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PORSGHE91 414 TUNE.UP .. TIAINTENANCE
TROUBTESHOOTING a

(
FUEL SYSTEffI
lg70-72 IGNITION
COOTING SYSTE'UI
shop manual ENGINE a

CTUTCH 71

This manual is intended to provide the car owner TRANStilSSTON

and the professional mechanic with information
necessary to perform the required service oper- DRIVE AXIE & DRIVELINE a

ations. The information, illustrations, and specifi-

cations in this manual are those available at the BRAKES I
time of publication. No responsibility can be as-
sumed for design or specification changes made to FRONT SUSPENSION I
the cars by the manufacturer which in any way
STEERING t
differs from that contained in this manual.

ETECTRICAT I(
The index on this page enables the user to fînd
any section by means of the black tabs on the
edge of the manual. The tab on the first page of
BODY 7,

each section is in line with the section name in

SPECIFICATIONS ts'
the index.

AN INDEPENDENT PUBLICATION
cARB00l($,lllc. NOT ASSOCIATED WITH VOLKSWAGEN AG

Brooklyn, ilY 11207 R, D BUCKLEY

?OI BANBURY RD
I,IUNOELEIN IL ôO060

@ 1972 E. S. SCHECHTER
TUNE-UP 1_1

TUNE.UP.. MAINTENANCE .. LUBRICATION I

INDEX
Page Page
Distributor ....1-1 Frontwheelalignment ......1-5
Ignitiontiming,static. ......1-1 Clutchpedaladjustment.. ...1-5
Ignitiontiming,withtiminglight .... .l-2 UNDERTHECAR .....1-5
Dwellangle ...1-2 Brakes .....1-5
Sparkplugs ...1*2 LUBR|CAT|ON.... ...1*6
Fuelinjectionsystem .......1-2 Acceleratorlinkage ....1*6
Fan belt . .l-4 Engineoil ... ......1-6
Battery .....1-4 Transmissionoil ... ...1-6
Brakefluidreservoir ....l-4 MAINTENANCESCHEDULE ...1-7
Headlight adjustment . .l-4 CAPACITIES& RECOMMENDED LUBRICANTS . . I-7
Parkingbrake .......1-5

Distributor the base of the fixed contact and moving it to achieve the
Distributor maintenance is confined to periodic checks of required clearance. The screw is retightened when the
the point gap, the condition of the inside of the proper gap has been obtained. Recheck after tightening.
distributor cap, the high voltage contacts, rotor and Point gap...... ..0.015-0.017 in.
carbon pencil in the center of the cap. The inside of the
cap must be clean, free of moisture and carbon dust and
with no signs of cracking or the formation of carbon
tracks, The high voltage pencil in'the center must be
unbroken and free to move in and out.
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@ volkswagen
Distributor
O Volkswagen
1 - Lockingscrew 4 - Felt lubricant
Cylinder Designation 2 - Adjustment slot for screwdriver 5 - Movable point pivot
3 - Electrical connection

I gnition timing, static

Static timing is done with the engine off and points set to
The gap should be measured by a feeler gauge when the proper gap. Remove the distributor cap and turn engine
pad on the movable arm is on one of the peaks of the over until the moving timing mark lines up with fixed
cam. The adjustment is made by loosening the screw on timing mark" Loosen clamp at base of distributor just
TUNE-UP 1_2

Fixed timing mark.."....... Notch in coo^ling blower housing.

Moving timing mark....Red notch (27'BTDC) on impellei.
Test speed 3500 rpm.
Vacuum advance hoses........,.,. ,"..,.. removed.

Dwell angle
Dwell angle is the duration that the points stay closed. It
is checked and adjusted with an oscilloscopà or dwell
meter, with the engine running at recommended speed.
Adjust. dwell by stopping engine, removing distributor cap
ald adjusting point gap. The smaller the gap, the biggei
the dwell angle. Retighten the fixed poini Jcrew, inJtal
rotor and cap. Start engine and check dwell angle. Repeat
adjustment steps, if necessary.

Recommended adjustment speed

1000-1200 rpm & 2000*2500 rpm
Dwell angle.". 44_iO'
Dwell angle, maximum..... 42_5g"
Spark plugs
The spark plugs should be cleaned and the gaps reset every
3000 miles. For maximum efficiency the spark plugs
Stattc timing marks should be replaced every I 2,000 miles. Check the plugs by
Rotor pointing to No, I cylinder position eye for cracks, defects of any kind, indicationi oi oii,
carbon, or blistering. A black plug may indicate need for a
plug of higher heat range, a very white plug may indicate
'nough so distributor can be rotated by hand. Rotate in need for a plug of a colder range.
same direction rotor turns, until points are fully closed,
then rotate distributor in opposite direction until points Recommended spark plug ......................... Bosch W lj 5 T 2
just open. A test light across the points will tell the precise
Spark plug gap............... ..................0.02g in.
moment. When the light goes out, points have opened. Tightening torque......"...
Retighten clamp and replace distributor cap. 25 ft-lb.
Fixed timing mark........,, Notch in coo^ling blower housing.
Moving timing mark ... Black notch (5"BTDC) on impellei.

lgnition timing, with timing light

Best results are obtained with a timing llght (Stroboscopic
light). Start engine and allow it to idle until it has reached
normal operating temperature. Connect timing light and
tachometer, run engine at recommended speed, and point
timing light at mark. The moving mark andthe fixed mark
should line up. To adjust, loosen distributor clamp and
slowly rotate it to bring marks together. Retighten clamp
and check to be sure timing has not changed. Great carè
should be taken when using timing light.

O Volkswagen

Removing spark plug

Fuel injection system

O Volkswagen Adjustment of the idle speed should be done with the
Timîng marks engine at normal operating temperature. Remove the air
TUNE-UP 1_3

CARBON-FOULED PLUGS WET OILY DEPOSITS may

show dry fluffy black deposits be caused by oil leaking past
which may result from over-rich worn piston rings. "Brerak-in"
carburetion, over-choking, of a new or orrerhauled engine
a sticking manifold heat valve or clogged air before rings are fully seated may also produce this
cleaner. Faulty breaker points, weak coil or con- condition. A porous vacuum booster pump dia-
denser, worn ignition cables can reduce voltage phragrrr or excessive valve stem guide clearances
and cause misfiring. Excessive idling, slow speeds can also cause oil fouling. Usually these plugs can
under light load also can keep plug temperatures be degreased, cleaned and reinstalled. While hotter
so low that normal cornbustion deposits are not type spark plugs will reduce oil-fouling, an engine
burned off. In such a case a hotter type spark overhaul may be necessary to correct this condition.
plug will better resist carbon deposits.

BURNED OR BLISTER!]D
INSULA'|OR nose and badly
erodcd electrodes are indications
NORMAL PLUGS liave brown of spark plug overheating. Im-
to greyish tan deposits and slight proper sparh tirning or low octane.' fuel can cau
electrode wear, indicating correct detonation and overheating. Lean air fuel mixturt
ËrtF spark plug heat range and mixed cooling system stoppages or sticking valves ma
periods of high and low speed driving. Spark plugs also result in this condition. Sustained high-speec
having this appearance may be cleaned, regapped heavy-load scrvice can produce high temperatu
and reinstalled. which require use of colder spark plugs.

Spark plug conditions

cleaner and check to determine if the auxiliary air unit which regulates closing the fuel supply during braking
regulator is completely closed. This is done by pulling off is functioning properly. Engine should be at operating
the hose between the air cleaner and the regulator and by temperature.
covering the opening with a hand. The engine speed must
not change much. If the speed does change, the engine is
not warm enough, or the auxiliary air regulator is faulty.
Adjust idle speed by turning idle screw on throttle valve
body clockwise to increase speed; counterclockwise to
lower speed. Recommended idle speed is 900 rpm. If the
speed cannot be lowered to this value, check the basic
setting of the throttle valve switch.

The throttle valve switch may be adjusted with an

ohmmeter across the two right hand plug connections (14
& l7) of the four found below the throttle valve. Turn the
throttle valve switch clockwise as far as possible. Now
turn it counterclockwise until the ohmmeter registers 0.
Then turn the switch 2 degrees further (one graduation
mark on the scale at the upper attaching screw) and secure
the unit. Check to determine if, when the throttle valve is
cracked open (2 degrees), the ohmmeter indicates it.

To check the setting of the throttle valve switch without

ohmmeter, remove the hose between the air cleaner and @ volkswagen
the auxiliary air regulator. The engine should now "rol1",
that is change speed between approximately 900 and Idle speed adiustment
1700 rpm. This indicates that the contacts in the throttle
valve switch are closed and that the section of the control A - Increase speed B - Decrease speed
TUNE.UP 1-4

Valve adjustment
The valves are adjusted from beneath the car. Remove the
clip that secures the valve cover; remove the cover. From
inside engine compartment, remove distributor cap and
turn engine over until rotor points to + I cylinder (notch
in distributor base). Check and adjust valves of +t 1
cylinder. Turn engine over until rotor points to spark plug
lead for next cylinder that side, Both valves are fully
closed.

@ volkswagen
Adjusting fan belt

Brake fluid reservoir

Clean area around brake fluid reservoir cap. Unscrew cap
and check level; it should be above center divider in
container. Only add fresh brake fluid SAE 1703a as
needed. Do not allow it to overflow.

@ volkswagen Headlight adjustments

The headlights can be aimed with any suitable equipment,
Checking valv e clearance but, if it is not available the following procedure should
be carried out.

Adjust so feeler gauge moves smoothly between valve end

and rocker arm. Check adjustment after tightening lock
nut.

Valve clearance, intake & exhaust

0.004 in. (cold)

Fan belt
Remove cover plate above alternator pulley. Loosen the
socket screw, but do not remove" Using arm pressure oniy,
push alternator against force of belt. Snug up the socket
screw" Check belt tension. If properly adjusted belt should
deflect about Il2 in. along longest straight surface under
heavy thumb pressure. Tighten socket screw and replace
cover plate. Do not use bar or other form of lever to force
alternator.

Battery
Remove the battery filler plugs and check the fluid ievel.
The eiectrolyte should be above the tops of the plates.
Add distilled water to cover plates, but do not overfill, as
this will dilute the battery acid. Tap water may be used,
unless it has a very high mineral content.
@ volkswaqen
Check battery state of charge. With battery temperature Adiusting headramps
at 80 degrees F., the specific gravity should be at least
i.250 in every ceil. A - Vertical adjustment B- Horizontal adjustment
TUNE.UP 1-5

Clutch pedal adjustrnent

The clutch pedal linkage should be adjusted when the
pedal free travel exceeds the recommended amount. Too
much free pedal movement will prevent the clutch from
fully disengaging. Too little can cause the clutch to
continually slip and wear prematurely. The adjustment is
made at the end of the cable, at the clutch. Grasp the
cable with a pair of pliers and turn the self-locking nut out
to increase pedal travel, and in to reduce pedal travel.
Recommended free pedal travel ........... 112-314 in.

Headlight aiming target o volkswagen

H -Horizontal center of headlights on car

V - Vertical center of headlights on car
a = Height of headlight center fiom floor
b = Distance between headlight centers
c= 2in.

Check tire pressure and park car on level ground facing a

wall 25 feet in front of headlights. Driver should be in car.
Measute height from ground to center of headlights and
draw a horizontal line on the wall at this height. Opposite
the center of each headlight, draw vertical lines intersect-
ing the horizontal. A vertical line indicating the center of
the car would be helpful.

Loosen the screw in the center below the headlight and

take the trim ring off. Aim the headlights individually by
turning the two aiming screws with the low beams
switched on. The lights are correctly aimed when the top
edge of the high intensity zone is on the horizontal line
and the left edge is 2 in. to the right of the vertical line. @ volkswagen
Parking brake CIu t ch P edal adiu s tment
The parking brake is self-adjusting, and should require no
attention. With the hand lever in the full down position,
the actuating levers at each disc should be just off the pin
stops. The cable rocker should be at 90- to pulling cable. UNDER THE CAR
Brakes
Front wheel alignment Check the brake fluid regularly; as the brake pads wear,
When an abnormal wear of tires is noticed, the toe-in the level will drop. Replenish as needed, but avoid
caster and camber should be checked. This should be overfilling. Check disc brake assemblies occasionally to see

checked with the car empty except for spare tire and if they. are wet. It would indicate a leaking cylinder.
filled gas tank. Bounce car up and down and move for
several feet back and forth to settle suspension. The disc brake pads should be replaced when the friction
material on them is less than l/8 in. thick. Replace by
Toe-in is set with the steering wheel set in the straight jacking up car and removing wheel, Remove wire safety
ahead position. It is adjusted by loosening and adjusting locks and retaining pins, depress spring and remove. If
the appropriate, right, left, or both track rods to obtain pads are to be reused, mark them with pencil before
the recommended figure. removing. Push pistons all the way in using a piece of
wood for leverage. Watch the fluid reservoir as the fluid
Total toe-in ......'.'.'.....30' I 10' will rise when the pistons are forced back. To prevent
spillage, drain some of the brake fluid before pushing the
Camber adjustments are made by loosening the socket pistons back, or wrap reservoir in with a large piece of
screws at top support bearing, after removing sealing cloth to absorb the overflow.
compound. Before moving, mark existing position of
plates. Note that changing camber also changes the caster Clean the pad seat, check dust covets and safety rings.
angle. One mm travel of support bearing equals 6' angle Replace hardened or porous covers, Slide the new pads in
change on shock strut. and install spring, retaining pins, and safety locks. The
brake pads should move freely in their wells.
Camber ang1e............. ....0"t Zo'
Caster anglè .........'..,...' 6o t 30' Recommended brake fluid SAE J 1703.
TUNE.UP 1_6

The oil level should be between the two marks on the

dipstick. If necessary, oil should be added to bring it up to
top mark. Never let the oil level fall below the lower
mark. If in doubt, it is better to have a bit too much oil
than too little. Avoid mixing oils of different brands, the
additives may not be compatible.

To change the oi1 remove drain plug when the engine is

warm, When oil has stoppeci running out, remove strainer
by removing center nut. When replacing screen use new
gaskets and sealing rings. The center nut should be
tightened to a maximum of 7*9 ft-lbs. Do not over-
tighten. Refill with the recommended grade of oil.

Oil capacity, with oil filter change. ,".,3.7 qts.

Oil capacity, without oil filter change ...."..........,....3.2 qts.
Recommended oil.
below^ 5oF
s-at'F....::..::.::..:::::
" ....,.......,...SA8 l0
above 32oF...............
' ' """"""sAE 20

Multigrade, urr t.-p*...... : :: :. : :.. :..... ::: :. ::: :... : ::':. : :. ?âti ;3
@ volkswagen
Transmission oil
Brake pad thickness Both transmission and final drive are combined in one
housing. To check oil level, remove filler plug, after
cleaning area around it. plug is located on side of
transmission. Place finger tip inside hole. The oil should
be just about level with the bottom edge of the hole. Add
LUBRICATION oil as needed, using a plastic syringe.
Accelerator linkage
Clean and lubricate the accelerator linkage at all pivot Recommended oil ..........,.. ..,.SAE 90 hypoid
points with a few drops of engine oil. Check for any Transmission capacity ....................2-l
binding condition that may hinder smooth operation. l2 qts.
Free up or correct as needed.

Engine oil
The car should be standing on level ground, with the
engine off for several minutes. Withdraw the dipstick,
wipe with a clean cloth, and push it back in as far as it will
go. Remove and check height oil has reached on dipstick.

O volkswagen

Oil drain plugs O Volkswagen

Transmission oil plugs

A - Oil drain plug B- Filter cover screw A - Drain plug B- Filler and level check plug
TUNE.UP 1_7

I-'!AINTENANCE SCHEDU LE Carburetors, rebuild (9 I 4 I 6)

,:-e time or mileage intervals indicated in this section are
-:ended as a guide for establishing regular maintenance Every 30,000 miles or 30 months, whichever comes first,
.:-j lubrication periods. Sustained heavy duty or high add the following service functions:
Transmission/diff erential oil, change
'peed driving or
operation under adverse conditions may
::quire more frequent servicing. Wheel bearing grease, change
Master cylinder & wheel cylinders, overhaul
Every 300 miles or 2 weeks, whichever comes first, Headlight aiming, check
perform the following service functions: Drive shaft splines & U-joints, grease
--:e pressure, check
:.:iery water level, check CAPACITI ES & R ECOMMENDED LUBRI CANTS
--- -:r'el in engine, check Engine fuel
98 octane ...........16-l 12 gallons
Erery 3000 miles or 3 months, whichever comes first, add
rhe following service functions: Engine oil (MS service grade)
:,-,:ne oil, change Temperature range anticipated before next oil change, and
--- srrainer, clean recommended SAE viscisity numbers.
Below 1OoF' 5o to 75oF
É,ery 6,000 miles or 6 months, whichever comes first, l0w,10w-30 20w,10w-30
dd the following service functions:
l:=smission and differential oil level, check 32o to gooF 60o to I looF
l::;rbutor point gap, check 30,20w-40 40,20w-s0
:- p1ugs, check or replace.
":< Capacity, approx. .3 qts. w/o filter change, 4 qts. with
:::re idle speed, check
l--- brake pads, check thickness change.
-:-<e s1,stem, check for leaks
:'- :elt tension, check Transmission with differential
.::rt-..utor, lubricate and coat cam face SAE 90 hypoid gear oil ..................2-l l2 qts.
.-':ing mechanism, check lubrication
1ter. change Torque converter, Sportomatic
;:cn timing, check SAE 20 HD oil ..........6-114 qts.
' ;: ;leatance, check
,'-::;l oedal play,
l-:;-e pedal olav. check
che
.;:asion components, check and tighten Symbol Amps Equipment
:..:. rotate and check balance
;ln
: - , -: --r check
:--;:r;al. -t^^1. î^*
for l^^-- ^* L-^
loose or broken wires I left headlight high beam

. ,., :r-lter. replace

Ë,erv 12,000 miles or 12 months, whichever comes first,

G 56a I right headlight hig beâm
iod the following service functions:
-- -:,: ;ompression, check I left headlight low beam

- :::i;ase ventilation system, check

: -:-;rmp oPeration, check
I,i: -.:-,'. check specific gravity
G 56t I right headlight Iow beam
tr*:.=3tor. regulator, starter function, check
::::-: mounts, check 8 left parking lights
I:.::-:utor breaker points, replace
.-- :,:aner, clean and change oil G
r-:' :-::net, replace filter element
: r,:,:>1 emission system, check
I right parking lights

EK I
,:.::-g n-rechanism, check and tighten
]::
license plate lights
tu --- Jgnment, check
- '
-.::,osion/differential nuts & bolts, retighten
-,,,-: -,1 lidhinges, lubricate
a, windshield wipers,
cigarette lighter
l:i:.:::rsion oi1, change
::-:: -;'heel bearings, change grease and adjust
"-e6T turn signals
stop lights, back-up light

.-:'- sîft lever switch contacts, clean/adjust (Sporto- I fan, horn

::'!,-: I

-: .:--i -''alve air filter, check (Sportomatic) G I (optional) fog lights

Gzr
iu,en,, 24,000 miles or 24 months, whichever
ffi*:.r :r:-re following service functions:
I . :--:rd. change
comes first,

Linkage, wiper motor linkage, window regu-

x
l-\\ ,
I
\ /,
emergency fl a sher

--i:-: -r:;ie Il-/)r .-r/^i/, retractable headlights,

_ - --!dLç 30 2T inlerior light
r : -,-:- =':-orbers, check
: r:.-.: s:'stem, check for leaks Fuse Sizes O volkswagen
TROUBLESHOOTING 2_1

TROUBLESHOOTING 2

FUELSYSTEM...
GNITIONSYSTEM
ENGINE
.....2-I
..., '2-2
ACCESSORYDRIVEBELTS .....2-3
........2-3
INDEX
Page
SHOCKABSORBERS
STEERING
BRAKES
PARKINGtsRAKES
Page
...2-8
....2*8
.....2-9
...2-TI
r
CLUTCH .....2-5 FRONT SYSPENSION AND STEERING
\IANUALTRANSMISSION.. ,..2-5 LINKAGE . . .2-12
REARAXLE ........2-6 STARTER_ELECTRICAL . .. .2-13
ALTERNATOR-REGULATOR-ELECTRICAL " .2-14

l:: basic design and construction of almost all cars built through a connecting rod. At the end of the crankshaft is
r: "1- is the same. Each has an engine that burns gasoline the flywheel, to which is attached the clutch (manual
-. sealed combustion chamber, Fuel and air are fed into transmission) or fluid coupling (automatic transmission)'
=
:. ;hamber through a cam operated poppet valve' The The shifting of the gears in the manual transmission is
:,-::: residue of combustion leaves through a similar done by hand, while those in the automatic are done by
,i.'e. Fuel is supplied to the engine by a carburetor or valves, oil pressure, and band brakes. From the trans-
--;- rnjection system. The fuel is ignited in the combusion mission the power goes to the differential gear unit, which
:-':::ber by a spark plug, which is fired by a distributor at redirects it to each driving wheel.
--:- appropriate time. A pair of Tungsten points and a
:,::inser in the distributor control the actions of the The hydraulic brake system in most cars is designed or
li' tension coil which provides the current for the spark made by one of a very few brake component manu-
:!*5. facturers. The operation and components are often the
same though not necessarily interchangeable. Their prob-
: :::ric energy for the distributor and the coil comes lems, causes, and cures are basic.
-:-- a wet cell battery, which is kept charged by a When using this troubleshooting section, use a logical
.E-::etor or alternator. The output of the generator, or
.r-::::râtor is controlled by a regulator' procedure to diagnose the cause of the condition. Start
with the simplest cause first, and eliminate those com-
1; burning of the fuel in the combustion chamber ponents and causes which do not apply to your particular
;,-::s down the piston, which turns the crankshaft model.

FUEL SYSTEM
Condition Possible Cause Correction

:T 6II{E DOES NOT START; (a) Wires to pump or relay defective (a) Check and repair or replace wires.
! U EI. PUMP NOT WOBKING (b) Fuse to pump relaY defective (b) Replace 8A fuse.
(c) Pump relay defective. (c) Check with voltmeter; replace if
necessary.
DOES NOT STABT; (a) Plug at pressure sensor disconnect- (a) Replace plug. Crank engine with
=IGIItE
:.I EL PUMP WOBKING ed, causing flooding. injector plug disconnected to clear
engine.
(b) Open circuit to cYlinder head (b) Check and correct. Check all plugs
temp. sensor. and connections.
(c) Pinched fuel line or defective pres- (c) Check fuel loop for 28 psi pressure
sure regulator. with starter turning engine.
EIOIIIE STARTS BUT (a) Plug at distributor loose or defec- (a) Check and replace contacts if nec-
i:1, À L Ls tive wiring. essary.
(b) Trigger contacts defective. (b) Replace.
Eù6IitE MISFIRES AND (a) Trigger contacts dirty or worn. (a) Check" clean and replace if neces'
f,ÎAL LS sary.
TROUBLESHOOTING 2_2

Condition Possible Couse Ccrrection

(b) Plugs loose (b) Check and press on securely.

(c) No fuel pressure (c) Check pressure.
ENGINE MISSES ON ONE (a) One fuel injector sticking or wind- (a) Replace.
CYI.INDEB. WHITE ings defective.
EXHAUST SMOKE (b) Plug connection loose (b) Press plug on securely.
ENGINE MISFIRES (a) Loose connections. Poor ground (a) Check connections and tighten
at injectors, ground screws.
ENGINE TACKS POWER (a) Low fuel pressure. (a) Check pressure and correct.
(b) Pressure sensor defective (b) Replace senso.r
(c) Throttle valve does not open fully. (c) Check and adjust.
(d) Pressure switch not working. (d) Check switch and wiring for open
circuits.
EXCESSIVE FUEL (a) Sensors not operating or voltage (a) Check hose connections and sen-
CONSUMPTION leaks in wiring. sors. Check wiring.
(b) Throttle valve switch (b) Check and adjust.
(c) Excessive fuel pressure. (c) Check regulator; replace if neces-
sary.
RPM RISES AND FALLS (a) Hose between auxiliary air regula- (a) Connect securely or replace.
(1000-2000 rpm) tor and intake air distributor loose
or broken.
(b) Throttlevalve stays open too wide. (b) Check and adjust
(c) ldle speed too high. (c) Adjust to correct speed.
ENGINE BACKFIBES (a) Mixture enrichment' in throttle (a) Check with tester.
DURING ACCELERATION valve switch not operating.
HIGI.I IDLE SPEED {a) Leak in idle air system. (a) Check and correct
(b) Rubber seals of injectors leaking. (b) Replace seals.
(c) Throttle valve needs adjusting. (c) Adjust.

IGNITION SYSTEM

Condilion Possible Cquse Correction

BURNED OR PITTED (al Dirt or oil on contacts. (a) lf oil is on contact face,
DISTRIBUTOR CONTACIS determine cause and correct
condition. Clean distributor cam
of dirt and grease, apply a light
film of distributor cam lubricant
to cam lobes; wipe off excess.
See "Distributor Lubrication."
Replace contact set and adjust
as necessary.
(bt Alternator voltage regulator (b) Test alternator voltage regulator
setting too high. setting, adjust as necessary.
Replace contact set and adjust
as necessafy.
(c) Contacts misaligned or gap too (c) Align and adjust contacts.
small.
(d) Faulty coil. (d) Test and replace coil if
necessary. Replace and adjust
contacts.
(el Ballast resistor not in circuit. (e) lnspect conditions, and correctly
connect the coil.
(f) Wrong condenser or faulty (f) Test condenser and replace if
condenser. necessary. Replace and adjust
contacts.
(s) Faulty ignitign switch. (s) Replace ignition switch.
(h) Bushings worn. (h) Replace housing.
TROUBLESHOOTING 2_3

Condition Possible Couse Correction

(i) Touching contacts with the (i) Replace and adjust contacts.
hands during installation.
IGNIIION COII. IAILURE (a) Coil damaged by excessive heat (a) Replace coil. lnspect condition
from engine. of the distributor contacts.
(b) Coil tower carbon-tracked. (b) Replace the coil.
(c) Oil leak at towêr. (cl Replace the coil.

ACCESSORY DRIVE BETTS

Condition Possible Couse Correclion

INSUFFICIENI ACCESSORY (a) Belt too loose. (a) Adjust belt tension.
OUTPUT OUE TO BETT
STIPPAGF
(b) Belt excessively glazed or worn. (b) Replace and tighten as
specif ied.
BEI.T SQUEAT WHEN (a) Belts too loose. (a) Adjust belt tension.
ACCETERATING ENGINT
(b) Belts glazed. (b) Replace belts.
BEIT SQUEAK AT IDI.E (a) Belt too loose. (a) Adjust belt tension.
(b) Dirt and paint imbedded in belt. (b) Replace belt.
(c) Non-uniform belt. (c) Replace belt.
{d) Misaligned pulleys. (d) Align accessories (file brackets
or use spacers as requiredl.
(e) Non-uniform groove or eccentric (e) Replace pulley.
pulley.

ENGINE
Condilion Possible Couse Correclion
ENGINE WIII, NOÏ SÎART (a) Weak battery. (a) Test battery specific gravitY.
Recharge or replace as
necéssary.
(b) Corroded or loose battery (b) Clean and tightên batterY
connections. connections. APPIY a coat of
petroleum to terminals.
(c) Faulty starter. (c) Refer to "Starting Motor".
(d) Moisture on ignition wires and (d) Wipe wires and cap clean and
distributor cap. dry.
(e) Faulty ignition cables. (e) Replace any cracked or shorted
cables.
(f) Faulty coil or condenser. (f) Test and replace if necessarY'
(g) Dirty or corroded distributor (s) Clean or replace as necessary.
contacts.
(h) lncorrect spark plug gap. (h) Set gap
(i) lncorrect ignition timing. (i) Refer to "lgnition Timing."
0) Dirt or water in fuel line U} Clean lines
EiGINE STAIIS (a) ldle speed set too low. (a) Adjust carburetor.
(b) Incorrect choke adjustment. (b) Adjust choke.
(c) ldle mixture too lean or too (c) Adjust carburetor.
rich.
(d) lncorrect carburetor float (d) Adjust float setting.
setting.
(e) Leak in intake manifold. (e) lnspect intake manifold gasket
and replace if necessary.
(f) Dirty, burned or incorrectly (f) Replace contacts and adjust.
gapped distributor cohtacts.
(g) Worn or burned distributor (s) lnstall new rotor.
rotor.
(h) lncorrect ignition wiring. (h) lnstall correct wiring.
TROUBLESHOS\\NçI 2-\

Condiiion Possible Couse Correclion

(i) Faculty coil or condenser. (it Test and replace if necessary.

(j) lncorrect tappet lash. rj) Adjust to specifications.
ENGINE TOSS OT POWER (a) lncorrect ignition timing. (a) Refer to "lgnition Timing."
(bl Worn or burned distributor (b) lnstall new rotor.
rotor.
(c) Worn distributor shaft or cam. (c) Remove and repair distributor.
(d) Dirty or incorrectly gapped (d) Clean plugs and set gap
spark plugs.
(e) Dirt or water in fuel line, (e) Clean lines, carburetor and
carburetor or filter. replace filter.
(h) lncorrect valve timing. (h) Refer to "Checking Valve
Timing."
Ùt Low compression. U)' Test compression of each
cylinder.
(k) Burned, warped or pitted valves. (k) lnstall new valves.
(l) Plugged or restricted exhaust (l) lnstall new parts as necessary.
system.
(m) Faulty ignition cables. (m) Replace any cracked or shorted
cables.
(n) Faulty coil or condenser. (n) Test and replace as nêcessary.
ENGINE MISSES ON (a) Dirty, burned, or incorrectly (a) Replace contacts and adjust.
ACCEIERATION gapped distributor contacts.
(b) Dirty, or gap too wide in spark (b) Clean spark plugs and set gap
plugs.
(c) lncorrect ignition timing. (c) Refer to "lgnition Timing."
(e) Acceleration pump in (e) lnstall new pump.
carburetor.
(f) Burned, warped or pitted valves. (f) lnstall new valves.
(g) Faulty coil or condenser. (s) Test and replace if necessary.
ENGINE MIS'ES AT HIGH (a) Dirty or incorrectly gapped (al Clean or replace as necessary.
SPÊED distributor contacts.
{b} Dirty or gap set too wide in (bl Clean spark plugs and set gap
spark plug.
(c) Worn distributor shaft or cam. (c) Remove and repair distributor.
(d) Worn or burned distributor (d) lnstall new rotor.
rotor.
(e) Faulty coil or condsnser. (e) Test and replace if necessary.
(f) lncorrect ignition timing. (f) Refer to "lgnition Timing."
(h) Dirt or water in fuel line, (h) Clean iines,
NO]SY VATVES (a) High or low oil level in (a) CÉeck for correct oil level.
crankcase.
(b) Thin or diluted oil. Change oil.
(b)
(c) Low oil pressure. Check engine oil level.
(c)
(d) Dirt in tappets. Clean tappets.
(d)
(e) Bent push rods. (e) lnstall new push rods.
'f) Worn rocker arrns. (f) lnspect g1; ctronlv to rockers.
(g) Worn tappets. (s) lnstall new tappets.
(h) Worn valve guides. (h) Ream and install new valves
with O/S stems.
(i) Excessive run-out of valve seats (i) Grind valve seats and valves.
or valvg faces.
(j) lncorrect tappet lash. û) Adjust to specifications.
CONNECTING ROO NOISE (a) lnsufficient oil supply. (a) Check engine oil level.
(bl Low oil pressure. (b) Check engine oil level. lnspect
oil pump relief valve and
spring.
(c) Thin or diluted oil. (c) Change oil to correct viscosity.
(d) Excessive bearing clearance. (d) Measure bearings for correct
(e) Connecting rod journals (e) Replace crankshaft or regrind
out-of-round. journals.
(f) Misaligned connecting rods. (f) Replace bent connecting
rods.
MAIN BEARING NOISE (a) lnsufficient oil supply. (a) Check engine oil level.
TROUBLESHOOTING 2_5

Condition Possible Cqure Correciion

(bl Low oil pressure. (b) Check engine oil level. lnspect
oil pump relief valve anci
spring.
(c) Thin or diluted oil. (c) Change oil to correct viscosity.
(d) Excessive bearing clgarance. (d) Measure bearings for correct
clearance.
(e) Excessive end play (e) Check thrust bearing for wear on
flanges.
(f) Crankshaft journal out-of-round (f) Roplace crankshaft or regrind
or worn. journals.
(s) Loose flywheel or torque (g) Tighten to correct torque.
converter.
OIt PUMPING AT RINGS (a) Worn, scuffed, or broken rings. (a) Hone cylinder bores and install
new rings.
(b) Carbon in oil rings slots. (b) lnstall new rings.
(c) Rings fitted too tight in (c) Remove the rings. Check

CLUTCH

Condition Possible Couse Correclion

CTUTCH CHATTER (al Worn or damaged disc (a) Replace disc assembly.
assembly.
(b) Grease or oil on disc facings. (b) Replace disc assembly and
correct cause of contamination.
(c) lmproperly adjusted cover (c) Replace' cover assembly.
assembly.
(d) Broken or loose engine mounts (d) Replace or tighten mounts
(e) Misaligned clutch housing (e) Align clutch housing
CIUTCH SIIPPING (a) Burned, worn, or oil soaked (a) Replace disc assembly and
facings. correct cause of contamination.
(b) Insufficient pedal free play. (b) Adjust release fork rod.
(c) We.ak or broken pressure (c) Replace cover assembly.
spnngs.
DIFFICUTT GEAR SHIFTING (al Excessive pedal free play. (a) Adjust release fork rod.
(b) Excessive deflection in linkage (b) Repair or replace linkage.
or firewall.
(c) Worn or damaged disc (c) Replace disc assembly.
assembly.
(d) lmproperly adjusted cover (d) Replace cover assembly.
assembly.
(e) Clutch disc splines sticking. (el Remove disc assembly and free
up splines or replace disc.
(f) Worn or dry pilot bushing. (f) Lubricate or replace bushing.
(s) Clutch housing misaligned. (g) Align clutch housing.
CIUTCH NOISY (a) Dry clutch linkage. (a) Lubricate where necessary.
(b) Wern release bearing. (b) Replace release bearing.
(cl Worn disc assembly. (c) Replace disc assembly.
(d) Worn release levers. (d) Replace cover assembly.
(e) Worn or dry pilot bushing. (e) Lubricate or replace bushing.
(f) Dry contact-prêssure plate lugs (f) Lubricate very lightly.
in cover.

MANUAT_TRANSMISSION

Condition Possible Cquse Correclion

I.TÂRD SHIFTING (a) lncorrect clutch adiustment. (a) Refer to Clutch Group for
corrections.
TROUBLESHOOTING 2_6

Condition Possible Cou:c Correclion

(b) lmproper linkage adjustment. (b) Perform linkage adjustment

(cl Synchronizer clutch sleeve (c- d-e) Causes noted can only be
damaged. corrected by disassembling
transmission and replacing
damaged or worn parts.
(d) Synchronizer spring improperly
installed.
(e) Broken or worn synchronizer
stop rings.
TRANSMISSION SLIPS OUI {a} Linkage interference. (a) lnspect and remove all linkage
OF GEAR interferences.
(b) Gearshift rods out of (b) Adjust gearshift rods
adjustment.
(c) Synchronizer clutch teeth worn.Disassemble transmission and
(c)
replace parts as necessary.
(d) Clutch housing bore or face out (d) Refer to Clutch Group for
of alignment. correction procedure.
TRANSMISSION NOISES (a) Excessive end play in (a) Replace thrust washers.
countershaft gear.
(b) Loose synchronizer hub splina tbl lnspect mainshaft and
fit on mainshaft. synchronizer hub and replaca
parts as necessarv.
(c) Damaged, broken or excessively (c! Replace wo.n gears.
worn gear teeth.
tdt Rough or pittod bearing races (d) Replace worn bearing.
or balls.

REAR AXIE

Condition Possible Couse Correclion

RTAR WHEEI NOISE (al Wheel loose. (a) Tighten loose wheel nuts.
(b) Spalled wheel bearing cup or (bl Check rear wheel bearings. lf
cone. spalled or worn. replace. -
(c) Defective, brinelled wheel (c) Defective or brinelled bearings
bearing. must be replaced. Check rear
.(d) axle shaft end play.
(d! Excessive axle shaft end play. Readjust axle shaft end play.
(e) Bent or sprung axle shaft (e) Replace bent or sprung axle
f lange. shaft.
SCORING OF DIFFERTNTIAI. (a) lnsufficient lubrication. (a) Replace scored gears. Scoring
GEARS AND PINIONS
marks on the pressure face 6f
gear teeth or in the bore are
caused by instantaneous fusing
of the mating surfaces. Scored-
gears should be replaced. Fill
rear axle to required capacity
with proper lubricant. See
Specification Section.
(b) lmproper grade of lubricant. (bl Replace scored gears. lnspect
all gears and bearings for
possible damage. Clean out and
refill axle to required capacity
with proper lubricant. See
Lubrication section.
(c) Excessive spinning of one (c) Replace scored gears. lnspect
wheel. all gears, pinion bores and shaft
for scoring, or bearings for
possible damage. Service as
necessary.
TROUBLESHOOTING 2_7

Condition Possible Couse Correclion

TOOTH BREAKAGE (RING (a) Overloading. (a) Replace gears. Examine other
GEAR AND PINION) gears and bearings for possible
damage. Replace parts as
needed. Avoid Overloading.
(b) Erratic clutch operation. (b) Replace gears, and examine
remaining parts for possible
damage. Avoid erratic clutch
operation.
(c) lce-spotted pavements. (c) Replace gears. Examine
remaining parts for possible
damage. Replace parts as
required.
(d) lmproper adjustment. (d) Repiace gears. Examine other
parts for possible damage.
Make sure ring gear and pinion
backlash is correct.

REAR AXI.E NOISE (al lnsufficient lubricant. (al Refill rear axle with correct
amount of the proper lubricant.
See Specification section. Also
check for leaks and correct as
necessary.
(b) lmproper ring gear and pinion (b) Clreck ring gear and pinion
adjustment. tooth contact.
(c) Unmatched ring gear and (c) Remove unmatched ring gear
pinion. and pinion. Replace with a new
matched gear and pinion set.
(d) Worn teeth on ring gear or (d) Check teeth on ring gear and
pinion. pinion for contact. lf necessary,
replace with new matched set.
(e) End play in drive pinion (e) Adjust drive pinion bearing
bearings. preload.
(f) Side play in differential (f) Adjust differential bearing
bearings. preload.
(q) lncorrect drive gearlash. (g) Correct drive gearlash.
LOSS OF TUBRICANT (a) Lubricant level too high. (a) Drain excess lubricant by
removing filler plug and allow
lubricant to level at lower edge
of filler plug hole.
(b) Worn axle shaft oil seals. (b) Replace worn oil seals with
new ones. Prepare new seals
before replacement.
(c) Crackdd rear axle housing. (c) Repair or replace housing as
required.
(d) Worn drive pinion oil seal. (d) Replace worn drive pinion oil
seal with a new one.
(e) Scored and worn companion (e) Replace worn or scored
f lange. companion flange and oil seal.
(f) Clogged vent. (f) Remove obstructions.
(s) Loose carrier housing bolts or (g) Tighten bolts or cover screws
housing cover screws. to specifications and fill to
correct level with proper
lubricant.
OVERHEATING OF UNIT (a) Lubricant level too low. (a) Refill rear axle.
(b) lncorrect grade of lubricant. (b) Drain, flush and refill rear axle
with correct amount of the
proper lubricant. See
Specification Section.
(c) Bearings adjusted too tightly. (c) Readjust bearings.
(d) Excessive wear in gears. (d) Check gears for excessive wear
or scoring. Replace as
necessary.
(e) lnsufficient ring gear to pinion (e) Readjust ring gear and pinion
clearance. backlash and check gears for
possible scoring.
TROUBLESHOOTING 2-8

Condilion Possible Cquse Correclion

DRTVE SHAFT VIBRATION (a) Undercoating or other foreign (a) Clean exterior of shaft and
matter on shaft. wash with solvent.
(b) Loose universal joint flange (b) Tighten bolt nuts to specific
bolts. torque.
(c) Loose or bent universal joint (c) lnstall new flange. Tighten to
flange or high runout. specif ications.
(d) lmproper drive line angularity. (d) Correct angularity. See
"Propeller Shaft {ngularity."
(f) Worn universal joint bearings or (f) Recondition universal joint.
missing rollers.
(g) Shaft dannaged (bent tube) or (gl lnstall new shaft.
out of balance.
(h) Broken rear spring. (h) Replace rear spring.
(i) Excessive runout or unbalance {i) Reindex propeller shaft 180
condition. degrees, reride and correct as
necessary.
UNIVERSAI JOINT NOISE (a) Stratt flange bolts nuts loose. (a) Tighten nuts to specified
torgue.
(b) Lack of lubrication (b) Recondition universal joint.

SHOCK ABSORBERS
Condition Possible Cnuse Correclion

SHOCK ABSORBER NOISY (a) Loose bolt or stud. (a) Tighten to specifications.
(b) Undercoating on shock absorber (bt Clean undercoating off shock
reservoir. absorber.
{c} Bushing excessively worn. (c) Replace bushing.
(d) Air trapped in systom. (d) Purge shock absorber.
SHOCK ABSORBER DRIPPING (a) Worn seal. (a) Replace shock absorber.
ort
(b) Damaged crimp or reservoir. (bl Replace shock absorber.

STEERING

Condition Possible Couse Correclion

HARD SITERING (a) Low or uneven tire pressure. (a) lnflate tires to recommended
pressures.
(b) lnsufficient lubricant in the (b) Lubricate as necessary.
steering gear housing or in
steering linkage.
(c) Steering.gear shaft adjusted too (c) Adjust according to instructions.
tight.
(d) Front wheels out of line. (d) Align the wheels. See "Front
Suspension."
PULI TO ONE SIDE (lendency (al lncorrect tire pressure. (a) lnflate tires to recommended
of lhe Vehicle lo veer in one pressures.
direclion only) (b) Wheel bearings improperly (bl See "Front Wheel Bearing
adjusted. Adjustment."
(c) Dragging brakes. (c) Inspect for weak, or broken
brake shoe spring, binding
pedal.
(d) lmproper caster and camber. (d) See "Front Wheel Alignment
Group."
(e) lncorrect toe-in. (e) See "Front Wheel Alignment
Group."
(f) Grease, dirt, oil or brake fluid in (f) lnspect, replace and adjust as
brake linings. necessary.
(g) Front and rear wheels out of (g) Align the front wheels. See
alignment. "Front Suspension Group"
TROUBLESHOOTING 2-9

Condition Possible Couse Ccrreciion

(h) Broken or sagging rear springs. (h) Replace rear springs.

(i) Bent suspension parts. (i) Replace parts necessary.
WHEET TRAMP (Excessive (a) lncorrect tire pressure. (a) lnflate tires to recommended
Verlicol Molion of Wheels) pressures.
(b) lmproper balance of wheels, (b) Lubricate as necessary.
tires and brake drums.
(c) Loose tie rod ends or steering (c) lnspect and repair as necessary.
connections.
(d) Worn or inoperative shock (d) Replace shock absorbers as
absorbers. necessary.
EXCESSIVE PIAY OR (a) Steering gearshaft adjusted too (a) Replace worn parts and adjust
LOOSENESS IN ÎHË SÎEERING loose or badly worn. according to instructions.
YYHEET
(b) Steering linkage loose or worn (b) Replace worn parts. See "Frbnt
Wheel Alignment."
(c) Front wheel bearings improperly (c) Adjust according to instructions.
adiusted.
(d) Steering arm loose on steering (d) lnspect for damage to gear
gear shaft. shaft and steering arm, replace
parts as necessary.
(e) Steering gear housing attaching (e) Tighten attaching bolts
bolts loose. according to tigntening
reference.
(f) Steering arms loose at steering (f) Tighten according to tightening
knuckles. reference.
(s) Worn ball joints. (g) Replace ball joints as necessary.
See "Front Suspension."
(ht Steering gear adjustment too (h) Adjust
loose.

BR.AKES

Condilion Possible Couse Correclion

ORAGGING BRAKES (AIT (a) Brake shoes improperly (a) Adjust brakes.
wHEETS) adjusted.
(b) Brake pedal linkage binding. (b) Free up linkage.
(c) Excessive hydraulic seal friction. (c) Lubricate seal.
(d) Compensator port plugged. (d) Clean out master cylinder.
(e) Fluid cannot return to master (e) lnspect pedal return.
cylinder.
(f) Parking brake not returning. (f) Free up as required.
(s) Disc brake metering valve (g) Replace metering valve.
malf unction.
(h) Contaminated brake fluid. (h) Drain and flush system-replace
all rubber parts in hydraulic
system.
GRABBING BRAKES (a) Grease or brake fluid on linings. (a) lnspect for a leak and reptace
lining as required.
PEDAL GOESïO FTOOR (OR (a) Self-adjusters not operating. (a) lnspect self-adjuster operations.
ALMOST TO FTOOR)
(b) Air in hydraulic system. (b) Bleed brakes.
(c) Hydraulic leak. (c) Locate and correct leak.
(d) Fluid low in master cylinder. (d) Add brake fluid.
(e) Shoe hanging up on rough (e) Smooth and lubricate platforms.
platform.
(f) Loose disc brake rotor (fl Check wheel bearing
ad justment.
HARD PEDAI (POWER UNIT (a) Faulty vacuum check valve. (al Replace check valve.
IROUBLE)
(b) Collapsed or leaking vacuum (bl Replace hose.
hose.
(c) Plugged vacuum fittings. {c) Clean out fittings.
(d) Leaking vacuum chamber. (d) Replace unit.
TROUBLESHOOTING 2_1O

Condition Possible Couse Correclion

(e) Diaphragm assembly out of {e} Replace unit.

place in housing.
(f) Vacuum leak in forward (f) Replace unit.
vacuum housing.
EXCESSIVE PEDAT TRAVEI. {al Rear brake adjustment required. (a) Check and adjust rear brakes.
(b) Air leak, or insufficient fluid in (b) Check system for leaks.
system or caliper.
(c) Warped or excessively tapered (c) lnstall new shoe and linings.
shoe and lining assembly.
(d) Excessive disc runout. (d) Check disc for runout with dial
indicator. lnstall new disc.
(e) Loose wheel bearing (e) Readjust wheel bearings to
adjustment. specified torque.
(f) lmproper brake fluid (boill. (f) Drain and install correct fluid.
(s) Damaged caliper piston seal. (s) lnstall new piston seal.
BRAKE ROUGHNESS OR (a) Excessive out-of-parallelism of (a) Check disc for runout with dial
CHATTER (Pedol Pulsoting) braking disc. indicator. lnstall new disc.
(c) Excessive lateral runout of (c) Check disc for lateral runôut
braking disc. with dial indicator. lnstall new
disc.
(d) Excessive front bearing (d) Readjust wheel bearings to
clearance. specified torque.
(e) Rear brak.e drums distorted by (e) Check drums for out-of-round
improper tightening of nuts. and reface if necessary.
EXCESSIVE PEDAT EFFORT (a) Power brake malfunction. (a) Replace
(b) Frozen or seized pistons. (b) Disassemble caliper and free up
pistons. Clean parts.
(c) Shoe and lining worn below (c) lnstall new shoe and linings.
.18O in. (Lining only- .3O in.)
(d) Erake fluid, oil or grease on (d) lnstall new shoe linings as
linings. required.
(e) lncorrect lining. (el Remove lining and install
correct lining.
PUil. {a} Loose calipers. (al Tighten caliper mounting bolts
from 45 to 60 ft. pounds.
(b) Frozen or seized pistons. (b) Disassemble caliper and free up
pistons.
(c) Rear brake pistons sticking. (c) Free up rear brake pistons.
(d) Front end out of alignment. (d) Check and align front end.
(e) Broken rear spring. (e) lnstall new rear spring.
(f) Out-of-round rear drums. (f) Check and reface drums if
necessary.
(g) lncorrect tire pressure. (g) lnflate tires to recommended
presures.
(h) Brake fluid, oil or grease on (h) lnstall new shoe and linings.
linings.
(i) Restricted hose or line. (i) Check hoses and lines and
correct as necessary.
U) Rear brakes out of adjustment. (j) Adjust rear brakes.
(k) Unmatched linings. (k) lnstall correct lining.
(ll Distorted brake shoes. (t) lnstall new brake shoes.
NOISE Groon-Broke noise (a) Not detrimental to function of
emoncling when slowly disc brakes-no corrective
releosing brokes action required. (lndicate to
(creep-groon) operator this noise may be
eliminated by slightly increasing
or decreasing brake pedal
efforts!.
Rottle-Broke noise or rollle
emonoting ol low speeds on
rough roods, (fronl wheels
only).
(a) Excessive clearance between (a) lnstall new shoe and lining
shoe and caliper. assemblies.
Scroping- (a) Loose wheel bearings. (a) Readjust wheel bearings to
correct specifications.
TROUBLESHOOTING 2_11

Condilion Possible Couse Correclion

(b) Braking disc rubbing housing. (b) Check for rust or mud builduP
on caliper mounting and bridge
bolt tightness.
(c) Mounting bolts too long. {c) lnstall mounting bolts of correct
lenoth.
FRONT BRAKES HEAT UP (al Residual pressure valve in (a) Reriove valve lrom cYlinder.
DURING DRIVING AND FAII' master cYlinder.
TO RETEASE
(b) Frozen or seized Piston. (b) Disassemble caliPer, hone
cvlinder bore, clean seal groove
and install new Pistons, seals
and boots.
(c) Operator riding brake Pedal. (c) lnstruct owner how to drive
with disc brakes.
(d) Sticking pedal linkage. (d) Free up sticking Pedal linkage.
(e) Power brake malfunction. (e) Replace
I"EAKY WHEEI. CYTINDER (a) Corroded bore. (a) Hone bore and rePlace boots
and cups.
{b) Damaged or worn caliPer Piston (b) Disassemble caliPer and install
seal. new seal.
(c) Scores or corrosion on surface (c) Disassemble caliPer and hone
of piston. cylinder bore. lf neccessarY,
install new Pistons.
GRABBING OR UNËVEN (a) Causes listed under "Pull." (a) Corrections listed under "Pull."
BRAKING ACTION
(b) Power brake malfunction. (b) Replace unit.
tsRAKE PEDAT CAN BE (a) Air in hydraulic system or (a) Bleed system.
D€PRESSED WITHOUT improper bleeding procedure.
ENAKING EFFECT
(b) Leak in system or caliPer. (b) ,Check for leak and rePair as
required.
(c) Pistons pushed back in cYlinder (c) Rei:osition brake shoe and
bores during servicing of caliPer lininq asdemblies. Depress Pedal
(shoe and lining not ProPerlY a seéond time and if condition
positioned). persists, check following causes:
(d) Leak past piston cuPs in master {d) hecondition master cYlinder.
cylinder.
(e) Damaged Piston seal in one or (e) Disassemble caliPer and rePlace
more of cylinders. piston seals as required. ..
(f) Leak in rear brake cYlinder' (f) ilone cylinder bore. lnstall new
piston cylinder cuPs.
(s) Rear brakes out of adjustment. (s) Adjust rear brakes.
(h) Bleeder screw open. (h) Close bleeder screw and bleed
entire system.

