alphabetical index at the back of the manual aswell as a contents list at the front. Each Chapter is also precededby its own individual contents list.References to the 'left' or 'right' of the vehicle are in thesense of a person in the driver's seat facing forwards.Unless otherwise stated, nuts and bolts are removed byturning anti-clockwise, and tightened by turning clockwise.Vehicle manufacturers continually make changes to specifications and recommendations, and these, when notified, areincorporated into our manuals at the earliest opportunity.Whilst every care is taken to ensure that theinformation in this manual is correct, no liability can beaccepted by the authors or publishers for loss, damageor injury caused by any errors in, or omissions from, theinformation given.IntroductionThe Volkswagen Type 2, more generally referred to as thebus, pick-up, Kombi, transporter, caravette, van or any othername that indicates that it is not an ordinary saloon, wasconceived very soon after VW Beetle production was seriouslyunder way in 1949.Heinz Nordhoff realised that in the reconstruction ofGermany after the war the demand for a cheap workhorsevehicle would be almost as great as that for saloons. The beautyof it all was that due to the basic Beetle design he could use thesame components. All he had to do was gear down the drivetrain to cope with increased engine loads; and this was achievedby the expedient of fitting simple spur reduction gears at theouter ends of the drive shafts. It was then possible to use thesame gearbox/final drive unit with the crownwheel the otherway round so that the drive shafts would rotate the other wayinto the reduction gears.The rest of the story is a legend comparable to that of theBeetle. The basic ideas were developed and improved as the yearswent by and it was not until 1967 that the development becamesignificantly different.In that model year the vehicle suddenly appeared larger andnoticeably different from its predecessors. The 1600 cc enginebecame standard, the rear suspension changed from swing axle todiagonal arm and, most noticeable of all, the familiar splitwindscreen changed to a larger one, curved, and in a single piece.It is perhaps significant that the 'mobile home' version, withbeds, cookers and all the other necessities for living on the movehas achieved such a significant (and expensive!) proportion ofthe overall model type. Traditionally commercial vehicle usersare interested solely in the economic attractions of theirtransport and do not generally fall into the category of 'Doit-yourself motorists. Consequently the strictly commercialmodels disappear from the scene when their worth in financialterms is no longer economic. The models that survive from thepast in the hands of private owners tend therefore, to consist ofthe multi-seat or conversion for a holiday home types.This manual gives practical insight into the workings of atransporter and will enable owners who are not familiar with thesomewhat unconventional layout to understand it better.The servicing and repair procedures explained in the manualare those which have been actually carried out by the team ofwriter, mechanic and photographer working together.
ContentsPageAcknowledgements2About this manual2Introduction2Tools and working facilities5Recommended lubricants and fluids7Vehicle identification and spare parts8Routine maintenance (also see Chapter 12, page 194)9Chapter 1 Engine (also see Chapter 12, page 194)12Chapter 2 Cooling, heating and exhaust systems (also see Chapter 12, page 194)42Chapter 3 Fuel system and carburation (also see Chapter 12, page 194)57Chapter 4 Ignition system (also see Chapter 12, page 194)74Chapter 5 Clutch and operating mechanism83Chapter 6 Transmission and final drive (also see Chapter 12, page 194)91Chapter 7 Wheel shafts, drive shafts and universal joints111Chapter 8 Braking system (also see Chapter 12, page 194)118Chapter 9 Electrical system (also see Chapter 12, page 194)138Chapter 10 Suspension, dampers and steering (also see Chapter 12, page 194)165Chapter 11 Bodywork and underframe (also see Chapter 12, page 194)182Chapter 12 Supplement: Revisions and information on later models194Conversion factors220Safety first!Index* ,221222
