96030
Q HAYNES
1973
(082)
•
byJH Haynes Member a t the GUlld of MOlt...Ong Writers
and DHStead Models covered: Al...
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96030
Q HAYNES
1973
(082)
•
byJH Haynes Member a t the GUlld of MOlt...Ong Writers
and DHStead Models covered: All Volkswagen Transporter 1600 models with 1584 cc (96.7 cu in) engine Ooes not cover the alternative bodies and con versions produced by specialist manufacrurers
ISBN O 85696 660 6
©
Haynes Norlh America, Inc.
1977,1981,1982,1986,1990
Wilh permission lrorn J. H. Haynes & Co. Ltd.
AH rights reserved . No part of this book may be reproduced or transmitted in any form or by any means, electrical or mechanical , including photocopying , recording or by any information storage or retrieval system , withoui permission in writing from the copyright holdar.
Printed in the USA
(BU1-OB2)
Haynes Publishing Group Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes North America, Inc 861 Lawrence Drive Newbury Park California 91320 USA
""~ ....., """ , FGHU
Acl<nowledgements Thanks are due to the VW organisation for the supp ly of technical information and certain illustrations. Castro! limited provided lubrication detaiJs and the Champion Sparking Plug Company supplied the illustratio ns showing the various spark
plug conditions. Lastly, thanks are due to all lhose people at Sparkford who heJ p ed in the productlon of this manual.
About IlS aim The aim of this manual is to hel p you get the best value from your vehicle. 11 can do so in severa ! ways. Il ca n heJ p you decide
what work must be done (even shou ld you choose to get il done by a garage). provide mformation on routine ma intena nce and serviei ng , and give a I09ical course of action and diag nosis when randem faults occur. However, it is hoped that you wi ll use the manual by tackling the work yourself. On simpler jobs it may even be quicker than booking the car into a garage and goi ng there twice, to leave and collect It. Perhaps most important. a lot of money can b e saved by avoiding the costs a garage must charge to cover its labour and overh eads. The manual has drawings and descnptlons to show the function of Ihe vanous compo nents so that their layou t can be understood. Then the tasks are described and photographed in a step-by-step sequence so that even a n ovice can do the work.
Its arrangement The manual is divided into twelve Chapters, each coveri ng a loglca l sub-division of the vehlcle. The Chapters are each divided in t o Sections, numbered with single figures, eg 5; and the Sections into paragraphs (or sub-sect ion s), with decimal numbers following on from the Sect ian they are in, e9 5. 1 , 5.2 , 5.3 etc.
The Volkswagen Type 2. more generally referred to as the bus, pick-up, Kom b i, t ra nsporter, caravette, van or any ot her name that indicates t hat it is not an ordinary sa loon, was concelved very scon after VW Beetle productian was seriously under way in 1949. Heinz Nordhoff realised that in t he reconstruction of Germany af ter the war th e demand for a cheap work horse vehicle w ould be almost as great as that for sa loons. The beauty of it all was that due to th e basic Beetle design he cou ld use the same components, All he had to do was gear down the drive train to cope with increased eng ine loads; and this was achieved by the expedlent of fitting simple spur redu ction gears at the outer ends of the drive shafts. It was then posslble to use the same gea rbo x/ final drive unit with Ihe crownwheel the other way round so that the drive sh afts would rota te the other way into the reduction gears. The rest of the story is a legend comparable to that of the Beetle . T he basic ideas were developed and improved as the years went by and it was nOl until 1967 that the development became signi f icantly different. In that model year the vehiclc sudden ly appeared larger and
It is freely iHustrated, esp ecia lly in those parts where there is a detailed seq uence o f operations t o be c arri ed o ut. There are two form s o f illustration : figures and photographs. The figu res are numbered in sequence wi t h decimal numbers, accordin g to their posi t ion in the Chap ter - eg Fig. 6.4 is the fourth drawing / illustration in Chapter 6. Photographs carry the same number (ei th er individually or in related groups) as the Section or sub-section to which they relate. There is an alphabetlcal index at the ba ck o f the manual as weil as a conten ts list at the front. Each Chapter is also preceded by its own individual conten ts list. References to the 'Iefr or 'right' of the vehicle are in the sen se of a person In the driver's sea t facing forwards. Un iess o th erwise stated, nUls and bolts are removed by turning anti-clockwise, and tightened by turn ing clockwise. Ve hicle manufacturers cont inually make changes to spec if ica t ions and recommendations, and these, whe n notified, are incorporated into our manua ls at the earliest opportunity. Whilst every care is taken to ensure that the information in this manual is correct, no liability can be accept ed by the authors or publishers for loss, damage or injury caused by any errors in, or omissians from, the information given ,
noticeably d ifferent from its predecessors. T he 1600 cc engine became stan dard, th e rear suspension changed from swing axle to diagonal arm and, most not iceabl e of all:- the familiar split windscreen changed to alarger one, curved, and in a single piece. Il is perhaps sigOlficant that th e 'mobile home' version, with beds, cooke rs and all the o ther necessit ies for living on the move has achieved such a significant (and ex pensive!) proportion o f th e ove rall model t ype. Trad it ionally commercia l vehicle users are interested solely in th e economic attractions of their transport and do not generally fall inta th e category of 'Doit -yourseW motorists. Consequently the strictly commercial mode Is d isappear f rom the scene w hen their worth in financial t erms is no longer economic. The models that survive from the past in th e hands o f private owners tend Iherefore, to consist of the multi-scal or conver sio n for a ho lid ay home types. Thi s manual gives practi cal inslght inta the workings of a transporter and will enable owners who are not familiar with the somewhat unconventionallayout to understand il better. The servicing and repa;r procedures ex plained in the manual are Ihose w hl ch have been actually carried out by the team of writer, mechanic and photographer working together.
Contents Page Acknowledgements
2
About this manual
2
Introduction
2
Toors and working facilities
5
Recommended lubricants and fluids
7
Vehicle identjf jcation and spare parts
8
Routine maintenance (a lso see Chapter 12, page 197)
9
Chapter 1 Eng ine (also see Chapter 12. page 197)
12
1
Chapter 2 eooling, heating and exhaust systems (also see Chapter 12. page 197)
42
2
Chapter 3 Fuel system and ca rburation (also see Chapter 12, page 197)
57
3
Chapter 4 Ignition system (also see Chapter 12. page 197)
74
4
Chapter 5 Clutch and operating mechanism
84
5
Chapter 6 Transmission and final drive (a l so see Chapter 12. page 197)
92
6
Chapter 7 Wheel shafts, drive shafts and universal joi nts
112
7
Chapter 8 Braking system (also see Chapter 12. page 197)
119
8
Chapter 9 Electrical system (also see Chapter 12. page 197)
139
9
Chapter 10 Suspension, dampers and steering (also see Chapter 12. page 197)
166
10
-----------------------------------------------------------Chaprer 11 Bodywork and underfr3me (also see Chapter 12. page 197) 183 ------------------------------------------------------------Chapter 12 Supplement : Revisions and information on l ater model s 197 ------------------------------------------------------------Conversion faetors 223
Sa fet y first!
224
Index
225
11
12
•
•
!
