Manual Transporter Caravelle T3

Instruction Manual
Volkswagen Transporter
Volkswagen Caravelle jk
www.WestfaliaT3.info - a useful website for owners and enthusiasts of VW Westfalia T25 / T3 / Vanagon Campervans
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Congratulations on your new
Volkswagen Transporter/Volkswagen Caravelle
You have made a wise decision
The Transporter I Caravelle is a versatile, million-fold proven vehicle.

But, you have not only opted for an outstanding vehicle with modern, low maintenance technical components,
you have also chosen quality.
A quality ensured by the most up-to-date production technology, careful selection of materials and conscientious
work by all involved.
And with the Transporter/Caravelle you have also chosen one of the largest and most efficient Service
Organizations.
In Europe alone there are around 7,000 V.A.G dealerships.
We wish you pleasant motoring:

Your
V0LKS WA G EN WER KA KTIEN GESELLSCHAFT

INTR0DUCT10 INDEX
This instruction manual is valid for all Transporter/Cara-

velle models, including vehicles with four-wheel drive and INSTRUMENT P A N E L 2
exhaust emission control systems.
The manual contains many important instructions on using OPERATION 4
your vehicle. You should therefore read it before driving the
car so that you get to know your vehicle quickly and know
how to drive it and look after it properly. DRIVING TIPS 53
Special attention is drawn to the chapter Driving tips: These
tell you how you can drive safely, economically and environ-
ment-conscious.
OPERATING INSTRUCTIONS ~63
However the other chapters are also important because the
correct treatment of the vehicle serves - in addition to C A R E AND M A I N T E N A N C E 85
regular care and maintenance - to maintain the value of the
vehicle and is in many cases also one of the stipulations for
the upholding of warranty claims. DO-IT-YOURSELF 91
Further information on warranty is given in the service
schedule. Here you will also find important data on the servic- TECHNICAL DESCRIPTION 104
ing of your car and exact details when the various services
are due.
T E C H N I C A L DATA 108
Please note that items of equipment marked with a * a r e IDENTIFICATION DATA 124
only standard on certain models or are only available as
options on certain models. Such equipment is not always
available in all export markets. A L P H A B E T I C A L INDEX 1~26
www.WestfaliaT3.info - a useful website for owners and enthusiasts of VW Westfalia T25 / T3 / Vanagon Campervans 1

f
NSTRUMENT PANE

INSTRUMENT P A N E L
Page Page Page
1 - Air vents 40 10 - Fog light/rear fog 21 Blower switch for

2 Air vents 40 light switch 36 passenger compartment
heat exchanger 42
3 Light switch and instrument 11- Air vents 40
22 Windscreen wiper and
lighting regulator 36 12- Ashtray 51 washer lever 39
4 - Brake warning light 33 13- Loud speaker opening 23 - Blower switch and
5 Speedometer 34 14 Fuse box 94 levers for ventilation
and heating 40
6 Warning lamps 32 15 Turn signal and dip switch . 38
24 Radio 11 or cover plate
7 Fuel gauge and coolant 16 - Horn control
25 - Socket/cigarette lighter . . . 51
temperature gauge 35 17 - Digital clock 34
26 - Air vents 40
Clock or rev counter 34 18- Steering lock/starter switch 28
27 - Shelf 51
8 - Heated rear window switch 36 19 Auxiliary heater switch ... 43
9 Emergency light switch . . . 36 20 - Cold starting aid Knobs and warning lamps
(diesel engine) 30 for the differential locks
and the manually controlled
four wheel drive on
Transporter/Caravelle
syncro - see page . . . . 23/25
Please note that some of the items of

equipment listed are only fitted on certain
models or are optional extras.
" For vehicles with a factory fitted radio, an
operating instruction leaflet is also enclosed.
See remarks on page 101 of "Do-it-yourself"
www.WestfaliaT3.info - a useful website for owners and enthusiasts of VW Westfalia
sectionT25
when/ T3 / Vanagon
service installing Campervans
a radio. 3

OPERATION
KEYS
Up to six keys are supplied with the Tag E

vehicle: On this tag is the number for key A. The
two keys A tag should be kept safety and separately
(in your wallet for example) so that no
two keys B *
unauthorized person can order a key.
two keys D * The numbers of keys B and C are stamp-
Key A ed on the key itself.
This key fits all locks except: With the aid of the number, a replace-
ment key can be ordered from a V.A.G
lockable glove box Workshop.
sliding door and rear flap with safety Caution
locks
When leaving the vehicle unattended
Key B - even only briefly - always take the
This key fits the lockable glove b o x * key with you.
Key C
This key fits the safety locks in sliding
door and rear flap.
It can only be withdrawn when the sliding
door or rear flap is locked.
JB25-450
4 www.WestfaliaT3.info - a useful website for owners and enthusiasts of VW Westfalia T25 / T3 / Vanagon Campervans

OPERATION
CENTRAL LOCKING SYSTEM*
With this system all the doors, Caution When the key is withdrawn in the vertical
and - depending on the position of the When the locking knobs in the driver's position and tailgate closed, it will be
tailgate lock also the tailgate can be and front passenger doors are pressed locked all the time. The tailgate can then
locked and unlocked. down all the doors are locked. Children only be unlocked with the key.
The system is operated from the driver's should therefore not be left on their The sliding door can be secured or
door, and front passenger door from own in the car because when the doors released separately with the safety catch.
outside with the key, from inside with are locked it would be difficult to help
the locking knob. in an emergency.
Note
Sliding door and tailgate can be locked
Note If the central locking system should
or unlocked separately with the key.
The central locking system can only develop a fault, all the locks can be
function correctly when the driver's and To unlock the tailgate insert key and turn operated normally, see next page.
front passenger doors are properly it to right. Hold in this position and press
closed. button in.
When locking, the locking knobs on all If the key ist withdrawn in the horizontal
doors must move down. If the knob on one position, locking of the tailgate will be
door does not move at any time, open the controlled by the central locking system
door concerned and close it properly. when it is closed again.

OPERATION
DOORS
Cab doors Sliding door

From outside both cab doors can be From outside the sliding door can be
locked and unlocked with the key. When locked and unlocked with the key. When
unlocking the locking knobs go up, when fully open the door is held by a hook.
locking they go down. To close sliding door from outside. -
The front passenger's door can be locked Press the door handle down to release
from outside without using the key: Just the hook and slide the door firmly for-
press locking knob down and close door. wards.
The driver's door cannot be locked when From inside the sliding door is locked
open by pressing the locking knob and by pushing down the locking catch near
closing door. This prevents you from the door opening lever.
leaving the key in the car and forgetting it. As long as the catch is in the lower po-
From inside the door can be locked by sition the door cannot be opened from
pressing down the locking knobs. As inside or outside.
long as the knobs are pressed down the When the vehicle is in motion, the door
doors cannot be opened from inside or must always be properly closed but
outside. when carrying passengers the locking
We advise you not to press the knobs catch should be left in the upper position
down when vehicle is in motion so that so that the door can be opened from
the door can be opened from outside in outside in an emergency.
an emergency.
Child-proof catch on sliding door*
When the child-proof catch is engaged -
lever on door lock turned upwards - the
inner lock release lever is inoperative.
The door can only be opened from out-
side with the locking catch in the up
position.

TAILGATE ENGINE COMPARTMENT COVER
To open the tailgate when key hole is The cover is in the luggage compart-
horizental, press the lock cylinder and ment. To remove cover turn the two
lift tailgate. catches to the left.
Note On the Pick-up, the flap is in the rear
The lock cylinder can also be pressed in panel.
with the key.
To close tailgate pull it down and slam
it to gently.
After closing the tailgate always pull up
on it briefly to make sure that it is pro-
perly closed - otherwise the tailgate
could open suddenly when vehicle is
moving even though the key has been
turned in lock.
Do not drive with the tailgate open as
exhaust gases are then able to enter
the vehicle interior.

OPERATION
WINDOWS
Door windows
These windows are opened and closed
with the crank in the door trim.
Electrical control*
When the ignition is on the windows
can be opened and closed electrically.
The switch is in the door trim.
The window in the passengers door can
be controlled from the driver's side.
Caution
Careless and uncontrolled closing of
the windows can cause injuries. Take
Vent wings* Sliding windows care therefore when closing the win-
To open - Press button in fastener and To open, press catch down and slide windows. When leaving the vehicle always
swing fastener clear. dow along. take the keys with you.
To close - Press window against seal at
front and turn fastener until button en-
gages.

MIRRORS
Normal exterior mirror

The mirror is adjusted by moving the
mirror housing.
Electrically adjustable mirrors Anti-dazzle interior m i r r o r *

are set by moving the lever in the driver's Mirror in normal position - Lever
door trim. to front
Turning the knob from L to R switches Mirror in anti-dazzle position - Lever
control from left to right mirror. to rear
If the electrical control of the mirror fails
at any time the mirrors can be adjusted
by hand by pressing on the edge of the
mirror surface.
The electrically operated exterior mirrors
are heated when the heated rear window
is switched on.

SEAT BELTS
Seat belts are only beneficial if they are Very small children should, depending Loose, bulky clothing (e.g. overcoats
worn at all times - also in town traffic. on size be carried in a reclining safety over jackets) affects the fit and function
For this reason all vehicle occupants seat or a child's seat. of the belts.
should always wear the seat belts - in- Children above 6 years of age can also The belt must not be jammed anywhere
cluding those on the rear seats. use a lap belt. or rub on any sharp edges.
With the three-point belts it is essential Larger children may use three point The slot for the belt tongue must not be
to ensure that the shoulder part of belt belts provided that the belt passes blocked with paper or anything as other-
runs roughly over the centre of the over centre of shoulder and not against wise the tongue cannot engage properly.
shoulder, as shown in Fig. on next page - the child's neck - see illustration on next
The belts must be kept clean as other-
on no account against the neck. page. If necessary, a safety seat cushion
wise the retractors may not work pro-
can be used. perly (see also "Care and Maintenance"
On the front seats the belts can be made
to fit properly with the aid of the adjust- The installation and use of child restraint section).
able belt anchorage (see next page). systems must be done in accordance Seat belts which are damaged or have
Contact your V.A.G workshop if necess- with instructions of the manufacturer
been stressed in an accident and stretch-
ary. concerned.
ed must be replaced - preferably by a
V.A.G workshop. The anchorages should
Safety for children General notes also be checked.
Children under 12 years old should be Only one person is to be secured with Belts can be service installed for all
carried on the rear seat (Caravelle and each belt. Never secure two people
seating positions on vehicles not fitted
Combi) and should, depending on age, (even children) with one belt.
with belts at the factory. The installation
be secured there with a childs restraint On vehicles with armrests*for the seats, of belts should be done by a V.A.G
system or the existing belt. always ensure that the belt runs under- workshop because these workshops
neath the armrests. have the information necessary to do
the job properly.
The belt should not be worn over hard or
breakable articles (glasses, ball pens, On the Van there are no belt anchorages
key rings, pipes, etc.) because this can in the load compartment.
cause injury to the body.

OPERATION
Belt height adjustment against the neck - and be firmly in

Two anchorage points are provided in contact with the body.
the cab for the upper belt attachment. The lap part of belt must always fit
This makes it possible to adapt belt to tightly across the lap. Pull belt tight if
body size. necessary.
The belt must not be twisted.
The backrest of the front seats must
not be inclined too far to the rear as
otherwise the belts are no longer effec-
tive.
I B33-518
Belt warning device*
The belt for the driver has a warning de-
Three-point inertia reel belts* vice.
The inertia reel belt gives complete free- When the ignition is switched on, a buzzer
dom of movement when pulled slowly. sounds to remind you to put the belt
Sudden braking however will cause the on. The buzzer stops after about 5 se-
belt to lock. conds or when belt has been put on.
The retractor mechanism will also lock Taking belt off
the belt when accelerating, driving down
steep gradients or cornering hard. To release the belt, press the orange-
coloured button in the lock. The tongue
Putting belt on will then spring out
Pull the tongue slowly and smoothly Pass the tongue towards the door by
across your chest and hips and push it hand so that the retractor can roll the
into the lock part fitted on the seat until belt up properly.
tongue engages audibly (pull to check).
The shoulder part of the belt must
run roughly across the centre of the
shoulder as shown - on no account

OPERATION
HEAD RESTRAINTS*
Lap belt* Two-point inertia reel belts Adjusting height

The buckle is used in the same way as on The individual s e a t s * in the passenger Grip at sides with both hands and pull
the three-point inertia reel belts. compartment are fitted with two point up or push down. The upper edge should
inertia reel belts. They give complete be roughly at eye level.
The belt must always fit tightly.
freedom of movement when pulled slow-
To lengthen belt hold the tongue at right ly but sudden braking however will cause Removing and installing
angles to belt and pull belt through to the the belts to lock. The automatic retractor Push spring clips out of slotted rings
required length. mechanism will also lock the belt when
in backrest with a small screwdriver and
The belt is easier to adjust if tongue and driving down steep gradients or corner-
lift head restraint out
cap are pressed together. ing hard.
To install, first press the spring clips
To shorten belt it is only necessary to Putting belt on into the guide rings so that the straight
pull the free end of belt. Pull the tongue slowly and smoothly part of clip is at the rear. Then push
The surplus belt length is taken up by across the hips and push it into the lock head restraint into the guides until it
moving the plastic slide. part fitted on the seat until tongue eng- engages.
ages audibly (pull to check).
Note:
The belt must not be twisted. The belt The spring clips need not be taken out on
must always fit tightly, pull belt up vehicles which have a rear seat/fully re-
slightly if necessary. clining seat bench.
Taking belt off It is quite sufficient to push the protrud-
To release the belt press the orange col- ing spring clip extensions back to the
rear, to enable the head restraints to be
oured button in the lock. The lock will
removed.
then spring out.
Pass the tongue across by hand so that
the retractor can roll the belt up properly.

SEATS IN CAB
|B25-396 [B25-397
Individual driver's and front passen-

ger seats
To move seats back or forward To take seat out
Lift lever (1) on outside of seat and move Slide seat forward into 1 st latch posi-
Caution seat. Then release lever and move seat tion.
For safety reasons the seats should further so that catch engages.
Lift hook (3) against spring-loading,
only be adjusted when vehicle is sta- To adjust backrest rake at the same time pull lever (1), hold it
tionary. and slide seat past stop.
Take weight off backrest, press lever (2)
Do not lower the backrest too far on right side of seat frame down and Release hook and lever and push
when on the move because the seat move backrest to desired position by seat forward out of runners.
belts are then no longer fully effective. moving upper part of body then release
The hook need not be lifted when
lever.
putting seat back as the seat, with the
Armrests* lever lifted, can just be pushed past the
stop.
The armrests on the front seats can be
hinged up if they are not required.

SEATS IN PASSENGER
COMPARTMENT*
Two seater b e n c h * Swivelling s e a t s * Removing and installing centre bench

On vehicles with swivelling seats the seat
The seat is moved back or forward in
same way as the single seats. The lever passenger's seat can be turned 180 to Remove four wing bolts under seat.
is at the front of seat. the right and the drivers seat 90 to the When putting seat back again ensure
left. To turn seats, push them forward that the runners are clean.
When seat is moved, the backrest rake
slightly or open door, and pull the release
is also altered. Head restraints*
lever. The handbrake must be released
before turning driver's seat. (Engage a The head restraints must be adjusted to
To remove gear to prevent vehicle from rolling body size - see page 12.
Remove in same way as the single seats. away.)
Bolts on right and left of backrest must Removing and installing rear bench seat
The swivelling seats must always be
be removed. The rear seat cushion is bolted to the
facing forward when vehicle is in mo-
tion. side panels on each side with one bolt
under the upholstery. Remove bolts and
Seat heating* take lower part of seat out.
Seat cushion and backrest of front seats The seat backrest is secured at each side
can be heated electrically when ignition with two bolts. The bolts between seats
is on. Further details are given under and backrests also serve as seat belt
"switches", page 27. anchorages.
When refitting the seat and backrest,
ensure that the seat belt is also correct-
ly installed.

INDIVIDUAL SEATS IN PASSENGER COMPARTMENT*
Centre seats
The centre seats can be turned and the
backrest angle adjusted.
Turning Adjusting backrest angle

Lift lever (see illustration), turn seat to Take weight off backrest and press lever
the desired position and let lever engage down (see illustration). Adjust backrest
again. to the desired position by moving upper
If the backrest is very low, it may be ne- part of body and release lever.
cessary to raise it slightly before the seat
can be turned. Removing
Lift the lever used to turn seat and take
seat out.
The base which remains can be removed
when carpet is lifted.
Caution
When the seats are installed again en-
sure that base and seats are secured
properly.

Rear seats Adjusting backrest angle
The height, seat angle and backrest Take weight off backrest and turn knob
angle of the rear seats can be adjusted. A at side of backrest.
Caution
When vehicle is in motion, the backrests
must not be inclined too far to the rear
as otherwise the belts are no longer
fully effective.
Mechanical adjustment
Adjusting seat angle
Press lever B to front or rear and adjust
position of seat as required by moving
body weight.
Adjusting seat height
Press lever B alternately at front and
rear and by moving weight of body to
front and rear lift or lower the seat.

OPERATIO
Adjusting seat height

Press switches A and B at front -
Seat is raised
Press switches A and B at rear -
Seat is lowered
Adjusting backrest angle

Press switch C at front -
Backrest moves up
Press switch C at rear -
Backrest moves down.
B25-382
Caution
Electrical adjustments When vehicle is in motion, the backrests
Adjusting seat angle should not be inclined too far to the
rear as otherwise the seat belts are no
Press switch A at front -
longer fully effective.
Front of seat is raised
Press switch A at rear -
Front of seat is lowered
Press switch B at front -
Seat is raised at rear
Press switch B at rear -
Seat is lowered at rear.
17

REAR SEAT/FULLY RECLINING SEAT BENCH*
The rear seat/reclining seat bench can Finally, fold the seat backrest fully to The space underneath the seat ben
be converted into a large sleeping area. the rear to form a flat sleeping area. can be used as a storage compartme
For this, it is necessary to lift the se
Before doing this, the backrests of the Returning seat bench to original
bench slightly at the front. It will rema
center row of seats must be tipped for- position
in the lifted position when the strut,
wards. The latching levers are located on Pull the seat backrest upwards out of cated on the left on the sliding door sid
the outsides of the right and left hand the horizontal position. is swung upwards.
backrests.
Slide the seat bench, together with
To convert reclining seat bench backrest to the rear again.
Remove head restraints* - Push backrest back into locking posi-
see page 12. tion.
Unlatch the backrest with the release Pull the seat belts out again between
grip on the reverse side of the backrest, backrest and seat, so that they are in a
and fold the backrest forwards. position for use.
By pulling the release grip further to- Install head restraints*-see page 12.
wards the front, the backrest and seat
bench are pulled in a forward direction.

LUGGAGE COMPARTMENT/
LOAD SURFACE ROOF RACK
To enlarge luggage space* When a roof rack is to be used, note the

following:
Release backrest by pulling loop
Only use roof racks which are sup-
Fold backrest down to seat
ported in the rain channel
The backrest locks automatically when
Distribute load uniformly.
hinged to the rear.
Do not exceed permissible roof load or
Instructions on using the rear/reclining permissible gross vehicle weight.
s e a t * are given on page 18. Further details on pages 117-119.
Notes on using the luggage compart- When carrying heavy or large objects
ment or the load surface on the roof, bear in mind that the vehicle
The load must be stowed so that it handling can change due to the altera-
cannot slip or even fly forward when the tsion in centre of gravity and the increas-
brakes are applied. ed area exposed to the wind. Driving
style and speed must be modified to
In the interests of good handling the allow for this.
load should, wherever possible, be carried
between the axles. The permissible axle
loads and the permissible gross vehicle
weight should on no account be exceed-
ed.

OPERATION
COVER* DROPSIDES HANDBRAKE
The handbrake is located between the

front seats.
To apply the handbrake pull lever up
firmly. On hilly roads the 1st gear or on
automatic gearboxes the parking lock
should also be engaged. The handbrake
should always be applied so firmly tha
it is not possible to drive off accidentally
with handbrake slightly on.
When handbrake is applied with the
ignition on, the brake warning l a m p
comes on.
To release handbrake, pull lever up
Ensure that the cover is secured proper- To drop side boards - pull handle out- slightly, press locking knob in and push
ly behind the cab. wards to release locking pin und swing lever right down.
down to lift hook.
The cover is correctly secured when the
rod incorporated in the cover engages in On vehicles with support cables for the
the rain channel at the rear of the cab tailboard, not more than 150 kg should
and the left and right hand ends are bolt- be placed on the tailboard when it is
ed to the canopy frame. down.
When the cover and rails have been re-
moved, care should be taken when refitt-
ing to ensure that the foam seal is stuck
properly in the rain channel (if necessary
renew seal).

