* Volkswagen

Vanagon

Official Factory Repair Manual

1980, 1981' 1982, 1983, 1984, 1985,
1986,1987,1988,1989,1990,1991
Including Diesel, Syncro and Camper

Robert Bentley
Cambridge, Massachusetts
 Information that makes 1734 Massachusetts Avenue
the difference.., Cambridge, MA 02138 USA
800-423-4595/617-547-4170
http://www.rb.com
e-mail: sales@rb.com

WARNING-Important Safety Notice

Do not use this manual unless you are familiar with basic automotive repair procedures and safe workshop practices. This manual
illustrates the workshop procedures required for most service work; it is not a substitute for full and up-to-date information from the
vehicle manufacturer or for proper training as an automotive technician. Note that it is not possible for us to anticipate all of the ways
or conditions under which vehicles may be serviced or to provide cautions as to all of the possible hazards that may result.
The vehicle manufacturer will continue to issue service information updates and parts retrofits after the editorial closing of this
manual. Some of these updates and retrofits will apply to procedures and specifications in this manual. We regret that we cannot
supply updates to purchasers of this manual.
We have endeavored to ensure the accuracy of the information in this manual. Please note, however, that considering the vast
quantity and the complexity of the service information involved, we cannot warrant the accuracy or completeness of the information
contained in this manual.
FOR THESE REASONS, NEITHER THE PUBLISHER NOR THE AUTHOR MAKES ANY WARRANTIES, EXPRESS OR IMPLIED, THAT THE
INFORMATION IN THIS BOOK IS FREE OF ERRORS OR OMISSIONS AND WE EXPRESSLY DISCLAIM THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND OF FITNESS FOR A PARTICULAR PURPOSE, EVEN IF THE PUBLISHER OR AUTHOR HAVE BEEN ADVISED
OF A PARTICULAR PURPOSE, AND EVEN IF A PARTICULAR PURPOSE IS INDICATED IN THE MANUAL THE PUBLISHER AND AUTHOR
ALSO DISCLAIM ALL LIABILITY FOR DIRECT, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH RESULT FROM ANY
USE OF THE EXAMPLES, INSTRUCTIONS OR OTHER INFORMATION IN THIS BOOK. IN NO EVENT SHALL OUR LIABILITY WHETHER
IN TORT, CONTRACT OR OTHERWISE EXCEED THE COST OF THIS MANUAL.
Your common sense and good judgment are crucial to safe and successful service work. Read procedures through before starting
them. Think about whether the condition of your car, your level of mechanical skill, or your level or reading comprehension might
result in or contribute in some way to an occurrence which might cause you injury, damage your car, or result in an unsafe repair.
If you have doubts for these or other reasons about your ability to perform safe repair work on your car, have the work done at an
authorized Volkswagen dealer or other qualified shop.
Part numbers listed in this manual are for identification purposes only, not for ordering. Always check with your authorized
Volkswagen dealer to verify part numbers and availability before beginning service work that may require new parts.
Before attempting any work on your Volkswagen, read the warnings and cautions on pages ix and x and any warning or caution
that accompanies a procedure in the service manual. Review the warnings and cautions on pages ix and x each time you prepare
to work on your Volkswagen.
Special tools required to perform certain service operations are identified in the manual and are recommended for use. Use of tools
other than those recommended in this service manual may be detrimental to the car's safe operation as well as the safety of the
person servicing the car.

Copies of this manual may be purchased from authorized Volkswagen dealers, most automotive accessories and parts dealers
specializing in Volkswagens, from selected booksellers, or directly from the publisher by mail.
The publisher encourages comments from the reader of this manual. These communications have been and will be carefully
considered in the preparation of this and other manuals. Please write to Robert Bentley, Inc. at the address listed on the top of
this page.
Library of Congress Catalog Card No. 91-74020
ISBN 0-8376-0336-6
VWoA Part No. LPV 800 148
VWC Inc. Part No. MAN 101 251F
Bentley Stock No. VV91
01 00 99 98 10 9 8 7
The paper used in this publication is acid free and meets the requirements of the National Standard for Information Sciences-
Permanence of Paper for Printed Library Materials. 8
©Copyright 1991 Volkswagen United States, Inc.
Editorial closing July 15, 1991
All rights reserved. All information contained in this manual is based on the information available to the publisher at the time of
editorial closing. The right is reserved to make changes at any time without notice. No part of this publication may be reproduced,
stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, without the prior written consent of the publisher. This includes text, figures, and tables. All rights reserved under
Berne and Pan-American Copyright conventions.
Manufactured in the United States of America
 Foreword ...........•..................•...••.......• viii
Warnings and Cautions ...........•••.........••....... ix, x

Type/Model Identification ............................................................. . page2

VIN, Engine No ........................................................................... . page2
General Transmission No., manual ............................................................
Transmission No., automatic ........................................................
page3
page4
Lifting car with floor jack/hoist ...................................................... pages
Towing Car ................................................................................... page5

Repair Groups
Engine-Assembly ....................................................................... 10
Crankshaft/Crankcase ................................................... 13
Cylinder HeadsNalve Drive ......................................... .. 15
Lubrication System ....................................................... . 17
Cooling System ............................................................ . 19
Engine Fuel Supply ..................................................................................
Fuel Injection-Diesel System .....................................................
20
23
Fuellnjection-AFC System ........................................................ 24
Fuel Injection-Water-cooled ....................................................... 24
Exhaust System/Emission Controls ............................................. 26
Electrical-Battery, Starter, Alternator ....................................... .. 27
Ignition System ............................................................................ . 28

Clutch, Controls ............................................................................ 30

Clutch Torque Converter ..........................................................................
Manual Transmission-Controls, Assembly ............................... ..
32
34
Case, Gears, Shafts .............................. .
Transmission Automatic Transmission-controls, Assembly ........................... ..
35
37
Case, Gears, Shafts ......................... .. 38
Differential .................................................................................... 39

Suspension Front Wheel Suspension-Shafts and Axle ............................... ..

Rear Wheel Suspension-Shafts and Axle ............................... ..
40
42
Brakes Wheels, Tires, Wheel Alignment ................................................ ..
Brakes-Mechanical Components ...............................................
44
46
Hydraulic Components, Regulator, Booster ................. . 47
Steering Steering ........................................................................................ 48

Body Dimensions ........................................................................ 50

Hoods/Lids .................................................................................... 55
Doors- Front ............................................................................... 57
Sunroof~~~~:.~.~~~~~~
58
.. ::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: 60
Tarpaulin ...................................................................................... 61
Bumpers ...................................................................................... 63
Glass, Window Regulators .......................................................... 64
Body Body Accessories, Exterior .........................................................
Seat Belt System .........................................................................
66
68
Heater Trim -Interior ...............................................................................
Seats ............................................................................................
70
72
Body-Seat Upholstery ............................................................... 74
Camper-Interior Panels, Roof .................................................... 75
Cabinets, Water Tank, Refrigerator ............................ . 76
Seats, Beds ................................................................. 77
HeaterNentilation ......................................................................... 80
Heater Booster ............................................................................ 82
Air Conditioner ............................................................................. 87

Instruments, Radio ..................................................................... .. 90

Windshield Wiper and Washer ..................................................... 92
Electrical Lights-Exterior ........................................................................... 94
Wiring ........................................................................................... 97

Vehicle Ca1'9 ••................•.•........•.....•.....• 1

Appendix Do-it-yourself Service .................................. 20
Technical Data ....................................... 26
Maintenance Tables ................................... 28
Foreword

Service to Volkswagen owners is a top priority of Volkswagen organization and has

always included the continuing development and introduction of new and expanded servic-
es. In line with this purpose, Volkswagen United States, Inc. has introduced this Volkswagen
Official Factory Repair Manual.

This Vanagon manual covers the model years 1980 through 1991 including Air-cooled
and Water-cooled Gasoline Engines, Diesel Engine, Syncro and Camper. This manual was
specifically written to cover U.S. and Canada models only.

For the Volkswagen owner with basic mechanical skills and for independent garages,
this manual gives all the specifications and procedures that were available in an authorized
Volkswagen service department as this manual went to press. In addition, the Volkswagen
owner who has no intention of working on his or her vehicle may find that reading and own-
ing this manual will make it possible to be better informed and to discuss repairs more intel-
ligently with a professional automotive technician.

This manual has been prepared from the repair information that the Volkswagen orga-
nization provides to its own factory-trained technicians and has been developed primarily
with the professional automotive technician in mind. The aim throughout has been clarity
and completeness with step-by-step procedures and accurate specifications.

The Volkswagen owner intending to do maintenance and repair should have a set of
metric wrenches and sockets, a torque wrench, screwdrivers, and feeler gauges, since
these basic hand tools will be used for a majority of the repairs described in this manual.
Usually, the text will note when a repair requires special tools.

This manual is organized so that, whenever possible, when a change has been made
within a model year, the vehicle identification number (VIN) of the first vehicle with this
change is given. The digits you need to know for this parts and service information are taken
from the seventeen digit VIN number. If, for example the VIN is WVWZZZ24ZBH000001,
you will need only nine of the last eleven digits of this number-or, more specifically, the dig-
its 24 8 000001. Your Volkswagen's VIN is found on the left doorjamb and on a plate mount-
ed on the driver's side of the instrument panel padding where the number can be seen
through the windshield. The VINs assigned to Vanagon models for the years 1980 through
1991 which are covered by this manual are:

1980: ______ 25_A_000001 to ______ 25_A_999999

1981: ______ 25_8_000001 to ______ 25_8_999999
1982: ______ 25_C_000001 to ______ 25_C_999999
1983: ______ 25_0_000001 to ______ 25_0_999999
1984: ______ 25_E_000001 to _____25_E_999999
1985: ______ 24_F_000001 to ______ 24_F_999999
______ 25_F_000001 to ______ 25_F_999999
1986: ______ 24_G_000001 to ______ 24_G_999999
______ 25_G_000001 to ______ 25_G_999999
1987: ______ 24_H_000001 to ______ 24_H_999999
______ 25_H_000001 to ______ 25_H_999999
1988: ______ 24_J_000001 to ______ 24_J_999999
______ 25_J_000001 to ______ 25_J_999999
1989: ______ 24_K_000001 to ______ 24_K_999999
______ 25_K_000001 to ______ 25_K_999999
1990: ______ 24_L_000001 to ------~4_L_999999
______ 25_L_000001 to ______ 25_L_999999
1991: ______ 24_M_000001 to ______ 24_M_999999
______ 25_M_000001 to ______ 25_M_999999

We have endeavored to ensure the highest degree of accuracy possible. When the
vast array of data presented in this manual is taken into account, however, no claim to infal-
libility can be made. We therefore cannot be responsible for the resukof any errors that may
have crept into the text. The Publisher encourages comments from the readers of this man-
ual in regard to any errors and, also, suggestions for improvement in the presentation of the
technical material. These communications have been and will be carefully considered in the
preparation of this and other manuals. Please write to Robert Bentley, Inc., Cambridge, Mas-
sachusetts 02138.

Volkswagen offers extensive warranties, especially on components of the fuel delivery

and emission control systems. Therefore, before deciding to repair a Volkswagen that may
still be covered wholly or in part by any warranties issued by Volkswagen United States, Inc.,
consult your authorized Volkswagen dealer. You may find that he can make the repair either
free or at minimum cost. Regardless of its age, or whether it is under wc::trranty, your Volkswa-
gen is both an easy vehicle to service and an easy vehicle to get serviced. So if at any time
a repair is needed that you feel is too difficult to do yourself, a trained Volkswagen technician
is ready to do the job for you.

Robert Bentley
Please read these warnings and cautions
before proceeding with maintenance and repair work.
WARNING-
• Some repairs may be beyond your capability. If you lack the
skills, tools and equipment, or a suitable workplace for any proce-
dure described in this manual, we suggest you leave such repairs
to an authorized Volkswagen dealer service department, or other
qualified shop.
• Volkswagen is constantly improving its cars. Sometimes these
changes, both in parts and specifications, are made applicable to
ear1ier models. Therefore, before starting any major jobs or repairs
to components on which passenger safety may depend, consult
your authorized Volkswagen dealer about Technical Bulletins that
may have been issued since the editorial closing of this manual.
• Do not re-use any fasteners that are worn or deformed in normal
use. Many fasteners are designed to be used only once and
become unreliable and may fail when used a second time. This
includes, but is not limited to, nuts, bolts, washers, self-locking
nuts or bolts, circlips and cotter pins. Always replace these fasten-
ers with new parts.
• Never work under a lifted car unless it is solidly supported on
stands designed for the purpose. Do not support a car on cinder
blocks, hollow tiles or other props that may crumble under contin-
uous load. Never work under a car that is supported Solely by a
jack. Never work under the car while the engine is running.
• If you are going to work under a car on the ground, make sure
that the ground is level. Block the wheels to keep the car from roll-
ing. Disconnect the battery negative(-) terminal (Ground strap) to
prevent others from starting the car while you are under it.
• Never run the engine unless the work area is well ventilated.
Carbon monoxide kills.
• Finger rings, bracelets and other jewelry should be removed so
that they cannot cause electrical shorts, get caught in running
machinery, or be crushed by heavy parts.
• lie long hair behind your head. Do not wear a necktie, a scarf,
loose clothing, or a necklace when you work near machine tools or
running engines. If your hair, clothing, or jewelry were to get
caught in the machinery, severe injury could result.
• Do not attempt to work on your car if you do not feel well. You
increase the danger of injury to yourself and others if you are
tired, upset or have taken medication or any other substance that
may keep you from being fully alert.
• Illuminate your work area adequately but safely. Use a portable
safety light for working inside or under the car. Make sure the bulb
is enclosed by a wire cage. The hot filament of an accidentally bro-
ken bulb can ignite spilled fuel or oil.
• Catch draining fuel, oil, or brake fluid in suitable containers. Do
not use food or beverage containers that might mislead someone
into drinking from them. Store flammable fluids away from fire haz-
ards. Wipe up spills at once, but do not store the oily rags, which
can ignite and bum spontaneously.
• Always observe good workshop practices. Wear goggles when
you operate machine tools or work with battery acid. Gloves or
other protective clothing should be worn whenever the job requires
working with harmful substances.
• Friction materials such as brake or clutch discs may contain
asbestos fibers. Do not create dust by grinding, sanding, or by
cleaning with compressed air. Avoid breathing asbestos fibers and
asbestos dust. Breathing asbestos can cause serious diseases
such as asbestosis or cancer, and may result in death.
• Disconnect the battery negative (-) terminal (Ground strap)
whenever you work on the fuel system or the electrical system. Do
not smoke or work near heaters or other fire hazards. Keep an
approved fire extinguisher handy.
• Batteries give off explosive hydrogen gas during charging.
Keep sparks, lighted matches and open flame away from the top
of the battery. If hydrogen gas escaping from the cap vents is
ignited, it will ignite gas trapped in the cells and cause the battery
to explode.
• Connect and disconnect battery cables, jumper cables or a bat-
tery charger only with the ignition switched off, to prevent sparks.
Do not disconnect the battery while the engine is running.
• Do not quick-charge the battery (for boost starting) for longer
than one minute. Wait at least one minute before boosting the bat-
tery a second time.
• Do not allow battery charging voltage to exceed 16.5volts. If the
battery begins producing gas or boiling violently, reduce the charg-
ing rate. Boosting a sulfated battery at a high charging rate can
cause an explosion.
• The air-conditioning system is filled with chemical refrigerant,
which is hazardous. The A/C system should be serviced only by
trained technicians using approved refrigerant recovery/recycling
equipment, trained in related safety precautions, and familiar with
regulations governing the discharging and disposal of automotive
chemical refrigerants.
• Do not expose any part of the A/C system to high temperatures
such as open flame. Excessive heat will increase system pressure
and may cause the system to burst.
• Some aerosol tire inflators are highly flammable. Be extremely
cautious when repairing a tire that may have been inflated using
an aerosol tire inflator. Keep sparks, open flame or other sources
of ignition away from the tire repair area. Inflate and deflate the tire
at least four times before breaking the bead from the rim. Com-
pletely remove the tire from the rim before attempting any repair.
• Some cars covered by this manual are equipped with a supple-
mental restraint system (SRS), that automatically deploys an
airbag in the event of a frontal impact. The airbag is inflated by an
explosive device. Handled improperly or without adequate safe-
guards, it can be accidently activated and cause serious injury.
• Greases, lubricants and other automotive chemicals contain toxic
substances, many of which are absorbed directly through the skin.
Read manufacturer's instructions and warnings carefully. Use hand
and eye protection. Avoid direct skin contact.
continued on next page
ix
Please read these warnings and cautions
before proceeding with maintenance and repair work.
CAUTION-
• If you lack the skills, tools and equipment, or a suitable work·
shop for any procedure described in this manual, we suggest you
leave such repairs to an authorized Volkswagen dealer or other
qualified shop.
• Volkswagen offers extensive warranties, especially on compo-
nents of fuel delivery and emission control systems. Therefore,
before deciding to repair a Volkswagen that may still be covered
wholly or in part by any warranties issued by Volkswagen United
States, Inc., consult your authorized Volkswagen dealer. You may
find that he can make the repair for free, or at minimal cost.
• Volkswagen part numbers listed in this manual are for identifica-
tion purposes only, not for ordering. Always check with your
authorized Volkswagen dealer to verify part numbers and avail-
ability before beginning service work that may require new parts.
• Before starting a job, make certain that you have all the neces-
sary tools and parts on hand. Read all the instructions thoroughly,
do not attempt shortcuts. Use tools appropriate to the work and
use only replacement parts meeting Volkswagen specifications.
Makeshift tools, parts and procedures will not make good repairs.
• Use pneumatic and electric tools only to loosen threaded parts
and fasteners. Never use these tools to tighten fasteners, espe-
cially on light alloy parts. Always use a torque wrench to tighten
fasteners to the tightening torque specification listed.
X
• Be mindful of the environment and ecology. Before you drain the
crankcase, find out the proper way to dispose of the oil. Do not
pour oil onto the ground, down a drain, or into a stream, pond or
lake. ConsuH local ordinances that govern the disposal of wastes.
• On cars equipped with anti-theft radios, make sure you know
the correct radio activation code before disconnecting the battery
or removing the radio. If the wrong code is entered into the radio
when power is restored, that radio may lock up and be rendered
inoperable, even if the correct code is then entered.
• Connect and disconnect a battery charger only with the battery
charger switched off.
• Do not quick-charge the battery (for boost starting) for longer
than one minute. Wait at least one minute before boosting the bat-
tery a second time.
• Sealed or "maintenance free" batteries should be slow-charged
only, at an amperage rate that is approximately 10% of the bat-
tery's ampere-hour (Ah) rating.
• Do not allow battery charging voltage to exceed 16.5 voHs. If the
battery begins producing gas or boiling violently, reduce the charg-
ing rate. Boosting a sulfated battery at a high charging rate can
cause an explosion.
 Index
Battery (Cont'd) Bumpers
WARNING- -Electrolyte level 27.4 -Front bumper/spoiler 63.2
• Automotive service and repair is serious -Filler caps 27.7 -Rear bumper 63.3
business. You must be alert, use common - Location(s) 27.8
sense, and exercise good judgement to
-Nomenclature 27.2 Camper Equipment
prevent persona/Injury and complete the
-Safety precautions 27.4 -Ceiling cabinet
K0/1( safely.
-Troubleshooting 27.10 with A/C, installing 76.9
• Before beginning any work on your with A/C, removing 76.7
Volkswagen, thoroughly read all the Body without A/C, removing/installing 76.6
cautions and warnings listed near the -Acid rain, removing spots 50.6 -Clothes closet
hont of this manual. -Adhesives materials 50.5 installing 76.11, 76.14
• Always read the complete procedure -Body Dimensions removing 76.9, 76.11
before you begin the work. Pay special door 50.4 -Curtains
attention to any Cautions and Warnings floor 50.2 removing/installing 76.3
that accompany that procedure, or other windshield 50.4 -Curtain rail w/fresh air duct
Information on a specific topic. -Painting installing 76.6
pop-up roof/luggage carrier 50.5 removing 76.5
Air Conditioner -Plastics, identifying 50.5 - Propane tank
-Adapter valve VAG 1637 repairing 50.5 removing/installing 76.23
installing 87.15 - Refrigerator
- Air distribution system Brakes-Hydraulic Components, air supply modification 76.25
components 87.9 Regulator, Booster installing 76.25
-Component locations 87.2 - Brake booster assembly 47.1 o removing 76.24
-Compressor (Sanden SD510) checking 47.10 -Sink cabinet
replacing 87.16 - Brake caliper installing 76.23
-Evaporator Girling (1980-1985) assembly 47.5 removing 76.15
removing/installing 87.14 Girling/Teves (1980-1985) -Storage chest w/water tank
-Evaporator housing disassembling/assembling 47.6 installing 76.17
disassembling/assembling 87.12 Girling/Teves (from 1986) removing 76.15
removing 87.1 0 assembly 47.7a -Storage shelf
-Expansion valve Teves (1980-1985) assembly 47.4 removing/installing 76.2
removing/installing 87.14 Teves (1980-1985), noise w/curtain rod
-Fuses, locations 87.4 dampening plates 47.7 removing/installing 76.4
- Refrigerant system Brake fluid, changing -Water faucet w/pump switch
capacity 87.7 with US 1116 47.8 removing/installing 76.20
cautions and warnings 87.7 without US 1116 47.8a -Water level sensor
controls 87.6 Brake hydraulic system removing/installing 76.20
discharging 87.8 general repair notes 47.8 -Water pump/kitchen
-Relays, locations 87.5 -Brake master cylinder removing/installing 76.18
assembly 47.2
Alignment Brake pressure regulator Clutch
-See Wheels checking 47.8a - Bearing shaft bushing
-Brake system, bleeding Syncro 30.9
Alternator with US 1116 47.8 -Brake/Clutch fluid
-Alternator/Regulator without US 1116 47 .8a reservoir 30.3
checking 27.18 -Check valve Clutch assembly
-Heater blower fan checking 47.10 diesel30.5
removing/replacing 27.22 -Rear wheel cylinder assembly 47.8 gasoline 30.4
-Indicator light, troubleshooting 27.23 Syncro 30. 10
-Mount, adjusting 27.22 Brakes-Mechanical Components Controls 30.2
-Removing/Installing 27.15 Brake pedaVIinkage Syncro 30.8
-Repairing assembly 46.1 o -Diaphragm spring 30.6
45A, 65A 27.16 -Front brake Syncro 30.11
90A 27.17 assembly (1980-1985) 46.2 -Hydraulic system 30.2
-System layout 27.19 assembly (from 1986 m.y.) 46.5 Syncro 30.8
-V-belt pads (1980-1985) -Pressure plate 30.6
adjusting 27.21 removing/installing 46.3 air-cooled modification 30.6
replacing 27.21 pads (from 1986 m.y.) Syncro 30.11
-Voltage regulator 27.20 removing/installing 46.5a Release bearing 30.7a
-Parking brake assembly 46.11 air-cooled only 30.7
Battery -Rear brake -Release shaft bushing 30.3
-Charging 27.5 assembly 46.6 Syncro 30.9
-Checking 27.4 shoes, adjusting 46.9 -Roll pin 30.3
shoes, removing/installing 46.7

xi
Index
Cooling System-Air-cooled AFC Differential-Automatic Trans. (cont'd) Do-it-yourself Service
-Cooling air control flap - Ring gear/pinion (Appendix) (cont'd)
adjusting 19.3 adjusting 39.57 -Jack and tools A20
-Cooling fan backlash 39.61 - Replacing bulbs A23
removing 19.3 -Torque converter oil seal39.51 -Spare wheel A20
-Fan housing assembly 19.2
removing 19.3 Differential-Manual Trans. Doors-Front
-Snap-lock wiring connectors 091, 091/1, 4-Speed -Adjusting 57.5
installing 19.19 094 5-Speed (except 4WD) -Assembly 57.2
-Thermostat -Assembly 39.2 -Glass 57.4
checking 19.3 -Bearings 39.3 -Guide channel57.5
-V-belt -Housing 39.3 -Handles 57.3
assembly 19.2 -Pinion, adjusting 39.1 0 -Lock/Lock rod 57.3
tension, adjusting 19.3 - Pinion/Side gears 39.6 - Lost/Broken keys
-Ring gear 39.3 code location 57.8
Cooling System-Diesel adjusting 39.12 -Power door locks 57.6
-Antifreeze hydrometer backlash 39.13 -Whistling noises
checking 19.7 - Ring/Pinion gears eliminating 57.1 0
-Coolant assembly 19.4 adjusting 39.7 -Window regulator 57.4
draining/filling 19.6 -Shim S3 39.11
mixture ratio 19.5 Doors-Rear
pipes, replacing 19. 7a Differential-Manual Trans. -Center hinge
-Snap-lock wiring connectors 094 5-Speed with 4WD adjusting 58.9
installing 19.19 - Differential with lock assembly 58.8
- Pressure cap, checking 19.7 assembly 39.20 removing/installing 58.9
bearing outer race 39.24 -Sliding door 1980-1984
Cooling System-Water-cooled bearings 39.21 bowden cables, adjusting 58.7
-Antifreeze hydrometer housing 39.21 door cover 58.3
checking 19.17 pinion shafts 39.22 door handle inner/outer 58.3
-Coolant assembly 19.8, 19.11, 19.14 ring gear 39.20 door lock buffer 58.3
draining/filling 19.15 "'-- Differential without lock lock, front 58.2
expansion tank, checking 19.18 assembly 39.15 lock, rear 58.6
hose layout 19.10 bearing outer race 39.19 lock plate, remote control 58.6
leak checks 19.17 bearings 39.16 lubricating 58.7
mixture ratio 19.18 housing 39.16 removing/installing 58.4
refill tank 19.9, 19.13 pinion shafts 39.17 striker plate, adjusting 58.5
-Hose spring clamps ring gear 39.15 -Sliding door, from 1985
removing/installing 19.16 - Driveshaft flange oil seal 39.44 assembly 58.10
-Hot footwell kit, installing 19.20 removing/installing 39.43 central lock 58.20
-Radiator assembly 19.12 -Front final drive 39.30 door cover 58.11
thermo-switch 19.12 adjusting rings 39.32 handle 58.22
axle flange 39.32 hinge link, adjusting 58.16
Cruise Control circlip 39.33 hinge link, assembly 58.21
-System, repairing 27.25 housing 39.34 modifications 58.11
-Troubleshooting 27.29 mounting 39.32 remote control lock 58.18
technical data 39.42 removing/installing 58.12
Current Flow Diagrams - Front pinion 39.39 roller guides, adjusting 58.14
- See Electrical Wiring bearing 39.40 striker pin, adjusting 58.15
grooved nut 39.40
Differential-Automatic Trans. turning torque 39.41 Electrical Wiring-Air-cooled AFC
-Adjusting ring 39.51 - Locking pin 39.28 -1980,1981
-Assembly 39.56 - Pinion/Side gears 39.25 cautions and warnings 97.2
-Cover plate 39.51 - Removing 39.33 fresh air fan 97.23
-Differential bearing outer race 39.53 - Ring gear/Pinion fuse/relay panel 97.10
-Drive flange oil seal 39.53 adjusting 39.26 heater booster 97.24
- Final drive assembly 39.50 main wiring diagram 97.12
-Governor oil seal 39.52 Do-it-yourself Service rear window wiper 97.26
- Pinion bearing (Appendix) seat belt interlock system 97.27
inner race 39.54 -Changing a wheel A21 -1982, 1983
outer race 39.53 -Emergency starting A25 cautions and warnings 97.2
- Pinion oil seals 39.52 -FusesA22 fresh air fan 97.23
- Ring gear 39.56 -Headlight adjustment A25 fuse/relay panel 97.10
heater booster 97.24

xii
 Index
Electrical Wiring-General (cont'd) Electrical Wiring-Water-cooled
WARNING- -Fuse/Relay panel, removing (cont'd)
• Automotive setvice snd repair is serious 1980-1985 97.10 -Main wiring diagram (cont'd)
business. Youmustbealert, use common from 1986m.y. 97.10a from VIN G 055 690 97.85
sense, snd exercise good judgement to -How to read wiring diagrams 97.4 198797.102
prevent personal injury snd complete the
-Main wiring harness 97.8 1988, 1989 97.119
worl< safely.
-Starter cable routing 97.9 from 1990 97.201
• Before beginning any work on your -Symbols used in wiring diagrams 97.5 -Power mirrors
Volkswagen, thoroughly read all the -Troubleshooting 97.3 1986uptoVING 10500097.183
cautions and Warnings listed near the -Working on the 1986 from VIN G 105 001 97.185
front of this manual. electrical system 97.3 from 1987 97.185
• Always read the complete procedure - Power windows
before you begin the work. Pay special Electrical Wiring-Water-cooled 1986 97.187
attention to any Cautions and Warnings Air conditioning from 1987 97.189
that accompany that procedure, or other 1984, 1985 97.137 -Radio 198697.191
information on a specific topic. 1986-1988 97.139 -Rear footwall heater blower
from 1989 97.142 1983-1985 97.194
Electrical Wiring-Air-cooled AFC -Automatic transmission Stereo radio
(confd) 1986-1989 97.146 1987-1989 97.195
-1982, 1983 (cont'd) from 1990 97.219 -Stereo radio with amplified speakers
main wiring diagram 97.18 -Auxiliary battery from 1988 97.197
rear window wiper 97.26 1986-1989 auto. trans. 97.221 - Stereo radio with 4 speakers
seat belt interlock system from 1990 97.224 from 1990 97.246
(1982 only) 97.27 See also 97.29 - 450-Watt radiator cooling fan
-Auxiliary heater BA6 1986-1989 97.200
Electrical Wiring-Camper from 1987 Canada only 97.148
-Auxiliary battery 1986·1989 -Auxiliary heater BBW46 Emission Controls
(man. trans.) 97.34 (Syncro) -Air-cooled AFC
(also see 97.53) 1986-1988 Canada 97.151 Calif. 1981 26.4
-Battery level indicator lights 97.30 from 1989 Canada 97.155 Calif. except 1981 26.3
-Camper electrical equipment -Central locking system -Catalytic converter
1980-1985 97.32 1986 97.165 checking 26.11
from 1986 97.33 1987-1989 97.162 -EGA valve26.5
-Water pump 97.31 from 1990 97.226 USA (except Calif.)
-Water tank level -Crankcase ventilation and Canada 26.2
indicator lights 97.30 heat element - Diesel26.6
1985 97.165 -Water-cooled Digifant
Electrical Wiring-Diesel 1986 97.166 assembly 26.9
-1982 -Cruise control -Oxygen sensor
auxiliary heater BA6 auto. trans. water-cooled Digijet 26.8
(Canada only) 97.47 1986 97.168
cautions and warnings 97.2 1987-1989 97.176 Engine-Air-cooled AFC
fuse/relay panel 97.10 from 1990 97.229 -Assembling
heater booster 97.49 -Cruise control man. trans. crankcase 13.6, 13.14
main wiring diagram 97.36 1986 97.174 . sheet metal 13.2
-current track index 97.36 1987-1989 97.171 -Camshaft 13.14
rear window wiper 97.26 from 1990 97.232 -Carbon deposits, reducing 15.25
-1983 -Daytime running lights -Carrier/Support 13.5
auxiliary heater BAS (Canada) -Compression pressure
(Canada only) 97.47 to Dec. 1989 97.234 checking 15.2
cautions and warnings 97.2 from Dec. 1989 to May 1990 97.238 values 2a
fuse/relay panel97.10 from May 1990 97.241 -Connecting rod 13.16
heater booster 97.49 - Differential lock -Crankshaft
main wiring diagram 97.41 1986-1989 Syncro 97.178 assembly 13.16
current track index 97.41 -Heated driver's seat circlips 13.16
rear window wiper 97.26 198697.179 end play 13.10
1987-1989 Canada 97.181 oil seals 13.9
Electrical Wiring-General from 1990 Canada 97.244 pilot bearing 13. 17
-Battery/Ground cables 97 .9a -Main wiring diagram -Cylinder 13.11
disconnecting/connecting 97.6 1983, 1984 97.54 -Cylinder head 15.2
-Cautions and Warnings 97.2 1985 97.60 -Disassembling
-Dashboard wiring harness 97.7 1986 crankcase 13.6
-Engine/Body up to VIN G 055 689 97.67 sheet metal13.2
ground connections 97.6

xiii
Index
Engine-Air-cooled AFC (cont'd) Engine-Diesel (cont'd) Engine-Water-cooled (confd)
- Distributor -Intermediate shaft oil seal 13.22 - Pushrod tubes
drive gear 13.16 Lubrication system replacing 15.25
driveshaft 13.8 assembly 17.4 -Removing 10.8
installing 13.9 oil cooler 17.4 -Torque converter drive plate 13.40
- Flywheel13.9 oil filter 17.4 - V-belt pulley 13.34, 13.42
Gasoline additive 15.25 oil pan 17.4 -Valves
Hydraulic valve lifters 15.6 oil pressure switch 17.4, 17.6 assembly 15.17
-Installing 10.5 oil pump 17.4 dimensions 15.18
-Lubrication -Pilot bearing 13.22 guides 15.20
assembly 17.2 -Piston 13.27 hydraulic lifters 15.23
oil cooler 17.2 clearance 13.29 seats, refacing 15.18
oil pressure switch 17.2 diameter 13.29 springs 15.18
oil pump 17.2 height 13.31
- Piston rings 13.11 identification 13.31 Exhaust System
-Pistons 13.11 marking 13.28 -Air-cooled AFC
-Removing 10.2 pin 13.28 Calif. 1981 26.4
-Rocker arm shaft 15.3 ring end gap 13.29 Calif. except 1981 26.3
-Torque converter drive plate 13.9 ring side clearance 13.29 USA (except Calif.)
-Valves rings 13.27 and Canada 26.5
assembly 15.2 - Removing 10.6 -Catalytic converter
dimensions 15.3 Valve assembly 15.10 checking 26.11
guides 15.4 - Diesel26.6
hydraulic lifters 15.6 Engine-Water-cooled -Oxygen sensor
seats 15.4 -Assembling/Disassembling 13.32 water-cooled Digijet 26.8
springs 15.2 -Camshaft 13.50 -Water-cooled
-Carbon deposits, reducing 15.25 Digifant 26.9
Engine-Diesel -Carrier/Support 13.37a Digijet 26.7
-Camshaft assembly 15.10 -Compression pressure
end play 15.15 checking 15.20 Fuel Injection-Air-cooled AFC
oil seal15.15 values2a AFC system check 24.15
radial clearance, checking 15.15a -Crankshaft assembly 13.52 -Air filter housing 24.8
run-out 15.15 circlips 13.54 -Auxiliary air regulator 24.8
-Camshaft drive belt 13.18 drive gear 13.54 -Cold-start valve 24.5
-Compression pressure end play 13.40 -Control unitJWiring harness 24.12
checking 15.16 oil seals 13.39 Deceleration valve 24.7
values 2a pilot bearing 13.56 -Double relay 24.13
Connecting rod 13.27 replacing (1.9L) 13.57 Full throttle enrichment
bearing clearance 13.30 -Cylinder 13.43 switch 24.13
bolts 13.30 -Cylinder head assembly 15.17 -Idle speed/CO 24.10
side clearance 13.30 installing 15.23 -Injector resistance 24.6
-Crankshaft 13.22 sealing 15.23, 15.26 -Injector spray pattern/
bearing caps 13.22 Distributor leak checking 24.7
drive belt cover 13.21a drive gear 13.38 -Intake air sensor housing 24.8
end play 13.24 driveshaft 13.38 -Intake air/temp. sensors 24.9
journal sizes 13.23 installing 13.38 -Oxygen sensor/Wiring 24.16
-main bearing clearance 13.25 Engine block assembly 15.22 Pressure regulator 24.5
oil seal - Flywheel 13.40 -Speed limit switch 24.14
drive belt side 13.26 -Gasoline additive 15.25 -System components 24.2
flywheel side 13.25 -Installing 10.10 Calif. 24.4
sprocket bolt 13.21 -Lubrication system USA (except Calif.)
-Cylinder block 13.27 assembly 17.7 and Canada 24.3
bore dimensions 13.30 crankcase breather, -Temperature sensor II 24.13
clearance 13.30 heating pipe 17.9 -Thermo-time switch 24.6
-Cylinder head oil pressure switch 17.9 Voltage supply/
assembly 15.8 oil pump 17.9 series resistance 24.6
bolts 15.9 -Piston pin hole burrs
distortion 15.11 removing 13.47 Fuel Injection-Diesel
gasket 15.9 - Pistons 13.43 -Cold start cable 23.5
-Cylinder head gasket 13.19, 13.31 classifications 13.44 - Engine speed 23.5
Flywheel 13.23 pin 13.44 -Fuel cut-off solenoid 23.5
Installing 10.7 rings 13.45 - Fuel delivery valve/housing 23.7
-Intermediate plate 13.23

xiv
 Index
Fuel Injection-Water-cooled Glass, Window Regulators
WARNING- Digijet (cont'd) -Gluing rubber window seals
• Automotive setvice and repair is serious -Full throttle enrichment switch 24.34 from 1986 MY
business. You must be alert, use common checking/adjusting 24.29
sense, and exercise good judgement to rear lid window 64.5
Idle speed/CO side window 64.4
prevent personal injury and complete the
worlc safely.
checking/adjusting 24.29 sliding door window 64.5
-Intake air sensor 24.28 -windshield 64.3
• Before beginning any work on your housing 24.27 - Power window motor
Volkswagen, thoroughly read aU the -Pressure regulator 24.25 from 1986 MY
Cautions and Warnings listed near the -System check 24.20
front of this manual.
installing 64.7
System components 24.22 removing 64. 6
• Always read the complete procedure early version 24.24 -Sliding window
before you begin the work. Pay special late version 24.24a replacing guides 64.2
attention to any Cautions and Warnings -Temperature sensor I 24.28
that accompany that procedure, or other -Temperature sensor II 24.32 Heater-Auxiliary BBW 46
information on a specific topic. -Throttle valve/deceleration/ -Combustion air blower
idle switch 24.33 adjusting 82.32
Fuel Injection-Diesel (cont'd)
removing/installing 82.32
- Fuel filter water indicator kit Fuel Supply-Air-cooled AFC -Components 82.20
installing 23.10 Accelerator linkage/cable -Electrical wiring 82.24
-Fuel injectors 23.8 auto. trans. 20.8 -Engine coolant system
-Injection pump 23.6 man. trans. 20.6 draining/refilling 82.35
-Injection pump/valve timing 23.3 -Fuel filter 20.4 -Felt pad
-Injection system 23.2 Fuel gauge sending unit 20.4 removing/installing 82.29
-Injection timing 23.4 -Fuel pump 20.7 -Flame head
- Fuel system 20.2 removing/installing 82.33
Fuel Injection-Water-cooled leak checking .20.5 -Flame switch
Dlglfant - Fuel tank 20.4 checking 82.30
-Deceleration fuel shutoff 24.60
removing/installing 82,30
-Electrical testing 24.61 Fuel Supply-Diesel -FuseS24
-Fuel injection system -Accelerator linkage/cable 20.14 removing/installing 82.33
components 24.48 - Fuel gauge sending unit 20.13 -Glow plug, checking 82.30
repairing 24.46 Fuel system 20.10 -Heater core
- Fuel injectors, checking 24.56 leak checking 20.13 removing/installing 82.33
- Full throttle enrichment - Fuel tank 20.12 -Metering pump
checking 24.60
flow rate checking 82.35
-Idle speed/CO content Fuel Supply-Water-cooled -Operating 82.25
checking/adjusting 24.50 Dlgifant - Recirculation pump
-Idle stabilizer -Accelerator linkage/cable removing/installing 82.32
checking 24.53 adjusting 20.32 -Series resistor
-Intake air sensor auto. trans. 20.31 removing/installing 82.32
checking 24.57 man. trans. 20.30 -Temperature sensor
-Oxygen sensor -Charcoal filter 20.33 checking 82.31
checking 24.54 -Fuel gauge sending unit 20.29 removing/installing 82.31
- Pressure regulator -Fuel pump 20.29 -Waterflow 82.22
checking 24.55 -Fuel system 20.26
-Safety precautions 24.42 leak checking 20.21 Heater Booster-Air-cooled AFC
-Technical data 24.43 -Fuel tank 20.28 -Air circulation blower 82.7
-Throttle valve -Assembly 82.3
basic adjustment 24.37 Fuel Supply-Water-cooled -Combustion air blower 82.3
-Throttle valve switch 24.58 Dlgijet -Control flaps 82.8
-Accelerator linkage/cable - Defroster/Footwall flaps 82.7
Fuel Injection-Water-cooled auto. trans. 20.23 -Flame switch 82.5
Dlgljet man. trans. 20.22 - Fuel pump 82.6
-Air filter housing 24.27 -Charcoal filter valve 20.20 -Glow/Spark plug 82.3
-Auxiliary air regulator 24.27 -Fuel filter 20.18 -Heater booster/components 82.2
-Control unit/Wire harness 24.31 -Fuel gauge sending unit 20.18 -Heater lever ~witch 82.8
checking 24.35 -Fuel pump 20.19 · -Ignition coil 82.6
Data/Specifications 24.18 -Fuel system 20.16 -Overheat switch 82.7
-Double relay 24.32 -Fuel tank 20.18 -Safety switch 82.7
-Fuel injectors 24.25 -Leak checking 20.21 -Temperature regulating switch 82.5
troubleshooting 24.38 -Temperature sensor 82.6
-Troubleshooting 82.10

XV
Index
Heater Booster-Water-cooled
-Air circulation blower 82.17
-Combustion air blower 82.14
-Control valve 82.17
-Flame switch 82.15
-Fuel pump 82.17
-Glow/Spark plug 82.14
-new style 82.14a
-Heater booster/Components 82.12
-Heater housing 82.14
Ignition coil 82.17
-Overheat switch 82.15
System components 82.12
-Temperature regulating switch 82.16
-Temperature sensor 82.16
-Troubleshooting 82.18
HeaterNentllatlon
-Controls/Assembly
air-cooled
with fresh air fan 80.8
without fresh air fan 80.5
water-cooled 80.12
Flap housing
air-cooled
with fresh air fan 80.1 0
water-cooled 80.14
-Heater, additional
under rear bench seat 80.16
Heater control flap cable 80.4
-Heater/Fresh air box housing
splitting 80.15
Rear air duct 80.3
-System components
air-cooled 80.2
water-cooled 80.11
Hoods/Lids
Rear door/lock cylinder 55.2
-Rear lid spring 55.4
-Rubber door stop 55.3
- Striker plate 55.3
Identification-Numbers/Codes
-Automatic trans. 4
-Engine2
-Front final drive Syncro 3b
-Manual trans. 3
-Type/Model/Assemblies 2
- VIN (Vehicle Identification
Number) 2 and Foreword
Ignition Distributor and Settings
-Air-cooled AFC
CAN/USA, (except Calif.) 8
Calif. 9
-Waterccooled Digijet 10
- Digifant 11
Ignition System-Air-cooled AFC
-California 28.8
distributor 28.11
distributor drive 28.20
Hall control unit/generator 28.14
Hall ignition, troubleshooting 28.17
xvi
Ignition System-Air-cooled AFC
(cont'd)
-California (cont'd)
idle stabilizer 28.16
ignition/distributor settings 28.9
ignition timing 28.11
rotor 28.10
vacuum advance/retard 28.13
vacuum unit 28.12
wires/coil, checking 28.10
-USA (except Calif.)
and Canada 28.2
distributor 28.6
distributor drive 28.4
ignition/distributor settings 28.3
ignition timing 28.5
rotor 28.4
vacuum unit/advance 28.7
wires/coil, checking 28.4
Ignition System-Diesel
-Glow plug light
troubleshooting 28.27
-Quick gloW
troubleshooting 28.24
Ignition System-Water-cooled
Digifant
-Distributor, installing 28.44
-Hall sender, checking 28.43
-Ignition and injection system
repairing 28.39
-Ignition distributor 28.40
-Ignition settings 28.41
-Ignition switching function
checking 28.44
-Ignition timing 28.42
Ignition System-Water-cooled
Digljet
-Centrifugal advance 28.34
-Distributor driveshaft 28.32
- Hall control unit 28.36
-Hall generator 28.37
-Idle stabilizer 28.38
-Ignition cable connectors
new style 28.30a
-Ignition coil 28.32
-Ignition distributor/
Hall generator 28.29
-Ignition distributor/settings 28.29
-Ignition wires/connectors 28.31
-Rotor 28.31
-Suppressor connectors 28.32
-Trigger wheel 28.38
-Vacuum advance/retard 28.35
-Vacuum unit 28.35
Instruments, Radio
198()..1984
-Cigarette lighter, replacing 90.31
-Fuel gauge
checking 90.5, 90.9
troubleshooting 90.13
Instruments, Radio
1980-1984 (cont'd)
-Fuel gauge sender
removing/installing 90.11
-Instrument cluster
assembling/disassembling
90.2, 90.6
removing/installing 90.10
-Light emitting diodes (LED)
checking 90.5
identifying 90.4, 90.8
-Multi-point connector
identifying 90.4, 90.8
-Speedometer calibration 90.30
-Speedometer cable
removing/installing 90.1 0
-Voltage stabilizer 90.4, 90.8
Instruments, Radio
From 1985
-Cigarette lighter, replacing 90.31
-Coolant temperature gauge
locating 90.14
troubleshooting 90.21
-Dynamic oil pressure system
assembly 90.22
removing/installing 90.23
troubleshooting 90.24
-Fuel gauge, locating 90.14
troubleshooting 90.20
-Instrument cluster
assembling/disassembling 90.14
removing/installing 90.10
-Light emitting diodes (LED)
checking 90.18
identifying 90.18
- Multi-point connector
identifying 90.18
Speedometer calibration 90.30
-Speedometer cable
installing
from VIN 25 H 040 185, except
Syncro 90.17
removing/installing 90.17
-Voltage stabilizer, checking 90.18
Instruments, Radio
From 1990
-Heidelberg VI fixed coded radio
coding. a new or remanufactured
radio 90.32
reactivating radio after.
reconnecting power 90.33
unlocking an electronically
controlled radio 90.34
Lifting Vehicle
Hoist/Floor jack 5
Lights
-Bulb holder 94.6
 Index
Mirrors Steering (cont'd)
WARNING- -Outside, electric -Power steering pump pressure
• Automotive sefVice and repair is serious adjustment range, increasing 66.3 checking 48.7
business. You must be alert, use common assembly 66.4 -Power steering system
sense, and exerr:::ise good judgement to
glass, removing/installing 66.2 filling/bleeding 48.7
prevent personal injury and complete the
~safely.
-Steering column switches 48.2
Radio -Steering drive/gear 48.4
• Before beginning any work on your -See Instruments, Radio -Steering lock assembly 48.3
Volkswagen, thoroughly read aR the -Steering wheeVcolumn 48.2
cautions and Warnings listed near the Refrigerator -Tie rods 48.4
front of this manual.
-See Gamper Equipment removing 48.5
• Always read the complete procedure -Troubleshooting 48.12
before you begin the work. Pay special Roof
attention to any cautions and Warnings Front headliner, installing 75.7a Sunroof
that accompany that procedure, or other removing 75.7 Panel
information on a specific topic. -Luggage rack, removing 75.8 adjusting 60.3
-Pop-up roof,. installing 75.3 guide plate adjusting 60.4
Lights (cont'd) removing 75.4 height alignment
-Headlight 94.4 -Pop-up roof seal, installing 75.6a front 60.3
aerodynamic 94.5a removing 75.6 rear60.4
adjusting 94.5 -Roof vent, installing 75.7 parallel adjustment 60.4
mounting frame 94.5 removing 75.6a removing/installing 60.2
removing 94.5 -Trim panel
-Ignition key, deburring 94.3a Seat belts removing/installing 60.3
-Intermittent windshield wiper 94.4 -Automatic 3-point seat belts -Water drains, cleaning 60.6
-Steering column retrofit installation 68.5 · rear drain hose, replacing 60.6
covers 94.3 -Automatic rear 3-point seat belts
lock 94.3 retrofit installation 68.7 Suspension-Front
lock cylinder 94.4 -Automatic 3-point left center seat -Assembly
switches 94.2 belt, retrofit installation 68. 10 early version 40.2
-Taillight 94.6 -Illuminated vanity mirrors late version 40.7
-Tum signal switch 94.3 replacing bulbs 68.13 -Ball joints assembly 40.10
-Seat belts, inspection 68.2 lower40.12
Lubrication System-Air-cooled AFC webbing defects 68.4 · -Coil spring
-Assembly 17.2 -Template measurements 68.6 removing/installing 40.3
-Oil cooler 17.2 -Lower control arm
-Oil pressure switch 17.2 Seats bushing, early version 40.6
-Oil pump 17.2 -Armrest, removing/installing 72.4 bushing, later version 40.8
Armrest, adjustable removing/installing 40.3
Lubrication System-Diesel assembly 72.5 -Shock absorber
-Assembly 17.4 removing/installing 72.6 removing/installing 40.4
-Oil cooler 17.4 -Front seat, removing/installing 72.2 -Steering arm, checking 40.12
-Oil filter 17.4 - Front seat backrest -Steering knuckle
-Oil pan 17.4 removing/installing 72.2 assembly 40.12
-Oil pressure switch 17.4 -Heated seats checking for wear 40.12
-Oil pump 17.4 component locations 74.2 modification, grease seal 40.13
heat elements 74.21 modification, brake disc
Lubrication System-Water-cooled - Rear seat with storage locker interference 40.14
-Assembly 17.7 removing/installing 77.2 - Subframe wax preservation 40.14
-Heating pipe, -Roof beds,·boards -Upper control arm
crankcase breather 17.9 removing/installing 77.3 bushing 40.5
-Oil pressure switch 17.9 lower40.6
-Oil pump 17.9 Steering removing 40.5
-Power steering wax preservation 40. 14
Maintenance Schedules checking for leaks 48.7 -Wheel bearing
-Lubrication, Emissions and Vehicle pressure/flow limiting valve 48.11 adjusting 40.11
Maintenance Schedules (Appendix) suspension changes 48.6 assembly 40.10
air-cooled, water-cooled system layout 48.6
and diesel models 1982-1985 A28 technical data 48.6 Suspension-Front, Syncro
water-cooled models from 1986 A32 Power steering pump -Axle shaft, assembly 40.29
removing/installing 48.9 length 40.30
repairing 48.1 0 removing/installing 40.28

xvii
Index
Suspension-Front, Syncro (cont'd)
-Ball joints
pressing 40.25
-Coil spring
removing/installing 40.20
-Components assembly 40.15
- CV joint, inner
assembly 40.29
disassembling/assembling 40.33
pressing 40.31
- CV joint, outer
assembly 40.29
disassembling/assembling 40.32
removing 40.31
- Guards, drive shaft/engine
removing/installing 40.28
-Lower control arm bushings 40.19
-Shock absorber
removing/installing 40.20
- Subframe, components 40.26
installing 40.28
removing 40.27
-Upper control arm bushings 40.19
removing/installing 40.18a
-Wheel bearing pressing 40.24
-Wheel bearing housing
assembly 40.23
removing/installing 40.17
-Wheel hub assembly 40.23
pressing 40.24
Suspension-Rear
-Axle shaft assembly 42.4, 42.7
removing/installing 42.4
-Constant velocity joint
assembly 42.7
disassembling/assembling 42.8
removing/installing 42.8
-Rear axle assembly 42.4
-Rear wheel suspension
assembly 42.2
-Shock absorber
bushing/sleeve 42.3
-Trailing arm bushing 42.3
-Wheel bearings, inner/outer
grease seals 42.5
removing/installing 42.5
-Wheel studs
removing/installing 42.6
Tarpaulin
-Canada 61.2
Technical Data
-Capacities Appendix 27
-Cylinder Location Appendix 27
-Digifant General 12
-Engine Appendix 27
-Vehicle identification Appendix 26
Tires
-Rotating 44.1 a
xviii
Torque Converter Transmission 4-speed 091/1 (cont'd)
-Bushing 32.3 -Assembly 35.32, 35.36
-Code letter 4, 32.2 mounting in repair stand 35.34
-Draining 32.2 -Clutch housing assembly 35.42
-Installing 32.3 -Differential 35.35
-Oil seal 32.3 -Drive flange 35.32
circlip, installing 35.35
Towing installing 35.35
-Procedure 6, 7 oil seal 34.18
removing 35.34
Transmission 4-speed 091 -Gear carrier 35.44
-Adjusting rings 35.3 assembling 35.40
-Assembly 35.2 assembly 35.36
-Clutch housing/ cover35.44
mechanism 35.12 installing 35.39
-Differential 35.4 removing 35.38
-Drive flange 35.3, 35.4 -Gears
oil seal34.18, 35.15 1st/2nd, removing 35.36
-Gear carrier/Gearshift 3rd, end play 35.59
housing 35.6, 35.18 3rd, installing 35.59
-Gear carrier housing 3rd, removing 35.56
assembly 35.8, 35.16 -Gear ratios 34.9, 35.60
-Gears -Gearshift lever 34.6
1st gear needle bearing 35.27 bearing 34.6
3rd gear end play 35.29 -Gearshift linkage 34.6
-Gearshift lever 34.3 assembly 34.6
-Gearshift linkage 34.2 adjusting 34.8
assembly 34.3 bearings 34.6
adjusting 34.4 -Installing 34.7
bearing plate 34.4 Lever bearing plate 34.6
-Installing 34.15 -Lubricant specifications 34.9, 35.60
-Interlock/detent plungers 35.17 -Main shaft 35.49
-Lever bearing plate 34.4 assembly 35.48
-Main shaft assembly 35.9, 35.20 ball bearing 35.51
ball bearing 35.23 lock ring 35.52
oil seal 35. 13 needle bearing 35.51
-Pinion needle bearing 35.23, 35.29 oil seal 35.43
-Pinionshaft assembly 35.9, 35.24 rear, removing/installing 35.35a
-Rear main shaft 35.5 -Pinion shaft 35.55
-Release shaft bushing 35.13 assembly 35.54
- Removing 34.14 needle bearings 35.57
-Retaining ring 35.7 roller bearings 35.56
-Reverse gear 35.14 -Removing 34.16
end play 35.17 -Retaining ring 35.37
shaft circlip 35.15 installing 35.40
- Rocker lever shaft 35.19 removing 35.38
-Selector shaft 35. 19 - Selector shaft
-Shift forks 35.10 modifications 35.60a
-Shift rod 34.3 parts for 35.60d
Starter bushing 35.13 -Shift forks/synchronizers
-Synchronizers modifications 35.60b
1st/2nd gear 35.26, 35.28 parts for 35.60d
3rd/4th gear 35.21 -Shift rod bushing 35.46
circlips 3rd/4th gear 35.21, 35.26 -Shift rod mounting 34. 7a
ring identification 35.30 -Shift shaft oil seal 35.46
-Tapered roller bearing 35.26 -Starter bushing 35.43
-Transmission housing 35.14 -Synchronizers
1st/2nd gear 35.58
Transmission 4-speed 091/1 3rd/4th gear 35.50
-Adjusting rings 35.32 -Technical data 34.1 a
installing 35.35 -Transmission housing 35.45
marking/removing 35.34 assembling 35.39
disassembling 35.38

Transmission 5-speed 094 (cont'd)
WARNING- -Removing 34.16
• Automotive service and repair is serious -Retaining ring 35.67
bUsiness. You must be alert, use common installing 35.70
sense, and exercise good judgement to
removing 35.68
prevent personal injury and complete the
-Shift rod bushing 35.78
worl< safely.
Shift shaft oil seal 35.78
• Before beginning any work on your Starter bushing 35.75
Volkswagen, thoroughly read aH the -Synchronizer rings
Cautions and Warnings listed near the checking 35.90
front of this manual.
identification 35.92
• Always read the complete procedure -Synchronizers
before you begin the work. Pay special 2nd/3rd gear 35.90
attention to any Cautions and Warnings 4th/5th gear 35.82
that accompany that procedure, or other assembling 35.90
information on a specific topic. checking 325.82
installing 35.90
Transmission S·speed 094 removing 35.82, 35.88
-Adjusting rings 35.62 -Technical data 34.1 b
installing 35.65 -Transmission housing 35.77
marking/removing 35.64 assembling 35.69
-Assembly 35.62, 35.66 disassembling 35.68
mounting in repair stand 35.64
-Clutch housing assembly 35.74 Transmission 5-speed 094 4WD
-Differential 35.65 -Adjusting rings
-Drive flange 35.62 installing 35.96
installing 35.65 marking/removing 35.95
oil seal 34. 18 -Assembling/Disassembling 35.99
removing 35.64 -Assembly 35.94, 35.98, 35.105
-Gear carrier 35.76 -Axle flange
assembling 35.70 installing 35.96
assembly 35.66 removing 35.95
cover35.76 -Bearing
cover35.76 installing/checking 35.123
installing 35.69 removing 35.122
removing 35.68 inner race, removing 35.122
-Gears -Clutch housing 35.111
1st, shim 35.72 -Differential lock components 34.24
2nd, removing 35.88 - Differential lock control
3rdl4th, removing 35.88 repairing 34.26
4th, end play 35.91 -Differential lock servo 34.25, 35.96
4th, installing 35.91 -Drive flange seal, installing 35.115
-Gearshift lever 34.10 -Drive pinion 35.121
bearing 34.10 - Driveshaft flange, removing 35.104
- Gea..Shift, adjusting 34.12 -Flange nut
assembly 34.10 loosening/tightening 35.104
Installing 34.16 -Flange seal, installing 35.104
-Lever bearing plate 34.10 -Gear carrier 35.1 07, 35.116
-Main shaft 35.81 disassembling/assembling 35.108
assembly 35.80 -Gears
ball bearing 35.83 1st, 2nd and 3rd, removing 35.122
lock ring 35.84 -Gearshift linkage assembly 34.20
needle bearings 35.83 adjusting 34.21
oil seal 35.75 -Housing 35.113
rear, removing/installing 35.65a -Installing 34.23
- Modifications to trans. -Intermediate housing
manufactured prior to removing 35.106
Dec. 15, 1982 35.65b -Low gear idler, removing 35.106
-Pinion shaft 35.87 -Low gear shim, measuring 35.101
assembly 35.86 -Lower gear bearing
needle bearings 35.89 removing/installing 35.126
roller bearings 35.88 -Main shaft 35.117
bearing, removing/installing 35.119
Index
Transmission 5-speed 094 4WD
(cont'd)
-Main shaft seal
removing/installing 35.12
-Needle bearing
inner race
loosening/tightening 35.123
outer race, installing 35.126
outer race, removing 35.125
removing/installing 35.115
-Output housing 35.103
-Output shaft bearing
removing/installing 35.114
-Rear driveshaft, measuring 35.97
-Removing 34.22
-Reverse gear idler
removing/installing 35.106
-Shift rod bushing
removing/installing 35.115
-Shift shaft seal
removing/installing 35.114
-Starter bushing
removing/installing 35.112
-Synchronizer rings
identification 35.127
-Technical data 34.19
-1st/2nd gear synchronizer
checking/installing 35.124
-3rd gear, installing 35.125
- 3rd/4th gear synchronizer 35.118
installing 35.119
Transmission, Automatic
-Accelerator cable/linkage
090 except code letters NH 37.12
code letters NH only 37.14
-Apply shell 38.1 0
-ATF
checking/filling 37.9
dipstick changes 37.9
troubleshooting 37 .9a
-Direct/Reverse/Forward clutches
installing 38.11
-Final drive
oil seal37 .1 0
Forward clutch 38.8, 38.17
-Governor
disassembling/assembling
090 code letters NG 38.22
removing/installing
090 except code letters NG 38.23
-Governor drive gear 38.14
-Installing
090 except code letters NH 37.5
090 code letters NH only 37.6
- Kickdown lever modification
090 code letters NH, NK 38.39
-Manual valve 38.35
-Modifications 37.19
-Oil pump 38.8, 38.22
-Operating rod 38.35
-Operation 37.17, 37.19
- Parking lock 38.34
xix
Index
Transmission, Automatic (cont'd) Trim-Interior (cont'd)
- Parking lock modification -Instrument panel
090 code letters NH, NK 38.39 removing 70.5
- Pressure test procedure 37.18 replacing 70.6
- Pump shaft 38.3 Sliding door trim panel
-Removing assembly 70.3
090 except code letters NH37.4 removing 70.4
090 code letters NH only 37.6
- Reverse planetary gear set 38.12 Vehicle Care
-Reverse planetary ring gear 38.14 -Air cleaner A 10
-Selector lever assembly 37.2 -Battery A 14
-Selector lever cable 37.3 · -Brake fluid A13
-Separation plate -Cleaning products A3
090 code letters NG 38.26 -Cooling system A 11
090 code letter NG -Corrosion protection A5
from trans. no. 17 07 0 38.28 -Engine compartment A6
090 code letters NH, NK 38.37 -Engine oil A7
- Shift points 37.19 Engine oil filter A9
-Spacer springs and roDers 38.15 -Exterior A3
Spring table -Fuel filter (diesel) A10
090 code letters NH, NK - Fuel supply A 1
up to trans. no. 16 07 0 38.30 lnterior4
090 code letters NG -Lubricants A 7
from trans. no. 17 07 0 38.32 ~Maintenance A5
-Technical data - Power steering A 10
code letters NG, NH 37.1a Replacing wiper blades A16
code letters NK 37.1b -Tires/Wheels A 17
-Transfer plate -V-beltA12
090 code letters NG 38.26
090 code letters NG Vehicle Identification Number {VIN)
from trans. no. 17 07 0 38.28 - VIN 2, foreword
090 code letters NH, NK 38.37
-Transmission Wheels
assembly 38.7 -Alignment
090 modifications front 44.3
code letters NH, NK 38.37 rear44.4
-Transmission/Final drive specifications 44.2
assembly 38.2 -Alignment Syncro
end play 38.5 determining front toe 44.3a
separating 38.3 specifications 44.5
-Transmission housing studs 38.4
-Turbine shaft 38.3 Windshield Wiper/Washer
-Valve body -Assembly 92.2
removing/installing 38.25 Rear window washer/wiper 92.5
090 code letters NG 38.26 washer pump 92.7
090 code letters NG -Spray jets 92.4
from trans. no. 17 07 0 38.29 -Troubleshooting 92.8
code letters NG -Windshield washer 92.4
up to trans. no. 16 07 0 -Wiper arms/motor 92.3
-1st/reverse brake piston 38.10 -Wiper blade rubber insert 92.3
-2nd gear brake band 38.12
-2nd gear brake band piston 38.10 Wiring Diagrams
disassembling/assembling 38.24 -See Electrical Wiring
Trim-Interior
Coffee cup bracket, repairing 70.9
-Front door trim panel
assembly 70.2
moisture barrier 70.2
-Headlining
removing/installing 70.8

XX
 General

Index
Identification (Numbers/Codes) Ignition distributor and settings
- Automatic transmi~SSion 4 - Air-cooled AFC
- Compression pressure Can/USA, not Calif. 8
values 2a California 9
- Engine2 .,.... Water-cooled Digijet 1o
- Front final drive - Digifant 11
Syncro 3b
- Manual transmission 3, 3a Technical data
- Type/ModeVAssemblies 2 - Digifant 12
- VIN (Vehicle Identification
Number) 2

Lifting Vehicle
- Hoist/Floor jack 5

Towing
- Procedure 6, 7

1
General
Type/model: Type: 25 Model: VANAGONNANAGON SYNCRO
Assemblies Code letters BHP (SAE) RPM

Engine (air-cooled) 2.0 Liter (AFC) cv 70 4200

Manual Transmission - 4 speed {091) DK

Automatic Transmission {090) NG

Engine (Diesel) 1.6 Liter cs 50 4200

Manual Transmission - 4 speed (091) DM/DZ

Manual Transmission - 5 speed (094) DX

Engine (water-cooled) 1.9 Liter (Digijet) DH 80 4800

Manual Transmission- 4 speed (091/1) DU/ABD

Automatic Transmission (090) NH
Engine (water-cooled) 2.1 Liter (Digifant) MV 95 4800

Manual Transmission- 4 speed {091/1) ABD/ACW

Automatic Transmission (090) NK
Manual Transmission - Syncro 5-speed (094-4WD)

(with differential lock) AANIAVN

(without differential lock) AAKIAW

CAUTION
SYNCRO TRANSMISSIONS

When checking engine performance,

only use dynamometer designed to
brake all four wheels at the same time.

Vehicle Identification

Engine number (Gasoline)

• stamped on crankcase below breather (arrow)

Vehicle identification number (YIN) Engine number (Diesel)

• on dashboard on driver's side (arrow) • on engine block (arrow) between injection pump
an vacuum pump

Type/Model/Assemblies identification

2 Vehicle identification number (YIN)

Engine number
 General

Beginning May 1987, engine codes are now either a Compression pressure values
two letter combination or a combination of one
number and one letter. Engine codes cv DH,MV cs
Engine code continues to precede the engine
number. Compression pressure 6-9 10-13 34
values bar (psi} (87- 131) (145- 190) (493)
CAUTION 5 8 26
Wear limit bar (psi)
Engines with identical code DO NOT (73) (116) (377)
necessarily have identical specifications. Maximum permissible 3 5
difference between all (44) (73)
four cylinders bar (psi)

new (water-cooled shown)

A-3
From May 1987 Engine code
Compression pressure values
2a
 General
Manual Transmission Type 091

Code letters and date of manufacture

Example DK 10 08 9
I I I I
code letters day month year (79)
of manufacture

A-4 4-speed Manual transmission code letters 3

General

Manual Transmission Type 094

134-16851

--++-1-++f......l..-1-1~---lllloolo"'earbox code letters and date of

manufacture:
Example: GP 12 02 5
I I
Code
I I
Dayof Month Year
I
letters manu- (85)
facture

3a Manual transmission code letters

5-speed
 General

Front Final Drive

134-16871

Front final drive code letters and

date of manufacture
Example: ADM 384
I
Code
I
Manufacturer's
letters consecutive
no.

Syncro
Frontfinal drive code letters 3b
General
Automatic Transmission Type 090

090 ..... .

Example NG 15 08 9
I I I I
code letters day month year (79)
of manufactu re

Converter code letter

• letter D or Z on lug ( arrow )

Valve body code letters

• on boss (arrow)

Transfer plate identification

• part number (arrow)

4 Automatic transmission code letters

 General

Lifting vehicle with hoist/floor jack

CAUTION CAUTION
Before driving, onto lift, check for clearance Do not lift vehicle by engine, transmission
between lifting arms and tires to avoid or front suspension. Doing so may result in
cutting sidewalls. damage to components
Extend arms and check to see if arms are
long enough to contact lifting points.
Lift only at points shown

Front
at crossmember next to jacking port

Rear
at rear crossmember

Note
When lifting vehicle with floor jack, use same
lifting points as with hoist

A-6
Lifting vehicle with hoist/floor jack 5
General
Emergency Towing
Note
All towing procedures are based on use of typical
sling-type tow truck equipment. If other types of
towing equipment are used, these procedures may
not apply
• whenever possible, tow with rear wheels off
ground
• if car with automatic transmission must be
towed with front wheels lifted because of
extensive damage, dollies should be used under
rear wheels if towing speed will exceed 30 mph
or distance over 30 miles. Exceeding these limits
will damage transmission Front hook-up-From 1986 m.y.
• selector lever must be in "N" position when
moving car with automatic transmission with rear - remove front license plate/bracket if interfere
wheels on ground with front hook-up

WARNING
Always secure front wheels with an external
steering wheel lock when towing with rear
wheels off ground.
~~--------4-·-----~CJ
Never use ignition steering lock to secure 4 x 4 x 48'' cross beam
front wheels.
Never allow passengers to ride in towed
vehicle

T-hooks

-attach T-hooks (above) to tie down slots in long

members (as shown)
-position four foot long 4x4 wooden crossbeam
under bumper (as shown)
-double wrap chains on tow bar
-attach safety chains on axle platform

IQO-A1891 CAUTION
Front hook-up - all models thru 1985 Do not attach hooks or chains around brake
-attach grab hooks under lower control arms lines
outboard of shock absorber mounts (as shown)
-place 4x4 wooden crossbeam under spare tire - raise vehicle to allow four inches clearance
- place tow bar under 4x4 between tires and road
-double wrap chains on tow bar
-attach safety chains to lower control arms (as
shown) Towing speed/distance
Front tow - all models EXCEPT Syncro
Automatic transmission
30 mph (48 kmh) for up to 30 miles (48 km)
Manual transmission
50 mph (80 kmh) for up to 50 miles (80 km)

6 Towing
Vanagon

Rear hook-up - air cooled gasoline models only
-attach grab hooks to trailing arms
-place 4x4 under engine carrier to space tow bar
away from heat exchangers
-attach safety chains to trailing arms
Rear hook-up - water-cooled/diesel models
The Vanagon cannot be towed with conventional
sling-type towing equipment to avoid damage to
valance panel.
Vanagon Syncro
Front/rear hook-up
The Vanagon Syncro cannot be towed with
conventional sling-type towing equipment nor with
wheel lift equipment or wheel dollies to avoid
damage to the all-wheel drive system.
- use flat-bed tow truck only.
A-8
Rear towing -
General
Flat Towing
Vehicles with automatic transmission may be
towed forward (in driving direction} at speeds up to
30 mph for maximum of 30 miles
CAUTION
Towing vehicles at more than 30 mph and/or
for distance greater than 30 miles with rear
wheels on ground will damage automatic
transmission due to lack of lubrication
If towing speed will be greater than 30 mph or
distance greater than 30 miles, temporary
modifications to vehicle are required as follows:
Work sequence
-remove drive shaft assemblies
-seal drive shaft flanges against water and dirt
-wrap drive shafts and store in vehicle
Manual transmission (Including Syncro)
There are no restrictions on speed or distance
when towing manual transmission cars behind
other vehicles
all I I Syncro-front/rear towing Towing 7
General