PARKING BRAKES
Condition Possible Couse Correclion

DRAGGING ERAKE (a) lmproper cable or brake shoe (al Properly adlust the service
adjustment. brakes. then arCjust the Parking
brake cable.
(b) Broken brake shoe return (b) Replace any brt:ken return
spring. spring.
(c) Broken brake shoe retainer (c) Replace the brolken retainer
spring. spring.
(d) Grease or brake fluid soaked (d) Replace the grease seal or
lining. recondition the wheel cylinders
and replace both brake shoes.
(e) lmproper stop light switch (e) Adjust stop light switch
adjustment
(f) Sticking or frozen brake cable. (f) Replace cable.
(gl Broken rear spring. (g) Replace the broken rear spring.
(h) Bent or rusted cable equalizer. (h) Straighten, or replace and
lubricate the equalizer.
TROUBLESHOOTING 2-'12

Condilion Possible Cquse Correclion

(h) Heat set parking brake cable (h) Replace parking brake cable.
spnng.
BRAKE WII.T NOT HOID (a) Broken or rusted brake cable.
(bt
(a) Replace cable.
lmproperly adjusted brake or (b) Adjust brakes and cable as
cable. necessary.
(cl Soaked brake lininq. (c) Replace the brake lining.
(d) Ratchet or pedal m-echanism (d) Replace pedal assembly.
worn.

FRONT SUSPENSION AND STEERING TINKAGE

Condition Possible Couse Correclion
FIONI END NOISE (al Ball joint needs lubrication. Lubricate ball joint.
(a)
{b )Loose shock absorber Tighten shock absorber
(b)
mounting. Shock absorber mounting nuts. Replace
iloperative or bushings worn. bushings or shock absorber.
(c) Worn strut bushings. (cl Replace bushing.
(dl Loose struts-Lower control arm (d) Tighten all bolts and nuts.
bolts and nuts,
(e) Loose steering gear on frame. (e) Tighten the steering gear
(f)
mounting bolts.
Worn upper control arm (ft Replace worn bushings.
bushings.
(g) Worn lower control arm shaft (s) Replace worn bushings.
bushings.
(hl Worn upper or lower joint. (h) Replace ball joint.
(i) Worn tie rod ends. ball (i) Replace tie rod end.
U) Loose or worn front wheel U) Adjust or replace bearings as
bearings. necessary.
(k) Steering knuckle arm contactinq (k) Smooth off the contacting area
the lower control arm wheel and lubricate with a water
stop. resistant grease.
INSTABII.IlY (a) Low or uneven tire pressure. (a) lnflate tires to correct pressure.
(b) Loose wheel bearings. (b) Adjust wheel bearing.
(c) lmproper steering cioss shaft (c) Adjust steering crosè shaft.
adjustment.
(d) Steering gear not centered. (d) Adjust steering gear.
(e! Worn idler arm bushing. (e) Replace bushing.
(fl Loose or excessively wôrn front (f) Replace bushings.
strut bushings.
(gl Weak or broken rear sorino. (s)
(hl lncorrect front wheel atign;.,ent. th) Replace spring.
Measure and adjust front wheel
alignment.
(il Shock absorber inoperative. (i! Replace shock absorber.
HARD STEERING (a) Ball joints-require lubrication. (a) Lubricate ball joints.
(b) Low or uneven tire pressure. (b) lnflate tires to recommended
pressures.
(e) lncorrect front wheel alignment (e) Replace bent parts and adiust
(particularly casterl resuliing the front wheel alignment.
from a bent control arm,
steering knuckle or steering
knuckle arm.
(f) Steering gear low on lubricant. (f) Fill gear to correct level.
(g) Steering gear not adjusted. (S) Adjust steering gear.
(h) ldler arm binding. (h) ReÈlace idter àrm.
CAR PUTIS TO ONE SIDE (a) Low or uneven tire pressure. (a) lnflate tires to recommended
pressure.
(b) Front brake dragging. (b) Adjust brakes.
(c) Grease, lubricani'or-brake fluid (c) Replace brake shoe and lining
. .. leaking onto brake lining.
(d) . -. g9 necessary and stop all leaks.
Loose or excessively wo-rn strut (dl Tighten or replace strut
bushings. bushings.
(e) Power steering control valve (e) Adjust steering gear control
ciut of adjustment. valve.
TROUBLESHOOTING 2-13

Condition Possible Couse Correclion

(f) lncorrect front wheel alignment (f) Adjust front wheel alignment.
(particularly camber).
(g) Broken or weak rear spring. (sl Replace spring.
EXCESSIVE PIAY lN SIEERING (a) Worn or loose front wheel (a) Adjust or replace whegl
bearings. bearings as necessary.
(b) lncorrect steering gear (b) Adjust steering gear.
adjustment.
(c) Loose steering gear to frame (c) Tighten steering gear to frame
mounting bolts. bolts.
(d) Worn ball joints or tie rod. Replace ball joints or tie rods
(d)
as necessary.
(e) Worn steering gear parts. (e) Replace worn steering gear
parts and adiust as necessary.
(f) Worn upper or lower ball joints. (f) Replace ball joints.
(g) Worn idler arm bushing. (s) Replace bushing.
FNONT WHEET SHIMMY (a) Tire, wheel out of balance. (a) Balance wheel and tire
assembly.
(b) Uneven tire wear, or excessively (b) Rotate or replace tires as
worn tires. necessary.
(c) Worn or loose wheel bearings. (c) Replace or adjust wheel
bearings as necessary.
(d) Worn tie rod ends. (d) Replace tie rod ends.
(e) Strut mounting bushings loose (el Replace strut mounting
or worn. bushings.
(f ) lncorrect front wheel (f) Adjust front wheel alignment.
alignment (particularly caster)'
(g) Worn or loose upper control (g) lnspect ball joints and replace
arm ball joints. where required.

STARTER,-ELECTRICAT
€ondition lPossible Couse Correction

STARTER FAITS IO OPERATE (A) Weak battery or dead cell in tal Test specific gravity. Recharge
battery. or replace batterY as required.
(b) lgnition switch faulty. (b) Test and rePlace switch if
necessary.
(c) Loose or corroded batterY cable (c) Clean terminals and clamPs,
terminals. replace if necessarY' APPIY a
light film of petrolatum to
terminals after tightening.
(d) Open circuit, wire between the (d) lnspect and test all the wiring'
ighition starter switch and
ignition -terminal on starter
relay.
(e) Starter relaY defective. (e) Test relay and rePlace if
necessary.
(f) Faultystarter. (f) Test and rePair as necessary'
(g) Armature shaft sheared. (g) Test and repair.
(h) Open solenoid Pull'in wire. (É) test and replace solenoid if
necessary.
STARTER FAII.S AND IIGHTS (a) Weak battery or dead cell in (a) Test for specified gravitY.
4ti battery. Recharge or rePlace battery as
. required.
(b) Loose or corroded battery cable (b) Clean terminals and clamPs,
terminals. replace if necessarY. APPIY a
light film of Petrolatum to
lerminals after tightening.
(c) lnternal ground in windings. (c) Test and rePair starter'
(d) Grounded starter fields. (d) Test and rePair starter.
(e) Armature rubbing on Pole (e) Test and rePair starter'
shoes.
TURNs, 8UT ENGINE {a} Starter clutch sliPPing. (a) Replace clutch unit.
NOT ENGAGE
'IARTER
DO€S
TROUBLESHOOTING 2_14

Condition Possible Couse Correclion

(b) Broken clutch housing. (b) Test and repair starter.

(c) Pinion shaft rusted, dirty or dry, (c) Clean, test and lubricate.
due to lack of lubrication.
(d) Engine basic timing \ rrong. (d) check engine basic timing and
condition of distributor rotor
and cap.
(e) Broken teeth on engine ring (e) Replace ring gear. lnspect teeth
gear. on starter clutch pinion.
IÎARTER REIAY DOES NOT (a) Battery discharged. (a) Recharge or replace battery.
crosE
(b) Faulty wiring. (b) Test for open circuit, wire
between starter relay ground
terminal post and neutral
starter switch (automatic
transmission only). Also test for
open circuit; wire between
ignition-starter switch and
ignition terminal and starter
relay.
(cl Clutch start switch or neutral (cl Test and replace the switch if
starter switch on automatic necessary.
transmission faulty.
(dt Starter relay faulty. ld) Test and replace if necessary.
RELAY OPERATES 8UT (a) Faulty wiring. (a) Test for open circuit wire
SOTENOID DOES NOT botween starter-relay solenoid
terminal and solenoid terminal
post.

A TTERNATOR.REGUTATOR-ETECTRICAL
Condition Possible Couse Correclion
AITERNATOR FAILS TO (a) Alternator drive belt loose. (a) Adjust drive belt to
CHARGE (No Output or Low specif ications.
Output)
(b) Regulator Base improperly (b) Connect regulator to a good
grounded. ground.
{c} Worn brushes and/or slip rings. (cl lnstall new brushes and/or slip
rings.
{d} Sticking brushes. (d) Clean slip rings and brush
holders. lnstall new brushes if
n0cessary.
(e) Open field circuit. (e) Têst all the field circuit
connections, and correct as
required.
(f) Open charging circuit. (f) lnspect all connections in
charging circuit, and correct as
required.
(g) Open circuit in stator windings. (gl Remove alternator and
disassemble. Test stator
windings. lnstall new stator if
necessary.
(h) Open recitfiers. (h) Remove alternator and
disassemble. Test ths recitfiers.
lnstall new recitfiers if
necessary.
LOw, UNSTEADY CHARGTNG (a) High resistance in body to (a) Tighten ground lead
RATE engine ground lead. connectaons. lnstall new ground
lead if nêcessary.
(bl Alternator drive belt loose. (b) Adjust altsrnator drive belt.
(cl High resistance at battery
ici Clean and tighten battery
terminals. terminals.
(d) H.igh.resistance in charging (d) Test charging circuit resistance.
circuit. Correct as required.
TROUBLESHOOTING 2-15

Condition Possible Couse Correclion

(e) Open stator winding. (e) Removs and disassemble

alternator. Test stator windings.
lnstall new stator if necessary.
tOW OUTPUT AND A LOW (a) High resistance in charging (a) Test charging circuit resistance
BATÎERY circuit. and correct as required.
(b) Shorted rectifier. Open recitfier. (b) Perform current output test.
Test the rectifiers and install
new rectifiers as required.
Remove and disassemble the
alternator.
(c) Grounded stator windings. (c) Remove and disassemble
alternator. Test stator windings.
lnstall new stator if necessary.
(d) Faulty voltage regulator. (d) Test voltage regulator.
EXCESSIVE CHARGING RATE (a) Faulty ignition switch. (a) lnstall new ignition switch.
TO A FUTLY CHARGED
TATTERY
(b) Faulty voltage regulator. (b) Test voltage regulator. Replace
as necessary.
È{OISY ATTERNATOR (a) Alternator mounting loose. (a) Properly install and tighten
alternator mounting.
(b) Worn or frayed drive belt. (b) lnstall a new drive belt and
adjust to specifications.
(c) Worn bearings. (c) Remove and disassemble
alternator. lnstall new bearings
as required.
(d) lnterference between rotor fan (d) Remove and disassemble
and stator leads or rectifiers. alternator. Correct interference
as required.
(e) Rotor or rotor fan damaged. (e) Remove and disassemble
alternator. lnstall new rotor.
(f) Open or shorted rectifier. (f) Remove and disassemble
alternator. Test rectifiers. lnstall
new recitfiers as required.
(s) Open or shorted winding in ts) Remove and disassemble
stator. alternator. Test stator windings.
lnstall new stator if necessary.
EXC[SSIVE AMMEIER (a) High resistance in the (a) Clean and tighten all
FIUCTUATION alternator and voltage regulator connections as necessary.
circuit.
FUEL SYSTEM 3-1

FUEL SYSTEM .. ETIISSION CONTROI. 3

INDEX
Page Page

DESCRIPTION... ....3-1 FTLTER ......3-8

Cold starting device
Airsystem
ELECTRICAL COMPONENTS OF THE SYSTEM .
The pressure feeler with full load enrichment . .
. -3-2
...3-3
.3-3
.3-3
*,Xiîùîl;;
PRESSURE FEELER
Removal
:::::::::::::::::::::: :.,'1_i
....3-8
. '3-8
f
The release contacts . .3-3 Installation
Thetemperaturefeelers ... ' '..3-3 TEMPERATUREFEELERI .... ......3-8
The throttle valve switch with acceleration Installation . . .3-8
enrichment ' .3-3 TEMPERATUREFEELERII ... " ..,...3-9
The temperature switch for cold starting device . .3-4 Removal ....3-9
The cold starting valve with swirl nozzle ' . . . . . .3-4 Installation ' .3-9
ûoNTROLUNIT. .......3-s PRESSUREREGULATOR .....3-9
Removal ....3-5 Removal ,....3-9
Installation . . .3-5 Installation . . .3-9
Checkingandadjusting ... -..3-9
Removal .'....3-7 TDLINGSPEED .......3*9
Installation . '3-7 Adjustment . .3-9
INTAKEPIPES. .......3-7 THROTTLE VALVE SWITCH . . .3-9
Removal ......3-7 Removal ,.,..,.3-9
Installation . .3-7 Adjustment . . .3*9
FUELPUMP ...3-7 Checkingequipment .. '... '3*11
Removal .'.'.3-7 Installation . . .3-11
Installation . . .3-8 197111972MOD|FICAT|ONS . . .3-15

SESCRIPTION fuel quantity must be injected when starting at low

1e fuel is drawn by the fuel pump from the tank via the temperatures, when warming up the engine and under full
'-:er and is delivçred into the ring line. To eliminate the load (warming-up enrichment). The warming up enrich-
::irsmission of noises, a damper has been connected to ment depends on the temperature of the engine. It is
:: pressure line. The pressure regulator at the end of the electrically measured by two feelers, in the intake
restricts the fuel pr.r.-.tt" to 2 kplcm2' The distributor and on the cylinder head.
=g'iin.
* -itro-mugt"tic injection valves are connected to the ring
r: via distributors. The pressure regulator serves to Under overrunning conditions (braking with engine while
running downhill) no fuel should be injected, when the
-::rn excessive fuel into the tank via a second line' speed is above 1,800 rpm. The throttle valve switch will
la: overflow line coming from the fuel pump also enters switch off the fuel delivery. When the speed reaches 1,250
j line. The fuel pump is provided with a pressure relief rpm under overrunning conditions the fuel delivery is
,i--;g which responds when the pressure rises considerably again switched on and the transition into idling operation
i:.:çe the rated value. A check valve'in the pressure is ensured.
:-:nection of the fuel pump prevents the pressure in the
:-g tine from dropping the moment the pump is cut out' These signals are also processed by the control unit in the
proper ratio with regard to the basic fuel requirements
l1: control unit opens the injection valves electrically in and are transmitted electrically to the valves. To keep the
groups (I and II). As a result of constant fuel structural requirements of the control unit small and the
-il costs of the systern low, two valves each are connected in
,.=ssure, the fuel is injected when the valves are opened'
parallel (valve group I = cylinders 1 and 4;valve group II =
-:r ejection duct of the injection valves is accurately cylinders 2 and 3). The two valves of one group inject
:,'brated; for this reason and because the fuel pressure is
ç,::t constant, the injected fuel quantity depends only on simultaneously.
-:: length of time the valve is opened.
While driving, the air volume is controlled by a throttle
l:- injection time is "computed" by the control unit. valve installed in front of the intake air distributor. At
*-: information which the electronic system processes in idling speed the throttle valve is completely closed. The
:: control unit, arrive from the individual information idling air arrives at the intake air distributor through the
:.:smitters on the engine. idling air duct in the throttle valve connection. The idling
speed is adjusted by changing the cross section of the
-- a,Jdition to the basic fuel requirements, an additional idling air duct by means of an adjusting screw on the
FUEL SYSTEM 3-2

@ volkswagen
Basic circuit diagram

1 - Fuel tank
2 - Fuel pump A+ B - from pressure feeler (signal load condition)
3 - Fuel filter C+ D - from ignition distributor contacts
4 - Pressure regulator -(signals speed and release)
5 - Pressure feeler E+ F -from temperature feelers
6 - Intake air distributor (signal warming up-
7 - Cylinder head G - from throttle valve switch
8 - Injectiôn valves (switching off fuel delivery under
9 - Fuel distributor overrunning cond.)
10 - Fuel distributor G1 - (Acceleration enrichment)
I 1 - Ignition distributor with releasing contacts H - from pressure switch
(ZY - contact I, ZV - contact II) (signal full load enrichment)
12-Controlunit from starter, terminal 50 solenoid switch
13 - Throttle valve switch with acceleration enrichment (signal start enrichment)
14 - Supplementary air valve Bridging of full load safety device
15 - Cold starting nozzle - to injection valves cylinder 1 and 4
16 - Thermal switch for cold starting device - to injection valves cylinder 2 and 3

throttle valve connection. housing. The rotary valve is turned by a bimetallic spring
which reacts on the temperature components. The electric
The engine which is not yet fully warmed up, requires heater of the supplementary air valve is connected to the
additional air. This is controlled by the supplementary air pump relay.
valve. It will change the effective cross section of the
supplementary air line in accordance with the engine Cold gtarting device
compartment temperature and the temperature of an At 5"C and below, additional fuel is injected directly into
electric heater installed in the supplementary air valve the intake air distributor to keep the mixture at max,
FUEL SYSTEM 3_3

:ificiency. For this purpose, a cold starting valve is connected to the intake air distributor by means of a hose
rstalled in the intake distributor. tine. This chamber is sealed, air-tight, against the outside
air by another diaphragm. The space behind the dia-
Air system phragm is connected to the outside air by a hole in the
The four cylinders are supplied with air via four intake housing and is subject to atmospheric pressure.
;ipes which are connected to an intake distributor. The
:put of the intake distributor is provided with an intake The pressure in the intake air distributor acts on the
;cnnection and throttle valve. The throttle valve is bellows length and determines the position of the arma-
Etuated by the accelerator pedal by means of a bowden ture in the coil arrangement. The pressure feeler is
:sble. The intake connection is connected to the air filter therefore converting a change of the pressure conditions
:1- means of a rubber elbow. The idling air system is in the in the intake pipe into a change of the inductivity of its
*hape of an idling air duct in the intake connection which coils. This change of inductivity can be read by the
sads behind the throttle valve. The effective cross section control unit.
:en be adjusted by means of the idling air adjusting screw
.dling speed adjustment). The release contacts
In the ignition distributor, the contacts determine when
ELECTRONIC COMPONENTS OF THE SYSTEM fuel is to be injected. Two sets of contacts, offset by I 80o
For a better understanding of the function of the fuel at the lower end of the ignition distributor, are actuated
-.jection system, the individual electric or electronic parts by an additional cam. The position of the cam and the
r--e described in detail here. position of the contacts in relation to the cam shaft
position are set so that the start of the fuel injection is
llhe pressure feeler with full load enrichment timed with the opening of the intake valves.
T"nis controls the basic fuel quantity in accordance with
lle pressure in the intake distributor and thereby of the
tr:rd imposed on the engine. The feeler consists of a set of
-ilows, for moving an iron core in a coil arrangement, to I*,
:b-ange the inductivity of the coil arrangement.
E'
F
*

@ volkswagen
Fuel iniection timing contdcts

@ volkswagen
Since both contacts are actuated by a single cam, the time
Pressure switch span between the opening of the first and the opening of
the second contact is a measure of the engine speed. The
Armature 5 - Diaphragm for full load enrichmenl contacts also serve the speed-dependent control of the
Winding 6 - Space with absolute pressure basic fuel quantity.
Leaf springs 7 - Space witn atmospheric pressure
Bellows The temperature feelers
The temperature feeler I in the intake air distributor and
the temperature feeler II on the cylinder head, control the
enrichment while the engine is warming up. The temper-
ature feelers are essentially resistors which change their
{.: additional diaphragm, which reacts to the difference resistance based on temperature,
TËl'een the pressure in the intake pipe and the atmos-
rL-:ric pressure, will also move the iron core to provide The throttle valve switch with acceleration enrichment
;r: enrichment required under a full load. The iron core is This switch serves the purpose of locking the fuel supply
s:ded in two leaf springs. The bellows are in a chamber under overrunning conditions by means of a contact
FUEL SYSTEM 3_4

which is closed when the throttle valve is in an idling

position. When the ^throttle valve is moved out of this
idling position, by 2" , the throttle valve switch will open.

In addition, the throttle valve switch is provided with two

contact decks with l0 contacts each (contacts for
acceleration enrichment). Another contact (trailing con-
tact) assures that the contact decks for acceleration
enrichment will be operative only when the throttle valve
moves from its closed position into its open position.

@ volks*agen
Throttle valve switch
1 - Slip contacts
2 - Switch pair for acceleration function
3 - Connection with throttle spindle
4 - Switch pair for fuel shut-off function

The temperature switch for the cold starting device

This switch connects the electro-magnetic cold starting
valve to the chassis grou-nd wlen the engine compartment
temperature is below 4l"F (5"C).
O volkswagen
Temperature'feeler I

O volkswagen
Temperature switchl cold starting device
Temperature feeler II

The cold starting valve with a swirl nozzle

The function of the acceleration enrichment consists in This controls the additional fuel quantity required during
the coverage of 9 * 10 contacts per contact deck during a a cold start. It is an electro-magnetic valve which receives
movement of the throttle valve from zero to full. This its operating voltage from the starter, This assures that the
transmits electric impulses to the control unit to deter- cold starting device is switched on only during a starting
mine the fuel quantity required for acceleration. operation.
FUEL SYSTEM 3*5

plug, with the assistance of a wire hook.

@ volkswagen
@ volkswagen
Cold starting valve Control unit removal

lnstallation
:ANTROL UNIT Installin reverse sequence of removal. Install the angle
*r: :ontrol unit consists essentially of the two end stages bracket and the slotted screw first.
,'a:-:hing transistors E I, E II), the switching loeic (SL)
,,n: :he time stage (ZS). The time stage is a monostable
l;:ng stage, which has the tendency of flipping back to
r:: .rable position without requiring a new releasing
rr; --se. The stable position is the "off" position.
Ît''::--::çer an impulse comes from one of the two releasing
.:i:,::ts in the ignition distributor, the time stage is
-"'.,.::ed on. Simultaneously, the same reieasing impulse
m:::es the switching logic to energize the end stage of
nr .ppropriate valve group. For example, this would
lre:- ihe injection valves for cylinders 4 and l. They will
ar:::r open until the time stage has flipped back to its
r-,-i.,= position (off position). The time between the
.'rr,:-:iing on and its flipping back to its off position
rr:.:rines the"QuantitY of fuel injected.
îl: ;ontrol is also provided with a time circuit which
TÈ:::ts operation of the fuel pump only when the starter O volkswagen
: l::rated or when the engine rotates at a speed above
.r- :,nm. As a result, the combustion spaces cannot fill up
,l:- iuel in the event of a defective engine or a fault in
-r: --ection system.
:-;,-:5g enrichment, which is temperature dependent, is
-:n:rlled from outside of the control unit. The switch
.:,{.- o inside the control unit to guarantee that, in the
rr'::- of contact bounce at the releasing contacts, double
rxi :,a3s will not trigger the wrong valve group.

frernoval
-l: - cntrol unit is screwed to a bracket in the engine
; -;:rtment at the right, behind the battery. Puil off the
r, ri :-f guide hose at the bottom right. Unscrew the two
,r,:!:i screws, and loosen one slotted screw. Pull the
. rr-::,1 unit out toward the left, together with the angle
n:-!: J:3 t.
O volkswagen
.:i.::ew the angle bracket. Open the cable clamp and pull
rL: ::e valve for the control unit. Pull out the multiple Removal hook
FUEL SYSTEM 3-6

@ volkswagen
Block circuit diagram of control unit

St - Start signal Zv - Ignition distributor contacts

VSi - Overflow safety device BA - Acceleration enrichment
BA - Acceleration enrichment DKS - Throttle valve switch
WL - Warming up enrichment TFI - Temperature feeler I
Zs - Time switch TF II - Temperature feeler II
DK - Engine speed correction DF - Pressure feeler
DS - Engine speed switch Zyl 4 - Injection valves for cyiinders 1 -4
AS - Shutoff function KS - Cold starting valve
SL - Switching logic TH - Thermo switch
EI,EII - End stages for valve groups I and II P - Fuel pump
FUEL SYSTEM 3_7

1 - Intake pipe
2 - Seal
3 - Spring washer
fue
ffii
#T,q
4 - Fastening nut for intake Pipe
5 - Valve bearing internal
6 - Valve bearing external
7 - Valve holder
8 - Spring washer
9-Nut
L0 - Injection valve
I
L1 - Hose clamp
I
I
3 6

@ volkswaqen
Injection valves

't,^.lECTlON VALVES
;:'rnoval
-,:sen the fastening nuts of both valves on one side.
,.:k the valves for proper function (eject) and leaks,
; -i,ace damaged valves.

-mallation
- -:,:rg installation note the following: Place the internal
, ,: bearing prior to installation, into the pertinent holes
, :re intake pipe. Place the valve holder on the valve
:.-. Then insert the external valve bearings. Be sure of
-:= ;orrect connection of valve plugs. Grey protective
"r'i at the front, black caps at the rear (seen in driving
-:.:lion).
ITTAKE PIPES
:e.noval
--:: ntake pipes of both sides can be separately removed
.lrsta11ed.
-::
i .:ove the valves. Unscrew the four nuts. Unbend the
i. -.:ring plates for the fuel valve 1ine, on the front intake
:, :. Remove the intake pipe, making sure that none of
j ;lrts drop into the cYlinder head'
-stal lation
-:j-lrl in reverse procedure of removal. Check the seal
-;-r.en the intake pipe and the cylinder head for
l:- - :qe.

:.- E L PUMP
:æl-loval Iniector
i --:r'ethe hose for guiding the hot air. Shut off all hose
L,-=, ieading to the pump by means of clamps. Remove 1- Filter 4 - Magnetic armature
:r: rump. Be sure that the two rubber metal bearings, 2 - Magnstic winding 5 - Sealing needle
;--::g for attachment, are not damaged' 3 - Return spring
FUEL SYSTEM 3_8

lnstallation PRESSURE FEELÊR

Check the plug connection for corrosiolr and replace if Removal
required. Do not distort the rubber metal bearings. The pressure feeler is attached in the engine compartment,
Connect the hoses and remove the clamps on the hoses. at the right, on the body.
Check the hose connections for leaks.
lnstallation
FI LTER When installing a new pressure feeler, the protective cap
Removal on the pressure connection may be removed only shortly
Disconnect both lines leading to the filter together with prior to the fitting hose.
the hose clamp and remove the hoses. Pull out the filter,
toward the left.

lnstallation
Be sure that the arrow on the filter points in the direction
of the flow (upwards). Be careful when inserting the filter
into the welded holder. Do not damage the bead of the
filter.

@ volkswagen
Pr e s sur e feeler re moval

Vol kswagen
TEMPERATURE FEELER I
Fuel pump plug lnstallation
Care should be taken to not tighten to excess during
installation.

O volkswagen
Fuel pump connections
O volkswagen
- Supply - D - Distributor
S
- R - Return Fuel pump
FUEL SYSTEM 3-9

TEMPERATURE FEELER II the throttle valve. Remove the intake connection, but do
iemoval not remove the bowden wire for the throttle valves and
-:.rsen the cable connector and remove the rubber gasket the connecting hoses to the ignition distributor. Remove
-r, the cylinder jacket with a tubular socket wrench. the throttle valve switch.

îstâllation
l::ck to see that the rubber cover is properly seated,
--.ia1l the rubber cover in such a manner that the cast-in
..:-ers are on the outside.

!RESSURE REGULATOR
Removal
- -: up the tube hose clamps. Unscrew the fastening nuts
r-: remove the pressure regulator.
ætallation
"-.:a1l
the pressure regulator in a reverse sequence, using
i;a' hose clamps. Measure the initial fuel pressure and
r:::ect, if required.

lhecking and Adjustment

,:i:rect the pressure gauge, Switch on the ignition and
:'-I off the wire between the ignition distributor and the
-'tion coil
l:;rate the starter and read the pressure on a pressure
.i:ge. The rated value is 28.4 psi. Adjust the pressure
::r:1ator only when the rated value is exceeded or is not O volkswagen
l::,lned.

fLING SPEED Air intake removal

ldjustment
i-.:rove the air filter. Turn slotted screw at throttle valve
:::";kwise to increase speed, and counterclockwise to
:;':r idle speed. Set the speed to 900 rpm.
Adiustment
The switch contact on the throttle valve switch should
open when the throttle valve is opened by fo from its
closed position. Connect the tester and close the throttle
valve. Turn the throttle valve switch ln direction of arrow
A until the ohmmeter indicates 0. Then turn it another
division mark (2o). Tighten the fastening screws.

@ vclkswagen
Idle sPeed adiustment
a-fastei-b-slower

TI.{ROTTLE VALVE SWITCH O volkswagen

iemoval
i-.rove the air filter and disconnect the return spring for Testing throttle valve switch
FUEL SYSTEM 3_10

--'.7- f r +.-

@oooo{ r5

23

;%i,l
,\É

Fuel iniection wiring diagram

FUEL SYSTEM 3-11

Checking equipment
The most significant piece of equipment for checking the
injection system is the Bosch tester. It is used to test all
the information transmitters as well as the pump and
injection valves according to an accurately determined test
program. Within this test program the fuel ring line is also
tested for pressure and the presence of leaks. It is
important that all these points are checked during a test.

Before starting the test, complete the following: Switch

off the ignition to deenergize the control unit. Remove
the control unit. Pull the multiple plug out of the control
unit and connect the plug of the tester to the multiple
plug of the cable line. Switch on the ignition and check all
functions in accordance with the test program.

1 - Control unit
2- Electronic cable line
3 - hessure feeler
4 - Throttle valve switch with acceleration enrichment
5 - Temperature feeler I (intake distributor)
6 - Temperature feeler II (cylinder head) i
r - Ignition distributor with impulse release
B - Injection valve
9 - Fuel pump
luw
I'J - Fuel valve ., u

I i - Thermo switch for fuel enrichment &.

:t"
1i - Supplementary air valve .. .-..,,,.

i3 - Earth connection (on engine housing) l. ,i.j

i-f - Ignition coil
'I i_
, . Line connectors
t-
i' - Regulator for alternator .. .:.1

I5- Alternator
-9 - Cable line alternator
lû - Starter (starter motor)
i1 - Voltage supply relay
11 - Pump relay
5 - Lines not included in main cable line I Volkswagen

Throttle valve switch connectionS

lnstallation
Install in reverse procedure of removal; note the follow-
ing: Prior to installing the intake connections again, adjust
the throttle valve switch.
FUEL SYSTEM 3-12

The fuel injection system can be checked accurately only has to be done in such cases in addition, is shown in the
with the tester. When testing acc. to the Check List, following list.
deviations from the rated value will be noticed. Whatever

Check. step Result Possible Cause (remedy)

1 No indication Interruptions terminal 85 on relay I no voltage (check

Voltage whether terminal L5/ignition coil has voltage, check line),
terminal 30 on relay I no voltage (check acc. to Wiring
Diagram),
terminal 86 on relay I no earth cotlnection (check earth
conneclion),
connection between terminal 8? of relay I and terminal 16
control unit interrupted (check line 16).

Voltage below Transfer resistance in line 16/conuol unit or on relay

11 Volt contacts (check line, change relay I)

2
similar to checkir-rg step 1, but check iine to terminal 24 control unit
Voltage II
3 No voltage, starter Line interruption from starter solenoid switch to control
Voltage Starter is running unir (check line 18).
No voltage, starter Ignitior-r starter lock defective, line interruption
is not running

Voltage below Battery discharged, voltage drop too high in line frort
9 Volt iglrition stârter lock to terminal 50 of starter solenoid
switch (check line with volt meter).

4 If no full deflection is obtained on instrument, battery voltage in vehicle is too low.

Align to oa Also refer to checking steps 1 and 2.

Pressure feeler Resistor 0 Earth connection in supply line or on pressure feeler (pull
eâlth conne ctior'l plug on pressure feeler, if indication is then @
exchange pressure feeler. If indication remains unchanged
at 0, short circuitin line ?.8, 10, 15, exchange cable line).
Indication under æ Insulatior-r damage (similar to 5, resislor 0)
but nor 0

5 Rated value Insuiating damage (puil plug on pressure feeler, if

Pressure feeler approx. 9o Ç) indication is then @ , exchange pressure feeler).
primary resistance consider ably
less

Resistor 0 Earth connection, short circuit of primary line (pull plug

on pressure feeler, if indication is then æ , exchange
pressure feeler).

Rated value High transition resistance (check plug and iines for
approx. 90 fl corrosion or interruption).
resistance considerably
higher

Resistor ooÇ) Interruption (Bridge on plug as

shown in illustration. If indication
is 0, exchange pressure feeler.
If indication is æ, repair line).
FUEL SYSTEM 3-13

Check. step Result Possible cause (lemedy)

6 Similar to5 rated Similar to 5 at resistance æ

Pressure feeler value but bridge the two other
se condary approx. 350 Q terminals.
"l Resistânce higher than 0 lfthe needle of the instrument does not deflect during
Ignition distributor or lower than æ Q "Starting" or remain in one position -æ or 0 - renew
contact I contacts. (Replace con!âct insert.)
8
Ignition disuibutor
colttâct ÏI
9 Needle remains at oo Throttle valve switch defective (replace)
Throttle valve or needle remains not at
switch I then @ when throttle valve
throttle valve is returned
switch II
Needle remains Short circuit (pull plug on throttle valve switch, if needle
ar0 is thena, , replace throttle valve switch, otherwise cable line)
10 Resistance @ with Throttle valve switch wrongiy set
Throttle valve throttle valve lever in or interruption in supply line.
switch lll position "Idling" (Check adjustment, pull plug, bri.dge.
If then still æ , replace cable line,
otherwise replace throttle valve switch).

Resistance 0 Ç2 Throttle valve switch wrongly adjusted or short circuit in

with throttle valve supply line. Pull plug, if indication is then still 0, adjust
opened more than 20 or replace calbe line, otherwise throttle valve switch).
11 Rated value 350 Q Rated value applies at 20oC (68oF), Resisrance decreases
Temperature resistance higher with increasing temp. Feeler is in order, if no 0 or@ is
feeler I or lower measured.
(in intake
distributor)
tndication @ Ç) Interruption. (Bridge , if indication
is then 0, replace temperature
feeler, otherwise cable line).
Indication 0 I Short ci.rcuit. (Puil plug, if indication remains unchanged,
cable defective. If indication is oo , replace temperature
feeier).
12 Similar to 11 with the following deviations; rated value 2.5 k Q, instead of bridging:
Temperature hold plug of cable line to mass.
feeler II
fcvlinder head
fJ Resistor 0 f) Short circuit in supply line or on valve. (Pull plug on
V alves respective valve, if indicatioD is then @ , replace vâlve,
(Resist. ) otherwise replace cable line).
Resistor oo Ç) Interruption in supply line or in valve coil. (Bridge contacts
in valve plug, if indication is then @ , cable line defective.
If then 0, valve defective).
Rated value 2.4 Q, at Earth connection of valves is badly connected to crankcase
20oC, resistance higher or flat plug connection is badly plugged (use contact spray,
but not oo tighten earth connection screw).
Resistor under 2.4 Ç) Interturn short circuits of vaive (replace)
but not 0
FUEI SYSTEM 3_14

Check. step Possible cause (remedy)

14 Pre ssure
Pressure in above 2 kp/cmz
ring line (28.4 psi) Presure regulator wrongly adjusted (adjust); if not
adjustable,pressure regulator defective (replace).
Pressure
below 2 kp/cmz
No pressure established Pump withour power. (pull two-pole plug on pump
(pump does not starr) housing and measure voltage with voltmeter. Voltage
should be indicated, when burton "pump. on rester is
pushed. )

Indication 12 Volt: R.eplace pump.

Indication 0 Volt: Lisren whether pump relay (under

irstrument panel). artracts.
I f :
Line interruption from pump relay, terminal g?,
ye s
to 2-pole plug or from 2-po1e plug to
mass connection, ol
pump relay defective.
I f n o: Line interruption from terminal g? voltage supply
relay to pump relay, terminal g6 or gb, to line 1g in
cable uee (line connector in engine compartment). If
line in order, replace pump re1ay.

15 Leak in pressue system (ftom fuel pump to pressure regurator).

Disconnect fuer ring
Pressure line prior to injection valve hrirh self-made clamp or suitable pliers.
dropps
If there is no
pressure 10ss, the leak is in the pressure line or pump;
if there is a loss of presswe
immediat. the leak is in the ring line connecdon to the injection valves,
in the injection valves
upon themselves or on the pressue regurator. Estabrish pressure
severar dmes during the
releasing test, if required.
button "pump"
slowly, but sight test for leaking hose connections (also pressu,e gauges).
If not: remove the two
valve groups one after the other, also remove cold starting valve. pustr
steadily burton ,,pump,.
and check for leaks by sight resr, varve opening may
becôme wer. (Bur there shouid
be nor more than 2 drops per minute). If nor leak is found,
replace pressure
regulator.
Fr.,'Et_ $Y$TEM 3-15

FUEL SYSTEM _ 197111972 MODIFICATIONS

Page Page
1971MODIFICATIONS ......3-1s INCREASED AIR SUPPLY DEV]CE . . . .3-15
19T2MOD|FrCATIONS ......3-1s Description .......3-15
Description .3-15 Checking ..3-15
AdjustingwithCOmeter. ...3-15 INTAKE AIR PRE-HEATING . .3-18
AdjustingwithoutCOmeter .......3-15 Description .3-18
THROTTLE VALVE SWITCH . .3-15 CRANKCASE AIR SUPPLY AND VENTING . . . .3-18
Adjusting ..3-15 Description .......3 18

'[971 MODIFICATIONS Adjusting, with CO meter

i1: overrun fuel cut-off device previously closed the Set the ignition timing and adjust the valves. Adjust the
:--ott1e valve @ 1 800 rpm. For 1971 the cut-off has been throttle valve switch and connect the CO meter. Follow
.-::eased to 3100 rpm. The control unit part number is maker's instructions. Start engine and adjust idle speed to
*-ll 906 021B. 800-900 rpm, with throttle closed. Oil temperature
should be between 122 and 158'F. Turn potentiometer
-:: pressure sensor has been changed to provide a leaner adjusting knob until emission level of 0.7% max. is
-.rture at partial load. The part number is obtained.
= -ll 906 051A.
Adjusting, without CO meter
1972 MODlFICATIONS Set the ignition timing and the valve clearances. Adjust
- rrder to conform to emission control regulations a the throttle valve switch. Turn the potentiometer knob
-,-:'iber of changes have been made to the fuel system' In counterclockwise as far as it will go. Do not force it. Turn
r-::tiod an oil baffle plate to ensure the oil intake pipe i2 clicks in a clockwise direction, for basic setting. Test
::-aùrlng submerged when car corners sharply. drive the car. If the engine backfires on the overrun, the
potentiometer should be turned clockwise, a maximum of
f,l€script'on three notches.
:::n August 1971, a new control unit was installed. This
::.irol unit contains an external adjusting potentiometer. THROTTLE VALVE SWITCH
i-; rurning the adjusting knob, the CO content of the Adiusting
:-ùaust gases can be varied. A protective eap is provided Before adjusting, check with tester EFWA 193, with
:: ;revent moisture from entering the control unit. The adaptor. Switch on the ignition. Select "throttle valve
:r; must be installed after the installation of the control switch I" on the adaptor. Slowly open the throttle valve
-:-:- switch. The needle of the ohmmeter should fluctuate ten
times between zero and infinity. Repeat with adaptor set
to "switch II".
If less than 10 movements occur, the throttle vaive switch
must be adjusted. It is recommended that the intake
manifold be removed. Loosen the two screws through
base of switch. Close the throttle and carefully turn the
throttle valve switch in a counterclockwise direction, up
to the stop. Retighten base screws and re-install intake
manifold.

INCREASED AIR SUPPLY DEVICE

Description
At high engine speeds with the throttle valve closed
(overrun condition) pressure in the intake air distributor is
less than atmospheric. In this condition the pheumatic
valve opens so air can pass from the air cleaner to the
intake air distributor. The fuel/air mixture is thus leaned
out with the additional air.
Checking
Pull off the hose between valve and air cleaner at the
O volkswagen cleaner end, Start engine and increase speed briefly to
Control unit with Potentiometer approx. 3000 rpm. Quickly close throttle. Check that air
FUEL SYSTEM 3_16

@ volkswagen
Diagram of hoses in engine

1- Oilbath air cleaner

2- Oil breather 9 - Cooling fan shroud
3- Distributor 10 - Pneumatic valve for overrun mixture adjustment
4- Intake air distributor 1 1 - not applicable for type 914

5- Additional air regulator 12 - Two-way valve for vacuum advance (California only)
6 - Cylinder head 13 - Non-return device
7 - Pressure sensor 14 - not applicable for type 914
8 - Activated carbon container 15 - Pre-heating of air intake
FUEL SYSTEM 3-'17

1 - Intake air distributor

2 - Pneumatic valve
3 - Hoses

O volkswagen
Intdke air distribution

A - Release ofhot air

B - Intake of cold air

1 - Regulating flap
2 - Intake scoop
3 - Vacuum box
4 - Intake manifold
,i - Ventilating valve
6 - Hoses

O Volkswagen

Thermo pressure air regulator system

FUEL SYSTEM 3-18

is being drawn into the hose (at the end removed from the incoming intake air is below 135"F., allowing the vacuum
air cleaner). If no suction effect is detected, replace the control to operate independently. When the temperature
valve. goes above l35oF the valve opens, allowing the outside air
to flow in. The hot air supply is shut off regardless of
INTAKE AIR PRE.HEATING throttle position.
Description
A vacuum box is incorporated in the air intake scoop, CRANKCASE AIR SUPPLY AND VENTING
with a diaphragm and lever operating flap. The vacuum Description
box is connected by hoses to the intake manifold by a Crankcase breathing has been increased to prevent con-
ventilating valve. It is thermostatically regulated. The load densation build-up in the crankcase and icing of breather
dependent control allows warm air to enter the intake lines in cold weather. Air from the air cleaner enters the
manifold during periods of high vacuum; when the valve covers, and then through the pushrod tubes to the
throttle is closed or only slightly open. The temperature crankcase. Here the air mixes with the fumes. It is then
control, ventilating valve, remains closed as long as the drawn out of engine into the air distributor.
lGNlTloN 4-1

IGNITION 4

INDEX
Page Page
DESCRIPTION... ....4-l Operation . . .4-5
Ignitioncoils.. .. '. '4-l Test in the event of faults . . ' .4-5
Ignitiondistributor -. -4-l SUPPRESSIONRESISTORS ... .......4-5

TI
Centrifugaladjustment .... '.4-l Checking . . .4-5
Vacuumadjustment , '.. ' '..4-1 DISASSEMBLED COMPONENTS OF
Sparkplugs ...4-1 IGNITIONSYSTEM ....4-5
CONTACT BREAKER POINTS . .4-2 Checkingsparkplugs .......4-5
Testingandadjusting '.. '...4-2 Checking ignition distributor on test bench . . . . .4-5
Adjusting breaker contacts with dwell meter ' . . .4-3 Adjusting curyes fot removed ignition distributors 4-5
TIMINGWITHSTROBOSCOPIC LIGHT . . . . . . . .4*3 |GNTTToND|STRIBUTOR ... ........4-s
Adjustment ........4-3 Removal ....4-5
A.UTOMATICADJUSTMENTOF TIMING . . . . . . .4-3 Installation ........4-5
Checkingthecentrifugaladvance .....4-3 Disassembly .......4-6
Checking the vacuum control unit ' . . . .4-4 Checking . . .4-6
Vacuumadjustment"retarded" ......4*4 Assembly . . .4-6
Vacuumadjustment"advanced",'....4-4 IGNITION DISTRlBUTOR DRIVE SHAFT .4,8
rGNlTloNcoll. .......4-4 Removal ....4-8
Testing ".'...4-4 Installation . . '4-8

SESCRIPTION current to each of the four spark plugs in the correct

with an sequence and at the accurate firing moment. A centrifugal
-:: ignition systeô operates as a battery ignition
a-'tiàn coil and an ignition distributor with an automatic and double-acting combination vacuum control installed
----rg point adjustment. The battery voltage is trans- in the ignition distributor will automatically adjust the
::r-rid to the required ignition voltage in the ignition most favorable firing point for each speed and load of the
-:'.. The distributor shaft with the contact breaker cams, engine.
:r:ns the breaker contact shortly before the piston has
.r.:::ined an upper TDC in the cylinder to be fired' As a Centrifugal adjustment
the current in the primary winding of the ignition Two weights on a supporting plate are forced outwards at
=:lt.
:s interrupted. increased engine speed. This turns the breaker cam in the
.:. -'-
direction of rotation (advancing ignition) via a lever.
I:: .:pses
magnetic fieldestablished by the current, suddenly Return springs pull the weights back in position when the
-- and induces the ignition voltage in the secondary speed drops.
u-:Jurg. This ignition voltage travels via an ignition cable
'- --:e rotor of the ignition distributor which, is exactly Vacuum adjustment
::::'site the contact in the ignition distributor head to The vacuum from in front of and behind the throttle valve
,s:-:l the spark plug of the cylinder to be ignited is is taken in separate lines to the two vacuum chambers
":--:cted. A spark can jump at the electrodes of the inside the vacuum unit of distributor. The diaphragm of
;"-i plug to ignite the compressed fuel/air mixture in the these chambers actuate the contact breaker plate via a pull
-- -:: der. rod. The vacuum for the adjustment in the direction of
"retarded ignition" required for idling speed, is from
ryrtion coils behind the completely closed throttle valve. It acts on the
î:= :gnition coil consists of a laminated iron core, which contact breaker plate via the angular vacuum diaphragm.
-.i:---,:s a primary winding and a secondary winding' The
rr: :nd of the primary winding is connected to the When the throttle flap is opened, the vacuum from in
rri-:a' together with the secondary winding via a front of the throttle valve dominates and the contact
i:i:lêi. The other end of the primary winding is breaker plate is adjusted in the direction of "advanced
.:--:;ted to ground via a terminal and the contact ignition".
r1-:-r.3: points. The secondary winding leads to the high
r-.:ie ijne connection.
r: Spark plugs
Since spark plugs are constantly subject to very high
ryr', ton distributor electrical, mechanical, chemical and particularly thermic
-r: :rstributor serves the purpose of feeding the ignition stresses, the startability, the idling speed characteristic,
rGNtTtoN 4-2

@ Volkswagen
Vacuum advance system

1 - Vacuum connection for advanced adjustment 9 - Supporting ring

2 - Vacuum connection for retarded adjustment 10 - Pull rod
3 - Compression springs for advanced adjustment 1 I - Adjusting cam for restricting retarded adjustment
4 - Compression springs for retarded adjustment 12 - Throttle valve
5 - Vacuum chamber (angular) for retarded adjustment 13 - Intake duct (intake distributor)
6 - Vacuum chamber for advanced adjustment 14 - Vacuum tapping point advanced adjustment
7 - Diaphragm for retarded adjustment 15 - Vacuum tapping point retarded adjustment
8 - Diaphragm for advanced adjustment

the acceleration and the maximum output of an engine

depend to a great extent oû the selection of the proper
plug. In addition to the mechanical and electrical prop-
erties of a spark plug, the thermal value is of considerable
importance,

The thermal value indicates the heat-carrying capacity.

