English dropdown-ico

Manual Volkswagen Transporter 1600 (1977)

222 pages Not applicable
Download

Go to site of 222

Summary
  • Volkswagen Transporter 1600 (1977) - page 1

    Owner s Worksho p Manua l ...

  • Volkswagen Transporter 1600 (1977) - page 2

    V W Transporte r 160 0 Owner s Worksho p Manua l b y J H Hayne s Membe r o f the.Guil d o f Motorin g Writer s an d D H Stea d Model s covered : Al l Volkswage n Transporte r 160 0 model s wit h 158 4 c c (96. 7 c u in ) engin e Does not cover the alternative bodies and conversions produced by specialist manufacturers ISB N 0 8569 6 66 0 6 © Hayne ...

  • Volkswagen Transporter 1600 (1977) - page 3

    Acknowledgement s Thank s ar e du e t o th e V W organisatio n fo r th e suppl y o f technica l informatio n an d certai n illustrations . Castro l Limite d provide d lubricatio n detail s an d th e Champio n Sparkin g Plu g Compan y supplie d th e illustration s showin g th e variou s spar k Abou t thi s manua l plu g conditions . , Lastly , thank ...

  • Volkswagen Transporter 1600 (1977) - page 4

    Content s Acknowledgement s Abou t thi s manua l Introductio n Tool s an d workin g facilitie s Recommende d lubricant s an d fluid s Vehicl e identificatio n an d spar e part s Routin e maintenanc e (also see Chapter 12, page 194) Chapte r 1 Engin e (also see Chapter 12, page 194) Chapte r 2 Cooling , heatin g an d exhaus t system s (also see Chap ...

  • Volkswagen Transporter 1600 (1977) - page 5

    Tool s an d workin g facilitie s Introduction A selectio n o f goo d tool s i s a fundamenta l requiremen t fo r anyon e contemplatin g th e maintenanc e an d repai r o f a moto r vehicle . Fo r th e owne r wh o doe s no t posses s any , thei r purchas e wil l prov e a considerabl e expense , offsettin g som e o f th e saving s mad e b y doing-it-y ...

  • Volkswagen Transporter 1600 (1977) - page 6

    produce d b y th e vehicl e manufacture r specificall y to r it s deale r network . Yo u wil l fin d occasiona l reference s t o thes e manufac - turers ' specia l tool s i n th e tex t o f thi s manual . Generally , a n alternativ e metho d o f doin g th e jo b withou t th e vehicl e manu - facturers ' specia l too l i s given . However ...

  • Volkswagen Transporter 1600 (1977) - page 7

    Recommende d lubricant s an d fluid s Componen t o r syste m Lubrican t typ e o r specificatio n Castro l produc t Engin e (1 ) Transmissio n (2 ) Transmissio n wit h limite d sli p differentia l (2 ) Whee l bearing s (3 ) Brak e hydrauli c flui d Driv e shaf t C V joint s SA E 3 0 o r 4 0 o r SA E 20W/5 0 SA E 9 0 Hypoi d SA E 9 0 Hypoi d L S NGL ...

  • Volkswagen Transporter 1600 (1977) - page 8

    Vehicl e identificatio n an d spar e part s Althoug h man y individua l parts , an d i n som e cases , su b assemblie s suc h a s distributors , fi t a variet y o f V W model s i t i s dangerou s t o assum e tha t jus t becaus e the y loo k th e sam e tha t the y ar e th e same . Difference s ar e sometime s no t visuall y detect - abl e a t all (e ...

  • Volkswagen Transporter 1600 (1977) - page 9

    Routin e maintenanc e For modifications, see Supplement at end of manual Introductio n Becaus e o f th e inheren t toughnes s an d reputatio n fo r reliabilit y an d lon g lif e ther e i s a tendenc y fo r owne r s t o b e a bi t sketch y o n V W maintenanc e - particularl y wit h vehicle s no t i n th e firs t flus h o f youth . Th e V W wil l pu ...

  • Volkswagen Transporter 1600 (1977) - page 10

    Th e windscree n washe r reservoi r i s mounte d o n th e vertica l pane l i n th e fron t o f th e ca b jus t belo w th e brak e flui d reservoir . Engin e oi l dipstick . t o th e fron t pane l o f th e ca b jus t belo w th e hydrauli c flui d reservoir . I t ha s a protectiv e cove r an d tucke d insid e i s a tub e wit h a n ordinar y tyr e val ...

  • Volkswagen Transporter 1600 (1977) - page 11

    Routin e maintenanc e 1 1 1 i n th e centr e o f th e botto m o f th e crankcase . Befor e starting , yo u mus t obtai n tw o ne w gasket s fo r it , an d i t i s als o desirabl e t o ge t si x ne w coppe r washer s fo r th e stu d nuts . Firs t drai n th e oi l b y removin g th e centr e plu g an d the n remov e th e cove r plate . Tak e car e whe ...

  • Volkswagen Transporter 1600 (1977) - page 12

    Genera l descriptio n an d typ e identificatio n .. . .. . .. . 1 Repai r an d maintenanc e procedure s - dismantlin g .. . .. . 2 Engin e remova l - preparatio n .. . .. . .. . .. . .. . 3 Engin e - remova l .. . .. . .. . .. . .. . .. . 4 Engin e dismantlin g - genera l .. . .. . .. . .. . .. . 5 Engin e ancilliarie s - remova l .. . .. . .. . .. ...

  • Volkswagen Transporter 1600 (1977) - page 13

    Chapte r 1/Engin e 1 3 ...

  • Volkswagen Transporter 1600 (1977) - page 14

    1 Genera l descriptio n an d typ e identificatio n Th e 160 0 versio n o f th e establishe d 'Beetle ' engin e wa s introduce d int o th e transporte r rang e i n 1967 . Th e basi c con - figuratio n o f th e 'Beetle ' engin e i s unchange d - th e coolin g syste m incorporatin g th e superimpose d typ e o f fa n an d housing . ...

  • Volkswagen Transporter 1600 (1977) - page 15

    1 Crankcase - right half 2 Generator pedestal 3 Gasket 4 Camshaft bearing - shell - rear 5 Oil selec tor pipe FIG.1. 1 ENGIN E STATI C PART S • EXPLODE D VIE W 6 Camshaft bearing shell- front gasket centre 8 Cylinder head stud 10 Cylinder barrel 7 Camshaft bearing shell - front 9 Cylinder base sealing 11 Cylinder head 12 Rocket cover gasket 13 Ro ...

  • Volkswagen Transporter 1600 (1977) - page 16

    1 6 Chapte r 1/Engin e cylinde r design . Th e shor t crankshaf t run s i n aluminiu m allo y shel l bearing s locate d betwee n th e tw o halve s o f a magnesiu m allo y crankcas e whic h joi n vertically . Th e camshaf t run s centrall y belo w th e crankshaf t an d i s gea r drive n fro m th e rea r en d o f th e crankshaft . Th e camshaf t i s ...

  • Volkswagen Transporter 1600 (1977) - page 17

    4. 1 Ope n th e engin e cove r an d hav e a goo d loo k round . 4. 6 Removin g th e cros s pane l (earl y models T 4.1 2 Suppor t th e gearbo x wit h a piec e o f rop e o r cha. n Not e t h woode n packin g piece . 4.1 6 V,e w o f th e bumpe r wit h bumpe r an d c r 4.18 A Removin g th e engin e o n a trolle y jac k 4.18 B Engin e lowere d t o th e ...

  • Volkswagen Transporter 1600 (1977) - page 18

    1 8 Chapte r 1 /Engin e plu g i t wit h a penci l o r punch . Fue l i s gravit y fed . 9 Pul l of f th e heate r pip e connection hoses . 1 0 Disconnec t th e heate r fla p cables . 1 1 Pul l th e accelerato r cabl e throug h th e fa n housing . 1 2 Suppor t th e gearbo x wit h a piec e o f rope , wir e o r chai n slun g fro m th e bod y sid e memb ...

  • Volkswagen Transporter 1600 (1977) - page 19

    4.1 4 Remov e th e engin e securin g nut s 4.1 7 Removin g on e o f th e lowe r engin e mountin g bolt s - d o no t forge t th e othe r on e 6. 1 Removin g engin e rea r suppor t bea m 8. 1 Und o stubbor n oi l pressur e regulato r 8. 4 Th e relie f valv e sprin g i s longe r tha n 8.6 a Replacin g th e relie f valv e pisto n plug s wit h a n impro ...

  • Volkswagen Transporter 1600 (1977) - page 20

    2 0 Chapte r 1 /Engin e pulle y whe n undoin g o r tightenin g th e bol t pus h a suitabl e articl e throug h on e o f th e hole s i n th e pulle y an d ja m i t agains t th e crankcas e flange . 3 If , whe n th e nu t ha s bee n removed , th e pulle y i s a ver y tigh t fit , d o no t appl y forc e a t th e edge s o r yo u ar e likel y t o distor ...

  • Volkswagen Transporter 1600 (1977) - page 21

    7 Crankshaft 2 Crankshaft gear 3 Woodruff key 4 Spacer 5 Distributor drive 6 Securing ring 7 Distributor drive FIG.1. 2 ENGIN E RUNNIN G PART S - EXPLODE D VIE W shaft 8 Spring 9 Washer 10 Oil baffle washer 11 Oil seal 12 Key for pulley 13 Crankshaft pulley 14 Washer 15 Bolt 16 Flywheel 17 Dowel 18 Spacer 19 Locking washer 20 Locking washer 21 Holl ...

  • Volkswagen Transporter 1600 (1977) - page 22

    2 2 Chapte r 1/Engin e o f sever e burnin g a t th e sealin g are a i n th e hea d the n th e cylinde r ca n b e lightl y groun d i n wit h carborundu m paste . However , i t shoul d b e understoo d tha t th e dept h t o th e matin g fac e fo r eac h cylinde r shoul d b e equa l (giv e o r tak e 3 t o 4 thousandth s o f a n inch ) otherwis e th e h ...

  • Volkswagen Transporter 1600 (1977) - page 23

    2 3 FIG.1. 3 LUBRICATIO N SYSTE M - DIAGRAMMATI C DRAWIN G FIG.1. 4 MEASURIN G OI L PUM P GEA R EN D CLEARANC E (Se c 10 ) FIG.1. 5 CRANKSHAF T PULLE Y WHEE L - CROS S SECTIO N (Se c 9 ) 1 Pulley 2 Oil return scroll 3 Woodruff key 4 Securing bolt 5 Lock washer 6 Oil thrower disc ...

  • Volkswagen Transporter 1600 (1977) - page 24

    2 4 Chapte r 1/Engin e i f yo u ar e goin g t o d o s o anywa y i t wil l b e simple r t o tak e th e connectin g rod s of f th e crankshaf t afterwards . Star t wit h No . 1 and , usin g a socke t wit h a n extension , slacke n th e tw o connect - in g ro d ca p nut s b y insertin g th e extensio n int o th e crankcase : I t i s importan t t o hav ...

  • Volkswagen Transporter 1600 (1977) - page 25

    FIG.1. 6 CAMSHAF T AN D VALVES - EXPLODE D VIE W (Se c 15 ) 1 Camshaft and gear assembly 2 Pushrod 3 Tappet 4 Pushrod tube 5 Pushrod tube seal 6 Rocker shaft 7 Shaft support bracket 8 Thrust washer 9 Corrugated washer 10 Securing clip 11 Rocker arm 12 Sealing ring 13 Tappet adjusting screw 14 Locknut 15 Inlet valve 16 Exhaust valve 17 Oil wiper 18 ...

  • Volkswagen Transporter 1600 (1977) - page 26

    2 6 Chapte r 1 /Engin e poin t o f th e too l use d mus t no t b e allowe d t o di g int o th e crankcase . 3 Whe n th e oi l sea l i s remove d a numbe r o f shim s whic h fi t betwee n th e flywhee l hu b an d th e flang e o n th e fron t mai n bearin g wil l b e observed . Ther e shoul d b e thre e o f the m normal - ly . Thes e gover n th e amo ...

  • Volkswagen Transporter 1600 (1977) - page 27

    2 7 FIG.1. 9 ENGIN E - CROS S SECTIO N VIEW S 1 Fan housing 2 Coil 3 Oil cover 4 Inlet manifold 5 Fuel pump 6 Distributor 7 Oil pressure switch 8 Valve 9 Cylinder 10 Piston 11 Oil pressure relief valve 12 Fan 13 Oil filler 14 Intake manifold preheater pipe 15 Connecting rod 16 Spark plug 17 Cylinder head 18 Thermostat 19 Rotor arm 20 Push rod 21 He ...

  • Volkswagen Transporter 1600 (1977) - page 28

    2 8 Chapte r 1 /Engin e 2 0 Crankcas e - examinatio n an d renovatio n Th e crankcas e shoul d b e fre e fro m crack s o r an y othe r for m o f damag e an d th e tw o matin g edge s mus t b e quit e fre e fro m dents , scratche s an d burr s whic h coul d i n an y wa y affec t thei r precis e alignmen t whe n bot h ar e clampe d together . Th e cr ...

  • Volkswagen Transporter 1600 (1977) - page 29

    ...

  • Volkswagen Transporter 1600 (1977) - page 30

    3 0 Chapte r 1 /Engin e shell s t o a n un-regroun d crankshaf t thi s i s possible . I f ver y noticeabl e however , i t indicate s tha t th e journa l i s ou t o f round . I f rod s o n a regroun d crankshaf t ar e slightl y tigh t th e engin e wil l nee d running-in . I f ver y tigh t the n th e regrindin g tolerance s ar e wron g an d i t shoul ...

  • Volkswagen Transporter 1600 (1977) - page 31

    23.3 a Th e connectin g ro d an d ca p hav e matchin g number s 23.3 b an d a forg e mar k whic h mus t 23.3 c Fi t th e bearin g shel l int o th e cap . b e uppermos t o n installation . 23.3 d Pu t th e ro d int o positio n o n th e 23.3 e an d matc h u p th e cap . journa l 23. 5 Tighte n all th e ca p nut s FIG.1.1 0 CRANKCASE ' CRANKSHAF ...