Tools and working facilities Introduction
•
•
•
A selection of good tools is a fundamental requirement for anyone contempiating the maintenance and repair of a motor vehicle. For the owner who does not possess any, their purchase will prove a considerable expense, offsetting som e of the savings made by doing - it-yourself. However, provided that the tools purchased meet the relevant national safety standards and are of good quality, they will last for many years and prova an extremely worthwhile investment. To hel p the average Qwner to dedda which tools are needed to carry out the various tasks detailed in this manual. we have compiled three lists of tools under the followinO headings: Maintenance and minor repair. Repair and overhaul, and Special. The newcomer to practical mechanics should start off with the Maintenance and minor repair tool kit and confine himself to the simpler jobs around the vehicle. Then, as his confidence and experience grow, he can undertake more difficult tasks. buying extra too Is as. and when. they are needed. In this way, a Maintenance and minor repa;' tool kit can be built- up inta a Repair and overhaul tool kit over a considerable period of time without any major cash outlays. The experienced do- it-yourselfer will have a tool kit good enough for most repair and overhaul procedures and will add tools from the Special category when he feels the expense is justified by the amount of use these tools will be put to. It is obviously not possible to cover the subject of tools fully here. For those who .wish to learn more about tools and their use there is a book entitled How to Choose and Use Car Tools available from the pubJishers of this manual.
Maintenance and minor repair tool kit
,
•
The tools given in this list should be eons ide red as a minimum requirement if routine maintenanee, servieing and minor repatr operations are to be undertaken. We recommend the purehase of eombination spanners (ring ona end, openended the other); although more expensive than open- anded ones. they do give the advantages of bot h types of spanner.
Combination spanners - 10, " , 12, 13, 14 & 17 mm Adjustable spanner - 9 inch Spark plug spanner {with rubber insertJ Spark plug gap adjustment tool Set of feeler gauges Brake bleed nipple spanner Screwdriver - 4 in long x in dia (flat blade) Screwdriver - 4 in long x t in dia {cross blade} Combination pliers - 6 inch Hacksaw (junior) Tyre pump Tyre pressure gauge Grease gun Oil can Fine emery cloth {I sheetJ Wire brush (smalII Funnel (medium size)
Repair and overhaul tool kit These tools are virtual1y essentiai for anyone undertaking any major repairs to a motor vehicle, and are additional to those given in the Maintenance and minor repa;' list. Included in this list is a comprehensive set of sockets. Although these are expensive they will be found invaluable as they are so versatile - particularly if various drives are included in the set. We recommend the t in square-drive type, as this can be used with most proprietary torque spanners. If you cannot afford a socket set. even bought piecemeal. then inexpensive tubu lar box wrenches are a useful alternative. The tools in this list will oecasionally need to be supplemented by tools from the Special list.
Sockets (or box spannersl to cover range in previous list Reversible 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 inch Ball pein hammer Soft-face d hammer, plastic or rubber Screwdriver - 6 in long x & in dia (flat blade) Screwdriver - 2 in long x t\ in square (flat bladel Screwdriver in long x t in dia (cross blade) Screwdriver - 3 in long x t in dia (electricians) Pliers - electricians side culters PIIers - needle nosed Pliers - circlip (intemal and externa!) Cold chisel inch Scriber Scraper Centre punch Pin punch Hacksaw Valve grinding tool Steel rule/scraight-edge Allen keys Selection of files • Wire brush (Iarge) Axle-stands Jack (strong scissor or hydraulic type)
,+
+
..t
Special lools The tools in this list are those whieh are not used regularly, are expensive to buy, or which need to be used in accordanee with their manufacturers' instruetions. Uniess relatively difficult mechanical jobs are undertaken frequently, it will not be eeonomic to buy many of these tooIs. Where this is the case, you could consider clubbing fogether with friends (or joining a motorists' club) to make a joint purchase , or borrowing the tools against a deposit from a local garage or tool hire spe cialist.
6
T o ol s and working facilities
produced by th e vehicle manufacturer specifically for its deaJer network. You will find occasion al referen ces to lhese manufacturers' spec ial tools in the text of this manual. Generally. an alternative metllod of doing the jOb witho ut the vehicle manu fac turers' special tool is given . Howeve r, someti mes . there is no al terna tive t o using them . Where th is is the case and the relevant too I cannot be bought o r borrowed you will have to en HuS! the work to a franchised garage. Va/ve spring compressor
Pistol , ring compressor Bal/joinl separator
Universal hub/bearing puller Impact screwdriver
Micrometer and/or vem/er gauge Dial gauge
Stroboscopic timing light Owefl angle meter!rac/)omerer Universal electrical multi~meter Cylinder compression gauge Lifting tackle Trolley jack Light with extension lead
Buying 100/S For prawcally all too Is. a tool factor is the best source Si nce he will have a very compre hensive range compared with the average garage or accessory shop. Having said that, accessory Shops ohen offer excellent quaiity tools at discoun t prices. so It pays lo shop around . There are plenty of good 100/5 around at reasonable prices, but always aim 10 purchase Il ems which meet the relevant national safety standards. If in doubl. ask the proprietor or ma nag er of Ihe shop for advice before making a purchase ,
Care and mainlenance of lools Having purchased a reasonable tool kit. il is necessa ry to keep the tools in a clean serviceable conditian . Aher use, always wipe off any dirt , grease and metat particles using a clean , dry clot h. before putting the l ools away, Never leave them Iying around af ter they have been used. A simple too I rack on the ga rage or workshop wall, for il ems su ch as screwdrivers and pliers is a good idea. Store all normal spann ers and sockets in a metal box. Any measuring instruments, gauges, meters, etc, must be ca refully stored where they c annOI be damaged or beeome rus ty, Take a little care when tools are lIsed. Hammer heads inevitably become marked and serewdrivers lose the keen edge on their bia des from lime to time. A litt le timely attention with emery cloth or a file will soon restare items like this to a good serviceable fi nish .
Working facilities Not to be forgatten when discllssing toois. is the workshop it sel f. If anything more than routine maintenance is to be ca rried out, som e form of suitable working area becornes esse ntiaI. It is appreciatecl that many an owner mechanic is forced by circumstances to remove an engine or similar item , without the benefil of a garage or workshop. Having don e this, any repairs should always be done under the cover of a roat. Wherever possible, any disman tl ing shou ld be done on a dean flat work ben ch or table at a suitable w orking height. Any workbench needs a vice: one w ith a jaw opening o f 4 in (100 mm) is suita ble for most jobs. As rnentioned previausly, same ele an clry storage space is also required for too Is, as weil as the lubricants, clea ning fl uids, touch- up paints and so on which beeome necessary. Another item which may be required , and which has a much more general usage, is an electric drill with a chuck capaci ty of at least i\ in (8 mm). This, tagether wi th a good range of twist drills, is virtually essential for f illing accessories such as w ing mirrors and reversing lights.
Last, but not least. always keep a supply of old newspapers and clean , lint-free rags available, and try to keep any working area as clea n as possible.