The higher this capacity, the higher the resistance against
spontaneous ignition (pre-ignition), and the lower the
resistance against contamination. These characteristics are
reversed in spark plugs with lower thermal values.

CONTACT BREAKER POINTS

Testing and adiusting
Contact breaker points are subject to burn-off, which
develops in tlle shape of small humps andlor pits (contact
creep with DC). This will generally not interrupt opera-
tion. But if the contacts are badly burnt, they must be @ volkswagen
replaced. Pits and humps with a bright contact surface,
indicate normal wear. Dwell angle meter

Greyish color of contact surfaces may be caused by A - red clip a- to ignition lock (15)
insufficient contact gap and/or contact pressure. If a B - black clip b - to ignition distributor (4)
bluish color appears on the contact surfaces, the ignition C - green clip c - to ignition distributor (l) (breaker contact)
tGNtTtcN 4-3

:f,il or capacitorare defective. The appearance of yellow

-.: black porous scars is caused by contamination (grease, ;: _l
::l or dust). Tli r, :ii;

llor to installing new contacts, blow out the inside of the

::.ruibutor well. In addition, be sure that the distributor
:::d is clean and dry inside and out, to prevent creeping
:":rents.

,Adjusting breaker contacts with dwell meter

!,:nove the distributor cap and the distributor rotor.
-::ck the breaker contact points. Badly burned, soiled or
-:r.-tinted contacts must be replaced. Set the contact gap
:: approx. 0.016 in. and make sure that the contact
i--aces are parallel to each other. Contact surfaces should
:.'ir be touched by grease or oil. Connect the dwell angle
: -:er and calibrate.
i;: the engine at 1000- to 1200 rpm and read the value.
1.:-usiing value: 44-50o or 49-5STa;Wear limit: 42-58" or
'- -'.lVo). Wear limit means that the timing angle need not t
o Volkswagen
:* .djusted as long as it is between 42and 58" or 47 and
:-r-:. Run the engine at 2000 to 2500 rpm and read values
]"{=:r1. Stroboscopic light

!-.i-1 contact gap gives a large dwell angle while a large 1 - Timing angle measuring instrument
-:--ract gap gives a small dwell angle. Evaluation of 2- Adjusting wheel
r.:s.rrement results: The contact gap should not be 3 - to ignition cable cylinder I
:e.:r' 0.012 in. If the timing angle measurements show 4 - in ignition distributor cap cylinder 1
:-l: a smaller gap would be required (measured with a
::-:r gauge), a mechanical fault in the distributor is
:r -":ated.

::ie speed is raised during measuring (to approx.

-:-J-1500 rpm), the dwell angle indicated should not
--.-re considerably (max. +1"). Larger deviations indi-
:"1.. a fault in the distributor, for example worn bearings
:r ::nout of distributor cams. Restless, jerky motions of
-:: needle are generally caused by burned-out and
;:;:ab1e contact breaker points.

-;:: the adjustment of the breaker contact points, be

,*:: io adjust the timing again, since a change of the
.:--lc-t gap by 0.004 in. corresponds to a change of the
-- rg by approx. 3" crankshaft.
: l'IING WITH STROBOSCOPIC LIGHT
{C justment
l-=,: to each adjustment of the timing, be sure to check
-*. iç'e11 angle of the contact b-reaker points and adjust if
n:--:sary. Be sure -that the engine oil temperature is
rÉ,;een 60 and 70"C. Check whether the timing marks
.Lr. .asily seen (mark with a colored stripe, if required). @ volkswagen

I -::ect the stroboscopic light and tachometer in accord- Timing mark location
,r:: çith instructions (into ignition line of cylinger no.
both vacuum hoses from the vacuum unit
P.r1l on the
.rr.::--butor. Run the engine at 3 500 rpm and direct
,-:-loscopic light at the impeller. The timing is correctly
,r. rsted when the red 27" mark on the impeller is in AUTOMATIC ADJUSTMENT OF TIMING
-q:-nent with the reference mark on the cooling blower Checking the centrifugal advance
t - :.ing. The effect of the centrifugal advance can be observed by
turning the attached distributor rotor manually and
. the ignition distrib-
-'-:ct faulty adjustments by turning clockwise. Upon release, the rotor should automatically
;:-:. The impeller has two notches. The black 5o mark return to its starting position. If not, the centrifugal
'*:-":. for the static adjustment of the timing, with the advance mechanism is either contaminated or the spring
ia=:.e stopped. tension of the return springs has declined.
rGNrTtoN 4-4

the black mark. Read the adjusting angle on the adjusting

angle measuring device and remember it.
Place the vacuum hose for advance unit on the retard unit.
The difference between the adjusting angle now indicated
and the remembered value, is the vacuum adjustment
"retarded".

Vacuum adjustment "advanced "

Connect the vacuum tester between the "advance unit"
and the vacuum line. Pull the vacuum line from the
"retard unit". Run the engine at 3500 rpm and flash the
black mark (the vacuum control valve must be opened).
Read the adjusting angle on the measuring instrument and
remember it. Close the vacuum control valve.

The difference'between the adjusting angle now indicated

O volkswagen and the remembered value is the vacuum adjustment
"advance". If the difference from the recommended
Timing marks values are exceeded during the test, proceed with the
following checkup. First check the contact breaker plate
27" beforc TDC = red for smooth operation, disassemble the distributor, if
50 before TDC = black required, and make the contact breaker plate operable.
A = notch in cooling blower housing Then check the vacuum line and the vacuum unit for leaks
and replace it if required.

The centrifugal adjustment of the ignition distributor can

be tested by means of an advance measuring instrument in
combination with a tachometer and strobe light. Check
the static adjustment of the timing and correct, if
required. 2

Pull both vacuum hoses from the vacuum unit of the 3

ignition distributor. Run the engine at max. 900 rpm and
flash black 5o mark. Determine the deviations from the 4
basic ignition adjustment resulting from the absent vac-
uum connections by means of the adjusting wtreel on the
adjusting angle measuring instrument. Remember the
difference. Increase the speed slowly. The beginning of
the adjustment is indicated by the shifting of the notch.
Adjust the speed to the proper values. Use the adjusting
wheel on the adjusting measuring instrument to "return
the notch to the mark in the blower housing". Read the
adjustment in degrees on the measuring instrument.
Deduction of the difference above will show the centrif-
ugal adjustment. If the test values are not in agreement
with the rated values, repair the adjusting mechanism of O volkswagen
the ignition distributor or replace the distributor.
Checking vacuum control unit
Checking the vacuum control unit
The action of the vacuum control unit can be checked by 1- Vacuum indiction 0-100 mm mercurv
placing the previously removed vacuum hoses back on the 2 - Change-over valve
engine, now running at an increased speed, The engine 3 - Control valve
speed should rise considerably. On double-acting vacuum 4 - Vacuum indication G600 mm metcurv
control units, the advanced and retarded adjustment is
checked separately, with the vacuum hose being pulled off
the box.

Vacuum adjustment "retarded" IGNITION COIL

Connect the stroboscopic light with the adjusting angle Testing
measuring device and switch the vacuum tester between Clean the insulating cap and keep it dry to eliminate
the "retard unit" of the ignition distributor and the arcing and creeping cuûents. Check the flat plug for a
vacuum line to the carburetor. Pull the vacuum hoses tight seat to eliminate r.oltage losses. Check the ignition
from the vacuum unit. Run the engine at 3500 rpm. Flash output with an iglition coil tesrer.
tcNtTtoN 4-5

Operation Attach the ignition distributor; check it for quiet opera-

The high voltage end of the ignition coil is loaded with a tion. Test the timing angle. If required, adjust the contact
resistance and operated with a constant impulse sequence gap and thereby the timing angle. Set the speed to 500
of the test instrument. The ignition voltage resuiting from rpm, watching out that the centrifugal adjustment has not
this load is measured. An approximate value is 18,000 V. yet begun. Check the vacuum units for leaks. With the
vacuum line closed, a vacuum of 100 mm mercury should
Test in the event of faults remain constant for approx. I minute.
If no ignition coil tester is available, test as follows. First
ioosen the central cable from the terminal on the ignition
distributor cap and hold it against a ground at a distance
cf approx. 0.394 in. The test should be made with
insulated pliers. When cranking the engine with the
starter, a spark should jump from the cable end to the
lass. When there is no spark, first measure the voltage on
:he terminal of the ignition coil with a voltmeter. ln a 12
;olt system, the voltage should be at least 9 volts.

li the voltage is above that value, check with a voltmeter

:,1 an inspection lamp to see whether there is voltage
.';ailable with the contacts open and no voltage with the
:ontacts closed. If the voltmeter does not deflect even
;:th the contact breaker points open, the ignition coil is
-:îerrupted and should be replaced.
SUPPRESSION RESISTORS
Checking
Ire resistance of the ignition lines, with the copper core,
. roo low to suit the radio suppression regulations of
o::ne countries. For this reason, suppression tesistors are
-<talled into spark plugs and into distributor rotors. In
::dition, upon installation of àn automobile radio the
;::gs of the ignition lines are suppressed in many cases.
Checking spark Plug gaP
l*::se suppression resistors may be the cause of misfiring'
-:ecking the distributor rotor with an ohmmeter: The
r;pressed distributor rotor has a cast-in resistor which
-:y be as high as 10 k ohm. If a higher value is shown,
:-=; iace distributor rotor. When the vacuum drops, check the advanced and retarded
adjustments separately, keeping the connection of the
-.eck the spark plugs and the ignition line plugs with an untested box open. Adjust as many points of the vacuum
:i-'"rmeter. The resistance rating of a spark plug or curve as possibie and read the actually attained adjusting
values on the scale of the test bench. The measured values
€::tion line plug may be (max.) 5-10 k ohm.
should be within the hatched fields of the adjusting curve.
trISASSEMBLED COMPONENTS OF If they are outside, repeat the measurements with a new
GNITION SYSTEM vacuum unit.
[frecking spark plugs
"- operation, the electrode gap of the spark plugs will Check the speed-dependent adjusting curye. Here too, the
:,:rase by natural burn-off. If the gap is too large, the measured values should remain within the hatched fields
:!-:g may fai1. In addition, there may be ignition trouble of the adjusting curve.
r:: to contaminated plugs. The electrode gap is measured
w-:h a spark plug gauge and the ground electrode is bent Adiusting curves for removed ignition distributors
,- -ùe specified value. The adjustment of the centrifugal force is measured
starting from I 500 rpm with declining speed'
- -:taminated plugs may be cleaned only with a cleansing
r:::. Steel brushes and similar tools are not suited for IGNITION DISTRIBUTOR
:rrning spark Plugs, Removal
Disconnect both cables between the ignition coil and the
ignition distributor. Pull the vacuum hoses from the
l$rccking the ignition distributor on test bench vacuum unit. Remove the distributor cap' Loosen the
l:: cam offset, the vacuum adjustment, the centrifugal screw on the hotder for the ignition distributor. Remove
a:.*'tment and the timing angle can be checked on an the ignition distributor. Cover the opening in the crank-
r5':ron timer test bench. Various test benches of this case.
1:. are available. The following equipment applies to all
:t --:em: Controllable drive motor, tachometer, vacuum lnstallation
r-:-p and vacuum measuring instrument, which must Adjust cylinder I to the firing point. The black notch
L.Lr. an additional measuring range of 0-100 mm mercury should be in alignment with the reference mark, and the
':r :"nition distributors installed in VW engines. center-off-set slot in the head of the ignition distributor
f GNtTtoN 4-6

1000 t500 U,/min C-->

150 250 mm Hg B-->
Bosch 022 905 205 A @ volkswagen

I l5'
t
A

10"

r000 r500 U/ min C l>

r50 250 mm Hg B->
Bosch 022 905 205 B O Volkswagen

Vacuum advance curves

drive shaft should be at angle of approx. I 2o in relation to Checking

the longitudinal axis of the engine. The larger sector is If the radial play between the distributor shaft and the
outside. distributor housing is too large, replace distributor shaft
and correct the axial play by means of compensating
Turn the distributor rotor on the ignition distributor until washers. If the bushings of the distributor housing show
it points toward the mark for cylinder I on.the distributor too much wear, replace the complete distributor.
housing. Insert the ignition distributor and adjust the
ignition. If the contact breaker plate shows too much tipping play,
replace the contact breaker plate. If the wear is shown on
the distributor housing itself, replace the distributor.
Disassembly
Remove the contact breakers and remove the vacuum Assembly
governor. Remove the releasing contacts. Mark the instal- The following points must be observed. Lubricate the
lation position of the fly weights and mark the installation distributor shaft. Watch out for the correct position and
position of the driver claw in relation to the distributor the number of the steel and fabric washers on the
shaft and the distributor housing. Knock out the pin for distributor shaft. Compensate for axial play. Slide the
the driver claw with a drift. Remove the driver claw, driver claw on the distributor shaft observing its instal-
noting the location and number of washers. lation position. Attach the weights according to the
lGNtTloN 4-7

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g,t**'
ds

f Ti --:+ 10

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1 - Holder for ignition distributor
2- Ignition distributor head
3 - Distributor rotor
30 4 - Fastening screw for contact breaker
5 - Contact breaker
6 - Cheesehead screw
7 - Fastening plate $/ith lug for holding spring
8 - Fastening plate for holding spring
9 - Holding spring
13 10 - Contact breaker Plate
11 - Circlip for pull rod attachment
12 - Cheesehead screw
'11 13 - Vacuum box

' =---_-___--\
*\
14 - Capacitor
15 - Cheesehead screw
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i'è
16 - Cheesehead screw
12 1? - Spring ring
18 - Holding spring for ball
19 - Ball
6 20 - Circlip for driver claw
21 - Pin for driver claw
22 - Driver claw
23 - Compensating washer 0.1 mm
24 - Fiber washer
25 - Rubber sealing ring
26 - Distributor housing
27 - Felt washer

_-23
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lGNtTtoN 4-8

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Position of distributor drfue Rotor pointing to cylinder No. I mark

installation marks. shaft for wear. If wear of the helical teeth is excessive, be
sure to check the teeth of the ignition distributor drive
IGNITION DISTRlBUTOR DRIVE SHAFT gear. Check the washers under lhe ignition distributor
Removal drive shaft for wear; use new washers, if required. Adjust
Remove the spacing spring from the drive shaft. Pull the cylinder 1 to the firing point. At that moment, the
ignition distributor drive shaft out in an upward direction, exhaust valve on cylinder 3 will close and the inlet valve
using a puller, and turning to the left. Remove the washer will begin to open.
from under the ignition distributor drive shaft.
Install the ignition distributor drive shaft. The center-off-
On the installed engine, the washer can be removed with a set slot in the head of the ignition distributor drive shaft
magnet. On^the removed engine, turn the crankcase by should be at an angle of approx. l2o in relation to
approx, 180o so that the washir will drop out. longitudinal.axis of engine and should point approx. to
the rear fastening screw of the air filter support. The
lnstallation larger sector is outside. Insert the spacing spring.
Check the helical teeth of the ignition distributor drive
COOLING SYSTEM 5.1

coouNc sYsTEm 5
INDEX
Page Page
DESCRTPTION... .....s-1 AUTOMATIC COOL AIR CONTROL . . . .5-3
V.BELT . . .5-1 Removal " " 5-3
Checkingtension .......5-l Installation ' ' '5-3
Adjustingtension .....5-1 Adjustment .... " "5-3
COOLINGBLOWERHOUSE ....5-1 THEdMOSTAT ... . '..s-3
Removal ....5-l Checking
Installation ....5-l

DESCRIPTION
-:oling is by means of a radial blower. The impeller of
is attached to the crankshaft hub by
-: cooling blower
-:ans of three screws. The blower sucks the air through
-:: opening in the cooling blower housing, forcing it
i::oss the heavily ribbed cylinders and cylinder heads.
--: air flows through guide plates surrounding the
--. inder heads and cylinders. Some of the fresh cooling air
'. .lsed for the heating system and is heated on the
: ùaust pipes via heat exchangers.

- :hermostat under cylinders I and 2 actuates two flaps

- -he inlet ducts of the front halves of the cooling blower
:-:sing via cable controls. The flaps control the cooling
i: rolume, so that the cold engine will heat up faster and
-:; operating temperature will remain as uniformly as
-ssible under all loads. The air volume for the heating
,.:em is not influenced by these controls.

,.BELT
Jhecking tension O volkswagen
l:: V-Belt tension is correct when the V-belt can be
:.::essed in the center by approximately 112 in. by V-belt tension
::.rgetic thumb pressure, The belt should not show any
:.:es of excessive wear, such as frayed edges or slit sides.
Adjusting tension
:::ove the cover plate cover and loosen socket screw.
:-rst tension of V-belt so that the belt can be depressed
, approximately 112 in. by energetic.thumb pressure.
J:: this purpose, push the alternator to the left or right.
-,: not pry alternator with metal bar. Tighten screw.
].OOLI NG BLOWER HOUSING
iernoval
-:--i--rew three socket screws and remove V-belt pulley
,:: blower impeller together. Remove spacing washer.
i;:rove the alternator and cover plate. Note that the
- -.:Lng blower housing can also be taken off without
-::-- oving the alternator.
l
l-':onnect the cool air control cable from the shaft. ç
--j,-rew four hex. nuts, and remove cooling blower
: - :sing halves, front and rear together. -#r#
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15tallation
l,: installation, proceed as follows: Adjust throttle flap I mpeller a t ta ching s cr ew s
COOLING SYSTEM 5-2

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F-"

55
r-. ri *t 23

31
q-------=__3o
'----.-=-29
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19

s=-=_16
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7

ro
9
5

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1 - Cover for cover plate 20 - Spring washer 39 - Cheesehead screw M 6 x 10

2 - Multi-tooth socket head screw M8 21 - Cover plate for alternator 40 - Spring washer
3 - Spring washer 22- Ntenalor 4 1 - Holding spring lor shaft
4-Hex.nutMS 23 - Sealing ring for alternator 42 - Throttle valve right with shaft
5- V-belt 24 - Connecting elbow for altemator 43 - Bearing piece
6 - Multi-tooth socket head screw M8 x 39 25 - Hex. nut M8 44 - Handle for throttle valve
7 - Spring washer 26 - Spring plate 45 - Throttle valve left
8 - Washer 27 - CooLing blower housing half, rear 46 - Plug
9 - Covering cap 28 - Cooling blower housing half, front 47 - Hex, screw M 6
10 - tul1ey 29 - Hex. screw M8 x 30 48 - Roller for cooling air control
11 - Cooling blower impeller 30 - Spring washer 49 - Sealing washer
12 - Squarehead nut M 7 31 - Cheesehead screw M 6 x 30 50 - Cable for cooling air control
13 - Spring washer 32 - Spring plate 51-Hex.screwM8xl5
14 - Multi-tooth socket head screw M ? x S2 33 - Ciosing flap for air return 52 - Washer
15 - Spacing washer 34 - Sight hole cover 53 - Washer for thermostat
16 - Hex. nut M8 35 - Plug 54 - Thermostat
17 - Spring washer 36-Hex.screwM4x8 55 - Holder for thermostat
18 - Hex. nut M8 37 - Washer
19 - Cheesehead screw M6 x 30 38 - Square nut
COOLING SYSTEM 5_3

ior the cool air control. Attach elbow for alternator into
lront cooling blower housing half. Adjust V-belt tension'

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ffi
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Cooling control spring Position

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Removing cooler blower housing

AUTOMATIC COOL AIR CONTROL

Removal
--::er loosening holding springs, the righthand throttle
i-.: with shaft can be removed and the lefthand throttle
i-.: can be disconnected.
nstallation
l:: return spring should rest with its bent ends against
:-: holding spring lug and behind the cable guide.

idjustment
r'semble all control parts, lubricate joints and bearing
::.nts with molybdenum disulfide grease. Push throttle
-:s into closing position and tighten cable control.
ÏHERMOSTAT
hecking @ volks*aqen
-.:i thàrmostat in water. At l4g-158o water tempera'
--::. the pressure capsule length should be at least 1.81 in. Thermostat
ENGINE 6_1

ENGINE 6

INDEX
Page Page
DESCRIPTION... ....6-1 Adjustment .... ...6-11
ENGTNE .......6-2 SEALING RINGSFOR CRANKSHAFT. . .. . . . .6-I
Removal ......6*2 Removal . . .6-l
Installation . .6-2 Installation .......6*l
TÀPPET .....,6-3 CRANKCASE .... ...6*12
Checkup ....6-3 Disassembly ......6-12
Installation ........6*3 Checkup . . .6-12
:YLINDERHEAD .....6-3 Assembly . . .6-12

r
--.-,-..-
- - :-KUP ...6-3 CAMSHAFT . .6*12
:::,'ration . . .6-3 Checking . . .6-12
ilnrrr[*TEGUIDES - -....6-4 Installation . .6*12
l:::i.rp ....6 4 PREASSEMBLEDCRANKSHAFT ....,6-12
,llr{r-*"E SEATS . .6-5 Installation .6-12
+ :_''::shing . .6-5 CRANKSHAFT... ....6-12
,ilrr[-.95 ......6-5 Disassembly ......6-12
ï::-:r-al
'-' iino
....6-5 Checking ..6-14
........6-5 Assembly ..6-14
-:i:'lation . . .6-5 CONNECTING RODS . .6-14
;,-:-:.1{no --_:-rulL6 ....6-6 Checkup ...6-14
l::-singforleaks ....6-6 Installation ..6-15
':-:jing-in . . .6-6 Reconditioning... ..6-15
L.-ance '...6-'7 o|LPUMP ....6-15
l!- IDERS ....6-'7 Removal ......6-15
i-:noval .....6-7 Checkup ....6-15
--:ecking ...'6-'l Installation . 6-1 5
-::staliation ..6-8 OILPRESSUREVALVES .....6-16
esToNs ......6-8 Removal .....6*16
lt;moval ..".6-8 Installation .6-16
-rstallation ..6-8 otL cooLER .6-t6
l'{arkingof piston ......6-8 Checking . .6-16
E-\^,VHEEL . .6-10 OILPRESSURESWITCH .....6-16
,:ecking ...6-10 Checking ..6-16
i-stallation . .6*10 ofLFfLTER ...6*17
:::ANKSHAFTAXIALPLAY . .......6-11 Installation .6-17
lecking . . .6-ll l9T2MOD|F|CAT|ONS ......6-18

:Ë-$cR tPTloN The camshaft is mounted in the crankcase at three points

: "ngine installed in the VW-Porsche 914 is an
: in split steel bearings with babbitt metal running surface
ur*,, :,led four-cylinder, four-cycle flat four engine with and is driven by the crankshaft via helical spur gears.
ri":::,nically controlled gasoline injection, horizontally Bearing 3 absorbs the axial thrust of the camshaft. The
.: -s'd cyiinders and overhead valves. Attachment to the camshaft gear wheel is made of light metal alloy and is
u:i::\ is by means of four screws. The power unit, that riveted to the camshaft. The valves are timed by cams via
Llr :'. gearbox and the engine - is attached at the front to tappets, push rods and rocker arms. Each cam is alter-
:r : I r]' side members by means of an engine support nately actuating one valve each of two opposed cylinders.
rii:"r il :: to the crankcase and at the rear to a cross
::ii :-:-: by means of rubber-metal antivibration mounts. The four cylinders are special castings and of uniform
design, permitting individual replacement together with
*
ùi , .-1'linders each carry a
common, removable and the pertinent piston. The cooling air flows past cooling
;s;.--r' ribbed light metal cylinder head with shrunk-fit ribs for the required heat exchange.
! ,: leet rings and valve guides. The valves are suspended
L i :::3f,d. The exhaust valves are clad with particularly The light metal pistons with steel inserts carry two
:i '--:ade chrome nickel steel. compression rings and one oil scraper ring. A hose spring
ENGINE 6-2

is fitted between the oil scraper ring and the piston. The close. Unscrew hex. nut for attaching starter. Raise
piston pins are floatingJy mounted in the connecting rod vehicle. Remove exhaust muffler molding, lower compo-
eye and are laterally secured in the piston by means of nents for warm air flow, and the protective cab and
locking rings. unscrew shift rod holder.

The split crankcase is a light metal alloy die casting. Both Pull off the protective cabs, unscrew hex. bolt with ball
halves are machined together and may also be replaced and remove the rear shift rod. Remove the heater flap box
together only. with hoses and cables. Loosen adjusting nut and hex, nut
for guide roller, bend holding plate and pull the clutch
The crankshaft is a symmetrical forging, all bearing points cable forward. Loosen the drive shaft for speedometer and
are induction-hardened. The shaft is supported in the pull forward.
crankcase in four bearings. Bearings l, 3 and 4 are
aluminum bushings with lead-coated running surface, Remove the starter and loosen against connection strap on
Bearing 2 - seen from clutch end - is a split three- luggage pan. Loosen the universal shaft on the trans-
component bearing. Bearing 1 simultaneously absorbs the mission and suspend it with wire hooks from the body.
axial thrust of the crankshaft. Lower vehicle slightly. Place a garage jack with engine
support VW 61214 in combination with the transmission
The four connecting rods are steel forgings with l-shaped extension WI 61213 under engine/transmission unit and
conrod shank. They are mounted on the crankshaft in raise slightly.
replaceable three-component bearings and are provided
with steel bushings with lead bronze running surface for Unscrew 4 hex. nuts, on transmission support. Unscreu
the piston pins. socket screws, left and right on engine mount. Carefully
lower engine/transmission unit.
ENGINE
Removal lnstallation
The engine and transmission should be removed together. During installation, the following points must be ob-
Mark installation position of trunk lid on hinges and served:
remove lid. Disconnect the ground connection cable on
the battery. Remove oil bath air filter and heating air Prior to attaching the transmission to the engine on cars
hoses. Pull the cables from the fuel injection components with manual transmission check clutch throwout bearing
and piace the cable in high position. for wear (do not wash out, only wipe off). Coat the guide
bushing of throwout bearing, splining input shaft and
Disconnect the throttle valve cable and push it through bushing for starter shaft lightly with moly grease.
engine cover plate. Unbend the metal plate and separate
fuel hoses on connecting points near to pressure feeler and When positioning the engine/transmission unit, be sure

O volkswagen

Engine compartemnt

1 - Voltage supply relay 4-poie 6 - Cold starting valve 2-pole

2 - Two injection valves left 2-pole 7 - Thermal switch l-pole
3 - One throttle valve switch 4-po1e 8 - Ignition distributor release contact 3-pole
4 - Temperature feeler l-pole 9 - Temperature feeler l-pole
5 - Mass connections 3-pole l0 - Two injection valves right 2-po1e
Ëf{GlNË 6-3

*"t the fuel lines near the injection valves are not
.::eezed in and that the hand brake cables are above the
.:ghe mount. Tighten socket screws on engine mount to
-l it.-lbs., hex. nut on transmission support to 14-1 12 ît.
.::. and socket screws of the universal shaft attachment to
i l-1,'2 ft.-lbs. Use new lock washers.

--:'ust free play of clutch. Pull the engine compartment

:ci i.nto proper position. Adjust the throttle valve cable.
- -:nect cable and protective rubber caps carefully.

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Rocker arms supports

ry--

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Trans mis sio n suppor t s crew s

"{,tr.PET
Iheckup
"rL:-l the tappet face and stem for wear and scoring
:"r-r'. fappet diameter .9433*.9441 inches' Wear limit
r :-li inches.
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.r::< the push rod between the two holding devices for
:i,*::rations. Out-of-true: max. "01 18 inches. Securing clips

.".r::c the rocker arm, bearing pieces and rocker arm shaft
rr ;'.ar. Rocker arm .78'74-.7882 inches. Wear limits:
-i :] inches. Rocker arm shaft: .7854-.7862 inches.
4:i: :mit: .7846 inches, If the axial thrust surface of the
'rLr:: arms or bearing pieces are showing score marks,
'rr* '-a with a fine emery cloth. CYLINDER HEAD
Checkup
Check cylinder heads for cracks in combustion areas and
mrrdlation exhaust ducts as well as for leaks on cylinder support.
ni:r- Ihe tappet with engine oil. Slide the protective Replace damaged cylinder heads. Check spark plug
rr:"i:tr nith new sealing rings up to stop. Do not damage threads and studs for damage and tight seat' Install
h* .e:ling rings. Slide bearing pieces on rocker arm shaft helicoil thread inserts, if required.
r i::i a manner that the slots will face downwards and
ff* ::oken edges outwards when settling o! studs. The lnstallation
rnr- -:::g clip for the protective tubes should enter the Replace the sealing ring for cylinder head. Pre-tension the
ir :r; :i the bearing pieces and should rest on the bottom cylinder head nuts slightly at first and then tighten well in
r:r.Ir li the protective tubes. correct sequence. Screw on the baffle plate.
ENGINE 6_4

19

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(,1"r

16 14 15 26 25
I24 23 2. 1

@ volkswagen
Exploded view of cylinder head

I - Cylinder head cover I I - Tappet

2 - Gasket for cylinder head cover 19 - Hex. nut M 10
3-Hex.nutMT 20 - Washer
4- Spring plate 21 - Cylinder head
5- Bearing piece 22 - Cheesehead screw M 5 x 10
6- Exhaust rocker arm 23 - Washer
7- Thrust washer 24 - Cheesehead screw M 6
8- Spring 25 - Washer
9 - Inlet rocker arm 26 - Baffle plate
10 - Valve adjusting screw 27 - Yalve cone piece
11 - Hex. nut M 8 x 1 28 - Yalve spring disk
12 - Rocker lever shaft 29 - Valve spring
13 - Securing clip for protective tubes 30 - Oil deflecting ring
14 - fush rod 31 - Inlet valve
l5 - Sealing ring white 32 - Exhaust valve
16 - Sealing ring black 33 - Inlet valve guide
17 - Protective tube for push rod 34 - Exhaust valve guide

VALVE GUIDES Remove residue with a cleaning tool. place the cylinder
Checking head on the clamping plate for the cylinder head VW
When repairing an engine with leaking valves, it is not 689 ll, with the combustion chamber ends up, and screw
enough to refinish or replace the valve seats and the down together with measuring bridge. Insèrt the dial
valves, but it is also required to check the valve guides for gauge into holder and attach the dial gauge extension.
wear and replace the guides, if required. This checkup is Place a new valve into the guide to be checked and hold it
particularly important on engines which have been run- in such a manner that the stem end is flush with the guide.
ning for a long time and exhaust valve guides. Adjust the dial gauge and determine the rocker play.
ENGINE 6_5

The width of valve seats are, Intake: .0709-.0866 inches.

Exhaust: .0787 -.0984 inches.

Finish 30o surface for inlet valve. Finish 45o surface for
exhaust valve. These seats must be finished with particular
care, to guarantee a perfect concentric seat. The material
removal should be restricted to a minimum to prevent
early unusability of the rings. The refinishing must be
terminated as soon as the entire seat surface has been
covered.

Refinish 75o surface. Chamfer the bottom edge of the

exhaust valve seat ring slightly.
O Volkswagen
Refinish l5o surface. Finish the upper edge of the seat
Cylinder head nut tightening sequenee ring until the specified seat width is obtained. The valve
seat can be checked with a new valve.

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Checking valve play

lUidth of valve seat

Intake Exhaust Wear
I - \Vidth of valve seats (a):
valve valve limit 2- Intake 1.8-2.2 mm (.079-.0866 in.)
quide guide 3 - Exhaust 2.0-2.5 mm (.078?-.0984 in.)
Rocker play 0.45 mn 0.45 mn 0.9 mm
(.01?7") (.01??"
I
( . 0354" )
VALVES
ID 8.00- 9.00- 8.06- Removal
8.02 mm 9.02 mm .9.06mm Remove the valves with a valve spring compresser VW
(.3150- (.3543- (.3r-?3- 31ls. After extended operation, some burr may develop
at the contact surfaces of the valve keepers, which must
.3158") .3551") . 356?" ) be removed with a smooth file prior to pulling out valve.

Checking
Check the tension of valve springs. Length under load: 1.2
inches. Load: 160-184 lbs.

'dALVE SEATS Check the valve keepers. Any valve keepers with score
tdnishing marks can be ground down at separating surfaces until the
-r'l_;e
seats showing evidence of wear or burnoff can be valve can be turned with the valve keepers compressed.
r-i:ished as long as ^ the permissible seat width is Check all valves for wear, particularly the seat and stems.
mrtained and the 15" chamfer at its outer circumfer- When no refinishing of seat on the machine is required,
mce does not exceed the OD of the valve seat ring. If it grind in valves on valve seat rings,
o:es. replace the engine head. Exchanging valve seat rings
s :=possible with conventional shop means, since the lnstallation
rr,x foave been inserted in a chilled condition. Coat valve stem with molybdenum disulfide grease and
ENGINE 6_6

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Intake valve seat angle Exhaust vcilve seat angle

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O Volkswagen

Top & bottom chamfer angles

insert the vaive into the guide. Slide the oil scraper ring on
the valve stem. Install the valves with a valve spring
compresser VW 31 ls.

Refinishing
Valves on which the valve seat surface shows evidence of
wear or burnout, can be refinished on a valve refacing
machine or a valve grinder.

Checking for leaks

Valves can be checked for leaks by establishing a contact
pattern: Coat valve face surface slightly with surface ink.
Place the valve into valve guide and rotate under slight
pressure on the valve seat by approximate|y l14 turn. Lift
the valve from the seat. The contact pattern will then
show which spot did not support the valve. Refinish
valves, if required.

Grinding-in
With perfectly finished valve seat rings and new valves, @ volkswagen
grinding-in is not necessarily required. To grind in, coat
Co mpr es sing v alv e springs
ENGINE 6_7

one valve seat with grinding paste and insert the valve into feeler gauge can be smoothly inserted in between the
the guide. Place rubber cup with handle on valve disk and adjusting screw and the valve stem. Inserting the feeler
rotate valve while grinding. Score marks on seats can be gauge with more or less force wouid be wrong.
prevented by constantly lifting and uniformly turning of
valve during the grinding. It is imperative to carefully
remove grinding paste following grinding operation.

Vol kswagen

Valve dimensions

Intake valve Ë<haust valve

A 39.1-39.3 mm dia. 32.7-33.0 mm dia.

.5394-l .54'.r2" )
('J. (1.2874-t.2992)
B 116.8-117.3 mm 1-17.0-L1?.5 mm O volkswagen
(4.5984-4.6181") (4.6063-4.6260" ) T.D.C. position No. I cylinder
7.94-'l .95 mm dia. 8.91 -8.92 mm dia.
(.3126 -.3130") (.3508 -.3512")
d 29ogo' 450

[Iearance
dnays check or adjust valve clearance when the engine is
:rid. The intake of exhaust should be 0.004 in. When the
:rgine is warming up, the clearance will at first increase
ord rvill finally return to the set values when the operating
:::nperature is attained, Inspections during the specified
-iervals must be completed with particular cafe, Adjust-
-:nt of the valves will have the desired success only if the
;ires are perfectly sealing, if there is no unpermissible
;l)- on the valve guides and if the stem ends are not worn
: -1t.

--.ufficient clearance may cause burning of valves ot valve

;:ts. distortion of valve stem, irregular performance by
:=iuced compression, irregular running . of engine or O volkswagen
. :ernations to engine timing.
Adjus ting valu e clearance
ir:essive clearance may cause increase in noise from valve
g*"r. irregular running of engine, alternation of engine
--ring or unsatisfactory performance of insufficient filling Hold adjusting screws and tighten lock nuts. Check
:: ;1'1inders. adjustment. For additional adjustment of valves on
cylinder 2, 3 and 4, keep turning crankshaft to the left
-*-;'re clearance is adjusted in the firing order, 1-2-3-4. until the finger of the distributor rotor is offset by 90o in
-:: piston of the cylinder to be adjusted must be at TDC each case.
:i the compression stroke, because both valves will then
:e --losed. CYLINDERS
Removal
l'[:,ve cylinder I to firing point (black notch). Measure Mark cylinders prior to removal to eliminate any confu-
r.-.;e clearance with feeler gauge. sion during installation.

r-:,';st valve clearance with valve adjusting wrench and Checking

--.er gauge. The valve clearance is set correctly when the Check cylinder for wear. Cylinder seat in crankcase and
ENGINE 6_8

cylinder head, seat surfaces on cylinder and sealing rings

must be kept absolutely clean during installation. Foreign
bodies at such points may result in distortions of cylinders
and leaks. The pairing size is indicated by colored dots
(blue, pink, green) on top cooling fin.

lnstallation
Lubricate piston and piston pin. Compress piston rings
with piston ring strap VW 123d. Watch out for uniform
alignment of gaps on piston ring. The gap of the oil
scraper ring should always be on top. Fit cylinder with
cyli.nder bore lubricated. The studs on the crankcase must
not touch the cooling fins of the cylinders.

O Volkswagen

Checking ring gaP

O volkswagen

Location of sealing rings lnstallation

Clean piston. Remove carbon residue in piston ring
grooves without damaging metallic surface. Bad contact
pattern and one-sided formation of residue on piston skirt
vertically in relation to piston pin axis may be the result
of badly angled connecting rods. Check piston for wear.
use a new piston of pertinent size class, if required. The
weight difference between pistons should not exceed a
maximum of l0 grams.

Marking of piston
The letter next to the arrow designates the index of the
spare parts number of the pertinent piston and serves as a
differentiating mark. Arrow (punched-in) indicates that
the piston must be instailed in the direction of the arrow
towards flywheel.

Indication of paired size is by color dot (blue, pink.

green). Statement of weight class (+ or
-) punched-in or
printed. Indication of weight class by color dot (brown =
- weight, grey = + weight).
Fit piston and oil scraper rings. Check clearance on gap of
O Volkswagen
rings. For this purpose, slide the ring at right angle into
the bottom cylinder opening (BDC), approximately 3116
Fitting cylinders in. from the cylinder rim, pushing it with the piston.
Measure clearance with feeler gauge. Position the piston
rings with piston ring pliers only. The designation ..TOp,,
of piston rings should point to piston head. Check vertical
clearance of rings in ring grooves with feeler gauge.
PISTONS
Removal Insert the locking rings on pistons of cylinders I and 2 on
Mark pistons to eliminate any shifting or confusion during side facing flywheel, on pistons of cylinders 3 and 4 on
reinstallation. Remove locking rings for piston pin with impeller side. The piston pin bores in the piston are offset
circlip pliers and the piston pin with mandrel YW 2O7c.lf 0. 197 in. When installing the piston, be sure that the
required, remove piston rings with piston ring pliers. arrow or the letters "front" are facing the flywheel.
ENGINE 6-9

Position of rings

a - Piston dng top

b - Piston ring bottom (baffle ring)
c - Oil scraper ring with hose spring

Vo lkswagen

Placement of pistons showing pin offset

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Volkswagen

Piston pin bore offset

A:0.0197 in.

r-heck and fit piston pin. Depending on occuring toler-

:-qces, the piston pin may aheady slide easily by hand into @ volkswagen
piston when it is still cold. This is absolutely normal, Che cking ring clearance
=e
:-';en if the piston pin should fall out by its own weight.
nhere is no reason to replace the piston pin, the piston or
:oth, in such a case.
Vertical clearance Wear limit
[: the clearance between the piston pin and the conrod in mm in mm
--':shing approaches the wear limit of .0016 in., replace
;sion pin and fit into a new conrod bushing. The piston Piston ring 0.06-0.09 0.12
uould be heated, whenever a pin does not easily enter the top (.0024-,0035") (.004?")
:iston. Heat the piston to âpproximately 1?6oF then,
.'de in piston manually with mandrel VW 207c and Piston ring 0.04-0,0? 0.10
;ilhout stopping against stop on locking ring. Insert bottom (. 0016 -.0028" ) (.0039")
locking ring. The locking ring should be seated Oil scraper 0.02-0.05 0 .10
'<,-ond
;:rfectly and all-around in the pertinent $oove of the ring (. 0008 -. 0020" ) (.0039")
:iton pin eye.
ENGINE 6-10

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Exploded view of uankcase & flywheel

1 - Hex. screw M 12 x 1.5, self-securing 12 - Hub for impeller 25 - Hex. screw M 8 x 113 oil tube
la - Multi-tooth socket screw M 12 x 1.5 13 - Plate spring attachment
2 - Washer 14 - Rubber sealing ring for hub 26 - Hex. nut
3 - Felt ring for needle bearing 15 - Sealing ring for crankshaft 62 mm dia, (2.4") 27 - Spring washer
4 - Flywheel 16 - Hex. socket screw 28 - Hex. screw M 8
4a - Carrier plate 17 - Spring ring 29-HexnutM6
5 - Needle bearing 18 - Engine mount 30 - Spring washer
6 - Rubber sealing ring for flywheel 19 - Hex. screw M 8, self-securing 31 - Ignition cable holder
7 - Clamping sleeve 20 - Support for engine mount 32 - Hex. screw M 6
8 - Sealing ring for crankshaft 95 mm dia, (3,7") 21 - Sealing nut M 10 x 1.25 33 - Sealing ring
9 - Spacing washer 22 - Washer 34 - Cover lor oil pan
10 - Hex. screw M 8 x 30 self-securing 23 - Hex. screw M 10 x 1.25 x 213 35 - Sealing ring for cover
11 - Washer 24 - Sealing ring 36 - Crankcase

FLYWHEEL
Checking lnstallation
Check the flywheel for broken or damaged teeth. Dam- Grease the needle bearing in the flywheel only with
aged teeth can be turned off from the clutch end up to a approximately 0.012 cu. in. multi-purpose gease, if
maximum of 0.080 in. Following the deburring, chamfer bearing has been washed. Moisten felt ring with engine oil.
tips of teeth again. Check bores for hex. screws and Wipe off excess lubricant.
clamping sleeve. If bores are wom out, replace flywheel.
Watch out for correct seat of needle bearing. The contact When tightening hex. bolts, hold the flywheel with
surface for the clutch lining must be free from oil, gtease holding clamp VW 215c. Adjust a\ial play of crankshaft.
and preservation agents, clean, if required. Lubricate running surface for seaLing ring.
ENGINE 6-11

On engines of vehicles with a Sportomatic transmission, gauge holder VW 65912 with one dial gauge to crankcase.
the flywheel is replaced by a carrier plate screwed to the Move crankshaft back and forth in axial direction. Read
crankshaft with five socket screws. The felt ring and the axial play on dial gauge.
needie bearing in the flywheel are also eliminated. When
loosening and tightening socket screws, hold carrier plate To compute thickness of third spacing washer: Measuring
with holding ring VW 184. result - 0. 10 mm mean axial play = 3rd spacing washer.

Remove flywheel. Insert sealing rings for crankshaft and

flywheei, as well as felt ring. Install flywheel with all three
spacing washers and new supporting ring. Check axial play
again.

Spacing washers are provided in several sizes, The thick-

nessof each washer is etched in for proper identification.
Measure thickness with screw gauge, if required. Always
install three spacing washers for the required total
thickness.

SEALING RINGS FOR CRANKSHAFT

Removal
Prior to removing sealing ring on impeller end, force off
impeller hub with the assistance of plate VW 185.

O volkswagen

Flywheel installation

I - Washer - Rubber sealing ring for flywheel

8
2 - Clamping sleeve - Flywheel
9
3- Felt ring 10 - Sealing ring for crankshaft
4 - Hex, screw 1l - Spacing washers
5 - Drive shaft 1 2 - Crankshaft bearing I
6 - Needle bearing 3 - Crankcase
1
O Volkswagen
7 - Spacing ring 14 - Crankshaft
Removing crankshaft seal

CRANKSHAFT AXIAL PLAY

Checking lnstallation
The axial play of the crankshaft is .0028-.005 1 inch. Clean seats for sealing rings in crankcase and coat thinly
sear limit is.0059 inch. The axial play is measured with with sealing compound. Chamfer outer edges with scraper,
::e engine assembled and the flywheel screwed on. if required, so that the circumference of the sealing rings
is not damaged, Remove clips. Insert new sealing ring on
>;rew dial gauge holder VW 65912 to an engine attach- flywheel end with fitting tool VW l9l. For this purpose,
::ent stud of the crankcase. Move the crankshaft back and screw tool into crankshaft and tighten guide piece with
:,rrrh in axial direction. The axial play is indicated on a the sealing ring attached. The sealing ring should be seated
l'al gauge. on the base of the recess of the crankcase and should not
be out of alignment, Insert new sealing ring on the
Adjusting impeller end with fitting tool VVV 190. Lubricate running
i:sta11 flywheelwith two spacing washers (but without surfaces for sealing rings on flywheel or impelier hub,
.e:ling rings for crankshaft and flywheel). Screw dial respectively.
ENGINE 6_12

axial play on guide bearing is, .00 16-.0051 inch with a

wear limit of .0063 inch.

Check backlash along the entire circumference of the

camshaft gear. The backlash between the camshaft and
crankshaft gear is .002 inch. The camshaft gear has the
correct size, when the play is hardly felt and when the
camshaft does not rise when the crankshaft is turned
backwards. To facilitate establishing the specified play.
camshafts with camshaft gears are available in several sizes
carrying different part numbers. The gears are marked on
the surface facing the cams by punched in numbers,

I nstallation
Install the camshaft gear in such a manner that the tooth
marked with O is located between the two teeth of the
crankshaft gear which are identified by a punch mark.

O Volkswagen
Installing seal

CRANKCASE
Disassembly
Loosen righthand crankcase half with assistance of a
rubber hammer. The parting surfaces of the housing
should not be damaged by sharp-edged objects, for
example a screw driver.

Checkup
Check crankcase for external damage and cracks, Clean
parting surfaces with solvent from residue of old sealing
compound. Check parting surfaces for flatness and clean-
liness. Lightly chamfer the edges of bearing bores, if
required. Flush oil ducts and blow out with compressed
air.
@ volkswagen
C_heck studs for tight seat. If tapped holes are worn out,
HeliCoil inserts may be screwed in. The tapped bores in Timing gear marks
the housing should be a diameter of .9449*.945j inch
with a wear .limit of .9469 inch. Assemble the crankcase
and tighten to specified torques. Check housing bores for
crankshaft bearing with internal measuring gauge and
screw gauge. PR EASSEMBLED CRAN KSHAFT
lnstallation
Assembly The oil outlet holes of the crankshaft bearing journals and
Coat the parting surfaces of housing halves uniformly thin the bearings should have no sharp edgesl If metallic
with sealing compound. Never permit sealing compound foreign bodies are embedded in the Àain bearings, remove
to enter the oil ducts of the crankshaft and camshaft with, sharp scraper. Do not damage the bearing shell.
bearings. Assemble housing halves and lightly screw down Check set pins for tight seat and peùect fit in crankshaft
fastening screw for oil intake pipe withnew sealing ring bearings., N-ote markings of timing gears when installing
first. Then screw on sealing nuts with the sealing ring on the camshaft.
the outside and tighten. Then tighten hex. nuts. Rotate
the crankshaft to check for easy running. CRANKSHAFT
Disassembly
CAMSHAFT Remove the locking rings for ignition distributor drive
Checking gear with circlip pliers. Do not store removed crankshaft
Check riveting of the camshaft gear and camshaft. Check without coating of oil or grease. Remove the ignition
camshaft for wear on bearing points and cams. Check distributor drive gear, intermediate ring and crankshaft
camshaft for out-of-true. The maximum limit is .00g inch gear on repair press
in combination with holding rails
with a wear limit of .0016 inch. Check camshaft gear for from VW 457. Slieht seizirig marks may be caiefully
wear and perfect contact pattern. Check axial play. The removed. but without impairing press seat.
ENGINE 6_13

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Disasse mbled crankcase & crankshaft

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1- Camshaft Parts not shown in illustration which must be inserted into

l - Crankshaft with conrods righthand crankcase half prior to assembly:
3 - Crankshaft bearing I
4 - Crankshaft bearing 4
5 - Closing cover for camshaft 1 2- Fitted pin for crankshaft bearing 2
6 - Bearing shell for camshaft bearing 1 13 - Bearing shell for crankshaft beating 2
? - Bearing shell for camshaft beaing2 14 - Bearing sheil for camshaft bearing 1
8 - Bearing shell left for camshaft bearing 3 (with guide collar) 1 5 - Bearing shell for camshaft bearing 2

9 - Fitted pin for crankshaft bearing 16 - Bearing shell right for camshaft bearing 3
iù - Bearing shell for camshaft bearing 2 17 - Oil intake pipe
i 1 - Crankcase housing left 18 - Sealing ring for oil intake pipe.
ENGINE 6_14

grams, which are also available as spare parts. Refinishing

is therefore not required. The color coding is on the
connecting rod cap.

