july 1985 vw t25 instruction manual westfaliat3wm

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Instruction Manual

Volkswagen TransporterVolkswagen Caravelle jk

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



Congratulations on your new

Volkswagen Transporter/ Volkswagen CaravelleYou have m ade a wise decision

The Transport er Caravelle is a versatile, million-fold proven vehicle.

But, you have not only opted for an outstanding vehicle with modern, low maint enance technical components,you have also chosen quality.

A quality ensured by the most up-to-date production technology, careful selection of mater ials and conscientiouswork by all involved.

And with the Transporter / Caravelle you have also chosen one of the argest and most efficient ServiceOrganizations.

In Europe alone there are around 7,0 00 V.A.G dealerships.

We wish you pleasant m otoring:

Your

V0LKS WA G EN WER KA KTIEN GESELLSCHAFT




INTR0DUCT10 INDEX

This instruction manual is valid for all Transporter/Cara-velle models, including vehicles with four-wheel drive andexhaust emission control systems.

The manual contains many important instructions on usingyour vehicle. You should therefore read it before driving thecar so that you get to know your vehicle quickly an d knowho w to drive it and look after it properly.

Special attention is drawn to the chapter Driving tips: Thesetell you how you can drive safely, economically and environment-conscious.

However the other chapters are also important because thecorrect treatment of the vehicle serves - in addition toregular care and maintenance - to maintain the value of thevehicle and is in many cases also one of the stipulations for

the upholding of warranty claims.Further information on warranty is given in the serviceschedule. Here you will also find important data on the servicing of your car and exact details when the various servicesare due.

Please note that items of equipment marked with a * a r eonly standard on certain models or are only available as

options on certain models. Such equipment is not alwaysavailable in all export markets.

I N S T R U M E N T PA N E L 2

O P E R AT I O N 4

DRIVING T I P S 53

O P E R AT I N G I N S T R U C T I O N S ~63

C A R E A N D M A I N T E N A N C E 85

D O - I T- Y O U R S E L F 91

T E C H N I C A L D E S C R I P T I O N 104

T E C H N I C A L DATA 108

I D E N T I F I C AT I O N DATA 124

A L P H A B E T I C A L INDEX 1~26

1www.WestfaliaT3.info - a useful website for owners and enthusiasts of VW Westfalia T25 / T3 / Vanagon Campervans



f

NSTRUMENT PANE




INSTRUMENT P A N E L

Page

1 - Air vents 40

2 — Air vents 40

3 — Light switch and instrument

lighting regulator 36

4 - Bra ke warning light 33

5 — Speedometer 34

6 — W arning lamps 32

7 — Fuel gauge and coolant

temperature gaug e 35

Clock or rev counter 348 - He ated rear window switch 36

9 — Emergency light switch . . . 36

Page

10 - F og light/rear foglight switch 36

1 1 - Air vents 40

1 2 - Ashtray 51

1 3 - Loud spe aker opening

14 — Fuse box 94

15— Turn signa l and dip switch . 38

16 - Horn control

17 - Digital clo ck 34

1 8 - S teering lock/s tarter switch 2819— Auxiliary heater switch . . . 43

20 - Cold starting aid(diesel engine) 30

Page

21 — Blower switch forpassenger compartment

heat excha nger 4222 — Windscreen wiper and

was her lever 39

23 - Blower switch andlevers for ventilationand heating 40

24 — Rad io 11 or cover plate

25 - S ocke t/cigarette lighter . . . 51

26 - Air vents 40

27 - S helf 51

Knobs and warning lampsfor the differential locksand the manually controlledfour wheel drive onTransporter/Caravellesyncro - see page . . . . 23/25

Please note that some of the items ofequipment listed are only fitted on certainmodels or are optional extras.

" For vehicles with a factory fitted radio, anoperating instruction leaflet is also enclosed.

See remarks on page 101 of "Do-it-yourself"section when service installing a radio. 3www.WestfaliaT3.info - a useful website for owners and enthusiasts of VW Westfalia T25 / T3 / Vanagon Campervans



O P E R AT I O N

K E Y S

U p to six keys are supplied with thevehicle:

• two keys A

• two keys B *

• two keys D *

Key A

This key fits all locks except:

• loc kable glove box

• sliding door and rear flap with safetylocks

Key B

This key fits the lockable glove b o x *Key C

This key fits the safety locks in slidingdoor and rear flap.It can only be withdrawn when the slidingdoor or rear flap is locked.

Tag E

O n this tag is the number for key A. Thetag should be kept safety and separately(in your wallet for example) so that no

unauthorized person can order a key.The numbers of keys B and C are stamped on the key itself.

With the aid of the number, a replacement key can be ordered from a V.A.GWorkshop.

Caution

When leaving th e vehicle unattended- even only briefly - always take th

key with you.

D

J B 2 5 - 45 0

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



OPERATION

CENTRAL LOCKING SYSTEM*

With this system all the doors,and - depending on the position of thetailgate lock — also the tailgate can belocked and unlocked.

The system is operated from the driver'sdoor, and front passenger door — fromoutside with the key, from inside withthe locking knob.

NoteThe central locking system can onlyfunction correctly when the driver's andfront passenger doors are properlyclosed.

When locking, the locking knobs on alldoors must move down. If the knob on onedoor does not move at any time, open thedoor concerned and close it properly.

CautionWhen the locking knobs in the driver'sand front passenger doors are presseddown all the doors are locked. Childrenshould therefore not be left on theirown in the car because when the doorsare locked it would be difficult to helpin an emergency.

Sliding door and tailgate can be lockedor unlocked separately with the key.

To unlock the tailgate insert key and turnit to right. Hold in this position and pressbutton in.

If the key ist withdrawn in the horizontalposition, locking of the tailgate will becontrolled by the central locking systemwhen it is closed again.

When the key is withdrawn in the verticalposition and tailgate closed, it will belocked all the time. The tailgate can thenonly be unlocked with the key.

The sliding door can be secured orreleased separately with the safety catch.

NoteIf the central locking system shoulddevelop a fault, all the locks can beoperated normally, see next page.




O P E R AT I O N

DOORS

Cab doorsFrom outside both cab doors can belocked and unlocked with the key. Whenunlocking the locking knobs go up, when

locking they go down.The front passenger's door ca n be lockedfrom outside without using the key: J ustpress locking knob down and close door.

The driver's door cannot be locked whenopen by pressing the locking knob andclosing door. This prevents you fromleaving the key in the car and forgetting it.From inside the door can be locked by

pressing down the locking knobs. Aslong as the knobs are pressed down thedoors cannot be opened from inside oroutside.W e advise you no t to press the knobsdown when vehicle is in motion so thatthe door can be opened from outside inan emergency.

Sliding doorFrom outside the sliding door can belocked and unlocked with the key. Whenfully open the door is held by a hook.

To close sl iding door from outside. -P ress the door handle down to releasethe hook and slide the door firmly for-wards.From inside the sliding door is lockedby pushing down the locking catch nearthe door opening lever.As long as the catch is in the lower position the door cannot be opened from

inside or outside.When the vehicle is in motion, the doormust always be properly closed butwhen carrying passengers the lockingcatch should be left in the upper positionso that the door can be opened fromoutside in an emergency.

Child-proof catch on s li ding d o o r*

When the child-proof catch is engaged -lever on door lock turned upwards - theinner lock release lever is inoperative.The door ca n only be opened from outside with the locking catch in the upposition.




TAILGATE ENGINE COMPARTMENT COVER

To open the tailgate when key hole ishorizental, press the lock cylinder andlift tailgate.

Note

The lock cylinder can also be pressed inwith the key.

To close tailgate pull it down and slamit to gently.

After clos ing the tailgate always pull upon i t briefly to make sure that it is properly closed - otherwise th e tailgatecould open suddenly when vehicle ismoving even though the key has beenturned in lock.

Do not drive with th e tailgate open asexhaust gases are then able to enterth e vehicle interior.

The cover is in the luggage compartment. To remove cover turn the twocatches to the left.

O n the P ick-up, the flap is in the rear

panel.




OPERATION

WINDOWS

Vent wings*To open - Press button in fastener andswing fastener clear.

To close - Press window against seal atfront and turn fastener until button engages.

Sliding windowsTo open, press catch down and slide window along.

Door windowsThese windows are opened and closedwith the crank in the door t r i m .

Electrical cont rol*When the ignition is on the windowsca n be opened and closed electrically.

The switch is in t he door t r i m .

The window in the passengers door canbe controlled from the driver's side.

CautionCareless and uncontrolled closing ofthe windows can cause injuries. Takecare therefore when closing the win-

dows. When leaving the vehicle alwaystake the keys with you.




MIRRORS

Normal exterior mirror

The mirror is adjusted by moving themirror housing.

Electrically adjustable mirrors

are set by moving the lever in the driver'sdoor t r im.

Turning the knob from L to R switchescontrol from left to right mirror.

If the electrical con trol of the mirror failsat any t ime the mirrors can be adjustedby hand by pressing on the edge of themirror surface.

The electrically ope rated e xterior m irrorsare heated whe n the heated rear windowis switched on.

Anti-dazzle interior mirror*

Mirror in normal posit ion

Mirror in anti-dazzle position

- Leverto front

- Leverto rear




SEAT BELTS

Seat belts are only beneficial if they areworn at al l t imes - also in town traffic.

For this reason all vehicle occupantsshould always wear the seat belts - in

cluding those on the rear seats.With the three-point belts it is essentialto ensure that the shoulder part of beltruns roughly over the centre of theshou lder, as sho wn in Fig. on next page -on no account agains t the neck.

On the front seats the b elts can be madeto fit properly with the aid of the adjustable belt anchorage (see next page).Contact your V.A.G workshop if necessary.

Safety for chi ldrenChildren under 12 years old should becarried on the rear seat (Caravelle andCombi) and should , depending on age ,be secured there with a childs restraintsys tem or the exis t ing be l t .

Very small children should, dependingon size be carried in a reclining safetyseat or a child's seat.

Children above 6 years of age can also

use a lap belt.Larger children may use three pointbelts provided that the belt passesover centre of shoulder and not againstthe child's neck - see illustration on nextpage. If necessary, a safety seat cushioncan be used.

The installation and use of child restraintsystems must be done in accordancewith instructions of the manufacturerconce rned .

General notesOnly one person is to be secured witheach belt . Never secure two people(even children) with one belt.

On vehic les wi th arm res ts* for the sea ts,always ensure that the belt runs underneath the armrests.

The belt should not be w orn over ha rd orbreakable articles (glasses, ball pens,key rings, pipes, etc.) because this cancause injury to the body.

Loose, bulky clothing (e.g. overcoatsover jackets) affects the fit and functionof the belts.

The belt must not be jamm ed anywh ere

or rub on any sharp edges.The slot for the belt tongue must not beblocke d with paper or anything as otherwise the tongue cann ot engage properly.

The belts must be kept clean as otherwise the retractors may not work properly (see also "Care and Maintenance"section).

Seat belts which are damaged or have

been stressed in an acciden t and stretched must be replaced - preferably by aV.A.G wo rkshop . The anchorage s shouldalso be checked.

Belts can be service installed for allseating positions on vehicles not fittedwith belts at the factory. The installationof belts should be done by a V.A.Gworkshop because these workshopshave the information necessary to do

the job properly.On the Van there are no belt anchorage sin the load com partm ent.




OPERATION

Belt height adjustmentTwo anchorage points are provided inthe cab for t he upper belt attachment.This m a k e s it possible to adapt belt tobody size.

I B 3 3 - 5 1 8

Three-point inertia reel belts*

The inertia reel belt gives complete freedom of movement when pulled slowly.Sudden braking however will cause thebelt to lock.

The retractor mechani sm will also lockthe belt when accelerat ing, driving downsteep gradients or cornering hard.

Putting belt onPull t he tongue slowly an d smoothly

across your chest and hips and push itinto the lock part fitted on the seat untiltongue engages audibly (pull to check).

The shoulder part of the belt mustrun roughly across the centre of theshoulder as shown - on no account

against the neck - and be firmly incontact with the body.

The lap part of belt must always fittightly across the lap. Pull belt tight ifnecessary.

The belt must not be twisted.

The backrest of the front seats mustnot be inclined too far to the rear asotherwise t he belts are no longer effective.

Belt warning device*

The belt for the driver has a warning device.

When the ignit ion is switched on, a buzzersounds to remind you to put the belton . The buzzer stops after about 5 seconds or when belt has been put on.

Taking belt off

To release the belt, press the orange-coloured button in the lock. The tonguewill then spring ou tPass the tongue towards t he door byhand so that the retractor can roll thebelt up properly.


O P E R AT I O N



O P E R AT I O N

Lap belt*The buckle is use d in the same way as onthe three-point inertia reel belts.

Th e belt must always fit tightly.

To lengthen belt hold the tongue at rightangles to belt and pull belt through to therequired length.

The belt is easier to adjust if tongue andcap are pressed together.

To shorten belt it is only necessary topull the free end of belt.

The surplus belt length is taken up bymoving the plastic slide.

Two-point inertia reel belts

The individual s e a ts * in the passe ngercompartment are fitted with two pointinertia reel belts. They give completefree dom of movement whe n pulled slowly but sudde n braking howeve r will caus ethe belts to lock. T he automatic retractormechanism will also lock the belt whendriving down steep gradients or cornering hard.

Putting belt on

Pull the tongue slowly and smoothlyacross the hips and push it into the lockpart fitted on the seat until tongue eng

ages audibly (pull to check).Th e belt must not be twisted. Th e beltmust always fi t tightly, pull belt upslightly i f necessary.

Taking belt off

To release the belt pres s the orange coloured button in the lock. T he lock willthen spring out.

Pass the tongue across by hand so thatthe retractor can roll the belt up properly.

HEAD RESTRAINTS*

Adjusting height

Grip at sides with both hands and pullup or push down. T he upper e dge sh ouldbe roughly at eye level.

Removing and installing

Push spring clips out of slotted ringsin backres t with a small screwdriver andlift head restraint outTo install, first press the spring clipsinto the guide rings so that the straightpart of clip is at the rear. Th en pushhead restraint into the guides until itengages.

Note:The spring clips nee d not be taken out onvehicles which have a rear seat/fully reclining seat bench.

It is quite sufficient to push the protruding spring clip extensions back to therear, to enable the head restraints to beremoved.




S E AT S IN CAB

Caution

• For safety reasons the seats shouldonly be adjusted when vehicle is sta-tionary.

• Do not lower th e backrest too farwhen on the move because the seat

belts are then no longer fully effective.

|B25-396

Individual driver's and front passen-ger seats

To move seats back or forward

Lift lever (1) on outside of seat and moveseat. Then release lever and move seatfurther so that catch engages.To adjust backrest rake

Take weight off backrest, press lever (2)on right side of seat frame down andmove backrest to desired position by

moving upper part of body then releaselever.

A r m r e s t s *

The armrests on the front seats can behinged up if they are not required.

[B25-397

To take seat ou t

• S lide sea t forward into 1 st latch position.• Lift hook (3) against spring-loading,at the same time pull lever (1), hold itand slide seat past stop.

• Release hook and lever and pushseat forward out of runners.

• The hook nee d not be lifted whenputting seat back as the seat, with thelever lifted, can just be pushed past thestop.




SEATS IN PASSENGERC O M PA RT M E N T *

Tw o s e at er b e n c h *The seat is moved back or forward insame way as the single seats. The lever

is at the front of seat.When seat is moved, the backrest rakeis also altered.

To removeRemove in same way as the single seats.Bolts on right and left of backrest mustbe removed.

S w i v e l l i n g s e a t s *On vehicles with swivelling seats thepassenger 's seat can be turned 180° to

the right and the drivers seat 90° to theleft. To turn seats, push them forwardslightly or op en do or, and pull the releaselever. The handbrake must be releasedbefore turning driver's seat. (Engage agear to prevent vehicle from roll ingaway.)

The swivel l ing sea ts must a lways befacing forward when vehicle is in mo-t ion .

S e a t h e a t i n g *Seat cushion and backrest of front seatscan be heated electrically when ignitionis on. Further details are given under"switches", page 27.

Removing and ins ta l l ing cent re benchseat

Remove four wing bolts under seat .

When putt ing seat back again ensurethat the runners are clean.

H e a d r e s t r a i n t s *

The head restraints must be adjusted tobody size - see page 12.

Rem oving and instal l ing rear bench seat

The rear seat cushion is bolted to theside panels on each side with one boltunder the upholstery. Remove bolts andtake lower part of seat out.

The seat backre st is secu red at each sidewith two bolts . The bolts between seatsand backrests also serve as seat beltanchorages .

When ref i t t ing the sea t and backres t ,ensure that the seat belt is also co rrect-ly instal led.




INDIVIDUAL SEATS IN PASSENGER COMPARTMENT*

Centre seats

The centre seats can be turned and thebackrest angle adjusted.

TurningLift lever (see illustration), turn seat tothe desired po sit ion and let lever engag eagain.

If the backrest is very low, it may be ne-cessary to raise it slightly before the seatca n be turned.

Adjusting backrest angleTake weight off backrest and press leverdown (see illustration). Adjust backrestto the desired posit ion by moving upperpart of body and release lever.

Removing

Lift the lever used to turn seat and takeseat out.

The base which remains can be removedwhen carpet is lifted.

Caut ionWhen the sea t s are instal led again en-sure that base and sea t s are securedproperly.




Rear seatsThe height, seat angle and backrestangle of the rear seats can be adjusted.

Mechanica l ad jus tment

Adjus t ing sea t anglePress lever B to front or rear and adjustposition of seat as required by movingbody weight.

Adjus t ing sea t he ight

Press lever B alternately at front an drear and by moving weight of body tofront and rear lift or lower the seat.

Adjus t ing backres t angle

Take weight off backrest and turn knobA at side of backrest.

Caut ion

When vehicle is in mo tion, the bac kres tsmust not be inclined too far to the rearas otherwise the belts are no longerfully effective.


OPERATIO



B 2 5 - 3 8 2

Elec t r i c a l ad ju s t men t s

Adjus t ing sea t anglePress switch A at front -Front of seat is raisedPress switch A at rear -Front of seat is lowered

Press switch B at front -Seat is raised at rearPress switch B at rear -Seat is lowered at rear.

Adjus t ing sea t he ight

Press switche s A and B at front -Seat is raisedPress switche s A and B at rear -Seat is lowered

Adjus t ing backres t angle

Press switch C at front -Backrest moves upPress switch C at rear -Backrest moves down.

Caut ion

When vehic le i s in mo t ion , the backre s tsshould not be inclined too far to therear as otherwise the seat belts are nolonger fully effective.




REAR SEAT/FULLY RECLINING S E AT B E N C H *

The rear seat/reclining seat bench canbe converted into a large sleeping area.Before doing this, the backrests of thecenter row of seats must be tipped for-wards. The latching levers are located onthe outsides of the right and left handbackrests.To convert reclining seat bench

• R emove head res traints* -see page 12.• Un latch the backrest with the releasegrip on the reverse side of the backrest,and fold the backrest forwards.

• By pulling the release grip further towards the front, the backrest and seatbenc h are pulled in a forward direction.

• F inally, fold the sea t bac kres t fully tothe rear to form a flat sleeping area.Returning seat bench to originalposition

• P ull the sea t bac kres t upwards out ofthe horizontal position.

• S lide the seat bench, together withbackrest to the rear again.

• Push backrest back into locking posi

tion.• P ull the sea t belts out again be tweenbackrest and seat, so that they are in aposition for use.

• Install head res train ts*- se e page 12.

The space underneath the seat benca n be used as a storage compartmeFor this, it is necessary to lift the sbench slightly at the front. It will remin the lifted position when the strut,cated on the left on the sliding door siis swung upwards.




L U G G A G E COM PA RT M ENT/LOAD SURFAC E ROOF RACK

To enlarge luggage s p a c e *• Release backrest by pulling loop• F old backres t down to se at

The backrest locks automatically whenhinged to the rear.

Instructions on using the rear/reclinings e a t* are given on page 18.

Notes on using the luggage compart-ment or the load surface

• The load must be stowe d so that itcannot slip or even fly forward when thebrakes are applied.