Tools and working facilitiesIntroductionA selection of good tools is a fundamental requirement foranyone contemplating the maintenance and repair of a motorvehicle. For the owner who does not possess any, their purchasewill prove a considerable expense, offsetting some of thesavings made by doing-it-yourself. However, provided that thetools purchased meet the relevant national safety standards andare of good quality, they will last for many years and prove anextremely worthwhile investment.To help the average owner to decide which tools areneeded to carry out the various tasks detailed in this manual, wehave compiled three lists of tools under the following headings:Maintenance and minor repair. Repair and overhaul, andSpecial. The newcomer to practical mechanics should start offwith the Maintenance and minor repair tool kit and confinehimself to the simpler jobs around the vehicle. Then, as hisconfidence and experience grow, he can undertake moredifficult tasks, buying extra tools as, and when, they are needed.In this way, a Maintenance and minor repair tool kit can bebuilt-up into a Repair and overhaul tool kit over a considerableperiod of time without any major cash outlays. The experienceddo-it-yourselfer will have a tool kit good enough for most repairand overhaul procedures and will add tools from the Specialcategory when he feels the expense is justified by the amountof use these tools will be put to.It is obviously not possible to cover the subject of tools fullyhere. For those who.wish to learn more about tools and theiruse there is a book entitled How to Choose and Use Car Toolsavailable from the publishers of this manual.Maintenance and minor repair tool kitThe tools given in this list should be considered as aminimum requirement if routine maintenance, servicing andminor repair operations are to be undertaken. We recommendthe purchase of combination spanners (ring one end, openended the other); although more expensive than open-endedones, they do give the advantages of both types of spanner.Combination spanners - 10, 11, 12, 13, 14 & 17 mmAdjustable spanner - 9 inchSpark plug spanner (with rubber insert)Spark plug gap adjustment toolSet of feeler gaugesBrake bleed nipple spannerScrewdriver - 4 in long x in dia (flat blade)Screwdriver - 4 in long x in dia (cross blade)Combination pliers - 6 inchHacksaw (junior)Tyre pumpTyre pressure gaugeGrease gunOil canFine emery cloth (1 sheet)Wire brush (small)Funnel (medium size)Repair and overhaul tool kitThese tools are virtually essential for anyone undertakingany major repairs to a motor vehicle, and are additional to thosegiven in the Maintenance and minor repair list. Included in thislist is a comprehensive set of sockets. Although these areexpensive they will be found invaluable as they are so versatile- particularly if various drives are included in the set. Werecommend the } in square-drive type, as this can be used withmost proprietary torque spanners. If you cannot afford a socketset, even bought piecemeal, then inexpensive tubular boxwrenches are a useful alternative.The tools in this list will occasionally need to be supplemented by tools from the Special list.Sockets (or box spanners) to cover range in previous listReversible ratchet drive (for use with sockets)Extension piece, 10 inch (for use with sockets)Universal joint (for use with sockets)Torque wrench (for use with sockets)Mole wrench - 8 inchBall pein hammerSoft-faced hammer, plastic or rubberScrewdriver - 6 in long x ,- in dia (flat blade)Screwdriver - 2 in long x in square (flat blade)Screwdriver - 1\ in long x y in dia (cross blade)Screwdriver - 3 in long x § in dia (electricians)Pliers - electricians side cuttersPliers - needle nosedPliers - circlip (internal and external)Cold chisel - \ inchScriberScraperCentre punchPin punchHacksawValve grinding toolSteel rule/straight-edgeAllen keysSelection of filesWire brush (large)Axle-standsJack (strong scissor or hydraulic type)Special toolsThe tools in this list are those which are not used regularly,are expensive to buy, or which need to be used in accordancewith their manufacturers' instructions. Unless relatively difficultmechanical jobs are undertaken frequently, it will not beeconomic to buy many of these tools. Where this is the case,you could consider clubbing together with friends (or joining amotorists' club) to make a joint purchase, or borrowing the toolsagainst a deposit from a local garage or tool hire specialist.