  • Volkswagen Transporter 1600 (1977) - page 32

    3 2 Chapte r 1/Engin e 1 9 Tighte n th e larg e nut s progressivel y t o a torqu e o f 2 0 f t lb s an d the n t o 2 5 f t lbs . Finall y tighte n th e smalle r nut s t o 1 4 f t lb s (photo) . 2 0 No w rotat e th e crankshaf t - i t shoul d revolv e smoothl y withou t an y stiffness . I f ther e i s stiffnes s however , slacke n al l th e crankcas ...

  • Volkswagen Transporter 1600 (1977) - page 33

    24.4 a Compar e ne w tappe t flang e thick - nesse s wit h th e ol d 24.4 b Pu t th e tappet s int o th e crankcas e 24.4 c Chec k th e ca m lob e clearance s 24. 5 N o 1 mai n bearin g i s flanged . Th e dowe l pe g hol e goe s toward s th e fly - whee l 24. 6 Th e onl y spli t mai n bearin g i s N o 2 . Fi t eac h hal f int o th e crankcas e halv ...

  • Volkswagen Transporter 1600 (1977) - page 34

    25. 4 Positio n th e pisto n ove r th e connec - tin g ro d smal l en d 25.5 a Th e maker s pu t a n arro w o n th e pisto n crow n pointin g toward s th e fly - wheel . Note th e arro w pointin g upward s an d th e pisto n N o 1 scratche d o n th e crow n a s wel l 25.5 b Fittin g a circli p fo r a V W pisto n 26.2 a Grindin g th e cylinder s int ...

  • Volkswagen Transporter 1600 (1977) - page 35

    27.3 a Insertin g a n exhaus t valv e int o th e hea d 27.3 b Fittin g th e sprin g an d retaine r 27.4 a Th e sprin g compresso r need s elon - gate d end s 27.4 b o r us e a piec e o f tub e wit h a hol e i n i t 27.6 a Us e greas e t o hol d th e collet s o n replacemen t 27.6 b Collet s i n positio n 28.1 a Stretchin g th e pushro d tube s 28. ...

  • Volkswagen Transporter 1600 (1977) - page 36

    3 6 Chapte r 1/Engin e valv e ste m an d the n th e sprin g an d sprin g collar . Not e tha t th e clos e coil s o f th e sprin g g o agains t th e hea d (photo) . 4 Nex t arrang e th e valv e sprin g compresso r wit h th e space r tub e fitte d i f require d an d carefull y compres s th e sprin g (photos) . Watc h tha t ther e i s n o likelihoo d ...

  • Volkswagen Transporter 1600 (1977) - page 37

    29.2 a Fi t ne w rocke r shaf t mountin g stu d 29.2 b Replac e th e rocke r shaf t assembly.. . 29. 3 makin g sur e th e pushrod s ar e seal s seate d correctl y 30. 2 Crankshaf t en d floa t shim s bein g assemble d 30. 3 Replacin g th e oi l sea l 31. 3 Flywheel/crankshaf t dowe l peg s i n positio n 31. 5 Offe r u p th e flywhee l 31. 8 Apiec e ...

  • Volkswagen Transporter 1600 (1977) - page 38

    3 8 Chapte r 1 /Engin e T o d o thi s a dia l gaug e micromete r i s use d agains t th e fac e o f th e flywheel . Th e crankshaf t i s the n move d i n an d ou t an d th e floa t measured . Th e thicknes s o f th e thir d shi m i s th e measure d floa t les s 0.1 0 mm . An y thre e shim s wil l d o o f cours e provide d the y ad d u p i n tota l t ...

  • Volkswagen Transporter 1600 (1977) - page 39

    32.5 c Th e oi l pum p complet e goe s o n 33.2 a Oi l coole r seal s o n th e mountin g las t bracket 33.2 b Fittin g th e oi l coole r t o th e bracke t 33.2 c Th e smal l seale r plat e goe s o n th e 33.3 a Oi l coole r seal s o n th e crankcas e bracke t stud s 33.3 b Fittin g th e coole r assembl y t o th e crankcas e 3 3 3 c Tighte n th e oi ...

  • Volkswagen Transporter 1600 (1977) - page 40

    4 0 Chapte r 1/Engin e housing . Als o ensur e tha t th e accelerato r cabl e i s i n a positio n wher e i t wil l no t ge t trappe d o r kinked . 4 Wit h th e rea r o f th e vehicl e raise d mov e th e engin e int o positio n underneat h s o tha t i t ca n b e lifted . Ideall y i t wil l b e raise d o n a trolle y jack . 5 Ther e is littl e for e ...

  • Volkswagen Transporter 1600 (1977) - page 41

    Chapte r 1 /Engin e 4 1 3 7 Faul t findin g Whe n investigatin g startin g an d uneve n runnin g fault s d o no t b e tempte d int o sna p diagnosis . Star t fro m th e beginnin g o f th e chec k procedur e an d follo w i t through . I t wil l tak e les s tim e i n th e lon g run . Poo r performanc e fro m a n engin e i n term s o f powe r an d eco ...

  • Volkswagen Transporter 1600 (1977) - page 42

    Chapte r 2 Cooling , heatin g an d exhaus t system s For extra information, see Supplement at end of manual Content s Genera l descriptio n Remova l o f component s - genera l Fa n bel t - adjustment , remova l an d replacemen t Fa n an d dynam o - remova l an d replacemen t .. . Fa n housin g - remova l an d replacemen t Hea t exchanger s - remova ...

  • Volkswagen Transporter 1600 (1977) - page 43

    2 6 2 5 2 7 2 4 2 3 2 2 2 1 2 0 1 9 1 8 1 7 1 2 1 3 1 6 1 5 1 4 1 0 1 1 8 9 1 0 7 6 5 4 3 1 3 2 3 3 3 0 3 6 3 7 3 5 3 4 4 1 k FIG.2. 1 FAN , FA N HOUSIN G AN D THERMOSTA T 17 Outer fan cover 18 Reinforcement flange 19 Inner fan cover 20 Lockwasher 21 Nut 22 Fan hub 23 Shim 24 Fan 25 Lockwasher 26 Special nut 27 Fan housing 28 Washer 29 Cheese head ...

  • Volkswagen Transporter 1600 (1977) - page 44

    4 4 FIG.2. 2 SPLI T PULLE Y FO R FA N BEL T SHOWIN G SPACER S WHIC H MA Y B E MOVE D T O ADJUS T BEL T TENSIO N FIG.2. 3 FA N ASSEMBL Y - CROS S SECTIO N / Spacer washers 7 Fan 2 Fan hub 8 Fan cover, inner 3 Woodruff key 9 Flange 4 Retaining nut 10 Fan cover, outer 5 Generator shaft a = 2 mm (0.08 in) 6 Shaped washer ...

  • Volkswagen Transporter 1600 (1977) - page 45

    3. 2 Positionin g pulle y spacer s 3. 3 Checkin g fa n bel t tensio n 3. 4 Fittin g th e oute r hal f o f th e fa n pulle y 4. 3 Disconnectin g th e dynam o lead s 4. 1 O a Fittin g th e fa n oute r cove r t o th e dynam o 4.10 b an d th e stiffenin g plate . ...

  • Volkswagen Transporter 1600 (1977) - page 46

    4 6 Chapte r 2/Cooling , heatin g an d exhaus t system s tensio n pulley . Th e pulle y o n th e generato r i s spli t int o tw o an d th e ga p betwee n th e tw o halve s govern s th e effectiv e diameter . Th e ga p i s regulate d b y space r ring s (photo) . I f th e bel t i s to o slac k th e ga p betwee n th e tw o halve s i s decrease d b y r ...

  • Volkswagen Transporter 1600 (1977) - page 47

    4.10 c Fi t th e inne r cove r plat e 4. 1 O d Not e th e space r o n th e dynam o shaf t 4. 1 O e Fi t th e fa n hu b an d shim s 4. 1 O f ... . followe d b y th e fan . 4. 1 O g Secur e wit h th e lockwashe r an d nu t 5. 6 Removin g th e uppe r par t o f th e oi l coole r duc t ...

  • Volkswagen Transporter 1600 (1977) - page 48

    4 8 Chapte r 2/Cooling , heatin g an d exhaus t system s (th e whol e manifol d o n earlie r models) , shoul d firs t b e posi - tioned . I t canno t b e manoeuvre d betwee n th e housin g an d th e generato r pedesta l afterwards . 1 2 Continu e wit h reassembl y b y carefull y lowerin g th e fa n housin g ove r th e oi l cooler . Th e pul l ro d ...

  • Volkswagen Transporter 1600 (1977) - page 49

    5.7 a Removin g th e lowe r hal f o f th e oi l coole r duc t 5.7 b Liftin g th e duc t fro m th e vertica l plat e 5. 8 Lookin g a t th e undersid e o f th e fa n housin g showin g th e ther - mostaticall y controlle d ai r baffl e plate s 5.1 2 Guidin g th e thermosta t ro d throug h th e cylinder s 5.1 4 Tightenin g th e fa n housin g sid e scre ...

  • Volkswagen Transporter 1600 (1977) - page 50

    5.16 a Replac e th e connectin g ro d fo r th e fa n housin g baffl e plate s 5.16 b Securin g th e specia l clip s 5.16 c an d retur n sprin g 6. 4 Unclampin g th e hea t exchange r contro l cable s 6. 6 Undoin g th e hea t exchange r sleev e cli p 6. 7 Drawin g th e hea t exchange r of f th e fron t stud s ...

  • Volkswagen Transporter 1600 (1977) - page 51

    7. 2 Slacke n th e thermosta t bellow s mountin g scre w 8. 4 Th e heate r contro l leve r showin g plasti c plu g 9.7 a Th e lowe r stu d als o carrie s th e war m ai r intak e pip e bracket 9.7 b D o no t us e an y pr e heate r gaske t wit h a smal l hole , fo r th e carburetto r ai r cleane r ...

  • Volkswagen Transporter 1600 (1977) - page 52

    5 2 Chapte r 2/Cooling , heatin g an d exhaus t system s th e ca b o r let s i t continu e t o th e tw o inne r slot s a t th e bas e o f th e windscreen . Th e heate r outpu t i s therefor e controlle d b y us e o f th e tw o lever s an d th e ho t ai r directio n ca n b e balance d betwee n floo r an d screen . 8 Passenge r carryin g model s hav ...

  • Volkswagen Transporter 1600 (1977) - page 53

    1 Tail pipe 2 Retaining ring 3 Seal 4 Self-locking nut 5 Clamp 6 Clamp bolt 7 Silencer 8 Seal 9 Air inlet hose 10 Hose clip FJG.2. 5 EXHAUS T SYSTE M AN D MOUNTING S (fo r Dampe r pipe , tai l pip e an d fitting s se e Fig.2.6 ) 11 Grommet 12 Connecting pipe 13 Gasket - pre-heater pipe (left) 14 Gasket - pre-heater pipe (right) 15 Gasket - exhaust ...

  • Volkswagen Transporter 1600 (1977) - page 54

    5 4 Chapte r 2/Cooling , heatin g an d exhaus t system s 1 1 Faultfindin g I t i s difficul t t o detec t heatin g system s fault s i n a rea r engine d ai r coole d ca r becaus e th e tell-tal e hea d o f stea m i s no t ther e t o sho w an d n o temperatur e gauge s ar e used . Th e firs t indication s o f ove r heatin g ar e a falljn g of f i n ...

  • Volkswagen Transporter 1600 (1977) - page 55

    4 3 6 7 Heat exchanger 2 Combustion chamber 3 Electric motor 4 Blower, fresh air 5 Casing 6 Regulator (pressure) 7 Solenoid valve 8 Fuel pump 9 Fuel jet 10 Combustion air blower 11 Spark plug (2 pole) 12 Coil VR Y HEATE R - DIAGRAMMATI C SECTIO N 13 Glow plug 14 Thermo-switch 15 Overheating switch 16 Safety switch 17 Warm air duct 18 Control flap 1 ...

  • Volkswagen Transporter 1600 (1977) - page 56

    56 " FIG.2. 8 SUPPLEMENTAR Y HEATE R - WIRIN G DIAGRAM S (above , t o Augus t 196 9 - below , fro m Augus t 196 9 t o 1973 ) 7 2 3 4 5 7 10 Electric motor Spark plug Breaker contact Safety switch Temperature regulating switch Glow plug Thermo switch 11 Overheating switch 17 Ignition coil 15 Fuel pump 17 Warning light 18 Fuse box 19 Fuse. 16 am ...

  • Volkswagen Transporter 1600 (1977) - page 57

    Chapte r 3 Fue l syste m an d carburatio n For modifications, and information applicable to later models, see Supplement at end of manual Content s Genera l descriptio n an d exhaus t emissio n contro l .. . .. . 1 Ai r cleane r .. . .. . .. . .. . .. . .. . .. . 2 Sole x carburetto r - descriptio n .. . .. . .. . .. . 3 Sole x carburetto r - remov ...

  • Volkswagen Transporter 1600 (1977) - page 58

    5 8 Chapte r 3/Fue l syste m an d carburatio n fu l t o humans . A s th e expor t o f VW' s t o th e State s i s a ver y significan t percentag e o f thei r tota l output , an d man y see m t o ge t t o th e Wes t Coast , i t i s natura l tha t V W activit y i n th e emissio n contro l fiel d ha s bee n intensive . A s developmen t i n thi s f ...

  • Volkswagen Transporter 1600 (1977) - page 59

    2.1 a Ai r cleane r remove d fro m vehicl e (kee p i t thi s wa y up ) 2. 1 b Th e to p hal f o f th e ai r cleane r withdraw n fo r servicin g FIG . 3.1 . DIAGRAMATI C CROS S SECTIO N O F SOLE X 3 0 PIC T CARBURETTO R WIT H AI R B Y PAS S ADJUSTMEN T 1 By pass air/fuel mixing 2 Choke tube 4 Volume control screw 5 By pass air drilling chamber 3 By ...

  • Volkswagen Transporter 1600 (1977) - page 60

    6 0 Fi g 3.2.A . CARBURETTO R SOLE X 3 0 PICT/ 2 7 Screw 2 Lockwasher 3 Upper body 4 Needle valve 5 Seal 6 Screw 7 Retaining ring 8 Spacer 9 Insert with spring and heater element 10 Cap 11 Screw 12 Cover 13 Spring 14 Vacuum diaphragm 15 Gasket 16 Accelerator cable spring 17 Main body 18 Float and pin 19 Float pin bracket 20 Air correction jet 21 Ma ...