• In the interes ts of good handling theload should, wherever possible, be carriedbetween the axles. The permissible axleloads and the permissible gross vehicleweight should on no account be exceeded.

When a roof rack is to be used, note thefollowing:• Only use roof racks which are supported in the rain channel

• Dis tribute load uniformly.Do not exceed permissible roof load orpermissible gross vehicle weight.Further details on pages 117-119.

• W he n carrying heavy or large objec tson the roof, bear in mind that the vehiclehandling can change due to the altera-tsion in centre of gravity and the increased area exposed to the wind. Driving

style and speed must be modified toallow for this.


O P E R AT I O N



C O V E R * DROPSIDES HAN DBRA KE

Ensure that the c over is se cure d properly behind the cab.

The cove r is correctly se cured when therod incorporated in the cover engages inthe rain channel at the rear of the caband the left and right hand ends a re bolted to the canopy frame.

When the cover and rails have been removed, care should be taken when refitt-ing to ensure that the foam seal is stuckproperly in the rain channel (if neces sa ry

renew seal).

To drop side boards - pull handle outwards to release locking pin und swingdown to lift hook.On vehicles with support cables for thetailboard, no t more than 150 kg shouldbe placed on the tailboard when it isdown.

The handbrake is located between thfront seats.

To apply the handbrake pull lever ufirmly. O n hilly roads the 1st gear or oautomatic gearboxes the parking lockshould also be en gaged. The handbrakshould always be applied so firmly thait is not possible to drive off accidentallwith handbrake slightly on.

When handbrake is applied with thignition on, the brake warning l a mpcomes on .To release handbrake, pull lever uslightly, press locking knob in and puslever right down.


- PERATION



M A N U A L G E A R B O X

4 speed gearbox

Engaging reverseMove lever in neutral to the left, press itdow n and move i t further to the left s topand then push i t forward.

Only engage reverse gear when vehicleis stationary.

Wh en en gine is running, depress clutchfully and wait a few seco nds be fore m oving gear lever, to prevent grating noises.

Wh en reverse gear is engaged with ignit ion on, the reversing l igh ts * come on.

5 s p e e d g e a r b o x

To engage 1st gear move lever pastpressure point to left stop and then pullit back.

One normally moves off in 1st gear buton vehicles with the 44, 57 and 82 kWengine and 5 speed gearbox the rearaxle ratio is different so that one canmove off on the level with a light loadin 2nd gear.

To engage reverse gear move lever pastpressure point to left stop, press it downand push it to front.

v1 <

R ^< L 2

| B 2 5 - 4 5 4

4 + G g e a r b o x ( 4 W D v e h i c l e s )

Engaging crawler gearMove lever in neutral to the left, press itdow n and move i t further to the left s topand then pull it to the rear.

NoteWhen driving you should not rest yourhand on the gear lever. The pressure ofyour hand is transm itted to the shift forksin the gearbox a nd can cause prem ature

wear of the forks.


OPERATION



DIFFERENTIAL LOCKS*

22

Wh en negotiat ing a curve, the whee ls ofa vehicle cover different distances. Tobalance out the differences in wheelspeeds, differentials are incorpora ted inthe driving axles. However, these diffe

rentials have a distinct characteristic: Assoon as one wheel on an axle commences to spin on a slippery surface, onlyvery little traction is available, eventhough the other wheel is on a hardsurface.

Using the differential locks the wheels ofone axle can be locked together and thetraction is once again abtained.

On the Transporter/Caravelle there aretwo different types of differential lock:Vehicles with rear wheel drive have alimited slip differential in the rear axleand 4 WD vehicles have selectable mechanical locks in front and rear differentials.

Lime ted s l i p d i f f e r en t i a l *(Rear wheel drive)

The locking effect is obtained by meansof plates which are arranged in the differential in a sort of multi-plate clutch.With this differential the locking effectis not 100% but only app rox. 45%. Contrary to vehicles w ith 1 00% locking , thesteering behaviour on the road, part icularly in sharp curves, remains almost unchanged.

The effective locking force is dependenton the speed difference of the two driving wheels. This means: the larger the

difference, the larger is the locking forceof the differential.

Driving t ipsIn normal conditions the vehicle can bedriven just like every o ther veh icle. At thebeginning it may take a bit of gettingused to when driving throug h sharp curves . This is due to the fact that a slightlocking effec t is always p resen t.

Furthermore in isolated borderl ine condit ions where, on the one hand the fr ic-tional resistance of the driving wheelson the ground differs a great deal and,on the other hand, a large amount ofpower must be transmitted to move off ,i t may be found that the maximum pos

sible locking effect is not obtained in tdifferential. One notices this becauone whe el spins while the othe r' donot turn at all. In this case one shouengage and disengage the clutch gentl

and repeatedly. This will prevent tdifferential from becoming overheate

Gear oilThe oil level does not need checking btween the intervals given in the ServiSchedule. The oil does also not neechanging. To top up or fill after a repa V.A.G workshop should be contactbecause the gearbox must be f i l led wi

a special oil.


O P E R AT I O N



Selectable differential l o c k s *(Four wheel drive)With the selectable differential locks,the wheels on one axle are fully lockedtogether (100%). As no compensationtakes pla ce when cornering, the handlingand the steerability is affected - particularly in the case of the front differentiallock.

AttentionTh e differential locks may only be usedunder th e limited specific conditionsdescribed on the following pages.

HP *

A Q Q I

U S E E S

Engaging the differential locks

The differential locks are engaged anddisengaged with the knobs shown in thecentre of the instrument panel withvehicle stationary or moving.

Left knob - F ront axle differentiallock

R ight knob - Rear axle differentiallock

When the knobs are pulled/pushed engagement or disengagement is only selected. The actual shifting process canbe delayed. If the whee ls are rotating atdifferent speeds, or if the drive train is

under strain, e.g. tight corner with differential lock engage d, it could even happenthat the lock will not engage or disengage at all. In such a case, throttle application should be reduced, or the vehicleshould be driven straight-ahead to enable the lock to engage/disengage.

Th e warning lamps above the knobs indicate the operational condition of thelocks:

• If the front axle differential lock hasbeen selected, the left hand warninglamp flashes. As soon as the lock engages the lamp lights up continuously.

• The right hand warning lamp monitors the function of the rear axle differential lock. It does not flash when thelock has been selected but only lightsup once the lock has engaged properly.


O P E R AT I O N



• Both warning lamps go out againonce the knobs have been pushed inthe locks have actually disengaged.

If after selecting the differential locks,and after driving some distance, thewarning lamps do not light up, the electri-cal system and the locks themselvesshould be checked at a V.A.G workshop.

Attention

The differential locks influence thesteerability of the vehicle. In particular,with the front axle differential lock engaged, the vehicle is no longer steera-ble. For this reason, the front axle diffe

rential lock must only be used under off-road conditions and then only at lowspeeds. Always di sengage the lock before driving on metalled road surfaces.

When may the differential locks not beengaged?• Neither the front nor the rear axledifferential locks may be engaged whendriving along metalled road surfaces.

Locking the front axle differential makes the vehicle unsteerable.

When the rear axle differential is locked,the rigid connection between the tworear wheels has a scrubbing effect onthe tyres when cornering. This leads toincreased tyre wear and also to "jerking" when the vehicle is being steered.In certain ci rcumstances it may even

damage the drive train.For this reason, the locks may only beengaged under off-road conditions or asan assistance when moving off.

See "Driving Tips" on page 60 also.

• When a wheel is spinning, if forexample the vehicle is stuck in snow.This would not only lead to increasedtyre wear but it could also damage thedrive train and lead to uncontrollable

acceleration. For this reason, the sp inning wheel must first be brought to astandstill before the differential locksare engaged.

When the vehicle is being towed - seepage 103 also.

When testing the vehicle on a dynamometer, e.g. when being tested by localauthorities.


O P E R AT I O N



S E L E C TA B L E FOUR-WHEEL DRIVE*

m m ®

Vehicles required for particularly arduousoperating conditions (e.g. predominantlycross-country work) can be equippedwith a manually controlled four-wheeldrive, as an optional extra.

Under normal driving conditions on dryroads, the vehicle should only be drivenby the rear axle.

When the road surface is wet, slippery,snow or ice covered, or when drivingunder off-road conditions, one is advised

to engage the four-wheel drive.The drive ca n be engage d or disengagedwhilst the vehicle is in motion.

Engaging four-wheel drive

Pull the knob (arrow) located in themiddle of the dash panel.

Wh en the knob is pulled/push ed, engage

ment or disengagement is only selected.The ac tual shifting proc es s can be delayed. If the wheels are rotating at differentspeeds, it could happen that the 4 WDcannot be engaged at all, or if the drivetrain is under strain, e.g. tight corner withdifferential lock e ngage d, it could evenhappen that the lock will not disengage .In such a case, the accelerator shouldbe released or the vehicle should bedriven straight-ahe ad to enable the 4 W Dto e ngage/disengage.The warning lamp above the knob lightsup or goes out only when the four-wheeldrive has actually engaged or disengaged.

Notes

• W he n engaging the cros s-c ountrygear, the four-whee l drive is automatical

ly engaged.• To keep the steering force s as low aspossible, the four-wheel drive should bedisengaged when a full lock is required -e.g. when parking.

• J ust how the differential locks are engaged, and important instructions on theiruse are to be found on pages 23 and 24.


OPERATION



AUTOMATIC GEARBOX

p

R UN d 1D21 [B16 -150 |

Selector lever p o s i t i o n s

P - Parking lock

The driving wheels are locked mechanically.The parking lock may only be engagedwhen vehicle is standing still. To movelever into and out of the "P " position thesafety catch in lever handle must bepressed.R - Reverse gear

The reverse gear must also be engaged when vehicle is stationary and the

engine idling. Before " R " can be engage dthe safety catch in lever handle must bepressed.

N - Neutral

D - Normal driving position

The three forward gears are shifted upand down automatically according to

throttle opening and road speed.2 - Positio n for hilly stretches

The 1 st and 2nd gears are shifted up anddown automatically according to throttleopening and road speed. The 3rd gearis not used. This increases the enginebraking effect.The road speed must not exce ed 90 km/h(56 mph).

The lever can be moved from "D" into"2" with accelerator pedal depressed.However as the shift into 2nd gear takesplace immediately this must only bedone at speeds below 85 km/h .

1 - Posit ion for steep hills

To engage this gear, the catch in leverhandle must be pressed. The vehicle remains in 1st gear and 2nd and 3rd gears

are not used. This gives maximum possible engine braking effect.

The road spe ed must not exce ed 50 km/h(30 mph).

The lever can be moved from "2" intowith accelerator pedal depressed. Hoever as the shift into 1st gear takplace immediately this must only done at speeds below 45 km/h .

Kick-down device

The kick-down device gives maximuacceleration. When the accelerator pdal is pressed right down past thethrottle position, depending on rospeed and engine speed, either the ushift is delayed (forced throttle) or box changes down into the next lowgear.


OPERATION



Notes on drivingStartingThe engine can only be started whenselector lever is at "N" or "P". See also

"Starting engine" on page 29.Selecting a driving range

Before selecting a gear with vehiclestationary and engine running, operatefootbrake or handbrake. This also applies when moving lever from "P" to "N".Particularly when the idling speed ishigh (after starting from cold) it is necessary to hold the vehicle with thehandbrake.This is necessary because with an automatic gearbox the transmission of poweris not completely stopped even at idlingspeed - the vehicle tends to "creep".

When selecting a gear with vehicle stationary, do not depress accelerator.When a driving range is selected withthe vehicle stationary, the throttle muston no account be opened (e.g. by handfrom engine compartment). The vehiclewill otherwise move immediately -possibly even with handbrake applied.

Before working on the engine when it isrunning, place selector lever at "P" and

apply handbrake.If the lever is moved accidentally into"N" when driving, release acceleratorand let the engine speed drop to idlingbefore selecting a forward gear again.Driving downhill in winterBefore driving down a long slipperygradient after starting from cold in a vehicle with a carburetor engine, ensurethat engine is warmed up enough toidle at normal speed. Otherwise the engine braking effect will be limited whenaccelerator pedal is released and gentlebraking on the slippery surface will notbe possible.

StoppingTo stop vehicle temporarily such as attraffic lights, all that is necessary is toapply the brakes. It is not necessary tomove lever to "N". The engine shouldhowever only be running at idling speed.

ParkingOn level ground all you need do is to engage th e handbrake. On a gradient the

handbrake should be applied firmly firstand then the parking lock engaged. Thiswillensure that the locking mechanism isnot too heavily loaded and makes lockeasier to disengage.

Emergency startingThe engine cannot be started by towingor pushing the vehicle.

When battery is flat, the engine can bestarted from the battery of another vehicle by using a jumper cable. See "Emergency starti ng", page 102.

TowingIf the vehicle has to be towed at anyt ime, you must read the instructions inthe section "Towing" on page 103.


OPERATION



STEERING LOCK/IGNITION SWITCH

Petrol engine1 - Ignition off - Steering can be

locked.2 - Ignition on3 - Starting engine

Diesel engine

1 - Fuel supp ly cut off - Steeringcan be locked

2 - Glow and drive posit ionWhile glow plugs are on, no otherheavy current consumers shouldbe switched on.

3 - Starting engine

For all vehicles:P osition 1:

To lock the s teering whee l withdraw keyand turn wheel until you hear the pinengage.

CautionDo not withdraw key until vehicle istationary.

P osition 2:If the key is difficult to turn in the lock orcannot be turned to this position at all,the steering wheel must be turned toand for slightly to release the locking pin.

P osition 3:In this position the headlights, the windscreen wipers, the blower* and theheated rear window* are switched off.Before the s tarter can be ope rated againthe key must be turned back to positionThe non-repeat lock in the ignition switchprevents the starter from being operatedwhen engine is running as this coulddamage the starter.


O P E R AT I O N



STARTING THE ENGINE

General notes

Be careful when running th e engine in aconf ined space . Danger of poisoning.

• Check that gear lever is in neutral.(On vehicles with automatic gearbox:Selector lever at "P " or "N") and applyhandbrake before starting.

• De press the clutch pedal on vehic leswith manual gearbox when starting sothat the starter only has to turn the engine.

• As soon as the engine starts, releas ethe ignition key so that the starter candisengage.

• Do not warm engine up by running itwith vehic le stationary. Drive off straightaway.

• Do not overrev or use full throttleuntil the engine has reached the normaloperating temperature.

Note for vehicles with catalyst

The engine must not be started bytowing the veh icle as otherwise unburntpetrol can get into the catalyst and beburned there - se e also page 83.

44 and 57 kW carburetor enginesStarting a cold engine

The carburetor is fitted with an automaticchok e which is actuated the first time theaccelerator pedal is depressed whenengine is cold.

• De press acc elerator pedal slowlyonly (twice when it is freezing) and thenrelease it

• S witch ignition on and start enginestraight away - do not use accelerator.

• The engine may rattle briefly afterbeing s tarted. This is caus ed by the hy-draulic tappets which have to build up acertain oil pressure first. The noise isharmless and no cause for alarm.

• The increa se in the idling speed whic htakes place as engine starts to warm upcan be reduce d by just tapping the accelerator pedal briefly.

On vehicles with an automatic gearboxthe engine should be run at fast idlingspeed for about one minute after startingwhen it is very c o l d .The pe dal sh ould then be tapped so thatthe speed drops and a gear can beselcted at normal idling speed.

Starting a warm engine

• De pres s pedal slowly while operatingstarter.

• Release pedal as soon as enginestarts.

Starting a hot engine

• De pres s peda l fully before operatingstarter and hold it in this pos ition - donot pump it.• Release pedal as soon as enginestarts.




Fuel injection enginesThe engine is fitted with a fuel injectionsystem which automatically supplies thecorrect fuel/air mixture for all operatingconditions. The starting procedure described here is applicable regardless ofambient or engine temperature:

• S witch ignition on and start enginestraightaway. Do not depress accelerator.

• O nly if the engine does not start thefirst time, should the accelerator pedalbe depressed slowly during the nextattempt to start. W he n engine s tarts

release accelerator pedal immediately.

Diesel enginesGlow plugs

The engine is fitted with glow plugs. Thetime the plugs are on is indicated by alamp which is controlled by the coolanttemperature - see page 33.

Cold starting aid

To facilitate starting from cold, there isa co ld starting device in the injectionpump. This cold starting aid is operatedwith the knob on the left near the steering column (see illustration on page 2,item 20).

Starting a cold engine

• At ambient temperatures down to-15° C , pull cold start knob out fullybefore operating starter.At lower temperatures, the knob shouldnot be pulled out until engine is firingregularly - the engine will then startmore readily.

• Turn ignition key to pos ition 2 glowplug lamp comes on. It goes out whenthe ignition temperature is reached (seepage 29).

To avoid draining battery unnecessar

ily, do not switch any other heavy current consumers on while glow plugsare on.

• As soon as lamp goes out, start engine. - Do not dep res s acc elera tor whenoperating the starter on an engine without turbocharger. O n engines with turbo-charger, depress accelerator about Vbofpedal travel. If engine only fires irregularly, continue to operate starter a fewseconds longer (30 seconds at maximum) until engine runs under its ownpower.

If engine does not start, wait about 30seconds, switch glow plugs on again andtry starting it again as de scrib ed .

If the engine still does not start thefuse for the glow plugs may have blown -page 95.


S O G G



STOPPING ENGINE

• Do not push the knob of co ld startingaid in until engine has reached normaloperating temperature as otherwise theengine may tend to stall when idling.

Starting a warm engine

• The glow plug warning lamp doe s notcome on - the engine can be startedstraight away.Do not pull cold starting aid knob and donot depress accelerator pedal.

• When vehicle has been driven hardfor a while do not switch engine off assoon as you stop. Let i t idle fo r about 2minutes to cool i t down slightly.

• W he n engine is hot, the fan may con

tinue to run when e ngine has been stopped or it may switch on suddenly - evenwhen ignition has been switched off.


A S



WARNING LAMPS

The layout of the warning lamps dependson the model and the engine fitted. Thesymbols shown here are also on theactual warning lamps.

V-p< - Engine oil pressu re

This warning lamp flashes when theihnition is switched on. After the enginehas started, the lamp must go out again.

If the warning lamp does not go out, orflashes when driving - at an enginespeed of approx. 2000 rpm a buzzer thensounds - stop at once and switch engine off. Check the oil level and if necessary, add oil - see page 68.

If the lamp com es on des pite the oil levelbeing correct, do not drive o n . In such acase, th e engine must not be run, evenat idling s peed - call in expert assistance.

Note:The oil pressure warning lamp is not anoil level indicator.

|" *\ Generator

Petrol engines

This lamp comes on when the ignition isswitched on and should go out when theengine is started.

If the lamp comes on when driving, stopat once, switch engine off and checkvee belt.If the belt is broken do not drive further

because the coolant pump is then nolonger being driven. Fit a new belt. (Forbelt sizes see "Technical data".)

If the warning lamp comes on althoughthe belt is not broken one can normallydrive on to next V.A.G workshop.However a s the battery is then discha rging continuously, all electrical components which are not absolutely essentialshould be switched off.

Diesel engine

This lamp comes on when the ignition iswitched on and should go out when thengine is started.

If the lamp comes on when driving, stoat once, switch engine off and check thvee belts for generator and coolanpump.

If the belt for the coolant pump is brokendo not drive further. Renew the beltfor belt size see "Technical data".

If the belt for the generator is broken thvehicle can still be driven to the nexV.A.G workshop but the battery will thedischarge continuously - see next paragraph.

If the belts are not broken one can normally drive on to the next V .A.G workshop. As the battery will be dischargincontinuously, all electrical componentwhich are not abs olutely esse ntial shoulbe switched off.


OPERATION



t - Coolant temperature/— coolant level

This lamp flashes for a few seconds asa functional check when ignition isswitched on.

If the lamp does not go out afterwardsor flashes when driving, either the coolanttemperature is too high or the coolantlevel is too low.

Stop a t once , switch engine of f andcheck if the radiator fan is running (bylistening). The fan is at the front behindthe radiator grille. If the fan is not running,check fuse and replace if necessary -se e page 94.

If the fan is in order, check coolant leveland top up if necessary.

Caution. Danger of sca ld ing .For further details see page 72.

