Volkswagen Vanagon Repair Manual: 1980-1991

Volkswagen repair manual index:

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A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

A

Air Conditioner
-Adapter valve VAG 1637
installing 87.15
-Air distribution system
components 87.9
-Component locations 87.2
-Compressor (Sanden SD510)
replacing 87.16
- Evaporator
removing/installing 87.14
- Evaporator housing
disassembling/assembling 87.12
removing 87.10
-Expansion valve
removing/installing 87.14
- Fuses, locations 87.4
-Refrigerant system
capacity 87.7
cautions and warnings 87.7
controls 87.6
discharging 87.8
-Relays, locations 87.5
Alignment
-See Wheels
Alternator
-Alternator/Regulator
checking 27.18
-Heater blower fan
removing/replacing 27.22
-Indicator light, troubleshooting 27.23
-Mount, adjusting 27.22
- Removing/Installing 27.15
- Repairing
45A, 65A 27.16
90A 27.17
-System layout 27.19
- V-belt
adjusting 27.21
replacing 27.21
-Voltage regulator 27.20

B

Battery
-Charging 27.5
-Checking 27.4
- Electrolyte level 27.4
- Filler caps 27.7
- Location(s) 27.8
-Nomenclature 27.2
-Safety precautions 27.4
-Troubleshooting 27.10
Body
-Acid rain, removing spots 50.6
-Adhesives materials 50.5
-Body Dimensions
door 50.4
floor 50.2
windshield 50.4
- Painting
pop-up roof/luggage carrier 50.5
- Plastics, identifying 50.5
repairing 50.5
Brakes-Hydraulic Components,
Regulator, Booster
- Brake booster assembly 47.10
checking 47.10
- Brake caliper
Girling (1980-1985) assembly 47.5
Girling/Teves (1980-1985)
disassembling/assembling 47.6
Girling/Teves (from 1986) assembly 47.7a
Teves (1980-1985) assembly 47.4
Teves (1980-1985), noise dampening plates 47.7
-Brake fluid, changing
with US 1116 47.8
without US 1116 47.8a
- Brake hydraulic system general repair notes 47.8
- Brake master cylinder assembly 47.2
- Brake pressure regulator checking 47.8a
- Brake system, bleeding with US 1116 47.8
without US 1116 47.8a
-Check valve checking 47.10
- Rear wheel cylinder assembly 47.8
Brakes-Mechanical Components
-Brake pedal/linkage assembly 46.10
- Front brake
assembly (1980-1985) 46.2
assembly (from 1986 m.y.) 46.5
pads (1980-1985) removing/installing 46.3
pads (from 1986 m.y.) removing/installing 46.5a
-Parking brake assembly 46.11
- Rear brake
assembly 46.6
shoes, adjusting 46.9
shoes, removing/installing 46.7
Bumpers
- Front bumper/spoiler 63.2
- Rear bumper 63.3

C

Camper Equipment
-Ceiling cabinet
with A/C, installing 76.9
with A/C, removing 76.7
without A/C, removing/installing 76.E
-Clothes closet installing 76.11, 76.14
removing 76.9, 76.11
- Curtains removing/installing 76.3
-Curtain rail w/fresh air duct installing 76.6
removing 76.5
- Propane tank removing/installing 76.23
- Refrigerator
air supply modification 76.25
installing 76.25
removing 76.24
- Sink cabinet installing 76.23
removing 76.15
- Storage chest w/water tank installing 76.17
removing 76.15
-Storage shelf removing/installing 76.2
w/curtain rod removing/installing 76.4
-Water faucet w/pump switch
removing/installing 76.20
-Water level sensor removing/installing 76.20
-Water pump/kitchen removing/installing 76.18
Clutch
- Bearing shaft bushing Syncro 30.9
- Brake/Clutch fluid reservoir 30.3
-Clutch assembly diesel 30.5
gasoline 30.4
Syncro 30.10
-Controls 30.2
Syncro 30.8
- Diaphragm spring 30.6
Syncro 30.11
-Hydraulic system 30.2
Syncro 30.8
- Pressure plate 30.6
air-cooled modification 30.6
Syncro 30.11
- Release bearing 30.7a
air-cooled only 30.7
- Release shaft bushing 30.3
Syncro 30.9
- Roll pin 30.3
Cooling System—Air-cooled AFC
Cooling air control flap adjusting 19.3
Cooling fan removing 19.3
Fan housing assembly 19.2
removing 19.3
Snap-lock wiring connectors installing 19.19
Thermostat
checking 19.3
V-belt
assembly 19.2
tension, adjusting 19.3
Cooling System-Diesel
Antifreeze hydrometer
checking 19.7
Coolant assembly 19.4
draining/filling 19.6
mixture ratio 19.5
pipes, replacing 19.7a
Snap-lock wiring connectors
installing 19.19
Pressure cap, checking 19.7
Cooling System-Water-cooled
Antifreeze hydrometer
checking 19.17
Coolant assembly 19.8, 19.1 1, 19.14
draining/filling 19.15
expansion tank, checking 19.18
hose layout 19.10
leak checks 19.17
mixture ratio 19.18
refill tank 19.9, 19.13
Hose spring clamps removing/installing 19.16
Hot footwell kit, installing 19.20
Radiator assembly 19.12
thermo-switch 19.12
Cruise Control -System. repairing 27.25
Troubleshooting 27.29
Current Flow Diagrams - See Electrical Wiring