  • Volkswagen Transporter 1600 (1977) - page 61

    6 1 Fig . 3.2B . SOLE X 3 0 PIC T - 3 CARBURETTO R (Sec . 4 ) / Top cover screw 2 Spring washer 3 Top cover 4 Needle valve washer 5 Needle valve 6 Gasket 7 Float pin retainer 8 Float 9 Air corrector jet 10 Carburettor body 11 Volume control screw 12 Nut 13 Lock washer 14 Accelerator cable spring 15 Spring washer 16 Plug 17 Plug washer 18 Main jet 1 ...

  • Volkswagen Transporter 1600 (1977) - page 62

    6 2 Chapte r 3/Fue l syste m an d carburatio n mixtur e t o ai d startin g a col d engine . A t idlin g speed s th e throttl e fla p i s shu t s o tha t n o ai r an d fue l ca n ge t t o th e engin e i n th e regula r way . Fo r thi s ther e ar e separat e route s leadin g t o smal l hole s i n th e sid e o f th e chok e tube , on th e engin e sid ...

  • Volkswagen Transporter 1600 (1977) - page 63

    4. 3 Liftin g th e carburetto r of f th e manifol d 4. 4 Lowe r hal f o f carburetto r showin g gaske t • r 4. 6 Uppe r hal f o f carburettor . Not e needl e valv e an d stranqle r fla p 'B ' 4. 9 Electr o magneti c fue l cu t of f valv e unscrewe d fro m carburet - to r bod y 4. 1 3 Reassemblin g th e tw o halve s o f th e carburetto r ...

  • Volkswagen Transporter 1600 (1977) - page 64

    6 4 Fig.3.2.C . SOLE X 31/3 4 PIC T 3 CARBURETTO R - EXPLODE D VIE W Difference between the two types is in pilot jet position — angled on the 31 PICT 3 (Sec 3) 1 Cover screw 2 Spring washer 3 Top cover 4 Needle valve washer 5 Needle valve 6 Gasket 7 Float pin bracket 8 Float and pin 9 Air correction jet and emulsion tube 10 Carburettor lower hou ...

  • Volkswagen Transporter 1600 (1977) - page 65

    6 5 FIG.3. 3 CARBURETTO R ADJUSTMEN T POINT S • NO T FIG.3. 4 CARBURETTO R ADJUSTMEN T POINT S - MODIFIE D MODIFIE D FO R EXHAUS T EMISSIO N CONTRO L REQUIRE - FO R EXHAUS T EMISSIO N CONTRO L (Se c 5 ) MENTS (Se c 5 ) 1 Throttle stop screw 1 3 1 1 1 0 2 Volume control screw 1 Air by pass serew 2 Volume control screw (sealed) 3 Throttle stop scre ...

  • Volkswagen Transporter 1600 (1977) - page 66

    6 6 Chapte r 3/Fue l syste m an d carburatio n fiv e carburettor s an d non e o r on e o f tw o type s o f throttl e valv e positioner . * Befor e attemptin g an y adjustmen t mak e sur e yo u kno w whic h on e yo u ar e dealin g with . Throttl e valv e positioner s ar e describe d i n Sectio n 11 , an d nee d adjustmen t afte r firs t settin g th ...

  • Volkswagen Transporter 1600 (1977) - page 67

    6 7 FIG.3. 6 FUE L PUM P (EARL Y TYPE ) COMPONENT S (Se c 8 ) 1 Cover screw 2 Washer 3 Cover 4 Gasket 5 Filter screen 6 Body screw 7 Washer 8 Pump body,upper 9 Diaphragm assembly 10 Pump body,lower 18 Gasket,pump to flange 19 Intermediate flange 20 Gasket flange to crankcase 21 Push rod ...

  • Volkswagen Transporter 1600 (1977) - page 68

    6 8 Chapte r 3/Fue l syste m an d carburatio n late r version s thi s cut-of f valv e wa s incorporate d int o th e bod y o f th e pump . 2 T o clea n th e filte r scree n remov e th e to p cove r securin g scre w an d carefull y lif t of f th e cove r an d gaske t (photo) . Th e gaske t ma y b e re-use d provide d i t remain s unbroken . Carefull ...

  • Volkswagen Transporter 1600 (1977) - page 69

    6. 2 Removin g th e fue l pum p cove r (late r types ) t o clea n th e filte r 7. 2 Removin g th e fue l pum p 7.3 a Th e fue l pum p actuatin g ro d 7.3 b Th e fue l pum p intermediat e flang e 7. 6 Fue l pum p an d externa l cu t of f valv e connection s 'A ' fro m th e fue l tan k an d 'B ' t o th e carburetto r 9. 1 Fue l ta ...

  • Volkswagen Transporter 1600 (1977) - page 70

    7 0 Chapte r 3/Fue l syste m an d carburatio n cylinde r an d th e pi n take n ou t o f th e cylinde r s o a s t o releas e th e floa t inside . 1 0 Fue l tan k - ventilatio n an d activate d carbo n filte r uni t 1 Ther e ma y b e on e o r mor e ven t pipe s o n th e fue l tan k t o cop e wit h expansio n du e t o hea t an d t o preven t spillag e ...

  • Volkswagen Transporter 1600 (1977) - page 71

    12.4 a Inle t manifol d aluminiu m gaske t 12.4 b Inle t manifol d centr e sectio n bein g positione d 12.4 c Th e section s o f th e inle t manifol d ar e joine d b y rubbe r boot s an d clips . 12.4 d Whic h mus t b e carefull y positione d 12.4 e Th e manifol d oute r section s ar e hel d b y th e cylinde r hea d stud s ...

  • Volkswagen Transporter 1600 (1977) - page 72

    7 2 FIG . 3.7 . SCHEMATI C DRAWIN G O F FUE L TAN K VENTILA - TIO N WIT H ACTIVATE D CARBO N FILTE R UNI T (Sec . 10 ) / Expansion chamberdncorporated in fuel tank design) 2 Breather line 3 Pressure line from fan housing 4 Suction line from air cleaner 5 Crankcase breather hose 1 2 / Pull rod 2 Pull rod diaphragm 3 Vacuum hose to carburettor FIG.3. ...

  • Volkswagen Transporter 1600 (1977) - page 73

    Chapte r 3/Fue l syste m an d carburatio n 7 3 1 3 Faul t diagnosi s I n additio n t o th e mor e basi c fault s whic h ma y occu r i n an y vehicl e fue l syste m ther e ar e som e peculiaritie s a s a resul t i n th e change s an d modification s neede d i n connectio n wit h exhaus t emissio n contro l - whic h wer e mad e t o th e carburetto r ...

  • Volkswagen Transporter 1600 (1977) - page 74

    Chapte r 4 Ignitio n syste m For information applicable to later models, see Supplement at end of manual Content s Genera l descriptio n .. . .. . .. . .. . .. . .. . 1 Contac t point s - adjustment , remova l an d replacemen t .. . 2 Distributo r - remova l an d replacemen t .. . .. . .. . 3 Condense r - testin g an d renewa l .. . .. . .. . .. . ...

  • Volkswagen Transporter 1600 (1977) - page 75

    7 6 FIG.4. 2 DISTRIBUTO R WIT H CENTRIFUGA L AN D VACUU M ADVANC E EXPLODE D VIE W - (Se c 5 ) FIG.4. 2 DISTRIBUTO R WIT H CENTRIFUGA L AN D VACUU M ADVANC E EXPLODE D VIE W - (Se c 5 1 1 2 3 4 5 6 7 a 9 Mounting clamp bracket Cap Rotor Contacts securing screw Contact points Clip screw Clip retainer Clip retainer Cap clip 10 Contact points mounting ...

  • Volkswagen Transporter 1600 (1977) - page 76

    Chapte r 4/lgnitio n syste m 7 7 2 Contac t point s - adjustment , remova l an d replacemen t 1 Volkswage n servic e procedure s chec k th e contac t point s b y measurin g th e ca m dwel l wit h specia l equipment . Al l els e bein g equa l th e correc t ca m dwel l give s a point s ga p o f . 4 mm/.O1 6 ins . T o chec k th e gap , firs t remov e ...

  • Volkswagen Transporter 1600 (1977) - page 77

    2.1 a Removin g th e distributo r ca p 2.1 b an d roto r 2. 3 Contac t point s read y fo r ga p chec k 2. 4 Checkin g th e point s ga p wit h a feele r blad e an d undoin g th e clam p scre w t o enabl e th e fixe d poin t t o b e move d 1 2. 5 Disconnectin g th e point s lea d 2. 7 Liftin g th e point s assembl y fro m th e pivo t pos t ...

  • Volkswagen Transporter 1600 (1977) - page 78

    Chapte r 4/lgnitio n syste m 7 9 a s describe d earlier . 4 Th e nex t jo b i s t o remov e th e drivin g colla r fro m th e botto m o f th e shaf t bu t befor e doin g thi s i t i s importan t t o not e whic h wa y i t i s fitted . Se e whic h wa y th e drivin g dog s ar e offse t i n relatio n t o th e roto r ar m notc h i n th e to p o f th e sh ...

  • Volkswagen Transporter 1600 (1977) - page 79

    6. 5 Fittin g th e distributo r driv e shaf t thrus t washe r ove r a suitabl e 6.8 a Replacin g th e distributo r driv e shaft . Not e th e fue l pum p guid e ro d driv e ca m o n th e shaf t FIG.4. 3 DISTRIBUTO R DRIV E SHAF T (Se c 6 ) 7 Spacer spring 2 Fuel pump drive cam 3 Thrust washer 6.8 b Replacin g th e thrus t sprin g FI G 4. 4 CORREC T ...

  • Volkswagen Transporter 1600 (1977) - page 80

    Chapte r 4/lgnitio n syste m 8 1 spee d wil l alte r s o i f i t fall s outsid e th e specifie d limit s adjus t th e by-pas s ai r scre w o n th e carburetto r unti l i t i s onc e mor e correct . The n chec k wit h th e stroboscop e again . 1 4 Whe n th e mar k line s u p wit h th e crankcas e joint , clam p u p th e distributor . Reconnec t th e ...

  • Volkswagen Transporter 1600 (1977) - page 81

    8 2 Chapte r 4/lgnitio n syste m circumstanc e wher e th e ignitio n i s bein g checke d fo r correc t operation . D o no t by-pas s an y par t o f thi s procedur e unles s th e faul t i s particularl y obviou s an d rectificatio n solve s th e problem . Suc h obviou s fault s woul d b e broke n o r detache d wires . I t i s assume d tha t th e bat ...

  • Volkswagen Transporter 1600 (1977) - page 82

    Chapte r 5 Clutc h an d operatin g mechanis m Content s Genera l descriptio n .. . .. . .. . .. . .. . .. . 1 Clutc h cabl e - removal , replacemen t an d adjustmen t .. . 2 Clutc h assembl y - removal , inspectio n an d replacemen t .. . 3 Clutc h releas e operatin g mechanism - inspectio n an d repai r 4 Faul t diagnosi s .. . .. . .. . .. . .. . ...

  • Volkswagen Transporter 1600 (1977) - page 83

    2. 2 Clutc h cabl e adjustin g win g nu t 2. 5 Mak e sur e th e rubbe r dir t excludin g cap s ar e refitte d 3. 9 Replacin g th e drive n plat e an d cove r assembl y 3.10 a Centr e th e clutc h plat e o n th e flywhee l (typica l components ) 3.10 b I f th e gea r bo x i s dismantle d us e th e inpu t shaf t t o centr e th e clutc h (typica l com ...

  • Volkswagen Transporter 1600 (1977) - page 84

    8 5 FIG.5. 1 EARL Y CLUTC H UNI T - COI L SPRIN G TYP E FIG.5. 2 LATE R CLUTC H UNI T - TYPICA L DIAPHRAG M SPRIN G TYP E / Cover securing screw 2 Lock washer 3 Release ring 4 Adjusting nut 5 Pressure collar 6 Release lever 7 Spring 8 Cover plate 9 Spring cap 10 Spring (white) 11 Spring (red) 12 Spring seat 13 Spring pin 14 Pivot pin 15 Clutch plat ...

  • Volkswagen Transporter 1600 (1977) - page 85

    8 6 FIG.5. 3 COMPARISO N O F EARL Y TYP E (LEFT ) AN D LATE R VERSIO N (RIGHT ) O F TH E DIAPHRAG M SPRIN G CLUTC H COVE R FIG.5. 4 CLUTC H OPERATIN G CABL E OUTE R SLEEV E A Adjustment washer location B Bend measurement (1 - 1 % in) ...

  • Volkswagen Transporter 1600 (1977) - page 86

    Chapte r 5/Clutc h an d operatin g mechanis m 8 7 relieved . Lif t of f th e cove r an d clutc h drive n plate . 4 Th e clutc h drive n plat e shoul d b e inspecte d fo r wea r an d fo r contaminatio n b y oil . Wea r i s gauge d b y th e dept h o f th e rive t head s belo w th e surfac e o f th e frictio n material . I f thi s i s les s tha n 0.02 ...

  • Volkswagen Transporter 1600 (1977) - page 87

    4. 6 Vie w o f th e bearin g attachmen t clip s 4.8 a Fittin g th e clutc h releas e shaf t bus h 4.8 b followe d b y th e shaf t 4.8 c an d bearin g sleev e an d seals . 4.8 d Mak e sur e th e bus h an d sea l d o no t com e ou t o n th e insid e lik e thi s 4.8 e Th e locatin g scre w fo r th e bus h an d sleev e ...

  • Volkswagen Transporter 1600 (1977) - page 88

    Chapte r 5/Clutc h an d operatin g mechanis m 8 9 5 Faul t diagnosi s Symptom s Reason/ s Remed y Judde r whe n takin g u p driv e Clutc h spi n (failur e t o disengage ) s o tha t gear s canno t b e meshe d Clutc h slip - (increas e i n engin e spee d doe s no t resul t i n increas e i n vehicl e spee d - especiall y o n hills ) Loos e engine/gear ...