If the warning lamp does not go out eventhough the coolant level, and fan fuse arein order, do not drive further - get expertassistance.

If the trouble is only caused by the fanand assuming coolant level is in orderand warning lamp is out - one can driveon to the next V.A.G workshop. In orderto make a good use of the air stream forcooling do not let engine idle or drivevery slowly.

- Glow plugs(Diesel engine only)

When engine is cold, the warning lampcomes on when key is turned to driveposition (ignition on).

When the lamp goes out, start engineimmediately - see page 30.

W hen engine is warm the glow plug lampdoes not come on - the engine can bestarted straight away.

O O - Turn signalsThe warning lamp flashes when turn signals are switched on. If a turn signal fails,

the warning lamp flashes twice as fast.(Not when towing a trailer). Further details are on page 38.

Q I - High beams

The warning lamp comes on when highbeams are on or headlight flasher isused.

(©) - Brake systemThe warning lamp* comes on when• the handbrake is applied• the fluid level is low

If the lamp does not go out when handbrake is released or comes on whendriving, the fluid level in reservoir istoo low. If at the same time the pedalfree travel increases, one of the twohydraulic circuits may have failed.

You can drive on to the nearest V.A.Gworkshop but allow fo r higher pedalpressures and longer braking dis tances on the way.

Trailer turn s i g n a l s *The warning lamp flashes when turn s ignals are switched on when towing atrailer.

If a turn signal fails on trailer or vehicle,the warning lamp does not flash.

Differential l o c k s * o r selectable fourwheel drive*

W arning lamps for the differentiallocks on four wheel drive models or forselectable 4 wheel drive - see page23/25.


O P E R AT I O N

INSTRUMENTS



INSTRUMENTS

The arrangement of the instruments depends on the model concerned and theengine fitted - see also "Instrument panel", page 2.

Speedometer

The permissible maximum speeds during the running-in period are given onpage 39.

The last figure of the mileage recorderor trip recorder* indicates 100 m or1/10 mile.

The trip recorder can be set back tozero by pressing the knob in the spe edometer dial.

Rev counter*

The permissible engine speeds duringthe running-in period are given on page53.The dotted zone on the scale shows themaximum engine spe ed permitted briefly when engine has been run in and iswarm. It is advisable to change up orreduce engine speed at the latest by thetime the needle reaches this zone.

Changing up in good time helps to savefuel an d keeps the noise down.

Always change down to the next lowergear before the engine starts labouring,

(no longer pulls smoothly).The green or green shaded area on thescale shows the speed at which the engine is developing its most favourabletorque.

C l o c k *Normal c lock

To set the time, press knob in centre ofdial and turn hands.

Digital c lock

The time is set with buttons on left andright of dial. The left button is for thehours and the right one for the minutes:

• If pre sse d briefly, preferably withball pen, the time changes one hour oron minute.

• If pre ss ed continuous ly the hours orminutes change continuously.

With the minute button the clock canbe set exactly to the second.

• Press button until time is one minutebefore time to be set.• Press button at the moment whenthe seconds indiator of a digital wrist-watch shows a full minute or when thetime signal is heard on the radio.


OPERATION



B28-031

t - Coolant temperature— gauge

The gauge starts to work when ignitionis switched on, but it takes a little timebefore the needle reaches the final position.When ignition is switched on the warning lamp (c) flashes for a few secondsas a functional check.

a - Cold zone

Avoid high engine speeds and do notwork engine too hard yet.

b - Normal zone

When vehicle is driven normally theneedle should settle down in the middleof this zone.

When engine is working hard and ambient temperature is high, the needlemay move further to the right.

This is not serious as long as the warning lamp (c) does not flash. When engine is pulling normally the needle shouldgo back to the middle.

c - Warning lamp

If the lamp flashes when driving eitherthe coolant temperature is too high orthe coolant level is too low. Stop at once,switch engine off and try to find thecause of the trouble - see page 33.

ft - Fuel gauge

The fuel gauge needle starts to movewhen the ignition is switched on but ittakes a few seconds to reach its finalposition.

The tank holds about 60 litres (syncro70 litres).

When the needle reaches the start ofthe reserve mark (R) there are about10 litres of fuel left in the tank.


SWITCHES



SWITCHES

IB25-336!

1 - Lighting sw itch

First dete nt - side lightsSecond detent - headlight high or low

beams

The headlights only work when the ignition is on. W he n the eng ine is beingstarted, the headlights are switched offautomatically.

W hen the lights are on, the level of theinstrument lighting can be regulated byturning the knur led d isc* be low the

switch.Dipping and flashing headlights - seepage 38.

2 - Emergency l ights

When the emergency l ights are on, awarning lamp in the switch flashes aswell .

The system also works whe n the ignit ionis switched off.

3 - Hea ted r ea r w in do w *

The heating works only when ignition ison. When heater is on a lamp in theswitch lights up.

As soon as window is clear, switch element off . The reduced current consumption helps to reduce the fuel consumption - see also "Driving economically".

4 - F o g l i g h t s *rea r fog l i gh t*

First dete nt - fog lightsSecond de tent - fog and rear fog l ights,

or only rear fog light.

At the seco nd po sit ion a warning lamp inthe switch comes on.

Th e fog l ights work only with the sidelights (ignition on), low or high beams.

Th e rear fog l ight works only with thefog lights or with the low or high beams.

NoteThe use of the lighting desc ribed at 1, 2and 4 is subject to local regulations.www.WestfaliaT3.info - a useful website for owners and enthusiasts of VW Westfalia T25 / T3 / Vanagon Campervans



Knur led d i sc for sea t hea t ing*The cushion and backrest of the frontseats can be heated electrically whenthe ignition is on.

The heating is switched on and regulat-ed with the knurled disc.

To switch heating off, turn knurled discto the detent posit ion.


OPERATIONTURN SIGNAL AND DIP LEVER



TURN SIGNAL AND DIP LEVER

The turn signals only work when the ignition is switched on.

Right turn signals - lever upLeft turn signals - lever down

When turn signals are working the warnin g lamp flashes as well. See also page3 3 .

When a turn signal fails, the warningl amp flashes roughly twice as fast.

The turn signals cancal automaticallyafter making a turn.

To signal a lane change

Move lever up or down to pressure pointand hold in position - the warning lampmust also be flashing.

To dip headlightsPull lever past pressure point towardssteering wheel . When high beams are on,a warning lamp in the dash lights up.

Headlight flasher

Pull lever towards steering wheel to pressure point - the high beam warning lam plights up.

Parking lights*

The parking lights only work when ignition key is removed.

Right parking lights - lever upLeft parking lights - lever down

3 8 www.WestfaliaT3.info - a useful website for owners and enthusiasts of VW Westfalia T25 / T3 / Vanagon Campervans

OPERATION

WINDSCREEN WIPER AND WASHER SYSTEM



Wipers and washers only work whenignition is switched on.

Wh en i t is freezing, check that the wipe rblades are not frozen to the glass beforeswitching wipers on for the f irst t ime.

Windscreen

Brief wipe

Lift lever to pressure point before stop 1.

Wiper slow

Lever at position 1.Wiper fast

Lever at position 2.

Windscreen washer

Pull lever towards steering wheel - thesystem works as long as lever is held inthis position.

A u t o m a t i c w a s h / w i p e f a c i l i t y *

Pull lever towards steering wheel -wipers and washer work.

Release lever.

The washer stops and the wipers carryon for about 4 seconds.

Lever at detent 3

The wipers work about every 6 seconds,(intermittent wipe)

Rear window

A u t o m a t i c w a s h / w i p e *

Press lever briefly away from steeringwheel - the wiper works about every 6seconds (intermittent wipe). Pressinglever briefly again switche s the wiper off.Press lever away from steering wheel,and hold in position -

The wiper and washer work as long aslever is held in position.

Release lever -

The washer stops and the wiper carrieson for about 4 seconds.

H ead l igh t w a sh e r s y s t em *Wh en the headlights are on, the lensesare washed every t ime the windscreenis washed.

At regular intervals such as when fillingthe tank, caked on dirt and insectsshould be removed.

Filling wash er container, see page 74.




OPERATION



Defrosting windscreen and sidewindows

• Move all levers fully to the right.• Switch blower to stage 2 withswitch E.• Switch off blower of additional heatexchanger*.

Demisting windscreen an sidewindows

When the windows mist up due to highair humidity, e.g. when it is raining, werecommend the following settings:

• Move levers A, C and D fully to the

right.• Move lever B slightly to the right intothe heating range, if necessary.• Blower switch E to stage 2 or 3.• Close vents 3.Heating interior as quickly as possible

• Levers A, B + D fully to the right• Lever C fully to the left

• Close vents 3• Switch blower to stage 2 withswitch E.

Heating interior normally

When the windows are clear and thedesired temperature has been reached,we recommend the following settings:• Lever A to the left

• Lever B to the desired heat output• Lever C to the left

• Blower switch E at stage 1

Ventilation

When heating is off, fresh air flows fromall vents. When heating is on, only fromvents 3.

Notes

• In order to ensure that the heatingand ventilation works properly, the blower should always be switched on whendriving slowly.

• To prevent contaminated air fromgetting into the vehicle, move lever Afully to left and levers C and D fully toright. The vents 3 must also be closed.

• The heat depends on the engine temperature - the full heat output is therefore only available when engine is warm.• All controls except blower switch Eca n be set to any intermediate position.

• The stale air can escape through slotsin the front doors. The slots can beopened or closed by means of slides.


OPERATION



J B 2 5 - 4 1 9

Additional heat exchanger* for thepassenger compartment

The addit ional heat exchanger is locat edunder the rear seat. The blower is controlled by a 3 stage switch on the dashpanel - see illustration above.

To obtain warm air from the heat exchanger, th e valve on the heat exchanger must be fully open.

To close or open the valve the trim underthe rear seat must be removed.

To do this, grip trim on the left side andpull it out. Then move valve lever asshown on right.

Lever upwards - opened (Winter position)

Lever to rear - closed (Summer position)

In the warm seasons the blower of theheat exchanger can be used to circulatethe air. When used in this wa y the valveon the heat exchanger should be closed .This will prevent unnecessary heat radiation reaching the footwell when theweather is warm.


O P E R AT I O N

AUXILIARY A IR H E A T E R *



The heater is switched on and off withthe knob (see Fig.) in the dash on theright of the steering column. This switchalso regulates the amount of heat.

Depending on model concerned the

warm air flows from the footwell ventsin the passenger compartment and/orfrom a controllable vent under thedriver's seat. The air distribution cannotbe regulated.

The heater can be used all the timewhen vehicle is moving. When engine isnot running the heater switches off automatically after about 25 minutes to avoiddraining the battery.

The heater is supplied with fuel from thevehicle tank. It can use up to one litre perhour according to operating conditions.The maximum heat output is 6000 kcal/h.

Switch positions

0 - Heater off

0 to 1 - Heating with engine notrunning

2 - Heating when driving

2 to 3 - R egulates amount of heat

Heating with engine no t running

(Ignition off)

To switch heater on -

Press switch knob in at position 0 and

turn it clockwise towards 1 (warninglamp lights up). The knob springs outagain when released.

The amount of heat can be regulated between 2 and 3 as required.NoteO n vehicles with Diesel engine it takesabout 40 seconds before the heat can befelt.

To switch heater off -The clockwork in the temperature regulating switch switches the heater off automatically after about 25 minutes andthe lamp goes out.

To switch heat off before clockwork hasrun down: turn knob anticlockwise to 0.The lamp goes out and clockwork runsdown.




Heating when driving Notes Maintenance

To switch heater on -

Turn switch knob clockwise to position 2(warning lamp in knob comes on)

The amount of heat can be regulatedbetween 2 and 3 as required.

NoteO n vehicles with Diesel engine it takesabout 40 seconds before the heat can befelt.

To switch heater off -

Turn switch knob anti-clockwise to position 0 (warning lamp goes out)

• E very time the heater is sw itched off,the warm air and combu stion air blowerscontinue running briefly to cool the heater down quicker.

• To avo id draining the battery, do notrun the heater repeatedly when the engine is not running.

• W he n the heater is running on thecloc kwork time s witch, it must be switched off by hand before attempting to startthe engine at low temperatures so that

the full battery capacity is available toturn the engine.

• In enclos ed sp aces and when fi llingth e fuel tank, th e heater must beswitched off.

Due to the risk of fire th e heater mustnot be used when vehicle is parked fo rinstance on dry grass or leaves.

When driving through mud and snow,the exhaust pipe may tend to get blocked. Have a look at it occasionally to seethat it is clear.

Accord ing t o offical German regula-t ion:

The heat exchanger in the heater is onlyto be used for 10 years. After this periodthe heat exchanger must be replaced ina V.A.G workshop. The year in which theheater is first put into operation is marked on the nameplate on the heater.

The V .A .G works hop must then put the

date of the repair on the plate on the heatexchanger.


O P E R A T I O N



If the heater on vehicles with a Diesel

engine will not start or stops after operating for a while, an automatic cut-outswitches the heater off. If the heatercannot be started by switching the rotaryswitch off and on, the heater is defectiveand must be repaired in a V.A.G workshop.

F u s e s

S ee page 95.

The heater on vehicles with a petrolengine has a safety switch which is lo

cated under the dash on theleft

nearthe steering column. If the heater doesnot start, or starts and then stops again,wait 3 minutes and then operate the redlever on the safety switch.

If the heater still does not work or if thesafety switch stops it again, there is adefect in the heater which can only berepaired by a V.A.G workshop.


O P E R A T I O N

AUXILIARY WATE R H E A T E R *



The auxiliary heater heats the coolant inthe heating circuit and supplies the heatexchanger in the normal heating systemand the additional heat exchanger* forthe pass enge r compartment heatingwith heated coolant. The coolant ciruitof the engine is not heated.The s ystem is switched off and on or theswitch-on time preselected by means ofa switch and indicator unit loca ted on theleft (or right) unter the instrument panel.

Air distribution and regulation is donewith the controls of the normal heatingand ventilation system (see page 40).

The auxiliary heater can be used with

vehicle stationary or when it is moving.When vehicle is stationary, the heateronly runs for a maximum of 30 Minutesin order to avoid draining the battery. Italso switches off automatically when acoolant temperature of 80° C is reached.

When the coolant temperature dropsbelow 70° C the heater is automaticallyswitched on again.

The heater is supplied with fuel from thevehicle tank and uses up to half a litre

per hour. The maximum heat output is4000 kcal/h.

Cont ro l s

A - Buttons for setting time and preselected time.B - Indicator lamp for preselected time

C - P rese lected time

D - Display

E - Actual time

F - Heater on/off

G - Warning lamp (heater on)


O P E R AT I O N



Setting th e time

• =ress and hold clo ck button E.

• Set clo ck with buttons A.m e display lights up as long as button= oressed. When button is released the: splay goes out or, if a time has beendeselected, the selected time lights up•r 2 sees.

To switch heater on or off

• This is done by pres sing button F.,Vhen heater is switched on the warningamp G lights up.

Preselecting starting time fo r heater(stationary operation, ignition off)

With buttons C two different switch-ontimes can be selected within 24 hours.• P ress and hold button. The appropriate figure 1 or 2 appears in display.The ready-for-action lamp lights up.

The heater can only work if the leverfor the heat output is pushed fully tothe right. This closes an electrical contact.

• S et required switch-on time withbuttons A. The display remains on forabout 20 seconds after releasing buttonC.

In order to ensure that the heater startsup at the s ele cted time, the leve r fot theheat output must be pushed fully overto the right. In addition to this the blowermust be switched to stage 1. O n acco untof the higher current consumption, ahigher stage should only be selected inisolated cases.

Switching preselected time off

• The pres elec ted time ca n be switched off by briefly pressing the appropriate

button C . The ready-for-ac tion lamp andthe figure in display then go out.

F u s e s

See page 95.

Notes

• E very time the heater is switched off,the warm air and combu stion air blowerscontinue running briefly to cool the heater down quicker.

• To avoid draining the battery, do notrun the heater repeatedly when the engine is not running.

When driving through mud and snow, theexhaust pipe may tend to get blocked.Have a look at it occasionally to se e thatit is clear.

According to official German regula-t ions :

The heat exchanger in the heater is onlyto be used for 10 years. After this periodthe heat exchanger must be replaced ina V.A.G workshop. The year in which theheater is first put into operation is marked on the nameplate on the heater.

The V .A .G works hop must then put thedate of the repair on the plate on theheat exchanger.

• In enclos ed sp aces and when fill ingth e fuel tank, th e heater must beswitched off.


O P E R AT I O NSLIDING R O O F * S U N R O O F *



The roof is opened and closed with thecrank above the driver's seat.

To open - F old crank down and turn itto the left, the fold crank intorecess again.

To close - Fold crank down and turn itto the right as far as it will gothen turn it back until it canbe folded into the recess.

For safety reasons, the crank shouldalways be in the recess.

The roof is opened and closed with theknurled disc in the headlining above the

front seats.The roof can be tilted at the rear asdesired or taken out altogether.

Raising

Turn knurled disc clockwise.

Lowering

Turn knurled disc anti-clockwise.

To take out

• Turn retaining sc rew (A) in centre ofknurled disc one quarter turn clockwise(e.g. with a coin) with roof closed.

• Then raise roof and pres s it up.

• Press locking lever (B) up.• Detac h roof.

• Lift roof from outs ide and pull it outto the rear.

To put back

• S lide roof bac k into the hinges andlet it drop lightly into the retainers.

Cautions

Ensure that th e roof is properly insert-ed into the two retaining hinges at thefront, and locked at the rear.

Th e roof must only be unlocked whenvehicle is stationary.


INTERIOR LIGHTS



Switch positions:

1 - Light on continuously

0 - Off2 - Door contact position, light comeson when cab doors are open.

Step illumination*

The step light comes on when slidingdoor is opened. It goes out a few seconds after the sliding door has beenclosed.

Table l ight*

Switch positions:To front - OnTo rear - Off

Reading l a m p s *

The reading lamps have separate

switches and can be moved about asrequired.

Switch positions:Ring turned to right - O nRing turned to left - Off

The reading lamp on the right at the rearlights up continuously when the slidingdoor is opened. When the sliding dooris clos ed it goes out in the off pos itiontogether with the step light after a delayof a few seconds.

Interior light in front of passengersea t*

Switch positions:Up - OffDown - On

Boot l ights*

The boot lights come on when the rearflap is opened.

NoteWhen leaving the vehicle ensure that alllights are switched off so that the batteryis not run down if the vehicle is leftstationary for some time.www.WestfaliaT3.info - a useful website for owners and enthusiasts of VW Westfalia T25 / T3 / Vanagon Campervans

O P E R A T I O N

SU N VISORS ILLUMINATED M A K E - U P MIRROR*



Both sun visors can be lifted out of theirbrackets and swung round towards thedoors.

An illuminated make-up mirror is fitted atthe back of the passenger's sun visor.

To switch light on - move switch to left.When the sun visor is moved up, themirror illumination goes out automatically.Note

When leaving the vehicle always ensurethat the light is switched off so that thebattery is not run down when vehicle isleft standing for some time.


ASHTRAYS CIGARETTE LIGH TER /SO CK ET* GLOVE BOX



Ashtray in dashTo take out:

Grip the strip on opened lid and lift atone side to take out.

To insert:

Press ashtray into opening with lid closed .

Asht ray in passenger com par tm entTo take out:

Open ashtray, press down and take out.

To insert:

Insert at top first then push in fully.

On vehicles with individual seats:

To take out:

Lift one side of the handle of the openedlid.

To insert:

Push ashtray into ope ning w ith lid close d.

Th e cigare t te l ighter is switched on bypushing in the element.

When the heating element glows, thelighter springs out automatically - pull itout immediately.

Th e s o c k e t can be used for a cigarettelighter or other electrical accessorieswith a capacity of up to 100 watts . Whe nthe engine is not running this will however discharge the battery.

Cigare t te l ighter and socket a l so workwhen the igni t ion key has been takenout .

Children should therefore never be leftalone in the car.

Vehicles with a lockable glove box havean additional key - see also page 4.


C U RTA I N S * EXTENDING TABLE*



The curtains which can be supplied forvehicles with seats/reclining seat benchare stored underneath the rear seatbench. They are secured to the windowsurrounds by press studs. A further curtain can be press-studded in posit ionbehind the front seats.