-
PERATION
MANUAL GEARBOX
1 <
v
R
<L
^
2
|B25-454
4 speed gearbox 5 speed gearbox 4 + G g e a r b o x (4 WD vehicles)

Engaging reverse To engage 1st gear move lever past Engaging crawler gear
Move lever in neutral to the left, press it pressure point to left stop and then pull
Move lever in neutral to the left, press it
down and move it further to the left stop it back.
down and move it further to the left stop
and then push it forward. One normally moves off in 1st gear but and then pull it to the rear.
Only engage reverse gear when vehicle on vehicles with the 44, 57 and 82 kW
is stationary. engine and 5 speed gearbox the rear Note
axle ratio is different so that one can When driving you should not rest your
When engine is running, depress clutch move off on the level with a light load hand on the gear lever. The pressure of
fully and wait a few seconds before mov- in 2nd gear. your hand is transmitted to the shift forks
ing gear lever, to prevent grating noises. in the gearbox and can cause premature
To engage reverse gear move lever past
When reverse gear is engaged with igni- wear of the forks.
pressure point to left stop, press it down
tion on, the reversing lights* come on. and push it to front.

OPERATION
DIFFERENTIAL LOCKS*
When negotiating a curve, the wheels of Limeted slip differential* sible locking effect is not obtained in th
a vehicle cover different distances. To differential. One notices this becaus
(Rear wheel drive)
balance out the differences in wheel one wheel spins while the other' doe
speeds, differentials are incorporated in The locking effect is obtained by means not turn at all. In this case one shoul
the driving axles. However, these diffe- of plates which are arranged in the dif- engage and disengage the clutch gentl
rentials have a distinct characteristic: As ferential in a sort of multi-plate clutch. and repeatedly. This will prevent th
soon as one wheel on an axle commen- With this differential the locking effect differential from becoming overheated
ces to spin on a slippery surface, only is not 100% but only approx. 45%. Cont-
very little traction is available, even rary to vehicles with 100% locking, the Gear oil
though the other wheel is on a hard steering behaviour on the road, particul-
surface. arly in sharp curves, remains almost un- The oil level does not need checking be
changed. tween the intervals given in the Servic
Using the differential locks the wheels of Schedule. The oil does also not nee
one axle can be locked together and the The effective locking force is dependent changing. To top up or fill after a repa
traction is once again abtained. on the speed difference of the two driv- a V.A.G workshop should be contacte
ing wheels. This means: the larger the because the gearbox must be filled wit
On the Transporter/Caravelle there are difference, the larger is the locking force
two different types of differential lock: a special oil.
of the differential.
Vehicles with rear wheel drive have a
limited slip differential in the rear axle
Driving tips
and 4 WD vehicles have selectable me-
chanical locks in front and rear different- In normal conditions the vehicle can be
ials. driven just like every other vehicle. At the
beginning it may take a bit of getting
used to when driving through sharp curv-
es. This is due to the fact that a slight
locking effect is always present.
Furthermore in isolated borderline con-
ditions where, on the one hand the fric-
tional resistance of the driving wheels
on the ground differs a great deal and,
on the other hand, a large amount of
power must be transmitted to move off,
it may be found that the maximum pos-
22

OPERATION
Selectable differential locks* When the knobs are pulled/pushed en-

(Four wheel drive)
With the selectable differential locks,
HP * gagement or disengagement is only se-
lected. The actual shifting process can
the wheels on one axle are fully locked be delayed. If the wheels are rotating at
Q QI
together (100%). As no compensation different speeds, or if the drive train is
takes place when cornering, the handling under strain, e.g. tight corner with differ-
and the steerability is affected - parti- ential lock engaged, it could even happen
A
cularly in the case of the front differential that the lock will not engage or diseng-
lock. age at all. In such a case, throttle appli-
cation should be reduced, or the vehicle
Attention should be driven straight-ahead to en-
The differential locks may only be used able the lock to engage/disengage.
under the limited specific conditions USEES
described on the following pages. The warning lamps above the knobs in-
Engaging the differential locks dicate the operational condition of the
locks:
The differential locks are engaged and
disengaged with the knobs shown in the If the front axle differential lock has
centre of the instrument panel with been selected, the left hand warning
vehicle stationary or moving. lamp flashes. As soon as the lock en-
gages the lamp lights up continuously.
Left knob - Front axle differential
lock The right hand warning lamp moni-
Right knob - Rear axle differential tors the function of the rear axle differ-
lock ential lock. It does not flash when the
lock has been selected but only lights
up once the lock has engaged properly.

OPERATION
Both warning lamps go out again When may the differential locks not be When a wheel is spinning, if for
once the knobs have been pushed in engaged? example the vehicle is stuck in snow.
the locks have actually disengaged. This would not only lead to increased
Neither the front nor the rear axle
tyre wear but it could also damage the
If after selecting the differential locks, differential locks may be engaged when
drive train and lead to uncontrollable
and after driving some distance, the driving along metalled road surfaces.
acceleration. For this reason, the spinn-
warning lamps do not light up, the electri- Locking the front axle differential ma- ing wheel must first be brought to a
cal system and the locks themselves kes the vehicle unsteerable. standstill before the differential locks
should be checked at a V.A.G workshop. are engaged.
When the rear axle differential is locked,
Attention the rigid connection between the two When the vehicle is being towed - see
The differential locks influence the rear wheels has a scrubbing effect on page 103 also.
steerability of the vehicle. In particular, the tyres when cornering. This leads to
When testing the vehicle on a dynamo-
with the front axle differential lock en- increased tyre wear and also to "jer-
meter, e.g. when being tested by local
gaged, the vehicle is no longer steera- king" when the vehicle is being steered.
authorities.
ble. For this reason, the front axle diffe- In certain circumstances it may even
rential lock must only be used under off- damage the drive train.
road conditions and then only at low For this reason, the locks may only be
speeds. Always disengage the lock be- engaged under off-road conditions or as
fore driving on metalled road surfaces. an assistance when moving off.
See "Driving Tips" on page 60 also.
24www.WestfaliaT3.info - a useful website for owners and enthusiasts of VW Westfalia T25 / T3 / Vanagon Campervans

OPERATION
SELECTABLE FOUR-WHEEL DRIVE*
Engaging four-wheel drive

Pull the knob (arrow) located in the Notes
middle of the dash panel. When engaging the cross-country
When the knob is pulled/pushed, engage- gear, the four-wheel drive is automatical-
ment or disengagement is only selected. ly engaged.
The actual shifting process can be delay-
To keep the steering forces as low as
ed. If the wheels are rotating at different
possible, the four-wheel drive should be
speeds, it could happen that the 4 WD
disengaged when a full lock is required -
cannot be engaged at all, or if the drive
e.g. when parking.
train is under strain, e.g. tight corner with
differential lock engaged, it could even Just how the differential locks are en-
mm happen that the lock will not disengage. gaged, and important instructions on their
In such a case, the accelerator should use are to be found on pages 23 and 24.
Vehicles required for particularly arduous be released or the vehicle should be
operating conditions (e.g. predominantly driven straight-ahead to enable the 4 WD
cross-country work) can be equipped to engage/disengage.
with a manually controlled four-wheel
The warning lamp above the knob lights
drive, as an optional extra.
up or goes out only when the four-wheel
Under normal driving conditions on dry drive has actually engaged or dis-
roads, the vehicle should only be driven engaged.
by the rear axle.
When the road surface is wet, slippery,
snow or ice covered, or when driving
under off-road conditions, one is advised
to engage the four-wheel drive.
The drive can be engaged or disengaged
whilst the vehicle is in motion.

OPERATION
AUTOMATIC GEARBOX
p N - Neutral The lever can be moved from "2" into "

with accelerator pedal depressed. How
D - Normal driving position
R U The three forward gears are shifted up
ever as the shift into 1st gear take
place immediately this must only b
N d 1 and down automatically according to done at speeds below 45 km/h.
D throttle opening and road speed.
2 2 - Position for hilly stretches Kick-down device
1 [B16 - 1 5 0 | The 1 st and 2nd gears are shifted up and The kick-down device gives maximu
down automatically according to throttle acceleration. When the accelerator p
opening and road speed. The 3rd gear dal is pressed right down past the fu
is not used. This increases the engine throttle position, depending on roa
Selector lever positions braking effect. speed and engine speed, either the u
P - Parking lock shift is delayed (forced throttle) or th
The road speed must not exceed 90 km/h
box changes down into the next low
The driving wheels are locked mechani- (56 mph).
gear.
cally. The lever can be moved from "D" into
The parking lock may only be engaged "2" with accelerator pedal depressed.
when vehicle is standing still. To move However as the shift into 2nd gear takes
lever into and out of the "P" position the place immediately this must only be
safety catch in lever handle must be done at speeds below 85 km/h.
pressed. 1 - Position for steep hills
R - Reverse gear To engage this gear, the catch in lever
The reverse gear must also be engag- handle must be pressed. The vehicle re-
ed when vehicle is stationary and the mains in 1st gear and 2nd and 3rd gears
engine idling. Before "R" can be engaged are not used. This gives maximum possi-
the safety catch in lever handle must be ble engine braking effect.
pressed. The road speed must not exceed 50 km/h
(30 mph).
www.WestfaliaT3.info
26 - a useful website for owners and enthusiasts of VW Westfalia T25 / T3 / Vanagon Campervans

OPERATION
Notes on driving
Starting Parking
The engine can only be started when Before working on the engine when it is On level ground all you need do is to en-
selector lever is at "N" or "P". See also running, place selector lever at "P" and gage the handbrake. On a gradient the
"Starting engine" on page 29. apply handbrake. handbrake should be applied firmly first
Selecting a driving range If the lever is moved accidentally into and then the parking lock engaged. This
"N" when driving, release accelerator will ensure that the locking mechanism is
Before selecting a gear with vehicle not too heavily loaded and makes lock
stationary and engine running, operate and let the engine speed drop to idling
before selecting a forward gear again. easier to disengage.
footbrake or handbrake. This also app-
lies when moving lever from "P" to "N". Driving downhill in winter Emergency starting
Particularly when the idling speed is Before driving down a long slippery The engine cannot be started by towing
high (after starting from cold) it is ne- gradient after starting from cold in a ve- or pushing the vehicle.
cessary to hold the vehicle with the hicle with a carburetor engine, ensure When battery is flat, the engine can be
handbrake. that engine is warmed up enough to started from the battery of another ve-
This is necessary because with an auto-
idle at normal speed. Otherwise the en- hicle by using a jumper cable. See "Emer-
matic gearbox the transmission of power
gine braking effect will be limited when gency starting", page 102.
accelerator pedal is released and gentle
is not completely stopped even at idling
braking on the slippery surface will not Towing
speed - the vehicle tends to "creep".
be possible. If the vehicle has to be towed at any
When selecting a gear with vehicle sta- time, you must read the instructions in
tionary, do not depress accelerator. Stopping the section "Towing" on page 103.
When a driving range is selected with To stop vehicle temporarily such as at
the vehicle stationary, the throttle must traffic lights, all that is necessary is to
on no account be opened (e.g. by hand apply the brakes. It is not necessary to
from engine compartment). The vehicle move lever to "N". The engine should
will otherwise move immediately - however only be running at idling speed.
possibly even with handbrake applied.

OPERATION
STEERING LOCK/IGNITION SWITCH
Petrol engine For all vehicles:

1 - Ignition off - Steering can be Position 1:
locked. To lock the steering wheel withdraw key
2 - Ignition on and turn wheel until you hear the pin
3 - Starting engine engage.
Diesel engine Caution
Do not withdraw key until vehicle is
1 - Fuel supply cut off - Steering stationary.
can be locked
2 - Glow and drive position Position 2:
While glow plugs are on, no other If the key is difficult to turn in the lock or
heavy current consumers should cannot be turned to this position at all,
be switched on. the steering wheel must be turned to
3 - Starting engine and for slightly to release the locking pin.
Position 3:
In this position the headlights, the wind-
screen wipers, the blower* and the
heated rear w i n d o w * are switched off.
Before the starter can be operated again
the key must be turned back to position 1.
The non-repeat lock in the ignition switch
prevents the starter from being operated
when engine is running as this could
damage the starter.

OPERATION
STARTING THE ENGINE
General notes 44 and 57 kW carburetor engines

Be careful when running the engine in a Starting a cold engine Starting a warm engine
confined space. Danger of poisoning. The carburetor is fitted with an automatic Depress pedal slowly while operating
Check that gear lever is in neutral. choke which is actuated the first time the starter.
(On vehicles with automatic gearbox: accelerator pedal is depressed when Release pedal as soon as engine
Selector lever at " P " or "N") and apply engine is cold. starts.
handbrake before starting. Depress accelerator pedal slowly
Starting a hot engine
Depress the clutch pedal on vehicles only (twice when it is freezing) and then
with manual gearbox when starting so release it Depress pedal fully before operating
that the starter only has to turn the en- starter and hold it in this position - do
Switch ignition on and start engine not pump it.
gine. straight away - do not use accelerator.
As soon as the engine starts, release Release pedal as soon as engine
The engine may rattle briefly after starts.
the ignition key so that the starter can being started. This is caused by the hy-
disengage.
draulic tappets which have to build up a
Do not warm engine up by running it certain oil pressure first. The noise is
with vehicle stationary. Drive off straight harmless and no cause for alarm.
away. The increase in the idling speed which
Do not overrev or use full throttle takes place as engine starts to warm up
until the engine has reached the normal can be reduced by just tapping the accel-
operating temperature. erator pedal briefly.
Note for vehicles with catalyst On vehicles with an automatic gearbox
the engine should be run at fast idling
The engine must not be started by
speed for about one minute after starting
towing the vehicle as otherwise unburnt
when it is very cold.
petrol can get into the catalyst and be
burned there - see also page 83. The pedal should then be tapped so that
the speed drops and a gear can be
selcted at normal idling speed.

Fuel injection engines Diesel engines Turn ignition key to position 2 glow
plug lamp comes on. It goes out when
The engine is fitted with a fuel injection Glow plugs
the ignition temperature is reached (see
system which automatically supplies the The engine is fitted with glow plugs. The page 29).
correct fuel/air mixture for all operating time the plugs are on is indicated by a
conditions. The starting procedure de- To avoid draining battery unnecessar-
lamp which is controlled by the coolant
scribed here is applicable regardless of temperature - see page 33. ily, do not switch any other heavy cur-
ambient or engine temperature: rent consumers on while glow plugs
Cold starting aid are on.
Switch ignition on and start engine
straightaway. Do not depress accelera- To facilitate starting from cold, there is As soon as lamp goes out, start en-
tor. a cold starting device in the injection gine. - Do not depress accelerator when
pump. This cold starting aid is operated operating the starter on an engine with-
Only if the engine does not start the with the knob on the left near the steer- out turbocharger. On engines with turbo-
first time, should the accelerator pedal ing column (see illustration on page 2, charger, depress accelerator about Vbof
be depressed slowly during the next item 20). pedal travel. If engine only fires irregular-
attempt to start. When engine starts
Starting a cold engine ly, continue to operate starter a few
release accelerator pedal immediately.
seconds longer (30 seconds at maxi-
At ambient temperatures down to mum) until engine runs under its own
-15 C, pull cold start knob out fully power.
before operating starter.
If engine does not start, wait about 30
At lower temperatures, the knob should seconds, switch glow plugs on again and
not be pulled out until engine is firing try starting it again as described.
regularly - the engine will then start
more readily. If the engine still does not start the
fuse for the glow plugs may have blown -
page 95.

STOPPING ENGINE
Do not push the knob of cold starting When vehicle has been driven hard
aid in until engine has reached normal for a while do not switch engine off as
operating temperature as otherwise the soon as you stop. Let it idle for about 2
engine may tend to stall when idling. minutes to cool it down slightly.
Starting a warm engine When engine is hot, the fan may con-
The glow plug warning lamp does not tinue to run when engine has been stopp-
come on - the engine can be started ed or it may switch on suddenly - even
straight away. when ignition has been switched off.
Do not pull cold starting aid knob and do
not depress accelerator pedal.

WARNING LAMPS
The layout of the warning lamps depends |" *\ Generator

on the model and the engine fitted. The Petrol engines Diesel engine
symbols shown here are also on the
actual warning lamps. This lamp comes on when the ignition is This lamp comes on when the ignition is
switched on and should go out when the switched on and should go out when the
V-p< - Engine oil pressure engine is started. engine is started.
This warning lamp flashes when the If the lamp comes on when driving, stop If the lamp comes on when driving, stop
ihnition is switched on. After the engine at once, switch engine off and check at once, switch engine off and check the
has started, the lamp must go out again. vee belt. vee belts for generator and coolan
If the warning lamp does not go out, or pump.
If the belt is broken do not drive further
flashes when driving - at an engine because the coolant pump is then no If the belt for the coolant pump is broken
speed of approx. 2000 rpm a buzzer then longer being driven. Fit a new belt. (For do not drive further. Renew the belt
sounds - stop at once and switch en- belt sizes see "Technical data".) for belt size see "Technical data".
gine off. Check the oil level and if ne-
cessary, add oil - see page 68. If the warning lamp comes on although If the belt for the generator is broken the
the belt is not broken one can normally vehicle can still be driven to the nex
If the lamp comes on despite the oil level drive on to next V.A.G workshop. V.A.G workshop but the battery will then
being correct, do not drive on. In such a discharge continuously - see next para
case, the engine must not be run, even However as the battery is then discharg-
graph.
at idling speed - call in expert assistance. ing continuously, all electrical compo-
nents which are not absolutely essential If the belts are not broken one can nor
should be switched off. mally drive on to the next V.A.G work
shop. As the battery will be discharging
continuously, all electrical components
which are not absolutely essential should
Note: be switched off.
The oil pressure warning lamp is not an
oil level indicator.

OPERATION
t - Coolant temperature/ - Glow plugs () - Brake system

coolant level (Diesel engine only) The warning l a m p * comes on when
This lamp flashes for a few seconds as When engine is cold, the warning lamp the handbrake is applied
a functional check when ignition is comes on when key is turned to drive
switched on. the fluid level is low
position (ignition on).
If the lamp does not go out afterwards If the lamp does not go out when hand-
When the lamp goes out, start engine brake is released or comes on when
or flashes when driving, either the coolant immediately - see page 30.
temperature is too high or the coolant driving, the fluid level in reservoir is
level is too low. When engine is warm the glow plug lamp too low. If at the same time the pedal
does not come on - the engine can be free travel increases, one of the two
Stop at once, switch engine off and started straight away. hydraulic circuits may have failed.
check if the radiator fan is running (by
listening). The fan is at the front behind You can drive on to the nearest V.A.G
O O - Turn signals workshop but allow for higher pedal
the radiator grille. If the fan is not running,
check fuse and replace if necessary - The warning lamp flashes when turn sig- pressures and longer braking distan-
see page 94. nals are switched on. If a turn signal fails, ces on the way.
the warning lamp flashes twice as fast.
If the fan is in order, check coolant level (Not when towing a trailer). Further de- Trailer turn signals*
and top up if necessary. tails are on page 38. The warning lamp flashes when turn si-
Caution. Danger of scalding. gnals are switched on when towing a
For further details see page 72. QI - High beams trailer.
If the warning lamp does not go out even The warning lamp comes on when high
If a turn signal fails on trailer or vehicle,
though the coolant level, and fan fuse are beams are on or headlight flasher is
the warning lamp does not flash.
in order, do not drive further - get expert used.
assistance. Differential locks* or selectable four
wheel drive*
If the trouble is only caused by the fan
and assuming coolant level is in order Warning lamps for the differential
and warning lamp is out - one can drive locks on four wheel drive models or for
on to the next V.A.G workshop. In order selectable 4 wheel drive - see page
to make a good use of the air stream for 23/25.
cooling do not let engine idle or drive
very slowly.

