Vanagon
Robert Bentley
Cambridge, Massachusetts
Information that makes 1734 Massachusetts Avenue
the difference.., Cambridge, MA 02138 USA
800-423-4595/617-547-4170
http://www.rb.com
e-mail: sales@rb.com
Copies of this manual may be purchased from authorized Volkswagen dealers, most automotive accessories and parts dealers
specializing in Volkswagens, from selected booksellers, or directly from the publisher by mail.
The publisher encourages comments from the reader of this manual. These communications have been and will be carefully
considered in the preparation of this and other manuals. Please write to Robert Bentley, Inc. at the address listed on the top of
this page.
Library of Congress Catalog Card No. 91-74020
ISBN 0-8376-0336-6
VWoA Part No. LPV 800 148
VWC Inc. Part No. MAN 101 251F
Bentley Stock No. VV91
01 00 99 98 10 9 8 7
The paper used in this publication is acid free and meets the requirements of the National Standard for Information Sciences-
Permanence of Paper for Printed Library Materials. 8
©Copyright 1991 Volkswagen United States, Inc.
Editorial closing July 15, 1991
All rights reserved. All information contained in this manual is based on the information available to the publisher at the time of
editorial closing. The right is reserved to make changes at any time without notice. No part of this publication may be reproduced,
stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, without the prior written consent of the publisher. This includes text, figures, and tables. All rights reserved under
Berne and Pan-American Copyright conventions.
Manufactured in the United States of America
Foreword ...........•..................•...••.......• viii
Warnings and Cautions ...........•••.........••....... ix, x
Repair Groups
Engine-Assembly ....................................................................... 10
Crankshaft/Crankcase ................................................... 13
Cylinder HeadsNalve Drive ......................................... .. 15
Lubrication System ....................................................... . 17
Cooling System ............................................................ . 19
Engine Fuel Supply ..................................................................................
Fuel Injection-Diesel System .....................................................
20
23
Fuellnjection-AFC System ........................................................ 24
Fuel Injection-Water-cooled ....................................................... 24
Exhaust System/Emission Controls ............................................. 26
Electrical-Battery, Starter, Alternator ....................................... .. 27
Ignition System ............................................................................ . 28
This Vanagon manual covers the model years 1980 through 1991 including Air-cooled
and Water-cooled Gasoline Engines, Diesel Engine, Syncro and Camper. This manual was
specifically written to cover U.S. and Canada models only.
For the Volkswagen owner with basic mechanical skills and for independent garages,
this manual gives all the specifications and procedures that were available in an authorized
Volkswagen service department as this manual went to press. In addition, the Volkswagen
owner who has no intention of working on his or her vehicle may find that reading and own-
ing this manual will make it possible to be better informed and to discuss repairs more intel-
ligently with a professional automotive technician.
This manual has been prepared from the repair information that the Volkswagen orga-
nization provides to its own factory-trained technicians and has been developed primarily
with the professional automotive technician in mind. The aim throughout has been clarity
and completeness with step-by-step procedures and accurate specifications.
The Volkswagen owner intending to do maintenance and repair should have a set of
metric wrenches and sockets, a torque wrench, screwdrivers, and feeler gauges, since
these basic hand tools will be used for a majority of the repairs described in this manual.
Usually, the text will note when a repair requires special tools.
This manual is organized so that, whenever possible, when a change has been made
within a model year, the vehicle identification number (VIN) of the first vehicle with this
change is given. The digits you need to know for this parts and service information are taken
from the seventeen digit VIN number. If, for example the VIN is WVWZZZ24ZBH000001,
you will need only nine of the last eleven digits of this number-or, more specifically, the dig-
its 24 8 000001. Your Volkswagen's VIN is found on the left doorjamb and on a plate mount-
ed on the driver's side of the instrument panel padding where the number can be seen
through the windshield. The VINs assigned to Vanagon models for the years 1980 through
1991 which are covered by this manual are:
We have endeavored to ensure the highest degree of accuracy possible. When the
vast array of data presented in this manual is taken into account, however, no claim to infal-
libility can be made. We therefore cannot be responsible for the resukof any errors that may
have crept into the text. The Publisher encourages comments from the readers of this man-
ual in regard to any errors and, also, suggestions for improvement in the presentation of the
technical material. These communications have been and will be carefully considered in the
preparation of this and other manuals. Please write to Robert Bentley, Inc., Cambridge, Mas-
sachusetts 02138.
Robert Bentley
Please read these warnings and cautions
before proceeding with maintenance and repair work.
WARNING-
• Some repairs may be beyond your capability. If you lack the • Friction materials such as brake or clutch discs may contain
skills, tools and equipment, or a suitable workplace for any proce- asbestos fibers. Do not create dust by grinding, sanding, or by
dure described in this manual, we suggest you leave such repairs cleaning with compressed air. Avoid breathing asbestos fibers and
to an authorized Volkswagen dealer service department, or other asbestos dust. Breathing asbestos can cause serious diseases
qualified shop. such as asbestosis or cancer, and may result in death.
• Volkswagen is constantly improving its cars. Sometimes these • Disconnect the battery negative (-) terminal (Ground strap)
changes, both in parts and specifications, are made applicable to whenever you work on the fuel system or the electrical system. Do
ear1ier models. Therefore, before starting any major jobs or repairs not smoke or work near heaters or other fire hazards. Keep an
to components on which passenger safety may depend, consult approved fire extinguisher handy.
your authorized Volkswagen dealer about Technical Bulletins that
may have been issued since the editorial closing of this manual. • Batteries give off explosive hydrogen gas during charging.
Keep sparks, lighted matches and open flame away from the top
• Do not re-use any fasteners that are worn or deformed in normal of the battery. If hydrogen gas escaping from the cap vents is
use. Many fasteners are designed to be used only once and ignited, it will ignite gas trapped in the cells and cause the battery
become unreliable and may fail when used a second time. This to explode.
includes, but is not limited to, nuts, bolts, washers, self-locking
nuts or bolts, circlips and cotter pins. Always replace these fasten- • Connect and disconnect battery cables, jumper cables or a bat-
ers with new parts. tery charger only with the ignition switched off, to prevent sparks.
Do not disconnect the battery while the engine is running.
• Never work under a lifted car unless it is solidly supported on
stands designed for the purpose. Do not support a car on cinder • Do not quick-charge the battery (for boost starting) for longer
blocks, hollow tiles or other props that may crumble under contin- than one minute. Wait at least one minute before boosting the bat-
uous load. Never work under a car that is supported Solely by a tery a second time.
jack. Never work under the car while the engine is running.
• Do not allow battery charging voltage to exceed 16.5volts. If the
• If you are going to work under a car on the ground, make sure battery begins producing gas or boiling violently, reduce the charg-
that the ground is level. Block the wheels to keep the car from roll- ing rate. Boosting a sulfated battery at a high charging rate can
ing. Disconnect the battery negative(-) terminal (Ground strap) to cause an explosion.
prevent others from starting the car while you are under it.
• The air-conditioning system is filled with chemical refrigerant,
• Never run the engine unless the work area is well ventilated. which is hazardous. The A/C system should be serviced only by
Carbon monoxide kills. trained technicians using approved refrigerant recovery/recycling
equipment, trained in related safety precautions, and familiar with
• Finger rings, bracelets and other jewelry should be removed so regulations governing the discharging and disposal of automotive
that they cannot cause electrical shorts, get caught in running chemical refrigerants.
machinery, or be crushed by heavy parts.
• Do not expose any part of the A/C system to high temperatures
• lie long hair behind your head. Do not wear a necktie, a scarf, such as open flame. Excessive heat will increase system pressure
loose clothing, or a necklace when you work near machine tools or and may cause the system to burst.
running engines. If your hair, clothing, or jewelry were to get
caught in the machinery, severe injury could result. • Some aerosol tire inflators are highly flammable. Be extremely
cautious when repairing a tire that may have been inflated using
• Do not attempt to work on your car if you do not feel well. You an aerosol tire inflator. Keep sparks, open flame or other sources
increase the danger of injury to yourself and others if you are of ignition away from the tire repair area. Inflate and deflate the tire
tired, upset or have taken medication or any other substance that at least four times before breaking the bead from the rim. Com-
may keep you from being fully alert. pletely remove the tire from the rim before attempting any repair.
• Illuminate your work area adequately but safely. Use a portable • Some cars covered by this manual are equipped with a supple-
safety light for working inside or under the car. Make sure the bulb mental restraint system (SRS), that automatically deploys an
is enclosed by a wire cage. The hot filament of an accidentally bro- airbag in the event of a frontal impact. The airbag is inflated by an
ken bulb can ignite spilled fuel or oil. explosive device. Handled improperly or without adequate safe-
guards, it can be accidently activated and cause serious injury.
• Catch draining fuel, oil, or brake fluid in suitable containers. Do
not use food or beverage containers that might mislead someone • Greases, lubricants and other automotive chemicals contain toxic
into drinking from them. Store flammable fluids away from fire haz- substances, many of which are absorbed directly through the skin.
ards. Wipe up spills at once, but do not store the oily rags, which Read manufacturer's instructions and warnings carefully. Use hand
can ignite and bum spontaneously. and eye protection. Avoid direct skin contact.
• Always observe good workshop practices. Wear goggles when
you operate machine tools or work with battery acid. Gloves or continued on next page
other protective clothing should be worn whenever the job requires
working with harmful substances.
ix
Please read these warnings and cautions
before proceeding with maintenance and repair work.
CAUTION-
• If you lack the skills, tools and equipment, or a suitable work· • Be mindful of the environment and ecology. Before you drain the
shop for any procedure described in this manual, we suggest you crankcase, find out the proper way to dispose of the oil. Do not
leave such repairs to an authorized Volkswagen dealer or other pour oil onto the ground, down a drain, or into a stream, pond or
qualified shop. lake. ConsuH local ordinances that govern the disposal of wastes.
• Volkswagen offers extensive warranties, especially on compo- • On cars equipped with anti-theft radios, make sure you know
nents of fuel delivery and emission control systems. Therefore, the correct radio activation code before disconnecting the battery
before deciding to repair a Volkswagen that may still be covered or removing the radio. If the wrong code is entered into the radio
wholly or in part by any warranties issued by Volkswagen United when power is restored, that radio may lock up and be rendered
States, Inc., consult your authorized Volkswagen dealer. You may inoperable, even if the correct code is then entered.
find that he can make the repair for free, or at minimal cost.
• Connect and disconnect a battery charger only with the battery
• Volkswagen part numbers listed in this manual are for identifica- charger switched off.
tion purposes only, not for ordering. Always check with your
authorized Volkswagen dealer to verify part numbers and avail- • Do not quick-charge the battery (for boost starting) for longer
ability before beginning service work that may require new parts. than one minute. Wait at least one minute before boosting the bat-
tery a second time.
• Before starting a job, make certain that you have all the neces-
sary tools and parts on hand. Read all the instructions thoroughly, • Sealed or "maintenance free" batteries should be slow-charged
do not attempt shortcuts. Use tools appropriate to the work and only, at an amperage rate that is approximately 10% of the bat-
use only replacement parts meeting Volkswagen specifications. tery's ampere-hour (Ah) rating.
Makeshift tools, parts and procedures will not make good repairs.
• Do not allow battery charging voltage to exceed 16.5 voHs. If the
• Use pneumatic and electric tools only to loosen threaded parts battery begins producing gas or boiling violently, reduce the charg-
and fasteners. Never use these tools to tighten fasteners, espe- ing rate. Boosting a sulfated battery at a high charging rate can
cially on light alloy parts. Always use a torque wrench to tighten cause an explosion.
fasteners to the tightening torque specification listed.
X
Index
Battery (Cont'd) Bumpers
WARNING- -Electrolyte level 27.4 -Front bumper/spoiler 63.2
• Automotive service and repair is serious -Filler caps 27.7 -Rear bumper 63.3
business. You must be alert, use common - Location(s) 27.8
sense, and exercise good judgement to
-Nomenclature 27.2 Camper Equipment
prevent persona/Injury and complete the
-Safety precautions 27.4 -Ceiling cabinet
K0/1( safely.
-Troubleshooting 27.10 with A/C, installing 76.9
• Before beginning any work on your with A/C, removing 76.7
Volkswagen, thoroughly read all the Body without A/C, removing/installing 76.6
cautions and warnings listed near the -Acid rain, removing spots 50.6 -Clothes closet
hont of this manual. -Adhesives materials 50.5 installing 76.11, 76.14
• Always read the complete procedure -Body Dimensions removing 76.9, 76.11
before you begin the work. Pay special door 50.4 -Curtains
attention to any Cautions and Warnings floor 50.2 removing/installing 76.3
that accompany that procedure, or other windshield 50.4 -Curtain rail w/fresh air duct
Information on a specific topic. -Painting installing 76.6
pop-up roof/luggage carrier 50.5 removing 76.5
Air Conditioner -Plastics, identifying 50.5 - Propane tank
-Adapter valve VAG 1637 repairing 50.5 removing/installing 76.23
installing 87.15 - Refrigerator
- Air distribution system Brakes-Hydraulic Components, air supply modification 76.25
components 87.9 Regulator, Booster installing 76.25
-Component locations 87.2 - Brake booster assembly 47.1 o removing 76.24
-Compressor (Sanden SD510) checking 47.10 -Sink cabinet
replacing 87.16 - Brake caliper installing 76.23
-Evaporator Girling (1980-1985) assembly 47.5 removing 76.15
removing/installing 87.14 Girling/Teves (1980-1985) -Storage chest w/water tank
-Evaporator housing disassembling/assembling 47.6 installing 76.17
disassembling/assembling 87.12 Girling/Teves (from 1986) removing 76.15
removing 87.1 0 assembly 47.7a -Storage shelf
-Expansion valve Teves (1980-1985) assembly 47.4 removing/installing 76.2
removing/installing 87.14 Teves (1980-1985), noise w/curtain rod
-Fuses, locations 87.4 dampening plates 47.7 removing/installing 76.4
- Refrigerant system Brake fluid, changing -Water faucet w/pump switch
capacity 87.7 with US 1116 47.8 removing/installing 76.20
cautions and warnings 87.7 without US 1116 47.8a -Water level sensor
controls 87.6 Brake hydraulic system removing/installing 76.20
discharging 87.8 general repair notes 47.8 -Water pump/kitchen
-Relays, locations 87.5 -Brake master cylinder removing/installing 76.18
assembly 47.2
Alignment Brake pressure regulator Clutch
-See Wheels checking 47.8a - Bearing shaft bushing
-Brake system, bleeding Syncro 30.9
Alternator with US 1116 47.8 -Brake/Clutch fluid
-Alternator/Regulator without US 1116 47 .8a reservoir 30.3
checking 27.18 -Check valve Clutch assembly
-Heater blower fan checking 47.10 diesel30.5
removing/replacing 27.22 -Rear wheel cylinder assembly 47.8 gasoline 30.4
-Indicator light, troubleshooting 27.23 Syncro 30. 10
-Mount, adjusting 27.22 Brakes-Mechanical Components Controls 30.2
-Removing/Installing 27.15 Brake pedaVIinkage Syncro 30.8
-Repairing assembly 46.1 o -Diaphragm spring 30.6
45A, 65A 27.16 -Front brake Syncro 30.11
90A 27.17 assembly (1980-1985) 46.2 -Hydraulic system 30.2
-System layout 27.19 assembly (from 1986 m.y.) 46.5 Syncro 30.8
-V-belt pads (1980-1985) -Pressure plate 30.6
adjusting 27.21 removing/installing 46.3 air-cooled modification 30.6
replacing 27.21 pads (from 1986 m.y.) Syncro 30.11
-Voltage regulator 27.20 removing/installing 46.5a Release bearing 30.7a
-Parking brake assembly 46.11 air-cooled only 30.7
Battery -Rear brake -Release shaft bushing 30.3
-Charging 27.5 assembly 46.6 Syncro 30.9
-Checking 27.4 shoes, adjusting 46.9 -Roll pin 30.3
shoes, removing/installing 46.7
xi
Index
Cooling System-Air-cooled AFC Differential-Automatic Trans. (cont'd) Do-it-yourself Service
-Cooling air control flap - Ring gear/pinion (Appendix) (cont'd)
adjusting 19.3 adjusting 39.57 -Jack and tools A20
-Cooling fan backlash 39.61 - Replacing bulbs A23
removing 19.3 -Torque converter oil seal39.51 -Spare wheel A20
-Fan housing assembly 19.2
removing 19.3 Differential-Manual Trans. Doors-Front
-Snap-lock wiring connectors 091, 091/1, 4-Speed -Adjusting 57.5
installing 19.19 094 5-Speed (except 4WD) -Assembly 57.2
-Thermostat -Assembly 39.2 -Glass 57.4
checking 19.3 -Bearings 39.3 -Guide channel57.5
-V-belt -Housing 39.3 -Handles 57.3
assembly 19.2 -Pinion, adjusting 39.1 0 -Lock/Lock rod 57.3
tension, adjusting 19.3 - Pinion/Side gears 39.6 - Lost/Broken keys
-Ring gear 39.3 code location 57.8
Cooling System-Diesel adjusting 39.12 -Power door locks 57.6
-Antifreeze hydrometer backlash 39.13 -Whistling noises
checking 19.7 - Ring/Pinion gears eliminating 57.1 0
-Coolant assembly 19.4 adjusting 39.7 -Window regulator 57.4
draining/filling 19.6 -Shim S3 39.11
mixture ratio 19.5 Doors-Rear
pipes, replacing 19. 7a Differential-Manual Trans. -Center hinge
-Snap-lock wiring connectors 094 5-Speed with 4WD adjusting 58.9
installing 19.19 - Differential with lock assembly 58.8
- Pressure cap, checking 19.7 assembly 39.20 removing/installing 58.9
bearing outer race 39.24 -Sliding door 1980-1984
Cooling System-Water-cooled bearings 39.21 bowden cables, adjusting 58.7
-Antifreeze hydrometer housing 39.21 door cover 58.3
checking 19.17 pinion shafts 39.22 door handle inner/outer 58.3
-Coolant assembly 19.8, 19.11, 19.14 ring gear 39.20 door lock buffer 58.3
draining/filling 19.15 "'-- Differential without lock lock, front 58.2
expansion tank, checking 19.18 assembly 39.15 lock, rear 58.6
hose layout 19.10 bearing outer race 39.19 lock plate, remote control 58.6
leak checks 19.17 bearings 39.16 lubricating 58.7
mixture ratio 19.18 housing 39.16 removing/installing 58.4
refill tank 19.9, 19.13 pinion shafts 39.17 striker plate, adjusting 58.5
-Hose spring clamps ring gear 39.15 -Sliding door, from 1985
removing/installing 19.16 - Driveshaft flange oil seal 39.44 assembly 58.10
-Hot footwell kit, installing 19.20 removing/installing 39.43 central lock 58.20
-Radiator assembly 19.12 -Front final drive 39.30 door cover 58.11
thermo-switch 19.12 adjusting rings 39.32 handle 58.22
axle flange 39.32 hinge link, adjusting 58.16
Cruise Control circlip 39.33 hinge link, assembly 58.21
-System, repairing 27.25 housing 39.34 modifications 58.11
-Troubleshooting 27.29 mounting 39.32 remote control lock 58.18
technical data 39.42 removing/installing 58.12
Current Flow Diagrams - Front pinion 39.39 roller guides, adjusting 58.14
- See Electrical Wiring bearing 39.40 striker pin, adjusting 58.15
grooved nut 39.40
Differential-Automatic Trans. turning torque 39.41 Electrical Wiring-Air-cooled AFC
-Adjusting ring 39.51 - Locking pin 39.28 -1980,1981
-Assembly 39.56 - Pinion/Side gears 39.25 cautions and warnings 97.2
-Cover plate 39.51 - Removing 39.33 fresh air fan 97.23
-Differential bearing outer race 39.53 - Ring gear/Pinion fuse/relay panel 97.10
-Drive flange oil seal 39.53 adjusting 39.26 heater booster 97.24
- Final drive assembly 39.50 main wiring diagram 97.12
-Governor oil seal 39.52 Do-it-yourself Service rear window wiper 97.26
- Pinion bearing (Appendix) seat belt interlock system 97.27
inner race 39.54 -Changing a wheel A21 -1982, 1983
outer race 39.53 -Emergency starting A25 cautions and warnings 97.2
- Pinion oil seals 39.52 -FusesA22 fresh air fan 97.23
- Ring gear 39.56 -Headlight adjustment A25 fuse/relay panel 97.10
heater booster 97.24
xii
Index
Electrical Wiring-General (cont'd) Electrical Wiring-Water-cooled
WARNING- -Fuse/Relay panel, removing (cont'd)
• Automotive setvice snd repair is serious 1980-1985 97.10 -Main wiring diagram (cont'd)
business. Youmustbealert, use common from 1986m.y. 97.10a from VIN G 055 690 97.85
sense, snd exercise good judgement to -How to read wiring diagrams 97.4 198797.102
prevent personal injury snd complete the
-Main wiring harness 97.8 1988, 1989 97.119
worl< safely.
-Starter cable routing 97.9 from 1990 97.201
• Before beginning any work on your -Symbols used in wiring diagrams 97.5 -Power mirrors
Volkswagen, thoroughly read all the -Troubleshooting 97.3 1986uptoVING 10500097.183
cautions and Warnings listed near the -Working on the 1986 from VIN G 105 001 97.185
front of this manual. electrical system 97.3 from 1987 97.185
• Always read the complete procedure - Power windows
before you begin the work. Pay special Electrical Wiring-Water-cooled 1986 97.187
attention to any Cautions and Warnings Air conditioning from 1987 97.189
that accompany that procedure, or other 1984, 1985 97.137 -Radio 198697.191
information on a specific topic. 1986-1988 97.139 -Rear footwall heater blower
from 1989 97.142 1983-1985 97.194
Electrical Wiring-Air-cooled AFC -Automatic transmission Stereo radio
(confd) 1986-1989 97.146 1987-1989 97.195
-1982, 1983 (cont'd) from 1990 97.219 -Stereo radio with amplified speakers
main wiring diagram 97.18 -Auxiliary battery from 1988 97.197
rear window wiper 97.26 1986-1989 auto. trans. 97.221 - Stereo radio with 4 speakers
seat belt interlock system from 1990 97.224 from 1990 97.246
(1982 only) 97.27 See also 97.29 - 450-Watt radiator cooling fan
-Auxiliary heater BA6 1986-1989 97.200
Electrical Wiring-Camper from 1987 Canada only 97.148
-Auxiliary battery 1986·1989 -Auxiliary heater BBW46 Emission Controls
(man. trans.) 97.34 (Syncro) -Air-cooled AFC
(also see 97.53) 1986-1988 Canada 97.151 Calif. 1981 26.4
-Battery level indicator lights 97.30 from 1989 Canada 97.155 Calif. except 1981 26.3
-Camper electrical equipment -Central locking system -Catalytic converter
1980-1985 97.32 1986 97.165 checking 26.11
from 1986 97.33 1987-1989 97.162 -EGA valve26.5
-Water pump 97.31 from 1990 97.226 USA (except Calif.)
-Water tank level -Crankcase ventilation and Canada 26.2
indicator lights 97.30 heat element - Diesel26.6
1985 97.165 -Water-cooled Digifant
Electrical Wiring-Diesel 1986 97.166 assembly 26.9
-1982 -Cruise control -Oxygen sensor
auxiliary heater BA6 auto. trans. water-cooled Digijet 26.8
(Canada only) 97.47 1986 97.168
cautions and warnings 97.2 1987-1989 97.176 Engine-Air-cooled AFC
fuse/relay panel 97.10 from 1990 97.229 -Assembling
heater booster 97.49 -Cruise control man. trans. crankcase 13.6, 13.14
main wiring diagram 97.36 1986 97.174 . sheet metal 13.2
-current track index 97.36 1987-1989 97.171 -Camshaft 13.14
rear window wiper 97.26 from 1990 97.232 -Carbon deposits, reducing 15.25
-1983 -Daytime running lights -Carrier/Support 13.5
auxiliary heater BAS (Canada) -Compression pressure
(Canada only) 97.47 to Dec. 1989 97.234 checking 15.2
cautions and warnings 97.2 from Dec. 1989 to May 1990 97.238 values 2a
fuse/relay panel97.10 from May 1990 97.241 -Connecting rod 13.16
heater booster 97.49 - Differential lock -Crankshaft
main wiring diagram 97.41 1986-1989 Syncro 97.178 assembly 13.16
current track index 97.41 -Heated driver's seat circlips 13.16
rear window wiper 97.26 198697.179 end play 13.10
1987-1989 Canada 97.181 oil seals 13.9
Electrical Wiring-General from 1990 Canada 97.244 pilot bearing 13. 17
-Battery/Ground cables 97 .9a -Main wiring diagram -Cylinder 13.11
disconnecting/connecting 97.6 1983, 1984 97.54 -Cylinder head 15.2
-Cautions and Warnings 97.2 1985 97.60 -Disassembling
-Dashboard wiring harness 97.7 1986 crankcase 13.6
-Engine/Body up to VIN G 055 689 97.67 sheet metal13.2
ground connections 97.6
xiii
Index
Engine-Air-cooled AFC (cont'd) Engine-Diesel (cont'd) Engine-Water-cooled (confd)
- Distributor -Intermediate shaft oil seal 13.22 - Pushrod tubes
drive gear 13.16 Lubrication system replacing 15.25
driveshaft 13.8 assembly 17.4 -Removing 10.8
installing 13.9 oil cooler 17.4 -Torque converter drive plate 13.40
- Flywheel13.9 oil filter 17.4 - V-belt pulley 13.34, 13.42
Gasoline additive 15.25 oil pan 17.4 -Valves
Hydraulic valve lifters 15.6 oil pressure switch 17.4, 17.6 assembly 15.17
-Installing 10.5 oil pump 17.4 dimensions 15.18
-Lubrication -Pilot bearing 13.22 guides 15.20
assembly 17.2 -Piston 13.27 hydraulic lifters 15.23
oil cooler 17.2 clearance 13.29 seats, refacing 15.18
oil pressure switch 17.2 diameter 13.29 springs 15.18
oil pump 17.2 height 13.31
- Piston rings 13.11 identification 13.31 Exhaust System
-Pistons 13.11 marking 13.28 -Air-cooled AFC
-Removing 10.2 pin 13.28 Calif. 1981 26.4
-Rocker arm shaft 15.3 ring end gap 13.29 Calif. except 1981 26.3
-Torque converter drive plate 13.9 ring side clearance 13.29 USA (except Calif.)
-Valves rings 13.27 and Canada 26.5
assembly 15.2 - Removing 10.6 -Catalytic converter
dimensions 15.3 Valve assembly 15.10 checking 26.11
guides 15.4 - Diesel26.6
hydraulic lifters 15.6 Engine-Water-cooled -Oxygen sensor
seats 15.4 -Assembling/Disassembling 13.32 water-cooled Digijet 26.8
springs 15.2 -Camshaft 13.50 -Water-cooled
-Carbon deposits, reducing 15.25 Digifant 26.9
Engine-Diesel -Carrier/Support 13.37a Digijet 26.7
-Camshaft assembly 15.10 -Compression pressure
end play 15.15 checking 15.20 Fuel Injection-Air-cooled AFC
oil seal15.15 values2a AFC system check 24.15
radial clearance, checking 15.15a -Crankshaft assembly 13.52 -Air filter housing 24.8
run-out 15.15 circlips 13.54 -Auxiliary air regulator 24.8
-Camshaft drive belt 13.18 drive gear 13.54 -Cold-start valve 24.5
-Compression pressure end play 13.40 -Control unitJWiring harness 24.12
checking 15.16 oil seals 13.39 Deceleration valve 24.7
values 2a pilot bearing 13.56 -Double relay 24.13
Connecting rod 13.27 replacing (1.9L) 13.57 Full throttle enrichment
bearing clearance 13.30 -Cylinder 13.43 switch 24.13
bolts 13.30 -Cylinder head assembly 15.17 -Idle speed/CO 24.10
side clearance 13.30 installing 15.23 -Injector resistance 24.6
-Crankshaft 13.22 sealing 15.23, 15.26 -Injector spray pattern/
bearing caps 13.22 Distributor leak checking 24.7
drive belt cover 13.21a drive gear 13.38 -Intake air sensor housing 24.8
end play 13.24 driveshaft 13.38 -Intake air/temp. sensors 24.9
journal sizes 13.23 installing 13.38 -Oxygen sensor/Wiring 24.16
-main bearing clearance 13.25 Engine block assembly 15.22 Pressure regulator 24.5
oil seal - Flywheel 13.40 -Speed limit switch 24.14
drive belt side 13.26 -Gasoline additive 15.25 -System components 24.2
flywheel side 13.25 -Installing 10.10 Calif. 24.4
sprocket bolt 13.21 -Lubrication system USA (except Calif.)
-Cylinder block 13.27 assembly 17.7 and Canada 24.3
bore dimensions 13.30 crankcase breather, -Temperature sensor II 24.13
clearance 13.30 heating pipe 17.9 -Thermo-time switch 24.6
-Cylinder head oil pressure switch 17.9 Voltage supply/
assembly 15.8 oil pump 17.9 series resistance 24.6
bolts 15.9 -Piston pin hole burrs
distortion 15.11 removing 13.47 Fuel Injection-Diesel
gasket 15.9 - Pistons 13.43 -Cold start cable 23.5
-Cylinder head gasket 13.19, 13.31 classifications 13.44 - Engine speed 23.5
Flywheel 13.23 pin 13.44 -Fuel cut-off solenoid 23.5
Installing 10.7 rings 13.45 - Fuel delivery valve/housing 23.7
-Intermediate plate 13.23
xiv
Index
Fuel Injection-Water-cooled Glass, Window Regulators
WARNING- Digijet (cont'd) -Gluing rubber window seals
• Automotive setvice and repair is serious -Full throttle enrichment switch 24.34 from 1986 MY
business. You must be alert, use common checking/adjusting 24.29
sense, and exercise good judgement to rear lid window 64.5
Idle speed/CO side window 64.4
prevent personal injury and complete the
worlc safely.
checking/adjusting 24.29 sliding door window 64.5
-Intake air sensor 24.28 -windshield 64.3
• Before beginning any work on your housing 24.27 - Power window motor
Volkswagen, thoroughly read aU the -Pressure regulator 24.25 from 1986 MY
Cautions and Warnings listed near the -System check 24.20
front of this manual.
installing 64.7
System components 24.22 removing 64. 6
• Always read the complete procedure early version 24.24 -Sliding window
before you begin the work. Pay special late version 24.24a replacing guides 64.2
attention to any Cautions and Warnings -Temperature sensor I 24.28
that accompany that procedure, or other -Temperature sensor II 24.32 Heater-Auxiliary BBW 46
information on a specific topic. -Throttle valve/deceleration/ -Combustion air blower
idle switch 24.33 adjusting 82.32
Fuel Injection-Diesel (cont'd)
removing/installing 82.32
- Fuel filter water indicator kit Fuel Supply-Air-cooled AFC -Components 82.20
installing 23.10 Accelerator linkage/cable -Electrical wiring 82.24
-Fuel injectors 23.8 auto. trans. 20.8 -Engine coolant system
-Injection pump 23.6 man. trans. 20.6 draining/refilling 82.35
-Injection pump/valve timing 23.3 -Fuel filter 20.4 -Felt pad
-Injection system 23.2 Fuel gauge sending unit 20.4 removing/installing 82.29
-Injection timing 23.4 -Fuel pump 20.7 -Flame head
- Fuel system 20.2 removing/installing 82.33
Fuel Injection-Water-cooled leak checking .20.5 -Flame switch
Dlglfant - Fuel tank 20.4 checking 82.30
-Deceleration fuel shutoff 24.60
removing/installing 82,30
-Electrical testing 24.61 Fuel Supply-Diesel -FuseS24
-Fuel injection system -Accelerator linkage/cable 20.14 removing/installing 82.33
components 24.48 - Fuel gauge sending unit 20.13 -Glow plug, checking 82.30
repairing 24.46 Fuel system 20.10 -Heater core
- Fuel injectors, checking 24.56 leak checking 20.13 removing/installing 82.33
- Full throttle enrichment - Fuel tank 20.12 -Metering pump
checking 24.60
flow rate checking 82.35
-Idle speed/CO content Fuel Supply-Water-cooled -Operating 82.25
checking/adjusting 24.50 Dlgifant - Recirculation pump
-Idle stabilizer -Accelerator linkage/cable removing/installing 82.32
checking 24.53 adjusting 20.32 -Series resistor
-Intake air sensor auto. trans. 20.31 removing/installing 82.32
checking 24.57 man. trans. 20.30 -Temperature sensor
-Oxygen sensor -Charcoal filter 20.33 checking 82.31
checking 24.54 -Fuel gauge sending unit 20.29 removing/installing 82.31
- Pressure regulator -Fuel pump 20.29 -Waterflow 82.22
checking 24.55 -Fuel system 20.26
-Safety precautions 24.42 leak checking 20.21 Heater Booster-Air-cooled AFC
-Technical data 24.43 -Fuel tank 20.28 -Air circulation blower 82.7
-Throttle valve -Assembly 82.3
basic adjustment 24.37 Fuel Supply-Water-cooled -Combustion air blower 82.3
-Throttle valve switch 24.58 Dlgijet -Control flaps 82.8
-Accelerator linkage/cable - Defroster/Footwall flaps 82.7
Fuel Injection-Water-cooled auto. trans. 20.23 -Flame switch 82.5
Dlgljet man. trans. 20.22 - Fuel pump 82.6
-Air filter housing 24.27 -Charcoal filter valve 20.20 -Glow/Spark plug 82.3
-Auxiliary air regulator 24.27 -Fuel filter 20.18 -Heater booster/components 82.2
-Control unit/Wire harness 24.31 -Fuel gauge sending unit 20.18 -Heater lever ~witch 82.8
checking 24.35 -Fuel pump 20.19 · -Ignition coil 82.6
Data/Specifications 24.18 -Fuel system 20.16 -Overheat switch 82.7
-Double relay 24.32 -Fuel tank 20.18 -Safety switch 82.7
-Fuel injectors 24.25 -Leak checking 20.21 -Temperature regulating switch 82.5
troubleshooting 24.38 -Temperature sensor 82.6
-Troubleshooting 82.10
XV
Index
Heater Booster-Water-cooled Ignition System-Air-cooled AFC Instruments, Radio
-Air circulation blower 82.17 (cont'd) 1980-1984 (cont'd)
-Combustion air blower 82.14 -California (cont'd) -Fuel gauge sender
-Control valve 82.17 idle stabilizer 28.16 removing/installing 90.11
-Flame switch 82.15 ignition/distributor settings 28.9 -Instrument cluster
-Fuel pump 82.17 ignition timing 28.11 assembling/disassembling
-Glow/Spark plug 82.14 rotor 28.10 90.2, 90.6
-new style 82.14a vacuum advance/retard 28.13 removing/installing 90.10
-Heater booster/Components 82.12 vacuum unit 28.12 -Light emitting diodes (LED)
-Heater housing 82.14 wires/coil, checking 28.10 checking 90.5
Ignition coil 82.17 -USA (except Calif.) identifying 90.4, 90.8
-Overheat switch 82.15 and Canada 28.2 -Multi-point connector
System components 82.12 distributor 28.6 identifying 90.4, 90.8
-Temperature regulating switch 82.16 distributor drive 28.4 -Speedometer calibration 90.30
-Temperature sensor 82.16 ignition/distributor settings 28.3 -Speedometer cable
-Troubleshooting 82.18 ignition timing 28.5 removing/installing 90.1 0
rotor 28.4 -Voltage stabilizer 90.4, 90.8
HeaterNentllatlon vacuum unit/advance 28.7
-Controls/Assembly wires/coil, checking 28.4 Instruments, Radio
air-cooled From 1985
with fresh air fan 80.8 Ignition System-Diesel -Cigarette lighter, replacing 90.31
without fresh air fan 80.5 -Glow plug light -Coolant temperature gauge
water-cooled 80.12 troubleshooting 28.27 locating 90.14
Flap housing -Quick gloW troubleshooting 90.21
air-cooled troubleshooting 28.24 -Dynamic oil pressure system
with fresh air fan 80.1 0 assembly 90.22
water-cooled 80.14 Ignition System-Water-cooled removing/installing 90.23
-Heater, additional Digifant troubleshooting 90.24
under rear bench seat 80.16 -Distributor, installing 28.44 -Fuel gauge, locating 90.14
Heater control flap cable 80.4 -Hall sender, checking 28.43 troubleshooting 90.20
-Heater/Fresh air box housing -Ignition and injection system -Instrument cluster
splitting 80.15 repairing 28.39 assembling/disassembling 90.14
Rear air duct 80.3 -Ignition distributor 28.40 removing/installing 90.10
-System components -Ignition settings 28.41 -Light emitting diodes (LED)
air-cooled 80.2 -Ignition switching function checking 90.18
water-cooled 80.11 checking 28.44 identifying 90.18
-Ignition timing 28.42 - Multi-point connector
Hoods/Lids identifying 90.18
Rear door/lock cylinder 55.2 Ignition System-Water-cooled Speedometer calibration 90.30
-Rear lid spring 55.4 Digljet -Speedometer cable
-Rubber door stop 55.3 -Centrifugal advance 28.34 installing
- Striker plate 55.3 -Distributor driveshaft 28.32 from VIN 25 H 040 185, except
- Hall control unit 28.36 Syncro 90.17
Identification-Numbers/Codes -Hall generator 28.37 removing/installing 90.17
-Automatic trans. 4 -Idle stabilizer 28.38 -Voltage stabilizer, checking 90.18
-Engine2 -Ignition cable connectors
-Front final drive Syncro 3b new style 28.30a Instruments, Radio
-Manual trans. 3 -Ignition coil 28.32 From 1990
-Type/Model/Assemblies 2 -Ignition distributor/ -Heidelberg VI fixed coded radio
- VIN (Vehicle Identification Hall generator 28.29 coding. a new or remanufactured
Number) 2 and Foreword -Ignition distributor/settings 28.29 radio 90.32
-Ignition wires/connectors 28.31 reactivating radio after.
Ignition Distributor and Settings -Rotor 28.31 reconnecting power 90.33
-Air-cooled AFC -Suppressor connectors 28.32 unlocking an electronically
CAN/USA, (except Calif.) 8 -Trigger wheel 28.38 controlled radio 90.34
Calif. 9 -Vacuum advance/retard 28.35
-Waterccooled Digijet 10 -Vacuum unit 28.35 Lifting Vehicle
- Digifant 11 Hoist/Floor jack 5
Ignition System-Air-cooled AFC Instruments, Radio
-California 28.8 198()..1984 Lights
distributor 28.11 -Cigarette lighter, replacing 90.31 -Bulb holder 94.6
distributor drive 28.20 -Fuel gauge
Hall control unit/generator 28.14 checking 90.5, 90.9
Hall ignition, troubleshooting 28.17 troubleshooting 90.13
xvi
Index
Mirrors Steering (cont'd)
WARNING- -Outside, electric -Power steering pump pressure
• Automotive sefVice and repair is serious adjustment range, increasing 66.3 checking 48.7
business. You must be alert, use common assembly 66.4 -Power steering system
sense, and exerr:::ise good judgement to
glass, removing/installing 66.2 filling/bleeding 48.7
prevent personal injury and complete the
~safely.
-Steering column switches 48.2
Radio -Steering drive/gear 48.4
• Before beginning any work on your -See Instruments, Radio -Steering lock assembly 48.3
Volkswagen, thoroughly read aR the -Steering wheeVcolumn 48.2
cautions and Warnings listed near the Refrigerator -Tie rods 48.4
front of this manual.
-See Gamper Equipment removing 48.5
• Always read the complete procedure -Troubleshooting 48.12
before you begin the work. Pay special Roof
attention to any cautions and Warnings Front headliner, installing 75.7a Sunroof
that accompany that procedure, or other removing 75.7 Panel
information on a specific topic. -Luggage rack, removing 75.8 adjusting 60.3
-Pop-up roof,. installing 75.3 guide plate adjusting 60.4
Lights (cont'd) removing 75.4 height alignment
-Headlight 94.4 -Pop-up roof seal, installing 75.6a front 60.3
aerodynamic 94.5a removing 75.6 rear60.4
adjusting 94.5 -Roof vent, installing 75.7 parallel adjustment 60.4
mounting frame 94.5 removing 75.6a removing/installing 60.2
removing 94.5 -Trim panel
-Ignition key, deburring 94.3a Seat belts removing/installing 60.3
-Intermittent windshield wiper 94.4 -Automatic 3-point seat belts -Water drains, cleaning 60.6
-Steering column retrofit installation 68.5 · rear drain hose, replacing 60.6
covers 94.3 -Automatic rear 3-point seat belts
lock 94.3 retrofit installation 68.7 Suspension-Front
lock cylinder 94.4 -Automatic 3-point left center seat -Assembly
switches 94.2 belt, retrofit installation 68. 10 early version 40.2
-Taillight 94.6 -Illuminated vanity mirrors late version 40.7
-Tum signal switch 94.3 replacing bulbs 68.13 -Ball joints assembly 40.10
-Seat belts, inspection 68.2 lower40.12
Lubrication System-Air-cooled AFC webbing defects 68.4 · -Coil spring
-Assembly 17.2 -Template measurements 68.6 removing/installing 40.3
-Oil cooler 17.2 -Lower control arm
-Oil pressure switch 17.2 Seats bushing, early version 40.6
-Oil pump 17.2 -Armrest, removing/installing 72.4 bushing, later version 40.8
Armrest, adjustable removing/installing 40.3
Lubrication System-Diesel assembly 72.5 -Shock absorber
-Assembly 17.4 removing/installing 72.6 removing/installing 40.4
-Oil cooler 17.4 -Front seat, removing/installing 72.2 -Steering arm, checking 40.12
-Oil filter 17.4 - Front seat backrest -Steering knuckle
-Oil pan 17.4 removing/installing 72.2 assembly 40.12
-Oil pressure switch 17.4 -Heated seats checking for wear 40.12
-Oil pump 17.4 component locations 74.2 modification, grease seal 40.13
heat elements 74.21 modification, brake disc
Lubrication System-Water-cooled - Rear seat with storage locker interference 40.14
-Assembly 17.7 removing/installing 77.2 - Subframe wax preservation 40.14
-Heating pipe, -Roof beds,·boards -Upper control arm
crankcase breather 17.9 removing/installing 77.3 bushing 40.5
-Oil pressure switch 17.9 lower40.6
-Oil pump 17.9 Steering removing 40.5
-Power steering wax preservation 40. 14
Maintenance Schedules checking for leaks 48.7 -Wheel bearing
-Lubrication, Emissions and Vehicle pressure/flow limiting valve 48.11 adjusting 40.11
Maintenance Schedules (Appendix) suspension changes 48.6 assembly 40.10
air-cooled, water-cooled system layout 48.6
and diesel models 1982-1985 A28 technical data 48.6 Suspension-Front, Syncro
water-cooled models from 1986 A32 Power steering pump -Axle shaft, assembly 40.29
removing/installing 48.9 length 40.30
repairing 48.1 0 removing/installing 40.28
xvii
Index
Suspension-Front, Syncro (cont'd) Torque Converter Transmission 4-speed 091/1 (cont'd)
-Ball joints -Bushing 32.3 -Assembly 35.32, 35.36
pressing 40.25 -Code letter 4, 32.2 mounting in repair stand 35.34
-Coil spring -Draining 32.2 -Clutch housing assembly 35.42
removing/installing 40.20 -Installing 32.3 -Differential 35.35
-Components assembly 40.15 -Oil seal 32.3 -Drive flange 35.32
- CV joint, inner circlip, installing 35.35
assembly 40.29 Towing installing 35.35
disassembling/assembling 40.33 -Procedure 6, 7 oil seal 34.18
pressing 40.31 removing 35.34
- CV joint, outer Transmission 4-speed 091 -Gear carrier 35.44
assembly 40.29 -Adjusting rings 35.3 assembling 35.40
disassembling/assembling 40.32 -Assembly 35.2 assembly 35.36
removing 40.31 -Clutch housing/ cover35.44
- Guards, drive shaft/engine mechanism 35.12 installing 35.39
removing/installing 40.28 -Differential 35.4 removing 35.38
-Lower control arm bushings 40.19 -Drive flange 35.3, 35.4 -Gears
-Shock absorber oil seal34.18, 35.15 1st/2nd, removing 35.36
removing/installing 40.20 -Gear carrier/Gearshift 3rd, end play 35.59
- Subframe, components 40.26 housing 35.6, 35.18 3rd, installing 35.59
installing 40.28 -Gear carrier housing 3rd, removing 35.56
removing 40.27 assembly 35.8, 35.16 -Gear ratios 34.9, 35.60
-Upper control arm bushings 40.19 -Gears -Gearshift lever 34.6
removing/installing 40.18a 1st gear needle bearing 35.27 bearing 34.6
-Wheel bearing pressing 40.24 3rd gear end play 35.29 -Gearshift linkage 34.6
-Wheel bearing housing -Gearshift lever 34.3 assembly 34.6
assembly 40.23 -Gearshift linkage 34.2 adjusting 34.8
removing/installing 40.17 assembly 34.3 bearings 34.6
-Wheel hub assembly 40.23 adjusting 34.4 -Installing 34.7
pressing 40.24 bearing plate 34.4 Lever bearing plate 34.6
-Installing 34.15 -Lubricant specifications 34.9, 35.60
Suspension-Rear -Interlock/detent plungers 35.17 -Main shaft 35.49
-Axle shaft assembly 42.4, 42.7 -Lever bearing plate 34.4 assembly 35.48
removing/installing 42.4 -Main shaft assembly 35.9, 35.20 ball bearing 35.51
-Constant velocity joint ball bearing 35.23 lock ring 35.52
assembly 42.7 oil seal 35. 13 needle bearing 35.51
disassembling/assembling 42.8 -Pinion needle bearing 35.23, 35.29 oil seal 35.43
removing/installing 42.8 -Pinionshaft assembly 35.9, 35.24 rear, removing/installing 35.35a
-Rear axle assembly 42.4 -Rear main shaft 35.5 -Pinion shaft 35.55
-Rear wheel suspension -Release shaft bushing 35.13 assembly 35.54
assembly 42.2 - Removing 34.14 needle bearings 35.57
-Shock absorber -Retaining ring 35.7 roller bearings 35.56
bushing/sleeve 42.3 -Reverse gear 35.14 -Removing 34.16
-Trailing arm bushing 42.3 end play 35.17 -Retaining ring 35.37
-Wheel bearings, inner/outer shaft circlip 35.15 installing 35.40
grease seals 42.5 - Rocker lever shaft 35.19 removing 35.38
removing/installing 42.5 -Selector shaft 35. 19 - Selector shaft
-Wheel studs -Shift forks 35.10 modifications 35.60a
removing/installing 42.6 -Shift rod 34.3 parts for 35.60d
Starter bushing 35.13 -Shift forks/synchronizers
Tarpaulin -Synchronizers modifications 35.60b
-Canada 61.2 1st/2nd gear 35.26, 35.28 parts for 35.60d
3rd/4th gear 35.21 -Shift rod bushing 35.46
Technical Data circlips 3rd/4th gear 35.21, 35.26 -Shift rod mounting 34. 7a
-Capacities Appendix 27 ring identification 35.30 -Shift shaft oil seal 35.46
-Cylinder Location Appendix 27 -Tapered roller bearing 35.26 -Starter bushing 35.43
-Digifant General 12 -Transmission housing 35.14 -Synchronizers
1st/2nd gear 35.58
-Engine Appendix 27
Transmission 4-speed 091/1 3rd/4th gear 35.50
-Vehicle identification Appendix 26 -Adjusting rings 35.32 -Technical data 34.1 a
installing 35.35 -Transmission housing 35.45
Tires marking/removing 35.34 assembling 35.39
-Rotating 44.1 a disassembling 35.38
xviii
Index
Transmission 5-speed 094 (cont'd) Transmission 5-speed 094 4WD
WARNING- -Removing 34.16 (cont'd)
• Automotive service and repair is serious -Retaining ring 35.67 -Main shaft seal
bUsiness. You must be alert, use common installing 35.70 removing/installing 35.12
sense, and exercise good judgement to
removing 35.68 -Needle bearing
prevent personal injury and complete the
-Shift rod bushing 35.78 inner race
worl< safely.
Shift shaft oil seal 35.78 loosening/tightening 35.123
• Before beginning any work on your Starter bushing 35.75 outer race, installing 35.126
Volkswagen, thoroughly read aH the -Synchronizer rings outer race, removing 35.125
Cautions and Warnings listed near the checking 35.90 removing/installing 35.115
front of this manual.
identification 35.92 -Output housing 35.103
• Always read the complete procedure -Synchronizers -Output shaft bearing
before you begin the work. Pay special 2nd/3rd gear 35.90 removing/installing 35.114
attention to any Cautions and Warnings 4th/5th gear 35.82 -Rear driveshaft, measuring 35.97
that accompany that procedure, or other assembling 35.90 -Removing 34.22
information on a specific topic. checking 325.82 -Reverse gear idler
installing 35.90 removing/installing 35.106
Transmission S·speed 094 removing 35.82, 35.88 -Shift rod bushing
-Adjusting rings 35.62 -Technical data 34.1 b removing/installing 35.115
installing 35.65 -Transmission housing 35.77 -Shift shaft seal
marking/removing 35.64 assembling 35.69 removing/installing 35.114
-Assembly 35.62, 35.66 disassembling 35.68 -Starter bushing
mounting in repair stand 35.64 removing/installing 35.112
-Clutch housing assembly 35.74 Transmission 5-speed 094 4WD -Synchronizer rings
-Differential 35.65 -Adjusting rings identification 35.127
-Drive flange 35.62 installing 35.96 -Technical data 34.19
installing 35.65 marking/removing 35.95 -1st/2nd gear synchronizer
oil seal 34. 18 -Assembling/Disassembling 35.99 checking/installing 35.124
removing 35.64 -Assembly 35.94, 35.98, 35.105 -3rd gear, installing 35.125
-Gear carrier 35.76 -Axle flange - 3rd/4th gear synchronizer 35.118
assembling 35.70 installing 35.96 installing 35.119
assembly 35.66 removing 35.95
cover35.76 -Bearing Transmission, Automatic
cover35.76 installing/checking 35.123 -Accelerator cable/linkage
installing 35.69 removing 35.122 090 except code letters NH 37.12
removing 35.68 inner race, removing 35.122 code letters NH only 37.14
-Gears -Clutch housing 35.111 -Apply shell 38.1 0
1st, shim 35.72 -Differential lock components 34.24 -ATF
2nd, removing 35.88 - Differential lock control checking/filling 37.9
3rdl4th, removing 35.88 repairing 34.26 dipstick changes 37.9
4th, end play 35.91 -Differential lock servo 34.25, 35.96 troubleshooting 37 .9a
4th, installing 35.91 -Drive flange seal, installing 35.115 -Direct/Reverse/Forward clutches
-Gearshift lever 34.10 -Drive pinion 35.121 installing 38.11
bearing 34.10 - Driveshaft flange, removing 35.104 -Final drive
- Gea..Shift, adjusting 34.12 -Flange nut oil seal37 .1 0
assembly 34.10 loosening/tightening 35.104 Forward clutch 38.8, 38.17
Installing 34.16 -Flange seal, installing 35.104 -Governor
-Lever bearing plate 34.10 -Gear carrier 35.1 07, 35.116 disassembling/assembling
-Main shaft 35.81 disassembling/assembling 35.108 090 code letters NG 38.22
assembly 35.80 -Gears removing/installing
ball bearing 35.83 1st, 2nd and 3rd, removing 35.122 090 except code letters NG 38.23
lock ring 35.84 -Gearshift linkage assembly 34.20 -Governor drive gear 38.14
needle bearings 35.83 adjusting 34.21 -Installing
oil seal 35.75 -Housing 35.113 090 except code letters NH 37.5
rear, removing/installing 35.65a -Installing 34.23 090 code letters NH only 37.6
- Modifications to trans. -Intermediate housing - Kickdown lever modification
manufactured prior to removing 35.106 090 code letters NH, NK 38.39
Dec. 15, 1982 35.65b -Low gear idler, removing 35.106 -Manual valve 38.35
-Pinion shaft 35.87 -Low gear shim, measuring 35.101 -Modifications 37.19
assembly 35.86 -Lower gear bearing -Oil pump 38.8, 38.22
needle bearings 35.89 removing/installing 35.126 -Operating rod 38.35
roller bearings 35.88 -Main shaft 35.117 -Operation 37.17, 37.19
bearing, removing/installing 35.119 - Parking lock 38.34
xix
Index
Transmission, Automatic (cont'd) Trim-Interior (cont'd)
- Parking lock modification -Instrument panel
090 code letters NH, NK 38.39 removing 70.5
- Pressure test procedure 37.18 replacing 70.6
- Pump shaft 38.3 Sliding door trim panel
-Removing assembly 70.3
090 except code letters NH37.4 removing 70.4
090 code letters NH only 37.6
- Reverse planetary gear set 38.12 Vehicle Care
-Reverse planetary ring gear 38.14 -Air cleaner A 10
-Selector lever assembly 37.2 -Battery A 14
-Selector lever cable 37.3 · -Brake fluid A13
-Separation plate -Cleaning products A3
090 code letters NG 38.26 -Cooling system A 11
090 code letter NG -Corrosion protection A5
from trans. no. 17 07 0 38.28 -Engine compartment A6
090 code letters NH, NK 38.37 -Engine oil A7
- Shift points 37.19 Engine oil filter A9
-Spacer springs and roDers 38.15 -Exterior A3
Spring table -Fuel filter (diesel) A10
090 code letters NH, NK - Fuel supply A 1
up to trans. no. 16 07 0 38.30 lnterior4
090 code letters NG -Lubricants A 7
from trans. no. 17 07 0 38.32 ~Maintenance A5
-Technical data - Power steering A 10
code letters NG, NH 37.1a Replacing wiper blades A16
code letters NK 37.1b -Tires/Wheels A 17
-Transfer plate -V-beltA12
090 code letters NG 38.26
090 code letters NG Vehicle Identification Number {VIN)
from trans. no. 17 07 0 38.28 - VIN 2, foreword
090 code letters NH, NK 38.37
-Transmission Wheels
assembly 38.7 -Alignment
090 modifications front 44.3
code letters NH, NK 38.37 rear44.4
-Transmission/Final drive specifications 44.2
assembly 38.2 -Alignment Syncro
end play 38.5 determining front toe 44.3a
separating 38.3 specifications 44.5
-Transmission housing studs 38.4
-Turbine shaft 38.3 Windshield Wiper/Washer
-Valve body -Assembly 92.2
removing/installing 38.25 Rear window washer/wiper 92.5
090 code letters NG 38.26 washer pump 92.7
090 code letters NG -Spray jets 92.4
from trans. no. 17 07 0 38.29 -Troubleshooting 92.8
code letters NG -Windshield washer 92.4
up to trans. no. 16 07 0 -Wiper arms/motor 92.3
-1st/reverse brake piston 38.10 -Wiper blade rubber insert 92.3
-2nd gear brake band 38.12
-2nd gear brake band piston 38.10 Wiring Diagrams
disassembling/assembling 38.24 -See Electrical Wiring
Trim-Interior
Coffee cup bracket, repairing 70.9
-Front door trim panel
assembly 70.2
moisture barrier 70.2
-Headlining
removing/installing 70.8
XX
General
Index
Identification (Numbers/Codes) Ignition distributor and settings
- Automatic transmi~SSion 4 - Air-cooled AFC
- Compression pressure Can/USA, not Calif. 8
values 2a California 9
- Engine2 .,.... Water-cooled Digijet 1o
- Front final drive - Digifant 11
Syncro 3b
- Manual transmission 3, 3a Technical data
- Type/ModeVAssemblies 2 - Digifant 12
- VIN (Vehicle Identification
Number) 2
Lifting Vehicle
- Hoist/Floor jack 5
Towing
- Procedure 6, 7
1
General
Type/model: Type: 25 Model: VANAGONNANAGON SYNCRO
Assemblies Code letters BHP (SAE) RPM
CAUTION
SYNCRO TRANSMISSIONS
Vehicle Identification
Type/Model/Assemblies identification
Beginning May 1987, engine codes are now either a Compression pressure values
two letter combination or a combination of one
number and one letter. Engine codes cv DH,MV cs
Engine code continues to precede the engine
number. Compression pressure 6-9 10-13 34
values bar (psi} (87- 131) (145- 190) (493)
CAUTION 5 8 26
Wear limit bar (psi)
Engines with identical code DO NOT (73) (116) (377)
necessarily have identical specifications. Maximum permissible 3 5
difference between all (44) (73)
four cylinders bar (psi)
A-3
From May 1987 Engine code
Compression pressure values
2a
General
Manual Transmission Type 091
Example DK 10 08 9
I I I I
code letters day month year (79)
of manufacture
134-16851
134-16871
Syncro
Frontfinal drive code letters 3b
General
Automatic Transmission Type 090
090 ..... .
Example NG 15 08 9
I I I I
code letters day month year (79)
of manufactu re
CAUTION CAUTION
Before driving, onto lift, check for clearance Do not lift vehicle by engine, transmission
between lifting arms and tires to avoid or front suspension. Doing so may result in
cutting sidewalls. damage to components
Extend arms and check to see if arms are
long enough to contact lifting points.
Lift only at points shown
Front
at crossmember next to jacking port
Rear
at rear crossmember
Note
When lifting vehicle with floor jack, use same
lifting points as with hoist
A-6
Lifting vehicle with hoist/floor jack 5
General
Emergency Towing
Note
All towing procedures are based on use of typical
sling-type tow truck equipment. If other types of
towing equipment are used, these procedures may
not apply
• whenever possible, tow with rear wheels off
ground
• if car with automatic transmission must be
towed with front wheels lifted because of
extensive damage, dollies should be used under
rear wheels if towing speed will exceed 30 mph
or distance over 30 miles. Exceeding these limits
will damage transmission Front hook-up-From 1986 m.y.
• selector lever must be in "N" position when
moving car with automatic transmission with rear - remove front license plate/bracket if interfere
wheels on ground with front hook-up
WARNING
Always secure front wheels with an external
steering wheel lock when towing with rear
wheels off ground.
~~--------4-·-----~CJ
Never use ignition steering lock to secure 4 x 4 x 48'' cross beam
front wheels.
Never allow passengers to ride in towed
vehicle
T-hooks
IQO-A1891 CAUTION
Front hook-up - all models thru 1985 Do not attach hooks or chains around brake
-attach grab hooks under lower control arms lines
outboard of shock absorber mounts (as shown)
-place 4x4 wooden crossbeam under spare tire - raise vehicle to allow four inches clearance
- place tow bar under 4x4 between tires and road
-double wrap chains on tow bar
-attach safety chains to lower control arms (as
shown) Towing speed/distance
Front tow - all models EXCEPT Syncro
Automatic transmission
30 mph (48 kmh) for up to 30 miles (48 km)
Manual transmission
50 mph (80 kmh) for up to 50 miles (80 km)
6 Towing
Vanagon
General
Flat Towing
Vehicles with automatic transmission may be
towed forward (in driving direction} at speeds up to
30 mph for maximum of 30 miles
CAUTION
Towing vehicles at more than 30 mph and/or
for distance greater than 30 miles with rear
wheels on ground will damage automatic
transmission due to lack of lubrication
Vanagon Syncro
Front/rear hook-up
The Vanagon Syncro cannot be towed with
conventional sling-type towing equipment nor with
wheel lift equipment or wheel dollies to avoid
damage to the all-wheel drive system.
- use flat-bed tow truck only.
A-8
Rear towing - all I I Syncro-front/rear towing Towing 7
General
l6 \2
I8 4 0-;;--
--
~~~~~~l~
__.
~
-..... 128·0501
Idle speed
manual 800- 950 rpm
automatic 850-1000 rpm
Vacuum hose disconnected
Vacuum advance
start 107-147 mbar (80-110 mm Hg)
s
~
4 0• 4 8 12 16
Idle adjustment
Vacuum hoses connected
Idle stabilizer plugs removed and
850-950 rpm
------- 128-0711
connected together
Vacuum advance
start 90-160 mbar (70-120 mm Hg)
Vacuum retard
start 90-160 mbar (70-120 mm Hg)
~
~
Idle speed 850±50 rpm
Vacuum advance
start 190-230 mbar (14.0-17.0 em Hg)
Vacuum retard
start 100-220 mbar (7.5-16.5 em Hg)
•-
., ,~, @~) 12&-3901
RPM* 2000.2500
Ignition adjustment ••
-· timing map --
RPM Approx. 3000
Degrees 35 :t: 5°
RPM limit Switch-off RPM of RPM 5600
digifant control unit
CAUTION
Part numbers are for reference only. Always
check with your parts department for latest part
information.
Digifant
Ignition settings 11
General
12 Technical data
Digifant
10
Engine
Assembly
Index
Engine (Air-cooled AFC)
- Removing 10.2
-Installing 10.5
Engine (Diesel)
- Removing 10.6
-Installing 10. 7
10.1
10 Engine- Assembly
Engine, removing
(Air cooled-AFC)
Work sequence
-disconnect ground cable from battery
-disconnect following
• plug 11 at double-relay
• plug A for resistors
• hoses B at deceleration valve
California only
-disconnect following:
- remove rubber boot for heater booster 4 • plug 1 at double-relay
-disconnect wire for alternator 5 • plug 2 at Hall control unit
-disconnect plug·& at control unit • plugs 3 at idle stabilizer
-pull engine oil level dip stick 7 • wire connection 4 for oxygen sensor
-disconnect wires at
• ignition distributor 8
• engine oil pressure switch 9 - remove nuts 12 of upper engine mounting bolts
-disconnect vacuum hose 10 for brake booste;- -disconnect accelerator cable 13
10 •2 Engine, removing
Air cooled - AFC
Engine-Assembly 10
Automatic transmission
Note
To gain access to bolts of torque converter,
engine must be rotated until each bolt -block fuel line from pressure regulator 17
appears in hole on top of transmission with clamp
housing
10 •4 Engine, removing
Air cooled - AFC
Engine - Assembly 10
Engine, installing
(Air cooled-AFC)
Proceed in reverse order of removing and
note following:
- check clutch release bearing for wear, replace
lf necessary
- lightly lubricate splines on main drive shaft
and contact points of clutch release bearing/
clutch release lever with MoSa grease
• do not lubricate clutch release bearing guide
sleeve
- always replace all self-locking nut~
Manual transmission
- adjust accelerah<!r cable at full throttle
position
Automatic transmission
- adjust accelerator cable
Tightening torques:
• engine to transmission 30 Nm (22ft Ib)
• engine carrier to mount 25 Nm (18ft lb)
• transmission mount 30 Nm(22 ft lb)
• torque converter to drive plate 30 Nm(18 ft lb) .
CAUTION
Coolant/antifreeze must not be reused when
replacing engine, cylinder head, cylinder head
gasket, radiator and heater core .
10 •6 Engine, removing
Diesel
Engine-Assembly 10
Engine, installing
Proceed in reverse order of removing and note
following:
CAUTION
Do not interchange fuel supply and fuel
-support engine with engine crane and adaptor return pipe union screws. For identification,
3058 fuel return pipe union screw Is marked with
• angle of engine to transmission can be OUT on hex. head. Fuel return line also has
adjusted by turning knob (arrow) smaller diameter than fuel supply line
Tightening torques:
• engine to transmission
M10 bolts 45 Nm (33 ft lb)
M12 bolts 80 Nm (59 ft lb)
• engine mounts 85 Nm (63 ft lb)
• support member 45 Nm (33 ft lb)
• fuel line union screws
on injection pump 22 Nm (16ft lb)
-remove nuts (arrow) from front engine mounts
on left and right sides
-remove bolts from both front and rear engine
mounts
-lower engine/transmission assembly until
engine can be separated from transmission
Diesel
Engine, removing/installing 10•7
10 Engine - Assembly
Engine, removing
CAUTION
Coolanttantifreeze must not be reused when
replacing engine, cylinder head, cylinder head
gasket, radiator and heater core.
-disconnect ground cable from battery
- remove air cleaner with air flow sensor and air
Intake duct
- disconnect following:
• plugs 1 at Injectors
• plug 2 at oxygen sensor
• plug 3 and 4 at ignition distributor
• plug 5 at oil pressure switch
• plug 6 at temperature sensor
• plug 7 at temperature sender
• plug at coolant level warning switch (not
shown-located In coolant expansion tank)
- remove ground connectors 8
Automatic Transmission
-remove circlip and spring 3 from
accelerator rod
- block coolant hoses with clamps a
• a= universal clamp-local supply
-open coolant expansion tank cap
10 •8 Engine, removing
Water-cooled
Engine-Assembly 10
Automatic Transmission
- remove accelerator rod 2
Syncro only
- remove rear skid plate under engine/transmission
Automatic Transmission
- remove three bolts which attach torque converter
to drive plate through hole on top of trans.
housing (arrow)
134-16751
- loosen mounting bolts for front transmission
bracket three turns (arrow)
B-9 Water-cooled
Engine, removing 10.9
10 Engine-Assembly
- loosen transmission mount bolt (arrow) - lower engine/transmission assembly until transmis-
sion rests on VW 785/1 B
-when lowering, adjust angle of inclination on floor
crane head and keep wiring harness aside so that it
can pass oil filler tube
-remove nuts 2 of lower engine mounting bolts
-remove engine from transmission and lower it out
of vehicle
Index
Air-cooled -Cylinder head gasket 13.19,
-Assembling 13.31
sheet metal 13.2 -Flywheel 13.23
crankcase 13.6, 13 ..14 -Intermediate plate 13.23
-Camshaft 13.14 -Intermediate shaft oil seal
-Carrier /Support 13.5 13.22
-Crankshaft -Pilot bearing 13.22
assembly 13.16 -Piston 13.27
clrclips 13.16 clearance 13.29
end play 13.10 diameter 13.29
oil seals 13.9 height 13.31
pilot bearing 13.17 identification 13.31
-Cylinder 13.11 marking 13.28
-Disassembling pin 13.28
sheet metal 13.2 rings 13.27
crankcase 13.6 ring end gap 13.29
-Distributor ring side clearance 13.29
installing 13.9
drive shaft 13.8 Water-cooled /Syncro
drive gear 13.16 -Assembling/disassembling 13.32,
-Flywheel 13.9 13.34
-Pistons 13.11 -Camshaft 13.50
-Piston rings 13.11 -Carrier/support 13.37a, 13.38
-Tor que converter ...;., CraJ"!kshaft
drive plat 13.9 assembly 13.52
circlips 13.54
Diesel drive gear 13.54
-Camshaft drive belt 13.18 end play 13.40
-Connecting rod 13.27 oil seals 13.39
bearing clearance 13.30 pilot bearing 13,56
bolts 13.30 replacing (1.9L) 13.57, 13.58
side clearance 13.30 -Cylinder 13.43
-Crankshaft 13.22 -Distributor
bearing caps 13.22 drive gear 13.38
drive belt cover 13.21 a drive shaft 13.38
end play 13.24 installing 13.38
journal sizes 13.23 -Flywheel 13.40
main bearing clearance 13.25 -Piston pin hole burrs
oil seal (flywheel side) 13.25 removing 13.47
oil seal (drive belt side) -Pistons 13.43
13.26 classifications 13.44
sprocket bolt 13.21 pin 13.44
-Cylinder block 13.27 rings 13.45
bore dimensions 13.30 -Torque converter
clearance 13.30 drive plate 13.40
-V-belt pulley 13.34, 13.35, 13.42
Index 13.1
13 Engine- Crankshaft, Crankcase
/ .
13 •2 Engine, disassembling/assembling
Air-cooled AFC
Engine-Crankshaft, Crankcase 13
Engine carrier/support----'
disassembling/assembling Fig. 5
Self·locking nuts
20 Nm (15 H lb)
NOTE always replace
Arrow on carrier must point to
front of vehicle when reinstalling.
To remove carrier only, unbolt
from mounts Heating air duct, lower
Air-cooled AFC
Engine, disassembllng/assemb11ng 13•3
13 Engine- Crankshaft, Crankcase
13 •4 Engine, disassembling/assembling
Air-cooled AFC
Engine-Crankshaft, Crankcase 13
Engine support
Air-cooled AFC
Engine carrier /support 13.5
C-5
13 Engine- Crankshaft, Crankcase
Distributor
remove together with bracket
installing Fig. 5
Oil s e a l - - - - - - - - - - - - .
Thrust spring
pry out carefully with screwdriver
installing Fig. 7
25 Nm (18 It lb)\
Cylinders/ platon a
011 cooler ----------,1 ~ marking page 13.1 1
replace oil cooler if there are o removing /Installing,
metal particles on pistons, checking page 13.1 1
crankcase bores, or in engine oil
\ ~25Nm(18ftlb)
Needle bearing
always replace
install with
locking compound
1
Clutch disc
Install with US 219
always replace
Spacer
Felt ring Flywheel
removing/Installing Fig. 9
adjusting crankshaft
Oil seal end play Fig. 11
used to adjust crankshaft
pry out carefully with
end play, see Fig. 11
screwdriver
installing Fig. 8
.....--cylinder head
/ Installing Fig . 1
r o.•
Rocker shaft
do not disassemble
15 Nm (11 ft lb)
-----
Air-cooled AFC
Engine, disassembling I assembling 13.7
C-7
13 Engine- Crankshaft, Crankcase
Cylinder head
13.8 Pistons
Distributor drive
Air-cooled AFC C-8
Engine - Crankshaft, Crankcase 13
113-1331
Fig. 7 Crankshaft oil seal, cooling fan side,
Installing
Air-cooled AFC
Distributor
Crankshaft oil seals
13 9
Flywheel/Torque converter drive plate •
13 Engine - Crankshaft, Crankcase
Example
dial indicator reading 0.44 mm (0.017 in.)
specified end play - 0.10 mm (0.004 in.)
thickness of 3rd shim 0.34 mm (0.013 in.)
Note
Thickness of shim is etched on shim.
Always recheck with micrometer
CAUTION
Always intall three shims to obtain
correct crankshaft end play
- remove flywheel
- Install 0-ring, crankshaft oil seal and felt ring
-install all three shims
- install flywheel
-tighten bolts to 110 Nm (80 ft Ib)
- recheck crankshaft end play
cyh2"him
7°
1.6 mm cylinder shim
71101 341
=i~~~lnotalllng Fig. 3
Piston
mark before removing Fig. 1
Cylinder Piston rings classifications Fig. 6
mark before removing Fig. 1 removing/installing Fig . 4 diameter/wear, checking Fig . 10
checking for wear Fig . 9 positioning Fig . 5 piston diameter I cylinder
Installing Fig. 11 end gap, checking Fig . 7 bore page 13.13
cylinder bore/piston side clearance, checking Fig . 8
diameter page 13.13
ll3-0l7J
Fig. 8 Piston ring side clearance, checking
clearance wear limit
upper/middle ring: 0.04-0.07 mm 0.12 mm
(0.002- (0.005 in.)
0.003 in .)
oil scraper ring: 0.02-0.05 mm 0.10 mm
(0.001- (0.004 in.)
0.002 in.)
13.12 Piston
Rings
Air-cooled AFC
Engine- Crankshaft, Crankcase 13
CAUTION
If measurement of piston I cylinder shows
that clearance is close to 0.2 mm (0.008 ln.),
piston/cylinder should be replaced by set
of same size group (standard or oversize).
Weight difference of pistons must not
exceed 10 grams.
If cylinder of damaged piston shows no
wear, install new piston of appropriate
matching size.
Cylinders/pistons must be of same size
group.
Piston
Air-cooled AFC Cylinder
13.13
13 Engine- Crankshaft, Crankcase
Crankcaae - - - - - - - . .
coat joining surfaces with
sealing compound
Camahalt
runout, checking Fig. 1
end play, checking Fig. 2
Installing Fig. 3
Crankcase
13.1 4 Crankshaft
Camshaft
Air-cooled AFC
Engine- Crankshaft, Crankcase 13
-turn crankshaft backward
• camshaft must not lift out of
bearings
• if camshaft lifts out of bearings,
install camshaft with smaller timing
gear
Note
To obtain specified backlash, camshafts
with various size timing gears are
available.
Markings are on Inner face of timing
gear.
CAUTION
Mark 0 on outer face of camshaft timing
gear is timing mark and must not be
confused with markings on inner face.
Crankshaft timing gear is available in one
size only
Air-cooled AFC
Camshaft 13."15
13 Engine- Crankshaft, Crankcase
Connecting rod bearing
note position,
do not Interchange
Dl1trlbutor drive gear
I
press off I install together w!th
crankshaft timing gear
Crankshaft pilot bearing
removing Fig. 3
removing Fig. 8
installing Fig. 4
Installing Fig. 9
removing Fig. 1
lnstallng Fie 2 Connecting rod nuts
35 Nm (25ft lb)
Crankshaft timing gear always replace,
press off /Install together with lubricate contact surface
distributor drive gear crankshaft web when Installing
removing Fig. 3
inBtalling Fig. 4
13.16 Crankshaft
Connecting rod
Air-cooled AFC
Engine - Crankshaft, Crankcase 13
VW428a VW415a -..
~
Fig. 4 Distributor drive gear/crankshaft timing
gear, installing
-heat gears to approx. 80"C (175"F)
before installing
Crankshaft sprocket
two types, installing page 13.21
see page 13.21
20 Nm (14ft lb)-
Cylinder h e a d - - - -
removing/installing,
Repair Group 15
20 Nm (15ft lb)
Cylinder
head gasket - - - - - - - '
installing, Vacuum pump
Repair Group 15
20 Nm (15ft lb)
10 Nm (7ft lb)
filter
Diesel
Engine, disassembling/assembling 13•19
13 Engine-Crank~haft, Crankcase
Drive belt, removing
Work sequence
,
-tighten to 25 Nm (18ft lb) • measure gap at other end of tool with feeler
gauge
• take half of measurement and insert feeler of
this thickness between tool and cyl inder
head
• turn camshaft so that tool rests on feeler
• insert second feeler of same thickness be-
tween other end of tool and cylinder head
New Version
200 Nm (148 ft lb)
lubricate threads before installing
Shown above are the two versions of drive belt
sprocket used on Diesel Vanagon . Ensure that the
correct tightening torque specification is used
when repairing these engines.
Note
Only the new version pulleys will be supplied as
service parts.
20 Nm (15ft lb)
65 Nm (47111b) i
. - - Pilot bearing
removing Fig. 3
installing Fig. 4
13.22 Crankshaft
Intermediate shaft
Diesel C·6
Engine- Crankshaft, Crankcase 13
WARNING
Friction materials such as brake and clutch
linings, or brake pads may contain asbestos
fibers.
Do not create dust by grinding. sanding or by
cleaning with compressed air.
Avoid breathing asbestos fibers and asbestos
dust.
Breathing asbestos. may result In serious Clutch disc - - - - - -
diseases, such as asbestosis or cancer. use 10-213 when installing
Flywheel - - - - - ,
removing/installing Fig. 1
75 Nm (54 ft lb)
always replace
insert with D6 locking compound
Intermediate plate
=ig. 10 must fit on dowel sleeves
Note
3 undersizes of bearing shells available in
graduations of 0.25 mm
Diesel
Flywheel 13.23
13 Engine - Crankshaft, Crankcase
Fig. 2 Intermediate shaft oil seal, Installing Fig. 5 Main bearing cap, positions
• bearing No. 1 on drive belt side
• bearing No.5 on flywheel side
CAUTION
Do not turn crankshaft
Removing
-remove drive belt cover and drive belt
-remove drive belt sprocket on crankshaft
-remove woodruff key from crankshaft
_.---~-Piston rings
offset gaps 120•
removing/installing Fig. 6
checking piston ri ng side clearance Fig. 7
checking piston ring end gap Fig. 8
Clrcllp - - - - - - . ( )
P i s t o n - - - - - - - -.....:.•
marking piston poslti9n Fig. 1
installing Fig. 5
checking clearance.'wear Fig. 9
c
- - - - - Piston pin
height Fig. 16 removing/installing Fig. 4
Identification Fig. 14
--------Connecting rod
removing Fig. 2
Cylinder bore---...:.....---..
Installing Fig. 3
checking Fig. 10
checking side clearance F i g.13
table page 13.30
checking bearing clearance Fig . 12
Cylinder block
)..12 C-1 1 Diesel Piston
Connectlng rod 13.27
13 Engine- Crankshaft, Crankcase
[ 13-347 I
Fig. 1 Pistons, marking Fig. 4 Piston pin, removing/Installing
-mark number on piston to match -remove circiips
cylinder number. Arrows point toward -if too tight, heat piston to approximately
drive belt side 60"C (140"F)
Connecting rod
13.28 Piston
Piston pin
Diesel
Engine-Crankshaft, Crankcase 13
Piston rings
Diesel Piston
Cylinder 13.29
13 Engine- Crankshaft, Crankcase
Cylinder bore
Bora Piston dia.
(mm) (mm)
Standard 76.51 76.48
76.52 76.49
76.53 76.50
1st oversize 76.76 76.73
76.77 76.74
76.78 76.75
2nd oversize 77.01 76.98
77.02 76.99
77.03 77.00
3rd oversize 77.51 77.48
77.52 77.49
77.53 77.50
CAUTION
rigid bolt:
- lubricate contact face of nut
-tighten to 45 Nm (33ft lb)
lt.5•262l
Fig. 13 Connecting rod side clearance, checking Fig. 15 Cylinder head gasket, identification
wear limit: 0.37 mm (0.014 in)
white arrow= identification notches
black arrow= part number
Note
Always select gasket thickness according to
piston height above top of cylinder block
Piston Identification
D-17 Diesel Piston height
Cylinder head gasket 13.31
13 Engine-Crankshaft, Crankcase
Note
Arrows on carrier must point to
front of vehicle when reinstalling.
Remove carrier as complete assembly
~'~
I
I
I
I
20 Nm (15 fl lb)
~ oJ
CAUTION
Coolant/antifreeze must not be· reused when
replacing engjne, cylinder head, cylinder head
gasket, radiator and heater- core.
7 Nm (61 in. lb)
Water pu•nP·---~
remove and install as
complete assembly
20 Nm (15 ft lb)
Gasket
E-3
1983-1 985 II Water-cooled
Engine, disassembling/assembling 13.33
13 Engine- Crankshaft, Crankcase
CAUTION
Coolant/antifreeze must not be reused when
replacing engine, cylinder head, cylinder head
gasket, radiator and heater core.
Coolant pump---.
- - - - - - - - - - - - - - - - v - belt
for Coolant pump
V-belt pulley
replacement part only has
TDC marking
Add timing notch:
5° BTDC = 7.5 mm to right of
TDC marking
13 •3 4 Engine, disassembling/assembling
Water-cooled-from 1986
Engine-Crankshaft, Crankcase 13
Socket
and handle
CAUTION
When assembling crankcase
halv.es, see f ig. 5
CAUTION
Coolant/antifreeze must not be reused when
replacing engine, cylinder head, cylinder head
Ignition distributor drive
gasket, radiator and heater core.
shaft
removing Fig. 1 When replacing coolant/antifreeze solution in
installing Fig. 2 all Volkswagen models, all model years, use
phosphate-free coolant/antifreeze
zvw 237102.
Crankcase halves
assembling Fig. 5
20 Nm (15 ft lb)
coat tx>th sides of washer
with AMV 188 001 02 sealing compound
TDC sender
installing Fig. 11
Oil seal ~
always replace
Thrust washers ~
install and position
with screwdriver
~
When replacing coolant/antifreeze solution in .w
all Volkwagen models, all model years, use
110 Nm (81 lllb)
phosphate-free coolant/antifreeze
zvw 237102.
Dowel pin
Oil seal - - - - - - -
pry out carefully with
screwdriver
installing Fig . 7
"•""") 1
)r
Pressure plate
mark position before
removing
\_Foil riog
L....,.....,..
Flywheel
removing/Installing Fig. 9
adjust ing crankshaft
(Manual Trans. only) end play Fig. 12
lubricate with MoS, grease
WARNING
:ompound Friction materials such as brake and clutch
Cylinder head linings, or brake pads may contain asbestos
Shims (thru 1985) drain coolant at fibers.
used to adjust crankshaft drain plug
end play, see Fig. 12 Installing and Do not create dust by grinding, sanding or by
1986 Models repairing, see Repair cleaning with compressed air.
see 13.41 for arrangement Group 15
Fig. 13 Avoid breathing asbestos fibers and asbestos
dust.
:e
Breathing asbestos may result in serious
diseases, such as asbestosis or cancer.
It may cause severe injury and death.
_ / , . - - - - - - - - - - - - - 5 0 Nm (37ft lb)
D drain coolant before
loosening.
ealing
Coat surface with
AKD 456 000 01
Rocker shaft sealing compound
slot points upward tightening, see
Repair Group 15
25Nm~8ftlb)J
Gasket
Sealing r i n g - - - - - - --
alway• <eplaoe J Cylinder head cover gasket
Coolant drain plug checkfordamageand
replace if necessary
E·7 Water-cooled
Engine, disassembling/assembling 13.37
13 Engine-Crankshaft, Crankcase
Engine c a r r i e r - - - - - "
note installation position,
arrow points In driving
direction
Engine, carrier/support
E-9
Water-cooled Engine, disassembling/assembling 13.38
13 Engine-Crankshaft, Crankcase
Example
dial indicator reading 0.44 mm (0.017 in.)
specified end play -0.10 mm (0.004in.)
thickness of 3rd shim 0.34 mm (0.013 in.)
Fig. 10 Torque converter drive plate, removing
Shims C on vehicles from 1986, see Fig. 13
- lock plate with VW 802
- to remove, screw in bolt 1 go to next page
(M 18 x 1.5 x 60). Thread length of bolt
must be at least 45 mm (1.77 in.)
E-11
Water-cooled
Torque converter drive plate
Crankshaft end play 13.40
13 Engine -Crankshaft, Crankcase
Note Parts required
Thickness of shim is etched on :shim . .Always
Description Part no. Quantity
recheck with micrometer
Thrust washer 025 105 283 1
81.0mm (3.2 in.) 025 105 281 1
CAUTION diameter shim
75.0mm (3.0 in.) 021 105 281 2
Always install three shims to obtain correct
diameter shims (0.30mm thickness)
crankshaft end play
021105 283
- remove flywheel (0.32mm thickness)
- install 0-ring, crankshaft oil seal and felt ring 021 105 285
install all three shims (o:a4mm thickness)
021 105 287
- install flywheel (0.36mm thickness)
-tighten bolts to 60 Nm (44ft lb) plus an add'l1/4 turn (90°)
021 105 289
- recheck crankshaft end play
(0.38mm thickness)
021 105 291
(0.24mm. thickness)
94.0mm (3.7 in.) 025 105 635
diameter shim
Oil seal 029 105 245 B
0-ring. 021 105 279
Sealing ring
~ olways 'eplace .
Engine carrier
13-A030
3102
Note
Triple V-belt pulleys supplied as spare
parts have only TDC mark 0. Cut timing
mark same as single V-belt pulley, see
page 13.33
Piston pin
removing Fig . 3
installing Fig. 12
13.43 Piston/Cylinder
Water-cooled
Engine- Crankshaft, Crankcase 13
A-
B
c
D
Fig. 1 Piston/cylinder sleeve, marking
• arrow points to flywheel
-before removing, mark matching
numbers on pistons and cylinder
sleeves
• cylinder boss 1 faces inward
3091
Fig. 3 Piston pins, removing
- remove pins as shown (arrow)
E-15 Water-cooled
Piston/cylinder sleeve
Piston pins/circlips
Piston classifications
13 44 •
13 Engine-Crankshaft, Crankcase
113-7771
Fig. 6 Piston distinguishing characteristics
• 2.1 L Dlglfant/Syncro Of'IIY -push ring in squarely from lower
cylinder opening about 4-5 mm
engine code dimension 'a' (3/16 in.)
- measure gap with feeler gauge
MV 15.5 mm
ring end gap wear limit
upper ring= 0.30-0.45 mm 0.90 mm
(0.012-0.018 ln.) (0.035 in.)
lower ring = 0.30-0.50 mm 0.90 mm
(0.012-0.020 ln.) (0.0351n.)
oil scraper= 0.25-0.40 mm 0.95 mm
ring (0.010-0.016 in.) (0.037 ln.)
~
·-
Fig. 9 Piston ring side clearance, checking
13-A032 I
Fig. 12 Piston and cylinder sleeve, installing
Fig.10 Piston, checking diameter/wear -replace rubber sealing rings for cylinder
sleeves:
-measure at bottom of skirt approx. • cylinder head end = thin ring (green)
15 mm (9/16 in.) from edge • crankcase end = thick ring (black)
(diameter stamped in top of piston)
-install piston into cylinder sleeve
(flywheel side first)
• arrow on piston points toward flywheel
• gap of oil scraper ring must be to top
• piston ring gaps offset by 180° (see
explosion view)
nit
- insert circlip for piston pin on flywheel
m side of piston
n.)
us 1033S
m
n.)
m
fl.)
113-6331
Fig. 11 Cylinder sleeve, checking for wear Fig. 13 Piston and cylinder sleeve, installing
-measure 10-16 mm (3/8-5/8 in.) from top - note markings on connecting rod
• piston to sleeve clearance is sleeve support 3090
diameter minus piston diameter • R = right side of engine
new = 0.03-0.06 mm (0.001-0.002 in.) • L = len side of ~ngine
wear limit = 0.2 mm (0.008 in.) -push connecting rod support onto
center stud so finger of tool supports
Cylinder sleeve bore/Piston diameter connecting rod; then secure it with
rubber band 1 to prevent it from slipping
nit cylinder matching piston -align connecting rod such that piston
size
m diameter diameter pin can be installed through hole in
n.) standard blue 94.005-94.016 mm 93.98 mm housing
1st • crankshaft must be at TDC
m oversize pink 94.016-94.027 mm 93.99 • lug on rod faces up
n.)
rn
n.)
E-17
Water-cooled
Piston/Cylinder sleeve 13.46
13 Engine - Crankshaft, Crankcase
j13-777a J
- remove circlip
Cutting teeth
CAUTION
When assembling crankcase halves, observe
tightening sequence and tightening torque
(see page 13.36 and page 13.39, Fig. 5)
Camshaft bearing
lubricate before installing.
Tabs must engage in
recess
Crankshaft
disassembling/assembling,
see page 13.54
runout, chec king Fig. 1
end play, checking Fig. 2
installing Fig. 3
CAUTION
When assembling crankcase halves, observe
tightening sequence and tightening torque.
Main bearing No. 1
color coded red/blue
Oil pickup line with filter screen. Fig. 4 corresponding to crankshaft
- - - - Crankcase dimensions
clean and blow through all lubricate before installing in
oil channels with compressed air crankshaft
Coat joining surfaces with tabs on bearing fit into recesses
AMV 1,88 001 02 sealing compound in crankshaft housing
oil holes in left side of
check for tight fit in case crankshaft
J
Camshaft end cap
install with sealing compound
Thrust washer - - - - - - - - - .
tab points toward crankshaft
bearing and separating line
Fig. 6
Crankshaft----'
Crankcase
13.49 Crankshaft
Camshaft
Water-cooled from 1986
Engine- Crankshaft, Crankcase 13
-turn crankshaft backward
• camshaft must not lift out of
bearings
• if camshaft lifts out of bearings,
install camshaU with smaller timing
gear
Note
To obtain specified backlash, camshafts with
various size liming gears are available.