Engine code letters cv

Distributor (Part No.) 022 905 205S

Ignition timing 7.5• BTDC

Timing mark location: crankshaft pulley

l6 \2
I8 4 0-;;--
--
~~~~~~l~
__.
~
-..... 128·0501
Idle speed
manual 800- 950 rpm
automatic 850-1000 rpm
Vacuum hose disconnected

Dwell angle new points 44-5o·

wear limit 42-58°

Centrifugal advance (crankshaft degrees)

start 1000-1200 rpm

9-14• at 1600 rpm

end 21-25• at 3400 rpm

Vacuum advance
start 107-147 mbar (80-110 mm Hg)

266 mbar (200 mm Hg)

end
8-12°

Spark plugs Bosch w 145M2. waco

Beru 14511413L '
Champion N 288

Spark plug tightening torque 30 Nm (22 ft lb)

Spark plug gap 0.6-0.7 mm (0.023-0.028 in.)

Firing order 1-4-3-2

·8 Ignition distributor and settings

Air-cooled AFC CAN/USA, not Calif.
 General
Engine code letters cv

Distributor (Part No.) 039 905 205C

Ignition timing s• ATDC

Timing mark location: crankshaft pulley

s
~
4 0• 4 8 12 16

Idle adjustment
Vacuum hoses connected
Idle stabilizer plugs removed and
850-950 rpm
------- 128-0711

connected together

Dwelt angle setting not adjustable

Centrifugal advance (crankshaft degrees)

start 1050-1300 rpm

9-13° at 1600 rpm

end 21-25 • at 3400 rpm

Vacuum advance
start 90-160 mbar (70-120 mm Hg)

240-280 mbar (180-210 mm Hg)

end
9-12°

Vacuum retard
start 90-160 mbar (70-120 mm Hg)

200-280 mbar (150-210 mm Hg)

end
11-13°

Spark plugs Bosch W 145M2, W 8 CO

Beru 145/14/3L
Champion N 288

Spark plug gap 0.6-0.7 mm (0.023-0.028 in.)

Spark plug tightening torque 30 Nm (22 ft lb)

Firing order 1-4-3-2

Transistorized ignition system cautions

Do not connect any condenser/suppressor or test
light to terminal 1. Do not connect test instruments
with a 12 volt supply on terminal 15 of ignition
coil. Do not crank engine before high tension wire
of distributor cap (terminal 4) is connected to
ground with jumper wire (example: compression
check etc.). Do not replace installed coil-
211 905 115 C-with conventional type. Do not
leave battery connected when electric welding
on car. Do not start engine after heating up to
more than 8o•c (176°F), example: paint drying
booth. Do not wash engine when it is running. Do
not use battery booster longer than 15 sec. nor
exceed 16.5 volts with booster. Allow 1 minute
pause between boosting attempts. Do not discon·
nect battery while engine is running. Disconnect
plug to ignition control unit when car has to be
towed.

A·10 (Oiir-cooled AFC II California I Ignition distributor

· and settings
g
General

Engine code letters DH

Distributor (Part No.) 025 905 205 D

Ignition timing 5±1 • ATDC

Timing mark location: crankshaft pulley

~
~
Idle speed 850±50 rpm

vacuum hoses connected

Idle stabilizer control unit electrical plugs disconnected from unit

and connected together

Centrifugal advance (crankshaft degrees)

start 1050-1150 rpm

16-20• at 2400 rpm

end 21-25 • at 3800 rpm

Vacuum advance
start 190-230 mbar (14.0-17.0 em Hg)

end 360 mbar (27.0 em Hg)

12-16°

Vacuum retard
start 100-220 mbar (7.5-16.5 em Hg)

end 260-360 mbar (19.5-27.0 em Hg)

9-11°

Spark plugs Bosch W7CO

Beru 14 L-7 C
Champion N288

Spark plug gap 0. 7 + 0.1 mm (0.028 + 0.004 in.)

Spark plug tightening torque 20 Nm (14ft lb)

Firing order 1-4-3-2

10 Ignition distributor and settings

Water-cooled Digijet
 10

Engine
Assembly

Index
Engine (Air-cooled AFC)
- Removing 10.2
-Installing 10.5

Engine (Diesel)
- Removing 10.6
-Installing 10. 7

Engine (Water-cooled Syncro)

-Removing 10.8
-Installing 10.1 o

10.1
10 Engine- Assembly
Engine, removing
(Air cooled-AFC)

Work sequence
-disconnect ground cable from battery

-disconnect following
• plug 11 at double-relay
• plug A for resistors
• hoses B at deceleration valve

California only

-detach air cleaner 1 with air flow sensor 2 and

air intake duct 3

-disconnect following:
- remove rubber boot for heater booster 4 • plug 1 at double-relay
-disconnect wire for alternator 5 • plug 2 at Hall control unit
-disconnect plug·& at control unit • plugs 3 at idle stabilizer
-pull engine oil level dip stick 7 • wire connection 4 for oxygen sensor

-disconnect wires at
• ignition distributor 8
• engine oil pressure switch 9 - remove nuts 12 of upper engine mounting bolts
-disconnect vacuum hose 10 for brake booste;- -disconnect accelerator cable 13

10 •2 Engine, removing
Air cooled - AFC
 Engine-Assembly 10
Automatic transmission

-remove heater flap housing bolt 14

- remove plug (black arrow) on top of

transmission housing
-pull ATF dip stick (lower white arrow)
-remove ATF filler tube grommet
(upper white arrow)

-block fuel line 15 with clamp

-disconnect wiring 16 on starter

- remove three 8 mm bolts of torque

converter through hole on top of
transmission housing
• use adaptor 3052, extension and T-handle
to turn crankshaft of engine
• make sure pin (arrow) engages in recess
of cooling fan hub

Note
To gain access to bolts of torque converter,
engine must be rotated until each bolt -block fuel line from pressure regulator 17
appears in hole on top of transmission with clamp
housing

Air cooled - AFC

Engine, removing 10 •3
10 Engine - Assembly

- loosen transmission mount bolt (arrow) - remove nuts 18 from engine mounting bolts

- remove bolts 19 from engine carrier

-lower engine/transmission assembly until '
- loosen accelerator cable A at selector lever transmission rests on support VW 785/1
and detach - remove engine from transmission
- loosen transmission carrier bolt B - lower engine with floor jack

- support transmission with VW 785/1

• when attaching keep distance
a = 80 mm (3 1/4 in.)
- support engine with floor jack
• use adaptor VW 612/5

10 •4 Engine, removing
Air cooled - AFC
 Engine - Assembly 10
Engine, installing
(Air cooled-AFC)
Proceed in reverse order of removing and
note following:
- check clutch release bearing for wear, replace
lf necessary
- lightly lubricate splines on main drive shaft
and contact points of clutch release bearing/
clutch release lever with MoSa grease
• do not lubricate clutch release bearing guide
sleeve
- always replace all self-locking nut~

Manual transmission
- adjust accelerah<!r cable at full throttle
position

Automatic transmission
- adjust accelerator cable

Tightening torques:
• engine to transmission 30 Nm (22ft Ib)
• engine carrier to mount 25 Nm (18ft lb)
• transmission mount 30 Nm(22 ft lb)
• torque converter to drive plate 30 Nm(18 ft lb) .

Air cooled - AFC

Engine, installing 10 •5
10 Engine- Assembly
Engine, removing

CAUTION
Coolant/antifreeze must not be reused when
replacing engine, cylinder head, cylinder head
gasket, radiator and heater core .

-disconnect battery ground cable

-remove top of air cleaner
-remove lower engine cover
-open coolant expansion tank cap

-remove fuel supply line 1 and fuel return line 2

from injection pump
-disconnect accelerator cable from pump lever
and remove retaining clip 3 at bracket and
place cable to one side
-disconnect cold start cable at lockscrew 4

-remove retaining clip at bracket and place cold

start cable to one side
-disconnect wire 5 from fuel shut-off solenoid

-disconnect lower hose from waterpump at con-

necting pipe 1 to radiator (see eatltion)
-disconnect cente[ hose~ from wateJpump
-disconnect hose 3 from cylinder head (lower
arrow) and from oil cooler (upper arrow) and
move it to one side
-remove vacuum hose 4 from vacuum pump

-remove coolant reservoir

-disconnect wiring from:

• oil pressure switch 1
• temperature sensors 2 and 3
• glow plugs 4
-remove coolant hose 5
-remove cap with dipstick 1
-remove nuts 2 from rear engine mounts on left
and right sides, but leave bolts in

10 •6 Engine, removing
Diesel
 Engine-Assembly 10

-remove all 7 engine/transmission mounting -support transmission with VW 785/1 B

bolts 1 -remove engine from transmission and lower it
-remove support member bolts 2 and remove out of vehicle
support member

Engine, installing
Proceed in reverse order of removing and note
following:

-adjust angle of engine to transmission before

joining engine and transmission

-support engine with engine crane and adaptor
3058
• angle of engine to transmission can be
adjusted by turning knob (arrow)
CAUTION
Do not interchange fuel supply and fuel
return pipe union screws. For identification,
fuel return pipe union screw Is marked with
OUT on hex. head. Fuel return line also has
smaller diameter than fuel supply line

-adjust cold start cable, see Repair Group 23

-refill coolant, see Repair Group 19

Tightening torques:
• engine to transmission
M10 bolts 45 Nm (33 ft lb)
M12 bolts 80 Nm (59 ft lb)
• engine mounts 85 Nm (63 ft lb)
• support member 45 Nm (33 ft lb)
• fuel line union screws
on injection pump 22 Nm (16ft lb)
-remove nuts (arrow) from front engine mounts
on left and right sides
-remove bolts from both front and rear engine
mounts
-lower engine/transmission assembly until
engine can be separated from transmission

Diesel
Engine, removing/installing 10•7
10 Engine - Assembly
Engine, removing
CAUTION
Coolanttantifreeze must not be reused when
replacing engine, cylinder head, cylinder head
gasket, radiator and heater core.
-disconnect ground cable from battery
- remove air cleaner with air flow sensor and air
Intake duct

- disconnect following:
• plugs 1 at Injectors
• plug 2 at oxygen sensor
• plug 3 and 4 at ignition distributor
• plug 5 at oil pressure switch
• plug 6 at temperature sensor
• plug 7 at temperature sender
• plug at coolant level warning switch (not
shown-located In coolant expansion tank)
- remove ground connectors 8

-disconnect wire 1 at alternator

- disconnect folfowing:
• plugs 2 at injectors
• plug 3 at throttle valve switch
• plug 4 at auxiliary air regulator
-disconnect hoses 5 and 6 at charcoal filter
valve

- block coolant hoses with clamps a

• a= univeral clamp-local supply

-disconnect and plug fuel hoses 1 and 2

- remove accelerator cable from throttle valve
lever

Automatic Transmission
-remove circlip and spring 3 from
accelerator rod
- block coolant hoses with clamps a
• a= universal clamp-local supply
-open coolant expansion tank cap

10 •8 Engine, removing
Water-cooled
 Engine-Assembly 10
Automatic Transmission
- remove accelerator rod 2

Vehicles with power steering

- remove power steering pump with hose left
attached, and place in engine compartment.

Vehicles with air conditioning

- remove compressor with hoses attached and
place In engine compartment.

- remove drain plugs 1 at cylinder heads and drain

coolant

- remove plates 1 on left and right sides

- remove bolts, 2, do not remove plate 3

Syncro only
- remove rear skid plate under engine/transmission

- disconnect brake booster line 1

- disconnect coolant hoses 2, 3 and 4
- remove coolant expansion tank 5
- remove engine/transmission bolt/nut 6 on left and
right sides

Automatic Transmission
- remove three bolts which attach torque converter
to drive plate through hole on top of trans.
housing (arrow)

134-16751
- loosen mounting bolts for front transmission
bracket three turns (arrow)

- disconnect wiring 1 at starter

B-9 Water-cooled
Engine, removing 10.9
10 Engine-Assembly

- loosen transmission mount bolt (arrow)
- lower engine/transmission assembly until transmis-
sion rests on VW 785/1 B
-when lowering, adjust angle of inclination on floor
crane head and keep wiring harness aside so that it
can pass oil filler tube
-remove nuts 2 of lower engine mounting bolts
-remove engine from transmission and lower it out
of vehicle

-attach VW 785/1 B so that distance

between support pad and transmission
housing is about 120 mm (4 3/4 in.)
-support engine with US 612/5 and floor

- mount engine on repair stand with engine hOlder

VW 307a
Engine, installing
Proceed in reverse order of removing and note
following:
-check clutch release bearing for wear and
replace if necessary
Syncro only
-clean joining faces of engine and transmission
and lightly coat joining surface of engine with
silicone adhesive seal Part No. AMV 176 000 05
-lubricate clutch release bearing and main shaft
splines lightly with MoS2 grease (do not lubricate
guide sleeve for release bearing)
-remove engine carrier bolts 15
-replace all self-locking nuts on engine mounts
-check and adjust, If necessary, accelerator
cable/throttle controls, see Repair Group 20
Tightening torques:
• engine to transmission 30 Nm (22 ft lb)
• engine carrier to body 25 Nm (18 ft lb)
• transmission mounts 30 Nm (22 ft lb)
• torque converter to drive place 20 Nm (15ft lb)

10.10 Engine, femovlng/installin9

Water-cooled
 General

Introduction October 1985

Engine code MV
Part no.: Ignition distributor 025 905 205M
Digifant control 025 906 0220 old
unit*** 025 906 0221022A new
Ignition timing Checking value 3° • r before TDC
Adjusting value so o
:t: 1 before TDC

Timing mark location

•-
., ,~, @~) 12&-3901
RPM* 2000.2500
Ignition adjustment ••
-· timing map --
RPM Approx. 3000
Degrees 35 :t: 5°
RPM limit Switch-off RPM of RPM 5600
digifant control unit

Firing order CYL. 1-4·3-2

Spark plugs Bosch W7CCO
(tightening Beru 14L·7CU, 14L-7C
torque: 20 Nm (14 ft lb) Champion N288
Spark plug gap mm (in) 0.7 ::: .1 mm (0.028 ::: 0.003 in)

·) Engine oil temperature 80" c. (176°F) connector

of temperature sensor II disconnected with
engine running.
··) Engine oil temperature BO"C, connector of
temperature sensor II connected.
• "") When replacing control unit always replace old
control unit with newer version.

CAUTION
Part numbers are for reference only. Always
check with your parts department for latest part
information.

Digifant
Ignition settings 11
General

Technical data/specified values

Engine code MY
Type 2. 1 liter 70 kW, 90 SAE net HP
Introduction October 1985
Part no.

Control unit 025 906 022

Ignition timing checking spec. 3· 7" before TDC

adjusting spec. 5 ± 1• before TDC
• Test and adjustment conditions no. 1 and 9
Idle adjustment
idle rpm 880 ±50 rpm
CO content 0.7 ± 0.4 Vol.%
• Test and adjustment conditions no. 1 to 6, 7, 8
Conditions and requirements: '

1 -engine oil temperature min. ao•c (17SOF)

2- electrical consumers turned off
3- crankcase breather hose on oil breather
removed and closed tightly
4- throttle valve switch turned on (continuity)
5- idle stabilizer OK (valve vibrates and hums)
6- ignition timing setting: OK
7- connector (single connector) for idle stabilizer
control valve disconnected
8- with ignition OFF, disconnect connector (single
connector) for oxygen sensor
9- with engine running, double connector for
temperature sender disconnected and rpm
increased to 2000·2500 rpm by depressing
throttle

12 Technical data
Digifant
 13
Engine
Crankshaft
Crankcase

Index
Air-cooled -Cylinder head gasket 13.19,
-Assembling 13.31
sheet metal 13.2 -Flywheel 13.23
crankcase 13.6, 13 ..14 -Intermediate plate 13.23
-Camshaft 13.14 -Intermediate shaft oil seal
-Carrier /Support 13.5 13.22
-Crankshaft -Pilot bearing 13.22
assembly 13.16 -Piston 13.27
clrclips 13.16 clearance 13.29
end play 13.10 diameter 13.29
oil seals 13.9 height 13.31
pilot bearing 13.17 identification 13.31
-Cylinder 13.11 marking 13.28
-Disassembling pin 13.28
sheet metal 13.2 rings 13.27
crankcase 13.6 ring end gap 13.29
-Distributor ring side clearance 13.29
installing 13.9
drive shaft 13.8 Water-cooled /Syncro
drive gear 13.16 -Assembling/disassembling 13.32,
-Flywheel 13.9 13.34
-Pistons 13.11 -Camshaft 13.50
-Piston rings 13.11 -Carrier/support 13.37a, 13.38
-Tor que converter ...;., CraJ"!kshaft
drive plat 13.9 assembly 13.52
circlips 13.54
Diesel drive gear 13.54
-Camshaft drive belt 13.18 end play 13.40
-Connecting rod 13.27 oil seals 13.39
bearing clearance 13.30 pilot bearing 13,56
bolts 13.30 replacing (1.9L) 13.57, 13.58
side clearance 13.30 -Cylinder 13.43
-Crankshaft 13.22 -Distributor
bearing caps 13.22 drive gear 13.38
drive belt cover 13.21 a drive shaft 13.38
end play 13.24 installing 13.38
journal sizes 13.23 -Flywheel 13.40
main bearing clearance 13.25 -Piston pin hole burrs
oil seal (flywheel side) 13.25 removing 13.47
oil seal (drive belt side) -Pistons 13.43
13.26 classifications 13.44
sprocket bolt 13.21 pin 13.44
-Cylinder block 13.27 rings 13.45
bore dimensions 13.30 -Torque converter
clearance 13.30 drive plate 13.40
-V-belt pulley 13.34, 13.35, 13.42

Index 13.1
13 Engine- Crankshaft, Crankcase

Cooling fan housing

removing Fig. 2
adjusting flaps Fig. 3

Ignition timing scale

/ .

Fan housing grille

Alternator\
install together with
ignition timing scale
20 Nm (15ft lb) \
20 Nm (15ft lb)
Heater blower

Cover plate, rear

13 •2 Engine, disassembling/assembling
Air-cooled AFC
 Engine-Crankshaft, Crankcase 13

Intake air distributor wllh

throllle valve housing ----...
removing /disassembling,
see Repair Group 24

Cylinder cover plate, left

r
Healing air duct,
left rear - - - - - ' " " \

Engine carrier/support----'
disassembling/assembling Fig. 5

Self·locking nuts
20 Nm (15 H lb)
NOTE always replace
Arrow on carrier must point to
front of vehicle when reinstalling.
To remove carrier only, unbolt
from mounts Heating air duct, lower

Air-cooled AFC
Engine, disassembllng/assemb11ng 13•3
13 Engine- Crankshaft, Crankcase

Fig. 1 Engine, mounting In engine stand

Fig. 4 Alternator V-belt, adjusting
-after loosening bolts 1 and 2, move alternator to
tension V-belt
-tighten bolts 1 and 2 to 20 Nm (15 ft lb)
-check belt tension by pressing belt firmly in
center
• deflection: approx. 10-15 mm (3/8-9/16 in.)

Fig. 2 Cooling fan housing, removing

- remove bolts (arrows) and detach

Fig. 3 Cooling air flaps, adjusting

• bent ends of return spring must rest
on boss of cooling fan housing
(arrow A) and on cable guide (arrow B)
- press flaps into closed position and
tighten cable clamp

13 •4 Engine, disassembling/assembling
Air-cooled AFC
 Engine-Crankshaft, Crankcase 13

Engine support

Fig. 5 Engine carrterlaupport,

dlaeaaembllng leaaembllng

Air-cooled AFC
Engine carrier /support 13.5
C-5
13 Engine- Crankshaft, Crankcase

Distributor
remove together with bracket
installing Fig. 5

Oil s e a l - - - - - - - - - - - - .
Thrust spring
pry out carefully with screwdriver
installing Fig. 7

011 f i l t e r - - - - - - - - . removing Fig. 3

note instructions on filter, installing Fig. 4
remove with US4462

25 Nm (18 It lb)\
011 cooler ----------,1 '
replace oil cooler if there are
metal particles on pistons,
crankcase bores, or in engine oil
Cylinders/ platon a
marking page 13.1 1
0 removing /Installing,
checking page 13.1 1

!._ 30 Nm (22 It lb)

coat with sealing
compound

20 Nm (15 tt lb) remove together with bracket

Hydraulic valve litter

installing, see Repair Group 15

13.6 Engine, disassembling/assembling

Air-cooled AFC C-6
 Engine-Crankshaft, Crankcase 13
WARNING
Friction materials such as brake and clutch
linings. or brake pads may conlain asbeslos Torque converter drive plate
fibers. moving Fig. 10
Do not create dust by grinding. sanding or by
cleaning with compressed air.
Avoid breathing asbestos fibers and asbestos £ 9 0 Nm (65ft lb)
dust.
Breathing asbeslos may result in serious
diseases, such as asbestosis or cancer.
Pre11ure plate
It may cause severe injury and death.
mark position before removing

\ ~25Nm(18ftlb)

60 Nm (44ft lb) plus an add'l1/4 turn (90°)

Needle bearing
always replace
install with
locking compound
1
Clutch disc
Install with US 219
always replace

Spacer
Felt ring Flywheel
removing/Installing Fig. 9
adjusting crankshaft
Oil seal end play Fig. 11
used to adjust crankshaft
pry out carefully with
end play, see Fig. 11
screwdriver
installing Fig. 8

r. Rocker shaft
do not disassemble

- - - - 1 5 Nm (11 ft lb)

Cylinder head cover gasket

check for damage and replace
Retaining spring for - if necessary
pushrod tubes
installing Fig. 2

Air-cooled AFC
Engine, disassembling I assembling 13.7
C-7
13 Engine- Crankshaft, Crankcase

Fig. 1 Cylinder head, Installing

- hand tighten nuts to align
components, then torque to 30 Nm
Fig. 3 Oistributor drive, removing
(22 ft lb) In sequence

Fig. 2 Retaining spring for push rod tubes,

Installing
• spring must rest on tubes (black
arrows) and engage supports (white
arrows)
Fig. 4 Distributor drive, Installing
-set crankshaft to.TOC on cylinder No. 1
- Install drive shaft so that offset slot is
at an angle of about 12" to engine
centerline (small segment to coil side)

Cylinder head

13.8 Pistons
Distributor drive
Air-cooled AFC C-8
 Engine - Crankshaft, Crankcase 13

Fig. 5 Distributor, installing Fig. 8 Crankshaft oil seal, flywheel side,

Installing
-set cylinder No. 1 to TDC
-turn rotor until mark on rotor is in line
with mark on distributor housing
(cylinder No. 1)

Fig. 9 Flywheel, removing/Installing

Fig. 6 Cooling fan hub, removing

Fig. 10 Torque converter drive plate, removing

I13- 133 1
Fig. 7 Crankshaft oil seal, cooling fan side,
Installing

Air-cooled AFC
Distributor
Crankshaft oil seals
13 9
Flywheel/Torque converter drive plate •
13 Engine - Crankshaft, Crankcase

Fig. 11 Crankshaft end play, checking/adjusting

- check crankshaft end play and adjust
if necessary
• new: 0.07-0.13 mm (0.003-0.005 in.)
•wear limit: 0.15 mm (0.006 in.)
if NO, proceed as follows:
- install flywheel with 2 shims but
without 0-ring and crankshaft oil seal
- mount dial Indicator wi th bracket on
crankcase
- move crankshaft in and out and
measure movement (crankshaft end
play)
-determine thickness of 3rd shim

Example
dial indicator reading 0.44 mm (0.017 in.)
specified end play - 0.10 mm (0.004 in.)
thickness of 3rd shim 0.34 mm (0.013 in.)

Note
Thickness of shim is etched on shim .
Always recheck with micrometer

CAUTION
Always intall three shims to obtain
correct crankshaft end play

- remove flywheel
- Install 0-ring, crankshaft oil seal and felt ring
-install all three shims

- install flywheel
-tighten bolts to 110 Nm (80 ft Ib)
- recheck crankshaft end play

13.10 Crankshaft end play

Air-cooled AFC C-10

Eliminate head gasket
when replacing lower
gasket with 1.6 mm
cyh2"him
Cylinder
mark before removing Fig. 1
checking for wear Fig . 9
Installing Fig. 11
cylinder bore/piston
diameter page 13.13
Fig. 1 Pistons/cylinders, marking
• arrow points to flywheel
Note
Before removing , mark matching
numbers on pistons and cylinders
Fig. 2 Circlip, removing /installing
Engine-Crankshaft, Crankcase 13
When installing new pistons
and cylinders Clrcllp - - - - - - - - - .
replace lower gasket with removing/ installing Fig . 2
7°
1.6 mm cylinder shim
71101 341
=i~~~lnotalllng Fig. 3
Piston
mark before removing Fig. 1
Piston rings classifications Fig. 6
removing/installing Fig . 4 diameter/wear, checking Fig . 10
positioning Fig . 5 piston diameter I cylinder
end gap, checking Fig . 7 bore page 13.13
side clearance, checking Fig . 8
Fig. 3 Piston pin, removing/installing
• if pin is too tight in piston, heat piston
to approx . 60 oc (140 °F)
Fig. 4 Piston rings, removing/installing
Air cooled-AFC Piston
Cylinder
13 -11
•I
13 Engine - Crankshaft, Crankcase

Fig. 5 Piston rings, positioning

• TOP mark on piston rings must face
top of piston
a= top ring
b =middle ring
c =oil scraper ring

Fig. 7 Piston ring end gap, checking

-push ring into cylinder about 4-5 mm
(approx. 3/16 in.)

ring end gap wear limit

upper/middle ring: 0.40-0.65 mm 0.90 mm
(0.016- (0.035 in.)
0.026 in.)
oil scraper ring: 0.25-0.40 mm 0.95 mm
(0.010- (0.037 in.)
0.016 in.)

Fig. 6 Piston, classifications

A =arrow must point toward
flywheel when installing
Band C =piston diameter in mm (blue
or pink paint dot indicates
matching size)
D and E =weight group
-(brown)=474-482 grams
+(gray) = 482- 490 grams

ll3-0l7J
Fig. 8 Piston ring side clearance, checking
clearance wear limit
upper/middle ring: 0.04-0.07 mm 0.12 mm
(0.002- (0.005 in.)
0.003 in .)
oil scraper ring: 0.02-0.05 mm 0.10 mm
(0.001- (0.004 in.)
0.002 in.)

13.12 Piston
Rings
Air-cooled AFC
 Engine- Crankshaft, Crankcase 13
CAUTION
If measurement of piston I cylinder shows
that clearance is close to 0.2 mm (0.008 ln.),
piston/cylinder should be replaced by set
of same size group (standard or oversize).
Weight difference of pistons must not
exceed 10 grams.
If cylinder of damaged piston shows no
wear, install new piston of appropriate
matching size.
Cylinders/pistons must be of same size
group.

Fig. 10 Piston, checking diameter/wear

Cylinder bore/Piston diameter -measure at bottom of skirt approx.
16 mm (3/8 in .) from edge (diameter
Cylinder Piston stamped In top of piston)
bore (mm) dla. (mm) • clearance new: 0.02-0.05 mm
(0.001-0.002 ln.)
Standard (94.0 mm)
blue 93.992-94.008 93.97 • wear limit: 0.2mm
pink 94.002-94.018 93.98 (0.0081n.)
1st oversize (94.5 mm)
blue 94.492-94.508 94.47
pink 94.502-94.518 94.48
2nd oversize (95.0 mm)
blue 94.992-95.008 94.97
pink 95.002-95.018 94.98

Fig. 11 Cylinder, Installing

• piston ring end gaps must be offset 120°

Fig. 9 Cylinder, checking for wear

-measure 10-16 mm (3/8-5/8 in.)
from top

Piston
Air-cooled AFC Cylinder
13.13
13 Engine- Crankshaft, Crankcase

Crankcaae - - - - - - - . .
coat joining surfaces with
sealing compound

Camahalt end cap

coat with sealing
compound when Installing

Main bearing No. 1----..

hole for dowel offset
toward flywheel

Camahalt bearing _ __/

tabs must engage In recess

Main bearing No. 4

groove faces
oil slinger

Camahalt
runout, checking Fig. 1
end play, checking Fig. 2
Installing Fig. 3

Crankcase

13.1 4 Crankshaft
Camshaft
Air-cooled AFC
 Engine- Crankshaft, Crankcase 13
-turn crankshaft backward
• camshaft must not lift out of
bearings
• if camshaft lifts out of bearings,
install camshaft with smaller timing
gear

Note
To obtain specified backlash, camshafts
with various size timing gears are
available.
Markings are on Inner face of timing
gear.

Fig. 1 Camshaft runout, checking Example

"-0.1", "+0.1", "+0.2", indicates In
• wear limit 0.04 mm (0.0015 in .) 1/100 mm how much pitch radius differs
from standard pitch radius "0"

CAUTION
Mark 0 on outer face of camshaft timing
gear is timing mark and must not be
confused with markings on inner face.
Crankshaft timing gear is available in one
size only

Fig. 2 Camshaft end play, checking

• wear limit 0.16 mm (0 .006 in .)
• if out of specification , replace
camshaft bearings

Fig. 3 Camshaft, Installing

- mark on camshaft gear tooth must be
between marks on crankshaft gear
teeth
-check backlash of timing gears
• 0.0-0.05 mm (0-0.002 in .)
• backlash must be hardly noticeable

Air-cooled AFC
Camshaft 13."15
13 Engine- Crankshaft, Crankcase
Connecting rod bearing
note position,
do not Interchange
Dl1trlbutor drive gear

I
press off I install together w!th
crankshaft timing gear
Crankshaft pilot bearing
removing Fig. 3
removing Fig . 8
installing Fig. 4
Installing Fig. 9

removing Fig. 1
lnstallng Fie 2 Connecting rod nuts
35 Nm (25ft lb)
Crankshaft timing gear always replace,
press off /Install together with lubricate contact surface
distributor drive gear crankshaft web when Installing
removing Fig. 3
inBtalling Fig. 4

Connecllnq rod - - - - - - ----.:11.

note posltlo1'1, do not interchange.
'r eplace In sets of four only
instanlng F'ig. 5 and Fig. 6
checking side clearance Fig. 7

Fig. 2 Clrclip, Installing

Fig. 3 Distributor drive gear/crankshaft liming

Fig. 1 Circlip, removing
gear, removing

13.16 Crankshaft
Connecting rod
Air-cooled AFC
 Engine - Crankshaft, Crankcase 13
VW428a VW415a -..

~
Fig. 4 Distributor drive gear/crankshaft timing
gear, installing
-heat gears to approx. 80"C (175"F)
before installing

Fig. 7 Connecting rod, checking side clearance

• wear limit 0.7 mm (0.028 in.)

Fig. 5 Connecting rod, Installing

-numbers (arrow) on rod and cap must
be on same side

Fig. 8 Crankshaft pilot bearing, removing

A = US 8028
B= US 1039 & US 1039/ 3

Fig. 6 Connecting rod, installing

-lightly tap both sides of connecting
rod with hammer to eliminate slight
pinching of bearing shells when
installing connecti ng rod
Fig. 9 Crankshaft pilot bearing, installing
- l ubricate with MoS, grease when
installing
• markings on beari ng cage must be
visibl e when installed

Air-cooled AFC Connecting rod

Crankshaft pilot bearing 13.17
13 Engine-Crankshaft, Crankcase
Engine
mounting in engine stand Fig. 1
Note
Defective injectors can cause violent knocking
noises which sound like faulty bearings. If this
occurs, r un engine-at idl.e and loosen injection
pipe unions one after the other. If knocking
stops when a union is loosened, that injector
is defective
Injection pump
checking/adjusting injection
timing, see Repair Group 23
removing/installing, see
Repair Group 23

10 Nm (7ft lb) - - - - . , Injection pump sprocket

removing Fig. 3
Drive belt tensloner - - - - - - . .
turn tensioner to right
with tool US 4493

Double V·belt pulley

Intermediate shaft pulley

Crankshaft sprocket
two types, installing page 13.21
see page 13.21

Water pump belt

check tension with thumb pressure,
deflection: 5-10mm (3/16-3/8 in)

Alternator belt -----------...,11

check tension with thumb pressure,
deflection: 10-15mm (3/8-9/16 in)

20 Nm (14ft lb)-

13.18 Engine, disassembling/assembling

Diesel
 Engine - Crankshaft, Crankcase 13
CAUTION
Coolant/antifreeze must not be reused when
replacing engine, cylinder head, cylinder head
gasket, radiator and heater core.

,....---- Cylinder head bolt

_..,...,.. tightening torque/sequence,
Repair Group 15

Cylinder h e a d - - - -
removing/installing,
Repair Group 15

20 Nm (15ft lb)
Cylinder
head gasket - - - - - - - '
installing, Vacuum pump
Repair Group 15
20 Nm (15ft lb)

10 Nm (7ft lb)

20 Nm (15 ft lb) _ __,

filter

Oil pan/gasket """'-----JI

removing/Installing,
Repair Group 17

Diesel
Engine, disassembling/assembling 13•19
13 Engine-Crank~haft, Crankcase
Drive belt, removing
Work sequence

-remove bolt cover and valve cover

Fig. 1 Engine, mounting In engine stand

-turn engine to TDC arrow on cylinder No. 1 and

-align tool as follows:
Ftg. 2 Fuel Injection pipes, removing/Installing
-remove wit h tool 3035
-tighten to 25 Nm (18ft lb)
fix camshaft In position with tool 2065A
• turn camshaft until one end of tool touches
cylinder head
• measure gap at other end of tool with feeler
gauge
• take half of measurement and insert feeler of
this thickness between tool and cyl inder
head
• turn camshaft so that tool rests on feeler
• insert second feeler of same thickness be-
tween other end of tool and cylinder head

Fig. 3 Injection pump sprocket, removing

-loosen sprocket retaining nut slightly
-carefully apply tension with puller
-hit puller spindle head (arrow) with
light hammer taps until sprocket
loosens from injection pump shaft
-remove puller and nut
-remove sprocket by hand

Fuel InJection pipes

13.20 Injection pump sprocket

Drfve belt
Diesel D-4
 Engine-Crankshaft, Crankcase 13
-turn crankshaft 2 turns in direction of engine
rotation (clockwise)
-strike belt once with rubber hammer between
camshaft sprocket and Injection pump
sprocket
-check belt tensiorn again
-check injection pump timing, see
Repair Group 23

Drive belt sprocket bolt, tightening

_llj
-lock injecti on pump sprocke t in position With 12 rnm boll
pin 2064
- check t hat marks on sproc ket, bracket and
pump body are align ed (eng ine at TDC)
- loosen tens loner

- rem ove V-belt pulley from crankshaft

-remove drive belt
Old Version
Drive belt, installing 150 Nm (108ft lb)
with locking compound
Work sequence

-check that TDC mark on clutch pressure plate

is aligned with refere nce mark
-loosen camshaft sprocket bolt 112 turn and
loosen gear from camshaft by tapping with
rubber hammer
-install drive belt and remove pin 2064 from
injection pump sprocket
-tension belt by turning tensioner to right

New Version
200 Nm (148 ft lb)
lubricate threads before installing
Shown above are the two versions of drive belt
sprocket used on Diesel Vanagon . Ensure that the
correct tightening torque specification is used
when repairing these engines.

-check that on VW 210, scale reads 12-13

• check belt tension between camshaft
sprocket and injection pump sprocket
-tighten camshaft sprocket bolt to
45 Nm (33ft lb)
-remove tool from camshaft

0-S Diesel Drive belt

Drive belt sprocket bolt 13.21
13 Engine-Crankshaft, Crankcase
-
Fully closed drive belt cover
Beginning in February 1984, the Diesel engine has
been produced with a fully closed drive belt cover.
Additional new parts include a revised injection
pump mounting bracket and intermediate shaft
pulley. The pulley now mounts closer to the engine
block.

Note
Only the new version pulleys will be supplied as
service parts.

When installing the new version pulley in earlier

engines (without fully closed belt cover) it is
necessary to provide at least 0.5 mm (0.020 in.)
clearance between pulley and injection pump
10 Nm (7ft lb) mounting bracket (arrows) . Rework pump bracket
as necessary.

Rear belt cover

removing: remove camshaft sprocket
(tap sprocket off taper with punch and
hammer through 6 mm hole), tensioner
and injection pump. Loosen pump mounting
bracket

Upper belt cover

Lower belt cover

20 Nm (15ft lb)

13.21 a Drive belt cover

Diesel
13 Engine-Crankshaft, Crankcase
Note
Defective injectors can cause violent knocking
noises which sound like faulty bearings. If this
occurs, run engine at idle and loosen injection
pipe unions one after the other. If knocking
stops when a union is loosened, that injector Is
defective

. -- - Main bearing caps

installing position Fig. 5

65 Nm (47111b) i
. - - Pilot bearing
removing Fig. 3
installing Fig. 4

Main bearing shells---- - --<

Crankshaft
when installing, be sure shells
checking end play Fig. 6
are seated correctly. Install shells
main bearing clearance Fig. 10
without lubrication groove in
journal sizes page 13.23
bearing caps. Install shells with
lubrication groove in block. Do not
interchange used bearing shells

Intermediate shaft - -- - - . .
before removing take out
vacuum pump;
max. end play 0.25 mm
Seating ua111ge1- - - -
oll return hole at bot

Intermediate shaft oil seal Crankshaft oil seal (pulley side)

removing: first remove removing / installing
sealing flange page 13.26
installing Fig. 2

13.22 Crankshaft
Intermediate shaft
Diesel C·6
 Engine- Crankshaft, Crankcase 13
WARNING
Friction materials such as brake and clutch
linings, or brake pads may contain asbestos
fibers.
Do not create dust by grinding. sanding or by
cleaning with compressed air.
Avoid breathing asbestos fibers and asbestos
dust.
Breathing asbestos. may result in serious Clutch disc - - - - - -
diseases, such as asbestosis or cancer. use 10-213 when installing

It may cause severe injury and death.

Flywheel - - - - - ,
removing/installing Fig. 1

75 Nm (54 ft lb)
always replace
insert with D6 locking compound

Intermediate plate
=ig. 10 must fit on dowel sleeves

Crankshaft oil seal (flywheel side)

removing Fig. 7
Installing Fig. 8 and Fig. 9

Crankshaft journal sizes (rrun)

Main bearing Max. out Connecting rod Max. out

Stage journals of round journals of round

Standard 53.96-53.98 0.03 47.76-47.78 0.03

1st undersize 53.71-53.73 0.03 47.51-47.53 0.03

2nd undersize 53.46-53.48 0.03 47.26-47.28 0.03

3rd undersize 53.21-53.23 0.03 47.01-47.03 0.03

Note
3 undersizes of bearing shells available in
graduations of 0.25 mm

Diesel
Flywheel 13.23
13 Engine - Crankshaft, Crankcase

Fig. 1 Flywheel, removing/Installing

• lettered side faces out
• Installation depth = 1.5 mm (0.060 In)

Fig. 2 Intermediate shaft oil seal, Installing Fig. 5 Main bearing cap, positions
• bearing No. 1 on drive belt side
• bearing No.5 on flywheel side

Fig. 3 Pilot bearing, removing

Fig. 6 Crankshaft end play, checking

-check with feeler gauge on main
bearing No.3
• new part = 0.07-0.17 mm
(0.003-0.007 in.)
• wear limit = 0.37 mm (0.015 in.)

Intermediate shaft oil seal

13.24 Pilot bearing

Crankshaft end play
Diesel D-10
 Engine- Crankshaft, Crankcase 13

Fig. 10 Main bearing clearance, checking

Fig. 7 Crankshaft oil seal (flywheel side), -remove bearing caps

removing -clean shells and journals
-measure clearance with Plastlgage
• new part: 0.03-0.08 mm
(0.001-0.003 ln.)
• wear limit: 0.17 mm (0.0071n.)

CAUTION
Do not turn crankshaft

Fig. 8 Crankshaft oil seal (flywheel side),

Installing
-center with sleeve first

Fig. 9 Crankshaft oil seal (flywheel side),

Installing
-press in seal until fully seated

D-11 Diesel Crankshaft oil s.eai

Main bearing clearance 13.25
13 Engine· Crankshaft, Crankcase
Crankshaft oil seal (pulley side), -loosen knurled screw and turn Inner part In
removing/installing against crankshaft until oil seal is pulled out
-clamp extractor In vise and remove oil seal
Note with pliers

Puller 2002 may also be used Installing

Work sequence -coat seal lips with oil

Removing
-remove drive belt cover and drive belt
-remove drive belt sprocket on crankshaft
-remove woodruff key from crankshaft

-press In seal to a depth of 2 mm (0.080 ln.)

below outer edge of cover
• use washer from sprocket bolt between bolt
head and tool

-unscrew inner part (arrow A) of oil seal extrac-

tor 2085 2 turns (approx. 3mm/1/8 ln.) out of
outer part
-lock in position with knurled screw (arrow B)
-to guide extractor, screw sprocket bolt into
crankshaft until It projects about 20 mm
(3/4 in.)
-lubricate threads on tapered end of seal
extractor

-position seal extractor and screw it into oil

seal as far as possible by pushing firmly in
direction of arrow

13.26 Crankshaft oil seal

Diesel D-12
 Engine-Crankshaft, Crankcase
Note
IUt
When installing new pistons or short block,
check piston height to determine head gasket
thickness, see Fig. 15and Fig. 16
13
Defective Injectors can cause violent knocking
noises which sound like faulty bearings. If this
occurs, run engine at Idle and loosen injection
pipe unions one after the other. If knocking
stops when a union Is loosened, that Injector Is
defective

_.---~-Piston rings
offset gaps 120•
removing/installing Fig. 6
checking piston ri ng side clearance Fig. 7
checking piston ring end gap Fig. 8

Clrcllp - - - - - - . ( )

P i s t o n - - - - - - - -.....:.•
marking piston poslt19n Fig. 1
Installing Fig. 5
checking clearance.'wear Fig. 9
c
- - - - - Piston pin
height Fig. 16 removing/installing Fig. 4
Identification Fig. 14
--------Connecting rod
removing Fig. 2
Cylinder bora---...:.....---..
Installing Fig. 3
checking Fig. 10
checking side clearance F ig.13
table page 13.30
checking bearing clearance Fig. 12

Bearing shell - - - - - - '

note position, do
not interchange

Connecting rod cap

removing Fig. 2
installing Fig. 3

Connecting rod boll nuts

two different types
tightening procedures Fig. 11

Cylinder block
)..12 C-1 1 Diesel Piston
Connectlng rod 13.27
13 Engine- Crankshaft, Crankcase

[ 13·347 I
Fig. 1 Pistons, marking Fig. 4 Piston pin, remo-ving/Installing
-mark number on piston to match -remove circiips
cylinder number. Arrows point toward -if too tight, heat piston to approximately
drive belt side 60"C (140"F)

Fig. 5 Pistons, Installing

Fig. 2 Connecting rod, removing
-mark rod and cap before removing

Fig. 6 Piston rings, removing/installing

- " Top " marks on piston rings must face
Fig. 3 Connecting rod, Installing toward piston crown
-casting marks and retaining lug for
bearing shell face toward intermediate
shaft (arrows)

Connecting rod

13.28 Piston
Piston pin
Diesel
 Engine-Crankshaft, Crankcase 13

Fig. 9 Piston, checking for wear

t t3·350 I
-measure about 15 mm (9/16 in.) from
lower edge
Fig. 7 Piston ring side clearance, checking
Piston diameter
Clearance Wear limit
Upper ring 0.06-0.09 mm 0.2mm Piston Cylinder
(0.002-0.004 ln.) (0.008 in.) dla. (mrn) bort(mm)
Lower ring 0.05-0.08 mm 0.2mm Standard 76.48 76.51
(0.002-0.003 in.) (0.008 in.) 76.49 76.52
76.50 76.53
Oil scraper 0.03-0.06 mm 0.15 mm
ring (0.001-0.002 in.) (0.006 in.) 1st oversize 76.73 76.76
76.74 76.77
76.75 76.78
2nd oversize 76.98 77.01
76.99 77.02
77.00 77.03
3rd oversize 77.48 77.51
77.49 77.52
77.50 77.53

Fig. 8 Piston ring end gap, checking

-push ring down squarely into cylinder
until It Is about 15 mm (9/16 in.) from
top edge
Fig. 10 Cylinder clearance, checking
Ring gap Wear limit -measure at points 1, 2 and 3 first in
direction A then direction 8
Upper and 0.3-0.5 1 mm
1 = 10 mm (3/8 in.) from top
lower rings (0.012-0.020 in.) (0.039 in.)
2 = middle of cylinder wall
Oil scraper ring 0.25-0.40 mm 1 mm 3 = 10 mm (3/8 in.) from bottom
(0.010-0.016 in.) (0.039 in.)
• piston to cylinder clearance
new part: 0.03 mm (0.0011 in.)
wear limit: 0.07 mm (0.0027 in.)
Note
Do not measure when block is mounted in repair
stand as measurements may be incorrect due to
distortion

Piston rings
Diesel Piston
Cylinder 13.29
13 Engine- Crankshaft, Crankcase

Cylinder bore
Bora Piston dia.
(mm) (mm)
Standard 76.51 76.48
76.52 76.49
76.53 76.50
1st oversize 76.76 76.73
76.77 76.74
76.78 76.75
2nd oversize 77.01 76.98
77.02 76.99
77.03 77.00
3rd oversize 77.51 77.48
77.52 77.49
77.53 77.50

Fig. 12 Connecting rod bearing clearance,

checking

-remove connecting rod cap

-clean bearing shell and crankshaft
journal
-place Plastlgage® across journal
-install cap and tighten nuts
• if rigid bolts, tighten nuts to
45 Nm (33 ft ib)
• If stretch bolts, tighten nuts to
30 Nm (22ft Ib) (to avoid stretching
bolts, do not turn stretch bolt nuts
extra quarter turn when measuring
bearing clearance)

CAUTION

rigid Do not turn crankshaft

stretch
bolt bolt
-remove connecting rod cap
-compare width of strip with measuring
scale; figure on scale gives bearing
Fig. 11 Connecting rod bolts, Identification/ clearance
tightening procedure • new part: 0.028-0.088 mm
rigid (0.0011-0.0034 in.)
stretch
• wear limit: 0.12 mm (0.0047 in.)
25mm 15mm
(1.0 in.) A = thread length (9/16 ln.)
smooth B = center part serrated
conical C = bolt head half round
Tightening procedure
stretch bolt:
-lubricate contact face of nut
-tighten to 30 Nm (22ft Ib)
-then tighten nut 1/4 turn (90°) more

rigid bolt:
- lubricate contact face of nut
-tighten to 45 Nm (33ft lb)

13.30 Cylinder bore

Connecting rod clearance
Diesel
 Engine- Cra,nkshaft, Crankcase 13

lt.5•262l

Fig. 13 Connecting rod side clearance, checking Fig. 15 Cylinder head gasket, identification
wear limit: 0.37 mm (0.014 in)
white arrow= identification notches
black arrow= part number

Note
Always select gasket thickness according to
piston height above top of cyl inder block

VW382/ 7-- ---....

VW385/ 17-- - '

Fig. 14 Piston Identification Fig. 16 Piston height, checking

• pistons are marked with figure 5 next
to installation direction Piston height of ALL cylinders must be measured
• arrow must point to drive belt side when installing new pistons or short block.

Head gasket is selected based on cylinder with

HIGHEST piston height.

Thickness of gasket Piston height Identification notches

(mm/in.) (mm/in.) in head gasket Part No.

0.63-{).82 (0.025-{) 032) 1.4 (0.055) 1 068 103 383 L

0.83-{).92 (0.033-{).036) 1.5 (0.059) 2 068 103 383M
0.93-1.02 (0.037-{).040) 1.6 (0.063) 3 068 103 383 N

Piston Identification
D-17 Diesel Piston height
Cylinder head gasket 13.31
13 Engine-Crankshaft, Crankcase
Note
Arrows on carrier must point to
front of vehicle when reinstalling.
Remove carrier as complete assembly

~'~
I

I
I

I
20 Nm (15ft lb)

~-- Engine carrier/support

See pages 13.37a, 13.38

Cover plate, rear

Exhaust pipe, rear

~ .,

l,. Nm (15 ft lb)

•metal surface faces cyl. head

13.32 Engine, disassembling/assembling

Water-cooled
 Engine-Crankshaft, Crankcase 13
Note
Tighten all hoses with hose clamps

CAUTION
Coolant/antifreeze must not be· reused when
replacing engjne, cylinder head, cylinder head
gasket, radiator and heater core.
7 Nm (61 in. lb)

Water pu•nP·---~
remove and install as
complete assembly

20 Nm (15 ft lb)

Gasket

cars with air conditioner and

-......__ _ _ _ _ Bolt power steering only.
see page 13.39
350 Nm(258 ft lb)

Bolt - - - - - - - - Single V-belt pulley

60 Nm (43 ft lb) adjust tension so belt • pulley supplied as spare
hold flywheel or torque deflects under thumb part has only TDC mark 0
converter drive plate pressure 10-15 mm • cutting timing mark:
through hole in crankcase (3/8-9/16 in.) 5° after TDC = 7.5 mm
when loosening or (0.294 in.) to left of TDC mark
tightening

E-3
1983-1 985 II Water-cooled
Engine, disassembling/assembling 13.33
13 Engine- Crankshaft, Crankcase
CAUTION
Coolant/antifreeze must not be reused when
replacing engine, cylinder head, cylinder head
gasket, radiator and heater core.

A/C compressor bracket

Coolant pump---.

..~.........- - - Power steering

pump bracket

Coolant and the!rmost~at·--.

bracket

- - - - - - - - - - - - - - - - v - belt
for Coolant pump

...., ___.......~..__ V-belt pulley race

(Syncro only)
press fit , pry off with
two screwdrivers

L,. Nm (44 n lb)

hold flywheel, drive torque
convertor in crankcase plate
V-belt pulley
replacement part only has
TDC marking
Add timing notch:
5° BTDC = 7.5 mm to right of
through hole TDC marking

13 •3 4 Engine, disassembling/assembling
Water-cooled-from 1986
 Engine-Crankshaft, Crankcase 13

Removal of three groove pulley

Retainer tool 3149 is required to hold crankshaft

from rotating while removing/installing the three CAUTION
groove pulley. Tightening torque applies only when socket
and handle is used in alignment with torque
It consists of three separate pieces: wrench.
• alignment plate
• pad Correct torque wrench setting must be
• socket and handle calculated to achieve 350 Nm (258 ft lb) at
crankshaft pulley bolt.
Work sequence
-torque crankshaft pulley bolt to 350 Nm
(258ft lb)
15ft lb)
HoW to compute torque when using adapter

Socket
and handle

- loosen power steering pump, if applicable, Torque· wrench

remove V-belt from crankshaft pulley
-loosen AIC compressor, if applicable, remove
TA= TW x (L + A) where:
V-belt from crankshaft pulley
L
- loosen alternator, remove V-belt from crankshaft
TA= Torque at end of adapter
pulley
TW = Torque wrench scale reading
- unscrew coolant expansion tank, lay to one side
L = Lever length of torque wrench
b) - remove expansion tank bracket .
A = l:ever length of adapter
- remove retaining screws and bolts from exhaust
Example:
heat shield
TA= Unknown
- reposition heat shield down and underits
original position
=
TW 100 lb.-ft.
L= 15 inches
A=. 7.5 inches
Note Now use the formula as follows:
When tool 3149 is used, it will not be necessary to TA= TW x (L + A)
remove muffler. L
TA= 100 x (15 + 7.5)
- rotate pulley so both alignment holes are 15
horizontal TA= 100 x (22.5)
- insert alignment plate into pulley 15
- place pad across engine mounts with tabs TA= 2250.0
pointing upward 15
- attach socket and handle TA= 150 ft.-lb.
- remove crankshaft pulley bolt and pulley
- installation of three groove pulley is in reverse - adjust all belts to specification
order - top off coolant level in expansion tank

E-5 Water..cooled from 1986 Three groove pulley,

removal/Installation
13 3 5 •
13 Engine- Crankshaft, Crankcase

CAUTION
When assembling crankcase
halv.es, see fig. 5

CAUTION
Coolant/antifreeze must not be reused when
replacing engine, cylinder head, cylinder head
Ignition distributor drive
gasket, radiator and heater core.
shaft
removing Fig. 1 When replacing coolant/antifreeze solution in
installing Fig. 2 all Volkswagen models, all model years, use
phosphate-free coolant/antifreeze
zvw 237102.
Crankcase halves
assembling Fig. 5

20 Nm (15 ft lb)
coat tx>th sides of washer
with AMV 188 001 02 sealing compound

TDC sender
installing Fig. 11

Oil seal~
always replace
Thrust washers ~
install and position
with screwdriver

Hydraulic valve lifter Pushrod tube

note instructions on do not interchange seam faces up.
filter or box. positions. Always replace pushrod
Remove with US 4462 Store vertical, base tube seals.
downward Tube can be replaced with
Note repairing, see Repair cyl. head installed, see
from 1986 oil cooler added Group 15 Repair Group 15
Preloading and repairing,
see Group 17, pg. 17.7
see Repair Group 15

13.36 Engine, disassembling/assembling

Water-cooled
 Engine- Crankshaft, Crankcase 13

~ 90 Nm (65ft lb)- thru 1985

Torque converter drive plate .11[ 110 Nm (81 ft Ib) - from 1986
removing Fig . 10
60 Nm (44ft lb) ~lutch ~lac
CAUTION plus an additional Install With US 219
1/4 turn (90°)
Coolant/antifreeze must not be reused when always replace 20Nm(15ft7
replacing engine, cylinder head, cylinder head install with
gasket, radiator and heater core. locking compound

~
When replacing coolant/antifreeze solution in .w
all Volkwagen models, all model years, use
110 Nm (81 lllb)
phosphate-free coolant/antifreeze
zvw 237102.
Dowel pin
Oil seal - - - - - - -
pry out carefully with
screwdriver
installing Fig . 7
"•""") 1
)r
Pressure plate
mark position before
removing
\_Foil riog

L....,.....,..
Flywheel
removing/Installing Fig. 9
adjust ing crankshaft
(Manual Trans. only) end play Fig. 12
lubricate with MoS, grease
WARNING
:ompound Friction materials such as brake and clutch
Cylinder head linings, or brake pads may contain asbestos
Shims (thru 1985) drain coolant at fibers.
used to adjust crankshaft drain plug
end play, see Fig. 12 Installing and Do not create dust by grinding, sanding or by
1986 Models repairing, see Repair cleaning with compressed air.
see 13.41 for arrangement Group 15
Fig. 13 Avoid breathing asbestos fibers and asbestos
dust.
:e
Breathing asbestos may result in serious
diseases, such as asbestosis or cancer.
It may cause severe injury and death.

_ / , . - - - - - - - - - - - - - 5 0 Nm (37ft lb)
D drain coolant before
loosening.
ealing
Coat surface with
AKD 456 000 01
Rocker shaft sealing compound
slot points upward tightening, see
Repair Group 15

25Nm~8ftlb)J
Gasket

Sealing r i n g - - - - - - --
alway• <eplaoe J Cylinder head cover gasket
Coolant drain plug check for damage and
replace if necessary

E·7 Water-cooled
Engine, disassembling/assembling 13.37
13 Engine-Crankshaft, Crankcase

Engine c a r r i e r - - - - - "
note installation position,
arrow points In driving
direction

13.37a Engine, carrier/support

Engine, disassembling/assembling
Water-cooled I I 1983-1985
 Engine.,Crankshaft, Crankcase 13
Engine mount/mount bracket can be
removed/installed with engine in vehicle .

~.20 Nm (15 tt lb)

•

Engine earner ': \ r Engine support

note installation position,
arrow points In driving direction
---

Water-cooled Muffler splash plate ~ 13-766

Engine, disassembling/assembling -All-water-cooled

Fig. 1 Ignition distributor drive shaft, removing

-use puller as shown Fig. 2 Ignition distributor drive shaft, installing
-set crankshaft to TDC on cyl. No. 1
-install drive shaft so that offset slot
faces bolt (arrow)
- small segment faces water pump
A = inserted position
B = installed position

Engine, carrier/support

E-9
Water-cooled Engine, disassembling/assembling 13.38
13 Engine-Crankshaft, Crankcase

When repairing engines, use only AMY 188 001 02

Fig. 3 Ignition distributor, installing
-set cylinder No. 1 to TDC (white arrow)
-turn rotor until mark on rotor is in line with
mark on distributor housing (cyl. No. 1)
(black arrow)
sealant.
- clean surfaces of crankcase to be joined
• if D 3 sealant (brownish color) was used
previously, the old sealant must be completely
removed
• if the engine was sealed previously with
AMY 188 000 02 sealant (green colored), only
excess material over the edge of the housing
should be removed
- apply a thin layer of AMY 188 001 02 sealant to
degreased crankcase surfaces to be joined
• the newly applied sealant dissolves the old
sealant and hardens on contact with metal and
in absence of air after assembly
- first tighten M 8 nut (arrow)
- then tighten all M 10 nuts
• up to engine number DH 027 404-35 Nm (26 ft lb)
• from engine number DH 027 404-45 Nm (33 ft lb)
• from engine number MY 041 599-50 Nm (37 ft lb)
-tighten remaining M 8 nuts to 20 Nm (15ft Ib)

Fig. 6 Crankshaft oil seal, removing

-pry out
Fig. 4 AIC compressor Y-belt, tightening
(if applicable)

Fig. 7 Crankshaft oil seals, Installing

Single pulley
- coat seal lips with oil and install seal with
3088 and pulley bolt without washer (3162
Fig. 5 Crankcase halves, assembling in Syncro)
- then tighten bolt with washer until stop
Note
Triple pulley
AMY 188 001 02 sealant is now being used when - coat seal lips with oil and install with 3088
assembling crankcase halves. and pulley bolt without washer and
tighten bolt until stop

Ignition distributor drive shaft

13.39 Crankcase halves

Crankshaft oil seal
Water-cooled
 Engi~e- Crankshaft, Crankcase 13

Fig. 11 TDC sender, Installing

Fig. 8 Crankshaft oil seal (flywheel side),
installing -use piston pin and plastic hammer to
drive TDC sender in until stop
-coat seal lips with oil and put on
-do not damage inner ring 1
guide A
- screw base B into crankshaft and
press in guide A with seal until
seated
shims and disks between crankshaft
bearing and oil seal must be installed in
correct order. See Fig. 13.

Fig. 12 Crank.s haft end play, checking/adJusting

-check crankshaft end play
• new: 0.07-0.13 mm (0.003-0.005 in.)
• wear limit: 0.15 mm (0.006 in.)
Fig. 9 Flywheel, removing - i f out of specification proceed as.
follows:
- lock flywheel with tool - install flywheel with 2 shims but
without 0-rlng and crankshaft oil seal
- mount dial !Indicator with bracket on
crankcaSE!
- move crankshaft in and out and
measure movement (crankshaft end
play)
-determine thickness of 3rd shim

Example
dial indicator reading 0.44 mm (0.017 in.)
specified end play -0.10 mm (0.004in.)
thickness of 3rd shim 0.34 mm (0.013 in.)
Fig. 10 Torque converter drive plate, removing
Shims C on vehicles from 1986, see Fig. 13
- lock plate with VW 802
- to remove, screw in bolt 1 go to next page
(M 18 x 1.5 x 60). Thread length of bolt
must be at least 45 mm (1.77 in.)

Crankshaft oil seal

E-11
Water-cooled
Torque converter drive plate
Crankshaft end play 13.40
13 Engine -Crankshaft, Crankcase
Note Parts required
Thickness of shim is etched on :shim . .Always
Description Part no. Quantity
recheck with micrometer
Thrust washer 025 105 283 1
81.0mm (3.2 in.) 025 105 281 1
CAUTION diameter shim
75.0mm (3.0 in.) 021 105 281 2
Always install three shims to obtain correct
diameter shims (0.30mm thickness)
crankshaft end play
021105 283
- remove flywheel (0.32mm thickness)
- install 0-ring, crankshaft oil seal and felt ring 021 105 285
install all three shims (o:a4mm thickness)
021 105 287
- install flywheel (0.36mm thickness)
-tighten bolts to 60 Nm (44ft lb) plus an add'l1/4 turn (90°)
021 105 289
- recheck crankshaft end play
(0.38mm thickness)
021 105 291
(0.24mm. thickness)
94.0mm (3.7 in.) 025 105 635
diameter shim
Oil seal 029 105 245 B
0-ring. 021 105 279

Fig. 13 Shim arrangement (from 1986)

A =
Thrust washer
• lip points toward crankshaft bearing
B = 0.81 mm shim
C = 0.75 mm shims
D = 0.94mm
E Oil seal
• pry out with screwdriver
F = 0-ring
• always replace
Apply light film of oil on both sides of thrust
washer A.
Install with lip (arrow) pointing toward crankshaft
bearing
- press shim 8 to A
- install flywheel without 0-rings, E, F
- mount dial indicator with bracket on crankcase
Proceed to determine thickness of shim C (see
fig. 12)
- remove flywheel
- install shims C, D, and oil seal E
- install flywheel with F
-tighten bolts to 60 Nm (44ft lb) plus an add'l 1/4 turn (90°)
- recheck crankshaft end play

13 •41 Crankshaft end play

Water-cooled from 1986
 Engine- Crankshaft, Crankcase 13

Triple V-belt pulley

to remove/install: insert pin of tool into
smaller hole of pulley
to loosen: smaller hole must be up
to tighten: smaller hole must be down

Sealing ring

~ olways 'eplace .

{tl--- Woodruff key .

insert so that 90 angled side of key
faces toward oil thrust ring

Rubber mount, right

remove bolt to insert support pin

wrench extension ex-

planation.

Engine carrier

13-A030
3102
Note
Triple V-belt pulleys supplied as spare
parts have only TDC mark 0. Cut timing
mark same as single V-belt pulley, see
page 13.33

E-13 Water-cooled Crankshaft end play

Triple V-belt pulley 13.42
13 Engine-Crankshaft, Crankcase
Note Note
Remove deposits (scale) from cylinders/crankcase Before proceeding with repairs, verify availability of
and cylinder head all tools.

Piston pin
removing Fig . 3
installing Fig. 12

~---- Rubber sealing ring, inner

always replace
identification: thick/black

Rubber sealing ring, outer

Piston---' always replace
max . weight difference identification : thin/green
between pistons 10 grams
marking Fig . 1
classification Fig. 4 4
recess depth Fig . 5
checking dia. Fig . 10
installing Fig . 12
Cylinder sleeve
mark before removing Fig. 1
checking cylinder bore Fig. 10
assembling Fig. 12
cylinder bore/piston dia, see
Piston rings
page 13.46
offset gap between rings 180°
as shown with oil scraper ring gap facing up.
Installation position in piston, "top" marking
toward piston head Fig. 6 end gap Fig. 8.

13.43 Piston/Cylinder
Water-cooled
 Engine- Crankshaft, Crankcase 13

A-
B
c
D
Fig. 1 Piston/cylinder sleeve, marking
• arrow points to flywheel
-before removing, mark matching
numbers on pistons and cylinder
sleeves
• cylinder boss 1 faces inward

Fig. 4 Piston classifications

A= arrow (stamped on) must point
toward flywheel when piston is
installed
B = paint dot (blue) indicates matching
size
C =weight group (+or-) stamped on
-weight= 448--456 grams
+weight=457-464 grams
Fig. 2 Circlips, removing/installing D =piston size in millimters (see table
on V·belt side: on page 13.46)

- with piston at TDC, pull out cylinder

sleeve with 3092 until piston pin
circlip visible (arrow)
at flywheel end:
-with first cylinder sleeve removed

3091
Fig. 3 Piston pins, removing
- remove pins as shown (arrow)

Note Fig. 5 Piston recess depth

if piston pin cannot be pulled out of piston, remove • measurement a= 11.65 mm (0.458 in.)
3091 and remove burr in piston pin bore with
reamer 315~.

E-15 Water-cooled
Piston/cylinder sleeve
Piston pins/circlips
Piston classifications
13 44 •
13 Engine-Crankshaft, Crankcase

113-7771
Fig. 6 Piston distinguishing characteristics
- 2.1 L Dlglfant/Syncro only -push ring in squarely from lower
cylinder opening about 4-5 mm
engine code dimension 'a' (3/16 in.)
- measure gap with feeler gauge
MV 15.5 mm
ring end gap wear limit
upper ring= 0.30-0.45 mm 0.90 mm
(0.012-0.018 ln.) (0.035 in.)
lower ring = 0.30-0.50 mm 0.90 mm
(0.012-0.020 in.) (0.035 ln.)
oil scraper= 0.25-0.40 mm 0.95 mm
ring (0.010-0.016 in.) (0.037 ln.)

Fig. 7 Piston rings, installation position

• TOP mark on piston rings must face to
top of piston
a= upper ring
b =lower ring
c =oil scraper ring

·-
Fig. 9 Piston ring side clearance, checking

clearance wear limit

upper ring= 0.05-0.08 mm 0.12 mm
(0.002-0.003 in.) (0.005 in.)
lower ring = 0.04- 0.07 mm 0.10 mm
(0.002-0.003 in.) (0.004 in.)
oil scraper= 0.02-0.05 mm 0.10 mm
ring (0.001-0.002 in.) (0.004 in.)

13.45 Piston rings

Piston
Water-cooled
 Engine-Crankshaft, Crankcase 13

13-A032 I
Fig. 12 Piston and cylinder sleeve, installing
Fig.10 Piston, checking diameter/wear -replace rubber sealing rings for cylinder
sleeves:
-measure at bottom of skirt approx. • cylinder head end = thin ring (green)
15 mm (9/16 in.) from edge • crankcase end = thick ring (black)
(diameter stamped in top of piston)
-install piston into cylinder sleeve
(flywheel side first)
• arrow on piston points toward flywheel
• gap of oil scraper ring must be to top
• piston ring gaps offset by 180° (see
explosion view)
nit
- insert circlip for piston pin on flywheel
m side of piston
n.)
us 1033S
m
n.)

m
fl.)

113-6331
Fig. 11 Cylinder sleeve, checking for wear Fig. 13 Piston and cylinder sleeve, installing

-measure 10-16 mm (3/8-5/8 in.) from top
• piston to sleeve clearance is sleeve
diameter minus piston diameter
new = 0.03-0.06 mm (0.001-0.002 in.)
wear limit = 0.2 mm (0.008 in.)
Cylinder sleeve bore/Piston diameter
- note markings on connecting rod
support 3090
• R = right side of engine
• L = left side of ~ngine
-push connecting rod support onto
center stud so finger of tool supports
connecting rod; then secure it with
rubber band 1 to prevent it from slipping

nit cylinder matching piston -align connecting rod such that piston
size
m diameter diameter pin can be installed through hole in
n.) standard blue 94.005-94.016 mm 93.98 mm housing
1st • crankshaft must be at TDC
m oversize pink 94.016-94.027 mm 93.99 • lug on rod faces up
n.)

rn
n.)

E-17
Water-cooled
Piston/Cylinder sleeve 13.46
13 Engine - Crankshaft, Crankcase

Piston pin hole burrs, removing

If a burr has formed in the outer piston pin hole from
the pin striking against the circlip, the burr must be
removed with reamer 3159 before you remove the
piston pin.

Fig. 14 Piston and cylinder sleeve, Installing

0

- install piston pin with 3091 and insert

circlip

j13-777a J

- remove circlip

Cutting teeth

- insert reamer 3159 into piston pin hole

-remove burr with reamer
- remove piston pin with tool 3091

13.47 Piston pin hole burrs, removing

Water-cooled
 Engine- Crankshaft, Crankcase 13

CAUTION
When assembling crankcase halves, observe
tightening sequence and tightening torque
(see page 13.36 and page 13.39, Fig. 5)

Oil pickup line with

filter screen Crankcase
cleaning Fig. 4 clean and blow through all
replacing Fig. 5 oil channels with
compressed air.
Coat joining surfaces with
AMY 188 001 02 sealing Main bearing No. 2
compound lubricate before installing
crankshaft.
Note installation position
when removing and install
In same position as
removed

Camshaft end cap

coat with sealing
compound when installing.
Watch installation position

Main bearing No. 1 - - - - .

lubricate before installing
crankshaft.
Hole for dowel offset
toward flywheel

Camshaft bearing
lubricate before installing.
Tabs must engage in
recess
Crankshaft
disassembling/assembling,
see page 13.54
runout, chec king Fig. 1
end play, checking Fig. 2
installing Fig. 3

E-19 1983-1985 II Water-cooled

Crankcase
Crankshaft
Camshaft 13.48
13 Engine- Crankshaft, Crankcase

CAUTION
When assembling crankcase halves, observe
tightening sequence and tightening torque.
Main bearing No. 1
color coded red/blue
Oil pickup line with filter screen. Fig. 4 corresponding to crankshaft
- - - - Crankcase dimensions
clean and blow through all lubricate before installing in
oil channels with compressed air crankshaft
Coat joining surfaces with tabs on bearing fit into recesses
AMV 1,88 001 02 sealing compound in crankshaft housing
oil holes in left side of
check for tight fit in case crankshaft
J
Camshaft end cap
install with sealing compound

Thrust washer - - - - - - - - - .
tab points toward crankshaft
bearing and separating line
Fig. 6

Crankshaft----'

Crankshaft bearing No. 3 - - - - - - . . /

oil holes in left half of
crankshaft housing tabs engage
in recess

Main bearing No. 2 -----......J

lubricate before installing
face marked with blue color coded blue or
runout Fig. 1 red corresponding to crankshaft
dimensions

Crankcase

13.49 Crankshaft
Camshaft
Water-cooled from 1986
 Engine- Crankshaft, Crankcase 13
-turn crankshaft backward
• camshaft must not lift out of
bearings
• if camshaft lifts out of bearings,
install camshaU with smaller timing
gear
Note
To obtain specified backlash, camshafts with
various size liming gears are available.
Markings are on Inner face of timing gear

Example
Fig. 1 Camshaft runout, checking "-0.1", "+0.1", "+0.2", Indicates In
• wear limit 0.04 mm (0.0015 in.) 11100 mm how much pilch radius
differs from standard pitch radius "0"

CAUTION
Mark 0 on outer face of camshaft timing
gear is timing mark and must not be
confused with markings on inner face.
Crankshaft timing gear is available in one
size only

Fig. 2 Camshaft end play, checking

• wear limit 0.16 mm (0.006 in.)
• if out of specification, replace
camshaft bearings

Fig. 4 Oil pickup line with filter screen,

cleaning
-clean oil channels by blowing through
with compressed air (arrow)

Fig. 3 Camshaft, installing

-mark on camshaft gear tooth must be
between marks on crankshaft gear
teeth (arrow)
-check backlash of timing gears
• 0.0-0.05 mm (0-0.002 in.)
• backlash must be hardly noticeable I t3 - o3s j
Fig. 5 Oil suction line with filter screen,
replacing

E-2 1 Water-cooled Camshaft

Oil pickup line
13 50 •
13 Engine-Crankshaft, Crankcase

Fig. 6 Thrust washer and main bearing 1,

installing

Arrow 1: projection on thrust washer points toward

main bearing and separating line of
crankcase.

Arrow 2: projection on main bearing fit into

notches in crankcase. Oil holes are in left
half of crankcase housing.

13.51 Thrust washer, main bearing

Water-cooled from 1986
13 Engine- Crankshaft, Crankcase

Connecting rod bearing

note position when
removing and install in
Main bearing No. 3 - - - - - - - - , .
same position from which
oil before installing hole for
removed
dowel faces crankshaft web
Colorcode 13.53

clean and blow drillings out with

Main bearing No. 4 compressed air , protect from
oil before installing rust when storing
groove toward oil thrust ring clamping in vice Fig . 1
Colorcode 13.53 dimensions : Col or code 13 .53

Spacer
Crankshaft pilot bearing
manual trans. only
removing Fig. 13
installing Fig . 14

J :-. '-
Circlip
removing Fig . 2 Connecting rod nuts
installing Fig . 3 45 Nm (33 ft lb)
lubricate contact surface
Distributor drive gear when installing
press off/install together From1986MY2 .1L
with crankshaft timing gear 30Nm (22 It lb)
removing Fig. 4 plus half turn
installing Fig. 5 always replace

Crankshaft timing gear Connecting rod

press off/install together note position when removing
with distrbutor drive gear and install in same position
removing Fig . 4 replace in sets of four only (pairs 1
installing Fig. 5
I
._ ______ g_~Woodruff key
1'3-772'!!..... I max. weight difference 10 grams
installing Fig. 6 to Fig. 11
checking side clearance Fig. 12
2.1 L DigifantJSyncro flat side toward check crank end of rods
for distortion
oil thrust ring
Main bearing No. 3
see color code pg . 13.·53
oil before installing
projections point to right
(as shown)
oil holes point down

13 •52 Crankshaft
Water-cooled
 Engine-Crankshaft, Crankcase 13
3 3

2 2 2
Crankshaft color code
1 = Color code green (2.1 L engine-Digifant!Syncro)
2 = Color code blue or red (crankshaft code/size)

Note
On some crankshafts the blue or red code can
appear in position three.

Crankshaft journal sizes (mm)

ce
Bearing No. 1 Bearing No. 2 Bearing No. 3 Bearing No. 4 Connecting rod
Standard
size
(thru 1985) 59.980-59.990 54.971-54.990 54.980-54.990
(marked: blue dot) (marked: blue dot)

59.971-59.979 54.971-54.979 39.984-40.00 54.983-54.996

2.1 L 54.980-54.990
(marked: red dot) (marked: red dot)
Digifant, (marked: blue dot)
Syncro
; 1986MY) 54.971-54.979
(marked: red.dot)

Note
If crankshaft has blue or red dot only main
bearings with same color code can pe used.
Code for main bearings, 1, 2, 3 = 001 (blue), 004
(red)

F·3
Water-cooled
Crankshaft journal sizes 13.53
13 Engine-Crankshaft, Crankcase

Fig. 1 Crankshaft, clamping in vise

Fig. 4 Distributor drive gearlcrankshaft timing

gear, removing

Fig. 5 Distributor drive gearlcrankshaft timing

gear, installing
- heat gears to approx. 80 oc (175 °F)
before installing
Fig. 2 Circlip, removing

Fig. 3 Circlip, installing

Fig. 6 Connecting rod, installing

- numbers (arrow) on rod and cap must
match and be on same side

Crankshaft/Circlip

13.54 Crankshaft timing gear

Connecting rod
Water-cooled
 Engine-Crankshaft, Crankcase 13
Connecting rod bolts, removal/installing
2.1 L Diglfant/Syncro

Fig. 10 Connecting rod, Installing

- lightly tap both sides of connecting rod
with hammer to eliminate slight pinching
of bearing shells when installing
Fig. 7 Mark matching connecting rod/bearing connecting rod
cover with cylinder

Fig. a Connecting rod bolts, removing Fig. 11 Connecting rods, Installation position
• forged mark on rods (arrows) must face
up when rods are installed

Fig. 9 Connecting rod bolts, installing

Fig. 12 Connecting rod, checking side clearance
• wear limit 0.7 mm (0.028 in .)

F·S
Water-cooled Removal/Installation,
Connecting rod bolts 13.55
13 Engine-Crankshaft, Crankcase

Fig. 13 Crankshaft pilot bearing, removing

A = US 8028
B = US 1039 & US 1039/3

Fig. 14 Crankshaft pilot bearing, installing

-lubricate with MoS, grease when
installing
• markings on bearing cage must
face outward

13.56 Crankshaft pilot bearing

Water-cooled
 Engine - Crankshaft, Crankcase 13
Replacing 1.9L crankcase Crankshaft end play, checking

Effective immediately, the replacement crankcase for

2.11.: waterboxer engines will also be uSed for 1.9l
waterboxer engines.
When replacing the 1.9l crankcase note the
following:

Intake air distributor

Install intake air distributor 025 133 055 B when
changing from a 1.9l cra!lkcase to a 2.1l crankcase.

Ttvust washer and main bearing 1

Installing

- check crankshaft end play

(main bearing 1 without shoulder)
• new: 0.07-0.13 mm (0.003~0.005 in.)
• wear limit: 0.15 mm (0.006 in.)
- if out of adjustment, adjU$t

Crankshaft end play, adjusting

Arrow 1: Tab on thrust washer points toward main

bearing and separating line of crankcase
halves.
Arrow 2: Tab on main bearing fits Into notches in
· crankcase. Oil holes are in left half of
crankcase housing.
on seal

Shim arrangement

Note
Shims are available In different thicknesses.
Thickness is etched on each shim.

Oil seal
• pry out with screwdriver
0-ring
•always replace

1_ 1983-1985 .I '1:9Ll
t...:.::.:J ._I________
Water-cooled _..I Crankcase, replacing 13 57 •
13 Engine - Crankshaft, Crankcase

Parts required Crankshaft color code

Description Part no. Quantity

75.0mm (3.0 in.) 021105281 3
diameter shims (0.30mm thickness)
. 021105283
(0.32mm thickness)
021105285
(0.34mmthickness)
021105287
(0.36mm thickness)
021105289
(0.38mm thickness)
021105291
(0.24mm thickness)

Oil seal 0291052458 1

2 2 2
0-ring 021105279 1
Position Color
Green (2.1 L crankshaft
- check crankshilft end play only)
• new: 0.07-0.13 mm (0.003-0.005 in.) 2 Red or blue (crankshaft
• wear limit: 0.15 mm (0.006 in.) journal size)
- If out of specification proceed as.
follows: Note
- install flywheel with 2 shims but
without O·ring and crankshaft oil seal On crankshafts the blue or red code can also appear
- mount dial indicator with bracket on in position three.
crankcase
- move crankshaft in and out and Crankshaft journal sizes (mm)
measure movement (crankshaft end
play) Note
- determine thickness of 3rd shim
If crankshaft has blue or red dot only main bearings
with same color code can be used.
Example
Code for main bearings; 1, 2, 3 001 (blue),
dial indicator reading 0.44 mm (0.017 in.)
004 (red)
specified end play - 0.10 mm (0.004in.)
thickness of 3rd shim 0.34 mm (0.013 in.) Bearing Standard Grinding
no. size dimensions
1 60.00 59.980-59.990
CAUTION (Flywheel (blue or red dot) (marked blue dot)
side) 59.971-59.979
Always install three shims to obtain correct (marked red dot)
crankshaft end play
2, 3 55.00 54.980-54.990
- remove flywheel (blue or red dot} (marked blue dot)
- install 0-ring, crankshaft oil seal and felt ring 54.971-54.979
- install all three shims (marked red dot)
4 40.00 39.984-40.00
- install flywheel
(no color code) (no color code)
-tighten bolts to 60 Nm (44ft lb) plus an add'l1/4 turn (90°)
- recheck crankshaft end play Connecting 55.00 54.983-54.996
rod (no color code) (no color code)

13 •58 Crankcase, replacing

Water-cooled 1983-1985
 15

Engine
Cylinder Head
Valve Drive

Index
Air-cooled Water-cooled Syncro
- Compression pressure - Gasoline additive
checking 15.2 reducing carbon deposits 15.31
- Cylinder head - Compression pressure
assembly 15.2 checking 15.20
- Gasoline additive - Cylnder head
reducing carbon deposits 15.25 assembly 15.17
- Rocker arm shaft installing 15.23
installing 15.3 sealing 15.23, 15.26
-Valves - Engine block
assembly 15.2 assembly 15.22
dimensions 15.3 - Pushrod tubes
guides 15.4 replacing 15.25
hydraulic lifters 15.6 -Valves
seats, refacing 15.4 assembly 15.17
springs 15.2 dimensions 15.18
hydraulic lifters 15.23
Diesel guides 15.20
-Camshaft seats, refacing 15.18
assembly 15.1 0 springs 15.18
end play 15.15
oil seal15.15
radial clearance 15.15a
run-out 15.15
-Compression pressure
checking 15.16
- Cylinder head
assembly 15.8
bolts 15.9
distortion 15.14
gasket 15.9
-Valves
assembly 15.1 o

15.1
15 Engine-Cylinder Head, Valve Drive

Compression, checking

WARNING
On vehicles with electronic ignition,
disconnect terminal 4 on ignition coil and
connect to ground before performing
compression test

Hydraulic valve lifter • compression pressure: 6-9 bar (87-131 psi)

mark position according to matching valve; minimum: 5 bar (73 psi)
store In vertical position • maximum pressure difference between
with base downward highest and lowest cylinder: 3 bar (44 psi)
adjusting/ bleeding page 15.6

dimensions Fig. 4
lapping, exhaust Fig. 6
refaclng, Intake Fig. 5

Cylinder head
installing Fig. 8
/ valve seat refacing page 15.4

30 Nm (22 ft lb)
tightening sequence Fig. 8

Valve spring
removing/installing Fig. 2

15 ~m (11 ft lb)

Push rod
max. run-out 0.3 rnm (0.012 ln.)
1 c
J_
--~
,

L. . . . .
installed position Fig. 3

Valve adjusting screw

adjusting hydraulic lifters page 15.6

15- 429

•
F

15 •2 Cylinder head
Air cooled- AFC
 Engine- Cylinder Head, Valve Drive 15
c ---------------~

Fig. 4 Valves, dimensions

Fig. 1 Rocker arm shaft supports, installing Intake valve

• slot downward (arrows) a= 39.3 mm (1.547 in.) diameter

• chamfer outward b = 7.95 mm (0.313 in .) diameter
c = 115.4 mm (4.540 in.) length
a= 29°30'

Exhaust valve
a = 33.0 mm (1.299 in.) diameter
b =- 8.92 mm (0.351 in.) diameter
c = 115.4 mm (4.540 in.) length
a =- 45°

CAUTION
Do not rework exhaust valves by machine;
lap by hand only

Fig. 2 Valve spring, removing/installing

d
_L _
~===========~ - T-
lls-o28l

Fig. 5 Intake valves, refacing

- check stem diameter
Fig. 3 Retaining spring for pushrod tube, - grind &eat angle to 29°30'
installed position (arrows) • valvEJ margin d must not be less than
0.5 mm (0.020 in:)

Rocker arm shaft

Air cooled - AFC Valve spring
Valves 15.3
15 Engine-Cylinder Head, Valve Drive
Valve seats, refacing
Work sequence
c

Fig. 6 Exhaust valves, lapping

- lift and turn frequently

CAUTION
Damaged or burnt seats can be refaced if:
• permissible width of seat A is maintained
• 15°chamfer 8 does not exceed outer
diameter of valve seat Insert In cylinder
heat at C

.
-
-- ,
-- mzm
-
Fig. 7 Valve guide checking for wear
- remove carbon
- insert new valve into valve guide
• valve stem must be flush with valve
guide end
- rock valve back and forth against dial
indicator (arrow)
• max. 1.2 mm (0.047 in.)

- reface Intake valve seats A to 30° angle

• stop cutting as soon as complete seat Is
cleaned

Fig. 8 Cylinder head, installing

-tighten nuts lightly by hand
-torque in numbered sequence to
30 Nm (22 ft lb)

Valve lapping

15.4 Valve guides

Valve seat
Air cooled-AFC G-4
 Engine-Cylinder Head, Valve Drive 15
Valve guides, replacing
Work sequence
- clean cylinder head
- check to~ cracks in head and in valve seats

- reface exhaust valve seats A to 45" angle

• stop cutting as soon as complete seat Is
cleaned

15-A015]

- mount head on US 4401A

- drill guides with shouldered drill to depth of
40-50 mm (1.575-1.968 in.)

l1s-A022 I
- lightly chamfer edges of intake and exhaust
valve seats A with 75" cutter

-using 15" cutter, narrow Intake valve seat

widths A to 1.8-2.2 mm (0.070-0.086 in.)
-using 15" cutter, narrow exhaust valve seat - drive out remaining part of guide
widths A to 2.0-2.5 mm (0.078-0.098 in.) - go to next page

G-5 Air cooled-AFC Valve seats

Valve guides 15.5
15 Engine-Cylinder Head, Valve Drive
Hydraulic valve lifters, adjusting
Note
Never repair valve lifters; if worn or damaged,
replace complete assembly.
Valve lifters can be removed and replaced
without engine removal and without major
engine disassemb ly.
Intermittent valve noises are normal upon
starting, sudden acceleration, high temperatu res
or high engine speed

CAUTION
If metal partic les are found In oil pan,
remove, disassemble, clean and reinstall all
- coat new guide with engine oil and press in valve lifters from position removed
If rocker shafts have been removed,
following standard adj ustment is necessary
CAUTION
Do not use more than 2 tons of pressure
Work sequence
- set adjusting screws in rocker arms so that
bali shaped end Is flush with surface of arm
-turn crankshaft until cylinder No. 1 Is at TDC
(mark on rotor in line with mark on distributor
housing)
- turn adjusting screws so they just touch valve
stems
- turn adjusting screws 2 turns clockwise and
tighten locknuts
-rotate crankshaft 180 " and adj ust next
cylinder
- repeal until all cylinders are adj usted

Hydraulic valve lifters, bleeding

Work sequence

CAUTION
After valve guides have been replaced,
valve seats must be refaced

-before installi ng, check that valve lifter Is bled

correctly
• check by applying firm thumb pressu re on
push rod socket in direction of arrow.
Resistance should be felt
if NO, bleed lifter as follows:

15.6 Valve guides

Hydraulic valve lifters
Air cooled-AFC G-6
 Engine-Qylinder Head, Valve Drive 15
(__/-Lock ring

Pushrod socket

Plunger

Ball check~
es. valve
~Check valve spring

Check valve_/
~~
~
Plunger eprlng

retai ner

Valve body

- insert pushrod socket

-place valve lifter (leave In can of oil) In
, press and force down slowly with Type 1
c pushrod until lock ring can be installed
!or -install lock ring
-fill tin can with engine oil
- cut an old Type 1 pushrod In half
lve - remove lock ring, pushrod socket, plunger,
ball check valve with spring and plunger
spring from body
- place valve lifter body in tin can
• body must be completely covered by oil
-insert plunger spring, check valve retainer,
check valve spring, ball check valve and
and plunger inlo valve body

led -open valve with scriber (arrow), so that oil

can flow out of lower part of plunger

i-6 G-7 Air cooled-AFC Hydraulic valve lifters 15.7

15 Engine-Cylinder Head, Valve Drive
CAUTION

CAUTION Coolant/antifreeze must not be reused when

replacing engine, cylinder head, cylinder head
Diesel cylinder heads cannot be resurfaced gasket, radiator and heater core.

Cylinder head cover gasket

always replace

Cylinder head bolt

loosen in reverse order;
always replace polygon head
12mm. bolts
reuse hex head 11mm bolts
tening sequence Fig. 2

Glow plug ---~ ::~-~~;::;!!

40 Nm (29 ft lb)

- - - - - Cylinder head gasket

determin ing thickness Fig. 3
identification/installation Fig. 4 / 15-4481

15.8 Cylinder head

Diesel
G-8
 Eng'l ne-Cylinder Head, Valve Drive 15
Note
Head can be removed and installed with engine
in car.
Removing and installing drive belt-see Repair
Group 13.
Before working on head, remove injectors and
glow plugs.
Every time head Is removed, cylinder head bolts
must be torqued, and again after about 1000
miles as described above

Fig. 1 Cylinder head, installing vw

-Install guide pins from tool set 3070 as
shown
-install head gasket
-Install head and Insert other 8 head
bolts and tighten by hand
-remove guide pins with tool and Install
other 2 head bolts and tighten by hand
-tighten head bolts, see Fig. 2
VW385/17---
_...,.._
Fig. 3 Cylinder head gasket, determining
thickness
• piston he!ght must be measured when
installing new pistons or short block
and head gasket selected
-measure piston height and select
gasket from following table

Piston Identification
height (notches In
mm (ln.) gasket) Part No_

• 0.63-0.82
(0.025-0.032)
0.83-0.92
1

2
068103 383L

068103 383M
(0.033-0.036)
Fig. 2 Cylinder head bolts, tightening sequence 0.93-1.02 3 068103 383N
(0.037-0.040)
-with engine cold , torque cylinder head
bolts in sequence in following steps:
step 1 to 40 Nm (30 ft lb)
step 2 to 60 Nm (44 ft lb)
step 3 to 75 Nm (55 ft lb)
-after step 3, turn bolts in sequence
with breaker bar 1/z turn (180°) further
(two 114 turns are O.K.)
-run engine until it reaches normal
operating temperature (engine oil
temperature 50°C/122°F or when
radiator fan starts running)
-stop engine and retighten head bolts in Fig. 4 Cylinder head gasket,
sequence 1/4 turn (90°) further with Identification/Installation
breaker bar without first loosening them
-after about 1000 miles (with engine • identified by Part No. and notches
either cold or warm) retighten cylinder (arrows)
head bolts with breaker bar, turning -always select gasket thickness accord-
bolts in sequence 1/4 turn (90°) with- ing to piston height above top of
out loosening them and without cylinder block
interruption • marking OBEN on gasket must face
cylinder head

G-9
Diesel
Cylinder head
Cylrnder head bolts
Cylinder head gasket
15 9 •
 15 Engine-Cylinder Head, Valve Drive
CAUTION
~--- Bearing caps
L _ _ __:__ _ _ _ _ _ _ _ _ _ _ _ _ _J ---::::::~'71 bores are offset
removing Fig. 3
installing Fig. 4

20 Nm (15ft lb)

Cam follower
mark position
before removing
Valve spring ret11lner
Valve spring seat
removing Fig. 9.
Valve guide - - - - - -.........
checking for wear Fig. 10
replacing Fig. 11 and Fig. 12

Stem seal
removing Fig. 6
installing Fig. 7
replacing with cylinder head installed Fig. 5

~---Cylinder head
refacing valve seats Fig. 13
check for distortion Fig. 17

Note
If combustion chamber insert
is damaged, replace
cylinder head

Jl5·254J

Compression
checking, page 15.16 clearance, checking/adjusting Fig. 1
refacing Fig. 14 and Fig. 15
tapping Fig. 16
CAUTION
Coolant/antifreeze must not be reused when
replacing engine, cylinder head, cylinder head
gasket, radiator and heater core.

Camshaft

15.10 Cylinder head

Valves
Diesel
G-10
 Engine-Cylinder Head, Valve Drive 15
Note
After cylinder head repairs, valve clearance must
be checked and if necessary adjusted after 1000
mrtes. Adjust to mid-point of range

Valve adjusting discs

Thick· Thick·
ness Part Number ness Part Number
3.00 056109555 3.65 056109 568
3.05 056109 556 3.70 056 109 569
3.10 056109 557 3.75 056109 570
3.15 056109 558 3.80 056109 571
3.20 056109 559 3.85 056 109 572
3.25 056109 560 3.90 056109 573
Fig. 1 Valve clearance, checking/adjusting 3.30 056109 561 3.95 056109 574
Warm 3 ..35 056109 562 4.00 056109 575
3.40 056109 563 4.05 056109 576
-warm up engine. Cylinder head
moderately warm. Coolant temperature 3.45 056109 564 4.10 056 109 577
above 35"C (95"F) 3.50 056109 565 4.15 056 109 578
-turn camshaft by pushing vehicle in 3.55 056109 566 4.20 056109 579
4th gear. Cam lobes of valve to be ad- 3.60 056109 567 4.25 056 109 580
justed should point upward
-check that valve clearances are:
• Intake: 0.20-0.30 mm
(0.008-0.0121n.)
• Exhaust: 0.40-0.50 mm
(0.016-0.020 ln.)

CAUTION
Do not turn camshaft by mounting bolt.
This will stretch drive belt

-If measured valve clearance Is larger

than given tolerance, remove existing
adjusting disc and Insert thicker disc
to specification (see Fig. 2)
-If measured valve clearance is smaller
than given tolerance, remove existing
disc and Insert thinner disc to Fig. 2 Valve adjusting disc, removing/Installing·
specification (see Fig. 2)
CAUTION
Example Intake Exhaust When adjusting valves, pistons must not be
specified 0.20-0.30 mm 0.40-0.50 mm at TDC. Turn crankshaft about 1/4 turn past
clearance (0.008-0.0121n.) (0.016-0.020 in.) TDC so that valves do not contact pistons
when cam followers are pressed down
measured 0.35 mm 0.35mm
clearance (0.014 ln.) (0.014 ln.) -press cam follower down with 2078
Insert disc 0.10 mm 0.10 mm -remove valve adjusting disc with US
that is (0.004 in.) 0,004 in.) 4476
thicker thinner
Note
Col'd
-with engine cold, check that valve Thickness of valve adjusting disc etched on
clearances are: underside. When Installing be sure that markings
• Intake: 0.15-0.25 rnm (0.006-0.010 in.) face downward (toward cam follower). Discs can
• Exhaust 0.35-0.45 mm be reused if not worn or damaged. Use tray
(0.014-0.018 in.) 10-212 for storing discs

G-11
Diesel Valve adjusting disc
Valve clearance
15.-41
I 1
15 Engine-Cylinder Head, Valve Drive

Fig. 5 Valve stem seal, removing (With cylinder

head Installed)
-remo.ve camshaft, adjusting discs and
followers
-turn crankshaft until piston of cylinder
concerned Is at TDC
-remove valve springs with VW 541
-replace valve stem seal

Fig. 3 Camshaft bearing caps, removing

-remove bearing caps 5, 1 and 3
-diagonally loosen bearing caps 2 and 4

Fig. 6 Valve stem seal, removing

Fig. 4 Camshaft bearing caps, Installing

-lubricate bearing surfaces and cam-
shaft journals
-install caps in proper order-observe
off center bearing position; numbers
Fig. 7 Valve stem seal, Installing
on bearing caps are not always on
same side -slide plastic sleeve A onto valve stem
-lightly tighten bearing caps 2 and 4 -lubricate valve stem seal B
diagonally -push seal carefully onto valve guide
-install caps 5, 1 and 3 using plastic seal protector, otherwise
-tighten all camshaft bearing cap nuts seal will be damaged and engine will
to 20 Nm (14ft lb) use too much oil

G-12
15:12
•
Camshaft bearing caps
Valve stem seals
Diesel
 Engine-Cylinder Head, Valve Drive 15

llt---1( -206

Fig. 8 Valve springs, removing/Installing Fig. 11 Valve guide, replacing

-first Install US 4477 under cylnder head
10-218 - --1
-first check cylinder head for cracks or
excessively worn seats
-press worn guides out from combus-
tion chamber side
-coat new guides with oil and press Into
cold cylinder head from camshaft side.
Press guides In as far as they will go

CAUTION
Once guide shoulder Is seated do not use
more than 1 ton pressure or guide shoulder
may break

Fig. 9 Valve spring seat, removing

US1026>---
or
us 1027

Fig. 12 Valve guides, replacing

Fig. 10 Valve guide, checking for wear
-ream guide by hand using proper cut·
-remove carbon
ting lubricant
-Insert new valve Into valve guide
-valve stem end must be flush with
valve guide end
-rock valve back and forth against dial
indicator. Dial Indicator reading shows
valve guide wear
• dial indicator reading = max. 1.3 mm
(0.051 in.)

G-13
Diesel Valve springs/seats
Valve guides
15...I 3
r
15 Engine-Cylinder Head, Valve Drive
----~-a--- CAUTION
- -- - - - b - - - Do not reface exhaust valves on a machine.

td Lap them in by hand only

I
I
Ii Fig. 15 lntakefExhaust valves, refaclng
Intake Exhaust
115-2701
a= 34.00mm(1.338in.) 31.00 mm (1.220 in.)
Fig. 13 Valve seats, refaclng
b = 7.97 mm (0.314 in.) 7.95 mm (0.313 in.)
• seat refaclng pilot must be properly c = 104.8 mm(4.125in.) 104.6 mm (4.117 in.)
installed a= 45° 45"
Valve seat angle = 45 •
Correction angle = 15"
Dimension d must not be more than
1.5 mm (0.059 ln.)
Intake Exhaust
a = 35.2 mm (1.3841n.) 33.2 mm (1.3061n.)
b = 32.8 mm (1.290 ln.) 30.4 mm (1.1961n.)
c = 2.0 mm (0.0781n.) 2.4 mm (0.0961n.)

Note
Valve seats which are worn or burned can be
refaced provided that correction angle and seat
width are maintained. Otherwise, cylinder head
Flg.16 Valves, lapping
must be replaced
~lift and turn regularly

Fig. 14 Intake/Exhaust valves, refaclng

• valve margin d must not be less than
0.5 mm (0.019 in.)
Fig. 17 Cylinder head dlatortlon, checking
• max. 0.1 mm (0.004 ln.)
• Diesel cylinder heads cannot be resur-
faced

Valve seats

15:14
•
Valves
Cylinder head
Diesel
G-14
c
 Engine-Cylinder Head, Valve Drive
US1026~
or
us 1027
Fig. 18 Camshaft end play, checking
-measure with cam followers removed
and caps 1 and 5 installed and torqued
-check that end play is not more than
0.15 mm (0.006 in.)
Fig. 19 Camshaft runout, checking
• max. 0.01 mm (0.0004 in.)
G-15
15
Camshaft oil seal, removing/Installing
Note
Puffer 2002 may also be used
Work sequence
Removing
-set engine at TDC for cyiinder No. 1
-remove drive belt cover and drive belt
-loosen camshaft sprocket bolt 1/2 turn and tap
sprocket with rubber hammer
-remove bolt and sprocket
-unscrew Inner part (arrow A) of oil seal extrac·
tor 2085 2 turns (approx. 3mm/1/8 ln.) out of
outer part
-lock In position with knurled screw (arrow B)
-to guide extractor, screw sprocket bolt Into
camshaft until it projects about 15 mm (5/8 in.)
-lubricate threads on tapered end of seal
extractor
Diesel Camshaft
Camshaft oil seal
1515 •
15 Engine-Cylinder Head, Valve Drive

Camshaft radial clearance, checking

Work sequence

- remove camshaft sprocket

- remove camshaft and cam followers (mark f ollowers )
-remove oil seal
-clean camshaft bearing caps, seats and journals

-place camshaft on cylinder head so cam lobes do

not touch valve spring retainers or valves
- lay Plastigage® across journal
-install bearing caps in correct posit ion and tighten
to 20 Nm (14ft lb)

-position seal extractor and screw it into oil CAUTION

seal as far as possible by pushing firmly in Do not rotate camshaft.
direction of arrow
-loosen knurled screw and turn inner part In
against camshaft until oil seal Is pulled out
-clamp extractor In vis~ and remove oil seal
with pliers
Installing
-coat seal lips and outer edge of seal with oil

- remove bearing caps

- compare width of Plastigage® with measuring
scale
wear limit- 0.1 mm (0.004 in.)

Note
If this limit is exceeded, check the radial clearance
again with a new camshaft.
-press seal in flush If the clearance with a new camshaft also exceeds
the wear limit, the cylinder head must be replaced.

-after completing repairs, check and adju,st valve

clearances

15.15a Camshaft oil seal, Installing

Camshaft radial clearance
Diesel
15 Engine-Cylinder Head, Valve Drive
Compression (Diesel), checking
Work sequence

CAUTION
To avoid damage, keep Injection parts
clean when removing, Installing,
disassembling and assembling

• engine oil temp 30"C (86°F)

-disconnect wire from fuel shutoff solenoid on
Injection pump and insulate
-clean all injector pipe fittings
-remove injector pipes with tool3035

-disconnect fuel return hoses

-remove injectors using US 2775 or equivalent
-remove heat shields
-place old heat shield in cylinder to be checked

-screw In adaptor and compression tester

-set parking brake and place transmission In
neutral
-operate starter
• 28-34 bar (406-493 psi)
• maximum pressure differential between
highest and lowest cylinder, 5 bar (73 psi)
-repeat for other three cylinders

L injector .J
~·~ heat shield
I 23-A0111

-install new heat shields as shown

-reinstall injectors and tighten to 70 Nm
(51 ft lb)
-reconnect fuel return hoses

-reinstall injector pipes and tighten to 25 Nm

(18ft lb)
-reconnect wire to fuel shutoff solenoid on
injection pump
-start engine and accelerate a few times to
clear air bubbles

15 •16 Compression, checking

Diesel
H
 Engine-Cylinder Head, Valve Drive
Note
Cylinder heads with cracks between valve seats
or between a valve seat and spark plug thread
can be used again without reducing service life
provided that cracks are small and not more than
0.5 mm (0.019 in.) wide or that only first coil of
plug thread is cracked
15
Note
Cylinder head can be removed and
installed with engine Installed
CAUTION
Coolant/antifreeze must not be reused when
replacing engine, cylinder head, cylinder head
gasket, radiator and heater core.

Valves
valve dimensions Fig. 2
intake valve refacing Fig. 3 Cylinder head
valve seat refacing page 15.18

Valve guides-----"
checking page 15.20

Compression
checking p age 15.20

H-2. Water-cooled Cylinder head 15.17

15 Engine-Cylinder Head, Valve Drive

Fig. 3 Intake valves, refaclng

• valve margin d must not be less than
0.5 mm (0.020 ln.)

Fig. 1 Valve springs, removing/Installing

Valve seats, refaclng
Work sequence
c

Fig. 2 Valve, dimensions

Intake valve
a= 40.0 mm (1 .575 ln.) diameter
b = 7.96-7.97 mm (0.313-0.314 in.) dia.
c = 122.5 mm (4.823 in.) length
o-G= 45 °
Exhaust valve
a= 34 mm (1.339 ln.) diameter
b = 8.91-8.92 mm (0.3508-.3512 ln.) dla. CAUTION
c = 122.5 mm (4.823 in.) length
o-G=45° Damaged or burnt seats can be refaced if:
• permissible width of seat A is maintained
• 15 o chamfer B does not exceed outer
CAUTION diameter of valve seat insert in cylinder
head at C
Do not rework exhaust valves by machine,
lap by hand only

-seat width a= 1.4-2.5 mm (0.055-0.098 in .)

15.18 Valves/springs/dimensions/
refaclng Water-cooled H·
 Engine-Cylinder Head, Valve Drive 15

- reface valve seats to 45 • angle - reface surface to 15 • angle

• stop cutting as soon as complete seat is • chamfer upper edge of valve seat until
cleaned correct seat width is obtained

Note
When new valves are installed in properly
reworked seats, it may not be necessary to lap in
valves

CAUTION
After lapping valve, remove all traces of
grinding paste

115-0861
- reface surface to 75 • angle
• slightly chamfer lower edge of valve seat

H-4 Water-cooled Valve seats, refacing 15.19

15 Engine-Cylinder Head, Valve Drive
Valve guides, checking Compression pressure, checking
• engine oil temperature minimum 30°C (86°F)
Note • throttle valve open fully (accelerator pedal in
When repairing engines with leaking valves it is full throttle position)
not sufficient to rework or replace valve seats
and valves. -remove all spark plugs
It is also netessary to check valve guides for -disconnect coil wire at ignition distributor and
wear. connect to ground with clamp
This is particularly important on engines which
have considerable mileage.

-check compression with tool US 1120

-operate starter until tester no longer indicates
a rise In pressure
- remove carbon Compression pressure values
- insert new valve into valve guide
• valve stem must be flush with valve Engine Compression
guide end code pressure
- rock valve back and forth against dial 1.9L 10- 13 bar
indicator (arrow) (145 - 189psi)
• max. 1.2 mm (0.047 in.) 2.1L

Minimum 8 bar
(116 psi)

15.20 Valve guides

Compression, checking Water-cooled
 Engine-Cylinder Head, Valve Drive 15
CAUTION
Coolant/antifreeze must not be reused when
replacing engine, cylinder head, cylinder head
gasket, radiator and heater core.
When replacing coolant/antifreeze solution in
all Volkswagen models, all model years, use
phosphate-free coolant/antifreeze only,
zvw 237104.

Cap nut, final torque

50 Nm (37 H lb)
drain coolant before
removing nuts;
always replace. de-grease and coat
Apply thin bead of sealing compound surface with
D 000 400 01 to gasket surface facing AKD 456 000 01
cylinder head
AdJusting ecrew
adjusting hydraulic valve
lifters, page 15.23

Coolant drain plug

Cylinder head
before removing, drain coolant. always replace
sealing Fig. 2
installing Fig. 3

H-6
Water-cooled
Cylinder head, assembly 15 •21
15 Engine-Cylinder Head, Valve Drive
CAUTION
Coolant/antifreeze must not be reused when
replacing engine, cylinder head, cylinder head
gasket, radiator and heater core.
When replacing coolant/antifreeze solution in
all Volkswagen models, all model years, use
phosphate-free coolant/antifreeze only,
zvW 237104.

Note
Cylinder head can be
removed and installed
with engine installed.

Metal sealing ring

always replace

Hydraulic valve lifter

do not interchange.
adjusting, page 15.23
bleeding, page 15.24
Pushrod tube
small end faces head.
Pretensioning Fig. 1
replacing page 15.25
max. run-out 0.3 mm
(0.012 in.).
guide pushrod carefully
into seat of hydraulic valve
lifter

15 •2 2 Engine block, as&embly

Water-cooled
 Engine-Cylinder Head, Valve Drive
-
Fig. 1 Pushrod tube, pretenslonlng
- pretension tube to correct length
• a = approximately 194 mm (7.6 in.)
- when installing, seam faces upward and
small end to cylinder head
- always replace sealing rings, head gasket
• pushrod tubes can be replaced with
engine installed
Fig. 2 Cylinder head, sealing
Applying sealant D ooo 400 01
To improve sealing of painted/unpaintedsealing
surfaces on cylinder head, use D 000 400 sealant.
-if paint is damaged, clean cylinder head sealing
surface with fine sand paper
- clean sealing surface with solvent
- apply 1 to 2 mm (3/64-5/64 in.) bead of sealing
compound D 000 400 in the center of the new
water jacket gasket (arrows)
CAUTION
DO NOT USE TOO MUCH SEALANT.
Excessive sealant could plug cylinder head
coolant passages or hydrolock cap nuts.
Note
Cylinder head must be installed within 45 minutes of
the sealant application.
H·S
15
Fig. 3 Cylinder head, Installing
- tighten cylinder head at stud 1 with cap nut just
enough so that all remaining 7 cap nuts can be
installed
- coat surface of cap nut with AKD 456 000 01
sealing compound
Torque sequence
CAUTION
Do NOT use click type torque wrench. Use
only beam or dial type wrench.
First stage: tighten cap nuts in numbered sequence
(see above) to 10 Nm (7 ft lb)
Note
Be. sure that push rod tubes are properly seated.
Second stage: tighten cap nuts, in numbered
sequence to 50 Nm (37 ft lb)
-recheck final 50 Nm (37ft lb)
- reinstall push rods, rocker arms
• push rods must be properly seated before
tightening rocker arms
• torque: 25 Nm (18 ft lb)
Hydraulic valve lifters, adjusting
Note
Never repair valve lifters; if worn or damaged,
replace complete assembly.
Valve lifters can be removed and replaced without
engine removal and without major engine
disassembly.
Intermittent valve noises are normal upon starting,
sudden acceleration, high temperatures or high
engine speed.
Water-cooled Cylinder head
Hydraulic valve lifters
15 23 •
15 Engine-Cylinder Head, Valve Drive
CAUTION
If metal particles are found in oil pan, remove,
disassemble, clean and reinstall all valve lifters
from position removed.

- guide pushrod carefully into $0cket of hydraulic

valve lifter
If rocker shafts have been removed, the following
adjustment is necessary:
- backout adjusting screws in rocker arms until ball
shaped end is flush with surface of arm
-turn crankshaft until cylinder No. 1 is at TDC
• mark on rotor in line with mark on distributor
housing
- turn adjusting screws in until they just touch valve
stems
- turn adjusting screws 2 turns clockwise and
Valve body
tighten lock nuts
- rotate crankshaft 180" and adjust next cylinder
- repeat until all cylinders are adjusted
-----~Bore

Hydraulic valve lifters, bleeding

- pry .out lock ring

- remove pushrod socket, plunger, ball check valve
with spring, check valve retainer and plunger
spring from body
- fill valve lifter body with oil up to bleed hole
- insert plunger spring
- install plunger with ball check valve, spring and
valve retainer and push downward; at same time,
open ball check valve with scribe

- before installing, ensure valve lifter is bled

correctly
• check by applying firm thumb pressure on push
rod socket In direction of arrow. Lifter should
not move.
If NO, bleed lifter as follows:

- insert pushrod in socket and slowly press together

with valve guide or sawed-off pushrod in vise
(bore A must face upward) or in press until lock
ring can be installed
- install lock ring

15 •2 4 Hydraulic valve lifers

Water-cooled
 Engine-Cylinder Head, Valve Drive 15
Pushrod tubes, replacing
Note
Pushro<! tubes supplied as replacement parts can be
installed with engine in place.
- remove valve cover
- remove rocker arm· shaft, pull push rod out
- remove lower cover plate
- remove defective pushrod tube with pliers or
screwdriver

- squeeze new pushrod tube together and insert

with new sealing rings as shown (arrow)
(tube seam faces upward, small end to head)
- insert pushrod and install rocker arm shaft

CAUTION
Guide pushrod carefully into seat of hydraulic
valve lifter.
If pushrod rests on edge of lifter basic setting
will be incorrect and lifter will be damaged
when engine is started.

-adjust hydraulic valve lifters, see page 15.23

H-10 Water-cooled I Pushrod tubes 15 •25

15 Engine-Cylinder Head, Valve Drive
Cylinder head, resealing
Note
To reseal cylinder heads, follow this
procedure. Always do both sides. Cylinder
heads can be removed without removing the
engine.

Removing
• disconnect battery ground strap
• remove rear mattress (where applicable),
carpet, engine cover
• remove air cleaner assembly
• remove AJC compressor from bracket,
leave hoses attached

WARNING.

Fire hazard. Do not smoke or have

anything in area that can ignite fuel.

• remove left/right fuel rails, injector ground

wires and intake manifolds
• remove left/right splash shields
• remove push rod tube shields
• disconnect oxygen sensor
• remove coolant drain plugs 1 at both
cylinder heads, drain coolant from engine
• drain engine oil, remove oil filter

Note
Do not reinstall oil drain plug until repair is
completed.
• remove spare tire cover under front of
vehicle, disconnect coolant hoses
• reconnect radiator coolant hoses
• close spare tire cover
• remove coolant pump

15 •2 6 Cylinder head resealing

Water-cooled
 Engine - Cylinder Head, Valve Drive 15
-
• remove exhaust system, including cross-
over pipes, muffler with converter and
exhaust heat shield
• remove crankshaft pulley
• see Repair Group 13
• remove power steering pump
• remove coolant cross-over pipes at front/
rear of cylinder head
• remove valve covers, rocker arms, push
rods, oil filler pipe

Note
Mark push rods for reinstalling to original
location.
• remove cylinder head cap nuts, push rod
tubes and cylinder head
• stuck cylinder sleeves may be removed
by lightly tapping with small solid rubber
mallet
• clean old gasket material from cylinder
heads, engine block, valve covers
• inspect sealing surface of cylinder head,
replace if pitting or cavitation present
• mark matching numbers on piston/cylinders
• pull out cylinder sleeves with tool 3092 until
piston circlip is visible
• see Repair Group 13
• remove piston circlips, wrist pins with tools
3091, 3159
• see Repair Group 13

Installing

CAUTION
Always replace gaskets, seals, 0-rings,
lubricants.

CAUTION
Part numbers are listed for reference
only. Always consult with the Parts
Department for latest information.

- Water-cooled Cylinder head resealing · 15 •27

15 Engine-Cylinder Head, Valve Drive
• inspect cylinder head studs for corrosion,
and replace as required
• clean wrist pins, cylinder sleeves, pistons
• replace both cylinder sleeve 0-rings
• reinstall piston and cylinder sleeve onto
corresponding connecting rod
• install wrist pin to connecting rod
• see Repair Group 13
• clean push rod tubes, rocker arms, valve
covers, cylinder head cap nuts
• measure and adjust push rod tubes to
length a
a = approximately 194 mm (approximately
7.6 in.)
• install new cylinder head gasket

;-------·--·a----~--~

CAUTION
Do not use too much sealant. Excessive
sealant could plug cylinder head coolant
passages or hydrolock cap nuts.

• apply cylinder head sealant Part No.

D 000 400 01 in 1.0-2.0 mm (3/64-5/64 in.)
bead (arrows) in center of gasket side
facing cylinder head
• install cap nut location in 1.0 mm (3/64 in.)
bead
• reinstall cylinder heads, push rod tubes,
seam side up

CAUTION
DO NOT use click type torque wrench.
Use only beam or dial torque wrench.

15 •2 8 Cylinder head resealing

Water-cooled
 Engine - Cylinder Head, Valve Drive 15
• tighten cylinder head at stud 1 with cap nut
just enough so that remaining 7 cap nuts
can be installed

Torque sequence

Note
Ensure that push rod tubes are properly
seated.
First stage: tighten cap nuts in numbered
sequence to 10 Nm (7ft lb)
Second stage: tighten cap nuts in numbered
sequence to 40 Nm (30 ft lb)
Third stage: tighten cap nuts in numbered
sequence to 50 Nm (37ft lb)
• recheck final 50 Nm (37 ft lb)
• reinstall push rods, rocker arms
• push rods must be properly seated
before tightening rocker arms
• torque: 25 Nm (18ft lb)

Hydraulic valve lifters, adjusting

• back out adjusting screws in rocker arms
until ball shaped end is flush with surface
of arm
• turn crankshaft until cylinder No. 1 is at
TDC
• mark on rotor must be in line with mark
on distributor housing
• turn adjusting screws in until they just
touch valve stems
• turn adjusting screws 2 turns clockwise and
tighen lock nuts
• rotate crankshaft 180° clockwise and adjust
next cylinder
• repeat until all cylinders are adjusted

-
Water-cooled Cylinder head resealing 15 •29
15 Engine-Cylinder Head, Valve Drive
• reinstall all other components in reverse
order of removal
• check expansion tank pressure cap with
VAG 1274/99

CAUTION
Coolant/antifreeze must not be reused
when performing this procedure. When
replacing coolant solution in all
Volkswagen models, all years, use
phosphate-free coolant ZVW 237 104.

• reinstall coolant drain plugs between

cylinders
• refill with coolant
• reinstall engine drain plug, refill with oil
• reconnect battery ground strap
• remove radiator grille
• raise front of vehicle approximately 40 em
(16 in.) under cross member
• bleed air from coolant system
• lower vehicle to ground
• reinstall radiator grille
• pressure check cooling system for leaks
with tool VAG 1274/99
• check and adjust engine specifications, as
necessary

15 •3 0 Cylinder head resealing

Water-cooled
 Engine-Cylinder Head, Valve Drive 15
Gasoline additive
"Autobahn Gasoline Additive" has been tested by
Volkswagen, and found to be effective in reducing
carbon deposits that result from fuel and
lubricating oil residue. The additive works best with
unleaded gasoline, but also works with leaded fuel.
"Autobahn Gasoline Additive" is supplied by
Volkswagen of America under Part No. ZVW 246 001 .

Note
Read product label for additional information. Read
all cautions and warnings.

Caution
Do not exceed this recommendation:

Oil change Max. Treatments

interval between oil
Miles changes
5,000 2
7,500 4

Excessive carbon deposits reduce engine

performance by:
• idle hunting (idle speed goes up and down)
• poor hot or cold starting (starter cranking takes
longer)
• engine run-on (dieseling)
• pinging during full-throttle acceleration
To help clean out carbon deposits and minimize
future carbon build-up:
- make sure that ignition and fuel systems are
adjusted to specifications
-add one (1) 20 oz. bottle "Autobahn Gasoline
Additive" to fuel tank. Fill tank completely. Do
not refill until the gauge reads "1 I 4"
- use only gasoline with a detergent additive
package. Information about fuel composition is
available from any gas station or from the
station's fuel supplier.

CAUTION
Part numbers are for reference only. Always
consult your Parts Department for latest
information.

-
H·16 Gasoline additive 15.31
 17

Engine
Lubrication System

Index
Alr-®oled Water-®Oied /Syncro
'~Assembly 17.2 -Assembly 17.7
-Oil cooler 17.2 ~Heating pipe,
checking 17.3 crankcase breather 17.9
-Oil pressure switch 17.2 -Oil pressure switch 17.9
checking 17.3 ~il pump 17.9
removing 17.3
-Oil pump 17.2
removing 17~3

Diesel
-Assembly
-Oil filter 17.4, 17.5
.:_Oil cooler 17.4
checking 17.5
-Oil pan 17.4, 17.6
-Oil pump 17.4, 17.5
-Oil pressure switch 17.4, 17.6

Index 17.1
 17 Engine-Lubrication System

Engine oil filling capacity - - - - - - . .

with all filter change-3.5 ltr (3.7 US Qt)
011 preaaure
without oil filter change-3.0 ltr (3.2 US qt)
checking Fig. 5

011 preaaure ewllch - - - - .

removing/Installing Fig. 4
011 dlpetlck ~'
difference between
checking Fig. 5 min. and max.
0.8 ltr (0.8 US qt)

Oilcool•'~
check lor leaks Fig. 3 n
011 pre..ure relief valve
20 Nm (15 H lb)
•' o')
Replace all cooler if there are
metal partic les on pistons,
'
<J Otl a trainer cover

' - - 13 Nm (9 It lb)
125 Nm (18 It lb)

~Oil drain plug

crankcase bores. or In engine 011 pump houelng
oil removing Fig. 1
25 Nm (18 It lb)
011 pump gears

011 pump

17.2 011 pressure switch

011 cooler
Air cooled-AFC
1-2
 Engine-Lubrication System 17

Fig. 1 Oil pump housing, removing

Fig. 4 Oil pressure switch, removlng/ln~taiHng

Fig. 2 011 pump Insert, removing

Fig. 5 Oil pressure/switch, checking

• engine oil temperature should be
so·c (176.F)
-Install oil pressure gauge/adapter in
place of oil pressure switch
-Install switch .in gauge
-connect wire 1 to Oil pressure switch
and to wire frorn oil pressure warning
light
-connect wire 2 to ground
- turn iQnition ON
• oil pressure warning light must
light up
if NO, switch is defective
-start engine
Fig. 3 011 cooler, checking for Je•ks •· oil pressure· warning light must go
• test pressure max. 5.9 bar (85 psi) out at oil pressure of 0.15-0.45 bar
(2-6.5 psi)
-Increase engine speed
• at 2000 rpm, pressure should be min.
2.0 bar (29 psi)

Oil pump
1·2 1-3 Air cooledwAFC f>il cooler
Oil pressure. 17.3
17 Engine-Lubrication System

Engine oU filling capacities

without ollllltOI' change 3.5 ltr (3.7 US ql)
with oil filter change -4.0 ltr (-4.2 US qt)

011 praeaura checking page 17.6 I

_..__ _ 011 presaura switch

t 2 Nm (8.5 It Ib)
Install with sealant
checking Ag. 5

Oil cooler
coat top sealing sur1ace
with AMV 188 100-02

011 pump gears -----~,.4.:.,...

checking backlash Fig. 3
checking end play Fig. •
Dlpetlcll
difference between
min. and max. 1.0 litOf (1 US qt)

on tiller cap

Oil IIIIer neck

__,.--- Strelnar
clean

._~-- ~-------Strainer houalne Fi~

pry oil with screwdriver
If
- - - - - . - - -....~- 011 pan gaakat
on
alwaya replace

No
AI\
wh
25 Nm (18 It lb)

-·
20 Nm (15 n lb)
to drain oil, loosen
and unscrew plug 3 turns

on pump

17.4 Oil filter

011 pan
Diesel

1-5
 Engine-Lubrication System 17
CAUTION
Oil contamination of coolant may have
deteriorated coolant h0$es. Inspect and
replace hoses depending on condition
and/ or length of time oil has been In
cooling system.

CAUTION
Do not loosen oil cooler
when removing oil filter

-when installing, hand tighten according

to instructions on filter element or carton
Fig. 1 011 filter, removing/Installing
-loosen with US 4474

Fig. 3 011 pump backlash, checking

• new: 0.05 mm (0.002 in.)
• wear limit : 0.2 mm (0.008 in .)

17-A029
Fig. 2 011 cooler, checking
If oil contamination is found in the cooling system,
one possible source of leakage is the oil cooler.
- remove oil cooler from veh icle
-plug one hose fitting and pressurize remaining
fitting with air
-submerge cooler in water and check for air bubbles
which indicate a leak i n cooler
-if leaking is noticed, replace cooler

Note
Always use a new seal coated with clean engine oi I
when reinstalling oil cooler. Fig. 4 011 pump end play, checking
• maximum 0.15 mm (0.006 in .)
- clean cooling system thoroughly (use Prestone Super
Flush AS- 107 or equivalent)

Oil filter
Diesel Oil pump
011 cooler, checking 17.5
1-5
17 Engine-Lubrication System

VW1342

Fig. 6 011 pan, Installing

3 (engine Installed)

\, -align oil pan to engine block with

straightedge (arrows)
-tighten bolts

(engine removed)
-start all bolts Including those In clutch
housing
-press oil pan by hand against clutch
Fig. 5 Oil pressure switch, checking housing so that there is no gap be-
-remove oil pressure switch and insert tween oil pan and clutch housing
Into tester -lightly tighten a.JI bolts
-connect tester Into cylinder head in -fully tighten all bolts
place of swltcl1 M6 to 10 Nm (7ft lb)
-connect test wire 1 (blue) of tester to oil M10 to 45 Nm (33ft lb)
pressure switch and wire 3 from oil
pressure switch CAUTION
Oil pan must be flush with end face of engine
-connect test wire 2 (brown) to ground block. If it protrudes or there is a gap, clutch
-turn Ignition ON, oil warning light must housing will be stressed and could break
light (assuming bulb and wire are OK)
• If NO, switch Is defective
-start engine and Increase speed slowly.
At oil pressure of 0.15-0.45 bar (2-6 psi)
oil pressure warning light must go out
• if NO, switch Is defective
-Increase speed further. At 2000 rpm
and oil temperature of 80 •c (176 •f)
minimum oil pressure must be 2.0 bar
(28ft lb)

17.6 Oil pressure/Switch

Oil pan Diesel
1-7
 Engine - Lubrication System 17
Note
Always replace all gaskets and sealing rings.
Crankcase breather heating pipe
Note (2.1 L Digifant/Syncro only)
If, as a result of engine damage, large quantities of arrow points toward intake hose
metal shavings are found in the engine oil, oil
passages should be cleaned and cooler replaced.
Engine oil filter capacity
with oil filter change - 4.5 Ltr. (4.7 US qt.)
without oil filter change - 4.0 Ltr. (4.2 US qt.)

L __ 0.3 bar (4.4 psi)

30 Nm (22ft lb)

011 pump cover

if scored, replace
117·4491
Note
Extreme cold weather can harden and split the seal
between the engine block and the oil cooler thus
creating an oil leak.
An ir:nproved cold-resistant seal was installed in
production as of 02187. ·
The new seal can be identified by its silver-grey
appearance and is available through your parts
deparment, part no. N 901 814.02.

Oil filter- thru 1985 Oil filter - 2.1 L Digifant/Syncro

from 1986. See pg. 17.8. CAUTION
Note Part numbers are for reference only. Always
Observe installation instructions on filter. check with your Parts Department for latest
information.

011 pump

1-7
Water-cooled 011 pressure awftch
011 filter
17•7
 17 Engine-Lubrication System

Oil CXJoler - from 1986

011 cooler
coat flange surfaces
with AMV 188 100 02
check clearance with other parts

titter
loosen with US 4462
note instructions on 17-448
filter or box

Fig.

1
Fig.
Oil viscosity grades
A - single weight oils
B - Multigrade oils
Only use oils marked 'SF' under API system.

17.8 011 viscosity

Oil cooler
Water-cooled - from 1986

- - - -
___
 Engine-Lubrication System 17

Fig. 1 011 pump housing, removing

Fig. 4 Oil pressure/switch, checking

• engi ne oil temperature should be
so·c (176.F)
-remove oil pressure switch and Install
in gauge
- install oil pressure gauge/adapter In
Fig. 2 011 pump end play, checking
place of oil pressure switch
• max. 0.1 mm (0.004 in.)
-connect wire 1 (blue) of gauge to oil
pressure switch and wire of oil
pressure warning light 3 as shown
-connect wire 2 (brown) to ground
-turn ignition ON
• oil pressure warning light must light
up

• if NO, switch is defective, replace

switch
-start engine
• oil pressure warning light must go
out at an oil pressure of
0.15-0.45 bar (2-6.5 psi)
- increase engine speed
I 24 - 1471 • at 2000 rpm, pressure should be
minimum 2.0 bar (29 psi)
Fig. 3 Checking heating pipe for crankcase
breather
A = resistance 4-17 ohms @ 25°C (77°F}
B = approx. 12V, with ignition on

Oil pump
Water-cooled Oil pump end play
Oil pressure/switch 17.9
17 Engine-Lubrication System

Oil pressure switch, checking 0.3 bar (4.4 psi) oil pressure switch.

0.9 bar (13.1 psi) switch, near oil pornp Note

Work procedure Tester connections are identicalto 0.9 (13.1.psi)

switch
- push back exhaust cover plate (mounting screw
under oil pump) with screw driver 0.3 bar(4A psi) oil pressure switch located
-remove 0.9 bar (13.1 psi) · between Jeft side push rod tubes

117- 4421

-screw oil pressure switch into tester VW1342 -disconnect conrtector 1

-connect wire 1 (blue) -connect testlamp to wire 2 of 0.3 bar (4.4 psl)
-screw tester into crankcase in place of oil oil pressure switch and to alternator positive
pressure switch -test lamp rnust light up
-connect test lamp 2 to wire 1 and alternator -start engine, raise RPM
positive connection
When pressure goes to 0.15-0.45 bar (2.2~6.5 psi)
-ground wire 3 (brown)
test lamp must go out.
-start engine, slowly raise RPM
-at tester reading 0.75-1.05 bar (10.9-14.8 psi) If not, replace oil pressure switch
test lamp must light up
• replace oil pressure switch if tester does not -raise RPM
light -at oil temperature of 80°C (176°F) and RPM of
2000, oil pressure should be 2.0 bar (29 psi)
Note
As necessary, check switching point of oil pressure
switch at starting RPM

17.10 Oil pressure switch,

checking
Water-cooled from 1986
 19
Engine
Cooling System

Index
Air-cooled Water-cooled
- Cooling air control flap - Antifreeze hydrometer
adjusting 19.3 checking 19.17
+ Cooling fan -Coolant
I removing 19.3 assembly 19.8, 19.11, 19.14
- Fan housing draining/filling 19.15
assembly 19.2 expansion tank, checking 19.18
removing 19.3 hose layout 19.1 0
- Snap-lock wiring connectors leak checks 19.17
installing 19.19 mixture ratio 19.18
- Thermostat refill tank 19.9, 19.13
checking 19.3 - Hose spring clamps
- V-belt removing/installing 19.16
assembly 19.2 - Hot footwall kit
tension, adjusting 19.3 installing 19.20
-Radiator
Diesel assembly 19.12
- Antifreeze hydrometer thermo-switch 19.12
checking 19.7
-Coolant
assembly 19.4
draining/filling 19.6
mixture ratio 19.5
pipes, replacing 19.7a
- Snap-lock wiring connectors
installing 19.19
- Pressure Cap
checking 19.7

19.1
19 Engine-Cooling System

r 15 Nm (11ft lb)

a~

Thermoe'-1
'E\
checking Fig. 5 '-
6'c ~

,-
Roller
check for free movement 20 Nm (15ft lb)

~
cooHne elr control •lap - -............
adJusting Fig. 4

(I
Fen houalne - -

~(15ftlbJ
removing Fig. 3

Coollne fen with pulley

removing Fig . 2

J-2
19.2 Cooling fan
Fan housing
Air cooled-AFC J-3
 Engine-Cooling System 19

Fig. 1 V-belt tension, adjusting
- loosen bolts 1 and 2
- move alternator to tension belt
• belt deflection must be 10-15mm
(3/8-9/16 in.) in middle when
pressing firmly with thumb
- tighten bolts
Ag. 4 Cooling air control flap, adjusting
- press flaps to fully closed position
and tighten cable clamp
Note
Bent ends of return spring must rest on boss of
housing (arrow A) and on cable guide (arrow B)

Fig. 2 Cooling fan with pulley, removing

- remove bolts (arrows)

Fig. 5 Thermostat, checking

-put thermostat in water ss-oo·c
(1BS-194 . F)
• &=min. 46 mm (1 13/16 in.)

Fig. 3 Fan housing, removing

-disconnect cooling air control flap
cable
- remove bolts (arrows)
- remove housing

V-belt
J-3
Air cooled-AFC Cooling fan
Thermostat 19.3
19 Engine-Cooling System
Note CAUTION
Aniifreeze other than specified by Volkswagen
The cooling systems of all Volkswagen vehicles are may cause corrosion of the cooling system
filled at the factory with a mixture of water and an thus leading to engine ovemeating and
antifreeze solution (G 11) with corrosion lnhibit()(s. damage.
This coolant mixture should be used year-round.
AlWays use new gaskets when Installing parts.
Phosphate-free anti-freeze prevents frost and Cooling system parts can be removed and Installed
corrosion damage, the formation of chalk and in with engine In vehicle, 1
addition, It raises the boiling point of water. Due to 3
the higher boiling point the coolant Is an aid to to radiator s
operational efficiency, when the engine Is operating 6
under full load, particularly in tropical climates.
.I T
3
s
s

,_
\'
I .It

" trom radtator

¥ - - Thennoetat
opening begins: approximately 85"C
(185°F)
fully open: approximately 105"C
(221°F)
stroke: minimum 7 mm (0.275
in.)

adjust belt tension by varying

; position of shims

L Nm (!5 ft lb)
',
~to expansion tank
CAUTION
I
Coolant/antifreeze must not be reused when
Wetar pump belt '\ /~ replacing engine, cylinder head, cylinder head
check tension with thumb
deflection: 5-10 mm
-. ...... ; '-... gasket, radiator and heater core.
(3!, 6-318 in.) / " - . . Coolllflt reservoir ·
note mu and min marks When replacing coolant/antitreeze solution in all
nlling system Fig. 4 Volkswagen models, all model years, use phosphate-
free coolant/antifreeze ZVW237 102.

19.4 Cooling system assembly

Diesel
 Engine-Cooling System 19
Coolant mixture ratio Coolant capacity 16.0 ltr(16.9 US qt)

Outside Temperature Antifreeze Water

6.4 ltr (6.75 US qt) 9.61tr (10.15 US qt)
8.0 ltr (8.45 US qt) 8.0 ltr (8.45 US qt)

Breather valve
open valve when filling
system Fig. 2
Thermoswltch for Ian atage 1 ~ / [ lO Nm (7ft lb)
30 Nm (22 It lb) w
switch ON: 93 to 98 ·c
(200 to 208 "F) ·.,
swllch OFF: 88to 93 •c (190 to 200 "F) . tt
Thermoswltch for fan stage II ~ 0
30Nm(22 fllb)
switch ON: 100"-tOS"C (212•-221"F}
•o
switch OFF: 95"-100 "C (203 ·-212•F)

----
_)
5
1

Fan shroud

CAUTION

J
ate·
CAUTION
Coolant/antifreeze must not be reused when
Use hose clamps with closed serrations only.
Improper use of open serrated clamps can
tear hose and cause coolant leaks.

replacing engine, cylinder head, cylinder head

gasket, radiator and heater core.

J-5 Diesel Coolant mixture ratio

Cooling system assembly 19.5
19 Engine- Cooling System

Cooling system, draining/filling

The cooling systems of •II Volkswagen vehicles are
filled at the factory wil.h a mixture of water and an
antifreeze solution (G 11) with corrosion inhibitors.
This coolant mixture should be used year-round.
PhOsphate-free anti-freeze prevents frost and
corrosion damage, the formation of chalk and In
addition, it raises the boiling point of water. Due to
the higher boiling point the coolant Is an aid to
operational efficiency, when the engine Is operating
under fuU load, particularly In tropical climates.

CAUTION
Coolant/antifreeze must oot be reused when Fig. 2 Cooling system, filling
replacing engine, cylinder head, cylinder head
gasket, radiator and heat~ cote. -set heater controls to position WARM
-open breather valve (arrow) on radiator
When replacing. coolant/antifreeze solution In all
Volkswagen models, all model years, use phosphate·
free coolant/antifreeze lVW237 102.

CAUTION
Part numbers are for reference only. Alwa~
check with your Parts Department for latest
information.

Fig. 3 Cooling system, filling

- fill cooling system via expansion tank
(arrow) until tank Is filled to brim and
remains filled
-run engine at about 2500 rpm until
coolant flows at breather valve with
NO bubbles
- close breather valve
- check coolant level and top up as
Fig. 1 Cooling system, draining necessary
- close expansion tank with cap
-fully open heater controls
- open cap on expansion tank
- disconnect lower coolant hose 1 from
water pump at connection pipe
-disconnect center coolant hose 2 from
water pump
Note • save coolant for reuse (see caution)

When removing radiator, drain rest of

coolant by detaching lower hose from
radiator
-
19.6 Cooling system, draining/filling
Diesel
 Engine-Cooling System 19

__
Fig. 6 Pressure cap, checking
Fig. 4 Cooling system, filling
-attach cap on tester A
-fill reservoir up to m~rk max (arrow) • A = Stant tester ST-255A, AC-PCT-3
/ or equivalent
-apply a pressure of 0.9 to 1.15 bar
(11 to 16 psi)
• if pressure relief valve opens within
this range, cap Is OK

Antifreeze hydrometer, checking

Calibration of hydrometer must be checked
frequently to ensure accuracy.
-mix a 50/50 mixture of antifreeze and water
together in a small container
- hydrometer should read - 35°C (- 30°F)
• if not, put a mark (paint dot) to Indicate where
-35°C ( -30°F) should be.

Ag. 5 Cooling system, ch.cklng

-attach tester A In place of pressure cap
• A :o: Stant tester ST·255A; AC-PCT-3
or equivalent
-apply pressure of approximately 1 bar
(14 psi)
• If pressure remains constant, system
is OK

Antifreeze hydrometer, checking

Diesel Cooling system
Pressure cap 19.7
19 Engine-Cooling System
Coolant pipes, replacing - remove fuel tank
- remove steel coolant pipes
Since March 1985 the steel coolant pipes have been - pull back hoses for heater to engine from cross
·member
replaced with plastic coolant pipes.
In cases of repair, the original steel coo. la.nt pipes
must be replaced with the new plastic pipes.
Since the diameter of the plastic coolant pipes is
larger than the steel pipes, tlte hose hole. openings. in
the engine compartment and cross members must
be enlarged.
Also, connecting hoses to engine and radiator must
be replaced.

Parts required

CAUTION
Part numbers are for reference only. Always
dleck with your Parts Department for latest
information.
- rework holes for heater to engine in cross
member (as shown)
- rework holes in cross member and engine
Deacrfptlon Part number Quantity
compartment wall to side and downward
Plastic pipe (from 251 121 397G 1 · - cover sheet metal edges on cross member with
cylinder head) trim bead
Plastic pipe 251 121 399G 1
(to coolant pump)
Engine hose (from 068 121 101H 1
cylinder head)
Engine hose 068 121 073G 1
(to coolant pump)
Radiator hose (from 251 121 082 1
cylinder head)
Radiator hose 251 121 083H 1
(to coolant pump)
Clamps 411 261 679 2
Worm drive hose obtain locally 2
clamps
Tie-wraps obtain locally X
Trim beading obtain locally X - push plastic pipes from engine side through cross
member and fasten to attachment tabs on cross
member and engine wall with a worm drive hose
clamp (as shown)

19 •7 a Coolant hoses, replacing

Diesel
 Engine - Cooling System
-bend and attach clamps Part No. 411 261 679 to
shape and secure plastic pipes to cross member
in front (arrow)
- attach clamp in back with self tapping screws
(arrow)
-tie coolant water·pipes and heater hoses together
with tie wraps (see illustration 19-437 at 30 em
(approximately 12 in.) intervals
-
J·9
Diesel
19
Installing new coolant water hoses -
to engine/radiator ·
Note
Vehicles up to 8/82
-shorten hose Part No. 251 121 083H for return
flow from the radiator to coolant pump to fit
*note the different hose diameters of 32 mm
(1-1/4 in.) and 38 mm (1-31/64 in.)
Vehicles from YIN 24C 017 500
(approximately 12/82)
- connecting sleeve diameter for hose Part
No. 06812110'LH on expansion tank was
increased from 20 mm /32 in.) to 32 mm
(1-1/4 in.)
Proceed as follows when ins alling connecting hose
Part No. 068 121 101H to hicles with 20 mm
(25/32 in.) connecting sl ve on the expansion tank:
-cut off original ant hose (with 20 mm sleeve)
approximately 120 mm (4·11/16 in.) from
expansion tank
-Install new coolant water hose, and shorten
connecting sleeve to expansion tank to match
IE!mgth of original part
- connect both ends of hose with aid of piece of
pipe (made locally) of 20 mm (25/32 in.) diameter
- secure with clamps
Coolant hoses, replacing 19.7b
19 Engine-Cooling System

Cooling ayW~m
draining Fig.1 to Fig. 4
checking lor leaks Fig. 9
Note
\
Atways replace all gaskets. All parts of ¢ooling
system can be removed and Installed whh engine
Installed. I
I

Coolant expMalon tank cap

checking Fig. 10
Coolant leYel wamlng
light awtlch

Coolant expanalon tank l c::>

.~ ..........

Spring clamp
removing/Installing Fig. 4

Temperature aeuve aender

10 Nm (7 tt lb)

Thermostat
checking : heat ltleiTOOtltat In water
opening begins : approximately ss·c (185°F)
opening ends : approximately 105"C (22t•F)
stroke : minimum 8 mm (0.315 in.)
] 19-280 1

19 •8 Cooling system
Water-cooled 11983-19851
J-1
 Engine-Cooling System 19
CAUTION I
CoolanUantifreeze must not be reuseq-~hen
replacing engine, cylinder head, cylinper head
gasket, radiator and heater core. i

Bleeder connection valve

open when filling or
bleeding cooling system
see Fig. 6

from heater core

g.4

Refill tank
note min. and max. marks
filling system Fig. 5 to Fig. 8
/

/
r'o coolant expansion
tank

~
)
F)

J·11
1983-1985 I I Water-cooled Cooling aystem 19.9
19 ine-Cooling System

Bleeder screw

Heat exchanger

Transmission cooler (ATF)

(Automatic Transmission)

--
Additional
heat exchanger
under rear seat

I
~
' I
I I
Cylinder! Cylinder I
head 1jacket I
I I
_.Ll
, I'\ I

Note
On water-cooled engines 1983-1985 m.y. a coolant
leak in the rear heat exchanger area may be due to
poor hose fit at the metal T-piece ,which connects the
feed hose to the main coolant hose. An improved,

~····
white plastic T-piece with slightly larger diameter is
available to correct this condition:
• replace metal T-piece with white plastic version
• remove flow restrictor from inlet fitting of heater
valve

19.10 Coolant hose layout

[!Saa-1985 I I Water-cooled
 Engine-Cooling System 19
CAUTION
CoolanVantifreeze must not be reused when
replacing engine, cylinder head, cylinder head
gasket, radiator and heater core.
ATF cooler tor
automatic transmission
Breather valve
open to lill coolant
I
I

I
I
.f l \
I
,..
,- I
I
I
I

'\
'
\

From
heat exc hanger
I
Thermostat - - - -----..
~ ...,
c~kmg: heat Jn water
Op11111nl} begins : approx. 85° C
[18S~Fl
heatmha7
To

opomng ends: approx. 105°C

tl21° F)
$\rOkll 1n111. 8 mm (0.35 in.}

Temperature
sender.
for Injection

Distribution unit

19-427

Water-cooled from 1986

Cooling system 19 •11
19 Engine- Cooling System
CAUTION
Note
CoolanVantifreeze must not be reused when
The cooling systems of all Volkswagen vehicles are replacing engin /cylinder head, cylinder head
filled at the factory with a mixture of water and an gasket, radl rand heater core.
antifreeze solution (G 11) with corrosion inhibitors. Thermo-switch lo
This coolant mixture should be used year-round. (located at.M tlc)'n
Phosphate-free anti-freeze prevents frost and radiator)
removing/Installing: remove
corrosion damage, the formation of chalk and in
radiator grille and move left
addition, it raises the boiling point of water. Due to
cardboard air deflector to
the higher boiling point the coolant Is an aid to side
operational efficiency, when the engine is operating
Thru 1985
under full load, particularly In tropical climates. I. Stage II. Stage
Cut-In temperature: 93°C-98°C 99°C-tosoc
When replacing coolanVantifreeze solution In all (199-208°F) (210°-221 ° F)
Volkswagen models, all model years, use phosphate-
free coolanVantifreeze ZVW237 102. Cut-out temperature: 88°C-93°C 91°C-97°C
(190-199°F) (196-206°F)
From 1986
1- Stage 11. Stage
Cut-In temperature: 89°C-94°C
Radiator-------., (192°·201 °F)
remove spare wheel
bracket and radiator Cut-out temperature: 81 ac
grille before removing or (178°F)
lowering radiator

Radiator tan-------.
can be removed and
lnstalle<l w ithout draining
coolant alter lowering
radiator

Lower bolts
remove bolts on both
aides before lowering
radiator
Note

.. Secure coolant hoses

with hose clamps

• 15 Nm (11 tt lb)

19.12 Radiator assembly

Thermo-switch
Water-cooled
 Engine-Cooling System 19
Note
Always replace all gaskets. All parts of cooling
system can be removed and installed with engine
installed in vehicle.

I
Coolant expansion tank

Coolant expansion ta~nk cap

••••
Refill tank
~Ia minimax markings I
19-410

J·15
Water-cooled from 1986
Cooling system 19 .13
19 Engine-Cooling System
!
I

.--
___/
10 Nm (7 It lb)

,
To Th ermostat

Fh

..
\ ,~
-- V__ 20 Nm (15 It lbl

fl

19.14 Cooling system I Water~coole d from 1986 I J-17


Coolant system, draining
-open coolant expansion tank cap
-drain coolant at drain plugs 1 on
cylinder heads
Fig. 2 Coolant system, draining (When removing
engine
- pinch coolant hoses with hose clamp
(A-local supply) (arrows) before
removing
-in case that coolant hoses 1 and 2 for
heat exchanger have to be removed,
pinch hoses with hose clamp (A-local
supply)
J·17
Water-cooled
-
Engine-Cooling System 19
Draining- From 1986
-close hose 1 from radiator to thermostat with
hose clamp
- close hose 2 from heat exchanger to coolant
pipe with hose clamp
- loosen hose clamp 1, close hose 2 from radiator
to distribution piece with hose clamp
- close hose 3 from heat exchanger to distribution
piece with hose clamp
-drain coolant at drain plugs (FiQ. 1)
• save coolant for reuse (see caution )
-open coolant expansion tank cap
CAUTION
Coolant/antifreeze must not be reused when
replacing engine. cylinder head. cylinder head
gasket, radiator and heater core.
Cooling system, draining/filling 19.15
- -
19 Engine-Cooling System

Fig. 4 Hose spring clamp, removing/Installing

- use universal pliers or hose clamp Fig. 6 Cooling system, filling
pliers to remove or Install clamp -open bleeder valve In engine
(arrow) compartment
A=open
B=closed

Fig. 5 Cooling system, filling

Fig. 7 Cooling system, filling
-set heater control to maximum - fill coolant until expansion tank Is full
heating
(approx. 4-5 litres/4.25-5.3 US qt)
- open control valve for auxiliary heater
under rear seat - start engine
-remove radiator grille -at approx. 2000 rpm, top up tank until!
- raise vehicle approx. 10 em (4 in.) coolant flows from bleeder screw on
at front under cross-member with floor radiator (bubble free), maintain 2000 rpm
jack and wooden support or - close bleeder screw on top of radiator
equivalent when coolant flows out
-open bleeder screw (arrow) on radiator - add coolant until tank is full and close
- have up to two gallons of tank with cap, allow engine to idle
pre-mixed coolant on hand - turn engine off and lower vehicle

- additional coolant may need to be added to

the expansion tank to top off

WARNING-
• Hot coolant can scald. Do not remove expansion
tank cap unless engine is cold.

• Engine must afso be running at approx. 2000 rpm

before removing coolant expansion tank cap to
prevent foss of coolant.

-
19.16 Cooling system, draining / filling
Water-cooled J-19
 Engine-Cooling System 19

Antifreeze hydrometer, checking

Calibration of hydrometer must be checked
frequently to ensure accuracy.
- mix a 50150 mixture of antifreeze and water
together In a smal contaJner
- hydrometM should read - 35"C ( - 30"F)
• U not, put a mark (paint dot) to Indicate where
-350C ( -30"F) should be.

Fig. 8 Cooling system, filling

- fi ll refi ll tank up to max. mark (arrow)

Fig. 9 Cooling system, checking for leaks

-attach tester in place a t press ure cap
• Stant tester St-255 A, AC- PCT3 or
equivalent
- apply press ure of approx. 1 bar
(14.5 psi)
• i f pre ssure remains constant,
system is OK
• If pressure drops, look for leaks and
el iminate

ll
II

J·19 Water.,~ooled
1
11
Antlfreer:e hydrometer, checking
Cooling system, fllllng,eak checking
19 17 1

•
19 Engine-Cooling System

\'

)
Fig. 10 Expansion tank cap, checking
-attach cap on tester
• Stant tester ST-255 A, AC-PCT-3 or
equivalent
-apply pressure of 0.9 to 1.15 bar
(13-17 psi)
• if pressure relief valve opens with in
this range, cap is OK

Note
Cap has 3 important functions:
1. It opens at pressure of 0.9-1.15 bar
(13-17 psi) allowing flow to expansion tank
2. it opens at a vacuum of 0.02-0.1 bar
(0.3-1.45 psi) allowing flow from expansion
tank
3. it seals radiator neck
Only item 1 can be checked with tester.
If it is suspected that Items 2 and 3 are not In
order, replace cap

Coolant mixture ratio

• coolant capacity 17.5 ltr (18.4 US qt)

Note
Cooling system is filled at factory with mixture
of water and antifreeze/corrosion protective
solution.
Coolant mixture should be used all year.
When replacing coolant only use ethylene glycol
based antifreeze (phosphate·free).
Due to higher boiling point, coolant is an aid to
operating on full load, particularly in warm
climates

Outside Temperature Antifreeze water

- 25 ·c (- 13 ·F) 7.0 ltr 10.5 ltr
(7.4 us qt) (11 us qt)
-35 "C ( -30•F) 8.75 ltr 8.75 ltr
(9.2 us qt) (9.2 us qt)

19.1 8 Expansion tank cap, checking

Coolant mixture ratio
Water-cooled
 Engine- Cooling System 19
Snap-lock connectors, installing ~ Two wire harness
Starting Jan. 1986, the electrical connection on Parts required
replacement radiator cooling fan motors is now a
Three pin connector
snap-lock connector.
Part No. 191 906 232B Oty1
, When replacing a fan motor also replace the
Rubber boot
connector on the wiring harness.
Part No. 191 972 525B Oty 1
This snap-lock connector was introduced on Terminals
Vanagon as a running change during Jan. 1986 Part No. N 902 644 02 Oty 2
production.
Work sequence
Note
disconnect battery ground strap
This work procedure will be applicable when all -cut off old connector from wiring harness
existing stocks of replacement radiator cooling fan - push wires through rubber boot
motors with a push-on connector are exhausted. - attach terminal to wire
insert wires into connector
Three wire harness (cavity numbers on connector)
• Red/Black to cavity 2
Parts required • Brown to cavity 1

Three pin connector - seal cavity 3 with sealer AMV176 000 05 or

Part No. 191 906 232B Qty 1 equivalent
Rubber boot - attach connector to fan motor
Part No. 191 972 5258 Qty 2 -attach rubber boot
Terminals - seal empty wire hole in rubber boot
Part No. N 902 644 02 Qty 3 - reconnect battery ground strap
- check fan for proper operation
Work sequence
- disconnect battery ground strap CAUTION
- cut off old connector from wiring harness
- push wires through rubber boot Part numbers are listed for reference only.
- attach terminal to wire Always consult with the Parts Department for
- insert wires into connector latest information.
(cavity numbers on connector)
• Red/Black to cavity 3
• Red/White to cavity 2
• Brown to cavity 1
- attach connector to fan motor
attach rubber boot
reconnect battery ground strap
- check fan for proper operation

Snap-lock wiring connectors, installing 19.19

19 Engine-Cooling System

Cardboard air deflector, left

·----- ___.J l.
~.
I

Cardboard air
I
deflector, lower-

Cardboard air
deflector, lower left Insulating mat

19.20 Hot footwell kit,

assembly
Water-cooled
 Engine- Cooling System 19
Hot footwell kit, installing
Parts
• Cardboard air deflector, left
-delete
• cardboard air deflector, lower
-modify
• Cardboard air deflector, lower left
-new part Part No. 251 121 291
• Insulating mat
-new part Part No. 251 864 249 8

CAUTION
Part numbers are for reference only. Always
check with your Parts Department for latest
parts information.

- pry out air deflector clip (upper arrow)

Work sequence
- remove Phillips screw from lower apron (lower
arrow)
disconnect radiator fan harness connector
remove left cardboard air deflector
- reinstall radiator fan harness connector, fresh air
intake trim, and radiator grille
- remove spare tire and left spare tire bracket

remove fresh air intake trim 1 {five securing

pins- upper arrows)
remove radiator grille 2 {three Phillips
screws-lower arrows)

- remove lower cardboard air deflector by removing

two Phillips screws (arrows)

J·23 Water-cooled Hot footwell kit,

installing 19.21
19 Engine- Cooling System

lI
I
I
I
I
I 0 0

-- b l-.-
a

170-3931

shorten lower cardboard air deflector by 50mm - push lower left cardboard air deflector over left
(2.0 in.) and reinstall longitudinal member (arrow A) and secure behind
• dimension a = 490 mm (19.1 in.) radiator fan shroud and brake lines (arrow B)
• dimension b = 50 mm (2.0 in.) reinstall spare tire bracket and spare tire

Note
Vehicles equipped with air conditioning. may already
have the lower deflector modified

Vehicles with air conditioning

- fold back floor covering 2 from left side of

170·A0591
- modify lower left cardboard deflector
• dimension a = 50 mm (2.0 in.)
console
- remove 25mm (1 .0 in.) of backing from
self-adhesive insulating mat 1 and apply to floor
panel
- remove remaining backing and finish applying
insulating mat
- reinstall floor covering 2

Note
If the floor pan continues to heat up, adjust
ventilation ducts so that fresh air is directed to the
floor pan.

19.22 Hot footwell kit,

Installing
Water-cooled

Index
Air-cooled AFC
-Accelerator linkage/cable
auto. trans. 20.8, 20.9
manual trans. 20.6, 20.7
-Fuel filter 20.4
-Fuel gauge sending unit 20.4
-Fuel pump 20.7
-Fuel system 20.2, 20.3
leak checking 20.5
-Fuel tank 20.4, 20.5
ind
Diesel
-Accelerator linkage/cable 20.14
-Fuel gauge sending unit 20.13
-Fuel system 20.10, 20.11
leak checking 20.13
-Fuel tank 20.12
20
/
Fuel
Supply
Water-cooled Digijet
-Accelerator linkage/cable
auto. trans. 20.23, 20.24
manual trans. 20.22
-Charcoal filter valve 20.20
-Fuel filter 20.18
-Fuel gauge sending unit 20.18
-Fuel pump 20.19
-Fuel system 20.16, 20.17
leak checking 20.21
-Fuel tank 20.18, 20.19
Water-cooled Diglfant
-Accelerator linkage/cable
adjusting 20.32
auto trans. 20.31
manual trans. 20.30
-Charcoal fiHer 20.33
-Fuel gauge sending unit 20.29
-Fuel pump 20.29
-Fuel system 20.26, 20.27
leak checking 20.21
-Fuel tank 20.28
20.1
20 Fuel Supply
Note
California models, from 1981, have a:
new fuel-tank filter that is self
cleaning and requires NO
SERVICING
new and enlarged fine-mesh in-line
Fuel gauge sending unit
fuel filter which requires NO removing Fig. 2
SERVICING installing Fig. 3

Fuel supply sy~tem c.omponents,

Removing and mstalhng 10 Nm (7 t lb7
·~Cl.l

Expansion tank _ /

Seal --------------~----~~~~
coat with graphite powder
before Installing

'
4.om pressure reguletor

I
Fuel filter----..
installing Fig. 1
Fuel pump ~
delivery rate page 20.7
checking, electrical page 20.7
(1/.ti CI~::.

To rfng line
7
Note

Check system tor leaks using a soap solution at

spots marked with an • . Seal if necessary .

I
2 0 •2 Fuel system
.__A_ir_-c_o_o_le_d_......~l L-I_A_F_c_ _.
 Fuel Supply 20

II

Grevlty vent valve

I checking: when tilted 180",

v~;trve must close

.,r-- 10 Nm (7 fllb)

25 Nm (18ft lb)

WARNING
Charcoal filter
Disconnect battery when working on fuel
system. Never smoke when wofl(ing with
fuel or have anything in area that can Ignite
it.
Always replace seals and fuel hose clamps

~--A-ir_-_co_o_l_e_d___~l ~~ ___A__F_c___~ Fuel system 2 0 •3

20 Fuel Supply ' '\
\
1
Fuel tank, removing
Work sequence /
WARNING
Fire hazard ! Do not smoke or have anything
in area that can ignite fuel

-disconnect battery ground cable

- drain fuel tank
Fig. 1 Fuel filter, installing
- install with arrow pointing toward fuel
pump

- loosen hose clamp 2

-remove filler neck 1
- remove vent hose 3
Fig. 2 Fuel gauge sending unit, removing
- first remove fuel tank

-remove vent hoses 1, 2 and 3

Fig. 3 Fuel gauge sending unit, Installing
-coat seal with graphite powder and
position carefully
- install sending unit with electrical
connector as shown (arrow points to
front of vehicle)

Fuel filter
20.4 Fuel gauge sending unit
Fuel tank, removing
Air-cooled AFC
 Fuel Supply 20
Fuel system, leak checking

Refer to illustration on pages 20.2 and 20.3 for

location of vent line indicated below.

l After removal/repairs on fuel tank, always check

fuel system for leaks as follows :

- remove small hose A fro m activated charcoal

filter and connect to leak tester US 4487.
- set leak tester scale to " 0".
-remove vent hoses 4 and 5 - pressurin system with hand pump to 1.3 in.
of mercury.

• system OK if pressure is 1.0 in. or greater

afte-r 5 minutes.

• system leaking if pressure drops below 1.0 in.

after 5 minutes .

Note

Oleck system for leaks using soap solution at

spots marked with an • . Seal If necessary.

-remove fuel supply hose 1 and fuel return

hose 2 from fuel tank

- loosen bolts on fuel tank mounting rails

(white arrows) and remove rails from rear
channel
- lower fuel tank and disconnect electrical
connector on fuel gauge sending unit
- remove fuel tank

A·5
Air-cooled AFC Fuel tank, removing
Fuel system leak checking 20.5
20 Fuel Supply
Accelerator linkage/cable
Manual transmission

Push r o d - - - - -....
lubricate when ins talling Acceleretor pedal

Clrcllp -----~
always replace

, ,.
'wJC ~ool
..,, ,., ""''

'
Accelerator cable
adjusting Fig. l
~-

Clampl. .
~

bcll1

20.6 Accelerator linkage / cable

Air-cooled AFC I I Manual Trans.
 Fuel Supply 20
Fuel pump delivery rate, checking
Work sequence

WARNING
Fire hazard! Never smoke or h<we anything
In area that can ignite fuel

Fig. 1 Accelerator cable, adjusting

-adjust cable so that clearance is
obtained between throttle valve lever
and stop on throttle valve housing
• a= 1.0-1.5mm (0.040-0.060 ln.)
-disconnect fuel return line at pressu re regulator
- attach hose to return line t ilting on presslJ're
regulator A and place other end of hose In
one quart measuring container
-turn on Ignition and open air sensor (or
bridge air sensor plug terminals 36 and 39).
Run pump exactly 30 seconds
• delivery quantity should be at least 500 cc
(approx. 1/ 2 quart)
If NO, check fue l filter Is not blocked, ground
connections are O.K. and voltage at pump is
at least 11 .5 volts before replacing pump

Fuel pump, checking (electricaQ

Note
Battery must be fully charged

-connect ammeter at fuel pu mp i n series with

pu mp and cu rrent supply

CAUTION
Do not touch posi t ive con nect ion to grou nd

-tu rn o n ig nition and open air sensor fl ap

(or bridge air sensor p lug termi na ls 36 and 39)
• ammeter shou ld read 6.5-8.5 amps
• lower reading may indi cate poor g rou nd
connections
• higher reading usually i ndi cates dragging
pum p motor and unit mus t be replaced

Air-cooled AFC
~----------------~
II Manual Trans. Accelerator linkage/cable
Fuel pump 20.7
20 Fuel Supply
Accelerator linkage/cable
Automatic transmission

Push rod - - - - - - - . .
lubricate when installing Accelen~tor pedal

check fOf cracks

-- -- .---Pin
must engage in lever
on transmission

Ad)111Ung rod
-- -...~
Shift lever on lransmisslon

djustlng page 20.9

~ Sprln~

~ __.clrcllp

20.8 Accelerator linkage/cable

Air-cooled AFC I I Auto. Trans.
 Fuel Supply 20
Accelerator linkage/ cable adjustment,
checking
(automatic transmission)

Work sequence
-depress accelerator pedal to full throttle
position
• throttle valve lever must contact stop, but
kickdown lever on transmission must not be
in kickdown position
-press accelerator pedal beyond full throttle to
floor
• override spring must be tensioned and
kickdown lever on transmiss ion must be in
kickdown position
if NO, adjust as follows: - press accelerator pedal to floor
• lever 6 must be in kickdown position (arrow),
Accelerator linkage/ cable, adjusting with approx. 1- 2mm ( 1/ 32-3132 in.) free
(automatic transmission) play between lever and stop
- release accelerator pedal
Work sequence -lever must be in idle position (out of klckdown)

-loosen nut 1
- remove override spring 2
- start engine and let idle
- adjust idle speed at screw 5
{see Repair Group 24) - if necessary, adjust accelerator cab le at
-shut engine OFF clamping bolt (arrow)
- press accelerator rod in d irection of arrow
to stop
- turn adjusting rod 3 with screwdriver until
shoulder of adjusting rod just con tacts p1vot
of throttle lever 4
- reinstall override spring 2
- start engine and check idle speed
• adjust if necessary by turning rod 3
- lock adjusting rod 3 in position with nut 1

Air-cooled AFC I Automatic Trans. I Ac celerator linkage/cable 20.9

 20 Fuel Supply
WARNING
Disconnect battery when working on fuel
system. Never smoke when working witt)
fuel or have anything in area that can
Ignite it.

Always replace seals and fuel hose clamps.

Always clean fuel lines before loosening
vent lines
Fuel supply system components,
Removing and Installing
Gravity vent v a l v e - - - :
Fuel gauge sending unit
checking: valve must ...
removing Fig. 1
close when t urned 180 "
installing Fig. 2

Fuel return line - - - - - - - - :21"

from injection pump

•Seal---
coat with
graphite powder
before installing

to Injection pump - - - - - - -

Vent screw - - - - - - - - "

open when draining
water from filler moisten with Diesel fuel
before installing filter
Fuel filter flange - - - - - . . . /

Fuel litter _ _ _ _ _ _ __,..

-~ Water drain plug
removing : use US 4462 or loosen and dratn
equivalent approx. 100 em' (3 II oz) of fuel
, - . - - - - - - - - - - - - - - - ,installing: tighten by hand

CAUTION
Use on ly approved fuel filters fo r
maintenance service or repai rs.
Not all after-market fil ters meet
the f iltering, fuel flow, o r water
separation requirements of the
injection system.

2 0 •1 0 Fuel system
Diesel
 Fuel Supply 20

WARNING
Disconnect battery when working on fuel
system. Never smoke when working with
fuel or have anything in area that can
ignite it.

Always replace seals and fuel hose clamps.

Always clean fuel lines before loosening

Fuel tan~! vent lines

Filler cap
replace gasket
if damaged

Filler neck
removing; turn to
release from side
panel

Gravity vent valve

checking: valve must
~ close when turned 180"

\ _ _ _ , . Nm (1 fill b)

\_Fuel expansion tank

Gasket

removing page 20.4

Note

Check system for leaks using a soap solution at spots

marked with an •. Seal if necessary.

Diesel
Fuel system
20 Fuel Supply

Fuel tank, removing

Work sequence

WARNING
Fire hazard! Do not smoke or have anyth ing in
area that can ignite fuel

-disconnect battery ground cable

-drain fuel tank

Fl
-remove vent hoses 4 and 5

-pull fuel suction line (to fuel f ilter on right side)

and fuel return line (from Injection pump, left
side) off fuel tank

Fh

- loosen bolts on fuel tank mounting rails (white

arrows) and remove rails from rear channel
-lower fuel tank and disconnect electrical
connector on fuel gauge sendmg unit
-remove fuel tank

-remove vent hoses 1, 2 and 3

20.12 Fuel tank, removal

Diesel
 Fuel Supply 20
Fuel system, leak checking

Refer to illustration on pages 20.10 and 20.11 for

location of vent lines indica ted below.

After repa irs/removal of fuel tank, always check fuel

system for l eaks as follows;

- pinch oH all j vent hoses A with clamp.

-remove vent hos~: 8 from canister and connect to
leak tester US 4481.
- set leak tester scale to "0".

- pressurize fuel 5V5tt!m with hand pump to 1.3 in.

of mercuf¥.

Fig. 1 Fuel gauge sending unit, removing • system OK if pressure remains at 1.0 in. Hg or
great er after 5 minutes.
-firs t remove fuel tan k
• system no t OK if pressure drops below t .0 in . Hg
after 5 minutes.

Note

Check system for leaks using a soap solution at spots

marked with an •. Seal if necessary.

Fig. 2 Fuel gauge sending unit, installing

-coat seal y~ith graphite powder and
position care fully
-install sending unit with electrica.l con -
nector as shown (a rrow points to front
of vehic le)

Diesel Fuel gauge sending unit

Fuel system leak chec king
20 13 •
20 Fuel Supply
Accelerator linkage/cable
Manual transmission
lubricate when
instal ling

Acelerator pedal

----Boot
check tor cracks

Clamping bolt
adjust cable so that
injection pump lever
contact s stop without
tension

1
Accelerator c : a b J
I je

t{)
Grommet
press into bracket
on inject ion pump
' ~
~
.. ,

20 •14 Accelerator linkage/cable

Diesel A-1!
 I

Fuel Supply 20

THIS PAGE INTENTIONALLY

LEFT BLANK

A-15
20.15
20 Fuel Supply
Fuel supply system components,
Removing and installing
Fuel system
checking for leaks, see
page 20.21

Fuel tanl

Seal---------
coat with graphite powder
before installing

~'
/ Fueltank---J
removing, page 20. 18
~

"
{ From p•e.,uro ••••laW
/ -------------------:7
Fuel filter
USAJCanada: installing Fig. 1
California only: installing Fig. 2

0 '
/
.~ Fuel pump '
To ring llne ~/
r
delivery rate, page 20.19 I
I
I
To distributor vacuum /

I [
advance unit

I
1

I \:~:~,: ----_/ /
\_ To throttle valve /
housing
I

To Intake air distributor ~ /

-------..~'
To auxiliary air reg~lator

20.16 Fuel system

Water-cooled II Digijet
 Fuel Supply 20
WARNING
Disconnect battery when working on fuel
system. Never smoke when working with
fuel or have anything In area that can Ignite
it.
AlWays replace seals and fuel hose clamps

Gravity vent valve

checking; valve must close
when tilted 180'

""-----..................
Charcoal filter

,
I :::---- Charcoal filter valve
checking, page 20.20
I
I
I
I ~ To air filter

I
I
I

Jlalor

....__w_a_t_e_r-_c_o_o_le_d_ _.l L..l_o_i_g_ij_e_t__, Fuel system 20.17

20 Fuel Supply

Ag. 1 Fuel filter, Installing

(USA and Canada)
• arrow on filter faces toward fuel pump
Fig. 4 Fuel gauge sending unit, Installing
- coat seal with graphite powder and
position carefully
- Install sending unit so that electrical
connector Is aligned with dotted line
• arrow points to front of vehicle

Fuel tank, removing

Work sequence
-disconnect battery ground strap
- draln fuel tank

Fig. 2 Fuel filter, Installing

(California only)
• arrow on filter faces toward engine

2A

-loosen clip 2 on filler elbow

- remove filler pipe 1 and pull out breather
pipe 3
-go to next page

Fig. 3 Fuel gauge sending unit, removing

-before removing unit, remove fuel tank

Fuel filter

20.18 Fuel gauge sending unit

Fuel tank
Water-cooled j I Digijet

-remove vent hoses (on right) 1, 2 and 3
- remove vent hoses 4 and 5
-remove fuel supply hose 1 and fuel return
hose 2 from fuel tank
A·19
Water-cooled
Fuel Supply 20
- loosen bolts on fuel tank mounting rails
(white arrows) and remove ralls from rear
channel
- lower fuel tank and disconnect electrical
connector on fuel gauge sending unit
-remove fuel tank
Fuel pump delivery rate, checking
Work sequence
WARNING
Fire hazard! Never smoke or have anything
In area that can Ignite fuel
-disconnect fuel return line at pressure
regulator and block line
-attach hose to return line fitting on pressure
regu lator and place other end of hose in one
quart measuring container
-remove relay C
- connect terminals 30 and 87 with tester
us 4480/3
- switch on for 30 seconds
• minimum fuel delivery rate should be
500 cmJ
l[ Digijet Fuel tank
Fuel pump delivery rate
20 19 •
20 Fuel Supply

Charcoal filter valve, checking

- disconnect hose 1 from charcoal filter valve 2

- connect vacuum pump to filter valve
connection Instead of hose 1
- disconnect hose 3 from T-piece 4

-operate vacuum pump and suck with mouth

on hose 3
• filter valve must be open
-without operating vacuum· pump suck with
mouth on hose 3
• filter valve must be closed

If NOT, replace charcoal filter valve

20.20 Charcoal filter valve

Water-cooled II Digijet
 Fuel Supply 20
Fuel system, checking for leaks
(Vehicles with rear wheel drive ONLY)

WARNING
Disconnect battery when working on fuel
system. Never smoke when working with fuel
or have anything in area that can ignite it.

Note
After performing repairs on fuel tank, always check
fuel system for leaks as follows:

Work sequence
- Remove small hose A at charcoal filter and
connect to leak tester US 4487
- Set leak tester scale to "0"
Pressurize system with hapd pump to
3.3 em (1.3 in) of mercury
• system OK if pressure is 2.54 em (1.0 in) or
greater after 5 minutes
• system leaking if pressure drops ·below
2.54 em (1.0 in} after 5 minutes
Note
Check system for leaks using soap solution at spots
marked with'f" Seal if necessary.

A·21
Water-cooled I I Diglfant I I Digljet . Fuel system,
checking for leaks
2 o21
•
20 Fuel Supply
Accelerator linkage/cable
Manual transmission

Push r o d - - - - - - - - . . .
lubricate when Installing
Accelerator pedal
Pin-----------.

Relay lever-------.
lubricate when Installing

Clrcllp~
alway• 1ep1oco \

---- -- --- --
--- -- - -
- - --_JI
Cl<ellp~
Accelerator cabla
adjust cable so that
clearance of about 1.0 mm (0.040 in.)
ia obtained between throttle
valve lever and stop on throttle

F
houalng

C"mplog bollo

Support

1 20-402 1

20.22 Accelerator c able/

linkage
Water~cooled I j Digijet II Manual Trans.
 Fuel Supply 20
Accelerator linkage/cable
Automatic transmission

Push r o d - - - - - -
lubricate when Installing
Accelerator pedal
Pin-...,----.

Clrcllp~
always replace ~

- - - - - - - Clamping bolts
linkage/ cable,
checking/ adjusting page 20.9
:----Boot

Housing

r----
1 (II
'
1
...
----
--
-- ----- ---- -
"'l
--J
Pin------~
must engage In lever
on transmission ---

Support l
---...
------ -- ---...
------ -- - Shift lever on transmission

--
I

I
. . ._ r
AdJusting rod --.......;:"'111111~
adj usting page 20.9
Spring
--- ~ - __J

~~Clrcllp

A·23
Water-cooled I j Digijet j I Auto. Trans. Accelerator cable/
linkage 20.23
20 Fuel Supply

Accelerator linkage/cable adjustment,

checking
(automatic transmission)

Work sequence
-depress accelerator pedal to full throttle
position
• throttle valve lever must contact stop, but
klckdown lever on transmission must not be
in kickdown position
- press accelerator pedal beyond full throttle to
floor
• override spring must be tensioned and
kickdown lever on transmission must be In
kickdown position - press accelerator pedal to floor
If NO, adjust as follows: • lever 4 must be on stop In kickdown
position (arrow A)
- release accelerator pedal
Accelerator linkage/cable, adjusting - lever must be In Idle posit ion (out of
(automatic transmission) klckdown) (arrow B)

Work sequence

- if necessary, adjust accelerator cable at

clamping bolt (arrow)

- loosen nut 1
-remove override spring 2
- start engine and let idle

-adjust idle speed at screw

(see Repair Group 24)
-shut engine OFF
- press accelerator rod in direction of arrow to
stop

-turn adjusting rod 3 with screwdriver until

shoulder of adjusting rod just contacts pivot
of throttle lever
- reinstall override spring 2
-start engine and check idle speed
• adjust If necessary by turning rod 3
-lock adjusting rod 3 In position with nut 1

20.24 Accelerator cable/

linkage
Water-cooled I J Digijet J I Auto. Trans.
 Fuel Supply 20

THIS PAGE INTENTIONALLY

LEFT BLANK

20.25
 Fuel supply system componen,ts,
Removing and installing

WARNING
Disconnect battery ground strap when working
on fuel system. Never smoke when working
with fuel or have anything in area that can
ignite it.
Always replace seals and fuel hose clamps.
Always clean fuel lines before loosening.

· · "'"· . . J
O.ring H&l --~

Retumllne~
• ooat with graphite
powder before Installing

Fuel lank
• removing - page 20.28

Fuel filter --~

• Installation :
arrow points
in direction of flow
going to engine Fuel pump
• checking - page 20.29
• minimum delivery
rate: 500 cm313Q sec.

20.26 B-5
 Fuel Supply 20
• Rules of cleanliness, 20.28
• Checking for leaks, 20.21

Filler pipe

Fuel tank
vent lines

- - - - -- -- - - - Gravity vent valve

- • checking: when lilted
1ao• (connection
downward), valve must
close

15 Nm (11ft lb)

25 Nm (18ft lb)

8·4 B·S Digifant Fuel supply parts

removing, Installing
20 27 •

- - - -- - - - - - -

------ ----
20 Fuel Supply
Rules of cleanliness
CAUTION
When working on the fuel system. the following
rules of c{eantiness must be carefully followed.
- Thoroughly clean connecting points and
surrounding areas before loosening.
- Ley ,p ieces that have been removed on a
clea11 surface and cover them with plastic
film or paper - do not use cJolhs with lint.
- Carefully wrap qr clOse parts that have been
opened if repair will not be completed.
-Use only clean parts.
• Do not unwrap replacement parts until
immediately before installing.
• Do not use parts that have been stored
unwrapped (i.e. in tool boxes).
-With system open:
• Avoid the use of compressed air as much
as possible.
• Avoid moving vehicle as much as
possible.
20.28 Fuel tank, removing
Digifant
Fuel tank, removing
Vehicles with rear wheel drive only
- Disconnect battery ground strap
- Empty fuel tank
- Remove Iiiier pipe
- Remove vent lines
- Remove feed and return lines from fuel tank
- Unscrew splash plaid from body and take out of
brackets
- tower fuel lank and' remove electrical connector
from fuel· gauge sender
- .Remove fuel tank
Syncro vehicles
Note
.Removing and Installing the fuel tank is possible
after removing the transmission.
For transmission removal and Installation: see Repair
Group 34.
- Disconnect battery ground strap
- Drain fuel tank
- Remove tiller pipe
- Remove vent and fuel lines
- Remove restraining straps
- When taking out fuel tank, carefully push or
secure coolant pipes and hoses to one side
 Fuel Supply 20
Fuel gauge sender, removing and Fuel pump delivery rate, checking
Installing
Vehicles with rear wheel drive only WARNING

- remove fuel tank - page 20.28 Fire hazard! Never smoke or have any1hing in
area ttlat can ignite fuel.

-remove and Install sender with tool2012 A

-disconnect fuel return line at pressure re<Julator
Note and block line
-attach hose to return line fitting on pressure
Installing: electrical connector must line up with
regulator and place other end of hose in one
dotted line. Arrow points in driving direction.
quart measuring container
Syncro vehlclel - remove relay C
- connect tenminals 30 and 87 with tester US 4480/3
- discoonect battery ground strap
- switch on for 30 seconds
- empty fuel tank until float lies below level of
• minimum fuel delivery rate should be 500 em:J
sender opening
- remove sender behind rear wheel house
-when installing the sender, make sure that return
line is inserted into expansion tank inside of fuel
tank (see Fig. 20-549, Page 20.34)

Note
After installation of sender:
Rocker arm must be able to be swung downwards.

Digifant
Fuel gauge sender,
Fuel pump delivery rate,
checking
20.29
20 Fuel Supply

Accelerator linkage/cable
Manual transmission

Push rod

Housing

Lock washer

Clamping boHa
• adjust accelerator cable in
such a way that the throttle
valve lever lies against the
stop on throttle housing
with approximately 1.0 mm
(0.039 in) play

Support

Accelerator
cable

20.30 Accelerator cable linkage,

repairing (manual trans)
Digifant
 Fuel Supply 20
Accelerator linkage/cable
Automatic transmission

Puahrod

Houalng

---~
,...-----Pin
• muse engage In lever
on transmission

Support
(II l
l
~-----
--------------------- ~ lever on transmission

Adjusting rod-------~
p•ge 2 0 3 2 - . . ~ Spriog
---- ---- _J
:

Clrcllp t

8·9 r Dlglfant Accelerator cable linkage, repairing

(automatic trans)
2~0 •31
20 Fuel Supply

Accelerator linkage/cable, adjusting

The accelerator linkage/cable should be adjusted in
such a way that with throttle valve closed, (idle), the
lever on transmission is against stop in no-gas
position; otherwise, shifting occurs too late in middle
speed ranges.
The accelerator linkage/cable should be adjusted as
follows at idle speed (engine at operating
temperature, with throttle valve closed}:

-Press gas pedal to floor. Lever (4) must be on

stop in kickdown position (arrow A)
- Release gas pedal. Lever must be in idle position
(out of kickdown) (arrow B)

- Loosen· nut (1)

- Remove spring (2)
- Pull accelerator rod in direction of arrow
-Tum adjusting rod (3) with screwdriver until
shoulder of adjusting rod just contacts pivot of
throttle lever
-Install spring (2)
Start engine and check to see if idle rpm is -If necessary, adjust accelerator cable at clamping
reached. If necessary, re-adjust by turning boll
adjusting rod (3)
-lock adjusting rod with nut (1) Checking adjustment
-Push gas pedal down to full throttle point. Throttle
valve lever must lie against stop (without
kickdown)
-Push gas pedal past full throttle point to stop.
Spring, rnust be compressed. Lever on
transmission must be in kickdown position (A).

20.32 Accelerator linkage/cable, adjusting

Digitant
 Fuel Supply 20
Charcoal filter assembly

~~=T:~
ven11tne

\
\

\
\
\
\
\
L To '"1ribu1o• ~<uum odvon<e unl1 \
\
\ Charcoal
\ filter
\
..
.. z:".
\
/

Charcoal filter valve

checking page 20.20

To Intake air
_/
... -
)
~
distributor

.,./
"----_
. _.......
:...._ _ _ _ _ _ _ To air cleaner

B·11 Digifant
Charcoal filter assembly 20.33
20 Fuel Supply

Fuel supply system, components

Syncro vehicles

Notes
r------------ Fuel tank
vent lines
• Rules of Cleanliness - page 20.28
• replace seals and spring clamps
Feed line
Fuel tank • from fuel filter to
• removing - page 20.28 engine ring line

-~------- Return line

-::::=;;;:::=:::::::;:::J •
from engine to sender

• from sender to expan·

sion tank in fuel
tank
Gravity vent valve
• checking: valve must
close when tumed
180" (connection
downward)

Fuel filter .
• installation location:
arrow points in flow direction Fuel gauge sender
to engine • removing and
installing - page 20.29

Bracket for
fuel lines

Fuel pump
• checking - page 20.29
• minimum delivery
quantity:
500 cm3f3Q sec .

20.34 Fuel supply system,

components
.j Diglfant II Syncro
 23
Diesel Injection System

Quick Data Index

Diesel Injection System
-Cold start cable 23.5
-Engine speed 23.5
-Fuel cut-off solenoid 23.5
-Fuel delivery valve/
housing 23.7, 23.8
-Fuel filter water indicator
kit, installing 23.1 0, 23.11
-Fuel injectors 23.8-23.10
-Injection pump 23.6, 23.7
-Injection pump/Valve timing
23.3, 23.4
-Injection system 23.2
-Injection timing 23.4

C-1 23.1
 23
Diesel Injection System

Quick Data Index

Diesel Injection System
-Cold start cable 23.5
-Engine speed 23.5
-Fuel cut-off solenoid 23.5
-Fuel delivery valve/
housing 23.7, 23.8
-Fuel filter water indicator
kit, installing 23.1 0, 23.11
-Fuel injectors 23.8-23.10
-Injection pump 23.6, 23.7
-Injection pump/Valve timing
23.3, 23.4
-Injection system 23.2
-Injection timing 23.4

C-1 23.1
23 Diesel Injection System
Accelerator cable
adjusting, see
WARNING
Repair Group 20 Disconnect battery when working on fuel
system. Never smoke when working with fuel
or have any1hing in area that can ignite it.
Always replace seals and fuel hose clamps

Injector pipes
25 Nm (18 It lb)

~--- Injectors
70 Nm (51 ft lb)
removing/Installing page 23.9
cleaning page 23.9
checking page 23.10

Cold start cable Fuel delivery valves

adjusting page 23.5 45 Nm (33 It lb)
checking/replacing
Engine speed page 23.8
checKing/adjusting
page 23.5
Injection pump~:---------~~
removing page 23.6
Glow plugs Installing page 23.7
checking, see adjusting page 23.4
Repair Group 28 checking page 23.3

Tensioner - - - - - - .
use tool US 4493
to tension

Injection pump sprocket

removing page 23.7

Intermediate shaft pulley

•s Nm (33 It lb)
CAUTION
Crankshaft sprocket
To avoid damage, keep injection parts clean
when removing, installing, disassembling
Crankshaft sprocket bolt
110 Nm (80 It Ib) and assembling. Do not spill diesel fuel on
do not use locking compound any rubber hoses
Double V-belt pulley

23.2 Injection system

Diesel
 Diesel Injection System 23
Injection pump/Valve timing, checking
Work sequence
Note
Drive belt must be checked for proper tension and
be centered In sprockets before checking injec-
tion pump/valve timing
-remove cylinder head cover/drive belt cover
~rotate engine until lobes of camshaft on
cylinder No. 1 point upward (TDC position}

(engine removed)
-attach tool 2068A to crankcase
-set scale to 100 mm (arrow A)
-tip ot scale must align with TDC mark on
clutch pressure plate (arrow B)

-in stall setting bar 2065A on C}tlinder head!

-turn camshaft unti I one end of setting bar
touches cylinder head
-measure gap at other end with feeler gauge
-take halt of measurement and insert feeler ot
this thickness between bar and cylinder head
at A
-turn camshaft so bar rests on feeler gauge
-insert second feeler gauge of same thickness
between other end of bar and cylinder head
at 8 (engine Installed)
-check that TDC mark on clutch pressure plate
is In line with boss on bell housing
if YES, valve timing OK; neKt check injection
timing (see page 23.4)
if NO, valve timjng incorrect, proceed as follows:

-loosen camshaft sprocket bolt 1 turn

-check that marks on sprocket , pump and
mounting plate (black arrow) are approximately
aligned
it YES, pump in correct position , continue with
work sequence
If NO, pump incorrectly positioned, adjust
pumpr'valve timing (see page 23.4)
-tap back of camshaff sprocket w ith rubber
hammer until it is loose
-hand tighten sprocket bolt until end play is
el iminated but sprocket still turns freely on
camshaft
-rotate engine until TDC marks align on flywheel
-torque camshaft bolt to 45 Nm (33ft lb)
-recheck marks
-check injection timing (see page 23.4)

Diesel
Injection pumpNalve timing 23,.3
23 Diesel Injection System

Injection pumpNalve timing, Injection timing, checking/adjusting

ad)usti.n g
Worit sequence
Work sequence
CAUTION
- remove cylinder head cover/drive belt cover
Push in cold start device completely when
- set engine to TDC No. 1 cylinder
checking or adj usting injection timing
-lock camshaft In position with setting bar
(see page 23.3)
-loosen camshaft sprocket bolt 1 turn
-tap back of camshaft sprocket with rubber
hammer until It Is loose
• hand tighten sprocket bolt until end play is
eliminated but sprocket still turns freely on
camshaft
-loosen belt tensloner
-remove belt from Injection pump sprocket
..
z·.
' /
r
~~. •
..... ~
/>
if. -remove center plug from injection pump cover

'-.,
/ -Install adaptor and dial gauge 0 to 3 mm
(0 to 0.118 ln.) in place of plug and preload
•• ; gauge to approx. 2.5 mm (0.097 in.)

' ~.
-turn pump sprocket until marks on sprocket,
pump and mounting plate are In line
- lock pump sprocket with pin 2064
- reinstall drive belt
mmJ
-turn engine slowly counterclockwise (opposite
to normal rotation) until dial gauge needle
stops moving
-zero gauge
- turn engine cloc kwise untii"TDC mark on clutch
pressure is aligned with boss on bell housing
- check that gauge reads 0.78-0.88 mm

-if necessary, loosen upper bolts on mounting

plate and bolt or rear support
- set lift by turning pump until gauge reads
0.86 ± 0.02 mm
- tighten pump mounting bolts and rec heck
injection timing

- tighten camshaft bolt to 45 Nm (33ft lb) and

remove setting bar
- remove lock pin from pump sprocket
-Install belt tension gauge VW 210
- tension drive belt by turning tensioner
clockwise
• read ing on belt tensioner = 12-13
(measured between camshaft sprocket and
pump sprocket)
- loc k tens ioner
- turn crankshaft 2 complete turns and recheck
belt tension
• eliminate play in drive belt by striking once,
between camshaft and pump sprockets, wi th
rubber hammer
- rechec k valve t iming
-check injec t ion t iming

23.4 lnjectlon pump / Valve timing

Injection timing
Diesel
 Diesel Injection System 23

l
Tightening totque. of the Diesel Injection pump center
~ (arrow) is:
-check that maximum speed Is 4800 ±50 RPM
• 17:!:3 Nm (12 !2 ft lb) with copper seal (reddish· if NO
brown In color) -loosen locknut (arrow)
-adjust maximum speed screw
• 22±2 Nm (16:!2 It lb) with bronze seal (yellow- • turning clockwise decreases RPM
brown in color) -lighten locknut

CAUTION Cold-start cable, adjusting

To avoid fuel leaks, always replace seal for Work sequence
center plug (arrow)

Engine speed, checking/adjusting

Work sequence

-start engine and warm up

-place engine RPM sensor US 1324
on cylinder head cover and attach to battery
-install positive lead of VAG 1367 to US 1324

-insert washer 1 onto cable·

-install cable In bracket with rubber bushing
and insert lnne( cable into pin 3
-install horseshoe lock clip 2
-push In cold-start knob fully
-move lever t.o
stop In direction of arrow
-pull Inner cable tight and sec~:.~re pin 3 with
clamping screw

WARNING
-check that Idle speed is 800.-850 RPM Disconnect bat1ery when working on fuel
• oil temperature so·c (140"F)
system. Never smoke when working with fuel
If NO
or have anything in area that can ignite it.
-loosen locknut (arrow)
-adjust idle speed screw Always replace seals and fuel hose clamps.
• turning clockwise increases RPM
-lighten locknut

Engine speeds
C-5 [ Diesel Cold-start cable
Fuel cut-oH solenoid 23.5
23 Diesel Injection System

-remove cylinder head cover

-lock camshaft with setting bar
-remove drive belt
23-A035 -loosen injection pump sprocket retaining nut
The following test procedure must be performed slightly
before replacement of fuel cut-off solenoid:
- Clean surrounding area and remove fuel cut-off
solenoid from injection pump
-Inspect solenoid plunger and seat for foreign
matter
- Clean solenoid plunger and check for free
movement in solenoid
-Clean solenoid mounting surfaces
- Reinstall fuel cut-off solenoid using new seal
and tighten to 20 Nm (14 ft jb)
- Check tor proper operation

Injection pump, removing

Work sequence

CAUTION -attach puller so jaws are at right angles to

When working on injection system, cros.s bar and point In direction of spindle
everything must be kept extremely clean. rotation
Wipe pipe unions clean beore loosening -carefully apply tension with puller

CAUTION
Never apply excessive tension with puller.
as this may damage sprocket

- turn engine until TDC mark on clutch pressure

plate is in li ne with boss on bell housing
-disconnect battery ground strap

23.6 Fuel cut-oH solenoid, testing

Injection pump
Diesel C-7
 Diesel Injection System 23
-hit puller spindle head (arr ow) with l igh t ham-
mer taps until sprocket loosens from injection
pump shalt taper
-remove puller and nut
-remove sprocket by hand
-detach all fuel pipes from pump. Cover unions
with clean cloth
-disconnect wire from fuel shutoff solenoid on
injection pump and detach accelerator and
cold start cables

CAUTION
Do not interchange fuel supply {arrow A) and
return (arrbw B) pipe union screws. For iden-
tification, fuel return pipe union screw is
marked O~li on hex. head
-remove three bolts from injection pump mount-
ing plate 2 -adjust injectioll ptJmp/valve timing
(see page 23.4)
CAUTION -adjust injection timing ~see page 23.4)
To avoid damage to distributor plunger, do Fuel delivery vatves-, c:hecking
not loosen bolts (arrows) on fuel distributor
Work sequence
head
Note
-remove bolt 1 from rear support and remove
Fuel leaks from fuel delivery valves are usually
pump
caused by improper removal of injector pipes. If
Injection pump, installing fuel delivery valve leaks proceed as follows:

Work sequence

-remove injector pipes

-retorque fuel delivery valves (arrows) to
-Install pump, align marks on pump and
45 Nm (33 ft lb)
mounting plate. Install pump sprocket
-reinstall injector pipes and tighten to
Tightening torques 25 Nm (18ft lb)
25 Nm (18ft I b) -start e ngine and check for leaks
• Pump bolts
25 Nm (18ft I b) • if fuel leak did not stop replace fuel delivery
• Fuel pipes
• Pump sprocket 45 Nm (33 It Ib) valve housing and seal

C·7 Diesel
Injection pump
Fuel delivery valves 23.7
 23 Diesel Injection System

Fuel delivery valve housing, replacing Fuel injectors, removing/installing

Wortt sequence Work sequence

CAUTION Note
When removing or replacing fuel delivery First signs of Injector trouble usually appear as
valves, do not Interchange valve assemblies follows:
• ,knocking In one or more cylinders
• engine overheating
• loss of power
• smoky black exhaust
• Increased fuel consumption

Faulty injectors can be located by loosening

pipe union on each Injector In turn with engine
at fast Idle. If engine speed remains constant
Valve
after loosening a pipe union, this Indicates a
asaembly faulty Injector

I Removing

CAUTION
To avoid damage, keep Injection parts clean
when removing, installing, disassembling
and assembling

-clean all injector pipe fittings

-remove Injector pipes
Houalng -disconnect fuel return hoses
-remove injectors using US 2775 or equivalent
- remove heat shields and discard

Installing

-clean all injector pipe fittings

-remove Injector pipes
-remove fuel delivery valve L injector .J
- transfer valve assembly to new housing
-Install fuel delivery valve, with new seal and ~·~ heat shield I23-A011I
tighten to 45 Nm (33 ft lb)
-reinstall Injector pipes and tighten to
25 Nm (18 ft lb) - install new heat shields as shown
-start engine and check for leaks -Install Injectors and tighten to 70 Nm (51 ft lb)
- Install Injector pipes and tighten to
25 Nm (18 ft lb)
-reconnect fuel return hoses
-start engine and accelerate a few times to
clear air bubbles
- check for leaks

23.8 Fuel Injectors

Fuel delivery valve housing
Diesel
 Diesel Injection System 23
Fuel injectors, checking
Work sequence

WARNING
Diesel fuel will penetrate skin If hands are o--Shlm
exposed to working pressure of injector
spray I- Spring
?--- Thruat pin
. - - Nozzle holder

t- Needle

o-Heat ahleld

-remove injector from tester and disassemble

-test Injectors with US 1111
Spray test
-fill tester container with clean diesel fuel
-attach Injector to tester
-pump tester a few times to clear air bubbles
-turn valve on tester so pressure gauge Is OFF
-pump tester with rapid short strokes (4 to 6
strokes per sec.)
• spray should be even, well atomized and
stop cleanly
• Injector must not drip
-remove shim and measure
-select proper shim
• thicker shim Increases pressure
• a change In thickness of 0 .05 mm
(0.0019 ln.) changes pressure approxi mately
5 bar (72 psi)
• shims are available from 1 to 1.95 mm
(0.039- 0.070 ln.) In steps of 0 .05 mm
(0.00191n.)
-reassemble injector and retest until correct
opening pressure Is reached
Note

Opening pressure test When servicing used Injectors, set opening

-turn valve on tester so pressure gauge is ON
-press pump lever down slowly
-note opening pressure when injector sprays
• used injectors = 120 to 130 bar
(1740 to 1885 psi)
• new injectors = 130-138 bar
(1885-2001 psi)
it NO-continue as follows
pressure to value for new Injectors
Leakage test
-pressure gauge still ON
-press pump fever down slowly
-hold pressure at approximately 110 bar
(1595 psi) for 10 seconds
• fuel should not drip from injector at nozzle

Note

All new and rebuilt injectors have a settling

effect of approx. 5 bar. When installing new/
rebuilt injectors, they must h ave a 5 bar
higher opening pressure .

C·9
Diesel Fuel Injectors 23.9
23 Diesel Injection System

Fuel injectors, cleaning Fuel filter water Indicator kit,

installing
Work sequence
Water level indicator light will light when it is
CAUTION necessary to drain water from trap in fuel filter

Disassemble and clean one injector at Parts required

a time. Effectiveness of Injectors will
change lf parts from other Injectors are
interchanged
-clamp upper part of injector in vise and loosen
lower part
-turn injector over, lightly clamp lower part of
injector in vise and disassemble
Oty Description Part No.
1 water level indicator kit
1 "double" (single female into
double male) electrical connector
1 "ring type" electrical connector
grommet
blue 18 ga. electrical wire

Installation procedure
Upper part
- disconnect battery ground cable
Shim - drop down Fuse/Relay Panel

J - sprlng
~ Thrust pin
. . . - -Nozzle holder

f---- Needle

Nozzle

Lower part

- remove trim cover from fro nt of f loor duct

-clean parts of injectors in clean diesel fuel
• gasoline may be used to clean carbon
deposits but part must be rinsed in diesel
fuel immediately
- visually check injector parts for
• damaged, carbonized or rough needle seat
• worn or damaged injection needle and nozzle
• needle binding in nozzle
-reassemble in jector and tighten halves to
70 Nm (51 ft lb)

23.10 Fuel Injectors

Fuel filter water Indicator kit
Diesel
 Diesel Injection System 23
Mount control unit as follows:
- mount retaining clip (included in Kit) to fresh air
tube with sheet metal screw (included in Kit) so
control unit will clip into position shown in photo
- also attach brown ground wire (included in K it)
under mounting screw with " ring type" connector
- install double connector on terminal 15 of control
unit and clip unit in place
- connect ground wire from mounting screw to
terminal 31 of control unit

Install and connect indicator light as follows :

- mark and drill a 9 mm hole approx. 50 mm to
righ t of cold start cable and mount indicator light
- connect white wire (included in Kit) to light
- route wire to control unit and attach to one male
terminal of double connector on terminal 15
- con nect yellow wire (included in Kit) to light
- route wire to control unit and attach to
terminal 31 b
Install and con nect water sensor as follows:
- replace water drain-screw in fuel filter with drain·
screw/sensor, included in Kit
-connect blue wire (included in Kit) to terminal A
of control unit
continue to route w ire under carpeting under left
side of rear seat
route wire out from under carpeting where shown
Note
Blue wire provided is too short and must be
lengthened to reach fuel filter i n engine
compartment
mark and drill a 13 mm hole at location shown in
rear panel under back seat
insert grommet in hole and route wire through
to left rear wheel well area
from wheel well, carefully route wire across
vehicle above transm ission, and then back to fuel
filter

connect wire to terminal on new drain-screw/

sensor
connect black w ire (included in Kit) to remaining
male terminal of double connector on terminal 15
of control unit
route wire to rear of Fuse/ Relay Panel and
connect to fused side of fuse 12

- route wire under left side of floor vent, between

reinstall Fuse/ Relay Panel
handbrake and left seat base. Continue around
reinstall trim cover for floor duct
back of left sea t base under carpeting and to rear
reconnect battery ground cable
along left side o f passenger compartment under
test system by switching ignition on and grounding
carpeting
blue wire from sensor on fuel filter casing. Light
should come on and remain on until ignition is
switched o ff

Suggested Installati on Time : 126 T.U.

Labor Operation: 20 34 31 0

Diesel Fuel filter water Indicator kit,

installing 23.11

Index
Air-cooled AFC
- Air filter housing 24.8
- AFC system check 24.15
- Auxiliary air regulator 24.8, 24.9
- Cold-start valve 24.5
- Control unit/wiring harness 24.12
-Deceleration valve 24.7
-Double relay 24.13
- Full throttle enrichment switch
24.13, 24.14
-Idle speed-CO 24.10, 24.11
- Intake air/temperature sensors 24.9
- Intake air sensor housing 24.8
- Injector resistance 24.6
- Injector spray pattern/leak
checking 24.7
-Oxygen sensor/wiring 24.16
- Pressure regulator 24.5
-Speed limit switch 24.14
- System components 24.2
California 24.4
USA and Canada,
except Calif. 24.3
-Temperature sensor D 24.13
-Thermo-time switch 24.6
- Voltage supply/series
resistance 24.6
D·1
Fuel Injection, AFC System
Water-cooled Dlgljet
- Air filter housing 24.27
- Auxiliary air regulator 24.27, 24.28
- Control unit/wire harness 24.31
checking 24.35
-Data/specifications 24.18, 24.19
- Double relay 24.32
- Fuel injectors 24.25, 24.26
troubleshooting 24.38-24.41
- Full throttle enrichment switch
24.34
checking/adjusting 24.35-24.37
- Idle speed/CO, checking/adjusting
24.29, 24.30
- Intake air sensor 24.28
.·
housing 24.27
- Pressure regulator 24.25
- System check 24.20, 24.21
.,.- System components 24.22-24.24b
early version 24.24
late version 24.24a 24.24b
- Temperature sensor I 24.28
-Temperature sensor D 24.32
- Throttle valve/deceleration/idle
switch 24.33
'
24
Water-cooled Dlglfant
- Deceleration fuel shutoff 24.60
-Electrical testing 24.61, 24.62
- Fuel injectors, checking 24.56
- Fuel injection system
components 24.48, 24.49
repairing 24.46, 24.47
- Full throttle enrichment,
checking 24.60
- Idle speed/CO content
checking and. adjusting
24.50-24.52
- Idle stabilizer, checking 24.53
- Intake air sensor, checking 24.57
- OXygen sensor, checking 24.54
.,.- Pressure regulator, checking 24.55
- Residual pressure, checking 24.55
- Safety precautions 24.42
- Technical Data 24.43-24.45
- Throttle valve basic adjustment
24.37
- Throttle valve switch 24.58, 24.59
Index 24.1
24 Fuel Injection, AFC System

CAUTION
During repairs always replace gaskets,
seals and clamps

- ---Idle adjusting screw

idle checking/ adjusting page 24.10

Throttle Yalve housing

Thermo-lime switch
checking Fig. 4

Intake air distribulor

Auxiliary air regulator

checking page 24.9

lnjeclor _ _ _ _ _ _ _ ____.
Series res ist ance (except Cali !.)
ctJeck 1ng F1g. 7 res1s1ance (Calif. o nly) c hecking Fig. 6
voltage su pply. checking F1g. 5
spray pat tern. checking F1g. 8
checking tc>r leal<s. page 24 .7

24.2 System component layout I Air-cooled!AFC j

 Fuel Injection, AFC System 24

Control unit

Thermo-time switch

Ignition distributor

·. 10

Temperature sensor IJ

----[leceleratlon valve
(manual transmiss ion)

Cold s tart valve

Catalytic converter
(USA on ly)

j Canada and USA except Calit.j Air-cooled AFC

System component layout 24.3
24 Fuel Injection, AFC System

Control unit

Auxiliary air regulator

Temperature aenaor II

Catalytic converter

Oxygen sensor

24.4 System component layout

Air-cooled AFC California
 Fuel Injection~ AFC System 24
..
1

Itch

I
Fig. 2 Cold star1 valve, checking

WARNING
Fire hazard. Do not smoke or have anything
In area that can ignite fuel

-connect gauge US 1076 to fuel ring

main
-operate starter briefly until fuel
Fig. 1 Pressure regulator, checking pressure is present
-pull electrical connector off cold-start
1 = return line
2 = from fuel pump
valve
-operate valve with two jumper wires
3 = fuel pressure chamber
(arrows)
4 = diaphragm
• fuel pressure should drop slowly
5 = spring
if NO, replace cold start valve
8 = Intake air distributor

Note
Pressure regulator controls fuel pressure
depending on Intake air distributor vacuum

WARNING
Fire hazard. Do not smoke or have anything
In area that can Ignite fuel

-connect gauge US 1076 to fuel ring

main
-disconnect hose between Intake air
distributor and pressure regulator
-start engine and run at Idle
• pressure should be: 2.5 bar {36 psi)
- re-connect hose
• pressure (at Idle) must drop to approx.
2.0 bar (29 psi)
If pressure too low, check fuel pump
delivery rate
if pressure too high, check return line
if readings still Incorrect, replace pressure
regulator
Fig. 3 Cold star1 valve, checking for leaks
-pull electrical connector ott cold start
valve
- remove cold start valve from intake air
distributor but leave valve connected
to ring main
-pull wire off Ignition coil terminal 1
- operate starter
• cold-start valve should not leak.
Replace if necessary

Air-cooled II AFC
Pressure regulator
Cold star1 valve
24 5 •
24 Fuel Injection, AFC System
Fig. 4 Thermo-time switch, checking
• engine cold, air temperature below
20"C (68"F)
-pull electrical connector off cold-start
valve
-connect test light
-pull wire off igniHon coil terminal 1
-operate starter
• test light must light up brightly
• after 11 seconds (maximum) test
light must dim or go otf
Fig. 5 Voltage supply at injectors, checking
-remove connector from jnjector
-connect test light to wlre connector
-operate starter, test light must flicker
if NO, refer to page 24.38
24 6 •
Thermo-time switch
Voltage supply/Series resistance' •
Injector resistance, checkingAir-cooledAFC
-
Fig. 6 Injector resistance, checking
- pull connector off injector and
connect ohmmeter to injector
• resistance should be 2-3 ohms
if NO, replace injector
Fig. 7 Series resistance, checking
(USA and Canada except Calif.)
-d isconnect connector to series
resistance
-connect ohmmeter with one lead to
center pin of connector and touch
other lead to each side pin
• resistance for each must be
5.5-6.5 ohms
if NO, replace series resista nce as
complete unit
Note
On California vehicles, series resistance is built
into fuel injection control unit and can not be
checked
I I
 Fuel Injection, AFC System 24
Injectors, checking for leaks
-remove electrical connector from injector
-remove injector but leave connected to ring
main line
- pull off wire from terminal 1 of ignition coil
- operate starter briefly
-check that no more than 2 drops leak from
each Injector In one minute

124-032A I
Fig. 8 Injector spray pattern, checking
-remove injector but leave connected
to ring main

WARNING
Fire hazard. Do not smoke or have anything
In area that can ignite fuel

- operate starter briefly

• spray pattern must be an even, cone-
shaped spray

Fig. 9 Deceleration valve, checking

(manual transmission only)
-pull off hose from deceleration valve
to air filter at fi lter
-start engine and ru n briefly at approx.
3000 rpm
- let throttle valve snap closed
-at same moment check for suction at
disconnected hose
if NO, replace deceleration valve

0·7 Air-cooled II AFC Injector spray pattern/Leak checking

Deceleration valve
24- 7 •
24 Fuel Injection, AFC System

Auxiliary air regulator

checking Fig. 3

........----lntaka·,alr hoaa
F
Plug
removing page 24 .10
- - - ' \ . V adJuall"ii acraw
Intake air sensor - - - -- adjusting page 24.10
checking Fig. 1

Temperature aansor · - - -
checking Fig. 2 / ,.-------
'---Electrical connector
f -- - - - - - - G a s k a t

Air filler - - - -

litter housing

Intake air sensor housing

24.8 Air filter housing

Auxiliary air regulator I Air-cooled! AFC I

1.10 - pull o)( electrical connector from
lntaj(e air sensor
- ch~ck fuel pump contacts in intake air
se~sor by connecting ohmmeter to
terminals 36 and 39
- pust\ air sensor flap open fully
• meter should read 0 ohms
- release air sensor flap
• meter shou ld read oo ohms
Note
If resistance specif ications are correct
but fuel pump does not work, check for
break in wi ring between control unit and
intake air sensor
-touch probes to following pairs of air
sensor connections (flap closed, room
temperature)
•6 &9 = 200-400 ohms
• 6 & a :::: 130-260 ohms
• 8 &9 = 70-140 ohms
• 6 & 7• = 40-300 ohms
• 7 & a· :;: 100-500 ohms
• 6 & 271f applicable = max .
2,800 ohms at 2o•c (68°F)
·To check that resistance strip in Intake
air sensor Is not burnt, proceed as
follows:
- check intake air sensor plate is in
closed posit ion
-connect ohmmeter to terminals 7 & 8
and open air sensor plate slowly.
• resistance should not be lower than
40 ohm and not above 500 ohms of
values
-repeat on terminals 6 & 7
0·9 Air-cooled
Fuel Injection, AFC System 24
I 24. o52
Fig. 2 Temperature sensor, checking
--
- check that intake air sensor (arrow)
has reached room temperature of
20 •c (68 "F) before checking
-connect ohmmeter to terminals 6 and
27
• meter should read 2300-2700 ohms
3 124-0351
Fig. 3 Auxiliary air regulator, checking
Note
When engine is cold, regulator is open
fully, allowing additional air to engi ne
1 = bimetal spring
2 = heating coil
3 = rotary gate valve
- check regulator electrically by pu lling
connector off and attaching ohmmeter
to both terminals
• meter should read approx. 30 ohms
- check mechanical ly by pull ing off both
hoses and blowing into regulator
• with engine cold, regulator must be
open
• with eng ine warm , regulator must be
closed
-turn ignition ON
• after 5 minutes, regulator must close
ll AFC
Intake air/Temperature sensors
Auxiliary air regulator
24 g •
24 Fuel Injection, AFC System
Idle speed/CO, checking/adjusting
(USA and Canada except Celif.)
Work sequence
Preliminary conditions:
• engine oil temperature min. eo·c (140.F)
• intake air sensor must be 2o•c (68•F)
• all electrical equipment must be OFF
• hose for charcoal filter must be disconnected
and blocked at air filter
• dwell and timing OK (see Repair Group 28)
Note
When vehicle has been parked outside at
temperatures below 1o•c (50.F), adjustment
must wait until intake air sensor has reached
room temperature 2o•c (68.F)
-connect tach/dwell meter according to
manufacturer's instructions
124-0961
-check idle speed and adjust if necessary,
with adjusting screw (arrow)
• manual transmission: 800-950 rpm
• automatic transmission: 850-1000 rpm
-connect CO meter according to manufacturer's
instructions
-connect CO probe ahead of catalytic converter
at probe receptacle
24.10 Idle speed/CO,
checking/adjusting I Air-cooled,AFC
- check CO and if necesssary adjust at
adjusting screw (arrow)
• 1.0 ± 0.5%
-secure CO adjusting screw with blue cap
Note
If CO cannot be adjusted foll owing components
may be defective:
• injectors
• spark plugs
• vacuum leak between cylinder head and intake
manifold
Idle speed/CO, checking/adjusting
(Calif. only)
Work sequence
Preliminary conditions:
• engine oil temperature min. 6o•c (140.F)
• intake air sensor must be 20 •c (68 "F)
• all electrical equipment must be OFF
• hose for charcoal filter must be disconnected
and blocked at ai r filter
Note
To check engine rpm on vehicles with oxygen
sensor and electronic ignition (Calif. vehicles),
resistor adaptor must be used in conjunction
with commercial tach /dwell meter
j
 Fuel Injection, AFC System 24
- if timing setting does not c hange with
changes in rpm , r!ilplace idle stabilizer

Note
Before checking or adjusting CO, idle speed and
ignition timing must be with in specification s
-connect CO meter according to manufacturer's
instructions
-connect CO probe ahead of catalytic converter
to
solder at probe receptacle
engine=
ground -

on coil to engine
ground I24-A0051

-assemble and connect adapter according to

illustration
-check idle speed (with idle stabilizer
connected)
• 850-950 rpm - disconnect oxygen sensor (arrow}
-check CO; if necessary adjust at CO adjusting
screw (see photo 24-097, page 24 .10)
• 0.7 ± 0.4%

Note
If CO cannot be adjusted following components
may be defective:
• injectors
• spark plugs
• vacuum leak between cylinder head and intake
air sensor
- reconnect oxygen sensor
• CO must be within spec ificatio ns
-secure CO adjusting screw with blue cap

-disconnect plugs on idle stabilizer and

connect together (arrow)
-check ignition tim ing and if necessary adjust
(see Repair Group 28)
-check idle speed and if necessary, adjust
• 850-950 rpm (at adjusting screw)
- reconnect idle stabilizer
-start engine and slowly increase engine speed
to at least 900 rpm
-release throttle
• idle must now be: 850-950 rpm

D·11 Air-cooled II AFC Idle speed/CO, checking/adjusting 24.11

24 Fuel Injection, AFC System

Control Unit
unol cannot be repaored.
locatoon: roght side ot engone oompanmen!.
It limits engine max . speed to approx.
5400 rpm and receives Information on:
• aor quantoty from intake a or sensor
/
• engonc temperature from otemperature sensor II
• engine speed from lgnitoon distrobutor
• position of throttle va1ve from swotch lor
fu11 throttle enrichment and uses thos
Information to determine amounl o~ luel
Multi -pin connector - - - k l to be injected
removo nl) press ~pnn g
down tarrnw}

To double relay
checking Fig. 1

.,.......__To series resistance

{USA and Canada except Calif .)

r T o temperature sensor II
checking Fig. 2

To ignition coil

To full throttle switch

enrichment, checking page 24. 13
switch , checking page 24.14
tch. adjusting page 24 .14

Speed limit switch (Calif.)

checkino, page 24. 14

O.o~ygen sensor (Calli.)

c hecking, page 24. 15

24.12 Control unit/Wire harness IAir-coolediAFc I

 Fuel Injection, AFC System 24
- "zero" ohmmeter and connect one
probe to temperature sensor and other
to ground
-check resistance at oil temperatures
below

Oil temperature Meter reading

-1o · c (14"F) 7,000-11,600Q
2o •c (68.F) 2,100-3, 100Q
ao·c (176.F) 270-39QQ

• if resistance reading too high, touch

Fig. 1 Double relay, checking
-detach relay from firewall (do not
unplug connectors)
-check for voltage at terminals at relay
by attaching one lead of test light to
terminal 85 and touching other lead to
following :
• 86a
• 88y
• 88d
- operate starter
• test light must I ighl up
if NO, check wire to battery or inline fuse
if wire or inJi'rie fuse OK. double relay
I
defectJvi'and must be replaced
ground probe to steel housing of
sensor
• if resistanc e now OK, problem is
corrosion between sensor and
cylinder head
• if resistance is sti ll incorrec t,
replace temperature sensor II
Full throttle enrichment, checking
Work sequence
Note
This check shows possible defec ts in control
unit or break in wiring between control unit and
full throttle switch. AI full throttle, this switch
signals control unit to increase amount of fuel
injected

California only
Vehicles for California are equipped with
speed limit switch located between full
throttle enrichment switch and control unit.
Full throttle enrichment will take place
when engine runs above 3000 rpm (at same
time oxygen sensor switches off)

-warm engine until oil temperature is at least

6Q•c (140.F)
- check that idle speed, CO, and ignition timing
are OK
-go to next page

Note
Temperature sensor in cyllnder head
supplies control unit with i nformat ion for
start ing and warm-up enrichment
-disconnect temperature sensor wire
from sensor

Double relay
D-13 Air-cooled Ill AFC Temperature sensor II
Full throttle enrichment 24.1 3
24 Fuel Injection, AFC System
-open throttle valve slowly
• just before reaching stop; ohmmeter must Nc
read 0 ohms
En
if NO, switch must be adjusted or replaced
CO•
ac ~
Full throttle enrichment switch,
adjusting c
Work sequence 11

13
Callfomla onlv 15.
- use jumper wire and make contact
18 ,
between terminal 4 and 8 (arrow A) 16 ,
of connector for speed limit switch 18 l
-pull off connectors for idle stabilizer and 16;
connect together (arrow B) 171
16<
*1~
- run engine at idle and adjust to specifications
in table 114
-depress accelerator pedal fully and hoi<;! in 115
USAf Canada Calif. position \ 132
-loosen switch and move it until ohmmete·~ 133
Manual 800-950 rpm 850- 950 rpm changes from oo ohms to 0 ohms 116
Automatic 850-1000 rpm 850-950 rpm • roller should be in center of curved le7e· 117
(arrow) 134
-operate full throttle switch by hand - tighten switch / 137
• idle speed must Increase approx. 100 rpm
if NO, check full throttle switch and Speed limit switch, checking
adjustment position
if OK, replace control unit or wiring between Wor1l sequence 14 c
control unit and switch
-on Calif. vehicles readjust idle speed to 110
specifications on sticker and reconnect idle
stabilizer 120

Full throttle enrichment switch,

checking
Work sequence

-connect positive lead ( +) of voltmeter to

switch terminal 8 and negative lead (-) to
switch terminal 6
-start engine and accelerate to approx.
3000 rpm
• voltmeter must Indicate battery voltage
If NO, replace speed limit switch

-"zero" ohmmeter and connect to contacts on

switch
• with throttle valve closed, ohmmeter must
read co ohms

24 14
•
Full thr?ttle enrichment switch
Speed hmlt switch
I Air-cooledjAFC j D-1!
 Fuel Injection, AFC System 24
Note
Entire AFC System can be checked electrically at
control unit plug using an ohmmeter or volt meter
according to following chart.

Ohmmeter to terminal: Specs Checks

#1 and Ground Disconnect white injection wire at Wire to#1 terminal on coil
coil oo ohms; hook wire to ground
Oohms
#3and #18 Press accelerator pedal down fully. Full throttle enrichment circuit
Oohms thru throttle switch
#5 and Ground Oohms Ground Circuit
#Sand#9 200-400 ohms Air Sensor Circuit
#Sand #8 130-260 ohms Air Sensor Circuit
#Sand #9 70-140 ohms Air Sensor Circuit
#Sand #7 --4Q-300 ohm's Air Sensor Circuit
#7 and #8 100-,500 ohms Air Sensor Circuit
#Sand #27 Max 2,800 ohms at 68 o F Air Sensor Circuit
#13and Ground 2,t00-2,~00ohmsat68° F Head Sens_or
270-390\at 176 o F
#14and#10 Approxtrtlately 7 ohms Injector wire and resistor
#15and#10 Appr:oxi ately 7 {)hms Injector wire and resistor
#32and#10 ApRr mately 7 ohms Injector wire and resistor
#33and#10 Appr ximately 7 ohms Injector wire and resistor
#1S and Ground 0 m~ Ground Circuit
#17 and Ground ohms Ground Circuit
#34 at control unit and Approximately 30 ohms Auxiliary air regulator
#37 on the double relay and wires

Voltmeter to terminal Specs Checks

\

#4 and Ground 12)volts during cranking 0 volts at Signal from starter

ptl other times
#10andGround 12 volts with key on 0 volts with Voltage supply to computer
key off
#20 and Ground 12 volts with key on and sensor Pump CircuiC
flap open

Air-cooled AFC
0·15
AFC system check 24.15
24 Fuel Injection, AFC System

Oxygen sensor, checking -reconnect oxygen sensor wire 1

(Calif. only) • CO must drop to 0.7 :t 0.4% it oxygen
sensor Is OK
Work sequence If NO, following components may be
defective:
Note • oxygen sensor
• wire between oxygen sensor and control unit
Oxygen sensor is located in exhaust system (in • leak In exhaust system between catalytic
front of catalytic converter). It produces varying converter and cylinder head
voltages (up to 1 volt) dependent on oxygen
content of exhaust gases. These voltage§ are
sent to electronic control unit which alter Wire between oxygen sensor and
injection time accordingly. Oxygen §ensor
operates at all engine speeds, except warm-up
control unit, checking
and full throttle

Preliminary conditions:
• engine oil temperature at least 60"C (140"F)
• air temperature 20•c (68"F). Before starting
following test proc~ures, wait until intake
air sensor housing has assumed room
temperature
-connect tachometer according to
manufacturer's instructions
-connect CO meter to ,t est receptacle in front
ot converter (do no( connect at tailpipe)
-check idle speed and adjust if necessary
• 850-950 rpm
- connect ohmmeter between oxygen sensor
and terminal 24 on control unit
• 0 ohm, sensor wiring OK
•"" ohm, sensor wiring defective

-disconnect oxygen sensor wire 1 to control

unit
-check CO
•0.7 ± .4%
-let engine idle, disconnect vacuum hose 2 at
pressure regulator 3 and plug hose
• CO must increase to approx. 2.5%

24.16 Oxygen eensor/Wirlng

Air-cooled II AFC
 Fuel Injection, AFC System 24

unit

\
\ THIS PAGE INTENTIONALLY
LEFT BLANK

~)

C·16 0.17
24.17
 24 Fuel Injection, AFC System

Technical data and specifications

Components-checking/adjusting Specifications Notes

Idle speed
!'lee chart page 24.19 • oxygen sensor connected

CO-value
checking spec. 0.3-1.1% • oxygen sensor and idle stabilizer
connected
adjusting spec. 0.7 ±0.4% * • oxygen sensor disconnected *

Ignition timing • idle stabilizer disconnected

Idle stabilizer control unit below 940 rpm under load, ignition • engage 4th gear at idle speed
timing advances and engage clutch slowly;
timing should advance

Fuel pump delivery rate • disconnect relay connection, turn

min. 500 cm'/30 sec. ignition ON, let fuel pump run by
using bridging--ad:aptor US 4480/3 ·.

Pressure regulator/fuel pressure

vacuum hose connected approx. 2.0 bar (29 psi) •Idle speed
vacuum hose disconnected approx. 2.5 bar (36 psi) • idle speed

Oxygen sensor
wiring disconnected CO above 2% • vacuum hose at pret$S'ure
wiring connected co 0.3-1.1% disconnected

Injectors
fuel spray pattern even, coneshaped spray • operate starter
voltage supply test light flickering • operate starter
resistance approx. 16-16.4 ohms

Auxiliary air regulator

cold open • pinch hose, rpm must drop
warm closed • after idling about 5 min. pinch
hose, rpm does not drop

Intake air sensor terminals:

6 and 9 or 3 and 4 approx. 560 ohms
7 and 9 or 2 and 3 ohms-changing • move sensor plate
6 and 22 or 1 and 4 2300-2700 ohms • intake air sensor about 20 oc (68 °F)
Throttle valve switches
for deceleration/Idle speed closed only during idle speed
for full throttle enrichment closed at full throttle

" note altitude; see adjustment procedure, page 24.29

I
24.18 Technical Data/specifications
Water-cooled II Digijet

l
 Fuel Injection, AFC System 24
Components-checkinglaidjustlr1g 1 Specifications Notes

Temperature sensor I and II

tor Intake air temperature
ohms_.,.
_ _ _ Temperature Sensor--- ohms
1000
.
and coolant temperature
900
800
7000~+4~~++~~~+4~~++~ 700
6000 t-ft++~H-t-+-H-t-i'ri'!H-HH-t-++1 600
izer
5000 500
4000 400
3000 300
2000 200
1000 100

0 10 20 30 40 50 60 70 80 90 100°C
Temperature of Temperature Sensor J24-n61

\\\
turn
I by
1013

Idle speed, specifications

Application/ Idle stab. controf-- ~Idle

Model year unit, identification/ speed
ator Test conditions rpm
CAL and CAN green, 251 ~ 083
unlt ~sed
1
1983-85 control 850±50
49 States control unit connected 900±50
1983-84
49 States black, 321 906 083
1985 control unit by-passed 750±80
control unit connected 800±50

Note
Replacing digital idle stabilization control unit can
lower idle speed rpm. When replacing control unit,
always recheck idle speed and adjust as
necessary.

Water-cooled II Digijet ITechnical data/specifications 24.19

24 Fuel Injection, AFC System

AFC System check with volt/ohmmeter

Note
Entire AFC system can b.e checked electrically at
disconnected multi-pin connector of control unit

1 2 4 5 6 7 11 12 13
8888888888888
888888888888
14 15 19 20 21 23 24 25
j24-A0081
- remove multi-pin connector and turn ignition ON

Tester to
terminal: Components Checks Specs

1 and 7 Hall control unit type: AEG • voltage with ignition ON voltage or
slightly l.ess
1 and HALL control unit type: FAIRCHILD • touch center wire of connector 1.5 volts or
ignition coli at ignition distributor to slightly less
termlnal15 ground

2and 7 Temperature sensor II • resistance at 20°C (68°F) 2300-2700 ohm

(coolant temperature) see diagram page 24.19

4*) and 7 Deceleration/idle switch • idle speed position Oohms

Full throttle enrichment switch • full throttle position Oohms

5 and 7 Oxygen sensor • connector disconnected and Oohms

grounded
• connector connected co ohms

6 and 19 Intake air sensor • resistance/potentiometer approx. 560 ohms

7 and 25 Ground connection/control unit • wiring Oohms

11 and 7 Fuel injector, cyl. 4 • injector and wiring approx. 16-16.4 ohms

12 and 7 Fuel injector, cyl. 3 • injector and wiring approx. 16-16.4 ohms

13 and 7 Relay, left; terminal 87 • ignition ON; function of relay, left battery voltage

14 and 6 Temperature sensor I • resistance at 20 oc (68 °F} 2300-2700 ohms

(intake air temperature)

15 and 19 Intake air sensor • resistance/potentiometer; ohms-changing

if sensor plate is moved

*)do not connect test light on this terminal if control unit is connected to multi-pin connector

24.20 AFC system check

Water-cooled II Digijet
 Fuel Injection, AFC System 24
1 2 4 5 6 7 11 12 13
8888888888888
lbl1l1888888888
14 15 19 20 21 23 24 25
124-Aoosj

Tester to
terminal: Checks Specs

20*) and Relay, right; terminal 86*) • ignition ON; function of relay, right fuel pump must run
25 bridged
Auxiliary air regulator ·.• ignition ON; function of auxiliary power must be
air regulator supplied to auxilla,Y
air regulator

21 and 7 Wiring from , • voltage at terminal 50 during cranking voltage

starting enrichment starting
- crank engine
(with Injector plugs OFF)

23 and 7 Fuel injectqr, cyl. 1 • injector and wiring 16-16.4 ohms

24 and 7 Fuel injector, cyl ..2 • injector and wiring 16-16.4 ohms

25and 7 Ground connection/control unit • wiring

do not connect test light on this terminal If control is connected to multi-pin connector

Water-cooled AFC system check 24. 21

24 Fuel Injection, AFC System

/
CAUTION
During repairs always replace gaskets,
seals and clamps

Pressure regulator
checking. page 24.25

··~o
Temperatu re sens.o r II
10 Nm (7ft I b)
checking. page 24.32 pressure gauge

24.22 System components

layout Water-cooled Digijet
 Fuel Injection, AFC System 24
Note

Later versions have throttle body with t switch

for idle speed, deceleration fuel shut off, and full
throttle enrichment
checking/ adjusting page 24.35
removing/ installing page 24.36

Idle speed adjusting screw

idle speed/CO. checking /adjusting
page 24.29

Full throttle enrichment switch

chocking/adjusting. page 24.34

Throttle valve housing

7 Nm (61 ln. lb.)
valve basic adJUStment page 24.37

Auxiliary air regulator

checlling. page 24.28

lp

5 Nm (43 ln. lb.)

Injector ---~
checking . page 24.25 and 24.26

D·23 L___W_a_t_e_r-_co_o_l_e_d____Jj _D_ig_i_je_t____J

L--1
System components layout 24.23
24 Fuel Injection, AFC System

Vacuum hose layout

(early version)

from charcoal canister

Intake air distributor

Charcoal fillet valve

checkina, page 20.20

Y·plece
with integral
restrict or

24.24 System components

layout (early version)
Water-cooled j [ Dlgijet
24 Fuel Injection, AFC System

Vacuum hose layout

(late version)

Reduc. tion orifice

L
0.15 mm (0.006 in)

- ~ c::J 9f c::::J ~--- .___.___

~ -----~ 0

· Throttle body

·\....,_----~
..
'\
C\
\
Ignition distributor
\
""

24.24a System components

layout (late version)
Water-cooled Digijet
 Fuel Injection, AFC System 24

-------·---~ c:.:::'\
u
~
·---- I

/,/ /
/ to charcoal __..----. .,___r,
/. cannister / · /

----- .~
.................valve,~
Vacuum shut-off
- il.g
.
I
•

T-connection Idle speed boost valves

1.4 mm (0.055 ln.) orifice
• power steering boost valve: open when
engine running with steering turned to
lock (pressure switch on P/S pump closed)
• A/C boost valve: open when engine
running with A/Con, and compressor
clutch engaged

Dlgijet II Water-cooled System components

layout (late version) 24.24b
24 Fuel Injection, AFC System

Pressure regulator, checking Fuel injectors, checking Yot

Work sequence

CAUTION
Do not disconnect terminal 1 at ignition
coil when operating starter

Spray pattern
-pull out fuel injectors In pairs but leave
electrical plugs and fuel lines connected
-disconnect electrical plugs at fuel Injectors
which are still installed (second pair)

WARNING
Fire hazard. Do not smoke or have anything
In area that can Ignite fuel

-~
-c
-c
-connect pressure gauge V.A.G. 1318 or
equivalent with adaptor to T-piece 1 of fuel lfN
line -c
-c
t
CAUTION -c
Pressure gauge lever must be in closed
position during measurement procedure

- run engine at idle speed and check pressure

-hold Injectors in jar or pan
Specifications: - operate starter briefly
bar (psi) • spray pattern must be an even, coneshaped
vacuum hose 2 (shown
spray
in above illustration)
- reinstall fuel injectors with new sealing
approx. 2.0 (29) connected rings 1

approx. 2.5 (36) disconnected Leak checking

-pull ott electrical plugs at fuel injectors
-pull out injectors in pairs but leave connected
to fuel ring line
- turn ignition ON for about 5 seconds (fuel
pump operates briefly)
-check that no more than 2 drops leak from
each injector in one minute

24.25 Pressure regulator

Fuel injectors
Water-cooled I I Digijet
 Fuel Injection, AFC System 24
Voltage supply

CAUTION
To prevent damage to control unit, do not
short-circuit connector contacts

•
J 4~.?9
-pull off all electrical plugs from fuel Injectors
-connect test light to one plug contact (arrow)
-operate starter
•test light must flicker
II NO
-check relays. see page 24.32
-check Impulse output of Hall control unit
terminal 7
-check all ground connections at cylinder head

E·5 L__W
_ a_l_
e_r-_c_o_o_le_d__..l Ll_0----'ig::_i_je_t____. Fuel Injectors 24.26
24 Fuel Injection, AFC System

Auxiliary air regulator

checking page 24.28

Temperature sensor
checking page 24.28

CO adjusting screw
iQie speediCO
checkingtadjustmg, page 24.29

Air f i l t e r - - - - --.

Air filter housing

II
Intake air sensor housing

24.27 Air filter housing

Auxiliary air regulator
Water-cooled Digijet
 Fuel Injection, AFC System 24
Intake air sensor, checking ohms--- Temperature Sensor - -- - ohms ... 1000
900
800
7000 700
6000 600
. l'i
5000 sao
~f'l.
4000 400
3000 300
1\
2000 200
1000 100

o 10 20 30 40 so 60 70 eo 90 100· c
Temperatu re ol Temperature Sensor 124·1161
Note
- pull off hose and electrical connector from Intake If specifications are not reached, replace intake air
air sensor sensor and readjust idle speediCO value (see pages
- connect US 1119 multimeter to following terminals 24.29, 24.30).
of potentiometer (arrows)
• 3 and 4 or 6 and 9 =- 500 to 1000 ohms Auxiliary air regulator, checking
• 2 and 3 or 7 and 9 wtten moving sensor
plate = resistance varies

Temperature sensor I, checking

Note
When engine Is cold; regulator is open fully, allowing
additional air to engine.

• engine cold
- run engine at idle speed
- connect US 1119 mu ltimeter to terminals 6 and 22 - pinch hose (arrow)
• multimeter reading should correspond to graph • RPM must d rop
- run engine at idle speed lor about 5 minutes more
- repeat above test
• RPM must not change
If NO
- disconnect electrical plug from auxiliary air
regulator
-check voltage supply with engine running
11 OK
-replace auxiliary air regulator

E-7
Water-cooled I I Digijet
Intake air sensor
Temperature sensor I
Auxiliary air regulator
24 28 •
24 Fuel Injection, AFC System
Idle speed/CO, checking/adjusting

CAUTION
It is important to follow work sequence when
checking and adjusting idle speed and CO
value
1. Check ignition timing; if necessary adjust
• idle stabilizer bypassed
• oxygen sensor connected
2. Check Idle speed; If necessary adjust
• Idle stabilizer bypassed
• oxygen sensor connected
3. Check CO value; If necessary adjust
• idle stabilizer connected
• disconnect oxygen sensor wiring
connection with Ignition OFF - rur
1 adjust CO value corresponding to -ch•
local altitude . See shaded area of adj
graph. shown bel ow. - stc
1 reconnect oxygen sensor at
electrical connection. ~
-connect tester V.A.G. 1367 as follows
• A to alternator or termi nal box
• 8 to TDC sender
- connect CO meter to receptacle In left
exhaust pipe

-Cht
• lc
0 500 1000 1500 2000 M -wit
0 1640 3281 4921 6562 Ft CO l

l24·132l - sta
•c
-check Igni tion timing and adjust If necessary
-disconnect electrical plugs at Idle stabilizer
Work sequence Note
control unit (squeeze to release-arrows)
Prel iminary conditions: -connect plugs together If CO
- start engine and check igni tion t iming and • co
• engine oil temperature min. 60"C (140.F) adjust if necessary if YE~
• all electrical equipment must be turned OFF • spec. = 5 ± 1 • A TDC oil dll
(radiator fan must not run) • rpm =below 1000 if NO,
ethrottie valve switch must be ON at idle - adjust ignition t iming, see Repair Group 28
-stc
CAUTION
Ignition must be switched OFF before
connecting tester

24.29 Idle speed/CO, checking/adjusting

Water-cooled II Digijet
E·9
 Fuel Injection, AFC System 24

- .... • - Eli:EII
-run engine at idle speed -adjust CO as follows:
-check RPM after 2 minutes, if necessary - remove Intake air sensor 2
adjust with screw (arrow) -center-punch plug In CO adjusting hole
-stop engine -drill 2 .5 mm (3/32 ln.) hole In center of plug
3.5-4.0 mil) (9164-5/32 ln.) deep

CAUTION
Clean up any metal shavings

-screw In 3 mm (1/8 ln .) sheet-metal screw

-remove pluQ with screw, using pliers
-reinstall Intake air sensor 2
- sti;t.rt engine (oxygen sensor disconnected)
-adjust CO to 0 .7:t0.4%
-stop engine
-drive In new plug flush with Intake air sensor
- reconnect electrical connection of oxygen
sensor

-check CO and adjust if necessary Note

• idle stabilizer connected
With oxygen sensor and idle stabilizer connected
-with engine OFF disconnect electrical
• CO must be: 0.3-1 .1%
connection at oxygen sensor (arrow)
• Idle speed: 850-950 rpm
-start engine and check CO value
• checking spec . = 0.3-1 .1 % Idle stabilizer control unit checking, see Repair
Group 28
Note Oxygen sensor checking, see Repair Group 26
If CO value is above 1.1% pinch crankcase hose.
• CO should drop below 1.1%
il YES, CO adjustment Is not necessary (engine
oil dilution-change eng ine oil)
if NO, adjust CO (continue with procedure)
-stop engine

Water-cooled II Digijet Idle speed/CO, checking/adjusting 24.30

24 Fuel Injection, AFC System

to Fuel pump

to Deceleration /Idle throttle switch

white, brown-yellow (4, 31)

to Full throttle enrichment awltch

white (50, 51)
to Intake air sensor

[
-I
to Main wiring hamess
red-black (21)

to Main wiring harness

red (37)

Relays---~
checking page 24.32

to Ignition c o l i - - -
terminal 15, black,
black-white (44, 39)
to Ignition colt--~
terminal 1, green (41)

to Oxygen •••,•nr--
-t
- (
f

•
Multi-point connector •
to remove: press spring upward to Tempsrature aensor II -c
•
It receives information on: •
• air quantity from intake air sensor •
• intake air temperature from temperature
sensor I in intake air sensor •
• engine temperature from temperature sensor II
• engine speed from ignition distributor •
• oxygen in exhaust gas from oxygen sensor
• position of throttle valve from full throttle Rei•
enrichment/deceleration switch and uses this -tl
information to determine amount of fuel to be
Injected
-c
•
Note Note
Always replace control unit if defective, can not Wiring has white color, note stamped number on It
be repaired in workshop •
If Nl

24.31 Control unit/Wire harness

Water-cooled II Digijet
'
 Fuel Injection, AFC System 24
Relays, checking (with relays Relay on adaptor C, checking
installed) -connect test light between
terminals 30 and 86
-crank engine

\ CAUTION
Do not connect any test light to terminal 86
ot adaptor C (shown in illustration) If
control unit is connected
-remove all electrical plugs at fuel injectors
• test light must light
it NO, check wire to terminal 20 of control unit
if OK, replace control unit
- connect test light to terminal 87
- crank engine
-test light must light
if NO, replace relay on adapter C
Temperature sensor II, checking
Note
Temperature sensor 11 In coolant thermostat
housing supplies control unit with Information
for starting and warm-up enrichment

-turn ignition ON
-connect test light to ground and check
following terminals for voltage:
• connection A= red wire terminal 30
• adaptor B =terminals 30, 85, 87 -check temperature and resistance of
• adaptor C =terminal s 30 and 85 temperature sensor II
• test light should li ght • check specifications, see diagram below:
-operate starter and check with test light
• adaptor C =terminal 87 ohms ---Temperature Sensor- -- - ohms
• test light should light 1000
• if test light does not light, check wiring by 900
using current flow diagram r-
800
• If wiring is OK and no voltage at tern1inal 87,
check relay 7000 700
..
• if relay Is OK, replace control unit 6000 600
~ +
5000 .500
Relay on adaptor B, checking
4000 400
-turn ignition ON ' -
3000 300
-connect test light to terminals 30 and 86 l-
• test light must light up 2000 200
N
I"'
if NO, check wiring with current flow diagram 1000
l. ""'
~ ; 100

, it - connect test fight to terminals 86 and 67 0 10 20 30 40 .50 6 0 70 80 90 lOO?C

• test light must light up Temperature of Temperature Sensor IH-nol
11 NO, replace relay on adaptor B

E-11 Water-cooled II Digijet Double relay

Temperature sensor II
24 32
•
24 Fuel Injection, AFC System

Throttle valve/deceleration/idle Third check (Deceleration) F

switch, checking ci
Test condition
Note • result of first and second check must be OK N~
• throttle valve switch connectors connected
This switch supplies control unit with F~
• temperature at temperature sensor II must
information that throttle valve is closed. cc
be minimum 60 •c (140 "F) and resistance
below 550 ohms or
If engine is above 1500 rpm with the throttle
-operate throttle valve switch by hand and
closed, fuel will be shut off to the Injectors.
accelerate slowly
At idle speed, this switch signals control unit to
regulate amount of fuel injected
• engine speed must fluctuate (surges)
If NO, replace control unit

Throttle valveldeceleratlonndle switch, adjusting

CAUTION
Do not connect test light to throttle valve
switch connectors i f control unit Is connected
First check (Throttle valve switch)
• throttle valve switch connectors
disconnected
[
• throttle valve closed Fl
-adjust screw 2 so that switch just closes
-from this position turn adjusting screw
exactly one turn farther In
- secure adjusting screw with sealant
Note
Correct adjustment Is very Important
If switch Is mls..adjusted engine may surge or
cut-<>ut during acceleration

- attach ohmmeter to switch 1

• throttle valve closed
switch turned ON =0 ohm s
• throttle valve open
switch turned OFF= oo ohm

Second check (Wiring •nd control unit)

-run engine at idle speed for a short time
-stop engine and turn ignition ON
-pull off connectors from both throttle valve
switches if
-check voltage between connectors of throttle
valve idle switch
• voltage should be approx. 5 volt
if NO, control unit is defective or break In wiring

24.33 Throttle valve/deceleration/

Idle switch
Water-cooled II Digijet E·13

Full throttle enrichment switch,
checking
Note
Full throttle enrichment switch supplies the
control unit with information to Increase amount
ot fuel injected at full throttle
CAUTION
Do not test light to throttle valve switch
connectors if control unit is connected
First check (Throttle valve switch)
• throttle valve switch connectors
disconnected
-attach ohmmeter to switch 3
1 throttle valve closed
switch turned OFF = oo ohms
• throttle valve full open
switch turned ON ::;:: 0 ohms
Second check (Wiring and control unit)
-run engine at idle for a short time
-stop engine and turn Ignition ON
-pull off connectors from both throttle valve
switches
-check voltage between connectors of full
throttle enrichment switch
• voltage should be approx. 5 volts
if NO, control unit is defective or break in wiring
Water-cooled II
Fuel Injection, AFC System 24
Third check (Full throttle enrichment)
Test conditions:
• result of first and second check must be OK
• throttle valve switch connectors connected
• temperature at temperature sensor II must
be minimum 60 ·c
(140 "F) and resistance
below 550 ohms
• CO tester and tachometer connected
-run engine for about 2 minutes at Idle speed
- Increase Idle speed slowly until tachometer
reads about 4000 rpm
• CO should be between 0.3 to 1.1 %
- with engine at about 4000 rpm, operate full
throttle enrichment switch 3 by hand for
about 15 seconds
• CO must Increase above 1.5%
if NO, control unit Is defective
Full throttle enrichment switch,
adjusting
-loosen retaining screw for switch
-open throttle valve fully and move switch until
cut-in position is reached
• position of roller should be nearly in center
of cam disk (arrow, photo, 24-127)
- retighten retalnjng screw for switch
Throttle valve switch
(design with 1 switch)
Function
With throttle valve closed, switch signals control
unit about the following
• idle injection quantity
• switching off injection during deceleration
With throttle valve open, switch signals control unit
about the following
1 full throttle injection quantity
CAUTION
DO NOT connect test light to terminals of
throttle switch unless control unit is
disconnected.
Digljet Full throttle enrichment switch 24.34
24 Fuel Injection, AFC System

Throttle valve switch, checking/ Note

adjusting Correct adjustment is important. Following are
conditions that are created by improper adjustment:
(combined switch In single housing)
• gap a too large
Engine surges with lean condition.
• gap a too small
With cold engine, stalling at full throttle acceleration.
With.engine warm, no deceleration fuel shut-off.

Control unit and wiring, checking

Work sequence
- switch ignition ON

- connect multimeter US 1119 across terminals of

unplugged switch connector 1
• multimeter must read 0 0 only when throttle
lever is at idle stop and full throttle stop ·
• check switch-on point of throttle switch as
follows
- open throttle valve and slowly close
- measure switch-on point with feeler gauge
between idle stop and idle adjusting screw
• must be 0.05-Q.10 mm (0.002-0.004 in) before
\
idle stop (gap a)
-using multimetetUS 1119, check voltage present
If measurement NOT OK across .terminals of connector 2
-correct by adjusting position. of switch. Loosen • must be approximately 5 volts
screw 2 and adjust screw 3
If voltage reading NOT OK
- check for open circuit in wiring according to
current flow diagram
CAUTION
If wiring OK
Basic throttle valve adjustment must NOT be - replace control unit
changed.

24.35
Throttle valve switch,
checking/adjusting
Control unit and wiring, checking
1985 Digijet ) I Water-cooled
 Fuel Injection, AFC System 24
Deceleration fuel shut-off, checking
Test conditions
• temp. sensor II minimum 60°C (140°F) with
resistance reading less than 5500
Work sequence

l usingnend of tool VW 1490, bridge terminals of

connector 2
• CO reading must increase above 1.5% Vol.
If CO readings NOT OK
- replace control unit

Throttle valve switch, removing/

Installing
- usingnend of tool VW 1490, bridge terminals of
connector 2 Work sequence
-accelerate engine slightly
• engine rpm must fluctuate (deceleration fuel - remove throttle body
shut-off system operates)
H rpm DOES NOT fluctuate
- replace control unit

Full throttle enrichment, checking

Test conditions
• temp. sensor II minimum 60°C (140°F)
• CO tester and VW 1367 connected
- start engine and let Idle approximately two
minutes
- slowly accelerate engine until 4000 rpm is
reached
• CO must read 0.3·1.1% Vol.

2~
1----@
- remove switch 4 following numerical sequence of
components 1 through 5
- install components in reverse order
- perform basic adjustment as follows

E-15
Water-cooled II 1985 Digijet
Deceleration fuel shut off,
Full throttle enrichment
Throttle valve switch 24.36
24 Fuel Injection, AFC System

Throttle valve, basic adjustment

Note
Stop screw is set at factory and should not be
moved. If screw position has 1been altered, check
basic adjustment as follows
Work sequence

- turn adjusting screw (~mow) out until gap exists

between stop and screw
- turn screw in until it touches stop

Note
In order to determine exact point of contact with
screw stop, place a thin piece of paper between
screw and stop. Slide paper and turn screw at same
time until screw pinches paper.
-turn screw clockwise additlonal1/2 turn
- check idle speed and CO; adjust if necessary

24.37 ThroWe val,., basic adjustment

I Water-cooled ·.j I ·Digifant I I Digljet I
 Fuel Injection, AFC System 24
No voltage at injectors,
troubleshooting
I from page 24.61
Jr
No voltage at Injectors

f-- • pull connector off one injector and connect test light
e operate starter, light should flicker weakly
test light
flickers weakly I test light
does not light I test light
stays on

l
go to
Jr
replace
.. ~.- page24.40 control unit

Temperature sensor on cylinder head has no continuity

or is shorted

e disconnect wire from temperature sensor

Voltage at injectors, checkinq/
- e
e
connect ohmmeter on cylinder No. 4
check that resistance is about 2.5 kQ
\, (engin~ atroom temperature)
~/
measured resistance is as
specified
I . ohmmeter shows
OQ oroo Q

<::
~
...... ..~{
replace
temperature sensor
Engine floods due to defective cold start valve

e pull <:(mnector off cold start valve

e start engine with throttle fully open,.becau8e spark
plugs may be wet

Engine does not start ' I Engine starts

~ ~
Temperature sensor, checking go to replace
page 24.39 thermo time switch

E·17 .___A_i_r-co
____ o_led_-..:.Jj ~....I_A_F_c_ _, No voltage at Injectors,
troubleshooting 24.38
24 Fuel Injection, AFC System

l from page 24.38!

J.
Engine floods due to leaky cold start valve

• detach cold st.art valve from mtake a~r dtstnbutor but

leave it co111nected to qng matn
• pull connector oft cold start valve
e pull wtre off ignrhon coil termtnal t
e operate starter
Val ve does not leal1:
i Vafye leaks (
Cold start valve. checking
1
replace
Do

cold start valve

...
Intake air sensor bad

e pull connector off a1r tnlake sensor

e connect ohmmeter to terminals 6 and 9 on Intake air
sensor (reading: tOO to 300 o)
• then check at ter-minals 7 and 8 (reading: 80 to 200 o )

Readings outside tolerances ] Readmgs as ::.pectfred

l
replace
l
Break in wire or connec-
tntake air sensor tions between control
unit and intake air sensor

Intake air sensor, checking

24.39 No voltage at Injectors,

tro ubleshootl ng
Air-cooled [ I AFC
 Fuel Injection, AFC System 24

Ifrom page 24.38/

l
Double relay defective

+-- • connect test light between center slot in molded

connector of series resistance and ground
• switch ignition on

Test light
lights
I Test light
does not light

J,
go to
page 24.41

\ ,.
Double relay, checking
No voltage at double relay

• switch ignition on
• connect test light between:
terminal 86c and 85 (to coil terminal 15)
terminal 88z and 85 (to battery)
terminal 88b and 85 (to series resistances)

Test light Test light

lights
I does not light

L J..
replace break in wire
double relay

E·19 Air-cooled II AFC No voltage at injectors,

troubleshooting 24.40
24 Fuel Injection, AFC System

I from page 24.401

,L
No triggering impulse from coit terminal 1

e pull multi-pin connector off control unit 1

e connect test light between terminal 1 and ground
e operate starter ·.

I
Test light Test light
flickers does not flicker
124-0121

Triggering impulse, che

Possible causes:
e break in wire between terminal 1 on distributor and
terminal 1 on control unit multi-pih connector
e breaker contacts in distributor bad or incorrectly
adjusted
e condenser ground connection
e ignition coil bad

Control unit has no ground connection

e switch on ignition
e test voltage between following terminals on multi-pin
connector of control unit:
terminal 10 and 5
terminal 10 and 16
terminal10 and 17

Test light
lights
I Test light
does not light

replace defective
control unit

Possible causes:
e break in ground wire of control unit

24.41 No voltage at Injectors,

troubleshooting ..___A_I_r-_co_o_le_d_.....~II..___A_F_C_ __,
 Fuel Injection, AFC System 24
CAUTION CAUTION
Do NOT touch or disconnect ignition cables When working on fuel system, always follow
when engine is running or starter Is cranked. these. precautions on cleanliness
Disconnect wires in ignition system only when - thoroughly clean all unions and area near
ignition is switched OFF. connections before disconnecting
- place removed parts on a clean surface and
Connect and disconnect tester leads to ignition
cover over. Use paper or plastic sheet. Use
system only when ignition is switched OFF.
only lint-free cloths
When high tension cable (terminal 4 from coil) - components· which have been opened or
is disconnected from distributor, always disassembled must be covered or sealed
connect it directly to ground using jumper carefully if repair cannot be carried out
cable. Otherwise, engine must NOT be immediately
cranked with starter (such as with compression
- only install clean components
test).
- only unpack replacement parts immediately
Vehicles that have a defect in the ignition before they are installed
system or are suspected of having one, may - do not use parts that have been stored
only be towed with the connt;~ctor from terminal loose (for instance, in toolboxes)
1 of the ignition coil (green wire) disconnected. - when fuel system is open, do not work with
compressed air if this can be avoided or
Fast charging may onjy be used for emergency
move car unless absolutely necessary
starting for up to 15;Seconds maximum with no
more than 16.5 volts. Wait at least one minute
after each starting attempt.
Do NOT replace Ignition cojl with conventional
type coil. I
Battery must be completely disconnected when
using arc, spot, or electrical welding
equipment.
If components are heated above 80°C (176°F)
such as from paint drier or steam cleaner, wait
for components to cool down before starting
engine.
Do NOT wash engine while It Is running or
ignition is switched ON.
Do NOT disconnect battery with engine
running.
Do NOT apply voltage to control unit to
simulate output signals.

E·21 Digifant
Safety precautions 24.42
24 Fuel Injection, AFC System

Technical data/specified values

Engine code MV
Type 2.1 liter 70 kW, 90 SAE net HP
Introduction October 1985
Part no.
/
Control unit 025 906 022

Ignition timing checking spec. 3-7" before TDC

adjusting spec. 5 ± 1o before TDC
• Test and adjustment conditions no. 1 and 9
Idle adjustment
idle rpm . 880 ± 50 rpm
CO content 0.7 7 0.4 Vol. o/o
• Test and adjustment conditions no. Ato 6, 7, 8
Conditions and requirements:
1 -engine Oil temperature m1n. 80°C (176°F)
\,
2- electrical consumers turned off
3- crankcase breather hose on oil breather
removed and closed tightly
4 - throttle valve switch turned on (continuity)
5 - idle stabilizer OK (valve vibrates and hums)
6- ignition timing setting: OK
7- connector (single connector) for idle stabilizer
control valve disconnected
8- with Ignition OFF, disconnect connector (single
connector) for oxygen sensor
9- with engine running, double connector for
temperature sender disconnected and rpm
increased to 2000-2500 rpm by depressing
throttle

24.43 Technical data

Digifant
 Fuel Injection, AFC System 24
Engine code MV
RPM limiter
(Control unit)
switch-off rpm: 5500-5800 rpm
Idle stabilizer:
valve (resistance) continuity
current
• connector (single connector)
for control valve: disconnected approx. 430 mA constant
connected approx. 430 ± 20 mA, fluctuating
under load per following conditions: depending on load
• steering turned all the way 440-1000 mA
• selector switch in drive position
• climate control switched on
• electrical consumers turned on
• engine cold
Power steering pressure switch )
• measured at idle speea/
Steering: straight ahead no continuity
Steering: turned all the way n display (continuity)
/ //(to either side)
Fuel pump:
delivery quantity min. 500 cm3/3Q sec
Pressure regulator
• fuel pressure measured at idle rpm
vacuum hose: connected approx. 2.0 bar (29 psi)
vacuum hose: disconnected approx. 2.5 bar (36 psi)

E·23 Digifant
Technical data 24.44
24 Fuel Injection, AFC System

Engine code MY
Injectors
Spray pattern cone shaped

Note
ONLY connector connected is valve being checked
Voltage supply diode test lamp flickers
• ALL connectors disconnected, starter operated
Resistance
• measured on valve 15-20,{}
Air flow sensor
Resistance between
terminals: 3 and 4 5oo-1ooo n
------------------~~------------------------------~----~
2 and 3 change in resistance when air sensor plate is moved
1 and 4 resistance dependent on t~ature of
air flow sensor - set\ diagram
Temperature sender
Q _ _ _ __
'"
• for engine temperature Q

• resistance dependent on coolant temperature - n:+++++=rn+f++rn++++=l=l::

see diagram at right
800
++++-H
7000 ++++-H700
6000 t--1\-t+t-++-++++ 600
5000 500
4000 400
3000 300
H--H--Nf!+-1-++~-+-++
2000 200
1000 100

0 10 20 30 40 50 60 70 80 90 100"C
32 50 68 86 104122140158176194 212"F

Temperature

24.45 Technical data

Digifant
 Fuel injection system, repairing
Technical data/specified value - pages 24 .43-24.45
Note Rules ol Cleanliness - page 24.42
Replace gaskets, sealing rings and spring clamps

Fuel return line

8 Nm
Control valve for
(6 tt lb)
Ieite stabilizer
• checking - pagd 24 .53

20 Nm --.........._ \
(15 tt lb) -............ \

Intake air Cllatrlbutor -

Pressure
regulator
• checking - page 24.55
Bolt
• coat with D2
sealing compound
I
I
I
I
I
I \
I \
~ 5Nm(4 tt lbl

r
l \,

.;~···~! ' , ~
--c• Fuel L

~ :. _-jf
T-connection
• with connector for
pressure gauge

Injector
• checking - page
Fuel Injection line
• from fuel pump

24.46 F-3
 Fuel Injection, AFC S tem 24

(jll1 Cap
• replace

I CO..adjusllng screw
• idle adjustment -
I page 24.51

I Intake air sensor

• checking- page 24.57
Throttle housing - - - - .
• basic adjustment of
I
lhrotlle - page 24 .37
l
I

Ib)

Intake air h ose

Throttle valve switch

• removing and installing,
page 24.58
• checking and adjusting ,
page 24.59

Temperature sensor 5 Nm (4ft lb)

• for intake air temper-
ature
• checking. see Intake
air sensor. checking -
page 24.57

F·3 Digifant Fuel Injection system,

repairing
24.47
 Fuel injection system components
Note
Electrical checking of ignition and fuel injection
system - pages 24.61, 24.62
Safety precautions - page 24.42

Connector
• connect or disconnect only
with ignition off
• to remove, press spring up

Control unit
• for fuel injection and
ignition system, oxygen
regulation
(
• installation location: on Fuel pump ret~
trunk floor behind rear • to current suppfY for
seat or in cargo area, fuel pump
in platform truck in • when turning ignition on
equipment box under load and off, relay must switch
surface perceptibly (requirement:
current supply relay and
control unit OK)

Idle stabilizer control unit

• connect and disconnect only L----------- Current supply relay
with Ignition off • for control unit, idle stabi-
• check idle stabilizer lizer control unit, pwr. steer-
pagii!24.53 ing pressure switch, injectors,
• installation location: oxygen sensor heating and
in front of right control for fuel pump relay
taillight terminal
• when switching ignition on
and off, relay must switch
perceptibly
• check connectors according
to current flow diagram

Relay adapter
• check electrical connec-
tors according to wiring
diagram

24.48 F
 Fuel Injection, AFC System 24

Sealing ring

Temperature sender ---...

• for engine temperature
• resistance dependent on
coolant temperature,
specified value:
dlog•om. page 24 45 ~
\1"'"'..:::;..------ Retaining spring
• not used on
syncro vehicles

Gasket

Power steering pressure

switch 15 Nm (11 ft lb)
• check with engine running
• steering straight ahead:
no continuity
• turning as far as the
wheel will go: continuity

Power steering pump

Connector -------....._
• for oxygen sensor heating
• checkvoltage with
ignition ON: approx. 12 V

Connector - - - - - - -
• for oxygen sensor heating
• resistance: continuity

Oxygen sensor 50 Nm (37ft lb)

• checking - page 24.54

F·5 Digifant
Fue~llnjection system components 24.49
24 Fuel Injection, AFC System

Idle checking Connecting test equipment

Note
WARNING
It is important to follow the sequence when
performing idle checking/adjusting. Ignition must be turned off when connecting
test equipment
- check timing, adjust if necessary
• temperature sensor II disconnected
• rpm - 2000-2500
- check idle speed and CO content, adjust if
necessary
• idle stabilization valve disconnected
• (with ignition off) disconnect oxygen sensor

Note
The oxygen sensor must be disconnected with the
ignition off, to cancel the memory in the Electronic
Control Unit (ECU).

Test and adjustment conditions

- engine oil temp min. 80°C (176°F) 128-6421
- all electrical consumers turned off (radiator fan
should not be running while performing checks or
adjustments) connect VW 1367 tester for ignition timing and
- crankcase breather hose removed from oil vent rpm display functions
and plugged - using adapter VW 1473, connect tester VW 1367
-throttle valve switch operating properly (closed to terminal 1 of ignition coil
when in idle position)
- ignition timing within specifications
- idle stabilizer operating properly (with ignition
turned on, valve should vibrate and hum)

The hose from charcoal cannister to air filter must be

pinched closed. See arrow

24.50 Idle checking

Digifant
 Fuel Injection, AFC
-connect CO tester to adapter on left exhaust pipe,
using Sun tool 120.239
Idle speed and CO content, checking
and adjusting
-with ignition switched off, disconnect oxygen
sensor connector (1) and idle stabilizer control
valve connector (2)
F·7
24
- check idle speed rpm, correct if necessary using
adjusting screw (1)
• .specification: 880 ± 50 rpm
- check CO content
• specification: 0.7 ± 0.4% vol.
For CO adjusting, remove screw cap as follows:
- drill CO adjusting screw cap using
2.5mm (0.098 in.) drill
-thread 3mm (0.137 in.) sheet metal screw into
drilled hole
- grasp screw with pliers, pull out cap
Set idle speed and CO content by alternately turning
adjusting screws (1 and 2) to obtain specifications
- reconnect oxygen sensor connector and idle
stabilizer control valve connector
- let engine idle approx. 2 minutes
- check CO content, correct if necessary by
repeating adjusting procedure
Diglfant Idle speed/CO content,
checking and adjusting
24 51 •
24 Fuel Injection, AFC System

Idle speed/CO· content, checking and - with Ignition switched off, re-connect oxygen
adjusting, continued sensor
- restart engine, let idle
· • CO content must read within specifications:
0.3 to 1.1% (not dependent upon elevation with
sensor connected)
""""" adjust if necessary
- secure CO adjusting screw with new safety cap
i ;··

Note I
\
After adjusting, the hoses for the crankc'ase_must be
reconnected. If the control current and the CO
content change, this is not due to an improper
adjustment,. but rather to oil dilution caused by short
distance driving. With long distance drives, the
amount of fuel in the oil will be reduced and the CO
value will normalize again. A short-term solution
would be an oil change.

Check oxygen regulation function as follows:

- remove hose (1) from pressure regulator (2) and
plug
CO should increase briefly, then drop in value.
- with Ignition switched off, disconnect oxygen
sensor
-restart engine, let idle
• CO content should correspond to chart
according to elevation of workshop

Note
CO content is altitude dependent, refer to the
following chart to compensate for the altitude of the
workshop.

CO (Vol.%)
7
~~~~++~~r+~4-~
6++4-~++~~r+~~~

5+-~~r-~+4--r-

4 ++-r--i-<--t-i-"1"""'"t"~-f:
3 -1--'--+--+-+-l-+-++
2 ++_,_,..-t
1
o~~~~~~~~--t-t-~~
0 500 1000 1500 2000 Meters
1640 3280 4920 6560 Feet
Height above sea level l2+1321
Example: At 1600 meters (approx. 1 mile) CO
should be 5% ± .5%

24.52 Idle speed/CO content,

checking and adjusting
Dlgifant
 Fuel Injection, AFC System 24
Idle stabilizer, checking 2nd check (regulator)
Requirements
1st check (function)
Engine oil temperature min. sooc
Electrical consumers turned OFF
No leaks in intake air system
Ignition timing OK
Idle rpm OK
CO-content OK
- remove crankcase breather hose and close tightly
-connect multimeter US 1119 with adapter VW
1315A/2 to idle stabilizer valve 1
- let engine idle
• specified value: approximately 430 = 20 rnA
(fluctuating)

Note
Idle stabilizer triggering can vary depending upon
specific vehicle wiring; however, in all cases the
following functional check applies.
- start engine and let idle
• idle stabilizer valve 1 must vibrate and hum
If OK,
go ahead with 2nd check
If NO,
remove connector from valve 1 and check resistance
of valve with multimeter US 1119
• specified value: display (continuity)
If specified value NOT obtained - Disconnect connector 2
- replace valve • specified value: approximately 430 rnA constant
If specified value IS obtained If test conditions have been met and specified values
- re-connect connector to valve and check electrical are NOT obtained
connections on control unit relay adapter (in front - replace idle stabilizer control unit
of right tail light) according to wiring diagram
If electrical connections OK
- replace idle stabilizer control unit

F-9 Digifant Idle stabilizer,

checking
24 •53
24 Fuel Injection, AFC System

Oxygen sensor and oxygen If NO:

regulation, checking proceed to determine whether the problem is with
the oxygen sensor or with the control unit
Engine code MY
Test step II
Requirement
-shut off engine
Engine oil temperature min. SO"C (176"F)
(
Note Terminal #1 _Input to \'-
Idle stabilization· control unit (rpm slgnai}---
There must be no leaks in the exhaust sytem (Left side of engine compartment)
between the cylinder heads and the catalytic
converter.

- connect CO test equipment hose to the sampling

point on left exhaust pipe using Sun 120.239
adapter (arrow)
Note
Test step I
As of 9-87 production this connection .has moved to
- let engine run approximately 2 minutes at idle and the right side of the engine compartment (in front of
read CO-content the air flow sensor). ·
- disconnect RPM signal wire
- disconnect oxygen sensor

Note
The oxygen sensor must be disconnected with the
Ignition OFF to cancel the memory In the control unit.
- start engine
-hold disconnected (green) oxygen sensor wire
from the control unit to ground ~
• CO content must increase
If NO
- check wire connection on control unit, page 24.62
test step II
If OK
- oxygen sensor connected - replace control unit and recheck
-remove hose (1) from pressure regulator (2) and
plug hose Note
• CO should increase briefly. then drop in value If test step I is not OK but test step II is OK, the
to 0.3-1.1% oxygen sensor is defective.

24.54 Oxygen sensor,

checking
Dlglfant

Pressure regulator, checking
ith
The pressure regulator regulates the
relation to the intake manifold pressure.
Fuel Injection, AFC System 24
Residual pressure, checking
in - shut off engine and wait ten minutes
• 2.0 to 2.5 bar (29 to 36 psi)
If pressure value NOT obtained there are three
possible causes

CAUTION
Use extreme care not to damage fuel lines
when clamping.

- check fuel pump check valve by clamping off line

from fuel pump
- check fuel pressure regulator by clamping off
return line to tank
- check fuel injectors by clamping off lines from
.... injectors to pressure regulator, if necessary go to
\ page 24.56 to check injectors

( In each of these cases, observe gauge pressure

-connect pressure measuring equipment VW 1318
with adapter VW 1318/17 and hose tot-connection
= 1 of fuel line
while clamping off the individual lines.
If the pressure drop ceases or slows dramatically,
the problem is in the indicated component.

CAUTION
The switch (arrow) on the pressure measuring
equipment must remain closed during the
J measuring process.

- run engine at idle and measure fuel pressure

• specified values
vacuum hose on
bar (PSI) pressure regulator
approx. 2.0 (29) connected
approx. 2.5 (36) disconnected
continue with next column

lit.

i2

F·11
Digifant Pressure regulator, checking
Residual pressure, checking
24.55
24 Fuel Injection, AFC System

Fuel injectors, checking Voltage supply, checking

Injector spray pattern, checldng CAUTION

- remove injectors in pairs, (connectors and fuel Avoid short circuits at the connector terminals,
lines remain connected) otherwise the control unit can be d~maged.
- disconnect connector from second pair of Injectors

- operate starter briefly, observe spray pattern: - remove all connectOfs from injectors and connect
• spray pattern must be cone shaped voltage teS1er US1115 on one connector (arrow)
- operate starter
- re-install injectors • LED must flicker
If NO
Note -see electrical checks, page 24.61 , 24.62,
test steps 1 and 5 or control unit defective
When installing, make sure seals (1) are present.
Checking for leaks
- disconnect all connectors from injectors
- remove injectors in pairs (fuel lines remain
connected)
- switch ignition on for about 5 seconds
• no more than 2 drops per minute per injector
may leak out

24.56 Fuel Injectors,

checking
Digifant
 Fuel Injection, AFC System 24
Intake air sensor, checking Intake air temperature sensor, checking (arrow)

- remove connector and hose from intake air

sensor and test with digital multimeter US1119
using adapter VW 1315A/1
Potentiometer, checking
- measure between terminals 3 and 4
specified value: approx. 0 .5-1.0 k
- move air sensor flap and measure resistance
between terminals 2 and 3
• specified value: resistance change
- measure resistance between terminals 1 and 4
• specified value:
20"C '= 2.3 -2.7 k
over 20•c = n less
under 20•c = n greater
(2o·c = sa· F)

F·13
Dlglfant Intake air sensor,
checking
24 •57
24 Fuel Injection, AFC System

Throttle valve switch, removing and Throttle val'(e switch, checking and
installing adjusting \
·~

- remove throttle valve housing

Note
The throttle valve switch supplies the following
information to the control unit:
Throttle valve closed
- injection quantity for idle
-switching off the Injection quantity during
deceleraton fuel shut-off
- ignition point setting in idle (DLS function)
Throttle valve completely open
- injection quantity for full throttle

2------®·.
1---@ 124-1521

- remove throttle valve switch 4 in sequence

numbered 1 to 5
- installation is reverse of removal

- check continuity of throttle valve switch at

connector 1
• switch must display continuity only during idle
and full throttle position of throttle valve switch

24.58 Throttle valve switch

Digifant
 Fuel Injection, AFC System 24
Throttle valve switch Throttle valve switch voltage,
checking, continued checking

-open throttle valve and close slowly. While doing CAUTION

so, check switching point (continuity) of switch
with feeler gauge at idle stop of throttle valve Do not connect test light to throttle valve switch
lever connectors IF control unit is connected.
• switching point: gap (a)- 0.05-0.10 mm
(0.002-0.004 in) before idle stop - disconnect connector 2 from connector 1 of
throttle valve switch
- If necessary, adjust gap (a) with eccentric screw 3 - switch ignition ON
(first loosen screw 2) - measure voltage on connector 2
• specified value: approx. 5 volts
Note
If NO
Proper adjustment is important. - check for break in wiring or control unit is
If gap (a) too LARGE defective
- engine will surge when throttled slightly
If gap (a) too SMALL
- cold engine will stall out when given gas and
:h warm engine will have NO fuel deceleration shut-
off or DLS function at idle

Note
The limiting screw for basic throttle valve adjustment
must not be changed.
If the screw is turned by mistake, it will be necessary
to carry out a basic adjustment of the throttle valve
page 24.37.

F·15
Digifant Throttle valve switch 24.59
24 Fuel Injection, AFC System

Deceleration fuel shut-off Full throttle enrichm~mt, checking

Requirement Requirements

Engine oil temperature minimum so•c Engine oil tElmperature minimum so•c (176°F)
Fuel shut-off will occur only when: RPM gauge connected

• throttle is closed CO tester connected (if catalytic converter

• coolant temperature is above 5o•c (122"F) present;) on sampling· point using Sun 120.239
• engine speed is above 1250 RPM adapter
• engine speed was above 2600 RPM
- let engine idle about 2 minutes

- bridge connections In connector 2 with,...., sidEl of

double adapter VW 1490 and give slight amount - remove connector 2 from connector 1 of throttle
of gas valve switch
- slowly increase engine speed to about 4500 RPM
• engine RPM must vary (surge, then • connections in connector 2 not bridged
deceleration fuel shut-off begins)
• break in wiring - check CO and record
• temperature sender for engine temperature - bridge connections in connector 2 with ,...., side of
defective double adapter VW 1490
• control unit defective • CO must raise at least 1 vol.% over recorded
value
If NO, check for
- break in wiring
-temperature sender for engine temperature
defective
- control unit defective

24.60 Deceleration fuel shut-off

Full throttle enrichment, checking
Digifant j From 1986 m.y.j
 Fuel Injection, AFC System 24
Electrical testing ~ lgnltion and CAUTION
injection system \'-_/
To avoid damage to circuitry, switch to the
Requirements proper measuring range before connecting the
test leads.
Battery OK
Fuel pump and fuel pump relay OK
Idle stabilizer control unit OK

Note
------13
Internal resistance of the test equipment and ambient
temperature have a strong influence on test results,
digital multimeter US1119 should be used to perform
testing.
The specified values given are .for ambient
temperatures of oo to +40°C (32"·104°F)
If the measured value deviates· from the specified
values, determine fault according to current flow
diagram. Check wiring and connectors before
replacing any parts.

Measuring range: switch to vonage measurement

Test (Connector) To test Test conditions, Specified values:
step: terminal: additional steps:
1 13 + 14 control unit switch ignition ON approx. battery
voltage supply voltage
14 + 19
2 13 + 25 wire to ignition coil ignition switched ON approx. battery
terminal 1 voltage
3 1 + 13 wire from starter Disconnect connector from injectors. min. 8 V
terminal 50 and from Operate starter (selector switch in P
of
adapter for idle or N)
stabilizer control unit
terminal 50
4 bridge wire to fuel ignition switched ON fuel pump must
3 + 13 pump relay run audibly

F·11 Diglfant
Electrical testing 24.61
24 Fuel Injection, AFC System

Requirements

1Switch ignition OFF

\ I

~easyring range: switch to resistance measurement n

Test (Connector) To test Test conditions, Specified values:
step: terminal: additional steps:
5 12 + 14 injectors connect only one injector 15-20 n
at a time
6 6+ 10 temperature sender see diagram,
for engine temp page
7 6 + 11 throttle valve switch throttle valve:
• closed continuity
• slightly open to shortly oo{l
before full throttle
• completely open continuity
8 6 + 17 intake air sensor o.5- 1.0 k n
17 + 21 potentiometer move air flow sensor change in resistance
9 6 + 9 intake air temperature see diagram,
sender In intake air page 24.45
sensor
10 6 + 8 wiring to Hall sender remove connector from Hall sender continuity
6 + 18 and bridge all three connectors
.•.

11 2 + 13 wiring to oxygen disconnect connector to oxygen sensor continuity

sensor and hold green wire to ground (-)
re-connect oxygen sensor wiring oo{l

Note
For additional tests of ignition parts of the digifant
system as well as Hall sender test see Repair
Group 28.

24.62 Electrical testing

Digitant.
 26
Exhaust System-Emi.ssion Controls

ick Data Index

Air-cooled AFC Water-cooled Digijet
-California 26.3 -Assembly 26.7
1981 26.4 -Oxygen sensor 26.8
-USA and Canada except -Catalytic converter
California 26.2 checking 26.11
EGA valve 26.5
-Catalytic converter
checking 26.11 Water-cooled Digifant
-Assembly 26.9, 26.1 o
.....;Catalytic converter
Diesel checking 26.11
-'-Assembly 26.6

Index 26.1
26 Exhaust System-Emission Controls

Note
Always replace gaskets, seals and
self-locking nuts. Tighten all M8 bolts and
nuts to 20 Nm (14ft lb)

\ Cooo~tloo to< hoot"

.
/_
;..-'

Heat exchanger

Tall p i p e \

CO test point - ...!liil. . .

0
tighten cap to
15 Nm (11ft lb)
.·\ _ _ 15 Nm (11ft lb)

I'
c
Catalytic converter
(not Canada)

26.2 Exhaust system

Air-cooled AFC II CAN/USA, not Calif
 Exhaust System-Emission Controls 26
Note
Always replace gaskets, seals
and self-locking nuts. Tighten all M8 bolts to
20 Nm (14ft lb)

Connection lor heater

Heat exchanger

' \___ 15 Nm (11 rt lb)

Oxygen sen•or CO test point Connection for warm air fan

55 Nm (40 It lb) tighten cap to
before installing. coat 15 Nm (11 It lb)
threads with anti·sieze
compound

/ California-~980 m.y.j
Air-cooled AFC
Exhaust system 26.3
26 Exhaust System-Emission Controls

Modified and additional parts - EGA system (California 1981)

•
-- J~.,..
EGA valve

Heat exchanger

2 6 •4 Exhaust system
Air-cooled AFC I California-from 1981 m.y.
 Exhaust System-Emission Controls 26
EG R valve, checking
Work sequence

-shorten rod by turning hex (arrow) unt il idle

speed drops suddenly (Valve opens)
-turn rod In opposite direction
• manual transmission 1 1I 16 turns
• automatic transmission 5/6 turns
Note
Note
EGA valve (arrow) is operated mechanically by
throttle valve lever Use pin in hex as referenc.e mark when adjusting

Checking In Idle speed position - tighten lock nuts

-run engine at idle

-check pipe to EGA valve
• pipe should not warm up

Checking In full throttle position

-disconnect rod for EGA valve
-run engine at idle
- push lever on EGA valve to full throttle
position
-check pipe to EGA valve
• pipe should not warm up

ERG valve, adjusting

Work sequence
- run engine at idle
• manual transmission: 8()0-950 RPM
• automatic transmission: 850-1000 RPM

Air-cooled AFC I I CAN I USA, not Calif. EGR valve 26.5

26 Exhaust System-Emission Controls
Note
Always replace self locking nuts
Nc
AI•
an
Mf

Gaaketa---
replaoe

rNm(1111 lb)~

~I t1

J
, ...._25 Nm (18ft lb)
25 Nm (18ft lb)--'•

.J,
• ..._25 Nm (18 ft lb)

Gaskets _ _ _......-
replace

.26.6 Exhaust sy1tem

Diesel
 Exhaust System-Emission Controls 26
Note
Always replace gaskets, seals
and self-locking nuts. Tighten all
MB bolts to 20 Nm (14ft lb)

Gaskets---.,.
metal surface

Exhaust pipe, left

Exhaust pipe, front

Gaskets
metal surface
toward cylinder
"ead

Catalytic converter

CO teat point (cap screw)

Diesel
Exhaust system 26.7
26 Exhaust System-Emission Controls

Oxygen sensor, checking

Preliminary condition:
• engine oil temperature at least 60•c (140"F)

Work sequence
-connect CO meter to test receptacle on
exhaust pipe (lett side)

-with Ignition turned OFF, disconnect

connection 1 between oxygen sensor and
control unit
-pull off vacuum hose 2 from pressure
regulator and block hose
- start engine
• CO must increase to above 1.5%

-after about 2 minutes reconnect connoction 1

• CG must drop to 0. 7 ± 0.4%
If NO, following components may be
defeC"tlve:
• wire between pxy.gen sensor and control
unit or controf unit
-check wiring by disconnecting connection 1
again and ground wire end coming from
control unit
• CO must increase
If OK, oxygen sensor must be defective or
leak in exhaust system between
catalytic converter and cylinder head

26.8 Oxygenaensor Water-cooled! Digijet

 Exhaust System - Emission Controls 26
Exhaust system components,
removing and installing
• replace gaskets
• replace self-locking nuts
• tightening torque for screws and nuts:
25 Nm (18 ft lb) . -- - Exhaust pipe, front

Bracket~~~-------------.!~
• on engine block

• metal side
toward cylinder
head
l
i
i i
'<!
Exhaust pipe, - - -- ---\-
rear

Exhaust manifold

Heat shield
• for rear exhaust
pipe
• FOR SYNCAO ONLY

0 (See page 26.1 0)

/
. Exlileust pipe- -

1 26-560 1

G·9
Digifant Exhaust system 26.9
26 Exhaust System-Emission Controls
Exhaust system components,
removing and installing
Continued

End pipe

Bracket ---~
• for muffler

Oxygen sensor 50 Nm (37 ft lb )

• checking·
Repair Group 24
- - - Retaining Strap

Catalytic converter

• replace gaskets
• replace self-locking nuts
• tightening torque for screws and nuts:
25 Nm (18ft lb)

I 26·552 I

26.10 Exhaust system

Dlgifant
 Exhaust System-Emission Controls
Catalytic converter, checking
Converter replacement can become necessary If
the ceramic Insert loosens
If exhaust "rattles"
-check that exhaust flanges are tight
If " rattle" was not due to loose exhaust flanges,
converter may have failed
If exhaust system is tight
-remove catalytic converter
-look through both flange openings against light
If ceramic insert appears broken or melted as
shown, converter has failed
G-11
26
lf ceramic insert appears OK, check if ceramic
insert is firmly seat&Q in converter housing
Check as follows:
-while holding converter vertically, firmly tap
flange onto solid wood from a distance of 20 em
(8 in.)
-turn converter over and firmly tap other flange
as before
If no knocking sound converter is OK
If no movement of the ceramic insert, converter is
OK
If light knocking sound is heard Inside converter,
ceramic insert is loose and converter has tailed
CAUTION
Avoid the following conditions on vechicles
equipped with catalytic converters
• usage of leaded gasoline
• turning off the engine with the vehicle in
motion
• excessive prolonged cranking with an
intermittent firing of a flooded engine
• prolonged operation under load with a
misfiring engine
Catalytic converter, checking 26.11
 27
Electrical
Battery
Starter
Alternator

Index
Alternator
-Alternator/Regulator. checking
27.18
-Heater blower fan. removing /
rep1ac1ng 27.22
-Indicator lighl.
troubleshooting 27.23. 27.24
-Mount adjusting 27.22
-Removing/Installing 27.15
-Repairing (45A. 65A) 27.16
-Repairing (90A) 27.17
~System layout 27.19
-V-belt, adjustinQ 27.21
-V-bell, replacing 27.4!1
-Voltage re<JulatOf 27.20

B1ttery
-Chargtng 27.5, 27.6
-Checking 27.4. 27.6
-Eiectrotyt~ level 27.4
-Filler caps 27.7
- Location(s) 27.8, 27.9
-Nomenclature 27.2. 27.3
-Safety precautions 27.4
-TroubleshOoting 27.10

Cruise Control
-System, repairing 27.25
-Troubleshooting 27.29
Starter
-Installing 27.14
- Removing/installing
(Syncro) 27.13a, 27.13b
-Repairing 27.11
- Troubleshooting 27.12, 27.13

H·l Index 27.1

 Battery, checking and charging
Battery - checking electrolyte specific gravity -
Page 27.4, 27.5
Battery- checking voltage, Page 27.5
Battery - charging - Page 27.5
Troubleshooting guide - battery discharges itself -
Page 27.10

Negative terminal - - - -
• clean off any oxidation
• grease lightly with
acid resistant grease

27.2
 Electrical-Battery, Starter, Alternator 27
CAUTION
Before beginning repairs on the electrical
system, disconnect battery ground strap.