OPERATION
INSTRUMENTS
The arrangement of the instruments de- Rev counter* Clock*

pends on the model concerned and the The permissible engine speeds during Normal clock
engine fitted - see also "Instrument pa- the running-in period are given on page
nel", page 2. To set the time, press knob in centre of
53. dial and turn hands.
Speedometer The dotted zone on the scale shows the Digital clock
maximum engine speed permitted brief-
The permissible maximum speeds dur- ly when engine has been run in and is The time is set with buttons on left and
ing the running-in period are given on warm. It is advisable to change up or right of dial. The left button is for the
page 39. reduce engine speed at the latest by the hours and the right one for the minutes:
The last figure of the mileage recorder time the needle reaches this zone. If pressed briefly, preferably with a
or trip recorder* indicates 100 m or Changing up in good time helps to save ball pen, the time changes one hour or
1/10 mile. fuel and keeps the noise down. on minute.
The trip recorder can be set back to Always change down to the next lower If pressed continuously the hours or
zero by pressing the knob in the speedo- gear before the engine starts labouring, minutes change continuously.
meter dial. (no longer pulls smoothly). With the minute button the clock can
The green or green shaded area on the be set exactly to the second.
scale shows the speed at which the en- Press button until time is one minute
gine is developing its most favourable before time to be set.
torque.
Press button at the moment when
the seconds indiator of a digital wrist-
watch shows a full minute or when the
time signal is heard on the radio.

OPERATION
b - Normal zone
When vehicle is driven normally the
needle should settle down in the middle
of this zone.
When engine is working hard and am-
bient temperature is high, the needle
may move further to the right.
This is not serious as long as the warn-
ing lamp (c) does not flash. When en-
gine is pulling normally the needle should
B28-031 go back to the middle.
c - Warning lamp
t - Coolant temperature If the lamp flashes when driving either
gauge the coolant temperature is too high or ft - Fuel gauge
The gauge starts to work when ignition the coolant level is too low. Stop at once, The fuel gauge needle starts to move
is switched on, but it takes a little time switch engine off and try to find the when the ignition is switched on but it
before the needle reaches the final po- cause of the trouble - see page 33. takes a few seconds to reach its final
sition. position.
When ignition is switched on the warn- The tank holds about 60 litres (syncro
ing lamp (c) flashes for a few seconds 70 litres).
as a functional check.
When the needle reaches the start of
a - Cold zone the reserve mark (R) there are about
10 litres of fuel left in the tank.
Avoid high engine speeds and do not
work engine too hard yet.

SWITCHES
4 - Fog l i g h t s *
rear fog l i g h t *
First detent - fog lights
Second detent - fog and rear fog lights,
or only rear fog light.
At the second position a warning lamp in
the switch comes on.
The fog lights work only with the side
lights (ignition on), low or high beams.
The rear fog light works only with the
IB25-336! fog lights or with the low or high beams.
1 - Lighting switch 2 - Emergency lights

First detent - side lights When the emergency lights are on, a
Second detent - headlight high or low warning lamp in the switch flashes as
beams well.
The headlights only work when the igni- The system also works when the ignition
tion is on. When the engine is being is switched off.
started, the headlights are switched off
automatically. 3 - Heated rear w i n d o w *
When the lights are on, the level of the The heating works only when ignition is
instrument lighting can be regulated by on. When heater is on a lamp in the
turning the knurled d i s c * below the switch lights up.
switch. As soon as window is clear, switch ele-
Dipping and flashing headlights - see ment off. The reduced current consump-
page 38. tion helps to reduce the fuel consump-
tion - see also "Driving economically".
Note
The use of the lighting described at 1, 2
and 4/ T3
www.WestfaliaT3.info - a useful website for owners and enthusiasts of VW Westfalia T25 is subject to local
/ Vanagon regulations.
Campervans

Knurled disc for seat heating*
The cushion and backrest of the front
seats can be heated electrically when
the ignition is on.
The heating is switched on and regulat-
ed with the knurled disc.
To switch heating off, turn knurled disc
to the detent position.

OPERATION
TURN SIGNAL AND DIP LEVER
Right turn signals - lever up Parking lights*
Left turn signals - lever down The parking lights only work when igni-
When turn signals are working the warn- tion key is removed.
ing lamp flashes as well. See also page Right parking lights - lever up
33. Left parking lights - lever down
When a turn signal fails, the warning
lamp flashes roughly twice as fast.
The turn signals cancal automatically
after making a turn.
To signal a lane change
Move lever up or down to pressure point
and hold in position - the warning lamp
The turn signals only work when the igni- must also be flashing.
tion is switched on.
To dip headlights
Pull lever past pressure point towards
steering wheel. When high beams are on,
a warning lamp in the dash lights up.
Headlight flasher
Pull lever towards steering wheel to pres-
sure point - the high beam warning lamp
lights up.

OPERATION
WINDSCREEN WIPER AND WASHER SYSTEM
Windscreen Rear window

Brief wipe Automatic w a s h / w i p e *
Lift lever to pressure point before stop 1. Press lever briefly away from steering
wheel - the wiper works about every 6
Wiper slow
seconds (intermittent wipe). Pressing
Lever at position 1. lever briefly again switches the wiper off.
Wiper fast Press lever away from steering wheel,
Lever at position 2. and hold in position -
Windscreen washer The wiper and washer work as long as
lever is held in position.
Pull lever towards steering wheel - the
system works as long as lever is held in Release lever -
this position. The washer stops and the wiper carries
Wipers and washers only work when
ignition is switched on. Automatic wash/wipe facility* on for about 4 seconds.
When it is freezing, check that the wiper Pull lever towards steering wheel - Headlight washer s y s t e m *
blades are not frozen to the glass before wipers and washer work.
switching wipers on for the first time. When the headlights are on, the lenses
Release lever. are washed every time the windscreen
The washer stops and the wipers carry is washed.
on for about 4 seconds. At regular intervals such as when filling
Lever at detent 3 the tank, caked on dirt and insects
should be removed.
The wipers work about every 6 seconds,
(intermittent wipe) Filling washer container, see page 74.

HEATING AND VENTILATION
HI
Controls
Levers A and C - Warm or fresh air Switch E - Blower Air vents
distribution The blower has 3 speeds. Warm or fresh air flows from the vents
Lever A to right - vents 1 and 2 are 1, 2, 4 and from the footwell outlets for
opened the passenger compartments*
Lever C to left - vents 4 and footwell Only fresh flows from the vents 3 and
vents in passenger compartment* are from the roof vents for the passenger
opened. compartment.
Lever B - Heat output The vents 3 can be adjusted separately:
To left - increases Lever down - vent opened
To right - decreases Lever up - vent closed
Lever D - Roof vents in passenger The direction of air flow can be controll-
compartment* ed with the tab in the vent.
To right - fresh air decreases
To left - fresh air increases

OPERATION
Defrosting windscreen and side Heating interior normally Notes

windows When the windows are clear and the In order to ensure that the heating
Move all levers fully to the right. desired temperature has been reached, and ventilation works properly, the blow-
we recommend the following settings: er should always be switched on when
Switch blower to stage 2 with
driving slowly.
switch E. Lever A to the left
Switch off blower of additional heat Lever B to the desired heat output To prevent contaminated air from
exchanger*. getting into the vehicle, move lever A
Lever C to the left fully to left and levers C and D fully to
Demisting windscreen an side Blower switch E at stage 1 right. The vents 3 must also be closed.
windows
The heat depends on the engine tem-
When the windows mist up due to high Ventilation perature - the full heat output is there-
air humidity, e.g. when it is raining, we When heating is off, fresh air flows from fore only available when engine is warm.
recommend the following settings: all vents. When heating is on, only from All controls except blower switch E
Move levers A, C and D fully to the vents 3. can be set to any intermediate position.
right.
The stale air can escape through slots
Move lever B slightly to the right into in the front doors. The slots can be
the heating range, if necessary. opened or closed by means of slides.
Blower switch E to stage 2 or 3.
Close vents 3.
Heating interior as quickly as possible
Levers A, B + D fully to the right
Lever C fully to the left
Close vents 3
Switch blower to stage 2 with
switch E.

OPERATION
JB25-419
Additional heat exchanger* for the

passenger compartment
The additional heat exchanger is located To do this, grip trim on the left side and
under the rear seat. The blower is con- pull it out. Then move valve lever as
trolled by a 3 stage switch on the dash shown on right.
panel - see illustration above. Lever upwards - opened (Winter posi-
To obtain warm air from the heat ex- tion)
changer, the valve on the heat exchan- Lever to rear - closed (Summer posi-
ger must be fully open. tion)
To close or open the valve the trim under In the warm seasons the blower of the
the rear seat must be removed. heat exchanger can be used to circulate
the air. When used in this way the valve
on the heat exchanger should be closed.
This will prevent unnecessary heat radia-
tion reaching the footwell when the
weather is warm.

OPERATION
AUXILIARY AIR H E A T E R *
The heater is switched on and off with Heating with engine not running
the knob (see Fig.) in the dash on the
(Ignition off)
ight of the steering column. This switch
r
also regulates the amount of heat. To switch heater on -

Depending on model concerned the Press switch knob in at position 0 and
warm air flows from the footwell vents turn it clockwise towards 1 (warning
in the passenger compartment and/or lamp lights up). The knob springs out
from a controllable vent under the again when released.
driver's seat. The air distribution cannot The amount of heat can be regulated be-
be regulated. tween 2 and 3 as required.
The heater can be used all the time Note
when vehicle is moving. When engine is On vehicles with Diesel engine it takes
not running the heater switches off auto- about 40 seconds before the heat can be
matically after about 25 minutes to avoid Switch positions felt.
draining the battery.
0 - Heater off To switch heater off -
The heater is supplied with fuel from the 0 to 1 - Heating with engine not
vehicle tank. It can use up to one litre per The clockwork in the temperature regu-
running lating switch switches the heater off au-
hour according to operating conditions.
2 - Heating when driving tomatically after about 25 minutes and
The maximum heat output is 6000 kcal/h. the lamp goes out.
2 to 3 - Regulates amount of heat
To switch heat off before clockwork has
run down: turn knob anticlockwise to 0.
The lamp goes out and clockwork runs
down.

Heating when driving Notes Maintenance
To switch heater on - Every time the heater is switched off, When driving through mud and snow,
the warm air and combustion air blowers the exhaust pipe may tend to get block-
Turn switch knob clockwise to position 2
continue running briefly to cool the hea- ed. Have a look at it occasionally to see
(warning lamp in knob comes on)
ter down quicker. that it is clear.
The amount of heat can be regulated
To avoid draining the battery, do not According to offical German regula-
between 2 and 3 as required.
run the heater repeatedly when the en- tion:
Note gine is not running. The heat exchanger in the heater is only
On vehicles with Diesel engine it takes
When the heater is running on the to be used for 10 years. After this period
about 40 seconds before the heat can be
clockwork time switch, it must be switch- the heat exchanger must be replaced in
felt.
ed off by hand before attempting to start a V.A.G workshop. The year in which the
To switch heater off - the engine at low temperatures so that heater is first put into operation is mark-
Turn switch knob anti-clockwise to posi- the full battery capacity is available to ed on the nameplate on the heater.
tion 0 (warning lamp goes out) turn the engine. The V.A.G workshop must then put the
In enclosed spaces and when filling date of the repair on the plate on the heat
the fuel tank, the heater must be exchanger.
switched off.
Due to the risk of fire the heater must
not be used when vehicle is parked for
instance on dry grass or leaves.

OPERATION
If the heater on vehicles with a Diesel

engine will not start or stops after ope-
rating for a while, an automatic cut-out
switches the heater off. If the heater
cannot be started by switching the rotary
switch off and on, the heater is defective
and must be repaired in a V.A.G work-
shop.
Fuses
See page 95.
The heater on vehicles with a petrol

engine has a safety switch which is lo-
cated under the dash on the left near
the steering column. If the heater does
not start, or starts and then stops again,
wait 3 minutes and then operate the red
lever on the safety switch.
If the heater still does not work or if the
safety switch stops it again, there is a
defect in the heater which can only be
repaired by a V.A.G workshop.

OPERATION
AUXILIARY WATER H E A T E R *
The auxiliary heater heats the coolant in

the heating circuit and supplies the heat
exchanger in the normal heating system
and the additional heat exchanger* for
the passenger compartment heating
with heated coolant. The coolant ciruit
of the engine is not heated.
The system is switched off and on or the
switch-on time preselected by means of
a switch and indicator unit located on the
left (or right) unter the instrument panel.
Air distribution and regulation is done
with the controls of the normal heating
and ventilation system (see page 40). The heater is supplied with fuel from the Controls
vehicle tank and uses up to half a litre A - Buttons for setting time and pre-
The auxiliary heater can be used with
per hour. The maximum heat output is
vehicle stationary or when it is moving. selected time.
4000 kcal/h.
When vehicle is stationary, the heater B - Indicator lamp for preselected time
only runs for a maximum of 30 Minutes
in order to avoid draining the battery. It C - Preselected time
also switches off automatically when a D - Display
coolant temperature of 80 C is reached.
E - Actual time
When the coolant temperature drops
below 70 C the heater is automatically F - Heater on/off
switched on again. G - Warning lamp (heater on)

OPERATION
Setting the time Set required switch-on time with Notes

=ress and hold clock button E. buttons A. The display remains on for
Every time the heater is switched off,
about 20 seconds after releasing button
Set clock with buttons A. the warm air and combustion air blowers
C. continue running briefly to cool the hea-
me display lights up as long as button In order to ensure that the heater starts ter down quicker.
= oressed. When button is released the up at the selected time, the lever fot the
: splay goes out or, if a time has been To avoid draining the battery, do not
heat output must be pushed fully over
deselected, the selected time lights up run the heater repeatedly when the en-
to the right. In addition to this the blower
r 2 sees. gine is not running.
must be switched to stage 1. On account
To switch heater on or off of the higher current consumption, a When driving through mud and snow, the
higher stage should only be selected in exhaust pipe may tend to get blocked.
This is done by pressing button F. isolated cases. Have a look at it occasionally to see that
,Vhen heater is switched on the warning it is clear.
amp G lights up. Switching preselected time off
According to official German regula-
Preselecting starting time for heater The preselected time can be switch-
tions:
(stationary operation, ignition off) ed off by briefly pressing the appropriate
button C. The ready-for-action lamp and The heat exchanger in the heater is only
With buttons C two different switch-on the figure in display then go out. to be used for 10 years. After this period
times can be selected within 24 hours. the heat exchanger must be replaced in
Press and hold button. The appro- Fuses a V.A.G workshop. The year in which the
priate figure 1 or 2 appears in display. heater is first put into operation is mark-
See page 95. ed on the nameplate on the heater.
The ready-for-action lamp lights up.
The heater can only work if the lever The V.A.G workshop must then put the
for the heat output is pushed fully to date of the repair on the plate on the
the right. This closes an electrical con- heat exchanger.
tact. In enclosed spaces and when filling
the fuel tank, the heater must be
switched off.

OPERATION
SLIDING ROOF* SUN ROOF*
The roof is opened and closed with the To take out

crank above the driver's seat. Turn retaining screw (A) in centre of
To open - Fold crank down and turn it knurled disc one quarter turn clockwise
to the left, the fold crank into (e.g. with a coin) with roof closed.
recess again. Then raise roof and press it up.
To close - Fold crank down and turn it
to the right as far as it will go Press locking lever (B) up.
then turn it back until it can Detach roof.
be folded into the recess.
Lift roof from outside and pull it out
For safety reasons, the crank should to the rear.
always be in the recess.
To put back
Slide roof back into the hinges and
The roof is opened and closed with the let it drop lightly into the retainers.
knurled disc in the headlining above the
Cautions
front seats.
Ensure that the roof is properly insert-
The roof can be tilted at the rear as
ed into the two retaining hinges at the
desired or taken out altogether.
front, and locked at the rear.
Raising
The roof must only be unlocked when
Turn knurled disc clockwise. vehicle is stationary.
Lowering
Turn knurled disc anti-clockwise.

INTERIOR LIGHTS
Switch positions: Reading lamps* Interior light in front of passenger

The reading lamps have separate seat*
1 - Light on continuously
0 - Off switches and can be moved about as Switch positions:
2 - Door contact position, light comes required. Up - Off
on when cab doors are open. Down - On
Switch positions:
Step illumination* Ring turned to right - On Boot lights*
Ring turned to left - Off The boot lights come on when the rear
The step light comes on when sliding
door is opened. It goes out a few se- The reading lamp on the right at the rear flap is opened.
conds after the sliding door has been lights up continuously when the sliding
closed. door is opened. When the sliding door
is closed it goes out in the off position
Table light* together with the step light after a delay
Switch positions: of a few seconds.
To front - On
To rear - Off Note
When leaving the vehicle ensure that all
lights are switched off so that the battery
is not run down if the vehicle is left
stationary
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T3some time. Campervans
/ Vanagon

OPERATION
SUN VISORS ILLUMINATED MAKE-UP MIRROR*
Both sun visors can be lifted out of their

brackets and swung round towards the
doors.
An illuminated make-up mirror is fitted at

the back of the passenger's sun visor.
To switch light on - move switch to left.
When the sun visor is moved up, the
mirror illumination goes out automatical-
ly.
Note
When leaving the vehicle always ensure
that the light is switched off so that the
battery is not run down when vehicle is
left standing for some time.

ASHTRAYS CIGARETTE LIGHTER/SOCKET* GLOVE BOX
Ashtray in dash The cigarette lighter is switched on by Vehicles with a lockable glove box have
pushing in the element. an additional key - see also page 4.
To take out:
When the heating element glows, the
Grip the strip on opened lid and lift at
lighter springs out automatically - pull it
one side to take out.
out immediately.
To insert:
The socket can be used for a cigarette
Press ashtray into opening with lid clos- lighter or other electrical accessories
ed. with a capacity of up to 100 watts. When
the engine is not running this will how-
Ashtray in passenger compartment ever discharge the battery.
To take out: Cigarette lighter and socket also work
Open ashtray, press down and take out. when the ignition key has been taken
out.
To insert:
Children should therefore never be left
Insert at top first then push in fully. alone in the car.
On vehicles with individual seats:
To take out:
Lift one side of the handle of the opened
lid.
To insert:
Push ashtray into opening with lid closed.

CURTAINS* EXTENDING TABLE*
The curtains which can be supplied for On vehicles with individual seats in the
vehicles with seats/reclining seat bench passenger compartment there is an ex-
are stored underneath the rear seat tending table on the left side.
bench. They are secured to the window The table can be pulled up out of its retai-
surrounds by press studs. A further cur- ners and folded down (see illustration).
tain can be press-studded in position
behind the front seats. Caution
For safety reasons the table must be
pushed in when vehicle is in motion.