Markings are on inner face of timing gear
Example
Fig. 1 Camshaft runout, checking "-0.1", "+0.1", "+0.2", Indicates In
• wear limit 0.04 mm (0.0015 in.) 11100 mm how much pitch radius
differs from standard pitch radius "0"
CAUTION
Mark 0 on outer face of camshaft timing
gear is timing mark and must not be
confused with markings on inner face.
Crankshaft timing gear is available in one
size only
Spacer
Crankshaft pilot bearing
manual trans. only
removing Fig. 13
installing Fig . 14
J :-. '-
Circlip
removing Fig . 2 Connecting rod nuts
installing Fig . 3 45 Nm (33 ft lb)
lubricate contact surface
Distributor drive gear when installing
press off/install together From1986MY2 .1L
with crankshaft timing gear 30Nm (22 It lb)
removing Fig. 4 plus half turn
installing Fig. 5 always replace
13 •52 Crankshaft
Water-cooled
Engine-Crankshaft, Crankcase 13
3 3
2 2 2
Crankshaft color code
1 = Color code green (2.1 L engine-Digifant!Syncro)
2 = Color code blue or red (crankshaft code/size)
Note
On some crankshafts the blue or red code can
appear in position three.
Note
If crankshaft has blue or red dot only main
bearings with same color code can pe used.
Code for main bearings, 1, 2, 3 = 001 (blue), 004
(red)
F·3
Water-cooled
Crankshaft journal sizes 13.53
13 Engine-Crankshaft, Crankcase
Crankshaft/Circlip
Engine
Cylinder Head
Valve Drive
Index
Air-cooled Water-cooled Syncro
- Compression pressure - Gasoline additive
checking 15.2 reducing carbon deposits 15.31
- Cylinder head - Compression pressure
assembly 15.2 checking 15.20
- Gasoline additive - Cylnder head
reducing carbon deposits 15.25 assembly 15.17
- Rocker arm shaft installing 15.23
installing 15.3 sealing 15.23, 15.26
-Valves - Engine block
assembly 15.2 assembly 15.22
dimensions 15.3 - Pushrod tubes
guides 15.4 replacing 15.25
hydraulic lifters 15.6 -Valves
seats, refacing 15.4 assembly 15.17
springs 15.2 dimensions 15.18
hydraulic lifters 15.23
Diesel guides 15.20
-Camshaft seats, refacing 15.18
assembly 15.1 0 springs 15.18
end play 15.15
oil seal15.15
radial clearance 15.15a
run-out 15.15
-Compression pressure
checking 15.16
- Cylinder head
assembly 15.8
bolts 15.9
distortion 15.14
gasket 15.9
-Valves
assembly 15.1 o
15.1
15 Engine-Cylinder Head, Valve Drive
Compression, checking
WARNING
On vehicles with electronic ignition,
disconnect terminal 4 on ignition coil and
connect to ground before performing
compression test
dimensions Fig. 4
lapping, exhaust Fig. 6
refaclng, Intake Fig. 5
Cylinder head
installing Fig. 8
/ valve seat refacing page 15.4
30 Nm (22 ft lb)
tightening sequence Fig. 8
Valve spring
removing/installing Fig. 2
15 ~m (11 ft lb)
Push rod
max. run-out 0.3 rnm (0.012 ln.)
1 a , --~
J_ ,
L. . . . .
installed position Fig. 3
15- 429
•
F
15 •2 Cylinder head
Air cooled- AFC
Engine- Cylinder Head, Valve Drive 15
c ---------------~
Exhaust valve
a = 33.0 mm (1.299 in.) diameter
b =- 8.92 mm (0.351 in.) diameter
c = 115.4 mm (4.540 in.) length
a= 45°
CAUTION
Do not rework exhaust valves by machine;
lap by hand only
d
_L _
~===========~ - T-
lls-o28l
CAUTION
Damaged or burnt seats can be refaced if:
• permissible width of seat A is maintained
• 15°chamfer B does not exceed outer
diameter of valve seat Insert In cylinder
heat at C
. -
-
- -
-- mzm
-
Fig. 7 Valve guide checking for wear
- remove carbon
- insert new valve Into valve guide
• valve stem must be flush with valve
guide end
- rock valve back and forth against dial
indicator (arrow)
• max. 1.2 mm (0.047 in.)
Valve lapping
15-A015]
l1s-A022 I
- lightly chamfer edges of intake and exhaust
valve seats A with 75" cutter
CAUTION
If metal partic les are found In oil pan,
remove, disassemble, clean and reinstall all
- coat new guide with engine oil and press in valve lifters from position removed
If rocker shafts have been removed,
following standard adj ustment is necessary
CAUTION
Do not use more than 2 tons of pressure
Work sequence
- set adjusting screws in rocker arms so that
ball shaped end is flush with surface of arm
-turn crankshaft until cylinder No. 1 Is at TDC
(mark on rotor in line with mark on distributor
housing)
- turn adjusting screws so they just touch valve
stems
- turn adjusting screws 2 turns clockwise and
tighten locknuts
-rotate crankshaft 180 " and adj ust next
cylinder
-repeal until all cylinders are adj usted
CAUTION
After valve guides have been replaced,
valve seats must be refaced fiEWl
-before installi ng, check that valve lifter Is bled
correctly
• check by applying firm thumb pressu re on
push rod socket in direction of arrow.
Resistance should be felt
if NO, bleed lifter as follows:
Pushrod socket
Plunger
Ball check~
es. valve
~~Check valve spring
Check valve_/
~
~ Plunger
6 eprlng
retai ner
Valve body
Piston Identification
height (notches In
mm (ln.) gasket) Part No•
• 0.63-0.82
(0.025-0.032)
0.83-0.92
1
2
068103 383L
068103 383M
(0.033-0.036)
Fig. 2 Cylinder head bolts, tightening sequence 0.93-1.02 3 068103 383N
(0.037-0.040)
-with engine cold , torque cylinder head
bolts in sequence in following steps:
step 1 to 40 Nm (30 ft lb)
step 2 to 60 Nm (44 ft lb)
step 3 to 75 Nm (55 ft lb)
-after step 3, turn bolts in sequence
with breaker bar 1/z turn (180°) further
(two 114 turns are O.K.)
-run engine until it reaches normal
operating temperature (engine oil
temperature 50°C/122°F or when
radiator fan starts running)
-stop engine and retighten head bolts in Fig. 4 Cylinder head gasket,
sequence 1/4 turn (90°) further with Identification/Installation
breaker bar without first loosening them
-after about 1000 miles (with engine • identified by Part No. and notches
either cold or warm) retighten cylinder (arrows)
head bolts with breaker bar, turning -always select gasket thickness accord-
bolts in sequence 1/4 turn (90°) with- ing to piston height above top of
out loosening them and without cylinder block
interruption • marking OBEN on gasket must face
cylinder head
G-9
Diesel
Cylinder head
Cylrnder head bolts
Cylinder head gasket
15 9 •
15 Engine-Cylinder Head, Valve Drive
CAUTION
~--- Bearing caps
L _ _ __:__ _ _ _ _ _ _ _ _ _ _ _ _ _J ---::::::~'71 bores are offset
removing Fig. 3
installing Fig. 4
20 Nm (15ft lb)
Cam follower
mark position
before removing
Valve spring ret~tlner
Valve spring seat
removing Fig. 9.
Valve guide - - - - - -.........
checking for wear Fig. 10
replacing Fig. 11 and Fig. 12
Stem seal
removing Fig. 6
installing Fig. 7
replacing with cylinder head installed Fig. 5
~---Cylinder head
refacing valve seats Fig. 13
check for distortion Fig. 17
Note
If combustion chamber insert
is damaged, replace
cylinder head
Jl5·254J
Compression
checking, page 15.16 clearance, checking/adjusting Fig. 1 CAUTION
refacing Fig. 14 and Fig. 15
tapping Fig. 16 Coolant/antifreeze must not be reused when
replacing engine, cylinder head, cylinder head
gasket, radiator and heater core.
Camshaft
CAUTION
Do not turn camshaft by mounting bolt.
This will stretch drive belt
G-11
Diesel Valve adjusting disc
Valve clearance
15.-41
I 1
15 Engine-Cylinder Head, Valve Drive
G-12
15:12
•
Camshaft bearing caps
Valve stem seals
Diesel
Engine-Cylinder Head, Valve Drive 15
llt---1( -206
CAUTION
Once guide shoulder Is seated do not use
more than 1 ton pressure or guide shoulder
may break
G-13
Diesel Valve springs/seats
Valve guides
15...I 3
r
15 Engine-Cylinder Head, Valve Drive
----~-a--- CAUTION
- -- - - - b - - - Do not reface exhaust valves on a machine.
I
I
Ii Fig. 15 lntakefExhaust valves, refaclng
Intake Exhaust
115-2701
a= 34.00mm(1.338in.) 31.00 mm (1.220 in.)
Fig. 13 Valve seats, refaclng
b = 7.97 mm (0.314 in.) 7.95 mm (0.313 in.)
• seat refaclng pilot must be properly c = 104.8 mm(4.125in.) 104.6 mm (4.117 in.)
installed a= 45° 45"
Valve seat angle = 45 •
Correction angle = 15"
Dimension d must not be more than
1.5 mm (0.059 ln.)
Intake Exhaust
a = 35.2 mm (1.3841n.) 33.2 mm (1.3061n.)
b = 32.8 mm (1.290 ln.) 30.4 mm (1.1961n.)
c = 2.0 mm (0.0781n.) 2.4 mm (0.0961n.)
Note
Valve seats which are worn or burned can be
refaced provided that correction angle and seat
width are maintained. Otherwise, cylinder head
Flg.16 Valves, lapping
must be replaced
~lift and turn regularly
Valve seats
15:14
•
Valves
Cylinder head
Diesel
G-14
c
Engine-Cylinder Head, Valve Drive 15
US1026~ Camshaft oil seal, removing/Installing
or
us 1027 Note
Puller 2002 may also be used
Work sequence
Removing
-set engine at TDC for cylinder No. 1
-remove drive belt cover and drive belt
-loosen camshaft sprocket bolt 1/2 turn and tap
sprocket with rubber hammer
-remove bolt and sprocket
G-15
Diesel Camshaft
Camshaft oil seal
1515 •
15 Engine-Cylinder Head, Valve Drive
Note
If this limit is exceeded, check the radial clearance
again with a new camshaft.
-press seal in flush If the clearance with a new camshaft also exceeds
the wear limit, the cylinder head must be replaced.
CAUTION
To avoid damage, keep Injection parts
clean when removing, Installing,
disassembling and assembling
L injector .J
~·~ heat shield
I 23-A0111
Valves
valve dimensions Fig. 2
intake valve refacing Fig. 3 Cylinder head
valve seat refacing page 15.18
Valve guides-----"
checking page 15.20
Compression
checking p age 15.20
15.18 Valves/springs/dimensions/
refaclng Water-cooled H·
Engine-Cylinder Head, Valve Drive 15
Note
When new valves are installed in properly
reworked seats, it may not be necessary to lap in
valves
CAUTION
After lapping valve, remove all traces of
grinding paste
115-0861
- reface surface to 75 • angle
• slightly chamfer lower edge of valve seat
Minimum 8 bar
(116 psi)
Cylinder head
before removing, drain coolant. always replace
sealing Fig. 2
installing Fig. 3
H-6
Water-cooled
Cylinder head, assembly 15 •21
15 Engine-Cylinder Head, Valve Drive
CAUTION
Coolant/antifreeze must not be reused when
replacing engine, cylinder head, cylinder head
gasket, radiator and heater core.
When replacing coolant/antifreeze solution in
all Volkswagen models, all model years, use
phosphate-free coolant/antifreeze only,
zvW 237104.
Note
Cylinder head can be
removed and installed
with engine installed.
Torque sequence
CAUTION
Do NOT use click type torque wrench. Use
only beam or dial type wrench.
Note
Be. sure that push rod tubes are properly seated.
Fig. 2 Cylinder head, sealing
Second stage: tighten cap nuts, in numbered
Applying sealant D ooo 400 01 sequence to 50 Nm (37 ft lb)
CAUTION
Guide pushrod carefully into seat of hydraulic
valve lifter.
If pushrod rests on edge of lifter basic setting
will be incorrect and lifter will be damaged
when engine is started.
Removing
• disconnect battery ground strap
• remove rear mattress (where applicable),
carpet, engine cover
• remove air cleaner assembly
• remove AJC compressor from bracket,
leave hoses attached
WARNING.
Note
Do not reinstall oil drain plug until repair is
completed.
• remove spare tire cover under front of
vehicle, disconnect coolant hoses
• reconnect radiator coolant hoses
• close spare tire cover
• remove coolant pump
Note
Mark push rods for reinstalling to original
location.
• remove cylinder head cap nuts, push rod
tubes and cylinder head
• stuck cylinder sleeves may be removed
by lightly tapping with small solid rubber
mallet
• clean old gasket material from cylinder
heads, engine block, valve covers
• inspect sealing surface of cylinder head,
replace if pitting or cavitation present
• mark matching numbers on piston/cylinders
• pull out cylinder sleeves with tool 3092 until
piston circlip is visible
• see Repair Group 13
• remove piston circlips, wrist pins with tools
3091, 3159
• see Repair Group 13
Installing
CAUTION
Always replace gaskets, seals, 0-rings,
lubricants.
CAUTION
Part numbers are listed for reference
only. Always consult with the Parts
Department for latest information.
;-------·--·a----~--~
CAUTION
Do not use too much sealant. Excessive
sealant could plug cylinder head coolant
passages or hydrolock cap nuts.
CAUTION
DO NOT use click type torque wrench.
Use only beam or dial torque wrench.
Torque sequence
Note
Ensure that push rod tubes are properly
seated.
First stage: tighten cap nuts in numbered
sequence to 10 Nm (7ft lb)
Second stage: tighten cap nuts in numbered
sequence to 40 Nm (30 ft lb)
Third stage: tighten cap nuts in numbered
sequence to 50 Nm (37ft lb)
• recheck final 50 Nm (37 ft lb)
• reinstall push rods, rocker arms
• push rods must be properly seated
before tightening rocker arms
• torque: 25 Nm (18ft lb)
-
Water-cooled Cylinder head resealing 15 •29
15 Engine-Cylinder Head, Valve Drive
• reinstall all other components in reverse
order of removal
• check expansion tank pressure cap with
VAG 1274/99
CAUTION
Coolant/antifreeze must not be reused
when performing this procedure. When
replacing coolant solution in all
Volkswagen models, all years, use
phosphate-free coolant ZVW 237 104.
Note
Read product label for additional information. Read
all cautions and warnings.
Caution
Do not exceed this recommendation:
CAUTION
Part numbers are for reference only. Always
consult your Parts Department for latest
information.
-
H·16 Gasoline additive 15.31
17
Engine
Lubrication System
Index
Alr-®oled Water-®Oied /Syncro
'~Assembly 17.2 -Assembly 17.7
-Oil cooler 17.2 ~Heating pipe,
checking 17.3 crankcase breather 17.9
-Oil pressure switch 17.2 -Oil pressure switch 17.9
checking 17.3 ~il pump 17.9
removing 17.3
-Oil pump 17.2
removing 17~3
Diesel
-Assembly
-Oil filter 17.4, 17.5
.:_Oil cooler 17.4
checking 17.5
-Oil pan 17.4, 17.6
-Oil pump 17.4, 17.5
-Oil pressure switch 17.4, 17.6
Index 17.1
17 Engine-Lubrication System
Oilcool•'~
check lor leaks Fig. 3 n
011 pre..ure relief valve
20 Nm (15 H lb)
•' o')
Replace all cooler if there are
metal partic les on pistons,
'
<J Otl a trainer cover
' - - 13 Nm (9 It lb)
125 Nm (18 It lb)
011 pump
Oil pump
1·2 1-3 Air cooledwAFC f>il cooler
Oil pressure. 17.3
17 Engine-Lubrication System
on tiller cap
~--- Strelnar
011 tillar neck
clean
No
Oil pan
Installing Fig. 6 AI\
wh
25 Nm (18 It lb)
-·
20 Nm (15 n lb)
to drain oil, loosen
and unscrew plug 3 turns
on pump
1-5
Engine-Lubrication System 17
CAUTION
Oil contamination of coolant may have
deteriorated coolant h0$es. Inspect and
replace hoses depending on condition
and/or length of time oil has been In
cooling system.
CAUTION
Do not loosen oil cooler
when removing oil filter
17-A029
Fig. 2 011 cooler, checking
If oil contamination is found in the cooling system,
one possible source of leakage is the oil cooler.
- remove oil cooler from veh icle
-plug one hose fitting and pressurize remaining
fitting with air
-submerge cooler in water and check for air bubbles
which indicate a leak i n cooler
-if leaking is noticed, replace cooler
Note
Always use a new seal coated with clean engine oi I
when reinstalling oil cooler. Fig. 4 011 pump end play, checking
• maximum 0.15 mm (0.006 in .)
- clean cool i ng system thoroughly (use Prestone Super
Flush AS- 107 or equivalent)
Oil filter
Diesel Oil pump
011 cooler, checking 17.5
1-5
17 Engine-Lubrication System
VW1342
(engine removed)
-start all bolts Including those In clutch
housing
-press oil pan by hand against clutch
Fig. 5 Oil pressure switch, checking housing so that there is no gap be-
-remove oil pressure switch and insert tween oil pan and clutch housing
Into tester -lightly tighten a.JI bolts
-connect tester Into cylinder head In -fully tighten all bolts
place of swltcl1 M6 to 10 Nm (7ft lb)
-connect test wire 1 (blue) of tester to oil M10 to 45 Nm (33ft lb)
pressure switch and wire 3 from oil
pressure switch CAUTION
Oil pan must be flush with end face of engine
-connect test wire 2 (brown) to ground block. If it protrudes or there is a gap, clutch
-turn Ignition ON, oil warning light must housing will be stressed and could break
light (assuming bulb and wire are OK)
• If NO, switch Is defective
-start engine and Increase speed slowly.
At oil pressure of 0.15-0.45 bar (2-6 psi)
oil pressure warning light must go out
• if NO, switch Is defective
-Increase speed further. At 2000 rpm
and oil temperature of 80 •c (176 •f)
minimum oil pressure must be 2.0 bar
(28ft lb)
011 pump
1-7
Water-cooled 011 pressure awftch
011 filter
17•7
17 Engine-Lubrication System
011 cooler
ooat flange surfaces
with AMV 188 100 02
check clearance with other parts
titter
loosen with US 4462
note instructions on 17-448
filter or box
Fig.
1
Fig.
Oil viscosity grades
A - single weight oils
B - Multigrade oils
Only use oils marked 'SF' under API system.
- - - -
___
Engine-Lubrication System 17
Oil pump
Water-cooled Oil pump end play
Oil pressure/switch 17.9
17 Engine-Lubrication System
Oil pressure switch, checking 0.3 bar (4.4 psi) oil pressure switch.
117- 4421
Index
Air-cooled Water-cooled
- Cooling air control flap - Antifreeze hydrometer
adjusting 19.3 checking 19.17
+ Cooling fan -Coolant
I removing 19.3 assembly 19.8, 19.11, 19.14
- Fan housing draining/filling 19.15
assembly 19.2 expansion tank, checking 19.18
removing 19.3 hose layout 19.1 0
- Snap-lock wiring connectors leak checks 19.17
installing 19.19 mixture ratio 19.18
- Thermostat refill tank 19.9, 19.13
checking 19.3 - Hose spring clamps
- V-belt removing/installing 19.16
assembly 19.2 - Hot footwall kit
tension, adjusting 19.3 installing 19.20
-Radiator
Diesel assembly 19.12
- Antifreeze hydrometer thermo-switch 19.12
checking 19.7
-Coolant
assembly 19.4
draining/filling 19.6
mixture ratio 19.5
pipes, replacing 19.7a
- Snap-lock wiring connectors
installing 19.19
- Pressure Cap
checking 19.7
19.1
19 Engine-Cooling System
r 15 Nm (11ft lb)
a~
Thermoe'-1
'E\
checking Fig. 5 '-
6'c ~
,-
Roller
check f()( free movement 20 Nm (15ft lb)
~
cooHne air control •lap - -............
adJusting Fig. 4
(I
Fen houalne - -
~(15ftlbJ
removing Fig. 3
J-2
19.2 Cooling fan
Fan housing
Air cooled-AFC J-3
Engine-Cooling System 19
Fig. 1 V-belt tension, adjusting Ag. 4 Cooling air control flap, adjusting
- loosen bolts 1 and 2 - press flaps to fully closed position
- move alternator to tension belt and tighten cable clamp
• belt deflection must be 10-15mm
(3/8-9/16 in.) in middle when
pressing firmly with thumb Note
- tighten bolts
Bent ends of return spring must rest on boss of
housing (arrow A) and on cable guide (arrow B)
V-belt
J-3
Air cooled-AFC Cooling fan
Thermostat 19.3
19 Engine-Cooling System
Note CAUTION
Aniifreeze other than specified by Volkswagen
The cooling systems of all Volkswagen vehicles are may cause corrosion of the cooling system
filled at the factory with a mixture of water and an thus leading to engine ovemeating and
antifreeze solution (G 11) with corrosion lnhibit()(s. damage.
This coolant mixture should be used year-round.
AlWays use new gaskets when Installing parts.
Phosphate-free anti-freeze prevents frost and Cooling system parts can be removed and Installed
corrosion damage, the formation of chalk and in with eoglne In vehicle, 1
addition, II raises the boiling point of water. Due to 3
the higher boiling point the coolant Is an aid to to radiator s
operational efficiency, when the engine Is operating 6
under full load, particularly in tropical climates.
.I T
3
s
s
,_
\'
I ,It
¥ - - Thennoetat
opening begins: approximately 8S'C
(185°F)
tully open: approximately 105"C
(221°F)
I stroke: minimum 7 mm (0.275
--l··~ in.)
----
_)
5
1
Fan shroud
CAUTION
J
ate·
CAUTION
Coolant/antifreeze must not be reused when
Use hose clamps with closed serrations only.
Improper use of open serrated clamps can
tear hose and cause coolant leaks.
CAUTION
Coolant/antifreeze must oot be reused when Fig. 2 Cooling system, filling
replacing engine, cylinder head, cylinder head
gasket, radiator and heat~ cote. -set heater controls to position WARM
-open breather valve (arrow) on radiator
When replacing. coolant/antifreeze solution In all
Volkswagen models, all model years, use phosphate·
free coolant/antifreeze ZVW237 102.
CAUTION
Part numbers are for reference only. Alwa~
check with your Parts Department for latest
information.
__
Fig. 6 Pressure cap, checking
Fig. 4 Cooling system, filling
-attach cap on tester A
-fill reservoir up to rp~rk max (arrow) • A = Stant tester ST·255A, AC-PCT·3
( / or equivalent
-apply a pressure of 0.9 to 1.15 bar
(11 to 16 psi)
• if pressure relief valve opens within
this range, cap Is OK
Parts required
CAUTION
Part numbers are for reference only. Always
dleck with your Parts Department for latest
information.
- rework holes for heater to engine in cross
member (as shown)
- rework holes in cross member and engine
Deacrfptlon Part number Quantity
compartment wall to side and downward
Plastic pipe (from 251 121 397G 1 · - cover sheet metal edges on cross member with
cylinder head) trim bead
Plastic pipe 251 121 399G 1
(to coolant pump)
Engine hose (from 068 121 101H 1
cylinder head)
Engine hose 068 121 073G 1
(to coolant pump)
Radiator hose (from 251 121 082 1
cylinder head)
Radiator hose 251 121 083H 1
(to coolant pump)
Clamps 411 261 679 2
Worm drive hose obtain locally 2
clamps
Tie-wraps obtain locally X
Trim beading obtain locally X - push plastic pipes from engine side through cross
member and fasten to attachment tabs on cross
member and engine wall with a worm drive hose
clamp (as shown)
-
J·9
Diesel
Coolant hoses, replacing 19.7b
19 Engine-Cooling System
Cooling ayW~m
draining Fig.1 to Fig. 4
checking lor leaks Fig. 9
Note
\
Atways replace all gaskets. All parts of ¢ooling
system can be removed and Installed whh engine
Installed. I
I
Sprtng clamp
removing/Installing Fig. 4
Thermostat
checking : heat ltlermoetat In water
opening begins : approximately ss·c (185°F)
opening ends : approximately 105"C (22t•F)
stroke : minimum 8 mm (0.315 in.)
] 19-280 1
19 •8 Cooling system
Water-cooled 11983-19851
J-1
Engine-Cooling System 19
CAUTION I
CoolanUantifreeze must not be reuseq-~hen
replacing engine, cylinder head, cylinper head
gasket, radiator and heater core. i
Refill tank
note min. and max. marks
filling system Fig. 5 to Fig. 8
/
/
r'o coolant expansion
tank
~
)
F)
J·11
1983-1985 I I Water-cooled Cooling aystem 19.9
19 ine-Cooling System
Bleeder screw
Heat exchanger
--
Additional
heat exchanger
under rear seat
I
~
' I
I I
Cylinder! Cylinder I
head 1jacket I
I I
_.Ll
, I'\ I
Note
On water-cooled engines 1983-1985 m.y. a coolant
leak in the rear heat exchanger area may be due to
poor hose fit at the metal T-piece ,which connects the
feed hose to the main coolant hose. An improved,
~····
white plastic T-piece with slightly larger diameter is
available to correct this condition:
• replace metal T-piece with white plastic version
• remove flow restrictor from inlet fitting of heater
valve
Temperature
sender.
for Injection
--- ....
Distribution unit
19-427
Radiator tan-------.
can be removed and
lnstalle<l w ithout draining
coolant alter lowering
radiator
Lower bolts
remove bolts on both
aides before lowering
radiator
Note
• 15 Nm (11 tt lb)
I
Coolant expansion tank
••••
Refill tank
~Ia minimax markings I
19-410
J·15
Water-cooled from 1986
Cooling system 19.13
19 Engine-Cooling System
!
I
.--
__/
10 Nm (7 It lb)
,
To Th ermostat
Fh
..
\ /;;
-- V__ 20 Nm (15 It lbl
fl
CAUTION
Coolant/antifreeze must not be reused when
replacing engine. cylinder head, cylinder head
-in case that coolant hoses 1 and 2 for gasket, radiator and heater core.
heat exc hanger have to be removed,
pinch hoses with hose clamp (A-local
supply)
J·17
Water-cooled Cooling system, draining/filling 19.15
19 Engine-Cooling System
WARNING-
• Hot coolant can scald. Do not remove expansion
tank cap unless engine is cold.
-
19.16 Cooling system, draining/filling
Water-cooled J-19
Engine-Cooling System 19
ll
p
J·19 Water"'~ooled
1
11
Antlfreer:e hydrometer, checking
Cooling system, fllllng,eak checking
19 17
1
•
19 Engine-Cooling System
\'
)
Fig. 10 Expansion tank cap, checking
-attach cap on tester
• Stant tester ST-255 A, AC-PCT-3 or
equivalent
-apply pressure of 0.9 to 1.15 bar
(13-17 psi)
• if pressure relief valve opens with in
this range, cap is OK
Note
Cap has 3 important functions:
1. It opens at pressure of 0.9-1.15 bar
(13-17 psi) allowing flow to expansion tank
2. it opens at a vacuum of 0.02-0.1 bar
(0.3-1.45 psi) allowing flow from expansion
tank
3. it seals radiator neck
Only item 1 can be checked with tester.
If it is suspected that Items 2 and 3 are not In
order, replace cap
Note
Cooling system is filled at factory with mixture
of water and antifreeze/corrosion protective
solution.
Coolant mixture should be used all year.
When replacing coolant only use ethylene glycol
based antifreeze (phosphate·free).
Due to higher boiling point, coolant is an aid to
operating on full load, particularly in warm
climates
·----- ___.J l.
~.
I
Cardboard air
I
deflector, lower-
Cardboard air
deflector, lower left Insulating mat
CAUTION
Part numbers are for reference only. Always
check with your Parts Department for latest
parts information.
lI
I
I
I
I
I 0 0
-- b l-.-
a
170-3931
shorten lower cardboard air deflector by 50mm - push lower left cardboard air deflector over left
(2.0 in.) and reinstall longitudinal member (arrow A) and secure behind
• dimension a = 490 mm (19.1 in.) radiator fan shroud and brake lines (arrow B)
• dimension b = 50 mm (2.0 in.) reinstall spare tire bracket and spare tire
Note
Vehicles equipped with air conditioning. may already
have the lower deflector modified
Note
If the floor pan continues to heat up, adjust
ventilation ducts so that fresh air is directed to the
floor pan.
Index
Air-cooled AFC Water-cooled Digijet
-Accelerator linkage/cable -Accelerator linkage/cable
auto. trans. 20.8, 20.9 auto. trans. 20.23, 20.24
manual trans. 20.6, 20.7 manual trans. 20.22
-Fuel filter 20.4 -Charcoal filter valve 20.20
-Fuel gauge sending unit 20.4 -Fuel filter 20.18
-Fuel pump 20.7 -Fuel gauge sending unit 20.18
-Fuel system 20.2, 20.3 -Fuel pump 20.19
leak checking 20.5 -Fuel system 20.16, 20.17
-Fuel tank 20.4, 20.5 leak checking 20.21
ind -Fuel tank 20.18, 20.19
Diesel
-Accelerator linkage/cable 20.14 Water-cooled Diglfant
-Fuel gauge sending unit 20.13 -Accelerator linkage/cable
-Fuel system 20.10, 20.11 adjusting 20.32
leak checking 20.13 auto trans. 20.31
-Fuel tank 20.12 manual trans. 20.30
-Charcoal fiHer 20.33
-Fuel gauge sending unit 20.29
-Fuel pump 20.29
-Fuel system 20.26, 20.27
leak checking 20.21
-Fuel tank 20.28
20.1
20 Fuel Supply
Note
California models, from 1981, have a:
new fuel-tank filter that is self
cleaning and requires NO
SERVICING
new and enlarged fine-mesh in-line
Fuel gauge sending unit
fuel filter which requires NO removing Fig. 2
SERVICING installing Fig, 3
Expansion unk _ /
Seal --------------~----~~~~
coat with graphite powder
before Installing
'
4.om pressure reguletor
I
Fuel filter----..
installing Fig. 1
Fuel pump ~
delivery rate page 20.7
checking, electrical page 20.7
(\/ ..c~~::.
To rfng line
7
Note
I
2 0 •2 Fuel system
.__A_ir_-c_o_o_le_d_......~l L-I_A_F_c_ _.
Fuel Supply 20
II
.,r-10 Nm (7 fllb)
v~;trve must close
25 Nm (18ft lb)
WARNING
Charcoal filter
Disconnect battery when working on fuel
system. Never smoke when wofl(ing with
fuel or have anything in area that can Ignite
it.
Always replace seals and fuel hose clamps
Fuel filter
20.4 Fuel gauge sending unit
Fuel tank, removing
Air-cooled AFC
Fuel Supply 20
Fuel system, leak checking
Note
A·5
Air-cooled AFC Fuel tank, removing
Fuel system leak checking 20.5
20 Fuel Supply
Accelerator linkage/cable
Manual transmission
Push r o d - - - - - ,
lubricate when ins talling Acceleretor pedal
Clrcllp -----~
always replace
, ,.
'wJC ~ool
..,. ,., """
~
'
Accelerator cable
adjusting Fig. l
~-
Clampl. .
~
bcll1
WARNING
Fire hazard! Never smoke or h<we anything
In area that can ignite fuel
CAUTION
Do not touch positive connection to grou nd
Air-cooled AFC
~----------------~
II Manual Trans. Accelerato r linkage/cab le
Fuel pump 20.7
20 Fuel Supply
Accelerator linkage/cable
Automatic transmission
Push rod - - - - - - - . .
lubricate when installing Accelen~tor pedal
-- -- .---Pin
must engage in lever
on transmission
Ad)111Ung rod
-- -...~
Shift lever on lransmisslon
~ Sprln~
~ __.clrcllp
Work sequence
-depress accelerator pedal to full throttle
position
• throttle valve lever must contact stop, but
kickdown lever on transmission must not be
in kickdown position
-press accelerator pedal beyond full throttle to
floor
• override spring must be tensioned and
kickdown lever on transmiss ion must be in
kickdown position
if NO, adjust as follows: -press accelerator pedal to floor
• lever 6 must be in kickdown position (arrow),
Accelerator linkage/ cable, adjusting with approx. 1- 2mm ( 1/ 32-3132 in.) free
(automatic transmission) play between lever and stop
- release accelerator pedal
Work sequence -lever must be in idle position (out of kickdown)
-loosen nut 1
- remove override spring 2
- start engine and let idle
- adjust idle speed at screw 5
{see Repair Group 24) - if necessary, adjust accelerator cab le at
-shut engine OFF clamping bolt (arrow)
- press accelerator rod in d irection of arrow
to stop
- turn adjusting rod 3 with screwdriver until
shoulder of adjusting rod just con tacts p1vot
of throttle lever 4
- reinstall override spring 2
- start engine and check idle speed
• adjust if necessary by turning rod 3
- lock adjusting rod 3 in position with nut 1
•Seal---
coat with
graphite powder
before installing
CAUTION
Use on ly approved fuel filters for
maintenance service or repai rs.
Not all after-market f il ters meet
the f iltering, fuel flow, o r water
separation requirements of the
injection system.
2 0 •1 0 Fuel system
Diesel
Fuel Supply 20
WARNING
Disconnect battery when working on fuel
system. Never smoke when working with
fuel or have anything in area that can
ignite it.
Filler cap
replace gasket
if damaged
Filler neck
removing; turn to
release from side
panel
\ _ _ _ , . Nm (1 fill b)
Gasket
Diesel
Fuel system
20 Fuel Supply
WARNING
Fire hazard! Do not smoke or have anyth ing in
area that can ignite fuel
Fl
-remove vent hoses 4 and 5
Fh
Fig. 1 Fuel gauge sending unit, removing • system OK if pressure remains at 1.0 in. Hg or
greater after 5 minutes.
-first remove fuel tank
• system not OK if pressure drops below 1.0 in . Hg
after 5 minutes.
Note
Acelerator pedal
----Boot
check tor cracks
Clamping bolt
adjust cable so that
injection pump lever
contacts stop without
tension
1
Accelerator c : a b J
I j.e
tf)
Grommet
press into bracket
on inject ion pump
' ·
~
.. ,
Fuel Supply 20
A-15
20.15
20 Fuel Supply
Fuel supply system components,
Removing and installing
Fuel system
checking for leaks, see
page 20.21
Fuel tanl
Seal----------
coat with graphite powder
before installing
~'
/ Fueftank---J
removing, page 20. 18
~
"
{ From p•e.,uro ••••laW
/ Fuel f i l t e r - - - - - - - - - - - - - - - - - -
USAJCanada: installing Fig. 1
California only: installing Fig. 2
0 •
.~
/ Fuel pump '
To ring llne ~/
r
delivery rate, page 20.19 I
I
To distributor vacuum /
I [
advance unit
\_ To throttle valve
I
housing
I
I
To Intake air distributor ~ /
-------..~'
To auxiliary air reg~lator
""-----..................
Charcoal filter
,
I ~-- Charcoal IIIler valve
checking, page 20.20
I
I
I
I ~ To air IIIler
I
I
I
Jfalor
2A
Fuel filter
WARNING
Fire hazard! Never smoke or have anything
In area that can Ignite fuel
A·19
Water-cooled l[ Digijet Fuel tank
Fuel pump delivery rate
20 19 •
20 Fuel Supply
WARNING
Disconnect battery when working on fuel
system. Never smoke when working with fuel
or have anything in area that can ignite it.
Note
After performing repairs on fuel tank, always check
fuel system for leaks as follows:
Work sequence
- Remove small hose A at charcoal filter and
connect to leak tester US 4487
- Set leak tester scale to "0"
Pressurize system with hapd pump to
3.3 em (1.3 in) of mercury
• system OK if pressure is 2.54 em (1.0 in) or
greater after 5 minutes
• system leaking if pressure drops ·below
2.54 em (1.0 in} after 5 minutes
Note
Check system for leaks using soap solution at spots
marked with'f" Seal if necessary.
A·21
Water-cooled I I Diglfant I I Digljet . Fuel system,
checking for leaks
2 o21
•
20 Fuel Supply
Accelerator linkage/cable
Manual transmission
Push r o d - - - - - - -.....
lubricate when Installing
Accelerator pedal
Pin-----------.
Relay lever-------.
lubricate when Installing
Clrcllp~
alway• 1ep1oco '),
---- -- --- --
--- -- - -
- - --_JI
Cl<ellp~
Accelerator cabla
adjust cable so that
clearance of about 1.0 mm (0.040 in.)
ia obtained between throttle
valve lever and stop on throttle
F
houalng
C"mplog bollo
Support
1 20-402 1
Push r o d - - - - - -
lubricate when Installing
Accelerator pedal
Pin-----.
Clrc:llp~
always replace "b
- - - - - - - Clamping bolts
linkage/ cable,
checking/ adjusting page 20.9
:----Boot
Housing
r----
1 (II
l
...
---
-- ------- ----- -
"'l
--J
Pin------~
must engage In lever
on transm(sslon ---
l
--------------
Support
--
I
I
AdJusting rod --.......;:"'111111~
adj usting page 20.9
. . ._ r Spring
--- ~ - __J
~~Clrcllp
A·23
Water-cooled I j Digijet j I Auto. Trans. Accelerator cable/
linkage 20.23
20 Fuel Supply
Work sequence
-depress accelerator pedal to full throttle
position
• throttle valve lever must contact stop, but
klckdown lever on transmission must not be
in kickdown position
- press accelerator pedal beyond full throttle to
floor
• override spring must be tensioned and
kickdown lever on transmission must be In
kickdown position - press accelerator pedal to floor
If NO, adjust as follows: • lever 4 must be on stop In klckdown
position (arrow A)
- release accelerator pedal
Accelerator linkage/cable, adjusting - lever must be In idle posit ion (out of
(automatic transmission) klckdown) (arrow B)
Work sequence
- loosen nut 1
-remove override spring 2
- start engine and let idle
20.25
Fuel supply system componen,ts,
Removing and installing
WARNING
Disconnect battery ground strap when working
on fuel system. Never smoke when working
with fuel or have anything in area that can
ignite it.
· · "'"· . . J
O.rlng H&l - - - - '
Retumllne~
• ooat with graphite
powder before Installing
Fuel lank
• removing - page 20.28
20.26 B-5
Fuel Supply 20
• Rules of cleanliness, 20.28
• Checking for leaks, 20.21
Filler pipe
Fuel tank
vent lines
15 Nm (11ft lb)
25 Nm (18ft lb)
- - - - - - - - - --
------ ----
20 Fuel Supply
- remove fuel tank - page 20.28 Fire hazard! Never smoke or have any1hing in
area ttlat can ignite fuel.
Note
After installation of sender:
Rocker arm must be able to be swung downwards.
Digifant
Fuel gauge sender,
Fuel pump delivery rate,
checking
20.29•
20 Fuel Supply
Accelerator linkage/cable
Manual transmission
Push rod
Housing
Lock washer
Clamping boHa
• adjust accelerator cable in
such a way that the throttle
valve lever lies against the
stop on throttle housing
with approximately 1.0 mm
(0.039 in) play
Support
Accelerator
cable
- . . . . . . . - - - - - - - - - - Clamping bolts
check and adjust
fuel supply - Page 20.32
Housing
,...-----Pin
• muse engage In lever
on transmission
Support
(II l
l
~----
-------------------- ~ laver on transmission
Adjusting rod-------~
p•ge 2 0 3 2 - . . ~ Spriog
---- ---- _J:
Clrcllp t
~~=T:~
ven11tne
\
\
\
\
\
\
\
L To '"1ribu1o• ~<uum odvon<e unl1 \
\
\ Charcoal
\ filter
\
..
.. z:".
\
/
To Intake air
_/
... -
)
~
distributor
.,./
"----_
. _.......
:...._ _ _ _ _ _ _ To air cleaner
B·11 Digifant
Charcoal filter assembly 20.33
20 Fuel Supply
Notes
r------------ Fuel tank
vent lines
• Rules of Cleanliness - page 20.28
• replace seals and spring clamps
Feed line
Fuel tank • from fuel filter to
• removing - page 20.28 engine ring line
Fuel filter .
• installation location:
arrow points in flow direction Fuel gauge sender
to engine • removing and
installing - page 20.29
Bracket for
fuel lines
Fuel pump
• checking - page 20.29
• minimum delivery
quantity:
500 cm3f3Q sec .
C-1 23.1
23 Diesel Injection System
Accelerator cable
adjusting, see
WARNING
Repair Group 20 Disconnect battery when working on fuel
system. Never smoke when working with fuel
or have any1hing in area that can ignite it.
Always replace seals and fuel hose clamps
Injector pipes
25 Nm (18 It lb)
~--- Injectors
70 Nm (51 ft lb)
removing/Installing page 23.9
cleaning page 23.9
checking page 23.10
Tensioner - - - - - - .
use tool US 4493
to tension
•s Nm (33 It lb)
CAUTION
Crankshaft sprocket
To avoid damage, keep injection parts clean
when removing, installing, disassembli ng
Crankshaft sprocket bolt
110 Nm (80 It Ib) and assembling. Do not spill diesel fuel on
do not use locking compound any rubber hoses
Double V-belt pulley
(engine removed)
-attach tool 2068A to crankcase
-se-t scale to 100 mm (arrow A)
-tip ot scale must align with TDC mark on
clutch pressure plate (arrow B)
Diesel
Injection pumpNalve timing 23,.3
23 Diesel Injection System
'-.,
/ -Install adaptor and dial gauge 0 to 3 mm
(0 to 0.118 ln.) in place of plug and preload
•• ; gauge to approx. 2.5 mm (0.097 in.)
' ~. mmJ
-turn engine slowly counterclockwise (opposite
to normal rotation) until dial gauge needle
-turn pump sprocket until marks on sprocket, stops moving
pump and mounting plate are In line -zero gauge
-lock pump sprocket with pin 2064
-turn engine clockwise untii· TDC mark on clutch
-reinstall drive belt
pressure is aligned with boss on bell housing
-check that gauge reads 0.78-0.88 mm
l
Tightening totque. of the Diesel Injection pump center
~ (arrow) is:
-check that maximum speed Is 4800 ±50 RPM
• 17:!:3 Nm (12 !2 ft lb) with copper seal (reddish· if NO
brown In color) -loosen locknut (arrow)
-adjust maximum speed screw
• 22 ±2 Nm (16:!2 It lb) with bronze seal (yellow- • turning clockwise decreases RPM
brown in color) -lighten locknut
WARNING
-check that Idle speed is 800.-850 RPM Disconnect bat1ery when working on fuel
• oil temperature so·c (140"F)
system. Never smoke when working with fuel
if NO
or have anything in area that can ignite it.
-loosen locknut (arrow)
-adjust idle speed screw Always replace seals and fuel hose clamps.
• turning clockwise increases RPM
-lighten locknut
Engine speeds
C-5 [ Diesel Cold-start cable
Fuel cut-oH solenoid 23.5
23 Diesel Injection System
CAUTION
Never apply excessive tension with puller.
as this may damage sprocket
CAUTION
Do not interchange fuel supply {arrow A) and
return (arrbw B) pipe union screws. For iden-
tification, fuel return pipe union screw is
marked O~li on hex. head
-remove three bolts from injection pump mount-
ing plate 2 -adjust injection pt.Jmp/valve timing
(see page 23.4)
CAUTION -adjust injection timing <see page 23.4)
To avoid damage to distributor plunger, do Fuel delivery valves-, c:hecking
not loosen bolts (arrows) on fuel distributor
Work sequence
head
Note
-remove bolt 1 from rear support and remove
Fuel leaks from fuel delivery valves are usually
pump
caused by improper removal of injector pipes. If
Injection pump, installing fuel delivery valve leaks proceed as follows:
Work sequence
C·7 Diesel
Injection pump
Fuel delivery valves 23.7
23 Diesel Injection System
CAUTION Note
When removing or replacing fuel delivery First signs of Injector trouble usually appear as
valves, do not Interchange valve assemblies follows:
• knocking In one or more cylinders
• •engine overheating
• loss of power
• smoky black exhaust
• Increased fuel consumption
I Removing
CAUTION
To avoid damage, keep Injection parts clean
when removing, installing, disassembling
and assembling
Installing
WARNING
Diesel fuel will penetrate skin If hands are o--Shlm
exposed to working pressure of injector
spray I- Spring
?--- Thruat pin
. - - Nozzle holder
t- Needle
o-Heat ahleld
Note
C·9
Diesel Fuel Injectors 23.9
23 Diesel Injection System
-
Fuel injectors, cleaning Fuel filter water Indicator kit,
installing
Work sequence
Water level indicator light will light when it is
CAUTION necessary to drain water from trap in fuel filter
Installation procedure
Upper part
- disconnect battery ground cable
Shim - drop down Fuse/ Relay Panel
J - sprlng
~ Thrust pin
. . . - -Nozzle holder
J - - - Needle
Nozzle
Lower part
Index
Air-cooled AFC Water-cooled Dlgljet Water-cooled Dlglfant
- Air filter housing 24.8 - Air filter housing 24.27 - Deceleration fuel shutoff 24.60
- AFC system check 24.15 - Auxiliary air regulator 24.27, 24.28 -Electrical testing 24.61, 24.62
- Auxiliary air regulator 24.8, 24.9 - Control unit/wire harness 24.31 - Fuel injectors, checking 24.56
- Cold-start valve 24.5 checking 24.35 - Fuel injection system
- Control unit/wiring harness 24.12 -Data/specifications 24.18, 24.19 components 24.48, 24.49
-Deceleration valve 24.7 - Double relay 24.32 repairing 24.46, 24.47
-Double relay 24.13 - Fuel injectors 24.25, 24.26 - Full throttle enrichment,
- Full throttle enrichment switch troubleshooting 24.38-24.41 checking 24.60
24.13, 24.14 - Full throttle enrichment switch - Idle speed/CO content
-Idle speed-CO 24.10, 24.11 24.34 checking and. adjusting
- Intake air/temperature sensors 24.9 checking/adjusting 24.35-24.37 24.50-24.52
- Intake air sensor housing 24.8 - Idle speed/CO, checking/adjusting - Idle stabilizer, checking 24.53
- Injector resistance 24.6 24.29, 24.30 - Intake air sensor, checking 24.57
- Injector spray pattern/leak - Intake air sensor 24.28 - OXygen sensor, checking 24.54
.·
checking 24.7 housing 24.27 .,.- Pressure regulator, checking 24.55
-Oxygen sensor/wiring 24.16 - Pressure regulator 24.25 - Residual pressure, checking 24.55
- Pressure regulator 24.5 - System check 24.20, 24.21 - Safety precautions 24.42
-Speed limit switch 24.14 .,.- System components 24.22-24.24b - Technical Data 24.43-24.45
- System components 24.2 early version 24.24 - Throttle valve basic adjustment
California 24.4 late version 24.24a 24.24b 24.37
USA and Canada, - Temperature sensor I 24.28 - Throttle valve switch 24.58, 24.59
except Calif. 24.3 -Temperature sensor D 24.32
-Temperature sensor D 24.13 - Throttle valve/deceleration/idle
-Thermo-time switch 24.6 switch 24.33
- Voltage supply/series
'
resistance 24.6
CAUTION
During repairs always replace gaskets,
seals and clamps
Thermo-lime switch
checking Fig. 4
lnjeclor _ _ _ _ _ _ _ ____.
Series res ist ance (except Cali !.)
ctJeck 1ng F1g. 7 res1s1ance (Calif. o nly) c hecking Fig. 6
voltage su pply. checking F1g. 5
spray pat tern. checking F1g. 8
checking tc>r leal<s. page 24 .7
Control unit
Thermo-time switch
Ignition distributor
·. 10
Temperature sensor IJ
----[leceleratlon valve
(manual transmiss ion)
Catalytic converter
(USA on ly)
Control unit
Temperature aenaor II
Catalytic converter
Oxygen sensor
Itch
I
Fig. 2 Cold star1 valve, checking
WARNING
Fire hazard. Do not smoke or have anything
In area that can ignite fuel
Note
Pressure regulator controls fuel pressure
depending on Intake air distributor vacuum
WARNING
Fire hazard. Do not smoke or have anything
In area that can Ignite fuel
Air-cooled II AFC
Pressure regulator
Cold star1 valve
24 5 •
24 Fuel Injection, AFC System
-
Note
On California vehicles, series resistance is built
into fuel injection control unit and can not be
checked
24 6 •
Thermo-time switch
Voltage supply/Series resistance' •
Injector resistance, checkingAir-cooledAFC
I I
Fuel Injection, AFC System 24
Injectors, checking for leaks
-remove electrical connector from injector
-remove injector but leave connected to ring
main line
- pull off wire from terminal 1 of ignition coil
- operate starter briefly
-check that no more than 2 drops leak from
each Injector In one minute
124-032A I
Fig. 8 Injector spray pattern, checking
-remove injector but leave connected
to ring main
WARNING
Fire hazard . Do not smoke or have anything
In area that can Ignite fuel
........----lntaka·,elr hoea
F
Plug
removing page 24 .10
---'\.V adJuell"ij ecraw
Intake air sensor - - - -- adjusting page 24.10
checking Fig. 1
Air filter - - - -
litter housing
I 24. o52
Fig. 2 Temperature sensor, checking
--
1.10 - pull o)( electrical connector from - check that intake air sensor (arrow)
lntaj(e air sensor has reached room temperature of
- ch~ck fuel pump contacts in intake air 20 •c (68 "F) before checking
se~sor by connecting ohmmeter to -connect ohmmeter to terminals 6 and
terminals 36 and 39 27
- pust\ air sensor flap open fully • meter should read 2300-2700 ohms
• meter should read 0 ohms
- release air sensor flap
• meter shou ld read oo ohms
Note
If resistance specif ications are correct
but fuel pump does not work, check for
break in wi ring between control unit and
intake air sensor
Work sequence
Preliminary conditions:
• engine oil temperature min. eo·c (140.F)
• intake air sensor must be 2o•c (68•F)
• all electrical equipment must be OFF
• hose for charcoal filter must be disconnected
and blocked at air filter
• dwell and timing OK (see Repair Group 28)
Note
When vehicle has been parked outside at
temperatures below 1o•c (50.F), adjustment - check CO and if necesssary adjust at
must wait until intake air sensor has reached adjusting screw (arrow)
room temperature 2o•c (68.F) • 1.0 ± 0.5%
-connect tach/dwell meter according to -secure CO adjusting screw with blue cap
manufacturer's instructions
Note
If CO cannot be adjusted following components
may be defective:
• injectors
• spark plugs
• vacuum leak between cylinder head and intake
manifold
Work sequence
Preliminary conditions:
• engine oil temperature min. 6o•c (140.F)
124-0961 • intake air sensor must be 20 •c (68 "F)
-check idle speed and adjust if necessary, • all electrical equipment must be OFF
with adjusting screw (arrow) • hose for charcoal filter must be disconnected
• manual transmission: 800-950 rpm and blocked at air filter
• automatic transmission: 850-1000 rpm
-connect CO meter according to manufacturer's Note
instructions
-connect CO probe ahead of catalytic converter To check engine rpm on vehicles with oxygen
at probe receptacle sensor and electronic ignition (Calif. vehicles),
resistor adaptor must be used in conjunction
with commercial tach/dwell meter
Note
Before checking or adjusting CO, idle speed and
ignition timing must be with in specification s
-connect CO meter according to manufacturer's
instructions
-connect CO probe ahead of catalytic converter
to
solder at probe receptacle
engine=
ground -
on coil lo engine
ground I24-A0051
Note
If CO cannot be adjusted following components
may be defective:
• injectors
• spark plugs
• vacuum leak between cylinder head and intake
air sensor
- reconnect oxygen sensor
• CO must be within spec ificatio ns
-secure CO adjusting screw with blue cap
Control Unit
unol cannot be repaored.
locatoon: roght side ot engone oompanmen!.
It limits engine max . speed to approx.
5400 rpm and recei ves Information on:
• aor quantoty from intake a or sensor
/
• engonc temoerature from otemperalure sensor II
• engine speed from lgniloon distrobutor
• position of throttle va1ve from swotch lor
fuU throttle enrichment and uses thos
Information to determine amounl o~ luel
Multi -pin connector - - - k l to be injected
removo nQ press ~pnn g
down (arrOW}
To double relay
checking Fig. 1
To ignition coil
California only
Vehicles for California are equipped with
speed limit switch located between full
throttle enrichment switch and control unit.
Full throttle enrichment will take place
when engine runs above 3000 rpm (at same
time oxygen sensor switches off)
Note
Temperature sensor in cyllnder head
supplies control unit with i nformat ion for
start ing and warm-up enrichment
-disconnect temperature sensor wire
from sensor
Double relay
D-13 Air-cooled Ill AFC Temperature sensor II
Full throttle enrichment 24.1 3
24 Fuel Injection, AFC System
-open throttle valve slowly
• just before reaching stop; ohmmeter must Nc
read 0 ohms
En
If NO, switch must be adjusted or replaced
CO•
ac ~
Full throttle enrichment switch,
adjusting c
Work sequence 11
13
Callfomla onlv 15.
- use jumper wire and make contact
18 ,
between terminal 4 and 8 (arrow A) 16 ,
of connector for speed limit switch 18 l
-pull off connectors for idle stabilizer and 16;
connect together (arrow B) 171
16<
t1~
- run engine at idle and adjust to specifications
in table 114
-depress accelerator pedal fully and hoi<;! in 115
USAf Canada Calif. position \ 132
-loosen switch and move it until ohmmete·~ 133
Manual 800-950 rpm 850- 950 rpm changes from oo ohms to 0 ohms 116
Automatic 850-1000 rpm 850-950 rpm • roller should be in center of curved le7e · 117
(arrow) 134
-operate full throttle switch by hand - tighten switch / 137
• idle speed must Increase approx. 100 rpm
if NO, check full throttle switch and Speed limit switch, checking
adjustment position
if OK, replace control unit or wiring between Woril sequence 14 c
control unit and switch
-on Calif. vehicles readjust idle speed to 110
specifications on sticker and reconnect idle
stabilizer 120
24 14
•
Full thr?ttle enrichment switch
Speed hmlt switch
I Air-cooledjAFC j D-1!
Fuel Injection, AFC System 24
Note
Entire AFC System can be checked electrically at
control unit plug using an ohmmeter or volt meter
according to following chart.
#1 and Ground Disconnect white injection wire at Wire to#1 terminal on coil
coil oo ohms; hook wire to ground
Oohms
#3and #18 Press accelerator pedal down fully. Full throttle enrichment circuit
Oohms thru throttle switch
#5 and Ground Oohms Ground Circuit
#Sand#9 200-400 ohms Air Sensor Circuit
#Sand #8 130-260 ohms Air Sensor Circuit
#Sand #9 70-140 ohms Air Sensor Circuit
#Sand #7 --4Q-300 ohm's Air Sensor Circuit
#7 and #8 100-,500 ohms Air Sensor Circuit
#Sand #27 Max 2,800 ohms at 68 o F Air Sensor Circuit
#13and Ground 2,t00-2,~00ohmsat68° F Head Sens_or
270-390\at 176 o F
#14and#10 Approxtrtlately 7 ohms Injector wire and resistor
#15and#10 Appr:oxi ately 7 {)hms Injector wire and resistor
#32and#10 ApRr mately 7 ohms Injector wire and resistor
#33and#10 Appr ximately 7 ohms Injector wire and resistor
#1S and Ground 0 m~ Ground Circuit
#17 and Ground ohms Ground Circuit
#34 at control unit and Approximately 30 ohms Auxiliary air regulator
#37 on the double relay and wires
Air-cooled AFC
0·15
AFC system check 24.15
24 Fuel Injection, AFC System
Preliminary conditions:
• engine oil temperatura at least 60"C (140"F)
• air temperature 20•c (68"F). Before starting
following test proc~ures, wait until intake
air sensor housing has assumed room
temperature
-connect tachometer according to
manufacturer's instructions
-connect CO meter to ,t est receptacle in front
ot converter (do no( connect at tailpipe)
-check idle speed and adjust if necessary
• 850-950 rpm
- connect ohmmeter between oxygen sensor
and terminal 24 on control unit
• 0 ohm, sensor wiring OK
•"" ohm, sensor wiring defective
unit
\
\ THIS PAGE INTENTIONALLY
LEFT BLANK
~)
C·16 0.17
24.17
24 Fuel Injection, AFC System
Idle speed
!'lee chart page 24.19 • oxygen sensor connected
CO-value
checking spec. 0.3-1.1% • oxygen sensor and idle stabilizer
connected
adjusting spec. 0.7 ±0.4% * • oxygen sensor disconnected *
Idle stabilizer control unit below 940 rpm under load, ignition • engage 4th gear at idle speed
timing advances and engage clutch slowly;
timing should advance
Oxygen sensor
wiring disconnected CO above 2% • vacuum hose at pret$S'ure
wiring connected co 0.3-1.1% disconnected
Injectors
fuel spray pattern even, coneshaped spray • operate starter
voltage supply test light flickering • operate starter
resistance approx. 16-16.4 ohms
I
24.18 Technical Data/specifications
Water-cooled II Digijet
l
Fuel Injection, AFC System 24
Components-checkinglaidjustlr1g 1 Specifications Notes
0 10 20 30 40 50 60 70 80 90 100°C
Temperature of Temperature Sensor J24-n61
\\\
turn
I by
1013
Note
Replacing digital idle stabilization control unit can
lower idle speed rpm. When replacing control unit,
always recheck idle speed and adjust as
necessary.
1 2 4 5 6 7 11 12 13
8888888888888
888888888888
14 15 19 20 21 23 24 25
j24-A0081
- remove multi-pin connector and turn ignition ON
Tester to
terminal: Components Checks Specs
1 and 7 Hall control unit type: AEG • voltage with ignition ON voltage or
slightly l.ess
1 and HALL control unit type: FAIRCHILD • touch center wire of connector 1.5 volts or
ignition coli at ignition distributor to slightly less
termlnal15 ground
11 and 7 Fuel injector, cyl. 4 • injector and wiring approx. 16-16.4 ohms
12 and 7 Fuel injector, cyl. 3 • injector and wiring approx. 16-16.4 ohms
13 and 7 Relay, left; terminal 87 • ignition ON; function of relay, left battery voltage
*)do not connect test light on this terminal if control unit is connected to multi-pin connector
Tester to
terminal: Checks Specs
20*) and Relay, right; terminal 86*) • ignition ON; function of relay, right fuel pump must run
25 bridged
Auxiliary air regulator ·.• ignition ON; function of auxiliary power must be
air regulator supplied to auxilla,Y
air regulator
24 and 7 Fuel injector, cyl ..2 • injector and wiring 16-16.4 ohms
do not connect test light on this terminal If control is connected to multi-pin connector
/
CAUTION
During repairs always replace gaskets,
seals and clamps
Pressure regulator
checking. page 24.25
··~o
Temperatu re sens.o r II
10 Nm (7ft I b)
checking. page 24.32 pressure gauge
lp
Injector ---~
checking . page 24.25 and 24.26
Y·plece
with integral
restrict or
L
0.15 mm (0.006 in)
· Throttle body
·\....,_----~
..
'\
C\
\
Ignition distributor
\
""
-------·---~ c:.:::'\
u
~
·---- I
/,/ /
/ to charcoal __..----. .,___r,
/. cannister / · /
----- .~
.................valve,~
Vacuum shut-off
- il.g
.
I
•
Work sequence
CAUTION
Do not disconnect terminal 1 at ignition
coil when operating starter
Spray pattern
-pull out fuel injectors In pairs but leave
electrical plugs and fuel lines connected
-disconnect electrical plugs at fuel Injectors
which are still installed (second pair)
WARNING
Fire hazard. Do not smoke or have anything
In area that can Ignite fuel
-~
-c
-c
-connect pressure gauge V.A.G. 1318 or
equivalent with adaptor to T-piece 1 of fuel lfN
line -c
-c
t
CAUTION -c
Pressure gauge lever must be in closed
position during measurement procedure
CAUTION
To prevent damage to control unit, do not
short-circuit connector contacts
•
J ,-,.?9
-pull off all electrical plugs from fuel Injectors
-connect test light to one plug contact (arrow)
-operate starter
•test light must flicker
I! NO
- check relays, see page 24.32
-check Impulse output of Hall control ynlt
terminal 7
-check all ground connections at cylinder head
E·5 L__W
_ a_l_e_r-_c_o_o_le_d__..l Ll_0----'ig::_i_je_t____. Fuel Injectors 24.26
24 Fuel Injection, AFC System
Temperature sensor
checking page 24.28
CO adjusting screw
iQie speediCO
checking tadjustmg, page 24.29
Air fll1er - - - - --
II
Intake air sensor housing
o 10 20 30 40 so 60 70 eo 90 100· c
Temperatu re ol Temperature Sensor 124·1161
Note
- pull off hose and electrical connector from Intake If specifications are not reached, replace intake air
air sensor sensor and readjust idle speediCO value (see pages
- connect US 1119 multimeter to following terminals 24.29, 24.30).
of potentiometer (arrows)
• 3 and 4 or 6 and 9 =- 500 to 1000 ohms Auxiliary air regulator, checking
• 2 and 3 or 7 and 9 wtten moving sensor
plate = resistance varies
Note
When engine Is cold; regulator is open fully, allowing
additional air to engine.
• engine cold
- run engine at idle speed
- connect US 1119 mu ltimeter to terminals 6 and 22 - pinch hose (arrow)
• multimeter reading should correspond to graph • RPM must d rop
- run engine at idle speed lor about 5 minutes more
- repeat above test
• RPM must not change
If NO
- disconnect electrical plug from auxiliary air
regulator
-check voltage supply with engine running
11 OK
- replace auxiliary air regulator
E-7
Water-cooled I I Digijet
Intake air sensor
Temperature sensor I
Auxiliary air regulator
24 28 •
24 Fuel Injection, AFC System
Idle speed/CO, checking/adjusting
CAUTION
It is important to follow work sequence when
checking and adjusting idle speed and CO
value
1. Check ignition timing; if necessary adjust
• idle stabilizer bypassed
• oxygen sensor connected
2. Check Idle speed; If necessary adjust
• Idle stabilizer bypassed
• oxygen sensor connected
3. Check CO value; If necessary adjust
• idle stabilizer connected
• disconnect oxygen sensor wiring
connection with Ignition OFF - rur
1 adjust CO value corresponding to -ch•
local altitude . See shaded area of adj
graph. shown bel ow. - stc
1 reconnect oxygen sensor at
electrical connection. ~
-connect tester V.A.G. 1367 as follows
• A to alternator or termi nal box
• 8 to TDC sender
- connect CO meter to receptacle In left
exhaust pipe
-Cht
• lc
0 500 1000 1500 2000 M -wit
0 1640 3281 4921 6562 Ft CO l
l24·132l - sta
•c
-check Igni tion timing and adjust If necessary
-disconnect electrical plugs at Idle stabilizer
Work sequence Note
control unit (squeeze to release-arrows)
Prel iminary conditions: -connect plugs together If CO
- start engine and check igni tion t iming and • co
• engine oil temperature min. 60"C (140.F) adjust if necessary if YE~
• all electrical equipment must be turned OFF • spec. = 5 ± 1 • A TDC oil dll
(radiator fan must not run) • rpm =below 1000 if NO,
ethrottie valve switch must be ON at idle - adjust ignition t iming, see Repair Group 28
-stc
CAUTION
Ignition must be switched OFF before
connecting tester
- -
- .... . - emil
-run engine at idle speed -adjust CO as follows:
-check RPM after 2 minutes, if necessary - remove Intake air sensor 2
adjust with screw (arrow) -center-punch plug in CO adjusting hole
-stop engine -drill 2 .5 mm (3/32 ln.) hole in center of plug
3.5-4.0 mil) (9164-5/32 ln.) deep
CAUTION
Clean up any metal shavings
to Fuel pump
[
-I
to Main wiring hamess
red-black (21)
Relays---~
checking page 24.32
to Ignition c o l t - - -
terminal 15, black,
black-white (44, 39)
to Ignition colt--~
terminal 1, green (41)
to Oxygen •••,•nr--
-t
- (
f
•
Multl·polnt connector •
to remove: press spring upward to Tempsrature sensor II -c
•
It receives information on: •
• air quantity from intake air sensor •
• intake air temperature from temperature
sensor I in intake air sensor •
• engine temperature from temperature sensor II
• engine speed from ignition distributor •
• oxygen in exhaust gas from oxygen sensor
• position of throttle valve from full throttle
,..,,
enrichment/deceleration switch and uses this -tl
information to determine amount of fuel to be
Injected
-c
•
If Nj
Note Note
Always replace control unit if defective, can not Wiring has white color, note stamped number on It
be repaired in workshop •
If Nl
\ CAUTION
Do not connect any test light to terminal 86
ot adaptor C (shown in illustration) If
• test light must light
it NO, check wire to terminal 20 of control unit
if OK, replace control unit
- connect test light to terminal 87
control unit is connected - crank engine
-test light must light
if NO, replace relay on adapter C
-remove all electrical plugs at fuel injectors
Temperature sensor II, checking
Note
Temperature sensor 11 In coolant thermostat
housing supplies control unit with Information
for starting and warm-up enrichment
-turn ignition ON
-connect test light to ground and check
following terminals for voltage:
• connection A= red wire terminal 30
• adaptor B =terminals 30, 85, 87 -check temperature and resistance of
• adaptor C =terminal s 30 and 85 temperature sensor II
• test light should light • check specifications, see diagram below:
-operate starter and check with test light
• adaptor C =terminal 87 ohms ---Temperature Sensor- -- - ohms
• test light should light 1000
• if test light does not light, check wiring by 900
using current flow diagram 1- r-
800
• If wiring is OK and no voltage at tern1inal 87,
check relay 7000
.. ,_ 700
• if relay Is OK, replace control unit 6000 600
~ + ..
5000 .500
Relay on adaptor B, checking ~f\ -
4000 400
-turn ignition ON ' -
3000 300
-connect test light to terminals 30 and 86 l-
• test light must light up 2000 200
f-~ N
I"' N
if NO, check wiring with current flow diagram 1000
1. ~ ; 100
Function
-attach ohmmeter to switch 3
• throttle valve closed
switch turned OFF = oo ohms With throttle valve closed, switch signals control
• throttle valve full open unit about the following
switch turned ON ::;:: 0 ohms • idle injection quantity
• switching oft injection during deceleration
Second check (Wiring and control unit)
With throttle valve open, switch signals control unit
-run engine at idle for a short time about the following
-stop engine and turn Ignition ON
-pull off connectors from both throttle valve • full throttle injection quantity
switches
-check voltage between connectors of full
CAUTION
throttle enrichment switch
• voltage should be approx. 5 volts DO NOT connect test light to terminals of
if NO, control unit is defective or break in wiring throttle switch unless control unit is
disconnected.
24.35
Throttle valve switch,
checking/adjusting
Control unit and wiring, checking
1985 Digijet ) I Water-cooled
Fuel Injection, AFC System 24
Deceleration fuel shut-off, checking
Test conditions
• temp. sensor II minimum 60°C (140°F) with
resistance reading less than 5500
Work sequence
2~
1----@
- remove switch 4 following numerical sequence of
components 1 through 5
- install components in reverse order
- perform basic adjustment as follows
E-15
Water-cooled II 1985 Digijet
Deceleration fuel shut off,
Full throttle enrichment
Throttle valve switch 24.36
24 Fuel Injection, AFC System
Note
In order to determine exact point of contact with
screw stop, place a thin piece of paper between
screw and stop. Slide paper and turn screw at same
time until screw pinches paper.
-turn screw clockwise additlonal1/2 turn
- check idle speed and CO; adjust if necessary
f-- • pull connector off one injector and connect test light
e operate starter, light should flicker weakly
test light
flickers weakly I test light
does not light I test light
stays on
l
go to
Jr
replace
.. ~.- page24.40 control unit
<::
~
...... ..~{
replace
temperature sensor
Engine floods due to defective cold start valve
~ ~
Temperature sensor, checking go to replace
page 24.39 thermo time switch
E·17 .___A_i_r-co
____ o_led_-..:.Jj ~....I_A_F_c_ _, No voltage at Injectors,
troubleshooting 24.38
24 Fuel Injection, AFC System
...
Intake air sensor bad
l
replace
l
Break in wire or connec-
tntake air sensor tions between control
unit and intake air sensor
Test light
lights
I Test light
does not light
J,
go to
page 24.41
\ ,.
Double relay, checking
No voltage at double relay
• switch ignition on
• connect test light between:
terminal 86c and 85 (to coil terminal 15)
terminal 88z and 85 (to battery)
terminal 88b and 85 (to series resistances)
L J..
replace break in wire
double relay
I
Test light Test light
flickers does not flicker
124-0121
Possible causes:
e break in wire between terminal 1 on distributor and
terminal 1 on control unit multi-pih connector
e breaker contacts in distributor bad or incorrectly
adjusted
e condenser ground connection
e ignition coil bad
e switch on ignition
e test voltage between following terminals on multi-pin
connector of control unit:
terminal 10 and 5
terminal 10 and 16
terminal10 and 17
Test light
lights
I Test light
does not light
replace defective
control unit
Possible causes:
e break in ground wire of control unit
E·21 Digifant
Safety precautions 24.42
24 Fuel Injection, AFC System
E·23 Digifant
Technical data 24.44
24 Fuel Injection, AFC System
Engine code MY
Injectors
Spray pattern cone shaped
Note
ONLY connector connected is valve being checked
Voltage supply diode test lamp flickers
• ALL connectors disconnected, starter operated
Resistance
• measured on valve 15-20,{}
Air flow sensor
Resistance between
terminals: 3 and 4 5oo-1ooo n
------------------~~------------------------------~----~
2 and 3 change in resistance when air sensor plate is moved
1 and 4 resistance dependent on t~ature of
air flow sensor - set\ diagram
Temperature sender
Q _ _ _ __
'"
• for engine temperature Q
0 10 20 30 40 50 60 70 80 90 100"C
32 50 68 86 104122140158176194 212"F
Temperature
20 Nm --.........._ \
(15 tt lb) -............ \
Pressure
regulator
• checking - page 24.55
Bolt
• coat with D2
sealing compound
I
I
I
I
I
I \
I
l
T-connection
• with connector for
pressure gauge
Injector
• checking - page
Fuel Injection line
• from fuel pump
24.46 F-3
Fuel Injection, AFC S 24
(jll1 Cap
• replace
I CO..adjusllng screw
• idle adjustment -
I page 24.51
Ib)
Connector
• connect or disconnect only
with ignition off
• to remove, press spring up
Control unit
• for fuel injection and
ignition system, oxygen
regulation
(
• installation location: on Fuel pump ret~
trunk floor behind rear • to current suppfY for
seat or in cargo area, fuel pump
in platform truck in • when turning ignition on
equipment box under load and off, relay must switch
surface perceptibly (requirement:
current supply relay and
control unit OK)
Relay adapter
• check electrical connec-
tors according to wiring
diagram
24.48 F
Fuel Injection, AFC System 24
Sealing ring
Gasket
Connector -------....._
• for oxygen sensor heating
• checkvoltage with
ignition ON: approx. 12 V
Connector - - - - - - -
• for oxygen sensor heating
• resistance: continuity
F·5 Digifant
Fue~llnjection system components 24.49
24 Fuel Injection, AFC System
Note
The oxygen sensor must be disconnected with the
ignition off, to cancel the memory in the Electronic
Control Unit (ECU).
-connect CO tester to adapter on left exhaust pipe, - check idle speed rpm, correct if necessary using
using Sun tool 120.239 adjusting screw (1)
• .specification: 880 ± 50 rpm
Idle speed and CO content, checking - check CO content
and adjusting • specification: 0.7 ± 0.4% vol.
For CO adjusting, remove screw cap as follows:
- drill CO adjusting screw cap using
2.5mm (0.098 in.) drill
-thread 3mm (0.137 in.) sheet metal screw into
drilled hole
- grasp screw with pliers, pull out cap
Set idle speed and CO content by alternately turning
adjusting screws (1 and 2) to obtain specifications
- reconnect oxygen sensor connector and idle
stabilizer control valve connector
- let engine idle approx. 2 minutes
- check CO content, correct if necessary by
repeating adjusting procedure
Idle speed/CO· content, checking and - with Ignition switched off, re-connect oxygen
adjusting, continued sensor
- restart engine, let idle
· • CO content must read within specifications:
0.3 to 1.1% (not dependent upon elevation with
sensor connected)
""""" adjust if necessary
- secure CO adjusting screw with new safety cap
i ;··
Note I
\
After adjusting, the hoses for the crankc'ase_must be
reconnected. If the control current and the CO
content change, this is not due to an improper
adjustment,. but rather to oil dilution caused by short
distance driving. With long distance drives, the
amount of fuel in the oil will be reduced and the CO
value will normalize again. A short-term solution
would be an oil change.
Note
CO content is altitude dependent, refer to the
following chart to compensate for the altitude of the
workshop.
CO (Vol.%)
7
~~~~++~~r+~4-~
6++4-~++~~r+~~~
5+-~~r-~+4--r-
4 ++-r--i-<--t-i-"1"""'"t"~-f:
3 -1--'--+--+-+-l-+-++
2 ++_,_,..-t
1
o~~~~~~~~--t-t-~~
0 500 1000 1500 2000 Meters
1640 3280 4920 6560 Feet
Height above sea level l2+1321
Example: At 1600 meters (approx. 1 mile) CO
should be 5% ± .5%
Note
Idle stabilizer triggering can vary depending upon
specific vehicle wiring; however, in all cases the
following functional check applies.
- start engine and let idle
• idle stabilizer valve 1 must vibrate and hum
If OK,
go ahead with 2nd check
If NO,
remove connector from valve 1 and check resistance
of valve with multimeter US 1119
• specified value: display (continuity)
If specified value NOT obtained - Disconnect connector 2
- replace valve • specified value: approximately 430 rnA constant
If specified value IS obtained If test conditions have been met and specified values
- re-connect connector to valve and check electrical are NOT obtained
connections on control unit relay adapter (in front - replace idle stabilizer control unit
of right tail light) according to wiring diagram
If electrical connections OK
- replace idle stabilizer control unit
Note
The oxygen sensor must be disconnected with the
Ignition OFF to cancel the memory In the control unit.
- start engine
-hold disconnected (green) oxygen sensor wire
from the control unit to ground ~
• CO content must increase
If NO
- check wire connection on control unit, page 24.62
test step II
If OK
- oxygen sensor connected - replace control unit and recheck
-remove hose (1) from pressure regulator (2) and
plug hose Note
• CO should increase briefly. then drop in value If test step I is not OK but test step II is OK, the
to 0.3-1.1% oxygen sensor is defective.
CAUTION
Use extreme care not to damage fuel lines
when clamping.
CAUTION
The switch (arrow) on the pressure measuring
equipment must remain closed during the
J measuring process.
lit.
i2
F·11
Digifant Pressure regulator, checking
Residual pressure, checking
24.55
24 Fuel Injection, AFC System
- operate starter briefly, observe spray pattern: - remove all connectOfs from injectors and connect
• spray pattern must be cone shaped voltage teS1er US1115 on one COMector (arrow)
- operate starter
- re-install injectors • LED must flicker
If NO
Note -see electrical checks, page 24.61 , 24.62,
test steps 1 and 5 or control unit defective
When installing, make sure seals (1) are present.
Checking for leaks
- disconnect all connectors from injectors
- remove injectors in pairs (fuel lines remain
connected)
- switch ignition on for about 5 seconds
• no more than 2 drops per minute per injector
may leak out
F·13
Dlglfant Intake air sensor,
checking
24 •57
24 Fuel Injection, AFC System
Throttle valve switch, removing and Throttle val'(e switch, checking and
installing adjusting \
·~
2------®·.
1---@ 124-1521
Note
The limiting screw for basic throttle valve adjustment
must not be changed.
If the screw is turned by mistake, it will be necessary
to carry out a basic adjustment of the throttle valve
page 24.37.
F·15
Digifant Throttle valve switch 24.59
24 Fuel Injection, AFC System
Engine oil temperature minimum so•c Engine oil tElmperature minimum so•c (176°F)
Fuel shut-off will occur only when: RPM gauge connected
Note
------13
Internal resistance of the test equipment and ambient
temperature have a strong influence on test results,
digital multimeter US1119 should be used to perform
testing.
The specified values given are .for ambient
temperatures of oo to +40°C (32"·104°F)
If the measured value deviates· from the specified
values, determine fault according to current flow
diagram. Check wiring and connectors before
replacing any parts.
F·11 Diglfant
Electrical testing 24.61
24 Fuel Injection, AFC System
Requirements
Note
For additional tests of ignition parts of the digifant
system as well as Hall sender test see Repair
Group 28.
Index 26.1
26 Exhaust System-Emission Controls
Note
Always replace gaskets, seals and
self-locking nuts. Tighten all M8 bolts and
nuts to 20 Nm (14ft lb)
~
.;.--
Heat exchanger
Tall p i p e \
Straight pipe
I'
(Canada only)
c
Catalytic converter
(not Canada)
Heat exchanger
'T
/ California-~980 m.y.j
Air-cooled AFC
Exhaust system 26.3
26 Exhaust System-Emission Controls
•
--J
~ .,...
EGA valve
Heat exchanger
2 6 •4 Exhaust system
Air-cooled AFC I California-from 1981 m.y.
Exhaust System-Emission Controls 26
EG R valve, checking
Work sequence
Gaaketa---
replace
r Nm (11111b)!
~It)
J
r ...__25 Nm (18ft lb)
25 Nm (18ft lb)--'•
.J,
• ..._25 Nm (18 ft lb)
Gaskets _ _ _......-
replace
Gaskets---.,.
metal surface
Gasket a
metal surface
toward cylinder
"ead
Catalytic converter
Diesel
Exhaust system 26.7
26 Exhaust System-Emission Controls
Work sequence
-connect CO meter to test receptacle on
exhaust pipe (lett side)
Bracket~~~-------------.!~
• on engine block
• metal side
toward cylinder
head
l
i
i i
'<!
Exhaust pipe, - - - -- - - \ -
rear
Exhaust manifold
Heat shield
• for rear exhaust
pipe
• FOR SYNCAO ONLY
/
. Exlileust pipe- -
1 26-560 1
G·9
Digifant Exhaust system 26.9
26 Exhaust System-Emission Controls
Exhaust system components,
removing and installing
Continued
End pipe
Bracket ---~
• for muffler
Catalytic converter
• replace gaskets
• replace self-locking nuts
• tightening torque for screws and nuts:
25 Nm (18ft lb)
I 26·552 I
If exhaust system is tight -turn converter over and firmly tap other flange
-remove catalytic converter as before
-look through both flange openings against light
If no knocking sound converter is OK
If no movement of the ceramic insert, converter is
OK
CAUTION
Avoid the following conditions on vechicles
equipped with catalytic converters
• usage of leaded gasoline
If ceramic insert appears broken or melted as
shown, converter has failed • turning off the engine with the vehicle in
motion
G-11
Catalytic converter, checking 26.11
27
Electrical
Battery
Starter
Alternator
Index
Alternator
-Alternator/Regulator. checking
27.18
-Heater blower fan. removing /
rep1ac1ng 27.22
-Indicator lighl.
troubleshooting 27.23. 27.24
-Mount adjusting 27.22
-Removing/ Installing 27.15
-Repairing (45A. 65A) 27.16
-Repairing (90A) 27.17
~System layout 27.19
-V-belt, adjustinQ 27.21
-V-bell, replacing 27.4!1
-Voltage re<JulatOf 27.20
B1ttery
-Charg•ng 27.5, 27.6
-Checking 27.4. 27.6
-Eiectrotyt~ level 27.4
-Filler caps 27.7
- Location(s) 27.8, 27.9
-Nomenclature 27.2. 27.3
- Safety precautions 27.4
-TroubleshOoting 27.10
Cruise Control
-System, repairing 27.25
-Troubleshooting 27.29
Starter
-Installing 27.14
- Removing/installing
(Syncro) 27.13a, 27.13b
-Repairing 27.11
- Troubleshooting 27.12, 27.13
Negative terminal - - - -
• clean off any oxidation
• grease lightly with
acid resistant grease
27.2
Electrical-Battery, Starter, Alternator 27
CAUTION
Before beginning repairs on the electrical
system, disconnect battery ground strap.
Filler cap
• measure state of charge
using hydrometer
• charge battery, if necessary
Negative plate
(metallic gray)
LEVEL INDICATOR
WARNING
Battery acid can cause severe burns. When MAX.
working with electrolyte always wear ~:::::=:=::::::::::::::::::::tt- MIN.
goggles, rubber gloves, and apron. If
electrolyte is spilled on skin or clothing, PLATES
flush at once with large quantities of water. I27-A0281.
If it gets into eyes, immediately flush with
large quantities of water for several - check that electrolyte covers battery plates
minutes and call a doctor. (including separators) by 5 mm (1/4 in.)
-check battery electrolyte level indicator on
Batteries produce explosive gases. Keep side of battery
flames and sparks away from batteries. Do
not smoke near batteries Note
Battery, jump starting Only use distilled water when refilling battery
• car with good battery must not be running when Battery condition, checking
connecting jumper cables
Note
Weak battery can be caused by:
• alternator belt slipping
(replace belt when glazed)
• ground straps corroded, loose or broken
• alternator or voltage regulator defective
~~~~~517 TO BOLT ATTACHING • alternator warning light bulb burned out
GROUND STRAP TO • poor ground connection between warning light
BODY socket and circuit board
1 RED BLACK
Battery terminals and cables should be coated
with grease or petroleum jelly and, if necessary,
cleaned to prevent corrosion and ensure good
connection
VIsual checks
I27-A0271
-check for
• cracked or leaking case
- connect jumper cables in following order:
• loose or corroded terminals
• 1 - one end of positive cable to + post of • low electrolyte level. If electrolyte is low,
good battery
refill with distilled water and fast charge
• 2 - other end of positive cable to + post of battery for several minutes after cells begin
dead battery
gassing (boiling)
• 3 --one end of negative cable to - post of
good battery
Hydrometer test
• 4 - other end of negative cable to bolt
(for batteries with removable caps)
attaching ground strap to body
- start car which has good battery first - test electrolyte In all cells
- next start car which has dead battery • average specific gravity should be at least
-disconnect jumper cables in reverse order 1.225
- correct for electrolyte temperature if necessary
• for every 10°F above 80°F add .004 to
hydrometer reading
• for every 10°F below 80°F subtract .004
from hydrometer reading
- if specific gravity is above 1.225, load test
battery
CAUTION WARNING
Do not expose fully discharged battery to Gases given off during charging are
freezing temperature because battery will explosive. Do not smoke or allow spa~ks or
be damaged by freezing flame near a charging battery.
Battery charger must be turned off when
Voltage test-engine not running connecting or disconnecting cables on
(for sealed batteries only) battery
~d Note
ary, Voltage %of charge
l(j Follow battery charger manufacturer's
12.6 or more 100% instructions. Before testing a battery that has
12.4 75% been charged, load battery with 15 amps for 1
12.2 50% minute to remove surface charge
12.0 25%
11.7 or less 0% Battery with removable caps
If battery level is low and water is added, fast
Load test charge battery for a few minutes after battery
I,
begins gassing (boiling). Slow charging current
Note should be approximately 10% of battery
!gin
Before load testing, battery must be at least 75% capacity. Fast charging should be approximately
charged 80-90% of battery capacity. Remove cell caps
while charging
-connect load tester according to manufacturer's
instructions - charge battery according to following table:
-load battery to 3 times amp/hour rating or 1/2
lSt 0°F cold cranking current rating
Specific Fast charge
-wait 15 seconds and read voltage
gravity up to
sary • battery voltage at room temperature should
be at least 9.6 volts 1.150 or less 1 hour
-if battery voltage at room temperature is below 1.150 to 1.175 3/4 hour
9.6 volts, replace battery 1.175 to 1.200 1/2 hour
-if battery is colder than room temperature, 1.200 to 1.225 1/4 hour
voltage under load will be lower. Use table above 1.225 slow charge ONLY
below If cold battery must be tested to 1.250-1.280
H·5
Battery, checking 27.5
27 E lectricai-Battery, Starter, Alternator
Sealed batteries
Only slow charge sealed· batteries. Sealed 2
batteries, sometimes called "maintenance free,"
will not accept high rate of charge, making it
necessary to charge it for up to twice as tong as 3
battery with removable caps. Also, voltmeter
reading will not increase as rapidly as when
charging battery with removable caps 4.---'
WARNING 5-----""
Battery acid can cause severe burns. When
working with electrolyte always wear goggles,
rubber gloves, and apron. If electrolyte is
spilled on skin or clothing, flush at once with
large quantities of water. If it gets into eyes, Battery, Installing
immediately flush with large quantities of water
for several minutes and call a doctor. 1 =nut, tighten to 10 Nm (7 ft lb)
2=washer
Batteries produce explosive gases. Keep
3= bracket
flames and sparks away from batteries. Do not
4 =shims (note number)
smoke near batteries
5 = base of battery case
Note
CAUTION
Bracket must press on base of battery case
Before working on any part of electrical
system disconnect battery ground strap.
Never run alternator with battery
disconner.ted
Battery, removing
-disconnect battery ground strap from negative
terminal of battery, not from body
-disconnect positive terminal from battery
- remove battery hold-down (note number of
shims)
- remove battery
Note
Special bolt is used to attach ground strap to
body. If bolt has been loosened, it must be
removed and cleaned free of paint and
undercoating. Mounting area must also be
cleaned free of paint and undercoating. After
installing, coat bolt and mounting area with
corrosion resistant material
H·7
Filler caps 27.7
Battery location
Test conditions
fully charged battery
clock disconnected
Battery discharges
Possible causes:
corroded and fouled contacts
chafed-through wirings
internal short-circuits in electrical
equipment
27.10 Battery
Electrical-Batte Starter, Alternator 27
Starter, repairing
Protective -----..
cap for solenoid
olenold
• lubricate with moly paste
Shift lever----~
• If damaged, replace
• lubricate with moly paste
Intermediate---...
bearing
'nffl"
I
Drive pinion------'.._
• do not clean
"~Spring
Connoct... bua.".--J
• lubricate with moly paste
Field c o l i - - - - - -
• replace if worn
End plate
H·11
Starter, repairing 27.11
27 E lectricai-Battery, Starter, Alternator
Starter turns engine too slowly or engages and will not turn engine
Note
Check that engine is filled with oil of
recommended viscosity
CAUTION
Before working on any part of electrical
system, disconnect battery ground strap.