Filler cap
• measure state of charge
using hydrometer
• charge battery, if necessary

Electrolyte level mark

• if necessary, fill to
mark with distilled
water

Negative plate
(metallic gray)

H-2 Battery, nomenclature 27.3

27 Electrical-Battery, Starter, Alternator
Battery
Battery precautions
WARNING
Battery acid can cause severe burns. When
working with electrolyte always wear
goggles, rubber gloves, and apron. If
electrolyte is spilled on skin or clothing,
flush at once with large quantities of water.
If it gets into eyes, immediately flush with
large quantities of water for several
minutes and call a doctor.
Batteries produce explosive gases. Keep
flames and sparks away from batteries. Do
not smoke near batteries
Battery, jump starting
• car with good battery must not be running when
connecting jumper cables
~~~~~517 TO BOLT ATTACHING
GROUND STRAP TO
BODY
1 RED BLACK
I27-A0271
- connect jumper cables in following order:
• 1 - one end of positive cable to + post of
good battery
• 2 - other end of positive cable to + post of
dead battery
• 3 --one end of negative cable to - post of
good battery
• 4 - other end of negative cable to bolt
attaching ground strap to body
- start car which has good battery first
- next start car which has dead battery
-disconnect jumper cables in reverse order
27.4 Battery, checking
Battery electrolyte level, checking
LEVEL INDICATOR
MAX.
~:::::=:=::::::::::::::::::::tt- MIN.
PLATES
I27-A0281.
- check that electrolyte covers battery plates
(including separators) by 5 mm (1/4 in.)
-check battery electrolyte level indicator on
side of battery
Note
Only use distilled water when refilling battery
Battery condition, checking
Note
Weak battery can be caused by:
• alternator belt slipping
(replace belt when glazed)
• ground straps corroded, loose or broken
• alternator or voltage regulator defective
• alternator warning light bulb burned out
• poor ground connection between warning light
socket and circuit board
Battery terminals and cables should be coated
with grease or petroleum jelly and, if necessary,
cleaned to prevent corrosion and ensure good
connection
VIsual checks
-check for
• cracked or leaking case
• loose or corroded terminals
• low electrolyte level. If electrolyte is low,
refill with distilled water and fast charge
battery for several minutes after cells begin
gassing (boiling)
Hydrometer test
(for batteries with removable caps)
- test electrolyte In all cells
• average specific gravity should be at least
1.225
- correct for electrolyte temperature if necessary
• for every 10°F above 80°F add .004 to
hydrometer reading
• for every 10°F below 80°F subtract .004
from hydrometer reading
- if specific gravity is above 1.225, load test
battery
 Electrical-Battery, Starter, Alternator
-if specific gravity is below 1.225, recharge
Approx. electrolyte Minimum acceptable
battery
temp. °F (°C) voltage under load
- if specific gravity varies by more than .050
between cells, replace battery 60 (16) 9.5
,TOR 50 (10) 9.4
Specific gravity % ofcharg~t 40 (4) 9.3
30 ( -1) 9.1
1.265 100% 20 (-7) 8.9
1.225 75% 10(-12) 8.7
1.190 50% 0 ( -18) 8.5
1.155 25%
1.120 0% Battery charging

CAUTION
Do not expose fully discharged battery to
freezing temperature because battery will
be damaged by freezing
Voltage test-engine not running
(for sealed batteries only)
WARNING
Gases given off during charging are
explosive. Do not smoke or allow spa~ks or
flame near a charging battery.
Battery charger must be turned off when
connecting or disconnecting cables on
battery

-tum headlights on high beam for 1 minute to

remove surface charge
- disconnect battery ground strap
- check battery voltage with an accurate
voltmeter
• voltage should be at least 12.4 volts
- if battery is above 12.4 volts, load test battery
lght - if battery is below 12.4 volts, charge battery
until voltage is at least 12.4 volts
CAUTION
Do not allow battery voltage to exceed 17
volts. If battery begins gassing (boiling)
violently when charging, reduce charging
rate. Do not disconnect battery while
engine is running

~d Note
ary, Voltage %of charge
l(j Follow battery charger manufacturer's
12.6 or more 100% instructions. Before testing a battery that has
12.4 75% been charged, load battery with 15 amps for 1
12.2 50% minute to remove surface charge
12.0 25%
11.7 or less 0% Battery with removable caps
If battery level is low and water is added, fast
Load test charge battery for a few minutes after battery
I,
begins gassing (boiling). Slow charging current
Note should be approximately 10% of battery
!gin
Before load testing, battery must be at least 75% capacity. Fast charging should be approximately
charged 80-90% of battery capacity. Remove cell caps
while charging
-connect load tester according to manufacturer's
instructions - charge battery according to following table:
-load battery to 3 times amp/hour rating or 1/2
lSt 0°F cold cranking current rating
Specific Fast charge
-wait 15 seconds and read voltage
gravity up to
sary • battery voltage at room temperature should
be at least 9.6 volts 1.150 or less 1 hour
-if battery voltage at room temperature is below 1.150 to 1.175 3/4 hour
9.6 volts, replace battery 1.175 to 1.200 1/2 hour
-if battery is colder than room temperature, 1.200 to 1.225 1/4 hour
voltage under load will be lower. Use table above 1.225 slow charge ONLY
below If cold battery must be tested to 1.250-1.280

H·5
Battery, checking 27.5
27 E lectricai-Battery, Starter, Alternator

Sealed batteries
Only slow charge sealed· batteries. Sealed 2
batteries, sometimes called "maintenance free,"
will not accept high rate of charge, making it
necessary to charge it for up to twice as tong as 3
battery with removable caps. Also, voltmeter
reading will not increase as rapidly as when
charging battery with removable caps 4.---'

WARNING 5-----""
Battery acid can cause severe burns. When
working with electrolyte always wear goggles,
rubber gloves, and apron. If electrolyte is
spilled on skin or clothing, flush at once with
large quantities of water. If it gets into eyes, Battery, Installing
immediately flush with large quantities of water
for several minutes and call a doctor. 1 =nut, tighten to 10 Nm (7 ft lb)
2=washer
Batteries produce explosive gases. Keep
3= bracket
flames and sparks away from batteries. Do not
4 =shims (note number)
smoke near batteries
5 = base of battery case

Note
CAUTION
Bracket must press on base of battery case
Before working on any part of electrical
system disconnect battery ground strap.
Never run alternator with battery
disconner.ted

Battery, removing
-disconnect battery ground strap from negative
terminal of battery, not from body
-disconnect positive terminal from battery
- remove battery hold-down (note number of
shims)
- remove battery

Note
Special bolt is used to attach ground strap to
body. If bolt has been loosened, it must be
removed and cleaned free of paint and
undercoating. Mounting area must also be
cleaned free of paint and undercoating. After
installing, coat bolt and mounting area with
corrosion resistant material

27.6 Battery, checking

 Electrical-Battery, Starter, Alternator 27
Battery filler cap ( new style )

Filler cap, removing

- cut filler cap skin at notch (arrow) with pocket
knife or sharp edged screwdriver

- insert suitable screwdriver into slot

-turn upper part of filler cap counter-clockwise to
stop
-remove filler cap
Ftller cap, Installing
- install new type of filler cap in same manner as
old type filler cap

H·7
Filler caps 27.7
 Battery location

Fig. 1 Battery location

Rg. 2 Installation detail (under right front seat)

27.8 Battery location

(single battery system)
 Electrical-Battery, Starter, Alternator 27
Battery locations, for non-propane
refrigerator equipped Camper (P21)

Fig. 3 Battery locations

Fig. 4 Installation detail (under front seats)

H·9 Battery locations,

(2 battery systems)
27 g
•
27 Electrical- Starter, Alternator
Battery discharges-troubleshooting
current draw suspected

Test conditions
fully charged battery
clock disconnected

Battery discharges
Possible causes:
corroded and fouled contacts
chafed-through wirings
internal short-circuits in electrical
equipment

disconnect battery ground ( ) strap

-connect test light between negative (-)
battery terminal and ground (-) strap ---+----ll..,...f
off all electrical consumers
e all doors
····- -- ~-~~-

' Test light does not

Test light lights up
light up

-eliminate individual circuits

by removing fuses
- if test light goes out in one
of interrupted circuits,
source of fault is to be
found there

- in place of test light, connect ammeter

(measuring range 0-200 Amp.) between
negative ( -) battery terminal and battery
ground strap ------------1--tl....
- reduce measuring range until a clear
reading is shown (1 -3 mAmp is permitted)

- eliminate individual circuits by removing

fuses • if no faults are found in fused circuits,
if reading drops to zero in one of disconnect wiring connectors from nonfused
interrupted circuits, source of fault is to be components:
found there alternator
starter
ignition system
cluster instruments
coolant fan and so on

27.10 Battery
 Electrical-Batte Starter, Alternator 27
Starter, repairing

Protective -----..
cap for solenoid

olenold
• lubricate with moly paste

Shift lever----~
• If damaged, replace
• lubricate with moly paste

Intermediate---...
bearing

• clean commutator (lint free cloth

with gasoline)
• if windings are burned or if
solder is loose, replace

'nffl"
I

Drive pinion------'.._
• do not clean
"~Spring
Connoct... bua.".--J
• lubricate with moly paste

Field c o l i - - - - - -

Field coli housing-----.

• replace if worn

End plate

Ccuntenounk '"aw~ @~ Socket head screw

H·11
Starter, repairing 27.11
27 E lectricai-Battery, Starter, Alternator

Starter turns engine too slowly or engages and will not turn engine
Note
Check that engine is filled with oil of
recommended viscosity

CAUTION
Before working on any part of electrical
system, disconnect battery ground strap.

-check V-velt tension

- check battery voltage and charge if necessary
- clean battery terminals and check wire connections for tightness
Starter turns engine I Starter does not turn engine

+
I End I
- clean starter terminals and tighten
connections
- clean and tighten ground strap between
transmission and body at transmission
Starter turns Starter does not
engine turn engine

+
I End I
Starter defective
- repair starter
Following defects could be cause of trouble:
Possible causes Remedy
• carbon brushes sticking - clean brushes and brush
or poor contact between guides; if necessary
brushes and commutator replace carbon brushes
• commutator dirty, or - clean commutator or
grooved and burnt replace starter armature

I End

27.12 Starter, troubleshooting

 Electrical-Battery, Starter, Alternator 27
Starter does not turn engine when ignition/starter switch Is operated
Note
An engine that won't crank or battery that is
repeatedly discharged while driving may be caused
by poor wiring connections that result from a loose
fastening nut on terminal 30 of the starter motor.
To repair this condition:
-disconnect battery ground terminal
- clean and inspect connections at terminal 30 of
starter. Repair burned/damaged connections as
necessary. Torque fastening nut to 10Nm (7.5 tt
lb)
- reconnect battery ground terminal
Also check connection on solenoid switch and
ground straps for corrosion and tightness.

Voltage at solenoid, rmeaauring

- disconnect connectors from terminal 1
on ignition coil befo re operating starter • terminal 30 "" from battery
• terminal16 '"' to ignition co~

l
- measure voltage at terminal 10 of
•
•
terminal 50 "" lrom ignition/starter switch
connection A = lor field windings

solenoid switch (min. '8 volts)

I
No voltage or Voltage OK
leaa than 8 volts

- measure voltage at terminal SO of

ign i~on/starte r switch (min. 8 volts)
-
'
measure votfage et connection A for
field winding on solenoid switch
(min. I volts)
No voltage
I Voltage OK
No voltage
I Voltage OK

I
- replace ignitioni - check wiring
starter switch between terminal -replace -repair
50 on ignition/ solenoid starter
starter switch and switch
terminal 10 on
starter solenoid
and make
necessary repairs
I End I l End j
- on vehicles with
automatic
transmission, also
check neutral/park
starter switch.
Replace if
defective

I End I I End J

Starter, troubleshooting 27.13

27 Electrical - Battery, Starter, Alternator

Starter motor, removing and

installing
- disconnect battery ground strap

- remove bolt A from differential lock servo

- loosen bolt B and withdraw as far as possible
(clearance limitations prevent complete removal of
bolt B)

- remove upper mounting nut 1 from starter motor CAUTION

while holding bolt 2 with wrench
Nuts C and Dare welded to the bracket. No
- release handbrake (to allow axle shaft rotation)
attempt should be made to loosen them.
- raise vehicle on hoist
-disconnect right rear axle shaft from transmission
(six bolts) (see Repair Group 34)
- cover exposed CV joint with plastic bag to prevenl
entry ot dirt or foreign material

Note
You can remove the starter motor without
disconnecting the axle shaft, however; il the starter
motor area of the engine is caked with dirt, axle
removal greatly improves accessibilily.

Differential lock servo, removing

- loosen clamp securing cooling hoses to chassis
-swing hoses to one side (and secure with wire if
necessary) to provide working clearance

- push back protec1ive sleeve and drive out roll pin

- with bolt B withdrawn as far as possible, give
servo a slight upward twist and remove from
bracket

27.13a Starter motor,

removing and Installing
Syncro
 Electrical- Battery, Starter, Alternator 27
Starter motor, removing and Starter, Installing
installing, continued - clean mating surfaces and apply sealer
AMV 188 000 02 before installing starter
- installation procedure is reverse of removal
Star1er motor mounting bolts torque:
• specification: 28 Nm (21 It lb)

CAUTION
Part numbers are for reference only. Nways
check with your Parts Department for latest
information.

of
- remove circlip 1
-remove bolls (arrows)
- remove bracket
Starter motor, removing
- disconnect wires from solenoid terminals 30 and
50

,
- loosen lower mounting nut on starter motor
(arrow)
- push up slightly on starter motor and remove

S
yncro
I Starter motor,
removing and Installing 27.13b
27 Electricai .. Battery, Starter, Alternator

Starter, Installing
Work sequence

CAUTION
Before starting work on any part of electrical
system disconnect battery ground strap

- attach battery/starter cable to warm air hose with

cable tie at:
• 1 = vehicles with manual transmission
ur
• 2 = vehicles with automatic transmission

- attach wiring from alternator and wiring for

terminal 50 from ignition/starter switch to starter
solenoid with cable tie 1

- attach battery/starter cable to frame side member

with cable clips (arrows)

27.14 Starter, Installing

 Electrical - Battery, Starter, Alternator 27
Alternator (90A), removing and
installing (Bosch)
Note
To prevent the alternator bolt from becoming loose
and breaking. the torque specification has been
increased.
The increased torque specification requires use of a
new bolt on 1.9L water cooled engine.
Alternator
To repair a loose/broken bolt: • chocking - page 27.18

1.9L Gas Engine 25 Nm (18 tt lb)

- install new bolt, Part Number N 014 400 4. Torque
to 25 Nm (18 ft lb)
Diesel Engine
- replace bolt ONLY If damaged, Part Number is AJtemator pulley
unchanged. Torque to 28-33 Nm (21·24 ft lb) • diameter 61 mm (2.40 in.)
• alternator pulley, removing
and Installing :
- hold pulley tightly with
wrench
- remove mounting screws

0.
Allemator - - - - - - - - .
aupport bracket
• mounting page 27.22 e-._ .._ ,...,r-25 Nm (18 tt lb: l
3~ .
Cradle
bracket Mounting nut
M14 - 35 :!.: 10 Nm (26 :!: 7 It lb)

Starting Feb 1985

M16 - 50 :<:. 10 Nm (37 :!.: 7 It lb)
V·belt
• check for wear
• impression depth:
new V-belt
approx . 2 mm (0.079 in)
V-belt 1n use
approx. 5 mm (0.197 in)
• replace squeaking
V-befts
CAUTION see page 27.21

Part Numbers are for reference only. Always

check with the Parts Department for the latest
information.

Alternator, removing
and Installing
27'.15
27 Electrical-Battery, Starter, Alternator

Alternator, 45A and 65A, repairing (Bosch)

Bearing (slip ring side)

• installing: press over
inner race to stop -
always use new bearing .
Bearing sealed on both sides

Voltage regulator
Rotor
diHerent types tor 45A
and 85A alternators Housing
• mark position
relalive to end pl.B!t

Voltage regulator/ - - - --...

carbon brushes
• removing and installing page 27.20
• checking, page 27.18

Bearing (drive side)

• always use new bearing

End plate
• mark position of housing
• note diHerent types !or
fastening flange

Diode plate
• when replacing. install
additional suppression
condenser-
Fig. 1 page 27.20

• note rotation direction,

shown by arrow

Stator
different types for
Belt pulley 45A and 65A
6 1 mm diamet er (2.40 in) alternators

27.1 6 Alternator, repairing

(45A and 65A models)
 Electricai.. Battery, Alternator, Starter 27
Alternator, repairing (90A, Bosch)
starting October 1982

Note
Always use new bearings, avoid damaging slip rings

Rotor

IJ)ate
Suppression condensor

Voltage regulator/carbon bruahea

• remoVing; can be removed
withoul removing alternator
• wear limit of carbon brushes
5 mm (0.197 in)

ews
End plate
• Mark position in relation to alternator housing

Diode plate
• removing and Installing: to heatsink
at soldering points use needle nose
pliers. use soldering iron 300 waHS
maximum
• if diode is damaged, replace
diode plate completely

V-belt pulley
diameter 61 mm (2.40 1n) • removing and installing:
to heatsink use needle
nose pliers, use soldering
iron, 300 walls maximum
0
. . . _ _ _ 40 Nm (30 ft lb)

H-19 Alternator, repairing

(90A model)
27.17
27 E lectrlcai-Batt.ery, Starter, Alternator

\lternator/regulator, checking Current drain test

(with Sun VAT-40 or equivalent)
Visual checks
-check for:
• loose or broken ground straps
• loose or damaged V-belt
• properly operating alternator charging light
• proper tightening of alternator
Work sequence
Alternator output test
- connect alternator/regulator fester according to
manufacturer's instructiOns
- start engine and run at 3,000 rprT'J
• all electrical accessories must be OFF
- adjust load to maximum ammeter reading
• do not allow voltage to go below 12 volts
• maximum ammeter reading shoultl be at least
alternator rated output minus 16 amps
• if ammeter reading i• more than 16 amps below
alternator rating, replace regulator and retest
• if ammeter reading ie still too low, alternator is
defective
Regulator test
• tester still comected
• all electrical components IDFF and NO ammeter
load
- run engine at 3,000 rpm untH voltage stops rising
• voltage should be•13.5-14.5 volts
it NO, replace regulator and retest
-turn OFF ignition switch, radio, and all lights
-leave rear window defogger switch and air
conditioning switches ON to check air conditioner
relay and load reduction relay
- disconnect ground cable from battery
-connect test light between ground cable and
negative battery terminal
• if test light burns brightly, something is switched
ON or short.ed and draining battery
- remove fuses from fuse/relay panel one at a time
until test light goes out to help locate problem
• if no faults are found in fused circuits,
disconnect cables from non-fused components,
i.e. alternator, starter motor, Ignition system and
dashboard instruments until test light goes out
Alternator charging light test
Note
If battery is still not being charged, even though
charging light operates properly, check alternator
charging light circuit
- disconnect battery ground strap
- remove instrument cluster

Diode test
• tester still connected
- run engine at 3,000 rpm
- adjust load according to manufacturer's
instructions
• if meter reads "bad," replace alternator

CAUTION
Never run alternator with battery disconnected - attach multimeter US1119 between contacts 9 and
13 on printed circuit board
• specification: 140-160 ohms
II value is greater than 160 ohms:
- replace printed circuit board

27.18 Alternator I Regulator,

checking
 Electrical-Battery, Starter, Alternator 27
Alternator and related components, CAUTION
layout
Before starling to work on any par1 of electrical
)ner system disconnect battery ground strap.
Never run alternator with battery disconnected.

~'me

'
:mts,
1 and
out

Cooling fan with NIIIA\1---1

V·Belt
adjusting 27.21
replacing page 2721

Warm air duct

9 and

H-2 l Alternator system,

layout
27.19
27 Electrical-Battery, Starter, Alternator

Voltage regulator, removal,

installation and maintenance

Fig. 3 Voltage regulator/carbon brushes,

removing and Installing
a = new = 10 mm, wear limit = 5 mm
11 necessary, remove solder from connecting wires
(arrows) and replace carbon brushes

AlternatorNoltage regulator
(from 1981 model)

Fig. 1 Suppression condenser, connecting

Note
VOltage regulator with black reclarliJular housing is
supplied as replacement PaJ'I N.o. 028 903 803A
Voltage regulator can be replaced without removing
alternator
• if voltage regulator is replaced, suppressor
condenser (Fig. 1, (if not already installed) must be
added

Fig. 3A
Voltage regulator ( hybrid-type ) now has longer
carbon brushes
a = approx. 13 mm (19132 in)
wear limit = approx. 5 mm (7/32 in)

Note
Do not install new-type voltage regulator (with longer
brushes) into old-type alternators
Fig. 2 Voltage regulator, removing and Installing Slip ring (on which brushes make contact) has been
reduced in diameter to 28 mm (1118 in) (was 32 mm)
CAUTION Shape of cooling openings in alternator housing
Part numbers are tor reference only. Always has been changed
chock with your Parts Department for latest
information.

27.20 Voltage regulator

 Electrical-Battery, Starter, Alternator 27
V-belt, adjustment V-belt, replacing
Work sequence
- disconnect battery ground strap
- remove bellows from heater blower housing
- remove warm air duct and elbow

- remove guard for fan and ignition timing scale

- loosen bolt for adjustment bracket on fan housing
- remove alternator pivot boiVupper heater blower
housing mounting bolt

- remove lower heater blower housing mounting

bolt (on right side of alternator)
- loosen bolt attaching adjustment bracketiheater
blower housing to alternator (on left side of
alternator)

Fig. 4 V-belt, adJusting

Oue to higher alternator output, present V-belt
~ension is insufficient.
Adjust belt tension as follows:
-loosen bolts 1 and 2 and pivot alternator
Altemator V-belts up to 1000 mm long (39.4 In)
• 2 mm max. (0.079 in) deflection with new belt,
lhumb pressure
• 5 mm max. (0.197 in) deflection with previously run
belt. thumb pressure

Alternator V-belts over 1000 mm long (39.4 In)

• 10 mm max. (0.394 in) deflection with new belt.

thumb pressure
• 15 mm max. (0.59 in) deflection with previously run -remove V-belt from V-belt pulley between
bell, thumb pressure alternator and heater blower fan
- install new V-belt and adjust
Note • after Installing new V-belt. bellows must fit
tightly on heater blower housing and fresh air
Extremely loud squealing may indicate· damaged
intake duct (see also, pages 27.19, 27.22)
V-belt that should be replaced

:er

en
m)

H-23
V-belt, adjustment,
replacing
27 •21
27 Electrical-Battery, Starter, Alternator

Heater blower fan, removing Alternator mount, adjusting

and installing (from Illustration 27-576 page 27.15)
If alternator mount is loose, with a consequent
ranling noise, the cause can be the elimination of the
spring washer under each bracket mounting bolt.
The mounting bolts may only partly touch the uneven
and rough surface of the cast iron bracket, causing
the preload force to be insufficient even with
correctly applied torque.

4 To correct,
- install spring washer, Part No. N012 24 111, on
8- -..... IIJ:I..I---tt-.---- 3 each bracket mounting bolt
9- -----. 1'1&1--+-t--2 -install bolts and torque to 22 Nm (16ft lb)

10-t=t~~~:lij Note
11
Spring washers are now Installed on cars beginning
with January, 1982 Vanagon production (from
VIN 25CH089151 ).
Fig. 5 Heater blower fan, removlnfJ'Instelllng
Mounting bolts, tightening
1 = alternator
If allernator mounting bolts become loose, follow this
2 = alternator cooling fan
procedure:
3 = support ring
4 = shim with collar Waterboxer
5 = V-belt pulley
8 = spacer - replace old bolts with new bolts of higher strength
7 = heater blower fan (New bolt PIN N14 400.4)
8 = thrust washer - re-torque new bolt to higher torque specification
8 = woodruff key Diesel motor
10 = spring washer
11 = nut, tighten to 35 Nm (25 ft lb) - re-torque old bolts
Torque specification:
• Waterboxer 24.0 Nm (18ft lb)
• Diesel motor 28.0-33.0 Nm (21.0-24.0 ft lb)

CAUTION
Part numbers are for reference only. Always
check with your Parts Department for latest·
information.

Fig. 8 Heater blower fan, removing/Installing

-hold pulley with V-belt and VW 420

27.22 Heater blower fan, removing/Installing

Alternator mount, adjusting
 Electrical-Battery, Starter, Alternator 27
Troubleshooting indicator light for alternator (LED)
Does not Illuminate with Ignition ON (engine NOT started)
he
Possible open circuit between alternator D + and indicator light (LED)
ren
- remove alternator cover
- remove D + wire from alternator
- connect jumper wire between D + and ground
- turn ON ignition
Alternator indicator light (LED) lights up

Possible causes:
- improper alternator ground Alternator indicator Ught (LEDI does NOT light
- wom out carbon brushE:s up
9
- defective voltage regulator Alternator indicator light (LED) burnt out
- defective rotor
- disconnect battery ground ,strap
- replace indicator lamp (LED)
- connect battetY 9round stra!)
lis
- turn on ignition
Check alternator grounding and brushes: Alternator indicator Alternator indicator
If NOT OK: If OK: light (LED) lights up light (LED) does
~h make necessaty - replace voltage NOT light up
corrections
- if light now
regulator
E~D
comes on-
END

Wiring between alternator D + and indicator

light (LED) is open

If light still fails to - correct break in wiring (or open circuit)

come on : between alternator 0 + and indicator light
(LED)
replace alternator
Note
I
END Consult specific current flow diagram lor
vehicle in question, to determine exact signal
path.

END

1-3
Alternator Indicator light
Troubleshooting
27 .23
...
27 Electrical-Battery, Starter, Alternator

Troubleshooting indicator light for alternator (LED) Cr

No1
Light is on with ignition OFF
-diode (or diodes) defective
Wh
-4
- replace alternator
I -4
END I

Alternator indicator light does NOT go out when RPM increases

Possible causes:
- slipping fanbelt, tighten if necessary
- ground short between alternator D + and indicator light (LED)
- Defective alternator

I
END

Possible short to ground betWeen alternator D + and indicator light (LED)

- disconnect alternator wiring
- turn ON ignition
Alternator indicator light (LED) lights up I Alternator indicator light (LED) does NOT light up

- short to ground in wiring between alternator

D+ and indicator light (LED) must be
corrected
I - Test alternator output
test voltage regulator

Note
Consult specific current flow diagram for
vehicle in question, to determine exact signal
path.
l - replace defective component

I E~D
END

27.24 Altemator Indicator light,

troubleshooting
 Electrical- Battery, Starter, Alternator 27
Cruise control system, repairing
Note
When troubleshooting:
- check vacuum hose on vacuum pump for wear
and condition; replace if necessary
Control unit for cruise control
- check all vacuum hoses for cracks, replace if
behind instrument panel right
necessary removing and installing:
Detach instrument panel shelf,
Inductive pickup tor cruise control
right and swing downwards.
on speedometer
Unscrew control unit and
removing and installing
Fig. 1 page 27.26 remove terminal connection

Switch tor cruise control

on steering column switch
removing and Installing -
Fig. 2 page 27.26

Relay panel
Brake light switch

Bracket tor _ __:::~=*---_L_ _/"'"": ~K

vent valve

Clip - - - - - - l ; > ' C "

on brake and clutch
pedal levers

J Vacuum servo
removing and
installing-
Adjustable link
adjustment to
throttle lever -
~vacuum hose
page 27.28
Fig. 6 page 27.28

J
routing in engine
compartment
Fig. 3 page 27.26

Cruise control system,

repairing
27 •25
27 Electrical - Battery, Starter, Alternator

Fig. 1 Inductive pickup for cruise control,

removing and Installing

- detach battery ground strap

- remove instrument panel insert cover and
foil, located underneath
- remove drive cable for speedometer
- remove electrical connections to
Instrument panel insert
- unscrew 4 mounting bolts from instrument
panel insert

- remove mounting bolts for steering column switch

and remove turn signal with switch for cruise
control

Fig. 3 Routing vacuum hoses In engine

compartment

- remove inductive pickup screws and

remove from harness connector

Fig. 2 Switch for cruise control removing and

Installing

- remove steering column trim

- secure vacuum hoses with tie wraps (arrows)

1- Vacuum pump
2- Vacuum unit with adjustable link
3- Vacuum hose to pump
4- Vacuum hose to vent valves
5- Vacuum hose to vacuum unit

- separate 4-pin terminal connection to

switch for cruise control
- pry off cap for hom and remove steering
wheel

27.26 Cruise control system,

repairing
 Electrical - Battery, Starter, Alternator 27
Fig. 4 Vacuum pump, removing and Installing

The vacuum pump is located at the rear right

side of the engine compartment.
- pull off vacuum hose and connector

When installing vent valve(s) set distance "a", so that

the valve(s) are closed when brake and clutch
pedals are in rest position, and opened when pedals
are actuated.

-remove mounting bolts (arrows)

Fig. 5 Vent valve(s), removing and Installing

Note
Vehicles with a manual transmission will have a vent
valve for the brake and a vent valve for the clutch.
Vehicles with an automatic transmission will have a
vent valve for the brake pedal only.
- remove steering column trim

-remove vacuum hose and terminal from brake

vent valve (1) and clutch vent valve (2)
- unscrew vent valve from the vent clip

CAUTION
Do not damage thread.

Cruise control system,

repairing
27 •27
27 Electrical - Batte Starter, Alternator

Fig. 6 Removing and Installing cruise control

vacuum servo

1- diaphragm
To check diaphragm:
- disconnect vacuum hose from pump
- press vacuum diaphragm inward, then plug
detached vacuum hose
• diaphragm must NOT move
2- adjustable link to throttle valve lever
3 - vacuum hose
4 - securing bracket on intake manifold with stud
and spacer
5- nut
torque: 4 Nm (3 ft lb)
6 - nut with shoulder
torque: 23 Nm (18 ft lb)

Note
The adjustable link is set to zero clearance at idling
speed (arrow).

Setting adjustable link

Attach link to throttle valve lever and-adjust ball head
on vacuum servo so that the adjustable link can be
clipped in place without altering the throttle valve
lever position.

27.28 Cruise control system

repairing
 Electrical- Battery, Starter, Alternator 27
Cruise control troubleshooting
Note
To perform following test, gear selector lever must be
in "D" or "2" (automatic transmission).

ground circuit to control

- disconnect control unit harness connector
- connect test light between terminals 8 of
harness connector and 12 volts positive
To positive ( +)
• test light lights • test light does connection
NOT light

127-A0571

ON/OFF switch not work

- connect test light between terminal 1 and
ground
-switch ignition ON
- turn cruise control switch ON
• test light lights

=
Ground
connection

127-A0581
Vacuum vent valves do NOT work
1 connect test light between terminal 1 and
terminal 3 of harness connector
1 switch ignition and cruise control ON
1 press brake pedal and clutch pedal one
at a time
• test light does
NOT go out

- repair break in
wiring
OR
- adjust vacuum
vent valve
127-A0591
OR
- replace defective
vacuum vent valve

Cruise control system,

troubleshooting
27 •2g
27 Electrical - Battery, Starter, Alternator

Cruise control switch does NOT work

- connect test light between terminal 6 of
harness connector and ground
- switch ignition and cruise control ON
- push RESUME on cruise control switch
• test light lights

Ground
connection
- repair break in
wiring
OR
I21-A060 I
- replace defective
switch

- connect test light between terminal 2 of

harness connector and ground
- push SET on cruise control switch
• test light lights • test light does
NOT light
Ground
connection
- repair break in
wiring
127-A061 I
OR
- replace defective
switch

Vacuum control motor does NOT work

- connect jumper wire between terminal 4 of
harness connector and ground
• pump runs • pump does NOT
Ground
connection

127-A062j
Go to
®
next page

27.30 Cruise control system,

troubleshooting
 Electrical- Battery, Starter, Alternator 27

Vent valve in vacuum control motor does NOT

wort<
- connect jumper wire to terminal 7 of harness
connector, then briefly touch to ground
• vent valve "clicks" • vent valve does
NOT "click"

-repair break in
wiring
OR Ground
- replace vacuum connection
control motor
127-A0631

Speed sensor does NOT operate

- switch ignition OFF
-connect multimeter US 1119 (set to ohms
range) between terminal 5 of harness
connector and ground
• 90·110 ohms • does NOT read
90·110 ohms

Ground
connection
127·A0641

Note
An inoperative cruise control system may
be caused by vacuum loss due to cracked
or leaking hoses.

Cruise control system,

troubleshooting
27 •31

Index
Air-cooled AFC
- California 28.8
distributor 28.11, 28.12
distributor drive 28.10
Hall control unit/generator 28.14
Hall ignition troubleshooting 28.17
idle stabilizer 28.16
ignition distributor/settings 28.9
ignition timing 28.11
rotor 28.10
vacuum advance/retard 28.13
vacuum unit 28.12
wires/coil checking 28.10
-USA (except Calif.) and Canada
28.2
distributor 28.6, 28.7
distributor drive 28.4, 28.5
ignition/distributor settings 28.3
ignition timing 28.5, 28.6
rotor 28.4
vacuum unit/advance 28.7
wires/coil checking 28.4
Diesel
- Glow plug light troubleshooting
28.27
- Quick glow troubleshooting
28.24
28
Ignition System
·.~
Water-cooled Digijet Water-cooled Digifant
- Centrifugal advance 28.34 - Distributor, installing 28.44
- Distributor driveshaft 28.32, 28.33 - Hall sender checking 28.43
- Hall control unit 28.36 - Ignition distributor 28.40
- Hall generator 28.37 - Ignition and injection system,
- Idle stabilizer 28.38 repairing 28.39
- Ignition cable connectors new style -Ignition settings 28.41
28.30a - Ignition switching function,
-Ignition coil 28.32 checking 28.44
- ignition distributor/Hall generator Ignition timing 28.42
28.29
- Ignition distributor/settings 28.29
- Ignition system 28.28
-Ignition wires/connectors 29.31
- Rotor 28.31
- Suppressor connectors 28.32
- Trigger wheel 28.38
- Vacuum unit 28.35
- Vacuum advance/retard 28.35
Index 28.1
28
.----1ermlnal1(-)

Terminal 4

only on vehicles
with radio

Termlnal15 ( +)

r----- Ignition ¥tires

checking Fig. 2

Distributor cap ----------~

check lor cracks and corroded contacts .
Clean before installing

Carbon brush and spring - - - - - - - -.....

check lor wear and free movement

Rotor - - - - -- - ----
checking Fig. 1

Condenser - - ----.

··~~
30 Nm (22 It lb)
types page 28.3
Spark plug connector
4000-SOOOQ (with radio)
800-1200Q (without radio)
Distributor - - - - - - - - - - - - - - '
Installing Fig. 6 advance unit
checking centri fugal advance, checking leakage page 28.7
pages 28.8 and 28.7 vacuum advance che cking page 28.7

Clamping bolt
adjusting ignition timing,
see pages 28.5 and 25.6

Distributor drive - - - - - - - - , 1 1
removing Fig. 4
installing Fig. 5

~---- Thrust ¥tasher

guide Into position with screwdriver

28.2 Ignition
system Air-cooled AFC CAN/USA, not California
 Ignition System 28
Engine code letters cv
Distributor (Part No.) 022 905 205S

l.gnition tim ing 7.5" BTDC

•
Timing mark location: crankshaft pulley

'6 12 8 4 0 4
~
~-
wires
1 Fig. 2
------... rw-~

Idle speed
manual 800- 950 rpm
I automatic 850-1000 rpm
Vacuum hose disconnected

Dwell angle new points 44-50°

wear limit 42.-58.

Centrifugal advance (crankshaft degrees)

start 1000-1200 rpm

9- 14 • at 1600 rpm

end 21-25• at 3400 rpm

Vacuum advance
start 107-147 mbar (80-110 mm Hg)
•.
266 mbar (200 mm Hg)
end
8 - 12"

Spark plugs Bosch W 145 M2, W 8 CO

Beru 145/1413L
Champion N 288

Spark plug tightening torque 30 Nm (22 ft lb)

Spark plug gap 0.6-0.7 mm (0.0.23-0.028 in.)

lio)
adio) Firin g order 1-4-3-2

ge 28.7

lmer

Air-cooled AFC I I CAN I USA, not Calit.l'gnltion

. .
distributor
. and settings
28 3
·• ·
28 Ignition System

Note
A rough idle or misfire during partial load could be
caused by ignitioo sparks jumping from the plug wire
connector to the noise suppression shield, or the
cylinder head.
- remove and Inspect the plug connector for white
spots or burn mari<s
- on those vehicles equipped with a suppressor
shield on the distributor cap, it Is necessary to
remove the shield and che<;k for white spots or
bum marks on the distributor cap
II white spots or bum marks are present, replace the
damaged components.

Fig. 3 Ignition coli, checking

- disconnect all wires from coil terminals

- measure resistance between terminals 1
and 15
• 2.6-3.1 ohms
- measure resistance between terminals 1
and 4
• 6000-12000 ohms

Fig. 1 Rotor, checking

• 4000·6000 ohms

Fig. 4 Distributor drive, removing

Fig. 2 Ignition wires, checking

- check wires between distributor and spark

plugs (including connectors) for continuity
• resistance should not vary greatly
- check wire between ignition coil and
distributor (including connector)
• resistance should not be greater than
2400 ohms

Rotor

28.4 Ignition wires/Coil

Distributor drive IAir-cooled AFcjcAN/USA, not Calif. I
 Ignition System 28
Ignition timing, checking/ adjusting
with SIEMENS 451 tester or equivalent
Won< sequence

Note
If SIEMENS 451 tester is not available, proceed
with check using procedure with liming light
(see page 28.6)
-run engine until engine oil js at least 3o•c
J (86.F)

'1 Fig. 5 Distributor drive, Installing

- set crankshaft to TDC on cylinder
No.1
- Install drive shaft so that offset
slot is at an angle of about 12• to
engine centerline (small segment to
coil side)
-connect SIEMENS tester according to
manufacture(s Instructions
- run engine at Idle speed
• manual: 800-950 rpm
• automatic: 850-1000 rpm
- pull off vacuum hose to distributor
- check dwell angle, adjust If necessary
• new points: 44-50•
• wear limit: 42-58•

-check timing. Ignition timing point will read

directly on SIEMENS tester
• 7.5• before TDC
if NO, loosen distributor clamping bolt and turn
distributor
- reconnect vacuum hose to distributor
- retighten clamping bolt
Fig. 8 Distributor, Installing
- set crankshaft to TDC on cylinder No. 1
- turn rotor until it Is pointing to No. 1
cylinder man< on edge of housing
- Install distributor
- clean distributor capJ check for
cracks, signs of tracking and rotor
tightness on shaft
-adjust ignition timing

Air-cooled AFC I I CAN I USA, not Calif.

Distributor drive
Ignition distributor
Ignition timing
2. 8 •
s· .
28 Ignition System

Ignition timing, checking/ adjusting Ignition distributor, checking

with timing light centrifugal advance with SIEMENS
451 tester or equivalent
Wot1t sequence
-run engine until engine oil is at least 30"C (86"F) Wot1t sequence
-connect dwell/ tach according to manufacturer's
instructions
- run.engine at idle speed
• manual: 800-950 rpm
• automatic: 850-1000 rpm
-pull off vacuum hose to distributor
-check dwell angle, adjust if necessary
• new points: 44-50"
• wear limit: 42-58"

- flash Ignition timing scale with timing light
• mark on pulley must align w ith red mark on
scale
if NO, loosen distributor clamping bolt and turn
distributor
-reconnect vacuum hose to distributor
- retighten clamping bolt
(&1371
-connect tester according to manufacturer's
Instructions
- start engine and run at Idle
• Ignition timing and rpm will register directly
on tester
-adjust idle speed if necessary
• manual: 800-950 rpm
• automatic: 850-1000 rpm
-pull hose off vacuum unit
-adjust ignition timing if necessary (see
pages 28.5-28.5)
- note advance angle on test instrument (basic
advance angle)
Note
Start of centrifugal advance is shown by
Increasing advance angle registered on test
Instrument while Increasing rpm

-increase engine speed slowly to 1600 rpm

- read off ad11ance angle on test i nstrument

Note
To determine centrifugal advance, subtract basic
advance angle from last advance angle measured

Example
last advance angle measured
( - ) minus basic advance angle
( =) centrifugal advance

- repeat check at 3400 rpm

- reconnect vacuum hose when test is
completed

28.6
Ignition timing
Ignition
distributor
IAir-cooled AFCICAN/USA, not Calif: l

Ignition distributor, checking
centrifugal advance with timing
advance tester
Work sequence
-connect tester according to manufacturer's
instructions
-start engine and run at idle
• manual: 800-950 rpm
• automatic: 850- 1000 rpm
-pull off hose· at vacuum unit
-check ignltioA timing and adjust if necessary
(see pages 28.S tO 28.6)·
1
-flash ignition timing acale with timing light
and note i.ndicated angle (basic angle)
Note
Start of centrifugal ad~ance is shown by
movement of notch while i-ncreasing rpm
-increase engine speed slowly to 1600 rpm
-bring notch back lo original setting by turning
knob on tester and read off advance value
ctly Note
To determine centrifugal advance, subtract basic
advance angle from last advance angle measured
Example
last advance angle measured
(-) minus basic advance angle
sic I = ) centrifugal advance
- repeat check at 3400 rpm
-reconnect vacuum hose when test completed
Vacuum advance unit, checking for
leakage
Wort! sequence
asic
ured
-connect vacuum tester Sun VPT 212-1 or
equivalent according to manufacturer's
instructions
Air-cooled AFC II CAN I USA, not Calif.
Ignition System 28
- run engine at approx. 2500 rpm and check that
vacuum at throttle valve housing is reaching
vacuum unit
If NO, vacuum connection on throttle valve housing
may be blocked
-increase engine speed until vacuum tester
indicates higflar reading than ~ mbar
(200 mm Hg)
-switch vacyurn ,te&ter sQ il holds vacuum on
side connected to vacuum unit
-turn engine OFF
- vacuum reading on 1es1er must not drop more
than 10°lo withirl 1 mlnufe, otherwise vacuum
unit m hose is defective
Vacuum advance,, checking
-connect SIEMENS 4§1tester ~Pr equivalent,
or tach and liming l·ig ~t acc0rding to
manl1facturer's instructions
-connect vacuum tester between throttle valve
housing and vacuum advance unit connection
-set vacuum tester to allow vacuum to pass
through
-start engine and run at idle
• manual: 800-950 rpm
• automatic: 850-1000 rpm
-It using SIEMENS tester or equivalent, read
off Indicated advance angle (basic angle)
and note
-If using timing light, flash scale and note
advance angle (basic angle)
- increase engine speed until reading on
vacuum tester is higher than 266 mbar
(200 mm Hg)
-switch vacuum tester so that it holds vacuum
on side connected to vacuum unit
- leave engine running at idle (adjust if
necessary)
- reduce vac uum oo vacuum tester to 266 mbar
(200 mm Hg)' or 107'- 147 mbar (80-110 mm Hg)
- note advance angles
-determine Yacuum ad-vance by subtracting
basic advance angle from measured advance
angle
Example
last advance angle measured
(-) minus basic advance angle
( =) vacuum advance
-compare vacuum advance angles with
specified values on page 28.3
Ignition distributor
Vacuum unit
Vacuum advance 28 1
· •
28 Ignition System
Hall control unit -----. WARNING
checking page 28. 14 Do not touch or remove ignition co il wire
when running o r cranking engine.
Only disconnect wires of ignition system or
connect/ disconnect test instruments when
Idle s t a b i l i z e r - - - - - - - - -.......~ ignition is turned OFF
before adiusting Idle,
disconnect connect ors
and plug together CAUTION
checking page 28.16
Do not connect any test instruments on
terminal 15 (+)of ignition coil, this could
damage electronic parts. Use fuse No. to
for connection. Safety precautions for
transistorized ignition system see page
28.9, 28.15

Distributor ( : a p - - - - - - ---ll-8l:!il
check tor crac ks and
corroded contacts.
Clean before installing

Advance connection
Carbon brush and spring ·- - - - - --1 checking vacuum
check for wear and tree advanc e, page 28. 13
movement

Rotor---- - -- - - - - - - J
marked R1
checking Fig. 1

Oust cover

~Spark plug
30 Nm (22 It lbl
types, see page 28 9
Plug lor Hall generator

Distributor
installing Fig. 6
Seal - - - - - -- - - - checking centrifugal advance, page 28. 11 and
always replace

Distributor drive - - -- - - - - -- - ---,.

removing /Installing Fig.3 and Flg.4

Thrust washer ~
In stall. with screwdri ver,
j zs- r06A J
then posi tion

28.8 Ignition timing

with Hall Generator Air... cooled AFC Calif.
 Ignition System 28
Engine code letters cv
Distributor (Part No.) 039 905 205C

ignition timing s• ATDC

Timing mark location ; crankshaft pulley

•
~
§:@]
-----=----
Idle adjustment 850-950 rpm
Vacuum lloses connected
Idle st~;~bilizer plugs removed and
connected together

Dwe{l angle setting not adjustable

Centrifugal advance (crankshaft degrees)

start 1050-1300 rpm

9-13• at 1'600 rpm

end 21-25• at 3400 tpm

...
Vacuum advance
start 90-16U mbar (70-120 mm Hg)

~clor
240-28.0 mbar (180-210 rnm Hg)
end 9 - 12.

Vacuum retard
start 90-160 mbar (70-120 mm Hg)

200-280 mbar (150-210 mm Hg)

end
11-13°

Spark plugs Bosch w 145M2. waco

Beru 145/14/3.L
~8.9 ChampiOn N 288

Spark plug gap 0.6 - 0.7 mm (0.023-0.028 in .)

Spark plug tightening torque 30 Nm (22 It lb)

d 2B.12
Firing order
Transistorized ignition system cautions
Do not connect any conden ser /suppressor or test
light to terminal 1. Do noll connect test instruments
wi!h a 12 volt supply on terminal 15 of ignition
coil. Do not crank engine before high tension wire
of distributor cap (terminal 4) is connected to
ground with jumper wire (example: compression
check etc.). Do not replace installed coil-
211 905 115 C-with conventional type. Do not
leave battery connected when electric welding
1- 4-3-2
I
on car. Do not start engine after heating up to
more than 80 •c (176 •F), example: paint drying
booth. Do not wash engine when it is running. Do
not use battery booster longer than 15 sec. nor
exceed 16.5 volts with booster. Allow 1 minute
pause between boosling attempts . Do not discon-
nect battery while engine is running. Disconnect
plug to ignition control unit when car has to be
towed.

Air-cooled AFC II California

Ignition distributor
and settings
28 9
·· •
28 Ignition System

Note - check wire between ignition coil and

A rough idle or misfire during partial load could be distributor, (including connectors)
caused by ignition sparks jumping from lhe plug wire • resislance should not be greater than
connector to the noise suppression shield, or the 12000 ohms
cylinder head.
- remove and inspect the plug connector for white
spots or bum marf<s
- on those vehicles equipped wl1h a suppressor
shield on the distributor cap, it Is necessary to
remove the shield and ched< for white spots or
bum marks on tk1e distributor cap
If white spots or bum marf<s are present, replace the
damaged components.

Fig. 3 Distributor drive, removing

Fig. 1 Rotor, checking

- check that resistance is approximately

1000 ohms
Note
Do not change rotor when installing radio;
rotor must be marked with R1.

Fig. 4 Distributor drive, Installing

- set crankshaft to TDC on cylinder No. 1

- install drive shaft so that offset slot is at
an angle about 12° to engine centerline
(smaller segment toward coil side)
- install spacer spring

Fig. 2 Ignition wires, checking

- check wires between distributor and spark

plugs (including connectors) for continuity
• resistance should not vary greatly
between wires

28.10
Rotor
Ignition wires
Distributor drive
California II Air-cooled AFC
 Ignition System 28
CAUTION

18n When working on vehicles with Hall ignition

system, observe following precautions to
prevent injury or damage to ignition system:
- do not touch or remove high tension wire
when running or cranking engine
-disconnect ignition wires only when
ignition is switched ott
-test Instruments should be connected/
disconnected only when ignition is
switched off

-do not connect any oonoonser to terminal 1 Ignition coilsecondltry r•i•tance, checking
-do not tow cars without disconnecting
plugs on ignition control unit - disconnect all wires from coil term inals
-do not crank engine until high tension - messure resistance between negative terminal 1
wire of distributor cap (terminal 4) is and coil high tension terminal 4
connected to ground with jumper wire • resistance:
(example: compression check, etc.) 2400 - 3500 ohms
- do not leave battery connected when - if not within tolerance, replace ignition coil
electric welding on car
-do not substitute rotor of ignition
distributor with one of different type
-when installing suppressor, use only
• 1000 ohms for high tension wires and
1000 to 5000 ohms for spark plug
connectors

-do not wash engine when It is running

-do not use battery booster longer than
' minute nor exceed 16.5 volts with
booster

Ignition c;oil primary resistance, checking

- di$COnnect all wires from coil terminali

- measure resistance between positive 15 and
negative 1 coil terminals
• resistance:
0.52-0.76 ohms
No.1 - if not within tolerance, replace ignition coil
:It is at
lertlne
1)

Air-cooled AFC II California tgnitioncoil 28.1Qa

28 Ignition System
- ·- ---
_,
'\,

'' _,
-I
_,

Not
Sta
Inc·
whl

_,
-I

-start engine Not

Fig. 8 Ignition distributor, Installing
-set crankshaft to TDC on cylinder
No. 1
-turn rotor until It Is pointing to No. 1
cylinder mark on edge of housing
- Install distributor
- clean distributor cap, check for cracks,
signs of tracking and rotor tightness
on shaft
-adjust engine idle to 850-950 rpm To
- flash timing mark with timing light adv
• mark on pulley must align with red mark
on scale
- If necessary, loosen distributor clamping bolt
and turn distributor
- reconnect idle stabilizer
- retighten clamping bolt
Ignition distributor, checking -c

-·-·
-adjust Ignition timing
centrifugal advance with SIEMENS
Ignition timing, adjusting with timing 451 tester or equivalent
light
Wort sequence Not
Wort sequence
Wit
to'
Note to I
011 temperature must be at least so•c (140"F) _,
lgr
ce
ad
Wo
-c
-connect tester according to manufacturer's
Instructions _, I

- remove idle stabilizer plugs and connect -c

together
-start engine and run at idle - :
• Ignition timing and rpm will register directly
on tester
-disconnect plugs from idle stabilizer
• squeeze connectors to release - adjust idle speed
manual: 850-950 rpm No·
- connect plugs together (arrow)
automatic: 850- 950 rpm Sta
-check and adjust Ignition timing if necessary mo
- go to next page
-i
-I

28. 11 Ignition distributor/timing

California I I Air-cooled AFC

-pull off both vacuum hoses from distributor
vacuum unit
-plug vacuum retard hose
- reset idle speed to specifications
- note advance angle on tester (basic advance
angle)
Note
Stan of centrifugal advance is shown by
increasing advance angle registered on tester
while increasing rpm
- increase engine speed slowly to 1600 rpm
- read off advance angle on tester
Note
To determine centrifugal advance, subtract basic
advance angle from last advance angle measured
Example
last advance angle rneasu red
(-) minus basic advance angle
(= ) centrifugal advance
-compare centrifugal advance angle to
specified value of page 28.9
- repeat test at 3400 rpm
- reconnect vacuum hoses when test completed
Note
With vacuum hoses connected, adjust Idle speed
to given specifications before connecting plugs
to idle stabilizer
- reconnect idle stabilizer
Ignition distributor, checking
centrifugal advance with timing
advance tester
Work sequence
- connect tester according to manufacturer's
,S instruct ions
-pull advanc e and retard hoses o ff vacuum unit
-di sconnect pl ugs from idle stabilizer and
connect together
-s tart engine and ad just idle speed to 900 rpm
ctly
- flash timing mark with timing l ight, and note
indicated angle (basic angle)
Note
Start of cent rifugal advance is shown by
ary movement of notch while increasing rpm
- increase engine speed slowly to 1600 rpm
- bring notch back to original setting by turning
knob on tester and read oft advance value
G-12
Air-cooled AFC I I California I
Ignition System. 28
Note
To determine centrifugal advance, subtract basic
advance angle from advance angle measured
Example
last advance angle measured
( - ) minus basic advance angle
( = ) centrifugal advance
-compare centrifugal advance to chart page 28.9
- repeat check at 340Q rpm
- when check completed, reconnect vacuum
hoses
-reconnect Idle stabilizer plugs
Distributor vacuum unit, leak checking
Work sequence
-connect vacuum tester between intake
manifold and retard connection on vacuum unit
- plug vacuum hose for retard connection
- set vacuum tester to allow vac uum to pass
through
- start engine and run at idle
-disconnect hose from advance connect ion on
vacuum unit
- .set vacuum tester so that it holds vacuum on
side connected to vacuum unit
Note
Vacuum registered on tester must not drop by
more than 10% within 1 minute
- connect vacuum tester betweefl throttle valve
housing and advance connection on vacuum
unit
- set vacuum tester to allow vacuum to pass
through
- increase engine speed until reading on vacuum
tester Is higher than 240-280 mbar
(180- 210 mm Hg)
- if no vacuum Is registered on tester, check If
connection at throttle valve housing is blocked
- set vacuum tester so that It holds vacuum on
side connected to vacuum unit
Note
Vacuum regi stered on tes ter must not drop by
more than 10% within 1 minute
Distributor centrifugal advance
Distributor vacuum unit
28-.1 2
28 Ignition System
Vacuum advance angle, checking
Work sequence
-connect SIEMENS tester or equivalent (or tach
and timing light) according to manufacturer's
Instructions
- connect vacuum tester between throttle valve
housing and vacuum advance unit connection
-set vacuum tester to allow vacuum to pass
through
-disconnect plugs from idle stabilizer and
connect together
- start engine and adjust idle speed to 900 rpm
- if SIEMENS tester or equivalent is being
used, read off indicated advance angle
(basic angle)
- if using timing light, flash scale and note
advance angle (basic angle)
- increase engine speed until reading on
vacuum tester is higher than 240-280 mbar
(180-210 mm Hg)
- switch vacuum tester so that tester holds
vacuum on side connected to vacuum unit
- let engine continue to run at Idle and
readjust to 900 rpm if necessary
- reduce vacuum on vacuum tester to 240-280
mbar (180-210 mm Hg) or 90-160 mbar
70-120 mm Hg)
- note advance angles
- determine vacuum advance by subtracting
basic advance angle from measured advance
angle
Example
last advance angle measured
(-) minus basic advance angle
( =) vacuum advance
-compare vacuum advance angles with
specified values on chart page 28.9)
- reconnect vacuum hoses and adjust idle
speed
- reconnect idle stabilizer
Distributor vacuum unit
28.13 :::~um advance. I Air-cooled AFclcalifornia I
Vacuum retard angle, checking with
SIEMENS 451 tester or equivalent
Work sequence
-connect tester according to manufacturer's
instructions
-disconnect plugs from idle stabilzer and
connect together
- check Ignition timing and adjust if necessary
- pull both vacuum hoses off distributor
vacuum unit and plug retard hose
- adjust idle speed to 900 rpm
- note indicated retard angle on tester
-add 5° to indicated retard angle
-compare with specifications in chart for retard
end (see page 28.9)
- reconnect vacuum hoses and adjust idle
speed to 850-950 rpm
-reconnect plugs to idle stabilizer
Vacuum retard angle, checking with
timing advance tester
Work sequence
-connect tachometer and timing advance tester
according to manufacturer's instructions
-disconnect plugs from idle stabilizer and
connect together
-start engine and flash ignition timing mark
and note
- pull vacuum retard hose off vacuum unit and
plug hose
- adjust Idle speed to 900 rpm
- flash timing mark again and bring mark back
to original setting by turning knob on timing
advance tester
- read off retard angle and compare with
specifications in chart (see page 28.9) for
retard end
-reconnect vacuum hose and adjust idle speed
to 850-950 rpm
- reconnect plugs to idle stablizer
 Ignition System 28
Hall control unit, checking
Wori< sequence

Test condition;
• ignition coil OK, ignition OFF

ry

:ard connect voltmeter with+ (plus) to terminal 15

and with- (minus) to terminal 1 of ignition coil
turn ignition ON
• spec. = 2 volts (min.) for tbout 1-2 seconds
and then drops to 0 volts
• if not , replace Hall control unit and ignition
coil
- disconnect both plugs from idle stabilizer and touch center wire of connector on distributor
connect them together (arrow) briefly to ground
• indicated voltage must increase briefly to
5-6 volts
1ster • if not, check for wire break in center wire and
repair or replace Hall control unit if wire. is OK
- turn ignition OFF

lCk
ng

- remove connector from Hall control unit

- connect voltmeter with+ (plus) to terminal 4
lu-JOa 1
and with- (minus) to terminal 2 in connector
- connect voltmeter to outer terminals of Hal l
- turn ignition ON
generator connector
• spec = approx . battery voltage
- turn ignition ON
• if not, check for wire breaks and repair
• spec. = 5 volts (min.)
(see current flow d iagram 97 .12)
- turn ignition OFF
Note
- reconnect connector to Hall control unit
- disconnect Hall generator connector from
If readings are within specifications, but defect
still exists, replace Hall control" unit or check for
ignition distributor
wire breaks between Hall generator connector and
Hall control unit; if necessary, repair

Air-cooled AFC I I California Hall control unit 28.14

28 Ig nition System

Hall generator, checking Idle

CAUTION

Teat conditions: Set tester to read 'Voltage before connecting

• disconnect both wire plugs from idle stabilizer test leads.
and connect them together
• Hall control unit OK - disconnect high tension wire from terminal 4 of
•
• ignition coil OK distributor and connect to ground, using adapter - dl
• wiring between Hall control unit and ignition coil cable
OK
• connector pins and sockets on Hall-generator
lti
de
CAUTION
When worl<ing on vehicles with Hall ignition
•
system, observe following precautions to c:o
prevent injury or damage to ignition system: eq
- do not touch or remove high tension wire ItI
when running or cranking engine
-ap
- disconnect ignition wires onfy when ignition
is switched off
- test instruments should be connected/
disconnected only when ignilion is switched
off

- do not connect any condenser to terminal 1

- do not tow cars without disconnecting plugs
on ignition control unit
- do not crank engine unitl high tension wire
of distributor cap (terminal 4) is connected
to ground with jumper wire (example:
compression check, etc.)
- do not leave battery connected when
electric welding on car
- do not substitute rotor of ignition distributor
with one of different type
- when installing suppressor, use only 1000
ohms for high t~nsion wires and 1000 to
5000 ohms for sparl< plug connectors
- pull rubber boot from control unit connector (with
connector connected) as shown
-connect + (plus) wire of voltmeter (VAG 1315A or lhlc
equivalent) to terminal 6 and - (minus) wire to IP
terminal 3
- turn Ignition On
- tum engine over slowly by hand (in running
direction) and watch tester reading
Note
Position of Hall-generator aperture rotor (in
distributor) changes when engine Is turning.

• spec = 0 to 0.7 volt

- do not wash engine when It is running
- do not use battery booster longer than 1
minute nor exceed 16.5 volts with booster
Note
Because internal resistance of tester and ambient
temperature can influence readings , test should be
done with V.A.G. 1315A tester, SUN VAT-40 or
equivalent.
Specified values given are valid for ambient
temperatures from 0 to 40°C (32 to 104°F).
primary current switch OFF - position
of aperture rotor open to Hall generator
1.8 volt up to battery voltage
primary current switched ON -
position o f aperature rotor-closed to
Hall generator
• it not, Hall generator is defective; replace
Note
Metal shavings or other debris between the ignition
control unit and head sink can cause stress which
may damage internal circuits of the control unit:
- when replacing ignition control unit, thoroughly
clean heat sink before assembly.

28.1 5 Hall generator

Air-cooled AFC II California
 Ignition System 28
Idle stabilizer, checking

• if engine is difficult to start, does not start,

of or engine misfin!s/cuts out, proceed as follows:
pter - disconnect both wire plugs from idle stabilizer
and connect them together
• if engine starting troubles are eliminated:
- check contact pins and sockets of both idle
stabilizer connectors. for correct position or
damage
• if OK: idle stabilizer unit must be defective;
replace
- connect V.A.G. 1315A tester, SUN VAT -40 or
equivalent according to manufacturer's in-
structions
- apply parking brake

WARNING
No one should be allowed to stand in front of
vehicle during this test. Vehicle's wheels
must be blocked
with

SA or Vehicles with manual transmission

to - apply foot brake
- start and accelerate engine( i.e. to 2500-3000 rpm)
briefly
- let engine idle and notice ignition timing
- select 4th gear and slowly engage clutch
• as engine speed drops below 940 rpm
ignition timing must move in direction
"advance"
- if not, replace idle stabilizer

iition with automatic transmission

~tor
- apply foot brake
- start and allow engine to warm up until idle
to speed drops below 1000 rpm
- switch ON all electrical consumers including
air conditioner (if equipped)
- let engine idle and notice ignition timing
- place selector lever in a speed range
• as engine speed drops below 940 rpm,
ion ignition timing must move in direction
::h "advance"
- if not, replace idle stabilizer
ly

Air-cooled AFC II California Idle stabilizer 28.16

28 Ignition System

Hall Ignition System Troubleshooting Note

In isolated cases only, there may be trouble in
Hall ignition system which cannot be traced
with this troubleshooting program.
Engine does not start or does not run properly
In such cases, try replacing Hall control unit
• starter speed normal
or Hall generator
• fuel system OK
CAUTION

G) Trouble in ignition system When working on vehicles with Hall ignition

system, observe following precautions to
pull center (high tension) cable with
prevent injuiy or damage to ignition system:
suppressor out of ignition distributor
- do not touch or remove high tension wire
cap and secure it so that it is 5 to 10 mm when running or cranking engine
(0.2 to 0.4 in.) from "ground"
-disconnect ignition wires only when
• at each end of cable there must be a ignition is switched off
1000-ohm suppressor (applies also
-test instruments should be connected/
when using a spark gap tester)
disconnected only when ignition is
- start engine switched off

Sparks jump to Sparks do not jump

- do not connect any condenser to terminal 1
"ground" to "ground"
-do not tow cars without disconnecting
plugs on ignition control unit

gotobox
+.® ---'do not crank engine until high tension
wire of distributor cap (terminal 4) is
connected to ground with jumper wire
(example: compression check, etc.)
- do not leave battery connected when
(2) Ignition coil damaged externally
electric welding on car
-do not substitute rotor of ignition
- check coil to see if sealing compound
distributor with one of different type
has oozed out
-when installing suppressor, use only
check connections for dirt, cracks and 1000 ohms for high tension wires and
sign of burning
1000 to 5000 ohms for spark plug
connectors
Coil OK Coil not OK
-do not wash engine when it is running
- do not use battery booster longer than
1
1 minute nor exceed 16.5 volts with
gotobox @ booster

replace ignition coil if

sealing compound has oozed
out
- go to box (i)

28.17 Hall Ignition system-troubleshooting

Air-cooled AFC II California
 Ignition System 2
in

@ Spark plugs, spark plug connectors, ignition cables,

distributor cap, rotor arm defective

I ~
~
check condition of parts
check resistance in rotor arm, spark plug
conr1ectors and suppressors with ohmmeter
• specs: see Fig. 1, Fig. 2 end Fig. 3

n:
1re Parts OK Parts not OK

Fig. 1 Rotor arm: 1000 ± 400 ohms

r
- replace defective parts

1al 1

,, -
I® Ignition timing incorrectly set or centrifugal/
vacuum spark control defective

I - check ignition timing

Fig. 2 Spark pluliJ connec:ton:
• 1000 ± 400 ohms (not suppressed) or
Ignition timing OK Ignition timing not OK • 5000 ± 1000 ohms (suppressed)

No trouble in ignition
system
-
r

adjust ignition timing

or repair ignition
-
distributor

Fig. 3 Suppressor: 1000 ± 400 ohms

.__A_i_r-_c_o_o_le_d_A_F_c____.l _C_al_if_o_r_
L--1 n_ia-----.1 Hall Ignition system · troubleshooting 28.18
28 Ignition System

@ Idle stab il izer defective (delete this step if idle

stabilizer is not installed)

remove idle stabilizer plugs and connect

together (see Fig. 4 arrow) - - - - - - - - - + - - - t l . ,
start engine

Trouble still exists Trouble no longer exists

Fig. 4 Idle stabilizer

check contacts and sleeves in
- connect plugs together (arrow)
plugs fo r correct location
and damage
• if OK, install new idle
stabilizer

@ Voltage supply for Hall control unit/ Hall generator

not OK

disconnec t Hall generator plug from ign ition

d istributor
co nnect voltmeter on outer contacts of plug
(see Fig. 5}--------------+----.~
turn ignition ON
read voltage
• should be at least 5 V
turn ignit ion OFF

Voltage OK Voltage not OK

Fig. 5 Hall generator plug on ignition distributor

(disconnected)

connect voltmeter (watch plus and minus

connection)
go to box Q) reconnect Hall generator p
and conti nue troubleshooting
at box @

28.19 Hall Ignition system-~

troubleshooting .
I
Air-cooled AFC California
I
 Ignition System 2~

(f) Hall control unit checking

- connect voltmeter to coil terminals 1 and 15

(see Fig. 6) -------------If---~
- turn ignition ON
- read voltage.
• should be 2 V and fall to 0 V
after 1-2 seconds
- turn ignition OFF; leave 11oltmeter connected

Measured values not OK Measured values OK

Fig. 6 lgniti{)n coil

- connect voltmeter to terminals 1 and 15

- replace Hall control unit

@ Hall control unit checking

- insert metal pin in center contact of Hall

generator plug
- turn ignition ON
-ground metal pin briefly (Fig. 7)-----+----....,~
- read voltage
• should increase briefly to at least 2 V
- turn ignition OFF; reconnect Hall generator
plug to ignition distributor

Hall control unit OK Hall control unit not 0 K

Fig. 7 Hall generator plug

ground center contact with metal pin

briefly (as shown)
utor

go to box ® check for open circuit in

minus wiring using current flow
diagram
• if OK,
- replace Hall control unit

Air-cooled AFC II California Hall Ignition system- troubleshooting 28.20

28 Ignition System

® Hall generator defective

- disconnect center (high tension) cable from

distributor and "ground" it
- pull boot on Hall generator plug back and
connect voltmeter to terminals 3 and 6 (plug
remains in position) see Fig. 8 ..
- turn ignition ON
- turn engine over by hand
- read voltage
• should alternate between 0 and at least 2 V
- turn ignition OFF

Fig, 8 Hall generator plug

Hall generator OK Hall generator not OK

connect voltmeter to terminals

3 and 6

- replace ignition coil - replace Hall generator

(see page 7) or
- replace ignition
distributor

@ No voltage at Hall control unit

disconnect plug from Hall control unit

connect voltmeter to terminals 2 and 4 in plug
(Fig. 9) -------------+-----1•
turn ignition ON
• voltage reading should be approx. battery
voltage
turn ignition off

Hall control unit OK Hall control unit not OK

Fig. 9 Hall control unit plug

check for open circuit in
wiring from battery to connect voltmeter to termi nals 2 and 4
go to box @ Hall co ntrol unit using in p lug
current flow diagram

28 21•
Hall Ignition system-~
troubleshooting
I
Air-cooled AFC California
I
 Ignition System 2S
@ Open circuit in wiring from Hall control unit to
Hall generator

- check for open circuit in wiring from Hall

control unit via idle stabilizer connection
to Hall generator

Wiring OK Wiring not OK

- replace Hall control - eliminate open circuit

unit in wiring

Air-cooled AFC California I·Hall Ignition system • troubleshooting·

,___ _ _ _,;.___....J
28 22
• .
28 Ignition System

Hall generator, replacing

Circlip·)~
Note
Wh en replacing Hall generator, use repair kit which Pin")-----
c
consists o f fol lowing pa rts :
• Hall g~nerator
Aperture rotor - - - - --
• circlips wmoving/installing Fig.
• washers
• pin Waved spring W<lsher(s) - -

-<oo
Washer(s) •) ==-----
number of washers:
Circlip(§) ·)

adjust wit h washers so that

( - )

gencrut or turns free ly

without play

Hall generator •) _ _ / t;
grease bearing surfaces
lightly

Ignition distributor - - - -1

[ 28-337!

•) parts in repair kit

Fig. 1 Aperture rotor, removing/ iJ1stalling

to avoid bending rotor when prying off,

insert screwdrivers thro ugh two opposing
slots until they contact circlip
check that aperture rotor turns freely
after installation by turning distributor
shaft
• if a per ture ro to r is bent, it must be
replaced
• aperture rotor identification:
4 gaps;
marking: 046

Hall Ignition s y s t e m - . - - - - - - - - - - - . - - - - - - - ,
28.23 troubleshooting j Air-cooled AFcjcalifornia j
 Ignition System 28
Quick glow system-troubleshooting

Test condition: battery OK

Check voltage supply

-connect test light between No.4 cylinder

glow plug and ground----------t-~
-disconnect wire from engine temperature
sensor
-turn ignition switch ON (max. 15 seconds)
• test light must light up
-re-connect wire to temperature sensor

Test light does not Test light lights up

light up

Check current supply to glow plugs

with tester such as with test light

SUN VAT-40, SUN
SX-224 or equivalent

-connect power supply for tester

-place glow plug lead in test clamp
-press button for current test
-disconnect wire frcm engine temperature
sensor
-turn ignition switch ON (max. 15 sec)

Current draw Current draw

approx. 48 A 0 or below 48 A

Glow plugs OK; Note

trouble is in fuel
Current draw should stabilize at about 12
system
amps per glow plug. If total current is:
36 A-one glow plug bad
24 A-two glow plugs bad
12 A-three glow plugs bad
0 A-ail glow plugs bad
These values can only be obtained w ith
battery voltage above 11.5 volts

Diesel
Quick glow system - troubleshooting 28.24
28 Ignition System

j from page 28.24 j

t
Checking glow plugs with test light

-remove wire and bus bar from plugs

-connect test light to bat1ery positive ( +)
terminal and touch test light probe to each
glow plug in turn
• light lights up; glow plug Is OK
• light does not light up; glow plug Is
inoperative, replace plug (tightening torque
30 Nm - 22 ft lb)

,,
Note
If glow plug tip (arrow) is worn away, in·
jector spray pattern may not be correct---+---;:.-
-remove corresponding injector
-check spray pattern, opening pressure
and leakage of injector, using tester
US 1111; see also pages 23.9 and 23.10
-check that spray pattern is compact and
well atomized when pump lever is
operated with short rapid strokes (4-6
strokes/sec)
• if NO
-clean Injector and recheck spray pattern
etc.
• if still NO
-install new injector and new glow plug

28.25 Quick glow system-troubleshooting

Diesel
 Ignition System ~

I from page 28.24 I

t
Glow plug fuse defective

-check glow plug fuse with test light

Test light lights up Test light does not

• fuse OK light up
• fuse not OK

'• I
-replace fuse

~0
End
r 87
11f
t
No voltage at terminal 30 on glow plug
relay

- connect test light to terminal 30 on relay

86~ © ~85
~

Test light lights up Test light does not

light up
ru ~30 DL
l9o4-188l
I

'
'It

Glow plug relay not working Possible causes:

• break in wire from terminal 30 to battery
l -connect test light to terminal 86 on relay • wire defective, replace
-turn ignition switch ON

Test light lights up Test light does not

light up

-repair connection
-repair con nee! ion
from replay terminal
85 to ground; or
-replace relay
t
Note
When engine is difficult to start, check
operation of automatic delay glow period
from fuseS 12 to
and preheat period during starting
relay terminal 86
• when temperature controlled preheat
period has ended (glow plug light out)

I ..- there should still be vo ltage at glow

plugs fo r additional 6 to 7 seconds. Do
not operate starter for this test. If no
voltage is present at glow plugs, replace
relay
• whe n starter is engaged there should be
voltage at glow plugs. If no voltage,
repair wire from glow plug relay term inal
50 to starter or replace glow plug re lay
• check Diesel Current Flo w Diagram

Diesel
Quick glow system - troubleshooting 28.2
28 Ignition System

Glow plug light-troubleshooting

CAUTION
Glow plug light defective
To. avoid glow plug damage from excessive
Check glow plug light as follows: voltage, DO NOT operate. glow plug system
-disconnect glow plug relay while charging battery with external battery
-ground terminal L in relay socket charger. ·
-turn ignition switch ON If using jumper cables to start Diesel
equipped vehicles, external power source
Glow plug light Glow plug light does must not exceed vehicle system voltage
lights up not light up (max. 13.5 V)

-replace glow plug light or check wire from

relay ter~inal L to glow plug light

Glow plug relay or engine temperature sensor The torque specification for all glow plugs Is:
defective • 30 Nm (22 ft lb)

Check operation of relay-see also Note on This torque must NOT be exceeded because
page 28.26 increasing the torque beyond the specification will
-disconnect glow plug wire cause closing of the ring gap, which can lead to
-disconnect wire from engine. temperature premature failure of the glow plug.
sensor
-turn ignition switch ON
• glow plug light should light up for 25-30
seconds
-ground disconnected wire from engine
temperature sensor
• glow plug light must go out

Glow plug light Glow plug light does

lights up not light up

-replace engine -replace glow plug

temperature sensor relay
123-151 I
1 - Ring gap OK (arrow) approximately 0.5mm
(0.02 in.)

2 - Ring gap closed (arrow) after being over-torqued

28.27 Glow plug light-troubleshooting

Diesel
 ~
Ignition System ~

,....:.,:.- - - Hall control unit

Idle stabilizer control unit -------~~ checking page 28.36
before adjusttng idle,
disconnect connectors
and plug together
checkmg page 28,38

Ignition coli Suppreuor connector&

checking Fig. 5 and Fig. 6 checking Fig. 4

Connector on dl•trlbutor

'"will
d to

Distributor cep - - - - - - - - -
check for cracks and
corroded contacts.
Clean before Installing

Carbon bru&h and spring _ _ _ _ _ _ _ _.,.

)
c heck for wear and free movement
Ignition wire ------111
checking Fig . 2

Spark plug connector _ _......,

checking Fig. 3

Ignition/ distributor and settings chart

page 28.30
·torqued
Ignition liming
adJusting page 28.33
Spertt plug ---~
20 Nm (14 It lb)
types page 28.30

Water-cooled II Digijet Ignition System 28.21

28 Ignition System

WARNING
Rotor - - - - - - - - - - - - - iw Do not touch or remove ignition coi l wire
checking Fig, 1 when running or cranking engine.
Only disconnect wires of ignition system or
connect/disconnect test instruments when
ignition is turned OFF

Trigger wheel
removing /installing page 28.38

Waved shim Pin

. , - - - - Shims
adjust number of shims until
Hall generator free of play
and easy to turn
Retaining button _ _ _ _ _ .
~~!-------- Hall generator
lightly lubricate bearing
surfaces
checking page 28.37
Magnet------

Vacuum unit
Dlstrlbu1or --------1•
installing Fig, 9

Seal----------~<:::>
always replace

Thrust washers -:-:-::.-z:::=:=:::::=:=;:;;:;====-g

guide Into posi tion wi th screwdriver

28.29 Ignition Distributor

with Hall generator Water-cooled Digijet
 Ignition System 2
r Engine code letters DH . I

Distributor (Part No.) 025 905 205 D

or i
'" I lgnllion timing 5± 1" ATDC

I Timing mark location: crankshaft pulley

~
~ I

Idle speed 850±50 rpm

[ Vacuum hoses connected

Idle stabilizer control unit electrical plugs disconnected from unit

and connected together

Centrifugal advance (crankshaft degrees)

start 1050-1150 rpm

16-20° at 2400 rpm

end 21-25" at 3800 rpm

Vacuum advance
start 190-230 mbar (14.0-17.0 em Hg)

end 360 mbar (27.0 em Hg)

12-16.

Vacuum retard
start 100-220 mbar (7.5-16.5 em Hg)

260-360 mbar (19.5-27.0 em Hg)

end
9-11°

Sf)ark pt ugs Bosch W7CO

Beru 14 L-7 C
Champion N288

Spark plug gap 0. 7 + 0.1 mm (0.028 + 0.004 in.)

Spark plug tiglltening torque 20 Nm {14 It lb)

Rring order 1-4-3-2

Water-cooled ll Digijet Ignition distributor and settings 28.3C

28 Ignition System

Ignition cable connectors

(new style)

To assure tight connections, ignition cables now

have new style (M4) connectors, as illustrated
below.

New style Old style

Connections at distributor cap, ignition coil,

interference suppressors and spark plugs ,have all
been changed to new style.

Note
Components with new style (M4) connectors are
not interchangeable with old style. If replacement is
required, install complete set with all connectors of
same style.

28.30a Ignition cable connectors

(new style)
Water-cooled J I Digljet
 Ignition System 2~

CAUTION

When working on vehicles with Hall ignition

system, observe following precautions to
prevent injury or damage to ignition system:
-do not touch or remove high tension wire
when running or cranking eng!ne
- disconnect ignition wires only when
ignition is switched off
- test instruments should be connected/
disconnected only when ignition Is
switched off
,,~-101
- do not connect any condenser to terminal 1
Fig. 2 Ignition wires and connectors, checking
- do not tow cars without disconnecting
plugs on ignition contfol unit -check wire 2 between Ignition coil and
-do not crank engine until high tension distributor (Including connectors 8)
wire of distributor cap (terminal 4) is • resistance should be= 2000 ± 800 ohms
connected to ground with jumper wire -check wires 2 between dlstrl butoT and
(example: compression check, etc.) spark plugs (including connectors
land 1)
-do not leave battery connected when
• resistance should be =6000 ± 1400 ohms
ele<::tric welding on car
- if values are not as specified, check
- do not substitute rotor of ignition wires and connectora Individually
distributor with one of different type • resistance of wi res (without
-when Installing suppressor, use only r.onnectors) must be= 0 ohm
1000 ohms for high tension wires and
1000 to 5000 ohms for spark plug
connectors

-do not wash engine when it is running

- do not use baHery booster longer than
1 minute nor exceed 16.5 volts with
booster

Fig. 3 Spark plug connectors, checking

- check connectors resistance
• specified value = 5000:!: 1000 ohms

Fig. 1 Rotor, checking

- check that resistance is
1000 ±400 ohms

Note
Rotor must be marked with A 1 for
Hall generator equipped cars

II Ignition system cautions 3l

Water-cooled Digijet Rotor
Ignition wires/Connectors 28 •
28 Ignition System

Note
A rough idle or misfire during partial load could be
caused by ignition sparks jumping from the plug wire
connector to the noise suppression sh!eld, or the
cylinder head.
- remove and inspect the plug connector for while
spots or bum marks
- on those vehicles equipped with a suppressor
shield on the distributor cap, it is necessary to
remove the shield and check for white spots or
bum marks on the distributor cap
If white spots or burn marks are present, replace the
damaged components. Fig. 6 Ignition coli secondary resistance,
checking

- connect ohmmeter between terminal ·

( -) and terminal 4
• resistance should be = 2400 - 35C
ohms
If NO, replace ignition coil

Note
If resistance readings are correct, but no high
voltage occurs at ignition coil, check Hall gener<
and Hall control unit. If necessary. replace ignili1
coil.

Ag. 4 Suppressor connectors, checking

-check resistance of supressor connectors
• specified value "" 1000±400 ohms

Fig. 7 Distributor drive shaft, removing

Fig. 5 Ignition coli primary resistance, checking
-use extractor with diameter 14.8-181
Note
(0.583-Q.728 ln.)
II traces of leakage from ignition coil are visible
check HALL control unit and replace ignition coil

- disconnect all wires from coil terminals

- connect ohmmeter between terminal 1
( - ) and terminal 15 ( + )
• resistance should be = 0.420 - 0. 760
ohms
-check secondary resistance (Fig. 6)

I
Suppressor connectors

28.32 Ignition coli

Distributor drive shaft
Digljet j Water-cooled
 Ignition System 2~

Ignition timing, adjusting

Work sequence

CAUTION
Ignition must be switched OFF before
connecting tester

Fig. 8 Distributor drive shaft, Installing

-set crankshaft to TDC on No. 1
cylinder
00 -insert drive shaft so that off-set slot in
top of drive shaft is pointing toward
tapped hole (arrow)
• smaller segment points to water
pump

Itor
~n

-connect tester according to manufacturer's

instructions
-connect + (plus) cable to alternator or
junction box

Fig. 9 Distributor, Installing

-set crankshaft to TDC on cyl inder No. 1
- turn rotor until it is pointing to No. 1
cylinder mark on edge of housing
- install distributor
- clean distributor cap, check for
cracks, signs of tracki ng and rotor
t ightness on shaft
mm
- adjust ignition timing

-disconnect idle stabilizer plugs from control

unit (squeeze plugs to release-upper arrows)
-connect plugs together (lower arrows)
- adjust idle speed to 850 :t: 50 rpm

• go t o n ext flilJe

Water-cooled Distributor drive shaft

Ignition liming
28.33
28 Ignition System
·- adjusting ignition timing with TOC sensor: - increase engine speed slowly.
centrifugal advance is indicated by an Increase
• ignition timing is indicated directly on tester.
in the number of degrees .
-specification"' 5° ATDC
- increase engine speed to next test speed.
- read advance angle on tester .
-adjusting ignitior: timing with timing light:
- shine timing light on timing mark . Note
• mark on pulley must align with crankcase
To determine centrifugal advance, subtract basic
half parting line.
advance angle from last advance angle measured.

Example
Ignition distributor, checking centrifugal last advance angle measured
advance with TOC sensor (- ) minus basic advance angle

(= ) eentfifugal advance

CAUTION - compare centrifugal advance angle. to speci fied

value on page 28.30.
Ignition must be switched OFF before
- repeat test at other tE'~t speecis.
connecting tester.
- reconnect vacuum hoses when completed testing.
- adjust idle speed. See Repair Group 24.

Ignition distributor, checking centrifugal

advance with timing light
-connect tester according to m11nufacturer's
Instructions.
- pull both hoses off distributor vacuum unit.
- d isconnect plugs from idle stabilizer and connP.Ct
together.
-start enAine and adjust idle speed to 900 RPM.
- shine t iming light on t iming mark and note indicate
indicated angle (basic angle~

Nota
Start of centrifugal advance is shown by r 10vement
o f notch while increasing RPM.
- increase engine speed slowly to 160(; RPM.
- bring back notch to original setting by turning
knob o n tester. Read off advance valcc.

Note
To dete rmine centrifugal advance, subtract basic
- connect tester according to manufacturer's advance angle from last advance angle measured.
instructions. Example
- connect ~usit ive lead to alternator or c onnection
last advance angle measured
box.
(- ) minus basic advance angle
- pull both hoses off distributor vacuum un it .

- disco nnect plugs f rom idle stabilizer and connect

together. - repeat check at other test speeds.
- start engine and adjust idle speed to 900 RPM. - reconnect vacuum hose when test completed.
- note basic advance angle shown on tester. - adjust idle speed. See Repair Group 24.

28.34 Distributor centrifugal advance

Water-cooled II Digijet

Vacuum advance unit, checking for
leaks
Work sequ~nee
-connect vacuum tester VAG 1368 or equivalent
according to manufacturer's instructions.
- run eng ine at approx. 2500 RPM and check that
vacuum at throttle valve housing is reaching
vacuum unit.
If NO, vacuum connection on throttle valve housing
may be blocked.
- increase engine speed until vacuum tester
indicates higher reading than 360 mbar (270mm
Hg).
-switch vacuum tester so It holds vacuum on
side connected to vacuum unit.
- turn engine OFF.
- vacuum reading on tester must not drop more
than 10% within 1 minute, otherwise vacuum
unit or hose is defective.
Vacuum advance, checking
-connect VAG 1368 tester or equivalent accor ding
to manufacturer 's instructions.
-connect :vact~um tester between thr·ottle valve
housing and vacuum advance unit connection.
-set vacuum lester to allow vacuum to pass 1hrough.
-pull off hose 'f rom vacuum retard unit. '.
. disconnect plugs from Idle stabi lizer control unit
and connec t together.
- start engine and adjust idle speed to 900 RPM.
- checking with TDC sensor:
- note advance angle on tester {basic advance angle).
Water-cooled
Ignition System 28
- checkinq with timing light:
-shine timing light on ignition timing scale and
note indicated angle {basic angle).
- increase engine speed un ti l reading on vacuum
tester is higher than 360 mbar {270 mm Hg).
- switch vacuum tester so that it holds vacuum on
side connecte<'l to vacuum unit.
- leave engine running at idle: 900 RPM
- reduce vacuum on vacuum test.er to 360 mbar
(270 mm Hg) or 190-230 mbar (140-170 mm Ha) .
- note ad-..;ance angles.
-determine vacuum advance by subtracting 'basic
advance angle from measured advance angle .
Example
last advance angle measured
( - ) minus basic advance angle
vacuum advance
-compare vacuum adva~ce angles with specified
values on page 28.30.
-readjust idle speed. See Repair Gr oup 24.
Vacuum retard angle, checking
-connect vacuum tester VAG 1368 or equivalent
aacording to. manufacturer's instructions .
-disconnect plugs from idte ftabilizer control uni t
and connect together.
-· start engine.
- pull off hose from vacuum advance unit.
-·check ignition timing; i f necessary adj•Jst to
5° ATOC.
- pu ll off hose from vacuum retard unit.
-check with TDC sensor:
-add 5° to indicated retard angle.
-compare with specifications on chart for retard
end (see page 28.30).
- check ing with timing light:
- shine timing I ight on t imi ng mark again and bring
mark back to original setting by turning knob on
timing advance tester .
- read off retard angle and compare witr
specifications on chart for retard end. {See page
28.30.)
- reconnect vacuum hose to vacuum unit.
- reconnect plugs to idle stabi lizer con trol unit.
II Digijet
Vacuum unit
Vacuum a(jvance
Vacuum retard
28..35
28 Ignition System

Hall control unit, checking

Requirement
• ignition coil OK

-connect multimeter with + (plus) to term

and with - (minus) to terminal1 of lgnlti
- turn Ignition ON
• 2 volts (min.) for about 1-2 seconds ar
drops to 0 volts
If NO
- disconned idle stabilizer plugs from control unit - replace Hall control unit and ignition coil
(squeeze plugs to release - upper arrows)
- connect plugs togelher (lower arrows)

- remove harness connector from Hall control unit - touch center wife of connector on dist.rib
-connect multimeter US 1119 with + (plus) to briefly to ground
terminal 4 and with (minus) to terminal 2 in • indicated voltage must increase briefly
connector volts (minimum)
- turn ignition ON
• approximately battery voltage If NO
-check for wire break in center wire and r
If NO necessary
- check for wire breaks using wiring diagram and
repair as necessary If wire OK
- turn ignition OFF - replace Hall control unit
- reconnect Hall control unit harness connector - turn ignition OFF
- disconned Hall generator harness connector from more
ignition distributor

28 •36 Hall control unit, checking

Water~cooled Digijet
 Ignition System 28
Hall generator, checking
Requirements
• disconnect both wire plugs from idle stabilizer
and connect them together
• Hall control unit OK
• ignition coil OK
• wiring between Hall control unit and ignition coil
OK
• connector pins and sockets on Hall-generator,
distributor, and Hall control unit OK
~] Specified values given are valid for ambient
] Note temperatures from 0 to 4CY'C (32 to 104.F).

Two different types of Hall controi units ~an be

installed. CAUTION
- connect Multimeter as follows: Switch multimeter to voltage range before
Fairchild, Bosch and Siemens - Hall control connecting test leads.
unit (Build #33)
-connection A to terminal 15 ( +) of ignition coil - disconnect center coil wire from terminal 4 of
and other connection to terminal 7 distributor and connect to ground, using jumper
wire
Fairchild and Telefunken (AEG) - Hall control
unit (Build #35)
-connection A to ground and other connection to
terminal 7
• multimeter must show approximately battery
voltage
checking procedure regardless of type:
- touch center wire of connector on distributor
briefly to ground (see illustr. 28-335)
• indicated voltage must drop briefly below 3
volts

1!2s-311 1.
- pull rubber boot from control unit connector (with
connector connected) as shown
- connect + (plus) wire of multimeter to te rminal 6
and - (minus) wire to terminal 3
iS -turn ignition ON
- turn engine over slowly by hand (in running
direction) and watch tester reading
• voltage must fluctuate between 0 and 2 volts
- connect multi meter to outer terminals of Hall minimum
generator connector If NO
- tum ignition ON - replace Hall generator.
• spec. = 5 volts (min.)
Note
Note
Metal shavings or other debris between the ignition
If readings are within specifications, but defect still control unit and heat sink can cause stress which
exists, replace Hall control unit or check for wire may damage internal circuits of the control unit:
breaks between Hall generator connector and Hall - when replacing ignition control unit, tho roughly
control unit: if necessary. repair. clean heat sink before assembly

Water-cooled I I Digijet Hall generator 28.37

28 Ignition System

Idle stabilizer, checking Trigger wheel, removinglinstallin

Work sequence

Note
If engine is difficult to start, does not start, or
engine misfires/stalls, proceed as follows:

-disconnect both wire plugs from Idle stabilizer

- check contact pins and sockets of both idle
stab.i llzer connectors for correct position or
damage

- connect both plugs together

- start engine
• If starting troubles are still experienced, idle
stabilizer control unit i s not defective
• if engine starting troubles are eliminated,
but troubles start again after reconnect ing
plugs to Idle stabilizer unit, Idle stabilizer
unit must be defective; replace
-connect VW 1367 tester or equivalent according
to manufacturer's instructions
-apply par1<ing brake
- remove circlip
- to avoid bending trigger wheel when p
off, Insert screwdrivers through two 0 1
slots until they contact circlip
- chec4< that trigger wheel turns freely a
installation by turning distributor shaf
• if trigger wheel is bent, It must be re

WARNING
No one should be allowed to stand in front ot
vehicle during this test. Vehicle's wheels
must be blocked

- apply foot brake

-start and accelerate engi ne (I.e. to
2500-3000 rpm) briefly
-let engine Idle and note Ignition timing
-select 4th gear and slowly engage clutch
• as engine speed drops be\ow 940 rpm
ignition timing must move in "advance"
direction
- i f not, replace idle stabilizer control unit

28.38 Idle stabilizer control unit

Trigger wheel
Water~cooled II Digijet
 Ignition System 2~
Ignition and injection system,
repairing Control unit
- for injection and
ignition system
Engine code: MV -installation location:
under rear seat bench or
- note safety precautions - page 28.31
in luggage compartment
- distributor data, spark plugs - page 28.41
-ignition timing, adjusting - page 28.42
-electrical testing of ignition and injection system-
Group 24 Connector
....:... connector must be
connected or disconnected
with ignition OFF
In case of replacement; - to remove, press spring
coils with gray labels should upward
be replaced wHh green
- primary resistance 0.5-0.Bn
(between terminals 1 and 15)
- secondary resistance 2.4·3.5 k!l
(between terminals 4 and 15)
ng
ISing Terminal 1 (-)

lCed

Ignition wire
- check for continuity

Ground wire

Spark plug connector

-4-6 k!l

J
~··

Connector Distributor cap

- check for cracks and
evidence of surface
leakage current
Carbon brush end spring - check for wear on
- check for wear, damage, contacts
and freedom of movement - clean before re-installing

Dlglfant Ignition and Injection system,

repairing
28 3 •
~
~
28 Ignition Syst~m

Ignition distributor

Dust cover

Distributor shaft

Screw

Plastic washer

Hall sender
-checking, page 28.43
- to·replace, remove
distributor shaft

Distributor - - -.....
- installing, page 28.44

Spring

Bracket
~Jir~butor drtve anatr
- removing and lnatallln<
page 28.44

Thrust washers
- Install and position
using screwdriver

Clutch
- installation location:
large segment points
toward notch for rotor
Retaining spring
In distributor shaft .;_replace

28.40 lgnHion distributor

Dlglfant
 Ignition m 2~
Introduction October 1985
Engine code MV
Part no.: Ignition distributor 025 905 205M

unit*** .
Digifant control 025 906 0220 old
025 906 022/022A new
Ignition timing Checking value 3" - 7" before TDC
Adjusting value 5• ± 1" before TDC
Timing mark location
'

::;v
'
\~ ~~
@~) 128-3901
RPM• "~ 2000.2500

~)
Ignition adjustment**
-- timing map --
RPM Approx. 3000
Degrees 35 ± 5"
RPM limit Switch-off RPM of RPM 5600
digifant control unit

Firing order CYL 1-4-3-2

ing, Spark plugs Bosch W7CCO

(tightening Beru 14L-7CU, 14L-7C
torque: 20 Nm (14ft lb) Champion N288
Spark plug gap mm (in) ().7 ± .1 mm (0.028 ± 0.003 in)

•) Engine oil temperature so· c.

(176"F) connector
of temperature sensor II disconnected with
engine running.
••) Engine oil temperature 80"C, connector of
temperature sensor II connected.
•••) When replacing control unit always replace old
control unit with newer version.
n

CAUTION
Part numbers are for reference only. Always
check with your parts department for latest part
information.

20 Digifant
Ignition settings 28•J.
28 Ignition System
Ignition timing, checking If NO
- check electrical connections for temperature
Requirement sensor II, air flow sensor and digifant control unit
according to wiring diagrams
Engine oil temp. minimum 80° C (176° F)
Ignition timing, adjusting
Requirement
Engine oil temp. minimum 80° C (176° F)
- connect test equipment for ignition timing and rpm
(see Fig. 1)

Note
Use adaptor VW 1473 for connecting tester VW 1367
to terminal 1 of ignition coil.
- start engine and allow to idle
-disconnect temperature sensor II (see Fig. 2)
- check ignition timing at 2000.2500 rpm correct
if necessary

Fig. 1 Connecting test equlpme~ Adjustment with TDC marker

- connect test equipment for ignition timing
Ignition timing Is ~ed directly on tester.
and rpm as shown in 28-642 ·
specifications: (
WARNING
• checking ~alue 3° • r BTDC
• adjusting ~lue
Ignition must be. switcbed off when connecting \
ignition timing tester and rpm display. Adjustment tvith timing light
\

- start engine and allow to idle Notch on V-belt pulley must match separating line
on crankcase
- correct Idle setting if necessary

Fig. 2 Temperature sensor II

- disconnect temperature sensor II
- raise engine speed to 2000·2500 rpm
- record timing value displayed on tester
- reconnect temperature sensor II
- raise engine speed to 3000 rpm
-read timing on tester, subtract
recorded value from this reading
• calculated value must be 35° ± 5°

28.42 Ignition timing,

checking 1adjusting
Dlgifant
 Ignition System 2
Hall sender, checking
Requirement .
Electrical checks (wiring and component checks)
OK
Voltage supply, checking

167

-connect voltage tester VS 1115 to center and

o\,lter contacts offlall sender connector
(if"f.{~essary, usejumper wire)

- o~rafiil starter and check signal from Hall sender

• if LEQ flickers, Hail sender is OK
If NO
- replace Hall sender
I
-disconnect Hall sender (di~JYand connect
multimeter US 1119 to outer terminals of Hall
sender connector
- switch ignition ON
• specified value: minimum 10 volts
If NO
- replace eontrol unit
-switch ignition OFF
Function, checking
- slip back rubber boot from Hall sender. connector
-ground coil wire (use adaptorifllecessary)

22 Digifant
'-------'·
I· Hall senper•
checking 28.4
28 Ignition System

Checking ignition switching function Distributor drive shaft; removing and

from control unit Installing
Requirements
Ignition coil OK
Electrical checks (wiring and component checks)
OK
See Group 24

- set crankshaft to cylinder 1 TDC

-remove (or install) using 14.5-18.5 mm
(0.57-0.73 in) diameter, extractor i.e. Kukko 21i2
- insert shaft as shown in position A
- push and twist until shaft seats
• should result in position B

- connect digital multimeter US 1119 between Note

terminal1 (-) and terminal15 (+ ) of ignition coil The small segment points toward coolant pump.
-disconnect Hall sender (on distributor)
- switch ignition ON
Distributor, installing

128-6301

- hold renter wire of connector from distributor to

-set crankshaft to timing notch (cylinder 1)
ground for approx. 3 seconds
- turn rotor far enough that it points toward mark for
• displayed voltage must increase briefly to
approx. 4.5 volts cylinder 1 on distributor housing

If NO
- replace control unit

Ignition switching function

28.44 Distributor drive shaft

Distributor, installing
Digifant
 3(
1nd Clutch
Control

Index ' '

Water-Cooled Gasoline Air-Cooled

- Brake/Ciu tch fluid rese.rvoir 30.3 - Brake/Clutch fluid reservoir 30.3

-Clutch assembly 30.4
controls 30.2
diaphragm spring 30.6
disc 30.7
hydraulic system 30.2
pressure plate 30.6, 30.7
- Release shaft bushing 30.3
- Roll pin 30.3
Diesel
-Clutch assembly 30.4
controls 30.2
diaphragm spring 30.6
disc 30.7
hydraulic system 30.2
p ressure plate 30.6, 30.7
mod ification 30.6, 30.7
- Release bearing 30.7
- Re lease shaft bushing 30.3
- Roll pin 30.3

-Brake/Clutch fluid reservoir 30.3

- Clutch assemt1ty 30.5
controls 30.2
diaphragm spring 30.6
disc 30.7
hydraulic system 30.2
pressure plate 30.6, 30.7

- Release shaft bushing 30.3

- Roll pin 30.3

'k for

A-1
30.1
30 Clutch, Controls
ClaYII WARNING
clearance between push rod and
piston In clutch master cylinder Brake fluid Is polson
0.5mm (0.020 ln.) max.
~\_ I~ Installation
Rollpln
position Fig. 1
Colter pin
always replace JO•..-- Pin
lubricate with
MoSa grease

Buahlnga
remove with VW 207,
Install !lush

Note
25 Nm (18 It lb)
Filling of system is done by removir
top of dashboard and adding approv
Clutch -··•-.r-
cyllndar
brake fluid (see caution page 30.3) I<
brake/clutch fluid reservoir

Brake/clutch fluid raaervolr

filling Fig. 2

BIHdar acraw
open valve only when
Coupling bleeding hydraulic system.
Bleed system only with
pressure bleeder

/ " " - - - - - - Clutch 1I1Y1 cyllndal

before Installing, insE
rear bolt

Pivot bolt
15 Nm (11 tt lb)
secures release shalt

Guida ••~
plastic, do

15 Nm (

re
RE

Clutch
grease

Clrcllp
alway& replace Clrcll~ Release bearing
lnsertlnto clip and do not clean in solvent
attach with release only lubricate pivot surface
bearing and clip to with MoS2 grease
Bu
release shalt replacing, Fig. 5 and page

30.2 Clutch hydraulic system

Clutch controls
14-speed 091-091/1 I 5-speed 094
 Clutch, Controls 3~

VW771 \

Fig. 3 Release shall bushing, removing

'Jlovlng cover Fig. 1 Roll pin, Installation position
pproved type
0.3) to • roll pin must be engaged In groove
(arrow) on side of bracket

CAUTION
Brake fluid must not come into contact
with paint .
Brake fluid absorbs moisture from air and
must be replaced every 2 years.
Only use new unused DOT 3 or DOT 4
brake lluid accordi.n g-t<.LMOTOR VEHICLE
SAFETY STANDARD 116. Do not add or
mix DOT 5 silicone type brake fluid with
brake truid in car', as severe component
corrosion may result . Such corrosion could Fig. 4 Release shaft bushing, Installing
yllnder lead to clutch and brake system failure -drive in flush
1g, insert

aft

Ide .....,.
~lie, do not greaae

5 Nm (11 ft lb)

"ahaft
t.t wlth
1reaae

- Buahlng
' replacing l et Fig. 5 Release bearing, Installing
I Repair Group
- new release bearings on which thrust
ring is not centrally positioned to
Brake/clutch fluid reservoir, filling housing (arrow) can be installed
- grasp two recesses on back of - thrust ring automatically centers ilself
dashboard cover and pull up oo first application of clutch pedal
!vent
- fi ll with brake fluid (see above caution)
1sm1eces
until level is between " MAX" and "MIN"
nd page 30.7a - replace cover by inse rti ng front edge
first then press cover do wn firmly

A-2 Roll pin

A·3
14-speed 091-091/1 1 S·speed 094
Brake/chJtch fluid reservoir
Release shaft bushing 30.
30 Clutch, Controls
Note
Only transmission must be removed for clutch
repairs

25 Nm (18ft I b)
diaphragm sprif'lg
loosen and tighten by stages in diagonal checking fi ngers Fig. 3 • Fig. 6
sequence Note
-install hexagon bolts or socket head Spring finger length increased;
screw1 MS x 16 without spring check for comp~tihle release
washer; or bearing
- install hexagon bolts or socket head
screws M8 x 18 with spring washer
-use only bolts or screws of same length

Clutch dla
checking

'----Clutch pressure plate [

removing/ installing Fig. f
WARNING chec king Fig. 1 and Fig. 8
Friction materials suc h as brake and clutch linings or
brake pads may contain asbestos fibers .
Do not create dust by grin ding, sanding or by cleaning
with compressed air.
Avoid breathing asbestos fibers and asbestos dust.
Breathing asbestos may result in serious diseases, such
as asbestosis or cancer.
Breathing asbestos may cause severe injury and death .

30.4 Clutch assembly

Gasoline
 ~
Clutch •

Flywheel
check lor wear and tightness
ol dowel pins (essential Clutch presaure plate
lor cOfrect position ol TDC mark removing/Installing Fig. 2
on pressure plate) checking Fig. 7 and Fig 8

:h disc
:king Flo . 9

Clutch dlac ----~

centering Fig. 2
checking Fig. 9
Installation position: spring cage
laces pressure plate

25 Nm (18 h lb)
loosen and tighten by stages and In
diagonal sequence
-install hexagon bolts or socket head screws
M 8 x 16 without spring washer; or
Note
-Install hexagon bolts or socket head screws
For clutch repairs, trar.smlss ion must M 8 x 18 with spring washer
be removed -use only bolts or screws ol same length

A·4 Diesel Clutch assembly 30.5

30 Clutch

Fig. 1 Clutch pressure plate, Gasoline

removing/Installing
-attach flywheel retainer VW 215c
- mark position of pressure olate on Fig. 4 Clutch pre1sura plate, 228 mm (9 ln.) dia
flywheel (arrow)
(modification only for air-cooled vehicles
- loosen bolts diagonally
distance a between fingers:
was'"' 55mm l2 3/16 in.) dia.
is now =46mml1 13/16 in.) dia.

Fig. 2 Clutch assembly, Diesel

removing/installing
Fig. 5 Production release bearing, air-cooled
-change retainer over when removing
•contact surface diameter is 46 mm (1

Fig. 3 Clutch diaphragm spring, checking

lingers
• scores (arrows) up to depth of 0.3 mm
(0.012 in.) are OK

30.6
Clutch disc
Clutch pressure plate
Clutch diaphragm spring
!4-speed 091-091/1 l5-speed 094I
 Clutch 3(

[3o-236l
Fig. 6 Replacement release bearing, air-cooled engines
Note Fig. 8 Clutch pressure plate, checking
Release bearing with wider contact surface - check lor cracks, burn marks and wear
(arrow) is the only bearing availahle as spare • inward taper: 0.3 mm (0.012 in.) max.
part. This release beari ng will work with either
old or new type pressure plates.
Engine replacement
If exchanging engines, be sure that wider-<:ontact-
surface release bearing is used if pressure plate is
of older type [where a, Fig. 4, =55 mm
(2 3/16 in.) dia. I

CAUTION
Do not install release bearing having narrow
contact surface [46 mm (1 13/ 16 in.) dia.)
together w ith short-fingered pressure plate
[a-- 55 mm (2 3/ 16 in.) dia,)

Jines
1/ 16 in.)
Ag. 9 Clutch disc, checklngflnstalllng

- check runout: 0.5 mm (0.020 in.) max.

Fig. 7 Clutch pressure plate, checking
-check straps (black arrows) between
plate and cover for cracks and
tightness of rivets (white arrows)
• clutches with loos e or damaged
rivet s must be replaced
• measured 2.5 mm (3/32 in.) from edge
of disc
- check lining and splines for wear and
rivets for tightness
- when installing, clean corrosion from
transmission mainshaft and clutch disc
splines
- lightly lubricate clutch splines with grease
• use grease part no. G 000 100
- place transmission into gear to lock
mainshaft and temporarily install clutch
disc to check movement
• spring cage must face pressure plate
• clutch disc must slide freely on
mainshaft
- remove excess grease

Clutch release bearing 30 7

j4-speed 091·091/1 I 5-speed 094 Clutch pressure plate
Clutch disc
•
30 Clutch

Fig. 10 Release bearing, lnetaiiJng

• New release bearing on which thrust ring

is not· centraHy. positioped to.· housing
{arrow) can be installed ·
• thrust rirlg.automllttically centers· itself
on first appli¢atlon Of clutch pedat

30.7'a Ciutch relea.e bearing

 Clutch Controls 30
Note Clutch, bleeding
For repairs on release bearing and release shaft, Connect brake bleeder US 1116
remdve transmission. For repairs on toOt pedals, Operating pressure = 2-2.5 bar.
remove Instrument panel.
Leav~J~teeder valve open until brake fluid drains
without any bubbles.
Clevie
adjust until clearance between push rod
and clutch master cylinder piston equals
a maximum of 0.5 mm

. {f- · Roll pin

Return spring~ installation position Fig. 1

~ ------Shaft
----Buahlnga
remove with VW 207
Install flush

Clutch pedal

Clutch slave cylinder

before installing, Insert rear bolt

Slave cylinder bracket

· .
Bleeder valve~
Connector---~ :

Pressure hose, center~ ~· > , Guide sleeve

_,..-· grease metBI sleeve with Mo
,__./
< Pressure hose, rear Do not grease plastic sleeve

·,~

Presaure hosa

Clrcllp ____,..
always replace

Clutch lever - - - - '

lightly lubricate ball

Release shaft bearing Release bearing

wipe dry, do not use solvent
Relesae shaft - - - Lubricate pivot surface with
install with multi-purpose grease Mo&.! grease
replacing, Fig. 4
Spring clip - - - - - - - - - - '
Into clip and attach with release
bearing and clip to release shaft

Syncro Clutch hydraulic system

Clutch controls
30 8 •
30 Clutch, Controls

Fig. 3 Bearing shaft bushing, installing

Fig. 1 Roll pin, Installation position - push bushing in to stop

- roll pin must be engaged in groove

(arrow) on side of bracket

VW771 Fig. 4 Release bearing, installing

New release bearing on which thrust ring is not
centrally positioned to housing (arrow) can be
installed.
The thrust ring automatically centers itself on first
Fig. 2 Release shaft bushing, removing
application of clutch pedal.
A- inner extractor 18.5-23.5 mm
e.g. Kukko 21/3

30.9 Release shaft bushing

Bearing shaft bushing
Syncro
- Clutch, Controls 30
CAUTION CAUTION
Clutches with damaged or loose riveted When replacing engines, transmissions or
connections should· be replaced. clutches, make sure the diameter and joint
surfaces of release bearing and diaphragm
spring match.
Note
Remove engine when working on the clutch

Pressure plate
removing and installing Fig. 1
checking for wear and warping Figs. 2, 3 and 4

Clutch disc
centering Fig. 1
checking runout Fig. 5
Note installation position,
spring cage faces pressure plate.
When installing, clean corrosion from
transmission mainshaft and clutch hub
splines. Ughtly grease clutch splines
with grease, part no. G 000 100

Flywheel
check that spring pin fits tightly
Clutch facing contact surface must be
free of cracks, oil and grease

Syncro Clutch assembly 3 0 •10

30 Clutch · Controls

- check straps between pressure plate and

cover for cracks and loose rivets (arrows)
• clutches with damaged or loose riveted
sections should be replaced

Fig. 1 Clutch removing/Installing

-mark installation position (arrow)

Fig. 4 Pressure plate, checking

- check pressure plate for cracks, burn

marks and distortion
• maximum inward taper 0.3 mm

Fig. 2 Clutch diaphragm spring, checking

- examine fingers (arrows)

• scores up to a maximum of 0.3 mm are
accep\able
!'

Fig. 5 Clutch disc, checking runout

• maximum runout = 0.5 mm

Fig. 3 Clutch, checking (measure 2.5 mm from outer edge)

30.11 Clutch diaphragm spring

Clutch pressure plate
Syncro
 32
llld
IWS)
Jted Torque Converter

Quick Data Index

-Bushing 32.3
-Code letter 32.2
-Draining 32.2
-Installing 32.3
-Oil seal 32.3

ge)

A·1

Index 32.1
32 Torque Converter
-cut free end of drain hose at an angle
-place converter in sloping pos ition

- squeeze plastic bottle and hold while

inserting free end of drain hose into
converter hub
-end of hose must rest on bottom of
converter
-release p lastic bottle so that ATF
starts draining
- loosen bottle cap so fluid can siphon

Fig. 1 Converter code letter

0- up to build date 3/27/81
Z-3181 to 7/85
H-Iram 8/85
Note
Torque converter with code letter Z has
a modified impeller and turbine vanes
and can be installed in earlier vehicles.
F

Fig. 3 Converter oil seal hub, check mg

-check hub (a rrow) fo r scoring from oi I
seal
-check that chamfer for oil seal is
rounded at front
-cover hub bore in converter
-remove sharp edges and burrs with
fine emery cloth
- do not damage surface where oil seal
contacts hub
Note
Torque converter bushing can be replaced
separately. If torque converter assembly
is defective. replace complete unit

Fig. 2 Torque converter, draining

- attach small inside diameter h ose,
about 8mm (5/16 in.) outside d iamete r,
to plastic bottle of about 2 liter (2 qt )
capacity
• hose connec ti on and cap must be air
tight

32.2 Converter assembly

 Torque Converter 32

Fig. 4 Converter bushing, checking Fig. 6 Converter bushing, Installing

e wear limit diameter 34 .25 mm ( 1.348 in ) -press bushing in unti l seated
• out of round max . 0 .03 mm ( 0.001 in )

CAUTION
om oil
When installed, bushing must have inside
II ~ Threaded Rod diameter of 34.03-34.05 mm (1.340- 1.341 in.).
If bushing is less than minimum inside
diameter, it may sieze.
After Installing bushing, check edge ot
ith converter hub for burrs

I seal
vw 201

US 691 or
replaced 40-103
.embly

Fig. 5 Converter bushing, removing

Fig. 7 Converter oil seal, removing

- pry damaged seal out, carefully clean
seat for seal

Converter bushing
Oil seal, removing
32 3 •
32 Torque Converter

I~
091
Converter oil seal, lnatalllng -[
- C:
-dip seal In ~TF and drive in as far as It a
will go
t
CAUTION li
- 1
Be careful when installing silicone seal.
Seal is soft and can be easily damaged.
Silicone seals must not contact gasoline or 091
similar cleaning solutions -I
-I

Converter assembly, Installing

• before installing converter, pump
-·
shaft must be inserted fully into
pump splines
- place converter carefully on one-way
clutch support
• do not tilt or misalign converter
- engage splines by turning converter
back and forth

09

32.4 Oil seal, installing

 34
Manual Transmission
Controls, Assembly

Index
091 094-4WD Syncro
- Drive flange oil seal 34. 18 -Differential
-Gearsh~t lock components 34.24
adjusting 34.4 lock control, repairing 34.26
assembly 34.3 lock servo, removing 34.25
bearing plate 34.4 -Gearshift linkage
linkage 34.2 adjusting 34.21
-Transmission assembly 34.20
removing 34.14 -Technical data chart 34.19
-Transmission
091/1 removing/installing 34.22
-Drive flange oil seal 34.18
-Gear ratios 34.9
- Gearsh~t
adjusting 34.8
assembly 34.6
bearings 34.6
linkage 34.6
-Lubricant
specifications 34.9
- Shnt rod
mounting 34.7a
- Technical data
chart 34.1a

094
- Drive flange oil seal 34. 18
-Gearshift
adjusting 34.12
assembly 34.10
-Technical data chart 34.1 b
-Transmission
removing/installing 34.16

34.1
34 Manual Transmission-Controls, Assembly

Technical data

• code letters
• application
• gear ratios

Transmission

code letters ACW

date of manufacture
from 01/86

to

type 091/1

Application to engine 2.1 liter, Digifant, 70 Kw (95 bhp)

Gear ratios
final drivP 29:6-4.83

1st gear 34:9-3.78

2nd gear 33:16-2.06

3rd gear 49:40-1.23

4th gear 41:48-0.85

reverse gear 33:9-3.67

Lubrication
capacity 3.0 liter (3.2 U.S. qt)1

specification hypoid API GL-4, Mii-L-21 05, SAE SOW, SOW /90
Clutch
actuation hydraulic

disc diameter 228 mm

drive flange diameter 100mm

speed in 4th gear
per 1000 rpm 29 Kph (18 mph)
'
1 refill capacity only; 1 .5 liters cannot be drained

34.1a Transmission
Technical data
091/1
 Manual Transmission-Controls, Assembly

Technical data

• code letters
• application
• gear ratios

Code letters DX
Production from 10/82
l to 11/83
Application type Vanagon
engine 1.6L Diesel37 kW (48 bhp)
Ratios final drive 38:7 =5.428
1st gear 37:9 =4.111
2nd gear 35:15 =2.333
3rd gear 31:21 = 1.476
4th gear 57:56 = 1.018
5th gear 49:64 =0.765
reverse gear 33:9 = 3.666
Lubricant capacity 4.0 Liters (4.2 US qt)
Specification hypoid GL-4, MIL-L 2105, SAE 80 or GSO synthetic oil
Clutch actuation hydraulic
Clutch disc diameter 215mm
Axle shaft flange diameter 100mm

s~speed 094
Technicaldata 34.1 b
34 Manual Transmission-Controls, Assembly
Note Not

// All connections must engage easily without

jamming. Lubricate all joints and friction surfaces
Lut
gre
with MoS2 grease (part no. G 000 602), Linkages luhl
already lubricated with white grease or solid first

fO?
lubricant must first be cleaned thoroughly,

k ...__.
------
'~

~I "-.....--....._, (

45 Nm (33 II lb) ~''l.A'---,..~~

.....- . . . . -
Relay lever

! 1
-
20 Nm (14 It lb)
-----~ply 06 locking compound
----- -... Oulde pin
fits on selector
shaft in one
position only

l Sl

Rear shift rod

r---.. . ___
removlng /instaUing page 34. 5

L•
d
8l
I -...
81

I
I

---~ \ I
------
-----.. . --J I

•
(,,
Center shift rod bushing------'
lubricating: - remove front and center shif t rods
•...,.•_1'
- fill lubrica tion grooves w1lh grease
replacing: - remove front and center shift rods Front ahlfl rod
removing/installing page 34. 5

34.2 Gearshift linkage

4-speed 091
 Manual Transmission-Controls, Assembly 34
Note
out Lubricate all joints and friction surfaces with MoS2
surfaces grease (part no. G 000 602) . Linkages already
Lin~ ages lubricated with white grease or solid lubricant must
;olid first be cleaned thoroughly.
ly.
CAUTION
Apply grease to shifter components inside the
vehicle with great care. MoS2 grease cannot
be removed from upholstery or carpets.

tley laver
s on selector
~aft In one
>Sition only

Gearshift lever----...
adjusti ng page 34.4

Bushing __fil ....___ Set screw

Shill linkage, adjusting page 34.4

lever bearing assembly - - - - - - - -

diSassemble tor lubricating only
wemblfng Fig. 1
id1ust ing page 34.4

~----Spacer ring
10 Nm (7 ft lb) -41-------. Shoulder faces up

/
Lever bearing plate, lower

Rubber stop plate

Front ahlll rod - - - f

5
Shift mechanlem houalng ---.J

4-speed 091 Gearshift lever

Shift rod
34 3 •
34 Manual Transmission~Controls, Assembly

With alignment holes

(up to 06-88)
Lever bearing plate,
upper

Rubber guide bushing - - -

shou lder laces up

Upper ball half~

'
Spring--------
._,
Bearing shells ~­
-- _;;:,

·. tf 11 . - align holes (arrows) of upper bearing plate with

Lower ball half ·::>- - 1.--~-s--67_6A....,I

holes of IQWer

Without alignment holes

Fig. 1 Lever bearing, assembling (beginning 06-88)
-push both bearing shells Into rubber
guide bushing
-press lower ball half into shells from
bottom (shouldered side of bearing
is top)
-insert spring on lower ball half
-pushing shells apart, push in upper
ball half
-push rubber guide bushing into upper
lever bearing plate (shouldered side
first)
-install spacer ring into bottom of
upper lever bearing plate with
shoulder facing rubber guide bushing
- rotate upper bearing plate so that the mounting
studs (black arrows) contact opposite sides of the
Shift linkage, adjusting bearing plate
- tighten mounting nut to 10 Nm (7ft. lb.)
Work sequence
-place shift lever in neutral position

Note
A revised shift lever bearing is installed in vehicles
beginning 06-88. In the revised bearing the bearing
plate alignment holes are delet~. The revised shift
lever bearing can be installed in vehicles
manufactured from 10-82 to 06-88.

- loosen shift rod clam p so selector lever can

move easily on shift rod
- remove spare tire
-move stop fmger of front shift rod to center of
rubber stop in housing

34.4 Shift UnkAge

Lever bearing plate
4-speed 091
 Manual Transmission-Controls, Assembly 34
Front and center shift rods,
removing I ins ta II ing
Work sequence
- loosen clamp
-remove spare tire
-remove bo lt holding shift lever t o front shift
rod
-pull off front a nd cente r shift rods In forward
- adjust shift rod end direction
• up to Chassis No. 25 BH 137 155 -when installing, assemble bot h shift rods and
a= 19 mm (3/4 in.) insert into center shift rod bushing located
• from Chassis No. BH 25 137 156 above fuel tank
a= 22 mm (7/8 in.)
(to measure use locally fabricated sheet
twith metal strip) Rear shift rod,
- tighten shift rod clamp removing/installing
- shift through all gears and check that they
Work sequence
engage easil y w ithout jamming
- check reverse lock -<Jut for proper operation - loosen c lamp
-remove rear shift rod retaining bolt from
Note transmiss ion housing and push bolt into
shift rod
From Chassis No. BH 25 137 156 a new type
-pull off rear shift rod
mechanism housing has been installed.
- install in reverse sequence
If 1st gear is jamming on vehicles up to
Chassis No. 8 H 137 155- even after
correct adjustment is made - install new
type shift mechanism housing and adjust
distance a to 22 mm (7/8 in.)

Jnting
!5of the

'·

r can

enter of

8-6
4-speed 091 Shift rod 34.5
34 Manual Transmission-Controls, Assembly
Note
Lubricate all joints and moving parts with grease
(part no. G 000 602) before installing. Linkages
already lubricated with white grease or solid
lubricant must be cleaned thoroughly before applying
moly grease.
4
Transmission, removing/installing
2
see pages 34.16 and 34.17 3

Gearshift lever housing

Gearshift lever ----IIJR
adjusting page 34.8 U

~g ~Bushing

Bushing~

Set screw (M5 x 8 ) - - - •

l§l:t---Sprlng
tRl
\§)
@l.il
~

~Gearshift lever
~ bearing housing

e.--upper ball half

Gearshift lever bearing----.
assembling: It---spring
- place shells In rubber guide
- push lower ball half into ~ Lower ball half
shells (collar faces upward)
- push shells apart and insert
spring and upper ball half
- push completed rubber guide ~B Shells
(
Into gearshift lever bearing
housing as far as it will go
9-- Rubber guide
I'
€J
e;D..____ Spacer ring
~ collar faces upward ! 34-12971

34.6 Gearshift linkage

4-Speed 091/1
 Manual Transmission-Controls, Assembly 34
1grease
lkages
olid
fore applying

IYCII'houslng

/ ,---Lever
fits only in one position
25 Nm (18 It lb) fj " / on shift rod
/®
~Shift rod
/

/
~Boot

- - - - - S h i f t lever

-housing
f------- Tensioning pin

I 34-12971
/
Bushing, rear

4-speed 091/1
Gearshiftlinkage 34.7
34 Manual Transmission-Controls, Assembly

Beginning in June 1987 a boot is installed on each

side of the shih rod bushing.

Lever~
Flange (gear carrier housing) ~'\f._\
for mounting support plate ~ ~
Clip Flg.1 G \)
installing Fig. 2

Support plate

~' Boot~ h\-~-((fomll) -~ --(

~- ~~ · ~IJW?J_rr~ Com~})
~
@

fjj-
-0:;:_ "J
iJ
Hex head bolt M8 X 40

ShiH rod bushing

with groove lor mounting boots

-·-O_j

Fig. 1 Flange on gear carrier housing, dimensions Fig. 2 Front boot, adjusting
a = 14.5 mm (previous version) a = 60.0 mm (in neutral position)
a = 21.0 mm (revised version)
Note
Note
The revised shift rod mounting can be
The shift rod bushing is positioned 6.5 mm further installed with the previous gear carrier
forward on the revised flange. This prevents the rear housing. Insert a nul, M8 x 6.5.
boot from being compressed too far causing a shill Part No. N 011 008 18, between flange
out ot gear. and support plate. Use M8 x 40 bolt.
Part No. N 010 340 4.
During repairs, a gear carrier housing can be
replaced with the revised housing on transmissions
from 10/82 on.

34.7a Shift rod mounting,

revised 4-speed 091 and 091/1 II 5-speed 094 II Syncro
34 Manual Transmission-Controls, Assembly

Gearshift lever, adiusting Without alignment holes

(beginning 06-88)
Note
A revised shift lever bearing is installed in vehicles
beginning 06-88. In the revised bearing the bearing
plate alignment holes are deleted. The revised shift
!ever bearing can be installed in vehicles
manufactured from 10-82 to 06-88.

Work sequence
- shift into neutral position

- rotate upper bearing plate so that the mounting

studs (black arrows) contact opposite sides of the
bearing plate slots
- tighten mounting nuts to 1o Nm ( 7 ft. lb.)

- align centering holes (arrows) of gearshift lever

housing and gearshift lever bearing housing

- loosen clamp nut (arrow)

-check that joints of shift rods slide freely
- remove spare wheel

34.8 Gearshift lever 4-speed 091/1

 Manual Transmission-Controls, Assembly 34
4-speed manual transmission 091/1
(1985 MY Vanagons)

Gear Ratios Trans. DU

1st gear . . . . . . . 34:9 3.78
2nd gear .... ... 33:16 2.06
3rd gear 63:50 1.26
4th gear . ...... 52:6t 0 85
Reverse . .. ' ... 33:9 3.67
Final drive . . 34:7 4.86

Gear Ratios Trans. ABO

t st gear 34:9 3.78
2nd gear 33:16 2.06
-set lever on transmission in vertical position, 3rd gear 49:40 1.225
>unting 4th gear 41 :48 0.85
les of the
as shown
Reverse 33:9 3.67
Final drive . .. .. . 29:6 4.83
.)
Lubricant specifications
lubricant capacity (incl. differential)
091/i . . . . . . . . . . . 3.0 I (3.2 US qt)
viscosity .. .. SAE BOW . SAE 80W/90
type . hypoid. MIL·L·2105; API/GL-4

-move stop finger of front shift rod to center of

shift mechanism housing
- adjust shift rod end
••= 23 mm (29/32 in.)
(use strip of sheet metal to measure)

CAUTION
~ely
Transm ission must be in neutral, lever on ;
transmission In verti cal position '·

-tighten shift rod clamp

-shi ft through all gears and check that they
engage easily without jamming
-check reverse lock-out for proper operation

Note
Check that with 1st gear engaged, distance
between shift lever and heater pipe Insulation is
min. 15 mm (19/32 ln.)

4-speed 091 I 1 Gear ratios

Lubricant specifications 34.9
34 Manual Transmission-Controls, Assembly

Note
Lubricate all joints and moving parts with grease
(part no. G 000 602) before installing. Linkage
already lubricated with white grease or solid
lubricant must first be cleaned thoroughly.
CAUTION
Apply grease to shifter components inside the
vehicle with great care. MoS:z grease cannot
be removed from upholstery or carpets.

Shift knob -----P~""-1

Gearshift lever
adjusting page 34.12
-----!J

Bushing~
Headless screw M 5 x 8 -.::::::._

Spring~ @
8
~

Gearshift lever bearing - - - - - - .

assembling:
- place shells in rubber guide
- push lower ball half into (5--- Upper ball half
shells {collar faces upward)
- push shells apart and insert
8- Spring ,,___ _ Spring
spring and upper ball half
- push completed rubber guide ~ Lower ball half ---Ball
into gearshift lever bearing
housing as far as it will go 58- Shells

g
Spacer ring-----~ flj @-- Shift guide
collar faces upward 'J
Reverse gear 1ock

Gearshift lever housing

Shift mechanism·housing

34.10 Gearshift linkage

5-speed 094
 Manual Transmission-Controls, Assembly 34
Shift rod, rear

~~ ·~.
E_ . )
~
1~~
Clamp
Knuckle joint

-;~,front ;_25N;(18ftlby
~
1
Leve~
~
/

/Ill f .•
25 Nm (18ft lb) -(I ./ fits only in one position
on sh;ft n>d

~Ht•od
t:!9--Boot
~ShHtlo"'
IJ- Tensioning pin
Iring

Ill
rguide pin

arlock
134-1280 f

5-speed 094 Gearshift linkage 34.11

34 Manual Transmission-Controls, Assembly

Gearshift lever, adjusting

Work sequence
- shift into neutral position

Note
A revised shift lever bearing is installed in vehicles
beginning 06-88. In the revised bearing the bearing
plate alignment holes are deleted. The revised shift
lever bearing can be installed in vehicles
manufactured from 10-82 to 6-88.

~h alignment holes
I ~ to 06.a&)

- loosen clamp nut (arrow)

- check that joints of shift rods slide freely
remove spare wheel

- align centering holes (arrows) of gearshift lever

housing and gearshift lever bearing housing

Without alignment holes

(beginning 06-88) - set lever on transmission in vertical position,
as shown
push shift rod into transmission until spring
tension is fel't; keep shift rodl in this position
(shift position 2/ 3 gear)

- rotate upper bearing plate so that the mounting

studs (black arrow s) contact opposite sides of the
bearing plate
- tighten mounting nuts to 10 Nm (7 ft. lb.)

34.12 Gearshift lever 5-speed 094

 Manual Transmission-Controls, Assembly 3
CAUTION

Transmission must be in neutral, lever on

transmission in vertical position

tighten clamp nut in this position to 25 Nm

(18ftlb)

- push shift rod to right ($.hift position for 1st/

rever~ gear) and move· in longitudinal cUrection
• so that measurement 11 between reverse gear j34- ssol
lock and stop of shift rod is 3mm 10.118 in.)
Note
Use 90° sheet metal angle piece of 3mm (0.118 in.) with 2nd gear engaged, check distance between
thickness gearshift lever and heater covering

CAUTION • measurement a must be at minimum 15 mm

transmission must be In neutral, lever (5/8 in.). If not, adjust gearshift lever bearing
gn tranimission in vertical position by pushing backward ,rn slotted holes
- check that all gears engage easily without jamming.
Particularly, check reverse gear lock out

;ion,

ring
ition

- let shift rod spring back to left into 2nd/3rd

gearshift position and push rod slightly to right
• boot must touch inside of shift mechanism
housing (arrow)

B-15
5-speed 094 Gearshift lever 34.1~
34 Manual Transmission-Controls, Assembly

Transmission, removing
(engine installed)

Work sequence
-disconnect battery ground strap
-remove right side upper engine/transmission
bolt

-disconnect starter cables 5

- remove hydraulic clutch line bracket 1 from
transmission
• do not disconnect hydraulic line
- remove clutch slave cylinder from bracket 2
and hang up cylinder with Wire
- remove right side drive shaft bolts 8 and
remove shaft from transmission
- hang shaf't up with wire
- remove right side tower engine/transmission
nut 7

- support engine with VW 785/1

-remove left side upper engine/transmission - go to next page
bolt 3A
-remove left side lower engine/transmission
nut 38
-remove left side drive shaft bolts 4
-remove shaft from transmission
-hang shaft up with wire

34 •14 Transmission, removing

14-speed 091 I
 Manual Transmission-Controls, Assembly 3

-disconnect back-up light wiring 8

-remove shift linkage 8 from transmission
-disconnect ground strap 10
-remove front transmission mount 11 from
body
• support transmission with US 618 together
with US 618/5
- lower front part of transmission (loosen
spindle of VW 785/1) until there Is enough
room to remove transmission
- separate transmission from engine and
remove from vehicle

Transmission, Installing
(engine Installed)

Work sequence
Proceed In reverse order of removing and note
following:
- Install transmission with US 618 together
with US 618/5
-clean splines of malnshaft and lubricate
lightly with Mos.
-note correct position of air deflector plates
IO body
- check engine compartment seals
-tighten front transmission mounts

Tightening torques:
• transmission to engine bolts/nuts 30 Nm (22 It Ib)
• drive shafts to transmission 45 Nm (33ft Ib)

4-speed 091 Transmission, removtng

Transmission, Installing
34 15
•
34 Manual Transmission-Controls, Assembly

Transmission, removing - remov& right drive shaft from transmission

(engine Installed) and hang up with wire

Work sequence
-disconnect battery ground strap
- remove upper engine/transmission bolt
-remove bracket for accelerator cable

- remove left drive shaft from transmission and

hang up with wire
-remove clutch cable bracket from transmission
-remove clutch slave cylinder from bracket and
hang up with wire

Note
Hydraulic system must be closed
-remove shift rod from transmission (arrows)
-disconnect backup light wiring -support transmission with suitable tool

- remove ground strap from body (right arrow)

- disconnect starter wiring and remove starter -remove front transmission mount from body
complete (arrows)

34.16 Transmission,
removing ]4-speed 091/115-speed 0941
 Manual Transmission-Controls, Assembly ~
sion

housing -lower front part of transm ission (loosen

spindle of VW 78511) until there Is enough
room to remove transmission
-remove lower engine/transmission bolts
-pull transmission off engine gui de bolts and
remove from vehicle

Transmission, installing
(engine Installed)

Proceed In reverse order of removing and note

following:

-clean splines of mainshaft and lubricate

lightly w ith MoS1 grease
-finally tighten front transmission mounts
(arrows)
tool Tightening torques:
• transmission to engine (M 10) 30 Nm (22 ft fb)
• drive shafts to transmission 45 Nm (33 ft lb)

ght arrow)
from body

4-speed 091/1 s~speed 094 Transmission, inotillllng 34.17

34 Manual Transmission-Controls, Assembly

Drive flange oil seal, removing Drive flange oil seal, Installing
(Transmission installed) (Transmission Installed)

Note Work sequence

A light film of oil on seal prevents seal lips from
running dry.
Replacement of seal is necessary only if there is a
large amount of oil on seal and transmission
housing

Work sequence
-remove drive shalt bOlts from transmission
and detach shaft upward
• hang up shaft with wire
-pierce cap in flange with screwdriver and pry
out

- drive In new seal until it contacts bearing race

- lill lips of seal with multi·purpose grease

-remove circlip and pull out flange

- Insert two bOtls A (M 8 x 30) through slots
in flange
- pull off flange with tool VW396

-install drive flange with tool VW391

-Insert wavy spacer washer and circllp
- press clrclip into groove with VW 244 b
and at same time check that washer is
centered
- press In new cap
- Install drive shaft and tighten socket head
bolts to 45 Nm (33 tt lb)
-check transmission oil level and add if
necessary

-pry out seal with tool VW681

34.18 Drive flange oil

seal 14-speed 091-0911115-speed 094j
 Manual Transmission-Controls, Assembly 3~
Technical data
• code letters
• application
• gear ratios

Transmission
code letters AAK AAN
date of manufacture
from 10/85 10/85
to
Application vehicle Vanagon Syncro
engine 2.1 Liter 95 bhp (net) SAE
Gear ratios
1st gear 34: 9 = 3.78
2nd gear 33: 16 = 2.06
3rd gear 49 : 40 = 1.225
ring race 4th gear 41 : 48 = 0.85
ase Low gear 31 : 9 X 28 : 16 = 6.03
Reverse gear 31 : 9 X 28: 16 = 6.03
Final drive ratio 38: 7 = 5.43
Capacity 4. 7 US qt (4.5 Liters)1
Lubricant specification Gear oil GL-4 SAE 80
Clutch mechanism hydraulic
Clutch disc diameter 228 mm
Driveshaft flange
diameter 100 mm
Overall ratio in 4th gear 4.15
Speed in 4th gear per
1000 rpm 18 mph (29 km/h)

p 1-When refilling only add 3.2 US qt (3.0 ltr) or fill

4b to edge of filler hole as 1.5 quarts (liters) cannot
is be drained off.

t head

Hf

I094-4WDI Transmission
technical data 34.1!
34 Manual Transmission-Controls, Assembly
Note
Lubricate all joints and moving parts with MoS2
grease (part no. G 000 602) before installing.
Unkages already lubricated with white grease or
solid lubricant must first be cleaned thoroughly.

Pins

Shift fork

MS x8 Q I
I
Lower bearing plate
I
I
. ~

Universal - j
~4 ~Bushing SNmU8fti: ~/S~•

~ 7
/~~-
fits in only one position on shift leve

~ ............ I
I

I
10 Nm (7 ft lb)
8 /®
1,..
8
8 Shift stop plate

Shift mechanism housing

Spacer ring Lever bearing assembly Rear bushing Support plate

collar faces upward assembling:
- place shells in rubber guide
- push lower ball half Into shells
(collar faces upward)
- push shells apart and Insert spring and
upper ball half
- push completed assembly Into
bearing housing as far as
possible

IU34-17851

3 4 •2 0 Gearshift linkage
Syncro

.......
 ~
Manual Transmission - Controls, Assembly 3~
Shift linkage, adjusting
- place shift lever in neutral

Note
A revised shift lever bearing is installed in vehicles
beginning 06-88. In the revised bearing the bearing
plate alignment holes are deleted. The revised shift
lever bearing can be installed in vehicles
manufactured from 10-82 to 06-88.
:rod
With alignment holes
(up to 06-88)

- loosen clamp (arrow)

• selector shaft connection must move freely
- remove skid plate

loot
- align holes (arrows) of upper bearing plate with
holes of lower bearin plate

Without alignment holes

I lever (beginning 06-88)

- set lever on transmission in vertical position

- move stop finger of front shift rod to center of shift
toning
mechanism housing

- rotate upper bearing plate so that the mounting

studs (black arrows) contact opposite sides of the
bearing plate
- tighten mounting nuts to 10 Nm (7 ft. lb.)

Syncro
Shift linkage, adjusting 34.2
34 Manual Transmission- Controls,

-adjust shift rod end a = 23"mm

• use strip of sheet metal to measure

CAUTION
Transmission must be in neutral, lever on
transmission in vertical position.

- tighten clamp in this position

- shift through all gears, they must engage
smoothly without jamming
- check reverse lock-out operation

Note
With 1st gear engaged, the distance between the
shift lever and heater pipe insulation must be at least
15 mm (19/32 in.).

34.21a Shift linkage, adjusting

Syncro
 Manual Transmission-Controls, Assemblv--34-
Transmission, removing/installing
(engine remains In vehicle)

Work sequence

Removing

- disconnect banery ground strap

- remove bolts fastening top of transmission to
engine
- remove rear skid plate (under engine and
transmission)

- remove left side axle shaft bolts (lower arrow)

and remove shaft from transmission
- remove hydraulic clutch line bracket from
transmission (center arrow) Do NOT disconnect
hydraulic line.
- remove clutch slave cylinder from bracket on
transmission (upper arrow) and hang cylinder
from body with wire

- disconnect back-up light wiring

- remove right side axle shaft from transmission

- loosen mounting bolt of front final drive (arrow)

Do NOT remove bolt.

-remove shift linkage from transmission (arrows)

Vehicles with rear differential lock:

- remove vacuum hoses from lock servo and
disconnect indicator light switch wiring
- loosen side bolts of front final drive mounting
bracket (arrow) Do NOT remove bolts.
- remove ground cable from body
- remove bolts fastening driveshaft to transmission
flange and tie driveshaft end to body

J Syncro I Transmission, removing 34 •22

 34 Manual Transmission-Controls, Assembly
-support transmission with V.A.G. 1383

134-16731

-pull transmission off engine guides and remove

- remove front transmission bracket (arrow) and
lower front of transmission approx. 15 em (6 in.) Installing
at driveshaft flange
- disconnect starter cables Proceed in reverse order of removing and note
- remove vent hose following:

- clean mating Jltlrfaces of engine and

transmission 'and coat lightly with silicone sealer,
Part No. 176\005 05
- clean splines of mainshaft and lubricate lightly
with MoS grease.
- grease needle roller bearing in crankshaft
-tighten mounting bolts of front final drive last

Tightening torques

Transmission to engine 30 Nm (22 ft lb)

Axle shaft to transmission 35 Nm (26ft lb)
Driveshaft to transmission 35 Nm (26 ft lb)
vw 785/18 l34-1674l

-support engine with VW 785/18

- remove bolts fastening bottom of transmission to
engine

34.23 Transmission, removing/Installing

Syncro
 Manual Transmission-Controls, Assembly 3~

Differential gear housing

Differential lock switch w/engagement sleeve
(shown in off position)

Vacuum servo

Vacuum line for disengagement (blue)

Differential lock switch

20 Nm (14ft lb)

Differential lock coupling

Vacuum line (black)

Vacuum from Intake manifold

Vacuum reservoir
mounted nex1 to right frame rail

134-16581

lsyncro I Differential lock components 34.2~

34 Manual Transmission - Controls, Assembly
Differential lock servo, removing

1 servo
2 bracket
3 spring pin
4 switch for lock indicator light
5 operating rod

Work sequence

- push protective casing back and drive out pin

(arrow)
- remove vacuum lines
- remove bolts attaching servo to bracket

Note
Only white vacuum hoses are supplied as spare
parts (Part No. N 20 139.1 ). When replacing hose,
cut to proper length and mark with tape of
appropriate color.

34.25 Differential lock servo, removing

Syncro
 Manual Transmission - Controls, Assembly 3~

Differential lock control, repairing

Switch, removing/installing

t
- press switch out of guide bushing

134-18881
- unscrew knob, if necessary hold switch piston
with needle nose pliers
-remove trim plate (arrows)

SRRRRRI

- detach vacuum hose

- note hose locations

134-18891
- remove bracket

- remove trim

Syncro Differential lock control,

repairing
34 2E
•

4-Speed 091
Manual Transmission
Case, Gears, Shafts
Quick Data Index
- Adjusting rings 35.3, 35.4
- Assembly 35.2
- Clutch housing/ mechanism
35.12
- Differential 35.4
- Drive flange 35.3, 35.4
oil seal34.18,35.15
-Gear
1st gear needle bearing 35.27
3rd gear end play 35.29
- Gear carrier/Gearshift housing
35.6, 35.7, 35.18
-Gear carrier housing assembly
35.8, 35.16
-Gearshift lever 34.3
-Gearshift linkage 34.2, 34.3
- Interlock/ Detent plungers 35.17
- Installing 34. 15
- Lever bearing plate 34.4
- Main shaft assembly 35.9, 35.20
ball bearing 35.23
oil seal 35.13
- Pinion needle bearing 35.23,
35.29
C·1
35
..._,- Pinion shaft assembly 35.9,
~ 35.24, 35.25
. ear main shaft 35.5
- Release shaft bushing 35.13
-Removing 34.14, 34.15
- Retaining ring 35.7
- Reverse gear 35.14
end play 35.17
shaft circfip 35.15
- Rocker lever shaft 35.19
- Selector shaft 35.19
-Shift forks 35.10. 35.11
- Shift rod 34.3
- Starter bushing 35.13
- Synchronizers
1st/2nd gear 35.26, 35.28
3rd/4th gear 35.21, 35.22
circlips 3rd/4th gear 35.21,
35.26
ring identification 35.30
-Tapered roller bearing 35.26,
35.27
-Transmission housing 35.14
4-Speed 091/1
-See page 35.31
S·Speed 094
-See page 35.61
094-4WD Syncro
-See page 35.93
35.1
35 Manual Transmission-Case, Gears, Shafts

Transmission/Final drtve lubricant:

Hypoid oil APIIGL-4: MIL-L2105
SAE SOW, SAE 80Wf90
Capacity: 3.5 ltr (3.7 US qt)

Adjusting ring, right - - - - - - ,

mark position before removing Fig.
removing Fig. 4 Driwe flange
installing Fig. 6 removing Fig. 2
installi"g Fig. 7

011 tiller plug~

20 Nm (14 It lb) ~
Tranamlaalon housing
mounting in repair stand
Fig. 1
.r Wuy spring washer

/ .,. _Cap
1
~..,., always replace

""--- Clrcllp
Installing Fig. 8

Clrcllp
always replace
Adjusting ring, lett
mark position before removing Fig. 3
removing Fig. 4

hMtno~
installing Fig. 6

Clutoh
mark position of adjusting ring
before removing , Fig . 3.
Before removing, loosen left with weahers
differential adjusting ring to 20 Nm (14ft lb)
redu ce tension in transmission
housing

Main shaf1, tront

cover splines to prevent
damage to main shaft oil
seal when disassembling /
assembli ng

35-685

4-speed 091
35.2 Transmission assembly
 Manual Transmission-Case, Gears, Shafts 35

Fig. 3 Adjusting ring, marking position

tee
Note

g.8 Before starting repair work (which does not

require final drive to be adjusted) mark position
of adjusting rings on transmission housing.
Measure depth to which they are installed with
VW 382/7 and write down readings
I Js·oa6 I
- scribe left side (ring gear side) with
35.5
Fig. 1 Transmission housing, mounting in repair one mark (arrow)
stand - scribe right side with two marks
- mount transmission In repair stand
-drain transmission oil

Fig. 4 Adjusting rings, removing

Fig. 2 Drive flange, removing

-remove circlip and wave washer
- attach VW391 to flang e w1th 2 bolts
• A = M8 x 30 bolts
-pull dnve flang e out
,,
1

C·2
C·3
4·speed 091 Drive flange
Adjusting rings
35 3
•
35 Manual Transmission-Case, Gears, Shafts

Fig. 5 Differential, removing Fig. 7 Drive flange, Installing

-remove adjusting rings and rear main
shaft
-lift out di fferential

Fig. 6 AdjusUng rings, Installing

- install left and right adjusting rings
and align marks at depth previously
measured
-lubricate threads with MoS, grease Fig. 8 Clrcllp for drive flange, lnltalllng
-Insert wave wastler
-press c irclip into groove with VW 244b
CAUTION and at same time check that washer is
centered
Do no t tighten left side adjust ing ring until
clutch housing has been installed and bolts
torqued

Differential

35.4 Adjusting rings

Drive flange 4-speed 091
 Manual Transmission-Case, Gears, Sha.fts 35
Rear main shatt;-nnnoVlng/installlng
Work sequence
/

136-685A I
Removing
-remove circllp (arrow)
- push reverse gear backward and screw out
mai n shaft ·

Installing
- screw front and rear rnain shafts together,
then back off one spline
-push reverse gear on and Install new circlip

ll
8

C·S
4~speed 091 Rear main shaft 35.5
 35 Manual Transmission-Case, Gears, Shafts
\
"·

!----1
----- I

__J
------ ---------
Retaining ring
remove with VW 381/14
installing Fig. 1
------ -------- ------ r /
Qearahlft housing
). Installing Fig. 5

locking F1g. 3
--------
------- 7 bolts M8 " 32

1----
with washers
20 Nm (14 It lb)

with washers
20 Nm (14ft lb)

always replace

. ,'i
determining thickness,
Repair Group 39
removing/installing Fig. 2
with washers
20 Nm (14 It lb)

Note

Differential must be removed

before gear carrier can be removed,
see page 35.4 35-689 1

35 •6 Gear carrier/Gearshift housing 4-speed 091

 Manual Transmission-Case, Gears, Shafts 35

Fig. 1 Retaining ring, Installing

Fig. 3 Retaining ring, locking
- tighten to 225 Nm (162ft l b), then back
- lock ring by peening twice with tool A
o ff and retighten to 225 N m (162 ft lb)

Fig. 4 Main shalt bearing locking key 8,

Installing
I ~-691 I -press locking key 8 into recess (arrow)
Fig. 2 Gear ca rrier, removing l installing

Note
If bearing and I or transm ission housmg are
replaced , and dimension r is not marked on ring
gear, pinion depth must be measured and noted
before gear carrier is removed. This is dimension
r. See Repair Group 39. When assembling. parts
must be installed in same position . See Ring
gearlpinion, adjusting, Repair Group 39

Work sequence

Removing
• use two M8 x 20 bolts to attach VW 457
-press gear carrier out with VW 296 /
Installing /
/
-tap on pinion with plastic hammer to install
-turn reverse shalt so that reverse sliding gear
..
slips onto splines properly
- align flat on bearing with recess in housing
Fig. 5
-•
Gear shill housing, installing
-guide inner shift lever into 3rd/4t h
gear selector shaft (arrow) when
install ing
C·7
.4-speed 091
Retaining ring
Gear carrier
Gear shift housing
35 7
•
35 Manual Transmission-Case, Gears,
(

\,
Clrcflp - - - - - - - . .
25 Nm (18 It lb) always replace;
when installing, circllp
3rd /4th gear shift fork mus.t be seated In groove
adjusting page 35. TO

1st/2nd aeat selectot rod

Pinion shaft assembly

removing Fig. T
1stl2nd gear shift lOft! Installing Fig. 2
adjusting page 35.10

35-7oo 1

Gear Ratios
1st gear 3.78(9:34)
2nd gear 2.06(1 7:35)
3rd gear , .26(50:63)
4th gear 0 .852(61 :52)
Reverse 3 .28(13:16 X 15:40)
Final drive 4.57(7:32)

35.8 Gear carrier housing 4-speed 091

 Manual Transmission-Case, Gears, Shafts 3!

VW402 --

Fig. 2 Main shaft/pinion shaft assemblies,

Fig. 1 Main shaft/pinion shaft assemblies, installing
removing
-insert 3rd/4th gear shift fork and
-remove circlip check for free movernent when
-remove shift fork for 1st/2nd gear
pressing in shafts
- move selector shaft back to neutral
-lift pinion shaft and guide carefully
-remove clarnp bolt for 3rd /4th gear when pressing in
shift fork - after Installing shafts, adjust shift
-engage 3rd gear, pull selector shaft forks, see page 35.10
back until shift fork is free
-engage 4th gear
- loosen union nut on relay lever support
-lift pinion shaft when pressing out and
guide it carefully so that gears and
needle bearings do not jam and get
dama~ed
J -check 3rd/4th gear for free movement

C·9
4-speed 091
Main shaft assembly
Pinion shalt assembly
35 9
•
35 Manual Transmission-Case, Gears, Shafts

Shift forks, adjusting

Work sequence
W294b/4 VW294b/2

- Install relay lever support together w ith relay

lever

-position gear carrier, with shim Sa (see Repair

Group 39), in tool VW 294b without gasket for
gear carrier
• length of bolts VW 294b; 106 mm (4-3/16 ln.)
-tighten retaining ring VW 294b /7 by hand
- Install shift forks for 1st/2nd and 3rd / 4th
gears

CAUTION
Sh ift fork for 1st/ 2nd gear (wider fork,
marking: No. 551 A) is instal led wi th flat
side away from gear carrier.
Shift fork for 3rd/4th gear (thinner fork,
marking: No. 561 A) is installed with flat
side toward gear carrier.

-put 1st/2nd gear selector shaft in 2nd gear

position
- sl ide operating sleeve with fork over
synchronizing teeth until it is against 2nd
gear
-center shift fork in groove of operating sleeve
and tighten cramp screw

35.1 0 Shift forks 4-speed 091

 Manual Transmission-Case, Gears, Shafts 35
"
CAUTION
Shift fork must not rub or exert pressure on
sides of groove in operating !ileeve when in
neutral position or when gear is engaged.
There must always be clearance

-select 1st and 2nd gears severaJ times while

turning main shaft ano chec" clearance of
shift fork in operating sleeve In each position
• If necessary, alter shift fork position until
there Is same amount of clearance on
selector shaft in both end positions
-tighten clamp screw to 25 Nm ~18 ft Ib)·
- put 3rd/4th gear selector shaft in 3rd gear
position -shift out of reverse gear and press sliding
- adjust 3rd/4th gear shift fork in same way as gear I ightly toward gear carrier housing.
1st/2nd gear shift fork Clearance between reverse gear and 2nd gear
on main shaft must be
• a = min. 0.5 mm (0.020 in.)
CAUTION
For correct adjustment of 3rd/4th gears,
main shaft ball bearing must be pressed
fully into gear carrier housing

-press reverse gear selector shaft Into reverse

gear position

Note
Alter repair work on gear carrier hous~ng, adjust
&)ial play In reverse sliding gear before adjusting
teverse gear

-engage 2nd gear

- check clearance between operating sleeve and
reverse sliding gear in this position and adjust
if necessary
-check interlock mechan ism
• when gear is engaged It must not be
possible to engage any other gear

I:W-6441

-adju st reverse gear so that sliding gear is fully

in mesh with teeth on operating sleeve for
1sll2nd gear (arrow)
-tighten union nut on relay lever support

4-speed 091 Shift forks 35.11

35 Manual Transmission-Case, Gears, Shafts

Starter buahlng
removing Fig. 5
installing Fig. 6
can be replaced with
t ransmission installed

45 Nm (33 ft lb) Releeae shatt

lubricate wi th mult i-
purpose grease

Release shaft bushing

amoving Fig. 3
stalling Fig. 4

Release shaft bushi ng\

'
.....
~
:,at

lubricate ball lightly

011 '"'"
20 Nm (14""" _f
It lb)
Release bearing guide slee11e
plast ic, do not 11rease

removing Fig. 1
installing Fig. 2
fill space between Ups
with multi-purpose grease

35.12 Clutch housing/mechanism

4-speed 091
 Manual Transmission-Case, Gears, Shafts 35

Fig. 4 Release shall bushing, Installing

-drive In flush

ling

Fig. 5 Starter bushtng, removing

(transmission Installed)
lng • when transmission is removed, use
)n drift VW 222a
with

Fig. 6 Starter bushing, installing

-lubricate bushing and drive in flush

C·13
C·12
4-speed 091
Main shaft oil seal
Release shaft bushi ng
Starter bushing
35.-41I 3
1
35 Manual Transmission-Case, Gears, Shafts /

Reverse gear shalt assembly - - - . . . , Clrcllp - - - - - .

removing: detach circlip and drive installing Fig. 3
out with plastic hammer

Clrcllp for reverse gear shaft

ring gear
"---Circllp
for needle bearing I main shaft
Drive flange oil aaal
removing Fig. 1
Differential bearing, outer race
installing Fig. 2
removing/ installing, Repair Group 39
can be replaced with
when replacing, readjust ri ng gear
transmission installed

35- 695 1

35.14 Transmission housing

Reverse gear
4-speed 091
 (
\ Manual Transmission-Case, Gears, Shafts
"'-.,
35
VW411

VW422

Fig. 1 Drive flange oil seal, removing

Fig. 3 Reverse gear shaft circlip, Installing
-press circlip into groove
-squeeze into groove with waterpump
pliers

oves
aring

eplace

Fig. 2 Drive flange oil seal, Installing

-press in flush

C-1C
Drive flange oil seal
Reverse gear shaft clrclip
a·5 15
•
 · ~,"--.""-..

35 Manual TranSmission-Case, Gears, Shafts

Detent ball
press down with screwdriver
to install selector shalt ,
installation position Fig. 2
Bracket/relay ahaft
adjusting page 35.17
Relay laver support
adjusting page 35.17

Plugldetent plunger

1
removing Fig. 1
install flush

3rd 14th gear

selector shaft

Plug/Interlock plunger
removing Fig . t
install flush

Intermediate pin
in reverse gear selector shalt,
installation position Fig. 2

35-703 1

35.16 Gear carrier housing

4-speed 091
 I
i

\
"'-·
Manual Transmission-Case, Gears, Shafts 35
Reverse gear clearance, adjusting
Note
When reverse relay shaft and brackets have been
removed, play between reverse gear and pin
(arrow) on relay shaft must be adjusted by
moving shaft and brackets vertically (as shown)

35.17

Fig. 1 Plug for Interlock/detent plunger,

remo'ring
-tap 6 mm thread in plug and pull out
with bolt (always use new plug)

It lb)
-install gear carrier with reverse gear in sett ing
tool VW 294b
- loosen bolts on both brackets
-slide bracket A down against shaft C until
pin (arrow) on relay shaft is firmly against
reverse gear
-pull bracket back slightly until there is
clearance between pin and reverse gear
- tighten bolts on bracket A

Fig. 2 Interlock plungers, positioning '

-check that when gear Is engaged it is
not possible to engage any other gear
34·3l7
-press bracket B against relay shaft until relay
shaft is installed firmly and w ithoul play
- tighten bolts on bracket B

C·17
4-speed 091 Interlock/Detent plungers
Reverse gear end play
35.-1I 7
1
35 Manual Transmission-Case, Gears, Shafts

Selector linger
Rocker lever shift
I its only in one
removing Fig. 2
position on selec tor
shaft
Rocker lever Stud M10 x 42 - - - - - - . .

r
for 3rd/ 4th gear projection: 21 mm (13/16 1n.)
selector shalt
Geer shift housing

Spring
1_ ThN.........
Clip
presses selector shall and
selec tor lever into 3rdl4th
shift gate

Plug/ rocker fever shall - -- -

removing Fig. t
install flush

Selector shaft bushing

removing Fig. 3
installing Fig . 4

Selector shalt oil seal

remoying F1g. 5
installing Fig. 6
can be replaced with
transmission installed

35-706 1

- - - - - Gear shill housing assembly

shows position of selector shaft and
rocker shaft parts when installed

1 35-%5 J

35.18 Gear shift housing

4-speed 091
 Manual Transmission-Case, Gears, Shafts 35

Fig. 4 Selector shaft bushing, installing

Fig. 1 Plug for rocker lever shaft, removing
-tap 6 mm thread In plug and pull out
with bolt (always use new plug)

l , ·• I
Fig. 5 Selector shaft oU seal, removing
- pull out wi th screwdriver
Fig. 2 Rocker lever shaft, removi ng
- first remove plug, see Fig. 1

with
llalled

VW423

Fig. 6 Selector shaft oil seal, Installing

- fill space between lips with mull •·
purpose grease

Fig. 3 Selector shaft bushing, removing

C·18 C·19
4-speed 091 Rocker lever shaft
Selector shaft
35.-tI 9
1
35 Manual Transmission-Case, Gears, Shafts

Clrcllp ----c_~

4th gear -----""T"'!::--.~

replace as matched '--'---.....,-~
C"""--~'~----
---- Spring

.
set only

•]-·.,·
Synchronizer ring 4th gNr __''-::::7""0::::::..._
c hecking Fig. 5
identif ication/installation
instructions page 35.30

4th gear needle bearing--"

before Installing lubricate
with transmission oil

Synchronlz• 3rd/4th gear

parts are not matched
removing Fig. 1
installing Fig. 6 and Fig. 7
installation position Fig. 8 Clrcllpa 3rd/4th gear
always repla<:e
removing Fig. 2
Synchronizer ring 3rd gear installing Fig. 3,
checking Fig . 5 Fig. 4 and Fig. 9
identificat ion / installation
instructions page 35.30 / 3rd gear
replace as matched
3rd gear needle beerlng _ . . . / set only
use only split cage with needles
in pairs. Spread cage and lift·
over splines on main shaft.
Before installing, lubricate - - - - - - - M a i n ahaft
with transmi ssion oil

Tranamlaalon houalng

.....---- Needle bearing

removing Fig. 12
installing Fig . 13

35.20 Main shaft

4-speed 091
 Manual Transmission-Case, Gears, Shafts 35

Fig. 4 Circllp 3rd/4th gear, installing

~er hub
-place new circllp (arrow) on sleeve and
push over splines with tube until
circlip snaps into groove

CAUTION
Circlip must be located inside relieved part
of installing tool while it is being pushed
on so that it expands uniformly over
complete circumference

Fig. 5 Synchronizer rings 3rd/4th gear, checking

- press synchronizer rings· onto gear by
tlan<:t and measure gap a with feeler
gauge

New Part Wear limit

mm (ln.) mm (in.)
1.0- 1.7 0.5
Gap a
(0.039- 0.067) (0.020)

Note
Synchronizer ring identification marks and
Fig. 3 Circllp 3rd/4th gear, installing installation instructions, page 35.30

- slide sleeve over shaft until it contacts

splines for hub (arrow). It may be
necessary to back out knurled scre·w
C-21
4-speed 091 Synchronizer 3rd/4th gear
Clrclip 3rd/4th gear
35.21
35 Manual Transmission-Case, Gears, Shafts
....,-- __

- VW412

p 4- J .j4

Fig. 6 Synchronizer 3rd/4th gear, assembling

Fig. 8 Synchronizer 3rd/4th gear, installing
• identification grooves (arrows) of
sleeve and hub are on opposite -turn synchronizer ring until grooves
sides. Groove on sleeve (white are in line with keys
arrow) faces 4th gear • identificatioll groove on sleeve
• sleeve and hub are not matched and (Fig. 6, white arrow) faces 4th gear
can be replaced separately
- assemble parts at several positions
before installing to determine position
of smoothest operation with minimum
backlash

Fig. 9 Circlip 3rd/4th gear, Installing

- slide sleeve over shaft and turn
knurled screw in until groove (arrow)
Is exposed. If necessary, use M6 x 60
bolt inst ead of knurled screw
--;- push circ lip o n until it snaps into
groove
Fig. 7 Synchronizer 3rd/4th gear, assembling
- sli de sleeve over synchronizer hub.
Matched position is no t necessary
-insert keys and install springs with
ends offset 120" . Angled ends of
springs must fit i nto keys

C-22

35.22 3rd/4th gear synchronizer

4-speed 091
 Manuat"Transmission-Case, Gears, Shafts 35
/ --

.........._
Fig. 12 Pinion needle bearing in housing,
removi ng

Fig. 10 Main shaft ball bearing, removing

II
lies

gear

Fig. 13 Pinion needle bearing in housing,

installing
- pres s i n fl ush

CAUTION
row) When install ing, lettered side o f bearing
;x 60 (thicker materi al) mus t face installi ng tool

Fig. 11 Main shaft ball bearing, installing

-press in so that recess in bearing is
aligned wit h recess (arrow ) in housing
- install locking key to p revent beari ng
from tu rning

C·22 C·23
4-speed 091 Main shaft ball bearing
Pinion needle bearing In housing
35 23
•
35 Manual Transmission-Case, Gears, Shafts
Transmission housing
Retaining rl119
removing/Installing page 35.7
35.24 Pinion shaft assembly
Tapered roller bearing-----....
when replacing, measure pinion
depth R before removing, 1st gear---------....,
see Repair Group 39 it teeth are damaged,
removing Fig. 3 and Fig. 4 replace together with
installing Fig. 5 main shalt (matched set)
turning torque, checking Fig. 7
bearing condition, checking Fig. 8
1st gear needle bearlr19
lubricate with tranamission
oil before Installing
note thickness
adjusting, see Repair Group 39
1st geer needle bearing Inner rac:e
matched with ring gear, secured by long collar pressed
when replacing adjust onto synchronizer hub
ring gearfpinion, loosening/tightening Fig. 8
see Repair Group 39 Installation position Fig. 12
4-speed 091
 Manual Transmission-Case, Gears, Shafts 35

Synchronizer ring 1st gur

checking Fig. 9
identification marks page 35.30

Synchronizer 1stl2nd gear

parts are not matched
removing Fig. 2
assembling Fig. 10 and Fig. 1 t 41h gear
installation posit ion Fig . 12 replace as matched set only,
Installing Fig. 13 shoolder faces spacer spring

Clrc:llp Clrcllp/4th gear

for synchronizer ring, always replace
must fit securely In groove removing/installing Fig. 1

Synchronizer ring 2nd gear

Pinion needle bearing
checking Fig. 9
removing Fig. 15
2nd gear needle bearing Installing Fig. 16
lubricate with transmission
oil before installing

Clrcllp/3rd gear
always replace,
must lit securely In groove,
adjusting 3rd gear end play,
Hub Fig. 14
pressed on long collar secures
tst gear needle bearing Inner race 3rd gear
replace as matched set only,
shoulder faces 2nd gear,
end play, adjusting Fig. 14

2nd o..r
If teeth are damaged, replace
together with main shaft
(matched set)

1 35- 717

0·2
0-3
4-speed 091 Pinion shaft assembly 35.25
35 Manual Transmission-Case, Gears, Shafts

• v

- press off by supporting outer race

- if necessary, press 2nd Inner race olf
separately, see Fig. 4

Fig. 1 Clrcflp/4th gear, removing/Installing

• must fit !lecurely In groove (arrow)

CAUTION
Hold 4th gear down (spring under tension)

VW4S7

Fig. 4 Tapered roller bearing 2nd Inner race,

removing

Fig. 2 Synchronizer sleeve/hub and 1st gear,

removing

Clrcllp/41h gear

35.26 Synchronizer/1st gear

Tapered roller bearing
4-speed 091
 Manual Transmission-Case, Gears, Shafts 35
VW408o

VW401

Fig. 7 Tapered roller bearing, checking turning

torque
-lubricate bearings with transmission
Fig. 5 Tapered roller bearing, Installing oil and tighten retaining ring, see page
35.7
-heat Inner races to about 100•c (212°F} -turn pinion shaft in both directions
and press on about 15-20 times
:e -before tightening needle bearing Inner -turn further and read turning torque
:e off race, let tapered roller bearing cool to • new bearings:
room temperature up to 210 Ncm ~180 in. lb)

\ • used bearings • :
up to 70 Ncm (61 in. lb)
("after running at least 30 miles)
• if no turning torque can be
measured, see Fig. 8

Fig. 6 1st gear needle bearing Inner race,

loosening /tightening
-hea t inner race to about 6o•c (140.F)
and screw on as far as possible by
hand
Fig. 8 Bearing condition, checking
CAUTION -check for rock at end of pinion. There
~ee,
Inner race is hot. Do not touch with bare must not be any detectable movement
hand if YES, replace tapered roller bearing

-place pinion shaft in tool 2052 and

tighten wing nut lightly
-tighten inner race to 210 Nm (152 ft lb)
-check turning torque of tapered ro ller
bearing, see Fig . 7

0· 4 0·5
4-speed 091 T1pered roller bearing
1st ge1r needle bearing
35.27
·
35 Manual Transmission-Case, Gears, Shafts

Fig. 9 Synchronizer ring 1st/2nd gear, checking

- press synchronizer rings onto gear by
hand and measure gap a with feeler
gauge

134-581 1
New Part Wear limit
Fig. 11 Synchronizer 1st/2nd gear, assembling
mm (ln.) mm(ln.)
1.0 - 1.7 0.5 - slide sleeve over sychroniter hub.
Gap a Matched position is not necessary
(0.039-0.067) (0.02<>)
- Insert keys and Install springs with
ends offset 120". Angled ends of
Note springs must fit into keys

Synchronizer ring identification marks and

installation instructions, page 35.30

I 34-51!0 I
Fig. 10 Synchronizer 1st/2nd gear, assembling
• gear teeth on sleeve and long collar on
hub must face 1st gear when installing
• sleeve and hub are not matched and
can be replaced separately
1st gear
needle bearing
Inner race
134-9511
Fig. 12 Synchronizer assembly 1st/2nd gear and
1st gear ,n eedle bearing Inner race,
installation position
- position synchronizer ~ssembly on
needle bearing inner race so that old
marks on long collat of synchronizer
hub (from lugs on needle bearing
inner race) are now opposite gaps on
needle bearing inner race
• sleeve and hub are not matched and
can be replaced separately

35.2,8 Synchronizer 1st/2nd gear 4-speed 091

 Manual Transmission-Case, Gears, Shafts 35
- VW408a
-VW412 ;-VW295o

- VW415o

...........
Fig. 15 Pinion needle bearing in gear carrier
housing, removing
- press out without damaging circlip

- VW409
Fig. 13 Synchronizer 1stl2nd gear, Installing
-turn synchronizer ring until grooves
are in line with keys (installation
position, see Fig. 10 and Fig. 11)

/
/ ....
,. '

Fig. 14 3rd gear end play, adjusting

ring
-measure end play wi th feeler gauge
-adjust by selecting suitable circlip Fig. 16 Pinion needle bearing In gear carrier
• play should be 0.05 mm-0.20 mm housing, Installing
(try to keep lower limit)
tnd -press in until seated
Clrcllps available:

Thickness Part
ld mm Color No.
~r
1.60 black 113 311 382
1.75 blue 113 311 383
Jn
1.90 brown 113 311 384
2.05 gray 113 311 385
2.20 copper 113 311 386
2.30 brass 113 311 387
2.40 silver 113 311 388

0·7
4...speed 091 3rd gear
Pinion needle bearing
35 29
•
35 Manual Transmission-Case, Gears, Shafts

Synchronizer rings, Identification marks/Installation Instructions

Note
When assembling transmission, install
synchronizer ring to same gear from which It
was removed

Synchronizer
ring 2nd gear 3rd gear 4th gear

markings

without notches
t
3 notches (arrow)

production brass ring coated brass ring coated special brass ri ng brass ring
with molybdenum, with molybdenum coated with
Part No. 091 311 247 B molybdenum, Part
No. 091 311 295 A,
shown below

spare part brass ring coated special brass ring

with molybdenum, coated with
Part No. 091 311 247 8 molybdenum, Part
No. 091 311 295 A,
marked as shown
on right \.,
teeth~ around circumference
.
)

35.30 Synch,onlze' ring Identification 14-speed 0911


4-Speed 091/1
Manual Transmission
Case, Gears, Shafts
Index
-Adjusting rings 35.32
installing 35.35
marking/removing 35.34
-Assembly 35.32, 35.33, 35.36,
35.37
mounting in repair stand 35.34
-Clutch housing assembly 35.42
-Differential 35.35
-Drive flange 35.32
circlip, installing 35.35
installing 35.35
oil seal 34.18
removing 35.34
-Gear carrier 35.44
assembly 35.36, 35.37
assembling 35.40, 35.41
cover 35.44
installing 35.39
removing 35.38
-Gear ratios 35.60
-Gears
1st/2nd, removing 35.56
3rd,
end play 35.59
installing 35.59
removing 35.56
-Gearshift lever 34.6
-Gearshift linkage 34.6, 34.7
-Installing 34.17
-Lever bearing plate 34.6
-Lubricant specifications 35.60
/ ~Speed
E·1
35
-Main shaft 35.49
assembly 35.48, 35.49
ball bearing 35.51
lock ring 35.52
needle bearing 35.51
oil seal 35.43
rear, removing/ installing 35.35a
-Pinion shaft 35.55
assembly 35.54, 35.55
needle bearings 35.57, 35.59
roller bearings 35.56, 35.57
-Removing 34.16, 34.17
-Retaining ring 35.37
installing 35.40
removing 35.38
-Selector shaft
modifications 35.60a
parts for 35.60d
-Shift forks/synchronizers
modifications 35.60b-35.60c
parts for 35.60d
-Shift shaft oil seal 35.46
-Shift rod bushing 35.46
-Starter bushing 35.43
-Synchronizers
1st/2nd gear 35.58
3rd/4th gear 35,50, 35.51
ring indentification 35.52
-Transmission, housing 35.45
assembling 35.39
disassembling 35.38, 35.39
091
- See page 35.1
5· peed 094
See page 35.61
09~4WD Syncro
- See page 35.93
35.31
35 Manual Transmission-Case, Gears, Shafts
Transmission/Final drive lubricant:
Hypoid oil API/GL-4; MIL-L2105
SAE BOW, SAE BOW/90
Capacities:
Vehicles with gasoline engines 3.0 L (3.2 US qt)
Vehicles with Diesel engines 4.0 L (4.2 US qt)
Note
To reduce shifting effort, transmission oil capacity
has been reduced. For production reasons, the oil
filler hole remains at the same location
Oil should only be poured into a level approximately
15 mm (9/16 in) below filler hole.

011 filler plug~

20 Nm (14ft lb) G

Transmission housing~
Mounting in repair stand. Fig. 1

Transmission 091/1
Gear Retlos Trans. DU
1st gear . . . . . . . . . . . . . . . . . . . . . . . . .34:9=3.78
2nd gear . . . . . . . . . . . . . . . . . . . . . . .33:16=2.06
3rd gear. . . . . . . . . . . . . . . . . . . . . . . .63:50 = 1.26
4th gear . . . . . . . . . . . . . . . . . . . . . . . . 52:61 = 0.85
Reverse. . . . . . . . . . . . . . . . . . . . . . . . .33:9 = 3.67
Final drive . . . . . . . . . . . . . . . . . . . . . . .34:7=4.86
Gear Ratios Trans. ABO
1st gear. . . . . . . . . . . . . . . . . . . . . . . . .34:9=3.78
2nd gear . . . . . . . . . . . . . . . . . . . . . . .33:16 2.06
3rd gear . . . . . . . . . . . . . . . . . . . . . . .49:40= 1.225
4th gear . . . . . . . . . . . . . . . . . . . . . . . .41:48=0.85
R~verse . . . . . . . . . . . . . ~ . . . . . .33:9:3.67
F~nal drive . . . . . . . . . . . . . . . . .~

3 5 •3 2 Transmission, assembly
4-speed 091/1
 Manual Transmission-Case, Gears, Shafts

Drive flange----....
removing Fig. 2
installing Fig. 7
Lock ring-----,

Adjusting ring, right

marking position
before removing Fig. 3
removing Fig. 4
installing Fig. 6

Clutch housing
mark position of adjusting ring
before removing, Fig. 3
Main shaft, rear . Before removing, loosen left
/ removing I installing page 35.35A differential adjusting ring to
/
/ reduce tension in transmission
/
/ housing
/

I
/
/
ace ' ...../ /

,.,....
--------------~ 6 bolts MS x 41
with washers
20 Nm (14 ft lb

:::!J
always replace

Main shaft, front

cover splines to prevent
damage to main shaft oil
seal when disassembling

...
assembling

~~·~e~~~~~~ ............ ·~j· ~~~~;=~~~

2nd gear . . . . . . . . . . . . . . . . . . . . . . .33.16-2.06
3rd gear . . . . . . . . . . . . . . . . . . . . . .49:40 = 1.225
~
4th gear. . . . . . . . . . . . . . . . . . . ....41:48=0.85
\ _ _ 011 dreln plug
Reverse. . . . . . . . . . . . . . . . . . . .....33:9 = 3.67
20 Nm (14ft lb)
''"" ..... . . . . . . . . . . . . . . ) . . . . . . .29c6 ~4.63
bolts MS x 28
with washers
20 Nm (14ft lb)

4-speed 091/1
Transmission, assembly 35.3
35 Manual Transmission-Case, Gears, Shafts

Fig. 3 Adjusting ring, marking position

Note
Before starting repair work (which does
not require final drive to be adjusted)
mark position of adjusting rings on
transmission housing. Measure depth to
which they are installed with VW 382/7
and write down readings
-scribe left side (ring gear side) with
Fig. 1 Transmission assembly, mounting In one mark (arrow)
repair stand - scribe right side with two marks
-drain transmission oil
-mount transmission in repair stand

Fig. 4 Adjusting rings, removing

Fig. 2 Drive flange, removing

- remove circlip and wavy spring washer
-attach VW391 to flange with 2 bolts
=
• A M8 x 30 bolts
-pull drive flange out
(
\

35.34 Drive flange

Adjusting ring
4-speed 091 /1
 Manual Transmission-Case, Gears, Shafts 3

Fig. 5 Differential, removing Fig. 7 Drive flange, installing

-remove adjusting rings and rear main
shaft
-lift out differential

:o

Rg. 6 Adjusting rings, installing

- install left and nght adjust ing rings
and align marks at depth previously
measured\
- lubricate U'l\eads with MoS 2 grease
\ - insert wavy spring washer and c irclip
CAUTION ) - press circlip into groove with VW 244b
and at same time check that washer is
Do not tighten le7tide adjusting ring until centered
c lutch housing ha b een installed and bolts
torqued

4-speed 091/1
Differential
Adjusting rings
Drive flange
35 I
•.:
35 Manual Transmission-Case, Gears, Shafts

Rear main shaft, removing/installing

Work sequence

I
I

34-1309 A
Removing

- remove circlip (arrow)

- push sleeve backward and screw out
main shaft

Installing

- screw front and rear main shafts together,

then back off one spline
- push sleeve on and install new circlip

35.35a Rear main shaft 4-speed 091/1

35 Manual Transmission-Case, Gears, Shaft

Note
Differential must be removed
before gear carrier can be removed,
see page 35.35

7boltsM8x38~ ynchronizer unit

with washers
20 Nm (14 ft lb)
\Reverse idler gear
~

(9) ~Q

2boltsM8x110~
with washers
20 Nm (14ft lb)
J
«t======:::::::::»
Gasket~
0

always replace Needle bearing

Washer

Gear carrier cover

Main shaft assembly

disass./ass. page 35.48

Pinion shalt

35.36
 Manual Transmission-Case, Gears, Shafts 3!
~Cover

~ 'W ~Seal

1· 0 ~··"··
~
L15Nm(10fllb)

always replace
-~omm S,
determining thickness,
Repair Group 39
J
Transmission housing

ork
Shift shaft lever~
25 Nm (18ft lb)-

nbly
1135.48

j34-1312j

natt

4-speed 091/1 Gear carrier, assembly

Transmission, assembly
35 3• • l
35 Manual Transmission-Case, Gears, Shafts

Transmission
Disassembling

Work sequence
-remove coverplate
-remove shift shaft

-loosen bolt until relay lever (arrow) can be

pulled against housing
-tighten bolt to lock lever in that position
-pull ott synchronizer hub and reverse gear
A-Puller US 1078
-remove inner circlip, washer and needle
bearing
-remove reverse gear together with needle
bearing and washer
-remove gear carrier housing bolts

-remove retaining ring

- remove gear shift housing
- remove reverse gear shift fork and hub
-remove outer circlip

35 •3 8 Transmission, disassembling
4-speed 091/1
 Manual Transmission-Case, Gears, Shafts 35
Assembling
Work sequence

VW412
30-100

-to remove gear carrier attach VW 457 with two

M8 x 20 bolts
-press gear carrier out with VW 296
-remove shim SJ and note thickness

Note
lf bearing and/or transmission housing are
replaced, and dimension r is not marked on ring
gear, pinion depth must be measured and noted
before gear carrier is removed. This is dimension
r. See Repair Group 39. When assembling, parts
must be installed In same position. See Ring
gear/pinion, adjusting, Repair Group 39
-press main shaft with shift rod into gear
carrier

~ VW409

]34-13 181

- install pinion shaft with shift rod

• shift into 3rd gear
- shift into neutra l
-install pinion shaft needle bearing
]34 ·1316 1

-press pinion shaft with main shaft and shift

rod out of gear carrier

4espeed 091/1 Gear carrier, removing

Transmission, assembling
35 39 •
35 Manual Transmission-Case, Gears, Shafts

Gear carrier
Assembling

Work sequence
-install shim 5 3
-install new gasket
-align shift rod
-align flat on piston with recess in housing
-tap on pinion with plastic hammer to install
• make sure teeth of gears match properly

-install circlip
• make sure lugs of circlip are below teeth of
pinion head (arrow)

-install retaining ring and tighten to

225 Nm (162ft lb), then loosen and retighten
to 225 Nm (162ft lb)

-peen retaining ring twice with suitable tool A

(local manufacture)
-attach gear carrier to transmission housing
and tighten bolts to 20 Nm (14ft lb)

35.40 Gear carrier, assembling 4-speed 091/1

 Manual Transmission-Case, Gears, Shafts 35
determining thickness of spacer for reverse gear

-install synchronizer
-install. circlip
-install reverse gear
• groove in gear must face cover
-install needle bearing and washers
-instal.! shift rod/fork bolt and tighten to
20 Nm (14ft lb)
• before installing coat thread of bolt with
D6-locking compound
134-1339!
-install new gasket
-install circlip -install cover
-measure distance C • align shaft and bore in cover
-tighten bolts to 20 Nm (14ft lb)
Example -install shift shaft
• slotted side toward differential housing
measurement c 29.1 mm -install new gasket
measurement d -.24.7 mm -install spring
n thickness of spacer 4.4mm -install cover and tighten bolts to
15 Nm (10ft lb)
thickness of spacers available -install back-up light switch
-install shift shaft lever
A gaptobeadjuste~ ·
I
(mm) Spare Jrt n~olor
..,..-
3.97-4.19 091 311 379 white

- 4.20-4.39
4.40-4.59
4.60-4.90
091
091
091
311
311
311
379 A
379 B
379 C
black
green
red

-install selected spacer, reverse gear, needle

bearing and circlip

4-speed 091/1 Gear carrier, assembling 35.41

35 Manual Transmission-Case, Gears, Shafts

.... ___
Starter bushing --....,
Pivot bolt removi ng Fig. 3
15 Nm (11 fllb) installing Fig. 4
can be replaced with
transmission Inst alled

Release shalt
lubricate with mulli-
purpose grease

Release shalt busflln-a

removing /instal lin')
see Rep. Group 30
Release shaft bushing\ \
(I
.;..- {;.
\-~

Circlip__/
always replace
Release bearing
do not clean in
solvent, wipe Willi
lubri cate ball lightly
\) dry c lot h

Release bearing guide sleeve

Oil drain p l u g _ _ / plastic, do not grease
20 Nm (14 It lb)

removing Fig. 1
installing Fig. 2
till space between lips
with multi ·purpose grease

35.42 Clutch housing 4-speed 091/1

 Manual Transmission-Case, Gears, Shafts 35

Fig. 1 Main shaft oil seal, removing Starter bushing, Installing

- lubricate bushing and drive In flush

bushing
Jaili ng
tp 30

Fig. 2 Main shaft oil seal, Installing..

~earing
tan in
1ipe with

Fig. 3 Starter bushing, removing

(transmission Installed)
• when transmission is removed, use
drift VW 222a

4-speed 091/1 Main shaft oil seal

Starter bushing
35.43
35 Manual Transmission-Case, Gears, Shafts

Reverse gear shalt

also locks bearing for drive shaft,
install so that bearing is evenly covered

Gear carrier cover

Pinion needle bearing outer race

Bearings
detach before removing
shif t rod

Gear carrier_/
Reverse gear shift rod

35.44 Gear carrier housing

Gear carrier housing cover
4-speed 091/1
 \
Manual ltansmission-Case, Gears, Shafts 35

Oil IIIIer plug

20 Nm (14 It lb)

Circlip

r
for needle beanng
Bushing

t$1 D•l" ohaft naadle be>Ong 20 Nm (14 It lb) ~ ~

··---0. l Q -------Sh i l l •h>ft

remov " ' '1
ing Fig.
instal ling Fi g. 2
can be repl aced with
transmission installed
~

Pin_/
gu1des shi ft shaft ,
drive In until seated

Relay lever
t or 1st an d 2nd gear

Transmission housing
'---Shift rod bushing
rem. / install. Fig. 3

1~- J:\ 191

4-speed 091/1
Transmission housing 35.45
35 Manual Transmission-Case, G , Shafts

Fig. 1 Shift shaft oil seal, removing Fig. 3 Shift rod bushing
-removing
• turn bushing so that lug (arrow) is in
recess of housing and press out
-installing
• align bushing and rod

Fig. 2 Shift shaft oil seal, installing

35.46 Shift shaft oil seal

Shift rod bushing
4-speed 091/1
Manual Transmission-Case, Gears, Shafts 35

THIS PAGE INTENTIONALLY

LEFT BLANK

35A7
35 Manual Transmisslon .. case, Gears, Shafts

Synchronizer hub

/Sleeve

,...........--Sprlng

1
(1 .6 mm dial

Synchronizer 3rd /4th gear

parts are not matched
removing Fig . 1
installing Fig. 4 and Fr Q. S
installation position Fig. J

'"'''"•~
ins tall ing Fi g. 10

Synchronizer ring 3rd gear

check ing Fig. 2
Synchronizer ring 4th ge identification/installation
check ing Fig. 2 instructions page 35.53
identification/installation
instructions page 35.53

4th gear needle bearing

before in stalling lubricate
with lransmission oil

35.48 Main shaft

4-speed 091/1
 Manual Transmission-Case, Gears, Shafts 35

'"9
mmdia)

Transmission housing
4th gear
;hed

nd Fig. 5
on Fig. 3

Needle bearing
removing F1g. 8
installing Fig. 9

lid gear needle bearing

bf\l or~ installing. lubricate
~ •th transmission oil

/
/

4-speed 091/1
Main shaft 35.49
35 Manual Transmission-Case, Gears, Shafts

!35-877)
Fig. 1 Synchronizer 3rd/4th gears, removing
-press off together with 3rd gear

Fig. 3 Synchronizer 3rdl4th gear, assembling

• Identification grooves (arrows A & B
of sleeve and hub are on opposite
sides. Groove on sleeve (arrow B)
faces 4th gear
• grooves (arrow C) are for
Identification:
Fig. 2 Synchronizer rings 3rd/4th gears, 1st & 2nd gear= 1 groove
checking 3rd & 4th gear= 2 grooves
-press synchronizer rings onto gear by
hand and measure gap a with feeler
gauge

Gap a

New Part Wear limit

Gear mm (in.) mm (in.)
3rd 1.25-1 .95 0.5
(0.049- 0.077) (0.020)
4th 1.0-1 . 7 0.5
(0.039- 0.067) (0.020)

Fig. 4 Synchronizer 3rd /4th gear, assembling

-slide sleeve over synchronizer hub.
Matched position is not necessary
-insert keys and install springs with
ends offset 120°. Angled ends of
springs must fit into keys

35 •50 Synchronizer
4-speed 09111
 Manual Transmission-Case, Gears, Shafts 35

Fig. 7 Main shaft ball bearing, Installing

-press in so that recess in bearing is
aligned with recess (arrow) in housing

B Fig. 5 Synchronizer 3rd/4th gear, Installing

-turn synchronizer ring until grooves
are in line with keys
• identification groove on sleeve
(Fig. 3, arrow B) faces 4th gear

Fig. 8 Needle bearing in housing, removing

Fig. 6 Main shaft ball bearing, removing

tl

lng
b.
ry
th

4-speed 091/1
Main shaft bearings 35.51
35 Manual Transmission-Case, Gears, Shafts

Fig. 9 Needle bearing in housing, installing

B
• lettered side of bearing (thicker
material) must face installing tool

135-10801

Fig. 11 Circlip, two types

A = previous circlip
Part No. 091 311 381

B = new circlip
Part No. 091 311 381 A

Note
Use either type of circlip during repairs. The
previous circlip will be discontinued when stock
is used up.

CAUTION
Always replace the eire lip during repairs.
Identifying marks on a new circlip (arrow)
Fig. 10 Circlip , installing
must face reverse gear splines.
• make sure ring is seated correctly
(arrow)

35.52 Circlip
Needle bearing
4-speed 091/1
 Manual fransmission-Case, Gears, Shafts 35
Synchronizer rings, identification
Note
When assembling transmission, Install syn-
chronizer ring to same gear from which it was
removed

production
3rd gear: special brass ring,
molybdenum coated,
teeth all around circumference

spare part
For all gears Install ring off 3rd gear which Is
supplied under Spare Part No.: 091 311 295 A

1st gear: brass ring,

molybdenum coated,
3 x 6 teeth,
without notches

2nd gear: brass ring,

molybdenum coated,
3 x 8 teeth,
with 3 notches (arrow)

4th gear: brass ring,

3 x 8 teeth,
with 3 notches (arrow)

4-speed 091/1
Synchronizer rings 35.53
35 Manual Transmission-Case, Gears, Shafts

Reverse gear sleeve

1st and reverse gear

synchronizer hub Needle bearing
removing Fig. 15 Cll
i nst alling Fig. 16

~~
Needle bearing
lub ric ale w ith transmission Gear carrier
oi l before inst allin g housing
Ft
-
------
I \:;:;~~oh,ooi'" ""'·
! \- m"" fit '"'"'"'' io 9 '00"
L __ -0
Synchronizer 1st /2nd gear
removing Fig. 2
assembling Fig. 10 and Fig. 11
in stallation position Fig. 12 1st gear needle bearing Inner race
loosening /tightening Fig. 6

Tapered roller bearing

when replacing, measure~
depth before removing,
see Repair Group 39
removing Fig. 3 and Fig. 4
installing Fig. 5
turning to rque, checking Fig. •
and Ftg. 8

"'-spring
(1.6 mm dia)

35.54 Pinion shaft assembly

4-speed 091/1
 Manual ltansmission-Case, Gears, Shafts 35

3rd gear
removing Fig. 1
Installi ng Fig. 13
shoulder fac es
2nd gear

r2ndgear

1 gear

' ----c I}~ ·-...I

Needle bearing/2nd gear

lubric ate with transmi ssion
Circlip/3rd gear
always rep lace,
oil before installing I
musl fit securely in groove,
a<IJUSti ng 3rd gear end play, __j
- - - - - --------
Fig. 14

ShimS,----------...
earing note thickness
1smi ssion adJu" ;ng, , .. Aopa;, G<oup 3~
,g

Pinion ohall _ /
matched with ring gear,
when replacing adjust
ri ng gearfpinion,
see Repair Group 39

Retaining ring
removing/installi ng p age 35.40

~king Fig. 7

4-s peed 091/1

Pinion shaft assembly 35.55
35 Manual Transmission-Case, G·ears, Shafts

VW401

Fig. 1 3rd and 2nd gears, removing

!
135-8861

Fig. 3 Tapered roller bearing, removing

Fig. 2 Synchronizer sleeve/hub and 1st gear,

removing

Fig. 4 Tapered roller bearing inner race,

removing

35 •56 Pinion shaft

4-speed 091/1
 Manual Tra.nsmission-Case, Gears, Shafts 35

2052 2 -
VW401 --

us 1064

Fig. 7 Tapered roller bearing, checking turning

torque
- lubricate bearings with transmiss ion
oil and tighten retain ing ring
Fig. 5 Tapered roller bearing, installing - turn pinion shaft In both directions
about 15-20 times
- heat Inner race to about 100°C (212 °F) -turn further and read turni ng torque
and press on • new bearings:
- before tightening needle bearing Inner up to 210 Ncm (180 ln. lb)
race, let tapered roller bearing cool to • used bearings• :
room temperature up to 70 Nc m (61 in. lb)
("after running at least 30 m i les)
• if no turning torque can be
measured, see Fig. 8

Fig. 6 Needle bearing, loosening/tightening

- heat Inner race to about 60 °C (140°F)
and screw on as far a s possible by Fig. 8 Bearing condition, checking
hand -check for rock at end of pini on. There
- place pinion shaft in tool 2052 and must not be any detectable movement
tighten wing nut lightly if YES, replace tap ered roll er bearing
- t ig hten Inner race to 210 Nm (152ft lb)
- check turnin g torque o f tapered roller
bearing, see Fi g. 7

4-speed 091/1
Pinion shaft 35.57
35 Manual Transmission-Case, Gears, Shafts

Fig. 9 Synchronizer ring 1st/2nd gear, checking

-press synchronizer rings onto gear by
hand and measure gap a with feeler
gauge

Fig. 11 Synchronizer 1st/2nd gear, assembling

New Part Wear limit
-slide sleeve over sychronizer hub.
mm On.) mm (ln.) Matched position is not necessary
Gap a 1.3-1 .9 0.5 -Insert keys and Install springs with
(0.051-0.075) (0.020) ends offset 120°. Angled ends of
springs must fit into keys

Fig. 12 Synchronizer 1st/2nd gear, Installing

Fig. 10 Synchronizer 1st/2nd gear, assembling -turn synchronizer ring unt il grooves are
in line with keys (Installation position,
-groove (arrow A) must face 2nd gear see Fig. 10)
-collar on hub must face 1st gear
-grooves (arrow B) are for identification:
• 1st gear & 2nd gear= 1 groove
• 3rd gear & 4th gear = 2 grooves

35.58 Synchronizer 4-speed 091/1

 Manual Transmission-Case, Gears, Shafts 35

!Js-s9• I
Fig. 13 3rd gear, Installing Fig. 15 Pinion needle bearing In gear carrier
housing, removing
-collar must face 2nd gear

Fig. 14 3rd gear end play, adjusting Fig. 16 Pinion needle bearing In gear carrier
-measure end play with feeler gauge housing, Installing
-adjust by selecting suitable circlip
• play should be 0.05 mm-0.20 mm (try
to keep lower limit)

Clrclips available:

Thickness Part
~are
mm Color No.
on, 1.60 black 113 311 382
1.75 blue 113 311 383
1.90 brown 113 311 384
2.05 gray 113311385
2.20 copper 113 311 386
2.30 brass 113311387
2.40 silver 113311388

4-speed 091/1 3rd gear

Pinion needle bearing
35 59
•
35 Manual Transmission-Case, Gears, Shafts
Listed below are gear ratios and lubricant To reduce shifting effort, transm issi on oil capucity
specifications for 1985 MY Vanagons equipped with has been reduced .
4-speed manual transmission 091/l:
For production reasons, the oil filler hole remai ns
Gear Ratios Trans. DU at the same location .
tst gear 34:9 3.78
2nd gear 33:16 206 Oil should only be poured in to a level approxim<>tely
3rd gear 63:50 1.26 15 mm (9/ 16 in.l below the filler hole.
4th gear 52:61 0.85
Reverse 33:9 3.67 Transmission filling capacities:
Final dr1ve . 34:7 4 .86 V ehicles with gasoline engines 3.0 liters (3.2 qt)
Vehicles with Diesel engines 4.0 liters (4.2 qt)
Gear Ratios Trans. ABO
1st gear 34:9 3.78
2nd gear 33:16 2 .06
3rd gear 49:40 1.225
4th gear 41:48 0.85
Reverse 33:9 3.67
Final drive 29:6 4 .83

lubncant capacity (incl. differential)

09111 . . 3.0 I (3.2 US qt)
viscos1ty. SAE BOW, SAE BOW/90
type hypo1cl. Mll·l-2105: API/GL-4

35.60 Gear ratios

Lubricant specifications
4-speed 091/1
 Manual Transmission-Case, Gears, Shafts 35

Transmissions installed in vehicles prpduced before Note

May, 1984 are subject to refinements currently
used in production. Transmissions needing repair Only latest version parts will be supplied as spare
should be inspected and repaired as necessary parts.
aly
according to following procedures with parts
required according to transmission date of
manufacture (see transmission housing code). CAUTION
Part numbers are for reference only. Always
check with your Parts Department for latest parts
information.
Selector shaft, modifications
• external repairs performed with transmission
installed A - Selector shaft
- replace complete shaft with new version
B- Selector shaft cover
• provided with shoulder for spring to maintain
proper position when assembling
- replace cover and 0-ring
Cover

~Retainer

Q'

Spring----'
• pushes gearshift lever into
3rd14th shift gate

Selector shaft

l35-969l

4-speed 091/1
Selector shaft modifications 35.60a
 ·"·:i£1;.]·. uu.·rP
35 Manual Transmission-Case, Gears, Shafts

Internal repairs (requiring

disassembly of transmission)
Shift forks/synchronizers, modifications

Gear carrier----""""~
r "'""" . . ohift ""' ••..,..,

I
Main shaft assembly

1st/2nd gear synchronizer -------------J

C -Shift forks/rails
• 1st/2nd and 3rd/4th gear shift forks/rails are
rivited and welded to maintain proper align-
ment to each other
- replace with new shift forks/rails

D- Synchronizers
• 1st/2nd and 3rd/4th gear synchronizers have
been changed to prevent jumping out of
gear
• changes cannot be detected visually
- replace with new version synchronizers

35.60b Shift forks/synchronizers

modifications
4-speed 091/1
 Manual Transmission-Case, Gears, Shafts 35
Reverse shift fork/rail, modifications
Gear carrier cover
Reverse shift rail

/rail

trod

!35-967)

E- Reverse shift fork/rail and has two bearing shells which ride in 3rd
• mating surfaces of fork/rail have splines to bearing which is housed in boss provided in
properly align to each other gear carrier cover
• reverse shift rail is lengthened - replace with all new version parts

Reverse gear/shaft, modifications

Reverse gear shaft

R Thrust washer
averse gear deleted
with shoulder
• shoulder faces reverse shaft
support plate
!35-9661

F - Reverse gear/shaft - replace with all new version parts only if

• diameter of reverse gear shaft bearing pin reverse shaft pin A is loose in bearing
A increased from 12 to 18 mm carrier
• bearing carrier hole increased to fit
• thickness of support plate B increased from Note
5 to 6 mm and thrust washer between plate
Thrust washer between support plate and reverse
and reverse gear is deleted
gear must be removed if new version reverse shaft
• reverse gear provided with shoulder
is installed.

4-speed 091/1 Reverse shift fork/rail modifications

Reverse gear/shaft modifications 35.60c
35 Manual Transmission-Case, Gears, Shafts

Parts requirements (based on

CAUTION
transmission date of manufacture)
Part numbers are for reference only. Always con·
Note suit your Parts Department for latest parts
information
Previous version parts are not available and must
be replaced by latest version listed below

Transmission date Parts Required I

/
of manufacture Description t'ar'r number (Quantity)
Prior to Selector shaft • • 091-311·534B'.
09 08 2 Selector shaft cover 091-301-232A
Selector shaft cover 0-ring 091c301-278A
Shift fork ( 112) 091·311-549A
Shift fork (3/4) 091-311-559A
Synchronizer (1/2) 091-311-241B
Synchronizer (3/4) 091-311-301 B
Reverse s.hift fork 091-311-571A
Reverse shift rail 091-311-577C
Reverse shift rail bearing shells 091-301-146(2)
Bearing carrier cover 091-301-205E
Reverse gear shaft* 091-311-514A
Bearing carrier* 091-301·173C
Reverse gear • 091·311·507A
*Only to be replaced if reverse
shaft is loose in bearing carrier
from Selector shaft*· 091·311-534B ••
10 08 2 Selector shaft cover 091-301-232A
to Selector shaft cover 0-ring 091-301·278A
25 08 2 Shift fork (112) 091·311·549A
Shift fork (3/4) 091-311-559A
Synchronizer (1/2) 091-31 t-241 B
Synchronizer (3/4) 091-311·301B
Reverse shift fork 091-311-571A
Reverse shift fork rail 091-311-577C
Reverse shift rail bearing shells 091-301-146(2)
Bearing carrier cover 091-301·205E
from Selector shaft* • 091-311-534B**
26 08 2 Selector shaft cover 091-301·232A
to Selector shaft cover 0-ring 091-301-278A
18 11 2 Shift fork (1/2) 091·311·549A
Shift fork (3/4) 091·311-559A
Synchronizer (1/2) 091-311·241B
Synchronizer (3/4) 091-311-301B
from Selector shaft" • 091·311·534B*.
19 11 2 Selector shaft cover 091-301·232A
to Selector shaft cover 0-ring 091-30 1·278A
24 11 2 Shift fork (1/2) 091·311-549A
Shift fork (3/4) 091-311-559A
from Selector shaft*· 091-311-534B**
25 11 2 Selector shaft cover 091·301-232A
to Selector Shaft cover 0-ring 091·301·278A
02 12 2
from 03 12 2
to vehicles produced Selector shaft*· 091-311-534B* *
up to May, 1984
** See page 35.60a

35.60d Parts for modifications

4-speed 091/1

Quick Data Index
-Adjusting rings 35.62
installing 35.65
marking/removing 35.64
-Assembly 35.62, 35.63, 35.66,
35.67
mounting in repair stand 35.64
-Clutch housing assembly 35.74
-Differential 35.65
-Drive flange 35.62
circlip, installing 35.65
installing 35.65
oil seal 34.18
removing 35.64
-Gear carrier 35.76
assembly 35.66, 35.67
assembling 35.70, 35.71
cover 35.76
installing 35.69
removing 35.68
-Gears
1st, shim 35.72, 35.73
2nd, removing 35.88
3rd/4th, removing 35.88
4th, end play 35.91
installing 35.91
-Gearshift lever 34.1 0
-Gearshift linkage 34.1 0, 34.11
-Installing 34.17
-Lever bearing plate 34.1 0
G·1
35
5-Speed 094
Manual Transmission
Case, Gears, Shafts
-Main shaft 35.81
assembly 35.80, 35.81
ball bearing 35.83
lock ring 35.84
needle bearings 35.83, 35.84
oil seal 35.75
rear, removing/installing
35.65a
-Modifications to trans.
manufactured prior to
Dec. 15, 1982 35.65b-35.65d
-Pinion shaft 35.87
assembly 35.86, 35.87
needle bearings 35.89, 35.91,
35.92
roller bearings 35.88, 35.89
-Removing 34.16, 34.17
-Retaining rings 35.67
installing 35.70
removing 35.68
-Shift rod bushing 35.78
-Shift shaft oil seal 35.78
-Starter bushing 35.75
-Synchronizers
assembling 35.90
checking 35.82
installing 35.90
removing 35.82, 35.88
ring, checking 35.90
identification 35.92
2nd/3rd gear 35.90
4th/5th gear 35.82, 35.83
-Transmission, housing 35.77
assembling 35.69
disassembling 35.68, 35.69
4-Speed 091
- See page 35.1
4-Speed 091/1
- See page 35.31
094-4WD Syncro
- See page 35.93
35.61
 Transmlss~n/F ;~~------------------------------------------------
Hypold oil API/:•' drive lubrlc .
SAE BOW, SAE BOL-4; MIL·l2105ani.
Capacity: 4.0 Itr (4.2
W/90US qt)

I
,
...
',
I '
I '
II ' ',
on tiller plug
I~ I '
20 Nm (14 tt
8 I
I
I '
'

I
I
I
/

Transmission
Mount'ing . housing
m repair stand . F IQ.
' T

35.62 Transmlss Ion, assembly

I 5-speed 094 1
 Manual Transmission-Case, Gears, Shafts 35

Drive rt81AG4t-----~
removing Fig. 2
installing fig. 7

Lock rtna - - - - - , .

Adjustlria rtna, right

marking position
belore removin.g Fig. {I
removing Fig._.
Installing Fig. 6

Main shaft, rear
removing/installing page 35.65A
Clutch hou11tna
mark positiOil of adjusting ring
before removing, Fig. 4
Bef'o re removing, loosen left
differential adjusting ring to
reduce tension In t.ransmission
housing

ace

~Steeve

--------------c::, ~ 6 bolts M8 :~~ 46

with washers
20 Nm {14 It tb)

c~::::_;
always replace

Main shaft. front

cover splines to prevent
damage to main shaft oil
seal when disassembling/
assembling

4 bolto M8' 28~ ~

with washers
20 Nm (14 ftlb) L Oil drain plug
20 Nm (14 It lb)

5-speed 094 Transmission, assembly 35.63

35 Manual Transmission-Case, Gears, Shafts

Fig. 3 Adjusting ring, marking position

Note
Before starting repair work (which does
not require final drive to be adjusted)
mark position of adjusting rings on
transmission housing. Measure depth to
which they are installed with VW 382/7
and write down readings
- scribe left side (ring gear side) with
Fig. 1 Transmission assembly, mounting In one mark (arrow)
repair stand
-scribe right side with two marks
- drain transmission oil
- mount transmission in repair stand

Fig. 4 Adjusting rings, removing

Fig. 2 Drive flange, removing

- remove circ lip and wavy spring washer
-a ttach VW391 to flange with 2 bolts
• A= M8 X 30 bolts
-pull drive flange out

35.64 Drive flange

Adju sting rings
5-speed 094
 Manual Transmission-Case, Gears, Shafts 35

Fig. 7 Drive llange, Installing

Fig. 5 Differential, removing
-remove adjusting rings and rear main
shaft
>es
-lift out differential

:h to
1)7

Fig. 6 Adjusting rings, installing

-install left and right adjusting rings
and align marks at depth previously
measured
-lubricate threads with MoS 2 grease Fig. 8 Clrcllp for drive flange, installing
L· 'lT2
CAUTION -insert wavy spring washer and circlip
-press circlip into groove with VW 244b
Do not tighten left side adj usting ring until and at same time check that washer is
clutch housing has been installed and bolts centered
torqued

5~speed 094
Differential
Adjusting rings
Drive flange
35.65
.
35 Manual Transmission-Case, Gears, Shafts

Rear main shaft, removing/installing

Work sequence

34-1309 A
Removing

remove circlip (arrow)

push sleeve backward and screw out
main shaft

Installing

screw front and rear main shafts together,

then back off one spline
push sleeve on and install new circlip

\
\

35.65a Rear main shaft 5-speed 094

 Manual Transmission-Case, Gears, Shafts 35
Transmission modifications
(manufactured prior to Dec. 15, 1982)

Transmissions with date of manufacture (see Note

transmission housing code) prior to 15 12 2
(December 15, 1982) are subject to refinements Only latest version parts will be supplied as spare
currently used in production. Transmissions needing parts.
repair should be inspected and repaired as
necessary according to following two groups of
procedures with required parts according to dates of CAUTION
manufacture. Part numbers are for reference only. Always
check with your Parts Department for latest
parts information.

Selector shaft, modifications

• external repairs performed without removing
transmission

Large spring (old)

~
I • pressed gearshift lever
into 2nd/3rd shift gate

Up to 1110 2
date of manufacture

Spring ( n e w ) - - - - - " "

• pushes gearshift lever
out of reverse/1st shift ~-.;:o.... _ _ Selector shaft {old)
gate with small preload
spring

Since 1210 2 - - - - - - - - - - - '

date of manufacture

Selector shaft ( n e w ) l - - - - - - - - - - - - - - '

5-speed 094 Modifications to transmissions

manufactured prior to Dec. 15, 1982 35.65b
35 Manual Transmission-Case, Gears, Shaft

A- Selector shaft Note

- replace complete shaft with new version
large spring may be left in transmissions in which
B- Selector shaft spring originally installed to accommodate driver's current
Gearshift lever is now moved by spring shifting habits.
pressure out of reverse/1st shift gate rather than
C- Selector shaft cover
into 2nd/3rd shift gate
• provided with shoulder for spring to maintain
- install new selector shaft spring
proper position when assembling
- replace cover and o-ring

Shift forks/synchronizers, modifications

• internal repairs requiring disassembly of
transmission

Main shaft assembly---, 4th/5th gear shift rod fork/rail

Gear carrier---~

2nd/3rd gear shift rod

fork/rail

Pinion shaft assembly - - - - - '

135-9711
2nd/3rd gear synchronizer _ _ ___,

D- Shift forks/rails E- Synchronizers

• 2nd/3rd and 4th/5th gear shift forks/rails are • 2nd/3rd and 4th/5th gear synchronizers have
riveted and welded to maintain proper been changed to prevent jumping out of gear
alignment to each other • changes cannot be detected visually
- replace with new shift forks/rails - replace with new version synchronizers

35.65c Modifications to transmissions

manufactured prior to Dec. 15, 1982
5-speed 094
 Manual Transmission-Case, Gears, Shafts 35
Parts requirements (based on transmission date of
manufacture)
lhich
ment Note
Previous version parts are not available and must be
replaced by latest version listed below.
aintain

CAUTION
Part numbers are for reference only. Always
check with your Parts Department for latest
parts information.

Transmission date Parts required

of manufacture
Description Part Number
Prior to 11 10 2 Selector shaft 091-311-5348
Selector shaft spring 091-311-5488
Selector shaft cover 091-301·232A
Selector shaft cover o-ring 094-301-278A
Synchronizer (2/3) 091-311-2418
Synchronizer (4/5) 091-311-3018
Shift fork (2/3) 091-311-549A
Shift fork (4/5) 091-311-559A
From 12 10 2 Selector shaft 091-311-5348
to 18 11 2 Selector shaft cover 091-301·232A
Selector shaft cover o-ring 094-301-278A
Synchronizer (2/3) 091-311-2418
Synchronizer (4/5) 091-311-3018
Shift fork (2/3) 091-311·549A
Shift fork (4/5) 091·311-559A
From 19 11 2 Selector shaft 091-311-5348
to 24 11 2 Selector shaft cover 091-301-232A
Selector shaft cover o-ring 094-301-278A
Shift fork (2/3) 091-311-549A
Shift fork (4/5) 091-311-559A
From 25 11 2 Selector shaft 091-311-5348
to02122 Selector shaft cover 091-301-232A
Selector shaft cover o-ring 094-301·278A
From 03 12 2 Selector shaft 091-311-5348
to 14 12 2

:ers have
Jt of gear

'
mizers

5-speed 094 Modifications to transmissions

manufactured prior to Dec. 15, 1982 35.65d
35 Manual Transmission-Case, Gears, Shaft

Note
Differential must be removed
before gear carrier can be removed,
Needle bearing
see page 35.65
Reverse idler gear

,----Gear carrier cover

Synchronizer unit
7 bolts M8 x 3 8 1 _
with washers
20 Nm (14ft lb)

Needle bearing

-1st gear
Shim for 1st gear-
determining thickness, page 35.73

35.66
 Manual Transmission-Case, Gears, Shafts 35

Boot~~·{i
ShimS,
determining thickness,
Repair Group 39
@
Shift shaft lever 9

\lo<lulog
25 Nm (18 ftlb)~
4th/5th gear shift rod fork

o~
Main shaft assembly
disass.fass. page 35.80

2nd/3rd gear shift rod fork

Pinion shaft assembly----

disass./ass. page 35.86

5-speed 094 Gear carrier, assembly

Transmission, assembly
35 67 •
35 Manual Transmission-Case, Gears, Shafts

Transmission
Disassembling

Work sequence
-remove coverplate
-remove shift shaft

L--~~~~=z~==~
-pull off synchronizer hub and reverse gear
• A-puller US 1078
-loosen bolt until relay lever (arrow) can be
pulled against housing -remove inner circlip, washer and needle
-tighten bolt to lock lever in that position bearing
-remove reverse gear together with needle bear-
~-----
ing and washer
-remove gear carrier housing bolts

I
I
I

-remove retaining ring

-remove gear shift housing
-remove reverse gear shift rod and hub
-remove outer circlip

3 5 •6 8 Transmission, disassembling
5-speed 094
 Manual Transmission-Case, Gears, Shafts 35
Assembling
I
Work sequence
I --------!F==~------~:

l VW412

I:
30-100

-to remove gear carrier attach VW 457 with two

M8 x 20 bolts
-press gear carrier out with VW 296
I
I -remove shim 5 3 and note thickness
~ Note
P) If bearing and/or transmission housing are
replaced, and dimension r is not marked on ring
~~ gear, pinion depth must be measured and noted
....--J
.r before gear carrier is removed. This is dimension
r. See Repair Group 39. When assembling, parts -press main shaft with shift rod into gear
must be installed in same position. See Ring carrier
gear/pinion, adjusting, Repair Group 39
t bear·

13.4-13181

-install pinion shaft with shift rod

• shift into 4th gear
-shift into neutral
-install pinion shaft needle bearing

-press pinion shaft with main shaft and shift

rod out of gear carrier

5-speed 094 Gear carrier, removing

Transmission, assembling
35 69 •
35 Manual Transmission-Case, Gears, Shafts

Gear carrier d

Assembling
Work sequence

-install shim 8 3
-install new gasket
-align shift rod
-align flat on piston withrecess In housing
-tap on pinion with plastic hammer to install
• make sure teeth of gears match properly

-install circlip
• make sure lugs of circlip are below teeth of
pinion head (arrow)

A -install retaining ring and tighten to

225 Nm (162ft lb), then loosen and retighten
to 225 Nm (162ft lb)

l3s-108ol

A = previous circlip B = new circlip

Part No. 091 311 381 Part No. 091 311 381 A
Note 1]3-!Q~

Use either type of circlip during repairs. The

previous circlip will be discontinued when stock -peen retaining ring twice with suitable tool A
is used up. (local manufacture)
-attach gear carrier to transmission housing
CAUTION and tighten bolts to 20 Nm (14 ft lb)
Always replace the circlip during repairs.
Identifying marks on a new circlip (arrow)
must face reverse gear splines.

35.70 Gear carrier, assembling

5-speeed 0941
 Manual Transmission-Case, Gears, Shafts 35
determining thickness of spacer for reverse gear

I
1.

134-13051

-install synchronizer
-install circlip
-install reverse gear
-install circlip
• groove in gear must face cover
-measure distance C
-Install needle bearing and washers
-install synchronizer for 1st/reverse gear and
Example
shift fork
measurement c 29.1 mm • molybdenum coated side of synchronizer
measurement d -24.7 mm ,ring faces 1st gear
thickness of spacer 4.4 mm -install shift rod/fork bolt and tighten to
20 Nm (14ft lb)
thickness of spacers available • before Installing coat thread of bolt with
A D6-locking compound
' gap to be adjusted -install 1st gear
(mm) Spare part no. color -install needle bearing
I I
+--i 3.97-4.19 091 311 379 white
4.20-4.39 091 311 379 A black
4.40-4.59 091 311 379 8 green
4.60-4.90 091 311 379 c red

-install selected spacer, reverse gear, needle

bearing and circlip

lA

5-speed 094 I Gear carrier, assembling

l _ __ _;;__ _ _ _- - - '
35 71 •
35 Manual Transmission-Case, Gears, Shaft

Shim for 1st gear

~L--a--
gear carrier housing cover

35.72 Shim for 1st gear

5-speed 094
 Manual Transmission-Case, Gears, Shafts 35
Determining thickness b=x-y
Example:
Work sequence b=77.6 mm
-1.0 mm
76.6 mm

Measurement= a- b
=77.8 mm
-76.6 mm
1.2mm
Following shims are available:
Shim Spare
Measurement thickness Part
(mm) (mm) No.
0.95 ... 1.14 0.6 094 311 379
1.15... 1.34 nn 094 311 379 A
1.35... 1.54 1.0 094 311 379 B

-measure depth a
1.55... 1.74 1.2 094 311 379 c
Example: a= 77.8 mm 1.75... 1.94 1.4 094 311 379 D
1.95... 2.14 1.6 094 311 379 E
2.15 ... 2.47 1.8 094 311 379 F

-select correct shim

-"install new gasket
-install cover
• align shaft and bore in cover
-tighten bolts to 20 Nm (14 ft lb)
-loosen relay lever bolt
-push lever into position and tighten bolt to
15 Nm (14ft lb)
-install shift shaft
• slotted side toward differential housing
-install new gasket
-install spring
-measure distance x -install cover and tighten bolts to
Example: x = 77.6 mm 15 Nm (10ft lb)
-install back-up light switch
-install shift shaft lever

-measure distance y
Example y = 1.0 mm

5-speed 094 Shim for 1st gear 35.73

35 Manual Transmission-Case, Gears, Shafts

.---·Pivot bolt
15 Nm (11ft lb) ..-----Starter bushing
removing Fig. 3
installing Fig. 4
can be replaced with
transmission Installed

45 Nm (33 It Release shalt

lubricate with multi·
purpose grease

Release shaft bushing

removing/Installing
see Rep. Group 30

Release shaft bushing\

~.
•. .,!,!I
.-.
Circlip_/
always replace

Clutch lever Release bearing

lubricate ball lightly do not clean in
solvent, wipe with
dry cloth

Release bearing guide sleeve

plastic , do not grease

Main shalt oil seal

removing Fig. 1
installing Fig. 2
till space between lips
with mu lti-purpose grease

35.74 Clutch housing 5-speed 094

 Manual Transmission-Case, Gears, Shafts 35

Yilh
ailed

rill · Fig. 4 Starter bushing, Installing

Fig. 1 Main shaft oil seal, removing
-lubricate bushing and drive In flush

ahing
ng
10

Fig. 2 Main shaft oil seal, Installing

ng

with

Rg. 3 Starter bushing, removing

(transmission Installed)
• when transmission i s removed, use
drift VW 222a

S.speed 094 J Starter

Main oil
sha ft
bushing
seal
35.75
35 Manual Transmission-Case, Gears, Shafts

Drive shalt needle bearing

Reverse gear shalt

also locks bearing lor drive shall,
install so lhat bearing is evenly covered

Pinion needle bearing outer race

___ !
\....
Pinion bearing

Shill rod bushing

rem./ i nsl. Fig. 3

Bearings
detach before removing
shift rod

Reverse/1st gear shift rod

Pin
gu i de~
drive i

35.76 Gear carrier housing

Gear carrier housing cover
&speed 094
 Manual Transmission-Case, Gears, Shafts 35

- 011 IIIIer pl ug
20 N m (1 4ft lb)

1
,
~'
Circlip
for needle bear ing
Pivot bolt for relay lever
20 Nm ( 14 I t lb)

Bushing

Q e ; , _ _ _ _ _ _Sh lft shaft seal

removing Fig. 1
installing Fig. 2
•
can be rep laced with
transmis sion ins talled

rler

Rel ay lever
for 2nd and 3rd gear

Qu1des sh ift shal t,

'I~IP tn un til sea ted
Shift rod bearing
rem./ instal l. Fig. 3
Transm ission housing

5-speed 094 Tran smission housing 35.77

35 Manual Transmission-Case, Gears, Shafts

Fig. 2 Shift shaft oil seal, installing

Fig. 3 Shift rod bushing

-removing
• turn bearing so that lug (arrow) is in
recess of housing and press out
-installing
• align bearing and rod

35 ·7 8
•
Shift shaft oil seal
Shift rod bushing
5-speed 094
Manual Transmission-Case, Gears, Shafts 35

THIS PAGE INTENTIONALLY

LEFT BLANK

35.79
35 Manual Transmission-Case, Gears, Shafts

Main shaft needle bearing 5 Nm (4ft lb)

removing Fig. 10
installing Fig. 11 5th gear needle bearing
Lockring before installing lubricate
installing Fig. 10 with transmission oil

Malo ohaft bea<ingj

removing Fig. 6
installing Fig. 7

Gear carrier cover

Synchronizer ring 5th gear

checking Fig. 2
identification/installation
instructions page 35.92

35.80 Main shaft

5-speed 094
 Manual Transmission-Case, Gears, Shafts 35

Synchronizer hub

Needle bearing
removing Fig. 8
t bearing
,installing Fig. 9
1g lubricate
ion oil Synchronizer 4th 15th gear
parts are not matched
removing Fig. 1
installing Fig. 4 and Fig. 5
Installation position Fig. 3 \
\

o·e~E
I

c....... \ l!'
\_4th gear needle bearing
Before installing, lubricate )~dj;
with transmission oil
I /Jr
Synchronizer ring 4th gear
checking Fig. 2
identification I installation
instructions page 35.92

\
~ear carrier

5-speed osi] Main shaft 35.81

35 Manual Transmission-Case, Gears, Shafts

Lvw4n

I Js-a7al
Fig. 1 Synchronizer, removing
-press off together with gear

Fig. 3 Synchronizer 4th/5th gear, assembling

• identification grooves (arrows A & B) of
sleeve and hub are on opposite sides.
Groove on sleeve (arrow 8) faces
4th gear
• grooves (arrow C) are for identification:
Fig. 2 Synchronizer rings, checking 2nd & 3rd gear= 1 groove
4th & 5th gear :;; 2 grooves
-press synchronizer rings onto gear by
hand and measure gap 1 with feeler
gauge

Gap a
New Part Wear limit
Gear mm (in.) mm (ln.)
4th/5th 1_0-1.7 0.5
(0.039-0.067) (0.020)

Fig. 4 Synchronizer 4th/5th gear, assembling

-slide sleeve over synchronizer hub.
Matched position is not necessary
- insert keys and install springs with
ends offset 120°. Angled ends of
springs must fit into keys

35.82 Synchronizer
Synchronizer rings
5-speed 094
 Manual Transmission-Case, Gears, Shafts 35

30-100
~ Fig. 7 Main shaft ball bearing, Installing
VW401 -press in so that recess in bearing is

k------~
aligned with recess (arrow) in housing

lng
Fig. 5 Synchronizer 4th/5th gear, Installing
l B) of
ides. -turn synchronizer ring until grooves are
in line with keys
• identification groove on sleeve
at ion: (Fig. 3, arrow B) faces 4th gear

Fig. 8 Needle bearing in housing, removing

Fig. 6 Main shaft ball bearing, removing

ing
b.
y
Fig. 9 Needle bearing in housing, installing
th
• lettered side of bearing (thicker
material) must face installing tool

5-speed 094 Main shaft bearings 35.83

35 Manual Transmission-Case, Gears, Shafts

Fig. 10 Main shaft needle bearing in gear carrier

housing cover, removing
-remove screw
-pull bearing out with
A-extractor US 1088 Fig. 12 Circlip, installing
B-puller US 1039
• make sure ring is seated correctly
(arrow)

Fig. 11 Main shaft needle bearing in gear carrier

housing cover, installing
-tighten screw to 5 Nm (4ft lb)

Fig. 13 Circlip, two types

A = previous circlip B = new circlip
Part No. 091 311 381 Part No. 091 311

CAUTION
Always replace the circlip during repairs.
Identifying marks on a new circlip (arrow)
must face reverse gear splines.

35.84 Main shaft bearings

Lockring
5-speed 094
 Manual Transmission-Case, Gears, Shafts 35

THIS PAGE INTENTIONALLY

rectly LEFT BLANK

It
,_.135--10.,...,8..,.,01

circlip
No. 091 311

35.85
35 Manual Transmission-Case, Gears, Shafts

Gear carrier housing cover

1st and reverse gear
synchronizer hub
Synchronizer 1st/reverse gear

always reptace

Pinion bearing
removing Fig. 17 Needle bearing
installing Fig. 18 lubricate with transmission

7
oil before installing

-------- -- -- -
,---- -
1
-- ----
Synchronizer ring 2nd gear~
checking Fig. 9
_____.
2nd gear needle bearing
lubricate with transmission
oil before installing
identification marks page 35.92

I -~

~~~~~
must fit securely in groove
0~.:;) i) (1 .#
2nd gear_)

Synchronizer 2nd/3rd gear---' 2nd gear needle bearing inner

removing Fig. 2 loosening/tightening Fig. 6
assembling Fig. 10 and Fig. 11
installation position Fig. 12

Spring
(1.6 mm dia)

35.86 Pinion shaft assembly

5-speed 094
 Manual Transmission-Case, Gears, Shafts 35
4th gear circlip - - - - - - .
determine thickness
Fig.14

4th gear
removing Fig. 1
installing Fig. 13
Spacer collar faces 3rd gear
determine thickness
page 35.73
se gear
\3rd gear

0
5th gear

----- ----
groove faces gear oil before installing
Needle bearing
removing Fig. 15 carrier housing cover

-- ----
installing Fig. 16

.---- ----- ShimS,-----------.

note thickness
adjusting, see Repair Group 39

_))),f~'m
fi
~
I '

Pinion shaft
o~n
matched with ring gear,
when replacing adjust
ring gear/pinion,.
1inner race
ig.6
see Repair Group 39 . -,. :__<_ Retaining ring
Tapered roller bearing Transmission housing
removing 35.68
when replacing measure pinion installing 35.70
depth before removing,
see Repair Group 39
removing Fig. 3 and Fig. 4
installing Fig. 5
torque, checking Fig. 7
and Fig. a

5-speed 094 Pinion shaft assembly 35.87

35 Manual Transmission-Case, Gears, Shafts

Fig. 1 3rd and 4th gear, removing

A-US 1103

,- ~VW411

Fig. 3 Tapered roller bearing, removing

-remove retaining ring first

Fig. 2 Synchronizer and 2nd gear, removing

A-US 1103

r-------------------~,3=5-=88~8,1
Fig. 4 Tapered roller bearing inner race,
removing

3 5 •8 8 Pinion shaft
5-speed 094
 Manual Transmission-Case, Gears, Shafts 35

VW401 --.
'\
..---'\''
J
..
Fig. 7 Tapered roller bearing, checking turning
torque
-lubricate bearings with transmission
oil and tighten retaining ring,
-turn pinion shaft in both directions
.m;:;m about 15-20 times
-turn further and read turning torque
• new bearings:
Fig. 5 Tapered roller bearing, Installing up to 210 Ncm (180 ln. lb)
-heat Inner race to about 100°C (212°F) • used bearings•:
and press on up to 70 Ncm (61 in. lb)
-before tightening needle bearing Inner (• after running at least 30 miles)
race, let tapered roller bearing cool to • If no turning torque can be
room temperature meaStJred, see Fig. 8

Fig. 6 Needle bearing, loosening/tightening Fig. 8 Bearing condition, checking

-heat inner race to about 60°C (140°F) -check for rock at end of pinion. There
and screw on as far as possible by must not be any detectable movement
hand if YES, replace tapered roller bearing
-place pinion shaft in tool 2052 and
tighten wing nut lightly
-tighten inner race to 210 Nm (152ft I b)

5-speed 094 Pinion shaft 35.89

35 Manual Transmission-Case, Gears, Shafts

Fig. 9 Synchronizer ring, checking

-press synchronizer rings onto gear by
hand and measure gap a with fee ler
gauge

New Part Wear limit Fig.11 Syncmonlzer, assembling

mm (in.) mm (ln.) -slide steeve over synchronizer hub.
Gap a 1.3-1 .9 0.5 Matched position Is not necessary
(0.051-0.075) (0.020) -insert keys and Install springs with
ends offset 120°. Angled ends of
springs must lit Into keys

VW4l1

Fig. 10 Synchronizer 2nd/3rd gear, assembling

-groove (arrow A) must face 3rd gear
-collar on hub must face 2nd gear
-grooves (arrow B) are for identification: Fig. 12 Synchronizer, Installing
• 2nd gear & 3rd gear== 1 groove -turn synchronizer ring until grooves are
=
• 4th gear & 5th gear 2 grooves in line with keys (installation position,
see Fig. 10)

35.90 Synchronizer 5-speed 094

 Manual Transmission-Case, Gears, Shafts 35

Fig. 13 4th gear, Installing Fig. 15 Pinion needle. bearing in gear carrier
housing, removing
-collar must face 3rd gear

Fig. 1& Pinion needle bearing In gear carrier

housing, Installing

Fig. 14 4th gear end play, ad}ustlng

-measure end play with feeler gauge
-adjust by selecting suitable circllp
• play should be 0.05 mm-0.20 mm
(try to keep lower limit)

Clrclips available:

Thickness Part
mm Color No.
1.60 black 113 311 382
1.75 blue 113 311 383
1 are 1.90 brown 113 311 384
on, 2.05 gray 113 311 385
2.20 copper 113311386
Fig. 17 Pinion bearing outer race in gear carrier
2.30 brass 113 311 387 housing cover, removing
2.40 silver 113 311 388
A-extractor US 1088
B-puller US 1039

5-speed 094 4th gear end play

Pinion shaft bearings
35 91 •
35 Manual Transmission-Case, Gears, Shafts

r-------------~--~-------------
Synchronizer rings, Identification
Note
When assembling transmission, install synchron-
izer ring to same gear from Which l.t was removed

production

Fig. 18 Pinion bearing in gear carrier housing

cover, installing
2nd gear:
special brass ring
molybdenum coated
3 x 6 teeth
with 3 lips (arrow)

3rd and 4th gear:

special brass ring
molybdenum coated
teeth all around circumference

5th gear:
brass ring
3 x 8 teeth
with 3 notches (arrow)

spare part
For all gears install ring (3rd and 4th gear) which
is supplied under Spare Part No: 091 311 295 A

35.92 Pinion bearings

Synchronizer 5-speed 094 G·1
 35
094-4WD
Manual Transmission
Case, Gears, Shafts

Quick Data Index

-Adjusting rings
installing 35.96
marking/removing 35.95
-Assembling/Disassembling 35.99
35.100
-Assembly 35.94, 35.98, 35.105
-Axle flange
installing 35.96
removing 35.95
-Bearing, removing 35.122
installing/checking 35.123
inner race, removing 35.122
-Clutch housing 35.111
-Differential lock servo 35.96
-Drive flange seal
installing 35, 115
-Drive pinion 35.121
-Drive shaft flange
removing 35.104
-Flange nut
loosening/tightening 35.104
Flange seal
installing 35.1 04
-Gear carrier 35.107, 35.116
disassembling/assembling
35.1 08-35.11 0
-Gears
1st, 2nd and 3rd,
removing 35.122
-Housing 35.113
-Intermediate housing
removing 35.106
-Low gear idler
removing 35.106
-Low gear shim
measuring 35.101, 35.102
-Lower gear bearing
removing/installing 35.126
-Main shaft 35. 117
bearing, removing/
installing 35.119
-Main shaft seal
removing/installing 35.112
Needle bearing
removing/installing 35.115,
35.119, 35.120
-Needle bearing
inner race, loosening/
tightening 35.123
outer race, installing 35.126
outer race, removing 35.125
-Output housing 35.103
-Output shaft bearing
removing/installing 35.114
- Rear driveshaft
measuring 35.97
-Reverse gear idler
removing/installing 35.106
-Shift rod bushing
removing/installing 35.115
-Shift shaft seal
removing/installing 35.114
-Starter bushing
removing/installing 35.112
-Synchronizer rings
identification 35.127
-1st/2nd gear synchronizer
checking/installing 35.124, 35.125
- 3rd gear installing 35.125
- 3rd/4th gear synchronizer 35.118
installing 35.119
4-Speed 091
- See page 35.1
4-Speed 091/1
- See page 35.31

5-Speed094
- See page 35.61

ch

G·1

35.93
35 Manual Transmission-Case, Gears, Shafts

Note
Before disassembling, mount transmission In
assembly stand (Fig. 1) and drain transmission fluid.
CAUTION
Protect driveshaft oil seal from damage by the
driveshaft splines before removing and
installing the clutch housing. Pull a wiring
harness conduit or similar covering over the
driveshaft.