DRIVING TIPS
THE FIRST 1500 KM - AND AFTERWARDS
During the first few operating hours the Diesel engines Important notes
engine internal friction is higher than Do not overrev the engine when cold
later on when all the moving parts have 0-1000 km
4 speed gearbox 5 speed gearbox - either in neutral or in the gears. All
bedded down. How well this running in speeds and revs are only valid when
process is done depends to a consider- 1st gear 20 20 engine is properly warm.
able extent on the way the vehicle is
2nd gear 40 35 Try to avoid running the engine at
driven during the first 1500 km.
3rd gear 65 55 maximum speed - changing up early
4th gear 95 85 helps to save fuel and reduces noise.
Up to 1000 km
do not use full throttle at all.
5th gear
- 95
Do not let engine labour - change
Furthermore the following speeds in The maximum permissible engine speed down when engine no longer runs
km/h should not be exceeded in the during the first 1000 km is 4000 rpm. smoothly.
gears: From 1000-1500 km
Petrol engines the speed can gradually be increased to
Manual 0-1000 km the road or engine maximum.
gearbox 4 speed gearbox 5 speed gearbox After the running-in period
1st gear 20 20 on vehicles with a rev counter one
2nd gear 40 40 should change into the next higher gear
3rd gear 70 60 at the latest by the time the red warning
4th gear 105 85 zone is reached.
-
5th gear 105 The maximum permissible engine
speeds are
Petrol engines about 5300 rpm
Automatic 0-1000 km Diesel engines about 4800 rpm
gearbox
A speed limiter prevents extremely high
Driving range 1 35 engine speeds.
Driving range 2 75
Driving range D 110

DRIVING TIPS
DRIVING SAFETY
The operational condition of your ve- Safety on the road depends to a large Stow all luggage correctly in boot -
hicle is essential to safe driving. extent on the personal attitude and style page 19.
of driving. on the roof rack - page 19
So before moving off, always check
To be on the safe side you should: Do not drive when you feel tired or
the lights and turn signals
always put seat belt on before mov- when your reactions are impaired in any
the brakes way.
ing off - even in town traffic - page 10
the amount of fuel In many countries the wearing of seat Stop for a break at the latest after driv-
the mirror settings belts is compulsory anyway. ing for two hours.
the cleanliness of headlights, lenses Ensure that all your passengers - Adapt vehicle speed to traffic and
and windows including those on the rear seat - are road conditions.
and at regular intervals wearing their belts - page 10. Remember that particularly on smooth
Passengers without seat belts can endan- slippery roads the handling and braking -
the tyre condition and pressures
ger not only themselves, but also the also on vehicles with four-wheel drive -
- pages 79-82, 116
driver. is limited by the adhesion of the tyres
the engine oil level - page 68 On wet roads the front wheels can
Adjust headrests to body size. aquaplane at high speeds. The vehicle
The oil level should be checked every
time fuel tank is filled, or in difficult The upper edge of headrest must be can then no longer be steered properly
conditions or full throttle operation, approximately at eye level.
Further instructions on safety are given
daily Ensure that no articles interfere with in the various chapters in this manual.
the coolant level - page 71 operation of pedals - page 77.
the brake fluid level - page 76
the windscreen washer

DRIVING ECONOMICALLY AND ENVIRONMENT-CONSCIOUS
The economy and the exhaust emissions Change down only when engine no
and noise depend to a great extent on longer runs smoothly.
the personal style of driving. Depending on gearbox you can normally
To use as little fuel as possible and drive on the level in the highest gear at
disturb the environment as little as pos- 40-60 km/h and still accelerate.
sible and keep wear of engine, brakes
Avoid driving continuously at top
and tyres to the minimum, the following
speed.
points should be noted:
Drive as smoothly as possible and
Do not run engine to warm it up with look well ahead.
the vehicle stationary.
Unnecessary acceleration and braking
Drive off immediately after starting. Do must be paid for with higher fuel con-
not overrev.
sumption and more disturbance of the
Avoid full throttle acceleration. environment.
Avoid high engine speeds Stop engine during traffic hold-ups.
The best consumption and least distur-
bance of environment is obtained at low
engine speeds in the highest possible
gear. Drive as often and as long as
possible in the highest gear.
The fuel consumption is for example
twice as high in 2nd gear and 1.5 times
as high in 3rd gear as in 4th gear.

DRIVING TIPS
~ - e individual operating conditions The engineers at the factory have d e - All electrical c o n s u m e r s (e.g. rea
-a-.-'aliy also affect fuel c o n s u m p t i o n . signed your c a r for m a x i m u m fuel effi- w i n d o w heating, additional headlights
c i e n c y . To m a k e use of this economy auxiliary heater) should only be le
~~e following factors for instance are not
potential please note the following s w i t c h e d on as long as n e c e s s a r y . Th
-avourable to fuel c o n s u m p t i o n :
points: higher load on alternator also increase
Traffic density, particularly large the fuel c o n s u m p t i o n .
Have your vehicle s e r v i c e d in a V.A.G
towns with n u m e r o u s traffic lights.
w o r k s h o p at the intervals laid d o w n in The fuel c o n s u m p t i o n should b
Frequent stop/start driving, particu- the service s c h e d u l e . Y o u will then o b - c h e c k e d regularly, preferably w h e n fi
larly driving from h o u s e to h o u s e s o that tain optimum e c o n o m y plus constant ling the tank, with the aid of the mileag
engine is never properly warm. reliability and long s e r v i c e life. recorder. O n e c a n then have the ca
i n s p e c t e d if the c o n s u m p t i o n has in
Driving in heavy, s l o w - m o v i n g traffic C h e c k the tyre p r e s s u r e s ar regular
creased.
in low gear s o that the engine s p e e d is intervals. L o w tyre p r e s s u r e s are not
relatively high in relation to the d i s t a n c e only detrimental to handling, the higher The oil c o n s u m p t i o n also d e p e n d
covered. rolling resistance also i n c r e a s e s the fuel on engine load and s p e e d . D e p e n d i n
consumption. on style of driving the c o n s u m p t i o n c a
O n e s h o u l d , therefore, plan trips in a d -
be up to 1.5 1/1000 km.
v a n c e to avoid unfavourable operating Do not drive about unnecessarily with
conditions. a roof rack on the vehicle. Particularly It is normal for the oil c o n s u m p t i o n of
at high s p e e d s the i n c r e a s e d air resis- new engine to reach its lowest valu
O b v i o u s l y the fuel c o n s u m p t i o n is also
t a n c e m a k e s itself felt. after a certain mileage has been c o v e
affected by factors over w h i c h the driver
ed. The c o n s u m p t i o n during the firs
has no influence. It is for e x a m p l e nor- Do not carry a lot of u n n e c e s s a r y
5 0 0 0 km c a n therefore be slightly a b o v
mal for the c o n s u m p t i o n to i n c r e a s e in ballast about in the vehicle. Particularly
the figure given.
the winter or in a r d u o u s conditions (bad in town traffic w h e n vehicle is being
roads, trailer towing etc.). frequently a c c e l e r a t e d the vehicle weight Similarly, the fuel c o n s u m p t i o n a n d e n
has a c o n s i d e r a b l e influence on fuel gine p e r f o r a m n c e c a n also not be co
consumption. rectly a s s e s s e d until this d i s t a n c e ha
been c o v e r e d .
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DRIVING TIPS
TRAILER TOWING
The vehicle must be specially equipped Note When towing a trailer in mountainous
to tow a trailer. The installation of a towing bracket in- regions note the following:
When a vehicle is supplied from the fac- creases the unladen weight slightly and The trailer weights given in "Technical
tory fitted with a towing bracket it will the payload must be reduced to corres- Data" are valid only for gradients up to
already have the necessary modifica- pond. 12%. If the vehicle and trailer weight is
tions. When a towing bracket is service To obtain the best handling of vehicle below the permissible maximum a cor-
installed, the following must be noted: and trailer it is advisible to make full respondingly steeper gradient can be
use of the maximum permissible draw climbed. Furthermore the given trailer
The towing bracket is a safety part.
bar weight. The tyres on towing vehicle weights are only applicable for altitudes
Only a bracket which has been develop-
should be inflated to the pressures for up to 1000 m above sea level. As the
ed for your vehicle is to be used and it
full load. engine output and thus the climbing
must be fitted in accordance with our
ability drops due to the decreasing air
instructions. For trailer and draw bar weights see density above 1000 m the weight of
Details are usually given in the fitting "Technical Data" page 120. vehicle and trailer must also be reduced
instructions supplied with the bracket. Please note any local regulations con- by 10% for each further 1000 m or part
A special warning lamp must be fitted cerning maximum speeds, driving res- thereof.
within the driver's range of vision to show trictions on Sundays, trailer towing, etc. The cooling effect of the radiator fan
that the trailer turn signals are working. In Germany for example the permissible cannot be increased by changing down
Check if the fitting of a bracket must maximum speed when towing a trailer because the speed of the fan is not de-
be entered in the vehicle documents. is 80 km/h. pendent on the engine speed. One
should therefore not change down even
Every V.A.G workshop has the neces- In any case the speed must be reduced when towing a trailer as long as the
sary information on fitting towing immediately as soon as the trailer shows engine can cope without vehicle speed
brackets. The installation should therefore the slightest sign of snaking. dropping too much.
be done by them.

DRIVING TIPS
DRIVING A FOUR-WHEEL DRIVE VEHICLE*
The drive concept

Contrary to the normal type of selectable
four-wheel drive, the four-wheel drive on
the Transport/Caravelle syncro is always
in action. Only the amount of power
being transmitted to the front wheels
changes according to the requirements.
This automatic distribution of the driving
forces to the rear and front wheels is
attained through a wear resistant vis-
cous coupling incorporated in the front
axle. This ensures, on the one hand,
that the driving force losses are kept
as low as possible, and on the other
Front axle final drive
hand, that the best possible traction is
and viscous coupling
attained when required.
Prop shaft
Note:
Vehicles for particularly arduous operat- Rear axle final drive
ing conditions (e.g. predominantly cross-
country work) can be fitted with a ma-
nually controlled four-wheel drive as an
optional extra. Further details are given
on page 23.

-zvantages of fo u r-whee l drive The acceleration Using winter tyres
-- e special drive concept of the Trans- As the driving force to be put onto the With the four-Wheel drive concept the
Dorter/Caravelle syncro, when corn- road goes to four wheels instead of two, Transporter/Caravelle syncro has good
e r e d with a vehicle which only has a the amount of slip is considerably re- winter driving properties even with stan-
:.-. o-wheel drive, has advantages in reduced. This improves the adhesion bet- dard tyres. However, the use of winter
spect of the following points: ween tyre and road surface and thereby, or allweather tyres, on all wheels, is re-
the acceleration capabilities on slippery commended in order to obtain even
~he drivability road surfaces. better cornering and braking behaviour.
decisive for the drivability - particularly The traction Snow chains see page 82.
: n slippery roads - is the grip between Four-wheel drive increases the traction
the four wheels and the road surface. a great deal. This is of particular benefit
On vehicles with two-wheel drive, the on snow and ice, when moving off, and
driving wheels can spin on slippery sur- when driving on difficult mountain roads.
faces if too much acceleration is applied.
Driving under such conditions is less
This greatly impairs their grip. Under un-
hazardous with the Transporter/Cara-
favourable conditions, this could cause
velle syncro:
the vehicle to break away.
There is no longer any need to drive past
By distributing the driving forces to four obstacles at speeds on slippery uphill
instead of two wheels the lateral forces stretches, because one is afraid of be-
which can be transmitted are increased coming stuck, one can approach slowly,
on the Transporter/Caravelle syncro, stop and then, start off again.
and the vehicle is less likely to break
away.

Driving on dry roads Driving on wet, slippery roads Notes
Under normal driving conditions, the dif- Due to the four-wheel drive, the engine The style of driving must always be
ferential locks must not be engaged. power is transferred even to a relatively adapted to suit the road surface and
They do not provide any advantages at smooth road surface. traffic conditions. The increased safety
all on dry road surfaces, but impair the On wet surfaces offered by this type of vehicle must not
vehicle's steerability. encourage one to take unnecessary
On wet roads one should also note that risks.
Particularly if the front axle differential even with the Transporter/Caravelle
lock is engaged, the vehicle is no longer syncro it is possible for the front wheels In particular, one must always remem-
steerable. to "swim" (aquaplaning) at high speeds. ber that the stopping ability is limited
by the adhesion of the tyres on the
Important instructions on the differential For this reason, one should avoid ex- road surface. The braking capability of
locks are to be found on page 24. cessive speed and drive at a speed the vehicle is the same as that of a
compatible to the road conditions. The normal two wheel drive vehicle. For this
differential locks* must not be engaged. reason, one should never be tempted
Important instructions on the differential by the good acceleration capabilities,
locks are to be found on page 24. even on slippery road surfaces, into
driving too fast.
On slippery surfaces
On slippery surfaces the rear axle diffe-
rential lock may only be engaged when
moving off, and at very low speed. The
lock should then be disengaged again.
The front axle differential lock must not
be engaged.

NG TIPS
Driving cross country Do not drive over small embank- After traversing water or mud one
Before driving for the first time over diffi- ments or declines at excessive speed. should drive a short distance with brakes
cult terrain, it is advisable to make your- This can lead to bouncing during which lightly applied. The linings must be dried
self familiar with the vehicle on normal it would be impossible to avoid any out properly. By doing this, one prevents
roads, and also under easier off-road obstacle which may suddenly appear. the brakes from pulling to one side, or a
conditions. For safe driving cross coun- In addition it could lead to vehicle da- delayed braking effect.
try, the following rules are of great im- mage.
After driving through deep water it is
portance. Drive down gradients in the same necessary to remove the engine oil dip-
Always wear your seat belt. gear as you would drive up. stick in order to check whether any
Embankments, gradients and similar drops of water are present, or to check
Timely gear changing takes care of whether the oil level has increased. If the
the engine and prevents the vehicle from obstacles should only be driven up or
down at right angles, i.e. directly in line answer is "yes" then the oil must be
bogging down. renewed immediately.
with the slope.
Never drive with the clutch slipping as
this leads to premature wear. If however one is forced to drive
across a slope and the vehicle tends to
The more uneven and creviced the tip, one should immediately steer di-
terrain is, the lower speed must be. Pay rectly into the slope.
attention to the vehicle's ground clear-
ance. Before driving through water, deter-
mine the depth - the permissible wading
depth (see technical data) must not be
exceeded.
Note
To prevent the engine from drawing in
water through the intake air preheater
and being damaged when wading, there
is a valve in the engine compartment on
the right behind the maintenance flap
with which the intake air preheating can
be closed. The valve is closed by press-
ing it down and turning it to the right.

DRIVING TIPS
After driving through mud, the brakes Note for vehicles with differential Output testing
must be checked and if dirty, cleaned. lock(s) If the Transporter/Caravelle is to be out-
This will prevent premature wear taking put tested on a dynamometer, the prop-
Before driving through a difficult
place in the brake system. shaft must be removed.
cross country stretch (e.g. mud, sand,
The engine compartment and the under- water, snow or steep gradients) it is ad-
side of the vehicle body must also be visable to engage the differential lock(s)* Brake test stand
cleaned so that the functioning of all at low speed. Important instructions For brake testing e.g at MOT, the prop-
moving parts and electric/electronic regarding the differential locks are to shaft must be removed. The differential
components is maintained. be found on pages 23 and 24. locks must not be engaged.
Note
To prevent damage to the underside of
the vehicle, the vehicle is equipped with
protective plates in front of the front axle
and underneath the engine and gearbox
and protective rails running along both
sides of the propshaft.

OPERATING INSTRUCTIONS
FUEL
Petrol engines
Vehicles without catalyst Vehicles with catalyst For all vehicles with catalyst:
44 and 57 kW carburetor engines 61 and 70 kW fuel injection engines Only lead-free petrol may be used in
_saded regular fuel to DIN 51600, Lead-free regular petrol to DIN 51607, these vehicles.
RON 1 not lower than 91
1
RON not lower than 91.
1 The use of leaded petrol does not lead,
or to engine damage but it is very detrimen-
ead-free regular fuel to DIN 51607, If lead-free regular petrol with adequate
tal to the functioning of the emission con-
RON not lower than 91. anti-knock properties is not available,
trol system because the lead is deposit-
use lead-free premium petrol or a suit-
if regular fuel with adequate anti-knock ed in the catalyst.
able mixture.
properties is not available, use premuim Even one tankful of leaded petrol will
or a suitable mixture. detract from the efficiency of the cata-
66 and 82 fuel injection engines lyst. Although lead-free fuel may again
Leaded premium petrol to DIN 51600, be used afterwards the original efficien-
RON" not lower than 98. cy of the catalyst is never fully attained.
On vehicles with Lambda probe the
mixture formation is also negatively
affected. This can cause poor engine
performance (jerking and stalling when
idling) combined with a higher fuel con-
sumption.
" Research Octane Number, indicates anti-

knock - a useful website for owners and enthusiasts of VW Westfalia T25 / T3 / Vanagon Campervans
properties of the petrol. 63

OPERATING INSTRUCTIO
Fuel additives Diesel engines As this additive reduces the engine out-
put, only the amount actually required
On carburetor engines with and without Diesel fuel to DIN 51601
should be used: (max. 30%)
catalysts carburetor icing can occur at C N not lower than 45
n
ambient temperatures between 0 C and When using summer Diesel trouble may Tempe- Sum- Winter-
+ 15 C when the air humidity is high be experienced at temperatures below rature mer Petrol Diesel Petrol
despite the automatically controlled in- 0 C because the fuel thickens due to in C Diesel
take air preheating. This can cause the wax separation.
engines to stall occasionally when idling
in the warm-up phase. For this reason, winter Diesel whcih is
- 0 to
- 5
85% 15% 100% -
more resistant to cold is sold during
Even the anti-icing additives contained
in some fuels in the cold season cannot
the winter and works satisfactorily down
to about -15 C.
- 5 to
-15 70% 30% 100% -
entirely prevent carburetor icing. When a
properly tuned engine stalls repeatedly
in the conditions described above it is
In countries with different climatic con-
ditions the Diesel fuels offered have a
- 1 5 to
-25 - - 70% 30%
advisable to mix Volkswagen AUDI petrol different temperature behaviour. Check

additive with the fuel. This additive pre- with V.A.G dealers or filling stations in This table is based on the fuels available
vents carburetor icing and also cleans the country concerned regarding the in Germany.
the carburetor and protects it against availability of Diesel fuels.
corrosion. It is obtainable from V.A.G Due to the inflammability of petrol the
When necessary summer and winter mixing should, for safety reasons, only
workshops in Germany and in many Diesel can be used at lower tempera-
export countries. be done in the vehicle tank. Where pos-
tures by mixing regular leaded or lead- sible, the petrol should be put into the
No other fuel additives should be mixed free petrol (not premium) with the Diesel. tank before the Diesel.
with the petrol.
" Cetane Number, indicates the ignitability of

64 www.WestfaliaT3.info - a useful website for owners
Diesel. and enthusiasts of VW Westfalia T25 / T3 / Vanagon Campervans

FILLING TANK
Mixing must take place before the wax The filler neck is on the right hand side Note for vehicles with Diesel engine:
starts to separate because subsequent of the vehicle.
Bleeding the fuel system
mixing is effective only in the tank but
The fuel tank capacity is approx. 60 The fuel system does not need bleeding
not in the rest of the fuel system. litres (syncro 70). when tank has been run dry - this takes
If the fuel is already waxed to such an Trouble-free refueling calls for correct place automatically while starting.
extent that the engine will not start it is use of filler nozzle.
sufficient to place the vehicle in a warm
Insert nozzle fully into tank neck and Note for vehicles with factory fitted
room for a while.
do not tilt it. catalyst
Other fuel additives (anti-waxing agents
and similar fluids) must not be mixed with Do not try to fill tank too quickly, Catalyst vehicles have a smaller dia-
the Diesel fuel. otherwise the fuel (especially Diesel) will meter tank filler neck which is closed
foam and this may cause nozzle to switch with a spring-loaded flap below the
off too soon. filler opening. Filler nozzles for lead-
free petrol are smaller to suit and open
As soon as the correctly operated auto- the flap when inserted in filler neck.
matic nozzle switches off for the first This is to ensure that only lead-free
time, the tank is full. Do not try then to petrol can be put into tank.
put more fuel in because otherwise the
expansion space in tank will be filled -
the fuel can then overflow when it gets
warm.

What to do when wrong fuel has

been put into tank.
Premium petrol instead of regular Lead-free petrol instead of leaded Petrol instead of diesel
The engine can be run on premium fuel The engine can be run on lead-free pe- The engine can be run on a concentra-
with no problems. trol. A stipulation however is that the tion of up to approx. 3 0 % leaded or
petrol has the correct anti-knock proper- lead-free regular petrol (not premium).
Regular petrol instead of premium However if premium petrol or a large
ties (RON) - see also section on "Fuel".
In isolated cases the engine can also be If the anti-knock properties are lower, quantity of regular petrol has been put
run on regular petrol. The vehicle must the instructions under "Regular petrol in the tank accidentally, the engine must
then however not be driven at top speed instead of premium" apply. not be run as otherwise damage will
and with full throttle. High engine loading occur. The fuel system must be emptied
with full throttle or high speeds can Leaded petrol instead of lead-free bearing in mind environmental control
cause engine damage. Fill tank with Vehicles with catalyst must not be driven regulations - preferably by a V.A.G work-
premium petrol as soon as possible. on leaded petrol because otherwise the shop.
function of the emission control system
is affected considerably - see also sec- Diesel instead of petrol
tion "Fuel". The fuel system must be The engine cannot be run on Diesel. The
emptied, in accordance with environ- fuel system must be emptied bearing in
mental regulations - preferably by a mind the environmental control regula-
V.A.G workshop. tions - preferably by a V.A.G workshop.