Spanner jaw gap comparison lable J aw g ap ( in)
0 .250 0 .276 0 .31 3 0 .315 0.344 0 .354 0 .375 0.394 0433 0 .438 0 .445 0 .472 0 .500 0 .512 0 .525 0.551 0.563 0 .591 0 .600 0.625 0 .630 0 .669 0 .686 0.709 0.710 0.748 0 .750 0.813 0 .820 0.866 0.875 0 .920 0 .938 0 .945 1.000 1.0 10 1.024 1.063 1.100 1.125 1.181 1.200 1.250 1 260 1.300 1.313 1.390 1.4 1 7 1.438 1.480 1.500 1.575 1.614 1.625 1.670 1.688 1 .811 1.813 1.860 1 .875 1.969 2.000 2.050 2.165 2.362
Spa nn e r size 1/ 4
in AF
7 mm 5 16 1nAF
8 mm 11 32 in AF; l . S In Whllworth 9 mm 3,S in AF 10 mm 11 mm 7: 16 In AF 3 16 In Whltworth. 1 4 In BSF 12 mm 1i 2 In AF , 3 mm 1 4 In Whllworlh; 5, 16 in BS F 14 mm 9 . 16 inAF 15 mm 5' 16 In Whllworlh; 3 a In BS F 5,8 In AF 16 mm 1 7 mm 11 16inAF 18 mm 3/ a In Whllworlh; 7 16 in BSF 19 mm 3/4 in AF 13/ 16 In AF 7' 16 In Whltworth ; 1/ 2 In BSF 22 mm 7 . . S In AF 11 2 In Whltworth ; 9/ 16 In BSF 15 161 nAF 24 mm 1 in A F 9/ 16 In Whilworth; 5/8 in BSF 26 mm 1 1/ 16 In AF ; 27 mm 5/ 8 In Whitworth; 1' / 16 In BSF 1 1/8 1n AF 30 mm 11 / 16 in Whltworth. 3/ 4 In BSF 1 1'41nAF 32 mm 3/ 4 III Whltworth; 718 In BSF 1 5/ 16 mAF 13' 16 In Whltworth; 15/ 16 In BSF 36 mm 1 7/ 16 In AF 7/ 8 in Whitworlh; 1 in BSF 1 1/ 21 n AF 40 mm ; 15/ 16 111 Whitworth 41 mm 1 5/ 8 in AF 1 in Whltworth ; 1 1/a in BSF 1 11 / 16inAF 46 mm 1 13/ 16 in AF , l/a tn Whi tworth; " /4 in BSF 1 7/ atnA F 50 mm 2 in AF '1 /4 In Whitworth; P /a In BSF 55 mm 60 mm
7 •
1
2
• :;-
•
-
• •
T
1
3
3
•
lubricants and fluids Component or system
lubricant typa or specification
Castrol product
Engine (1)
SAE 30 or 40 or SAE 20W/50
Castrol CR1 30 or 40 or Castrol GTX
Transmission (2)
SAE 90 Hypoid
Castrol HVpoy 90
Transmission with limited slip differential (2)
SAE 90 Hypo id L$
Castrol 90 LS
Wheel bearings (3)
NGL1 No 2
Castrol LM Grease
Brake hydraulic fluid
SAE J1703
Castro I Girling Universal Brake and Clutch Fluid
Lithium grease wi th molybdenum disulphide
Castrol MS3 Grease
Drive shaft
ev joints
Note: The above are general recommendations on/y. Lubrication requ;rements may varv with opera ting condirions and from rerritory to territory. If in doubt consult the operaror's handbook or your Vl'V dea/er.
Vehicle identification and spare parts Although many individual parts, and in same cases, sub assemblies 5uch as distributors, fit a variety of VW models it is
dangerous to assume that just because they look the same that thevare the same. Differences a re sometimes not visually delect· able at all (except by serial numbers). Components are being modified and developed all the time and do not necessarily coincide with publicly :tnnounced model
changes. Make sure therefore, that both the chassis number and the engine number are known when a part is ordered. The chassis number is to be found on a plate fitted to the panel alongside the drivers seat (photo) . The tirst two numbers of the chassis number denote the bask type. For example '21' is the van, '22' and '24' the Microbus in standard or de luxe versions, '23' the Kombi, '26' the pick-up range and '27' is an ambulance. The third figure denotes the model year. '8' for example is model year 1968 which runs from August 1967 to July 1968. The remaining digits are the serial numbers for the model year changes. The engine number is stamped on the engine crankcase below t he pedestal w h ich supports the genera t or . I t has one or two prefix letters followed by aseriai number. Prefix letters change when there is a sigfli f icant difference between engin es. Al l engines covered by this manual are the '1600' (1584 ccl version. Engine prefix letters for this series are: -
'AS' August 1974 on - compression ratio 7.5: 1 'S' - 47 bhp - early versions with or without exhaust emission controi systems 'AD' - 50 bhp - 1971 mode I year 'AE' the same as AD but with exhaust emission contro i 'AF' - Iow compressian (6.6: H. As far as the UK is concerned the main source of spares is the VW dealer network. If they cannot supply you with what you want immediately then it is most probably due to the fact that they do not reckon on keeping large stocks for over the counter sales, and although they may have one or two of what you need, can not afford to risk being out of stock for a customer who bfings his car in for repair. VW agents are very helpful but one
- ---~-----
cannot b lame them for this insistance on keeping a mInImum stock level for the ir own use. It applies particu larly to t he less common items. So before tearing your vehic le to pieces check the spa res position at your VW agency; you could save yourseif a lot of trouble. With gasket sets - for both engine and gearbox • do not be alarmed if there seem to be many items included in the set you buy, which do not fit your vehicle. To save a lot of variety of kits they include in one enough to cover a variety of types over a period of time so you are certain to have same left over. H owever, it is a good idea to check the set before leaving the parts store. Same of the ones you may need cou ld be omitted. Oil seals particu larly are not all included . and t h is applies to same of the sma ller ones . (Oi l coolerl.
•
SEAT BELT
AN~~!~GE
Vehicle identification plate.
Routine For mod/ficatlons, see Supplement at end of manual
~~~~~~~------------------------------------------Introduction
Because of the inherent taughness and reputat ion for reliability and long life there is a ten de ncy for awner s to be a bit sketchy on VW ma inten ance - particularly wit h vehic les not in the first flush o f youth. The VW will put up with neglect for a long time but when the cr u nch eventual ly does come il is likely to be drastic. Regular maintenance th erefore , is ju st as important as on any o ther ve h icle.
b) BraKes Hydraulic fluid reservai r level 1 month Effi ciency and fao t pedal free play · Check and adjust as re· qu ired 3 mon ths Handbrake efficiency • Check and adj ust as requ ired Brake frictia n lining material· Check thickness 6 months Hydraulic lines , hOses, master cylinder wheel cylinders and calipers . Exami ne exteriors f or leaks or corrosion 6 months Renew all sea ls and fluid 3 years
The service procedures listed hereafter CQver all the poinls o f required r egular service. The frequency of service tends to va rV
according to changes in design of various components. the cond itions under w h ich the veh icle is used, and the way in which it is driven. Th e f requenc ies given are based on a mil eage of 12000 per year in a temperat e climate which is malnly non dusty. Variations from I:,is will be taken inta accOun t by VW s{!rvice agen des in different condi t ions. Variations in driving style must be the responsibility of the d ri ver where servicing reqUlrer:lenls could be affccted . Where maintenance is sole ly a matt er of inspection (ralher than lubrication, cleaning or adjustment) the tindings from su ch inspections wil l determine whether or no t further action is required. Such further act ion is no longer with in the scope o f Routine maintenance. I t is a workshop procedur e requirir.g repair or ren ewal. H ow to do the maintenance is detailed af t er the schedules. If the details are already in the main chapters then reference is made appropr iately . A revised Maintenance Schedule based on a 'milcage covcred ' frequency is included in Chapter 12 Supplement. 1 SAFETY MAINTENANCE aj Steering tie rod ball io ints· Check for wear 3 months Steering gear . Check worm 10 roller play and worm shaf, bearings. Adjust if neeessary 3 months Front wheel bearings· Check end p lay an d adju st i f necessary 3 months
NOTE: A sig ni ficant drop in fluid reserva ir level o r any other indica tion o f fl uid leakage is a danger signal. A co mplete and thorough examination of th e hydr auli c system should be made. c) Suspension Tyr es · I ntlati on pressure check Weekly Tyres· Wear and d am age check As suspect Front torsion arm ball ioints· Check fo r wear 3 months Dampers . Check f or leakage and malfunction 3 month s d) Vision Lights fun ctio ning Oncluding direction and stop lights) Screen washer operative
2 SAFETY MAIN T ENANCE PROCEDURES a) St eering See Chap t er 10 bJ Brakes Hydrau lic fluid reservarr level· The reserva ir is mounted on the vertieal panel in the front of the eab T op up to the indi cated level with approved flu id as required. R emaining items - See Chapt er 8. ej Suspension See Chapter 10 . d) Vision Lights · See Chapter 9. Screen washer reservair . The washer liqu id reservair is f itted
10
Routine maint ena nce to the front panel of the eab just below the hydraulic fl uid
reservoir. 11 has a protective cover and tueked inside is a tube with an ordinary tyre valve f or pressurisation purpases (ph oto I. The screen washer reserveir should be full of clean wat er with an additive o f anti-smear compounds as wished. The tank
should be pressurised from an ordinary tyre inflalar to the maximum pressure of 42 psi/3 kg cm 2 which is marked on the tank. If the jets do not direct water on to the SCreen as they should, f efer to Chapter 9 for details. I n t he UK correctly f unct ioning screen washers are a legal ly required fitment t o all cars.