Differential lock servo

Drain plug 20 Nm (15 ft lb)
Indicator lamp switch
Transmission housln!ll
removing/installing earner, page 35.107 Orlng
check condition
installation position: hole faces
indicator lamp switch
• can be changed when Installed in
vehicle
Right adjusting ring
mark before removing Fig. 3
removing Fig. 4
installing Fig. 6
coat threads with MoS2 grease

Axle flange
removing Fig. 2
installing Fig. 7

Lock pin
always replace
removing Fig. 5
Shift fork

always replace
Differential
Before assembling;
remove adjusting rings, rear driveshaft
and shift fork for differential lock
disassembling/assembling, see Repair
Group 39
Rear main sheft - - - - - - - - - - - - '
removing: remove circlip, push back
splined sleeve and remove main shaft
installing: connect rear main shaft and
front main shaft, back off one spline,
push on splined sleeve and install
new circlip
M 8 x 28 20 Nm (15 ft lb)
Clutch housing-------' four bolts with washers
repairing, page 35.19
Left adjusting ring before removing:
mark before removing Fig. 3 loosen left adjusting ring to reduce M 8 x 46 20 Nm (15 ft lb)
removing Fig. 4 tension in transmission housing. six bolts with washers
installing Fig. 6 Mark position of adjusting ring before
coat threads with MoS 2 grease removing Fig. 3 134-18771

35 •9 4 Transmission assembly
094-4WD
 Manual Transmission - Case, Gears, Shafts 35
le

edin

Fig. 3 AdJusting ring, marking position

When differential is not being replaced:

• mark position of adjusting rings in
relation to transmission (arrow)
• mark left side (ring gear side with one
lace scratch, mark right side with two
ig. 7 scratches
• measure installed depth with VW 38217
ter
Fig. 1 Transmission, mounting In repair stand

•. 2 - remove shift rod lever and backup lights

I· 7 switch before mounting transmission in
repair stand

Fig. 4 AdJusting rings, removing

Fig. 2 Axle flange, removing

'lib)
A = screw 2 bolts (M 8 x 30) through slots
in axle flange

t lb)

134-18771

...._094
• WD I Axle flange, removing
_ _4_ __, Adjusting rings, removing
35 •95
35 Manual Transmission- Case, Gears, Shafts

Fig. 5 Differential lock servo, removing Fig. 7 Axle flange, Installing

- drive out shift fork lock servo

- remove differential lock servo from shift
fork

Fig. 6 Adjusting rings, Installing

- install adjusting rings into transmission

housing using previously marked position
- check that depth equals previous
measurement Fig. 8 Clrcllp, Installing

- install spring washer and circlip

CAUTION - press circlip into groove
• make sure spring washer is fully seated
Tighten left bearing ring after the clutch
housing is installed and torqued.

Differential lock servo, removing

35.96 Adjusting rings, Installing

Axle flange, installing
.094-4WD
 Manual Transmission - Case, Gears, Shafts 35

Fig. 9 Rear drlveshaft, measuring

-dimension b = 27 mm (1.06 in.)

-total length = 298 mm (11.73 in.)

seated

094-4WD
Rear drlveshaft, measuring 35 •97
35 Manual Transmission- Case, Gears, Shafts
Note
If the bearings and/or transmission housing are being Low gear housing
disassembling/assembling, page 35.105
replaced and the r dimension is not specified on the
ring gear, the position of the drive pinion to the
housing must be determined before disassembling. always replace
When installing, this position must be the same. See
Repair Group 39. Low gear shim
determining thickness, page 35.102

Output housing----'
disassembling/assembling, page 35. 103

~-·-·-·-·-·~
20 Nm (15 ft lb) ~0 Nm (15 ft lb)
with washer . , - - - Bearing retainer

~ /--t'.V~A
1
install with grease
I
15 Nm (11 ft lb)

0 ring I

~Spring
I
Shift shaft cover ~~ Transmission
disassembling/assembling, page 35.105 .
I
·-·-·-·--·--·--·J
I ~--- Shift shaft

I slotted side faces differential gear

I ~~lm
L._
~ ............
(1._

Gasket

Shim 53
note thickness (j)

Transmission housing
t,. Nm ~Bft lb)

repairing, page 35.113

Shift shaft lever

35.98 Transmission assembly

094-4WD
 Manual Transmission - Case, Gears, Shafts 35
Transmission, disassembling/
assembling
Disassembling
- remove output housing bolts
- remove housing
135.102

- remove splined sleeve (arrow)

-rotate transmission 180° (1/2 tum)
- remove cover for reverse idler gear
- remove low gear housing along with low gear,
needle bearing and shim
- unboH shift shaft cover
- remove shift shaft

-remove bolt (arrow)

- remove low gear housing bolts

- loosen bolt until relay lever (arrow) pulls against

housing
- tighten boH by hand to lock lever in that position

094-4WD Transmission,
dlsassembllng/asaembllng
3 5 99 •
35 Manual Transmission- Case, Gears, Shafts

-remove retaining ring -tighten retaining ring to 225 Nm (162ft lb), loosen
- remove end shield from housing and tighten again to 225 Nm (162ft lb)

- attach VW 457 with two M 8 x 20 bolts - secure retaining ring at two places by staking
-push out gear carrier ~ bolt end shield to transmission housing
- remove shim S3 and note thickness Ex
- loosen relay lever bolt
-position lever and tighten bolt to 20 Nm (15ft lb)
Assembling
- install shift shaft with slotted side facing
Before Installing gear carrier:
differential gear
- position shim S3 and new gasket
- install new seal in cover
- position shift rail
- position cover with spring and tighten bolts to
- position bearing to opening in housing
15 Nm (11 ft lb)
- heat bearing seat in transmission housing to
40-60" C (130·166° F)
- seat bearing using a plastic hammer on drive
pinion
- check for binding
- install retaining ring and shim (75 mm wide)

35.100 Transmission,
disassembling/assembling
094-4WD
 Manual Transmission - Case, Gears, Shafts 35
4

Adjustment range = a b
Dimension b = x- y

Low gear shim, determining

oosen thickness Example

I x = 77.6 mm
- measure dimension y

- measure dimension a
ng
Example Example

'ft lb)
I a= 77.8 mm y = 1.0 mm
- measure dimension x Dimension b =x- y

to Example

x = 77.6 mm
-y = 1.0 mm
76.6 mm

Adjustment range =a - b
Example

a= 77.8 mm
-b = 76.6 mm
1.2 mm

094-4WD Low gear shim, measuring 3 5 •1 0 1

35 Manual Transmission- Case, Gears, Shafts

Available shims:

Adjustment range Shim

Part Number
(mm) Thickness
0.95-1.14 0.6 094 311 379
1.15-1.34 0.8 094311379A
1.35-1.54 1.0 094 311 379 8
1.55-1.74 1.2 094 311 379 c
1.75-1.94 1.4 094 311 379 D
1.95-2.14 1.6 094 311 379 E
2.15-2.47 1.8 094 311 379 F

- Install bearing retainer with grease (arrow)

-rotate transmission 180° (1/2 tum)
- push low gear housing from below, guiding gear
and shim to drive pinion
- Install mounting bolt and tighten to 20 Nm
(15 ft lb)
- Install reverse Idler gear cover
- push splined sleeve onto drive pinion '
-'- install output housing, tighten bolts to 20 Nm
(15ft lb)
- Install back up light switch and shift shaft lever
after removing transmission from repair stand

- install shim, low gear disc and needle bearing in

low gear housing
- position new gasket

35.102 Low gear shim, measuring

094-4WD
 Manual Transmission - Case, Gears, Shafts 35
Note
To remove low gear housing, completely remove
output housing.
Drlveshaft flange removing/installing Ag. 3 20 Nm (15 ft lb)
removing Ftg 2
r--- Clrcllp

l
I
I
I
Output shaft
~~. I
'"--J

Spllned sleeve
Drive pinion

134-1880 I

094-4WD
Output housing 3 5 •1 03
35 Manual Transmission- Case, Gears, Shafts

134-17eo I
Fig. 1 Flange nut, loosening/tightening Fig. 3 Flange seal, Installing

- secure flange with tool . - press seal in to stop

-loosen or tighten to 160 Nm (112 ft lb)

VW434

Fig. 2 Drlveshaft flange, removing

- if necessary, pull off flange with a two

armed extractor
A- two armed extractor of commercial size,
e.g. Kukko 44-2

nut, loosening/tightening

35.104 Drlveshaft flange, removing

Flange seal, installing
094-4WD
 Manual Transmission - Case, Gears, Shafts 35

Low gear Idler

Orfng

Banjo bolt

Orlng\

r® C' 0' ~Circllp

1 r-~0'
.J Idler gear shaft

,.. . _l//
/@

Bearing with clrcllp

Supporting ring
Cover

Needle bearing
install with transmission oil
Reverse gear Idler
removing Fig. 2
installing Fig. 3

094-4WD
Transmission assembly 35.105
35 Manual Transmission- Case, Gears, Shafts

134·17961
Flg.1 Low gear Idler, removing Fig. 3 Reverse. gear Idler, Installing

- remove idler gear shaft - install with groove pointing up

A- Puller, e.g. Kukko 22-1
B- Reducing thread bolt MS

Fig. 4 Intermediate bearing, removing

- clamp separation device behind bearing

Fig. 2 Reverse gear Idler, removing
A - Separation device,
A- Puller, e.g. Kukko 22-1 e.g. Kukko 15-15, Gr. 2

B- Reducing thread bolt MS

Low gear Idler, removing

35.106 Reverse gear Idler, removing/Installing

Intermediate housing, removing
094-4WD
 Manual Transmission - Case, Gears, Shafts 35

Gear carrier
repairing, page 35.108

Low/reverse synchronizer
install molybdenum coated
synchronizer ring facing low gear 3rd/4th gear shift rail

Synchronizer hub
Main shaft
Needle bearing
install with transmission oil

I 1st/2nd gear shift rail

I
I
Second clrcllp '--
First clrcllp

·\·-~-~ Install with transmission oil

Ball valve
Thrust washer

094-4WD
Gear carrier 35.107
35 Manual Transmission-Case, Gears, Shafts

Gear carrier, disassembly/assembly

Dlsaaaembly L----VW411
- remove low/reverse gear shift fork
- remove low/reverse gear synchronizer
- remove synchronizer hub first circlip

- press out main shaft with drive pinion and shift

rails

Assembly

- remove synchronizer hub with control gear

A - two armed extractor, e.g. Kukko 20110
- remove second clrclip, thrust washer and needle
bearing
- remove main shaft circlip

134-1771 I
- press in main shaft with shift rail

35.108 Gear carrier,

disassembling/assembling
094-4WD
 Manual Transmission - Case, Gears, Shafts 35
A

134-13181

- install drive pinion with shift rail

- shift into 3rd gear - secure retaining ring at two places by staking
- shift into neutral - Install end shield to transmission housing
- install needle bearing for drive pinion - determine thickness of reverse gear thrust washer
- install main shaft circlip (75 mm wide)

Before installing gear carrier:

- position shim S3 and new gasket
- position shift rail
Ht - position bearing facing opening in housing
- heat bearing seat in transmission housing to
40·60° C (130-166° F)
- seat bearing using a plastic hammer on drive
pinion
- check for binding

134-13391

- position circlip and measure dimension c

Example

-tighten retaining ring (75 mm wide) to 225 Nm c = 29.1 mm

(162ft lb), loosen and tighten again to 225 Nm
(162ft lb) - measure dimension d

Example

d = 24.7 mm

094-4WD Gear carrier,

disassembling/assembling
35 1 09•
35 Manual Transmission-Case, Gears, Shafts

Example

Dimension c = 29.1 mm
- Dimension d = 24.7 mm
- Adjustment range - 4.4 mm

Shims available:

Adjustment
range (mm) Part N Color
3.97-4.19 091 311 379 white
4.2()-4.39 091 311 379 A black
4.40-4.59 091 311 379 B green
4.60-4.90 091311379C red

-position thrust washer, reverse gear, needle

bearing and second circlip

134·17721
- Install synchronizer hub
- position first circlip
- position low/reverse synchronizer with shift fork
- place molybdenum coated clrclip on low gear
- fasten shift fork to shift rail
• coat bolt with D 6 and tighten to 20 Nm
(15ft lb}

35.110 Gear camer,

disassembling/assembling
~WD
 Manual Transmission - Case, Gears, Shafts 35

Clutch housing
Starter bushing
removing Fig. 3
installing Fig 4

Release shaft
install with
multi-purpose grease

Clutch lever
lightly grease ball end

removing Fig. 1
Ring
installing Fig. 2
only with plastic sleeve
fill space between lips with Clrcllp
multi-purpose grease always replace

Release bearing
wipe dry only, do not use solvent

Guide sleeve
metal sleeve greased with MoS2
plastic sleeve not greased Retaining clip

Drain plug 20 Nm (15 tt lb) Retaining spring

135-10131

094-4WD
Clutch housing 3 5 •111
35 Manual Transmission- Case, Gears, Shafts

Fig. 1 Main shaft seal, removing Fig. 3 Starter bushing,. removing

(installed transmission)

Note
For disassembled transmission, remove with
VW 222a.

Fig. 2 Main shaft seal, Installing

Fig. 4 Starter bushing, Installing

- drive in flush

35.112 Main shaft seal, removing/Installing

Starter bushing, removing/Installing
094-4WD
 Manual Transmission - Case, Gears, Shafts 35
Clrcllp Pinion needle bearing

Low gear housing

Main shaft needle bearing

Pinion needle bearing outer race

S.~ngs----------~ -----
clip off before removing
shift rod
-----·
Main shaft bearing
Gear carrier
---- .

011 tiller bolt 20 Nm (15 ft lb)

removing Fig. 7
installing Fig. 8

Low/reverse shift rod

Shift shaft seal

removing Fig. 3
installing Fig. 4
seal can also be
replaced on installed
transmission

Bushing
install with lug
facing end shield

2nd/3rd gear relay lever

Main shaft needle bearing
removing/isntalling, page 35. 119
lhlnsmlsslon housing
when replacing, adjust drive pinion to
previously determined installation
position, see Repair Group 39 134-18821

094-4WD
Transmission housing 35.113
35 Manual Transmission- Case, Gears, Shafts

VW412

t---VW295

3074

Fig. 3 Shift shaft seal, removing

Fig. 1 Output shaft bearing, removing

Fig. 4 Shift shaft seal, Installing

- remove wire circlip

drive i.n seal with 3077
- replace wire circlip

Fig. 2 Output shaft bearing, Installing

- push bearing in to stop

35.114 Output shaft bearing, removing/Installing

Shift shaft seal, removing/Installing
094-4WD
 Manual Transmission - Case, Gears, Shafts 35
A

134·1341 I 134-18831

Fig. 5 Shift rod bushing, Fig. 7 Needle bearing, removing

removing/Installing
A- Puller e.g. Kukko 22-2
- to remove, rotate until lug (arrow) is
positioned over recess in housing B- Inner extractor 31 - 37 mm e.g. Kukko
- push out shift rod bushing 21/5

134-18841

Fig. 6 Drive flange seal, Installing Fig. 8 Needle bearing, Installing

- push in seal up to stop - push in needle bearing to stop

Shift rod
094-4WD Drive flange seal, Installing
Needle bearing, removing/Installing 35.115
35 Manual Transmission - Case, Gears, Shafts

Input s h a f t - - - - - - - - - ,

Drive flange

Output housing

Low gear houlalnt~_J

Drive pinion
disassembling/assembling, page 35.121

134-18851

35.116 Gear carrier

094-4WD
 Manual Transmission - Case, Gears, Shafts 35
4th gear needle bearing
lubricate with transmission oil

~--Needle bearing ,
before removing bearing, remove low gear
idler gear, page 35.1 06
removing Fig. 10
installing Fig. 11

l
7 I

Bearing __ j
'--'
removing Fig. 6

l installing Fig. 7

--·
Clrcllp

--·
' 4th gear synchronizer ring

--· --' -- ---'

checking Fig. 2
3rd/4th gear synchronizer identification, page 35.127
Installed position Fig. 5

· 3rd gear synchronizer ring

I
I

L. always replace

Spring
diameter 1.6 mm

Spring------'
diameter 1.6 mm

094-4WD
....__ I
_ _ ___, Malnshaft 35.117
35 Manual Transmission- Case, Gears, Shafts

135-10151

Fig. 1 Synchronizer 3rcl/4th gears, removing

- press off with 3rc:l gear

a Fig. 3 3rd/4th gear synchronizer, assembling

~~~~~..J-1 • sleeve and hub identification grooves
~~~~t (arrows A & B) are on opposite sides
• clutch sleeve groove (arrow B) faces
4th gear
• the grooves (arrows C) are for
identification:
1st/2nd gear = one groove
3rc:l/4th gear = two grooves

Fig. 2 Synchronizer rings, checking

- push synchronizer rings on to gear cones

and measure gap a with a feeler gauge

Gap a New Part Wear limit

mm (ln.)
1.25-1.95 mm 0.5 mm
3rc:l gear (0.049-0.077) (0.020)
1.00-1.70 mm 0.5 mm
4th gear (0.039-0.067) (0.020)

Fig. 4 Synchronizer 3rdl4th gear, assembling

- push sleeve over hub

-insert keys and install spring ends 120°
apart
• angled ends of spring must fit into
hollow key

35.118 3rcl/4th gear synchronizer

094-4WD
 Manual Transmission - Case, Gears, Shafts 35
VW412
30-14

30-100
Fig. 7 Main shaft bearing, Installing
VW401
- press bearing into carrier to stop
• recess on bearing aligns with recess in
carrier (arrow)

ng
Fig. 5 Synchronizer 3rd/4th gear, Installing
wes
sides - rotate synchronizing ring until grooves are
aces in line with keys
- clutch sleeve identification groove (Fig. 3,
arrow B) faces 4th gear

Fig. 8 Needle bearing, removing

- drive bearing out of transmission housing

134-13291
Fig. 6 Main shaft bearing, removing

- push bearing out of gear carrier

lng

to

094-4WD
35 Manual Transmission- Case, Gears, Shafts

Fig. 9 Needle bearing, Installing Fig. 11 Low gear needle bearing, Installing

CAUTION
The lettered side of bearing (thicker material)
must face installing tool.

Fig. 10 Low gear needle bearing, removing

- shear off rivet head before removing

bearing
A- Inner extractor 18.5·23.5 mm, e.g.
Kukko 21/3
B- Extension
C- Yoke, e.g. Kukko 2212

35.120 Needle bearings,

removing/installing
094-4WD
 Manual Transmission - Case, Gears, Shafts 35
Low gear housing

Shim
determining thickness,
page 35.102

Reverse gear
Needle bearing----
install with transmission oil

Low/reverse hub

2nd gear

3rd gear
removing Fig. 1
installing Fig. 13
Clrcllp - - - - - - - - . . . . . _ l&l.. conlar faces 2nd gear
always replace
must fit securely in groove
~1st gear neadle
Synchronizer hub
l
,
bearing Inner race
loosening/tightening Fig. 6
collar on the synchronizer

9)~ I hub secures against

twisting
Spring------' ~ 1st gear needle bearing
diameter = 1.6 mm \._ Key
install with transmission oil

1st/2nd clutch synchronizer sleeve ---...../ 1st gear synchronizer ring

removing Fig. 2 checking Fig. 9
assembling Figs. 10 and 11 identification, page 35.127
installing Fig. 12

Bearing - - - - . . !
removing Fig. 3
installing Fig. 5
Transmission housing
if replacing, measure position of pinion and ring gear are
drive pinion before removing, replaced as a matched set
see Repair Group 39 when replacing drive set, adjust note thickness
turning torque, checking Figs. 7 and 8 pinion and ring gear adjusting see Repair Group 39 l3s,1oso 1

I 094-4WD I Drive pinion 35.121

35 Manual Transmission- Case, Gears, Shafts

VW411

Fig. 1 3rd and 2nd gears, removing

A- Separation device 22-115 mm,

e.g. Kukko 17/2

Fig. 3 Bearing, removing

- unscrew needle bearing inner race

- push bearing over outer race

Fig. 2 Synchronizer sleeve/hub and 1st gear,

removing

A- Separation device 22-115 mm, e.g.

Kukko 17/2
- secure separation device behind gear ~-----------------------135~0191

Fig. 4 Bearing Inner race, removing

A- Separation device 12-175 mm, e.g.

Kukko 17/1

1st, 2nd and 3rd gears, removing

35.122 Bearing, removing

Bearlnglnner~.removtng
094-4WD
 Manual Transmission - Case, Gears, Shafts 35

Fig. 7 Bearing, checking turning torque

Fig. 5 Bearing, Installing
A - Torque gauge, Q--600 Nm
- heat inner race to 100° C (212° F) (D-54 in. lb.)
- before tightening needle bearing inner - lubricate bearings with transmission oil
race, let bearing cool to room temperature and tighten tension nut
- turn pinion shaft in both directions 15-20
times
turn and read turning torque
• new bearings:
up to 210 Ncm (19 in. lb.)
• used bearings (after 30 miles):
up to 70 Ncm (6.2 in. lb.)

Fig. 6 Needle bearing Inner race, loosening/

tightening

- heat inner race to 60° C (140° F)· and

screw on by hand as far as possible
- install pinion shaft into tool 2052/1. and
tighten wing nut lightly
-tighten inner race to 210 Nm (152ft lb)

Fig. 8 Bearing condition, checking

- if turning torque cannot be measured,

check for rock at end of pinion
- if there is detectable rock, replace bearing

094-4WD Bearing, Installing/checking

Needle bearing, Inner race, loosening/tightening
35 123 •
35 Manual Transmission- Case, Gears, Shafts

Fig. 10 1st/2nd gear synchronizer sleeve,

assembling
Rg. 9 1st/2nd gear synchronizer ring, checking
- groove (arrow A) faces 2nd gear
- press synchronizer rii"!Q onto gear by hand
- hub collar faces 1st gear
and measure gap A with feeler gauge - grooves (arrow B) are for identification:
• 1st/2nd gear = 1 groove
• 3rd/4th gear = 2 grooves
New part mm (ln.) Wear limit mm (ln.)
1.3-1.9 0.5
Gap a
(0.051-Q.075) (0.020)

Rg. 11 1st/2nd gear synchronizer, assembling

- slide sleeve over hub, matched position is

not necessary
-insert keys and install spring ends 120"
apart. Angled ends of springs fit into keys

35.124 1st/2nd gear synchronizer,

checking/Installing
094-4WD
 Manual Transmission - Case, Gears, Shafts 35

Fig. 14 3rd gear end play, adjusting

- measure end play with feeler gauge

- adjust by selecting suitable circlip
• play should be 0.05 mm-0.20 mm
(try to meet lower limit)
The following circlips are available:

Flg.12 1st/2nd gear synchronizer, Installing

Thickness mm Color Part No.
- turn synchronizer ring until grooves are in 2.20 copper 113 311 386
:ation: line with keys (installation position, see 2.30 brass 113 311 387
Fig. 10)

Fig. 13 3rd gear, Installing Fig. 15 Needle bearing outer race, removing

nbllng
- collar faces 2nd gear
position is

ds 120°
t into keys

094-4WD 3rd gear, Installing

Needle bearing outer race, removing
35 125 •
35 Manual Transmission- Case, Gears, Shafts

Fig. 16 Needle bearing outer race, Installing Fig. 18 Bearing, Installing

Fig. 17 Low gear bearing, removing

35.126 Needle bearing outer race, Installing

Low gear bearing, removing/Installing
094-4WO
 Manual Transmission - Case, Gears, Shafts 35
Synchronizer rings, Identification
Note
When assembling transmission, install synchronizer
rings to the same gears from which they were
removed.

3rd gear:
special brass ring
molybdenum coated teeth around entire
outer surface

Note
For all gears, install synchronizer ring which is
1st gear: supplied under Spare Part No. 091 311 295 A
brass ring (standard production on 3rd gear).
molybdenum coated 3 x 6 teeth
without identification

2nd gear:
brass ring
molybdenum coated 3 x 8 teeth
identification 3 notches
4th gear:
brass ring
3 x 8 teeth
identification 3 notches

094-4WD Synchronizer rings,

Identification
35.127
 37

• Automatic Transmission
Controls, Assembly

Index
- Accelerator cable/linkage
090-except code letters NH
37.12, 37.13
code letters NH only 37.14, 37.15
-ATF
checking/filling 37.9
dipstick changes 37.9
troubleshooting 37.9a
- Rnal drive oil seal 37.10
-Installing
090-except code letters NH
37.5, 37.6
code letters NH only 37.8
-Modifications 37.19
-Operation 37.17, 37.19
- Pressure test procedure 37.18
-Removing
090-except code letters NH
37.4
code letters NH only 37.6, 37.7
-Selector lever assembly 37.2
-Selector lever cable 37.3
-Shift points 37.19
-Technical data
code letters NG, NH 37.1a
code letters NK 37.1b

37.1
37 Automatic Transmission-Controls, Assembly
Technical Data
• code letters •
• application
• number of splined plates and springs
• gear ratios

Transmission
code letters NG NH
date of manufacture
from 06/79 10/82
to 10/82
Type No. 090
Torque converter
code letter Z1 z
Valve body
code letters AH BH FF FFA
date of manufacture
from 06/79 07/80 10/82 01/85
to 07/80 10/82 01/85
Forward clutch inner outer inner outer
number of splined plates 4 3 4 3
Direct/Reverse clutch
number of springs 24 24
inner outer inner outer
number of splined plates 4 4 4 4
1st/reverse gear clutch inner 2 outer 2 inner outer
number of splined plates 4 4 4 4
2nd gear brake band
first tighten, then loosen: 2112 turns 2112 turns
Application to engine 2.0 ltr. 1.9 ltr.
air-cooled water-cooled
67 bhp SAE net 82 bhp SAE net
Final drive ratio 45:11 = 4:09
Gear ratios
1st gear 2.55 2.71
2nd gear 1.45 1.50
3rd gear 1.00 1.00
Reverse 2.46 2.43
ATF cooler forward
flow
3-row
1 up to build date 03/27/81 = code letter D
2 up to build date 10/1/81 = 5 inner and 5 outer plates

37.1a Technical data

Automatic 090
 Automatic Transmission - Controls, Assembly 37
Technical data

Transmission
Code letters NK
Manufacture date 07/85 to
Automatic transmission 090
Torque converter
Code letter H
Valve body
Code letters FFA
Manufacture date 07/85 to
Number of splined plates Inner outer
forward clutch 4 3
Number of springs 24
Number of splined plates Inner outer
direct/reverse clutch 4 4
Number of splined plates .Inner outer
1st gear clutch 4 4
Brake band
first tighten, then loosen 2·1/2 turns
Engine application
Type Vanagon
Engine 2.1 Liter
90 bhp
lhlnsmlsalon ratios
Final drive 45:11 = 4.09
1st gear 2.71
2nd gear 1.50
3rd gear 1.00
Reverse gear 2.43
ATF cooler supply flow
3row

~ Technical data 37.1 b

 37 Automatic Transmission-Controls, Assembly
CAUTION
Before starting to work on any part of __ _ Set screw
electrical system disconnect battery
ground cable

Note
Lubricate all moving parts with G-6 grease.
Accelerator/Pedal cable adjustment see pages
37.13, 37.15.

Fig

Lock lever

Spring----

Neutral/Park/------------=
Back-up light
'
Rollpln--1 contact plate
after installing, starter must
operate in selector lever Selector aupport
positions N and P only
Pivot pin _ /

Neutral/ Park/
Back-up light
contact bridge

install with selector

lever cable

38-392 I
A-6

37.2 Selector lever assembly

A
 Automatic Transmission-Controls, Assembly 37
- press roll pin out of shift rod
- separate selector lever cable from
shift rod

Fig. 4 Selector lever cable, adjusting

- loosen shift rod bolt (Fig. 3)
-shift selector lever into position P
- push transmission operating lever to
rear (arrow), Into P position

IUpport

37-437

- remove bracket for selector lever

'1 I
cable/shift rod

Fig. 5 Selector lever cable, adjusting

- push shift rod to rear (arrow)
It
- tighten shift rod bolt

Fig. 3 Selector lever cable, removing

- remove shift rod bolt (arrow)
- guide shift rod with se lec tor lever
I 38-392 I cable to rear

A·6
A-9
Selector lever cable 37.3
37 Automatic Transmission-Controls, Assembly

Automatic transmission, removing

(except transmission 090-code letters NH)
Engine installed
Work sequence

- disconnect both drive shafts from

transmission
- disconnect wires from starter
- remove starter
- loosen bracket for ATF dipstick tube

- remove battery ground strap

- remove fan housing grille

-disconnect accelerator linkage 1

- pry off accelerator cable 2
- remove circlip from selector lever cable 3
Note - re:
cc:
To gain access to torque converter bolts,
crankshaft must be rotated until each bolt
appears in hole on top of transmission housing
(arrow)
- remove three torque converter bolts through
hole (arrow) on top of transmission housing
• use adaptor 3052, extension and T-handle to
turn crankshaft
• pin on tool must engage in recess of
cooling fan hub

37.4 Transmission, removing

(except trans. 090-code letters NH)
 Automatic Transmission-Controls, Assembly 37

- support transmission with lifting tool US 618

and US 618/5
- remove rear transmission mount from body
(4 bolts)
-remove lower engine/transmission bolts
- lower transmission out of vehicle

CAUTION
When lowering transmission out of vehicle,
converter must be secured so it does not
slide off transmission

Automatic transmission, installing

(except transmission 090-code letters NH)
Engine installed
Proceed in reverse order of removing and note
following:

:able 3 -remove ground strap 4

-remove mounting bracket 5 and selector lever
cable 6

Note
When attaching transmission to engine, torque
converter must be fully seated on one-way clutch
support (arrow) and can be turned by hand.
When converter is properly seated,
a= 10mm (3/8 in.)
- go to next page

A-8
Transmission, removing/installing
(except trans. 090-code letters NH) 37.5
37 Automatic Transmission-Controls, Assembly

Automatic transmission, removing Nott

(transmission 090-code letters NH only)
Crar
Engine installed torq1

CAUTION
If torque converter (left arrow) should slip
off of one-way clutch support, It could pull
oil pump shaft out of oil pump (right arrow).
This could cause serious damage when
bolting transmission to engine

-tighten lower engine/transmission bolts to 30

Nm (22ft lb)

Note
While tightening engine/transmission bolts, turn
torque converter to check for proper seating on
one-way clutch support

- tighten 4 rear transmission mount bolts to

body
- attach ATF dipstick tube
- install starter
- tighten drive shaft bolts to 45 Nm (33 ft lb)
-tighten upper engine/transmission bolts to
30 Nm (22 ft lb)
- tighten torque converter bolts to
30 Nm (22 ft lb)
-install fan housing grille
-attach ground strap to transmission/body
- check selector lever cable adjustment (see
page 37.3)
- check accelerator/pedal adjustment (see
page 37.13)

- remove three torque converter bolts through

hole (arrow) on top of transmission housing

37.6 Transmission, removing

(trans. 090-code letters NH only)
 Automatic Transmission-Controls, Assembly 37
tving
y)
Crankshaft must be rotated to gain access to
torque converter bolts

-clamp coolant hoses and remove

Its

-disconnect ground strap 4

-remove mounti11g bracket bolts 5 and
selector lever cable

-disconnect push rod from transmission kickdown

lever by removing nut 1
-pry off ball socket 2 for accelerator cable and
remove cable from bracket
-remove circlip 3 for selector lever cable to
disconnect cable

-support transmission with US 4470

Transmission, removing
(trans. 090-code letters NH only) 37.7
37 Automatic Transmission-Controls, Assembly

Note
When attaching transmission to engine, torque con-
verter must be fully seated on one-way clutch sup-
port (arrow) and able to be turned by hand. When
torque converter is properly seated, a = 10 mm
(3/8 in)

-support engine with VW 785/1 or VW 785/1 B

- remove rear transmission mount from body
(4 bolts)
- lower transmission slightly and remove lower
engine/transmission bolt

CAUTION
Torque converter must be secured from sliding
off transmission when lowering transmission out
of vehicle.
CAUTION

-separate transmission from engine If torque converter (left arrow) should slip off of
- lower transmission carefully out of vehicle one-way clutch support, it could pull oil pump
shaft out of pump (right arrow). This could cause
serious damage when bolting transmission to
Automatic transmission, installing engine.
(transmission 090-code letters NH only)
Engine installed
-tighten lower engine/transmission bolts to
Work sequence 55 Nm (41 ft lb)

Proceed in reverse order of removal and note Note

following:
While tightening engine/transmission bolts, turn
torque converter to check for proper seating on
one-way clutch support.

- tighten four rear transmission mount bolts to

body to 40 Nm (30ft lb)
-tighten axle shaft bolts to 45 Nm (33 ft lb)
- tighten upper engine/transmission bolts to
55 Nm (41 ft lb)
-tighten torque converter bolts to 30 Nm (22 ft lb)
-check selector lever cable and accelerator
linkage adjustment (see pages 37.14, 37.15)

37.8 Transmission, Installing

(trans. 090-code letters NH only)
 Automatic Transmission- Controls, Assembly 37
ATF, filling
:on-
CAUTION
~p­

:m Automatic transmission fluids labeled

DEXRON® or DEXRON It® must be used. All Max.
makes or brands of DEXRON® ATF may be
mixed with one another. Do not use
additives. Min.
Tiny particles, dirt or even lint can clog
transmission valves. Use only clean funnel
and hose to add ATF and wipe dipstick
only with clean lint-free cloth

-refill transmission with approved type ATF

fluid through ATF dipstick tube with funnel
New A TF dipstick
and hose
• refill capacity 2.5 ltr (2.6 US qt) • difference between Min./Max. marks:
- set parking brake, start engine 0.24 qts. (0.23 L)
- move selector lever through all gear positions • when cold, fill to 20°C mark, warm up
to operating temperature and fill to
-check ATF level and top up to lower mark if
between marks
necessary
-warm up ATF and check fluid level again
• must be between two marks on dipstick CAUTION

Do NOT overfill. Too much ATF can cause

ATF level, checking damage and must be drained.
• ATF at operating temperature of approx. 60°C Use only ATF marked DEXRON. Do NOT use
(attained after driving approx. 6 miles after a any lubricant additives.
of cold start)
• vehicle on a level surface
lUSe • parking brake engaged The ATF used in production vehicles has changed
• selector lever at "P" in composition and color from that used in previous
• engine idling years ( 1980-84 ).
• use a lint-free cloth to wipe dipstick
previous color: red
new color: red/brown
The new ATF discolors to black/brown after only
short running times. This discoloration has no
effect on the quality of the fluid . Changing the fluid
rn is necessary at the recommended service intervals
>n only.

The new ATF and types of ATF DEXRON used

to previously can be mixed.

2 ft lb)

Current A TF dipstick
• difference between Min./Max. marks:
0.35 qts. (0.33 L)
• when cold, fill to below the Min. mark, warm up
to operating temperature and fill to
between marks

ATF dipstick
ATF, checking/filling 37.9
 Automatic Transmission-Controls, Assembly 37
ATF level, checking/troubleshooting

I Check ATF level I

l
~ l
ATF level OK
I ATF level too low ATF level too high

I End I Check oil level in final drive

Oil level in final drive OK I I 1\ l

I Oil level in final drive too low

Too much ATF added; drain Oil seals between the final
off drive and transmission
leaking; seal transmission

I End
I I End
I

I Check transmission for leaks l #

•
No leak visible externally
l
Leaks visible externally 1
Check oil level in final drive Seal transmission
I

I End

t
Oil level in final drive too high Oil level in final drive OK I
Governor shaft oil seal or
drive shaft seals leaking;
Top off ATF in transmission I
repair transmission

I End
I I End

16 ATF level, troubleshooting 37.9a

37 Automatic Transmission-Controls, Assembly

Final drive oil seals, replacing

(Transmission Installed)

Work sequence
- detach drive shaft from flange

Note
When installing oil seals, fill space between seal
lips with multi-purpose grease
-drive seal in until fully seated
- place drip pan underneath
- remove drive shaft flange

- tighten drive flange bolt to 25 Nm (18 ft lb)

and drive shaft mounting bolts to 45 Nm
- pry out seal (33 ft lb)
- check transmission oil level and add· if
necessary

37.10 Final drive oil seal

A-11
 Automatic Transmission-Controls, Assembly 37

THIS PAGE INTENTIONALLY

LEFT BLANK

8
37.11
37 Automatic Transmission-Controls, Assembly

Accelerator linkage
(except transmission 090-code letters NH)

Accelerator pedal

Pin

if

Accelerator cable

~ Guide tube

Hose

/""Push rod

c----- ---
------ -------
---- '~
~

-----------
------ ----
/Adjusting rod
I
--
- - - - - ._
I
J
Sprtng ------ ._

Accelerator cable/linkage rCircllp

adjusting page 37. 13

37.12 Accelerator cable /linkage

(except trans. 09G-code letters NH) A-~
 Automatic Transmission~Controls, Assembly 37
Accelerator linkage/cable adjustment,
checking
(except transmission 090-code letters NH)

Work seq\Jence
-depress accelerator pedal to full throttle
position
• throttle valve lever must contact stop, but
ki ckdown lever on transmission must not be
in kickdown position
-press accelerator pedal beyond full throttle to
floor
• override spring must be tensioned and
kickdown lever on transmission must be in
kickdown position
if NO, adjust as follows : - press accelerator pedal to floor
• lever 6 must be in kickdown position (arrow),
Accelerator linkage/cable, adjusting with approx. 1-2mm (1/32-3/32 in.) free
play between lever and stop
- release accelerator pedal
- lever must be in idle position (out of kickdown)

-remove override spring 2

- start engine and let idle - if necessary, adjust accelerator cable at
clamping bolt (arrow)
-adjust idle speed at screw 5
(see Repair Group 24)
- shut engine OFF
-press accelerator rod in direction of arrow
to stop
......, -turn adjusting rod 3 with screwdriver until
I shoulder of adjusting rod just contacts pivot
1lsslon
of throttle lever 4
-reinstall override spring 2
-start engine and check idle speed
• adjust if necessary by turning rod 3
-lock adjusting rod 3 in position with nut 1

Accelerator cable/linkage
(except trans. 090-code letters NH) 37. 3
37 Automatic Transmission-Controls, Assembly
·-
Accelerator linkage
(transmission 090-code letters NH only)

Push r o d - - - ,

Pin---_.....,

Clrcllp----...

.......__ _ Accelerator cable

~-----Transm~~n
shift lever

r---Sprlng

AdJusting rod----"
-----~~iii~;.,
37.1 4 Accelerator linkage
(trans. 090-code leHers NH only)
 Automatic Transmission-Controls, Assembly 37
Accelerator linkage/cable adjust- - reinstall override spring 2
ment, checkin.g - start engine and check idle speed
(transmission 090-code letters NH only) -if necessary, adjust idle speed by turning rod 3
- lock adjusting rod 3 in position with nut 1
Work sequence
-depress accelerator pedal to full throttle position
• throttle valve lever must contact stop, but
kickdown lever on transmission must not be
in kickdown position
- press accelerator pedal beyond full throttle
to floor
• override sping must be compressed and kick-
down lever on transmission must be in kick-
down position
If NO, adjust as follows:
Accelerator linkage/cable, adjusting
Work sequence

- press accelerator pedal to floor

• klckdown lever 4 must be in kickdown position
on slop (arrow A)
- release accelerator pedal
• kickdown lever 4 must be in closed throttle
position on stop (arrow B)

-loosen nut 1
- remove override spring 2
-start engine and run at idle
- check and adjust idle if necessary
(see Repair Group 24)
-shut engine OFF
-pull accelerator rod in direction of arrow to stop -if necessary, adjust accelerator cable at
(closed throttle position) clamping bolt (arrow)

-turn adjusting rod 3 with screwdriver until

should$r of adjusting rod just contacts pivot
of throttle lever

37-585

Accelerator linkage/cable
(trans. 090-code letters NH only) 37.15
 37 Automatic Transmission-Controls, Assembly
Transmission operation, checking
CAUTION
All work on vehicle calling for running
engine must be done with selector lever at
N or P and parking brake applied. Only
exceptions are pressure test and stall
speed test
For proper transmission operation, engine idle
speed, ignition timing, etc. must be correct.
Poor engine output because of incorrect
adjustments or worn parts may give impression
of problems with automatic transmission.
Before checking operation, try to find out how
problem developed and whether any repairs had
been done before.
Trouble is often caused by out of adjustment
selector lever cable/ accelerator cable, low ATF
level or Improperly tuned engine.
Before performing tests, do general checks A
and road test E. If problem still exists, proceed
a
with tests to E •
A - General Checks
-check engine idle speed, Ignition timing
-check for leaks (ATF or hypoid oil),
external damage, loose or missing
screws, etc.
a- Transmission fluid level, checking
- check that vehicle Is level
-place selector lever In P aild apply
parking brake. Idle engine. (ATF must be
lukewarm)
- check that ATF level is between two
marks on dipstick
• difference between upper and lower
marks is approx. 0.5 ltr (0.5 US qt)
-add ATF fluid If necessary
CAUTION
Tiny particles, dirt or even lint can clog
transmission valves. Use only clean ·funnel
and hose to add ATF and wipe dipstick
only with clean lint-free cloth
37.16
B-2
Transmission operation
• do not overfill, too much fluid will
upset operation of transmission
-check smell and appearance of ATF.
Burnt smell may indicate burnt friction
linings and trouble in control system
CAUTION
Automatic transmission fluids labeled
DEXRON® or DEXRON II® must be used. All
makes or brands of DEXRON® ATF may be
mixed with one another. Do not use
additives.
C- Final drive oil level, checking
• final drive oil level must be up to edge
of oil filler hole
• if level is too high or too low it may
indicate transfer of oil between
transmission and final drive
D- Stall speed test
Check stall speed only if vehicle shows poor
performance or poor acceleration
• engine must be warm
- connect tachometer (use adapter to avoid
damage to electronic ignition, see Repair
Group 28)
- start engine and hold vehicle firmly with
parking brake and foot brake
- put selector lever in D and depress
accelerator pedal briefly to full throttle
-check that engine now runs between
• 1950 and 2250 rpm (stall speed) for all
automatic transmissions except 090-code
letters NH
• 2450 and 2750 rpm (stall speed) for
transmissions 090-code letters NH only
• 2500 and 2750 - code letters
CAUTION
Do not continue stall speed test longer
than time required to read tachometer.
Maximum stall speed test time 5 seconds.
If necessary to repeat test, walt at least 20
seconds.
Note
Normal stall speed will drop 125 rpm per 3200 ft
altitude. Stall speed will also drop slightly at
high ambient air temperature
 Automatic Transmission-Controls, Assembly 37
- if stall speed is not as specified, refer to
Transmission 090- from transmission
troubleshooting table as follows:
No. 17 07 0 ( ex~ept code letters NH)
Effect Cause -see page 37.19
ion
n Stall speed too high forward clutch or one-
way clutch for 1st When checking shift points, speedometer readings
,g ear slipping may vary within permissible manufacturing
H s,tall speed•rpm in tolerances.
range 0 is too high
repeat test in range 1 - note shift points and compare to chart
All
above. Shifts should be smooth and should
be • if stall speed rpm is
take place quickly and without lag in
within specifications
power transmission
one-way clutch for
- listen for any sign of engine speedup
1st gear Is defective
between shifts which indicates slipping
• If stall speed rpm is
brake bands or clutches
still too high,
-after road test, check transmission for
edge forward clutch Is
fluid leaks
defective
ay Stall speed too low Note
a..:..if approx. poor engine If shift points are incorrect or transmission does
200 rpm below performance (ignition not kick down, check accelerator cable
specified figure timing, fuel injection, adjustments.
compression)
b-if approx. stator one-way
400 rpm below clutch defective F - Pressure test
specified figure (replace torque
'avoid converter) Note
Repair
Pressure test only if defect cannot be found
E- Road test during other checks.
f with
Vehicle should be driven In all gear ranges and This test will locate defects In ATF circuit
i under all possible road conditions. Do not road (internal leakage, wear, sticking control valves or
ottle test if there is obvious mechanical damage dirt in ATF system)

•r all Shift Points In km/h (mph)

0-code
Transmission 090 up to transmission No. 16 07 0
>r automatic
IHonly (except code letters NH)
Shift Full throttle Kickdown
1-3 26-33 (16-21) 48-52 (30-32)
2-3 67-72 (42-45) 88-91 (55-57)
3-2 41-48 (25-30) 84-86 (52-53)
2-1 19-22 (12-14) 43-47 (27-29)
ldS.
t 20
Transmission 090-code letters NH only

Shift Full throttle Klckdown

• gauge connection (arrow)
1·2 25-40 (16-25) 50-53 (31-33) -go to next page
3200 ft
y at 2-3 59-74 (37-46) 85-87 (53-55)
3·2 43-58 (27-36) 80-83 (50-52)
2·1 17-22 (11-14) 39-42 (24-26)

Transmission operation 37.17

37 Automatic Transmission-Controls, Assembly

Teat procedure
-connect gauge with 0-10 kg/cm2 (0-142 psi) scale
- measure three different main pressures as
follows:

Selector lever Accelerator Code Main pressure

-n.st conditions
position pedal position letters kg/cm2 (psi)
accelerate to
50 km/h (31 mph),
NG release accelerator
idle speed NH 2.90-3.00 (41-43)
pedal (idle speed)
NK and check pressure
D
on gauge*
NG 5.85-5.95 (83-84)
full throttle NH *
NK 6.80-6.90 (96-98)

NG 7.62·8.22 (108-117)
NG 9.10·9.70 (129-138)
R idle speed (from17 070) vehicle stationary
NH 9.00-10.00 (128-142)
NK
*These tests should be performed on a dynamometer

If specified values are not reached, check following:

Fault Remedy
Oil pump defective Check pump for wear, replace if necessary
Oil leaks at seals and sealing surfaces or Check for leaks, particularly at valve body
leakage in housing transfer plate
Sticking control valve Disassemble and clean valve body, check valves for
free movement
"

3 7 •18 Pressure test procedure

 Automatic Transmission - Controls, Assembly 37
Shift points In km/h (mph)

Transmission 090 - code letters NG

(from transmission 17 07 0)
Shift Full throttle Klckdown
1·2 25-36 (16-22) 49-52 (30-32)
2-3 60-76 (37-47) 89-90 (55-56)
3-2 43-60 (27-37) 84-86 (52-53)
l), 2-1 17-20 (11-12) 44-47 (27-29)
1tor
:t)
ure "A'ansmlsslon 090 - code letters NK
Shift Full throttle Klckdown
1-2 22-38 (13-24) 48-58 (30-36)
2-3 59-73 (37-45) 86-95 (53-59
3-2 36-56 (22-35) 76-86 (47-53)
2-1 14-19 (9-12) 37-47 (23-29)

y Clutch and brake band operation

This table shows which shift components are in
operation in various gears.
It provides basis for determining which shift
components are not worldng properly when
complaints are made of poor acceleration, faulty
shifting or ~eneral transmission defects.

Example: No drive in 3rd and R gears

Possible cause; D + R clutch
does not work (must be applied)

Selector lever posHion 1 2 or D 2 or D D R

Gears 1st 1st 2nd 3rd Reverse
Forward clutch applied applied applied applied released
0 + R clutch released released released applied applied
1st + R gear brake plates applied released released released applied
2nd gear brake band released released applied released released
One-way clutch inactiv~ holding overrun overrun inactive

Shift points
Transmission operation
37 19 •

Index
- Apply shell 38.1 0
-Direct/Reverse/Forward clutches
installing 38.11
- Forward clutch 38.8, 38.17
-Governor
disassembling/assembling
trans. 090 code letters NG 38.22
removing/installing
trans. 090 except code letters NG
38.23
-Governor drive gear 38.14
- Kickdown lever modification
trans 090 code letters
NH, NK 38.39
- Manual valve 38.35
- Oil pump 38.8, 38.22
- One-way clutch 38.12, 38.14
with plastic cage 38.16
- Operating rod 38.35
- Parking lock 38.34
modification trans. 090
code letters NH, NK 38.39
- Pump shaft 38.3
- Reverse planetary gear set 38.12
- Reverse planetary ring gear 38.14
- Separation plate
trans. 090 code letters NG 38.26
trans. 090 code letters NG from
trans. no. 17 07 0 38.28
trans. 090 code letters
NH, NK38.37
-Spacer springs and rollers 38.15
- Spring table
trans. 090 code letters NH, NK
up to trans. no. 16 07 0 38.30
trans. 090 code letters NG from
trans. no. 17 07 0 38.32
38
Automatic Transmission
Case, Gears, Shafts
- Transfer plate
trans. 090 code letters NG 38.26
trans. 090 code letters NG from
trans. no. 17 07 0 38.28
trans. 090 code letters
NH, NK 38.37
-Transmission
assembly 38.7
-Transmission 090 modifications
code letters NH, NK 38.13
-Transmission/Final drive
assembly 38.2
end play 38.5
separating 38.3
- Transmission housing studs 38.4
- Turbine shaft 38.3
-Valve body
removing/installing 38.25
trans 090 code letters NG 38.26
trans 090 code letters NG
from trans. no. 17 07 0 38.28
code letters NG
up to trans. no. 16 07 0 38.29
trans 090 code letters
NH, NK 38.36
- 1sVreverse brake piston 38.1 0
-2nd gear brake band 38.12
-2nd gear brake band piston 38.1 0
disassembling/assembling 38.24
38.1
38 Automatic Transmission-Case, Gears, Shafts

Note

Final drive/transmission oil seal is installed in

final drive, but sealing lip fits shoulder on
governor drive gear in transmission.
CAUTION

When final drive or transmission are

repaired, check transmission/final drive
-
end play (see page 38.4)
If only oil seal is to be replaced, transmission Fi
should not be tilted when removing from final
drive to avoid oil leakage and mixing

Turbine s h a f t - - - - - - - - - - ,
removing: transmission must
be removed first
Installing: place in pinion shaft
before joining transmission
and final drive
length Fig. 4
checking turbine shaft rings Fig . 5

T arque installing,
before converter pump shaft .;::~!!!!!!!!!!!!'r!!!!!!!!!!!!!!!!!!!!~...._
must be inserted fully
into pump splines Fig. 2

Transmission
separating from final
drive Fig. 3
Final drive
disassembling page 38.6
disassembling/ assembling
Repair Group 39
Torque converter oil seal
removing/ installing
Repair Group 32

38.2 Transmission/ Final drive assembly

 Automatic Transmission-Case, Gears, Shaft 38
- remove final drive
-drain oil from final drive
e

a - ·----,------lJ [38·4221

Fig. 1 Pump shaft length

• a = 546 .7 mm (21.524 ln.)
~------- 0 -------

Fig. 4 Turbine shaft, length

• a = 457 .8 mm (18.024 in.)

!SS

38- 676"
Fig. 5 Turbine shaft rings, checking
ba-•• J ! - check rings (arrows) for wear and
right wrong
proper seating
Pump shaft, inserting

,,
38.6

Fig. 6 Turbine shaft, early version

• turbine shaft for forward clutch with
thrust washer

Note
Do not install together with thrust bearing

@~ -176
Transmission/ Final drive, separating
- mount transmission/final drive
assembly as shown
-drain ATF

Pu mp/Turbine shafts
Transmission/Final drive
38 3 •
38 Automatic Transmission- Case, Gears, Shaft
- Tre
&dj

No1
Enc
mu:
pia•

Wo1

Fig. 7 Turbine shaft, later version

• turbine shaft for forward clutch with
thrust bearing
• identification: groove for circlip on
splines (arrow)

CAUTION
Never install shaft without circlip
Note
New shaft with circlip can be installed together
with early version oil pump and thrust washer
Fig. 9 Transmission housing studs, Installing
• a and b =18 mm (23/32 in.)
Note
Housings supplied as Spare Parts are without
studs. When installing studs, use studs of
correct length and install to proper depth

Mea
•Fil
• Tr;
to

Dim

Fig. 8 Transmission housing studs, installing

•a = 31 .5 mm(11/4 in.)

- m
Sf

38.4 Turbine shaft, later version

Transmission housing studs
 Automatic Transmission-Case, Gears, Shaft 38
Transmission/ Final drive end play,
adjusting
Note
End play y between transmission and final drive
must be adjusted to limit end play of reverse
planetary ring gear

Work sequence

- measure dimension from straight edge to final

Reverse planetary drive housing joint
ring gear
Example
from straight edge to oil seal
bushing 18.7 mm
from straight edge to joint - 8.0 mm
alllng
Dimension a = 10.7mm

Dimension b, measuring

thout
Pinion shaft
)f

38·244

Measuring points:
1 Final drive housing: joint to oil seal bushing a
1 Transmission housing: shim contact shoulder
to separation plate with gasket b

Dimension a, measuring

- measure dimension from straight edge on

housing to gasket on plate

Transmission/Final drive end play 38.5

38 Automatic Transmission-Case, Gears, Shaft

- measure dimension from straight edge to

shoulder for shims

Example
from straight edge to plate 19.2 mm
from straight edge to shoulder -10.0 mm
Dimensionb = 9.2mm

Shim thickness, determining

- deduct b from a
• result is dimension x

Example
Dimension a 10.7 mm
Dimension b - 9.2mm
Dimensionx = 1.5mm

- select shims from table (shims are available

in two thicknesses, 0.4 mm and 1.2 mm)

Dimension x Shim
mm mm
0.23-0.84 none
0.85-1 .24 1 x0.4
1.25-1.64 2x0.4
1.65-2.04 1 X 1.2
2.05-2.44 1 X 0.4
1 X 1.2
2.45-2.84 2x0.4
1 X 1.2
2.85- 3.24 2x 1.2
3.25- 3.64 1 X 0.4
2 X 1.2
3.65-3.88 2x0.4
2x 1.2

c
38.6 Transmission/Final drive end play
 Automatic Transmission-Case, Gear·s, Shafts 38
2nd gear brake band piston - - - - - - - - , r---Push rod for
remove before taking out brake band adjusting screw
removing Fig. 2
installing Fig . 8
checking Fig . 10
disassembling / assembling
page 38.20
Oil pump - - - - - - - - . .
installing Fig. 3
Spring plate with springs
disassembling/assembling
installing Fig. 6
page 38.19
modification page 38.8

Thrust washers
smear with grease and stick
to forward clutch
modification page
and 38.9

Direct/Reverse clutch
installing Fig . 9
disassembling/assembling

~............
page 38.15

Forward clutch------>
disassembling/ assembling
page 38.12
installing Fig. 9
modification page 38.8

Outer-spllned plate
lnner-spllned plate
1st/Reverse brake
1st/Reverse brake
before installing, soak 15 min. In ATF

Thrust washer
smear with grease
and stick to planetary
gear set
Reverse planetary gear set
Retaining key install ing Fig. 11
Separation P"lte·--' take out after One-way clutch
after installing, check Reverse planetary ring gear/ removing disassembling/
transmission/ final drive Governor drive gear one-way clutch assembling page 38.10
end play, adjust if checking/ assembling installing Fig. 13 installing Fig . 13
necessary see page 38.4 page 38.10

C·7
Transmission 38.7
38 Automatic Transmission-Case, Gears, Shaft

Oil pump and forward clutch,

modifications
Up to Dec. 1981 From Dec. 1981

Oil pump with thrust washer

Oil pump with thrust bearing
Note
Can be installed together with thrust bearing Note
Do not install with thrust washer only

J3a-52o I
Forward clutch with thrust washer Forward clutch with thrust bearing
• identification : drillings (arrows) • identification: no drillings

Note Note
Do not install together with thrust bearing Do not install together with thrust washer

38.8 Oil pump

Forward clutch
 Automatic Transmission-Case, Gears, Shafts 38
Thrust washers

Up to Dec. 1981 'From Dec. 1981

between oil pump and D + R clutch, also

between oil pump and D + R clutch between forward clutch and D + R clutch
( plastic )

Note
New thrust washers can also be installed in
previcus transmissions

Thrust washer 38.9

38 Automatic Transmission-Case, Gears, Shaft

Fig. 1 Circlip, removing

Fig. 4 Apply shell, Installing
-remove from groove (arrow)
- insert lug (arrow) in groove shown

Fig. 2 2nd gear brake band piston, removing

- remove circlip
Fig. 5 Apply shell, measuring
-remove piston by tapping lightly with
rubber hammer
• a =91 .4 mm (3.598 in.)

1_8 · 081!
Fig. 6 Spring plate with springs, Installing
Fig. 3 1st/ Reverse brake piston/Oil pump,
installing - place springs on plate
- place in housing with springs facing
- push piston onto pump housing and down and tighten in this position
insert pump in housing. Thin rib
(arrow) must point up
- insert pump shaft in drive plate and
turn pump. Pump should turn freely

2nd gear brake band piston

38.10 1st/Reverse brake piston/Oil pump

Apply shell
 Automatic Transmission-Case, Gears, Shafts 38

138·1 86 1

Fig. 7 1st/Reverse gear brake, checking
- apply low air pressure to port (arrow)
• piston must compress springs
• piston must return to original
position, when compressed air Is
released
-VW281a
Fig. 9 Direct/Reverse and Forward clutches,
Installing
-assemble direct/reverse and forward
clutches first
-angle transmission housing downward
and slide clutches onto neck of oil
pump
- turn transmission so opening faces up

Fig. 10 2nd gear brake, checking

- apply low air pressure to port (arrow)
• brake band must apply
• brake band must release when air
pressure removed
Fig. 8 2nd gear brake band piston, Installing
- press piston down and Insert circllp

1st/Reverse gear brake

2nd gear brake band piston
Direct/Reverse/Forward clutches 38.11
38 Automatic Transmission- Case, Gears, Shaft

Fig. 11 Reverse planetary gear set, Installing

-first insert planetary gear set
- insert wavy spring washer and plates - clrcllp opening must be opposite
retaining key

Fig. 12 1st gear brake splined plates, Fig. 15 2nd gear brake band adjusting screw,
Identification adjusting

• plates are marked 81 (arrow) - first loosen locknut and tighten

adjusting screw to 10 Nm (87 ln. lb)
- loosen and retighten to 5 Nm (43 ln. lb)
- loosen from this position exactly
2 1/2 turns and tighten locknut

CAUTION
Transmission must be horizontal when
adjusting brake bands; otherwise bands
may jam

Flg. 13 One·way clutch, installing

• parts are installed properly if groove
for circlip is exposed (arrow)
• it must not be possible to turn planetary
gear set counterclockwise

Reverse planetary gear set

38.12 One-way clutch

2nd gear brake band
 Automatic Transmission-Case, Gears, Shafts 38
Modifications for transmission 090- New piston with ball valve and apply shell with drill-
code letters NH, NK ing may be installed in previous transmissions with
following requirements:
Note • do not use wavy spring washer
• only use 4 inner and 4 outer splined plates
Wavy spring washer for 1st gear brake has been
deleted. Apply shell has been lengthened as a
result. 1st gear brake piston now' has a ball valve.

Fig. 16 1st gear brake piston, installing

-lubricate with ATF
• ball valve in piston (arrow 2) must line
up with drilling in transmission housing
(arrow 1)
jJS - 598 I
Fig. 18 ATF cooler, Installing
• transmission is equipped with ATF
cooler secured to transmission with
union bolts and sealed with 0-rings
(arrows).
-tighten union bolts to 40 Nm (30 ft lb)

Fig. 17 Apply shell, installing

• a= 97mm
• drilling (arrow) must line up with bali valve
on 1st gear brake piston

Note
Number of inner and outer splined plates used with
this length apply shell is 4 each.

Modifications for trans. 090

code letters NH, NK 38.13
38 Automatic Transmission-Case, Gears, Shaft

Reverse planetary ring gear/Governor drive gear, checking/assembling

---Ring gear
check parking lock
notches for wear

One-way clutch, disassembling/ assembling

Spacer springs and rollers --~ 11.

installing - --........
early version Fig . 3
later version Fig . 5
Cage
drive out carefully with hammer
assembling
early version Fig. 2
later version Fig. 4

Outer r i n g - - - - - -
inserting lower circlip Fig. 1

Reverse planetary ring gear 1 B-13

38.1 4 Governor drive gear

One-way clutch
 Automatic Transmiss.i on-Case, Gears, Shafts 38

Fig. 3 Spacer springs and rollers, installing

One-way clutch outer ring, assembling
-rollers/springs must be installed in
-place lower circlip in ring (arrow) proper relation to each other
(as shown)

-
One-way clutch cage, assembling
-heat outer ring to at least 150"C
(300"F) on a hot plate. Set hot plate to
at least 19o•c (375"F)
-grip upper shoulder of cage with two
pairs of pliers and place it quickly in
outer ring When installing spring with guide lug (arrow),
-short sides of retaining lugs on cage
always point lug toward roller to ensure best
must be firmly against shoulders in
outer ring (arrow). If necessary, turn lateral guidance
cage slightly immediately after
mer Note
inserting it

Both springs can be installed together,

CAUTION
with and without lug
If cage is not properly located on lower
circlip and inside of outer ring, do not
press it into position. Knock cage out
carefully, let cool and repeat procedure

8·13
One-way clutch
Spacer springs and rollers 38.15
38 Automatic Transmission-Case, Gears, Shafts

One-way clutch with plastic cage for

rollers and springs
Note
New plastic cage can be service-installed In earlier
transmissions. Circlips previously used have been
discontinued and cannot be used with plastic cage.

Fig. 6 Installation position of cage

- insert cage into outer r!ng from below
(direction of-arrow A)
• small ledge (1) at top
• large ledge (2) at bottom

Fig. 4 Plastic cage segments

- assemble 10 segments to form a ring

Fig. 7 Securing cage

-turn in direction of arrow

Fig. 5 Springs and rollers, installing

• spring tab (arrow) toward roller

38.1 6 One-way clutch with plastic cage

 Automatic Transmission-Case, Gears, Shafts 38
Forward clutch assembly
checking operation Fig. 4

.:..____ Pressure plate

different thicknesses.
adjusting end play Fig . 2

Outer splined plates (3) --+-----_...

if radial grooves are found,
replace plates. If discolored
but no grooves, reuse plates
-----i~ Inner spllned plates (4)
Installing Fig. 1

Forward planetary ring gear Circllp

before installing, insert thrust when installed,
plate and one inner splined plate diaphragm spring must
under ridge be lightly tensioned;
if not, replace
diaphragm spring

Thrust plate

Diaphragm spring
convex side faces
bottom of clutch drum

Piston
before installing,
dip in ATF

Clutch d r u m - - - - - - - - - - -
assembling Fig. 3
checking: blow compressed air in direction
of arrow to check that ball valve is
free and seals properly.
Check that valve is not obstructed
by blowing compressed air in
opposite direction of arrow

Forward clutch 38.1 7

38 Automatic Transmission-Case, Gears, Shaft

Fig. 3 Forward clutch drum, assembling

Fig. 1 Inner splined plates, installing
- measure depth of grooves
• only install plates with linings • a = 29.8 mm (1.173 in.)
marked as shown
- before installing, soak new plates in
ATF for 15 minutes

Fig. 4 Forward clutch assembly, checking

VW387
Fig. 2 Forward clutch, adjusting end play
- check that play (arrow) Is between
0.5-0.9 rnm (0.020-0.035 in.)
If NO, select new pressure plate from
table
operation
- install both forward clutch and
direct/reverse clutch with thrust
washers on oil pump
-apply compressed air to port (arrow A)
• piston must compress clutch plates
• piston must release plates when
compressed air is removed

Thickness (mm) Part No.

6.0 010 323 253 F
6.4 010 323 253 A
6.8 010 323 253 8
7.2 010 323 253 c
7.6 010 323 253 D

38.18 Forward clutch

 Automatic Transmission-Case, Gears, Shafts 38
Direct I Reverse clutch assembly
checking operation Fig . 8

._----Circllp
different thicknesses
adjusting end play Fig . 6

Inner spllned plates (4) -cO:::::::,------. ----71>-- Outer spllned plates (4)
installing Fig. 5 if radial grooves are found,
replace plates. If discolored
but no grooves, reuse plates

~-~Ctrcllp
removing/ installing Fig. 1

- - - - - - Springs (24)

----'-----Spring plate

-----Piston
sealing lips are vulcanized
to piston
before Installing dip in ATF
IW A)
ates

Bushing
removing Fig. 2
Installing Fig. 3 and Fig. 4

Clutch d r u m - - - - - - - - - - -
assembling Fig. 7
checking: apply compressed air in direction
of arrow to check that ball valve is
free and seals properly.
Check that valve is not obstructed
by applying compressed air in
opposite direction of arrow

C·19
Direct/Reverse clutch 38.19
38 Automatic Transmission-Case, Gears, Shaft

1 VW460/3 VW408o
I .
VW433

VW401
}

J
.._38-099 Fig. 3 Bushing In clutch drum, installing
Fig. 1 Circlip (small), removing/installing - press bushing in flush
- press spring plate down

VW420 -

VW40Ba

!38·326
Fig. 4 Bushing in clutch drum, installing
- use old bushing A to press new
bushing 1.7 mm (0.067 in.) below top
edge
Fig. 2 Bushing in clutch drum, removing
-press out

38.20 Direct/ Reverse clutch

 Automatic Transmission-Case, Gears, Shafts 38

71 ]
Fig. 7 Clutch drum/Circlip groove, asse mbling

Fig. 5 Inner splined plates, installing Note

• only use plates with lining marked Different size clutch drums are available.
as shown Only install drum with correct dimension
-soak new plates in ATF for 15 minutes
before installing • a = 31.25 mm (1.230 in.)

!38-126,

Fig. 6 Direct/ Reverse clutch end play, adjusting Fig. 8 Direct/ Reverse clutch assembly,
checking operation
- check that play is
2.05- 2.50 mm (0.081 - 0.098 in.) - install both forward clutch and
-adjust if necessary by replacing direct/reverse clutch with thrust
circlip until correct clearance is washers on oil pump
obtained -apply compressed air to port (arrow B)
• piston must compress clutch plates
Circlip available • piston must release plates when
compressed air is removed
Thickness (mm) Part No.
1.5 010 323 157 A
1 top 1.7 010 323 157 B
2.0 010 323 157
2.3 010 323 157 c
2.5 010 323 157 D

Direct/Reverse clutch 38.21

38 Automatic Transmission-Case, Gears, Shaft
Oil pump, disassembling/assembling Piston rings (small) - - - - - - . . . , .
removing: unhook ends and take off
carefully
Installing: ends of rings must
Screws be hooked together
when removing be careful,
cover plate Is under spring tension

Drive p l a t e - - - - - - - - ,
check for wear and scoring

install before installing

piston rings
modification page 38.8
11 mm (0.433 ln.) dia.
gear
'--C:JUIIIr

Cover plate dip in ATF before Installing.

check for scoring. Side with code letter must
After assembling pump, face cover plate
insert pump shaft into drive
plate and turn pump by hand.
Gears must turn smoothly
without jamming

Governor, disassembling/assembling
(transmission 090-code letters NG only)

Transfer plate
note installation position

Strainer
deleted as of trans. No • .09 04 0
During transmission repairs,
(prior to trans No. 09 04 0),
do not reinstall strainer

Balance weight
do not interchange,
governor is balanced

check for wear.

Can be replaced
separately

38.22 Oil pump

Governor
 Automatic Transmission-Case, Gears, Shafts 38
Governor, removing/installing
(Transmission 090---except code letters NG) Note
New governor may only be used with new type
valve body. Previous type governor may also be
used with new valve body.

,e off

!Ja -599 1

Flat Governor
Governor, removing/installing
1 - Flat governor
2-0-ring
• always replace
3 - Governor cap
4-Ciip
• must be secure

.Q

Governor, identification
Code letters (listed below) are stamped on
governor head. New type governors are used only
with new type valve bodies (see pages 38.37,
38.38).
Transmission Valve body Governor
Code Letters Code Letters Code letters
NH FF A
NH FFA A
NK FFA A

Governor 38.23
 Automatic Transmission-Case, Gears, Shafts 38
2nd gear brake band piston, disassembling/assembling

replacement parts supplied

pre-assembled and adjusted.
Check piston diameter
see Fig. 1

Accumulator spring

lip poin ts to bottom lip points toward open

of cover, see Fig. 1 side of cover, see Fig. 1
Cover
with 2 0-rlng grooves

~------------a------------~

Fig. 1 Piston and piston seals, positions

• a = 96.5 mm (3.799 in.)

2nd gear brake band piston 38.24

38 Automatic Transmission-Case, Gears, Shaft
Valve body, removing/installing CAUTION
Do not run engine or tow vehicle when oil
Note
pan is off or with no oil in transmission
Valve body can be removed and installed with
automatic transmission in vehicle. Drain ATF and
remove oil pan first

20 Nm (14 ft lb)

'-----Gasket
always replace

.....__ _ _ _ 011 strainer cover

4 Nm (35 in. ! b ) - - - - - - - ------011 strainer

quantity 11
" - - - - - Gasket
Accumulator piston - - - -

Valve body
Strainer in pressure channel
Installing Fig. 1
deleted asdf trans. No. 21 04 0 disassembling / assembling see page 38.24
During repairs on transmissions
(prior to No. 21 04 0), do not
reinstall strainer

Fig. 1 Valve body, installing

- attach valve body to housing
- connect manual valve (arrow A) and
operating lever (arrow B)
- tighten all bolts diagonally

38.25 Valve body

 Automatic Transmission-Case, Gears, Shafts 38

J
CAUTION Transmission 090
(code letters NG only)
Tighten screws evenly in diagonal
sequence
.
l--screwa (quantity 3)
....
1
..
1

Screws (quantity 19) -

u
3 Nm(261n.lb)
1
..
4 Nm (35 in. lb)

0 ..
-- - •
••
--
-- .. -.,

Sealing
--
c,.

Accumulator cover plate~ u Transfer plate

Identification Fig. 3
e 38.24

Separation plate
Identification Fig. 4

Valve body
Ball valves~ code letter Fig. 2
location Fig. 1 'i <J disassembling/assembling page 38.25
Q

Valve body
0·6 Separation plate
Transfer plate 38.26
38 Automatic Transmission-Case, Gears, Shaft

A
tr;
(fl

Fig. 1 Ball valves, locations In valve body

• all balls (arrows) 6 mm diameter
Fig. 4 Separation plate, Identification
• at arrows 1 = 3 notches
• at arrow 2 = 1 notch

Fig. 2 Valve body, code letter/application

• code letter located on boss (arrow)

• •
• •
• ••
Fig. 3 Transfer plate, Identification

Valve body

38.27 Transfer plate

Separation plate
 Automatic Transmission-Case, Gears, Shafts 38
Automatic transmission modifications
transmission 090--code letters NG
(from transmission no. 17 07 0)

Transfer plate identification (arrow)

Valve body code letters

Transmission Valve body

Code letters code letters

NG BH

Note
New valve body can be installed in transmissions
from transmission No. 01 06 8

Ball valve locations in valve body

5 balls 6 mm diameter (arrows except A)
1 ball 3 mm diameter (arrow A)

Separation plate marking

2 notches at arrow 1
3 notches at arrow 2

Valve body
Separation plate
Transfer plate 38.28
38 Automatic Transmission-Case, Gears, Shafts
Valve body assembly transmission 090
code letters NG
(up to trans. no. 16 07 0} CAUTION

Note Several valve springs have same

dimensions. However, do not interchange
Slight scoring on valves will because they have different tolerances
not cause operating problems 0
Spring measurements
see spring table page 38.26 i
Circled numbers correspond to
those In spring table • ----Adjusting screw/ main pressure valve
do not turn, can only be set on test stand
Adjustt.-,g screw/main pressure limiting valve Spring/ main pressure valve
do not turn, can only be set on test stand
(do not lnterchang~)

Adjusting screw for throttle pressure

limiting valve
do not turn, can only be set on test stand
(do not interchange)

® Spring/ main pressure limiting valve--...· -

ThrotUe pressure limiting--------..

valve with spring seat

Governor 1·2

Main regulating valve Control valve 3-2

Spring I control
valve 3-2

® Spring/throttle - - --i-.-...-
t---:::~---,...-- Modulator pressure valve
pressure valve
1-.- --1+-Shlft valve 2-3

1- 3·2 klckdown control valve

with spring seat

Sprlng/3·2 klckdown

valve ~®
- controf valve

Guide sleeve/klckdown
,

Valve body

38.29 code letters NG

(up to trans. no. 16 07 0)
 Automatic Transmission-Case, Gears, Shafts 38
Spring table
CAUTION
This table allows identification of springs by
Several valve springs have similar
their dimensions. Coil diameter and free length
dimensions. However, they must not be
can vary between new and used springs (due to
interchanged because they have different
settling) so check spring wire thickness and
tolerances
number of coils first, as a means of identifying
springs. If this is not enough, also use inner coil
diameter and free length

Transmission 090-code letters NG up to transmission no. 16 07 0

Transmission 090-code letters NH, NK
Inner dlameter2
Number Wire thickness Free length' of coil
Description of coils mm (in.) mm (in.) mm (in.)

C0 Spring I throttle pressure

limiting valve
14 1/2 1.1 (0.043) 35.3 (1.389) 7.7 (0.303)

® Spring/main pressure limiting

valve
11 1.2 (0.047) 32.4 (1.275) 7.7 (0.303)

0 Spring/main pressure valve 16 1/2 1.5 (0.059) 77.0 (3.031) 11.9 (0.468)
2 0 Spring/control valve 3-2 12 1/2 1.0 (0.039) 32.4 (1.275) 7.7 (0.303)

·3
® Spring/ throttle pressure valve 16 1.25 (0.049) 43.4 (1.708) 7.75 (0.035)

® Spring/ shift valve 1-2

except code letters NH 9 1/2 0.8 (0.031) 26.0 (1.024) 8.2 (0.323)
rol Spring/shift valve 1-2
code letters NH only 8 1/2 0.9 (0.035) 28.8 (1.134) 8.1 (0.318)

0 Spring/converter pressure valve e 112 1.25 (0.049) 22.2 (0.874) 7.7 (0.303)

® Spring/ modulator pressure valve 11.1/2 0.8 (0.031) 28.6 (1.126) 7.75 (0.305)

ody ® Spring/shift valve 2-3 9 1/2 0.8 (0.031) 26.0 (1.024) 8.2 (0.323)

@) Spring/kickdown control 11 1/2 0.9 (0.035) 28.4 (1.118) 8.1 (0.318)

valve 3-2
@ Spring/apply valve . 11 1/2 0.9 (0.035) 28.4 (1.118) 8.1 (0.318)
1st/ reverse gear brake
1lve
'Free length can vary due to tolerances and settling
2
1nner coil diameter is within a tolerance of ± 0.3 mm (0.012 in.)
rette

own

0·10
Spring table
trans. 090 code letters NH, NK
code letters NG up to trans. no 16 07 0
38 3Q •
38 Automatic Transmission-Case, Gears, Shaft
Valve body modifications
transmission 090--code letters NG
(from transmission no. 17 07 0)

~Bushing

Throttle pressure limiti ng

valve with spring $eat

Governor plug 1-2

rw·-----=~- Apply valve for

1st/reverse gear brake

Throttle pressure valve

·.,.---Valve body

~ Rtl(Shat.oWo2-3
~ ¥' ~
II~ I
0
-- I

38.31
Valve body
trans. 090 code letters NG
(from trans. no. 17 07 0)
' 138-4891
 Automatic Transmission-Case, Gears, Shafts 38
Automatic transmission modifications
transmission 090--code letters NG
(from transmission no. 17 07 0)

Spring table
This table allows identification of springs by their CAUTION
dimensions. Coil diameter and free length can vary Several valve springs have similar
between new and used springs (due to settling) so dimensions. However, they must not be
check spring wire th ickness and number of coils interchanged because they have different
first, as means of identifying springs. If this is not tolerances
enough, also use inner coil diameter and free length

Inner diameter 12 )
Description Coils Wire thickness Free length (1 ) of coil
mm mm mm

Spring/throttle pressure
limiting valve 14.5 1.1 37.9 7.7

Spring/main pressure
brake limiting valve 12.5 12 27.5 7.6

Spring/main pressure valve 16.5 1.4 692 11.9

Spring/control valve 3-2 16.5 1.1 44 7.75

Spring/throttle pressure valve 11.5 0.8 28.6 7.75

Spring/shift valve 1-2 6.5 0.9 19.9 8.1

Spring/shift valve 2-3 8.5 0.8 17A 6.95

Spring/modulator pressure valve 12.5 1.0 32.4 7.7

Spring/converter pressure valve 8.5 1.25 22.2 7.7

Spring/kickdown control valve 3-2 11.5 0.9 28.4 8.1

Spring/apply valve 1st/reverse gear brake 10.5 0.63 36.3 9.0

(1) Free length can vary due to tolerances and set.tling

(2) Inner coil diameter is within tolerance of± 0.3 mm

Spring table
trans. code 090--code letters NG
(from trans. no. 17 07 0) 38.32
38 Automatic Transmission-Case, Gears, Shafts

Valve body, disassembling/cleaning Valve body, assembling

Note
Valve body should only be disassembled for
cleaning or when transmission failure was
caused by burnt friction linings or excessively
dirty ATF. If ATF is still fairly clean, place the
complete valve body in cleaning solution and
then dry it afterwards with compressed air.
Storage tray, tool number 2008, Is used to store
all valves, springs and screws from valve
assembly.
Note
Lubricate all parts with ATF when assembling
and check for free movement. Valves shou ld
slide under their own weight.
Valves which are slightly scored may be reused.
This will not affect operation of transmission.
3-2 klckdown control valve must be cleaned
separately, because those parts cannot be put
into storage tray.

Tray outer shape corresponds to shape of valve All parts must be completely clean.
body. Valves and springs must be put back Into same
To be sure parts are reinstalled in their original holes from which they were removed
location, they should be placed in storage tray.
- insert springs and valves into one side in
Ball valves can be stored in space provided for locations shown in exploded view (see page
bolts 38.25) and then install end plate before
- remove rear end plate, take out valves and proceeding with other side
springs one after another and place them in
tray
- remove end plate from other side and repeat
procedure
- place lid on tray
- immerse tray complete with parts in cleaning
solution. Dry with compressed air. Do not use
water, fluffy rags or cloths when cleaning parts

38.33 Valve body

 Automatic Transmission-Case, Gears, Shafts 38
Pin tor parillng lock pawl
end of pin must be
flush with housing edge

Operating lever/Parillng lock

check that rollers move easily

.
Spring for shift segment

,-20 Nm (14ft lb)

:-1~-\:;1---Parillng lock pawl

check for wear

Operating lever

Support rlng :-L ,.

~':I'J

~- rin~
L Lever :haft
positioning Fig. 2

Lever for selector cable

4 Nm (35 ln. lb)

Operating lever with shift segment

tor manual vatve
check notches for wear
Operating lever for klckdown valve
installing Fig. 1

I.

e Fig. 2 Lever shaft, positioning

Fig. 1 Operating lever for kickdown valve,

Installing
• angled ends of operating lever points
toward center of transmission

0·14
Parking lock 38.34
38 Automatic Transmission-Case, Gears, Shafts
Manual valve, operating rod and
parking lock, modifications

Version I Version II Version Ill

Operating lever with shift

'
segment lor manual valve

Operating rod~

- Operating lever/parking lock

~4 38-508

CAUTION
Only install parts combinations illustrated
for each respective version

Manual valve

38.35 Operating rod

Parking lock
 Automatic Transmission-Case, Gears, Shafts 38
. I
Valve Body Assembly,
disassembling/assembling
Transmission with code letters NH, NK

---Adjusting screw/main pressure limiting valve

do not turn, can only be set on test stand

Adjusting screw/Intermediate--------=-:
pressure valve
do not turn, can only be set on test stand

Spring/Intermediate pressure vallve· -- - ---'1:1

Spring/main pressure limiting val've----~

..---Control valve 3·2

41L- - ---11r-----Appfy valve · 1st and

reverse gear brake

Spring/control valve 3·2

Kick-down valve•·-------- - - 1 pressure valve

-I•
Spring/converter
----Spring
3-2 kick-down control valve
Guide sleeve/kick-down valve---.. Spring
Shift valve 2-3

'modified parts

Note
The modulator pressure valve has
Modified spring shift valve 1· 2 been deleted.
Total coils 8 .5, wire thickness 0 .9 mm To clean the valve assembly use
Length 28 .8 mm, internal coil dia. 8 .1 mm tray 2 008 A. 1 38· 573 1

C-12
0·16 Valve body assembly
(trans. 090--code letters NH, NK only) 38.36
38 Automatic Transmission-Case, Gears, Shafts

Transfer Plate, Separation Plate,

Valve Body CAUTION

Tighten screws evenly when assembling

Transmission with code letters NH, NK
Modified valve assembly and separation plate

U ,....--Screws (galvanized, 3 total)

4 Nm (35 in lb) -screws (19 total)
4 Nm (35 in lb)

Fl!

• •
L _Transfer plate
Identification Fig. 3

Separation Dlate----:illl
identification Fig. 4

Ball valve - - - - -::-...- .

location Fig. 1

Fl

Valve body
identification Fig. 2
disassembling/assembling
page 38.36

Transfer plate, Separation plate

38.37 Valve body

(trans. 090-code letters NH, NK only)
 Automatic Transmission-Case, Gears, Shafts 38

J
Fig. 1 Ball valves, location
• 1 ball (arrow A) 3 mm dia.
• 5 balls (arrows) 6 mm dia.

Fig. 4 Separation plate, Identification

• 2 notches at arrow 1
• 3 notches at arrow 2
• 1 notch at arrow 3

Fig. 2 Valve body, identification

• code letters on boss (arrow): FF,
FFA (w/NH trans.), NK w/FFA valve body

Fig. 3 Transfer plate, identification

• Part No. 010 325 283 J

Valve body
0·18 Separation plate
Transfer plate 38.38
38 Automatic Transmission-Case, Gear~, Shafts

Parking lock rod and Kickdown lever,

modification
Transmission 09o-NH, NK only

Parki ng lock operati ng rod, modification

With modified operating rod (on hexagon, arrow), park·

ing lock engagement lever is secured with only one circlip

Kl ckdown valve operating lever, modification

Kickdown valve operating lever has been flattened slightly

at contact surface A

Note

New kickdown valve operating lever can be installed In

previous transmissions , but earlier-type operating lever
must not be installed in transmissions with new kickdown
valve .

Parking lock

38.39 Kickdown lever,

modifications

Differential
Manual Transmission
Quick Data Index
4-Speed 091, 091/1
5-Speed 094
-Assembly 39.2
-Bearings 39.3-39.5
-Housing 39.3
-Pinion
adjusting 39.1 0, 39.11
-Pinion/Side gears 39.6
-Ring gear 39.3, 39.4
adjusting 39.12, 39.13
backlash 39.13, 39.14
-Ring/Pinion gears
adjusting 39.7-39.9
-Shim S3 39.11
Differential-Auto. Trans.
- See page 39.49
1- 1
)
39
094-4WD Syncro
- Differential with lock
assembly 39.20
bearing outer race 39.24
bearings 39.21-39.23
housing 39.21
pinion shafts 39.22 '
ring gear 39.20-39.23
-Differential without lock
assembly 39.15
bearing outer race 39.19
bearings 39.16-39.18
housing 39.16
pinion shafts 39.17
ring gear 39.15-39.18
- Driveshaft
flange oil seal 39.44
removing/installing 39.43
-Front final drive 39.30, 39.31
adjusting rings 39.32, 39.33
axle flange 39.32, 39.33
circlip 39.33
housing 39.34
mounting 39.32
technical data 39.42
-Front pinion 39.39
bearing 39.40
grooved nut 39.40
turning torque 39.41
-Locking pin 39.28, 39.29
backlash 39.29
-Pinion/Side gears 39.25
-Removing 39.33
-Ring gear/Pinion
adjusting 39.26
backlash 39.27
screw-in depth 39.26, 39.27
Index 39.1
39 Differential- Manual Transmission
CAUTION
Inner and outer races of tapered roller
bearings are matched and must not be , G ---Adjusting ring
interchanged. Replace both bearings at
same time. Ring gear/ pinion must be
adjusted after replacing differential
housing, cover or bearings. Side gear end
play must be adjusted if differential Differential bearing/ outer race
housing, cover or side gears have been removing Fig . 10
replaced installing Fig . 11

qj!UIJJII"" ' - - - - - - Differential bearing/inner race

Note
Drive flange oil seal
can be replaced with
final drive installed,
see Repair Group 34
Ring gear I pinion adjusting,
page 39.7-39.14
backlash adjusting, page 39.13
(ring gear side)
50 Nm (36 It lb) - - - removing Fig . 4
tighten diagonally installing Fig. 7
Differential cover
removing Fig . 3
when installing, oil
holes (arrow) must be
offset approximately goo
to differential pinion shaft

Spacer I

determining size page 39.6

~----'..__ _ _ _ Thrust washers
?
Fig.
check for wear

-.....____ Differential pinion gears

installing page 39.6

Differential pinion shalt - - - - -

drive out with drift. When
installing, do not damage
thrust washers ./'""--- Differential housing
disassembling Fig. 1

.,....-----Ring gear
(matched to pinion)
removing Fig. 2
installing Fig. 9
Pin _ _ _ __,
drive in flush

Differential bearing/ outer race

removing Fig . 10
Differential bearing/ inner race _ ___,.. installing Fig . 11
(housing side)
removing Fig. 5 and Fig. 6
Installing Fig. 8

-/ -..;._ _ _ _ Transmission housing

135-7191

39.2 Ring gear

Differential
j4-speed 091-091/11_
.
5-speed 094
 Differential- Manual Transmission 39

·ace
- VW771

tace

1shers
· wear
- use jaw covers on vise Fig. 3 Differential cover, removing

gea rs
.6

ousing
rg Fig . 1

opin ion) 34 -289

' ig. 2
=ig. 9
- use drift to separate ring gear fro m
housing
uter race
CAUTION Fig. 4 Differential bearing/ inner race (ring gear
side), removing
Do not damag e threads in rin g gea r

n housing

1-2
14-speed 091-091/111 5-speed 094
Ring gear
Differential housing
Differential bearings
39 3•
39 Differential-Manual Transmission
-

Fig. 5 Differential bearing/inner race (housing

side), removing
-drill hole in VW 457/1 as shown above
(arrow)
• a = 8 mm (5116 ill.)
• b = 9.5 mm (3/8 In'.~

40 -21
VW457'1 -

Dllferential bearingliilner race (housing

side), installing
-heat to approx. 1oo•c (212•F) and
press on

3~ • 'OQ

Fig. 6 Differential bBaring/ inner race (housing

side), re mo~ l ng

CAUTION
Clean contact surfaces are essential to
ensure that ring gear, differential housing,
and cover fit properly. Remove all burrs and
pressure marks with oil stone

- heat ring gear to approx. 100 •c (212'Fl

and install
Fig. 7 Differential bearing/Inner race (ring gear • A = centering pins (local manufacturt
side), installing
Note
-heat to approx. 100"C (212"F) and
press on If ring gear/pinion are replaced,
readjustment is necessary

39 4 •
Ring gea~
Differential bearings
14-speed 091-091 /1 1 5-speed 094
-~-------- -L-_ _ _....:..__ _ _ _ _
L. __J
 Differential-Manual Transmission 39

Fig. 10 Differential bearing/outer race, removing

~using

and

Fig. 11 Differential bearing/ outer race, installing

- press race in until seated

to
JSing,
rrs and

·c (212°F)
mufacture)

1-4
J4-speed 091·091/11 5-speed 094 Differential bearings 39.5
39 Diff'erential-. Manual Transmission

Differential pinion/side gears,

adjusting end play . VW387
Note
Spacer sleeve ensures adequate backlash
between side gears and differential pinion gears
even when there is axial pressure on side gears.
If differential housing , cover, side gear or spacer A
sleeve is replaced , size of spacer sleeve must be
determined again

- install dial Ind icator with 3 mm range

• A = M10 X 25 bolt
• VW 381/13 = 52 mm
- zero dial indicator with 2 mm preload
- find end play by moving slde gear up and
down
- add measured play and length of measuring
134- 2971 sleeve together. Find this figure In table under
- measure shortest spacer sleeve, Part No. x range and select proper sleeve
002 517 241 , with micrometer and mark
dimension on sleeve with electric marker or x range Sleeve length Part No.
similar device. Sleeve should then always be
31 .87-31.95 31 .84 002 517 24!
used as measuring sleeve
31 .96-32.04 31.93 002 517 242
32.05-32.13 32.02 002 517 243
32.14-32.22 32.11 002 517 244
32.23-32.33 32.20 002 517 245

-disassemble differential and remove measurin~

sleeve
- install sleeve selected from above table and
assemble differential without differential
pinion shaft
-recheck play. Play should be
• 0.03-0.17 mm

- place side gear (with short shaft) and both

thrust washers in cover
-attach clamping sleeve VW 381/5a and clamp
gear tightly against cover
-place side gear (with long shaft) in differential
housing
- insert measuring sleeve, and bolt housing and
cover together with 4 M8 x 20 bolts

39.6 .,, . . . .d
D1 erent1a 1 pm1on 1s1 e gears
14-speed 091-09 1/111 5-speed 094
. ~--------..1..1 - - - - - ' - - - - - - - - - '
L-
 Differential- Manual Transmission 39
Ring gear/pinion, adjusting

Ring gear/ pinion must always be replaced as

-- matched set, never individually

Ring gear/pinion markings

~
bfTf
I
Jring

J ~-j
e under 1 2 3
2 3

t No.
o17 241
Ro
R 34·367
-
;,(
----Po
Service gears
i17 242 Fig. 2 Production gears
i17 243 1 = Marking K 738 means
i17 244 Klingelnberg gear set with ratio of X = Markings x'ed-out are not shown on
i17 245 7:38 teeth production gears
2 =Matching number of gear set 312 Po= Setting dimension for production
~suring gears
3 = Deviation r based on master gauge
e and used in special test machine in
ial production. Deviation r is always CAUTION
given in 1/100 mm. 25 shown in
example means that r = 0.25 mm In production, position of pinion is
determined by dimension Po (ring gear
Ro = Length of master gauge in centerline to back of pinion head)
production: Ro = 63 mm
Marking of deviation ron ring gear and
R =Actual dimension between ring gear matching number have been discontinued.
centerline and end face of pinion at It is therefore necessary to measure
quietest running point for this position of pinion before removing it when
gear set parts which affect position of pinion are to
Vo= Hypoid offset= 10 mm be replaced. See page 39.9-

1-6 14-speed 091-091/1 ll._____s-_s_pe_e_d_0_9_4___. Ring gear/pinion 39.7

39 Differential-Manual Transmission
Ring gear/pinion, adjusting
CAUTION
Maximum possible care and cleanliness
during all assembly and measuring
operations are essential for satisfactory
results
Note
Ring gear/pinion must be adjusted if gears
themselves have been replaced. If other parts
which affect position of pinion are to be
replaced, pinion depth R must be measured
before disassembling, and pinion set to this
dimension when assembling. See page 39.9

Fig. 3 Ring gear/pinion adjustment points

• s,:;:: Screw-in depth of adjusting
ring
(ring gear side)
• S2 =Screw-in depth of adjusting ring
(housing side)
• Sa= Shim for pinion

Ring gear/ pinion adjustment procedure

Work sequence
- find screw-in depth s, and S2
• tapered roller bearing preload is determined
by ring gear turning torque
- adjust pinion and check S3
• adjust pinion with shims so that correct
dimension R is attained
- adjust backlash

39.8 Ring gear/pinion j4-speed 091-091/11 5-speed 094

I
1-8
 Differential-Manual Transmission 39
Ring gear/pinion, adjusting
s Note
It is only necessary to adjust pinion, ring gear, or both, or shift forks if parts which directly influence
setting have been replaced. See table to avoid unnecessasry adjustments

~
Pinion S3 Pinion S3
Shift forks from actual I from Riflg gear
see dimension R deviation r s, and S2
Repair see see see
Part Group 35 page 39.9 page 39.10 page 39.12
Transmission case X X X
Adjusting ring for final drive X
Differential housing X
Cover for differential housing X
Differential tapered roller bearings X
Double tapered roller bearing for pinion X X
Ring gear/pinion X X X
Ball· b~aring for drive shaft X .
Finding position of pinion -measure difference from Ro. This measurement
(actual dimension) corresponds to deviation r. Note reading
Example: r = 0.25 mm
Finding position of pinion is only necessary -after installing new parts, adjust pin ion. See
when deviation r is not marked on ring gear, and pages 39.10-39.11. Deviation r is used to
parts are to be replaced which directly influence determine thickness of shim S3
position of pinion. These are: both pinion
bearings and transmission housing.

Work sequence
-remove differential housing
-assemble measuring bar as described on page
39.10 and place it in transmission housing

..
VW 385/11 or VW 385/30
VW385/1

=
-set gauge VW 385/30 to Ro 63.00 mm, place
on bar and zero dial indicator (3 mm range)
with 1 mm preload

1-8
5-speed 094
14-speed 091 -091/11
Ring gear/pinion, adjusting 39.9
39 Differential"' Manual Transmission
Pinion, adjusting VW385l'l6 r VW385/ 14

Note
Ring gear/pinion need adjusting if gears
themselves have been replaced. If other parts
which affect position of pinion are to be VW385/4
replaced, setting must be measured before
disassembiing and pinion set to this dimension
when assembling. See page 39.9

Work sequence
- install tapered roller bearing and needle
bearing inner race for 1st gear on pinion shaft
-torque needle bearing inner race to
210 Nm (152 ft lb)

-place measuring disc VW 385/17 on end of

- install pre-assembled pinion in transmission
housing without shim 53
- install retaining ring and tighten with
VW 381/14 to 225 Nm (162ft lb)
-back off and retighten to 225 Nm (162 ft lb)
pinion
- place measuring bar in housing and screw
2nd adjusting ring in until flush with housing
-move 2nd centering ring VW 385/4 outward
with movable setting ring on measuring bar
until bar can just be turned by hand
VW 385/11 or
vw 385/30

Finding dimension e
- screw in one adjusting ring until flush with
transmission housing

-a -

- adjust setting ring on measuring bar VW 385/1

- set universal gauge VW 385/30 to Ro=
to dimension a
63.00 mm and place it on measuring bar
• a = approx. 57 mm -zero dial gauge (3 mm range) with 1 mm
preload

Note
Gauge VW 385/11 can be used instead of
universal gauge VW 385/ 30

3 9 •10 Pinion, adjusting

4-speed 091-091/1 II 5-speed 094
 Differential-Manual Transmission 39
53 shims available

Part No. Thickness (mm)

001 311 391 0.15
001 311 392 0.20
001 311 393 0.30
001 311 394 0.40
I 001 311 395 0.50
= 12.3 mm 001 311 396 0.60

Note
Shim tolerances make it possible to select any
required thickness for s,
Measure shims at several points with micrometer
-turn bar until measuring pin touches measuring and check for burrs and damage
disc on end of pinion, and needle shows
Use only shims which are in good condition
maximum deflection. This is dimension e
Example: e = 0.40 mm
Adjustment (dimension r), checking
Shim 53, determining thickness - install pinion with measured shims 53 and
turn several times in both directions
- place measuring bar in position and check
measurements
• if shims have been selected correctly, dial
e = measured figure (max. deflection) gauge (reading counterclockwise), should
d of r = deviation (marked on ring gear in 1/100 mm show deviation r within tolerance of 0.04 mm
or found by actual measurement)
rew
)USing
Nard
J bar Dial gauge reading fore 0.40 mm
Deviation r +0.25 mm
Ss shim thickness =0.65 mm

)/1

VW385/14
'385/17
l.QiU

ar
m

14-speed 091-091/1 II 5-speed 094 Pinion, adjusting

Shim 5 3
3 g .11
39 Differential-Manual Transmission

Ring gear, adjusting
(pinion removed)
Note
Ring gear must be adjusted if transmission
housing, differential bearings, differential
housing/cover, adjusting rings or ring gear/
pinion have been replaced. Also see table on
page 39.9
-turn in adjusting ring on ring gear side with
VW 381/15 until upper edge is approximately
0.20 mm below surface of housing
-turn in adjusting ring. on other side with
VW 381/15 unti I differential is free of play
and without preload
- attach VW 381/5a to ring gear side and lock
with hex nut
- turn transmission housing so differential is
top and attach bridge VW 381/8 on dowel

Work sequence

CAUTION
Differential bearing outer races must be
fully seated in adjusting rings

-install differential with ring gear on driver's

side
- install dial indicator (3 mm range) with
extension VW 382/9 into bar VW 382/7
-.zero dial indicator with 1 mm preload

vw 382/7

vw 381115
I •

rr
39.12 Ring gear, adjusting
14-speed 091·091/tj 5-speed 094
 Differential-Manual Transmission 39,
vith Backlash, adjusting
rately
Work sequence
- install pin fon Witt1 shims,
ay
- install d il feren ~ial wi ttl adl usting rings on
correct sides
lock
- attach bridge VW 381/8
- turn in a€lEus,ting rings while turni ng
il is at
differential until measured screw-in depths
·el pins
s, and Sa have been reached

-attach torque gauge US 1064

-turn differential in both directions while oiling
bearings with transmission oil
-increase bearing preload slowly by turning in
adjusting ring on side opposite ring gear with
VW 381/15 while turning differential with
US 1064 until specified turning torque is
reached

Turning torque

New bearings Used bearings•

300-350 Ncm 30-70 Ncm
-attach measuring tools as shown
(27-31 in. lb.) (2.7-6.2 in. lb.)
'after running at least 30 miles
vw 381 ;a 4-speed 091
VW381/11

VW 381/ Sa
- lock pinion with bar VW 381/11

-measure screw-in depth of adjusting rings and

note readings s, and Sa
-mark adjusting rings and do not interchange

Note
If ring gear is being readjusted, check pinion
adjustment, see page 39.10

1-12
[4-speed 091-091/11 5-speed 094 Ring gear, adjusting
Backlash, adjusting
39.-4I 3 1
39 Differential- Manual Transmission

CAUTION
If backlash readings vary by more than 0.06
mm from one another, there is something
wrong with installation of ring gear or gear
set itself. Check all assembling operations
and replace gear set if necessary

-to adjust backlash, proceed as follows

- turn adjusting ring on si~e opposite ring gear
out
- turn adjusting ring on ring gear side In by
same amount
- continue adjusting until backlash is
0.15-0.25 mm (0.006-0.010 in.)

- lock pinion with clamp Note

• A = bolt M8 x 125
Keep within tolerance of ± 0.01 mm

5-speed094
Backlash, checking
- check backlash each 1/4 turn
• backlash should be
0.15-0.25 mm (0.006-0.010 in.)

Note
Individual readings must not differ by more than
0.05 mm

lock pinion with clamp

~
• A = bolt M8 x 125
- turn ring gear to stop and set dial indicator
to zero
- turn ring gear in opposite direction and read
backlash
-check backlash each 1/4 turn
• backlash should be
0.15-0.25 mm (0.006-0.010 in.)

Note
Individual readings must not differ from one
another by more than 0.05 mm

3 9 •14 Backlash, adjusting

14-speed 091-091/1 II 5-speed 094
39 Differential - Manual Transmission
Note
CAUTION
Clamp differential gear into a vise before
disassembling (Fig. 1). Bearing inner and outer races are matched
and must not be interchanged. Replace both
Adjusting ring bearings at the same time. Ring gear and
pinion must be adjusted after replacing
Differential bearing/outer race differential housing, cover and bearings. Side
removing Fig. 13 gear end play must be adjusted if differential
installing Fig. 14 housing, cover or side gears have been
replaced.
Differential bearing/Inner race
(ring gear side)
removing Fig. 4
installing Fig. 10
, - - - - - - Thrust washer
50 Nm (36 ft lb) check for wear
tighten diagonally

Differential cover ---------'(1=?~~"'--·--'.D

removing Fig. 3
When installing, oil holes must be
offset approximately 90° to ~ _~Thrust washers
differential pinion shaft ..., ~ check for wear
~Differential pinions
Thrust washer @
check for wear

Differential side gears---'

~
fJ®~ =tionpooltOnFO.I
long shaft in housing,
C.> Differential side gears
short shaft in cover. long shaft in housing,
When replacing, adjust end play
short shaft In cover.
When replacing, adjust end play
Spacer - - - - - "
determining size, page 39.25
- - - - - - Thrust washere
Differential pinions check for wear

Thrust washers
check for wear

--------Pin
drive in flush

Differential pinion shaft

removing Fig. 6
when installing, do not
Differential housing damage thrust washer

Ring gear
Pin (matched to pinion) Differential gear set with four
drive in flush removing Fig. 2 small differential pinions
installing Fig. 12
Differential bearlng/oute1 race
removing Fig. 13 Differential bearing/Inner race
installing Fig. 14 (housing side)
removing Fig. 5
ll'ansmlaslon housing installing Fig. 14

Differential gear set with two

small differential pinions

39.15 Ring gear

Differential
094-4WD
 Differential - Manual Transmission 39
hed
1both
nd

. Side
·entia!

pinions

Fig. 1 Differential housing, disassembling Fig. 3 Differential cover, removing

lr&

- use jaw covers on vise

1st end play

lr&
.r
alng

~aft (short)

m shaft

lonot
asher

Fig. 2 Ring gear, removing

- use drift to separate ring gear from

housing

CAUTION Fig. 4 Differential bearing/Inner race (ring gear

side), removing
Do not damage threads in ring gear.

139-11331

094·4WD
Ring gear
Differential housing
Differential bearing
39 .1 6
39 Differential - Manual Transmission

VW412

VW439 _ _____,

A
VW402
0

Fig. 5 Differential bearing/Inner race (housing Fig. 7 Differential pinion shafts (short),
side), removing removing

- insert greased ball A (17 mm diameter)

into bore hole of spacer up to stop and
secure
- press on shaft

Fig. 6 Differential pinion shaft (long), removing

- drive out axle until it projects 70 mm on

one side
134·18031
Fig. 8 Differential pinion shafts, Installing

- align short shafts with slots parallel to

flange
- drive in all shafts until thrust washers and
differential pinions can be positioned
- install spacer with large bore hole a facing
long axle
- drive in long axle until it matches pin hole

39.17 Differential bearings and

pinion shafts
094-4WD
 Differential - Manual Transmission 39

VW411
VW402

134-18041
Fig. 9 Shafts, Installing

Fig. 11 Differential bearing/Inner race (housing

aide), Installing

-heat to approximately 100°C (212"F) and

press on

Fig. 10 Differential bearing/Inner race (ring gear

side), Installing

-heat to approximately 100°C (212°F) and

press on

CAUTION
Clean contact surfaces are essential to ensure
that ring gear, differential housing and cover fit
properly. Remove all burrs and pressure marks
with oil stone.
Fig. 12 Ring gear, Installing

- heat ring gear to approximately 100°C

(212"F) and install
A centering pins (fabricate)
and
Note
acing If ring gear/pinion are replaced, readjustment is
necessary.
hole

I
094-4WD . DifferentialRing
bearings
gear
39 .1 8
39 Differential - Manual Transmission

Fig. 13 Differential bearing/outer race, removing

Fig. 14 Differential bearing/outer race, Installing

- press race in until seated

39.19 Differential bearing/outer race

094-4WD
 Differential - Nlanual Transmission 39
Note
CAUTION
Clamp differential gear into a vise before
disassembling (Fig. 1). Bearing inner and outer races are matched
and must not be interchanged. Replace both
AdJusting ring
bearings at the same time. Ring gear and
pinion must be adjusted after replacing
differential housing, cover or bearings. Side
gear end play must be adjusted if differential
housing, cover or side gears have been
Dltrerentlal bearing/outer race replaced.
removing Fig. 13
installing Fig. 14
Differential cover
removing Fig. 3
when Installing, oil holes must be
offset approximately 90•
to differential pinion shaft

- - - Thrust waahera
check for wear

Differential aide gears

long shaft in housing, short shaft in cover.
When replacing, adjust end play

Spacer
installation position Fig. a

.....__ _ _ ___. Differential pinion shaft (long)

Pin----' r-::-:=--...;..~-""!"'"------. removing Fig. 6

drive In flush Differential gear aet with four when installing, do not damage
Sll1811 differential pinions thrust washers
Differential lock sleeve
' - - - - Ring gear
(matched to pinion)
Dlllel'lntlal bearing/Inner race
removing Fig. 2
aide)
installing Fig. 12
Fig. 5
Fig. 14
Differential bearing/outer race
removing Fig. 13
installing Fig. 14

ltanamlaalon housing
Differential gear aet with two
small differential pinions

094-4WD Ring gear

Differential with lock
39 20 • ·
39 Differential - Manual Transmission

Fig. 1 Differential housing, disassembling Fig. 3 Differential cover, removing

- use jaw covers on vise

Fig. 2 Ring gear, removing

- use drift to separate ring gear from

housing

CAUTION
Fig. 4 Differential bearing/Inner race (ring gear
Do not damage threads in ring gear. side), removing

Ring gear

39.21 Differential housing

Differential bearing
094-4WD
 Differential - Manual Transmission 39

l34-11so I 134-10981
Fig. 5 Differential bearing/Inner race (housing Fig. 7 Differential pinion shafts (short),
aide), removing removing

-insert greased b~ll a (17 mm diameter)

Into bore hose of spacer up to stop and
secure
..,... press on axle

VW412

VW439----1i
134-10961
A
Fig. 6 Differential pinion shaft (long), removing

VW402 0
- drive out shaft until it projects 70 mm on
one side

134-10971
Fig. 8 Differential pinion shafts, Installing

- align short shafts with slots parallel to

flange
- drive in all shafts until thrust washers and
differential pinions can be positioned
- install spacer with large bore hole A
facing long shaft
"'rive in long shaft until it matches pin hole

E-9
094-4WD Dffferentlal bearings and
pinion shafts
39 •22
39 Differential - ·Manual Transmission

VW412
-+---40-103
VW411

Fig. 9 Shafts, Installing Fig. 11 Differential bearing/Inner race (housing

side), Installing

-heat to approximately 1000C (212"F) and

press on

Fig. 10 Differential bearing/Inner race (ring gear

side), Installing

-heat to approximately 100°C (212"F) and

press on Flg.12 Ring gear, Installing

CAUTION
Clean contact surfaces are essential to ensure
that ring gear, differential housing and cover fit
properly. Remove all burrs and pressure marks
with oil stone.

- heat ring gear to approximately 1000C

(212"F) and install
A = centering pins (fabricate)

Note
If ring gear/pinion are replaced, readjustment is
necessary.

39.23 Differential bearings

Ring gear
 Differential - Manual Transmission 39

nd

Fig. 13 Differential bearing/outer race, removing

1re Fig. 14 Differential bearing/outer rece, Installing

fit
.rl<s - press race in until seated

094-4WD Differential bearing/outer race 3 9 •2 4

39 Differential - Manual Transmission

Differential pinion/side gears,

adjusting end play ---VW387
Note
The spacer sleeve ensures adequate backlash
between side gears and differential pinion gears
even when there is axial pressure on the side gears.
If differential housing, cover or spacer sleeve is
replaced, the size of the spacer sleeve must be A
redetermined.

- install dial indicator with 3 mm range

A = M10 X 25 bolt
30-45 = 76 mm long
VW 381/13 = 52 mm long
- zero dial indicator with 2 mm preload
- find end play by moving side gear up and down
- add measured play and length of measuring
sleeve together
- find this figure in the table below under x range
and select proper sleeve

-measure shortest spacer sleeve, Part No. 002 517

241, with a micrometer x range Sleeve length mm Part No.
- mark dimension on sleeve with electric marker or 31.87-31.95 31.84 002 517 241
similar device 31.96-32.04 31.93 002 517 242
-this sleeve should always be used as a 32.05-32.13 32.02 002 517 243
measuring device 32.14-32.22 32.11 002 517 244
32.23-32.33 32.20 002 517 245

- disassemble differential and remove measuring

sleeve
...._ install sleeve selected from table and assemble
differential wHhout differential pinion shaft
-recheck play, play should be 0.03-0.17 mm

- place side gear (with short shaft) and both thrust

washers in cover
-attach clamping sleeve VW 381/5a and clamp
gear tightly against cover
- place side gear (with long shaft) in differential
housing
- insert measuring sleeve, bolt housing and cover
together with four M8 x 20 bolts

39.25 Differential pinion/side gears

094-4WD
 Differential - Manual Transmission 39
, Ring gear/pinion, adjusting
Pinion removed
Screw-In depth, determining

CAUTION
Note
Differential bearing outer races must be fully
Ring gear/pinion must always be replaced as a seated in adjusting rings
matched set, never Individually.
Adjustment of ring gear Is required if any of the
following are replaced:
Adjusting rings
Transmission housing
Differential cover
Differential bearings
Differential housing
Ring gear/pinion

wn - install differential with ring gear into housing (ring

gear lies on left side)
-install dial indicator (3 mm range) with extension
VW 38219 (18 mm long) Into bar VW 38217
- zero gauge with 3 mm preload
- tum In adjusting ring on ring gear side with VW
381/14 until upper edge is approximately 0.20 mm
•o. below surface of housing
'241 - turn in. adjusting ring on other side with VW
, 242 381/15 until differential is free of play and without
, 243 · preload
'244 -attach VW 381/58 to ring gear slde and lock with
'245 hex nut
- turn transmission housing until differential is at top
ing and attach bridge VW 381/8 on dowel pins

1ble

13 094.4WD 1·
...__ _ _ ___._
Ring gear/pinion, adjusting
Screw-In depth
39 26
. ·•
39 Differential - Manual Transmission

Note
If ring gear is being readjusted, check pinion
adjustment, see page 39.25

Backlash, adjusting
- install pinion with shim 83
- install differential with adjusting rings on correct
sides
- attach bridge VW 381/8
- turn in adjusting rings while turning differential
until measured screw-in depth S1 and S2 have
been reached

A = Commercial torque wrench, 0-600 Ncm

(Q-54 in. lb)

-insert torque wrench with socket wrench (19 mm)

- tum differential in both directions while oiling
bearings with transmission oil
- increase bearing preload slowly by .turning in
adjusting ring on side opposite ring gear with VW
381/15 while turning differential until specified
turning torque is reached

Turning torque

New bearings Used bearings*

30Q-350 Ncm 30-70 Ncm
(27-31 in. lb) (2.7-6.2 in. lb)
*after running at least 30 miles

- measure screw-in depth of adjusting rings and

note readings S1 and S2
- mark adjusting rings and do not interchange
(arrow)

39.27 Screw-In depth

Backlash 094-4WD I
 Differential - Manual Transmission 39
Locking pinion, front final drive

----2~5

t:::3mm

~--- 70 - - - - - -
- attach measuring tools as shown
,_,34-_1_805_,,
-press in bridge VW 381/7 on two plate screws up
to stop
- attach special tool 386/A to final drive housing
(manufacture a retaining plate from 3 mm thick
Locking pinion, standard sheet metal plate)
transmission

- lock pinion with clamp

- lock pinion with clamp
A = M8 x 125 bolt A = M8 x 60 bolt with M8 nut
B = Self manufactured retaining plate
C M8 X 20 bolts
- tum ring gear to stop and set dial indicator to zero
- tum ring gear in opposite direction and read
backlash
- note values
- remove bridge
-check backlash 3 more times, 1/4 turn apart each
time

094-4WD
Locking pinion 39 •2 8
39 Differential - Manual Transmission

CAUTION
If backlash readings vary by more than 0.06
mm from one to another, there is something
wrong with installation of ring gear or the gear
set itseH. Check all assembling operations and
replace gear set if necessary.

- to adjust backlash, proceed as follows

- turn out adjusting ring on side opposite ring gear
- turn In adjusting ring on ring gear side by the
same amount
- readjust adjusting ring on oppo.site side of ring
gear one more time after screwing in adjusting
ring behing the ring gear
• keep within tolerance of ± O.o1 mm

Note
81 + 82 must always equal 8 total to insure that
ring gear preload is not changed.
- continue adjusting until backlash is 0.15-0.25 mm
(0.006·0.010 ln.)

Note
To obtain the required backlash quickly, the
determined backlash minus 0.20 mm (0.008 in.) can
be used for the first adjustment of the adjusting
rings.

Backlash, checking
-check backlash each 1/4 turn
• backlash should be 0.15-0.25 mm
(0.006-0.01 0 in.)

Note
Individual readings must not differ by more than
0.05 mm.

39.29 Locking pinion

Backlash
094-4WD
 Differential - Manual Transmission 39

Front final drive housing with viscous coupling

Needle bearing

Retaining ring VIscous coupling

7
094-4WD
Front final drive 39•30
39 Differential - Manual Transmission

Note
Before disassembling, mount to repair stand (Fig. 1)
and drain transmission oil.

Right adjusting ring - - - - - - - - - . . ,

identify before removing Fig. 3 cap------.
removing Fig. 4 always replace
before removing: installing Fig. 6
loosen left adjusting ring for final drive. disassembling/assembling, pages 39.32 and 39.33
Identify position of adjusting ring Fig. 3 coat thread with MoS 2

Differential
disassembling/assembling, pages 39.29-39.32

~ 20 Nm (15 ft lb)
with washer
Lock ring

Final drive housing - - - - - - '

disassembling/assembling, page 39.34

Lock ring

always replace
t 2lJ Nm ~5 ft lb)
Drive housing
repairing, page 39.34
Left adjusting ring
Axle flange identify before removing Fig. 3
removing Fig. 2 removing Fig. 4
installing Fig. 6
installing Fig. 7 disassemblin~;~/assembling, pages 39.32 and 39.33
coat thread w1th MoS2

39.31 Front final drive

094-4WD
 Differential - Manual Transmission 39

Fig. 3 Adjusting ring position, d•termlnlng

Fig. 1 Final drive, mounting
- clamp final drive in repair stand
Note
For differential assemblies which do not need
readjustment, the adjusting rings position in relation
to the transmission housing must be identified with a
marked tool (arrow)
- measure screw-in depth with VW 382/7
- note values
-mark left side (ring gear side) with 1 scratch
- mark right side with 2 scratches

VW391

139·11021

14
Fig. 2 Axle flange, removing Fig. 4 Adjusting rings, removing

A = 2 MB x 30 hex bolts through slots in

joint flange

E-19 094·4WD I Final drive

Axle flange
39 32 •
L - - - - - - - ' Adjusting rings
39 Differential - Manual Transmission

Fig. 5 Differential, removing Fig. 7 Axle flange, tightening

Fig. 6 AdJusting rings, Installing

- screw adjustment rings into transmission

housing to scratch mark and rneasure
depth

CAUTION
Tighten left adjusting ring first if housing cover
is installed and bolted into place.
Fig. 8 Clrcllp, Installing
- position spring washer and clrclip
- press circlip into groove
- watch for central fit of spring washer

39.33 AdJusting rings

Axle flange
094-4WD
 Differential - Manual Transmission 39
Retaining ring
removing/installing, page 39.35

always replace

Pinion shaft guide

~~. ShlmS3
--------· ---._ ---._adj"'tme"t oompoo;te, page 39.35
-.............. ~te thickness
I
VIscous coupling
lubricatebearing
Needle with transmission oil ·------·------·
I before assembling Spacer ring

l ~
Output housing

Drlveshaft flange
Flange shaft

20NmP5ftlbJJ
with washer

&ni--------------_J
can also be replaced on an installed
transmission

F-2
094-4WD
Final drive housing 3 9 •34
39 Differential - Manual Transmission

Front final drive, disassembling/

assembling
Final drive housing, disassembling/
assembling
Disassembling
- remove output housing bolts
- remove housing
- remove spacer ring and viscous coupling
- drive out pin for speedometer drive
- pull out speedometer drive

- push out pinion

- fasten VW 457 with two M8 x 20 bolts
- remove shim S3 and note thickness

3145

- remove retaining ring

VW457/2
- mount support to flange and remove hex nut

139-11071

-drill an additional 9.0 mm (0.35 ln.) diameter hole

in bracket VW 457/2

39.35 Front final drive

Final drive housing
094-4WD
 Differential - Manual Transmission 39

A
VW434

- remove flange, use two-armed extractor if

necessary
- remove flange shaft

139-11231

- remove both ball bearings

A- Puller, e.g. 22-2
B-Inner extractor, 30-37 mm, e.g. Kukko 21/5

B Assembling
139-11221
- remove needle bearing from flange shaft
A- Puller, e.g. Kukko 22-1
B-Inner extractor 12- 14.5 mm, e.g. Kukko
21/1
- pry seal out from ciover ·
- remove seals for outer and inner ball bearing .
Before assembling:
- position shim S3
- place 12 point of dual bearing on opening in
housing
- heat pinion housing at dual bearing seat to
40-SO"C (130-166°F)
- drive pinion in using a plastic hammer
- position washer and install retaining ring

-tighten retaining ring to 225 Nm (166ft lb)

- loosen retaining ring and retighten to 225 Nm
(166 ft lb)

094-4WD Front final drive 39.36

39 Differential - Manual Transmission

- drive seal in to stop

- secure retaining ring by staking in two places
A - fabricated staking tool
- Install speedometer drive

VW447i

VW415a

- press in flange shaft needle bearings

- install flange shaft into output housing
139-11091

- push both ball bearings up to stop in back cover

- install circlips

39.37 Front final drtve

094-4WD
 Differential - Manual Transmission 39

- push on driveshaft flange

- Insert washer
- mount puller and tighten hex nut to 160 Nm
(118ft lb)
- position viscous coupling on pinion

- coat spacer ring with grease and align on viscous

coupling
- position output housing and tighten

094-4WD
Front final drive 39 •38
39 Differential - Manual Transmission

Retaining ring
tightening/loosening, pages 39.36 and 39.37

Dual taper roller bearing - - - - - ,

removing Fig. 2
installing Fig. 3
determine position of pinion
prior to removing, page 39.25
check turning torque Figs. 4 and 5

ShlmS3

Shim

Final drive houalng

Pinion
pinion and ring gear are matched set
Speedometar drive geer - - - '
adjusting, pages 39.26 and 39.29
position with turned In
groove facing outwards

Grooved nut 210 Nm (155 ft lb)

removing Fig. 1
chamfer faces locking plate

39.39 Front pinion

 Differential - Manual Transmission 39
3132 3136

Flg.1 Grooved nut, removing/Installing

(at final drive with viscous coupling)

- Install and tighten grooved nut to 210 Nm
(155 ft lb)
- check turning torque of bearing

Fig. 3 Bearing, Installing

- heat Inner rings to approximately 100°C

(21~F)
- position and press jn

VW401

139-11321
Fig. 2 Bearing, removing

F-8 094-4WD Grooved nut

Bearing 39.40
39 Differential - Manual Transmission

Fig. 4 Bearing turning torque, checking

A- Commercial gauge, 0-600 Ncm

(0-54 in. lb)
- lubricate bearing with hypoid transmission
oil
- tighten retaining ring as specified
-rotate pinion in both directions 15-20 times
without interruption
- rotate again and read turning torque

Tumlng torques

New bearings Used bearings"

to 210 Ncm to 70 Ncm
(19 in. lb) (6.2 in. lb)
*after running at least 30 miles

Fig. 5 End play, checking

- If turning torque equals zero, check pinion

shaft bearing for end play
- if any end play is felt, replace bearing

39.41 Bearing tumlng torque

End play
094-4WD
 Differential-Manual Transmission 39
Technical data
• code letters
• application
• gear ratios

Front final drive

code letters ACU
date of manufacture
from 10/85
to
Application vehicle Vanagon Syncro
engine 2.1 Liter 70 kw (95 bhp SAE net)
manual transmission AAK I AAN
Ratio 34: 7- 4.86
Capacity 1.6 US qt (1.5 Liters)
Lubricant specification Gear oil GL-4 SAE 80
Axle shaft flange 100mm

0 ISyncro I Front final drive

technical data
39.42
39 Differential - Manual Transmission
Drlveshaft, removing/installing
Work sequence

Removing

- remove bolts (arrow) at front and rear driveshaft

flanges and remove driveshaft

Installing

- install driveshaft and tighten bolts to 35 Nm

- loosen mounting bolt of front final drive (arrow) (26 ft lb)
Do NOT remove bolt.

- loosen side bolts of front final drive mounting Note

bracket (arrow) Do NOT remove bolts.
On vehicles with fuel injection and rubber damper
CAUTION on driveshaft (arrow), damper faces transmission.

Front final drive mounts MUST be loosened - align front final drive in longitudinal direction and
to prevent damage to the driveshaft universal tighten mounting bolts
joints when removing driveshafts.

CAUTION CAUTION

The installed position of the driveshaft must be Front final drive alignment must be done to
noted for reinstallation. Vibrations due to ensure driveshaft is installed without distortion.
incorrect installation can cause cracks in the
transmission housing or engine block.

Note
The universal joints cannot be replaced using
standard workshop tools and are not available as
replacement parts.

39.43 Drlveshaft, removing/installing

Syncro
 Differential-Manual Transmission 39
Driveshaft flange· oil seal, replacing
(on front final drive or transmission)

Work sequence

-remove driveshaft (see page 39.43)

iveshaft

Nm 134-16661

- mount handle on flange and remove flange

shaft nut ·

- drive in flange
-mount handle 3145 and tighten flange shaft
nut to 160 Nm.(1f8 ft lb)
- install driveshaft and tighten bolts to 35 Nm
(26ft lb)

- remove driveshaft flange. Use two-arm puller

damper if necessary ·
1ission. -remove oil seal with VW 681 or similar tool

ction and

~
~

f-12 ISyncro·l Drlveshaft flange oil seal 39.44

39 Differential - Manual Transmission
Front final drive axle flange on
seals, replacing
If both left and right oil seals are to be replaced,
remove front final drive (see page 39.47).
If the oil seal is to be replaced on one side only,
remove suspension. as .described below.

Work sequence

- remove bolts connecting axle shaft to flange

- remove spacer ring

- remove brake line bracket from wheel bearing

housing (arrow)

- remove ball joint from upper control arm by

removing bolts (arrows)

- remove bolts (arrows) and separate radius rod,

wheel bearing housing and lower control arm

more

39.45 Front final drive

axle shaft seals
Syncro
 Differential-Manual Transmission
- remove wheel bearing housing complete with
axle shaft
- pierce cap In drive flange with screwdriver and
pry out
- remove circlip and wave washer
- remove drive flange with VW 391
- remove lock ring
39
- install wheel bearing housing with axle shaft
- install bolts for radius rod, wheel bearing
housing and lower control arm
CAUTION
Do not damage axle shaft boot.
- install tie rod, brake caliper and upper ball
joint
-install brake hose bracket
- bolt axle shaft flange with spacer washer
to drive flange

Tightening torques
radius rod/wheel bearing housing on control arm
100 Nm (73 ft lb)
brake caliper to housing 240 Nm (177ft lb)
wheel bolts 180 Nm (132ft lb)
axle shaft to drive flange 35 Nm (26 ft.lb)
ball joint to upper control arm 60 Nm (44 ft lb)

- pry out oil seal

134-1681 I
- drive in new oil seal to stop
- install lock ring
- install drive flange with VW 391
- install wave washer
- press circlip into groove with VW 454 and at
same time check that washer is centered
- replace cap

.dius rod,
:rol arm

14 ISyncro I Front final drive

axle shaft seals
39 •4·5
39 Differential - Manual Transmission
Front final drive, removing/installing
Work sequence

Removing

- loosen mounting bolt of front final drive (arrow).

Do NOT remove bolt.

- loosen side bolts of front final drive mounting

bracket (arrow). Do NOT remove bolts.

more

39.47 Front final drive, removing

Syncro
 Differential-Manual Transmission 39
-support final drive with transmission jack and
small adapter

rrow)

- remove bolts from front mounting (arrows) and

take bracket out by pulling forward

rive
tr cable
- lower final drive and remove from vehicle
(2 mechanics required)

Installing

Proceed in reverse order of removal and note the

following:

- tighten mounting bolts of front and rear brackets

last

Tightening torques

axle shaft to final drive 35 Nm (26 ft lb)

driveshaft to final drive 35 Nm (26 ft lb)

Front final drive,

removing/Installing
39 48
•
 39
Differential
Automatic Transmission

Index
-Adjusting ring 39.51
-Assembly 39.56
-Cover plate 39.51
-Differential bearing outer race
39.53
-Drive flange oil seal 39.53
-Final drive assembly 39.50
-Governor oil seal 39.52
-Pinion bearing outer race
39.52, 39.54
inner race 39.54, 39.55
-Pinion oil seals 39.52-39.54
-Ring gear 39.56
-Ring gear/Pinion adjusting
39.57- 39.60
backlash 39.61, 39.62
-Torque converter oil seal 39.51

39.49
 39 Differential-Automatic Transmission
Final drive ratio:
4.09:1
Final drive lubricant:
Hypoid oil SAE 90, Mil-l2105 B
Capacity:
1.25 ltr (1 .3 US qt)
Pinion oil seals
removing Fig. 13
installing Fig. 14
and Fig. 15
Shims, _ _ ___:._ _- . J
determining
thickness
page 39.59 inner race
removing Fig . 18
install/rig Fig. 20
Differential bearing outer race
remove with drift
installing Fig. 12
Drive flange oil seal
can be replaced with
final drive installed
see Repair Group 37
'nstalling Fig. 11
39.50 Final drive
CAUTION
If ring gear/pinion bearings can be reused it
is necessary to measure backlash (page
39.13) and turning torque on pinion (page
39.14) before disassembling final drive. Note
these measurements and adjust during
reassembly to obtain same settings
Pinion bearing outer race
removing Fig. 16
installing Fig. 17
Oil seal sleeve
removing Fig. 18 Governor
install ing Fig. 19 disassembling / assembling
see Repair Group 38
Governor oil seal - - -......
removing /i nstall ing Fig. 10
mounting in repair
fixture Fig. 1
ring gear/pinion
must be readjusted
If replaced,
see page 39.57
Torque convert81
oil seal
removing Fig. 2
in stalling Fig. 3
Pinion bearing
Pinion oil seal
removing Fig. 6
installing Fig. 9
Differential
disassembling
page 39.56
AdJusting ring
mark position before removing . 5 minutes
When replacing bearings,
readjust ring gear page 39.60
removing/installing Fig. 5
 D:ifferent'iai-Automat'ic Transmi·ssion 39
used it
ge
>age
3. Note
g

sembling
38

Fig. 3 Torque converter oil seal, installing

1f drive housing
111ting in repair
re Fig. 1
.gear/pinion
;t be readjusted
placed,
,page 39.57

Fig. 4 Cover plate/Oil hole seal, installing

- first insert seal (arrow) for oil hole
·que converter - install cover plate and tighten to
seal 25 Nm (18 It lb). Use sleeve 2058 when
noving Fig . 2 installing cover
.tailing Fig. 3
1ion bearing
l er race
moving Fig . 7
;tailing Fig . 8
1ion oil seal
11oving Fig . 6
;tailing Fig. 9
itlerentlal
sassembling Fig. 2 Torque converter oil seal, removing
~ge 39.56

J Nm (7ft lb)
ghten diagonally;
!torque twice more
Iter intervals of
minutes
Fig. 5 Adjusting ring, removing/installing
-when reusing ring , mark position
before removing

E·2
E·3
Torque converter oil seal
Cover plate
Adjusting plate
3 g 51
•
 39 Differential-Automatic Transmission

Fig. 6 Pinion oil seal, removing

us 1039

Fig. 7 Pinion bearing outer race, removing

F~

- remove seal with VW 248/1 together

with adapter 248/2
-drive in oil seal until seated using
VW 248/1 without adapter (seal lip
faces governor)

Pinion oil seal

39 .52 Pinion bearing outer race

Governor oil seal
E·
 Different,iai-Automatic Transmission 39

/ us 4450
VW401

or
KUKKO 21/7
39-262
ing Fig. 13 Pinion oil seals In cover plate, removing
Fig. 11 Drive flange oil seal, Installing
- press out seals Individually
- fill space between lips with multi-
purpose grease and press in flush

VW295

QI]ill
Fig. 12 Differential bearing outer race, Installing
Fig. 14 Pinion oil seal (inner) in cover, Installing
-press in until seated
tailing -drive seal into cover until seated.
Open side of seal faces final drive
ogether

using
eallip

Drive flange oil seal

E·S
E-4 Differential bearing outer race
Pinion oil seals 39.53
39 Differential-Automatic Transmission

VW408a - --11

VW510 \

VW401 1

QEECJ
Fig. 15 Pinion oil seal (outer) In cover, Installing
-drive seal into cover until flush.
Open side of seal faces transmission

VW408a

. VW402 l
us 1037
or
KKO 21/7

Fig. 16 Pinion bearing outer race In cover,

removing

Fig. 18 Pinion bearing Inner race/Oil seal sleeve,

removing
- press off bearing together with seal
sleeve (tool US 1103 can be used)

Pinion oil seal

39.54 Pinion bearing outer race

Pinion bearing Inner race
 Differential-Automatic Transmission 39

·r,

Fig. 19 Pinion bearing Inner race/Oil seal sleeve,

Installing
- heat bearing and sleeve to approx.
100"C (212"F)
- press onto pinion shaft

al sleeve,

lh seal
sed)

- heat inner race to approx. 100"C (212"F)

and press into shaft

E·7
E-6
Pinion bearing inner race 39.55
39 Differential-Automatic Transmission
Differential pinion shaft
remove and install with drift

........ ~~ ..."""""""
Differential bearing/
Inner race (rlng gear aide)
removing Fig. 1
installing Fig. 4
when replacing, readjust
ring gear, page 39.60 matched with pinion race (housing side)
removing Fig. 2 removing Fig. 1
Drive flange nut Differential housing installing Fig. 3 installiog Fig. 4
align lugs when when replacing, readjust adjusting, page 39.60 whe11 replacing, readjust
installing ring gear, page 39.60
( """-·"""' 39.6<1

40-105
or
VW 295a

139-078]

Fig. 1 Differential bearing/Inner race, removing

Fig. 2 Ring gear, removing

- mount d ifferenti al in vi se
- loosen bo lt s and tap li ghtly on bolt - heat bearing to approx. 100 " C (212 . F)
heads and press on

39.56 Differential
Ring gear
 DHferentiai-Automatic Trans~mission 39
Ring gear/ Pinion, adjusting
Note
Ring gear/ Pinion may only be replaced as
matched set

J•c (212"F)
~ anufacture)

Position of shims S3/S.

Ro= Length of master gauge used in factory
testing machine. Ro = 52.60 mm
r = Deviation measured against master gauge
of testing machine used in production.
Deviation r is always given in 0.01 mm. For
example 52 means r = 0.52 mm
2
Sl =Shim for bearing preload (behind pinion head)
s. =Shim for pinion position (opposite end)
3
Note
II pinion bearings will not be changed, measure
turning torque of pinion before disassembly and
adjust to same turning torque during assembly Marks on ring gear
1 = Identification G 1145 refers to Gl easo n gear
!, installing set with ratio of 11 :45
i'C (212"F) 2 = Serial number of matc hed gear set
3 = Deviation r

E·8 E·9

Ring gear/ Pinion, adjusting 39.57

39 Differential-Automatic Transmission
Pinion, adjusting
Work sequence
- install bearing outer race into cover plate and
housing
-heat pinion bearing inner races to approx.
100°C (212.F)
- press ir,ner bearing races, without shim, on
pinion shaft with approx. 3 tons pressure
- insert pinion In housing, Install cover plate
and tighten to 25 Nm (18 ft lb)
-Install dial gauge holder VW 387 on housing
- place measuring plate VW 385/17 on pinion
shaft
- install dial gauge and set to zero with 1 mm
preload
- move pinion up and down without turning and
note measurement
CAUTION
Measurement will be inaccurate if pinion
turns
-add 0.10 mm for bearing preload and 0.10 mm
for bearing settling to reading. Result is
s total
3 9 •58 Pinion, adjusting
Example
measured reading
bearing preload
settling allowance (constant)
Total shim thickness (S total)
-remove pinion shaft
- install shims corresponding to total shim
thickness S total on end opposite pinion head
- reinstall pinion
- turn pinion several times in both directions
-attach measuring plate VW 385/22 with
support VW 385/19 to pinion
-set clamping ring on universal measuring bar
• a =approx. 74 mm (2.913 in.)
VW385/14 - · VW385/20
- assemble measuring bar with dial indicator
extension VW 385/20
- turn adjusting ring on left side into housing
until flush
 Differential-Automatic Transmission 39
-insert measuring bar into housing and screw Shim s., determining thickness
in adjusting ring
2.46mm
+0.10 mm
I s. = S total - 53

t0.10mm Example
=2.66mm total shim thickness 2.66 mm
53 thickness -1.30 mm

I shim s. thickness = 1.36 mm

)inion head
- select shims from table below
rections Shims available

Shim thickness Shim to be

range in mm Installed Part No.
1.050-1 .100 1.1 00 082 519 141 AE
1.105-1 .125 1.125 082 519 141 AF
1.130-1.150 1.150 082 519 141 AG
-move centering disc outward with movable
1.155-1.175 1.175 082 519 141 AH
setting ring until measuring bar can just be
1.180-1.200 1.200 082 519 141 AJ
turned by hand
1.205-1.225 1.225 082 519 141 AK
1.230- 1.250 1.250 082 519 141 AL
1.255-1.275 1.275 082 519 141 AM
1.280-1.300 1.300 082 519 141 AN
1.305-1 .325 1.325 082 519 141 AP
1.330-1.350 1.350 082 519 141 AQ
1.355-1.375 1.375 082 519 141 AR
with 1.380-1.400 1.400 082 519 141 AS
1.405-1.425 1.425 082 519 141 AT
1.430-1.450 1.450 082 519 141 BA
1.455-1.475 1.475 082 519 141 BB
1.480-1 .500 1.500 082 519 141 BC
t.:I'Hll]
1.505-1.525 1.525 082 519 141 BD
-place master gauge VW 385/21 on measuring
1.530- 1.550 1.550 082 519 141 BE
bar and zero dial Indicator with 3 mm preload
1.155-1.575 1.575 082 519 141 BF
-turn measuring bar until dial indicator pin
1.580-1.600 1.600 082 519 141 BG
asuring bar contacts end plate and gauge shows
maximum deflection (return point) 1.605- 1.625 1.625 082 519 141 BH
-note reading e (example: 1.72 mm) and 1.630-1 .650 1.650 082 519 141 BJ
determine thickness of shims 53 and s. 1.655-1.675 1.675 082 519 141 BK

Note 1.680- 1.700 1.700 082 519 141 BL

1.705-1 .725 1.725 082 519 141 BM
Master gauge VW 385/30 can be used instead of 1.730-1.750 1.750 082 519 141 BN
VW 385/21. Set Ro to 52.60 mm
1.755-1.775 1.775 082 519 141 BP
Shim 53, determining thickness 1.780-1 .800 1.800 082 519 141 BQ
1.805-1.825 1.825 082 519 141 BR
Indicator

:o housing
I S3=e-r 1.830-1.850
1.855-1 .875
1.850
1.875
082 519 141 BS
082 519 141 BT
1.880-1.900 1.900 082 519 141 CA
Example
Note
dial indicator reading e 1.72 mm
deviation r marked on ring gear -0.42 mm Measure shims at several points with
micrometer. Check for burrs and damage. Use
s, thickness =1.30mm only good shims
-select shims from table
- go to next page

E-10
E·11
Pinion, adjusting 39.59
39 Differential-Automatic Transmission
Ring gear, adjusting
Ba
Work sequence '
Wo
- install dlfferentla_l and pinion
- coat O·rlngs and threads of adjusting rings -t
lightly with muJti-purpose grease
- lubricate bea,rfngs lightly with hypoid gear oil
- screw in both adjusting rings until outer
surface is flu$rl~ouslng surface

- install shims selected from table

• S3 behind pinion
• s. opposite pinion
- install pinion
-lubricate bearings with hypold gear oil
-c
-turn pinion several times in both directions
- Install universal measuring bar ·
-zero dial Indicator with 1 mm preload·
- check that Indicator reading equals recorded
deviation r within a tolerance of ± 0.04 mm - carefully turn adjusting ring behind ring gear
until ring gear meshes with pinion with no
backlash
-screw in adjusting ring opposite ring gear as
far as possible and preload slightly so that
there Is no bearing play

-s
\

-after installing selected shims and pinion

shaft, check that turning torQue Is at least
140 Ncm (12.4 in. lb)

Note
This figure is for new bearings. If bearings are to
be reused, turning torque should be measured
before disassembly. When replacing parts that e
affect ring gear/ pinion setting, check page 39.9 h
to determine which parts need to be adjusted h

- turn adjusting ring behind ring gear 2 1/2

tooth divisions out (right arrow)
- turn adjusting ring opposite ring gear 5 tooth
divisions in (left arrow). This correctly sets
bearing preload and gear backlash

39.60 Pinion, adjusting

Ring gear, adjusting
 Differential-Automatic Transmission 39
Backlash, checking
Work sequence

rings -turn pinion several times in both directions

gear oil
;ter

" ' - - -- --VW521/4

139-2871

-turn ring gear until measuring lever contacts

pin of dial indicator a and preloads it to
g gear as
1.0 mm. Reset dial indicator to zero
.so that
[~19JJ
- set measuring lever to 80 mm and place on
vw 521/4

-install dial indicator (3 mm range) with

extension VW 382/10 (6 mm flat end) in
holder VW 387 and bolt holder to transmission
housing
- attach clamp VW 386 to cover plate and lock
Note pinion with clamping screw
ar 2 1/2
Dial indicator must be located at right angle to
lear 5 tooth measuring bar - go to next page
!ctly sets
,
E·13
E·12
Backlash, checking 39.61
 39 Differential-Automatic Transmission

- check backlash at four positions

• backlash should be: 0.15-0.25 mm

CAUTION
Individual readings must not differ by more
than 0.05 mm. Backlash figure given above
only aplies to new ring gear/pinion.
If used se't o t gears is reinstalled, they
should be set to give same backlash with
which they were running before they were
removed

Note
If backlash of new ring gear/pinion is outside
tolerance, it must be corrected by turning both
adjusting rings by same amount (in opposite
directions) so that bearing preload is not
changed

-measure total turning torque of all 4 bearings

with torque wrench on pinion shaft
-total turning torque must be at least
20 Ncm (1.8 ln. lb) more than turning torque
of pinion shaft alone. If necessary, increase
turning torque by screwing in both adjusting
rings by same amount

3 9 •62 Backlash checking

E·14
 40

Front Wheel Suspension

Shafts & Axle

Index
-Assembly syncro ·- .;.;;..... Wheel bearing housing
early version 40.2 -Axle shaft assembly 40.23
late version 40.7 •embly 40.29 removing/installing 40.17
-Ball joints l~gth 40.30 -Wheel hub
assembly 40.1 0 ·!'"removing/installing 40.28 assembly 40.23
lower 40.12 - Balljoints pressing 40.24
- Coil spring ' . pressing 40.25
removing/installing 40.3 .....;. Components
- Lower control arm assembly 40.15
bushing, early version 40.6
bushing, later version 40.8
- Coil spring
removing/installing 40.20
..
removing/installing 40.3 . - CVjpint, inner
- Shock absorber assembly 40.29
removing/installing 40.4 .·.·· di~sembling/assembling 40.33
- Steering arm ·. pressing 40.31
checking 40.12 ·~ CV~joint, outer
- Steering knuckle · as~embly 40.29
assembly 40.12 disassembling/assembling 40.:3.2
checking for wear 40.12 removing 40.31
modification, grease seal 40.13 ··.
.,-;Guards, ·drj,ve sha.ftlengine
modification, brake disc removing/installing 40.28
interference 40.14 - Lower control arm
-Subframe bushings'40.19
wax preservation 40.14 .....; Shock absorber
- Upper control arm rernovinglinstalling 40.20
bushing 40.5 .....; Subframe
lower40.6 components 40.26
removing 40.5 installing 40.28
wax preservation 40.14 removing 40.27
-Wheel bearing --'Upper control arm ·
adjusting 40.11 bushings40.19
assembly 40.1 o removinQ{installing 40.18a
-Wheel bearing
pressing 40.24
<.i . i

40.1

E·14
40 Front Wheel Suspension, Shafts and Axle
~30 Nm (22ft lb)

Washer --------------------=
concave side faces rubber bushing

Front Suspension
(up to October 31, 1984)
Bushing - - - - - - - - - -
I
\
--C-, "m •h•fl
note position before removm;;
After installing , adjust cam

Upper control arm bushing _ _ _ _ __,

removing/installing page 40.5 ----Bump stop/ Dust sleeve
checking, J:')age 40.5a modification page 40.4
Spacer sleeve --------....J
modification page 40.4

i!!li. ---Coil spring

removing page 40.3
installing page 40.4

=:::!::-'~~""I Steering knuckle

removing 40.3
installing 40.4

20 Nm (14 It lb)

90 Nm (65ft lb) -------11-

Lower control arm bushing - - - - - - - - - - -
removing/installing page 40.6

Strut bar

and advance to
next cotter pin hole

40.2 Front suspension

(up to Oct. 31, 1984)
A·2
 Front Wheel ·Suspension, Shafts and Axle 40

·m shaft
!lore removing .
Strut bar bolts
adjust camber (up to October 31, 1984) WARNING
Do not re-use any fasteners that are worn or
deformed in normal use. Many fasteners are
When repairing front axle always install designed to be used only once and become un·
iage 40.5
spring washer under bolt head reliable and may fail when used a second time.
This includes, but is not limited to, nuts, bolts,
washers, self-locking nuts or bolts, circlips and
cotter pins. Always replace these fasteners with
Note new parts.
Do not install spring washer under self·
locking nut

Spring washer
· Parts No.'s:
N12 230.5

1er
tailing

I Nm (115ft lb) Self-locking n u t _ _ / II

1rod end
always replace
noving page 40 .3 first tighten to 65 Nm (47 ft I b)
then retighten to 70 Nm (51 ft lb)

40·A006

'0 Nm (123ft lb)

A·2
Front suspension
(up to Oct. 31 , 1984) 40.2a
40 Front Wheel Suspension, Shafts and Axle

Steering knuckle/coil spring/lower

control arm, removing
Work sequence
-remove wheel
-remove stabilizer bar from strut bar

• - QU I
-remove nuts (arrows) holding strut bar, - hang caliper up on body with hook
steering knuckle and lower control arm
together

Note

Length of strut bar determines caster angle. If

us 1014
or
setting at body mounting Is changed, caster us 1015
mu st be readjusted , see Repair Group 44

- remove tie rod end nut and press tie rod

end out
- remove upper ball joint from upper control arm
-detach steering knuckle from upper and lower
control arms \
-loosen shock absorber on lower ~nlrol arm

'~

- remove brake caliper and brake hose bracket

(arro ws)

Steering knuckle

40.3 Coli spring

Lower control arm
 Front Wheel Suspension - Shafts and Axle 40
Shock absorber, removing/installing
- remove shock absorber from control arm at
bottom
- lower vehicle onto wheels and pull shock
absorber bolt out of control arm
- lift vehicle
- remove shock absorber from body and install new
shock absorber to body
- lower vehicle and tighten shock absorber to
control arm

Note
When lifting vehicle without shock absorber, avoid
damage to upper ball joint.
Bump stop/dust sleeve and spacer sleeve,
modification

- support lower control arm with jack, and pull

shock absorber bolt out of lower control arm
- lower jack slowly and remove coil spring
- •

- remove control arm from body

Steering knuckle/coil spring/lower

control arm, Installing
Work sequence
- install control arm

A = spacer sleeve
B = bump stop/dust sleeve

- check correct position of spring (straight end of
spring must be at bottom)
- attach damping ring to top of spring with tape
- install coil spring in correct position (lower end of
spring in depression in control arm)
- lift control arm with jack and attach shock
absorber to control arm
- attach steering knuckle to control arm. At lower
connection, strut bar must also be attached
- install stabilizer bar, tie rod and brake caliper
- reinstall wheel
Note
From VIN 25A 007 7959, following parts have been
modified:
• new spacer sleeve (length 28.5 mm/1.122 in.),
Part No. 251 413 439A
• contact surfaces of bump stop and body
If new bump stop must be installed in vehicles up to
VIN 25A 007 7958, spacer sleeve, length 24. 5 mm
(0.965 in.), Part No. 251 413 4398, must be installed.

A·4 A·5
Coil spring
lower control arm
Shock absorber
40 4 •
40 Front Wheel Suspension, Shafts and Axle

Upper control arm, removing

- remove wheel
-remove bolts holding upper ball joint to
control arm
-swing steering knuckle carefully to one side
- remove control arm shaft and detach upper
control arm

Upper control arm, installing

- attach control arm to body and note position
of control arm shaft

-press bushing out

Upper control arm bushing, installing

• flat on control arm shaft must be vertical

and face center of vehicle. Larger side of
/
eccentric washers face down
-lubricate control arm shaft with multi-purpose
grease
-install ball joint in control arm I.L--VW439(
Upper control arm bushing; removing

-press bushing in

- grind off spot welds (arrows)

-secure bushings with spot welds (arrows) to

prevent them from turning
-clean up welds and paint

40.5 Upper control arm

Upper control arm bushing
 Front Wheel Suspension - Shafts & Axle 40

An insufficient seal at the outer ends of the upper

control arm bushings can cause premature wear to
the bushings.

Upper control arm bushings,

checking
• both front wheels must be dn ground
• bolt head (or nut/wash~rhust be positioned in
center of bonded rub\r bushing
If bolt head (or nut/washer) COQ1es in contact with
supporting ring (arrow), wear limit\ as been reached
and bushing must be replaced. \

A·6 Upper control arm bushing, checking 40.5a

 Front Wheel Suspension - Shafts and Axle 40
Lower control arm bushing, removing/installing

- press bushing out

VW411

- press bushing in

Lower control arm bushing 4 0 •6

40 Front Wheel Suspension, Shafts and Axle

Front suspension modifications

(from November 1, 1984)

Beginning in November 1984, the sheet metal Also, the eye in the steering arm for the tie rod end
lower control arm has been replaced by a cast arm. has been made wider.

The strut bar, which was previously bolted to the Note

arm with the ball joint adapter, is now screwed into
New version parts cannot be installed together with
the cast arm. The ball joint is installed directly in
parts of the old version . Parts of the old version will
the arm and the adapter has been discontinued .
remain available.

Upper ball joint

removing Fig. 3

Lower control arm - - - - -

removal/installation
procedure unchanged .

Lower control arm

removing/installing
bushing~
WI'
Fig. 4 and Fig. 5
\

........,__/
180 Nm (133 H lb)
removing/installing Fig. 1

30 Nm (22 H lb) / . , 1 4o-sosl

Tie rod end - - - - ' 30 Nm (22 H lb)

pressing out Fig. 2 and advance to next
cotter pin hole
WARNING
Do not re-use any fasteners that are worn or
deformed in normal use. Many fasteners are
designed to be used only once and become un-
reliable and may fail when used a second time.
This includes, but is not limited to, nuts, bolts,
washers , self-locking nuts or bolts, circlips and
cotter pins. Always replace these fasteners with
new parts.

40.7 Front suspension

(modlflcaUons from Nov. 1, 1984)
 Front Wheel Suspension, Shafts and Axle 40

id

:h
rill

140-9071

Fig. 1 Strut bar, removing/Installing Fig. 3 Steering knuckle, removing

- measure dimension a from end of thread - press ball joints out o~ arms
to rear nut before removing

Note
When installing rod, the rear nut must be
set to the old position or the caster angle
VW408a
reset.

, (118ft

Fig. 4 Control arm bushing, pressing out

ft lb) 140-9061

Fig. 2 Tie rod end, pressing out

Strut bar, Tie rod end

Steering knuckle, Control arm bushing
(modifications from Nov. 1, 1984)
4o 8 •
40 Front Wheel Suspension, Shafts and Axle

VW415a
VW401

Fig •. 5 Control arm bushing, pressing in

40.9 Control arm bushing

(modHicatlons from Nov. 1, 1984)
 Front Wheel Suspension, Shafts and Axle 40
WARNING
Do not re-use any fasteners that are worn or
deformed in normal use. Many fasteners are
designed to be used only once and become un-
reliable and may fail when used a second time.
This includes, but is not limited to, nuts, bolts,
washers, self-locking nuts or bolts, circlips and
cotter pins. Always replace these fasteners with
new parts.

Wheel bearing, Inner

remove with copper drift
installing Fig . 4

Grease seal and seal ring (not shown) Self-locking nuts - - - - ,

modification Fig . 12 always replace
Peening nut
lock after adjusting checking for wear Fig. 10 110 Nm (80 It lb)
wheel bearings, Fig . 3 position Fig . 12 do not tighten until
in stalling Fig. 5 steering knuckle is
-Thrust washer installed
Brake hose bracket - - - - - .
Wheel bearing, outer When tightening nut,
remove with copper drift do not bend bracket.
installing Fig . 6 Check clearance of brake hose,
see above note

-Brake disc

-~-Shouldered bolt
Lower ball joint
160 Nm (115 It lb) replace If boot
is damaged
Steering knuckle removing Fig . 8
modification Fig . 12 installing Fig . 9
-160 Nm (115 It lb)
check ing for wear Fig. 10
checking for distortion Fig. 11
Ball joint adapter _ __,
Circlip - - - - ' removing Fig. 7
for lower ball joint Do not Install ball
joint until adapter
has been bolted to
control arm. If installed
incorrectly, boot on ball
Note joint will be damaged

If brake hose bracket is removed, clearance

between wheel and hose must be checked when
reinstalling . With wheels at full left and right
locks, there must be a minimum clearance of
25 mm (1 in.). If not, bend bracket to adj ust

Steering knuckle

A·11
A·12 Ball joints
Wheel bearing 40.10
40 Front Wheel Suspension, Shafts and Axle

Fig. 1 Grease cap, removing

Fig. 4 Wheel bearing (inner), Installing outer race

Fig. 2 Wheel bearing, adjusting

- Hghten nut firmly to seat bearing, at
same time turn wheel so bearing does Fig. 5 Grease seal, installing
not jam
- back off nut - press in flush
• wheel bearing clearance Is correctly
adjusted when thrust washer can be
moved slightly with screwdriver
(arrow) and finger pressure. Do not
pry or twist screwdriver
- peen nut (see Fig . 3)
- install grease cap

Fig. 6 Wheel bearing (outer), installing outer race

I A0 - 645 I
Fig. 3 Peening nut, locking
- peen nut on shoulder (arrow)
-do not reuse peened nut, always
replace

40.11 Wheel bearing

Grease seal
 Front Wheel Suspension, Shafts and Axle 40

Fig. 7 Ball joint adapter, removing

-press lower ball joint adapter off lower
ball joint
- press upper ball joint out with same
tool
Fig. 10 Wheel bearing/grease seal seats,
checking for wear
VW407- -•
- check for scoring or ridges at these
3051 points
VW401 A = outer bearing seat
VW402 B = inner bearing seat
C = oil seal seat/seal ring
- replace seal ring or steering knuckle if
necessary

Fig. 8 Lower ball j oint, removing

-remove circlip for ball joint
- press lower ball joint out of steering
knuckle

~I
Fig. 11 Steering arm on steering knuckle,
· checking
• measurement must be: 54-56 mm
(2.126-2.205 in.)
Fig. 9 Lower ball joint, Installing
- press in, flat side of shoulder faces
spindle
CAUTION
-attach adapter loosely to ball joint
Bent steering knuckles must be replaced.
Note Do not straighten
Do not tighten adapter fully. Adapter
must be aligned with control arm when
steering knuckle is installed; otherwise,
rubber boot will be stretched and torn
when steering is in full lock position

Lower ball joint

Wheel bearing/grease seal seats
Steering arm 40.1 2
40 Front Wheel Suspension, Shafts and Axle

Fig. 12 Steering knuckle, modification

1 steering knuckle
2 = seal ring (not shown on page 40.10)
3 = oil seal
• steering knuckle has a seal ring for
grease seal
• if seal ring is scored, seal ring and
grease seal must be replaced
• position of grease seal: dust lip
(arrow) points away from seal lip
-fill up space between seal lips with
multi-purpose grease

40.13 Steering knuckle A·15

 Front Wheel Suspension-Shafts & Axle 40
The internal portions (cavities) of the front lower
control arms and rear trailing arms are sprayed with
preservation wax during vehicle production.

Spray wax into the cavities of replacement parts

during repairs to ensure the same quality of
corrosion resistance as the original parts.

When installing replacement steering knuckles with

the following Part Numbers:
251 407 311 AE
251 407 312 AE
contact could be made with the brake disc in the area
indicated. (arrow)

• arrows indicate openings to be used for wax

spraying

CAUTION
Preserve parts with wax after installation only.
Do not allow wax to get into bolt threads or
mating surface areas of suspension parts.
Material
CavitY preservation wax
Part No. AKR 316 038 10
or equivalent
Note
For a description of Volkswagen wax application
equipment and its use, see Cavity and Underbody
Preservation, service literature No. W42-701.Q04-1.
l40·A0221
Grind down the cast lug on the steering knuckle
approx. 8.0 to 10.0 mm (5/16 to 3/8 in.) to provide
clearance for the brake disc. (arrow)
If necessary, also modify the splash plate, Part No.
251 407 343 C, to prevent contact in the same area.
CAUTION
Modified parts must not show scoring marks
from grinding and must have smooth, rounded
edges.
Paint parts after modification to provide
protection against corrosion.

Wax preservation
Steering knuckle modification 40.14
40 Front Wheel Suspension-Shafts & Axle

CAUTION
Welding or straigbtening procedures must not
be performed on load bearing front suspension
components and components that position the
wheels.
Always replace seH-Iockil'lg nuts.
If vehicles that have an axle shaft removed
must be moved, an outer joint must be
installed to prevent damage to wheel bearing;

Wheel bearing housing /

/
replacing wheel bearing page 40.24, 40.2~ ·
removing/Installing 40.17 ·. /

Tie rod end /'

removing 40.8 /
(
I
350 Nm (258 tt lb)
grease nut on contact
surface with MoS2

...........' ·1 . / · 250 Nm (185 tt lb)

. "-J. .
-~

30 Nm (22 ft lb)
then tighten to next
cotter pin hole

Spacer washer
WARNING
Do not re-use any fasteners that are worn or
deformed in normal use. Many fasteners are
designed to be used only once and become un-
reliable and may fail when used a second time.
This includes, but is not limited to, nuts, bolts, 140·A0231
washers, self-locking nuts orbolts, circlip9 and
cotter pins. Always replace these fasteners with
new parts.

40 •15 Front suspension components

Syncro
 Front Wheel Sus - Shafts & Axle 40

Camber adjustment bolt

"'adjust after installation

Upper control arm - - - - - " "

removing/Installing page 40.18

/
/

Upper spring plate Coli spring

removing/installing page 40.20
fasten to coil spring
in 3 places with
5 ft lb) adhesive tape

lb)

Shock absorber
removing/installing page 40.20
note Installation position

·washer
Bonded rubber bushing
removing/installing page 40.19

l40-A023l

~=~~
Lower control arm l40·A0241

Syncro
Front suspension components 40.16
40 Front Wheel Suspension, Shafts & Axle

Wheel bearing housing,

removing/installing
Work sequence
Removing
- remove axle nut (vehicle on wheels)
- remove wheel

- remove brake caliper (arrows) and tie to body

- remove brake line bracket from wheel bearing

housing (arrow)

- press tie rod end out

A= US 1014

- remove upper ball joint from control arm by

removing bolts (arrows)

...... remove bolts (arrows) and separate radius rod,

wheel bearing housing and lower control arm

40.17 Wheel bearing housing

Syncro
 Front Wheel Suspension - Shafts & Axle 40
Installing

CAUTION
Splines on drive shaft and wheel hub must be
free of oil, grease and old locking compound.

- apply locking compound 06 around splines of

outer CV joint in a bead approximately 20 mm
(25/32 in.) wide

ody - press axle shaft out of wheel hub

A standard commercial puller

Note
If a suitable commercial puller is not available,
remove wheel bearing housing together with axle
shaft. Press out axle shaft.

Remainder of installation procedure is the reverse of

removal.

Note
Allow locking compound 06 at least 60 minutes to
harden before driving vehicle.