D

Differential-Automatic Trans.
Adjusting ring 39.51
Assembly 39.56
Cover plate 39.51
-Differential bearing outer race 39.53
Drive flange oil seal 39.53
Final drive assembly 39.50
Governor oil seal 39.52
Pinion bearing
inner race 39.54
outer race 39.53
Pinion oil seals 39.52
Ring gear 39.56
- Ring gear/pinion
adjusting 39.57
backlash 39.61
Torque converter oil seal 39.51
Differential-Manual Trans. 091, 091/1,
4-Speed 094 5-Speed (except 4WD)
Assembly 39.2
Bearings 39.3
Housing 39.3
Pinion,, adjusting 39.10
Pinion/Side gears 39.6
Ring gear 39.3
adjusting 39.12
backlash 39.13
- Ring/Pinion gears
adjusting 39.7
Shim S3 39.11
Differential-Manual Trans.
094 5-Speed with 4WD
- Differential with lock assembly 39.20
bearing outer race 39.24
bearings 39.21 housing 39.21
pinion shafts 39.22
ring gear 39.20
- Differential without lock assembly 39.15
bearing outer race 39.19
bearings 39.16 housing 39.16
pinion shafts 39.17
ring gear 39.15
- Driveshaft flange oil seal 39.44
removing/installing 39.43
- Front final drive 39.30
adjusting rings 39.32
axle flange 39.32
circlip 39.33
housing 39.34
mounting 39.32
technical data 39.42
- Front pinion 39.39
bearing 39.40
grooved nut 39.40
turning torque 39.41
Locking pin 39.28
Pinion/Side gears 39.25
Removing 39.33
Ring gear/Pinion adjusting 39.26
Do-it-yourself Service (Appendix)
-Changing a wheel A21
- Emergency starting A25
- Fuses A22
- Headlight adjustment A25
Jack and tools A20
- Replacing bulbs A23
-Spare wheel A20
Doors-Front
Adjusting 57.5
Assembly 57.2
Glass 57.4
Guide channel 57.5
Handles 57.3
Lock/Lock rod 57.3
Loost/Broken keys
code location 57.8
Power door locks 57.6
Whistling noises
eliminating 57.10
Window regulator 57.4
Doors-Rear
Center hinge
adjusting 58.9
assembly 58.8
removing/installing 58.9
Sliding door 1980-1984
bowden cables, adjusting 58.7
door cover 58.3
door handle inner/outer 58.3
door lock buffer 58.3
lock, front 58.2
lock, rear 58.6
lock plate, remote control 58.6
lubricating 58.7
removing/installing 58.4
striker plate, adjusting 58.5
Sliding door, from 1985
assembly 58.10
central lock 58.20
door cover 58.11
handle 58.22
hinge link. adjusting 58.16
hinge link, assembly 58.21
modifications 58.11
remote control lock 58.18
removing/installing 58.12
roller guides, adjusting 58.14
striker pin, adjusting 58.15