3
EF F ICIENCY AND PE RFORMANC E MAINTENANCE
al Engine
The wIndscreen washer reservoir
1$
mounted on the vertical panel in t he front of the cllb just below the brake fluid reservoir.
Lubricating oil - Top up to level Weekly Lubricating oil - Drain, clean filter screen and refill with Lubricatiny oil - fresh oi l. 3 mon t hs Fan belt - Check tension and adjust if required. 1 month Air cleaner - elean ou t bowl and refill with o il {o il bath lYpeJ. 3 months Air c leaner - Renew paper element (paper element type) 6 mo nths Air cleaner - Check correct operation of warm air contro i flaps. 1 mont h Battery - Check electro l yte level. Weckly Distributor - Check contact points gap. Adjust Dist ribu to r - an d/or re new. 3 month s Dist ributor - L ubricate cam. 3 mo n ths Valve clearances - Check and adjust as requ ired Valvc clearances - (renew rocker cover gasket sl. 6 mont hs Spark plugs - Remova l clean and reset. 6 mo nt hs Spar k pl ugs - Renew. 12 mont hs F uel pump - Clean filter. 6 mo nth s Carburettor - Check sett ing of throttle cable earburettor - and lubricate linkage. 6 months Cover plates and fan housing - Check security of aH serews and grammets. 3 months b) Suspension Front wheel bearings - Repack with grease. 2 years R ear w h eel hearings - Repack with grease. 2 years c) Transmission and final drive Gearbox oil - Check level and top up as needed. 3 months Gearbox o il - Drain and re f ill with fresh oi l except type 091 manual gearbox (August 1975 on) which is 'fi ll ed for life' 2 yea rs Clutch pedal free play - Check 1TI0vement and adjust . As necessar y Axle shaft flexibl e gaiters - Check lor sp lits 3 mont h s Renew charcoal filter (Fuel Evaporativc System ) 30 000 mi les 4 E F F lel E NCY PRQCEDURES a)
Engine oj[ dipstick.
AND
PER FQRMANCE
MAINTENANCE
Engine
Lubricating oil. To 10p up the oil. remove the fdh~r ear from the filler pipe at the fight hand side of the engine. Remove the dlpstick 10 prevent posslble b low back up the filler pipe when pouflng oil in. A suitable container or funnel IS needed in order to add oit without spillage. The top dipsti.ck mark is the correct capacity leve!. T he lower mark is hall full. Do not overIiII or let the level drop significantJy below the full mark. When changing the engine oil th e filter screen - which is sirnply wire gauze sh ou Id be ftush ed out with paraffin to clear th e gauze. This entails removing the circular retaining p late
11
Routine maintenance in the centre of the bottom of the crankease. Before starting, you must obta;n two new gaskets for it, and it is also ('iesirable to get six new copper washers for the stud nuts. First drain the oil by removing the centre plug and then remove the cover plate. Take care when removing the stra in er. Do not distort it. Later engines do not have th e central plug so a suitably large container will be needed to catch the aB as it leaks out when the plate nuts are loosened. The oil suction pipe which goes inta the centre of the strainer gauze must be quite firm. If il is loose then it is likely that suction is being lost and the oil c irculation is not 100% efficient. !The engine needs completely stripp in g to put this right). The strainer incorporates a relief valve in case the filter mesh shou ld get completely blocked up . Having thoroughly cleaned everything refit the stra iner with a gasket on each side of the flan~e. See that the suction pipe is proper ly located in the slrai"er Fil new copper washers followed by the cap nuts. Do not overtighten the cap nuts ot herwise the threads may strip. Replace lhe drain plug and refill with 4% pints o f approved engine oi l. Fan belt - See Chapter 2. Air cleaner - See Chapter 3. Battery - See Chapter 9. Distributor - See Chapter 4. Valve clearances - See Chapter 1. Spark plugs - See Chapter 4. Fuel pump - See Chapter 3. Carburettor - See Chapter 3.
Transmission magnetic oil level plug.
bl Suspension Front wheel bearings - See Chapter 10. Rear wheel bearings - See Chapter 7. cl Transmission and final drive Gearbox oil - To check the level stand the vehicle on leve l ground and undo the leve I plug which is halfway up the side of the casing on the left - just abead of the axle shafts. This plug is a recessed hexagon which could be very difficult to undo_ Use a tubular spanner or balt head which fits snugly. If the plug is burred by makeshih methods il will get progressive ly more difficult to adjust. Add oil from a suitable oil gun or squeeze pack with flexible filler spout. Add oil slowly until it runs out from the fillerllevel hale. Clean the plug and replace it tightly. When changing the transmission oil it is best to run it warm first. Then undo the magnetic drain plug which is in the centre of the casing at an angle at the rear Let the oil drain out for at least 15 minutes. Clean the magnetic drain pllog and replace it. Before beginning to refill get the exact amount of oil needed ready, and then start to fill up through the filler/level plug. It is possible that oil will overflow before you have put it all in. Wait so that the air pockets have time to bubble out and then continue until all the oil is put in. Clutch pedal free play - See Chapter 5. Axle shaft gaiters - See Chapter 7.
ENGINE Oll DRAIN PlATE AND 'FILTER GAUZE TYPICAL CHARCOAL CANISTER (FUEl EVAPORATIVE SYSTEM) AIR CLEANER REMOVEO FOR ACCESS
Chapter 1 For extra information. see Supplement at end of manual Contents General description and type identification ...
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Repair and maintenance procedures · dismantling
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Engine rem oval - preparation... Engine - removal .. Engine dismantling - general o.. 0
Engine ancilliaries - removal
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O jl cool er • removal and renovation o.. o •• • •• • •• Ojl pressure relief and contral valves - removal and renovation CrankshaH pulley wheel - removal and replacement .,' Oil pump - removal and replacement _'o o.. .,' Cy l inder heads - removal o.. o.. o.. o.. ...