CAUTION
Always remove stub axle with mechanical or
hydraulic hub puller only. Do not heat up
wheel bearing housing or wheel bearing will be
damaged.

ius rod,
I arm

8-5 Syncro
Wheel bearing housing 40.18
40 Front Wheel Suspension-Shafts & Axle

Upper control arm, removing/

installing
Work sequence
Removing
- remove wheel
-remove bolts attaching upper ball joint to control
arm
- remove camber adjustment bolt and take out
control arm

Installing
- fasten control arm to body

• installation position:
flat surfaces of adjustment bolt must be
vertical and larger side of eccentric washers
downward

CAUTION
A maximum play of 0.5 mm (0.020 in.) is
allowable on each side between the bonded
rubber bushing in the control arm and the
eccentric washer when the bolt is loosened.
The following eccentric washers are available
to adjust the clearance:

Thickness Part No.

4.0mm 251 407133 A
5.0mm 251 407133 8
5.5 mm 251 407133 c

- lubricate camber adjustment bolt with all purpose

grease
attach upper ball joint to control arm

40 •1 8 a Upper control arm

Syncro
40 Front Wheel Suspension, Shafts & Axle

Lower control arm bonded rubber Upper control arm bonded rubber
bushing, removing/installing bushing, removing/installing

VW 408a

Bonded rubber bushing, pressing out Bonded rubber bushing, pressing out

VW460/2

Bond~ rubber bushing, pressing In

Bonded rubber bushing, pressing In

40.19 Control arm bushings

Syncro
 Front Wheel Suspension-Shafts & Axle 40
~r Coil sprin~/shock absorber,
removing/mstalling
Work sequence
Removing

~39

- remove upper ball joint from control arm (a.rrows)

105
522
l-40-9161
-402 - depress lock catch A, push seat to full forward
position and release lock catch

12

- pry out rubber plug (arrow) under seat

- remove wheel - attach spring compressor and compress spring

8·8 Syncro
Coli spring/shock absorber 40 •20
40 Front Wheel Suspension-Shafts & Axle

Installing

- install shock absorber to lower control arm and

hand tighten nut
• Installation position
right side: spring end stop B at front
left side: spring end stop B at rear
..
- push piston rod A in enough for installation
clearance
- remove shock absorber from upper attachment on
...,... install coil spring with lower spring end in spring
body
end stop
- push piston rod down
• installation position:
-swing shock absorber and spring . outward
evenly coiled end downwards
- remove spring and spring plate
- fasten spring plate to top of spring with tape in at
- remove bolt from shock absorber attachment to
least 3 places
lower control arm and take shock absorber out
-swing shock absorber and spring inward
Not's on shock absorber testing/replacing
A defective shock creates a rumbling noise during
driving.
Slight oil seepage from the shock is normal. If
greater oil loss occurs, performance will be affected.
It will be possible to compress or extend a defective
shock in increments, rather than with the smooth
stroke charac!eristic of normal shock testing.
Shocks are maintenance-free and must be replaced
rather than repaired. Shock absorber oil cannot be
replenished.
Install only original replacement shock absorbers.
Shock absorbers of different manufacturers that have
the same part number are interchangeable.
It is not necessary to replace both shock absorbers if
only one is defective.
- insert T-handle wrench into piston rod through
access hole

·40 •21 Coil spring/shock absorber

Syncro
 Front Wheel Suspension - Shafts & Axle 40
- pull piston rod upward
- tighten nut attaching shock absorber to lower
control arm, to 150 Nm (110ft lb)
- install upper ball joint to control arm and tighten
to 60 Nm (44 ft lb)
- lift control arm with jack and remove spring
compressor
-pull piston rod upward and remove T-handle
wrench

- attach shock absorber to body and tighten to

30 Nm (26ft lb)
- insert plug in access hole
- reposition seat
- install wheel

8·10 Syncro
Coil spring/shock absorber 4 0 •2 2
40 Front Wheel Suspension-Shafts & Axle

Ball joint, upper

pressing out Fig. 6

Wheel bearing housing

Splash shield

Wheel bearing
pressing out Fig. 2
pressing in Fig. 4
when installing, coat outer
circumference with Moly paste,
Part No. AOS 115 000 01 or
equivalent to prevent clicking
noises while driving

Seal
pry out with VW 681
Ball joint, lower pressing in Fig. 11
pressing out Fig. 7 and Fig. 8 i
pressing in Fig. 9 ®
Seal----'
pry out with VW 681
pressing in Fig. 10

100 Nm (74 ft lb)

Wheel hub _ _ _ _ _ __,-

pressing out Fig. 1
pressing in Fig. 1
removing from bearing inner race Fig. 3

Brake disc - - - - - " '

WARNING remove before pressing
out wheel hub
Do not re-use any fasteners that are worn or 20 Nm (14 ft lb)
deformed in normal use. Many fasteners are
designed to be used only once and become un-
reliable and may fail when used a second time.
This includes, but is not limited to, nuts, bolts,
washers, self-locking nuts or bolts, circlips and
cotter pins. Always replace these fasteners with
new parts.

40 •2 3 Wheel bearing/hub
Syncro
 Front Wheel Suspension - Shafts & Axle 40

Fig. 1 Wheel hub, pressing out Fig. 3 Inner bearing race, pulling out

Note
When pressing out hub, wheel bearing is destroyed.

-----3144

Fig. 4 Inner seal, driving in

Fig. 2 Wheel bearing, pressing out

-remove oil seal first; replace
- remove circlip

Fig. 5 Outer seal, driving In

8·12 Syncro
Wheel bearing/hub/seals 40.24
40 Front Wheel Suspension-Shafts & Axle

VW412 ---.3124

VW267a

Fig. 6 Wheel bearing, pressing In Fig. 9 Lower ball joint, pressing out of wheel
bearing housing
- install circlip after pressing
in wheel bearing

VW412

Fig. 10 Lower ball joint, pressing out of bracket

Fig. 7 Wheel hub, pressing In

VW267a

Fig. 11 Lower ball joint, pressing into bracket

Fig. 8 Upper ball joint, pressing out

40 •2 5 Lower ball joint

Syncro
 Front Wheel Suspension - Shafts & Axle 40

I
Washer----
• collar downward

Spacer sleeve

25 Nm (18 ft lb) """"\.

..... (33ftlb)~ ~·
Stabilizer

"'· I

Self·locklng bolt
85 Nm (63 ft lb)

ket

Washer
• collar away from
rubber bushing

150 Nm (111 ft lb) WARNING

Do not re-use any fasteners that are worn or

-
)-9041
deformed in normal use. Many fasteners are
designed to be use.d only once and become un-
reliable and may fail when used a second time.
This includes, but is not limited to, nuts, bolts,
washers, self-locking nuts or bolts, circlips and
cotter pins. Always replace these fasteners with
new parts.

8·14 Syncro
Subframe components 40.26
40 Front Wheel Suspension, Shafts & Axle

Subframe, removing/installing
Work sequence
Removing

- fasten final drive support to body (arrows)

- remove radius rods from subframe and stabilizer

(arrows)

- remove protection bars and bonded rubber

bushings (arrows)

-remove control arm from subframe (arrow)

- tie up final drive

- remove final drive support from subframe

(arrows)

40.27 Subframe, removing

Syncro
 Front Wheel Suspension - Shafts & Axle 40
- use universal transmission jack to support
subframe
- remove bolts that attach subframe to body
- carefully lower subframe and remove

Installing
Proceed in reverse order of removal and note the
following:
- tighten bolts fastening subframe to body last (see
page 40.26 for tightening torques)

Note
After installation of subframe, vehicle must be
14()..10461
aligned. (see group 44)

Guards for drive shaft/engine, -remove and install engine guard (skid plate)
removing/Installing • tighten to 45 Nm (33 ft lb)

Front axle shaft, removing/installing

Removing
The axle shaft cannot be removed without first
loosening the wheel bearing housing. It is practical,
therefore, to remove the axle shaft and the wheel
bearing housing together, then press out the axle
shaft.
Refer also to Wheel bearing housing, removing.

Installing
Refer to Wheel bearing housing, Installing.
140·10451

Note
Protection bars for drive shaft can be removed
independently of the engine guard (skid plate).
- install protection bars with front and rear recesses
to the right, as seen from the driving direction
• tighten to 45 Nm (33ft lb)

8·16 Syncro
Subframe, removing/installing
Protection guards, removing/Installing
Front axle shaft, removing/Installing
4O•28
40 Front Wheel Suspension-Shafts & Axle
Note
When replacing CV joint boots, grease joint if
necessary.
inner: 45 grams G6.3 grease each side (total 90)
outer: 90 grams G6.3 grease

--·-~-l

i
Axle s h a f t - - - - - -
I · ~Circllp
~
Rubber sleeve--.......
I always replace

pull over clamp I CV joint, Inner

I replace as complete set only

Clamp------~
always replace I cE3r------ Dished washer
I with teeth on inner
diameter for solid shaft
Boot - - - - - - - - - - - - I
~
check for cracks and
wearing

Clamp-----.
replacing Fig. 6
I
I
~Clamp
~~L
~ always replace .
I 35 Nm (26 ft lb)

Rubber s l e e v e - - - -
pull over clamp ~
Clrcllp - - - - - - -
always replace
Splash ring-----..
pressing off Fig. 2
pressing on Fig. 3
011 seal - - - - -
installing Fig. 4
C) I
I check for cracks and
wearing
I
I
Note
I If CV joint boots are squeezed
while being installed, a vacuum
I may be created inside the boot.
This causes an inward fold in the
boot during use. Lift the small
I diameter end of the boot after in·
stalling to equalize the pressure.
I
I
__ _j
CV joint, outer
replace as complete set only
installing: insert circlip,
press joint on shaft until
circlip engages

40 •2 9 Axle shaft components

Syncro
 Front Wheel Suspension - Shafts & Axle 40

Fig. 1 Axle shaft length

Transmission -asurement a
right left
side side
570 mm 570 mm
all
(22.440 in.) , (22.440 in.)

set only

er
j shaft

Ag. 2 Splash ring, pressing off

<Sand - use separating fixture with aperture of

Fig. 3 Splash ring, pressing on
22-115 mm (7/8-4.5 in.)

eezed
'8CUUm
19 boot.
)ld in the
small
t after in·
nessure.

Fig. 4 011 seal, pressing Into splash ring

Syncro Axle shaft length

Splash ring/oil seal
4 o 3o
•
40 Front Wheel Suspension-Shafts & Axle

Fig. 5 Outer CV joint, removing

Fig. 7 Circlip, removing/installing
- expand circllp and remove joint from shaft

Note
If joint is seized on splines, drive it off shaft by
tapping against hub with copper drift or mallet.

CAUTION
Don't jam hub on splines, or otherwise damage
splines, during this procedure.

Fig. 8 Inner CV joint, pressing off

- support hub during procedure

.I
I

Fig. 6 Outer CV joint boot clamp, replacing

- a new clamp made of a stiffer transparent
material is used in production beginning
in February 1988
- the new clamp requires a force of 400 kg
to tighten properly
- tool KD 424 will apply the necessary
force if squeezed very hard with both
hands when compressing the clamp
- a gap in the compressed clamp of 1 to 2
mm is permissible after installation
Fig. 9 Diaphragm spring, correct posHioning

40.31 Outer CV joint, removing

Inner CV joint, pressinA off
Syncro
 Front Wheel Suspension - Shafts & Axle 40

- swivel hub and cage

remove balls one at a time
Fig. 10 Inner CV joint, pressing on
- press joint onto seat
- engage circlip into groove

CAUTION
Chamfer on inside diameter of ball hub
(splines) must face contact shoulder on
axle shaft.

Outer CV joint, disassembling/

assembling
Work sequence

Note
CV joint should be disassembled, and grease -turn two larger openings of cage (arrow)
replaced, when joint is very dirty or when checking until level with joint edge, then remove
ball tracks for wear and damage. cage with hub

Disassembling
- mark position of hub in relation to cage and
housing

ling
- swing hub until one segment can be
pushed into larger rectangular opening
of cage, then tilt hub out

8·20 Syncro Inner CV joint, pressing on

Outer CV joint, disassembling
40 32
•
40 Front Wheel Suspension-Shafts & Axle

Disassembling
CAUTION
Set of 6 balls in each joint belong to one
tolerance group. Therefore, always replace
hub, outer ring, ball cage and balls toget!'ler.

Note
Check housing, hub, cage and balls .for pitting.
Excessive radial clearance in joint is noticeable when
shifting gears. When this occurs, replace joint.
Do not replace joint because of polished
appearance, or because. ball track can be seen.

Assembling
-lube joint with 45 g (1.6 oz) G 6.3 grease (half of
total amount)
- install cage with hub, into housing
- pivot ball hub and cage out of outer ring and push
• balls must be installed from opposite side
outward (arrow)
• marked position of hub, cage, and housing
- press balls out of cage
must match
- install new circlip in hub
- fill joint with remaining G 6.3 grease for a total CAUTION
amount of 90 g (3.2 oz) Ball hub and housing are paired. One hub, or
one housing, must not be exchanged with
Inner CV joint, disassembling/ another.
assembling
Work sequence

Note
CV joint should be disassembled, and grease
replaced, when joint is very dirty or when checking
ball tracks for'wear and damage.

- align two grooves (arrows) and remove ball hub

out of ball cage

Note
Check housing, hub, cage, and balls for pitting.

40.33 Outer CV joint, assembling

Inner CV Joint, disassembling
Syncro
 Front Wheel Suspension - Shafts & Axle 40
Assembling

I push -insert ball hub along both grooves in ball cage

• installation position not important • when pivoting ball hub with cage and balls in
- push balls into cage outer ring, hub should be pivoted out of cage
- insert ball hub into proper outer ring (arrows) until balls are spaced to fit groove

J
• chamfer on inside diameter of ball hub (splines)
must point to contact shoulder on axle shaft
and to large diameter of outer ring

- press cage firmly (arrow) until hub swings fully

into position
- fill each side of joint with 45 g (1.6 oz) of G 6.3
grease
- insert hub with cage and balls into outer ring
dlhub vertically
Note
• wide ball groove in outer ring a, and a narrow
groove in hub b are together on one side when Joint is correctly assembled when ball hub can be
hub is swung into outer ring moved in and out, by hand, over full range of axial
motion.
rg.

B·22 Syncro
Inner CV joint, assembling 40.34
 42

Rear Wheel Suspension

Shafts & Axle

.. c

Index
-Axle shaft
assembly 42.4, 42.7
removing /installing 42.4
- Constant velocity joint
assembly 42.7
disassembling/assembling 42.8
removing/installing 42.8
-Rear axle
assembly 42.4
- Rear wheel suspension
assembly 42.2
-Shock absorber
bushing/sleeve 42.3
-Trailing arm
bushing 42.3
-Wheel bearings, inner/outer
grease seals 42.5
removing/installing 42.5
-Wheel studs
removing/installing 42.6

42.1
42 Rear Wheel Suspension, Shafts and Axle

Note
CAUTION
Replace self-locking nuts.
Do not attempt to straighten or weld wheel
suspension parts.

Upper spring seat

end of spring must fit
in depression

Trailing arm - - - - - - - - - - - - - - - - ,
left and right differ in , . . - - - - - Coil spring
can be installed with
production; replacement
either end at top.
parts use same trailing arm
Note different tolerance
for both sides
groups (color code). Only
toe/camber adjusting, see
install springs of same
Repair Group 44
color code on one axle
100 Nm (74 ft lb)
Inner bracket for trailing arm
Outer bracket for trailing arm with horizontal slots for
with vertical slots for toe adjustment
camber adjustment

' - - - - - - - - - Trailing arm bushing

removing/installing page 42.3

Lower spring seat

depressions for end of spring
In seat and arm must be
aligned

.........____ Socket head screws with

\ lock washers
45 Nm (33 ft lb)

Sleeve - - - - - - ' :....,__ _ Shock absorber

removing/installing page 42.3
check for flat spots
over full stroke

Wheel bearings Shock absorber bushing

assembly page 42.4 removing/installing page 42.3
removing/installing page 42.5

Axle shaft
assembly page 42.4, 42.7
removing/installing page 42.4

Coil spring

42.2 Axle shaft

Rear suspension
 Rear Wheel Suspension, Shafts and Axle 42

J VW442 - - - -
30-14 -~

1 with Fig. 3 Shock absorber bushing and sleeve,

'P· removing
tolerance
ode). Only • B = press tube
of same
Jne axle

ailing arm
ts for
Flg. 1 Trailing arm bushing, removing
• A = threaded rod
- coat washer with oil and put between nut
1hlng and tool
19 page 42.3 - pull bushing out of trailing arm

;eat
1r end of spring
n must be
Fig. 4 Shock absorber bushing and sleeve,
installing
screws with
I
- break ~harp edge on one end of sleeve
lb) before installing
- coat parts with soap solution
- press sleeve half way into bushing with
vise

bsorber
l r flat spots
stroke VW416b

Fig. 2 Trailing arm bushing, lnJtalllng

• A = thrust pad and threaded rod
- coat installation tool, bushing, and hole in
trailing arm with soap solution
- pull bushing Into trailing arm until sleeve
contacts tool, then wait about 30 seconds
before removing tool. Bushing will seat Fig. 5 Shock absorber bushing and sleeve,
itself pressing
- if necessary, press edge of bushing out
- press bushing and sleeve in fully

Trailing arm bushing

Shock absorber bushing
42 3 •
42 Rear Wheel Suspension-Shafts & Axle

WARNING
Vehicle MUST be on ground when axle nut is
loosened/tightened.

Spacer sleeve
Wheel stud - - - . Wheel bearing housing thickness: 5.4 mm (0.21 in.)
removing Fig. 8
installing Fig. 9

Inner wheel bearing

removing Fig. 5
Installing Fig. 6
Outer wheel bearing Fill wheel bearing and space
with 10 slots in crown removing: first remove spacer
If removed, between bearings with
sleeve and drive bearing out multi-purpose grease
inspect threads; replace as necessary with brass drift
Tighten to 500 Nm (360 It lb), installing Fig. 7
tum to next slot, then insert Fill wheel bearing
cotter pin Grease seal and space between
removing Fig. 3 bearings with
Installing Fig. 4 multi-purpose grease CAUTION
On any repairs which require removal of the
axle nut, ALWAYS reassemble using a 10-slot
Note crown nut tightened to the exact torque
specification. Failure to tighten the axle nut to
During repairs on vehicles prior to VIN 25ZBH119362, the correct specification, could result In
install new sleeves and axle nuts and.torque nuts to damage to the hub/axle splines.
500 Nm (360 ft lb)

\.... VW412

30-100

Fig. 1 Axle shaft, removing Fig. 2 Axle shaft, installing

- press shaft out of wheel bearing housing - press shaft into wheel bearing housing

42.4 Rear axle assembly

Axle shaft
 Rear Wheel Suspension, Shafts and Axle 42

Fig. 5 Inner wheel bearing, removing

Fig. 3 Grease seals in wheel bearing housing,
removing - remove inner race of outer wheel
bearing and spacer sleeve
- pry out with screwdriver
~le shaft - drive outer wheel bearing out with
9111ovlng Fig. 1 brass drift
nstalllng Fig. 2 - press out inner wheel bearing

1e
slot

1t to

Fig. 6 Inner wheel bearing, installing

- grease bearing
- press bearing in until seated

Fig. 4 Grease seals in wheel bearing housing,

installing
- first install spacer sleeve and inner race
of outer wheel bearing
- press in flush on wheel side and against
circlip on flange side

Fig. 7 Outer wheel bearing, installing

- grease bearing and fill space between ·
inner and outer bearings with multi·
purpose grease
ousing - press bearing in until seated

Grease seals
Inner wheel bearing
Outer wheel bearing
42 5 •
42 Rear Wheel Suspension, Shafts and Axle

Fig. 8 Wheel studs, removing

Fig. 9 Wheel studs, installing

- press in unt il seated

42.6 Wheel studs

 Rear Wheel Suspension, Shafts and Axle 42
Note
Constant velocity joint must be checked for wear if Constant velocity joint
boot is torn and dirt has entered joint. If joint was removing Fig. 5
disassembled, pack 45 grams of G-6.3 grease into installing Fig. 6
each side of joint when assembling. If boot was torn, disassembling/checking/
apply grease as necessary. assembling page 42.8 and 42.9

ffi»] ) )
Boot----""'
check for cracks and
signs of rubbing
length Fig. 1 Protective cap
removing Fig. 3

Fig. 1 Axle shaft, length

Measurement a
right left
Transmission side side
547.8 mm 547.8 mm
manual (21.567 in.) (21 .567 in.)
579.3 mm 531.0 mm
automatic (22.807 in.) (20.906 in.)

Fig. 2 Circllp, removing Fig. 3 Protective cap, removing

- drive off with drift

C·6
Axle shaft 42.7
42 Rear Wheel Suspension-Shafts & Axle

Constant velocity joint, disassembling

Work sequence

VW408a -~

14o-oosl
.
lI
Fig. 5 Constant velocity joint, removing
- press out axle shaft

- pivot ball hub and cage out of outer ring and push
out (arrow)
- pull out balls

CAUTION
Ball hub and outer ring are paired. One hub, or
one ring, must not be exchanged with another.
The 6 balls for each joint belong to one
tolerance group, therefore always replace hub,
outer ring, ball cage and balls together.

Fig. 6 Circlip/Constant velocity joint, Installing

- press joint onto shaft until circlip can be
pressed into groove
• if necessary, squeeze circlip into
groove with pliers

-align two grooves (arrows) and take ball hub out

o!
ball cage

Note
Check housing, hub, cage, and balls for pitting.

4 2 •8 Constant velocity joint

 Rear Wheel Suspension, Shafts and Axle 42
Constant velocity joint, assembling
Work sequence

• when pivoting ball hub with cage and balls into

J outer ring, hub should be pivoted out of cage
(arrows) until balls are spaced to fit grooves
- insert ball hub along both grooves in ball cage
ISh
• installation position is not important
- push balls into cage
-insert ball. hub into proper outer ring
• chamfer on inside diameter of ball hub (splines)
must point to contact shoulder on axle shaft
and to larger diameter of outer ring

- press cage firmly (arrow) until hub swings fully

into position
-fill each side of joint with 45 g (1.6 oz) of G-6.3
grease

Note
Joint is correctly assembled when ball hub can be
- insert hub with cage and balls into outer ring moved in and out, by hand, over full range of axial
vertically motion.
- be sure that in each case a wide ball groove in
outer ring a and a narrow groove in hub b are
together on one side when hub is swung into
1 out outer ring

C·9
Constant velocity joint 42.9
 44

Wheels-Tires,
Wheel Alignment

Index
-Tires Syncro
rotating 44.1 a - Wheel alignment
- Wheel alignment determining front toe 44.3a
front 44.3 specifications 44.5
rear 44.4
specifications 44.2

44.1
 Wheels-Tires, Wheel Alignment 44
Tires, rotating
Most tire manufacturers have changed their tire
rotation policy on radial belted tires. Previously,
radial belted tires were to be rotated only from front
to rear and rear to front on the same side of the
vehicle.
All radial belted tires approved for use on
Volkswagen vehicles can be rotated diagonally if
unusual wear, such as feather-edging, is observed.

nres. rotating 44.1 a

44 Wheels-Tires, Wheel Alignment

Wheel alignment data for front and • tire pressures correct

rear axles • testing surface level and horizontal
• vehicle bounced several times
When checking wheel alignment, the following • steering gear correctly adjusted
conditions are important: • steering linkage free of play
• except in emergency, alignment should not be
checked until vehicle has run 625-1250 miles
and coil springs have settled
• vehicle empty

Front axle
Empty Half load* Maximum load*
800 kg 1000 kg 1100-1200 kg
(1764 lbs.) (22041bs.) (2425-2646 lbs.)
Toe per wheel (not pressed) +10' ± 15' +10' ± 15' oo ± 15'

Total toe (wheels not pressed) +20' ± 30' +20' ± 30' 0° ± 30'
2.0 ± 3.5 mm 2.0 ± 3.5 mm 0 ± 3.5 mm
(0.08 ± 0.138 in.) (0.08 ± 0.138 in.) (0.08 ± 0.138 in.)
Camber 0 ± 30' 15' ± 30' 0 ± 30'
(wheels in straight-ahead position)
Total angle difference,
at 20° lock to left and right 1° 10' ± 20' 1° 10' ± 20' 1° 50' ± 20'
(not adjustable)
Caster (vehicle on level)** +7° 15' ± 15' a· 30' ± 15' 6° ± 15'
corresponds to camber difference of wheel
on lock from 20° left and right 4° 50' ± 10' 4° 20' ± 10' 40 ± 15'
maximum permissible difference between
left and right 10 10 10

Rear axle
Empty Half load* Maximum load*
700 kg 1050 kg 1300-1400 kg
(1543 lbs.) (2314 lbs.) (2865-3086 lbs.)
Toe per wheel 0° ± 10' +10' ± 10' +10' ± 10'
Total toe (at specified camber) oo ± 20' + 20' ± 20' +20' ± 20'
Camber 50' ± 30' 1° 30' ± 30' -2° 10' ± 10'
maximum permissible difference between
left and right 30' 30' 30'

*Measurements given for "half load" and "full load" apply for vehicles which cannot be measured unladen because
of special equipment installed
Some models, from 1986 on, have a lower chassis height. For these vehicles use the "half-load" measurements as
"empty" settings.
**If vehicle is Inclined to front or rear, 10' must be added or subtracted for each 15' angle off level (measured In
sliding door opening)
Example: Angle measured on stand :6• 40'
correction angle for vehicle angle W to front) : 40'
actual caster angle :7° 20'

Note
Angle of vehicle: to front - add correction figure
to rear - subtract correction figure

44 •2 Wheel alignment data

 Wheels - Tires, Wheel Alignment 44
Front wheels, aligning Toe adjusting
- set steering gear to center position by turning
Work sequence steering wheel from lock to lock and counting
number of turns
Note
Caster, camber and toe must always be adjusted in
this sequence with vehicle on its wheels.

Caster, adjusting

-turn wheel back, 1/2 the total number of turns,

and align lug on rubber washer on pinion shaft
with notch in steering housing (arrow)

- set caster by adjusting length of radius bar A at

location B

Camber, adjusting - loosen lock nuts and turn both tie rods until
setting for toe is reached
- tighten lock nuts

Note
ause Steering must remain in center position.

1ts as - after turning tie rods, check that bellows are not
twisted
- perform road test and check that steering wheel is
in center position

Note
For non-Syncro vehicles only, if steering wheel
- loosen nut (left arrow) on upper control arm shaft
cannot be centered by adjusting tie rods, remove
- set camber by turning upper control arm shaft
steering wheel and center it on splines.
(right arrow)
-tighten nut to 75 Nm (54 ft lb)

0·4
Wheel alignment, front 44.3
44 Wheels-Tires, Wheel Alignment

The specification for total toe at the front axle is a dimension (mm) between wheel center and
determined by the jounce condition (ride height) of lower edge of wheel house
the vehicle. b - toe per wheel
total toe = toe per wheel x 2
Front toe specification, determining (values in parentheses = total toe in mm)
c - tolerance band for total toe
- bounce front of vehicle several times to settle
suspension Note
If measured distance a falls outside the range on the
Note graph, use the toe specification last shown at the
The vehicle must be empty of cargo and occupants appropriate end of the graph's vertical axis. Toe
during measurement. values must be adjusted as precisely as possible.

- remove one front wheel cover

- measure from center of bore in axle shaft to lower
edge of wheel hous~ (measurement a)

y
\
140-09961

use measurement a to find corresponding toe

specification on the following graph:

c
483r-~-.--.-.--.-.-.--.-.-br-~~

488r-~~-+-1--~~~-t~~~~~

493
498
503~4--+~~~~~~--~4--+~~

508
b
513
-26 -24' -22'-2ft -ll5'-15' -13' -11' -8,5'-6,5' -It -2' ±0'
(-6,0) (-5,0) l--\0) (-3,0) (-2,0) l-1,01

140..()9971

44 •3a Wheel alignment

Syncro
44 Wheels, Tires, Wheel Alignment

Rear wheels, aligning

Work sequence

Camber, adjusting

-loosen outer bolt (right arrow) on trailing arm

-adjust camber by moving trailing arm up or
down with screwdriver
-tighten bolt to 105 Nm (76 ft lb)

Toe, adjusting
-loosen inner bolt on trailing arm

( .U·llO l
-adjust toe by moving trailing arm to front
or rear with screwdriver
-tighten bolt to 105 Nm (76 ft lb)

44.4 Wheel alignment, rear

 Wheels - Tires, Wheel Alignment 44
Wheel alignment data for front and • tire pressures correct
rear axles • test surface level and horizontal
• vehicle bounced properly
When checking wheel alignment, the following • steering gear correctly adjusted
conditions are important: • steering linkage free of play

• alignment should not be checked, until vehicle

has run 625-1250 miles and coil springs have
settled

Front axle Empty Full load

Toe per wheel (not pressed) see page 44.3a
Camber, wheels in straight ahead position +20' ± 20' -30'
Maximum permissible difference between sides 20' 20'
Caster, with zero vehicle tilt +4° 40' ± 15' +3° 35'

Rear axle Empty Full load

Camber 15' + 30' 1° 10'
10'
Maximum permissible difference between left and
right 20'- 20'
Toe of each wheel (at specified camber) +5' ± 10' +0° 5'

D·7 Syncro
Wheel alignment data 44.5
 46

Brakes-
Mechanical Components

Index
WARNING Brake pedaVIinkage
assembly 46.1 0
Friction materials such as brake and
- Front brake
clutch linings or brake pads may
assembly (1980-1985) 46.2
contain asbestos fibers.
assembly (from 1986 m.y.} 46.5
Do not create dust by grinding, pads (1 980-1 985}
sanding or by cleaning with removing/installing· 46.3
compressed air. pads (from 1986 m.y.)
Avoid breathing asbestos fibers and removing installing 46.5a
asbestos dust. - Parking brake
assembly .46. 11
Breathing asbestos may result in
-Rear brake
serious diseases, such as asbestosis
aSsembly 46.6
or cancer.
shoes, adjusting 46.9
Breathing asbestos may cause shoes, removing/installing 46.7
severe injury and death.

46.1
46 Brakes-Mechanical Components

CAUTION Note

Always remove brake caliper before
removing disc.
Never try to remove disc by using force.
Force may cause caliper mounting frame to
crack or break
When removing caliper only, never disconnect
brake hose, hang caliper on frame .
Disconnect brake hoses only when repairing
brake calipers

Grease cap
remove with VW 637/2 always replace, peen after adjusting wheel bearings
(see Repair Group 40)

Wheel bearing
adjusting see Repair Group 40

Shouldered bolt
160 Nm (116 ft lb)

Splash shield

thickness: 13 mm (0.512 in.)

wear limit: 11 mm (0.433 in.)
minimum thickness after machining: 11.5 mm (0.453 in .)
maximum runout: 0.1 mm (0.004 in.)
Brake caliper
Teves or Girling calipers Brake pads
may be installed checking thickness Fig. 1 and Fig. 2
removing page 46.3
installing page 46.4

CAUTION
After installing new brake pads, depress
brake pedal firmly several times before
driving to permit piston and brake pads to
adjust to brake disc
When machining brake discs, equal
amounts rnust be taken off each side of
disc.
Never machine one side only

46.2 Front brake assembly

1980-1985 E·2
E-~

----- ----- ---

 Brakes - Mechanical Components 46
Brake pads, removing
Work sequence

Fig. 1 Brake pad thickness, checking

(Teves caliper)

- drive out brake pad retaining pins

Note
On Girling calipers, remove circlips first.

Fig. 2 Brake pad thickness, checking

(Girting caliper)
- with wheel mounted, slide gauge from
6 It lb) inside between rim and brake caliper
- try to insert gauge into gap at lower
retaining pin, between spreader spring
and brake pad backing plate
• if gauge cannot be inserted, brake - pull out brake pads
pads are worn to wear limit of 2 mm
(0.080 in.) and must be replaced
WARNING
Friction r:naterials such as brake and clutch
CAUTION
linings or brake pads may contain asbestos
Always replace all pads on one axle and use fibers.
same manufacturer of linings.
Do not create dust by grinding, sanding or by
cleaning With compressed air.
CAUTION Avoid breathing asbestos fibers and asbestos
dust.
When re-using brake pads, mark pads to
prevent changing inside to outside or from one Breathing asbestos may result in serious
caliper to another. Mixed pads can cause diseases, such as asbestosis or cancer.
uneven braking.
Breathing asbestos may cause severe injury
and death.

E-2
E-3 1980-1985
Front brake pads 46.3
46 Brakes-Mechanical Components

Brake pads, installing

Work sequence

WARNING
Brake fluid Is poisonous.
Do not siphon by mouth

CAUTION
When piston Is pushed Into cali per, brake
flu id Is pushed into reservoir. To prevent
overflowing, siphon some f luid out with an
appliance which is used for th ~s purpose
only. Brake fluid will damage paint -if necessary , correct position of piston using
pliers US 1023/2

Note
Girling calipers have arrows on noi se damping
plates. Arrows must point up

-Install notse damping plates, brake pads and

spreader springs

. ;::[ill
- press piston Into caliper with tool
- clean brake pad contact surfaces In caliper

- Install retaining pins (on Glrllng calipers

- install new cl rclips on retaining pins)

CAUTION
After installing brake pads, depress brake
pedal firmly several times before driving to
permit pistons and brake pads to adjust to
brake disc

- check position of piston (Teves caliper on ly)
• recess in piston (arrows) must face bottom.
Lugs on noise damping plate engage in
recess
Note
If brake hose brackets were removed, reinstall
with clearance of 25 mm (1 ln.) between hose
and tire.
Check clearance by turning wheel from left to
rig ht.
Correct clearance by bending bracket

46.4 Front brake pads

1980-1985
 Brake- Mechanical Components 46

'Brake disc
replace both left and right sides together
Grease cap diameter: 258 mm (10.158 in.)
remove with VW 637/2 thickness: 15 mm (0.591 in.)
wear limit: 13 mm (0.512 in.)

ng

nd

Self·locklng bolts
35 Nm (26 ft lb)
always replace
hold guide pin when loosening and tightening

IL------- Brake pads

replace pads on both wheels
thickness (new): 14 mm (0.551 in.)
wear limit: 2 mm (0.79 in.) Wheel boll tightening tor,..
wear limit including backing plate: 7 mm (0.276 in.) • 180 Nm (132 ft lb)

CAUTION
,ke
After installing new brake pads, depress brake Always remove brake caliper before removing
g to
pedal firmly several times before driving to permit disc.
,tto
piston and brake pads to adjust to brake disc.
When removing caliper only, never disconnect
When machining brake discs, equal amounts brake hose, hang caliper on frame.
must be taken off each side of disc.
Disconnect brake hoses only when repairing
1stall Never machine one side only. brake calipers.
iOS9

~ft to

E·4
E·S From 1986 m.y.
Front brake assembly 46.5
46 Brakes-Mechanical Components
Brake pads, removing
Work sequence
- remove lower fastening bolt for brake caliper
housing while holding guide pin
CAUTION
When re-using brake pads, mark pads to
prevent changing inside to outside or from one
caliper to another. Mixed pads can cause
uneven braking.
- swing brake caliper housing upward and remove
brake pads
WARNING
Friction materials such as brake and clutch
linings or brake pads may contain asbestos
fibers.
Do not create dust by grinding, sanding or by
cleaning with compressed air.
4 6 •5 a Front brake pads
From 1986 m.y.
- press piston back in brake caliper housing
WARNING
Brake fluid is poisonous . Do NOT siphon by
mouth.
CAUTION
When caliper piston is pushed back, fluid is
forced out of caliper and into reservoir. To
prevent overflowing , always siphon some fluid
out with equipment which is used for this
purpose only. Brake fluid will damage paint.
After pads are installed, refill reservoir only to
MAX mark.
Brake pads, installing
Work sequence
- insert brake pads into carrier
- swing caliper housing down and tighten bolts to
35 Nm (26 It lb)
Note
New self-locking bolts MUST be used when
refastening brake caliper hous.ing.
- depress brake pedal firmly several times before
driving
Avoid breathing asbestos fibers and asbestos
dust.
Breathing asbestos may result in serious
diseases, such as asbestosis or cancer.
Breathing asbestos may cause severe injury
and death.
46 Brakes-Mechanical Components

Note
Lightly lubricate all moving parts and contact
surfaces with MoS2 .

CAUTION

Always reline or replace all shoes on one axle

and use same manufacturer of linings.

Wheel cylinder - - - - - - - - .
diameter: 23.81 mm (0.937 in.)

Brake backing plate

Push /adjusting rod

left side has right hand thread,
right side has left hand thread.
Install as shown

Return springs
Brake lining
longer hooks point
checking thickness Fig. 1
to wheel cylinder.
Install as shown

Brake drum - - - - - - - - - - - - - - - - - -
removing page 46.7
diameter: 252 mm (9.921 in .)
maximum diameter after machining : 253 mm (9.960 in .)
(use oversize linings after machining 0.5 mm (0.020 in.) or more
wear limit: 253.5 mm (9.980 in .)

Cotter pin
always repl~

500 Nm (369 ft lb) - ---" ·""'

loosen and tighten
with wheels on ground

4 6 •6 Rear brake assembly

 Brakes - Mechanical Components 46

Fig. 1 Brake linings, checking (arrow) - pull off drum and hub

• standard lining thickness: Note

6.0 mm (0 .236 in.)
• oversize lining thickness: Drum must rotate freely when being pulled off.
6.5 mm (0.256 in.)
• wear limit: Brake shoes, removing
2.5 mm (0. 098 in.)
Work sequence
Brake drum, removing
Work sequence

!U.b

- remove spring retainers and hold down springs

(arrow)
- unhook parking brake cable at lever on brake
- release parking brake cables by loosening nuts at shoe
parking brake equalizer -remove lower return spring
- back off adjuster through hole in backing plate - remove adjuster spring
- go to next page

Warning
lb)
Friction materials such as brake and clutch
linings or brake pads may contain asbestos
fibers.
Do not create dust by grinding, sanding or by
cleaning with compressed air.
Avoid breathing asbestos fibers and asbestos
dust.
Breathing asbestos may result in serious
diseases, such as asbestosis or cancer.
Breathing asbestos may cause severe injury
and death.

E·B
Brake shoes 46.7
46 Brakes-Mechanical Components

- move brake shoes out of lower support

- unhook return springs
- remove brake shoes together with push/
adjusting rod

CAUTION
Do not press pistons out of wheel cylinder

Brake shoes, installing

Work sequence

- lubricate thread of push/ adjusting rod and

check that adjuster moves freely
- install brake shoes together with return
springs
- insert brake shoes into lower supports

46.8 Brake shoes

 Brakes - Mechanical Components 46

- make basic adjustment of brake shoes by turning

with
adjuster until measurement a is obtain~d
d

Example
brake drum inner diameter: 252.2 mm (9.929 in.)
minus clearance: 1.5 mm (0.059 in.)
measurement a = 250.7 mm (9.870 in.)

- adjust parking brake cables at parking brake

equalizer (see page 46.11)
• there must be no play between lever on brake
shoe and push/adjusting rod
- install brake drum
-tighten slotted nut to 500 Nm (369ft lb) and turn
further until new cotter pin fits into hole in axle
shaft

CAUTION
Depress brake pedal several times before
driving so that rear brakes self adjust.

E·9
Rear brake assembly 46.9
46 Brakes-Mechanical Components

Note
Instrument panel must be removed before
booster and bracket with pedal connected, can
be taken out

.------ Brake push rod

adjust length before installing
pedal cluster with booster and pedal
a= 111.5 mm (4 3/8 in.)

5 Nm (10 It lb)

Ctn::llp

~---~-Roll pin
locks shaft
in bracket

Bushings
drive out with drill,
press In with vise

Shaft ----~
lubricate before installation

Return s p r i n g - - - - ---'
remove/ install with screwdriver

46.10 Brake pedal/ Linkage

E·11
 Brakes-Mechanical Components 46
Nola

Lubricate all joints and moving parts lightly

before installing.
As of Chassis No. 25 CH 028 686, following
new type parts are installed:
• Left and right parking brake cables (now plastic ----Boot
coated)
' Parking brake actuator rod (was cable)
' Equalizer
New type parts can be installed into earlier vehicles

Parking brake actuator cable/rod

c:- (

g
--- ----
.
--- ..

----
Left parking brake cable--

------,
't ---.......... ---J
I

Self-locking adjusting nut

with drift,
~ithvise

Parking brake, adjusting

Work sequence

CAUTION
Rear brakes must be properly adjusted before
adjusting parking brake
1dal
- release parking brake
- tighten adjusting nut (self locking) until there
is no noticeable play at brake components
• check by pulling slightly on brake cable
housings
-apply and release parking brake several times
-check proper adjustment of parking brake
• rear wheels can not be turned by hand when
brake lever is pulled 2-4 notches
• rear wheels must rotate freely when parking
brake is released

E-11
E·12
Parking brake 46.11

Index
WARNING
Friction materials such as brake and
clutch linings or brake pads may
contain asbestos fibers.
Do not create dust by grinding,
sanding or by cleaning with
compressed air.
Avoid breathing asbestos fibers and
asbestos dust.
Breathing asbestos may result in
serious diseases, such as asbestosis
or cancer.
Breathing asbestos may cause
severe injury and death.
47
Brake-Hydraulic Components,
Regulator, Booster
- Brake booster
assembly 47.10
checking 47.10
- Brake caliper
Girting (1980-1985) assembly 47.5
Girling/Teves (1980-1985),
disassembling/assembling 47.6
Girling/Teves (From 1986 m.y.)
assembly 47.7a
Teves (1980-1985}, assembly 47.4
Teves (1980-1985),
noise damping plates 47.7
- Brake fluid, changing
with US 1116 47.8
without US 1116 47.8a
- Brake hydraulic system
general repair notes 47.8
- Brake master cylinder
assembly 47.2
- Brake pressure regulator
checking 47.8a
- Brake system, bleeding
with US 1116 47.8
without US 1116 47.8a
- Check valve
checking 47.10
- Rear wheel cylinder
assembly 47.8
47.1
47 Brake-Hydraulic Components, Regulator, Booster
WAR NING
Brake fluid is poisonous

CAUTION
When repairing brake master cylinder
always use all parts in repair kit. Lubricate
shaft of primary piston with silicone grease
supplied in repair kit. Coat all other cups
and pistons lightly with VW brake cylinder
paste before installation

= =----------"7""- Plug
coat with brake cylinder paste
or brake fluid and press
In reservoir
Brake master cylinder housing
check for wear, replace If necessary

Seal - - - - -.....
always replace

Stop screw - - - - - - - - -111

remove before detaching circlip
to install: move secondary piston
if necessary

WARNING
Never interchange primary and secondary
cups. See cut-aways

-------
Secondary piston ----
Secondary cups
insert wit.h sealing lips
facing opposite directions
installing Fig. 2

Primary piston aasambly

assemble before Inserting

Primary piston
Note
When Installing pistons, guide lips of cups / seals
Into housing with blunt tool

47.2 Brake master cvllnder

 Brake-Hydraulic Components, Regulator, Booster 47
J Note
DOT 4 brake fluid is now used in all production
vehicles. The new fluid is recommended tor all
Volkswagen brake systems and is completely
compatible with the previous DOT 3 fluid .
DOT 4 brake fluid has been phased into the spare
parts program effective June, 1984.
The previous DOT 3 version brake fluid, Part No.
ZVW 247 101, has been superseded to the new
DOT 4 version, Part No. ZVW 239 102.

47~1

Fig. 3 Secondary piston, Installing

-hold brake master cylinder w ith
opening facing down
-guide lips of cups in carefully with
blunt tool
.t7-0~
Note
Fig. 1 Clrcllp, removing/installing
After Installing brake master cylinder bl eed brake
system (see page 47.8)

us 4425
o-osol

Fig. 2 Secondary cups, lrn;talllng

• always use fitting sleeve US 4425

F·2
F-3
Brake master cylinder 47.3
47 Brake-Hydraulic Components, Regulator, Booster

WARNING CAUTION
Brake fluid is poisonous Use all parts in repair kit. Coat seals and
pistons lightly with VW brake cylinder
paste or equivalent before installing

"
;~Drain screw
do not bleed caliper
from th is screw
Caliper housing
do not split,
replace if leaking

Noise damping plate

removing page 47.6 installing page 47.7

Piston-----' Dust cap Brake pad

removing page 47.6 removing page 47;6 install after caliper is Installed
Installing page 47.6 installing page 47.6

Note
Cars may have either Teves or Girllng calipers

47.4 Brake caliper

Teves I I 1980-1985
 Brake-Hydraulic Components, Regulator, Booster 47
CAUTION WARNING

J Use all parts in repair kit. Coat seals and

pistons lightly with VW brake cylinder
paste or equivalent before installing
Brake fluid is poisonous

Bleeder screw

L
bleed caliper from Retaining pin clips
this screw only always replace

Drain screw
do not bleed caliper
from this screw

Brake caliper housing

do not split,
replace if leaking
per

Retaining ring
opening points toward disc

Noise damping plate

removing page 47.6 arrow points up

)
Piston---~
removing page 47.6
installing page 47.6
l .......
removing page 47.6
installing page 47.6
Brake pad
install after caliper is installed

Note
Cars may have either Girling or Teves calipers

F-4
F·5
...__1_9_so_-_19_a_s___.l j Girting Brake caliper 47.5
47 Brake-Hydraulic Components, Regulator, Booster

Brake caliper, disassembling

Work sequence

- remove seal without scratching cylinder

- pry dust cap out without scratching piston
WARNING
Friction materials such as b'rake and clutch
linings or brake pads may contain asbestos
fibers.
Do not create dust by grinding, sanding or by
cleaning with compressed air.
Avoid breathing asbestos fibers and asbestos
dust.
Breathing asbestos may result in serious
diseases, such as asbestosis or cancer.
Breathing asbestos may cause severe injury
and death.

- blow out piston with compressed air

Note

Hold other piston with clamp US 1023/5. Place

wooden block in caliper to prevent damage to piston

4 7 •6 Brake caliper
1980-1985 I Girling/Teves j
 47
- Brake-Hydraulic Components, Regulator, Booster

Brake caliper, assembling Noise damping plates, installing

(Teves caliper)
Work sequence
Work sequence

- install seal
- lubricate piston and cylinder bore lightly with
brake cylinder paste
- press in piston with installing clamp
- insert noise damping plates and check position of
piston
• recess in piston (arrows) point against direction
of brake disc rotation when moving forward.
Lugs on noise damping plates engage in recess
on piston

- install dust cap by hand

- if necessary readjust position of piston by using

turning pliers US 1023/2

- press dust cap with VW 442 against recess

• piston is now fully seated

F-7
1980-1985 Girllng/Teves brake caliper
Teves noise damping plates
47 7 •
47 Brake-Hydraulic Components, Regulator, Booster

Brake caliper housing

Piston seal
remove with screwdriver
Fig. 2

Dust cap
installing Fig. 3 and Fig. 4
do not" damage while
installing piston

removing Fig. 1
installing Fig. 4 and Fig. 5

CAUTION
Use all parts in repair kit. Coat seals and
pistons lightly with VW brake cylinder paste or
equivalent before installing.

47.7a Brake caliper

From 1986 m.y.
 Brake-Hydraulic Components, Regulator, Booster 47
-

Fig. 1 Caliper piston, removing with Fig. 4 Piston and dust cap, installing
compressed air
- insert inner lip of cap into groove in cylinder while
Note holding piston

Place a wooden block in caliper to prevent damage

to piston.

Fig. 5 Piston, installing

- press piston as far as it will go

Fig. 2 Piston seal, removing

CAUTION
Outer lip of dust cap must slip into groove in
piston.

Fig. 3 Dust cap, installing

F-9
From 1986 m.y.
Brake caliper 4 7 •7 b
47 Brake-Hydraulic Components, Regulator, Booster

Rear wheel cylinder, CAUTION

disassembling/assembling
When repairing wheel cylinders always use all
parts of repair kit

Cup
always replace always replace
coat with brake cylinder
paste before inserting

- - - - Bleeder screw

Piston _ _ _ _ ........~

check for wear

coat with brake
cylinder paste before inserting
Wheel cylinder housing
check for wear (grooves, rust pitting, etc.)
if necessary, replace complete wheel cylinder

Brake hydraulic system Brake system, bleeding

General repair notes Whenever possible use pressure bleeder (US 1116).
To bleed brake system, use bottle with transparent
hose attached so that brake fluid can be checked for
WARNING air bubbles.

Brake fluid is poisonous. Do NOT siphon by Do NOT re-use fluid removed from reservoir. Water
mouth. and other contaminants in fluid can cause brake
performance problems.
On vehicles with brake booster, turn engine OFF and
CAUTION then disconnect vacuum hose/check valve from
brake booster prior to bleeding brake system. When
Brake fluid must NOT come into contact with bleeding brake system push lever on brake
paint. pressure regulator in direction of rear axle.
Brake fluid absorbs moisture from air and must
be replaced every 2 years. (With pressure bleeder US 1116)

Only use new DOT 3 or DOT 4 brake fluid
according to SAE recommendation J 1703 and
conforming to MOTOR VEHICLE SAFETY
STANDARD 116. Do NOT add or mix DOT 5
silicone type brake fluid with brake fluid in car
as severe component corrosion may result.
Such corrosion could lead to brake system
failure.
- connect pressure bleeder US 1116 to brake fluid
reservoir. Turn bleeder switch to ON position
- connect hose from bleeder bottle to bleed
screws and bleed brakes in following sequence:
1. Right rear wheel cylinder/caliper
2. Left rear wheel cylinder/caliper
3. Right front caliper (upper screw)
4. Left front caliper (upper screw)
- after bleeding, fill reservoir to maximum mark

47.8 Rear wheel cylinder assembly

Brake system bleeding
 Brake-Hydraulic Components, Regulator, Booster 47
(Without pressure bleeder US 1116) Brake pressure regulator, checking
- connect hose from bleeder bottle to bleed
screws using previously mentioned sequence
- pump brake pedal several times and then hold
pedal down
-open bleed screw, with pedal depressed
-close bleed screw , with pedal depressed
- release brake pedal
- repeat operation until brake fluid flows without air
bubbles

Brake fluid, changing

CAUTION
The brake fluid level in the reservoir must
never fall below the MIN mark during the fluid
replacement procedure .

(With pressure bleeder US 1116)

-connect pressure bleeder US 1116 to brake fluid
reservoir. Turn bleeder switch on ON position
- connect hose from bleeder bottle to bleed screws,
using sequence in the table provided
• specified amount of fluid must flow out

Volume of brake 147-1331[

fluid to be extracted
Bleeding sequence from cylinders/calipers '
right rear 500 cm3 (30.5 ln .3) - lift vehicle with hoist

left rear 500 cm3 (30.5 in .3)

or right front, lower 500 cm3 (30.5 in.3)
right front. upper 100 cm 3 (6.1 in.3)
left front, lower 500 cm J (30.5 in .3)
left front, upper 100 cm3 (6.1 ln.3) I

nd
-fill the system with new brake fluid
I
tn - bleed as described previously

(Without pressure bleeder US 1116)

Follow the same procedure for bleeding brakes
without a pressure bleeder, covered in this section .
Remove brake fluid until the new fluid flows without
air bubbles.
- connect gauge US 1016 to front brake caliper

F·11
Brake fluid changing
Brake pressure regulator
47 8a •
4 7 Brake-Hydraulic Components, R.egulator, Booster
- increase pressure on brake pedal until gauge
connected to front brake caliper reads 100 bar
(1450 psi)
• pressure at gauge connected to rear wheel
cylinder must read 55-65 bar (798-943 psi)
if NO, replace brake pressure regulator
- reinstall regulator

CAUTION

Note installation position. Bolt heads must face

forward (driving) direction.

- disconnect gauges
- bleed brakes
- connect gauge US 1016 to rear wheel cylinder
- bleed both gauges
- depress brake pedal several times

- remove nuts holding regulator

- press brake pedal until both gauges read 50 bar
(725 psi)
- lilt regulator forward 30°

CAUTION

Do not damage brake lines.

4 7 •9 Brake pressure regulator

 Brake-Hydraulic Components, Regulator, Booster
-
Brake booster, checking
- depress brake pedal firmly several times with
engine off to exhaust vacuum in system
- depress pedal with medium pressure and hold
- start engine
• if brake booster is working properly, pedal will
fall slightly and then hold
47
Note
Brake boosters are supplied from two different
manufacturers. They are identified, "ATE" for the
Teves Co. and "BENDIX" for the Bendix Co.
A Teves booster is shown in the illustration.
Complete boosters can be used as replacements for
each other, independent of manufacturer (i.e. a
Teves booster can be combined with a Bendix
master cylinder or vice versa).

CAUTION
Do not repair brake booster. If necessary,
replace.

Brake master cylinder

f 15 Nm (11 tt lb)

@@y

r Filter
always replace

Dampl•g woshe< ,
always replace
0
Check valve, checking
(install in vacuum hose)
- remove valve (arrow) from hose
-blow through valve in direction of arrow (on
housing)
• air must pass through valve
- blow through valve in opposite direction
• no air must pass through valve

F·13
Brake booster
Check valve 47.10
 48

Steering

Index
- Power steering
checking for leaks 48.7
pressure/flow limiting valve 48.1 1
suspension changes 48.6
system layout 48.6
technical data 48.6
- Power steering pump
removing/installing 48.9
repairing 48.1 0
- Power steering pump pressure
checking 48.7
- Power steering system
filling/bleeding 48.7
- Steering column
switches 48.2
-Steering drive/gear 48.4
- Steering lock
assembly 48.3
- Steering wheel/column 48.2
- Tie rods 48.4
removing 48.5
-Troubleshooting 48.12-48.17

48.1
48 Steering

Spacer sleeve - - - - - - - " '

remove together with steering
lock housing
removing Fig. 1
installing Fig . 2 and F1g . 3
fitting dimension Fig. 4
Steering column switches
gap between switch and steering
wheel hub must be 2·4 mm (3/32-5/32 in.).
After installing, tighten shear bolt

Steering lock housing

removing Fig. 1
installing Fig . 2 and Fig . 3
Upper column - - - - - - - - - -l• repairing , see Repair Group 94
assemble with tube first ,
then install , see Fig . 5

Column tube-------.
assemble with column first,
then install, see Fig . 5

Shear bolt
drill out to remove .
Before installing , first set gap between hub and
switch, then tighten until head of bolt shears off

Column brae

I
Plastic ring
press onto tube
I
Spreader r i n g A
~~Spring
I Lower column

Washer ' j
I I _/~
/__ - - - - - _ _ _ } 20 Nm (14ft lb)

WARNING
Do not re -use fasteners that are worn or
deformed in normal use. Many fasten-
ers are designed to be used only once
and may fail when used a second time .
This includes, but is not limited to, nuts, Boot retainer--.._
bolts, washers, self-locking nuts or
bolts, circlips and cotter pins. Always re-
place these fasteners with new parts.

48.2 Steering wheel/column

Steering column switches
G-2
 Steering 48

Fig. 4 Spacer sleeve, Installation dimension

Fig. 1 Steering ock housing, removing
A = spacer sleeve
- pull off steering lock housing together a = 51 mm + 5 mm (2.0 in. + 13/64 in.)
with spacer sleeve b = 2·4 mm (3/32·5/32 in.)

Fig. 5 Upper steering column/column tube,

assembling
Fig. 2 Steering lock housing/spacer sleeve,
Installing
- when installing spacer sleeve, clamp
steering column at top and bottom

Fig. 3 Steering lock housing/spacer sleeve,

installing
- note dimension a of Fig. 4

G-2
G-3
Steering column
Steering lock assembly
48 3 •
48 Steering

WARNING CAUTION

Do not weld or straighten any steering Only use special steering gear grease
components. Replace if damaged. Part Number AOF 063 000 04, or equivalent,
to lubricate steering gear.

Rubber boot
always replace when repairing/replacing
Steering gear - - - - - - - - - - - - . tie rods, or replacing steering gear
not adjustable. To remove,
detach connecting shaft at ~~=~ (18 H lb)*
coupling disc and remove tie rods !rom ~-' replace
steering knuckles . Then take
steering gear out. After installing,
adjust toe, see Repair Group 44

,Ao Nm (14 H lb)*

/ always replace

_r Cotter pin
\ _/ always replace

\._ 30 Nm (22 H lb) Tie rod

1 ..., ..
and advance to next left and right sides adjustable.
cotter pin hole Before adjusting, set steering
to center position, see .

25Nm~Bftlb)
Repair Group 44.
removing Fig. 1
unlocking Fig . 2
locking Fig. 3 /

Transfer gear
cannot be repaired. Lubricate
*Self-locking nuts with steering gear grease

48.4 Tie rods

Steering drive/gear
 Steering 48

US1014

Fig. 1 Tie rod, removing

-press tie ro9 off steering knuckle

Fig. 4 Bushing, removing/installing

- press out or in as shown
• flat surface of bushings must be
vertical when rack is installed in
vehicle

Fig. 2 Tie rod, unlocking

- unlock tie rod (arrow) from steering
gear

Fig. 3 Tie rod, locking

- tighten tie rod to 70 Nm (51 ft lb)
and loc k

G·S
Tie rods 48.5
48 Steering
When working on the power steering
system

CAUTION
Always follow these "rules" for cleanliness
when repairing the power steering system:
1. Clean connections and surrounding area
thoroughly before loosening.
2. Place removed parts on a clean surface and
cover them. Use plastic, paper or lint-free
cloths.
3. Carefully cover opened components or plug
openings if repair is not going to be done
immediately.
4. Install clean parts only.
• do not remove replacement parts from
packaging until just before installation
• do not use parts that were stored
unpacked
5. When the power steering hydraulic system
is opened:
• do not use compressed air in the
immediate area
• do not move the vehicle unless absolutely
necessary

Power steering system layout

Steering gear pinion---,

Steering gear assembly ---1

Suspension changes for power

steering
Technical data for power steering
• steering knuckles are different
• coupling disc {between steering gear pinion and Lubricant capacity 1.25L (1.3 US qt)
transfer gear connecting shaft) has been Type ATF Dexron®
replaced by universal joint System pressure (at idle) 115-120 bar/1668-1740 psi

System repair rules/layout

48 6
•
Suspension changes
Technical data
Power Steering

Steering system, checking for leaks
(engine running)
- rotate steering wheel lock to lock and hold at limit
of travel (no longer than 5 sec.)
- check all line connections and tighten if necessary
- if leak occurs at steering pinion, replace steering
gear assembly
- if steering rack seals are leaking (pull boot off
steering gear to check), replace steering gear
assembly
- check power steering pump for leaks
Steering 48
Power steering system, filling/
bleeding
CAUTION
If ATF level is too low, always check power
steering system for leaks. Always fill and bleed
power steering system with ATF after opening
system for repair. Do not reuse fluid which has
been drained. Always replace power steering
filter in reservoir when changing ATF.

Power steering pump pressure,

checking
Cover Foam material

0-ring

Filter cover

~ line

- connect pressure gauge US 1074 B between

r line pressure line and valve housing (valve in open Max. mark
position)
Min. mark
Note
When installing gauge, turn it upwards as far as
possible.
- start engine and run at idle
- top up ATF in reservoir if necessary
- close valve (no longer than 5 sec.)
- read pressure '--- - - -- - - Suction
• 115-120 bar (1668-1740 psi) fitting
- if pressure differs, check pressure/flow limiting
valve, see page 48.12
- if pressure/flow limiting valve OK, replace power Return flow fitting
steering pump
Power steering reservoir

G-7 Power Steering

Checking for leaks
Pump press~re
Filling/bleeding
48 7 •
48 Steering

- fill power steering reservoir to MAX with ATF

- lift front of vehicle
- with engine off, rotate steering wheel from lock to
lock
- top up reservoir to MAX mark
- start engine briefly several times (switch OFF
immediately after engine starts)
-add ATF until level is maintained at MAX mark

CAUTION
Do not allow reservoir to be pumped dry.

-when ATF level no longer drops, start and run

engine
- rotate steering wheel lock to lock several times

Note
Do not use more force on steering wheel than
necessary to turn wheel.

- add more ATF if level drops below MAX mark

- check that no bubbles appear in reservoir and level
remains constant

48.8 Filling /bleeding

Power Steering
 Steering 48
Power steering pump,
removing/installing

. . - - - - - Sealing rings
20 Nm (14 tt lb)
always replace
Pressure line
to steering gear

Pump
mounting
bracket

Front pump bracket Suction line

from reservoir

20 Nm (14ft lb) L - - - - Sealing rings

always replace

' - - - - Power steering pump

repairing page 48.11

~IF--- :2o Nm (14 tt Ib)

·-.:;.,..__ _ _ _ 35 Nm (25 ft Jb)

loosen to tension V-belt

- - - - - V-belt
size: 9.5x1080mm

P.ower Steering Pump,

removing/installing
48 9
•
G-9
48 Steering

Power steering pump, repairing

Note
r-----~
When repairing pump, replace all parts marked with
an asterisk.
Coat all sealing components with ATF on installation. I
20 Nm (14 ft lb) 7 I
I
Stator - - - - - -
position:
long pins downward
I

I I

I
I Clrcllp• --------------<:~

Housing
I
I
removing/installing Fig. 2

blow through channels

I
I
Rotor------....../
removing/installing Fig. 2

I I
0-rlng•

I I
Pressure/flow
limiting valve
installing Fig. 1
I
I
Housing _ _ _ ___.,
sealing ring oil channel
(arrow) in both housing
halves must line up
checking page 48.12

Valve retainer - _ v. tl"

/J
I
I
20 Nm (14 ft lb) _ _ _ __,

installing Fig. 1 Seat• - - - - - - - -

I removing : use VW 681
installing : drive in to stop
I fill space between sealing lips

Seal support
I with multi-purpose grease

Pump shaft with flange - -

Seal• check for scoring and
wear marks. If necessary,
replace complete pump

48 .1 0 Pump,repalring
Power Steering
 Steering 48
- Pressure/flow limiting valve, checking
Note
Incorrect functioning of pressure/flow limiting valve
causes periodic lack of steering assistance.

- check valve and housing bore for wear

• valve drillings must be completely clear of any
dirt or restriction
• valve must move freely in housing bore
- if maximum pump pressure is not obtained after
checking pressure/flow limiting valve, replace
complete power steering pump

Fig. 1 Pressure/flow limiting valve retainer,

installing

-install angled ends of retainer in housing slot

- press down angled ends with screwdriver

Fig. 2 Rotor and shaft, removing/installing

Note
Rotor and shaft must be removed from housing to
replace pump shaft seal.

- press rotor down

- remove circlip from groove (arrow)
- after installing rotor and shaft, secure circlip by
pulling rotor up

Note
Circlip must fit properly in groove and be secured by

Power .Steering Pump, repairing

Pressure/flow limiting valve 48. 11
48 Steering

Troubleshooting
Use the following procedure to troubleshoot
complaints of heavy or stiff steering:
Test conditions
• vehicle at room temperature
(approximately 68°F)
• vehicle raised on hoist
• steering turned 3 times from lock to lock at
steering wheel

- measure turning torque of complete steering gear at

steering wheel
value tess than
300 Ncm (26 in. lb)*
I value greater than
300 Ncm (26 in. lb)*

I steering system OK I
lgotoAon
page 48.13 I
I End I
*vehicles with
0·1000 km (1600 mi) = 300 Ncm (26 in. lb)
vehicles with
1000-3000 km (1600-4800 mi)
230 Ncm (20 in. lb)
vehicles with more than
3000 km (4800 mi) = 170 Ncm (15 in. lb)

48 •12 Troubleshooting
 Steering 48

r
- remove connecting shaft between steering gear and relay gear
and measure tuming torque again
value greater than 150 Ncm
(13 in. lb)**
I value less than
150 Ncm (13 in. lb)**

lgotoBon
page 48.14 I I go to Don
page 48.16 I
**vehicles with
o-1000 km (1600 mi) = 150 Ncm (13 in. lb)
vehicles with
1D00-3000 km (1600-4800 mi)
= 130 Ncm (11 in. lb)
vehicles with more than
3000 km (4800 mi) = 110 Ncm (10 in. lb)

Troubleshooting 48.1 3
48 Steering

- measure clearance at joint of upper and lower

steering column
a = 3.5 mm (0.138 in.) ~

measurement is measurement is NOT

3.5 mm 3.5 mm

- measure on both the right and left sides, turn

column 90° and measure again
go to Con - correct clearance
page 48.15 to correct:
- rework holes if clearance is different between
sides
- place shims under bracket (upper arrow) to
- measure turning torque again adjust height
value greater than value less than
150 Ncm (13 in. lb)** 150 Ncm (13 in. lb)**

go to Con
page 48.15

**see page 48. 13

4 8 •14 Troubleshooting
 Steering 48
c

- remove relay gear

- measure turning torque on upper splined shaft

value greater than
150 Ncm (13 in. lb)
Ivalue less than
150 Ncm (13 in. lb)

I replace relay
gear
I I relay gear OK I

I End I I End I

15 1\'oubleshootlng 48 .15
48 Steering

-
<f
remove steering gear and measure turning torque at pinion
Note
Do NOT close off hydraulic lines on power steering gears. Drain ATF before measuring turning torque.
value less than 120 Ncm (10 in. lb) I value greater tl)an 120 Ncm (10 in. lb)

- replace steering gear I -check both outer CV-joints and ball joints for
stiffness during movement.
-replace damaged parts.

I End I I End I

48 •16 Troubleshooting

- Troubleshooting
Condition/fault
Fluid level in ATF reservoir low
Fluid level in ATF reservoir low again Additional air trapped in steering
after refilling - no external leaks
evident
Steering effort becomes greater as
wheel is turned
Noises In power steering system
G-17
Possible cause
Air trapped in steering system has
escaped during normal operation
Valve housing seal leaking, ATF leaks
out at steering gear pinion
Leaks at connections on steering
gear, hoses, pump or reservoir
system has escaped during normal
operation
Steering rack seal defective (leaking
fluid is found inside steering gear
boot)
Pressure/flow limiting valve in pump
housing is sticking
Dirt/foreign matter in valve control slot
Insufficient pump pressure
ATF level in reservoir too low
Insufficient pump drive belt tension
Reservoir filter dirty
Loose connection at pump drawing air Tighten pump connections
into system (ATF foaming in reservoir)
Power steering
Steering 48
Remedy
Fill reservoir to "MAX" mark
Replace seal and 0-rings
Check system for leaks and repair
Fill reservoir to "MAX" mark
Replace seal (install complete
repair kit)
Clean or replace pressure/flow
limiting valve in pump housing
Clean valve unit
Check pump pressure and replace
pump if necessary
Fill reservoir to "MAX" mark
Tighten or replace belt
Replace filter
Troubleshooting 48.17
 50

Body

Index
-Acid rain
removing spots 50.6
-Adhesives
materials 50.5
- Body dimensions
door 50.4
floor 50.2
windshield 50.4
-Painting
pop-up roof/luggage carrier 50.5
-Plastics
identifying 50.5
repairing 50.5

50.1
50 Body
14-----1328 ± 8 mm - - . . - l
(52 7/32 ± 1/41n.)

.5 --
E~
E;:
en..-
+t+t
..... co
cn..-
co-
NM
8
c

--
.5
-
CD
C') ......

+t+t
CD CD
............
C')-
C')
......
......
!!!.

•measured 200 mm (7 31/32 in.)
from outer edge of frame rail
• •measured with gauge
± 4 mm---1..!
(39 1/4 ± 5/32 ln.)
.._- -1175 ± 5 mm -----~~
(48 1/4 ± 3/181n.)

50.2 Floor section dimensions

A·2
 Body 50

Please note the following floor dimension

measurements for Vanagon Syncro.
All other dimension measurements remain valid.

Note
Measurement Key
A = 750 ± 2mm (29'/a ± 3
/3a in.)
B = 704 ± 1mm (2731. ± '/"in.)
C = 683 ± 1mm (26 7 /a ± '1,. in .)
D = 225 ± 1 mm (8 7 /a ± 1/ 16 in.)
E = 253mm (9.96 in.)
F = 289 ± 1mm (113/e ± ''•• in.)

00-2221

1-2 A-3 Vanagon Syncro Floor section dimensions 50.3

50 Body

Rear door
J =
1050 ± 2 mm (41 11/32 ± 3/32 in.)
I = 1618 :t 5mm(6311/16 ± 3/16in.)
Front door a = 340 mm (13 3/8 in.)

a = 1157 ± 3 mm (45 9/16 ± 1/8 ln.)

b = 1270 ± 4 mm (50 ± 5/32 ln.)
c = 1564 ± 1 mm (61 9/16 ± 1/321n.)
• largest distance between welded body seams
d = 1566 :t 1 mm (61 21/32 :t 1/32 ln.)
• distance between door contact switch holes

Windshield
k = 723 ± 4 mm (28 15/32 ± 5/32 in.)
I =
1469 ± 5 mm (57 27/32 ± 3/ 16 in.)

Side door
g = 1185 ± 5 mm (46 21/32 ± 3/16 in.)
h::;; 1348 ± 4 mm (531/16 ± 5/32 in.)

50 •4 Door/Windshield dimensions

Identifying/painting and repairing
plastic parts
Refer to the Volkswagen of America Refinishing
Guide, Lit. No. W42-701-008-1.
Body assembly materials
Refer to the Volkswagen of America Refinishing
Guide, Lit. No. W42-701-008-1.
CAUTION
Part numbers are for reference only. Always
check with your Parts Department for latest
parts information.
Identifying/painting and repairing plastic parts
Body 50
Pop-up roof/luggage carrier, painting
Color determination
- locate pop-up roof/luggage color on vehicle
identification plate
- if pop-up roof/luggage carrier is painted in a color
other than the body, consult a color chart for the
correct color code
Surface preparation
- thoroughly clean and dry pop-up roof/luggage
carrier
- roughen surface with steel wool
- reclean and thoroughly leave dust free
Painting
- paint surface with synthetic resin, acrylic, or two-
component paint in selected color
• adhesive promoter is not necessary
Body assembly materials
Pop-up roof/luggage carrier, painting
5Q 5 •
50 Body

Acid rain spots on paint, removing

Note
Applies to all vehicles without acrylic transport
protection

Acid rain spots are most visible under fluorescent

light and look like water spots.
In most cases. you can remove these spots by
performing the following procedures and thus avoid
re-painting.
Do NOT confuse the effects of acid rain damage with
industrial fallout. Industrial fallout consists of small
airborne metallic particles that settle onto the paint and
eventually eat their way into the finish. Rubbing your
hand across the clean surface will reveal a gritty
texture.
If acid rain spot removal is new to you, we recommend
that you contact a good body shop or reconditioning
center.

WARNING
Before using any chemicals or
cleaning compounds, carefully read
all of the cautions and medical
information on the container. Always
follow all of the manufacturer's
recommendations.

Most makers of professional automotive reconditioning

products recommend the following six steps IN
SEQUENCE to repair acid rain paint spots:

Step 1: Inspection

• wash vehicle with mild soap and water, then

dry completely

CAUTION
Do NOT wash or dry vehicle in direct
sunlight. Ordinary water spots could
form and confuse the inspection.

50 •6 Acid rain spots on paint, removing

 Body 50
-
• inspect the following surfaces under a
fluorescent light

• hood, roof, rear deck, tops of fenders, painted

surfaces of bumpers and doors from the belt line
up

Step 2: Neutralization
The continuing effect of the acid must be stopped by
neutralizing.

• mix a solution of baking soda and water

(4 tablespoons per gallon) and stir until
completely dissolved
• apply solution to all affected areas and let
stand for a few minutes before rinsing off
with clear water

j Commercial neutralizing products such as "Blue Max"

by Car Brite® or equivalent work well.

Step 3: Buffing
You can buff by hand or with a low speed orbital buffer
or with a high speed buffer.

CAUTION
It is extremely important that power
buffing be done by an experienced
lg person. If done incorrectly, power
buffing can quickly and easily damage
the paint finish.
Use clean buffing pads at ALL times.

• mask off any trim or glass close to affected

areas
• buff small areas at a time, no larger than
two feet by two feet
• buff using a light polishing compound such
as "Finesse-It" by 3M A, "Acid Rain Creme"
by Car Brite®, or equivalent. Follow the
manufacturers instructions to achieve the
best possible results.

- A·7 Acid rain spots on paint, removing 5~0,. 7

50 Body

CAUTION
Do NOT use general purpose rubbing
or buffing compounds. They are too
coarse for this application and could
damage the finish.

• buff surface until acid spots are removed

Note
Inspect the work surface frequently during
buffing to ensure that only a minimum of
original finish is removed. If the color of the
vehicle shows up on the buffing pad, you have
cut through the clearcoat and you have to
repaint the affected area.

Step 4: Cleaning
• wash vehicle thoroughly with a solution of
mild soap and water
• rinse vehicle with clear water then dry
completely
• inspect vehicle to see if another application
is necessary

Step 5: Polishing
Polish the finish to restore the original luster either by
hand or with a power buffer. Always follow polishing
with an application of wax.

CAUTION
It is extremely important that power
buffing be performed by an experienced
person. If done incorrectly, power
buffing can quickly and easily damage
the paint and finish.
Use clean buffing pads at ALL times.

• buff with polishes such as "Uquid Polish" by

3MR, "Crystal Shine" by Car Brite®, or
equivalent. Follow the manufacturers
instructions to get the best possible results.

50 •8 Acid rain spots on paint, removing

 Body 50
Step 6: Waxing
Waxing (unlike polishing) will seal the finish and
prevent acid rain from leaving spots.
• HAND WAX using clean cheesecloth and a
good quality non-abrasive wax.
If, in extreme cases, you can still see acid rain spots
after the previous six steps, or if the clearcoat has been
rubbed through, it will be necessary to re-paint the
affected areas.

Acid Rain Spot Removal Flowchart

(See detailed instructions on previous pages)
1. INSPECTION
• wash with mild soap and water
• dry completely
• under fluorescent lighting, inspect horizontal areas

Are acid rain/water spots visible?

No
Yes
•
2. NEUTRALIZATION
• wash with neutralization solution

3. BUFFING
• buff with light polishing compounds (clean buffing
pads are essential)

4. CLEANING
• remove buffing compound using mild soap and water
I

5. POLISHING
• to restore luster, polish buffed surfaces

6. WAXING
• hand wax vehicle

SATISFACTORY FINISH WAS OBTAINED

.NoI Yes
I
I End
PAINT REPAIR NECESSARY

Acid rain spots on paint, removing 50•9

 55
Hoods, Lids

Index
-Rear door/lock cylinder 55.2
- Rear lid spring 55.4
- Rubber door stop 55.3 .
-Striker plate 55.3

55.1
55 Hoods, Lids

Washerl
Hinge

10Nm(7ftlb)~~

Gasket~
upto6/82 ~ •;;;:..~1u

Au bber waahera
Clrcllp

Washer

17·
~~, waaher
··,

Cap

Lock w~ hen installing.

h lock cylinder
do not tilt w t operation,

~usting
A bber door atop
Fig. 3
To
lockensure
cylinder
horizontally
correc
must be installed

Striker pia~
adjusting Fig. 4

55.2 Rear door/lock cyIinder, assembly

 Hoods, Lids 55

l='lg. 1 Rear door, removing

- pry off circlip (arrow A) and pull off gas
spring from ball headed stud
- disconnect rear window defogger wire
connection (arrow B), connection for Fig. 3 Rubber door stop, adjusting
heated side mirror, remove ground cable
- adjust rubber stop 1, by screwing in or out
and pull wiring harness out of rear door
until rear door is flush with outer panel
- remove socket head screws (arrow C)
and take off rear door

Fig. 2 Rear door, adjusting

- loosen hinge socket head screws and
move door up or down as necessary
• a = 12 ± 1.0 mm (15/32 ± 3/64 in.)
- move door to left or right to obtain even
gap at rear door sides
Fig. 4 Striker plate, adjusting
- loosely attach striker plate (arrow)
- close rear door
- open rear door and tighten screws
• 10 Nm (7ft lb)

A·12
Rear door, removing/adjusting
Rubber door stop, striker plate, adjusting
55 3 •
55 Hoods, Lids

Rear lid variable gas spring

For complaints that rear·lid gas spring causes rear
hatch to open completely, such that lid is too high
for some people to reach to close, correct as
follows:

install new-type variable gas cylnders, Part No.

251829331 B/332 (in pairs only). These cylinders
allow the rear hatch to stay open in various
positions

Note
New-type gas cylinders are installed in current
production vehicles (starting May, 1982;
VIN No. 25 CH 126332)

CAUTION
Part numbers are for reference only. Always
check with your Parts Department for latest
parts information

55.4 Rear lid spring

 57
-
Body
Front Doors

Index
- Front doors
adjusting 57.5
assembly 57.2
glass 57.4
guide channel 57.5
handles 57.3
lock/lock-rod 57.3
power door locks 57.6
whistling noises, eliminating 57.10
window regulator 57.4
- Lost/broken keys
code location 57.8

57.1
57 Body - Front Doors

Note
When disassembling door, remove in numerical
order; install in reverse order.

@ Window front guide channel

Quarter-window glass with recess seal
when installing, glue seal, removing page 57.5
overlap areas to window front
and upper guide channels @ Window upper guide channel (i) Door window glass
install starting at corner removing, Fig. 5
installing Fig. 6
@ Door handle, outer
coat threads on bolts
with 06 locking compound
before installing
~~~~~::":':'ZE:EEEE==::;:::=::::;:::=:::::s=:z::==:~~5z::::::z::::;::~~removing Fig. 2

r--~'#+-1- @ Window slot

G) weatherstrip,
, -.:+lf-1-- Door handle (Inner) with connecting rod lnnerfouter
removing Frg. 1 press into
window seal clips

Door-lock button

Locking rod with slaeve

plastic lugs on sleeve
must engage in opening
installing Fig. 4

oloan thread:"~ and apply

US IOOkina oomoound
Defore lnllallina

(!) Door lock

removing, Fig. ~
installing Fig. 4

Bolts
clean threads and
apply 06 locking
compound before
installing

@ Door handle seal

Front air duct seal

install so that longer
sealing lip is toward
inside of vehicle

57.2 Front door, assembly

 Body - Front Doors 57

md

Fig. 1 Door handle (Inner) with connecting rod,

removing Fig. 3 Door lock, removing
-remove bolts (arrows) - remove two socket head screws
- detach connecting rod and remove door (arrows)
handle - pull door lock out of locking rod sleeve
and remove lock complete with
connecting rod

·157-1261
Fig. 2 Door handle (outer), removing
- remove door weatherstrip and remove
screw (arrow)
- push door handle to front of vehicle and
remove

Fig. 4 Door lockllocldng ..-od, Installing

- set locking rod 1 in installed position
- push locking sleeve 2 through door
opening 3 so that plastic lugs prevent it
from springing back
- push sleeve 2 onto locking lever and at
same time install door lock

Door handles, Inner/outer, removing

Door lock/locking rod, removing/Installing
57 3 •
B-3
 57 Body- Front Doors

- -- - - - -- -~
Window regulator, removing

Fig. 5 Door window gle~ss, removing

- wind window down slightly
- remove two bolts (arrows) from window - remove bolt (arrow)
regulator
- push door window up fully and remove

-remove bolt (arrow) from underneath door

ls7-130 f"

Fig. 6 Door window glass, Installing

- loosely attach window glass to window
regulator (arrows)
- wind up window fully
- align window in front window guide and
upper window guide channel
- wind window down slightly
- tighten bolts through hole in inner door
frame

- remove window regulator seal

-remove bolts (arrows)
-bend back metal lug 5 and remove window
regulator

B-4

57.4 Door window glass, removing/installing

Window regulator, removing
 Body - Front Doors 57
Window front guide channel, Front doors, adjusting
removing
Note
Front door is correctly adjusted when there is an
even gap all around door when shut. Door and body
belt-line must align and door must be flush with
body.

- pull off weatherstrip and remove screw (arrow)

- i f door does not line up with outer panel, or an

even gap does not exist all around , loosen hinge
bolts (arrows) and move door as required

- remove bolt (arrow)

- pull guide channel down and remove

Window front guide channel,

installing
- adjust door at rear by moving striker plate
Reinstall all components in reverse order of removal.
(arrows)

8-5
Window front guide channel, removing/installing
Front doors, adjusting
57 5 •
57 Body - Front Doors

Starting March 1986, power door locks are available Power door lock motors, installing
for Vanagon vehicles.
Installation is in reverse order of removal noting the
Power door lock motors, removing following:
-carefully reinstall plastic moisture barrier, replace
- disconnect battery ground strap if damaged
- remove door trim panel - check locks for proper functioning
- carefully pull off plastic moisture barrier as
necessary Sliding door lock motor, removing
- pull off electrical connection for power window
switch
- pull off electrical connection from power door lock
motor

(j
A - power door lock motor
B-lock rod
C - remove control lock
- disconnect battery ground strap
-remove doortrim panel
- pull off electrical connection from power lock
motor
- remove two sheet metal screws
- take out power door lock motor
- remove sheet metal screws
- remove power door lock motor
Sliding door lock motor Installing
Installation is in reverse order of removal noting the
following:
• check lock for proper functioning

57.6 Power door lock motors, removing/Installing

Sliding door lock motors, removing/Installing
From March 1986
 Body- Front Doors 57

Operating knob unhook to remove motor

Rear lid

Mounting holes

B-7
From March 1986 Rear lid door lock motor,
assembly
57 7
•
 57 Body - Front Doors

Rear lid door lock motor, removing Power door lock motor/bracket
installation, spare parts only
- disconnect battery ground strap
- remove rear lid trim panel
- pull off electrical connection from power door lock • Outside vehicle Power door lock motor
motor

Power door lock motor

• Outside vehicle

• Inside vehicle ¥ ~m"<?

. Mjounntlng holes

Pop rivets f ..JP ~

• Inside vehicle
l ~~lngholes
c:f:> "'9
'

Replacement rear lids are provided with holes pre-

punched for pop rivets in the inner sheet metal.
a a ls1-2a2l
Additionally, both mounting holes for fastening power
door lock motor to bracket are provided.
- remove sheet metal screws
Installing
Note - position bracket and fasten with pop rivets
Sheet metal screws are recessed into rear lid frame.

- remove power door lock motor

Rear lid door lock motor, Installing

Installation is in reverse order, noting the following:
• check door lock for proper function

-from inside of lid drill two 4 mm (5/32 in.) holes

for lower pop rivets

Note
Drill bit must extend at least 65 mm (2.5 in.) out of
chuck.
- remove any burrs from holes and touch up with
paint and corrosion protection
-install rivets (arrows) from outside with a riveting
tool

B·B 57.8 Rear lid door lock motor, removing/installing

Power door lock motor/bracket Installation, spare parts only
From March 1986
 Body - Front Doors 57
Lost/broken keys, key code

ls7-A0581
In the event of a lost or broken key, the key code
can be obtained from three possible locations on the
outside door handle (after removal).
A - Release lever.
B - Front hold-down hook.
C - Transfer lever

8-9 Lost/broken keys, key code 51 •9

57 Body-Front Doors

Whistling noises, eliminating

Since the routing of ventilation from driver's door to
rear side windows, whistling noises have occurred at
approximately 70km (42 mph), or when vehicle is
parked and fresh air blower is running at 2nd or 3rd
speed.
Teat drive vehicle to determine location.

Whistling noises from center of Instrument panel,

eliminating

- check fit of door seal at area over window guide

(arrow)
• seal with adhesive D 002 100 or equivalent

Note
Procedure applies only to vehicles with:
• gearshift lever bracket Part No. 251 711 231A
• without raised center instrument panel
• up to YIN 25JH087797
- pull up boot 1
- seal assembly holes (arrows) with 5.0mm
(13164 in.) dla. bead of adhesive strip
AKD 476 KDS 05 or equivalent

Whistling noises at drlver's/passenger front door,

eliminating
- check and adjust driver's/passenger front door as
required

- check for secure fit at quarter window (arrow A)

replace if necessary

57 •1 0 Whistling noises, eliminating

From 1988 my
 Body- Front Doors 57
-
- check bonding at overlap area of seal (window
guide and channel seal) (arrow B)
• reseal with adhesive D 002 100 or equivalent

- check fit of door glass in guide when closed

• adjust as required

- check plastic moisture barrier for damage

• replace or resecure as necessary
- seal opening for cables for door speakers, power
windows or mirrors, if equipped (arrow)
- check correct fit of foam for window crank 3,
inside door opening mechanism 2
j

___]
- check bracket seal (arrow)
• replace if defective

- pry out seal for front air channel seal 4

- seal gaps with sealant AKD 476 KD5 05 or
equivalent at inlet area of door air channel
- reinstall seal for from air channel 4

11
From 1988 my Whistling noises,
eliminating
57.11
57 Body-Front Doors

- remove door
-seal cowl weld flange (arrow A), door hinges
(arrow B)
- test drive or operate fresh air blower and check
for whistling noises

57 •12 Whistling noises, eliminating

From 1988 my
 58
Body
Rear
Doors

Quick Data Index

Center hinge
-Adjusting 58.9
-Assembly 58.8
-Removing/installing 58.9
Sliding door,
1980-1984 m.y. !
!
-Bowden cables
adjusting 58.7
-Door cover 58.3
!
-Door handle
inner/outer 58.3
-Door lock buffer 58.3
Lock, front 58.2
Lock, rear 58.6
-Lock plate, remote control 58.6
-Lubricating 58.7
-Removing/installing 58.4
-Striker plate, adjusting 58.5
Sliding door,
from 1985 m.y.
-Assembly 58.10
-Central lock 58.20
-Door cover 58.11
-Handle 58.22
-Hinge link, adjusting 58.16
Hinge link, assembly 58.21
- Modifications 58.11
-Remote control lock 58.18
-Removing/installing 58.12
-Roller guides
adjusting 58.14
-Striker pin, adjusting 58.15

H·1
Index 58.1
58 Body -Rear Doors

- ; " ' - - - - - - - Outer door handle

removing Fig. 1

,..---- Front sliding-door lock

removing Fig. 3

Trim ring

clean threads and install

with D 6 locking compound

Door-lock knob

Door lock buffer - - - - '

-+--+--- Inner door handle
removing Fig. 1
removing/installing Fig. 3

58 •2 Front sliding door lock

1980-1984
 Body - Rear Doors 58

Fig. 1 Inner/outer door handles, removing
- remove Phillips screw 1 and take off inner
handle
- remove screw 2 and remove outer handle
together with seal and, trim ring
Fig. 3 Front sliding-door lock/door lock buffer,
removing/Installing
- remove three screws (arrows)
- remove lock buffer 11
- slide front sliding-door lock 12 out
- install in reverse order

t)le Note
ig. 2
Coat threads of screws for door handles with
D 000 600 locking compound or equivalent before
installing.

Sliding door cover, removing

Note
Before sliding door can be removed, cover for center
guide rail must be removed. Cover and plastic
beading are pressed together into U-shaped channel.
.II
lund
Fig. 2 Release cable/door-lock knob, removing
- remove circlip 3 from release cable 8 and
rod 4
- loosen securing nut 5 and adjustment nut
6 toward front sliding-door lock
- pry out nut 7 and lift out release cable
mdle and rod
I· 1 - remove lock plate 9 by removing screws
(arrows)
- remove door-lock knob 10

-remove Phillips screw (arroYtr 1

more

C-3 1980-1984
Sliding door cover/Inner/outer door handles, removing
Release cable/door-lock knob, removing
Front sliding-door lock/door lock buffer, removing/Installing
58 3•
58 Body - Rear Doors

Sliding door, removing

- remove cover

- remove Phillips screw (arrow)

- slide door back until roller and safety guide can
Note be lifted from guide rail at cut-outs (arrows)
Phillips screw in area of door lock can only be
removed with door partially opened.
- remove cover, starting at rear, using hammer and
plastic wedge

Note

Since cover will be firmly seated after it has been in

place for some time, apply silicone spray first to ease
removal.

Sliding-door cover, installing

Note

To make installation of cover with plastic beading

easier, first glue beading to cover with
AKD 476 KD5 05 adhesive or equivalent. - slide door back until upper guide (arrow) can be
removed
- install cover by pressing lip with beading into
U-shaped channel
- drive in fully with hammer and plastic wedge
-using belt-line as reference, align cover with rear
corner panel and sliding door. Beading must be
seated evenly all around
- install both Phillips screws

58.4 Sliding door cover, Installing

Sliding door, removing
1980--1984
 Body - Rear Doors 58
- if door height at front is not correct, adjust guide
carrier A
- adjust height of upper door guide with minimum
play between guide and guide rail

- tilt door slightly away from car

- pull lower lateral and horizontal rollers (upper
arrow) out of cut-outs in guide rail (lower arrow)

Sliding door, installing

- i f door does not line up with upper door opening,
- check guide rails, replace if necessary
remove protective cap on bolt and adjust by
-check upper center, and lower guides/rollers,
relocating guide block C
replace if necessary
- after adjusting, check fit of door over entire travel
- replace plastic beading on cover or reattach with
- if fit still incorrect, adjust striker plate
AKD 476 KD5 05 adhesive or equivalent
- insert door into l'owef guide fail first and "then into
upper guide rail Sliding-door striker plate, adjusting
- slide door forward far enough to insert roller and
safety guide into cut-outs of cenief guide 'rail ·
- check operatiQn of· sliding door by repeated
opening and closing. If necessary, door may have
to be adjusted
- reinstall cover

Sliding door, adjusting guide/roller/

guide carrier

• sliding door can be adjusted by moving striker

plate in direction of arrows

Note
After striker plate adjustment, always adjust sliding-
door center hinge (page 58.9).

- if door does not line up with door opening,

readjust lower guide/roller assembly 8

C-5 1980-1984 Sliding door, Installing/adjusting

Sliding door striker plate, adjusting
58 5 •
 58 Body- Rear Doors

Front sliding-door lock plate, Rear sliding-door lock, Installing

adjusting
Note
Bowden cable is protected by clip from disengaging
from lock. Changing of clip can only be done after
removal of rear sliding-door lock.

- loosen lock plate slightly

- close door from inside to center lock plate
- hold lock plate in position and open door - to prevent rattling noise, foam rubber pads 14 and
- tighten both screws securely center guide 15 must be installed
- after lock plate is adjusted, check that door locks
easily from outside with key and with lock knob
from inside. If necessary, instatt one or two
spacers behind lock plate

Rear sliding-door lock, removing

- turn locking pawl to locked position while pulling

inner door handle
- pull out Bowden cable from center guide
(15 on illustration 58-202)
- remove three screws (arrows)
- remove rear sliding-door lock 13

58.6 Front sliding door lock plate, adJusting

Rear sliding door lock, removing/installing
1980- 1984
 Body - Rear Doors 58
Bowden cable, adjusting Bowden cable adjustment, checking
- adjust door for correct fit in door frame
- if door does not close properly, adjust door striker
plate and center hinge (see pages 58.5 and 58.9)

Sliding door, lubricating

- tum locking pawl of rear sliding-door lock to

locked position while pulling inner door handle
- insert 4 mm screw 16 into opening 17 and fasten
actuating lever

Bowden cable for remote control

lock, adjusting

Side Panel runner

- engage Bowden cable 8 on pull-rod 4 of front

sliding-door lock and secure with clip 3
- press nut 7 into opening of front sliding-door lock
- press in guide for Bowden cable
- guide pull rod of front sliding-door lock through Lower roller track
adjustment screw 6 to mounting point 18 of pull
rod
Note
- secure adjustment screw 6 with lock nut 5
For the sliding door to work properly, it must be
lubricated at the side-panel runner and lower roller
track at front end where door goes in.
-clean runner and roller track with an oil-soaked
cloth
- apply a thin coat of multi-purpose grease to
each roller track (arrows)

C-7
1980-1984
Bowden cables, adjusting
Sliding door, lubricating 58.7
58 Body - Rear Doors

Lower/upper locking Ievere

- remove roller with bushing
- remove circlip from locking
lever pin
- press out locking lever pin and
remove both locking levers with
swivel spring
- lubricate moving parts with
G 4 grease before installing

~~=!~~) ______ Swivel aprlng

----Spacer sleeve
Seal Roller pin

Houalng - - - - - . . .

Tenalon aprlng --------J.

- remove circlip and detach spring
housing logether with spring
mount from hinge link
- remove pin from spring attachment
and take off spring
- when installing, attach spring to
pin in housing first and then insert
hinge link in housing and spring
mount Guide-----'
- grind off rivet to remove
Roller with buahlng - install with screw, nut
press pin out and remove and lockwasher and pleen nut
roller with bushing

58.8 Sliding door center hinge

'
1980-1984
 Body - Rear Doors 58
Sliding-door center hinge, removing Sliding-door center hinge, adjusting

--

- before installation of sliding door, tighten front bolt

Note 1 of sliding-door center hinge to 23 Nm (17 ftlb)
- hand-tighten bolls 2
Center hinge can only be removed when sliding door
has been removed. - install sliding door and close from outside
- check front and rear gap, correct if necessary
-remove bolts (arrows) and remove hinge after loosening bolt 1
assembly - after correction is made, retighten bolt to 23 Nm
(17 fl lb)
Sliding-door center hinge, Installing
\

lsa-3131 - pry down on guide carrier (arrow) until guide/

roller 3 is positioned on center guide rail

-before installing lubricate with oil (arrows)

- lubricate return spring 6 with multi-purpose grease
-after installation, adjust hinge assembly

- open sliding door carefully while supporting rear

of door in area of belt line
-tighten bolts 2 to 23 Nm (17 fllb)

C-9
1980-1984 Sliding door center hinge, removing/Installing
Sliding door center hinge, adjusting
58 9 •
58 Body - Rear Doors

Edge protection - - - - - - - .

----Seal

Washer

Doo<handle,ou... ~

Escutcheon~

'"'

Lock washer
Terminal for power door locks
for vehicles with power door locks

Locking knob
Power door lock motor
Door handle, outer
Phillips screw
3.4 Nm (2.5 ft lb)
secure with locking compound D 000 600

Bearing arm roller guide - - - '

58.10 Sliding door, assembly ·

From 1985 m.y.
 Body - Rear Doors 58
Sliding door, modifications Sliding door cover, removing
(1985 model year) Note

The sliding door has been redesigned for the 1985
model year.
Some of the following procedures differ from those
for earlier models.
Before sliding door can be removed, cover for center
guide rail must be removed. Cover and plastic
beading are pressed together into U-shaped channel.

Procedure Page
Sliding door cover, removing/installing 58.11
Sliding door, removing/installing 58.12
Adjustments to sliding door
a lower roller guide 58.14
10r b upper roller guide 58.14
c striker pin with hinge link 58.15
d hinge link 58.16
Remote control lock 58.18
Central lock 58.20
Hinge link/parts subject to wear, replacing 58.21
rver
,,"'
Problem"\ Adjustment - remove Phillips screw (arrow)
Door height at front incorrect a
Door height incorrect c
Door is not flush with outer contour
of B·pillar at bottom a
Door not flush with outer contour
Ktlt
of C-pillar c
It lb) Front of door not flush with outer contour
of B-pillar at top b
Gap around door differs front to rear C, d
acrew
1)
When opening from outside, door sticks
in C-pillar area d

- open sliding door slightly

- remove screw (arrow) at front of cover
- spray beading with silicone or similar lubricant
- using hammer and plastic wedge, carefully tap
cover out towards top. Start from rear and work
oor locks forward.

Sliding door cover, installing

- glue beading to cover with adhesive or equivalent
- press cover and beading into securing rail and tap
downward with hammer and plastic wedge
- check position of cover relative to body lines of
rear panel and sliding door. The beading must
make even contact along entire length
- reinstall screw (arrow)

Sliding door, modifications •,

C-11 From 1985 m.y. Sliding door cover,
removing/Installing 58 11
58 Body - Rear Doors

Sliding door, removing

- remove sliding door cover

- swing door outward and pull guide and bearing

rollers out of guide rail opening

Sliding door, Installing

- push door back until roller carrier 1 is positioned
- check. and replace door seal if necessary
beneath recess in guide rail (arrow) /-~

- lift door at rear and pivot roller carrier 1 out of "\

Note
guide rail
- lower door slightly and pivot hinge link upper Before applying adhesive, Part Number AKD 476 KD5
rollers 2 out of guide rail or equivalent, ensure that the old adhesive has been
completely cleaned off.

- push door back as far as possible and lift at rear

until upper roller can be taken out of guide rail

58.12 Sliding door, removing/installing

From 1985 m.y.
 Body-Rear Doors 58
-
- check upper roller guide and lower bearing and
guide rollers on door. Replace if necessary
- insert door in lower guide rail first, then in upper
guide rail
- push door forward until bearing roller of carrier
is located in guide rail recess area

- insert guide rollers into rail

- pivot roller carrier in direction of rail and locate
bearing roller on guide rail beneath recess
-check operation of door during opening and
closing. Adjust door as required
- install sliding door cover
Iss -22s1

Iss- 22sl

-check upper 3 and lower 4 stops and replace

if necessary

Iss- 2211

-lightly lubricate front opening of lower roller

guide with multi-purpose grease (shaded area)

From 1985 m.y. Sliding door,

Installing 58.13
58 Body - Rear Doors
Sliding door, adjusting
Note
Two mechanics are required to perform the adjust- The door waistline (depression) must be in line with
ment operations on the sliding door. that on the body. Also, the door must not be posi-
tioned too far in or out.
The sliding door is correctly positioned when the
gap with the door closed is even all the way
around.

Socket head b o l t s - - - - - - - - . . /
M8x 18
23 Nm (16.9 ft lb)

I58. 228l
a - Adjusting lower roller guide -from inside vehicle, loosen bolt on door
side slowly
• Door height incorrect at front:
-when door is flush with B-pillar outer panel,
- relocate bearing arm roller guide by loosening retighten bolt
upper bolts and moving door to proper height. - open door and tighten both bolts to specified
Retighten bolts to proper torque torque
• Front of door not flush with outer contour of
b - Adjusting upper roller guide
B-pillar at the bottom:
• Front of door not flush with outer contour of
B-pillar at the top:

...,.,,~~/'-----Upper roller
guide assembly

Iss -2291

- push plastic cap in floor up from beneath vehicle

- loosen two bolts fastening lower roller guide
assembly
-press roller guide as far as door stop and tighten -remove cap
bolt on door side only - loosen bolt and reposition roller in elongated
-carefully close door hole. Retighten bolt to proper torque

58.14 Lower roller guide, adjusting

Upper roller guide, adjusting
From 1985 m.y.
 Body - Rear Doors 58
c • AdJusting striker pin w/hlnge link
• door not flush with outer contour of C-pillar
• door height incorrect
• gap around door differs frontto rear

- insert plastic spacer clip (arrow) in lock opening

Note
New locks are supplied with plastic clips.

- open door and remove beading from C-pillar

(arrows)

Note
Each time before repositioning or installing the striker
pins, the hinge link bolts must be loosened and the
link must be pushed upward and to the rear as far as
possible (arrows). The bolts should be tightened by
hand only. 1 Striker pin
2 Spring plate
(collar must always face outward)
3 Adjustment aid line for striker pin
4 Striker pin/spring plate mounting bracket

- install striker pin 1 and spring plate 2 to mounting

bracket 4. Ensure that spring plate is located
centrally in adjustment line 3
- slowly push door to front, lifting door slightly at
same time in waistline area

C-15
From 1985 m.y. Striker pin with hinge link,
adJusting
58 .15
58 Body - Rear Doors

d - Adjusting hinge link separately

-with door closed, check for height and flushness
with outer panel at center of door. Measure • gap around door differs
amount of correction needed • when opening door from outside, door sticks in
- open door and mark amollnt of correction on C-pillar area.
striker pin mounting bracket
If the striker pin does not .need repositioning, the
-move striker· pin into position marked hinge link can be adjusted separately:
- close door and recheck position in opening
- when door is correctly adjusted for height and
flushness with outer panels, loosen hinge link
bolts ~
- align door longitudinally from outside using plastic ~
wedge
Hinge link arm

~Waahar

ZM8x15
23 Nm (17 ft lb)

t------------------------ls~s~l

- pull roller carrier 1 down by hinge link until bearing

roller rests on rail 2
- tighten hinge lin~ bolts from inside
-open door and remove spacer clip from lock
- tighten all bolts to correct torque
• hinge link bolts: 23 Nm (17 ft lb)
• striker pin: 50 Nm ± 5 (36 ft lb ± · 3.6)
- install beading on C-pillar flange

- open door and remove beading from C-pillar (arrows)

- remove door complete with hinge link out of
center guide rail (see sliding door, removing/
installing) and rest rear of door on suitable
support
- loosen hinge link bolts

58.16 Striker pin with hinge Unk, adjusting

Hinge link, adjusting
From 1985 m.y.
 Body - Rear Doors 58

........ ........

(®t
-----

- push hinge link upward and to the rear as far as

possible (arrows). Hand tighten boHs
- hang door with hinge link into center guide rail

r------------------ ~~~I
- insert piece of wood or plastic wedge 3 between
roller carrier and rail 2 until roller 1 rests on rail 2
- tighten hinge link bolts from inside
• tightening torque: 23 Nm (17 tt lb)
- open door and remove spacer clip from lock
- install beading on C-pillar flange

-insert plastic spacer clip (arrow) into lock opening

- carefully push door to front slowly, lifting door
slightly at same time in waistline area
- loosen hinge link bolts from inside vehicle
- check door gap at front and rear and adjust door
with plastic wedge

WS)

C-17
From 1985 m.y. Hinge link, adjusting 58.17
58 Body - Rear Doors

Remote control lock

Phillips head screw

secure with D 000 600
3.5 Nm (2.6 tt lb)

-----Phillips screw
10 Nm (7 tt lb)

Catch plate

Locking knob

58.18 Remote control lock, assembly

From 1985 m.y.
 Body - Rear Doors 58
Remote control lock, removing

1 -remove circlip 6 from.remote control lock pin and

remove cable 7
- remove screws 1 and 2 from inner and outer door - remove screw (arrow) and pull remote control
handles lock out between door inner and outer panels
- remove inner and outer door handles and spacer
washer Remote control lock, Installing
- push lock in between inner and outer panels,
align catchplate and screw loosely in position
- coat inner and outer door handle fastening screws
with 0 000 600 or equivalent and install
- install cable on remote control lock pin and secure
with circlip
- tighten lock securing screws

Note
For tightening torques see Fig. 58-238 on preceding
page.
- install locking knob

- remove catchplate 3
- remove locking knob 4 .
- remove door latch plate 5

C-19
From 1985 m.y. Remote control lock,
removing/Installing
58.19
58 Body - Rear Doors

Central lock, removing

- remove circlip 4 from pin on remote control lock

and remove cable 3
- remove screws 2 (see Fig. 58-239)
- remove central lock with cable
- remove circlip 4 and remove cable from central
lock (see Fig. 58-239)

Central lock, installing

- install cable on central lock pin and .secure with
circlip
1 Central lock - push cable into door and push foam pad onto
2 Countersunk screw cable
• 23 mm (17ft lb) - screw lock to sliding door
3 cable • tightening torque~ 23 Nm (17 ft lb)
4 Circllp
5 Sliding door/rear contact surface - install cable on remote control lock pin and secure
6 Foam cable pad with circlip
• 20 mm (25/32 ln.) - stick foam cable pad to center of door

Note
The central lock can be removed and installed with
the door on the vehicle.
- remove sliding door trim panel

58.20 Central lock,

removing/Installing
From 1985 m.y.
 Body - Rear Doors 58
Hinge link/parts subject to wear,
replacing
Note
All Illustrated parts are available as Individual
items. Replace only those parts which are actually
damaged.//
---------

~~Bearing roller asaembly

Lower hinge link seal - - - - . / ~~·-·

~~Nut 2.5 Nm (1.8 ft lb)

·;. . , Lower hinge link seal

C-21
From 1985 m.y. Hinge link, assembly 58 •21
58 Body, ~ Bear Doors
Outside sliding door handle with
option M145, installing
(Transporter, Canada only)

Note
When performing repairs to the sliding door or loc;k,
it has been found that the outer door handle locking
cylinder is often being damaged as a result of
incorrect installation.
Before re-installing the handle, turn the lock with the
key so that the locking tab is fully retracted (arrow).

58 •2 2 Sliding door handle, installing

From 1985 m.y.11 Transporter - Canada only
 60
Sunroof

Quick Data Index

-Guide plate adjusting 60.4
Height alignment, front 60.3
-Height alignment, rear 60.4
-Parallel adjustment 60.4
-Rear drain hose
replacing 60.6
-Sunroof panel
adjusting 60.3
removing/installing 60.2
-Sunroof trim panel
- removing/installing 60.3
-Sunroof water drains
cleaning 60.6

H·1 60.1
J
60 Sunroof

Sunroof panel, removing

-remove both Phillips screws (arrows) from front

guide
- open sunroof panel slightly
-snap out 5 trim-panel clips (arrows) at front edge
of sunroof with plastic wedge

To remove sunroof panel

- push trim panel to rear as far as stop (arrow) -lift panel at front (arrow)
- lift out panel at rear through openings in guide rail

Sunroof, installing
- install in reverse order of removal

. . .. .; ~

- pull sunroof panel forward

• stop pulling before lifter starts activating
- swing leaf spring 1 to center
- pull crank 2 out of support 3

6 0 •2 Sunroof panel, removing/installing

 Sunroof 60
Sunroof trim panel, removing
- remove sunroof panel

- remove screws of rail 3 on one side

- push ran to rear and tift together with sunroof trim
panel 5
- remove sunroof trim panel 5 by slightly pushing
rail 3 to outside
- remove drive handle
- loosen both Phillips screws (arrows)
approximately 6 turns Sunroof trim panel, Installing
- detach cables at drive
- install in reverse order of removal

Sunroof panel, adjusting

- detach trim panel first and push to rear (see
page 60.2)

Height alignment, front

- remove guide block 1

- move guide plate 2 to front and slide out of rail 3

A
tb_B

- loosen Phillips screws (arrows A)

-align sunroof panel by turning adjusting screw
(arrow B)
- tighten Phillips screws (arrows A)

- move cable guides 4 to front and slide out of rail

3 with cable from opening

D-3
Sunroof trim panel, removing/Installing
Sunroof panel, adjusting
Height alignment, front
6O 3 •
60 Sunroof

Height alignment, rear

- lower sunroof panel

- lower sunroof panel at rear
- swing leaf spring 1 to center
- pull crank 2 out of support
- loosen nut 7 and screw 8
- adjust front height alignment by moving pin 9 in
crank slot 2
- tighten screw 8 and nut 7
- slide crank 2 into support
- close sunroof and check height alignment
• readjust if necessary
Guide plate, adjusting
Note
- loosen Phillips screws (arrows C)
- adjust guide plate 10 in height by turning adjusting
screw {arrow D)
• guide plate 10 must not have play in rail
(arrow X)
- tighten Phillips screws (arrows C)
Note
Misadjustment of guide plates can cause noises and
make sunroof hard to open and close.
Parallel adjustment
,..... first detach trim panel and push it to rear (see
page 60.2)

Always adjust guide plates after sunroof panel rear-

height alignment.

- lower sunroof panel at rear (turn drive handle

- adjust guide plate 10 with sunroof panel closed
and plates located above slot in rails (arrow)
approximately 2 turns counterclockwise)
- remove handle and cover plate
-loosen both Phillips screws (arrows)
approximately 6 turns
- detach control cables at drive
- move sunroof panel forward and back in guide rail
several times by hand

Height alignment, rear

60.4 Guide plate, adjusting

Parallel adjustment
 Sunroof 60
\
\

- push panel to front stop - install cover plate

- press panel upwards by hand at rear ~ install drive handle so it rests in recess when
- tum both cranks 2 into upright position sunroof is closed

Note
If necessary, replace both control cables.

Note
The sunroof operates with cables exposed. This is
so if cables are replaced or panel is hard to move,
cables may b.e lubricated with multipurpose grease.

- turn drive, wHh handle attached, to the right

to stop
- lubricate control cables and attach to drive

D-5 Parallel adjustment 60.5

60 Sunroof

Sunroof water drains, cleaning Rear water drain 'hose, replacing

Front - carefully loosen headliner at rear door opening
~ pull hose 12 off pipe, and from 'grOI'Tlrnet 13
- pull out flap 11 and clean
- install new hose in reverse order
Rear
Note
- clean hose opening in air intake duct (arrow)
.Grommet 13 can be rePlaced or adjusted without
loosening headliner by going through the air intake
Note duct.
Use a speedocable to clean out drains.

60.6 Sunroof water drains, cleaning

Rear water drain. hose, replacing
I 61
~
Tarpaulin

Index
-Tarpaulin 61.2, 61.3
(Canada)

61.1
-' 1·7
Index
61 Tarpaulin

Tarpaulin frame and tarpaulin,

service installation

- drill two 10 mm (3/8 in.) diameter holes, one at

each dimple located at rear corners of load
platform (arrow)

CAUTION -clean rain channel (arrows) and stick sealing strip

Drill carefully through floor plate and do not A in position
damage captive nuts underneath. Touch up - remove plastic plugs from holes at each front
drilled holes, apply corrosion protection as comer of load platform
required.

-drill 8.5 mm (21/64 in.) diameter holes at dimples

in each side of cab rear panel (arrow)

- mount rail B at front corner and fasten securely to

floor with bolt 1 and washer 2

61.2 Tarpaulin, service installation

Canada
 Tarpaulin 61

- mount rear rail to floor with boH 1 and washer 2 - install deflector plate E in position and securely
- press rubber buffers 3 into both sides of rail D fasten to rail B and cab rear panel with bolt 4,
washer 5 and nut 6
- mount and align tarpaulin on frame starting at rear

Note
Three mechanics are required to install tarpaulin.

- mount longitudinal rails C .in position and fasten to

front and rear rails with countersunk screw and
nut L

Note
Upon reassembly after dismantling frame,
countersunk screws are to be installed with 06
locking compound.

- fasten tarpaulin frame G to rail B at front with bolt 7

Note
The tarpaulin frame must seal tightly in the rain
channel (arrows).
Tailboard bump stops which do not line up with the
tarpaulin can be removed and the holes plugged.

D-9
Canada Tarpaulin, service Installation 61.3
 63
Bumpers

Quick Data Index

- Front bumper/spoiler
removing/installing 63.2
-Rear bumper
removing/installing 63.3

G·S 63.1
63 Bumpers

Allen head bolt

6.5 Nm {4.8 ft lb)

Spoiler side panel

Spoiler, right side

Spoiler, left side

163·A0081

Front bumper/spoiler, removing Front bumper/spoiler, installing

- remove screws A from spoiler side panels - install all components in reverse order of removal
- remove right and left spoiler side panels
- remove screws B from right, and left spoiler
sections
- remove right, left and center spoiler sections
- remove hex head and allen head bolts
- remove bumper by pulling straight from body

63 2 ·
• Front bumper/spoiler, removing/installing
From 1987-Wolfsburg edition
 Bumpers 63

Hex head bolt A

Hex head bolt 23 Nm (17 ft lb)
23 Nm (17 ft lb)

Hex head bolt

23 Nm (17 ft lb) Washer

Hex head bolt A

6.5 Nm (4.8 ft lb)

washer
Bumper bracket

Retaining bracket

Spring nut

~Washer
Hex head bolt A

Phillips hasd screw

Hex head bolt

6.5 Nm (4.8 ft lb)
Hex.head bolt
23 Nm (17 ft lb)

Rear bumper, removing Rear bumper, installing

- remove hex head bolts A with washers from both
sides
- remove bumper by pulling straight from body
Reinstall all components in reverse order of removal,
noting the following:
- place bumper first into position, tighten bolts
slightly
- align bumper, and fully secure all bolts

E-3 Rear bumper, removing/Installing 63.3

 64
Glass, Window Regulators

Index

-Sliding window FrOm 1986 M.Y.

replacing guides 64.2 -Giueing rubber window seals
side window 64.4
sliding door window 64.5
rear lid window 64.5
windshield 64.3
-Power window motor
removing 64.6, 64.7
installing 64.7

'

,.,

·;h
1

1·10 Index 64.1

64 Glass, Window Regulators

Sliding window guides, replacing

Note

If the nylon sliding window guides are loose in the

wi ndow track. channel, guide pieces,
Part No. 281 647 723, can be installed as follows:

Work sequence
- remove slidinQ window interior latch
- remove outer window channel weatherstrip/seal
- lift sliding window up and remove loose guide
piece

-lightly sand surfaces of guide piece and window

channel to be glued
-clean out window channel with cleaning solvent

- glue replacement guide piece using 3M® brand

structural adhesive or equivalent two-part epoxy
-reinstall window channel weatherstrip/seal
- reinstall interior latch

Note

Mechanically fastened guides were introduced

during 4/ 85 production. These new guides cannot
be retrofitted on earlier models.

CAUTION
Part numbers are for reference only. Always
consult your Parts Department for latest
information

64 •2 Sliding window, replacing guides

 Glass, Window Regulators 64
-
With start of production M.Y. 1986, the rubber
seals for the windshield, side windows and rear lid
are glued into place.

Note
To insure a satisfactory seal, use adhesive
AMV 172 003 05 or equivalent specifically made for
EPDM rubber.

Windshield seal, removing

Work procedure

~"((
\\
- pull seal from flange and window glass
- from outside place suction cups on glass and
remove windshield
- with plastic wedge remove rest of rubber seal
and remaining adhesive to height of
1-2 mm (3/64-5/64 in)
Note
If paint has been damaged, repair before installing
new rubber seal.

- carefully remove trim strip, if applicable, from

rubber gasket
- cut through seal at area of A-pillar (as shown)

CAUTION
Prevent paint damage by placing piece of
flat plastic (as shown) between seal and
body.

F-3
From 1986 m.y. Gluelng window
rubber seals 64.3
64 Glass, Window Regulators

Installing Side window seal, removing/installing

Work procedure Inside
- reinstall trim strip, if applicable vehicle
- install seal on glass Outside vehicle
- place plastic cord for installing window into
seal lip Glass
- clean sealing area around window opening

Rubber seal

, ~ r-·Body
/. ·... · . Adhesive
1..._0-..._ bead

Cross section • Windshield
A = 7 - 2 mm (9/32 - 5Jij4. in)
B "' 7 - 2 mm (9132 - 5/64 in)
C = 3 + 1 mm (1/8 + 3/64 in)
- place bead of adhesive as shown
- reinstall windshield, checking for proper fit
--b
--
Cross section • Side window
A = 7 - 2 mm{9/32 - S/64 in)
B. = 7 - 2 mm (9/32 - 5164. in)
C = 3 + .1 mm (1/8 + 3/64 in)
- removal/installation procedure is identical to that
of windshield
• note proper placement of adhesive bead

64.4 Gluelng window

rubberseala ·
From 1986 m.y.
 Glass, Window Regulators 64

Rear lid window seal, Sliding door window seal,

removing/installing removing/installing
Outside vehicle
Outside vehicle
Inside vehicle
.r-'---- Rubber
seal

Adhesive
bead
l64·139J
Cross section - Rear lid window
Adhesive
A = 7 - 2 mm (9/32 - 5/64 in) bead
B = 7 - 2 mm (9132 - 5/64 in)
C = 3 + 1 mm (1/8 +3/64 in)

- removal/installation procedure· is identical to that

of windshield seal
• note proper placement of adhesive bead Cross section - Sliding door window
A = 7 - 2 min '(9/32 - 5/64 in)
B =7 - 2 mm (9/32 - 5/64 in)
C • 3 + 3 mm (1/8 + 118 in)

- r~moval/installation procedure is identical to that

of windshield
• note proper placement of adhesive bead

Note
The dimension of adhesive bead ensures no
adhesive will get into interior of vehicle. Any excess
adhesive must be cleaned off immediately with
suitable solvent such as 3M <!' General Purpose
Adhesive Cleaner or equivalent.

Adhesive material hardening times

After repairs, vehicle should not be exposed to
temperatures beloW OOC (320F) for. 12 hours .before
being driven.

F·S From 1986 m.y. Gluelng window

rubber seals 64.5
64 Glass, Window Regulators

Power window motor, removing

- fully raise door window glass
- disconnect battery ground strap
- remove door trim panel
- disconnect electrical connectors and press out
window operating switch
- carefully pull off plastic moisture barrier

- disconnect battery ground strap

- reconnect window operating switch - cut off tie-wrap for cable guide (arrow)
- temporarily reconnect battery ground strap - disconnect window operating switch
- lower glass sufficiently to remove two hex head
bolts (arrows) from regulator

CAUTION
Always use care and wear protective gloves for
safety to prevent injury if glass breaks.

- remove window regulator fasteners (arrows)

- pu~h window guide rail toward outside of door
·with one hand

- fully push up glass and secure with wooden

wedges (as shown)

64 6 • Power window motors, removing I

_
From March, 19861
_
 Glass, Window Regulators 64
- Power window motor, installing

157-2741

- while holding window guide, proceed to withdraw

electric motor (as shown)
• this position will allow threaded bolts to clear
- guide window motor assembly into Ctoor shell (as
door assembly (arrows)
shown)

CAUTION
Do not apply excessive force. Plastic cable
guides may break.

ls7-277l

-tum and place electric motor into position (as

-turning electric motor 180° (as shown) remove
window regulator through assembly hole in door
shell
• electric motor and cables are one unit
shown)
-remount electric motor, guide rail and window
glass
- push window operating switch into position
- replace tie-wrap for cable guide
- temporarily reconnect battery ground strap and
window operating switch
- check window for proper functioning
- disconnect battery ground strap and window
operating switch
- starting at top, carefully reinstall plastic moisture
barrier, noting
• replace if damaged
• ensure adhesive areas are clean
• ensure installed wrinkle free
- reinstall all electrical connectors and window
operating switch
- reinstall door trim panel
- reconnect battery ground strap
- check window for proper functioning

F-7 From March, 1986 Power window motors, removing/Installing 64.7

 66

Body
Access·ories
Exterior

Index

-Body side moldings

assembly 66.5
bracket locations 66.6,
66.7
removing/installing 66~ 7
-Mirror glass
increasing mirror glass
adjustment range 66.3
removing/installing 66.2
-Outside mirrors, electric
assembly 66.4
removing/installing 66.4

Index 66.1
66 Body Accessories-Exterior

Mirror glass, removing Mirror glass, installing

.
~
@I B

l
\

Installation is in reverse order:

- ensure dust boot is properly seated
- locking pins must be engaged in pin holder
- check mirror for proper function

CAUTION
Wear protective gloves to prevent Injury if
glass breaks.
Hold glass to prevent falling out.

- push mirror glass at outer edge A until locking

lever B Is accessible
- push locking lever B (arrow) counterclockwise to
unlatch mirror assembly
- tilt and remove mirror glass
- disconnect electric heater element

66 •2 Mirror glass, removing/installing

From 1986 m.y.
 Body Accessories - Exterior 66
Increasing mirror glass adjustment
range
The mirror glass adjustment range for electric
outside mirrors can be increased by shortening the
four stop tabs on the mirror drive motor mounting
plate.

Note
See page 66.2 for mirror glass removal/installation
work procedure.

Mirror drive plate stop tabs,

removing

I 66-A019 I
-using hacksaw, cut 3-4mm (7/64-11/64 in.) from all
four stop tabs
- install all mirror components in reverse order
- reconnect battery ground strap
- check mirror for proper functioning

ss-A01a I
- disconnect battery ground strap
- remove mirror glass
- remove mirror drive motor
- unscrew and remove mirror drive motor mounting
plate

G-3 From 1986

Increasing mirror glass adjustment range 66.3
66 Body Accessories - Exterior

Electric mirror assembly, removing

- disconnect battery ground. strap

- pry off ptastic cap at base of mirror bracket and

- pry out disconnect electric mirror switch from door
trim panel
- remove door trim panel
- carefully pull back plastic moisture barrier
remove three screws (arrows)
- remove mirror assembly together with wire
harness
Electric mirror assembly, installing
-reinstall all components in reverse order, noting:

- cut tie wraps holding wire harness to door
- cut open cable sleeve A to expose individual
wires
- label and remove mirror wires from plug
connector
- position seal (arrow) to proper fit
- secure wire harness to door frame with tie wraps
- check mirror for proper function

66.4 Mirror assembly, removing/Installing

 . _ Exterior
Body Accessories 66
Bodyaldemoldlng, aide panel

Body aide molding, alldIng door

Body aide moldlng, sliding door panel

Body aide moldlng, door

G-6 Body side moldings, assembly 66.5

66 Bod Accessories - Exterior

Rg. 1 Body aide molding bracket locations, sliding door

a- 30 mm (1.2 ln.) e- 60 mm (2.3 in.)
b-15 mm (19/32 in.) f - 33 mm (1.3 in.)
c- 53 mm (2.1 in.) g- 65 mm (2 1/2 in.)
d- 365 mm (13.2 in.) h -180 mm (7.0 in.)

n r- ~ . -. -

k k k k

-
~Q
I
~

-~ ..

!
=:.!,. l J
·~
ti
"' .. ~·. .
I +
~
·•
\
. .1

--
~ ~ .....
~ --'\~~ j
?""
~.y ~~
166-2288 1
Fig. 2 Body side molding bracket locations, aide panel
a- 30 mm (1.2 in.)
i -10 mm (25/64 in.) CAUTION
·If- 390 mm (15.2 in.) De-burr, touch-up and apply anti-corrosion
primer to bored holes in b?dY as required.

66.6 Body side molding bracket locations,

sliding door/side panel
 Body Accessories - Exterior 66
Body side moldings, removing
- loosen hex head nuts
e

Fig. 3 Body side molding bracket locations,

front doors
a- 70 mm (2.7 in.)
b - 25 mm (63/64 in.) - swing molding outward (arrow A)
c- 35 mm (1.4 in.) - remove molding from top (arrow B)
d - 80 mm (3.1 in.)
e - 226 mm (8.8 in.) Body side moldings, installing
...
Reinstall all components in reverse order of removal.
CAUTION
De-burr, touch-up and apply anti-corrosion to
bored holes as required.

G-8
Body ~lng bracket locations, front doors
Body side moldings, removing/Installing
66 7 •
 68
Body-Interior

Index
- Automatic 3-point seat belts
retrofit installation 68.5
- Automatic rear 3-point seat belts
retrofit installation 68.7
- Automatic 3-point left center
seat belt "
retrofit installation 68.1 0
- Illuminated vanity mirrors
replacing bulbs 68.13
-Seat belts
inspection 68.2
webbing defects 68.4
-Template measurements 68.6

68.1
68 Seat Belt System
Complete seat belt system
Note
A visual and functional inspection of seat belts is
recommended to assure maximum protection for
vehicle occupants.
CAUTION
Seat belt assemblies must be replaced after
being subjected to loading by occupants in a
collision.
The following inspection is described separately for
front, rear and center seat belt positions. It includes
all continuous loop, single retractor 3-point restraint
systems, 2-point automatic (passive) front seat
restraint systems, and all non-retractable belt
systems.
System inspection, front seat
Webbing Inspection
- check for twisted webbing due to improper
alignment when connecting buckle
-fully extend webbing from retractor. Inspect
webbing and replace with new assembly if
following conditions are noted:
• cut or damaged webbing
• broken or pulled threads
• cut loops at belt edge
• color fading as a result of exposure to sun or
chemical agents
• bowed webbing
see page 68.4 for examples of webbing defects
CAUTION
Do not bleach or redye seat belt webbing.
Webbing that is severely faded will not meet
strength requirements and must be replaced.
Belt assemblies must be installed in sets. Do
not interchange buckle and retractor
assemblies with those designated for other
seating positions or other car models.
68.2 Complete seat belt system
System Inspection, front seat
If webbing cannot be pulled out of retractor or will
not retract to stowed position, check for the following
conditions and clean or correct as necessary:
• dirty webbing coated with gum, syrup, grease or
other foreign material
• twisted webbing
• retractor or loop on B-pillar out of position
Cleaning
Clean the belt webbing only with a mild soap solution
recommended for cleaning upholstery or carpets.
Follow the instructions provided on soap container.
Buckle Inspection
- insert tongue of seat belt into buckle until audible
click is heard. Pull back on webbing quickly to
assure buckle is latched properly
- replace seat belt assembly if buckle will not latch
- depress button on buckle to release belt
• belt should release with a pressure of approx.
21bs.
- replace seat belt assembly if buckle cover is
cracked, push button is loose or pressure required
to release buckle is too high
Retractor inspection
Front retractors are dual sensing and will lock up in
two modes. The unit will lock up as the belt is being
withdrawn from the retractor if the inertia increases
dramatically. Also, the unit will lock up with a change
in vehicle motion such as rapid braking.
-grasp seat belt webbing and, while pulling from
jretractor, give belt a fast jerk
Note
For automatic belt vehicles this mode is difficult to
inspect due to a low setting of the inertia unit.
- drive vehicle in an open area away from other
vehicles at a speed of approx. 5 to 15 mph and
quickly apply footbrake
- if retractor does not lock up under these
conditions, remove and replace seat belt
assembly

~ote
g A passenger can be used to test the right hand
retractor. The driver alone can test both retractors
simultaneously by grasping the right hand webbing,
extracting approx. 26 inches from the retractor and
holding the belt while braking.
Seat belt warning light/buzzer
A light in the instrument panel displaying the words
"fasten seat belts" or "fasten belts" along with an
audible signal that lasts for four to eight seconds
should be noticed when the ignition switch is moved
to the "on" or "start" position and the drivers belt is
unlatched. If the driver's belt is latched the buzzer
should not activate.
For 2-point automatic belts, both belts must be
connected to the door in order to start the vehicle.
The "fasten belts" light should activate if either
automatic belt is disconnected after starting.
Note
ed Correct any malfunctions in this system if the
customer desires.
Anchorage Inspection
Seat belt mounting bolts are installed at 35.3 Nm to
n belts do not have a retractor. In addition to checking
47.0 Nm (20 to 35ft lb). Retractors must be securely
lg
anchored in place. The bolts at the lower belt anchor
point (not the retractor) and upper seat belt loop
ge
must be tight and still allow the hardware to swivel.
Anchorage areas must be sound and uncorroded.
Note
Reinforce bolt mounting area if necessary.
G-11
Seat Belt System 68
System inspection, rear seat
Webbing/buckle inspection
same as for front seat
Retractor Inspection
Rear seat retractors lock automatically when the
webbing is extended and allowed to feed back into
the retractor.
- check retractor by extending webbing and
fastening to buckle. Allow several inches to feed
back into retractor and then jerk belt sharply
- if retractor does not lock up, remove and replace
seat belt assembly
Lap and shoulder belts (rear seat)
The 3-point system for the rear seat is the same as
for front seat except for the light and buzzer warning
system.
Anchorage Inspection
same as for front seat
Center seat position (and non-retractable belts)
Some models have a rear center seat belt. These
the webbing and anchorages, the adjustable slide
locking of the belt must be checked.
- fasten tongue to buckle and adjust by pulling
webbing end at right angle to connector and
buckle
- release webbing and pull upward on connector
and buckle
- If slide lock does not hold, remove and replace
seat belt assembly
Center seat position (retractable belts)
same as for rear seat retractor inspection
System inspection,
rear seat 68.3
68 Seat Belt System

Examples of webbing defects

Cut or damaged webbing

Cut loops at belt edge
(damage from being caught in door)

Color fading
Broken or pulled threads

Cut loops at belt edge

Bowed webbing

68.4 Webbing defects

 Body Accessories - Interior 68
Automatic rear 3-point seat belts,
Retrofit Installation

I CAUTION
Always consult with the Parts Department for

I -
Part numbers.

- remove rear cushion and floor carpet

- remove rear seat bottom assembly
- remove rear seat back
remove D-pillar trim - install belt through cut hole in trim panel
- remove left rear luggage area trim panel - mount upper belt guide onto D-pillar
• 40 Nm (30ft lb) .
- remove existing 2-point left/right side lap
belt - install belt anchor (arrow) to original lap

t - using template for luggage area trim panel, mark

and cut hole in panel as shown
belt anchor point
•• 40 Nm (30 ft lb)
- using template for D-panel, mark and cut side of - repeat procedure for right side belt assembly,

I D-pillar for belt guide noting to reverse template dimensions accordingly

- reinstall rear seat back and seat bottom
assemblies
-replace both outer seatDelt buckles
- reinstall rear cushion and floor carpet
- check rear 3-point belts for proper function

- using bolts 2, mount retractor assembly 1 to side

panel 3
• 40 Nm (30 ft lb)

G·14 Vanagon only II From 1986 m.y. ~lth AJC Automatic 3-polnt seat belts,
retrofit installation
68 5 •
68 Body Accessories - Interior

Luggage area trim panel

40mm
(1.61n.)

17mm
55mm
(2.11n.) 240 mm (0.71n.) 203 mm

Tapered

60mm
(2.3 ln.)
I ~.': .; (7.01n.) "---------"""l
(~7n~ ~ ~---310
147 mm _ .. ..,I
(5.7 ln.)
mm
(12.1 ln.)
___j
TJ
335 mm
(1 3•1 ln.)
290mm
(11.3 ln.)

~ll

68 •6 Template measurements
Vanagon only II From 1986 m.y. with A/C
Body Accessories - Interior 68

Automatic rear 3-point seat belts,

retrofit installation

CAUTION
Part numbers are for reference only.
Always check with your Parts
Department for latest information.

Parts required
Part Number Description Quantity
253 857 815D Rear 3-point seat 1
belt (left side)
253 857 816D Rear 3-point seat 1
belt (right side)

Note
Check with your Parts Department for
additional installation parts. Not all parts listed .
may be applicable to all vehicles.
• remove rear seat bottom
• remove existing 2-point left/right side lap
belt
• remove rear floor carpet
• remove right rear luggage area trim panel
. • mark and cut rear luggage area trim panel
using dimensions as shown on page 6 8 • 9
• locate, by feel, threaded hole under D-pillar
trim (arr6w)
• cut hole in trim to expose threaded bolt
hole

Automatic rear3-point seat belts,

retrofit installation
68 7 •
68 Body Accessories-Interior

• using bolts 2, mount retractor assembly 1,

to side panel 3
• 40 Nm (30 ft lb)
• install belt through cut hole in trim panel
• mount upper belt guide onto D-pillar
• 40 Nm (30ft lb)

• install belt anchor (arrow) to original lap

belt anchor point
• 40 Nm (30 ft lb)
• reinstall right rear luggage area trim panel
• repeat procedure for left side belt
assembly, noting to reverse dimensions
accordingly
• reinstall all other components in reverse
order
• check rear 3-point belts for proper function

iss-Aos21

/
I

68.8 Automatic rear 3-point seat belts,

retrofit installation
- Body Accessories - Interior 68

Luggage area trim panel

Top

203mm
(8 in.)

403 mm
1-4----'-(15 7 / B i n . ) - - - -..\

408mm - - " " '

(16 1116 ln.)

~-----------569mm--------------~
( 22 318 ln.)·

t Front of vehicle

"\

J Automatic rear 3-point seat belts,

retrofit installation
68 g•
68 Body Accessories-Interior

Automatic 3-point left center seat

belt, retrofit installation
CAUTION
Part numbers are for reference only.
Always check with your Parts
Department for latest information.

Parts required
Part Number Description
253 857 811 D 3-point seat belt
(left side)

Note
Check with your Parts Department for
additional installation parts.
• remove rear seat back
• remove rear seat bottom
ii remove original left center belt
• remove rear lett .side_panel trim
• measure location of belt retractor, belt
guide, and mounting holes, using
dimensions on page 6 8 • 12
• cut panel as required
• reinstall trim panel
//
I
• ;install seat belt retractor on outside of
/ panel, as shown
/ • 40 Nm (30 ft lb)
• hand tighten forward bolt only

68.10 Automatic 3·point left center seat

belt, retrofit installation
 Body Accessories - Interior 68

• locate, by feel, threaded hole inC-pillar

jJ ll (arrow) for belt guide D-ring
• cut C-pillar trim from threaded hole, install
belt guide D-:-ring

~~~c:
• 40 Nm (30ft lb)

/
//I jsa-Ao.s41

• install anchor of 3-point belt into forward

mounting hole of retractor bracket (arrow A )
• ·4o Nm (30 ft lb)
• align bracket for belts, reinstall rear seat
bottom and belts
• reinstall rear seatback
• install new buckle for 3-point belt
• check seat belt for proper function

All w/center seat (except Camper/Multivan}

From 1980 m.y.
Automatic 3-point left center seat belts,
retrofit installation
68.11
68 Body Accessories-Interior

TOP

67 tnrn
(2 ·518 in.)

( 138 ~tn LCjt::--i

-112 in.) ----+----~- 38 mm
· - - - - - 1 - - - - - - l - (1-1/2 in.)

I
442 mm
(17-3/8 in.)

31 mm
298 mm
(11-3/4 in.) (1-1/4 in.)
245 mm 327 mm
(9-5/8 in.) (12-7/8 in.) 203 mm
(8-1/8 in.)
216 mm
(8·1/2 in.)

w center seat except Camper

68.12 Automatic 3-polnt left center aeat
belt, retrofit installation From 1980 m.y.
 Body Accessories-Interior 68

Illuminated vanity mirrors, replacing bulbs

• locate clips under lower edge of vanity mirror

assembly (arrows)
• carefully pry mirror assembly out of sunvisor with
small flat bladed screwdriver (as shown)
• replace bulbs

)
-
J G·23 All w/llluminated Vanity Mirrors Illuminated vanity mirrors,
replacing bulbs 68.13
 72
Body
Seats

Quick Data Index

-Armrest, adjustable
assembly 72.5
removing/installing 72.6
-Armrest, fold down
removing/installing 72.4
-Front seat
removing/installing 72.2
-Front seat backrest
removing/installing 72.2,
72.3

---~

1·5 72.1
72 Body-Seats

Front seat, removing Front seat backrest, installing

- insert backrest 5, fold forward and lock
- reinstall socket head bolts 4
-reinstall cover caps 3

Front seat backrest, removing

From 1985 m.y.

- pull front seat adjusting lever 1 upward and push

seat forward
- pry locking lever 2 upward with screwdriver and
push seat forward out of seat tracks
~-----3
Front seat, installing
ln-112!
Reinstall all components in reverse order of removal,
noting the following:
- pry off cover caps 3 from both sides
- check seat for proper function
- remove socket head bolts 4 from both si~

Front seat backrest, removing

From 1980 - 1984 m.y.

- pry out clamp 6 from outer side of seat with

screwdriver
- pull out clamp 6

- pry off left/right cover caps 3

- fold backrest 5 to front and lock
- remove socket head bolts 4 from both sides
- fold back backrest all the way back to horizontal
(
- pull off backrest 5

72.2 Front seat, removing/installing

Front seat backrest, removing/installing
 Body - Seats 72

- remove four socket head bolts (arrows)

- remove right seat rail 7
- remove left seat rail 8 to side
- remove backrest

Front seat backrest, Installing

Reinstall all components in reverse order of removal,
noting the following:
- check seat for proper function

H·12
H·13
From 1985 m.y.
Front seat backrest, removing/Installing 72.3
72 Body- Seats

Teflon washer

Spring washer

Flat head screws - - - - '

Fold down armrest, removing

-
-
remove cover cap
remove socket head bolt (
- carefully pull off armrest from flange

Fold down armrest, Installing

Reinstall all components in reverse order of removal,
noting the following:
- check armrest for proper function

72.4 Fold down armrest, removin$J/installlng

 Body - Seats 72

Pin

F~

H·15 'AdJustable armrest, assembly 7 2•5

72 Body- Seats

Adjustable armrest, removing

- push covering of armrest to side in order to

expose pin (arrow)
- drive out pin with punch 6
- pull off armrest

Adjustable armrest, installing

Reinstall all components in reverse order of removal,
noting the following:
- check armrest for proper function

72.6 Adjustable armrest, removing/installing

 74

Body
Seat Upholstery

Quick Data· Index

-Heated seats (Canada)
component location 74.2.
74.3
heat element
removing/installing 74.2

1·7 74.1
74 -Seat U

Heated seat, seatback element, Heated seat switch,

removing removing/installing
~ '
disconnect battery. ground strap - disconnect battery ground strap
- disconnect electrical plug under seat - unscrew lower steering column cover
- remove seat from vehicle - lift upper steering column cover
- remove wires from electrical plug
- remove seat back
- remove seat or seatback cover
- remove defective element

Heated seat, seatback element,

Installing
Installation is In reverse order. Note the following:

- push heated seat switch (arrow) up and

disconnect electrical plug
- remove. switch
Installation Is In reverse order. Note the following:
- route wires to switch around bracket 1
- reconnect battery ground strap
- check system for proper function

- ensure replacement element is installed wrinkle

Electric component location
free Control unit
- check heated seat, seatback for proper function
- remove access trim cover for relay board

74.2 Heated seat elements, removing/installing

Component location
Canada
 Body - Seat Upholstery 74
Electrical wiring to heated seat elements

r--, _.. - - - ... - - - - - - · . . J I

--~

0( ~
' ...... ~2
0 ''~,
0 1
- control unit is identified by number 59 stamped on
the top (as shown)
1 - six cavity electrical plug
Electrical wiring to river's seat 2 - wire to seat element
3 - wire to seatback element
Note 4 -tie wrap
Wiring is taped to floor with fabric tape.
Electrical troubleshooting
For electrical troubleshooting, refer to appropriate
Wiring Diagrams .

·-·~1
. ... -~>>

1 - wire routed through seat crossmember

2 - six cavity electrical plug to driver's seat

1·3 Heated seat elements,

Component location
74 3 •
 75

Interior Panels,
Roof

Index
- Front headliner
installing 75.7a
removing 75.7
- Luggage rack
removing 75.8
- Pop-up roof
installing 75.3
removing 75.2
- Pop-up roof C$11Vas
installing 75.5
removing 75.4
-Pop-up roof seal.
installing 75.6a
removing 75.6
-Roof vent
installing 75.7
removing 75.6a

1.

.,

·.

75.1
75 Interior Panels, Roof

Pop-up roof, removing

CAUTION
Do not damage inside of roof when swinging
front mattress and board

- swing front mattress and board forward

- open snaps of front mattress and remove
mattress

- release lock latches 1 behind lock cover 2 by

pulling down firmly with both hands until lock pin 3
disengages at lock plate 4
- push lock cover 2 and roof up as high as possible
- push up roof with crossbar 5 until support struts
are locked into position

- remove screws (arrows) In cj annel

-open snaps (lower arrows) for rear mattress

- pull front mattress and board 7 as far as possible
to front with overcentering hinges 8

- remove circlip 9 from pin 10 for support struts 6

Note
Pins 10 remain in brackets 11 .

7 5 •2 Pop-up roof, removing

 Interior Panels, Roof 75

~
i - --
- lower roof halfway and loosen bolts (arrows) on - apply 014 sealing com~und to corners of roof
each side reinforcements (arrows) to ensure proper sealing
between canvas and roof
Note - lift pop-up roof with canvas onto vehicle
- let pop-up roof rest at rear of roof
Following procedure requires three mechanics. - keep pop-up roof open at front approximately
-pull pins 10 out of brackets (see 75.2 figure 500 mm (20 ln.) and place linkage into position
75-006)
- remove linkage bolts on each side and tie linkage
together

CAUtiON
Do not damage paint with front support struts
when removing roof

- lift pop-up roof off vehicle

Pop-up roof, Installing

- apply sealing compound under all linkage bolt

!leads (arrow) as shown
- install bolts and tighten
- position strut supports into brackets and install
pins
- install new circlips
- lower pop-up roof slightly and let canvas rest on
vehicle roof
- make two cuts In beading at each corner to
ensure proper seating and sealing
- position retain'ing rails, align and tighten screws
from front to rear

- staple roof canvas to wooden frame on left and

right sides to temporarily hold strut supports in
position (arrow)

J-3
Pop-up roof, removing/Installing 75.3
75 Interior Panels, Roof

Note
CAUTION
Serial no. of camper equipment Is found on I.D. Plate
When loWering top, gather in canvas sides,
at left on rear seat.
making sure that no part of canvas is pinched
between support struts or latch. Grasp lock • with equipment serial no. up to E.OOO 871
cover with both hands and pull down until lock
engages in latch

- remove lock cover ~ and nuts (arrows)

- remove lock cover "-.._

- lower pop-up roof and engage latch

- check alignment of pop-up roof to luggage rack
and seating of seal (arrows)

- remove strut supports 6, bracket screws and bolts

(arrows)

\
\.
- if necessary realign roof by moving rear linkages
in erongated holes (arrow) and tighten bolts

Pop-up roof canvas, removing

Note
When canvas must be replaced cut it along vehicle
roof. This ensures easy removal of screws in
channel. Pop-up roof must be removed to replace
roof canvas.
- remove plastic strip held to wooden frame with
staples (arrows)
-pull out staples holding canvas to wooden frame

7 5 •4 Pop-up roof/canvas, installing/removing

 Interior Panels, Roof 75
Note
With equipment serial no. from E.OOO 872.

- staple plastic strips to wooden frame (stretching

!ham to required length)

- remove screws and aluminum rails (see arrows) )

- remove staples and canvas ----

Note
When removing canvas, save 8x8x10 mm (5/16 x
5/16 x 3/8 in.) wooden blocks for reuse.

Pop-up roof canvas, installing

Note
Up to equipment serial no. 1::.000 871.

- fit canvas to all four corners of wooden frame with

staples
-----·175-0181
- a.ttach canvas to front, rear and side sections of Note
wooden frame with staples starting from center of
sections and working to corners l If replacing roof shell only, staple mosquito net to
reinforcement strip (arrow).
- cut 4 plastic strips to following lengths 1
• 2 each 2200 mm (86 5/8 ln.) I
• 2 each 1150 (45 9/32 in.) "-. Note

- soften plastic strips in warm water before From equipment serial no. E.OOO 872.
installing
I Note
""- Position seams of canvas at left and right edges of
roof, approximately 35 mm (1 3/8 in.) from front
corners.

J-5
Pop-up roof canvas, removing/installing 75.5
75 Interior Panels, Roof

Pop-up roof seal, removing

General Information

- fit canvas and staple to front center of wooden

frame. Pull toward two front corners and staple
- pull canvas evenly to rear corners and staple
- staple rear and sides, working from center
• seal with cross section A-A is Installed around
rear, left and rlghteC!ges of pop-up roof

~~~
• seal with cross section B-B is installed on front
edge of pop-up roof

0 --~ "7
- ~ "' ,

' 17s-0391
- bolt canvas to rails and ensure bead 1 is centered
In guide groove 2 of pop-up roof

Note
Bolt rails starting from center and progressing toward
comers.

• seal with cross section B-B (photo 75-019)

(installed on front)
A = inserted steel clamps
B = rubber part of seal

75.6 Pop-up roof canvas, Installing

Pop-up roof seal, removing
 Roof Vent 75

• seal with cross section A·A (photo 75-019)

(installed on rear and left and right sides)
A = inserted steel clamps
B = rubber part of seal
- to make sure seal with inserted steel clamps is
Note seated pmperly on roof, press It into edges with
\ plastic wedge 1
Correct tension of inserted steel clamP,s can be
restored by squeezing seal together. \
- open roof and pull off seal ) Roof vem, removing

Pop-up roof seal, installing

-open roof vent approximately 1-1/2 turns with

hand knob 1
- turn out set screw from hand wheel1 and remove
- coat seal with talcum powder I hand knob
- slide seal on roof starting at bolh front ~ners -pry off plastic caps from hex. nuts (arrows) and
(arrows) ,I ··
remove nuts
- remove cross-head screw 2
- remove roof vent bracket cover 3

CAUTION
Part numbers are for reference only. Always
check with your Parts Department for latest
information.

J-7 Pop-up roof seal, removing/Installing

Roof vent, removing
75 •6a
75 Interior Panels, Roof

Front headliner, removing

Note
Up to model year 1984.

- remove bracket 4 downward from bolts

- remove roof window 5 with support bracket 4,
support arm 6 and hinges (upward)

Roof vent weather molding, removing • location of front headliner (arrow)

- pull old molding out of roof hole

- clean old silicon sealant from roof mating area
with a suitable solvent

- remove screw (arrow) from end plate 1 and

storage shelf and remove both parts

Roof vent weather molding, Installing

- fit roof vent weather molding into place

'
- seal weather molding from outside (arrows) with
a suitable transparent silicon adhesive compound
- use sealant on vent mounting bolts 7 also

Roof vent, installing

- install a reverse order of removal, noting the
following:
• use a suitable sealing compound D 001 900 05
or equivalent on six mounting bolts 7

- remove all14 screws headliner (arrows)

75.7 Roof vent, removing/Installing

Front headliner, removing
 Interior Panels, Roof 75
CAUTION
Front headliner, removing
Before working on any part of electrical From model year 1985
system, disconnect battery Qrouncl strap
Note
- remove interior liglilt and insulate 't\ot wire
- unclip sun visor Prior to removal of front headliner, roof rail with
- turn inside rear mirror toward windshield curtain molding on right must be removed
see Repair Group 77.

- remove beadings 2 and seals 3

-pry off cover, tum out one screw (arrow), bend

support bracket slightly downward

- pull down headliner slightly at center ~i'Td-slide out

of retaining rails (arrow)
- remove headliner
- remove interior light and insulate hot wire
Front headliner, Installing - clip out sun visors and pull toward windshield ,
turn interior mirror as far as possible toward
- have second mechanic hold headliner ih position windshield
- slide headliner into left retaining rail ·. - turn out screws (arrows) from front headliner
- bend headliner down slightly to slide Into ~ght
retaining rail /
- install seals between front and side headliners
-install all14 screws and tighten
- install beadings and seals at corners
- connect and install interior light and sunvisors
- install end plate

J ·9
Front headliner, removing/Installing 75.7a
75 Interior Panels, Roof

- pull headliner downward in center and push out of - remove screw (arrow) and end plate 1 from
side retaining rails storage shelf
- remove headliner

Front headliner, Installing

- installing reverse order of removal

Luggage rack, removing

- remove 7 screws (arrows) at rear of front

headliner

• location of luggage rack (arrow)

- remove rubber caps (arrows)

- remove nuts

75.8 Front headliner, installing

Luggage rack, removing
 Interior Panels, Roof 75

- if necessary, hold bolts from underneath roof Luggage rack, Installing

(arrows)
- place 2 rubber washers on each hole 2
- place luggage rack on roof of vehicle and align
holes
- insert screws and tighten loosely in brackets 3
- install bolts and nuts and tighten loosely
- ' check alignment of luggage rack on vehicle
__rgof and finally lighten all screws and nuts
- reinstall front headliner and end plate

-remove 4 screws (arrows)

- lift luggage rack off vehicle roof

I
\

J-11
Luggage rack, removing/installing 75.9
 76
Cabinets, Water Tank,
Refrigerator

Index
- Ceiling cabinet · - Storage shelf
with AIC, installing 76.9 removing/installing 76.2
with A/C, removing 76.7 w/curtain rod
without AIC, removing/ removing/installing 76.4
installing 76.6 -Water faucet w/pump switch
- Clothes closet removing/installing 76.17
installing 76.11, 76.14 - Water level sensor
removing 76.9, 76.11 removing/installing 76.20
-Curtains - Water pump, kitchen
curtain rail w/fresh air duct, removing/installing 76.18
installing 76.6
curtain rail w/fresh air duct,
removing 76.5
removing/installing 76.3
- Propane tank
removing/installing 76.23
- Refrigerator
air supply modification 76.25
installing 76.25
removing 76.24
-Sink cabinet
installing 76.23
removing 76.20 ·.,

-Storage chest w/wat.er tank

installing 76.17
removing 76.15

76.1
76 Cabinets, Water Tank, Refrigerator

Storage shelf, removing

Note
Up to 1984 model year.

- remove nut (arrow) and push bolt through storage

shelf 3 and clothes closet 4
- swing shelf upward and pull out

Storage shelf, installl'ng

- place shelf in position and' install bolt and screws
-remove screws (arrows) and end plate 1
in reverse order
- connect interior light wiring

CAUTION

Do not cross wires when reconnecting Interior

light.

CAUTION

Before working on any part of electrical

system, disconnect battery ground strap.

- disconnect wiring for interior light after pulling out

of roof reinforcement
- insulate hot wire 2

76 •2 Storage shelf, removing/installing

Thru 1984 m.y.
 Cabinets, Water Tank, Refrigerator 76
Curtains (left side), removing Curtains (right side), removing
Note Note
Up to model year 1984. Up to model year 1984.

Note
Remove storage shelf first see page 76.4.

- remove cover screws 1

- remove curtain oord screw (arrow A) In clothes

closet
- remove curtain rail screw (arrow B)
- push rear curtain toward front
- remove both curtain rail screws at front
- pull curtains off rails

Curtains (left side), installing

- place curtains on rails
- install curtain rails and tighten screws
- push curtain behind clothes closet
- loosen rail and retighten
- remove rail screws C
- remove rail screws for sliding door curtain (lower
arrows)
- pull curtains off rails

Curtains (right side), installing

- place curtains on rails
- install rails and tighten screws
- install cover

K-3
Thru 1984 m.y.
Curtains, removlng/lnatalllng 76.3
76 Cabinets, Water Tank, Refrigerator

Storage shelf (left) with curtain rail,

removing
Note 3 3 3
From model year 1985.
- unhook curtain at left front ("B"~pillar)
;::

- remove two screws 2 from left hinge of front bed

board
- pry off cover caps, unscrew four screws 3

- remove cover 1 from center roof frame

reinforcement·(four Phillips head screws).

- pry off four cover caps and unscrew four screws
(arrows· A) · - remove storage shelf with curtain rail
- remove nut (in clothes closet) from bolt (arrow B)
and push out carriage bolt
Note
To prevent damage to front headliner when removing
storage shelf with curtain rail on left side, support
bracket of end plate must be bent slightly downward.
- move storage shelf with curtain rail to the left side
and disconnect wiring connections for passenger
compartment light
- insulate battery pos. wire
Storage shelf with curtain rail (left),
instalfing
- install in reverse order of removal

76.4 Storage shelf with curtain rail

removing/installing
From 1985 m.y.
 Cabinets, Water Tank, Refrigerator 76
Fresh air duct with curtain rail
(right), removing ·
Note
From model year 1985.

- remove screw (arrow)

...,.... remove cover 1 from center roof frame

reinforcement, four screws
- remove snaps for curtains on the "8 and C-plllar",
right side
-pry off caps, remove seven screws (arrows) from
below curtain rail htt:

-remove two screws (arrows) from right hinge of

front bed board

- pry off cap, remove one screw (arrow) from cover

plate
- bend supporting bracket slightly downward

K·5 From 1985 m.y. Fresh air duct with curtain rail (right), removing 7 6 •5
76 Cabinets; Water Tank, Refrigerator

lll•••-=::17s-o1o I
- pry off five protective caps and remove screws -remove both nuts (arrowe) of right side brackets
(arrows) holding ceiling cabinet
- carefully pull off right curtain rail

Fresh air duct with curtain rail

(right), Installing
- install in reverse order of removal

Ceiling cabinet, removing

Vehicles without AJC

- remove both nuts (arrows) on left side and push

bolts in to clothes closet

• location of ceiling cabinet (arrow)

- remove roof-bed mattress
- remove part of lower-bed mattress on engine
compartment deck

- remove nut (arrow) on left side and push bolt into

clothes closet
- lift cabinet out (2 mechanics needed)

Ceiling cabinet, installing

- install in reverse order

76.6 Fresh air duct with curtajn rail, removing/installing

Ceiling cabinet, removing/installing
Vehicle without A/C K·7
 Cabinets, Water Tank, Refrigerator 76
Ceiling cabinet, removing

I Vehicles with AJC

Note
Ceiling cabinet can only be removed if storage shelf
with curtain rail, left, is removed ffrst, seep. 76A,
and front bed board with mattress, see repair group
75, has been removed.

- remove two screws each <•rows) from left and

right air intake grills, remove grills

- remove vent 1 with cover 2 (20 screws with

protective caps)

..
]

' • water drain hoses 3

- unhinge clothes closet doors

I
CAUnON
Before working on any part of electrical system,
disconnect battery ground strap.

- remove fiVe countersunk screws (arrows) from

above rear bed board, support vent channel with
cover from below with one hand
- lower vent channel with cover and remove

Into

K·7 Vehicle with AIC

Ceiling cabinet, removing 7 6 •7
76 Cabinets, Water Tank, Refrigerator

- remove four screws (arrows) -remove nut and push out carriage bolt (arrow)
from clothes. closet
- carefully lower ceiling cabinet and disconnect left
and .right speaker wires

-loosen nut and push carriage bolt (arrow) out of

clothes closet

-remove two screws (arrows) while second

mechanic supports ceiling cabinet
- pull ceiling cabinet slightly downward and remove
cross wall4 - disconnect water drain hoses (arrow) right and
left from drip pan 6

76 •8 Ceiling cabinet, removing

Vehicle with A/C
 Cabinets, Water Tank, Refrigerator 76
Clothes closet, removing
Note
Up to 1984 model year, without air conditioning.
Remove ceiling closet first, see page 76.6.

- continue to lower ceiling cabinet and support on

backrest
·ft - disconnect two terminals 7 and disconnect both
series resistors for evaporator fans 8

CAUTION
Discormect series resistors for evaporator fan
very carefully. If one of the series resistors is
damaged, the entire resistor block must be
replaced.

- remove ceiling cabinet

- remove part of lower bed mattress on engine

compartment deck
- remove both closet doors

• when installing water drainage hoses, care

must be taken that flapper valves are not
obstructed with foreign material
- prior to installation, heat water drainage hoses
with hot air blower to ease installing

Ceiling cabinet, installing

- install in reverse order of removal - remove nut (arrow) below closet and push bolt
out of bracket

K·9 Ceiling cabinet, removing/installing

Clothes closet, removing
76 g •
76 Cabinets, Watef Tank, Refrigerator

(j)

- remove both nuts (arrows) in storage chest and

push bolts through closet wall into closet

- remove screw In bracket 1 (upper arrow)

- remove nut (left arrow) and push bolt out of
bracket
- remove both screws (arrows) holding bracket 2

-remove screws (arrows) for roof rail 5

-remove screws (arrows) for center roof
reinforcement 6

-remove nut (arrow) and push bolt through storage

shelf 3 and closet wall 4 into closet

76 •10 Clothes closet, removing

 Cabinets, Water Tank, Refrigerator
- loosen screws holding roof bed board on left and
right sides
-lift bed board (left arrow) up approximately 10 em
(4 in.) and support with wedge as shown
- remove engine compartment deck lid
- slightly lift backrest of rear seat bench
- using 2 mechanics pull closet to center of vehicle
and lower into engine compartment
- swing closet to front and lift to rear, out of vehicle
(arrows)
CAUTION
Do not damage engine components when
lowering closet into engine compartment.
K·11
76
Clothes closet, installing
- pull up backrest of rear-seat bench as far as
it will go
-place closet into position (arrows)
- slide backrest of rear-seat bench into position
- Install engine-compartment deck lid
- Install all remaining parts in reverse order
Clothes closet, removing
Note
From 1985 model year, without air conditioning.
Clothes closet can be removed if storage shelf with
curtain rail, left, and ceiling cabinet have been
dismantled first. See 76.4, 76.6
- remove mattress on engine compartment deck
- unhinge both doors of clothes closet and remove
-remove one nut (arrow) below closet and push
bolt out of bracket
Clothes closet, removing/Installing 76.11
76 Cabinets, Water Tank, Refrigerator

' 1

- unscrew left and rear bed board, seven screws

- lift rear bed board on left side approximately
15-20 mm (3/4 in.) pushing a wedge underneath
(arrow)

Note
Procedure requires 2 persons.

- remove one screw in lower front area from Clothes closet, Installing
support bracket 1
- remove one nut at support angle and push bolt - install in reverse order
out - swing clothes closet to side, tilt onto engine
- remove two Phillips head screws from engine compartment lid and remove
compartment deck and remove support angle on
floor 2 Clothes closet, removing
Note
With air conditioning, remove ceiling cabinet first, see
76.6.

- remove two nuts in stowage pan of storage chest

and push bolts through chest and clothes closet
- loosen stop for seat bench and pull seat bench
forward approximately 10 em (4 in.)
- remove evaporator drain hose 3

7 6 •12 Clothes closet, removing/installing

- Cabinets, Water Tank, Refrigerator 76

-pull evaporator housing 4 towards front (arrow),

and remove

- remove one screw at lower front from support

bracket 1 (arrow)
- remove one nut at support bracket 2 and push
bolt out
- remove two screws from engine compartment
deck and remove floor support bracket 2

- remove nut (arrow) below closet and push bolt

out of bracket

- remove both nuts in stowage pan of storage chest

and push bolts through chest and clothes closet

- K·13
Clothes closet, removing 7 6.13
76 Cabinets, Water Tank, Refrigerator

...,.- remove support bracket In left front 5 and support
bracket In left and right rear 6 from rear bed
board
- loosen stop for bench seat and pull bench seat
with backrest forward approximately tO em (4 ln.)
- remove two evaporator mounting screws (arrows)
Note
This procedure may require a second technician to
support evaporator and wiring hamess 7.

CAUTION
Wear protective gloves when holding
evapOrator.

- unscrew seven left and right bed board screws

- lift rear bed board on left side approximately
15-20 mm (3/4 in.) with wedge from underneath
(arrow)

- lower evaporator slightly

- swing clothes closet to left and swing out
evaporator to rear at same time
- remove clothes closet

Clothes closet, installing

-install in reverse order

76 •14 Clothes closet, removing/installing

 Cabinets, Water Tank, Refrigerator 76
Storage chest with water tank, CAUTION
removing
Note Before working on any part of electrical
system, disconnect battery ground strap.
Storage chest with water tank
can be removed after rear
bench seat, See Repair Group 77.

J - remove water tank drain pipe cap 1 under left

center bottom panel and drain water tank
- remove waterdraln cover plate and seal 2

- pull water filler hose 3 and ventilation hose 4 into

storage room of chest
-remove two clamps from electric cable (arrows)
from bottom panel

- remove four screws (arrows) from water filler

cover plate
- pull filler neck out to access hose clamp 6
- loosen clamp for water filler hose 3
- remove ventilation hose 4 and remove water filler
hose from filler neck
- open storage locker lids and door of storage chest
and remove - remove wall outlet cover 5
- remove chest divider - remove cover with fuse from circuit breaker 6 and
remove cable connnections from fuse

K·15
Storage chest with water tank, removing 16 .15
 76 Cabinets, Water Tank, Refrigerator

~-----
. ./
'
-remove four screws (arrows) from socket mount - unscrew two screws and remove cover plate 8
- remove socket housing, tilt 90" backward and
push back into recess

-remove four wire connections from plug terminal

(arrow A)
- remove four screws from circuit breaker housing - release clamp (arrow B) and remove water hose
- remove circuit breaker housing far enough for
screws (arrows) to be exposed
- loosen both screws (arrows) and remove upper
support bracket 7
- push circuit breaker housing back into recess

'··I

(@

- remove two nuts (arrows) in storage space of

chest and push bolts through chest and clothes
closet

76 •16 Storage chest with water tank, removin~

 Cabinets, Water Tank, Refrigerator 76

- remove three bolts from sink cabinet (arrowa) - remove plastic nut 1 and pull off with spacer 2
- lift chest with water tank approximately 10 em
(4 in.) and pull out

Storage chest with water tank,

installing
- install in reverse order
- check all water connections for leaks

Water faucet with pump switch,

removi ng
Note
Up to Equipment No. C.OOO 858.
- remove kitchen cabinet drawer
- remove cabinet door
- disconnect battery ground strap

- remove faucet from counter

- disconnect city water connection 4 and disconnect
hose 5

Water faucet with pump switch,

Installing
Note
Warm hose 5 prior to pushing onto water faucet.
- install in reverse order

-disconnect 12V DC electric connection from pump

switch at plug terminal 3

K·17 Storage chest with water tank, removing/installing

Water faucet w/pump switch, removing/installing
76.17
76 Cabinets, Water Tank, Refrigerator

Water pump (kitchen), removing Water faucet with pump switch,

removing
Note
Note
Up to equipment serial number C.OOO 858.
From equipment serial No. C.OOO 859.
- remove kitchen cabinet door
- disconnect battery ground strap - remove kitchen cabinet drawer
- unhinge cabinet door
- disconnect battery ground strap

-pull out three pump cover keepers (arrows)

- remove cover 1
- disconnect 12V DC electric connection from pump
switch at plug terminal 1

- disconnect 12V DC wire connections at pump lead

-loosen hose clamps 2 and disconnect pump
hoses
- loosen 2 mounting bracket screws 3 and remove
water pump in direction of arrow
Water pump (kitchen), installing
- open cabinet lid and loosen three screws
(arrows)
- remove faucet 4 from kitchen counter and
disconnect city water connection,
see fig. 76-107, 3

- install in reverse order

Water faucet with pump switch,
Note
installing
Be sure to check all fluid connections in pump circuit - install in reverse order
for leaks.

76.18 Water faucet, w/pump switch, removing/installing

 Cabinets, Water Tank, Refrigerator 76
Water pump (kitchen), removing
Note
From equipment serial number C.OOO 859.
- disconnect battery ground strap

- remove water pump 3 from tank, release clamp 4

and disconnect hose
- pull 12V DC wires through rubber sleeve 5 inward
to water tank
- remove water pump with leads from tank

Note
Do not cross 12 V DC wire connections. Pump works
- open left lid of chest and remove cover, two
in one direction only.
screws (arrows)

Water pump (kitchen), installing

- install in reverse order

- check all fluid connections in pump circuit for
leaks

- disconnect 12V DC connections at water pump

lead 1
- turn out water tank cap 2 and remove pump with
sensor

K·19
Water pump (kitchen), removing/Installing 76.19
76 Cabinets, Water Tank, Refrigerator

Water level sensor, removing Sink cabinet, removing

Note Note
For vehicles from 1988. On vehicles up to equipment number C.OOO 858,
water pump must be removed, see page 76.18.
Equipment number can be found on back left side of
CAUTION rear seat.

Before wol1dng on any part of electrical

system, disconnect battery ground strap.

- close propane gas tank valve 1 located under left

center floor panel

- open left lid of chest and remove cover, two

screws (arrows)
WARNING
Fire hazard! Do not smoke or have anything in
the area that could ignite propane fuel. Ensure
adequate ventilation.

- disconnect gas lines at connections 2

- remove sealing panel 3, six screws

- disconnect 12V DC wire connections from sensor

at lead connector 1
- remove water tank cap 2 and remove with sensor
- remove sensor from water tank lid, three screws 3

Water level sensor, installing

- remove vent cover, 4 washer, mounting plate and
- install in reverse order gasket

76.20 Water level sensor, removing/installing

Sink cabinet, removing
 Cabinets, Water Tank, Refrigerator 76

- remove table leg and top 5 from mount 6 - remove drain hose 13 at bottom
- remove table mount 6, four screws (arrows) - remove four clamps arrows

..'@ - (@!]LV VI I 10=

I~

~
•
If
{ (E) ;-1 =
0 !---

Jl lfi'''•=Jjr
([) 7~\
:::::::;
'P
'-' _J I 1~ \-
:=:d
::l.
.
~"::::

(~
"./~II
8 ln~1ol

- remove retainer strap for sink cabinet door 7 -disconnect gas lines at union nuts 14 and remove
- unhinge refrigerator door 8 and sink cabinet door 9
- remove drawer 10

r
llllllllllllll r;_ -~~"
0
,, ~
!l 1~
~2
[[[[[Jl ~ ~n
\.. Jt
0
0
J~ J ln~711
- remove water hose 15 from faucet
- remove hose clamp from valve 16 and disconnect
- remove shelf 11 and water pump cover 12
hose

K·21
Sink cabinet, removing 7 6 •21
76 Cabinets, Water Tank, Refrigerator

-remove nut (arrow) from wall support bracket and

CAUTION push out bolt

Before working on any part of electrical system,

disconnect battery ground strap.

- disconnect 12V DC water pump switch

connection 17
- pull110 disconnect V.A.C. wire from refrigerator 18
- remove cover from 110 V.A.C. outlet
-remove 110 V.A.C. socket (four screws)

'
- remove bolt (arrow) from floor bracket
-lift sink cabinet and refrigerator over floor stud,
towards center of vehicle

- remove three boHs (arrows) from side wall of

chest

7 6 •2 2 Sink cabinet, removing

 Cabinets, Water Tank, Refrigerator 76
WARNING
Fire hazard! Do not smoke or have anything in
area that can ignite propane fuel. Ensure
adequate ventilation.

- remove two clamps (arrows) from rear of cabinet

and remove 110V socket with cable harness.
- lift sink cabinet with refrigerator from vehicle

Sink cabinet, Installing

WARNING
If propane gas lines are opened during repair
work, a pressurized leak test must be
performed, prior to returning the vehicle to
service. Use soap water or equivalent to check
all fittings.

- install in reverse order of removal

-remove nuts (811'0W'S A) and loosen nuts (811'0W'S B)
- remove propane tank
2 1
Propane tank, installing
- install in reverse order, noting the following

WARNING
Always replace self-locking nuts. After installing
gas lines, check all fittings for leaks. Apply
soap solution to joints and watch for bubbles
with lines under pressure.

Propane tank, removing

- close valve 1
- disconnect line fittings 2

WARNING
During repair work on any part of electrical
system, the electrical hook-up for 110/220 volt
power source must be disconnected.

K·23
Deluxe Sink cabinet, removing/Installing
Propane tank, removing/Installing ·
76 •23
76 Cabinets, Water Tank, Refrigerator

Refrigerator, removing

- Close valve 1 on propane tank

WARNING
During repair work on any part of electrical
system, the electrical hook-up for 110/220 voH
power source must be disconnected.

WARNING
Fire hazard! Do not smoke or have anything in
area that can ignite propane fuel. Ensure
adequate ventilation.

- remove screws (arrows) and remove vent cover 4
- remove cabinet doors and drawer
- remove shelf
- I
CAUTION
Before working on any part of electrical
system, disconnect battery ground strap.
-remove plug 5 for 110 volt AC supply
- disconnect connector 6 for refrigerator
- place wiring harness on top of refrigerator
- disconnect gas pipe 7
-remove both screws·(arrows)

1/
- remove strap 3
- remove cabinet and refrigerator doors
- remove drawer
- remove shelf 4 - remove shelf in storage chest and screws
(arrows)

7 6 •2 4 Refrigerator, removing
Deluxe
 Cabinets, Water Tank, Refrigerator 76
Refrigerator air supply modification
(Dometic 182 models)
Note
When troubleshooting ignition problems on the
refrigerator unit, verify spark and fuel are adequate
prior to performing air supply modification

orG~--Q~~"""l"r'"';;;;;;;;;;;;;;;"""' Air Pump

J
- remove plugs 8 in cover plate 9 and remove

] -

Note
screws
remove cover plate 9 by pulling lower part forward
(arrow A) and then to side (arrow B)
remove refrigerator

176-A020 I

] Ventilator must slide easily out of air duct.

Refrigerator, Installing
- install in reverse order
Air pump Installed (arrow)

] WARNING
After installing gas lines, check all fittings for
leaks. Apply soap solution to joints and watch
for bubbles with lines under pressure.

176-A021 I
Air pump removed (arrow)

remove air pump assembly from refrigerator

\
1

l·3
Refrigerator, removing/Installing •
Deluxe Refrigerator air
pump modification 76 25
76 Cabinets, Water Tank, Refrigerator

Air Pump

176·A022j 176-A024j

-disassemble air pump - disassemble air pump piston assembly

• 0-ring (arrow) is not part of original assembly

17e-A0251
- drill out air outlet (arrow) of pump housing, using
a #40 drill bit (3.54mm, approximately 9/64 in.) - install 0-ring
• 0-ring may be obtained at local hardware or
auto supply store
- reassemble air pump piston
assembly with circlip in groove approximately mid-
shaft !arrow)
- reassemble air pump

76 •2 6 Refrigerator air pump modification

 Cabinets, Water Tank, Refrigerator 76

Air Pump

176·A020 I
- remove existing plastic air supply line (left arrow)
with one-way check valve and discard
- reinstall air pump (right arrow)
Tie Wrap
- install replacement one-way valve between two
lengths of 4mm (approximately 5/32 in.) ID x
65mm .(2.5 in.) long, surgical tubing or equivalent,
(arrows)

CAUTION
Part numbers are for reference only. Always
check with your Parts Department for latest
information.

l 7s.A0291
-secure replacement check valve to ignitor with tie-
wrap (arrow)

17&-A0271
CAUTION
To avoid pinching ignitor wire when reinstalling
assembly, secure wire with tie wrap to rear of
CAUTION unit.
Be careful not to puncture one way valve
diaphragm

-drill out one-way check valve PIN 055 131101 at

inlet and outlet (arrows) using a #40 drill bit
(3.5mm approximately) 9/64 in.)

L·S Refrigerator air

pump modification
76 27 .•
 77

Seats, Bed

Index
- Rear seat with storage locker
removing/installing 77.2
- Roof bed, boards
removing/installing 77.3

77.1
77 Seats, Beds

Rear seat with storage locker,

removing
/-:remove mattress from engine compartment deck
',

- remove bolts 3 in bottom panel on both sides

- remove bracket on locker

- remove screws 1 from rear seat back-rest bracket

on left and right sides
- loosen screws (arrow A) from arm rest B and pull
out toward rear (upper arrow)
- lift up rear seat bench
- pull seat belts into storage locker

-remove 3 screws (arrows) if Digifant equipped

- disconnect Digifant control unit 4, if applicable
- remove nut 5 on each left and right, push
bolts out
- pull out storage locker toward front

CAUTION
-pry off caps (arrows), remove screws, and Circuit breaker can be easily damaged.
cover 2
Rear seat, with storage locker,
installing
- install in reverse order with the following
- check seat mechanism for proper function

77 •2 Rear seat with storage locker, removing/in~Jrtalling

 Seats, Beds 77
Roof bed, removing
Note
For vehicles up to 1984 model year.
Before removing roof-bed, first remove storage shelf,
ceiling cabinet and clothes closet, see group 76.

Removing bed boards

Note
Up to model year 1984.
Before bed boards can be removed, storage pan,
wall cabinet and clothes closet must be dismantled,
see repair group 76.
-remove roof-bed board screws (arrows)
- Loosen left headliner and remove from retaining
rails. See "removal of right air duct, Repair Group
76

Note
From model year 1985.
Before bed boards can be removed, storage pan
with curtain molding, left, cover with curtain molding,
right, wall cabinet and clothes closet must be
dismantled, see repair group 76.

- remove hinge 1 screws (arrows) in roof frame

- remove front bed board
- remove screws (arrows) for cover plate 3
- remove rear bed board

Roof bed, installing

- install in reverse order

-remove screws (~rrows) for roof rail 5

-remove screws (arrows) for center roof
reinforcement 6

L·B
Roof bed, removing/installing 77.3
 80
Heater
Ventilation

Quick Data Index

Additional heater, under rear
bench seat
-Water-cooled 80.16
Controls assembly
-Aircooled without fresh air fan 80.5
- Aircooled with fresh air fan 80.8
-Water-cooled 80.12
Flap housing
-Aircooled with fresh air fan 80.10
-Water-cooled 80.14
Heater/Fresh air box housing
-Water-cooled 80.15
Heater control flap cable 80.4
Rear air duct 80.3
System components
-Aircooled 80.2
-Water-cooled 80.11

A-1 80.1
80 Heater and Ventilation

Fresh air outlet in roof pillar

supplies fresh air only
.....---- Center vent
removing/installing page 80.5

r - - - - - Fresh air vent

removing/ installing page 80. 5
Rear air duct gasket - - - - - . .
installing Fig. 1

Heater vent

Warm air hose

Warm air distributor (passenger compartment)

remove fuel tank to remove
installing Fig. 4 Heater control flaps
adjusting Fig. 2
....___ Heater/Ventilation controls
removing/installing page 80.5

Ventilation chamber/Warm air distributor (driver's compartment)

disassembling/assembling page 80. 5 Heater control flap cable
installing Fig. 3
disassembling I assembling page 80.7

80.2 HeaterNentilation system

System components
Air-cooled A·2
 Heater and Ventilation 80

Fig. 1 Rear air duct gasket, Installing

Fig. 3 Heater control flap cables, installing
- install gasket with louvers pointed
down (arrow) - install sleeve with cable on bracket B
in hole 1 (long end of cable to outside
of vehicle)

Fig. 2 Heater control flaps, adjusting

-move center heater/ventilation control
lever to left side to stop
-check that spring-loaded heater
control flap is at end position (arrow)
- tighten clamping bolt on cable in end
position Fig. 4 Warm air distributor for passenger
compartment, installing
-first, install connecting rod 1 for
cable in slot 2 of lever and secure
with circlip

age 80.7

A-2 Rear air duct

A-3 Air-cooled Heater control flaps/cables
Warm air distributor 80.3
80 Heater and Ventilation

Note
Heater control tlap outer cable is pressed
in guide sleeve

Inner cable reinforcement

ushing

insert in bushing to stop

welded to frame

Heater control flap outer cable

insert in guide sleeve to stop

slide over bushing

80.4 Heat control flap cable

Air-cooled

~---t-leatter outlet
removing: press in two lugs (arrows)
below dashboard
installing: left and right outlets are
different, note part numbers
Heater and Ventilation 80
Heater outlet
removing: press in two lugs (arrows)
below dashboard
installing: left and right outlets are
different, note part numbers

;-----Outlet gasket
glue to ventilation chamber
with 0 17

~----Trim plate
ply off dashboard
with screwdriver

Heater /Ventilation controls

remove instrument cluster
Fresh air before adjusting controls.
removing: press in four lugs (arrows) Installing and adjusting cables, page 80.6
below dashboard

A·S Air-cooled without Fresh Air Fan

Heater /Ventilation controls assembly 80.5
80 Heater and Ventilation

Heater/Ventilation controls,
installing/adjusting cables

Work sequence
-install controls
-install trim plate
- press on levers
- loosen two heater control flap cables at
heater control flaps

-push lever on ventilation chamber against

spring tension (arrow)

-install both inner cables of heater control

flaps in center slide (as shown) and tighten
outer cable to controls a
- push center control lever to extreme left
(arrow)

-engage inner cable for vent ilation chamber

in lower lever
-push lever in direction of arrow toward right
side of vehicle
-tighten ventilation chamber outer cable with
lever in this position

- go to next page

-check that spring-loaded heater control flap

is in end posit ion (arrow)
-tighten clamping bolt and lock inner cable
in end position

80 6•
Heater/Ventilation
controls
IAir-cooled without Fresh Air Fan I
 Heater and Ventilation 80

-pull inner cable for warm air distributor

(passenger compartment) against spring - hook inner cable for warm air distributor
tension (arrow) toward warm air distributor (driver's compartment) in upper control lever
- secure outer cable on bracket

Ieo-ml
- hook inner cable for warm air distributor
(passenger compartment) in upper control
lever

leo-2231
- push control lever on warm air distributor
(driver's compartment) in direction of arrow
and hold in position

I Aircooled without Fresh Air Fan I HeaterNentilation controls 80.7

80 Heater and Ventilation

Heeter outlet
Heater outlet
removing: press in two lugs (arrows)
removing: press in two lugs
below dash
below dash
installing: left and right outlets are
installing: left and right outlets are
different; note part numbers
different; note part numbers

.;; r
Outlet gasket
glue to ventilation chamber
with D 17

esh air fan

moving/installing 80.10

Heater and fresh air fan

Warm air hose
disassemble/ assemble 80.10

Air deflector

Heater /Ventilation controls

remove instrument cluster
before removing controls.
removing: press in four lugs Installing and adjusting cables,
below dash 80.9

-+-Warm air from engine

80-261

80.8 Heater /Ventilation system

Air-cooled with Fresh Air Fan
 Heater and Ventilation 80

Fig. 1 Control cables:

o n lever 4 -- passenger-compartment
ventilation
(cable conduit has 2 green paint marks
and projects out of clamp approx.
a = 3 mm (1,/8 in.)
on lever 3 -· main cut-off flap
(cable conduit has green/yellow paint
mark and projects out of clamp approx.
a= 3 mm (1/8 in.)
Fig. 3 Control e<able
on lever 1 -heated air distributor in
passenger compartment
cable conduit has red paint mark and
projects out of clamp approx. a = max
30 mm ( 1 3/16 in.)
on lever 2 -heater flap cable (arrow)

n plate
off dash with
lwdriver

ver
II off

Jls

:ables,

-261 Fig. 2 Flap-housing cables

1 -passenger compartment flap
2 - main cut-off flap
3 -defroster flap and footwell flap
Fig 4 Control cable
on lever 1- defroster/flap footwellflap
cable conduit has red paint mark and
projects out of clamp approx . a= 30 mm
( 1 3/16 in. )

A·9
Air-cooled with Fresh Air Fan Heater /Ventilation controls,
installing 1adjusting cables 80.9
80 Heater and Ventilation

Flap housing, upper part

Defroster flap

Flap housing, lower part

Flap housing, insert

/ Series resistance
... I
~
when installing.
to avoid leaks
I
1\

_/ )
/
Housing cover_/
engage lugs and slots
properly when assembling >• - . _ / /

lso-262!

80.10 Flap housing,

disassembling I assembling
Air-cooled with Fresh Air Fan
 Heater and Ventilation 80
-

Heater/ventilation
with fresh air fan
disassembly/assembly, page 80.12 Control vaive
removing/installing, page 80.12

Fresh air/heating control Air distributor

removing/installing, page 80.12 removing/installing, page 80.12

A-11
All Water-cooled HeaterNentilation/Heater Exchanger
System components
80 .11
80 Heater and Ventilation

Heater /Ventilation and

fresh air fan
disassembling / assembling Fresh air fan I
80.14 removing / installing 80.14

/-to~~., pump

closed
from cylinder head

Control unit/cover plate

removing : first remove dash insert
installing and adjusting control cables,
page 80.13

I so-2ssl

80.12 HeaterNentlla1ion and Fresh Air Fan,

disassembling/assembling
All Water-cooled A·12
 Heater and Ventilation 80

Fig. 1 Control Ieven Fig. 3 Control cable:

on lever 4 - passenger compartment on lever 1 ·· defroster flap/footwell flap
ventilation (cable conduit has red paint mark)
cable conduit has 2 green paint marks
on lever 2 ·· to control valve
and projects out of clamp approx.
(cable conduit has 2 blue/yellow paint
a= 3 mm (1/8 in . )
marks)
conduits project out of clamp approx.
a= 30 mm (1 3/16 in.)
b = 20 mm (3/4 in.)

Fig. 2 Flap-housing cabies:

1 - passenger compartment flap Vehicles with auxiliary heater DA 6 only

2 - main cut-off flap
3 - defroster flap and footwell flap Fig. 4 Control cable:
on lever 1 ·· ~eated air distributor in
passenger compartment
(cable conduit flas red paint mark and
projects out of clamp approlC.
a= max. 38 mm (1 1/2 in.)
30-256]

A-13

··12
All Water-cooled Heater / Ventilation controls,
lnstaUing/adjusUng cables 80.13
80 Heater and Ventilation

Defroster flap

Fresh air fan

Flap housing, lower part*

r--- Heat exchanger

.-- £ Series resistance

coat with D17 ~

when installing
to avoid leaks

Housing cover _ /
engage lugs and slots
properly when assembling

* Note
Seal the locating grooves in upper and
lower part of housing with sealing
compound, Part No. AMV 176 00 05

80.14 Flap housing: disassembling/assembling

All Water-cooled
A-14
 Heater and Ventilation 80
\
\
Heater/fresh air box, splitti~g
/
The heater/fresh air box halves are welded together
at 18 flange areas.

To split case apart when repairs are needed,

-insert knife along welded flange seam (1)

- hit knife sharply with hammer
- break all18 welds

To assemble case halves after welded seams have

been broken,
- attach clip (3) at clamp flange (2)
• requires 11 clips
• part number 321 819 059

CAUTION
Part numbers are for reference only. Always
check with your Parts Department for latest
parts information.

A·14
A-15
Water-Cooled From 1986 Heater/fresh air box housing,
splitting
8o.15
80 Heater and Ventilation

~--1

10

t 2
;
4

1 1

CD - Water hose to and from engine

® - Restr1ctor
@-Heater valve (additional heating)
@-Heater core (additional heating)
@-Clamp
@ - Heater core (in heater box)
Note (!)-Engine
Double arrows indicate direction of coolant flow. @ - Engine radiator
Single arrows indicate flow direction of heater valves. ® - Heater valve
@l - Additional heater

80.16 Additional heater,

under rear bench seat
All Water..Cooled

Quick Data Index
Air cooled - AFC
-Air circulation blower 82.7
-Combustion air blower 82.3,
82.4
hose 82.4
-Control flaps 82.8
-Defrost/Footwall flaps 82.7
-Flame switch 82.5
-Fuel pump 82.6
-Glow/Spark plug 82.3, 82.14a
-Heater booster/components 82.2
assembly 82.3
-Heater lever switch 82.8
-Ignition coil 82.6
-Overheat switch 82.4
-Safety switch 82.7, 82.8
-Temperature regulating switch
82.5
-Temperature sensor 82.6
-Troubleshooting (heater
booster) 82.1 0, 82.11
Diesel
-Air circulation blower 82.17
-Combustion air blower 82.14
-Control valve 82.17
-Flame switch 82.15
-Fuel pump 82.17
-Glow/Spark plug 82.14
-Heater housing 82.14
-Ignition coil 82.17
-Overheat switch 82.15
-System components 82.12
-Temperature regulating switch
82.16
-Temperature sensor 82.16
-Troubleshooting 82.18
8·1
82
Heater
Booster
Auxiliary heater BBW 46
-Auxiliary heater
components 82.20
electrical wiring 82.24
operating 82.25
waterflow 82.22
-Combustion air blower
adjusting 82.32
removing/installing 82.32
-Engine coolant system
draining/refilling 82.35
-Felt pad
removing/installing 82.29
-Flame head
removing/installing 82.33
-Flame switch
checking 82.30
removing/installing 82.30
-Fuse S24
removing/installing 82.33
-Glow plug
checking 82.30
- Heater core
removing/installing 82.33
-Metering pump
flow rate checking 82.35
-Recirculation pump
removing/installing 82.32
- Series resistor
removing/installing 82.32
-Temperature sensor
checking 82.31
removing/installing 82.31
82.1
82 Heater Booster

Temperature sensor
checking Fig. 14

Glow/spark plug
checking Fig. 2
replacing Fig. 3

Heater relay------~
with 1 ohm resistor for air
circulation blower

Heater lever switch Air circulation blower

replacing Fig. 24 checking Fig. 20
replacing Fig. 21
Defroster/footwell flaps
checking Fig. 19

Main fuse
16A

Heater blower
(on alternator)
removing/installing
see Repair
relay panel
Group 27
Heat exchanger

in supplemental fuse holder

Temperature regulating
switch Exhaust pipe
checking Fig. 12 clean or replace if necessary
replacing Fig. 13
Combustion air blower
checking Fig. 4
replacing Fig. 5 and Fig. 6 Combustion air hose
must fit tightly on blower

Fuel filter/water separator

drain water; note fuel flow direction (arrow)
Ignition coil Fuel pump
replacing Fig. 17 and Fig. 18 checking Fig. 15
adjusting Fig. 16
Overheat switch
checking Fig. 7 and Fig. 8
replacing Fig. 9

82.2 Heater booster/components

Air cooled-AFC
 Heater Booster 82
/

ls~-170A I

Fig. 1 Heater booster, checking

1 =glow/spark plug adaptor. If carbon-
fouled, clean with toothbrush Fig. 3 Glow/spark plug
2 =combustion air blower vane housing.
If burned, replace
3 =combustion chamber. If carbon-fouled, CAUTION
clean
Connectors for terminals 1 and 2 rnust not
4 =fresh air inlet. If dirty, clean
contact plug connector 3. This may cause
5 =exhaust outlet. If tar-like deposits are ignition trouble
noticeable, replace
6 =heater booster housing. If distorted
by overheating, replace
7 =ceramic ring for overheat switch. If
damaged, replace

11er
Jr)
stalling

Fig. 4 Combusion air blower, checking

- check for damage caused by
overheating at points marked 1
Fig. 2 Glow/spark plug, checking -check blower bearing 2 for free
movement in both directions
1 =high tension terminal
2 =glow element terminal Note
3 =ground terminal
Fuel is injected by pump every 33rd
• electrode gap a : 2.5 mm (3/32 in.) revolution of blower shaft. Each injection
• voltage :12 volts stroke can be detected by ticking noise
• resistance :4000-6000 ohms from pump
• current draw of :10 A
glow element Number of pump strokes x 33 =blower
speed
speed: 6400-7000 rpm
(at 12 volts after running for 10 minutes)
• equivalent to 190-210 pump strokes per
minute

8·3 Air cooled-AFC Heater booster assembly

Glow/spark plug
Combusliofl air blower
82 3•
82 Heater Booster

Fig. 5 Combustion air blower, installing Fig. 8 Overheat switch, checking

• condensation drain hole in housing
must be at bottom (arrow)
-disconnect wiring (arrow) from blower
• if overheat switch operates within
60 seconds after blower is
di"·COnnected, switch is OK
(replace fuse)
• if NO, replace overheat switch and
fuse

Fig. 6 Combustion air hose, Installing

• combustion air hose must fit tightly on
blower connection and in rear frame
cross member.
If hose comes off, heater flame will
damage blower
Fig. 9 Overheat switch, Installing
-crimp green wire to terminal A
- crimp brown wire to terminal B
-solder wires (use rosin-core solder)

ia2-118l
Fig. 7 Overheat switch, checking
(switch installed)
- remove ceramic ring 1 first
- turn heater on (engine not running)
• heater must start working within
70 seconds

Combustion air blower

82.4 Combustion air hose

Overheat switch
 Heater Booster 82

Fig. 12 Temperature regulating switch, checking

j82-,Q10A I (switch installed)
Fig. 10 Flame switch, checking - turn heater on
(switch installed) -disconnect either wire to temperature
sensor (very briefly or overheat switch
- turn heater ON
will operate)
• heater must ignite within 70 seconds
• fuel pump should continue to run
at 20.C/68•F
If YES, temperature regulation OK
- turn heater OFF
If NO, replace temperature regulating
• run on time must be between 80 and
switch
160 seconds at 2o•cJ68·F
-bridge temperature sensor terminals
If NO for either condition, replace flame
• fuel pump should stop running
switch
If YES, temperature regulation OK
If NO, replace temperature
regulating switch
• if temperature regulation is still not
correct, check temperature sensor
Fig. 14

Fig. 11 Flame switch, removing

- pull rubber grommet off carefully
-remove union nut and pull switch out

CAUTION I IJD I
Do not bend sensor tube Fig. 13 Temperature regulating switch, replacing

CAUTION
Disconnect battery ground strap before
starting to work

- remove escutcheon with VW 674/1

• do not interchange wires of
terminals 31 and K (outside of multi-
pin connector) as this will cause
short circuit in sw itch

B·S Air cooled-AFC Flame switch

Temperature regulating switch
82 5
•
82 Heater Booster

I 82-014A I
Fig. 14 Temperature sensor, checking
-place in warm water (60.C/140.F)
• resistance: 3500-5000 ohms
Fig. 16 Fuel pump, adjusting
• to increase amount of delivery:
turn hose adaptor C in direction of
arrow B
• to decrease amount of delivery:
turn hose adaptor C in direction of
arrow A
- lock and seal with paint after
adjustment

Fig. 15 Fuel pump, checking

(pump installed)
• arrow A= direction of fuel flow

WARNING
Fire hazard! Do not smoke or have anything
in area that can ignite fuel
Fig. 17 Ignition coil, connections

- remove hose on pressure side of pump A= high tension wire

- connect piece of hose to pump and B =terminal 15
hold into measuring glass C =terminal 1
- turn on heater
- check amount of fuel in measuring
glass after 200 strokes of pump
• amount: 18.4 to 21.7 cm 3

Note
To count 200 strokes write down number every
10 strokes.
If delivery rate is not correct, adjust fuel pump
per Fig. 16

Temperature sensor
Air-cooled AFC
82.6 Fuel pump
Ignition coil
8·6
 Heater Booster 82

Fig. 18 Ignition coil, location

Fig. 21 Air circulation blower, replacing
Z= ignition coil
• condensation drain hole (arrow) must
be at bottom

ls2- 193A f
Fig. 19 Defrosterlfootwell flap, checking
-check flap (arrow) for free movement
Fig. 22 Safety switch, checking
(switch removed)

CAUTION
Disconnect battery ground strap.
Temperature regulation switch will be
damaged if disconnected wires touch one
another or ground

-connect ohmmeter to terminals A

- .apply 12 volts to terminals NO
-measure elapsed time when voltage is
applied until contact is interrupted
Fig. 20 Air circulation blower, checking at terminals A
(blower installed) • switch response time:
• current draw: 150 to 230 seconds at 20°C/68°F
(engine not running) If NO, replace switch
low speed: 3 to 4A
high speed: 6.5 to 7.5A Note
If safety switch has operated within
required time, press reset lever in
direction of arrow

Air cooled-AFC
Defroster/footwall flap
Air circulation blower
Safety switch
82 7
•
~-6
82 Heater Booster

Fig. 25 Control flaps, checking

Fig. 23 Safety switch, replacing - remove hoses
- disconnect battery ground strap -check operation of flaps (arrows)
• safety switch (arrow)

182 -190)

Fig. 24 Heater lever switch contact, location

• switch contact (arrow)
-removing/installing, see Repair
Group 80

Safety switch

82.8 Heater lever switch

Control flaps
Air-cooled AFC
 Heater Booster 82
i
I

THIS PAGE INTENTIONALLY

LEFT BLANK

8·9 82.9
82 Heater Booster
2b 5 6 21 8 9 11 12 13 1~

1 2a 19 3 20 7 15 16

Trouble Operating conditions

10th fuse (16 A) in fuse relay panel blown Engine running

Heater lever switch 5 ON
Temperature regulating switch 3 ON

Main fuse (16 A) in fuse holder blown Temperature regulating switch 3 ON

Heater lever switch 5 ON

Overheat switch 9 has operated and fuse 26 (8 A) has blown Temperature ~gulating switch 3 ON
Heater lever switch 5 ON

Safety switch 19 has operated Temperature regulating switch 3 ON

Heater lever switch 5 ON

Heater does not run on Heater and engine turned OFF

Air circulation blower does not run at two speeds Temperature regulating switch 3 ON
Heater lever switch 5 ON
Ignition turn ON and OFF

Heater output inadequate and/or heater uses too much fuel Engine running; heater turned ON

Air circulation blower 13 and combustion air blower 20 Engine running

continue to run after run on period although heater is turned Heater lever switch 5 ON
OFF Temperature regulating switch 3
just turned OFF

Heater smokes Temperature regulating switch 3 ON

Heater lever switch 5 ON

Heater does not start up at all Temperature regulating switch ON

Heater lever switch 5 ON

Note
At least 10 volts required for voltage check at flame switch

Air cooled-AFC B-10

82.1 0 Troubleshooting-Heater booster
 -I -1 -~- I I"' ~
~I
I I r
Cll
.:..
0

I
lXI
.:..
....
Ot>O~
II II II 3
cnz::z::cr
lllo-·o
11111111
I I I 0 I
~-
1-10th fuse (16A) in fuse/relay panel
see
page
Wiring Diagrams
c:-cg.;.;;
0(/.1-c.. 2a- Main fuse (16A) in inline fuse holder Wiring Diagrams
30'<Q)
-o"O:::l 2b-Overheat fuse (SA) in supplemental
a as.
crCTIIl
0 0 0
fuse holder Wiring Diagrams
Ill Ill c.
~~Ill t> 0 0 0 3- Temperature regulating switch 82.5
QllllCC

m 0 4- Defroster/footwell flaps 82.7

,---
--
0

ac:
0 I I
t>
I I
I I 0
I I
I I 0 0 0
5- Heater lever switch
6- Heater relay
82.8
82.2
;e: cr
'"'I ,i)
1 0 0 7 -Glow/spark plug 82.3 1
a
8 ll
g
0
t> I 0
t>
I t> I I
8- Temperature sensor
9- Overheat switch
82.6
82.4
& ~ t> I t> I I I 10- Heater booster 82.3

.,:J>0
I
0 0 0
0
I
0
I I I 11 -Flame switch
12-Exhaust outlet
82.5
82.2
I..__ 0 0 t> 13-Air circulation blower 82.7
t> 0 t> 14-Exhaust pipe 82.2
0 15-Control flaps 82.8
16- Heater flap 82.2
0 17- Heat exchanger 82.2
g~ t> 18- Heater blower 82.2
cr
:
::r
0 I o I I t> I I 19-Safety switch 82.7

~
t> t> I 0 I t> I I 20-Combustion air blower 82.3 :::t:
j" 0 I I I I 21 -Fuel inlet 82.2 CD
I
::z::

-..
CD
Ill
CD
r T I
0 I
t>
t>
0
0
22 -Ignition coil
23-Fuel pump
24- Fuel filter/water seoarator
82.6
82.6
82.2
. a
CD
m
I..
Iii
-f--
0 I I I 25-Combustion air hose 82.2 0
0
i.
t> 0 0 I 0 I 0 I -Trace circuit in current flow diagram Wiring Diagrams

~
.....
•
.....
CD
N
82 Heater Booster
Rear footwall outlet
Warm air outlet is controlled by
upper lever which never allows
all hot air to flow either to
Main fuse (16 A) windshield/front footwall outlets
Overheating fuse (8 A) or rear footwall outlet. Stop
Control unit screw keeps check valve in such
Heater relay a position that warm air can never
flow only into front of car.
Overheating with air circulation
blower is thereby prevented

Relays

Air circulation
Temperature regulating blower relay
switch
checking Fig. 11
replacing Fig. 12

Fuel filter/water separator

drain water; note fuel flow
direction (arrow)

Fuel pumps--......,.
checking Fig. 14

Fuse panel
Glow/spark plug
heater wiring is connected
checking Fig. 2
to 7th and 10th fuse holders
Combustion air blower Overheat switch
checking Fig. 4 checking Fig. 7
replacing Fig. 3 and Fig. 6 replacing Fig. 8
Combustion air valve
removing Fig. 3
checking Fig. 5

Current flow diagram see wiring diagram, repair group

Troubleshooting page 82.18, 82.19

82.12 Heater booster/components

All Water·cooled
 I
I Heater Booster 82

h
ver

Air circulation blower

checking Fig. 17
replacing Fig. 16
iS Or

Combustion air hose

must fit tightly on blower

--Heater housing
checking Fig. 1

8·13
All Water-cooled
Heater booster/components 82.13
82 Heater Booster

Fig. 1 Heater booster, checking

Fig. 3 Combustion air blower/combustion air
1 = Glow/spark plug adaptor. If carbon- valve, removing
fouled, clean with toothbrush
2 = Combustion air blower vane housing.
If burned, replace
3 = Combustion chamber. If carbon·
fouled, clean
4 = Fresh air inlet. If dirty, clean
5 = Exhaust outlet. If tar-like deposits
are noticeable, replace
6 = Heater booster housing. If distorted
by overheating, replace
7 = Ceramic ring for overheat switch. If
damaged, replace

Fig. 4 Combustion air blower, checking

-check for damage caused by
overheating at points marked 1
- check blower bearing 2 for free move-
ment in both directions

+ 15

- 31
Fig. 2 Glow/spark plug, checking
1 = high tension terminal
2 = glow element terminal
3 = ground terminal
Fig. 5 Combustion air valve, checking
• electrode gap a : 2.5 mm (3/32 in.)
• voltage : 12volts -connect ground wire to terminal 31
• resistance : 4000-6000 ohms -connect hot wire to terminal 15
• current draw of : 9A at 11V • air intake valve must open
glow element - press valve plate against stop
• check for current flow between ter-
See page 82.14a for additional information minals 15 and 15a

Heater housing, assembly

82.1 4 Glow/spark plug

Combustion air blowerNalve
All Water-cooled i·
 Heater Booster 82

Engineering tests show that a spark plug is not Note

needed to ignite the diesel fuel/air mixture in the
auxiliary heater combustion chamber.
Therefore, the combination glow/spark plug has been
superceded by glow plug Part No. 251 963 319F.
Modify wiring when replacing old style combination
spark/glow plug with new style glow plug.
Work sequence
- install new style glow plug
- connect positive ( +) and ground (-) wires to
glow plug
- remove and discard high voltage cable from
auxiliary heater ignition coil
-disconnect power supply wire to terminal15 of
auxiliary heater ignition coil and insulate terminal
end with electrical tape

la2-316l .

Old style spark/glow plug

New style glow plug Part No. 251 963 319F

8·15
New style glow plug 82.14a
 Heater Booster 82

Fig. 6 Combustion air blower, installing

• combustion air hose must fit tightly on
blower.
If hose comes off, heater flame will
damage blower
Fig. 8 Overheat switch, replacing
-crimp green wire to terminal A
-crimp brown wire to terminal B
-solder wires (use rosin-core solder)

Fig. 9 Flame switch, checking

(switch installed)
Fig. 7 Overheat switch, checking
-turn heater ON
-turn heater ON and select highest
• heater must ignite within 100
heating
seconds at 20 "C/68 "F
-wait until blowers run at highest speed
(flame switch has cut off glow plug) -turn heater OFF
-disconnect air circulation blower • run -on time must be approx. 180
(arrow) seconds at 20"C/68"F
If NO for either condition, replace flame
-wait for 90 seconds and reconnect air
switch
circulation blower
• if fuel pump starts running, overheat
switch is OK
• if fuel pump does not start running
within 90 seconds, overheat fuse is
blown
-replace overheat switch

Combustion air blower

B-16
All Water-cooled Overheating switch
Flame switch 82.1 5
-
82 Heater Booster

Fig. 10 Flame switch, removing

-pull rubber grommet off carefully
-remove union nut and pull switch out
1 a2 - 012 I

CAUTION Fig. 12 Temperature regulating switch, replacing

Do not bend sensor tube
CAUTION

Disconnect battery ground strap before

starting to work

-remove escutcheon with VW 674/1

• do not interchange wires of terminals
31 and K (outside of multi-pin con·
nectar) as this will cause short circuit
in switch

Fig. 11 Temperature regulating switch, checking

(switch installed)
-turn heater ON and wait until blower Fig. 13 Temperature sensor, checking
speed increases
-bridge temperature sensor terminals -place in warm water (60.C/140.F)
(arrow) • resistance: 3500-5000 ohms
• one fuel pump (small quantity) must
start running
-remove bridge on connector for
temperature sensor
• other fuel pump (large quantity) must
start running
if under both conditions, fuel pumps are
running, temperature regulating switch
is OK

Flame switch

82.1 6 Temperature regulating switch

Temperature sensor
All Water-cooled
 Heater Booster 82

Fig. 14 Fuel pump, checking

(pump installed)
1-Fuel pump for small quantity (Spare Fig. 16 Air circulation blower, replacing
Part No. 251 261 467 A) • condensation drain hole (arrow) must
2-Fuel pump for large quantity (Spare be at bottom
Part No. 251 261 467 B)
3-T·connector
-disconnect hose between heater and
T-connector (3) at connector and hold
into measuring glass
-turn heater ON and wait until pump
starts pumping
-check amount of fuel in measuring
glass after 100 strokes of pump
• amount: 4.5-5 cm 3
-connect green/yellow wire of fuel
pump (1) to fuel pump (2)
-turn heater ON and wait until pump
starts pumping
-check amount of fuel in measuring
glass after 100 strokes of pump
Fig. 17 Air circulation blower, checking
• amount: 8-9 cm 3
(blower installed)
• current draw:
(engine not runn ing)
l.ow speed: 3 to 4A
high speed: 6.5 to 7.5A

Fig. 15 Ignition coil, connections

Fig. 18 Control flap, checking
A = high tension wire
B = terminal 15 -if SA overheat fuse is blown, check for
C = terminal 1 free movement of flap

Fuel pump
B-18
All Water-cooled Ignition coil
Air circulation blower/Control valve 82.17
 82 Heater Booster
Troubleshooting Main fuse 16A
(in fuse panel)

Relays In holder for: - - - " " Overheat fuse SA

• glow/spark plug resistor (in fuse panel)
• flame switch
• fuel pumps Filter
• compulsory starting

Temperature---
regulating switch

Note
At least 10.3 volts required for voltage check at flame switch

Trouble Operating conditions

main fuse (16 A) blown engine running,
I
j: temperature regulating switch ON
i
overheat switch operates and overheat fuse blows temperature regulating switch ON
heater cannot be shut OFF heater switched OFF
heater does not run on heater switched OFF
air circulation blower does not run at 2 speeds temperature regulating switch ON,
wait until heater responds,
switch ignition ON and OFF
heater output inadequate, temperature regulating switch ON,
small quantity fuel pump always works switch turned to high heating,
wait until heater responds
heater output too hot, temperature regulating switch ON,
large quantity fuel pump always works switch turned to low heating,
wait until heater responds
heater does not start working at all temperature regulating switch ON
heater stops working after run-on time temperature regulating switch ON
heater smokes temperature regulating switch ON
air circulation blower and combustion air blower engine running,
~ontinue to run on although heater is turned OFF temperature regulating switch was turned ON

B-19
82.18 Troubleshooting
All Water-cooled
 1:111
Trouble caused by D!>O~
~ II II II~
0 0 main fuse (16 A) OOZIQ.
0 !> 0 0 overheat fuse (8 A) ~ 9.!0" (II
C.(l):::ra.
oo.:C:<ll
D !> 0 0 !> 0 temperature regulating switch 3-o-o5
D !> 0 !> !> control unit ao;-
CTCTa.
IUIII<ll
D 0 relays for: • glow/spark plug resistor ~~(C)
<1l <1l a;
D 0 D • flame switch <1l
e.
0
D !> D
D
• fuel pumps
• compulsory starting
-
3c:
CT
(i)
D 0 D air circulating blower relay
"0
!> 0 glow/spark plug 3
CT
Ill
D 0 0 temperature sensor !:!.
;:;:
!> 0 overheat switch '<

D 0 heater housing
0 0 0 !> flame switch
;e: D D !> air injector

~
CD D 0
0 !> air circulation blower
exhaust pipe
"';'

8 D
D
fuel pump (small delivery quantity)
fuel pump (large delivery quantity)
& !> 0 \, combustion air valve
0 !> I
combustion air blower
~ D fuel injection connection
g !> ignition coil ::1:
CD

I
i
!>
0
0
!>
0

0
check valve
fuel filter
combustion air hose
aCD
.
m
footwell outlet
0
CD !> 0 0 troubleshoot according to current flow diagram 0
1\)
....c.o
• ;..
CD
1\)
82 Heater Booster
Auxiliary heater BBW 46
This heater is offered as optional equipment on
Vanagon Syncro models only sold in Canada.

Flame switch - - - - - . Glow plug - -.....

removing/installing, Fig. 6 checking, Fig. 5
checking, Fig. 7

Felt pad---'"'
removing, Fig. 1
repairing, Fig. 2
installing, Fig. 4
Felt pad -----..
,
.... ......
...........
"'\
I
.....
I
removing, Fig. 1 I I
repairing, Fig. 3 I I Flame tip-----.
I I removing, Fig. 16
Installing, Fig. 4
I I installing, Fig. 17
I I
I I
I I
......... !,..
":.....
.................
........... ....,.,,,...,,"7\,>.

Cover

Tension spring-----'

Intake air sound darnpt~ne1r _ _...

removing/Installing, Fig. 15
adjusting, Fig. 14

Metering pump
checking pump capacity, Figs. 20
and 21

Combustion air blower

removing/installing, Fig. 13
adjusting, Fig. 14

Combustion air adjusting screw ----J

(pre-set at factory, do not adjust)

82.20 Components
Auxiliary heater BBW 46
 Heater Booster 82
Cap

Temperature sensor
removing, Fig. 8
installing, Fig. 9

'-----Overheating fuse
removing/installing, Fig. 10
checking, Fig. 10

Series resistance
removing/installing. Fig. 11

Wiring harness connector

Q..rlng

Circulation pump
removing/installing, Fig. 12

CAUTION
Coolant/antifreeze must not be reused when
replacing engine, cylinder head, cylinder head
gasket. radiator and heater core.

-
Auxiliary heater BBW 46
Compof'181lts 82.21
82 Heater Booster
Water flow through heater system
~~~~~~~rrn~rrnnTrrnTrrnnTITnn

Heater core _ __.