E

Electrical Wiring-Air-cooled AFC
-1980, 1981
cautions and warnings 97.2
fresh air fan 97.23
fuse/relay panel 97.10
heater booster 97.24
main wiring diagram 97.12
rear window wiper 97.26
seat belt interlock system 97.27
-1982, 1983
cautions and warnings 97.2
fresh air fan 97.23
fuse/relay panel 97.10
heater booster 97.24
main wiring diagram 97.18
rear window wiper 97.26
seat belt interlock system (1982 only) 97.27
Electrical Wiring-Camper
Auxiliary battery 1986-1989
(man. trans.) 97.34 (also see 97.53)
Battery level indicator lights 97.30
Camper electrical equipment
1980-1985 97.32
from 1986 97.33
Water pump 97.31
Water tank level
indicator lights 97.30
Electrical Wiring-Diesel
1982
auxiliary heater BA6 (Canada only) 97.47
cautions and warnings 97.2
fuse/relay panel 97.10
heater booster 97.49
main wiring diagram 97.36
current track index 97.36
rear window wiper 97.26
-1983
auxiliary heater BA6 (Canada only) 97.47
cautions and warnings 97.2
fuse/relay panel 97.10
heater booster 97.49
main wiring diagram 97.41
current track index 97.41
rear window wiper 97.26
Electrical Wiring-General
Battery/Ground cables 97.9a
disconnecting/connecting 97.6
Cautions and Warnings 97.2
Dashboard wiring harness 97.7
Engine/Body
ground connections 97.6
Fuse/Relay panel, removing
1980-1985 97.10
from 1986 m.y. 97.10a
How to read wiring diagrams 97.4
Main wiring harness 97.8
Starter cable routing 97.9
Symbols used in wiring diagrams 97.5
Troubleshooting 97.3
-Working on the electrical system 97.3
Electrical Wiring-Water-cooled
-Air conditioning 1984, 1985 97.137
1986-1988 97.139
from 1989 97.142
Automatic transmission
1986-1989 97.146
from 1990 97.219
Auxiliary battery
1986-1989 auto. trans. 97.221
from 1990 97.224 See also 97.29
Auxiliary heater BA6
from 1987 Canada only 97.148
Auxiliary heater BBW46 (Syncro)
1986-1988 Canada 97.151
from 1989 Canada 97.155
Central locking system
1986 97.165
1987-1989 97.162 from 1990 97.226
Crankcase ventilation heat element
1985 97.165 1986 97.166
Cruise control auto. trans.
1986 97.168
1987-1989 97.176
from 1990 97.229
Cruise control man. trans.
1986 97.174
1987-1989 97.171
from 1990 97.232
Daytime running lights (Canada)
to Dec. 1989 97.234
from Dec. 1989 to May 1990 97.238
from May 1990 97.241
Differential lock 1986-1989
Syncro 97.178
Heated driver's seat
1986 97.179
1987-1989 Canada 97.181
from 1990 Canada 97.244
-Main wiring diagram
1983, 1984 97.54 1985 97.60 1986
up to VIN G 055 689 97.67
from VIN G 055 690 97.85
1987 97.102
1988, 1989 97.119
from 1990 97.201
- Power mirrors
1986 up to VIN G 105 000 97.183
1986 from VIN G 105 001 97.185
from 1987 97.185
- Power windows 1986 97.187
from 1987 97.189
Radio 1986 97.191
Rear footwell heater blower 1983-1985 97.194 Stereo radio 1987-1989 97.195
Stereo radio with amplified speakers from 1988 97.197
Stereo radio with 4 speakers from 1990 97.246
450-Watt radiator cooling fan
1986-1989 97.200
Emission Controls
Air-cooled AFC
Calif. 1981 26.4
Calif. except 1981 26.3
Catalytic converter checking 26.11
EGR valve 26.5
USA (except Calif.) and Canada 26.2
Diesel 26.6
Water-cooled Digit ant assembly 26.9
Oxygen sensor water-cooled Digijet 26.8
Engine-Air-cooled AFC
Assembling
crankcase 13.6, 13.14
sheet metal 13.2
-Camshaft 13.14
Carbon deposits, reducing 15.25
Carrier/Support 13.5
Compression pressure
checking 15.2
values 2a
Connecting rod 13.16
Crankshaft
assembly 13-16
circlips 13.16
end play 13.10
oil seals 13.9
pilot bearing 13.17
Cylinder 13.11
Cylinder head 15.2
Disassembling
crankcase 13.6
sheet metal 13.2
Distributor
drive gear 13.16
driveshaft 13.8
installing 13.9
Flywheel 13.9
Gasoline additive 15.25
Hydraulic valve lifters 15.6
Installing 10.5
Lubrication
assembly 17.2
oil cooler 17.2
oil pressure switch 17.2
oil pump 17.2
-Piston rings 13.11
Pistons 13.11
Removing 10.2
Rocker arm shaft 15.3
-Torque converter drive plate 13.9
Valves
assembly 15.2
dimensions 15.3
guides 15.4
hydraulic lifters 15.6
seats 15.4
springs 15.2
Engine-Diesel
Camshaft assembly 15.10
end play 15.15
oil seal 15.15
radial clearance, checking 15.15a
run-out 15.15
-Camshaft drive belt 13.18
-Compression pressure checking 15.16
values 2a
-Connecting rod 13.27
bearing clearance 13.30
bolts 13.30
side clearance 13.30
-Crankshaft 13.22
bearing caps 13.22
drive belt cover 13.21
a end play 13.24
journal sizes 13.23
-main bearing clearance 13.25
oil seal
drive belt side 13.26
flywheel side 13.25
sprocket bolt 13.21
-Cylinder block 13.27
bore dimensions 13.30
clearance 13.30
- Cylinder head assembly 15.8
bolts 15.9
distortion 15.11
gasket 15.9
Cylinder head gasket 13.19, 13.31
Flywheel 13.23
Installing 10.7
Intermediate plate 13.23
Intermediate shaft oil seal 13.22
Lubrication system
assembly 17.4
oil cooler 17.4
oil filter 17.4
oil pan 17.4
oil pressure switch 17.4, 17.6
oil pump 17.4
Pilot bearing 13.22
Piston 13.27
clearance 13.29
diameter 13.29
height 13.31
identification 13.31
marking 13.28
pin 13.28
ring end gap 13.29
ring side clearance 13.29
rings 13.27
Removing 10.6
Valve assembly 15.10
Engine-Water-cooled
- Assembling/Disassembling 13.32
- Camshaft 13.50
- Carbon deposits, reducing 15.31
- Carrier/Support 13.37a
- Compression pressure checking 15.20
values 2a
- Crankshaft assembly 13.52
circlips 13.54
drive gear 13.54
end play 13.40
oil seals 13.39
pilot bearing 13.56 r
eplacing (1.9L) 13.57
- Cylinder 13.43
- Cylinder head assembly 15.17
installing 15.23
sealing 15.23. 15.26
- Distributor
drive gear 13.38
driveshaft 13.38
installing 13.38
- Engine block assembly 15.22
- Flywheel 13.40
- Gasoline additive 15.31
- Installing 10.10
- Lubrication system assembly 17.7
crankcase breather, heating pipe 17.9
oil pressure switch 17.9
oil pump 17.9
- Piston pin hole burrs removing 13.47
- Pistons 13.43
classifications 13.44
pin 13.44
rings 13.45
- Pushrod tubes replacing 15.25
-Removing 10.8
-Torque converter drive plate 13.
-V-belt pulley 13.34, 13.42
- Valves
assembly 15.17
dimensions 15.18
guides 15.20
hydraulic lifters 15.23
seats, refacing 15.18
springs 15.18
Exhaust System
-Air-cooled AFC
Calif. 1981 26.4
Calif. except 1981 26.3
USA (except Calif.) and Canada 26.5
-Catalytic converter checking 26.11
- Diesel 26.6
-Oxygen sensor
- water-cooled Digijet 26.8
- Water-cooled Digifant 26.9
Digijet 26.7