Cylinder heads - dismantling and renovation of (ocker gear, valves and springs o" ••• 0.0
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0'0
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Cylinders, pistans and rings - rem oval and renovation Connecting rads and bearings· removal and renovation Camshaft and tappets - removal and renovation ... Flywheel . removal and renovation ... ... ... Crankshaft oil seal . remova l ... ... ... Crankshaft and main bearings - removal and renovation Distri butor drive shaft - removal .. ... ...
1
2 3 4 5 6 7
8 9 10 11
12 13 14
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15 16
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17
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... 18 •••
Crankcase · examination and renovation ... .. . • •• Engine reassembly . general ... ... .. . • •• Crankshaft - asseambly of gears and main bearings Connecting rods - assembly to crankshaft ... . __ Crankcase, crankshaft, camshaft and cam followers - reassembly __ . ... ... ... ... . .. Piston s, r ings and connecting rads· reassembly ... ... Cylinders - replacement ... ... ... ... ... Cylinder heads, valves and springs· reassembly ... .. Cylinder heads - replacement ... ... ... . .. Rocker gear and pushrods . replacement ... ... ... Crankshaft oil seal - replacement... ... ... ... Flywheel . replacement ...... __ . Oil pump - replacement ... ... ... ... ••• Oil cooler - replacement '" ... ... ... ... Valve 10 rocker clearances - adjustment... ... ... Engine - reassembly of ancilliaries ... ... ... • •• Engine - replacement and starting up ... . .. . .. Fauh finding ... ... ... ..' ...
19
Specifications Type ... ••• Weight ••• Bore ... ••• Stroke Capacity ... Compression ralie:
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To April '68 ... From Apri l '68 Power output (to August '70) .. . (from August '70) .. . Torque (tO August '70) ... ... (from August '70)... ... Compression pressure ... •• • Loca tion of No 1 cylinder ... ••• Firing order ... •• • • •• Engine mounting ... ... •• • Camshuft and camshaft bearings Camshaft drive ... ... Camshaft bearings ... • •• Camshaft journal diameters Journal /beari ng radial cJearance End flo at ... ... ... Gear backlash ••• •••
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Connecting rods and hearings Type... ... ... ... .__ ... ... Big end bearings ... ... .. . Crankpin (big end) diameter .. . ... ... Small end bush ... ... .. . Undersize big end shei is available ... • •• Crankpin to bearing c learance limits ••• Crankpin end float .:. ... ... ... Gudgeon pin/bush radial cle;irance l imits Gudgeon pin diamtHer ... ... •••
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4 cyl:nder, horizontally opposed flat, pushrod ohv 240 Ibs 1 109 kgs approx . 85.5 mm 69 mm 1584 cc 7.7: 1 7.5: 1 47 DI N bhp at 4000 rpm 50 DI N bhp at 4000 rpm 82 Ib fl at 3000 rpm 81. 7 Ib ft at 3000 rpm 114-142psi (B.0 - l0.0kgcm 2 ) Right hand front (nearest front of vehicle) 1 fR. Frontl4 (L. Rear) 3 (L. Front) 2 (R. Read By cross member carrier and gearbox mountings .
Ughtweight alloy gear direct from crankshaft Steel backed white m eta l she lI s 24.99 - 25.00 mm (Q.9837· 0.9842 in) 0.02 - 0.12 mm (Q.0008 - 0.0047 in) 0.04 - 0.16 mm (0.0016 - 0.0063 in) 0.00 - 0.05 mm (0.00 - 0.002 in)
Forged steel 31ayer thin-wall shelIs 54.98 - 55.00 mm (2.1644 - 2.1653 in) Lead/bronze coated steel - pressed in. 0.25 mm, 0.50 mm, 0.75 mm . 0.02 - 0.15 mm (0.0008 - 0.006 ;n) 0.1 - 0.7 mm (0.004 - 0.028 inJ 0.01 . 0.04 mm (0.0004 . 0.0016 in) 21.996 - 22 mm (0.8658 - 0.8661 ;n)
20 21 22 23 24
25 26 27
28 29
30 31 32
33 34 35
36 37
Chapter 1/Engine
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580 - 588 grams 592 - 600 grams 0.03 mm (0.0011 in)
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54.97·54.99 mm 12.164·2.1648 in)
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Split· 3 layer steel backed
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0.04 . 0.18 mm (0,0016 - 0,007 in) 0,03 - 0.1 7 mm (0,0011 - 0.0066 in)
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0.05 - 0.19 mm (0,0019 - 0.0074 in)
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Taken by flange of No. 1 main hearing and adjusted by shims 0.07 • 0.13 mm (0.0027 • 0.0051 in) 0.03 mm 10.0011 in)
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65.00 - 65.03 mm (2.559 - 2.5601 in) 50.00·50.04 mm (1.9685 -1.9700 in) 90.00 - 90.05 mm (3.5433 - 3.5452 in) 27.5 - 27.52 mm (1.0825·1.0852 in) 70.00 - 70.03 mm (2.756 - 2.758 in) 19.00· 19.05 mm (0.748 - 0.750 in)
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Single barrels - finned - east iron 112 mm (4.41 in)
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Aluminium· 1 per pair of cylinders One exhaust port per cylinder. Once siamesed inlet port per pair of eylinderson 47 bhp engines. One inlet port per cylinder, with twin branch inlet manifold on 50 bhp engines.
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Fully floating, steel tube retained by cirelips 21.996· 22.00 mm (0.8658·0.8661 iri)
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Crankshaft and majn bearings Number or bearings o..
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Main bearing journal diameters Nos l, 2 and 3 No 4
Regrind diameters undersize
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Bearing shelIs . type Nos 1, 3 and 4 Bearing shelIs - type No 2 o.. ... Journal/bearing radial clearance limit
Nosland3 No 2 ... No 4 ...
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Cran kshaft end float End float limits .. . Main journal maximum ovality
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Crankcase Main bearing bare diameters Nos 1, 2 and 3 No 4 ... Oil sea I bare diameter (flywheel end) • •• Camshaft bearing bare diameter ... ... Oil pump housing bare diameter ... ... Tappet kam followed bore diameters ... Cylinders Type ... .. . ... •• • Distance between pair centres
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39.98 - 40.00 mm (1.5739 -1.5748 in) .25 mm, .50 mm, .75 mm Aluminium. lead caated 1 piece
Gudgeon pins
TyP'( ...
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Lubrication !lystem Type ... . .. ... ... ... ... 011 filter ... ... ... ... ... Sump capacity ... ... ... . .. Dil pump type ... ... ... . .• Oil pressure (SAE 30, JOoC at 2500 rpm) Od pressure warning light ... ... . .. Oil cooler ... ... ... ... Dillevei dipstick ... ... ...
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Oil pump Gear/body end clearance (no gasket) Gear backlash ... ...
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0.1 mm (0.004 in) max . 0·0.2 mm (0.008 in)
Oil pressure relief valve Springlcngthloadedat7.75kg(17Ibs) ...
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23.6 mm 10.928 in)
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Maintains bearing pressure at 28 p.s.; .
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Oil pressure regulating valve
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Pistons Type ... ... .. . ... ... .. . Clearance in cylinder limits ... ..' Number of rings ... ... ... ... Ring/groove side clearance· top compression lower compression oi l contro i ... Piston oversizes available ... ... ... Piston pin bare offset ... ... Piston rings Top compression Thickness
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Wet sump· pressure and splash Wire gauze suction strainer in sump 2Y2 litres (4.4 Imp pints) Twin gear 42 p.s.L (min 28 p.s.L) Comes on between 2 • 6 p.s.L Pressure fed multitube type in eooling fan housing Upper mark, fu tl. Lower mark, half full.