Heater
control
valve

Rear heater core ---.....

(under rear bench seat)

Rear heater control valve - - - -

Check valve-----....., Check

valve

Coolant
distributor

t t
' - - - - Monovalve
closed when coolant
Auxiliary temperature is
heater BBW 46 below ss•c (131.F)

Bleeder valve

Engine water pump _ ___, Engine

82.22 Waterflow
Auxiliary heater BBW 46
 Heater Booster 82
-

THIS PAGE INTENTIONALLY

LEFT BLANK

82.23
82 Heater Booster

Auxiliary heater, electrical wiring

*Fresh air blower relay

@ (123=591 ~ *Monovalve relay

o!I) (!) ~ ltlo
Heater control panel •cOculatlon pump '"'"' --.:L.
·n- ..,.. -1U Uj

*The relays are located on the

Heater switch right side of the steering column.
on heater control levers

Wiring harness connector

Auxiliary heater control unit - - - - - - . ,

behind left tail light

Materlng pump
in front of left rear wheel

Monovalve
in engine compartment, right side

82.24 Electrical wiring

Auxiliary heater BBW 46
 Heater Booster 82
Setting time of day
8 7 I( the display is flashing 8:88 in the indicator field 7,
or~~ted is not the same as actual time,

9 6 - push and hold down button 3 and at the same

time push either of the two time setting buttons 6
5 or 9 to set the correct time

Immediate heating operation

- push button 4 any time to start or stop heating
• green indicator light 5 lights when heat is
switched ON
Heating begins when the engine coolant temperature
is below 800C (176°F) and the heater output lever is
pushed all the way to the right until stop.
1,2 - buttons for pre-selecting times Heating is limited to 30 minutes.
3 - time indicator display button
more
4 - immediate heat button
5 - immediate heat indicator light
6 - clock set button. forward movement
7 - time display
8 - pre-selected time indicators
9 -clock set button, backward movement
10 - pre-selected time ready indicator Hght
(yellow)

Indicating time of day

- push button 3
• time of day appears in display as long as
button is depressed
- release button 3
• indicator goes out or pre-selected time will
appear if one has been selected (this will last
about two seconds)

C·7 Auxiliary heater BBW 46

Auxiliary heater, operating 82.25
82 Heater Booster

Pre-selecting time for heat operation Auxiliary heater BBW 46, operation
A specific time to start heating may be selected up to
24 hours in advance.

Setting pre-selected time

- push button 1 or 2
• respective pre-selected indicator time will
appear in display (7) with numeral 1 or 2 at
display area 8
• yellow ready light lights
- change pre-selected time by pushing button 9
or 6
• after 20 seconds, pre-selected time display
shuts OFF
• numeral 1 or 2 in the indicator field remains lit
• pre-selected time is now activated
move heater output lever all the way to right until
stop
- switch fresh air blower to position 1
Note
Heater will not operate at pre-selected time unless
the heater output lever is in the full right position and
the fresh air blower is in position 1.
Cancelling a pre-selected time
- push button 1 or 2
• yellow ready light goes OFF
• numeral 1 or 2 in display area 8 will go OFF
• pre-selected time is now cancelled
8 7
6
5
10 1
- push button 4 to switch heater ON
- slide heater output lever fully to right
The following occurs:
• positive ( +) voltage from battery via Fuse SSS
travels to auxiliary heater control panel and
through output contact of time relay {17/87) to
contact T6/5 of Auxiliary Heater Control unit
• green "ready" control light lights
• Auxiliary Heater Control Unit switches Glow
Plug and Recirculation Pump ON
• after pre-glowing (approximately 5 seconds),
Metering Pump is switched ON by voltage from
terminal T2a/1
Note
Voltage at T2al1 is supplied via Fuse S24 by
Auxiliary Heater Control terminal T2c/2.
• a 90 second safety period begins
• fuel advances for approximately 5 seconds and
Auxiliary Heater Control Unit TS/1 sends signal
to Combustion Air Blower to run at full speed
During this time, if a flame occurs, (this is normal
operation)
• Flame Switch sends signal to Auxiliary Heater
Control Unit and Control Unit switches Glow
Plug OFF
• safety period is automatically reset

Note
If a flame does not occur during the pre-glowing and
safety period,
• a new pre-glow period (approximately 30
seconds) and safety period (approximately 90
seconds) are started automatically

82.26 Operating sequence

Auxiliary heater BBW 46

Combustion operation
The Auxiliary Heater operates at full load
immediately after being switched ON.
• temperature sensor resistance increases as
temperature rises ~-
• Monovalve separates Auxiliary Heater water
circulation from circulation of engine coolant up
to temperature of 55°C (131°F) if Auxiliary
Heater and vehicle engine operate
simultaneously
When water temperature reaches 55°C (131°F) the
Auxiliary Heater Control Unit begins to regulate
heater operation.
Vehicle fresh air/warm air operation
When water circulation temperature rises above 55°C
(131°F), voltage is supplied to terminal T6/6 of
Auxiliary Heater Control Unit.
• Heater Fan Relay and Fresh Air Fan Relay
contacts close and Warm Air Blower and Fresh
Air Fan operate
When water circulation temperature falls below 50°C
(92°F),
• Heater Fan Relay and Fresh Air Fan Relay
contacts open and operation of fans stops
Partial load operation
When water circulation temperature rises above aooc
(176°F),
• current to Combustion Air Blower goes through
resistor and blower speed decreases
• Metering Pump output decreases by 50%
C-9 Auxiliary heater BBW 46
Heater Booster 82
Full load operation
If the temperature drops below 70°C (128°F) during
partial operation,
• Auxiliary Heater Control Unit switches back to
full load operation
• Metering Pump operates at full capacity
Regulation pause
If water circulation temperature should rise above
85°C (185°F) during partial load operation, the
Auxiliary Heater Control Unit does the following:
• shuts Metering Pump OFF
After Flame Switch cools,
• after-run period begins
After-run operation
After-run operation serves to end the combustion
operation in an orderly manner. After the flame is
extinguished,
• Flame Detector indicates "dark"
• Fresh Air and Warm Air Blowers continue to
run
• Combustion Air Blower runs at full load for
approximately 60 seconds
Note
The after-run period is always approximately 60
seconds long. It is not shortened by a shut down or
rapid reduction of temperature.
Starting Auxiliary Heater after a regulation pause
If the temperature drops below 80°C (176°F) during a
regulation pause,
• a new start procedure is automatically begun
When Flame Detector indicates "light,"
• C011Jbustion operation begins at full load and
switches to partial load operation when the
temperature rises above 80°C (176°F)
Operating sequence 82.27
82 Heater Booster

Shutting heater OFF

During combustion operation,

8 7

9 6
5

10 1

- push button 4 to switch heater OFF

• Heater Indicator Light (green) goes out
• Metering Pump and Fresh Air/Warm Air blowers
shut OFF
After Flame Switch indicates "dark,"
• after-run begins

Note
Auxiliary Heater can always be shut OFF (even if the
Flame Detector switch is defective.) If the Flame
SWitch does not signal "dark" 80 seconds after shut
down, a forced shut down and after-run period will
occur.
To reactivate Auxiliary Heater,
- switch Auxiliary Heater OFF
- wait one minute
- switch Auxiliary Heater ON

82.28 Operating sequence

Auxiliary heater BBW 46
 Heater Booster 82

Fig. 1 Felt pad, removing Fig. 3 Felt pad, servicing (Diesel heaters)

- remove tension springs Note

- pry off cover with two screwdrivers in
recesses A
0-rings A and B must be replaced after each
disassembly.
Do NOT glue pad C into place.
- insert assembly with felt pad Into Heater until
recesses in ring fit together with tabs on Heater

Fig. 2 Felt pad, servicing

Note
0-rings A and B must be replaced after each
disassembly. Fig. 4 Felt pad, Installing
Do NOT glue pad C into place. - slide assembly in noting position of lug B
- insert assembly with felt pad into Heater until
recesses in ring fit together with tabs on Heater

Auxiliary heater BBW 46

Felt pad, removing/installing 82.29
82 Heater Booster

Fig. 5 Glow plug, checking

- disconnect wire to glow plug

- remove glow plug
• 30 Nm (22ft lb)
Fig. 7 Flame switch, checking
-connect glow plug to externai12V source
- connect jumper wire between nut of glow
- switch heater ON
plug and ground connection of 12V source
If Auxiliary Heater switchE!S to restart after 30
- measure amperage draw of glow plug
seconds (without after-running),
using ohmmeter
• approximately 20A ± 10% - repair short circuit in wiring to Flame
Switch
Note
If Auxiliary Heater shuts off 120 seconds after
Remove carbon deposits on glow plug by glowing successful start and switches to restart
the plug and carefully scraping. (without after-run) after 240 seconds,
- repair break in wiring to Flame Switch
1

II
Fig. 6 Flame Switch, removing/installing

Removing
- remove oval-head screw
- pull Flame Switch out
- remove wires

Installing
- slide 0-ring on to tip of Flame Switch at 1
- install oval head screw
- install wire

CAUTION
Do not reverse polarity of Flame Switch wires.

82.30 Glow plug, checking

Flame switch, removing/installing/checking
Auxiliary heater BBW 46
 Heater Booster 82
Temperature sensor, removing/
installing

0
Fig 10. Fuse 824, removing/installing

CAUTION
CAUTION Before removing Fuse S24, open cap on
engine coolant expansion tank to relieve
Before removing Temperature Sensor, open
pressure on engine cooling system.
cap on engine coolant expansion tank to
relieve pressure on engine cooling system.
disconnect wires from fuse
- unscrew fuse
-remove wires from Temperature Sensor
- check fuse for continuity with ohmmeter
-unscrew Temperature Sensor
• 30 Nm (22.0 ft lb)
Note
Fuse S24 is installed and tightened by hand. Make
sure that the fuse point contacts the Heater tube.
1750

1500 1/ - screw fuse in until cap of fuse is approximately

O.Bmm from body of heater
• a O.Bmm (.003 in)
1250 /
~/
~

Cl
T
0::
1000
750
v
v
500
-40 0 40 80 120
V•(°C) ja2-281 I
Fig. 9 Temperature Sensor, checking

This temperature sensor is a Positive Temperature

Coefficient (PTC) type resistor.
- connect ohmmeter between terminal end and
body of Temperature Sensor
- compare measured resistance and temperature of
Temperature Sensor with graph
• difference between measured resistance and
graph must not be more than 1.0mA

C·13
Auxiliary heater BBW 46
Temperature sensor, removing/installing
Temperature sensor, checking
Fuse 824, removing/Installing
82 31 •
82 Heater Booster /

Installing
- insert Recirculation Pump slanted connection into
Heater Core
- install clamp

Note
Do not reverse wires for Recirculation Pump or it will
run in the wrong direction.

Fig. 11 Series resistor (for partial load operation),

removing/Installing/checking

CAUTION
Before removing series resistance, open cap
on engine coolant expansion tank to relieve
pressure on engine cooling system.

- remove oval head screw

Fig. 13 Combustion Air Blower, removing/
- remove wire connectors
- measure resistance with ohmmeter Installing
• 3.3 ohm± 3%
- remove air intake sound dampener
- install in reverse order of removal - mark electrical wires (for identification)
and remove
• loosen screw B and remove
combustion air blower
I,

1 B

Fig. 12 Recirculation pump, removing/Installing

Flg.14 Combustion Air Blower, adjusting
-mark electrical wires (for identification)
and remove
- loosen clamp A and remove pump CAUTION
The Combustion Air Blower is pre-set at the
factory. The adjustment screw (arrow) should
not be moved.

Series resistor,

82.32 Recirculation pump, removing/installing

Combustion air blower, removing/Installing
Auxiliary heater BBW 46
 82
- Heater Booster

6 ,_.)
Fig. 17 Flame head, Installing

- coat area between Flame Head and heat

tube (C) with sealing paste
Flg.15 Intake air noise dampener, removing/ - install in reverse order of removal
Installing/checking

- unclip reuseable plastic band A

- remove noise dampener from bracket B
- check noise dampener for cracks

I Fig. 18 Heater core, removing

Fig. 16 Flame head, removing
CAUTION
Before removing Flame head, open cap on
engine coolant expansion tank to relieve
pressure on engine cooling system.
CAUTION
Before removing Temperature Sensor and
Fuse S24, open cap on engine coolant
expansion tank to relieve pressure on engine
cooling system.
-remove Temperature Sensor and Fuse S24
- remove Flame Head
- insert two screwdrivers into recesses and pry
Flame Head out
- clean combustion residue off with water spray and
brush

- pinch off water hoses to heater

- unscrew clamps
- insert screwdrivers at recesses B and pry off
Aame Head
- clean dirt accumulation from all parts

C-15 Auxiliary heater BBW 46 Flame head, removing/Installing

Heater core, removing
82 •33
82 Heater Booster

Fig. 19 Heater core, Installing

- coat area between Flame Head and

Heat Tube at C with sealing paste
- install Heater Core in reverse order of
removal

82.34 Heater core, installing

Auxiliary heater BBW 46
 Heater Booster 82

Supply
Volume

I
I
+ - - -1--t--1--±:---±--+
9 10 11
Voltage

Fig. 20 Metering Pump, checking flow rate - close hose 1 from radiator to thermostat with hose
clamp
- remove connector to glow plug - close hose 2 from heat exchanger to coolant pipe
- remove fuel feed hose from heater and with hose clamp
place open end in measuring glass
- connect voltmeter between contacts
T2a/2 and T6/4 of Auxiliary Heater
Control Unit
- switch Auxiliary Heater ON
• after 90 seconds Auxiliary Heater
switches OFF
• automatic re-start begins
- switch Auxiliary Heater ON again
- measure fuel volume after two 90 minute
periods and compare voltage and
volume with graph
For example,
If voltage measured at Auxiliary Heater is 12.0V,
Then, volume output must fall between
-loosen hose clamp 1, close hose 2 from radiator
approximately 29ml and 35ml after two 90 minute
to distribution piece with hose clamp
measuring periods.
- close hose 3 from heat exchanger to distribution
piece with hose clamp
Engine coolan·t system, draining/ -drain coolant at drain plugs (Fig. 1)
refilling - open coolant expansion tank cap

CAUTION CAUTION
Use coolant Part No. ZVW 237 102 which has Coolant/antifreeze must not be reused when
corrosion inhibiting agents especially replacing engine, cylinder head, cylinder head
formulated to prevent corrosion damage to the gasket, radiator and heater core.
water jacket sealing surfaces of the cylinder
head.
Anti-freeze other than specified by Volkswagen
may cause corrosion of the cooling system
thus leading to engine overheating and
damage.

C·17 Auxiliary heater BBW 46 Metering pump, checking flow rate

Engine coolant system, draining/refilling
82 35 •
82 Heater Booster

Refilling
Coolant mixture ratio
• coolant capacity 17.5 ltr (18.4 US qt)

Note
Cooling system is filled at factory with mixture of
water and antifreeze/corrosion protective solution.
Coolant mixture should be used all year.
When replacing coolant only use ethylene glycol
based antifreeze (phosphate-free).
Due to higher boiling point, coolant is an aid to
operating on full load, particularly in warm climates
Outside temperature Antifreeze Water - open bleeder valve in engine
compartment
-25°C (-13°F) 7.0 ltr 10.5 ltr
A= open
(7.4 us qt) (11 us qt)
B =closed
8.75 ltr 8.75 ltr
(9.2 us qt) (9.2 us qt)

- remove electrical connector from

- set heater control to maximum heating
- open control valve for auxiliary heater under
rear seat
- remove radiator grille
- raise vehicle approximately 40 em
(15-3/41n.) at front under cross-member with
floor jack and wooden support or equivalent
- open bleeder screw (arrow) on radiator
CAUTION
Coolant/antifreeze must not be reused when
replacing engine, cylinder head, cylinder head
gasket, radiator and heater core.
monovalve
- fill coolant until expansion tank is full
(approximately 4-5 ltr/4.25-5.3 US qt)
- start engine
- at approximately 2000 RPM, top up tank
until coolant flows from bleeder screw on
radiator (bubble free)
- add coolant until tank is full and close
tank with cap
- turn ignition off and start engine again
after approximately 20 seconds
- at about 2000 RPM open cap of
expansion tank
- close bleeder screw on radiator when
coolant flows out
- add coolant if necessary and close
expansion tank
- close bleeder valve in engine
compartment
- switch engine off

82.36 Engine coolant system, draining/refilling

Auxiliary heater BBW 46
 Heater Booster 82

min.

- refill overflow tank to maximum mark

(arrow)
- reconnect wiring connector to Monovalve

C·19 Auxiliary heater BBW 46

Engine coolant system, draining/refilling 82•37
 87

Air Conditioner

Index
- A/C adapter valve VAG 1637
installing 87.15
- A/C components
locations 87.2
- A/C compressor (Sanden SD51 0)
replacing 87.16
- A/C evaporator
removing/installing 87.14
- AIC evaporator housing
assembling/disassembling 87.12
removing 87.10
- Air distribution system
components 87.9
outlets, removing 87.13
- Expansion valve
removing/installing 87.14
\
-Fuses
locations 87.4
- Refrigerant system
capacity 87.7
cautions and warnings 87.7
controls 87.6
discharging 87.8
-Relays
locations 87.5

87.1
87 Air Conditioner

r=-:~~~~'~0~-15

'--"---L---14

1 87-882 1

1 - Front housing 10- Low pressure refrigerant hose

2 - Round air outlet 11 - High pressure refrigerant hose
3- Outlet 12 - Condenser
• condenser can be lowered from vehicle with
4 - Front air duct
radiator without discharging AIC refrigerant
5 - Center air duct system

6 - Rear air duct 13- Receiver/drier

7 - Evaporator housing 14 - AJC compressor
8- Water drain tubes 15 - AJC compressor clutch
9 - Expansion valve
Note
Discharge AIC refrigerant system before removing
components represented with underlined numbers

87.2 Component locations

From 1986
 Air Conditioner 87

3 15
,.....----1

187-8971

1 - AIC thermostat 12 - Evaporator fan relay

2 - AIC switch 13 - A!C compressor clutch
3 - Evaporator fan switch ! 14 - Radiator cooling fan sarles resistance
4 - Radiator cooling fan thermoswltch 15 - Evaporator fan sarles resistance
5 - A!C refrigerant high pressure switch 16 - Radiator cooling fan fuse
6- Ambient air temperature switch 17 - Fuse SO (50A)
7 - A!C refrigerant low pressure switch 18- Fuse S1 (30A)
8-AIC relay 19- Fuse S12 {15A)
9 - A!C compressor clutch relay 20 - Fuse S51 (20A) for evaporator fan
10 - Radiator cooling fan relay, 2nd stage 21 - Radiator cooling fan
11 - Radiator cooling fan relay, 3rd stage 22 - Evaporator fan

Note
As of the 1987 Model Year, the A/C refrigerant
high pressure service valve was changed.

On the Vanagon, the service valve location is under

the left rear evaporator panel.

On the Vanagon camper, the service valve is located

in the left rear cabinet.

D.S From 1986 Component locations 87.3

87 Air Conditioner

Components
Fuse locations

19 20 21 22 23 24

13 14 15 16 17 18

Additional Fuse/relay panel (behind left rear 'D'

pillar cover)
Fuse SO
• 50A - to A/C relay and evaporator fan relay
Fuse/relay panel
Fuse S1
• 30A- to Rad. cool. fan thermoswitches and
Rad. cool. fan relay 2nd stage
Fuse S12
• 15A- to Fresh air fan and AIC switch

Additional Fuse/relay panel (behind left rear 'D'

pillar cover)
Fuses S51
• 20A - one fuse for each A/C evaporator fan

Additional Fuse/relay adaptor (behind left air vent

In Instrument panel)
Fuse S
• 50A- to Rad. cool. fan relay 3rd stage

87.4 Fuse locations

From 1986
 Air Conditioner 87
Relay locations
A

ls7-ooea I

Additional Fuse/relay panel (behind left front

fresh air vent)
Picture with vent removed
Fuse/relay panel A - Radiator cooling fan relay 3rd stage
Radiator cooling fan relay 2nd stage (arrow)
Radiator cooling fan series
resistance

Additional Fuse/relay panel (behind left rear 'D'

pillar cover)
Radiator cooling fan series resistance
A- A/C compressor clutch relay
• behind left headlight
B Evaporator fan relay A - Resistor block
C-AlC relay
0- Fuse SO

0·5 From 1986 Relay locations 87.5

87 Air Conditioner

AJC refrigerant system controls

Locations

Ambient temperature switch and AJC thermostat

(behind left rear 'D' pillar cover)
A- Ambient temperature switch
AJC refrigerant high pressure switch (arrow) • switches NC compressor OFF when outside
temperature is under 38°F
• switches Aad. cool fan to higher speed if
refrigerant pressure becomes too high B- NC thermostat
Opens • switches NC compressor OFF wtlen
• 12.0 bar ( 174.0 psi) evaporator temperature reaches pre-
Closes determined value
• 14.5 bar ( 210.2 psi )
Thread size
• 1/8" · 27 NPT
Torque
• 25.0 Nm

A/C thermostat capillary tube (A)

- insert through hole in upper evaporator
AJC refrigerant low pressure switch (arrow) housing
• approx. 50mm ( 2.0 in )
• switches NC compressor clutch OFF when
refrigerant pressure is too low
Opens
•2.0 bar+ 0.3 bar ( 29.0 psi + 4.3 psi )
Closes
•3.0 bar + 0.3 bar ( 43.5 psi + 4.3 psi )
Thread size
•3/8" · UNF
Torque
•20.0 Nm

87.6 Refrigerant system controls

From 1986
I
~ Air Conditioner 87
1- Evaporator
2 - Expansion valve
3- Receiver/drier
4 - Safety plug
5 - Condenser
6 - Service valve
7 - AIC refrigerant high pressure swHch
8 - AIC refrigerant low pressure switch
3
9 - AIC compressor
'
10 - Drain plug
6---+i!E:
LOW I
HIGH
11 - AIC compressor clutch
PRESSURE. PRESSURE

Refrigerant R-12 capacity

•1450 grams ( 50.75 oz I

Refrigerant oil
eevaporator 2.02 oz
eaccumulator 0.3 oz
•high pressure hose 0.3 oz
low pressure hose o.3 oz
•compressor 5.07 oz

WARNING
Always wear safety goggles when charging or
discharging system.
Be sure work area is well ventilated. R-12 is
heavier than air and can accumulate in areas
of poor air circulation.
Avoid inhaling fumes when using flame-type
leak detector. R-12 becomes poisonous gas
after coming into contact with open flame
CAUTION
Always discharge refrigerant from air
conditioner system before loosening
connections, hoses, etc.
CAUTION
Discharge refrigerant from system when it is
necessary to weld near refrigerant hoses with
arc or resistance welding systems. During
electrical welding process invisible ultraviolet
rays are given off which penetrate refrigerant
hoses and decompose refrigerant
Note
Plug all openings in system when removing/replacing
parts. This prevents entry of dirt and moisture which
may foul system.
Drops of moisture may cause expansion valve to ice
up, blocking refrigerant flow and stopping cooling
action

0·7 Refrigerant system,

Cautions and warnings 87.7
87 Air Conditioner

Refrigerant system, discharging

Note
Follow safety precautions on pg 87.7 when
discharging or charging AJC refrigerant system
- disconnect wires at A/C compressor

High pressure

- connect hose from high pressure gauge to high

pressure serifice valve (A)
- connect hose from low pressure gauge to suction
service valve (B)
- open low pressure gauge valve until bubbles are
visible in water or hiss is heard from discharge
hose
To suction To high pressure
- open high pressure valve slightly
service valve service valve

CAUTION
Discharge AJC refrigerant system slowly to
prevent loss of refrigerant oil

- close manifold gauge valves when refrigerant

OR stops flowing
Bucket filled
with water

I87·A1131
- close both valves on AJC manifold gauge set

WARNING
Always wear safety goggles when charging or
discharging system. Be sure work area is well
ventilated. Refrigerant-12 is heavier than air
and can accumulate in areas of poor air
circulation.
Avoid inhaling fumes when using flame type
leak detector. Refrigerant-12 becomes
poisonous gas after coming into contact with
open flame.

87.8 Refrigerant system, discharging

From 1986
 Air Conditioner 87
Air distribution system

Evaporator housing---~

Evaporator-----~

Front housing

ls7-A1osl

0·9 From 1986 Air distribution system 87.9

\ \
87 Air Conditioner

AIC evaporator housing,

removing
Work sequence

CAUTION
Before starting to work on any part of electrical
system, disconnect battery ground strap

Note
It is possible to lower A/C evaporator housing without
discharging A/C refrigerant system.
- remove center air duct attaching screws (arrows)
Discharge A/C refrigerant only when replacing parts - remove center air duct
in refrigerant system.

f•uml!m' ImmvrmB

187-A1061 187-A1ool
-remove rear air duct attaching screws (arrows)
- remove sunvisors and sunvisor retaining clips - remove rear air duct
- remove front housing attaching screws (arrows)
- lower front housing and front air duct
more
- disconnect wiring connectors to A/C switches
- remove front housing and front air duct

87.10 A/C evaporator, removing

From 1986
 Air Conditioner 87

ja7·A111 I
-remove left side rear trim panel screws (arrows) - support evaporator housing with universal lift
- remove trim panel crane
- remove left side evaporator housing attaching
bolts (arrows)

-remove right side rear trim panel screws (arrows)

- remove trim panel
- remove right side evaporator housing attaching
bolts (arrows}
-lower evaporator housing
- remove evaporator housing covers
- remove evaporator
Installing
- install In reverse order of removal
- re-charge A/C refrigerant system

0·11 From 1986 A/C evaporator, removing 87.11

87 Air Conditioner

Evaporator housing, assembling/disassembling

Note
Evaporator housing can be lowered and
disassembled without discharging A/C refrigerant
system.

Evaporator housing (upper half)

- seal wiring harness opening (arrow)
to prevent air leaks
Hole------...
for AJ.C thermostat
capillary tube see Note on page 87.13

Evaporator with expansion valve

I ...-! ..- -

.... =-

Evaporator fan Drain hose

Evaporator housing
(lower half)
-see Note on page 87.13

Radio speaker

Series resistance brackets

/
87.12 A/C evaporator housing
From 1986 /
 87
-
r

Air outlets, removing

Air Conditioning

Evaporator housing - modified

Work sequence Starting April 1988, a running change was made to
the evaporator housing and intoduced into produc-
tion. To prevent cracking, the body attachement
points have been relocated.
See your Volkswagen Parts Department for the lat-
est information regarding this upgrade. Also see
Technical Bulletin Group 87, Number 89-01, dated
IW) August31, 1989.

Je7-A11sl

- push in retaining tab with screwdriver

- pry vent out

0·13 From 1986 I· Air ouUets, removing 87.13

 87 Air Conditioner

AIC evaporator or expansion valve,

removing/Installing
Work sequence

CAUTION
Before starting to work on any part of electrical
system disconnect battery ground strap

- disconnect wiring to A/C compressor clutch at AIC

compressor
- discharge A/C refrigerant system

Note - support evaporator housing with universal lift

crane
Plug all openings in system when removing/replacing - remove left side evaporator housing attaching
parts. This prevents entry of dirt and moisture which bolts (arrows)
may foul system.
Drops of moisture may cause expansion valve to ice
up, blocking refrigerant flow and stopping cooling
action

- remove sunvisors and retaining clips

- remove front housing and front air duct
- disconnect wiring harness to AIC switches

- remove center air duct

- remove rear air duct

- remove carpet in luggage area ls7-A1121

- remove left rear trim panel
- remove right rear trim panel
- remove right side evaporator housing attaching
bolts (arrows)
- lower evaporator housing
- remove evaporator housing covers
- remove A/C refrigerant hoses from expansion
valve
- remove evaporator from housing
- remove expansion valve from evaporator
Installing
- install in reverse sequence

CAUTION
Always replace O·rings when replacing AIC
refrigerant components.
Coat 0-rings lightly with refrigerant oil before
assembly

- re-charge A/C refrigerant system

- connect battery ground cable
- re-connect wiring at A/C compressor clutch

,j 87.14 AIC evaporator or expansion valve

removing/Installing
From 1986
- Air Conditioner 87
AIC adaptor valve VAG 1637,
installing
Beginning with Vanagon production in May, 1988,
the threaded connection on the AIC high pressure
service valve has been changed from 7116"-20 UNF
to 3/8"- 24 UNF. Use special adaptor valve,
VAG 1637, when making connections to the high
pressure service valve.

Installation position
1 - AIC high pressure line
2 - AIC high pressure service valve
(3/8" - 24 UNF)
3 - Adaptor valve VAG 1637
4 - Service hose (to pressure gauge set)
-install adaptor valve VAG 1637 onto AIC high
pressure service valve
- install A!C service hose onto adaptor valve
VAG 1637
Adaptor valve VAG 1637
1 - Schrader valve
2-Adaptor
3 - Valve opener
4 - Sealing gasket

-
0·15
From 1988
A/C adaptor valve VAG 1637, Installing 87.15
87 Air Conditioner

A!C compressor (Sanden SD 510), Note

replacing As of VIN HH 056 819, all Vanagon vehicles are
equipped with the Sanden SD 709 A!C compressor.
The Sanden SD 510 AIC compressor is no longer
available as a spare part and has been superseded Use the following procedure when replacing the
to the Sanden model SD 709. If AIC compressor model SD 510 with the model SD 709.
replacement is necessary, install the SD 709 in place
of the SD 510. Parts required:
PIN 253 260 797 A Compressor - SD 709
PIN 253 260 708 E A!C refrigerant line
PIN 253 260 716 A AIC refrigerant line
PIN 803 260 749 B 0-ring (two required)
P/N 431 260 749 0-ring (two required)

discharge AJC system, page 87.8

- remove AIC compressor belt and remove AIC
compressor
- remove low pressure AIC line leading from
compressor to AIC hose and discard

Ie7-952a I
Fig. 1 AIC compressor SD 510 factory
6
Installation

1e7-952b 1

Fig. 3 A/C compressor SD 709 installation

(conversion from SD 510)
i:
rzr:r:!J -install AJC line 2, P/N 253 260 716 A to AIC
hose 1 using new 0-ring 3, P/N 803 260 749 B
- install AIC line 4, PIN 253 260 708 E and 0-ring
3, PIN 803 260 749 B to AJC line 2
-install new AJC compressor 7, PIN 253 260 797 A
-connect AIC lines 4 and 5 to compressor using
new 0-rings 6, P/N 431 260 749

I e7-952c 1 - install AJC compressor belt and adjust

- evacuate AIC system and recharge
- check AIC system operation
Fig. 2 AIC compressor SD 709 factory
Installation (from VIN HH 056 819) CAUTION
Part numbers are for reference only. Always
check with your Parts Department for latest
parts information.

87.16 AICcompressor(SandenSD510),replacing

-
Index
1980-1984
- Cigarette lighter
replacing 90.31
-Fuel gauge
checking 90.5, 90.9
troubleshooting 90.13
- Fuel gauge sender
removing/installing 90.11
- Instrument cluster
assembling/disassembling
90.2, 90.6
removing/installing 90.10
- Light emitting diodes (LED)
checking 90.5
identifying 90.4, 90.8
- Muhi-point connector
identifying 90.4, 90.8
- Speedometer
calibration 90.30
- Speedometer cable
removing/installing 90.1 o
-Voltage stabilizer 90.4, 90.8
-
90
Electrical System-
Instruments,, Radio
From1985 From1990
- Cigarette lighter - Heidelberg VI fixed coded radio
replacing 90.31 coding a new or remanufactured
- Coolant temperature gauge radio 90.32
locating 90.14 reactivating radio after
troubleshooting 90.21 reconnecting power 90.33
- Dynamic oil pressure system unlocking an electronically
assembly 90.22 controlled radio 90.34
removing/installing 90.23
troubleshooting 90.24
-Fuel gauge
locating 90.14
troubleshooting 90.20
- Instrument cluster
assembling/disassembling 90.14
removing/installing 90.10
-Light emitting diodes (LED)
checking 90.19
identifying 90.18
- Multi-point connector
identifying 90.18
- Speedometer
calibration 90.30
- Speedometer cable
installing (from VIN
25 H 040 185)
except Syncro 90.17 ·.
removing/installing 90.17
- Voltage stabilizer
checking 90.18
90.1
90 Electrical System-Instruments, Radio

CAUTION
Before starting to work on any part of
electrical system, disconnect battery
Printed circuit foil
ground strap use ohmmeter to check conductors
for continuity
connections on multipoint connector Fig. 1
Note identification of LED's! resistors on
printed foil Fig . 4
To replace printed circuit LED's/ bulb, first
checking LED's Fig. 6
remove warning light housing replacing LED's Fig. 7

Mounting plate for warning light housing

pry off carefully to prevent damage
to printed circuit foil

Voltage stabilizer
LED--------------~
checking Fig. 2
identification of LED's! resistors
on printed circuit foil , Fig. 4
checking Fig. 6
replacing Fig. 7
polarity Fig. 8

Speedometer - - - - - - - - - - , .
cable, removing/installing page 90.10

Warning light housing

Plastic clip
for mounting clock
positive ( +) terminal

gauge
Instrument cluster - - - checking Fig . 5
removing/installing page 90.10 removing/installing sender, page 90.11
troubleshooting , page 90.13

E·2
90.2 Instrument cluster with clock USA I ,L-_19_8_0 -_19
_8_4 __,
 Electrical System-Instruments, Radio 90
Note
CAUTION
To replace printed circuit LED's/bulb, first
remove warning light housing Before starting to work on any part of
electrical system, disconnect battery
ground strap

Instrument cluster------..
removing/Installing page 90.10
ousing

Warning light housing

clock
erminal

Fig . 3 Fuel gauge-----------~

checking Fig. 5
pening removing/installing fuel gauge
sender, page 90.11
troubleshooting, page 90.13

LED------"
g plate identification of LED's/resistors
on printed circuit foil Fig. 4
checking Fig. 6
replacing Fig. 7
polarity Fig. 8
e 90.11
Fuel gauge retaining plate

-------J
Printed circuit foil
use ohmmeter to check conductors
for continuity
connections on multipoint connector Fig. 1
identification of LED's/resistors on Warning housing mounting plate
printed foil, Fig. 4 pry off carefully to prevent
checking LED's (=ig. 6 damage to printed circuit foil
replacing LED's Fig. 7

E·3
E·2
1980-1984 I I USA Instrument cluster without clock 90.3
90 Electrical System-Instruments, Radio

Fig. 3 Clock terminal connections

Fig. 1 Multi-point connector terminals
- place foil 1 under ground terminal of
1 = vacant clock
2 = ground terminal 31
3 = instrument lights
4 = high beam terminal 56a
5 = ground terminal 31 CAUTION
6 = vacant (air-cooled) When tighten ing terminal, do not twist
coolant temperature gauge (water-cooled, circuit foil or damage to foil may result
diesel)
7 = clock (if not installed, vacant)
8 = fuel gauge sender
-secure terminal 2 with plastic clip
9 = positive terminal 15
10 = oil pressure switch
11 = EGA or OXS (air-cooled, water-cooled)
glow plug indicator (1983 diesel only)
12 = vacant (air-cooled, water-cooled)
glow plug indicator (1982 diesel only)
13 = alternator warning light terminal 61 or D+
14 = indicator terminal 49a

Fig. 4 Identification of LED's/resistors on

printed circuit foil
K1 =LED (red) high beam
K2 = LED (red) alternator
K3 =LED (red) oil pressure
K5 =LED (green) turn indicator
K21/22 =LED (red) EGA or OXS
Fig. 2 Voltage stabilizer, checking R1 =Resistor for K1 (470Q)
R2 =Resistor for K3 (470Q)
- connect voltmeter between positive R3 =Resistor for K21/22 (470Q)
connection 1 and ground 2 R4= Resistor for voltage stabilizer (150Q)
- turn ignition switch ON R5 =Resistor for K2 (470Q)
• voltage should be approximately 10V R6 =Resistor for K5 (470Q)
• if voltage is above 10.5V or below
9.5V, voltage stabilizer is defective
and must be replaced

Multi-point/Clock terminals E·4

90.4 Voltage stabilizer

Light emitting diode .___u_s_A___.I _1_9_8_0-_1_9_84_ _.
L..l
 Electrical System-Instruments, Radio 90
Empty

Fig. 5 Fuel gauge, checking

-set tester VW 1301 to following test
values :

Tester dial setting Fuel gauge reading*

55 full
560 empty
Fig. 7 LED's, replacing
•deviation of one needle width to left or right is
- note polarity of LED's (see Fig. 8)
OK
when plugging into printed circuit

Fig. 6 LED's, checking Fig. 8 LED polarity, checking

1 =negative terminal
-connect battery positive lead to LED
K1 (+) 2 =positive terminal
-connect negative battery lead to LED • negative terminal Is slightly wider
K1 (- ).
- repeat this test step consecutively on
remaining LED's
• LEOS must light

E·S
1980-1984 I I USA Fuel gauge
Light emitting diode
90 5
•
90 Electrical System-Instruments, Radio

CAUTION
Before starting to work on any part of
electrical system, disconnect battery
ground strap
Printed circuit foil
use ohmmeter to check conductors
Note for continuity
connections on multipoint connector Fig. 1
To replace printed circuit LED's/bulb, first
identification of LED's! resistors on
remove warning light housing printed foil, Fig. 4
checking LED's Fig. 6
replacing LED's Fig. 7

Mounting plate for warning light housing

pry off carefully to prevent damage
to printed circuit foil

Voltage stabilizer
LED----------------, checking Fig. 2
identification of LED's/resistors
on printed circuit foil, Fig. 4
checking Fig. 6
replacing Fig. 7
polarity Fig. 8

Speedometer--------.......
cable, removing/installing page 90.10

Plastic clip
for mounting clock
positive (+)terminal

Clock
termil)al connections Fig. 3

Fuel gauge
Instrument cluster
checking Fig. 5
removing/installing page 90.10
removing/installing sender, page 90.11
troubleshooting, page 90.13

Bulb (blue) in warning light housing

identification of bulb/resistors
on printed circuit foil, Fig. 4
checking bulb Fig. 6
installing bulb Fig. 9

90.6 Instrumen t cluster with clock

Canada I I 1980-1984 E·6
 Electrical System-Instruments, Radio 90
Note
CAUTION
To replace printed circuit LED's/bulb, first
remove warning light housing Before starting to work on any part of
electrical system, disconnect battery
ground strap

Instrument c l u s t e r - - - - -
removing/installing page 90.10
Warning light housing

DUSing Bulb (blue)

identification of bulb/resistors on
printed circuit foil Fig . 4
checking bulb Fig. 6
installing bulb Fig . 9
7
Speedometer
cable, removing/installing
page 90.10
')

~lnotrumeol
Illumination

~k
jnal Fuel gauge-----~
checking Fig. 5
remov ing/installing fuel gauge
y ·
~ ··
; Fig . 3 sender, page 90.11
troubleshooting, page 90.13

plate LEO-------"
identification of LED's/resistors
on prir)ted circuit foil Fig . 4
checking bulbs/LED's Fig. 6
replacing Li:D's Fig. 7
polarity of LED's Fig . 8

! 90.11
Retaining plate for fuel gauge

Printed circuit foil _ _ _ _ _,/

ing
use ohmmeter to check conductors
for continuity
connections on multipoint connector Fig. 1
identification of LED's! resistors on Mounting plate for warning light housing
printed foil, Fig . 4 pry off carefully to prevent
checking bulb/ LED's Fig . 6 damage to printed circuit foil
replacing LED's Fig. 7

E·6
E-7
1980-1984 I I Canada Instrument cluster without clock 90.7
90 Electrical System-Instruments, Radio

Fig. 3 Clock terminal, connections

Fig. 1 Multi-point connector terminals
- place foil 1 under ground terminal of
1 =vacant clock
2 = ground terminal 31
3 = instrument lights
4 = high beam terminal 56a
5 = ground terminal 31 CAUTION
6 = vacant (air-cooled) When tightening terminal, do not twist
coolant temperature gauge (water-cooled,
circuit foil or damage to foil may result
diesel)
7 = clock (if not installed, vacant)
8 = fuel gauge sender
9 = positive terminal 15 -secure terminal 2 with plastic clip
10 = oil pressure switch
11 = vacant (air-cooled, water-cooled)
glow plug indicator (1983 diesel only)
12 = vacant (air-cooled, water-cooled)
glow plug indicator (1982 diesel only)
13 = alternator warning light terminal 61 or D+
14 = indicator terminal 49a

Fig. 4 Identification of LED's/resistors/bulb on

Fig. 2 Voltage stabilizer, checking
- connect voltmeter between positive
connection 1 and ground 2
• voltage should be approximately 10V
• if voltage is above 10.5V or below
9.5V, voltage stabilizer is defective
and must be replaced
printed circuit foil
K1 =bulb (blue) high beam
K2 = LED (red) alternator
K3 = LED (red) oil pressure
K5 = LED (green) turn indicator
R1 =Series resistor for K1 (270Q)
R2 =Series resistor for K3 (470Q)
R3 =Series resistor for alternator pre-
exciter circuit (150Q)
R4 =Series resistor for K2 (470Q)
R5 =Series resistor for K5 (470Q)

Multi-point/Clock terminals E·B

90.8 Voltage stabilizer
LEOs
~C_a_n_a_d_a~l ~1_1_9_80_-_1_9_84~
 Electrical System-Instruments, Radio 90

Fig. 5 Fuel gauge, checking

-set tester VW 1301 to following test
values:

Tester dial setting Fuel gauge reading•

55 full
560 empty
Fig. 8 LED polarity, checking
*deviation of one needle width to left or right Is 1 =negative terminal
OK 2 =positive terminal
• negative terminal Is slightly wider

e
Fig. 6 Bulb/LED's, checking
-connect battery positive lead to LED
K1 (+)
- connect negative battery lead to LED Fig. 9 Bulb In warning light housing, Installing
K1 (-)
- press blue bulb through slot into
-repeat this test step consecutively on
guide with screwdriver
remaining LED's
• bulb must be heard to engage (LED's
• warning lights must light
slide freely into gUide)

!7

Fig. 7 LED's, replacing

- note polarity of LED's (see f=:ig. 8)
when plugging into printed circuit
E·8
E·9 Fuel gauge
L....--1_9_80_-_19_8_4____.1 I Canada I Warning light bulbs
LEOs 90.9
 /
I
90 Electrical System-Instruments>Radio

Instrument cluster, Installing

removing/Installing
Work sequence
Removing
-disconnect battery ground strap

-insert cover Into retaining lugs

-press frame down and tilt cover forward to
engage

Speedometer cable,
removing/Installing
- put fingers Into recesses (arrows) and pull up
cluster cover Work sequence
Removing
-disconnect battery ground strap
- disconnect speedometer cable
-remove spare tire

USA only

- pull hazard warning switch forward

-pull dual circuit brake/parking brake warning
light housing forward (driving direction)
- remove screws (arrow) and Instrument cluster

- disconnect spee~ometer cables from EGA/

oxygen sensor mileage counter (arrows)

E·10

90.10 Instrument cluster

Speedometer cable
1980-1984
 Electrical System-Instruments, Radio 90

- remove nut from bracket (arrow)

-when installing cable, align marks (arrows)

on cable
-after installing circlip on speedometer cable
end, seal with silicone seal

CAUTION
To avoid premature cable failure, position
cable so It is free of strain or sharp bends.
Do not grease connection to speedometer;
this could cause needle to stick

Fuel gauge sender,

-remove circllp from speedometer cable (arrow)
removing/installing
Work sequence
Removing
-disconnect battery ground strap
- remove fuel tank (see Repair Group 20)

- remove speedometer cable from rubber sleeve

in steering knuckle (arrow)

- mark position before removing

-remove sender by turning it counter-clockwise
- go to next page

E·10
E·1 1
1980-1984 Speedometer cable
Fuel gauge sender
90....I 1
1
 (

90 Electrical System-Instruments, Radio

Installing

[90 ·

-coat sealing ring (arrow) with graphite

- install sender unit so float Is facing driving

direction (arrow)
-turn sender unit clockwise to stop

-attach positive and negative wires as shown

• 1 =fuel gauge connection
• 2 =ground connection

E·12
90.12 Fuel gauge sender
1980-1984
 Electrical System-Instruments, Radio 90
Fuel gauge, troubleshooting
Work sequence

- remove wire connector from fuel gauge

sender unit at single plug connection (arrow),
or possibly from multi-point plug connection
-connect VW 1301 to ground connection
behind instrument cluster and to wire
removed from fuel gauge
-start engine and check values (page 90.9)
• following results may be shown:

Needle deflection corresponds with setting No needle deflection or reading not in

tolerance range

Sender unit defective Voltage stabilizer or fuel gauge defective

- replace sender

-remove instrument cluster

-check output voltage of stabilizer
• should be 9.5-10.5 V

Voltage not OK Voltage OK

- replace voltage stabilizer - replace fuel gauge

E-12 E-13
1980-1984
Fuel gauge 90.13
90 Electrical System-Instruments, Radio

Instrument cluster, with tachometer

Voltage stabilizer
checking- Fig. 2

Lamp for Instrument Illumination ------.. r---""--- Mounting plate

12V/1.2W for indicator light housing
-pry ou't carefully to avoid
damaging printed circuit

LED's - - - - - - - - - . .
identification Fig. 4
checking Fig. 5, Fig. 6

Dynamic oil pressure control unit

removing pg. 90.22-90.23

Speedometer - - - - - - - - -.......
removing/installing pg. 90.15-90.17

Indicator light housing - - - - -.....

Bracket for digital clock - - - - - - .

connector identification Fig. 1

Digital clock -------....

Tachometer

Mounting plate
for fuel gauge and
coolant temperature indicator

Coolant temperature lndlcat.o r

checking 90.21

Fuel gauge
checking 90.20
removing / installing sender 90.11
Instrument cluster - - - - '
removing and installing pg. 90.15

90.14 Instrument cluster with tachometer

Water-cooled from 1985
 Electrical System - Instruments, Radio 90
Instrument cluster, Installing
removing/installing

CAUTION
Before starting to work on any part of the
electrical system, disconnect battery ground
strap

Work sequence
Removing
~ disconnect battery ground strap

- insert cover Into retaining lugs

- press frame down and tilt cover forward to
engage

Speedometer cable,
removing/Installing
Work sequence
Removing
- dlsconr:~ect battery ground strap
- disconnect speedometer cable
- remove spare tire
- put fingers into recesses (arrows) and pull up
cluster cover
USA only

t.1

- pull hazard warning switch forward

- disconnect speedometer cables from EGRI
- pull dual circuit brake/parking brake warning light oxygen sensor mileage counter (arrows)
housing forward (driving direction)
- remove screws (arrows) and instrument cluster

E·15
Water-cooled from 1985 Instrument cluster
Speedometer cable 90.15
90 Electrical System-Instruments, Radio

-squeeze tabs together (arrows)

- pull cable from speedometer - remove speedometer cable from rubber sleeve
in steering knuckle (arrow)

-remove nut from bracket (arrow) - when Installing cable, align marks (arrows) on
cable
- after Installing circllp on speedometer cable end,
seal with silicone seal

CAUTION
To avoid premature cable failure, position
cable so it is free of strain or sharp bends.
Do not grease connection to speedometer;
this could cause needle to stick.

more

-remove circlip from speedometer cable (arrow)

90.16 Speedometer cable

Water-cooled from 1985
 Electrical System - Instruments, Radio 90
CAUTION Speedometer, removing
When replacing the drive cable, the rubber
sleeve in the steering knuckle must be
replaced.

- remove instrument cluster

- remove printed circuit for dynamic oil pressure
system (A)
- remove screws (arrows)
-push rubber sleeve to stop (arrow) with socket - remove speedometer
wrench
• sleeve must be flush with steering knuckle
Speedometer cable, Installing (from
-push cable through rubber sleeve and through VIN: 25H H 040 185- except Syncro)
dust cap
- fasten circlip on speedometer and seal with
sealing material

~0-7891

A new SP,eedometer cable has been i~talled In

vehicles from VIN: 25H H 040 185. Gable housing 2
has been lengthened and ,fhe installation ma.rk found
on previous cables has
been· delefed·. ·
- measure distance a from end of cable· 1 and mark
cat>le housing 2 '
• a = 740 miT' (29.1 in.)
- install cable clamp 3 on _cable housing and center
over mark
- install speedometer cable and tighten cable clamp

E·17
Water-cooled from 1985
Speedometer cable 90.17
90 Electrical System-Instruments, Radio

Fig. 1 Wiring of 14 pin connector Fig. 3 Clock terminal, connections

1- instrument illumination - place foil 1 under ground terminal of clock
2- high beam warning - terminal 56a
3- ground, terminal 31
4- open CAUTION
5- clock
When tightening terminal, do not twist circuit
6- coolant temperature display - to sensor
foil or damage to foil may result
7- fuel gauge - to sender
8- plus, terminal 15
- secure terminal 2 with plastic clip
9- tachometer, terminal 1/W
10 - blinker warning, terminal 49a
11 - alternator warning, terminal 61
12 - open (1985 only)
oil pressure warning, 0.9 bar (1986-1987)
13 - oil pressure warning, 1.8 bar (1985)
oil pressure warning, 0.3 bar (1986-1987)
14 - OXS indicator light

K2 K3

K29

Fig. 4 Identification of LED's/resistors/bulb on

printed circuit foil
K1 = bulb (blue) high beam
K2 = LED (red) alternator
K3 = LED (red) oil pressure
KS = LED (green) turn indicator
Fig. 2 Voltage stabilizer, checking K29 = LED (yellow) glow plugs
- connect voltmeter between positive
connection 1 and ground 2
• voltage should be approximately 1OV
• if voltage is above 10.5V or below 9.5V,
voltage stabilizer is defective and must
be replaced

Multi-point connector

90.18 Voltage stabilizer

LED's
Water-cooled from 1985
 Electrical System - Instruments, Radio 90

Fig. 5 LED's, checking Fig. 7 Digital clock (LED quartz clock), replacing
- connect battery positive lead to LED - remove mounting screws (arrows)
K1 ( +) - remove clock light (A)
- connect negative battery lead to LED
- remove connector
K1 (- ).
- remove digital clock
- repeat this test step consecutively on
remaining LED's
• LED's must light

CAUTION
When replacing LED's do not reverse polarity

Fig. 6 LED polarity, checking

1 = negative terminal
2 = positive terminal
• negative terminal is slightly wider

E-19
Water-cooled from 1985
LED's 90.19
90 Electrical System-Instruments, Radio

Fuel gauge, troubleshooting

Work sequence .,,, .
\\\
\\\
\

Fuel gauge, checking

- set tester VW 1301 to following test values:

Test dial setting Fuel gauge reading*

50 full
320 empty
- remove multi-point connector (B) (RED)
- connect tester VW 1301 on ground star behind •deviation of one needle width to left or right is OK
the instrument panel and on multi-point connector
terminal B3
- start engine
- check specified values with VW 1301
Full: 50 Empty: 320

Needle deflection corresponds with setting No needle deflection or reading not in

I tolerance range

Sender unit defective

- replace sender I I Voltage stabilizer or fuel gauge defective

I
- remove instrument cluster
- check output voltage of stabilizer
• should be 9.5-10.5 V
Voltage not OK I Voltage OK

!
- replace voltage stabilizer I I - replace fuel gauge

! 1
I End I r End I

90.20 Fuel gauge

Water-cooled from 1985
 Electrical System - Instruments, Radio 90
Coolant temperature display,
troubleshooting
Test requirement: Battery OK
- remove wire on coolant temperature sensor
- connect tester VW 1301
A - to coolant temperature display
8 - to ground
- switch ignition ON
- set VW 1301 to the following values:
50 - warning range (11 ), engine too hot
red LED flashes
510- transition area (1), engine cold
• permissible deviation, one needle width right or B
left.
The following results may be obtained :

II
190-3181

In both test points, the needle travel corresponds

to the specified value
I No needle travel or display not in tolerance range

I ~
- replace defective sensor I voltage stabilizer or display instrument
L defective

I - remove instrument cluster and check

voltage at stabilizer outlet

- check voltage stabilizer

• specified value: 9.5-10.5V

] no voltage
or under 9.5 V I voltage
9.5-10.5 v

- replace voltage stabilizer I I- replace defective temperature gauge

E-21
Water-cooled from 1985
Temperature gauge 90.21
90 Electrical System-Instruments, Radio

Dynamic oil pressure warning system

Dynamic oil pressure system - -...... Speedometer

control unit
removing Fig. 2
troubleshooting pg. 90.24

.1 -- - - - - Speedometer and dynamic oil

preuure system housing

" " - - - - - - - - - - - - Mountln~ screws

' - - - - Printed circuit

identification of terminals Fig. 3

90.22 Dynamic oil pressure system

Water-cooled from 1986
 Electrical System - Instruments, Radio 90

Fig. 1 Speedometer, removing Fig. 3 Dynamic oil pressure control unit,

terminal Identification
- remove printed circuit (A) and dynamic oil
pressure system connection 1 - oil pressure switch 0.3 bar
- remove mounting screws (arrows) 2 - oil pressure switch 0.9 bar
- remove speedometer 3 - plus
4 - oil pressure warning light
5 - ground
6 - terminal 1

Ill

Fig. 2 Control unit for dynamic oil pressure

system, removing
-remove screw (1)
- push mounting clips in direction of arrows
- remove dynamic oil pressure control unit

E-23
Water-cooled from 1986
Dynamic oil pressure system 90.23
90 Electrical System-Instruments, Radio

System operation

Test sequence Operation of flashing LED (red) and buzzer*

engine not running - LED must flash
• ignition ON -buzzer must not sound
engine running less than 2000 rpm - LED must flash
• wire on 0.3 bar oil pressure switch pulled off and - buzzer must not sound
-

connected to ground
engine running more than 2000 rpm - LED must flash
• wire on 0.9 bar oil pressure switch pulled off but - buzzer must sound
not connected to ground

Note
If system is still not operating properly, check by
Troubleshooting
Troubleshooting
Dynamic oil-pressure system light (LED) does not
flash when ignition Is switched ON
check these first:
• flashing LED (red) for fuel gauge and coolant
temperature gauge is OK

- check 0.3 bar oil-pressure switch

- remove wire on oil-pressure switch and
connect to ground
LED
flashes
~.LED
does not flash

- check oil pressure check wiring to

switch, Repair instrument cluster
Group 17

- go to next page
®

90.24 Dynamic oil pressure system,

troubleshooting
Water-cooled from 1986
 Electrical System - Instruments, Radio 90

check dynamic oil-pressure

- remove instrument cluster (for following
tests use 12 Volt battery as power source
and voltmeter)
- connect battery ground to voltage stabilizer
1 with test probe
- connect battery ground to terminal 5 with
test probe
- connect voltmeter to terminals 2 and 3
- connect battery plus to voltage stabilizer 4
with test probe

Test shows voltmeter reading possible causes

LED approx. 8.5 V Zener diode defective
flashing
approx. 5.5 V track of printed circuit
LED approx. 5.0 V LED defective
not
and Zener diode defective replace printed circuit and LED
flashing

Go To
@
NEXT PAGE

f·3
Water-cooled from 1986 Dynamic oil pressure system,
troubleshooting 90.25
90 Electrical System-Instruments, Radio

- check printed circuit

- check tracks for continuity with ohmmeter
(see current-flow diagram)

-replace - replace printed

dynamic oil- circuit
pressure system
control unit

END

90.26 Dynamic oil pressure system,

troubleshooting
Water-cooled from 1986
 Electrical System - Instruments, Radio 90
Troubleshooting
LED flashes and buzzer sounds while driving car
although oil pressure is correct
Check these first:
• fuel gauge, coolant-temperature gauge, 0.3 bar
and 0.9 bar oil-pressure switches are OK

- check wiring of 0.3 bar oil pressure switch

- start engine
- run engine below 2000 rpm
-pull off black/blue wire on oil pressure
switch and connect to ground
LED LED
does not flash flashes

- check wiring to
dashboard Insert

I END

- check wiring of 0.9 bar oil-pressure switches

- start engine
- run engine above 2000 rpm
-pull off wire on oil-pressure switch (0.9 bar)
• do not connect to ground
LED flashes LED does not LED does
and buzzer flash, buzzer not flash,
sounds does·not buzzer sounds
sound

wiring to
instrument cluster
I continued at
page 90.28
® on
OK

I END

I continued at
page 90.28
@ on
I

F·5
Water-cooled from 1986 Dynamic oil pressure system,
troubleshooting 90.27
90 Electrical System-Instruments, Radio

@
continued
from page 90.27

check these first:

• voltage from ignition coil terminal 1 present at
instrument cluster connector T14/9

voltage from ignition coil terminal 1 is not

reaching oil-pressure warning-system control
unit
- disconnect battery ground cable
- swing instrument cluster out
• do not pull off connectors from instrument
cluster
- connect battery ground cable
- switch ignition ON
- connect test light at 1
test light does not test light lights up
light up

- replace printed
circuit

I END I
®
continued
from page 90.27

check dynamic oil-pressure system

- remove dashboard cluster (for following
tests use 12 Volt battery as power source
and voltmeter)
- connect battery ground to voltage stabilizer
1 with test probe
- connect battery ground to terminal 5 with
test probe
- connect voltmeter to terminals 2 and 3
- connect battery plus to voltage stabilizer 4
with test probe

I continued
on page 90.29 I
90.28 Dynamic oil pressure system,
troubleshooting
Water-cooled from 1986
 Electrical System - Instruments, Radio 90
continued
from page 90.28

Test shows voltmeter reading possible causes repair Instructions

~

LED approx. 8.5 v Zener diode defective replace printed circuit and LED
flashing approx. 5.5 v track of printed circuit broken replace printed circuit

LED approx. 5.0V LED defective replace LED

not approx. 12.0 V LED and Zener diode defective replace printed circuit and LED
flashing
approx. 0.0 v
I
J
- check printed circuit
- check tracks for continuity with ohmmeter
(see current-flow diagram)
printed circuit printed circuit
OK not OK

- replace dynamic oil- -replace

pressure system printed circuit
control unit

I END I END I

f·7
Water-cooled from 1986 Dynamic oil pressure system,
troubleshooting 90.29
90 Electrical System-Instruments, Radio

Speedometer head Odometer

As of May 1983 the existing regulations The odometer reading is independent of the speed
(FMVSS 127) concerning vehicle speed indication indication and is regulated by the Federal Trade
were cancelled by the Department of Commission (FTC). The tolerance of the odometer
Transportation (DOl). Starting May 1983, the only indication is (-) 1OAJ to ( +) 3. 750Al of the actual
requirement is that the vehicles' speedometer number of miles driven.
indicate a higher speed than is actually being
driven. Note
Speedometers having European calibration The number printed on the speedometer face plate
specifications were installed in vehicles for model beneath the word MPH shows the number of
years 1984 through 1985 (until December 1984 revolutions required by the speedometer cable
production). These speedometer heads have· a multiplied by 100 to travel a distance of 1/100th of
basic tolerance of ( +) 6.2 miles per hour with an a mile (52 feet, 9.5 inches).
additional ( +) 50fo of the actual speed driven.
For example:
Actual Speed 50 Miles Per Hour
+ Basic Tolerance 6.2
+ 50AJ of Actual 2.5
Maximum indicated speed: 58.7 miles per hour*
Speedometers with the former FMVSS 127
calibration are installed starting with December
1984 production. These speedometer heads have a
tolerance of ( +) 3 miles per hour.
For example:
Actual Speed 50 Miles Per Hour
+ Basic Tolerance 3 Miles Per Hour
Maximum indicated speed: 53 miles per hour*

*Note
It is required that vehicles be equipped with OEM
tires and wheels showing only normal tire wear.

90.30 Speedometer calibration

Water-cooled from 1984
 Electrical System - Instruments, Radio 90
d
Two different cigarette lighters are used in
Volkswagen vehicles and they are NOT interchange-
able. If installed in the wrong vehicle it is possible
that the lighter will not release properly, thus creating
a possible safety hazard.

te

190·A0781

Fig. 1 Part number 175.919.3078

Application: Rabbit - all
Pickup- all
Golf- all
GTI-all

190-A0791

Fig. 2 Part number 171 919 305

or 191 919 305
Application: Cabriolet - all
Jetta- all
Vanagon- all
Quantum- all
Scirocco- all

F-9
Cigarette lighters, replacing 90.31
 90 Electrical System-Instruments, Radio

Heidelberg VI fixed coded radio,

coding
The Heidelberg VI radio is assigned a fixed
four digit security code from the factory.
Unlike previous coded radios, the security
code cannot be changed.
The Heidelberg VI radio can be identified by
white lettering on the face plate and separate
knobs for fader, bass and treble control.
The radios are not coded at the factory. To
activate the theft protection, the radio must be
coded during the Pre-Delivery Inspection.

The security code and serial number of the

radio are printed on a removable sticker
located on the right "B" post near the vehicle
191-A0471 identification sticker.

Coding a new or remanufactured radio

• remove radio security code/serial number
sticker and attach to radio card in radio
owner's manual
Radio-Card
Morlei-Narne

CAUTION
DO NOT keep the security code or radio
card with the vehicle. Always instruct
customers to detach radio card from
191-A0481
operating instructions manual and keep
in a safe place.

Note
The security code/serial number sticker for
remanufactured replacement radios comes in
the box with the new radio. Place the new
sticker over the old sticker on the radio card.
• switch radio ON
• radio plays and radio station frequency is
displayed

90.32 Coding
·Heidelberg VI radio
- Electrical System - Instruments, Radio 90
• push and hold AM/FM and SCAN buttons
to activate coding procedure
• radio display changes to CODE and then
1000
• release AM/FM and SCAN buttons
• 1000 will remain on display
• enter radio's security code using first four
program station buttons
• security code will appear on display
• push and hold AM/FM and SCAN buttons
once again until display changes to SAFE

Note
FM .- - . - DX
MTL ''J L•C A new or remanufactured radio will only
CCAM - I " CHE accept its factory assigned security code. If
an incorrect code is entered, the radio display
will not change to SAFE.
• release AM/FM and SCAN buttons
191·A0461 • radio display changes to a radio station
frequency
• radio is now coded

Reactivating radio after reconnecting

power
After disconnecting power (fuse, battery, etc.),
the radio will lock up electronically.
To reactivate:
• obtain radio's security code
• located on radio card
• switch radio ON
• radio will not play
• radio display shows SAFE
• push and hold AM/FM and SCAN buttons
• display changes to 1000
• release AM/FM and SCAN buttons
• 1000 remains on display

- Heidelberg VI _
radio I 90 33
....___ ____ ___. Coding •
90 Electrical System-Instruments, Radio

Note
If the AM/FM and SCAN buttons are held
down too long or pushed again, the radio will
misinterpret the 1000 as an attempt at coding
and one incorrect attempt will be logged.
• enter radio's security code using first four
program station buttons
• security code will appear on display
• push and hold AM/FM and SCAN buttons
once again until display changes to SAFE
• release AM/FM and SCAN buttons
• radio display dhanges ~o a radio station
coc
::Jill
frequency \~
• radio is now coded and plays

Unlocking an electronically locked radio

After two incorrect attempts at entering the
security code, the radio will lock-up
electronically. The display shows SAFE and
will not change.

To unlock:
• leave radio switched ON for approximately
one hour
• after one hour, reactivate (code) radio as it
would be after a power interruption

Note
The radio will never permanently lock-up no
matter how many incorrect coding attempts
are made. The reactivation procedure can be
repeated indefinitely.

90 3 4
• Coding IL----------'
Heidelberg VI radio
 92
Electrical System
Windshield Wiper
Windshield Washer

Quick Data Index

-Assembly 92.2
-Rear window
washer /wiper 92.5, 92.6
washer pump 92.7
-Spray jets 92.4
- TroubiE:)shooting 92.8, 92.9
-Windshield washer 92.4
-Wiper arms/motor 92.3
-Wiper blade rubber insert 92.3

- Index 92.1
92 Electrical System-Windshield Wiper and Washer

CAUTION
Before starting to work on any part of
electrical system, disconnect battery
ground strap
Wiper motor
park position adjusting Fig. 2

=
....._....c......_----Relay rods, left and right, removing/Installing
-remove glove compartment
- remove instrument cluster
- remove 4 phillips head screws on instrumenl
Wiper blade rubber Insert cluster near wi ndshield
removing Fig. 3 - remove wiper arms
Installing Fig. 4 - remove windsh ield wiper re lay rods
(extend fully to passenger side)
0
Wiper arms _ _ _ _......,
positioning Fig. 1

, ,Nm (43 ln. lb)

~--Intermittent wiper relay

service installation:
- remove plastic wedge in windshield wiper switch
- install relay in fuse / relay panel

G·2
92.2 Windshield wiper assembly
 Electrical System-Windshield Wiper and Washer 92

Fig. 1 Wiper arms, positioning

-position wiper blades parallel to
windshield seal
• a=70 mm (2 3/4 in.) 192·016 ]

Fig. 4 Wiper blade rubber Insert, Installing

-slide metal inserts into rubber insert
upper grooves. Notch in metal insert
must face rubber insert
-slide rubber insert into retainers.
Retainers must engage recess in
second groove (arrow)

Fig. 2 Wiper motor park position, adjusting

-run wiper motor to stop position
-align crank 1 and relay rod 2 in
direction of line
- attach crank 1 to wiper motor shaft
as tailing

nstrument

Fig. 3 Wiper blade rubber insert, removing

- squeeze metal inserts at open end of
rubber insert
-pull metal inserts out of retainer
-remove rubber insert

G-2 G-3
Wiper arms/motor
Wiper blade rubber Insert
92 3•
92 Electrical System-Windshield Wiper and Washer

~7---_,;,.;."'-Spray jets----....,
~ adjusting Fig. 1

~.. ~
~--~
~~~
~~ '
A
u ~~'
~--./

Water container

Fig. 1 Spray jets, adjusting

- adjust spray jets using pin, until water
is directed onto windshield as shown
a= 490 mm (19 in.)
=
b 220 mm (9 ln.)
c= 190 mm (7 112 in.)
=
d 330 mm (13 ln.)

G·4
92.4 Windshield washer
Spray jets
 Electrical System - Windshield Wiper & Washer 92
Rear window washer and wiper system, repairing

Fluid reservoir - - - - , r - - - Rear washer pump

Stopper---.,

Mounting screw

,___ _ _ Wiper arm

adjusting Fig. 1

Spray j e t - - -
adjusting Fig. 3

....__ Mounting nut

6.0 Nm (4.5 ft lb)

Hex head screw - - - - ' Mounting nut

4.0 Nm (3.0 ft lb) 6.0 Nm (4.5 ft lb)
Mounting screw
4.0 Nm (3.0 ft lb)

G-4
G·S
Rea" window washer/wiper 92 •5
 Electri'cal 'System - Windshield Wiper & Washer 92

Fig. 1 Rear window wiper arm, adjusting end Fig. 3 Spray nozzle, adjusting
position - center of wiping field
a= 27 mm
Rear window wiper, removing and
installing
Removing
- remove cover in back hatch

Fig. 2 Wiper motor, park position, adjusting

- let wiper motor run to stop position
- attach crank and adjust as in illustration
a= 8°

- remove screws (arrows) and pull out connector

Installing
- install in reverse order

G·6
Rear window washer/wiper 92.6
92 Electrical System-Windshield Wiper & Washer

Rear window washer pump,

removing and installing
Removing

- remove right rear trim panel

-remove screws (arrow)
- remove fluid reservoir

- take pump out of guides on fluid reservoir

Installing
- install in reverse order

9 2 •7 Rear washer pump

G
 Electrical System-Windshield Wiper & Washer 92
Windshield wipers chatter or do not clean
window properly

Windshield wiper blade chatter and skipping of blade

across windshield can be caused by incorrect wiper Correct lncori'Kt
ann angle. blade to blade to
wlndehlekl wlndlhleld
The incorrect wiper arm angle will not allow the wiper angle angle
blade to flip and follow the wiper arm.
It is most noticeable on the downward stroke of the
wiper.
To adjust wiper arm,

192·A0391
Angle of blllde to windshield

- hold wiper ann with duckbill pliers at A

- bend wiper blade arm at B to obtain correct wiper
blade angle
Wax and dirt build up on windshield wiper blades
can cause streaking and smearing on windshield
when using wipers.
- do not replace windshield blades that may only
need to be cleaned
- clean wax and dirt build up from wiper blades and
entire windshield with alcohol based cleaning
solution or rubbing alcohol and water
- see troubleshooting chart on page two
- refer customer to instructions in Owner's Manual

more

Windshield wiper troubleshooting 92.8

G·8
 Electrical System-Windshield Wiper & Washer
Windshield wiper troubleshooting chart
Symptoms Possible causes
Bad wiping (sheeting) • dirty blade lip
• blade lip worn, torn or
broken
• old blade lip
Some water remains in the wiping area, • windshield glass
forming droplets contaminated by
pollutants, oil or film from
diesel engine exhaust
Windshield wiper blades clean to one side and • blade lips are deformed or
are deficient to the other (chatter) filled with dirt or foreign
matter on one side.
• windshield wiper arms are
twisted. Rubber lips do
not touch glass properly
• glass is dirty-or not wet
enough, resulting in
varying friction between
blade and glass
Windshield wiper troubleshooting
92
Solutions
- clean blade lip with wet
cloth and soap
- rinse with water
- replace blades
- replace blades
- clean windshield glass
with clean cloth soaked
in solution of alcohol (or
ammonia) and warm
water
- replace blades
- bend wiper arm to
obtain proper blade
contact
- clean the glass with clean
cloth soaked in solution
of alcohol (or ammonia)
and warm water
92.9
 94
Electrical System
Lights

Quick Data
..;.;.Aerodynamic 94.5a
-Bulb holder 94.6
-Headlight 94.4
adjusting 94.5
mounting frame 94.5
removing 94.5
-Ignition key
. deb\IJ'flrig 94.3a
- tntermittent windshield wiper
94.4 .
- Steering column
covers 94.3
lock 94.3
lock cylinder 94.4
switches 94.2
- Tail-light 94.6
- Turn signal switch 94:3

1 94.1
94 Electrical System- Lights
Tum signal cancelling ring with slip
grease slip ring with multi-purpose grease.
If slip ring is defective, press
out and replace

Tum signal switch --""""'\

installing Fig. 6

Spacerslee•ve - - ,
removing Fig. 3
installing Fig . 4
-~----Windshield wiper switch
intermittent windshield wiper,
service installation Fig . 8

...
Steering lock housing _ _ _.......,
removing Fig. 2 and Fig. 3
installing Fig. 4 and Fig . 5

Ignition/Starter switch
Lower column switch cover
(with warning buzzer contact)
removing/installing Fig. 1
to remove: first remove
steering column lock, then
unscrew clamping bolt

10 Nm (7 ft lb)
before tightening, adjust clearance
between top of spacer sleeve and
top of steering column, see Fig. 5

H·2
94.2 Steering column swllches
 Electrical System- Lights 94

Fig. 1 Upper/ Lower column switch covers,

removing/installing Fig. 4 Steering lock housing/ Spacer sleeve,
- remove two screws (arrows) installing
-remove clip on lower cover from - installing steering lock housing with
column tube support ring onto column tube
- remove both column switch covers -drive spacer sleeve on column using
vw 420
- adjust clearance (see Fig. 5)

1witch cover
lling Fig . 1

Fig. 2 Steering lock housing,

removing /installing
Fig. 5 Steering lock housing, installing
-hold coupling together using VW 267a
- adjust clearance between top of
spacer sleeve and top of column
• a=51 mm (2 in.)

cover
'ig. 1

Fig. 3 Steering lock housing/Spacer sleeve,

removing Fig. 6 Turn signal switch, installing
- pull off steering lock housing together -adjust clearance between steering
with spacer sleeve wheel and turn signal switch
• a= 2 to 4 mm (1/16 to 3/16 in.)

H·2 H·3
Upper/ Lower column switch covers
Steering column lock
Turn signal switch
94 3
•
94 Electrical ·S ystem- Lights

Note

Burrs on ignition key and/or metal shavings in the

lock cylinder could make key insertion difficult.
If this occurs,

- deburr the keys

If key insertion and operation is still difficult,

- replace ignition lock cylinder and deburr new keys

94.3a
94 Electrical System-Lights

Fig. 7 Steering lock cylinder, removing
-carefully drill 3 mm (1/8 in.) hole into
housing
• a= 12 mm (1/2 in.)
• b= 10 mm (3/8 in.)
- press in pin with punch through
drilled hole and pull out lock cylinder
Fig. 8 Intermittent windshield wiper, service
installation
- remove plastic wedge (arrow) from
opening in windshield wiper switch
-install windshield wiper/washer
intermittent relay

Mounting frame
removing Fig. 3

L. . . . . . ... . . .. Seolod beem ~

removing Fig. 1 and Fig. 2
<Hoodllght od)uotlng .. ~
adjusting screw locations Fig. 4
194-2381

Steering column lock cylinder

94.4 Intermittent windshield wiper
Headlight
 Electrical System- Lights 94

Sealed beam, removing Fig. 4 Headlight, adjusting screw locations

- remove grille by turning retainers • arrow A= left! right adjustment

(arrow) go• • arrow B =high/low adjustment

Note
Always adjust headlights using Weaver WX-50
tester or equivalent in accordance with local
laws

Fig. 2 Sealed beam, removing

- remove retainer ring screws (arrows)
- remove sealed beam

Fig. 3 Mounting frame, removing

- remove screws (arrows)

H·6
Sealed beam
Mounting frame
Headlight adjusting
94 5
•
94 Electrical System-Lights

Aiming requirements
- park vehicle on flat surface

Note
It is not necessary that the surface be exactly level.
- remove any large accumulations of mud or ice
from wheel wells, fender undersides, bumpers etc.
- check and correct tire pressures
- verify that vehicle has no loads other than driver
- rock vehicle to settle suspension
- clean headlight lenses and aiming pads
- check hi and low beam headlight operation 194-A0491

Setting up universal adaptor Fig. 2 Placing the adaptor assembly on the

aiming pads
Note
- attach aiming device to adaptor
Use adaptor 0203 when aiming Vanagon - mount assembly to headlight lens. See
aerodynamic headlights with Hoppe headlight aiming Fig. 2.
equipment.
- locate aim setting pads on headlight lens

Note
The settings are designated by the letters V and H,
followed by a number.

Aerodynamic headlight (driver side)

Universal
Adaptor

Fig. 3 Adaptor installation, right and left side

194-Ao4el
- check headlightaim using mechanical
Fig. 1 Aiming pad locations aiming procedure provided by equipment
manufacturer
V = vertical setting - correct if necessary
H horizontal setting
0 inside aiming pad (set always to zero)
-locate
- move adjustable rods of adaptor to
correspond to settings found on headlight

9 4 •5 a Aerodynamic headlights
94 Electrical System-Lights
Bulb holde•·------.
removing Fig. 1
wiring Fig. 2

Turn signal b u l b \
12V/21W \

Tail-light bulb
12 V / 5 W

!s4- 239A I

Fig. 1 Bulb holder, removing Fig. 2 Bulb holder, wiring connections

- squeeze at arrows and remove 1 =to tail-light bulb 12 V/ 5 W

2 =vacant
3= to ground
4=to brake light bulb 12 V/21 W
5=to back-up light bulb 12 V/21 W
6 =to turn signal light bulb 12 V/21 W

94.6 Tail-light
Bulb holder
H-8
 97

Electrical System-Wiring,
General

Index
I General
- Battery/Ground cables
97.9a, 97.9b
disconnecting/connecting 97.6
- Cautions and Warnings 97.2
. Air-cooled AFC
- Referto 97.11

Camper
· - Refer to 97.29
-Dashboard wiring harness 97.7
- Engine/Body ground Diesel
connections 97.6 - Refer to 97.35
- Fuse/Relay panel, removing
(1980-1985) 97.10 Waterboxer/Syncro
(from 1986 m.y.) 97.10a (Water-cooled Digifant, Digijet)
- How to read wiring diagrams 97.4 - Refer to 97.53
- Main wiring harness 97.8
- Starter cable routing 97.9
- Symbols used in
wiring diagrams 97.5
-Troubleshooting 97.3
-Working on the electrical
system 97.3

97.1
H·8
97 Electrical System-Wiring, General
Cautions and Warnings
Whenever working on Volkswagen cars, follow pro·
cedures described in the appropriate section of the
Repair Manual. Use of tools or procedures other than
those recommended may be detrimental to the safe
operation of the vehicle as well as the safety of the
person doing the repair.
Before working on any car, read Cautions and
Warnings:
CAUTION
• If you lack the skills, tools and equipment,
or a suitable workshop for repair on the
electrical system, we suggest you leave
such repairs to an Authorized Dealer or
other qualified shop.
• Before starting a job, make certain that you
have all necessary tools and parts on hand.
Read all instructions thoroughly; do not
attempt shortcuts. Use tools appropriate to
the work and use only replacement parts
meeting Volkswagen specifications.
Makeshift tools, parts, and procedures will
not make good repairs.
• Before working on any part of electrical
system, disconnect battery ground cable.
Do not substitute fuse links with fuse links
of other wire gauge or with standard wire.
Always replace entire length of fuse link.
• Relay locations are subject to change and
may vary from vehicle to vehicle depending
on options.
• Use extreme care when troubleshooting the
electrical system.
• If you encounter problems identifying a par-
ticular relay, consult your Parts Department.
97.2 Cautions and warnings
WARNING
• Never work under a lifted car unless it is
solidly supported on stands intended for the
purpose. Do not support a car on cinder
blocks, hollow tiles, or other props that may
crumble under continuous load. Do not work
under a car that is supported solely by a
jack.
• If you are going to work under a car on the
ground, make sure that the ground is level.
Block the wheels to keep the car from
rolling. Disconnect the battery ground strap
to prevent others from starting the car while
you are under it.
• Never run the engine unless the work area
is well-ventilated. Carbon monoxide kills.
• Tie long hair behind your head. Do not wear
a necktie, scarf, loose clothing, or necklace
when you work near machine tools or
running engines. If your hair, clothing, or
jewelry were to get caught in the machinery,
severe injury could result.
• Illuminate your work area adequately_ but
safety. Use a portable safety light for
working inside or under the car. Make sure
its bulb is enclosed by a wire cage. The hot
filament of an accidentally broken bulb can
ignite spilled fuel or oil.
• Finger rings should be removed so that they
cannot cause electrical shorts, get caught in
running machinery, or be crushed by heavy
parts.
• Keep sparks, lighted matches, and open
flame away from the top of the battery. If
hydrogen gas escaping from the cap vents is
ignited, it will ignite gas trapped in the cells
and cause the battery to explode.
• Always observe good workshop practices.
Wear goggles when you operate machine
tools or work with battery acid. Gloves or
other protective clothing should be worn
whenever the job requires it.
 Electrical System-Wiring, General
Working On The Electrical System
The electrical system of our cars is getting more and
more sophisticated. If guesswork and hit-and-miss
replacement of parts did not work In the. past when
attempting repairs, it surely won't work today.
The schematics In this book are called "Wiring
Diagrams." By showing how electrical current flows
through electrical components that work together in
circuits, troubleshooting is much easier with these
schematics.
Each diagram in this book shows the powerflow
through all wires, connectors, switches, and motors
beginning at the top of the page down to ground at
the bottom. A test light, or better still, a volt/ohm
meter can be very helpful for testing circuits.
97
Troubleshooting Procedure
Verify the complaint:
If you are a professional mechanic, check customer's
complaint to understand what the problem is. If pos-
sible, let customer show you what happens.
Analyze the problem:
Find the diagram in the book that applies to the car.
Identify the circuit that most likely affects your
problem. By following the circuit from ground to
power source, get an understanding of how the
circuit works.
Find the problem:
You will find the problem if you follow a simple and
logical step-by-step procedure. Test portions of the
circuit, one at a time, starting with the most likely
area. Test at points that you can reach easily.

FUSE Repair the problem:

RELAY
PANEL When you find the cause of the problem, make the
repair.

Check the results:

- IGNITION
SWITCH
BATTERY±
....... Be sure it works. Check all parts of the circuit that
you worked on .

To trace a circuit you should start with the ground

and then follow the wires back to the source of
power. Note the color of wires in the diagram.
Sometimes the color will be different on the car.
Don't be concerned, just be sure to learn that the
wires connect the proper terminals.

To learn more about the details in the diagrams,

see 'How to read wiring diagrams' on page 97.4.

World11$J on the electrical system

troubleshooting procedure 97.3
97 Electrical System-Wiring, General
Note
All switches and contacts are in mechanically
neutral position. The various contacts are shown
in current tracks in which they operate

Fuse/relay panel
across top of diagram
contains individual fuse(s)
symbols and rat ings

Letter I number combIna tlon

Identifies wiring connection on fuse/ relay
board to component
Example: E18 = multipoint connector E,
termlnal18
Wire size/color
American Wire Gauge (awg) as shown, or
metric cross-section. Example: 1.5 (mm);
color codes correspond to wire colors in vehicle

Internal connections (thin lines)

not actual wires but ground connections
which go through parts

Terminal with number found on

actual part

,,.
FAll
tm .,
.,
MD

Component symbol \
(here: motor) '·

Component designation
(here: windshield wiper motor)

Circled numbers
ground connections, numbers appear in
legend telling you where
to find connector
Current track numbers
help find components In diagram

Note: All wire sizes American Wire &auge

Where to find a wire connector on car

Sample legend

Description Current Track Wire Connectors Current Track

Parking light. right front T2d - Dehind dash
Rear window defogger element T2e- Dehind dash
Rear window defogger indicator light
Rear window defogger relay
@ -Ground connector, instrum. clstr.
Rear window defogger switch @ - Ground connector, body
Sidemarker, righttront
Sidemarker, rear
Tail light. right
Windshield Wiper intermittent switch
Windshield wiper motor

97.4 How to read wlr'lng diagrams

 Electrical System-Wiring, General 97
¢ 1~
'" 0 Resistor Meter or gauge
I
Wire size In Amencan
Wire Gauge

$ Wire connector, detachable

T~ Toggle or rocker switch

~
(manually operated)
Varlabl• resistor

~1.
+ Semiconductor diode Hydraulically operated

X~
·switch .
Electrically
operated valve .··~ E_lectromagnetlc relay

~-~-:_t:-
.l-# Ignition distributor

+ !
Condenser (capacitor)
<l
~-'\=- ·. _· . Starter solenoid

Ignition coil
T

~--~
t 1

Solld·state relay

1
Spark plug
m
~ -®- }--i
Alternator Thermally operated
Fuse (bimetallic) switch

~- Motor

$ .~
Manually operated
Light bulb multi-position switch

+ ""----/
Wire junction, detachable

~
·one filament in a
multifilament light bufb /+·~lr.~ crossing (no connection)
I
\.

\ ~ Wire junction, permanent

® Solid·state circuitry

~ Heating element ...J.!

T-
Battery
.~ Manually operated switch

--
~
Mechanically operated
switch
I
\
\

l Shielded conductors u-t--9 Hom

cff Light-emitting
diode (LED)

Color Code Wire Connector Code

Black -BK Green -G T1 -single T6 -&point
Brown -BR Light Green- LT. G T2 -double ts -8-polnt
Clear -CL Blue -BL T3 -3-point T12--12·point
Red -R Violet -V T4 -4-point T14-14·point
Yellow-Y Gray -GY
White -W

F·10

Symbols used lri wiring diagrams 97.5

97 Electrical $rstem-Wirlng, General

Engine/Body ground connections WARNING

Poor ground connections may cause
speedometer or brake warning light problems.
If speedometer needle will not return to zero or if
brake warning light will nof go out, ground
connections may be bad or may have been
connected to the wrong location on the vehicle.
Poor grounds may weaken speedometer needle
return spring by allowing battery current to flow
through speedometer cable.
Battery/Ground cables,
disconnecting/ connecting
Disconnecting
- disconnect battery ground cable from negative
terminal of battery
- disconnect ground cable from transmission
(not from body)
Connecting·
- clean ground connection on transmission to
bare metal
- connect ground cable to transmission
- connect ground able to negative terminal of
battery
Batteries produce explosive gasses. Keep
flames and sparks away from batteries. Do
not smoke near batteries
CAUTION
To avoid. voltage drops and corrosion
damage, ground cables on vehicle body
must not be disconnected. Disconnect
ground cables from battery or transmission
ends only.
When connecting cables/ ground straps, all
connections must be cleaned to bare metal.
Be sure mounting bolts are tight.
Note
A special bolt. is used to attach the ground strap to
the body. If the bolt has been loosened, it must be
removed and cleaned free of paint and
undercoating. The mounting area must also be
cleaned free of paint and undercoating. After
installing, coat the bolt and mounting area with
corrosion resistant mater.ial. ·

4 6 5

Ground straps
1 =Battery
2 =Transmission
3= Engine
=
4 Negative terminal of battery
5 = Ground point (transmission)
6 = Ground point (body)
• do not disconnect

97.6 Engine/Body ground connections

Battery/Ground cablee
 Electrical System-Wiring, General 97
-
CAUTION
Before working on any part of electrical
system, disconnect battery ground strap

to rear courtesy light

to heater/ventilation controls
4bles and to cigarette lighter
to front courtesy light

Ground point
behind fuse/relay panel to neutral/park
starter switch
(vehicles with automatic
transmission)

_/

F-3
Dashboard wiring harness 97.7
97 Electrical SyStem-Wiring, General

CAUTION
Before working on any part of electrical
system, disconnect battery ground strap

C a b l e - - - - - -..
to ground point on
cross member, from to plug connections T4,6.nd T4c
fuel gauge sender behind dashboard and' to fuse/relay panel

Cables

Cebles---'
to Ignition distributor,
starter, on pressure switch Forward-
and Ignition coil ,

Cables
to neutral/ park starter to fuse I relay panel and ]
switch (vehicles with au.tomatic. to switches for heater booster ,
transmission) '
Left slde·member

97.8 Main wiring harness

 Electrical System~Wiring, General 97
- Starter cable routing CAU.TION
Before working on any part of electrical
system, disconnect battery ground strap
Starter cable - - - . . ,
from battery to Cable grommet
starter; to replace,
remove fuel tank

• fl)rward

Cable
from battery to
fuse/ relay panel

a Forward

Main
harness '1-
wiring~~ ....
~~===================::]

Rear crossmember
Tie wrap

Starter connection,
tetmlnal30

- F-5
Starter cab~ routing 97.9•
97 Electrical System-Wiring, General

Battery cables, location

Wiring from battery-~

to ltllrter

197·2150 I

)
\ /
cables---
to battery
~ cut-out relay
197·21491

97.9a
 Electrical System-Wiring, General 97
Ground cable from body to automatic transmission

Ground c a b l e - - - - - - - "
from body to transmission

"'hhnsmlaalon mount

on transmission mount 197-21451

Ground cable from body to manual transmission .

Ground cable
from body to
transmission

ound cable------'
on transmission mount

197-21461

H-7
Ground cables 97.9b
97 Electrical System-Wiring, General

Fuse/ relay panel, removing CAUTION

CAUTION
Before working on any part of electrical
system, disconnec't battery ground strap
Relay locations are subject to change and may
vary from vehicle to vehicle depending on options.
Use extreme care when troubleshooting the
electrical system.

If you encounter problems identifying a particular

relay, consult your Parts Department.

- remove screws (arrows)

-pull down fuse/relay panel

1 :::; emergency flasher relay

2:::; vacant
3:::; load reduction relay
4:::; ignition key warnln?rbuzzer/relay
5:::; windshield wiper/washer intermittent relay
(optional)
6:::; overheat fuse (SA) for heater booster (not
shown in illustration), see Repair Group 82

97.10 Fuse/Relay panel

1980-1985
 Electrical System - Wiring, General 97

- pull fuse/relay panel cover upward and unhook

0
-remove screw (arrow)
- unhook fuse/relay panel and pull down

Note
Before working on the electrical system, disconnect
battery ground cable.

From 1986 m.y.

Fuse/Relay panel, removing 97.10a
 97 Electrical System-Wiring, General

Connector terminal rubber insulating

grommet, modifying
A rubber insulating grommet (arrow) is
installed on some connector terminals at the
factory. During wiring repair, the rubber
insulating grommet must be reversed before
re-inserting into the connector housing.
• remove and discard terminal 1
• slide rubber insulating grommet from wire
197-32261
and rotate end-to-end (180°)
• inspect grommet and replace if damaged

CAUTION
New replacement grommet must be the
same color as original to ensure proper
sealing between wire, grommet and
housing.

• reinstall grommet onto wire so that collar

197-32391 (arrow) faces terminal 1

• properly crimp new terminal 1 to wire

9 1 •10 b Connector terminal rubber insulating grommet, modifying

1-14

Index
General
- Battery/Ground cables
97.9a, 97.9b
disconnecting/connecting 97.6
l - Cautions and Warnings 97.2
-Dashboard wiring harness 97.7
- Engine/Body ground
connections 97.6
- Fuse/Relay panel, removing
(1980-1985) 97.10 ./'
(from 1986 m.y.) 97.10a
-How to read wiring diagrams 97.4
-Main wiring harness 97.8
-Starter cable routing 97.9
-Symbols used in
wiring diagrams 97.5
-Troubleshooting 97.3
-Working on the electrical
system 97.3
97
Electrical System-Wiring,
Air-cooled-AFC
1980, 1981 Air-cooled AFC Camper
- Cautions and Warnings 97.2 - Refer to 97.29
- Fresh air fan 97.23
- Fuse/Relay panel 97.10 Diesel
- Heater booster 97.24, 97.25
- Main wiring diagram 97.12-97.17
- Refer to 97.35
- Rear window wiper 97.26 Waterboxer/Syncro
-Seat belt interlock system 97.27 (Water-cooled Digifant, Digijet)
- Refer to 97.53
1982, 1983 Air-cooled AFC
- Cautions and Warnings 97.2
- Fresh air fan 97.23
- Fuse/Relay panel 97.10
- Heater booster 97.24, 97.25
- Main wiring diagram 97.18-97.22
- Rear window wiper 97.26
- Seat belt interlock system
(1982 only) 97.27
97.11
97 Electrical System-Wiring, Air-cooled-AFC

•IGliiTION
CONTIOI
UNIT • OIJ MIAY

I ® I I ® I
~· i· t+
*'~
*3 w·
*'
16
BR
20 20 20 16 16 20
*'
18
w
16
w
18 18
w w

18 18
'II w
Wiring TMIOT
• IDII
Color Code STAI
Ylf

Black - BK
~:~:IOi u_~~--~~--~
IW
,..
IIIJ
lUll
.I .J
lUll

Brown - BR en Crt Crt

Clear
Red
- CL
- R
• I l

Yellow - Y

1
Green - G
light Green- LT.Q
Blue - BL
Violet - V
Gray - GY 20 \8 18 18 \8 18 18
RJBK G BKIW w w w w w w w
White - W
~ ~ l DISTIIIUTO• ~· ¥3 ~ . i .. ~" ~3l ¥WI
I® ~ - ---
I

••Au
f!) I IIIII

---
16 17
·ca~ronlia only ( •.
GINIUTO• IIIJ
CONTIOI
UNIT

Note
On 49 state and
Canada vehicles, a SI'UI
"'UG TDC
series r~slstance is CDNNICTOIIf IINor•

~
located between
fuel injection
control unit and

~tit.
Injectors.
On California
vehicles, series
resistance Is built
Into fuel Injection
control unit.

I g n i t i o n - - - - - - - - - - - - - - + - - Fuel InJection/~
Note: All wire sizes American Wire Gauge
Current Current Current
Description Track Description Track Description Track
Alternator Brake warning light Emergency flasher relay
Alternator charging indicator light Cigarette lighter Emergency flasher switch
Auxiliary air regulator Cigarette lighter light Fuel gauge
Back·up light, left Clock
Back-up light, right Fuel gauge sender
Cold start valve Fuel injection control unit
Back ·up light switch Distributor
Battery Fuel pump
Door switch. left front, with buzzer contact Fuel pump relay
Brake light, left Door switch, right front
Brake light. right Fuses S 1·S 12 on fuse/relay panel
Elapsed mileage switch lor OXS indicator' (under dash)
Brake light switch Emergency flasher indicator light llall generator•
'California only

97.1 2 Main wiring diagram AFC 1980, 1981 F·12

 utmnrrrc•

!s.
20
GY/BK
~

ll 20
BUBR
8
RIBK
20
BL
AIf
CIAK
liD
1m
WTU/13

~i t,

~~.., ,.l_j
18 18 18
w
8
R/BK
20
BL

.~
l-SI~~-
ot~ CNrl
,.,"
=~
>7 nAif~

/
/
( t..
\,
\ 18 18 18 18 18 18 18 10 8 20
w w w w w w A A BL
)!,,. lll() u.

T..,

IMIIl
rvwr
I
~
ij
16
BA
T
~Oxygen sensor/Fuel pump ------------+-----Startlng/Charglng------i
Current Current Current
Description Track Description Track Description Track
Headlight dimmer switchlftasher Ignition coil Intake air sensor
Headlight, left, high Ignition control unit" Interior light, front
Headlight, left, low Ignition key warning buzzer Interior light, rear
Headlight, right, high ignition/starter switch Ucense plate light
Headlight, right, low Injector, cylinder 1 Light switch
Heaterllresh air controls light Injector, cylinder 2 Load reduction relay
High beam indicator light Injector, cylinder 3 Oil pressure light
F·1 2 Horn Injector, cylinder 4 Oil pressure switch
Horn button Instrument light dimmer O)(}'gen sensor (OXS)"
Idle stabilizer control unit• Instrument panel lights O)(}'gen sensor (OXS) indicator light"
·ea~Hornia only

F·13 AFC 1980, 1981

Main wiring diagram 97.13
 20
BK L..............!::::::::::~;:~~~~----~~~~~~----------------
IAOIO CONNICTION I+ I
... ,BKs.
18 wr,.
BKIY ,: II
t)
'OHGIN
16 20

Lr ============== 2~ ::=
JliiSOI
IND BKIY R R
UTI T ... /9

.T" I
fUll

UTI~: ffl
011 GAUGI
1'111

Tl4/ll
UTI
Jwnc•.L .~ .I

~ ~~I
~fl-4/8
is ~>6 ~SB ~::Ob=I"'I=:ZI:ZI=IZ:I=:ZI:Zi=z:i
"''""" .,. .... , ...
20 20 z:z= 1:21C:: 20 -
20
VIBK
,,~-
~~
20
BUG
B~~~ 20
BLIBK
20
VIBK
:~ l
~::"4~
~­
Wiring
Color Code
Black
Brown
Clear
Red
Yellow -
-
-
-
-
BK
BR
CL
R
Y
20
BL
r-
,2
WIBK
16
W
Green - G
Light Green- LT. G 18
GY
Blue
Violet
-
-
BL
V s, s.
Gray - GY
White - W

,\~1
·eamotn&a only

16
y
~
20
BUW
20
GYIR
20
GYIG
T..
i
20
GYIBK

fUll
,..,
NO
liTI
IIIJ
::~" ~m:•:_~====~~~
.Tl-414 _t.t

-
.0.
Ull
lifT
1101
/IIIII
1111
IIAI

I
~ lnatrument cluster - + - - - - - - - - Lighting/Radio connection
Note: All wire stzes American Wire Gauge
Current Current Current
De&crlpllon Track Description Track Description Track
Oxygen sensor (OXS) relay• Sliding door switch Turn signal, left Iron!
Parking brake indicator light switch Spark plug connectors Turn signal, left rear
Parking light, left Spark plugs Turn signal, right llont
Parking light, right Starter Turn signal, right rear
Radio connection ( - ) Taillight, left Turn signal switch
Radio connection ( + ) Tail light. right Voltage regulator
Rear window defogger TDC sender Voltage stabilizer
Rear window defogger switch Temperature sensor Windshield washer pump
Side marker light. left Thermo hme switch Win dshield wiper motDI'
Side marker ltght, right Thronle valve switch Windshield wiper switch
Turn signal indicator light Windshield wiper/wa.sner interminent relay
• California only

97.14 Main wiring diagram AFC 1980, 1981

F-14
 .16 . . . . . . . . . . . . . . . . . .. .
BK

16
BK

"'"20
BK '

,j Sn

16
I fI
RIW
16
BKIBL

lO "

J IMI'IG G9 ~
ri.IMt
IHD
~~· "" 31 ~

1a 1a I 1h
BKIW BKJG BR

18 18
~
Tm.
Pd ~
J ucr

I ll 1a
~· ~ 18 20 20
I BR BKIBL BR BUR

I ~t. r.• ~
~ ~
j
T. T.
20 20 18 18 18 18 18 20
GYIBL R BRIBL BKIW BK/W BKIG BK/G BR
lin~l2
lllfiiW~fll l
HnuJ "'lliiD
¥
J HUT

1"' ctocr HOIH fiiSif

IUTIOH
IU
Aa
IU lUll' IUIII IUIH I UIII COMito I
1111
IIH
1111
IIGHI
IIGHI
lt
SIGH I
lf ,
SIGH I JIOHl
tt
1111

t~ Y14 I~

20 Ia
BR BR

---------~-------Horn/ Emerge ncy flasher/Directional signals ------~

197-6641
Current Current Current
Description Track Description Track Description Track
Al1erna1or Brake warning light Emergency flasher relay
Al1erna1or charging 1nd1ca1or light Cigarette lighter Emergency flasher sw1tch
AuXI~ary air regulator Ci<Jarette lighter light fuel gauge
lack·up hght, lelt Clock Fuel gauge sender
Back-uj) hght, nght Cold star! valve Fuel Injection control un1t
Back ·up ligh1 sw1tch Dts1rlbutor Fuel pump
Battery DoO< sw1tch. lelt lront, w1th buzzer contact Fuel pump relay
Brake light, lel1 OoOt switch, nght front Fuses S1·S 12 on fuse/relay panel
Brake hght. right Elapsed m~eage swi1ch for OXS indicator• (under dash)
Brake light sw1lch Emergency flasher indiCator light Hall generatO<•
•California only

F-15 AFC 1980, 1981

Main wiring diagram 97.15
 ....s•

lff1 Note: For 1981 vehicles only

20
BUBK

T8f7 ani/A

16 20 18 20
R GYIG RIY R

Blo~82a

.....
llrl
SWrJCN

18 ~18
ffi"'
20
GYIBL

~ - "i:
18 20
RIBK GYIBK

IGII
m
WIIIG "'
IUllY

IADIO
COHHKTIOH
(-)

20 20
GYIBL

......
,
IHD
llrl
sw
..... .....
llrl llrl
lffT
SUDf
Dool
sw
liGHT

Fresh air fan/Cig ltr - - + - Brake lights ---~--Interior lights - - - - - 1

Note: All wire sizes American Wire Gauge
Current Current
Description Description Description
Headlight dimmer switch/flasher Ignition control unit• Interior light, rear
Headlight, lefl, high lgnilibll key warnmg buzzer License plate light
Headlight, tell, low lgnlttMistarter sw1tch light SWitCh
lleadlighl. righl, high lojec·tor. cylinder 1 Load reduct1on relay
lleadllghl. righl, low ln;ector . cylinder 2 Ool pressure light
Hea!flr/1resh air controls light Injector, cyli~er 3 Oil pressure switch
HIQh beam llld~eator light Injector, cylinder 4 Oxygen sensor (OXS)•
Horn Instrument light d1mmer Oxygen sensor (OXS) Indicator light•
Horn button Instrument panel lights Oxygen SG.I IS« (OXS) relay•
Idle stabilizer control un~· Intake a11 sensor Parking brake indicator light switch
lgnotion coil Interior light. tronl
• camornla only

97.16 Main wiring dlagram

AFC 1980, 1981 F-16
 Note
---~

)
L .. llfDCICTION
IRAY
- --- - - - - - - - - - - - -
.
USA and Canada vehicles are equipped
with EGA system instead of OXS system.
OXS system is for California only .

Wire Connectors
20 BR

10
1" 20
~ T1 a
T1 b
T1 c
at fuse/relay panel
behind dash
behind dash
BKIY BR T1 d in engine com part. near alternator
T1 e behind 1nstr. panel
Tlt behind 1nstr. panel
T1 g behind dash
T1 h in engine com part.
T11 behind dash
T1 j behind dash
T1 j in engine com part.
T1 k in engine com part.
T2 behind dash
T2a behind dash
T3a 1n engine compart.
T4 beh1nd dash
T4a at fuse/relay panel
T4b at fuse/relay panel
llfAI
T4c beh1nd instr. panel
llfAI
w•D
••o
DffOG T8 at brake warning light

~~~~==~~~~~~~~~::~~~
T14 at instr. panel insert

31 ~~~ ~86 L_j ~31

18 18 20 18 18 18 t6 20 Ground Connectors
BKIGY GIR BRISK G GIBK BR WIG BR
CD - from banery to body
~ ,; l @ - from transmission to body
@ behind instr. panel. to left of
fuse/relay panel
18 @ beh1nd 1nstr. panel, to left ot
G/R
fuse/relay panel
@ - on steering gear
@ - at left front of crossmember
@ - near fuse I relay panel
w1r11
@ - near ignit1on distributor
IWSIII
IIITIIMIT
16 @ - at fuse I relay panel
I BK
llflAY
I ~T,i
I
20 18 16 Wiring
GIR BR RIBK Color Code

$~·
>3 >lb
Black - BK
!I! lfiiiD lfiiiD Brown - BR
DfGI Clear - CL
"'"
MOTOI Red - R

I=
31
16 BR Yellow - Y
Green - G
Ught Green - LT. G
Blue - BL
20 r
16
Vieltt
Gray
-
-
V
GY
White - W

I
~Windshield wos,..lpe•------+-Reat window defogger •cahtornta only

Current Current
Description Track Description Track Description
Parking ligh1. left Spark plugs Turn signal, left rear
Parkmg light, nght Starter Turn signal, nght front
Radio connect1on ( - ) Tail light, left Turn signal, nght rear
Rad1o connection ( + ) Ta11 light, right Turn signal switch
Rear wuldow defogger TDC sender Voltage regulator
Rear window dQ!~r sw1tch Temperature sensor Voltage stabilizer
S1de marker light, left Thermo time sw1tch Windshield washer pump
S1de marker light. nght ThroUie valve switch Winds~teld wiper motor
Sl1dmg door switch Turn s1gna1 mdicator light Windshield wiper switch
Sp~rk plug connectors Turn s1gnal. left lront Windshield wiper/washer 1ntermit1ent relay

• California only

·16 F-17 AFC 1980, 1981

Main wiring diagram 97.17
97 Electrical System-Wiring, Air-cooled-AFC
1982-1983 Vanagon
Air-cooled-AFC CurTent Track
O..crlptlon Current Track Deacrlptlon

Alternator 31,32 Side marker light, left

•
.....
Alternator charging indicator light 32 Side marker light, right 41
Auxiliary air regular 22 Sliding door switch 83
Spark plug connector H
Back-up light, left 58 Spark plugs H
Back-up light, right 59 Starter
Back-up light switch 58
Battery 26 Tail light, left 11

.... .......
Brake light, left 78 Tail light, right
Brake light, right 75 TDC sender 11-t1
Brake light switch 75. 78 Temperature sensor tt ca•n10
Brake warning light 73-78 Thermo time switch IIIII'
Throttle valve switch 11
Cigarette lighter 71 Turn signal indicator light tf1
70 Turn signal, left front 1M

..••
Cigarette lighter light
Clock 58 Turn signal, left rear
Cold start valve 24 Turn signal, right front II
Turn signal, right rear
Distributor 5-8 Turn signal switch
Door switch, left front, with buzzer
78,79 Voltage regulator 11
•
contact
Door switch, right front 80 Voltage stabilizer

Elapsed mileage switch for OXS Windshield washer pump

indicator 33,34 Windshield wiper motor
Emergency flasher indicator light 87 Windshield wiper switch
Emergency flasher relay 58-81 Windsh ield wiper/washer intermittent
Emergency flasher switch 81~ relay

Fuel gauge 38 Wire Connectors

Fuel gauge sender 39
Fuel pump 23 T1 a - at fuse/relay panel
Fuel pump relay 1~ T1b -behind dash
Fuses S1-S12 on fuse/relay panel T1c -behind dash
(under dash) T1d -in engine compart, near alternator
T1e -behind instr. panel
Hall generator 2-4 T1f -behind instr. panel
Headlight dimmer switch/flasher 43.44 T1g -beh ind dash
Headlight, left, high 42 T1 h - in engine compart.
Headlight, left, low 40 T1 i - behind dash
Headlight, right, high 43 T1 j - behind dash
Headlight, right, low 41
Heater/fresh air controls light
High beam indicator light
Horn
•
44
57
T1j
T1 k
T2
-in engine compart.
- in engine compart .
- behind dash
T2a - behind dash
Horn button 57 T3a - in engine compart
T4 -behind dash
Idle stabilizer control unit 2-4 T 4a - at fuse/relay panel
Ignition coil 7 T 4b - at fuse/relay panel
Ignition control unit 1~ T 4c - behind instr. panel
Ignition key warning buzzer 77,78 TB - at brake warning light
Ignition/starter switch 30-40 T14 - at instr. panel insert
Injector, cylinder 1 15
Injector. cylinder 2 18
Injector, cylinder 3 17 Ground Connectors
Injector, cylinder 4 14 1 - from battery to body
Instrument light dimmer .a 2 - from transmission to body
Instrument panel lights 63-65 1o - behind instr. panel to left of fuse/relay panel
Intake air sensor 1~ 11 - behind instr. panel to left of fuse/relay panel
Interior light, front 71-11 12 - on steering gear
Interior light, rear 82,83 15 - at left front of crossmember
16 - near fuse/relay panel
License plate light .a,.ct 17 - near ignition distributor
Light switch 44-47 1B - at fuse/relay panel
Load reduction relay 88-93

Oil pressure light 38

Oil pressure switch 38
Oxygen sensor (OXS) 111
Oxygen sensor (OXS) indicator light 34
Oxygen sensor (OXS) relay 9-12

Parking brake indicator light switch 73

Parking light, lett 50
Parking light, right 45
Radio connection (-) 72
Radio connection ( +) .a
Rear window defogger 11
Rear window defogger switch 111, ta

97.1 8 Main wiring diagram

current track Index
AFC 1982, 1983
 Electrical System-Wiring, Air-cooled-AFC 97
IGolfiJIOIII

ln
COtfJIOI
UJUl ID IILtJ

t·~~l
I ® I I ®
~· i· ft' t+ tr'
16
BR RIBK
10
GIW
*'
10
BKJW
16 16 10
BK 9K BK
*'
18
w
16
w
18 18
w w

I~ I
~
i
,,
16
IlK

...JHIOJ)
18
w
)(
18
w
18
w
18
w
Jl :;. . ,.U 18 18
w
18

Jl
.
,,,..,...
IOU

l ® I
... ,...
., p IUt
.!:
/_-"~~~-
.....'"~
-~~
01
,., 1 11m ~1' (010

1
""
~ "" JUIJ

~ "'• "' "' " YAIYf

I
'

0 10
~
10 18 18 18 18 18 18 1 18 18 18 18 18 18 18 ,, 18 18
w w w w w w w w w
R/8K

~ ~
G BKIW

l r7 l ~JIIIVJOI
Jl., ij,
w
)l,
w
\(..
w

"
)I, )~, Jl~ )1, Jl, rr.. Jt. ~ .. ,.....wL!
R/Bl w
oJl
I® ~) ~---- ·-+;- I ®. J/Mf
llfiJ(If
, .. II
,.,
""'
"~
GHN'. . JOI ")(
COifJICH 18
Ulfll w

T., T.~10
BK
BK

....
lrUI

'"" 0
II)(
COIII.Ifi(JOIS
~ ~ ~
~ .. J,.....
~
SllfDII
OUCUI l...
SllfSO• .....
,.., ru• -

~
l'lUCJ

~bt~ 16 16
8R
(!!)
f> Gl
S 17 I f 2s
IOIII213M 11 16 17 II
" JO 21 22 23 311

~------~~~--------~----------~---FuellnfeetloniOxygen NnsoriFuel pump

AFC 1982, 1983

Main wiring diagram 97.19
97 Electrical System-Wiring, Air-cooled-AFC

18 BK/V
8A
10 A
16 A
16 A

I~ A..
GVIBK fjDjO CD,IfJtf(fN). I+!

~
B~V ~~
.-.
OJYGP
....... z. i 16 10

••
Yl-Y
11 '"'
UR

10 20
~~. =========
12 18 10~~:

-l "
BU8A

~:
WIBK GV Gr

Wiring
8 10 10 10
AIBK Bl BLIG BlJ8I( Color Code
.,.. -IlK
Brown -IIR

r
a- - Cl
Red -A
Yfiii:M -Y
<lteen - G
~ <lteen - U. G

- -Bl
10 20 20 12 16 V1olot -V
A BL BL WIBK Glay - GY
~P====de====::;> - -w
s, s,

97.20 Main wiring diagram

AFC 1982, 1983
 Electrical System-Wiring, Air-cooled-AFC 97
18 BKIY w

v
8R
10 R
16 R
16 R

16
r~T
.... ...s. ....s.
81(

f 16
81(

... ~
' ....5,2 ....Sn

i
~
16 16
RIW R
16
BKIBL

I
I
-81<
-BR I 301

l, l l l
..
IMfltG lUll SW
-CL
I ,::1~"." ~9

t· ~I'
-A

I ·~·
~t ~0
-Y UTI Jl

r
-G
-U.G . l1s 18 18
-Bl BKIW BKIG BR GYIBL

~ ~
-V ~ !"'""=-
-GY
I ~ ~ T.. t T. t.
-W

I
IADIO
CONNKUON
(-1

t t T""
20 18 18 20 20
GY/BL BKIG BKIG ilR GY/BL
Hn. IJ ' llTIA/2

IU IU run run JUIIf JUIN

UJf
un
IIJf
116NJ
S'GNl
ll
JIGifl
"
.,
SHiNI JHiNl
H

••• 11" 11•• :111 n - n

AFC 1982, 1983

Main wiring diagram 97.21
97 Electrical System-Wiring, Air-cooled-AFC

,. IDAD
.....,
aoucno• ..

rw
,.
----------------

208R
il<lJ
20 10 20
BUB!< BI<IY

1,.,, w",.
SIO

20 20 18 20 16
GYIG BUR RIY R 8KIGY BKIW

t ~~l-·
-- -
•••

Eu
••o

.. A''
18 18 18 16
80

20
]I

RIB!< RIBK 8KIGY WIG 8R

it w 18
~ Wiring
Color Code
_,.
18 20 GIR Blocll
GYIBK Blown -II

·-
""
l•ffiiOI"'
llff
2
R 0,,.,
'.ffi.OI
UJf
y-
c.-
Red
- Ci.
-R

·rfi
m -Y
IUZZII " Gloen -G
BRIW ~GIOIII-
16 8lJo - I.
,T,,
81( VIOiot -Y

-·
Gtay - Gl
White

20 20 20 20 18 16
GI R BR RIBK
11

~·j=
sw ru•r

20

n • , • a .. • ••
.............
lf ID a
ll 7l
"

97.22 Main wiring diagram

AFC 1982, 1983
 Electrical System-Wiring, Air-cooled-AFC 97

••
""<'
s, ---·---.:~·--·~1... 0
•• -,

..
II( It

fUH
Alii
•
ll.•
"l
. /

:~· 7~11'
••
y

tng
or Code
-BK
-BR
-Cl
-A
-Y Wiring
-G Color Code
:;..., -U. G
-BL
Black - BK
-V
Brown - 8R
-GY
Clear -CI.
-W Red -R
Yellow - Y
Green - G
light Green- l T.G
Blue - BL

..
•• Violet
Gray
White
- V
-GY
-W

_l Ground Connector
@ behind dash
NOTE: All wire oil• Americoln Wire G•uao

AFC
Fresh air fan 97.23
97 Electrical System-Wiring, Air-cooled-AFC
ro aAmtr
I'OSiriVf
JftAI.Al

S2J
(16A)

TO UlfiGIIIICJ JUII'fiA JUif

fUSiffl SWIJCII SID)I
Sib

20 20 12
BUY BL
---- .....
R

20
R
T
20
BUR
T~a

t'·
20
BUY
20
BL
r••

BUW
20 16
R

JaAD• } C
RAII'fiA FUll c___---4--J
lfGULUIIIG
SWIFCII
---® ,
'j'S
~20GVR~
'j'8 'j'H
=::G..t-y--~-r
l
16
K IRAJ 'f'
16
G 'j'D
16
20 BA/W BK/Y G BK

r•• 'r••

16 16 20
y BKIW BL

r=r~
OVfiiiUJ
fUSI 511
(BA) N:-
16 18 16 20 20
G BKIW BKIW BR BUR

, r•• 'r•• SUI'I'IISSOI !

16 18
BKIY G SII'PIGIOI

20 20 16 UUIII18
I'OIIIJS

J1J_
BR BR AIW CIICUU-
JIOIIIlOWII

J~::: Sfii'I'IIISSOI
(COIIDfiiSII)
~ SWIJCII
~fiiiUJ
16 SWIJCII
20
BR BR
y,

97.24 Heater booster

AFC 1980-1983
 Electrical System-Wiring, Air-cooled-AFC 97
Current
Description Track
Air circulation blower
Breaker points for fuel pump
Breaker points for Ignition coil
Combustion air blower
(to) Emergency flasher switch, term. 58b
Flame switch
Fuel pump
Glow/spark plug-element
Glow/spark plug-electrode
Heater Indicator light
Heater lever switch
Heater relay
Ignition coil
Ignition/ starter switch S10= Fuse In fuse/relay panel (16A)
Main fuse S23 S23 = Main fuse, In-line (16A)
Overheat fuse S17 12
Overheat switch 11
Safety switch 17, 18
Suppressor for air circulation blower 10
Suppressor for glow/spark plug 18
Suppressor for ignition coil 14.16
Temperature regulating switch 1-8
Temperature sensor

Wire connectors
T1a-at fuse holder
T2 -at air circulation blower
T4a-at heater
T4b-at heater

@-ground connector, at heater

@-ground connector, at combustion air blower S17 =Overheat fuse (8A)

Wiring
Color Code
Black -BK
Brown -BR
Clear -Cl
Red - A
Yellow -Y
Green -G
Light Green - LT.G
Blue -BL
Violet -V
Gray -GY
White -W

CAUTION
Before working on any part of electrical
system, disconnect battery ground strap
:JIODf) J10 =Safety switch

Note
To reset switch, wait three minutes and then

I press reset lever in direction of arrow

AFC 1980-1983
Heater Booster 97.25
97 Electrical System-Wiring, Alr-cooled-AFC

intermittent
wiper switch
-- -rl ::;;:.b
f, J, r.________,l,
Wife ConnectOfl

T1 -single, behind dash

Rear-window T2 -double, behind dash, right
•• wiper/washer relay T2a - double, on roof, rear, right
T2b - double, on rear window-wiper motor

Ground Connectors

9 - behind dash, right

10 - near fuse panel
11 - near rear washer-fluid container, right
12 - on rear lid, near rear window-wiper motor

Wiring
Color Code

Blad< - BK
Brown - BR
CIOII' -Cl
Red -R
y- -Y

-
Green -G
To ~Green -Lt. G
-BL

):.
II II II 20 II ,, 18
Voolol -v

t~:i ~4 hT
Gray -GY
Whitt -w

Windshield-wiper 'j' Rear-window

motor Windshield- Rear-window
washer wiper motor
washer pump
pump

••'0
18 18 18
8R
•• ••

97.26 R.e ar window wiper

F 1981-1 983
Waterboxer 1983- 1985
 Electrical System-Wiring, Air.,cooled-AFC 97
to
FUSE
N0.8
•
10
II

130 IGNITION/STARTER SWITCH

l..,y
12
~l--1
10
R/IK
18
Ill(
16
·~
20
Ill(
to I I
to to
LIGHT STARTER 14-POINT
SWITCH TERM. 50 PLUG
TERM. I

Sn
8A
Current
Wire connecton Track
18 18

T1c
T2a
single, behind dash
double, under driver's seat
3
4
111(/Y
to
HORN
·t
to
BACK-UP
T3 3-point, behind dash 4,6 LIGHT
T4 4-point, behind dash 8 Sa SWITCH

T4a 4.point, in engine

compartment 8
1..
20 20 20 18
II( GY/G IR ll R/Y

T3

tor

to IS 81 82
INTERIOR l81o __]82o " l I "
LIGHT
CFRONTl toLOAD o:I\...BRAKE-
LIGHT ~·
I
20
REDUCTION~
RELAY 1 SWITCH
IB R/BK
18---1
'i'
81

Wiring Color Code BR 'w R/8K

Black - BK
$T4
18
Brown - BR

h
Clear - CL
Red - R
Yellow -Y
Green - G
Light Green- l T.G to
Blue - Bl 04{ ot{o ( Fl f.
EMERG .. 1'
FLSHR "1-PARKING 0 IRI 0
Violet - V (RFI ~ RLY !BRAKE
'WARNING
i I (LI

DOOR LIGHT BRAKE

Gray - GY SWITCHES SWITCH LIGHTS
White - W

AFC 1980-1982
Seat-belt Interlock system 97.27
97 Electrical System-Wiring, Alr-cooled-AFC

THIS PAGE INTENTIONALLY

LEFT BLANK

97.28
 97
Electrical System-Wiring,
Camper

Index
General Camper Air-cooled AFC
- Battery/Ground cables - Auxiliary battery -Refer to 97.11
97.9a, 97.9b 1986-1989 (man. trans.) 97.34
disconnecting/connecting 97.6 (also see 97.53} Diesel
- Cautions and Warnings 97.2 -Battery level indicator - Refer to 97.35
-Dashboard wiring harness 97.7 lights 97.30
- Engine/Body ground - Camper electrical equipment Waterboxer/Syncro
connections 97.6 1980-1985 97.32 {Water-cooled Digifant, Digljet)
- Fuse/Relay panel, removing from 1986 97.33 - Refer to 97.53
(1980-1985) 97.10 -Water pump 97.31
(from 1986 m.y.) 97.10a - Water tank level indicator
- How to read wiring diagrams 97.4 lights 97.30
- Main wiring harness 97.8
- Starter cable routing 97.9
- Symbols used in
wiring diagrams 97.5
-Troubleshooting 97.3
. - Working on the electrical
system 97.3

97.29
97 Electrical System-Wiring, Camper
Battery level indicator lights, checking Water tank level indicator lights,
checking
Note

Ignore indicator lights which light but are not Note

mentioned in test being performed
-check indicator light panel fuse located under
driver's seat
-remove indicator light panel from sink cabinet
and disconnect multi-point connector
Ignore indicator lights which light but are not
mentioned in test being performed
-check indicator light panel fuse located under
driver's seat
-remove indicator light panel from sink cabinet
and disconnect multi-point connector

1 2
-connect indicator light panel to fully charged 2
12-volt battery as follows: -connect indicator light panel to fully charged
• terminal 1 to battery positive terminal 12-volt battery as follows:
• terminal 2 to battery negative terminal • terminal 1 to battery postive terminal
Red • terminal 2 to battery negative terminal
Green Yellow Pilot light Green
(K55) (K56) (K51) (K52) Red
Green Yellow Pilot light Green
(K55) (K56) (K51) (K52)

Red Red Yellow Red

(K58) (K57) (K53) (K54) [97- 68J

- red pilot light(K51) and green battery level
indicator light(K52) will light-battery level
above 12.5 volts
-using Sun VAT-40 or equivalent, load battery
to maximum 110 A. Battery voltage will start
to drop
-battery level indicator lights will light in the
following sequence:
• green(K52)-battery level above 12.5 volts
• yellow(K53)-battery level below 12.5 volts
• red(K54)-battery level above 12 volts
- i f any indicator light does not light during
test, indicator light panel is defective
-replace complete indicator light panel if
necessary
- if indicator light panel OK, check wiring
(K58) (K57) ~ - 68j
-red pilot light(K51) and red water level
indicator light(K58) will light
- connect green wire from known good water
tank sender unit to terminal 3 in multi-point
connector
- connect one end of jumper wire to battery
negative terminal
- connect other end of jumper wire to white,
yellow, and green wire of sender unit one
after another
• water tank level indicator lights red(K57),
yellow(K56), and green(K55), will light-
red water tank level light(K58) will go out
- go to next page

97.30 Battery level indicator lights

Water tank level indicator lights
Camper
 Electrical System-Wiring, Camper
- i f any indicator light does not light during
test, indicator light panel is defective
-replace complete indicator light panel if
necessary
- if indicator light panel OK, check wiring
- if wiring OK, replace water tank sender unit
Water pump, checking
- visually check level of water in water tank-
must be minimum 1 US gal. (approximate)
Note
Water pump shuts off automatically if water level
is below 0.5 US gal. (Basic model) or 0.8 US gal.
(Deluxe model) to prevent pump from running
dry
- check fuse on water pump and fuse located
under driver's seat
-remove indicator light panel from sink cabinet
but do not disconnect multi-point connector
97
- if test light does not light, indicator light
panel is defective
- replace complete indicator light panel if
necessary
- if test light lights, check wiring and water
pump switch in faucet
- if wiring and switch OK, replace water pump
WARNING
Never remove/ install external electrical
outlet, inside electrical outlets, circuit
breaker with switch, or refrigerator if
vehicle is connected to 115 volts AC.
Check for good ground connections on
115-volt system after installing electrical
equipment or components.
Use suitable test equipment to check
voltage on 115-volt system.

2
-connect test light to back-side of terminal 4
(arrow)

Red
Green Yellow Pilot light Green
(K55) (K56) (K51) (K52)

(K54) 197-683 I
- if either green(K55), yellow(K56), or red(K57)
water tank level indicator light is lit, test light
must also light

Camper
Water pump 97.31
97 Electrical System-Wiring, Camper

Current Wire connectors

Description
track
T1 - single, on refrigerator
Amber light diode, battery voltage T3a- three-point, on refrigerator
below 12.5 volts 25 T4 - four-point, on water tank
Amber light diode, water tank level full 24 T6 - six-point, on display unit
Display unit 21-27 Ground connections
Display unit switch 23
@- behind refrigerator, left side
Exterior socket (11 0 V) 2-7
Gas flame ON sensor 44
Gas flame ON warning light 24
Green light diode, battery voltage
above 12.5 volts 25
Green light diode, water tank level full 24
Interior light, center 49-50
Interior socket (11 0 V) 3-12
Red light diode, battery voltage
below 12.0 volts 25
Red light diode, water tank level
part empty 24
Refrigerator 12-16,
41-46
Refrigerator 11 0 volt resistance 13
Refrigerator 12 Volt resistance 45
Refrigerator 12-Volt heater relay 24-26
Refrigerator condenser fan 42
Refrigerator fan thermoswitch 42
Refrigerator socket (11 0 V) 16
Refrigerator switch (11 0 V, 12 V) 14,45
Refrigerator thermostat
(11 0 V/gas system) 14
Thermo fuse (Camper) 3-8
Water pump 31
Water pump switch 31
Water tank low level sensor 34

9 7 •3 2 Electrical equipment
Camper
 Electrical System-Wiring, Camper 97
-
EXTERIOR SOCKET
(110 V)

2.5 1.5 1.5 1.5

G G w BK E79 REFRIGERATOR SWITCH (110 V, 12 V)
F56 REFAIGERATQEI THERMOSTAT
(110 'VLOAS SYSTEM)
Z15 AEFRIGERA108 110 VOLT RESISTANCE

REFRIGERATOR
SOCKET(110 V)

1.5 1.5 1.5

BK W G

WIRING
COLORCOOE
BK - BLACK
8R -BROWN
Cl. - CI.EAR
R -RED
y -YELLOW
1.5 1.5 1.5 G -GREEN
BK Lr G - UGH r GREEN
BL -BLUE
v - VIOLEr
GY -GRAY
w -WHITE
DR - ORANGE

INT£RIOR SOCKET
(110 V)

6 7

Camper 1980-1985
Electricalequlpment 97.328
97 Electrical System-Wiring, Camper

TO
ALTERNATOR,
TERMINAL
0+ TOIGNmONI E130 DISPLAY UNIT SWITCH

I
TO BATTERY(+) STARTER SWITCH, K52 GREEN UGHT DIODE, BATTERY VOLTAGE
TERMINAL 50
I I K53
ABOVE 12.5 VOLTS
AMBER UGHT DIODE, BATTERY VOLTAGE
2.5 0.5 0.5 BELOW 12.5 VOLTS
R/BK K54 RED LIGHT DIODE, BATTERY VOLTAGE

I..
BELOW 12.0 VOLTS
K55 GREEN LIGHT DIODE, WATER TANK LEVEL
FULL
A" K56 AMBER LIGHT DIODE, WATER TANK
r-1a7 K57
LEVEL FULL
RED LIGHT DIODE, WATER TANK LEVEL
REFRIGERATOR -~~'----l-J··:-1-::. ~~..J
-::--.,.."--'
... t K87
PART EMPTY
GAS FLAME ON WARNING LIGHT
12·VOLT ""30 85
H E A T E R 2 .5 ......_
RELAY 8
!I

r
1.5 1.5
I
1.5
I
1.5
II

•·
BK R R BK

FVSE l
523
SA
~
1.5

WIRING
COLOR CODE
1.5 1.5
y G IlK - BLACK

~··~
BR -BROWN
Cl - CLEAR
R -REO
y -YELLOW
G -GREEN
DISPLAY UNIT
PUMP L T_ G - LIGHT GREEN
SWITCH BL -BLUE
- VIOLET
'i' GY - GRAY
1.5 w - WHITE
y OR -ORANGE

T4

WATER WATER TANK LOW

PUMP LEVEL SENSOR

1.5 1.5
BR BR

T4

@
20 21 22 23 27 28 31 32 33 3-4 37 38

97.32b Electrical equipment

Camper 1980-1:985
 Electrical System-Wiring, Camper 97
-
TO FRONT TO FRONT
INTfRIOR LIGHT, INTERIOR LIGHT,
PLUS CONNECT10N TERMINAL 31

I I
1.5
R
1.5
BK

1.5
13K
I
1.5
R
I
1.5
BK
I
2.5
R

®~·· 561
16A

I
2.5
R

REFRIGERATOR

WIRING
COLOR CODE

BK ~ BLA CK

BR -BROWN
Cl - CLEAR
R -RED
- YELLOW
INTERIOR
G - GREEN
UGHT,
LT G - LIGHT GREEN
CENTER ~~=:!L..J
BL - BLUE
- VIOLET
GY - GRA Y
E79 REFRIGERATOR SWITCH (110 V. 12 V)
W -WHITE
F57 REFRIGERATOR FAN THERMOSWITCH
OR - ORANGE
G103 GAS FLAME ON SENSOR
V19 REFRIGERATOR CONDENSER FAN
Z14 REFRIGERATOR 12 VOLT RESISTANCE

39 -41 -42 -43 -46 -47 50 51 52 53 55 56 51

l97-36tJ(

Camper 1980-1985
Electrical equipment 97.32c
 Electrical System-W,iring, Camper 97
Current Wire connectors
Description
track
T1 - single, on refrigerator
Amber light diode, battery voltage T2a- two-point, behind dashboard
below 12.5 volts T3a - three-point, on refrigerator
Amber light diode, water tank level full T4 - four-point, on water tank
Display unit T6 -six-point, on display unit
Display unit switch Ground connections
Exterior socket ( 11 0 V) @-behind refrigerator, left side
Gas flame ON sensor
Gas flame ON warning light
Green 1ight diode, battery voltage
above 12.5 volts
Green light diode, water tank level full
Interior light, center
Interior socket ( 11 0 V)
Red light diode, battery voltage
below 12.0 volts
Red light diode, water tank level
part empty
Refrigerator

Refrigerator 11 0 volt resistance

Refrigerator 12 volt resistance
Refrigerator 12-volt heater relay
Refrigerator condenser fan
Refrigerator fan thermoswitch
Refrigerator socket (11 0 V)
Refrigerator switch ( 11 0 V, 12 V)
Refrigerator thermostat
(110 V/gas system)
Thermo fuse (Camper)
Water pump
Water pump switch
Water tank low level sensor

Camper from 1986

Electrlcalequipment 97.33
97 Electrical System~Wiring; Camper

REFRIGERATOR
FIEFRJGERA TOR
EXTERIOR SOCKET THERIIOS'TAT {liD
REFRIGERATOR ttO VJGAS SYSTEM)
Jllll"''--'----'-"'--..;__.....,._ _ _ _.....u {110 V) VOlT RESISTANCE

2.5 1.5 1.5 1.5

G G w BK
REFRIGERATOR
~
:- ,,~~
. 'L swrrcH
(110 v, 12 V}
~~~ >~. ·• ,_,.... .
" ,~
,.-c 7~.::_~;:
~
TJ THERIIO FUSE

t. :
I•
,.;~ -- ..._-
1
{CAMPER)
~, J> \ ..:.J
REFRIGERATOR
SOCKET (110 V)

1.5 1.5 1.5 1.5 1.5 1.5

G w BK BK w G

1.5 1.5
I 1.5
I
G w BK

,..~ ·;
_,..
,... ....
..,
_,..
.. ,.
WIRING
COL OR CODE

' .. . -. :' '

" ]INTERIOR SOCKET
(ttO V} BK
BR
- BLACK
-BROWN
Ct - CLEA R
R -RED
Y - YELLOW
G - GREEN
LT. G- LIGHT GREEN
BL - BLUE
V - VIOLET
GY - GRAY
W -WHI TE
OR - ORANGE

@
2 3 4 5 7 8 10 11 12 13 14
!97-36161

9 7 •3 3 a Electrical equipment
Camper from 1986
 Electrical System-Wiring, Camper 97
30 30
15 15
X X
31 - 31
E130 OISPt.AY UN" SWITCH
1(16
~- UQHT DIODE, WA1D 71INIC
LEV&. FULL
K52 GREEN UCJHT DIODE, BATTfRY \IOLTAQE
IC5f AMBER UGHF DIODE, IIMliR ~NK
ABOVE 12.5 K>LTS LEVEL FULL
K53 AMBER LIGHT DIODE, IMTTERY Kn.TAGE
BELOW 12.5 W>LTB
K67 RED IJQHr ~ WA'Ia TIUM LEVEL
MRT SIPT'I
K54 REO LIGHT DIODE, BATTERY W>LaGE la7 GAS FLAME ON WAIIMMJ UGHf'
BELOW 12.0 K>LTB

I
-
T04
WIRING
C2 p

2.5 0.5
G4
r
J C18
0.5
T
1 024
6.0
ra
I

4.0
A16 61
0.5
E13
0.5
COLOR CODE A BL RIBK RIBK RISK BL BL

L r 2o/2
IR BK -BLACK
I T2atl
(110

f=l
BR - BROWN
II) CL - CLEAR
R -RED

j
y - YEL LOW
G - GREEN FUSE 187 86
LT G - LIGHT GREEN REFRIGERATOR
IR
BL
v
-
-
BLUE
VIOLET
523 --- 12-VOLT
TO ALTERNATOR,
TERIItNAL D t
GY - GRA Y
w - WHI TE
OR - ORANGE

1.5 1.5 1.5 1.5

BK G BK y

t!JT6!3 t!JT6!2 T6n ~T6!6

W G GY BK
0/SPLA Y UNIT

WATER PUMP
SWFTCH

WATER
TANK
WATER P/JIIIP LOW
LEVEL
SENSOR

1.5BA _ __ , 1.5
BR

15 16 17 18 19 20 21 22 23 24 25 26
)®

Camper from 1986

Electrical equipment 97 •33 b
97 El.ectrical System-Wi·ring, Camper

WIRING
COLORCOOE
BK -BLACK
BR -BROWN
CL -CLEAR
R -REO
- YELLOW
G -GREEN
L T G - LIGHT GREEN TO FRONT TO FRONT
BL -BLUE
INTlRIOR LIGHT, INTERIOR LJGHT,
PUIS CONNECTION TERIIINAL 31 •
- VIOLET
GY -GRAY
W -WHITE
OR - ORANGE

~~§=.=r=l'11"--11 1.5 1.5 1.5 2.5 1.5 1.5

BK R BK R R BK

FUSE
561
16A

REFRIGERATOR IITPIOR
swrrCH (110 v, 11 VJ UGHT,
CENTER

REFRIGERATOR 12
CONDENSER VOLT RESISTANCE
FAN

REFRIGERATOR

@ I G103 GAS FLAME ON SENSOR

29 30 31 32 33 35 37 38 39 40 .., ~2

197-36181

97 •3 3 C Electrical equipment
Camper from 1986
 Electrical System - Wiring, Camper 97
Description Current
Track
Alternator 6
Auxiliary battery 2
Battery 3
Battery cut-out relay 1-2
Ignition/start switch 12-15
Starter 4-5
Voltage regulator 6-7

Wire connectors
T1d- single, wire distributor, LF eng. compart.
T2k - double, under fusefrelay panel
T2m- double, under fuse/relay panel
T7a/- seven point, wire distributor, LF eng. compart.
T14/- fourteen point, on inst. cluster
Ground Connections
G)- ground from battery to body
@-ground from transmission to body
@-ground from aux. battery to body

..._Manual
____ trans. II
_ _......_'-·_Camper
_ _ _1986-1989 I
_..._ _ ___. Auxiliary battery 97 34
• .
97 Electrical System - Wiring, Cam~er

CIS 04 p 024

0.5 0 .5 0.5 6.0 6.0 TO

RIBK BL BL A A/BK OIGIFANT
COIIBI
I
TO
RELAY

CAT
ELAPSED
111/LE
COUNTER

T2k 1 T2m I Tid

a
BATTERY'f 85
CUT-OUT
RELAY 1.0
RIBK
87
2 .5
A

T2k

6 .0 6.0 6 .0 2.5 2.5

AIW A A AIW RIW

+
WIRING
COLOR CODE
BJ( -BLACK
1= +
70,0
BATTERY
Bt-
ALTERNATOR
o ...

BR -BROWN
P- VOLTAGE
CL -CLEAR (

I
REGULATOR
R -RED
y - YELLOW
G -GREEN
LT G - LIGHT GREEN 25,0 25,0 25,0
BL -BLUE
v - VIOLET
GY -GRAY
w - WHITE
OR -ORANGE

0 CD 0
2 3 4 5 6 7 8
197-22981

97.34a Auxiliary battery

Manual trans. II Camper 1986-1989
 Electrical System - Wiring, Camper 97
30------~----~--~------~------------------~~~-----------------------------30
15 15
X X

a -"--------- ---

88 p AS

1.0 0.5 1.0 4 .0 4 .0 1.5

R/BK R/BK R/BK R/BK R BK

t
I. T7a/6

IGNITION/START
SWITCH

TO
BRAKE 50 I X p I SU
WARN.
Rfl.AY

0 .5 0 .5 2.5 0 .5 0.5
w w BKIY BK GY/BK

I I
1

I I
TO
DIGIFANT
CONTROL
UNIT
45

TO
IDLE
STAB.
CONTROL
WIRING
COLOR CODE
BK
BR
CL
R
-BLACK
-
-
-
BROWN
CLEAR
REO
I II
TO
LITE
SWITCH
Et/X
TO
INST.
CLUSTER
T1418
TO
BRAKEtPARK
BRAKE
IND.
y ·-· YELLO W
G - - GREEN
LT G - LIGH T GREEN
BL -- BLUE
v -· \IIOLET
GY - GRA Y
w - - WHITE
OR - ORANGE

9 10 11 12 13 14 15
197-22 991

Manual trans. II Camper 1986-1989

97.34b

Index
General
- Battery/Ground cables
97.9a, 97.9b
disconnecting/connecting 97.6
- Cautions and Warnings 97.2
-Dashboard wiring harness 97.7
- Engine/Body ground
connections 97.6
- Fuse/Relay panel, removing
(1980-1985) 97.10
(from 1986 m.y.) 97.10a
- How to read wiring diagrams 97.4
- Main wiring harness 97.8
-Starter cable routing 97.9
- Symbols used in
wiring diagrams 97.5
-Troubleshooting 97.3
-Working on the electriCal
system 97.3
97
Electrical System-Wiring,
Diesel
1982 Diesel Air-cooled AFC
- Auxiliary heater BA6 - Refer to 97.11
·(Canada only) 97.47, 97.48
- Cautions and Warnings 97.2 Camper
-Fuse/Relay panel97.10 - Refer to 97.29
- Heater booster 97.49-97.51
- Main wiring diagram 97.36-97.40 Waterboxer/Syncro
current track index 97.36 (Water-cooled Digifant, Digijet)
- Rear window wiper 97.26 - Refer to 97.53
1983 Diesel
- Auxiliary heater BA6
{Canada only) 97.47, 97.48
_. Cautions and warnings 97.2
- Fuse/Relay panel 97.10
-Heater booster 97.49-97.51
- Main wiring diagram 97.41 -97.46
current track index 97.41
-Rear window wiper 97.26
97.35
97 Electrical System-Wiring, Diesel
1982 Vanagon
Diesel
Description Current Treck Description Cutfent Treck

Alternator Safety belt switch, left 4

Alternator warning light Safety belt warning system warning
light I
Back-up light, left 14 Safety belt warning system relay M
Back-up light, right 15 Sealed-beam unit, left 40-41
Back-up light switch 14 Sealed-beam unit, right 41,43
Banery
,
22 Side-marker light, rear 47,1112
•
..
Brake light, left Side-marker lights, rear
Brake light, right 8 Starter 14-11
Brake light switch &-12
Brake warning/parking brake warning Tail light, left 51
light, dual circuit

Cigarene lighter 84
Taillight, right
Turn signal, front left
Turn signal, front right
•
7e
17
Cigarene lighfer light 83 Turn signal, rear left 76
Clock l5e Turn signal, rear right 78
Coolant over-temperature warning Turn signal swilch 73
light 38 Turn signal warning light 32
Coolant temperature gauge 34
Coolant temperature gauge sender

Door contact switch/buzzer, front left

34

3
Voltage regulator
Voltage stabilizer •
37
Door contact switch, front right

Electro-magnetic cut-off 18
Windshield washer pump
Windshield wiper motor
Windsheild wiper switch
•
&He
liiHI
Emergency flasher relay 88-71 Windshield wiper/washer interminent
Emergency flasher switch ~78 relay IH3
Emergency flasher warning light 79
Engine oil pressure switch 31 Wire Connectors
Engine oil pressure warning light 31
Engine temperature sender Tt b - single, behind dash
(pre-glow system) 17 T1c - single, behind dash
Ttd -single, in engine compartment next to alternator
Fresh air controls light 82 T - single, behind dash
Fresh air fan 158 T1f - single, next to interior light rear, left
Fresh air fan resistor 57 T1 k - single, behind dash
Fresh air fan switch 57,58 T2 - double, behind dash
Fuel gauge 33 T3 -double, under driver's seat
Fuel gauge sender 33 T3b - three-point, in connector
Fuses, in fuse/relay panel (S-1 to S13) T3c - three-point, behind dash
Fuse strip for glow plug, in engine T4a -four-point, in connection
compartment 20 T4b -four-point, in connection
T4c -four-point, behind dash
Glow plugs 20,21 T1 4/ - fourteen-point, on instrument cluster
Glow plugs relay
Ground Connectors
Headlight dimmer and flasher switch 43-44
Headlight high-beam warning light 38 CD - Banery ground strap, to body
Horn 13
Horn bunon .13 ®- transmission/body

Instrument panel light 53-55

®- in connection box
Instrument panel light resistor 48 @ - behind dash, next to fuse/relay panel holder
Interior light, front 86, 87
Interior light, rear 88-89 @ - on rear lid

License plate light 48,49 @ - on steering box

Light switch 44-47
Load reduclion relay (X·contact) 8H8
@ - behind fuse box

@ - in engine compartment, next to glowing-time

Parking brake warning light switch 6 relay
Parking light, left 50
Parking light, right 45 @- on crossmember, front left
Pre-glow/starter swjtch 24-31
Pre-glow lime indicator light 30
Radiator cooling fan 90
Radiator cooling fan relay for 2nd
stage 91.92
Radiator cooling fan thermoswitch
(switch on at gs•c t203.F) 90
Radiator cooling fan thermoswitch
(switched on at 11o•Ct230.F) 92
Radio connectors 46,85
Rear-window defogger heating
element 81
Rear-window defogger switch 81-33
Rear-window defogger switch light 82
Rear-window defogger warning light 81

97.36 Main wiring diagram

current track Index
Diesel1982
 Electrical System-Wiring, Diesel 97

,.
II(

...s,, So2
20
II( ...
II

Wiring
Color Code
IIIQ 10
-BK
bon -BR
SHY
(1011
&ol
- CL
-R
BELT " .u
\·30
GLOW
WIING ... l'f.UGS
1.... -Y SYST RELAY
WIING l 87
Grton -G
UTE

lti
~ Green - lt. G
l!oe
\'oil(
-BL
-v
20
G'VG IR ....
20

!by -GY
WI -w

20 20 20
GY~IK

SHY
BELT
.a.,
WIING
SYST K
i BK-UI'

p
RELAY UTE
)'( SW
20
GY/JI
••
18

'""~T. .
18 18
IIC,..l

~
y,
T, , 20
TJ 18
iT,.
20 Yr2.

..
20 20
r,.
"{::_, T•• 18 18
II(
20
Bl/ W ..
20 10
•

011
CNTCT
••

l'ftK
8111(
BilK
UTE
·II
BilK
UTE
-L
JriiN
BTN
11

!!'
ELECT ENG
MAG TEMP
GLOW
l'f.UGS

swt
au z
WIING
UTE
II
••
If
•••• 18
CUT· SNOII
Off J:E·
.Lf sw u •• ow
SYST)

@ @)
' 2 :II 4 • 6 'I • t 1011 12 Ia I~ 1'1
~Door 8wtlohelltet.tr ....
All wire sizes American Wire Gauge
.,.....-+-.,. u... --t-1 -Honll I
IS 16 17 11 "

...""' Ughii/Qiow ...... ~

20

Diesel 1982
Main wiring diagram 97.37
97 Electrical Syst~m-Wirlng, Diesel

II -
----~------~~------~~~
10

-I~ •
r
II
y

UDIO
CONN

,.., 22

11 10
_,."" ..
20
fNG
GlOW Oil
TIME
IND
TIIN
l'flfSS SIG
WIING WIING
II
GY

T., UTI UTI UTf

I
// //
AlT
WRNG
UTI

t~' '""" t..,. '"" 11414

20
•• 12
w Y/1«
......20 20

& ./1 ., TJ,

T.. G~J T,b

SIDf
MiliCI!
•• ••
~o·~i~
20 II 20 20

r~·~
ll K w "'ff« GV)I

'~NOI
lNG TAll ·
Oil UTI
MESS -II U
SW II
••

--~~~ ~ ,,. '··.J ...-.----..

~1-.,....., -~--...-.J, .
· ,_~.. ·r 7~~ "--~ ·..- ·· · -;;,:.
··· ·i i ,i ·· -- .- .
-~::=-~::- --~--:.:.-~o-.....--. -·-··,·,:£~ '. ·,._;~----. :_·_ .._,_.- _.. - ··- ' . ~.

97.38 Main wtrlng diagram

Dlesel1982
 Electrical System-Wiring, Diesel 97

---- - ,
10 II

n,. 1~LOAD
1------1 ::En
r10
&1./ Y
fi~"""
20
IR
20
81

= 18
•• y

Wiring ,.

-y-
Color Code
-BK
""f.
).'Alii
lUSH

8<..... -BR IAN

~1l
Cleat -CL
Red -R
-Y
Gr... -G
\Jijll Green -LI. G
Ill& -Bl
l(oOiel -v
Gray -GY
Mille -W 16 16 16
W Y/ U: y

IIISH
Alii
IAN
llfSIST

20 20 16
y

SIDf INSTil
MIIICII 'ANfL
UTfS LITf 20

••

Diesel1982
Main wfrfng diagram 97.39
 97 Electrlc~l System-Wiring, Diesel

16 16 10
I
I
I I

10
I

s. s. s,
OA
OA

18 20
R/Y I

..
20

t
II 18 11 II
EMEII.G w 10(/w/G IK/W IK/C

==FJJ LJ~~
..
20

]
20 12 sw

1/BK~ ~~~
12

~ r2 r2 T,,
ij'
203°, ;FJ

18 18
e¥./ W IK W
II
BK/G
II
IK/C ..
20
••••
20
G't/ Bl
I 2

~ ~ 11 Tl4/1
FII.SH
Alii.
CNTIUS

c~II.N ~TII.N ~1/.N

LITE
~.~ --..._ CIG SLIDING

.., •••
UTEII. Dll.
...
SIG SIG SIG SIG II.fAll.
LifE LITE UTE UTE WIND sw
-lf DEFOG
HTNG 20 ,.
ElEMNT II •• u

97.40 Main wiring diagram

Diesel1982
 Electrical System-Wiring, Diesel 97
1983 Vanagon
Diesel

Description Current Track Description Current Track Wire Connectors

Alternator Ignition/starter switch 2N7 Tt - single, in engine compart. left

Alternator warning light Instrument panel light •• 150 Tla - single, in connector housing
Battery Instrument-panel light Tl b - single, in connector housing
Back-up light, left dimmer Tic -single, near alternator in
Back-up light, right Interior light, front engine compart.
Back-up light switch Interior light, rear Tid - single, behind dash
Blower fan
Blower-fan control-lever light
Blower-fan resistance
license plate light ...... Tie
Ttl
- single, in connector housing
- single, behind dash

Blower switch
light switch
*"'
21
Ttg
Tt h
-single, behind dash
- behind dash

..•
Brake light, left Oil-pressure switch ( 1.8 bar) Ttl - at roof cross-beam, rear right
Brake light, right Oil pressure warning light Tt k - single, behind dash
Brake-light switch T2 - double, on fuse/relay panel
Brake warning light Parking light, left T2a - double, behind dash
Parking light, right 41 T2b - double, behind dash
Cigarette lighter 70 Parking-brake warning T2c -double, behind dash

•
....
Cigarette lighter light light switch 'N T2d - double, behind dash
Clock t1 T2e - double, in connector housing
Coolant low-level-warning Radiator fan fl7 T2f -double, behind dash
control unit Radiator-fan relay 8NO T2g - double, in connector housing

...•
Coolant low-level-warning Radiator-fan thermoswitch I 17 T2h -double, in connector housing
switch Radiator-fan thermoswitch II 80 T2i - double, in connector housing
Coolant over-temperature Radio connection IO.M T2k - double, behind dash
warning light Rear side-marker lights 45,48 T21 -double, below driver's seat
Coolant-temperature gauge
Coolant-temperature sending unit •• Rear-window defogger
heater element
Rear-window defogger
812
T3

T3a
- 3-point, near alternator in
engine compart.
- 3-point, behind dash
Defogger cut-out relay indicator light 98 T4 - 4-point, behind dash
(X-contact) t147 Rear-window defogger switch 812 T4a - 4-point, behind dash
Door contact/buzzer switch, Rear-window defogger T7 - ?-point, in connector housing
left 71.78 switch light M TB - 8-point, behind dash, near
Door contact switch, front right 71 brake warning lights

.......
Door contact switch, right Seat-belt buzzer contact, left 74 Tl4 - 14-point on instrument cluster
sliding door 14 Seat-belt warning light 75
Seat-belt warning relay 73,75 Ground Connectors
p 20 Electromagnetic fuel cut-off 1e Starter 22,2S
G) -

f· l
Emergency-flasher relay from battery to body
Emergency-flasher switch Tail light, left 47
Emergency-flasher warning Tail light, right 44 ®- from transmission to body
light
• Temperature sensor II I
®-
II~~D
Engine temperature sender Turn-signal indicator light 30 behind dash near fuse/relay panel

2
coot
IAH
(pr81Jiow system)

Fuel gauge
·17

11
Turn-signal light, front-left
Turn-signal light, front-right
Turn-signal light, rear-left
••
14
@
@
-
-
behind dash

at steering-gear housing

~r
I ~':y Fuel-gauge sending unit 11 Turn-signal light, rear-right 83
2nd
Fuse for glow plugs (S2D) ao Turn-signal switch 11 @ - behind air vent
STAGI Fuses (SI-SI3) on fuse/relay
panel Voltage regulator 14-28 @ - at rear deck
Voltage stabilizer 36 @ - near fuel pump at floor
Glow plugs ao.a1 board/crossmember
Glow plugs relay 1740 Washer/wiper intermittent
relay 98-100 @- near ignition distributor
Headlight dimmer/flasher Windshield-washer pump 118
switch »-10 Windshield-wiper intermittent @- left at cylinder head

•
..
Headlight-high-beam light switch 98-103
Headlight, left I?, at Windshield wiper motor 1~10$ @- near ignition coil
Headlight, right 11.40 in engine compart., left
Horn
Horn button
@ - plus connection, in connector
housing

I
Diesel 1983 Main wiring diagram
current track index 97.41
97 Electrical System-.Wiring, Diesel

fUSE
fOil
A GtOW
l'liJG

Wiring
Color Code

-
10
Block -BK I

Clolr
Aid
-BR
-CI.
-R
t~
---
GtOW
l'liJGS
lfi.AY
y- -Y 17
a.- -G

.,.,.
~..~!# Groen -U.G
-Bl.
Vlolol -V
a.., -GY
~ -W

97.42 Main wiring diagram

Dlese11983
 Electrical System-Wiring, Diesel 97

9
••
IJ'(
12
W«
II
GY
20
Gl'&

T2. ~

r~·
12 12
w Y«

16 6 ,. 16 2d
W W« Y' v.- GY..t:

} .. -Jl~- T2,

= STIITII
= IATT Oil
I'IIESS
sw
(1.1 !Jor}

I
Dlesel1 983
Main wiring diagram 97.43
97 Electrical System-Wiring, Diesel

v
I 0
10 •
1611'1
1611'1

~
s....

I_· T! 16 16

lA
s, ...s.. l;

UDfO
COHN
Wiring ~T.

{Jl
Color Code 16 ,, 20

Bladt -BK

'. k
Brown -BR

y-
Clw
Red
-Cl
-R
-v

-
Groen -G
1..911Gr- -U. G
-Bl
-v
10 II

" -
II ll
w
II II
>()

-·
V!Ciol
Glay -GY
-w

IKUI' fMf.G
UTf fUHI
tl =====II GV ======m=:=::l( sw

¢(
10
GV4t
~-J~}·
10
GY.-

7/S
10
GV.-:
II
i If\
II :W lO
. ._ _ _ _ _ .·"'
10

ir~. -~~ ~ ~
>o
A ....II II
ll.G
II
ll.G

llfi.C/7

<ClOCK J H•N
WTTN
lf(UI1 IICUI'
UJI UTI
" 4t

16
• •"
~ ~®
. . .
,,~

___.:: ~

.. . - -- --- . . ·---------!.l~~ ~~~~~.~u..:_~

-

~ _,_:__ ~!.- ..._~-.-·-~~· ··= -c;~~

Note: All wire tizes Americ1n Wire huoe

97.44 Main wtrlng diagram

Dlesel1983
 Electrical System- Wiring, Diesel 97
••
•
100 =========================================================

--

f EMERG
- n
FLSHR
WRNG 31 511b

LITE ~ ~o
II 20
M 8R GVrli GV>tl
'""
T.. ~8~ T•• T••

"
"""' Jl/3

"
TU/2

PRKG
~ BRK 011
TIH WRNG BilK BilK CNTCT
SIG LITE UTI liTE sw
UTI SW -II -l -II
./l SLIDING
011

r-
OR SEAT

l CNTCT
BUZZ
SW
-1
BELT
BUZZ
CNTCT
-R

t1 ,. , ,. , ,. ., 71 '' 10 .. u ..
r-------------~U.~._~~~up~------------~

Diesel1983
Main wiring diagram 97.45
97 Electrical System~Wiring, D,iesel

Wiring
b
Color Code
Blocll -BK
Brown -BR
Cloor -CI.
Red -R
y- -Y

-
Groon -G
~Groon -UG
-81.
VIOio! -v
Gtay -GY
WNII -w
S1o

UA.
WIND
DEIOG
sw
...
12 IIAD
IAN
11
-..;v
11

l
J
THE liMO

::~ IlEA/I 'l~tWII

N' "i sw
·WIND
DEIOG

1~11,
THfiiMO r/11 sw
SWI ~ UTE

...
12 12
I
20
llAI
20
llAI
16 20 10 20 .. .. ,.
w v v

~-~
WIG II

1h ~ IIADIO
CONN

ILWII
fAN

~·1 IllS 1115/ST

ll
I
10
M
20
M .
16 20
..
11

Slo

IlEA•
WINO C!l
DfroG WINO
Hr• w1n• ILW•
flMNr Mfll fAN

.
12 16
• ..
16

@) @)
- '
--·-=· --- -- '"'"

97.46 Main wiring diagram

Dlesel1983
 Electrica' System-Wiring, Diesel 97
Description Current
Track

Air recirculation blower 8

Combustion air blower 11

Condensot 14

Flame switch 12
Fuel pump 10
Fuel pump contact breaker 10

Glow plug 13

Heater contact breaker 12

Heater element 14
Heater ignition coil 12
Heater indicator lite 6
Heater relay 7-12

Main suppressor 8

Overheat switch 9

Safety switch 15, 16

Suppressor 12, 13

Temp. regulating switch 1-6

Temp. sensor 8
To load reduction relay 6

Wire Connectors

T1a -single, under instrument

panel
T2 - double, on air recirc. blower
T4a- four point, on heater control
T4b- four point, on heater control

Ground Connections

@ - bolt on heater control

@ - bolt on heater ignition coil Go to next page •

Diesel 1982, 1083 (Canada) Auxiliary heater BA 6

current track index 97.47
97 Electrical System-Wiring, Diesel
TO BATTERY + TERMINAL

Ft
25

Sn

~~=F~==~~~--·

n
Sn ~~Z~oR
(NTC)

0.5 0 .5
BL Y BL

T~a T.ot.

05
A
I
05
BL BK 0 5 BL·A
TO
LOAD
RED.
RELAY
0 .5
BL
0 .5
BLW

y.., T""

0.5 1.5 1.5 0.5 OS

BA y BKW BL BL

517 SAFETY
SWITCH ~r --

1.5 1.0 1.5 0.5 05

G BK·W BKW BA BL A

T•• T•b
r~~ !
1.5 1.0
BK Y B\VW

WIRING
COLOR CODE
FUEL HEATER
BLACK - BK PUMP IGNITION
BROWN -BR COIL
CLEAR - CL
REO -R
YELLOW -Y
GREEN -G
LIGHT GREEN - LT. G
BLUE -BL
VIOLET -V
GRAY -GY
WHITE -W
15 1.0
ORANGE -OR G G

J fi_
~~~~
BA CONTACT .
BREAKER
I
OVERHEAT

2 3 .4 s 6 7 8 9 10 11 12 13 15 16
(12.·267(

97.48 AuxBiary heater BA 6

Dlesel1982, 1983 (Canada)
 Electrical System-Wiring, Diesel 97
Heater Booster
Diesel

..
Description Current Track

Air circulation blower 10

Air circulation blower relay 1-18
Combustion air blower
Combustion air valve 10

"""
Compulsary start relay
Contact breaker for fuel pumps
(in combustion air blower)
Contact breaker for heater •
(in combustion air blower)
Control unit

Diode (behind dash next to relay)

....
7

11. , ..
Flame switch 11
Flame switch relay U·17

=
Fuel pump (large quantity)
Fuel pump (small quantity)
Fuel pump relays 1,HI
Fuse main ( 16A) a
Fuse, overheating (SA) IS
Fuses on fuse/relay panel
S7, 8, 9, 10

Glow plug 15
Glow/spark plug resistance wire 16
Glow/spark plug resistor relay 15-17

__, 0.5
BL Heater control light I
' Ignition coil 7
Light switch 1
Load-reduction relay 4
;
R Overheat switch

Spark plug
•
I
Suppressor for air circulation blower 10
Suppressor for glow/spark plug 15
Suppressor for ignition coil 7.a
Temperature regulator control 4-5
Temperature regulator switch t.S
Temperature regulator unit 4-6
Temperature sensor 4

Wire Connectors

T1 a - single, fuse relay panel

T1 b - single, fuse relay panel
T2a - two-point, behind dash, left
T4a -four-point, behind dash, left
T4b -four-point, behind dash. left Go to next page •

Diesel 1982, 1983 Heater Booster

current track Index 97.49
97 Electrical System-Wiring, Diesel

UTf

~
sw
1~2 ~,;, ~.:~· ~;;)9
7
';

!
s..
lOAD
lfD
T.. lf&AY

\2 20 12
IK/Y II(
•

All All
CIIC CIIC
18 I&WI 20 20 16 I& WI

··.w:ct~
lf&AY lf&AY

~11/W GI.O'II/
20.