+
I End I
- clean starter terminals and tighten
connections
- clean and tighten ground strap between
transmission and body at transmission
Starter turns Starter does not
engine turn engine
+
I End I
Starter defective
- repair starter
Following defects could be cause of trouble:
Possible causes Remedy
• carbon brushes sticking - clean brushes and brush
or poor contact between guides; if necessary
brushes and commutator replace carbon brushes
• commutator dirty, or - clean commutator or
grooved and burnt replace starter armature
I End
l
- measure vortage at terminal 10 of
•
•
terminal 50 "' lrom ignition/starter switch
connection A = lor field windings
I
No voltage or Voltage OK
leaa than 8 volts
I
- replace ignitioni - cheek wiring
starter switch between terminal -replace -repair
50 on ignition/ solenoid starter
starter switch and switch
terminal 10 on
starter solenoid
and make
necessary repairs
I End I l End j
- on vehicles with
automatic
transmission, also
check neutral/park
starter switch.
Replace if
defective
I End I I End J
Note
You can remove the starter motor without
disconnecting the axle shaft, however; if the starter
motor area of the engine is caked with dirt, axle
removal greatly improves accessibilily.
CAUTION
Part numbers are for reference only. Nways
check with your Parts Department for latest
information.
of
- remove circllp 1
-remove bolls (arrows)
- remove bracket
Starter motor, removing
- disconnect wires from solenoid terminals 30 and
50
,
- loosen lower mounting nut on starter motor
(arrow)
- push up slightly on starter motor and remove
S
yncro
I Starter motor,
removing and Installing 27.13b
27 Electricai .. Battery, Starter, Alternator
Starter, Installing
Work sequence
CAUTION
Before starting work on any part of electrical
system disconnect battery ground strap
Diesel Engine
- replace bolt ONLY If damaged, Part Number is
AJtemator pulley
unchanged. Torque to 28-33 Nm (21·24 ft lb) • diameter 61 mm (2.40 in.)
• alternator pulley, removing
and Installing:
- hold pulley tightly with
wrench
- remove mounting screws
0.
Allemator - - - - - - - - .
aupport bracket
• mounting page 27.22 e-._ .._ ,../25 Nm (18 tt lb
:l
3~ .
Cradle
bracket Mounting nut
M14 - 35 :!.: 10 Nm (26 :!: 7 It lb)
Alternator, removing
and Installing
27'.15
27 Electrical-Battery, Starter, Alternator
Voltage regulator
Rotor
diHerent types tor 45A
and 85A alternators Housing
• mark position
relalive to end pl.Bll:
End plate
• mark position of housing
• note diHerent types !or
fastening flange
Diode plate
• when replacing. install
additional suppression
condenser-
Fig. 1 page 27.20
Stator
different types for
Belt pulley 45A and 65A
6 1 mm diamet er (2.40 in) alternators
Note
Always use new bearings, avoid damaging slip rings
Rotor
IJ)ate
Suppression condensor
ews
End plate
• Mark position in relation to alternator housing
Diode plate
• removing and Installing: to heatsink
at soldering points use needle nose
pliers. use soldering iron 300 waHS
maximum
• if diode is damaged, replace
diode plate completely
V-belt pulley
diameter 61 mm (2.40 1n) • removing and installing:
to heatsink use needle
nose pliers, use soldering
iron, 300 walls maximum
0
. _ _ _ _ 40 Nm (30 ft lb)
Diode test
• tester still connected
- run engine at 3,000 rpm
- adjust load according to manufacturer's
instructions
• if meter reads "bad," replace alternator
CAUTION
Never run alternator with battery disconnected - attach multimeter US1119 between contacts 9 and
13 on printed circuit board
• specification: 140-160 ohms
II value is greater than 160 ohms:
- replace printed circuit board
:ched
:mts,
1 and
out
removing/installing
Fig. 5 and Fig. 6 page 27.22
9 and
AlternatorNoltage regulator
(from 1981 model)
Note
VOltage regulator with black reclarliJular housing is
supplied as replacement PaJ'I N.o. 028 903 803A
Voltage regulator can be replaced without removing
alternator
• if voltage regulator is replaced, suppressor
condenser (Fig. 1, (if not already installed) must be
added
Fig. 3A
Voltage regulator ( hybrid-type ) now has longer
carbon brushes
a = approx. 13 mm (19132 in)
wear limit = approx. 5 mm (7/32 in)
Note
Do not install new-type voltage regulator (with longer
brushes) into old-type alternators
Fig. 2 Voltage regulator, removing and Installing Slip ring (on which brushes make contact) has been
reduced in diameter to 28 mm (1118 in) (was 32 mm)
CAUTION Shape of cooling openings in alternator housing
Part numbers are tor reference only. Always has been changed
chock with your Parts Department for latest
information.
:er
en
m)
H-23
V-belt, adjustment,
replacing
27 •21
27 Electrical-Battery, Starter, Alternator
4 To correct,
- install spring washer, Part No. N012 24 111, on
8- -, IIJ:I..I---tt-r-- 3 each bracket mounting bolt
9- - - - - . l'lll-1--+-t--2 -install bolts and torque to 22 Nm (16ft lb)
10-t=t~~~:lij Note
11
Spring washers are now Installed on cars beginning
with January, 1982 Vanagon production (from
VIN 25CH089151 ).
Fig. 5 Heater blower fan, removlnfJ'Instelllng
Mounting bolts, tightening
1 = alternator
2 = alternator cooling fan If allernator mounting bolts become loose, follow this
3 = support ring procedure:
4 = shim with collar Waterboxer
5 = V-belt pulley
8 = spacer - replace old bolts with new bolts of higher strength
7 = heater blower fan (New bolt PIN N14 400.4)
8 = thrust washer - re-torque new bolt to higher torque specification
8 = woodruff key Diesel motor
10 = spring washer
11 = nut, tighten to 35 Nm (25 ft lb) - re-torque old bolls
Torque specification:
• Waterboxer 24.0 Nm (18ft lb)
• Diesel motor 28.0-33.0 Nm (21 .0-24.0 ft lb)
CAUTION
Part numbers are for reference only. Always
check with your Parts Department for latest·
information.
Possible causes:
- improper alternator ground Alternator indicator Ught (LEDI does NOT light
- wom out carbon brushE:s up
9
- defective voltage regulator Alternator indicator light (LED) burnt out
- defective rotor
- disconnect battery ground ·strap
- replace indicator lamp (LED)
- connect battetY 9round stra!)
lis
- turn on ignition
Check alternator grounding and brushes: Alternator indicator Alternator indicator
If NOT OK: If OK: light (LED) lights up light (LED) does
~h make necessaty - replace voltage NOT light up
corrections
- if light now
regulator
E~D
comes on -
END
END
I
END
Note
Consult specific current flow diagram for
vehicle in question, to determine exact signal
path.
l - replace defective component
I E~D
END
Relay panel
Brake light switch
J Vacuum servo
removing and
installing-
Adjustable link
adjustment to
throttle lever -
~vacuum hose
page 27.28
Fig. 6 page 27.28
J
routing in engine
compartment
Fig. 3 page 27.26
Note
Vehicles with a manual transmission will have a vent
valve for the brake and a vent valve for the clutch.
Vehicles with an automatic transmission will have a
vent valve for the brake pedal only.
- remove steering column trim
CAUTION
Do not damage thread.
1- diaphragm
To check diaphragm:
- disconnect vacuum hose from pump
- press vacuum diaphragm inward, then plug
detached vacuum hose
• diaphragm must NOT move
2- adjustable link to throttle valve lever
3 - vacuum hose
4 - securing bracket on intake manifold with stud
and spacer
5- nut
torque: 4 Nm (3 ft lb)
6 - nut with shoulder
torque: 23 Nm (18 ft lb)
Note
The adjustable link is set to zero clearance at idling
speed (arrow).
127-A0571
=
Ground
connection
127-A0581
Vacuum vent valves do NOT work
1 connect test light between terminal 1 and
terminal 3 of harness connector
1 switch ignition and cruise control ON
1 press brake pedal and clutch pedal one
at a time
• test light does
NOT go out
- repair break in
wiring
OR
- adjust vacuum
vent valve
127-A0591
OR
- replace defective
vacuum vent valve
Ground
connection
- repair break in
wiring
OR
I21-A060 I
- replace defective
switch
127-A062j
Go to
®
next page
-repair break in
wiring
OR Ground
- replace vacuum connection
control motor
127-A0631
Ground
connection
127·A0641
Note
An inoperative cruise control system may
be caused by vacuum loss due to cracked
or leaking hoses.
Index
·.~
Index 28.1
28
.----1ermlnal1(-)
Terminal 4
only on vehicles
with radio
Termlnal15 ( +)
Rotor - - - - -- - ----
checking Fig. 1
Condenser - - ----.
··~~
30 Nm (22 It lb)
types page 28.3
Spark plug connector
4000-SOOOQ (with radio)
800-1200Q (without radio)
Distributor - - - - - - - - - - - - - - '
Installing Fig. 6 advance unit
checking centri fugal advance, checking leakage page 28.7
pages 28.8 and 28.7 vacuum advance che cking page 28.7
Clamping bolt
adjusting ignition timing,
see pages 28.5 and 25.6
Distributor drive - - - - - - - - , 1 1
removing Fig. 4
installing Fig. 5
28.2 Ignition
system Air-cooled AFC CAN/USA, not California
Ignition System 28
Engine code letters cv
Distributor (Part No.) 022 905 205S
•
Timing mark location: crankshaft pulley
'6 '2 8 4 0 4
~
~-
wires
1 Fig. 2
------... rw-~
I Idle speed
manual 800- 950 rpm
I automatic 850-1000 rpm
Vacuum hose disconnected
9- 14 • at 1600 rpm
Vacuum advance
start 107-147 mbar (80-110 mm Hg)
•.
266 mbar (200 mm Hg)
end
8 - 12"
ge 28.7
lmer
Note
A rough idle or misfire during partial load could be
caused by ignitioo spari<s jumping from the plug wire
connector to the noise suppression shield, or the
cylinder head.
- remove and inspect the plug connector for white
spots or burn mari<s
- on those vehicles equipped with a suppressor
shield on the distributor cap, it Is necessary to
remove the shield and che<;k for white spots or
bum marks on the distributor cap
II white spots or bum marl<s are present, replace the
damaged components.
• 4000·6000 ohms
Rotor
Note
If SIEMENS 451 tester is not available, proceed
with check using procedure with liming l ight
(see page 28.6)
-run engine until engine oil js at least 3o•c
J (86.F)
(&1371
-connect tester according to manufacturer's
Instructions
- start engine and run at Idle
• Ignition timing and rpm will register directly
on tester
-adjust idle speed if necessary
• manual: 800-950 rpm
• automatic: 850-1000 rpm
-pull hose off vacuum unit
-adjust ignition timing if necessary (see
pages 28.5-28.5)
- flash Ignition timing scale with timing light - note advance angle on test instrument (basic
• mark on pulley must align w ith red mark on advance angle)
scale
if NO, loosen distributor clamping bolt and turn Note
distributor Start of centrifugal advance is shown by
-reconnect vacuum hose to distributor Increasing advance angle registered on test
- retighten clamping bolt
Instrument while Increasing rpm
Note
To determine centrifugal advance, subtract basic
advance angle from last advance angle measured
Example
last advance angle measured
( - ) minus basic advance angle
( =) centrifugal advance
28.6
Ignition timing
Ignition
distributor
IAir-cooled AFCICAN/USA, not Calif: l
Ignition System 28
Ignition distributor, checking - run engine at approx. 2500 rpm and check that
vacuum at throttle valve housing is reaching
centrifugal advance with timing vacuum unit
advance tester If NO, vacuum connection on throttle valve housing
may be blocked
Work sequence
-increase engine speed until vacuum tester
-connect tester according to manufacturer's indicates higflar reading than ~ mbar
instructions (200 mm Hg)
-start engine and run at idle
-switch vacyuf11 ,fe&ter sQ il holds vacuum on
• manual: 800-950 rpm
side connected to vacuum unit
• automatic: 850-1000 rpm
-turn engine OFF
-pull off hose· at vacuum unit
- vacuum reading on les1eJ must not drop more
-check ignltioA timing and adjust if necessary
than 10°lo withirl 1 mlnufe, otherwise vacuum
(see pages 28.S tO 28.6)·
1
Ignition distributor
Distributor UP - - - - - - ----11-8!.::!1
check tor crac ks and
corroded contacts.
Clean before installing
Advance connection
Carbon brush and spring ·- - - - - --1 checking vacuum
check for wear and tree advanc e, page 28. 13
movement
Rotor---- - -- - - - - - - J
marked Rl
checking Fig. 1
~Spark
Oust cover
plug
30 Nm (22 It lbl
types, see page 28 9
Plug lor Hall generator
Distributor
installing Fig. 6
Seal - - - - - -- - - - checking centrifugal advance, page 28. 11 and
always replace
Thrust washer ~
In stall. with screwdri ver,
then posi tion
•
~
§:@]
-----=----
Idle adjustment 850-950 rpm
Vacuum lloses connected
Idle st~;~bilizer plugs removed and
connected together
~clor
240-28.0 mbar (180-210 rnm Hg)
end 9 - 12.
Vacuum retard
start 90-160 mbar (70-120 mm Hg)
d 2B.12
Firing order 1- 4-3-2
I
Transistorized ignition system cautions
Do not connect any conden ser /suppressor or test on car. Do not start engine after heating up to
light to terminal 1. Do noll connect test instruments more than 80 •c (176 •F), example: paint drying
wi!h a 12 volt supply on terminal 15 of ignition booth. Do not wash engine when it is running. Do
coil. Do not crank engine before high tension wire not use battery booster longer than 15 sec. nor
of distributor cap (terminal 4) is connected to exceed 16.5 volts with booster. Allow 1 minute
ground with jumper wire (example: compression pause between boosling attempts . Do not discon-
check etc.). Do not replace installed coil- nect battery while engine is running. Disconnect
211 905 115 C-with conventional type. Do not plug to ignition control unit when car has to be
leave battery connected when electric welding towed.
28.10
Rotor
Ignition wires
Distributor drive
California II Air-cooled AFC
Ignition System 28
CAUTION
-do not connect any conoonser to terminal 1 Ignition coilsecondltry r•i•tance, checking
-do not tow cars without disconnecting
plugs on ignition control unit - disconnect all wires from coil t erm inals
-do not crank engine until high tension - messure resistance between negative t erminal 1
wire of d istributor cap (terminal 4) is and coil high tension terminal 4
connected to ground with jumper wire • resistance:
(example: compression check, etc.) 2400 - 3500 ohms
- do not leave battery connected when - if not within tolerance, replace ignition coil
electric welding on car
-do not substitute rotor of ignition
distributor with one of different type
-wh en installing suppressor, use only
• 1000 ohms for high tension wires and
1000 to 5000 ohms for spark plug
connectors
Not
_,
-I
-·-·
-adjust Ignition timing
centrifugal advance with SIEMENS
Ignition timing, adjusting with timing 451 tester or equivalent
light
Wort sequence
Wort sequence
Note
011 temperature must be at least so•c (140"F) _,
IQr
ce
ad
Wo
-c
-connect tester according to manufacturer's
Instructions _, I
To determine centrifugal advance, subtract basic Distributor vacuum unit, leak checking
advance angle from last advance angle measured
Work sequence
Example -connect vacuum tester between intake
last advance angle rneasured manifold and retard connection on vacuum unit
(-) minus basic advance angle - plug vacuum hose for retard connection
- set vacuum tester to allow vacuum to pass
(= ) centrifugal advance
through
-compare centrifugal advance angle to
- start engine and run at idle
specified value of page 28.9
-disconnect hose from advance connection on
- repeat test at 3400 rpm
vacuum unit
- reconnect vacuum hoses when test completed
- .set vacuum tester so that it holds vacuum on
Note side connected to vacuum unit
G-12
Air-cooled AFC I I California I Distributor centrifugal advance
Distributor vacuum unit
28-.1 2
28 Ignition System
Test condition;
• ignition coil OK, ignition OFF
ry
lCk
ng
WARNING
No one should be allowed to stand in front of
vehicle during this test. Vehicle's wheels
must be blocked
with
gotobox
+.® ---'do not crank engine until high tension
wire of distributor cap (terminal 4) is
connected to ground with jumper wire
(example: compression check, etc.)
- do not leave battery connected when
(2) Ignition coil damaged externally
electric welding on car
-do not substitute rotor of ignition
- check coil to see if sealing compound
distributor with one of different type
has oozed out
-when installing suppressor, use only
check connections for dirt, cracks and 1000 ohms for high tension wires and
sign of burning
1000 to 5000 ohms for spark plug
connectors
Coil OK Coil not OK
-do not wash engine when it is running
- do not use battery booster longer than
1
1 minute nor exceed 16.5 volts with
gotobox @ booster
I ~
~
check condition of parts
check resistance in rotor arm, spark plug
conr1ectors and suppressors with ohmmeter
• specs: see Fig. 1, Fig. 2 end Fig. 3
n:
1re Parts OK Parts not OK
1al 1
,, -
I® Ignition timing incorrectly set or centrifugal/
vacuum spark control defective
No trouble in ignition
system
-
r
.__A_i_r-_c_o_o_le_d_A_F_c____.l _C_al_if_o_r_
L--1 n_ia------' Hall Ignition system · troubleshooting 28.18
28 Ignition System
28 21•
Hall Ignition system-~
troubleshooting
I
Air-cooled AFC California
I
Ignition System 2S
@ Open circuit in wiring from Hall control unit to
Hall generator
-<oo
Washer(s) •) ==-----
number of washers:
Circlip(§) ·)
Hall generator •) _ _ / t;
grease bearing surfaces
lightly
Ignition distributor - - - -1
[ 28-337!
Hall Ignition s y s t e m - . - - - - - - - - - - - . - - - - - - - ,
28.23 troubleshooting j Air-cooled AFcjcalifornia j
Ignition System 28
Quick glow system-troubleshooting
Diesel
Quick glow system - troubleshooting 28.24
28 Ignition System
,,
Note
If glow plug tip (arrow) is worn away, in·
jector spray pattern may not be correct---+---;:.-
-remove corresponding injector
-check spray pattern, opening pressure
and leakage of injector, using tester
US 1111; see also pages 23.9 and 23.10
-check that spray pattern is compact and
well atomized when pump lever is
operated with short rapid strokes (4-6
strokes/sec)
• if NO
-clean Injector and recheck spray pattern
etc.
• if still NO
-install new injector and new glow plug
'• I
-replace fuse
~0
End
r 87
11f
t
No voltage at terminal 30 on glow plug
relay
'
'It
-repair connection
t
-repair con nee! ion
Note
When engine is difficult to start, check
operation of automatic delay glow period
from replay terminal from fuseS 12 to
and preheat period during starting
85 to ground; or relay terminal 86
• when temperature controlled preheat
-replace relay period has ended (glow plug light out)
Diesel
Quick glow system - troubleshooting 28.2
28 Ignition System
Glow plug relay or engine temperature sensor The torque specification for all glow plugs Is:
defective • 30 Nm (22 ft lb)
Check operation of relay-see also Note on This torque must NOT be exceeded because
page 28.26 increasing the torque beyond the specification will
-disconnect glow plug wire cause closing of the ring gap, which can lead to
-disconnect wire from engine. temperature premature failure of the glow plug.
sensor
-turn ignition switch ON
• glow plug light should light up for 25-30
seconds
-ground disconnected wire from engine
temperature sensor
• glow plug light must go out
Connector on dl•trlbutor
'"will
d to
Distributor cep - - - - - - - - -
check for cracks and
corroded contacts.
Clean before Installing
WARNING
Rotor - - - - - - - - - - - - - iw Do not touch or remove ignition coi l wire
checking Fig, 1 when running or cranking engine.
Only disconnect wires of ignition system or
connect/disconnect test instruments when
ignition is turned OFF
Trigger wheel
removing /installing page 28.38
. , - - - - Shims
adjust number of shims until
Hall generator free of play
and easy to turn
Retaining button _ _ _ _ _ .
~~!-------- Hall generator
lightly lubricate bearing
surfaces
checking page 28.37
Magnet------
Vacuum unit
Dlstrlbu1or --------1•
installing Fig, 9
Seal----------~<:::>
always replace
~
~ I
f
Idle speed 850±50 rpm
Vacuum advance
start 190-230 mbar (14.0-17.0 em Hg)
Vacuum retard
start 100-220 mbar (7.5-16.5 em Hg)
Note
Components with new style (M4) connectors are
not interchangeable with old style. If replacement is
required, install complete set with all connectors of
same style.
CAUTION
Note
Rotor must be marked with A 1 for
Hall generator equipped cars
Note
A rough idle or misfire during partial load could be
caused by ignition sparks jumping from the plug wire
connector to the noise suppression sh!eld, or the
cylinder head.
- remove and inspect the plug connector for while
spots or bum marks
- on those vehicles equipped with a suppressor
shield on the distributor cap, it is necessary to
remove the shield and check for white spots or
bum marks on the distributor cap
If white spots or burn marks are present, replace the
damaged components. Fig. 6 Ignition coli secondary resistance,
checking
Note
If resistance readings are correct, but no high
voltage occurs at ignition coil, check Hall gener<
and Hall control unit. If necessary. replace ignili1
coil.
I
Suppressor connectors
Work sequence
CAUTION
Ignition must be switched OFF before
connecting tester
Itor
~n
• go t o n ext flilJe
Example
Ignition distributor, checking centrifugal last advance angle measured
advance with TOC sensor (- ) minus basic advance angle
(= ) eentfifugal advance
Nota
Start of centrifugal advance is shown by r 10vement
o f notch while increasing RPM.
- increase engine speed slowly to 160G RPM.
- bring back notch to original setting by turning
knob o n tester. Read off advance valcc.
Note
To dete rmine centrifugal advance, subtract basic
- connect tester according to manufacturer's advance angle from last advance angie measured.
instructions. Example
- connect ~usit ive lead to alternator or c onnection
last advance angle measured
box.
(- ) minus basic advance angle
- pull both hoses off distributor vacuum un it .
-pull off hose 'f rom vacuum retard unit. '. - check ing with timing light:
. disconnect plugs from Idle stabi lizer control unit - shine timing I ight on t imi ng mark again and bring
and connec t together. mark back to original setting by turning knob on
- start engine and adjust idle speed to 900 RPM. timing advance tester .
- read off retard angle and compare witr
- checking with TDC sensor: specifications on chart for retard end. {See page
- note advance angle on tester {basic advance angle). 28.30.)
Water-cooled II Digijet
Vacuum unit
Vacuum a(jvance
Vacuum retard
28.35
28 Ignition System
- remove harness connector from Hall control unit - touch center wife of connector on dist.rib
-connect multimeter US 1119 with + (plus) to briefly to ground
terminal 4 and with (minus) to terminal 2 in • indicated voltage must increase briefly
connector volts (minimum)
- turn ignition ON
• approximately battery voltage It NO
-check tor wire break in center wire and r
II NO necessary
- check for wire breaks using wiring diagram and
repair as necessary If wire OK
- turn ignition OFF - replace Hall control unit
- reconnect Hall control unit harness connector - turn ignition OFF
- disconned Hall generator harness connector from more
ignition distributor
,j2s-311 1.
Note
If engine is difficult to start, does not start, or
engine misfires/stalls, proceed as follows:
WARNING
No one should be allowed to stand in front ot
vehicle during this test. Vehicle's wheels
must be blocked
lCed
Ignition wire
- check for continuity
Ground wire
J
~··
Ignition distributor
Dust cover
Distributor shaft
Screw
Plastic washer
Hall sender
-checking, page 28.43
- to·replace, remove
distributor shaft
Distributor - - -.....
- installing, page 28.44
Spring
Bracket
~Jir~butor drtve anatr
- removing and lnatallln<
page 28.44
Thrust washers
- Install and position
using screwdriver
Clutch
- installation location:
large segment points
toward notch for rotor
Retaining spring
In distributor shaft .;_replace
unit*** .
Digifant control 025 906 0220 old
025 906 022/022A new
Ignition timing Checking value 3" - 7" before TDC
Adjusting value 5• ± 1" before TDC
Timing mark location
'
::;v
'
\~ ~~
@~) 128-3901
RPM• "~ 2000.2500
~)
Ignition adjustment**
-- timing map --
RPM Approx. 3000
Degrees 35 ± 5"
RPM limit Switch-off RPM of RPM 5600
digifant control unit
CAUTION
Part numbers are for reference only. Always
check with your parts department for latest part
information.
20 Digifant
Ignition settings 28•J.
28 Ignition System
Ignition timing, checking If NO
- check electrical connections for temperature
Requirement sensor II, air flow sensor and digifant control unit
according to wiring diagrams
Engine oil temp. minimum 80° C (176° F)
Ignition timing, adjusting
Requirement
Engine oil temp. minimum 80° C (176° F)
- connect test equipment for ignition timing and rpm
(see Fig. 1)
Note
Use adaptor VW 1473 for connecting tester VW 1367
to terminal 1 of ignition coil.
- start engine and allow to idle
-disconnect temperature sensor II (see Fig. 2)
- check ignition timing at 2000.2500 rpm correct
if necessary
- start engine and allow to idle Notch on V-belt pulley must match separating line
on crankcase
- correct Idle setting if necessary
167
22 Digifant
'-------'·
I· Hall senper•
checking 28.4
28 Ignition System
128-6301
If NO
- replace control unit
- Brake/Ciu tch fluid reservoir 30.3 - Brake/ Clutch fluid reservoir 30.3
-Clutch assembly 30.4 -Clutch assembly 30.4
controls 30.2 controls 30.2
diaphragm spring 30.6 diaphragm spring 30.6
disc 30.7 disc 30.7
hydraulic system 30.2 hydraulic system 30.2
pressure plate 30.6, 30.7 p ressure plate 30.6, 30.7
mod ification 30.6, 30.7
- Release shaft bushing 30.3 - Release bearing 30.7
- Roll pin 30.3 - Re lease shaft bushing 30.3
- Roll pin 30.3
Diesel
'
'k for
A-1
30.1
30 Clutch, Controls
ClaYII WARNING
clearance between push rod and
piston In clutch master cylinder Brake fluid Is polson
0.5mm (0.020 ln.) max.
~\_ I~ Installation
Rollpln
position Fig. 1
Colter pin
always replace Ji•..-- Pin
lubricate with
MoSa grease
Buahlnga
remove with VW 207,
Install !lush
Note
25 Nm (18 It lb)
Filling of system is done by removir
top of dashboard and adding approv
Clutch -··•-.r-
cyllndar
brake fluid (see caution page 30.3) I<
brake/clutch fluid reservoir
BIHdar acraw
open valve only when
Coupling bleeding hydraulic system.
Bleed system only with
pressure bleeder
Pivot bolt
15 Nm (11 tt lb)
secures release shalt
Guida ••~
plastic, do
15 Nm (
re
RE
Clutch
grease
Clrcllp
alway& replace Clrcll~ Release bearing
lnsertlnto clip and do not clean in solvent
attach with release only lubricate pivot surface
bearing and clip to with MoS2 grease
Bu
release shalt replacing, Fig. 5 and page
VW771 \
CAUTION
Brake fluid must not come into contact
with paint .
Brake fluid absorbs moisture from ai r and
must be replaced every 2 years.
Only use new unused DOT 3 or DOT 4
brake lluid accordi.n g-tq_MOTOR VEHICLE
SAFETY STANDARD 116. Do not add or
mix DOT 5 silicone. type brake fluid with
brake truid in car', as severe component
corrosion may result . Such corrosion could Fig. 4 Release shaft bushing, Installing
yllnder lead to clutch and brake system failure -drive in flu sh
1g, insert
aft
Ide .....,.
~lie, do not greaae
5 Nm (11 ft lb)
"ahaft
t.t wlth
1reaae
- Buahlng
' replacing l et Fig. 5 Release bearing, Installing
I Repair Group
- new release bearings on which thrust
ring is not centrally positioned to
Brake/clutch fluid reservoir, filling housing (arrow) can be installed
- grasp two recesses on back of - thrust ring automatically centers itself
dashboard cover and pul l up on first application of clutch pedal
!vent
- fi ll w ith brake fluid (see above caution)
1sm1eces
until level is between " MAX" and "MIN"
nd page 30.7a - replace cover by inserti ng f ront edge
fi rs t then press cover do wn fi rmly
25 Nm (18ft I b)
diaphragm sprif'lg
loosen and tighten by stages in diagonal checking fi ngers Fig. 3 · Fig. 6
sequence Note
-install hexagon bolts or socket head Spring finger length increased;
screw1 MS x 16 without spring check for comp~tihle release
washer; or bearing
- install hexagon bolts or socket head
screws M8 x 18 with spring washer
-use only bolts or screws of same length
Clutch dla
checking
Flywheel
check lor wear and tightness
of dowel pins (essential Clutch presaure plate
lor correct position ol TDC mark removing/Installing Fig. 2
on pressure plate) checking Fig. 7 and Fig 8
:h disc
:king Flo. 9
25 Nm (18 h lb)
loosen and tighten by stages and In
diagonal sequence
-install hexagon bolts or socket head screws
M 8 x 16 without spring washer; or
Note
-Install hexagon bolts or socket head screws
For clutch repairs, trar.smlss ion must M 8 x 18 with spring washer
be removed -use only bolts or screws of same length
30.6
Clutch disc
Clutch pressure plate
Clutch diaphragm spring
!4-speed 091-091/1 l5-speed 094I
Clutch 3(
[3o-236l
Fig. 6 Replacement release bearing, air-cooled engines
Note Fig. 8 Clutch pressure plate, checking
Release bearing with wider contact surface - check lor cracks, burn marks and wear
(arrowl is the only bearing availahle as spare • inward taper: 0.3 mm (0.012 in.) max.
part. This release bearing will work with either
old or new type pressure plates.
Engine replacement
If exchanging engines, be sure that wider-<:ontact-
surface release bearing is used if pressure plate is
of older type [where a, Fig. 4, =55 mm
(2 3/16 in.l dia.l
CAUTION
Do not install release bearing having narrow
contact surface [46 mm (1 13/ 16 in.) dia.)
together w ith short-fingered pressure plate
[a-. 55 mm (2 3/ 16 in.l dia,)
Jines
1/ 16 in.)
Ag. 9 Clutch disc, checking/Installing
~ ------Shaft
----Buahlnga
remove with VW 207
Install flush
Clutch pedal
·,~
Presaure hosa
Clrcllp ____,..
always replace
Pressure plate
removing and installing Fig. 1
checking for wear and warping Figs. 2, 3 and 4
Clutch disc
centering Fig. 1
checking runout Fig. 5
Note installation position,
spring cage faces pressure plate.
When installing, clean corrosion from
transmission mainshaft and clutch hub
splines. Ughtly grease clutch splines
with grease, part no. G 000 100
Flywheel
check that spring pin fits tightly
Clutch facing contact surface must be
free of cracks, oil and grease
ge)
A·1
Index 32.1
32 Torque Converter
-cut free end of drain hose at an angle
-place converter in sloping pos ition
CAUTION
om oil
When installed, bushing must have inside
II ~ Threaded Rod diameter of 34.03-34.05 mm (1.340- 1.341 in.).
If bushing is less than minimum inside
diameter, it may sieze.
After Installing bushing, check edge ot
ith converter hub for burrs
I seal
vw 201
US 691 or
replaced 40-103
.embly
Converter bushing
Oil seal, removing
32 3 •
32 Torque Converter
I~
091
Converter oil seal, lnatalllng -[
- C:
-dip seal In ~TF and drive in as far as It a
will go
t
li
CAUTION
- 1
Be careful when installing silicone seal.
Seal is soft and can be easily damaged.
Silicone seals must not contact gasoline or 091
similar cleaning solutions -I
-I
09
Index
091 094-4WD Syncro
- Drive flange oil seal 34. 18 -Differential
-Gearsh~t lock components 34.24
adjusting 34.4 lock control, repairing 34.26
assembly 34.3 lock servo, removing 34.25
bearing plate 34.4 -Gearshift linkage
linkage 34.2 adjusting 34.21
-Transmission assembly 34.20
removing 34.14 -Technical data chart 34.19
-Transmission
091/1 removing/installing 34.22
-Drive flange oil seal 34.18
-Gear ratios 34.9
- Gearsh~t
adjusting 34.8
assembly 34.6
bearings 34.6
linkage 34.6
-Lubricant
specifications 34.9
- Shnt rod
mounting 34.7a
- Technical data
chart 34.1a
094
- Drive flange oil seal 34. 18
-Gearshift
adjusting 34.12
assembly 34.10
-Technical data chart 34.1 b
-Transmission
removing/installing 34.16
34.1
34 Manual Transmission-Controls, Assembly
Technical data
• code letters
• application
• gear ratios
Transmission
date of manufacture
from 01/86
to
type 091/1
Gear ratios
final drivP 29:6-4.83
Lubrication
capacity 3.0 liter (3.2 U.S. qt)1
specification hypoid API GL-4, Mii-L-21 05, SAE SOW, SOW /90
Clutch
actuation hydraulic
34.1a Transmission
Technical data
091/1
Manual Transmission-Controls, Assembly
Technical data
• code letters
• application
• gear ratios
Code letters DX
Production from 10/82
l to 11/83
Application type Vanagon
engine 1.6L Diesel37 kW (48 bhp)
Ratios final drive 38:7 =5.428
1st gear 37:9 =4.111
2nd gear 35:15 =2.333
3rd gear 31:21 = 1.476
4th gear 57:56 = 1.018
5th gear 49:64 =0.765
reverse gear 33:9 = 3.666
Lubricant capacity 4.0 Liters (4.2 US qt)
Specification hypoid GL-4, MIL-L 2105, SAE 80 or GSO synthetic oil
Clutch actuation hydraulic
Clutch disc diameter 215mm
Axle shaft flange diameter 100mm
s~speed 094
Technicaldata 34.1 b
34 Manual Transmission-Controls, Assembly
Note Not
fO?
lubricant must first be cleaned thoroughly,
k ...__.
-----.
'~
~I "--.....--....._, (
I 1
-
20 Nm (14 It tb)
-----~ply 06 locking compound
----- -... Oulde pin
fits on selector
shaft in one
position only
l Sl
r---.. . ___
removlng /instaUing page 34. 5
L•
d
8l
I -...
81
I
I
---~ \ I
------
-----.. . --J I
•
(,,
Center shift rod bushing------'
lubricating: - remove front and center shif t rods
....,.._}
- fill lubrica tion grooves w1th grease
replacing: - remove front and center shift rods Front ahlfl rod
removing/installing page 34. 5
tley laver
s on selector
~aft In one
>Sition only
Gearshift lever----...
adjusling page 34.4
/
Lever bearing plate, lower
5
Shift mechanlem houalng ---.J
·. {f 1, .
- align holes (arrows) of upper bearing plate with
Note
A revised shift lever bearing is installed in vehicles
beginning 06-88. In the revised bearing the bearing
plate alignment holes are delet~. The revised shift
lever bearing can be installed in vehicles
manufactured from 10-82 to 06-88.
Jnting
!5of the
'·
r can
enter of
8-6
4-speed 091 Shift rod 34.5
34 Manual Transmission-Controls, Assembly
Note
Lubricate all joints and moving parts with grease
(part no. G 000 602) before installing. Linkages
already lubricated with white grease or solid
lubricant must be cleaned thoroughly before applying
moly grease.
4
Transmission, removing/installing
2
see pages 34.16 and 34.17 3
~g ~Bushing
Bushing~
~Gearshift lever
~ bearing housing
IYCII'houslng
/ ,---Lever
fits only in one position
25 Nm (18 It lb) fj " / on shift rod
/®
~Shift rod
/
/
~Boot
- - - - - S h i f t lever
-housing
f------- Tensioning pin
I 34-12971
/
Bushing, rear
4-speed 091/1
Gearshiftlinkage 34.7
34 Manual Transmission-Controls, Assembly
Lever~
Flange (gear carrier housing) ~'\f._\
for mounting support plate ~ ~
Clip Flg.1 G \)
installing Fig. 2
Support plate
-·-O_j
Fig. 1 Flange on gear carrier housing, dimensions Fig. 2 Front boot, adjusting
a = 14.5 mm (previous version) a = 60.0 mm (in neutral position)
a = 21.0 mm (revised version)
Note
Note
The revised shift rod mounting can be
The shift rod bushing is positioned 6.5 mm further installed with the previous gear carrier
forward on the revised flange. This prevents the rear housing. Insert a nul, M8 x 6.5.
boot from being compressed too far causing a shill Part No. N 011 008 18, between flange
out ot gear. and support plate. Use M8 x 40 bolt.
Part No. N 010 340 4.
During repairs, a gear carrier housing can be
replaced with the revised housing on transmissions
from 10/82 on.
Work sequence
- shift into neutral position
CAUTION
~ely
Transm ission must be in neutral, lever on ;
transmission In verti cal position '·
Note
Check that with 1st gear engaged, distance
between shift lever and heater pipe Insulation is
min. 15 mm (19/32 ln.)
Note
CAUTION
Lubricate all joints and moving parts with grease
(part no. G 000 602) before installing. Linkage Apply grease to shifter components inside the
already lubricated with white grease or solid vehicle with great care. MoS:z grease cannot
lubricant must first be cleaned thoroughly. be removed from upholstery or carpets.
Bushing~
Headless screw M 5 x 8 -.::::::._
Spring~ @
8
~
g
Spacer ring-----~ flj @-- Shift guide
collar faces upward 'J
Reverse gear 1ock
Shift mechanism·housing
~~ ·~.
E_ . )
~
1~~
Clamp
Knuckle joint
-;~,front ;_25N;(18ftlby
~
1
Leve~
~
/
/Ill f .•
25 Nm (18ft lb) -(I ./ fits only in one position
on sh;ft n>d
~Ht•od
t:!9--Boot
~ShHtlo"'
IJ- Tensioning pin
Iring
Ill
rguide pin
arlock
134-1280 f
Work sequence
- shift into neutral position
Note
A revised shift lever bearing is installed in vehicles
beginning 06-88. In the revised bearing the bearing
plate alignment holes are deleted. The revised shift
lever bearing can be installed in vehicles
manufactured from 10-82 to 6-88.
~h alignment holes
I ~ to 06.a&)
;ion,
ring
ition
B-15
5-speed 094 Gearshift lever 34.1~
34 Manual Transmission-Controls, Assembly
Transmission, removing
(engine installed)
Work sequence
-disconnect battery ground strap
- remove right side upper engine/transmission
bolt
Transmission, Installing
(engine Installed)
Work sequence
Proceed In reverse order of removing and note
following:
- install transmission with US 618 together
with US 618/5
-clean splines of malnshaft and lubricate
lightly with Mos.
-note correct position of air deflector plates
IO body
-check engine compartment seals
-tighten front transmission mounts
Tightening torques:
• transmission to engine bolts/nuts 30 Nm (22 It Ib)
• drive shafts to transmission 45 Nm (33ft Ib)
Work sequence
-disconnect battery ground strap
- remove upper engine/transmission bolt
-remove bracket for accelerator cable
Note
Hydraulic system must be closed
-remove shift rod from transmission (arrows)
-disconnect backup light wiring -support transmission with suitable tool
34.16 Transmission,
removing ]4-speed 091/115-speed 0941
Manual Transmission-Controls, Assembly ~
sion
Transmission, installing
(engine Installed)
ght arrow)
!rom body
Drive flange oil seal, removing Drive flange oil seal, Installing
(Transmission installed) (Transmission Installed)
Work sequence
-remove drive shalt bOlts from transmission
and detach shaft upward
• hang up shaft with wire
-pierce cap in flange with screwdriver and pry
out
Transmission
code letters AAK AAN
date of manufacture
from 10/85 10/85
to
Application vehicle Vanagon Syncro
engine 2.1 Liter 95 bhp (net) SAE
Gear ratios
1st gear 34: 9 = 3.78
2nd gear 33: 16 = 2.06
3rd gear 49 : 40 = 1.225
ring race 4th gear 41 : 48 = 0.85
ase Low gear 31 : 9 X 28 : 16 = 6.03
Reverse gear 31 : 9 X 28: 16 = 6.03
Final drive ratio 38: 7 = 5.43
Capacity 4. 7 US qt (4.5 Liters)1
Lubricant specification Gear oil GL-4 SAE 80
Clutch mechanism hydraulic
Clutch disc diameter 228 mm
Driveshaft flange
diameter 100 mm
Overall ratio in 4th gear 4.15
Speed in 4th gear per
1000 rpm 18 mph (29 km/h)
t head
Hf
I094-4WDI Transmission
technical data 34.1!
34 Manual Transmission-Controls, Assembly
Note
Lubricate all joints and moving parts with MoS2
grease (part no. G 000 602) before installing.
Unkages already lubricated with white grease or
solid lubricant must first be cleaned thoroughly.
Pins
Shift fork
MS x8 Q I
I
Lower bearing plate
I
I
. ~
Universal - j
~4 ~Bushing SNmU8fti: ~/S~•
~ 7
/~~-
fits in only one position on shift leve
~ ............ I
I
I
10 Nm (7 ft lb)
8 /®
1,..
8
8 Shift stop plate
IU34-17851
3 4 •2 0 Gearshift linkage
Syncro
.......
~
Manual Transmission - Controls, Assembly 3~
Shift linkage, adjusting
- place shift lever in neutral
Note
A revised shift lever bearing is installed in vehicles
beginning 06-88. In the revised bearing the bearing
plate alignment holes are deleted. The revised shift
lever bearing can be installed in vehicles
manufactured from 10-82 to 06-88.
:rod
With alignment holes
(up to 06-88)
loot
- align holes (arrows) of upper bearing plate with
holes of lower bearin plate
Syncro
Shift linkage, adjusting 34.2
34 Manual Transmission- Controls,
CAUTION
Transmission must be in neutral, lever on
transmission in vertical position.
Note
With 1st gear engaged, the distance between the
shift lever and heater pipe insulation must be at least
15 mm (19/32 in.).
Work sequence
Removing
134-16731
Tightening torques
Vacuum servo
Vacuum reservoir
mounted nex1 to right frame rail
134-16581
1 servo
2 bracket
3 spring pin
4 switch for lock indicator light
5 operating rod
Work sequence
Note
Only white vacuum hoses are supplied as spare
parts (Part No. N 20 139.1 ). When replacing hose,
cut to proper length and mark with tape of
appropriate color.
t
- press switch out of guide bushing
134-18881
- unscrew knob, if necessary hold switch piston
with needle nose pliers
-remove trim plate (arrows)
SRRRRRI
134-18891
- remove bracket
- remove trim
4-Speed 091/1
-See page 35.31
S·Speed 094
-See page 35.61
094-4WD Syncro
-See page 35.93
C·1
35.1
35 Manual Transmission-Case, Gears, Shafts
/ '>~..,.,
. . -Cap
always replace
1
""--- Clrcllp
installing Fig. 8
Clrcllp
always replace
Adjusting ring, lett
mark position before removing Fig. 3
removing Fig. 4
hMtno~
installing Fig. 6
Clutoh
mark position of adjusting ring
before removing, Fig . 3.
Before removing, loosen left with weahers
differential adjusting ring to 20 Nm (14ft lb)
reduce tension in transmission
housing
35-685
4-speed 091
35.2 Transmission assembly
Manual Transmission-Case, Gears, Shafts 35
C·2
C·3
4·speed 091 Drive flange
Adjusting rings
35 3
•
35 Manual Transmission-Case, Gears, Shafts
Differential
136-685A I
Removing
-remove circllp (arrow)
-push reverse gear backward and screw out
main shaft ·
Installing
- screw front and rear main shafts together,
then back off one spline
-push reverse gear on and Install new circlip
ll
8
C·S
4~speed 091 Rear main shaft 35.5
35 Manual Transmission-Case, Gears, Shafts
\
"·
'~Gasket
• \. always replace
!----1
..----- I
__J
------ ---------
Retaining ring
remove w ith VW 381/14
installing Fig. 1
------ -------- ------ r /
Gearahlft housing
). Installing Fig. 5
locking F1g. 3
--------
------- 7 bolts M8 " 32
1----
with washers
20 Nm (14 It lb)
with washers
20 Nm (14ft lb)
always replace
with washers
20 Nm (14 It lb)
determining thickness, removing /i nstalling Fig. 2
Repair Group 39
Note
Note
If bearing and I or transmission housmg are
replaced, and dimension r is not marked on ring
gear, pinion depth must be measured and noted
before gear carrier is removed. Thi s is dimension
r. See Repair Group 39. When assembling. parts
must be installed in same position. See Ring
gearlpinion , adjusting, Repair Group 39
Work sequence
Removing
• use two M8 x 20 bolts to attach VW 457
-press gear carrier out with VW 296 I
Installing /
/
-tap on pinion with plastic hammer to install
-turn reverse shalt so that reverse sliding gear
..
slips onto splines properly
-align flat on bearing with recess in housing
Fig. 5
-•
Gear shill housing, installing
-guide inner shif t lever into 3rd/ 4t h
gear selector shaft (arrow ) when
installing
C·7
.4-speed 091
Retaining ring
Gear carrier
Gear shift housing
35 7
•
35 Manual Transmission-Case, Gears,
(
\,
Clrcflp - - - - - - - - .
25 Nm (18 It lb) always replace;
when installing, circllp
3rd /4th gear shift fork mus.t be seated In groove
adjusting page 35. TO
35-7oo 1
Gear Ratios
1st gear 3.78(9:34)
2nd gear 2.06(1 7:35)
3rd gear , .26(50:63)
4th gear 0 .852(61 :52)
Reverse 3 .28(13:16 X 15:40)
Final drive 4.57(7:32)
VW402 --
C·9
4-speed 091
Main shaft assembly
Pinion shalt assembly
35 9
•
35 Manual Transmission-Case, Gears, Shafts
CAUTION
Sh ift fork for 1st/ 2nd gear (wider fork,
marking: No. 551 A) is instal led wi th flat
side away from gear carrier.
Shift fork for 3rd/4th gear (thinner fork,
marking: No. 561 A) is installed with flat
side toward gear carrier.
Note
Alter repair work on gear carrier housing, adjust
&)ial play In reverse sliding gear before adjusting
teverse gear
I:W-6441
Starter buahlng
removing Fig. 5
installing Fig. 6
can be replaced with
t ransmission installed
'
.....
~
:.It
011 '"'"
20 Nm (14""" _f
It lb)
Release bearing guide slee11e
plast ic, do not 11rease
removing Fig. 1
installing Fig. 2
fill space between Ups
with multi-purpose grease
ling
C-12
4-speed 091
Main shaft oil seal
Release shaft bushi ng
Starter bushing
35.-41I 3
1
35 Manual Transmission-Case, Gears, Shafts /
ring gear
"---Circllp
for need le bearing I main shaft
Drive flange oil aaal
removing Fig. 1
Differential bearing, outer race
installing Fig. 2
removing/ installing, Repair Group 39
can be replaced with
when replacing, readjust ri ng gear
transmission installed
35- 695 1
VW422
oves
aring
eplace
C-1C
Drive flange oil seal
Reverse gear shaft clrclip
35 15
•
· ~,"--.""-..
Detent ball
press down with screwdriver
to install selector shalt ,
installation position Fig. 2
Bracket/relay ahaft
adjusting page 35.17
Relay laver support
adjusting page 35.17
Plugldetent plunger
1
removing Fig. 1
install flush
3rdl4th gear
selector shaft
Plug/Interlock plunger
removing Fig . t
install flush
Intermediate pin
in reverse gear selector shalt,
installation position Fig. 2
35-703 1
\
"'-·
Manual Transmission-Case, Gears, Shafts 35
Reverse gear clearance, adjusting
Note
When reverse relay shaft and brackets have been
removed, play between reverse gear and pin
(arrow) on relay shaft must be adjusted by
moving shaft and brackets vertically (as shown)
35.17
It lb)
-install gear carrier with reverse gear in sett ing
tool VW 294b
- loosen bolts on both brackets
- slide bracket A down against shaft C until
pin (arrow) on relay shaft is firmly against
reverse gear
-pull bracket back slightly until there is
clearance between pin and reverse gear
- tighten bolts on bracket A
C·17
4-speed 091 Interlock/Detent plungers
Reverse gear end play
35.-1I 7
1
35 Manual Transmission-Case, Gears, Shafts
Selector linger
Rocker lever shaft
I its only in one
removing Fig. 2
position on selec tor
shaft
Rocker lever Stud M10 x 42 - - - - - - . .
r
for 3rd/ 4th gear projection: 21 mm (13/16 1n.)
selector shalt
Gear shift housing
\ _ _ ThN.........
Spring Clip
presses selector shall and
selec tor lever into 3rdl4th
shift gate
35-706 1
•
1 35-%5 J
[ , ·• I
Fig. 5 Selector shaft oU seal, removing
- pull out wi th screwdriver
Fig. 2 Rocker lever shaft, removing
- first remove plug, see Fig. 1
with
llalled
VW423
C·18 C·19
4-speed 091 Rocker lever shaft
Selector shaft
35.-tI 9
1
35 Manual Transmission-Case, Gears, Shafts
Clrcllp~-~
4th gear-----~:--.~
replace as matched -..;;.~-.....,-~
C"""'-'~'~-------- Spring
.
set only
•]-·.,·
Synchronizer ring 4th gNr __''-:::7""0::::::..._
chec king Fig. 5
identif ication/installation
instructions page 35.30
Tranamlaalon houalng
CAUTION
Circlip must be located inside relieved part
of installing tool while it is being pushed
on so that it expands uniformly over
complete circumference
Note
Synchronizer ring identification marks and
Fig. 3 Circllp 3rd/4th gear, installing installation instructions, page 35.30
- VW412
\;} 4- 3-14
C-22
.........._
Fig. 12 Pinion needle bearing in housing,
removi ng
II
lies
gear
CAUTION
row) When install ing, lettered side o f bearing
ix 60 (thicker materi al) mus t face installi ng tool
C·22 C·23
4-speed 091 Main shaft ball bearing
Pinion needle bearing In housing
35 23
•
35 Manual Transmission-Case, Gears, Shafts
Clrcllp/3rd gear
always replace,
must lit securely In groove,
adjusting 3rd gear end play,
Hub Fig. 14
pressed on long collar secures
1st gear needle bearing Inner race 3rd geet
replace as matched set only,
shoulder faces 2nd gear,
end play, adjusting Fig. 14
2nd o..r
If teeth are damaged, replace
together with main shaft
(matched set)
1 35- 717
0·2
0-3
4-speed 091 Pinion shaft assembly 35.25
35 Manual Transmission-Case, Gears, Shafts
•
v
CAUTION
Hold 4th gear down (spring under tension)
VW4S7
Clrcllp/41h gear
VW401
\ • used bearings • :
up to 70 Ncm (61 in. lb)
("after running at least 30 miles)
• if no turning torque can be
measured, see Fig. 8
D-4 0·5
4-speed 091 T1pered roller bearing
1st ge1r needle be1rlng
35.27
·
35 Manual Transmission-Case, Gears, Shafts
134- 581 1
New Part Wear limit
Fig. 11 Synchronizer 1st/2nd gear, assembling
mm (ln.) mm(ln.)
1.0 - 1.7 0.5 - slide sleeve over sychroniter hub.
Gap a Matched position is not necessary
(0.039-0.067) (0.02<>)
- insert keys and install springs with
ends offset 120". Angled ends of
Note springs must fit into keys
1st gear
needle bearing
I 34-51!0 I Inner race
134-9511
Fig. 10 Synchronizer 1st/2nd gear, assembling
• gear teeth on sleeve and long collar on Fig. 12 Synchronizer assembly 1st/2nd gear and
hub must face 1st gear when installing 1st gear needle bearing Inner race,
• sleeve and hub are not matched and installation position
can be replaced separately - position synchronizer ~ssembly on
needle bearing inner race so that old
marks on long collat of synchronizer
hub (from lugs on needle bearing
inner race) are now opposite gaps on
needle bearing inner race
• sleeve and hub are not matched and
can be replaced separately
- VW415o
...........
Fig. 15 Pinion needle bearing in gear carrier
housing, removing
- press out without damaging circlip
- VW409
Fig. 13 Synchronizer 1stl2nd gear, Installing
-turn synchronizer ring until grooves
are in line with keys (installation
position, see Fig. 10 and Fig. 11)
/
/ ....
,. '
Thickness Part
mm Color No.
1.60 black 113 311 382
1.75 blue 113 311 383
1.90 brown 113 311 384
2.05 gray 113 311 385
2.20 copper 113 311 386
2.30 brass 113 311 387
2.40 silver 113 311 388
0·7
4...speed 091 3rd gear
Pinion needle bearing
35 29
•
35 Manual Transmission-Case, Gears, Shafts
Note
When assembling transmission, install
synchronizer ring to same gear from which It
was removed
Synchronizer
ring 2nd gear 3rd gear 4th gear
markings
. .... J .. .
~
..
~
'It
' """ t
3 notches (arrow)
without notches
production brass ring coated brass ring coated special brass ring brass ring
with molybdenum, with molybdenum coated with
Part No. 091 311 247 B molybdenum, Part
No. 091 311 295 A,
shown below
Index
-Adjusting rings 35.32 -Main shaft 35.49
installing 35.35 assembly 35.48, 35.49
marking/removing 35.34 ball bearing 35.51
-Assembly 35.32, 35.33, 35.36, lock ring 35.52
35.37 needle bearing 35.51
mounting in repair stand 35.34 oil seal 35.43
-Clutch housing assembly 35.42 rear, removing/ installing 35.35a
-Differential 35.35 -Pinion shaft 35.55
-Drive flange 35.32 assembly 35.54, 35.55
circlip, installing 35.35 needle bearings 35.57, 35.59
installing 35.35 roller bearings 35.56, 35.57
oil seal 34.18 -Removing 34.16, 34.17
removing 35.34 -Retaining ring 35.37
-Gear carrier 35.44 installing 35.40
assembly 35.36, 35.37 removing 35.38
assembling 35.40, 35.41 -Selector shaft
cover 35.44 modifications 35.60a
installing 35.39 parts for 35.60d
removing 35.38 -Shift forks/synchronizers
-Gear ratios 35.60 modifications 35.60b-35.60c
-Gears parts for 35.60d
1st/2nd, removing 35.56 -Shift shaft oil seal 35.46
3rd, -Shift rod bushing 35.46
end play 35.59 -Starter bushing 35.43
installing 35.59 -Synchronizers
removing 35.56 1st/2nd gear 35.58
-Gearshift lever 34.6 3rd/4th gear 35,50, 35.51
-Gearshift linkage 34.6, 34.7 ring indentification 35.52
-Installing 34.17 -Transmission, housing 35.45
-Lever bearing plate 34.6 assembling 35.39
-Lubricant specifications 35.60 disassembling 35.38, 35.39
/ ~Speed 091
- See page 35.1
5· peed 094
See page 35.61
09~4WD Syncro
- See page 35.93
E·1
35.31
35 Manual Transmission-Case, Gears, Shafts
Transmission/Final drive lubricant:
Hypoid oil API/GL-4; MIL-L2105
SAE BOW, SAE BOW/90
Capacities:
Vehicles with gasoline engines 3.0 L (3.2 US qt)
Vehicles with Diesel engines 4.0 L (4.2 US qt)
Note
To reduce shifting effort, transmission oil capacity
has been reduced. For production reasons, the oil
filler hole remains at the same location
Oil should only be poured into a level approximately
15 mm (9/16 in) below filler hole.
Transmission housing~
Mounting in repair stand. Fig. 1
Transmission 091/1
Gear Retlos Trans. DU
1st gear . . . . . . . . . . . . . . . . . . . . . . . . .34:9=3.78
2nd gear . . . . . . . . . . . . . . . . . . . . . . .33:16=2.06
3rd gear. . . . . . . . . . . . . . . . . . . . . . . .63:50 = 1.26
4th gear . . . . . . . . . . . . . . . . . . . . . . . . 52:61 = 0.85
Reverse. . . . . . . . . . . . . . . . . . . . . . . . .33:9 = 3.67
Final drive . . . . . . . . . . . . . . . . . . . . . . .34:7=4.86
Gear Ratios Trans. ABO
1st gear. . . . . . . . . . . . . . . . . . . . . . . . .34:9=3.78
2nd gear . . . . . . . . . . . . . . . . . . . . . . .33:16 2.06
3rd gear . . . . . . . . . . . . . . . . . . . . . . .49:40= 1.225
4th gear . . . . . . . . . . . . . . . . . . . . . . . .41:48=0.85
R~verse . . . . . . . . . . . . . ~ . . . . . .33:9:3.67
F~nal drive . . . . . . . . . . . . . . . . .~
3 5 •3 2 Transmission, assembly
4-speed 091/1
Manual Transmission-Case, Gears, Shafts
Drive flange----....
removing Fig. 2
installing Fig. 7
Lock ring-----,
Clutch housing
mark position of adjusting ring
before removing, Fig. 3
Main shaft, rear . Before removing, loosen left
/ removing I installing page 35.35A differential adjusting ring to
/
/ reduce tension in transmission
/
/ housing
/
I
/
/
ace ' ...../ /
,.,....
--------------~ 6 bolts MS x 41
with washers
20 Nm (14 ft lb
:::!J
always replace
...
assembling
4-speed 091/1
Transmission, assembly 35.3
35 Manual Transmission-Case, Gears, Shafts
Note
Before starting repair work (which does
not require final drive to be adjusted)
mark position of adjusting rings on
transmission housing. Measure depth to
which they are installed with VW 382/7
and write down readings
-scribe left side (ring gear side) with
Fig. 1 Transmission assembly, mounting In one mark (arrow)
repair stand - scribe right side with two marks
-drain transmission oil
-mount transmission in repair stand
:o
4-speed 091/1
Differential
Adjusting rings
Drive flange
35 '
.- • ~
35 Manual Transmission-Case, Gears, Shafts
Work sequence
I
I
34-1309 A
Removing
Installing
Note
Differential must be removed
before gear carrier can be removed,
see page 35.35
(9) ~Q
2boltsM8x110~
with washers
20 Nm (14ft lb)
J
«t======:::::::::»
Gasket~
0
Pinion shalt
35.36
Manual Transmission-Case, Gears, Shafts 3!
~Cover
~ 'W ~Seal
1· 0 ~··"··
~
L15Nm(10fllb)
always replace
-~omm S,
determining thickness,
Repair Group 39
J
Transmission housing
ork
Shift shaft lever~
25 Nm (18ft lb)-
nbly
1135.48
j34-1312j
natt
Transmission
Disassembling
Work sequence
-remove coverplate
-remove shift shaft
35 •3 8 Transmission, disassembling
4-speed 091/1
Manual Transmission-Case, Gears, Shafts 35
Assembling
Work sequence
VW412
30-100
Note
lf bearing and/or transmission housing are
replaced, and dimension r is not marked on ring
gear, pinion depth must be measured and noted
before gear carrier is removed. This is dimension
r. See Repair Group 39. When assembling, parts
must be installed In same position. See Ring
gear/pinion, adjusting, Repair Group 39
-press main shaft with shift rod into gear
carrier
~ VW409
]34-13 181
Gear carrier
Assembling
Work sequence
-install shim 5 3
-install new gasket
-align shift rod
-align flat on piston with recess in housing
-tap on pinion with plastic hammer to install
• make sure teeth of gears match properly
-install circlip
• make sure lugs of circlip are below teeth of
pinion head (arrow)
-install synchronizer
-install. circlip
-install reverse gear
• groove in gear must face cover
-install needle bearing and washers
-instal.! shift rod/fork bolt and tighten to
20 Nm (14ft lb)
• before installing coat thread of bolt with
D6-locking compound
134-1339!
-install new gasket
-install circlip -install cover
-measure distance C • align shaft and bore in cover
-tighten bolts to 20 Nm (14ft lb)
Example -install shift shaft
• slotted side toward differential housing
measurement c 29.1 mm -install new gasket
measurement d -.24.7 mm -install spring
n thickness of spacer 4.4mm -install cover and tighten bolts to
15 Nm (10ft lb)
thickness of spacers available -install back-up light switch
-install shift shaft lever
A gaptobeadjuste~ ·
I
(mm) Spare Jrt n~olor
..,..-
3.97-4.19 091 311 379 white
- 4.20-4.39
4.40-4.59
4.60-4.90
091
091
091
311
311
311
379 A
379 B
379 C
black
green
red
..... ___
Starter bushing -......,,
Pivot bolt removing Fig. 3
15 Nm (11 It lb) installing Fig. 4
can be rep laced wi th
transmission Install ed
Release shalt
lubricat e with mulli-
purpose grease
Circlip __/
always replace
Release bearing
do not clean in
solvent , wipe Willi
lubri cate ball lightl y dry c lot h
removing Fi g. 1
inst alli ng Fig. 2
fi ll space between lips
with multi-purpose grease
bushing
Jailing
tp 30
Bearings
detach before removing
shift rod
Gear carrier_/
Reverse gear shift rod
Circlip
r
for needle beanng
Bushing
Pin_/
gu1des shift shaft ,
drive In until seated
Relay lever
t or 1st and 2nd gear
Transmission housing
'---Shift rod bushing
rem./ install. Fig. 3
4-speed 091/1
Transmission housing 35.45
35 Manual Transmission-Case, G , Shafts
Fig. 1 Shift shaft oil seal, removing Fig. 3 Shift rod bushing
-removing
• turn bushing so that lug (arrow) is in
recess of housing and press out
-installing
• align bushing and rod
35A7
35 Manual Transmission-Case, Gears, Shafts
Synchronizer hub
/Sleeve
,...........--Sprlng
1
(1 .6 mm dial
'"'''"•~
ins tall ing Fi g. 10
'"9
mmdia)
Transmission housing
4th gear
:hed
nd Fig. 5
on Fig. 3
Needle bearing
removing F1g. 8
installing Fig. 9
/
/
4-speed 091/1
Main shaft 35.49
35 Manual Transmission-Case, Gears, Shafts
~VW408a
!35-877)
Fig. 1 Synchronizer 3rd/4th gears, removing
-press off together with 3rd gear
Gap a
35 •50 Synchronizer
4-speed 09111
Manual Transmission-Case, Gears, Shafts 35
lng
b.
ry
th
4-speed 091/1
Main shaft bearings 35.51
35 Manual Transmission-Case, Gears, Shafts
135-10801
A = previous circlip
Part No. 091 311 381
B = new circlip
Part No. 091 311 381 A
Note
Use either type of circlip during repairs. The
previous circlip will be discontinued when stock
is used up.
CAUTION
Always replace the eire lip during repairs.
Identifying marks on a new circlip (arrow)
Fig. 10 Circlip , installing
must face reverse gear splines.
• make sure ring is seated correctly
(arrow)
35.52 Circlip
Needle bearing
4-speed 091/1
Manual fransmission-Case, Gears, Shafts 35
Synchronizer rings, identification
Note
When assembling transmission, Install syn-
chronizer ring to same gear from which it was
removed
production
3rd gear: special brass ring,
molybdenum coated,
teeth all around circumference
spare part
For all gears install ring off 3rd gear which is
supplied under Spare Part No.: 091 311 295 A
4-speed 091/1
Synchronizer rings 35.53
35 Manual Transmission-Case, Gears, Shafts
~~
Needle bearing
lub ricale w ith t ransmission Gear carrier
oil before inst allin g housing
Ft
-
------
I \:;:;~~oh,ooi'" ""'·
! \- m"" fit '"'"'"'' io 9 '00"
L __ -0
Synchronizer 1st / 2nd gear
removing Fi g. 2
assembling Fig. 10 and Fig. 11
in stallation position Fig. 12 1st gear needle bearing Inner race
loosening /tightening Fig. 6
"'-spring
(1.6 mm dia)
3rd gear
removing Fig. 1
Installi ng Fig. 13
shoulder fac es
2nd gear
r2ndgear
1 gear
' ----c.!)~
Needle bearing/2nd gear
lubric ate with transmission
Circlip /3rd gear .
always rep lace, oil before ins talli ng I
musl fit securely in groove,
a<IJUSti ng 3rd gear end play, __j
Fig. 14
----- --------
ShimS, - - - - - - - - - - . . .
earing note thickness
1smi ssion adJu" ;ng, , .. Aopa;, G<oup 3~
,g
Pinion ohall _ /
match ed with ring gear,
when replac ing adjust
ri ng gearfpinlon,
see Repair Group 39
Retaining ring
removing/installi ng p age 35.40
~king Fig. 7
VW401
2052 2 -
VW401 --
us 1064
4-speed 091/1
Pinion shaft 35.57
35 Manual Transmission-Case, Gears, Shafts
Fig. 10 Synchronizer 1st/2nd gear, assembling -turn synchronizer ring unt il grooves are
in line with keys (Installation position,
-groove (arrow A) must face 2nd gear see Fig. 10)
-collar on hub must face 1st gear
-grooves (arrow B) are for identification:
• 1st gear & 2nd gear= 1 groove
• 3rd gear & 4th gear = 2 grooves
!Js-s9• I
Fig. 13 3rd gear, Installing Fig. 15 Pinion needle bearing In gear carrier
housing, removing
-collar must face 2nd gear
Fig. 14 3rd gear end play, adjusting Fig. 16 Pinion needle bearing In gear carrier
-measure end play with feeler gauge housing, Installing
-adjust by selecting suitable circlip
• play should be 0.05 mm-0.20 mm (try
to keep lower limit)
Clrclips available:
Thickness Part
~are
mm Color No.
on, 1.60 black 113 311 382
1.75 blue 113 311 383
1.90 brown 113 311 384
2.05 gray 113311385
2.20 copper 113 311 386
2.30 brass 113311387
2.40 silver 113311388
~Retainer
Q'
Spring----'
• pushes gearshift lever into
3rd14th shift gate
Selector shaft
l35-969l
4-speed 091/1
Selector shaft modifications 35.60a
·"·:i£1;.]·. uu.·rP
35 Manual Transmission-Case, Gears, Shafts
Gear carrier----""""~
r "'""" . . ohift ""' ••..,..,
I
Main shaft assembly
C -Shift forks/rails
• 1st/2nd and 3rd/4th gear shift forks/rails are
rivited and welded to maintain proper align-
ment to each other
- replace with new shift forks/rails
D- Synchronizers
• 1st/2nd and 3rd/4th gear synchronizers have
been changed to prevent jumping out of
gear
• changes cannot be detected visually
- replace with new version synchronizers
/rail
trod
!35-967)
E- Reverse shift fork/rail and has two bearing shells which ride in 3rd
• mating surfaces of fork/rail have splines to bearing which is housed in boss provided in
properly align to each other gear carrier cover
• reverse shift rail is lengthened - replace with all new version parts
R Thrust washer
averse gear deleted
with shoulder
• shoulder faces reverse shaft
support plate
!35-9661
4-Speed 091
- See page 35.1
4-Speed 091/1
- See page 35.31
094-4WD Syncro
- See page 35.93
G·1
35.61
Transmlss~n/F ;~~------------------------------------------------
Hypold oil API/:•' drive lubrlc .
SAE BOW, SAE BOL-4; MIL·l2105ani.
Capacity: 4.0 Itr (4.2
W/90US qt)
I
,
...
',
I '
I '
II ' ',
on tiller plug
I~ I '
20 Nm (14 tt
8 I
I
I '
'
I
I
I
/
Transmission
Mount'ing . housing
m repair stand . F IQ.
' T
Drive rt81AG4t-----~
removing Fig. 2
installing fig. 7
Lock rtna - - - - - , .
Clutch hou11tna
mark positiOil of adjusting ring
before removing, Fig. 4
Main shaft, rear Bef'o re removing, loosen left
removing/installing page 35.65A differential adjusting ring to
reduce tension In t.ransmission
housing
ace
~Steeve
c~::::_;
always replace
Note
Before starting repair work (which does
not require final drive to be adjusted)
mark position of adjusting rings on
transmission housing. Measure depth to
which they are installed with VW 382/7
and write down readings
- scribe left side (ring gear side) with
Fig. 1 Transmission assembly, mounting In one mark (arrow)
repair stand
-scribe right side with two marks
- drain transmission oil
-mount transmission in repair stand
:h to
1)7
5~speed 094
Differential
Adjusting rings
Drive flange
35.65
35 Manual Transmission-Case, Gears, Shafts
Work sequence
34-1309 A
Removing
Installing
\
\
~
I • pressed gearshift lever
into 2nd/3rd shift gate
Up to 1110 2
date of manufacture
Gear carrier---~
CAUTION
Part numbers are for reference only. Always
check with your Parts Department for latest
parts information.
:ers have
Jt of gear
'
mizers
Note
Differential must be removed
before gear carrier can be removed,
Needle bearing
see page 35.65
Reverse idler gear
Needle bearing
-1st gear
Shim for 1st gear-
determining thickness, page 35.73
35.66
Manual Transmission-Case, Gears, Shafts 35
Boot~~·{i
ShimS,
determining thickness,
Repair Group 39
@
Shift shaft lever 9
\lo<lulog
25 Nm (18 ftlb)~
4th/5th gear shift rod fork
o~
Main shaft assembly
disass.fass. page 35.80
Transmission
Disassembling
Work sequence
-remove coverplate
-remove shift shaft
L--~~~~=z~==~
-pull off synchronizer hub and reverse gear
• A-puller US 1078
-loosen bolt until relay lever (arrow) can be
pulled against housing -remove inner circlip, washer and needle
-tighten bolt to lock lever in that position bearing
-remove reverse gear together with needle bear-
~-----
ing and washer
-remove gear carrier housing bolts
I
I
I
3 5 •6 8 Transmission, disassembling
5-speed 094
Manual Transmission-Case, Gears, Shafts 35
Assembling
I
Work sequence
I --------!F==~------~:
l VW412
I:
30-100
13.4-13181
Gear carrier d
Assembling
Work sequence
-install shim 8 3
-install new gasket
-align shift rod
-align flat on piston withrecess In housing
-tap on pinion with plastic hammer to install
• make sure teeth of gears match properly
-install circlip
• make sure lugs of circlip are below teeth of
pinion head (arrow)
l3s-108ol
I
1.
134-13051
-install synchronizer
-install circlip
-install reverse gear
-install circlip
• groove in gear must face cover
-measure distance C
-Install needle bearing and washers
-install synchronizer for 1st/reverse gear and
Example
shift fork
measurement c 29.1 mm • molybdenum coated side of synchronizer
measurement d -24.7 mm ,ring faces 1st gear
thickness of spacer 4.4 mm -install shift rod/fork bolt and tighten to
20 Nm (14ft lb)
thickness of spacers available • before Installing coat thread of bolt with
A D6-locking compound
' gap to be adjusted -install 1st gear
(mm) Spare part no. color -install needle bearing
I I
+--i 3.97-4.19 091 311 379 white
4.20-4.39 091 311 379 A black
4.40-4.59 091 311 379 8 green
4.60-4.90 091 311 379 c red
lA
~L--a--
gear carrier housing cover
Measurement= a- b
=77.8 mm
-76.6 mm
1.2mm
Following shims are available:
Shim Spare
Measurement thickness Part
(mm) (mm) No.
0.95 ... 1.14 0.6 094 311 379
1.15... 1.34 nn 094 311 379 A
1.35... 1.54 1.0 094 311 379 B
-measure depth a
1.55... 1.74 1.2 094 311 379 c
Example: a= 77.8 mm 1.75... 1.94 1.4 094 311 379 D
1.95... 2.14 1.6 094 311 379 E
2.15 ... 2.47 1.8 094 311 379 F
-measure distance y
Example y = 1.0 mm
.---·Pivot bolt
15 Nm (11ft lb) ..-----Starter bushing
removing Fig. 3
installing Fig. 4
can be replaced with
transmission Installed
•
~.
,4/1
.-.
Circlip_/
always repl ace
Yilh
ailed
ahing
ng
10
ng
with
___ !
\....
Pinion bearing
Bearings
d etach before removing
sh ift rod
Pin
g u i de~
d rive i
- 011 IIIIer pl ug
20 N m (1 4ft lb)
1
,
~'
Circlip
for needle bear ing
Pivot bolt for relay lever
20 Nm ( 14 I t lb)
Bushing
'--
rler
Rel ay lever
for 2nd and 3rd gear
35 ·7 8
•
Shift shaft oil seal
Shift rod bushing
5-speed 094
Manual Transmission-Case, Gears, Shafts 35
35.79
35 Manual Transmission-Case, Gears, Shafts
Synchronizer hub
Needle bearing
removing Fig. 8
t bearing
,installing Fig. 9
1g lubricate
ion oil Synchronizer 4th 15th gear
parts are not matched
removing Fig. 1
installing Fig. 4 and Fig. 5
Installation position Fig. 3 \
\
o·e~E
I
c....... \ l!'
\_4th gear needle bearing
Before installing, lubricate )~dj;
with transmission oil
I /Jr
Synchronizer ring 4th gear
checking Fig. 2
identification I installation
instructions page 35.92
\
~ear carrier
Lvw4n
I Js-a7al
Fig. 1 Synchronizer, removing
-press off together with gear
Gap a
New Part Wear limit
Gear mm (in.) mm (ln.)
4th/5th 1_0-1.7 0.5
(0.039-0.067) (0.020)
35.82 Synchronizer
Synchronizer rings
5-speed 094
Manual Transmission-Case, Gears, Shafts 35
30-100
~ Fig. 7 Main shaft ball bearing, Installing
VW401 -press in so that recess in bearing is
k------~
aligned with recess (arrow) in housing
lng
Fig. 5 Synchronizer 4th/5th gear, Installing
l B) of
ides. -turn synchronizer ring until grooves are
in line with keys
• identification groove on sleeve
at ion: (Fig. 3, arrow B) faces 4th gear
ing
b.
y
Fig. 9 Needle bearing in housing, installing
th
• lettered side of bearing (thicker
material) must face installing tool
CAUTION
Always replace the circlip during repairs.
Identifying marks on a new circlip (arrow)
must face reverse gear splines.
It
,_.135--10.,...,8..,.,01
circlip
No. 091 311
35.85
35 Manual Transmission-Case, Gears, Shafts
always reptace
Pinion bearing
removing Fig. 17 Needle bearing
installing Fig. 18 lubricate with transmission
7
oil before installing
-------- -- -- -
,---- -
1
-- ----
Synchronizer ring 2nd gear~
checking Fig. 9
_____.
2nd gear needle bearing
lubricate with transmission
oil before installing
identification marks page 35.92
I -~
~~~~~
must fit securely in groove
0~.:;) i) (1 .#
2nd gear_)
Spring
(1.6 mm dia)
4th gear
removing Fig. 1
installing Fig. 13
Spacer collar faces 3rd gear
determine thickness
page 35.73
se gear
\3rd gear
0
5th gear
----- ----
groove faces gear oil before installing
Needle bearing
removing Fig. 15 carrier housing cover
-- ----
installing Fig. 16
_))),f~'m
fi
~
I '
Pinion shaft
o~n
matched with ring gear,
when replacing adjust
ring gear/pinion,.
1inner race
ig.6
see Repair Group 39 . -,. :__<_ Retaining ring
Tapered roller bearing Transmission housing
removing 35.68
when replacing measure pinion installing 35.70
depth before removing,
see Repair Group 39
removing Fig. 3 and Fig. 4
installing Fig. 5
torque, checking Fig. 7
and Fig. a
,- ~VW411
r-------------------~,3=5-=88~8,1
Fig. 4 Tapered roller bearing inner race,
removing
3 5 •8 8 Pinion shaft
5-speed 094
Manual Transmission-Case, Gears, Shafts 35
VW401 ~
'\
~---
J
..
Fig. 7 Tapered roller bearing, checking turning
torque
-lubricate bearings with transmission
oil and tighten retaining ring,
-turn pinion shaft in both directions
. ry;:;m about 15-20 times
'l - turn further and read turning torque
• new bearings:
J Fig. 5 Tapered roller bearing, Installing up to 210 Ncm (180 ln. lb)
-heat Inner race to about 100°C (212°F) • used bearings•:
and press on up to 70 Ncm (61 in. lb)
-before tightening needle bearing Inner (• after running at least 30 miles)
race, let tapered roller bearing cool to • If no turning torque can be
~
room temperature meaStJred , see Fig. 8
VW4l1
Fig. 13 4th gear, Installing Fig. 15 Pinion needle. bearing in gear carrier
housing, removing
-collar must face 3rd gear
Clrclips available:
Thickness Part
mm Color No.
1.60 black 113 311 382
1.75 blue 113 311 383
1 are 1.90 brown 113 311 384
on, 2.05 gray 113 311 385
2.20 copper 113311386
Fig. 17 Pinion bearing outer race in gear carrier
2.30 brass 113 311 387 housing cover, removing
2.40 silver 113 311 388
A-extractor US 1088
B-puller US 1039
r-------------~--~-------------
Synchronizer rings, Identification
Note
When assembling transmission, install synchron-
izer ring to same gear from Which l,t was removed
production
5th gear:
brass ring
3 x 8 teeth
with 3 notches (arrow)
spare part
For all gears install ring (3rd and 4th gear) which
is supplied under Spare Part No: 091 311 295 A
5-Speed094
- See page 35.61
ch
G·1
35.93
35 Manual Transmission-Case, Gears, Shafts
Note
CAUTION
Before disassembling, mount transmission In
assembly stand (Fig. 1) and drain transmission fluid. Protect driveshaft oil seal from damage by the
driveshaft splines before removing and
installing the clutch housing. Pull a wiring
harness conduit or similar covering over the
driveshaft.
Axle flange
removing Fig. 2
installing Fig. 7
Lock pin
always replace
removing Fig. 5
Shift fork
always replace
Differential
Before assembling;
remove adjusting rings, rear driveshaft
and shift fork for differential lock
disassembling/assembling, see Repair
Group 39
Rear main sheft - - - - - - - - - - - - '
removing: remove circlip, push back
splined sleeve and remove main shaft
installing: connect rear main shaft and
front main shaft, back off one spline,
push on splined sleeve and install
new circlip
M 8 x 28 20 Nm (15 ft lb)
Clutch housing-------' four bolts with washers
repairing, page 35.19
Left adjusting ring before removing:
mark before removing Fig. 3 loosen left adjusting ring to reduce M 8 x 46 20 Nm (15 ft lb)
removing Fig. 4 tension in transmission housing. six bolts with washers
installing Fig. 6 Mark position of adjusting ring before
coat threads with MoS 2 grease removing Fig. 3 134-18771
35 •9 4 Transmission assembly
094-4WD
Manual Transmission - Case, Gears, Shafts 35
le
edin
t lb)
134-18771
...._094
• WD I Axle flange, removing
_ _4_ __, Adjusting rings, removing
35 •95
35 Manual Transmission- Case, Gears, Shafts
seated
094-4WD
Rear drlveshaft, measuring 35 •97
35 Manual Transmission- Case, Gears, Shafts
Note
If the bearings and/or transmission housing are being Low gear housing
disassembling/assembling, page 35.105
replaced and the r dimension is not specified on the
ring gear, the position of the drive pinion to the
housing must be determined before disassembling. always replace
When installing, this position must be the same. See
Repair Group 39. Low gear shim
determining thickness, page 35.102
Output housing----'
disassembling/assembling, page 35. 103
~-·-·-·-·-·~
20 Nm (15 ft lb) ~0 Nm (15 ft lb)
with washer . , - - - Bearing retainer
~ /--t'.V~A
1
install with grease
I
15 Nm (11 ft lb)
0 ring I
~Spring
I
Shift shaft cover ~~ Transmission
disassembling/assembling, page 35.105 .
I
·-·-·-·--·--·--·J
I ~--- Shift shaft
I ~~lm
L._
~ ............
(1._
Gasket
Shim 53
note thickness (j)
Transmission housing
t,. Nm ~Bft lb)
094-4WD Transmission,
dlsassembllng/asaembllng
3 5 99 •
35 Manual Transmission- Case, Gears, Shafts
-remove retaining ring -tighten retaining ring to 225 Nm (162ft lb), loosen
- remove end shield from housing and tighten again to 225 Nm (162ft lb)
- attach VW 457 with two M 8 x 20 bolts - secure retaining ring at two places by staking
-push out gear carrier ~ bolt end shield to transmission housing
- remove shim S3 and note thickness Ex
- loosen relay lever bolt
-position lever and tighten bolt to 20 Nm (15ft lb)
Assembling
- install shift shaft with slotted side facing
Before Installing gear carrier:
differential gear
- position shim S3 and new gasket
- install new seal in cover
- position shift rail
- position cover with spring and tighten bolts to
- position bearing to opening in housing
15 Nm (11 ft lb)
- heat bearing seat in transmission housing to
40-60" C (130·166° F)
- seat bearing using a plastic hammer on drive
pinion
- check for binding
- install retaining ring and shim (75 mm wide)
35.100 Transmission,
disassembling/assembling
094-4WD
Manual Transmission - Case, Gears, Shafts 35
4
Adjustment range = a b
Dimension b = x- y
I x = 77.6 mm
- measure dimension y
- measure dimension a
ng
Example Example
'ft lb)
I a= 77.8 mm y = 1.0 mm
- measure dimension x Dimension b =x- y
to Example
x = 77.6 mm
-y = 1.0 mm
76.6 mm
Adjustment range =a - b
Example
a= 77.8 mm
-b = 76.6 mm
1.2 mm
Available shims:
l
I
I
I
Output shaft
~~. I
'"--J
Spllned sleeve
Drive pinion
134-1880 I
094-4WD
Output housing 3 5 •1 03
35 Manual Transmission- Case, Gears, Shafts
134-17eo I
Fig. 1 Flange nut, loosening/tightening Fig. 3 Flange seal, Installing
VW434
nut, loosening/tightening
Orfng
Banjo bolt
Orlng\
,.. . _l//
/@
Supporting ring
Cover
Needle bearing
install with transmission oil
Reverse gear Idler
removing Fig. 2
installing Fig. 3
094-4WD
Transmission assembly 35.105
35 Manual Transmission- Case, Gears, Shafts
134·17961
Flg.1 Low gear Idler, removing Fig. 3 Reverse. gear Idler, Installing
Gear carrier
repairing, page 35.108
Low/reverse synchronizer
install molybdenum coated
synchronizer ring facing low gear 3rd/4th gear shift rail
Synchronizer hub
Main shaft
Needle bearing
install with transmission oil
I
I
Second clrcllp '--
First clrcllp
Ball valve
Thrust washer
094-4WD
Gear carrier 35.107
35 Manual Transmission-Case, Gears, Shafts
Assembly
134-1771 I
- press in main shaft with shift rail
134-13181
134-13391
Example
d = 24.7 mm
Example
Dimension c = 29.1 mm
- Dimension d = 24.7 mm
- Adjustment range - 4.4 mm
Shims available:
Adjustment
range (mm) Part N Color
3.97-4.19 091 311 379 white
4.2()-4.39 091 311 379 A black
4.40-4.59 091 311 379 B green
4.60-4.90 091311379C red
134·17721
- Install synchronizer hub
- position first circlip
- position low/reverse synchronizer with shift fork
- place molybdenum coated clrclip on low gear
- fasten shift fork to shift rail
• coat bolt with D 6 and tighten to 20 Nm
(15ft lb}
Clutch housing
Starter bushing
removing Fig. 3
installing Fig 4
Release shaft
install with
multi-purpose grease
Clutch lever
lightly grease ball end
removing Fig. 1
Ring
installing Fig. 2
only with plastic sleeve
fill space between lips with Clrcllp
multi-purpose grease always replace
Release bearing
wipe dry only, do not use solvent
Guide sleeve
metal sleeve greased with MoS2
plastic sleeve not greased Retaining clip
135-10131
094-4WD
Clutch housing 3 5 •111
35 Manual Transmission- Case, Gears, Shafts
(installed transmission)
Note
For disassembled transmission, remove with
VW 222a.
- drive in flush
S.~ngs----------~ -----
clip off before removing
shift rod
-----·
Main shaft bearing
Gear carrier
---- .
Bushing
install with lug
facing end shield
lhlnsmlsslon housing
Main shaft needle bearing when replacing, adjust drive pinion to
removing/isntalling, page 35. 119
previously determined installation
position, see Repair Group 39 134-18821
094-4WD
Transmission housing 35.113
35 Manual Transmission- Case, Gears, Shafts
VW412
t---VW295
3074
134·1341 I 134-18831
134-18841
Shift rod
094-4WD Drive flange seal, Installing
Needle bearing, removing/Installing 35.115
35 Manual Transmission - Case, Gears, Shafts
Input s h a f t - - - - - - - - - ,
Drive flange
Output housing
Drive pinion
disassembling/assembling, page 35.121
134-18851
~--Needle bearing ,
before removing bearing, remove low gear
idler gear, page 35.1 06
removing Fig. 10
installing Fig. 11
l
7 I
Bearing __ j
'--'
removing Fig. 6
l installing Fig. 7
--·
Clrcllp
--·
' 4th gear synchronizer ring
I
I
L. always replace
Spring
diameter 1.6 mm
Spring------'
diameter 1.6 mm
094-4WD
....__ I
_ _ ___, Malnshaft 35.117
35 Manual Transmission- Case, Gears, Shafts
135-10151
30-100
Fig. 7 Main shaft bearing, Installing
VW401
- press bearing into carrier to stop
• recess on bearing aligns with recess in
carrier (arrow)
ng
Fig. 5 Synchronizer 3rd/4th gear, Installing
wes
sides - rotate synchronizing ring until grooves are
aces in line with keys
- clutch sleeve identification groove (Fig. 3,
arrow B) faces 4th gear
134-13291
Fig. 6 Main shaft bearing, removing
to
094-4WD
35 Manual Transmission- Case, Gears, Shafts
Fig. 9 Needle bearing, Installing Fig. 11 Low gear needle bearing, Installing
CAUTION
The lettered side of bearing (thicker material)
must face installing tool.