On vehicles with individual seats in thepassenger compartment there is an extending table on the left side.

The table can be p ulled up out of its retainers and folded down (see illustration).

Caut ion

For safety reasons the table must bepushed in when vehicle is in motion.


TH E FIRST 1500 KM - AND AFTERWARDS

DRIVING TIPS

i h f f i h h Di l i I



During the first few operating hours theengine internal friction is higher thanlater on when all the moving parts havebedded down. How well this running inprocess is done depe nds to a considerable extent on the way the vehicle is

driven during the first 1500 km.

Up to 1000 kmdo not use full throttle at all.

Furthermore the following speeds inkm/h should not be exceeded in thegears:

Petrol engines

Diesel engines

Manual 0-1000 kmgearbox 4 speed gearbox 5 speed gearbox

1st gear 20 202nd gear 40 403rd gear 70 604th gear 105 855th gear - 105

Automatic

gearbox0-1000 km

Driving range 1 35Driving range 2 75Driving range D 110

0-1000 km4 speed gearbox 5 speed gearbox

1st gear 20 202nd gear 40 353rd gear 65 554th gear 95 855th gear - 95

The maximum permissible engine spee dduring the first 1000 km is 4000 rpm.

From 1000-1500 km

the speed can gradually be increased tothe road or engine maximum.

After th e running-in period

on vehicles with a rev counter oneshould change into the next higher gearat the latest by the time the red warningzone is reach ed.

The maximum permissible enginespeeds are

P etrol engines about 5300 rpmDiesel engines about 4800 rpmA speed limiter prevents extremely highengine speeds.

Important notes

• Do not overrev the engine when co ld- either in neutral or in the gea rs. Allspeeds and revs are only valid whenengine is properly warm.

• Try to avoid running the engine atmaximum speed - changing up earlyhelps to save fuel and reduces noise.

• Do not let engine labour - changedown when engine no longer runssmoothly.


D R I V I N G T I P S

DRIVING SAFETY

Th e ti l condit ion of your ve Safety on the road depends to a large • Stow all luggage correctly in boot



Th e operational condit ion of your vehicle is essential to safe driving.S o before moving off, always check

• the lights an d turn signals

• the brakes

• the amount of fuel

• the mirror settings

• the cleanliness of headlights, lensesan d windows

and at regular intervals

• the tyre condit ion and pressures- pages 79-82, 116

• the engine oil level - page 68

The oil level should be checked everytime fuel tank is filled, or in difficultcondit ions or full throttle operation,daily

• the coolant level - page 71

• the brake fluid level - page 76

• the windscreen washer

Safety on the road depends to a largeextent on the personal attitude and styleof driving.

To be on the safe side you should:

• always pu t seat belt on before mov-

ing off - even in town traffic - page 10In many countries the wearing of seatbelts is compulsory anyway.

• Ensure that all your passengers -including those on the rear seat - arewearing their belts - page 10.

P assengers without seat belts can endanger not only themselves, but also thedriver.

• Adjust headrests to body size.The upper edge of headrest must beapproximately at eye level.

Ensure that no articles interfere withoperation of pedals - page 77.

• Stow all luggage correctly in bootpage 19.

on the roof rack - page 19• Do not drive when yo u feel tired owhen your reactions are impaired in an

way.Stop for a break at the latest after driving for two hours.

• Adapt vehicle speed to traffic anroad condi t ions .

Remember that particularly on smoothslippery roads the handling and braking -also on vehicles with four-wheel driveis limited by the adhesion of the tyres.O n wet roads the front wheels caaquaplane at high speeds. The vehiclecan then no longer be steered properly.

Further instructions on safety are givein the various chapters in this manual.


DRIVING ECONOMICALLY AND ENVIRONMENT-CONSCIOUS

The economyandtheexhaust emissions • Change down only when engine no



The economy and the exhaust emissionsand noise depend to a great extent onthe personal style of driving.

To use as little fuel as possible anddisturb the environment as little as possible and keep wear of engine, brakesand tyres to the minimum, the followingpoints should be noted:

• Do not run engine to warm it up withthe vehicle stationary.

Drive off immediately after starting. Donot overrev.

• Avoid full throttle acceleration.

• Avoid high engine speeds

The best consumption and least distur-bance of environment is obtained at lowengine speeds in the highest possiblegear. Drive as often and as long aspossible in the highest gear.The fuel consumption is for exampletwice as high in 2nd gear and 1.5 timesas high in 3rd gear as in 4th gear.

• Change down only when engine nolonger runs smoothly.

Depending on gearbox you can normallydrive on the level in the highest gear at40-60 km/h and still accelerate.

• Avoid driving continuously at topspeed.

• Drive as smoothly as possible andlook well ahead.

Unnecessary acceleration and brakingmust be paid for with higher fuel consumption and more disturbance of theenvironment.

• Stop engine during traffic hold-ups.


D R I V I N G T I P S

~ e individual operating condit ions T h e engineers at the factory have de • A ll ele ctrical co ns ume rs (e g rea



~- e individual operating condit ions-a-.- 'aliy also affect fuel c ons umption.

~~ e following factors for instance are not-avourable to fuel consumption:

• T raffic de ns ity, particula rly large

towns with numerous traffic lights.• F requ ent stop/s tart driving, particularly driving from house to house so thatengine is never properly warm.

• Driving in hea vy, slo w- movin g trafficin low gear so that the engine speed isrelatively high in relation to the distancecovered .

O ne sh oul d, therefore , plan trips in ad

vance to avoid unfavourable operatingconditions.

Obvious ly the fuel consumption is alsoaffected by factors over which the driverha s no influence. It is for example normal for the consumption to increase inthe winter or in arduous conditions (badroads , trailer towing etc.).

T h e engineers at the factory have des igned your car for maximum fuel efficiency. To make use of this economypotential pleas e note the followingpoints:

• H ave your veh icle se rvic ed in a V. A . Gworkshop at the intervals laid down inthe servic e sc hedu le. Y ou will then o btain optimum economy plus constantreliability and long service life.

• C h e c k the tyre pressures ar regularintervals. Low tyre pressures are notonly detrime ntal to han dling , the highe rrolling res istance also increa se s the fuelconsumption.

• Do not drive abou t unne ce ss arily witha roof rack on the vehicle. P articularlyat high speeds the increased air res istance makes itself felt.

• D o not carry a lot of un ne ce s s ar yballast about in the vehicle . P articularlyin town traffic when vehicle is beingfrequently a cc ele rated the vehicle we ightha s a considerable influence on fuelconsumption.

A ll ele ctrical co ns ume rs (e.g. reawind ow he ating, additional he adlightsauxiliary heater) should only be leswitch ed on as long as nec es sa ry. Thhigher load on alternator also increasethe fuel consumption.

• T he fuel co ns umptio n should bc h e c k e d regularly, preferably when filling the tank, with the aid of the mileagrecorde r. O ne ca n then have the cainspected if the consumption has ic reased .

• The oil co nsu mption also de pe ndon engine load and s p e e d . Depend inon style of driving the consumption cabe up to 1.5 1/1000 km.

It is normal for the oil consumption ofnew engine to reach its lowest valuafter a certain mileage has been coveed. The consumption during the fi5000 km can therefore be slightly abovthe figure given.

Similarly, the fuel consumption and egine perforamnce can also not be corectly a s s e s s e d until this distance ha

been covered .


DRIVING TIPS

T R A I L E R TOWING

The vehicle must be specially equipped Note W he n towing a trailer in mountainous



The vehicle must be specially equippedto tow a trailer.

When a vehicle is supplied from the fac-tory fitted with a towing bracket it willalready have the necessary modifica-tions. When a towing bracket is serviceinstalled, the following must be noted:

• The towing bracke t is a sa fety part.Only a bracket which has been develop-ed for your vehicle is to be used and itmust be fitted in accordance with ourinstructions.

Details are usually given in the fittinginstructions supplied with the bracket.

A special warning lamp must be fittedwithin the driver's range of vision to showthat the trailer turn signals are working.

• Check if the fitting of a bracket mustbe entered in the vehicle documents.

• E very V.A.G workshop has the neces-sary information on fitting towingbrackets. The installation should thereforebe done by them.

Note

The installation of a towing bracket in-creases the unladen weight slightly andthe payload must be reduced to corres-pond.

• To obtain the bes t handling of veh icleand trailer it is advisible to make fulluse of the maximum permissible drawbar weight. The tyres on towing vehicleshould be inflated to the pressures forfull load.

F or trailer and draw bar weights see"Technical Data" page 120.

Please note any local regulations con-cerning maximum speeds, driving res-trictions on Sundays, trailer towing, etc.In G ermany for example the pe rmissiblemaximum speed when towing a traileris 80 km/h.

In any case the speed must be reducedimmediately as so on as the trailer showsthe slightest sign of snaking.

W he n towing a trailer in mountainousregions note the following:• The trailer weights given in "TechnicalData" are valid only for gradients up to12%. If the vehicle and trailer weight isbelow the permissible maximum a cor-respondingly steeper gradient can beclimbed. F urthermore the given trailerweights are only applicable for altitudesup to 1000 m above sea level. As theengine output and thus the climbingability drops due to the decreasing airdensity above 1000 m the weight ofvehicle and trailer must also be reducedby 10% for ea ch further 1000 m or partthereof.

• The cooling effect of the radiator fancannot be increased by changing downbecause the speed of the fan is not de-pendent on the engine speed. O neshould therefore not change down evenwhen towing a trailer as long as theengine can cop e without ve hicle spe eddropping too much.


DRIVING TIPS

DRIVING A FOUR-WHEEL DRIVE V E H I C L E *

Th e drive concept



Th e drive concept

Contrary to the normal type of selectablefour-wheel drive, the four-wheel drive onthe T ransport/Ca ravelle syncro is alwaysin action. Only the amount of power

being transmitted to thefront

wheelschanges according to the requirements.This automatic distribution of the drivingforces to the rear and front wheels isattained through a wear resistant viscous coupling incorporated in the front

axle. This ensures, on the one hand,that the driving force losses are keptas low as poss ible, and on the otherhand, that the best possible traction isattained when required.

Note:

Vehicles for particularly arduous operating conditions (e.g. predominantly crosscountry work) can be fitted with a manually controlled four-wheel drive as anoptional extra. Further details are givenon page 23.

Front axle final driveand viscous coupling

Prop shaftRear axle final drive


-z vantages of fo ur -w he el dri ve The acceleration Using winter tyres



vantages of fo ur w he el dri ve The acceleration Using winter tyres- - e special drive concept of the Trans-Dorter/Caravelle syncro, when cornered with a vehicle which only has a:.-. o -wheel drive, has advantages in respect of the following points:

~he drivability

decisive for the drivability - particularly:n slippery roads - is the grip betweenthe four wheels and the road surface.

On vehicles with two-wheel drive, thedriving wheels can spin on slippery surfaces if too much acceleration is applied.This greatly impairs their grip. Under un

favourable conditions, this could causethe vehicle to break away.

By distributing the driving forces to fourinstead of two wheels the lateral forceswhich can be transmitted are increasedon the Transporter/Caravelle syncro,and the vehicle is less likely to breakaway.

As the driving force to be put onto theroad goes to four wheels instead of two,the amount of slip is considerably red u c e d . This improves the adhesion between tyre and road surface and thereby,the acceleration capabilities on slipperyroad surfaces.

The traction

Four-wheel drive increases the tractiona great deal . This is of particular benefiton snow and ice, when moving off, andwhen driving on difficult mountain roads.

Driving under such conditions is lesshazardous with the Transporter/Caravelle syncro:There is no longer any need to drive pastobstacles at speeds on slippery uphillstretches, because one is afraid of becoming stuck, one can approach slowly,stop and then, start off again.

With the four-Wheel drive concept theTransporter/Caravelle syncro has goodwinter driving properties even with standard tyres. However, the use of winteror allweather tyres, on all wheels, is recommended in order to obtain evenbetter cornering and braking behaviour.

Snow chains see page 82.


Driving on dry roads Driving on wet, slippery roads Notes



Driving on dry roads

Under normal driving conditions, the dif-ferential locks must not be engaged.They do not provide any advantages atall on dry road surfaces, but impair thevehicle's steerability.

Particularly if the front axle differentiallock is engaged, the vehicle is no longersteerable.

Important instructions on the differentiallocks are to be found on page 24.

g , pp y

Due to the four-wheel drive, the enginepower is transferred even to a relativelysmooth road surface.On wet surfaces

O n wet roads one should also note thateven with the Transporter/Caravellesyncro it is possible for the front wheelsto "swim" (aquaplaning) at high speeds.

For this reason, one should avoid ex-cessive speed and drive at a speedcompatible to the road conditions. Thedifferential locks* must not be engaged.

Important instructions on the differential

locks are to be found on page 24.On slippery surfaces

O n slippery surfaces the rear axle differential lock may only be engaged whenmoving off, and at very low speed. Thelock should then be disengaged again.The front axle differential lock must notbe engaged.

The style of driving must always beadapted to suit the road surface andtraffic conditions. The increased safetyoffered by this type of vehicle must notencourage one to take unnecessaryrisks.

In particular, one must always remem-ber that the stopping ability is limitedby the adhesion of the tyres on theroad surface. The braking capability ofthe vehicle is the same as that of anormal two wheel drive vehicle. For thisreason, one should never be temptedby the good acceleration capabilities,even on slippery road surfaces, intodriving too fast.


NG TIPS

Driving c ros s country • Do not drive over small embank • After traversing water or mud one



Before driving for the first time over difficult terrain, it is advisable to make yourself familiar with the vehicle on normalroads, and also under easier off-roadconditions. For safe driving cross country, the following rules are of great importance.

• Always wear your seat belt.• Timely gear changing takes care ofthe engine and prevents the vehicle frombogging down.

• Never drive with the clutch slipping asthis leads to premature wear.

• The more uneven and creviced theterrain is, the lower speed must be. Payattention to the vehicle's ground clearance.

ments or declines at excessive speed.This can lead to bouncing during whichit would be impossible to avoid anyobstacle which may suddenly appear.In addition it could lead to vehicle da

mage.• Drive down gradients in the samegear as you would drive up.

• Embankments, gradients and similarobstacles should only be driven up ordown at right angles, i.e. directly in linewith the slope.

• If however one is forced to driveacross a slope and the vehicle tends to

tip, one should immediately steer directly into the slope.

• Before driving through water, determine the depth - the permissible wadingdepth (see technical data) must not beexceeded.

NoteTo prevent the engine from drawing inwater through the intake air preheaterand being damaged when wading, thereis a valve in the engine compartment onthe right behind the maintenance flapwith which the intake air preheating canbe closed. The valve is closed by press-ing it down and turning it to the right.

should drive a short distance with brakeslightly applied. The linings must be driedout properly. By doing this, one preventsthe brakes from pulling to one side, or adelayed braking effect.

After driving through deep water it isnecessary to remove the engine oil dipstick in order to check whether anydrops of water are present, or to checkwhether the oil level has increased. If theanswer is "yes" then the oil must berenewed immediately.


DRIVING TIPS

• After driving through mud, the brakes Note for vehicles with differential Output testing



must be checked and if dirty, cleaned.This will prevent premature wear takingplace in the brake system.The engine compartment and the underside of the vehicle body must also becleaned so that the functioning of allmoving parts and electric/electroniccomponents is maintained.

NoteTo prevent damage to the underside ofthe vehicle, the vehicle is equipped withprotective plates in front of the front axleand underneath the engine and gearboxand protective rails running along bothsides of the propshaft.

lock(s)

• Before driving through a difficultcross country stretch (e.g. mud, sand,water, snow or steep gradients) it is advisable to engage the differential lock(s)*at low speed. Important instructionsregarding the differential locks are tobe found on pages 23 and 24.

If the Transporter/Caravelle is to be output tested on a dynamometer, the prop-shaft must be removed.

Brake test standF or brake testing e.g at MOT, the prop-shaft must be removed. The differentiallocks must not be engaged.


O P E R AT I N G I N S T R U C T I O N SFUEL

P e t r o l e n g i n e s



Vehic les wi thout ca ta lys t

44 and 57 kW carburetor engines_saded regular fuel to DIN 51600,RON 11 not lower than 91

o read-free regular fuel to DIN 51607,RON not lower than 91 .if regular fuel with adequate anti-knockproperties is not available, use premuimor a suitable mixture.

66 and 82 fuel injection enginesLeaded premium petrol to DIN 51600,R O N " not lower than 98.

Vehic les wi th ca ta lys t

61 and 70 kW fuel injection engines

Lead-free regular petrol to DIN 51607,RON1 not lower than 91 .

If lead-free regular petrol with adequateanti-knock properties is not available,use lead-free premium petrol or a suitable mixture.

For al l vehicles with catalyst:

Only lead-free petrol may be used inthese vehic les .

The use of leaded petrol does not lead,to engine dam age but i t is very de trimental to the functioning of the em ission cont rol system because the lead is deposited in the catalyst.

Even one tankful of leaded petrol wil lde t rac t f rom the eff ic iency of the ca talyst . Although lead-free fuel may againbe used afterwards the original efficiency of the catalyst is never fully attained.

On vehicles with Lambda probe themixture formation is also negativelyaffected. This can cause poor engineperformance (jerking and stal l ing whenidling) combined with a higher fuel consumpt ion .

" Research Octane Number, indicates antiknock properties of the petrol. 63www.WestfaliaT3.info - a useful website for owners and enthusiasts of VW Westfalia T25 / T3 / Vanagon Campervans

O P E R AT I N G INSTRUCTIO

Fuel additives Diesel engines As this additive reduces the engine outt l th t t ll i d



O n carburetor engines with and without

catalysts carburetor icing can occur atambient temperatures between 0° C and+ 15° C when the air humidity is highdespite the automatically controlled intake air preheating. This can cause theengines to stall occasionally when idlingin the warm-up phase.

Even the anti-icing additives containedin so me fuels in the c old se aso n cannotentirely prevent carburetor icing. When aproperly tuned engine stalls repeatedlyin the conditions described above it isadvisable to mix Volkswagen AUDI petroladditive with the fuel. This additive prevents carburetor icing and also cleansthe carburetor and protects it againstcorrosion. It is obtainable from V.A.Gworkshops in Germany and in manyexport countries.

No other fuel additives should be mixedwith the petrol.

Diesel fuel to DIN 51601C N n not lower than 45

W hen using summer Diesel trouble maybe experienced at temperatures below

0° C because the fuel thickens due towax separation.

F or this reason, winter Dies el whcih ismore resistant to cold is sold duringthe winter and works satisfactorily downto about -15° C.

In countries with different climatic conditions the D iesel fuels offered have adifferent temperature behaviour. C hec kwith V.A.G dealers o r filling stations inthe country concerned regarding theavailability of Diesel fuels.

When necessary summer and winterDiesel can be used at lower temperatures by mixing regular leaded or lead-free petrol (not premium) with the Diesel.

put, only the amount actually requiredshould be used: (max. 30%)

Temperature

in ° C

Summer

Diesel

PetrolWinter-Diesel P etrol

- 0 to- 5 85% 15% 100% -- 5 to-15 70% 30% 100% --15 to-25

- - 70% 30%

This table is bas ed on the fuels ava ilablein Germany.

Due to the inflammability of petrol th emixing should, for safety reasons, onlybe done in the vehicle tank. Where pos -sible, the petrol should be put into th etank before the Diesel.

64" C etane Number, indica tes the ignitability of

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

O P E R AT I N G INSTRUCTIONSFILLING TANK

Mixing must take place before the waxstarts to separate because subsequent

The filler neck is on the right hand sideof th vehicle

Note for vehicles with Diesel engine:



starts to separate because subsequentmixing is effective only in the tank butnot in the rest of the fuel system.

If the fuel is already waxed to such anextent that the engine will not start it issufficient to place the vehicle in a warmroom for a while.

Other fuel additives (anti-waxing agentsand similar fluids) must not be mixed withthe Diesel fuel.

of the vehicle.

The fuel tank capacity is approx. 60litres (syncro 70).

Trouble-free refueling calls for correct

use of filler nozzle.• Insert noz zle fully into tank nec k anddo not tilt it.