Check conrod bushing. In a new bushing, the normalLy

tempered piston pi.n should slip in easily under light finger
pressure. Square connecting rod in testing fixture V\l-
214fl7O; and straighten if required.

@ volkswagen
Bearing securing pins

During Wear
installation limit
(new)

Crankshaft 0.04-0.10 mm 0.18 mm

bearings 1+3 (0.0016 -0.0039") (0" 0071")
Crankshaft 0.03-0.09 mm 0.1? mm
bearing 2 (0.0012-0.0035") (0.006?")
Crankshaft 0.05-0.10 mm 0.19 mm
bearing 4 (0.002 -0.0039" ) (0.0075 ")
@ Volkswagen

Removing ignition distributor drive gear

Checking
Check the crankshaft for out-of-true, cracks (resonance
test) and wear. If required, regrind the crankshaft or
replace. Clean the crankshaft and blow compressed air
through oil ducts. Inspect bore of crankshaft gear and
ignition distributor drive gear lor seizing marks and check
contact pattern of teeth.

Disassembly
Heat the crankshaft gear in oil bath to approximately
176-F and fit in combination with VW 42i and VW 415a.
The chamfer should face the crankshaft bearing. Fit
intermediate ring. The ignition distributor drive gear is
pressed on in the same manner. Slide on the locking ring
in combination with VW 428 and VW 415a. The cônical
guide sleeve VW 428 prevents any damage to the
crankshaft bearing pin. Check gears for tight seat when
cold.

CONNECTING RODS
Checkup
Check connecting rods for externai damage. Replace the
entire connecting rod, even if only the bolts are damaged.
Check connecting rod weight. The difference in weight of
the connecting rods in one engine should not exceed 6
grams. Conrod weight = conrod complete, but without
bearing shells. Two weight classes are available for O volkswagen
installation, white = 746-752 grams, black = 769-7j5 Corre c ting s ligh t dis t ortions
ENGINE 6_15

lnstallation Reconditioning
The code numbers on the parting joint of the connecting Connecting rods which are slightly bent or have worn
rod top and bottom should be located on same side. Slight bushings, must be squared and provided with new
distortion which may occur when tightening the conrod bushings, Remove small end bushings in VW repair press
bolts between the bearing halves may be removed by in combination with VW 402,VW 409, VW 416b, and VW
applying light hammer blows against both sides of the 421.
connecting rod. The connecting rod should slide under its
own weight. Any refinishing or recessing of bearings is Insert the connecting rod in fixture VW 214f l7O. Turn the
never permitted. mandrel in such a manner that the milied surface is
crosswise to the center axis of the connecting rod. After
fitting washer, tighten locking lever only to the extent
that the connecting rod is still movable in both directions.
Support is loose.

Introduce bolt into the conrod eye and push with two
fingers in the direction of mandrel in such a manner that
no canting will occur between the receiving mandrel and
the conrod bearing or between the conrod eye and the
bolt. Check the connecting rod for distortion and parallel
alignment. If there are deviations, tighten locking lever
well and straighten the connecting rod with straightening
mandrel.

Install small end bushing on WV repair press in combina-

tion with VW 402, VW 409, and VW 421. DrtJl, oil holes
(.14 inch). Place rod of reamer through the conrod eye
and pertinent bore of fixture, with the conical guide
bushing serving for centering the small end bushing.
Tighten locking lever and support for holding the connect-
ing rod.

Following the reaming, the inside surface of the bushing

should be free of score and chatter marks. The piston pin
O volkswagen should slide in easily under finger pressure and without
Checking conrod end PlaY using oil. If the bushings have been reamed too much by
mistake, the excessive play between the piston pin and the
bushing should not be compensated for by installing an
oversized piston pin. Always use a new bushing and ream.
l le axial play of the connecting rod, measured with a
::eler gauge, should be .004-.016 inch, with a wear limit Check parallel alignment and distortion once again, this
:: .026 inch. Secure hex. nuts with peening punch. time with the piston pin inserted as described above. Any
slight differences can be straightened out by introducing a
mandrel into the piston pin.

OIL PUMP
Removal
Remove oil pump with two mounting levers. Pull oil
pump cover with puller VW 803.

Checking
Check the oil pump housing and the oil pump cover, in
particular bearing points of gear wheels prior to instal-
lation, for wear. Scored parts will result in pressure losses.
Check contact surface for oil pump on the crankcase for
cleanliness and damage.

lnstallation
The following points must be observed: Lubricate the gear
wheel and the drive shaft and insert into oil pump
housing. Install oil pump cover with lubricated rubber
sealing ring into the housing. Following assembly, check
the gear wheels for perfect running. Install the oil pump
with new seal into the crankcase. The journal of the drive
Voikswaqen shaft should be in alignment with the slot in the camshaft
gear. Center oil pump by two crankshaft revolutions and
Securing conrod bolt tighten hex. nuts.
ENGINE 6-16

@ volkswagen
Exploded view of oil pump (Sportomatic)

1 - Sealing nut M 8 9 - Sealing ring for intermediate plate

2 - Closing screw 10 - Intermediate plate
3 - Spring 1l - Plate spring
4 - Piston 12 - Shaft bottom with gear wheel inside
5 - Cover 13 - Shaft top with gear wheel inside
6 - Seal for intermediate plate and cover 14 - Housing for double oil pump
7 - Gear wheel outside top l5 - Seal for oil pump housing
8 - Gear wheel outside bottom

lnstallation
Check piston and bore in the housing for score marks.
Remove score marks carefully and leplace piston, if
required. Check spring. To prevent any dàmage to bore in
the housing, be sure that the upper end of thà spring does
not wipe against housing.

OIL COOLER
Checking
Check oil cooLer for leaks and tight seat of all welded
plates. Test pressure to 85 psi. Leaking oil cooler: check
oil relief valve.

Check oil relief valve in the event of trouble in the oil

circuit, but definitely if the oil cooler leaks. If the piston
binds at TDC there is the danger fhat the oil coolèr will
develop a leak when the oil is thick. Binding at BDC will
cause the oil to flow directly into the ciankcase and
lubrication of the warm engine will then be insufficient.
@ Voikswagen
OIL PRESSURE SWITCH
Removing oil pump cover Checking
The check is made with the engine at operating tem-
perature, using a plain tester with pressure gauge and
inspection lamp. Unscrew oil pressurè switch ànd screw
OIL PRESSURE VALVES into tester. Insert the tester into the crankcase instead of
Removal the oii pressure switch, and connect inspection iight to oil
A binding piston can be pulled out after screwing in a tap. pressure switch on the one hand and to terminal l5
of the
ËNtGlNË 6-17

'Cnition coil on the other. Switch on the ignition, and the

rspection light should go on. If the light does not go on,
::piace switch.

i=rt engine, Pressure rise on pressure gauge as the speed

:;reases, while the light should go out. The contact of
:: switch should rernain closed and the lamp should light
-; as long as the oil ptessure is under 6.4 psi. Stop engine.
Ile lighting up of the inspection light might be delayed
r:,rewhat, since the oil pressure drops slowly. The oil
;:.issure switch is sealed by means of the tapered threads.
--ron installation, the switch should not be tightened
*-;essively to prevent any damage to threads,

O{L FILTER
mrtallation
,-:ck the sealing surface on the flange of the oil filter for
:reanliness. Lubricate rubber seal slightly. Screw the filter
.r =anually until seal is seated. Tighten the oil filter with
ffanrrer. Fill up with engine oil. Start engine and check
::: leaks. Check oil level and fill up with oil, if required.
O Volkswagen
Removing oil pressure switch

O volkswagen

Oil circuit diagram

ËNGINE 6_18

1972 MODIFTCAT|ONS in earlier engines, from engine + W 0 074 387. From this
engine number on, the crankcase has been provided with
OIL BAFFLE PLATE the required special ribs.
Description
The engine is provided with an oil baffle plate to ensure
the oil intake pipe remains submerged in oil when car
corners sharply. A shaped seal around the baffle increases
the baffles efficiency while preventing noise. The baffle,
in conjunction with a new oil intake pipe, can be installed

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@ yolkswagen @ Volkswagen
Oil baffle plate installed Oil baffle plate
CLUTCH 7_1

ctuTcH 7
INDEX
Page Page
DESCR|PT|ON... .....7-l CLUTCH DISC . .7-2
Removal .....7-l Inspection . .7 -2
Installation . . .'7-l CLUTCH DISC LINING . .7-2
Inspecting .....7-2 Removal and replqcement . . . .7 -2

DESCRIPTION lnstallation
he single plate dry clutch between the engine and the Clean the contact surface of the clutch disc in the
-ain gearbox is fitted to the flywheel. The clutch disk is flywheel and check it for wesr. Surface cracks and score
-red on two sides and slides on the splined input shaft of marks can be removed by grinding or machining. If
transmission in axial direction. The clutch cover, the required, replace the flywheel. Coat lightly the needle
=:
:-;tch pressure plate and the diaphragm spring are bearing in the flywheel with multipurpose grease, only
::ncentrically screwed to the flywheel. In engaged con- after it has been cleaned. Moisten the felt ring with engine
'rion, the clutch disk is pressed by the clutch pressure oil. Wipe off the excess lubricant. Check the clutch and
;ite against the clutch facing of the flywheel by the the clutch disc.
çring force of the diaphragm spring. The power con-
rrction between the engine and the transmission is
:3reby established.
Flernoval
1e original position of the clutch on the flywheel should
le marked, to eliminate a major unbalance during
Loosen the fastening bolts uniformly. Loosen
=;ssembly.
:: bolts alternately and crosswise, by one or two turns,
r::i-l the spring action stops, in order to eliminate any
rsrortion of the cover.

O Volkswaoen

Clutch with alignment shaft installed

Check the splines of the input shaft and coat lightly with
molybdenum disulfide powder. Apply the powder with a
brush or a piece of non-fraying cloth. The clutch disc
should slide easily without excessive radial play. Check
the clutch throwout bearing. The throwout bearing
requires no service. Do not wash or flush with cleaning
O volkswagen gasoline or other cleaning agents, but only with a clean
Alignment marks cloth.
CLUTCH 7_2

Replace the bearings which are contaminated or defective. up to 0.012 in. are of no significance. Check rl-:
Check to see that the holding springs are properly seated. supporting surface of the pressure plate for cracks, burne:
Grease the guide bushing lightly with molybdenum spots and wear, Pressure plates which are bent inwards. u:
disulfide paste. Now, insert a clutch with a clutch disc to 0.01 2 in. are still fit for installation.
into the flywheel. Accurate centering of the clutch disc is
performed with the assistance of an extra input shaft. Inspect the spring connections between the pressure plal.
and the cover for cracks. Check all rivet connections for i
Check the balancing marks. When a new clutch is tight seat. The diaphragm spring is mounted on the cov;:
installed, the balancing marks on the clutch and the between two wire rings by means of a rivet connectior
flywheel should be offset by 1 80o. Clutches with visible wear on the rivet head or the wi::
ring should be replaced.
Tighten the fastening bolts uniformly and crosswise to
t4-r l2 ftltb. CLUTCH DISC
lnspection
lnspecting The clutch disc should slide easily on the input sha;:
The inspection of the diaphragm spring clutch is restricted without excessive radial play, Replace worn parts. Checi
to a thorough sight test. Any reconditioning or repairing all riveting; ieplace the clutch disc, if required. If th..
of the clutch in workshops is not intended. spring elements or the driver plate are cracked, completei;..
replace the clutch disc.

Replace worn, cracked, oily or burned clutch lining:.

Check the clutch disc for lateral wobble. A max. of 0.01[r
in. at a 8.2'74 in. dia. is permitted. Straighten slightli
distorted discs with a rubber hammer.

CLUTCH DISC LININGS

Removal and replacement
Unusable linings may not be removed by tearing them oif.
but by drilling the rivets on the rivet head end. Use on1)-
linings that are approved by Volkswagen. - Flywheel end:
Jurid or Textar; Clutch end: Textar. For attaching the
clutch linings on the clutch disc, use 2 mm (0.078 in.) dia.
rivets.

@ volkswagen
Checking flatness of pressure plate

O volkswagen
O volkswagen
Riveting on new clutch facings
Mounting of diaphram spring

When riveting, be sure that the rivet shoulder is always

Check the ends of the diaphragm spring for wear marks inserted into the larger bore of the double lining spring.
(support of the clutch throwout bearing). Wear marks of Riveting is done on the clutch lining. Riveting the clutch
i

CLUTCH 7_3

rivet header, but be sure not to turn the header.

Double-punch the individual rivet segments with a die.

Upon application of the iining, check the clutch disc for

out-of-true. The maximum permissible lateral out-of-true
(measured at 8.274 in. dia.) is 0.020 in.
MANUAL TRANSMISSION 8-1

TRANSMISSION, MANUAL 8

INDEX
Page Page
IESCRrPT|ON.... ...8-1 Disassembly .8-10
Transmission removal and assembly . . . .8-1 Assembly . . .8-10
SII.IIFTLEVERASSEMBLY .....8-1 SHIFTFORKS ......8-11
Disassembly ........8-1 Adjusting . . 8-11
.\ssembly . . .8-l INTERMEDIATEPLATE ..,..8-12
-TNKAGE ....8-3 Disassembly .8-12
-\djusting . . .8-3 Assembly . ' 8-12
*BANSMISSION.. .....8-3 DRIVESHAFT "...'8-12
Disassembly ........8-3 Disassembly ......8-12
-{ssembly .. . .8-6 Assembly '..8-14
iEARTRANSMISSIONCOVER .......8-9 SYNCHRONIZER. ...8-16
Disassembly .......8-9 Disassembly . '. '. '8-16
-\ssembly . .8-10 Assembly ' .8-16
-RANSMTSSTONHOUSING ...8-10 Checking . ' 8-17

:.ÊSCRIPTION
la. Porsche synchromesh system uses servo-thrust forces
: s1'nchronize the transmission gears. Friction created
:r-.,ieen synchronizing ring is increased by the servo-lock
:. -;onent contained within the synchronizing ring.

,- :orward speeds of the transmission have identical

'-:hromesh components with the exception of the lst
*,: *hich is used for starting. Care was taken to ensure
.r:: thts starting gear engages with the least amount of
r: ,:i when the car is not in motion.
-:rnsmission removal & installation
-:. transmission is removed complete with the engine'
i.- :ngine section for details'
îrrFT LEVER ASSEMBLY
I'sassembly
' r-r the shift iever in a vise equipped with soft jaws' Pry
i': àe shift knob using a self-made lever' Pull the
":::-:rrig ring out of the shift knob with a hook' Remove
::* ::;fi bodt and pry the plastic ball socket off the shift O volkswagen
;".=: n'ith a screwdriver.

- r-p the shift lever mounting bracket into the vise' Use Removing gear shift knob
.;-: l*hen removing the bracket because the guide pin
ffr--:gs are under tension and may fly out. Remove the
.rL-:: pin snap springs and the retaining parts.
Assembly
Push the lower spring seat on the shift lever compression
spring until the spring is seated. Coat the lower part of the
shift lever with moly grease and insert the lever into the
shift bracket.

To install the guide pin springs, first position the stop

plate to the shift bracket of the guide pins. Next, insert
O volkswagen the second guide pin with the snap ring at an angle and
Tool for removing knob slip the spring over the pin. Carefully push one end of the
MANUAL TRANSMISSION A_2

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Exploded view of shift lever assembly

MANUAL TRANSMISSION 8-3

LINKAGE
Adjusting
The linkage can be adjusted at the front shift rod, the
connector rod and the rear shift rod by either changing
the lengths or by turning the rods. Loosen the clamp
between the lront shift rod and the connector rod. Move
the shift lever into neutral. The lower end of the shift
lever should be in the vertical position when seen from the
side. Rest the shift lever against the left stop.

Remove the dust cap on the transmission for the rear shift
rod. Move the selector lever into the neutral position and
center the selector lever by sliding the rear shift rod.
Tighten the clamp between the front shift rod and the
connector rod.

Select 3rd gear with the gear shift lever. Check whether
the selector lever, at the transmission, is correctly en-
gaged. Adjust if necessary. Test drive and check to see
that all gears engage smoothly.

TRANSMISSION
Disassembly
Attach the transmission to a stand and drain the transmis-
sion oil. Loosen the nuts on the rear transmission cover.
Remove the four nuts and take off the shift lever cover
plate, on the bottom of the transmission cover. When
removing the transmission cover, the components on the
O Volkswagen idler shift may fall out. Remove the rear transmission
cover while turning the shift lever shaft siightly counter-
Installing guide pin springs clockwise. This disengages the shift lever from the shift
rod.

Loosen the bolt on the shift fork for lst and reverse gear
and remove the shift gear together with the shift fork.
n'n:: rnto the cutout. Align the spring and push the pin
u :--pletely. Now, install the spring on the other guide
ml - Ihe same manner and then slide on the shift boot.
nnic:' a new retaining ring into the shift knob. Place the
iun:': linob on the lever so that the shift pin is in the
-ilr:::i position.

O volkswagen O Volkswagen

Shift rod clamp First & reverse gear shift fork bolt
MANUALTRANSMISSION 8-4

Withdraw the intermediate plate with the gear assembi,,

-f from the transmission housing until it clears the studs
Then turn the intermediate plate assembly slightly to th-:
.w right and remove it. (If necessary, tap the intermedia:.
plate lightly with a soft mallet.) Note the quantity an:
xrt- thickness of the gaskets between the transmission housir;
and the intermediate plate. Place the intermediate pla:.
with the gear assembly in a vise equipped with soft ja:
caps.

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Engaging 5th gear

Engage 5th gear (turn the shift rod to the right and pull it O volks*agen
out). Lock the drive shaft with a holding plate. Loosen
the expansion bolt of the pinion shaft with an insert (do Removing inter mediate plate
not remove it). Remove the spiral pin of the castle nut on
the drive shaft with a mandrel and loosen the castle nut
(do not unscrew it).

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Removing backup light contact pin

Engage neutral. Unscrew the backup light switch and pull

out the contact pin. Loosen the nuts on the fork piece for
the internal shift lever and pull out the fork piece. Pull the O voikswagen
irtternal shift rod out of its guide. Engage 5th gear, by
placing a screw driver through the hole in the fork piece. Removing guide sleeve, lst & reverse gear
MANUALTRANSMISSION 8-5

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MANUALTRANSMISSION 8-6

Remove the pinion shaft expansion bolt. Remove the

guide sleeve and lst and reverse gear using two screw
drivers. Remove large first gear (gear II), the race, the
needle bearing cage, and the thrust washer. Remove the
castle nut and small first gear (gear I) from the drive shaft.
Engage neutral. Loosen the gear interlock retaining bolt
and remove the spring,

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Installing drive & pinion shafts

To prevent damage to the gears, make sure that the gears

are properly meshed before pressirrg on the inner half oi
the pinion bearing race. Engage 5th gear, and install th;
intermediate plate assembly in the transmission. Tempo-
rarily fasten the intermediate plate to four of the housin,s
@ volkswagen studs (use spacer bushings). Hand tighten in a crisscros
pattern.
Removing drive shaft from intermediate plate
Lock the drive shaft with a holding plate. place small firsr
gear (gearI) on the drive shaft. Install the castle nut with
a washer and tighten to the specified torque. Then secure
the castle nut with a lock pin. Slide the thrust washer.
with the small collar toward the bearing, on to the pinion
Remove the shift rod for lst and reverse gear as well as shaft, together with the race for the needle bearing.
the ball for the gear interlock. Put identifying marks on
the assembly to ensure proper installation. Loosen the Install the needle bearing and large gear of lst gear (gear
retaining bolts for the 2nd and 3rd gear shift forks. II). Install the guide sleeves for lst and reverse gear.
Remove the shift rod, the shift fork and the locking piece. Lubricate the thrust surface of the pinion shaft bolt (with
speedometer drive), and adjust to specifications. Remove
Loosen the retaining bolt of the 4th and 5th gear shift the intermediate plate with the pinion and drive shafts.
fork. Remove the shift rod, and the ball for the gear Clamp the intermediate plate with the gear assembly into
interlock. Remove the gear interlock, the ball, the spring a vise equipped with aluminum jaw caps.
and the locking pin. When pressing out the pinion and the
drive shaft, ball bearings may fali out. Press out the pinion Engage neutral. Install the shift rods and the shift forks as
and the drive shafts from the intermediate plate using a described below. Place the shift forks for 4th and 5th gear
thrust piece. on their respective shifting sleeves. Slide the shift rods for
4th and 5th gear up into the hole of the intermediate
Assembly plate. Attach the shift piece on the shift rod with a lock
Position the intermediate plate on the inner race halves of pin. Tighten the bolt for the shift fork with a wave
the pinion and the drive shaft bearings. Slide the tubing washer,
on the drive shaft. Position the shaft on the thrust plate.
Press on the inner bearing race using suitable tubing. Hold Insert a ball into the connecting duct of the shift rod
the pinion shaft in position. Remove the tube from the bores. Coat the lock pin and the iong spring with grease
drive shaft. Position the pinion shaft on the thrust plate and insert them at the same time. Next, insert another
and press on the inner half of the bearing race, ball.
MANUAL TRANSMISSION 8_7

lst and reverse gear, together, on to the guide sleeve and

the shift fork. Slightly tighten the bolt (with a wave
washer) for the shift fork. Adjust the shift forks. Check
the interlock springs and replace them if necessary.

Attach the selector lever to the inner shift rod with a

clevis pin. Make sure that the lever is properly positioned
and fastened with a cotter pin. Place the correct number
of gaskets on the transmission housing. When inserting the
gear assembly, be careful not to damage the drive shaft
seal. Replace the seal if necessary.

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Installing thrust washer l3

14

15

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1,.:e the shift fork for 2nd and 3rd gear on to their
:-i?ective shift sleeves and slide the shift rod for 2nd and Shift rod detent assembly
i:: gear up into the hole of the intermediate plate. The
tr--: and 5th gear shift rod should be in the neutral
1 - Intermediate plate
;':srtion. Push the 2nd and 3rd gear shift rod until the ball
'-":s in the groove. Slightly tighten the bolt (with a wave 2 - Shift rod for 4th and 5th gear
i.il1s1)for the shift fork. 3 - Ball
4 - Bushing for gear lock
-,.:rt detent for the gear interlock. Make sure that the 5 - Spring (large) for gear interlock pin
-:: and 3rd gear shift rod is in the neutral position. Insert
--.
6 - lnterlock pin
shift rod for lst and reverse gear. Now, insert a ball 7 - Ball
,-: a short spring. Tighten the retaining bolt to the B - Shift rod for 2nd and 3rd gear

- -:::ct torque, Slide the shift fork and the shift gear for 9 - Bushing for gear lock
10 - Detent
11 - Shift rod for 1st and reverse gear
12 - BaIl
13 - Bushing for gear lock
*iff L.,g:,,r:;jri;l"WM I&r&X S 14 - Spring (small) for gear interlock
15 - Retaining bolt

Engage 5th gear and insert the intermediate plate with the
gear assembly into the housing. Engage neutral and insert
the inner shift rod into its bushing. Make sure that the
selector lever engages correctly in the shift rod gates.
Install the fork piece with a new gasket. Be sure that the
inner shift lever is guided in the fork piece.

Tighten the nuts to the specified torque. Place the needle

cages and the spacer sleeve on the first and reverse idler
gear shaft (located in the rear transmission cover). Place a
new paper gasket on the intermediate plate. Insert the
O volkswagen bearing cages and the spacer bushing onto the reverse idler
shaft. Install the reverse idler gear axial bearing and the
Installing fork piece for internal shift lever thrust washer.
MANUAL TRANSMISSION 8_8

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MANUALTRANSMISSION 8-9

;'-th the cover ready for installation, pull the thrust from the idler shaft. Check all parts for wear and damage
":shet, the axial bearing and the idler gear as far to the and replace, if necessary.
: :nt of the idler shaft as possible. This enables the idler
i-:r to be guided across the first and reverse shifting gears.
ll:-ke sure that the thrust washer is aligned in such a way
.:.rt the outer collar of the pinion shaft ball bearing fits
-:c the indentation of the thrust washer.
!,.1t pushing the rear transmission on cover toward the
-:;rmediate plate. Engage the shift lever with the shift
:-: before positioning the rear transmission cover on the
:,=:e. Tighten the nuts for the rear transmission cover and
:; ;over inspection plate to the specified torque. Position
:; contact pin for the backup light switch. The long end
;:u1d point toward the shift rod. Tighten the switch to
-:: >pecified torque.

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Shaft lever pin

O volkswagen

Removing seal & bushing

O voikswagen
Position of thrust washer prior to final assembly

T :.AR TRANSMISSION COVER

!rsassembly
- :,-!!n the bolt for the speedometer drive and pull out
rhi::iter drive. Remove the cover plate from the bottom
ri :- transmission cover. Knôck the lock pin out of the
:nr:, lever shaft. Pull out the shaft, while removing the
iu-: lever from the shaft. Pull out the seal and the
-.-.- :.g with a pullet/washer combination.

ti*:,,:., out the lock pin for the reverse idler shaft. Heat
i:* ::ansmission cover to approx. 120oC (250oF) and
iir -:i out the idler shaft in an inward direction. Then
rr:-;i the thrust piece and the bushing for the speed- @ volkswagen
n -::r drive, Remove the inner bronze thrust washers Reverse idler shaft lock pin
MANUAL TRANSMISSION 8-10

Assembly drive shaft assembly installed, remove the seal rvith r

Heat the transmission cover to approx. 248oF.lnstall the suitable tool. Do not damage the bore or the seat.
reverse idler shaft. Make sure that the oil hole points
downward at an angle. Be sure that the hole for the lock
pin, in the housing and in the shaft, align. Install the lock
pin. Insert the bushing for the speedometer drive pinion
and the thrust piece for the speedometer drive.

Install the bushing for the shift lever shaft and insert the
seal. Insert the shift lever shaft while simultaneously
sliding the shift lever onto the shaft.

The opening of the shift lever shaft and the shift lever
should point upward. Heat the bronze thrust washer to
approx. 248-F and slide it on the reverse idler shaft. Make
sure that the thrust washer is flush against the cover, so as
not to reduce the end play of the reverse idler gear. Insert
the miter drive for the speedometer. Align the blind hole
in the guide piece with the hole in the housing. Install the _Y
bolt with a spring washer and tighten to the specified
torque. O volkswagen

Removing bearing races

TRANSMISSION HOUSING
Disassembling
Remove the transmission cover, manual gear shift and the
differential. Loosen the fillister head screw on the clutch
throwout fork and remove the fork and the bearing. Do Loosen the ball pin for the clutch throwout fork. Remove
not wash the throwout bearing. Loosen the nuts on the the ball pin with the sealing washer. Next. remove the
guide tube for the throwout bearing and remove the tube. breather. Remove both snap rings from the drive shaf:
bearing and the rear snap ring of the drive shaft bearing ir
the housing, with a small screw driver.

The snap ring in front of the bearing race of the drive

shaft is pressed against the housing by the bearing race.
*;-:--\ First loosen the bearing race from the snap ring with a
punch. Heat the transmission housing to 24goF and
remove both bearing outer races using an extractor and a
plastic mallet.

Assembling
When cleaning the transmission housing, do not use
corrosive cleaning materials as they will damage the
magnesium alloy. Clean the transmission housing and

@ volkswagen
Securing screw for clutch throwout fork

Knock out the seal for the drive shaft from inside of the @ Volkswagen
transmission with a suitable piece of tubing. With the Installing drive shaft bearing outer race
MANUAL TRANSMISSION 8-11

:leck for cracks, wear, and external damage. In the event Install the breather and tighten it to the correct torque.
--: damage to the pinion shaft or the ring gear (for Make sure the drilling in the head of the breather is at a
:rample fracture), check to see that the bearing bores in 45" angie toward the front, when viewed from the top.
--:e center housing wall are not damaged. Replace the The bore in the hexagon of the breather should be at an
:cusing if necessary. angle of 45o in a forward direction, toward the longitudi-
nal axis of the transmission. Insert the ball pin with the
sealing washer and tighten it to the correct torque.

Install the intermediate plate with the gear assembly

before installing the drive shaft seal. This prevents damage
to the seal lip. Install the drive shaft seai making sure the
seal is fully seated. Install the remaining components
(refer to individual chapters). After making repairs to the
Ylt, ir,
.r'l: rr transmission, apply a new protective undercoating to the
entire outside of the housing.

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I nstallîng pinio n shaft outer race

-..::k all the other components for damage and replace as

::::ssary. Insert the front into the groove of the
snap ring
shaf[ bearing outer race. Heat the transmission
---;:
r -!ins to 248"F and install the drive shaft bearing outer
-:-" iito the bearing bore. Install the rear snap ring.
--.::11 the pinion shaft bearing outer race (with the snap
--: installed) into the bearing bore. Insert the rear circlip.

O vo ks*agen

Installing crankcase breather

SHIFT FORKS
Adjusting
Slide a holding plate onto the shift rods. Adjust the shift
fork. Put the transmission in neutral. Press the assembled
reverse idler gear with the axial bearings and the thrust
washer in the direction of the intermediate plate. The
cleatance between the shift gear and the idier shaft should
be I mrn Eliminate any play between the shift fork and
O voTkswagen
the shift gear by pushing the shift gear forward (in the
drive direction) and reposition the shift fork on the shift
Installing drive shaft seal rod.
MANUAL TRANSMISSION 8-12

Tighten the shift fork retaining bolt to 18 ft. 1bs. Make

sure that the lst and reverse shift piece has a 2
- 3 mm
side play between the 2nd and 3rd gear shift piece. Adjust
the 4th and 5th gear shift forks as well as the 2nd and 3rd
gear shift forks. Make sure that the shift sleeve is
positioned in the center, between the synchronizing rings
when the transmission is in neutral.

Tighten the shift fork retaining bolts to 18 ft. lbs. Make

sure that the 4th and 5th shift piece t.asa2 3 mm side
-
play between the 2nd and 3rd gear shift piece. Put the
transmission in neutral. Make sure that the shift sleeve is
centered between the synchro rings. Adjust the shift
sleeve by repositioning the shift fork. Check its operation
and readjust if necessary.

INTERMEDIATE PLATE
Disassembly
Loosen the screws for the clamping plate and remove the O volkswaqe-
plate and its support. Heat the intermediate plate to
248oF. Push out the 4 point ball bearing and the Assembling clamping plate & supporting plate
double-row angular contact ball bearing with a suitable
tool. Knock the lock pin out of the intermediate plate.
Pull out the bushings securing the gear lock, in sequence,
using a hook, Assembly
Check all parts for wear or damage and replace them '-
necessary. Heat the intermediate plate to 248oF. N{ak:
sure that all the balls are in the bearing sockets. Install th:
two bearings in the intermediate plate. Ensure that th;
bearing flanges are flush with the intermediate plare
Position the clamping plate together with the supportil;
p1ate.

Install the retaining bolts with washers and tighten ther

to the correct torque. Install the bushings for the securing
gear lock with a mandrel. When installing the bushings.
make sure that they do not project into the shift bore"
Install the long bushing up to the stop on the mandre,
iIr Install the short bushing up to the second mark on th:

&
#"
mandrel. Finally, install the center bushing up to the fini
mark on the mandrel.

DRIVE SHAFT
Disassembly
Clamp the holding plate in a vise and then secure the drir-e
O volks*agen shaft. Bend back the lock plate to expose the nut, with :
special tool. Press the roller bearing from the drive shafi.
Removing gear lock bushing Pull the remaining parts from the drive shaft. Wire the
needle bearings, races and the respective gears together tc
ensure the correct installation.

@ Volkswagen

@ volkswagen
Position of bearings Removing inner bearing race
MANUAL TRANSMISSION 8_13

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O volkswagen

Exploded view of cover plate

I - Bolt 13 - Shift lever shaft 914/6

2 - Washer 14 - Shift lever
3 - Helicoil 15 - Seal
4 - Speedometer drive 16 - Bushing
5 - O-ring 17 - lock pin
6 - Drive shaft 18 - Idler shaft
7 - SelfJocking nut 19 - Thrust washer
8 - Washer 20 - Bushing for speedometer drive pinion
9 - Cover plate 21 - Thrust piece
10 - Seal 22 - Transmission cover 914
11 - Lock pin 23 - Transmission cover 914/6
I 2 - Shift lever shaft 9 14
MANUAL TRANSMISSION 8-14

Using a brass drift, slightly separate the inner half of the

ball bearing race from the contact surface (use care so as c
not to damage the race or seat). Remove the race with a i
t\,61'-
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claw puller. st o
3
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î
Assembly
Install all parts of the drive shaft dry. Make sure that oil
does not enter between the contact surfaces, Slide gear I
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qdDv --t o
from 3rd gear on the drive shaft, with the narrow flange i-+
(lq) ro
toward the splined shoulder. When installing the needle
bearings and races, make sure that they are not inter- 6))-- - - - (0
changed with those of another gear.

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Installing guide sleeve

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Installing tapered thrust washer

MANUALTRANSMISSION 8_15

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MANUAL TRANSMlSSION 8,16

Install the thrust washer and the needle bearing race. Then Lubricate the threads and the thrust surface of the r_:
instali the needle bearing. Install gear I for 4th gear and Install the nut with the curved face in the outrr'--:
then the guide sleeve, Position the shift sleeve, the needle direction. Tighten the nut to the correct torque using -_::
bearing race, the needle bearing, and, gear l, for 5th gear. proper tool. Secure the nut by bending back the tab ::
the lock plate. Heat the inner half of the ball bearing ra:.
Next, mount the tapered thrust washer (5.9 mm, 0.232 in oil, to approx. 212"F and, press the inner half of --:*
in.). Install the roller bearing with the ring of the bearing race on the shaft.
cage toward the splinesof the pilot stub. Install the roller
bearing with a thrust plate and a thrust piece. Install a SYNCHRONIZER
new lock plate. Make sure that tbe locking tab is located Disassembly
in the groove on the drive shaft so that it fits under the Remove the circlip and check all parts for wear -:
inner race of the roller bearing. damage, Replace parts if necessary.
Assembly
Make sure the synchronizing ring, anchor block, thr,;;:
block and the brake band are installed properly. positir:
the synchronizing lllng so that the rough surface faces i-:

@ Volkswage.
O Volkswagen

Installing roller plate & lock plate

@ Vo ks*agen

O Volkswagen
Sy n c hro nizing r ing in s tallatio n and
Correct position of roller cage ring first gear assembly
MANUAL TRANSMISSION B-17

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\\t I - Shiftsleeve
'k lWr'l / \ \ 2 - Synchro hub
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il
3-
4-
Circlip
Synchronizing ring

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l;g

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5-
6-
7-
Anchor block
Brake band one only, for lst gear
Thrust block, 2nd to 5th
I - Thrust block, 1st gear
9 - Gear
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@ volkswaqen

Exploded view of synchronizers

'r:r sleeve. Insert the thrust block and the anchor block
':-::lher with the brake bands. When assembling the first
p:- synchronrzer, be sure that only one brake band is
-";:ted,

l-:e the tong of the circlip into the anchor block cutout.
1" .: the circlip into the gtoove, while pushing the
:,::hronizer ring on its seat. Now, spread the circlip pliers
'*: ;:at the circlip.
lll-ecking
l:::-< the diameter of synchronizer ring with a microm-
ï':-. Position the micrometer at the highest point of the @ volkswagen
:'::i-ronizing ring. Maximum allowable play between the
m-:: ;ork and the shift sleeve, lst to 5th gear, is 0.5 mm Side clearance of shift fork in shift sleeve
I - l0 in.). la - 0.020 in.)
MANUAL TRANSMISSION 8-18

O volkswagen

Ty pical Por s che s y nchro niz er

1 - Shift sleeve 5- Thrust block

2 - Synchro-hub 6 - Anchor block
3 - Gear 7 - Brake band
4 - Synchronizing ring 8 - Circlip
AUTOMATIC TRANSMISSION 8A-1

TRANSMISSION, AUTOiIAÏIC 8A
INDEX
Page Page
TRANSMISSIONHOUSING ...8A_1 TRANSMTSSTON.. ...8A-8
Disassembly . .8A-1 Disassembly ......84-8
Assembly . . .8A-2 Assembly . .8A-10
CONVERTERHOUSING ......8A-2 SHIFT FORK . 8A-I2
Removal ....8A-2 Adjusting ..8A-12
Installation . . .8A-4 INTERMEDIATEPLATE ....8A-12
FRONTGEARBOXCOVER ....8A_4 Disassembly .....8A-12
Disassembly . . .8A-4 Assembly ..8A-13
Assembly . . .84-4 INPUTSHAFT .....8A-I3
TRANSMISSIONCLUTCH ,....8A_6 Disassembly 8A-13
Removal;.... ......8A-6 Assembly .8A-13
Installation . . .8A-6 Checkingforout-of-true ... 8A-16
ÊIEW CLUTCH PLATE . .8A-7 PINION SHAFT . .8A_16
Basicadjustment.. .8A-7 Disassembly
Checkingclutchplay ......8A-7 Assembly . . 8A-16
CLUTCH CARRIER PLATE SYNCHROMESHASSEMBLY.. 8A-I7
ICLUTCH REMOVED} . .8A*7 Disassembly 8A- l7
Removal . . .8A-7 Assembly .8A-17
Installation . .8A*8 Inspection . .8A-18
Transmission removal and installation .8A-8

TRANSMISSION HOUSING Remove both covers above the shaft of the throwout
}isassembly lever. Knock the clamping sleeve out of the throwout
i.;rnove the torque converter and the converter housing. lever and force the shaft out toward one side. Force out
\:rI. remove the transmission cover, gearbox assembly, both bushings one after the other, using the proper
rj the differential. Now extract the cotter pin on the mandrel, Remove the intermediate lever and force the
r:-i for the pull rod, and pull out the bolt and the fork bushing out of the intermediate lever with an offset guide.
leed from the intermediate lever. Remove the cotter pin
::: the push rod on the intermediate lever, and disconnect The shaft for the intermediate lever can be removed by
:; pull rod. Disconnect the push rod on the throwout heating the gearbox housing to 248oF and then pulling
.Frit. out the shaft. Unscrew the oil filter plug and the oil drain
plug. Carefully force out the thrust washer for the needle

@ volkswagen
Throw out cover clamping sleeve (pin) Removing input bearing circlip
AUTOMATIC TRANSMISSION 8A-2

bearing by means of a mandrel. Remove both circlips of lithium grease and insert it together with the throwou:
the input shaft bearing in the housing web and the front lever and the two spacing washers, The notch in the shaf:
circlip of the pinion bearing with a small screw driver. is off-center. Insert the shaft in such a manner that th:
notch on the shaft and the bore on the throwout lever are
Heat the gearbox housing to approx. 248oF and pull both in alignment. The clamping sleeve must be inserted intc
bearing outer races, one after the other, Force the sealing the throwout lever and fit both closing caps.
ring for the input shaft out in an inward direction.

Assembly
C1ean the gearbox housing and check for wear, external
damage, and cracks. If the pinion or ring gear are
damaged, check whether the bearing holes in the central
housing web are also involved. If required, replace the
gearbox housing.

Insert the rear circlip for the bearing outer race of the
input shaft bearing into the groove, Again, heat the
gearbox housing to approx. 248"F and force the bearing
outer race for the input shaft into the bearing bore by
means of a thrust piece, and secure it with a front circlip,
Force the bearing outer race for the pinion with assem-
bled circlip into the bearing bore by means of a thrust
piece and fit a front circlip. Insert a thrust washer for the
axial needle bearing of a reversing gear, and insert the
bearing bolts and a dowel pin, if required,
O Volkswage.

Bearing bolts and dowel pin position

A - Bearing bolt
Installation dimensions in mm.
B - Sprial pin

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Removing pinion bearing outer race

Force the bearing bushing into the intermediate lever for

clutch actuation, with an offset guide piece, to the extent O volkswagen
that the bushing is flush on top. Coat the bearing bolt
with lithium grease and assemble the intermediate lever in Removing throw out lever bushings
the sequence described. Insert the push rod on the
throwout lever and secure it with a new cotter pin.

Force the bushings for the shaft of the throwout lever CONVERTER HOUSING
with a mandrel into the housing to the extent that the Removal
cover can later still be fitted. Coat the shaft lightly with Place the transmission on a bench and pull the torque
AUTOMATIC TRANSMISSION 8A-3

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12 11 14 b 7 20 21

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Exploded view of converter housing

1- Internal multi-tooth screw 14 - Sealing ring

2 - Springring 15 - Double connection
3 - Plate spring clutch with pressure plate 16 - Sealing ring
4 - Throwout bearing 17 - Tele-thermometer transmitter
5 - Clutch plate 18 - Temperature switch
6 - Internal multi-tooth screw 19 - Sealing ring
7 - Sealing washer 20 - Pressure pipe
8 - Sealing ring 21 - Return flow pipe
9 - Freewheeling unit 22-NutM6
I0- Lockingring 23 - Spring plate B 6
11 - Carrier plate 24 - Switch housing
1 2 - Sealing ring and needle bearing 25 - Converter housing
13 - Grooved ball bearing

..-:;erter from the freewheeling unit. Cover the hub

::.:mg, so that no foreign bodies will enter.
' :"e event of leaks within range of the freewheeling
-:-.. lirst repair the leaks even when the converter is
-:.;:]' oiled up. Exchange the converter only when the
:-: sirows deep scoring marks on the sealing rings, or
r:.:, other faults occur, for example, on the bearing
r'-::.i19 or on the ring gear.

.:i::ew the hex. nuts for outside attachment of con-

:--::: housing. Unscrew the hex. nuts inside the converter
: -i-:.s. Remove the cotter pin of the push rod on the
:: :::ediate lèver and disconnect it. Remove the con-
i'*:.: housing from the transmission housing while o volkswagen
Removing push rod
AUTOMATIC TRANSMISSION 8A-4

simultaneously removing the clutch throwout bearing piece and bearing bushing for the speedometer drive. pre*
from the throwout lever. the thrust washer from the shaft for the reverse gee
Check parts for wear and replace any, if required.
lnstallation
Insert the lefthand engine fastening screw into the
converter housing (hex. screw can no longer be inserted
because of the seryo motor). Assemble the converter
housing and transmission, making sure that the clutch
throwout lever enters into the two lugs of the clutch
throwout bearing. Tighten the hex. nuts uniformly to the
specified torque. Insert the push rod on the intermediate
lever and secure it with a new cotter pin, Complete the
basic adjustment of the clutch. Place the torque converter
on the freewheeling unit and keep turning for the
insertion into the turbine shaft.

FRONT GEARBOX COVER

Disassembly
Loosen the hex. screw for the speedometer drive and pull
out the angle drive. Unscrew the cover for the shift
actuation. Knock the clamping sleeve out of the shifting
shaft. Pull out the shifting shaft, removing the shifting
fingers from the shaft. Pull out the sealing ring and
bushing with the proper tools. Knock out the clamping
sleeve for the shaft of the reverse gear.
@ volkswagen
Shifting shaft sleeve (pin)

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Reverse gear shaft clamping sleeve (pin)

Assembly
O volkswagen Heat the gearbox cover to approx. 248"F and force in the
shaft for the reverse gear, Be sure that the bore in the
Removing sealing rîng & bushing housing and in the shaft are in alignment, so that the
clamping sleeve can be forced in later.

Insert the bushing for the pinion and thrust piece for the
speedometer drive. Force in the bushing for the shifting
Heat the gearbox cover to approx, 248"F and force out shaft, with a mandrel, and insert a sealing ring. Insert the
the shaft in an inward direction. Then remove the thrust shifting shaft while simultaneously sliding the shifting
AUTOMATIC TRANSMISSION 8A_5

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17 19

18 20
3 11

2 10

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Exploded view of front gear box cover

-
1 Screw 1l - Shift finger
-
2 Helicoil 12 - Shifting shaft 914
3- Spring plate t3 - Shifting shaft 914/6
4- Speedometer driver 14 - Sealing ring
5 - O-ring 15 - Bushing
6 - Nuts 16 - Clamping sleeve
7 - Spring Ring 17 - Shaft for reversing gear w. thrust washer
I - Cover 18 - Bushing for speedometer drive pinion
9 - Seal 19 - Thrust piece
10 - Clamping sleeve 20 - Gearbox cover 914
21 - Gearbox cover 914 16
AUTOMATIC TRANSMISSION 8A-6

fingers on the shaft. Turn the shaft slightly and force it in pressure plate with a socket spanner insert. Loosen tr-,-.
the clamping sleeve. Insert the clamping sleeve for the screws uniformly so that the pressure plate is n::
shaft of the reversing wheel, distorted. Remove the clutch pressure platè and clut_:
plate, being careful not to drop the throwout bearinr
Heat the bronze washer for the reversing shaft to approx. Slide the clutch throwout bearing out of the pressu--.
248"F and, slide it on to the shaft. Inseît the angle drive plate at an angle toward the rear, and wipe off th:
for the speedometer. Align blind hole in guide piéce with bearing"
bore in housing. Screw in hex. screw with spring washer
and tighten to specified torque. lnstallation
Check the clutch plate, pressure plate, and throwou:
bearing for wear or damage and replace, ifrequired. Checc
the clutch carrying plate, as well as the neèdle bearil*
and sealing ring in the clutch carrier plate for wear arl:
replace, if required.
If the clutch. has been oiled up by ATF or engine o.-
replace sealing ring of clutch carrier plate (seal l-
converter). If there is emerging oil, replace ihe sealing ri_r-s
in the transmission housing (seal on the input shaft).

To replace the seal, pult out sealing ring with self-mai.

hook. Fit the new sealing ring for the input shaft b..
sliding a sleeve on the input shaft. Then stde the seaLi::.
ring on the sleeve and force it in with thrust piece un:_
the tool knocks against the bearing tube. Lubricate th;
needle bearing in the carrier plate with some lithiu-
grease and position the driven plate on the carrier plar.
This requires centering the plate with a clutch mandre-
Use grease sparingly to keep the clutch plate clean.