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Light alloy with steel insarts 0.04 - 0.20 mm (0.0015·0.008 in) 3 - two compression, one oi! controi 0.07 - 0.12 mm 10.0027 • 0.0047 in) 0.05 - 0.10 mm 10.0019 - 0.0039 in) 0.03· 0.10 mm 10.0012 - 0.0039 in) 0.5 mm and 1.0 mm 10.020 and 0.040 in) 1.5 mm (0.060 in)
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14
Chapter l/Engine
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Tappets· (Cam followersl Ty pe ... ... . .. Diameter •• • • •• Pushrods and rocker arms Pushrod type
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Rocker shaft diameter size limits Valves Intet: head diameter stem diameter seat width
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0 .3 - 0 .9 mm (0,012 . 0 .035 in) Bevelled. angle l aei ng top o f pisron
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seat angle ... . .. ... guide bore diameter ... • •• maximum rock in gu i de ... Exhaust: head d iamet er ••• st em diameter ... seat width ._. ••• seat angl e ... ••• Gu ide bare diameter maximum rock in gu ide Seat width correc t ion angle - inner outer Roc ker armlva lve clearance Timing Inlet opens .. . Inle t closes • • • Ex hau st opens Exhaust cia ses
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Cylindrical flat based 18.96 - 18.89 mm tO.7463 - 0 .7471 in)
Tube with hemisp herical ends 272.5 mm 18.00 - 18.04 mm (0.7086 - 0.7093 in) 17.97 - 17.95 mm (0.7073 - 0.7066 in)
35.6 mm (August 1976 on 33.0 mm)
7.94 ·7.95 mm 1.3 - 1.6 mm
44° 8.00 - 8.06 mm 0.8 mm 32.1 mm 7.92 - 7.94 mm 1.7 - 2.0 mm
45°
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75° 15°
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BTDC ABDC BBDC ATDC
NQTE : Rocker arm t O val ve clea rances are set at 1 mm (0.040 inI for the purpose of valve tim ing only. Valve springs Type... . .. Laaded l ength
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Torque wrench settings Crankshaft pulley nu t ad pump nuts .. . Oil drain plug .. . Di l strain e.,- cover nuts Racker shaft nuts ... Cylinde r head nuts ... Flywhee l boll ... Crankcase nuts & screws
M8 Ml0
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Connectin g rad cap nut s Engine securing nu t s
1
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Single co il spring 31 mm al 53-61 kg (116 - 134 Ibsl Ibs ft
m kg
33 14 33
4.5 4.5
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General description and type identification
The 1600 version 0 1 the establ ished 'Beetie' eng ine was in t ro du ced into the transporter range in 1967. The basic con fi guration of the 'Bee tie ' engine is u nchanged - the cooli ng system incorpora ting the superi mposed type o f f an and housing. Modification s were made to the l ubrication syste m by fitting an addi tiona! spring loaded val ve wh i ch mainlains oil pressure at the crank shah bP-arings. In 1970 furth er modificatlons increased the powe r output an d at the same time th e coo l ing syst em was
2.0
2
3.5 3.3 3.0
improved by fitting alarger capacIty fan and tnovlllg the oil cooler . As a guide to identifi ca t ion the engines have prefix letters to their 7 figure seria l numbers. These numbers are to be f'lund on the crankcase at t he base o f the generator pedeslal B - 4 7 bhp (DIN) AD - 50 bhp (DIN) (1971 onwards) AE · 50 bhp (D IN ) - emission controi AF • Low compression 6.6 : 1 AS - A ugust 1974 on· compressian ratio 7.5 : 1 T he engine is an air-coo led horizontally opposed fial four
1
2 -_ _
@9 3 ___
@@ 8 ent w;th the synchro sleeve and should be refiued on
a trial and error basis until the two components exhibit the best sliding fit. 53 When fining the springs make sure that they run in opposite directions when viewed from each side of the unit, that they engage fully with the sliding key s and th eir angled ends are located in the hollow key, but on no account have both the angled ends of the two springs engaged in th e same key.
61 With all parts dean and renewed where necessary, assemble the gearbox in the following sequence. Apply oil to each ca mpenent as it is assembled and observe absolute cleanliness. Mainshaft 62 Aeassembly is a reversal of dismantling but note the following points. 63 When fitting 3rd/4th synchro make sure that the groove on the sleeve (arrowed Fig .12.1 31 is towards 4 th gear. Pinion driveshaft 64 When titting the tapered roller bearing, the inner [rack should be heated to 212 0 F (1000 C) in water before titting. 65 Th e combined 1st gear needle bearing inner track and ring nut should be heated in water to 140°F (60 0 e) before fitting to the main shaft but make sure that th e tapered roller bearing track has cooled down first . 66 Using the spec ial tool (VW 2052) tighten the ring nut (still hot) to 145 Ib ft (177 kgf ml. 67 The pinion driveshaft should now be fitted in the transmission case and its turning to rque checked either with a torque wrench or by winding a cord round the shaft splines and attaching its end to a spring balance . Oil the bearing and turn it several times in both directions to settJe the bearin9s. The turning torque for new hearings should be between 6 and 21 kgf cm (5.2 and 18.3 Ibf in) or if the original bearings have been used again, 3 to 7 kgf cm (2.6 to 6 .1 Ibf inl. 68 Once the torque has been checked, remove the driveshaft from the transmission casing and continue reassembly, which is in the reverse order of dismantling. Fit 1st gear and needle bearing, 1st/2nd synchro, 2nd gear and needle bearing, 3rd gear
22
20
19,
~ (e 21 24
18,
17 l.v"llll l IP-""!!.L......
I
14
r --.::: \- ",'-
I 23
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15
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6 5 FIG,12.13 COMPONENTS OF THE GEAR CARRIER l
2 3 4 5
Inrermediate se/eetor
6
Stop
lever Bafljo inr
7
Link Se/eetor lever shafr
8 9
eoil springs
10
Intermediate se/eetor lever braeket 3rd/4th se/eetor rad Reverse se/eetor rod tstl2nd se/eetor rad
"
Detent hale p /ug Detent baJ! Detent spring Detent sleeve
12 13 14 15 P/ug 16 Pinion driveshafr needfe
17
18 19 20 21
bearing Mainshafr bearing Lockplate
Clamp sleeve Union nut
22 23 24 25 26
Re/ay shafr braeker
Racker lever Re/ay shafr Re/av shaft braeker Circlip
Racker lever support
~
... II)
208----------------------------------------------------------~
FIG.12 .15 SYNCHRO SIDE TO SIDE SPRING LOCATION
FIG.12.14 3RD/ 4TH SYNCHRO HUB AND SLE EV E
Line on hub must be at bortom (black arrow) when groove on sleeve is uppermosr (wh i te arrowJ
....--.... 3RD/4TH--
O
/
/2ND
O FIG .12 .161 ST / 2ND SYNCHRO HUS AND SLEEVE FIG .12.17 SECTlONAL VIEW OF DETENT/ SEl ECTOR SHAFT ARRANGEMENT SHQWING POSITION OF INTERlOCK PLUNGERS
294b(
FIG .12.18 USING SPECIAL JIG TO SET REVERSE SELECTOR PIN
FIG.12.19 RQC KE R LEVER e aU A L C l EARANCE POINTS
Chapter 12/Supplement
209
Grey
really satisfactory way to set up the selector mechanism is to use the special setting jig VW 294 b. If this cannot be borrowed then this work should be left to your dealer by taking the assembled gesr carrier to him. 86 If the jig is available, fit the gear carrier complete with reverse sliding gear and seleetor tork. 87 Release the balts on the reverse relav shaft braekets and slide the braeket (on the selector pin side of the relay shaft) until the seleetor pin contacts the reverse sliding gear. 88 Now press the opposite bracket against the shaft until all endplay is eliminated. Tighten the bracket balts to a torque of 141bf ft (1.9 kgf mI. 89 Check that the clearance at both ends of the rocker lever is equal. If it is not, release the union nut and rotate the revene lever support as necessarv. Retighten the union nut to 22 Ibf f t
Copper
13.0 kg! mI.