Shim
determining thickness,
page 35.102
Reverse gear
Needle bearing----
install with transmission oil
Low/reverse hub
2nd gear
3rd gear
removing Fig. 1
installing Fig. 13
Clrcllp - - - - - - - - . . . . . _ l&l.. conlar faces 2nd gear
always replace
must fit securely in groove
~1st gear neadle
Synchronizer hub
l
,
bearing Inner race
loosening/tightening Fig. 6
collar on the synchronizer
Bearing - - - - . . !
removing Fig. 3
installing Fig. 5
Transmission housing
if replacing, measure position of pinion and ring gear are
drive pinion before removing, replaced as a matched set
see Repair Group 39 when replacing drive set, adjust note thickness
turning torque, checking Figs. 7 and 8 pinion and ring gear adjusting see Repair Group 39 l3s,1oso 1
VW411
Fig. 13 3rd gear, Installing Fig. 15 Needle bearing outer race, removing
nbllng
- collar faces 2nd gear
position is
ds 120°
t into keys
3rd gear:
special brass ring
molybdenum coated teeth around entire
outer surface
Note
For all gears, install synchronizer ring which is
1st gear: supplied under Spare Part No. 091 311 295 A
brass ring (standard production on 3rd gear).
molybdenum coated 3 x 6 teeth
without identification
2nd gear:
brass ring
molybdenum coated 3 x 8 teeth
identification 3 notches
4th gear:
brass ring
3 x 8 teeth
identification 3 notches
• Automatic Transmission
Controls, Assembly
Index
- Accelerator cable/linkage
090-except code letters NH
37.12, 37.13
code letters NH only 37.14, 37.15
-ATF
checking/filling 37.9
dipstick changes 37.9
troubleshooting 37.9a
- Rnal drive oil seal 37.10
-Installing
090-except code letters NH
37.5, 37.6
code letters NH only 37.8
-Modifications 37.19
-Operation 37.17, 37.19
- Pressure test procedure 37.18
-Removing
090-except code letters NH
37.4
code letters NH only 37.6, 37.7
-Selector lever assembly 37.2
-Selector lever cable 37.3
-Shift points 37.19
-Technical data
code letters NG, NH 37.1a
code letters NK 37.1b
37.1
37 Automatic Transmission-Controls, Assembly
Technical Data
• code letters •
• application
• number of splined plates and springs
• gear ratios
Transmission
code letters NG NH
date of manufacture
from 06/79 10/82
to 10/82
Type No. 090
Torque converter
code letter Z1 z
Valve body
code letters AH BH FF FFA
date of manufacture
from 06/79 07/80 10/82 01/85
to 07/80 10/82 01/85
Forward clutch inner outer inner outer
number of splined plates 4 3 4 3
Direct/Reverse clutch
number of springs 24 24
inner outer inner outer
number of splined plates 4 4 4 4
1st/reverse gear clutch inner 2 outer 2 inner outer
number of splined plates 4 4 4 4
2nd gear brake band
first tighten, then loosen: 2112 turns 2112 turns
Application to engine 2.0 ltr. 1.9 ltr.
air-cooled water-cooled
67 bhp SAE net 82 bhp SAE net
Final drive ratio 45:11 = 4:09
Gear ratios
1st gear 2.55 2.71
2nd gear 1.45 1.50
3rd gear 1.00 1.00
Reverse 2.46 2.43
ATF cooler forward
flow
3-row
1 up to build date 03/27/81 = code letter D
2 up to build date 10/1/81 = 5 inner and 5 outer plates
Transmission
Code letters NK
Manufacture date 07/85 to
Automatic transmission 090
Torque converter
Code letter H
Valve body
Code letters FFA
Manufacture date 07/85 to
Number of splined plates Inner outer
forward clutch 4 3
Number of springs 24
Number of splined plates Inner outer
direct/reverse clutch 4 4
Number of splined plates .Inner outer
1st gear clutch 4 4
Brake band
first tighten, then loosen 2·1/2 turns
Engine application
Type Vanagon
Engine 2.1 Liter
90 bhp
lhlnsmlsalon ratios
Final drive 45:11 = 4.09
1st gear 2.71
2nd gear 1.50
3rd gear 1.00
Reverse gear 2.43
ATF cooler supply flow
3row
Note
Lubricate all moving parts with G-6 grease.
Accelerator/Pedal cable adjustment see pages
37.13, 37.15.
Fig
Lock lever
Spring----
Neutral/Park/------------=
Back-up light
'
Rollpln--1 contact plate
after installing, starter must
operate in selector lever Selector aupport
positions N and P only
Pivot pin _ /
Neutral/Park/
Back-up light
contact bridge
38-392 I
A·6
37.2 Selector lever assembly
A
Automatic Transmission-Controls, Assembly 37
- press roll pin out of shift rod
- separate selector lever cable from
shift rod
37- 437
'1 I
cable/shift rod
A·6
A-9
Selector lever cable 37.3
37 Automatic Transmission-Controls, Assembly
CAUTION
When lowering transmission out of vehicle,
converter must be secured so it does not
slide off transmission
Note
When attaching transmission to engine, torque
converter must be fully seated on one-way clutch
support (arrow) and can be turned by hand.
When converter is properly seated,
a= 10mm (3/8 in.)
- go to next page
A-8
Transmission, removing/installing
(except trans. 090-code letters NH) 37.5
37 Automatic Transmission-Controls, Assembly
CAUTION
If torque converter (left arrow) should slip
off of one-way clutch support, It could pull
oil pump shaft out of oil pump (right arrow).
This could cause serious damage when
bolting transmission to engine
Note
While tightening engine/transmission bolts, turn
torque converter to check for proper seating on
one-way clutch support
Its
Transmission, removing
(trans. 090-code letters NH only) 37.7
37 Automatic Transmission-Controls, Assembly
Note
When attaching transmission to engine, torque con-
verter must be fully seated on one-way clutch sup-
port (arrow) and able to be turned by hand. When
torque converter is properly seated, a = 10 mm
(3/8 in)
CAUTION
Torque converter must be secured from sliding
off transmission when lowering transmission out
of vehicle.
CAUTION
-separate transmission from engine If torque converter (left arrow) should slip off of
- lower transmission carefully out of vehicle one-way clutch support, it could pull oil pump
shaft out of pump (right arrow). This could cause
serious damage when bolting transmission to
Automatic transmission, installing engine.
(transmission 090-code letters NH only)
Engine installed
-tighten lower engine/transmission bolts to
Work sequence 55 Nm (41 ft lb)
2 ft lb)
Current A TF dipstick
• difference between Min./Max. marks:
0.35 qts. (0.33 L)
• when cold, fill to below the Min. mark, warm up
to operating temperature and fill to
between marks
ATF dipstick
ATF, checking/filling 37.9
Automatic Transmission-Controls, Assembly 37
ATF level, checking/troubleshooting
Too much ATF added; drain Oil seals between the final
off drive and transmission
leaking; seal transmission
I End
I I End
I
•
No leak visible externally
l
Leaks visible externally 1
Check oil level in final drive Seal transmission
I
I End
t
Oil level in final drive too high Oil level in final drive OK I
Governor shaft oil seal or
drive shaft seals leaking;
Top off ATF in transmission I
repair transmission
I End
I I End
Work sequence
- detach drive shaft from flange
Note
When installing oil seals, fill space between seal
lips with multi-purpose grease
-drive seal in until fully seated
- place drip pan underneath
- remove drive shaft flange
8
37.11
37 Automatic Transmission-Controls, Assembly
Accelerator linkage
(except transmission 090-code letters NH)
Accelerator pedal
Pin
if
Accelerator cable
~ Guide tube
Hose
~:...,.:
-~
c----- ---
/""Push rod
~
------ -------
Bracket }(.
---- '") ~ k~
-----------
------ ----
/Adjusting rod
I
--
- - - - - ._
I
J
Sprtng ------ ._
Work seq\Jence
-depress accelerator pedal to full throttle
position
• throttle valve lever must contact stop, but
ki ckdown lever on transmission must not be
in kickdown position
-press accelerator pedal beyond full throttle to
floor
• override spring must be tensioned and
kickdown lever on transmission must be in
kickdown position
if NO, adjust as follows : - press accelerator pedal to floor
• lever 6 must be in kickdown position (arrow),
Accelerator linkage/cable, adjusting with approx. 1-2mm (1/32-3/32 in.) free
play between lever and stop
- release accelerator pedal
- lever must be in idle position (out of kickdown)
Accelerator cable/linkage
(except trans. 090-code letters NH) 37. 3
37 Automatic Transmission-Controls, Assembly
·-
Accelerator linkage
(transmission 090-code letters NH only)
Push r o d - - - ,
Pin-----"'
Clrcllp----...
~-----Transm~~n
shift lever
r---Sprlng
AdJusting rod
-loosen nut 1
- remove override spring 2
-start engine and run at idle
- check and adjust idle if necessary
(see Repair Group 24)
-shut engine OFF
-pull accelerator rod in direction of arrow to stop -if necessary, adjust accelerator cable at
(closed throttle position) clamping bolt (arrow)
37-585
Accelerator linkage/cable
(trans. 090-code letters NH only) 37.15
37 Automatic Transmission-Controls, Assembly
37.16
B-2
Transmission operation
Automatic Transmission-Controls, Assembly 37
- if stall speed is not as specified, refer to
Transmission 090- from transmission
troubleshooting table as follows:
No. 17 07 0 ( ex~ept code letters NH)
Effect Cause -see page 37.19
ion
n Stall speed too high forward clutch or one-
way clutch for 1St When checking shift points, speedometer readings
,g ear slipping may vary within permissible manufacturing
H stall speed•rpm in tolerances.
range 0 is too high
repeat test in range 1 - note shift points and compare to chart
All
above. Shifts should be smooth and should
be • if stall speed rpm is
take place quickly and without lag in
within specifications
power transmission
one-way clutch for
- listen for any sign of engine speedup
1st gear Is defective
between shifts which indicates slipping
• If stall speed rpm is
brake bands or clutches
still too high,
-after road test, check transmission for
edge forward clutch Is
fluid leaks
defective
ay Stall speed too low Note
a..:..if approx. poor engine If shift points are incorrect or transmission does
200 rpm below performance (ignition not kick down, check accelerator cable
specified figure timing, fuel injection, adjustments.
compression)
b-if approx. stator one-way
400 rpm below clutch defective F - Pressure test
specified figure (replace torque
'avoid converter) Note
Repair
Pressure test only if defect cannot be found
E- Road test during other checks.
f with
Vehicle should be driven In all gear ranges and This test will locate defects In ATF circuit
i under all possible road conditions. Do not road (internal leakage, wear, sticking control valves or
ottle test if there is obvious mechanical damage dirt in ATF system)
Teat procedure
-connect gauge with 0-10 kg/cm2 (0-142 psi) scale
- measure three different main pressures as
follows:
NG 7.62·8.22 (108-117)
NG 9.10·9.70 (129-138)
R idle speed (from17 070) vehicle stationary
NH 9.00-10.00 (128-142)
NK
*These tests should be performed on a dynamometer
Fault Remedy
Oil pump defective Check pump for wear, replace if necessary
Oil leaks at seals and sealing surfaces or Check for leaks, particularly at valve body
leakage in housing transfer plate
Sticking control valve Disassemble and clean valve body, check valves for
free movement
"
Shift points
Transmission operation
37 19 •
38
Automatic Transmission
Case, Gears, Shafts
Index
- Apply shell 38.1 0 - Transfer plate
-Direct/Reverse/Forward clutches trans. 090 code letters NG 38.26
installing 38.11 trans. 090 code letters NG from
- Forward clutch 38.8, 38.17 trans. no. 17 07 0 38.28
-Governor trans. 090 code letters
disassembling/assembling NH, NK 38.37
trans. 090 code letters NG 38.22 -Transmission
removing/installing assembly 38.7
trans. 090 except code letters NG -Transmission 090 modifications
38.23 code letters NH, NK 38.13
-Governor drive gear 38.14 -Transmission/Final drive
- Kickdown lever modification assembly 38.2
trans 090 code letters end play 38.5
NH, NK 38.39 separating 38.3
- Manual valve 38.35 - Transmission housing studs 38.4
- Oil pump 38.8, 38.22 - Turbine shaft 38.3
- One-way clutch 38.12, 38.14 -Valve body
with plastic cage 38.16 removing/installing 38.25
- Operating rod 38.35 trans 090 code letters NG 38.26
- Parking lock 38.34 trans 090 code letters NG
modification trans. 090 from trans. no. 17 07 0 38.28
code letters NH, NK 38.39 code letters NG
- Pump shaft 38.3 up to trans. no. 16 07 0 38.29
- Reverse planetary gear set 38.12 trans 090 code letters
- Reverse planetary ring gear 38.14 NH, NK 38.36
- Separation plate - 1sVreverse brake piston 38.1 0
trans. 090 code letters NG 38.26 -2nd gear brake band 38.12
trans. 090 code letters NG from -2nd gear brake band piston 38.1 0
trans. no. 17 07 0 38.28 disassembling/assembling 38.24
trans. 090 code letters
NH, NK38.37
-Spacer springs and rollers 38.15
- Spring table
trans. 090 code letters NH, NK
up to trans. no. 16 07 0 38.30
trans. 090 code letters NG from
trans. no. 17 07 0 38.32
38.1
38 Automatic Transmission-Case, Gears, Shafts
Note
Turbine s h a f t - - - - - - - - - - ,
removing: transmission must
be removed first
Installing: place in pinion shaft
before joining transmission
and final drive
length Fig. 4
checking turbine shaft rings Fig . 5
Transmission
separating from final
drive Fig. 3
Final drive
disassembling page 38.6
disassembling/ assembling
Repair Group 39
Torque converter oil seal
removing/ installing
Repair Group 32
a - ·----,------lJ [38·4221
!SS
38- 676'
Fig. 5 Turbine shaft rings, checking
ba-•• J I - check rings (arrows) for wear and
right wrong
proper seating
Pump shaft, inserting
,,
38.6
Note
Do not install together with thrust bearing
@~ -176
Transmission/ Final drive, separating
- mount transmission/final drive
assembly as shown
-drain ATF
Pu mp/Turbine shafts
Transmission/Final drive
38 3 •
38 Automatic Transmission- Case, Gears, Shaft
- Tre
8dj
No1
Enc
mu:
pia•
Wo1
CAUTION
Never install shaft without circlip Fig. 9 Transmission housing studs, Installing
• a and b =18 mm (23/32 in.)
Note
New shaft with circlip can be installed together Note
with early version oil pump and thrust washer Housings supplied as Spare Parts are without
studs. When installing studs, use studs of
correct length and install to proper depth
Mea
•Fil
• Tr;
to
Dim
- m
Sf
Work sequence
Dimension b, measuring
thout
Pinion shaft
)f
38·244
Measuring points:
1 Final drive housing: joint to oil seal bushing a
1 Transmission housing: shim contact shoulder
to separation plate with gasket b
Dimension a, measuring
Example
from straight edge to plate 19.2 mm
from straight edge to shoulder -10.0 mm
Dimensionb = 9.2mm
Example
Dimension a 10.7 mm
Dimension b - 9.2mm
Dimensionx = 1.5mm
Dimension x Shim
mm mm
0.23-0.84 none
0.85-1 .24 1 x0.4
1.25-1.64 2x0.4
1.65-2.04 1 X 1.2
2.05-2.44 1 X 0.4
1 X 1.2
2.45-2.84 2x0.4
1 X 1.2
2.85- 3.24 2x 1.2
3.25- 3.64 1 X 0.4
2 X 1.2
3.65-3.88 2x0.4
2x 1.2
Thrust washers
smear with grease and stick
to forward clutch
modification page
and 38.9
Direct/Reverse clutch
installing Fig . 9
disassembling/assembling
~............
page 38.15
Forward clutch------>
disassembling/ assembling
page 38.12
installing Fig. 9
modification page 38.8
Outer-spllned plate
lnner-spllned plate
1st/Reverse brake
1st/Reverse brake
before installing, soak 15 min. In ATF
Thrust washer
smear with grease
and stick to planetary
gear set
Reverse planetary gear set
Retaining key install ing Fig. 11
Separation P"lte·--' take out after One-way clutch
after installing, check Reverse planetary ring gear/ removing disassembling/
transmission/ final drive Governor drive gear one-way clutch assembling page 38.10
end play, adjust if checking/ assembling installing Fig. 13 installing Fig . 13
necessary see page 38.4 page 38.10
C·7
Transmission 38.7
38 Automatic Transmission-Case, Gears, Shaft
J3a-52o I
Forward clutch with thrust washer Forward clutch with thrust bearing
• identification : drillings (arrows) • identification: no drillings
Note Note
Do not install together with thrust bearing Do not install together with thrust washer
Note
New thrust washers can also be installed in
previcus transmissions
2_8 · 081!
Fig. 6 Spring plate with springs, Installing
Fig. 3 1st/ Reverse brake piston/Oil pump,
installing - place springs on plate
- place in housing with springs facing
- push piston onto pump housing and down and tighten in this position
insert pump in housing. Thin rib
(arrow) must point up
- insert pump shaft in drive plate and
turn pump. Pump should turn freely
138·1 86 1
Fig. 7 1st/Reverse gear brake, checking Fig. 9 Direct/Reverse and Forward clutches,
Installing
- apply low air pressure to port (arrow)
• piston must compress springs -assemble direct/reverse and forward
• piston must return to original clutches first
-angle transmission housing downward
position, when compressed air Is
and slide clutches onto neck of oil
released
pump
- turn transmission so opening faces up
-VW281a
Fig. 12 1st gear brake splined plates, Fig. 15 2nd gear brake ba"d adjusting screw,
Identification adjusting
CAUTION
Transmission must be horizontal when
adjusting brake bands; otherwise bands
may jam
Note
Number of inner and outer splined plates used with
this length apply shell is 4 each.
---Ring gear
check parking lock
notches for wear
Outer r i n g - - - - - -
inserting lower circlip Fig. 1
-
One-way clutch cage, assembling
-heat outer ring to at least 150"C
(300"F) on a hot plate. Set hot plate to
at least 19o•c (375"F)
-grip upper shoulder of cage with two
pairs of pliers and place it quickly in
outer ring When installing spring with guide lug (arrow),
-short sides of retaining lugs on cage
always point lug toward roller to ensure best
must be firmly against shoulders in
outer ring (arrow). If necessary, turn lateral guidance
cage slightly immediately after
mer Note
inserting it
8·13
One-way clutch
Spacer springs and rollers 38.15
38 Automatic Transmission-Case, Gears, Shafts
Thrust plate
Diaphragm spring
convex side faces
bottom of clutch drum
Piston
before installing,
dip in ATF
Clutch d r u m - - - - - - - - - - -
assembling Fig. 3
checking: blow compressed air in direction
of arrow to check that ball valve is
free and seals properly.
Check that valve is not obstructed
by blowing compressed air in
opposite direction of arrow
._----Circllp
different thicknesses
adjusting end play Fig . 6
Inner spllned plates (4) -cO::::::,-----. ----71>-- Outer spllned plates (4)
installing Fig. 5 if radial grooves are found,
replace plates. If discolored
but no grooves, reuse plates
~-~Ctrcllp
removing/installing Fig. 1
- - - - - - Springs (24)
----'-----Spring plate
-----Piston
sealing lips are vulcanized
to piston
before Installing dip in ATF
IW A)
ates
Bushing
removing Fig. 2
Installing Fig. 3 and Fig. 4
Clutch d r u m - - - - - - - - - - -
assembling Fig. 7
checking: apply compressed air in direction
of arrow to check that ball valve is
free and seals properly.
Check that valve is not obstructed
by applying compressed air in
opposite direction of arrow
C·19
Direct/Reverse clutch 38.19
38 Automatic Transmission-Case, Gears, Shaft
I VW460/3 VW408o
VW433
VW401
I
J
.._38-099 Fig. 3 Bushing In clutch drum, installing
Fig. 1 Circlip (small), removing/installing - press bushing in flush
- press spring plate down
VW420 -
VW408o
!38·326
Fig. 4 Bushing in clutch drum, installing
- use old bushing A to press new
bushing 1.7 mm (0.067 in.) below top
edge
Fig. 2 Bushing in clutch drum, removing
-press out
h b-171 J
Fig. 7 Clutch drum/Circlip groove, assembling
!38-126,
Fig. 6 Direct/ Reverse clutch end play, adjusting Fig. 8 Direct/ Reverse clutch assembly,
checking operation
- check that play is
2.05- 2.50 mm (0.081 - 0.098 in.) - install both forward clutch and
-adjust if necessary by replacing direct/reverse clutch with thrust
circlip until correct clearance is washers on oil pump
obtained -apply compressed air to port (arrow B)
• piston must compress clutch plates
Circlip available • piston must release plates when
compressed air is removed
Thickness (mm) Part No.
1.5 010 323 157 A
1 top 1.7 010 323 157 B
2.0 010 323 157
2.3 010 323 157 c
2.5 010 323 157 D
Drive p l a t e - - - - - - - - ,
check for wear and scoring
Governor, disassembling/assembling
(transmission 090-code letters NG only)
Transfer plate
note installation position
Strainer
deleted as of trans. No • .09 04 0
During transmission repairs,
(prior to trans No. 09 04 0),
do not reinstall strainer
Balance weight
do not interchange,
governor is balanced
,e off
!Ja -599 1
Flat Governor
Governor, removing/installing
1 - Flat governor
2-0-ring
• always replace
3 - Governor cap
4-Ciip
• must be secure
.Q
Governor, identification
Code letters (listed below) are stamped on
governor head. New type governors are used only
with new type valve bodies (see pages 38.37,
38.38).
Transmission Valve body Governor
Code Letters Code Letters Code letters
NH FF A
NH FFA A
NK FFA A
Governor 38.23
Automatic Transmission-Case, Gears, Shafts 38
2nd gear brake band piston, disassembling/assembling
Accumulator spring
~------------a------------~
20 Nm (14 ft lb)
'-----Gasket
always replace
Accumulator piston - - - -
Valve body
Strainer in pressure channel
Installing Fig. 1
deleted asdf trans. No. 21 04 0 disassembling / assembling see page 38.24
During repairs on transmissions
(prior to No. 21 04 0), do not
reinstall strainer
J
CAUTION Transmission 090
(code letters NG only)
Tighten screws evenly in diagonal
sequence
.
l--screwa (quantity 3)
....
1
..
1
0 ..
-- - •
••
-- .. •
- -.,
Sealing
--
c.
Separation plate
Identification Fig. 4
Valve body
Ball valves~ code letter Fig. 2
location Fig. 1 'i <J disassembling/assembling page 38.25
Q
Valve body
0·6 Separation plate
Transfer plate 38.26
38 Automatic Transmission-Case, Gears, Shaft
A
tr;
(fl
• •
• •
• ••
Fig. 3 Transfer plate, Identification
Valve body
NG BH
Note
New valve body can be installed in transmissions
from transmission No. 01 06 8
Valve body
Separation plate
Transfer plate 38.28
38 Automatic Transmission-Case, Gears, Shafts
Valve body assembly transmission 090
code letters NG
(up to trans. no. 16 07 0} CAUTION
Governor 1·2
Spring I control
valve 3-2
® Spring/throttle - - --i-.-...-
t---:::~---,...-- Modulator pressure valve
pressure valve
1"""1- --f+-Shlft valve 2-3
Sprlng/3·2 klckdown
~
- controf valve
Valve body
0 Spring/main pressure valve 16 1/2 1.5 (0.059) 77.0 (3.031) 11.9 (0.468)
2 0 Spring/control valve 3-2 12 1/2 1.0 (0.039) 32.4 (1.275) 7.7 (0.303)
·3
® Spring/ throttle pressure valve 16 1.25 (0.049) 43.4 (1.708) 7.75 (0.035)
0 Spring/converter pressure valve e 112 1.25 (0.049) 22.2 (0.874) 7.7 (0.303)
® Spring/ modulator pressure valve 11.1/2 0.8 (0.031) 28.6 (1.126) 7.75 (0.305)
ody ® Spring/shift valve 2-3 9 1/2 0.8 (0.031) 26.0 (1.024) 8.2 (0.323)
own
0·10
Spring table
trans. 090 code letters NH, NK
code letters NG up to trans. no 16 07 0
38 3Q •
38 Automatic Transmission-Case, Gears, Shaft
Valve body modifications
transmission 090--code letters NG
(from transmission no. 17 07 0)
~Bushing
·.,.---Valve body
~ Rtl(""""'W• 2-3
~ ¥' ~
II~ I
0
-
- I
38.31
Valve body
trans. 090 code letters NG
(from trans. no. 17 07 0)
' 138-4891
Automatic Transmission-Case, Gears, Shafts 38
Automatic transmission modifications
transmission 090--code letters NG
(from transmission no. 17 07 0)
Spring table
This table allows identification of springs by their CAUTION
dimensions. Coil diameter and free length can vary Several valve springs have similar
between new and used springs (due to settling) so dimensions. However, they must not be
check spring wire th ickness and number of coils interchanged because they have different
first, as means of identifying springs. If this is not tolerances
enough, also use inner coil diameter and free length
Inner diameter 12 )
Description Coils Wire thickness Free length (1 ) of coil
mm mm mm
Spring/throttle pressure
limiting valve 14.5 1.1 37.9 7.7
Spring/main pressure
brake limiting valve 12.5 12 27.5 7.6
Spring table
trans. code 090--code letters NG
(from trans. no. 17 07 0) 38.32
38 Automatic Transmission-Case, Gears, Shafts
Tray outer shape corresponds to shape of valve All parts must be completely clean.
body. Valves and springs must be put back Into same
To be sure parts are reinstalled in their original holes from which they were removed
location, they should be placed in storage tray.
- insert springs and valves into one side in
Ball valves can be stored in space provided for locations shown in exploded view (see page
bolts 38.25) and then install end plate before
- remove rear end plate, take out valves and proceeding with other side
springs one after another and place them in
tray
- remove end plate from other side and repeat
procedure
- place lid on tray
- immerse tray complete with parts in cleaning
solution. Dry with compressed air. Do not use
water, fluffy rags or cloths when cleaning parts
.
Spring for shift segment
Operating lever
~- rin~
L Lever :haft
positioning Fig. 2
I.
0·14
Parking lock 38.34
38 Automatic Transmission-Case, Gears, Shafts
Manual valve, operating rod and
parking lock, modifications
Operating rod~
CAUTION
Only install parts combinations illustrated
for each respective version
Manual valve
Adjusting screw/lntermedlate--------=-
pressure valve
do not turn, can only be set on test stand
'modified parts
Note
The modulator pressure valve has
Modified spring shift valve 1· 2 been deleted.
Total coils 8 .5, wire thickness 0 .9 mm To clean the valve assembly use
Length 28 .8 mm, internal coil dia. 8 .1 mm tray 2 008 A. 1 38· 573 1
C-12
0·16 Valve body assembly
(trans. 090--code letters NH, NK only) 38.36
38 Automatic Transmission-Case, Gears, Shafts
Fl!
• •
L _Transfer plate
Identification Fig. 3
Separation Dlate----:111
identification Fig. 4
Ball valv-e - - - - -: : - - . - .
location Fig. 1
Fl
Valve body
identification Fig. 2
disassembling/assembling
page 38.36
J
Fig. 1 Ball valves, location
• 1 ball (arrow A) 3 mm dia.
• 5 balls (arrows) 6 mm dia.
Valve body
0·18 Separation plate
Transfer plate 38.38
38 Automatic Transmission-Case, Gear~, Shafts
Note
Parking lock
1- 1
Index 39.1
39 Differential- Manual Transmission
CAUTION
Inner and outer races of tapered roller
bearings are matched and must not be 4----Adjusting ring
interchanged. Replace both bearings at --· ~
same time. Ring gear/ pinion must be
adjusted after replacing differential
housing, cover or bearings. Side gear end
play must be adjusted if differential Differential bearing/ outer race
housing, cover or side gears have been removing Fig . 10
replaced installing Fig . 11
Spacer I
.,....-----Ring gear
(matched to pinion)
removing Fig. 2
installing Fig . 9
Pin _ _ _ __,
drive in flush
135-7191
·ace
- VW771
race
1shers
· wear
- use jaw covers on vise Fig. 3 Differential cover, removing
1 gea rs
.6
ousing
rg Fig . 1
n housing
1-2
14-speed 091-091/111 5-speed 094
Ring gear
Differential housing
Differential bearings
39 3•
39 Differential-Manual Transmission
-
40 -21
VW457'1 -
3~ . 50Q
Fig. 6 Differential bBaring/ inner race (housing
side), re mo~ l ng
CAUTION
Clean contact surfaces are essential to
ensure that ring gear, differential housing,
and cover fit properly. Remove all burrs and
pressure marks with oil stone
39 4 •
Ring gea~
Differential bearings
14-speed 091-091 /1 1 5-speed 094
-~-------- -L-_ _ _....:..__ _ _ _ _
L. __J
Differential-Manual Transmission 39
~using
and
to
JSing,
rrs and
·c (212°F)
mufacture)
1-4
J4-speed 091·091/11 5-speed 094 Differential bearings 39.5
39 Diff'erential-. Manual Transmission
39.6 .,, . . . .d
D1 erent1a 1 pm1on 1s1 e gears
14-speed 091-09 1/111 5-speed 094
. ~--------..1..1 - - - - - ' - - - - - - - - - '
L-
Differential- Manual Transmission 39
Ring gear/pinion, adjusting
~
bfTf
I
Jring
J ~-j
e under 1 2 3
2 3
t No.
o17 241
Ro
R 34·367
-
;,(
----Po
Service gears
i17 242 Fig. 2 Production gears
i17 243 1 = Marking K 738 means
i17 244 Klingelnberg gear set with ratio of X = Markings x'ed-out are not shown on
i17 245 7:38 teeth production gears
2 =Matching number of gear set 312 Po= Setting dimension for production
~suring gears
3 = Deviation r based on master gauge
e and used in special test machine in
ial production. Deviation r is always CAUTION
given in 1/100 mm. 25 shown in
example means that r = 0.25 mm In production, position of pinion is
determined by dimension Po (ring gear
Ro = Length of master gauge in centerline to back of pinion head)
production: Ro = 63 mm
Marking of deviation ron ring gear and
R =Actual dimension between ring gear matching number have been discontinued.
centerline and end face of pinion at It is therefore necessary to measure
quietest running point for this position of pinion before removing it when
gear set parts which affect position of pinion are to
Vo= Hypoid offset= 10 mm be replaced. See page 39.9-
~
Pinion S3 Pinion S3
Shift forks from actual I from Rlpg gear
see dimension R deviation r s, and S2
Repair see see see
Part Group 35 page 39.9 page 39.10 page 39.12
Transmission case X X X
Adjusting ring for final drive X
Differential housing X
Cover for differential housing X
Differential tapered roller bearings X
Double tapered roller bearing for pinion X X
Ring gear/pinion X X X
Ball· bearing for drive shaft X .
Finding position of pinion -measure difference from Ro. This measurement
(actual dimension) corresponds to deviation r. Note reading
Example: r = 0.25 mm
Finding position of pinion is only necessary -after installing new parts, adjust pin ion. See
when deviation r is not marked on ring gear, and pages 39.10-39.11. Deviation r is used to
parts are to be replaced which directly influence determine thickness of shim S3
position of pinion. These are: both pinion
bearings and transmission housing.
Work sequence
-remove differential housing
-assemble measuring bar as described on page
39.10 and place it in transmission housing
..
VW 385/11 or VW 385/30
VW385/1
=
-set gauge VW 385/30 to Ro 63.00 mm, place
on bar and zero dial indicator (3 mm range)
with 1 mm preload
1-8
5-speed 094
14-speed 091 -091/11
Ring gear/pinion, adjusting 39.9
39 Differential"' Manual Transmission
Pinion, adjusting VW385l'l6 r VW385/ 14
Note
Ring gear/pinion need adjusting if gears
themselves have been replaced. If other parts
which affect position of pinion are to be VW385/4
replaced, setting must be measured before
disassembiing and pinion set to this dimension
when assembling. See page 39.9
Work sequence
- install tapered roller bearing and needle
bearing inner race for 1st gear on pinion shaft
-torque needle bearing inner race to
210 Nm (152 ft lb)
Finding dimension e
- screw in one adjusting ring until flush with
transmission housing
-a -
Note
Gauge VW 385/11 can be used instead of
universal gauge VW 385/30
Note
Shim tolerances make it possible to select any
required thickness for s,
Measure shims at several points with micrometer
-turn bar until measuring pin touches measuring and check for burrs and damage
disc on end of pinion, and needle shows
Use only shims which are in good condition
maximum deflection. This is dimension e
Example: e = 0.40 mm
Adjustment (dimension r), checking
Shim 53, determining thickness - install pinion with measured shims 53 and
turn several times in both directions
- place measuring bar in position and check
measurements
• if shims have been selected correctly, dial
e = measured figure (max. deflection) gauge (reading counterclockwise), should
d of r = deviation (marked on ring gear in 1/100 mm show deviation r within tolerance of 0.04 mm
or found by actual measurement)
rew
)USing
Nard
J bar Dial gauge reading fore 0.40 mm
Deviation r +0.25 mm
Ss shim thickness =0.65 mm
)/1
VW385/14
'385/17
~
ar
m
Ring gear, adjusting -turn in adjusting ring on ring gear side with
(pinion removed) VW 381/15 until upper edge is approximately
0.20 mm below surface of housing
Note -turn in adjusting ring. on other side with
VW 381/15 unti I differential is free of play
Ring gear must be adjusted if transmission and without preload
housing, differential bearings, differential - attach VW 381/5a to ring gear side and lock
housing/cover, adjusting rings or ring gear/ with hex nut
pinion have been replaced. Also see table on - turn transmission housing so differential is
page 39.9 top and attach bridge VW 381/8 on dowel
Work sequence
CAUTION
Differential bearing outer races must be
fully seated in adjusting rings
vw 382/7
vw 381115
I •
rr
39.12 Ring gear, adjusting
14-speed 091·091/tj 5-speed 094
Differential-Manual Transmission 39,
vith Backlash, adjusting
rately
Work sequence
- install pin fon Witt1 shims,
ay
- install d il feren ~ial wi tfcl adl usting rings on
correct sides
lock
- attach bridge VW 381/8
- turn in a€lEus,ting rings wh ile turni ng
il is at
differential until measured screw-in depths
·el pins
s, and Sa have been reached
Turning torque
VW 381/ Sa
- lock pinion with bar VW 381/11
Note
If ring gear is being readjusted, check pinion
adjustment, see page 39.10
1-12
[4-speed 091-091/11 5-speed 094 Ring gear, adjusting
Backlash, adjusting
39.-4I 3 1
39 Differential- Manual Transmission
CAUTION
If backlash readings vary by more than 0.06
mm from one another, there is something
wrong with installation of ring gear or gear
set itself. Check all assembling operations
and replace gear set if necessary
5-speed094
Backlash, checking
- check backlash each 1/4 turn
• backlash should be
0.15-0.25 mm (0.006-0.010 in.)
Note
Individual readings must not differ by more than
0.05 mm
Note
Individual readings must not differ from one
another by more than 0.05 mm
Thrust washers
check for wear
--------Pin
drive in flush
Ring gear
Pin (matched to pinion) Differential gear set with four
drive in flush removing Fig. 2 small differential pinions
installing Fig. 12
Differential bearlng/oute1 race
removing Fig. 13 Differential bearing/Inner race
installing Fig. 14 (housing side)
removing Fig. 5
ll'ansmlaslon housing installing Fig. 14
. Side
·entia!
pinions
lr&
.r
alng
~aft (short)
m shaft
lonot
asher
139-11331
094·4WD
Ring gear
Differential housing
Differential bearing
39 .1 6
39 Differential - Manual Transmission
VW412
VW439 _ _____,
A
VW402
0
Fig. 5 Differential bearing/Inner race (housing Fig. 7 Differential pinion shafts (short),
side), removing removing
VW411
VW402
134-18041
Fig. 9 Shafts, Installing
CAUTION
Clean contact surfaces are essential to ensure
that ring gear, differential housing and cover fit
properly. Remove all burrs and pressure marks
with oil stone.
Fig. 12 Ring gear, Installing
I
094-4WD . DifferentialRing
bearings
gear
39 .1 8
39 Differential - Manual Transmission
- - - Thrust waahera
check for wear
Spacer
installation position Fig. a
ltanamlaalon housing
Differential gear aet with two
small differential pinions
CAUTION
Fig. 4 Differential bearing/Inner race (ring gear
Do not damage threads in ring gear. side), removing
Ring gear
l34-11so I 134-10981
Fig. 5 Differential bearing/Inner race (housing Fig. 7 Differential pinion shafts (short),
aide), removing removing
VW412
VW439----1i
134-10961
A
Fig. 6 Differential pinion shaft (long), removing
VW402 0
- drive out shaft until it projects 70 mm on
one side
134-10971
Fig. 8 Differential pinion shafts, Installing
E-9
094-4WD Dffferentlal bearings and
pinion shafts
39 •22
39 Differential - ·Manual Transmission
VW412
-+---40-103
VW411
CAUTION
Clean contact surfaces are essential to ensure
that ring gear, differential housing and cover fit
properly. Remove all burrs and pressure marks
with oil stone.
Note
If ring gear/pinion are replaced, readjustment is
necessary.
nd
CAUTION
Note
Differential bearing outer races must be fully
Ring gear/pinion must always be replaced as a seated in adjusting rings
matched set, never Individually.
Adjustment of ring gear Is required if any of the
following are replaced:
Adjusting rings
Transmission housing
Differential cover
Differential bearings
Differential housing
Ring gear/pinion
1ble
13 094.4WD 1·
...__ _ _ ___._
Ring gear/pinion, adjusting
Screw-In depth
39 26
. ·•
39 Differential - Manual Transmission
Note
If ring gear is being readjusted, check pinion
adjustment, see page 39.25
Backlash, adjusting
- install pinion with shim 83
- install differential with adjusting rings on correct
sides
- attach bridge VW 381/8
- turn in adjusting rings while turning differential
until measured screw-in depth S1 and S2 have
been reached
Turning torque
----2~5
t:::3mm
~--- 70 - - - - - -
- attach measuring tools as shown
,_,34-_1_805_,,
-press in bridge VW 381/7 on two plate screws up
to stop
- attach special tool 386/A to final drive housing
(manufacture a retaining plate from 3 mm thick
Locking pinion, standard sheet metal plate)
transmission
094-4WD
Locking pinion 39 •2 8
39 Differential - Manual Transmission
CAUTION
If backlash readings vary by more than 0.06
mm from one to another, there is something
wrong with installation of ring gear or the gear
set itseH. Check all assembling operations and
replace gear set if necessary.
Note
81 + 82 must always equal 8 total to insure that
ring gear preload is not changed.
- continue adjusting until backlash is 0.15-0.25 mm
(0.006·0.010 ln.)
Note
To obtain the required backlash quickly, the
determined backlash minus 0.20 mm (0.008 in.) can
be used for the first adjustment of the adjusting
rings.
Backlash, checking
-check backlash each 1/4 turn
• backlash should be 0.15-0.25 mm
(0.006-0.01 0 in.)
Note
Individual readings must not differ by more than
0.05 mm.
Needle bearing
7
094-4WD
Front final drive 39•30
39 Differential - Manual Transmission
Note
Before disassembling, mount to repair stand (Fig. 1)
and drain transmission oil.
Differential
disassembling/assembling, pages 39.29-39.32
~ 20 Nm (15 ft lb)
with washer
Lock ring
Lock ring
always replace
t 2lJ Nm ~5 ft lb)
Drive housing
repairing, page 39.34
Left adjusting ring
Axle flange identify before removing Fig. 3
removing Fig. 2 removing Fig. 4
installing Fig. 6
installing Fig. 7 disassemblin~;~/assembling, pages 39.32 and 39.33
coat thread w1th MoS2
Note
For differential assemblies which do not need
readjustment, the adjusting rings position in relation
to the transmission housing must be identified with a
marked tool (arrow)
- measure screw-in depth with VW 382/7
Fig. 1 Final drive, mounting - note values
-mark left side (ring gear side) with 1 scratch
- clamp final drive in repair stand - mark right side with 2 scratches
VW391
139·11021
14
Fig. 2 Axle flange, removing Fig. 4 Adjusting rings, removing
CAUTION
Tighten left adjusting ring first if housing cover Fig. 8 Clrcllp, Installing
is installed and bolted into place.
- position spring washer and clrclip
- press circlip into groove
- watch for central fit of spring washer
always replace
~~. ShlmS3
--------· ---._ ---._adj"'tme"t oompoo;te, page 39.35
-.............. ~te thickness
I
VIscous coupling
lubricatebearing
Needle with transmission oil ·------·------·
I before assembling Spacer ring
l ~
Output housing
Drlveshaft flange
Flange shaft
20NmP5ftlbJJ
with washer
&ni--------------_J
can also be replaced on an installed
transmission
F-2
094-4WD
Final drive housing 3 9 •34
39 Differential - Manual Transmission
3145
VW457/2
- mount support to flange and remove hex nut
139-11071
A
VW434
139-11231
B Assembling
Before assembling:
- position shim S3
- place 12 point of dual bearing on opening in
139-11221 housing
- heat pinion housing at dual bearing seat to
- remove needle bearing from flange shaft 40-SO"C (130-166°F)
A- Puller, e.g. Kukko 22-1 - drive pinion in using a plastic hammer
- position washer and install retaining ring
B-Inner extractor 12- 14.5 mm, e.g. Kukko
21/1
- pry seal out from ciover ·
- remove seals for outer and inner ball bearing .
VW447i
VW415a
094-4WD
Front final drive 39 •38
39 Differential - Manual Transmission
Retaining ring
tightening/loosening, pages 39.36 and 39.37
ShlmS3
Shim
Pinion
pinion and ring gear are matched set
Speedometar drive geer - - - '
adjusting, pages 39.26 and 39.29
position with turned In
groove facing outwards
VW401
139-11321
Fig. 2 Bearing, removing
Tumlng torques
Removing
Installing
Front final drive mounts MUST be loosened - align front final drive in longitudinal direction and
to prevent damage to the driveshaft universal tighten mounting bolts
joints when removing driveshafts.
CAUTION CAUTION
The installed position of the driveshaft must be Front final drive alignment must be done to
noted for reinstallation. Vibrations due to ensure driveshaft is installed without distortion.
incorrect installation can cause cracks in the
transmission housing or engine block.
Note
The universal joints cannot be replaced using
standard workshop tools and are not available as
replacement parts.
Work sequence
iveshaft
Nm 134-16661
- drive in flange
-mount handle 3145 and tighten flange shaft
nut to 160 Nm.(1f8 ft lb)
- install driveshaft and tighten bolts to 35 Nm
(26ft lb)
ction and
~
~
Work sequence
more
Tightening torques
radius rod/wheel bearing housing on control arm
100 Nm (73 ft lb)
brake caliper to housing 240 Nm (177ft lb)
wheel bolts 180 Nm (132ft lb)
axle shaft to drive flange 35 Nm (26 ft.lb)
ball joint to upper control arm 60 Nm (44 ft lb)
134-1681 I
- drive in new oil seal to stop
- install lock ring
- install drive flange with VW 391
- install wave washer
- press circlip into groove with VW 454 and at
same time check that washer is centered
- replace cap
.dius rod,
:rol arm
Removing
more
rrow)
rive
tr cable
- lower final drive and remove from vehicle
(2 mechanics required)
Installing
Tightening torques
Index
-Adjusting ring 39.51
-Assembly 39.56
-Cover plate 39.51
-Differential bearing outer race
39.53
-Drive flange oil seal 39.53
-Final drive assembly 39.50
-Governor oil seal 39.52
-Pinion bearing outer race
39.52, 39.54
inner race 39.54, 39.55
-Pinion oil seals 39.52-39.54
-Ring gear 39.56
-Ring gear/Pinion adjusting
39.57- 39.60
backlash 39.61, 39.62
-Torque converter oil seal 39.51
39.49
39 Differential-Automatic Transmission
Final drive ratio:
CAUTION
4.09:1
Final drive lubricant: If ring gear/pinion bearings can be reused it
Hypoid oil SAE 90, Mil-l2105 B is necessary to measure backlash (page
Capacity: 39.13) and turning torque on pinion (page
1.25 ltr (1.3 US qt) 39.14) before disassembling final drive. Note
these measurements and adjust during
reassembly to obtain same settings
mounting in repair
fixture Fig. 1
ring gear/pinion
must be readjusted
If replaced,
Shims, _ _ ___:._ _- . J see page 39.57
determining
thickness
page 39.59 inner race
removing Fig . 18
install/rig Fig. 20
Torque convert81
oil seal
Differential bearing outer race
remov ing Fig. 2
remove with drift
installing Fig. 3
installing Fig. 12
Pinion bearing
sembling
38
1f drive housing
111ting in repair
re Fig. 1
.gear/pinion
;t be readjusted
placed,
,page 39.57
J Nm (7ft lb)
ghten diagonally;
!torque twice more
Iter intervals of
minutes
Fig. 5 Adjusting ring, removing/installing
-when reusing ring , mark position
before removing
us 1039
F~
/ us 4450
VW401
or
KUKKO 21/7
39-262
ing Fig. 13 Pinion oil seals In cover plate, removing
Fig. 11 Drive flange oil seal, Installing
- press out seals Individually
- fill space between lips with multi-
purpose grease and press In flush
VW295
using
eallip
VW408a - ---11
- VW551
VW510 \
VW401 1
(EECJ
Fig. 15 Pinion oil seal (outer) In cover, Installing
-drive seal into cover until flush.
Open side of seal faces transmission
. VW402 l
us 1037
or
KKO 21/7
·r,
al sleeve,
lh seal
sed)
E·7
E-6
Pinion bearing inner race 39.55
39 Differential-Automatic Transmission
Differential pinion shaft
remove and install with drift
........ ~.............."""""""
Differential bearing/
Inner race (ring gear aide)
removing Fig. 1
installing Fig. 4
when replacing, readjust
ring gear, page 39.60 matched with pinion race (housing side)
removing Fig. 2 removing Fig. 1
Drive flange nut Differential housing installing Fig. 3 installiog Fig. 4
align lugs when when replacing, readjust adjusting, page 39.60 whe11 replacing, readjust
installing ring gear, page 39.60
( """-·"""' 39.6<1
40-105
or
VW 295a
139-078]
39.56 Differential
Ring gear
DHferentiai-Automatic Trans~mission 39
Ring gear/ Pinion, adjusting
Note
Ring gear/ Pinion may only be replaced as
matched set
)'C (212"F)
~ anufacture)
E·8 E·9
CAUTION
Measurement will be Inaccurate if pinion
turns
- assemble measuring bar with dial indicator
extension VW 385/20
-add 0.10 mm for bearing preload and 0.10 mm - turn adjusting ring on left side into housing
for bearing settling to reading. Result is until flush
S total
t0.10mm Example
=2.66mm total shim thickness 2.66 mm
5 3 thickness -1 .30 mm
:o housing
I S3=e-r 1.830- 1.850
1.855-1 .875
1.850
1.875
082 519 141 BS
082 519 141 BT
1.880-1.900 1.900 082 519 141 CA
Example
Note
dial indicator reading e 1.72 mm
deviation r marked on ring gear -0.42 mm Measure shims at several points with
micrometer. Check for burrs and damage. Use
s, thickness =1.30mm only good shims
-select shims from table
- go to next page
E-10
E·11
Pinion, adjusting 39.59
39 Differential-Automatic Transmission
Ring gear, adjusting
Ba
Work sequence '
Wo
- install dlfferentla,l and pinion
- coat O·rlngs and threads of adjusting rings -t
lightly with muJti-purpose grease
- lubricate bea,rfngs lightly with hypoid gear oil
- screw in both adjusting rings until outer
surface is flu!rl~ouslng surface
-s
\
Note
This figure is for new bearings. If bearings are to
be reused, turning torque should be measured
before disassembly. When replacing parts that e
affect ring gear/ pinion setting, check page 39.9 h
to determine which parts need to be adjusted h
gear oil
;ter
' - - - -- --VW521/4
139-2871
CAUTION
Individual readings must not differ by more
than 0.05 mm. Backlash figure given above
only aplies to new ring gear/pinion.
If used se't ot gears is reinstalled, they
should be set to give same backlash with
which they were running before they were
removed
Note
If backlash of new ring gear/pinion is outside
tolerance, it must be corrected by turning both
adjusting rings by same amount (in opposite
directions) so that bearing preload is not
changed
Index
-Assembly syncro ·- .;.;;..... Wheel bearing housing
early version 40.2 -Axle shaft assembly 40.23
late version 40.7 •embly 40.29 removing/installing 40.17
-Ball joints l~gth 40.30 -Wheel hub
assembly 40.1 0 ·!'"removing/installing 40.28 assembly 40.23
lower 40.12 - Balljoints pressing 40.24
- Coil spring ' . pressing 40.25
removing/installing 40.3 .....;. Components
- Lower control arm assembly 40.15
bushing, early version 40.6
bushing, later version 40.8
- Coil spring
removing/installing 40.20
..
removing/installing 40.3 . - CVjpint, inner
- Shock absorber assembly 40.29
removing/installing 40.4 .·.·· di~sembling/assembling 40.33
- Steering arm ·. pressing 40.31
checking 40.12 ·~ CV~joint, outer
- Steering knuckle · as~embly 40.29
assembly 40.12 disassembling/assembling 40.:3.2
checking for wear 40.12 removing 40.31
modification, grease seal 40.13 ··.
.,-;Guards, ·drj,ve sha.ftlengine
modification, brake disc removing/installing 40.28
interference 40.14 - Lower control arm
-Subframe bushings'40.19
wax preservation 40.14 .....; Shock absorber
- Upper control arm rernovinglinstalling 40.20
bushing 40.5 .....; Subframe
lower40.6 components 40.26
removing 40.5 installing 40.28
wax preservation 40.14 removing 40.27
-Wheel bearing --'Upper control arm ·
adjusting 40.11 bushings40.19
assembly 40.1 o removinQ{installing 40.18a
-Wheel bearing
pressing 40.24
<.i . i
40.1
E·14
40 Front Wheel Suspension, Shafts and Axle
~30 Nm (22ft lb)
Washer - - - - - - - - - - - - - - - - - - - - -
concave side faces rubber bushing
Front Suspension
(up to October 31, 1984)
Bushing - - - - - - - - - -
I
\
--C-, "m •h•fl
note position before removmg;
After installing , adjust cam
75 Nm (54 ft lb)---=---..J
20 Nm (14 It lb)
Bushings
Strut bar
and advance to
next cotter pin hole
·m shaft
!lore removing .
Strut bar bolts
adjust camber (up to October 31, 1984) WARNING
Do not re-use any fasteners that are worn or
deformed in normal use. Many fasteners are
When repairing front axle always install designed to be used only once and become un·
.age 40.5
spring washer under bolt head reliable and may fail when used a second time.
This includes, but is not limited to, nuts, bolts,
washers, self-locking nuts or bolts, circlips and
cotter pins. Always replace these fasteners with
Note new parts.
Do not install spring washer under self·
locking nut
Spring washer
· Parts No.'s:
N12 230.5
1er
tailing
40·A006
A·2
Front suspension
(up to Oct. 31 , 1984) 40.2a
40 Front Wheel Suspension, Shafts and Axle
• -au I
-remove nuts (arrows) holding strut bar, - hang caliper up on body with hook
steering knuckle and lower control arm
together
Note
'~
Steering knuckle
Note
When lifting vehicle without shock absorber, avoid
damage to upper ball joint.
Bump stop/dust sleeve and spacer sleeve,
modification
A = spacer sleeve
B = bump stop/dust sleeve
Note
- check correct position of spring (straight end of From VIN 25A 007 7959, following parts have been
spring must be at bottom) modified:
- attach damping ring to top of spring with tape • new spacer sleeve (length 28.5 mm/1.122 in.),
- install coil spring in correct position (lower end of Part No. 251 413 439A
spring in depression in control arm) • contact surfaces of bump stop and body
- lift control arm with jack and attach shock If new bump stop must be installed in vehicles up to
absorber to control arm VIN 25A 007 7958, spacer sleeve, length 24. 5 mm
- attach steering knuckle to control arm. At lower (0.965 in.), Part No. 251 413 4398, must be installed.
connection, strut bar must also be attached
- install stabilizer bar, tie rod and brake caliper
- reinstall wheel
A·4 A·5
Coil spring
lower control arm
Shock absorber
40 4 •
40 Front Wheel Suspension, Shafts and Axle
-press bushing in
VW411
- press bushing in
Beginning in November 1984, the sheet metal Also, the eye in the steering arm for the tie rod end
lower control arm has been replaced by a cast arm. has been made wider.
........,__/
180 Nm (133 H lb)
removing/installing Fig. 1
id
:h
rill
140-9071
- measure dimension a from end of thread - press ball joints out o~ arms
to rear nut before removing
Note
When installing rod, the rear nut must be
set to the old position or the caster angle
VW408a
reset.
, (118ft
ft lb) 140-9061
VW415a
VW401
-Brake disc
-~-Shouldered bolt
Lower ball joint
160 Nm (115 It lb) replace If boot
is damaged
Steering knuckle removing Fig . 8
modification Fig . 12 installing Fig . 9
-160 Nm (115 It lb)
checki ng for wear Fig. 10
checking for distortion Fig. 11
Ball joint adapter _ __,
Circlip - - - - ' removing Fig. 7
for lower ball joint Do not Install ball
joint until adapter
has been bolted to
control arm. If installed
incorrectly, boot on ball
Note joint will be damaged
Steering knuckle
A·11
A·12 Ball joints
Wheel bearing 40.10
40 Front Wheel Suspension, Shafts and Axle
- - --VW407
~I
Fig. 11 Steering arm on steering knuckle,
· checking
• measurement must be: 54-56 mm
(2.126-2.205 in.)
Fig. 9 Lower ball joint, Installing
- press in, flat side of shoulder faces
spindle
CAUTION
-attach adapter loosely to ball joint
Bent steering knuckles must be replaced.
Note Do not straighten
Do not tighten adapter fully. Adapter
must be aligned with control arm when
steering knuckle is installed; otherwise,
rubber boot will be stretched and torn
when steering is in full lock position
CAUTION
l40·A0221
Preserve parts with wax after installation only.
Do not allow wax to get into bolt threads or
mating surface areas of suspension parts. Grind down the cast lug on the steering knuckle
approx. 8.0 to 10.0 mm (5/16 to 3/8 in.) to provide
clearance for the brake disc. (arrow)
Material
CavitY preservation wax If necessary, also modify the splash plate, Part No.
Part No. AKR 316 038 10 251 407 343 C, to prevent contact in the same area.
or equivalent
CAUTION
Modified parts must not show scoring marks
Note
from grinding and must have smooth, rounded
For a description of Volkswagen wax application edges.
equipment and its use, see Cavity and Underbody
Preservation, service literature No. W42-701.Q04-1. Paint parts after modification to provide
protection against corrosion.
Wax preservation
Steering knuckle modification 40.14
40 Front Wheel Suspension-Shafts & Axle
CAUTION
Welding or straigbtening procedures must not
be performed on load bearing front suspension
components and components that position the
wheels.
Always replace seH-Iockil'lg nuts.
If vehicles that have an axle shaft removed
must be moved, an outer joint must be
installed to prevent damage to wheel bearing;
30 Nm (22 ft lb)
then tighten to next
cotter pin hole
Spacer washer
WARNING
Do not re-use any fasteners that are worn or
deformed in normal use. Many fasteners are
designed to be used only once and become un-
reliable and may fail when used a second time.
This includes, but is not limited to, nuts, bolts, 140·A0231
washers, self-locking nuts orbolts, circlip9 and
cotter pins. Always replace these fasteners with
new parts.
/
/
lb)
Shock absorber
removing/installing page 40.20
note Installation position
·washer
Bonded rubber bushing
removing/installing page 40.19
l40-A023l
~=~~
Lower control arm l40·A0241
Syncro
Front suspension components 40.16
40 Front Wheel Suspension, Shafts & Axle
CAUTION
Splines on drive shaft and wheel hub must be
free of oil, grease and old locking compound.
Note
If a suitable commercial puller is not available,
remove wheel bearing housing together with axle
shaft. Press out axle shaft.
Note
Allow locking compound 06 at least 60 minutes to
harden before driving vehicle.
CAUTION
Always remove stub axle with mechanical or
hydraulic hub puller only. Do not heat up
wheel bearing housing or wheel bearing will be
damaged.
ius rod,
I arm
8-5 Syncro
Wheel bearing housing 40.18
40 Front Wheel Suspension-Shafts & Axle
Installing
- fasten control arm to body
• installation position:
flat surfaces of adjustment bolt must be
vertical and larger side of eccentric washers
downward
CAUTION
A maximum play of 0.5 mm (0.020 in.) is
allowable on each side between the bonded
rubber bushing in the control arm and the
eccentric washer when the bolt is loosened.
The following eccentric washers are available
to adjust the clearance:
Lower control arm bonded rubber Upper control arm bonded rubber
bushing, removing/installing bushing, removing/installing
VW 408a
Bonded rubber bushing, pressing out Bonded rubber bushing, pressing out
VW460/2
~39
12
8·8 Syncro
Coli spring/shock absorber 40 •20
40 Front Wheel Suspension-Shafts & Axle
Installing
8·10 Syncro
Coil spring/shock absorber 4 0 •2 2
40 Front Wheel Suspension-Shafts & Axle
Splash shield
Wheel bearing
pressing out Fig. 2
pressing in Fig. 4
when installing, coat outer
circumference with Moly paste,
Part No. AOS 115 000 01 or
equivalent to prevent clicking
noises while driving
Seal
pry out with VW 681
Ball joint, lower pressing in Fig. 11
pressing out Fig. 7 and Fig. 8 i
pressing in Fig. 9 ®
Seal----'
pry out with VW 681
pressing in Fig. 10
40 •2 3 Wheel bearing/hub
Syncro
Front Wheel Suspension - Shafts & Axle 40
Fig. 1 Wheel hub, pressing out Fig. 3 Inner bearing race, pulling out
Note
When pressing out hub, wheel bearing is destroyed.
-----3144
8·12 Syncro
Wheel bearing/hub/seals 40.24
40 Front Wheel Suspension-Shafts & Axle
VW412 ---.3124
VW267a
Fig. 6 Wheel bearing, pressing In Fig. 9 Lower ball joint, pressing out of wheel
bearing housing
- install circlip after pressing
in wheel bearing
VW412
VW267a
I
Washer----
• collar downward
Spacer sleeve
..... (33ftlb)~ ~·
Stabilizer
"'· I
Self·locklng bolt
85 Nm (63 ft lb)
ket
Washer
• collar away from
rubber bushing
-
)-9041
deformed in normal use. Many fasteners are
designed to be use.d only once and become un-
reliable and may fail when used a second time.
This includes, but is not limited to, nuts, bolts,
washers, self-locking nuts or bolts, circlips and
cotter pins. Always replace these fasteners with
new parts.
8·14 Syncro
Subframe components 40.26
40 Front Wheel Suspension, Shafts & Axle
Subframe, removing/installing
Work sequence
Removing
Installing
Proceed in reverse order of removal and note the
following:
- tighten bolts fastening subframe to body last (see
page 40.26 for tightening torques)
Note
After installation of subframe, vehicle must be
14()..10461
aligned. (see group 44)
Guards for drive shaft/engine, -remove and install engine guard (skid plate)
removing/Installing • tighten to 45 Nm (33 ft lb)
Installing
Refer to Wheel bearing housing, Installing.
140·10451
Note
Protection bars for drive shaft can be removed
independently of the engine guard (skid plate).
- install protection bars with front and rear recesses
to the right, as seen from the driving direction
• tighten to 45 Nm (33ft lb)
8·16 Syncro
Subframe, removing/installing
Protection guards, removing/Installing
Front axle shaft, removing/Installing
4O•28
40 Front Wheel Suspension-Shafts & Axle
Note
When replacing CV joint boots, grease joint if
necessary.
inner: 45 grams G6.3 grease each side (total 90)
outer: 90 grams G6.3 grease
--·-~-l
i
Axle s h a f t - - - - - -
I · ~Circllp
~
Rubber sleeve--.......
I always replace
Clamp------~
always replace I cE3r------ Dished washer
I with teeth on inner
diameter for solid shaft
Boot - - - - - - - - - - - - I
~
check for cracks and
wearing
Clamp-----.
replacing Fig. 6
I
I
~Clamp
~~L
~ always replace .
I 35 Nm (26 ft lb)
Rubber s l e e v e - - - - C) I
pull over clamp ~
I check for cracks and
wearing
Clrcllp - - - - - - -
always replace I
I
Note
I If CV joint boots are squeezed
while being installed, a vacuum
Splash ring-----..
pressing off Fig. 2
I may be created inside the boot.
This causes an inward fold in the
boot during use. Lift the small
pressing on Fig. 3
I diameter end of the boot after in·
stalling to equalize the pressure.
I
011 seal - - - - -
I
__ _j
installing Fig. 4
CV joint, outer
replace as complete set only
installing: insert circlip,
press joint on shaft until
circlip engages
Transmission -asurement a
right left
side side
570 mm 570 mm
all
(22.440 in.) , (22.440 in.)
set only
er
j shaft
eezed
'8CUUm
19 boot.
)ld in the
small
t after in·
nessure.
Note
If joint is seized on splines, drive it off shaft by
tapping against hub with copper drift or mallet.
CAUTION
Don't jam hub on splines, or otherwise damage
splines, during this procedure.
.I
I
CAUTION
Chamfer on inside diameter of ball hub
(splines) must face contact shoulder on
axle shaft.
Note
CV joint should be disassembled, and grease -turn two larger openings of cage (arrow)
replaced, when joint is very dirty or when checking until level with joint edge, then remove
ball tracks for wear and damage. cage with hub
Disassembling
- mark position of hub in relation to cage and
housing
ling
- swing hub until one segment can be
pushed into larger rectangular opening
of cage, then tilt hub out
Disassembling
CAUTION
Set of 6 balls in each joint belong to one
tolerance group. Therefore, always replace
hub, outer ring, ball cage and balls toget!'ler.
Note
Check housing, hub, cage and balls .for pitting.
Excessive radial clearance in joint is noticeable when
shifting gears. When this occurs, replace joint.
Do not replace joint because of polished
appearance, or because. ball track can be seen.
Assembling
-lube joint with 45 g (1.6 oz) G 6.3 grease (half of
total amount)
- install cage with hub, into housing
- pivot ball hub and cage out of outer ring and push
• balls must be installed from opposite side
outward (arrow)
• marked position of hub, cage, and housing
- press balls out of cage
must match
- install new circlip in hub
- fill joint with remaining G 6.3 grease for a total CAUTION
amount of 90 g (3.2 oz) Ball hub and housing are paired. One hub, or
one housing, must not be exchanged with
Inner CV joint, disassembling/ another.
assembling
Work sequence
Note
CV joint should be disassembled, and grease
replaced, when joint is very dirty or when checking
ball tracks for'wear and damage.
Note
Check housing, hub, cage, and balls for pitting.
J
• chamfer on inside diameter of ball hub (splines)
must point to contact shoulder on axle shaft
and to large diameter of outer ring
B·22 Syncro
Inner CV joint, assembling 40.34
42
.. c
Index
-Axle shaft
assembly 42.4, 42.7
removing /installing 42.4
- Constant velocity joint
assembly 42.7
disassembling/assembling 42.8
removing/installing 42.8
-Rear axle
assembly 42.4
- Rear wheel suspension
assembly 42.2
-Shock absorber
bushing/sleeve 42.3
-Trailing arm
bushing 42.3
-Wheel bearings, inner/outer
grease seals 42.5
removing/installing 42.5
-Wheel studs
removing/installing 42.6
42.1
42 Rear Wheel Suspension, Shafts and Axle
Note
CAUTION
Replace self-locking nuts.
Do not attempt to straighten or weld wheel
suspension parts.
Trailing arm - - - - - - - - - - - - - - - - ,
left and right differ in , . . - - - - - Coil spring
can be installed with
production; replacement
either end at top.
parts use same trailing arm
Note different tolerance
for both sides
groups (color code). Only
toe/camber adjusting, see
install springs of same
Repair Group 44
color code on one axle
100 Nm (74 ft lb)
Inner bracket for trailing arm
Outer bracket for trailing arm with horizontal slots for
with vertical slots for toe adjustment
camber adjustment
Axle shaft
assembly page 42.4, 42.7
removing/installing page 42.4
Coil spring
J VW442 - - - -
30-14 -~
ailing arm
ts for
Flg.1 Trailing arm bushing, removing
• A = threaded rod
- coat washer with oil and put between nut
1hlng and tool
19 page 42.3 - pull bushing out of trailing arm
;eat
1r end of spring
n must be
Fig. 4 Shock absorber bushing and sleeve,
installing
screws with
I
- break ~harp edge on one end of sleeve
lb) before installing
- coat parts with soap solution
- press sleeve half way into bushing with
vise
bsorber
lr flat spots
stroke VW416b
WARNING
Vehicle MUST be on ground when axle nut is
loosened/tightened.
Spacer sleeve
Wheel stud - - - . Wheel bearing housing thickness: 5.4 mm (0.21 in.)
removing Fig. 8
installing Fig. 9
\__ VW412
19
slot
1t to
Grease seals
Inner wheel bearing
Outer wheel bearing
42 5 •
42 Rear Wheel Suspension, Shafts and Axle
ffi»] ) )
Boot----""'
check for cracks and
signs of rubbing
length Fig. 1 Protective cap
removing Fig. 3
Measurement a
right left
Transmission side side
547.8 mm 547.8 mm
manual (21.567 in.) (21 .567 in.)
579.3 mm 531.0 mm
automatic (22.807 in.) (20.906 in.)
C·6
Axle shaft 42.7
42 Rear Wheel Suspension-Shafts & Axle
VW408a -~
14o-oosl
.
lI
Fig. 5 Constant velocity joint, removing
- press out axle shaft
- pivot ball hub and cage out of outer ring and push
out (arrow)
- pull out balls
CAUTION
Ball hub and outer ring are paired. One hub, or
one ring , must not be exchanged with another.
The 6 balls for each joint belong to one
tolerance group, therefore always replace hub,
outer ring, ball cage and balls together.
Note
Check housing, hub, cage, and balls for pitting.
Note
Joint is correctly assembled when ball hub can be
- insert hub with cage and balls into outer ring moved in and out, by hand, over full range of axial
vertically motion.
- be sure that in each case a wide ball groove in
outer ring a and a narrow groove in hub b are
together on one side when hub is swung into
1 out outer ring
C·9
Constant velocity joint 42.9
44
Wheels-Tires,
Wheel Alignment
Index
-Tires Syncro
rotating 44.1 a - Wheel alignment
- Wheel alignment determining front toe 44.3a
front 44.3 specifications 44.5
rear 44.4
specifications 44.2
44.1
Wheels-Tires, Wheel Alignment 44
Tires, rotating
Most tire manufacturers have changed their tire
rotation policy on radial belted tires. Previously,
radial belted tires were to be rotated only from front
to rear and rear to front on the same side of the
vehicle.
All radial belted tires approved for use on
Volkswagen vehicles can be rotated diagonally if
unusual wear, such as feather-edging, is observed.
Front axle
Empty Half load* Maximum load*
800 kg 1000 kg 1100-1200 kg
(1764 lbs.) (22041bs.) (2425-2646 lbs.)
Toe per wheel (not pressed) +10' ± 15' +10' ± 15' oo ± 15'
Total toe (wheels not pressed) +20' ± 30' +20' ± 30' 0° ± 30'
2.0 ± 3.5 mm 2.0 ± 3.5 mm 0 ± 3.5 mm
(0.08 ± 0.138 in.) (0.08 ± 0.138 in.) (0.08 ± 0.138 in.)
Camber 0 ± 30' 15' ± 30' 0 ± 30'
(wheels in straight-ahead position)
Total angle difference,
at 20° lock to left and right 1° 10' ± 20' 1° 10' ± 20' 1° 50' ± 20'
(not adjustable)
Caster (vehicle on level)** +7° 15' ± 15' a· 30' ± 15' 6° ± 15'
corresponds to camber difference of wheel
on lock from 20° left and right 4° 50' ± 10' 4° 20' ± 10' 40 ± 15'
maximum permissible difference between
left and right 10 10 10
Rear axle
Empty Half load* Maximum load*
700 kg 1050 kg 1300-1400 kg
(1543 lbs.) (2314 lbs.) (2865-3086 lbs.)
Toe per wheel 0° ± 10' +10' ± 10' +10' ± 10'
Total toe (at specified camber) oo ± 20' + 20' ± 20' +20' ± 20'
Camber 50' ± 30' 1° 30' ± 30' -2° 10' ± 10'
maximum permissible difference between
left and right 30' 30' 30'
*Measurements given for "half load" and "full load" apply for vehicles which cannot be measured unladen because
of special equipment installed
Some models, from 1986 on, have a lower chassis height. For these vehicles use the "half-load" measurements as
"empty" settings.
**If vehicle is Inclined to front or rear, 10' must be added or subtracted for each 15' angle off level (measured In
sliding door opening)
Example: Angle measured on stand :6• 40'
correction angle for vehicle angle W to front) : 40'
actual caster angle :7° 20'
Note
Angle of vehicle: to front - add correction figure
to rear - subtract correction figure
Caster, adjusting
(8=-
B
Camber, adjusting - loosen lock nuts and turn both tie rods until
setting for toe is reached
- tighten lock nuts
Note
ause Steering must remain in center position.
1ts as - after turning tie rods, check that bellows are not
twisted
- perform road test and check that steering wheel is
in center position
Note
For non-Syncro vehicles only, if steering wheel
- loosen nut (left arrow) on upper control arm shaft
cannot be centered by adjusting tie rods, remove
- set camber by turning upper control arm shaft
steering wheel and center it on splines.
(right arrow)
-tighten nut to 75 Nm (54 ft lb)
0·4
Wheel alignment, front 44.3
44 Wheels-Tires, Wheel Alignment
The specification for total toe at the front axle is a dimension (mm) between wheel center and
determined by the jounce condition (ride height) of lower edge of wheel house
the vehicle. b - toe per wheel
total toe = toe per wheel x 2
Front toe specification, determining (values in parentheses = total toe in mm)
c - tolerance band for total toe
- bounce front of vehicle several times to settle
suspension Note
If measured distance a falls outside the range on the
Note graph, use the toe specification last shown at the
The vehicle must be empty of cargo and occupants appropriate end of the graph's vertical axis. Toe
during measurement. values must be adjusted as precisely as possible.
y
\
140-09961
c
483r-~-.--.-.--.-.-.--.-.-br-~~
488r-~~-+-1--~~~-t~~~~~
493
498
503~4--+~~~~~~--~4--+~~
508
b
513
-26 -24' -22'-2ft -ll5'-15' -13' -11' -8,5'-6,5' -It -2' ±0'
(-6,0) (-5,0) l--\0) (-3,0) (-2,0) l-1,01
140..()9971
Camber, adjusting
Toe, adjusting
-loosen inner bolt on trailing arm
c .U·llO l
-adjust toe by moving trailing arm to front
or rear with screwdriver
-tighten bolt to 105 Nm (76 ft lb)
D·7 Syncro
Wheel alignment data 44.5
46
Brakes-
Mechanical Components
Index
WARNING Brake pedaVIinkage
assembly 46.1 0
Friction materials such as brake and
- Front brake
clutch linings or brake pads may
assembly (1980-1985) 46.2
contain asbestos fibers.
assembly (from 1986 m.y.} 46.5
Do not create dust by grinding, pads (1 980-1 985}
sanding or by cleaning with removing/installing· 46.3
compressed air. pads (from 1986 m.y.)
Avoid breathing asbestos fibers and removing installing 46.5a
asbestos dust. - Parking brake
assembly .46. 11
Breathing asbestos may result in
-Rear brake
serious diseases, such as asbestosis
aSsembly 46.6
or cancer.
shoes, adjusting 46.9
Breathing asbestos may cause shoes, removing/installing 46.7
severe injury and death.
46.1
46 Brakes-Mechanical Components
CAUTION Note
Always remove brake caliper before When removing caliper only, never disconnect
removing disc. brake hose, hang caliper on frame .
Never try to remove disc by using force. Disconnect brake hoses only when repairing
Force may cause caliper mounting frame to brake calipers
crack or break
Grease cap
remove with VW 637/2 always replace, peen after adjusting wheel bearings
(see Repair Group 40)
Wheel bearing
adjusting see Repair Group 40
Shouldered bolt
160 Nm (116 ft lb)
Splash shield
CAUTION
After installing new brake pads, depress When machining brake discs, equal
brake pedal firmly several times before amounts rnust be taken off each side of
driving to permit piston and brake pads to disc.
adjust to brake disc Never machine one side only
----- ----- --
Brakes - Mechanical Components 46
Brake pads, removing
Work sequence
Note
On Girling calipers, remove circlips first.
E-2
E-3 1980-1985
Front brake pads 46.3
46 Brakes-Mechanical Components
WARNING
Brake fluid Is poisonous.
Do not siphon by mouth
CAUTION
When piston Is pushed into cali per, brake
flu id Is pushed into reservoir. To prevent
overflowing, siphon some f luid out with an
appliance which is used for th ~s purpose
only. Brake fluid will damage paint -if necessary, correct position of piston using
pliers US 1023/2
Note
Girling calipers have arrows on noi se damping
plates. Arrows must point up
. ;::[ill
- press piston Into caliper with tool
- clean brake pad contact surfaces in caliper
CAUTION
After Installing brake pads, depress brake
pedal firmly several times before driving to
permit pistons and brake pads to adjust to
brake disc
Note
If brake hose brackets were removed, reinstall
with clearance of 25 mm (1 in.) between hose
- check position of piston (Teves caliper on ly) and tire.
• recess in piston (arrows) must face bottom. Check clearance by turning wheel from left to
Lugs on noise damping plate engage in right.
recess Correct clearance by bending bracket
'Brake disc
replace both left and right sides together
Grease cap diameter: 258 mm (10.158 in.)
remove with VW 637/2 thickness: 15 mm (0.591 in.)
wear limit: 13 mm (0.512 in.)
ng
nd
Self·locklng bolts
35 Nm (26 ft lb)
always replace
hold guide pin when loosening and tightening
CAUTION
,ke
After installing new brake pads, depress brake Always remove brake caliper before removing
g to
pedal firmly several times before driving to permit disc.
,tto
piston and brake pads to adjust to brake disc.
When removing caliper only, never disconnect
When machining brake discs, equal amounts brake hose, hang caliper on frame.
must be taken off each side of disc.
Disconnect brake hoses only when repairing
1stall Never machine one side only. brake calipers.
iOS9
~ft to
E·4
E·S From 1986 m.y.
Front brake assembly 46.5
46 Brakes-Mechanical Components
Brake pads, removing
Work sequence
WARNING
- remove lower fastening bolt for brake caliper Brake fluid is poisonous . Do NOT siphon by
housing while holding guide pin mouth.
CAUTION
When re-using brake pads, mark pads to CAUTION
prevent changing inside to outside or from one
When caliper piston is pushed back, fluid is
caliper to another. Mixed pads can cause
forced out of caliper and into reservoir. To
uneven braking.
prevent overflowing, always siphon some fluid
out with equipment which is used for this
purpose only. Brake fluid will damage paint.
After pads are installed, refill reservoir only to
MAX mark.
Note
New self-locking bolts MUST be used when
refastening brake caliper hous.ing.
- swing brake caliper housing upward and remove - depress brake pedal firmly several times before
brake pads driving
WARNING
Friction materials such as brake and clutch Avoid breathing asbestos fibers and asbestos
linings or brake pads may contain asbestos dust.
fibers.
Breathing asbestos may result in serious
Do not create dust by grinding, sanding or by diseases, such as asbestosis or cancer.
cleaning with compressed air.
Breathing asbestos may cause severe injury
and death.
Note
Lightly lubricate all moving parts and contact
surfaces with MoS2 .
CAUTION
Wheel cylinder - - - - - - - - .
diameter: 23.81 mm (0.937 in.)
Return springs
Brake lining
longer hooks point
checking thickness Fig. 1
to wheel cylinder.
Install as shown
Brake drum - - - - - - - - - - - - - - - - - -
removing page 46.7
diameter: 252 mm (9.921 in .)
maximum diameter after machining : 253 mm (9.960 in .)
(use oversize linings after machining 0.5 mm (0.020 in.) or more
wear limit: 253.5 mm (9.980 in .)
Cotter pin
always repl~
Fig. 1 Brake linings, checking (arrow) - pull off drum and hub
IU.b
Warning
lb)
Friction materials such as brake and clutch Avoid breathing asbestos fibers and asbestos
linings or brake pads may contain asbestos dust.
fibers.
Breathing asbestos may result in serious
Do not create dust by grinding, sanding or by diseases, such as asbestosis or cancer.
cleaning with compressed air.
Breathing asbestos may cause severe injury
and death.
E·B
Brake shoes 46.7
46 Brakes-Mechanical Components
CAUTION
Do not press pistons out of wheel cylinder
Example
brake drum inner diameter: 252.2 mm (9.929 in.)
minus clearance: 1.5 mm (0.059 in.)
measurement a = 250.7 mm (9.870 in.)
CAUTION
Depress brake pedal several times before
driving so that rear brakes self adjust.
E·9
Rear brake assembly 46.9
46 Brakes-Mechanical Components
Note
Instrument panel must be removed before
booster and bracket with pedal connected, can
be taken out
5 Nm (10ft lb)
Ctn::llp
~---~-Roll pin
locks shaft
in bracket
Bushings
drive out with drill,
press In with vise
Shaft ----~
lubricate before installation
Return s p r i n g - - - - ---'
remove/ install with screwdriver
c:- (
g
--- ----
.
--- ..
----
Left parking brake cable--
------,
't ---.......... ---J
I
CAUT ION
Rear brakes must be properly adjusted before
adjusting parking brake
1dal
- release parking brake
- tighten adju s ting nut (self locking) until there
is no noticeable play at brake components
• c heck by pulling slightly on brake cable
housings
-apply and release parking brake several times
- c heck proper adjustment of parking brake
• rear whee ls can not be turned by hand when
brake lever is pu ll ed 2-4 notc hes
• rear wheel s mu st rotate freely when parking
brake is released
E-11
E·12
Parking brake 46.11
47
Brake-Hydraulic Components,
Regulator, Booster
Index
- Brake booster
WARNING
assembly 47.10
Friction materials such as brake and checking 47.10
clutch linings or brake pads may - Brake caliper
contain asbestos fibers. Girting (1980-1985) assembly 47.5
Do not create dust by grinding, Girling/Teves (1980-1985),
sanding or by cleaning with disassembling/assembling 47.6
compressed air. Girling/Teves (From 1986 m.y.)
Avoid breathing asbestos fibers and assembly 47.7a
asbestos dust. Teves (1980-1985}, assembly 47.4
Teves (1980-1985),
Breathing asbestos may result in noise damping plates 47.7
serious diseases, such as asbestosis - Brake fluid, changing
or cancer. with US 1116 47.8
Breathing asbestos may cause without US 1116 47.8a
severe injury and death. - Brake hydraulic system
general repair notes 47.8
- Brake master cylinder
assembly 47.2
- Brake pressure regulator
checking 47.8a
- Brake system, bleeding
with US 1116 47.8
without US 1116 47.8a
- Check valve
checking 47.10
- Rear wheel cylinder
assembly 47.8
47.1
47 Brake-Hydraulic Components, Regulator, Booster
WARNING
Brake fluid is poisonous
CAUTION
When repairing brake master cylinder
always use all parts in repair kit. Lubricate
shaft of primary piston with silicone grease
supplied in repair kit. Coat all other cups
and pistons lightly with VW brake cylinder
paste before installation
= =----------"7""- Plug
coat with brake cylinder paste
or brake fluid and press
In reservoir
Brake master cylinder housing
check for wear, replace If necessary
Seal
always replace
Seal - - - - -.....
always replace
~
--
Stop screw ---
remove before detaching circlip ___ -
to install: move secondary piston ---
if necessary ---
-- - Secondary piston assembly
assemble before installing WARNING
Installing Fig. 3
Never interchange primary and secondary
cups. See cut-aways
-------
Secondary piston ----
Secondary cups
insert wit.h sealing lips
facing opposite directions
installing Fig. 2
Primary piston
Note
When Installing pistons, guide lips of cups / seals
Into housing with blunt tool
47::00Sj
Fig. 3 Secondary piston, Installing
-hold brake master cylinder with
opening facing down
-guide lips of cups in carefully with
blunt tool
Note
Fig. 1 Clrcllp, removing/installing
After Installing brake master cylinder bl eed brake
system (see page 47.8)
us 4425
o.osol
1hsr
F·2
F·3
Brake master cylinder 47.3
47 Brake-Hydraulic Components, Regulator, Booster
WARNING CAUTION
Brake fluid is poisonous Use all parts in repair kit. Coat seals and
pistons lightly with VW brake cylinder
paste or equivalent before installing
"
;~Drain screw
do not bleed caliper
from th is screw
Caliper housing
do not split,
replace if leaking
Note
Cars may have either Teves or Girllng calipers
Bleeder screw
L
bleed caliper from Retaining pin clips
this screw only always replace
Drain screw
do not bleed caliper
from this screw
Retaining ring
opening points toward disc
)
Piston---~
removing page 47.6
installing page 47.6
l .......
removing page 47.6
installing page 47.6
Brake pad
install after caliper is installed
Note
Cars may have either Girling or Teves calipers
F-4
F·5
...__1_9_so_-_19_a_s___.l j Girting Brake caliper 47.5
47 Brake-Hydraulic Components, Regulator, Booster
WARNING
- pry dust cap out without scratching piston Friction materials such as b'rake and clutch
linings or brake pads may contain asbestos
fibers.
Do not create dust by grinding, sanding or by
cleaning with compressed air.
Avoid breathing asbestos fibers and asbestos
dust.
Breathing asbestos may result in serious
diseases, such as asbestosis or cancer.
Breathing asbestos may cause severe injury
and death.
Note
Hold other piston with clamp .US 1023/5. Place
wooden block in caliper to prevent damage to piston
4 7 •6 Brake caliper
1980-1985 I Girling/Teves j
47
- Brake-Hydraulic Components, Regulator, Booster
- install seal
- lubricate piston and cylinder bore lightly with - insert noise damping plates and check position of
brake cylinder paste piston
- press in piston with installing clamp • recess in piston (arrows) point against direction
of brake disc rotation when moving forward.
Lugs on noise damping plates engage in recess
on piston
F-7
1980-1985 Girllng!Teves brake caliper
Teves noise damping plates
47 7 •
47 Brake-Hydraulic Components, Regulator, Booster
Piston seal
remove with screwdriver
Fig. 2
Dust cap
installing Fig. 3 and Fig. 4
do not" damage while
installing piston
removing Fig. 1
installing Fig. 4 and Fig. 5
CAUTION
Use all parts in repair kit. Coat seals and
pistons lightly with VW brake cylinder paste or
equivalent before installing.
Fig. 1 Caliper piston, removing with Fig. 4 Piston and dust cap, installing
compressed air
- insert inner lip of cap into groove in cylinder while
Note holding piston
F-9
From 1986 m.y.
Brake caliper 4 7 •7 b
47 Brake-Hydraulic Components, Regulator, Booster
Cup
always replace always replace
coat with brake cylinder
paste before inserting
- - - - Bleeder screw
Piston _ _ _ _ ........~
Brake fluid is poisonous. Do NOT siphon by Do NOT re-use fluid removed from reservoir. Water
mouth. and other contaminants in fluid can cause brake
performance problems.
On vehicles with brake booster, turn engine OFF and
CAUTION then disconnect vacuum hose/check valve from
brake booster prior to bleeding brake system. When
Brake fluid must NOT come into contact with bleeding brake system push lever on brake
paint. pressure regulator in direction of rear axle.
Brake fluid absorbs moisture from air and must
be replaced every 2 years. (With pressure bleeder US 1116)
Only use new DOT 3 or DOT 4 brake fluid - connect pressure bleeder US 1116 to brake fluid
according to SAE recommendation J 1703 and reservoir. Turn bleeder switch to ON position
conforming to MOTOR VEHICLE SAFETY
STANDARD 116. Do NOT add or mix DOT 5 - connect hose from bleeder bottle to bleed
silicone type brake fluid with brake fluid in car screws and bleed brakes in following sequence:
as severe component corrosion may result. 1. Right rear wheel cylinder/caliper
Such corrosion could lead to brake system 2. Left rear wheel cylinder/caliper
failure. 3. Right front caliper (upper screw)
4. Left front caliper (upper screw)
- after bleeding, fill reservoir to maximum mark
CAUTION
The brake fluid level in the reservoir must
never fall below the MIN mark during the fluid
replacement procedure .
nd
-fill the system with new brake fluid
I
tn - bleed as described previously
F·11
Brake fluid changing
Brake pressure regulator
47 8a •
4 7 Brake-Hydraulic Components, R.egulator, Booster
- increase pressure on brake pedal until gauge
connected to front brake caliper reads 100 bar
(1450 psi)
• pressure at gauge connected to rear wheel
cylinder must read 55-65 bar (798-943 psi)
if NO, replace brake pressure regulator
- reinstall regulator
CAUTION
- disconnect gauges
- bleed brakes
- connect gauge US 1016 to rear wheel cylinder
- bleed both gauges
- depress brake pedal several times
CAUTION
CAUTION
Do not repair brake booster. If necessary,
replace.
f 15 Nm (11 tt lb)
@@y
r Filter
always replace
Dampl•g woshe< ,
always replace
0
Check valve, checking
(install in vacuum hose)
- remove valve (arrow) from hose
-blow through valve in direction of arrow (on
housing)
• air must pass through valve
- blow through valve in opposite direction
• no air must pass through valve
F·13
Brake booster
Check valve 47.10
48
Steering
Index
- Power steering
checking for leaks 48.7
pressure/flow limiting valve 48.1 1
suspension changes 48.6
system layout 48.6
technical data 48.6
- Power steering pump
removing/installing 48.9
repairing 48.1 0
- Power steering pump pressure
checking 48.7
- Power steering system
filling/bleeding 48.7
- Steering column
switches 48.2
-Steering drive/gear 48.4
- Steering lock
assembly 48.3
- Steering wheel/column 48.2
- Tie rods 48.4
removing 48.5
-Troubleshooting 48.12-48.17
48.1
48 Steering
Column tube-------.
assemble with column first,
then install, see Fig . 5
Shear bolt
drill out to remove .
Before installing , first set gap between hub and
switch, then tighten until head of bolt shears off
Column brae
I
Plastic ring
press onto tube
I
Spreader r i n g A
~~Spring
I Lower column
Washer ' j
I I _ /'a
/__ - - - - - _ _ _ } 20 Nm (14ft lb)
WARNING
Do not re -use fasteners that are worn or
deformed in normal use. Many fasten-
ers are designed to be used only once
and may fail when used a second time .
This includes, but is not limited to, nuts, Boot retainer---...
bolts, washers, self-locking nuts or
bolts, circlips and cotter pins. Always re-
place these fasteners with new parts.
G-2
G-3
Steering column
Steering lock assembly
48 3 •
48 Steering
WARNING CAUTION
Do not weld or straighten any steering Only use special steering gear grease
components. Replace if damaged. Part Number AOF 063 000 04, or equivalent,
to lubricate steering gear.
Rubber boot
always replace when repairing/replacing
Steering gear - - - - - - - - - - - - . tie rods, or replacing steering gear
not adjustable. To remove,
detach connecting shaft at ~~=~ (18 H lb)*
coupling disc and remove tie rods !rom ~-' replace
steering knuckles . Then take
steering gear out. After installing,
adjust toe, see Repair Group 44
_r Cotter pin
\ _/ always replace
1 ..
and advance to next left and right sides adjustable.
cotter pin hole Before adjusting, set steering
to center position, see . ·.,;
25Nm~Bftlb)
Repair Group 44.
removing Fig. 1
unlocking Fig . 2
locking Fig. 3 /
Transfer gear
cannot be repaired. Lubricate
*Self-locking nuts with steering gear grease
. ~
,. l.J
-~
US1014
-.I
Fig. 1 Tie rod, removing
-press tie ro9 off steering knuckle
G·S
Tie rods 48.5
48 Steering
When working on the power steering
system
CAUTION
Always follow these "rules" for cleanliness
when repairing the power steering system:
1. Clean connections and surrounding area
thoroughly before loosening.
2. Place removed parts on a clean surface and
cover them. Use plastic, paper or lint-free
cloths.
3. Carefully cover opened components or plug
openings if repair is not going to be done
immediately.
4. Install clean parts only.
• do not remove replacement parts from
packaging until just before installation
• do not use parts that were stored
unpacked
5. When the power steering hydraulic system
is opened:
• do not use compressed air in the
immediate area
• do not move the vehicle unless absolutely
necessary
48 6
•
Suspension changes
Technical data
Power Steering
Steering 48
Steering system, checking for leaks Power steering system, filling/
(engine running) bleeding
- rotate steering wheel lock to lock and hold at limit
of travel (no longer than 5 sec.) CAUTION
- check all line connections and tighten if necessary
- if leak occurs at steering pinion, replace steering If ATF level is too low, always check power
gear assembly steering system for leaks. Always fill and bleed
- if steering rack seals are leaking (pull boot off power steering system with ATF after opening
steering gear to check), replace steering gear system for repair. Do not reuse fluid which has
assembly been drained. Always replace power steering
- check power steering pump for leaks filter in reservoir when changing ATF.