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Shifting shaft & finger relative position ffi"&;'' 4

TRANSMISSION CLUTCH
Removal
Unscrew the internal multi-tooth screw of the clutch

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@ volkswagen
Fitting new sealing ring

Grease tongues of the diaphragm spring for the clutch

pressure plate on both sides with some lithium grease
and
insert the clutch throwout bearing at an angle into the
@ volkswagen clutch pressure plate from inside in an outward direction.
Removing sealing ring Screw down the clutch pressure plate, with internal
AUTOMATICTRANSMISSION 8A_7

rilti-tooth screws uniformly and then tighten. Be sure opposite position down for approx. 0.3 I 5 in. and care-
-::r the throwout bearing does not jam in the plate spring fully knock out the freewheeling unit together with radial
r:j that the clutch pressure plate engages with the sealing ring by means of light blows against the screw.
:;:tering pin.
a':â11y, grease the guides of the throwout bearing on the
::rsmission housing neck as well as the two claws lightly
rr:-a lithium grease and MOS 2 additive.

bEW CLUTCH PLATE

Sasic adjustment
i::rove the cotter pin on the bolt for the pull rod and
-r:::inediate lever and pul1 out the bolt. Pull the rod
l:.=;hed to the servo engine out up to the stop while
, -;itaneously pushing the intermediate lever in the

ir::tion of the servo motor against the stop. In this

:i,:sr:ion, the fork head of the pull rod should be set in
:"rc: a manner that the bore of the fork head extends 10
: ,I mm beyond the bore of the intermediate lever.
Ihecking clutch play
n i new clutch, the play has been properly set during the
ru-: adjustment. The normai wear of the clutch linings
e: :educe this play in the course of time.
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Removing free wheeling unit

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Pull rod setting

A = approx. 1/2 in.

i :;:çer, there should always be a minimum play, so that

llc :-"utch canbe fully engaged. [f not, the clutch will slip @ volkswagen
ul: "rcessive heating and increased wear will follow. For
:h:s: reasons, the clutch play must be checked at the Removing turbine shaft lock ring
nr-ied internals and, if required, adjusted by pulling the
lu'-:il hose from the servo motor and pushing the
r-:::rediate lever with your left hand away from the
u:r: motor. The intermediate lever should move for a Now remove the locking ring on the turbine shaft. Knock
!L:r.:,Jê of at least 0.197 in. If it is less, the clutch play the carrier plate out of the bearing by tapping the turbine
::rui- ':e newly adjusted. shaft with a rubber hammer. Wash it out for good support
of converter housing. Pull the sealing ring and needle
T.IJTCH CARRIER PLATE (CLUTCH REMOVED) bearing in the carrier plate by means of a puller. Force out
fts-rcval the grooved ball bearing and sealing ring for the carrier
,:s:.ew the internal multi-tooth screw through the holes plate one after the other with a punch. Replace bearings
: ,:e clutch carrier plate. Screw two hex. screws in which are damaged or too noisy.
AUTOMATIC TRANSMISSION 8A-8

lnstallation
Lubricate the new sealing ring (silicon ring) on the seat of
the converter housing well and force it in by means of a
thrust piece with sealing lip pointing toward the con-
verter. Insert the clutch carrier plate into the converter
housing and position it with a thrust piece. Then force the
grooved ball bearing into the converter housing against the
stop by means of a thrust piece fitting sleeve. place the
locking ring on the turbine shaft.

O Volkswagen

Nuts for internal shift lever .fork piece

Disconnect the draw springs for the parking lock an:

remove the pawl as well as the lever for the parking loc.-
Loosen the hex. nut on the fork piece for the intern-
shift lever. Remove the fork piece and pull the intern:
@ volkswagen shift lever out of the rear guide bore. Now, engage the 4r-_
gear.
Removing ball bearing & sealing ring
Block the input shaft with a supporting angle piece an:
loosen the expanding screw on the pinion with an insen
Insert the freewheeling unit into the converter housing. Pull off the spline shaft sleeve and knock out the clampin;
Insert the internal multi-tooth screws with new sealing sleeve of the castle nut for the input shaft with a mandre-.
rings, through the holes into the carrier plate and tighten Loosen the castle nut and remove the washer. Unscre,,i
the screws to a specified torque. Lubricate the new sealing the bridging switch and switch for the backup lights anc
ring for the torque converter (silicon ring) well on seat for pull out the plunger for both switches. pul tÈe shift roc
converter housing and force it in with a thrust piece. for reverse gear and parking lock up to the stop on th:
Force in the needle bearings for the input shaft with a intermediate plate.
thrust piece.

Finally, force in the sealing ring for the input shaft with a
thrust piece and grease the needle bearing for the input
shaft wi.th some lithium grease. Use greaie sparingly to
keep clutch plate clean.

Transmission removal & installation

The transmission is removed complete with the engine.
See engine section for details.
TRANSMISSION
Disassembly
Attach the transmission in combination with the holding
plate to the holder (screw transmission down at all four
points). Unscrew the closing screw for the parking iock,
and remove the spring and ball. Now loosen the hex. nuts
on the front gearbox cover. Remove the gearbox cover.
Then remove the bott and 7 mm (0.2j5 in.) ball for the
parking lock from the shift lever for reverse gear. Remove
the circlip from the shift rod for the reverse gear and
parking lock and remove the shift fork together with the O volkswagen
slide wheel. Ist & 2nd gear shift fork lock screw
AUTOMATIC TRANSMISSION 8A_9

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AUTOMATIC TRANSMISSION 8A_10

Pull the gear set with the intermediate plate, out of the Place the washer (with chamfer outwards) to the inp_:
transmission housing, turning intermediate plate slightly shaft, and screw on the castle nut to specified torq';:
toward the left. Clamp the intermediate plate with a gear Secure the castle nut with a clamping sleeve. Slide r::
set into a soft jawed vise. Loosen the closing screw for the splining sleeve on the pinion with the internal proi,.:
gear lock. Remove the compression spring and ball, and pointing outwards.
take the shift rod for reverse gear and the parking lock, as
well as the parking bit, out of the intermediate plate. Lubricate the expanding screw for the pinion (u.-.
Loosen the hex. screw for the shift fork from first and speedometer pinion) on the pressure surface and tight;:
second gear; force out the shift rod and remove it, to specified torque with an insert. Remove the intermei-
together with the shift fork. ate plate with the pinion and input shaft again to adju,
the shift forks, and clamp into a vise (use soft jarr-
Mark the shift fork for 3rd and 4th gear to prevent Assemble the shift rods and shift forks in the sequen;:
confusion during installation. Loosen the hex. screw and described next.
remove the shift rod together with the shift fork.
Check the springs for the securing shift rods. Relax leng-:
Finally, press the drive pinion and driving shaft out of the of springs for lst to 4th gear. Free length should :,:
intermediate plate using a thrust piece. 1.469-1.517 in. Relax length of the spring for reve:-,.
gear and parking lock. Place the shift rod for 3rd and j-:
Assembly gear on the pertinent shifting sleeve and slide the shifr r_:
Place the intermediate plate on the bearing inner race for 3rd and 4th gear through the bore of the shift fc:r
halves of the pinion and the driving shaft and fit the other into the intermediate plate. Tighten hex. screws \\--::
halves of the bearing inner races. First slide a tube on to spring washer for shift fork slightly. (First attach the sL_::
the input shaft and place it against the pressure p1ate. Fit piece with clamping sleeve on the shift rod).
the bearing inner -race white holding the pinion in
position. Then pull the tube from the input shaft, placing
the pinion on the pressure plate and also fit the bearing
inner race.

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Shift rod gear lock arrangement

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1 - Intermediate piate
2- Shift rod for 3rd and 4th gear
3 - Bail
4 - Bushing for gear lock
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6 - Pin for gear lock
Removing pinion shaft 7 - Ball
8 - Shift rod for lst and 2nd gear
9 - Bushing for gear lock
10 - Iocking piece for gear lock
Engage the 4th gear and slide the intermediate plate with 11 - Shift rod for reverse gear and parking lock
the pinion and the input shaft into the transmission 12 - Ball
housing. Attach the intermediate plate crosswise to the 4 13 - Bushing for gear lock
studs of the housing with nuts (placing several washers 14 - Spring for gear lock (reverse gear and parking lock)
under the nuts). 15 - C'losing screw
AUTOMATIi] TRAI\SMISSION 8A-1'!

Insert one ball, pin for shift lock, long compression spring fork and shift rod. Place the pawl and lever for park lock
,or the gear lock lst to 4th gear and another ball into the on the intermediate piate and connect both draw springs.
:onnecting duct of the shift rod bores. It will be Place the needle bearing and the spacer bushing on the
.dvantageous to insert the pin into the spring first and shaft for reverse gear. Mount the gearbox cover and
:ren assemble both parts together. Replace the shift fork tighten the nuts to specified torque.
:,rr lst and 2nd gear on the pertinent shift sleeve and slide
-re shift rod for lst and 2nd gear through the bore of the
'::.ift fork into the bore of the intermediate plate. For this
:,rrpose, the shift rod of 3rd and 4th gear should be at
-:Lng and the ball for the shift rod lst and 2nd gear must
:: pushed into the duct.
,:ghten the hex. screw with spring washer for the shaft
:,rk slightly. Insert the locking piece for the gear lock (set
,::e shift rod for 1st and 2nd gear to idling). Next, insert
:-e strift rod for reverse gear and the parking lock. Insert
_.e ball and spring for the gear lock (reverse gear and
:.iking lock), screw down the closing screw and tighten.
--ssemble the internal shift 1ever, noting its position. Slide
:-: internal shift lever through the cutout in the interme-
:--rte plate.

-:at the axial needle bearings with some grease and insert
-::m with needles pointing toward the thrust washer in
-:: transmission. Slide seals (same number as removed) in
-::per size on the studs of the gearbox housing. Insert the
:-::rmediate plate with the input shaft and pinion into
*--: housing. Slide the shift rod for reverse gear and the
:.:king lock into the housing. Insert the internal shift
:;:r into its bearings in the gearbox housing.

,l:rnt the fork piece with a new seal, making sure that
:: internal shift lever is guided in the fork piece. lnsert
:--1.' when no gear is engaged. Tighten both of the hex.
r-:s to specified torque. Slide the shift fork and reverse
ls:: on the shift rod or splining shaft sleeve and position O volkswaqen
-:: ,ocking ring,
Parking lo ck arrangement

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Shift lever correct position w

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.: :olts and 7 mm (0.276 in.) ball for the parking lock

it into the bore of the shift
,{ll:': :rme grease and insert 7 mm ball for parking lock
AUTOMATICTRANSMISSION 8A_12

Insert the plunger for the backup lights and bridging screws of the shift forks to the specified torques, mak:4
switch; screw in both switches and tighten to specified sure that the shifting piece of 3rd and 4ttl gear has a p-;r
torque. Install the sealing ring for the input shaft into the of approx. 0.079 in. in relation to the shift rod of 1st a:l
gearbox housing, sliding the sleeve onto the input shaft 2nd gear.
first, and then forcing in the sealing ring with its lip
pointing toward the transmission well, using a thrust Remove the holding plate and pull the shift rod i:r
piece. reverse gear and the parking lock as far as possible in ri*
outward direction toward the intermediate plate.
SHIFT FORK
Adjusting INTERMEDIATE PLATE
Slide the holding plate on the shift rods and adjust the Disassembly
shift forks for lst and 2nd, as weil as 3rd and 4th gear. Pull the wheel for reverse gear with a puller and thrur
Adjust shifting sleeve via shifting fork in such a manner piece. This will destroy the circlip. Carefully remove :-
that it will be accurately in the center between the the parts of the destroyed circlip so that no remnants rr:-
synchronizing rings in idling position. Compensations for enter the transmission. Unbend the lock washers of tt=
any deviations must be made very accurately to guarantee fastening screws for the clamping plate. Loosen the scre*r
perfect function of synchronization. Tighten the hex. and remove the plate.

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Exploded view of intermediate plate

1 - Axial needle bearing 7-ScrewM8

2 - Shaft for accelerator lever 914 16 8 - Lock washer
3 - Spring washer B 8 9 - Clamping plate
4 - Gear wheel/rev. gear l0 - Double tapered ball bearing
5 - Locking ring l1 - Four-point bearing
6 - Gear wheel/rev. gear 12 - Intermediate plate
AUTOMATIC TRANSMISSION 8A-13

-.'at the intermediate plate to approx. 248oF and press washers, noting their correct position. Force in the
:,-: the four-point ball bearing, Then, press out the double bushings securing the gear lock with a mandrel. Force in
::ered ball bearing. Knock the fitted pins out of the the long bushing against the stop of the mandrel. Force in
-:ermediate plate and pull out the bushings securing the the short bushing until the guide bores of the shift rods
g:"r locks by means of a pulling hook. are exposed. Now, force in the medium-long bushing up
to the first mark on the mandrel. Make sure that none of
4ssembly the bushings extend into the guide holes of the shift rods.
,:eck all parts for wear or damage and replace, if
::uired. Heat the intermediate plate to approx. 248oF
,:j press in the double tapered ball bearing using the
:r.rper tools. Press in the four-point ball bearing with the
::3ssure plate, pressure pin and the pressure piece, from
::i same side. lnsert any loose balls of double-row tapered
:Jl bearings with grease. Now, position the clamping

O volkswagen

Position of lock washers

Insert gear 2 for reversing speed from the outside, in an

O volkswagen
inward direction into the intermediate plate and fit the
circlip into the groove of the gear. Slide gear 3 onto the
Removing gear lock securing bushings teeth of gear 2 and compress the circlip with a pair of
pliers until gear 3 engages the circlip while applying light
blows with a plastic hammer.
ù:unt the fastening screws with new lock washers and
--:lren the screws to the specified torque. Bend the lock
INPUT SHAFT
Disassembly
Press off the gear wheel of lst gear with the inside race
half of the tapered ball bearing by means of a pressure
plate and a thrust piece. Clamp the holding plate into a
vise. Mount the input shaft and knock back the lock for
the hex. nut. Then loosen the hex. nut with a nut spanner.
Press the cylindrical roller bearing from the input shaft
with a pressure plate and a pressure pin.

Pull off the remaining parts from the input shaft. Be sure
to mark the needle cages to eliminate any confusion
during installation.

Assembly
All the parts ol the input shaft must be mounted dry, so
that no oil enters in between the mating surfaces. Slide
second gear onto the input shaft, with the narrow flange
against the stop. Fit the thrust washer and the bushing for
the needle bearing. Next, mount the needle cage, the gear
wheei and 3rd gear and the guide sleeve.
O Volkswagen

Installing clamping plate If needle cages are reinstalled, they must be fitted with
AUTOMATIC TRANSMISSION 8A-14

14
15
6 16
5 T7
3 18
2 22
19
30 æ
11 21
I 1

10 Ë. 25

13 24

12 re
31 27

29

æ
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23
O volkswagen
Exploded view of gear box housing

I - Breather 17 - Spacer sleeve

2- Cotter pin l8 - Intermediate lever
3-WasherB6 19 - O- ring
4 - Push rod 20 - Washer
5- Cotter pin 21 - Torsion spring
6-WasherB5 22 - Bushing f. inrerm. lever
7- Bolt 23 - Closing screw with magnet
I - Clamping sleeve 24 - Closing screw
9 - Closing cap 25 - Thrust ring
10 - Clutch shaft 26 - Circlip
11 - Throwout lever 27 - Beafing outer race
l2-Spacerring 28 - Circlip
13 - Bushing 29 - Bearing outer race
14 - Locking ring 30 - Sealing ring
15 - Washer 3 i - Housing
16 - Sleeve

the same gear wheel they were removed from. Mount the Press on the cylindrical roller bearing using a pressure
çJrifting sleeve, the bushing for the needle bearing, the plate and a pressure pin. Do not chafe or damage the
needle cage and the gear wheel for 4th gear. position the threads on the driving shaft. Position the new lock washer,
tapered thrust washer and the cylindrical roller bearing in making sure that the tab of the washer rests in the groove
the correct lateral position (the mounted ring of the roiler on the shaft and under the inner race of the cylindrical
cage should face the splining of the clutch plate). roller bearing.
AUTOMATIC TRANSMISSION 8A-15
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AUTOMATIC TRANSMISSION 8A.16

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Fitting thrust washer & bushing Installing new lock washer

Checking for out-of-true

The shaft should always be checked for "out-of-true" in
the assembled condition, since the tightening of the hex.
nut may cause some wobble on the shaft. For checking
purposes, press the double-row tapered ball bearing out of
the intermediate plate and the outer race of the roller
bearing out of the gearbox housing. The check can also be
made by means of the auxiliary bearings. Place the
assembled input shaft with bearings attached on V-blocks
and check on trueness of the needle sleeve. Max.
out-of-true 0.004 in.

PINION SHAFT
Disassembly
Remove the bearing inner race of the four-point ball
bearing and the cylindrical roller bearing from pinion
shaft using a pressure plate, pressure pin, tube and a thrust
piece. Remove all the parts from the pinion shaft. Identify
the needle cages to prevent confusion during installation.

Note the number and thickness of the washers (for the

pinion shaft lring gear adjustment) between the roller
O volkswagen bearing and the thick spacer washer, so that the adjusting
washers dimensions need not be calculated during as-
Installing guide sleeve sembly.

Assembly
All parts of the pinion shaft must be assembled in a dry
condition so that no oil enters between mating surfaces.
The pinion and the ring gear must be provided with a
pairing number. Be sure that these numbers match during
Lubricate the threads and the pressure surface of the hex. installation.
nut and fit the spherical end of the nut outwards. Tighten
the hex, nut to specified torque with a nut spanner and Fit the pinion shaft bearing with a pressure plate and
secure it with a lock washer. Fit the gear wheel for lst pressure pin. Mount the bearing in such a manner that the
gear, with the narrow flange outwards and press on the washer on the temporary roller cage faces the gear set.
inside half of the race of the tapered ball bearing by Position the removed adjusting washers or the newly
means of a pressure pin and tube. determined adjusting washers for the replaced pinion shaft
AUTOMATIC TRANSMISSION 8A-17

:ssembly. Then fit the thick spacer washer' Fit the gear

-:i the spacer bushing and the gear wheel for 3rd gear
:gainst the spacer bushing with the narrow collar facing
::rvnwards.

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Correct position of synchronizing body & energizer

In the event of repairs, the synchronizing ring should be

turned, so that the coarse surface faces the sliding sleeve'
When assembling the synchronizing components, for lst
gear, note that only one break band is inserted' The
c mating surfaces of the synchronizing body and the
ri ':'l'i:::: :.., I
energiier are matched and should be instalted accordingly'
r:i

aÎ O volkswaqen Place the nose of the retaining ring into the cutout for the
energizer and push the retaining ring into the groove at
)e
Fitting adiusting washers
this Ënd, pushing the synchronizing ring against its seat, if
;lÊ
b
required. Apply the pliers once again, to secure the ring
completely. Using the retaining pliers, spread the ring
I.:: the thrust washer and the bushing for the needle
rrrrtgs on the shaft. Fit the needle cage, the gear wheel
:, lnd gear and the guide sleeve' Used needle cages must
ba- lr:
'-stall'ed with the same gear wheel as before' Now slide
ior *= bushing for the needle bearing, the needle cage and
gear wheel for lst
rîto- shift sléeve on the shaft. Install the Finally, press the
tt[*. and the tapered thrust washer.
using a pressure plate,
iià.r*--ng inner racè half on the shaft,
[ ::3ssure Pin, and a PiPe tool.
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.-*i"ilrsæsemblv
*".
1"."i*..=-ot. th! retaining ring for the synchronizing ring from
^u :lutch body. For this purpose' insert the retaining
(outside) and spread' Simultaneously, tilt the pliers
r':s
, t-r.h u manner that the noseless end of the retaining
a dm. is raised out of the groove in an upward direction'
riacei-=i spreading the pliers and force the ring out of the
with r: tve by twisting it in a lateral direction.
durin
semblY
::-,ion the synchronizing ring on the clutch body, and
ate aru;:1 the energizer and stop' together with the braking
ittot tU-:. The rough surface of the synchronizing ring has- a O volkswagen
,ear sec-l'bdenum coating' During the shifting operation, the
Shift rod lateral clearance.
3 ."*r-, sides of the synchronizing ring are subject to different a = 0.2 in.
ion sha:sses.
AUTOMAT!C TRANSM ISSION 8A.1 8

while simultaneously twisting the pliers laterally in such a be checked. First, measure the built-in synchronizing
manner that the ring can be pushed into the groove using (with a micrometer), to check its diameter. Position
the thumb of the other hand. micrometer at the highest point of the synchronizing
Diameter should be 2.998 - 3.014 in. Then check
lnspection clearance between the shift fork and the shifting
To guarantee perfect synchronization, two items should the shifting gear (lst to 4th gear). Clearance should
0.0197 in.
DRIVE AXLE 9-1

DRIVE AXLE & DRIVELINE 9

INDEX
Page Page
YUHEELTRACK ........9-I Assembly . . .9-6
Adjusting .....9-1 DIFFERENTIAL (MANUAL TRANSMISSION) . . .9,7
GAMBER .......9-l Removal ,...9-7
Adjusting . . .9-1 Installation ....9-9
SPRINGSTRUT ...9-I DIFFERENTIAL (SPORTMATIC TRANSMISSION) 9-9
Removal .......9-l Removal ....9-9
Installation ,...9-l Installation . .9-9
Disassembly . . .9-3 DIFFERENTIAL (with anchor piece) . . . .9-9
Assembly .,...9-3 Disassembly .......9-9
REAR AXLE CONTROL ARM . . .9-3 Assembly . . .9-10
Removal . .9*3 DIFFERENTIAL (withoutanchorpiecel . . . . . . .9-11
Inspection ,...-9-3 Disassembly .......9-11
Installation ....9-3 Assembly . .9-11
SHoCKABSORBERS .....9-4 RING GEAR AND PINION . . . .9-12
Checking ..,...9-4 Adjusting . .9-12
Assembly ......9-4 SHIMS FOR PINION SHAFT . . .9*13
UNIVERSALSHAFT .....9-5 Determiningthickness ......9-13
Removal ......9-5 P|N|oNSHAFT.i.... .9-13
Installation
SYNCHRONIZINGJOINT
Removal
Installation
Disassembly
.....9-5
.....9-6
. .9-6
.....9-6
....9-6
Adjusting

ifl:,:trffl*:Ïff
Adjustment
::l lllY:ly:il i _ii
. . 9-13

.....9-15
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WHEEL TRACK Installation
Adiusting Replace the self-locking hex. nut" Tighten the self-locking
Slightly loosen the hex. bolts for the control arm bearing hex. nut, as well as the hex. nut for the bearing bolt, to
and push the rear axle control arm outside, back or the specified torque.
iorward as required until the specified track value is
lriained. Tighten the hex. bolts to the specified torque
rnd replace the lock washers if required.

CAMBER
Adjusting
Uark the position of the rear axle control arm on the base
plate (track setting) and unscrew the central hex. bolt.
The other two hex. bolts are only slightly slackened.
Uount the pertinent intermediate shims to obtain the
;pecified camber. Intermediate shims are available in 2.3
and 4 mm thicknesses, a I mm shim results in approx.
0"10' change of camber" A bore at the outside permits the
rmoval of the shims,

T'ghten the hex. bolts to the specified torque and replace

Ae lock washers, if required. Check the camber and the
:r'eck values once again,

SPRING STRUT
Removal
Loosen the hex. nut for the bearing bolt on the spring
;mrt (bottom) and remove the bearing bolt. Loosen the @ Volkswagen
*elf-locking hex. nut on the spring strut (top) and remove
::re spring strut in a downward direction. Removîng rear wheel hub
DRIVE AXLE 9_2

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Exploded view of rear axle

1 - Hex, nut l7 - Spring washer

2 - Spring ring 18 - Holding plate
3 - Bearing bolt 19 - Protective cover
4 - Washer 20 - Hex. bolt
5 - Spring strut 2l - Lock washer
6 - Hex. bolt 22 - Shim plate
7 - Spring washer 23 - Shim
8 - Caliper 24 - Self-locking hex. nut
9 - Hex. bolt 25 - Hex. bolt
10 - Brake disk 26 - Spring ring
11 - Cotter pin 27 - BeaÀngcap
l2 - Castle nut 28 - Radial taper ball bearing
13 - Washer 29 - Self-locking hex. nut
14 - Universal shaft 30 - Control arm bearing
15 - Wheel hub 31 - Rear axle control arm
16 - Hex. bolt
DRIVE AXLE 9_3

suitable thrust piece. Finally, loosen the self{ocking hex.

nut for the control arm bearing and remove the bearing.
lnspection
Check the rear axle control arm for visible damage and
distortion. Replace if required. The rubber bearings of the
rear axle control arm cannot be replaced. Replace the rear
axle control arm, if required.
lnstallation
Attach the control arm bearing, on the rear axle control
arm, in such a manner that the bearing surface of the
control arm bearing is in parallel with the connecting line
of the two control arm shafts. Replace the self-loôking
hex. nuts and tighten them to the specified torque. Install
the radial taper ball bearing with a special tool.

@ volkswagen

True relation of control arm bearing surface

with control arm shafts @ Volkswagen

Installing rear wheel hub

Disassembly
tlamp the coil spring with a special tool. Loosen the
-ireaded bushing and remove the spring retainer on the Tighten the hex. bolts for the bearing cover to the
:cp. Slacken the coil spring by alternately screwing back specified torque. Tighten the rear axle control arm in a
--ne clamping bolts, removing the coil spring, the supple- horizontal position. Install the rear wheel hub, with a
:rentary spring and the stop washer from the piston rod. special tool, in the taper ball bearing.

ir-nock the cap from the shock absorber with a mandrel.

Remove the bottom spring retainer in the direction of the
;ston rod.
llssembly
{>semble in reverse procedure of disassembly.

REAR AXLE CONTROL ARM

Removal
.trosen the brake line on the brake hose, Disconnect the
- -nd brake cable and remove the caliper. Remove the
:-ake disk and the universal shaft (unscrew the heat
:r.:hanger first). Remove the rear wheel hub with a special
:,o1. Mark the position of the rear axle control arm on the
.-'m plate and hold the shims for adjusting the camber in
--e position.

rcsen the bolts or the self-locking hex. nut on the rear

::tle control arm and remove the arm. Remove the bearing @ volkswagen
:rver and force out the radial taper ball bearin! with a Position of rear axle control arm'
DRIVE AXLE g_4

Install the universal shaft. Connect the hand brake cab-.

and adjust the hand brake. Bleed the brake lines. Measur;
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the rear axle optically.
1
.*}-3'f-
2 SHOCK ABSOBBER
,#'. r:w Checking
s' ËË* 3 The shock absorber is checked manually by pulling an;
pushing it, while holding the shock absorber in th;
installation position. It should move under a uniform loa;
and be free of jerks along its entire stroke. Compare wirt
a new one, if required.
The damping effect while pushing or pulling, must L,t
clearly felt up to the end position. Dampers which haç;
been in storage for extended periods may require somr
pumping action until their full effect shows up. Whil:
driving, defective shock absorbers are noticed bv :
rumbling noise.

Shock absorbers require no servicing and have an adequar.

supply of oil to compensate for small losses. If only sligL:
amounts of shock absorber oil are leaking out, but th:
shock absorber operates otherwise perfectly, no exchang;
is required. Shock absorber oil cannot be replenishel
Defective shock absorbers must be replaced.

Assembly
Mount the bottom spring retainer on the shock absorbe:
in such a manner that the water drain hole is in a later:,
(inside) position with the spring strut installed. Fit on th;
cap. Mount the stop plate with the grooves facing the cap.
so that no oil will be sucked out of the shock absorber.

Coil springs should rest correctly against the spring

retainers. Tighten the threaded bushings to the speCifie;
torque.

10

fi
I - Self-locking hex, nut
2 - Washer
3 - Ring joint
4 - Ring joint
5 - Threaded bushing
6 - Spring retainer, top
7 - Rear axle spring
8 - Supplementary spring
9 - Stop washer
Vo I kswagen
10 - Cap
11 - Spring retainer, bottom
Exploded view of spring and shock 12 - Shock absorber
DRIVE AXLE 9-5

the universal shaft on the universal flange. Use a flat chisel

to separate the universal shaft from the universal flange in
the range of the flange seal and remove the universal shaft.
Be careful not to damage the flange surfaces.

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Correct position oJ srop plate
@ volkswagen
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Removirlg universal shaft J\ange

Jl',IlVERSAL SHAFï
Bemoval
-:lock the castle nut of the universal shaft and loosen it. lnstallation
l.:rrove the heat exchanger. Loosen the socket screws of Use the new seal for the flange and make sure that the

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11 64
Exploded view of universal shafts O volkswaqen

1 - Cheesehead screw 7- Synchronizingjoint

2 - Lock washer 8 - Spring retainer
3 - Shim plate 9 - Sealing bellows
4 - Seal l0 - Universal shaft
5 - Clamping strap 11 - hotective cap
6 - Locking ring 12 - Spiral pin
DRIVE AXLE 9_6

flange surfaces are without a burr and are absolutely free

of grease.

Tighten the socket screws to the specified torque, using

new lock washers and making sure that the lock washers
will rest with their hollow end against the shim plate.
Tighten the castle nut of the universal shaft to the
specified torque.

SYNCHRONIZING JOINT
Removal
Loosen the clamping strap of the sealing bellows and push
the bellows back. Remove the locking ring from the ball
hub. Now, press the joint from the universal shaft with
the proper tool. Remove the plate spring and pull off the
sealing bellows.

The protective sheet metal cap is sealed with Curil K

against the joint. When the cap is removed, do not swivel
the ball hub more than 20o otherwise the balls may fall
out.

lnstallation O volkswage'.
Check the universal shaft, the sealing bellows, synchron-
izingjoint, protective cap and the plate springs for wear or Removing ball hub and cage
damage. Replace them if required. Glue the plate spring,
with the specified grease, to the joint, with the hollow end
facing the joint. If the cap has been removed from the
joint, seal it again with the sealing compound Curit K.

Seal the sealing bellows on the large diameter with a

sealing compound. Attach the hose clips in such a manner
that the clamping points are at the level of the spiral pins.

Grease the synchronizing joints. Use multi-purpose grease,

such as Molykote BR 2 or Shell-Retinax AM. Fill 2/3 of
the specified grease quantity through the smaller diameter
of the sealing bellows. Slide the joint with the sealing
bellows on the universal shaft. Be sure that the plate
spring fits correctly and widen the ball hub with a special
tool.

Install the locking ring and make sure that the ring is
correctly located in the groove of the universal shaft, Push
the remaining grease, from outside, into the joint and
squeeze the sealing compound somewhat, so that the
grease will enter the joint from the inside as well.

Disassembly
Loosen the protective cap from the joint by means of a O volkswagen
mandrel. Swivel the ball hub with the ball cage by 90" and
push it out of the joint. Push the balls out of the cage. Correct pre-assembly position
Remove the ball hub via the ball races,
a = Large distance in outer race b = Small distance hub
The ball hub and the joint are mated and should not be
interchanged. The 6 balls for each joint are also included
in one tolerance group. Exchange the ball hub, the joint, Press the balls into the cage. Insert the ball hub with the
the ball cage and balls as a set. Knock the spiral pins out cage and balls into the joint. The bevelled end of the
with a mandrel. inside splines must point toward the bearing surface on
the universal joint.
Assembly
Check the joint, the ball hub, ball cage and the balls for Insert the ball hub with the cage and balls, edgewise, into
wear. E,xcessive radial play in the joint is noticed by the joint. Be sure that a large distance "a" of the ball races
knocks during load changes, In such cases, replace the at the joint, lies together on one side, with a small
pertinent joint. Press the spiral pins in, against the stop. distance "b" of the ball hub after swivelling the ball hub
lnsert the ball hub, via both ball races, into the ball cage. into the joint. In order to swivel the ball hub with the
The mounting position is at choice. cage and balls into the joint, the ball hub must be pushed
DRIVE AXLE 9-7

:ut of the cage (so that the balls have the distance of the
@
rall races), c
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a
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Position of hub cage in outer race
at moment of assembly
N

DI F FERENTIAL (MANUAL TRANSMISSION)

Flemoval
i.efore removing the differential, the transmission gears
- rst be removed. Block the universal flange with a special
::ol and loosen the expansion bolts. Now remove the
::?osite universal flange, LooSen the lock nuts on the
'-d drive cover. Remove the cover (tap the cover lightly
n--ih a plastic mallet if necessary).

i-::riove the differential from the housing. Knock the seal

r.1 bearing outer races from the cover and housing with a
::-it.

Exploded view of differential

1 - Shaft 7 - Spacer washer

2 - Small differential pinion 8 - Lock plate
3 - Threaded lock piece 9 - Bolt
4 - Larye differential 10 - Ring gear
@ Volkswagen 5 - Tapered roller bearing ll - Differential housing
Removing flange with puller 6 - Shim
DRIVE AXLE 9-8
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DRIVE AXLE 9_9

I nstallation Loosen the hex, nuts on the lateral transmission cover and
Check the tapered roller bearings and the differential for remove the cover. Now, remove the differential from the
excessive wear or damage, Replace if necessary. When transmission housing. Knock the sealing ring and bearing
reating the transmission components, do not use an open outer race out of the transmission cover and the transmis-
r-lame. Heat the final drive cover Io 248-F using either an sion housing, by means of a punch.
electric hot plate or hot oil. A drop of water on the
ieated surface will sizzle at the correct temperature. Press,
or drive, in the bearing outer race with an appropriate
piece of tubing.

Install a seal in the cover using a thrust piece, Now, heat

-he housing to 298oF by placing the bearing side of the
housing on an electric hot plate and install the bearing
:uter race. Use a press or drive it in with a hammer and an
appropriate adaptor. Install a seal in the housing using a
:hrust piece. Make sure the seal is fully seated. Insert the
Jifferential. Then lightly lubricate a new O-ring for the
:over and install it.

\ow install the cover. Position the washers and tighten

:he self-locking hex. nuts to the specified torque. Insert
:be universal flanges, block them with a special tool, and
-:glrten the expansion bolts to the correct torque.

O volkswagen
Re m ov in g u niv er sal flange

lnstallation
Check the tapered roller bearing and the differential.
Replace if ^required. Heat the transmission cover to
approx. 248"F and press the bearing outer ring into the
cover using a pressure plate, a pressure pin, a pipe tool and
a thrust piece. Press in the sealing ring with a pressule
plate, a pressure pin and a thrust piece.

Heat the transmission housing to approx. 248oF and force

the bearing outer race into the transmission housing using
a thrust piece and a pipe tool. Next, force the sealing ring
against the stop in the transmission housing using a thrust
piece. Instali the differential in the transmission housing.
Insert a new paper seal for the lateral transmission cover,
position the transmission cover, screw on the hex. nut
with spring washers and tighten them to the specified
O volkswagen torque.

Installtng seal Insert the flange shafts and tighten the stretch bolts to the
specified torque, Screw the breather screw into the
transmission housing. The bore in the hex. head should be
at an angie of 45o, in the forward direction, in relation to
lr FFERENTIAL (SPORTMATIC TRANSMISSION) the logitudinal axis of the transmission. Attach the servo
îernoval motor.
ï..:'iove the servo motor. Unscrew the breather screw for
:= transmission housing. Unscrew the stretch bolt for the DIFFERENTIAL (with anchor piece)
'r-se shaft and remove the flange. Remove the universal Disassembly
fu:ge on the opposite erd. Drive out the pinion shaft roll pin. Knock out the
DRIVË AXLE 9_10

differential shaft with a mandrel and remove anchor piece.

Turn the differential gears so that the small pinions can be
taken out through the side openings. Take out the large z/
pinions and threaded lock pieces. ----_s
H\,t

--:a)

@ volkswagen
Pinion shaft roll clantping sleeve (roll pin)

Remove both tapered ro11er bearings with a puller and

thrust piece. Do not inter-change shims or spacer washers.
Attach tags tc prevent mixing up right side with left or
vice versa. Remove the lock plates from the ring gear
retaining bo1ts" Remove bolts and take off ring gear.

Exploded view differential with anchor piece

o Vo lkswaoen

Removing differential shaft

1 - Roll pin B - Shim
2 - Shaft 9 - Spacer washer
3- Anchor piece 10 - Lock plate
Assembly 4- Small differential pinion (spider gear) 11 - Boit
Check the differential housing, differential pinions, 5- Threaded lock piece 12- Ringgear
tapered roller bearings, and anchor piece for wear and 6- Large differential pinion (side gear) 13 - Differential hou.-::
damage. Replace if necessary. 7 - Tapered roller bearing
DRIVE AXLE 9-11

Place the ring gear on the flange of the differential

:ousing and tighten bolts to correct torque. Slide the lock
1lates into grooves of bolts heads. Attach the plates to the
:olt heads by closing the open ends with pliers. Secure
:olts by bending the plates down on one side of the hex
*rface. Coat thrust surfacç of the differential pinions in t
I

ùe differential housing with Molykote or similar lubri-

:alt. Insert the large pinions (side gears) through the oval
:pening in the housing. Center the pinions by inserting
--re flange shafts.

rnsert the small differential pinions (spiders) between the

-"rge differential pinions. Turn the small pinions until the
:cres align with those of the housing. Insert threaded lock
;reces with snap rings into the large differential pinions.
Sljde the anchor piece between the threaded lock pieces.
?osition the locating hole of the differential pinion shaft
=r it aligns with the holes of the anchor piece. @ Volkswagerr

:{c1d the anchor piece in place (to prevent binding) and Removing differential shaft
iive in the differential pinion shaft. Make sure the bore
:r the shaft and anchor piece is aligned, then drive the roll
:n in place,
l-ace marked or measured bearing shims and spacer Do not interchange the shims or the spacer washers.
r:shers on the differential housing. Install tapered roller Attach tags to prevent mixing up the right side with the
:eanng using thrust piece P 264. Re-adjust ring and pinion left or vise versa. Remove the lock washers on the bolts of
g::rs if necessary. the ring gear. Loosen the bolts and remove the ring gear.

Assembly
Check the differential housing, the small and large
differential pinions, and the tapered roller bearings for
wear or damage. Replace them as necessary. Replace the
ring gear on the flange of the differential housing and
tighten the bolts to the correct torque. Slide the lock
plates into the grooves of the bolt heads. Bend them
together at the front with pliers. Knock down one side of
the lock plate against the hex. surface

&
ll ....L

@ volkswaqen
Installing large pinion gears

li FFERENTIAL (without anchor piece) @ volkswagen

lrsassembly Securing bolts
(::;k out the differential shaft with a mandrel. Turn the
i,-:cns in, so that the small pinions can be removed
:::ugh the openings in the differential housing. Remove
:i: -arge pinions together with the threaded lock pieces.
both of the tapered roller bearings with a puller
{,,,,,,,,,,,,,,,,:-,rve Coat the thrust surfaces of the differential pinions in the
.Ln: : thrust piece. differential housing with moly paste. Insert the differen-
DRIVE AXLE 9-12

tial pinions through the oval opening on the differential Insert the threaded lock piece, with snap rings, into the
housing. Center the pinions by inserting flange shafts. large differential pinion and install the differential shaft.
Insert the small differential pinions between the large The locating hole in the differential shaft must be
differential pinions and turn them until the bores of the concentric with the differential, in the axial direction. The
gears are in alignment with the bores of the housing. tips of the expansion bolts extend into the locating holes
and thereby retain the shaft. Place the identified, or
measured shims, and the spacer washer for the tapered
roller bearing on the differential housing. Now, install the
tapered roller bearing using thrust prece P264.

Adjust the pinion shaft and the ring gear if necessary.

RING GEAR AND PINION

Adjusting
Adjustment of the ring gear and pinion is very important
for quiet operation of the rear axle assembly. For this
reason the pinion shaft and ring gear are already matched
as a pair during production. They are checked on testing
machines for the correct contact pattern and low noise
level in both directions of rotation. When the ring gear
and pinion set is tested, set according to the design
dimension "R". The dimension "R" is the distance from
the face of the pinion to the ring gear center line. The
pinion is then moved in or out of mesh until the quietest
operation is determined.

The deviation from the design dimension is called "r" and

is etched on the face of the pinion. While making this test.
the ring gear backlash is kept within a tolerance of
O volkswagen 0.0047-0.0070 in. The ring gear and the pinion shaft are
designed in such a way that the deviation "r" must always
Correct position differential shaft Iocating hole be added to the design dimension "R".

2 @ volkswagen

Ring gear & pinion markings & tolerances

1 - Deviation r
2 - Mating number R - Blue print value (54.20 mm for Sportomatic transmission)
3 - Backlash r - Deviation from R indicated in mm (N 18)
DRIVE AXLE 9-13

Earlier versions of the pinion assemblies had either a plus

(+) or a minus (-) etched in front of the deviation "r",
whereas on the newer pinion assemblies, the letter "N"
(\-_- precedes the deviation "r" on the pinion shaft.

The ring gear and pinion sets are also stamped with a
matching set number and should always be replaced as a
complete set.
c
o SHIMS FOR PINION SHAFT
o
G
3 Determining thickness
-ô By adding the design dimension "R" and the deviation
"r" you obtain the adjusting dimension "E". The dimen-
o sion "E" is the distance from the ring gear center line to
the face of the pinion at which the ring and pinion set has
been found to operate best.

If the pinion shaft were installed without the shims you

would find a "basic distance", from the face of the pinion
to the ring gear center line, of 64.70 mm. To find the
shim thickness, subtract the adjusting dimension "8"
from the "basic distance". The shims are available in 0.25
mm, 0.30 mm and 0.40 mm thicknesses' Therefore, the
correct adjustment for this example requires the following
shims: 2 each 0.40 mm, 1 each 0.30, 1 each 0.25 mm. The
co
values are always rounded off to the next 0'05 mm.

PINION SHAFT
Adiusting
Insert the assemblied intermediate plate with the gear
assembly and shift rods into the housing' Do not use a
gasket between the intermediate plate and the housing'
install the four spacer bushings and nuts and tighten them
in a crisscross pattern. Tighten the expansion bolt of the
differential pinion shaft to the correct torque before
making your measurements.

w_e Place a mandrel on the adjusting piece. Insert a dial

indicator and adjust it to I mm preload. Determine the
dimension of the mandrel and the adjusting piece. These
dimensions are marked on the sides of the tools' By
adding these two dimensions, the "actual adjusting dimen-
sion" is obtained.

Install the proper mandrel with the side bearings in the

transaxle housing. Make sure the mandrel is under approx'
0,1 mm axial preload. The mandrel must not have any
axial play when taking measurements. Axiai play can be
eliminated by inserting shims'

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Exploded view of limited slip differential Êdorf,n\OræcÈjc)ÊN
ê**
DRIVE AXLE 9-14

Watch the dial indicator through the hole in the mandrel. The differential can be removed or installed only when tb:
Bring the sensor of the dial indicator into contact with the transmission gears are removed. Insert the differential, wir:
end face of the pinion. A notch on the end of the mandrel the tapered roller bearings, into the housing and install thi
shows the location of the dial indicator sensor. Turn the gasket and the'side cover (without an oi1 seal). LightlS
pinion slowly until the dial indicator shows the highest tighten the side cover using two nuts that are opposite eact
reading. other. This operation preloads the roller bearings. Check tl:
gap between the cover and the gasket with a feeler gauge
Ifthe pointer deflects to the right, the distance is smaller The nominal value for the side bearing preload is appror.
than the "actual adjusting dimension" (63.53 mm). 0. 15 mm.
Therefore, subtract the dial indicator reading from the
"actual adjusting dimension" to determine the distance If the nominal value of 0,15 mm is not attained, replace thl
from the ring gear center to the face of the pinion. Sl spacer on the ring gear side, with an appropriate spacer
To determine the thickness of the paper gasket between the Install the rest of the nuts (with lock washers) on the side
intermediate plate and the housing, subtract the distance cover. Tighten the nuts to the correct torque before making
from the face of the pinion to the ring gear center (63.27 any further measurements. Place the disc of the specia-
mm) from the adjusting dimension "E" (63.38 mm - flange tool on the axle flange and insert it. Slightly tightec
obtained by adding "R" * 1'r"). the expansion bolt.

If the pointer deflects to the left, the distance from the ring When measuring the differential drag, the pinion shaft mus;
gear center to the face of the pinion is larger than the be disengaged and the axle flange oil seal must be removeJ
"actual adjusting dimension" (63.53 mm). Therefore, add from the side cover to prevent additional drag. Measure th;
the dial indicator reading to the "actual adjusting dimen- drag of the assembled differential with a torque wrench.
sion" to determine the distance from the face of the pinion The following values must be obtained to ensure the prope:
to the ring gear center, side bearing preload:
25-35 cmkp (22-30 in. lbs.) with SKF side bearings
Gaskets between the housing and the intermediate plate are 40-65 cmkp (35-57 in. lbs.) with FAG side bearings
available in thicknesses of 0. I mm, 0. 15 mm, and 0.2 mm.
The total thickness of gaskets must not exceed 0.50 mm.
After inserting the gaskets, check the adjusting dimension
"E" once again. The tolerance is t 0.03 mm. No contact
pattern check is required. \
If the gasket thicknessis not enough to obtain the correct
adjusting dimension, the pinion shaft must be disassembled
and the pinion shaft adjusting shims changed accordingly.

SPACERS FOR RING GEAR ADJUSTMENT

Determining thickness
Make sure that the tapered roller bearing outer races are
fully seated in the housing and side cover. Install a 3.5 mm
spacer 51 on the ring gear side, beneath the side bearing.
Install a 3.0 mm spacer S2 on the opposite side, beneath the
other side bearing.

O volkswagen

Measuring differential gear drag

If the differential drag is not within the specified tolerance,

replace the spacer washer. Now remove the differential. Do
not interchange the spacer washers after removal. Remove
both the tapered roller bearings and the spacers. Measure
O volkswagen the thickness of the two spacers with a micrometer. Add
these measurements to obtain the total thickness of the
Checking for required spaces spacers for the ring gear adjustment.
DRIVE AXLE 9-15

RING GEAR BACKLASH

Adiustment
The accurate backlash is marked on the ring gear. The
backlash tolerance is 0.12 to 0.18 mm. Insert the
differential with the tapered roller bearings and the correct
spacers (Sl and 52) into the housing. Install the assembled
transmission intermediate plate with the gears, shift rods
and the predetermined gaskets. Place the spacer bushings on
ihe four opposing studs. Tighten the intermediate plate in a
;risscross pattern.

Install the side cover with an O-ring. Apply a light coat of oil
to the O-ring. Tighten the differential pinion shaft
expansion bolt before tightening the side cover to the
;orrect torque. When tightening the side cover, make sure
rhe ring and pinion does not bind. There should always be
;ome backlash-
@ volkswagen
Tighten the side cover to the correct torque. Block the
Cifferential pinion shaft with a holding fixture at the Securing differential securing shaft
:xpansion bolt. Place the disc of the special flange tool on
rhe axle flange. Insert the axle flange. Attach a dial indicator
ro the bracket. Fasten the bracket to the flange surface
usingaM l0x 130bolt.
In order to check backlash correctly, the spacer Sl should
-\ttach a sensor to the dial indicator. Set the dial indicator be 0. 1 mm thinner than one half of the sum of spacers S I
;o that it contacts the bracket for the clutch cable with a and 52. The spacer 52 should be 0.1 mm thicker than one
:iight preload. Move the dial indicator bracket back and half of the sum of spacers S I and 52.
:orth. Read the backlash on the dialindicator.
Spacers are available in increments of 0. I 0 mm from 2.5 to
Turn the ring gear approximately 90o and measure the 3.7 mm. A shim, 0.25 mm thick, permits adjustments to the
racklash again, The readings should not vary by more than nearest 0.05 mm. The rounded off spacer thickness should
-1.05 mm. not differ from the calculated spacer thickness.

The spacers S1 and 52 can be exchanged byusingspecial Before measuring, remove any burrs that may be on the
edges of the spacers. Measure the thickness of the two
'co1s, to obtain
the permissible backlash. Be sure that the
:Jtal thickness of the spacers is not varied. Check the axle spacers with a micrometer at four different points; the
,..'raft oil seals for damage and replace them if necessary, thickness tolerance is 0.02 mm.
BRAKES 10-1

BRAKES IO

INDEX
Page
Page
-dN4DEM MASTER BRAKE CYLINDER .. 1O-1 LATERAL WOBBLE l0-8
Removal .......10_1 inspection
Instaliation .....10-1 REAR BRAKE LININGS
10-8
:CAKE FLUIDRESERVOIR .....10-3 Removal
I 0-8
Removal l0-8
....... 10_3 Installation I 0-8
Installation 10-3 VENTINGCLEARANCE.... l0-9
:qAKE LIGHT SWIT'CH 10-3 Adjustment
Removal 10-9
10-3 TANDEM BRAKE MASTER CYLINDER
Installation l0-10
.\djustment
1 0-3 Disassembly .......... l0-10
10-3 Assembly
:iONT BRAKE DISC l0-10
- 10-3 DUAL CIRCUIT BRAKE SYSTEM
R.emoval
lrstallation
10-3 wARr\tNc DEVTCE ...... 10_10
lo-4 Checking ...... 10_10
-.ITERAL WOBB'-E ta-4 Disassembly ....10-10
rlhecking Assembly
l0-4 .....,10_12
:;AKE PADS. l0-4 BRAKECALIPERHOUSING ...".10-12
, lecking Rec.onditioning...
10-4 ....10-12
:\TING CLEARANCF r0-4 Disassembly .... 10_12
- irecking 10-4 ,A.ssembly ."....10_12
;:
id.lustment
CNT BRAKE PADS
1:movai
I:rstallation
r:dR BRAKE DISC
.
10-4
ro-4
10-4
I 0-5
l0-6
BRAKE PRESSURE REGULATOR
Removing
Installing
Checking and
REAR BRAKE
Removing
adjusting
FRICTION
..,. .. 1O-12
.....10-12
., "...10_i2
" l0_1
. 10.13
2
q
R.emoval 10-6 .....10_13
.:lsrallation 10-6 Installing ...... 10_13

*,I!NDEM
MASTER BRAKE CYLINDER
;*.loval
i::: rhe brake fluid from both chambers of the brake
. - :cntainer. Remember that brake fluid is toxic. The
r --, should not come into contact with the paintwork,
'':-:-SC it contains acid. Remove the floor lining (front
. lnd pul1 the accelerator peda1, toward the rear, out
: :---: push rod.

i ... loosen the hex. bolts for the floor board attachment
.r : :3nove the floor board. Now, remove the underfloor
'-'":J:ion from the front axle, and unscrew the brake
.r::: rn the tandem master brake cylinder. Loosen the
:: 1, nuts on the flange of the tandem master brake
Pull the connecting lines fiom the brake fluid
, ---ler.
.;r. lir and remove the tandem master brake cvlinder.

n5.=[lation O Volkswagen
I
' )rie to position the piston rod correctly when
r:r:::-.r1g the tandem master brake cylinder. Molsten the
Removing master cylinder
-::::: sleeves with some brake fluid to facilitate the
.::i:.: ltion of the connecting lines from the brake fluid
'ri :.;Jir to the tandem master brake cylinder.

vehicle. Tighten the hex. nuts for the tandem master

.,.:,- :eal the master brake cylinder flange with a sealing
- - , ro prevent water from
brake cylinder to the specified torque. Check to see that
entering the interior of the the protective cap on the piston rod is seated correctly.
BRAKES 1O_2

2 1 14 15

11

4 6 8 12 r0 16 O Volkswagen

Exploded view of front wheel assembly

I - Hex. boit 5- Cheesehead screw 9 - Tapered roller bearing 13 - Bearing outer race
2- Locking plate (only 914) 6- Clamping nut 10 - Sealing ring 14 - Hex. bolt
3 - Caliper 7- Nose washer 1l - Tapered roller bearing l5 - Spring ring
4 - Hub cap 8- Brake disc 12 - Beaing outer race 16 - Guard plate
BRAKES 10-3

the hex. screws for the floor board attachment and

remove the floor board. Clamp a piece of sheet metal,
0.158 in. thick, between the brake pedal and the stop for
the brake pedal.