LUBRICANTS
Engine C F
Aspecial very high quality multi-grade 100
oil is put in at the factory and this can

80
oe used all the year round - except in
very cold climates. -60
Mineral or synthetic oils may be used 55

40
;or topping up or changing regardless of
Ml in engine. The container must be 20
O O
narked with the correct specifications 0 ss
*or the engine concerned.
20
The viscosity classes of the oil must
Z3 selected as shown on the right. The
hi does not have to be changed when
:ne ambient temperature is briefly above B28-083 - Petrol engines B28-88-DieselandTurboDieselengines
:ne range shown. A - Single grade oils, B - Multi-grade oils, C - Improved lubricity oils
When using single-grade oil SAE10 W
:- multi-grade oil SAE 5 W-20 or SAE Petrol engines for topping up if unavoidable, also
I W-30 do not drive with full throttle for Good quality oils, specification Good quality oils, specification
:ng periods if the temperature is above API - SF or API - CD
n e range shown. Improved lubricity oils, Manual gearbox and final drive
specification VW 50000 Gear oil, specification API - GL 4,
Diesel engines (except turbodiesel) SAE 80
Good quality oils, specification Automatic gearbox
API - C C or API - CD or Final drive:
Oils for turbodiesel engines, Gear oil, specification API GL 5,
specification VW 50500 or SAE 90
Improved lubricity oils Gearbox part:
specification VW 50000 ATF Dexron
Turbodiesel engines Power assisted steering
ATF Dexron
Oil for turbodiesel engines,
specification VW 50500, No additives should be mixed with the
lubricating oils.

ENGINE OIL
The vehicle must be on a level surface Changing engine oil

when checking oil level. After stopping The engine oil should be changed at the
engine wait a few minutes for the oil to intervals given in the service schedule.
drain back to the sump. Then pull the
dipstick out, wipe it with a clean cloth and If the vehicle is used continuously in very
insert again. Then pull dipstick out again dusty areas or in countries with arctic
and check the oil level: climates where the temperature is nor-
mally below about -20 C, the engine oil
The level must be between the two should be changed at shorter intervals -
marks. see also "Difficult operating conditions"
The difference in quantity between the page 84.
min. and max. marks is 1.0 litre. Recommended oils and viscosity
When the engine is working hard such classes - see previous page.
as in sustained high-speed motorway Permissible oil consumption - see pages
Checking oil level cruising in summer, when towing a trailer 108/109.
The engine oil level must be checked at or when climbing mountain passes, the
regular intervals, preferably when filling oil level should be kept up to the max.
the tank. In arduous operating condi- mark.
tions or when engine is working hard it Topping up engine oil
should be checked daily before moving
off. Unscrew the cap from the oil filler and
pull extension pipe out fully.
The dipstick and filler pipe can be reach-
ed through a flap behind the rear num- Add oil.
ber plate. Push extension pipe in again and screw
The dipstick location is shown in the the cap back on tightly.
illustration: Check the level with the dipstick - the
oil should not be above the max. mark.

GEARBOX OIL
Checking oil level Changing oil

With the manual gearbox the oil level With the manual gearbox the oil does
does not need checking in between the not need changing.
intervals given in service schedule. With the automatic gearbox the oil in
With the automatic gearbox the oil level the final drive also does not need chang-
in the final drive also does not need ing. The ATF in gearbox part must how-
checking between services. ever be changed at the intervals given in
service schedule. This should preferably
The ATF level in gearbox part must how-
be done by a V.A.G dealer.
ever be checked in between the inter-
vals given in service schedule.
To do this the vehicle must be standing
on a level surface. The level must only
be checked when the ATF is warm (about To check, pull dipstick (see Fig.) out,
10 km after starting from cold the ATF wipe with a clean lint-free rag and then Note
is at the correct temperature). If fluid is insert it fully again. When there is no lubricant in the manu-
cold or too hot the reading will be in- al or automatic gearbox the engine
correct. The engine must be running at Pull dipstick out and check ATF level. must not be started and the vehicle
idle speed, the handbrake must be When the ATF is warm the level must may only be towed with driving wheels
applied and the selector lever at "P". be between the two marks - otherwise lifted.
the vehicle must be taken to a V.A.G
workshop without delay so that they can
find the reason for the incorrect level.
It is not sufficient to merely top up or
drain off ATF.

POWER ASSISTED S T E E R I N G *
Note
If the power assisted steering fails at any
time or when engine is not running (ve-
hicle on tow) the vehicle can still be
steered but more force will be required
to turn the steering wheel.
To ensure satisfactory operation of the

system it is essential that the fluid level
in reservoir is correct.
The reservoir is in the engine compart-
ment on the right behind the mainten-
ance flap.
The check must only be done with the
engine running and the wheels in straight-
ahead position.
The fluid should always be between the
"max" and "min" marks. When level has
dropped to min. mark, ATF (Dexron)
should be added after removing the red
cap in top of reservoir.

OPERATING INSTRUCTIO
POOLING S Y S T E M
-sservoir E x p a n s i o n tank - Petrol engines E x p a n s i o n tank - Diesel engine

" h e cooling s y s t e m is filled at the f a c - In the engine c o m p a r t m e n t there is a Checking coolant level
:ory with a long lasting mixture of water reservoir and an e x p a n s i o n tank. The c o r r e c t coolant level is essential to
and o u r c o o l a n t additive G11 (anti-freeze the satisfactory operation of cooling
The coolant level is normally only c h e c k -
:n glycol basis with anti-corrosion addi- system.
ed in the reservoir. It only needs c h e c k -
Bves). This mixture gives the n e c e s s a r y
ing in the e x p a n s i o n tank if a large O p e n flap behind number plate. The level
frost and c o r r o s i o n protection, prevents
amount of coolant has b e e n lost or if the should be b e t w e e n min. and max. marks
scaling and i n c r e a s e s the boiling point
warning lamp for coolant temperature/ w h e n engine is c o l d or just a b o v e the
of the coolant.
coolant level lights up. max. mark w h e n engine is w a r m .
Caution
The level can only be checked properly
The coolant is poisonous. It must there- when engine is not running.
fore only be stored in the original con-
tainer out of reach of children.

Coolant losses Topping up coolant In order to maintain the corrosion protec-

Topping up is normally done in the re- tion at all times and prevent the system
In normal conditions the cooling system
servoir only. from scaling up and the boiling point
is almost maintenance-free.
from being lowered the mixture should
Coolant loss normally indicates leakage Do not fill above the max. mark. not be altered even in the summer or
in the system. In this case the cooling The excess coolant will be forced out of in warm countries by adding plain wa-
system should be checked by a V.A.G the system when engine gets hot. ter: the coolant additive proportion
workshop without delay. It is not suffi- should be at least 40% (anti-freeze
cient to merely add coolant. If the coolant warning lamp comes on protection down to about -25 C).
the expansion tank must also be check-
In a water-tight system losses can only ed and filled to brim if necessary. Screw cap on again tightly.
occur if the boiling point of the coolant
is exceeded as a result of overheating. First switch the engine off and let it cool The system must then be bled with en-
down slightly, then turn cap one turn to gine running (at a fast idle). Take air
Overheating can occur if: the left and let pressure escape first. intake grille off (see page 69), open vent
the flow of cooling air is reduced, e.g. Then take cap off. screw at top of radiator and set heater
by a radiator muff, very dirty radiator fins lever to "warm". As soon as coolant
Caution emerges, close vent screw. Top level up
(leaves, dust, insects) or additional driv-
ing lights in front of radiator grille Do not remove cap when engine is hot. in reservoir and expansion tank.
Danger of scalding.
the radiator fan is not working - see System is under pressure.
next page "Radiator", or
vehicle is driven up a long hill in too
low a gear with engine speed very high
and at very high ambient temperatures -
see next page "Radiator".
If the cause of the overheating cannot be
found and eliminated, contact a V.A.G
dealer as soon as possible as otherwise
serious damage may be done to the
engine.

Fan Driving in winter

_n e fan is driven electrically and con- The mixture put in the system by the fac-
rolled by a thermoswitch which is ac- tory provides frost protection down to
:jated by the coolant temperature. about -25 C. To ensure that frost pro-
.'/hen the engine is hot, the fan may tection is adequate, the coolant should
:ontinue to run when the engine has be checked before the cold season be-
gins and if necessary coolant additive
:een stopped or it may switch on
G 11 (undiluted) added.
suddenly - even when ignition is off.
If greater protection against frost is re-
Notes
quired, the proportion of G 11 additive
If the fan is not running although the can be increased, but only up to 60%
loolant temperature is very high, the otherwise the anti-freeze protection is
^jse should be checked and renewed if reduced and furthermore the cooling
-ecessary - see page 94. effect is impaired.
The speed of the fan does not depend Vehicles for export to cold countries
: n engine speed. The cooling effect can- usually have frost protection down to
ot therefore be increased by changing -35 C.
aown.
-s long as the engine runs amoothly and
a gradient can be taken without a large
3rop in speed it is not necessary to
mange down.

^^^^^^^^^^^^^^^^^^^^^^^ ONS
WINDSCREEN WASHER SYSTEM

To fill container
Lift carpet, open flap and unscrew cap.
Fill container to top with water and screw
cap on again. Switch ignition on and
check that washer is working.
It is advisable to add a window cleaner
solution (with anti-freeze additive in win-
ter) to the water because plain water is
not usually sufficient to clean the glass
and headlight lenses quickly and tho-
roughly.
The filler opening of the container is Adjusting washer jets

under the carpet on left hand side of When vehicle is stationary, the water
front footwell. The container holds about should hit the windscreen at the follow-
3.5 litres. On vehicles with a headlight
ing points:
washer the capacity is 6.5 litres.
a = 490 mm c = 180/190 ' mm
1
On vehicles with rear window washer* b = 220 mm d = 450/330 ) mm
1
there is an additional container on the
right in the luggage compartment. This The water jet for the rear window should
container holds about 1 litre. hit the window in the centre of the wiped
area.
The jets can be adjusted with a needle.
The jets for the headlight washer sys-
t e m * can only be adjusted with a special
tool. When adjustment is necessary,
contact your V.A.G workshop.
74 www.WestfaliaT3.info - a useful website for owners and enthusiasts of VW Westfalia T25

only /vehicles
T3 / Vanagon
11 Campervans
with 37, 44 or 51 kW engines

BRAKE SYSTEM
The following points are of particular Brake lining wear depends to a large Brake servo
importance to the safe operation of the extent on the operating conditions and
The servo is operated by vacuum which
brakes. style of driving. On vehicles which are
is only available when engine is running.
New brake linings must also be run in used mainly in town traffic and stop/start
conditions or are driven hard it may be Caution
and do not have the optimum friction
properties during the first 200 km. The necessary to have the thickness of the For this reason the vehicle should not
slightly reduced braking effect can be brake linings checked in a V.A.G work- be allowed to roll with engine not runn-
compensated for by slightly more pres- shop in between the intervals given in ing.
sure on the brake pedal. This also applies the service schedule.
When the brake servo is not working be-
.vhen new linings have been fitted. If the brake pedal travel increases cause, for example, the vehicle is being
On hills change down in good time to suddenly, it may be that one of the two towed or because a defect has occured
~iake use of the braking effect of engine, brake circuits has failed. You can still on the brake servo, the brake pedal must
"his relieves strain on the brake system. drive on to the next V.A.G workshop but be pressed harder.
,Vhen brakes are applied do not keep be prepared to use more pressure on
:nem on continuously, apply and release the pedal and allow for longer braking
alternately. distances on the way.
After driving through water, driving in The failure of a brake circuit is shown by
~eavy rain or washing the car, the brak- the lighting up of the brake warning
ng effect can be retarded slightly. The l a m p * (see also page 33).
cads must be dried first by applying the The brake fluid level must be checked
crake. regularly - see next page.
~he full braking force may also be re-
tarded when vehicle has been driven for
some time on heavily salted roads with-
out using the brakes because the layer
Df salt on discs and pads has to be re-
moved first.
urther details - particularly for vehicles
r
.vith four wheel drive - are given on

cage 61.

OPERATING IN MI
However, if the level sinks noticeably in Caution

a short time or drops below the "min"
Brake fluid is poisonous.
mark the system may be leaking. Take
the vehicle to a V.A.G workshop at once It must therefore only be stored in the
and have the brake system checked. original container out of reach of child-
ren.
The failure of a brake circuit is shown by
the lighting up of the brake warning Brake fluid will also damage paintwork
l a m p * (see also page 33). When this and the plastic material of which the
happens take the vehicle to a V.A.G work- dash is made. Take great care not to
shop immediately and have the brake spill any fluid when topping up the re-
system checked. servoir. Cover area round reservoir if
necessary.
Brake fluid
Brake fluid reservoir Brake fluid absorbs moisture. As too high
a water content becomes detrimental to
The fluid reservoir is in the dash under
the entire system after a period of time,
the dash cover panel. The panel can be
the brake fluid must be renewed every
lifted to fill the reservoir. To do this grip
two years. The brake system must be
in the recess at the back of the cover.
bled afterwards.
When installing insert the lower front
edge first. Use only our genuine brake fluid (spe-
cification to US standards FMVSS 116
Checking fluid level DOT 4). The fluid must be new and un-
used.
The correct fluid level is essential to the
satisfactory operation of the brake sys-
tem. The fluid level must always be bet-
ween the "max" and "min" marks.
The level of fluid tends to sink slightly
when the vehicle is used due to the auto-
matic adjustment of brake lining wear.
This is quite normal.

PEDALS
h e m o v e m e n t of t h e p e d a l s m u s t n o t b e
-estricted.
-or t h i s r e a s o n , d o n o t p u t a r t i c l e s in t h e
l o o t w e l l w h i c h c o u l d roll o r s l i d e u n d e r -
-eath the pedals.
Around the pedal area there should also

oe no f o o t m a t s or o t h e r a d d i t i o n a l floor
covering materials:
In t h e c a s e of d e f e c t s o n t h e b r a k e
system, a greater pedal travel may be
-ecessary.
It s h o u l d a l w a y s b e p o s s i b l e to d e -
press the clutch and accelerator pedals
hilly.
All p e d a l s m u s t b e a b l e to return, u n -
n i n d e r e d , to their rest p o s i t i o n s .
For t h e s e r e a s o n s therefore, the only

*oot m a t s w h i c h m a y b e u s e d , a r e t h o s e
which leave the pedal area completely
free a n d w h i c h are p r e v e n t e d f r o m slipp-
ing.

NG I N S T R U C T I O N S
BATTERY
Checking acid level The level should therefore only be topp-

In normal operating conditions the bat- ed up in a V.A.G workshop.
tery requires hardly any maintenance. At Never short the battery terminals as
high ambient temperatures however it is this causes the battery to heat up very
advisable to check the acid level at regu- quickly and it may burst. Furthermore,
lar intervals. It should always be between the sparks can ignite the gas generated
the min. and max. marks on the side of during the charging process.
the battery. If level is low contact V.A.G
To prevent any possibility of short
workshop and have level corrected.
circuiting, detach battery earth wire be-
fore doing any work on the electrical
Winter driving system. When changing a bulb, it is
Winter weather is particularly hard on sufficient to switch the lamp concerned
the battery. Furthermore at low tempera- off.
On vehicles with a petrol engine the bat- tures it has only a part of the capacity
To remove the battery detach the
tery is under the righthand seat. It can be it has at normal temperatures. We re-
minus wire first and then the plus wire.
reached when seat is pushed fully for- commend therefore that the battery
Then remove retainer. To install, reverse
ward. should be checked in a V.A.G workshop
the sequence.
before the onset of cold weather and
On vehicles with a Diesel engine the bat- Never run the engine with the battery
charged if necessary. This will not only
tery is on the righthand side of the engine disconnected as this will damage the
result in quicker, more reliable starting
compartment. electrical system (electronic compo-
but will help to prolong the life of the
The 2nd battery* is under the lefthand battery. nents).
seat. It can be reached by pushing the Both terminals must be taken off
seat fully forward. Caution
before the battery is given a quick
Battery acid is corrosive and must charge while in the vehicle.
not get into the eyes or on to skin and
clothes. Any acid splashes must be Starting by connecting an additional
washed off thoroughly with water. See a battery is described in the Do-it-yourself
doctor if necessary. section.

WHEELS
Wheels and tyres are important design also affect the vehicle under the Con- Keep grease, oil and fuel off the tyres.
eatures. The wheels and tyres approved
f struction and Use regulations. Replace missing dust caps as soon as
by us are specially matched to the model If wheel trim discs are subsequently possible.
concerned and contribute largely to the installed, ensure that the air flow re-
excellent roadholding and safe driving Mark wheels before taking them off
mains adequate to cool the brakes. so that they rotate in the same direction
characteristics.
V.A.G workshops are fully informed ab- when put back.
If you wish to fit your car with non- out the possible conversions of tyres,
standard wheels or tyres please note: When taken off, the tyres should be
wheels and wheel trims. stored in a cool, dry and preferably dark
For technical reasons it is not pos- General notes place. Tyres which are not on wheels
sible in every case to use wheels from should be stored in a vertical position.
other vehicles - in certain conditions Check tyres for damage from time to
not even wheels from the same vehicle time and remove any foreign bodies em-
New tyres
model. bedded in treads.
To avoid damage to tyres and wheels New tyres do not give maximum grip
Wheels and wheel bolts are match- straight away and should therefore be
ed to one another. drive over curbs and similar obstacles
run in at moderate speeds for about the
very slowly and as nearly at right angles
On changing to a different type of wheel first 100 km. This will help to make the
as possible.
(e.g. alloy wheels or wheels with winter tyres last longer.
tyres) the correct bolt with the proper If you think that a wheel is damaged,
length and conical shape must be used. it must be checked by a V.A.G workshop.
The security of the wheels and the
functioning of the brake system depend
on this.
Using types of wheel and/or tyre
which have not been approved by us
for your vehicle model can be detrimen-
tal to the safety of the vehicle. It can

Tyre wear Mode of driving

Tyre life depends to a considerable ex- Fast cornering, hard acceleration and
tent on the following factors: violent braking also increase tyre wear.
Inflation pressure Incorrect wheel alignment
Pressure which are too high or too low Incorrect wheel alignment not only
shorten tyre life - quite apart from the causes excessive, usually uneven tyre
detrimental influence on vehicle handl- wear but can also impair the car's safe
ing. handling. If unusual tyre wear is noticed,
contact a V.A.G workshop.
At continuous high speeds a tyre in
which the pressure is too low flexes Wear indicators
more and heats up excessively. This can At the bottom of the tread of the original
cause tread separation and tyre blow tyres there are 1.6 mm high "wear indi-
out. cators" running across the tread - see speeds on wet roads and the vehicle
In addition low tyre pressures increase Fig. There are 6 - 8 of these indicators - tends to aquaplane sooner, it is advisable
the fuel consumption. according to make - evenly spaced not to let the tyres wear down so far.
round the tyre circumference. Marks on
The inflation pressures should therefore
the flanks of the tyre (for example the
be checked twice a month and always
letters "IWI" or triangles) show the lo-
before a long trip, not forgetting the
cations of the wear indicators.
spare wheel. Always check pressures
when tyres are cold. When warm, the When tread depth is down to 1 mm -
pressure is higher but do not reduce. The measured at any point on the tread - the
pressures are given on page 116 and on official permissible minimum tread depth
left door pillar between the hinges. has been reached (in export countries
this figure may differ).
As worn tyres cannot grip the road
surface properly when driving at high

OPERATING INSTRUCTION
Replacing tyres Balancing wheels

For safety reasons the tyres should The wheels on new vehicles are balanc-
if ^
be replaced in pairs and not singly. The ed. However when vehicle is running,
tyres with the deepest tread should al- various influences can cause wheels to
ways be on the front wheels. become unbalanced and this causes
steering vibration.
Only radial ply tyres of the same type,
size and the same tread pattern may be As imbalance also increases steering,
combined. suspension and tyre wear the wheels
should be balanced again.
For safety reasons a new rubber
valve should be fitted when a new tube- Furthermore a wheel should always be
|B43-155| less tyre has been installed. rebalanced when the tyre has been re-
Tubes should only be used in tube- paired or when a new tyre has been
less tyres in an emergency. fitted.
Changing wheels round
I the tyres are wearing unevenly, it is When this is done, ensure that the air
advisable to change them round as trapped between tube and tyre can
;^own. All the tyres will then last for escape from the valve.
aoout the same mileage. Repairing tyres calls for special equip-
.'.hen the wheels have been changed ment and knowledge and should there-
'3und it may be necessary to have the fore only be done by a specialist.
-ont wheels balanced again.