  • Volkswagen Transporter 1600 (1977) - page 89

    FIG.5. 6 CLUTC H RELEAS E MECHANIS M - COMPONENT S 7 2 3 4 5 Clutch housing Bush - starter pinion Bush - operating shaft Oil return sleeve Oil seal • drive shaft 6 7 8 9 10 Clutch operating shaft Release bearing Retaining spring Circlip Washer 11 Rubber seal 16 Spring locating collar 12 Bush 17 Return spring 13 Sleeve 18 Clutch lever 14 Lock scre ...

  • Volkswagen Transporter 1600 (1977) - page 90

    Chapte r 6 Transmissio n an d fina l driv e For modifications, and information applicable to later models, see Supplement at end of manual Content s Genera l descriptio n .. . .. . .. . .. . .. . .. . 1 Transmissio n - remova l an d replacemen t .. . .. . .. . 2 Transmissio n - dismantlin g .. . .. . .. . .. . .. . 3 Inspectio n fo r wea r i n tran ...

  • Volkswagen Transporter 1600 (1977) - page 91

    FIG.6. 1 FINA L DRIV E AN D DIFFERENTIA L (T O AUGUS T 1968 ) (Se c 3 ) 7 Differential 4 Oil seal 2 Side covers 5 '0' ring 3 Outer race taper 6 Shim roller bearings 7 Shim 8 Cap nut 9 Spring washer 10 Joint flange 11 Spacer ring 12 Circlip 13 Sealing cap 14 Drive shaft, rear (input) 15 Stud (connecting) 16 Reverse gear sleeve 17 Circlip 1 ...

  • Volkswagen Transporter 1600 (1977) - page 92

    FIG.6. 2 FINA L DRIV E AN D DIFFERENTIA L (FRO M AUGUS T 1968 ) (Se c 3 ) 1 Differential 2 Adjusting ring 3 Outer race, taper roller bearings 4 Oil seal 5 'O' Rir.j 6 Lock washer 7 Screw 8 Lock plate 9 Flange 10 Spacer washer 11 Circlip 12 Cap 13 Drive shaft - rear part (input) 14 Stud (connecting) 15 Reverse gear sleeve 16 Circlip 17 Clu ...

  • Volkswagen Transporter 1600 (1977) - page 93

    FI G 6.3 . GEARBO X AN D GEA R TRAI N (Se c 3 ) Mote : thi s drawin g i s correc t fo r gearboxe s u p t o Augus t 196 8 afte r whic h th e pinio n shaf t fastening s (8 ) wer e change d an d a pinio n retainin g nu t replace d them . Se e tex t Sectio n 3.12 . r Casing 5 ? Gear carrier 6 3 Drive shaft (mainshaft) 7 1 Drive pinion shaft 8 Shim (to ...

  • Volkswagen Transporter 1600 (1977) - page 94

    Chapte r 6/Transmissio n an d fina l driv e 9 5 ver y ba d stat e the n th e cos t o f th e componen t part s ma y wel l excee d th e cos t o f a ne w replacemen t unit . Thirdly , remembe r tha t a basi c knowledg e o f gearbo x constructio n an d functio n i s a bar e necessit y befor e tacklin g thi s one . I f yo u ar e doin g on e fo r th e fi ...

  • Volkswagen Transporter 1600 (1977) - page 95

    1. 1 Th e transmissio n fro m belo w showin g 2. 6 Und o th e squar e heade d scre w layou t an d support s 2.7 a Und o th e tw o nut s holdin g th e gear - bo x a t th e fron t mountin g 2.7 b Remov e th e eart h stra p 2.8 a Remov e th e uni t t o th e re a 2.8 b an d lowe r i t t o th e groun d 2.9 a Assembl e th e starte r moto r 2.9 b Fil l u ...

  • Volkswagen Transporter 1600 (1977) - page 96

    Chapte r 6/TransmissiO n an d fina l driv e 9 7 1 8 Th e pinio n shaf t i s a ver y tigh t fi t i n th e bal l bearin g i n th e casing . Havin g remove d th e circli p an d dishe d washe r fro m th e en d o f th e shaf t (watc h ou t tha t th e springines s o f th e washe r doe s no t caus e th e circli p t o fly ' whe n i t i s released ) th ...

  • Volkswagen Transporter 1600 (1977) - page 97

    ...

  • Volkswagen Transporter 1600 (1977) - page 98

    Chapte r 6/Transmissio n an d fina l driv e 9 9 plasti c plug s fro m th e drilling s opposite . Befor e doin g thi s mak e sur e yo u obtai n som e ne w plug s t o driv e i n whe n reassembling . Chec k th e sprin g fre e lengt h whic h shoul d b e 2 5 m m ( 1 inch) . I f les s tha n 2 2 m m the y shoul d b e changed . Th e ball s shoul d b e fre ...

  • Volkswagen Transporter 1600 (1977) - page 99

    5.B 1 Th e pinio n shaf t assembl y 5.B 4 Fittin g firs t gea r o n th e pinio n 5.B 5 Fittin g 1st/2n d gea r clutc h shaf t hu b 5.B 8 Fittin g 2n d gea r an d baul k rin g 5.B 9 Fittin g 3r d gea r an d rolle r bearin g 5.B1 0 Fi t 3r d gea r retainin g cli p 5.B1 2 Fi t th e space r ring , 4t h gea r an d th e 5.B1 3 Drivin g o n th e bearin g ...

  • Volkswagen Transporter 1600 (1977) - page 100

    Chapte r 6/Transmissio n an d fina l driv e 10 1 5 E Gea r carrie r - fittin g shaft s an d selecto r fork s 1 I t i s assume d tha t th e selecto r rail s ar e i n orde r (se e Sectio n 4 , paragrap h 7 ) an d th e fork s ar e a correc t fi t i n th e hu b sleev e groove s (Sectio n 4 , paragrap h 6) . 2 Holdin g bot h shaft s togethe r pu t the m ...

  • Volkswagen Transporter 1600 (1977) - page 101

    5E.2 A Replacin g th e shaft s i n th e bear - 5E.2 B Th e shaft s i n positio n ing s 5E.4 A Fi t th e dishe d washer s an d circli p 5b.4 B Driv e hom e th e circli p ont o th e pinio n shaf t 5E. 5 Assembl e th e selecto r fork s t o th e correc t rail s 5E.6 A Th e cros s shaf t brackets , rela y leve r an d post s fo r revers e gea r 5E.6 B D ...

  • Volkswagen Transporter 1600 (1977) - page 102

    5F.4 a Lowe r th e carrie r an d th e shaft s int o th e casin g 5F.6 b followe d b y th e circli p 5F.4 b I t ma y b e necessar y t o juggl e th e gea r wit h a screwdrive r t o ge t revers e gea r ont o it s shaf t 5F.6 a Replac e th e pinio n shim s 5F.8 a Tighte n th e nut s t o a torqu e o f 2 2 lbs/f t 5F.8 b Lug s correctl y i n positio n 5G ...

  • Volkswagen Transporter 1600 (1977) - page 103

    5H. 2 Rene w th e 'O ' ring s o n th e bearin g 5H. 4 Pu t th e differentia l assembl y int o c° ve r th e casin g 5H.5 a Replac e th e shim s .. . 5H.5 b ... . an d th e sid e bearing s 5H.5 c chec k th e mark s mad e whe n dis - mantlin g 5H. 7 replac e th e revers e gea r sleev e ont o th e inpu t shaf t 5H. 8 Fi t th e extensio n sha ...

  • Volkswagen Transporter 1600 (1977) - page 104

    FIG.6. 5 GEA R CARRIE R AN D SELECTO R LEVER S - COMPONENT S (Se c 5G ) 1 Gear carrier 2 Bearing drive shaft 3 Needle bearing - pinion shaft 4 Support - shift lever 5 Screw 6 Bracket - relay shaft 7 Relay shaft 8 Reverse lever 9 Support 10 Union nut 11 Clamp sleeve 12 Selector rail. 3rd/4th gear 13 Selector rail - reverse 14 Selector rail - 1st/2nd ...

  • Volkswagen Transporter 1600 (1977) - page 105

    10 6 FIG.6. 6 DIFFERENTIA L ASSEMBL Y (Se c 8 ) 1 Taper roller side bearing 2 Crown wheel (ring gear) 3 Differential housing 4 Shaft retaining pin 5 Thrust washer 6 Differential gear and drive shaft 7 Spacer sleeve 8 Differential pinion 9 Thrust washer 10 Pinion shaft 11 Differential gear and drive shaft,short 12 Housing end cover 13 Bolt with spri ...

  • Volkswagen Transporter 1600 (1977) - page 106

    Chapte r 6/Transmissio n an d fina l driv e 10 7 6 Synchromes h hu b assemblie s - dismantling , inspectio n an d reassembl y 1 Unles s th e transmissio n i s th e victi m o f neglec t o r misuse , o r ha s covere d ver y hig h mileages , th e synchr o hu b assemblie s d o no t normall y nee d replacement . Unti l recentl y the y coul d onl y b e r ...

  • Volkswagen Transporter 1600 (1977) - page 107

    5H.1 3 a Fi t a ne w gaske t , 5H.13 b ... . an d replac e th e clutc h housin g 6.3 b Th e indente d spline s i n th e sleev e mus t lin e u p wit h th e slidin g key s 7. 6 Drivin g a ne w sea l int o positio n 1 Housing bolt 2 Cover 3 Shaft - short 4 Friction cone FIG.6. 8 LIMITE D SLI P DIFFERENTIA L - CON E TYP E (Se c 9 ) 5 Adjusting shim 6 S ...

  • Volkswagen Transporter 1600 (1977) - page 108

    Chapte r 6/Transmissio n an d fina l driv e 10 9 Whe n th e leve r i s i n 2n d gea r gea r positio n i t shoul d b e exactl y vertica l wit h th e cranke d uppe r sectio n incline d a t abou t 30 ° t o th e rear . Sideway s movemen t measure d a t th e leve r knob , wit h a gea r engage d shoul d no t excee d 3 5 mm . I n neutra l i t shoul d no ...

  • Volkswagen Transporter 1600 (1977) - page 109

    FIG.6. 9 GEA R CHANG E / Knob 2 Gear lever 3 Bellows 4 Moun ting bracket bolt 5 Spring washer 6 Washer 7 Bracket 8 Spring 9 Stop plate 10 Guide sleeve 11 Shift rod front 12 Muff coupling LEVE R AN D ROD S - COMPONENT S (Se c 10 ) 13 Shift rod, rear 14 Bellows 15 Bush, front 16 Bush, rear 17 Self tapping screw 18 Locking cap 19 Insert 20 Housing 21 ...

  • Volkswagen Transporter 1600 (1977) - page 110

    Chapte r 7 Whee l shafts , driv e shaft s an d universa l joint s Content s Genera l descriptio n .. . .. . .. . .. . 1 Driv e shaft s - remova l an d replacemen t .. . .. . .. . 2 Constan t velocit y universa l joint s - removal , repai r an d replacemen t .. . .. . .. . .. . .. . .. . .. . 3 Rea r whee l shaft s an d bearing s - remova l an d rep ...

  • Volkswagen Transporter 1600 (1977) - page 111

    2. 1 Undoin g driv e shaf t ca p screw , oute r end . Not e spli t rubbe r boo t 2.3 a Removin g th e shaf t fro m th e gea r bo x 2.3 b Removin g th e shaf t fro m th e whee l hu b 3.1 a Fittin g a ne w boot . Firs t th e inne r circlip. . 3.1 b ...the n th e boot.. . 3.1 c pu t th e oute r circli p on.. . ...

  • Volkswagen Transporter 1600 (1977) - page 112

    3. 1 d eas e th e boo t ove r th e C. V join t an d tighte n u p 3.5 a Pris e ou t th e en d ca p 3.5 b .. . remov e th e circli p 3.5 c remov e th e C. V join t fro m th e shaf t 3.5 d Discar d th e concav e washer , i f on e i s fitted , behin d th e join t 3.7 a Examinin g a spli t boo t ...

  • Volkswagen Transporter 1600 (1977) - page 113

    3.7 b Damag e (arrowed ) o n th e join t oute r rin g 3.7 c Damag e (arrowed ) o n th e join t hu b 3. 8 Constan t velocit y join t - placin g th e hu b sectio n i n th e cag e 3. 9 Fittin g th e ball s int o th e cag e 3.1 0 Fittin g th e hub , balls , an d cag e int o th e oute r sectio n ...

  • Volkswagen Transporter 1600 (1977) - page 114

    Chapte r 7/Whee l shafts , driv e shaft s an d universa l joint s 11 5 ma y hav e gon e un-notice d fo r a lon g perio d an d le t i n wate r an d dirt , i t ma y nee d carefu l examinatio n t o decid e whethe r renewa l i s needed . Th e track s i n whic h th e ball s ru n shoul d no t b e groove d o r damage d a t th e edge s i n an y way . Th e ...

  • Volkswagen Transporter 1600 (1977) - page 115

    3.1 2 Placin g th e join t o n th e shaf t 3.13 a Placin g th e circli p ove r th e en d o t th e shaf t 3.1 3 b Drivin g th e circli p hom e 3.14 a Repac k th e C. V join t wit h greas e 3.14 b Tappin g th e boo t retaine r plat e bac k ont o th e join t j ...

  • Volkswagen Transporter 1600 (1977) - page 116

    11 7 / Split pin 2 Nut 3 Brake drum and hub 4 Back plate assembly 5 Bolt FIG.7. 1 REA R WHEE L SHAF T AN D BEARING S (T O AUGUS T 1970 ) 6 Spring washer 7 Bolt 8 Lock washer 9 Dowel pin 10 Bearing housing 11 Spacer ring 12 Grease seal 13 Ore lip 14 Roller bearing 15 Spacer sleeve 16 Ball bearing 17 Wheel shaft 1 Split pin 2 Nut 3 Bolt 4 Brake drum ...