0-ring
Filter cover
~ line
CAUTION
Do not allow reservoir to be pumped dry.
Note
Do not use more force on steering wheel than
necessary to turn wheel.
. - - - - - - - Sealing rings
always replace
Pressure line
to steering gear
Pump
mounting
bracket
- - - - - V-belt
size: 9.5x1080mm
Note
r-----~
When repairing pump, replace all parts marked with
an asterisk.
Coat all sealing components with ATF on installation. I
20 Nm (14 ft lb) 7 I
I
Stator - - - - - -
position:
long pins downward
I
I I
I
I Clrcllp• --------------<:~
Housing
I
I
removing/installing Fig. 2
I I
0-rlng•
I I
Pressure/flow
limiting valve
installing Fig. 1
I
I
Housing _ _ _ ___.,
sealing ring oil channel
(arrow) in both housing
halves must line up
checking page 48.12
Seal support
I with multi-purpose grease
48 .1 0 Pump,repalring
Power Steering
Steering 48
- Pressure/flow limiting valve, checking
Note
Incorrect functioning of pressure/flow limiting valve
causes periodic lack of steering assistance.
Note
Rotor and shaft must be removed from housing to
replace pump shaft seal.
Note
Circlip must fit properly in groove and be secured by
Troubleshooting
Use the following procedure to troubleshoot
complaints of heavy or stiff steering:
Test conditions
• vehicle at room temperature
(approximately 68°F)
• vehicle raised on hoist
• steering turned 3 times from lock to lock at
steering wheel
I steering system OK I
lgotoAon
page 48.13 I
I End I
*vehicles with
0·1000 km (1600 mi) = 300 Ncm (26 in. lb)
vehicles with
1000-3000 km (1600-4800 mi)
230 Ncm (20 in. lb)
vehicles with more than
3000 km (4800 mi) = 170 Ncm (15 in. lb)
48 •12 Troubleshooting
Steering 48
r
- remove connecting shaft between steering gear and relay gear
and measure tuming torque again
value greater than 150 Ncm
(13 in. lb)**
I value less than
150 Ncm (13 in. lb)**
lgotoBon
page 48.14 I I go to Don
page 48.16 I
**vehicles with
o-1000 km (1600 mi) = 150 Ncm (13 in. lb)
vehicles with
1D00-3000 km (1600-4800 mi)
= 130 Ncm (11 in. lb)
vehicles with more than
3000 km (4800 mi) = 110 Ncm (10 in. lb)
Troubleshooting 48.1 3
48 Steering
go to Con
page 48.15
4 8 •14 Troubleshooting
Steering 48
c
I replace relay
gear
I I relay gear OK I
I End I I End I
15 1\'oubleshootlng 48 .15
48 Steering
-
<f
remove steering gear and measure turning torque at pinion
Note
Do NOT close off hydraulic lines on power steering gears. Drain ATF before measuring turning torque.
value less than 120 Ncm (10 in. lb) I value greater tl)an 120 Ncm (10 in. lb)
- replace steering gear I -check both outer CV-joints and ball joints for
stiffness during movement.
-replace damaged parts.
I End I I End I
48 •16 Troubleshooting
Steering 48
- Troubleshooting
Body
Index
-Acid rain
removing spots 50.6
-Adhesives
materials 50.5
- Body dimensions
door 50.4
floor 50.2
windshield 50.4
-Painting
pop-up roof/luggage carrier 50.5
-Plastics
identifying 50.5
repairing 50.5
50.1
50 Body
14-----1328 ± 8 mm - - . . - l
(52 7/32 ± 1/41n.)
..-.
.5
E~
E;:
en..-
+t+t
..... co
cn..-
co-
NM
8
c
..-.
.5
-
CD
C') ......
+t+t
CD CD
............
C')-
C')
......
......
!!!.
± 4 mm---1..!
(39 1/4 ± 5/32 ln.)
•measured 200 mm (7 31/32 in.) .._- -1175 ± 5 mm -----~~
from outer edge of frame rail (48 1/4 ± 3/181n.)
• •measured with gauge
Note
Measurement Key
A = 750 ± 2mm (29'/a ± 3
/3a in.)
B = 704 ± 1mm (2731. ± '/"in.)
C = 683 ± 1mm (26 7 /a ± '1,. in .)
D = 225 ± 1mm (8 7 /a ± 1/ 16 in.)
E = 253mm (9.96 in.)
F = 289 ± 1mm (113/e ± ''•• in.)
00-2221
Rear door
J =
1050 ± 2 mm (41 11/32 ± 3/32 in.)
I = 1618 :t 5mm(6311/16 ± 3/16in.)
Front door a = 340 mm (13 3/8 in.)
Windshield
k = 723 ± 4 mm (28 15/32 ± 5/32 in.)
I =
1469 ± 5 mm (57 27/32 ± 3/ 16 in.)
Side door
g = 1185 ± 5 mm (46 21/32 ± 3/16 in.)
h::;; 1348 ± 4 mm (531/16 ± 5/32 in.)
50 •4 Door/Windshield dimensions
Body 50
Identifying/painting and repairing Pop-up roof/luggage carrier, painting
plastic parts
Color determination
Refer to the Volkswagen of America Refinishing
- locate pop-up roof/luggage color on vehicle
Guide, Lit. No. W42-701-008-1.
identification plate
- if pop-up roof/luggage carrier is painted in a color
Body assembly materials other than the body, consult a color chart for the
correct color code
Refer to the Volkswagen of America Refinishing
Guide, Lit. No. W42-701-008-1. Surface preparation
- thoroughly clean and dry pop-up roof/luggage
CAUTION carrier
Part numbers are for reference only. Always - roughen surface with steel wool
check with your Parts Department for latest - reclean and thoroughly leave dust free
parts information.
Painting
- paint surface with synthetic resin, acrylic, or two-
component paint in selected color
• adhesive promoter is not necessary
Note
Applies to all vehicles without acrylic transport
protection
WARNING
Before using any chemicals or
cleaning compounds, carefully read
all of the cautions and medical
information on the container. Always
follow all of the manufacturer's
recommendations.
Step 1: Inspection
CAUTION
Do NOT wash or dry vehicle in direct
sunlight. Ordinary water spots could
form and confuse the inspection.
Step 2: Neutralization
The continuing effect of the acid must be stopped by
neutralizing.
Step 3: Buffing
You can buff by hand or with a low speed orbital buffer
or with a high speed buffer.
CAUTION
It is extremely important that power
buffing be done by an experienced
lg person. If done incorrectly, power
buffing can quickly and easily damage
the paint finish.
Use clean buffing pads at ALL times.
CAUTION
Do NOT use general purpose rubbing
or buffing compounds. They are too
coarse for this application and could
damage the finish.
Step 4: Cleaning
• wash vehicle thoroughly with a solution of
mild soap and water
• rinse vehicle with clear water then dry
completely
• inspect vehicle to see if another application
is necessary
Step 5: Polishing
Polish the finish to restore the original luster either by
hand or with a power buffer. Always follow polishing
with an application of wax.
CAUTION
It is extremely important that power
buffing be performed by an experienced
person. If done incorrectly, power
buffing can quickly and easily damage
the paint and finish.
Use clean buffing pads at ALL times.
3. BUFFING
• buff with light polishing compounds (clean buffing
pads are essential)
4. CLEANING
• remove buffing compound using mild soap and water
I
5. POLISHING
• to restore luster, polish buffed surfaces
6. WAXING
• hand wax vehicle
.NoI Yes
I
I End
PAINT REPAIR NECESSARY
Index
-Rear door/lock cylinder 55.2
- Rear lid spring 55.4
- Rubber door stop 55.3 .
-Striker plate 55.3
55.1
55 Hoods, Lids
Washerl
Hinge
10Nm(7ftlb)~~
Gasket~
upto6/82 ~ •;;;:..~1u
Au bber waahera
Clrcllp
Washer
17·
~~, waaher
··,
Cap
~usting
A bber door atop
Fig. 3
To
lockensure
cylinder
horizontally
correc
must be installed
Striker pia~
adjusting Fig. 4
A·12
Rear door, removing/adjusting
Rubber door stop, striker plate, adjusting
55 3 •
55 Hoods, Lids
Note
New-type gas cylinders are installed in current
production vehicles (starting May, 1982;
VIN No. 25 CH 126332)
CAUTION
Part numbers are for reference only. Always
check with your Parts Department for latest
parts information
Index
- Front doors
adjusting 57.5
assembly 57.2
glass 57.4
guide channel 57.5
handles 57.3
lock/lock-rod 57.3
power door locks 57.6
whistling noises, eliminating 57.10
window regulator 57.4
- Lost/broken keys
code location 57.8
57.1
57 Body - Front Doors
Note
When disassembling door, remove in numerical
order; install in reverse order.
Door-lock button
Bolts
clean threads and
apply 06 locking
compound before
installing
md
·157-1261
Fig. 2 Door handle (outer), removing
- remove door weatherstrip and remove
screw (arrow)
- push door handle to front of vehicle and
remove
-
Window regulator, removing
--~-
-~ -~
B-4
8-5
Window front guide channel, removing/installing
Front doors, adjusting
57 5 •
57 Body - Front Doors
Starting March 1986, power door locks are available Power door lock motors, installing
for Vanagon vehicles.
Installation is in reverse order of removal noting the
Power door lock motors, removing following:
-carefully reinstall plastic moisture barrier, replace
- disconnect battery ground strap if damaged
- remove door trim panel - check locks for proper functioning
- carefully pull off plastic moisture barrier as
necessary Sliding door lock motor, removing
- pull off electrical connection for power window
switch
- pull off electrical connection from power door lock
motor
(j
A - power door lock motor
B-lock rod
C - remove control lock
- disconnect battery ground strap
-remove doortrim panel
- pull off electrical connection from power lock
motor
- remove two sheet metal screws
- take out power door lock motor
- remove sheet metal screws
- remove power door lock motor
Sliding door lock motor Installing
Installation is in reverse order of removal noting the
following:
• check lock for proper functioning
Rear lid
Mounting holes
B-7
From March 1986 Rear lid door lock motor,
assembly
57 7
•
57 Body - Front Doors
Rear lid door lock motor, removing Power door lock motor/bracket
installation, spare parts only
- disconnect battery ground strap
- remove rear lid trim panel
- pull off electrical connection from power door lock • Outside vehicle Power door lock motor
motor
Note
Drill bit must extend at least 65 mm (2.5 in.) out of
chuck.
- remove any burrs from holes and touch up with
paint and corrosion protection
-install rivets (arrows) from outside with a riveting
tool
ls7-A0581
In the event of a lost or broken key, the key code
can be obtained from three possible locations on the
outside door handle (after removal).
A - Release lever.
B - Front hold-down hook.
C - Transfer lever
Note
Procedure applies only to vehicles with:
• gearshift lever bracket Part No. 251 711 231A
• without raised center instrument panel
• up to YIN 25JH087797
- pull up boot 1
- seal assembly holes (arrows) with 5.0mm
(13164 in.) dla. bead of adhesive strip
AKD 476 KDS 05 or equivalent
___]
- check bracket seal (arrow)
• replace if defective
11
From 1988 my Whistling noises,
eliminating
57.11
57 Body-Front Doors
- remove door
-seal cowl weld flange (arrow A), door hinges
(arrow B)
- test drive or operate fresh air blower and check
for whistling noises
H·1
Index 58.1
58 Body -Rear Doors
Trim ring
Door-lock knob
Fig. 1 Inner/outer door handles, removing Fig. 3 Front sliding-door lock/door lock buffer,
removing/Installing
- remove Phillips screw 1 and take off inner
handle - remove three screws (arrows)
- remove screw 2 and remove outer handle - remove lock buffer 11
together with seal and, trim ring - slide front sliding-door lock 12 out
- install in reverse order
~le Note
ig. 2
Coat threads of screws for door handles with
D 000 600 locking compound or equivalent before
installing.
more
C-3 1980-1984
Sliding door cover/Inner/outer door handles, removing
Release cable/door-lock knob, removing
Front sliding-door lock/door lock buffer, removing/Installing
58 3•
58 Body - Rear Doors
Note
Note
After striker plate adjustment, always adjust sliding-
door center hinge (page 58.9).
C-7
1980-1 984
Bowden cables, adjusting
Sliding door, lubricating 58.7
58 Body - Rear Doors
Houalng - - - - - . . .
--
~·
I
·-~ -)
~! • r:•• I
I
I
-\\
.
Em
- open sliding door carefully while supporting rear
of door in area of belt line
-tighten bolts 2 to 23 Nm (17 fllb)
C-9
1980-1984 Sliding door center hinge, removing/Installing
Sliding door center hinge, adjusting
58 9
•
58 Body - Rear Doors
Edge protection - - - - - - - .
----Seal
Washer
Doo<handle,ou... ~
Escutcheon~
'"'
Lock washer
Terminal for power door locks
for vehicles with power door locks
Locking knob
Power door lock motor
Door handle, outer
Phillips screw
3.4 Nm (2.5 ft lb)
secure with locking compound D 000 600
The sliding door has been redesigned for the 1985 Before sliding door can be removed, cover for center
model year. guide rail must be removed. Cover and plastic
beading are pressed together into U-shaped channel.
Some of the following procedures differ from those
for earlier models.
Procedure Page
Sliding door cover, removing/installing 58.11
Sliding door, removing/installing 58.12
Adjustments to sliding door
a lower roller guide 58.14
10r b upper roller guide 58.14
c striker pin with hinge link 58.15
d hinge link 58.16
Remote control lock 58.18
Central lock 58.20
Hinge link/parts subject to wear, replacing 58.21
rver
,,"'
Problem"\ Adjustment - remove Phillips screw (arrow)
Door height at front incorrect a
Door height incorrect c
Door is not flush with outer contour
of B·pillar at bottom a
Door not flush with outer contour
Ktlt
of C-pillar c
It lb) Front of door not flush with outer contour
of B-pillar at top b
Gap around door differs front to rear C, d
acrew
1)
When opening from outside, door sticks
in C-pillar area d
Iss- 22sl
Iss- 2211
Socket head b o l t s - - - - - - - - . . /
M8x 18
23 Nm (16.9 ft lb)
I58. 228l
a - Adjusting lower roller guide -from inside vehicle, loosen bolt on door
side slowly
• Door height incorrect at front:
-when door is flush with B-pillar outer panel,
- relocate bearing arm roller guide by loosening retighten bolt
upper bolts and moving door to proper height. - open door and tighten both bolts to specified
Retighten bolts to proper torque torque
• Front of door not flush with outer contour of
b - Adjusting upper roller guide
B-pillar at the bottom:
• Front of door not flush with outer contour of
B-pillar at the top:
...,.,,~~/'-----Upper roller
guide assembly
Iss -2291
Note
New locks are supplied with plastic clips.
Note
Each time before repositioning or installing the striker
pins, the hinge link bolts must be loosened and the
link must be pushed upward and to the rear as far as
possible (arrows). The bolts should be tightened by
hand only. 1 Striker pin
2 Spring plate
(collar must always face outward)
3 Adjustment aid line for striker pin
4 Striker pin/spring plate mounting bracket
C-15
From 1985 m.y. Striker pin with hinge link,
adJusting
58 .15
58 Body - Rear Doors
~Waahar
ZM8x15
23 Nm (17 ft lb)
t------------------------ls~s~l
........ ........
(®t
-----
r------------------ ~~~I
- insert piece of wood or plastic wedge 3 between
roller carrier and rail 2 until roller 1 rests on rail 2
- tighten hinge link bolts from inside
• tightening torque: 23 Nm (17 tt lb)
- open door and remove spacer clip from lock
- install beading on C-pillar flange
WS)
C-17
From 1985 m.y. Hinge link, adjusting 58.17
58 Body - Rear Doors
-----Phillips screw
10 Nm (7 tt lb)
Catch plate
Locking knob
Note
For tightening torques see Fig. 58-238 on preceding
page.
- install locking knob
- remove catchplate 3
- remove locking knob 4 .
- remove door latch plate 5
C-19
From 1985 m.y. Remote control lock,
removing/Installing
58.19
58 Body - Rear Doors
Note
The central lock can be removed and installed with
the door on the vehicle.
- remove sliding door trim panel
C-21
From 1985 m.y. Hinge link, assembly 58 •21
58 Body, ~ Rear Doors
Outside sliding door handle with
option M145, installing
(Transporter, Canada only)
Note
When performing repairs to the sliding door or loc;k,
it has been found that the outer door handle locking
cylinder is often being damaged as a result of
incorrect installation.
Before re-installing the handle, turn the lock with the
key so that the locking tab is fully retracted (arrow).
H·1 60.1
J
60 Sunroof
Sunroof, installing
- install in reverse order of removal
. . .. .; ~
A
tb_B
D-3
Sunroof trim panel, removing/Installing
Sunroof panel, adjusting
Height alignment, front
6O 3 •
60 Sunroof
Note
If necessary, replace both control cables.
Note
The sunroof operates with cables exposed. This is
so if cables are replaced or panel is hard to move,
cables may b.e lubricated with multipurpose grease.
Index
-Tarpaulin 61.2, 61.3
(Canada)
61.1
-' 1·7
Index
61 Tarpaulin
- mount rear rail to floor with boH 1 and washer 2 - install deflector plate E in position and securely
- press rubber buffers 3 into both sides of rail D fasten to rail B and cab rear panel with bolt 4,
washer 5 and nut 6
- mount and align tarpaulin on frame starting at rear
Note
Three mechanics are required to install tarpaulin.
Note
Upon reassembly after dismantling frame,
countersunk screws are to be installed with 06
locking compound.
Note
The tarpaulin frame must seal tightly in the rain
channel (arrows).
Tailboard bump stops which do not line up with the
tarpaulin can be removed and the holes plugged.
D-9
Canada Tarpaulin, service Installation 61.3
63
Bumpers
G·S 63.1
63 Bumpers
63 2 ·
• Front bumper/spoiler, removing/installing
From 1987-Wolfsburg edition
Bumpers 63
washer
Bumper bracket
Retaining bracket
Spring nut
~Washer
Hex head bolt A
Index
'
,.,
·;h
1
Work sequence
- remove slidinQ window interior latch
- remove outer window channel weatherstrip/seal
- lift sliding window up and remove loose guide
piece
Note
CAUTION
Part numbers are for reference only. Always
consult your Parts Department for latest
information
Note
To insure a satisfactory seal, use adhesive
AMV 172 003 05 or equivalent specifically made for
EPDM rubber.
~"((
\\
- pull seal from flange and window glass
- from outside place suction cups on glass and
remove windshield
- with plastic wedge remove rest of rubber seal
and remaining adhesive to height of
1-2 mm (3/64-5/64 in)
Note
If paint has been damaged, repair before installing
new rubber seal.
CAUTION
Prevent paint damage by placing piece of
flat plastic (as shown) between seal and
body.
F-3
From 1986 m.y. Gluelng window
rubber seals 64.3
64 Glass, Window Regulators
Rubber seal
, ~ r-·Body
/. ·... · . Adhesive
1..._0-..._ bead
--b
--
Cross section • Side window
A = 7 - 2 mm{9/32 - S/64 in)
Cross section • Windshield B. = 7 - 2 mm (9/32 - 5164. in)
C = 3 + .1 mm (1/8 + 3/64 in)
A = 7 - 2 mm (9/32 - 5Jij4. in)
B "' 7 - 2 mm (9132 - 5/64 in) - removal/installation procedure is identical to that
C = 3 + 1 mm (1/8 + 3/64 in) of windshield
• note proper placement of adhesive bead
- place bead of adhesive as shown
- reinstall windshield, checking for proper fit
Adhesive
bead
l64·139J
Cross section - Rear lid window
Adhesive
A = 7 - 2 mm (9/32 - 5/64 in) bead
B = 7 - 2 mm (9132 - 5/64 in)
C = 3 + 1 mm (1/8 +3/64 in)
Note
The dimension of adhesive bead ensures no
adhesive will get into interior of vehicle. Any excess
adhesive must be cleaned off immediately with
suitable solvent such as 3M <!' General Purpose
Adhesive Cleaner or equivalent.
CAUTION
Always use care and wear protective gloves for
safety to prevent injury if glass breaks.
157-2741
CAUTION
Do not apply excessive force. Plastic cable
guides may break.
ls7-277l
Body
Access·ories
Exterior
Index
Index 66.1
66 Body Accessories-Exterior
.
~
@I B
l
\
CAUTION
Wear protective gloves to prevent Injury if
glass breaks.
Hold glass to prevent falling out.
Note
See page 66.2 for mirror glass removal/installation
work procedure.
I 66-A019 I
-using hacksaw, cut 3-4mm (7/64-11/64 in.) from all
four stop tabs
- install all mirror components in reverse order
- reconnect battery ground strap
- check mirror for proper functioning
ss-A01a I
- disconnect battery ground strap
- remove mirror glass
- remove mirror drive motor
- unscrew and remove mirror drive motor mounting
plate
- cut tie wraps holding wire harness to door - position seal (arrow) to proper fit
- cut open cable sleeve A to expose individual - secure wire harness to door frame with tie wraps
wires - check mirror for proper function
- label and remove mirror wires from plug
connector
n r- ~ . -. -
k k k k
-
~Q
I
~
-~ ..
!
=:.!,. l J
·~
ti
"' .. ~·. .
I +
~
·•
\
. .1
--
~ ~ .....
~ --'\~~ j
?""
~.y ~~
166-2288 1
Fig. 2 Body side molding bracket locations, aide panel
a- 30 mm (1.2 in.)
i -10 mm (25/64 in.) CAUTION
·If- 390 mm (15.2 in.) De-burr, touch-up and apply anti-corrosion
primer to bored holes in b?dY as required.
G-8
Body ~lng bracket locations, front doors
Body side moldings, removing/Installing
66 7 •
68
Body-Interior
Index
- Automatic 3-point seat belts
retrofit installation 68.5
- Automatic rear 3-point seat belts
retrofit installation 68.7
- Automatic 3-point left center
seat belt "
retrofit installation 68.1 0
- Illuminated vanity mirrors
replacing bulbs 68.13
-Seat belts
inspection 68.2
webbing defects 68.4
-Template measurements 68.6
68.1
68 Seat Belt System
Complete seat belt system If webbing cannot be pulled out of retractor or will
not retract to stowed position, check for the following
Note conditions and clean or correct as necessary:
• dirty webbing coated with gum, syrup, grease or
A visual and functional inspection of seat belts is
recommended to assure maximum protection for other foreign material
vehicle occupants. • twisted webbing
• retractor or loop on B-pillar out of position
CAUTION Cleaning
Seat belt assemblies must be replaced after Clean the belt webbing only with a mild soap solution
being subjected to loading by occupants in a recommended for cleaning upholstery or carpets.
collision. Follow the instructions provided on soap container.
Seat belt mounting bolts are installed at 35.3 Nm to Some models have a rear center seat belt. These
n belts do not have a retractor. In addition to checking
47.0 Nm (20 to 35ft lb). Retractors must be securely
lg the webbing and anchorages, the adjustable slide
anchored in place. The bolts at the lower belt anchor
point (not the retractor) and upper seat belt loop locking of the belt must be checked.
ge
must be tight and still allow the hardware to swivel. - fasten tongue to buckle and adjust by pulling
Anchorage areas must be sound and uncorroded. webbing end at right angle to connector and
buckle
Note - release webbing and pull upward on connector
and buckle
Reinforce bolt mounting area if necessary.
- If slide lock does not hold, remove and replace
seat belt assembly
Color fading
Broken or pulled threads
Bowed webbing
I CAUTION
Always consult with the Parts Department for
I -
Part numbers.
G·14 Vanagon only II From 1986 m.y. ~lth AJC Automatic 3-polnt seat belts,
retrofit installation
68 5 •
68 Body Accessories - Interior
40mm
(1.61n.)
17mm
55mm
(2.11n.) 240 mm (0.71n.) 203 mm
Tapered
60mm
(2.3 ln.)
I ~.': .; (7.01n.) "---------"""l
(~7n~ ~ ~---310
147 mm _ .. ..,I
(5.7 ln.)
mm
(12.1 ln.)
___j
TJ
335 mm
(1 3•1 ln.)
290mm
(11.3 ln.)
~ll
68 •6 Template measurements
Vanagon only II From 1986 m.y. with A/C
Body Accessories - Interior 68
CAUTION
Part numbers are for reference only.
Always check with your Parts
Department for latest information.
Parts required
Part Number Description Quantity
253 857 815D Rear 3-point seat 1
belt (left side)
253 857 816D Rear 3-point seat 1
belt (right side)
Note
Check with your Parts Department for
additional installation parts. Not all parts listed .
may be applicable to all vehicles.
• remove rear seat bottom
• remove existing 2-point left/right side lap
belt
• remove rear floor carpet
• remove right rear luggage area trim panel
. • mark and cut rear luggage area trim panel
using dimensions as shown on page 6 8 • 9
• locate, by feel, threaded hole under D-pillar
trim (arr6w)
• cut hole in trim to expose threaded bolt
hole
iss-Aos21
/
I
203mm
(8 in.)
403 mm
1-4----'-(15 7 / B i n . ) - - - -..\
~-----------569mm--------------~
( 22 318 ln.)·
t Front of vehicle
"\
Parts required
Part Number Description
253 857 811 D 3-point seat belt
(left side)
Note
Check with your Parts Department for
additional installation parts.
• remove rear seat back
• remove rear seat bottom
ii remove original left center belt
• remove rear lett .side_panel trim
• measure location of belt retractor, belt
guide, and mounting holes, using
dimensions on page 6 8 • 12
• cut panel as required
• reinstall trim panel
//
I
• ;install seat belt retractor on outside of
/ panel, as shown
/ • 40 Nm (30 ft lb)
• hand tighten forward bolt only
~~~c:
• 40 Nm (30ft lb)
/
//I jsa-Ao.s41
TOP
67 tnrn
(2 ·518 in.)
I
442 mm
(17-3/8 in.)
31 mm
298 mm
(11-3/4 in.) (1-1/4 in.)
245 mm 327 mm
(9-5/8 in.) (12-7/8 in.) 203 mm
(8-1/8 in.)
216 mm
(8·1/2 in.)
)
-
J G·23 All w/llluminated Vanity Mirrors Illuminated vanity mirrors,
replacing bulbs 68.13
72
Body
Seats
---~
1·5 72.1
72 Body-Seats
H·12
H·13
From 1985 m.y.
Front seat backrest, removing/Installing 72.3
72 Body- Seats
Teflon washer
Spring washer
Pin
F~
Body
Seat Upholstery
1·7 74.1
74 -Seat U
0( ~
' ...... ~2
0 ''~,
0 1
- control unit is identified by number 59 stamped on
the top (as shown)
1 - six cavity electrical plug
Electrical wiring to river's seat 2 - wire to seat element
3 - wire to seatback element
Note 4 -tie wrap
Wiring is taped to floor with fabric tape.
Electrical troubleshooting
For electrical troubleshooting, refer to appropriate
Wiring Diagrams .
·-·~1
. ... -~>>
Interior Panels,
Roof
Index
- Front headliner
installing 75.7a
removing 75.7
- Luggage rack
removing 75.8
- Pop-up roof
installing 75.3
removing 75.2
- Pop-up roof C$11Vas
installing 75.5
removing 75.4
-Pop-up roof seal.
installing 75.6a
removing 75.6
-Roof vent
installing 75.7
removing 75.6a
1.
.,
·.
75.1
75 Interior Panels, Roof
CAUTION
Do not damage inside of roof when swinging
front mattress and board
Note
Pins 10 remain in brackets 11 .
•
-
" j - --
lower roof halfway and loosen bolts (arrows) on -apply 014 sealing com~und to corners of roof
each side reinforcements (arrows) to ensure proper sealing
between canvas and roof
Note - lift pop-up roof with canvas onto vehicle
- let pop-up roof rest at rear of roof
Following procedure requires three mechanics. - keep pop-up roof open at front approximately
- pull pins 10 out of brackets (see 75.2 figure 500 mm (20 ln.) and place linkage into position
75-006)
- remove linkage bolts on each side and tie linkage
together
CAUtiON
Do not damage paint with front support struts
when removing roof
J-3
Pop-up roof, removing/Installing 75.3
75 Interior Panels, Roof
Note
CAunON
Serial no. of camper equipment Is found on I.D. Plate
When loWering top, gather in canvas sides,
at left on rear seat.
making sure that no part of canvas is pinched
between support struts or latch. Grasp lock • with equipment serial no. up to E.OOO 871
cover with both hands and pull down until lock
engages in latch
\
\.
- if necessary realign roof by moving rear linkages
in erongated holes (arrow) and tighten bolts
Note
When canvas must be replaced cut it along vehicle
roof. This ensures easy removal of screws in - remove plastic strip held to wooden frame with
channel. Pop-up roof must be removed to replace staples (arrows)
roof canvas. - pull out staples holding canvas to wooden frame
Note
When removing canvas, save 8x8x10 mm (5/16 x
5/16 x 3/8 in.) wooden blocks for reuse.
- soften plastic strips in warm water before From equipment serial no. E.OOO 872.
installing
I Note
""- Position seams of canvas at left and right edges of
roof, approximately 35 mm (1 3/8 in.) from front
corners.
J-5
Pop-up roof canvas, removing/installing 75.5
75 Interior Panels, Roof
~~~
• seal with cross section B-B is installed on front
edge of pop-up roof
0 --~ "7
- ~ "' ,
' 17s-0391
- bolt canvas to rails and ensure bead 1 is centered
In guide groove 2 of pop-up roof
Note
Bolt rails starting from center and progressing toward
comers.
CAUTION
Part numbers are for reference only. Always
check with your Parts Department for latest
information.
'
- seal weather molding from outside (arrows) with
a suitable transparent silicon adhesive compound
- use sealant on vent mounting bolts 7 also
J ·9
Front headliner, removing/Installing 75.7a
75 Interior Panels, Roof
- pull headliner downward in center and push out of - remove screw (arrow) and end plate 1 from
side retaining rails storage shelf
- remove headliner
I
\
J-11
Luggage rack, removing/installing 75.9
76
Cabinets, Water Tank,
Refrigerator
Index
- Ceiling cabinet · - Storage shelf
with AIC, installing 76.9 removing/installing 76.2
with A/C, removing 76.7 w/curtain rod
without AIC, removing/ removing/installing 76.4
installing 76.6 -Water faucet w/pump switch
- Clothes closet removing/installing 76.17
installing 76.11, 76.14 - Water level sensor
removing 76.9, 76.11 removing/installing 76.20
-Curtains - Water pump, kitchen
curtain rail w/fresh air duct, removing/installing 76.18
installing 76.6
curtain rail w/fresh air duct,
removing 76.5
removing/installing 76.3
- Propane tank
removing/installing 76.23
- Refrigerator
air supply modification 76.25
installing 76.25
removing 76.24
-Sink cabinet
installing 76.23
removing 76.20 ·.,
76.1
76 Cabinets, Water Tank, Refrigerator
CAUTION
CAUTION
Note
Remove storage shelf first see page 76.4.
K-3
Thru 1984 m.y.
Curtains, removlng/lnatalllng 76.3
76 Cabinets, Water Tank, Refrigerator
Note
To prevent damage to front headliner when removing
storage shelf with curtain rail on left side, support
bracket of end plate must be bent slightly downward.
- move storage shelf with curtain rail to the left side
and disconnect wiring connections for passenger
compartment light
- pry off four cover caps and unscrew four screws - insulate battery pos. wire
(arrows· A) · - remove storage shelf with curtain rail
- remove nut (in clothes closet) from bolt (arrow B)
and push out carriage bolt Storage shelf with curtain rail (left),
instalfing
- install in reverse order of removal
K·5 From 1985 m.y. Fresh air duct with curtain rail (right), removing 7 6 •5
76 Cabinets; Water Tank, Refrigerator
lll•••-=::17s-o1o I
- pry off five protective caps and remove screws -remove both nuts (arrowa) of right side brackets
(arrows) holding ceiling cabinet
- carefully pull off right curtain rail
..
]
I
CAUnON
Before working on any part of electrical system,
disconnect battery ground strap.
Into
- remove four screws (arrows) -remove nut and push out carriage bolt (arrow)
from clothes. closet
- carefully lower ceiling cabinet and disconnect left
and .right speaker wires
CAUTION
Disconnect series resistors for evaporator fan
very carefully. If one of the series resistors is
damaged, the entire resistor block must be
replaced.
(j)
CAUTION
Do not damage engine components when
lowering closet into engine compartment.
K·11
Clothes closet, removing/Installing 76.11
76 Cabinets, Water Tank, Refrigerator
' 1
Note
Procedure requires 2 persons.
- remove one screw in lower front area from Clothes closet, Installing
support bracket 1
- remove one nut at support angle and push bolt - install in reverse order
out - swing clothes closet to side, tilt onto engine
- remove two Phillips head screws from engine compartment lid and remove
compartment deck and remove support angle on
floor 2 Clothes closet, removing
Note
With air conditioning, remove ceiling cabinet first, see
76.6.
- K·13
Clothes closet, removing 7 6.13
76 Cabinets, Water Tank, Refrigerator
...,.- remove support bracket In left front 5 and support - remove two evaporator mounting screws (arrows)
bracket In left and right rear 6 from rear bed
board Note
- loosen stop for bench seat and pull bench seat This procedure may require a second technician to
with backrest forward approximately tO em (4 ln.) support evaporator and wiring hamess 7.
CAUTION
Wear protective gloves when holding
evapOrator.
K·15
Storage chest with water tank, removing 16 .15
76 Cabinets, Water Tank, Refrigerator
~-----
. ./
'
-remove four screws (arrows) from socket mount - unscrew two screws and remove cover plate 8
- remove socket housing, tilt 90" backward and
push back into recess
'··I
(@
- remove three bolts from sink cabinet (arrowa) - remove plastic nut 1 and pull off with spacer 2
- lift chest with water tank approximately 10 em
(4 in.) and pull out
Note
Do not cross 12 V DC wire connections. Pump works
- open left lid of chest and remove cover, two
in one direction only.
screws (arrows)
K·19
Water pump (kitchen), removing/Installing 76.19
76 Cabinets, Water Tank, Refrigerator
- remove table leg and top 5 from mount 6 - remove drain hose 13 at bottom
- remove table mount 6, four screws (arrows) - remove four clamps arrows
~
•
If
{ (E) ;-1 =
0 !---
Jl lfi'''•=Jjr
([) 7~\
:::::::;
'P
'-' _J I 1~ \-
:=:d
::l.
.
~"::::
(~
"./~II
8 ln~1ol
- remove retainer strap for sink cabinet door 7 -disconnect gas lines at union nuts 14 and remove
- unhinge refrigerator door 8 and sink cabinet door 9
- remove drawer 10
r
llllllllllllll r;_ -~~"
0
,, ~
!l 1~
~2
[[[[[Jl ~ ~n
\.. Jt
0
0
J~ J ln~711
- remove water hose 15 from faucet
- remove hose clamp from valve 16 and disconnect
- remove shelf 11 and water pump cover 12
hose
K·21
Sink cabinet, removing 7 6 •21
76 Cabinets, Water Tank, Refrigerator
'
- remove bolt (arrow) from floor bracket
-lift sink cabinet and refrigerator over floor stud,
towards center of vehicle
WARNING
If propane gas lines are opened during repair
work, a pressurized leak test must be
performed, prior to returning the vehicle to
service. Use soap water or equivalent to check
all fittings.
WARNING
Always replace self-locking nuts. After installing
gas lines, check all fittings for leaks. Apply
soap solution to joints and watch for bubbles
with lines under pressure.
WARNING
During repair work on any part of electrical
system, the electrical hook-up for 110/220 volt
power source must be disconnected.
K·23
Deluxe Sink cabinet, removing/Installing
Propane tank, removing/Installing ·
76 •23
76 Cabinets, Water Tank, Refrigerator
Refrigerator, removing
WARNING
During repair work on any part of electrical
system, the electrical hook-up for 110/220 voH
power source must be disconnected.
WARNING
Fire hazard! Do not smoke or have anything in
area that can ignite propane fuel. Ensure
adequate ventilation.
CAUTION
Before working on any part of electrical
system, disconnect battery ground strap.
- remove screws (arrows) and remove vent cover 4
- remove cabinet doors and drawer -remove plug 5 for 110 volt AC supply
- remove shelf - disconnect connector 6 for refrigerator
- place wiring harness on top of refrigerator
- I - disconnect gas pipe 7
-remove both screws·(arrows)
1/
- remove strap 3
- remove cabinet and refrigerator doors
- remove drawer
- remove shelf 4 - remove shelf in storage chest and screws
(arrows)
7 6 •2 4 Refrigerator, removing
Deluxe
Cabinets, Water Tank, Refrigerator 76
Refrigerator air supply modification
(Dometic 182 models)
Note
When troubleshooting ignition problems on the
refrigerator unit, verify spark and fuel are adequate
prior to performing air supply modification
J
- remove plugs 8 in cover plate 9 and remove
] -
Note
screws
remove cover plate 9 by pulling lower part forward
(arrow A) and then to side (arrow B)
remove refrigerator
176-A020 I
Refrigerator, Installing
- install in reverse order
Air pump Installed (arrow)
] WARNING
After installing gas lines, check all fittings for
leaks. Apply soap solution to joints and watch
for bubbles with lines under pressure.
176-A021 I
Air pump removed (arrow)
\
1
l·3
Refrigerator, removing/Installing •
Deluxe Refrigerator air
pump modification 76 25
76 Cabinets, Water Tank, Refrigerator
Air Pump
176·A022j 176-A024j
17e-A0251
- drill out air outlet (arrow) of pump housing, using
a #40 drill bit (3.54mm, approximately 9/64 in.) - install 0-ring
• 0-ring may be obtained at local hardware or
auto supply store
- reassemble air pump piston
assembly with circlip in groove approximately mid-
shaft !arrow)
- reassemble air pump
Air Pump
Tie Wrap
176·A020 I
- remove existing plastic air supply line (left arrow) - install replacement one-way valve between two
with one-way check valve and discard lengths of 4mm (approximately 5/32 in.) ID x
- reinstall air pump (right arrow) 65mm .(2.5 in.) long, surgical tubing or equivalent,
(arrows)
CAUTION
Part numbers are for reference only. Always
check with your Parts Department for latest
information.
l 7s.A0291
-secure replacement check valve to ignitor with tie-
wrap (arrow)
17&-A0271
CAUTION
To avoid pinching ignitor wire when reinstalling
assembly, secure wire with tie wrap to rear of
CAUTION unit.
Be careful not to puncture one way valve
diaphragm
Seats, Bed
Index
- Rear seat with storage locker
removing/installing 77.2
- Roof bed, boards
removing/installing 77.3
77.1
77 Seats, Beds
CAUTION
-pry off caps (arrows), remove screws, and Circuit breaker can be easily damaged.
cover 2
Rear seat, with storage locker,
installing
- install in reverse order with the following
- check seat mechanism for proper function
Note
Up to model year 1984.
Before bed boards can be removed, storage pan,
wall cabinet and clothes closet must be dismantled,
see repair group 76.
-remove roof-bed board screws (arrows)
- Loosen left headliner and remove from retaining
rails. See "removal of right air duct, Repair Group
76
Note
From model year 1985.
Before bed boards can be removed, storage pan
with curtain molding, left, cover with curtain molding,
right, wall cabinet and clothes closet must be
dismantled, see repair group 76.
L·B
Roof bed, removing/installing 77.3
80
Heater
Ventilation
A-1 80.1
80 Heater and Ventilation
Heater vent
age 80.7
Note
Heater control tlap outer cable is pressed
in guide sleeve
ushing
welded to frame
;-----Outlet gasket
glue to ventilation chamber
with 0 17
~----Trim plate
ply off dashboard
with screwdriver
Heater/Ventilation controls,
installing/adjusting cables
Work sequence
-install controls
-install trim plate
- press on levers
- loosen two heater control flap cables at
heater control flaps
- go to next page
80 6•
Heater/Ventilation
controls
IAir-cooled without Fresh Air Fan I
Heater and Ventilation 80
Ieo-ml
- hook inner cable for warm air distributor
(passenger compartment) in upper control
lever
leo-2231
- push control lever on warm air distributor
(driver's compartment) in direction of arrow
and hold in position
Heeter outlet
Heater outlet
removing: press in two lugs (arrows)
removing: press in two lugs
below dash
below dash
installing: left and right outlets are
installing: left and right outlets are
different; note part numbers
different; note part numbers
.:; r
Outlet gasket
glue to ventilation chamber
with D 17
Air deflector
80-261
n plate
off dash with
lwdriver
ver
II off
Jls
:ables,
A·9
Air-cooled with Fresh Air Fan Heater /Ventilation controls,
installing 1adjusting cables 80.9
80 Heater and Ventilation
Defroster flap
/ Series resistance
... I
~
when installing.
to avoid leaks
I
1\
_ / ~)
/
Housing cover_/
engage lugs and slots
properly when assembling
lso-262!
Heater/ventilation
with fresh air fan
disassembly/assembly, page 80.12 Control vaive
removing/installing, page 80.12
A-11
All Water-cooled HeaterNentilation/Heater Exchanger
System components
80 .11
80 Heater and Ventilation
/-to~~., pump
closed
from cylinder head
I so-2ssl
A-13
··12
All Water-cooled Heater / Ventilation controls,
lnstaUing/adjusUng cables 80.13
80 Heater and Ventilation
Defroster flap
Housing cover _ /
engage lugs and slots
properly when assembling
* Note
Seal the locating grooves in upper and
lower part of housing with sealing
compound, Part No. AMV 176 00 05
CAUTION
Part numbers are for reference only. Always
check with your Parts Department for latest
parts information.
A·14
A-15
Water-Cooled From 1986 Heater/fresh air box housing,
splitting
8o.15
80 Heater and Ventilation
~--1
10
t 2
;
4
1 1
8·1 82.1
82 Heater Booster
Temperature sensor
checking Fig. 14
Glow/spark plug
checking Fig. 2
replacing Fig. 3
Heater relay------~
with 1 ohm resistor for air
circulation blower
Main fuse
16A
Heater blower
(on alternator)
removing/installing
see Repair
relay panel
Group 27
Heat exchanger
Temperature regulating
switch Exhaust pipe
checking Fig. 12 clean or replace if necessary
replacing Fig. 13
Combustion air blower
checking Fig. 4
replacing Fig. 5 and Fig. 6 Combustion air hose
must fit tightly on blower
ls~-170A I
11er
Jr)
stalling
ia2-118l
Fig. 7 Overheat switch, checking
(switch installed)
- remove ceramic ring 1 first
- turn heater on (engine not running)
• heater must start working within
70 seconds
CAUTION I an i
Do not bend sensor tube Fig. 13 Temperature regulating switch, replacing
CAUTION
Disconnect battery ground strap before
starting to work
I 82-014A I
Fig. 14 Temperature sensor, checking Fig. 16 Fuel pump, adjusting
-place in warm water (60.C/140.F) • to increase amount of delivery:
• resistance: 3500-5000 ohms turn hose adaptor C in direction of
arrow B
• to decrease amount of delivery:
turn hose adaptor C in direction of
arrow A
- lock and seal with paint after
adjustment
WARNING
Fire hazard! Do not smoke or have anything
in area that can ignite fuel
Fig. 17 Ignition coil, connections
Note
To count 200 strokes write down number every
10 strokes.
If delivery rate is not correct, adjust fuel pump
per Fig. 16
Temperature sensor
Air-cooled AFC
82.6 Fuel pump
Ignition coil
8·6
Heater Booster 82
ls2- 193A f
Fig. 19 Defrosterlfootwell flap, checking
-check flap (arrow) for free movement
Fig. 22 Safety switch, checking
(switch removed)
CAUTION
Disconnect battery ground strap.
Temperature regulation switch will be
damaged if disconnected wires touch one
another or ground
Air cooled-AFC
Defroster/footwall flap
Air circulation blower
Safety switch
82 7
•
~-6
82 Heater Booster
182 -190)
Safety switch
8·9 82.9
82 Heater Booster
2b 5 6 21 8 9 11 12 13 1~
1 2a 19 3 20 7 15 16
Overheat switch 9 has operated and fuse 26 (8 A) has blown Temperature ~gulating switch 3 ON
Heater lever switch 5 ON
Air circulation blower does not run at two speeds Temperature regulating switch 3 ON
Heater lever switch 5 ON
Ignition turn ON and OFF
Heater output inadequate and/or heater uses too much fuel Engine running; heater turned ON
Note
At least 10 volts required for voltage check at flame switch
Relays
Air circulation
Temperature regulating blower relay
switch
checking Fig. 11
replacing Fig. 12
Fuel pumps--......,.
checking Fig. 14
Fuse panel
Glow/spark plug
heater wiring is connected
checking Fig. 2
to 7th and 10th fuse holders
Combustion air blower Overheat switch
checking Fig. 4 checking Fig. 7
replacing Fig. 3 and Fig. 6 replacing Fig. 8
Combustion air valve
removing Fig. 3
checking Fig. 5
h
ver
--Heater housing
checking Fig. 1
8·13
All Water-cooled
Heater booster/components 82.13
82 Heater Booster
+ 15
- 31
Fig. 2 Glow/spark plug, checking
1 = high tension terminal
2 = glow element terminal
3 = ground terminal
Fig. 5 Combustion air valve, checking
• electrode gap a : 2.5 mm (3/32 in.)
• voltage : 12volts -connect ground wire to terminal 31
• resistance : 4000-6000 ohms -connect hot wire to terminal 15
• current draw of : 9A at 11V • air intake valve must open
glow element - press valve plate against stop
• check for current flow between ter-
See page 82.14a for additional information minals 15 and 15a
la2-316l .
8·15
New style glow plug 82.14a
Heater Booster 82
~- ~..... -~
...... ~ :~
.,
c
~
.-- /
'·
..
I
/
[~
Fig. 9 Flame switch, checking
(switch installed)
Fig. 7 Overheat switch, checking
-turn heater ON
-turn heater ON and select highest
• heater must ignite within 100
heating
seconds at 20 "C/68 "F
-wait until blowers run at highest speed
(flame switch has cut off glow plug) -turn heater OFF
-disconnect air circulation blower • run -on time must be approx. 180
(arrow) seconds at 20"C/68"F
If NO for either condition, replace flame
-wait for 90 seconds and reconnect air
switch
circulation blower
• if fuel pump starts running, overheat
switch is OK
• if fuel pump does not start running
within 90 seconds, overheat fuse is
blown
-replace overheat switch
Flame switch
Fuel pump
B-18
All Water-cooled Ignition coil
Air circulation blower/Control valve 82.17
82 Heater Booster
Troubleshooting Main fuse 16A
(in fuse panel)
Temperature---
regulating switch
Note
At least 10.3 volts required for voltage check at flame switch
B-19
82.18 Troubleshooting
All Water-cooled
1:111 D!>O~
Trouble caused by
~ II II II~
0 0 main fuse (16 A) OOZIQ.
~ 9.!0" (II
0 !> 0 0 overheat fuse (8 A) C.(l):::ra.
oo.:C:<ll
D !> 0 0 !> 0 temperature regulating switch 3-o-o5
D !> 0 !> !> control unit ao;-
CTCTa.
IUIII<ll
D 0 relays for: • glow/spark plug resistor ~~(C)
<1l <1l a;
D 0 D • flame switch <1l
D 0 heater housing
0 0 0 !> flame switch
;e: D D !> air injector
0 !> air circulation blower
~
CD D 0 exhaust pipe
"';'
D fuel pump (small delivery quantity)
8 D fuel pump (large delivery quantity)
& !> 0 \, combustion air valve
0 !> I
combustion air blower
~ D fuel injection connection
g !> ignition coil ::1:
CD
!> 0 check valve
0 fuel filter
aCD
0
I
i
!> 0
combustion air hose
.
m
footwell outlet
!> 0 0 0
CD troubleshoot according to current flow diagram 0
1\)
• ;..
CD
....c.o
1\)
82 Heater Booster
Auxiliary heater BBW 46
This heater is offered as optional equipment on
Vanagon Syncro models only sold in Canada.
Felt pad---'"'
removing, Fig. 1
repairing, Fig. 2
installing, Fig. 4
Felt pad -----..
,
.... ......
...........
"'\
I
.....
I
removing, Fig. 1 I I
repairing, Fig. 3 I I Flame tip-----.
I I removing, Fig. 16
Installing, Fig. 4
I I installing, Fig. 17
I I
I I
I I
......... !,..
":.....
.................
........... ....,.,,,...,,"7\,>.
Cover
Tension spring-----'
Metering pump
checking pump capacity, Figs. 20
and 21
82.20 Components
Auxiliary heater BBW 46
Heater Booster 82
Cap
Temperature sensor
removing, Fig. 8
installing, Fig. 9
'-----Overheating fuse
removing/installing, Fig. 10
checking, Fig. 10
Series resistance
removing/installing. Fig. 11
Q..rlng
Circulation pump
removing/installing, Fig. 12
CAUTION
Coolant/antifreeze must not be reused when
replacing engine, cylinder head, cylinder head
gasket. radiator and heater core.
-
Auxiliary heater BBW 46
Compof'181lts 82.21
82 Heater Booster
Water flow through heater system
~~~~~~~rrn~rrnnTrrnTrrnnTITnn
Coolant
distributor
t t
' - - - - Monovalve
closed when coolant
Auxiliary temperature is
heater BBW 46 below ss•c (131.F)
Bleeder valve
82.22 Waterflow
Auxiliary heater BBW 46
Heater Booster 82
-
82.23
82 Heater Booster
Materlng pump
in front of left rear wheel
Monovalve
in engine compartment, right side
Pre-selecting time for heat operation Auxiliary heater BBW 46, operation
A specific time to start heating may be selected up to
24 hours in advance.
Note
If a flame does not occur during the pre-glowing and
safety period,
• a new pre-glow period (approximately 30
seconds) and safety period (approximately 90
seconds) are started automatically
• temperature sensor resistance increases as • Auxiliary Heater Control Unit switches back to
temperature rises ~- full load operation
• Metering Pump operates at full capacity
• Monovalve separates Auxiliary Heater water
circulation from circulation of engine coolant up
Regulation pause
to temperature of 55°C (131°F) if Auxiliary
Heater and vehicle engine operate If water circulation temperature should rise above
simultaneously 85°C (185°F) during partial load operation, the
Auxiliary Heater Control Unit does the following:
When water temperature reaches 55°C (131°F) the
Auxiliary Heater Control Unit begins to regulate • shuts Metering Pump OFF
heater operation.
After Flame Switch cools,
• after-run period begins
Vehicle fresh air/warm air operation
When water circulation temperature rises above 55°C After-run operation
(131°F), voltage is supplied to terminal T6/6 of
Auxiliary Heater Control Unit. After-run operation serves to end the combustion
operation in an orderly manner. After the flame is
• Heater Fan Relay and Fresh Air Fan Relay extinguished,
contacts close and Warm Air Blower and Fresh
Air Fan operate • Flame Detector indicates "dark"
• Fresh Air and Warm Air Blowers continue to
When water circulation temperature falls below 50°C run
(92°F), • Combustion Air Blower runs at full load for
approximately 60 seconds
• Heater Fan Relay and Fresh Air Fan Relay
contacts open and operation of fans stops
Note
Partial load operation The after-run period is always approximately 60
seconds long. It is not shortened by a shut down or
When water circulation temperature rises above aooc rapid reduction of temperature.
(176°F),
• current to Combustion Air Blower goes through Starting Auxiliary Heater after a regulation pause
resistor and blower speed decreases
If the temperature drops below 80°C (176°F) during a
• Metering Pump output decreases by 50%
regulation pause,
• a new start procedure is automatically begun
When Flame Detector indicates "light,"
• C011Jbustion operation begins at full load and
switches to partial load operation when the
temperature rises above 80°C (176°F)
8 7
9 6
5
10 1
Note
Auxiliary Heater can always be shut OFF (even if the
Flame Detector switch is defective.) If the Flame
SWitch does not signal "dark" 80 seconds after shut
down, a forced shut down and after-run period will
occur.
To reactivate Auxiliary Heater,
- switch Auxiliary Heater OFF
- wait one minute
- switch Auxiliary Heater ON
Fig. 1 Felt pad, removing Fig. 3 Felt pad, servicing (Diesel heaters)
Note
0-rings A and B must be replaced after each
disassembly. Fig. 4 Felt pad, Installing
Do NOT glue pad C into place. - slide assembly in noting position of lug B
- insert assembly with felt pad into Heater until
recesses in ring fit together with tabs on Heater
II
Fig. 6 Flame Switch, removing/installing
Removing
- remove oval-head screw
- pull Flame Switch out
- remove wires
Installing
- slide 0-ring on to tip of Flame Switch at 1
- install oval head screw
- install wire
CAUTION
Do not reverse polarity of Flame Switch wires.
0
Fig 10. Fuse 824, removing/installing
CAUTION
CAUTION Before removing Fuse S24, open cap on
engine coolant expansion tank to relieve
Before removing Temperature Sensor, open
pressure on engine cooling system.
cap on engine coolant expansion tank to
relieve pressure on engine cooling system.
disconnect wires from fuse
- unscrew fuse
-remove wires from Temperature Sensor
- check fuse for continuity with ohmmeter
-unscrew Temperature Sensor
• 30 Nm (22.0 ft lb)
Note
Fuse S24 is installed and tightened by hand. Make
sure that the fuse point contacts the Heater tube.
1750
Cl
T
0::
1000
750
v
v
500
-40 0 40 80 120
V•(°C) ja2-281 I
Fig. 9 Temperature Sensor, checking
C·13
Auxiliary heater BBW 46
Temperature sensor, removing/installing
Temperature sensor, checking
Fuse 824, removing/Installing
82 31 •
82 Heater Booster /
Installing
- insert Recirculation Pump slanted connection into
Heater Core
- install clamp
Note
Do not reverse wires for Recirculation Pump or it will
run in the wrong direction.
CAUTION
Before removing series resistance, open cap
on engine coolant expansion tank to relieve
pressure on engine cooling system.
1 B
Series resistor,
6 ,_.)
Fig. 17 Flame head, Installing
CAUTION
Before removing Temperature Sensor and
Fuse S24, open cap on engine coolant
expansion tank to relieve pressure on engine
cooling system.
Fig. 16 Flame head, removing
-remove Temperature Sensor and Fuse S24
- remove Flame Head
CAUTION - insert two screwdrivers into recesses and pry
Flame Head out
Before removing Flame head, open cap on - clean combustion residue off with water spray and
engine coolant expansion tank to relieve brush
pressure on engine cooling system.
Supply
Volume
I
I
+ - - -1--t--1--±:---±--+
9 10 11
Voltage
Fig. 20 Metering Pump, checking flow rate - close hose 1 from radiator to thermostat with hose
clamp
- remove connector to glow plug - close hose 2 from heat exchanger to coolant pipe
- remove fuel feed hose from heater and with hose clamp
place open end in measuring glass
- connect voltmeter between contacts
T2a/2 and T6/4 of Auxiliary Heater
Control Unit
- switch Auxiliary Heater ON
• after 90 seconds Auxiliary Heater
switches OFF
• automatic re-start begins
- switch Auxiliary Heater ON again
- measure fuel volume after two 90 minute
periods and compare voltage and
volume with graph
For example,
If voltage measured at Auxiliary Heater is 12.0V,
Then, volume output must fall between
-loosen hose clamp 1, close hose 2 from radiator
approximately 29ml and 35ml after two 90 minute
to distribution piece with hose clamp
measuring periods.
- close hose 3 from heat exchanger to distribution
piece with hose clamp
Engine coolan·t system, draining/ -drain coolant at drain plugs (Fig. 1)
refilling - open coolant expansion tank cap
CAUTION CAUTION
Use coolant Part No. ZVW 237 102 which has Coolant/antifreeze must not be reused when
corrosion inhibiting agents especially replacing engine, cylinder head, cylinder head
formulated to prevent corrosion damage to the gasket, radiator and heater core.
water jacket sealing surfaces of the cylinder
head.
Anti-freeze other than specified by Volkswagen
may cause corrosion of the cooling system
thus leading to engine overheating and
damage.
Refilling
Coolant mixture ratio
• coolant capacity 17.5 ltr (18.4 US qt)
Note
Cooling system is filled at factory with mixture of
water and antifreeze/corrosion protective solution.
Coolant mixture should be used all year.
When replacing coolant only use ethylene glycol
based antifreeze (phosphate-free).
Due to higher boiling point, coolant is an aid to
operating on full load, particularly in warm climates
Outside temperature Antifreeze Water - open bleeder valve in engine
compartment
-25°C (-13°F) 7.0 ltr 10.5 ltr
A= open
(7.4 us qt) (11 us qt)
B =closed
8.75 ltr 8.75 ltr
(9.2 us qt) (9.2 us qt)
min.
Air Conditioner
Index
- A/C adapter valve VAG 1637
installing 87.15
- A/C components
locations 87.2
- A/C compressor (Sanden SD51 0)
replacing 87.16
- A/C evaporator
removing/installing 87.14
- AIC evaporator housing
assembling/disassembling 87.12
removing 87.10
- Air distribution system
components 87.9
outlets, removing 87.13
- Expansion valve
removing/installing 87.14
\
-Fuses
locations 87.4
- Refrigerant system
capacity 87.7
cautions and warnings 87.7
controls 87.6
discharging 87.8
-Relays
locations 87.5
87.1
87 Air Conditioner
r=-:~~~~'~0~-15
'--"---L---14
1 87-882 1
3 15
,.....----1
187-8971
Note
As of the 1987 Model Year, the A/C refrigerant
high pressure service valve was changed.
Components
Fuse locations
19 20 21 22 23 24
13 14 15 16 17 18
ls7-ooea I
"
,.- ...... .
'
-
Refrigerant oil
eevaporator 2.02 oz
eaccumulator 0.3 oz
•high pressure hose 0.3 oz
low pressure hose o.3 oz
•compressor 5.07 oz
WARNING CAUTION
Always wear safety goggles when charging or Discharge refrigerant from system when it is
discharging system. necessary to weld near refrigerant hoses with
arc or resistance welding systems. During
Be sure work area is well ventilated. R-12 is electrical welding process invisible ultraviolet
heavier than air and can accumulate in areas
rays are given off which penetrate refrigerant
of poor air circulation.
hoses and decompose refrigerant
Avoid inhaling fumes when using flame-type
leak detector. R-12 becomes poisonous gas
Note
after coming into contact with open flame
Plug all openings in system when removing/replacing
parts. This prevents entry of dirt and moisture which
CAUTION may foul system.
Always discharge refrigerant from air
Drops of moisture may cause expansion valve to ice
conditioner system before loosening
up, blocking refrigerant flow and stopping cooling
connections, hoses, etc.
action
High pressure
CAUTION
Discharge AJC refrigerant system slowly to
prevent loss of refrigerant oil
I87·A1131
- close both valves on AJC manifold gauge set
WARNING
Always wear safety goggles when charging or
discharging system. Be sure work area is well
ventilated. Refrigerant-12 is heavier than air
and can accumulate in areas of poor air
circulation.
Avoid inhaling fumes when using flame type
leak detector. Refrigerant-12 becomes
poisonous gas after coming into contact with
open flame.
Evaporator housing---~
Evaporator-----~
Front housing
ls7-A1osl
CAUTION
Before starting to work on any part of electrical
system, disconnect battery ground strap
Note
It is possible to lower A/C evaporator housing without
discharging A/C refrigerant system.
- remove center air duct attaching screws (arrows)
Discharge A/C refrigerant only when replacing parts - remove center air duct
in refrigerant system.
f•uml!m' ImmvrmB
187-A1061 187-A1ool
-remove rear air duct attaching screws (arrows)
- remove sunvisors and sunvisor retaining clips - remove rear air duct
- remove front housing attaching screws (arrows)
- lower front housing and front air duct
more
- disconnect wiring connectors to A/C switches
- remove front housing and front air duct
ja7·A111 I
-remove left side rear trim panel screws (arrows) - support evaporator housing with universal lift
- remove trim panel crane
- remove left side evaporator housing attaching
bolts (arrows)
.... =-
Evaporator housing
(lower half)
-see Note on page 87.13
Radio speaker
/
87.12 A/C evaporator housing
From 1986 /
87
-
r
Je7-A11sl
CAUTION
Before starting to work on any part of electrical
system disconnect battery ground strap
CAUTION
Always replace O·rings when replacing AIC
refrigerant components.
Coat 0-rings lightly with refrigerant oil before
assembly
Installation position
1 - AIC high pressure line
2 - AIC high pressure service valve
(3/8" - 24 UNF)
3 - Adaptor valve VAG 1637
4 - Service hose (to pressure gauge set)
-install adaptor valve VAG 1637 onto AIC high
pressure service valve
- install A!C service hose onto adaptor valve
VAG 1637
Adaptor valve VAG 1637
1 - Schrader valve
2-Adaptor
3 - Valve opener
4 - Sealing gasket
-
0·15
From 1988
A/C adaptor valve VAG 1637, Installing 87.15
87 Air Conditioner
Ie7-952a I
Fig. 1 AIC compressor SD 510 factory
6
Installation
1e7-952b 1
87.16 AICcompressor(SandenSD510),replacing
90
-
Electrical System-
Instruments,, Radio
Index
1980-1984 From1985 From1990
- Cigarette lighter - Cigarette lighter - Heidelberg VI fixed coded radio
replacing 90.31 replacing 90.31 coding a new or remanufactured
-Fuel gauge - Coolant temperature gauge radio 90.32
checking 90.5, 90.9 locating 90.14 reactivating radio after
troubleshooting 90.13 troubleshooting 90.21 reconnecting power 90.33
- Fuel gauge sender - Dynamic oil pressure system unlocking an electronically
removing/installing 90.11 assembly 90.22 controlled radio 90.34
- Instrument cluster removing/installing 90.23
assembling/disassembling troubleshooting 90.24
90.2, 90.6 -Fuel gauge
removing/installing 90.10 locating 90.14
- Light emitting diodes (LED) troubleshooting 90.20
checking 90.5 - Instrument cluster
identifying 90.4, 90.8 assembling/disassembling 90.14
- Muhi-point connector removing/installing 90.10
identifying 90.4, 90.8 -Light emitting diodes (LED)
- Speedometer checking 90.19
calibration 90.30 identifying 90.18
- Speedometer cable - Multi-point connector
removing/installing 90.1 o identifying 90.18
-Voltage stabilizer 90.4, 90.8 - Speedometer
calibration 90.30
- Speedometer cable
installing (from VIN
25 H 040 185)
except Syncro 90.17 ·.
removing/installing 90.17
- Voltage stabilizer
checking 90.18
90.1
-
90 Electrical System-Instruments, Radio
CAUTION
Before starting to work on any part of
electrical system, disconnect battery
Printed circuit foil
ground strap use ohmmeter to check conductors
for continuity
connect ions on multipoint connector Fig. 1
Note identification of LED's! resistors on
printed foil Fig . 4
To replace printed circuit LED's/ bulb, first
checking LED's Fig. 6
remove warning light housing replacing LED's Fig . 7
Voltage stabilizer
LED--------------~
checking Fig . 2
identification of LED's! resistors
on printed circuit foil , Fig. 4
checking Fig. 6
replacing Fig. 7
polarity Fig. 8
Speedometer - - - - - - - - - - , .
cable, removing/installing page 90.10
Plastic clip
for mounting clock
positive ( + ) terminal
gauge
Instrument cluster - - - checking Fig . 5
removing/i nstalling page 90.1 0 removing/install ing sender, page 90.11
troubleshooting , page 90.13
E·2
90.2 Instrument cluster with clock USA I ,L-_19_8_0 -_19
_8_4 __,
Electrical System-Instruments, Radio 90
Note
CAUTION
To replace printed circuit LED's/bulb, first
remove warning light housing Before starting to work on any part of
electrical system, disconnect battery
ground strap
Instrument cluster------..
removing/Installing page 90.10
ousing
clock
erminal
LED------"
g plate identification of LED's/resistors
on printed circuit foil Fig. 4
checking Fig. 6
replacing Fig. 7
polarity Fig. 8
e 90.11
Fuel gauge retaining plate
-------J
Printed circuit foil
use ohmmeter to check conductors
for continuity
connections on multipoint connector Fig. 1
identification of LED's/resistors on Warning housing mounting plate
printed foil, Fig. 4 pry off carefully to prevent
checking LED's (=ig. 6 damage to printed circuit foil
replacing LED's Fig. 7
E·3
E·2
1980-1984 I I USA Instrument cluster without clock 90.3
90 Electrical System-Instruments, Radio
E·S
1980-1984 I I USA Fuel gauge
Light emitting diode
90 5
•
90 Electrical System-Instruments, Radio
CAUTION
Before starting to work on any part of
electrical system, disconnect battery
ground strap
Printed circuit foil
use ohmmeter to check conductors
Note for continuity
connections on multipoint connector Fig. 1
To replace printed circuit LED's/bulb, first
identification of LED's! resistors on
remove warning light housing printed foil, Fig. 4
checking LED's Fig. 6
replacing LED's Fig. 7
Voltage stabilizer
LED----------------, checking Fig. 2
identification of LED's/resistors
on printed circuit foil, Fig. 4
checking Fig. 6
replacing Fig. 7
polarity Fig. 8
Speedometer--------.......
cable, removing/installing page 90.10
Plastic clip
for mounting clock
positive (+)terminal
Clock
termil)al connections Fig. 3
Fuel gauge
Instrument cluster
checking Fig. 5
removing/installing page 90.10
removing/installing sender, page 90.11
troubleshooting, page 90.13
Instrument c l u s t e r - - - - -
removing/installing page 90.10
Warning light housing
~lnokumeol
Illumination
~k
jnal Fuel gauge-----~
checking Fig. 5 y ·
"•'
removing/installing fuel gauge
; Fig . 3 sender, page 90.11
troubleshoot ing, page 90.13
plate LEO-------"
ident ification of LED's/resistors
on prir)ted circuit foil Fig . 4
checking bulbs/LED's Fig. 6
replacing Li:D's Fig. 7
polarity of LED's Fig . 8
! 90.11
Retaining plate for fuel gauge
E·6
E-7
1980-1984 I I Canada Instrument cluster without clock 90.7
90 Electrical System-Instruments, Radio
e
Fig. 6 Bulb/LED's, checking
-connect battery positive lead to LED
K1 (+)
- connect negative battery lead to LED Fig. 9 Bulb In warning light housing, Installing
K1 (-)
- press blue bulb through slot into
-repeat this test step consecutively on
guide with screwdriver
remaining LED's
• bulb must be heard to engage (LED's
• warning lights must light
slide freely into gUide)
!7
Speedometer cable,
removing/Installing
- put fingers Into recesses (arrows) and pull up
cluster cover Work sequence
Removing
-disconnect battery ground strap
- disconnect speedometer cable
-remove spare tire
USA only
E·10
CAUTION
To avoid premature cable failure, position
cable so It is free of strain or sharp bends.
Do not grease connection to speedometer;
this could cause needle to stick
E·10
E·11
1980-1984 Speedometer cable
Fuel gauge sender
90....I 1
1
(
Installing
[ 90·
E·12
90.12 Fuel gauge sender
1980-1984
Electrical System-Instruments, Radio 90
Fuel gauge, troubleshooting
Work sequence
E-12 E-13
1980-1984
Fuel gauge 90.13
90 Electrical System-Instruments, Radio
Voltage stabilizer
checking- Fig. 2
LED's - - - - - - - - - . .
identification Fig. 4
checking Fig. 5, Fig. 6
Speedometer---------.......
removing/installing pg. 90.15-90.17
Tachometer
Mounting plate
for fuel gauge and
coolant temperature indicator
Fuel gauge
checking 90.20
removing / installing sender 90.11
Instrument cluster - - - - '
removing and installing pg. 90.15
CAUTION
Before starting to work on any part of the
electrical system, disconnect battery ground
strap
Work sequence
Removing
~ disconnect battery ground strap
Speedometer cable,
removing/Installing
Work sequence
Removing
- dlsconr:~ect battery ground strap
- disconnect speedometer cable
- remove spare tire
- put fingers into recesses (arrows) and pull up
cluster cover
USA only
t.1
E·15
Water-cooled from 1985 Instrument cluster
Speedometer cable 90.15
90 Electrical System-Instruments, Radio
-remove nut from bracket (arrow) - when Installing cable, align marks (arrows) on
cable
- after Installing circllp on speedometer cable end,
seal with silicone seal
CAUTION
To avoid premature cable failure, position
cable so it is free of strain or sharp bends.
Do not grease connection to speedometer;
this could cause needle to stick.
more
~0-7891
E·17
Water-cooled from 1985
Speedometer cable 90.17
90 Electrical System-Instruments, Radio
K2 K3
K29
Multi-point connector
Fig. 5 LED's, checking Fig. 7 Digital clock (LED quartz clock), replacing
- connect battery positive lead to LED - remove mounting screws (arrows)
K1 ( +) - remove clock light (A)
- connect negative battery lead to LED
- remove connector
K1 (- ).
- remove digital clock
- repeat this test step consecutively on
remaining LED's
• LED's must light
CAUTION
When replacing LED's do not reverse polarity
E-19
Water-cooled from 1985
LED's 90.19
90 Electrical System-Instruments, Radio
I
- remove instrument cluster
- check output voltage of stabilizer
• should be 9.5-10.5 V
Voltage not OK I Voltage OK
!
- replace voltage stabilizer I I - replace fuel gauge
! 1
I End I r End I
II
190-3181
I ~
- replace defective sensor I voltage stabilizer or display instrument
L defective
] no voltage
or under 9.5 V I voltage
9.5-10.5 v
E-21
Water-cooled from 1985
Temperature gauge 90.21
90 Electrical System-Instruments, Radio
Ill
E-23
Water-cooled from 1986
Dynamic oil pressure system 90.23
90 Electrical System-Instruments, Radio
System operation
connected to ground
engine running more than 2000 rpm - LED must flash
• wire on 0.9 bar oil pressure switch pulled off but - buzzer must sound
not connected to ground
Note
If system is still not operating properly, check by
Troubleshooting
Troubleshooting
Dynamic oil-pressure system light (LED) does not
flash when ignition Is switched ON
check these first:
• flashing LED (red) for fuel gauge and coolant
temperature gauge is OK
- go to next page
®
Go To
@
NEXT PAGE
f·3
Water-cooled from 1986 Dynamic oil pressure system,
troubleshooting 90.25
90 Electrical System-Instruments, Radio
END
- check wiring to
dashboard Insert
I END
wiring to
instrument cluster
I continued at
page 90.28
® on
OK
I END
I continued at
page 90.28
@ on
I
F·5
Water-cooled from 1986 Dynamic oil pressure system,
troubleshooting 90.27
90 Electrical System-Instruments, Radio
@
continued
from page 90.27
- replace printed
circuit
I END I
®
continued
from page 90.27
I continued
on page 90.29 I
90.28 Dynamic oil pressure system,
troubleshooting
Water-cooled from 1986
Electrical System - Instruments, Radio 90
continued
from page 90.28
LED approx. 8.5 v Zener diode defective replace printed circuit and LED
flashing approx. 5.5 v track of printed circuit broken replace printed circuit
I END I END I
f·7
Water-cooled from 1986 Dynamic oil pressure system,
troubleshooting 90.29
90 Electrical System-Instruments, Radio
*Note
It is required that vehicles be equipped with OEM
tires and wheels showing only normal tire wear.
te
190·A0781
190-A0791
F-9
Cigarette lighters, replacing 90.31
90 Electrical System-Instruments, Radio
CAUTION
DO NOT keep the security code or radio
card with the vehicle. Always instruct
customers to detach radio card from
191-A0481
operating instructions manual and keep
in a safe place.
Note
The security code/serial number sticker for
remanufactured replacement radios comes in
the box with the new radio. Place the new
sticker over the old sticker on the radio card.
• switch radio ON
• radio plays and radio station frequency is
displayed
90.32 Coding
·Heidelberg VI radio
- Electrical System - Instruments, Radio 90
• push and hold AM/FM and SCAN buttons
to activate coding procedure
• radio display changes to CODE and then
1000
• release AM/FM and SCAN buttons
• 1000 will remain on display
• enter radio's security code using first four
program station buttons
• security code will appear on display
• push and hold AM/FM and SCAN buttons
once again until display changes to SAFE
Note
FM .- - . - DX
MTL ''J L•C A new or remanufactured radio will only
CCAM - I " CHE accept its factory assigned security code. If
an incorrect code is entered, the radio display
will not change to SAFE.
• release AM/FM and SCAN buttons
191·A0461 • radio display changes to a radio station
frequency
• radio is now coded
- Heidelberg VI _
radio I 90 33
....___ ____ ___. Coding •
90 Electrical System-Instruments, Radio
Note
If the AM/FM and SCAN buttons are held
down too long or pushed again, the radio will
misinterpret the 1000 as an attempt at coding
and one incorrect attempt will be logged.
• enter radio's security code using first four
program station buttons
• security code will appear on display
• push and hold AM/FM and SCAN buttons
once again until display changes to SAFE
• release AM/FM and SCAN buttons
• radio display dhanges ~o a radio station
coc
::Jill
frequency \~
• radio is now coded and plays
To unlock:
• leave radio switched ON for approximately
one hour
• after one hour, reactivate (code) radio as it
would be after a power interruption
Note
The radio will never permanently lock-up no
matter how many incorrect coding attempts
are made. The reactivation procedure can be
repeated indefinitely.
90 3 4
• Coding IL----------'
Heidelberg VI radio
92
Electrical System
Windshield Wiper
Windshield Washer
- Index 92.1
92 Electrical System-Windshield Wiper and Washer
CAUTION
Before starting to work on any part of
electrical system, disconnect battery
ground strap
Wiper motor
park position adjusting Fig. 2
=
....._....c......_----Relay rods, left and right, removing/Installing
-remove glove compartment
- remove instrument cluster
- remove 4 phillips head screws on instrumenl
Wiper blade rubber Insert cluster near wi ndshield
removing Fig. 3 - remove wiper arms
Installing Fig. 4 - remove windsh ield wiper re lay rods
(extend fully to passenger side)
0
Wiper arms _ _ _ _......,
positioning Fig. 1
G·2
92.2 Windshield wiper assembly
Electrical System-Windshield Wiper and Washer 92
nstrument
G-2 G-3
Wiper arms/motor
Wiper blade rubber Insert
92 3•
92 Electrical System-Windshield Wiper and Washer
~7---_,;,.;."'-Spray jets----....,
~ adjusting Fig. 1
~.. ~
~--~
~~~
~~ '
A
u ~~'
~--./
Water container
G·4
92.4 Windshield washer
Spray jets
Electrical System - Windshield Wiper & Washer 92
Rear window washer and wiper system, repairing
Stopper---.,
Mounting screw
Spray j e t - - -
adjusting Fig. 3
G-4
G·S
Rea" window washer/wiper 92 •5
Electri'cal System - Windshield Wiper & Washer 92
Fig. 1 Rear window wiper arm, adjusting end Fig. 3 Spray nozzle, adjusting
position - center of wiping field
a= 27 mm
Rear window wiper, removing and
installing
Removing
- remove cover in back hatch
G·6
Rear window washer/wiper 92.6
92 Electrical System-Windshield Wiper & Washer
192·A0391
Angle of blllde to windshield
more
Some water remains in the wiping area, • windshield glass - clean windshield glass
forming droplets contaminated by with clean cloth soaked
pollutants, oil or film from in solution of alcohol (or
diesel engine exhaust ammonia) and warm
water
Windshield wiper blades clean to one side and • blade lips are deformed or - replace blades
are deficient to the other (chatter) filled with dirt or foreign
matter on one side.
• windshield wiper arms are - bend wiper arm to
twisted. Rubber lips do obtain proper blade
not touch glass properly contact
Quick Data
..;.;.Aerodynamic 94.5a
-Bulb holder 94.6
-Headlight 94.4
adjusting 94.5
mounting frame 94.5
removing 94.5
-Ignition key
. deb\IJ'flrig 94.3a
- tntermittent windshield wiper
94.4 .
- Steering column
covers 94.3
lock 94.3
lock cylinder 94.4
switches 94.2
- Tail-light 94.6
- Turn signal switch 94:3
1 94.1
94 Electrical System- Lights
Tum signal cancelling ring with slip
grease slip ring with multi-purpose grease.
If slip ring is defective, press
out and replace
Spacerslee•ve - - ,
removing Fig. 3
installing Fig . 4
-~----Windshield wiper switch
intermittent windshield wiper,
service installation Fig . 8
...
Steering lock housing _ _ _.......,
removing Fig. 2 and Fig. 3
installing Fig. 4 and Fig . 5
Ignition/Starter switch
Lower column switch cover
(with warning buzzer contact)
removing/installing Fig. 1
to remove: first remove
steering column lock, then
unscrew clamping bolt
10 Nm (7 ft lb)
before tightening, adjust clearance
between top of spacer sleeve and
top of steering column, see Fig. 5
H·2
94.2 Steering column swllches
Electrical System- Lights 94
1witch cover
lling Fig . 1
cover
'ig. 1
H·2 H·3
Upper/ Lower column switch covers
Steering column lock
Turn signal switch
94 3
•
94 Electrical ·S ystem- Lights
Note
94.3a
94 Electrical System-Lights
Fig. 7 Steering lock cylinder, removing Fig. 8 Intermittent windshield wiper, service
installation
-carefully drill 3 mm (1/8 in.) hole into
housing - remove plastic wedge (arrow) from
• a= 12 mm (1/2 in.) opening in windshield wiper switch
• b= 10 mm (3/8 in.) -install windshield wiper/washer
- press in pin with punch through intermittent relay
drilled hole and pull out lock cylinder
Mounting frame
removing Fig. 3
L. . . . . . . . . . ... Seolod...., ~
removing Fig. 1 and Fig. 2
<Hoodl ..ht od)uotlng .. ~
adjusting screw locations Fig. 4
194-2381
Note
Always adjust headlights using Weaver WX-50
tester or equivalent in accordance with local
laws
H·6
Sealed beam
Mounting frame
Headlight adjusting
94 5
•
94 Electrical System-Lights
Aiming requirements
- park vehicle on flat surface
Note
It is not necessary that the surface be exactly level.
- remove any large accumulations of mud or ice
from wheel wells, fender undersides, bumpers etc.
- check and correct tire pressures
- verify that vehicle has no loads other than driver
- rock vehicle to settle suspension
- clean headlight lenses and aiming pads
- check hi and low beam headlight operation 194-A0491
Note
The settings are designated by the letters V and H,
followed by a number.
Universal
Adaptor
9 4 •5 a Aerodynamic headlights
94 Electrical System-Lights
Bulb holde•·------.
removing Fig. 1
wiring Fig. 2
Turn signal b u l b \
12V/21W \
Tail-light bulb
12 V / 5 W
!s4- 239A I
94.6 Tail-light
Bulb holder
H-8
97
Electrical System-Wiring,
General
Index
I General
- Battery/Ground cables
97.9a, 97.9b
disconnecting/connecting 97.6
- Cautions and Warnings 97.2
. Air-cooled AFC
- Referto 97.11
Camper
· - Refer to 97.29
-Dashboard wiring harness 97.7
- Engine/Body ground Diesel
connections 97.6 - Refer to 97.35
- Fuse/Relay panel, removing
(1980-1985) 97.10 Waterboxer/Syncro
(from 1986 m.y.) 97.10a (Water-cooled Digifant, Digijet)
- How to read wiring diagrams 97.4 - Refer to 97.53
- Main wiring harness 97.8
- Starter cable routing 97.9
- Symbols used in
wiring diagrams 97.5
-Troubleshooting 97.3
-Working on the electrical
system 97.3
97.1
H·8
97 Electrical System-Wiring, General
Fuse/relay panel
across top of diagram
contains individual fuse(s)
symbols and rat ings
,,.
FAll
tm .,
.,
MD
Component symbol (
---
(here: motor) '·
Component designation
(here: windshield wiper motor)
Circled numbers
ground connections, numbers appear in
legend telling you where
to find connector
Current track numbers
help find components In diagram
~
(manually operated)
Varlabl• resistor
~1.
+ Semiconductor diode Hydraulically operated
X~
·switch .
Electrically
operated valve .··~ E_lectromagnetlc relay
~-~-:_t:-
.l-# Ignition distributor
+ !
Condenser (capacitor)
<l
~-'\=- ·. _· . Starter solenoid
Ignition coil
T
~--~
t 1
Solld·state relay
1
Spark plug
m
~ -®- }--i
Alternator Thermally operated
Fuse (bimetallic) switch
~- Motor
$ .~
Manually operated
Light bulb multi-position switch
+ ""----/
Wire junction, detachable
~
·one filament in a
multifilament light bufb /+·~lr.~ crossing (no connection)
I
\.
T-
Battery
.~ Manually operated switch
--
~
Mechanically operated
switch
I
\
\
cff Light-emitting
diode (LED)
F·10
4 6 5
Ground straps
1 =Battery
2 =Transmission
3= Engine
=
4 Negative terminal of battery
5 = Ground point (transmission)
6 = Ground point (body)
• do not disconnect
to heater/ventilation controls
4bles and to cigarette lighter
to front courtesy light
Ground point
behind fuse/relay panel to neutral/park
starter switch
(vehicles with automatic
transmission)
_/
F-3
Dashboard wiring harness 97.7
97 Electrical SyStem-Wiring, General
CAUTION
Before working on any part of electrical
system, disconnect battery ground strap
C a b l e - - - - - -..
to ground point on
cross member, from to plug connections T4,6.nd T4c
fuel gauge sender behind dashboard and' to fuse/relay panel
Cables
Cebles---'
to Ignition distributor,
starter, on pressure switch Forward-
and Ignition coil ,
Cables
to neutral/ park starter to fuse I relay panel and ]
switch (vehicles with au.tomatic. to switches for heater booster ,
transmission) '
Left slde·member
• fl)rward
Cable
from battery to
fuse/ relay panel
a Forward
Main
harness '1-
wiring~~ ....
~~===================::]
Rear crossmember
Tie wrap
Starter connection,
tetmlnal30
- F-5
Starter cab~ routing 97.9•
97 Electrical System-Wiring, General
197·2150 I
)
\ /
cables---
to battery
~ cut-out relay
197·21491
97.9a
Electrical System-Wiring, General 97
Ground cable from body to automatic transmission
Ground c a b l e - - - - - - - "
from body to transmission
"'hhnsmlaalon mount
Ground cable
from body to
transmission
ound cable------'
on transmission mount
197-21461
H-7
Ground cables 97.9b
97 Electrical System-Wiring, General
0
-remove screw (arrow)
- unhook fuse/relay panel and pull down
Note
Before working on the electrical system, disconnect
battery ground cable.
CAUTION
New replacement grommet must be the
same color as original to ensure proper
sealing between wire, grommet and
housing.
Electrical System-Wiring,
Air-cooled-AFC
Index
General 1980, 1981 Air-cooled AFC Camper
- Battery/Ground cables - Cautions and Warnings 97.2 - Refer to 97.29
97.9a, 97.9b - Fresh air fan 97.23
disconnecting/connecting 97.6 - Fuse/Relay panel 97.10 Diesel
l - Cautions and Warnings 97.2
-Dashboard wiring harness 97.7
- Heater booster 97.24, 97.25
- Main wiring diagram 97.12-97.17
- Refer to 97.35
97.11
97 Electrical System-Wiring, Air-cooled-AFC
•IGliiTION
CONTIOI
UNIT •OIJMIU
I ® I I ® I
~· i· t+
*'~
*3 w·
*'
16
BR
20 20 20 16 16 20
*'
18
w
16
w
18 18
w w
18 18
'M w
Wiring TMIOT
• IDII
Color Code STAI
Ylf
Black - BK
~:~:IOi u_~~--~~--~
IW
,..
IIIJ
lUll
.I .J
lUll
Yellow - Y
1
Green - G
light Green- LT.Q
Blue - BL
Violet - V
Gray - GY 20 \8 18 18 \8 18 18
RJBK G BKIW w w w w w w w
White - W
~ ~ l DISTIIIUTO• ~· ¥3 ~ . ~·· ~" ~ll ¥WI
I® ~ - ---
I
f!) I
--
••Au ltlll 16 17
·ca~ronlia only ( •.
GINIUTO• IIIJ
CONTIOI
UNIT
Note
On 49 state and
Canada vehicles, a SI'UI
"'Uii TDC
series r~slstance is CONNICTOIIf IINor•
~
located between
fuel injection
control unit and
~tlta
Injectors.
On California
vehicles, series
resistance Is built
Into fuel Injection
control unit.
I g n i t i o n - - - - - - - - - - - - - - + - - Fuel InJection/~
Note: All wire sizes American Wire Gauge
Current Current Current
Description Track Description Track Description Track
Alternator Brake warning light Emergency flasher relay
Alternator charging indicator light Cigarette lighter Emergency flasher switch
Auxiliary air regulator Cigarette lighter light Fuel gauge
Back·up light, left Clock
Back-up light, right Fuel gauge sender
Cold start valve Fuel injection control unit
Back ·up light switch Distributor
Battery Fuel pump
Door switch. left front, with buzzer contact Fuel pump relay
Brake light, left Door switch, right front
Brake light. right Fuses S 1·S 12 on fuse/relay panel
Elapsed mileage switch lor OXS indicator' (under dash)
Brake light switch Emergency flasher indicator light llall generator•
'California only
!s.
20
GY/BK
~
ll 20
BUBR
8
RIBK
20
BL
AIf
CIAK
liD
1m
WTU/13
~i t,
~~.., ,.l_j
18 18 18
w
8
R/BK
20
BL
.~
l-SI~~-
ot~ CNrl
,.,"
=~
>7 nAif~
/
/
( t..
\,
\ 18 18 18 18 18 18 18 10 8 20
w w w w w w A A BL
)!,,. lll() u.
T..,
IMIIl
rvwr
I
~
ij
16
BA
T
~Oxygen sensor/Fuel pump ------------+-----Startlng/Charglng------i
Current Current Current
Description Track Description Track Description Track
Lr ============== 2~ ::=
JliiSOI
IND BKIY R R
UTI T ... /9
.T" I
fUll
UTI~: ffl
011 GAUGI
1'111
Tl4/ll
UTI
Jwnc•.L .~ .I
~ ~~I
~fl-4/8
is ~>6 ~SB ~::Ob=I"'I=:ZI:ZI=IZ:I=:ZI:Zi=z:i
"''""" .,. .... , ...
20 20 z:z= 1:21C:: 20 -
20
VIBK
,,~-
~~
20
BUG
B~~~ 20
BLIBK
20
VIBK
:~
~4~
l ~
Wiring
Color Code
Black
Brown
Clear
Red
Yellow -
-
-
-
-
BK
BR
CL
R
Y
20
BL
r-
,2
WIBK
16
W
Green - G
Light Green- LT. G 18
GY
Blue
Violet
-
-
BL
V s, s.