Winter tyres Snow chains
-. winter conditions, the handling of the Snow chains may be fitted on the rear
vehicle including four wheel drive ve- wheels only. Only thin chains which do
nicles - can be improved by winter tyres. not stand clear more than 15 mm (in-
When fitting winter tyres, note the follow- cluding tensioner) should be used.
ing: When driving over roads which are free
Only radial ply winter tyres should be of snow you should remove the chains.
used. The factory recommended tyre On such roads they are detrimental to
sizes are given on page 116. vehicle handling, damage the tyres and
wear out quickly.
With winter tyres, the PR figures on
the sidewalls should also be noted. The In Germany the maximum, permissible
tyres must not be below the specified speed with snow chains is 50 km/h.
carcass strength. The following should also be noted on
To obtain the best possible handling Transporter/Caravelle syncro vehicles:
characteristics, winter tyres must be fitt- Snow chains should, where possible, be
ed on all four wheels. fitted on all four wheels. If only two
Winter tyres are no longer fully effec- chains are available they must be fitted
tive when rhe tread has worn down to a on the rear wheels.
depth of 4 mm.

EMISSION CONTROL SYSTEM*
- e n vehicle is u s e d normally there is To e n s u r e that the catalyst is not d a m a g -

- : v i n g s p e c i a l to b e noted - apart f r o m ed by overheating, the following points
: _~:ng leadfree petrol in the tank - s e e must also be noted:
r. 9 i " o n p a g e 63. In certain e x c e p t i o n a l
The vehicle must not be started by
: ' : u m s t a n c e s the following points
towing.
s - : u l d h o w e v e r be o b s e r v e d for safety
T=sons: The ignition must not be switched off
as long as vehicle is rolling with a gear
I _e to the high t e m p e r a t u r e s w h i c h o c -
engaged.
in the catalyst, the vehicle should not
r e driven or p a r k e d over easily inflamm- If a defect occurs in the ignition
iz.e materials (e.g. dry grass or leaves). system when driving (can be recogniz-
ed by misfiring, uneven engine running,
Additional heat shields are fitted over
loss of power) the speed must be re-
"-e catalyst. U n d e r b o d y sealant must not
duced immediately. The defect should
applied to these shields, the catalyst
be eliminated in the next V.A.G work-
: ' the exhaust pipes.
shop.
In t h e s e conditions, unburnt petrol c a n
get into the catalyst a n d be burned
there.
A functional description of the e m i s s i o n
control s y s t e m is given o n p a g e 106.

DIFFICULT OPERATING CONDITIONS, DRIVING ABROAD
The vehicle construction and equipment If the vehicle is to be taken abroad, the When the vehicle is used in a country
is designed for normal operating con- following must also be born in mind: which drives on the opposite side of the
ditions. This also applies to the frequency In many countries there is a large net- road to the home country the wedge
and the extent of the maintenance laid work of V.A.G workshops where your shaped areas on the headlight lenses
down in the maintenance schedule. vehicle can be serviced. Despite this must be masked - see page 100.
If the vehicle is used in difficult operat- there are certain countries in which there
ing conditions (e.g. continuous trailer is only a limited amount of V.A.G service
towing, exceptionally high or low ambient or even none at all.
temperatures, very dusty conditions,
In certain countries it is also possible
poor quality fuel, etc.) it may be neces-
that your vehicle model is not sold so that
sary to carry out special technical pre-
certain spare parts are not available for
parations, such as using oil of the appro-
your vehicle or that the V.A.G personnel
priate viscosity, installing special air clea-
is not familiar with the repair procedure
ners (cyclone filters), modifying the igni-
should anything go wrong.
tion timing etc. Furthermore the mainten-
ance must also be matched to the ope- The Volkswagen factory or the Importer
rating conditions. concerned will be only too pleased to
give advice on the necessary technical
preparation of the vehicle, on the main-
tenance required and on the repair pos-
sibilities.
The addresses are given in the vehicle
wallet.

AND MAINTENANCE
CAR CARE
-egular and careful care helps to main- Washing Waxing

tain the value of the vehicle. The best protection against environmen- Wax as often as possible. This will pre-
:jrthermore it can be one of the stipu- tal influences is frequent washing and vent dirt from sticking to the paint and
ations for the upholding of warranty waxing. industrial grime from penetrating into the
: aims should corrosion damage and paint.
After the period when salt is put on the
:aint defects occur. roads, the underside of the vehicle
E. ery V.A.G workshop carries stocks of
r should always be washed thoroughly. Polishing
citable car care materials. The instruc- The longer salt, road dust, industrial Should only be done if paint has lost its
I ons for use on the container should be grime, insects and bird droppings etc. shine and gloss cannot be brought back
*:Ilowed. are left on the paintwork the more da- with wax. If the polish used does not
mage they are liable to do to the finish. contain preservative compounds, the
Caution
paint must be waxed afterwards.
These materials can be injurious to When the load compartment has been
-ealth if misused and should be kept cleaned, the sliding door hinges or the Matt painted and plastic parts should
out of reach of children. side board hinges must be regreased. not be treated with wax or polish.
When vehicle is washed with a hose, do

not point the jet of water directly at the
lock cylinders - otherwise they will freeze
up in winter.
Tar spots, traces of oil, industrial griime,
insects, etc. cannot always be removed
by washing. As they damage the paint if
left on too long they should be removed
as soon as possible with a suitable pre-
paration.

CARE AND MAINTENANCE
Touching up paint damage Cleaning windows Door, lid and window weatherstrips
Small marks in the paint s u c h as T r a c e s of rubber, oil, grease or silicone The weatherstrips will remain flexible
s c r a t c h e s or stone d a m a g e s h o u l d be c a n be r e m o v e d with w i n d o w cleaner or and last longer if they are rubbed lightly
t o u c h e d up immediately with paint a silicone remover. with a rubber protective c o m p o u n d from
(Volkswagen t o u c h -u p brushes or spray time to time. This will also stop the
Do not dry the w i n d o w s with the leather
cans) before the metal starts to rust. weatherstrips freezing on in the winter.
u s e d for the paintwork b e c a u s e traces of
However, s h o u l d rust be f ou nd at any paint c l e a n e r will c a u s e streaks to a p p e a r Cleaning plastic
time it must be r e m o v e d thoroughly and on the glass.
If normal w a s hing is not sufficient, plastic
then the area treated first with an anti-
The windscreen wiper blades should be parts and leatherette may only be c l e a n -
c o r r o s i o n primer and then the c o r r e c t
c l e a n e d regularly and new blades fitted ed with s p e c i a l plastic c l e a n e r s.
paint applied.
o n c e or twice a year a c c o r d i n g to c o n -
Cleaning cloth upholstery
Y o u c a n of c o u r s e have this work do ne dition.
by any V . A . G w o r k s h o p . Upholstery cloth and similar materials
To avoid d a m a g i n g the heating element
must be c l e a n e d with s p e c i a l c l e a n e r s or
The nu mb e r of the original vehicle paint wires in the rear w i n d o w do not put
dry f o a m and a soft brush.
is given on the data sticker (see page 124). stickers over the wires on the inside.

CARE AND MAINTENANCE
Care of chromed parts Cleaning seat belts Alloy wheels

=eiove spots and marks with a chrome Keep belts clean because they may not In order to maintain the smart appear-
eteaner. A chrome protective compound retract properly if very dirty. ance of alloy wheels for a long period,
can be applied to give long-term protec- Dirty belts can be cleaned by washing regular care is necessary. In particular,
lon. Ensure that the chromed parts are with a mild soap solution without taking salt and brake pad dust must be washed
ccvered completely and uniformly with the belts out of the vehicle. off thoroughly at least every two weeks
r e compound. otherwise the surface of the alloy will be
Do not have the belts cleaned chemically damaged. After being washed, the wheels
because the cleaning compounds da- should be treated with an acid-free
mage the webbing material. Ensure that cleaner for alloy wheels. About every
the belts do not come into contact with three months it is necessary to give the
corrosive fluids. wheels a good rubbing with hard wax.
Inertia reel belts should be completely Paint polish or other abrasive solutions
dry before they are allowed to roll up. must not be used.
If the protective paint coat has been
damaged, e.g. by stone impact, the dam-
aged spots should be dealt with as soon
as possible.

C A R E AND MAINTENANCE
Cleaning and anti-corrosion treat- Undercoating Cavity preservation

ment of engine compartment The underside of the vehicle is coated Various cavities in the body are also pro-
The engine compartment and the out- with a special compound to protect it tected against corrosion and this protec-
side surface of the power unit are given from chemical and mechanical influen- tion can be intensified by repetition of
anti-corrosion treatment at the factory. ces. the preservation.
If the engine compartment is cleaned at However, as this protective layer gets The best results are obtained when the
any time with grease removing solu- damaged when the vehicle is in use, the first subsequent treatment is done about
tions'* or if one has the engine washed, coating under the body and on the runn- one year after the vehicle is put on the
the anti-corrosion compound is nearly ing gear should be examined at certain road.
always removed as well. It is therefore intervals - preferably before and after
All V.A.G workshops know how and
essential to ask for durable preservation the winter season - and any damage
where this treatment has to be carried
of all surfaces, seams, joints and compo- made good.
out and have the factory approved com-
nents in the engine compartment to be Every V.A.G workshop has stocks of the pound and the equipment required.
carried out. This applies also when corro- correct compound, has the necessary
sion protected parts are renewed. equipment and is familiar with the appli-
Every V.A.G dealer has stocks of the cation procedure. We advice you there-
cleaning and preservation solutions re- fore to have the patching up or additional
commended by the factory for this pur- coating done by a V.A.G workshop.
pose and has the equipment necessary
to apply them. Note for vehicles with a catalyst
Due to the high temperatures which
occor in the afterburning process, ad-
ditional heat shields are fitted over the
catalyst. Underbody sealant must not
be applied to these shields, the catalyst
or the exhaust pipes.
11 Only the correct cleaning solutions may be

88 www.WestfaliaT3.info - a useful
used - on no account petrol website for owners and enthusiasts of VW Westfalia T25 / T3 / Vanagon Campervans
or Diesel.

MAINTENANCE
- 5 the vehicle is fitted with modern low carried out between the intervals given Complete proof of servicing by a V.A.G
-aintenance technical components only in the service schedule. workshop can be one of the stipulations
small amount of regular servicing is re- for the upholding of any warranty claims
This applies in particular to:
red in order to maintain the roadwor- during the one year warranty period.
riness, economy and-reliability. Changing the engine oil
Safety regulations and anti-pollution
_~ e inspection service offered by the Cleaning or changing the air cleaner laws place very strict limits on the
. A.G workshop takes into account to a element amount of repairs and adjustments to en-
= -ge extent the individual annual mileage Lubricating the hinges of sliding and gine and running gear parts which can be
::vered and helps thus to keep the Double Cab doors, dropsides, locker lid done by the owner, By tinkering with
::sts as low as possible. The service and rear doors. parts which affect the safety of a motor
: :nedule supplied with the vehicle shows vehicle one can endanger oneself and
"at has to be done and when. Draining water from or renewing the other road users.
fuel filter on the Diesel engine.
- difficult operating conditions, e.g. ex- In addition, altering the settings of the
'emely low ambient temperatures, very The service operations should be carried carburetor or fuel injection system, igni-
S t y conditions, building site work, etc. out in a V.A.G workshop because this tion or valves, changes the emission
:e-tain service operations should be work requires special knowledge, work- values and also increases the fuel con-
shop appliances and special tools. Fur- sumption.
thermore this work must be done in
accordance with our instructions.

C A R E AND M AINTEN A N C
LIFTING VEHICLE
Vehicle hoist
Before driving over a vehicle hoist en-
sure that there is sufficient clearance
between hoist and low parts of vehicle.
The vehicle may only be lifted at the
points shown here.
Trolley jack
The vehicle should also only be lifted
with a trolley jack at the points shown
here.
To prevent damage it is essential to use
a suitable piece of rubber or wooden Lifting points for hoist and trolley jack.
packing.
Front Rear
On no account should the vehicle be
At the front jacking point (see Fig.) At rear cross member (see Fig
lifted under the engine sump, gearbox,
rear axle or the front axle as this can
cause serious damage.
Vehicle jack
Using the jack is described on the follow-
ing pages.

DO-IT-YOURSELF
HRST AID KIT, WARNING TRIANGLE TOOLS, JACK
The First Aid kit and triangle can be The jack and tools are located under
stowed under the drivers seat. the drivers seat. They can be taken out
when the seat is pushed fully forward
Note
and the cover underneath lifted up.
The First Aid kit and triangle are not part
:* vehicle equipment. On vehicles with a second battery or a
swivelling seat, the tools and jack are
located either behind the driver's seat or
under the rear seat, depending on ar-
rangement of seats in passenger com-
partment. The trim under the rear seat
can be pulled out to the front.
The screwdriver blade is reversible.

DO-IT-YOURSELF
SPARE WHEEL
The spare wheel in luggage compart-

ment is bolted to the left side panel.
To remove wheel, take bolt out by hand.
For safety reasons the spare wheel must
always be bolted securely to side panel
when vehicle is moving.
The spare wheel is either located on a vehicle before removing the spare wheel.
hinged pan under front of body or at If necessary the front can be lifted slight-
rear in luggage compartment. ly with the jack or the spoiler taken off.
To take wheel under body out, remove To stow spare wheel, place it on the pan
bolt with wheel nut spanner and pull with offset downwards and swing pan up
hook away (left Fig.). until hook engages. Then insert bolt and
tighten it.
Caution: Keep clear as the pan falls
down. Danger of injury. For safety reasons the pan must al-
Then pull wheel forward off the pan. ways be bolted in position so that it
cannot release accidentally.
On vehicles with a front spoiler, it may
be necessary to take weight off front of

CHANGING WHEELS
Insert jack into the appropriate lift- Notes

ing socket (Fig.) as far as possible. If W h e n a w h e e l has b e e n c h a n g e d , the
necessary, clean the socket before- pressure in the w h e e l which has been
hand. Place jack vertically. fitted and the tightening torque of the
If ground is soft, place a large strong w h e e l bolts should be c h e c k e d as s o o n
piece of p a c k i n g under the jack b a s e as possible. U s e a torque s p a n n e r for
plate. the bolts. The torque for the w h e e l s
supplied by the factory is 170 N m (17
Lift vehicle until the w h e e l is clear of kgm).
j B25-319 | the ground.
Caution
R e m o v e bolt/nuts and take wheel off.
The jack supplied by the factory is only
Fit s p a r e w h e e l and tighten bolts/nuts designed to lift your vehicle model. On
lightly first. no account should heavier vehicles or
Apply h a n d b r a k e firmly. If the car is To ensure that the wheel is secured other loads be lifted. Do not work un-
: I a slope, p l a c e a stone or s o m e similar properly the contact surfaces for the der the vehicle when it is on the jack.
zzect behind one of the w h e e l s on the wheel hub or drum and for the wheel
: : o o s i t e side.
If the vehicle is to be subsequently
nuts/bolts must not be dirty or rusty. fitted with wheels or tyres which differ
~"~e wheel trim c a p s are r e m o v e d with L o w e r vehicle to ground and tighten from those fitted by the factory, it is
r e bar a n d wire hook: the bolts/nuts in a diagonal s e q u e n c e . essential to read the remarks on page
ace hook in the two holes on e d g e 79.
:
Install trim c a p .
:~ cap, insert bar through hook and lever
off.
L o o s e n wheel nuts/bolts with box
scanner and bar approximately o n e turn.

-YOURSELF
FUSES
The individual current circuits are pro- Changing a fuse Notes

vided with fuses.
Switch off the component concerned. If the newly inserted fuse blows again
The fuses are located on left under the after a short time, the electrical system
With the aid of the list of fuses, find
dash. must be checked by a V.A.G workshop
out which fuse belongs to the compo-
nent which has failed. as soon as possible.
Pull out the blown fuse with the plas- On no account should fuses be
tic clip (located on the cover in front patched up because this can cause
of fuse box). serious damage elsewhere in the electri-
cal system.
Replace blown fuse - can be recog-
nised by the burnt metal strip - with a
fuse of same capacity.
Spare fuses can be inserted on the un-
derside of the fuse box. These fuses can
be obtained from a V.A.G workshop.

DO-IT-YOURSELF
= use layout
"om left to right)
' 13. Component Amp.
Radiator fan 30 17 Windscreen wiper 10 Additional fuses in holders
2 Brake lights 10 18 Brake warning lamp, under right rear seat:
3 Reading lamps, interior heated driving seat 10 Amp.
lights, illuminated make-up 19 Turn signals 10 Reading lamp, right 8
mirror, clock 15 20 Number plate light, Boot lights 8
A
Emergency light system 15 headlight washer 10 16
Electrically adjustable seat right
5 Vacant 21 Low beam right 10 16
Electrically adjustable seat left
5 Fog lights 15 22 Low beam left 10
7 Tail and side light left 10 above fuse box:
B Tail and side light right 10 Instrument lighting 10
9 Headlamp right 10 Rear fog light 10
-3 Headlamp left 10 Overheating fuse for
"1 Windscreen washer 15 auxiliary heater 10
"2 Rear window wiper 15 Main fuse for
or rotating auxiliary heater 20
emergency light, Emergency horn 15
cruise control system 30 Central locking 20
"3 Rear window heating, Automatic fuse for
fresh air blower 25 electric windows 20
"4 Additional heat exchanger,
light for lighting switch 20 In engine compartment on left in
'5 Reversing lights 15 black box.
16 Dual tone horn 15 Diesel glow plugs' 50.
i) This fuse should only be renewed by a

V.A.G workshop.
95

CHANGING BULBS
Before starting to replace a bulb, switch

off the light concerned.
Do not touch the glass part of the new
bulb with bare fingers because the finger
marks left on the glass evaporate when
the bulb gets hot, the vapour settles on
the reflector and dims it.
Always use the same type of bulb. The
designation is marked on the base of the
bulb.
It is advisable to always carry a box of
spare bulbs in the vehicle. This can be
obtained from any V.A.G dealer.
Headlight
For safety reasons this box should con-
To change a headlight bulb or side light
tain the following bulbs.
bulb the headlight must be taken out:
12 V 45/40 W - Normal headlights
Turn 5 quick-release clips in upper grille
12 V 60/55 W - H 4 headlights
90 with a screw-driver. Pull grille for-
12 V 4 W - Side lights and
ward slightly at the top and lift it out.
license plate light
Then remove 3 screws (see Fig.) and
12 V 10 W - Taillight
take headlight out.
12 V 2 W - Stoplight and turn
signal

mmmt O-IT-YOURSELF
Side light bulb

The side light bulbs are l o c a t e d in the
headlight reflectors.
Turn bulb holder fully to the left and
take it out of reflector.
Press defective bulb into holder turn
it to left and take it out.
Insert new bulb.
Insert bulb holder in reflector and turn
holder fully to the right.
Normal headlight bulb H4 headlight bulb
Headlight bulb
(Normal and H a l o g e n H 4) Install ring, press it against reflector
and turn it to right as far as possible,
Pull c o n n e c t o r off.
or fold spring clip over bulb base.
Take c a p off. S q u e e z e clip together and e n g a g e it in
Turn ring to left and take it off or the retaining lugs.
s q u e e z e spring clip of the bulb holder Press c a p b a c k on.
together and fold it clear.
Attach c o n n e c t o r .
Take bulb out and insert new bulb so
Install headlight and air intake grille
that the locating lug on the bulb plate
again.
engages the r e c e s s in the reflector. The
centre of the three terminals on bulb Have headlight beam alignment
base is then at the top. checked.

DO-IT-YOURSELF
Headlight bulb (H3)* Fog lights (H3)* Rear lights

(Inner headlight on vehicles with dual Remove screw on underside of fog Remove screws and take off lens and
headlights.) light bulb holder.
Turn cap to left and take off. Take insert out. Squeeze tabs together and take hol-
der out. (On some versions there is only
Pull wire connector off. Pull wire for bulb out of cable connec- one tab.)
tor.
Unhook spring clip holding bulb and Press bulb in, turn it to left and take
swing it away. Unhook spring clip and fold it away. it out.
Take bulb out and insert new bulb so Take bulb out. Insert new bulb so that Fit new bulb.
that the locating lug on bulb plate en- locating lug on reflector engages recess
gages recess in reflector. on bulb plate. Install holder - tabs must engage -
and install screws.
Swing spring clip over bulb plate. Swing clip over bulb plate. Squeeze
Squeeze clip together and engage it in ends together and engage in retaining Front turn signals
the retaining lugs. lugs.
Take lens off.
Attach wire again. Insert bulb wire in cable connector.
Pull rubber cap off.
Install cap and turn to right. Install insert - upper side first - in the
housing and secure with screw. Press tab on bulb holder inwards and
Have headlight setting checked. take holder out of housing.
Have setting of light checked.
Turn bulb slightly to left and renew.
Press rubber cap on again carefully
and install lens.