  • Volkswagen Transporter 1600 (1977) - page 117

    Chapte r 8 Brakin g syste m For information applicable to later models, see Supplement at end of manual Content s Genera l descriptio n .. . .. . .. . .. . .. . .. . 1 Brak e adjustmen t (includin g th e han d brake ) .. . .. . 2 Fron t drum s an d brak e shoe s - inspectio n an d renewa l .. . 3 Rea r drum s an d brak e shoe s - inspectio n an a r ...

  • Volkswagen Transporter 1600 (1977) - page 118

    Chapte r 8/Brakin g syste m Serv o Boostin g facto r Torqu e wrenc h setting s Tande m maste r cylinder/suppor t screw s .. . Fron t whee l cylinde r an d backplat e o n steerin g knuckl e Dis c calipe r o n steerin g knuckl e .. . Rea r axl e shaf t (fo r brak e drum ) .. . Rea r bac k plat e bolt s 2.0 5 lbs/f t 29/3 3 40/4 3 7 2 25 3 2 5 mk g 4/ ...

  • Volkswagen Transporter 1600 (1977) - page 119

    2. 7 Th e handbrak e adjuste r # & unde r th e rubbe r gromme t (earl y models ) 3. 2 Fron t dru m brak e B FIG . 8. 1 BRAK E ADJUSTMEN T - MOVEMEN T O F ADJUSTE R WHEEL S T O PU T SHOE S NEARE R THE DRUM S (Sec . 2 ) A Front drum LEFT B Front drum RIGHT viewed from drum side viewed from drum side C Rear drums viewed from either side FI G 8. 2 ...

  • Volkswagen Transporter 1600 (1977) - page 120

    9 1 5 FIG . 8. 3 FRON T WHEE L DRU M BRAK E ASSEMBL Y (SEC . 3 ) / C washer (for speedo cable only) 2 Dust cover 3 Bearing clamp nut 4 Thrust washer 5 Wheel bearing 6 Brake drum 7 Brake shoe 8 Return spring 9 Connecting line 10 Adjusting screw 11 Adjusting wheel 12 Bolt 13 Lock washer 14 Brake cylinder 15 Plug 16 Back plate 17 Steering knuckle IS ) ...

  • Volkswagen Transporter 1600 (1977) - page 121

    I FIG . 8. 4 REA R WHEE L BRAK E ASSEMBL Y (DETACHABL E DRUMS ) 7 2 3 4 5 6 Split pin Nut Socket head screw Brake drum Wheel hub Slotted cup washer 7 8 9 10 11 12 Spring Steady pin Return spring Brake shoe Distance piece Return spring 13 Locating clip 14 Adjuster screw 15 Knurled adjuster 16 Plug 17 Retaining pin 18 Wheel cylinder bolt 19 Spring wa ...

  • Volkswagen Transporter 1600 (1977) - page 122

    Chapte r 8/Brakin g syste m 12 3 plat e an d se e tha t th e othe r sho e i s move d b y th e hydrauli c pisto n whe n th e brak e peda l i s depressed . D o no t le t th e pisto n com e righ t ou t o r th e syste m wil l nee d bleedin g afte r reassem - blin g it . I f eithe r pisto n wil l no t mov e i t mus t b e seized . Thi s wil l requir e ov ...

  • Volkswagen Transporter 1600 (1977) - page 123

    4.8 a Fittin g th e stead y pin , sprin g an d washe r whils t assemblin g th e righ t rea r brak e sho e assembl y 4.8 b Hookin g th e handbrak e cabl e t o th e leve r o n a righ t rea r brak e assembl y FIG . 8. 5 REA R WHEE L BRAK E ASSEMBL Y (ON E PIEC E HU B AN D BRAK E DRUM ) (SEC . 4 ) 1 Split pin 2 Nut 3 Brake drum and hub 4 Slotted cup wa ...

  • Volkswagen Transporter 1600 (1977) - page 124

    Chapte r 8/Brakin g syste m 12 5 6 I f th e pad s ar e t o b e use d agai n mar k wher e the y cam e fro m beforehan d s o the y ma y b e pu t bac k i n th e sam e position . Driv e ou t th e retainin g pin s fro m th e outsid e wit h a lon g nose d punch . Lif t of f th e sprin g plate . 7 Befor e removin g th e ol d pad s i t i s bes t t o forc e ...

  • Volkswagen Transporter 1600 (1977) - page 125

    12 6 FIG . 8. 6 FRON T WHEE L HYDRAULI C BRAK E CYLINDE R (SEC . 6 ) 1 Boot 2 Piston 3 Cup 4 Housing 5 Bleed valve 6 Dust cap 7 Adjusting nut 8 Adjusting screw FIG . 8. 7 REA R WHEE L HYDRAULI C BRAK E CYLINDE R (SEC . 6 ) 1 Boot 2 Piston 3 Seal 4 Circlip 5 Housing 6 Bleed valve 7 Dust cap FIG . B B DIS C BRAK E CALIPE R ASSEMBL Y (SEC . 7 ) / Pad ...

  • Volkswagen Transporter 1600 (1977) - page 126

    Chapte r 8/Brakin g syste m 12 7 •1 1 Fi t th e ne w oute r seal . 1 2 Repea t th e proces s fo r th e othe r piston . 1 3 Refi t th e calipe r t o th e knuckle , tightenin g th e securin g bolt s t o 7 2 I b ft/1 0 mkg . Replac e th e pisto n retaine r plate s notin g tha t the y shoul d li e flus h agains t th e pisto n an d hav e th e tw o sta ...

  • Volkswagen Transporter 1600 (1977) - page 127

    8. 4 Mountin g bol t an d union , maste r cylinde r 8. 6 Fillin g th e maste r cylinde r flui d reservoi r FIG . 8. 9 HYDRAULI C MASTE R CYLINDE R (SINGL E CIRCUIT ) CROS S SECTIO N (SEC . 9 ) 1 Piston 2 Intake port 3 Piston washer 4 Primary cup seal 5 Residual pressure valve 6 Spring 7 Compensating port 8 Secondary cup seal 9 Stop plate tO Circlip ...

  • Volkswagen Transporter 1600 (1977) - page 128

    12 9 FIG . 8.1 0 TANDE M MASTE R BRAK E CYLINDE R (SEC . 10 ) Top : Cros s Sectio n 1 Rear brake circuit piston 4 Port 2 Primary cup 5 Primary cup 3 Port I Rear brake circuit TJ Front brake circuit Centre : Tande m brak e maste r cylinde r wit h hydrauli c warnin g devic e u p t o Chassi s 21906156 7 Lower : Tande m brak e maste r cylinde r wit h e ...

  • Volkswagen Transporter 1600 (1977) - page 129

    13 0 FIG . 8.1 1 MASTE R CYLINDE R PRESSUR E DIFFERENTIA L INDICATO R PISTO N AN D WARNIN G LAM P SWITCH ; CROS S SECTIO N (SEC . 10 ) / Plug 2 Sealing washer 3 Spring 4 Connecting port 5 Piston 6 Seal cups 7 Warning lamp plunger switch / Primary piston 2 Secondary piston 3 Spring between pistons A From master cylinder FIG . 8.1 2 REA R BRAK E PRES ...

  • Volkswagen Transporter 1600 (1977) - page 130

    Chapte r 8/Brakin g syste m 13 1 9 Som e cylinder s incorporat e a pressur e differentia l warnin g system . Thi s consist s o f a singl e pisto n hel d centrall y i n balanc e b y th e equa l pressur e o f th e tw o circuits . I f unequa l pressur e betwee n th e tw o circuit s develop s th e pisto n move s on e wa y o r th e othe r an d operate s ...

  • Volkswagen Transporter 1600 (1977) - page 131

    12. 5 Flexibl e hos e mountin g bracke t an d cli p 13. 4 Blee d nippl e ca p removed , righ t han d fron t whee l 1 0 FIG . 8.1 3 BRAK E PEDA L CLUSTE R - EARL Y VERSION S R.H.D . AN D AL L VERSION S L.H.D . (SEC . 14 ) / Bolt 2 Lock washer 3 Nut 4 Seal 5 Brake pedal 6 Split pin 7 Washer 8 Pin 9 Push rod 10 Nut 11 Lock washer 12 Bolt 13 Return spr ...

  • Volkswagen Transporter 1600 (1977) - page 132

    13 3 FI G 8.1 4 TYPICA L BRAK E PRESSUR E REGULATO R (Sec . 11 ) FIG . 8.1 5 BRAK E (AN D CLUTCH ) PEDA L CLUSTE R - LAT E VERSION S R.H.D . (SEC . 14 ) 7 Split pin 2 Washer 3 Clevis pin 4 Push rod 5 Master cylinder cap 6 Pin and clip 7 Return spring 8 Nut 9 Lock washer 10 Bolt 11 Push rod 12 Seal 13 Clamp screw 14 Lock washer 15 Brake pedal lever ...

  • Volkswagen Transporter 1600 (1977) - page 133

    13 4 1 2 3 4 5 6 Roll pin Handle Ratchet bar stop Cover Screw Lock washer 7 Trim plate 8 Guide sleeve 9 Spring 10 Split pin 11 Washer 12 Pin FIG . 8.1 6 HANDBRAK E LEVE R ASSEMBL Y (SEC . 15 ) 13 Ratchet bar 14 Eye bolt 15 Screw 16 Ratchet bar bracket 17 Boot 18 Nut 19 Washer 20 Anchor pin 21 Spring clip 22 Pin 23 Handbrake lever ...

  • Volkswagen Transporter 1600 (1977) - page 134

    Chapte r 8/Brakin g syste m 13 5 th e prope r fluid , a clea n receptacl e an d a tub e whic h wil l fi t ove r th e blee d nippl e securel y an d whic h i s convenientl y lon g enough . A usefu l devic e i s th e tub e whic h i s fitte d wit h a non-retur n valve . Thi s avoid s th e necessit y o f keepin g th e othe r en d o f th e tub e submerge ...

  • Volkswagen Transporter 1600 (1977) - page 135

    13 6 732454 1 6 3 FIG . 8.1 7 MODIFICATIO N T O TANDE M BRAK E MASTE R CYLINDE R FO R SERV O ASSISTE D SYSTE M (SEC . 16 ) 15. 5 Vie w o f th e handbrak e cabl e fro m belo w 7 Seal 2 Circlip 3 Washer 5 Washer 7 Rear brake piston 1 Retaining ring 2 Circlip FIG . 8.1 8 SERV O MECHANISM . EXPLODE D VIE W (SEC . 16 ) 3 Air connection 4 Rubber dust exc ...

  • Volkswagen Transporter 1600 (1977) - page 136

    Chapte r 8/Brakin g syste m 13 7 1 7 Faul t diagnosi s an d remedie s Befor e diagnosin g fault s i n th e brak e syste m chec k tha t an y irregularitie s ar e no t cause d by : 1 Uneve n an d incorrec t tyr e pressure s 2 Incorrec t 'mix ' o f radia l an d cross-pl y tyre s 3 Wea r i n th e steerin g mechanis m 4 Defect s i n th e suspe ...

  • Volkswagen Transporter 1600 (1977) - page 137

    Chapte r 9 Electrica l syste m For modifications, and information applicable to later models, see Supplement at end of manual Content s Genera l descriptio n .. . .. . .. . .. . .. . .. . 1 Batter y - remova l an d replacemen t .. . .. . 2 Batter y - maintenanc e an d inspectio n .. . .. . .. . 3 Electrolyt e replenishmen t .. . .. . .. . .. . .. . ...

  • Volkswagen Transporter 1600 (1977) - page 138

    Chapte r 9/Electrica l syste m 13 9 Fuse s N o o f fuse s No 1 N o 2 N o 3 N o 4 N o 5 N o 6 N o 7 N o 8 N o 9 No1 0 No1 1 No1 2 Identification ; Re d 1 6 amp . Whit e 8 am p 196 7 1968-8 9 197 0 1971-7 2 8 1 0 1 2 1 2 Lef t headlamp . Lo w Brak e light s Interio r ligh t Parkin g light s bea m Hor n . Righ t rea r lam p Flasher s Numbe r plat e Ri ...

  • Volkswagen Transporter 1600 (1977) - page 139

    14 0 2. 1 Disconnec t th e batter y FIG . 9. 1 DYNAM O COMPONENT S (TYPICA L LAYOUT ) (SEC . 12 ) / Through bolt 2 Lock washer 3 Spacer ring 4 Screw 5 Lock washer 6 Commutator end plate 7 Brush spring 8 Screw 9 Lock washer tO Carbon brush 11 Lock washer 12 Splash shield 13 Ball bearing 14 Splash shield 15 Thrust washer 16 Retaining plate 17 Splash ...

  • Volkswagen Transporter 1600 (1977) - page 140

    Chapte r 9/Electrica l syste m 14 1 2 A s wel l a s keepin g th e terminal s clea n an d covere d wit h petroleu m jelly , th e to p o f th e batter y an d especiall y th e to p o f th e cells , shoul d b e kep t clea n an d dry . Thi s help s preven t corrosio n an d ensure s tha t th e batter y doe s no t becom e partiall y discharge d b y leakag ...

  • Volkswagen Transporter 1600 (1977) - page 141

    14 2 FIG . 9. 2 DYNAM O AN D REGULATO R TEST S A Voltmete r connectio n fo r n o loa d regulate d voltag e chec k B Voltmete r connectio n fo r n o loa d unregulate d voltag e chec k C Ammete r connectio n fo r curren t outpu t chec k an d revers e curren t chec k ...

  • Volkswagen Transporter 1600 (1977) - page 142

    14 3 FIG . 9. 3 STARTE R MOTO R COMPONENT S (BOSCH ) 1 Nut 2 Lock washer 3 Screw 4 Rubber seal 5 Disc 6 Solenoid switch 7 Stop ring 8 Circlip 9 Screw 10 Washer 11 End cap 12 C washer 13 Shim 14 Sealing ring 15 Housing screw 16 End plate 17 Spring 18 Brush holder 19 Grommet 20 Housing 21 Insulating washer 22 Thrust washer 23 Pin 24 Nut 25 Lock washe ...

  • Volkswagen Transporter 1600 (1977) - page 143

    14 4 FIG . 9. 4 STARTE R MOTO R COMPONENT S V.W . 1 Nut and lock washer 2 Connecting strip 3 Nut and lock washer 4 Solenoid housing and winding 5 Insulating disc 6 Moulded seal 7 Insulating plate 8 Cap 9 Circlip 10 Steel washer 11 Bronze washer 12 Brush inspection cover 13 Commutator end plate 14 Brush holder and brushes 15 Screw and lock washer 16 ...