Gray - GY
White - W
,\~1
·eamotn&a only
16
y
~
20
BUW
20
GYIR
20
GYIG
T..
i
20
GYIBK
fUll
,..,
NO
liTI
IIIJ
::~" ~m:•:_~====~~~
.Tl-414 _t.t
-
.0.
Ull
lifT
1101
/IIIII
1111
IIAI
I
~ lnatrument cluster - + - - - - - - - - Lighting/Radio connection
Note: All wire stzes American Wire Gauge
Current Current Current
De&crlpllon Track Description Track Description Track
Oxygen sensor (OXS) relay• Sliding door switch Turn signal, left Iron!
Parking brake indicator light switch Spark plug connectors Turn signal, left rear
Parking light, left Spark plugs Turn signal, right llont
Parking light, right Starter Turn signal, right rear
Radio connection ( - ) Taillight, left Turn signal switch
Radio connection ( + ) Tail light. right Voltage regulator
Rear window defogger TDC sender Voltage stabilizer
Rear window defogger switch Temperature sensor Windshield washer pump
Side marker light. left Thermo hme switch Win dshield wiper motor
Side marker ltght, right Thronle valve switch Windshield wiper switch
Turn signal indicator light Windshield wiper/wa.sner interminent relay
• California only
16
BK
r- BK20 '
,j Sn
16
I fI
RIW
16
BKIBL
lO "
J IMIIG G9 ~
run
IHD
~~· "" 31 ~
1a 1a I 1h
BKIW BKJG BR
18 18
~
Tm.
Pd ~
J ucr
ll 1a
~· ~ 18 20 20
BR BKIBL BR BUR
~t. r.• ~
~ ~
j
T. T.
20 20 18 18 18 18 18 20
GYIBL R BRIBL BKIW BK/W BKIG BK/G BR
li n~l2
llffiii(J~flj l
HnuJ "'lliiD
¥
J HUT
t~ Y14 I~
20 Ia
BR BR
T8f7 ani/A
16 20 18 20
R GYIG RIY R
Blo~82a
.....
llrl
SWrJCN
18 ~18
ffi"'
20
GYIBL
~ - "i:
18 20
RIBK GYIBK
IGII
m
WIIIG "'
IUllY
IADIO
COHHKTIOH
(-)
20 20
GYIBL
......
,
IHD
llrl
sw
..... .....
llrl llrl
lffT
SUDf
Dool
sw
liGHT
)
L ..
- --- - -----
llfDCICTION
IRAY
------
.
USA and Canada vehicles are equipped
with EGA system instead of OXS system.
OXS system is for California only .
Wire Connectors
10
I" 20
20 BR
~ T1 a
T1 b
T1 c
at fuse/relay panel
behind dash
behind dash
BKIY BR T1 d in engine com part. near alternator
T1 e behind 1nstr. panel
Tlt behind 1nstr. panel
T1 g behind dash
T1 h in engine com part.
T11 behind dash
T1 j behind dash
T1 j in engine com part.
T1 k in engine com part.
T2 behind dash
T2a behind dash
T3a 1n engine compart.
T4 beh1nd dash
T4a at fuse/relay panel
T4b at fuse/relay panel
llfAI
T4c beh1nd instr. panel
llfAI
w•D
••o
DffOG T8 at brake warning light
~~~~==~~~~~~~~~::~~~
T14 at instr. panel insert
~T,i
20 18 16 Wiring
GIR BR RIBK Color Code
$~·
>3 >lb
Black - BK
!I! lfiiiD lfiiiD Brown - BR
DfGI Clear - CL
"'"
MOTOI Red - R
I=
31
16 BR Yellow - Y
Green - G
Ught Green - LT. G
Blue - BL
20 r
16
Vieltt
Gray
-
-
V
GY
White - W
Current Current
Description Track Description Track Description
Parking ligh1. left Spark plugs Turn signal, left rear
Parkmg light, nght Starter Turn signal, nght front
Radio connect1on ( - ) Tail light, left Turn signal, nght rear
Rad1o connection ( + ) Ta11 light, right Turn signal switch
Rear wuldow defogger TDC sender Voltage regulator
Rear window du!~r sw1tch Temperature sensor Voltage stabilizer
S1de marker light, left Thermo time sw1tch Windshield washer pump
S1de marker light. nght ThroUie valve switch Winds~teld wiper motor
Sl1dmg door switch Turn s1gna1 mdicator light Windshield wiper switch
Sp~rk plug connectors Turn s1gnal. left lront Windshield wiper/washer 1ntermit1ent relay
• California only
.......
Brake light, left 78 Tail light, right
Brake light, right 75 TDC sender 11-t1
Brake light switch 75. 78 Temperature sensor tt
Brake warning light 73-78
71
Thermo time switch
Throttle valve switch
Turn signal indicator light
".11
tf1
ca•n10
IIIII'
Cigarette lighter
70 Turn signal, left front 1M
..••
Cigarette lighter light
Clock 58 Turn signal, left rear
Cold start valve 24 Turn signal, right front II
Turn signal, right rear
Distributor 5-8 Turn signal switch
Door switch, left front, with buzzer
•"
contact 78,79 Voltage regulator
Door switch, right front 80 Voltage stabilizer
ln
COtfJIOI
UJUl ID IILtJ
t·~~l
I ® I I ®
~· i· ft' t+ tr'
16
BR RIBK
10
GIW
*'
10
BKJW
16 16 10
BK 9K BK
*'
18
w
16
w
18 18
w w
I~ I
~
i
.
,,,..,...
IOU
l I
,,
..
16
IlK
,...
...JHIOJ)
18
w
)(
18
w
18
w
18
w
Jl :;. . .u
/_-"~~~-
18 18
w
18
Jl
.....'"~
®
. ., p IUt
.!: ,
-~~
01
,., 11m ~1' (010
1
""
~ "" JUIJ
0 10
~
10 18 18 18 18 18 18 1 18 18 18 18 18 18 18 ,, 18 18
w w w w w w w w w
R/8K
~ ~
G BKIW
l r7 l ~JIIIVJOI
Jl., ij,
w
)l,
w
\(..
w
"
)I, )~, Jl~ )1, Jl, rr.. Jt. ~ .. ,.....wL!
R/Bl w
oJl
I® ~) ~---- ·-+;- I ®
'
J/Mf
llfiJ(If
, .. II
,.,
""'
"~
GHN'. . JOI ")(
COifJICH 18
Ulfll w
T., T.~10
BK
BK
....
lrUI
'"" 0
II)(
COIII.Ifi(JOIS
~ ~ ~
~ .. J,.....
~
SllfDII
OUCUI )..
SllfSO• .....
,.., ru• -
~
l'lUCJ
~bt~ 16 16
.
8R
(!!)
~ Gl
' ,, ' IOIII213M 11 16 17 II
" JO 21 22 23 311 2s
18 BK/V
B~V ~~
tJjJ===
11 20
~ft"$6
12
WIBK
'f(SI
18
~~b
20~~:
Gr
======
Wiring
Color Code
IIB:II -IlK
Brown -IIR
r
a- - Cl
Red -A
Yfiii:M -Y
<lteen - G
~ <lteen - U. G
- -Bl
10 20 12 16 V1olot -V
WIBK Glay - GY
- -w
v
8R
10 R
16 R
16 R
16
r~T
.... ...s. ....s.
81(
f 16
81(
... ~
' ....5,2 ....Sn
i
~
16 16
RIW R
16
BKIBL
I
I
-81<
-BR I 301
l, l l l
..
IMfltG lUll SW
-CL
I ,::1~"." ~9
t· ~I'
-A
I ·~·
~t ~0
-Y UTI Jl
r
-G
-U.G . l1s 18 18
-Bl BKIW BKIG BR GYIBL
~ ~
-V ~ !"'""=-
-GY
I ~ ~ T.. t T. t.
-W
I
IADIO
CONNKUON
(-1
t t T""
20 18 18 20 20
GY/BL BKIG BKIG ilR GY/BL
Hn. IJ ' llTIA/2
11" 11•• M n - n
,. IDAD
.....,
aoucno• ..
rw
,.
----------------
208R
il<lJ
20 10 20
BUB!< BI<IY
1,.,, w",.
SIO
20 20 18 20 16
GYIG BUR RIY R 8KIGY BKIW
t ~~l-·
-- -
•••
Eu
••o
.. A''
18 18 18 16
80
20
]I
it w 18
~ Wiring
Color Code
_,.
18 20 GIR Blocll
GYIBK Blown -II
·-
""
l•ffiiOI"'
llff
2
R 0,,.,
'.ffi.OI
UJf
y-
c..
Red
- 0.
-R
·rfi
m -Y
IUZZII " Gloen -G
BRIW ~GIOIII-
16 8lJo - I.
,T,,
81( VIOiot -v
-·
Gtay - GI
White
20 20 20 20 18 16
GI R BR RIBK
11
~·j=
sw ru•r
20
n • ., • a .. • ••
..............
ID IJ
15 ll 7l
"
••
""<'
s, ---·---.:~·--·~1... 0
•• -,
..
II( It
fUH
Alii
•
ll.•
"l
. /
:~· 7~11'
••
T
tng
or Code
-BK
-BR
-Cl
-A
-Y Wiring
-G Color Code
:;..., -U. G
-BL
Black - BK
-V
Brown - 8R
-GY
Clear -CI.
-W Red -R
Yellow - Y
Green - G
light Green- l T.G
Blue - BL
..
•• Violet
Gray
White
- V
-GY
-W
_l Ground Connector
@ behind dash
NOTE: All wire oil• Americoln Wire G•uao
AFC
Fresh air fan 97.23
97 Electrical System-Wiring, Air-cooled-AFC
ro aAmtr
I'OSiriVf
TftAI.Al
S2J
(16A)
20 20 12
BUY BL
---- .....
R
20
R
T
20
BUR
T~a
t'·
20
BUY
20
BL
r••
BUW
20 16
R
JaAD• } C
RAII'fiA FUll c___---4--J
lfGULUIIIG
SWIFCII
---® ,
'j'S
~20GVR~
'j'l 'j'H
=::G..t-y--~-r
l
16
K IRAT 'f'
16
G 'j'D
16
20 BA/W BK/Y G BK
r•• 'r••
16 16 20
y BKIW BL
r=r~
OVfiiiUT
fUSI 511
(SA) N:-
16 18 16 20 20
G BKIW BKIW BR BUR
20 20 16 UUIII18
I'OIIIJS
J1J_
BR BR AIW CIICUU·
TIOIIIlOWII
J~::: Sfii'I'IIISSOI
(COIIDUISII)
~ SWITCII
~fHUTSWITCII
20 16
BR BR
y,
- . -
' • 'l _":" I •,. •
c f':~:::[ :. -
Wire connectors
T1a-at fuse holder
T2 -at air circulation blower
T4a-at heater
T4b-at heater
Wiring
Color Code
Black -BK
Brown -BR
Clear -Cl
Red - A
Yellow -Y
Green -G
Light Green - LT.G
Blue -BL
Violet -V
Gray -GY
White -W
CAUTION
Before working on any part of electrical
system, disconnect battery ground strap
:JIODf) J10 =Safety switch
Note
To reset switch, wait three minutes and then
AFC 1980-1983
Heater Booster 97.25
97 Electrical System-Wiring, Alr-cooled-AFC
intermittent
wiper switch
-- -rl ::;;:.b
f, J,T~~,
Wife ConnectOfl
Ground Connectors
Wiring
Color Code
Blad< - BK
Brown - BR
CIOII' -Cl
Red -R
y- -Y
-
Green -G
r~ ~Green -Lt. G
-BL
):.
II II II 20 II ,, 18
VIOlet -v
t~:i ~~ hT
Gray -GY
Whitt -w
••'0
18 18 18
8R
•• ••
l..,y
12
~l--1
10
R/IK
18
Ill(
16
·~
20
Ill(
to I I
to to
LIGHT STARTER 14-POINT
SWITCH TERM. 50 PLUG
TERM. I
Sn
8A
Current
Wire connecton Track
18 18
T1c
T2a
single, behind dash
double, under driver's seat
3
4
111(/Y
to
HORN
·t
to
BACK-UP
T3 3-point, behind dash 4,6 LIGHT
T4 4-point, behind dash 8 Sa SWITCH
T3
tor
to IS 81 82
INTERIOR l81o __]82o " l I "
LIGHT
CFRONTl toLOAD o:I\...BRAKE-
LIGHT ~·
I
20
REDUCTION~
RELAY 1 SWITCH
IB R/BK
18---1
'i'
81
Black - BK
$T4
18
Brown - BR
h
Clear - CL
Red - R
Yellow -Y
Green - G
Light Green- l T.G to
Blue - Bl 04{ ot{o ( Fl f.
EMERG .. 1'
FLSHR "1-PARKING 0 IRI 0
Violet - V (RFI ~ RLY !BRAKE
'WARNING
i I (LI
AFC 1980-1982
Seat-belt Interlock system 97.27
97 Electrical System-Wiring, Alr-cooled-AFC
97.28
97
Electrical System-Wiring,
Camper
Index
General Camper Air-cooled AFC
- Battery/Ground cables - Auxiliary battery -Refer to 97.11
97.9a, 97.9b 1986-1989 (man. trans.) 97.34
disconnecting/connecting 97.6 (also see 97.53} Diesel
- Cautions and Warnings 97.2 -Battery level indicator - Refer to 97.35
-Dashboard wiring harness 97.7 lights 97.30
- Engine/Body ground - Camper electrical equipment Waterboxer/Syncro
connections 97.6 1980-1985 97.32 {Water-cooled Digifant, Digljet)
- Fuse/Relay panel, removing from 1986 97.33 - Refer to 97.53
(1980-1985) 97.10 -Water pump 97.31
(from 1986 m.y.) 97.10a - Water tank level indicator
- How to read wiring diagrams 97.4 lights 97.30
- Main wiring harness 97.8
- Starter cable routing 97.9
- Symbols used in
wiring diagrams 97.5
-Troubleshooting 97.3
. - Working on the electrical
system 97.3
97.29
97 Electrical System-Wiring, Camper
Battery level indicator lights, checking Water tank level indicator lights,
checking
Note
Ignore indicator lights which light but are not Note
mentioned in test being performed Ignore indicator lights which light but are not
-check indicator light panel fuse located under mentioned in test being performed
driver's seat -check indicator light panel fuse located under
-remove indicator light panel from sink cabinet driver's seat
and disconnect multi-point connector -remove indicator light panel from sink cabinet
and disconnect multi-point connector
1 2
-connect indicator light panel to fully charged 2
12-volt battery as follows: -connect indicator light panel to fully charged
• terminal 1 to battery positive terminal 12-volt battery as follows:
• terminal 2 to battery negative terminal • terminal 1 to battery postive terminal
Red • terminal 2 to battery negative terminal
Green Yellow Pilot light Green
(K55) (K56) (K51) (K52) Red
Green Yellow Pilot light Green
(K55) (K56) (K51) (K52)
- red pilot light(K51) and green battery level (K58) (K57) ~ - 68j
indicator light(K52) will light-battery level -red pilot light(K51) and red water level
above 12.5 volts indicator light(K58) will light
-using Sun VAT-40 or equivalent, load battery - connect green wire from known good water
to maximum 110 A. Battery voltage will start tank sender unit to terminal 3 in multi-point
to drop connector
-battery level indicator lights will light in the - connect one end of jumper wire to battery
following sequence: negative terminal
• green(K52)-battery level above 12.5 volts
• yellow(K53)-battery level below 12.5 volts - connect other end of jumper wire to white,
• red(K54)-battery level above 12 volts yellow, and green wire of sender unit one
after another
- i f any indicator light does not light during • water tank level indicator lights red(K57),
test, indicator light panel is defective yellow(K56), and green(K55), will light-
-replace complete indicator light panel if red water tank level light(K58) will go out
necessary - go to next page
- if indicator light panel OK, check wiring
2
-connect test light to back-side of terminal 4
(arrow)
Red
Green Yellow Pilot light Green
(K55) (K56) (K51) (K52)
Yellow
(K53) (K54) 197-683 I
- if either green(K55), yellow(K56), or red(K57)
water tank level indicator light is lit, test light
must also light
Camper
Water pump 97.31
97 Electrical System-Wiring, Camper
9 7 •3 2 Electrical equipment
Camper
Electrical System-Wiring, Camper 97
-
EXTERIOR SOCKET
(110 V)
REFRIGERATOR
SOCKET(110 V)
WIRING
COLORCOOE
BK - BLACK
8R -BROWN
Cl. - CI.EAR
R -RED
y -YELLOW
1.5 1.5 1.5 G -GREEN
BK Lr G - UGH r GREEN
BL -BLUE
v - VIOLEr
GY -GRAY
w -WHITE
DR - ORANGE
6 7
Camper 1980-1985
Electricalequlpment 97.328
97 Electrical System-Wiring, Camper
TO
ALTERNATOR,
TERMINAL
0+ TOIGNmONI E130 DISPLAY UNIT SWITCH
I
TO BATTERY(+) STARTER SWITCH, K52 GREEN UGHT DIODE, BATTERY VOLTAGE
TERMINAL 50
I I K53
ABOVE 12.5 VOLTS
AMBER UGHT DIODE, BATTERY VOLTAGE
2.5 0.5 0.5 BELOW 12.5 VOLTS
R/BK K54 RED LIGHT DIODE, BATTERY VOLTAGE
I..
BELOW 12.0 VOLTS
K55 GREEN LIGHT DIODE, WATER TANK LEVEL
FULL
A" K56 AMBER LIGHT DIODE, WATER TANK
r-1a7 K57
LEVEL FULL
RED LIGHT DIODE, WATER TANK LEVEL
REFRIGERATOR - ~~'----l"/··~1-::. ~~..!
-::--.,.."'
..."""t
K87
PART EMPTY
GAS FLAME ON WARNING LIGHT
12·VOLT ""30 85
H E A T E R 2 .5 ......_
RELAY 8
!I
I
r
1.5 1.5
I
1.5
I
1.5
II
BK R R BK
FVSE l
523
SA
~
1.5
WIRING
COLOR CODE
1.5 1.5
y G IlK - BLACK
~··~
BR -BROWN
Cl - CLEAR
R -REO
y -YELLOW
G -GREEN
DISPLAY UNIT
PUMP L T_ G - LIGHT GREEN
SWITCH BL -BLUE
- VIOLET
'i' GY - GRAY
1.5 w - WHITE
y OR - ORANGE
T4
1.5 1.5
BR BR
T4
@
20 21 22 23 27 28 30 31 32 33 3-4 37 38
I I
1.5
R
1.5
BK
1.5
13K
I
1.5
R
I
1.5
BK
I
2.5
R
®~·· 561
16A
I
2.5
R
REFRIGERATOR
WIRING
COLOR CODE
BK ~ BLA CK
BR -BROWN
Cl - CLEAR
R -RED
- YELLOW
INTERIOR
G - GREEN
UGHT,
LT G - LIGHT GREEN
CENTER ~~=:!L..J
BL - BLUE
- VIOLET
GY - GRA Y
E79 REFRIGERATOR SWITCH (110 V. 12 V)
W -WHITE
F57 REFRIGERATOR FAN THERMOSWITCH
OR - ORANGE
G103 GAS FLAME ON SENSOR
V19 REFRIGERATOR CONDENSER FAN
Z14 REFRIGERATOR 12 VOLT RESISTANCE
Camper 1980-1985
Electrical equipment 97.32c
Electrical System-W,iring, Camper 97
Current Wire connectors
Description
track
T1 - single, on refrigerator
Amber light diode, battery voltage T2a- two-point, behind dashboard
below 12.5 volts T3a - three-point, on refrigerator
Amber light diode, water tank level full T4 - four-point, on water tank
Display unit T6 -six-point, on display unit
Display unit switch Ground connections
Exterior socket ( 11 0 V) @-behind refrigerator, left side
Gas flame ON sensor
Gas flame ON warning light
Green 1ight diode, battery voltage
above 12.5 volts
Green light diode, water tank level full
Interior light, center
Interior socket ( 11 0 V)
Red light diode, battery voltage
below 12.0 volts
Red light diode, water tank level
part empty
Refrigerator
REFRIGERATOR
FIEFRIGERA TOR
EXTERIOR SOCKET THERIIOS'TAT {liD
REFRIGERATOR ttO VJGAS SYSTEM)
Jllll"''---'----'~_,__..;__,......_ _ _ _.....u {110 V) VOlT RESISTANCE
~ ~~ ·~
,.-c~::.=.o;.~;:
~
TI .. THERIIO FUSE
{CAMPER) REFRIGERATOR
..:~ ~- ~
1 L :..~~~~ ~, ~ \ ..:.J SOCKET (110 V)
1.5 1.5
I 1.5
I
G w BK
~ ·;
_,..
,... ,....
..
,- WIRING
COL OR CODE
I'"
' ... . -.
:_ ·"-' '
" ]INTERIOR SOCKET
(ttO V}
BR
BK -
-BROWN
BLACK
Ct - CLEA R
R -RED
Y - YELLOW
G - GREEN
LT. G- LIGHT GREEN
BL - BLUE
V - VIOLET
GY - GRAY
W - WHI TE
OR - ORANGE
@
2 3 4 5 7 8 10 11 12 IJ 14
!97-36161
9 7 •3 3 a Electrical equipment
Camper from 1986
Electrical System-Wiring, Camper 97
30 30
15 15
X X
31 -- 31
E130 OISPt.AY UN" SWITCH
ICf6 ~- UQHT DIODE, WA7D 71INIC
LEV&. FULL
K52 GREEN UCJHT DIODE, BATTfRY KX.TAQE
IC5f AMBER LJGHF DIODE, IIMliR mNK
ABOVE 12.5 K>LTS LEVEL FULL
K53 AMBER UOHT DIODE, IMTTERY I/Ol.TAGE
BELOW 12.5 W>LTB
Kti7 Rr=D UOHT ~ WA'Ia TIUM LEVEL
MRTSIPT'I
K54 REO LIGHT DIODE, BATTERY K>L'JJUlE 1(81 OAS FLAME ON WARMMJ UGHf'
BELOW 12.0 K>LTB
I
-
T04
WIRING
C2 p
2.5
G4
0.5
J
JC18
0.5
T
1 024
6.0
ra
I
4.0
A16 61
0.5
E13
0.5
COLOR CODE A BL RIBK RIBK RISK BL BL
L r2o/2
IR BK -BLACK
I T2atl
(110
f=l
BR - BROWN
II) CL - CLEAR
R -RED
j
y - YELLOW
G -GREEN FUSE 187 86
LT G - LIGHT GREEN REFRIGERATOR
IR
BL
v
-
-
BLUE
VIOLET
523 --- 12-VOLT
TO ALTERNATOR,
TERIItNAL D+
GY - GRAY
w - WHITE
OR - ORANGE
WATER PUMP
SWfTCH
WATER
TANK
WA TER P/JIIIP LOW
LEVEL
SENSOR
1.5BA _ __ , 1.5
BR
15 16 17 18 19 20 21 22 23 24 25 26
)®
WIRING
COLORCOOE
BK -BLACK
BR -BROWN
CL -CLEAR
R -REO
- YELLOW
G -GREEN
L T G - LIGHT GREEN TOFIIOI(r TO FRONT
BL -BLUE
INTlRIOR LIGHT, INTERIOR LIGHT,
PUJS CONNECTION TERMINAL 31 •
- VIOLET
GY -GRAY
W -WHITE
OR - ORANGE
FUSE
561
16A
REFRIGERATOR INTPIOR
swrrCH (110 v, 12 'IJ UGHr,
CENTER
REFRIGERATOR 12
CONOENSER VOLT RESISTANCE
FAN
REFRIGERATOR
29 30 31 32 33 35 37 38 39 40 .., ~2
197-36181
97 •3 3 C Electrical equipment
Camper from 1986
Electrical System - Wiring, Camper 97
Description Current
Track
Alternator 6
Auxiliary battery 2
Battery 3
Battery cut-out relay 1-2
Ignition/start switch 12-15
Starter 4-5
Voltage regulator 6-7
Wire connectors
T1d- single, wire distributor, LF eng. compart.
T2k - double, under fusefrelay panel
T2m- double, under fuse/relay panel
T7a/- seven point, wire distributor, LF eng. compart.
T14/- fourteen point, on inst. cluster
Ground Connections
G)- ground from battery to body
@-ground from transmission to body
@-ground from aux. battery to body
..._Manual
____ trans. II
_ _......_'-·_Camper
_ _ _1986-1989 I
_..._ _ ___. Auxiliary battery 97 34
• .
97 Electrical System - Wiring, Cam~er
CIS 04 p 024
CAT
ELAPSED
111/LE
COUNTER
a
BATTERY'f85
CUT-OUT
RELAY 1.0
RIBK
87
2 .5
A
T2k
+
WIRING
COLOR CODE
BJ( -BLACK
1= +
70,0
BATTERY ALTERNATOR
0+
BR -BROWN
P- VOLTAGE
CL -CLEAR (
I
REGULATOR
R -RED
y - YELLOW
G -GREEN
LT G - LIGHT GREEN 25,0 25,0 25,0
BL -BLUE
v - VIOLET
GY -GRAY
w - WHITE
OR -ORANGE
0 CD 0
2 3 4 5 6 7 8
197-22981
E4 88 p AS
t
I. T7a/6
IGNITION/START
SWITCH
TO
BRAKE 50 I X p I SU
WARN.
Rfl.AY
0 .5 0 .5 2.5 0 .5 0.5
w w BKIY BK GY/BK
I I
1
I I
TO
DIGIFANT
CONTROL
UNIT
45
TO
IDLE
STAB.
CONTROL
WIRING
COLOR CODE
BK
BR
CL
R
-BLACK
-
-
-
BROWN
CLEAR
REO
I II
TO
LITE
SWITCH
Et/X
TO
INST.
CLUSTER
T1418
TO
BRAKEtPARK
BRAKE
IND.
y ·-· YELLO W
G - · GREEN
LT G - LIGH T GREEN
BL -- BLUE
v -· \IIOLET
GY - GRA Y
w - - WHITE
OR - ORANGE
9 10 11 12 13 14 15
197-22 991
Electrical System-Wiring,
Diesel
Index
General 1982 Diesel Air-cooled AFC
- Battery/Ground cables - Auxiliary heater BA6 - Refer to 97.11
97.9a, 97.9b ·(Canada only) 97.47, 97.48
disconnecting/connecting 97.6 - Cautions and Warnings 97.2 Camper
- Cautions and Warnings 97.2 -Fuse/Relay panel97.10 - Refer to 97.29
-Dashboard wiring harness 97.7 - Heater booster 97.49-97.51
- Engine/Body ground - Main wiring diagram 97.36-97.40 Waterboxer/Syncro
connections 97.6 current track index 97.36 (Water-cooled Digifant, Digijet)
- Fuse/Relay panel, removing - Rear window wiper 97.26 - Refer to 97.53
(1980-1985) 97.10
(from 1986 m.y.) 97.10a 1983 Diesel
- How to read wiring diagrams 97.4 - Auxiliary heater BA6
- Main wiring harness 97.8 {Canada only) 97.47, 97.48
-Starter cable routing 97.9 _. Cautions and warnings 97.2
- Symbols used in - Fuse/Relay panel 97.10
wiring diagrams 97.5 -Heater booster 97.49-97.51
-Troubleshooting 97.3 - Main wiring diagram 97.41 -97.46
-Working on the electriCal current track index 97.41
system 97.3 -Rear window wiper 97.26
97.35
97 Electrical System-Wiring, Diesel
1982 Vanagon
Diesel
Description Current Treck Description Cul'fent Treck
Cigarene lighter 84
Taillight, right
Turn signal, front left
Turn signal, front right
•
7e
17
Cigarene lighfer light 83 Turn signal, rear left 76
Clock l5e Turn signal, rear right 78
Coolant over-temperature warning Turn signal swilch 73
light 38 Turn signal warning light 32
Coolant temperature gauge 34
Coolant temperature gauge sender 34 Voltage regulator
Voltage stabilizer •37
Door contact switch/buzzer, front left
Door contact switch, front right
Electro-magnetic cut-off
Emergency flasher relay
3
18
88-71
Windshield washer pump
Windshield wiper motor
Windsheild wiper switch
Windshield wiper/washer interminent
....•
liiHI
Emergency flasher switch ~71 relay ICH3
Emergency flasher warning light 79
Engine oil pressure switch 31 Wire Connectors
Engine oil pressure warning light 31
Engine temperature sender Tt b - single, behind dash
(pre-glow system) 17 T1c - single, behind dash
Ttd - single, in engine compartment next to alternator
Fresh air controls light 82 T - single, behind dash
Fresh air fan 158 T1f - single, next to interior light rear, left
Fresh air fan resistor 57 T1 k - single, behind dash
Fresh air fan switch 57,58 T2 - double, behind dash
Fuel gauge 33 T3 -double, under driver's seat
Fuel gauge sender 33 T3b - three-point, in connector
Fuses, in fuse/relay panel (S-1 to S13) T3c - three-point, behind dash
Fuse strip for glow plug, in engine T4a -four-point, in connection
compartment 20 T4b -four-point, in connection
T4c -four-point, behind dash
Glow plugs 20,21 T1 4/ - fourteen-point, on instrument cluster
Glow plugs relay
Ground Connectors
Headlight dimmer and flasher switch 43-44
Headlight high-beam warning light 38 CD - Banery ground strap, to body
Horn 13
Horn bunon .13 ®- transmission/body
,.
II(
...s,, So2
20
II( ...
II
Wiring
Color Code
IIIQ 10
-BK
bon -BR
SHY
(1011
&ol
- CL
-R
BELT " .u
\'30GLOW
WIING ... l'f.UGS
1.... -Y SYST RELAY
WIING l 87
Grton -G
UTE
lti
~ Green - lt. G
l!oe
\'IIIII(
-BL
-v
20
G'VG IR ....
20
!by -GY
INi -w
20 20 20
GY~IK
SHY
BELT
.a.,
WIING
SYST K
i BK-UI'
p
RELAY UTE
)'( SW
20
GY/JI
·~
18
'""~T. .
18 18
IIC,..l
~.
~
20
y,
T, , TJ 18
20 Yr2.
20 20
r,.
"{::_, T•• 18 18
II(
20
Bl/ W
20 10
•
J
M
u
•• 11
BilK BilK
UTE UTE !!' GLOW
011 l'ftK ·II -L l'f.UGS
riiN
BTN ELECT ENG
CNTCT 8111( MAG TEMP
swt
au z
WIING
UTE
II
••
If
•••• 18
CUT· SNOII
Off J:E·
.Lf sw u •• ow
SYST)
@ @)
' 2 :II 4 • 6 'I • t 1011 12 Ia I~ 11
~Door 8wtlohelltet.tr ....
All wire sizes American Wire Gauge
.,.....-+-.,. u... --t-1 -Honll I
IS 16 11 11 "
...""' Llghii/Qiow ...... ~
10
Diesel 1982
Main wiring diagram 97.37
97 Electrical Syst~m-Wirlng, Diesel
II -
----~------~~------~~~
10
-I~ •
r
II
y
UDIO
CONN
,.., 22
11 10
_,."" ..10 GLOW
TIME
IND
fNG
OIL TIIN
l'flfSS SIG
WIING WIING
II
GY
20 16 12
w Y/1«
......20 20
~o·~i~
20
ll K w GV)I
lNG TAIL ·
OIL UTI
l'flfSS -II U
SW
---- - ,
• ...,v
1------!~. ::En
10 II
~ 30 LOAD
r
10
11</ Y
20
fi~"""
•• ••
20
S1o
16A
= 16
II(~W
18
•• y
Wiring ..
-y-
Color Code
-BK
uf.
).'Alii
lUSH
~1l
Cleat -CL
Red -R
-Y
Gr... -G
\Jijll Groen -LI. G
!Ill& -Bl
l(oOiel -v
Gray -GY
Mille -W 16 16 16
W Y/ U: y
IIISH
Alii
IAN
llfSIST
20 20
SIDf INSTil
MIIICII ,ANfL
LIJf 20
UTfS
••
Diesel1982
Main wtrfng diagram 97.39
97 Electrlc~l System-Wiring, Diesel
16 16 10
I
I
I I
10
I
s. s. s,
OA
6A
18 20
R/Y I
'
..
20
t
II 18 II II
EMEII.G w IK/w/G OK/W IK/C
==~LJ~~
..
20 20 l2 sw 12
~ ] r2 r2 T,,
1/BK~ ~~~ ij'
203°, ;F)
18 18
e¥./ W IK W
II
BK/ G
II
IK/C ..
20
,.
8K
20
G't/ Bl
I 2
~ ~ 11 Tl4!1
FII.SH
Alii.
CNTIUS
•
....
Cigarette lighter light light switch 'N T2d - double, behind dash
Clock t1 T2e - double, in connector housing
Coolant low-level-warning Radiator fan fl7 T2f -double, behind dash
control unit Radiator-fan relay 8NO T2g - double, in connector housing
...••
Coolant low-level-warning Radiator-fan thermoswitch I 17 T2h -double, in connector housing
switch Radiator-fan thermoswitch II 80 T2i - double, in connector housing
.
Coolant over-temperature Radio connection 10,14 T2k - double, behind dash
warning light Rear side-marker lights 45,48 T21 - double, below driver's seat
Ouo COOl
FA/4
THitM
Coolant-temperature gauge
Coolant-temperature sending unit
98
812
T3
T3a
T4
T4a
- 3-point, near alternator in
engine compart.
- 3-point, behind dash
- 4-point, behind dash
- 4-point, behind dash
sw Door contact/buzzer switch, Rear-window defogger T7 - ?-point, in connector housing
(0.0 •
110•
left 71.73 switch light M TB - 8-point, behind dash, near
23Qe Door contact switch, front right 71 brake warning lights
.......
Door contact switch, right Seat-belt buzzer contact, left 74 T14 - 14-point on instrument cluster
sliding door 14 Seat-belt warning light 75
Seat-belt warning relay 73,75 Ground Connectors
p 20 Electromagnetic fuel cut-off 1e Starter 22,2S
G) -
f· l
Emergency-flasher relay from battery to body
Emergency-flasher switch Tail light, left 47
®-
Emergency-flasher warning
light
•
Tail light, right
Temperature sensor II "30I ®-
from transmission to body
II~~D
Engine temperature sender Turn-signal indicator light behind dash near fuse/relay panel
2
COOl
IAN
(pr81Jiow system)
Fuel gauge
·17
11
Turn-signal light, front-left
Turn-signal light, front-right
Turn-signal light, rear-left
••
14
@
@
-
-
behind dash
at steering-gear housing
~r
I ~':y Fuel-gauge sending unit 11 Turn-signal light, rear-right 83
2nd
Fuse for glow plugs (S2D) ao Turn-signal switch It @ - behind air vent
STAGI Fuses (SI-SI3) on fuse/relay
panel Voltage regulator 14-28 @ - at rear deck
Voltage stabilizer 36 @ - near fuel pump at floor
Glow plugs ao.a1 board/crossmember
Glow plugs relay 1740 Washer/wiper intermittent
relay 98-100 @- near ignition distributor
Headlight dimmer/flasher Windshield-washer pump IMI
switch -..o Windshield-wiper intermittent @- left at cylinder head
•
..
Headlight-high-beam light switch 98-103
Headlight, left I?, at Windshield wiper motor 1~10$ @- near ignition coil
Headlight, right 11.40 in engine compart., left
Horn
Horn button
@ - plus connection, in connector
housing
I
Diesel 1983 Main wiring diagram
current track index 97.41
97 Electrical System-.Wiring, Diesel
fUSE
fOil
A GtOW
l'liJG
Wiring
Color Code
-
10
Block -BK I
Clolr
Aid
-BR
-CI.
-R
t~
---
GtOW
l'liJGS
lfi.AY
y- -Y 17
a.- -G
.,.,.
lJi# Groen - U. G
-Bl.
Vlolol -V
a.., -GY
WNia -W
9
••
IJ'(
12
W«
II
GY
20
Gl'&
T2. ~
r~·
12 12
w Y«
16 6 ,. ,. 2d
W W« Y' v.- GY..t:
} .. -Jl~- T2,
= STIITII
= IATT Oil
I'IIESS
sw
(1.1 !Jor}
I
Dlesel1 983
Main wiring diagram 97.43
97 Electrical System-Wiring, Diesel
v
I 0
10 •
1611'1
1611'1
~
s....
I_· T! 16 16
lA
s, ...s.. I;
UDfO
COHN
Wiring ~T.
Color Code 20
Bladt -BK
'. k
Brown -BR
y-
C!w
Red
-Cl
-R
-v
-
Groen -G
1..911Gr- -U. G
-Bl
-v
10 II
" -
II ll
w
II II
>()
-·
V!Ciol
Glay -GY
-w
IKUI' fMf.G
UTf fUHI
tl =====II GV ======m=:=::l( sw
¢(
10
GV4t
~-J~}·
10
GY.-
7/S
10
GV.-:
II
i If\
II :W lO
. ._ _ _ _ _ .·"'
10
ir~. -~~ ~ ~
>o
A ....II II
ll.G
II
ll.G
llfi.C/7
<ClOCK J H•N
WTTN
lf(UI1 IICUI'
UJI UTI
" 4t
16
• •"
~ ~®
·.~
' . . ~~
f EMERG
·-
FLSHR
WRNG
n.
31 511b
LITE ~ ~o
II 20
M 8R GVrli GV>tl
'""
T.. ~8~ T•• T••
"
"""' Jl/3
"
TU/2
PRKG
~ BRK OR
TIH WRNG BilK IRK CNTCT
SIG LITE UTI liTE sw
UTI SW ·II .t ·II
./l SLIDING
OR
r-
DR SEAT
l CNTCT
BUZZ
SW
-1
BELT
BUZZ
CNTCT
-R
.. ., .. .. • h ,. , ,. , ,. ., 71 ''
r-------------~U.~._~~~up~------------~
10 ...,..
Diesel1983
Main wiring diagram 97.45
97 Electrical System~Wiring, D,iesel
Wiring
b
Color Code
Blocll -BK
Brown -BR
Cloor -CI.
Red -R
y- -Y
-
Groen -G
~Groen -UG
-81.
VIOle! -v
Gtay -GY
WNII -w
Slo
110111
WIND
DEIOG
sw
...
12 IIAD
IAN
II
~·
II
l
::~ Jrl"
THERMO
IlEA II
N'
'lllWII
·WIND
DEIOG "i sw
sw
fTI'
THfiiMO
SWI ~ UTE
...
12 12
I
20
llAI
20
llAI
16 20 10 20 .. .. ,.
w v v
~-~
WIG M
lh ~ RADIO
CONN
ILWII
fAN
ll
I
10
M
20
M .
16 20 II
•
Slo
IlEA II
WINO C!l
DfroG WINO ILWII
H111 w1n11 fAN
flMNr Mfll
12 16 16
• • •
@ @
- '
--·--· --- -- ~
Flame switch 12
Fuel pump 10
Fuel pump contact breaker 10
Glow plug 13
Main suppressor 8
Overheat switch 9
Wire Connectors
Ground Connections
Ft
25
Sn
~~=F~==~~~--·
n
Sn ~~Z~oR
(NTC)
0.5 0 .5
BL Y BL
T~a T.ot.
05
A
I
05
BL BK 0 5 BL·A
TO
LOAD
RED.
RELAY
0 .5
BL
0 .5
BLW
y.., T""
517 SAFETY
SWITCH ~r --
T•• T•b
r~~ !
1.5 1.0
BK Y B\VW
WIRING
COLOR CODE
FUEL HEATER
BLACK - BK PUMP IGNITION
BROWN -BR COIL
CLEAR - CL
REO -R
YELLOW -Y
GREEN -G
LIGHT GREEN - LT. G
BLUE -BL
VIOLET -V
GRAY -GY
WHITE -W
15 1.0
ORANGE -OR G G
J fi_
~~~~
BA CONTACT .
BREAKER
I
OVERHEAT
2 3 .4 s 6 7 8 9 10 11 12 13 15 16
(12.·267(
..
Description Current Track
=
Fuel pump (large quantity)
Fu~l pump (small quantity)
Fuel pump relays 1,HI
Fuse main ( 16A) a
Fuse, overheating (SA) IS
Fuses on fuse/relay panel
S7, 8, 9, 10
Glow plug 15
Glow/spark plug resistance wire 16
Glow/spark plug resistor relay 15-17
__, 0.5
BL Heater control light I
' Ignition coil 1
Light switch 1
Load-reduction relay 4
;
R Overheat switch m
Spark plug I
Suppressor for air circulation blower 10
Suppressor for glow/spark plug 15
Suppressor for ignition coil 7.a
Temperature regulator control 4-5
Temperature regulator switch t.S
Temperature regulator unit 4-6
Temperature sensor 4
Wire Connectors
UTf
~
sw
1~2 ~,;, ~.:~· ~;;)9
7
';
!
s..
lOAD
lfD
T.. lf&AY
\2 20 12
IK/Y II(
•
All All
CIIC CIIC
18 I&WI 20 20 16 I& WI
., y
h.~r ~~
lf&AY lf&AY
~ll/W GI.O'II/
20.
.f;kJiU~
J,. SUI'f'll Sill«
--- --- I'WG
Kll7
fOI lfSIST
-
IGH
COil lfiAY
20CMilSIY GlOW/ ,. 20
w STAIT
lf&AY
Slif!IC W/11<
"UG
••
lfSIST
________ !V!~--
Ill>
...
:€}----it:----.- - ---- -
lVIII
T••
IK/Y
,. I SUI'f'll
Wiring fOI
-
GlOW/
COlor. Code 51'1« "UG
-BK
Brown -BR II
Cloow -Cl •
N~\~
Red -A
y-
Gloon
~Gioen
!lUI
-Y
-G
-U.G
-BL
.
20
All
CIIC f&AMf GI.OW
I& WI
VIOlet
Glay
-V
-GY
:g:r- Tsw "UG
All
While -w ••
12
CIIC u
11
I& WI
16 20 20
G BR 81:
Wf
[
;
ST
r.. r..
I 'I'
COMBUSTION
20 ,. 1• Alii
••
30
~1
J~-l
- -r 20 16
GY/ IK 1K
f'~ t:J I 18
fUfl
PUMP
/UIG
.. ,~~, OT'I') ••JW
18
fUfL
PUMP
(SMAU
QT'I')
JJ :J
l OVIIHT
sw
..1
I•
,. 11 • 11 a
97.52
97
Electrical System-Wiring,
Waterboxer
Index
General - Air conditioning - Differential lock
- Battery/Ground cables '
1984, 1985 97.137 1986-1989 Syncro 97.178
97.9a, 97.9b 1986-1988 97.139 - Heated driver's seat
disconnecting/connecting 97.6 from 1989 97.142 1986 97.179
- Cautions and Warnings 97.2 - Automatic transmission 1987-1989 Canada 97.181
-Dashboard wiring harness 97.7 1986-1989 97.146 from 1990 Canada 97.244
- Engine/Body ground from 1990 97.219 - Main wiring diagram
connections 97.6 - Auxiliary battery 1983, 1984 97.54
- Fuse/Relay panel, removing 1986-1989 (Auto. trans.) 97.221 1985 97.60
(1980-1985) 97.10 from 1990 97.224 1986
(from 1986 m.y.) 97.10a See also 97.29 up to VIN G 055 689 97.67
- How to read wiring diagrams 97.4 - Auxiliary heater BA6 from VIN G 055 690 97.85
-Main wiring harness 97.8 from 1987 Canada only 97.148 1987 97.102
-Starter cable routing 97.9 -Auxiliary heater BBW46 (Syncro) 1988, 1989 97.119
- Symbols used in 1986-1988 Canada 97.151 from 1990 97.201
wiring diagrams 97.5 from 1989 Canada 97. 155 - Power mirrors
- Troubleshooting 97.3 - Central locking system 1986 up to VIN G 105 000 97.183
Working on the electrical 1986 97.159 1986 from VIN G 105 001 97.185
system 97.3 1987-1989 97.162 from 1987 97.185
from 1990 97.226 - Power windows
Air-cooled AFC - Crankcase ventilation heat element 1986 97.187
- Refer to 97.11 1985 97.165 from 1987 97.189
1986 97.166 -Radio
Camper - Cruise control 1986 97.191
-Refer to 97.29 auto. trans. - Rear footwen heater blower
1986 97.168 1983-1985 97.194
Diesel 1987-1989 97.176 -Stereo radio 1987-1989 97.195
- Refer to 97.29 from 1990 97.229 - Stereo radio with amplified
man. trans. speakers from 1988 97.197
1986 97.174 - Stereo radio with 4 speakers
1987-1989 97.171 from 1990 97.246
from 1990 97.232 - 450-Watt radiator cooling fan
- Daytime running lights (Canada) 1986-1989 97.200
to Dec. 1989 97.234
from Dec. 1989 to May 1990
97.238
from May 1990 97.241
97.53
97 Electrical System-Wiring, Waterboxer
1983-84 Vanagon
Waterboxer
Dt8ctlptlon Current Tr•ck Description Current Track Wire Connectors
Air flow sensor u Ignition distributor 1-3 T1 - single, in engine compart, left
Alternator 24-26 Ignition/starter switch 22·27 T1a - single, in connector housing
Alternator warning light 26 Injector cylinder 1 11 T1b - single, in connector housing
Auxiliary air regulator 13 Injector cylinder 2 12 T1c - single, near alternator in engine comp~
Injector cylinder 3 13 T1d - single, behind dash
Bat1ery 20 Injector cylinder 4 14 T1e - single, in connector housing
Back-up light, left 55 Instrument panel light 41,50 T1f - single, behind dash
Back-up light, right 58 Instrument-panel light T1g - single, behind dash
Back-up light switch 65 dimmer 42 T1h - behind dash
Blower fan 105 Interior light, front 81-113 T1 i- at roof cross-beam, rear right
Blower-fan control-lever light 87 Interior light, rear 84--88 T1k - single, behind dash
Blower-fan resistance 104 T2 - double, on fuse/relay panel
Blower switch 104, 105 License plate light 42.43 T2a - double, behind dash
Brake light, left eo Light switch 40-42 T2b -double, behind dash
Brake light, right
Brake-light switch
Brake warning light
78
79,80
88
Oil-pressure switch (1.8 bar)
Oil pressure warning light
2t
29
T2c
T2d
T2e
- double, behind dash
- double, behind dash
- double, In connector housing
,.
Oxygen sensor 7 T2f - double, behind dash
Cigarel1e lighter 70 Oxygen sensor elapsed- T2g - double, in connector housing
Cigarel1e-lighter light 88 milage indicator light 28 T2h - double, in connector housing
Clock 51 Oxygen-sensor elapsed T2i - double, in connector housing
Coolant low-level-warning milage switch 28 T2k -double, behind dash
control unit 33,34 T21 - double, below driver's seat
Coolant low-level-warning Parking light, left 48 T3 - 3-point, near alternator In
switch 33 Parking light, right 41 engine compart.
Coolant over-temperature Parking-brake warning T3a - 3-point, behind dash
warning light 34 light switch 78 T4 - 4-point, behind dash
Coolant-temperature gauge 32 Power supply relay 18, 17 T4a - 4-point, behind dash
Coolant-temperature sending T7 - 7-polnt, in connector housing
unit 32 Radiator fan 87 T8 - 8-polnt, behind dash
Defogger cut-out relay Radiator-fan relay 88-80 T14 - 14-point on instrument cluster
(X-contact) 81-97 Radiator-fan thermoswitch I 87
Door contacl/buzzer switch , Radiator-fan thermoswitch II 90 Ground COnnector•
left 72,13 Radio connection 60,84
Door contact switch, Rear side-marker lights 45,48 Q) - from ballery to body
front right 71 Rear-window defogger
Door contact switch, right heater element 82 @ - from transmission to body
sliding door 84 Rear-window defogger
indicator light 83 ®- behind dash near fuse/relay panel
Emergency flasher relay 151-58 Rear-window defogger switch 82
Emergency-flasher switch 6H8 Rear-window defogger
@- beh ind dash
Emergency-flasher warning switch light 94 @- at steering-9ear housing
light 88
Fuel control unit 8-15 Seat-belt buzzer contact, left 74 @- behind air vent
Fuel gauge 31 Seat-bell warn ing light 75
Fuel-gauge sending unit 31 Seat-bell warning relay 73, 75 @- at rear deck
Fuel pump 18 Spark plugs 1-3 @- near fuel pump at floor
Fuel pump relay 18, 18 Spark plug connectors 1-3 boardicrossmember
Full-throt11e enrichment Starter 22,23
switch 11 @- near ignition distributor
Fuses (S1-S13) on fuse/relay Tail light, left 47
panel Tail light, right 44 @- left at cylinder head
Temperature sensor II 6
Hall generator 4, 5 Timing/RPM sensor 4, 5 @- near ignition coil,
Headlight dimmer/flasher Transistorized ignition in engine compart., left
switch 38-40 control un it 3-6
Headlight-high-beam light 38 Turn-signal indicator light 30
@- plus connection , in connector
housing
Headlight, left 37,39 Turn-signal light, front-left 65
Headlight, right 38,40 Turn-signal light, front-right 82
Hom 53 Turn-signal light, rear-left 84
Hom but1on 53 Turn-signal light, rear-right 83
Idle stabilizer 4, 5 Turn-signal switch 61
Idle switch 4, 5
Ignition coil 1-3 Voltage regulator 24-26
Voltage stabilizer 35
Washer/wiper intermit1ent
relay 98-100
Windshield-washer pump 86
Windshield-wiper intermil1ent
switch 98-103
Winsh ield-wiper motor 100.103
Note:
Wiring
~~
ine compart. Color Code
,. Block -BK b
Blown -BR
Clear -CL
Tl/IISTII
IGN
Red -R .....
II
CNTIIL Yolow -Y
UNIT Groen -G
I-I.~.
II 16 16 16 20 20 20 10 II
" ·.~--, G II
w
~21
~--------------------~~--------------------~
rr rr"..
,~:11 -
Q
er G!W
II
w
2
II
w
11
w w
II
..
16 II
w
16
w
ll
w
II
w
18
w
10
w
20
II
w
IJ
I• IS
"
I
! panel
' I
II!I*
IN~IN~INrlr~
~it ~~~ ~ ~YL ~~~t
10
j~t.,
1--J:ll f_ -- - ~~~p
T7II6 A .
11
RELAY
11 ll 11 II PWR 16 11 11
w w w w SPPLY • w
21 29 26 27 RELAY
SPK
PI.UG
CONN
TMNG
RPM
SNSII
lfctj) : "'i',uu
1_1 ~THIITL AUX
lOr
SPK
PI.UGS M AIR
ILOW II
w
ENIIICH
sw
J
AIR
REG
t.t:l
TEMP SNSR
SNSII II "
.
- .,
18
• t
.,,.,
II
10 t1 tl
II
M/'1
D li
•
..
------~~------------~~~~~--------------~-1
Note: All wire sizes Amer ican Wire Gauge
r===:===r~~~~~~~]
IGN
STRTR
sw
30
16M
X CONTACT
-
"
9
16
lti'f
12
we "
GV
20
GY. .
~· l
T2• ~
r"1...
SW
12 12
w
16 20
YC GYAI
•
±-2·
5
••
10 •
I Oliff
10 Off
"\
s•
••
v
~~
II!
16 10
s, ~.Sn
•• ••
IADIO
COHN
T,.
Wiring
Color Code
10
"' •
w·
20
s;Ji't<>o
FLSHR
Blown -BR sw
'/i't L1
Clear - CL
Red -A
'{
n"
Yellow -Y I ••
Gteeo -G
~·
-
light Gteeo -Lt.G I
Blue -Bl 18 II II liS 18
-v
IL~
VIOlet
Gtay -GY
While -W
Gv========,;=::::::Q HORN
rl~·
= 18
c:::a r.:.~~
9
20 20 20
G't'~
11/6 .a,,
GY... GY.tk
..
18 II >O >O >O
~t.
fl~~
f7/> rlfl
'~tl
REAR
20
h'i\n.
SIDf
MRKR
G[
0
INSTR
>O
'
~f14{l
..,.
18 18
IIOG
II
IIOG
--
II II
J
1 PNL
"'I' LITE
LIC
PL
c~TAILC~ ~~ G~TAIL~ PRKG;.~9'
2' ~ ~ <CLOCK C~KU; 98KUP 9TRN~ ~TIN ~~TRN ~TRN
UT
..
18
LITE ~
·• .. ..
>O 20
LITE
-L
UTE
·L
HRN
BUTTN UTE
-L ..
UTE SIG
UTE
-IR
SIG
UTE
-Ill
SIG
LITE
-IL
SlG
UTE
-IL
~
~ll
..•• ==='
II
= .
10 i! II
~-------~----~--~~----~~·~--~.,~--~----·
..
Note: All wire sizes American Wire Gauge
fMfiGU
ILSHI
WING~
UTI II~
sao
30 30 20 20
~~1
I'IIKG
BIK
WING
UTI
sw
~=F==================~=====F===c
b
Wiring
Color Code
Black - BK
B<own -BR
Clear -CI.
Red -R
Yelow -Y
Groen -G
l..ightGreiKI -U. G
Blue -Ill
VIOlet -v
Gray -GY
White -w
REAR
WINO
OEFOG
sw
RAO
.,.
12
FAN
J Nl
THERMO
:!Z
THERMO ~f1a
SWI ~
-12 12
I
20
IIAI
20
IIAI
ILWR
FAN
~87 llr"
RESIST
12 20 20
..•• 20
.. ..
II II 16
[, ~ .
Golt
'
j
~ ~WWD
REAR
WJHO
OEFOG ·
HTR
fLMNT WSHR
)'f ~UM,
..
12
..•• ..
20
••
Bll
@ @
11 •• fO " H t:l ,. " f6 t7 " " .ioo 101 10:1 104 105
......__ _ _ _ _ _ _ Rad..torF•n!Oelotter/WindahlelciW•Iher/Wiper _ _...;...._ _ _- l
Air flow sensor 8,9 License plate light 42.43 T1 - single, In engine compart., left
Atternator 24 Light switch 40-42 na - single, In connector housing
Alternator warning light 26 T1c - single, In connector housing
Au~iliary air regulator t3 Oil-pressure switch (1.8 bar) 29 T1d - single, behind dash
Oil-pressure warning light 29 T1e - single, In conneclor housing
Battery 20 ~ygen sensor 7 T1f - single, behind dash
Back-up light, left 55 Oxygen-sensor elapsed-mileage indicator n~ - behind dash
Back-up light, right 54 light 28 T1i - at roof cross-beam, rear left
Back-up light switch 54 Oxygen-sensor elapsed-mileege switch 28 T2 - double, on fuse/relay panel
Blower fan 105 T2b - double, behind dash, felt
Blower-fan control-lever light 87 Parking light, left 48 T2c - double, behind dash
Blower-fan resistance 104 Parking light, right 42· T21 - double, behind dash
Blower sw~ch 104, 105 Parking-brake warning light switch 76 T2h - double, In connector housing
Brake light, lelt 80 Power supply relay 18, 17 T21 - double, behind dash
Brake light, right 79 T3 - 3-poin!, near ahernator in engine compart.
Brake light switch 79,80 Radiator fan 88 T4 - 4-point, behind dash
Brake warning light 77-79 Radiator-fan relay 88-90 T4b - 4-point, in connector housing
Radiator-fan thermosw~ch I 88 T7 - 7-point, in connector housing
Cigarette lighter -69 Radiator-fan lhermoswitch II 90 T7a - 7-point, In connector housing
Cigarette-lighter light 68 Radio connection 80 T14 - 14-point on Instrument cluster
Clock 51 Rear side-marker lights 48,47
Coclant low-level-warning control unit 33,34 ' Rear-window defogger heater element 93 Ground Connector•
Coolant low-level-warning switch 33 Rear-window defogger indicator light 94
Coolant over-temperature warning light
Coclant-ternperature gauge
34
32
Rear-window defogger switch
Rear-window defogger switch light
93-95
95
0 - from battery to body
Defogger cut-out relay (X-contact) 91·97 Seat-belt warning Ught 75 G) - behind dash near fuse/relay panel
Door contact/buzzer switch, left "72, 73 Seat-beh warning relay 73,75
Door contact sw~h. front right 71 Spark plugs 1-3 • @ - behind dS$11
Door contact sw~ch, right sliding door 84 Spar!< plug connectors 1·3
Starter 20,22 @ - at steering-gear housing
Emergency-flasher relay ~7
Emergency-flasher switch 57~ Tail light, fait 48 @ - behind alr vent
Emergency-flasher warning light 66 Tail light, right 45
Temperature sensor
Timing/RPM sensor
6
4, 5
@ - at rear deck
Fuel control unit 8-15
Fuel gauge
Fuel-gauge sending unit
31
31
Transistorized ign~ion control unit
Turn-signal indicator light
3-6
30
@ - near fuel pump at floor boardlcrossmernber
Fuel pump
Fuel pump relay
18
18-19
Turn-signal light, front·lelt
Turn-signal light, front-right
84
82
@ - near ignition distributor
Hall generator 4, 5
Turn-signal switch 61 @ - near ignition coil, in engine compart., left
Headlight dimmerlllasher switch 37,39
Headlight-high-beam light 36
Vohage stabilizer 35 @ - plus connection, in connector housing
Headlight, left 37, 39
Washer/wiper interm. relay 98-100
Headlight, right 36, 40 Windshield-washer pump 96
Horn 53
Windshield-wiper lnterm. switch 98-103
Horn button 53
Windshield-wiper motor 100-103
Idler stabilizer 4, 5
Idle switch 10
Ignition coil 1-3
Ignition distributor 1-3
Ignition/starter switch 22-27
Injector cylinder 1 11
Injector cylinder 2 12
Injector cylinder 3 13
Injector cylinder 4 14
lnstrument-panel light 49.. 50
Instrument-panel light dimmer 43
Interior light, front 81-83
Interior light, rear 86,87
y
1.5
BK
TRNSTR
IGN
CNTRL
UNIT
WIRING
COLOR CODE
BLACK
BROWN
-
-
BK
BR
I1.0
RtBK
k ® I
CLEAR
RED
-
-R
CL
~ rlrrrrl
YELLOW - Y
GREEN -G
LIGHT GREEN - LT G
BLUE - BL
VIOLET -V
GRAY -GY
T2
WHITE -W
ORANGE -OR
1.0 1.5 1.5 1.5 0.5 0.5 0.5 1.5 1.0 0.75
BJ<tW 8K BK G GrW RISK 8R1W BR w w
1ij ~·
FUEL 21
CNTRL
t
r rr rrrrril
UNIT
K I ®
rr
IDLEr
STAB
1 14
1, I,
f
0 .5 0.5 0.5 0.5
G G WBK BR!W
lber ~ 2
I
•
I I" I"
,.
I
23 20
I 1.5I I
13
0.75 0 75 0.75 0.75 1.5 1.5 0.75 0.75 0.75 0 .75 0 .75 0.75
0 75 w w w w w
w w w
w
,.
JJJJ
w G G W BR1W BR
,.
l
I I I
IS
I
6
,ft
HALL
j iNJ iiNJ
t
INJ iiNJ
'( CYL ]'CJL CYL '(CY
3 0.75 4
. . .
GEN I 0.75 f 0 75 0.75
w w '!' w
28 29 26 27
I
SPK
PLUG
... +CONN
TMNG
RPM
SNSR
~~
I•
I
so-'~J
*+ux .
3•
1.0
w
l
t~.c
~
AIR
1.0
BRIY
-1 AIR
REG
FLOW FULL
TEMP SNSR THRTL
•, - ---<;)- -- ' SNSR/1 ENRICH
y y SW
BK
r:rr3 t:fr>t]t
1.0 1.0
"
BR·BI. BR' Y
@
y
@@ @ @ @
5 6 7 8 9 10 II 12 13 14 15
Water-cooled-Digijet 1985
Main wiring diagram 97.61
97 Electrical System-Wiring, Waterboxer
r---<>-'l'-'-C'-R-TR---..-----.f~ 40 R
f sf-1
~ f, -\ ct,
5
r
0.3
GY!llK
4.0
RIBK
1.0
R!llK
1.5BK-::==================
. .~. . .- - 2.5 BKIY
X CONTACT
~ ~
WIRING
COLOR CODE
BLACK -BK
BROWN -BR
CLEAR - CL
RED -R
YELLOW -Y
GREEN -G
LIGHT GREEN - LT. G
BLUE - BL
-V
8.0 6.0 HOLT
VIOLET R R!llK
GRAY -GY Hf.BM
WHITE -W LITE
ORANGE -OR
/NO
Vt::=Tt
r
0.5
BLIW
]_ _ r: J-__IJ
.:J 1.. I 1
0.5
l
J
I
PWR
SPPLY
RELAY
FUEL
PUMP
SNSR
Y:"~
oXY_/I ~wss
(1.8
FUEL
GAGE
SNDNG
UNfT
~tt: BAR)
SW
COOL
TEMP
SNDNG
UNIT
05
BR
@
16 17 18 19 20 21 22 23 2.ol 25 26 27 28 29 30 31 32 33 3.ol 35 . 36
-- I
~
0.5
BK' Y
L L
I 5
R•Y
0.5
R I
0.5
R
tl--4:.J
INSTR
£----j PNL WIRING
LITE LITE COLORCOOE
SW DIM
BLACK -BK
rrr
BROWN -BR
CL EAR -CL
RED - R
YEL LOW - Y
GREEN -G
LIGHT GREEN - LT. G
BLUE - BL
1.5 2.5 1.0 0.5
l
~y
1
W•BK GY GY•BL VIO< ET -V
~s,
GRAY -GY
HOLT
OIMM WHITE - W
r~~H~
ORANGE -OR
rn
I
8A
~
0.5
~
GY•BL 0. 5 0.5
GYIBL GYIBL
~ ~
2.5 2.5 0.5
w
n~ fi&
Y•BK GY·BL
1.0 GY
1.5
w
1.5
WIBK
1.5
y
1.5
Y•BK
0.5
G Y:R
0.5
rl&
0.5
GY•BK
0.5
GY·BK
GY<R
tl l l
fms
p o.5
GY•O
'';1 0.5
0.5
GY•BK
GY:R
2h
Tl4 /5
I 5 1.5
BR
BR@
@ @ @
37 38 39 40 41 42 43 44 45 46 47 48 49 so 51
\97- 20821
Water-cooleci-Digijet 1985
Main wiring diagram 97.63
97 Electrical System-Wiring, Waterboxer
-
a~ ==:::;-,
"
B.OR
-~ 4.0R
~=== 1.5R<Y - -- - - + , .
~ 1.5 ~v -----~
0.5 1.5
BK BKIBL
RADIO
CONN
~
t-F•· '-----0.5
o.5
R EMERG
R -------------+-.. ,-------, -EMERG
FLSHR
WIRING
COLORCOOE
FLSHR WRNG
f
~
\J..
SW
\... , ... u ~~
LITE BtACI(
BROWN
-BK
- BR
l
l..~
CLEAR - CL
RED - R
YELLOW - Y
G.5
BK GREEN -G
110
!
LIGHT GREEN - LT. G
BK/WIG BK'G ~ GYIBL B LUE - BL
BKUP :a. :a. H ~ VIOLET
GRA Y
-v
- GY
LITE
r.o ra
sw ro ro r.o r.o r.o r.o r.o r.o o,s
WHITE -W
ORANGE - OR
BK1W BI«G BKIG BI«G BK1W BI«W BR
~J. G~
HORN '·' ~. • ·- lJiW ~BLWR ~r
~hl~ ~
0.5
BR
TRN
~:·l·~kt--
., ~·
t.O 1.0 1.0 SIG
BRIBL BKIBL BK11li
LITE
l l
1
11 -LF
TRN TRN
HRN
BUTTN
~,
,
~~ BKUP
LITE ~~E ~ G~ fWE
-, -R ·RF -RR · r-cto
0
: - . ' 5 BR LITER
1.5
BR
1 TRNJ
ll S/G
r.o 1.0LITE
~:::t::::::::::::::::::::::::::::::::::B~R---.Ji -LR
62 63 64 65 66 67 68 69 70
-----------•.oR --------------------------------------------~------------------
n1.0
R ·Y
05
R
WIRING
COL-DRCOOE
BI..IICK -BK
BROWN - BR
CLEAPt - Cl
REO -R
YELLOW -Y
GREEN -G
liGHT GREEN - lT. G
BLUE -BI.
0.5 0.5 I0
l
BK SEAT BK R'BK VIOLET -V
BELT J r I c R, Y
GRAY
WHITE
-GY
-W
~~~ 1 151
1
T8/7 ~ CIJtJ BR~ ORANGE -OR
r -~
ILI'Jr818 'Jnu BRK ilii'Jr•ll
TLITE
'WSW 11
os os 18•IWRNG os l1 oR-aK
GY,G auaR LITE BR
I 0
RBK
Tla
i"· fr·
IO
GYIW
10
BK•R
T71<4
o.s
GYR
DOOR DR
CNTCT JPRKG CNTCT
sw BRK sw
·RF I WRNG
' j LITE
BRK
LITE
·R
·R
SLIDING
DR
~~ sw
SEAT
BELT
BUZZ
CNTCT
·R
0 ~
71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87
Water-cooled-Digljet 1985
Main wiring diagram 97.65
97 Electrical System-Wiring, Waterboxer
WIRING
COLOR CODE
BLACK -BK
BROWN -BR
CLEAR - CL
REO -R
'r'El.LOW -Y
RELAY GREEN -G
(X-CNTCT) LIGHT GREEN - LT. G
0.5
BR BLUE -BL
.. o ~ VIOLET
GRAY
-v
-GY
1.5 BKIY _ __ ,
REAR RADIO
WIND CONN
DEFOG
SW
~
0.5 a~i~y WINO 1.0 l.o
GYrSL
FAN
RAD7 WIPER BKILGY JBI(IIf
THERMO
L. INTERMIT
II
LrrE 0.5 1.0 I0 1.0 1.0 1.5 1.5 1.5
G>R BR-sK G GYIEJK GIY W YIBK Y
t.
WASH
2.5 1.5 1.5
WIPER
PJBK R.eL BK INTERMIT
t-=~
RELAY
T 1----+BLWR
r7 -
2.5
R
±RELAY
0.6
FAN
RESIST
Bll
lt.J
REAR
WINO
DEFOG
HTR
ELMNT
WINO
1 FAN WSHR
2.5
0.5
BR
I PUMP Ji$
1.5
BR
t~
1.5 0.5
BK BR.
2.5
BR 1.5
BR
H D K
. ~~ ~ ~
~~~~ RJ]~N
9iF
~-a
~ ..1 ~ •o -.s~
..7 ~ ~ •
11 21 ~5~6.,_ 2 .,_ 3 ~ltx
L 3141 E 21 31
sl 61 ~~~~·5 41 sl
"~ea~~o
71al ~~~·4
~ ~~1 ~2eaeo~
es~~ ~ew'2~ eo ~ ~ ~~ .4 ~ .7 61 71
91101
~~ ..,
~4~5~~6t!2 ~7~
~ I
.16
~~~~ ~~·4
5" ~~~1 ~2~~
0 197-14951
ErnE
ErnE
Eng
Eng
A - multi-point connector (blue) for instrument panel wiring harness Eng
B - multi-point connector (red) for instrument panel wiring harness
C - multi-point connector (yellow) for front wiring harness
Fres
Fres
D - multi-point connector (white) for windshield wiper harness and main wiring harness
Fres
E - multi-point connector (black) for main wiring harness Fuel
F - single connector Fuel
H - multi-point connector (brown), relay connections for rad. cool. fan, 2nd stage Fuel
K - multi-point connector (colorless), connectors for low coolant warning control unit Fuel
L - multi-point connector (gray), horn connections Fuel
M- multi-point connector (black), open terminal (used for light switch terminal 56) and switch for hand operated Fuel
brights and dimmers terminal 56b Fuel
N - single plug Fuel
P - single plug - terminal 30 Hall
R -open Heac
Heac
Heac
CAUTION Heac
Relay locations are subject to change and may Heac
vary from vehicle to vehicle depending on options. Heac
Heat
Heat
Use extreme care when troubleshooting the
Heat
electrical system. Horn
Hom
If you encounter problems identifying a particular
relay, consult your Parts Department. Idle 1
Idle 1
Idle 1
lgn. c
lgn. c
·····26
Series resist. for heater fan
Side marker lites, rear
® -under instrument panel near relay
panel
Fuel inj. cyl. 2 'Z1 Spark plug connectors
Fuel inj. cyl. 3 28 Spark plugs
Starter
® - on rear deck lid
Fuel inj. cyl. 4
Fuel gauge
29
57
@- under instrument panel near relay
Tachometer panel
Fuel gauge sender 64 Tail lite, left
Fuel pump 30 Tail lite, right @ -on rear deck lid
Hall generator 17·18 TDC sensor
Temp. sensor II
@ - on left front crossmember
Headlite flash/dim sw. 92-93 @ - on rear washer fluid bracket
Headlite, hi-beam Ind. :''·55 Tum sig. Ind.
Turn sig. lite, LF
Headlite, hi-beam, left 87
Turn sig. lite, LA
@ - In eng. compart. under ign. coil
Headlite, hi-beam, right 99
Headlite, left 88;.e9 Turn sig. lite, RF @ - on sheet metal bracket near fuel
Headlite, right '97.f8' Turn sig. lite, RR pump
Heater fan 14i Voltage regulator @- on left side of cylinder head
Heater switch 142-143 Voltage stabilizer
Heater switch lite ;'14'1;. @- in instrument panel wiring hgrness
Horn 121 Washer motor
Horn bu.tton 11$ Wash/wipe intermit!. relay @- ill Digifant wiring hemess
Wash/wiper intermit!. switch Welded wiring points ( +)
Idle stab. control unit Wiper motor
Idle stab. velva @- terminal 58b in inst. panel wiring
Wire connectore harness
Idle switch
T1 - single, in eng. compart., left
lgn. coil
lgn. distributor T1a -single, in eng. compart., left
@- + connection bolted to wire
distributor box
T1b - single, in wire distributor box
31 31
r---~==~==t=====================~~1
p p p p p p 024 88 p AS
6.0 6.0 0.5 0.5 0.5 1.0 4.0 4.0 1,5
A A/BK BL BL RIBK RIBK A sw
f
2.5
A
BK -BLACK
BR -BROWN
CL - CLEAR
R -RED
y - YELLOW
G -GREEN
LT G - LIGH T GREEN
BL -BLUE
v - VIOLET
+
--~==--~50~8~·==~· ALT.
VOLT
REG.
4.0
BA
2 3 4 5 6 7 8 9 10 11 12
j97-2252l
97.70 Alternator/Starter/Ignition
up to YIN G 055 689
Water-cooled- Dlgifant 1986
Electrical System - Wiring, Waterboxer 97
30 30 30
15 15 15
~
X X
- -
31 31 131
~1 61 61
l a a
~1 ~5
~ n~~
4 I 2
~
ID
,,.? ' 8 ' 6 3
b
I r-1 l
'E12 C21 019 026 A15 C12 C18 06 013 N E14
0.5 0.5
G G
I
1.5
BKIW
1 d~!15 DIGIFANT
CONTROL
12
I
I 3
0.5
I
BRIW
.1
1.0
BR
0 .5
BRIW
0 .75
w
.4 l J, t
I (~ © I II tJi:I~w
h~
SENSOR
WIRING
COLOR CODE
HALL BK -BLACK
GENERATOR BR - BRCWN
CL -CLEAR
R - REO
y - YELLOW
I Tic G -GREEN
LT. G - LIGHT GREEN
BL - BLUE
FUEL v - VIOLET
IDLE ENRICH. GY - GRAY
sw. sw. I I w -WHI TE
I ~·~{ I
~ SENSORn
TEMP. OR -ORANGE
SPARK
PLUGS I~ ~
I
~ .. AIY
o.5~0.75 w-48 d
e
f
13 14 15 16 17 18 19 20 21 22 23
/97-22 53 /
------------~E~4~------------------------------~D=1~~j~G~6--~~~4~--~~~0~23~~--D~15~--
1.0 u
RISK sw
'T7o6
I
1.0 RISK
c ------------~--------------------------------.
SA SA G
I~
SK 1.0 R
! ! \ '
~ ~ ~~JOR
~FUEL
I[A_J
~ PUMP
----~
L. -,.-'. HEATER
>J
1.0 w
15 19 18 15
•
24 25 26 27 28 29 30 31
!97 225~
61
131
61
311
I
BR - BROWN
CL - · ClEAR
R - REO
- YEU.OW
G - GREEN
LTG- LIGHT GREEN
BL - BLUE
V - VIOLET .4{
G'r' - GRAY
g-0.5W•45~ W -WHITE
OR - ORA NGE
________________________________
L----~1_6 ~
IDLE
I~:.TROL
STAB.
©
1114
0.5 BK 0.5
rs r r3
0.75 0.75
18
0.5
r
0.5
tll
0.5
r
0.5
r7
0.5
h _ _ _.... ~ w w RIY w y WIG G
I
53 8 48I
T.D.C.
SENSOR
r.
- ----- ~
~
30
,.
15
- --
~
..... - - 15
X
~ ~- /
"""" X
131 31
~1:
61
'
~3 t II
6 4
7 '2 5
k
r----, .r--1
~
E15 D21 81 824 819 :.\3 08 A27 03 818 815 821 K3 82 El 0
T
0.5 0.5
BK R
1,8 __ ~
J 114 l f-9u-l ® ~~
15
< Ka
1
T7a 7 T7a 1
WIRING
COLOR CODE
BK -BLACK
BR -BROWN K2 ALT. WARN. I.JrE
CL - CLEAR K21 OXS IND. LITE
R -REO Y2 CLOCK
I Tlk 1 Tle G5 TACHOMETER
Y - YELLOW
J114 ENG. OIL PRESS. CONT. UNrr
G -GREEN K3 OIL PRESS. WARN. LrrE
0.5 ENG. 0.5 ENG. Lr G - LIGHT GREEN
BR OIL BR OIL BL -BLUE
1 PRESS. I PRESS. V - VIOLET
0 sw. 0 sw.
I:Jl (0.9 Ol(0.3
GY - GRAY
.T143
0.5
BR
lw t,o
•
41 •
42 43 44 45 46 47
12-o
48 49 50 51
..
,97--2-2-5---,61
97.74 lnatruments
up to VIN G 055 689
Water-cooled- Dlgifant 1986
Electrical System - Wiring, Waterboxer 97
30--------------~
, ----------------------~
.-.~~---------------------------------30
0 15 r _ 15
5 X X
31 -.• 31
0.5
'I
GY/BL
"'"
LtO
L8
K5
INST. PANEL LITES
CLOCK LITE
TURN SIG. IND.
II
C'
I COOLANT
Kt
Gl
G3
1<28
J6
HEADLITE HI-BEAM IND.
FUEL GAUGE
COOLANT TEMP. GAUGE
COOLANT TEMP. IND. LITE
VOLT. STABILIZER
8J LOW·
LEVEL
'
II
.------......
WIRING
COLOR CODE
F-1
0.5
BR
0.5
BR
I ,G
BK - BLACK COOLANT
TEMP. I s~~ I FUEL
GAUGE
BR - BROWN SENDER SENDER
CL - CLEAR I
I
R - RED
Y - YELLOW
G - GREEN
LT G - LIGHT GREEN
BL - BLUE I T7 7
V
GY
-
-
VIOLET
GRAY 1.0
•
1.5 1.0
W - WHITE BR BR BR
I OR
52
- ORANGE
53 54 55 56 57 58
r~
59 60
I
61
15
62 63 64
1 1
2
/97-2257/
I
1.5 0.5 0.5
R R R
WIRING
COLOR CODE
BK -BLACK
BR -BROWN
CL -CLEAR
[47 R -RED
T
Y - YELLOW
G -GREEN
LT. G - LIGHT GREEN
BL -BLUE
0.5 0.5 0.5 V - VIOLET
GY/BL R R GY -GRAY
W -WHITE
OR -ORANGE
T4
rn
0.5 RADIO 0.5
GY/BL CONNECTIONS R
30
MAKE· INTERIOR IUTE,NTERIOR
UP LITE,
MIRROR FRONT REAR
LITE 31
T Ji" --t1
0.5 0.5 0.5 0.5 0.5 0.5
RADIO
CONNECTIONS
BR BR l
B;:; l _ _ _ _ _ _ _ _ _ _.. BR!BL BR
T
0.5
iT4
0.5
I T2d
BR BR
CIGAR
UGHTER
Rl
L1J
I
DOOR
CONTACT
CIGAR sw.
LIGHTER (SUDE
31 1
LITE DOOR)
1.5
BR
65
1 20
66 67
.20
68
:I~
69 70 71 72 73
lr-97---22-5--,81
810 Ml 827 El
I
C
92 Jb; 931
2.5 2.5
BKIY W!BK
INST.
PANEL
LITE
I 30 ,3o
58l! DIMMER
IL UTE
.. I
!I r8b
SWITCH
WIRING
COLOR COO~ 0.5
GY/BL
BK - Bl..ACI(
I~Sso
BR -BROWN
CL - CLE~R
R - RoD LICENSE
y - YELLOW Pt.ATE
G - GREEN
UTES
I. T G - LIGHT GREEN
9
BL - BLUE
v - VIOLET lli1 lOA
GY - GRA Y 0.5111()
w - WHITE BR I
OR - ORANGE
0.5
BR
~Jli ~ _LQ_ZJt
co_: _, c. J ~ ~ ~~
74 75 76 77 78 79 80 81 82 83 84 85 86
"1
9-7-2_2_5 9--,J
1.5 1.5 0.5 0.5 2.5 2.5 0.5 0.5 1.5 1.5
w Y GYIBK GY/BK y w GY/R GY/R Y/BK W/BK
75
I
1.0
RIY
2.5
WiBK
r
79
I T7i6
LHEADLrrE
FLASH!
DIM
sw.
0.5 0.5
Y/BK GY/R
HEADUTE, '·
I 58 I 58 II SIDE SIDE 1\ 158 1
58 56o
HEADLITE,
HI- r' ~+ \ )
PARK TAIL
. LITE, Q UTE,
MARKER
o· LrrES
MARKER
LITES, +
TAIL
LITE, 0
PARK
LITE, (
.
.]
I
(\ HI-
J.
BEAM, ', I LEFT_ • LEFT REAR \ , .- J BEAM,
LEFT
1~
,31 ,31V_ v•31 131 RIGHT
1':\ 1~5 r:~LITE, 0.5
REAR l . i : rlHT
HEADLrrE, 1~5 ~
BLJ Bi
B~ L:i BIR L:i BL.J BIR RIGHT
l.
- - - - - -··
- --~----
_ _,
-- u
- v
- w
8 15 10
87 88 89 90 91 92 93 94 95 96 97 98 99
197-2260!
97.78 Ughts
up to VIN G 055 689
Water-cooled- Dlglfant 1986
Electrical System - Wiring, Waterboxer 97
30 30
15-,----------~--=------------------------------------------------------------------15
X X
31 t 31
ms19 ms4 ~m
! lOA 15A
1 , J(o49a 2
I -1----- ~- I ~r::.· T
RELAY
tr,_i-
1 I A18 828 A10 All A7 C19 Ell C8
1.5 1.0 1.5 1.0 1.0 1.0 1.0 1.0 1.0 1.0
BK!BL W RIW BKJ\WG BK!G BKJW BKJW BK!W BK!G BK!G
49a
TURN
SIG.
SWITCH
1.0
~R
1.0
f
1.0
BKJW/G BKiG BKIW
WIRING
COLOR CODE
BK -- BLACK
BR - BROWIJ
CL CLEAR
- nED Bl BL Bl BL
" - YELLOW
•1
TURN TURN
1
TURN TURN
G
tT G
fk
GY
- GREEN
· LIGHT GREEN
BLUE
\.i /Ot.E T
•. GRAY
() 5/G.
LITE,
LR r-·- i
() 5/G.
'J LITE,
LF
() SIG.
. UTE,
RR i
() SIG.
LITE,
RF
~\l -· Wf-IITE
1.0 1.0
OR O~ANGE
~ 31 .84 .
J BR BR
w
u
v
- .--~· -=t
.20 10 10
u
I
100 101 102 103 104 105 106 107 108 109 110 111 112
§iii]
,---
r I ~
C3 )Cl IE16 016 C20 l1 L-4 L2 825 C15 L3 C13
I T2g T2g
lfl~K:
liJsw.
'I'
1.0
BKIBL
T 73 I T1b
i
1.0
RIBK
WIRING
71 COI.ORCODE
[}lHORN
BK -BLACK
L:JBUTTON
~ll - BllOWN
CL -CLEAR
i
1.0
R
Y
G
LT G -
-REV
-
-
YELLOW
GllEEN
LIGHT GllEEN
BR
BL -BLUE
I,
V -VIOLET
GY -GRAY
u W -WHITE
OR -ORANGE
-
GR EEN
LIGHT GREEN
DLUE
...
12
0.5 0.5
-.--
100
0.5 1.5
V - VIOLET
GY - GRAY GY/BK R/BK GY/BL BK!W
£ ''" '
W - WHI TE
OR - ORANGE
'+
l~l39
jT85 jT8 1 .T84 .31
0.5 0.5 0.5 0.5
GY/G BR BU BR BR
i79l 1 T3a
I 250 6 15
'IlliG
0 .5
GY/R
rr
1 T1 a
0.5 T2 I T2 0.5
BR/W BR
! [:I] SEAT
PARK
1
BRAKE ,_ REAR
8J BJ
BELT
l8
sw,. BRAKE FLUID DEFOGG
LF LITE LEVEL HEAT
sw. sw. _ ELEMENT
i
DOOR DOOR
CONTACT
sw.,
RF
CONTACT
sw.,
LF
l
0.5 1.5
BR BK
10 8 20 20 9
122 12 3 124 12 5 126 127 128 129 130 131 132 133
197-2263 1
30 .
15
-~
. :.<
-
- ,r tr:-
',)
··-~ JP ..J
X
31
. .-·
'- .·
' l , r:--
rns13
,125'A
~51 30A
HI cP..-----;\
6/86 8187
IJtot
7
'"
.T
I St4
20A
A22 C7 H6 H3 IH1
\L H4 H2 H5 A23
RAD.
1.5 2.5 1.5 2.5 1.0 COOL 1.5
BK/R RJW RIBL R BR FAN BK/Y
RELAY
2ND
STAGE
GY/BL
8.3 .
0.5
I FRESH
AJR
so
-.-
0.5
GY/BL
' Tu
FAN
FRESH ~ , .. sw.
f~TROL IpL16 --~~~
HEATER HEATER
SWITCH
i
SWITCH
[ LITE
LITE
0.5
BR
1.5
y
rrr 1.5
Y/BK
1.5
w
2.5
BK/R
0.5
BR
1.5
y
i1
1.5
w
I I~ ~~~· FOR
FRESH
AIR HEATfR
FAN
FAN
1.5 1.5
y y
,67 I T3b
+C._ __. 2
·~--
~HEATER
.....
~[~!r ·--
FRESH
AIR ~FAN
FAN
-~ r;;- -Q
1.5 2 .5 1.5
BR BR BR
8 10 8 20 6
134 135 136 137 138 139 140 141 142 143
197-22641
97.82 Fans
up to YIN G 055 689
Water-cooled- Dlglfant 1986
Electrical System ... Wiring, Waterboxer 97
1.5 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 0.5 1.0 0.5 0.5
BR BR G/BK GfY GY/BK G G GY/BK GfY G/BK BRISK GIW G/R G/R
WASH!
WIPER
INTERMITT.
swrrcH
WIRING
COLOR CODE
BK - BL.ACK
I 53b 1 53a I 53e
_._t _
I
I
T\
• IMOTOR
WIPER
BR
CL
-BROWN
- CLEAR ~~WASHER
R -RED L.YJMOTOR
Y - YELLOW
G
BL
v
-
LT G -
-
-
GREEN
LIGHT GREEN
BLUE
VIOLET
t
0.5
GY -GRAY BR
I w - WHITE
I.
OR - ORANGE
10
~512
15A
D
4 3
~
ES Rl R2
Fuse/Relay Panel
IJ - coolant level control unit
g - rad . cool. fan relay, 2nd stage
m- load reduction rel ay
mJ - intermit!. wash/wiper relay
m- rear window wash/wiper rel ay
m1 - emerg. flash/turn sig . relay
Fuse arrangement
according to numbers on fuse panel as seen from
left to right :
Amp .
1 Radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2 Stop lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Cigarette lighter, radio, clock. interior lights,
central locking system . . . . . . . . . . . . . . . . . . . 10
197-1392 1
4 Emergency flasher system . . . . . . . . . . . . . . . 15
5 Electric fuel pump . . . . . . . . . . . . . . . . . . . . . . . 15
6 Vacant
Connections and plugs on fuse/relay panel
7 Tail , parking and side marker lights, left . . . 10
8 Tail , parking and side marker lights, right . . . 10 A - multi-point connector (blue) for instrument
9 High beam right, high beam indicator light . . 10 panel wiring harness
10 High beam left . . . . . . . . . . . . . . . . . . . . . . . . . . 10 B - multi-point connector (red) for instrument panel
11 Wind . wipers and washer . . . . . . . . . . . . . . . . 15 wiring harness
12 Heated seats, outside rear view mirror C - multi-point connector (ye llow) for front wiring
adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 harness
13 Rear window defogger, heated rear view D - multi-point connector (white) for windshield
mirror ......... .. .......... . . . ....... . . . 15 wiper and main wiring harness
14 Fresh air fan , glove compartment light . . . . . 20 E - multi-point connector (black) for main wiring
15 Back-up lights, shift console light (Auto. harness
Transmission) ... . .. . . . . . ..... .. ...... . . 10 G - single connector
16 Horn (single tone) . ............. . ....... . 15 t-1 - multi-point connector (brown) to connector for
17 Vacant rad . cool fan relay , 2nd stage
18 Dual horn, coolant level and temp . warning K - multi-point connector (colorless) to radiator
light .. . . .. . ...... .. . . . . ..... . ...... ... . 10 coolant low-level control unit
19 Turn signals , brake warning light ......... . 10 L - multi-point connector (gray) for horns
20 License plate lights . ... .. . .............. . 10 M - opoil position
21 Low beam left .. . .... . ......... . .. . .... . 10 N - single connector
22 Low beam right 10 P - single connector (terminal 30)
A - open position
CAUTION
Relay locations are subject to change and may
vary from vehicle to vehicle depending on options.