Loosen the lock nut for the adjusting screw on the brake
light switch and turn it so that the brake light will go on.
Tighten the lock nut and check the brake light switch
again to insure that it is working properly.

@ volkswagen
Adjusting piston rod end play

l,ljust for approx. 0.039 in. clearance between the piston

::.1 and the piston in the tandem master brake cylinder. If @ volkswagen
::.iuûed, loosen the lock nut on the piston rod and turn
:-e piston rod as required. Bleed the brake system, check Brake light switch screw
re brake lights and the warning device for the dual circuit
ïr-ke.

BRAKE FLUID RESERVOIR

Removal
::1d back the front end cover and pull the overflow hose
:rm the brake fluid reservoir. Extract the brake fluid
::m the reservoir, Remove the screws for the holding
;:ap and remove the strap from the brake fluid reservoir.
1:1l the intermediate hoses from the brake fluid con-
:-r:-ner, making sure that the connecting lines to the
:;:dem master brake cylinder are not puiled in an upward
:-ction.
hrstallation
lr:ring installation, moisten the connecting sockets of the
:r-:lie fluid reseryoir with some brake fluid to facilitate
::: attachment of the intermediate hoses.

SRAKE LIGHT SWITCH

Renroval @ volkswaqen
lùe out the floor covering (front left) and remove the Adiusting brake light switch
r,:;elerator pedal out of the push rod toward the rear.
-:osen the hex. bolts for the floor board attachment and
:srove the floor board. Loosen the fasteneing screws for
:: brake light switch. Pull off the cable connections and FRONT BRAKE DISC
jsaove the switch. Removal
Unscrew the brake line on the ring fitting of the caliper.
Gtallation Depress the brake pedal and the pedal arrester and lock it
l: install the brake light switch, proceed in the reverse in this position. This prevents the brake fluid from
:rler of removal. Adjust the switch, if necessary. flowing out of the tank. Remove the caliper at ambient
temperature. Remove the cap for the front wheel hub,
ldjustment alternately, with the proper tool. Loosen the socket screw
}ke out the floor cover (front left) and remove the for the clamping nut. Unscrew the clamping nut and
:ru:;:lerator pedal of the push rod toward the rear. Loosen remove the brake disc together with the wheel bearing.
BRAKES 1O_4

@ volkswagen
Loosening clamping nut

@ volkswagen
lnstallation
Check to see that the wheel bearing is properly adjusted. Brake pads mtnimum thickness 0.078
Tighten the clamping nut slightly while turning the wheel, between arrowheads
or hub, so that the taper rollers can rest firmly against the
bearing races. Loosen the clamping nut until the nose
washer can barely be pushed along from the side with a
screw driver and no noticeable bearing play is indicated
during axial movements of the wheel hub. Do not support VENTING CLEARANCE
the screw driver against the hub. Checking
If the pedal travel is too long, though the brake is
Tighten the socket screw of the clamping nut to the correctly adjusted and bled, the fault is often due to
specified torque. Check the adjustment once agâin by excessive venting clearance of the front brake linings, The
moving the nose washer and without turning the clamping venting clearance is measured with a feeler gauge, placed
nut. Correct it if required. The slot width of the clamping between the brake pad and the brake disc, and should be
nut should be 0.098-0.1l2 in., so that perfect clamping is approx. 0.002-0.008 in. A ventinC play in excess of
obtained even under unfavorable tolerance overlaps. 0.008 in. is generally the result of the stationary rubber
Tighten the caliper bolt to the specified torque using new ring "glueing" to the piston. This glueing may occur after
lock washers. Bleed the brake lines. long parking periods.

LATERAL WOBBLE FRONT BRAKE PADS

Checking Removal
Remove the brake pads and adjust the front wheel bearing Knock out the holding pins for the brake pads with a
play to specifications. Fasten the measuring tool, with the punch. Pull the brake pads out of the caliper with a
holding pins. Align the tool and tighten it with a wing pulling hook. Do not push the holding bolt of the pulling
screw, Insert a dial gauge and tighten it with a fastening hook on the brake pad too far inwards, since the hook
screw, might be caught on the piston anti-rotation lock and the
brake lining can no longer be pulled out.
Slide a feeler pin on the dial gauge and attach it under a
slight tension. The feeler tip should touch 0.394-0.591 Adjustment
in. inside the brake disc OD. In borlerline cases, the lateral Remove one brake pad and slide a wooden board at least
wobble must be measured on both sides of disc. 0.236 in. thick, between piston and disc. Step energeti-
cally on the brake pedal in order to release the piston and
The max. permissible lateral wobble is 0.008 in. Brake make it run smoothly. Push the piston back with piston
discs with a higher lateral wobble must be replaced, Install setting pliers.
the brake pads.
Repeat the operations several times and then install the
BRAKE PADS brake lining. Proceed in the same manner for the other
Checking pistons. If this method is unsuccessful, remove the caliper
Brake pads must be replaced when the remaining thick- and recondition it. Also replace the stationary rubber ring.
ness is 0.078 in. Always change the four brake pads of one
axle simultaneously. Replacing only one or two pads of When the piston is set back, brake fluid will be forced out
one wheel is not recommended. In addition, replace the of the caliper into the filling tank, resulting in an
spreading springs of both calipers when changing the overflow; for this reason, remove some brake fluid prior
brake pads. to starting the work and fill it up again when finished.
BRAKES 1O_5

For cleaning, use only alcohol. Sharp-edged tools are not

to be used. Blow out the caliper with compressed air.
Check the protective cap for damage. Hardened, brittle or
torn protective caps must be replaced. Correct the
position of the piston with piston rotating pliers, if
required.

@ volkswagen

Removing holding pins

lnstallation
Replace pads which are oil soaked, have deep cracks or
iave separated from the lining plate. Push both pistons
back to their basic position with a piston setting tool'
Check reservoir during this operation as brake fluid
:ehind pistons will be forced back into reservoir' This
rray cause it to overflow, out of reservoir. Draw some
:iuid out, as needed, or wrap reservoir with sponge or
:hick dry cloth to absorb overflow. Clean the seat and the
r*ide surfaces of the brake linings in caliper, which
:;quires the removal of the piston anti-rotation locks'

@ volkswagen
Protective caP

Accurately check the position of the piston with a piston

gauge. The gauge should always be held against the upper
guide surface in caliper, that is, opposite to the direction
àf rotation of the brake disc when driving forward, Install
the piston anti-rotation lock in the correct position' The
ring-shaped portion of the anti-rotation lock should be
pushed into piston head. In addition, the anti-rotation
lock should be under the piston recess.

A perfect seat of the piston anti-rotation lock also

guaiantees the specified 20o position of the piston.
Ôorroded or damaged piston anti-rotation locks must be
replaced. Check the brake disc for wear. Insert the brake
pad into the caliper.

Install used pads in same position and side from which

they were removed. Insert a new spreading spring for the
brake pads in the correct position. Install holding pins for
the brake pads in the caliper.

Never knock a holding pin in with a punch that is smaller

in diameter than the pin, since this may cause the front
@ volkswagen collar to be cut off by the clamping sleeve. The holding
pins should always be knocked in with a hammer only'
Pushing back piston with special tool Corroded or damaged holding pins must be repiaced.
BRAKES 10-6

REAR BRAKE DISC

Removal
Depress the brake pedal (with arrester) and lock them ti
this position. This prevents the loss of brake fluid.
Unscrew the brake line on the brake hose of the rear ari.
controi arm. Loosen the countersunk screws on the brake
disc and remove the disc.

O Volkswagen
Correct position of piston O Volkswagen
Rear disc attdchment screws

lnstallation
Clean all parts and replace those that are worn. Tightec
the caliper to the specified torque, and bleed the brake
lines,

@ Volkswagen
Piston with anti-rotation lock inserted

Step several times, energetically, on the brake pedal with

the vehicle stopped, so that the pistons and the brake
linings will take their proper position for correct opera- O volkswagen
tion. Then check the level of the brake fluid in the fluid
container. Replenish the fluid if required. Returning pistons to end of stroke
BRAKES 1O_7

7'.t

1 - Closing screw - cover end

2 - Counter nut
3 - Housing - cover end
4 - Spindle
5 - Threaded sleeve
6 - Compression spring
7 - Piston
8 - Cone
9- Friction pads
10 - Friction pads
11 - Piston
12 - Housing - flange end
13 - Spring
14 - Spindle
15 - Thrust piece
16 - Shaft
17 - Actuating lever
18- Brake cable
19 - Closing screw - flange end
20 - Resetting shaft
21 - Connection
25 - Inclined slot
'25 - Canier
27 - Housing
28 - Spring ring (safety connection)
29 - Sealing ring
30 - Hexagon

@ volkswagen

Rear brake assembly

BRAKES 1O-8

3 î

.l I

@ volkswagen

Exploded view of rear wheel assembly

1 - Hex. bolt 6 - Hex. bolt

2 - Spring washer 7 - Spring washer
3 - Caliper 8 - Holding Plate
4 - Countersunk screw 9 - Cover plate
5 - Brake disc

LATERAL WOBBLE lnstallation

lnspection Replace pads having large cracks, are oil soaked, as well as
Attach a measuring device, as described under "Inspection pads which have separated from the plate. Always place
of Front Axle Brake Disc Lateral Wobble". Pull the brake new pads against new plates. Place the piston resetting
disc toward the hub by means of wheel studs' To tool between the pistons and apply a light load. Remove
eliminate distortion of the disc, place flat steel washers the closing screw on the cover housing of the caliper.
under the wheel studs.

Tighten the wheel studs to the specified torque. The max' Loosen the counter nut and set the piston back by turning
permissible lateral wobble is 0.008 in. Replace discs, if the the spindle clockwise, by means of a hex. pin spanner
lateral wobble is above this level. while maintaining the tension of the setting pliers.
Remove the closing screw on the flange end of the caliper.
REAR BRAKE LININGS
Removal This requires a 3lS" extension with a 4 mm (5132 in.)
Pull out the locking eyes and knock out the holding pins socket, which is introduced through the bore of the rear
of the brake pads with a punch (in the direction of the axle control arm. Set the piston back while maintaining
vehicle center). Pull the pads with a pulling hook out of the tension of the resetting pliers by rotating the setting
the caliper. shaft counterclockwise.
BRAKES 1O_9

cover housing of the caliper. Loosen the lock nut and

adjust the venting play between the brake disc and the
brake pad by means of a 0.008 in. feeler gauge by rotating
the spindle with a wrench.

Æ
@ volksw agen
Removing closing screw @ volkswagen
Adjustin{ inside v enting clearance

::sert the brake linings into the caliper. Always install

.:sed linings in accordance u.ith their markings on the
r,lusing half. Locate the brake linings with holding pins'
*:ihout the spreading spring, and adjust the 0'008 in'
r:rting clearance on both ends of the brake disc. Remove
-: holding pins and insert the disc again together with
:: spreading spring and secure.

TTTENTING CLEARANCE
Adjustment
::: a better adjustment of the venting clearance, remove
--: spreading spring and locate the brake pads with
r:lCing pins. In addition, the brake disc wobble should
r,: exieed 0.008 in. Remove the closing screw on the

@ volkswagen

Adiuster and brake disc deflection compensator

1 - Piston 6 - Spacing sleeve

2 - Stop washer 7 - Compression spring
3 - Lock washer 8 - Spacing washer
O volkswagen
9- Friction.pin
4 - Spring housing
Adiusting v enting clearance 5- Friction disc
BRAKES 1O_10

Tighten the lock nut. Actuate the hand brake once and
check the venting clearance. Adjust ciearance, if required.
Now, mount the closing screw. When new calipers are
installed, the venting clearance also requires adjustment,
since the calipers are supplied with a iarger adjusting
dimension due to the permitted adjusting limits. Do not
actuate the caliper until the venting clearance has been
set.

TANDEM BRAKE MASTER CYLINDER

Disassembly
Loosen the stop screrv for the intermediate piston and
blow the intermediate piston out of the housing with O volkswagen
compressed air. Clamp the pressure piston lightly in a vise Se c tio n t hr ough sleev es
and loosen the pressure piston stop screw. Compress the
pressure spring slightly so that the threads for the stop Primary Separating
screw in the pressure piston arynot damaged.

DUAL CIRCUIT BRAKE SYSTEM WARNING DEVICE

Checking
Check the warning device whenever the hydraulic brake
system is being repaired. Turn on the ignition. The hand
brake warning light should go on. Now, start the engine.
Depress the brake pedal to the pressure point. A second
mechanic can simulate the loss of one brake circuit by
opening a bleeder on one of the wheel cylinders. The
warning light should go on.

Close the bleeder and release the brake pedal. The light
should go out. Repeat this operation on the second brake
circuit. If no lamps are lighting up during one of the tests,
check the warning system in the tandem brake master
cylinder.

BRAKE CALIPER
Disassembly
Remove the caliper from the vehicle. Loosen the bleeder
valve and blow any brake fluid carefully out of caliper.
Clamp the caliper with the flange into a vise. Use soft vise
jaws. Remove the piston retaining plate, clamping ring and
the protective cap.
O Volkswagen
Loosening pressure piston stop screw

Loosen the brake warning light switch. Loosen the closing

screw and remove the piston together with the com-
pression spring by blowing them out of the housing with
compressed air.

Assembly
Clean all parts with alcohol, and blow out particles with
compressed air. Push the intermediate piston, with a
non-metallic object, into the housing until the hole for the
hex. stop screw is freed. Screw in the stop screw together
with a new sealing ring.

Check the stop screw positioning. The stop screw should

be in front of the intermediate piston and the inter- O v.tl
mediate piston should move up to the housing bottom.
When changing the sleeves, position them correctly. Removing pisron rera[ning plate
BRAKËS 1O_11

Gl n /F,w
-*fuf,u

'trry ll:ge lt 14 t3

fwtu,*
24 =@ ,êi la
26 À. â*y
2Br
27
l

26

22 23
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Exploded view of master cylinder

I - Friction pad retaining pin 1 2 - Fillister head bolt 22 - Btake warning switch
3 - Spreader spring 13 - Cover housing 23 - Round cord ring
I - Brake friction pad 14 - Seal 24 - Screw
-{ - Piston retaining plate 15 - Flange housing 25 - Round cord ring
5 - Clamp ring 16 - Brake disc 26 - Compression spring
6 - Seal 17 - Rubber seal 27 - Piston
? - Piston 18 - Dust cap 28 - Sleeve
3 - Rubber seal 19 - Filling disc 29 - Tank plug
9 - Dust cap 20 - Separating sleeve 30 - Washer
ll - Bleeder valve 21 - Intermediate piston 31 - Tamdem brake master cylinder housing
---! - Ilexagon nut
BRAKES 10_12

Push one piston out of the caliper with compressed air.

Start with approximately 28 psi and increase, if necessary.
Hold the piston in position with a piston setting fixture.
In addition, a hardwood or rubber block about
0.197-0.394 tn (3116-3 18") thick must be inserted into
the housing grooves so that the piston is not damaged.

,:::

O volkswaqen

Piston with retaining plate in correct posttion

Check the 20o position of the piston with a piston gauge.

Correct this value with piston rotating pliers if necessary.
Insert the piston retaining plate in the correct position.
Push the second piston out of the caliper and repeat the
respective steps in sequence.

BRAKE CALIPER HOUSING

Reconditioning
The brake caliper may be disassembled only if the joint
between the two housings becomes leaky and the fluid
channel O-rings have to be replaced.

Disassembly
Remove the four fillister head caliper housing bolts.
Remove the cover housing.

Assembly
O volkswagen Instail two new fluid channel O-rings. Use new nuts and
bolts. Observe the different bolt lengths. The shorter bolts
Removing piston are on the outside. Align the housing halves with each
other. Tighten the bolts in the specified sequence to 7
ft.-lb. Check the relative position of the housing halves
once again. Tighten the bolts in the same sequence to the
The cylinders can only be repaired one at a time, since no specified torque.
pressure can be built up in the caliper when one piston has
been removed, Remove the rubber seal using a plastic or BRAKE PRESSURE REGULATOR
hard rubber rod so that the seal ring groove is not Removing
damaged. Depress the brake pedal slightly with the pedal retainer
and lock them, so that the brake fluid will not run out
Assembly
when the brake lines are disconnected. Remove the brake
Clean all parts with alcohol or brake fluid. Check the parts lines at the brake pressure regulator. Remove the bolts on
for wear and replace as necessary. If a cylinder is the flange of the regulator and remove the regulator.
damaged, the entire caliper must be replaced. Replace the
seals when repairing the caliper. Coat the piston and new lnstalling
rubber seal with a thin coat of brake cylinder paste, Bleed the brake system and check the operation of the
brake pressure regulator.
Install a new rubber seal in the cylinder groove. Insert a
piston into the correct position using a piston gauge and Checking and adjusting
push it into the cylinder with a piston setting fixture. Do To determine whether or not the brake pressure regulator
not cant the piston, always use a piston retaining tool. is operating, one mechanic must step down hard on the
Install a new seal and clamp ring. brake pedal while another mechanic places his hand on
BRAKES 1O_13

the valve to feel if the piston in the regulator is moving. system, if necessarY.
(When the brake pedal is released, a slight knock should
be felt on the regulator).
REAR BRAKE FRICTION
Check the following items in the sequence shown: Removing
Remove the bleeder valve on the left front caliper and Pull out the ctips and drive out the friction pad retaining
install a connector. Install a similar connection on the left pins (toward vehicle center) using a punch. Pull the
rear caliper. Remove the caps from the hose connections friction pads out of the caliper with an extractor. If the
and connect both hoses. Bleed both hoses and pressure friction pads are to be reused, they must be marked to
gauges via the bleeder valveg of the pressure gauges. .Apply match their respective housing halves. Friction pads must
the brake pedal several times with force so that a pressure not be interchanged as this can cause unever braking.
of at least 1422 psi is attained in the front brake circuit.
lnstalling
Then apply a load to the brake pedal until the pressure Oily or cracked friction pads or pads which separated
gauge of the front brake circuit shows a pressure of 924 from the metal plate must be replaced, Here too, all four
psi. At this pressure the second pressure gauge in the rear rear linings must be replaced. Place the piston retaining
brake circuit should indicate 793.5 psi ! 28 psi. The same tool in between the pistons and lightly preload the
measurements must be made at a pressure of 1422 psi in pistons. Remove the closing screw on the cover housing of
ihe front brake circuit. Here the pressure in the rear brake the caliper. Loosen the lock nut and set the piston back
;ircuit should be 1023.8 psi + 43 psi. by turning the spindle clockwise with a hex. pin spanner
(4 mm) maintaining the preload on the setting pliers.
If the specified pressures in the rear brake circuit are not
attained or are exceeded, the preload of the spring should Insert the brake friction pads into the caliper. Install used
be changed by turning the adjusting screw until the friction pads into the housing halves according to their
:equired pressure is attained. By turning in, the pressure markinls from removal. Position the friction pads with
-ncreasesin rear axle circuit; by turning out, the pressure retaining pins without the expanding spring and set for a
decreases. 0.2 mm clearance on both sides of the brake disc.

Ii the specified tesf pressure is not attained even after Remove the retaining pins again and install the pads with
naking adjustments, the brake pressure regulator must be the expanding spring and secure. Do not disassemble the
leplaced. Seal the adjusting screw and nut with sealing rear caliper, since disassembly of the piston may damage
:ompound after tightening the lock nut. Bleed the brake the automatic adjusting fixture.

O volkswagen

Brake pr es sure regulator

1 - Spring 5 - Spring
2 - Piston 6 - Pressure chamger
3 - Plug 7 - Clhamber
4 - Check valve
FRONT SUSPENSION '11-1

FRONT SUSPENSION IT

INDEX
Page Page

FRONT AXLE l-l " " " 11-5

Inspectionofcomponents ...
Measuring l- 1 Inslalation ' 11-5
Height adjustment . 1- I rnÀlvsvensEcRossARM. . '.t1-7
Adjustment 1*l Removal " ' tl-'
r-3 ôheckingtheindividualparts'' "''' 11-7
TOE.IN
Adjustment t-3 Instaltation ' l1-"1
Track differential angle t-4 T.RSI'NBAR ' ""'ll-8
CAMBERANDCASTER.... t-4 Removal ""'ll-8
Adjustment of camber t*4 Checking " ll-9
Adjusting the caster -4 Installation ' I 1-9
FRONT WHEEL BEARINGS -4 AUiTLTARYCARRIER .-....11-9
Removal -4 Removal " " ' 11-9
Adjustment t-4 Checking "'ll-9
Installation 1-5 Installation " 1 1-9
SHOCK ABSORBER STRUT l-5 SUPPORTING BEARING AND
Removal 1-5 eEÂntNeRUBBER ""ll-9
""" 11-9
Replacement

FRONT AXLE
lteasuring
Iie heigirt adjustment of the front axle as well as the
wheels is an important factor in deter-
-:ing of the holding
:.:sition
the road and cornering char.acteristics of a
t:liclé. Excessive deviations from the specified values for
--e height adjustment, track, camber, caster and the track
angle may considerably influence otherwise
='t.t.tTtlut
fiod. driving Jharacteristics and result in abnormal
tire

\{lasuring of the vehicie requires an optical axle meas-

*i-ng deiice of the type offered by dealers^ in various
::akes. For this reason, the actual measuring of the vehicle
i not described in detail and only instructions for
rCjusting and making corrections are given.
O volkswagen
['leight adjustment
Height adiustment screw
te.- u..tiut" height adjustment of the front axle is the
:asis for m.ar.rring the vehicle. Prior to making adjust-
ll.n,r, ,"" that the vehicle has the proper dead weight
rrth the fuel tank filled and a spare wheel'
\ext, check the tire pressure. Drive the vehicle on to a Clean the closing cover on the adjusting lever of the
;;;t bar so ttiat the marking for the center of the
-easuring platform or level ground.
;i;;itg cover is easily seen. Loosen- or. tighten the
Adjustment screw of the tàrsion bar until the dimension "b"
.Oittli"e"marking
Itait ttre center on the front wheel hub caps' Push the ." ift" for the center of the closing cover is
rehicle down several times near the front shock absorber àttui""O. Depréss the front of the vehicle again and
:ld permit it to rise due to its own strength' Measure the permit it to rise under its own strength'
rertiial distance from a level surface or measuring "b" again, on both sides, and correct it
:iatform to the center of the front wheel (dimension Check
- dimension
:-a"). Dimension "a" less 90 mm is dimension "b"' This if tequiteO. Though tolerance of t 5 mm for
ihe
dimention "b" may be exploited' the difference between
::rnension "b", may be set on a height gauge for the
the lefthand and righthand end may not exceed the max'
:avorable measuring of the adjusting lever for the torsion
:ar on the closing cover.
of 5 mm.
FRONT SUSPENSION 11_2

Difference ongle of 20o lurninE rodius l-î"h'tF]

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10'=0.423" I strur oorustm.nt I
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ot 20o left turning rodius ond 20o right turning
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comber

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Measuring chart

Small triangles in the measuring card arc marking the

permissible adjusting values for a quick checkup and
evaluation of the measuring results.
FRONT SUSPENSION 11_3

Volkswagen

Front axle assemblY

4 - Dust boot 7 - Transverse control arm with rubber mounts

1 - Suspension strut
5 - Rack & Pinion steering 8 - AuxiliarY support
l - Strut support bracket with grommet 9 - Ball joint
3 - Steering shaft support bearing with $ommet
6 - Brake caliPer, comPlete

TOE.IN
Adiustment
thé toe-ln must be set with the steering gear in the center
p"Jti.", àtfterwise the total wheel lock left and right will
turning circle'
i;ty;;lii.h in turn, will result in a varying side'
f"iti tft. ,i..ring wheel to full lock on one Hold the
*tt"tt iniiris position and estimate the position of
rt.rtl"g
the bo"ttom steering wheel spokes in relation to the
A - center of hub horizontal.
B - center of torsion
Turn the steering wheel toward the other end up to the
tutt toct< position and estimate the location of the bottom
steering wheel spokes' If the position of the bottom
;;;;td wheel spokes is different at the lefthand and
riÀitiftrîO lock, t-he steering wheel must be loosened and
adjusted.

Turn the steering wheel to the center position (straight

ahead) and adjuJ the lefthand and righthand track rod'
Uy -Éuttt of àn optical axle measuring device, in such a
Vol kswagen ,nurrrr., that each wheel has the specified toe-in' (Wheels
should be loaded with 33 1b.). The vehicle weight should
Height of front axle correspond to the dead weight specifications'
FRONT SUSPENSION 11_4

Track differential angle Example: Camber at 20" leftinand lock = r 3o. Camber
A faulty track differential angle cannot be compensated at righthand lock = - 2o (20" lock set on righthand
for by adjusting the track rods. If the differential angle wheei). To-tal camber_odifference = 5o. Total camber
deviations are higher, the steering arm, the track rod or dltterence 5 x I.5= /.5 caster.
the king pin on the shock absorber strut are distorted.
FRONT WHEEL BEARINGS
CAMBER AND CASTER Removal
Adjustment of camber Depress the brake pedal, and the pedal support so that the
Fold back the front end covering. Completely remove the brake fluid will not run out of the refill tank. Loosen the
sealing compound on the pressure plates and the support- hollow screw of the brake line on the caliper. Loosen the
ing bearing. Mark the position of the single-hole and the fastening bolts for the caliper and remove it. Pry off the
double-hold pressure plates and loosen the cheesehead cap of the front wheel hub with the proper tool.
screws.
Loosen the cheesehead screw of the clamping nut for the
wheel bearing. Unscrew the clamping nut and remove the
tab washer. Remove the front wheel hub along with the
brake disc and bearing. Extract the front wheel bearing
using a shop press. The brake disc may have to be
removed, depending on the type of shop press.

Mark the brake disc and hub. Loosen the screws on the
brake disc and remove the hub. Heat the hub to
l2O 150"C. Press out the internal tapered roller bearing
with the sealing ring. Press out the outer race of the outer
tapered roller bearing.

Adiustment
Push off the cap for the front wheel hub with the proper
tool" Loosen the screw of the clamping nut. Tighten the
clamping nut slightly while turning the wheel or hub, so
that the taper rollers will be positioned correctly against
the bearing races.

O volkswagen

Camber and caster adiusting screws

Shift the supporting bearing with the shock absorber strut

in accordance with the desired adjusting values for the
camber, crosswise to the vehicle length. A 0.039 in.
movement on the supporting bearing, càrresponds to a 0o
6' angle change on the shock absorber strut,

Shifting the supporting bearing with the shock absorber

struts in a lengthwise direction will change the caster
adjustment. Tighten the socket screws, Seal the plates, as O Volkswagen
well as the supporting bearing with a permanently elastic
sealing compound. Loosening clamping nut

Adjusting the caster

Complete the pertinent steps as described under "Adjust-
ing the Camber". Shift the supporting bearing with the
shock absorber strut in an axial direction. Any shift in the Loosen the clamping nut until the tab washer can be
transverse direction will change the camber adjustment. pushed easily and laterally by means of a screwdriver, so
that no perceptible bearing play is felt when the wheel
On certain optical measuring instruments the caster hub is moving axially.
cannot be directly read. The caster can be determined
from the total camber difference at 20" lefthand lock and Do not support the screwdriver against the hub but hold it
20o righthand lock x 1.5. freely in hand. Tighten the socket screw of the ciamping
FRONT SUSPENSION 11_5

nut to the specified torque without turning the clamping

nut and check the adjustment once again by moving the
tab washer. Correct, if required.

O volkswagen

Removing outer rdce of outer tapered bearing

Adjust the front wheel bearings. Tighten the hex. bolts for
O volkswagen the caliper, together with the spring washers, to the
specified torque. Tighten the hollow screw of the brake
Checking tab washer play line on the caliper to the specified torque.

SHOCK ABSORBER STRUT

Removal
Loosen the brake line on the holder of the spring strut
The slot width of the clamping nut should be (first push the brake pedal with the pedal support slightly
0.098-0. 118 in., so that perfect clamping is obtained downwards, so that the brake fluid cannot run out of the
even under unfavorable tolerance overlaps. Coat the refilling tank). Loosen the fastening bolts for the caliper
clamping nut and the tab washer lightly with lithium and remove the complete caliper. Push off the front wheel
grease and fit the cap without grease by means of a plastic hub cap with the proper tool.
hammer or the like.

lnstallation
Tapered roller bearings of various makes (SKF, FAG and
Timken) are installed as standard equipment. New bearing
parts (bearing outer race and the bearing inner race with
taper rollers) can be interchanged for parts of the same
make; be sure that a complete bearing consists of parts
made by the same manufacturer.

Clean both tapered roller bearings carefully and check for

wear and damage; replace, if required, Heat the hub to
120 1 50oC. Press in the outer race of the inner tapered
roller bearing. Insert the inner race of the inner tapered
roller bearing and press in the sealing ring, until the sealing
ring is flush with the hub.

Press in the outer race of outer tapered roller bearing.

Position the brake disc on the hub in such a manner that
the marks are in alignment. O volkswaqen

Tighten the hex. bolts of the hub brake disc to the Removing brake line
specified torque, Be sure that the bolts are mounted from
the inside, so that the screw head comes to rest against the
brake disc. Place new spring washers under the nuts. Fill
ihe hub with approx. 65 cc of iithium grease (multi- Loosen the socket screw of the wheel bearing clamping
purpose grease), coating the bearings well. The space nut; screw out the clamping nut and remove the tap
between the sealing lips of the sealing ring should also be washer. Now, remove the brake disk and the bearing.
jlled with grease, so that the outer sealing lip will not run Next, loosen the hex. bolt for the guard plate and remove
Jry. the guard plate.
FRONT SUSPENSION 11- 6

Unlock the castle nut of the track rod joint and pull off oil moves in between its cylinder and determine the idle
the ball joint with a puiler. Unscrew the adjusting screw of travel of the shock absorbers by a short counter move-
the torsion bar and remove the adjusting lever. Loosen the ment. If the idle travel is too high, replace the shock
hex. screw for the ball joint of the shock absorber strut. absorber strut. Check the steering arm using a special tool.
Push the transverse control arm downwards and puil the
ball joint out of the shock absorber strut.

Uniock the hex. nut on the shock absorber strut. Loosen

and remove the lock washer, tab washer and the shock
absorber strut. Loosen the socket screw for the guard clip
on the front transverse control arm bearing and remove
the guard clip

I nspection of components

Check the shock absorber strut, with the steering knuckle

using a special tool. Clamp the special tool in a vise and
slide the bearing pins of the shock absorber strut into the
test holes of the tool.

If the bearing pin cannot be pushed in up to the stop

against the flange section, the bearing pin is bent and the
shock absorber strut must be replaced. Check the seats of
the front wheel bearings for seizing marks.

Rotate the shock absorber strut between the measuring @ Volkswaoen

pin and locate it with the holding pin. If the shock Checking steering arm
absorber strut cannot be rotated between the two
measuring pins, replace the shock absorber strut. In
addition, a maximum distance of only 0.087 in. is
permissible between the shock absorber strut outer tube The attaching of the special tool to the steering knuckle
and the face-end measuring surface of the measuring pin. by means of 3 screws should be readily effected in such a
If this dimension is exceéded, the shock absorber strut manner, that the steering arm is between the inspection
should also be replaced, holes. The large bore dia. for the track rod joint in the
steering arm should not be outside the inspection hole oi
the special tool. (Sight test). Replace the shock absorber
strut if the deviation exceed the permissible dimensions.
I nstallation
Install the hollow rubber spring without any lubricant.
Tighten the hex. nut on the shock absorber strut to the
specified torque. Use a new lock washer and be sure that
the tab of the lock washer points upwards when fitted.
Tighten the hex. bolt for the ball joint to the specified
torque. Be sure to fit a steel washer between the sealing
bellows of the ball joint and the shock absorber strut.

@ volkswagen
Checking straightness of shock absorber

Check the shock absorber strut for hydraulic defects and

leaks.If the entire shock absorber tube is covered with oil,
replace the entire shock absorLrer strut, Clamp the shock
absorber strut vertically into a vise, with the piston rod
up.

Push the shock absorber down several times, so that the placement of steel washer
o volkswagen
FRONT SUSPENSION 11_7

\{ount the adjusting lever to the torsion bar as described.

Push the transverse control arm, with the shock absorber
stnrt connected, down against the stop on the shock
absorber strut using a mounting lever. Slide the adjusting
iever as closely as possible against the stop of the auxiliary
carrier for the adjusting screw on the torsion bar. The
adjusting lever must be provided with a closing cover.

Grease the threads of the adjusting screw with lithium

_sease and tighten the adjusting screw slightly. Check to
see that the closing cover in the transverse control arm is
;roperly seated since inadequate assembly of the adjusting
lever may force the torsion bar out of the teeth of the
Tansverse control arm (at the front). Screw down the
;rotective member for the transverse control arm"
Tighten the castle nut of the track rod joint to the
specified torque. Tighten the hex. bolts for the guard O volkswagen

;late to the specified torque. Install the front wheel Removing control arm carrier bôlt
rearing and adjust it. Tighten the hex. bolts for the caliper
ro the specified torque. Bleed the brake system and test it
Ior leaks. Measure the vehicle optically.

TRANSVERSE CROSS ARM If both transverse control arms must be removed, remove
Removal one at â time, Clamp the transverse control arm into a vise
Lnscrew the adjusting screw on the torsion bar. Pull the (use soft jaws); unlock the grooved nut of the ball joint
il.iusti-ng lever from the torsion bar and remove the seal. and loosen it by using a special tool.
Loosen the hex. bolt for the ball joints of the shock
.1.'rsorber strut. Push the transverse control arm down-
;ards and pull the ball joints out of the shock absorber
sirrt. Loosen the hex. bolt fcr the transverse control arm
ud the auxi.liary carrier.

O Volkswagen
Removing grooved nut of ball ioint

@ volkswagen
Checking the individual parts
Removing torsion bar adiusting screw Check the transverse control arm with a special tool.
Force the closing cover for the torsion bar toothing (with
a suitable pipe tool) out of the transverse control arm.
Hold the transverse control arm in a special tool,

The transverse control arm should turn easily when

;llsen the socket screw for the protective member on the mounted with its ball joint supporting hole on the test pin
::at transverse control arm bearing and remove the of the special tool and with the ball joint seat resting
g-:Iective member, Next, unscrew the hex. bolts on the against the test pin flange. Repiace distorted or damaged
transverse cross arm bearing. Push the transverse transverse cross arms.
=:nt
;:rtrol arm, together with the torsion bar, out of the
u:riliary carrier and remove it. Mount the closing cover on the transverse control arm
FRONT SUSPENSION 11-8

with its spherical end facing outwards. Knock the closing absorber strut, using a mounting lever. Slide the adjus ing
cover in with a mandrel. Check the rubber bearing of the lever, as close as possible, against the stop of the auxiliatç
transverse control arm for visible wear, Replace the carrier for the adjusting screw on the torsion bar. Tbe
transverse control arm, if the rubber bearings are de- adjusting lever must be provided with a closing cover.
fective.

Now check the ball joint. Some friction torque should be

felt when moving the ball pin. If the ball pin can be
moved without resistance and if end play is shown,
replace the ball joint. In the event of a damaged sealing
bellows, replace the bellows as follows.

Loosen the damaged sealing bellows from the ball joint

with a flat chisel. Fit a new sealing bellows alternately
with a mandrel. Do not damage the bellows. Grease the
ball joint with multi-purpose grease if required. Check the
torsion bar for any damage of serrations and paintwork,
particularly for evidence of rust. Replace, if required.

Installation
Tighten the grooved nut for the ball joints to the specified
torque and secure it by bending a pertinent tab on the
lock washer. Coat the torsion bar lightly with lithium
grease. Grease the serrations well and insert the torsion
bar into the transverse control arm. Do not push the @ volkswagen
closing cover out of the transverse control arm. Insert the
transverse control arm with the torsion bar into the Sliding adiusting lever against
auxiliary carrier. auxiliary carrier stop

Grease the threads of the adjusting screw with multi-

purpose grease and tighten the adjusting screw slightly.
Check to see that the closing cover in the transverse
control arm is seated correctly since bad assembly of the
adjusting lever may force the torsion bar out of the
serrations of the transverse control arm (at the front).

Screw down the protective member for the transverse

control arm. Now, complete the height adjustment of the
front axle and measure the vehicle optically.

TORSION BAR
Removal
Unscrew the adjusting screw of the torsion bar. Pull the

O Volkswagen
Ball ioint lock washer in place

The torsion bars are pretensioned during production.

Never interchange the righthand and lefthand torsion bar.
Lefthand torsion bars are identified by an "L", and
righthand torsion bars by a "R" on the face of the bar.
Tighten the hex. bolts for the transverse control arm
(front) to the specified torque. Tighten the hex. bolts for
the transverse control arm and the auxiliary carrier to the
specified torque.

Tighten the hex. bolt for the ball joint to the specified
torque. Slide the seal across the torsion bar and mount the
adjusting lever for the torsion bar on the bar as described.
Push the transverse control arm, with the shock absorber O Volkswagen
strut connected, down against the stop in the shock Removing torsion bar adiusting screw
FRONT SUSPENSION 11-9

r,Jjusting lever from the torsion bar and remove the seal'
zuff tn." torsion bar out toward the rear' Loosen the
:heesehead screw for the protective member and remove

Checking
Ctreck tËe torsion bar for damage of the serrations, and
:u-t*otf., and for evidence of rust' Replace the bar if
:equired.

I nstallation
',oat the torsion bar lightly with lithium
grease' Grease
-ire serrations particularly well and slide the torsion bar
-lto the transverse control arm' Do not knock out the
,i"ti"g cover in the transverse control arm' Slide the seal
rn thJ totsion bar. Slide the adjusting lever for the torsion
:ar on the bar by doing the following' O volkswagen
Steering gear bolts

auxiliary carrier. Unscrew the adjusting screws on the

torsion'-bars. Pull the adjusting levers from the torsion bars
and remove the seals. Unscrew the hex. bolts for the
auxiliary carrier and the transverse control arm and
remove the auxiliary carrier. Loosen the socket screw for
the protective member and remove it.

Checking
Place thé auxiliary carrier on a level surface and check it
for distortion. In the event of distortions or unpermissible
dimensional deviations, replace the auxiliary carrier'
Check the auxiliary carrier for cracks or visible damage
and replace it if required.
lnstallation
in the
Be sure that the auxiliary carrier is correctly located
@ volkswagen fitted bolts on the body. Tighten the hex' bolts for the
Screw for guard cliP auxiliary carrier .and- the transverse control arm, to the
;;ii;â toiqu"''Tighien the hex' bolts for the steering
liat to the spècified torque, using new spring rings'
lever
Slide the seal on the torsion bar' Slide the adjusting
Fush the transverse control arm, with the connected
shock for the torsion bar on the bar as described following' Push
itr" trunru"tte control arm, with shock absorber strut
.UiotU.t strut, against the stop in shock absorber strut absorber
,t*À u *o""ting1ever. Push the adjusting lever as close as ;;;";-;t.d, down against the stop on th9 sho.ck adjusting
totriui. against
-the
stop of the auxiliary carrier for the ttt* UV means of a-mounting lever' Sliding the
;J";ilg i"r.* ot the torsion bar' The adjusting lever lever as closely as possible-, against the, stop of the
rrust be provided with a closing cap'
*ttl"ifo. thè adjusting screw on.the torsion bar'
"ï-iii"tv
ihe aOjïsting lever must be provided with a closing cap'
Grease the threads of the adjusting screw with multi- the threads of the adjusting screw with muiti-
grease and tighten the adjusting screw slightly' Grease
;;;;;. ;;ô;t. ;;."se and tighten adjusting screw slightlv' Check
Ctr".f. to see that the closing cover in the transverse io t.. tnât the closing cover in the transverse control arm
.onttof arm is correctly seated since inadequate assembly ir pÀp"tfv seated, iince inadequate assembly of the
ri- the adjusting lever may force the torsion^bar out of the
adjusting i.u., *uy push the torsion bar out of the
:errations of trânsverse control arm (at the front)'
seiratioris of the transverse control arm (at the front)'
Screw on the protective member for the transverse
control control
Screw on the protective member for the transverse
À. Co*pi.ie the height adjustment of the front axle
ur*. Co*pt.ie the height adjustment of the front axle
and measure the vehicle optically' vehicle optically'
and measure the
AUXILIARY CARRIER SUPPORTING BEARING AND BEARING RUBBER
Removal
ti;;;"; the underfloor protection on the front axle' Replacement
the hex. bolts lor the steering gear on the Foid back the front end covering' Unlock the hex' nut on
L';;;;"
FRONT SUSPENSION 11_10

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FRONTSUSPENSION 11_1'I

the shock absorber strut (top). Loosen and remove the

lock washer as well as the tab washer. Push the transverse
control arm, with the spring strut, down and extend the
!) piston rod out of the bearing rubber.
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Support bearing

pressure plate. Loosen tirê socket screws and remove the

supporting bearing with the bearing rubber. Install neri
supporting bearing, with a bearing rubber, and tighten the
screws to the specified torque.
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Tightening shock absorber strut nui
STEERING 12-1

STEERING I2
INDEX
Page Page
DESCRTPTTON... ..,t2-l Installation '.'.'. .12 -4
STEERINGGEAR .,.,12 1 RAcK AND prNroNsriiàiruc'iËÂR : . . .t2_-4
Removal ....12-l Disassembly ......12-4
Installation aa Assembly . . .12*4
EYEBOLTS î. STEERINGWHEEL ....12-6
Removal ....12-4 Removal ... .12-6
Checkingparts.. ....12*4 Installation .12 -6

DESCRIPTION STEERING GEAR

The steering rack is mounted in two replaceable bushings, Removal
one at each outer end of the housing. The pinion is Loosen the self-locking hex. nut from the bottom hex.
mounted on two ball bearings in the steering housing. A bolt on the bottom of the universal joint and remove the
pressure block spring, and adjusting shims, press the bolt. Unlock the slotted nuts of the track rod joints and
steering rack against the pinion, thereby ensuring con- pull off the ball joints with a track rod puller. Remove the
tiauous contact between rack and pinion, The correct underfloor protection from the front axle.
drag can be obtained by inserting and/or removing
adjusting shims. Loosen the hex, bolts for the steering gear on the
auxiliary carrier. Unscrew.the adjusting screws of the
The rack and pinion steering assembly is lubricated during torsion bars. Pull the adjusting lever from the torsion bars
manufacture and requires no additional lubrication. and. remove the seals. Unscrew the hex. bolts for the
transverse control arm and the auxiliary carrier.

O Volkswagen
O volkswagen
Cross section Steering gear bolts

1 - Filler plug M 8x8 9 - Spacer

2 - Housing 10 - Connecting flange
3 - Steering pinion 11 - Oil seal
4 - Ball bearing 12 - Self-locking nut, M 10 Remove the auxiliary carrier. Next, remove the steering
5 - Steering rack 13 - Gring gear with the track rods. Unlock the bolt on the fork-type
6 - Pressure block 14 - Snap ring joint for the track rods; loosen and remove them. If the
7 - Spring 15 - Housing cover steering shaft bearing must be replaced, remove the fuel
8- Adjusting shim 16 - Hex. bolt M 8x1 8 tank first.
STEERING 12_2

O volkswagen

Stde sectton
1 - Thread for tie rod joint 5 - Steering pinion
2 - Housing 6 - Steering rack
3 - Pressure block 7 - Dust boot
4 - Spring 8 - Bushing

lnstallation
Check the track arms for damage, Also, check the track
rod ball joints. Moving the ball pin should produce a smail
friction torque. If the ball pin moves without resistance
and end play is showing up, replace the ball joint.

Install the joint bolts with multi-purpose grease and

tighten to the specified torque and lock them. Slide the
sealing bellows upwards on the bearing rubber. Make sure
that the bellows are seated correctly. Grease the running
surface of the needle bearing on the steering shaft with
some multi-purpose grease and insert the steering gear
upwards in such a manner that the steering shaft is resting
in the needle bearing.

When the steering gear is installed, the bottom universal

joint in the passenger compartment must be mounted on
the splines of the steering shaft in such a manner that the
O volkswagen
hex, screw can be fitted. The universal joint cannot be
Removing torsion bar adiusting screws fitted when the steering gear is installed.

Install the auxiliary carrier, making sure that the auxiliary

carrier is properly located on the fitted pins of the body.
Use new spring rings for the hex. bolts of the steering gear
and tighten them to the specified torque. Push the
trans"erse control arm down against the stop in the shock
absorber strut by means of a mounting lever, pushing the
adjusting lever as closely as possible against the stop of the
auxiliary carrier for the adjusting screw on the torsion bar.

Screw the bottom universal joint, in the passenger

compartment, down and make sure that the universal
joints are not distorted. Use a new self-locking hex. nut.
Tighten the hex. nut to the specified torque, Unscrew the
protective member on the front transverse control arm
bearing and check to see that the closing cover in the
transverse control arm is correctly seated. Tighten the
cheesehêad screws for the protective member to the
specified torque. Complete the height adjustment of the
front axle and measure the vehicle optically.
EYEBOLTS
O volkswagen The eyebolts must be installed in a precise position to
ensure free movement of the steering components and the
Removing carrier screw exact guiding of the track rod.
STEERING 12-3

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STEERING 12_4

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Eye bolts Iocation

Checking parts
Check the eyebolt for any visible wear and replace it if
required. Check the bellows for cracks and leaks and
replace them if required. Replace defective holding
springs.

lnstallation
Mount both bellows on the housing. Screw the bellows
holder on the eyebolts. Coat the threads of the eyebolts
with sealing compound and install the eyebolts. Attach
the steering gear without the 3 mm washers on the special
tool. The locating pins should enter easiiy into the
eyebolts, with the flattened end of the locating pins
resting, with a slight play, against the outer fitted pin.

Tighten the bellows holder to the correct torque. Attach

the bellows, with the holding spring, to the bellows
holder.

RACK AND PINION STEERING GEAR

Disassembly
Clamp the steering gear in a vise (use soft jaws), loosen the
O volkswagen
hex. bolts for the housing cover and remove the cover.
The adjusting washers, if any, will fall out. Remove the
Checking eye bolt with tool'P 285b locking ring and take off the compensating washers.