J,. SUI'f'll SI'IIIC

--- --- I'WG
Kll7
fOI lfSIST

-
IGH
COil lfiAY
20CMnSIY GlOW/ 16 20
w STAIT
lf&AY
Sl'fiiC W/11<
"UG
••
lfSIST
________ !V!~--

Ill>
...
:€}----it:---- - - ---- -
lVIII

T••

16
IK/Y I SUI'f'll
Wiring fOI

-
GlOW/
COlor Code 51'1« "UG

-BK
Brown -BR II
Cloow -Cl •

N~\~
Red -A
y-
Gloon
~Gioen
!lUI
-Y
-G
-U.G
-BL
.
20
All
CIIC f&AMf GI.OW
I& WI "UG
VIOlet
Glay
-V
-GY
:g:r- Tsw
All
While -w ••
12
CIIC
11
10
I& WI

. l t '. .!"".--: ,.. . ~. ,._ ,____ 1 •

Note All wire sizes American Wire Gauge

97.50 Heater Booster

Diesel 1982, 1983
 Elect~rical System-Wiring, Diesel 97

16 20 20
G BR 81:

Wf
[
;
ST
r.. r..
I 'I'
COMBUSTION
20 ,. 1• Alii
••

30
~1
J~-l
- -r 20 16
GY/ IK 1K

f'~ t:J I 18
fUfl
PUMP
/UIG
.. ,~~, OT'I') ••JW
18
fUfL
PUMP
(SMAU
QT'I')

------ - --- ---- - -- --- - ------- ___"'!~!-

~b fOil
fUfL '

JJ :J

l OVIIHT
sw

..1
________ _
I•

,. 11 • 11 a
....._

Diesel 1982, 1983

Heater Booster 97.51
97 Electrical System-Wiring, Diesel

THIS PAGE INTENTIONALLY

LEFT BLANK

97.52
 97
Electrical System-Wiring,
Waterboxer

Index
General - Air conditioning - Differential lock
- Battery/Ground cables '
1984, 1985 97.137 1986-1989 Syncro 97.178
97.9a, 97.9b 1986-1988 97.139 - Heated driver's seat
disconnecting/connecting 97.6 from 1989 97.142 1986 97.179
- Cautions and Warnings 97.2 - Automatic transmission 1987-1989 Canada 97.181
-Dashboard wiring harness 97.7 1986-1989 97.146 from 1990 Canada 97.244
- Engine/Body ground from 1990 97.219 - Main wiring diagram
connections 97.6 - Auxiliary battery 1983, 1984 97.54
- Fuse/Relay panel, removing 1986-1989 (Auto. trans.) 97.221 1985 97.60
(1980-1985) 97.10 from 1990 97.224 1986
(from 1986 m.y.) 97.10a See also 97.29 up to VIN G 055 689 97.67
- How to read wiring diagrams 97.4 - Auxiliary heater BA6 from VIN G 055 690 97.85
-Main wiring harness 97.8 from 1987 Canada only 97.148 1987 97.102
-Starter cable routing 97.9 -Auxiliary heater BBW46 (Syncro) 1988, 1989 97.119
- Symbols used in 1986-1988 Canada 97.151 from 1990 97.201
wiring diagrams 97.5 from 1989 Canada 97. 155 - Power mirrors
- Troubleshooting 97.3 - Central locking system 1986 up to VIN G 105 000 97.183
Working on the electrical 1986 97.159 1986 from VIN G 105 001 97.185
system 97.3 1987-1989 97.162 from 1987 97.185
from 1990 97.226 - Power windows
Air-cooled AFC - Crankcase ventilation heat element 1986 97.187
- Refer to 97.11 1985 97.165 from 1987 97.189
1986 97.166 -Radio
Camper - Cruise control 1986 97.191
-Refer to 97.29 auto. trans. - Rear footwen heater blower
1986 97.168 1983-1985 97.194
Diesel 1987-1989 97.176 -Stereo radio 1987-1989 97.195
- Refer to 97.29 from 1990 97.229 - Stereo radio with amplified
man. trans. speakers from 1988 97.197
1986 97.174 - Stereo radio with 4 speakers
1987-1989 97.171 from 1990 97.246
from 1990 97.232 - 450-Watt radiator cooling fan
- Daytime running lights (Canada) 1986-1989 97.200
to Dec. 1989 97.234
from Dec. 1989 to May 1990
97.238
from May 1990 97.241

97.53
97 Electrical System-Wiring, Waterboxer

1983-84 Vanagon
Waterboxer
Dt8ctlptlon Current Tr•ck Description Current Track Wire Connectors

Air flow sensor u Ignition distributor 1-3 T1 - single, in engine compart, left
Alternator 24-26 Ignition/starter switch 22·27 T1a - single, in connector housing
Alternator warning light 26 Injector cylinder 1 11 T1b - single, in connector housing
Auxiliary air regulator 13 Injector cylinder 2 12 T1c - single, near alternator in engine compilli
Injector cylinder 3 13 T1d - single, behind dash
Bat1ery 20 Injector cylinder 4 14 T1e - single, in connector housing
Back-up light, left 56 Instrument panel light 41,50 T1f - single, behind dash
Back-up light, right 58 Instrument-panel light T1g - single, behind dash
Back-up light switch 65 dimmer 42 T1h - behind dash
Blower fan 105 Interior light, front 81-113 T1i - at roof cross-beam, rear right
Blower-fan control-lever light 87 Interior light, rear 84-88 T1k - single, behind dash
Blower-fan resistance 104 T2 - double, on fuse/relay panel
Blower switch 104, 105 License plate light 42.43 T2a - double, behind dash
Brake light, left 80 Light switch 40-42 T2b -double, behind dash
Brake light, right 78 T2c - double, behind dash
Brake-light switch 79,80 Oil-pressure switch (1.8 bar) 2t T2d - double, behind dash 18
Brake warning light 88 Oil pressure warning light 29 T2e - double, in connector housing
Oxygen sensor 7 T2f - double, behind dash
Cigarel1e lighter 70 Oxygen sensor elapsed- T2g - double, in connector housing
Cigarel1e-lighter light 88 milage indicator light 28 T2h - double, in connector housing
Clock 51 Oxygen-sensor elapsed T2i - double, in connector housing
Coolant low-level-warning milage switch 28 T2k -double, behind dash
control unit 33,34 T21 - double, below driver's seat
Coolant low-level-warning Parking light, left 48 T3 - 3-point, near alternator In
switch 33 Parking light, right 41 engine compart.
Coolant over-temperature Parking-brake warning T3a - 3-point, behind dash
warning light 34 light switch 78 T4 - 4-point, behind dash
Coolant-temperature gauge 32 Power supply relay 18, 17 T4a - 4-point, behind dash
Coolant-temperature sending T7 - 7-polnt, in connector housing
unit 32 Radiator fan 87 T8 - 8-polnt, behind dash
Defogger cut-out relay Radiator-fan relay 88-80 T14 - 14-point on instrument cluster
(X-contact) 81-97 Radiator-fan thermoswitch I 87
Door contacl/buzzer switch , Radiator-fan thermoswitch II 90 Ground COnnector•
left 72,73 Radio connection 60,84
Door contact switch, Rear side-marker lights 45,48 Q) - from ballery to body
front right 71 Rear-window defogger
Door contact switch, right heater element 82 @- from transmission to body
sliding door 84 Rear-window defogger
indicator light 83 ®- behind dash near fuse/relay panel
Emergency flasher relay !1-58 Rear-window defogger switch 82 @- beh ind dash
Emergency-flasher switch 6H8 Rear-window defogger
Emergency-flasher warning switch light 94 @- at steering-9ear housing
light 88
Fuel control unit 8-15 Seat-belt buzzer contact, left 74 @- behind air vent
Fuel gauge 31 Seat-belt warn ing light 75
Fuel-gauge sending unit 31 Seat-belt warning relay 73, 75 @- at rear deck
Fuel pump 18 Spark plugs 1-3 @- near fuel pump at floor
Fuel pump relay 18, 18 Spark plug connectors 1-3 boardicrossmember
Full-throt11e enrichment Starter 22,23
switch 11 @- near ignition distributor
Fuses (S1-S13) on fuse/relay Tail light, left 47
panel Tail light, right 44 @- left at cylinder head
Temperature sensor II 6
Hall generator 4, 5 Timing/RPM sensor 4, 5 @ - near ignition coil,
Headlight dimmer/flasher Transistorized ignition in engine compart., left
switch 38-40 control un it 3-6
Headlight-high-beam light 38 Turn-signal indicator light 30
@- plus connection , in connector
housing
Headlight, left 37,39 Turn-signal light, front-left 65
Headlight, right 38,40 Turn-signal light, front-right 62
Hom 53 Turn-signal light, rear-left 84
Hom but1on 53 Turn-signal light, rear-right 83
Idle stabilizer 4, 5 Turn-signal switch 61
Idle switch 4, 5
Ignition coil 1-3 Voltage regulator 24-26
Voltage stabilizer 35
Washer/wiper intermit1ent
relay 98-100
Windshield-washer pump 86
Windshield-wiper intermil1ent
switch 98-103
Winsh ield-wiper motor 100.103
Note:

97.54 Main wiring diagram

current track Index
Water-cooled-Digijet 1983, 1984
 Electrical System-Wiring, Waterboxer 97

Wiring

~~
ine compart. Color Code
,. Block -BK b

Blown -BR
Clear -CL
Tl/IISTII
IGN
Red -R .....
II

CNTIIL Yolow -Y
UNIT Groen -G

I ~ I Light Groen -Lt. G

Blue -BL

• t· n *. *' w, n rr' 1 2 VIOlet

<Wy
White
-v
-GY
-w

I-I.~.
II 16 16 16 20 20 20 10 II

" ·.~--, G II
w

~21
~--------------------~~--------------------~

rr rr"..
,~:11 -
Q

er G!W
II
w
2
II
w
11
w w
II
..
16 II
w
16
w
ll
w
II
w
18
w
10
w
20
II
w
IJ
I• IS
"
I
! panel
' I

II!I*
IN~IN~INrlr~
~it ~~~ ~ ~YL ~~~t
10

j~t.,
1--J:ll f_ -- - ~~~p
T7II6 A .
11

RELAY

11 ll 11 II PWR 16 11 11
w w w w SPPLY • w
21 29 26 27 RELAY

SPK
PI.UG
CONN
TMNG
RPM
SNSII
lfctj) : "'i',uu
1_1 ~THIITL AUX

!or
SPK
PI.UGS M AIR
ILOW II
w
ENIIICH
sw
J
AIR
REG

t.t:l
TEMP SNSR
SNSII II "

.
- .,
18

• t
.,,.,
II

10 t1 tl
II
M/'1

D W If • IF
•
-· ..
------~~------------~~~~~---------------~-1
Note: All wire sizes American Wire Gauge

Water-cooled-Digljet 1983, 1984

Main wiring diagram 97.55
97 Electrical System-Wiring, Waterboxer

r===:===r~~~~~~~]
IGN
STRTR
sw
30

16M

X CONTACT

-
"

9
16
lti'f
12
we "
GV
20
GY. .

~· l
T2• ~

r"1...
SW

12 12
w

16 20
YC GYAI

•
±-2·

97.56 Main wiring diagram

Water-cooled-Digljet 1983, 1984
 Electrical System-Wiring, Waterboxer 97
0

5
••
10 •
IORft'
16 Off

"\
s.
v
6A

~~
II!
16 16

512 Sn
lA lA

UDIO
COHN
y,,
Wiring
Color Code
10 10
w·
20

Black -BK - RIW • EMEIIG

s;Ji't<>o
FLSHII
Blown -BR sw

'/i't L1
Clear - CL
Red -A
'{
- n"
Yellow -Y I ••
Gteeo
light Gteeo
-G
-Lt.G I
~·
Blue -Bl 18 18 18 11 II 18 liS 18
-v

IL~
VIOlet fi!JW<G fi(JW

Gtey -GY
While -W

BKU,
LITE
===== le Gv===========~===Q HOIIN sw

9
20
rl~·
20 20
c:::a r.:.~~
G't'~

11/0 .a,,
GY... GY.tk

..
18

~t. rm r1/l

20 18 Ill II II II
• "'"" IIOG IIOG

~f14{l
fi(JW -

<CLOCK J HIIN
BUTTN
BKUP BKU,
UTE
-L
UTE
-II
TIIN
SIG
UTE
TIIN
SIG
UTE
TIIN
SIG
LITE
TIIN
SIG
UTE
-Ill -1111 -IlL -IL

10 16

~@
•2•J••., .. 47-. "Q .. ...

~-------~----~--~~----~~·~--~.,~--~----·
~®
..
Note: All wire sizes American Wire Gauge

Water-cooled-Digljet 1983, 1984

Main wiring diagram 97.57
97 Electrical System-W1
Irlng, Waterboxer
rr=====================================================·
•••
•o•================================================b

fMfiGU
fLSHI
WING~
UTI II~
sao

20 20 20 20

~~1

~ ltWI ~
R fAN R
20 CNTIL DOC« 20
LVI CIG °
1
CNTCT

ffJ~~
.. 20 U111
PIIKG
BIK
WING
UTI
sw
••

~=F==================~=====F===c

97.58 Main wlrtng diagram

Waterooeooled-Digljet 1983, 1984
 Electrlca'l System-Wirln.g, Waterboxer 97

b
Wiring
Color Code
Black - BK
B<own -BR
Clear -CI.
Red -R
Yelow -Y
Groen -G
l..ightGreiKI -U. G
Blue -Ill
VIOlet -v
Gray -GY
White -w

REAR
WINO
OEFOG
sw
RAO
.,.
12
FAN

J Nl
THERMO

:!Z
THERMO ~f1a
SWI ~

-12 12
I
20
IIAI
20
IIAI

ILWR
FAN

~87 llr"
RESIST

12 20 20
..•• 20
..
II II 16

[, ~ .
Golt

'
j
~ ~WWD
REAR
WJHO
OEFOG ·
HTR
fLMNT ,UM,
)'1 WSHR
..
12
..•• ..
20
••
Bll

@ @
II If fO
f:l H f5 f6 f7 91
tl H 99 .100 101 10:1 104 105
......__ _ _ _ _ _ _ Rad..torF•n!Oelotter/WindahlelciW•Iher/Wiper _ _...;...._ _ _- l

Note: All wire sizes American Wire Gauge

Water-cooled-Digijet 1 ~83, 1984

Main wiring diagram 97.59
97 Electrical System-Wiring, Waterboxer
Deacrlptlon Current Description Current
Track Track Wire Connectors

Air flow sensor 8,9 License plate light 42.43 T1 - single, In engine compart., left
Atternator 24 Light switch 40-42 na - single, In connector housing
Alternator warning light 26 T1c - single, In connector housing
Au~iliary air regulator t3 Oil-pressure switch (1.8 bar) 29 T1d - single, behind dash
Oil-pressure warning light 29 T1e - single, In conneclor housing
Battery 20 ~ygen sensor 7 T1f - single, behind dash
Back-up light, left 55 Oxygen-sensor elapsed-mileage indicator n~ - behind dash
Back-up light, right 54 light 28 T1i - at roof cross-beam, rear left
Back-up light switch 54 Oxygen-sensor elapsed-mileege switch 28 T2 - double, on fuse/relay panel
Blower fan 105 T2b - double, behind dash, felt
Blower-fan control-lever light 87 Parking light, left 48 T2c - double, behind dash
Blower-fan resistance 104 Parking light, right 42· T21 - double, behind dash
Blower sw~ch 104, 105 Parking-brake warning light switch 76 T2h - double, In connector housing
Brake light, lelt 80 Power supply relay 18, 17 T21 - double, behind dash
Brake light, right 79 T3 - 3-poin!, near ahernator in engine compart.
Brake light switch 79,80 Radiator fan 88 T4 - 4-point, behind dash
Brake warning light 77-79 Radiator-fan relay 88-90 T4b - 4-point, in connector housing
Radiator-fan thermosw~ch I 88 T7 - 7-point, in connector housing
Cigarette lighter -69 Radiator-fan thermoswitch II 90 T7a - 7-point, In connector housing
Cigarette-lighter light 68 Radio connection 80 T14 - 14-point on Instrument cluster
Clock 51 Rear side-marker lights 48,47
Coclant low-level-warning control unit 33,34 ' Rear-window defogger heater element 93 Ground Connector•
Coolant low-level-warning switch 33 Rear-window defogger indicator light 94
Coolant over-temperature warning light
Coclant-ternperature gauge
34
32
Rear-window defogger switch
Rear-window defogger switch light
93-95
95
0 - from battery to body

Coclant-temp. sending unit 32

Seat-belt buzzer contact. left 73
0 - from transmission to body

Defogger cut-out relay (X-contact) 91·97 Seat-belt 1'/&rning Ught 75 G) - behind dash near fuse/relay panel
Door contact/buzzer switch, left "72, 73 Seat-beh warning relay 73,75
Door contact sw~h. front right 71 Spark plugs 1-3 • @ - behind dS$11
Door contact sw~ch, right sliding door 84 Spar!< plug connectors 1·3
Starter 20,22 @ -at steering-gear housing
Emergency-flasher relay 55-67
Emergency-flasher switch 57~ Tail tight, felt 48 @ - behind alr vent
Emergency-flasher warning light 66 Tail light, right 45
Temperature sensor
Timing/RPM sensor
6
4, 5
@ - at rear deck
Fuel control unit 8-15
Fuel gauge
Fuel-gauge sending unit
31
31
Transistorized ign~ion control unit
Turn-signal indicator light
3-6
30
@ - near fuel pump at floor boardlcrossmernber

Fuel pump
Fuel pump relay
18
18-19
Turn-signal light, front·lelt
Turn-signal light, front-right
84
82
@ - near ignition distributor

Full-throttle enrichment switch 11-12 Turn-signal light, rear-left

Turn-signal light, rear-right
65
63
@) - left at cylinder head

Hall generator 4, 5
Turn-signal switch 61 @ - near ignition coil, in engine compart., left
Headlight dimmerlllasher switch 37,39
Headlight-high-beam light 36
Vohage stabilizer 35 @ - plus connection, in connector housing
Headlight, left 37, 39
Washer/wiper interm. relay 98-100
Headlight, right 36, 40 Windshield-washer pump 96
Horn 53
Windshield-wiper lnterm. switch 98-103
Horn button 53
Windshield-wiper motor 100-103
Idler stabilizer 4, 5
Idle switch 10
Ignition coil 1-3
Ignition distributor 1-3
Ignition/starter switch 22-27
Injector cylinder 1 11
Injector cylinder 2 12
Injector cylinder 3 13
Injector cylinder 4 14
lnstrument-panel light 49.. 50
Instrument-panel light dimmer 43
Interior light, front 81-83
Interior light, rear 86,87

97.60 Main wiring diagram

current traek Index
Water-cooled-Digijet 1985
 Electrical System-Wiring, Waterboxer 97

y
1.5
BK
TRNSTR
IGN
CNTRL
UNIT
WIRING
COLOR CODE

BLACK
BROWN
-
-
BK
BR
I1.0
RtBK

k ® I CLEAR
RED
- CL
-R

~ rlrrrrl
YELLOW - Y
GREEN -G
LIGHT GREEN - LT G
BLUE - BL
VIOLET -V
GRAY -GY
T2
WHITE -W
ORANGE -OR 0.75
1.0 1.5 1.5 1.5 0.5 0.5 0.5 1.5 1.0
BJ<tW 8K BK G Gt W RIBK BRI W BR w w

1ij ~·
FUEL 21
CNTRL
t

r rr rrrrril
UNIT

K I ®
rr
IDLEr
STAB
1 14

1, I,

f
0 .5 0. 5 0.5 0.5
G G R'!JK BRIW

lber ~ 2
I
•
I I" I"
,.
I
23
I I I
20 13

0.75 0 75 0.75 0.75 1.5 1.5 0.75 0.75 0.75 0 .75 0 .75 1.5 0.75
0 75 w w w w w
w w w
w
,.
JJJJ
w G G W BR1W BR

,.

l
I I I
IS
I
6

,ft

HALL
j iNJ iiNJ
t
INJ iiNJ
'( CYL ]'C]L CYL '(CY
3 0.75 4
. . .
GEN I 0.75 f 0 75 0.75
w w '!' w
28 29 26 27

I
SPK
PLUG
... • CONN
TMNG
RPM
SNSR
~~
I•

I
so-'.J J *+ux .
3•
1.0
w
l

t~.c
~ AIR
1.0 _ ] REG
AIR BRIY
FLOW FULL
TEMP SNSR THRTL
•, ----<;r- -- ' SNSR/1 ENRICH
y y SW
BK

r:rr3 t:fr>t]t

IS 1.0 1.0
BR' Y y
BR·BI.
@@ @ @ @ @
5 6 7 8 9 10 II 12 13 14 15

Water-cooled-Digijet 1985
Main wiring diagram 97.61
97 Electrical System-Wiring, Waterboxer

r-----<>-'l'-'-C'-R-TR_-.-____..f~ 40 R

f sf-1
5
~ f, -\ ct,
r
0.3
GY!llK
4.0
RIBK
1.0
R!llK
1.5BK-::==================
. .~. . .- - 2.5 BKIY
X CONTACT

~ ~

WIRING
COLOR CODE

BLACK -BK
BROWN -BR
CLEAR - CL
RED -R
YELLOW -Y
GREEN -G
LIGHT GREEN - LT. G
BLUE - BL
-V
8.0 6.0 HOLT
VIOLET R R!llK
GRAY -GY HI-BM
WHITE -W LITE
ORANGE -OR
/NO

Vt::=Tt
r
0.5
BLIW

]_ _ r: J-__IJ
.:J 1.. I 1
0.5

l
J
I

PWR
SPPLY
RELAY

0.5 0.5 0.5 0.5

8L 8L BUG BLIBK

FUEL
PUMP
SNSR
Y:"~
oXY_/I ~wss
(1.8
FUEL
GAGE
SNDNG
UNfT
~tt: BAR)
SW
COOL
TEMP
SNDNG
UNIT

05
BR

@
16 17 18 19 20 21 22 23 2.ol 25 26 27 28 29 30 31 32 33 3.ol 35 . 36

97.62 Main wiring diagram

Water-cooled-DigJjet 1985
 Electrical System-Wiring, W.aterboxer 97
-- ------------------------------------------------~.·

-- I
~
0.5
BK' Y

L L
I 5
R•Y
0.5
R I
0.5
R

tl--4:.J
INSTR
£----j PNL WIRING
LITE LITE COLORCOOE
SW DIM
BLACK -BK

rrr
BROWN -BR
CL EAR -CL
RED - R
YEL LOW - Y
GREEN -G
LIGHT GREEN - LT. G
BLUE - BL
1.5 2.5 1.0 0.5

l
~y

1
W•BK GY GY•BL VIO<ET -V

~s,
GRAY -GY
HOLT
OIMM WHITE - W

r~~H~
ORANGE -OR

rn
I
8A

~
0.5

~
GY•BL 0. 5 0.5
GYIBL GYIBL

~ ~
2.5 2.5 0.5
w

n~ fi&
Y•BK GY•BL

1.0 GY

1.5
w
1.5
WIBK
1.5
y
1.5
Y•BK
0.5
GY:R
0.5
rl&
0.5
GY•BK
0.5
GY·BK
GY<R

tl l l
fms
p o.5
GY·O
'';1 0.5
0.5
GY•BK
GY:R
2h
Tl4 /5

I 5 1.5
BR
BR@
@ @ @
37 38 39 40 41 42 43 44 45 46 47 48 49 so 51
\97- 20821

Water-cooleci-Digijet 1985
Main wiring diagram 97.63
97 Electrical~ System-Wiring, Waterboxer
-
a~ ==:::;-,
"
..,,...._ B.OR
4.0R

~=== 1.5R<Y - -- - - + , .
~ 1.5 ~v -----~

1.5 1.5 1.5 1.5

BK BK R.w R
. J'

0.5 1.5
BK 8Kt8L
RADIO
CONN
~

R
1"-F··~----0.5 R
o.5
EMERG
-------------+-.. ,-------, -EMERG
FLSHR
WIRING
COLORCOOE
FLSHR WRNG

f
~
\ J..
SW
,... , ... u ~~
LITE 8tACI(
BROWN
- BK
- BR

l
l..~
CLEAR - CL
RED - R
YELLOW - Y
G.5
BK GREEN -G
110

!
LIGHT GREEN - LT. G
BK/WIG BK'G ~ GYIBL BLUE - BL

BKUP
LITE
:a. :a. •6 ~ VIOLET
GRA Y
-v
- GY

r.o ro
sw ro ro r.o r.o r.o r.o r.o r.o o.s
WHITE - W
ORANGE - OR
BK1W BI«G BKIG BI«G BK1W BI«W BR

~J.
HORN •.• ~. • ·- lJiW ~BLWR
G~

~r

~hl ~ ~
0.5
BR

TRN

~: 'lkt-·~ ~·
t.O 1.0 1.0 SIG
BRIBL BKIBL BKIEJi
LITE
l l
1
11 -LF
TRN TRN
.,
HRN
BUTTN
~.
,
~~ BKUP
LITE ~~E ~ G~ fWE
-, -R ·RF -RR · r-cto
0
: - . ' 5 BR LITER
1.5
BR

1 TRNJ
ll S/G
r.o 1.0LITE

~:::t::::::::::::::::::::::::::::::::::B~R---.Ji -LR

62 63 64 65 66 67 68 69 70

97.64 Main wlrfng diagram

Water-cooled-Digljet 1985
 Electrical System-Wiring, Waterboxer 97
.............. oR .._.____________________________________.____.._____________________

-----------•.oR --------------------------------------------~------------------

n1.0
R ·Y
05
R

WIRING
COLORCOOE

BI..IICK -BK
BROWN - BR
CLEAPt - Cl
REO -R
YELLOW - Y
GREEN -G
liGHT GREEN - lT. G
BLUE - BI.
0.5 0.5 I0

l
BK SEAT BK R'BK VIOLET - V

BELT J r I c R, Y
GRAY
WHI TE
-GY
-W

~~~ 1 151
1
T8/7 ~ CIJtJ BR~ ORANGE -OR

r -~
ILI'Jr818 'Jnu BRK ilii'Jr•ll
TLITE
'WSW 11
os os 18•IWRNG os l1 oR-aK
GY,G BUBR LITE BR
I 0
RBK

Tla
i"· fr·
IO
GYIW
10
BK•R

T71<4

o.s
GYR

DOOR DR
CNTCT JPRKG CNTCT
sw BRK sw
·RF I WRNG
' j LITE
BRK
LITE
·R
·R
SLIDING
DR
~~ sw

SEAT
BELT
BUZZ
CNTCT
·R

0 ~
71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87

Water-cooled-Digljet 1985
Main wiring diagram 97.65
97 Electrical System-Wiring, Waterboxer

WIRING
COLOR CODE
BLACK -BK
BROWN -BR
CLEAR - CL
REO -R
'r'El.LOW -Y
RELAY GREEN -G
(X-CNTCT) LIGHT GREEN - LT. G
0.5
BR BLUE -BL
.. o ~ VIOLET
GRAY
-v
-GY

2.5 2.5 0.5 4.0

WHITE -w
RM RM BR ~y ORANGE - OR

1.5 BKIY _ __ ,

REAR RADIO
WIND CONN
DEFOG
SW
~
0.5 a~i~y WINO 1.0 l.o
GYrSL
FAN
RAD 7 WIPER BKILGY JBI(IIf
THERMO
L. INTERMIT

- ~ -f:,- -.-!-- l -Effi-.-.-t+---.-'•{,._ ={;.,WR

SW/1
RAD 3
FAN ~ F-- s I
THERMO
SWI
ifl] REAR
CSJ WINO
DEFOG
sw
En Tf.i.r--'
.L IT f~ f~ll3

II
LrrE 0.5 1.0 I0 1.0 1.0 1.5 1.5 1.5
G>R BR-sK G GYIBK GIY W YIBK Y

t.
WASH
2.5 1.5 1.5
WIPER
PJBK R.eL BK INTERMIT

t-=~
RELAY

T 1----+BLWR

r7-
2.5
R
±RELAY

0.6
FAN
RESIST

Bll

~
REAR
WINO
DEFOG
HTR
ELMNT

WINO
1 FAN WSHR

2.5
0.5
BR

I PUMP Ji$
1.5
BR

t~
1.5 0.5
BK BR.

2.5
BR 1.5
BR

@> @> @> @ @ @ 0 @ @ @

88 89 90 91 92 93 9~ 95 96 97 98 99 100 101 102 103 10~ 105
\97-2083j

97.66 Main wiring diagram

Water-cooled- Dlgljet 1985
 Electrical System -· Wiring, Waterboxer 97
Fuse Arrangement
according to numbers on fuse panel as seen from
19 20 21 22 23 24 left to right:
No. Component Amp.
13 16 17 18 1 Radiator fan 30
2 Brake lights 10
3 Interior lights, illuminated Make-up
mirror, clock 15
4 Emergency flasher system 15
5 Vacant
6 Vacant
1 Tail and side light left 10
8 Tail and side light right 10
9 Higi'J beafll right 10
10 High beam 'left 10
11 Wiflldshield washer 15
197·21991
12 Rear wiper, Cruise control system 15
13 Rear window heating, fresh air fan 25
Fuse/Relay Panel 14 Auxiliary heat exchanger, light for
lighting switch 20
IEJ - coolant level control unit 15 Back-up lights 10
16 Double tone horn 15
Ill- rad. cool. fan relay, 2nd stage 17 Windshield wiper 10
llJ - load reduction relay 18 Brake warning light, heated driver's
seat 10
ml- intermit!. wash/wiper relay 19 Turn signals 10
m- rear window wash/wiper relay 20 Number plate light, headlight washer 10
m- emerg. flash/turn sig . relay
21
22
Low beam right
Low beam left
10
10
Additional Fuses
(in separate holders)
CAUTION
above the fuse box:
Relay locations are subject to change and may
Instrument lighting 10
vary from vehicle to vehicle depending on options.
Overheating fuse for auxiliary heater 10
Main fuse for auxilial)' heater 20
Use extreme care when troubleshooting the
Emergency horo system 15
electrical system.
Central locking 20
Automatic fuse for power windows 20
If you encounter problems identifying a particular
relay, consult your Parts Department.

Main wiring diagram

Water-cooled- Digifant 1986 Fuse/Relay panel
up to VIN G 055 689 97.67
97 Electrical System- Wiring, Waterboxer

Fuse/relay panel, rear view

H D K
. ~~ ~ ~
~~~~ RJ]~N
9iF
~-a
~ ..1 ~ •o -.s~
..7 ~ ~ •
11 21 ~5~6.,_ 2 .,_ 3 ~ltx
L 3141 E 21 31
sl 61 ~~~~·5 41 sl
"~ea~~o
71al ~~~·4
~ ~~1 ~2eaeo~
es~~ ~ew'2~ eo ~ ~ ~~ .4 ~ .7 61 71
91101
~~ ..,
~4~5~~6t!2 ~7~
~ I
.16

~~~~ ~~·4
5" ~~~1 ~2~~

~~1 ,7~ 2 "t!3 ~

p
~4 ~5 ~6 ~7~
G ea ~ en
A ,2\ ~~ ~~ ~ B
~ ~7~ ~2
M --- c -..r-

0 197-14951
ErnE
ErnE
Eng
Eng
A - multi-point connector (blue) for instrument panel wiring harness Eng
B - multi-point connector (red) for instrument panel wiring harness
C - multi-point connector (yellow) for front wiring harness
Fres
Fres
D - multi-point connector (white) for windshield wiper harness and main wiring harness
Fres
E - multi-point connector (black) for main wiring harness Fuel
F - single connector Fuel
H - multi-point connector (brown), relay connections for rad. cool. fan, 2nd stage Fuel
K - multi-point connector (colorless), connectors for low coolant warning control unit Fuel
L - multi-point connector (gray), horn connections Fuel
M- multi-point connector (black), open terminal (used for light switch terminal 56) and switch for hand operated Fuel
brights and dimmers terminal 56b Fuel
N - single plug Fuel
P - single plug - terminal 30 Hall
R -open Heac
Heac
Heac
CAUTION Heac
Relay locations are subject to change and may Heac
vary from vehicle to vehicle depending on options. Heac
Heat
Heat
Use extreme care when troubleshooting the
Heat
electrical system. Horn
Hom
If you encounter problems identifying a particular
relay, consult your Parts Department. Idle 1
Idle 1
Idle 1
lgn. c
lgn. c

97.68 Fuse/Relay panel

up to YIN G 055 689
Water-cooled- Dlgifant 1986

- Description
Air flow sensor
Alternator
Alt. warn. lite
Back-up lite, L
Back-up lite, R
Back-up lite switch
Battery
Brake fluid level switch
Brake lite, L
Brake lite, R
Brake lite switch
Brake/park brake warn. lite
Cigar lighter
Cigar lighter lite
Clock
Clock lite
Coolant low-level control unit
Coolant low-level switch
Coolant temp. gauge
Coolant temp. sender
Coolant temp. warn. lite
Digifant control unit
Door contact sw., LF
Door contact sw., RF
Emerg. flasher relay
Emerg. flasher switch
Eng. oil press. control unit
Eng. oil press. sw. (0.3 bar)
Eng. oil press. sw. (0.9 bar)
Fresh air controllvr. lite
Fresh air fan
Fresh air fan switch
Fuel enrich switch
Fuel inj. cyl. 1
~ ,-19 - " ;~/'~
Electrical System - Wiring, Waterboxer 97
CUrrent Description CUrrent Wire Connectors
Track Track
lgn./start sw. T1c - single, in eng. compart., left
Ins!. panel lite dimmer Ttd - single, in wire distributor box
lnst. panel lites T1e - single, in eng. compart., middle
interior lite, front T1f -single, under instrument panel
Interior lite, rear T1k -single, in eng. compart., middle
T2 - double, under driver's seat
Ucense plate lites
T2a - double, in eng. compart., left
Ute switch
T2b - double, in the relay panel
Load reduction relay
T2c - double, under instrument panel, left
Make-up mirror lite T2d - double, in upper right "A" pillar
T2e - double, in rear deck lid
OXSICAT elapsed mile counter T2f - double, behind RR side trim panel
OXS Ind. lite T2j - double, under instrument panel; left
OXS sensor with heater T2i - double, in wire distributor box
Park brake lite sw. T2m -double, in the relay panel
Park lite, left T3 - three point, in eng. compart. on
Park lite, right alternator
Power steer. press. sw. T3a - three point, under instrument panel
T3b - three point, behind upper air intak&
Rad. cool fan flap (near radiator)
Rad. cool fan relay 2nd stage T3c - three point, behind instrument panel
Rad. cool fan thermoswitch T3d - three point, behind ·c· pillar cover
Radio connections T4 -four point, under instrument panel
Rear defogg. heat element T4a - four point, on series resistor for
Rear defogg. ind. lite heater fan, under rear seat
Rear defogg. sw. T11 - seven point, in wire distributor box
Rear defogg. sw. lite T7al -seven point, in wire distributor box
Rear .washer motor T8 - eight point, on brake warning
Rear wiper motor indicator
Rear wiper/washer relay T14/ - 14 point, on instrument cluster
Seat belt switch, LF Ground connections
134 Seat belt warn. lite
Seat belt warn. relay
@- under rear bench seat
135
135"1$ Series resist. for fresh air fan 0 - on steering gear box

·····26
Series resist. for heater fan
Side marker lites, rear
® -under instrument panel near relay
panel
Fuel inj. cyl. 2 'Z1 Spark plug connectors
Fuel inj. cyl. 3 28 Spark plugs
Starter
® - on rear deck lid
Fuel inj. cyl. 4
Fuel gauge
29
57
@- under instrument panel near relay
Tachometer panel
Fuel gauge sender 64 Tail lite, left
Fuel pump 30 Tail lite, right @ -on rear deck lid
Hall generator 17·18 TDC sensor
Temp. sensor II
@ - on left front crossmember
Headlite flash/dim sw. 92-93 @ - on rear washer fluid bracket
Headlite, hi-beam Ind. :''·55 Tum sig. Ind.
Turn sig. lite, LF
Headlite, hi-beam, left 87
Turn sig. lite, LA
@ - In eng. compart. under ign. coil
Headlite, hi-beam, right 99
Headlite, left 88;.e9 Turn sig. lite, RF @ - on sheet metal bracket near fuel
Headlite, right '97.f8' Turn sig. lite, RR pump
Heater fan 14i Voltage regulator @- on left side of cylinder head
Heater switch 142-143 Voltage stabilizer
Heater switch lite ;'14'1;. @- in instrument panel wiring hgrness
Horn 121 Washer motor
Horn bu.tton 11$ Wash/wipe intermit!. relay @- ill Digifant wiring hemess
Wash/wiper intermit!. switch Welded wiring points ( +)
Idle stab. control unit Wiper motor
Idle stab. velva @- terminal 58b in inst. panel wiring
Wire connectore harness
Idle switch
T1 - single, in eng. compart., left
lgn. coil
lgn. distributor T1a -single, in eng. compart., left
@- + connection bolted to wire
distributor box
T1b - single, in wire distributor box

Main wiring diagram

Water-cooled- Diglfant 1986 Current track index
up to VIN G 055 689 97.69
97 Electrical System -Wiring, Waterboxer

31 31

r---~==~==t=====================~~1

p p p p p p 024 88 p AS
6.0 6.0 0.5 0.5 0.5 1.0 4.0 4.0 1,5
A A/BK BL BL RIBK RIBK A sw

f
2.5
A

2.5 0.5 0.5

BKIY BK GY/BK
T2m
WIRING
COLOR CODE

BK -BLACK
BR -BROWN
CL - CLEAR
R -RED
y - YELLOW
G -GREEN
LT G - LIGH T GREEN
BL -BLUE
v - VIOLET

6.0 2.5 2.5

GY
w
- GRA Y
-WHI TE
ln . ~.3 · )25
A RIW RIW OR - ORANGE

+
--~==--~50~8~·==~· ALT.

VOLT
REG.

4.0
BA

2 3 4 5 6 7 8 9 10 11 12
j97-2252l

Main wiring diagram

97.70 Alternator/Starter/Ignition
up to YIN G 055 689
Water-cooled- Dlgifant 1986
 Electrical System - Wiring, Waterboxer 97
30 30 30
15 15 15
~
X X
-
31 31 131
~1 61 61
l a a
~1 ~5

~ n~~
4 I 2

~
ID
,,.? ' 8 ' 6 3

b
I r-1 l
'E12 C21 019 026 A15 C12 C18 06 013 N E14

0.5 0.5
G G

I
1.5
BKIW

1 d~!15 DIGIFANT
CONTROL

12
I
I 3
0.5
I
BRIW
.1
1.0
BR
0 .5
BRIW
0 .75
w
.4 J, t
I (~
HALL
GENERATOR
© I II "
h~
t-Ji:I~w SENSOR
WIRING
COLOR CODE
BK
BR
CL
R
-
-
-CLEAR
-
BLACK
BRCWN

REO
y - YELLOW
I Tic G -GREEN
L T. G - LIGHT GREEN
BL - BLUE
FUEL v - VIOLET
IDLE ENRICH. GY - GRAY
sw. sw. I I w -WHI TE

I ~·~{ I
~ SENSORn
TEMP. OR -ORANGE

SPARK
PLUGS I~ ~
I
..,_ .. 0 .5 ~0.75
AIY
w- 48 d
e
f

13 14 15 16 17 18 19 20 21 22 23
/97-22 53 /

Main wiring diagram

Water-cooled- Digifant 1986 Digifant control unit
up to YIN' G 055 689 97.71
97 Electricai'System - Wiring, Waterboxer
30 JO
15 15
X X
t31 311
a
61 61

------------~E~4~------------------------------~D=1~~)~G~6--~~~4~--~~~0~23~~--D~15~--
1.0 L5
RISK sw

'T7a6
I
1.0 RISK

c ------------~--------------------------------.

SK 1.0 A

! ! \ '

~ ~ ~~JOR
~FUEL

I[A_J
~ PUMP
----~
L. -,.-'. HEATER
'J
1.0 w

15 19 18 15
•
24 25 26 27 28 29 30 31
/97 225~

Main wiring diagram

97.72 Fuel Injection

up to YIN G 055 689
Water-cooled- Dlglfant 1986
 Electrical System - Wiring,. Waterboxer 97
L
30----------------------------------------------------------------------------30
15 15
X X

61
131
61
311

6G4 104 iA16 ~C2 tCll

I WIRING
COLOR CODE
0.5 0.5 0.5
BL BL BUG
8K - BUIC K

I
BR - BROWN
CL - · ClEAR
R - REO
- YEU.OW
G - GREEN
LTG- LIGHT GREEN
BL - BLUE
V - VIOLET .4{
G'r' - GRAY
g-0.5W•45~ W -WHITE
OR - ORA NGE

________________________________
L----~1_6 ~
IDLE

I~:.TROL
STAB.
©
1114
0.5 BK 0.5
rs r r3
0.75 0.75
18
0.5
r
0.5
tll
0.5
r
0.5
r7
0.5
h _ _ _.... ~ w w RIY w y WIG G
I
53 8 48I
T.D.C.
SENSOR

Main wiring diagram

Water-cooled - Dfglfant 1986 Idle stabilizer
up to VIN G 055 689 97.73
97 Electrical System -Wiring, Waterboxer
30 ,~·
- ---.- ~

30
.... -
~
r.
,.
15
- --
~

15
X /
"""" X
131 ·' ~- 31
~1:
61

'
~3 t II
6 4

7 '2 5
k

t-l .r---1
~
E15 D21 81 824 819 :.\3 08 A27 03 818 815 821 K3 82 El 0

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

y BUBK BL BL W/R G BUBK y
-- ·
:fa
T
11

T
0.5 0.5
BK R

L.. Tl4 II Tl4. 14 L. 5 Tl . . I T1413

0,3
T14 12

1,8 __ ~

J 114 l f-9u-l ® ~~
15
< Ka

1
T7a 7 T7a 1

WIRING
COLOR CODE

BK -BLACK
BR -BROWN K2 ALT. WAR"!. I.JrE
CL - CLEAR K21 OXS IND. LITE
R -REO Y2 CLOCK
I Tlk 1 Tle G5 TACHOMETER
Y - YELLOW
J114 ENG. OIL PRESS. CONT. UNrr
G -GREEN K3 OIL PRESS. WAR"!. LrrE
0.5 ENG. 0.5 ENG. Lr G - LIGHT GREEN
BR OIL BR OIL BL -BLUE
1 PRESS. I PRESS. V - VIOLET
0 sw. 0 sw.
I:Jl (0.9 Ol(0.3
GY - GRAY

L:r_j BAR) LiJ BAR) W

OR
-WHITE
-ORANGE

.T143

0.5
BR

lw t,o
•
41 •
42 43 44 45 46 47
12-o
48 49 50 51
r-197--2-2-5-,61

Main wiring diagram

97.74 lnatruments
up to YIN G 055 689
Water-cooled- Dlgifant 1986
 Electrical System - Wiring, Waterboxer 97
30
0 15 - ,_. 30
15
5 X
~

X
31 .. 31

~
2 6131 5115

~
COOLANT
ur © lJ120 t~L
fJ:rTROI.
. '7 1 ' 3185 .C/86
I
m
~-
1
A17 A28 B3 IB7 K2 B17 Kl K5 Bl4 K4 r-1"029 E5

0.5 0.5 0 .5 0.5 0 .5 0.5 0.5 1.0

BUR BLJW V/BK Y/R BUG yr Y/R V/BK
fSl]
'I
0.5
GY/BL

Tl4, 10 T14.2 T14 : 7 Tl46

"'"
LtO
L8
INST. PANEL LITES
CLOCK LITE
II
C'
I COOLANT

8J
K5 TURN SIG. IND.
Kt HEADI.ITE HI-BEAM IND. LOW·
Gt FUEL GAUGE LEVEL
G3 COOLANT TEMP. GAUGE
K28 COOLANT TEMP. IND. LITE '
J6 VOLT. STABILIZER
II

.---------.
WIRING
COLOR CODE
F-1
0.5
BR
0.5
BR
I ,G

BK - BLACK COOLANT
TEMP. I s~~ I FUEL
GAUGE
BR - BROWN SENDER SENDER
CL - CLEAR I

I
R - RED
Y - YELLOW
G - GREEN
LT G - LIGH T GREEN
BL - BLUE I T7 7
V
GY
-
-
VIOLET
GRAY 1.0
•
1.5 1.0
W - WHITE BR BR BR
I OR

52
- ORANGE

53 54 55 56 57 58
r~
59 60
I
61
15
62 63 64
1 1
2

/97-2257/

Main wiring diagram

Water-cooled- Digifant 1986 Instruments
up to VIN G 055 689 97.75
97 Electrical System - Wiring, Waterboxer
30--~~~~-----------------------------.----------------------~---------------30
15 15
X X
31 31

I
1.5 0.5 0.5
R R R

WIRING
COLOR CODE

BK -BLACK
BR -BROWN
CL -CLEAR
[47 R -RED

T
Y - YELLOW
G -GREEN
LT. G - LIGHT GREEN
BL -BLUE
0.5 0.5 0.5 V - VIOLET
GY/BL R R GY -GRAY
W -WHITE
OR -ORANGE

T4

rn ~N~RIOR
0.5 RADIO 0.5
GY/BL CONNECTIONS R
30
MAKE· INTERIOR
UP LITE, ~,..,
MIRROR FRONT REAR
LITE 31
T Ji" --t1
0.5 0.5 0.5 0.5 0.5 0.5
RADIO
CONNECTIONS
BR BR l
B;:; l _ _ _ _ _ _ _ _ _ _.. BR!BL BR

T
0.5
iT4
0.5
I T2d

BR BR
CIGAR
LIGHTER
Rl
L1J
I
DOOR
CONTACT
CIGAR sw.
LIGHTER (SLIDE
31 1
LITE DOOR)

1.5
BR

65
1 20
66 67
.20
68
:I~
69 70 71 72 73
lr-97---22-5--,81

Main wtrlng diagram

97.76 Interior lights

up to VIN G 055 689
Water-cooled- Digifant 1986
 Electrical System - Wiring, Waterboxer 97

810 Ml 827 El

1.0 1.0 2.5 1.0 0 .5 0.5 0.5 0 .5 0.5

RIY AIY BK.IY BKtW GY GY GY/R GY/BL GY/G

I
[92 ] b;

2.5 2.5
BK.IY W!BK

INST.
PANEL
LITE
I 30 ,3o
58l! DIMIIER

IL UTE
.. I
!I r8b
SWITCH
WIRING
COLOR COO~ 0.5
GY/BL
BK - Bl..ACI(

I~Sso
BR -BROWN
CL - CLE~R
R - RoD LICENSE
y - YELLOW Pt.ATE
G - GREEN
UTES
LT G - LIGHT GREEN

9
BL - BLUE
v - VIOLET lli1 lOA
GY - GRA Y 0.5111()
w - WHITE BR I
OR - ORANGE

,- .
0.5
BR

,:h; l I ~T2;
0.5 0.5 0.5 0.5 0.5 1.0
GY!BL GY/BL GY/BL GY/BL GY/BL BR

~Jli ~ _LQ_ZJt
co_: _, c. J ~ ~ ~~
74 75 76 77 78 79 80 81 82 83 84 85 86
"1
9-7-2_2_5 9--,J

Main wiring diagram

Water-cooled-Digifant 1986 Light switch
up to YIN G 055 689
97 77 •
97 ElectricaJ System - Wiring, Waterboxer
30 30
15 15
X X
31 31
n
0
p p
r
rh
~S1o ~
'I

{,
522 ms21 59
lOA "'lOA 1 10A lOA
"'I
m
I )_ i
C17 IC5 IC4 IE9 M2 A21 822 I E18 r 14 1C6 813 Cl6

1.5 1.5 0.5 0.5 2.5 2.5 0.5 0.5 1.5 1.5
w Y GYIBK GYIBK y w GY/R GY/R Y/BK W/BK

75

I
1.0
RIY
2.5
WiBK
r
79

T75 I T7i6

L HEADLITE
FLASH!
DIM
sw.
0.5 0.5
Y/BK GY/R

I 58 I 58 II SIDE SIDE 1\ 158 1

58 56o
HEADLITE,
HEADUTE, '·
r'
PARK TAIL
. LITE, Q UTE,
MARKER
o· LITES
MARKER
+
TAIL
0
PARK . I

v•31~5 ~131
HI- LITES, LITE, LITE, .] (\ HI-
~+ \ ) (

J.
BEAM, ', I LEFT_ • LEFT REAR \ , .- J BEAM,
LEFT

1~
,31 ,31V_ RIGHT

1':\ 1~5 r:~LITE, 0.5

REAR l . i : rlHT
HEADLITE,
BLJ Bi
1

B~ L:i BIR L:i BL.J BIR RIGHT

_ _,
l. --~------ u
- v
- w
8 15 10
87 88 89 90 91 92 93 94 95 96 97 98 99
197-2260!

Main wiring diagram

97.78 Ughts
up to VIN G 055 689
Water-cooled- Dlglfant 1986
 Electrical System - Wiring, Waterboxer 97
30 30
15-,----------~--=------------------------------------------------------------------15
X X
31 31
p p
I
'i'
ms19
.t 10A
"-'

I _j_ ---- 1---· -.;_____.

I I

-r~~ B28 A10 All A7

1.5 1.0 1.5 1.0 1.0 1.0 1~ 1~ 1~ 1~

BK!BL W RIW BKI\WG BKIG BK!W BKIW BKIW BKIG BKIG

49a
TURN
SIG.
SWITCH

1.0
~R
1.0
f
1.0
BKIW/G BKiG BKIW

WIRING
COLOR CODE

BK -- BLACK
BR - BROWIJ
CL CLEAR
- m:o Bl BL Bl Bl
" - YELLOW
•1
TURN TURN
1
TURN TURN
G
tT G
fk

GY
- GREEN
· LIGHT GREEN
BLUE
\.i/Ot.ET
•. GRAY
Q S/G.
LITE,
LR 1·- i
() 5/G.
'J LITE,
LF
() SIG.
. UTE,
RR i
() SIG.
LITE,
RF

~\l -· Wf-IITE
1.0 1.0
OR O~ANGE

~ 31 .84 ,
J BR BR

w
u
v
-=·-=t .20 10 10
u

I
100 101 102 103 104 105 106 107 108 109 110 111 112
§iii]

Main wiring diagram

Water-cooled- Digifant 1986 Flashers/Turn signals
up to VIN G 055 689 97.79
97 Electrical System - Wiring, Waterboxer
~ ~
15 ,, 15
X X
31 . I
·~
31
p --- - p
~4 h
~515
'i' I'
m52 B 516
V5A lOA yl .-·3 ~
!Jl5A -

,---
r I ~
C3 )Cl IE16 016 C20 l1 L-4 L2 825 C15 L3 C13

1.0 1.0 1.0 1.0 1.0 1.5 1.5

RIY R/BK BKIR BKIGY BR/BLBR/Bl BKJY

I T2g T2g

lfl~K:
liJsw.
'I'
1.0
BKIBL

T 73 I T1b

~l~KE T. f-_ _m_!_;_jl

IL_rnl_

i
1.0
RIBK

WIRING
71 COI.ORCODE
[}lHORN
BK -BLACK
L:JBUTTON
~ll - BllOWN
CL -CLEAR

i
1.0
R
Y
G
LT G -
-REV
-
-
YELLOW
GllEEN
LIGHT GllEEN
BR
BL -BLUE

I,
V -VIOLET
GY -GRAY
u W -WHITE
OR -ORANGE

113 114 115 116 117 118 119 120 121

Main wiring diagram

97.80 Rear lights

up to YIN G 055 689
Water-cooled- Dlgifant 1986
 Electrical System - Wiring, Waterboxer 97
30--------------- ------------ -- ------ ---------- ------------ -------------------- --30
15 15
3
~- L1 I 1 ~,
~~~ ~~i
~A--25--------------~~ 0-7 -~GS l 22
I"
0.5
I
0.5
WIRING BK BK
COLOR CODE K19 SEAT BELT WARN. LITE
K7 BRAKE/PARK BRAKE WARN. LITE
BK - BLACK L39 REAR DEFOGG SW. LITE
BR - BROWN L10 REAR DEFOGO IND. LITE
CL - CLEA R
R - REO
Y - YEL L O W
G
LT G -
BL
-

-
GR EEN
LIGHT GREEN
DLUE
...
12
0.5 0.5
100
-.--
0.5 1.5
V - VIOLET
GY - GRAY GY/BK R/BK GY/BL BK!W

£ ''" '
W - WHI TE
OR - ORANGE
'+
l~l39
jT85 jT8 1 .T84 .31
0.5 0.5 0.5 0.5
GY/G BR BU BR BR

i79l 1 T3a

I 250 6 15

olilG
0 .5
GY/R

8l
0.5
BR/W

! rr T2

SEAT
[ j ] BELT
sw,.
LF
I T2 0.5
BR

BJ
PARK
BRAKE
LITE
sw.
1
BRAKE
FLUID
LEVEL
sw.
,_
l8
_
REAR
DEFOGG
HEAT
ELEMENT

i
DOOR DOOR
CONTACT
sw.,
RF
CONTACT
sw.,
LF
l
0.5 1.5
BR BK

10 8 20 20 9
122 123 124 12 5 126 12 7 128 129 130 131 132 133
197-22 6 3 1

Mafn wiring diagram

Water-cooled- Digifant 1986 Warning lights
up to VIN G 055 689 97.81
97 Electrical System ... Wiring, Waterbo~xer

30 ,,. .
15
. ··- ~
.~

. JP - '.J ..J
...
-,r tr:-
X
31 '-
' I ' r:---
t-$85 4130 1 I··

rns13
,125A
~51 30A
HI cP..-----;\
6/86 8187
IJtot
7
•_u

'·-
I St4
20A

A22 C7 H6 H3 IH1
\L H4 H2 H5 A23
RAD.
1.5 2.5 1.5 2.5 1.0 COOL 1.5
BK/R RJW RIBL R BR FAN BK/Y
RELAY
2ND
STAGE

GY/BL
8.3 .
0.5
I FRESH
AJR
so
-.-
0.5
GY/BL
•Tu

FAN
FRESH ~ , .. sw.
f~TROL IpL16 --~~~
HEATER HEATER
SWITCH SWITCH

LITE i [

rrr
LITE

0.5 1.5
i1
1.5
0.5 1.5 1.5 1.5 2.5 BR y w
BR y Y/BK w BK/R

I I~ ~~~· FOR
FRESH
AIR HEATfR
FAN
FAN

1.5 1.5
y y
,67 I T3b

+C._ __. 2
·~--
~HEATER
.....
~[~!r ---
FRESH
AIR ~FAN
FAN
-~ r;;- -Q
1.5 2 .5 1.5
BR BR BR

8 10 8 20 6
134 135 136 137 138 139 140 141 142 143
197-22641

Main wiring diagram

97.82 Fans
up to YIN G 055 689
Water-cooled- Dlglfant 1986
 Electrical System ... Wiring, Waterboxer 97

1.5 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 0.5 1.0 0.5 0.5
BR BR G/BK GfY GY/BK G G GY/BK GfY G/BK BRISK GIW G/R G/R

WASH!
WIPER
INTERMITT.
swrrcH

WIRING
COLOR CODE
BK - BL.ACK
I 53b 1
53a 1
53e I

.t _T\. I
BR -BROWN
WIPER CL - CLEAR ~~WASHER
MOTOR R -RED LY.JMOTOR
Y - YELLOW
G

BL
v
-
LT G -
-
-
GREEN
LIGHT GREEN
BLUE
VIOLET
t
0.5
GY -GRAY BR

I w - WHITE

I.
OR - ORANGE

10

144 145 146 147 148 149 150

197·22651

Main wiring diagram

Water-cooled- Digifant 1986 Wiper/Washer
up to VIN G 055 689 97.83
97 Electrical System - Wiring, Waterboxer
30----------------------------------~------------------------------_.------~ 30
15----~--~--------~~--~~~~--~~~------~~~~--~---------4--~---­ 15
x----~~--~------------------------~----------~_.--~------~---4--~---- X
31----~~~~----------~==~--~--~====~~~-t--~~----~--i-~~-- 31

~512
15A
D
4 3
~
ES R1 R2
1.0 1.0 1.0
G/W GIBK BK!GY

T3c 1 T3c 1 T3c

WIRING
COLORCOOE
BK - BLACK I
BR - BROWN
CL - CLEAR
R -REO
y - YELLOW
G - GREEN
LT G - liGHT GREEN
BL - BLUE
v - VIOLET
GY - GRA Y
w - WHI TE T3d T3d I T3d
OR - ORANGE

151 152 153 154

Main wiring diagram

97.84 Rear wiper

up to YIN G 055 689
Water-cooled- Dlglfant 1986
 Electrical System -Wiring, Waterboxer 97
Separate fuses above fuse panel
Power windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
A!C .................. ..................... 30

Fuse/Relay Panel
IJ - coolant level control unit
g - rad . cool. fan relay, 2nd stage
m- load reduction rel ay
mJ - intermit!. wash/wiper relay
m- rear window wash/wiper rel ay
m1 - emerg. flash/turn sig . relay

Fuse arrangement
according to numbers on fuse panel as seen from
left to right :
Amp .
1 Radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2 Stop lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Cigarette lighter, radio, clock. interior lights,
central locking system . . . . . . . . . . . . . . . . . . . 10
197-1392 1
4 Emergency flasher system . . . . . . . . . . . . . . . 15
5 Electric fuel pump . . . . . . . . . . . . . . . . . . . . . . . 15
6 Vacant
Connections and plugs on fuse/relay panel
7 Tail , parking and side marker lights, left . . . 10
8 Tail , parking and side marker lights, right . . . 10 A - multi-point connector (blue) for instrument
9 High beam right, high beam indicator light . . 10 panel wiring harness
10 High beam left . . . . . . . . . . . . . . . . . . . . . . . . . . 10 B - multi-point connector (red) for instrument panel
11 Wind . wipers and washer . . . . . . . . . . . . . . . . 15 wiring harness
12 Heated seats, outside rear view mirror C - multi-point connector (ye llow) for front wiring
adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 harness
13 Rear window defogger, heated rear view D - multi-point connector (white) for windshield
mirror ......... .. .......... . . . ....... . . . 15 wiper and main wiring harness
14 Fresh air fan , glove compartment light . . . . . 20 E - multi-point connector (black) for main wiring
15 Back-up lights, shift console light (Auto. harness
Transmission) ... . .. . . . . . ..... .. ...... . . 10 G - single connector
16 Horn (single tone) . ............. . ....... . 15 t-1 - multi-point connector (brown) to connector for
17 Vacant rad . cool fan relay , 2nd stage
18 Dual horn, coolant level and temp . warning K - multi-point connector (colorless) to radiator
light .. . . .. . ...... .. . . . . ..... . ...... ... . 10 coolant low-level control unit
19 Turn signals , brake warning light ......... . 10 L - multi-point connector (gray) for horns
20 License plate lights . ... .. . .............. . 10 M - opoil position
21 Low beam left .. . .... . ......... . .. . .... . 10 N - single connector
22 Low beam right 10 P - single connector (terminal 30)
A - open position
CAUTION
Relay locations are subject to change and may
vary from vehicle to vehicle depending on options.

Use extreme care when troubleshooting the

electrical system.

If you encounter problems identifying a particular

relay, consult your Parts Department.

Main wiring diagram

Water-cooled- Digifant 1986 Fuse/Relay panel
from VIN G 055 690 97.85
97 Electrical System -Wiring, Waterboxer
Description Current Description Current
track track Wire Connectora
Air flow sensor potentiometer 22·24 Injector, cyl. 1 27 T1a -single, under Instrument panel
Alternator 5,6 Injector, cyl 2 28 T1c - single, eng. compart., left
Alternator warning lite 51 Injector, cyl. 3 29 T1d -single, in wire distributor box
Injector, cyl. 4 30 T1e -single, eng. compart., left
Back-up lite switch 127 Instrument panel lite 58-60 T1f - single, under Instrument panel
Back-up lite, left 127 Instrument panel lite dimmer T1g -single, under instrument panel
Back-up lite, right 126 T1h -single, eng. compart., left
switch 94
SatiSfY 1 Interior lite, front 77.78
Brake and parking brake indicator Interior lite, rear T2a -double, eng. compart., left
62,63
lite 134 Interior lite, right T2b - double, eng. compart., left
80,81
Brake fluid level warning contact 136 T2c - double, under ins!. panel, left
Brake lite switch 122,123 License plate lite 95,96 T2d -double, behind sunvisor attaching
Brake lite, left 125 Lite switch 85,94 screws, right
Brake lite, right 124 Load reduction relay 86-88 T2e - double, in rear decklid
T2f - double, behind right 'c' pillar cover
CAT elapsed mileage counter 45,46 Make-up mirror lite 76 T2g - double, under instrument panel
Cigarette lighter 72 Map/reading lite, right front 75 T2m - double, near fuse/relay panel
Cigarette lighter lite 73 T2x - double, eng. compart., middle
Clock lite 61 OXS ~lapsed mileage indicator 52
Coolant low level control unit 68,69 Oxygen sensor 25,26 T3 - three-point, on alternator
Coolant low level warning switch 68 T3a -three-point, under instrument panel
Coolant overheat warning lite 67 Parking brake warning lite switch 134 T3b - three-point, behind front air duct
Coolant temperature gauge Parking lite, left 100
65 T3c -three-point, under instrument panel
Coolant temperature sending unit 70 Parking lite, right 106 T3d -three-point, under right 'c' pillar
Power steering pressure switch 38,37
cover
Digifant control unit 16-27
Digijet control unit relay 32,34 Radiator cooling fan 143 T4 -four-point, under instrument panel
Digital clock 53 Radiator cooling fan relay (2nd T4a -four point, under rear seat bench
Door contact switch, left front n,78 stage) 147
Door contact switch, right front 81 Radiator cooling fan thermoswitch 143,144 T7/ - seven-point, in wire distributor box
Rear window defogger indicator T7a/ - seven-point, In wire distributor box
Emergency flasher relay 111 lite 38 T14/ -fourteen-point, on Instrument cluster
Emergency flasher switch 110,117 Rear window defogger switch 139
Emergency flasher warning lite 117 Rear window defogger switch lite 137 Ground Connections
Engine oil pressure control unit 55,56 Rear window washer pump 157 G) - battery to body
Engine oil pressure switch (0.3 Rear window wiper motor 159,160
bar)
Engine oil pressure switch (1.8
48 RMr window wiper/washer relay 158,159 ® - from body to transmission
bar) 47 Safety bell switch, right 131,132 (j) - on steering rack
Engine oil pressure warning lite 57 Seat belt warning lite 133
Seat belt warning relay 130-133 @ - near fuse/relay panel
Fresh air blower series resistance 142 Side marker lites, rear 102,104
Fresh air control lever lite 140 Spark plug connectors 13-15 @ - in rear decklid
Fresh air fan 141
Fresh air fan switch 141,142
Spark plugs
Starter
13-15
3,4
@ - on left front crossmember
Fuel gauge 64
T.D.C. sensor 43,44
@ - near rear washer fluid bottle
Fuel gauge sending unit 71
Fuel pump 31 Tachometer 54 @ -under rear seat bench
Fuel pump relay 30,31 Tail lite, left 101
Tail lite, right 105 @ - under ignition coil
Hall generator 17·19 Temperature sensor II 21
Headlite dimmer/flasher switch 102.103 Throttle valve switch (enrichment) 20 @ - under rear seat bench
Headlite high beam warning lite 63 Tum signal indicator lite 62
Headlite, left 97,99 Turn signal lite, left front 119
@ - near fuel pump
Headlite, right 107,108 Turn signal lite, left rear 118 @ -on cylinder head
Heater blower series resistance 149 Turn signal lite, right front 121
Heater fan switch illumination lite 147 Turn signal lite, right rear 120 @ - in instrument panel wiring harness
Heating element (crankcase Turn signal switch 113,114
ventilation) 12 @ - near digifant wiring harness
High-beam headlite, left 98 Voltage regulator 5,8 .
High-beam headlite, right 109 Voltage stabilizer 64 Plus Connections
Hom button 126 @- terminal 30, in wire distributor box
Warm air blower 148
Horns 129
Warm air blower switch 148,149
Idle speed stabilizer valve 40,41 Washer/wiper intermittent relay 153-155
@- tenninal 58b, in instrument panel
Idle stabilizer control unit wiring harness
36,42 Windshield washer pump 156
Ignition coil
Ignition distributor
14
13-15
Windshield wiper motor
Windshield-wiper intermittent
150,151 @- in digifant wiring harness
Ignition/starter switch 8-11 switch 152-155

Main wiring diagram

97.86 Current track Index

from VIN G 055 690
Water-cooled- Digifant 1986
 Electrical System - Wiring, Waterboxer 97

~----------~--+------+---.---+-------------------4--b

0.5 0.5 1.0 4.0 4.0 1.5

R BL R/BK R/BK R BK

2.5
R

2.5 0.5 0.5

BKIY BK GY/BK

1.5
R

6.0 2.5 87 49 131

R R

o... WIRING
COLOR CODE
BK -BLACK
BR -BROWN
VOLTAGE
CL - CLEAR
REGULATOR
R -REO
Y - YELLOW

4.0 25.0 G - GREEN

BR L T G- LIGHT GREEN
BL -BLUE
V - VIOLET
GY - GRAY
W - WH!fE
OR - ORANGE

~) CD
2 3 4 5 6 7 8 9 10 11
'197--2-4-10-,1

Main wiring diagram

Water-cooled- Digifant 1986 Alternator/Starter
from VIN G 055 690 97.87
97 Electrical System -Wiring, Waterboxer
30 30
15 15
X X
31 311
~ ~
a
.. 2
a

D Ss
7 8 6 3 10A

023 015 E12 C18 06 013 N C21 019 026

1.5 0.5 WIRING 0.5

BK G COLORCOOE G
BK -BLACK
BR -BROWN
Ct. - CLEAR.
R -RED
Y - YELL.OW
G - GREEN
LT G - LIGHT GREEN

T2~ T7a/5 BL
V
-
-
BLUE
VIOI..ET
_ _, . 1.0
GY - GRAY
BKIW W -WHITE
OR -ORANGE. OIGIFANT CONTROL
15 UNff

IGNITION
COIL
®
t25 .8 ~ .6 .9 .21 .17 .10 tn
~.0 1.5 0.5 0.5 0.5 w 0.5 1.0 0.5 0.5 1.0 0.5
BK BR/W w w w w w
G A/BK G 57
_,
I
I
1(~4)
I I I I
~ .,-~~-=:---....--

L I

u,
9 21 17 10 11
0 .5 0.5
BRIW 1.0 BR/W 1.0 w
•
IONfTION BR 20
DISTRIBUTOR

HAU GENERA TOR

2/0

<D
.1/-

lr ~ AIR FLOW SENSOR

POTEN170/IIETER
I

HTG
ELMNT
(CRKCASE
VENT)
SPARK PLUG
CONNECTORS

SPARK PLUGS
1HIIOffi<VALI'E
SWTTCH
(ENRICH/IIENT)
8.l [!]TEMPERATURE

I
SENSOR I

1.0 0.5 0.5

BR RIY w
I

12
@
13 14 15 16 17 18 19
l20
48

~
21 22 23 24
l®iil

Main wiring diagram

97.88 Dlgifant system

from VIN G 055 690
Water-cooled- Digifant 1986
 Electrical System - Wiring, Waterboxer 97

E4 01 G6
WIRING
COLOR CODE
1.0
RIBK 8K -BLACK
8R -BROWN

f
1 T7a/6 CL -CLEAR
R -RED
Y - YEU OW
0.5 G -GREEN
w LT G - liGHT GREEN
BL -BLUE
I V - VIOLET
45 GY -GRA Y
W - WHITE

0.5W OR -ORANGE

1.0 BKIW

1.0 2.5 1.0 1;0 1.0 1.0 1.0 0.5 1.5 1.0
w w w w w w W BK BRIR BR
I I I I I I
55 12 26 f7 28 29 32

0.5 1.0
BK R INJ, /NJ, INJ, INJ,
CYL CYL CYL CYL

~. ~ ~ ~
FUEL
PUMP

'I 'i 'i'

1.0 1.0 w 1.0 w 1.0 w 1.0
BR I I I BR
15 22 23
T2a

® ®
25 26 27 28 29 30 31 32 33 34
197-2412 1

Main wiring diagram

Water-cooled- Dlglfant 1986 Dlglfant system
from VIN G 055 690
97 •89
97 Electrical System - Wiring, Waterboxer

C2 Cll
0.5 0.5 0.5
BL BL BUG

~
T
0.5
w WIRING
COLOR CODE
I
45
IlK - BLACK
/IR - lliiOWN
Cl. - CLEAR
R -RED
IJU STABILIZER Y - YELLOW
t/50 CONTROL UNIT G ~GREEN

L r. G - LIGI·Ir GREEN
81. - BLUE

A 1:
14/15 t 5/LH t 5/31 ;13/T ;8/LS i4/ST2 ill/STl ;2/K ;17/1
V
GY
W
OR
-
-
VIOI.Er
GRA Y
-WHir£
- ORANGE
0.5 0.5 0.5 1.0 1.0 0.5 0.5 0.5 0.5 0.5
BK W W BR W RIY W Y WIG w
I I I I I
53 52 48 46 58

T.D.C. SENSOR

r--:. ;_ •1
------ -
32 21 20 Tic

0.5
T1e
,
(

~-- -r--
\
'

w y BK y
~OXS
[tJi [tj I
57
CAT
I
l
POWfR STEEIIINO IOU SPEED ELAPSED
PRESSURE SwrrcH STABILIZER YALYE 11/I.EAGE
COUiirER
0.5
BR
T3 T3 T3

35 36 37 38 39 40 41 42 43 44 45
I®
46
197-2413 1

MaJn wiring diagram

97.90 Idle stabilizer control

from VIN G 055 690
Water-cooled- Dlgifant 1986
 Electrl,eal .System- Wiring, Waterboxer 97
~
15
=-. .-,==-:-..-,
..... .
-~
-,
.. . ..........
~. · .
•...
·.£ .... . ...
..
r· .

" -"-
I
m
15
--~
--~

X c= ~ - -.
~

X
131 -~· 31
6~
. :' ... .. ·'
. ' l-1t 1.6 , 4

; !~~ ...::.
,.
.
7 \2 •\

·~ ~- . t----1 r-1
E15 021 II ~ 81 824 819 :.\3 DB A27 03 818 815 821 K3 82 El 0

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

y BLJBK BL BL BLJG G BLJBK y

~
1
'
0.5
BK
0.5

T14114L./5
R

Tl-4/9 T14/13
0.3 1,8
,71
5 Jn-4 ®
15

T7at7 Tiib/1

G5 -TA~R
Jl14 - ENGINE OIL PRESS CNTRL I/NIT
IC2 -ALTERNAToR WARNING LITE
K3 -ENGINE· OIL PRESS WARN UTE
IC21 - OXS ELAPSED 11/LE /NO
Y:l - DIGITAL CLOCK

T2x T2x
0.5 0.5
BR BR

SJ_
WIRING
COLOR CODE
ENGINE OIL BK -BLACK
PRESSURE SWITCH
(0.3 BAR) BR -BROWN
CL -CLEAR
R -RED
Otl. y - YELLOW
PRESSURE
SWITCH G -GREEN
(1.8 LT. G- LIGHT GREEN
BAR) n4/3 BL -BLUE

1
0.5 1.5
v
GY
w
-
-
VIOLET
GRAY
-WHITE
BR BR OR -ORANGE

@ @ @)
47 48 49 50 51 52 53 54 .5 5 56 57
197-24141

Main wiring diagram

Water-cooled- Digifant 1986 Instrument cluster
from VIN G 055 690 97.91
97 Electrical System - Wiring, Waterboxer

A17 A28 83 87 K2 817 K1 029 E5

0 .5 0.5 0.5 0.5 1.0

BUR BLJW V/BK Y/R V/BK

'0.5
GY/BL

L" T14/IO Tl4/2

T7a/3 T7a/2

G1 -FUEl. GAUGE

~
G3 -COOLANT TEMPERATURE GAUGE
J6 - VOt.TAGE STABIUZE,R
Kt - HEADUTE HI-BEAM WAIWNG UTE
K5 - TURN SIGNAL I#DICATOR UTE
K28- COOLANT OVERifEAT WARNING UTE
U - Cl.OCK UTE
1.10 -INSTRUMENT PANEl. I."E
0.5
BR

~[fJ rn~
WIRING
COLOR CODE

r-
SEND .9 GAUGE
BK -BLACK UNIT SEND
BR -BROWN
CL -CLEAR
J31
R - RED
y - YELLOW
G - GREEN
LT. G - LIGHT GREEN
BL -BLUE
v - VIOLET 0.5 1.5 1.5 1.0
GY -GRAY BR BR BR BR

I~R -WHITE
-ORANGE
c& rrL I@ I(i~')
58 59 60 61 62 63 64 65 66 67 68 69 70 71
197-24151

Main wiring dJagram

97.92 Instrument cluster

from VIN G 055 690
Water<ooled - Diglfant 1986
 Electrical System - Wiring, Waterboxer 97
30 ~
. ----~----~-----=======~--~~--~--~~~--
~==~~~~=============-~- 30
15 - 15
X X
31 -- - ... 31

1.5 0.5 0.5

A R R
.-------------~ T2c ~

GY/BL
rjr.rjr.
0.5
'0.5
GY/BL

TO
RADIO
CONN
TO
0.5
A

RADIO
CONN
0.5
A

I T2d
0.5
A
30
MAP INTERIOR
READ LITE,
LT. REAR
RF
31 T
0.5
TO RADIO BR 0.5 0.5 0.5 0.5
0.5 CONNEC'OON 0.5
BA i T2d
BA BA!W BR!W BR!W BR
T4

~ ~
0,5 0,5
BR BA

oooOOM~
WIRING
DOOR COLOR CODE
LTR · UGHTER CONTACT
UTE SWITCH, BK - BLACK
RIGHT BR - BRO WN
FRONT
31 CL - C LEAR
R - RED
- YELLOW
1.5 G - GREEN
BR LTG - LIGH T GREEN
BL - BLUE
- VIOLET
GY - G RA Y
w - WHI TE
OR - O RANGE

'20)
~~ @ rio! ~~)
'-~

72 73 74 75 76 77 78 79 80 81 82 83
197-2416 1

Main wiring diagram

Water-cooled- Oiglfant 1986 Interior lights
from VIN G 055 690 97.93
97 Electrical System - Wiring, Waterboxer

810 Ml 827 A24 G9 El

1.0 1.0 0.5 1.0 0.5 0.5 0.5 0.5 0.5

RIY RIY BKIY W/BK GY GY GY/R GY/BL GY/G

WIRING
10 COLOR CODE T2i
BK -BlACK
BR -BROWN
CL -CLEAR
R -RED
y -YELLOW
G -GREEN
LT G - LIGHT GREEN
BL -BLUE
V - VIOLET
GY -GRAY
W -WHITE
2.5 2.5
OR - ORIWGE
BKIY W/BK

LITESWTTCH 158b
0.5
GY/BL

I 0.5
S5orflm
lOA~
LICENSE
PLATE
l,ITE £ GY/G

0.5
BR
0.5
BR

f"
@I I I I
0.5 0.5 0.5 0.5 0.5
GY/BL GY/BL GY/BL GY/BL GY/BL

~ Ju ~ Jg
84 85 86 87 88 89 90 91 92 93
'94 95 96
'197--2-4-17'1

Main wlrtng d1agram

97.94 Light switch

from YIN G 055 690
Water-cooled-Digifant 1986
 Electrical System -Wiring, Waterboxer 97

1.5 1.5 0.5 0.5 2.5 2.5 0.5 0.5 1.5 1.5
w Y GY/BK GY/BK y w GY/R GY/R Y/BK W/BK

1T
1.0
RIY
2.5
WIBK

Main wiring diagram

Water-cooled- Digifant 1986 Exterior lights
from VIN G 055 690 97.95
97 Electrical System - Wiring, WaterDoxer

1.5 1.0 1.5 1.0 1.0 1.0 1~ 1~ 1~ 1~

BK!BL W RIW BKIW/G BK!G BKIW BK!W 13KIW BK!G BK!G

~
~ TURN
IGNAL
WTTCH
!
\
I

1.0
BKIW/G
I
r r
1.0
BK!G
1.0
BKIW
T711 1 Tm
' EMERGENCY
FLASHER
15 49 30
~
~49o ~ ~l WARNING
UTE

:__;_J '[..__ •T -· -'T ~0

EMERGENCY
FLASHER SWTTCH r--158b r1
WIRING 0.5 0.5
0.5
COLOR CODE GY/BL GY/BL BR
BK -BLACK
BR - BROWN
CL - CLEAR
R -REV Bl BL BL BL
y TURN
- YELLOW TURN TURN TURN
(9W.- -fW. C) f~ Q9LT,
G -GREEN S/G
LT. G- LIGHT GREEN
LR LF RR~ RF
BL -BLUE
v
GY
w
OR
-
-
-
-
VIOLET
GRAY
WHITE
ORANGE
I
1.0
I
1.0
BR BR
~ 94

u u
v
w

® @) @
110 111 112 113 114 115 116 117 118 119 120 121
197-24191

Main wiring diagram

97.96 Tum signals

from VIN G 055 690
Water-cooled- Digifant 1986
 Electrical System -Wiring, Waterboxer 97
30 30
15 15
X X
31 31
58 I 58
I I' I r-:t-• A2
~2 515· D 516
~UA , lOA
1 ·~3
, 15A

:::---1 rl
C3 IC1 JE16 016 C20 l1 L4 L2 IB25,C15 C13 L3

1.0 1.0 1.0 1.0 1.0 1.5 1.5

RIY R/BK BKIR BKIGY BRIBL BR/BL BKIY

BACK-UP
LITE
SWITCH

'i'
1.0
BKIBL

T1b

HORN

1[:1}tfJI
BRK
LT
'--+-----}-J sw

1.0
BKIBL

BRAKE
LITE,
LEFT
LBCK-lJP
LT,
R
RF
BACK-UP
LITE,
LEFT
71
HORN
BUTTON
-
WIRING
COLOR CODE

BK - BLACK
BR - BROWN
CL -CLEAR
R - RED
1.0 Y - YELLOW
BR G - GREEN
LT G - LIGHT GREEN
BL - BLUE

u-------------------+---------~ V - VIOLE T
GY - GRA Y
W - WHITE
OR - ORANGE

122 123 124 125 126 127 128 129

Main wiring diagram

Water-cooled- Dlglfant 1986 Brake lights/Horns
from YIN G 055 690 97.97
97 Electrical System - Wiring, Waterboxer
30
~

u ,,••
. 30
J 15
15
X !X
I
31 ~
31
58
....·

a. '
12

I~ ~Su
Lf3 518
lOA 20A

~25 C22
B20

0 .5
.
0.5
07 G2 G5 B16

1.5
A23

BK BK BK!W

K7 -BRAKE AND PARKING BRAXE INDICATOR LITE

K10- REAR WINDOW DEFOGGER INDICATOR LffE
K19- SEAT BELT WARNING LITE
L39- REAR WINDOW DEFOGGER SWITCH LITE

DtJ CiJ ripl

WIRING 0.5 0.5 0 .5
COLOR CODE GY!BK R/BK GY/BL
BK -BLACK 7/ 15 • 8 /50

'11--;:~=~=~~==::ty~~,:. ;1.~ )/31 !"""

BR -BROWN
CL
R
-CLEAR
-RED
I L39
Y - YELLOW
G - GREEN (4131
LT G - LIGHT GREEN
0.5 0.5 0.5 0.5 0 .5
-BLUE
BL
Y/R GY/G BUBR BR BR
v - VIOLET
GY -GRAY
l
w -WHITE
DR -ORANGE

1.5
BK

0.5 0.5 0.5

GY BR
T1 9 1 T1a

PARKING BRAKE
BR~~>'E FLUID
WARN;."JG LEVEL

SAFETY BELT
SWITCH. RIGHT
LITE
SWITCH I WARNIIiiG
CONTACT

0 .5 1.5
BR BK
77

®
130 131 132 133 134 135 136 137 138 139
j97-2421 l

Main wiring diagram

97.98 Indicator lights

from VIN G 055 690
Water-cooled - Digifant 1986
 Electrical System - Wiring, Waterboxer 97
30
15
. - - 30
15
X X
31 31

1 r.l I
r--

~ sis , -4/3011
513 St H(c :r-----:\ IRADCOOLFAN
RLY (ZND STG}
~20A ~30A ~6'86 8/87 ' 7

J
A22 C7 H6 H3 'Hl H4 H2 H5

1.0 2.5 1.5 2.5 1.0

BK/R RJW R/Bl A BR

'
E9 -FRESH AIR FAN SWITCH
EIOO- WARM AIR BLOWER SWITCH
L16 - FRESH AIR CONTROL LEVER LITE 1.5
L50 -HEATER FAN SWITCH ILLUMINATION
LITE BKIY

FRESH
AIR
CONTROL
LEVER
~
0 .5
GY/Bl
FRESH
AIR
FAN
SWITCH

WJ=il
RADIATOR
COOUNG FAN
HTR
FAN
SW
ILLUM
LT
~
0.5
GY/Bl
WARM
AIR
BLOWER
SWITCH

'-±---+-:::---+-::---+-:---'
I T
TH

f
LITE
'12
.--'j~1~~ O.!j 1.5 1.5 1.0
0.5 1.5 1.5 1.5 2.5 WIRING BR Y Y/BK W
BR Y Y/BK w BK/R COLOR CODE
I T4a T4a T4a
8K - BI.ACI(
~ -BROWN
CL -CLEAR
R -REV
FRSH Y - YELLOW
AIR G -GREEN
BLWR LT. G- LIGHT GREEN
SERIES Ill. - BI.UE
RESIS V - VIOt.ET
GY - GRIIY
W -WHITE
1.5 OR -ORANGE
y
7 I T3b I T3b

2
RADIATOR WARM AIR
COOLING FAN BLOWER

1.5 2.5 1.5

BR BR BR

t'
'T3b

140 141 142 143 144 145 146 147 148 149
l,-97--2-4-2---,
21

Main wiring diagram

Water-cooled- Digifant 1986 Fans
from YIN G 055 690 97.99
97 Electrical System - Wiring, Waterboxer
30~=;====~~~~~~--~====~--~~~----~------~==~--~------~30
15 15
X X
31 31

A6 89 A5 A2 A12 A14 A19 C9

1.5 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 0.5 1.0 0.5 0.5
BR BR G/BK G!Y GY/BK G G ~~ ~ G~ ~~ GM ~ G/R

WINDSHIEL().MPER
INTERMITTENT
SWITCH

WIRING
Cot.OR COOE
53 53b 53a 53e +

!" ~- --~----~----;s I:~IELDMPER ~--

BK -BLACK
BR -BROWN WASHER
I CL
R
- CL EAR
-REO
PUMP
y
G
- YELLOW
- GREEN
LT. G - LIGHT GREEN
I
0.5
BL - BLUE BR
v - VIOLET
GY - GRAY
w -WHITE
OR -ORANGE

(10) (@)
150 151 152 153 154 155 156
197- 24231

Main wiring diagram

97.100 Windshield wipers

from YIN G 055 690
Water-cooled- Diglfant 1986
 Electrical System - Wi ring, Waterboxer 97
30 30
15 15
X X
31 31

1vs3c I 4/31 3153a J 2 L

ml ® G--- ;\'IREWASHRLY
WINO WTPRI 512 D

y
z
T
D5
l
'-'GlO E7

1.0
2/53

E2

1.0
lE84GI.
1.0 1.5
r:· [ l
BKIW G/BK BK!GY BKIY

T3c T3c ! T3c 14

WIRING
COLOR CODE

T3d BK -BLACK
BR - BROWN
CL -CLEAR
R - RED
Y - YELLOW
G -GREEN
L T_ G- LIGHT GREEN
BL - BLUE
V - VIOLET
GY - GRAY
W -WHITE
OR - ORANGE

SHIELD 53 53a
~ER
r*l ~ REAR WINDOW
I
L¥1 REAR WINDOW
~WIPER MOTOR

r1
WASHER PUIIP

I
1.0 1.0
BA BR

I@
157 158
I®
159 160 161

Water-cooled-Dlgifant 1986
Main wiring diagram
Reat window wiper
from VIN G 055 690
97.1o1
 Electrical System - Wiring, Waterboxer 97
Separate fuses above fuse panel
Power windows ..... . . .. ... .. ... . ........... 30
AIC . ......... .. .. . ... ... .. .. . ... . . . . . ...... 30
Fuse/Relay Panel
IJ - coolant level control unit
II - rad . cool. fan relay, 2nd stage
II - load reduction relay
IDJ - intermit!. wash/wiper relay
II - rear window wash/wiper realy
II - emerg. flash/turn sig . relay
IIJ- not used
Fuse arrangement
IIJ -fuse, terminal 58b
according to numbers on fuse panel as seen from
left to right:
Amp.
Radiator fan . . . . . . . . . . . . . . . . . . . . . . . . 30
2 Stop lights . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Cigarette lighter, radio, clock, interior lights,
central locking system . . . . . . . . . . . . . . . . . 10
4 Emergency flasher system . . . . . . . . . . . . . . 15
5 not connected
6 Vacant
7 Tail, parking and side marker lights, left 10 197·13921
8 Tail, parking and side marker lights, right . . . 10
9 High beam right, high beam indicator light . . 10
10 High beam left . . . . . . . . . . . . . . . . . . . . . . . 10 Connections and plugs on fuse/relay panel
11 Wind. wipers and washer . . . . . . . . . . . . . . . 15 A - multi-point connector (blue) for instrument
12 Heater fan, rear wiper, cruise control, A/C, panel wiring harness
outside rear view mirror adjustment . . . . . . . 20 B - multi-point connector (red) for instrument
13 Fresh air fan . . . . . . . . . . . . . . . . . . . . . . . . . 15 panel wiring harness
14 Rear window defogger . . . . . . . . . . . . . . . . . 20
C - multi-point connector (yellow) for front wiring
15 Back-up lights, shift console light
harness
(Auto. Transmission) . . . . . . . . . . . . . . . . . . 10
D - multi-point connector (white) for windshield
16 Horn (single tone) ..... ..... .......... 15
wiper and main wiring harness
17 Windshield wiper motor . . . . . . . . . . . . . . . . 10
E - multi-point connector (black) for main wiring
18 Dual horn, coolant level and temp.
warning light . . . . . . . . . . . . . . . . . . . . . . . . . 10 harness
19 Turn signals , brake warning light . . . . . . . . . 10 G - single connector
20 License plate lights . . . . . . . . . . . . . . . . . . . 10 H - multi-point connector (brown) to connector for
21 Low beam left . . . . . . . . . . . . . . . . . . . . . . . . 10 rad . cool. fan relay, 2nd stage
22 Low beam right . . . . . . . . . . . . . . . . . . . . . . 10 K - multi-point connector (colorless) to radiator
coolant low-level control unit
L - multi-point connector (gray) for horns
M - open position
N - single connector
P - single connector (terminal 30)
R - open position

Water-cooled- Digifant 1987

Fuse/Relay panel 97.102
97 Electrical System - Wiri ng, Waterboxer

DMcrlpllon Cunent triCk Description Current track Wire conllllttors

AIC compressor ovemeat fuse 151 Instrument panel t~e dimmer sw~ch 95 T2c -double, under inst. panel, left
Air flow sensor potentiometer 22-24 Interior lite, front 77,78 T2d - double, under upper right 'A' pillar
Alternator 5 T2e - double, in decklid near washer motor
License plate lite 96,97
Alternator warning l~e 51 T2f -double, under upper right 'C' pillar cover
L~e switch 85-95
T2g -double, under inst. panel
Back-up l~e ~h 128 Load reduction relay 86·88 T2i -double, in wire distrib., eng compart.
Back-up l~e. lelt 128 T2k ~ 9oo!J~. eng. compart., left
Back-up l~e. right 129 Make-up mirror lite 76
Map/reading l~e. right front 75 T2m- double, in relay plate, eng. compart.
Battery T2o - double, near seat beij sw~ch
Braka and parlting brake indicator l~e 137 OXS elapsed mileage indicator 52 T2p - doullle, near hom
Brake fluid level warning contact 138 Oxygen sensor 25,26 T2x - double, eng. compart., middle
Brake l~e sw~ch 125,126
Brake l~e. lelt 127 Par1<ing brake warning l~e switch 137 T3 - three-point, near alternator
Brake l~e. right 126 Par1<ing l~e. left 101 T3a -three-point, under inst. panel, right
Par1<ing lite, right 107 T3b - three-point, under inst. panel, lelt
CAT elapsed rrileage counter 45,46 Power steering pressure switch 36,37 T3d - three-point, behind upper front grille
Cigarette light81' 72 T3x - three point, under inst. panel
Cigarette lighter l~e 73 Radiator cooling ian 145
Clock l~e 61 Radiator cooling fan relay (2nd stage) 147-150 T71 -seven point, in wire distrib., eng. compart.
Coolant low level control un~ 68,69 Radiator cooling fan thermoswitch 145, 146 T7al- seven point, in wire distrib., eng. compart.
Coolant low level warning sw~ch 68 Reading l~e. behind driver's seat 80,81
Coolant overheat warning l~e 66 Reading l~e. left rear 82,83 T141- fourteen point, on inst. cluster
Coolant temperature gauge 65 Rear window defogger indicator lite 140
Coolant temperature sending un~ 70 Rear window defogger switch 139-141 Ground connections
Rear window defogger swrtch lrte 139
Digifant control un~ 16-27 Rear window heater element 141 G) - battery to body
Digijet control un~ relay 32-34 Rear window washer pump 160
Digital clock 53 Rear window wiper motor 162,163
G) - transmission to body
Door contact sw~ch. lelt front n,78
Door contact switch, right front 81
Rear window wiper/Washer relay 161,162 @- in eng. compart., left
Safety beij sw~ch, left 134
Emergency Hasher relay 114.115 Seat beij warning l~e 136
@- on engine block
Emergency flasher switch 111-120
Emergency flasher warning lrte 120
Seat beij warning relay 133-136 @- ground cable, above steering box
Side mar1<er t~es, rear 104,105
Engine oil pressure control un~
Engine oil pressure switch (0.3 bar)
55;56
48
Spar1< plug connectors 13-15 @- near Digifant control unit
Spar1< plugs 13-15
Engine oil pressure swrtch (0.9 bar) 47 Starter 3.4 @- under relay panel
Engine oil pressure warning l~e 57
T.D.C. sensor 43,44 @- in rear decklid, left
Fresh air blower series resistance 144 Tachometer 54
Fresh air control lever l~e 142 Taill~e. tell 102 @- in rear decklid, right
Fresh air fan 143,144 Tail l~e. right 106
Fresh air fan switch 142-144 Temperature sensor II 21
@- near rear washer bottle bracket
Fuel gauge 64
Fuel gauge sending un~ 71
Terminal 58b fuse 95 @- near rear wiper motor
Throttle valve switch (enrichment) 20
Fuel pump 31 Tum signal indicator lite 62 @- near left rear decklid hinge
Fuel pump relay 30,31 Tum signal lite, left front 122
Fusa 12 Tum signall~e. lelt rear 121 @- in inst. panel wiring harness
Turn signal lite, right front 124
Hall generator 17-19
Tum signall~e. right rear 123
@- in Digifant wiring harness
Headl~e dimmerlftasher switch 103,104
Tum signal switch 116,117
Heedl~e high beam warning l~e 63
Plus ( +) connections
Headl~e. lelt 98,100 Voltage regulator 5
Headl~e. right 108,110
151,152
Voltege stabilizer 64 @- (term. 30) in wire distrib., eng. compart.
Heater blower series resistance
Heater fan sw~ch illumination lrte 149 Warm air blower 150-152 @- in Digifant wiring harness
Hea!ilg element (crankcase ventilation) 12 Warm air blower sw~ch 149-152
High-beam headl~e. lelt 99 Washer/Wiper intermittent relay 158-158 @- in Digifant wiring harness
High-beam headl~e. right 109 Windshield washer pump 159
Hom button 130 Windshield wiper motor 153,154 @- (term. 586) in inst. panel wiring
Windshield-wiper intermittent sw~ch 155-158 harness
Horns 132

Idle speed stabilizer valve 40,41 Wire connectors

Idle stabilizer control unrt 36-42
T1a -single, near left rear roof bow
lgn~ coil 14
T1b -single, in wire distrib., eng. compart.
lgn~ distributor 13-15
T1d -single, in wire distrib., eng. compart.
lgn~ionistarter sw~ch 8-11
T1e -single, under inst. panel, left
Injector, cyl. 1 27
T1f - single, under inst. panel
Injector, cyl. 2 28
T1g -single, in wire distrib., eng. compart.
Injector, cyt. 3 29
T1h -single, in eng. compart., left
Injector, cyt. 4 30
T1i - single, under inst. panel
Instrument panel l~e 58-60
T1k -single, in eng. compart., left

97.1 03 Main wiring diagram

Current track Index
Water-cooled - Dlgifant 1987
 Electrical System - Wiring, Waterboxer 97
30 30
15 15
X X
31 31
61
a

p -c p p p p p 024 E13 ,/1 B4 B8 p A8

6.0 6.0 0.5 0.5 1.0 4.0 4.0 1.5

R R/BK BL RIBK R/BK R BK

138

1.5
R

2.5 0.5 0.5

BKJY BK GY/BK

1.5
R

~)

2.5 87 49 13
6.0
A A

D811. D+
70.0
WIRING
COLOR CODE
BAITERY ALT
8K -BLACK
BR - BROWN

j CL
R
y
-
-RED
-
CLEAR

YELLOW
25.0 25.0 G - GREEN
LT G - LIGHT GREEN
BL - BLUE
v - VIOLET
GY -GRAY
w -WHITE
OR - ORANGE

CD (2j'1
2 3 4 5 6 7 8 9 10 11
197-26241

MaJn wiring diagram

Water-cooled- Dlgifant 1987 AHemator/Starter/
Ignition swHch 97.104
97 Electrical System -Wiring, Waterboxer
30 --------------------------------~------------------------------------------ 30
15------~~------------------~--+------------------------------------------- 15
X------~--------------------+---+------------------------------------------- X

3161a ;;;;l;;;;;;;;~;;~t;~~~~~~~~~~~~ a61

311

4 2
lfl
7 8 6 3

023 015 E12 CIS 06 013 N 019 026

1.5 0.5 WIRING 0.5
BK G COLORCOOE G
BK -~CK

BR -BROWN
CL - CLEAR
R - RED
Y - YELLOW
G - GREEN
LT G - LIGHT GREEN

lig~ T7a/5 BL
V
-
-
BLUE
VIOLE T
_ _, . 0.5 GY -GRA Y
BK W -WHITE
Ofl - ORAN(K DIGIFANT CONTROL
15 UNIT

f25 .8 ~ t6 .9 .21 .17 .10 t ll

1.0 1.5 0.5 0.5 0.5 w 0.5 0.75 0.5 0.5 0.75 0.5
BK G R!BK G 57 BR!W @ W W W w w

~.~--~~--~·t-----l~-0-.7~ w I~
I I

II
10 11
2111 1117

1GNmON
DISTRIBUTOR
1 31+ 1 210 l11- \ o, ~ f'lJ'
~~ L.....±---±-±----,1:-'- - ------4~) © I 1 . ~ ~.
1
HALL GENERATOR AIR FLOW SENSOR
POTENTIOIIETER

1.0
BK

HTG
ELMNT rrtTI
I SPK PLG CNCTRS
(CRKCASE
VENT} ' .,_.-+----+--+-'SPARK PLUGS

I
1.0
BR
0.5
R/Y
0.75
w
I

12 13 14 15 16 17 18 19
l20
~
48

21 22 23 24
197·26251

97.105 Main wiring diagram

Dlgifant Injection system
Water-cooled- Dlgifant 1987
 Electrical System - Wlrlhg, Waterboxer 97
-30
-15
-X
-31
1
=61
-a

E4 A4
WIRING
COLOR CODE
1.0
R!BK BK - BLACK
BR - BRO W!\'

T
1 T7a/6 CL - CLEAR
R -RED
y - YELLOW

0.5 G - GREEN

w L T G - - LIGHT GREEN
BL - BLUE
I v - VIOLET

[osw-J~
45 GY - · GRAY
w - WHITE

0.5 w OR - ORANGE

~1 DIGIFANT CONTROL
UNrr 3 ~~

F @ :1 ~. ------
~
1 12

~
.14

r
2.5 R/W
I
1 0.5 BKIW .w
2.5
30
@)
2.5 1.0 0.5 1.0 1.0 2.5 0.75 0.75 0.75 0.75 1.0 0.5 0.5 0.5
BR BR w w w w w w w w BK BR/R BR
I I I I I I I I
42 55 12 26 27 28 29 32
~

1.0
BR
•
1.0
BRIG

(12)
25 26 27 28 29 30 31 32 33 34
j97-2626j

Water-cooled- Digifant 1987 Main wiring diagram

Digifant injection system 97.106
97 Electrical System -Wiring, Waterboxer
30----------------------------------------------------------------------------30
15 15
X X
131 311
~ ~

C2 Cll
WIRING 0.5 0.5 0.5
COLOR CODE
BL BL BUG
BK
BR
-BLACK
-BROWN ~
CL - CLEAR
R -REO

0.5 Y - YELLOW

w G -
LT G -
GREEN
LIGHT GREEN

I
45
BL
V
-
-
BLUE
VIOLET
GY - GRAY
W -WHITE
OR -ORANGE
IDLE STASILaER
16/50 CONrFIOI. UNfr

14/15 f5/LH 15/31 r3/T 18/LS r/ST2

1
11/STl r/K 1 17/1

0.5 0.5 0.5 0.5 0.75 0.5 0.5 0.5 0.5 0.5
BK w w BR w RIY w y WIG w
I I I I I
53 52 48 46 58

21 20 T1k T1n
,--r-
(
----- -

~
')

PWR
STRG
PRESS
SW
~ , .
SPEED
STABILIZER
VALVE
0.5
w
I
57
y BK y 1/61 4/0XS
CAT
ELAPSED
11/LEAOE
COUNTER

l T3 T3 T3
1 5/31
0.5
BR

I@
35 36 37 38 39 40 41 42 43 44 45 46
J97-2627 j

97.107 Main wiring diagram

Idle stabilizer
Water-cooled- Diglfant 1987
 Electrical System - Wiring, Waterboxer 97
30 30
15 15
X X
31 31
1
c61
n 31, 6 4

ID
7 2 5

I ~ J II
~
E15 ID21 Bl B24 B19 A3 DB A27 D3 B18 )B15 B21 K3 B2 ElO

0.5 0 .5 0 .5 0.5 0.5 0.5 0.5 0 .5

Y BU BK BL BL BLIG G BLIBK Y

~
cr
0 .5
~
0 .5
BK R

L" Tl4111 Tl4/14 t./5 T14/9 T14/13 T14/12

T7a/7 ' T7all

G5 - TACHOftiETER
Jt14 - ENGINE OIL PRESSURE CONTROL UNIT
K2 -ALTERNATOR WARNING LITE
K3 -ENGINE OIL PRESSURE WARNING LITE
K21 - OXS ELAPSED ftiiLEAGE INDICATOR
Y2 -DIGITAL CLOCK

'T2x T2x WIRING

COLOR CODE
0 .5 0 .5
BR BR BK - &ACK
ENG BR - BROWN
OIL CL - CLEAR
PRESS ENGINE OIL R -REO
SW PRESSURE SW"CH Y - YELLOW
(0.9 fl (0.3 BAR) G - GREEN
BAR)
0,9bar 0.3bar LT G - LIGHT GREEN
BL - BLUE
V - VIOLET
GY - GRAY
W - WHITE
OR - ORANGE
fT14/3
0 .5 1.5
BR BR

®
47 48 49 50 51 52 53 54 55 56 57
197-26281

Main wiring diagram

Water-cooled- Digifant 1987 Oil pressure warning
Instrument cluster 97.1 08
97 Electrical System- Wiring, Waterboxer

30----------------------------------------------------------------------------------30
~

~ 1~&31 !j'"
15 15

D
2
CLNT LOW LVL
CNTRL UN"
;,
7 3/85 4/86
49o
56o

A17 A28 83 87 K2 817 K1 029 E5

0.5 0.5 0.5 0.5 0.5 0.5 0.5 1.0

BUR BL!W V!BK Y/R BUG YIR Y/R V!BK

T
0.5
GY!BL

L" T14!10 Tl4/2 T14/7 T14/6

T7a/3 T7a/2

G1 - FUEL GAUGE
G3 - COOL.ANr TEMPERATURE GAUGE
J6 - vot.TAGE STABILIZER
Kl - HEADLITE HIGH BEAM WARNING UTE
KS - TURN SIGNAL INDICATOR UTE G COOL.ANr LOW
K2B- COOLANT OVERHEAT WARNING WE LEVEL WARNING
LB - CLOCK UTE SWITCH
LIO -INSTRUMENT PANEL WE
311
* Note 0.5
BR
Fuel gauge sending unit on Vanagon Syncro
grounds in engine compartment on left side

m-
WIRING

~[lJ
COLOR CODE
BK - BLACK TEMP 9 GAUGE
BR - BROWN T7a/4 SEND SEND
UN" UNIT

r
CL - CLEAR
R -REO 0.5 BR »31
- YELLOW
0.5 BR

~
G -- GREEN
LT G - LIGHT G REEN
Bl - BLUE
- VIOLE r
GY - GRA Y
0.5 1.5 1.5 1.0
w - - WHtr£:
BR BR BR BR
OR - ORANGE

~ Jr@~ 1* 29
58 59 60 61 62 63 64 65 66 67 68 69 70 71
@ifuj]

97.109 Main wiring diagram

Instrument cluster
Water-cooled - Digifant 1987
 Electrical System - Wiring, Waterboxer 97
30-----------------------------------------.-----------------------------------------30
15 15
X X
~ ~

1.5
R

I~Tat6~Tat7
0.5
GY/BL
ro-a
' 0.5
GYiBL

I roa
RADIO
CONN
0.5
A
0.5
R

RADIO
CONN
0.5
R

0.5
R
30
MAKE
UP
111/RR
LT
T
0.5
TORAD/0 BR
0. 5 CONNECTION 0.5 0.5 Q. 5 0.5 0.5
BR Tats T2d BR BR!W BA!W BRIW BR

WIRING
COLOR CODE
BK -BLACK
BR -BROWN
CL -CLEAR
R -RED
y - YELLOW
G -GREEN

~
L T_ G - LIGHT GREEN
BL -BLUE
V - VIOLET

lO
0.5 0.5 0.5
BR BR BR/W GY
W
-GRAY
-WHITE
+ 58b
OR - ORANGE
DR
CIGARETTE CIGARETTE CONTCT
UGHTER LIGHTER
LITE sw,
RF
31

1.5
BR

@@
72 73 74 75 76 77 78 79 80 81 82 83

Water-cooled- Digifant 1987 Main wiring diagram

Interior lights 97.11 0
97 Electrical System - Wiring, Waterboxer

30--~--------------~--------------------------------------------------------30
15 ~
X X
31-~------~r-------r-----r-~==============~====~~~~~~~~~~~~~3~8L
58R 58
1/85 2/30

u[f------{ 1:f~o
4/B6 3/87
~57 lOA
520~
lOA~

==~====~====~==~i===========~==~=================i=~
49a
56a

810 G7 Ml 827 G8 826 A24 G9 El

1.0 1.0 0.5 1.0 0.5 0.5 0.5 0.5 0.5

RIY RIY BKIY WiBK GY GY GY/R GY/BL GY/G

9 [!]~

2.5 2.5
BKIY WiBK IT2i
0.5
INSTR GY/G

I~
·~ ~ 56 ~
~
58L 58R - .,
J
58
PNL
LT
DIMR
sw

fl
.·

~-T
-n -I! -IT
LITE SWTTCH 158b

0.5
GYiBL

WIRING
COLOR CODE

BK
BR
CL
-

-
BLACK
-BROWN
CLEAR TERM 588 FUSE
Im_m 0.5
GYiG

•f ~':' f
R -RED
-- YELLOW
lOALt.J
G

V
--- GREEN
L T G- LIGHT GREEN
BL -
-
BLUE
VIOLET
ol
f5 no.5
BR BR
~T2i
GY - GRAY
W - WN/Tf @)
OR -ORANGE
0.5 0.5 0.5 0.5 0.5 0.5
GYIBL GY/BL GYIBL GY/BL GYiBL BR

~ ~ ~ ~ ~ r!J
84 85 86 87 88 89 90 91 92 93 94 95 96 97
197-2631 I

Main wiring diagram

97.111 Load reduction relay,

Light switch
Water-cooled- Digifant 1987
 Electrical System - Wiring, Waterboxer 97
30 30
15 15
X X

~k58
31

49a
~ 510
lOA
.
~521
lOA
"7,>

~522
lOA
1
~59lOA
58

49o
56a
;_ r--
C17 C5 C4 E9 M2 A21 B22 C14 C6 C16 B13
r18

1.5 1.5 0 .5 0.5 2 .5 2 .5 0.5 0 .5 1.5 1 .5

w Y GY/BK GY/BK y w GY/R GY/R Y/BK W/BK

WIRING
COLOR CODE

SK -BLACK
Ti
1.0
RIY
2 .5
W/BK
BR - BROWN
CL - CLEAR
R - RED
- YELL O W
G - GREEN
LT G - LIGHT GREEN
BL - BLUE
V - VIOLET I T7/5 T7t6
GY - GRAY
W -WHI TE
OR - ORANGE

~ii£R
~SW
56o 56_b___ .
..

Water-cooled- Digifant 1987 Main wiring diagram

Exterior lights 97.112
97 Electrical System - Wiring, Waterboxer
30 30
15 15
X X
31 31
58 58

~519
lOA
54
15
~ 1tvE+r
EMER
RLY
®If)
FLSH -
3/49o 2
49o

I I I I I
A13 A18 828 AlO All JA7 025 JA20 011 IC19 Ell
r6 r8
1.5 1.0 1.5 1.0 1.0 1.0 1.0 1.0 1.0 1.0
BKIBL W W/R BKIW/G BK!G BK!W BK!W BK!W BK!G BK!G

49o
II' TURN
SIGNAL
SWfTCH

1.0
IR
1.0
f
1.0
BKIW/G BKIG BK!W
Tm Tm

15 49 30
....,_
ljlll'49o

...
-
,..R ~ L
EIIERG
FLSH
WRNG
LT

~)
II

L....:....1 '[___ •T ""'I_

EMERGENCY ,....,58b ( 31
FLASHER SWITCH

WIRING 0 .5 0.5 0.5

GY/BL GY/BL BR

r
COLOR CODE
BK
BR
-
-
BLACK
BROWN
.
CL - CLEAR BL BL B BL
- RED
R
y
TURN TURN TVFIN
~ c~ ~ ~ f'f. 9~
- YEL LOW
G -GREEN
~
c~ - -
~
LT G - LIGHT GREEN LR LF RF
BL
v
GY
-
-
BLUE
VIOLET
-GRAY
I
1.0
I
1.0
w - WHITE
- ORANGE
BR BR
OR
Jj)~ 95

u u
v
w
@) ® @
111 112 113 114 115 116 117 - 118 119 120 121 122 123 124
!97-26331

Main wiring diagram

97.113 Emergency flashers

Tum signals
Water-cooled- Digifant 1987
 Electrical System - Wiring, Waterboxer 97
~ ~
15 15
X X
31 31
~ ~
),4 J2

~5215A ~515
lOA
lf:l ~516
15A
1 3

I I I r 1
C3 016 C20 L1 L4 L2 C13 L3
IC1 r16 r25 IC15

1.0 1.0 1.0 1.0 1.0 1.0 1.0

RIY RISK BKIR BKIGY BR/BL BR/BL BKIY

T29 T29 Tm

dl'tfJK·UP
Q.JswrrcH
'i'
1.0
BKIBL

T1b
1.0
RIY
1.0
BKIBL

4 1.0
BR

T2p
1.0
BKIR
154 Rf RF
BRK BCIC-UP BCK·UP WIRING
LT, LT, LT, COLORCOOE
R L R HORN
BUTToN BK -BUICK
BR -BROWN
CL -CLEAR

1.0 R -RED
y
BA - YELLOW
G -GREEN
LT. G - LIGHT GREEN
BL - BLUE

u
v - VIOLET
GY -GRAY
w - WHITE
OR - ORANGE
@
125 126 127 128 129 130 131 132
J97-2634J

Main wiring diagram

Water-cooled- Dlglfant 1987 Brakellghta
Horns 97.114
97 Electrical System • Wiring, Waterboxer

30----------------------------------------------------------------------------30

:~ II 2
lf.l
1
I~518
l
~56
I
~514
~
3 lOA 15A 20A
u4

J ), ),
~25 ~GS
820

0.5
.
0.5
07 G2 C22 816

1.5
A23

BK BK BKIW

WIRING
COLOR CODE
BK - BLACK
BR -BROWN
CL -CLEAR
R
Y
-RED
- YELLOW
OJ] BRK
G - GREEN 0.5
& REAR
PRK WINDOW
LT G - LIGHT GREEN GY/BK BRK DEFOGGER
SEAT BELT /NO

~'i£
BL - BLUE
V - VIOLET WARNING UTE 6/15 LT
GY - GRAY
W -WHITE

j21~~
OR - ORANGE

1.5
WIG

IT2c

1.5
BA

I - I oo ~~~
~ 11/G l "-
4/-31_ +_ _ __ .
0.5 0.5 0.5 0.5
GY GY GY/A BA
~Tle T3x T3x T3x
0.5 0.5
GY GY/G
SFTY
BLT PARKING RE
sw. BRAKE MHO
L WARNING HTR
UTE ELMNT
SWITCH

1.5
BK
7
1.5
BK

@ @ @ @ ® @
133 134 135 136 137 138 139 140 141
197-26351

Main wiring diagram

97.115 Seat beH system

Rear defogger
Water-cooled - Digifant 1987
 Electrical System - Wiring, Waterboxer 97
15 =
3 0 - - - - . - - - - I- - - 3 0
15

~ I ~
~513
I 5/85 14/30 I L 2RAO
COOL I
20A ~S1
.. .It tJ.----~ IFAN
RLY
30A (2ND
6/86 8/87 7 STG)

,___
I
A22 C7 H6 H3 JH1 H4 H2 H5

BK -BLACK
BR -BROWN
CL - CLEAR
R - RED
v - VEL LOW
G -GREEN
LT G- LIGHT GREEN
BL - BLUE
v - VIOLET
GV - GRAY
w -WHITE
OR -ORANGE

T3d T3d

FRSH
AIR
FAN
.!l RADIATOR
COOLING FAN
2

!"..,.
-
WARM
1.5
BR-.
'j AIC
~
HTR
2.5 AIR COMPRSR BLWR
BR BLWR 1.5 OVERHT SERIES
BR FUSE R£SIS
T3d
~
I

@ @ ®
142 143 144 145 146 147 148 149 150 151 152
197-26361

Main wiring diagram

Water-cooled- Digifant 1987 Radiator cooling fan
Fresh air fan 97.116
97 Electrical System - Wiring, Waterboxer
30-------------------------------------------------------------------------~
15 15
X X
31 31

6/5351 +3/15 I 4!31

~Sn
15A
~517
lOA
WASHIWIPR
INTERIIT
RLY
IV-~ ® lmJ
2/53M rVJ 5/T

I I I I I I
~020 012 109 02 1017 IA6 89 IA5 A2 A12
JAl:
A19 JC9
1.5 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 0 .5 1.0 0.5 0.5
BR BR G/BK GIY GY/BK G G GY/BK G/Y G/BK BRIBK G/W G/R G/R

53b 53 J L T
~,.c---:.J
1.. -.,.. -
i53a
-or '~T

53e
-~~ +
WINOSHIE~wrPER
21 roo· I
/NT'ERIIITTENT
SwrTCH

WIRING
COlORCOOE
53 53b 53a 53e

II" E - --E\ I~LDMPER BK

BR
Ct.
R
v
- Bt.AOK
-BROWN
-CLEAR
-REO
~=
I
-YElLOW
G -GRE~

LT. G- LIGHT GRE~

Bl -BLU£ 0.5
v - VIOLET BR
GV - GRAV
w -WHITE
OR - ORANGE

@ @)
153 154 155 156 157 158 159
197-26371

97.11 7 Main wlrtng diagram

Windshield Wipers
Water-cooled-Dlgifant 1987
 Electrical System - Wiring, Waterboxer 97
30 30
15 15
X X
31 31
- '

J1/53c 4/31 3/53a 2

I
Al
mr ® C¥--~1 ~512
20A •
REAR WINDOW ' 2/53 4 <' 3
WII'EMrASHER
RELAY
l )... )...
05 ~G10 E7 E2 E8 G3 Rl R2
'Gl
1.0 1.0 1.0 1.5
GIW GIBK BKIGY BKIY

T3b T3b I T3b 152

WIRING
COLOR CODE
flK -BLACK
BR -BROWN
CL -CLEAR
R -RED
· T3o T3a T3a y - YELLOW
G -GREEN
LT. G - LIGHT GREEN
BL - BLUE
v - VIOLET
GY -GRAY

T2f w - WHITE
T2f OR -ORANGE

1 T2e T2e

53 53a
~REAR WINDOW ~REAR WIVDOW
L¥J WASHER PUMP ~WIPER MOTOR

I r,
1.0
BR

I@
160 161 162 163 164

Water-cooled- Dlglfant 1987 Main wiring diagram

Rear window wiper
97.118
97 Electrical System - Wiring, Waterboxer

Fuse/relay panel
IJ- coolant level control unit
IJ rad. cool. fan relay, 2nd stage
II- load reduction relay
IDJ -'- intermittent wash/wiper relay
m- rear window wash/Wiper relay
m- emerg. flash/turn sig. relay
111J-fuse S50

Fuse arrangement
according to numbers on fuse panel as seen from
left to right:

Amp.
1 Radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2 Stop lights ............................... 15
3 Cigarette lighter, radio, clock, interior lights, 197-13921
central locking system ..................... 10
4 Emergency flasher system ................. 15 Connections and plugs on fuse/relay panel
5 Not used A - multi-point connector (blue) for instrument panel
6 Not used wiring harness
7 Tail, parking and side marker lights, left ...... 10 B -multi-point connector (red) for instrument panel
8 Tail, parking and side marker lights, right .... 10 wiring harness
9 High beam right, high beam indicator light ... 10 C - multi-point connector (yellow) for front wiring
10 High beam left ............................ 10 harness
11 Windshield, wipers and washer ............. 15 D mutli-point connector (white) for windshield
12 Heated seats, outside rear view mirror wiper and main wiring harness
adjustment ............................... 15 E - multi-point connector (black) for main wiring
13 Fresh air fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 harness
14 Rear window defogger .. . . .. . . . . .. . . . .. .. . 20 G - single connector
15 Back-up lights, shift console light (auto. H -multi-point connector (brown) to connector for
transmission) ............................. 10 rad. cooL fan relay, 2nd stage
16 Horn (single tone) ......................... 1b K - multi-point connector (colorless) to radiator
17 Windshield wipers ......................... 10 coolant low-level control unit
18 Seat belt warning relay, brake and L -multi-point connector (gray) for horns
park brake indicator ....................... 10
M - open position
19 Turn signals, brake warning light ....... : . ... 10 N - single connector
20 License plate lights ........................ 10 P - single connector (terminal 30)
21 Low beam left . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
R - open position
22 Low beam right ....................... , ... 10

97.119 Main wiring diagram

Fuse/Relay panel
Water..cooled- Dlgifant ·1988, 1989
 Electrical System - Wiring, Waterboxer 97
Deecrlptlon Current Description Current Description Current
track track track
Air flow sensor potentiometer 22,24 Fuel gauge sending unit 73 Radiator cooling fan 144
Alternator 5 Fuel pump 33 Radiator cooling fan relay
Alternator warning light 54 Fuel pump relay 32,33 (2nd stage) 146-149
Radiator cooling fan
Back·up light switch 128 Hall generator 17,18
thermoswitch 144,145
Back-up light, left 128 Headlight dimmer/flasher switch 104,105
Radio connection 76-79
Back·up light, right 129 Headlight high beam warning
Reading light, driver's seat 83
Battery 1 light 66
Reading light, left rear 85,86
Brake and parking brake Headlight, left 99,101
Rear window defogger indicator
indicator light 136,137 Headlight, right 109,111
light 139
Brake fluid level warning Heater blower 149
Rear window defogger switch 140
contact 137 Heater blower switch 148·152
Rear window defogger switch
Brake light switch 125,126 Heater blower series resistance 150-152
light 138
Brake light, left 127 Heater fan switch illumination
Rear window heater element 140
Brake light, right 126 light 148
Rear window washer pump 160
Heating element (crankcase
Cigarette lighter 74 Rear window wiper motor 162,163
ventilation) 12
Cigarette lighter light 75 Rear window wiperlwasher
High-beam headlight, left 100
Clock light 64 relay 161,162
High-beam headlight, right 110
Coolant low level control unit 70,71
Hom button 130 Safety belt switch, left 133
Coolant low level warning
Horns 131 Seat bel1 warning light 135
sw~ch 70
Seat bel1 warning relay 132·135
Coolant overheat warning light 69 Idle speed stabilizer valve 43,44
Side marker lights, rear 105,106
Coolant temperature gauge 68 Idle stabilizer control unit 39-45
Spark plug connectors 13,15
Coolant temperature sending Ignition coil 13,15
Spark plugs 13,15
unit 72 Ignition distributor 13,15
Starter 3,4
Ignition/starter switch 8·11
Digifant control unit 16,29
Injector, cyl. 1 29 T.D.C. sensor 46,47
Dlgifant control unit 16,29
Injector, cyl. 2 30 Tachometer 57
Digifant control unit relay 34-37
Injector, cyl. 3 31 Tail light, left 103
Digital dock 56
Injector, cyl. 4 32 Tail light, right 107
Door contact switch, left front 81,82
Instrument panel light 61-63 Temperature sensor II 21
Door contact sw~ch. right front 84
Instrument panel light dimmer Throttle valve switch
ECS·Malfunction indicator light switch 96 (enrichment) 20
and switch 20 Interior light, front 81,82 Turn signal indicator light 65
Emergency flasher relay 114,115 Turn signal light, left front 122
License plate light 97·98
Emergency flasher switch 112,120 Tum signal light, left rear 121
Light switch 88-96
Emergency flasher warning light 120 Tum signal light, right front 124
Load reduction relay 89·91
Engine oil pressure control unit 58,59 Turn signal light, right rear 123
Engine oil pressure switch Make-up mirror light 80 Tum signal switch 116,117
(0.3 bar) 52 Map/reading light, right front 78
Voltage regulator 5
Engine oil pressure switch
OXS Elapsed mileage counter 48,49 Voltage stabilizer 67
(1.8 bar) 50
OXS elapsed mileage indicator 55
Engine oil pressure warning Washer/wiper intermittent relay 156·158
light Oxygen sensor 27,28
60 Windshield washer pump 159
Parking brake warning light Windshield wiper motor 153,154
Fresh air blower series
switch 136 Windshield-wiper intermittent
resistance 142,143
Parking light, left 102 switch 155·158
Fresh air control lever light 141
Parking light, right 108
Fresh air fan 142,143
Power steering pressure switch 39,40
Fresh air fan switch 141·143
Fuel gauge 67

Water-cooled- Digifant .1988, 1989 Main wiring diagram

Current track Index 97.120
97 Electrical System - Wiring, Waterboxer

Wire connectors Ground connections

T1 - single, under instrument panel, left side G)- battery to body

T1 a - single, above left rear window
T1d -single, in wire distributor box, engine
@- transmission to body
compartment @- in engine compartment, left
T1 e - single, under instrument panel, left side
T1g -single, in wire distributor box, engine @- on engine block
compartment @- ground wire, above steering gear
T1 h - single, engine compartment, left side
T11 - single, under instrument panel @-near Digifant control unit
T1 k - single, engine compartment, left @- near relay panel
T1m- single, near relay panel, engine
compartment · @-under instrument panel, middle
T1n -single, near relay panel, engine @-in rear decklid, left
compartment
T1o -single, under instrument panel, left side @- in rear decklid, right
T2c -double, under instrument panel, left side
T2d - double, upper right 'A' pillar
@- near rear washer bottle holder
T2e -double, in rear deck lid @- near rear window wiper motor
T2f -double, behind left 'C' pillar cover
T2g -double, under instrument panel Welded wiring connections
T21 - double, in wire distributor box, engine
compartment @-ground connection, instrument panel wiring
T2k - double, in engine compartment, left harness
T2m - double, near relay panel, engine
@-ground connection, In Digifant wiring harness
compartment
T2o - double, under driver's seat @- plus ( + ), terminal 58, Instrument panel wiring
T2x - double, in engine compartment, middle harness
T3 - three-point, near alternator
T3a - three-point, behind instrument panel, right @- plus ( + ), in Digifant wiring harness
side @-in Digifant wiring harness
T3b - three-point, behind instrument panel, left side
T3c - three-point, near instrument cluster @- plus ( +) 30 terminal, in wire distributor box,
T3d - three-point, behind front grille engine compartment
T3x - three-point, under instrument panel
T7 - seven-point, in wire distributor box, engine
compartment
T7a - seven-point, in wire distributor box, engine
compartment
TB - eight-point, under instrument panel, middle
T14 - fourteen-point, on instrument cluster

Main wiring diagram

97.121 Connector locations

Ground connections
Water-cooled- Dlglfant 1988, 1989
 Electrical -System - Wiring, Waterboxer 97
~· ~--~~--~--~~~~~c---------~~~~~~--.-~~~~--~~----~
X-t--t--t--~--,_--t---~2-~~~~~~~~~~~--~--~~~~~~--+--~
~ ~

r-~--~==;=~============;===~==~1

p p p p p p

6.0 6.0 0.5 0 .5 1.0 4.0 4.0 0.5 1.5

R RIBK BL RIBK RIBK R BK BK

1.5
R

2.5 0.5 0.5

BKIY BK GY/BK

10.0 2.5 90
R R

WIRING
COlOR CODE
81< -BLACK
BR -BROWN
CL - CLEAR

25.0
i
25.0 VOLTAGE
R
Y
G
LT G -
- RED
-
-
YELL OW
GREEN
LIGHT GREEN
REGULATOR
BL - BLUE
V - VIOLE T
GY - GRA Y
W - WHITE
OR - ORANGE

11
,9-7
,... -2_9_1.....,,

Main wiring diagram

Water-cooled- Dlgifant 1988, 1989 Alternator/Starter/
Ignition Switch 97.122
97 Electrical System - Wiring, Waterboxer
30--------------------------------.--------------------- - - -- -- -- - - - - - - - - - - - - 30
15 _
~-----4~------------ 15
X--.---~r-------------------4---4-------------------------------------~---- X

31;±;±:;-;;;;;;;;t;t;±~~~~~~~~~~E~
311
61 61
0 0
4 2 ~

7 8
10
6 3
~55
lOA

b----~------~====t-~---~~====
023 015 E12 C1 8 86 013 N 019 026
I
1.5 0.5 1.0 0.5 0.5

"If f"l
BK G GYIW BK G
EC5-MAL

~Tlo
IND

0.5
!r1n
"'"
"'

0.5
BR
~ 31
LT
AND
SWTCH
T
0.5
BKIW
~ lig ~]
.I
T7a/5
~
L
o
GYIW
_ _, . 0.5
11
BK T1m
DIGIFANT CONTROL
;115 1 20 UNff

l
fl_ ~' ~ ~
IGNffiON
COIL
4 f• ® f• f" f" A'o

I I~ .e-------.------..-- -t I I I
1.0 1.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 1.0 1.0 0.5
BK G G GY/G G BRIW @ BLJW BUR BUBK GY GY R/BL RIBL

...._..I 0.5 0.5 0.5

rrn .-----It---, IGNfTION I 31+ I 2/0 B~- BRIW£Bt:' 1 2 3

l_;~~!1 l~ ~ ~TR~~U!Q~~ ~D [) i s_....._"_-cs:>--+-'

~ HALL
I GENERATOR
INTAKEAIR
1.0 TEMP. SENSOR
BK
41 42

--~
tHROTTLE VALVE AIRFLOW
SPAR/( PLUG SWITCH SENSOR
CONNECTORS (ENRICHMENT} POTENTIOMETER

I ......... jI
~~ ~ ~~ ~~
SPARK
WIRING
COLOR CODE
PLUGS 1 - - - - - - - - l
en istl
qJ YJ ENG. COOLANT
TEMP. SENSOR

ELEMENT
/CRANKCASE
I
VENTILATION)
BK
BR
Ct
R
y
-

-
BLAC!<
-BROWN
CLEAR
RED
l .,
- YE"LLOW
1.0 G - GREEN
BR LT G- LIGHT GREEN
BL
v
-
-
Bi..UE
VIOL E 1
T0.5
GY -GRAY
BR
w

I®
- WH/Tf:
OR - ORANGE
12

12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
1r-
9-7-2- 9-15--,l

Main wiring diagram

97.123 Ignition system

Dlglfant system
Water-cooled - Dlgifant 1988, 1989
 Electrical System - Wiring, Waterboxer 97

E4
WIRING
1.0 COLOR CODE
A/BK
BK - BLACK

Tla/6 BR - BROWN 14
CL - CLEAR
R -REO
Y - YELLOW
0.5 G - GReEN
RIW L T. G - LIGHT GRE:EN
BL - BLU£

1[1~!
V - VI(}(H
1 T2m
GY - GRAY
W -WHITE
0.5 0.5 0.5
OR - ORANG£ RIY A A BK!W BK BK

11
DIGIFANT CONTROL
UNIT
F<p~~p- ~ 1 6/85
.,..
RELAY .
I / 0
'\...-~+----!-
~_,.' 3 i 1'
I~ ~ ~
2/30
I {8
6
.,
II
,.,,5"!15
OOU:ANT
®

rnr
1.5
BA BRIW W
1.0 0.5 1.0 1.0
AIY
1.5
w
1.0
RIW
. __ _ 1.5 BK!Y

I
1.0
A/W
----4---..11-_.~

I
1.0
A/W
-&-- --.:-a.- - -·t1
1.0
RN-1
1.0
R/W
A/W
1.5

1.0 0 .5 0 .5
RIW R/W BA
0 .5
BA

INJECTOR, INJECTOR, INJECTOR, INJECTOR,

CYL. CYL. CYL. CYL.

OXYGEN
' ~~ SJ•Sjm ~N
'i' 'I
F<UEL
PUMP

SENSOR 'i' 'I •

1.0 1.0 1.0 1.0 1.0 1.0
BR w w w w BA

--el--1-----~·t----·1 G2 I T2k

12 12,
27 28 29 30 31 32 33 34 35 36 37 38
l97-29t6 !

Main wiring diagram

Water-cooled - Dlglfant 1988, 1989 Dlgifant power supply,
fuel injectors 97.124
97 Electrical System - Wiring, Waterboxer

C2 Cll

0.5 0.5 0.5

BL BL BUG
~
0.5
RIBK

L, IDC.E STAJ/LIZER
CONTROL UNIT
WIRING
COLOR CODE

BK
8R
Cl.
R
V
-
-BUCK

-RED
-
BROWN
-ClEAR

YfllOW
1: G -GREEN
114/15 i15/LH i5/31 i13/T ~8/LS ~4/ST2 ill/ST1 i2/K *17/1 lT G- liGHT GREEN
BL - BWE
V - VIOlET
1.0 0.5 1.0 0.5 0.5 1.0 1.0 0.5 0.5 GY -GRAY
RJW W/Y BR GY RIBL W Y WIG G W - WHI7f
~ OR - ORANGE

,_1 • 1~

DfJ 25 26 T1k 'T1n

0.5
RJW
y
i y

c~r=:=
BK

~a£ SPEED
STABILIZER
VALVE COUIITER
POWER
STEERING 15/31
PRESSUWE
SWJTCIJ. • 0.5
BR
18 T3 T3 T3

42 43 45 46 47 48
1-q
49
197-29171

97.125 Main wiring diagram

Idle stabilizer conlrol
Water-cooled- Digifant 1988, 1989
 Electrical System - Wiring, Waterboxer 97
,. ~ 30
"' 15
~

r
-·
.. 31
X

n311 6 4
I'
D
7 2 5
-
El5
I
1021
-- -- -
~Bl 824 Bl9 A3 os-·A27- ~1-B15 B21 K3
II
82 ElO

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

Y BUBK BL BL BUG G BUBK Y

~
?
'L/8
0.5
BK

Tl4/ll
0.5
A

Tl4/14l14/5 Tl4/9 Tl4/13 T14112

-

K21~, +A<
---;),1 0.3 1,8
,, ,
'·
K2
0 E:QY:
) 2
~G
•( s
It§ ID <D I ~~:
< KJ
Jn4 15 -

--
..! ~-

G5 - TACHOMETER
J114 - ENGINE OIL PRESSURE CONTROL UNIT
K2 - ALTERNATOR WARNING LITE
11.3 - ENGINE OIL PRESSURE WARNING LITE
K21 - OXS ELAPSED MILEAGE INDICATOR
Y2 - DIGrrAL CLOCK

I T2x 1 T2x
0.5 0.5
BR BR ENGINE
OIL
PRESSURE WIRING
SWITCH COLOR CODE
(0.3
. BAR)
ENGINE BR -- BROWN
OIL
I0.9BAR 0.3BAR Cl CLEAR
PRESSURE Ht.O
"
swrrcH
I - YELLOW

[J5~~---
(1.8 G liRt.t.N
BAR) LT G UGHT GRft.!IJ
I jTl4/3 !l:. ·· BLVE

j ___
VfOtE1
0.5
(;'( GHAY
BR R
w .. WH11E

-·----- ---- --· ··

(c@ 011 OAANGE:

50 51 52 53 54 55 56 57 58 59 60
197-29181

Main wiring diagram

Water-cooled- Dlgifant 1988, 1989 Oil pressure switches
Instrument cluster 97.126
97 Electrical System - Wiring, Waterboxer

~
A17 A28 B3 B7 K2 B17 Kl 029 E5

0.5 0 .5 0.5 0.5 0.5 0.5 0.5 1.0

BUR BLIW V/BK Y/R BUG Y/R ViR V/BK

T0.5
GY/BL

L"La
T14!10

K5
T14/2

K1
T14/7 T14/6

1 T7a/3 I T7a/ 2

Gt - FUEL GAUGE
G3 - COOI..AifT TEIIPERATVRE GAUGE
J8 - W)C.TAGE STABILIZER
Kt - HEADUGHT HIGH BEAM 111ARMteG UTE
KS - TURN SIGNAL INDICATOR UTE
K2B - COOLANT OVERHEAT WARNING UTE
U - CLOCK LITE .
Lto -INSTRUIIENIPANEL LrrE

COOLANT _
TEMPERATURE
SENDING
WIRING UNrr CIGA
COLOR CODE LfGJj
BK - BLA CK
BR -BROWN
Ct.. - CLEAR
R -REO
0.5 BR
y - YELLOW
G

8L
v
GY
- GREEN
L T G- LIGHT GREEN
-BL UE
- VIOLET
-GRAY
0.5
BR
k:-1
1.5
BR
1.5
BR
1.0
BR
w -WHITE

61 62
OR -ORANGE

63 64 65 66 67
}ru
68 69
j __l2 -~--_.._129
70 71 72 73
/97-2919/

97.127 Main wiring diagram

Instrument cluster
Water-cooled- Digifant 1988, 1989
 Electrical System - Wiring, Waterboxer 97
~ ~-~1~~30
X ~ ~
~ ~

~53
~==1~B=ll====~rE=3====~==~~=====B=1~21~lS=A========~~==~~==========~~
1.5
A

T
0.5 1.0
T 0.5 1.5 05

I .h \iT"' ~ T2d
ri:,
0.5 CONN
~010 T3c 0.5 RADIO
CONNECTION
0.5
R
GY/BL A

~~~'if1=~
,, I
31
~3 1
FRONT ' l_ LIGHT

RADIO CONN
I_ RADIO
CONNECnoN
05
·
0.5 0.5 0.5
05 0.5 0.5
BR BRIW BRIW BRIW BR
WT8/3 suT818
0.5 1.5
BUW BR

[ill]
T
U
32;
.- WIRING
COLOR CODE
0.5 1.5 0.5 BK BL4.CK
BR BR GY BR - BRO WN

~D] b
8 CL cu:AR
R - R[ O
CIGARETTE DOOR Y -- YELLO W
'UEL CONTACT
~
iAUGE LIGHTER
I
SW.,
G - GREE N

~
LT G - LIGHT GREEN
RF
31 1 BL - BLUE
-- VJOtE _r
GY - - GRAY

1.5
BR
l CIGARETTE
LIGHTER
W
OR
-
-
W HI TE
ORANGE

LIGHT

(~1 ) @) i~3~~ ·Jo··

-' I

74 75 76 77 78 79 80 81 82 83 84 85 86
197-292~

Water-cooled- Oiglfant 1988, 1989 Main wiring diagram

Interior lights 97.128
97 Electrical System - Wiring, Waterboxer

810 M1 827 826 A24 E1

1.0 1.0 0.5 1.0 0.5 0.5 0.5 0.5 0.5

R1Y RIY BK/Y W/BK GY GY/R GYIBL GYIBL GY/G

14

2i
0.5
GY/G

UOHTSWtTCH

WIRING
COLOR CODE
BK -BUICK
0.5
BR - BROWN
GY/G
CL
R
-
-
CLEAR
R£D
I
Y
G

8L
V
-
-
LT. G -
-BLUE
-
YELLOW
GREEN
LIGHT GREEN

VIOLET
0.5
f=f
olf1o.5
1
BR5 _
GY - G!MY
W - WHITE GY/Bl BR
OR -ORANGE
8 .___,--------,-------r_., IT2i
0.5 0.5 0.5 0.5 0.5
GYIBL GYIBL GYIBL GY/BL BR

~ ~
89 90 91

Main wiring diagram

92
r!J
93
r!J
'98 .
197:2f2tl

97.129 Load reduction relay,

light awltch
Water-cooled- Dlglfant 1988, 1989
 Electrical System .. Wiring, Waterboxer 97
,--.r ::. --,-,-
30 _u - ~
- 30
15 - - 15
""" - X

~
-~-·· -~
31
58
'
510
lOA
521
lOA
' ·_:-, 522 I 59
lOA, 10A
1."

I I

l r--
C17 C5 ca E9 M2 A21 B22 E18 C14 C6 C16 B13

1.5 1.5 0.5 0.5 2.5 2.5 0.5 0.5 1.5 1.5
w Y GY/BK GY/BK y w GY/R GY/R Y/BK W/BK

HEADLIGHT---.,
DIMMER/FLASHER
SWTTCH

WIRING
COLOR CODE
BK -BLACK
iT
1.0
AN
2.5
W/BK
BR -BROWN
CL -CLEAR
R - RECi
Y - YELLOW
G -GREEN
LT G - LIGHT GREEN
BL -BLUE
V - VIOLET I T7t5
GY -GRAY
W -WHITE
OR -ORANGE

1.5 0.5
w GY/BK GY/R
ls6a 56a 56b 58 I I ~ 58

~
~
1
HEADLIGHT,
LEFT ~IGEUBEAII
HEADLIGHT,
" LEFT
I . .
SIDE
MARKER
·y
LIGHTS, ( ··
TAIL
UGHT, )
RIGHT

1
REAR I J-

W
1 31
1.5
BR
1.5 LEFT
BR
HEADI.IGHT,
J5 ofu.51.:
BR BR BR
.....+--....
P~KING­ - --u
' -- - -- -·- - - - --- ~--!- - - -- -------
LIGHT,
LEFT - - --+--· - -- v
----- -- - - - -- - - - - -- -- - - - -- -- ·- -- - - -W
@ @
101 102 103 104 105 106 107 108 109 110 111
197-29221

Water-cooled - Dlglfant 1988, 1989 Main wiring diagram

Exterior lights 97.130
97 Electrical Sy$te.m - Wiring, Waterboxer

30----------~----~~~~~~~--~~~~~~--------------------------~~--30
15 15
X X
31 31
58 58

~"519
~lOA
49a-+----~----+---~

A13 AlB 828 A10 All A7 ca

1.5 1.0 1.5 1.0 1.0 1.0 1.·o 1.0 1.0 1.0
BKIBL W AlW BKIW/G BKIG BKIW BKIW BKIW BKIG BKIG

I;

~
TURN
IGNAL
WTTCH

1.0
BKIW/G
r r
1.0
BKIG
1.0
BKIW
'Tm •Tm

15 49 30 - -
~9o ,.-R ~ l
EIIERGENCY
FLA SHER
WARNING
UGHT

L___:_t t : _ _ .... 't_

EIIERGENCY
... T

FLASHER SWfTCH
·~~ .-
""T

r--'158b
tl
.,

31

WIRING
COLOR CODE
0.5 0.5 0.5
GYIBL GYIBL BR
BK
BR
-
-
BLACK
BROWN
r~

~ ~ RIGHT
CL -CL EAR
R - RED Bl BL BL REAR
y
G
- YELLOW
- GREEN I
') TURN (
l TURN
) SIGNAL
LT G - LIGHT GREEN TURN
SIGNAL SIGNAL. UGHT.
BL - BLUE L~ ,

I~
UGHT,
v
GY
w
- VIOLET
--GRAY
- WH ITE
LEFT
REAR
1.0
t=
1.0
OR - ORANGE
BR BR
t.!~ ~
- u
v---------------------------------------------
w-------------------------------
30 30
112 113 114 115 116 117 118 119 120 121 122 123 124
J97-2923 j

Ma.ln wlrfng diagram

97.131 Emergency flashers,

tum signals
Water-cooled- Dlglfant 1988, 1989
 Electrical System - Wiring, Waterboxer 97

1.0 1.0 1.0 1.0 1.0 1.0 1.0

RN R/BK BKIR BKIGY BRIBL BRIBL BKIY

' T29 1 T29 Tm

cfl~uP
q_JswrrcH
•
1.0
BKIBL

I T7i4
1.0
RN
1.0

3
BKIBL

'IRN WIRING

~
COLOR CODE
1.0
'OHT BKIR BK -BLACK
:AR BR - BROWN
ls4 RF RF CL
A
-
-RED
CLEAR

BRAKE BACK·UP
Y - YELLOW
UGHT, , UGHT, HORN
RIGHT ' RIGHT BUTTON G - GREEN
Lr G - LIGHT GREEN
BL -BLUE
'-BACK-UP v - VIOLET
UGHT, 1.0 GY - GRAY
LEFT BR w -WHITE
OR - ORANGE

u ----------------------~----

128 129 130 131

Water-cooled- Digifant 1988, 1989 Main wiring diagram

Brake lights, homs 97.1 32
97 Electrical System- Wiring, Waterboxer

•
4 3

S20 C22 816 A23

0.5 0.5 1.5

BK BK BKJW

WTRING'

~
COLOR CODE
8K -BLACK REAR
BR -BROWN
1.5 WINOOW
GY/BK DEFOOQER
CL -CLEAR
INDICATOR II

~·-
R -RED

I:;ER
Y - YELLOW
G -GREEN
LT. G - L/OHT GREEN
8L - BLUE
V - VIOLET .4/31 .2/86
GY -GRAY 0.5 0.5 1.5
Y/R BR
,T,,
W -WHITE
W/G
OR -ORANGE

1.5
2/SU BR

~~~ I® I 8/86 ~1/G ~~4/•3•1_ . . ._ _ __ .

0.5 0.5 0.5 0.5
GY GY GY/R BR
=Tie I T3x 1 T3x T3x 1 T1a
o.5
GY
T2 0 T2o 0.5
GY/G

PARKING ~ REAR
BRAKE WINDOW
WARNING H!AT!R
LIGHT ELEMENT
SWfTCH
SAFETY
BELT
SWfTCH, 1.5
LEFT BK
81

132 133 134 135

30
l
136

Main wiring diagram

97.133 Seat belt system,

rear defogger
Water-cooled- Diglfant 1988, 1989
 Electrical System - Wiring, Waterboxer 97
,_, ~r-- ~-...-:·~~

3D 30
15 15
X X
31 31

5185 4130 I, 13 2
St3
20.\
St
30A. • ~ l

'\
· 6/86 8187

~ 7-
"- I
A22 C7 H6 H3 lHl H4 H2 H5
RADIATORJ
1.0 2.5 1.5 2.5 0.5 COOIJNG
BK!R AIW RJBL R BR FAN
RELAY
(:IND
STAGE}

T
0.5
I Tii
T
0.5
T1.5
GY/BL GY/BL BKIY

FRESH
AIR FRESH HEATER WAR.,
CONrROL AIR BLOWER AIR
LEVER FAN SWITCH BLOWER
58b LIGHT + 58b LIGHT SWITCH +
SwrTCH

31 'f3 'f2 'fl f3 f2 'fl

0.5 1.5 1.5 1.5 1.5 1.5 1.0
BR y Y/BK w
WIRING
y Y/BK w
COLOR CODE
BK - BLACK
BR -BROWN
Cl - CLEAR
,. -RED
y - YELLOW
G -GREEN
LT G- LIGHT GREEN
Bl -BLUE
v ·- VIOLET
GY -GRAY
w -WHITE
OR -ORANGE
I
77 I T3d I T3d
I

FRESH
AIR
FAN
RADIATOR
COOLING
FAN
2
r·.,_
-
M
R
1.5
BR ...
s
3 1

rL
4

2.5 21' HEATER

BLOWER
BR 1.5 MOTOR
BR
I T3d
Ju

143 144 )45 146 147 148 149 ISO 151 152
191-29261

Main wiring diagram

Water-cooled- Digifant 1988, 1989 Radiator cooling fan,
fresh air fan 97.134
97 Electrical System- Wiring, Waterboxer

30--~----------~~~--~----------------------------------------~-=~~-~
-.
15 15 .i i
X X
31 31

I• 6/53 sl 3i15 4/31

I~ ~Sn
15A
~517
lOA
WASHEMfiPS! ® IBD
I'

~020 012 09 02
I
'1 017
I
IA6 B9 A5 A2 A12 ~A14 A19 f c9
1.5 1.0 1.0 , .0 1.0 1.0 1.0 , .0 , .0 1.0 0.5 1.0 0.5 0.5
BR BR G/BK GIY GY/BK G G GY/BK GIY G/BK BR/BK G!W G/R G/R

WIRING

t ~:5:'1
3
l ~53e
COLOR CODE

C~
31
;=
53b 53o
WINDSHIELD BK -BUCK
.. WINDSHIELD
· · WIPER BR - BROWN
"!> WASHER
PUIIP
~==~============== MOroR CL -CLEAR

I
R -RED
Y - YELLOW
G - GREEN
LT. G - LIGHT GREEN 0.5
BL -BLUE BR

I~
V - VKJLET
GV - GRAY
W -WHITE
OR -ORANGE

30
153 154 155 156 157 158 159
1 97- 292~

97.1 35 Main wiring diagram

Windshield wipers
Water-cooled - Digifant 1988, 1989
 Electrical System - Wiring, Waterboxer 97

2
512
20A
-4
• 3

E2 EB G3 Rl R2

1.0 1.0 1.0 1.5 1.5

GIW G/BK BK!GY BK!Y BK!Y

T3b I T3b I T3b 152 ll

I T3a 'T3a 1 T3a

WIRING
COLOR CODE

BK -BLACK
BR -BROWN
CL - CLEAR
R -RED
Y - YELLOW
G - GREEN
LT G - LIGHT GREEN
BL - BLUt.
V - VIOLET
GY - GRAY

1 T2e I T2e W -WHITE

OR - ORANGE

ELD
'
REAR
WINDOW
WASHER
~3~ MOTOR
PUIIP
131
1.0 1.0
BR BR

1~4
160 . 161
J~.
162 163 16-4

Water-cooled - Olgifant 1988, 1989 Main wiring diagram

Rear window wiper 97.136
 Electrical System-Wiring, Waterboxer 97
Description Current Connectors
Track
T1 - single , behind left 'B' pillar cover
AJC compressor clutch 14 T1a -single, eng . comp., left
AJC compressor cut-out relay 12·13 T1b -single , eng. comp ., left
AJC thermostat 13 T2 -double , in evaporator housing
Evaporator fan 18 T2a -double , In air tunnel
Evaporator fan range switch 16, 17 T2b - double, in air tunnel
Evaporator fan relay 3 T2c -double , behind left 'B' pillar cover
Evaporator fan switch 13·15 T2d - double, above fuse panel

Idle speed stabilizer valve 13 Ground Connections

Rad ./condensor cool. fan relay 9, 10 G) - near fuse panel

Rad. cooling fan
Rad . cool. fan relay
2
1·3
®· - in engine compartment
Rad. cool. fan thermoswitch 3, 4 @ -in evaporator housing (near left side)

Go to next page •

Water-cooled - Dlgl)et 1984, 1985

Air conditioning 97.1 37
97 Electrical System-Wiring, Waterboxer

EVAPORATOR
FAN
8 SWITCH

2.5
YISR

FROII FROM TO
FUSE FUSE BATT.
S1 SfO +30

.-JI
2.5
RIW
2.5
RIW
I
0.5
BR
4.0
R
4.0
R'BK
1.5
R
0.7
G

2
12b
SERIES
RESISTANCE . ._ _.

RAD. 3
COOLING
FAN
THERMIJ.
SWITCH

t5
RIBR
1.5
RI8K
0.5
8R
4.0
BKIR T2c

,.--.,__ _.,.__, AIC

COMPRESSOR
CUT..OUT
..._,....--e---i.- RELAY

0.5
8R

RAD.!
CONDENSOR
COOLING
FAN EVAPORATOR
RELAY FAN

,4IC
12d T2d COMPRESSOR
CLUTCH
1.5
RiiiL

1.5
RcBK
0.5 0.5
BR BR

CD @ @

2 3 4 6 5. 7 8 9 10 11 12 13 14 15 16 17 18

97.138 Air conditioning

Water-cooled- Dlgijet ·1984, 1985
 Electrical System - Wiring, Waterboxer 97
Description Current
Track
AIC compress. clutch 15
AJC compress. clutch relay 15-17
AJC refrig. high press. sw. 14
AJC refrig. low press. sw. 15
AJC switch 1-3
AJC thermostat 1-3
Ambient air temp. sw. 15
Evap. fan 7-8
Evap. fan sw. 6-8
Evap. fan relay 5-6
Evap. series resistance 7-8
Rad. cool fan 20
Rad. cool fan relay 2nd stage 21-23
Rad. cool fan relay 3<d stage 18-20
Rad. cool fan resistance 22
Rad. cool fan thermoswitches 18-20
Wire Connectors
T1 - single, behind instrument panel
T1a :-single, in engine compartment
T1b - single, behind instrument panel
T1c - single, behind instrument panel
T1d- single, behind instrument panel
T2 -double, left rear C-pillar
T2a- double, left rear C-pillar
T2b- double, on evaporator
T2c- double, left rear C-pillar
T2e- double, left rear C-pillar
T2f - double, at AJC compress. clutch
T2g - double, left rear C-pillar
T2h - double, left rear C-pillar
T3a - three-point, left rear C-pillar
T4a- four-point, in air duct
T6a- six-point. in left rear C-pillar
Ground Connections
@-near fuse/relay panel
@-near left rear C-pillar

Water-cooled- Digifant 1986-1988

Air condHioning 97.139
97 Electricai _System - Wiring, Waterboxer

I a
1.5 2.5 2.5
BKIR BKIY 6fl0
I So _________________________
R ~5-0_A
RIW

~T1d T..ta/1
~~v 4.0f'--------------------------•2.5I I
1.5 8+
BKIR R R
:o
FRESH
T6a!1
b

AIR
FAN
AIC
SWITCH EVAPORA TOR

ll.=;·-}1 ~B~.5K ~:. I

~t-
4----~~~~--~
AIC
RELAY
0.5
't 0.5
't 0.5
' ' - -...- 0.5
BK BK G/BK y

T2c T2c T6o/2 T6a~6

,a,...-:&:---6,AIC 3~--.....a
THERMOSTAT
~~~~~ L~~~~~
4
1.5 BK

lidl2 T2a/1 0.5 WIRING

BR COlOR CCOE
8K -BLACK
BR -BROWN
CL -CLEAR
R -RED
11
Y - YELLOW
G -GREEN
LT. G - LIGHT GREEN
2.5 BL -BLUE
V - VIOLET
GY - GRAY
W -WHITE
OR -ORANGE

@
2 3 4 5 6 7 8 9 10 11 12 13
.-,8-7--88-1-,aj

97.140 Air condlHonlng

Water-cooled - Dlglfant 1986-1988
 Electrical System - Wiring, Waterboxer 97
31 .. . 31

H3 HI

a----------------~----------~
0.5 RIBL
AIC
REFRIG. 2.5 2.5 2.5
LOW
T1b~ PRESS.
sw.
BK TO
BATTERY
RIBK BA

0.5
BKIA
2.5
RJW
2bar
I
6.0
?
2.5
A RIBK
b-----~ 'Wo/2 T2 9
0.5 RAD.
BKIY COOL
FAN
3 THERMOSWFJ.CHES

J~, ~L~~.
AMBIENT
AIR
TEMP.
sw.
2.5 1.0 2.5 6.0
AIBL RIBL A/W A

T2 T2e T2g T2h

0.5
0.5 2.5
BKIA AIC B~ RIBK
COMPRESS
CLUTCH

It~~~------~-~}.1'2
87/2 '18616 '18616 ~ 1'8718

1
2.5 A/BL
T4a/3
0.5
BA
0.5
BA
FAN 6.0
RELAY A
3RD
STAGE

WIRING Ate RAD.

COLOR CODE COMP/1£5$ COOL
CLUTCH FAN
BK -BLACK
8R -BROWN
CL - CLEAR 6.0
R -RED TO BA
Y - YElLOW IDLE
G -GREEN STAB.
LT. G- LIGHT GREEN CONTROL
BL -BLUE
V - VIOLET
T4a l4
GY -GRAY 2.5
W -WHITE BA
OR - ORANGE
@ @ @
14 15 16 17 18 19 20 21 22 23
187-880~

Water-cooled- Dfgifant 1i986-1988

Air conditioning 97.141
97 Electrical System-Wiring, Waterboxer

Current Wire connectors

Description
track
T1 - single, behind instrument panel
AJC clutch relay, J44 26-28 T1a- single, near ignition coil

I
NC compressor clutch, N25 26 T1b -single, behind instrument panel
NC pressure switch, F129 23-24 T1c - single, behind Instrument panel
NC relay, J32 18-21 T1d- single, behind C-pillar trim
AJC switch, E35 2-4 T2a- double, behind C-pillar trim
AJC thermostat, E33 2-5 T2b- double, behind C-pillar trim
Ambient temperature switch, F38 26 T2c - double, behind C-pillar trim
Cooling fan fuse, S42 33 T2d- double, behind C-pillar trim
T2e- double, on left rear pillar
Evaporator blower relay, J157 7-8 T2f - double, near A/C compressor
Evaporator blower series resistor, N81 10-12 T2g- double, on left rear pillar
Evaporator blower switch, E 11 0 7-12 T2h- double, on radiator
Evaporator fan, V20 8, 12 T2i - double, behind C-pillar trim
Fuse,
Fuse,
S12
S51
..10, 14 T2k- double, behind C-pillar trim
T3a - three-point, on left rear pillar
Fuse, S23 17 T3b - three-point, on left rear pillar
Fuse, S1 31 T4a- four-point, on left rear pillar
T4b- four-point, on left rear pillar
Radiator cooling fan, V7 ·33
Radiator cooling fan relay (2nd stage), Ground connections
J101 37-38 @-near fuse/relay panel
Radiator cooling fan relay (3rd stage),
J135 31-33 @-on left rear pillar
Radiator cooling fan series resistance,
N39 36-37
Radiator cooling fan thermoswitch , F18 31-32
Temperature sensor II, G18 3

97 •14 2 Air conditioning

Water-cooled-Digifant from 1989
 Electrical System-Wiring, Waterboxer 97
~---------------------~-~------~--~-~~----~------------------~-----------~
15 - 15
X X
31 - _'o 31

1
...T
E8 G1
E110

J·
. - - - • 2.5 GiBK - - - - - - - - . EVAPORATOR
BLOWER SWITCH

lj
t4
0.5 2.5 2.5 0.5
y BKIW BKIG w

trf==tl
T3b/3 T3bll T3ol3~ ~T2kl1 T2k l2 ~T3o/2
1.5
4.0 t:::... 0.5 W - a
BKIR
4/86 12/87 ~~!'!""""""~!'!""""""~~~
.: N81

~~~ ~'.JJP
EVAPORATOR
2 <;:--...--IIQ2 BLOWER SERIES
f17\
IL,---,--,-:x:-----:If,----fr
\!Y
116/85
lrHERAIOSTAT ~ BLWR
j813~LY
3 ~-...
~------.-----?C-.'4
3
RESISTOR

4
0.5 0.5 0.5 0.5 05 2.5
BR BR BR BL ·R BK 1.5 1.5
8

t
BK BK • 1.5 W - b
TO FRESH AIR FAN, r T2al 2 T2all ~2 c 12 ..._ ...._ _ _ 1.5 w - c
~ ~-----t--•
0.5 0.5 2~5
BL BR BK

~a "
;G18
TEAIP
SNSR

. _ - - t - - + - - - - - + - - + - - - - - - l t - - - 0 . 5 BR - d

19 ~2b
2.5 2.5
BK BK

~~:n~~ FUSE~~
WIRING
COLOR CODE V20 SsT
EVAP
BK -BLACK FAN 20A
BR -BROWN
CL -CLEAR I'
R -RED 2.5 2.5 2.5 2.5 2.5 2.5
Y - YELLO W BR BR BR BR BR BR

~T2i!T ~T2i/2
G - GREEN
LT G - LIGHT GREEN
BL - BLUE
V - VIOLET
GY - GRAY
W -WHITE
OR - ORANGE

2 3 4 5 6 7 8 9 10 11 12 13 14

19N!7451

Water-cooled-Digifant from 1989

Air conditioning 9 7 •143
97 Electrical System-Wiring, Waterboxer

H6

0.5 r-f

f1
AIBL
F38 0.5
AMBJENr BKIY
TEMPERATURE
SWITCH

. . - - - - 2.5 Am ----lt--.. 1.5 1.5

BL A/BL

~ lib
c:rJ
0.5 2.5 0.5
T'"" iT'"" T4oll
BL AIBK BKIA

r~--~~:l1
.3/2 5/7 615

¥-----&------¥ I~, M 1
j4/6 j 111 0.5 ~~CH p !B7 6/B6i
1.5 0.5 BKIA RLY 2.5 0.5
w A/BL BA
b---.1
c--. ~ell
BA !l4bl3 T4bi4 T4bi1 T4bt2 T4o/3
1.5 1.5 1.5 1.5 1.5 1.5
w w A/BK AIBK BL BL

F129
- - AIC
PRESS
sw

Tia
2.5 0.5
WIRING R/BL A/BL
COLOR CODE

BK - BLACK
N25
BR -· BROWN
A!C
CL - CL EAR COMPRESSOR
R . RED CLUTCH
- Yf: U.OW
G - GREEN
LT G · LiGHT GREEN
BL ·• B LUE
V -· VIOLE f
GY - GRAY
W - WHITE
TO
T IDLE
OR ORANGE 14o/4 STABILIZER
CONTROL
UNIT,
® J142 @
16 17 18 19 20 21 22 23 24 25 26 27 28
[r-9-7-8-7-46...,,

9 7 •144 Air condit io ning

Water-cooled- Digifant from 1989
 Electrical System - Wiring, Waterboxer 97
-, -, I, ~- .;J
30 --.--.-- ~
30
15 15
X .J- -
X
~ ~
e •
-~ -

RISE
J1tl1
t"'JO 1'6/86

[~ RAQIA7Dfl
COOLINOFAN
1;-------cri a
Rfi.AY (2110 SWiE) 8/87 5185

:{ .._
-
Cl H3 Hl
2.5 1.5
•
0.5 2.5 TO R/BK BR
BATTERY,
BKIY BK A
I
6.0
~
2.5
R R/BK

lie T2 9

S42
COOLING
FAN
FUSE
50A

0.5 6.0 2.5

R/BL R
Rl 0~5T2h/l

-------------
2/~~35
'tJ:~FAN
' - - ! - - - - - + - ' RELAY (3RD STAGE)
~K
s23 ~
~~L
}6 /86 }8/87 'fl ~~~ST
0.5 6.0 6.0
BR R R WIRING
COLOR CODE

BK. - BLACK.
BR - BROWN
CL - CLEAR
R - RED
- YELLOW
V7 G - GREE-~
RADIA TOR LT G - LIGH T GREEN
COOLING BL - BLUE
FAN V - VIOLET
GY - G RAY
6.0 W - WHITE

BR OR - ORANGE

29 30 31 32 33 34 37 38 39 40 41 42
197.-87471

Water-cooled-Digifant from 1989

Air conditioning 97.145
97 Electrical System -Wiring, Waterboxer

Description Current
Track
Auto trans. console lites 1-2
Back-up lite, left 3
Back-up lite, right 5
Brake lite, left 2-3
Brake lite, right 5-6
Neutral safety/back-up lite sw. 2-5
Side marker lite, LR 1
Side marker lite, RR 8
Tail lite, left 2
Tail lite, right 7
Turn sig., LR 2-3
Turn sig., RR 6
Wire Connectors
T1b- single, wire distributor, eng. compart.
Ground Connections
@-on sub-frame, LF
@-eng. compart., under ignition coil

97.146 Automatic transmission

Water-cooled- Digifant 1986-1989
 Electrical System - Wiring, Waterboxer 97
30--~======~============----~~~~~~~~~~~----~==~==~-----===~~30
15 15
X X

lf.l
7

016 88 C18 024

1.0
R/BK
4 .0
R/BK
6.0
R/BK

0~5
GY/R 0.5
GY /R
TO
STARTER/SO
I
6.0
RIBK
I
TO
IGNJSTART
SWJ50
---..~
l AUTO 15 ( 50A
TRANS~
f
I'
0.5
CONSOLE
LITES ~~~
iRF
1.0
50
p R N
ISAFETY!
NEUTRAL
BACK-UP
· UTE
sw.

BR BKIBL
WIRING
COLOR CODE

BK -BLACK
BR -BROWN
CL - CLEAR
R - RED
Y - YELLO W
G - GREEN
LT. G - LIGHT GREEN
BL -BLUE
v - VIOLET
GY -GRAY
w - WHITE
00 - ORANGE
I T1b

1.0
BKIBL

~--- - ·
~BACK· 1 TURN 1 SIDE
UP MRAKE , SIG. I TAIL : MARKER
LITE, LITE, f.0 LffE,
RIGHT RIGHT Y RR
LITE,
RIGHT
':<LffE,
RR

1\--.u
1.5
BR
0.5
BR

@
2 3 5 6 7 8

Water-cooled-Diglfant 1986-1989
Automatic transmission 97.147
 Electrical S.ystem - Wiring, Waterboxer 97
CUrrent
Description Wire connectors
track
T1 a- single, under instrument panel
By-pass air blower
T2 - double, on fresh air blower
Combustion air blower T4a - four-point, under Instrument panel
Combustion air blower suppressor T4b - four-point, under Instrument panel
Fuel pump Ground connections
Fuel pump contact breaker
®- near fuse/relay panel
Glow/spark plug
Glowplug/heater condenser
@- on crossmember near fuel pump

Heater contact breaker

Heater Indicator lite
Heater relay
Heater relay
Heater-time temperature control switch
Heater/combustion sensor
Heater/overheat control switch
Ignition coil
Main suppressor
Safety switch (relay)
Temperature sensor (NTC)

Go to next page •

.___c_a_n_ad_a_~l I Water-cooled- Digifant from 1987· j Auxiliary heater BAS 97.148

97 Electrical System - Wiring, Waterboxer

:~·.

0.5
BK

.---------------------------------------------------------0
---------------------------------------b
0.5
Bl..JW
~o~

..--------- ~~ ----------· T.t.a/2

1.5
BKIY

MAIN IY.PASS AJR

SUPPRESSOR ItOWER

2 s 7
,-~-2-3-73--,l

9 7 •14 9 Auxiliary heater BA6

Water-cooled Oigifant from 1987 II Canada
 Electrical System -Wiring, Waterboxer 97

0.5
R
9
523
a----:>

- II
Canada Water-cooled-Digifant from 1987
Auxiliary heaterBAs9 7 .150
97 Electrical System - Wiring, Waterboxer

Description
Wire connectors
T1 - single, under Instrument panel, right side
AIC diode T1a - single, near fuse/relay panel
Combustion air blower T1b - single, near fuse/relay panel
T1d - single, In engine compartment
Flame detector T1e - single, In engine compartment
Fresh air fan relay T1f - single, near fuse/relay panel
Glow plug T2 -double,
Glow plug relay T2a - double,
T2c- double,
Heater control lever switch 8
Heater control unit .18-24. T6a - six-point, in engine compartment, left side
Heater fan relay 1·3 . T6b - six-point, near fuse/relay panel
Metering pump 20 T12 - twelve-point, on heater control unit
Monovalve 8 .
Monovalve relay 7!- · Ground connections
Programmable timer @-in engine compartment, left side
11· .
Programmable timer Indicator light t.C @-near fuse/relay panel
Programmable timer light 11
@- on Instrument cluster
Recirculation pump 13:
Recirculation pump relay 1~17
@-near steering column
Resistor .28 Plus connection
Series resistor M (6)- + connection (30) wire distributor box,
Temperature sensor (NTC) ft engine compartment
Thermoswitch 7
Time relay 8,10-

97.151 Auxiliary heater

BBW 48
Syncro II Canada II Water-cooled-Digifant 1986·1988
 Electrical System - Wiring, Waterboxer 97

512
20A

Gl

2.5
p

I ---lr-r~
r--
1.0 1.5 1.5
1.5 2.5
A A A BK BKAN R
WIRING
COLOR CODE
81( - BI.ACI(
BR -BROWN

T
CL - CLEAR
R -RED
Y - YELLOW
G -GREEN 1.0
LT G - LIGHT GREEN BUR
BL - BLUE
V - VIOLET

556 GY .-GRAY
W -WHITE
5ss
7,5A 15A
OR - ORANGE

2.5
R 0.5

[
BKIR

I
1.0BUR

1 ~e~=--fi~~
L. ""'
If----t:;l 1=:·"'
12/30 16/85 16/85 12/30 f7/86 14187 87a
1.5 0.5 0.5 0.5 R/BK 1.0 BKIY
1.5
BKIY BR BR BKIR

I
T6b/6 T6bls

T6a!6

m<ROOSMTCH~ IIONOVALVE

•
0.5
BR
1.0
BR

TO WARM AIR TO FRESH AIR FAN

BLOWER SWITCH SWTTCH

@
2 3 4 5 6 7 8
197-27411

..___s_y_n_c_ro_ _.ll Canada IJWater-cooled-Digifant 1986-19881 Auxiliary heater

BBW46 97.152
97 Electrical System - Wiring, Waterboxer

023
a-----1 .0BK------------------------------------------------------.
b -----1.5 BKIW - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - . .-------~--+-----d
1.5
1.5
c - 1.5 R - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - . BKIR
BKIW

0.5 1.5 BK 0.5 0.5

BR
0.5 0.5
BR!W BR!W
1.5
BKIR
I
0.5
BR '- T6bt3
~
T6b11
BK BR!W

1.5 1.5
BK BKIR

T6at6 ~~c DIODE

1i2/2

WIRING
COLOR CODE

t~~
HEATER

E
BK -BLACK
CONTROL 1!1 RECIRCULATION BR -BROWN
LEVER PUIIP CL - CL EAR
SWTTCH
R -RED
y - YEL LOW
1.5 0.5 G -GREEN
BR BR L T G- LIGHT GREEN
Bl. - BLUE

~
v - VIOL ET
GY - GRAY
'1 1.0 w -WHITE

@ @
l T @
OR - ORANGE

9 10 11 12 13 14 15 16 17

197-26831

II II [
97.153 Auxiliary heater
BBW46
Syncro Canada Water-cooled-Digifant 1986-1988 1
 Electrical System - Wiring, Waterboxer 97

TO EIIERGENCY
4J FLASHER SWTTCH
1.0
BUR
I
0.5
523
16A BK!BL
T6bl4
1.5 2.5 6.0

L®
R BKIY R

C''"-~L
T6a/4 TH

L :TWJ
I I
. :'·~ I :11: :~~
fT6/5 JT2a/2 JT2c/2 r 1 T2a/1 fT8/5 fT8/8 fT8/7 JT811 fT8/4 fT8/2
1.5 1.0 1.0 1.0 1.0 0.5 1.0 0.5 1.0 2.5
BK!R BR RIY BUBK W G W/G V R Y

T6a!1 .112/6
2.5Y - ,
1.0
BUBK
rl!J2
1
) 2!30 4/86

I_..
RESISTOR I[J'----f I~& rT RELAY

_ 5/87a r /87 ,6/85

e tall o.5
2.5 Y BR
li2/12 112/11 l6a/5 li2/10 li2/8 T212
li2/4
1.0 1.0 2.5 WIRING
BL y
OR 'LAIIE ~1
.0 V
COLOR CODE

~&OW
DETECT

~l
BK - BLA CK
BR - BROWN
COIIBUS . .M CL
524 ·AIR
- CL EA R
,PLUG R - RED
BLWR ' y - YELLOW
IIETERING G -GREEN
PUIIP 1.0 1.0 1.0 2.5 LT G- LIGHT GREEN
BR G BR BR BL - BLUE
v -VIOLE T

lli2/3 T211 GY -- GRA Y

w -WHITE

~
OR - ORANGE

li2/7
@ @ @ @
18 19 20 21 22 23 24 25 26 27
l97-2684l

Syncro II Canada II Water-cooled-Digifant 1986-19881 ::~i:z heater 97.1 54

97 Electrical System- Wiring, Waterboxer

Current Wire connectors

Description
track
T1 - single, under instrument panel, right side
T1a - single, near fuse/relay panel
T1b- single, near fuse/relay panel
Combustion air blower 38 T1d - single, in engine compartment
Diode 25,28 T1e - single, in engine compartment
T1f - single, near fuse/relay panel
Emergency flasher switch 20 T2 - double, on heater control
T6a- six-point, in engine compartment, left
Flame detector 38
T6b - six-point, near fuse/relay panel
Fresh air fan relay 9
T12- twelve-point, on heater control
Fresh air fan switch 8
Fuse 38 Plus ( +) wiring connections
Glow plug 39

-
Glow plug relay 40 @-in wire distributor, engine compartment

Heater control lever switch 15 Ground connections

Heater control unit 39
Heater fan relay 3 in engine compartment, left side
Main heater fuse (16 amp)
Metering pump
Monovalve
Monovalve relay
Overheat fuse
Programmable timer
39
33
13
14
32
21
1 -
-
-
near fuse/relay panel
on instrument cluster
near steering column

Programmable timer indicator light 22

Programmable timer light 19
Recirculation pump 21
Recirculation pump relay XI
Resistor 38
Temperature sensor (NTC) 34
Thennoswitch 12
Time relay 18

97.155 Auxiliary heater

BBW46
Syncro II Canada II Water-cooled-Di gifant from 1989 [
 Electrical System - Wiring, Waterboxer 97

512
20A

Gl G3 p
a

1.5
R
2.5
R
2.5
R
I
1.0
BK
1.5
BKIW
rr=~
1.5
R

~
1.0
BUR

Ss6 Sss
7.5A 15A

1.5 0.5
R B~R

L87 5/87o Las

r-+-1
4/86

t--------------+----r----t---,1
J6185 (2 /30
=··,.. t-----b :=,.. .
1
'17/86
2/YJ

j4/87 87a

~·~ 0. ,RI~:16 ~6 b/5

5 81
s1JR
T6ai6

-MT<HrSJ MONOVALVE

0.5
BR
• 1.0
BR

TO WARM AIR TO FRESH AIR FAN

BLOWER SWJTCH SWITCH

@ @ @
2 3 5 6 7 8 9 10 11 12 13 14
!97-31721

~......-_s_y_n_c_ro_....JII Canada II Water-cooled-Digifant from 1989 1 Auxiliary heater

BBW 46 97.156
97 Electrical System - Wiring, Waterboxer

a-1.0 BK-------------------------IIIIiiii--...
b - 1 . 5 - - -- -- -- - - - - - - - - -- - -....
015

.--------4--~~-d
D23

c - 1 . 5 A - - -- - - -- - - - - - - - - -. . 1.5 1.5
BKIW BKIR
70 EMERGENCY
Cf:l FLAiER SwrTCH

0.5 0.5

I] ~~ GG
.k;-l 8a:1
..-+-----'!-=::..::..._--,
8a/9
B
IK GYI/IlK

Sa/4
~
OR'

Sa/11PRGRIIBLE niiR
PROGRAIIIIABLE
1.5
BKIR

® =~ ~ =INDICATOR
~/85 TillE RECIRCULATION
I '--I RELAY PUIIPRELAY
0.5 0.5
0.5 0.5 1.5 0.5 BRIW
BRIW BRIW BKIR BR BR 1.5 BK-.-----~
I T6bi3

BK
1.5

1.5
T6ai6 BKIR BLOCKING
DIODE

Tr2/2 1.5 BKIR-e

BK
1.5

HEATER
CONTROL
LEVER
SwrTCH
$~~- PUIIP
BLOCKING
DIODE

1.5 0.5
BR BR

DjJ
1.0
BR

§ @ @
17 18 19 20 21 22 23 24 25 26 27 28
!97-317~

97.1 57 Auxiliary heater

BBW 46
Syncro II Canada II Water-cooled-Digifant from 19891
 Electrical System - Wiring, Waterboxer 97

d....., 4J D(J TO EMERGENCY

FLASHr SWTTCH

1.5 1.0
BKIW BUR 0.5 0.5
FUSE I BK BKIBL
6b/4 8A

1.5
R
i1'6a/2 iT6a/4
1.5
1.0 R
BUR
T8/3 T8/6 lr6/6 T6/4
HEATER
®
~----~--~--------~~--~----~--~----~----~--~UNTT
CONTROL

T2a/2 Jr2c/2 T2a /1 r8/5 T8/7 fT8/1

1.5 1.0 1.0
BKIR 1.0 1.0 1.0 0.5 1.0 0.5
BR RIY BUBK BUBK w G WiG v
T6a/1

t
d/
2
2.5 y
GLOW
PLUG
:I 2/30
lie
0.5
BKIBL
14/86
RELAY

1.5
BKIR
e~ li2/12 li2/11
1.0
T6a/5 li2/10 li2/8
RESISTOR
J li2/4
T212

Bl 1.0 v 2.5 y

OVERHEAT
FUSE
~

1.0
FLAME
DETECTOR

1.0
~~··
2.5
PLUG

G BR BR
COMBUSnON ~
AIR
METERING BLOWER li213 T211
PUMP
1.0
li2i7 BR

@ ® ctJJ @ @)
29 30 31 32 33 34 35 36 37 38 39 40 41 42
!97-31741

Syncro II Canada II Water-cooled-Digifant from 1989 1 :~~':Z heater 97.158

97 Electrical System - Wiring, Waterboxer
Description Current
track
Door lock contact, sliding door 9·11
Lock motor, driver door 1,2
Lock motor, passenger door 7,8
Lock motor, rear door 12, 13
Lock motor, sliding door 9·11
Wire connectors
T1 - single, in driver door
T1a- single, in passenger door
T3 - three point, in driver door
T3a- three point, in passenger door
T3b - three point, under instrument panel
T3c - three point, in sliding door
T3d - three point, in rear door
T4 - four point, under instrument panel
T4a- four point, under instrument panel
Ground connector
@- under instrument panel

Go to next page •

97.159 Central locking system

Water-cooled- Digifant 1986
 Electrical System - Wiring, Waterboxer 97

Ss2 ..----------- b

1.0
R 1.0 1.0
w 1.0 R
y
4

LOCK E
30 IIOTOR, E A A 30
Dlf/VER
DOOR

LOCK
MOTOR, 1.0
PASSENGER BR
DOOR

T3a

WIRING
COLOR CODE
BK -BLACK
BR - BROWN
CL - CLEAR
R - REO
Y - YELLOW
G - GF:EEN
l T. G - LIGHT GREEN
BL - BLUE
V - VIOLET
GY -GRAY
W - WHI TE
1.0
. __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _OR
__ - ORANGE
_ _____________________ d
BR c

2 3 5 6 7 8
l§ili]

Water-cooled - Dlglfant 1986

Central locking system 97.1 60
97 Electrical System - Wiring, Waterboxer

b----...
a _..............._....__,..~

1.0
w
1.0
y

DOOR
LOCK
CONTACT,
SLIDINQ
DOOR

1.0 1.0 1.0 1.0

BR BR y w
T3c T3c T3c T3d T3d

E A 31 A E

LOCK LOCK
MOTOR, MOTOR,
SIJIJING REAR
DOOR DOOR

WIRING
COLOR CODE
BK -BLACK
BR -BROWN
CL -CLEAR
R -RED
Y - YELLOW
G -GREEN
L T G -· LIGHT GREEN
BL - BLUE
V - VIOLET
GY - GRAY
W - WHITE
OR -- ORANGE

9 10 11 12 13
197-22831

97.161 Centnl locklng aywtem

Water-cooled- DlgHant 1986
97 Electrical System- Wiring, Waterboxer

Description Current
track
Central locking system motor, decklid 11,12
Central locking system motor, driver
door 1,2
Central locking system motor,
passenger door 5,8
Central locking system motor. sliding
door 7·9
Sliding door contact switch 7-10

Wire connectors
T1 - single, in LF door
T1a- single, in RF door
T3 - three-point, in LF door
T3a- three-point, in RF door
T3b- three-point, under inst. panel, right side
T3c - three-point, near upper right "B" pillar
T3d - three-point, upper half of left rear window fJl - fuse for central locking system
T3e- three-point, in rear decklid
Ground connection
@-near fuse/relay panel

97.162 Central locking system

Water-cooled - Diglfant 1987-1 989
 Electrical System - Wiring, Waterboxer 97

p
1.0
R

m OOs, 20A
1.0 y
1.0 w
0

b
'W 1.0 R
1.0
R 1.0 w

"
I'- 1.0 -
y ~
T4 T4 T4 T4a T4o T4a
WIRING
COLOR CODE

BK -BLACK
BR - BRCWN
CL - CLEAR
R -REV
Y - YELLOW
G - GREEIV
LT G - UGHr GREEN
BL - BLUE
v - VIOLET
GY - GRAY
T1 T3 T3 T3a T3a T1o w
OR
-WHI TE
- ORANGE
1.0 1.0 1.0 1.0 1.0 1.0
R W Y Y W R

~~~:T\~r~~"-f·
31 CENTRAL LOCKING
SYS Jai iiOTOR,
'L__A ----'='======EEl .--T---~~~~::;~
CENTRAL LOCKWG;1
SYST£11110TOR,
,

1.0 DRIVER DOOR PASSEJKJER DOOR 1.0

BR BR

~ ~

water-cooled - Diglfant 1987-1 989

Central locking system 97.163
97 Electrical System- Wiring, Waterboxer

a 1.0 y
b
I
1.0 1.0 w
w 1.0 y
1.0 BR
T3b TJb
cr
1.0
BR
TJd TJd TJd

TJe TJe TJe

1.0 1.0 1.0 1.0 1.0 1.0
w y BR BR y w
SUDING
DOOR
CONTACT ,
S~H ~~~----~--~~~~--~~~

WIRING
COLOR CODE
E A 31
BK -BLACK
~bl~~==:r--~~~~- C~L~WG BR -BROWN
SYSTEIIIIOTOR, Cl. -CLEAR
t-..a-,.;,;,"""",.,;_,_,...,.,..,..~,, SLIDING DOOR R -RED
Y - YELLOW
G -GREEN
LT G - LIGHT GREEN
BL -BLUE
V - VIOLET
GY -GRAY
W -WHITE
OR -ORANGE

97.164 Central locking system

Water-cooled- Digifant 1987-1989
 Electrical System - Wiring, Waterboxer 97
Description Current TO
Track
5,, DIG/FANT
I RELAY
Heat element (crankcase vent) 6 1.5
BK
Ignition coil 4-5
Wire connectors
T1 - in wire distributor
T1a- in engine compartment

1.0
BKIW

0.5
BK

0.5 1.5
R/W G BK

I
TO
I
TO
/GN.
OISTR.
IGN.
CONTROL
TO
1.0
BK

~
5,
TACHOMETER >A

1.0
BK

WIRING
COLOR CODE HEAT
ELEMENT
BK - BLACK
(CRANKCASE
BR -BROWN VENT.)
CL -CLEAR
R -RED
y - YELLOW 1.0
G -GREEN BR
LT G - LIGHT GREEN
BL -BLUE
V - VIOLET
GY -GRAY
W -WHITE
OR -ORANGE

2 J 4 5 6
197-21061

Water-cooled- Digljet 1985 Crankcase ventilation

Heat element 97.165
97 Electrical System - Wiring, Waterboxer
Description Current
Track
Heat element (crankcase vent) 4
Ignition coil 2-3
Wire connectors
T1 - single, eng. compartment
T2 - double, wire distributor, eng. compart, LF
li2a- double, under rear seat, left
T3 - three-point, under rear seat, right
Groufld connections
@-on left cylinder head

97.166 Crankcase ventilation

Heat element
Water-cooled- Digifant 1986
 Electrical System - Wiring, Waterboxer 97

--- lE12 023

0.5 1.5
R/BK BK TO
0/GIFANT
RELAY

T2
0.5 1.0
BK BKtW

dtj
r· 15
1ciiimoN
COIL

BK
i4 1
1.0
BK

Icps, 5A

0.5
BK

r
WIRING
COLOR CODE

BK - BLACK
BR -BROWN
CL - CLEAR
R - RED [}]HEAT
Y - YELLOW ELEMENT
G -GREEN
LT. G -
BL -
LIGHT GREEN
BLUE
TO
IGN.
DISTRIBUTOR i (CRANKCASE
VENT)

V - VIOLET
GY - GllAY
1.0
W - WHITE
BR

I~
OR - ORANGE

2 3 4
~7-2349 1

Water-cooled- Digifant 1986 Crankcase ventilation

Heat element 97.1 67
 Electrical System - Wiring, Waterboxer 97
Current
Description
track
Automatic transmission console lite 4,5
Automatic transmission relay 12,13
Back-up lite, left 7
Back-up lite, right 6
Brake lite switch 9,10
Brake lite, left 8
Brake lite, right 9
Cruise control inductive sender 16
Cruise control switch 15-17
Cruise control, main control unit 14-18
Starter 2,3
Starter cut-out/back-up lite switch 3,4
Vacuum control motor 17,18
Vacuum vent valve, brake 11
Wire connectors
T1 - single, under instrument panel
T1a- single, under instrument panel
T1c -single, eng. compart., near starter
T11 - single, in wire distributor
T2 - double, under instrument panel
T2a- double, under instrument panel
T2b -- double, under instJument panel
T3 - three point, .in eng. compartment
T3a- three point, under instrument panel
T4 - four point, near eruise control main control
T4b- four point, under instrument panel
T7! -seven point. in wire distributor box
Ground connections
@-under instrument panel
@- on left front crossmember
@-in eng. compart., under ign. coil

Go to next page •

Auto. trans. II Water-cooled- Dlgifant 1986 ]

Cruise control 97.168
97 Electrical System - Wiring, Waterboxer

TO
BAT 0.5 1.0
BK'BL
I
GY/R

35,0

0.5
BR
I I
1.5
BR
1.5
BR

@
2 3 5 6 7 8 9 10

97.169 Cruise control

Auto. trans. II Water-cooled- Digifant 1986
 Electrical System ... Wiring, Waterboxer 97
----~----~--~~~~~~----~--~--------------~--~--~~~~~---36
----~----------~~----~~~~~-+---~~~--~------~--~~~--~~---15
------------~~~~--~--~~~~-+--~--~~------~~--~~~~~~---x
------~~--~----~~~~~~~~-+----~----~------~--~------~~---31

0.5 05 05 05
RISK RIY BL BKIBL

0 .5
R/BK

12
If.-·- - iltws I
T2

3 t"
,..a
®
T4b

6
~T4
0.5
BK
T4b
1111...

.......... . . ,1
I
CRUISE
CONTROL,
MAIN
CONTROL
... 5
~ 1'4 1'7 UNIT
0 .5 1.0 0.5 1.0

r Ic~ t t t'
0.5 0.5 0.5
R/BL W/BL W/BL BR/BL G/W GIY

T2 T4 ~T4 TJ T:

0.5 0.5
BR BR
VACUUM VAC
VENT CNTRL CNTRL
VALVE, INDUC MTR
BRAKE SNDR

12 14 15 17 18

Auto. trans. j I Water-cooled- Digifant 1986

Cruise control 97.170
97 Electrical System- Wiring, Waterboxer

Current
Description Wire connectors
track
Automatic transmission console lite 4,5 T1f -single, in wire distributor, eng. compart.
Automatic transmission relay 13, 14 T2a- double, under instrument panel
T2b- double, under instrument panel
Back-up lite, left 8 T2j - double, near fuse/relay panel
Back-up lite, right 8 . T2k - double, near fuse/relay panel
Brake lite switch 10, 11 Til -seven point, In wire distributor, eng. compart.
Brake lite, left ~
Brake lite, right 10 Ground connections

Cruise control inductive sender 17 @-in engine compart., left

Cruise control switch 15-19 @- on left front crossmember
Cruise control, main control unit 15-19
Starter 1-3_
Starter cut-out/back-up lite switch 1·4
Vacuum control motor 18-21
Vacuum vent valve, brake 12

97.171 Cruise control

Automatic transmission
Water-cooled- Digifant 1987-1989
 Electrical~ System - Wiring, Waterboxer 97
~~---'-~~~i~~~
3
~ 1 i ~.
~~~ ~~!
4.0
RIBK
•02•
6.0
RIBK
~o••
1.0
BK!GY
.,.Am
0.5
BL
0.5
BL
,,. icJ
1.0
BK!R
1.0
R1Y
1.0
RIBK

TO
I TO
I
tGNmONISTARTER ALTERNATOR
swrrcH 1.0
RIBK
T2b

F,
T2b I

1'"'--c
T2j I

0 .5 1.0
RIBK RIBK

6 .0 1.0
RIBK BKIBL
Tm

TO
BATTERY

I
70.0

I TH
M 1~
~R B~

J RF 54 1s4
~ BCK-UP B~K
STARTER

AU~UI
CONSL LT AUTCJ-TRANS
CONSL LT
· L~
BCK·UP
R
L-----------~-
L~
L

131
L~
L
BRK
. L~

131
R

0.5 1.5 1.5

BR BR BR

2 3 4 5
67
6 7 B
l" 1(1~
9 10 11
[97-2532[

Water-cooled- Digifant 1987-1989 Cruise control

Automatic transmission 97.172
97 Electrical System- Wiring, Waterboxer

30 30
15 15
X X
31

I
~512
20A: • 3
31

0.5 1.0
0.5 0.5 0.5 RIBKRIBK

I ~T7a/6
BKIR BKIY BK
TO
TO TO
REAR ALT IGNmoN
WINDOW WRNG SWTTCH/50
WIPER LT
IIOTOR

ra~~~~~~~~~~~~~~~CRU~E
CONTROL
~--~~----~--~~--~--~~~SW"CH

0.5 05 05 05
RIBK RIY BL BKIBL

T2 T4b ~T4
0 .5
RIBK
12 3
IT"
T2 6
0.5

---...
BK
J4b

If ----- ll~
I " 1 CRUISE

..-s
I ~
'•
:® ..
'i'7
1
CCNTROL,
IIAIN
CONTROL

~ 1.0
'i'4 UN"
0 .5 0.5 0.5 0.5 0.5 1. 0
RlBL BR W/BL W/BL BRIBL G/W GN

T2 ~T, ~T4 T3 ~T3 T3

1.0
0.5 0.5
BR BR
VACUUII
VENT
VALVE, INDUCTIVE
SENDER
T3a T3a T3a
BRAKE
0.5 0.5 0.5
BRIBL G/W G

rI
3

1$4
L..===~~====:::'J IIOTOR
VACUUII
CONTROL

6o'
'·._ ,./

12 13 14 16 1!7 18 19 20 21
.-,9-7--25-3..,31

97.1 73 Cruise control

Automatic transmission
Water-cooled -Diglfant 1987-1 989
 Electrical System - Wiring, Waterboxer 97
Description Current
Track
Brake lite, left 1
Brake lite, right 3
Brake lite, switch 2-3
Cruise control main control 4-9
Cruise control switch 5-9
Inductive sender 6
Vacuum control motor 8-10
Vacuum vent valve, brake pedal 4
Vacuum vent valve, clutch pedal 4
Wire Connectors
T1a- single, under instrument panel
T2 - double, under instrument panel
T3 - three-point, in eng . compart.
T4 -four-point, near cruise control main control
T4b- four-point, under instrument panel
T71 - seven-point, in wire distributor box
Ground Connections
@-under instrument panel
@-in eng . compart., under coil

Go to next page •

Manual trans. II Water-cooled - Digifant 1986

Cruise control 97.174
97 Electrical System - Wiring, Waterboxer

El6 C3 Cl

WIRING
1.0
BKIR
1.0
RIY
1.0
R/BK
f"BJ - VACUUM
VENT
VALVE,
0.5
BK
1.0
BK
COLOR CODE

BK
BR
- BLACK
-BROWN

L
CLUTCH CL -CLEAR
0.5 ~ PEDAL R - RfV
R/BK 0.5 Y - YELLOW
G -GREEN
RIBK LT. G - LIGHT GREEN

T4b BL
V
-BLUE
- VIOLET
GY -GRAY
W -WHITE
1.0 --. OR -ORANGE
RIY ~

fMKEdl fM"EQl
SWfTCHL'f-J SWITCHq_l

1.0
R/BK
....J
I T7 3

1.0
BKIR
I 54
,<-, BRAKE
v UTE,
LEFT

f31 .31
1.5 1.5
BR BR

((4)
2 3 4 5 6 7 8 9 10
[9Bm)

97.175 Cruise control

Manual trans. II Water-cooled- Diglfant 1986
 Electrical System - Wiring, Waterboxer 97
Current Wire connectors
Description
track
T2 - double, under fuse/relay panel
Brake lite switch 2, 3 T3 - three point, near fuse/relay panel
Brake lite, left 1 T3a - three point, in wire distributor, eng. compart.
Brake lite, right 3 T4 -four point, near cruise control main control unit
T4b- four point, under fuse/relay panel
Cruise control inductive sender 7
T71 - seven point, in wire distributor, eng. compart.
Cruise control switch 5-9
Cruise control, main control unit 5·9 Ground connections
Vacuum control motor 8 @-in engine compart., left side
Vacuum vent valve, brake 4
Vacuum vent valve, clutch 4 @-near fuse/relay panel

Water-cooled- Digifant 1987-1989 Cruise control

Manual transmission 97.176
97 Electrical System - Wiring, Waterboxer

--~t-Et-6~~------~--~~~~~~~~~ ~~~~6~G-5_·~~-2-5--~~----~~~~~
1.0 1.0 1.0 0.5
BKIR RIY RIBK BK

T4b

VAC
VENT
~IIJF:~~ijt:;~~==+::;;:;;:;~;::=~21iOJ CRUISE
VALVf; CONTROL
CLUTCH ~~~----~~~~--~--~~--~s~~H
'I'
~5 ~5 ~5 0.5
RIBK R1Y BL BKIBL

[" t
1.0
GIY
TJ

tl tl VACUUM
CONTROL I M .I
MOTOR L=::::=::::!::::=:::::::=..
1.5 1.5
BR BR

S· 6 7 8 9 10
~7-25291

97.177 Cruise control

Manual transmission
Water-cooled- Digifant 1987-1989
 Electrical System - Wiring, Waterboxer 97
Deaerlptlon Current
track
Differential lock indicator lite 2
Differential lock switch 2
Wire connectors
T3 - three point, under instrument panel
T3a- three point, under inst. panel, near fuse/relay
panel
Ground connections
@-in eng. compart, under ign. coil

Note

Differential switches on instrument panel are

vacuum operated and do not appear on the
wiring diagram. ..,.._ _ _ _ _JT3a

I
0.5
"'I
0.5
BKIBL BKIBL
I
EIIERGENCY
FLASHER
SWITCH
KL 15

,4
I DIFFERENTIAL
(/) LOCK
T ~CATOR
.3
0.5
BUBR
~T3
WIRING
COLOR CODE
81( -BLACK 1.0
BR -BROWN BUBR
CL
R
y
G
-CLEAR
-RED
- YELLOW
-GREEN
LT. G- LIGHT GREEN
• DIFFERENTIAL
LOCK
SWITCH
BL -SLUE
v
GY
w
OR
- VIOLET
-GRAY
-WHITE
-ORANGE
I
1.0
BR

lc~
2
197-233~

Syncro I I Water-cooled- Diglfant 1986-1989

Differential lock 97.178
97 Electrical System -Wiring, Waterboxer

Description Current
Track
Heated seat control unit 1-4
Heated seat indicator lite 5
Heated seat switch 1-2
Heated seat temp. sensor 1
Heat element, backrest 3
Heat element, seat 3
Wire connectors
T1 - single, behind instrument panel
T2 - double, behind instrument panel
T5/ - five-point, behind instrument panel
T6/ - six-point, behind instrument panel
Ground connections
@-behind inst. panel, near fuse/relay panel
@-behind instrument panel

97.179 Heated driver's seat

Water-cooled- Digifant 1986
 Electrical System - Wiring, Waterboxer 97
~~--~-.~~===-~~---------------------------=~~----~------=---~~
15 15
X X
31 ~

G2 D7 Al

1.0 0.5 0.5 0.5

BK GYIBL GY/BL GY/BL

'J'861F
0.5
RIW R1Y
J'
0.5
BKJY
lT515 lT5/4 UT5!3
0.5

L,
~lr :.
LL I
®I
L
$I
HEATED
SEAT
IND.
LfTE
S5o

UN"
j4/T f2 iH j7i3l 3lj
0.5 BUY 1.0 BKIR
0.5 0.5

1~:/6
BR BR

i:/4
1 HEAT
HEATED
SEAT ELEMENT,
TEMP; SEAT
SENSOR
0.5 1.0
BR BR
'-'.T6:2 WIRING
lr6i5 T5i2 COLOR CODE
jT6/3 BK -BUCK
BR -BROWN
CL -CLEAR
R - RED
Y - YELLOW
HEAT G -GREEN
ELEMENT, LT. G- LIGHT GREEN
IACKREST BL -BLUE
v - VIOLET
GY - GRAY
1'.0
BR w -WHITE
OR - ORANGE

T6' 1
I
1.0
BA

@
2 3 4 5 6

Water-cooled- Digifant 1986

Heated driver's seat 97.180
97 Electrical System - Wiring, Waterboxer

Current
Description
track
Driver seat heater control unit 3-6
Driver seat temperature sensor 3
Heat element, driver backrest 5
Heat element, driver seat 4
Heat regulating switch, driver 3,4
Seat heater switch indicator lite 2

Wire connectors

T1 - single, under fuse/relay panel

T1a- single, under fuse/relay panel
T2 - double, under instrument panel
T6 - six-point, under left front seat

Ground connections

@-near fuse/relay panel Fuse/relay panel

Plus ( +) connections mJ- S50 10A
@-in instrument panel wiring harness (58b) mJ - Seat heat control unit

97.1 81 Heated seats

canada II Water-cooled - Dlglfant 1987-1989
 Electrical System - Wiring, Waterboxer 97
~--~------------------------~~--~~~~~~~~------~--~~~~~~30

~~
~ I
- ~·
~

~~s~
GS
0.5 GY/8 L . - - - - - - - - - - - - - - - .
G~i~L $J1158b .3/15
I'~~lH~~~E~NG
1IO 1.0 1.0

3
t BK BK BK
~T~ . {

't.f J2i31 J5186/ F f" iPIF

0.5 0.5 0.5
BR R/W RIY

L
u{
L
: :·1:.....,
':/'JER CONTROL

'f4/T f2/H )'7/31

0.5 1.0 0.5
0.5 BUY BKIR BR
GY/BL

WIRING
COLOR CODE

BK - BlACK
BR - BROWN
CL - CLEAR
R - RED
Y - YELLO W
G -GREEN
LT G - LIGHT GREEN
BL - BLUE
V - VIOLE T
--~--1A4 T6!6 T6/4 n l 6 / 2 GY - GRAY
W - WHITE
0.5 1.0 0.5 1.0 OR - ORANGE

$
RIBK BK BR BRIBK

~x~$
TEMP
SNSR
HT
S.EIINT,
ORV1f
SEAT
$HEAT ELEMENT,
DRIVER
BACKREST

0.5 1.0 10
BR BRIBK a·R

tl615 tl·/3 A,l·" BR

@
2 3 4 5 6
l97-2736l

Canada II Water-cooled-Digifant 1987-1989

Heated seats 97.182
97 Electrical System- Wiring, Waterboxer
Description Current
Track

Mirror adj. switch 1-4

Mirror heat element, driver 6
Mirror heat element, passenger 7
Mirror magnetic clutch, driver 4
Mirror magnetic clutch, passenger 5
Mirror motor, driver 2
Mirror motor, passenger 1
Mirror selector switch 1-2

Wire connectors
T2 - double, in driver door
T2a- double, under instrument panel
T2b- double, under instrument panel
T2c - double, under instrument panel
T2d- double, under instrument panel
T2e- double, in passenger door
T3 - three-point, in passenger door
T3a- three-point, under instrument panel
T3b- three-point, in driver door
T4 - four-point, under instrument panel
Ground connector
@-under instrument panel

97.183 Power mirrors

up to VIN G 105 000
Water-cooled - Dlglfant 1986
 Electrical System - Wiring, Waterboxer 97
.- - . 1: .• ~
-, ,,. = _1_11 i
.