• Do not try to fill tank too quickly,otherwise the fuel (especially Diesel) willfoam and this may cause nozzle to switchoff too soon.

As soon as the correctly operated automatic nozzle switches off for the firsttime, the tank is full. Do not try then toput more fuel in because otherwise theexpansion space in tank will be filled -the fuel can then overflow when it getswarm.

Bleeding the fuel sys tem

The fuel system does not need bleedingwhen tank has been run dry - this takesplace automatically while starting.

Note for vehicles with factory fittedcatalyst

Catalyst vehicles have a smaller diameter tank filler neck which is closedwith a spring-loaded flap below thefiller opening. Filler nozzles for lead-free petrol are smaller to suit and openthe flap when inserted in filler neck.This is to ensure that only lead-free

petrol can be put into tank.


OPERATING INSTRUCTIONS

What to do when wrong fuel hasb i k



been put into tank.Premium petrol instead of regular

The engine can be run on premium fuelwith no problems.

Regular petrol instead of premiumIn isolated cases the engine can also berun on regular petrol. The vehicle mustthen however not be driven at top speedand with full throttle. High engine loadingwith full throttle or high speeds cancause engine damage. Fill tank withpremium petrol as soon as possible.

Lead-free petrol instead of leaded

The engine ca n be run on lead-free petrol. A stipulation however is that the

petrol has the correct anti-knock properties (RON) - see also section on "Fuel".If the anti-knock properties are lower,the instructions under "Regular petrolinstead of premium" apply.

Leaded petrol instead of lead-free

Vehicles with catalyst must not be drivenon leaded petrol because otherwise thefunction of t he emission control systemis affected considerably - see also section "Fuel". The fuel system must beempt ied , in accordance with environmental regulations - preferably by aV.A.G workshop.

Petrol instead of diesel

The engine can be run on a concentration of up to approx. 3 0 % leaded or

lead-free regular petrol (not premium).However if premium petrol or a largequantity of regular petrol has been putin the tank accidental ly, the engine mustnot be run as otherwise damage willoccur. The fuel system must be emptiedbearing in mind environmental controlregulations - preferably by a V.A.G workshop.

Diesel instead of petrol

The engine cannot be run on Diesel. Thefuel system must be emptied bearing inmind the environmental control regulations - preferably by a V.A.G workshop.


LUBRICANTS

O P E R A T I N GINSTRUCTIONS

Engine

A i l hi h li l i d°C °F



• A spe cial very high quality multi-gradeoil is put in at the factory and this canoe used all the year round - exc ept invery cold climates.• Mineral or synthetic oils may be used;or topping up or changing regardless ofMl in engine. The container must benarked with the correct specifications*or the engine concerned.

• The visco sity classes of the oil mustZ 3 selected as shown on the right. Thehi does not have to be changed when:ne ambient tempera ture is briefly above:ne range shown.

• W hen using single-g rade oil S A E 1 0W:- multi-grade oil S A E 5 W -20 or S AEI W-30 do not drive with full throttle for:ng periods if the temperature is above

ne range shown.

100

80

- 6 0

40

20

0

20

55

O O

s s

B28-083 - P etrol engines B28 -88-D ieselandT urboDies elengines

A - S ingle grade oils, B - Multi-grade oils, C - Improved lubricity oils

Petrol engines

• G oo d quality oils, spe cificationAPI - S F or• Improved lubricity oils ,specification VW 50000

Diesel engines (except turbodiesel)

• G oo d quality oils, spe cificationAPI - C C or API - C D or• O ils for turbodiesel engines ,specification VW 50500 or• Improved lubricity oilsspecification VW 50000

Turbodiesel engines• O il for turbodiese l engines ,specification VW 50500,

for topping up if unavoidable, also• G oo d quality oils, spe cificationAPI - CD

Manual gearbox an d final drive• Gear oil, specification AP I - G L 4,S AE 80

Automatic gearboxFinal drive:• Gear oil, specification AP I G L 5,S AE 90Gearbox part:• ATF Dexron®

Power as s i s t ed steering• ATF Dexron®No additives s h o u l d b e mixed with the 57

lubricating o i l s .www.WestfaliaT3.info - a useful website for owners and enthusiasts of VW Westfalia T25 / T3 / Vanagon Campervans

O P E R AT I N G INSTRUCTIONSENGINE OIL

The vehicle must be on a level surfacewhen checking oil level After stopping

Changing engine oil

Th i il h ld b h d h



Checking oi l level

The engine oil level must be checked at

regular intervals, preferably when fillingthe tank. In arduous operating cond i -tions or when engine is working hard itshould be checked daily before movingoff.

The dipstick and filler pipe can be reached through a flap behind the rear number plate.

The dipstick location is shown in theillustration:

when checking oil level. After stoppingengine wait a few minutes for the oil todrain back to the sump. Then pull thedipstick out, wipe it with a clean cloth andinsert again. Then pull dipstick out again

and check the oil level:The level must be between the twomarks.The difference in quantity between themin. and max. marks is 1.0 litre.When the engine is working hard suchas in sustained high-speed motorwaycruising in summer, when towing a traileror when climbing mountain passes, the

oil level should be kept up to the max.mark.

Topping up engine oil

Unscrew the cap from the oil filler andpull extension pipe out fully.

A dd oil.Push extension pipe in again and screwthe cap back on tightly.

Check the level with the dipstick - theoil should not be above the max. mark.

The engine oil should be changed at theintervals given in the service schedule.If the vehicle is used continuously in verydusty areas or in countries with arcticclimates where the temperature is normally below about -2 0° C , the engine oilshould be changed at shorter intervals -see also "Difficult operating conditions"page 84.

Recommended oils and viscosityclasses - see previous page.

P ermissible oil consumption - see pages108/109.


GEARBOX OILO P E R AT I N G INSTRUCTIONS

Checking oi l level

With th e l g b the oil levelChanging oi lWith th l b the oil does



With th e manual gearbox the oil leveldoes not need checking in between theintervals given in service schedule.

With th e automatic gearbox the oil levelin the final drive also does not needchecking between services.

The AT F level in gearbox part must however be checked in between the intervals given in s ervice sc hedule.

To do this the vehicle must be standingon a level surface. The level must onlybe che cked when the ATF is warm (about10 km after starting from cold the ATFis at the correct temperature). If fluid is

cold or too hot the reading will be incorrect. The engine must be running atidle speed, the handbrake must beapplied and the selector lever at " P " .

To check, pull dipstick (see Fig.) out,wipe with a clean lint-free rag and theninsert it fully again.

P ull dipstick out and chec k AT F level.When the ATF is warm th e level mustbe between the two marks - otherwisethe vehicle must be taken to a V.A .Gworkshop without delay so that they canfind the reason for the incorrect level.It is not sufficient to merely top up ordrain off ATF.

With th e manual gearbox the oil doesnot need changing.

With th e automatic gearbox the oil inthe final drive also does not need changing. The A T F in gearbox part must however be changed at the intervals given inservice sc hedule. T his should preferablybe done by a V.A.G dealer.

NoteWhen there is no lubricant in the manu-

al or automatic gearbox th e enginemust not be started and the vehiclemay only be towed with driving wheelslifted.


O P E R A T I N G I N S T R U C T I O N S

P O W E R A S S I S T E D S T E E R I N G *

Note

If the power assisted steering fails at any



To ensure satisfactory operation of thesystem it is essential that the fluid levelin reservoir is correct.

The reservoir is in the engine compartment on the right behind the maintenance flap.The check must only be done with theengine running and the wheels in straight-ahead position.

The fluid should always be between the"max" and "min" marks. When level hasdropped to min. mark, ATF (Dexron®)should be added after removing the redcap in top of reservoir.

If the power assisted steering fails at anytime or when engine is not running (vehicle on tow) the vehicle can still besteered but more force will be requiredto turn the steering wheel.


O P E R AT I N G INSTRUCTIOP O O L I N G S Y S T E M



-sservoir"he cooling system is filled at the fac-

:ory with a long lasting mixture of waterand ourcoolant additive G11 (anti-freeze:n glycol basis with ant i-corrosion addi-Bves). T his mixture gives the nec es sa ryfrost and corrosion protection, preventsscaling and incre as es the boiling pointof the coolant.

Caution

Th e coolant i s po i sonous . I t must there-fore only b e stored in the original c o n -tainer ou t o f reach o f c h i l d r e n .

E x p a ns i o n tank - P etrol en gine s

In the engine compartment there is a

reservoir and an expansion tank.T he coolant level is normally only checked in the reservoir. It only needs checking in the expansion tank if a largeamount of coolant has been lost or if thewarning lamp for coolant temperature/coolant level lights up.

E x pa n s i on tank - Dies el engine

C h e c k i n g coolant level

T he correct coolant level is essential tothe satisfactory operation of coolingsystem.

O p e n flap beh ind numbe r plate. T he levelshould be between min. and max. markswhen engine is cold or just above themax. mark when engine is warm.

Th e level c an only b e c h e c k e d properlywhen engine i s no t runn ing .


O P E R AT I N G INSTRUCTIONS

Coolant lossesIn normal conditions the cooling system

Topping up coolant

Topping up is normally done in the re

In order to maintain the corrosion protection at all times and prevent the systemf l d h b l



In normal conditions the cooling systemis almost maintenance-free.

Coolant loss normally indicates leakagein the system. In this case the coolingsystem should be c hec ked by a V.A .Gworkshop without delay. It is not sufficient to merely add coolant.

In a water-tight system losses can onlyoccur if the boiling point of the coolantis exceeded as a result of overheating.Overheating can occur if:

• the flow of cooling air is reduced, e.g.by a radiator muff, very dirty radiator fins(leaves, dust, insects) or additional driving lights in front of radiator grille• the radiator fan is not working - seenext page "R adiator", or

• vehic le is driven up a long hill in toolow a gear with engine speed very highand at very high ambient temperatures -see next page "Radiator".

If the cause of the overheating cannot befound and eliminated, contac t a V.A.Gdealer as soon as poss ible as otherwiseserious damage may be done to theengine.

Topping up is normally done in the reservoir only.

Do not fill above the max. mark.

The excess coolant will be forced out of

the system when engine gets hot.If the coolant warning lamp comes onthe expansion tank must also be checked and filled to brim if necessary.

First switch the engine off and let it cooldown slightly, then turn cap one turn tothe left and let pressure escape first.Then take cap off.

Caution

Do not remove cap when engine is hot .Danger of sca ld ing .System is under pressure.

from scaling up and the boiling pointfrom being lowered the mixture shouldnot be altered even in the summer orin warm countries by adding plain water: the coolant additive proportionshould be at least 40% (anti-freezeprotection down to about -25° C) .

Screw cap on again tightly.

The system must then be bled with engine running (at a fast idle). Take airintake grille off (see page 69), open ventscrew at top of radiator and set heaterlever to "warm". As soon as coolantemerges, close vent screw. Top level upin reservoir and expansion tank.



Fan

ne fan is driven electrically and con-

Driving in winter

The mixture put in the system by the fac



_ ne fan is driven electrically and conrolled by a thermoswitch which is ac-:jated by the coolant temperature..'/hen the engine is hot, the fan may

:ontinue to run when the engine has:een stopped or it may switch onsuddenly - even when ignition is off.

Notes• If the fan is not running although theloolant temperature is very high, the^se should be checked and renewed if-ecessary - see page 94.• The speed of the fan does not depend: n engine speed. The cooling effect can-•ot therefore be increased by changingaown.-s long as the engine runs amoothly anda gradient can be taken without a large3 r o p in speed it is not necessary tomange down.

The mixture put in the system by the factory provides frost protection down toabout -25° C. To ensure that frost protection is adequate, the coolant shouldbe checked before the cold season begins and if necessary coolant additiveG 11 (undiluted) added.

If greater protection against frost is required, the proportion of G 11 additivecan be increased, but only up to 60%otherwise the anti-freeze protection isreduced and furthermore the coolingeffect is impaired.

Vehicles for export to cold countries

usually have frost protection down to-35° C.


^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^

WINDSCREEN WASHER SYSTEM

O N S

To f i l l containerLift carpet , open flap and unscrew cap.



The filler opening of the container isunder the carpet on left hand side offront footwe ll . The container holds about

3.5 litres. On vehicles with a headlightwasher the capacity is 6.5 litres.

On vehic les wi th rear window washer*there is an additional container on theright in the luggage compartment. Thiscon tainer h olds about 1 litre.

p p p pFill container to top with water and screwcap on again. Switch ignition on andcheck that washer is working.

It is advisable to add a window cleanersolution (with anti-freeze additive in winter) to the water because plain water isnot usually sufficient to clean the glassand headlight lenses quickly and thoroughly.

Adjus t ing washer je t s

When vehicle is stat ionary, the watershould hit the windscreen at the following points:

a = 490 mm c = 180 /190 1 ' m mb = 220 mm d = 450/330 1) m m

The water jet for the rear window shouldhit the windo w in the cen tre of the wipe darea.

The jets can be adjusted with a needle.

The jets for the headlight washer sys

t e m * can only be adjusted with a specialtool . When adjustment is necessary,contact your V.A.G workshop.

74 1 1 on ly veh ic le s wi th 37 , 44 o r 51 kW eng ine swww.WestfaliaT3.info - a useful website for owners and enthusiasts of VW Westfalia T25 / T3 / Vanagon Campervans

B R A K ESYSTEMO P E R AT I N G INSTRUCTIONS

The following points are of particularimportance to the safe operation of thebrakes

• Brake lining wear depends to a largeextent on the operating conditions andstyle of driving On vehicles which are

Brake servoThe servo is operated by vacuum which



brakes.

• New brake linings must also be run inand do not have the optimum frictionproperties during the first 200 km. The

slightly reduced braking effect can becompensated for by slightly more pressure on the brake pedal. This also applies.vhen new linings have been fitted.

• On hills cha nge down in good time to~iake use of the braking effect of engine,"his relieves strain on the brake sys tem.,Vhen brakes are applied do not keep:nem on continuously, apply and releas ealternately.

• After driving through water, driving in~eavy rain or washing the car, the brak-ng effect can be retarded slightly. Thecads must be dried first by applying thecrake.

~he full braking force may also be retarded when ve hicle has been driven forsome time on heavily salted roads without using the brakes because the layerDf salt on discs and pads has to be removed first.

rurther details - particularly for vehicles.vith four wheel drive - are given oncage 61.

style of driving. On vehicles which areused mainly in town traffic and stop/startconditions or are driven hard it may benecessary to have the thickness of thebrake linings checked in a V.A.G workshop in between the intervals given inthe s ervice sche dule.

• If the brake peda l travel increasessuddenly, it may be that one of the twobrake circuits has failed. Y ou can stilldrive on to the next V.A.G workshop butbe prepared to use more pressure onthe pedal and allow for longer brakingdistances on the way.

The failure of a brake circuit is shown bythe lighting up of the brake warninglamp* (see also page 33).

The brake fluid level must be checkedregularly - see next page.

is only available when engine is running.Caution

For this reason the vehicle should not

be allowed to roll with engine not runn-ing.

W hen the brake servo is not working because, for example, the vehicle is beingtowed or because a defect has occuredon the brake servo, the brake pedal mustbe pressed harder.


O P E R AT I N G I NM I

However, if the level sinks noticeably ina short time or drops below the "min"mark the system may be leaking Take

Caution

Brake fluid i s poisonous .



Brake fluid reservoir

The fluid reservoir is in the dash under

the dash cover panel. The panel can belifted to fill the reservoir. To do this gripin the recess at the back of the cover.When installing insert the lower front

edge first.

Checking fluid level

The correct fluid level is essential to thesatisfactory operation of the brake sys-tem. The fluid level must always be bet-

ween the "max" and "min" marks.The level of fluid tends to sink slightlywhen the vehicle is used due to the auto-matic adjustment of brake lining wear.This is quite normal.

mark the system may be leaking. Takethe vehicle to a V.A.G workshop at onceand have the brake system checked.

The failure of a brake circuit is shown bythe lighting up of the brake warninglamp* (see also page 33). When thishappens take the vehicle to a V.A.G work-shop immediately and have the brakesystem checked.

Brake fluid

Brake fluid abs orbs moisture. A s too higha water content becomes detrimental tothe entire system after a period of time,the brake fluid must be renewed everytwo years. The brake system must bebled afterwards.

U se only our genuine brake fluid (spe-cification to U S standards F M V S S 116DO T 4). The fluid must be new and un-used.

p

It must therefore only be stored in theoriginal container out of reach of child-ren.

Brake fluid will als o dama ge paintworkand the plastic material of which thedash is made. Take great care not tospill any fluid when topping up the re-servoir. Cover area round reservoir ifnecessary.



P E D A L S

h e m o v e m e n t o f t h e p e d a l s m u s t n o t b e- e s t r i c t e d .

th i d t t t i l i th



-or th i s r ea s o n , do no t pu t a r t i c l es in thel o o t w e l l w h i c h c o u l d r o ll o r s l i d e u n d e r -- e a t h t h e p e d a l s .

A r o u n d t h e p e d a l a r e a t h e r e s h o u l d a l s o

oe no foot m a t s o r o t h e r a d d i t i o n a l f l o o rc o v e r i n g m a t e r i a l s :

• In th e c a s e o f d e f e c t s o n t h e b r a k es y s t e m , a g r e a t e r p e d a l t r a v e l m a y b e- e c e s s a r y .

• It s h o u l d a l w a y s b e p o s s i b l e t o d ep r e s s t h e c l u t c h a n d a c c e l e r a t o r p e d a l shi l ly.

• Al l pe da l s mu s t be ab le to re tu rn , un-

n i n d e r e d , t o t h e i r r e s t p o s i t i o n s .

F o r t h e s e r e a s o n s t h e r e f o r e , t h e o n l y*oot m a t s w h i c h m a y b e u s e d , a r e t h o s ew h i c h l e a v e t h e p e d a l a r e a c o m p l e t e l yf r e e a n d w h i c h a r e p r e v e n t e d f rom s l i p ping.

7 7www.WestfaliaT3.info - a useful website for owners and enthusiasts of VW Westfalia T25 / T3 / Vanagon Campervans

B AT T E R Y

N G INSTRUCTIONS

C h e c k i n g a c i d level

In normal operating conditions the battery requires hardly any maintenan ce At

Th e level should therefore only be topp-ed up in a V.A.G workshop.

• Never short th e battery terminals as



O n vehicles with a petrol engine the battery is under the righthand sea t. It can bereached when seat is pus hed fully for

ward.O n vehicles with a Diesel engine the battery is on the righthand side of the enginecompartment.

The 2nd battery* is under the lefthandseat. It can be reached by pushing theseat fully forward.

tery requires hardly any maintenan ce. Athigh ambient temperatures however it isadvisable to check the acid level at regular intervals. It should always be betweenthe min. and max. marks on the side ofthe battery. If level is low contact V.A.Gworkshop and have level corrected.

Winter driving

Winter weather is particularly hard onthe battery. F urthermore at low temperatures it has only a part of the capacityit has at normal temperatures. W e recommend therefore that the battery

should be checked in a V.A.G workshopbefore the onset of cold weather andcharged if ne ces sa ry. This will not onlyresult in quicker, more reliable startingbut will help to prolong the life of thebattery.

Caution

• Battery acid is corrosive and mustnot get into the eyes or on to skin andclo thes . Any ac id sp lashes must bewashed off thoroughly with water. See adoctor if necessary.

• Never short th e battery terminals asthis causes the battery to heat up veryquickly and it may burst. Furthermore,the sparks can ignite the gas generated

during the charging process .• To prevent any possibil i ty of shortcircuit ing, detach battery earth wire be-fore doing any work on the electricalsys t em. When changing a bulb, it issufficient to switch th e lamp concernedoff.

• To remove th e battery detach th eminus wire first an d then the plus wire.Then remove retainer. To instal l, reverse

the sequence.• Never run the engine with the batterydisconnected as this will damage theelectrical system (electronic components).

• Bo th terminals must be taken offbefore the battery is given a quickcharge while in the vehicle.

• S tarting by connec ting an additionalbattery is described in the Do-it-yourselfsection.