~----------~--+------+---.---+-------------------4--b
2.5
R
1.5
R
i REGULATOR Cl - CLEAR
R -REO
y - YELLOW
~) CD
2 3 4 5 6 7 8 9 10 11
197-24101
D Ss
7 8 6 3 10A
T2~ T7a/5 BL
V
-
-
BLUE
VIOI..ET
_ _, . 1.0
GY - GRAY
BKIW W -WHITE
OR -ORANGE. OIGIFANT CONTROL
15 UNff
IGNITION
COIL
®
t25 .8 ~ .6 .9 .21 .17 .10 tn
~.0 1.5 0.5 0.5 0.5 w 0.5 1.0 0.5 0.5 1.0 0.5
BK BR/W w w w w w
G A/BK G 57
_,
I
I
1(~4)
I I I I
~ .,-~~-=:---....----
L I
u,
9 21 17 10 11
0 .5 0.5
BRIW 1.0 BR/W 1.0 w
•
IONfTION BR 20
DISTRIBUTOR
<D
.1/-
HTG
ELMNT
(CRKCASE
VENT)
SPARK PLUG
CONNECTORS
SPARK PLUGS
1HIIOffi<VALI'E
SWTTCH
(ENRICH/IIENT)
8.l [!]TEMPERATURE
I
SENSOR I
12
@
13 14 15 16 17 18 19
l20
48
~
21 22 23 24
l®iil
E4 01 G6
WIRING
COLOR CODE
1.0
RIBK 8K -BLACK
8R -BROWN
f
1 T7a/6 CL -CLEAR
R -RED
Y - YEU OW
0.5 G -GREEN
w LT G -
BL
liGHT GREEN
-BLUE
I V - VIOLET
45 GY -GRA Y
W - WHITE
0.5 w OR -ORANGE
1.0 BKIW
1.0 2.5 1.0 1;0 1.0 1.0 1.0 0.5 1.5 1.0
w w w w w w W BK BRIR BR
I I I I I I
55 12 26 J7 28 29 32
0.5 1.0
BK R INJ, /NJ, INJ, INJ,
CYL CYL CYL CYL
~. ~ ~ ~
FUEL
PUMP
® ®
25 26 27 28 29 30 31 32 33 34
197-2412 1
C2 Cll
0.5 0.5 0.5
BL BL BUG
~
T
0.5
w WIRING
COLOR CODE
I
45
IlK - BLACK
IIR - llROWN
Cl. -CLEAR
R -RED
IJU STABILIZER Y - YELLOW
t/50 CONTROL UNIT G ~GREEN
A1: 14/15 t 5/LH t 5/31 ;13/T ;8/LS i4/ST2 ill/STl ;2/K ;17/1
V
GY
W
OR
-
-
VIOI.Er
GRAY
-WHITE
-ORANGE
0.5 0.5 0.5 1.0 1.0 0.5 0.5 0.5 0.5 0.5
BK W W BR W RIY W Y WIG w
I I I I I
53 52 48 46 58
T.D.C. SENSOR
r--:. ;_ •1
- - ---- -
32 21 20 Tic
0.5
T1e
,
(
~-- -r--
\
'
w y BK y
~OXS
&:j [tj I
57
CAT
I
l
POWfR STEEIIINO IOU SPEED ELAPSED
PRESSURE SwrrcH STABILIZER YALYE 11/I.EAGE
COUiirER
0.5
BR
T3 T3 T3
35 36 37 38 39 40 41 42 43 44 45
I®
46
197-24131
~
1
'0.5
BK
0.5
R
T7at7 Tiib/1
G5 -TA~R
Jl14 - ENGINE OIL PRESS CNTRL I/NIT
IC2 -ALTERNAToR WARNING LITE
K3 -ENGINE' OIL PRESS WARN UTE
IC21 - OXS ELAPSED 11/LE /NO
Y:l - DIGITAL CLOCK
T2x T2x
0.5 0.5
BR BR
SJ_
WIRING
COLOR CODE
ENGINE OIL BK -BLACK
PRESSURE SWITCH
(0.3 BAR) BR -BROWN
CL -CLEAR
R -RED
Otl. y - YELLOW
PRESSURE
SWITCH G -GREEN
(1.8 LT. G- LIGHT GREEN
BAR) n4/3 BL -BLUE
1
0.5 1.5
v
GY
w
-
-
VIOLET
GRAY
-WHITE
BR BR OR -ORANGE
@ @ @)
47 48 49 50 51 52 53 54 .5 5 56 57
197-24141
'0.5
GY/BL
T7a/3 T7a/2
G1 -FUEl. GAUGE
~
G3 -COOLANT TEMPERATURE GAUGE
J6 - VOt.TAGE STABIUZE,R
Kt - HEADUTE HI-BEAM WAIWNG UTE
K5 - TURN SIGNAL I#DICATOR UTE
K28- COOLANT OVERifEAT WARNING UTE
U - Cl.OCK UTE
1.10 -INSTRUMENT PANEl. I."E
0.5
BR
~[fJ rn~
WIRING
COLOR CODE
r-
SEND .9 GAUGE
BK -BLACK UNIT SEND
BR -BROWN
CL -CLEAR
J31
R - RED
y - YELLOW
G - GREEN
LT. G - LIGHT GREEN
BL -BLUE
v - VIOLET 0.5 1.5 1.5 1.0
GY -GRAY BR BR BR BR
I~R -WHITE
-ORANGE
c& rrL I@ I(i~')
58 59 60 61 62 63 64 65 66 57 68 69 70 71
197-24151
GY/BL
rjr.rjr.
0.5
'0.5
GY/BL
TO
RADIO
CONN
TO
0.5
A
RADIO
CONN
0.5
A
I T2d
0.5
A
30
MAP INTERIOR
READ LITE,
LT. REAR
RF
31 T
0.5
TO RADIO BR 0.5 0.5 0.5 0.5
0,5 CONNEC'OON 0.5
BA i T2d
BA BA!W BR!W BR!W BR
T4
~ ~
0,5 0,5
BR BA
oooOOM~
WIRING
DOOR COLOR CODE
LTR · UGHTER CONTACT
UTE SWITCH, BK - BLACK
RIGHT BR - BROWN
FRONT
31 CL - C LEAR
R - RED
- YELLOW
1.5 G - GREEN
BR LTG - LIGHT GREEN
BL - BLUE
- VIOLET
GY - G RAY
w - WHI TE
OR - ORANGE
'20)
~~ @ rio!
'-~
~q)
72 73 74 75 76 77 78 79 80 81 82 83
197-2416 1
WIRING
10 9 COLOR CODE T2i
BK -BlACK
BR -BROWN
CL -CLEAR
R -RED
y -YELLOW
G -GREEN
LT G - LIGHT GREEN
BL -BLUE
v - VIOLET
GY -GRAY
UT£SWTTCH 158b
0.5
GY/BL
I 0.5
S5orflm
10Alf-J
LICENSE
P!ATE
l,fTE £ GY/G
0.5
BR
0.5
BR
f"
@I I I I
0.5 0.5 0.5 0.5 0.5
GY/BL GY/BL GY/BL GY/BL GY/BL
~ Ju ~ Jg
84 85 86 87 88 89 90 91 92 93
'94 95 96
'197--2-4-17'1
1.5 1.5 0.5 0.5 2.5 2.5 0.5 0.5 1.5 1.5
w Y GY/BK GY/BK y w GY/R GY/R Y/BK W/BK
1T
1.0
RIY
2.5
WIBK
5a rr,~~~=*.~~---1----~~~--------------------~-----------
~
~ TURN
IGNAL
WTTCH
I
I
I
1.0
BKIW/G
~
r r
1.0
BKIG
1.0
BKIW
T711 1 Tm
' EMERGENCY
FLASHER
15 49 30
~
~49o ~ ~l WARNING
UTE
EMERGENCY
FLASHER SWTTCH
WIRING
r--158b f'
0.5 0.5 0.5
COLOR CODE GY/BL GY/BL BR
BK -BLACK
BR - BROWN
CL - CLEAR
R -REV Bl BL Bl Bl
y TURN
- YELLOW TURN TURN TURN
(9W.- -fW. C) f~ Q9LT,
G -GREEN S/G
LT. G- LIGHT GREEN
LR LF RR~ RF
BL -BLUE
v
GY
w
OR
-
-
-
-
VIOLET
GRAY
WHITE
ORANGE
I
1.0
I
1.0
BR BR
~ 94
u u
v
w
® @) @
110 111 112 113 114 115 116 117 118 119 120 121
197-24191
:::---1 rl
C3 IC1 JE16 016 C20 l1 L4 L2 IB25,C15 C13 L3
BACK-UP
LITE
SWITCH
'i'
1.0
BKIBL
T1b
HORN
1[:1}tfJI
BRK
LT
'--+------}-J sw
1.0
BKIBL
BRAKE
LITE,
LEFT
LBCK-lJP
LT,
R
RF
BACK-UP
LITE,
LEFT
r -.
WIRING
COLOR CODE
BK - BLACK
BR - BROWN
CL - CL EAR
R - RED
1.0 Y - YELLOW
BR G - GREEN
LT G - LIGHT GREEN
BL - BLUE
u--------------------+---------~ V - VIOLE T
GY - GRAY
W -WHI TE
OR - ORANGE
a. '
12
I~ ~Su
Lf3 518
lOA 20A
0.5
.
0.5
07 G2 G5 B16
1.5
A23
BK BK BK!W
1.5
BK
PARKING BRAKE
BR~~>'E FLUID
WARN;,"JG LEVEL
SAFETY BELT
SWITCH. RIGHT
LITE
SWITCH I WARNIIiiG
CONTACT
0 .5 1.5
BR BK
77
®
130 131 132 133 134 135 136 137 138 139
j97-2421 l
1 r.l I
r---
~ sis , -4/3011
513 St H(c :>-----:\ IRADCOOLFAN
RLY (ZND STG}
~20A ~30A ~6'86 8/87 ' 7
J
A22 C7 H6 H3 'Hl H4 H2 H5
'
E9 -FRESH AIR FAN SWITCH
EIOO- WARM AIR BLOWER SWITCH
L16 - FRESH AIR CONTROL LEVER LITE 1.5
L50 -HEATER FAN SWITCH ILLUMINATION
LITE BKIY
FRESH
AIR
CONTROL
LEVER
~
0 .5
GY/Bl
FRESH
AIR
FAN
SWITCH
WJ=il
RADIATOR
COOLING FAN
HTR
FAN
SW
ILLUM
LT
~
0.5
GY/Bl
WARM
AIR
BLOWER
SWITCH
'-±---+-:::---+-::---+-:--'
I T
TH
f
LITE
'12
.--'j~1~~ O.!j 1.5 1.5 1.0
0.5 1.5 1.5 1.5 2.5 WIRING BR Y Y/BK W
BR Y Y/BK w BK/R COLOR CODE
I T4a T4a T4a
8K - lltACI(
!IR -BROWN
CL -CLEAR
R -REV
FRSH Y - YELLOW
AIR G -GREEN
BLWR LT. G- LIGHT GREEN
SERIES Ill. - BI.UE
RESIS V - VIOI..ET
GY - GRAY
W -WHITE
1.5 OR -ORANGE
y
7 I T3b I T3b
2
RADIATOR WARM AIR
COOLING FAN BLOWER
t'
'T3b
140 141 142 143 144 145 146 147 148 149
l,-97--2-4-2-,
21
WINDSHIEL().MPER
INTERMITTENT
SWITCH
WIRING
Cot.ORCOOE
53 53b 53a 53e
-;s I:~IELD
+
(10) (@)
150 151 152 153 154 155 156
197- 24231
y
z
T
D5
l
'-'GlO E7
1.0
2153
E2
1.0
lE84GI.
1.0 1.5
r:· [ l
BKIW G/BK BK!GY BKIY
WIRING
COLOR CODE
T3d BK -BLACK
BR - BROWN
CL -CLEAR
R - RED
Y - YELLOW
G -GREEN
L T_ G- LIGHT GREEN
BL - BLUE
V - VIOLET
GY - GRAY
W -WHITE
OR - ORANGE
SHIELD 53 53a
~ER
r*l ~ REAR WINDOW
I
L¥1 REAR WINDOW
~WIPER MOTOR
r1
WASHER PUIIP
I
1.0 1.0
BA BR
I@
157 158
I®
159 160 161
Water-cooled-Dlgifant 1986
Main wiring diagram
Reat window wiper
from VIN G 055 690
97.1o1
Electrical System - Wiring, Waterboxer 97
Separate fuses above fuse panel
Power windows ....... .. ........ . ........... 30
AIC . ......... ..... ... ... ... . . ... ........... 30
Fuse/Relay Panel
IJ - coolant level control unit
II - rad . cool. fan relay, 2nd stage
II - load reduction relay
IDJ - intermit!. wash/wiper relay
II - rear window wash/wiper realy
II - emerg. flash/turn sig . relay
IIJ- not used
Fuse arrangement
IIJ -fuse, terminal 58b
according to numbers on fuse panel as seen from
left to right:
Amp.
Radiator fan . . . . . . . . . . . . . . . . . . . . . . . . 30
2 Stop lights . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Cigarette lighter, radio, clock, interior lights,
central locking system . . . . . . . . . . . . . . . . . 10
4 Emergency flasher system . . . . . . . . . . . . . . 15
5 not connected
6 Vacant
7 Tail, parking and side marker lights, left 10 197·13921
8 Tail, parking and side marker lights, right . . . 10
9 High beam right, high beam indicator light . . 10
10 High beam left . . . . . . . . . . . . . . . . . . . . . . . 10 Connections and plugs on fuse/relay panel
11 Wind. wipers and washer . . . . . . . . . . . . . . . 15 A - multi-point connector (blue) for instrument
12 Heater fan, rear wiper, cruise control, A/C, panel wiring harness
outside rear view mirror adjustment . . . . . . . 20 B - multi-point connector (red) for instrument
13 Fresh air fan . . . . . . . . . . . . . . . . . . . . . . . . . 15 panel wiring harness
14 Rear window defogger . . . . . . . . . . . . . . . . . 20
C - multi-point connector (yellow) for front wiring
15 Back-up lights, shift console light
harness
(Auto. Transmission) . . . . . . . . . . . . . . . . . . 10
D - multi-point connector (white) for windshield
16 Horn (single tone) ..... ..... .......... 15
wiper and main wiring harness
17 Windshield wiper motor . . . . . . . . . . . . . . . . 10
E - multi-point connector (black) for main wiring
18 Dual horn, coolant level and temp.
warning light . . . . . . . . . . . . . . . . . . . . . . . . . 10 harness
19 Turn signals , brake warning light . . . . . . . . . 10 G - single connector
20 License plate lights . . . . . . . . . . . . . . . . . . . 10 H - multi-point connector (brown) to connector for
21 Low beam left . . . . . . . . . . . . . . . . . . . . . . . . 10 rad . cool. fan relay, 2nd stage
22 Low beam right . . . . . . . . . . . . . . . . . . . . . . 10 K - multi-point connector (colorless) to radiator
coolant low-level control unit
L - multi-point connector (gray) for horns
M - open position
N - single connector
P - single connector (terminal 30)
R - open position
AIC compressor ovemeat fuse 151 Instrument panel t~e dimmer sw~ch 95 T2c -double, under inst. panel, left
Air flow sensor potentiometer 22-24 Interior lite, front 77,78 T2d - double, under upper right 'A' pillar
Alternator 5 T2e - double, in decklid near washer motor
License plate lite 96,97
Alternator warning l~e 51 T2f -double, under upper right 'C' pillar cover
L~e switch 85-95
T2g -double, under inst. panel
Back-up l~e ~h 128 Load reduction relay 86·88 T2i -double, in wire distrib., eng compart.
Back-up l~e. lelt 128 T2k ~ 9oo!J~. eng. compart., left
Back-up l~e. right 129 Make-up mirror lite 76
Map/reading l~e. right front 75 T2m- double, in relay plate, eng. compart.
Battery T2o - double, near seat beij sw~ch
Brake and parlting brake indicator l~e 137 OXS elapsed mileage indicator 52 T2p - doullle, near hom
Brake fluid level warning contact 138 Oxygen sensor 25,26 T2x - double, eng. compart., middle
Brake l~e sw~ch 125,126
Brake l~e. lelt 127 Par1<ing brake warning l~e switch 137 T3 - three-point, near alternator
Brake l~e. right 126 Par1<ing l~e. left 101 T3a -three-point, under inst. panel, right
Par1<ing lite, right 107 T3b - three-point, under inst. panel, lelt
CAT elapsed rrileage counter 45,46 Power steering pressure switch 36,37 T3d - three-point, behind upper front grille
Cigarette light81' 72 T3x - three point, under inst. panel
Cigarette lighter l~e 73 Radiator cooling ian 145
Clock l~e 61 Radiator cooling fan relay (2nd stage) 147-150 T71 -seven point, in wire distrib., eng. compart.
Coolant low level control un~ 68,69 Radiator cooling fan thermoswitch 145, 146 T7al- seven point, in wire distrib., eng. compart.
Coolant low level warning sw~ch 68 Reading l~e. behind driver's seat 80,81
Coolant overheat warning l~e 66 Reading l~e. left rear 82,83 T141- fourteen point, on inst. cluster
Coolant temperature gauge 65 Rear window defogger indicator lite 140
Coolant temperature sending un~ 70 Rear window defogger switch 139-141 Ground connections
Rear window defogger swrtch lrte 139
Digifant control un~ 16-27 Rear window heater element 141 G) - battery to body
Digijet control un~ relay 32-34 Rear window washer pump 160
Digital clock 53 Rear window wiper motor 162,163
G) - transmission to body
Door contact sw~ch. lelt front n,78
Door contact switch, right front 81
Rear window wiper/Washer relay 161,162 @- in eng. compart., left
Safety beij sw~ch, left 134
Emergency Hasher relay 11 4.1 15 Seat beij warning l~e 136
@- on engine block
Emergency flasher switch 11'1-1 20
Emergency flasher warning lrte 120
Seat beij warning relay 133-136 @- ground cable, above steering box
Side mar1<er t~es, rear 104,105
Engine oil pressure control un~
Engine oil pressure switch (0.3 bar)
55;!56
48
Spar1< plug connectors 13-15 @- near Digifant control unit
Spar1< plugs 13-15
Engine oil pressure swrtch (0.9 bar) 47 Starter 3.4 @- under relay panel
Engine oil pressure warning l~e 57
T.D.C. sensor 43,44 @- in rear decklid, left
Fresh air blower series resistance 144 Tachometer 54
Fresh air control lever l~e 142 Taill~e. tell 102 @- in rear decklid, right
Fresh air fan 143,144 Tail l~e. right 106
Fresh air fan switch 142-144 Temperature sensor II 21
@- near rear washer bottle bracket
Fuel gauge 64
Fuel gauge sending un~ 71
Terminal 58b fuse 95 @- near rear wiper motor
Throttle valve switch (enrichment) 20
Fuel pump 31 Tum signal indicator lite 62 @- near left rear decklid hinge
Fuel pump relay 30,31 Tum signal lite, left front 122
Fusa 12 Tum signall~e. lelt rear 121 @- in inst. panel wiring harness
Turn signal lite, right front 124
Hall generator 17-19
Tum signall~e. right rear 123
@- in Digifant wiring harness
Headl~e dimmerlftasher switch 103,104
Tum signal switch 116,117
Heedl~e high beam warning l~e 63
Plus ( +) connections
Headl~e. lelt 98,100 Voltage regulator 5
Headl~e. right 108,110
151,152
Voltege stabilizer 64 @- (term. 30) in wire distrib., eng. compart.
Heater blower series resistance
Heater fan sw~ch illumination lrte 149 Warm air blower 150-152 @- in Digifant wiring harness
Hea!ilg element (crankcase ventilation) 12 Warm air blower sw~ch 149-152
High-beam headl~e. lelt 99 Washer/Wiper intermittent relay 158-158 @- in Digifant wiring harness
High-beam headl~e. right 109 Windshield washer pump 159
Hom button 130 Windshield wiper motor 153,154 @- (term. 586) in inst. panel wiring
Windshield-wiper intermittent sw~ch 155-158 harness
Horns 132
138
1.5
R
1.5
R
~)
2.5 87 49 13
6.0
A A
D811. D+
70.0
WIRING
COLOR CODE
BAITERY ALT
8K -BLACK
BR - BROWN
j CL
R
y
-
-RED
-
CLEAR
YELLOW
25.0 25.0 G - GREEN
LT G - LIGHT GREEN
BL - BLUE
v - VIOLET
GY -GRAY
w -WHITE
OR - ORANGE
CD (2j'1
2 3 4 5 6 7 8 9 10 11
197-26241
4 2
111
7 8 6 3
BR -BROWN
CL - CLEAR
R - RED
Y - YELLOW
G - GREEN
LT G - LIGHT GREEN
lig~ T7a/5 BL
V
-
-
BLUE
VIOLE T
_ _, . 0.5 GY -GRA Y
BK W -WHITE
Ofl - ORAN(K DIGIFANT CONTROL
15 UNIT
~.~--~~--~·t-----l~-0-.7~ w I~
I I
II
10 11
2111 1117
IGNmON
DISTRIBUTOR
1 31+ 1 210 l11- \ o, ~ f'lJ'
~~ L.....±---±-±----,1:-'- - ------4~) © I 1 . ~ ~.
1
HALL GENERATOR AIR FLOW SENSOR
POTENTIOIIETER
1.0
BK
HTG
ELMNT rrtTI
I SPK PLG CNCTRS
(CRKCASE
VENT} ' .,_.-+----+--+-'SPARK PLUGS
I
1.0
BR
0.5
R/Y
0.75
w
I
12 13 14 15 16 17 18 19
l20
~
48
21 22 23 24
197·26251
E4 A4
WIRING
COLOR CODE
1.0
R!BK BK - BLACK
BR - BRO W!\'
T
1 T7a/6 CL - CLEAR
R -RED
y - YELLOW
0.5 G - GREEN
w L T G - - LIGHT GREEN
BL - BLUE
I v - VIOLET
[osw-J~
45 GY - · GRAY
w - WHITE
0.5 w OR - ORANGE
~1 DIGIFANT CONTROL
UNrr 3 ~~
F ® :1 ~. ------
~
1 12
~
.14
r
2.5 R/W
I
1 0.5 BKIW .w
2.5
30
@)
2.5 1.0 0.5 1.0 1.0 2.5 0.75 0.75 0.75 0.75 1.0 0.5 0.5 0.5
BR BR w w w w w w w w BK BR/R BR
I I I I I I I I
42 55 12 26 27 28 29 32
~
•
1.0
BR
1.0
BRIG
(12)
25 26 27 28 29 30 31 32 33 34
j97-2626j
C2 Cll
WIRING 0 .5 0.5 0.5
COLOR CODE
BL BL BUG
BK
BR
-BLACK
-BROWN ~
CL -CLEAR
R -REO
0.5 Y - YELLOW
w G -
LT G -
GREEN
LIGHT GREEN
I
45
BL
V
-
-
BLUE
VIOLET
'f!/;f,f,{.,_~'
GY - GRAY
W -WHITE
Lso OR -ORANGE
©
J14/15 .15/LH .5/31 .13/T ~8/LS ~4/ST2~11/ST1 ~2/K 117/1
0.5 0.5 0.5 0.5 0.75 0.5 0.5 0.5 0.5 0.5
BK W W BR W R/Y W Y WIG w
I I I I I
53 52 48 46 58
21 20 T1k T1n
,---r-
(
----- -
')
~
PWR
STRG
PRESS
SW
~ , .
SPEED
STABILIZER
VALVE
0.5
w
I
57
y BK y 1/61 4/0XS
CAT
ELAPSED
11/LEAOE
COUNTER
l T3 T3 T3
15/31
0.5
BR
I@
35 36 37 38 39 40 41 42 43 44 45 46
J97-2627 j
ID
7 2 5
I ~ J II
~
E15 ID21 Bl B24 B19 A3 DB A27 D3 B18 )B15 B21 K3 B2 ElO
~
cr
0 .5
~
0 .5
BK R
G5 - TACHOftiETER
Jt14 - ENGINE OIL PRESSURE CONTROL UNIT
K2 -ALTERNATOR WARNING LITE
K3 -ENGINE OIL PRESSURE WARNING LITE
K21 - OXS ELAPSED ftiiLEAGE INDICATOR
Y2 -DIGITAL CLOCK
®
47 48 49 50 51 52 53 54 55 56 57
197-26281
30----------------------------------------------------------------------------------30
~
~ 1~&31 !j'"
15 15
D
2
CLNT LOW LVL
CNTRL UN"
;,
7 3/85 4/86
49o
56o
T
0.5
GY!BL
T7a/3 T7a/2
G1 - FUEL GAUGE
G3 - COOI.ANr TEMPERATURE GAUGE
J6 - vot.TAGE STABILIZER
Kl - HEADLITE HIGH BEAM WARNING UTE
KS - TURN SIGNAL INDICATOR UTE G COOI.ANr LOW
K2B- COOLANT OVERHEAT WARNING WE LEVEL WARNING
LB - CLOCK UTE SWITCH
LIO -INSTRUMENT PANEL WE
311
* Note 0.5
BR
Fuel gauge sending unit on Vanagon Syncro
grounds in engine compartment on left side
m-
WIRING
COLOR CODE
BK
BR
-
-
BLACK
BROWN T7a/4
CQXm[lJ
TEMP
SEND
9. GAUGE
SEND
UN" UNIT
r
CL - CLEAR
R -REO 0.5 BR »31
- YELLOW
0.5 BR
~
G - - GREEN
LT G- LIGHT GREEN
Bl - BLUE
- VIOLEr
GY - GRA Y
0.5 1.5 1.5 1.0
w -- WHtr£:
BR BR BR BR
OR - ORANGE
~ 1(@ ~ 1* 29
58 59 60 61 62 63 64 65 66 67 68 69 70 71
@ifuj]
1.5
R
I~Tat6~Tat7
0.5
GY/BL
ro-a
' 0.5
GYiBL
I roa
RADIO
CONN
0.5
A
0.5
R
RADIO
CONN
0.5
R
0.5
R
30
MAKE
UP
111/RR
LT
T
0.5
TORAD/0 BR
0. 5 CONNECTION 0.5 0.5 Q. 5 0.5 0.5
BR Tats T2d BR BR!W BA!W BRIW BR
WIRING
COLOR CODE
BK -BLACK
BR -BROWN
CL -CLEAR
R -RED
y - YELLOW
G -GREEN
~
L T_ G - LIGHT GREEN
BL -BLUE
V - VIOLET
lO
0.5 0.5 0.5
BR BR BR/W GY
W
-GRAY
-WHITE
+ 58b
OR - ORANGE
DR
CIGARETTE CIGARETTE CONTCT
UGHTER LIGHTER
LITE sw,
RF
31
1.5
BR
@@
72 73 74 75 76 77 78 79 80 81 82 83
30--~--------------~--------------------------------------------------------30
15 ~
X X
31-~------~r-------r-----r-~==============~====~~~~~~~~~~~~~3~8L
58R 58
1/85 2/30
u[f------{ l:~o
4/B6 3/87
~57 lOA
520~
lOA~
==~====~====~==~i===========~==~=================i=~
49a
56a
9 [!]~
2.5 2.5
BKIY WiBK IT2i
0.5
INSTR GY/G
I~
·~ ~ 56 ~
~
58L 58R - .,
J
58
PNL
LT
DIMR
sw
fl
.·
~-T
-n -I! -IT
LITE SWTTCH 158b
0.5
GYiBL
WIRING
COLOR CODE
BK
BR
CL
-
-
BLACK
-BROWN
CLEAR Tf101588-
Im_ m
0.5
GYiG
•f ~':' f
R -RED
-- YELLOW
lOALt.J
G
V
--- GREEN
L T G- LIGHT GREEN
BL -
-
BLUE
VIOLET
olnf5o.5
BR BR
~T2i
GY - GRAY
W - WN/Tf @)
OR -ORANGE
0.5 0.5 0.5 0.5 0.5 0.5
GYIBL GY/BL GYIBL GY/BL GYiBL BR
~ ~ ~ ~ ~ r!J
84 85 86 87 88 89 90 91 92 93 94 95 96 97
197-2631 I
~k58
31
49a
~ 510
lOA
.
~521
lOA
"7,>
~522
lOA
1
~59lOA
58
49o
56a
;_ r--
C17 C5 C4 E9 M2 A21 B22 C14 C6 C16 B13
r18
WIRING
COLOR CODE
SK -BLACK
Ti
1.0
RIY
2 .5
W/BK
BR - BROWN
CL - CLEAR
R - RED
- YELL O W
G - GREEN
LT G - LIGHT GREEN
BL - BLUE
V - VIOLET I T7/5 T7t6
GY - GRAY
W -WHI TE
OR - ORANGE
~ii£R
~SW
56o 56_b___ .
..
~519
lOA
54
15
~ 1tvE+r
EMER
FLSH
RLY
®If) -
3/49o 2
49o
I I I I I
A13 A18 828 AlO All JA7 025 JA20 011 IC19 Ell
r6 r8
1.5 1.0 1.5 1.0 1.0 1.0 1.0 1.0 1.0 1.0
BKIBL W W/R BKIW/G BK!G BK!W BK!W BK!W BK!G BK!G
49o
jll TURN
SIGNAL
S'MTCH
1.0
IR
1.0
f
1.0
BKIW/G BKIG BK!W
Tm Tm
15 49 30
~
ljllll'49o
...
-
,..R ~ L
EIIERG
FLSH
WRNG
LT
~)
II
EMERGENCY ,....,58b ( 31
FLASHER SWITCH
r
COLOR CODE
BK
BR
-
-
BLACK
BROWN
.
CL - CLEAR BL BL B BL
- RED
R
y
TURN TURN TVFIN
~ c~ ~ ~ f'f. 9~
- YEL LOW
G -GREEN
~
c~ - -
~
LT G - LIGHT GREEN LR LF RF
BL
v
GY
-
-
BLUE
VIOLET
-GRAY
I
1.0
I
1.0
w - WHITE
- ORANGE
BR BR
OR
Jj)~ 95
u u
v
w
@) ® @
111 112 113 114 115 116 117 - 118 119 120 121 122 123 124
!97-26331
~5215A ~515
lOA
lf:l ~516
15A
1 3
I I I r 1
C3 016 C20 L1 L4 L2 C13 L3
IC1 r16 r25 IC15
T29 T29 Tm
dl'tfJK·UP
Q.JswrrcH
'i'
1.0
BKIBL
T1b
1.0
RIY
1.0
BKIBL
4 1.0
BR
T2p
1.0
BKIR
154 Rf RF
BRK BCIC-UP BCK·UP WIRING
LT, LT, LT, COLORCOOE
R L R HORN
BUTToN BK -BUICK
BR -BROWN
CL -CLEAR
1.0 R -RED
y
BA - YELLOW
G -GREEN
LT. G - LIGHT GREEN
BL - BLUE
u
v - VIOLET
GY -GRAY
w - WHITE
OR - ORANGE
@
125 126 127 128 129 130 131 132
J97-2634J
30----------------------------------------------------------------------------30
:~ II 2
lf.l
1
I~518
l
~56
I
~514
~
3 lOA 15A 20A
u4
J ), ),
~25 ~GS
820
0.5
.
0.5
07 G2 C22 816
1.5
A23
BK BK BKIW
WIRING
COLOR CODE
BK - BLACK
BR -BROWN
CL -CLEAR
R
Y
-RED
- YELLOW
OJ] BRK
G - GREEN 0.5
& REAR
PRK WINDOW
LT G - LIGHT GREEN GY/BK BRK DEFOGGER
SEAT BELT /NO
~'i£
BL - BLUE
V - VIOLET WARNING UTE 6/15 LT
GY - GRAY
W -WHITE
j21~~
OR - ORANGE
1.5
WIG
IT2c
1.5
BA
I - I oo ~~~
~ 11/G l "-
4/-31_ +_ _ __ .
0.5 0.5 0.5 0.5
GY GY GY/A BA
~Tle T3x T3x T3x
0.5 0.5
GY GY/G
SFTY
BLT PARKING RE
sw. BRAKE MHO
L WARNING HTR
UTE ELMNT
SWITCH
1.5
BK
7
1.5
BK
@ @ @ @ ® @J
133 134 135 136 137 138 139 140 141
197-26351
~ I ~
~513
I 5/85 14/30 I L 2RAO
COOL I
20A ~S1
10 .It tJ.----~ IFAN
RLY
30A (2ND
6/86 8/87 7 STG)
,___
I
A22 C7 H6 H3 JH1 H4 H2 H5
BK -BLACK
BR -BROWN
CL - CLEAR
R - RED
v - VEL LOW
G - GREEN
LT G- LIGHT GREEN
BL - BLUE
v - VIOLET
GV - GRAY
w -WHITE
OR -ORANGE
T3d T3d
FRSH
AIR
FAN
.!l RADIATOR
COOLING FAN
2
!"..,.
-
WARM
1.5
BR-.
'j AIC
~
HTR
2.5 AIR COMPRSR BLWR
BR BLWR 1.5 OVERHT SERIES
BR FUSE RESJS
T3d
~
I
@ @ ®
142 143 144 145 146 147 148 149 150 151 152
197-26361
~Sn
15A
~517
lOA
WA~PR
INTERIIT
RLY
IV-~ ® lmJ
2/53M rVJ 5/T
I I I I I I
~020 012 109 02 1017 IA6 89 IA5 A2 A12
JAl:
A19 JC9
1.5 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 0 .5 1.0 0.5 0.5
BR BR G/BK GIY GY/BK G G GY/BK G/Y G/BK BRIBK G/W G/R G/R
53b 53 J L T
~,.c---:J
1.. -.,.. -
i53a
-or '~T
53e
-~~
WINOSHIE~wrPER
+ {f roo· I
/NT'ERIIITTENT
SwrTCH
WIRING
COlORCOOE
53 53b 53a 53e
@ @)
153 154 155 156 157 158 159
197-26371
WIRING
COLOR CODE
flK -BLACK
BR -BROWN
CL -CLEAR
R -RED
· T3o T3a T3a y - YELLOW
G -GREEN
LT. G - LIGHT GREEN
BL - BLUE
v - VIOLET
GY -GRAY
T2f w - WHITE
T2f OR -ORANGE
1 T2e T2e
53 53a
~REAR WINDOW ~REAR WIVDOW
L¥J WASHER PUMP ~WIPER MOTOR
I r,
1.0
BR
I@
160 161 162 163 164
Fuse/relay panel
IJ- coolant level control unit
IJ rad. cool. fan relay, 2nd stage
II- load reduction relay
IDJ -'- intermittent wash/wiper relay
m- rear window wash/Wiper relay
m- emerg. flash/turn sig. relay
111J-fuse S50
Fuse arrangement
according to numbers on fuse panel as seen from
left to right:
Amp.
1 Radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2 Stop lights ............................... 15
3 Cigarette lighter, radio, clock, interior lights, 197-13921
central locking system ..................... 10
4 Emergency flasher system ................. 15 Connections and plugs on fuse/relay panel
5 Not used A - multi-point connector (blue) for instrument panel
6 Not used wiring harness
7 Tail, parking and side marker lights, left ...... 10 B -multi-point connector (red) for instrument panel
8 Tail, parking and side marker lights, right .... 10 wiring harness
9 High beam right, high beam indicator light ... 10 C - multi-point connector (yellow) for front wiring
10 High beam left ............................ 10 harness
11 Windshield, wipers and washer ............. 15 D mutli-point connector (white) for windshield
12 Heated seats, outside rear view mirror wiper and main wiring harness
adjustment ............................... 15 E - multi-point connector (black) for main wiring
13 Fresh air fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 harness
14 Rear window defogger .. . . .. . . . . .. . . . .. .. . 20 G - single connector
15 Back-up lights, shift console light (auto. H -multi-point connector (brown) to connector for
transmission) ............................. 10 rad. cooL fan relay, 2nd stage
16 Horn (single tone) ......................... 1b K - multi-point connector (colorless) to radiator
17 Windshield wipers ......................... 10 coolant low-level control unit
18 Seat belt warning relay, brake and L -multi-point connector (gray) for horns
park brake indicator ....................... 10
M - open position
19 Turn signals, brake warning light ....... : . ... 10 N - single connector
20 License plate lights ........................ 10 P - single connector (terminal 30)
21 Low beam left . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
R - open position
22 Low beam right ....................... , ... 10
r-~~~==~~============;===~==~1
p p p p p p
1.5
R
10.0 2.5 90
R R
WIRING
COlOR CODE
81< -BLACK
BR - BROWN
CL - CLEAR
25.0
i
25.0 VOLTAGE
R
Y
G
LT G -
- RED
-
-
YELLOW
GREEN
LIGHT GREEN
REGULATOR
BL - BLUE
V - VIOLET
GY - GRA Y
W - WHITE
OR - ORANGE
11
....
,9-7-2_9_1.....,,
31;±;±:;;-;;;;;;;;t;t;±~~~~~~~~~~E~
311
61 61
0 0
4 2 ~
7 8
R
6 3
~55
lOA
b----~------~====t-~---~~====
023 015 E12 C1 8 86 013 N 019 026
I
1.5 0.5 1.0 0.5 0.5
"If f"l
BK G GYIW BK G
EC5-MAL
~Tlo
IND
0.5
!r1n
"'"
"'
0.5
BR
~ 31
LT
AND
SWTCH
T
0.5
BKIW
~ lig~]
.I
T7a/5
~
L
o
GYIW
_ _, . 0.5
11
BK T1m
DIGIFANT CONTROL
;115 1 20 UNff
l
IGNffiON
COIL
4
fl ~' ~ f• ® f• f" f" A'o ~
I I~ .e--------.------..-- -t I I I
1.0 1.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 1.0 1.0 0.5
BK G G GY/G G BRIW @ BLJW BUR BUBK GY GY R/BL RIBL
--~
tHROTTLE VALVE AIRFLOW
SPAR/( PLUG SWITCH SENSOR
CONNECTORS (ENRICHMENT} POTENTIOMETER
I ....... +Ij
~~ ~ ~~ ~~
SPARK
WIRING
COLOR CODE
PLUGS 1 - - - - - - - - l
en istl
qJ YJ ENG. COOLANT
TEMP. SENSOR
ELEIIENT
/CRANKCASE
I
VENTILATION)
BK
BR
Ct
R
y
-
-
BLAC!<
-BROWN
CL EAR
RED
l .,
- YE"LLOW
1.0 G - GREEN
BR LT G- LIGHT GREEN
BL
v
-
-
Bi..UE
VIOL E1
T0.5
GY -GRAY
BR
w
I®
- WH/Tf:
OR - ORANGE
12
12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
1r-
9-7-2_9_15--,l
E4
WIRING
1.0 COLOR CODE
A/BK
BK - BLACK
Tla/6 BR - BROWN 14
CL - CLEAR
R -REO
Y - YELLOW
0.5 G -GReEN
RIW L T. G - LIGHT GRE:EN
BL - BLU£
1u~ ~~
V - VI(}(H
1 T2m
GY - GRAY
W -WHITE
0.5 0.5 0.5
OR - ORANG£ RIY A A BK!W BK BK
11
DIGIFANT CONTROL
UNIT F<P~~P- ~
.,..
RELAY
'\...
.
1
6/85J
-~+----!-_,.' i ~j'
I~
J •I 0
~
' 2130
{8
.,
II
"'I5"/ls
OOU:ANT
®
rnr
1.5
BA BRIW W
1.0 0.5 1.0 1.0
AIY
1.5
w
1.0
RIW
. __ _ 1.5 BK!Y ----4---11-. .~ 1.5
I
1.0
A/W
I
1.0
A/W
-&-- - -.:-a.- - -•t1 '
1.0
RN-1
1.0
R/W
A/W
1.0 0 .5 0 .5
RIW R/W BA
0 .5
BA
OXYGEN
' ~~ SJ• Sjm ~N
'i' 'I
F<UEL
PUMP
-----tl.---•1-~la-----1 G2 I T2k
12 12,
27 28 29 30 31 32 33 34 35 36 37 38
l97-29t6 !
C2 Cll
L, IDC.E STAJ/LIZER
CONTROL UNIT
WIRING
COLOR CODE
BK
8R
Cl.
R
V
- IIUCH
-BROWN
-ClEAR
-RED
- YfllOW
1: G -GREEN
114/15 i15/LH i5/31 i13/T ~8/LS ~4/ST2 ill/ST1 i2/K *17/1 lT G- liGHT GREEN
BL - BWE
V - VIOlET
1.0 0.5 1.0 0.5 0.5 1.0 1.0 0.5 0.5 GY -GRAY
RJW W/Y BR GY RIBL W Y WIG G W - WHI7f
~ OR - ORANGE
~-- ~ ~
c~r=:=
BK
~a£ SPEED
STABILIZER
VALVE COUNTER
POWER
STEERING 15/31
PRESSUWE
SWJTCIJ. • 0.5
BR
18 T3 T3 T3
42 43 45 46 47 48
1-q
49
197-29171
I~ n311 6 4
D
7 2 5
El5
I
1021
-- -- -
~Bl 824 Bl9 A3 os--A27- ~1-B15 B21 K3
II
82 ElO
~
?
'L/8
0.5
BK
Tl4/ll
0.5
A
K21~, +A<
---;),1 0.3 1,8
,, ,
'·
K2
0 E:QY:
) 2
~G
•( s
It§ ID <D I ~~:
< KJ
Jn4 15 -
--
~~·
..!
G5 - TACHOMETER
J114 - ENGINE OIL PRESSURE CONTROL UNIT
K2 - ALTERNATOR WARNING LITE
11.3 - ENGINE OIL PRESSURE WARNING LITE
K21 - OXS ELAPSED MILEAGE INDICATOR
Y2 - DIGrrAL CLOCK
I T2x 1 T2 x
0.5 0.5
BR BR ENGINE
OIL
PRESSURE WIRING
SWITCH COLOR CODE
(0.3
. BAR)
ENGINE BR -- BROWN
OIL
I0.9BAR 0.3BAR Cl CL EAR
PRESSURE Ht. O
"
swrrcH
I - YELLOW
[J5~~---
(1.8 G li Rt.t. N
BAR) LT G UGHT G Rft. !IJ
I jTl4/3 !l:. ·· BLVE
j ___
VfOtE1
0.5
(;'( GHAY
BR R
w .. WH11 E
50 51 52 53 54 55 56 57 58 59 60
197-29181
~
A17 A28 B3 B7 K2 B17 Kl 029 E5
T
0.5
GY/BL
L"
La
T14!10
K5
T14/2
K1
T14/7 T14/6
1 T7a/3 I T7a/ 2
Gt - FUEL GAUGE
G3 - COOI..AifT TEIIPERATVRE GAUGE
J8 - W)C.TAGE STABILIZER
Kt - HEADUGHT HIGH BEAM 111ARMteG UTE
KS - TURN SIGNAL INDICATOR UTE
K2B - COOLANT OVERHEAT WARNING UTE
U - CLOCK LITE .
Lto -INSTRUIIENIPANEL LrrE
COOLANT _
TEMPERATURE
SENDING
WIRING UNrr CIGA
COLOR CODE LfGJj
BK - BLA CK
BR -BROWN
Ct.. - CLEAR
R -REO
0.5 BR
y - YELLOW
G
8L
v
GY
- GREEN
L T G- LIGHT GREEN
-BL UE
- VIOLET
-GRAY
0.5
BR
k:-1
1.5
BR
1.5
BR
1.0
BR
w -WHITE
61 62
OR -ORANGE
63 64 65 66 67
}ru
68 69
j __l2 -~--_.__129
70 71 72 73
/97-2919/
~53
~==1~B=ll====~rE=3====~==~~=====B=1~21~lS=A========~~==~~==========~~
1.5
A
T0.5
I
1. 0
Cf
0.5 1.5 05
n
GY/BL R
r1ra/6RADIO
0.5 CONN
T3 c
0.5
\iT"' T2d
RADIO
CONNECTION
~ 0.5
R
~pir·j f1 :/toW
GY/BL
31 31
05
RADIO ·
RADIO CONN CONNECnoN BR BR 0.5 0.5 0.5 0 .5 0.5
0.5 BRIW BRIW BR
s u T 8i8 I T2d BR BRIW
WT8/3
0.5 1.5
BUW BR
[ill] il.-
32; WIRING
,
T3c COLOR CODE
T
0.5 1.5 0.5 BK BL4.CK
BR BR GY BR - BROWN
+
58b CL cu:AR
R - R[O
'IJEL
iAUGE
~
CIGARETTE
LIGHTER
\]] DOOR
CONTACT
I
SW.,
RF
G
Y
LT G -
BL
--
-
YELLOW
GREEN
LIGHT GREEN
BL UE
~1 \ -- VJOtE _r
GY - - GRAY
1.5
BR
l CIGARETTE
UGHTER
OR
W -
-
WHITE
ORANGE
UGHT
74 75 76 77 78 79 80 81 82 83 84 85 86
197-292~
14
2i
0.5
GY/G
UOHTSWtTCH
WIRING
COLOR CODE
BK -BUICK
0.5
BR - BROWN
GY/G
CL
R
-
-
CLEAR
R£D
I
Y
G
8L
V
GY
-
-
LT. G -
-BLUE
-
-
YELLOW
GREEN
LIGHT GREEN
VIOLET
G!MY 0.5
f=f
olf1
5 _o.5
1
W - WHITE GY/BL BR BR
8 .___,--------,-------r~t
OR -ORANGE
IT2i
0.5 0.5 0.5 0.5 0.5
GYIBL GYIBL GYIBL GY/BL BR
~ ~
88 89 90 91
~
-~-·· -~
31
58
'
510
lOA
521
lOA
' ·..:-, 522 I 59
lOA, 10A
I ··
I I
r---
l
C17 C5 ca E9 M2 A21 B22 E18 C14 C6 C16 B13
1.5 1.5 0.5 0.5 2.5 2.5 0.5 0.5 1.5 1.5
w Y GY/BK GY/BK y w GY/R GY/R Y/BK W/BK
HEADLIGHT---.,
DIMMER/FLASHER
SWTTCH
WIRING
COLORCOOE
BK -BLACK
iT
1.0
AN
2.5
W/BK
BR -BROWN
CL -CLEAR
R - RECi
Y - YELLOW
G -GREEN
LT G - LIGHT GREEN
BL -BLUE
V - VIOLET I T7t5
GY -GRAY
W -WHITE
OR -ORANGE
1.5 0.5
w GY/BK GY/R
f56a 56a 56b 58 I I ~ 58
~
~
1
HEADLIGHT,
LEFT ~IGEUBEAII
HEADLIGHT,
" LEFT
I . .
SIDE
·y
MARKER
LIGHTS, ( ··
TAIL
UGHT, )
RIGHT
1
REAR I J-
W
1 31
1.5
BR
1.5 LEFT
BR
HEADI.IGHT,
J5 ofu.51.:
BR BR BR
.....+--....
P~KING - --u
' -- - -- -·- - - - --- ~--!- - - -- ------
LIGHT,
LEFT
......- -- - - - -- - - - - - - -- - - - -- -- ·- -- - - -W
@ @
101 102 103 104 105 106 107 108 109 110 111
197-29221
30----------~----~~~~~~~--~~~~~~--------------------------~~--30
15 15
X X
31 31
58 58
~"519
~lOA
49a-+----~----+---~
I;
~
TURN
IGNAL
WTTCH
1.0
BKIW/G
r r
1.0
BKIG
1.0
BKIW
'Tm •Tm
15 49 30 - -
~9o ,.-R ~ l
EIIERGENCY
FLA SHER
WARNING
UGHT
EIIERGENCY
... T
FLASHER SWfTCH
·~~ .-
""T
r--'158b
tl
.,
31
WIRING
COLOR CODE
0.5 0.5 0.5
GYIBL GYIBL BR
BK
BR
-
-
BLACK
BROWN
r~
~ ~ RIGHT
CL -CL EAR
R - RED Bl BL BL REAR
y
G
- YELLOW
- GREEN I
') TURN (
TURN
) SIGNAL
LT G - LIGHT GREEN TURN
SIGNAL SIGNAL LIGHT.
BL - BLUE L~ ,
I~
LIGHT.
v
GY
w
- VIOLET
--GRAY
- WH ITE
LEFT
REAR
1.0
t=
1.0
OR - ORANGE
BR BR
t.!~ ~
u------------------------------------------------- - u
v---------------------------------------------
w-------------------------------
, ___ 30 30
112 113 114 115 116 117 118 119 120 121 122 123 124
J97-2923 j
cfl~uP
q_JswrrcH
•
1.0
BKIBL
I T7i4
1.0
RN
1.0
3
BKIBL
WIRING
COLOR CODE
1.0
BKIR BK - BLACK
BR - BROWN
ls4 RF RF CL
A
-
-RED
CLEAR
BRAKE BACK·UP
Y - YELLOW
UGHT, , UGHT, HORN
RIGHT ' RIGHT BUTTON G - GREEN
Lr G - LIGH T G REEN
BL - BLUE
'-BACK-UP v - VIOLET
UGHT, 1.0 GY -GRA Y
LEFT BR w -WHI TE
OR - ORANGE
u----------------------~----
•
4 3
WTRING'
~
COLOR CODE
8K -BLACK REAR
BR -BROWN
1.5 WINOOW
GY/BK DEFOOQER
CL - CLEAR
INDICATOR II
~·-
R -RED
I:;ER
Y - YELLOW
G -GREEN
LT. G - L/OHT GREEN
8L - BLUE
V - VIOLET .4/31 .2/86
GY -GRAY 0.5 0.5 1.5
Y/R BR
,T,,
W -WHITE
W/G
OR -ORANGE
1.5
2/SU BR
PARKING ~ REAR
BRAKE WINDOW
WARNING H!AT!R
LIGHT ELEMENT
SWfTCH
SAFETY
BELT
SWfTCH, 1.5
LEFT BK
81
5185 4130 I, 13 2
St3
20.\
S1
30A. • ~ l
'\
· 6/86 8187
~ 7.
~ - I
A22 C7 H6 H3 lH1 H4 H2 H5
RADIATORJ
1.0 2.5 1.5 2.5 0.5 COOIJNG
BK/R R/W RJBL R BR FAN
RELAY
(IND
STAGE}
T
0.5
I Tii
T
0.5
T1.5
GY/BL GY/BL BK/Y
FRESH
AIR FRESH HEATER WA R.,
CONTROL AIR BLOWER AIR
LEVER FAN SWITCH BLOWER
58b LIGHT SwrTCH + 58b LIGHT SWITCH +
FRESH
AIR
FAN
RADIATOR
COOLING
FAN
2
r·.,_
-
M
R
1.5
BR ...
s
3 1
rL
4
141 142 143 144 )45 146 147 148 149 ISO 151 152
191-29261
30--~----~----~~~--~----------------------------------------~-=~~-~
-.
15 .i i 15
X X
31 31
"
I' 6/53 sl 3i15 4/31
I•
~Sn
15A
~517
lOA
WASHEMfiPS! ® IBD
I'
~020 012 09 02
I
'1 017
I
IA6 B9 A5 A2 A12 ~A14 A19 f c9
1.5 1.0 1.0 , .0 1.0 1.0 1.0 , .0 , .0 , .0 0.5 1.0 0.5 0.5
BR BR G/BK GIY GY/BK G G GY/BK GIY G/BK BR/BK G!W G/R G/R
WIRING
t ~:5:'1
3
l ~53e
COLOR CODE
C~
31
;=
53b 53o
WINDSHIELD BK -BUCK
.. WINDSHIELD
· · WIPER ~ WASHER
BR - BROWN
PI/liP
~==~============== MOroR CL -CLEAR
I
R -RED
Y - YELLOW
G - GREEN
LT. G - LIGHT GREEN 0.5
BL -BLUE BR
I~
V - VKJLET
GV - GRAY
W -WHITE
OR -ORANGE
30
153 154 155 156 157 158 159
1 97- 292~
2
512
20A
-4
• 3
E2 EB G3 Rl R2
BK -BLACK
BR -BROWN
CL - CLEAR
R -RED
Y - YELLOW
G - GREEN
LT G - LIGHT GREEN
BL - BLUt.
V - VIOLET
GY - GRAY
ELD
'
REAR
WINDOW
WASHER 51]'~ MOTOR
PUIIP
131
1.0 1.0
BR BR
1~4
160 161
J~.
162 163 16-4
Go to next page •
EVAPORATOR
FAN
8 SWITCH
2.5
YISR
FROII FROM TO
FUSE FUSE BATT.
S1 SfO +30
.-JI
2.5
RIW
2.5
RIW
I
0.5
BR
4.0
R
4.0
R'BK
1.5
R
0.7
G
2
12b
SERIES
RESISTANCE . ._ _.
RAD. 3
COOLING
FAN
THERMIJ.
SWITCH
t5
RIBR
1.5
RI8K
0.5
8R
4.0
BKIR T2c
0.5
8R
RAD.!
CONDENSOR
COOLING
FAN EVAPORATOR
RELAY FAN
,4IC
12d T2d COMPRESSOR
CLUTCH
1.5
RiiiL
1.5
RcBK
0.5 0.5
BR BR
CD @ @
2 3 4 6 5. 7 8 9 10 11 12 13 14 15 16 17 18
I a
1.5 2.5 2.5
BKIR BKIY 6fl0
I So _________________________
R ~5-0_A
RIW
~T1d T..ta/1
~~v 4.0f'--------------------------•2.5I I
1.5 8+
BKIR R R
:o
FRES#
T6a!1
b
AIR
FAN
AIC
SWITCH EVAPORA TOR
,a,...-:&:---6,AIC 3~--.....a
THERIIOSTAT
~~~~~ L~~~~~
4
1.5 BK
@
2 3 4 5 6 7 8 9 10 11 12 13
.-,8-7--88-1--,aj
H3 HI
a----------------~----------~
0.5 RIBL
AIC
REFRIG. 2.5 2.5 2.5
LOW
T1b~ PRESS.
sw.
BK TO
BATTERY
RIBK BA
0.5
BKIA
2.5
RJW
2bar
I
6.0
?
2.5
A RIBK
b-----~ 'Wo/2 T2 9
0.5 RAD.
BKIY COOL
FAN
3 THERMOSWFJ.CHES
J~, ~L~~.
AMBIENT
AIR
TEMP.
sw.
2.5 1.0 2.5 6.0
AIBL RIBL A/W A
If!~~------~-~¥1'2
87/2 '18616 '18616 ~ 1'8718
1
2.5 A/BL
T4a/3
0.5
BA
0.5
BA
FAN 6.0
RELAY A
3RD
STAGE
I
NC compressor clutch, N25 26 T1b -single, behind instrument panel
NC pressure switch, F129 23-24 T1c - single, behind Instrument panel
NC relay, J32 18-21 T1d- single, behind C-pillar trim
AJC switch, E35 2-4 T2a- double, behind C-pillar trim
AJC thermostat, E33 2-5 T2b- double, behind C-pillar trim
Ambient temperature switch, F38 26 T2c - double, behind C-pillar trim
Cooling fan fuse, S42 33 T2d- double, behind C-pillar trim
T2e- double, on left rear pillar
Evaporator blower relay, J157 7-8 T2f - double, near A/C compressor
Evaporator blower series resistor, N81 10-12 T2g- double, on left rear pillar
Evaporator blower switch, E 11 0 7-12 T2h- double, on radiator
Evaporator fan, V20 8, 12 T2i - double, behind C-pillar trim
Fuse,
Fuse,
S12
S51
..10, 14 T2k- double, behind C-pillar trim
T3a - three-point, on left rear pillar
Fuse, S23 17 T3b - three-point, on left rear pillar
Fuse, S1 31 T4a- four-point, on left rear pillar
T4b- four-point, on left rear pillar
Radiator cooling fan, V7 ·33
Radiator cooling fan relay (2nd stage), Ground connections
J101 37-38 @-near fuse/relay panel
Radiator cooling fan relay (3rd stage),
J135 31-33 @-on left rear pillar
Radiator cooling fan series resistance,
N39 36-37
Radiator cooling fan thermoswitch , FlB 31-32
Temperature sensor II, G18 3
1
...T
E8 G1
E110
J·
. - - - • 2.5 GiBK - - - - - - - - . EVAPORATOR
BLOWER SWITCH
lj
t4
0.5 2.5 2.5 0.5
y BKiW BKiG w
trf==tl
T3b/3 T3bll T3ol3~ ~T2kl1 T2k l2 ~T3o/2
1.5
4.0 t:::... 0.5 W - a
BKiR
4/86 12/87 ~~!'!""""""~!'!""""""~~~
.: N81
~~~ ~'.JJP
EVAPORATOR
2 <;:--...--IIQ2 BLOWER SERIES
f17\
IL,----,--,r----,:t,-----tr
\!Y lrHERAIOSTAT
116/85
~ BLWR
j8t3~L r
3 ~-...
~----..-----?c-r4
3
RESISTOR
4
0.5 0.5 0.5 0.5 05 2.5
BR BR BR BL
8
·R BK 1.5 1.5
t
BK BK • 1.5 W - b
TO FRESH AIR FAN, r T2al 2 T2all ~2 c 12 ..._ ...._ _ _ 1.5 w - c
~ ~-----t--•
0.5 0.5 2~5
BL BR BK
~a "
;G18
TEAIP
SNSR
. _ - - t - - + - - - - - + - - + - - - - - - l t - - - 0 . 5 BR - d
19 ~2b
2.5 2.5
BK BK
~~:n~~ FUSE~~
WIRING
COLOR CODE V20
EVAP
Ss1
BK -BLACK FAN 20A
BR -BROWN
CL -CLEAR I'
R -RED 2.5 2.5 2.5 2.5 2.5 2.5
Y - YELLOW BR BR BR BR BR BR
~T2ill ~T2i/2
G - GREEN
LT G - LIGHT GREEN
BL - BLUE
V - VIOLET
GY - GRAY
W -WHITE
OR - ORANGE
2 3 4 5 6 7 8 9 10 11 12 13 14
197~7451
H6
0.5 r-f
f1
AIBL
F38 0.5
AMBJENr BKIY
TEMPERATURE
SWITCH
1.5 1.5
. . - - - - 2.5 Am ----lt--.. BL A/BL
~ lib
c:rJ
0.5 2.5 0.5
T'"" iT'"" T4oll
BL AIBK BKIA
r~--~~:l1
.3/2 5/7 615
¥-----&------¥ I~, M 1
j4/6 j11l 0.5 ~~CH p !B7 6/B6i
1.5 0.5 BKIA RLY 2.5 0.5
w A/BL BA
~ ---.1 T2cll
BA !l4bl3
T4bi4 T4bi1 T4bt2 T4o/3
1.5 1.5 1.5 1.5 1.5 1.5
w w A/BK AIBK BL BL
F129
- - AIC
PRESS
sw
Tia
2.5 0.5
WIRING R/BL A/BL
COLOR CODE
BK - BLACK
N25
BR -· BROWN
A!C
CL - CL EAR COMPRESSOR
R . RED CLUTCH
- Yf: U.OW
G - GREEN
LT G · LiGHT GREEN
BL ·• B LUE
V -· VIOLE f
GY - GRAY
W - WHITE
TO
T IDLE
OR ORANGE 14o/4 STABILIZER
CONTROL
UNIT,
® J142 @
16 17 18 19 20 21 22 23 24 25 26 27 28
[r-9-7-8-7-46...,,
RISE
J1tl1
t"'JO 1'6/86
[~ RADWDfl
COOLIIOFAN
1;-------c ri a
Rfi.AY (2110 moE) 8/87 5185
"
i{ ...
Cl H3 Hl
2.5 1.5
•
0.5 2.5 TO R/BK BR
BATTERY,
BKIY BK A
I
6.0
~
2.5
R R/BK
lie T2 9
S42
COOLING
FAN
FUSE
50A
-------------
2/~~35
'tJ:~FAN
' - - ! - - - - - + - ' RELAY (3RD STAGE)
~K
s23 ~
~~L
}6 /86 }8/87 'fl ~~~ST
0.5 6.0 6.0
BR R R WIRING
COLOR CODE
BK. - BLACK.
BR - BROWN
CL - CLEAR
R - RED
- YELLOW
V7 G - GREE-~
RADIA TOR LT G - LIGH T GREEN
COOLING BL - BLUE
FAN V - VIOLET
GY - G RAY
6.0 W - WHITE
BR OR - ORANGE
29 30 31 32 33 34 37 38 39 40 41 42
197.-87471
Description Current
Track
Auto trans. console lites 1-2
Back-up lite, left 3
Back-up lite, right 5
Brake lite, left 2-3
Brake lite, right 5-6
Neutral safety/back-up lite sw. 2-5
Side marker lite, LR 1
Side marker lite, RR 8
Tail lite, left 2
Tail lite, right 7
Turn sig., LR 2-3
Turn sig., RR 6
Wire Connectors
T1b- single, wire distributor, eng. compart.
Ground Connections
@-on sub-frame, LF
@-eng. compart., under ignition coil
Ill
7
1.0
R/BK
4 .0
R/BK
6.0
R/BK
0~50.5
TO
STARTER/SO
I
6.0
I
TO
IGNJSTART
---
GY/R GY/R RIBK SWJ50
~ AUTO ~ 15 ( 50A
TRANS~
f
I'
0.5
CONSOLE
LITES ~~~
iRF
1.0
50
p R N
ISAFETY!
NEUTRAL
BACK-UP
· UTE
sw.
BR BKIBL
WIRING
COLOR CODE
BK -BLACK
BR - BROWN
CL - CLEAR
R - RED
Y - YELLO W
G - GREEN
LT. G - LIGHT GREEN
BL -BLUE
v - VIOLET
GY -GRAY
w - WHITE
00 - ORANGE
I Ttb
1.0
BKIBL
~--- - ·
~BACK· 1 TURN 1 SIDE
UP ~RAKE, SIG. I TAIL : MARKER
LITE, LITE, f.0 LffE,
RIGHT RIGHT Y RR
LITE,
RIGHT
':<LffE,
RR
1\--.u
1.5
BR
0.5
BR
@
2 3 5 6 7 8
Water-cooled-Diglfant 1986-1989
Automatic transmission 97.1 47
Electrical S.ystem - Wiring, Waterboxer 97
CUrrent
Description Wire connectors
track
T1 a- single, under instrument panel
By-pass air blower
T2 - double, on fresh air blower
Combustion air blower T4a - four-point, under Instrument panel
Combustion air blower suppressor T4b - four-point, under Instrument panel
Fuel pump Ground connections
Fuel pump contact breaker
®- near fuse/relay panel
Glow/spark plug
Glowplug/heater condenser
@- on crossmember near fuel pump
Go to next page •
0.5
BK
.---------------------------------------------------------0
---------------------------------------b
0.5
BLJW
~o~
1.5
BKIY
MAIN IY.PASSAJR
SUPPRESSOR &OWER
0.5
R
9
523
a----:>
- II
Canada Water-cooled-Digifant from 1987
Auxiliary heaterBAs9 7 .150
97 Electrical System - Wiring, Waterboxer
Description
Wire connectors
T1 - single, under Instrument panel, right side
AIC diode T1a - single, near fuse/relay panel
Combustion air blower T1b - single, near fuse/relay panel
T1d - single, In engine compartment
Flame detector T1e - single, in engine compartment
Fresh air fan relay T1f - single, near fuse/relay panel
Glow plug T2 -double,
Glow plug relay T2a - double,
T2c- double,
Heater control lever switch 8
Heater control unit .18-24. T6a - six-point, in engine compartment, left side
Heater fan relay 1·3 . T6b - six-point, near fuse/relay panel
Metering pump 20 T12 - twelve-point, on heater control unit
Monovalve 8 .
Ground connections
7~-·
Monovalve relay
@-in engine compartment, left side
Programmable timer 11· .
Programmable timer Indicator light t.C @-near fuse/relay panel
Programmable timer light 11
@- on Instrument cluster
Recirculation pump 13:
Recirculation pump relay 1~17
@-near steering column
Resistor .28 Plus connection
Series resistor It · (6)- + connection (30) wire distributor box,
Temperature sensor (NTC) ft engine compartment
Thermoswitch 7
Time relay 8,10-
512
20A
Gl
2 .5
p
I ---lr-r~
r--
1.0 1.5 1.5
1.5 2.5
A A R BK BKAN R
WIRING
COLOR CODE
81( - BI.ACI(
BR -BROWN
T
CL - CLEAR
R -RED
Y - YELLOW
G -GREEN 1.0
LT G - LIGHT GREEN BUR
8L - BLUE
V - VIOLET
556 GY .-GRAY
W -WHITE
5ss
7,5A 15A
OR - ORANGE
2.5
A 0.5
[
BKIR
I
1.0BUR
1 ~e~=--fi~~
L. ""'
If-----t:;l 1=:·"'
12/30 16/85 16/85 12/30 f7/86 14187 87a
1.5 0.5 0.5 1.5
0.5 R/BK 1.0 BKIY
BKIY BR BR BKIR
I
T6b/6 T6bts
T6at6
m<ROOSMTCH~ IIONOVALVE
•
0.5
BR
1.0
BR
@
2 3 4 5 6 7 8
197-27411
023
a-----1 .0BK------------------------------------------------------.
b -----1.5 BKIW - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - . .-------~--+-----d
1.5
1.5
c - 1.5 R - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - . BKIR
BKIW
1.5 1.5
BK BKIR
1i2/2
WIRING
COLOR CODE
t~~
HEATER
E
BK -BLACK
CONTROL 1!1 RECIRCULATION BR - BROWN
LEVER PUIIP CL - CL EAR
SWTTCH
R -RED
y - YEL LOW
1.5 0.5 G - GREEN
BR BR L T G- LIGHT GREEN
Bl. - BLUE
~
v - VIOL ET
GY - GRAY
'1 1.0 w -WHITE
@ @
l T @
OR - ORANGE
9 10 11 12 13 14 15 16 17
197-26831
II II [
97.153 Auxiliary heater
BBW46
Syncro Canada Water-cooled-Digifant 1986-1988 1
Electrical System - Wiring, Waterboxer 97
TO EIIERGENCY
4J FLASHER SWTTCH
1.0
BUR
I
0.5
523
16A BK!BL
T6bl4
1.5 2.5 6.0
L®
R BKIY R
C''"-~L
T6a/4 TH
L :TWJ
I I
. :'·~ I :11: :~~
fT6/5 JT2a/2 JT2c/2 r 1 T2a/1 fT8/5 fT8/8 fT8/7 JT811 fT8/4 fT8/2
1.5 1.0 1.0 1.0 1.0 0.5 1.0 0.5 1.0 2.5
BK!R BR RIY BUBK W G W/G V R Y
T6a!1 .112/6
2.5Y - ,
1.0
BUBK
rTW2
1
) 2!30 4/86
I_..
. RESISTOR I[J'----f I~& r" RELAy
~&OW
DETECT
~l
BK - BLA CK
BR - BROWN
COIIBUS . .M CL
524 ·AIR
- CL EA R
,PLUG R - RED
IJLWR ' y - YELLOW
IIETERING G -GREEN
PUIIP 1.0 1.0 1.0 2.5 LT G- LIGHT GREEN
BR G BR BR BL - BLUE
v -VIOLE T
~
OR - ORANGE
li2/7
@ @ @ @
18 19 20 21 22 23 24 25 26 27
l97-2684l
-
Glow plug relay 40 @-in wire distributor, engine compartment
512
20A
Gl G3 p
a
1.5
R
2.5
R
2.5
R
I
1.0
BK
1.5
BKIW
rr=~
1.5
R
~
1.0
BUR
Ss6 Sss
7.5A 15A
1.5 0.5
R B~R
t----------------r
J6185
-+-----t---,1
(2 /30
=··,.. t-----b:=,.. .
1
'17/86
2/YJ
j4/87 87a
-MT<HrSJ MONOVALVE
0.5
BR
• 1.0
BR
@ @ @
2 3 5 6 7 8 9 10 11 12 13 14
!97-31721
a-1.0 BK-------------------------IIIIiiii--...
b - 1 . 5 - - -- -- -- - - - - - - - - -- - -....
015
.--------4--~~-d
D23
c - 1 . 5 A - - -- - - -- - - - - - - - - -. . 1.5 1.5
BKIW BKIR
70 EMERGENCY
Cf:l FLAiER SwrTCH
0.5 0.5
I] ~~ GG
.k;-J 8a:1
..-+-----'!-=::..::..._--,
8a/9
B
IK GYI/IlK
Sa/4
~
OR'
Sa/11PRGRIIBLE niiR
PROGRAIIIIABLE
1.5
BKIR
® =~E ~ =INDICATOR
BK_.,.__,
Jrei85 TillE RECIRCULATION
I '--I RELAY PUIIPRELAY
0.5 1.5 0.5
0.5 0.5 1.5 0.5 BRIW
BRIW BRIW BKIR BR BR
I T6bi3
BK
1.5
1.5
T6ai6 BKIR BLOCKING
DIODE
BK
1.5
HEATER
CONTROL
LEVER
SwrTCH
$~~- PUIIP
BLOCKING
DIODE
1.5 0.5
BR BR
DjJ
1.0
BR
§ @ @
17 18 19 20 21 22 23 2.4 25 26 27 28
!97-317~
1.5 1.0
BKIW BUR MAIN 0.5 0.5
FUSE I HTR BK BKIBL
6b/4 8A FUSE
(ti
AMP}
1.5 6.0
R R
i1'6a/2 iT6a/4 ~@
1.5
1.0 R
BUR
T8/3 T8/6 lr6/6 T6/4
HEATER
®
~----~--~--------~~--~----~--~----~----~--~UNTT
CONTROL
t
d/
2
2.5 y
GLOW
PLUG
:I 2/30
lie
0.5
BKIBL
14/86
RELAY
1.5
BKIR
e~ li2/12 li2/11
1.0
T6a/5 li2/10 li2/8
RESISTOR
J li2/4
T212
Bl 1.0 v 2.5 y
OVERHEAT
FUSE
~
1.0
FLAME
DETECTOR
1.0
~~··
2.5
PLUG
G BR BR
COMBUSnON ~
AIR
METERING BLOWER li213 T211
PUMP
1.0
li2i7 BR
@ ® ctJJ @ @)
29 30 31 32 33 34 35 36 37 38 39 40 41 42
!97-31741
Go to next page •
Ss2 ..----------- b
1.0
R 1.0 1.0
w 1.0 R
y
4
LOCK E
30 IIOTOR, E A A 30
DIIIVER
DOOR
LOCK
MOTOR, 1.0
PASSENGER BR
DOOR
T3a
WIRING
COLOR CODE
BK -BLACK
BR - BROWN
CL - CLEAR
R - REO
Y - YELLOW
G - GF:EEN
l T. G - LIGHT GREEN
BL - BLUE
V - VIOLET
GY -GRAY
W - WHI TE
1.0
. __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _OR
__ - ORANGE
_ ___________________ d
BR c
2 3 5 6 7 8
l§ili]
b----...
a _.............._....__,..~
1.0
w
1.0
y
DOOR
LOCK
CONTACT,
SLJDINQ
DOOR
E A 31 A E
LOCK LOCK
MOTOR, MOTOR,
SIJIJING REAR
DOOR DOOR
WIRING
COLOR CODE
BK -BLACK
BR -BROWN
CL -CLEAR
R -RED
Y - YELLOW
G -GREEN
L T G -· LIGHT GREEN
BL - BLUE
V - VIOLET
GY - GRAY
W - WHITE
OR -- ORANGE
9 10 11 12 13
197-22831
Description Current
track
Central locking system motor, decklid 11,12
Central locking system motor, driver
door 1,2
Central locking system motor,
passenger door 5,6
Central locking system motor. sliding
door 7·9
Sliding door contact switch 7-10
Wire connectors
T1 - single, in LF door
T1a- single, in RF door
T3 - three-point, in LF door
T3a- three-point, in RF door
T3b- three-point, under inst. panel, right side
T3c - three-point, near upper right "B" pillar
T3d - three-point, upper half of left rear window fJl - fuse for central locking system
T3e- three-point, in rear decklid
Ground connection
@-near fuse/relay panel
p
1.0
R
Dl OOs, 20A
1.0 y
1.0 w
0
b
'W 1.0 R
1.0
R 1.0 w
"
I'- 1.0 -
y ~
T4 T4 T4 T4a T4o T4a
WIRING
COLOR CODE
BK -BLACK
BR - BRCWN
CL - CLEAR
R - REV
Y - YELLOW
G - GREEIV
LT G - UGHr GREEN
BL - BLUE
v - VIOLET
GY - GRAY
T1 T3 T3 T3a T3a T1o w
OR
-WHI TE
- ORANGE
1.0 1.0 1.0 1.0 1.0 1.0
R W Y Y W R
~~~r~.~t~~~=.~'l_E_jf•
1.0 DRIVER DOOR
'L_A ---===''~= = =EY.--T-ST~EI~,l:-~~ft
-;: :=:;:•,!
PASSEJKJER DOOR 1.0
BR BR
~ ~
a 1.0 y
b
I
1.0 1.0 w
w 1.0 y
1.0 BR
T3b TJb
cr
1.0
BR
TJd TJd TJd
WIRING
COLOR CODE
E A 31
BK -BLACK
~~~~==:r--~~~~- C~L~WG BR -BROWN
SYSTEIIIIOTOR, Cl. -CLEAR
t-..a-,.;,;,"""",.,;_,_,...,.,.,..~,, SLIDING DOOR R -RED
Y - YELLOW
G -GREEN
LT G - LIGHT GREEN
BL -BLUE
V - VIOLET
GY -GRAY
W -WHITE
OR -ORANGE
1.0
BKIW
0.5
BK
0.5 1.5
R/W G BK
I
TO
I
TO
/GN.
OISTR.
IGN.
CONTROL
TO
1.0
BK
~
5,
TACHOMETER >A
1.0
BK
WIRING
COLOR CODE HEAT
ELEMENT
BK - BLACK
(CRANKCASE
BR -BROWN VENT.)
CL -CLEAR
R -RED
y - YELLOW 1.0
G -GREEN BR
LT G - LIGHT GREEN
BL -BLUE
V - VIOLET
GY -GRAY
W -WHITE
OR -ORANGE
2 J 4 5 6
197-21061
--- lE12
0.5 1.5
R/BK BK TO
0/GIFANT
RELAY
T2
0 .5 1.0
BK BKtW
dtj
r· 15
1ciiimoN
COIL
BK
i4 1
1.0
BK
Icps, 5A
0 .5
BK
r
WIRING
COLOR CODE
BK - BLACK
BR -BROWN
CL - CLEAR
R - RED [}]HEAT
Y - YELLOW ELEMENT
G -
LT. G -
BL -
GREEN
LIGHT GREEN
BLUE
TO
IGN.
DISTRIBUTOR i (CRANKCASE
VENT)
V - VIOLET
GY - GllAY
1.0
W - WHITE
BR
I~
OR - ORANGE
2 3 4
~7-2349 1
Go to next page •
TO
BAT 0.5 1.0
BK'BL
I
GY/R
35,0
0.5
BR
I I
1.5
BR
1.5
BR
@
2 3 5 6 7 8 9 10
0.5 05 05 05
RISK RIY BL BKIBL
0 .5
R/BK
12
If.-·- - iltws I
T2
3 t"
,..a
®
T4b
6
~ T4
0.5
BK
T4b
1111...
.......... . . ,1
I
CRUISE
CONTROL,
MAIN
CONTROL
... 5
~ 1'4 1'7 UNIT
0 .5 1.0 0.5 1.0
r Ic~ t t t'
0.5 0.5 0.5
R/BL W/BL W/BL BR/BL G/W GIY
T2 T4 ~T4 TJ T:
0.5 0.5
BR BR
VACUUM VAC
VENT CNTRL CNTRL
VALVE, INDUC MTR
BRAKE SNDR
12 14 15 17 18
Current
Description Wire connectors
track
Automatic transmission console lite 4,5 T1f -single, in wire distributor, eng. compart.
Automatic transmission relay 13, 14 T2a- double, under instrument panel
T2b- double, under instrument panel
Back-up lite, left 8 T2j - double, near fuse/relay panel
Back-up lite, right 6 . T2k - double, near fuse/relay panel
Brake lite switch 10, 11 Til -seven point, In wire distributor, eng. compart.
Brake lite, left ~
Brake lite, right 10 Ground connections
TO
I TO
I
tGNmONISTARTER ALTERNATOR
swrrcH 1.0
RIBK
T2b
F,
T2b I
1'"'--c
T2j I
0 .5 1.0
RIBK RIBK
6 .0 1.0
RIBK BKIBL
Tm
TO
BATTERY
I
70.0
I TH
M 1~
~R B~
J RF 54 1s4
~ BCK-UP B~K
STARTER
AU~UI
CONSL LT AUTD-TRANS
CONSL LT
· L~
BCK·UP
R
L-----------~-
L~
L
131
L~
L
BRK
. L~
131
R
2 3 4 5
67
6 7 B
l" 1(1~
9 10 11
[97-2532[
30 30
15 15
X X
31
I~512
20A: • 3
31
0.5 1.0
0.5 0.5 0.5 RIBKRIBK
I ~T7a/6
BKIR BKIY BK
TO
TO TO
REAR ALT IGNmoN
WINDOW WRNG SWTTCH/50
WIPER LT
IIOTOR
ra~~~~~~~~~~~~~~~CRU~E
CONTROL
~--~~----~--~~--~~~~~SW"CH
0.5 05 05 05
RIBK RIY BL BKIBL
T2 T4b ~T4
0 .5
RIBK
12 3
IT"
T2 6
0.5
---...
BK
J4b
If --- ll~
I " 1 CRUISE
..-s
I ~
'•
:® ..
'i'7
1
CCNTROL,
IIAIN
CONTROL
~ 1.0
'i'4 UN"
0 .5 0.5 0.5 0.5 0.5 1. 0
RlBL BR W/BL W/BL BRIBL GIW GN
rI
3
1$4
L..===~~====:::'J
VACUUII
CONTROL
IIOTOR
6o'
'·._ ,./
12 13 14 16 1!7 18 19 20 21
.-,9-7--25-3..,31
Go to next page •
El6 C3 Cl
WIRING
1.0
BKIR
1.0
RIY
1.0
R/BK
f"BJ - VACUUM
VENT
VALVE,
0.5
BK
1.0
BK
COLOR CODE
BK
BR
- BLACK
-BROWN
L
CLUTCH CL -CLEAR
0. 5 ~ PEDAL R - RfV
R/BK 0.5 Y - YELLOW
G -GREEN
RIBK LT. G - LIGHT GREEN
T4b BL
V
-BLUE
- VIOLET
GY -GRAY
W -WHITE
1.0 --. OR -ORANGE
RIY ~
fMKEdl fM"Edl
SWfTCHL'f-J SWITCHq_l
1.0
R/BK
....J
I T7 3
1.0
BKIR
I 54
,<-, BRAKE
vUTE,
LEFT
f31 .31
1.5 1.5
BR BR
((4)
2 3 4 5 6 7 8 9 10
[9Bm)
--~t-Et-6~~------~--~~~~~~~~~ ~~~~6~G-5_·~~-2-5--~~----~~~~~
1.0 1.0 1.0 0.5
BKIR RIY RIBK BK
T4b
VAC
VENT
~W:~~ijt:;~~==+:;;:;;:;::;::;;::=~21iOJ CRUISE
VALVf; CONTROL
CLUTCH ~~~----~~~~--~--~~--~s~~H
t
~5 ~5 ~5 0.5
RIBK R1Y BL BKIBL
[" t
1.0
GIY
TJ
tl tl VACUUM
CONTROL I M .I
MOTOR L=::::=::::!::::===..
1.5 1.5
BR BR
s 6 7 8 9 10
~7-25291
Note
I
0.5
"'I
0.5
BKIBL BKIBL
I
EIIERGENCY
FLASHER
SWITCH
KL 15
,4
I DIFFERENTIAL
(/) LOCK
T ~CATOR
.3
0.5
BUBR
~T3
WIRING
COLOR CODE
81( -BLACK 1.0
BR -BROWN BUBR
CL
R
y
G
-CLEAR
-RED
- YELLOW
-GREEN
LT. G- LIGHT GREEN
• DIFFERENTIAL
LOCK
SWITCH
BL -SLUE
v
GY
w
OR
- VIOLET
-GRAY
-WHITE
-ORANGE
I
1.0
BR
lc~
2
197-233~
Description Current
Track
Heated seat control unit 1-4
Heated seat indicator lite 5
Heated seat switch 1-2
Heated seat temp. sensor 1
Heat element, backrest 3
Heat element, seat 3
Wire connectors
T1 - single, behind instrument panel
T2 - double, behind instrument panel
T5/ - five-point, behind instrument panel
T6/ - six-point, behind instrument panel
Ground connections
@-behind inst. panel, near fuse/relay panel
@-behind instrument panel
G2 07 Al
'J'861F
0.5
RIW AJY
J'
0.5
BKJY
lT515 lT5/4 UT5!3
0.5
L,
~lr :.
LL I
®I
L
$I
HEATED
SEAT
IND.
LfTE
Sso
UN"
j4/T f2 iH j7i3l 3lj
0.5 BUY 1.0 BKIR
0.5 0.5
1~:/6
BR BR
i:/4
1 HEAT
HEATED
SEAT ELEMENT,
TEMP; SEAT
SENSOR
0.5 1.0
BR BR
'-'.T6:2 WIRING
lr6i5 T512 COLOR CODE
jT6/3 BK -BUCK
BR -BROWN
CL -CLEAR
R - RED
Y - YELLOW
HEAT G -GREEN
ELEMENT, LT. G- LIGHT GREEN
IACKREST BL -BLUE
v - VIOLET
GY - GRAY
1'.0 w -WHITE
BR
OR - ORANGE
T6' 1
I
1.0
BA
@
2 3 4 5 6
Current
Description
track
Driver seat heater control unit 3-6
Driver seat temperature sensor 3
Heat element, driver backrest 5
Heat element, driver seat 4
Heat regulating switch, driver 3,4
Seat heater switch indicator lite 2
Wire connectors
Ground connections
~~-~~~1--:----
jl--------~--------~------~----------~------~-------+~--~------,~~~
~~s~
GS
0.5 GY/8 L . - - - - - - - - - - - - - - - .
G~i~L $Jll58b .3/15
I'~~lH~~~E~NG
1IO 1.0 1.0
3
t BK BK BK
~T~ . {
L
u{
L
: :·1:.....,
':/'JER CONTROL
WIRING
COLOR CODE
BK - BlACK
BR - BROWN
CL -CLEAR
R - RED
Y - YELLOW
G - GREEN
LT G - LIGHT GREEN
BL - BLUE
V - VIOLET
--~--1A4 T6!6 T6/4 nl6/2 GY -GRAY
W - WHITE
0 .5 1.0 0 .5 1.0 OR - ORANGE
$
RIBK BK BR BRISK
~x~$
TEMP
SNSR
HT
S.EIINT,
ORV1f
SEAT
$HEAT ELEMENT,
DRIVER
BACKREST
0.5 1.0 10
BR BRISK a·R
@
2 3 4 5 6
l97-2736l
Wire connectors
T2 - double, in driver door
T2a- double, under instrument panel
T2b- double, under instrument panel
T2c - double, under instrument panel
T2d- double, under instrument panel
T2e- double, in passenger door
T3 - three-point, in passenger door
T3a- three-point, under instrument panel
T3b- three-point, in driver door
T4 - four-point, under instrument panel
Ground connector
@-under instrument panel
~ ~3 1 ' ,.
ms12 ID
~w.
-
'2 ,
...
G1 G3 E8 E2 E7 A14
WIRING TO
COLOR CODE TO REAR
REAR DEFOGG.
81( - BlACK DEFOGGER HEAT
BR - BROWN SWITCH ELEMENT
CL
R
-
-
CLEAR
RED I I
HT,,
0.5 - YELL OW 1.5 1.5
BKIY G - GREEN G/W G/W
t~
LT. G - LIGHT GREEN
Bl - BLUE
- VIOLE T
GY - GRA Y
w -WHITE
.,
MIRROR OR - ORANGE
.. ,..
ADJ.
SWITCH 1 0.5 0 .5
.•i• ~
G/W G/W
~~
MIRROR
SELECT!OR
SWITCH
1' 3
0.5
BUBK
..
0.5
~
0.5
12 11
0.5 0.5
6
BL BK BR w T2a
I T4 T3 T3a T4 I T3a T2b
T3a
I T3 T3b T3 T2e T2
0.5
BUBK
$=...
MIRROR MIRROR
MAGNEnC MAGNETIC MIRROR
MIRROR CLUTCH, HEAT
MOTOR, DRIVER ELEMENT,
DRIVER PASSENGER'_ _
CI.UTCH, PASSENGER
orBuI 0.5
BK
T3b
0.5
BR
T2
0.5
BR
T2e
T4 T2b
@ @)
2 3 4 5 6 7
197-21921
Current
Description
track
Window motor, left front door 3
Window motor, right front door 7
Window relay 1,2
Window switch, left front 2·5
Window switch, RF (in LF door) 6-9
Window switch, right front 6·9
Wire connectors
T1 -single, under fuse/relay panel
T2a- double, in driver door
T2b- double, in driver door
T2c - double, in passenger door
T3a - three-point, in passenger door
T3b - three-point, in driver door
T3c - three-point, in driver door
T3d - three point, in driver door
T3e- three point, in passenger door
Ground connections
@-near fuse/relay panel
2.5
R
~537
tf30A
0.5 2.5 2.5 2.5 2.5 2.5
L,
BKIY BKIY R BR BK!R BK/R 2.5 2.5
w
L5 ~T,
W/BK
T3d
iT2b iT2b
2.5 2.5
BKIY y
WINO
RLY I f----------f.l T3b
4/31 8!87
2.5 BK!R
I T3b
2.5 2.5 2.5
2.5 BKIY BR y
BK!R
T3c T3c ~T3e 'T3e ~T3e
2.5 BKIR 2.5 BKIR
5 4 5 03
WIND WIND
SW, SW,
LF RF
2 2 1
0.5 2.5 2.5 2.5 2.5 2.5 2.5
BR W/BK w BR W/BK w BR
® ®
2 3 5 6 7 8 9
Current
Description
track
Window motor, left front door 4
Window motor, right front door 9
Window relay 1,2 .
Window switch, left front 3·6
Window switch, RF (in LF door) 7·12
Window switch, right front 7·12
Wire connectors
T1 - single, under fuse/relay panel
T2a - double, in LF door
T2b- double, in RF door
T2c -double, in RF door
T2d - double, in LF door
T2e- double, in LF door
T3a- three-point, under inst. panel, right side
T3b- three-point, under inst. panel, left side 197-2540 1
T3e- three point, in RF door
EIJ - power window relay
Ground connection
m- thermo fuse for power windows
@- near fuse/relay panel
Dl
3
G1 p G3 ES
1.5 R
l 4 WINDOW
SWITCH,
m 00s37
20A
1.5
BR
1.5
BKIR
RF
(IN
LF
2 1 DOOR)
0.5 1.5
BKIY BKIY
"
1.5
R
1.5
W/BK
1.5
w
~T1 ~T2b
6/85
WINDOW
RELAY L m
T2e T2e
1.5
BR
1.5
BKIY
T3b
T3a T3a
!r2b
1.5
y
T3b
T3a
1
1.5 1.5 1.5 1.5
W/BK W W/BK W
~-~lJ lJ WIRING
WINDOW MOTOR, COLOR CODE
RIGHT FRONT Ill 1--------1
DOOR BK - BlACK
BR -BROWN
CL - CLEAR
R -REO
Y - YELLOW
G - GREEN
LT G - LIG HT GREEN
BL - BLUE
V - VIO LET
tiY - GRA Y
W - WHI TE
OR - ORANGE
2 3 4 5 6 7 8 9 10 11 12
197-2733/
Description Current
Track
Antenna 3
Balance control 9-12
/
Cigar lighter / 1
Cigar lighter lite 5-6
Radio 4-8
Speaker, LF 12
Speaker, LR 11
Speaker, RF 9
Speaker, RR 10
Wire connectors
T2 - double, behind instrument panel
T2a- double, behind instrument panel
T2b- double, behind instrument panel
T2c - double, behind instrument panel
T3 - three-point, behind instrument panel
Ground connections
@- in balance control wiring harness
97.191 Radio
Water-cooled - Dlglfant 1986
Electrical System -Wiring, Waterboxer 97
- __,...._ - - 30
15
X
... 'P"l!!l'. . "'"' •
,..