produced by the vehicle manufacturer specifically tor its dealernetwork. You will find occasional references to these manufacturers' special tools in the text of this manual. Generally, analternative method of doing the job without the vehicle manufacturers' special tool is given. However, sometimes, there is noalternative to using them. Where this is the case and therelevant tool cannot be bought or borrowed you will have toentrust the work to a franchised garage.Valve spring compressorPiston ring compressorBalljoint separatorUniversal hub/bearing pullerImpact screwdriverMicrometer and/or vernier gaugeDial gaugeStroboscop/c timing lightDwell angle meter/tachometerUniversal electrical multi-meterCylinder compression gaugeLifting tackleTrolley jackLight with extension leadBuying toolsFor practically all tools, a tool factor is the best sourcesince he will have a very comprehensive range compared withthe average garage or accessory shop. Having said that,accessory shops often offer excellent quality tools at discountprices, so it pays to shop around.There are plenty of good tools around at reasonableprices, but always aim to purchase items which meet therelevant national safety standards. If in doubt, ask theproprietor or manager of the shop for advice before making apurchase.Care and maintenance of toolsHaving purchased a reasonable tool kit, it is necessary tokeep the tools in a clean serviceable condition. After use, alwayswipe off any dirt, grease and metal particles using a clean, drycloth, before putting the tools away. Never leave them lyingaround after they have been used. A simple tool rack on thegarage or workshop wall, for items such as screwdrivers andpliers is a good idea. Store all normal spanners and sockets ina metal box. Any measuring instruments, gauges, meters, etc,must be carefully stored where they cannot be damaged orbecome rusty.Take a little care when tools are used. Hammer headsinevitably become marked and screwdrivers lose the keen edgeon their blades from time to time. A little timely attention withemery cloth or a file will soon restore items like this to a goodserviceable finish.Working facilitiesNot to be forgotten when discussing tools, is the workshopitself. If anything more than routine maintenance is to be carriedout, some form of suitable working area becomes essential.It is appreciated that many an owner mechanic is forced bycircumstances to remove an engine or similar item, without thebenefit of a garage or workshop. Having done this, any repairsshould always be done under the cover of a roof.Wherever possible, any dismantling should be done on aclean flat workbench or table at a suitable working height.Any workbench needs a vice: one with a jaw opening of 4in (1 00 mm) is suitable for most jobs. As mentioned previously,some clean dry storage space is also required for tools, as wellas the lubricants, cleaning fluids, touch-up paints and so onwhich become necessary.Another item which may be required, and which has amuch more general usage, is an electric drill with a chuckcapacity of at least in (8 mm). This, together with a goodrange of twist drills, is virtually essential for fitting accessoriessuch as wing mirrors and reversing lights.Ldbl, UU1 IILH icdbi, always MJC J a j u p ) j i w. * . ,,w.*, and clean, lint-free rags available, and try to keep any workingarea as clean as possible.Spanner jaw gap comparison tableJaw gap (in)Spanner 1.8751.9692.0002.0502.1652.362i/4 in AF7 mm5/16 in AF8 mm11/32 in AF; 1 8 in Whitworth9 mm3/8 in AF10 mm1 T mm7/i6 in AF3;16 in Whitworth; 1/4 in BSF12 mm1/2 in AF1 3 mm1/4 in Whitworth; 5 /i6 in BSF1 4 mm9/16 in AF1 5 mm5/16 in Whitworth; 3/8 in BSF5/8 in AF1 6 mm17 mm11/16 in AF18 mm3/8 in Whitworth; 7,'16 in BSF19 mm3/4 in AF13/i6 in AF7;'16 in Whitworth; 1/2 in BSF22 mm7/8 in AF1/2 in Whitworth; 9 /i6 in BSF15/i6 in AF24 mm1 in AF9/i6 in Whitworth; 5 / 8 in BSF26 mm11/16 in AF; 27 mm5/8 in Whitworth; 11/16 in BSF11/8 in AF30 mm11/16 in Whitworth; 3/4 in BSF11/4 in AF32 mm3/4 in Whitworth; 7/8 in BSF15/16 in AF13/16 in Whitworth; 15/16 in BSF36 mm17/16 in AF7/8 in Whitworth; 1 in BSFT/2 in AF40 mm; 15 /i6 in Whitworth41 mm15/8 in AF1 in Whitworth; 11/8 in BSF111/16 in AF46 mm113/i6 in AF11/8 in Whitworth; I'M in BSF17/8 in AF50 mm2 in AF1V4 in Whitworth; 1 3/8 in BSF55 mm60 mm
Recommended lubricants and fluidsComponent or systemLubricant type or specificationCastrol productEngine (1)SAE 30 or 40 or SAE 20W/50Castrol CR1 30 or 40 or Castrol G T XTransmission (2)SAE 90 HypoidCastrol Hypoy 90Transmission with limited slip differential (2)SAE 90 Hypoid LSCastrol 90 LSWheel bearings (3)NGL1 No 2Castrol LM GreaseBrake hydraulic fluidSAE J1703Castrol Girling Universal Brake andClutch FluidDrive shaft CV jointsLithium grease with molybdenumdisulphideCastrol MS3 GreaseNote: The above are general recommendations only. Lubrication requirements may vary with operating conditions and fromterritory to territory. If in doubt consult the operator's handbook or your VW dealer.