O P E R AT I N G I N S T R U C T I O N S

W H E E L S

Wheels and tyres are important designfeatures. The wheels and tyres approvedby us are specially matched to the model

also affect the vehicle under the C o n -struction and Use regulations.• If wheel trim d i s c s are subsequently

• Keep grease, oil and fuel off the tyres.• Replace missing dust caps as soon aspossible



concerned and contribute largely to theexcellent roadholding and safe drivingcharacteristics.

If you wish to fit your car with nonstandard wheels or tyres please note:• For technical reasons it is not p o s -sible in every case to use wheels fromother vehicles - in certain conditionsnot even wheels from the same vehiclemodel.• Wheels and wheel bolts are matched to one another.

On changing to a different type of wheel(e.g. alloy wheels or wheels with wintertyres) the correct bolt with the properlength and conical shape must be used.The security of the wheels and thefunctioning of the brake system dependon this.• Using types of wheel and/or tyrewhich have not been approved by usfor your vehicle model can be detrimen

tal to the safety of the vehicle. It can

If wheel trim d i s c s are subsequentlyinstalled, ensure that the air flow remains adequate to cool the brakes.

V.A.G workshops are fully informed ab

out the possible conversions of tyres,wheels and wheel trims.

General notes

• Check tyres for damage from time totime and remove any foreign bodies em-bedded in treads.• To avoid damage to tyres and wheelsdrive over curbs and similar obstaclesvery slowly and as nearly at right anglesas possible.If you think that a wheel is damaged,it must be checked by a V.A.G workshop.

possible.• Mark wheels before taking them offso that they rotate in the same directionwhen put back.• When taken off, the tyres should bestored in a cool, dry and preferably darkplace. Tyres which are not on wheelsshould be stored in a vertical position.

New tyres

New tyres do not give maximum gripstraight away and should therefore berun in at moderate speeds for about thefirst 100 km. This will help to make thetyres last longer.


OPERATING INSTRUCTIONS

Tyre wear

Tyre l ife depends to a considerable ex-tent on the following factors:

Mode of driving

Fast cornering, hard acceleration andviolent braking also increase tyre wear.



g

Inflat ion pressure

Pressure which are too high or too lowshorten tyre life - quite apart from thedetrimental influence on vehicle handl-ing.

At continuous high speeds a tyre inwhich the pressure is too low flexesmore and heats up excessively. This cancause t read separa t ion and tyre b lowout .

In addition low tyre pressures increasethe fuel consumption.

The inflat ion pressures should thereforebe checked twice a month and alwaysbefore a long trip, not forgett ing thespare wheel. Always check pressureswhen tyres are cold. When warm, thepressure is higher but do not reduce. Thepressu res are given on page 116 and onleft door pillar between the hinges.

g y

Incorrec t wheel a l ignment

Incorrect wheel al ignment not onlycauses excessive, usually uneven tyrewear but can also impair the car's safehandling. If unusual tyre wear is not iced ,contac t a V.A.G workshop.

Wear indica tors

At the bottom of the tread of the originaltyres there are 1.6 mm high "wear indi-cators" running across the tread - seeFig. There are 6 - 8 of these indicators -according to make - evenly spaced

round the tyre circumference. Marks onthe flanks of the tyre (for example thelet ters "IWI" or triangles) show the locations of the wear indicators.

When t read depth is down to 1 mm -measu red at any point on the tread - th eofficial permissible minimu m tread de pthhas been reached (in export countriesthis figure may differ).

As worn tyres cannot grip the roadsurface properly when driving at high

speeds on wet roads and the vehicletend s to aquap lane soo ner, it is advisablenot to let the tyres wear down so far.


O P E R A T I N G INSTRUCTION

i f ^

Replacing tyres

• For safety reas ons the tyres shouldbe replaced in pairs and not singly. The

Balancing wheels

The wheels on new vehicles are balanced. However when vehicle is running,



| B 4 3 - 1 5 5 |

Changing wheels round

I the tyres are wearing unevenly, it isadvisable to change them round as; ow n. A ll the tyres will then last foraoout the same mileage.

.'.hen the wheels have been changed'3und it may be necessary to have the•-ont wheels balanced again.

be replaced in pairs and not singly. Thetyres with the deepest tread should always be on the front wheels.• O nly radial ply tyres of the same type,size and the same tread pattern may becombined.• For safety reasons a new rubbervalve should be fitted when a new tube-less tyre has been installed.• Tubes shou ld only be used in tube-less tyres in an emergency.When this is done, ensure that the airtrapped between tube and tyre ca nescape from the valve.• R epairing tyres calls for specia l equipment and knowledge and should therefore only be done by a specialist.

ed. However when vehicle is running,various influences can cause wheels tobecome unbalanced and this causessteering vibration.

As imbalance also increases steering,suspension and tyre wear the wheelsshould be balanced again.

Furthermore a wheel should always berebalanced when the tyre has been repaired or when a new tyre has beenfitted.


Winter tyres

-• winter conditions, the handling of thevehicle including four wheel drive ve-

Snow chainsSnow chains may be fitted on the rearwheels only. Only thin chains which do



nicles - can be improved by winter tyres.When fitting winter tyres, note the following:

• Only radial ply winter tyres should beused. The factory recommended tyresizes are given on page 116.

• With winter tyres, the PR figures onthe sidewalls should also be noted. Thetyres must not be below the specifiedcarcass strength.

• To obtain the best possible handlingcharacteristics, winter tyres must be fitt-ed on all four wheels.

• Winter tyres are no longer fully effective when rhe tread has worn down to adepth of 4 mm.

not stand clear more than 15 mm (including tensioner) should be used.

When driving over roads which are free

of snow you should remove the chains.O n such roads they are detrimental tovehicle handling, damage the tyres andwear out quickly.

In Germany the maximum, permissiblespeed with snow chains is 50 km/h.

The following should also be noted onTransporter/Caravelle syncro vehicles:

Snow chains should, where possible, be

fitted on all four wheels. If only twochains are available they must be fittedon the rear wheels.


EMISSION CONTROL SYSTEM*

-en vehicle is used normally there is- :ving special to be noted - apart from: _~:ng leadfree petrol in the tank - see

9 i " g 63 I t i ti l

T o ensure that the catalyst is not damaged by overheating, the following pointsmust also be noted:



r . 9 i " on page 63. In certain exceptional: ':umstances the following pointss-:uld however be observed for safety

T =sons :

I _e to the high temperatures which o c -in the catalyst, the vehicle should not

re driven or parked over easily inflamm-iz.e materials (e.g. dry grass or leaves).

• Additional heat shields are fitted over"- e catalyst. Underbody sealant must not• applied to these shields, the catalyst: ' the exhaust pipes.

• The vehicle must not be started bytowing.

• The ignition must not be switched off

as long as vehicle is rolling with a gearengaged.

• If a defect occurs in the ignitionsystem when driving (can be recogniz-ed by misfiring, uneven engine running,loss of power) the speed must be re-duced immediately. The defect shouldbe eliminated in the next V.A.G work-shop.

In these co nditi ons, unburnt petrol c a nget into the catalyst and be burnedthere.

A functional description of the emissioncontrol system is given on page 106.


DIFFICULT OPERATING CONDITIONS, DRIVING A B R O A D

The vehicle construction and equipmentis designed for normal operating conditions. This also applies to the frequencyand the extent of the maintenance laid

If the vehicle is to be taken abroad, thefollowing must also be born in mind:• In many coun tries there is a large net

• W hen the vehic le is use d in a countrywhich drives on the opposite side of theroad to the home country the wedgeshaped areas on the headlight lenses



and the extent of the maintenance laiddown in the maintenance schedule.

If the vehicle is used in difficult operat

ing conditions (e.g. continuous trailertowing, exceptionally high or low ambienttemperatures, very dusty conditions,poor quality fuel, etc.) it may be necessary to carry out special technical preparations, such as using oil of the a ppropriate viscos ity, installing specia l air cleaners (cyclone filters), modifying the ignition timing etc. F urthermore the maintenance must also be matched to the operating conditions.

work of V.A .G worksho ps where yourvehicle can be serviced. Despite thisthere are certain countries in which there

is only a limited amount of V.A.G serviceor even none at all.

• In certain countries it is also pos siblethat your vehicle mode l is not sold so thatcertain spare parts are not available foryour vehicle or that the V.A.G personnelis not familiar with the repair procedureshould anything go wrong.

The Volkswa gen factory or the Importerconcerned will be only too pleased togive advice on the necessary technicalpreparation of the vehicle, on the maintenance required and on the repair possibilities.

The addresses are given in the vehiclewallet.

shaped areas on the headlight lensesmust be masked - see page 100.


A N D M A I N T E N A N C E

CAR CARE

-egular and careful care helps to maintain the value of the vehicle.

: j r thermore i t can be one of the s t ipu-

WashingThe best protection against environmental influences is frequent washing and

WaxingWax as often as possible. This will prevent dirt from sticking to the paint and



ations for the upholding of warranty: a ims should corros ion d ama ge a nd:aint defec ts occur.

E. rery V.A.G workshop carries stocks ofcita ble car care materials . The instruc-I ons for use on the container should be*: I lowed.

Caution

These materials can be injurious to-ealth if misused and should be keptout of reach of children.

waxing.

After the period when salt is put on theroads, the underside of the vehicleshould always be washed thoroughly.The longer salt , road dust, industrialgrime, insects and bird droppings etc.are left on the paintwork the more damage they are liable to do to the finish.

When the load compartment has beencleaned, the sliding door hinges or theside board hinges must be regreased.

When vehicle is washed with a hose, do

not point the jet of water directly at thelock cylinders - o therw ise they will freez eup in winter.

Tar spots, traces of oil, industrial griime,insects, etc. cannot always be removedby washing. As they damage the paint ifleft on too long they should be removedas soon as possible with a suitable preparation.

industrial grime from penetrating into thepaint.

PolishingShould only be done if paint has lost itsshine and gloss cannot be brought backwith wax. If the polish used does notcontain preservative compounds, thepaint must be waxed afterwards.

Mat t pa in ted and p las t ic par t s shouldnot be treated with wax or polish.


C A R E AND MAINTENANCE

Touching up paint damage

Smal l marks in the paint such ass c r a t c h e s or stone damage should be

Cleaning windows

Tr a c e s of rubber, oil, grease or siliconec a n be removed with window cleaner or

Door, lid and window weatherstrips

T he weatherstrips will remain flexiblea nd last longer if they are rubbed lightly



touched up immediatel y with paint(Volkswagen touch-up brushes or spraycans ) before the metal starts to rust.

However, should rust be found at anytime it must be remove d thoroughly andthen the area treated first with an anti-co r ros ion primer and then the correctpaint applied.

Y o u ca n of cours e have this work doneby any V.A .G works hop.

T he number of the original vehicle paintis given on the data sticker (see page 124).

a silicone remover.

D o not dry the windows with the leatherused for the paintwork b e c a u s e traces ofpaint cleaner will ca us e streaks to appea ron the glass .

T he windscreen wiper blades should bec l e a n e d regularly and new blades fitted

o n c e or twice a year according to con-dition.

T o avoid damaging the heating elementwires in the rear window do not putstickers over the wires on the inside.

with a rubber protective compound fromtime to time. This will also stop theweatherstrips freez ing on in the winter.

Cleaning plastic

If normal washing is not sufficient, plasticparts and leatherette may only be c lean -ed with s peci al plastic clea ners .

Cleaning cloth upholstery

Upholstery cloth and similar materialsmust be cle aned with s peci al cleaners ordry foam and a soft brush.


CARE AND MAINTENANCE

Care of chromed parts=e™ ove spots and marks with a chromeeteaner. A chrome protective compound

Cleaning seat beltsKeep belts clean because they may notretract properly if very dirty.

Alloy wheelsIn order to maintain the smart appearance of alloy wheels for a long period,

l i l



can be applied to give long-term protec-l o n . Ensure that the chromed parts areccvered completely and uniformly with

r e compound.

Dirty belts can be cleaned by washingwith a mild soap solution without takingthe belts out of the vehicle.

Do not have the belts cleaned chemical lybecause the cleaning compounds da-mage the webbing material. Ensure thatthe belts do not come into contact withcorrosive fluids.

Inertia reel belts should be completelydry before they are allowed to roll up.

regular care is necessary. In particular,salt and brake pad dust must be washedoff thoroughly at least every two weeks

otherwise the surface of the alloy will bedamaged. After being washed, the wheelsshould be treated with an acid-freecleaner for alloy wheels. About everythree months it is necessary to give thewheels a good rubbing with hard wax.Paint polish or other abrasive solutionsmust not be used.

If the protective paint coat has beendamaged , e.g. by stone impact, the d a m -

aged spots should be dealt with as soonas possible.


C A R E AND M A I N T E N A N C E

Cleaning and anti-corrosion treatment of engine compartment

The engine compartment and the outid f f h i i

Undercoating

The underside of the vehicle is coatedwith a special compound to protect itfrom chemical d mechanical influen

Cavity preservation

Various cavities in the body are also protected against corrosion and this protection canbe intensified by repetition of



side surface of the power unit are givenanti-corrosion treatment at the factory.

If the engine compartment is cleaned atany time with grease removing solutions'* or if one has the engine washed,the anti-corrosion compound is nearlyalways removed as well. It is thereforeessential to as k for durable preservationof all surfaces, seams, joints and components in the engine compartment to becarried out. This applies also when co rrosion protected parts are renewed.

Every V.A.G dealer has stocks of thecleaning and preservation solutions recommended by the factory for this purpose and has the equipment necessaryto apply them.

from chemical and mechanical influences.

However, as this protective layer gets

damaged when the vehicle is in use, thecoating under the body and on the running gear should be examined at certainintervals - preferably before and afterthe winter season - and any damagemade good.

Every V.A.G workshop has stocks of thecorrect compound, has the necessaryequipment and is familiar with the application procedure. We advice you therefore to have the patching up or additionalcoating done by a V.A.G workshop.

Note for vehicles with a catalyst

Due to the high temperatures whichoccor in the afterburning process, additional heat shields are fitted over thecatalyst. Underbody sealant must notbe applied to these shields, the catalystor the exhaust pipes.

tion can be intensified by repetition ofthe preservation.

The best results are obtained when the

first subsequent treatment is done a boutone year after the vehicle is put on theroad.

All V.A.G workshops know how andwhere this treatment has to be carriedout and have the factory approved compound and the equipment required.

11 Only the correct cleaning solutions may be88 used - on no account petrol or Diesel.www.WestfaliaT3.info - a useful website for owners and enthusiasts of VW Westfalia T25 / T3 / Vanagon Campervans

M A I N T E N A N C E

- 5 the vehicle is fitted with modern low-a intena nce technical compone nts only

small amount of regular servicing is re-red in order to maintain the roadwor-

carried out between the intervals givenin the service schedule.This applies in particular to:

C h i h i il

Complete proof of servicing by a V.A.Gworkshop can be one of the stipulationsfor the upholding of any warranty claimsduring the one year warranty period.



r iness , economy and-reliability._ ~e inspection service offered by the. A .G workshop takes into account to a= -ge extent the individual annual mileage::vered and helps thus to keep the::sts as low as possible. The service: :nedule supplied with the vehicle shows

"at has to be done and when.

- difficult operating conditions, e.g. ex-•'emely low ambient temperatures, very•S ty conditions, building s ite work, etc.:e-tain service operations should be

• C hanging the engine oil• C leaning or changing the air cleanerelement

• Lubricating the hinges of sliding andDouble C ab doors, dropsides, locker lidand rear doors.• Draining water from or renewing thefuel filter on the Diesel engine.The service operations should be carriedout in a V.A.G works hop bec aus e thiswork requires spe cial knowledge, work-shop appliances and special tools. Furthermore this work must be done inaccordance with our instructions.

Safety regulations and anti-pollutionlaws place very strict limits on theamount of repairs and adjustments to engine and running gear parts which can bedone by the owner, By tinkering withparts which affect the safety of a motorvehicle one can endanger oneself andother road users.

In addition, altering the settings of thecarburetor or fuel injection system, ignition or valves, changes the emissionvalues and also increases the fuel consumption.


C A R E AND M AINTEN ANC

LIFTING VEHICLE

Vehicle hoist

Before driving over a vehicle hoist en-sure that there is sufficient clearancebetween hoist and low parts of vehicle



between hoist and low parts of vehicle.

The vehicle may only be lifted at thepoints shown here.

Trolley jack

The vehicle should also only be liftedwith a trolley jack at the points shownhere.To prevent damage it is essential to usea suitable piece of rubber or woodenpacking.

On no account should the vehicle be

lifted under the engine sump, gearbox,rear axle or the front axle as this cancause serious damage.

Vehicle jack

Using the jack is described on the follow-ing pages.

Lifting points for hoist and trolley jack.

Front Rear

At the front jacking point (see Fig.) At rear cross member (see Fig


D O - I T - Y O U R S E L F

HRST AID KIT, WARNING TRIANGLE TOOLS, J A C K

The First Aid kit and triangle can bestowed under the drivers seat.

NoteThe First Aid kit and triangle are not part

Th e jack an d tools are located underthe drivers seat. They can be taken outwhen the seat is pushed fully forwardand the cover underneath lifted up.



g p:* vehicle equipment. O n vehicles with a second battery or a

swivelling seat, the tools and jack arelocated either behind the driver's seat orunder the rear seat, depending on ar-rangement of seats in passenger com-partment. The trim under the rear seatcan be pulled out to the front.

The screwdriver blade is reversible.



S PA R E W H E E L

The spare wheel in luggage compart-ment is bolted to the left side panel.To remove wheel, take bolt out by hand.

For safety reasons the spare wheel must



o sa ety easo s t e spa e w ee ustalways be bolted securely to side panelwhen vehicle is moving.

The spare wheel is either located on ahinged pan under front of body or atrear in luggage compartment.

To take wheel under body out, removebolt with wheel nut spanner and pullhook away (left Fig.).

Caution: Keep clear as the pan fallsdown. Danger of injury.

Then pull wheel forward off the pan.

O n vehicles with a front spoiler, it maybe necessary to take weight off front of

vehicle before removing the spare wheel.If necessary the front can be lifted slight-ly with the jack or the s poiler taken off.

To stow s pare wheel, place it on the panwith offset downwards and swing pan upuntil hook engage s. Then insert bolt andtighten it.

For safety reasons the pan must always be bolted in posit ion so that itcannot release accidentally.


C H A N G I N G W H E E L S

• Insert jack into th e appropriate lift-ing socket (Fig.) as far as possible. Ifnecessary, clean th e socket before-hand. Place jack vertically.

NotesW he n a whee l has been cha nged , thepressure in the wheel which has beenfitted and the tightening torque of thewheel bolts should be checked as soon



j B25-319 |

• A ppl y ha nd bra ke firmly. If the ca r is: I a slope, place a stone or some similarzzect behind one of the wheels on the: :oosi te s ide.

~"~e wheel trim caps are removed with

r e bar an d wire ho ok:

: ace hook in the two holes on edge:~ ca p, insert ba r throu gh hoo k and le ver

off.

If ground is soft, place a large strongpiece of packing under the jack baseplate.

• Lift vehicle until the wheel is clear ofthe ground.

• R em ov e bolt/nuts and take whe el off.

• Fit s pa re wh ee l and tighten bo lts/nu tslightly first.

To ensure that th e wheel is securedproperly th e contact surfaces for thewheel hub or drum and for the wheelnuts/bolts must not be dirty or rusty.

• L ow er ve hic le to gro und and tightenthe bolts/nuts in a diagonal sequence.

• Install trim cap .

wheel bolts should be checked as soonas possible. Use a torque spanner forthe bolts. The torque for the wheels

s upp lie d by the fac tory is 170 N m (17kgm).

Caution

Th e jack supplied by the factory is onlydesigned to lift your vehicle model. Onno account should heavier vehicles orother loads be lifted. Do not work un-der the vehicle when i t is on the jack.

If the vehicle is to be subsequently

fitted with wheels or tyres which differfrom those fitted by the factory, it isessential to read th e remarks on page79.

• Lo os en wheel nuts/bolts with bo xscanner and bar approximately one turn.


F U S E S

- Y O U R S E L F

The individual current circuits are provided with fuses.

The fuses are located on left under thedash.