- .. ~. 15
X
-
31 31
:
..
153
,15A '-
\
.OJ
j
811 ~ 812 E3
1.5
r
0.5 0.5
-
r------------------------0
RIGY R R
.---------------b
pill-lllilil-lliiiilil--c
HF
~58b h
0.5 0.5 0 .5 0.5
T2c GY/BL GY/BL BR BR
TO
I I
CLOCK TO
FRESH 0.5
AIR R
FAN
CONTROL
UTE
I
I
05
TO
INTERIOR
LITE,
TO
EIIERG.
FLASH
TO
READING
UTE,
GYiBL FRONT sw. RF
WIRING
COLOR CODE
BK -BLACK
CIGAR BR - BROWN
CIGAR UGHTER CL -CLEAR
UGHTER
..
1.5
UTE R
y
G
- R£0
-YELLOW
-
LT. G -
GREEN
LIGHT GREEN
BR BL -BLUE
v - VIOLET
GY -GRAY
w - WN/1£ .
OR - ORANGE
@ @
2 3 4 5 6 7 8
/97-22931
~----------------------------------~----------~----------------------------~?~
X X
31 31
I
b
c
d
0.5
BR/R
I I
0.75
BK!GY
I
0.75
BR
0.75
BK
R BALANCE
CONTROL
VR HR
0.75 0.75 0.75 0.75
BR/R R BL BK!G
~~a ~~ ~~ ~~
1.0 0.5 0.5 1.0
R R ~ R
SPEAKER, SPEAKER,$SPEAKER,
RF LR LF WIRING
COLOR CODE
~iiiii.........ii~
BK -BLACK
1.0 0.5 1.0 BR -BROWN
R GY BR CL -CLEAR
~T2a ~T3
R -RED
Y - YELLOW
G -GREEN
Lr G- L/GHr GREEN
BL -BLUE
0.5 0.75 0.75 v - VKJLET
BR/R GY BK GY - GRAY
w -WHITE
OR -ORANGE
(19)
9 10 11 12
197-22941
97.193 Radio
Water-cooled - Digifant 1986
.Electrical System- Wiring, Waterboxer 97
Rear footwell heater blower
Description Current track
Fuse 810 1
Series resistance 2
Warm air blower 1
Warm air blower switch 1-2
Wire connectors
T4 - 4-point, under rear bench seat 2.5
WI'/
~s.
Ground connectors
@ - under rear bench seat
1.0 1.5
····~ ~T· I
BLOWER SWITCH ~
t' t l
t5
v
t .S
y,st< w
1.5
r. r. ~r.
1.0
w
SERIES RESISTANCE
Wiring
Color Code
Black - BK 1.5
Brown - BR y
Clear - CL
Red - R
Yellow - Y
r
(ire en -G
L1ght Green -ll G
Blue - BL
VIOleI - v
Gray - GY WARM AIR BlOWEil
While -VI
1.5
bR
r.
I
0.5 0.5
R R
TO
I
114/5
0.5
CIGARETTE R
LIGHTER
LITE I
I
TO TO
INTERIOR MAKE-UP
LITE, MIRROR
FRONT LITE
WT8o/6{58b
f~@~
HF IIADIO LL,.=..
...;:-~~~..=..,=,.,=,.=,,=,"=II=,.=,..~..=.H=._,=,,=.=..=..~...="=If:::u::•u::;.=..,=..=.. ,=,.=,.,=,,=,,~...=..=.u=·.. ,=..=:,="="'::";-J~.::;.@;J:--l
T8a/8/-
·~
+ +
SPEAKER, SPKR, SPEAKER, SPKR,
LEFT RF LEFT RR
FRONT REAR
2 3 5 6 7 8
Water-cooled-Digifant 1987-1989
Stereo radio 97.1 96
97 Electrical System - Wiring, Waterboxer
~----~--~r~E-
3----------------a
WIRING 1.5
COLOR CODE R
-r0.5
GY/BL
BK
BR
CL
R
y
G
LT G -
• - -~
-
-
- BLACK
8RO WN
-· CLEAR
- REO
- YELLOW
GREEN
LIGH T G REEN
VIOLET
. .--fr'' I
0.5
R
I
0.5
R
I I
1.5
R
I
TO CIGARETTE
UGHTER LIGHT
SPEAKER, SPEAKER,
LEFT LEFT
SPEAKER, REAR SPEAKER,
FRONT RIGHT RIGHT
FRONT REAR
2 3 5 6 7
mANTENNA
(
•
HF
't - - - - - ,
IIIIIIIUIIIII!tfi!UUIII!UIIUIIIIIIIIIUIIIIIIUijlllllltlllll @
.Tl0/5 .Tl0/8 jT1()(9 jT8/3 ~8
1.0 1.0 1.0 0.5 1
1.5 ' - - - - - - - - - - -. .
I
BRIY G BL.JW W/BL BR
T3 T3
0.5
BR
IIAPIREADINQ
I.2 ll
©
AMPUFIED SPEAKER,
I LIGHT, RIGHT
FRONT
LEFT FRONT
1.0 1.0 1.5 0.5
G1W BR/BL R R
T3
!J,
AMPUFIED SPEAKER,
LEFT CENTER
WIRING
COLOR CODE
81(
BR
CL
-
-
-
BLACK
BROWN
CLEAR
R - RED
y· - YELLOW
G - GREEN
LT G - 1../GHT GAEEN
BL - BLUE
v - VIOLET
GY -GRAY
w - WHITE
OR - ORANGE:
@
8 9 10 12
3 ~
542
FAN 50A
THERIIOSW
f2 fl
I 1J4~0:I
2.5 1.0 4.0
RIBK BL RJW
12 FAN
RELAY
RAOCOOLFAN
AFTER RUN SER
RESIST
2.5
1f' ~~:ir
f6/86
0.5
fB/87
6.0
R BR R
6.0
BR
@ @
2
197-24361
Fuse/relay panel
IJ- Low coolant level control unit (43)*, J120
II- Rad. cool. fan relay 2nd stage (53)*, J101
II- Load reduction relay (18)*, J59
Ill- Intermittent wash/wiper relay (19)*, J31
Ill - Rear window wash/wiper relay (72),* J30
I& - Emerg. flash/turn sig. relay (21 )*, J2
ml- Seat belt warning system control unit, J34
RJ]WN
2j Jl
•I 51
·I~
p
Fuse arrangement
according to numbers on fuse panel as seen from
left to right:
Amp. 197·14951
1 Radiator cooling fan . . . . . . . . . . . . . . . . . . . .. . • 30
2 Brake lights .. .. . . .. .. . . . .. .. .. .. .. • .. .. .. 15 Connections and plugs on fuse/relay panel
3 Cigarette lighter, radio, clock, interior lights,
illuminated make-up mirror . . . . . . . . . . . . . . . . . 15 A - multi-point connector (blue) for instrument
4 Emergency flasher system .......... , . . . . . . 15 panel wiring harness
5 Open B - multi-point connector (red) for instrument panel
6 Open wiring harness
7 Tail, parking and side marker lights, left 10 C - multi-point connector (yellow) for front wiring
8 Tail, parking and side marker lights, right .... 10 harness
9 High beam right, high beam indicator light . . . 10 0 -multi-point connector (white) for windshield
10 High beam left . .. .. . . .. . . . . .. . . .. . . . . .. . . 10 wiper and main wiring harness
11 Windshield wipers and washer . . . . . . • . . . . . . 15 E - multi-point connector (black) for main wiring
12 Cruise control, A/C, power windows, auxiliary harness
heater fresh air fan, power mirrors, rear window G - single connector
wiper .................................... 20 H - multi-point connector (brown) to connector for
13 Fresh air fan ............... ; ............. 20 rad. cool. fan relay, 2nd stage
14 Rear window defogger . . . . . . . . . . . . . . . . . . . . 20 K - multi-point connector (colorless) to radiator
15 Back-up lights . . . .. . . . .. . .. .. . .. .. . . .. .. .. 10 coolant low-level control unit
16 Hom .................................... 15 L - multi-point connector (gray) for horns
17 Windshield wipers . . . . . . . . . . . . . . . . . • . . . . . . 10 M -open
18 Seat belt warning relay, brake and park brake N - single connector
indicator, cruise control, heated driver's seat . 10 P - single connector (terminal 30)
19 Turn signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 R -open
20 License plate lights . . . . . . . . . . . . . . . . . . . . . . . 10
*Numbers in parentheses indicate production control
21 Low beam left . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
number stamped on relay housing.
22 Low beam right . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
-
9 1 •2 0 3 Current track index for Main wiring diagram
Water-cooled-Digifant from 1990
Electrical System-Wiring, Waterboxer 97
~~--~~---.--~--~------------------------------~~----~-------------~
x-r--r--r--i---t--i--------------------------~--}---------------~--~31
31
r---~======1================i==~1
r-------------,_----~--~--~--------~~~--+--b
p p p p p p 024 E13 AS
WIRING
COLOR CODE
BK - BLACK
T1.5
A 30
BR - BROWN
CL -CLEAR
R - RED
y - YELLOW
G - GREEN
LT G - LIGHT GREEN
BL -BLUE
v - VIOl.ET 2.5 0.5 0.5
GY - GRA Y BKIY BK GY/BK
w -WHITE T2m Tld
OR - ORANGE
1.5
A
10.0 2.5 90 52
R A
25.0
i
25.0
CD 0
2 3 s 6 7 8 9 10 11
,_,9-7--81-47-.[
7 •
8 (j 3
BX -BLACK
r T BR -BROWN
CL - CLEAR
R -RED
Y - YELLOW
I
G -GREEN
TTn 0.5
LT G - LIGHT GREEN
0.5 BKJW
lig~
GY~~1 m
BL - BLUE
_ _, . 0.5 I T7a/5 V
GY
-
-
VIOLET
GRAY
W -WHITE
BK J161
DIGIFANT CONTROL OR -ORANGE
"15 15
N
IGNIT10N
COIL
.25 .8
T
.18 .6 .9 .21 1 ATO
1
17 ~
--------~5--------1~o---------1~o---o1
5
1
'05 sem K
FUSE r---11----------, ~ M
~~1 !?f~!:B_U!~l! @): ~ j: 'i. ~I
G40 G42 G1g
1.0
I HALL GENERATOR 1NrAKE AIR
TEIIPERATURE
SENSOR
AIR
FLOW
SENSOR
POTENTIOMETER
BK
41 42
I 8J ®
p
r-1'--¥---¥---¥-. SPARK PLUG G62
CCNNECTORS WROrnE VALVE
SWI'ICH ' ·,
a,[$]
1
ffff8ASE
Q
'--+--1--t--t--' SPARK PLUGS (ENRICHIIENT) ·. =::IruRE
SENSOR
1.0
BR
12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
197-81481
E4 Dl G6 A4
1.0
R/BK
]4
T7a/6
T0 .5
R/BK
T2m
0.5
Jt69
DIGIFANT CCNTROL
liNf1' 3
r r- ·
Ill\ J11
W FIJEL
PIJIIP 4-___;~..:..~
___~. .::----tl~~·5
----r____.:... _·=R£_l..A=Y
B_KJY-:, ___
,...:_.:
- ~=RJW- - l .l- -8/_8_7~
1.5 1.0 0 .5 1.0 1.0 1.5 1.0 1.0 1.0 1.0 1 .0
BR BR/BK W R/Y W RJW R/W R/W R/W R/W
L, /
WIRING
COLOR CODE
BK -BLACK
8R - BROWN
CL - CLEAR
R -RED
Y - YELLOW
G -GREEN
LT. G - LIGHT GREEN
BL -BLUE
v - VIOLET
n m Gf
FIJE1. PIJIIP
GY -GRAY
w - WHITE
OR - ORANGE
N30 'ti{N31 'til N32 'til N33 'til
l INJ, CYL t •INJ, CYL 2 • INJ, CYL 3. INJ, CYL 4 •
1.0 1.0 1.0 1.0 1.0 1.5
BR w w w w BR
---~~--6----~--~@0 ~T2k
1.0
BRIG
@ @ @
28 29 30 31 32 33 . 34 35 36 37 38
197-81491
~
T
0.5
RISK WIRING
COLOR CODE
BK - BlACK
BR -BROW!¥
Lo
Ct - CLEAR
R -RED
Y -YELLOW
G - GREE!¥
tT G- LIGHT GREEI¥
8t -BlUE
V - VKXET
GY - GRAY
f4/15 f5/LH 15/31 W -WHITE
OR - ORA!VGE
1.0 0.5 1.0
RIW WIY BR
~
~ 25 T1k
0.5
R/W
3 1 y BK y I 1/61 , 4/0XS
FN
POWER
STEERING
PRESSURE
'"'
IDI.E
STABfUZER
SWITCH VALVE
t5/31
0.5
BR
T3 T3 T3
41 42 43 44 45 46 47 48
l@
49
197'81501
n311 6 ..
7 2
• 5
h rl
~
E15 021 81 824 819 AJ 08 A27 03 818 815 821 KJ B2 E10
'
0.5
BK
'
0.5
A
T7a/7 T7a/1
G5 TACHOMETER
J114 ENGINE OIL PRESSURE CONTROL UNIT
K2 ALTERNATOR WARNING UOHT
K3 ENGINE OIL PRESSURE WARNING UOHT
Y2 DIGITAL CLOCK
WIRING
COLOR CODE
BK -BLACK
BR -BROWN
T2x T2x CL -CLEAR
R - RED
0.5 0.5 y - YELLOW
BR BR G - GREEN
LT. G - LIGHT GREEN
BL -BLUE
F1 FZ2
v - VIOLET
0.5 1.5
BR BR
® ® @
50 51 52 53 54 55 56 57 58 59 60
197-81511
~ ~
15 15
X X
31 31
7
.2
~
A17 A28 83 87 K2 817 K1 029 ES
T
0.5
GY/BL
• s. K1 .
T7a/3 I T7a/2
G1 FUEL GAUGE
G3 COOLANT TEMPERATURE GAUGE
J6 VOLTAGE STABILIZER WIRING G G32
K1 HEADLIGHT HIGH BEAM WARNING COLOR CODE COOLANT
LIGHT LOW
K5 TURN SIGNAL INDICATOR LIGHT BK -BLACK LEVEL
K28 COOLANT OVERHEAT WARNING LIGHT BR -BROWN 31~ SENSOR
L8 CLOCK LIGHT CL - CLEAR
L10 INSTRUMENT PANEL LIGHT R -RED 0.5
- YELLOW BR
G -GREEN
LT G - LIGHT GREEN
BL -BLUE
V - VIOLET G2
GY - GRAY COOLANT
W -WHITE TEl/PERATURE
-ifl
OR -ORANGE G G
8 ~
FUEL
. - - - - - _ , 0 . 5 BR ··----··31
1.0
k;,
1.5 1.5 1.0
BR BR BR BR
~ I@ ~ I@
61 62 63 64 65 66 67 68 69 70 71 72 73
I' RJBE
~~3
, 11 15A
~
I J
JB11 EJ 812
1.5 1.5
R R
r0.5
Cf I
0.5 1.5 0.5
)r2c11
0.5
GY/BL R R R R
fir&O
0.5
0
RADIO,
'irat7
TO
RADIO,
T2d/1
0.5
Y/BLR R R
W13
IIAPIREADING 31 T
UGHT,
RIGHT TO 0.5
FRONT RADIO, BR
0.5 R 0.5 0.5 0.5 0.5 0.5
BR BRIW BRIW BRIW BR
BUTBtB 2d/2
1.5
BR WIRING
COLOR CODE
BK -BLACK
BR - BROWN
CL - CLEAR
R -RED
y - YELLOW
G -GREEN
LT. G - LIGHT GREEN
~ ~
BL - BLUE
v - VIOLET
GY -GRAY
0.5 0.5
BR BKIBR w - WHITE
OR -ORANGE
U1
CIGARETTE
n
DOOR CONTACT
~R SwntH, RIGHT
FRONT
1.5
BR Ul~
CIGARETTE
LIGHTBf
UGHT
® @ @ @
74 75 76 77 78 79 80 81 82 83 84 85 86
197·81531
30 30
15 - 15
X X
31 31
58L
~5:"
58Rs8
[FUSE
lOA
~Sa
lOA s:4 lOA
~ 49a
56o
810 Ml B27 G9 El
9 WIRING
COLOR CODE
BK -BUCK
BR -BROWN
CL -CLEAR
R - R£0
Y - YELLOW
G - GREEN
l T. G - LIGHT GREEN
BL -BLUE
V - VIOLET
GY -GRAY
2.5 2.5
W -WHITE
BKIY W!BK T2;12
OR -ORANGE
0.5
GY/G
E20
ltSTRUIIENT
PANEL
LIGHT
DIIIIIER
E1 SWITCH
LIGHT SWITCH
0.5
GY/G
I
+o•m5
~+0.5
BR BR
~T2;11
0.5 0.5 0.5 0 .5 0.5 1.0
GY/BL GY/BL GY/BL GY/BL GY/BL BR
87 88 89 90 91 92
~ '
93 94
du ~ ~
95 96 97
~
98
!97-81541
t
- -D.;. -'
31
I
,.. 58
~-
RIK RISE'
I 522
~"
510 521
lOA lOA lOA
49o ., - ,._ -' 49a
566 "f~
-~ -:;>
=~ J..
,. C17 C5 C.4 E9 M2 A21 822 E18 C1.4 C6 C16 813
1.5 1.5 0.5 0.5 2.5 2.5 0.5 0.5 1.5 1.5
w Y GY/BK GY/BK y w GY/R GY/R Y/BK W/BK
:.
,.
TT1.0
RIY
2.5
W/BK
I•'
I~I
WIRING
It COLOR CODE
BK - BLACK
BR -BROWN
CL -CLEAR
R - RED
y - YELLOW
T7!S T116 G - GREEN
LT. G - LIGHT GREEN
II BL - BLUE
V - VIOLET
30 56 E~ GY - GRAY
ft.~ ~Jj
I.···;
~-.~ =:
FLSHR
W
OR
-
-
WHITE
ORANGE
sw
56a 56b
I
1.5
3~~ 1~~1
Bi u
L---------------------------+-------_,~-------- u
L--------.---------v
~--~----------------------------.-------------~---------w
@ @
100 101 102 103 lO<t 105 106 107 108 109 110 111
197-29221
~ ~
15 15
X ~· ~
X
31 31
58 58
,j-V49 4!31
~FUSE
519
lOA
s..~ IJ.=i!ilci)lltJ
3/49a 2~y
49a FLASHER
RELAY
I
A13 A18 828 AlO All A7 025 'A20 011 'C19 Ell C8
'E6
1.5 1.0 1.5 1.0 ' 1.0 1.0 1.0 1.0 1.0 1.0
BKIBL W RNJ BKIW/G BK!G BKIW BKIW BKIW BKIG BK!G
WIRING
COLOR CODE
BK - BLACK
li BR
CL
R
-
-
-
BROW N
CLEAR
RED
y - YELLOW
~~
G - GREEN
I· SWfTCH LT. G - LIGHT GREEN
BL - BLUE
v - VIOLE T
I ~<
1.0
BKIW/G
r r
1.0
BK!G
1.0
BKIW
GY
w
OR
-
-
GRA Y
WHITE
- OR ANGE
Tm Tm
-
I
K6
EMERGENCY
FLASHER WARNING
15 49 30 f49a ~ II "' L
LIGHT
__J t _ .., .. : GP
I
E3
EIIERGENCY
FLASHER SWITal
, rl58b 31
0.5 0 .5 0.5
GY/BL GY/BL BR
BL BL BL BL
116 M5 118 117
. TliRN
C~ 'fVRN C~ TVRN CQ,TVRN ' SJGNAL
SIG~ S1G SIG
LT.
LR I LT,
LF
LT,
RR
I ~R
LIGHT,
IGHT
ONT
1.0 1.0
BR BR
[]; ~ 96
u u
v
w
® @ (39
112 113 11.4 115 116 117 118 119 120 121 122 123 124
197-29231
,..
-
58
' ,. ,1..4 A2 ,. .,
58
IS2
15A
I, 515
10A
~J6
15A
' 1 3
I
C3 C1 E16 016 C20 l1 L4 L2 825 C15 C13 L3
F4 WIRING
IIACIC-l/P COLOR CODE
LIGHT
SwrTCH BK - BLACK
l BR
CL
-BROWN
- CLEAR
1.0 R -RED
BKIBL y - YELL OW
G - GREEN
LT G - LIGHT GREEN
1.0 BL -BLUE
RIY V - VIOL ET
I
GY -GRA Y
1.0
W - WHITE
BKIBL
OR - ORANGE
1.0
BKJR
154 RF RF 71
1110
BRAKE H
LIGHT, HORN
RIGHT 119 1116 1117 BUTTON
BRAKE BACK-UP BACK-UP
LIGHT, LIGHT, LIGHT,
LEFT LEFT RIGHT 1.0
BR
U-----------------------+--~
w
15
~
15
X X
31 31
sa
2 1 FIIBE
~s:
RIE
u--•
518 56
lOA ISA
r:
' 3
0.5 1.5
BK BK!W
WIRING
COLORCOOE
BK -BLACK
BR - BROWN
CL
R
-CLEAR
-RED
CVJ
y - YELLOW 0.5
G -GREEN GY/BK
LT G- LIGHT GREEN
8L -BLUE
v -VIOLET
GY - GRAY
W - WHITE
OR - ORANGE"
0.5
GY
~T1e 0.5
BUBR
I T1a
0.5 0.5
GY BK
F9
PARKING
I F34
BRAKE
Zl
REAR
BRAKE FLUID WINDOW
WARNING LEVEL HEATER
E24
SEAT BELT SWITCH,
LEFT
LIGHT
SWITCH
I
0.5
WARNING
CONTACT
1.5
ELEMENT
BR BK
81
1.5
BK
® ® @ @ @ @
132 133 134 135 136 137 138 139 140
l9r81ssl
5185 4130 I, . 13 2
FUSE
513
20A
:~
30A - ~ 6186 "'8187
. .
- ·-v- --- .ntn IIAilfAroff
COOCIGFAN
RB.Ar(2ND
7
~
I
A22 C7 H6 H3 fHl H-4 H2 H5
1.0 2.5 1.5 2.5 0.5
BKIR RJW R!BL R BR
T
' '
li;
0.5 0.5 1.5
GY/BL GY/BL BKIY
L16
FRESH E100
AIR WARM
CONTROL AIR
LEVER BLOWER
58b
LIGHT
+ 58b SWTTCH +
31 '(3 {2 31 '(3 l2 lt
0.5 1.5 1.5 2.5 0.5 1.5 1.5 1.0
BR y Y/BK R/BK WIRING BR y Y/BK w
COlORCOOE
ElK - BI.ACI(
.BR - BROWN
Cl. - CtEAR
R -RED
y - YELLOW
G -GREEN
LT. G- LIGHT GREEN
81. - SLUE
v - VIOLET
GY -GRAY
w - WHITE
OR - ORANGE
77 T3dl2 T3dll
2
V2
FRESH
AIR • V7
FAN
1.5
.-
2.5
RADIA'TDR
COOLING FAN
S24
OVERHEAT
N72
HEATER
BR BR 1 5 FUSE
B.R BLOWER
SERIES
T3dt3
Ju BESJ$TANCE
@ @ @ ®
1-41 1-42 1-43 1-44 145 1-46 1-47 1-48 1-49 150 151 152
191-81561
i~----------------------------------------------------------------------------~
:X X
~
31 31
I I T
~020 012 09 02 1017 IA6 89 A.5 A2 A12 A14 . Al9 IC9
1.5 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 0.5 1.0 0.5 0.5
BR BR G/BK GIY GY/BK G G GY/BK GIY G/BK BRIBK G/W G/R G/R
53b 53 J l T
t! .a.
t.. ·""- -~·"
-......, '""' .. {f·rru J
53o 53e E22
WINDSHIEL~W1PER
INTERII!rTENr
SWITCH
WIRING
COLOR CODE
BK
BR
-BLACK
-BROWN
V5
WINDSHIELD ~+
CL -CLEAR WASHER PUIIP
R -RED
Y
G
LT. G -
YELLOW
-GREEN
LIGHT GREEN
I
0.5
BL -BLUE BR
V - VIOLET
GY -GRAY
W -WHITE
OR - ORANGE
97 21 1
li Main wiring diagram
Water-cooled-Digifant from 1990
Electrical System-Wiring, Waterboxer 97
jo 30
15 15
X X
31 31
.
11/53c I 4/31 3153o
FIM
2 L
•I (~ [_]J-~~-, 512 II
M 20A
I 2/53 ~ I 3
IIIA/IIKWJOW
MI'EJI1IQHER
RELAY
I J. -r
DS '"'G10
11,0
E7
1.0
E2
1.0
E8
N.!
1.5 1.5
G3 R1 R2
WIRING
COLOR CODE
BK -BLACK
T3o T3o T3o BR -BROWN
CL - CLEAR
R -RED
y -YELLOW
G -GREEN
LT. G - LIGHT GREEN
BL -BLUE
T2e T2e
V13
REAR WINDOW
IIIUHER PI/liP
~':.. REAR WINDOW
WIPER 11070R
131
1.0 1.0
BR BR
I@ I@
160 161 162 163 164
I
.
Water-cooled-Digifant from 1990 J
_ Main wiring diagram
97 218 •
97 Electrical System-Wiring, Waterboxer
Ground connections
/
@- beside fuse/relay panel
@- on left tail light bulb holder
@- on right tail light bulb holder
Welded wiring harness points
@-plus connection (58b), in instrument panel
wiring harness
,...../1GB lA1
0.5 0.5 0.5
'C20
1.0
016
6.0
024 C18
rs
I
4.0
GY/BL GY/BL GY/BL BK!GY R/BK R/BK
TO
0.5 IGNITION/STARTER
t"'
GY/BL SWITCH,
TERMINAL
50
AUTOMATIC
TRANSMISSION
CONSOLE
L19
AUTOMATIC
TRANSMISSION T
CONSOLE T
I.
15 50
r-;:===F=~~---;:---------~ Et7
.1
I======F====*====t==':l===t.t---=--1
T "RND12swm;H
1·~~:~~ f%!:/UTI
LIGHT LIGHT
iRF 50 A
0.5 0.5 1.0 6.0
BR BR BK!BL R/BK
T7t4
Mt6 RF RF
T2pt2 L
BACIHII' f6o/~5
T6b/2
LIGHT, TO
LEFT STARTER,
r;:::;., i4\ TERMINAL
~ M17 ~50
BACK-UP
LIGHT,
RIGHT
2 3 4 s 6 7 8 9 .10 11 12 13 14
\ \97-8213\
Ground Connections
p A16 81 E13
6.0 0.5 0.5 0.5 0.5 0.5
A BL BL BL BL TO BL
DIGIFANT
I I COfiBI-RELAY
TO TO
CAT
EI..APSED
IIILE
INST.
CLUSTER,
T14111
I
2.5
COUNTER
A
T2m T1d
I
6.0
A
WIRING
COLOR CODE
BK -BLACK
BR -BROWN
CL -CLEAR
R -RED
y - YELLOW
G -GREEN
~})
f
LT G - LIGHT GREEN
BL - BLUE
v - VIOLET
G~ -GRAY
w -WHITE 6.0 6.0 2.5 2.5
OR -ORANGE A RIB' RIW A!W
~----7o,o-
~
r=_:::- BATTERY
.. ----~
+
AUXILIARY
BATTERY
D+
25,0
i
25,0 25,0
2 3 4 5 6 7
I'9-7-2-2-9-.61
~~ II
7
'f
T2m
I .tS
6.0
• •
30 0 .5 0.5
RISK w w
I I
TO TO TO
BRAKE OIGIFANT IDlE
WARN. CONT1fOL STAB.
RELAY UNff CONT.
2.~ 0.5 0 .5
B 'f BK GYi SK
I I 1·=
0.5
GYtR GYIR
TRANS. NEUTRAL
CONS«£ SAFETY
1'0
tiT£
S'NffCH
l1T.
TO TO
SEATBELT j --
USTfR. WARt( 'I'
UTS SW.
WIRING 1.0
COLOR CODE
BK!Bl
• -WOO<
/1111 - IJIIOWN BACK-uP
~ - CL!Wf v LITE.
A - ~D
~HT
y
G
lTG-
IJ:.
-~
-
"'!UDW
97.223 Auxiliarybattery
IAuto. trans., 1986-1989
Electrical System-Wiring, Waterboxer 97
- Current
Description Wire connectors
track
T2K- double, behind instrument panel, left
Auxiliary battery. A 1 5
Bal1ery, A
Ground connections
9
Bat1ery cut-out relay, J7 4-5 G)- ground strap, battery to body
®-ground strap, auxiliary battery to body
~ ~
15 15
X X
~ • 7
D24 BS A16 p
86 87
1J IifA TTERY
cur-our
I RELAY
85 30
6.0 6.0
R R
'LOCATED UNDER
DRIVER SEAT TO
I
STARTER,
"LOCATED UNDER FRONT TERMINAL
PASSENGER SEAT 30
0
2 3 5 6 7 · 8 9 10 II 12 13 1.4
197- 86511
30 3Q
15
X ~!
3t 31
~ ~
p
1.0
A
r,j
1.0 A
1.0
A
T4n
Fow
T·/2
1.0
T4a/3 T4a/ 2 T4a/1
WIRING
COLOR CODE 1.0 1.0 1.0 1.0 1.0
BK - BLACK
w y y w R
OA - BROWN
CL -CLEAR
n ·- RED
y - - YELLOW
G - GREEN
LT G -- LIGHT G.qEEN
BL - BLUE
v - VIOLET
GY - GRA Y
w - WHI T£
T1 T3i2 T311 T3a/l T3a/2 Tla
DR -ORANGE
V57
CENTRAL
30 A E E A 30 LOCKING
SYSTEM
MOTOR,
PASSENGER
OOOR
V56 31
CENTRAL
1.0 LOCKING 1.0
BR SYSTEM BR
MOTOR,
DRIVER
T3i3 OOOR T3a /3
T4 ;4 T4a/4
1.0
BA
T3b/3
1.0
BR
@ o!J
- --
2 3 5 6
197-85761
.---t~------- 1 .0W
1.0 1.0 . -- - - - - • 1.0Y
w y
. .- - - 1.0BR
T3b/T T3dt3 T3d/2 T3di
1.0 WIRING
BR COL OR CODE
BK -BLACK
BR - BROWN
CL - CLEAR
R - REO
y - YELLOW
G -GREEN
LT. G - LIGHT GREEN
BL -BLUE
v - VIOLET
GY -GRAY T3e/3 T3e/2 T3e!1
w -WHITE
1.0 1.0 OR -ORANGE
y BR
31 A E V53
F7
CENTRAL
Ie.-----=:!~ I
SUD/NG
DOOR LOCKING
CONTACT SYSTEM
SWITCH MOTOR,
DECKLID
w y BR
A E 31
r'f-;;::;:==:::::T-----;t--, ~NTRAL LOCKING
SYSTEM MOTOR,
L--k================~SUDWG~
7 8 9 10' 11 12
9 7 •2 2 9 Cruise control
Water-cooled-Digifant from 1990 IAuto. trans. I
Electrical System- Wiring, Waterboxer 97
30
15
X
31
0
~
Al E4 .0 24 C]
0.5 0.5 0 .5 4.0 1.0 1.0 6.0 1.0 1.0 1.0 1.0
GY/BL GY/BL GY/BL R/BK RIBK R/BK RIBK BK!GY BKIR RIY R/BK
T2 bt l
1.5
R/BK
l.b
8 ro IGNITION/STARTER
T7a/6
SWITCH,
TERMINAL 50
0.5
BR
L19
AUTOMATIC
TRANSMISSION
CONS'Ot:E
LIGHT
!"'
0.5
BR
AUTOMATIC
TRANSMISSION
CONSOLE
LIGHT
Ell
~~0-
012 N R
STARTER
CUT-OUT/BACK-UP
UGHT
SWITCH
p
6.0
R/BK
I
50 A
1.0
BKIBL
wf
1.0
RIBK
-F
BRAKE
LIGHT
SWITCH
T7!4
r:
10 STARTER,
TERMNAL50
WIRING 1.0
BK!BL
COLOR CODE
6a/5 T6b/ 2 h6b/6
BK
BR
CL
-
-
-
BLAC K
BROWN
CL H A.R
; ,,,
RF
flACK-UP MIT
RF 54
MIO
BRAKE
A LIGHT, BACK-UP LIGHT,
- REO
LEFT LIGHT, RIGHT
- YEL LOW
RIGHT
G - GREEN
L
BL
T G -
-
tiGI-ff GREEN
Bi..Uf
@
GY
-
-
VfOLET
GRA Y
@
IV - WHITE
OR - ORANGE
2 3 5 6 7 8 9 10 11 12 13 14
~7-84431
30
15 ----~----------------------------------------------~----------~--------30
--------~~----------------------~~----------------·--------------------15
31X----------------------------------~--------·----------~--~--------------X
----------------------------------~----------------------~------~~----31
~ a
- C18
7
b .....TO
II
TO
ALTERNATOR ALTERNATOR,
WARNl'NG
UGHT,
K2
TERMINAL D+
T4bt4
J60
AUTOMAn c
TRANSMISSION
0 .5 RELAY
RlBK
I
0.5
RtBK
T211
4 .2
l P.-- ·· ----- -
c
Im
6 1'5
0.5
RIBL
I T2 t2
WIRING
COLOR CODE
F41
VACUUM
VENT
VALVE,
BRAKE
8J 8H
6R
CL
R
y
-
-
-
-
-
-
BLACf\
BROWN
CLEAR
REO
YELLOtV
GREEN
0.5
BR
1
0.5
T3all
G
t1 G - LtGHT GREE N G
r
BL -BLUE
v - Vf0l.. E T
GY - GRA Y
w - WHITE
OR - ORANGE
V18
VACUUM CONTROL
MOTOR
15 16 17 18 19 20 21 22 23 24 25 26
/97-8506/
30 30
15 15
L.
X X
31 31 .
~518
tE16
1.0
BK/R
1.0
RIY
fc1
1.0
RIBK
~::
0.5
BK
lD7 (')G5 IA25
0.5 RIBK
J. F36
VACUUM
T2a/1 T2a/2 VENT
VALVE,
~ CLUTCH
L, . - -- -~ ~:=-4-b/_3
RIBK RIY BL BKIBL
VACUUM IV\
____ 1. ~. T.: . :_b /2-~ -·~T-4/3--L.:---,
CNTRL,
f,ltsE
\!Y CNTRL
~----r------.------,----,-1 UNIT
0.5
RIBK
1.0
BKIR
~T6b/6
54 WIRING
MtO COLOR CODE
BRAKE LIGHT;
BK -BLACK
RIGHr
8R -BROWN
CL - CLEAR
A - REO
Y - YELLOW
G - GREEN
31 31 LT G - LIGHT GREEN
@ @
2 3 5 6 7 8_ 9 10
l9it-3951 /
J!il
.,c LOAD
REDUC7JON
• 1/85 RaA r
~----------- ~I
2130
II
FUSI
~~20
r
lOA
~/86 t3187
~ B23
J..
~G7
I 1 A26
J. 1
~G9
BIO A.9 Ml ~ A24 GS Al El
r
1.0 1.0 1.0
BKIY
1.0
W/BK
I
1.0 1.0
GY/G
0.5 0.5
RIY RIY GY/G GY/BL GY/G
l 1.0
BK!Y
1.0
BKIY
20
0.5
GY/BL
! i
up oo- Sso
lOA
TO
0.5
GY/BK
•
~M
IGNmONISTARTER 2.5 0.5
SwrTCH, W/BK GY/BL
T!RMINAL.
X
•
2.5
T211
BKIY
E20
INSTRUMENT
1.0 PANEL.UGHT
RIY DIIIMER SWITCH
WIRING
COLOR CODE
0.5,.!'1
GY/"!
f ~ICENSE'
BK -BlACK 0.5 0.5 . 0.5 0.5 0.5
BR -BROWN GY/BL GY/BL GY/BL GY/BL GYIBL
PLATE
CL -CLEAR
I
LIGHT
I
R -RED
y
a
-
-
YELLOW
GREEN
'ill..
0~5,BR
o.5J
LT. G - LIGHT GREEN
BL -BLUE
BR
V - VIOLET
GY -GRAY TO TO TO TO TO
W -WHITE
INSTRUMENT EMERGENCY FRESH
CLUSTER, FLASHER AIR
HTR
FAN
RADIO,
CONNECTOR
12!2
OR -ORANGE CONNECTOR SWTTCH, CONTROL sw Jal6
11411 TERIIINAL LEVER ILLUM
588 LIGHT, LT,
L16 L50
@
2 3 5 6 7 8 9 10 . 11 12 13 l4
r !97-80481
0.5 0.5 1.0 1.0 2.5 2.5 0.5 1.0 1.0 1.0
Y/R GY/G GY/G GY/G y W GYIBK BKIW BKIW BKIW
cp
0.5
T2b/2
0.5
T2a11 7
cp cp TO
EMERGENCY
2.5 1.0 FLASHER
GY/BK GY SWITCH,
W/BK RIY
TERMINAL L
16/85
0.5
BR
1.0
Y/R
a 56b
E4
56a
HEADLIGHT
DIMMER/FLASHER
SWITCH
WIRING
COLOR CODE
BK -BLACK M1 w58 Bll
BR -BROWN PARKING
CL -CLEAR UGHT,
3 LEFT
R -REO
MS
y - YELLOW
-GREEN
f TURN
1 .RO
G SIGNAL
LT. G - LIGHT GREEN LIGHT,
BL -BLUE B LEFT
v - VIOLET FRONT
GY - GRAY
w - WHITE
OR -ORANGE
@
15 16 17 18 19 20 21 22 23 24 25 26 27 28
197-39711
~ ~
~ ~
X X
~ ~
a
b -
c ~
- ~iE
FUSE FUSE RJSB
~~A I 522
lOA ,, lOA
10
lOA
r'l' Js
I I_ T
lA7 C14 - Cl6 D25 A28 co (17 C5 E18 '.E9
1.0 1.0 1.0 0.5 1.5 0.5 1.5 1.5 1.5 0.5 0.5
BK!G BKIG BK!G GY/R W/BK BLJW Y/BK W Y GY/R GY/BK
TO TO
EMERGENCY HEADLIGHT
FLASHER HIGH
SWffCH, BEAll
TERIIJNAL WARNING
R UGHT,
Kt
WIRING
COLOR CODE
BK -BLACK
BR - BROWN
CL - CLEAR T71s
R -REO
Y - YELLOW
G - GREEN
LT G - LIGHT GREEN
BL - BLUE
V - VIOLET
GY - GRAY
W
OR
-WHITE
-ORANGE _ _,
1.5
.
1.5
W/BK W
118
=Lf.
w::lf
REAR
1
BlR
31
w nJ hJ
117 _
BlR 58
~1VRN,SIGNARIGHTL I31
rn.,.,
~~K
~T, 156~H-BEAM
~~IGHT, ~
OTUTJ I
156a 56b
'f,ftt;IGHT,
f5~~~
'
LEFT
f.
0:
156a
L
~hu: ,
Lt
56b
/1
)I
~~DI.IGHT,'
k'2 4M4
58
TAIL
IGHT,
RIGHT I
58
TAIL
LIGHT,
LEFT
1.5 1.0 1 5
A 1.5 1.5
BR 1.5 1.5
I@ I@ l@ I I@ I @I @I
29 30 31 32 33 34 35 36 37 38 39 40 41 42
197-39721
~ ...._
l==:J Water-cooled -Digifant from Dec. 1989 to May 1990
_____________________ . runnmg
__. Daytime . lights
. 97 238
•
97 Electrical System-Wiring, Waterboxer
30
~0
:
31
15
X
!Ia
~ ..
~DAa
~-ll/86
810
- ..
A26.
' FUSE
S2o
El
lOA
G9
~
1.0
ro 0.5
LT
BKIY sw, GY/G
TERM
X
AND
70 IGNITION/
STARTER SWITCH,
TERMINAL X
I
'
TO TO TO TO
ALT, C, ALT LIGHT LICENSE
TERMINAL WRNG SWITCH, PLATE
D+ LT, El 1.0 LIGHT, 1.0
K2 TERMINAL BKIY X y
WIRING 58
COLOR CODE
BK - BLACK
BR - BROWN
CL - C LEAR
R -RED
Y - YELLOW
G -GREEN
LT G - LIGHT GREEN
BL - BLUE T2a
r
V - VIOLET
GY - GRAY 1.0 0 .5
BKIY y
r rt
W - WHITE
OR - ORANGE
I ----_---- .I J277'
DAY RUN
t.lS RLY
1----t--~------ t/56o=~ I '{J';tlf
(PRK f5 /56b 18/5 8 6/31
f4 /31 f2!X AND
TAIL 0.5 0.5
1.0 0.5 LTS)
BR GY/G Y/R BR
em
2 3 .. 5 6 7 8 9 10 II 12 13 14
197-92801
I
C14 p1a C4 JE9 M2 A21 C5 C6 B22 C17 ~- r16
0.5 0.5 0.5 0 .5 0.5 2.5 1.5 1.5 2.5 1.5 1.0 0.5 1.5
GY/R GY/R GY/BK GY/BK Y/R y y YIBK w w y BL..JW W/BK
TO TO T2b/2 ro ro TO TO TO
14 TO TO
TO TO
PARKING TAIL PARKING TAIL HOLT HOLT HOLT HOLT HOLT HOLT HEADLIGHT
LIGHT, LIGHT, LIGHT, LIGHT, 0/MR LEFT, RIGHT, 0/MR RIGHT, HI-BEAM LEFT,
RIGHT,
M3
RIGHT.
M2 ,,
LEFT, LEFT,
M4
FLSHR
SW, E4,
TERM
Lt,
TERM
568
L.2,
TERM
568
FLSHR
SW. E4,
TERM
L.2,
TERM
56A
/NO
LT,
Kt
Lt,
TERM
56A
NS3 568 56A
OAYnME
RUNNING
LIGHTS
RESISTOR
T2bil WIRING
COLOR CODE
BK - BUICK
0.5
BR -BROWN
ViR
CL - CLEAR
R - REO
- YELLOW
G -GREEN
LT G- LIGHT GREEN
8L - BLUE
- VIOLET
GY - GRAY
w - WHITE
11 OR - ORANGE
15 16 17 18 19 20 21 22 23 24 25 26 27 28
l97-9281l
.. ~-
31 3\,
JSI. . b
~ -
LOAD
~
REDUCTION
RELAY
4 lRISE
S1 S20
lOA lOA
4/86
G4 04 B10 A26 E1 G9
1.0 1.0 0 .5
TO GY/G GY/G
IGNITION/ BK!Y
STARTER
SWITCH,
TERMINAL
X
TO
UGHT
SWITCH
TERMINAL
TO TO
ALTERNATOR, ALT
TERMINAL WRNG
X
I TO
LIGHT
SWITCH,
TO
LICENSE
PLATE
cy
D+ LT, 1.0 E1 LIGHT, 1.0
K2 BKIY TERMINAL X y
58
T2o
0 .5
WIRING 1.0 y
COLOR CODE BKIY
l21x
=-f--ir--
!4/56a
BK
BR
CL
R
y
-
-
-
-RED
-
BLACK
BROWN
CLEAR
YEL LO W
(
1'4/31 f5
2/X
8/58
--------... mr
DAYTIME RUNNING
LIGHTS RELAY
(PARKING AND TAIL
[c__------t-----f I =·~
l5/S6b 8 6/31
G - GREEN
I LIGHTS)
LT G - LIGHT GREEN
1.0 0 .5 0 .5 0 .5
BL - BLUE
BR BL Y/R BR
GY
-
-
VIOLET
GRA Y
~T1a o2J
W -WHI TE
OR - ORANGE
2 3 4 5 6 7 8 9 10 11 12 13 14
197-92821
30 30
15 15
X X
31 31
ba
~ ~
IIJ$E FUSE
521
lOA
~522
lOA
0.5 0.5 0.5 0.5 0.5 2.5 1.5 1.5 2.5 1.5 1.0 0 .5 1.5
GY/R GY/R GY/BK GY/BK Y/R y y Y/BK w w y BUW WiBK
T2bi2 14
TO TO TO TO ro ro ro ro ro ro ro
PARKING TAIL PARKING TAIL HOLT HOLT HOLT HOLT HOLT HOLT HEADLIGHT
LIGHT. LIGHT, LIGHT. LIGHT, 0/MR LEFT, RIGHT; OIMR RIGHT, HI-BEAM LEFT,
RIGHT. RIGHT. LEFT, LEFT, FLSHR Lt, L2, FLSHR L2, /NO Lt,
M3 M2 Mt M4 SW. E4 TERM TERM SW, E4, TERM LT, TERM
TERM 568 568 TERM 56A Kt 56A
N53
CMYnME 568 56A
RUNNING
UGHTS
RESISTOR
T2bll WIRING
COLOR CODE
BK - BLACK
0.5
BR - BROW"
Y/R
CL ~ CLEAR
R -RED
y - YELLOW
G - GREEN
LT G - LIGHT GREEN
Bl - BLUE
v - V/OLEr
GY - GRAY
w -WHITE
11 OR - ORANGE
Wire connectors
T1 - single, behind fuse/relay panel
T1a -single, behind fuse/relay panel
T1b- single, behind instrument panel, left
T2 -double, behind instrument panel, left
T6 - six-point, under driver's seat 1 97-2540 1
Ground connections
@-near fuse/relay panel Fuse/relay panel
Welded wiring harness points ml - Fuse S50, terminal 58b 10A
@-plus (+)connection, terminal 58b in
I& - Driver's seat heater control unit
instrument panel wiring harness
~ ~
15 15
X X
31 31
I l
JAI
0.5
GY/BL
TO LIGHT SWI1CH,
E1
I
0.5
GY/BL
I
~
FUSE J131
m Sso II;]
®
DRIVER SEAT
HEATER CONTROL
lOA UNIT
'f4/T J'21H 'f7131
0.5 1.0 0.5
0.5 R/BK BK BR
GY/BL
Ttb T212 I T211
Z6
HEAT ELEMENT, WIRING
DRIVER SEAT COLOR CODE
BK - BLAC K
BR - BROWN
A4 T6t6 nT6i2 CL - CLEAR
R - REO
0.5 0.5 0 .5 1.0 y - YELLOW
BR/BK R/BK BR BR/BK G - GREEfV
$~ DRIVER SEAT
TEMPERATURE
SENSOR
$E HEAT
ELEMENT,
DRIVER
BACKREST
LT
BL
v
GY
w
OR
G-
-
-
-
LIGHT GRE.EN
BL UE
VIOLE T
GRA 'I'
-WHI TE
- ORANGE:
0 .5 1.0 1.0
BR BR/BK BR
IT6/3 T•11
tT•" )
0
BR
2 6
97 24 5
1!1 Heated driver's seat
Water-cooled-Digifant from 1990 II Canada
Electrical System-Wiring, Waterboxer 97
Current Wire connectors
Description track
T2 - double, behind instrument panel, left
Antenna, R11 5 T2a- double, behind instrument panel, right
.7 T2b- double, behind instrument panel, left
Fuse, S3 TB - eight-point, on radio
Radio, R 2-10 TBa - eight-point, on radio
T14 -fourteen-point, on instrument cluster
Speaker, left front, R2 3
Speaker, left rear, R4 e Ground connections
Speaker, right front, R3 4 @-behind instrument panel, center
Speaker, right rear, R5 7
Welded wiring harness points
@__:_plus connection (58b), in instrument panel
wiring harness
Water-cooled-Digifant from1990
Stereo radio with 4 speakers 9 7 •2 4 6
97 Electrical System-Wiring, Waterboxer
~
53
1SA
r---t---~----+t"-
isn
1.5
R
fE3
WIRING
1.5
R
COLOR CODE
.-....... tr,~,
18 1 I
BK -BLACK
BR - BROWN r n R ANTENNA
II
•
CL - CLEAR
0.5
I R -
-
RED
YELLOW
HF 0.5 0.5 1.5 0.5
G - GREEN
GY/BL U G - LIGHT GREEN
R R R R
BL -
-
BL UE
V/OLEf
(
\ ' I I ,I_T14/5
10 CIGARETTE 10 MAKE-UP TO TO
GY - GRAY MIRROR LIGHT, INTERIOR
LIGHTER, U1 DIGITAL
w - WHJrE RIGHT, W14 LIGHT, CLOCK,
OR - ORANGE FRONT, Y2
R W
,
I TBa/6 ATB/8
0.5 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 0.5 1.5
GY/BL BRIBL BL R BR/W BR/R BUG RIG BR/BK BR BR
'
TO
I
CIGARETTE
LIGHTER
LIGHT,
TO
DASHBOARD
READING
LIGHT,
W26
L28
R2 R3 R4 RS
SPEAKER, + SPEAKER, SPEAKER, + ,+ SPEAKER,
LEFT RIGHT LEFT RIGHT
FRONT FRONT REAR REAR
2 3 s 6 7 8 9 10
lr97--866
- ---,~
Index
Do-it-yourself Service Lubrication, Emissions and Vehicl.e
-Changing a wheel21 Maintenance Schedules
- Emergency starting 25 - Air-cooled, Water-cooled and
- Fuses22 Diesel models 1982-1985 28
- Headlight adjustment 25 - Water-cooled models
- Jack and tools 20 from 1986 32
- Replacing bulbs 23
- Spare wheel20
Technical Data
- Capacities 27
-Engine 27
-Vehicle identification 26
Vehicle Care
-Air cleaner 10
-Battery 14
- Brake fluid 13
- Cleaning products 3
- Cooling system 11
- Corrosion protection 5
-Engine compartment 6
- Engine oil 7
- Engine oil filter 9
-Exterior 3
-Fuel filter (diesel) 10
- Fuel supply 1
-Interior 4
- Lubricants 7
- Maintenance 5
- Power steering 10
- Replacing wiper blades 16
-Tires/Wheels 17
- V-belt 12
I
I VEHICLE CARE
FUEL SUPPLY
Octane rating
Octane rating indicates a gasoline's ability to ,:' Piston
resist detonation. Therefore, buying the cor- and
rect octane gas is important to prevent en- Bore
gine "knock", which reduces performance
and may cause engine damage. advertise and sell gasoline that contains
Under high load operating conditions, un- l2s-A23s the proper deposit control additives that
leaded premium gasoline may be used. will keep intake valves and injectors clean.
After an extended period of using inade-
The 91 RON octane rating which you will quate fuels, built-up carbon deposits can To assure the long term performance of
find above the filler neck is based on the re- rob your engine of peak performance. And your car's engine, you should use gasoline
search method. The AKI octane rating unsu- carbon deposits like those in the illustra- brands that include these deposit control
ally displayed on USA gasoline pumps is tion can lead to other engine performance additives.
calculated as follows: Research octane problems such as: If gasolines with additives are not avail-
number plus motor octane number, divided able, contact your Volkswagen dealer
by2. • unstable idling
about proper fuel additives.
• surging
Regular fuels have an octane rating ranging • misfiring
from 91 to 95 RON (Research Octane • power less
Number) or 87 to 91 AKI. • engine run-on
• engine pinging or knocking
Do not use any fuel with octane ratings
lower than 91 RON or 87 AKI. If these problems continue over a long
period of time, engine damage can be are-
Gasolines containing alcohol sult.
Gasoline containing alcohol is available at
gas stations in some areas. The gas pump
may not be labeled to identify that alcohol ·Intake Valve
is present in the gasoline. If it is labeled, it
may not identify what amount and type(s)
of alcohol are used. We recommend you
use quality gasoline that is NOT blended
with alcohol. The use of fuel containing
alcohol can cause loss of fuel economy
and driveability and performance prob-
lems. If these problems are experienced, -·
we recommend you switch to another
}
1
I VEHICLE CARE
If wrong fuel was put into your tank Diesel engine: Diesel Fuel No. 2
Premium gasoline instead of regular Service stations offering Diesel fuel are Temperature Diesel Fuel Kerosene
generally located on truck routes of major No.2
Your engine runs equally well on premium highways Directories of Diesel fuel
gasoline, however neither fuel consump- stations are usually sold at Diesel fuel 20° to 14° F
tion nor engine output are likely to be af- stations. (-?PCto-10°C) 75% 25%
fected. below 14° F
Some U.S. states require permits to
purchase Diesel fuel. Check with your (-10° C) 50% 50%
Regular gasoline with RON/AKI rating
(lower than 91 RON or 87 AKI) State Motor Vehicle Department.
• Only if neither Diesel Fuel No. 1,
Your engine will run but avoid full power as Diesel fuel may not be available outside winterized Diesel Fuel No. 2, nor Kero-
engine can be damaged. Fill up with cor- the continental U.S. and Canada, we sene are available, use up to 30% leaded
rect fuel as soon as possible. recommend you do not take your vehicle or unleaded gasoline.
to countries where Diesel fuel may not be
obtainable. • Do not use Premium gasoline.
Diesel fuel instead of gasoline
• Mixing Diesel Fuel No. 2 with Kero-
Your gasoline engine must not be started Your Diesel engine has been specifically
sene (or gasoline) must be done be-
with Diesel fuel in the tank. In such case designed to operate on Diesel fuel only.
fore wax starts to separate. Later mix-
the fuel tank must be drained while observ- Therefore, do not use home heating oil
ing may be effective in the fuel tank but
ing all environmental and fire hazard pre- or regular gasoline.
not in the rest of the fuel system.
cautions. The properties of these fuels may cause
• Always add the correct amount of
serious damage to the fuel injection
Leaded instead of unleaded gasoline Kerosene (or gasoline) to the fuel tank
system and to the engine. This could
first, and then fill up with Diesel Fuel
Do not drive your car. Have your fuel tank lead to additional expense and may also
No.2.
drained immediately as otherwise the affect your warranty.
emission control system will be damaged. • Do not use "starting assist fluids",
Winter operation they will cause engine damage.
The fuel system must be drained while ob-
serving all environmental regulations, it is A~ temperatures below 20° F ( -7° C), • Do not use fuel line anti-freeze of-
best to have this performed by your Volks- D1esel Fuel No. 2 loses its fluidity due to fered for gasoline engines.
wagen dealer. wax separation, which may clog the fuel
filter or tank strainer and keep the engine It is normal that the engine noise level
from running. {dieseling) is louder during the warm-
up period in winter. It is also normal that
If you expect temperatures below 20° whitish-blue smoke may be emitted from
F(-7°C): the exhaust after starting and during
• Use Diesel Fuel No. 1, if available in warm-up. The amount of smoke depends
your area. on the outside temperature.
• If Diesel Fuel No. 1 is not available, ask Do not let your Diesel engine idle unnec-
your fuel dealer whether his Diesel Fuel essarily after a cold start-up. Driving off
No. 2 is sufficiently winterized for the slowly will shorten the warm-up period.
prevailing temperatures.
• As a measure of precaution, add a WARNING
commercially available Diesel Fuel flow
improver {pour point depressant) to your • Do not use "starting assist fluids".
Diesel Fuel. Because of the many They may be potentially explosive or
different flow improvers on the market, as cause a "run-away" engine condition.
well as differences in Diesel Fuel, their This could result in serious engine
effectiveness varies. Use only according damage and personal injury.
to instructions on containers.
• Any amount of gasoline added to
• !f winterized Diesel Fuel No. 2 is not Diesel fuel makes the mixture as
available, mix Diesel Fuel No.2 with up to flammable as pure gasoline.
50% Kerosene. Engine power may drop,
therefore keep percentage of kerosene • Handle all fuels in well ventilated
added to Diesel Fuel as low as the areas. Do not smoke or have anything
temperature allows. in the area that can ignite fuel.
• Never carry additional fuel con-
tainers in your vehicle. Such con-
tainers, full or emply, may leak, cause
an explosion, or result in fire in case
of a collision.
2
J I VEHICLE CARE
CLEANING PRODUCTS EXTERIOR
3
I VEHICLE CARE
INTERIOR
where applicable
4
] I VEHICLE CARE
CORROSION PROTECTION MAINTENANCE
The transmission , front and rear axle Chassis Your vehicle has been designed to help
:IX·
assembly surfaces have been treated at keep maintenance requirements to a mini-
the fac.tory wit.h a wax based coating for !he lower body shell of your Volkswagen
mum. However, a certain amount of regu-
IS thoroughly protected against corrosion.
protection agamst corrosion. However, we lar maintenance is still necessary to as-
recommend to have the and the underside However, it is recommended to have the
sure your vehicle's safety, economy and re-
inspected twice a year for any damage to underside inspected twice a year. Any de-
liability.
the protective coating preferably before tected damage to the undercoating, due to
and after the winter season. Have neces- road hazards, should be repaired prompt- Maintenance Service is required every
sary repairs done as soon as possible. ly. Oil based protective sprays must not be 12 months or every 15,000 miles (24,000
See your dealer for correct procedures applied. Only tar or wax based anticorro- kilometers), whichever occurs first.
and materials. sion protectors are compatible with the
fa?to~y applied .undercoating. Before ap-
In addition, it is necessary to perform an oil
plication, road d1rt, salt spray deposits and change 6 months after each Maintenance
oily substances must be removed. Service, or after each 7,500 miles (12,000
WARNING kilometers) whichever occurs first.
Do not apply additional undercoating Whene~e~ the lower body shell, axle,
transm1ss1on or engines assemblies The first oil change must be performed 6
.or ruatprooflng on or near the exhau8t months after the delivery of the vehicle or
manifold, exhaust pipes, catalytic have been repaired, the lost anti-corrosion
coating of the affected surfaces should be after 7,500 miles (12,000 kilometers).
converter or heat shields. During drlv·
lng, the substance used for under· reapplied.
Under difficult operating conditions, for
coating could overheat and cause a Your Volkswagen dealer has the appro- example at extreme low outside tempera-
fire. priate materials, the necessary equipment tures or in very dusty regions , etc., some
and is familiar with the application proce- service work should be performed bet-
dure. Therefore, any additional corrosion ween the intervals specified.
Engine Compartment protection work should be performed by a
Volkswagen dealer. This applies particularly to:
When washing the engine compartment,
onl~ use commercially available grease • oil changes, and
cuttmg solvents made especially for this Body cavity sealing
• cleaning or replacing the air filter.
purpose. Carefully follow directions print- All body cavities which could be affected
ed on the container by the manufacturer. by corrosion have been given a thorough The maintenance work should be per-
protection at the factory. formed by Volkswagen dealers because
they have the expertise, the workshop
WARNING This sealing does not require any inspec- fac.iliti~s and the special tools required.
or tion or additional treatments. If any wax It IS Important that this work is per-
l's Never UM geeotlne. Dlelef fuel or IOI- should seep out of the cavity when the
Yent8 which could dlrnege rubber formed according to the manufacturer's
ambient temperature is high, it can be instructions.
perta or painted eurfacea and could removed with a plastic scraper and a
cauae a tire. suitable solvent. Be sure to observe all Proof of servicing in accordance with the
safety and environmental regulations. maintenance schedule may be a condition
for upholding a possible warranty claim
made within the warranty period.
5
VEHICLE CARE
LUBRICANTS ENGINE OIL
ranges of the different oil grades overlap, • Make It a habit to have tt"le engine oil
has fuel saving capabilities. level checked with every fuel filling;
brief variations in outside temperatures
are no cause for alarm . It is also permissi- • Lack of sufficient engine oil may lead
ble to mix oil of different viscosities if you Transmission
to severe engine·damage.
find it necessary to add oil. Manual transmission:
• The oil pressure warning light is not
Hypoid oil SAE 80 (Mii-L-2105 or an oil level indicator.
Gasoline engine: API/GL4).
Automatic transmission:
Multi grade oil
ATF Oexron@or Dexron II® for torque con-
verter and hypoid oil SAE 90 (Mii-L-2105 B
or API/GL 5) for final drive.
Power steering
ATF Dexron '~J
Lubricant additives
Volkswagen does not recommend the
use of oil additives. It may adversely af-
fect your warranty.
7
I VEHICLE CARE [
Checking the engine oil level • Turn off the engine. Changing the engine oil A
The best time to check the engine oil level • To get a true reading, the vehicle should Have your engine oil changed regularly,
is when the oil is warm. be on level ground. After turning ott the en- but at least twice a year (see Maintenance
gine, wait a few minutes for the oil to return booklet).
The engine oil dipstick and the oil filler
to the crankcase.
neck are located behind the license plate This is very important because the lubri-
lid. • Flip license plate down. cating properties of oil diminish gradually
during normal operation of the vehicle.
• Pull out dipstick and wipe it clean with a
Air-cooled engine: rag. If you drive mostly short distances, or if
you operate the vehicle in dusty areas, or
• Reinsert dipstick; push it in all the way. under predominantly stop-and-go traffic
• Pull dipstick out again. The oil level is conditions, or when temperatures remain
correct if it is between the "max" and "min" below freezing for extended periods, the
marks on the dipstick. engine oil should be changed more fre-
• If oil level is below "min" mark, or not quently.
showing on dipstick, add oil immediately. Due to the detergent additives in the oil, R
• Make sure that the dipstick is com- the fresh oil will look dark after the engine iE
pletely in. has been running for a short time. This is rE
normal and there is no reason to change u
Adding engine oil the oil more often than recommended by
the manufacturer. lr
• Unscrew cap from oil filler neck. T
• Pull extension tube out of filler neck as s
far as it will go. WARNING v.
• Only add the amount of oil needed. The • Drain the oil Into a container that Is (1
difference between the "min" and "max" designed for this pu~. one that Is
marks on the dipstick is about 1 U.S. quart large enough to hold at least the oil
Diesel engine: or 1 liter. Always select a quality oil with the filling of your engine.
correct specification. See "Lubricants" on
page 7. • Wear eye protection.
Do not exceed the MAX marking. • To reduce the risk of bums from hot
engine oil let the engine cool down to
Otherwise, the excess oil may be drawn in the touch.
through the crankcase breather into the
exhaust system. The oil would then burn in • When removing the oil drain plug
the catalytic converter and cause dam- with your fingers, keep as far away as
age. possible. Always keep your forearm
• Push in the extension tube, replace fil- parallel to the ground to hefp prevent
ler cap and hand tighten securely. hot oil from running down your arm.
• Engine ollie polaonoua. Keep It well
out of the reach of children. Con-
WARNING tinuous contact with used engine oil Js.
The oil filler cap muat be secure to harmful to your skin. Always protect y
•!old ollepill cau.lng fire hazard. your skin by washing thoroughly with
Water-cooled engine: soap and water.
• Always dispose of used engine oil
properly. Do not dump it on garden soil,
wooded areas, into open streams or
down sewage drains.
• Recycle used engine oil by taking it to
a used engine oil collection facility in
your area, or contact a service station.
8
I VEHICLE CARE
ENGINE OIL FILTER
Diesel engine:
Water-cooled engine:
Water-cooled engine:
en
1to
9
I VEHICLE CARE
FUEL FILTER AIR CLEANER POWER STEERING*
Fuel filter replacements should be per- A dirty filter element reduces engine out-
formed by your VW dealer or a qualified put and increases fuel consumption and
mechanic. can cause premature engine wear.
On Diesel engine equipped vehicles, Normally, it is not required to service the
accumulated water should be drained air cleaner more often than recommended
regularly. in the Maintenance booklet. If the vehicle
is driven on very dusty roads, the air
Fuel filter replacement and water drain- cleaner must be serviced more frequently,
age intervals are specified in your even daily. We recommend that you have
Warranty & Maintenance booklet. the air cleaner serviced by your Volks-
Should it become necessary to drain the wagen dealer or a qualified workshop.
fuel filter of water between scheduled If your air filter must be changed more
maintenance intervals, prQceed as frequently, we recommend that you have
follows. your Volkswagen dealer show you the The fluid reservoir is located behind the
procedure before you attempt doing it licence plate lid.
To drain water from Diesel fuel filter yourself. The power steering is filled with ATF
The paper filter element must never be Dexron®.
WARNING
cleaned or soaked with gasoline, clean- A correct fluid level in the reservoir is im-
• Turn the engine off and let it cool ing solvents or oil. portant for the proper functioning of
down. Hot components can burn skin power steering .
on contact and Ignite fuel.
With the engine running, the fluicl lo Ho l ;n
• Do not smoke or have anything in the power steering system n ..J;:;l be
the area that can Ignite fuel. checked at regular intervals. The fluid
• Handle fuel only In well ventilated level should always be between the "max"
areas. and "min" markings. If the level should go
below the "min" marking, have the power
• Disconnect ground strap from steering system inspected by your Volks-
battery to prevent sparking. wagen dealer. It is not sufficient to just add
hydraulic fluid.
WARNING
• Be ..... not to contuea bt'8U fluid
.,....may,...
and hydraulotlutd.lfthewrong ftuktll
ueed, . .
• .,... POIIIIIW .-rtng ayttem ehould
fall, or lfttae engine It noii\IIWng (for
example while billing towed). JOU wll
still be able to ...... the Whlcle. horl-
ever, more effort wll~ be required.
"where applicable
10
l VEHICLE CARE
COOLING SYSTEM
The cooling system is sealed and gener- Coolant losses On the refill tank, the coolant level must be:
ally requires little attention. between the min. and max. marks when
Coolant losses may indicate a leak in the engine is cold and not running . When
The cooling system has been filled at the cooling system. In this case, the cooling
engine is warm , coolant level may be
factory with a permanent coolant which system should be inspected immediately
slightly above max. mark.
does not need to be pharnged. The coolant by your Volkswagen dealer. It is not suffi-
consists of a mixture of water and the cient merely to add coolant.
manufacturer'S coolant additive G 11 - Diesel engine:
antifreeze on glycol basis with anticorro- In a sealed system, losses can only occur
sion additives (40 % for USA models; 50% if the boiling point of the coolant is ex-
for Canadian models). This mixture ceeded as a tesult of overheating.
assures the necessary frost protection Overheating can occur if:
and protects the entire cooling system
against corrosion and scaling, and raises • the flow of air to the radiator is
the boiling point of the coolant. obstructed by leaves, dust, insects or by
additional lights installed in front of the
Do not reduce the concentration of the radiator grille;
coolant in the summer by adding plain
water. The coolant additive proportion • the boiling point of the coolant has been
must be at least 40% but not more than reduced due to an incorrect mixture of Water-cooled engine:
60%, to maintain the antifreeze protection coolant and water;
and the cooling efficiency. • the radiator fan is not working - see
"Radiator fan", or;
For year round driving, antifreeze is added
at the factory for temperatures down to: • the vehicle is being driven up a long hill
in a low gear with engine speed very high
-13° F/-25° C (USA) and at very high ambient temperature -
-40° F/ -40° C (Canada) see "Radiator fan".
Only use quality phosphate-free anti- If the cause for the overheating cannot be
freeze containing ethylene glycol. Such determined and corrected, contact your
antifreeze is available at your Volkswagen Volkswagen dealer immediately, other-
dealer. wise serious engine damage could result.
11
I VEHICLE CARE
V-BELT
12
) I VEHICLE CARE
BRAKE FLUID
13
I VEHICLE CARE
BATIERY
Battery acid level Charging of battery
Under normal operating conditions, the
battery in your Volkswagen is mainten- WARNING
ance-free. • Always $hleld your eyes and avoid
leaning over the battery whenever poe-
At high outside temperatures it is advis-
albia.
able, however, to check the fluid level at
regular intervals through the transparent • Charge battery In a well ventilated
battery housing . The fluid level should al- area. Keep away from open flame or
ways be between the "min" and "max" 'electrical spark. Do not smoke. Hvd~
marks in each cell. =generated by the battery fa ex-
If the fluid level is below the "min" mark , let
your Volkswagen dealer correct the condi-
• Battery acid that may spill during
charging should be washed off with a
The battery is located under the front pas- tion.
solution of warm water and baking
senger seat. To check the battery, move toda to neutralize the acid.
the seat all the way forward.
WARNING • Hyou get battery acid In your eyes or
On vehicles with swivel seats, turn the on your skin, Immediately rinse with
seat 180° (half circle) an then push for- • Always ahleld your eyea and avoid cold Water for several minutes and call
ward. leaning over the battery whenever pos- a doctor.
sible.
• Never charge a frozen battery. It may
Diesel: • Do not let battery acid come In con- explode because of gas trapped In the
tact with akin, eyes, fabric. or painted Ice. Allow a frozen battery to thaw out
The battery is in the engine compartment on IIUrface. first.
the right.
• Hyou get battery acid lnyoureyesor • Never use a fast charger as a boo-
Auxiliary battery* on your akin, Immediately rlnee with ster to start the engine. This will seri-
cold water for eeveral minutes and call ously damage sensitive electronic
The auxiliary battery is located under the a doctor. components, such as relays, radio,
left seat. Push the seat all the way forward etc., as well as the battery charger.
to gain access to the battery. • Donotexpoeethebatterytoanopen
flame or electric epark. Hydrogen gu
The auxiliary battery supplies power when generated by the battery can explode • Fast charging a battery Ia dangeroua
the vehicle is stationary. A special relay be- and cause peraonellnjury. and should only be attempted by a
tween the vehicle battery and the auxiliary competent mechanic with the proper
battery prevents the vehicle battery from equipment.
discharging . This way, you still have power Winter operation
to start your vehicle. While driving, both During the winter months, battery capacity
the vehicle battery and the auxiliary bat- tends to decrease as temperatures drop.
tery are charged. Additionally, more power is consumed
while starting, and the headlights, heater,
rear window defogger, etc., are used more
frequently. Curtail unnecessary power
consumption, particularly in city traffic or
when travelling short distances only. Let
your Volkswagen dealer test the battery 's
capacity before winter sets in. A well
charged battery will not only prevent
starting problems but will also live longer.
If your vehicle is left standing for several
weeks at extremely low temperatures, the
battery should be removed and stored
where it will not freeze. This will prevent it
from being damaged.
When removing the battery, first discon-
nect both cables (see Charging of Bat-
tery), then unscrew the battery mounting.
WARNING
Always keep the battery well out of the
reach of children.
"where applicable
14
IVEHICLE CARE
Slow battery charging To remove battery from vehicle Replacing battery
• Disconnect negative ground cable . A replacement battery must have the
WARNING same specifications and dlmer~sions as
• Disconnect positive cable. the original equipment battery. Specifica-
• Heed all WARNINGS and follow In-
structions that come with your battery • Unscrew bolt of holding plate with open tions are listed on the battery housing.
charger. end wrench. Make sure the replacement battery is in-
stalled correctly and securely. See "Re-
moving and reinstalling battery".
• It is not necessary to remove the bat- To reinstall battery in vehicle
tery from the engine compartment, and it
is also not necessary to disconnect the • Place battery in vehicle and tighten bolt
cables. of holding plate.
• Make sure the electrolyte level in each • Reconnect positive cable.
cell is between the "min" and "max" marks.
If the fluid level is below the "min" mark, let • Reconnect negative ground cable.
your Volkswagen dealer correct the condi-
tion. WARNING
• Connect charger cables. Do not reverse polarity.
Charger cables must be connected
POSITIVE ( +) to POSITIVE ( +) and Cleaning terminals and
NEGATIVE (-)to NEGATIVE (-). connections
Do not connect or disconnect charger
cables while charger is operating to re- WARNING
duce the danger of exploding.
• Before wo.-tc Ia done on the electrical
• Switch on charger. eyatam, di8COf'lnect the negative
ground cable.
• Ct1arglng rate not over 6 Amp,
Normally, a battery should .be 'eharged at • When working on the bat*y, be
no more than 10 percent of lfs rated capa- aure not to ahort circuit the tennlnala
city. wllh too1a or other metal ob)ecta. lbla
would cause the battery to heel up very
For example, a ctlarging GUrrent of 4.5 ~which could leed todMtageor
Amp. would be usect on a battery having exploalon end personal Injury.
45 Ah . Rated capacity of the battery in
your vehicle is listed on the battery The terminals and connections should be
housing. kept clean and greased with silicone spray
• After charging, turn off charger and dis- or petroleum jelly. Make sure the ground
connect charger cables. connection to the body is tight and free of
corrosion .
With a disconnected battery the engine
must not run because the electrical sys-
tem will be damaged.
15
l VEHICLE CARE
WINDSHIELD I REAR WINDOW WASHER CONTAINER* REPLACING WIPER BLADES
Notes
The filler cap is located at the left side of Adjusting washer jets • Commercial hot waxes applied by auto-
the driver's footwell. matic car washes have been known to
When vehicle is stationary, the water affect the cleanability of the windshield.
Vehicles with rear window wiper and should hit the windshield as illustrated .
washer have an additional container on • To prevent damage to wiper blades,
The washer jet for the rear window should do not use gasoline, kerosene, paint
the right in the luggage compartment. be adjusted so that the fluid hits the glass thinner, or other solvents on or near the
The capacities of the containers are: in the center of the wiped area. wiper blades.
Windshield washer The jets can be adjusted with a needle.
container . . . . . . 4.3 qt/4.2 liters • To prevent damage to the wiper arms
Rear window washer The jets for the headlight washer system* or other components, do not attempt to
container . . . . . . 1.1 qU1.0 liters can only .be adjusted with a special tool. If move the wipers manually.
necessary contact your Volkswagen deal-
Filling the containers er.
To fill the container, unsnap cover and un-
screw the filler cap. After filling the con-
tainer, screw the cap on tightly and close
cover.
• where applicable
16
I VEHICLE CARE
TIRES/WHEELS
New tires Since tire imbalance can cause wear on Tire care
the steering, suspension and tires, you Inspect your tires at least every 2,000
New tires do not possess maximum trac- should have your wheels rebalanced . A
tion and should be driven at moderate miles (3,000 km) for wear and damage.
wheel should always be balanced if a new
speeds and with caution for the first 100 tire has been mounted or a tire was re-
miles (160 kilometers). paired. WARNING
Tire traction • Avoid damaging tires and wheel
rime. If you must drive over a curb or
other obstacle, drive slowly and at an
WARNING angle. Frequently check tires for un-
When driving on wet or eluehy roed8, a even wear and damage.
wedge of water may build up between • Remove Imbedded material.
the t1rea and the road. Thle phenomeo
nonlaknownaaaquaplanlngorhyd• • Replace wom or damaged tires
planing and may caUM perllal or com- lmmec:Uately. ·
plete lou of traction, vehicle control or
atopp1ng abl~ Alwaya reduce lpeed • Replace mlsalng valve dust caps.
on wet roads. • Keep oil, fuel, brake fluid, etc. away
frorntlree.
Tire service life • Keep tlrealnflated correctly.
The service life of your tires depends for Tire wear
• Mark tires before removing them.
the most part on the following factors: The original tires on your vehicle have Remount tires on the same vehicle side
built-in wear indicators. They are molded because the rotation direction should stay
Tire pressures into the bottom of the tread grooves and the same.
will appear as approximately V2 inch
(12 mm) bands when the tire tread depth • Store removed tires in a cool, dry and
wears down to V1e inches (1.6 mm) . preferably dark place. Tires which are not
Depending on the tire manufacturer, there on wheels should be stored standing up.
are six to eight wear indicators evenly
Tires age even if they are not being used.
spaced around the circumference of the
Tires which are older than 6 years should
tire. Markings on the sides of the tires (e.g.
only be used cautiously in an emergency.
the letters "TWI" or a triangle) show the
locations of the wear indicators.
When the indicators appear in two or more
adjacent grooves, it is time to replace the
tires. We recommend, however, that you
Check your tire pressures twice a month, do not let the tires wear down to this
and especially before taking a long trip. Be extent. Worn tires cannot grip the road
sure not to forget to check the spare tire. surface properly, and are even less effec-
Always check tire pressures when the tires tive on wet roads.
are cold. When the tires are warm, the
pressure will be higher. Do not reduce the
pressure of warm tires.
Use an accurate tire pressure gauge when
checking inflation pressures. Do not
exceed the maximum tire inflation pres-
sure listed on the tire sidewall. Cold tire
inflation pressure means: when a vehicle
has been standing for at least 3 hours or
driven for less than 1 mile.
Always include the spare tire during a pres-
sure check.
Driving habits
Fast cornering, heavy acceleration and
hard braking all increase tire wear.
Incorrect wheel alignment
Incorrect wheel alignment causes exces-
Wheel balancing sive and uneven tire wear impairing the
safety of the vehicle. If you notice exces-
The front wheels on new vehicles are sive tire wear, contact your Volkswagen
balanced. When driving, however, various dealer.
conditions can cause a wheel to become
unbalanced. This may be noticed as vibra-
tions in the steering.
17
j VEHICLE CARE
18
( VEHICLE CARE
WINTER DRIVING
WARNING
• Ute the Jack bnty. for chlnlllna a
wheel. Never "" the )lick lo 11ft ather
vehlclee or other IOedaaathle ftiiiYieed
to accidents and peraonalln)ury; The spare wheel is located underneath the • When re-installing the spare wheel,
=
• The jack must never be ueed • a floor panel of the driver cab, where it rests slide spare wheel onto metal plate.
to work underneath the on a hinged metal plate.
• Give the plate a hard upward push and
If the jack .. eccldantally tt. • To take out the spare wheel , remove make sure the catch hook is securely
lodged.youcouldbeeerlouely lnJurad. the bolt (curved arrow) from the holding engaged.
• Do notralae 118 vehlcleualngabumo bracket with wheel wrench.
• Replace bolt and tighten firmly.
per Jack. The buinper aya11m would be
damaged. Aleo, the jack may allpwhlch
coutd 08UI8 peraonatln)ury. WARNING WARNING
• Do nollupport your car on cinder Keep handa and arms away from undel'-
blocU. brtclca or other propa that may body of vehicle. Never drive the vehicle without a firmly
crumble under continuous load. tightened bolt on the holding bracket.
Should the catc:h hook disengage accl·
• Do not 1ta1 or Nn the engine while • Stand in front of the vehicle and pu ll the dentally, you could lose control of the
the vehicle .. 8UppOI't.d by the jack. catch hook (arrow) forward to let the metal car.
• When working under the vehicle, plate drop.
. . . . . . . . aafety 8tanda 8piCiflcelly Check the inflation pressure periodically to
• Pull out the spare wheel. keep the tire ready for use.
dleiQned for"''"-'*Pufll~
WARNING
Under no clrcurnstancee lhould you
store the apare wheel unsecured In the
luggage compartment. This could
cause eerloue pereonal InJury to pas-
sengers In the vehltle In caee of acolli-
sion.
20
DO-IT-YOURSELF-SERVICE
CHANGING A WHEEL
WARNING Step 1
• H you have a flat tire, move a sara • Take out the bag with jack and tools
distance off the road. 1\lrn off the from under the driver's seat.
engine, the emergency flaaher on and
use other warning devices to alert. Step2
other motorists.
• With the wheels still firrnly resting on
• Pusengeta must not remain In the the ground, remove the hub cap/wheel
vehicle when HIs )acked up. cover of the defective wheel.
• Make sure that pusengers wan In a
Wheels with hub cap
ufe p~Jce away from the vehicle and
well away from the roadway and traffic. • The wheel cover can be pulled off with
• Before you change a wheel, be sure puller clip and lug wrench .
Step3
the ground '- level and firm. Hneces-
sary, use a board under the jack. • Loosen wheel nuts or bolts counter-
clockwise about one turn with the lug
• Set the parking brake and block the wrench. Do not yet remove the nuts or
wheel oppoaHe the de(ective wheel on bolts.
the other side of the vehicle. Engaging
a gear or placing th8 Automatic trans- To loosen - turn counterclockwise
mission selector lever In P (Pari() posi- To tighten - turn clockwise
tion Is not a substHute for fully aettlng
the parking brake. Step4
There are two jack ports on each side
under the car body for front and rear wheel
changing - see right illustration.
WARNNG
......... ltlefecklt.-tt other place
:=a,..~ car or may IMUit In
21
I DO-IT-YOURSELF-SERVICE
FUSES
• To lower the vehicle, turn the handle • Have flat tire repaired and replaced
counterclockwise. promptly.
22
I DO-IT-YOURSELF-SERVICE
REPLACING BULBS
Headlights
Should it become necessary to replace a
headlight bulb, the air intake grille must be
removed first.
1980-1984:
From1985:
• Install new bulb so that the locating lugs
on the headlight housing engage the
recesses on the bulb.
• Reinstall lock ring so that its recesses
engage the locating. lugs on the headlight
housing.
• Twist lock ring clockwise until firmly
seated.
• Reconnect wire connector. Have head-
light beam alignment checked.
~· ~
off. that the locating lug on bulb plafe engages
recess in reflector.
When installing a new sealed beam unit,
be sure the three lugs on the headlight • Swing spring clip over bulb plate.
engage properly in the support ring. Squeeze clip together and engage it in the
retaining lugs.
If no other headlight part as described 2 3
here was removed or its position changed, • Attach wire again .
it should not be necessary to aim the • Install cap and turn to right.
headlights. If in doubt have the adjustment
checked by your dealer. • Have headlight setting checked.
Outer headlights
• Disconnect wire connector (1)
• Twist lock ring (2) counterclockwise,
pull bulb (3) out of headlight housing and
discard.
23
I DO-IT-YOURSELF-SERVICE
t 825-325 1
24
I DO-IT-YOURSELF-SERVICE
HEADLIGHT ADJUSTMENT EMERGENCY STARTING
25
I TECHNICAL DATA
VEHICLE IDENTIFICATION
1980-1985:
4 L
I The engine number (arrow) is located on
5 11NG. (01)1/1UIII.<DDI
011 .IGITI.li.CJ D the engine block next to the injection pump.
LlCIUa/IIIIIIIWI!ST. D
6 PliiiT D D
110./ IIITIJIOI
•·AUSIT./
7 OPIIOIII
Water-cooled:
I ~ ~ Iw:Js'J
1. Production control no.
2. Vehicle identification no.
3. Type code number
4. Type designation
5. Engine and transmission code letter
6. Paint no./lnterior
7. Optional equipment nos.
26
ifECHNICAL DATA
ENGINE
Water-cooled Water-cooled
Air-cooled Diesel
up to 1986 (Digijet) from 1986 (Digifant)
Maximum output, 67 hp @ 4200 rpm 48 hp @ 4200 rpm 82 hp @ 4800 rpm 90 hp @ 4800 rpm *
SAE net:
Maximum torque, 101 ft-lb@ 3000 rpm 97 tt-lb @ 2000 rpm 105 ft-lb@ 2600 rpm 117.3 ft-lb @ 3200 rpm
SAE net:
Displacement: 120 cu . in. (1970 cc) 97 cu. in . (1588 cc) 117 cu. in. (1913 cc) 129 cu. in. (2109 cc)
Stroke: 2.80 in. (71 mm) 3.40 in. (86.4 mm) 2.70 in. (68.9 mm) 2.99 in. (76.0 mm)
Bore: 3.70 in . (94 mm) 3.01 in. (76.5 mm) 3.70 in. (94.0 mm) 3.70 in. (94.0 mm)
Cylinder Location
Capacities
(Air-cooled and Water-cooled)
Fuel tank
(total with reserve) 16 gal. (60 liters)
Syncro: 18.5 gal. (70 liters)
Reserve: 2.5 gal. (10 liters)
Engine oil
(with filter change)
Air-cooled: 3.7 US qt. (3.5 liters)
Diesel: 4.2 US qt. (4.0 liters)
Water-cooled: 4.8 US qt. (4.5 liters)
(without filter change)
Air-cooled: 3.2 US qt. (3.0 liters)
Diesel: 3.7 US qt. (3.5 liters)
Water-cooled: 4.2 US qt. (4.0 liters)
Cooling System
Diesel: 16.9 US qt. (16 liters)
Water-cooled: 18.6 US qt. (17.5 liters)
27
Lubrication, Emissions and Vehicle Maintenance Schedules
Air-cooled, Water-cooled and Diesel models: 1982-1985
first 1 ,000 miles (1 ,600 km):
Cooling system: check tightness of hoses and clamps, check coolant level,
add if necessary
During Road Test: Check efficiency of braking, steering, heating and ventilation system,
automatic transmission kickdown (where applicable)
1982-1985
28
Lubrication, Emissions and Vehicle Maintenance Schedules
Air-cooled, Water-cooled and Diesel models: 1982-1985
every 15,000 milese (24,000 km): (cont'd)
Cooling system: check tightness of hoses and c'lamps, check coolant level,
add if necessary
Front axle: check dust seals on ball joints and tie rod ends
check tie rods for wear and damage
Ignition: check vacuum hoses, ignition wires, distributor cap and rotor, replace if neces-
sary
Sliding door: lubricate mounting points, guide tracks and roller guides
During Road Test: Check efficiency of braking, steering, heating and ventilation system, auto-
matic transmission kickdown (where applicable)
continued
1982-1985
29
Lubrication, Emissions and Vehicle Maintenance Schedules
Air-cooled, Water-cooled and Diesel models: 1982-1985
every 30,000 miles (48,000 km):
Ignition distributor: replace breaker points, adjust dwell and timing (air-cooled
except California)
Oxygen sensor (air-cooled): replace, reset OXS mileage counter (California only)
Oxygen sensor (water- replace every 30,000 miles regardless of time since delivery
cooled): {1984 models, 1985 models except California)
Cooling system: check tightness of hoses and clamps, check coolant level,
add if necessary
1982-1985
30
Lubrication, Emissions and Vehicle Maintenance Schedules
Air-cooled, Water-cooled and Diesel models: 1982-1985
every 30,000 miles (48,000 km): (cont'd)
Front axle: check dust seals on ball joints and tie rod ends
check tie rods for wear and damage
Ignition: check vacuum hoses, ignition wires, distributor cap and rotor, replace if neces-
sary
Sliding door: lubricate mounting points, guide tracks and roller guides
During Road Test: Check efficiency of braking, steering, heating and ventilation system, auto-
matic transmission kickdown (where applicable)
Oxygen sensor: replace every 60,000 miles {96,000 km) regardless of time
after delivery
I
1982-1985
31
Lubrication, Emissions and Vehicle Maintenance Schedules
Water-cooled models from 1986
every 7,500 miles (12,000 km):
Sliding door: lubricate mounting points, guide tracks and roller guides
During Road Test: Check efficiency of braking, steering, automatic transmission kickdown (where
applicable), heating, ventilation and air conditioning, power accessories and
electrical systems
Automatic transmission: change automatic transmission fluid (ATF), clean pan and strainer, replace
pan gasket*
from 1986
32
Lubrication, Emissions and Vehicle Maintenance Schedules
Water-cooled models from 1986
every 30,000 miles (48,000 km): (cont'd)
Front axle: check dust seals on ball joints and tie rod ends
check tie rods for wear and damage
Sliding door: lubricate mounting points, guide tracks and roller guides
During Road Test: Check efficiency of braking, steering, automatic transmission kickdown (where
applicable), heating, ventilation and air conditioning, power accessories and
electrical systems
Oxygen sensor: replace every 60,000 miles (96,000 km) regardless of time after
delivery (1986-1987 models only)
Oxygen sensor: replace every 90,000 miles {144,000 km) regardless of time after delivery
(models from 1988)
from 1986
33