F

Fuel Injection-Air-cooled AFC
-AFC system check 24.15
-Air filter housing 24.8
-Auxiliary air regulator 24.8
-Cold-start valve 24.5
-Control unit/Wiring harness 24.12
- Deceleration valve 24.7
-Double relay 24.13
- Full throttle enrichment switch 24.13
- Idle speed/CO 24.10
- Injector resistance 24.6
- Injector spray pattern/leak checking 24.7
- Intake air sensor housing 24.8
-Intake air/temp. sensors 24.9
-Oxygen sensor/Wiring 24.16
- Pressure regulator 24.5
-Speed limit switch 24.14
-System components 24.2
Calif. 24.4
USA (except Calif.)
and Canada 24.3
-Temperature sensor II 24.13
-Thermo-time switch 24.6
- Voltage supply/
series resistance 24.6
Fuel Injection-Diesel
- Cold start cable 23.5
- Engine speed 23.5
- Fuel cut-off solenoid 23.5
- Fuel delivery valve/housing 23.7
- Fuel filter water indicator kit
installing 23.10
- Fuel injectors 23.8
- Injection pump 23.6
-Injection pump/valve timing 23.3
- Injection system 23.2
-Injection timing 23.4
Fuel Injection-Water-cooled Digifant
-Deceleration fuel shutoff 24.60
- Electrical testing 24.61
-Fuel injection system
components 24.48
repairing 24.46
- Fuel injectors, checking 24.56
-Full throttle enrichment
checking 24.60
- Idle speed/CO content
checking/adjusting 24.50
- Idle stabilizer
checking 24.53
- Intake air sensor
checking 24.57
-Oxygen sensor
checking 24.54
-Pressure regulator
checking 24.55
-Safety precautions 24.42
-Technical data 24.43
-Throttle valve
basic adjustment 24.37
-Throttle valve switch 24.58
Fuel Injection-Water-cooled Digijet
-Air filter housing 24.27
-Auxiliary air regulator 24.27
-Control unit/Wire harness 24.31
checking 24.35
- Data/Specifications 24.18
-Double relay 24.32
- Fuel injectors 24.25
troubleshooting 24.38
- Full throttle enrichment switch 24.34
checking/adjusting 24.29
- Idle speed/CO
checking/adjusting 24.29
- Intake air sensor 24.28
housing 24.27 -Pressure regulator 24.25
-System check 24.20
System components 24.22
early version 24.24
late version 24.24a
-Temperature sensor 124.28
-Temperature sensor 1124.32
-Throttle valve/deceleration/
idle switch 24.33
Fuel Supply-Air-cooled AFC
-Accelerator linkage/cable
auto. trans. 20.8
man. trans. 20.6
- Fuel filter 20.4
- Fuel gauge sending unit 20.4
-Fuel pump 20.7 - Fuel system 20.2
leak checking 20.5
- Fuel tank 20.4
Fuel Supply-Diesel
-Accelerator linkage/cable 20.14
- Fuel gauge sending unit 20.13
-Fuel system 20.10
leak checking 20.13
- Fuel tank 20.12
Fuel Supply-Water-cooled Digifant
-Accelerator linkage/cable
adjusting 20.32
auto. trans. 20.31
man. trans. 20.30
-Charcoal filter 20.33
- Fuel gauge sending unit 20.29
-Fuel pump 20.29
- Fuel system 20.26
leak checking 20.21
- Fuel tank 20.28
Fuel Supply-Water-cooled
Digijet
-Accelerator linkage/cable
auto. trans. 20.23
man. trans. 20.22
-Charcoal filter valve 20.20
- Fuel filter 20.18
- Fuel gauge sending unit 20.18
- Fuel pump 20.19
- Fuel system 20.16
- Fuel tank 20.18
- Leak checking 20.21

G

Glass, Window Regulators
-Gluing rubber window seals from 1986 MY
rear lid window 64.5
side window 64.4
sliding door window 64.5
-windshield 64.3
- Power window motor from 1986 MY
installing 64.7
removing 64. 6
- Sliding window replacing guides 64.2