  • Volkswagen Transporter 1600 (1977) - page 144

    Chapte r 9/Electrica l syste m 14 5 th e voltag e shoul d b e approximatel y 1 2 volts . A t twic e thi s spee d th e voltag e shoul d increas e t o 3 6 volts . Chec k quickl y an d switc h of f withi n a fe w seconds . I f th e voltag e i s ni l o r lo w the n th e generato r i s faulty . 1 0 Dynam o - curren t outpu t chec k an d revers e curren ...

  • Volkswagen Transporter 1600 (1977) - page 145

    10. 2 Terminal s D+an d D F o n th e generato r 11. 1 Th e regulato r i s behin d th e ai r cleane r i n th e engin e compartmen t 12.2 a Removin g th e apertur e cove r fro m th e dynam o 12.2 b Hookin g u p sprin g t o pul l th e brus h fro m th e holde r 1 2.2 c Und o th e brus h termina l ta g scre w 12. 4 Brus h an d sprin g correctl y fitte d ...

  • Volkswagen Transporter 1600 (1977) - page 146

    13. 2 Removin g th e starte r to p bolt . Not e th e bol t hea d an d ter - mina l (arrowed ) fo r th e mai n cabl e connectio n 13. 3 D o no t confus e th e tw o nut s o n th e solenoi d 14.2 a Undoin g th e connectin g stra p termina l nu t 14.2 b Removin g th e solenoi d retainin g screw s 14. 3 Unhoo k th e solenoi d fro m th e operatin g leve ...

  • Volkswagen Transporter 1600 (1977) - page 147

    14.6 a Remov e th e U cli p fro m th e en d o f th e shaf t 14.6 b an d th e shi m washer s 14.7 a Remov e th e throug h bolt s 14.7 b Tak e of f th e en d cove i 14. 8 Lif t th e yok e an d brus h holde r assembl y of f th e armatur e 14. 1 2 Refi t th e yok e s o tha t th e tongu e an d cu t ou t fi t togethe r ...

  • Volkswagen Transporter 1600 (1977) - page 148

    Chapte r 9/Electrica l syste m 14 9 holder s an d pus h the m t o on e sid e s o tha t th e pressur e i s relieved . Th e yok e complet e wit h th e brus h holde r mountin g plat e ma y the n b e draw n ,of f th e armature . Watc h ou t fo r th e washer s o n th e en d o f th e shaf t (photo) . 9 T o rene w th e brushes , tw o ma y b e detache d b ...

  • Volkswagen Transporter 1600 (1977) - page 149

    FIG . 9. 5 WINDSCREE N WIPE R SPINDL E AN D BEARIN G ASSEMBL Y 7 Cap nut (early models had clamp nuts) 2 Lock washer 3 Wiper arm 4 Bearing cover 5 Circlip 6 Nut 7 Washer 8 Seal 9 Shaft bearing 10 Spring washer 11 Brass nut 12 Spring washer 13 Wiper shaft 15. 1 Th e fus e bo x i s locate d unde r th e das h panel . 15. 4 Pr e Augus t 196 9 th e rela ...

  • Volkswagen Transporter 1600 (1977) - page 150

    Chapte r 9/Electrica l syste m 15 1 o f th e remova l procedure . Whe n refittin g th e uni t t o th e ca r mak e sur e th e spindle s ar e a t righ t angle s t o th e windscreen . Th e mountin g hol e i n th e fram e i s slotte d t o permi t adjustment . Th e earthin g stri p contac t a t th e mountin g scre w shoul d b e clean . 9 Th e sealin g w ...

  • Volkswagen Transporter 1600 (1977) - page 151

    23. 1 Th e sto p ligh t switc h i s connecte d t o th e fou r wa y distribu - to r jus t ove r th e maste r cylinde r 24. 2 Pris e ou t th e ca p fro m th e centr e o f th e steerin g whee l 24. 5 A s a las t resor t tr y movin g th e adjustin g scre w 25.1 a Tw o screw s t o remov e th e rea r lam p len s 25. 1 b Tw o screw s t o remov e th e fron ...

  • Volkswagen Transporter 1600 (1977) - page 152

    15 3 FIG . 9. 6 BRAK E LIGHT/BRAK E PRESSUR E WARNIN G SWITCHES . CIRCUI T DIAGRA M (SEC . 23 ) a. b. current feed to brake lights 1 Rim securing screw 2 Rubber washer 3 Rim FIG . 9. 7 SEALE D BEA M HEADLAMP S - COMPONENT S (SEC . 25 ) 4 Securing ring screw 5 Retaining ring screw 6 Retaining ring 7 Sealed beam unit 8 Aiming ring with 2 aiming screw ...

  • Volkswagen Transporter 1600 (1977) - page 153

    15 4 FIG . 9. 8 HEADLAM P BEA M AIMIN G DIMENSION S SEALE D BEA M UNITS . RIGH T SID E DI P A Distanc e betwee n lam p centre s (108 0 mm/42. 5 ins ) B Heigh t o f lam p centr e abov e groun d (measur e o n vehicle ) D 2. 0 ins/5 0 m m H Lam p horizonta l centr e lin e V Lam p vertica l centr e line s FIG . 9. 9 HEADLAM P BEA M AIMIN G DIMENSIONS , ...

  • Volkswagen Transporter 1600 (1977) - page 154

    Chapte r 9/Electrica l syste m 15 5 plu g i s connecte d th e correc t wa y roun d — gre y wir e positive . 3 Al l doubl e filamen t bulb s fi t onl y on e wa y roun d becaus e th e wattag e o f eac h filamen t i s differen t - th e flashe r filamen t bein g brighter . Fo r thi s reaso n th e bayone t pin s ar e offset . Se e tha t yo u ge t the ...

  • Volkswagen Transporter 1600 (1977) - page 155

    26. 2 Eas e th e pane l forwar d an d disconnec t th e speed o cabl e 26. 3 Th e connection s a t th e rea r o f th e pane l 28.1 a Und o th e screw s holdin g th e switc h t o th e colum n (Not e steerin g whee l ha s bee n remove d t o giv e a bette r photo ) 28.1 b Disconnec t th e cable s t o tak e th e switc h of f 25. 5 Tur n th e bul b holde ...

  • Volkswagen Transporter 1600 (1977) - page 156

    Chapte r 9/Electrica l syste m 15 7 secon d perio d an d measure s to e an d cambe r an d print s ou t th e answe r i n degree s an d minutes . Th e ignitio n an d chargin g system s ar e measure d b y th e resistance s o f th e variou s circuits . I t i s importan t tha t al l connection s ar e clea n an d tha t cabl e size s ar e standard . Th e ...

  • Volkswagen Transporter 1600 (1977) - page 157

    15 8 WIRIN G DIAGRA M 196 8 T O 196 9 EXCEP T NORT H AMERICA N MODEL S A B C C 1 D L U E 1 E 2 E 6 E 9 F F 1 G H H 1 J J 1 J 3 K 1 K 2 K 3 K 4 K 5 L 1 L 2 L 6 L 7 L 8 M 1 M 2 M 3 M 4 M 5 M 6 M 7 M 8 N N 1 N 3 0 P 1 P 2 P 3 P 4 Q 1 Q 2 Q 3 Q 4 R S T T 1 V V 2 Batter y Starte r Generato r Regulato r Ignition/starte r loc k Windscree n wipe r switc h ...

  • Volkswagen Transporter 1600 (1977) - page 158

    15 9 WIRIN G DIAGRA M 196 8 T O 196 9 NORT H AMERICA N MODEL S A B C C 1 D E F G H H 1 J J 1 J 2 J 3 J 4 J 5 J 6 J 7 J 9 K 1 K 2 K 3 K 4 K 5 K 6 K 7 K 8 K 9 L 1 L 2 M l M 2 N 0 0 1 0 2 P 1 P 2 P 3 P 4 Q 1 Q 2 Q 3 Q 4 R R 1 S S 1 T 1 U 1 U 2 W X 1 X 2 Y Y 1 Z Z 1 Batter y Starte r Generato r Regulato r Ignition/starte r switc h Windshiel d wipe r sw ...

  • Volkswagen Transporter 1600 (1977) - page 159

    WIRIN G DIAGRA M 197 2 ONWARD S EXCEP T NORT H AMERICA N MODEL S O A B C C 1 D E E 1 E 2 E 3 E 6 F F 1 F 2 F 3 F 4 G G 1 H H 1 J J 2 K K 1 Batter y Starte r Generato r Regulato r Ignition/starte r loc k Windscree n wipe r switc h Lightin g switc h Tur n signa l switc h (switc h fo r han d dimme r an d headligh t flasher ) Emergenc y flashe r switc ...

  • Volkswagen Transporter 1600 (1977) - page 160

    WIRIN G DIAGRA M 197 2 ONWARD S EXCEP T NORT H AMERICA N MODEL S O ) ...

  • Volkswagen Transporter 1600 (1977) - page 161

    WIRIN G DIAGRA M 197 2 ONWARD S NORT H AMERICA N MODEL S A Batter y B Starte r C Generato r C 1 Regulato r D Ignition/starte r switc h E Windshiel d wipe r moto r E 1 Lightin g switc h E 2 Tur n signa l an d headligh t dimme r switc h E 3 Emergenc y flashe r switc h E 6 Switc h fo r interio r light , rea r E 9 Fa n moto r switc h E1 5 Heate d rea r ...

  • Volkswagen Transporter 1600 (1977) - page 162

    M WIRIN G DIAGRA M 197 2 ONWARD S NORT H AMERICA N MODEL S s ...

  • Volkswagen Transporter 1600 (1977) - page 163

    H 105*1 FIG . 9.1 2 INSTRUMEN T CONSOL E (CLOC K NO T SHOWN ) Turn signal warning lights Generator warning light High beam warning light Parking light warning light Oil pressure warning light 6 Instrument illumination light 7 Warning light holder 8 Fuel gauge 9 Speedometer ...

  • Volkswagen Transporter 1600 (1977) - page 164

    Chapte r 1 0 Suspension , damper s an d steerin g For information applicable to later models, see Supplement at end of manual Contint s Specification ! Wheelbei B 2,40 0 m m (94. 5 in ) Trac k Front - dru m brake s 138 4 m m (54. S In ) Fron t - dis c brake s 138 6 m m (54. 6 in ) Rea r 142 6 m m (56. 1 in ) Turnin g circl e Kerb s 11. 3 m (37. 1 f ...

  • Volkswagen Transporter 1600 (1977) - page 165

    7 3 FIG.10. 1 FRON T AXL E ASSEMBL Y (Se c 1 an d 17 ) 7 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Caliper bolt Shouldered bolt Spring washer Caliper Hub cap Bearing nut clamp screw Bearing clamp nut Thrust washer Taper roller bearing, outer Brake drum Socket head screw Brake disc Wheel hub Backplate bolt Spring washer Front brake 17 Bolt 18 Spring washer ...

  • Volkswagen Transporter 1600 (1977) - page 166

    Chapte r 10/Suspension , damper s an d steerin g Steerin g geometr y To e i n *fron t whee l unpresse d .. . .. . .. . .. . 1571. 6 m m •fron t whee l 1 5 K g pressur e .. . .. . .. . 570. 6 m m rea r whee l t5'±10 ' *Not e to e i n variation s o f 1 571. 6 m m eithe r wa y ar e acceptabl e f Cambe r angl e Fron t whee l + 40' 1 2 ...

  • Volkswagen Transporter 1600 (1977) - page 167

    1.1 a Vie w o f th e steerin g knuckle s an d bal l joint s (whee l an d dru m remove d t o giv e cleare r photo ) 1.1 b Genera l vie w o f th e fron t suspensio n an d steerin g linkag e fro m beneat h I • 2.1 a Greas e poin t i n th e centr e o f th e axl e bea m an d 2.1 b on e a t eac h en d FIG.10. 2 DIMENSION S O F SPECIA L LEVE R REQUIRE D ...

  • Volkswagen Transporter 1600 (1977) - page 168

    Chapte r 10/Suspension , damper s an d steerin g 16 9 Prio r t o 197 2 th e steerin g gea r wa s o f th e wor m an d pe g typ e bu t i n 197 2 thi s change d t o wor m an d roller . A t th e sam e tim e th e steerin g rati o wa s increase d makin g th e steerin g lighte r tha n before . Th e linkag e fro m th e steerin g gea r t o th e wheel s requ ...

  • Volkswagen Transporter 1600 (1977) - page 169

    3.7 a Bearin g packe d wit h greas e 3.7 b fi t th e oute r bearin g 3.7 c followe d b y th e thrus t washe r 3.7 d replac e th e clam p nu t t 3. 8 an d tighte n th e socke t hea d ser e 4. 1 Th e plu g ma y b e replace d b y a greas e nippl e ...

  • Volkswagen Transporter 1600 (1977) - page 170

    Chapte r 10/Suspension , damper s an d steerin g ar m the y shoul d b e renewe d b y a specialis t wit h th e correc t tools . I f yo u hav e alread y carrie d th e dismantlin g o f th e fron t axl e a considerabl e wa y i t ma y b e simples t t o disconnec t th e brake s an d steerin g gea r a s wel l an d detac h th e whol e assembl y fro m th e ...

  • Volkswagen Transporter 1600 (1977) - page 171

    17 2 1 8 1 Frame 2 Diagonal arm 3 Bearing housing 4 Spring plate 5 Torsion bar 6 Inner and outer bushes FIG.10. 3 REA R SUSPENSIO N ASSEMBL Y (Se c 9 ) 7 Cover for spring plate bearing 13 Bolt 8 Bolt 14 Washer 9 Spring washer 15 Spring washer 10 Bolt 16 Nut 11 Spring washer 17 Shock absorber 12 Bolt 18 Bolt 19 Lock washer 20 Spring washer 21 Nut 22 ...