DO-IT-YOURSELF
Number plate light Reading lamps* Interior light in front of passenger

"he number plate lights are pushed into seat, step light, boot lights.*
Lever adjusting ring out at side recess
:ne cross panel from the rear. with flat blade of screwdriver. Lever glass out at side with flat screw-
Press lugs together and pull light Press bulb into fitting slightly, turn it driver blade.
-.ousing out to the rear. to right and take it out. Change bulb.
Remove lens. Install new bulb. Press glass into the trim again.
Press bulb into holder, turn it to the Fit adjusting ring so that recesses in
eft and renew it. ring are in line with those on lamp hous-
Install lens. ing.
Ensure that the lug in the lens engages Press adjusting ring on.
:he opening in the bulb-holder as other-
wise the number plate will not be illumi- Table light*
nated properly.
Push flat screwdriver blade behind
Do not overlighten lens screws. light housing on left so that the spring
Install light again. Ensure that housing behind it is pushed to one side and then
fits over the metal tab at the top and en- lever housing off.
gages the hole in cross panel at the front. Pull reflector out.
Change bulb.
Interior light
Insert reflector again.
Press retaining spring at opposite
end to switch inwards and take light out. Push lug on right of lamp housing
behind trim on right first and then press
Renew bulb. light on.
Insert light at switch end first.

ADJUSTING HEADLIGHTS MASKING HEADLIGHTS
Correct headlight adjustment is very im- The illustrations show the adjusting When the vehicle is used in a country
portant for vehicle and traffic safety. The screws for the right headlight. The screws which drives on the opposite side of the
adjustment should therefore only be for the left headlight are symmetrically road to the hpme country, the asym-
done with a special appliance. opposite. metric headlights will dazzle oncoming
traffic.
The headlights are adjusted from the A - Lateral setting
front through the grille with a Phillips B - Vertical setting To prevent this, the wedge-shaped sec-
screwdriver. tor on the headlight lenses must be co-
Turning screw to right lowers the vered up with an opaque adhesive strip.
headlight beam.
The illustration shows the strip installed
for the change from right hand to left
hand traffic.

SSTALLING OR REPLACING A RADIO SET
-e following points should be noted

-en installing a radio set:
It is advisable to use radio sets from The wiring is already installed at the
:~e V.A.G Accessory programme as well radio fitting location. The plug on this
as the fitting kits, aerials and suppression wiring loom fits all radio sets in the
sets which have been specially deve- V.A.G Accessory Programme which have
sted for the individual vehicle model a separate connection for the scale
and are available from all V.A.G work- lighting.
t o p s . These parts are supplied with Radio sets with other connections must
:etailed fitting instructions. be connected with an adapter wire which
"he use of other parts or parts from the can also be obtained from V.A.G work-
crevious models may cause faulty ope- shops. If the adapter wire is not used or
-ation of the system. Furthermore the if wires are cut off and left without insu-
istallation of non-approved suppres- lation there is a risk of short circuiting.
sion sets can affect the registration of This can cause the wiring to burn out.
the vehicle under the Construction and
Jse regulations, in cases of doubt V.A.G
.vorkshops will advise.
When installing the aerial it is essen-
tial to ensure that the hole provided by
the factory where the aerial enters the
Dody is sealed very carefully. In addition
the aerial cable, the connecting wires
and loudspeaker wires must be routed
so that they cannot chafe, rattle or get
tangled up with moving parts (e.g. pedals,
steering, heating controls etc.). Other-
wise the operation of the controls may
be affected or vehicle safety impaired.

EMERGENCY STARTING
The j u m p e r c a b l e s must be heavy Do not c o n n e c t the cable to the battery

e n o u g h to carry the load. Note cable minus terminal. The sparks c o u l d ignite
manufacturer's data. the explosive gas flowing out of the
battery.
A flat battery c a n freeze at - 1 0 C
and if a battery is frozen it must be Take great care to ensure that the
thawed out before c o n n e c t i n g a jumper jumper cable clips do not touch one
c a b l e as otherwise it c o u l d e x p l o d e . another and that the plus cable does
not touch current conducting vehicle
There must be no c o n t a c t between
parts - short circuit danger.
the vehicles as otherwise current c a n
flow as s o o n as the plus terminals are Caution
connected.
|B43-174| Do not stand with your face over
The flat battery must be properly c o n - the battery - danger of acid burns.
n e c t e d to the electrical s y s t e m .
A - Flat battery Route the jumper c a b l e s s o that they
B - Boosting battery The engine of the boosting vehicle cannot c o m e into c o n t a c t with rotating
must be running. parts in the engine compartment.
The battery is under the righthand seat
in the c a b . C o n n e c t jumper c a b l e s only as fol- Start the engine as d e s c r i b e d in the
lows: "Starting and S t o p p i n g Engine" section.
O n vehicles with a Diesel engine it is in
the engine compartment. 1. O n e e n d of (+) c a b l e (usually red) to W h e n engine is running, d i s c o n n e c t
the (+) terminal of flat battery. c a b l e s in reverse s e q u e n c e .
If the engine will not start b e c a u s e the
2. Other end of red c a b l e to (+) terminal
battery is flat, jumper cables c a n be Note for vehicles with catalyst
of boosting battery.
c o n n e c t e d to the battery of another The engine must not be started by towing
3. O n e end of (-) c a b l e (usually black)
vehicle to start the engine. The following the vehicle as otherwise unburnt petrol
to () terminal of boosting battery.
points should be noted: c a n get into the catalyst and be burned
4. Other end of black cable (x) to the
Both batteries must be 12 Volt types. bolt s e c u r i n g earth wire to body. there - s e e also page 106.
The c a p a c i t y (Ah) of the boosting battery
must not be a lot lower than that of the
flat one.

DO-IT-YOURSELF
TOWING
owing eyes are provided on the right If your vehicle has to be towed at any If the vehicle has an automatic gearbox
jnder front and rear bumpers. time note the following points. the following additional points must also
Check whether there are any local be noted:
Towropes or bars should be attached at
:hese points only. traffic regulations concerning the towing Selector lever at "N".
Avoid excessive towing effort and do not of vehicles. Do not have vehicle towed faster than
jerk. During towing operations on other Turn ignition key to "Drive" position 30 mph (50 km/h).
than surfaced roads there is always the so that the steering wheel is free and the Do not tow further than 30 miles (50
danger that the attachment points on the turn signals, horn, and, if necessary, the kilometers).
body will be overloaded and damaged. windscreen wiper and washer can be
used. If the vehicle has to be towed long dis-
Note the following also when using a tances it must be lifted at the rear.
towrope: As the brake servo only works when
the engine is running, more pressure is Reason: When the engine is not running,
The driver of the towing vehicle must en- the gearbox oil pump is not working and
required on the brake pedal when the
gage the clutch very smoothly when the gearbox is not adequately lubricated
engine is not running.
moving off or changing gear. The driver for high speeds or long distances.
of the vehicle being towed must keep When there is no lubricant in the ma-
the towrope taut. nual or automatic gearbox the vehicle Emergency starting - see page 27.
may only be towed with driving wheels The following should also be noted on
The towrope should be slightly elastic to
lifted. four wheel drive vehicles:
reduce the risk of damage to both ve-
hicles. It is advisable to use only ropes If the vehicle has to be towed with either
of synthetic materials or with elastic front or rear axle lifted, one must ensure
links. that the wheels on the raised axle are
free to rotate.

ICAL DESCRIPTION
ENGINE POWER TRANSMISSION
Petrol engines Dry air c l e a n e r with paper element, Manual gearbox

c y c l o n e filter for very dusty c o u n t r i e s *
4 stroke petrol engine M e c h a n i c a l l y or hydraulically operat-
4 cylinder horizontally o p p o s e d ed single plate clutch
L o n g life spark plugs
Cast-iron cylinders Baulk s y n c h r o n i z e d four or five s p e e d
Optical a n d a c o u s t i c oil pressure
manual gearbox with final drive in o n e
4 bearing crankshaft monitor*
housing
Light alloy cylinder h e a d s
Diesel engines Filled for life.
Light alloy c r a n k c a s e
Four stroke Diesel engine, installed Rear wheel drive
Valves o p e r a t e d via push rods and longitudinally, inclined 50
rocker arms Transporter/Caravelle syncro
4 cylinders in line
M a i n t e n a n c e free valve gear with Baulk s y n c h r o n i s e d 4 - s p e e d manual
C a s t iron block
hydraulic tappets gearbox with additional c r o s s country
5 bearing crankshaft gear (4+G gearbox).
C o o l i n g s y s t e m filled for life of vehicle
Sheet metal s u m p Permanent four-wheel drive through
Radiator with separate expansion
tank v i s c o u s coupling, m e c h a n i c a l l y e n g a g e -
Light alloy cylinder head
able four-wheel drive available as op-
Electric radiator fan controlled by Valves operated by o v e r h e a d c a m - tional extra.
thermo switch shaft, toothed belt drive
Manually o p e r a t e d differential locks
L o w aintenance electronic ignition Liquid cooling for front a n d / o r rear final drives avail-
system. able as optional extra.
Radiator with separate expansion
Single or twin c h o k e d o w n draft car- tank
buretor (44 and 57 k W engines) Automatic g e a r b o x *
T h e r m o s w i t c h controlled electric fan H y d r o - d y n a m i c torque converter and
Petrol injection s y s t e m * with over- planetary gear train with three forward
M e c h a n i c a l fuel injection
run fuel cut-off s p e e d s and reverse
Distributor type injection p u m p with
Emission control s y s t e m * Final drive flanged on
c o l d starting aid, exhaust turbocharger
Thermostatically, controlled intake air on 51 k W engine Rear wheel drive
preheating and electrical mixture pre-
Dry air cleaner with paper element. Filled for life.
heating.

DESCRIPTION
STEERING/AXLES BRAKES BODY
Steering Hydraulic dual circuit brakes Unitary b o d y / c h a s s i s

M a i n t e n a n c e free rack a n d pinion Disc brakes at front Floor frame reinforced by side a n d
steering with relay idler cross members
Self-adjusting drums at rear with re-
Safety steering c o l u m n tardation-sensitive pressure regulator
Power assisted s t e e r i n g * Brake servo
M e c h a n i c a l h a n d b r a k e effective on
Front axle
rear wheels
Independent w h e e l s u s p e n s i o n with
,vishbones/track control arms, coil
springs a n d t e l e s c o p i c d a m p e r s
Anti-roll bar
Additional on Transporter/Ca ravel I e

syncro
D o u b l e jointed shafts
Differential l o c k *
V i s c o u s coupling
Rear axle
Independent s u s p e n s i o n with diago-
nal trailing arms, coil springs a n d tele-
scopic dampers
D o u b l e jointed drive shafts
Additional on Transporter/Caraveile
syncro
Differential l o c k *

tdtf.HMijji.i*H;ii:Mi
EMISSION CONTROL SYSTEM*
Functional description
The e m i s s i o n control s y s t e m effectively
r e d u c e s the amount of pollutants in the
exhaust gas. The s y s t e m is so d e s i g n e d
that it requires no additional mainten-
a n c e . With normal vehicle use, no s p e -
cial operating instructions need be ob-
s e r v e d - apart from filling the tank with
leadfree petrol. Only in certain e x c e p -
tional c a s e s is it n e c e s s a r y , for safety
reasons, to note a few points - s e e
page 83.
The main parts of the e m i s s i o n control
s y s t e m are The catalyst is installed in the exhaust A stipulation for the proper functioning
pipe. It c o n s i s t s of a s t e e l - c a s e d c e r a m i c of the catalyst, however, is that the
an electronically controlled fuel me-
body containing a multitude of longitu- exhaust gas has a certain specific c o m -
tering s y s t e m (fuel injection)
dinal p a s s a g e s which are vapour c o a t e d position and minimum temperature w h e n
the catalyst with a thin layer of platinum or rhodium. it enters the catalyst. To obtain this
the L a m b d a probe c o m p o s i t i o n e x a c t regulation of the fuel/
The exhaust gas flows through the c a t a -
air mixture is required. O n vehicles w h i c h
lyst and reacts with an afterburning pro-
are fitted at the factory with a e m i s s i o n
c e s s w h e n it c o n t a c t s the noble metal
control s y s t e m this is d o n e with the aid
coating. In this p r o c e s s the c a r b o n m o -
of a L a m b d a probe.
noxide and h y d r o c a r b o n s are c o n v e r t e d
to harmless c a r b o n dioxide and water The L a m b d a probe is fitted in the ex-
and the o x i d e s of nitrogen are c o n v e r t e d haust pipe in front of the catalyst and
to nitrogen (four fifths of the air w e m e a s u r e s the exhaust gas c o m p o s i t i o n
breathe is nitrogen). continuously. The information signal is
fed to an electronic control unit w h i c h
in turn regulates the fuel injection s y s -
tem s o that the mixture is kept c o n -
stantly correct.

CHNICAL DESCRIPTION
Vehicles with "emission control The date for the conversion should be Vehicles without emission control
package" arranged with the V.A.G workshop well system
in advance because before the emission
.Vith the factory prepared parts and the control system is installed at least two Vehicles which have neither factory
Darts in the package supplied with the full tanks of leadfree petrol must be fitted emission control systems nor the
. ehicle for the service installation of an used in order to ensure that all traces of "package" solution can be subsequently
emission control system, it is possible leaded petrol are out of the fuel system. fitted with an emission control system.
to have the vehicle converted with little See your V.A.G workshop for details.
effort by a V.A.G workshop when ade- A specimen expertise is available from
quate supplies of leadfree petrol are the Volkswagen factory for the conver-
available. sion. After conversion, the vehicle must
be taken to an authorized testing agency
After this conversion the system is equi- (e.g. TUV in Germany) for the necessary
valent to the factory fitted version. Up to entries in the vehicle documents.
the installation of the emission control
system, leadfree or leaded petrol can be After the conversion the pollutants in the
used. The minimum octane rating is 91 exhaust gas are very effectively reduced.
RON (Regular petrol). It is however important to use only lead-
The emission control parts required for free petrol. Further details are given on
the service installation are packed in a page 63.
carton and put in the boot. The contents
of carton are:
Catalyst
Lambda probe
3 "Leadfree" stickers
Small parts
These parts are carefully packed and
protected against corrosion. The carton
should therefore be stored, unopened,
in a dry place where it cannot become
damaged.

TECHNICAL DATA
ENGINE DATA
Where not otherwise indicated all tech- Carburetor engines

nical data is for standard vehicles in 44 kW 57 kW
Germany.
For special vehicles and vehicles for Output
other countries these figures may be (DIN 70020 Part 6) kw (bhp) at rpm 44 (60)/3700 57 (78)/4600
different. Maximum torque Nm at rpm 140/2200 141/2600
Capacity cms 1913 1913
Please note that the details in the official Stroke mm 68.9 68.9
vehicle documents can be taken as the Bore mm 94 94
correct figures. Compression 8.6 8.6
Fuel') Regular Regular
Oil consumption max. litres/1000 km 1.5 1.5
Diesel engines
37 kW 51 kW
Output
(DIN 70020 Part 6) kw (bhp) at rpm 37 (50)/4200 51 (70)/4500
Maximum torque Nm at rpm 103/2000 138/2500
Capacity cms 1588 1588
Stroke mm 86.4 86.4
Bore mm 76.5 76.5
Compression 23 23
Fuel" Diesel Diesel
" For octane/Cetane ratings and further details see page 63

Petrol injection engines
66 kW 82 kW
Dutput
DIN 70020 Part 6) kw (bhp) at rpm 66 (90)/4600 82 (112)/4800
Maximum torque Nm at rpm 147/2800 174 (17.4)/2800
Dapacity cm 1913 2109
Stroke mm 68.9 76
3ore mm 94 94
Dompression 8.6 10.5
=uel >
2 Premium Premium
Dil consumption max. litres/1000 km 1.5 1.5
61 kW> 70 k W "
Output
(DIN 70020 Part 6) kW (bhp) at rpm 61 (83)/4800 70 (95)/4800
Maximum torque Nm (kgm) at rpm 143/2600 160/2800
Capacity cm 3 1913 2109
Stroke mm 68,9 76
Bore mm 94 94
Compression 8.6 9.0
Fuels' Regular leadfree Regular leadfree
" Engines with factory fitted emission control system
21For octane ratings and further details see page 63

ATA
FUEL CONSUMPTION
T h e s e c o n s u m p t i o n figures w e r e deter- The m e a s u r e m e n t s for 9 0 k m / h (56 D e p e n d i n g on driving style, road and

mined in a c c o r d a n c e with r e c o m m e n d a - mph) and traffic conditions, environmental inf-
tion A 70 of the E C E . l u e n c e s and v e h i c l e condition, the fi-
120 k m / h (75 mph) are carried out at
gures obtained in actual practice m a y
In order to obtain true-to-iife figures the a constant test s p e e d .
differ from t h o s e given in the standards.
tests are carried out in three different For the urban m e a s u r e m e n t normal
conditions:
town traffic driving is simulated.
Carburetor engines 44 k W 57 k W 57 k W s y n c r o 4 + G
4 speed 5 speed 4 speed 5 speed Automatic
gearbox gearbox gearbox gearbox gearbox
Caravelle and Combi

90 k m / h 1/100 km (mpg) 10.5 (26.9) 10.3 (27.4) 9.7 (29.1) 9.5 (29.7) 11.2 (25.2) 10.6(26.6)
120 k m / h " 1/100 km (mpg)
Urban 1/100 km (mpg) 12.9 (21.8) 11.9 (23.7) 12.8 (22.0) 13.9(20.3) 12.6 (22.4) 12.8 (22.0)
High-roofed Combi
90 k m / h 1/100 km (mpg) 11.2 (25.2) 10.8 (26.1) 10.6 (26.6) 10.2 (27.6) 12.4 (22.7)
120 km/hi) 1/100 km (mpg) 11 Figures not available at time of
Urban 1/100 km (mpg) 12.9 (21.8) 11.9 (23.7) 12.8(22.0) 13.9 (20.3) 12.6(22.4) going to press
110

T E C H N I C A L DATA
Petrol injection engines 61 kW 66 kW 70 kW 82 kW

5 speed Automatic 5 speed Automatic 5 speed Automatic 5 speed Automatic
gearbox gearbox gearbox gearbox gearbox gearbox gearbox gearbox
Caravelle and C o m b i
90 k m / h 1/100 km (mpg) 9.5 (29.7) 1 1 0 . 5 (26.9)
120 km/hi> 1/100 k m (mpg) 14.0 (20.1) 15.8 (17.8)
Urban 1/100 km (mpg) 10.9 (25.9)112.1 (23.3)
High-roofed Combi
90 k m / h 1/100 k m ( m p g ) 10.5 (26.9) 11.5 (24.5)
120 k m / h 1/100 k m (mpg) Figures not available at 16.3(17.3) Figures not available at Figures not available at
Urban 1/100 km (mpg) time of going to press 10.9 (25.9) 12.1 (23.3) time of going to press time of going to press
Caravelle Carat
90 k m / h 1/100 km (mpg) 9.6 (29.4) 10.6 (26.6)
120 k m / h 1/100 k m (mpg) 14.2 (19.8) 16.0 (17.6)
Urban 1/100 k m (mpg) 11.7 (24.1) 12.7 (22.2)
Diesel engines 37 kW 51 kW
4 speed 5 speed 4 speed 5 speed
Caravelle and C o m b i
90 k m / h 1/100 k m (mpg) 9.0(31.6) 7.7(36.6) 7.6 (37.1) 7.5 (37.6)
120 k m / h 1/100 k m (mpg)
Urban 1/100 k m (mpg) 9.0 (31.6) 10.1 (27.9) 8.0 (35.3) 6.7 (42.1)
High-roofed Combi
90 k m / h 1/100 k m (mpg) 9.7 (29.1) 8.7 (32.4) 8.2 (34.4) 8.1 (34.8)
120 k m / h 1/100 k m (mpg)
Urban 1/100 km (mpg) 9.0 (31.6) 10.1 (27.9) 8.0 (35.3) 6.7 (42.1)
111

TECH

T E C H N I C A L DATA
PERFORMANCE
The maximum speeds were measured according to DIN 70020 Part 3. Vehicle not
fitted with any equipment such as mud flaps which affects the performance.
Maximum speed 44 kW 57 kW 57 kW
approx in km/h manual gearbox automatic gearbox syncro
Carburetor engines
Caravelle, Combi, Van 118 130 125 125