H

Heater-Auxiliary BBW 46
- Combustion air blower
adjusting 82.32
removing/installing 82.32
-Components 82.20
- Electrical wiring 82.24
- Engine coolant system
draining/refilling 82.35
- Felt pad
removing/installing 82.29
- Flame head
removing/installing 82.33
- Flame switch
checking 82.30
removing/installing 82.30
- Fuse S24
removing/installing 82.33
-Glow plug, checking 82.30
- Heater core
removing/installing 82.33
- Metering pump
flow rate checking 82.35
-Operating 82.25
- Recirculation pump
removing/installing 82.32
-Series resistor
removing/installing 82.32
-Temperature sensor
checking 82.31
removing/installing 82.31
- Waterflow 82.22
Heater Booster-Air-cooled AFC
-Air circulation blower 82.7
-Assembly 82.3
-Combustion air blower 82.3
-Control flaps 82.8
-Defroster/Footwell flaps 82.7
- Flame switch 82.5
- Fuel pump 82.6
- Glow/Spark plug 82.3
- Heater booster/components 82.2
- Heater lever switch 82.8
- Ignition coil 82.6
- Overheat switch 82.7
-Safety switch 82.7
-Temperature regulating switch 82.5
-Temperature sensor 82.6
-Troubleshooting 82.10
Heater Booster-Water-cooled
- Air circulation blower 82.17
-Combustion air blower 82.14
-Control valve 82.17
- Flame switch 82.15
- Fuel pump 82.17
-Glow/Spark plug 82.14
new style 82.14a
- Heater booster/Components 82.12
-Heater housing 82.14
- Ignition coil 82.17
-Overheat switch 82.15
-System components 82.12
-Temperature regulating switch 82.16
Temperature sensor 82.16
Troubleshooting 82.18
Heater/Ventilation
Controls/Assembly
air-cooled
with fresh air fan 80.8
without fresh air fan 80.5
water-cooled 80.12
- Flap housing
air-cooled
with fresh air fan 80.10
water-cooled 80.14
Heater, additional
under rear bench seat 80.16
- Heater control flap cable 80.4
-Heater/Fresh air box housing
splitting 80.15
- Rear air duct 80.3
- System components
air-cooled 80.2
water-cooled 80.11
Hoods/Lids
- Rear door/lock cylinder 55.2
- Rear lid spring 55.4
- Rubber door stop 55.3
- Striker plate 55.3

I

Identification-Numbers/Codes
-Automatic trans. 4
- Engine 2
- Front final drive Syncro 3b
- Manual trans. 3
- Type/Model/Assemblies 2
-VIN (Vehicle Identification Number) 2 and Foreword
Ignition Distributor and Settings
-Air-cooled AFC
CAN/USA, (except Calif.) 8
Calif. 9
-Water-cooled Digijet 10
- Digifant 11
Ignition System-Air-cooled AFC
-California 28.8
distributor 28.11
distributor drive 28.20
Hall control unit/generator 28.14
Hall ignition, troubleshooting 28.17
idle stabilizer 28.16
ignition/distributor settings 28.9
ignition timing 28.11
rotor 28.10
vacuum advance/retard 28.13
vacuum unit 28.12
wires/coil, checking 28.10
- USA (except Calif.)
and Canada 28.2
distributor 28.6
distributor drive 28.4
ignition/distributor settings 28.3
ignition timing 28.5
rotor 28.4
vacuum unit/advance 28.7
wires/coil, checking 28.4
Ignition System-Diesel
-Glow plug light
troubleshooting 28.27
-Quick glow
troubleshooting 28.24
Ignition System-Water-cooled
Digifant
- Distributor, installing 28.44
- Hall sender, checking 28.43
- Ignition and injection system
repairing 28.39
Ignition distributor 28.40
- Ignition settings 28.41
- Ignition switching function
checking 28.44
Ignition timing 28.42
Ignition System-Water-cooled
Digijet
-Centrifugal advance 28.34
-Distributor driveshaft 28.32
- Hall control unit 28.36
Hall generator 28.37
- Idle stabilizer 28.38
-Ignition cable connectors
new style 28.30a
- Ignition coil 28.32
- Ignition distributor/Hall generator 28.29
- Ignition distributor/settings 28.29
- Ignition wires/connectors 28.31
- Rotor 28.31
- Suppressor connectors 28.32
-Trigger wheel 28.38
-Vacuum advance/retard 28.35
- Vacuum unit 28.35
Instruments, Radio
1980-1984
-Cigarette lighter, replacing 90.31
- Fuel gauge
checking 90.5, 90.9
troubleshootinq 90.13
- Fuel gauge sender removing/installing
90.11 Instrument cluster
assembling/disassembling 90.2, 90.6
removing/installing 90.10
Light emitting diodes (LED) checking 90.5
identifying 90.4, 90.8
- Multi-point connector identifying 90.4, 90.8
-Speedometer calibration 90.30
Speedometer cable removing/installing 90.10
- Voltage stabilizer 90.4, 90.8
Instruments, Radio
From 1985
- Cigarette lighter, replacing 90.3
-Coolant temperature gauge locating 90.14
troubleshooting 90.21
- Dynamic oil pressure system assembly 90.22
removing/installing 90.23
troubleshooting 90.24
Fuel gauge, locating 90.14
troubleshooting 90.20
- Instrument cluster assembling/disassembling 90.1
removing/installing 90.10
-Light emitting diodes (LED) checking 90.18
identifying 90.18
-Muiti-point connector identifying 90.18
-Speedometer calibration 90.30
- Speedometer cable
installing
from VIN 25 H 040 185, except Syncro 90.17
removing/installing 90.17
-Voltage stabilizer, checking 90.h
Instruments, Radio
From 1990
-Heidelberg VI fixed coded radio coding a new or remanufactured radio 90.32
reactivating radio after reconnecting power 90.33
unlocking an electronically controlled radio 90.34