  • Volkswagen Transporter 1600 (1977) - page 172

    Chapte r 10/Suspension , damper s an d steerin g 17 3 clockwis e o n th e oute r en d b y 8 spline s (60° ) th e ne t increas e i n th e angl e wil l b e 65 ° 20 ' les s 60 ° whic h i s 5 ° 20 ' an d a s nea r a s on e ca n get . I n exampl e B B th e inne r en d o f th e ba r i s rotate d clockwis e 3 spline s (24 ° 30' ) an d ...

  • Volkswagen Transporter 1600 (1977) - page 173

    17 4 nea r suspensio n sprin g plat e angl e bod y lin e angl e FIG.10. 4 REA R SUSPENSION . SPRIN G PLAT E SETTIN G ANGL E CALCULATION - (Se c 10 ) B FI G 10. 5 ADJUSTIN G REA R WHEE L CAMBE R B Y ALTER - IN G THE TORSIO N BA R ANGLE S THROUG H ROTATIO N O F TH E DIAGONA L ARM S (Sec . 10 ) FI G 10. 6 ADJUSTIN G REA R WHEE L TOE-I N USIN G SPECIA ...

  • Volkswagen Transporter 1600 (1977) - page 174

    17 ! FIG . 10. 7 WOR M AN D PE G STEERIN G GEA R - COMPONENT S (Se c 13 ) Bolt and washer 7 Spring washer Adjusting screw and lock nut 8 Special washer Cover for gear case 9 Taper rollers Nut 10 Lever shaft Tab washer 11 Peg Washer 12 Dust seal 13 Bolt and washer 14 End cover 15 Shim 16 Retaining ring 17 Ball race 18 Steel balls 19 Steering worm 20 ...

  • Volkswagen Transporter 1600 (1977) - page 175

    17 6 15. 4 Th e bal l join t betwee n th e dra g lin k an d th e dro p arm ; not e th e numbe r o f thread s visibl e befor e undoin g th e clam p FIG . 10. 8 WOR M AN D ROLLE R STEERIN G GEA R - CROS S SECTION S (Se c 13 ) 1 Roller shaft dust seal 2 Oil seal 3 Roller shaft 4 Worm shaft 5 Housing 6 Lower ball thrust bearing 7 Upper ball thrust bear ...

  • Volkswagen Transporter 1600 (1977) - page 176

    Chapte r 10/Suspension , damper s an d steerin g 1 3 Steerin g gea r - overhau l 1 Th e decisio n t o dismantl e an d rebuil d a steerin g gea r assem - bl y wil l depen d t o a larg e exten t o n th e availabilit y o f parts . I t i s inevitabl e tha t i f adjustment s fai l t o rectif y pla y adequatel y the n mos t o f th e interio r component s ...

  • Volkswagen Transporter 1600 (1977) - page 177

    17 8 FIG . 10. 9 STEERIN G COLUM N ASSEMBL Y (Se c 14 ) 1 Nut 2 Fillister head screw 3 Lock washer 4 Cancelling ring 5 Steering wheel 6 Cheese head screw 7 Spring washer 8 Plastic clamping ring 9 Cap 10 Seal 11 Screw 12 Lock plate 13 Nut 14 Flange 15 Cotter pin 16 Slotted nut 17 Spring washer 18 Screw 19 Coupling disc 20 Column shaft 21 Insulating ...

  • Volkswagen Transporter 1600 (1977) - page 178

    Chapte r 10/Suspension , damper s an d steerin g 17 9 axl e tube ) b y fittin g th e securin g bolt s an d nut s an d tightenin g the m t o th e specifie d torques . 1 7 Fron t axl e assembl y - remova l an d replacemen t 1 I f th e fron t axl e assembl y i s badl y wor n o r damage d requirin g a considerabl e amoun t o f repai r (o r tota l repla ...

  • Volkswagen Transporter 1600 (1977) - page 179

    FIG . 10.1 0 STEERIN G LINKAG E AN D BAL L JOINT S (Se c 15 ) / Screw 2 Lock washer 3 Split pin 4 Nut 5 Spring washer 6 Screw 7 Washer 8 Steering damper 9 Sleeve 10 Bush 11 Split pin 12 Nut 13 Left tie rod 14 Right tie rod 15 Nut 16 Spring washer 17 Screw 18 Clip 19 Tie rod ball joint R.H.thread 20 Tie rod ball joint L.H. thread 21 Dust seal 22 Loc ...

  • Volkswagen Transporter 1600 (1977) - page 180

    Chapte r 10/Suspension , damper s an d steerin g 18 1 2 1 Faul t diagnosi s Befor e diagnosin g fault s i n th e mechanic s o f th e suspensio n an d steerin g itself , chec k tha t an y irregularitie s ar e no t cause d by: — p Bindin g brake s Incorrec t 'mix ' o f radia l an d cross-pl y tyre s Incorrec t tyr e pressure s Misalignmen ...

  • Volkswagen Transporter 1600 (1977) - page 181

    Chapte r 1 1 Bodywor k an d underfram e For modifications, and information applicable to later models, see Supplement at end of manual Content s Genera l descriptio n .. . .. . .. . .. . .. . .. . 1 Maintenanc e - bodywor k .. . .. . .. . .. . .. . 2 Maintenanc e - upholster y an d floo r covering s .. . .. . 3 Mino r bod y damag e - repai r .. . . ...

  • Volkswagen Transporter 1600 (1977) - page 182

    Chapte r 1 1 /Bod y 18 3 th e hea d linin g clea n i n th e sam e wa y a s th e upholstery . Whe n usin g liqui d cleaner s insid e th e ca r d o no t over-we t th e surface s bein g cleaned . Excessiv e dam p coul d ge t int o th e seam s an d padde d interio r causin g stains , offensiv e odour s o r eve n rot . I f th e insid e o f th e ca r get ...

  • Volkswagen Transporter 1600 (1977) - page 183

    18 4 FIG.11. 1 FLOO R FRAM E 1 Side member, rear 2 Side member insert, rear 3 Cross tube with flange 4 Outrigger, rear 5 Outrigger, centre 6 Support, rear member 7 Heater tube 8 Side member, front 9 Outrigger, front 10 Side member insert 11 Seat box 12 Stiffener between side member inserts 13 Cross member, front 14 Front cross support FIG.11. 2 BOD ...

  • Volkswagen Transporter 1600 (1977) - page 184

    Chapte r 1 1 /Bod y 18 5 wil l ensur e tha t a ver y smoot h finis h i s imparte d t o th e fille r a t th e fina l stage . A t thi s stag e th e den t shoul d b e surrounde d b y a rin g o f bar e metal , whic h i n tur n shoul d b e encircle d b y th e finel y 'feathered ' edg e o f th e goo d paintwork . Rins e th e repai r are a wit h ...

  • Volkswagen Transporter 1600 (1977) - page 185

    9.4 a Chec k stra p lubricatio n 9.4 b Doo r hing e lubricatio n 10.1 a Remov e th e windo w winde r handl e 10. 1 b Pris e ou t th e doo r latc h finge r plat e 10.1 c Remov e th e escutcheo n retainin g scre w 10. 3 D o no t forge t th e rubbin g washe r behin d th e windo w winde r handl e ...

  • Volkswagen Transporter 1600 (1977) - page 186

    Chapte r 1 1 /Bod y 18 7 vehicl e b y fou r countersun k crosshea d screws . Ther e i s als o a doo r chec k stra p whic h i s hel d b y a pin . Th e pi n ca n b e take n ou t afte r retainin g cli p i s take n of f it s lowe r end . 2 T o slacke n th e hing e screw s a n impac t screwdrive r i s essen - tial . Similarl y fo r tightenin g the m pro ...

  • Volkswagen Transporter 1600 (1977) - page 187

    18 8 FIG . 11. 3 DOO R LATC H STRIKE R PLAT E (Se c 15 ) Slackening of screws enables plate to be moved in any direction FIG.11. 4 CA B DOO R HANDL E AN D LOC K CYLINDE R - EARL Y MODEL S (Se c 16 ) / 2 3 4 Operating pin Rotary spring Circlip Locating ring 5 6 7 Spring Lock cylinder housing Casket 8 9 10 Setscrew Seal O • ring 11 Lock cylinder 12 ...

  • Volkswagen Transporter 1600 (1977) - page 188

    Chapte r 1 1 /Bod y 18 9 1 7 Slidin g doo r mechanis m - descriptio n an d adjustmen t 1 Th e slidin g doo r run s i n thre e channels . A t th e bottom , a rolle r bracke t fitte d a t th e fron t corne r support s weigh t an d guide s th e doo r i n a channe l fitte d alon g th e botto m o f th e doo r opening . I n th e centr e a rolle r bracke ...

  • Volkswagen Transporter 1600 (1977) - page 189

    19 0 FIG.11. 6 SLIDIN G DOOR-LOWE R ROLLER S AN D BRACKE T FIG.11. 7 SLIDIN G DOO R - TO P GUID E ROLLE R AN D (Se c 17 ) BRACKE T (Se c 17 ) Arrows indicate movement and shims Arrow indicates roller movement for door position adjustment. Bracket screws are loosened to move roller into channel recess. FIG.11. 8 SLIDIN G DOO R - HING E LIN K SHOWIN ...

  • Volkswagen Transporter 1600 (1977) - page 190

    FIG.11.1 1 REMOTECONTRO L LATC H (LEFT ) AN D CENTR E LATC H (RIGHT ) SHOWIN G POSITION S O F SETTIN G SCREW S O R PIN S (Se c 17 ) FIG.11.1 3 SLIDIN G DOO R - REMOVIN G TH E DOO R RETAINE R CATC H (Se c 18 ) FIG.11.1 4 SLIDIN G DOO R - CENTR E RUNNE R COVE R COMPONENT S (Se c 18 ) 7 Beading 2 Cover 3 Retaining strip FIG.11.1 5 SLIDIN G DOO R - CEN ...

  • Volkswagen Transporter 1600 (1977) - page 191

    19 2 7 Return spring 2 Hinge link 3 M6nut 4 Lock washer 5 Roller bracket 6 Guide block FIG.11.1 6 SLIDIN G DOOR - HING E LIN K ASSEMBL Y COMPONENT S (Se c 18 ) 7 Roller and bearing 8 Phillips screw 9 Spring washer 10 M 6 nut (thin) 11 Housing 12 Circlip 13 Pivot 14 Pin 15 Operating cam 16 Spring washer 17 M8 nut 18 Washer 19 Lower locking lever 20 ...

  • Volkswagen Transporter 1600 (1977) - page 192

    Chapte r 11/Bod y 19 3 4 Chec k th e hekjh t o f th e rea r en d o f th e roof . Thi s i s don e b y swingin g th e lea f spring s ou t t o on e sid e an d the n slackenin g th e hexago n loc k nu t an d screw . Mov e th e lifte r pi n i n th e elongate d hol e t o correc t th e height , (Fig.11.17) , a t th e sam e tim e th e rea r guide s ca n b ...

  • Volkswagen Transporter 1600 (1977) - page 193

    Chapte r 1 2 Supplement : Revision s an d informatio n o n late r model s Content s Introductio n .. . .. . .. . .. . .. . .. . .. . 1 Revise d routin e maintenanc e schedule s (196 8 t o 1974 ) .. . 2 Specification s .. . .. . .. . .. . .. . .. . .. . 3 Engin e .. . .. . .. . .. . .. . .. . .. . .. . 4 Pushro d tube s - remova l wit h engin e i n ...

  • Volkswagen Transporter 1600 (1977) - page 194

    Chapte r 12/Supplemen t 19 5 3 Specification s Fuel system Carburetto r (Augus t 197 5 on ) Typ e Mai n je t Ai r correctio n je t Pilo t je t Auxiliar y fue l je t Enrichmen t Needl e valv e washe r Idl e spee d C O level ' Fue l octan e Ignition system Distributo r (fro m Augus t 197 5 - Numbe r 04 3 90 5 20 5 L ) Timin g Dwel l angl e Centr ...

  • Volkswagen Transporter 1600 (1977) - page 195

    19 6 Chapte r 12/Supplemen t 1 0 1 1 1 2 Fuse identification Supplementar y heate r (Nort h America ) Rea r interio r lam p (u p t o 1974 ) Supplementar y heate r (Nort h America ) Heate d rea r windo w Windscree n wiper s Reversin g lamp s Fue l gaug e Kickdow n (automati c transmissio n excep t 1976 ) Directio n indicator s Generato r warnin g la ...

  • Volkswagen Transporter 1600 (1977) - page 196

    Chapte r 12/Supplemen t 19 7 4 Engin e Pushrod tubes - renewal with engine in position 1 Damage d o r leakin g pushro d tube s ca n b e renewe d withou t th e necessit y o f removin g th e engine . 2 Refe r t o Chapte r 1 an d remov e th e rocke r cover . 3 Remov e th e rocke r shaf t an d withdra w th e pushrods . 4 Usin g a screwdriver , leve r t ...

  • Volkswagen Transporter 1600 (1977) - page 197

    19 8 Chapte r 12/Supplemen t FIG.12. 5 CROS S SECTIONA L VIE W O F MODIFIE D 1ST/2N D SYNCHR O HU B GROOV E (ARROWED ) FIG.12. 6 GEARCHANG E RO D BUS H FITTIN G DIAGRA M a 43.03 in (1093 mm) 9 Hav e th e engin e a t th e norma l operatin g temperatur e an d idlin g speed . Mak e sur e tha t th e chok e i s full y OFF . 1 0 Pul l th e distributo r v ...

  • Volkswagen Transporter 1600 (1977) - page 198

    19 J FIG.12. 7 TYP E 09 1 GEARBO X FINA L DRIV E AN D BELLHOUSIN G COMPONENT S / 2 3 4 Clutch bellhousing Input shaft Circlip Reverse gear 5 6 7 8 Differential Gasket Gearcase Adjusting ring 9 10 11 12 Lockplate Plate Driving flange Thrust washer 13 14 Circlip Plastic plug ...

  • Volkswagen Transporter 1600 (1977) - page 199

    20 0 Chapte r 12/Supplemen t FIG.12. 8 REMOVIN G A N ADJUSTE R RIN G USIN G TH E SPECIA L TOO L FIG.12. 9 REMOVIN G PINIO N DRIVESHAF T RIN G NU T USIN G TH E SPECIA L TOO L nut . Mak e sur e thi s i s marke d als o befor e movin g it . Th e bracket s whic h suppor t th e revers e selecto r cros s shaft s ar e als o adjust - abl e an d mus t b e ma ...