Changing a fuse

• S witch off the compo nent conce rned .

• With the aid of the list of fus es , findout which fuse belongs to the compo

Notes

• If the newly inserted fuse blows againafter a short time, the electrical systemmust be checked by a V.A.G workshop

bl



out which fuse belongs to the component which has failed.

• P ull out the blown fuse with the plastic clip (located on the cover in frontof fuse box).

• R epla ce blown fuse - can be reco gnised by the burnt metal strip - with afuse of same capacity .

Spare fuses can be inserted on the underside of the fuse box. These fuses canbe obtained from a V.A.G workshop.

as soon as possible.

• O n no acc ount should fuses be

patched up because this can causeserious damage elsewhere in the electrical system.



= u s e layout"o m left to right)

' 1 3 . Component Amp.

Radiator fan 30 17 Windscreen wiper 10 Additional fuses in holders



2 Brake lights 103 Reading lamps, interior

lights, illuminated make-upmirror, clo ck 15

A Emergency light system 155 Vacant5 F og lights 157 Tail and side light left 10B Tail and side light right 109 Headlamp right 10

-3 Headlamp left 10"1 Windscreen washer 15"2 Rear window wiper

or rotatingemergency light,

15

cruise control sys tem 30"3 Rear window heating,

fresh air blower 25"4 Additional heat exchanger,

light for lighting swi tch 20'5 Reversing lights 1516 Dual tone horn 15

18

1920

2122

Brake warning lamp,heated driving seatTurn signalsNumber plate light,headlight washerLow beam rightLow beam left

1010

101010

• under right rear seat:

Reading lamp, rightBoot lightsElectrically adjustable seat rightElectrically adjustable seat left

• abo ve fuse box:

Instrument lightingRear fog lightOverheating fuse forauxiliary heaterMain fuse forauxiliary heaterE mergency hornCentral lockingAutomatic fuse forelectric windows

Amp.

881616

1010

10

201520

20

• In engine compartment on left inblack box.

Diesel glow plugs' 50.

i) This fuse should only be renewed by aV. A . G workshop.


CHANGING BULBS

Before start ing to replace a bulb, switchoff the l ight concerned.

Do not touch the glass part of the newbulb with b are f ingers be cause the f ingermarks left on the glass evaporate when



marks left on the glass evaporate whenthe bulb gets hot, the vapour settles onthe reflector and dims it.

Always use the same type of bulb. Thedesignation is marked on the base of thebulb.

It is advisable to always carry a box ofspare bulbs in the vehicle. This can beobtained from any V.A.G dealer.

For safety reasons this box should contain the following bulbs.

12 V 45/40 W - Normal headlights12 V 60/55 W - H 4 headlights12 V 4 W - Side lights and

license plate light12 V 10 W - Taillight12 V 2 W - Stoplight and turn

signal

HeadlightTo change a headlight bulb or side lightbulb the headlight must be taken out:

Turn 5 quick-release clips in upper grille90° with a screw-driver. Pull grille forward slightly at the top and lift it out.Then remove 3 screws (see Fig.) andtake headlight out .


mmmtO - I T- Y O U R S E L F

Side light bulb

T he side light bulbs are located in theheadlight reflectors.

• Turn bulb holder fully to the left and



Normal headlight bulb

Headlight bulb

(Normal and Halogen H 4)• Pul l connector off.

• Take cap off.

• Turn ring to left and take it off ors q u e e z e spring clip of the bulb holdertogether and fold it clear.

• Take bulb out and insert new bulb sothat the locating lug on the bulb plateengages the r e c e s s in the reflector. Thecentre of the three terminals on bulbbase is then at the top.

H 4 headlight bulb

• Install ring, press it against reflectorand turn it to right as far as poss ib le ,or fold spring clip over bulb base .S q u e e z e clip together and engage it inthe retaining lugs.

• P r e s s cap back on.

• Attach connector.

• Install headlight and air intake grilleagain.

• Have headlight beam alignmentc h e c k e d .

Turn bulb holder fully to the left andtake it out of reflector.

• P r e s s defective bulb into holder turn

it to left and take it out.

• Insert new bulb.

• Insert bulb holder in reflector and turn

holder fully to the right.



Headlight bulb (H3)*

(Inner headlight on vehicles with dualheadlights.)• Turn cap to left and take off.

Fo g lights (H3)*

• R emove sc rew on underside of foglight

• Take insert out.

Rear lights

• R emove sc rews and take off lens andbulb holder.

• S queeze tabs together and take hold t (O i th i l



• P ull wire conne ctor off.

• Unhook spring clip holding bulb andswing it away.

• Take bulb out and insert new bulb sothat the locating lug on bulb plate engages recess in reflector.

• S wing spring clip over bulb plate.Squeeze clip together and engage it inthe retaining lugs.

• Attach wire again.

• Install ca p and turn to right.• Have headlight setting chec ked .

• Pull wire for bulb out of cab le conn ector.

• Unhook spring clip and fold it away.

• Take bulb out. Insert new bulb so thatlocating lug on reflector enga ges rece sson bulb plate.

• S wing clip over bulb plate. S queez eends together and engage in retaininglugs.

• Insert bulb wire in cab le connector.

• Install insert - upper side first - in thehousing and secure with screw.

• Have se tting of light ch ec ked.

der out. (On some versions there is onlyone tab.)

• Press bulb in, turn it to left and takeit out.

• Fit new bulb.• Install holder - tabs must engage -and install screws.

Front turn signals• Take lens off.

• P ull rubbe r ca p off.

• Press tab on bulb holder inwards andtake holder out of housing.• Turn bulb slightly to left and renew.• Press rubber cap on again carefullyand install lens.



Number plate light

"he number plate lights are pushed into:ne cross panel from the rear.• P ress lugs together and pull light

i h

Reading l a m p s *

• Lever adjus ting ring out at side rec es swith flat blade of screwdriver.• Press bulb into fitting slightly, turn it

Interior light in front of passengerseat, step light, boot lights.*

• Lever glas s out at side with flat screwdriver blade.



-.ousing out to the rear.

• R emove lens.

• Press bulb into holder, turn it to theeft and renew it.

• Install lens .Ensure that the lug in the lens engages:he opening in the bulb-holder as otherwise the number plate will not be illuminated properly.

• Do not overlighten lens sc rews .

• Install light again. Ensure that housingfits over the metal tab at the top and engages the hole in cross panel at the front.

Interior light

• Press retaining spring at oppositeend to switch inwards and take light out.

• R enew bulb.

• Insert light at switch end first.

g yto right and take it out.

• Install new bulb.

• Fit adjus ting ring so that recess es inring are in line with those on lamp housing.

• P ress adjusting ring on.

Table light*• P ush flat screwdriver blade behindlight housing on left so that the springbehind it is pushed to one side and thenlever housing off.• P ull reflector out.

• C hange bulb.• Insert reflector again.• P ush lug on right of lamp housingbehind trim on right first and then presslight on.

• C hange bulb.

• Press glass into the trim again.


ADJUSTING HEADLIGHTS M A S K I N G H E A D L I G H T S



Correct headlight adjustment is very important for vehicle and traffic safety. Theadjustment should therefore only bedone with a special appliance.

The headlights are adjusted from thefront through the grille with a Phillipsscrewdriver.

The illustrations show the adjustingscrew s for the right head light. The screw sfor the left headlight are symmetricallyopposite.

A - Lateral setting

B - Vertical setting

Turning screw to right lowers theheadlight beam.

When the vehicle is used in a countrywhich drives on the opposite side of theroad to the hpme country, the asymmetric headlights will dazzle oncomingtraffic.To prevent this , the wedge-shaped sector on the headlight lenses must be covered up with an opaque adhesive str ip.

The illustration shows the strip installedfor the change from right hand to lefthand traffic.


S S TA L L I N G O R R E P L A C I N G A RADIO S E T

-e following points should be noted-e n installing a radio set:

• It is advisable to use radio se ts from:~e V.A.G Accessory programme as wellas the fitting kits, aerials and suppres sion

• The wiring is already installed at theradio fitting location. The plug on thiswiring loom fits all radio sets in the



g ppsets which have been specially devested for the individual vehicle model

and are available from all V .A .G workto p s . T hese parts are supplied with:etailed fitting instructions.

"he use of other parts or parts from thecrevious models may cause faulty ope--ation of the system. Furthermore theistallation of non-approved suppres

sion sets can affect the registration oft h e vehicle under the Construction andJ se regulations, in cases of doubt V.A.G.vorkshops will advise .• W he n installing the aerial it is essential to ensure that the hole provided bythe factory where the aerial enters theDody is sealed very carefully. In additionthe aerial cable, the connecting wiresand loudspeaker wires must be routedso that they cannot chafe, rattle or gettangled up with moving parts (e.g. pedals ,steering, heating controls etc.). Otherwise the operation of the controls maybe affected or vehicle safety impaired.

V.A.GAccessory P rogramme which havea separate connection for the scale

lighting.Radio sets with other connections mustbe conne cted with an adapter wire whichca n also be obtained from V .A .G workshops. If the adapter wire is not used orif wires are cut off and left without insulation there is a risk of short circuiting.This can cause the wiring to burn out .


EMERGENCY STARTING

• T he jump er cab les must be heavyeno ugh to carry the load. No te cablemanufacturer's data.

• A flat battery can freeze at -10° Cand if a battery is frozen it must be

D o not co nn ec t the ca ble to the batteryminus terminal. The sparks could ignitethe explosive gas flowing out of thebattery.

Take great care t o ensure that t h e



| B 4 3 - 1 7 4 |

A - Flat batteryB - Boosting battery

The battery is under the righthand seat

in the cab.O n vehicles with a Diesel engine it is inthe engine co mpartme nt.

If the engine will not start because thebattery is flat, jumper c a b l e s can beconnected to the battery of anothervehicle to start the engine. The followingpoints should be noted:

• B oth batteries must be 12 Vo lt type s.The cap ac ity (Ah) of the boo sting batterymust not be a lot lower than that of theflat one.

ythawed out before connecting a jumpercab le as otherwise it could explode.

• T here must be no co ntac t betwe enthe vehicles as otherwise current canflow as soon as the plus terminals areconnec ted .

• T he flat battery must be properly connected to the electrical system.

• T he eng ine of the boo stin g veh iclemust be running.

• C on ne ct jumpe r ca ble s only as follows :

1. O ne end of (+) c ab le (usua lly red) tothe (+) terminal of flat battery.

2. O ther en d of red cab le to (+) terminalof boosting battery.

3. O ne end of (-) ca ble (usually black)to (—) terminal of boosting battery.

4. O ther en d of black ca ble (x) to thebolt securing earth wire to body.

gjumper cable c l i p s d o n o t touch o n eanother an d that t he p lus cable d o e sn o t touch current c o n d u c t i n g vehicleparts - short circuit danger.

Caution

• Do not stand with your face overth e battery - danger o f a c i d b u r n s .

Route the jumper cables so that theycannot come into contact with rotatingparts in the engine co mpar tment.

• S tart the eng ine as de s c rib ed in the"Starting and Stopping Engine" section.

• W he n engine is running, disc onne ctcables in reverse sequence.

Note fo r vehicles with catalyst

The engine must not be started by towingthe veh icle as otherwis e unburnt petrolca n ge t into the catalyst and be burnedthere - see also page 106.


D O - I T- Y O U R S E L F

TOWING

owing eyes are provided on the rightjnder front and rear bumpers.Towropes or bars should be attached at:hese points only.Avoid excessive towing effort and do not

If your vehicle has to be towed at anytime note the following points.

• Check whether there are any localtraffic regulations concerning the towingof vehicles.

If the vehicle has an automatic gearboxthe following additional points must alsobe noted:• Selector lever at "N".• Donothavevehicletowed faster than



Avoid excessive towing effort and do notjerk. During towing operations on otherthan surfaced roads there is always thedanger that the attachment points on thebody will be overloaded and damaged.

Note the following also when using atowrope:

The driver of the towing vehicle must engage the clutch very smoothly whenmoving off or changing gear. The driverof the vehicle being towed must keepthe towrope taut.

The towrope should be slightly elastic toreduce the risk of damage to both vehicles. It is advisable to use only ropesof synthetic materials or with elasticlinks.

• Turn ignition key to "Drive" positionso that the steering wheel is free and theturn signals, horn, and, if necessary, thewindscreen wiper and washer can beused.

• As the brake servo only works whenthe engine is running, more pressure isrequired on the brake pedal when theengine is not running.

• When there is no lubricant in the manual or automatic gearbox the vehicle

may only be towed with driving wheelslifted.

Do not have vehicle towed faster than30 mph (50 km/h).

• Do not tow further than 30 miles (50kilometers).

If the vehicle has to be towed long distances it must be lifted at the rear.Reason: When the engine is not running,the gearbox oil pump is not working andthe gearbox is not adequately lubricatedfor high speeds or long distances.

Emergency starting - see page 27.

The following should also be noted onfour wheel drive vehicles:

If the vehicle has to be towed with eitherfront or rear axle lifted, one must ensurethat the wheels on the raised axle arefree to rotate.


ICAL DESCRIPTION

ENGINE

Petrol engines

• 4 stro ke petrol engine

• 4 cylinde r horizontally op po s ed

• C ast-iron cylinders

• Dry air cl ea ne r with paper element,cyc lone filter for very dusty countries*

• L on g life sp ark plugs

• O ptical an d ac ou stic oil pres su re

P O W E R TRANSMISSION

Manual gearbox

• M ec han ica lly or hydraulically opera ted single plate clutch

• B aulk sy nc hro niz ed four or five s pe edmanual gearbox with final drive in one



• 4 bearing cran ksh aft

• Lig ht alloy cyl inde r he ad s• Light alloy cr an kc as e

• V alve s ope rated via pus h rods androcker arms

• M ain tena nc e free valve gear with

hydraulic tappets

• C oo lin g sy s tem filled for life of vehi cle

• R adia tor with separate expansiontank

• E lec tric radiator fan co ntro lle d bythermo switch

• L ow ainten anc e elec tronic ignitionsys tem.

• S ingle or twin choke down draft carburetor (44 and 57 kW engines)

• P etrol injection s y s te m * with overrun fuel cut-off

• E mission control s ys te m*

• T hermos tatically, con trolled intake airpreheating and electrical mixture preheating.

m o n i t o r *

Diesel engines

• F our strok e Die sel engine, installedlongitudinally, inclined 50°

• 4 cy lind ers in line

• C a s t iron block

• 5 bearing cran ksh aft

• S hee t metal su mp

• Light alloy cy lind er he ad

• Va lves operated by ove rhead c a mshaft, toothed belt drive

• Liq uid co oling

• R adiator with separate expansiontank

• T he rmos witc h con trolled elec tric fan

• M ec ha nic al fuel injection

• Dis tributor type injec tion pu mpwith

co ld starting aid, exha us t turboc harg eron 51 kW engine

• Dry air cle an er with paper element.

manual gearbox with final drive in onehousing

• F illed for life.

• R e a r wheel drive

Transporter/Caravelle s y n c r o

• Baulk sync hronise d 4-s peed manualgearbox with additional cross countrygear (4+G gearbox).

• P erma nen t four-w heel drive throughv i scous coupling, mechanically engage-able four-wheel drive available as optional extra.

• M anua lly ope rated differential loc ksfor front and/or rear final drives available as optional extra.

Automatic gearbox*• Hy dro- dyna mic torque conve rter andplanetary gear train with three forwards p e e d s and reverse

• F inal drive flan ge d on

• R e a r wheel drive

• F illed for life.


STEERING/AXLES

Steering

• M ainte nan ce free rack and pinionsteering with relay idler

• S afety steering co lumn

i d i

BRAKES BODY

DESCRIPTION

• Hy draulic dual circuit brake s

• Disc brakes at front

• S elf-adjus ting drums at rear with re-tardation-sensitive pressure regulator

k

• Unitary bod y/c has sis

• F loor frame reinfo rce d by side andc ross members



• P ower ass is ted s te er ing *

Front axle

• Independent whee l su spe nsio n with,vishbones/track control arms, coilsprings and te lescopic dampers

• A nti-roll bar

Additi onal on Transp ort er/Ca ravel I e

syncro

• D ou ble jointed shafts

• Differential l o c k *

• Vi s c o u s coupl ing

Rear axle

• Independent sus pens ion with diagonal trailing arms, coil springs and telescop ic dampers

• D ou ble jointed drive sh afts

Additional on Transporter/Caraveilesyncro

• Differential l o c k *

• B rake se rvo

• M ec han ica l handbra ke effective onrear wheels


t d t f .HMi j j i . i *H; i i : »MiEMISSION C ON TR OL S Y S T E M *

Functional description

The emission control system effectivelyr educes the amount of pollutants in theexhaus t gas. T he system is so des ignedthat it requires no additional mainten

Wi th l hi l



ance . Wi th normal vehi cle use, no special operating instructions need be ob

se rved - apart from filling the tank withleadfree petrol. Only in certain exceptional c a s e s is it nece ss ary , for safe tyreasons, to note a few po ints - s eepage 83.

The main parts of the emission controlsystem are

• an elec tronically con trolled fuel metering system (fuel injection)

• the ca taly st• the L am bd a prob e

The catalyst is installed in the exhaustpipe. It cons ists of a stee l-c as ed cerami cbo dy contai ning a multitude of longitudinal p a s s a g e s which are vapour coatedwith a thin layer of platinum or rhodium.The exhaust gas flows through the ca talyst and reacts with an afterburning proc e s s when it contacts the noble metalcoat ing. In this pro ce s s the carbo n monoxide and hydrocarbons are convertedto harmless carbon dioxide and waterand the oxides of nitrogen are convertedto nitrogen (four fifths of the air webreathe is nitrogen).

A stipulation for the proper functioningof the catalyst, however, is that theexhaust gas has a certain specific c o mpos ition and minimu m tempera ture whe nit enters the catalyst. To obtain thiscomposition exact regulation of the fuel/air mixture is required . On vehicle s wh ichare fitted at the factory with a emissioncontrol system this is done with the aidof a Lambda probe.

The Lambda probe is fitted in the exhaust pipe in front of the catalyst andmeasures the exhaust gas compositioncontinuously. The information signal isfed to an electronic control unit whichin turn regulates the fuel injection system so that the mixture is kept c o nstantly correct.


C H N I C A L D E S C R I P T I O N

Vehic les wi th "emiss ion cont ro lpackage".Vith the factory prepared parts and theDarts in the package supplied with the. ehicle for the s ervice installation of anemission control system it is possible

The date for the conversion should bearranged with the V.A.G workshop wellin advance beca use be fore the emissioncontrol system is installed at least twofull tanks of leadfree petrol must beused in order to ensure that all traces of

Vehic les wi thout emiss ion cont ro ls y s t emVehicles which have neither factoryfi t ted emission control systems nor the"package" solution can be subsequentlyfi t ted ith an emission control s stem



emission control system, it is possibleto have the vehicle converted with littleeffort by a V.A.G workshop when adequate supplies of leadfree petrol areavailable.

After this conversion the system is equivalent to the factory fitted version. Up tothe installation of the emission controlsystem, leadfree or leaded petrol can beused. The minimum octane rating is 91RON (Regular petrol).

The emission control parts required forthe service installation are packed in acarton and put in the boot. The contentsof carton are:

CatalystLambda probe3 "Leadfree" st ickersSmall parts

These parts are carefully packed andprotected against corrosion. The cartonshould therefore be stored, unopened,in a dry place where i t cannot becomedamaged .

leaded p etrol are out of the fuel system .

A specimen expert ise is available fromthe Volkswagen factory for the conversion. After conversion, the vehicle mustbe taken to an authorized test ing agency(e.g. TUV in Germa ny) for the necessaryentries in the vehicle documents.

After the conv ersion the po llutants in theexhaust gas are very effectively reduce d.

It is however important to use only lead-free petrol. Further details are given onpage 63.

fi t ted with an emission control system.See your V.A.G workshop for details.


TECHNI CAL DATA

ENGINE DATA

Where not otherwise indicated all tech-nical data is for standard vehicles inGermany.

F or special vehicles and vehicles forother countries these figures may bedifferent

Carburetor engines44 kW 57 kW

Output(DIN 7002 0 P art 6) kw (bhp) at rpm 44 (60)/3700 57 (78)/4600Maximum torque Nm at rpm 140/2200 141/2600



different.