L

Lifting Vehicle
- Hoist/Floor jack 5
Lights
- Bulb holder 94.6
- Headlight 94.4
aerodynamic 94.5a
adjusting 94.5
mounting frame 94.5
removing 94.5
- Ignition key, deburring 94.3a
-Intermittent windshield wiper 94.4
Steering column covers 94.3
lock 94.3
lock cylinder 94.4
switches 94.2
-Tail light 94.6
-Turn signal switch 94.3
Lubrication System—Air-cooled AFC
-Assembly 17.2
-Oil cooler 17.2
-Oil pressure switch 17.2
-Oil pump 17.2
Lubrication System-Diesel
-Assembly 17.4
-Oil cooler 17.4
-Oil filter 17.4
-Oil pan 17.4
-Oil pressure switch 17.4
-Oil pump 17.4
Lubrication System-Water-cooled
-Assembly 17.7
- Heating pipe,
crankcase breather 17.9
-Oil pressure switch 17.9
-Oil pump 17.9
Maintenance Schedules
- Lubrication, Emissions and Vehicle Maintenance Schedules (Appendix)
air-cooled, water-cooled and diesel models 1982-1985 A28
water-cooled models from 1986 A32

M

Mirrors
-Outside, electric
adjustment range, increasing 66.3
assembly 66.4
glass, removing/installing 66.2

R

Radio
-See Instruments, Radio
Refrigerator
- See Camper Equipment
Roof
- Front headliner, installing 75.7a
removing 75.7
- Luggage rack, removing 75.8
- Pop-up roof, installing 75.3
removing 75.4
-Pop-up roof seal, installing 75.6a
removing 75.6
- Roof vent, installing 75.7
removing 75.6a
Seat belts
-Automatic 3-point seat belts
retrofit installation 68.5
-Automatic rear 3-point seat belts
retrofit installation 68.7
-Automatic 3-point left center seat
belt, retrofit installation 68.10
- Illuminated vanity mirrors
replacing bulbs 68.13
- Seat belts, inspection 68.2
webbing defects 68.4
- Template measurements 68.6
Seats
-Armrest, removing/installing 72.4
-Armrest, adjustable
assembly 72.5
removing/installing 72.6
- Front seat, removing/installing 72.2
- Front seat backrest
removing/installing 72.2
- Heated seats
component locations 74.2
heat elements 74.21
- Rear seat with storage locker
removing/installing 77.2
-Roof beds, boards
removing/installing 77.3

S

Steering
- Power steering
checking for leaks 48.7
pressure/flow limiting valve 48.11
suspension changes 48.6
system layout 48.6
technical data 48.6
- Power steering pump removing/installing 48.9
repairing 48.10
- Power steering pump pressure
checking 48.7
- Power steering system
filling/bleeding 48.7
-Steering column switches 48.2
-Steering drive/gear 48.4
Steering lock assembly 48.3
-Steering wheel/column 48.2
-Tie rods 48.4
removing 48.5
-Troubleshooting 48.12
Sunroof
- Panel
adjusting 60.3
guide plate adjusting 60.4
height alignment front 60.3
rear 60.4
parallel adjustment 60.4
removing/installing 60.2
-Trim panel removing/installing 60.3
-Water drains, cleaning 60.6
rear drain hose, replacing 60.6
Suspension-Front
- Assembly
early version 40.2
late version 40.7
- Ball joints assembly 40.10
lower 40.12
-Coil spring removing/installing 40.3
- Lower control arm
bushing, early version 40.6
bushing, later version 40.8
removing/installing 40.3
Shock absorber removing/installing 40.4
-Steering arm, checking 40.12
-Steering knuckle
assembly 40.12
checking for wear 40.12
modification, grease seal 40.13
modification, brake disc interference 40.14
-Subframe wax preservation 40.14
-Upper control arm bushing 40.5
lower 40.6
removing 40.5
wax preservation 40.14
-Wheel bearing adjusting 40.11
assembly 40.10
Suspension-Front, Syncro
-Axle shaft, assembly 40.29
length 40.30
removing/installing 40.28
- Ball joints
pressing 40.25
-Coil spring
removing/installing 40.20
-Components assembly 40.15
- CV joint, inner
assembly 40.29
disassembling/assembling 40.33
pressing 40.31
-CV joint, outer
assembly 40.29
disassembling/assembling 40.32
removing 40.31
-Guards, drive shaft/engine
removing/installing 40.28
- Lower control arm bushings 40.19
- Shock absorber removing/installing 40.20
-Subframe, components 40.26
installing 40.28
removing 40.27
- Upper control arm bushings 40.19
removing/installing 40.18a
-Wheel bearing pressing 40.24
-Wheel bearing housing assembly 40.23
removing/installing 40.17
-Wheel hub assembly 40.23
pressing 40.24
Suspension-Rear
- Axle shaft assembly 42.4, 42.7
removing/installing 42.4
-Constant velocity joint
assembly 42.7
disassembling/assembling 42.8
removing/installing 42.8
- Rear axle assembly 42.4
- Rear wheel suspension
assembly 42.2
- Shock absorber
bushing/sleeve 42.3
-Trailing arm bushing 42.3
-Wheel bearings, inner/outer
grease seals 42.5
removing/installing 42.5
-Wheel studs
removing/installing 42.6