  • Volkswagen Transporter 1600 (1977) - page 200

    FIG.12.1 0 MAINSHAF T COMPONENT S ; 2 3 4 4th speed gear Baulk ring Needle bearing Circlip 5 6 7 3rd/4th synchro assembly Circlip Baulk ring 8 9 10 11 3rd speed gear Needle bearing Mainshaft Spring 12 13 14 15 Synchro sleeve Synchro hub Sliding keys Spring ...

  • Volkswagen Transporter 1600 (1977) - page 201

    20 2 FIG.12.1 1 COMPONENT S O F TH E PINIO N DRIVESHAF T 1 3 5 6 1 Anti-rotation ring 2 1st gear needle bearing 3 Combined 1st gear needle bearing/locknut 4 Tapered roller bearing Pinion shaft Circlip 7 4th speed gear 8 Spacer spring 9 Circlip 10 3rd speed gear 11 2nd speed gear 12 2nd gear needle bearing 13 Baulk ring 14 Circlip 15 1st/2nd synchro ...

  • Volkswagen Transporter 1600 (1977) - page 202

    Chapte r 12/Supplemen t 20 3 FIG.12.1 2 REMOVIN G ANTI-ROTATIO N RIN G FRO M 1ST/2N D SYNCHR O HU B betwee n th e baul k rin g an d th e gea r teet h wit h feele r blades . Th e ga p shoul d b e withi n th e followin g limits : 1st/2nd 0.023 and 0.071 in (0.60 and 1.80 mm) 3rd/4th 0.023 and 0.075 in (0.60 and 1.9 mm) Otherwis e rene w th e componen ...

  • Volkswagen Transporter 1600 (1977) - page 203

    FIG.12.1 3 COMPONENT S O F TH E GEA R CARRIE R / 2 3 4 5 Intermediate selector lever Ball joint Link Selector lever shaft Coil springs 6 7 8 9 10 Stop Intermediate selector lever bracket 3rd'/4th selector rod Reverse selector rod 1st/2nd selector rod 11 12 13 14 15 16 Detent hole plug Detent ball Detent spring Detent sleeve Plug Pinion drivesh ...

  • Volkswagen Transporter 1600 (1977) - page 204

    20 5 FIG.12.1 5 SYNCHR O SID E T O SID E SPRIN G LOCATIO N FIG.12.1 4 3RD/4T H SYNCHR O HU B AN D SLEEV E Line on hub must be at bottom (black arrow) when groove on sleeve is uppermost (white arrow) FIG.12.1 6 1ST/2N D SYNCHR O HU B AN D SLEEV E FIG.12.1 7 SECTIONA L VIE W O F DETENT/SELECTO R SHAF T ARRANGEMEN T SHOWIN G POSITIO N O F INTERLOC K P ...

  • Volkswagen Transporter 1600 (1977) - page 205

    206 Chapte r 12/Supplemen t (shoulde r toward s 2n d gear) , circlips , space r spring , 4t h gea r (shoulde r toward s spring ) an d th e circlip , bu t not e th e followin g points . 6 9 Befor e pressin g th e 1st/2n d synchr o ont o th e driveshaft , fi t a ne w anti-rotatio n ring . 7 0 Onc e 3r d spee d gea r i s fitted , us e feele r blade s ...

  • Volkswagen Transporter 1600 (1977) - page 206

    Chapte r 12/Supplemen t 20 7 9 9 Adjus t th e unio n nu t o n th e revers e rocke r leve r suppor t unti l th e suppor t i s jus t fre e t o slid e i n an d ou t o f it s clam p sleeve . 10 0 Pus h th e revers e (middle ) selecto r shaf t unti l it s circli p contact s th e fac e o f th e gea r carrier . Han d tighte n th e unio n nut . 10 1 Withou ...

  • Volkswagen Transporter 1600 (1977) - page 207

    20 8 Chapte r 12/Supplemen t / Housing 2 Bush FIG . 12.2 4 GEARSHIF T HOUSIN G COMPONENT S 3 Inner selector lever 4 Spacer Seal 12 1 Se t th e left-han d differentia l bearin g adjustin g rin g t o it s originall y marke d positio n (se e paragrap h 54 ) b y screwin g i t i n th e tur n whic h i t wa s backe d off . 12 2 Refi t th e component s det ...

  • Volkswagen Transporter 1600 (1977) - page 208

    Chapte r 12/Supplemen t 20 9 FIG.12.2 5 GIRLIN G TYP E CALIPE R ; 2 3 Disc/hub Caliper body Bleed screw 4 5 6 Anti-rattle spring Pad retaining pin Pin securing clip 7 8 9 Piston seal Piston Dust excluder 10 11 12 Retaining ring Anti-squeal shim Friction pad o f th e calipe r together . I f flui d i s see n t o b e leakin g fro m th e joint , rene w ...

  • Volkswagen Transporter 1600 (1977) - page 209

    21 0 1 5 2 2 FIG.12.2 6 BRAK E MASTE R CYLINDE R (WITHOU T SERVO ) / 2 3 4 5 6 7 Stop lamp switch Stop lamp switch Sealing plug Master cylinder body Stop bolt Spring Support ring 8 9 10 11 12 13 14 Washer Cup seal Cup washer Secondary piston Piston seal Piston seal Stroke limiting screw 15 16 17 18 19 20 21 Stop sleeve Spring Support ring Washer Cu ...

  • Volkswagen Transporter 1600 (1977) - page 210

    21 1 FIG.12.2 7 BRAK E MASTE R CYLINDE R (WIT H SERVO ) / 2 3 4 5 6 7 Plug Stop bolt Stop lamp switch Stop lamp switch Master cylinder body Sealing ring Spring 8 9 10 11 12 13 14 Support ring Cup seal Cup washer Secondary piston Piston seal Piston seal Stroke limiting screw 15 16 17 18 19 20 21 Stop sleeve Spring Support ring Cup seal Support ring ...

  • Volkswagen Transporter 1600 (1977) - page 211

    21 2 Chapte r 12/Supplemen t FIG.12.2 8 INSTRUMEN T PANE L RETAININ G CLIP S th e pane l an d twis t th e pane l securin g clip s unti l th e pane l ca n b e draw n forwar d fa r enoug h fo r th e speedomete r cabl e t o b e disconnected . 4 Disconnec t th e wirin g havin g firs t identifie d th e wire s an d terminals . 5 Remov e th e instrumen t ...

  • Volkswagen Transporter 1600 (1977) - page 212

    Chapte r 12/Supplemen t 21 3 a - To starter b - Diagnosis leads X - Battery cut-out switch FIG. 12.3 0 ALTERNATO R TES T CIRCUI T A - Ammeter (0 to 50 amps) V - Voltmeter 10 to 18V) R - Load resistance (0.2 to 2 ohms/50 amp) Speedometer drive cable - renewal 1 1 Th e speedomete r i s drive n throug h a flexibl e cabl e fro m th e left-han d fron t ...

  • Volkswagen Transporter 1600 (1977) - page 213

    21 4 Chapte r 12/Supplemen t 2 5 Th e alternato r system s us e a negativ e earth . Car e mus t b e take n no t t o revers e th e batter y connectio n o r damag e t o th e diode s wil l b e extensive . Neve r ru n th e alternato r wit h th e outpu t wir e disconnected . 2 6 Alway s disconnec t th e batter y completel y i f a n outsid e chargin g op ...

  • Volkswagen Transporter 1600 (1977) - page 214

    1 7 FIG.12.3 2 EXPLODE D VIE W O F TH E ALTERNATO R ; 2 3 4 5 Spacer Fan end plate Bearing Bearing retainer Washer 6 7 8 9 Cover plate Regula tor/brush assembly Body Insulating plate 10 11 12 13 14 Diode assembly Stator Rotor Washer Bearing 15 16 17 Spacer Spring Drive end plate ...

  • Volkswagen Transporter 1600 (1977) - page 215

    216 FIG.12.3 3 WINDSCREE N AN D HEADLAM P WASHE R SYSTE M 1 Washer fluid reservoir 2 Headlamp washer pump 3 Headlamp washer jets 4 Windscreen washer jets 5 Windscreen washer pump FIG.12.3 4 STEERIN G COLUM N LOC K HOUSIN G SECURIN G SCREW S FIG.12.3 5 STEERIN G COLUM N LOC K (T O HOUSING ) SCREW S O N LATE R MODEL S ...

  • Volkswagen Transporter 1600 (1977) - page 216

    Chapte r 12/Supplemen t 21 7 FIG.12.3 6 STEERIN G COLUM N LOC K AN D SWITCHE S (197 5 ON ) 1 2 3 4 5 6 Direction indicator switch Wiper switch Column/switch upper trim Cover plate Spacer Switch/lock housing 7 8 9 10 Lock cylinder Lock spear head screw Ignition switch Column/switch lower trim housin g lowe r tri m t o th e bas e o f th e steerin g l ...

  • Volkswagen Transporter 1600 (1977) - page 217

    21 8 Chapte r 12/Supplemen t rolle r shaf t t o preven t the m cuttin g th e lip s o f th e oi l sea l a s i t i s fitted . 9 Appl y greas e t o th e lip s o f th e sea l an d driv e i t int o positio n usin g a piec e o f tubing . 1 0 Refi t th e dro p arm , correctl y aligned , fi t a ne w lockplat e an d tighte n th e nu t t o a torqu e wrenc h ...

  • Volkswagen Transporter 1600 (1977) - page 218

    ^ ...

  • Volkswagen Transporter 1600 (1977) - page 219

    Conversio n factor s Inche s (in ) X Fee t (ft ) X Mile s X Volume (capacity) Cubi c inche s (c u in ; in 3 ) X Imperia l pint s (Im p pt ) X Imperia l quart s (Im p qt ) X Imperia l quart s (Im p qt ) X U S quart s (U S qt ) X Imperia l gallon s (Im p gal ) X Imperia l gallon s (Im p gal ) X U S gallon s (U S gal ) X Mass (weight) Ounce s (oz ) X ...

  • Volkswagen Transporter 1600 (1977) - page 220

    Safet y first ! Professiona l moto r mechanic s ar e traine d i n saf e workin g proce - dures . Howeve r enthusiasti c yo u ma y b e abou t gettin g o n wit h th e jo b i n hand , d o tak e th e tim e t o ensur e tha t you r safet y i s no t pu t a t risk . A moment' s lac k o f attentio n ca n resul t i n a n accident , a s ca n failur e t o ...

  • Volkswagen Transporter 1600 (1977) - page 221

    Inde x Ai r cleane r 58,19 7 Ai r contro l flap s - 4 8 Alternato r adjustment - 214 descriptio n an d precautions - 21 3 driveshaft-21 4 overhau l - 214 remova l an d refittin g - 214 testin g i n positio n - 214 Auxiliar y heate r 5 2 Axle , front , remova l 17 9 Axl e shafts - 11 5 B Balljoin t steerin g - 17 7 suspensio n - 16 9 Batter y chargi ...

  • Volkswagen Transporter 1600 (1977) - page 222

    Inde x headlam p washers - 21 4 ' heate d rea r window-21 2 horn - 15 1 instrumen t pane l - 20 9 lamps - 15 1 regulato r - 14 5 speedomete r driv e cabl e - 21 3 starte r moto r - 14 5 steerin g colum n switche s - 21 4 stoplight - 15 1 warnin g buzzer - 21 2 windscree n washe r - 15 1 windscree n wiper - 149,15 1 wirin g diagram s - 157,15 9 ...

Manufacturer Volkswagen Category Car

Documents that we receive from a manufacturer of a Volkswagen Transporter 1600 (1977) can be divided into several groups. They are, among others:
- Volkswagen technical drawings
- Transporter 1600 (1977) manuals
- Volkswagen product data sheets
- information booklets
- or energy labels Volkswagen Transporter 1600 (1977)
All of them are important, but the most important information from the point of view of use of the device are in the user manual Volkswagen Transporter 1600 (1977).

A group of documents referred to as user manuals is also divided into more specific types, such as: Installation manuals Volkswagen Transporter 1600 (1977), service manual, brief instructions and user manuals Volkswagen Transporter 1600 (1977). Depending on your needs, you should look for the document you need. In our website you can view the most popular manual of the product Volkswagen Transporter 1600 (1977).

Similar manuals

A complete manual for the device Volkswagen Transporter 1600 (1977), how should it look like?
A manual, also referred to as a user manual, or simply "instructions" is a technical document designed to assist in the use Volkswagen Transporter 1600 (1977) by users. Manuals are usually written by a technical writer, but in a language understandable to all users of Volkswagen Transporter 1600 (1977).

A complete Volkswagen manual, should contain several basic components. Some of them are less important, such as: cover / title page or copyright page. However, the remaining part should provide us with information that is important from the point of view of the user.

1. Preface and tips on how to use the manual Volkswagen Transporter 1600 (1977) - At the beginning of each manual we should find clues about how to use the guidelines. It should include information about the location of the Contents of the Volkswagen Transporter 1600 (1977), FAQ or common problems, i.e. places that are most often searched by users in each manual
2. Contents - index of all tips concerning the Volkswagen Transporter 1600 (1977), that we can find in the current document
3. Tips how to use the basic functions of the device Volkswagen Transporter 1600 (1977) - which should help us in our first steps of using Volkswagen Transporter 1600 (1977)
4. Troubleshooting - systematic sequence of activities that will help us diagnose and subsequently solve the most important problems with Volkswagen Transporter 1600 (1977)
5. FAQ - Frequently Asked Questions
6. Contact detailsInformation about where to look for contact to the manufacturer/service of Volkswagen Transporter 1600 (1977) in a specific country, if it was not possible to solve the problem on our own.

Do you have a question concerning Volkswagen Transporter 1600 (1977)?

Use the form below

If you did not solve your problem by using a manual Volkswagen Transporter 1600 (1977), ask a question using the form below. If a user had a similar problem with Volkswagen Transporter 1600 (1977) it is likely that he will want to share the way to solve it.

Copy the text from the picture

Captcha
New picture

Comments (0)