Vehicle identification and spare partsAlthough many individual parts, and in some cases, subassemblies such as distributors, fit a variety of VW models it isdangerous to assume that just because they look the same thatthey are the same. Differences are sometimes not visually detectable at all (except by serial numbers).Components are being modified and developed all the timeand do not necessarily coincide with publicly announced modelchanges. Make sure therefore, that both the chassis number andthe engine number are known when a part is ordered. The chassisnumber is to be found on a plate fitted to the panel alongsidethe drivers seat (photo). The first two numbers of the chassisnumber denote the basic type. For example ' 2 1 ' is the van, '22'and '24' the Microbus in standard or de luxe versions, '23' theKombi, '26' the pick-up range and '27' is an ambulance. Thethird figure denotes the model year. '8' for example is modelyear 1968 which runs from August 1967 to July 1968. Theremaining digits are the serial numbers for the model yearchanges.The engine number is stamped on the engine crankcase belowthe pedestal which supports the generator. It has one or twoprefix letters followed by a serial number. Prefix letters changewhen there is a significant difference between engines. Allengines covered by this manual are the '1600' (1584 6c) version.Engine prefix letters for this series are:—'AS' August 1974 on - compression ratio 7.5 : 1'B' - 47 bhp - early versions with or without exhaust emissioncontrol systems'AD' - 50 bhp - 1971 model year'AE' the same as AD but with exhaust emission control'AF' - low compression (6.6 : 1).As far as the UK is concerned the main source of spares is theVW dealer network. If they cannot supply you with what youwant immediately then it is most probably due to the fact thatthey do not reckon on keeping large stocks for over the countersales, and although they may have one or two of what you need,cannot afford to risk being out of stock for a customer whobrings his car in for repair. VW agents are very helpful but onecannot blame them for this insistance on keeping a minimumstock level for their own use. It applies particularly to the lesscommon items. So before tearing your vehicle to pieces checkthe spares position at your VW agency; you could save yourself alot of trouble.With gasket sets - for both engine and gearbox - do not bealarmed if there seem to be many items included in the set youbuy, which do not fit your vehicle. To save a lot of variety ofkits they include in.one enough to cover a variety of types over aperiod of time so you are certain to have some left over.However, it is a good idea to check the set before leaving theparts store. Some of the ones you may need could be omitted.Oil seals particularly are not all included - and this applies tosome of the smaller ones. (Oil cooler).
Routine maintenanceFor modifications, see Supplement at end of manualIntroductionBecause of the inherent toughness and r
The Volkswagen Type 2, more generally referred to as the bus, pick-up, Kombi, transporter, caravette, van or any other name that indicates that it is not an ordinary saloon, was conceived very soon after VW Beetle production was seriously under way in 1949. Heinz Nordhoff realised that in the reconstruction of
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Rapid STED manual - A Practical guide Contents (suite) 5.3 Guidance on Conducting the Rapid STED Technical and Policy Foresight Workshop 33 5.3.1 Scope of Guidance 33 5.3.2 Workshop Materials 33 5.3.3 Workshop Location 33 5.3.4 Workshop Staffing 33 5.4 Workshop Content 34 5.4.1 Workshop Introduction 34