^ick-up and Double Cab without cover 118 130 125 122
High roofed Van 113 125 120 120
arge platform Pick-up 115 127 122 120
61 kW 66 kW 70 kW 82 kW
Petrol injection engines 5 speed automatic 5 speed automatic 5 speed automatic 5 speed automatic
Caravelle, Combi, Van 136 133 131 133 141 136 150 146
Caravelle Carat i) i) 139 133 141 136 150 146
High roofed Van 131 126 132 127 136 131 145 141
37 kW 51 kW
Diesel engines 4 speed 5 speed 4 speed 5 speed
Caravelle, Combi, Van 103 110 127 127

Pick-up and Double Cab without cover 103 110 127 127
High roofed Van 103 105 122 122
Large platform Pick-up 103 107 124 124
Figures not available at time of going to press

1
113

tHiii;u*y.v DATA
HILL CLIMBING ABILITY
With full load on good roads driving non-

stop in 1st gear . . .
Values in %, approx.
Carburetor engines 44 kW 57 kW 47 kW syncro
4 speed 5 speed 4 speed 5 speed automatic 185 R 14 C 205 R 14 C
28 30 30 33 46 54 60
Petrol injection engines 61 kW 66 kW 70 kW 82 kW

5 speed automatic 5 speed automatic 5 speed automatic 5 speed automatic
i) 34 47 38 49
Diesel engines 36 kW 51 kW
4 speed 5 speed 4 speed 5 speed
26 26 33 32
" Figures not available at time of going to press
114

ECHNICAL DATA
SPARK PLUGS VEE BELTS
44 and 57 kW engines Petrol engines

Bcsch W7CTC With 45 and 65
Beru 14-7CTU Amp alternator: 9.5 1070 LA
Champion N4BC With 90 Amp alternator: . 9.5 1110 LA
61 and 66 kW engines Diesel engines

Bosch W7CO Crankshaft/coolant
Beru 14L-7C pump 9.5 x 643 LA
Champion N288 Coolant pump/
alternator 9.5 x 600 LA
70 kW engine
Bosch W7CCO
Beru 14L-7CU/14L-7C
Champion N288
82 kW engine
Bosch W5DTC
Beru 14-5DTU
Champion N6BYC
Electrode gap in mm 0,6-0,8
115

TECHNICAL DATA
WHEELS
Steel wheels 5'/2 J x 14 6 J x 14 If you wish to fit the vehicle with tyres
Alloy wheels 6 J x 14 6 J x 14 6 J x 14 or wheels of types different to those
fitted by the factory (e.g. alloy wheels
Tyres or wheels with winter tyres), you must
Tubeless 185 R 14 C 6 PR 185 R 14 C 205/70 R 14205/R 14 C 205 R 14 C pay attention to the instructions given
radials 6 PR/8 PR 6 PR/8 PR 6 PR/8 PR on page 79.
Recommended winter tyres/wheels: 185 R 14 C on 5V2 J x 14 wheel The most suitable combination is given
for winter tyres. Details of further tyre/
Tyre pressures wheel combinations can be obtained
in bar (psi) Front Rear Spare from your V.A.G Dealer. Further details
185 R 14 C PR on winter tyres are given on page 82.
Ambulance 2.5 (35) 2.5 (35) 2.5 (35) These pressures are for cold tyres - the
all other models 2.7 (38) 3.3 (47) 3.3 (47) pressure is higher when tyres are warm
205/70 R 14 2.1 (30) 2.5 (35) 2.5 (35) but it must not be reduced.
Syncro The tyre pressures must be checked
regularly. Correct pressures are of great
185 R 14 C importance, particularly at high speed -
6 PR/8 PR 2.8 (40) 3.3 (47) 3.3 (47) see page 80.
205/70 R 14 2.3 (33) 2.5 (35) 2.5 (35)
205 R 14 C
6 PR/8 PR 2.5 (35) 3.0 (42.5) 3.0 (42.5)
116

//EIGHTS (KG)
Unladen weight Permissible Permissible Permissible

GVW (with driver) Payload ' 2 front rear axle load roof l o a d '
4
Normal payload Petrol Diesel Petrol Diesel Petrol Diesel ' 5 axle load
/an 2390 2460 1395 1465 995 995 1200 1300 100
High R o o f e d Van
Combi
2390
2390
2460
2460
1445
1395"
1515
1465"
945
9953>
945
9953)
1200
1200
1300
1300 -
100
High R o o f e d C o m b i 2390 2460 1445" 1515" 9453> 9953) 1200 1300 -
Caravelle, C o m b i L 2390 2460 1480" 1550" 9103) 9103) 1200 1300 100
Caravelle Carat 2340 - 1730" - 610" - 1200 1300 75
Caravelie G L 2390 2360 1510" 1580" 880 880 1200 1300 100
'Joker" with pop-up roof 2340 2410 1640" 1710" 700 700 1200 1300 50
"Joker" with high roof
Ambulance
2340
2300
2410
2400
1700"
1680
1770"
1750
640
710
640
650
1200
1200
1300
1200 -
100
High roofed a m b u l a n c e
Pick-up
2390
2390
2400
2460
1900
1395
1950
1465
490
995
430
995
1200
1200
1200
1300 --
Pick-up with large platform 2390 2460 1490 1560 900 900 1200 1300 -
Double C a b 2390 2460 1480 1550 910 940 1200 1300 75
Notes
Optional extras s u c h as sliding roof, Inthe interest of good handling, g o o d s
towing bracket etc. and s e r v i c e installa- should always be carried between the
tion of a c c e s s o r i e s i n c r e a s e s the un- axles. The permissible axle a n d gross
laden weight and the payload has to be weights must not be e x c e e d e d .
r e d u c e d by this amount.
" Without driver

21On vehicles with automatic gearbox the payload is reduced by about 40 kg.
31On vehicles without seats the payload is increased by about 65 kg.
41Use only racks supported in rain channel. Load evenly and do not exceed the GVW. Further details are given on page 19.
51On vehicles with Turbo Diesel engine the payload is reduced by 15 kg.

TECHNICAL
Permissible Unladen weight Permissible Permissible Permissible

(with driver) . Payload ' 2 front rear roof load '
4
Higher payload GVW Petrol Diesel Petrol Diesel ' 5 axle load axle load
Van 2600 1395 1465 1205 1135 1300 1400 100
High Roofed Van
Combi
2600
2600
1445
1395')
1515
1465"
1155
12053)
1085
11353)
1300
1300
1400
1400
-
100
High Roofed Van
Caravelle, Combi L
2600
2600
1445"
1480H
1515"
1550"
11553>
1 1203)
10853)
10903)
1300
1300
1400
1400
-
100
Pick-up 2600 1395 1465 1205 1135 1300 1400
-
Pick-up with large platform
Double Cab
2600
2600
1490
1450
1560
1520
1110
1150
1040
1080
1300
1300
1400
1400
-75
Notes
Optional extras such as sliding roof, In the interest of good handling,
towing bracket etc. and service installa- heavy goods should always be carried
tion of accessories increases the un- between the axles. The permissible axle
laden weight and the payload has to be and gross weights must not be exceed-
reduced by this amount. ed.
11 Without driver
21 On vehicles with automatic gearbox the payload is reduced by about 40 kg.
31 On vehicles without seats the payload is increased by about 65 kg.
41 Use only racks supported in rain channel. Load evenly and do not exceed the GVW. For further details see page 19.
51 On vehicles with Turbo Diesel engine the payload is reduced by 15 kg.

CHNICAL DATA
WEIGHTS (FOUR WHEEL DRIVE)
In kg GVW Unladen weight Payload ' 2 Permissible Permissible Permissible

(with driver) front axle load rear axle load roof l o a d '
3
Van 2500 1540 960 1300 1380 100

High R o o f e d Van
Combi
2500
2500
1590
1540"
910
9602)
1300
1300
1380
1380 -
100
High R o o f e d C o m b i
Caravelle/Combi L
2500
2500
1590"
1625"
9102)
8752)
1300
1300
1380
1380 -
100
Caravelle G L 2500 1655" 845 1300 1380 100
" J o k e r " with pop-up roof 2500 1785" 715 1300 1380 50
" J o k e r " with high roof
Ambulance
2500
2500
1845"
1825
655
675
1300
1300
1380
1380 -
100
Pick-up 2500 1540 960 1300 1380 100
Pick-up with large platform 2500 1635 865 1300 1380 100
Double C a b 2500 1595 905 1300 1380 75
Notes
Optional extras s u c h as sliding roof, In the interest of g g o d handling, The payload must be r e d u c e d by
rowing bracket etc. and s e r v i c e installa- g o o d s should always be carried between 200 kg w h e n travelling cross-country.
tion of a c c e s s o r i e s i n c r e a s e s the un- the axles. The permissible axle and gross
laden weight and the payload has to be weights must not be e x c e e d e d .
r e d u c e d by this amount.
" Without driver

21On vehicles without seats the payload is increased by about 65 kg.
31Use only racks supported in rain channel. Load evenly and do not exceed the GVW.

TRAILER WEIGHTS
See also "Trailer t o w i n g " Petrol engines Diesel engine Turbo Diesel syncro
on page 57 4 speed 5 speed
gearbox gearbox Automatic
Permissible weights
Trailer with brakes,
gradients up to 12% kg 1500/1300" 1500/1300" 1500 1200/1000" 1500/1300" 2000
with special c e r t i f i c a t e '
2 kg 1800/1600i> 2000/1800" - 1400/1200" 2000/1800'*
( 1 0 % gradient)
-
Trailer without brakes kg 600 600 600 600 600 600
Permissible nose weight max. kg 50/75 >3 50/753> 50/753) 50/753) 50/753' 75
mm. 4 % of actual trailer weight
11 Vehicles with higher payload.

21 V.A.G dealers have details.
3 i With special certificate.

C H N I C A L DATA
DIMENSIONS
Height Ground Turning

with without clear- Overhang Wheel- Track circle
in mm Length Width cover cover ance" front rear base front rear in m
Van 4570 1845 1965 190 1160 950 2460 1583 1570 10.7
---
High Roofed Van 4570 1845 2365 190 1160 950 2460 1583 1570 10.7
Combi 4570 1845 1960 190 1160 950 2460 1583 1570 10.7
High Roofed Combi 4570 1845 2360 190 1160 950 2460 1583 1570 10.7
Caravelle CL, GL, Combi L
Caravelle Carat
4600
4605
1845
1845
1950
1960 -- 190
190
1175
1180
965
965
2460
2460
1583
1603
1570
1588
10.7
10.9
"Joker" with pop-up roof
"Joker" with high roof
4570
4570
1845
1845
2075
2650 -- 190
190
1160
1160
950
950
2460
2460
1583
1583
1570
1570
10.7
10.7
Ambulance
Pick-up
4570
4570
1845
1870
2215
1930 2235- 190
190
1160
1160
950
950
2460
2460
1583
1583
1570
1570
10.7
10.7
Pick-up with large platform 4570 2000 1930 2235 190 1160 950 2460 1583 1570 10.7
Double Cab 4570 1870 1925 2230 190 1160 950 2460 1583 1570 10.7
at permissible GVW
1
When negotiating steep ramps, driving over

poor surfaces, curbs etc., particularly with the
"Joker" with a spoiler, gas containers and
heater mounted underneath the floor, care
must be taken not to "bottom" and thus cause
damage to these fittings.

L DATA
DIMENSIONS
Height Ground Turning

with without clear- Overhang Wheel- Track circle Wading
in mm Length Width cover cover a n c e " front rear base front rear in m Depth
Van 4570 1845 1990 _ 200 1160 950 2455 1568 1560 10.9 350
High Roofed Van 4570 1845 2390
- 200 1160 950 2455 1568 1560 10.9 350
Combi 4570 1845 1990
- 200 1160 950 2455 1568 1560 10.9 350
High Roofed Combi 4570 1845 2390
- 200 1160 950 2455 1568 1560 10.9 350
Caravelle CL, GL, Combi L 4600 1845 1990
- 200 1175 965 2455 1568 1560 10.9 350
"Joker" with pop-up roof 4570 1845 2105
- 200 1160 950 2455 1568 1560 10.9 350
"Joker" with high roof 4570 1845 2680
- 200 1160 950 2455 1568 1560 10.9 350
Ambulance
Pick-up
4570
4570
1845
1870
2245
1995 -
2265
200
200
1160
1160
950
950
2455
2455
1568
1568
1560
1560
10.9
10.9
350
350
Pick-up with large platform 4570 2000 1995 2265 200 1160 950 2455 1568 1560 10.9 350
Double Cab 4570 1870 1995 2265 200 1160 950 2455 1568 1560 10.9 350
" at permissible GVW with 185 R 14 C tyres

When negotiating steep ramps, driving over
poor surfaces, curbs etc., particularly with ve-
hicles with a spoiler, gas containers and heater
mounted underneath the floor, care must be
taken not to "bottom" and thus cause damage
to these fittings.

TECHNICAL DATA
CAPACITIES
Fuel tank .. approx. 60 litres (13 galls) Petrol engines

Fuel tank
Cooling system
s y n c r o . . . approx. 70 litres (15.3 galls)
(with heater) approx. 17.5 litres
W i n d s c r e e n w a s h e r .. approx. 3.5 litres
Engine oil -
With headlight
with filter c h a n g e . . . approx. 4.5 litres
washer approx. 6.5 litres
Engine oil -
Rear window
without filter change approx. 4.0 litres
washer approx. 1.0 litre
Difference between
Max.-Min. marks on dipstick . . 1 . 0 litre
Diesel engines
Cooling system
(with heater) approx. 16 litres
Engine oil -
with filter c h a n g e . . . . approx. 4.5 litres
Engine oil -
without filter c h a n g e . approx. 4.0 litres
Difference between
Max.-Min. marks
on dipstick approx. 1.0 litre

17-182
The identification plate is on right hand The chassis number is stamped under The vehicle data sticker is located on
door pillar between the hinges. vehicle on front cross member cross member on left under dash. The
Vehicles for export to certain countries sticker contains the following data:
have no identification plate. 1. Production control number
2. Chassis number
3. Model code number
4. Model explanation
5. Engine and gearbox code letters
6. Paint number/interior trim code
7 Optional extra number
The vehicle data 2 - 7 is also given in the
Service Schedule.


ALPHABETICAL IND
Page Page Page
Additional heat exchanger 42 compartment 88 Emission control system 83

Adjusting jets 74 Clock 34 Engine
Anti-freeze 71 Cold starting aid 30 - data 108
Ashtray 51 Coolant additive 71 - number 125
ATF 67, 69 Coolant level 71 -oil 68
Automatic gearbox 26 Coolant temperature gauge 35 - oil capacity 123
Auxiliary heater 43, 46 Cooling system 71 - oil consumption 56, 108
Cover, engine 7 - oil level 68
Battery 78 Curtains 52 - starting/stopping 29
Blower switch 40, 42 Engine compartment fiap 7
Brake fluid 76 Defrosting windows 41
Brake servo 75 Diesel fuel 64 Filling tank 65
Brake system 75 Differential locks 22 First Aid Kit 91
Brake warning light 38 Difficult conditions 84 Fog lights 36
Bulb changing 96 Digital clock 34 Fuel 63
Dimensions 121 - additives 64
Care of car 85 Dip switch 38 - consumption 110
Canopy 20 Do-it-yourself 102 - gauge 35
Capacities 123 Doors 6 - saving 55
Cavity preservation 88 Driving abroad 84 Fuses 94
Centre seat 14 Driving economically 55
Central locking 5 Driving environment - conscious . . . 55 Gear lever 21
Cetane number 64 Driving safely 54 Gear oil 69
Changing bulbs 96 Dropsides 20 Glow plugs 28, 30
Changing wheels 93
Chassis number 124 Electric window lifters 8 Handbrake 20
Child-proof lock 6 Electric seat adjustment 17 Headlights 36, 96
Cigarette lighter 51 Emergency light system 36 Headlights flasher 38
Cleaning and preserving engine Emergency starting 102 Head restraints 12

ALPHABETICAL INDEX
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Heating 40 Octane number 63 Seat belts 10

High beam 33 Oil additives 67 Seats 13
Horn 3 Oil consumption 56, 108 Seat heating 14
Oil dipstick 68 Selector lever 26
Identification data 124 Oils 67 Side lights 36
Identification plate 124 Sliding door 6
Instrument lighting 36 Package - emission control 107 Sliding roof 48
Instrument panel 2 Parking lights 38 Sliding windows 8
Instruments 34 Payload 118 Snow chains 82
Interior light 49 Performance 113 Socket 51
Power assisted steering 70 Spare wheel 92
Jack 91 Spark plugs 115
Jacking points 91 Radiator fan 73 Speedometer 34
Jets adjusting 74 Radio 3, 101 Starting engine 29
Rear fog light 36 Steering lock/ignition switch 28
Keys 4 Sun roof 48
Rear lights 98
Rear seat 14 Switches 3
Lead free petrol 63
Rear window heated 36 Syncro
Lifting vehicle 90
Rear wiper and washer 39 - differential locks 22
Lighting 36
Reclining seat 18 - driving with 4 wheel drive 58
Lighting switch 36
Rev counter 34 - selctable 4 wheel drive 25
Limited slip differential 22
Reverse gear 21 - snow chains 82
Load surface 19
Reversing lights 21 - technical description 104
Locks 6
Revolving seats 14 - technical data 108
Lubricants 67
Roof load 75 - towing 103
Luggage compartment 19
Roof rack 19
Mirrors 9 Running in 58 Table 52
Tailgate 7
Number plate lighting 99 Safety switch 45 Taillights 98
127

ALPHABETICAL IND
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Tank capacity 123 Wheel changing 93

Technical data 108 Windscreen washer system 39, 74
Technical description 104 Windscreen wipers 89
Tools 91 Winter driving
Towing 103 - battery 78
Tow starting 27, 29 - care of vehicle 85
Trailer towing 57 - cooling system 73
Trailer weights 120 - Diesel 64
Trip recorder 34 - engine oil 67
Turn signals 98 - snow chains 82
Turn signal lever 38 - tyres 82
Tyres - windcreen wipers 74
- inflation pressures 116 Winter tyres 82
- running in 79
Undercoating 88
Vee belts 115

Vehicle care 85
Vehicle data sticker 124
Ventilation 40
Vent wings 8
Viscosity grades 67
Warning lamps 32
Warning triangle 91
Water auxiliary heater 46
Weights 117
Wheels 79, 116

The factory is working continuously on the development of all models. We trust, there-
fore, that you will appreciate that we must reserve the right to alter, without notice,
any part of the vehicle or equipment. No legal commitment is thus implied by the
data, illustrations or descriptions in this manual.
1985 Volkswagenwerk AG
May not be reproduced or translated in whole or in part without the written consent of
Volkswagenwerk AG
All rights reserved. Specifications subject to alteration without notice.
Printed in Germany


Manual Transporter Caravelle T3

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Manual Transporter Caravelle T3

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Instruction Manual

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The Transporter I Caravelle is a versatile, million-fold proven vehicle.

We wish you pleasant motoring:

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This instruction manual is valid for all Transporter/Cara-

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1 - Air vents 40 10 - Fog light/rear fog 21 Blower switch for

Please note that some of the items of

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Up to six keys are supplied with the Tag E

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Cab doors Sliding door

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Normal exterior mirror

Electrically adjustable mirrors Anti-dazzle interior m i r r o r *

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Belt height adjustment against the neck - and be firmly in

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Lap belt* Two-point inertia reel belts Adjusting height

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Individual driver's and front passen-

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Two seater b e n c h * Swivelling s e a t s * Removing and installing centre bench

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Turning Adjusting backrest angle

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Adjusting seat height

Adjusting backrest angle

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To enlarge luggage space* When a roof rack is to be used, note the

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The handbrake is located between the

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4 speed gearbox 5 speed gearbox 4 + G g e a r b o x (4 WD vehicles)

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Selectable differential locks* When the knobs are pulled/pushed en-

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Engaging four-wheel drive

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p N - Neutral The lever can be moved from "2" into "

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Petrol engine For all vehicles:

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General notes 44 and 57 kW carburetor engines

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The layout of the warning lamps depends |" *\ Generator

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t - Coolant temperature/ - Glow plugs () - Brake system

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The arrangement of the instruments de- Rev counter* Clock*