T

Tarpaulin
- Canada 61.2
Technical Data
-Capacities Appendix 27
-Cylinder Location Appendix 27
-Digifant General 12
-Engine Appendix 27
-Vehicle identification Appendix 26
Tires
-Rotating 44.1 a
Torque Converter
- Bushing 32.3
-Code letter 4, 32.2
- Draining 32.2
- Installing 32.3
-Oil seal 32.3
Towing
- Procedure 6, 7
Transmission 4-speed 091
-Adjusting rings 35.3
-Assembly 35.2
-Clutch housing/
mechanism 35.12
- Differential 35.4
-Drive flange 35.3, 35.4
oil seal 34.18, 35.15
-Gear carrier/Gearshift
housing 35.6, 35.18
-Gear carrier housing
assembly 35.8, 35.16
- Gears
1st gear needle bearing 35.27
3rd gear end play 35.29
-Gearshift lever 34.3
- Gearshift linkage 34.2
assembly 34.3
adjusting 34.4
bearing plate 34.4
- Installing 34.15
-Interlock/detent plungers 35.17
- Lever bearing plate 34.4
- Main shaft assembly 35.9, 35.20
ball bearing 35.23
oil seal 35.13
- Pinion needle bearing 35.23, 35.29
- Pinion shaft assembly 35.9, 35.24
- Rear main shaft 35.5
- Release shaft bushing 35.13
- Removing 34.14
- Retaining ring 35.7
- Reverse gear 35.14
end play 35.17
shaft circlip 35.15
- Rocker lever shaft 35.19
- Selector shaft 35.19
-Shift forks 35.10
-Shift rod 34.3
-Starter bushing 35.13
- Synchronizers
1st/2nd gear 35.26, 35.28
3rd/4th gear 35.21
circlips 3rd/4th gear 35.21, 35.26
ring identification 35.30
-Tapered roller bearing 35.26
-Transmission housing 35.14
Transmission 4-speed 091/1
-Adjusting rings 35.32
installing 35.35
marking/removing 35.34
- Assembly 35.32, 35.36
mounting in repair stand 35.34
-Clutch housing assembly 35.42
- Differential 35.35
- Drive flange 35.32
circlip, installing 35.35
installing 35.35
oil seal 34.18
removing 35.34
- Gear carrier 35.44
assembling 35.40
assembly 35.36
cover 35.44
installing 35.39
removing 35.38
- Gears
1st/2nd, removing 35.36
3rd, end play 35.59
3rd, installing 35.59
3rd, removing 35.56
- Gear ratios 34.9, 35.60
- Gearshift lever 34.6
bearing 34.6
-Gearshift linkage 34.6
assembly 34.6 adjusting 34.8
bearings 34.6
- Installing 34.7
- Lever bearing plate 34.6
- Lubricant specifications 34.9, 35.60
- Main shaft 35.49
assembly 35.48
ball bearing 35.51
lock ring 35.52
needle bearing 35.51
oil seal 35.43
rear, removing/installing 35.35a
- Pinion shaft 35.55
assembly 35.54
needle bearings 35.57
roller bearings 35.56
- Removing 34.16
- Retaining ring 35.37
installing 35.40
removing 35.38
- Selector shaft
modifications 35.60a
parts for 35.60d
- Shift forks/synchronizers
modifications 35.60b
parts for 35.60d
-Shift rod bushing 35.46
-Shift rod mounting 34.7a
- Shift shaft oil seal 35.46
- Starter bushing 35.43
- Synchronizers
1 st/2nd gear 35.58
3rd/4th gear 35.50
-Technical data 34.1a
-Transmission housing 35.45
assembling 35.39
disassembling 35.38
Transmission 5-speed 094
-Adjusting rings 35.62
installing 35.65
marking/removing 35.64
-Assembly 35.62, 35.66
mounting in repair stand 35.64
-Clutch housing assembly 35.74
- Differential 35.65
- Drive flange 35.62
installing 35.65
oil seal 34.18
removing 35.64
-Gear carrier 35.76
assembling 35.70
assembly 35.66
cover 35.76
cover 35.76
installing 35.69
removing 35.68
- Gears
1st, shim 35.72
2nd, removing 35.88
3rd/4th, removing 35.88
4th, end play 35.91
4th, installing 35.91
-Gearshift lever 34.10
bearing 34.10
-Gearshift, adjusting 34.12
assembly 34.10
- Installing 34.16
- Lever bearing plate 34.10
-Main shaft 35.81
assembly 35.80
ball bearing 35.83
lock ring 35.84
needle bearings 35.83
oil seal 35.75
rear, removing/installing 35.65a
-Modifications to trans. manufactured prior to Dec. 15, 1982 35.65b
- Pinion shaft 35.87
assembly 35.86
needle bearings 35.89
roller bearings 35.88
-Removing 34.16
- Retaining ring 35.67
installing 35.70
removing 35.68
- Shift rod bushing 35.78
- Shift shaft oil seal 35.78
- Starter bushing 35.75
-Synchronizer rings checking 35.90
identification 35.92
- Synchronizers 2nd/3rd gear 35.90
4th/5th gear 35.82
assembling 35.90
checking 325.82
installing 35.90
removing 35.82, 35.88
-Technical data 34.1b
-Transmission housing 35.77
assembling 35.69
disassembling 35.68
Transmission 5-speed 094 4WD
-Adjusting rings
installing 35.96
marking/removing 35.95
- Assembling/Disassembling 35.99
-Assembly 35.94, 35.98, 35.105
-Axle flange
installing 35.96
removing 35.95
- Bearing
installing/checking 35.123
removing 35.122
inner race, removing 35.122
-Clutch housing 35.111
- Differential lock components 34.24