Screw the hex. nut on the drive pinion and push the
pinion out of the housing by means of two heavy screw
Removal drivers. Now, pull the bearing bushing. Pull the grooved
Clamp the steering gear into a special tool without the 3 ball bearing out of the steering gear housing and remove it
mm (0.118 in.) washers. Remove the holding spring on from the housing (laterally).
the outside of the bellows, and pull the bellows from the
bellows holder. Loosen the bellows holder with a hook Assembly
spanner and unscrew the eyebolt together with a bellows During assembly, coat all parts with a multi-purpose
holder. grease LM-KFZ 3 or LM- 7 L. During assembly, provide
STEERING 12-5

ùe steering gear with a one-time supply of 25 grams of Measure the recess in the housing cover. The dimension of
nuiti-purpose grease. Adjust the play of the thrust piece. the recess in the housing cover, with the seal, must be
lfeasure the distance of the thrust piece up to the 0,008 in. larger than the distance A. Compensate any
xrpporting surface on the housing (Distance A). difference by means of adjusting washers. The thrust piece

17 21 20 13 15 12 r0 9

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Exploded view of rack and pinton unit

I - Hex, bolt M 8x18 9 - Coupling flange 16 - Rack

2 - Spring washer 10 - Radial sealing ring 1 7- Circlip
3- Housing cover 11 - Locking ring 18 - Supporting ring
4- Seal 12 - Compensating washer 19 - Bearing bushing
5- Adjusting washer 13 - Drive pinion 20 - Grooved ball bearing
6- Compression spring 14 - Round cord ring 2l - Hex. bolt (fi11er screw M 8x 8)
7- Thrust piece 15 - Grooved ball bearing 22 - Steeing gear housing
8 - Self-locking hex. bolt M 10
STEERING 12-6

should have a 0.008 in. piay with the housing cover and remove it. Now pull out the contact finger' Loosen
attached. Check the torque of the steering gear along the the steering wheel retaining nut. Mark the position of the
entire turning range of the steering system. A torque of steering wheel in relation to the steering column. Remor-e
5-7 in. lb. should be obtained. the steering wheel watching out for the supporting ring
and the compression spring of the steering spindle bearing

@ volkswagen

Removing horn ring

@ volkswagen

Measuring height of thrust Piece lnstallation

Position the compression spring and the supporting ring
on the steering wheel hub. Lightly grease the contact ring
for the signal horn. Use electrical contact grease. Position
the steering wheel according to the disassembly markings.
Place the wave washer under the steering wheel retaining
nut. Tighten the nut.

Check the operation of the release ring (canceller). Insen

the contact finger. Turn the horn ring slightly to the left
so that it aligns with the recesses in the steering wheel
Then press down and turn the horn ring to the right untii
it locks.

I
@ volkswagen
Measuring recess in housing cover

STEERING WHEEL
Removal
Disconnect the battery' Turn the horn ring toward the left Compression spring and supporting ring installed
ELECTR ICAL 13_1

ETECTRICAT 13

INDEX
Page Page
ALTERNATORTESTER .....I3-1 Description .l3-8
Testing the exciting diodes . . . l3-l Removalandinstallation .. .13-8
Testingthepowerdiodes. .....13,1 INTERIORLAMP. ...I3-8
Testing the individual diodes . .13-2 Removalandinstallationofbulb . . . . . 13-8
Testingthestatorwindings ....13-3 BRAKE, BLINKER AND TAIL LAMPS
Testingthe alternatorfor body contact . . . . . . l3-3 WITH BACKUP LAMPS ,13-9
Disassembly .13-3 Installation of bulb bracket . . l3-9
Inspectingandrepairing ....13-5 TRUNKLAMP. ..^...I3-9
Installingthediodes ....13-5 BULB BRACKET FOB TRUNK LAMP . .T3-9
Installing the brush holder . . . 13*5 Removalandinstallation...
Startertestingwhileinstalled, . . .
.13-9
. . .13*6 BRAKE LIGHTSWITCH ..,...13-9
Testingwhenremoved ... ..13-6 Removal
Idlingtest ...13-6 Installation "..13-9
Loadtest .....13*6 . . l3-9
Short circuit test . . . 13 -6
Adjusting . t3-10
WINDSHIELD WIPER SYSTEM 13*10
Testing the magnetic switch . . . 13-6
RETRACTABLE HEADLAMPMOTOR . .13*6
InspectingwhileinstallinC . ... . . . . 13-10
WINDSHIELD WIPER MOTOR I3-IO
Removal ....13-6 Removal
Installation . .13-7 Installation 13*10
RETRACTABLEHEADLAMPS ..,....13-7
Removal ....13-7 Inspectingdisassembly ....13-12
Installation .13-7 WINDSHIELD WIPER FRAME WITH MOTOR . .13-12
Aimingwithheadlampadjuster .... . .13-7 Removal . .13-12
Aimingwithoutadjuster ....13-7 Installation . 13-12
HALOGEN HIGH BEAM HEADLAMPS. . . . . . . . 13-8 WINDSHIELD WIPER SHAFT . I3-I3
Removal ...13-8 Removal ....13-13
Installation .13-8 Installation 13-13
Aiming ....13-8 WORM GEAR 13-13
FAULTSINHEADLAMPSYSTEM .....13-8 Adjusting end play . 13-13
Excessivevoltagedrop ... ".13-8 ARMATURE " 13-13
Bulbnotinorder
Aimingwithoutadjuster
FRONT BLINKER AND SIDE MARKER LAMP . . 13-8
....13-8
....13-8
Adjusting end play
WINDSHIELDWASHERSYSTEM ....13*14
Removal
Installation
. 13-13
...13-15
13-l 5
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ALTERNATOR TESTER
The alternator tester serves for testing installed and
connected exciting and power diodes, as well as individual
diodes, and for testing stator and rotor.windings. During
the test, place the test points of the instrument securely
but only momentarily against the measuring points. Be
lrre that with the alternator partially disassembled the
tilted positive diode carrier is not becoming connected to
the housing,

Testing the exciting diodes

Set the test type switch to the extreme left position. Hold
the test points one after the other against the collecting
points. The connection of the test points is arbitrary. The
aeedle will deflect to the left or to the right. The diodes
are in order, when the needle deflects during all three
measurements up into the green range at the right or left
at the end of the scale.

Testing the power diodes Te s ting ex citing dio de s

The test type switch is maintained in the extreme left lf the needle deflections are showing deviation, the
position. following faults apply:
ELECTRICAL 13_2

Needle deflections Faults mA at housing temperature. If the needle remains at O

during both measurements, the diode is interrupted. If the
2x in green range Interruption of diode lecated needle deflects entirely to the left during both meas-
1x in red range in red range urements, the diode is shorted.

2x in red range Short circuit of diode at

1x no deflection which no deflection occurs.
Note: The diodes in the red
range may be in order and
should be checked after un-
soldering the defective diode.

lx red range Short circuit of diodes, at

2x no deflection which no deflection occurs
(check the third one)
8": l'

To test the negative diodes place one lead in the fixed

position and the other lead after the other against the
collecting points. Negative diodes are the diodes which are
in conrlection with the fixed connection. Needle deflec-
ions and faults are similar to exciting diodes.

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Te s ting po sitiv e dio de s

a = red plug b = black plug

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Te sting ne gativ e dio de s

a = red plug b = black plug

@ Volkswagen
To test the positive diodes, place one lead in the fixed Testing individual diodes
position and the other lead, one after the other against the
collecting points. Positive diodes are the diodes which are a = red plug b = black plug
in connection with the fixed position. Needle deflections
and faults are similar to exciting diodes.

Testing of individual diodes

Set test type switch to the extreme left position. The The same switch position can be used to determine the
diodes are tested individually in unsoldered condition in polarity of an intact diode. A direct voltage between the
both directions. When the needle deflects completely test points amounts to approx. 40 Volt. The red point is
toward the left, it is an indication that the diode has been the positive connection, the black point the negaiive
connected in the forward direction. When the needle connection. Example for determining the polarity: Place
deflection is less, the diode has been connected in the the red point against the connecting wire of the diode, the
inverse direction. The inverse current may be a max. 0.8 black point against the diode housing. If a high current
ELECTRICAL 13_3

rlows (approx. 1 mA) the diode has been connected in

iorward direction, that is, the negative pole of the diode is
on the housing (negative diode). If wiih the same
connection there is no or only a low current, the diode
has been connected in the reverse direction, that is, the
positive pole of the diode is on the housing (positive
diode).

Testing the stator windings

Set the test type switch to the second position from the
left. Place the test points against two collecting points.
\take a total of three measurements. During the measure-
ments, the resistances should be of uniform size. If there
are differences in the resistance ratings between the
iadividual measurements, the stator winding has a winding
short. When in doubt, unsolder the stator assembly and
measure the stator winding with a measuring bridge. @ Volkswagen

Testing for shorts

a = black plug b = red plug

Prior to disassembling the alternator, pull back both

carboni with a wire hook. The carbons can be held down
with the aid of the pressure spring by pulling them wide
enough out of the brush holder. Press the claw pole rotor
with a repair press and suitable support out of the drive
bearing, holding the rotor in position.

@ volkswagen
Testing stator windings

Testing the alternator for body contact

A test for a ground short circuit can be completed only
when the negative diodes are in order. Defective negative O Volkswagen
diodes may simulate body contact. Set test type switch to
Pressing out rotor bearing
the extreme right position. Place the black test point
against the housing, and the red test point in sequence
against the collecting points on the soldering strip. The
alternat'or has body contact if, during all the three
measurements the needle deflects against the stop toward Press off the ball bearing at the slip ring end on a repair
the left. press using a suitable fixture. The ball bearing can also be
pulled off with a claw-type puller against the inner race.
Disassembly When the ball bearing is pulied off at the outer race, a new
Test the alternator with the alternator tester EFAW 192 ball bearing must be installed.
(Bosch) or an Ohmmeter in accordance with test instruc-
tions given under inspection procedure' Hold a pulley in Prior to disassembling the slip ring bearing further, test
recesses provided and loosen the fastening nuts. Remove the diodes with diode tester EFAW 192 (Bosch) or with
ùe pulley (use three-legged puller, if required). Mark the an ohmmeter. The diode carrier shouid not rest against
housing, since this will falsify the measurements'
;osition of the swivel arm in relation to the housing.
ELECTRICAL 13*4

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ELECTRICAL 13-5

Loosen the connecting tine to the exciting diodes on the

exciting diode carrier, Unscrew the fastening screws for
the brush holder. The brush holder can then be removed'
Unsolder the connections of positive diodes, negative
diodes and stator winding from the soldering strip of the
exciting diode carrier, using pointed pliers. The individual
o parts of the alternator may be washed with gasoline or
.: trichlorethylene for short periods only.
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€!85:i ;PE" Ë€È,; Using pliers as heat sink
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Test the stator with an ohmmeter for ground short circuit.
Test the resistance of the stator windings between phase
outlets. Resistance rating: 0.2 + 0.02 ohms.
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meter). Measure the exciting winding (field rotor) with
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the resistance measuring switch. Resistance rating: 4.0 +
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0.4 ohms. Note that the slip rings should be machined in a
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ÈôH special shop only. The minimum dia. is 31.5 mm, the
E*à max. permissible runout 0.03 mm and the max. permis-
fr Ë E I8 sible runout for field spider 0.05 mm.

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installation of the diodes, measure all the diodes with
?.b5.e.zZ?:i?: ;ai? tester EFAW 192 ot with an ohmmeter. Prior to installing
eooèô^cMotrgg:ÉEù the exciting diode carriers, solder the three connecting
lines of the positive diodes from below to the exciting
##ËrËË;tËËsFE;gÊ't diode carrier. Use rosin-core solder only. Upon instaliation
Ê ôl o $ h \o F.- æ o. O i d m + n \o r
**lÊt-Êt of the exciting diode carrier, solder the line outlets of
stator winding negative diodes as well as exciting diodes to
soldering strip. Solder carefuliy so that the negative diodes
are not overheated.

Installing the brush holder

Pull up the carbons prior to installation and hold. Screw
the connecting line to the exciting diode carrier, watching
out for corlect layout of the line.
ELECTRICAL 13_6

excessively heated starter will result in a lower speed. This

test also permits inspecting the pinion for proper meshing
in and out. Under light braking, the pinion should mesh in
and out accurately when the starter is switched on or off.

Short circuit test

During the short circuit test the starter-driven flywheel is
braked momentarily to a stop. The test should not take
longer than 5 seconds. The short circuit power input is a
power rating for the break-away torque created by the
starter. The torque depends on the power input. Release
the brake immediately after reading the measured values.
Switch off starter only then.

Testing the magnetic switch

For judging the two coils of the magnetic switch only the
power input need be measured, For this purpose, an
ammeter and a battery are connected to the switch. The
test values are 35 A for a draw-in coil and 11 A for
@ Votkswagen holding coil. Magnetic switches with defective pulling or
holding coil cannot be repaired.
Installing brush holder

Starter testing while installed

A faulty starter should first be tested at terminal 50 of the
magnetic switch for the required voltage of at least 7
Volts for pulling. If the voltage is under that rating, the
electric system, and in particular the lines of the starter
circuit must be checked.

Testing the starter for pull at full battery voltage can be

done by lifting the car and crossing terminals 30 and 50
on the starter. If the starter meshes perfectly, the fault is
in the line to the starter, If the starter does not mesh,
remove and check.

Testing when removed

Function and output of the starter can be checked on a
starter test stand. At least a 135 ampere hour battery
should be used. The indicated test sequence should be
maintained to prevent any faulty measurements by
heating of the starter or battery discharge.

ldling test @ volkswagen

Place the starter on a test stand and adjust the pinion for Testing magnetic switch
correct distance to ring gear of braking fixture, The
meshed pinion should enter the flywheel teeth with its
entire tooth width. Connect starter, terminal 30, to A - Ammeter D - Holding winding
battery + and test stand control line to terminal 50 of the B - Battery M - Magnetic switch
magnetic switch. During the idling test, the starter is C - Draw-in winding
operated in such a manner that the pinion is in full mesh
with the flywheel teeth and the flywheel is not braked.
These measurements determine the speed, the power
input and the battery voltage. During idling operation, the RETRACTABLE HEADLAMP MOTOR
starter speed should be high and the power input low. Removal
This will indicate that there is no winding or ground short Run the retractable headlarnp completely up by means of
circuit and that the armature rotates easily in its bearings. the hand wheel, Pull the crank from the retractable
headlamp motor, use a Kuko puller, if required. Unscrew
Load test the three fastening screws for the headlamp motor and
For the load test, the starter is braked from idling to a remove the headlamp. Loosen the ground connection
given speed (approx. 1,000 rpm) by means of the braking screw. Connection of headlamp cables: red to red, blue to
fixture of the test stand. During this test the power input grey, black to green.
and voltage are measured. The load test should not take
longer than 10 seconds, Insufficient battery voltage or an The headlamp motor cannot be repaired.
ELECTRICAL 13-7

lnstallation and set the distance between the focusing lens in the
Put the motor into "up" position of headlamps prior to optics carrier and the headlamp to approximately 10
nstallation. Connect negative to the brown line (cable inches. Move the adjuster in front of the vehicle center
shoe), and to the red and blue lines. The motor will run and switch on the light beam projector.
rnto its end position and remain there automatically. If
rhe motor does not start, see if it is in its end position Direct the light beam left and right to one prominent
already. This is done by connecting plus to both the black point of vehicle each (for example upper edges of
and the red line, which will cause the motor to run into ietractable headlamps). The aiming is done by loosening
rhe position "down". Then let the engine run again into the pedal lever on the column guide. Move the adjuster in
position "up". For this purpose, the standard relay, spare froni of headlamp and align to the headlamp center' The
part No. 90 I 6l 5 109 0l , must be inserted into the relay deviation of the àptical axis (headlamp - optical carrier)
holding bracket. may amount to a maximum I'18 inch vertically or
latËraly. Set the inclination of headlamp on scale of
RETRACTABLE HEADLAMPS knurleà disk to 10. Adjust the headlamps with the
Removal dimmer switched on. Remove the front plastic cover or.t
.{ctuate the headlamp switch. Disconnect the battery the headlamP.
ground connection cable, Loosen the three screws of the
iiont panelling and Temove the panelling' Loosen two Adjust the headlamps vertically in such a manner that the
screws of the rear panetling and remove' Remove the boider line between the light and dark runs at the left of
rubber cover on bulb socket and pull lines from contacts. the adjusting cross horizontally on the adjusting line'
Loosen three screws of headlamp, not the two adjusting Adjust the headlamps laterally in such a manner that the
screvr's, and then remove the headlamp. border line between light and dark runs along the sloping
line ( I 5o) and the break in the border between bright and
dark is in the center of the focusing cross' With the border
line beiween bright and dark of the dimmer accurately
positioned, the center of the high beam should be on the
iocusing cross. The permissible deviation is 0.4 inch to the
right and left, 0.3 inch toward the top and 0.2 inch to the
bottom.

O volkswagen

Headlamp securing screws

lnstallation O volkswagen
To install reverse the removal procedures.
Headlisht pattern
Aiming with headlamp adiuster
*'hen using headlamp adjusters of other makes, the
cperating instructions of the manufacturer must be
oLserved. Headlamp adjustments obtained with such
equipment must meet legal regulations' Aimin g without adjuster
The headlamps can be aimed by using an adjustable,
Position the vehicle as vertically as possible in relation to vertical surface, The test surface should be light in color
-lie adjuster. Check the specified tire pressure and correct and must be provided with markings for the centers of the
:t, if require{. Load the vehicle with one person or 154 lb' headlamps and a marking for the border line between light
on the-driver's seat' Push the vehicle back and forth and dark.
several feet so that the suspension conforms to load
:onditions. Move the adjuster in front of the headlamps Position the vehicle 16.5 ft. from test surface on level
ELECTRICAL 13-8

ground. The test surface should be verticai in relation to FRONT BLINKER AND SIDE MARKER LAMP
the direction of driving and the separating line should be Description
parallel to the base of the vehicle. The tires should be The front blinker and side marker lamps are installed in
inflated to the specified pressure. Move the vehicle several the front fenders, The rear blinker lamps are in the
feet back and forth to settle the suspension. Check the brake-blinker-tail lamps. The blinker switch is installed i-r.
headlamps individually. Always cover the other. Aim the the steering column switch. The two indicating lamps fot
headlamps vertically and laterally with the dimmer the blinker system are installed in the time clock. Thel'
switched on, with the vehicle loaded with one person or indicate which directional blinker is switched on. With the
1 55 lb. on driver's seat. warning lamp system switched on, one indicator lamp ia
the pull knob of the warning lamp switch indicates the
Aim the headlamps vertically in such a manner that the function of the warning lamp system. When the warning
border line between light and dark to the left of the lamp system is actuated with the ignition switched on, the
focusing cross proceeds horizontally along adjusting line. indicator lamp for the blinker system in the speedometer
Aim the headlamps laterally in such a manner that the will light up.
border line between light and dark proceeds along-side the
sloping Iine (15") and the break of the border line Removal and installation
between light and dark is accurately in the center of the Loosen the two window screws and remove. Loosen screw
focusing cross. nut (SW l0) inside the fender. Pull off the spring ring and
washer. Remove the fastening clamp. Pull out the blinker
HALOGEN HIGH BEAM HEADLAMPS and side marker lamp in the forward direction. Pull the
Removal rubber sleeve and line from the socket.
Unscrew the front deflector plate and trim. Unscrew the
fastening screw of the headlamp and remove. Loosen the Proceed vice versa for installation. Spray contact lugs with
fastening screw of the reflector. Remove the reflector contact spray, if required. The lamp sockets are noî
from the housing and pull off the lines. exchangeable.

lnstallation INTERIOR LAMP

Reverse the instructions for removal. Then aim the The interior lamp in the backrest between the two seats
headlamps as per instructions given under Aiming Head- can be switched on and off by means of the installed
lamps, switch, as well as by the switch position "top" above the
door contact switch.
Aiming
The high beam is adjusted with the retractable headlamps Removal and installation of bulb
covered. Align the adjuster to the high beam center. Set Disconnect the negative battery cable. Apply a scre\À
the inclincation scale to 10. The center line of the high driver to push back the clamping spring behind the
beam should be against the upper focusing cross, that is, headlamp housing and pull the interior lamp out of the
when the luxmeter indicates maximum light intensity. backrest cutout. Replace the bulb, making sure to have a
The high beam radiates parallel to the lane. Halogen good seat and good contact of bulb.
headlamps can be adjusted vertically only.
Proceed vice versa for installation. Be sure that the
FAULTS IN HEADLAMP SYSTEM interior lamp is installed into backrest cutout with the
Excessive voltage drop clamping spring end first (watch out for the ground line).
If in spite of accurate aiming of the headlights, the
illumination is insufficient, check the voltage on the
headlamp connections, The reason for weak headlamps is
often an excessive voltage drop caused by loose line
connections, defective switch contacts or bad ground
connection. The fusebox can also be the cause of
excessive voltage drop as a result of corroding transition
points between the fuse and the holder. At a voltage drop
of only ljVo the light intensity will drop by approxi-
mately 3O%. The voltage drop in the headlamp lines
should generally not exceed 0.6 Volt.

Bulb not in order

Another cause of unsatisfactory light may be the position
of ihe filament in the bulb. The bulb or the socket can
also be badly inserted.

Aiming without an adiuster

The high beam is adjusted with the retractable headlamps
covered. In addition, the general instructions given for the
retractable headlamps apply. The center of the light beam
shoutd be at the same height as the bulb center. The high
beam headlamps are adjustable only in height, but not
laterally. Loosen the fastening screw of headlamps for @ volkswagen
making adjustments. Interior light remover
ELECTRICAL 13-9

BRAKE. BLINKER AND TAIL LAMPS WITH BACKUP lnstallation of bulb bracket
LAMPS Use original VW profiled rubber glue for glueing the
Replacing bulbs rubber seal. Spray the contacts at their centers with
Fle two triple chamber tail lamps with built-in backup contact spray, if required.
llrps are installed in the rear side members and the rear
panel. Loosen the three plastic nuts from the trunk TRUNK LAMP
=d and pull out the window toward the rear.
=d The trunk lamp has no switch of its own^ It is connected
in parallel with the two license plate lights and lights up
together with the parking lamp.

BULB BRACKET FOR TRUNK LAMP

Removal and i nstallation
Loosen the felt cover and the two fastening screws.
Remove the bulb bracket. Pull off the window. Dis-
connect the cable.

Proceed vice versa for installation,

BRAKE LIGHT SWITCH

Removal
Pull the accelerator pedal out of the trust rod in the
rearward direction" Loosen the two hex. nuts for the floor
board attachment and remove the floor board. Loosen the
fastening screws for the brake light switch, remove the
switch ànd pull off the cable connections.

lnstallation
Proceed vice versa for installation. The brake light switch
O volkswagen must be adjusted.
Tail light connections

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Rear light assembly @ volkswagen

1 - Bulb for brake and parking lamp 4 - Plastic nuts for window attachment 7 - Recess for bulb bracket
sL 12Vl2tls W 5 - Window for SBBR lamps 8 - Notched washers
2 - Bulb for backup lamp RL 12Y l21W 6 - Bulb bracket 9 - Fastening nuts for bulb bracket
3 - Bulb for blinker lamp (yellow)
E T2Vlzs w
ELECTRICAL 13-10

provided with three carbon brushes, with one brush

installed offset to the earth brush. In combination with
the switch (terminal 53b) this brush serves for switching
directly to full speed.

@ volkswaqen
Brake light switch screws

Adjusting
The brake light switch is adjusted while installed. Loosen
the counter nut and adjusting screw. Clamp a sheet metal
strip 1/6 inch thick between the brake pedal lever and the
brake pedal stop. Turn the adjusting screw until the brake
lamp lights up. The cut-in point can also be checked with O Volkswagen
an ohmmeter. Remove the brake light switch and lock the
adjusting screw. Reinstall the brake light switch, connect l|indshield wiper motor brushes
the cable and check the switch for proper funçtion.
I - Earth brush
2 - Brush for slow speed
3 - Brush for high speed

lnspecting while installed

Measuring the current (by connecting an ammeter to the
line toward switch, terminal 30) permits checking the
operating condition of the system. The power input is 3.5
amps under fast operation and 2.5 amps under slou-
operation. These values are attained when with the system
switch on the wiper arms and their blades are folded away
from the windshield. Measuring with the wiper blades
resting against the windshield will result in wrong values.
since the friction pressure varies considerably as a result of
the condition of blades and windshields.

If the input is considerably above the specified values and

if the windshield wiper operates more slowly in combina-
tion with squeaking noises, the fault is mainly caused by
non-lubricated bearings. lncreased input without loud
O volkswaqen
running noises indicates a short in the armature winding.
Brake light switch adiustment screw
WINDSHIELD WIPER MOTOR
Removal
Remove the wiper frame complete with motor per
instructions given under windshield wiper frame with
WI NDSHI ELD WIPER SYSTEM motor-removal. Remove hex. nut and washer from the
The windshield wiper motor, both wiper shafts and the windshield wiper motor shaft. Pull the linkage drive crank
wiper rod are mounted on a common frame. The wiper from the shaft of the windshield wiper motor with puller.
arms are attached to the serrated windshield wiper shaft Loosen the three hex. bolts and remove the motor.
with cap nuts. When the windshield wiper switch is turned
to its first stop, the motor and contact plate on the worm lnstallation
gear are energized via terminal 53 of the switch. The When installing the windshield wiper motor into the
system runs at its slowest speed. The brush holder plate is windshield wiper frame, move the windshield wiper motor
ELECTRICAL 13-11

J
e

L - Cheesehead screw
2 - Hex. nut
3 - Adjusting screw
4 - Cover with contacts
5 - Seal
6 - Worm gear with drive shaft
7 - Thrust washer
8 - Adjusting screw
9- Bearing of gear unit
10 - Hex. screw
11 - Springring
12 - Rubber bearing
13 - Brush holder plate
14 - Spring
15 - Earth carbon
L6 - Cheesehead screw
17 - Armature
18 - Pole housing with permanent magnet
19 - Holding bracket

Vol kswagen
Windshield wiper motor assembly
ELECTRICAL 13_12

@ volkswagen
Windshield wiper motor schematic

A - Armature D - Sliding contacts

B - Permanent magnet E - Switch
C - Contact plate F - to fusebox (terminal 15)

into parking position prior to attaching the drive crank. I nspecting disassembly
Connect the ground wire from the engine to the ground of If the collector is oily or contaminated, wipe with a cleara
the battery. Connect the line from terminal 53 and 53a to cloth moistened in gasoline. If the collector shows traces
the positive pole and run the motor for a few minutes. of wear or burnt spots, reconditioning is required,
When the line is then disconnected from terminal 53, the Machining of the collector is permitted to a maximum 0.6
motor will stop in its parking position. Then place the in. only. The insulation between the laminations is theo
drive crank in parallel with the drive rod on the drive shaft refinished with a collector saw. Make sure that no meta-l
of the worm gear and attach by means of a lock washer chips collect between the laminations, so that no shorî
and a hex.^nut. The parking position of the crank may circuit between the armature windings will result. The
vary by I 5-. permissible radial wobble of the armature is 0.0012 in
Damages on the armature aie often not seen from the
outside. The electrical checkup also includes a test for
interruptions, as well as for winding and grounding shorts.
These tests are conducted in a manner similar to measure.
ments on the armature of the alternator.

WINDSHIELD WIPER FRAME WITH MOTOR

Removal
Disconnect the battery ground. Unscrew the cap nut oo
the clamp piece of the two wiper arms and remove the
arms. Remove the bearing cap, unscrew the hex. nut, and
remove the hollow washer and rubber seal. Remove the
container. Remove fresh air blower housing, referring to
the chapter body.

Loosen the hex. nut of rubber/metal anti-vibration bear-

ing from the interior of the vehicle (under the instruemnr
panel), making sure that the anti-vibration bearing is nor
twisted. Pull out the windshield wiper frame with motor
in a downward direction, Disconnect the lines.

lnstallation
Connect the lines according to a wiring diagram. Insert the
O Volkswagen
windshield wiper frame with motor. Make sure that the
Setting position of crank antivibration bearing is in the bore provided. Screw the
a : 0.33 in. hex. nut to the antivibration bearing, holding the bearing
ELECTRICAL 13_13

in position to prevent distortions. Position the windshield lnstallation

*iper arms, observing the parking position of arms. Rub the shafts prior to installation with molybdenum
Connect the battery and check the windshield wiper disulphide (MoSZ) grease. Watch out for correct and tight
lrstem for function. Install the fresh air blower housing seat of circlips. The distance between the bottom hex. nut
aad fuel tank. When installing a new or'repaired wind- and the crank should be 0.33 in.
shield wiper motor, be sure that the motor is in the
parking position. WORM GEAR
Adjusting end play
YVINDSHIELD WIPER SHAFT The end play should be approximately .008 inch. To
Removal adjust loosen the counter nut, Screw the adjusting screw
For removing the wiper shaft, remove the complete wiper carefully up to stop and then screw back by 1/4 turn.
i-rame together with motor, Remove the motor from the Counterlock the adjusting screw
çindshield wiper frame. To pull the two wiper shafts from
the wiper bearings, remove the circlips from the wiper ARMATURE
shafts by means of pointed pliers and a rubber hammer. Adjusting end play
-{pply only light blows against the pointed pliers with a The play should be approximately .008 inch. Adjustments
rubber hammer. are made sigrilar to the end play adjustment of worm gear.

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llll
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1 r3 87
Windshield wiper linkage
ll
32 I

@ volkswagen
1 - Wiper linkage 8- Hollow washer
2 - Citclip 9 - Bottom rubber seal
3 - Spring washer l0 - Top rubber seal
4 - Washer 11 - Bearing cap (rubber)
5 - Shaft bearing 12 - Wiper arm
6 - Frame for wiper system 13 - Washer
7 - Hex. nut 14 - Cap nut
ELECTRICAL 13-14

lq

ttttaaa--

--ar'

@ volkswagen
llind shield washe r as se mb ly
1 - Releasing Button 5 - Double spray nozzle 9 - Rotary closing cap
2 - Switch with valve insert 6 - Hose between fluid container and switch 10 - Compressed air tapping hose
3 - Rubber sleeve 7 - Coupling nut 11 - Spare wheel
4 - Hose with T-piece between switch and nozzle 8- Fluid container

& WINDSHI ELD WASHER SYSTEM

The windshield washer cleans the windshield by using the
windshield wipers. The fluid container is pressurized to a
maximum 43 psi for a capacity of 1.5 lits. and is mounted
at the right between the front trunk and the instrument
panel. The excess air in the spare wheel puts the contents
of the fluid tank under pressure via a plastic connecting
line and a pressure tapping hose. A shutoff valve installed
in the closing cap of the container disconnects the
compressed air when the air pressure in the spare wheel is
down to 28 psi, so that the minimum pressure in the spare
wheel will be maintained. The excess pressure in the fluid
tank wi.ll force the washing fluid to the two spray nozzles
under the windshield.

To protect the washing fluid against freezing during the

winter, add a window cleaning agent of pertinent con-
o volkswagen centration to the water, Fuel alcohol can also be used as
wiper motor adjustment an anti-freeze. In such a case, a mixture of one part fuel
alcohol and three parts water will provide anti-freeze
A - Gear end play B - llorm gear end play protection up to approximately + 10"F.
ELECTRICAL 13_15

iemoval forward direction. Pull the lines and indicating [ghts,

l--connect the battery ground. Remove the steering which will release the instrument panel insert. Push the
m:eel by removing the turn signal spoke by means of a individual instruments out in the forward direction,
llrrt lefthand turn and unscrewing the hex. nut. Loosen making sure that the pertinent rubber clamping ring is not
:'e four sctews of the instrument panel insert. Unscrew damaged. Remove the clamping ring, if required.
speedometer shaft and Bowden wire of the tachom-
=e
::tt. lnstallation
Proceed vice versa for installation. Connect lines to
l:lt the complete instrument panel insert out in the individual indicating points according to a wiring diagram.

O volkswagen
Instrument lights and wiring connections

The numbers in parantheses are the terminal designations.

1 - Instrement lights
2 - Side marker indicating light - green
3 - Blinker indicating light - green
4 - HiCh beam indicating light - blue
5 - Charging control light - red
6 - Warning light fuel reserve - red
7 - Oil temperature warning light - red, only on 914/6
8 - Hand brake warning light - red
9 - Oil pressure indicating light - green
ELECTRICAL 13_16

zt
@ volkswagen
Fresh air blower assembly

I - Fresh air blower 8 - Washer l5 - Motor housing with motor

2 - Line 9 - Lock washer 16 - Clamping ring
3 - Cable sleeve 10 - Hex. nut 1 7 - Blower housing half front
4 - Cheesehead screw 11 - Lock washer L8 - Connecting rod
5 - Washer l2-Hex,screw 19 - Circlip
6 - Blower housing half rear 13 - Bimetaltic switch with resistance 20 - Impeller
7 - Screw for cable control attachment 14 - Flap with seal 21 - Spring clip
ELECTRICAL 13_17
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Grey/brown
Green/red
Greeniblack
Yellow
Black/purple
Black/Red

White
Green

4 Governor
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Rear window heater relay (optional)
55 Belay for heater blower
AA
Relay for power supply
ac
Relay for gasoline pump
90 Regulator plate
91 Fuses for rear window heater, heater blower,
gasoline pump

CAUTION!
O volkswagen
Disconnection of battery with the engine running will result in immediate destruction
of alternator.
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EODY 14-1

BODY 14

INDEX
Page Page
DEScRlPTloN... ....14-1 Removal ....14-10
Heatingsystem .. ' '14-l Installation 14-10
FRONTBUMPER ....14-I Removal ....14-10
Removalandinstallation . .'...."14-1 LOCKCYLINDER .. .14-1
FRONTPANEL ......14-3 Removal .. l4-1
Removal . '..14-3 Disassembly .....14-l
Installation . ' 14-3 Installation ......14-l
REARBUMPER .....r4-3 WINDOW REAR GUIDE CHANNEL . . . .1.4 1

Removalandinstallation... '.14-3 Removal . .14-1

HooD '. '. -.14-3 Installation 14-12
Removal . - '14-3 WINDOW FRONT GUIDE CHANNEL AND FRONT
Installation .".14-3 OUARTER WINDOW . L4-12
HOOD SPRING AND HINGE . . .14-3 Removal ....14-12
Removal - - '14-3 Installation . 14-12
Installation . " l4-4 DOOR LOCK t4-12
HOOD LOCKTOP .. ...r4-4 Removal ...14-12
Installation " .l4-4
Installation " 14-12
HOOD LOCK BOTTOM .14-4 DOORiTTruOOW ....r4-r3
- Removal . '.14-4 Removal ...,14-13
Installation - .14-4 Installation . , 14-13
TRUNK LOCKTOP .,.14-5 Adjusting . . 14*13
Removal and installation - - l4-5 WINDOWLIFTER ...14-14
LID LOCK BOTTOM , .I4-5 Removal ....14-14
Installation . .14-5 Installation 14*14
TRUNK HINGES AND TORSION ROD . .14-5 W|NDSHIELD.... ...14--15
Removal -. '14*5 Removal ....14-15
Installation " 14-6
Installation .14-15
ENGINE COMPARTMENT LID . ,14-6 REARWINDOW ^. ...14-15
Removal .....14*6 Removal .....14-15
Installation .14-6 Installation . 14*16
TORSIONBARSPRING ,..,..14-6 DRIVERSSEAT. ....14-16
Removal . - -14-6 Removal . . .14-16
Installation .14-6 Installation 14-16
ENGINECOMPARTMENTLOCK,,....14-6 HEIGHT ADJUSTMENT WITH GUIDE RAIL " . .14-16
Removal
Installation
. . .14-6
.14-6
Removal
Installation
. . .14-16

FRONT PASSENGER SEAT, CENTER SEAT AND

14-16 ET
ENG|NEL|DGRILL ....14-6
Installation ' 14-6 REARWALLPANELING ....14-T6
ENGINELIDRELEASECABLE ......14-6 Removal ' . 14-16
Removal . "..14-6 FRESH AIR AND BLOWER BOX . . .. .14 16
Installation ' ' l4-7 Removal .....14-16
DOOR "14-7
Installation . 14-16
Removal .. -14-'l CONTROL BOX LEFT/RIGHT AND
Installation . . l4-7 DEFROSTERNOZZLES ..,..14-17
H|NGEPIN.. ...14-7 Removal . . .14-17
Removal . - - -14-7 Installation . . 14-17
Installation . .14-7 INSTRUMENT PANEL . 14-18
DOOR LOCKINGPLATE . ". ^..14-'7 Removal "...14-18
Adjustment . .l4-7 LOCK FOR INSTRUMENTPANELBOX . . . . . . 14-I8
DOORPANELING .,...14-9 Removal and installation " . 14- 1 8
Removal . . .14-9 ROOFLOCK ..14-18
Unscrew the oval head screw 14-10 Removal ...14 18
Installation 14-10 Installation 14-18
DOORSAFETYLOCK. .. "..14-10
BODY 14-2

DESCRIPTION Heating system

The two-door unitized body of Type 914 is provided with The vehicle is equipped with a fresh air heater. The fresh
an integrated ro11 bar and a detachable roof panel made of air is heated by heat exchangers. The heat flow is
glassfiber-reinf orced vinyl. generated by the engine fan or the electric fan. During
city traffic with low engine speed, the electric fan supplies
The body is subdivided by bulk heads into the front fresh air for the heater, at higher speed only the engine
luggage compartment, the compartment for the fuel tank, fan supplies the air.
passenger compartment, engine compartment and rear
luggage compartment. To operate the heater pull the lever with the red handle
between the front seats up. In fully raised position an
The body consisting of side and cross beams, bulk heads electric contact starts the electric fan.
and door pillows, front and rear side members (fenders)
and the roll bar is welded to the frame to form a unitized The red lever in the center of the dashboard controls
body. warm air supply by an air distributor to the defroster
outlets as well as to the outlet for the footwell.
The front and rear panels as well as side member panelling
and the bumpers are made of steel sheet and bolted on. FRONT BUMPER
Removal and lnstallation
The rear luggage compartment and the engine com- Unscrew the two hex. screws from the direction of the
partment have individual lids, the front luggage com- mudguard and remove the bumpers. During installation, a
partment and the compartment for the fuel tank have a uniform spacing between the bumpers and the front
common lid. overriders, as well as parallel alignment from bumper to

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Disassembly of front bumper

I - Sheet metal screw 6 - Washer

2 - Sound-absorbing grille 7 - Serrated disc
3 - Sheet metal nut 8 - Hex. screw
4 - Bumper 9 - Bead strip
5 - Shim 10 - Washer
End plate front 11 - Hex. nut
BODY 14-3

front lid should be attained before tightening the hex. During installation, make sure that a uniform distance
nuts. Do not forget the washers and serrated discs. between the bumper and the overriding rear, and that a
parallel alignment in relation to the styling bead in the
FRONT PANEL rear end plate, is maintained. Tighten the hex. screws. Do
Removal not forget washers and serrated discs.
Remove the self tapping bolt from wheel housing side.
Remove sheet metal screws from inside of the front trunk
and remove the front panel. HOOD
Removal
The work should be done with extreme care to eliminate
any possibi-lity of damaging the windshield vents. In
addition, the vents should be covered. When the hood is
used again, mark the position of the hinges on the inside
hood plate with a tracing needle.

lnstallation
Make sure there is perfect seating and that the condition
of hood sealing strips is good prior to installation. Prior to
glueing new rubber sealing strips down, remove re-
mainders of old glue with gasoline from the sealing ways,
coat with original VW universal glue D 12 and let set.
Then insert the new seal, When the same hood is put back
again, align according to the hinge marks on the hood and
screw it down well..No fitting of the hood is required.

A new hood should be fitted prior to applying paint finish

to prevent scratching. Screw the hood loosely to the
hinges and shift in the oblong holes until a perfect seating
and sealing is attained along its entire circumference. Then
tighten the screws well. Align the lid at the level of the
O volkswagen blinker lights by screwing the adjustable rubber buffer in
Inside sheet metal screws or out. Check the operation of the hood lock by repeated
opening and closing. Adjust the hood lock top in the
oblong holes - or engaging depth of tap lock in oblong
holes of cover lock bottom.
lnstallation
Loosely attach the front panel with the two sheet metal HOOD SPRING AND HINGE
screws. Loosely attach the two sheet metal screws in the The hood hinge can be installed only with the hood
wheel housing. Align the front panel and tighten. removed.

REAR BUMPER Removal

Removal and lnstallation Bend the lug from the welding wire and attach it to the
Unscrew the license plate lights prior to removal. Unscrew
one hex. screw each from under the mudguard. Pull the
paneling and unscrew the hex. screw on each side from
direction of the trunk. Remove the bumper.

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O volkswagen
Luggage co mp ar t me nt s crew Spring installing {a -4 in.)
BODY 14-4

upper eye of the hood spring. Use a long mounting lever oblong holes of the wheel arch hinge section for height, if
to remove the hood spring carefully from its mountings. required. Attach the hood spring carefully to the spring
The head of the spring strut is used as a counter suppolt. mount. The spring mount has three holding slots for the
The lateral section must be covered for this job. Unscrew spring. If the preload of the spring is too low, attach it to
the hinge from reinforcement wheel arch. Disconnect the another slot.
hood spring from the hole on the hinge section of the
cover. Loosen the hood hinge section by unscrewing the HOOD LOCK TOP
bearing pin from the wheel arch hinge section, if required. lnstallation
Replace the hood lock top, if required, but first try
greasingwith lock grease. Check for a perfect seat of the
top by opening and closing the hood several times. If
required, correct the seat of the top by shifting the
assembly in the oblong holes. Check the operation of the
safety hook. If required, unbend the bent tab on the hood
lock bottom up to the engagement point of the safety
hook. The engagement depth of the tap lock can be
adjusted at the lid lock bottom by shifting the assembly in
the oblong holes.

HOOD LOCK BOTTOM

Removal
Loosen the clamping screw for the lock cable controls.
Unscrew the 3 hex. screws. Pull the bottom of the hood
lock laterally from the hood lock cable controls.

lnstallation
When new cable controls are used, grease lightly when
inserting them into the guide tube as a protection against
corrosion. Slide the cable controls through the guide of
the base and screw provisionally to the clamping piece.
Screw the base to the front of the lock cross wall. Loosen
@ volkswagen the clamping screw, pull the cable controls tight and screw
down. Then bend the cable controls behind the clamping
Stretching the spring piece,

lnstallation
Screw the hood hinge section to the wheel arch hinge
section. Attach the hood spring to the hinge section.
Screw the preassembled hinge to the reinforcement of the
wheel arch. Mount the hood and fit. Align the hinge in the

O volkswagen
Lid lock
I - Cable controls 2 - Clamping piece

To check the lock cable controls for perfect operation,

permit the latch to engage and disengage several times
with the hood opened. Check for a perfect seat of lock
O volkswaqen bottom'by opening and closing the hood several times. If
required, shift the assembly in the oblong holes to correct
Adiusting depth engagement the seat of the base.
BODY 14-5

TRUNK LOCK TOP LID LOCK BOTÏOM

Removal and installation lnstallation
The lid lock top with lock tap can be adjusted lengthwise Check the locking cylinder and replace, if required, but
and crosswise in the rectangular cutouts for the fastening first try greasing or using graphite. Insert the locking
screws. Screw the lid loosely to its hinges and shift in the cylinder from the outside through the hole in the end
oblong holes until a uniform seating and sealing is plate. Watch the installation position of the locking
obtained along the entire circumference" Then tighten the cylinder in relation to the end plate. The snap lock is
screws, Align the lid in relation to the lateral member by installed correctly when the closing tap points in, between
screwing the adjustable rubber buffers in and out. Check the two upper grooves of the end cross wall when in the
the operation of the lid lock by repeatedly opening and opened position.
closing the lid. If required, adjust the lock top in the
rectangular cutout or change the depth of engagement of Fit the spacer bushing to the snap lock with the flat
the lock tap by adding or removing spacer washers surface toward the end plate. Screw the hex. nut to the
between the molding and the lock top. snap lock and tighten. Check the lid lock top and replace,
if required, but first try lubricating. Then screw the lock
to the lid supports.

TBUNK HINGES AND TORSION ROD

Disassembly
The two torsion rod springs assist in opening the trunk lid
and hold it in the open position. Use caution when
rernoving the trunk lid as the torsion rod springs are under
tension.

Removê the trunk lid as described under trunk lid

removal. Placc assembly tool P 304 (local manufacture)
behind the upper bend of the torsion rod spring. Always
position the assembly tool in such a manner that the
opening of the slot faces the center of the vehicle.
Remove the torsion rod from the guide roller by pushing
the guide roller sideways with a screw driver until the
torsion rod clears the roller, Allow the torsion bar to press
the assembly tool against the body. Hold the torsion bar
with a box wrench and remove the assembly tool. Slacken
the spring completely. Continue to release the tension
using the box wrench. Remove the two clamps then pull
O volkswagen the torsion rod to the right out of the welded-on retaining
eye, Remove shoulder bolt: the hinge can be removed.
Rear lid lock

1 - Hex. screw 6- Undulatetl washer

2 - Locking ring 7- Spacer washer
3 - Washer 8- Spring
4 - Molding 9- Bushing
5 - Hex. nut 10 - Lock tap

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Rear lid lock adjustment Removing torsion rod spring

BODY 14-6

1 - Hex. screw
2 - Locking wahser
3 - Washer
4 - Lid lock base
5 - Clamping screw for lock cable controls
6 - Lid lock cable controls
Lid support
7 - Holding plate

O Volkswagen
Engine compartment lid lock

Assembly ENGINE COMPARTMENT LOCK

Install the hinge and position the guide roller. Install the Removal
torsion rod and align it with the guide roller. Tighten the Loosen the clamping screw for the lock cable controls.
securing clamps. Preload the torsion bar spring with a box Unscrew the two hex. screws and remove the lid lock
wrench until the assembly tool (P 304) can be positioned base.
behind the upper bend. Remove the box wrench and set
the spring on the guide rollers using a screw driver. lnstallation
Check the lid lock base, and replace, if required, but first
ENGINE COMPARTMENT LID try to lubricate it. New lid lock cable controls must be
Removal slightly greased when inserting into the guide tube.
Using the two mechanics, unscrew one hex. screw each.
Carefully remove the lid. Screw the lock cable controls provisionally to the clamp-
ing piece, Screw the base to the lock support. Loosen the
lnstallations clamping screw, pull the cable controls tight and screw
Prior to installation, watch out for a perfect seat and down. Then bend the clamping piece.
condition of the seals between the engine compartment
lid and the rear window. Use a new seal, if required. A Check the lock cable controls for perfect function. Engage
new lid must be fitted prior to painting to eliminate and disengage the latch several times with the lid opened.
subsequent scratching. Screw the lid loosely to the hinges Check for a perfect seat of the lid lock base by repeatedly
and align to provide a uniform distance laterally and at opening and closing the lid: if required, shift the base in
the rear, so that a reliable seal will be provided between the oblong hole or change the engagement depth of the
the lid and the rear window. Then tighten the screws well. lock hook on the engine compartment lid by screwing it
Align the lid in relation to the lateral engine compartment in or out.
molding by screwing the adjustable rubber buffer in or
out. Check the operation of the lid lock by opening and ENGINE LID GHILL
closing it several times" Change the depth of engagement Installation
of the lock hook by screwing it in or out. Position the drip pan on the compartment lid pins and
press on the clamping discs. Install the rubber stop with
TORSION BAR SPRING reinforcing elbow on the left side of the lid and tighten
Removal the screw. Connect the right side of the pan to the lid. t:
Remove the tightening piece after unscrewing one cross- Insert a spacer bushing and tighten the screw.
slotted screw. Disconnect one spring bar each at the left
and right, and pull out. Water pump pliers may be used.
ENGINE LID RELEASE CABLE
lnstallation Removal
For installation, insert the spring, first into the guide To remove the grill, the engine compartment lid should
holes, then attach and screw to the tightening piece. first be removed.
BODY 14-7

Assembly that the door can be opened and closed without jamming.
Install grill before painting to prevent any scratching later This requires removal of the locking plate. The door
on. Place the seven plastic washers on the grill pins, then hinges are screwed to movable, threaded, plates located in
install the grill in the engine compartment lid. The plastic the hinge pillar. This permits reliable adjustment and
washers must be placed between the grill and the lid to fitting of the door to the external contours of the vehicle.
prevent rattling. Press on the center and side edge Screw the locking plate back again and adjust in such a
molding. manner that the depression for the handle in the door is in
alignment with the depression in the lateral member at the
rear. Simultaneously, see that the door does not extend
too far outwards or inwards. Lubricate the door hinges,
coat the mating surfaces of the door catch housing on the
locking plate and on the latch, lightly, with vaseline.

HINGE PIN
Removal
Pull the cotter pin out of the bearing bolt and extract the
bolt for the door safety lock.

Remove the hinge bolt with special tool P 290, which can
be used both, for the upper and the lower hinge pin by
only changing the bottom section of the tool.