(shouider towards 2nd gearl. circlips, spacer spring, 4th gear (shouider towards spring) and the circlip. but note the following points. 69 Before pressing the lstl2nd synchro onto the driveshaft, fit a new anti-rotation ring.
70 Once 3rd speed gear is fitted. use feeler blades to check the endfloat. This should be between 0.05 and 0.20 mm. Adjust
by using a selective thickness circlip from the following which are available. Try and set the endfloat to the lower tolerance. Thickness (mm)
C%ur of circJip
1.60 1.75 1.90 2.05 2.20 2.30 2.40
Black Blue Brown
Brass Silver
Transmission case 71 Retit the mainshaft and reverse shaft bearings to the trans-
mission ease using new circlips. 72 Fit reverse shaft and reverse driven gear, the latter having the oH grooves towards the needle bearing. If the complete reverse shaft/gear assembly has been removed the n it is simpler to refit completely assembled, including the shaft needle bearing, cirdip and thrust washer. Tap home, using a plastic faced hammer. Gear carrier 73 Fit the seleetor detent balls and springs. 74 Depress the detent balls and springs and fit the seleetor shahs. Make sure that the interlock pins are in position. 75 Drive in new detent plugs. 76 Press the mainshaft bearing inta the gear carrier so that the numbers engraved on the bearing outer track are visible when viewed from outside the carrier. Once the milled edge of the bearing aligns with the recess in the gear carrier, press the semi· circular JockpJate inta the recess. 77 Fit the cirdip and press in the pin ian driveshaft bearing. 78 Fit the damp sleeve, reverse Jever support and the umon nut. Tighten the sleeve to 32 Ibf fl (4.4 kgf mI. 79 laosely fit the reverse gear relay shah and braekets. 80 Fit the selector link bracket and tighten the balts to 18 Ibf ft
(2.5 kg! mI.
90 Adjustment of the 1st/2nd and 3rd/4th seleetor forks is rather more complicated because if the final drive requires resetting due to the installation of new components, then this must be done tirst (see paragraph 110J. 91 Install the gear carrier to the special jig and then hand tighten the special retaining ring at the pinion gear bearing. This ring is supplied as part of the setting jig. 92 Loosen the nut on the reverse lever support and move the support and lever aside. 93 Fit 1 st/2nd seleetor tork to its shaft but leave it tree to slide on the shaft. 94 Reconnect the reverse lever and slightly tighten the union nut on the support. 95 Pull the 1 st/2nd seleetor shaft unt" 2nd gear detent engages. Now slide the svnchro sleeve/tork in the same direction as the shaft was moved until the sleeve slides over the teeth on the baulk ring, and is against 2nd gear. 96 Now centralise the fork in the groove in the synchro sleeve and tighten the tork lock bolt. 97 Turn the mainshaft and select 1st, 2nd and neutral several times and at each gear position check that the fork does not rub against the side of the synchro sleeve groove. If it does, slight readjustment must be carried out. 98 With the gear train in neutral, move the 3rd/4th selector rod until it engages in 3rd gear detent. Adjust the 3rd/4th tork in a sim ilar way to that described tor the 1st/2nd fork. During these adjustments, the mainshaft bearing in the gear carrier must be fully seated.
81 Fit the seleetor !ink and seleetor link shaft. 82 The selector shafts and forks will require adjustment (as described later) once the gear train has been fitted to the carrier. 83 To fit the gear train, mesh together the mainshaft and the pin ian driveshaft. Slip the 3rd/4th seleetor fork anta its shaft and make sure that it si ides freely. Support the ends of the gear shafts and then lower the gear carrier down anta the oppasite end 5 of the shafts. Apply pressure to the inner track of the mainshaft bearing using a tubular distance piece and a press. A heavy hammer may do the job if an assistant is available to guide the pin ian driveshaft inta the carrier and to retain the selector fork anta its shaft. 84 The dished washer and a new circlip must now be titted to the mainshaft. Make sure that the circlip snaps inta its groove against the pressure of the washer and then compress it fully with a pair of pipe grips until it bonoms in its groove. Selector forks . refitting and adjustment 85 Correct setting of the seJector forks is vital for smooth gearchange and minimum wear on the selector components. Basically, what must be achieved is to so adjust the selector forks that when a gear is seleeted, the tork is central in its synchro sleeve groove (or pin in reverse sliding gear groove) without any side pressure to cause the fork to rub against the sides of the groove. A great deal of trial and error work will be needed to achieve this uniess the original components are being refitted and their exact relative positions were marked before dismantling. Where new parts have been fitted, then the on ly
12 FIG.1220 SPECIAL PIN lON BEARING ADJUSTER NUT SUPPllED WITH SELECTOR SETTING JIG
210
Chapter 12/Supplement
99 Adjust the union nut on the reverse rocker lever support
until the support is just fre e to slide in and out of its damp sleeve . 100 Push the reverse (middle) se leetor shaft until ilS circlip cont8cts the face of the gear carrier. Hand tighten the union nut.