- Differential lock control
repairing 34.26
- Differential lock servo 34.25, 35.96
- Drive flange seal, installing 35.115
- Drive pinion 35.121
- Driveshaft flange, removing 35.104
- Flange nut
loosening/tightening 35.104
- Flange seal, installing 35.104
-Gear carrier 35.107, 35.116
disassembling/assembling 35.108
- Gears
1st, 2nd and 3rd, removing 35.122
- Gearshift linkage assembly 34.20
adjusting 34.21 -Housing 35.113
- Installing 34.23
-Intermediate housing
removing 35.106
- Low gear idler, removing 35.106
-Low gear shim, measuring 35.101
- Lower gear bearing
removing/installing 35.126
- Main shaft 35.117
bearing, removing/installing 35.119
- Main shaft seal
removing/installing 35.12
- Needle bearing
inner race
loosening/tightening 35.123
outer race, installing 35.126
outer race, removing 35.125
removing/installing 35.115
-Output housing 35.103
- Output shaft bearing
removing/installing 35.114
- Rear driveshaft, measuring 35.97
- Removing 34.22
- Reverse gear idler
removing/installing 35.106
-Shift rod bushing
removing/installing 35.115
-Shift shaft seal
removing/installing 35.114
- Starter bushing
removing/installing 35.112
-Synchronizer rings
identification 35.127
-Technical data 34.19
- 1 st/2nd gear synchronizer
checking/installing 35.124
-3rd gear, installing 35.125
-3rd/4th gear synchronizer 35.118
installing 35.119
Transmission, Automatic
-Accelerator cable/linkage
090 except code letters NH 37.12
code letters NH only 37.14
-Apply shell 38.10 -ATF
checking/filling 37.9
dipstick changes 37.9
troubleshooting 37.9a
-Direct/Reverse/Forward clutches
installing 38.11
- Final drive
oil seal 37.10
- Forward clutch 38.8, 38.17
-Governor
disassembling/assembling
090 code letters NG 38.22
removing/installing
090 except code letters NG 38.23
- Governor drive gear 38.14
- Installing
090 except code letters NH 37.5
090 code letters NH only 37.6
- Kickdown lever modification
090 code letters NH, NK 38.39
- Manual valve 38.35
- Modifications 37.19
-Oil pump 38.8, 38.22
-Operating rod 38.35
-Operation 37.17, 37.19
- Parking lock 38.34
- Parking lock modification
090 code letters NH, NK 38.39
- Pressure test procedure 37.18
- Pump shaft 38.3
Removing
090 except code letters NH 37.4
090 code letters NH only 37.6
- Reverse planetary gear set 38.12
Reverse planetary ring gear 38.14
Selector lever assembly 37.2
-Selector lever cable 37.3
-Separation plate
090 code letters NG 38.26
090 code letter NG
from trans. no. 17 07 0 38.28
090 code letters NH, NK 38.37
- Shift points 37.19
Spacer springs and rollers 38.15
Spring table
090 code letters NH, NK
up to trans. no. 16 07 0 38.30
090 code letters NG from trans. no. 17 07 0 38.32
-Technical data
code letters NG, NH 37.1a
code letters NK 37.1b
-Transfer plate
090 code letters NG 38.26
090 code letters NG
from trans. no. 17 07 0 38.28
090 code letters NH, NK 38.37
- Transmission
assembly 38.7 090
modifications
code letters NH, NK 38.37
-Transmission/Final drive assembly 38.2
end play 38.5 separating 38.3
-Transmission housing studs 38.4
-Turbine shaft 38.3
-Valve body
removing/installing 38.25
090 code letters NG 38.26
090 code letters NG
from trans. no. 17 07 0 38.29
code letters NG up to trans. no. 16 07 0
- 1st/reverse brake piston 38.10
-2nd gear brake band 38.12
-2nd gear brake band piston 38.10
disassembling/assembling 38.24
Trim-Interior
-Coffee cup bracket, repairing 70.9
Front door trim panel assembly 70.2
moisture barrier 70.2
Headlining removing/installing 70.8
Instrument panel removing 70.5
replacing 70.6
Sliding door trim panel assembly 70.3
removing 70.4

V

Vehicle Care
-Air cleaner A10
- Battery A14
-Brake fluid A13
-Cleaning products A3
-Cooling system A11
Corrosion protection A5
- Engine compartment A6
- Engine oil A7
Engine oil filter A9
Exterior A3
Fuel filter (diesel) Al 0
-Fuel supply Al
- Interior 4
- Lubricants A 7
- Maintenance A5
Power steering A10
Replacing wiper blades A16
-Tires/Wheels Al 7
- V-belt Al 2
Vehicle Identification Number (VIN)
-VIN 2, foreword

W

Wheels
- Alignment
front 44.3
rear 44.4
specifications 44.2
-Alignment Syncro determining front toe 44.3a
specifications 44.5
Windshield Wiper/Washer
-Assembly 92.2
- Rear window washer/wiper 92.5
washer pump 92.7
-Spray jets 92.4
-Troubleshooting 92.8
-Windshield washer 92.4
-Wiper arms/motor 92.3
-Wiper blade rubber insert 92.3
Wiring Diagrams
- See Electrical Wiring