1 ' ,.

~ ~3

ms12 ID
~lSA
-

'2 ,
...

G1 G3 E8 E2 E7 A14
WIRING TO
COLOR CODE TO REAR
REAR DEFOGG.
81( - BlACK DEFOGGER HEAT
BR - BROWN SWITCH ELEMENT
CL
R
-
-
CLEAR
RED I I

HT,,
0.5 - YELLOW 1.5 1.5
BKIY G - GREEN G/W G/W

t~
LT. G - LIGHT GREEN
Bl - BLUE
- VIOLE T
GY - GRA Y
w -WHITE

.,
MIRROR OR - ORANGE

.. ,..
ADJ.
SWITCH 1 0.5 0 .5
.•i• ~
G/W G/W

~~
MIRROR
SELECT!OR
SWITCH
1' 3
0.5
BUBK
..
0.5
~
0.5
12 11
0.5 0.5
6

BL BK BR w T2a
I T4 T3 T3a T4 I T3a T2b

0.5 0.5 0.5 0.5

BK w WIG W/G

T3a

I T3 T3b T3 T2e T2

0.5
BUBK

$=... .......
MIRROR MIRROR
MIRROR
~
MIRROR MAGNEnC HEAT
MOTOR, CLUTCH, CI.UTCH, ELEMENT,
DRIVER DRIVER PASSENGER PASSENGER

orBuI 0.5
BK
T3b
0.5
BR
T2
0.5
BR
T2e

T4 T2b

@ @)
2 3 4 5 6 7
197-21921

IWater-cooled- Digifant 19861 Power mirrors

up to VIN G 105 000 97.184
97 Electrical System - Wiring, Waterboxer
Description Current
track
Mirror adjustment switch 1-4
Mirror heat element, left 6
Mirror heated element, right 7
Mirror magnetic clutch, left 4
Mirror magnetic clutch, right 5
Mirror motor, left 2
Mirror motor, passenger side 1
Mirror selector switch 1,2

Wire connectors
T2 -double, in passenger door
T2a- double, under instrument panel
T2b - double, under instrument panel
T2c - double, under instrument panel
T2d- double, under instrument panel
T2e- double, in driver door
T3 -three point, in passenger door
T3a - three point, under instrument panel
T3b- three point, in driver door
T4 -under instrument panel
Ground connections
@-under instrument panel

97.1 85 Power mirrors

from VIN G 105 001
Water-cooled- Digifant from 1986
 Electrical System -Wiring, Waterboxer 97

Gl G3
TO TO
REAR REAR
WINDOW WINDOW
HEATER DEFOGGER
ELEMENT SWITCH

I I
0.5
BKIY

~~,, H y,
1.5
BK
1.5
GNV

0.5 0.5
GNV GNV

J3 l' 12 11 6
0.5 BUBK
0.5 0.5 0.5 0.5
BL BK BR w T4 I T3a T2a T2b
0.5 0.5 0.5 0.5
BK w WIG WIG

TJo

Water-cooled-Digifant from 1986 Power mirrors

from VIN G 105 001 97.1 86
97 Electrical System - Wiring, Waterboxer

Current
Description
track
Window motor, left front door 3
Window motor, right front door 7
Window relay 1,2
Window switch, left front 2·5
Window switch, RF (in LF door) 6-9
Window switch, right front 6·9
Wire connectors
T1 -single, under fuse/relay panel
T2a- double, in driver door
T2b- double, in driver door
T2c - double, in passenger door
T3a - three-point, in passenger door
T3b - three-point, in driver door
T3c - three-point, in driver door
T3d - three point, in driver door
T3e- three point, in passenger door
Ground connections
@-near fuse/relay panel

97.187 Power windows

I
Water-cooled-Digifant 19861
 Electrical System -Wiring, Waterboxer 97

2.5
R

~537
tf30A
0.5 2.5 2.5 2.5 2.5 2.5

L,
BKIY BKIY R BR BK!R BK/R 2.5 2.5
w

L5 ~T,
W/BK
T3d
iT2b iT2b
2.5 2.5
BKIY y

WINO
RLY I f----------f.l T3b
4/31 8!87
2.5 BK!R
I T3b
2.5 2.5 2.5
2.5 BKIY BR y
BK!R
T3c T3c ~T3e 'T3e ~T3e
2.5 BKIR 2.5 BKIR
5 4 5 03
WIND WIND
SW, SW,
LF RF
2 2 1
0.5 2.5 2.5 2.5 2.5 2.5 2.5
BR W/BK w BR W/BK w BR

T2a T2a T2c T2c

WINDOW MOTOR, WINDOW MOTOR,

LEFT FRONT ODOR RIGHT FRONT
DOOR

® ®
2 3 5 6 7 8 9

Water-cooled- Digifant 1986

Power windows 97.188
97 Electrical System - Wiring, Waterboxer

Current
Description
track
Window motor, left front door 4
Window motor, right front door 9
Window relay 1,2 .
Window switch, left front 3·6
Window switch, RF (in LF door) 7·12
Window switch, right front 7·12

Wire connectors
T1 - single, under fuse/relay panel
T2a - double, in LF door
T2b- double, in RF door
T2c -double, in RF door
T2d - double, in LF door
T2e- double, in LF door
T3a- three-point, under inst. panel, right side
T3b- three-point, under inst. panel, left side 197-2540 1
T3e- three point, in RF door
EIJ - power window relay
Ground connection
m- thermo fuse for power windows
@- near fuse/relay panel

97.189 Power windows

Water-cooled- Digifant from 1987
 Electrical System .. Wlrl·ng, Waterboxer 97
30--~~----~~~------------~~------------~------------------------------30
15 15
X X
~ ~

Dl
3

G1 p G3 ES
1.5 R
l 4 WINDOW
SWITCH,

m 00s37
20A
1.5
BR
1.5
BKIR
RF
(IN
LF
2 1 DOOR)
0.5 1.5
BKIY BKIY
"
1.5
R
1.5
W/BK
1.5
w
~T1 ~T2b
6/85
WINDOW
RELAY L m
T2e T2e

1.5
BR
1.5
BKIY

T3b

T3a T3a
!r2b
1.5
y

T3b

T3a

T3b T2d T2d T3e T3e T3e

1.5 1.5 1.5 1.5
BKIR BR BKIR BR

1
1.5 1.5 1.5 1.5
W/BK W W/BK W

!T2a ~T2a ~T2c ~T2c

2.5 2.5 2.5 2.5
BK R BK R

~-~lJ lJ WIRING
WINDOW MOTOR, COLOR CODE
RIGHT FRONT Ill 1--------1
DOOR BK - BlACK
BR -BROWN
CL - CLEAR
R -REO
Y - YELLOW
G - GREEN
LT G - LIG HT GREEN
BL - BLUE
V - VIO LET
tiY - GRA Y
W - WHI TE
OR - ORANGE

2 3 4 5 6 7 8 9 10 11 12
197-2733/

II Water-cooled-Digifant from 1987 Power windows 97.190

97 Electrical System - Wiring, Waterboxer

Description Current
Track

Antenna 3
Balance control 9-12
/
Cigar lighter / 1
Cigar lighter lite 5-6
Radio 4-8
Speaker, LF 12
Speaker, LR 11
Speaker, RF 9
Speaker, RR 10
Wire connectors
T2 - double, behind instrument panel
T2a- double, behind instrument panel
T2b- double, behind instrument panel
T2c - double, behind instrument panel
T3 - three-point, behind instrument panel
Ground connections
@- in balance control wiring harness

97.191 Radio
Water-cooled - Dlglfant 1986
 Electrical System -Wiring, Waterboxer 97
15
-
·9 ';iil-l!li.: I"- • - .. • • ;r.;o,.
__,.._., - - 30
IS
X ,.. X
31 31
..

153
,15A \ ' . '~

J
811 ~ 812 E3

1.5
r
0.5 0.5
-
r------------------------0
RIGY R R
.---------------b
p~~-llliil-llliilil-- c

l d
lr2b
HF

~58b h
0.5 0.5 0 .5 0.5
T2c GY/BL GY/BL BR BR
TO

I I
CLOCK TO
FRESH 0.5
AIR R
FAN
CONTROL
UTE
I
I
05
TO
INTERIOR
LITE,
TO
EIIERG.
FLASH
TO
READING
UTE,
GYiBL FRONT sw. RF

WIRING
COLOR CODE
BK -BLACK
CIGAR BR - BROWN
CIGAR LJGHTER CL -CLEAR
LJGHTER
..
1.5
UTE R
y
G
- R£0
-YELLOW
-
LT. G -
GREEN
LIGHT GREEN
BR BL -BLUE
v - VIOLET
GY -GRAY
w - WN/1£ .
OR - ORANGE

@ @
2 3 4 5 6 7 8
/97-22931

Water-cooled- Digifant 1986

Radio 97.192
97 Electrical System - Wiring, Waterboxer
~ ~
Hi 15
X X
31 31

I
b
c
d

0.5
BR/R
I I
0.75
BK!GY
I
0.75
BR
0.75
BK

R BALANCE
CONTROL

VR HR
0.75 0.75 0.75 0.75
BR/R R BL BK!G

~~a ~~ ~~ ~~
1.0 0.5 0.5 1.0
R R ~ R

SPEAKER, SPEAKER,$SPEAKER,
RF LR LF WIRING
COLOR CODE
~iiiii.........ii~
BK -BLACK
1.0 0.5 1.0 BR -BROWN
R GY BR CL -CLEAR

~T2a ~T3
R -RED
Y - YELLOW
G -GREEN
Lr G- L/GHr GREEN
BL -BLUE
0.5 0.75 0.75 v - VKJLET
BR/R GY BK GY - GRAY
w -WHITE
OR -ORANGE

(19)
9 10 11 12
197-22941

97.193 Radio
Water-cooled - Digifant 1986
 .Electrical System- Wiring, Waterboxer 97
Rear footwell heater blower
Description Current track
Fuse 810 1
Series resistance 2
Warm air blower 1
Warm air blower switch 1-2

Wire connectors
T4 - 4-point, under rear bench seat 2.5
WI'/

~s.
Ground connectors
@ - under rear bench seat

1.0 1.5

····~ ~T· I
BLOWER SWITCH ~
t' t l
t5
Y
t .S
y,st(
1.5
W

r. r. ~r.
1.0
w

SERIES RESISTANCE
Wiring
Color Code
Black - BK 1.5
Brown - BR y

Clear - CL
Red - R
Yellow - Y

r
(ire en -G
L1ght Green -ll G
Blue - BL
VIOleI - v
Gray - GY WARM AIR BlOWEil
While -VI

1.5
bR

r.

Water-cooled- Digljet 1983-1985

Rear footwell heater blower 97.194
97 Electrical System - Wiring, Waterboxer

Current Wire connectors

Description
track T2a- double, under instrument panel, left
Antenna 3 T2b- double, under instrument panel, right
T2c- double, under instrument panel, left
Map/reading lite, right front 8 T4 -four point, under instrument panel
Radio 1·8 TS - eight point, back of radio, middle
T8a - eight point, back of radio, bottom
Speaker, left front 2 T14 - fourteen point, under instrument panel
Speaker, left rear 6
Speaker, right front 3 Ground connections
Speaker, right rear 7 @- in instrument panel wiring harness
Welded wire connections
@-plus (+)connection 586 in inst. panel wire
harness

97.195 Stereo radio

Water-cooled- Digifant 1987-1989
 Electrical System - Wiring, Waterboxer 97

I
0.5 0.5
R R

TO
I
114/5

0.5
CIGARETTE R
LIGHTER
LITE I

I
TO TO
INTERIOR MAKE-UP
LITE, MIRROR
FRONT LITE

0.5 0.5 0.5 0.5 0.5

GY/BL GYIBL R R BR

WT8o/6{58b
f~@~
HF IIADIO

...;:-~~~..=..,=,.,=,.=,,=,"=ll="=,..~ll='H::M::"'::"*::"::"~'..="=If:::u::•u::;.=.. ,=..=
LL,.=..
.. ,=,.=....=.,=,,~...=..=.u=·.. ,=..=:,="=,,=..;-,~.::;.@;,:--l
T8a/8/-

'j'TB/6 'j'T8/5 T8/3 'j'TB/4 'j'TB/8 'j'TB/7 J'TS/1 'j'TB/2

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
BRIBL BL R BRIW BRIR BUG RIG BRIBK BR
~12a 12a ~12b ~12b 1414 14t3 14tl 1412
0.5 0.5 0.5
BRIR BL BRIR

·~
+ +
SPEAKER, SPKR, SPEAKER, SPKR,
LEFT RF LEFT RR
FRONT REAR

2 3 5 6 7 8

Water-cooled-Digifant 1987-1989
Stereo radio 97.1 96
97 Electrical System - Wiring, Waterboxer

Current Wire connectors

Description
track
T2 - double, under instrument panel, left side
T2a- double, under instrument panel, right side
Amplified speaker, left center 8·9 T2c- double, under instrument panel, left side
Amplified speaker, left front 8-10 .
T3 -three-point, under instrument panel, left side
Antenna 9
T8 - eight-point, on radio
Map/reading light, right front 11 T8a - eight-point, on radio
T1 0 - ten-point, on radio
Radio 2-10
Speaker, left front 3 Welded wire connections
Speaker. left rear 6 @-plus (+)connection, terminal 58b in
Speaker, right front 4 instrument panel wiring harness
Speaker, right rear 7
Ground connections

@-under instrument panel, middle

97.197 Stereo radio with

amplified speakers
Water-cooled-Digifant from 1988
 Electrical System - Wiring, Waterboxer 97

a
rE3
WIRING 1.5
COLOR CODE R

-r 0.5
GY/BL
BK
BR
CL
R
y

G
LT G -
-

-
- BLACK
8ROWN
-· CLEAR
- REO
- YELLOW
GREEN
LIGHT GREEN
I
0.5
R
fr'' I
0.5
R
1.5
R

L,
BL -
-
BLUE
VIOLET I I
GY - - GRA\' TOMAKE·UI' TO INTERIOR
w - WHffE MIRRORUGHT LIGHT, FRONT
OR - ORANGE

T8/6 RADIO

© lulU IU I I I I I t I I I I t i l l 111111111 I l l l f i i ! U I I I I I I t l f I t I I I I I U U I I I I I I l U I U t l t l l f l ! I I 'it I l l l l l l l l l l l l l l l l l l l l l l ! U I I l l UUIIIIII I I I I I I I I ! I l l l l l l l l l

jTBo/6 JT8o/5 f8a/3 rsa/4 JT8o/8 ~TSo/ 7 ~TSo/1 t8o/ 2

0.5 1.0 U) 1.0 1.0 1.0 1.0 1.0 1.0

GY/BL BR!BL BL R BRIW BRIR BUG RIG BRtW

I
TO CIGARETTE
UGHTER LIGHT

SPEAKER, SPEAKER,
LEFT LEFT
SPEAKER, REAR SPEAKER,
FRONT RIGHT RIGHT
FRONT REAR

2 3 5 6 7

Water-cooled-Digifant from 1988 Stereo radio with

amplified speakers 97.1 98
97 Electrical System - Wiring, Waterboxer

mANTENNA

(
•
HF

't - - - - - ,

IIIIIIIUIIIII!tfltllUIII!UIIUIIIIIIIIIUIIUIIUijlllllltlllll @
.Tl0/5 .Tl0/8 jT1()(9 jT8/3 ~8
1.0 1.0 1.0 0.5 1
1.5 ' - - - - - - - - - - -. .

I
BRIY G BL.JW W/BL BR

T3 T3
0.5
BR

IIAPIREADINQ

I.2 ll
©
AMPUFIED SPEAKER,
I LIGHT, RIGHT
FRONT

LEFT FRONT
1.0 1.0 1.5 0.5
G1W BR/BL R R
T3

!J,
AMPUFIED SPEAKER,
LEFT CENTER
WIRING
COLOR CODE
81(

BR
CL
-BLACK
-
-
BROWN
CLEAR
R - RED
y· - YELLOW
G - GREEN
LT G - 1../GHT GAEEN
BL - BLUE
v - VIOLET
GY -GRAY
w - WHITE
OR - ORANGE:
@
8 9 10 12

97.199 Stereo radio with

amplified speakers
Water-cooled-Digifant from 1988
 Electrical System - Wiring, Waterboxer 97
Current
Description
track
Radiator cooling fan
Radiator cooling fan after run series
resistance 1
Radiator cooling fan relay (2nd stage) 2·4
Radiator cooling fan thermoswitch 1,2
Wire connectors
T1 - single, under fuse/relay panel
T1a - single, under instrument panel
T2 - double, under instrument panel
2.5
( + ) connectors RJW

@-terminal 30, in wire distributor In eng.

compart.
j®
·G round connectors 6.0
R
@-near fuse/relay panel
Tt

3 ~
542
FAN 50A
THERIIOSW
f2 fl

I IJ4~0:I
2.5 1.0 4.0
RIBK BL RJW

12 FAN
RELAY

RAOCOOLFAN
AFTER RUN SER
RESIST

2.5
1f' ~~:ir
f6/86
0.5
fB/87
6.0
R BR R

6.0
BR

@ @
2
197-24361

Water-cooled- Digifant 1986-1989 45o-Watt radiator

cooling fan 97.200
97 Electrical System-Wiring, Waterboxer

Fuse/relay panel
IJ- Low coolant level control unit (43)*, J120
II- Rad. cool. fan relay 2nd stage (53)*, J101
II- Load reduction relay (18)*, J59
Ill- Intermittent wash/wiper relay (19)*, J31
Ill - Rear window wash/wiper relay (72),* J30
I& - Emerg. flash/turn sig. relay (21 )*, J2
ml- Seat belt warning system control unit, J34

RJ]WN
2j Jl
•I 51
·I~
p
Fuse arrangement
according to numbers on fuse panel as seen from
left to right:

Amp. 197·14951
1 Radiator cooling fan . . . . . . . . . . . . . . . . . . . .. . • 30
2 Brake lights .. .. . . .. .. . . . .. .. .. .. .. • .. .. .. 15 Connections and plugs on fuse/relay panel
3 Cigarette lighter, radio, clock, interior lights,
illuminated make-up mirror . . . . . . . . . . . . . . . . . 15 A - multi-point connector (blue) for instrument
4 Emergency flasher system .......... , . . . . . . 15 panel wiring harness
5 Open B - multi-point connector (red) for instrument panel
6 Open wiring harness
7 Tail, parking and side marker lights, left 10 C - multi-point connector (yellow) for front wiring
8 Tail, parking and side marker lights, right .... 10 harness
9 High beam right, high beam indicator light . . . 10 0 -multi-point connector (white) for windshield
10 High beam left . .. .. . . .. . . . . .. . . .. . . . . .. . . 10 wiper and main wiring harness
11 Windshield wipers and washer . . . . . . • . . . . . . 15 E - multi-point connector (black) for main wiring
12 Cruise control, A/C, power windows, auxiliary harness
heater fresh air fan, power mirrors, rear window G - single connector
wiper .................................... 20 H - multi-point connector (brown) to connector for
13 Fresh air fan ............... ; ............. 20 rad. cool. fan relay, 2nd stage
14 Rear window defogger . . . . . . . . . . . . . . . . . . . . 20 K - multi-point connector (colorless) to radiator
15 Back-up lights . . . .. . . . .. . .. .. . .. .. . . .. .. .. 10 coolant low-level control unit
16 Hom .................................... 15 L - multi-point connector (gray) for horns
17 Windshield wipers . . . . . . . . . . . . . . . . . • . . . . . . 10 M -open
18 Seat belt warning relay, brake and park brake N - single connector
indicator, cruise control, heated driver's seat . 10 P - single connector (terminal 30)
19 Turn signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 R -open
20 License plate lights . . . . . . . . . . . . . . . . . . . . . . . 10
*Numbers in parentheses indicate production control
21 Low beam left . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
number stamped on relay housing.
22 Low beam right . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

97.201 Fuse/Relay panel

Water-cooled- Digifant from 1990
 Electrical System-Wiring, Waterboxer 97
Descrtpllon CUrrent Description Current Description Current
Track Track Track
" ')',
Air flow sensor potentiometer, 619 Fuse, 59 Parking brake warning light switch, F913P
Alternator, C Fuse, 519 Parking fiQht, left, M1 102,
Alternator warning l~ht, K2 Fuse, S4 Parking l~ht. right, M3 1$ ,
Fuse, 52 Power steering pressure switch, F88 39-(0. ··•· •
Back-up light switch, F4 Fuse, 515
Back-up light, left, M16 Fuse, 516
Radiator cooling fan, V7 .144' ,.
Back·up light, ~hi, M17 Radiator cooling tan relay (2nd stage), •• ·
Fuse, 518
Batter;, A Fuse, S6
J101 1*149 ···.
Brake and parking brake indicator Radiator cooling fan thermoswitch,
Fuse, 514
l~ht, K7 F18 ·~~1*5.
Fuse, 513
Brake fttOO level Wlllling mntad, F34 Reading light, behind drive(s seat,
Fuse, 51
Brake l~ht swHch, F W22 83·84
Fuse, 511
Brake light, left, M9 Fuse, 517
Reading light, left rear, W11 ·85-116 ·
Brake fiQht, right, M10 Rear window defogger ind"IC8Ior Hght,
Fuse, 512
K10 13&
Cigarette lighter, U1 Hall generator, 640 Rear window delogger swilch, E15 1•14fl
Cigarelle l~hter l~ht, L28 Headlight dimmernlasher switch, E4 Rear window defogger switch light,
Clock light, l8
Headl~tt ~ beam warning l~tt. K1 l39 138
Coolant low level control un~ J120 Headlight. left, l1 Rear window heater element, Z1 140
Coolant low level sensor, 632 Headligh~ left, l1 Rear window washer pump, V13 160
Coolant overheat warning light, K28 Headlight, right, l2 Rear window • motor, V12 162•163
Coolant temperature gauge, 63 Headlight, right, l2 Rear window wiper/washer relay, J30 ''$1;j62.•
Coolant temperature sensor, 662 Heater blower series resistance, N72
Coolant temperature sending unit, G2 Seat belt switch, left, E24 ·~· ·
Heater fan swHch iUumination I~
Seat belt warning light, K19 1~ •
Digifant cordrol unit, J169 l50
Heating element (crankcase
Seat belt warning system control unit, : :•. /.'
Digilant cordrol unH relay, J176 J34 132JI3S :
ventilation), N79
Digital clock, Y2
Door contact switch, left Iron!, F2 High·beam headl~ht. left, l13
Side marker lights, rear, M12 .;1fi
Spark plug connectors, P ;13-1S ·
Door contact switch, righllront, F3 High·beam headlight; right, l14
Spark plugs, Q 13:-1$• .
Hom button, H
Emergency flasher relay, J2 Starter, B S:..l
Horns, H1
Emergency flasher switch, E3 T.D.C. sensor, 67
Emergency flasher warning light, K6 Idle stabilizer control unH, J142
Tachometer, 65
Engine oil pressure control unft, J114 kle stabilizer valve, N71
Taillig~ left, M4
Engine oil pressure switch (0.3 bar), Ignition coil, N
Tail light, ~ht, M2
F22 ignition distributor, 0
Throtlle valve switch (enrichment),
Engine oil pressure switch (1.8 bar), Ignition/starter switch, D
F25
Engine oil pressure warning light, K3 !~ector, cyl. 1, N30
Turn signal indicator l~ht, K5
!~ector. cyl. 2, N31
Fresh air ~:tw~r series reance, l~ector, cyl. 3, N32
Turn signal light, left Iron!, M5
Fresh air control lever light, l16 Tum signall~ht left rear, M6
l~ector, cyt. 4, N33
Fresh air fan, V2 Tum signal light, right• M7
Instrument panell~ht, l10
Fresh air fan switch, E9 Tum signall~tt, ~rear, M8
Instrument panel light dimmer switch,
Fuel gauge, 61 Tum s~nal swHch, E2
E20
Fuel gauge sending unit, 6 Intake air temperature serm, G42 Voftage regulator, C1
Fuel pump, G6 Interior light, front, W Voftage stabnizer, J6
Fuel pump relay, J17
Fuse, S5 Ucense plate light, X Warm air blower, V47 149
Fuse, 551 light switch, E1 Warm air blower switch, E100 151}.152
Fuse, S3 load reduclion relay, J59 Washer/wiper intermittent relay, J31 15&-158 ·
Fuse, 57 Windshield washer pump, V5 1$11
Make-up mirror light, right, W14
Fuse, S8 Windshield wiper motor, V 1~154
Mapireading l~tt, ~. W13
Fuse, S20 Windshield-wiper intennittent switch,
Fuse, 510 Overheat fuse, 524 E22 155·158
Fuse, S21 Oxygen sensor, 639
Fuse, S22

Water-cooled-Digifant from 1990

Current track index for Main wiring diagram 9 7 •2 0 2
97 Electrical System-Wiring, Waterboxer

Wire connectors Ground connections

T1 - single, under instrument panel, left side G)- battery to body
T1a - single, above left rear window
T1d - single, in wire distributor box, engine @-transmission to body
compartment @-in engine compartment, left
T1e -single, under instrument panel, left side
T1g - single, in wire distributor box, engine @-on engine block
compartment @-ground wire, above steering gear
T1h - single, engine compartment, left side
T1i --' single, under instrument panel @- near fuel gauge sending unit
T1k- single, engine compartment, left
T1m- single, near relay panel, engine compartment
@- near relay panel
T1n - single, near relay panel, engine ·compartment @-under instrument panel, middle
T1o - single, under instrument panel, left side
@-in rear decklid, left
T2c - double, under instrument panel, left side
T2d - double, upper right 'A' pillar @-in rear decklid, right
T2e- double, in rear deck lid, near wiper motor
T2f - double, on upper right 'C' pillar, behind cover
@- near rear washer bottle holder
T2g- double, under instrument panel, left side @- near rear window wiper motor
T2i - double, in wire distributor box, engine
compartment @- near rear decklid opening
T2k- double, in engine compartment, left @-ground connection, instrument panel wiring
T2m- double, near relay panel, engine harness
compartment
T2o- double, near driver's seat belt buckle @-ground connection, in Digifant wiring harness
T2x - double, in engine cOmpartment, middle
T3 - three-point, near alternato'r Welded wiring connections
T3a- three-point, behind instrument panel, right @-plus (+),terminal 58b, in instrument panel
side wiring harness
T3b- three-point, behind instrument panel, left side
T3d - three-point, behind front grille @- plus ( + ), in Digifant wiring hamess
T3x- three-point, under instrument panel, left side
T7 - seven-point, in wire distributor box, engine
@- in Digifant wiring harness
compartment ®-plus ( +) 30 terminal, in wire distributor box,
T7a- seven-point, in wire distributor box, engine engine compartment
compartment
TB - engine-point, under Instrument panel, middle
T14- fourteen-point, on instrument cluster

-
9 1 •2 0 3 Current track index for Main wiring diagram
Water-cooled-Digifant from 1990
 Electrical System-Wiring, Waterboxer 97
~~--~~---.--~--~------------------------------~~----~-------------~
X-t--t--t---r--;---t-------------------~~--~----~----------------~~31
31

r---~======1================i==~1

r-------------,_----~--~--~--------~~~--+--b

p p p p p p 024 E13 AS
6.0 6.0 0.5 1.5
A RIBK BL BK

WIRING
COLOR CODE

BK
BR
- BLACK
-BROWN
T1.5
A 30
CL -CLEAR
R - RED
y -YELLOW
G - GREEN
LT G - LIGHT GREEN
BL -BLUE
v - VIOl.ET 2.5 0.5 0.5
GY - GRAY BKIY BK GY/BK
W -WHITE
OR - ORANGE

1.5
A

10.0 2.5 90 52
R A

25.0
i
25.0

CD 0
2 3 s 6 7 8 9 10 11
,_,9-7--81-47-.[

Water-cooled-Digifant from 1990

Main wiring diagram 97.204
97 Electrical System-Wiring, Waterboxer

7 •
8 (j 3

023 015 E12 CIS 86 013 N C21 019 026

1.5 0.5 0.5 WIRING

BK G R/BK COLOR CODE

BX -BLACK

r T BR -BROWN
CL - CLEAR
R -RED
Y - YELLOW

I
G -GREEN
TTn 0.5
LT G - LIGHT GREEN
0.5 BKJW
lig~
GY~~1 m
BL - BLUE

_ _, . 0.5 I T7a/5 V
GY
-
-
VIOLET
GRAY
W -WHITE
BK J161
DIGIFANT CONTROL OR -ORANGE
15 15
N
IGNITTON
COIL
1''7 fi'o ~
j25 j8
T
iT8 j6 j9 j21

. . . . . . . r·I ,,0 By0 BAm BAm Brl5. I I01·3

1.0 1.5 0.5 0~5 1.0 0.5 0.:> 0.5 1.0 1.0 0.5
BK G G hu BR!W @ BL/W BUR GY GY RJBL R/BL

--------~5--------1~o---------1~o---o1
5
1
'05 sem K
FUSE r---11-------, ~ M
~~1 !?f~!:B__U!~l! @): ~ j: 'i. ~I
G40 G42 G19

1.0
I HALL GENERATOR 1NrAKE AIR
TEIIPERATURE
SENSOR
AIR
FLOW
SENSOR
POTENTIOMETER
BK
41 42

I 8J ®
p
.--'i'--¥--¥---¥-1 SPARK PLUG G62
CCNNECTORS WROrnE VALVE

a,[$]
1 Q SWI'ICH · ·. =::IruRE
'--+--1--t--t--' SPARK PLUGS (ENRICHIIENT) ·.
SENSOR
fff:tASE
1.0
BR

12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
197-81481

9 7 •2 05 Main wiring diagram

Water~c ooled- Digifant from 1990
 Electrical System-Wiring, Waterboxer 97
3~------------------------------------------------------------------------- ~
1~ 15
X X
131 3~
~ ~
a

E4 Dl G6 A4

1.0
R/BK
]4
T7a/6
T0 .5
R/BK

T2m
0.5
Jt69
DIGIFANT CCNTROL
UNrr 3

r r- ·
Ill\ J11
W FIJEL
PIJIIP 4----=~..:.~

___~4::----tl~~·5B_KIY-:,
----r____.:... _·=R£_l..A=Y
___ ~=RJW- - l .l- -8/_8_7~
,-"':_.:

1.5 1.0 0 .5 1.0 1.0 1.5 1.0 1.0 1.0 1.0 1 .0

BR BR/BK W R/Y W RJW R/W R/W R/W R/W

L, /

WIRING
COLOR CODE

BK -BLACK
8R - BROWN
CL - CLEAR
R -RED
Y - YELLOW
G -GREEN
LT. G - LIGHT GREEN
BL -BLUE
v - VIOLET
n m Gl
FIJE1. PIJIIP
GY -GRAY
w - WHITE
OR - ORANGE
N30 'ti{N31 'til N32 'til N33 'til
l INJ, CYL t •INJ, CYL 2 • INJ, CYL 3. INJ, CYL 4 •
1.0 1.0 1.0 1.0 1.0 1.5
BR w w w w BR

---~~--6----~--~@0 ~T2k
1.0
BRIG

@ @ @
28 29 30 31 32 33 . 34 35 36 37 38
197-81491

Water-cooled-Digifant from 1990

Main wiring diagram 97.206
97 Electrical System-Wiring, Waterboxer

G4 04

1.0 0.5 0.5

BL BL BUG

~
T
0.5
RIBK WIRING
COLOR CODE

BK -BlACK
BR -BROW!¥
Ct -CLEAR
R -RED
Y -YELLOW
G -GREEN
tT G- LIGHT GREEN
8t - BWE
V - VKXET
17/1 GY - GRAY
W -WHITE
OR - ORAIVGE
1.0 0.5 1.0 0.5 0.5 1.0 1.0 0.5 0.5
RIW W/Y BR GY R!BL W y WIG G
[MJ

~ 25 T1k
0.5
R/W
3 1 y BK y I 1/61 ,4/0XS
FN
POWER
STEERING
PRESSURE
'"'
IDI.E
BTABfLIZER
SWITCH VALVE
ts/31
0.5
BR
T3 T3 T3

41 42 43 44 45 46 47 48
l@
49
l97'815ol

97.207 Main wiring diagram

Water-cooled-Digifant from 1990
 Electrical System-Wiring, Waterboxer 97

n311 6 ..
7 2
• 5

h rl
~
E15 021 81 824 819 AJ 08 A27 03 818 815 821 K3 B2 E10

0 .5 0.5 1.0 0.5 0.5 0.5 0.5

y BUBK BL BL G BUBK y

'
0.5
BK
'
0.5
A

T7a/7 Tla/1

G5 TACHOMETER
J114 ENGINE OIL PRESSURE CONTROL UNIT
K2 ALTERNATOR WARNING UOHT
K3 ENGINE OIL PRESSURE WARNING UOHT
Y2 DIGITAL CLOCK

WIRING
COLOR CODE
BK - BLACK
BR - BROWN
T2x T2x CL - CLEAR
R - RED
0.5 0.5 y - YELLOW
BR BR G - GREEN
LT. G - LIGHT GREEN
BL -BLUE

F1 FZ2
v - VIOLET

ENGINE ENGINE GY - GRA Y

OIL 011. w -WHITE
PRESSURE PRESSURE OR - ORANGE
SWtTCH SWTTCH
~R)
(1.1
BAR)

0.5 1.5
BR BR

® ® @
50 51 52 53 54 55 56 57 58 59 60
197-81511

Water-cooled-Digifant from 1990

Main wiring diagram 97.208
97 Electrical System-Wiring, Waterboxer

~ ~
15 15
X X
31 31

7
.2

A17 A28 83 87 K2 817 K1 029 ES

0.5 0.5 0.5 0.5 0.5 1.0 0.5 1.0

BUR BLJW V/BK Y/R BUG Y/R Y/R V/BK

1
0.5
GY/BL

L/l Tl-4/10 T 14/2 T14/7 T14/6

• s Kt .

T7a/3 I T7a/2

G1 FUEL GAUGE
G3 COOLANT TEMPERATURE GAUGE
J6 VOLTAGE STABILIZER WIRING G G32
K1 HEADLIGHT HIGH BEAM WARNING COLOR CODE COOLANT
LIGHT LOW
K5 TURN SIGNAL INOICATOR LIGHT BK -BLACK LEVEL
K28 COOLANT OVERHEAT WARNING LIGHT BR -BROWN 31~ SENSOR
L8 CLOCK LIGHT CL -CLEAR
L10 INSTRUMENT PANEL LIGHT R -RED 0.5
- YELLOW BR
G -GREEN
LT G - LIGHT GREEN
BL -BLUE
V - VIOLET G2
GY - GRAY COOLANT
W -WHITE TEl/PERATURE

-ifl
OR -ORANGE G a
8 ~
FUEL
GAUGE

. - - - - - _ , 0 . 5 BR ··----··31

1.0
k;,
1.5 1.5 1.0
BR BR BR BR

~ I@ ~ I@
61 62 63 64 65 66 67 68 69 70 71 72 73

9 7 •2 0 9 Main wiring diagram

Water-cooled-Digifant from 1990
 Electrical System-Wiring, Waterboxer 97
30 r.
30
15 15
X X
31 31

I' RISE
~~3
, 11 15A

~ ~
I J
)811 EJ 812
1.5 1.5
R R

r0.5
Cf I
0.5 1.5 0.5
)r2c11

0.5
GY/BL R R R R

fir&O
0.5
0
RADIO,
'irar7
TO
RADIO,
T2d/1
0.5
Y/BLR R R

W13
IIAPIREAOING 31 T
UGHT,
RIGHT TO 0.5
FRONT RADIO, BR
0.5 R 0.5 0.5 0.5 0.5 0.5
BRIW BR
surara 2d/2
BR BRIW BRIW

1.5
BR WIRING
COLOR CODE
BK -BLACK
BR - BROWN
CL - CLEAR
R -RED
y - YELLOW
G -GREEN
LT. G - LIGHT GREEN

~ ~
BL - BLUE
v - VIOLET
GY -GRAY
0.5 0.5
BR BKIBR w - WHITE
OR -ORANGE

U1
CiGARETTE
n
DOOR CCNTACT
~R SwntH, RIGHT
FRONT

1.5
BR Ul~
CIGARETTE
LIGHTBf
UGHT

® @ @ @
74 75 76 77 78 79 80 81 82 83 84 85 86
197·81531

Water-cooled-Digifant from 1990

Main wiring diagram 97.210
97 Electrical System-Wiring, Waterboxer

30 30
15 - 15
X X
31 3158L

~5:"
58Rs8
[FUSE
lOA
~Sa
lOA s:4 lOA

~ 49a
56o

810 Ml B27 G9 El

1.0 1.0 0.5 1.0 0.5 0.5

RIY RIY BK!Y W/BK GY/G GY!G

9 WIRING
COLOR CODE
BK -BUCK
BR -BROWN
CL -CLEAR
R - R£0
y - YELLOW
G - GREEN
LT. G - LIGHT GREEN
BL -BLUE
v - VIOLET
GY - GRAY
2.5 2.5
BK!Y W!BK w - WHITE
OR -ORANGE
T2;12
0.5
GY/G

E20
ltSTRUIIENT
PANEL
LIGHT
DIIIIIER
E1 SWITCH
LIGHT SWITCH

0.5
GY/G
I

+~+
o•m5
0.5
BR BR
~T2;11
0.5 0.5 0.5 0.5 0.5 1.0
GY/BL GY/BL GY/BL GY/BL GY/BL BR

87 88 89 90 91 92
~ '
93 94
du ~ ~
95 96 97
~
98
!97-81541

97.211 Main wiring diagram

Water-cooled-Digifant from 1990
 Electrical System-Wiring, Waterboxer 97
.::· ---;:. ',;t ·:'!"~~ ~~ :~~~
~-
J
30
15 - -~~· - - 30
15
...._ - --- ,-...'=- ~

t I
' - "" ...
,..
31
58

~-
RIK RISE'
I 522
~"
510 521
lOA lOA lOA
49o ., - ,._ -' 49a
566 "!;:'
-~ -::;>
=~ J..
~~
C17 C5 C-4 E9 M2 A21 822 E18 C14 C6 C16 813

1.5 1.5 0.5 0.5 2.5 2.5 0.5 0.5 1.5 1.5
w Y GY/BK GY/BK y w GY/R GY/R Y/BK W/BK

:,
,.

TT1.0
RIY
2.5
W/BK
I•'
I ~I
WIRING
I \~ COLOR CODE

BK - BLACK
BR -BROWN
CL -CLEAR
R - RED
y - YELLOW
T11s T116 G -GREEN
LT. G - LIGHT GREEN
I• BL -BLUE
V - VIOLET
30 56 E~ GY - GRAY

,,rt..~...;
~ ,.ij ~~ =:
FLSHR
W
OR
-WHITE
-ORANGE

sw
56a 56b

I
1.5

56b 58 58 56b 56a is6a

Lt Mt M3 L2 L74 f2.
. HOLT, PRK fJ..K ~ HOLT, f ?' ="~ , >, HEADLIGHT,
L LT,
L
R' " R ' 'y RIGHT
,)';>' RIGHT

3~~ 1~~1
Bi u
L---------------------------+-------_,~-------- u
L--------.---------v
~--~----------------------------.-------------~---------w
@ @
100 101 102 103 104 105 106 107 108 109 110 111
197-29221

Water-cooled-Digifant from 1990

Main wiring diagram 97 •212
97 Electrical System-Wiring, Waterboxer

~ ~
15 15
X ~· ~
X
31 31
58 58
tV49 4!31
~FUSE
519
lOA
s..~ 1 ~601 -
3/49a 2~y
49o FLASHER
RELAY
I
A13 A18 828 AlO All A7 025 'A20 Dll 'C19 Ell C8
'E6
1.5 1.0 1.5 1.0 ' 1.0 1.0 1.0 1.0 1.0 1.0
BKIBL W RNJ BKIW/G BK!G BKIW BKIW BKIW BKIG BK!G

WIRING
COLOR CODE
BK - BLACK

li BR
CL
R
-
-
-
BROW N
CLEAR
RED
y - YELLOW

~~
G - GREEN
SWfTCH LT. G - LIGHT GREEN
BL - BLUE
v - VIOLE T

1.0
BKIW/G
I"
r r
1.0
BK!G
1.0
BKIW
GY
w
OR
-
-
GRA Y
WHITE
- OR ANGE

Tm Tm
I•

-
I
K6
EMERGENCY
FLASHER WARNING
15 49 30 f49a ~ II "' L
LIGHT

__J t _ .., .. : GP
I

E3
EIIERGENCY
FLASHER SWITal
, rl58b 31

0.5 0 .5 0.5
GY/BL GY/BL BR

BL BL BL BL
116 M5 118 117
C~ 'fVRN C~ TVRN CQ,TVRN . Tli11N
, SIGNAL
SIG~ S1G SIG
LT.
LR I LT,
LF
LT,
RR
I ~R
LIGHT,
IGHT
ONT

1.0 1.0
BR BR
[]; ~ 96

u u
v
w

® @ (39
112 113 ll4 115 116 117 118 119 120 121 122 123 124
197-29231

97 •213 Main wiring diagram

Water-cooled -Digifant from 1990
 Electrical System-Wiring, Waterboxer 97
-
30 30
15 15
X ;:"n'
X
31 31

,..
-
58 58
',. ,1..4 A2 ,. .,
152
15A
I, 515
10A
~J6
15A
' 1 3

I
C3 C1 El6 016 C20 l1 L4 l2 825 C15 C13 L3

1.0 1.0 . 1.0 1.0 1.0 1.0 1.0

RIY R/BK BKIR BK!GY BRIBL BRIBL BKIY

I T2g I T2g T7/3

F4 WIRING
IIACIC-l/P COLOR CODE
LIGHT
SwrTCH BK - BLACK

l BR
CL
-BROWN
- CLEAR
1.0 R -RED
BKIBL y - YELLOW
G -GREEN
LT G - LIGHT GREEN
1.0 BL -BLUE
RIY V - VIOLET

I
GY -GRAY
1.0
W - WHITE
BKIBL
OR - ORANGE

1.0
BKIR

154 RF RF 71
1110
BRAKE H
LIGHT, HORN
RIGHT 119 1116 1117 BUTTON
BRAKE BACK-UP BACK-UP
LIGHT, LIGHT, LIGHT,
LEFT LEFT RIGHT 1.0
BR

U-----------------------+--~

125 126 127 128 129 130 131

Water-cooled- Dig ifant from 1990

Main wiring diagram 97.214
97 Electrical System-Wiring, Waterboxer

w
15
~
15
X X
31 31
sa
2 1 FIIBE
~~
RIE

u--•
518 56
lOA ISA

r:
' 3

820 A25 07 G2 GS C22 816

0.5 1.5
BK BK!W

WIRING
COLORCOOE
BK -BLACK
BR -BROWN
CL
R
-CLEAR
-RED
cyJ'
y - YELLOW 0.5
G -GREEN GY/BK
LT G- LIGHT GREEN
8L -BLUE
v -VIOLET
GY - GRAY
W - WHITE
OR - ORANGE"

0.5
GY
~T1e 0.5
BUBR
I T1a
0.5 0.5
GY BK

F9
PARKING
I F34
BRAKE
Zl
REAR
BRAKE FLUID WINDOW
WARNING LEVEL HEATER
E24
SEAT BELT SWITCH,
LEFT
LIGHT
SWITCH
I
0.5
WARNING
CONTACT
1.5
ELEMENT

BR BK
81
1.5
BK

® ® @ @ @ @
132 133 134 135 136 137 138 139 140
l91-81ssl

9 7 •21 5 Main wiring diagram

Water-cooled-Digifant from 1990
 Electrical System-Wiring, Waterboxer 97
30 30
15 15
X X
31 31

:;: 5185 4130 I, . 13 2

· y-- ---
FUSE
. . .ntn
513
- ~ 6186 "'8187 - IIAilfAroR
20A 30A COOCIGFAN
RB..Ar(2ND
7

~
I
A22 C7 H6 H3 fHl H-4 H2 H5
1.0 2.5 1.5 2.5 0.5
BKIR RIW R!BL R BR

T
' '
li;
0.5 0.5 1.5
GY/BL GY/BL BKIY
L16
FRESH E100
AIR WARM
CONTROL AIR
LEVER BLOWER
58b
LIGHT
+ 58b SWTTCH +

31 '(3 {2 31 '(3 l2 11
0.5 1.5 1.5 2.5 0.5 1.5 1.5 1.0
BR y Y/BK R/BK WIRING BR y Y/BK w
COlORCOOE
8K - BI.ACI(
.BR - BROWN
Cl. - CtEAR
R -RED
y - YELLOW
G -GREEN
LT. G- LIGHT GREEN
81. - BLUE
v - VIOLET
GY -GRAY
w - WHITE
OR - ORANGE

77 T3dl2 T3dll

2
V2
FRESH
AIR • V7
FAN

1.5
.-
2.5
RADIA'TDR
COOLING FAN
S24
OVERHEAT
N72
HEATER
BR BR 1 5 FUSE
B.R BLOWER
SERIES
T3dt3
Ju BESJ$TANCE

@ @ @ ®
141 142 143 144 145 146 147 148 149 150 151 152
191-81561

Water-cooled-Digifant from 1990

Main wiring diagram 97.216
97 Electrical System -Wiring, Waterboxer

i~----------------------------------------------------------------------------~
:X X
~
31 31

RISE 6/535~ -~~15 ' 4131 R1

FIIU
[ Sn
) 1511\
S11
lOlA
14~.;41il . ® lm~~
51t REUY
t2~M 1/J

I I T
~020 012 09 02 1017 IA6 89 A.5 A2 A12 A14 . Al9 IC9
1.5 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 0.5 1.0 0.5 0.5
BR BR G/BK GIY GY/BK G G GY/BK GIY G/BK BRIBK G/W G/R G/R

53b 53 J l T

t.. ·""- -......, '""' -~ .. t!. .a. 11·rru J

53o 53e E22
WINDSHIEL~W1PER
INTERII!rTENr
SWITCH

WIRING
COLOR CODE

BK
BR
-BLACK
-BROWN
V5
WINDSHIELD ~+
CL -CLEAR WASHER PUIIP
R -RED
Y
G
LT. G -
YELLOW
-GREEN
LIGHT GREEN
I
0.5
BL -BLUE BR
V - VIOLET
GY -GRAY
W -WHITE
OR - ORANGE

153 15"' 155 156 157 158 159

197-292~

97 21 1
li Main wiring diagram
Water-cooled-Digifant from 1990
 Electrical System-Wiring, Waterboxer 97
jo 30
15 15
X X
31 31

. .., 11/53c I 4/31 3153o

FIM
2 L
(~ [_]J-~~-, 512 II
M 20A
I 2/53 ~ I 3
IIIA/I IWWJOW
llni'D1IIUIHER
RELAY
I J. -r
DS '"'G10

11,0
E7

1.0
E2

1.0
E8
N.!
1.5 1.5
G3 R1 R2

,G/W G/BK BKIGY BKIY BKIY

T3b 1s2 T1

WIRING
COLOR CODE

BK -BLACK
T3o T3o T3o BR -BROWN
CL - CLEAR
R -RED
y -YELLOW
G -GREEN
LT. G - LIGHT GREEN
BL -BLUE

T2f I T2f v - VIOLET

GY -GRAY
w -WHITE
OR - ORANGE

T2e T2e

V13
REAR WINDOW
lfiUHER PI/liP
~':.. REAR WINDOW
WIPER 11070R

131

1.0 1.0
BR BR

I@ I@
160 161 162 163 164

I
.
Water-cooled-Digifant from 1990 J
_ Main wiring diagram
97 218 •
97 Electrical System-Wiring, Waterboxer

Current Wire connectors

Description
track
T1a -single, behind fuse/relay panel
Automatic transmission console light, L 19 1, 3
T1u- single, behind instrument panel
Back-up light, left, M16 5 T2p- double, behind fuse/relay panel
Back-up light, right, M 17 6 T6a- six-point, at left back-up light
Fuse, 815 6 T6b- six-point, at right back-up light
Starter cut-ouUback-up light switch, E17 5-12
T7 - seven point, on wire distributor, engine
compartment

Ground connections
/
@- beside fuse/relay panel
@- on left tail light bulb holder
@- on right tail light bulb holder
Welded wiring harness points
@-plus connection (58b), in instrument panel
wiring harness

97 •21 9 Automatic transmission

Water-cooled-Digifant from 1990
 Electrical System-Wiring, Waterboxer 97

,...../1GB lA1
0.5 0.5 0.5
'C20

1.0
016

6.0
024 C18
rs
I

4.0
GY/BL GY/BL GY/BL BK!GY R/BK R/BK

TO
0.5 IGNITION/STARTER

t"'
GY/BL SWITCH,
TERMINAL
50

AUTOMATIC
TRANSMISSION
CONSOLE
L19
AUTOMATIC
TRANSMISSION T
CONSOLE
I.
T
15 50
r-;:===F=~,-::--:----;:---------~ Et7
.1
J:::=== ===F====*====t==':l===t.t--:-1
T " R N D ,1 2swm;H
1·~~:~~ f%!:/UTI
LIGHT LIGHT
iRF 50 A
0.5 0.5 1.0 6.0
BR BR BK!BL R/BK

T7t4

1.0 0.5 1.0

BKIBL R/BK R/BK

Mt6 RF RF
T2pt2 L
BACIHII' f6o/~
5 T6b/2
LIGHT, TO
LEFT STARTER,
r;:::;., i4\ TERMINAL
~ M17 ~50
BACK-UP
LIGHT,
RIGHT

2 3 4 s 6 7 8 9 .10 11 12 13 14
\ \97-8213\

Water-cooled-Digifant from 1990

Automatic transmission 97.220
97 Electrical System-Wiring, Waterboxer
Description Current
Track
Alternator 6
Auto trans . console lites 13-14
Auxiliary battery 2
Back-up lite, left 15
Back-up lite, right 17
Battery
Battery cut-out relay 2-4
lgn./start sw. 9-12
Neutral safety switch 15-17
Wire connectors
T1b - single. wire distributor, LF eng . compart.
T1d - single, wire distributor, LF eng. compart.
T2j - double, under fuse/relay panel
T2m- double. under fuse/relay panel
T?a!- seven-point , wire distributor, LF eng.
com part.
T14/ - fourteen -point. on inst. cluster

Ground Connections

G)- ground from battery to body

@-ground from transmission to body
@-ground from aux. battery to ground
@-on LF cross member
@-in eng. compart. near ign. coil

97.221 Auxiliary battery

IAuto. trans., 1986-1989
 Electrical System-Wiring, Waterboxer 97
30 ~~~~====~~======~~-----=========~~~~====~----~~========~-30
15 15
X X
31 31

p A16 81 E13
6.0 0.5 0.5 0.5 0.5 0.5
A BL BL BL BL TO BL
DIGIFANT
I I COfiBI-RELAY
TO TO
CAT
EI..APSED
IIILE
INST.
CLUSTER,
T14111
I
2.5
COUNTER
A

T2m T1d

I
6.0
A
WIRING
COLOR CODE
BK -BLACK
BR -BROWN
CL - CLEAR
R -RED
y - YELLOW
G - GREEN

~})
f
LT G - LIGHT GREEN
BL - BLUE
v - VIOLET
G• - G8AY
w -WHITE 6.0 6.0 2.5 2.5
OR -ORANGE A RIB' RIW A!W

~----7o,o-
~
r=_:::- BATTERY
.. ----~
+
AUXILIARY
BATTERY
D+

25,0
i
25,0 25,0

2 3 4 5 6 7
I'9-7-2-2-9-.61

I Auto. trans. I 1986-1989

Auxiliary battery 97.222
97 Electrical System-Wiring, Waterboxer
·- -· - 30
15
X 15
X
31 31

~~ II
7

0 .5 0 .5 4.0 4.0 1.5

RtBK RISK RIBK R BK

'f
T2m
I .tS
6.0
• •
30 0 .5 0.5
RtBK w w
I I
TO TO TO
BRAKE OIGIFANT IDlE
WARN. CONT1fOL STAB.
RELAY UNff CONT.

2.~ 0.5 0 .5
8 '( BK GYIBK

II1
0.5
GYIR GYIR

Auro
TRANS. NEUTRAL
ro ~0 SAFETY
UTf
S'NffCH
lJT.
TO TO
SEATBELT j --
USTfR, WANt 'I'
SW.

I RELAY 0.5 1.0

BA BK!BL

WIRING 1.0
COLOR CODE
BK!Bl
• - I!UOO<
BACK-uP
"*'c.' -
-
(}llOIIfN
CI..!Wf v LITE.
A - ~D
~HT
y
G -~
"'!UDW

&.T G - &:.fi1 Hr <~N

IJ:. - lllL'E
r
1.5
r
1.5
v - l'lOUi'l BR BR
GY -.-...ov
w
()A - ""'''"
-~

(12'.
,/ 05) 1t
8 9 10 II 12 13 14 15 16 17 18
197-2297 1

97.223 Auxiliarybattery
IAuto. trans., 1986-1989
 Electrical System-Wiring, Waterboxer 97
- Current
Description Wire connectors
track
T2K- double, behind instrument panel, left
Auxiliary battery. A 1 5
Bal1ery, A
Ground connections
9
Bat1ery cut-out relay, J7 4-5 G)- ground strap, battery to body
®-ground strap, auxiliary battery to body

Water-cooled-Digifant from 1990

Auxiliary battery 97 •2 24
97 Electrical System-Wiring, Waterboxer

~ ~
15 15
X X

~ • 7

D24 BS A16 p

6.0 4.0 1.0 6.0

RIBK RIBK BL R
.I
TO
I
STARTER,
TERMINAL
TO
I
ALTERNATOR
WARNING
50 LIGHT,
K2
TO
T2ki2 T2ki1 TO
IGNIT70NISTARTER ALTERNATOR,
SWTTCH, TERIIINAL
TERMINAL 1.0 D+
50 R/BK

86 87
1J IifA TTERY
I CUT..(JUT
RELAY
85 30

6.0 6.0
R R

25.0 25.0 70.0

'LOCATED UNDER
DRIVER SEAT TO
I
STARTER,
"LOCATED UNDER FRONT TERMINAL
PASSENGER SEAT 30

0
2 3 5 6 7 · 8 9 10 II 12 13 1.4
197- 86511

97 •22 5 Auxiliary battery

Water-cooled-Digifant from 1990
 Electrical System-Wiring, Waterboxer 97
Current Wire connectors
Description
track
T1 - single, in driver's door
Central locking system fuse, S52 T1a- single, in passenger's door
Central locking system motor, T3 - three-point, in driver's door
decklid, V53 11-12 T3a- three-point, in passenger's door
Central locking system motor, T3b- three-point, behind instrument panel , right
driver door, V56 1-3 T3c - three-point, near upper right 8-pillar
Central locJ<ing system motor, T3d - three-point, above left rear window
passenger door, V57 T3e- three-point, on rear deck lid
Central locking system motor, T4 -four-point, behind instrument panel, left
sliding door, V58 7-9 T4a- four-point, behind instrument panel, right
Sliding door contact switch, F7 7-10 Ground connections
@-near fuse/relay panel

Water-cooled- Digifant from 1990

Centrallockingsystem 97.226
97 Electrical System-Wiring, Waterboxer

30 3Q
15
X ~$
3t 31

~ ~
p
1.0
A

m oo~ CENTRAL LOCKING

SYSJFMFUSE
20A
1.0 w
1.0 y
a
b
..,

r,j
1.0 A
1.0
A

T4n
Fow
T·/2
1.0
T4a/3 T4a/ 2 T4a/1
WIRING
COLOR CODE 1.0 1.0 1.0 1.0 1.0
BK - BLACK
w y y w R
OA - BROWN
CL -CLEAR
n ·- RED
y - - YELLOW
G - GREEN
LT G -- LIGHT G.qEEN
BL - BLUE
v - VIOLET
GY - GRA Y
w - WHI T£
T1 T3i2 T311 T3a/l T3a/2 Tla
DR -ORANGE
V57
CENTRAL
30 A E E A 30 LOCKING
SYSTEM
MOTOR,
PASSENGER
OOOR
V56 31
CENTRAL
1.0 LOCKING 1.0
BR SYSTEM BR
MOTOR,
DRIVER
T3i3 OOOR T3a /3

T4 ;4 T4a/4

1.0
BA
T3b/3
1.0
BR

@ o!J
- --
2 3 5 6
197-85761

9 7 •2 2 7 Central locking system

Water-cooled-Digifant from 1990
 Electrical System-Wiring, Waterboxer 97

...- ....~--------- 1 .0 w
1.0 1.0 .-- - - - - - 1.0 y
w y
. .- - - 1 .0BR
T3b/T T3dt3 T3d/2 T3di

1.0 WIRING
BR COL OR CODE
BK -BLACK
BR - BROWN
CL - CLEAR
R - REO
y - YELLOW
G -GREEN
LT. G - LIGHT GREEN
BL -BLUE
v - VIOLET
GY -GRAY T3e/3 T3e/2 T3e!1
w -WHITE
1.0 1.0 OR - ORANGE
y BR
31 A E V53
F7
CENTRAL

Ie.-----=:!~ I
SUD/NG
DOOR LOCKING
CONTACT SYSTEM
SWITCH MOTOR,
DECKLID

w y BR

A E 31
ri-;;:::;:==:::f-----;t--, ~NTRAL LOCKING
SYSTEM MOTOR,
L--k================~SUDWG~

7 8 9 10 11 12

Water-cooled-Digifant from 1990

Central locking system 91 •2 2 8
97 Electrical System-Wiring, Waterboxer

Current Wire connectors

Description
track
T1a -single, behind fuse/relay panel
Automatic transmission console light, T2 - double, behind instrument panel
L19 1, 3 T2a- double, behind instrument panel
Automatic transmission relay, J60 16-17 T2b- double, behind instrument panel
Back-up light, left, M16 T3 - three-point, near fuse/relay panel
6
Back-up light, right, M17 T3a - three-point, in wire distributor, engine
9
Brake light switch, F 11, 13 compartment
Brake light, left, M9 T4 -four-point, near cruise control main
10
Brake light, right, M10 control unit
13
T4b- four-point, behind steering column
Cruise control inductive sender, G38 22 switch cover
Cruise control switch, E45 19-25 T6a- six-point, on taillight bulb holder, left
Cruise control, control unit, J213 19-25 . T6b- six-point, on taillight bulb holder, right
T7 - seven-point, in wire distributor, engine
Fuse, S2 11
compartment
Fuse, S15 9
T?a- seven-point, in wire distributor, engine
Fuse, S18 20
compartment
Starter cut-out/back-up light switch, E17 6-9
Vacuum control motor, V18 24-26 Ground connections
Vacuum vent valve, brake, F47 15 @- near fusel relay panel
@-on taillight bulb holder, left
@-on taillight bulb holder, right

Welded wiring harness points

@-plus connection 58b , in instrument cluster
wiring harness

9 7 •2 2 9 Cruise control
Water-cooled-Digifant from 1990 IAuto. trans. I
 Electrical System- Wiring, Waterboxer 97
30
15
X
31

0
~
Al E4 .0 24 C]
0.5 0.5 0 .5 4.0 1.0 1.0 6.0 1.0 1.0 1.0 1.0
GY/BL GY/BL GY/BL R/BK RIBK R/BK RIBK BK!GY BKIR RIY R/BK

T2 bt l

1.5
R/BK
l.b
8 ro IGNITION/STARTER
T7a/6

SWITCH,
TERMINAL 50

·Tm T2a/ l T2a / 2

0.5 1.0
GY/BL RIY

0.5
BR
L19
AUTOMATIC
TRANSMISSION
CONS'Ot:E
LIGHT
!"'
0.5
BR
AUTOMATIC
TRANSMISSION
CONSOLE
LIGHT
Ell
~~0-

012 N R
STARTER
CUT-OUT/BACK-UP
UGHT
SWITCH
p

6.0
R/BK
I
50 A
1.0
BKIBL
wf
1.0
RIBK
-F
BRAKE
LIGHT
SWITCH

T7!4
r:
10 STARTER,
TERMNAL50
WIRING 1.0
BK!BL
COLOR CODE
6a/5 T6b/ 2 h6b/6
BK
BR
CL
-
-
-
BLAC K
BROWN
CLHA.R
; ,,,
RF
flACK-UP MIT
RF 54
MIO
BRAKE
A LIGHT, BACK-UP LIGHT,
- REO
LEFT LIGHT, RIGHT
- YEL LOW
RIGHT
G - GREEN
L

BL
T G -
-
tiGI-ff GREEN
Bi..Uf
@
GY
- VfOLET
-GRA Y
@
IV - WHITE
OR - ORANGE

2 3 5 6 7 8 9 10 11 12 13 14
~7-84431

I Auto. trans.j Water-cooled-Digifant from 1990

Cruisecontrol 97.230
97 Electrical System-Wiring, Waterboxer

30
15 ----~----------------------------------------------~----------~--------30
--------~~----------------------~~----------~~--·--------------------15
31X----------------------------------~--------·----------~--7---------------x
----------------------------------~----------------------~------~~----31

~ a
- C18
7

04 A16 81 E13 G2 07 G5 A25

0.5 0.5 1.0 0.5 0.5 0.5

BKIR BKIY BL BL BL BK

b .....TO
II
TO
ALTERNATOR ALTERNATOR,
WARNl'NG
UGHT,
K2
TERMINAL D+
T4bt4

J60
AUTOMAn c
TRANSMISSION
0 .5 RELAY
RlBK

I
0.5
RtBK
T211

4 .2
l P.-- ·· ----- -
c
Im
6 1'5
0.5
RIBL
I T2t2
WIRING
COLOR CODE

F41
VACUUM
VENT
VALVE,
BRAKE
8J 8H
6R
CL
R
y
-
-
-
-
-
-
BLACf\
BROWN
CLEAR
REO
YELLO tV
GREEN
0.5
BR
1

0.5
T3all

G
t1 G - LtGHT GREE N G

r
BL -BLUE
v - Vf0l.. E T
GY - GRA Y
w - WHITE
OR - ORANGE

V18
VACUUM CONTROL
MOTOR

15 16 17 18 19 20 21 22 23 24 25 26
/97-8506/

97.231 Cruise control

Water-cooled- Digifant from 1990 I
Auto. trans.j
 Electrical System-Wiring, Waterboxer
-
Description
Brake light switch, F
Brake light, left, M9
Brake light, right, M 10
Cruise control inductive sender, G38
Cruise control switch, E45
Cruise control, control unit, J213
Fuse, S2
Fuse, S18
Vacuum control motor, V18
Vacuum vent valve, brake, F47
Vacuum vent valve, clutch, F36
Manual trans. II
97
Current Wire connectors
track
T2 - double, behind instrument panel
2-3 T2a- double, behind instrument panel
1 T2b- double, behind instrument panel
3 T3 - three point, near fuse/relay panel
T3a- three point, in wire distributor, eng. compart.
7 T4 - four point, near cruise control main control unit
5-9 T4b - four point, behind instrument panel
5-9 T6a- six point, on taillight bulb holder, left
2 T6b- six point, on taillight bulb holder, right
6 T7 - seven point, in wire distributor, eng. compart.
8-10 Ground connections
4 @-in engine compart. , left side
4
@-near fuse/relay panel
@-on taillight bulb holder, left
@-on taillight bulb holder, right
Water-cooled-Digifant from 1990
Cruise control 9 7 •2 32
97 Electrical System-Wiring, Waterboxer

30 30
15 15

L.
X X
31 31

~518

tE16
1.0
BK/R
1.0
RIY
fc1
1.0
RIBK
~::
0.5
BK
lD7 (')G5 IA25

T713 T2bl1 I T2b/2 T4bt4

0.5 RIBK

J. F36
VACUUM
T2a/1 T2a/2 VENT
VALVE,
~ CLUTCH

0.5 0.5 0.5 0.5

L, . .--- -~ ~:=-4-b/3_
RIBK RIY BL BKIBL

VACUUM IV\
____ 1. ~. T.: . :_b /2-~ -·~T-4/3--L.:---,
CNTRL,
f,ltsE

\!Y CNTRL
~----r------.------,----,-1 UNIT

0.5
RIBK

1.0
BKIR
~T6b/6
54 WIRING
MtO COLOR CODE
BRAKE LIGHT;
BK -BLACK
RIGHr
8R -BROWN
CL - CLEAR
A - REO
Y - YELLOW
G - GREEN

31 31 LT G - LIGHT GREEN

}T6a/3 .T6b/3 BL -BLUE

V - VIOLET
1.5 1.5 GY - GRAY
BR BR W -WHITE
OR - ORANGE

@ @
2 3 5 6 7 8_ 9 10
l9it-3951 /

97.233 Cruise control

Water-cooled -Digifant from 1990 I '-I_
M_a_n_u_a_l_tr_a_n_s_.__,
 Electrical System-Wiring, Waterboxer 97
Current Wire connectors
Deacrlptlon
track
T1 -single, behind instrument panel, left
Daytime driving light relay, J89 15-17 T2 - double, in wire distributor, engine
Daytime driving lights resistor, N53 16 compartment
T2a- double, behind instrument panel, left
Fuse, 820 9 T2b- double, behind instrument panel, left
Fuse, S7 17
T7 - seven-point, in wire distributor, engine
Fuse, SB 19
compartment
Fuse, S9 35 TB - eight-point, on radio
Fuse, 822 36 T14 - fourteen-point, on instrument cluster
Fuse, 810 37
Fuse, 821 40 Ground connections
Fuse, 850 11
@-in engine compartment, left side
Headlight dimmer/flasher switch, E4 22-23
Headlight, left, L 1 39, 40
@- near fuse/relay panel
Headlight, right, l2 35,36
High-beam headlight, left, L13 37 Welded wiring harness points
High-beam headlight, right, L 14 33 @- plus connection (58b) , in instrument cluster
Instrument panel light dimmer switch, wiring harness
E20 10
License plate light, X 13-14
Ught switch, E1 4-10
Load reduction relay, J59 3-5
Parking light, left, M1 25
Parking light, right, M3 32
Tail light, left, M4 42
Tail light, right, M2 41
Tum signal light, left front, M5 26
Tum signal light, left rear, M6 27
Turn signal light, right front, M7 31
Tum signal light, right rear, MB 30

Canadp II Water-cooled-Digifant to Dec. 1989

Daytimerunninglights 97.234
97 Electrical System-Wiring, Waterboxer

~ ~
~ ~
X X
~ ~
J!il
LOAD
REDUC7JON
• 1/85 RaA r 2130
IIIJ c~-----------~ II

--~ B23
il4186

BJO
t3187

~G7 A.9
I
Ml
r ~ A24
1 A26 Al
1
~G9

r .........-., GS El

1.0 1.0 1.0 1.0 1.0 1.0 0.5 0.5

RIY AN BKJY W/BK GY/G GY/G GY/BL GY/G

l 1.0
BKJY
1.0
BKJY
20
0.5
GY/BL

! i
up
0.5
GY/BK
!
rn• Sso
lOA
FUSE

TO

~M
tGNmONISTARTER 2.5 0.5
SWITCH, W/BK GY/BL
TERMINAL
X
•
2.5
T211
BKJY

E20
INSTRUMENT
1.0 PANEL LIGHT
AN DIMMER SWITCH

WIRING
COLOR CODE
0.5,.!'1
GY/"!

f ~ICENSE'
BK -BlACK 0.5 0.5 . 0.5 0.5 0.5
BR -BROWN GY/BL GY/BL GY/BL GY/BL GYIBL
PLATE
CL -CLEAR

I
LIGHT

I
R -RED
y
a
-
-
YELLOW
GREEN
'ill..
0~5,BR
o.5J
LT. G - LIGHT GREEN
BL -BLUE
BR
V - VIOLET
GY -GRAY TO TO TO TO TO
W -WHITE
INSTRUMENT EMERGENCY FRESH
CLUSTER, FLASHER AIR
HTR
FAN
RADIO,
CONNECTOR
12!2
OR -ORANGE CONNECTOR SWTTCH, CONTROL sw Jal6
T1411 TERMINAL LEVER ILLUM
588 LIGHT, LT,
L16 L50
@
2 3 5 6 7 8 9 10 . 11 12 13 l4
r !97-80481

97.235 Daytime running lights

~-w_a_t_e_r-_c_o_o_le_d_-_o_i_g_if_a_n_t_to__o_e_c_._1_9_89~~~~__c_a_n_a_da--~
 Electrical System-Wiring, Waterboxer 97
-
30---------------------------------------------------------------------------30
15 15
X X
~ ~
.--------------------------------------------.~------------------0
.---------------------------------r--------------------b
r---~----------------~--------------------lC
RISE r---~r--------------------d
57
lOA

A21 Dll 822 C4 C19 E6

0.5 0.5 1.0 1.0 2.5 2.5 0.5 1.0 1.0 1.0
Y/R GY/G GY/G GY/G y W GYIBK BKIW BKIW BKIW

cp
0.5
T2b/2
0.5
T2a11 7
cp cp TO
EMERGENCY
2.5 1.0 FLASHER
GY/BK GY SWITCH,
W/BK RIY
TERMINAL L

16/85
0.5
BR
1.0
Y/R
a 56b
E4
56a
HEADLIGHT
DIMMER/FLASHER
SWITCH

WIRING
COLOR CODE
BK -BLACK M1 w58 Bll
BR -BROWN PARKING
CL -CLEAR UGHT,
3 LEFT
R -REO
MS
y - YELLOW
-GREEN
f TURN
1 .RO
G SIGNAL
LT. G - LIGHT GREEN LIGHT,
BL -BLUE B LEFT
v - VIOLET FRONT
GY - GRAY
w - WHITE
OR -ORANGE

@
15 16 17 18 19 20 21 22 23 24 25 26 27 28
197-39711

~-c_a_n_ad_a__~l ~'--w_a_t_e_~_c_o_o_le_d_-_o_i_g_if_a_n_t_to__o_e_c_._1_9_89~ Daytime running lights 97.236

97 Electrical System-Wiring, Waterboxer

~ ~
~ ~
X X
~ ~
a
b -
c ~

d
FUSE FUSE FIJSB ~!FUSE
-52J
~~A I 522
lOA ,, lOA
10
lOA

r'l' Js
I I_ T
lA7 C14 - Cl6 D25 A28 co (17 C5 E18 '.E9

1.0 1.0 1.0 0.5 1.5 0.5 1.5 1.5 1.5 0.5 0.5
BKIG BKIG BKIG GY/R W/BK BLJW Y/BK W Y GY/R GY/BK

TO TO
EMERGENCY HEADt..IOHT
FLASHER HIGH
SWffCH, BEAll
TERIIJNAL WARNING
R UGHT,
Kt

WIRING
COLOR CODE

BK -BLACK
BR - BROWN
CL - CLEAR T71s
R -REO
Y - YELLOW
G - GREEN
LT G - LIGHT GREEN
BL - BLUE
V - VIOLET
GY - GRAY
W
OR
-WHITE
-ORANGE _ _,

1.5
.
1.5
W/BK W

w
118

=Lf.
1
=
= nJ hJ
LIGHT,
BlR

31
117
~
BlR

TVRN,SKJNARIGHTL I31R
rm•n•
58

~~K 156~H-BEAM
LT, ~~IOHT, ~
""""'
156a 56b

'f,ftt;IOHT,
f5~~
'
f.
LEFT-0: L
156a

~hu: '
Lt
56b

/1
)I

~~DI.IOHT,'
k'2 4M4
58

TAIL
IGHT,
RIGHT I
58

TAIL
LIGHT,
LEFT

1.5 1.0 1 5
R 1.5 1.5
BR 1.5 1.5

I@ I@ l@ I I@ I @I @I
29 30 31 32 33 34 35 36 37 38 39 40 41 42
197-39721

9 7 •2 3 7 Daytime running lights

Water-cooled -Digifant to Dec. 1989 II Canada
 Electrical System-Wiring, Waterboxer 97
Current Wire connectors
Description
track
T1 - single, behind instrument panel, left
Daytime running lights relay, J89 11-14 T1b -single, behind instrument panel , left
Daytime running lights relay (parking and T2 -double, behind instrument panel, left
tail lights), J277 6-8 T2a- double, behind instrument panel , left
Daytime running lights resistor, N53 19
Ground connections
Fuse, S7 7
Fuse, S8 9
@- beside fuse/relay panel
Fuse, S20 13
Fuse, S21 22
Fuse, S22 23
Fuse, S1 0 25
Fuse, S9 26

~ ...._
l==:.J Water-cooled -Digifant from Dec. 1989 to May 1990
_____________________ . runnmg
__. Daytime . lights
. 97 238
•
97 Electrical System-Wiring, Waterboxer

30
~0
:
31
15
X
!Ia

~ ..
~DAa

~-ll/86

810
- ..

A26
' FUSE
S2o

El
lOA

G9
~
1.0
ro 0.5
LT
BKIY sw, GY/G
TERM
X
AND
70 IGNITION/
STARTER SWITCH,
TERMINAL X

I
'
TO TO TO TO
ALT, C, ALT LIGHT LICENSE
TERMINAL WRNG SWITCH, PLATE
D+ LT, El 1.0 LIGHT, 1.0
K2 TERMINAL BKIY X y
WIRING 58
COLOR CODE

BK - BLACK
BR - BROWN
CL - C LEAR
R -RED
Y - YELLOW
G -GREEN
LT G - LIGHT GREEN
BL - BLUE T2a

r
V - VIOLET
GY - GRAY 1.0 0 .5
BKIY y

r r t.
W - WHITE
OR - ORANGE

I ----- ---- I J277'

DAY RUN
t.lS RLY
1----t--~------ t/56o=~ I '{J';tlf
(PRK f5 /56b 18/5 8 6/31
f4 /31 f2!X AND
TAIL 0.5 0.5
1.0 0.5 LTS)
BR GY/G Y/R BR

em

'LOCATED ABOVE FUSE/RELAY PANEL

2 3 5 6 1 8 9 10 II 12

97 239 . • Dayt1me runnmg hghts

.. Water-cooled-Digifant from Dec. 1989 to May 1990
L-----------------------...J
jcanada j
L Electrical System-Wiring, Waterboxer 97
30
15 ~====================~========~--~================~ ~
15
X X
~!_ 31

FI/Sf1FIISE IFIISE FUSE

I S21 ~S22
lOA lOA
~S1o
lOA
~59
lOA
!I

I
C14 pta C4 JE9 M2 A21 C5 C6 B22 C17 ~- r16
0.5 0.5 0.5 0 .5 0.5 2.5 1.5 1.5 2.5 1.5 1.0 0.5 1.5
GY/R GY/R GY/BK GY/BK Y/R y y YIBK w w y BL..JW W/BK

TO TO T2b/2 ro ro TO TO TO
14 TO TO
TO TO
PARKING TAIL PARKING TAIL HOLT HOLT HOLT HOLT HOLT HOLT HEADLIGHT
LIGHT, LIGHT, LIGHT, LIGHT, 0/MR LEFT, RIGHT, 0/MR RIGHT, HI-BEAM LEFT,
RIGHT,
M3
RIGHT.
M2 ,,
LEFT, LEFT,
M4
FLSHR
SW, E4,
TERM
Lt,
TERM
568
L.2,
TERM
568
FLSHR
SW. E4,
TERM
L.2,
TERM
56A
/NO
LT,
Kt
Lt,
TERM
56A
NS3 568 56A
OAYnME
RUNNING
LIGHTS
RESISTOR

T2bil WIRING
COLOR CODE
BK - BUICK
0.5
BR -BROWN
ViR
CL - CLEAR
R - REO
- YELLOW
G -GREEN
LT G - LIGHT GREEN
8L - BLUE
- VIOLET
GY - GRAY
w - WHITE

11 OR - ORANGE

15 16 17 18 19 20 21 22 23 24 25 26 27 28
l97-9281l

~ Water-cooled-Digifant from Dec. 1989 to May 1990

c::::J '-------------------------.....1 Daytime runnmg lights
. . . 97 240 •
97 Electrical System-Wiring, Waterboxer

Current Wire connectors

Deacrlptlon
track
T1 - single, behind instrument panel, left
Daytime running lights relay, J89 14 T1a -single, behind instrument panel, left
Daytime running lights relay (parking T2a- double, behind instrument panel, left
and tail lights), J277 4-6 T2b- double, behind instrument panel, left
Daytime running lights resistor, N53 19
Fuse, S21 22 Ground connections
Fuse, S22 23
Fuse, S10 25 @- beside fuse/relay panel
Fuse, S9 26
Fuse, S7 7
Fuse, S8 9
Fuse, S20 13
Load reduction relay, J59 6

97.241 Daytime running lights

Water-cooled-Digifant from May 1990 j L..l_c_a_n_a_da
_ _.
 Electrical System-Wiring, Waterboxer 97
30 30
15 15
X X
31 3\,
.

• ~-
JSI. b

~
I
-
LOAD

~
REDUCTION RISE 4 lRISE
~Sa
RELAY
S1 S20
lOA lOA lOA
4/86

G4 04 B10 A26 E1 G9

1.0 1.0 0 .5
TO GY/G GY/G
IGNITION/ BK!Y
STARTER
SWITCH,
TERMINAL
X
TO
UGHT
SWITCH
TERMINAL
X
TO
TERMINAL
D+
TO
ALTERNATOR, ALT
WRNG
LT,
I
1.0
TO
LIGHT
SWITCH,
E1
TO
LICENSE
PLATE
LIGHT,
T
1.0
y
K2 BKIY TERMINAL X
58

T2o
0 .5

E=-f--ir--
WIRING 1.0 y
COLOR CODE BKIY
l21x !4/56a
BK
BR
CL
R
y
-
-
-
-RED
-
BLACK
BROWN
CLEAR

YEL LO W
1'4/ 31 f5
2/X

8/58
--------... mr
DAYTIME RUNNING
LIGHTS RELAY
(PARKING AND TAIL
[c__------t-----f I =·~
l5/S6b 8 6/31
G - GREEN
I LIGHTS)
LT G - LIGHT GREEN
1.0 0 .5 0 .5 0 .5
BL - BLUE
BR BL Y/R BR

GY
-
-
VIOLET
GRA Y
~T1a o2J
W -WHI TE
OR - ORANGE

'LOCATED ABOVE FUSE/RELAY PANEL

2 3 4 5 6 7 8 9 10 11 12 13 14
197-92821

Canada II Water-cooled-Digifant from May 1990

Daytime running lights 97.242
97 Electrical System-Wiring, Waterboxer

30 30
15 15
X X
31 31
ba

~ ~
IIJ$E FUSE
521
lOA
~522
lOA

E18 C4 E9 M2 A21 C5 C6 822 C17

0.5 0.5 0.5 0.5 0.5 2.5 1.5 1.5 2.5 1.5 1.0 0 .5 1.5
GY/R GY/R GY/BK GY/BK Y/R y y Y/BK w w y BLJW WiBK

T2bi2 14
TO TO TO TO ro ro ro ro ro ro ro
PARKING TAIL PARKING TAIL HOLT HOLT HOLT HOLT HOLT HOLT HEADLIGHT
LIGHT. LIGHT, LIGHT. LIGHT, 0/MR LEFT, RIGHT, OIMR RIGHT, HI-BEAM LEFT,
RIGHT. RIGHT. LEFT, LEFT, FLSHR Lt, L2, FLSHR L2, /NO Lt,
M3 M2 Mt M4 SW. E4 TERM TERM SW, E4, TERM LT, TERM
TERM 568 568 TERM 56A Kt 56A
N53
CMYnME 568 56A
RUNNING
UGHTS
RESISTOR

T2bll WIRING
COLOR CODE
BK - BLACK
0.5
BR - BROW"
Y/R
CL ~ CLEAR

R -RED
y - YELLOW
G - GREEN
LT G - LIGHT GREEN
Bl - BLUE
v - V/OLEr
GY - GRAY
w -WHITE

11 OR - ORANGE

l.S 16 17 19 19 20 :n 22 2l 24 2.5 26 '21

197-92811

97.243 Daytime running lights

Water-cooled-Digifant from May 1990 II.__c_a_n_a_d_a__.
 Electrical System-Wiring, Waterboxer 97
Current
Description
track
Driver's seat heater control unit, J131 3-6
Driver's seat temperature sensor, G59 3
Fuse, S18 6
Fuse, S50 1
Heat element, driver's backrest, Z7 5
Heat element, driver's seat, Z6 4
Heat regulating switch, driver's seat, E94 2-4
Seat heater switch indicator light, L44 2-4

Wire connectors
T1 - single, behind fuse/relay panel
T1a -single, behind fuse/relay panel
T1b- single, behind instrument panel, left
T2 -double, behind instrument panel, left
T6 - six-point, under driver's seat 1 97-2540 1

Ground connections
@-near fuse/relay panel Fuse/relay panel
Welded wiring harness points ml - Fuse S50, terminal 58b 10A
@-plus (+)connection, terminal 58b in
I& - Driver's seat heater control unit
instrument panel wiring harness

Canada II Water-cooled-Digifant from 1990

Heated driver's seat 9 7 •2 44
97 Electrical System-Wiring, Waterboxer

~ ~
15 15
X X
31 31

I l
JAI
0.5
GY/BL

TO LIGHT SWI1CH,
E1
I
0.5
GY/BL

I
~
FUSE J131
m Sso II;]
®
DRIVER SEAT
HEATER CONTROL
lOA UNIT
'f4/T J'21H 'f7131
0.5 1.0 0.5
0.5 R/BK BK BR
GY/BL
Ttb T212 I T211

Z6
HEAT ELEMENT, WIRING
DRIVER SEAT COLOR CODE
BK - BLAC K
BR - BROWN
A4 T6t6 n T 6i2 CL - CLEAR
R - REO
0.5 0.5 0 .5 1.0 y - YELLOW
BR/BK R/BK BR BR/BK G - GREEfV

$~ DRIVER SEAT
TEMPERATURE
SENSOR
$E HEAT
ELEMENT,
DRIVER
BACKREST
LT
BL
v
GY
w
OR
G-
-
-
-
LIGHT GRE.EN
BL UE
VIOLE T
GRA 'I'
-WHI TE
- ORANGE:

0 .5 1.0 1.0
BR BR/BK BR

IT6/3 T•11
tT•" )

0
BR

2 6

9 7 •2 4 5 Heated driver's seat

Water-cooled-Digifant from 1990 II Canada
 Electrical System-Wiring, Waterboxer 97
Current Wire connectors
Description track
T2 - double, behind instrument panel, left
Antenna, R11 5 T2a- double, behind instrument panel, right
.7 T2b- double, behind instrument panel, left
Fuse, S3 TB - eight-point, on radio
Radio, R 2-10 TBa - eight-point, on radio
T14 -fourteen-point, on instrument cluster
Speaker, left front, R2 3
Speaker, left rear, R4 e Ground connections
Speaker, right front, R3 4 @-behind instrument panel, center
Speaker, right rear, R5 7
Welded wiring harness points
@__:_plus connection (58b), in instrument panel
wiring harness

Water-cooled-Digifant from1990
Stereo radio with 4 speakers 9 7 •2 4 6
97 Electrical System-Wiring, Waterboxer

,..
53
1SA

r----t---~----+t"-
isn
1.5
R
fE3
WIRING
1.5
R
COLOR CODE

.-....... tr,~,
18 1 I
BK -BLACK
BR - BROWN r n R ANTENNA
II

•
CL - CLEAR

0.5
I R -
-
RED
YELLOW
HF 0.5 0.5 1.5 0.5
G - GREEN
GY/BL U G - LIGHT GREEN
R R R R
BL -
-
BL UE
V/OLEf
(
\ ' I I ,I_T14/5
10 CIGARETTE 10 MAKE-UP TO TO
GY - GRAY MIRROR LIGHT, INTERIOR
LIGHTER, U1 DIGITAL
w - WHJrE RIGHT, W14 LIGHT, CLOCK,
OR - ORANGE FRONT, Y2
R W

,
I TBa/6 ATB/8

0.5 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 0.5 1.5
GY/BL BRIBL BL R BR/W BR/R BUG RIG BR/BK BR BR

'
TO
I
CIGARETTE
LIGHTER
LIGHT,
TO
DASHBOARD
READING
LIGHT,
W26
L28

1 T2n I T2i2 1 T2o/2 1 T2a 11

R2 R3 R4 RS
SPEAKER, + SPEAKER, SPEAKER, + ,+ SPEAKER,
LEFT RIGHT LEFT RIGHT
FRONT FRONT REAR REAR

2 3 s 6 7 8 9 10
lr97--866
- ----,~

9 7 •2 4 7 Stereo radio with 4 speakers

Water-cooled-Digifant from 1990
 Appendix

Index
Do-it-yourself Service
-Changing a wheel21
- Emergency starting 25
- Fuses22
- Headlight adjustment 25
- Jack and tools 20
- Replacing bulbs 23
- Spare wheel20
Lubrication, Emissions and Vehicl.e
Maintenance Schedules
- Air-cooled, Water-cooled and
Diesel models 1982-1985 28
- Water-cooled models
from 1986 32

Technical Data
- Capacities 27
-Engine 27
-Vehicle identification 26

Vehicle Care
-Air cleaner 10
-Battery 14
- Brake fluid 13
- Cleaning products 3
- Cooling system 11
- Corrosion protection 5
-Engine compartment 6
- Engine oil 7
- Engine oil filter 9
-Exterior 3
-Fuel filter (diesel) 10
- Fuel supply 1
-Interior 4
- Lubricants 7
- Maintenance 5
- Power steering 10
- Replacing wiper blades 16
-Tires/Wheels 17
- V-belt 12

I
I VEHICLE CARE
FUEL SUPPLY

Your vehicle is equipped with a catalytic

converter and requires unleaded fuel.
For maximum engine performance, un-
leaded fuel with an octaine rating of 91
RON, which corresponds to an anti-knock
index (AKI) of 87, is recommended.
Do not use leaded gasolines.
Deposits from leaded gasolines deacti-
vate the catalytic converter and thus
defeat its purpose to control exhaust emis-
sions.
Unleaded fuels may not be available
outside the continental USA and Cana-
da. Therefore, we recommend you do
not take your vehicle to areas or coun-
tries where unleaded fuel may not be
available.
Gasoline additives
A major concern among many auto
manufacturers is carbon deposit build-up
caused by the type of gasoline you use.
Although gasolines differ from one
manufacturer to another, there is a com-
mon thread. All gasolines contain proper-
ties that can cause deposits to collect on
essential engine components, specifically
fuel injectors and intake valves. Although
most gasoline brands include additives to
keep engine and fuel systems clean, they
are not equally effective.
Recent fuel developments
Over the past few years, more manufactu-
rers have been advertising detergent addi-
tives in their gasoline. These additives are
primarily intended to keep fuel injectors
clean.
However, they are not all equally effective
in reducing carbon deposit build-up on
intake valves. We are aware that, as of the
time of printing, some manufacturers

Octane rating
Octane rating indicates a gasoline's ability to ,:' Piston
resist detonation. Therefore, buying the cor- and
rect octane gas is important to prevent en- Bore
gine "knock", which reduces performance
and may cause engine damage. advertise and sell gasoline that contains
Under high load operating conditions, un- l2s-A23s the proper deposit control additives that
leaded premium gasoline may be used. will keep intake valves and injectors clean.
After an extended period of using inade-
The 91 RON octane rating which you will quate fuels, built-up carbon deposits can To assure the long term performance of
find above the filler neck is based on the re- rob your engine of peak performance. And your car's engine, you should use gasoline
search method. The AKI octane rating unsu- carbon deposits like those in the illustra- brands that include these deposit control
ally displayed on USA gasoline pumps is tion can lead to other engine performance additives.
calculated as follows: Research octane problems such as: If gasolines with additives are not avail-
number plus motor octane number, divided able, contact your Volkswagen dealer
by2. • unstable idling
about proper fuel additives.
• surging
Regular fuels have an octane rating ranging • misfiring
from 91 to 95 RON (Research Octane • power less
Number) or 87 to 91 AKI. • engine run-on
• engine pinging or knocking
Do not use any fuel with octane ratings
lower than 91 RON or 87 AKI. If these problems continue over a long
period of time, engine damage can be are-
Gasolines containing alcohol sult.
Gasoline containing alcohol is available at
gas stations in some areas. The gas pump
may not be labeled to identify that alcohol
is present in the gasoline. If it is labeled, it
may not identify what amount and type(s)
of alcohol are used. We recommend you
use quality gasoline that is NOT blended
with alcohol. The use of fuel containing
alcohol can cause loss of fuel economy
and driveability and performance prob-
lems. If these problems are experienced,
we recommend you switch to another
brand of gasoline.
. ~2;A238A
Seasonally adjusted gasoline
Damage or malfunction due to poor fuel
Many gasolines are blended to perform quality is not covered by the Volkswagen
especially well for winter or summer driv- New Vehicle Limited Warranty.
ing. During seasonal change-over, we
suggest that you fill up at busy gas stations
where the seasonal adjustment is more
likely to be made in time.

1
I VEHICLE CARE
If wrong fuel was put into your tank
Premium gasoline instead of regular
Your engine runs equally well on premium
gasoline, however neither fuel consump-
tion nor engine output are likely to be af-
fected.
Regular gasoline with RON/AKI rating
(lower than 91 RON or 87 AKI)
Your engine will run but avoid full power as
engine can be damaged. Fill up with cor-
rect fuel as soon as possible.
Diesel fuel instead of gasoline
Your gasoline engine must not be started
with Diesel fuel in the tank. In such case
the fuel tank must be drained while observ-
ing all environmental and fire hazard pre-
cautions.
Leaded instead of unleaded gasoline
Do not drive your car. Have your fuel tank
drained immediately as otherwise the
emission control system will be damaged.
The fuel system must be drained while ob-
serving all environmental regulations, it is
best to have this performed by your Volks-
wagen dealer.
Diesel engine: Diesel Fuel No. 2
Service stations offering Diesel fuel are
generally located on truck routes of major
highways Directories of Diesel fuel
stations are usually sold at Diesel fuel
stations.
Some U.S. states require permits to
purchase Diesel fuel. Check with your
State Motor Vehicle Department.
Diesel fuel may not be available outside
the continental U.S. and Canada, we
recommend you do not take your vehicle
to countries where Diesel fuel may not be
obtainable.
Your Diesel engine has been specifically
designed to operate on Diesel fuel only.
Therefore, do not use home heating oil
or regular gasoline.
The properties of these fuels may cause
serious damage to the fuel injection
system and to the engine. This could
lead to additional expense and may also
affect your warranty.
Winter operation
A~ temperatures below 20° F ( -7° C),
D1esel Fuel No. 2 loses its fluidity due to
wax separation, which may clog the fuel
filter or tank strainer and keep the engine
from running.
If you expect temperatures below 20°
F(-7°C):
• Use Diesel Fuel No. 1, if available in
your area.
• If Diesel Fuel No. 1 is not available, ask
your fuel dealer whether his Diesel Fuel
No. 2 is sufficiently winterized for the
prevailing temperatures.
• As a measure of precaution, add a
commercially available Diesel Fuel flow
improver {pour point depressant) to your
Diesel Fuel. Because of the many
different flow improvers on the market, as
well as differences in Diesel Fuel, their
effectiveness varies. Use only according
to instructions on containers.
• !f winterized Diesel Fuel No. 2 is not
available, mix Diesel Fuel No.2 with up to
50% Kerosene. Engine power may drop,
therefore keep percentage of kerosene
added to Diesel Fuel as low as the
temperature allows.
2
Temperature Diesel Fuel Kerosene
No.2
20° to 14° F
(-?PCto-10°C) 75% 25%
below 14° F
(-10° C) 50% 50%
• Only if neither Diesel Fuel No. 1,
winterized Diesel Fuel No. 2, nor Kero-
sene are available, use up to 30% leaded
or unleaded gasoline.
• Do not use Premium gasoline.
• Mixing Diesel Fuel No. 2 with Kero-
sene (or gasoline) must be done be-
fore wax starts to separate. Later mix-
ing may be effective in the fuel tank but
not in the rest of the fuel system.
• Always add the correct amount of
Kerosene (or gasoline) to the fuel tank
first, and then fill up with Diesel Fuel
No.2.
• Do not use "starting assist fluids",
they will cause engine damage.
• Do not use fuel line anti-freeze of-
fered for gasoline engines.
It is normal that the engine noise level
{dieseling) is louder during the warm-
up period in winter. It is also normal that
whitish-blue smoke may be emitted from
the exhaust after starting and during
warm-up. The amount of smoke depends
on the outside temperature.
Do not let your Diesel engine idle unnec-
essarily after a cold start-up. Driving off
slowly will shorten the warm-up period.
WARNING
• Do not use "starting assist fluids".
They may be potentially explosive or
cause a "run-away" engine condition.
This could result in serious engine
damage and personal injury.
• Any amount of gasoline added to
Diesel fuel makes the mixture as
flammable as pure gasoline.
• Handle all fuels in well ventilated
areas. Do not smoke or have anything
in the area that can ignite fuel.
• Never carry additional fuel con-
tainers in your vehicle. Such con-
tainers, full or emply, may leak, cause
an explosion, or result in fire in case
of a collision.
J I VEHICLE CARE
CLEANING PRODUCTS
Any automobile is subjected to abuse from
industrial fumes, corrosive road salt, aban-·
doned lollipops, muddy dog feet, etc.; to
name just a few. A well cared for Volkswa-
gen can look like new many years later.
Regular and correct care will contribute to
maintaining the beauty and the value of
your Volkswagen.
Your Volkswagen dealer has a number of
car-care products and can advise you
1' which ones to use for cleaning the exterior
0-
and interior of your vehicle.
ed
Whether you use Volkswagen recom-
mended products or other, commercially
available cleaning agents, make sure first
of their correct application.
o-
le-
lx-
ut WARNING
• Cleaning agents may be por.onoue.
Keep them out of the reach of children.
• Obeerve all caution labels.
• Always read dlrecllona on the con-
talrw before ualng any product.
• Most chemical cleanenlereconcen-
1",
tratea which require dilution.
• Only uae apot removing ftulda In
' f- wall ventilated ......
• Do not Utl8 gaaollne, keroeene,
naphtha, nan pollah remover or other
el
volatile Cleaning fluid&. 1bey may be
toxic, flammable or hazardoualn other
waya.
e-
ft
EXTERIOR
Washing and waxing
The paint on your Volkswagen is very dura-
ble but must be protected from losing its
luster due to outside influences. There-
fore, wash and wax your Volkswagen
often. The longer the dirt is left on the
paint, the greater the risk of damaging the
glossy finish, either by scratching if the dirt
is rubbed into the paint, or simply by the
chemical effect dirt particles have on the
paint surface.
Do not wash or wax in direct sunlight, or
when the sheet metal is hot. Do not use
hot water. Lukewarm to cool water is
kinder to the paint.
WARNNG
• Do not waeh, wax or dry the vehicle
with the engine running.
• Do not ellen the Wlderllde or chee-
ale, fendere, wheel covera, etc., without
protecting your handl and arm&. '\bU
may cut yourMif on 11wp«1gec1 metal
parte.
• Moletunt, lceanct roec1 ee11on brak88
may effect braking em~ "AAet the
brakes carefully after each vehicle
waeh.
Do not aim the water jet directly at door,
hatch or rear lid locks. Tape the key holes
to prevent water from seeping into the lock
cylinders. Water in lock cylinders should
be removed with compressed air. To pre-
vent locks from freezing in the winter,
squirt glycerine or lock de-icer into the lock
cylinders. Do not use any solution that
can damage the body paint.
Use plenty of water, a car-wash and wax
solution and a soft sponge or hose brush.
Begin by spraying water over the dry sur-
face to remove all loose dirt before apply-
ing the car-wash and wax solution. Use
plenty of water to rinse the vehicle off.
Wipe everything dry with a chamois to
avoid water spots.
When having your vehicle washed at an
automatic car wash, be sure to observe all
the precautions suggested by the esta-
blishment.
The underside of the vehicle picks up dirt
and road salt. To guard against corrosion,
it is important to remove mud, debris and
road salt from the underside with a
powerful jet of water. Be sure to include the
wheel housings, bumpers, muffler, tailpipe
and brackets. This should be done twice a
year and is best accomplished after the ve-
hicle has been driven through a heavy
rain. Let engine and exhaust cool down
before washing.
3
Waxing is not really needed when you
have used a car-wash and wax solution. If
you do not use a car-wash liquid with wax,
apply wax to preserve the natural shine of
the body paint. To obtain a long lasting
finish, apply hard wax. Wax again when
water remains on the surface in large
patches instead of forming beads and
rolling off.
This will make dirt easier to remove and
will prevent the paint from being damaged
from industrial dust, tree sap or bird drop-
pings.
Use a polish when it becomes evident that
waxing no longer accomplishes the job. If
the polish you are using does not contain
wax, apply hard wax after polishing.
Tar or oil
Do not allow tar or oil to remain on the
paint. Remove as soon as possible with a
cloth soaked with a special paint cleaner. If
you do not have a tar or oil remover, you
may $.Ubstitute with turpentine. After apply-
ing a cleaning fluid, always wash with a
lukewarm soap water solution and apply a
new wax coat.
Insects
Remove as soon as possible with a
lukewarm soap water solution or insect re-
mover.
Tree sap
Do not allow tree sap or bird droppings to
harden on the paint. Remove with a
lukewarm soap water solution.
Windows
Clean all windows regularly to remove
road film and car-wash wax buildup. Use a
lukewarm soap water solution or an al-
cohol base commercial window cleaning
agent. If a chamois is used for polishing
the glass, it should exclusively be used for
that purpose.
Also, be sure to clean all windows
regularly on the inside.
Use a plastic scraper to remove snow and
ice from windows and mirrors. To prevent
dirt from scratching the window, always
scrape in a forward direction - never back
and forth.
Wiper blades
Always loosen frozen wiper blades from
glass otherwise they may tear.
Clean wiper blades regularly with an al-
cohol base solution. If necessary, use a
sponge or a brush to remove accumulated
road film. To assure good visibility, replace
wiper blades at least once a year, or more
often when wiping becomes streaky.
I VEHICLE CARE
Weatherstrips
Keep silicone sprays off the windshield
to avoid wiper smear in rain.
To seal properly, weatherstrips around
hood, hatch, windows, doors, etc., must
be pliable. Spray with silicone or coat with
talcum powder or glycerine to retain
flexibility of the rubber and to protect
against freezing in the winter.
Sliding roof quide rails
To assure that the sliding roof* function
properly, clean the guide rails and lubri-
cate with silicone spray at least once a
year. See your Volkswagen dealer for cor-
rect procedures and lubricant.
Touch-up paint
Your Volkswagen dealer has touch-up
paint for minor scratches and stone chips.
Scratches should be touched up soon
after they occur to prevent corrosion . If cor-
rosion formation becomes visible, how-
ever, a simple touch-up job will not suffice.
The affected surface must be smoothed
with sand paper and covered with an anti-
rust primer, before restoring the painted
finish.
The number for the original vehicle paint
can be found on the vehicle identification
label.
Dull finishes and plastics
Plastic parts, such as light bulb lenses,
decorative stripes, panels, bumpers, etc.,
w111 come clean with regular washing .
Should additional cleaning or spot re-
moval be necessary, use a soft brush or
cloth soaked with a mild detergent solu-
tion. Then nnse thoroughly and im-
mediately with clear water.
Do not use anything which could mar the
plastic or dull finished surface, such as
wax, polish, abrasive detergents or
chemical cleaning solvents.
where applicable
Steel wheels
Always include the hub caps and wheel
rims when washing your vehicle to remove
road dirt, salt sprays and brake dust. If nec-
essary, use a commercial wheel cleaner to
remove accumulated brake dust. Paint
scratches should be touched up to prevent
corrosion.
Light alloy wheels
To preserve the decorative appearance of
the light aluminium cast, some special
care is necessary. In addition to road dirt
and salt sprays, brake metal dust is also
corrosive. If left on too long, brake metal
dust can cause pitting. Wash the wheels
with a sponge or hose brush every other
week. Road salt should be removed
weekly with an acid free cleaning solution.
Every three months (after regular clean-
ing) the wheels should be coated with
petroleum jelly or car wax. Rub it in firmly
with a soft cloth. Never use abrasive or
metal polishing cleaning agents.
Remember that moisture, ice and road
salt on brakes may affect braking effi-
ciency. Test the brakes carefully after
each washing.
Sliding door
The sliding door mounting points, the
gUide tracks and the roller guides should
be lubricated regularly and as often as
necessary.
Bright metal trim
Bright or black anodized trim will come
clean with regular washing . To protect
metal trim , use car wax. Remove spots or
d1rt from chrome and stainless steel with a
chrome cleaner. Apply a chrome polish for
continued luster and protection.
4
INTERIOR
Glass
Use the same cleaning agents as for ex-
terior and polish dry.
Fabric
Use a vacuum cleaner or a soft bristle
brush to remove dust and loose dirt from
carpeting, upholstery, headliner and other
trim. Dirt stains can usually be removed
with a lukewarm soap water or all purpose
cleaner solution, or a dry foam cleaner. For
greasy, oily and other stubborn stains, use
a spot remover. Do not pour the liquid on
the fabric. Dampen a clean cloth and rub
carefully, starting at the edge and working
inward.
Plastic, vinyl and leather/leatherette
Use a clean, damp cloth or sponge to keep
this trim free from dust. For other soilage,
use a lukewarm solvent free all purpose
cleaning solution or a mild saddle soap for
vinyl and leather trim. Remove water spots
and soap traces with a clean , damp cloth
or sponge. Use a clean, soft cloth to rub
dry.
Grease, tar or oil stains can be removed
with a clean cloth or sponge soaked with
all purpose cleaner or with a solvent type
vinyl or leather cleaning agent.
Occasionally apply a colorless vinyl or
leather preservative to retain the material's
luster and pliability.
Safety belts
Keep belts clean. Dirty belts may not re·
tract properly. Do not remove belts from
the vehicle. Do not use chemical clean-
ing agents, bleach or dyes. They contain
corrosive properties which will weaken
the webbing. Do not allow inertia reel
safety belts to retract before they are
completely dry.
For cleaning , use a mild soap water solu-
tion. Let belts dry out thoroughly and away
from direct sun light.
Use the opportunity to inspect the belts
for damage. If you discover damage, see
your dealer.
] I VEHICLE CARE
CORROSION PROTECTION
The transmission , front and rear axle
:IX·
assembly surfaces have been treated at
the fac.tory wit.h a wax based coating for
protection agamst corrosion. However, we
recommend to have the and the underside
inspected twice a year for any damage to
the protective coating preferably before
and after the winter season. Have neces-
sary repairs done as soon as possible.
See your dealer for correct procedures
and materials.
WARNING
Do not apply additional undercoating
.or ruatprooflng on or near the exhau8t
manifold, exhaust pipes, catalytic
converter or heat shields. During drlv·
lng, the substance used for under·
coating could overheat and cause a
fire.
Engine Compartment
When washing the engine compartment,
onl~ use commercially available grease
cuttmg solvents made especially for this
purpose. Carefully follow directions print-
th ed on the container by the manufacturer.
e protection at the factory.
WARNING
or
l's Never UM geeotlne. Dlelef fuel or IOI-
Yent8 which could dlrnege rubber
pel18 or painted eurfacea and could
cauae a tire.
Chassis
!he lower body shell of your Volkswagen
IS thoroughly protected against corrosion.
However, it is recommended to have the
underside inspected twice a year. Any de-
tected damage to the undercoating, due to
road hazards, should be repaired prompt-
ly. Oil based protective sprays must not be
applied. Only tar or wax based anticorro-
sion protectors are compatible with the
fa?to~y applied .undercoating. Before ap-
plication, road d1rt, salt spray deposits and
oily substances must be removed.
Whene~e~ the lower body shell, axle,
transm1ss1on or engines assemblies
have been repaired, the lost anti-corrosion
coating of the affected surfaces should be
reapplied.
Your Volkswagen dealer has the appro-
priate materials, the necessary equipment
and is familiar with the application proce-
dure. Therefore, any additional corrosion
protection work should be performed by a
Volkswagen dealer.
Body cavity sealing
All body cavities which could be affected
by corrosion have been given a thorough
This sealing does not require any inspec-
tion or additional treatments. If any wax
should seep out of the cavity when the
ambient temperature is high, it can be
removed with a plastic scraper and a
suitable solvent. Be sure to observe all
safety and environmental regulations.
5
MAINTENANCE
Your vehicle has been designed to help
keep maintenance requirements to a mini-
mum. However, a certain amount of regu-
lar maintenance is still necessary to as-
sure your vehicle's safety, economy and re-
liability.
Maintenance Service is required every
12 months or every 15,000 miles (24,000
kilometers), whichever occurs first.
In addition, it is necessary to perform an oil
change 6 months after each Maintenance
Service, or after each 7,500 miles (12,000
kilometers) whichever occurs first.
The first oil change must be performed 6
months after the delivery of the vehicle or
after 7,500 miles (12,000 kilometers).
Under difficult operating conditions, for
example at extreme low outside tempera-
tures or in very dusty regions , etc., some
service work should be performed bet-
ween the intervals specified.
This applies particularly to :
• oil changes, and
• cleaning or replacing the air filter.
The maintenance work should be per-
formed by Volkswagen dealers because
they have the expertise, the workshop
fac.iliti~s and the special tools required.
It IS Important that this work is per-
formed according to the manufacturer's
instructions.
Proof of servicing in accordance with the
maintenance schedule may be a condition
for upholding a possible warranty claim
made within the warranty period.
Safety and environmental concerns
place very strict limits on the nature of re-
pairs and adjustment on engine and trans-
mission parts which an owner can per-
form. Tampering with safety-related parts
can endanger you as well as other
motorists.
Always observe environmental regula-
tions when disposing of old engine oil,
used brake fluid, dirty engine coolant,
spent batteries or worn out tires .
 VEHICLE CARE
LUBRICANTS ENGINE OIL

Engine Engine Oil Identification Symbol Engine oil consumption

Your engine was factory filled with an all-
season high quality engine oil. If you need
to add oil between oil changes use any
high quality petroleum or synthetic based
oil with correct specifications.
The following term must appear on the oil
container singly or in combination with
other designations: "API Service SF or
SG" (Gasoline engine) or "API Service
CD" (Diesel engine).
Engine oils are graded according to their
viscosity. The proper grade to be used in
your engine depends on existing climatic
or seasonal conditions.
Refer to the temperature chart when
selecting engine oil. As temperature
Select an oil for your vehicle which con-
forms to the standards of the American Pe-
troleum Institute (API). A symbol has been
added to the top of some oil containers to
help in selecting the correct oil.
(1) The top portion indicates the oil quality
by API designations.
(2) The center portion shows the SAE oil
viscosity grade.
(3) The lower portion indicates that the oil
It is normal for your engine to consume oil.
The rate of oil consumption depends on
the quality and viscosity of oil, the speed at
which the engine is operated, the climate,
road conditions as well as the amount of
dilution and oxidation of the lubricant.
Because of these variables, no standard
rate of oil consumption can be esta-
blished, but drivers should expect an in-
creased oil consumption 1a t high speeCls
and whell the engine is new.
• Tile engine 11'11 your vehicle depends
-o n oil to lubricate an<t cool all Qf its FJIOV-
Ing parts. Therefore the engine oil
shOuld be checked regularly and kept at
the required lever.
• I

ranges of the different oil grades overlap,
brief variations in outside temperatures
are no cause for alarm. It is also permissi-
ble to mix oil of different viscosities if you
find it necessary to add oil.
Gasoline engine:
Multi grade oil
• Make It a habit to have tt"le engine oil
has fuel saving capabilities. level checked with every fuel filling;
• LAck of sufficient engine oil may lead
Transmission
to severe engine·damage.
Manual transmission:
• The oil pressure warning light is not
Hypoid oil SAE 80 (Mii-L-2105 or an oil level indicator.
API/GL4).
Automatic transmission:
ATF Oexron@or Dexron II® for torque con-
verter and hypoid oil SAE 90 (Mii-L-2105 B
or API/GL 5) for final drive.

Front axle differential (Syncro only)

Hypoid oil SAE 80 (Mil-L 2105 B or
API/GL 4) or synthetic transmission oil
G 50, SAE 75 W-90.
The lubricant used does not have to be
changed.
Gasoline Engines 825 - 565121
Should the need arise to add oil, it should
only be done with the necessary workshop
Diesel engine: equipment.

Power steering
ATF Dexron '~J

Lubricant additives
Volkswagen does not recommend the
use of oil additives. It may adversely af-
fect your warranty.

When using SAE 10 W or SAE 5 W-20 or

SAE 5 W-30 engine oil, avoid high speed
long distance driving if outside tempera-
ture rises above the indicated limits.

7
I VEHICLE CARE [

Checking the engine oil level
The best time to check the engine oil level
is when the oil is warm.
The engine oil dipstick and the oil filler
neck are located behind the license plate
lid.
Air-cooled engine:
Diesel engine:
Water-cooled engine:
• Turn off the engine.
• To get a true reading, the vehicle should
be on level ground. After turning ott the en-
gine, wait a few minutes for the oil to return
to the crankcase.
• Flip license plate down.
• Pull out dipstick and wipe it clean with a
rag.
• Reinsert dipstick; push it in all the way.
• Pull dipstick out again. The oil level is
correct if it is between the "max" and "min"
marks on the dipstick.
• If oil level is below "min" mark, or not
showing on dipstick, add oil immediately.
• Make sure that the dipstick is com-
pletely in.
Adding engine oil
• Unscrew cap from oil filler neck.
• Pull extension tube out of filler neck as
far as it will go.
• Only add the amount of oil needed. The
difference between the "min" and "max"
marks on the dipstick is about 1 U.S. quart
or 1 liter. Always select a quality oil with the
correct specification. See "Lubricants" on
page 7.
Do not exceed the MAX marking.
Otherwise, the excess oil may be drawn in
through the crankcase breather into the
exhaust system. The oil would then burn in
the catalytic converter and cause dam-
age.
• Push in the extension tube, replace fil-
ler cap and hand tighten securely.
WARNING
The oil filler cap muat be secure to
•!old ollepill cau.lng fire hazard.
Changing the engine oil A
Have your engine oil changed regularly,
but at least twice a year (see Maintenance
booklet).
This is very important because the lubri-
cating properties of oil diminish gradually
during normal operation of the vehicle.
If you drive mostly short distances, or if
you operate the vehicle in dusty areas, or
under predominantly stop-and-go traffic
conditions, or when temperatures remain
below freezing for extended periods, the
engine oil should be changed more fre-
quently.
Due to the detergent additives in the oil, R
the fresh oil will look dark after the engine iE
has been running for a short time. This is rE
normal and there is no reason to change u
the oil more often than recommended by
the manufacturer. lr
T
s
WARNING v.
• Drain the oil Into a container that Is (1
designed for this purpose, one that Is
large enough to hold at least the oil
filling of your engine.
• Wear eye protection.
• To reduce the risk of bums from hot
engine oil let the engine cool down to
the touch.
• When removing the oil drain plug
with your fingers, keep as far away as
possible. Always keep your foreann
parallel to the ground to hefp prevent
hot oil from running down your arm.
• Engine ollie polaonoua. Keep It well
out of the reach of children. Con-
tinuous contact with used engine oil Js.
harmful to your skin. Always protect y
your skin by washing thoroughly with
soap and water.
• Always dispose of used engine oil
properly. Do not dump it on garden soil,
wooded areas, into open streams or
down sewage drains.
• Recycle used engine oil by taking it to
a used engine oil collection facility in
your area, or contact a service station.

• Turn off the engine.

• Remove the oil drain plug (arrow) when
the engine is still warm and allow the oil to
drain .
• Always use a new gasket when
reinstalling the plug. Do not overtighten.
• Fill the engine with oil. Do not overfill.
Always check engine oil level with dipstick
as described on previous page.

8
 I VEHICLE CARE
ENGINE OIL FILTER

Air-cooled engine: Changing the oil filter Air-cooled engine:

The oil filter should be changed at the inter-
vals listed in your Maintenance booklet.
• Remove old oil filter element and dis-
card.

• Lightly coat seal of new filter element

with oil.
• Screw on filter element and hand-
tighten according to manufacturer's
instructions on the carton or on the filter
element.
re-
• Fill engine with appropriate amount of
engine oil.
oil , Remove the drain plug A first. After the oil
·ne is drained, take out the oil strainer by • Run engine at various speeds for three
removing the center nut B and clean it. to five minutes and check for leaks.
c. is
ge Use new washers and gaskets. • Check dipstick for correct oil level, top
by up if necessary. Diesel engine:
Important
The center nut 8 for the oil strainer
should be tightened with a torque
wrench. The correct torque is 7-9 ft lb
(1.0-1.3 mkg).

Diesel engine:

Water-cooled engine:

Water-cooled engine:

en
I to

9
I VEHICLE CARE
FUEL FILTER
Fuel filter replacements should be per-
formed by your VW dealer or a qualified
mechanic.
On Diesel engine equipped vehicles,
accumulated water should be drained
regularly.
Fuel filter replacement and water drain-
age intervals are specified in your
Warranty & Maintenance booklet.
Should it become necessary to drain the
fuel filter of water between scheduled
maintenance intervals, prQceed as
follows.
To drain water from Diesel fuel filter
WARNING
• Turn the engine off and let it cool
down. Hot components can burn skin
on contact and Ignite fuel.
• Do not smoke or have anything in
the area that can Ignite fuel.
• Handle fuel only In well ventilated
areas.
• Disconnect ground strap from
battery to prevent sparking.
• Open vent screw at top of fuel filter.
• Loosen drain plug underneath filter
and, using a container, drain about half
a cup or until drained fuel .is pure.
• Tighten drain plug and vent screw.
• Do not let Diesel fuel spill on rubber
hoses. Such connecting hoses may
develop leaks and cause serious
engine damage.
• Do not dump Diesel fuel from the old
canister on the ground, into open
streams or down sewage drains.
Should the discarding of Diesel fuel
present a problem, we suggest you
have filter changes performed by your
VW dealer or at a service station.
AIR CLEANER
A dirty filter element reduces engine out-
put and increases fuel consumption and
can cause premature engine wear.
Normally, it is not required to service the
air cleaner more often than recommended
in the Maintenance booklet. If the vehicle
is driven on very dusty roads, the air
cleaner must be serviced more frequently,
even daily. We recommend that you have
the air cleaner serviced by your Volks-
wagen dealer or a qualified workshop.
If your air filter must be changed more
frequently, we recommend that you have
your Volkswagen dealer show you the
procedure before you attempt doing it
yourself-
The paper filter element must never be
cleaned or soaked with gasoline, clean-
ing solvents or oiL
10
POWER STEERING*
The fluid reservoir is located behind the
licence plate lid.
The power steering is filled with ATF
Dexron®.
A correct fluid level in the reservoir is im-
portant for the proper functioning of
power steering .
With the engine running, the fluicl lo Ho l ;n
the power steering system n ..J;:;l be
checked at regular intervals. The fluid
level should always be between the "max"
and "min" markings. If the level should go
below the "min" marking, have the power
steering system inspected by your Volks-
wagen dealer. It is not sufficient to just add
hydraulic fluid.
WARNING
• Be ..... not to confula bt'8U fluid
and hydraulctlutd.lftha wrong ftuktle
ueed, ... . , . . . . may fill.
• .,... POIIIIIW .a.rtng aptem ehoulcl
fall, or Iftile enelnllt noii\IIIMig (for
example while . . towed). JOU wll
still be able to ...... the Whlde. horl-
ever, more effort will be required.
Note
Since the hydraulic fluid also functions as
a lubricant, serious damage to the pump
and to other components of the system
could result if there is insufficient hydraulic
fluid in the system.
"where applicable
l VEHICLE CARE
COOLING SYSTEM
The cooling system is sealed and gener-
ally requires little attention.
The cooling system has been filled at the
factory with a permanent coolant which
does not need to be phanged. The coolant
consists of a mixture of water and the
manufacturer'S coolant additive G 11 -
antifreeze on glycol basis with anticorro-
sion additives (40 % for USA models; 50%
for Canadian models). This mixture
assures the necessary frost protection
and protects the entire cooling system
against corrosion and scaling, and raises
the boiling point of the coolant.
Do not reduce the concentration of the
coolant in the summer by adding plain
water. The coolant additive proportion
must be at least 40% but not more than
60%, to maintain the antifreeze protection
and the cooling efficiency.
For year round driving, antifreeze is added
at the factory for temperatures down to:
-13° F/-25° C (USA)
-40° F/ -40° C (Canada)
Only use quality phosphate-free anti-
freeze containing ethylene glycol. Such
antifreeze is available at your Volkswagen
dealer.
WARNING
Antifreeze Is poisonous. Alwaye store
antifreeze In Its original container and
well out of the reach of children. If you
drain the coolant, it must be caught and
safely stored. Drained coolant should
normally not be reused. Always des-
pose of uaed coolant observing all en-
vironmental regulations.
Coolant losses On the refill tank, the coolant level must be:
between the min. and max. marks when
Coolant losses may indicate a leak in the engine is cold and not running . When
cooling system. In this case, the cooling
engine is warm , coolant level may be
system should be inspected immediately
slightly above max. mark.
by your Volkswagen dealer. It is not suffi-
cient merely to add coolant.
Diesel engine:
In a sealed system, losses can only occur
if the boiling point of the coolant is ex-
ceeded as a tesult of overheating.
Overheating can occur if:
• the flow of air to the radiator is
obstructed by leaves, dust, insects or by
additional lights installed in front of the
radiator grille;
• the boiling point of the coolant has been
reduced due to an incorrect mixture of Water-cooled engine:
coolant and water;
• the radiator fan is not working - see
"Radiator fan", or;
• the vehicle is being driven up a long hill
in a low gear with engine speed very high
and at very high ambient temperature -
see "Radiator fan".
If the cause for the overheating cannot be
determined and corrected, contact your
Volkswagen dealer immediately, other-
wise serious engine damage could result.
Checking the coolant level
The coolant level should be checked from The expansion tank needs checking only if
time to time, and always before going on a a large amount of coolant is lost or if the
longer trip. warning light in the water temperature
gauge lights up.
WARNING
Diesel engine:
1b reduce the risk of being burned,
never open the hood If you see or hear
steam or coolant escaping from the en-
gine compartment. waH until no steam
or coolant can be seen or heard before
carefully opening the hood.
The refill tank and the expansion tank are
in the engine compartment.
On the refill and the expansion tank, the Water-cooled engine:
cap need not be taken off, since the tanks
are transparent.
The coolant level is normally checked only
in the refill tank (behind the license plate
lid).
11
I VEHICLE CARE
V-BELT

Adding coolant Radiator fan Tension checking

Turn off the engine and allow it to cool The electric radiator fan (located in front of Correct V-belt tension is important for over-
down. the car behind grille) is controlled by ther- all vehicle performance.
moswitches from the coolant and engine
compartment temperature. Tensioning and replacing of vehicle V-
,WARNING belts should be performed by your
After turning off the engine, the radiator Volkswagen dealer or a qualified work-
Reduce the rlak of scalding from hot fan can continue to run (up to 10 mi- shop.
coolant by following these atepe. nutes). It may also suddenly start to run
again even with the ignition switched off.
• If the cep from the expansion tank WARNING
must be removed walt until the engine
Notes To prevent personal Injury etay well
has cooled down. The cooling system
Is under praeeure. • If the radiator fan does not come on clear of the ¥-belt when the engine Ia
when the coolant temperature is very high, Nnnlng. Before checldng V-beft ten-
• Protect face, hande Mid anna by check the fuse and replace it if necessary elon turn the engine off and let ncool
'covering the cap with a large. thick rag down. Hot components can bum akin
to protect against escaping fluid and • The speed of the radiator fan does not on contact.
steam. depend on the engine speed , therefore
• Carefully and slowly turn cap one cooling effect cannot be increased by
turn to allow excess pressure to es- downshifting . As long as the engine runs
cape before completely removing cap. smoothly and driving an uphill road does
not considerably reduce speed, there is no
Top up coolant in refill tank . Only when need to downshift.
cooling system was drained or a lot of cool-
ant needs to be added, also fill expansion
tank .
To maintain the anti-corrosion properties
of the coolant, the antifreeze concentra-
tion should not be reduced, even during
the warm season.
Increasing the antifreeze in the coolant
to more than 60% is not only unecono-
mical, it is also detrimental to engine
cooling.
Only use quality phosphate-free anti-
freeze containing ethylene glycol. Such
antifreeze is available at your Volkswagen
dealer.
Antifreeze, other than specified by Volks-
wagen, may cause corrosion of the cool-
ing system, leading to engine over-
heating and damage.
Only for topping-up coolant, a small
amount of antifreeze containing ethylene
glycol and phosphates may be used, if rec-
ommended antifreeze is not available.
• After adding coolant, run the engine at
idle speed for a few seconds.
• Wait for the radiator fan to switch on
and off again.
• Check coolant level. Add more coolant
if necessary.
Do not overfill the system.
Excess coolant will be forced out through
the pressure relief valve in the reservoir
when the engine becomes hot.
Screw cap on again tightly.

12
) I VEHICLE CARE
BRAKE FLUID
tr-
V·
Jr
k·
Brake fluid reservoir
The brake fluid reservoir is located under
the instrument cluster in the dashboard
panel.
To gain access to the reservoir, grasp the
two recesses provided on back of the
frame cover and pull up.
When replacing the cover, insert the front
edge first, then press the cover qown
firmly. Make sure it is correctly seated.
Checking fluid level Changing brake fluid
The correct fluid level is important for the Brake fluid absorbs moisture from the at-
proper functioning of the brake system. mosphere. If the water content in the brake
The fluid level in the brake fluid reservoir fluid is too high, corrosion in the brake sys-
should always be between the MAX and tem may result after a period of time. The
MIN markings. Your brake fluid level is boiling point of the brake fluid will also de-
automatically monitored by the brake crease · considerably. If the brakes are
warning light under constant and extreme use, a vapor
lock may result impairing the effectiveness
The fluid level may drop slightly after some of the brakes and the vehicle safety.
time due to the automatic adjustment of
the brake pads . This is no cause for alarm.
WARNING
If the orake fluid level falls considerably
below the mark "MIN", the brake warning The brake fluid must be replaced eNerY
light will come on . Do not continue to oper- 2 years. Your Volkswagen dealer will
perform this service for you.
ate the vehicle. The complete brake sys-
tem should be thoroughly checked by your
Volkswagen dealer and the cause cor-
rected.
WARNING
• Brake fluid Is poisonous. Brake fluid
Ia also hannful to the paint of your
vehicle.
When adding or replacing brake fluid,
make certain to avoid spilling. Brake
fluid will damage fabric, paint, plastics
and metal. Cover the area sorround-
lng the reservoir ·befOre removtng the
filler cap.
• H brake fluid must be added to the
reservol~ uee only new and unused
DOT 4 brake fluid that meets SAE
specification J 1703 and conforms to
Federal Motor Vehicle Safety Standard
116.
• Do not uee ant other brake fluid, or
.brake fluid that bas abeorbed molature
from the optn at-. or brake fluid that Is
~ n may ceuee premaiUnt wear or
unreliable braking ectfon.
• Do not add or mix DOT 5 elllcone
type brake fluid With the brake fluid In
your vehicle aa I8Y8f8 component COI'-
roelon may NSUit. Such corroelon
could lead to brake eyatem failure.
13
I VEHICLE CARE
BATIERY
The battery is located under the front pas-
senger seat. To check the battery, move
the seat all the way forward.
On vehicles with swivel seats, turn the
seat 180° (half circle) an then push for-
ward.
Diesel:
The battery is in the engine compartment on
the right.
Auxiliary battery*
The auxiliary battery is located under the
left seat. Push the seat all the way forward
to gain access to the battery.
The auxiliary battery supplies power when
the vehicle is stationary. A special relay be-
tween the vehicle battery and the auxiliary
battery prevents the vehicle battery from
discharging . This way, you still have power
to start your vehicle. While driving, both
the vehicle battery and the auxiliary bat-
tery are charged.
"where applicable
Battery acid level Charging of battery
Under normal operating conditions, the
battery in your Volkswagen is mainten- WARNING
ance-free. • Always 8hleld your eyes and avoid
leaning over the battery whenever poe-
At high outside temperatures it is advis-
albia.
able, however, to check the fluid level at
regular intervals through the transparent • Charge battery In a well ventilated
battery housing . The fluid level should al- area. Keep away from open flame or
ways be between the "min" and "max" 'electrical spark. Do not smoke. Hyd~
marks in each cell. =generated by the battery fa ex-
If the fluid level is below the "min" mark , let
your Volkswagen dealer correct the condi-
• Battery acid that may spill during
charging should be washed off with a
tion.
solution of warm water and baking
toda to neutralize the acid.
WARNING • Hyou get battery acid In your eyes or
on your skin, Immediately rinse with
• Always ahleld your eyea and avoid cold water for several minutes and call
leaning over the battery whenever pos- a doctor.
sible.
• Never charge a frozen battery. It may
• Do not let battery acid come In con- explode because of gas trapped In the
tact with akin, eyes, fabric, or painted Ice. Allow a frozen battery to thaw out
IIUrface. first.
• Hyou get battery acid lnyoureyesor • Never use a fast charger as a boo-
on your akin, Immediately rlnee with ster to start the engine. This will seri-
cold water for eeveral minutes and call ously damage sensitive electronic
a doctor. components, such as relays, radio,
etc., as well as the battery charger.
• Do notexpoeethebattetytoan open
flame or electric epark. Hydrogen gas
generated by the battery can explode • Fast charging a battery Ia dangeroua
and cause pei'80NIInjury. and should only be attempted by a
competent mechanic with the proper
equipment.
Winter operation
During the winter months, battery capacity
tends to decrease as temperatures drop.
Additionally, more power is consumed
while starting, and the headlights, heater,
rear window defogger, etc., are used more
frequently. Curtail unnecessary power
consumption, particularly in city traffic or
when travelling short distances only. Let
your Volkswagen dealer test the battery 's
capacity before winter sets in. A well
charged battery will not only prevent
starting problems but will also live longer.
If your vehicle is left standing for several
weeks at extremely low temperatures, the
battery should be removed and stored
where it will not freeze. This will prevent it
from being damaged.
When removing the battery, first discon-
nect both cables (see Charging of Bat-
tery), then unscrew the battery mounting.
WARNING
Always keep the battery well out of the
reach of children.
14
IVEHICLE CARE
Slow battery charging
WARNING
• Heed all WARNINGS and follow In-
structions that come with your battery
charger.
• It is not necessary to remove the bat-
tery from the engine compartment, and it
is also not necessary to disconnect the
cables.
• Make sure the electrolyte level in each
cell is between the "min" and "max" marks.
If the fluid level is below the "min" mark, let
your Volkswagen dealer correct the condi-
tion.
• Connect charger cables.
Charger cables must be connected
POSITIVE ( +) to POSITIVE ( +) and
NEGATIVE (-)to NEGATIVE (-).
Do not connect or disconnect charger
cables while charger is operating to re-
duce the danger of exploding.
• Switch on charger.
• Ct1arglng rate not over 6 Amp ..
Normally, a battery should .be 'charged at
no more than 10 percent of lfs rated capa-
city.
For example, a ctlarging GUrrent of 4.5
Amp. would be usect on a battery having
45 Ah . Rated capacity of the battery in
your vehicle is listed on the battery
housing.
• After charging, turn off charger and dis-
connect charger cables.
To remove battery from vehicle Replacing battery
• Disconnect negative ground cable . A replacement battery must have the
same specifications and dlmer~sions as
• Disconnect positive cable. the original equipment battery. Specifica-
• Unscrew bolt of holding plate with open tions are listed on the battery housing.
end wrench. Make sure the replacement battery is in-
stalled correctly and securely. See "Re-
moving and reinstalling battery".
To reinstall battery in vehicle
• Place battery in vehicle and tighten bolt
of holding plate.
• Reconnect positive cable.
• Reconnect negative ground cable.
WARNING
Do not reverse polarity.
Cleaning terminals and
connections
WARNING
• Before wo.-tc Ia done on the electrical
eyatam, di8COf'lnect the negative
ground cable.
• When working on the bat*y, be
aure not to ahort circuit the tennlnala
wllh too1a or other metal ob)ecta. lbla
would cause the betleryto heel up very
~which could lead todMtageor
exploalon end personal Injury.
The terminals and connections should be
kept clean and greased with silicone spray
or petroleum jelly. Make sure the ground
connection to the body is tight and free of
corrosion .
With a disconnected battery the engine
must not run because the electrical sys-
tem will be damaged.
15
l VEHICLE CARE
WINDSHIELD I REAR WINDOW WASHER CONTAINER* REPLACING WIPER BLADES

Wiper blades must be in good condition to

provide clear vision.
Clean your wiper blades regularly with a
windshield washer solution to prevent
streaking. If the blades are very dirty, for
example with insects, carefully clean the
blades with a sponge or a soft brush.
Replace your wiper blades once or twice a
year. See your Volkswagen dealer for re-
placement blades.

Notes
The filler cap is located at the left side of Adjusting washer jets • Commercial hot waxes applied by auto-
the driver's footwell. matic car washes have been known to
When vehicle is stationary, the water affect the cleanability of the windshield.
Vehicles with rear window wiper and should hit the windshield as illustrated .
washer have an additional container on • To prevent damage to wiper blades,
The washer jet for the rear window should do not use gasoline, kerosene, paint
the right in the luggage compartment. be adjusted so that the fluid hits the glass thinner, or other solvents on or near the
The capacities of the containers are: in the center of the wiped area. wiper blades.
Windshield washer The jets can be adjusted with a needle.
container . . . . . . 4.3 qt/4.2 liters • To prevent damage to the wiper arms
Rear window washer The jets for the headlight washer system* or other components, do not attempt to
container . . . . . . 1.1 qU1.0 liters can only .be adjusted with a special tool. If move the wipers manually.
necessary contact your Volkswagen deal-
Filling the containers er.
To fill the container, unsnap cover and un-
screw the filler cap. After filling the con-
tainer, screw the cap on tightly and close
cover.

Removing wiper blades

• Raise the wiper arm and hold wiper
blade horizontally.
• Depress locking spring (A) and remove
blade by pulling it towards the glass (B) .
Since clear water is usually not adequate Installing new wiper blades
for cleaning the glass, add a cleaning solu-
tion to the water. • The locking spring must click into place
on the wiper arm .
Use winterized washer solvent during the
cold season. It helps to keep your
windshield and rear window clean and pre-
vents the fluid from freezing in the winter.
Do not use engine coolant antifreeze or
any other solution that can damage the
vehicle paint.
Follow the directions on the can for the
correct amount to be used.
After filling the container press the cap
onto the filler neck.

• where applicable

16
I VEHICLE CARE
TIRES/WHEELS
New tires
New tires do not possess maximum trac-
tion and should be driven at moderate
speeds and with caution for the first 100
miles (160 kilometers).
Tire traction
WARNING
When driving on wet or eluehy roecl8, a
wedge of water may build up between
the t1rea and the road. Thle phenomeo
nonlaknownaaaquaplanlngorhyd•
planing and may caUM perllal or com-
plete 1oM of traction, vehicle control or
atopp1ng abl~ Alwaya reduce epeed
on wet roads.
Tire service life
The service life of your tires depends for
the most part on the following factors:
Tire pressures
Check your tire pressures twice a month,
and especially before taking a long trip. Be
sure not to forget to check the spare tire.
Always check tire pressures when the tires
are cold. When the tires are warm, the
pressure will be higher. Do not reduce the
pressure of warm tires.
Use an accurate tire pressure gauge when
checking inflation pressures. Do not
exceed the maximum tire inflation pres-
sure listed on the tire sidewall. Cold tire
inflation pressure means: when a vehicle
has been standing for at least 3 hours or
driven for less than 1 mile.
Always include the spare tire during a pres-
sure check.
Driving habits
Fast cornering, heavy acceleration and
hard braking all increase tire wear.
Wheel balancing
The front wheels on new vehicles are
balanced. When driving, however, various
conditions can cause a wheel to become
unbalanced. This may be noticed as vibra-
tions in the steering.
Since tire imbalance can cause wear on Tire care
the steering, suspension and tires, you Inspect your tires at least every 2,000
should have your wheels rebalanced . A
miles (3,000 km) for wear and damage.
wheel should always be balanced if a new
tire has been mounted or a tire was re-
paired. WARNING
• Avoid damaging tires and wheel
rime. If you must drive over a curb or
other obatacle, drive slowly and at an
angle. Frequently check tires for un-
even wear and damage.
• Remove Imbedded material.
• Replace wom or damaged tires
lmmedtately.
• Replace mlsalng valve dust caps.
• Keep oil, fuel, brake fluid, etc. away
frorntlree.
• Keep tlrealnflated correctly.
Tire wear
• Mark tires before removing them.
The original tires on your vehicle have Remount tires on the same vehicle side
built-in wear indicators. They are molded because the rotation direction should stay
into the bottom of the tread grooves and the same.
will appear as approximately V2 inch
(12 mm) bands when the tire tread depth • Store removed tires in a cool, dry and
wears down to V1e inches (1.6 mm) . preferably dark place. Tires which are not
Depending on the tire manufacturer, there on wheels should be stored standing up.
are six to eight wear indicators evenly
Tires age even if they are not being used.
spaced around the circumference of the
Tires which are older than 6 years should
tire. Markings on the sides of the tires (e.g.
only be used cautiously in an emergency.
the letters "TWI" or a triangle) show the
locations of the wear indicators.
When the indicators appear in two or more
adjacent grooves, it is time to replace the
tires. We recommend, however, that you
do not let the tires wear down to this
extent. Worn tires cannot grip the road
surface properly, and are even less effec-
tive on wet roads.
WARNING
• Do not drive with wom tlrN or a...
lhowtngcta, bndleeorotherdlmeae
becaulelhermayleadtoiUdden....
=~Ofvehlclecontroland
• 81nceworn._don:=tllel08d
..,_~When on w
I'OICII, VehiCle ..., tend to . . . .
plane 800I1K We~urge you to
replace your tlraa when remaining
tread depth Is .121nches (3 mm).
Incorrect wheel alignment
Incorrect wheel alignment causes exces-
sive and uneven tire wear impairing the
safety of the vehicle. If you notice exces-
sive tire wear, contact your Volkswagen
dealer.
17
j VEHICLE CARE
Wheels and tire replacement
Wheels and tires approved by the manu-
facturer have been specially matched to
your vehicle and contribute largely to the
road-holding and driving characteristics of
the vehicle.
• Fitting and repairing tires requires
expert knowledge and special tools. This
work should only be performed by a spe-
cialist.
• For safety reasons, tires should be
replaced in pairs and not individually. The
tires with the deepest tread should always
be mounted on the front wheels.
• In the interest of maximum safety and
best all-around vehicle handling, always
buy replacement radial tires that have the
same specifications with regard to tire
size, design, load carrying capacity, tread
pattern, tread depth etc. This also applies
to Volkswagen recommended alternate
replacement tires.
• Never mount used tires if you are not
sure of their previous history.
• Whenever replacing a tubeless tire,
always install a new valve stem. Tire repair
should only be performed by a specialist.
WARNING
• Never mix tires of different design
such as steel belted radiale with radial
bias belted or blaa ply tires etc. Mixing
tire types will adversely affect road
holding and can lead to loaa of vehicle
control and personal InJury.
• New tires do not possess maximum
traction. Tbey tend to be slippery.
Break new tires In by driving cautiously
at moderate speed for the first 100
miles (160 kilometers).
Applies additionally to the Syncro:
All four wheels on the vehicle must always
have tires of the same size, construction
and tread type so that the viscous coupling
does not abnormally activate the front
wheel drive. Different tires on the front or
rear wheels exert additional stress on the
drive train components, causing increa-
sed tire wear and impair vehicle control.
General notes
The original equipment tires and wheel
rims on your vehicle comply with all
applicable Federal Motor Vehicle Safety
Standards.
If you wish to equip your vehicle with tires
or wheels other than those installed at the
factory, please note the following :
• If you plan to install other than the ori-
ginal equipment tires and wheel rims,
ask your Volkswagen dealer.
• For technical reasons it Is not possi-
ble in every case to use wheels from
other vehicles - under certain condi-
tions not even wheels from the same
vehicle model.
• Wheel rims and wheel bolts or lug
nuts are matched to fit your Volkswagen.
• When installing different wheels (for
example, wheels with winter tires), the
correct wheel bolts or lug nuts with the
proper length and conical shape must
be used. The secure fit of the wheels and
the proper functioning of the brake
system are dependent upon this.
• Using tires and/or wheels which have
not been approved by the manufacturer
for your vehicle type can be detrimental
to vehicle safety.
• If wheel trim discs or a front spoiler are
installed, make sure the air flow for cooling
the brakes is not obstructed.
• Before you plan on exchanging steel
wheels, light alloy wheels, or snow tires
already mounted on wheel rims, consult
your Volkswagen dealer. He has the tech-
nical information necessary to advise
you which wheel rims and wheel bolts or
lug nuts are compatible with the original
factory installations.
WARNING
• The uee of the wheel rtma and wheel
bolts or lug nuts that do not meetepecl-
tlcallona of the original feotory Install-
ed equipment wiH affect the uf8 oper·
at1on of your vehicle and may cause an
accident and pereonallnjury.
18
Tire specifications
Tire specifications are imprinted on the
sidewall of the tires. If in doubt, check with
your Volkswagen dealer.
All passenger car and some light trucks
tires must conform to Federal Safety
Requirements in addition to these
grades.
Treadwear
The. treadwear grade is a comparative
rating based ·on the wear rate of the tire
when tested on a government test course.
FO£ example, a tire graded 150 would wear
one and a half (11!2) times as well as a tire
§Faded 100. The relative performance of
tires depends on actual conditions of use,
however, and may depart significantly
from the norm due to variations in driving
habits, service practices and differences
in road characteristics and climate.
Traction A, B, C
The traction grades, from highest to
lowest, are A, B and C and represent the
tire's ability to stop on wet pavement as
rneasured on government test surfaces of
asphalt and concrete. A tire marked C may
have poor traction performance.
WARNING
The traction grade Is baaed on brak·
lng (etralghtahlad) traction tests and
cloee not Include cornering (turning}
traction.
Temperature A, B, C
The temperature grades A (the highest), B
and C, represent the tire's resistance to the
generation of heat. Sustained high tem-
peratures can reduce tire life, and lead to
sudden tire failure. Grade C corresponds
to a performance which all passenger car
tires must meet under the Federal Motor
Vehicle Safety Standard No. 109. Grades
B and A represent higher levels than the
minimum required by law.
MNING
The temperature grade for thll tire 18
established for a tire that It propetty
Inflated and not overtoeded. Excelelve
apeed, underlntlatlon, or excessive
loedlng, either eeparetely or In combJ.
nation, can cause heel buildup. poul-
ble tire failure, loea of control and .,....
sonallnjury.
( VEHICLE CARE
Snow tires
The tires for your vehicle were selected for
optimal performance unc;ler normal driving
conditions.
For winter driving, the roadability of your
vehicle can be improved by installing all
season tires or radial snow tires (M + S)
with or without studs1).
That applies also to the Syncro
When installing snow tires, please note
the following:
• Only radial ply snow tires must be
installed. Ask your Volkswagen dealer for
the recommended tire size.
• Snow tires should be mounted on all
four wheels.
• The tire pressures for snow tires are the
same as for summer tires. However, do not
exceed the maximum tire pressure listed
on the sidewall.
• Snow tires should have the same load
capacity as original equipment tires and
should be mounted on all four wheels.
• Snow tires do not fulfill their purpose, if
the tread depth is less than s;32 in (4 mm).
WARNING
• Tlrea with bedly worn treada and
8lude are very dangerouL Mike aura
they are rwplaced lmmedlataly.
• Never mix tlree of dllrerant clellgn
IUCh ...... belted ..... with ......
blu belled or blu ply llrea eiC.. •XIna
tire typee wll adver88ly affeot IDIMI
=and can lead to loea of vehicle
and ~I Injury.
• Snow tires with studs should be run at
moderate speeds when new in order to
give the studs time to settle.
Do not drive a vehicle equipped with snow
tires at prolonged high speed. Snow tires
do not have the same degree of traction on
dry, wet or snowfree roads as a normal tire.
Furthermore, snow tires wear rapidly
under these conditions.
• Where snow tires are compulsory on
certain roads , this also applies to vehicles
with all-wheel-drive.
') Check with your local Motor Vehicle Bureau for
possible restrictions.
Snow chains
Snow chains can be used on the rear
wheels only.
Only use chains with fine pitch links pro-
truding no more than 1/2 in/15 mm from tire
tread and side walls, including tensioner.
Wheels must rotate freely in all steering
positions with chains mounted to prevent
damage to body, axle or brake compo-
nents. Drive slowly and follow the chain
manufacturer's instructions.
Remove chains when roads are free of
snow. Otherwise, they can be damaged
and impair vehicle handling.
Syncro models only
Conventional snow .chains may not be
used with 205/70 x 14 tires on 5 1/ 2 J x 14
whe.els which are mounted on your
vehicle. The use of conventional snow
chains is only possible on smaller tires
(e.g. 185 R 14C). Ask your VW dealer.
Where possible, snow chains should be
fitted to all four wheels. If only two chains
are available, these must be fitted to the
rear wheels.
Cable type chains may also be fitted on all
standard tires and wheels (including
205/70 x 14 tires on 5 112 J x 14 wheels),
however, they should only be used when
road conditions require them. Always
remove snow chains when road condi-
tions improve. Be sure to follow all state
and local regulations pertaining to the use
of snow chains.
WARNING
To prevent peraonat Injury, wear pr~
tect1ve glovee when fitting cable
chalna on your wheels. AJwaya follow
the Instruction• of the manufacturer.
WINTER DRIVING
Remember the following points when
driving in the winter:
• Winter weather is particularly hard on
the battery. We recommend having the
battery checked, preferably by a Volks-
wagen dealer, before the cold weather
starts
If the vehicle is left standing for several
weeks at extremely low temperatures, the
battery should be Femoved
• Have the antifreez.e concentration in
the cooling system checked before the
cold weather starts
• The engine oil must have the correct
viscosity grade for the .outside tempera-
tures to be expected
• The best way to protect the bodywork is
to wash and wax it frequently, especially In
winter
• Always use a windshield washer fluid
with antifreeze for the windshield and rear
window washer system in winter
• Use a scraper to remove snow and Ice
from the windows
• On winter roads the use of winter tires
or all-weather tires will improve handling;
this also applies to vehicles with all-wheel
drive
• When driving in the mountains in winter
it is best to take along a set of snow chains.
Snow chains may be compulsory for some
mountain roads, and this restriction also
applies to vehicles with all-wheel drive
I DO-IT-YOURSELF-SERVICE
JACK AND TOOLS
The jack and the tools necessary to
change a wheel are in a bag stored under
the driver's seat.
On vehicles with swivel seats they are
stored under the rear seat bench.
The screwdriver has a reversible blade.
WARNING
• Uae the Jack bnly. for chlnlllna a
wheel. Never U8t the )lick lo 11ft ather
vehlclee or other IOedaaathlemayleed
to accidents and personal InJury.
=
• The Jack must never be ueed • a
to work underneelh the
If the jack .. accldantally tt.
lodged.youcouldbeeerlouely InJured.
• Do notralae the vehlcleualngabumo
per Jack. The buinper ayallm would be
damaged. Aleo. the jack may allpwhlch
coutd ..... peraonatln)ury.
• Do nollupport your car on cinder
blocU. brtclca or other propa that may
crumble under contlnuoua load.
• Do not 1ta1 or Nn the engine while
the vehicle .. 8UppC)IWd by the jack.
• When working under the vehicle,
alw. . . . . aafety atanda 8piCitlcllly
dlelpedfor lhltjuq:~
SPARE WHEEL
The spare wheel is located underneath the
floor panel of the driver cab, where it rests
on a hinged metal plate.
• To take out the spare wheel , remove
the bolt (curved arrow) from the holding
bracket with wheel wrench.
WARNING
Keep handa and anne away from undel'-
body of vehicle.
• Stand in front of the vehicle and pu ll the
catch hook (arrow) forward to let the metal
plate drop.
• Pull out the spare wheel.
20
U\
• When re-installing the spare wheel,
slide spare wheel onto metal plate.
• Give the plate a hard upward push and
make sure the catch hook is securely
engaged.
• Replace bolt and tighten firmly.
WARNING
Never drive the vehicle without a flnnly
tightened bolt on the holding bracket.
Should the catch hook disengage acd·
dentally, you could lose control of the
car.
Check the inflation pressure periodically to
keep the tire ready for use.
WARNING
Under no clrcurnstancee lhould you
atore the apare wheel unsecured In the
luggage compartment. Thla could
cause eerloua personal InJury to pa•
sengera In the vehiCle In caee of acolli-
sion.
 DO-IT-YOURSELF-SERVICE
CHANGING A WHEEL
WARNING
• H you have a flat tire, move a sara
distance off the ~d. 1\lrn off the
engine, the emergency ftaaher on and
use other warning devices to alert.
other motorists.
• Pusengeta must not remain In the
vehicle when H Is )acked up.
• Make sure that pusengers wan In a
ufe p~Jce away from the vehicle and
<Well away from the roadway and traffic.
• Before you change a wheel, be sure
the ground Is level and firm. Hneces-
sary, use a board under the jack.
• Set the parking brake and block the
wheel oppoaHe the de(ectlve wheel on
the other side of the vehicle. Engaging
a gear or placing th8 Automatic trans-
mission selector lever In P (Pari() posi-
tion Is not a substitute for fully aettlng
the parking brake.
Step 1
• Take out the bag with jack and tools
from under the driver's seat.
Step2
• With the wheels still firrnly resting on
the ground, remove the hub cap/wheel
cover of the defective wheel.
Wheels with hub cap
• The wheel cover can be pulled off with
puller clip and lug wrench .
Step3
• Loosen wheel nuts or bolts counter-
clockwise about one turn with the lug
wrench. Do not yet remove the nuts or
bolts.
To loosen - turn counterclockwise
To tighten - turn clockwise
Step4
There are two jack ports on each side
under the car body for front and rear wheel
changing - see right illustration.
Wheels with wheel cover
• Remove chrome plated hub cap with
puller clip and lug wrench. Insert clip in
holes at rim of a hub cap. Put wheel
wrench through clip, brace one end of
wrench on wheel rim and pull lightly on
other end.
When you place the hub cap face down,
you can use it as a tray for lug bolts (front
wheels) or lug nuts (rear wheels).
WARNNG
......... thelecklt.-tt other place
:=a,..~ car or may IMUit In
• PnMcle a finn a bale for the )aclt on
the gftMJnd.lf MCMI~ . . . . boerd.
• Securely insert the jack into the jack
port closest to the wheel to be changed.
• Before inserting jack, clear jack port.
• Place jack as straight as possible, as
shown.
21
I DO-IT-YOURSELF-SERVICE
StepS
NeWir .._.~up by the bum-
per or body.·
Do not ...r• the vehicle until you eM
aurelhe Jackie -=urwlyengagecl. ·
Pu.ngera muat not NINIIn In the
vehicle when Jaclc8d up.
• Make eurethat .,....,.n
welt In a
. . place away fiom tM vttdcle and
wellawayfnMn theroadwey endtfdle.
• To raise the vehicle, turn the handle
clockwise.
Only raise the vehicle as much as is
needed to change a wheel.
Step6
WARNNG
Before lnataiHng the spare wheel, accu-
mulated road dirt must be removed
from the lnelde and outside of the
wheel nutlbolt holM to asaura a secure
mount on front hub or reardNm.
• Fully unscrew wheel nuts or bolts and
place them into the hub cap. Take the top
nut or bolt off last. Place the spare wheel
against the wheel hub and slightly rotate
the wheel until a bolt hole in the wheel is in
line with a threaded stud in the whe.el hub.
Reinstall nuts or bolts and tighten them
crosswise by hand before jacking the car
down.
Step7
• To lower the vehicle, turn the handle
counterclockwise.
StepS
• Then go crosswise from one nut or bolt
to another tightening them firmly with the
lug wrench.
• Correct tightness of the wheel nuts is
important.
• Correctly tightened nu~s or bolts should
have a torque of 130ft lb/180 Nm. This tor-
que can be obtained with the lug wrench
by any person of average strength. If in
doubt about the correct tightness of the
wheel nuts, have them checked with a tor-
que wrench by your dealer or at service
station.
Step9
• To install the hub cap, place it around
the lower part of the wheel center. With a
firm blow of your hand on the upper part,
the hub cap will snap into place. Make sure
It is firmly seated.
Step 10
• Fully lower the vehicle and remove
jack.
• Correct the air pressure of the tire you
have just put on. For correct tire inflation
pressures, see the sticker on the left door-
jamb.
• Store the jack and tools under the
driver's seat.
• Store damaged tire in spare wheel
metal plate under front of vehicle.
• Engage lock for metal plate and firmly
secure plate with bolt.
• Have flat tire repaired and replaced
promptly.
22
FUSES
A failure in the electrical system may be
caused by a burned fuse.
Fuses are arranged in one centralized
unit. The unit is located on the left side
under the dashboard behind a cover.
Removing cover:
Detach cover at front, swing downwards
and take it off .
Installing cover:
Hang cover in the eyes of fuse box
bracket, swing it upwards and press it
firmly into position.
Replacing a fuse
Before replacing a fuse, turn off all lights
and accessories and remove the ignition
key to avoid damaging the electrical
system.
• Consult the appropriate electrical wir-
ing diagram to find out which fuse
belongs to the component that has failed.
• Remove blown fuse with the plastic clip
located on cover in front of fuse box.
Three spare fuses can be attached to the
bottom of the fuse panel. It is good plan-
ning to keep a supply of spare fuses on
hand. They are available at your Volks-
wagen dealer.
• Replace the blown fuse which can be
recognised by the burnt metal strip, with a
fuse of equal ampere rating .
WARNING
Do not uae a fuae of higher amperage,
because this could damage the elec-
trical part and fire can result.
If a fuse blows repeatedly, do not keep on
replacing it. The cause of the short cir-
cuit or overload must be found. On no
account should fuses be patched up
with tin foil or wire as this may cause
serious damage elsewhere in the electri-
cal circuit or cause a fire.
I DO-IT-YOURSELF-SERVICE
REPLACING BULBS

Before starting to replace a bulb, switch off

the respective circuit.
Do not touch the glass part of the new bulb
with bare fingers. ·Finger prints left on the
glass eva,porate when the bulb gets hot,
the vapor settles on the reflector surface
and dims it.
Always use the same type of bulb. The
designation is marked on the bulb.

Headlights
Should it become necessary to replace a
headlight bulb, the air intake grille must be
removed first.

• With a screwdriver loosen the five

quick-release screws along upper edge of
grille.
• Pull the grille slightly toward you .
• Then lift the grille out of its retainer.

1980-1984:

From1985:
• Install new bulb so that the locating lugs
on the headlight housing engage the
recesses on the bulb.
• Reinstall lock ring so that its recesses
engage the locating. lugs on the headlight
housing.
• Twist lock ring clockwise until firmly
seated.
• Reconnect wire connector. Have head-
light beam alignment checked.

Auxiliary driving lamps

• Remove the three short screws in the
sealed beam retaining ring and take the
ring off.
• Do not alter the position of the long
headlight adjustment screws.
• Take the sealed beam unit out of the
support ring and pull the cable connector
• Remove the four screws (arrows) and
take the headlight out.
• Turn cap to left and take off.
• Pull wire connector off.
• Unhook spring clip holding bulb and
swing it away.
• Take I:Julb out and Insert new bulb so

~· ~
off. that the locating lug on bulb plafe engages
recess in reflector.
When installing a new sealed beam unit,
be sure the three lugs on the headlight • Swing spring clip over bulb plate.
engage properly in the support ring. Squeeze clip together and engage it in the
retaining lugs.
If no other headlight part as described 2 3
here was removed or its position changed, • Attach wire again .
it should not be necessary to aim the • Install cap and turn to right.
headlights. If in doubt have the adjustment
checked by your dealer. • Have headlight setting checked.
Outer headlights
• Disconnect wire connector (1)
• Twist lock ring (2) counterclockwise,
pull bulb (3) out of headlight housing and
discard.

23
I DO-IT-YOURSELF-SERVICE

License plate light bulb

Front turn signal/ parking light bulb/
front side marker light bulb
• Remove the two Phillips screws and
take off the lens cover.
• Pull out bulb holder and push down the
rubber boot.
• Press spring clip inward and take out
bulb holder.
• Give bulb a left turn and remove.
• Replace bulb and reverse the above
procedure fo install bulb holder and lens
cover.
Rear side marker bulb
• Remove the two Phillips screws and
take off lens cover.
• Pull out bulb holder and push down the
rubber boot.
• Press spring clip outward and take out
bulb holder.
• Give bulb a right turn and remove.
• Replace bulb and reverse the above
procedure to install bulb holder and lens
cover.
There is one bulb housing on each side of
the license plate. Only if both bulbs are
operative is the license plate properly
illuminated.
• Take the bulb housing off by pulling it
down.
• Remove the two Phillips screws and
take off lens cover.
• Press bulb into housing, turn left and
take out.
• Replace bulb and reverse above proce-
dure to install bulb housing and lens cover.
Make sure the spring clip on each side of
the housing is securely engaged in the
cutouts provided at upper edge of cross
panel.

Rear turn signal, stop/tail/

back-up light bulb
• Remove the four Phillips screws and
take off lens cover with bulb housing.
Interior light
• To remove lamp, press against spring
clip on left side and lift out the housing.
• Take out bulb from between the two
spring contacts and install new bulb.
• Install lamp by inserting switch side of
housing into cut-out first.
• Then press in the other side until spring
clip engages.

t 825-325 1

• Squeeze the two side springs inward

(arrow) and lift out the bulb housing.
• Press defective bulb into bulb holder,
turn left and take out bulb.
• Replace bulb and reverse the above
procedure to install bulb housing with lens
cover.

24
I DO-IT-YOURSELF-SERVICE
HEADLIGHT ADJUSTMENT
The proper headlight adjustment is very
important for traffic safety. The headlight
adjustment should therefore only be done
with a special appliance.
Adjust the headlight using the Phillips
screwdriver from the vehicle tools.
The illustration show the adjustment on
the right headlights. On the left headlights
the adjustment are symmetrically oppo-
site.
A - lateral adjustment
B - hight adjustment
To reduce the beam range, turn the
screwdriver clockwise.
EMERGENCY STARTING
Starting with jumper cables
• Applying a higher voltage booster
battery will cause expensive damage to
sensitive electronic components, such as
relays, radio, etc ...
• Vehicle with discharged battery: turn off
lights and accessories, move lever to Nor
P (Automatic transmission) or into Neutral
(Manual transmission) and set parking
brake.
Use of jumper cables
Improper hook-up of jumper cables can
ruin the alternator.
25
A - Discharged battery
B - Booster battery
X - To bolt securing ground strap to body
Always connect
POSITIVE (+) to .POSITIVE (+), and
NEGATIVE (-)to bolt securing ground
strap to body.
1. Connect clamp of plus-cable to positive
(+ ) terminal (1) of discharged battery.
2. Connect clamp on opposite end of
cable to positive ( +) terminal (2) of boos-
ter battery.
3. Connect clamp of minus-cable to nega-
tive (-) terminal (3) of booster battery.
4. Connect clamp on opposite end of
cable to a bare metal part bolted directly to
bolt securing ground strap to body (4) of
vehicle with discharged battery. Connect
clamp as far away from battery as possi-
ble.
5. Start the engine of the vehicle with
the booster battery. Run the engine at a
moderate speed.
6. Start engine with discharged battery in
the usual manner. If engine fails to start, do
not continue to crank but contact nearest
workshop.
7. With engine running, remove jumper
cables from both vehicles in exact reverse
order: Steps 4 through 1.
Starting by pushing or towing
Vehicles with Automatic Transmission
cannot be started by pushing or towing .
Vehicles with Manual Transmission must
not be started by pushing or towing .
Damage to the catalytic converter and/or
other parts of the vehicle may result.
. .= .•..•.•• : .. . . ; • ·.i::;~. ··...· t_ .· .•.
I TECHNICAL DATA
VEHICLE IDENTIFICATION

The Vehicle Identification Label The Engine Number

is located on the left side under the dash-
Air-cooled:
board. The label contains the following
information:

1980-1985:

The engine number (arrow) is located on

The Vehicle Identification Number
the right side of the engine compartment
(VIN)
directly in front of the fan housing.
is located on the instrument panel on the
driver's side so that it is visible from the out- Diesel:
side through the windshield.

The safety compliance sticker

is your assurance that your new vehicle
complies with all applicable Federal Motor 1 Vehicle Identification Number
Vehicle Safety Standards which were in 2 Vehicle Code
effect at the time the vehicle was manufac- 3 Engine and Transmission Code
tured. You can find this sticker on the left 4 Paint and Interior Code
doorjamb. It shows the month and year of 5 Option Codes
complete and incomplete (campmobile
only) production and the vehicle identifica- From 1986:
tion number of your vehicle (perforation)
as well as the Gross Vehicle Weight Rating
11TSOIT.IIL I \ l
and the Gross Axle Weight Rating. MHUi.·IDUIT~-IIl;;,--;:::::
,=====:::!]
2 1'IIIIQ( ·1111111'-110.

JlTYPmPl I I
4 L ~ I

5 11MOTOIIKI.~GITI.li.JI
1NG. Cli01/11AIIs.<DDI [__J
LlCIUa/IIIIIIIWI!ST. ! I I I I I
~
f._....J
The engine number (arrow) is located on
the engine block next to the injection pump.
6 PliiiT 110./ INTiliOI f._....J f._....J f._....J

7 ~T./ ~~===;~ Water-cooled:

\1 -~

1. Production control no.

2. Vehicle identification no.
3. Type code number
4. Type designation
5. Engine and transmission code tetter
6. Paint no./lnterior
7. Optional equipment nos.

The engine number (arrow) is located on

the right side of the engine block.

26
ifECHNICAL DATA
ENGINE

Air-cooled Diesel Water-cooled

• Four-cylinder, horizontally opposed
with four crankshaft main bearings
• Air cooling with thermostatically-
controlled cooling fan
• Self-adjusting hydraulic valve lifters
(no adjustment)
• AFC (air-flow controlled) electronic
fuel injection
• Breaker-point ignition with combined
vacuum and centrifugal advance and
speed limiter
• Breakerless electronic ignition on
California models
• Four-stroke, four-cylinder diesel
• Five main-bearing crankshaft and
spur-belt driven overhead camshaft
• Liquid cooling (thermostatically-
controlled) with thermostatically-
controlled electric radiator cooling fan
• Mechanical fuel-injection pump
• Four-cylinder, horizontally opposed
with four crankshaft main bearings
• Liquid cooling (thermostatically-
controlled) with thermostatically-
controlled electric radiator cooling fan
• Digijet/Digifant air-flow controlled
electronic fuel injection
• Breakerless electronic ignition

Water-cooled Water-cooled
Air-cooled Diesel
up to 1986 (Digijet) from 1986 (Digifant)

Maximum output, 67 hp @ 4200 rpm 48 hp @ 4200 rpm 82 hp @ 4800 rpm 90 hp @ 4800 rpm *
SAE net:

Maximum torque, 101 ft-lb@ 3000 rpm 97 tt-lb @ 2000 rpm 105 ft-lb@ 2600 rpm 117.3 ft-lb @ 3200 rpm
SAE net:

Displacement: 120 cu . in. (1970 cc) 97 cu. in . (1588 cc) 117 cu. in. (1913 cc) 129 cu. in. (2109 cc)

Stroke: 2.80 in. (71 mm) 3.40 in. (86.4 mm) 2.70 in. (68.9 mm) 2.99 in. (76.0 mm)

Bore: 3.70 in . (94 mm) 3.01 in. (76.5 mm) 3.70 in. (94.0 mm) 3.70 in. (94.0 mm)

Compression ratio: 7 .3:1 23:1 7.3:1 9.0:1

Firing order: 1-4-3-2 -- 1-4-3-2 1-4-3-2

*1987-1988: 90 hp@ 5500 rpm

Cylinder Location
Capacities
(Air-cooled and Water-cooled)
Fuel tank
(total with reserve) 16 gal. (60 liters)
Syncro: 18.5 gal. (70 liters)
Reserve: 2.5 gal. (10 liters)

Engine oil
(with filter change)
Air-cooled: 3.7 US qt. (3.5 liters)
Diesel: 4.2 US qt. (4.0 liters)
Water-cooled: 4.8 US qt. (4.5 liters)
(without filter change)
Air-cooled: 3.2 US qt. (3.0 liters)
Diesel: 3.7 US qt. (3.5 liters)
Water-cooled: 4.2 US qt. (4.0 liters)

Automatic transmission fluid (ATF)

refill: 3.2 US qt. (3.0 liters)

Cooling System
Diesel: 16.9 US qt. (16 liters)
Water-cooled: 18.6 US qt. (17.5 liters)

Windshield washer reservoir: 4.3 US qt. (4.2 liters)

Rear window washer reservoir: 1.1 US qt. (1 .0 liters)

27
 Lubrication, Emissions and Vehicle Maintenance Schedules
Air-cooled, Water-cooled and Diesel models: 1982-1985
first 1 ,000 miles (1 ,600 km):

Engine: change oil (air-cooled)

check oil level, add if necessary
check for leaks

Engine (diesel only): retorque cylinder head bolts

adjust valve clearance
replace cover gasket

Brakes: check for damage and brake flu id leaks

Cooling system: check tightness of hoses and clamps, check coolant level,
add if necessary

Exhaust system: check for damage

Fuel system: check visually for leaks

V-belt: check tension, adjust if necessary (diesel)

During Road Test: Check efficiency of braking, steering, heating and ventilation system,
automatic transmission kickdown (where applicable)

After Road Test:

Engine: check for leaks
Engine idle speed: check
Engine idle mixture (CO): check (1 984-1985 models)
Exhaust system: check for exhaust leaks

every 7,500 miles (12,000 km):

Engine: change oil

replace oil filter
check for leaks

Brakes: check for damage and brake fluid leaks

check brake pad thickness

Cooling system: check coolant level, add if necessary

Fuel filter: drain water (diesel only)

every 15,000 miles (24,000 km):

Engine: change oil

replace oil filter
check for leaks
--
Engine (diesel only): adjust valve clearance
replace cover gasket
clean valve cover breather screen

Fuel filter: replace (except diesel)

Ignition distributor: replace breaker points, adjust dwell and timing

(air-cooled except California)

1982-1985

28
 Lubrication, Emissions and Vehicle Maintenance Schedules
Air-cooled, Water-cooled and Diesel models: 1982-1985
every 15,000 milese (24,000 km): (cont'd)

Spark plugs: replace (air-cooled)

Automatic transmission final check for leaks

drive: check gear oil level, add if necessary

Battery: check electrolyte level, add distilled water if necessary

Brakes: check for damage and brake fluid leaks

check brake fluid level, add if necessary

Brake linings and pads: check thickness

Brake pressure regulator: check (where applicable)

Cooling system: check tightness of hoses and c'lamps, check coolant level,
add if necessary

Crankcase ventilation system: inspect hoses and connections {1982-1983 models)

Door check rods: lubricate

Drive shafts: check protective boots for damage

EGR system: inspect, reset EGR mileage counter (air-cooled except

California)

Exhaust system: check for damage

Front axle: check dust seals on ball joints and tie rod ends
check tie rods for wear and damage

Fuel filter: drain water (diesel only)

Fuel system: check visually for leaks

Headlights: check alignment and adjust if necessary

Ignition: check vacuum hoses, ignition wires, distributor cap and rotor, replace if neces-
sary

Manual transmission: check gear oil level, add if necessary

Sliding door: lubricate mounting points, guide tracks and roller guides

Steering: check protective boots for damage

V-belt(s): check tension and condition, adjust/replace if necessary

Wheels and tires: check for wear and damage

During Road Test: Check efficiency of braking, steering, heating and ventilation system, auto-
matic transmission kickdown (where applicable)

After Road Test:

Automatic transmission: check automatic transmission fluid (ATF) level
Engine: check for leaks
Engine idle speed: check
Engine idle mixture (CO): check (1984-1985 models)
Exhaust system: check for exhaust leaks
Power steering: check fluid level, add if necessary

continued
1982-1985
29
 Lubrication, Emissions and Vehicle Maintenance Schedules
Air-cooled, Water-cooled and Diesel models: 1982-1985
every 30,000 miles (48,000 km):

Air cleaner: replace filter element

Automatic transmission: change automatic transmission fluid (ATF)

clean pan and strainer, replace pan gasket

Brake fluid: replace every two years regardless of mileage

Engine: change oil

replace oil filter
check for leaks
compression test (except diesel)

Engine (air-cooled only): clean oil strainer

Engine (diesel only): adjust valve clearance

replace cover gasket
clean valve cover breather screen

Fuel filter(s): replace

Ignition distributor: replace breaker points, adjust dwell and timing (air-cooled
except California)

Oxygen sensor (air-cooled): replace, reset OXS mileage counter (California only)

Oxygen sensor (water- replace every 30,000 miles regardless of time since delivery
cooled): {1984 models, 1985 models except California)

Spark plugs: replace

V-belt: replace (diesel)

Valve cover gaskets: replace (air-cooled)

Automatic transmission final check for leaks

drive: check gear oil level, add if necessary

Battery: check electrolyte level, add distilled water if necessary

Brakes: check for damage and brake fluid leaks

Brake linings and pads: check thickness

Brake pressure regulator: check (where applicable)

Brake warning light switch : check function

Cooling system: check tightness of hoses and clamps, check coolant level,
add if necessary

Crankcase ventilation syste'm: inspect hoses and connections (1982-1983 models)

Door check rods: lubricate

Drive shafts: check protective boots for damage

EGR system: inspect, reset EGR mileage counter (air-cooled except

California)

Exhaust system: check for damage

1982-1985
30
 Lubrication, Emissions and Vehicle Maintenance Schedules
Air-cooled, Water-cooled and Diesel models: 1982-1985
every 30,000 miles (48,000 km): (cont'd)

Front axle: check dust seals on ball joints and tie rod ends
check tie rods for wear and damage

Fuel system: check visually for leaks

Headlights: check alignment and adjust if necessary

Ignition: check vacuum hoses, ignition wires, distributor cap and rotor, replace if neces-
sary

Manual transmission : check gear oil level, add if necessary

Sliding door: lubricate mounting points, guide tracks and roller guides

Steering: check protective boots for damage

check play

V-belt(s): check tension and condition, adjust/replace if necessary

Wheels and tires: check for wear and damage

During Road Test: Check efficiency of braking, steering, heating and ventilation system, auto-
matic transmission kickdown (where applicable)

After Road Test:

Automatic transmission: check automatic transmission fluid (ATF) level, add if necessary
Brakes: check brake fluid level, add if necessary
Engine: check for leaks
Engine idle speed: check
Engine idle mixture (CO): check {1984-1985 models)
Exhaust system: checkforexhaumleaks

every 60,000 miles (96,000 km):

all items listed for 30,000 mile (48,000 km) interval, plus:

Oxygen sensor: replace every 60,000 miles {96,000 km) regardless of time
after delivery
I

1982-1985

31
 Lubrication, Emissions and Vehicle Maintenance Schedules
Water-cooled models from 1986
every 7,500 miles (12,000 km):

Engine: change oil

replace oil filter

Brakes: check brake pad thickness

every 15,000 miles (24,000 km):

Engine: change oil

replace oil filter

Automatic transmission final check for leaks

drive: check gear oil level, add if necessary

Brakes: check for damage and brake fluid leaks

check brake fluid level, add if necessary

Brake linings and pads: check thickness

Cooling system: check coolant level, add if necessary

Drive shafts: check protective boots for damage

Exhaust system: check for damage

Manual transmission: check gear oil level, add if necessary

Sliding door: lubricate mounting points, guide tracks and roller guides

During Road Test: Check efficiency of braking, steering, automatic transmission kickdown (where
applicable), heating, ventilation and air conditioning, power accessories and
electrical systems

After Road Test:

Automatic transmission : check automatic transmission flu id (ATF) level
Engine: check for leaks
Engine idle speed: check
Exhaust system: check for exhaust leaks
Power steering: check fluid level, add if necessary

every 30,000 miles (48,000 km):

Air cleaner: replace filter element

Automatic transmission: change automatic transmission fluid (ATF), clean pan and strainer, replace
pan gasket*

Brake fluid: replace every two years regardless of mileage

Engine: change oil

replace oil filter
check for oil leaks
compression test

*Specified in the case of severe conditions such as extremely high temperatures,

continuous mountain driving, trailer towing, and predominantly stop-and-go traffic

from 1986

32
 Lubrication, Emissions and Vehicle Maintenance Schedules
Water-cooled models from 1986
every 30,000 miles (48,000 km): (cont'd)

Spark plugs: replace

Automatic transmission final check for leaks

drive: check gear oil level, add if necessary

Brakes: check for damage and brake fluid leaks

Brake linings and pads: check thickness

Cooling system: check coolant level, add if necessary

Drive shafts: check protective boots for damage

Exhaust system: check for damage

Front axle: check dust seals on ball joints and tie rod ends
check tie rods for wear and damage

Manual transmission: check gear oil level, add if necessary

Sliding door: lubricate mounting points, guide tracks and roller guides

V-belt(s): check tension and condition, adjusVreplace if necessary

During Road Test: Check efficiency of braking, steering, automatic transmission kickdown (where
applicable), heating, ventilation and air conditioning, power accessories and
electrical systems

After Road Test:

Automatic transmission: check automatic transmission fluid (ATF) level, add if necessary
Engine: check for leaks
Engine idle speed: check
Exhaust system: check for exhaust leaks
Power steering: check fluid level, add if necessary

every 60,000 miles (96,000 kr'n):

all items listed for 30,000 mile (48,000 km) interval, plus:

Oxygen sensor: replace every 60,000 miles (96,000 km) regardless of time after
delivery (1986-1987 models only)

every 90,000 miles (144,000 km):

all items listed for 30,000 mile (48,000 km) interval, plus:

Oxygen sensor: replace every 90,000 miles {144,000 km) regardless of time after delivery
(models from 1988)

from 1986

33