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Engine compdrtment lid release

1- Lid release knob

2 - Rubber washer
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DOOR
Removal @ volkswagen
Extract the pin for the door safety lock, after pulling out Door hinges
the cotter pin, If the same door is to be reinstalled, mark
the position of the hinges on the hinge pillar with a 1 - Hinge pin
tracing point. Unscrew the 6 hex. screws and remove the 2 - Hinge half
door. Spray rusted screws with a solvent or loosen by 3 - Spring washer
means of an impact screw driver.

lnstallation
Check the door seals and replace, if required. Glue in new lnstallation
seals using VW profile glue D 21. In the upper range of the Insert the hinge half and spring washer into the hinge half
door, the seal is glued under the outer window channel on the pillar end. Force the hinge pins into the hinge from
seal and clamped to the door inside panel with a spreader the door center. The pin is far enough in the hinge when it
pin" If the same door is ieinstalled, simply align in rests against the small lug. ll4 inch will remain between
accordance with the markings on the hinge pillar. Fitting the hinge and the collar to receive the extractor.
the door into the body cutout is not required.
POOR LOCKING PLATE
When a new doot is installed, proceed as follows: Screw Adjustment
on the door and fit into the body cutout in such a manner To eliminate any back-and-forth movements of the catch
that a uniform all-around of the rubber seal is assured and while driving, the locking plate is provided with a resilient
BODY 14_8

rubber-metal latch. This latch cannot be adjusted. Occa- replaced or a shim must be added. "For this purpose,
sionally, door chatter cannot be completely avoided unscrew two counter-sunk screws out of the angle portion
merely by adjusting the locking plate. In such a case, the of the locking plate. Insert the shim and reassemble.
locking plate need not be replaced. Simply place a sheet
metal shim approximately 1125 inch thick between the Upon removal of the locking plate, the seating of the door
latch and the locking plate. in the door cutout is checked as follows: Tight seat of
hex. screws for fastening the door hinges, Alignment of
the door and front lateral member. Uniform distance
between door and door cutout. Alignment of the door
and rear side member. Alignment of the door handle
depression with the depression inside the member rear.

If the above does not apply, proceed as follows: Loosen

the hinges and displace the door as required inwards,
outwards or upwards. Tighten the hex. screws well.

Install the locking plate and adjust. The plate is adjusted

correctly if: the door is in alignment with the rear side
member, the depression of the door handle is in alignment
with the depression in side member rear, no play is felt
between the lock and the latch when pulling or pushing
door, the door can be opened from outside and inside
without excessive energy.

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Locking plate adiusting screws

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Locking plate assembly
I - Latch
2 - Shim
3 - Locking plate

A poorly adjusted locking plate can be adjusted as

O volkswagen follows: If the door closes too tightly, the handle will be
Checking locking plate and catch hard to move. The reason is, that the locking plate tilts
too far inwards in the upper range. Correct the locking
plate by rotating it to the short end of the latch.

If the door does not engage in its end position when it is

To check whether the latch is resting well against the latch slammed, but jumps back into the safety position, the
of the locking plate, proceed as follows: Remove the locking plate is screwed down with too much outward tilt
locking plate. Insert the locking plate first at the bottom at the top. The door can be easily opened with handle.
into the lock catch and then push down completely to the Correct the locking plate by rotating it toward the long
closed position. Then swing the locking plate around in an end of the latch.
upward direction. If swinging the locking plate up and
down in this position shows play, the latch must be When the locking plate is set too high, the door is hard to
BODY 14-9

open by means of the handle. When the door is opened, it

will not move out of the door cutout in parallel qF
alignment, but will sag. Displace the locking plate in a
downward direction.

When the locking plate is set too low, the door will merely
engage in the safety position when slammed. But it will
jump out of the end position. Displace the locking plate in
an upward direction.

DOOR PANELING
Removal
Press off the inside handle shell by using a screw driver as
a lever, unscrew one cross-slotted screw of the cover plate
and remove the plate. Unscrew the window crank after
pressing off the cap. Unscrew the 3 sheet metal screws in
the lower range of door. Unscrew the 2 hex. socket screws
out of the door pocket on driver's side. @ volkswagen
Removing inner handle shell

17 8 9 l0ll 12 7 5 6 2 3 1 4 14131516
Door paneling @ volkswagen
I - Cover for window crank
2 - Cross-slotted screw l0 - Hex. socket screw
3 - Window crank 11 - Washer
4 - Shim 12 - Cage nut
5 - Handle shell for inside actuation 13 - Crip
6 - Cross-slotted screw 14 - Door panelling
7' Cover plate for inside actuation assy. 1 5 - Seal for cliP
8 - Cross-slotted sheet metal screw 16 - PVC foil
9 - Washer 17 - Door pocket
BODY 14-10

The door pocket can be removed, if required, by lnstallation

unscrewing 6 sheet metal screws from the arm rest. When Check that the water drain holes are free. Check the foam
removing the door paneling on the front passenger side, covers and be sure to replace it if damaged, to keep out
observe the following: Unscrew the three sheet metal drafts. Coat the inside door sheeting lightly with universal
screws from the arm rest bottom, and remove by sliding it glue D 12 and glue on the foil free of wrinkles. Perforate
towards its fat end parallel to the screws. the foil with a pin where the seals for the clips must be
pushed in. When fitting the door paneling, first attach the
plate clips to the opening of the inside door sheeting.

DOOR SAFETY LOCK

Removal
Extract the cotter pin from the bearing bolt of the door
plate and push out the bott. Remove the door paneling
and pull the foil from the inside door sheeting. Unscrew
the two hex. screws holding the door safety lock from the
inside door sheeting, Remove the safety lock from
between the inside and outside door sheeting. Unscrew
the two hex. screws holding the door safety lock from the
inside door sheeting. Remove the safety lock from
between the inside and outside door sheeting.

lnstallation
Prior to installation, lubricate the bearing points of the
rollers in the door safety lock with HD oil, SAE 30. Insert
and screw the safety lock in between the inside and
outside sheeting. Reinsert the bearing bolt, seal it with a
cotter pin. Slightly lubricate the safety lock joint, Glue in
the foil, and assemble the door completely.

DOOR HANDLE
Removal
Prior to removal, move the door window pane in the
topmost position and. then remove the door paneling.
O volkswagen Unscrew the hex. nut. Unscrew the hex. socket screw
Inside door pull screws between the door inside and outside sheeting. Remove the
door handle. Use only new, self-locking nuts for instal-
lation.

Unscrew the oval head screw

Remove the door paneling from the inside door sheeting.
Proceed carefully to prevent any damage to the door
paneling and paint. The door paneling is attached to three 5
slots in the inside door sheeting by means of three
welded-on sheet metal clips. For this reason, the door
paneling must first be pulled off slightly and then 4
removed in the upward direction. For the front passenger
door, after unscrewing the 2 screw bolts from the door
paneling, the arm rest can also be replaced. Pull the glued 2
on foil from the inner door sheeting and push out the clip
seals. {b.
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Q volkswagen

I - Door handle 3 - Hex. nut self{ocking

o Volkswagen Door outside sheeting 4 - Spring ring
Three door paneling slots 2 - Wahser 5 - Hex. socket screw
BODY 14_11

LOCK CYLINDER lnstallation

Removal
Insert the tock cylinder with the inserted key and
Remove the flat head screw and cone washer and pull the attached seal into door handle. Install the spring on the
eccentric from the lock cylinder. Remove the lock lock cylinder end, keeping the spring under tension
cylinder return spring. Insert a key and push the lock between the eccentric and housing. push the eccentric on
cylinder with seal in the forward direction o,rt of th" doo, the square end of the lock cylinder and install the flat
handle. The inserted key prevents the loss of the tumblers head screw with the cone lock washer, Install the door
and springs which are only loosely assembled in the guide handlq and packing.
ducts of the lock cylinder.
WINDOW REAR GUIDE CHANNEL
Disassembly Removal
Remove the lock cylinder and push the tumblers and Remove the door panel and pull
springs out. The tumblers and springs are loose in the lock
off the pVC sheeting.
Then crank the window completely down. pul tÈe
cylinder and are not peened, window weatherstrip back until the window guide piece

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Front channel guide O volkswagen

I- Nut, washer 8 - Countersunk screw

2- Adjusting screw 9 - Protective cap
3 - Window front guide channel 10 - Bolt
4 - Bolt, M6x12 1l - Lock washer
5 - Flat washer 12 - Flat washer
6 - Lock washer 13 - Quarter window
7 - Hex. nut 14 - Sealing frame
BODY 14-12

moves freely. Remove the Philips head screw from the quarter window and sealing frame with D l0 cement.
guide piece. Pull the guide piece out in an upward Install the door panel. Glue the front of the sealing frame
direction. Remove the screw at the bottom of the rear to the door seal with SICOMET 85 or similar adhesive.
guide channel of the door. Remove the guide channel
through the opening in the inner door panel. DOOR LOCK
Removal
lnstallation First remove the door panel and the window rear guide
Clean the guide channel and, if necessary, coat it lightly channel. Pull off the PVC sheeting from inside the door
with grease at the inner edges. Crank the window panel.
completely down. Install the speed nut, replacing it, if
necessary. Insert the guide channel through the lower
panel opening. Push the window guide piece on the
window guide channel and window duct.

Align the rear guide channel with the window and tighten
the screw from outside of the panel. Check the window
operation. Readjust the bottom fastening screw if nec-
essary. Instail the PVC sheeting and door panel.

WINDOW FRONT GUIDE CHANNEL AND FRONT

OUARTER WINDOW
Removal
Remove the door panel first. The door glass and lifter
assembly need not be removed. Remove the hex. nut from
the adjusting screw located at the bottom of the door.
Turn the adjusting screw into the door until the window
front guide channel is loose, Remove the anchor bolt from
the door, using an open end wrench to hold the nut. Pull
the guide rail with quarter window approximately four
inches out of the door duct. Remove the front guide
adjusting screw and pull the guide rail out completely.

432t
@ Volkswagen
Door lock
1 - Actuating lever 4 - Spring
2 - Pawl 5 - Remote control lever
3 - Rachet wheel 6 - Draw spring

Wind the window up completely. Remove the retaining

spring clip for the pull rod and disconnect rod. Move the
lock latch to the vertical position, remove the three
Philips head screws and pull the lock downward out of the
door.

lnstallation
Move the lock latch to the vertical position and insert the
lock into the door from below. Fasten with three Philips
head screws. Attach the pull rod to the remote control
lever on the 1ock. Slide the retaining spring clip at the end
O volkswagen of the pull rod toward the opposite end of the hook.
Connect the pull rod to the lock and turn the retaining
Cha nne I a djus ting s crew clip on the rod until it snaps in place. Betôre further
assembly check the operation of the door lock release
lever and safety catch. To make adjustments to the length
of the pull rod use a bending tool or pliers as required.
lnstallation The corre;i length of the pull rod is attained if the
Slide the front guide channel with the front quarter opening lever on the inside door handle is aligned with the
window into the window duct. Align the quarter window safety lever. To prevent any rattling of the pull rod, be
with the front guide channel to the windshield frame. sure that the pull rod holder is properly inserted in the
Close the door and check the fit of the door glass in inside door panel. Install the window rear guide channel
relation to the seals on the roof and roll bar. Seal the and door panei. Glue on the PVC sheeting.
BODY 14-13

lnstallation
Insert the door glass with guide rollers into the window
channel. Clean guide rail, if necessary, and coat it slightly
with grease at the inner edges. Then slide on the guide
roller and fasten it to the window lifter channel with two
Philips head screws. Insert the window rear channel guide
piece and fasten it with Philips head sheet metal screw.
Press on the door duct weatherstrip on the flange of the
inside door panel. Open and close the window several
times to check for free operation. Close the door and
check the glass alignment with seals on the roof and ro11
bar.

O volkswagen
Lock retaining screws

DOOR WINDOW
Removal
Remove the door panel first, Pull off the inside door duct O volkswagen
weatherstrip. Remove the guide piece from the window
rear guide channel. Remove the two Philips head screws to Installing guide roller in channel
loosen the window lifter channel. Remove the two Philips
head screws and pull off the protective cap on the front A - Guide rail B - Guide roller
quaïter window. Lift the door glass out of the window
duct.
Adjusting
If the window cannot be cranked high enough: Loosen
the lock nut on the adjusting screw and release the screw
several turns. Move the window to the top position and
check adjustment. Make the required correction and
tighten lock nut again.

If the window can be cranked up too high: Crank the

window down approximately one turn. Loosen the lock
nut on the adjusting screw and tighten the screw several
turns. Move the window to the top position and check the
adjustment. Make the required correction and tighten the
iock nut again.

If the glass tilts too far inward:

Loosen the lock nut on
the adjusting screw and release the screw severai turns.
The pane will tilt outward. Check the adjustment. Make
the required correction and tighten the lock nut again.

If the pane tilts too far outward: Loosen the lock nut on
the adjusting screw and turn the screw several turns to the
left and check the adjustment, Make the required coffec-
O volkswagen tion and tighten the iock nut again. Glue on PVC sheeting
l|indow lifter channel screws and instaii the door panel.
BODY ',t4-14

WINDOW LIFTER spots cannot be eliminated, replace the window lifter. If

Removal the coil in the slotted tube of the window raiser rattles,
Remove the door paneling and door glass first. Unscrew carefully squeeze the tube at the location where the
the lock nut from the adjusting screw and remove the rattling occurs.
adjusting screw. Push the window lifter out of the rubber
sleeve. Loosen the lock nut from the adjusting screw and Insert the window lifter in the door duct. Insert the
turn the adjusting screw down until the front window window lifter with stop into the rubber sleeve of the
guide rails are loose. Remove the hex. head bolt (hold the inside door panel. Turn in the adjusting screw with nut
nut with an open end wrench.) Pull the window front and lock. Insert the adjusting screw for the window tilt
guide channel toward the rear. Push the window lifter into the inside door panel together with the window front
drive from inside the door panel and remove the window guide channel, Loosely attach the lock nut. Loosely
lifter from the door duct. attach the window front guide channel with anchor bolt.
Insert the window duct weatherstrip near the front
quarter window. If the window duct weatherstrip at the
lnstallation quarter window end should become loose during assem-
Check the operation before installing the lifter. If neces- bly, glueit to the door seal with SICOMET 85 cement or
sary straighten the slotted tube and oil drive coil. If tight similar adhesive.

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@ volkswagen
Window lifter

I - Phillips head screw, lock washer, flat washer 4 - Window lifter

Inside door panel 5 - Hex. nut (to lock lateral tilt adjusting screw)
2 - Adjusting screw (winding height) 6 - Flat washer
3 - Hex, nut 7 - Foam strip
BODY 14-15

Attach the window iifter with six Philips head screws. of pane with a brush. Connect Solbit sealing strip to a
Install the door glass. Crank up and check fit with the power source for 10 to l5 secs. For this purpose, a quick
door closed, then make corrections, if necessary. Fasten charger can be set to 24 Volt for an I I Amp. current to
the lock nut on the window tilt adjusting screw. Fasten two l2 Volt batteries can be connected in series (positive
the anchor bolt for the window front guide channel. Glue pole of first battery to negative pole of second battery).
PVC sheeting to the inside door panel and install the door Press the sealing strip on the edge of the pane, Bend the
panel. strip ends at a right angle. The ends should meet at the
lateral portion of the pane. Press the ends projecting from
WINDSHIELD the pane edge and twist"
Removal
Loosen the windshield trimstrip. Use 2 spatulas or flat Insert the pane. Place two wooden strips .16 inch thick
steel blades I inch wide. Tool A serves for locating clips. between the pane and frame in the lower range. Watch for
Tool B serves to lift clips so that trimstrip is released. a uniform, lateral spacing of the pane in relation to the
Unscrew the upholstering parts from the windshield frame frame. The sealing strip in the lower range should rest
laterally and at top. Pull the edge protection from the against the outermost edge of the pane. If not, the edge
lower window flange. To prevent any damage to the protection can be fitted badly or not at all. lnsert two
instrument panel when subsequently "cutting out" the wooden spacer blocks , each, at the top and bottom.
pane, cover the instrument panel adjacent to the pane
with adhesive tape. Punch a steel wire of approximately Mask the body below the connecting point. Connect the
.02 inch diameter through the sealing layer and "cut out" ceiling stripto the power source. After heating for
the pane, Carefully remove the remaining sealing material approximately three minutes squeeze it for a distance of
from the window flange with a sharp knife. I16 inch. Push uniformly with one hand against the pane
for 5 seconds. Heat the pane for t hour. After heating, cut
off any projecting ends of the ceiling strip close to the
'the pane
edge of and smooth out with a flat knife.

Pull out the assembly block and wooden strips. Screw the
upholstery components to the windshield frame. Fit the
windshield trim strip and edge protection.

REAR WINDOW
Removal
The rear window safety glass is bound with its weather-
strip to the frame. Remove both seats and remaining
backrest, the engine compartment lid release, the interior
light, the rear wall panel and roll bar padding. Remove the
rear window flange seal. Push a thin baling wire through
the rubber seal and pass along the glass to break the
bonding. Clean the glass of any remaining seal.

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@ volkswagen

Removing windshield

1 - Spatula or flat steel blade

2- Trimstrip
3 - Plastic clips
4 - "Solbit"
5 - Windshield

lnstallalion
Install the pane with Solbit TWS 8 mm diameter made by
the Bostik GmbH" If required, insert a spreader pin for the
O volkswagen
trirn strip attachment in the windshield frame. Clean the
wiadshield frame with nitro solution. Apply Solbit Primer
5014 10 mm wide on the circumferential glueing surface Removing rear window
BODY 14-16

lnstallation the seat cushion for the front passenger seat, Remove the
Install the window with "Solbit TWS 8 mm" manufac- support for the front passenger seat cushion after un-
tured by Bostik or similar. Ciean the window seal contact screwing four hex. nuts and two hex. screws. Unscrew the
surfaces with lacquer thinner. Apply a primer to the two sheet metal screws in the lower range of the rear wall.
bonding surface with a brush. Cut the Solbit strip to a IJnhook the rear wall lining in the downward direction. It
length of 10 ft. 6 in. Connect the ends to a powersource is attached to the rear wall with four clips. The rear wall
for approximately 1 minute. The recommended power lining can be disassembled in three parts: Front passenger
source is indicated under Windshield Pane-Installation. seat backrest, after unscrewing two continuous screws. At
the top, the backrest is hooked to the lining with two wire
Press the Solbit strip against the edge of the window glass. gears. Drivers seat lining, after unscrewing six sheet metal
The ends should meet at the center of the lower edge. screws.
Twist the ends. Install the window from inside the
passenger compartment. Position the 2 spaces (Part No. FRESH AIR AND BLOWER BOX
914 541 907 l0) between the frame and the bottom edge Removal
of the glass. Protect the engine compartment lid from First remove the fuel tank. Unscrew one hex. screw on
profile wires by masking the area with tape. each box end, as well as one hose clip, after unscrewing a
cheese head screw and pull off the hoses. Pull off the two
Reconnect the Solbit strip to the power source. When the water drain hoses in a downward direction. Remove the
strip is plyable, press it evenly against the window by wire cable underneath the blower by loosening the
hand for 5 secs. to assure proper sealing. Heat the window clamping nut and pushing off the holding clip. Do not
for about one hour. When finished heating, cut off the bend or distort the cable, since only a straight cable will
projecting ends of the Solbit strip at the edge of the glass. function properly.
Smooth out using a flat blade.
Pull off the multiple plug for the electrical connection.
Install the seal to the flange between the engine com- Remove the fresh air box.
partment lid and rear window by pressing it on. Apply 3i4
inch electrical tape all around the inside window edge. lnstallation
Apply additional tape, approximately 8 inches wide on Position the box without screwing it on and provisionally
the lower corners, Reinstall the roll bar padding, rear attach the cable. Attach the cable envelope with holding
paneling, engine compartment lid release and interior clip. The envelope is properly attached if it ends ap-
light. proximately l14 inct' in front of the holding clip. Screw
the box to the holding bracket.
DRIVERS SEAT
Removal
The seat cushion is held to the drivers seat at the front by
means of a sheet metal clip. Raise the cushion at the rear
end and unhook it at the front. Pull up the longitudinal
adjustment lever and slide the seat out in the forward
direction until the stop is reached. Raise the spring
underneath the left running rail and slide the seat out. If
required, remove the running rails after unscrewing the
eight hex. socket screws.

lnstallation
If required, screw the running rails to the seat with eight
hex. socket screws. Ciean the guide rails and coat them
thinly with universal grease. Insert the running rails into
the guide rails. Slide the seat toward the rear and let it
engage.

HEIGHT ADJUSTMENT WITH GUIDE RAILS

Removal
Remove the drivers seat. Unscrew the four hex. socket
screws and remove the height adjustment. Remove the
retaining plate after unscrewing the two hex. bolts.

lnstallation @ volkswagen
Unscrew the retaining ptate. Install the height adjustment. Adiusting cable length
Slide the drivers seat into position. a : 7/32 in.
FRONT PASSENGER SEAT, CENTER SEAT AND
REAR WALL PANELING Adjust the cable: Adjust in such a manner that in position
Removal III on the actuating lever for fresh air, both opening flaps
Remove the interior light and pull knob for the engine on the fresh air box are open. Check the function several
compartment lid. Remove the drivers seat and take out times. Position the air hoses and screw the hose clips tight.
the center seat cushion. Remove the center seat bracket Attach the water drain hoses. Attach the multiple plug for
after unscrewing the four cross-slotted screws. Remove the electrical connection. Install the fuel tank.
BODY 14-17

CONTROL BOX LEFT/RIGHT AND DEFROSTER

NOZZLES
Removal
First remove the fuel tank and fresh air blower box.
Loosen the hose clips from the control boxes by
unscrewing the cheesehead screws. Pull off the hoses.
Loosen the control box from the passenger side by
unscrewing two hex. nuts. Unscrew the supports for the
venting section from below and swing it up. Remove the
cable controls for fresh and warm air from the control
box by loosening the two clamping nuts and pushing off
the two holding clips.

lnstallation
- No. 10 and l1
Assemble the connecting cable controls
- with control boxes - No. 6 and 7 - white removed,
Connect the cable controls to the actuating levers of the
control box. Attach the cable controls with the holding
clips. Insert the cable controls crosswise into the clamping
screws on the control box. Tighten the clamping screws
O volkswagen
lightly. Clamp the cable controls with holding clips.
Relative positive of control knob and flap

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O volkswagen
Defrosters

1 - Defroster nozzle left 6 - Control box left 10 - Connection controls fresh air
2 - Defroster nozzle n$rl 7- Control box right I 1 - Connection controls warm air
3 - Air hose 8 - Cable controls fresh air 12 - Holding clip
4 - Seal 9 - Cable controls warm air 13 - Clamping nut with spring ring and washer
5 - Clip
BODY 14-18

Move the opening flaps of each control box into the upper section. Unscrew the two sheet metal screws from the
end position and then tighten the clamping nuts well. instrument panel. Carefully remove the instrument panel,
Check the function several times. Place the defroster beginning on the instrument cutouts, by means of a
nozzLes on the control boxes and clamp down. Insert the wooden or a plastic wedge.
preassembled control boxes with defroster nozzles into
the car. Insert the fresh and warm air cable controls into
the clamping screws on the control box, Tighten the LOCK FOR INSTRUMENT PANEL BOX
clamping nuts lightly. Clamp the cable controls down with Removal and installation
the holding clips. Remove the instrument panel box before removing the
lock.
Move the opening flaps into the end position on the
instrument panel then tighten the clamping nuts well. For installation of the lock, observe the following: Set the
Check the function several times. Screw on the supports lock into the opened closing position. Insert the lock with
for the venting section. Screw on the control boxes on the lugs into the grooves in the supporting plate.
passenger side. Position the air hoses and attach them with
clips. Install the fresh air and blower box. Install the fuel
tank. ROOF LOCK
Removal
Remove the supporting plate padding strip. Disconnect
the spring. Move the closing hook to the downward
position. Remove the roof lock after unscrewing two hex,
screws,

lnstallation
Replace the roof lock, if required, or grease. Screw on the
roof lock. Connect the spring. Screw on the supporting
plate padding strip. Check the function of the roof lock
several times.

O volkswagen

Adiusting fresh air control cable

a :7132 in.

INSTRUMENT PANEL
Removal
@ volkswagen
Remove the knee protection strip, heater and blower,
fresh air actuator, fuel tank and container for windshield Roof lock adiusting screws
washer. Unscrew the four hex. nuts below the venting A - Closing hook B - Screws
sPÊclFtcATtoNS 15-1

SPECIFICATIONS 15
GENERAL DATA
Wheelbase 2,450 mm (96.5")
Track width front (at dead weight acc.
to DIN) 1,337 mm (52.i")
Track circle dia. . , approx. 10.35 mm (33.9 ft.)
' Smallest turning circle dia. I 1.0 m (36 ft.)
Centerof tirecontact..... 40.5mm(1.594,')
Front axle load at perm. total load . . 650 kp (1,433 lbs.)
Torsionbar: .. ...Length 611.5mm(24.0l-5',)
Dia. 17.9 mm (0.705")
Number of teeth 29
Total reduction of steering gear . . lj.j8
Steering wheel turns from lock to lock Approx. 3.1

GENERAL SPECI FICATIONS

Rims 4/zJ x 15, optional 5%I x 15
Tires . I 55 SR I 5; optional 165 SR I 5 on either

!(:"i::::":;;,;'r.',f l;îo.oiuentrvinstarred'
Wheelbase 96.5 in. (2450 mm)
'52.40in (1331 mm); with 5/zJ x 15 rims 52.87 in.
Track (DIN curb weight) .. Front
(1343 mm)
Rear 53.98in.(1371 mm);wit,t.5%J x l5rims 54.45in.

overau rength . !i'r:3 rîÏàr85 mm)

&:lii''iig#(;;;;-;tyi
Ground Clearance (car
::::: ::: : : ::: : :
loaded)
: :: : .3';",iÏ{13iff'
4.7 in. (120 mm)
Turning circle . Approx. 36 feet ( 1 I m)

CAPACITIES
Engine Approx 3.7 US qts. without oil filter,
3.2 US qts. premium quality HD oil, acc. to API
specification SD or SE
sAE 30 = 320F (00C)
SAE 20 W 20 = from r 5oto 32oF (-15o to OoC)
SAE 10 W = below + 5'F (-i5"C)
Transmission and differential . . . Approx. 2.6 US qts, SAE 90
Torque convertor 6.3 US qts. HD oil SAE 20 W 20
Fuel tank 16.4 US gals. including approx. 1.6
US gals. reserve
octane
Brake nuid fiiiài.u,ilii,:i'lioSt
ENGINE
Type . . aircooled 4-stroke gasoline injection
engine
Number of cyiinders 4
Cyiinder arrangement 2 cylinders each opposed, flat flour
Bore . . 90 mm (3.543") dia.
Stroke 66 mm (2"598")
Total pistondisplacement 1,6'79 cc (102.5 cu. in.)
Compressionratio.. 8.2
Max. performance (SAE) 85 HP at 5,000 rpm
Max. torque (SAE) . 99.45 ft.lb. at 3,500 rpm
Mean piston speed . 10.8 m/s (35"4 ft/sec) at 4,900 rpm
Octane number 98 (Research Method)
SPECtFTCATTONS 15-2

IGNITION battery ingntion

Ignition coil . . Bosch 022 905 I 1 5
Ignition distributor Bosch 022 905 205 Sportomatic: 022 905 2O5B
Firing point 27" BTDC at 3,500 rpm (vacuum hoses removed)
Firing order 1-4-3-2
Ignition timing . by cent^rifugal governor and intake vacuum
Timing angle . 44 - 50"
Spark plugs 14 mm (0.55") plug threads (long),
thermal value 175
Spark gap 0.7 mm (0.0276")

COOLING aircooled by radial blower on crankshaft

Delivery volume approx. 800 lits/sec (211 US eal.)
at n (engine) = 4,600 rpm

LUBRICATION . . . . forced feed by gear pump

Oil cooling oil cooler in blower air stream

SiliXlil";;i"il
oil capacity
:: :

3.0 lits (0.79 us gal) without oil filger change

Oil consumption . . . 0.5-1.0 lits/1,000 km
(0.13-0.26 US ga1l6,214 miles)

CYLINDER HEAD one each for 2 cylinders with cast-on

varveseatrings..
guides
Valve
. ;,illtllf,l:#âXi$i""'
shrunk-in, special brass
Spark plug threads cut into cylinder head

VALVES I inlet and I exhaust valve per cylinder

,
Exhaust valve with hard-faced seat
Arrangement overhead
Clearance . . .Inlet 0.10 mm (0.0039") with cold engine
Exhaust o. l0 mm (0.0039") with cold engine
VALVE TIMING WITH .04" valve clearance:
Intake opens 12o BTDC
Intake closes 42o ABDC
Exhaust opens . 43o BTDC
Exhaust closes . 4o ATDC

CYLINDERS individual cylinders, special grey

iron casting with cooling ribs
Center distance 4.90"
PISTON light metal alloy with steel insert
Piston pin floating, secured by circlips
Piston rings 2 compression rings
1 oil scraper ring
CRANKCASE split, with vertical center division
by crankshaft and camshaft bearings,
aluminum alloy

CAMSHAFT grey casting, 3 plane bearings

Camshaft bearings thin-walled steel half shells with
babbitt metal running surface
Camshaft drive spur gears, helical

CRANKSHAFT forged, fine steel, 4 plane bearings

Main bearings l, 3 and 4 aluminum sleeves with lead-coated
running surface
Main bearing 2 (center bearing) half shells, three-component bearing
Main bearings l-3 . 60 mm dta. (2.36")
Mainbearing4.... 40mmdia.(1.8?")
Conrod bearing 55 mm dia. (2.17")
Flywheel forged, with starter ring geear, one-piece
SPECtFtCATtONS 15_3

CONNECTING RODS forged, with l-shaped shank cross section

conrod bearings thin-walled half shells,
three-comPonent bearings
Piston pin bearings pressed-in steel bushing with
lead-bronze running surface

CLUTCH Diaphragm spring clutch

Type single-plate dry clutch
Total facing area 47.3 sq. in.

BRAKES
Tandem main brake cylinder
Bore . . I'l.46 mm dia. (.6874")
Stroke 18i 13 mm (.1 I .s")
Play: actuating rod/Piston I mm (.04")
Front wheel brake
Brake disc (dia.) . 281 mm (11.063")
Min. thickness after refinishing . . 10.5 mm (.391")
(The brake disc maY be refinished
only symmetrically, this is.
uniformly from both sides.)
Thickness tolerance max. 0.02 mm (.0008")
Lateral wobble 0.2 mm (.008")
Caliper piston dia. 42 mm (1.'7")
'10
Thickness of lining mm (.4")
Release clearance . . . . . 0020-.0079"
Lining surface of four linings 16.4 sq. in.
Rear wheel brake
Brake disc (OD) . 282 mm (l 1.102")
Thickness, new .. 9.5 mm (.374")
Lateral wobble 0.2 mm (.008")
Caliper piston dia. 33 mm (1.3")
Thickness of lining 10 mm (.4")
Release clearance 008"
Lining surface of four linings 12.4 sq. in.

SUSPENSION 1

+20'! 10'
Total track of front wheels under pressure
Size of force for front wheel pressure
15 kp (331bs.)
Camber of front wheels o!20'
Max. permissible difference in camber
between both sides . . . 20'
Track difference ange at'2bb lock " g+30'
;" ;;" i.;;
to the right 0+30'
Caster of front wheels 6o+ 3o'
Height adjustment of front axle . . 90mm+5mm
(wheel center above torsion bar center-
rear) .
(3.s !.2")
Height difference left to right max. 5 mm (.2")
Total Frictional torque (steering
assembled)
6-8cmkp
Frame . Weided pressed steel box section frame, welded to body
Front suspension . . Independent, suspension struts and track control arm
Front springs Round section longitudinal torsion bar for each wheel
Rearsuspension... Independent, semi-trailing arms
Rearsprings..... Coll spring, double acting telescopic shock absorber
and piogressive rate hollow rubber spring for each wheel
ELECTRICAL SYSTEM
1 2 volts
Operatingvoltage . . . . .

Battery capacitY 45 Ah
Alternator outPut 50 amps at 14 volts AC,
700 watts caPacitY
SPECIFICATIONS 15-4

$SPEED TRANSMISSION
Transmission Porsche, servo-lock synchronization
Number gears . 5 forward, I reverse
Gearshift location Floor-mounted, central
Final-drive Spiral bevel pinion and differential -
4.43:l
Drive ratio 7:31(4.429't
Rear axle drive . Over double joint half axles
Gear ratios lst - 3.09:1
2nd - 1.88:1
3rd,- 1.26:l
4th - 0.93: I
5th - 0.71: I
Reverse - 3.13:1

MAINTENANCE
Complete the following maintenance and lubrication jobs in accordance with valid service instructions:

Air filier Check, clean base and fill in fresh oil.

Fuel filter Replace.
Ignition distributor Lubricate, check contact points and replace,
if required.
Adjust timing angle and firing point.
Spark plugs Clean, check spark gap and adjust,
check compression pressure.
Exhaust system Check for damage.
V-belts Check and tighten, if required, or replace.
Engine Check oil level and replenish,
if required or change oil.
Full-flow oil filter Replace
Valves . Adjust valve clearance and replace seals
for cylinder head cover.
Engine Sight test for leaks.
Clutch Adjust clutch play.

TOROUE SETTINGS
ENGINE ft.lb,
Screws for universal shaft . 32.5
Nuts for transmission support 14.5
Nuts for engine support (body) 21.7
Screws for torque converter 21.7
Nuts for engine attachment to transmission 21.'l
Spark plugs 25.3
Nut for small pulley 43.4
Screws for blower impeller 14.5
Nuts for oil pump 14.5
Oil drain plug . . 15.9
Closing nut for oil strainer cover . . 9.4
Nuts for rocker arm shaft . I 0. I
Cylinder head nuts 23.1
Screws for engine support (crankcase) 21.'l
Screw for blower wheel hub 23.1
Screws for flywheel '19.6
Screws for carrier plate . . 61.5
Screws and nuts for crankcase halves . 14.5
Nuts for crankcase halves . 23,9
Conrodnuts.. 23.9
Screws for clutch 14.5
SPECIFICATIONS 15_5

MANUAL TRANSMISSION ft.lb.

Side and rearcover on transmission housing(studs) nut . . .' .. .' 16-18
Fork piece on housing nut . . t5-t'l
Guide tube for throwout bearing on housing nut . . 7
Transmission housing plug (oil filler hole) 15-18
Transmission housing plug (oil drain hole) 15-18
Transmission housing ball pin (bearing throwout fork) . . 15-17
Transmission housing breather (breathing) t5-22
Backup light switch on housing 25-29
Holding plate on throwout fork screw 6-7
Starter on transmission housing nut , . 33-35
Clamping plate on intermediate plate screw l5-l'7
Bolt for guide lever on intermediate plate t5-t7
Lock on intermediate plate screw (gear shift lock) , 16-18
Speedometer drive on rear housing cover bolt t2-t3
Miter drive in guide bushing screw . 16-1 8
Drive shaft nut , . 72-86
Drive shaft nut . . 6 5-80
Pinion shaft expansion bolt . . 80-87
Shift forks on shift rods hex. screws (m 8 x 25) 18-19
Ring gear on differential housing bolt . . . 72-86
Constant velocity flange on differential expansion bolt . . 25-29
Shift rod bearings on rear nut transmission cover
(9l4only) ..!... r5-l'7
Cover plate on rear transmission cover nut 6-',1

TRANSMISSION _ SPORTOMATIC
Hex. nuts on transmission housing M8 . . , 18.0
Hex. screw with trunnion (angle drive) M8 . . . 10.8
Closing screw on intermediate plate M 12 21.7
Closing screw oil inlet M24 18.0
Magnetic plug oil drain M24 18.0
Hex, screws for intermediate plate clamping plate . 18.0
Hex. nut on input shaft M24 80
Crown nut on input shaft M14 . . 72
Expanding screw of pinion shaft M12 . . 87
Hex. screws of shift forks M8 18.0
Hex, screws for ring gear attachment M 12 .....i i2
Expanding screws for universal flange of differential Ml0 . ' . ' ' . 25.3-18.9
Hex. nuts onconvetterhousingandservomotor M 8 ... . . ..'. . 18.0
Hex. nuts on converter housing and starter M l0 . 32.5
Closing screw on front gearbox cover for parking lock
M12x1.5.... 34.0
Double hex. socket screws for clutch pressure plate M 6 . . . . . . . 10.8
Double hex. socket screws for freewheel support M 6 . . l 0.8
Double hex. screw for converter-drive plate M 8 . . . 17.4-18.8
Bridging switch M l8 x 1.5 25.3-28.9
Backup light switch M 18 x 1.5 . . . 25.3-28.9
Hollow screw of angle drive in guide bushing
M24x 1.5... 15.9-t7.4

FRONT AXLE AND STEERING ft. 1bs.

Fillister head bolt for clamp nut . . . 11
Hollow bolt on caliper 14
Caliper on steering knuckle bolt . . 50
Wheel hub on brake disc nut ( 17)
Guard plate on steering knuckle bolt . . l8
Shock absorber leg bottom on balljoint bolt . . 4'7
Shock absorber leg on supporting bearing nut . . 58
Supporting bearing on body socket . 34.0
Protective ciamp on body socket 32
Front wishbone bearing on body bolt . . . 34
Ball joint on wishbone nut . . 108
Floor pan on body bolt . . 34
Floor pan on auxiliary support bolt . . 1 0.8
Auxiliary support on body bolt . . 65. I
Hub stud bolt, 25 mm . . 108
SPECTFtCATtONS 15-6

Hub stud bolt, 39 mm . . 94

Hubnut .,.... (e4)
Steering gear housing cover bolt 1l
Steering gear housing filler bolt l1
Drive pinion coupling flange nut 34
Dust boot retainer for universal bushing nut . . . 50
Fork on joint bushing bolt . . 34
Steering shaft on steering coupling bolt . . 18
Steering gear on auxiliary support bolt . . 34
Ball joint at tie rod end nut 32
Bottom universal joint on steering shaft lock nuts . . 18
Tie rod clamp nut 11
Steering wheel retaining nut . (s+;
Steering and control switch components on body screw 7.2
Control switch components/steering post extension screw '7.2

REAR AXLE
Spring strut bottom nut on control arm . . 72-87
Spring strut top on body nut 36-43
Threaded bushing on piston rod . . . I 1-14
Castle nut on universal shaft . . 21'.l-253
Synchronizingjoint on universal flange screw 31
Control arm bearing on body bolt 50
Control arm bearing on control arm nut ,, . 108
Bearing cover on control arm bolt l8
Wheel bolt 914 bolt 108
Wheel nut 91416 r,rtt 94

BRAKES
Tandem brake master cylinder on bulkhead nut . . . 18
Brake line to tandem master brake cylinder . . . . I l-14
Bolt for clamp nut screw . 1l
Hollow bolt on brake caliper l4
Caliper on steering knuckle bolt . . 50
Guard plate on steering knuckle bolt . . l8
Bleed valve in caliper 1.5-2.5
Wheel hub on brake disc nut ( 16.6)
Housing bolt for front caliper t6
(24.4-3.6)
Caliper on rear axle steering arm bolt 50
Brake disc on wheel hub bolt 3.6
Guard plate on rear axle steering arm bolt 18
Bleed valve in caliper 1.5-2.5
Wheel on wheel hub bolt (25 mm), nut 103.5 (94)
Wheel on wheel hub bolt (39 mm) . 94
SPECTFtCATTONS 15-7

TOLERANCES AND WEAR LIMITS Upon installation

(new) Wear limit
COOLING
Thermostat Opening temp. 65-700C
( 149-1 58'F)
Impeller/V-belt pulley Unbalance max. 5 cmg

OIL CIRCUIT
Oil pressure^(for SAE 30 grades only) at
7o"c ( I 58"F) oil remp.: . approx. a
at2,S0}rpm.. .Pressure 3 kg/cm'(43 psi) zYelcm2(28 psl)
Spring f. oil pressure relief valve
Length under load: 23.4 mm(.921") . . . . .Load 1 1.1 kg (24.5 lbs)
Spring f. oil pressure contr. valve
Length under load: 16.8 mm (.661") . . . . .Load 4.35 kg (9.59lbs)
Oil pressure switch opens at . . . . Pressure 0.15-0.45 kglcm2
(2.13-6.40 psi)

CYLINDER HEAD WITH VALVES

Depth of cylinder seat in 5.4-6.5 mm
cylinder head . (.2t3-.256")
Combustion chamber capacity 51.1-52.6 cc
(3.12-3.21 cu.in.)
a)Rockerarm... .....ID 20.0-20.02 mm 20.04 mm
(.'7874-.'t882"\ dia. (.7890") dia.
b) Rockerarmshaft ........Dia 19.95-19.9'7 mm 19.93 mm
(.7854-.7862") dia. (.7846") dia.
Valve spring 72.5-83.5 kg
Lengthunderload 30.0 mm (1.18") . ... . .Load (1s9.8-184.1 lbs)
Valve seat a) Inlet . . Width 1.8-2.2 mm
(.0708-.0866")
b)Exhaust ......Width 2.0-2.5 mm
(.0787-.0984")
c)Inlet . Seat angle 300
d)Exhaust ....Seatangle 45"
e) External corection angle . 150
f) Internal correction angle . /)
--o
Valve guides 8.00-8.02 mm dia. 8.06 mm dia.
Inlet .. .......ID (.31s0-.3 158") (.31'73")
Exhaust ......ID 9.OO-9.02 mm dia. 9.06 mm dia.
(.3543-.3551") (.3s67")
Valve stem 7.94-'7.95 mm dia. 7.90 mm dia.
Intake. ..... Dia. (.3r26-.3130") (.3 I 10")
Exhaust .... Dia. 8.91-8.92 mm dia. 8.87 mm dia.
(.3 s08-.3 s 12") (.3492")
out-of- max.0.01 mm
round (.0003 9")
Valveguide-valvestem .... Rockerplay max. 0.45 mm 0.9 mm
Inlet and exhaust (.017'7") (.03 s4")
Valvedisclnlet.. ... Dia. 39.0 mm dia
( 1.s4")
Exhaust .....Dia 33"00 mm dia.
(1.30")
Valve clearance (cold) Inlet . Adjustment 0,10 mm (.0039")
Exhaust .... Adjustment 0.1Omm (.0039")
Compression pressure
(with throttle valve open and engine at
operating temp., all plugs unscrewed,
with practically no-loss pressure
gauge in plug seat, cranking with 9.0-11.0 kplcm2 7.0 kplcm2
starter) . Pressure (128-156 psi) (100 psi)
Pressure di.fference between max. 1.5 kglcm2
individual cylinders (21.3 psi)
SPEC|F|CATtONS 15-8

CYLINDERS AND PISTONS

2 Excess sizes, each with 0.5 mm
(.0197") higher dia.
Cylinder . . out-of- max. 0.01 mm
round (.0004)
Cylinder/Piston.... ... Clearance 0.04-0.06 mm 0.20 mm
(.0016-.0024") (.007e")
a) Upperpistonring ....... Side 0.06-0.09 mm 0. 12 mm
clearance (.0024-.003 5 ") (.0048')
b) Lowerpistonring ....... Side 0.04-0.07 mm 0. 10 mm
clearance (.0016-.0028") (.0039")
Oilscraperring.. ... Side 0.02-0.05 mm 0. l0 mm
clearance (.0008-.0020") (.003e")
a) Upper piston ring . . Gap width 0.35-.055 mm 0.90 mm
(.013 8-.0216") (.03 54")
b) Lower piston ring . . Gap width 0.30-0.35 mm 0.90 mm
(.0118-.0138") (.03 54 ")
Oil scraper ring . . Gap width 0.25-0.40 mm 0.95 mm
(.0098-.0157") (.0374")
Piston weight
- Weight (brown) 472-480 grams
+ Weight (erey) . 480-488 grams
Weight difference of pistons
of one engine rhax, 4 grams max. l0 gramsx
*)In the event of repairs

CRANKCASE
Bore for crankshaft bearings 70.00-70.02 mm 70.03 mm
a) Bearings 1-3 Dia. dia. dia.
(2.7 ss9-2.7 s67") (2.7 s71")
b)Bearing4.... ...Dia. 50.00-50.04 mm 50.04 mm
dia. dia.
Bore for sealing ring/
( 1.968s-1.970 1 ") ( 1.9701 ')
95.00-95.05 mm
flywheelend.,. Dia. dia
(3.7402-3.7 422")
Bore for sealing ring/ 62.00-62.05 mm
blower gear end dia.
(2.4409-2.4429")
Bore for camshaft bearing Dia, 27.5Q-27.52 mm
dia.
( 1.0827- 1.083 s ")
Bore for oil pump housing . . Dia. 70.00-70,03 mm
dia.
(2.7 ss9-2.7 s"t 1,,)
Borefortappet. .... Dia. 24.00-24.02 mm 24.05 mm
dia. dia.
(.9449-.94s7") (.9469")

CAMSHAFT
Bearings 1-3 Dia. 24.99-25.00 mm dia.
(.983 e-.9843 ")
Measured on center bearins max. 0.02 mm
(lst and 3rd bearing ojtiiT 0.04 mm
v:ul;;k;i :::::: : (.008") (.0016")
Camshaft/camshaft bearings ""
(including bearing pressure
0.02-0.05 mm 0.12 mm
tlrogehhousing ....Radialplay (.0008-.0020") (,0048")
Guide bearing .Axial play 0.04-0. l3 mm 0.16 mm
(.001 6-.00s I ") (.0063')
Camshaft gear , . .. ... .Backlash 0.00-0.05 mm
(.00-.0020")
Tappet ..... Dia. 23.96-23.98 mm 23.93 mm
dia dia.
(.9433-.9441") (.942t")
SPECtF ICATtONS 1s-9

Housing borei tappet . . Radial play 0.02-0.06 mm 0. l2 mm

(.0008-.0024") (.0047")
Pushrod ...out-of max.0.3 mm
true (.01 I 8")

CRANKSHAFT WITH CONNECTING RODS

3 Undersizes, with dia. reduced in
0.25 mm (.0098") steps
a)Bearingsl-3... .'Dia. 59.97-59.99 mm
dia.
(2.3610-2.3618"\
b)Bearing{.... ...Dia' 39.98-40.00 mm dia.
(r .57 40-r .5'.7 48")
c) Connecting rod bearing .. . Dia. 54.98-55.00 mm dia.
(2.t646-2.r654")
Crankshaft on 2nd and 4tt' bearing point
( l st and 3rd bearing point on Out-of 0.02 mm
V-blocks "' true (.008")

Unbalance max. 12 cmg

Main bearing pin . . . . .Out-of-true 0.03 mm (.0012")
Conrod bearing pin . . . . .. . . .Out-of-true 0.03 mm (.0012")
Crankshaft/main bearing
(including bearing pressure through housing) 0.05-0.10 mm 0. 18 mm
a)Bearings I and 3 ..Radialplay (.0020-.0039") (.0071")
b)Bearing2.... ...Radialplay 0.03-0.09 mm 0. 17 mm
(.0012-.003s") (.006 7")
c)Bearing4 .... ...Radialplay 0.05-0. 10 mm 0. 19 mm
(.0020-.0039") (.0075")
Crankshaft/mainbearing1 .... ......Axialplay 0.07-0.13 mm 0. l5 mm
(.0028-.00s 1") (.00se")
Crankpin/conrod.. ..Radialplay 0.02-0.07 mm 0.15 mm
(.0008-.0029") ("oos9")
Axial play 0.10-0.40 mm 0.70 mm
(.003e-.01s7") (.0276")
Conrod weight
-Weight (white) 746-7 52 grams
+ Weight (black) 769-775 grams
Weight difference of conrods of one engine max. 6 grams
Pistonpins .. Dia. 23.996-24.000 mm dia.
(.94472-.94488"\
Smallendbushing .^. Dia. 24.O15-24.024 mm dia.
(.9454't-.94582")
Piston pin/small end 0.02-0.03 mm 0.04 mm
bushing . . . . .Radial play (.0008-.0012") (.0016")
Fly wheel (measured in max. 0.4 mm
center of clutch area) " Lt. wobble (.0 I s 7")
Out-of-balance max, 20 cmg
Shoulderforsealingring.. ...OD '74.9-75.1 mm dia. 74.4 mm dia.
(2.949-2.9s7") (2.e29")
Refinishing of tooth width . max.2 mm (.08")
Driven plate . Unbalance max. 5 cmg

CLUTCH
Totalclutchpressure ... Pressure 420-480 kg
(926-1,058 lbs)
Total clutch unbalance max. 15 cmg
Clutchpressureplate. ......Out-of-true 0.10 mm (.0039")
Clutch disc . . Lat. wobble max.0.5 mm
(measured at 210 mm dia. = 463") (.0197")