101 Without touching its sh ift tor k, press reverse slidi ng gea r towards the gear carrier until th ere is a clearance between the sliding gear and the mainshaft 2nd gear of between 0.020 and 0.039 in (0.50 and 1.00 mm). Tighten the union nut to 22 Ibf Ib 13.0 kgf mI. 102 Disengage reverse gear and select 2nd gear. Check that there is a clearance between the teet h of reverse sl idin g gear and 1stl 2nd gear sleeve. If not, readjust the reverse lever support after releasing the union nut . 103 FinaUy check that the interl ock mechanism is doing its job by on ly aliowing the se lection of one gear at a time. Check that the selector for k lock balts are all tight at 18 Ibf f t (2.5 kgf mI. 104 Stick a new gasket to the fla nge of the transmission case and locate the pin ian driveshaft bearing shims in position (refer to paragraph 110 if th e pinion/crownwheel has yet to be adjustedJ. 105 Insert the gear train inta the casing so that the twelve sided shoulder o f the pin ia n bearing seats in its recess. 106 F it a new reta ining nut and with t he special tool u sed to release il, tighten it to 160 Ibf Ib (21 .8 kgf m J. Release the nut one Quarter o f a turn and retighten to the correct torQue. Stake the nut by means o f its retaining ring . 107 Insert and tighten the balts which hold the gear carrier to the transmissio n case. Work in a diagonal sequence and tighten to a torqueof 141bf ft 11.9 kgf m). 108 To the face of the gear carrier ba lt on the seleetor link and bracket, th e selector link and link shaft. 109 If the gearchange lever housing was overhauled. fit a new bush /oil seal. Fit the ho using to th e gear carrie r making sure that the selector inner lever engages with the ba lljoint o f the link. Fit the securing bolts and tighten to 11 Ibf ft (1.5 kgf mI. Final drive - fitting 110 If the differential has been dismantled or certain compon· ents renewed (see paragraph 127) then it is essentiai that the setting o f the crownwheel and pinion is left to your dealer due to the need for special gauges. Under these circumstances, the jig setting of the selector mechanism (paragrap hs 85 to 103) should b e carried o u t by h im at the same time. 111 Where the differential /final drive has remained undisturbed during the gearbox overhaul operations, then reHt it in the following way. 112 Fit the differential inta the transmission housing so that the crownwhee l and pinion mesh . 113 Fit a new oil seal and O-ring to each of the adjusting rings. 114 Screw in the right-hand adjusting ring (they sh ou Id have been marked L or R before removalI by the exact number of turns recorded at dismantling until its mark is correctly aligned . 115 Centralise th e d iff erential in the transmission housing and screw in the opposite b earin g adjuster ring again to the original depth and stopp in g when the marks on ring and housing are in alignment . Release this ring o ne complete turn until the clutch bellhousing has been fitted . 116 To the right· hand side fit a new spacer, a lockplate seal, the lockplate, the kidney shaped plates and the Phillips screws. 117 Into the open end of t he gearcase , locate t he reverse gear sleeve a nta the end of the mainshaft. 118 Insert the input shaft, without its c ircl ip but with a threaded connecting stud screwed into its end, and pick up the reverse sleeve . Draw the sleeve towards you on the input shaft and screw th e shaft up tight with the mainshaft. Now unscrew il just a fraction (o ne spline) until th e sleeve can be pushed forward fre ely . 119 Fit a new circlip inta the input shaft groove. 120 Using a new joint gasket, bolt th e clutch bellhousing to the front of the transm ission case. Tighten the balts to 14 Ibf ft (1.9 kgf mI.
FIG .1221 REVERSE SlIDING GEAR CLEARANCE (a) TO MAINSHAFT
A
FIG.1222 PINlON DRIVESHAFT NUT STAKING DIAGRAM
A
0 '----"
StiJking tool
o
o o
o FIG .1 223
INTERMEDIATE
SELECTOR
LEVER
ARRANGEMENT 1 Weaker spring
2
Stronger spring
SPRING
211
Chapter 12/Supplement
\3
\5
4
FIG.1224 GEARSHIFT HOUSING COMPONENTS
l
2
Housing Bush
3
Inner selector lever
121 Set the left-hand differentia l bearing adjusting ring to its originally marked position (see paragraph 541 by screwing it in t he turn which it was backed off. 122 Refit the components detailed in paragraph 116. 123 F it the drive fl anges, th e thrust washers and using a piece of tublng, drive on new circlips. 124 Fit new plastic sealing caps to the centres of the drive flanges. 125 Refer to Chapter 4 for details of the clutch release mechanism and retit the components. 126 The gearbox may be filled with oil now or after the unit is fitted in the vehic le. 127 If any of the following components have been renewed then the final drive will require adjusting and settJng up by your VW dealer.
Transmission case Differential tapered roller bearings Pinjon bearing (double tapered roller) Pinion bearing circ/ip Crawnwheel and pinion Differential carrier or cover plate 128 The differential is adjusted in two ways : (il by shims at t he pin ian driveshaft tapered roller bearing to controi the dePth of mesh of the pinian teeth with those of the crownwheel, and (jj) by threaded adjust ing rings at the differential tapered roller bearings. Tightening or releasing the rings has the effect of moving the comp lete differential hOoJsing sideways within the transmission case, agaln altering the meshing depth of the crownwheel and pin ian teeth. 129 Without the special tools and gauges w hich your dealer will have for this work, it is virtually impossible to ca rry out adjustments which w ill not on ly cause noisy operation of the final drive but wil l also rapidly wear the transmission components.
4
Type
091
Spacer
manual gearbox
lubrication
5
(January
Seal
1976 on)
-
•
130 Commencing January 1976, this type of gearbox is 'fi lled for life' a nd periodic oil changes are not required. 131 A larger magnet is fitt ed to the drain plug to ensure that the lubricant is kePt free from swarf now that oil chang ing is no longer required.
8
Brak ing system
Disc calipers (Girling type) 1 As from SePtember 1975, Girling disc brake cal ipers are fittad as an alternative to the Teves type. 2 Pads shou ld be inspected regularly a nd renewed if th eir friction material hasworn down to 0.08 in (2.0 mml. 3 To renew the pads, remove the roadwhee l, extract the spring cl ips from the ends of the pins and tap out th e pins with a thin drift. 4 Remove the spring plate and pu ll the pads from the cal iper gripping them with a pair of pliers if necessary. 5 On the back of each pad is an anti-squeal sh im. Nate that the directional arrow points upwards_ 6 In order to accept the new thicker pads, the ca liper pistans will have to be depressed fully inta their cylinder bores. Use a flat bar such as a tyre lever to do this and anticipate a rise in the reservair fluid level by syphoning same fluid out before depressing the pistans. 7 Insert the pads ([dctian lining against th e disc) the antisqueal shims and insert t h e pins and spring clips. B Apply the footbrake hard severa l times to plJsition the pads against the disc. 9 Overhaul of a Girling caliper follows very dosely the operations described in Chapter B, Section 7 for the Teves type. Neve r attempt to release the bal ts which hold the two halves
12
212
Chapter 12/SuppJement
,
oJ} •
• •
(':\
••
I4
'j
\ '--
I
5
•
6
c,
l
.-
-3 2
I I
FIG.1225 GIRLlNG TYPE CALlPER
10
Retaining ring
8
Piston seal Piston
11
Anti-squeaf shim
9
Dust excluder
12
Friction pad
l
Discthub
4
Anti-ratt/e spring
7
2
Caliper body
5
Pad retaining pin
3
BJeed screw
6
Pin securing clip
of the caliper together. If fluid is seen to be leaking from the
joint, renew the caliper complete. 10 Girling and Teves caljpers can be interchanged but o nly in pairs on the same axle.
9
Electrical system
1974 on) - removal and
Master cylinder
Instrument panel (August refitting
11 On later modeis, the master cylinder used in con junctio n with a vacuum servo differs in detail from that used on systems without servo assistance. 12 Overhaul is similar with both types of cy linder.
1 Disconnect the battery. 2 Pull the knobs from the heater and ventilator controi levers . 3 Unscrew the instrument pan el securing 5crews a few turns but do not remove them completely and then reach behind
•
213
2
I
5-
o
--------------
... -C-- ---o
_ o _- - - -
22 - /
FIG.12.26 BRAKE MASTER CYLINDER IWITHOUT SERVO) l
2 3 4 5 6 7
Stop lamp switch St op lamp switch Sealing plug
8 9
Washer
Cup seal Cup washer
M aster cylinder bodY
10 ll
Secondary piston
Stop b olt Spring Support ring
12 13 14
Piston seal Piston seal Stroke limiting screw
15 16 17 18 19
Stop sleeve Spring
Support ring
20
Washer Cup seal Cup washer
21
Primary piston
22 23 24 25
Cup seal S top washer Dust exclud ing b o o t Circlip
12
214----------------------------------------------------------------~
1-,
--3
2
-..,-- .
• •
-
•
-
-- -
- -