Please note that the details in the officialvehicle documents can be taken as thecorrect figures.

q pCapacity cms 1913 1913

S troke mm 68.9 68.9Bore mm 94 94Compression 8.6 8.6Fuel') Regular RegularOil consumption max. litres/1000 km 1.5 1.5

Diesel engines37 kW 51 kW

Output

(DIN 70020 Part 6) kw (bhp) at rpm 37 (50)/4200 51 (70)/4500Ma ximum torque Nm at rpm 103/2000 138/2500Capacity cms 1588 1588S troke mm 86.4 86.4Bore mm 76.5 76.5Compression 23 23Fue l " Diesel DieselOil consumption max. litres/1000 km 1.5 1.5

" For octane/C etane ratings and further details see page 63


Petrol injection engines

66 kW 82 kW

DutputDIN 70 02 0 Part 6) kw (bhp) at rpm 66 (90)/4600 82 (112)/4800

Maximum torque Nm at rpm 147/2800 174 (17 4)/2800



Maximum torque Nm at rpm 147/2800 174 (17.4)/2800Dapacity cm 1913 2109Stroke mm 68.9 763ore mm 94 94Dom pression 8.6 10.5=uel2> Premium PremiumDil con sum ption max. litres/100 0 km 1.5 1.5

6 1 k W > 7 0 k W "

Output

(DIN 70 02 0 Part 6) kW (bhp) at rpm 61 (83)/4800 70 (95)/4800Maximum torque Nm (kgm) at rpm 143/2600 160/2800Capacity c m 3 1913 2109Stroke mm 68,9 76Bore mm 94 94Compress ion 8.6 9.0Fuels' Regular leadfree Regular leadfreeOil con sum ption max. litres/10 00 km 1.5 1.5

" Engines with factory fitted emission control system2 1 For octane ratings and further details see page 63


F U E L C O N S U M P T I O N

A T A

T h e s e consumption figures were determined in accordance with r e c o m m e n d ation A 70 of the E C E .

In order to obtain true-to-iife figures thetests are carrie d out in three differentcondi t ions:

• T he me as ure me nts for 90 km/h (56mph) and

• 120 km /h (75 mph) are ca rrie d out ata constant test s p e e d .

• Fo r the urban mea su reme nt normaltow n traffic driving is s imul ate d

Depending on driving style, road andtraffic conditions, environmental inf-

l uences and vehicle condition, the figures obtained in actual practice maydiffer from those given in the standards.



tow n traffic driving is s imul ate d.

Carburetor e n g i n e s 44 kW4 spe ed 5 spe edgearbox gearbox

57 kW4 sp ee d 5 sp ee d Automaticgearbox gearbox gearbox

57 kW syncro 4+G

Caravelle a n d C o m b i90 km/ h 1/100 km (mpg)120 k m / h " 1/100 km (mpg)Urban 1/100 km (mpg)

High-roofed C o m b i90 km/ h 1/100 km (mpg)120 km/ hi ) 1/100 km (mpg)Urban 1/100 km (mpg)

10.5 (26.9) 10.3 (27.4)

12.9 (21.8) 11.9 (23.7)

11.2 (25.2) 10.8 (26.1)

12.9 (21.8) 11.9 (23.7)

9.7 (29.1) 9.5 (29.7) 11.2 (25.2)

12.8 (22.0) 13. 9(2 0.3 ) 12.6 (22.4)

10.6 (26.6) 10.2 (27.6) 12.4 (22.7)

12.8 (22.0 ) 13.9 (20.3) 12.6 (22.4 )

10.6(26.6)

12.8 (22.0)

11 Figures not available at time ofgoing to press


T E C H N I C A L D ATA

P e t r o l i n j e c t i o n e n g i n e s 6 1 kW5 s p e e d A u t o m a t i cg e a r b o x g e a r b o x

6 6 kW5 s p e e d A u t o m a t i cg e a r b o x g e a r b o x



C a r a v e l l e an d C o m b i9 0 km /h 1/100 km (mpg ) 9.5 (29.7) 1 1 0 . 5 (26.9)



1 2 0 k m / h i > 1/100 km (mpg )

U r b a n 1/100 km (mpg)H i g h - r o o f e d C o m b i9 0 km/ h 1/100 km (mp g)120 km/ h 1/100 km (mpg)U r b a n 1/100 km (mpg)

C a r a v e l l e C a r a t9 0 km/ h 1/100 km (mpg )120 km/ h 1/100 km (mpg)U r b a n 1/100 km (mpg)

Figures not available attime of going to press

14.0 (20.1) 15.8 (17 .8 )

10.9 (25.9 )1 12.1 (23.3)

10.5 (26.9) 11.5 (24 .5 )1 6 . 3 ( 1 7 . 3 )10.9 (25.9) 12.1 (23 .3 )

9.6 (29.4) 10.6 (26.6)14.2 (19.8) 16.0 (17.6)11.7 (24.1) 12.7 (22 .2 )

Figures not available attime of going to press

Figures not available att ime of going to press

D i e s e l e n g i n e s 3 7 kW4 s p e e d 5 s p e e d

51 kW4 s p e e d 5 s p e e d

C a r a v e l l e an d C o m b i9 0 km/ h 1/100 km (mpg)1 20 km /h 1/100 km (mpg )U r b a n 1/100 km (mpg)

H i g h - r o o f e d C o m b i9 0 km/ h 1/100 km (mpg)

120 km /h 1/100 km (mpg)U r b a n 1/100 km (mpg)

9 . 0 ( 3 1 . 6 ) 7 . 7 ( 3 6 . 6 )

9.0 (31.6) 10.1 (27.9)

9.7 (29.1) 8.7 (32.4)

9.0 (31.6) 10.1 (27 .9 )

7.6 (37.1) 7.5 (37.6)

8.0 (35.3) 6.7 (42 .1 )

8.2 (34.4) 8.1 (34 .8 )

8.0 (35.3) 6.7 (42 .1 )


T E C H




T E C H N I C A L D A T A

P E R F O R M A N C E

The maximum speeds we re me asured ac cording to DIN 7002 0 Part 3. Vehicle notfi t ted with any equipment such as mud flaps which affects the performance.

Maximum speedapprox in km/hCarburetor engines

44 kWmanual gearbox

57 kWautomatic gearbox

57 kWsyncro



Caravelle, Combi, Van^ick-up and Double Cab without coverHigh roofed Van

arge platform Pick-up

Petrol injection engines

11 811811311 5

61 kW5 speed automat ic

13 013 012 5127

66 kW5 speed autom atic

12 512 512012 2

70 kW5 speed automat ic

125122120120

82 kW5 speed autom atic

Caravelle, Combi, VanCaravelle CaratHigh roofed Van

136 133i) i)

131 126

131 133139 133132 127

141 136141 136136 131

150 146150 146145 141

37 kW 51 kWDiesel engines 4 speed 5 speed 4 speed 5 speed

Caravelle, Co mb i, Van 103 110 127 127Pick-up and Double Cab withou t cover 103 110 127 127High roofe d Van 103 105 122 122Large platform Pick-up 103 107 124 124

1» Figures not available at time of going to press


D ATAtH»iii;u* y.vHILL CLIMBING ABILITY

With full load on good roads driving non-stop in 1st gear . . .

Values in %, approx.

Carburetor engines 44 kW 57 kW 47 kW syncro4 d 5 d 4 d 5 d i 185 R 14 C 205 R 14 C



4 speed 5 speed 4 speed 5 spe ed automatic 185 R 14 C 205 R 14 C

28 30 30 33 46 54 60

Petrol injection engines 61 kW 66 kW 70 kW 82 kW5 speed automatic 5 speed automatic 5 speed automatic 5 speed automatic

i) 34 47 38 49

Diesel engines 36 kW 51 kW4 spe ed 5 spee d 4 spe ed 5 spe ed

26 26 33 32

" F igures not available at time of going to press


E C H N I C A L D A T A

S PA R K P L U G S

44 and 57 kW engines

Bcsch W 7 C T CBeru 14-7CTUChampion N4BC

61 and 66 kW engines

V E E B E L T S

Petrol engines

With 45 and 65Amp alternator: 9.5 1070 LAWith 90 Amp alternator: . 9.5 1110 LA

Diesel engines



Bosch W 7 C OBeru 14L-7CChampion N288

70 kW engine

Bosch W 7 C C OBeru 14L-7CU/14L-7CChampion N288

82 kW engine

Bosch W 5 D T CBeru 14-5DTUChampion N 6 B Y C

E lectrode gap in mm 0,6-0,8

Crankshaft/coolant

pump 9.5 x 643 LACoolant pump/alternator 9.5 x 600 LA


TECHNICAL DATAWHEELS

Steel wheelsAlloy wheels

5'/2 J x 146 J x 14 6 J x 14 6 J x 14

6 J x 14

TyresTubelessradials

185 R 14 C 6 PR6 PR/8 PR

185 R 14 C6 PR/8 PR

205/70 R 14 205/R 14 C6 PR/8 PR

205 R 14 C

Recommended winter tyres/wheels: 185R14Con 5V2 J x 14 wheel

If you wish to fit the vehicle with tyresor wheels of types different to thosefitted by the factory (e.g. alloy wheelsor wheels with winter tyres), you mustpay attention to the instructions givenon page 79.

The most suitable combination is given



Recommended winter tyres/wheels: 185 R 14 C on 5V2 J x 14 wheel

Tyre pressuresin bar (psi) Fron t Rear Spare

185 R 14 C PRAm bula nce 2.5 (35) 2.5 (35) 2.5 (35)all othe r mo dels 2.7 (38) 3.3 (47) 3.3 (47)205/70 R 14 2.1 (30) 2.5 (35) 2.5 (35)

Syncro

185 R 14 C

6 PR/8 PR 2.8 (40) 3.3 (47) 3.3 (47)205/70 R 14 2.3 (33) 2.5 (35) 2.5 (35)

205 R 14 C3.0 (42.5)6 PR/8 PR 2.5 (35) 3.0 (42.5) 3.0 (42.5)

The most suitable combination is givenfor winter tyres. Details of further tyre/wheel combinat ions can be obtainedfrom your V.A.G Dealer. Further detailson winter tyres are given on page 82.

These pressures are for cold tyres - th epressure is higher when tyres are warmbut it must not be reduced.

The tyre pressures must be checkedregularly. Correct pressures are of greatimportan ce, part icularly at high speed -

see page 80.


//EIGHTS (KG)

Unladen weight Pe rmiss ib le P ermiss ib le P e rmiss ib leG V W (with driver) P a y l o a d 2 ' front rear axle load roof load 4 '

Normal payload Petrol Diese l P etrol Dies el P etrol D i e s e l 5 ' axle load

/an 2390 2460 1395 1465 995 995 1200 1300 100High Roofed Van 2390 2460 1445 1515 945 945 1200 1300 -

o m b i 2390 2460 1 3 9 5 " 1 4 6 5 " 9953> 9953) 1200 1300 100



High R oo fed C omb i 2390 2460 1 4 4 5 " 1 5 1 5 " 9453> 9953) 1200 1300 -Carave l le , C omb i L 2390 2460 1 4 8 0 " 1 5 5 0 " 9103) 9103) 1200 1300 100Caravel le C a r a t 2340 - 1 7 3 0 " - 6 1 0 " - 1200 1300 75Caravel ie G L 2390 2360 1 5 1 0 " 1 5 8 0 " 880 880 1200 1300 100' J o k e r" with pop-up roof 2340 2410 1 6 4 0 " 1 7 1 0 " 700 700 1200 1300 50" J o k e r" with high roof 2340 2410 1 7 0 0 " 1 7 7 0 " 640 640 1200 1300 -

m b u l a n c e 2300 2400 1680 1750 710 650 1200 1200 100High roofed a mbula nce 2390 2400 1900 1950 490 430 1200 1200 -

ick-up 2390 2460 1395 1465 995 995 1200 1300 -Pick-up with large platform 2390 2460 1490 1560 900 900 1200 1300 -Double C ab 2390 2460 1480 1550 910 940 1200 1300 75

Notes

• O ptional extras su ch as sliding roof,towing bracket etc. and service installation of a c c e s s o r i e s i n c r e a s e s the un-laden weight and the payload has to ber educed by this amount.

" W ithout driver2 1 On vehicles with automatic gearbox the payload is reduced by about 40 kg.3 1 On vehicles without seats the payload is increased by about 65 kg.4 1 Use only racks supported in rain channel. Load evenly and do not exceed the G V W . Further details are given on page 19.5 1 On vehicles with Turbo Diesel engine the payload is reduced by 15 kg.

• Inthe interest of good handl ing, goodsshould a lways be carr ied between theaxles . The permissible axle and grossweights must not be e x c e e d e d .


T E C H N I C A L

P ermissible Unladen weight Permissible P ermissible P ermissible(with driver) . Payload 2 ' front rear roof load 4 '

Higher payload G V W Petrol Diesel Petrol Diesel 5 ' axle load axle load

Van 2600 1395 1465 1205 1135 1300 1400 100High R oo fed V an 2600 1445 1515 1155 1085 1300 1400 -

ombi 2600 1395') 1465" 12053) 11353) 1300 1400 100Hi h R f d V 2600 1445" 1515" 11553 10853) 1300 1400



High Roofed Van 2600 1445" 1515" 11553> 10853) 1300 1400 -aravelle, Combi L 2600 1480H 1550" 1 1203) 10903) 1300 1400 100

Pick-up 2600 1395 1465 1205 1135 1300 1400 -ick-up with large platform 2600 1490 1560 1110 1040 1300 1400 -oub le C ab 2600 1450 1520 1150 1080 1300 1400 75

Notes

• Optional extras su ch as sliding roof,towing bracket etc. and service installation of accessories increases the unladen weight and the payload has to bereduced by this amount.

• In the interest of good handling,heavy goods should always be carriedbetween the axles. The permissible axleand gross weights must not be exc ee ded.

11 W ithout driver2 1 On vehicles with automatic gearbox the payload is reduced by about 40 kg.3 1 On vehicles without seats the payload is increased by about 65 kg.4 1 Us e only racks s upported in rain channel. Lo ad evenly and do not exc eed the G V W . For further details5 1 On vehicles with Turbo Diesel engine the payload is reduced by 15 kg.

se e page 19.


CHNICAL DATA

WEIGHTS (FOUR W H E E L DRIVE)

In kg G V W Unladen weight P a y l o a d 2 ' P ermiss ib le P ermiss ib le P ermiss ib le(with driver) front axle load rear axle load roof load 3 '

V an 2500 1540 960 1300 1380 100High Roofed Van 2500 1590 910 1300 1380 -

o m b i 2500 1540" 9602) 1300 1380 100High R oo fed C omb i 2500 1590" 9102) 1300 1380 -



a r a v e l l e / C o m b i L 2500 1625" 8752) 1300 1380 100Caravel le G L 2500 1655" 845 1300 1380 100"J o k e r" with pop-up roof 2500 1785" 715 1300 1380 50"J o k e r" with high roof 2500 1845" 655 1300 1380 -

m b u l a n c e 2500 1825 675 1300 1380 100P ick-up 2500 1540 960 1300 1380 100P ick-up with large platform 2500 1635 865 1300 1380 100D o u b le C a b 2500 1595 905 1300 1380 75

Notes

• O ption al extras s uc h as slidingroof,

rowing bracket etc. and service installation of ac ce ss orie s increas es the unladen weight and the payl oa d has to bereduced by this amount.

• In the interes t of gg o d hand ling,goo ds should always be carr ied b etweenthe axles . The pe rmiss ible axle and gro ssweights must not be ex ce ed ed .

• The payloa d must be red uce d by200 kg whe n travelling c ros s- co untry.

" Without driver2 1 On vehicles without seats the payload is increased by about 65 kg.3 1 Us e only racks supported in rain channel. Lo ad evenly and do not exc eed the G V W .


TRAILER WEIGHTS

See a l so "Tra i l e r t owing"on page 57 4 s p e e d

g e a r b o x

Pe t ro l eng ines5 s p e e dg e a r b o x A u t o m a t i c

Diese l eng ine Turb o Diese l syn c ro

P e r m i s s i b l e w e i g h t sTra i l e r w i th b rakes ,g r a d i e n t s u p to 1 2 % k g 1 5 0 0 / 1 3 0 0 " 1 5 0 0 / 1 3 0 0 " 1 5 00 1 2 0 0 / 1 0 0 0 " 1 5 0 0 / 1 3 0 0 " 2 0 0 0



w i t h s p e c i a l c e r t i f i c a t e 2 ' k g 1 8 0 0 / 1 6 0 0 i > 2 0 0 0 / 1 8 0 0 " - 1 4 0 0 / 1 2 0 0 " 2 0 0 0 / 1 8 0 0 ' *

-i t h s p e c i a l c e r t i f i c a t e 2 '

( 1 0 % g r a d i e n t )Tra i l e r w i th ou t b ra kes k g 6 0 0 6 0 0 6 0 0 6 0 0 6 0 0 6 0 0

Permis s ib l e nose we igh t max . kg 5 0 / 7 5 3 > 50/753> 50 /753) 50 /753) 5 0 / 7 5 3 ' 7 5m m . 4 % of ac tua l t r a i l e r we igh t

11 Vehicles with higher payload.2 1 V.A.G dealers have details.3 i With special certificate.

1 2 0 www.WestfaliaT3.info - a useful website for owners and enthusiasts of VW Westfalia T25 / T3 / Vanagon Campervans

DIMENSIONS

C H N I C A L D A T A

Height Ground Turningw ith w ithou t clear Overhang W heel- Track c ircle

in m m Length W idth cover cover an ce " front rear base front rear in m

Van 4570 1845 1965 — 190 1160 950 2460 1583 1570 10.7High Roo fed Van 457 0 1845 2365 - 190 1160 950 2460 1583 1570 10.7Combi 4570 1845 1960 - 190 1160 950 2460 1583 1570 10.7High Roofed Com bi 4570 1845 2360 19 0 1160 950 2460 1583 1570 10 7



High Roofed Com bi 4570 1845 2360

-19 0 1160 950 2460 1583 1570 10.7

Caravelle CL, GL, Co mb i L 4600 1845 1950 - 19 0 1175 965 2460 1583 1570 10.7Caravelle Carat 4605 1845 1960 - 190 1180 965 2460 1603 1588 10.9"Joker" with pop-up roof 4570 1845 2075 - 190 1160 950 2460 1583 1570 10.7"Joker" with high roof 4570 1845 2650 - 190 1160 950 2460 1583 1570 10.7Amb ulance 4570 1845 2215 - 190 1160 950 2460 1583 1570 10.7Pick-up 4570 1870 1930 2235 190 1160 950 2460 1583 1570 10.7Pick-up with large platform 4570 2000 1930 2235 190 1160 950 2460 1583 1570 10.7Double Cab 4570 1870 1925 2230 190 1160 950 2460 1583 1570 10.7

1 at permissible GVWWhen negotiating steep ramps, driving overpoor surfaces, curbs etc., particularly with the"Joker" with a spoiler, gas containers andheater mounted underneath the floor, caremust be taken not to "bottom" and thus causedamage to these fittings.


DIMENSIONS

L D AT A

Height Ground Turningwith without clear O verhang Wheel- Track circle W ading

in mm Length W idth cover cove r ance" front rear base front rear in m Depth

Van 4570 1845 1990 _ 200 1160 950 2455 1568 1560 10.9 350High Roofed Van 4570 1845 2390 - 200 1160 950 2455 1568 1560 10.9 350Combi 4570 1845 1990 - 200 1160 950 2455 1568 1560 10.9 350High R oofed C ombi 4570 1845 2390 - 200 1160 950 2455 1568 1560 10.9 350



High R oofed C ombi 4570 1845 2390 - 200 1160 950 2455 1568 1560 10.9 350

Caravelle C L, G L, C ombi L 4600 1845 1990 - 200 1175 965 2455 1568 1560 10.9 350"J oker" with pop-up roof 4570 1845 2105 - 200 1160 950 2455 1568 1560 10.9 350"J oker" with high roof 4570 1845 2680 - 200 1160 950 2455 1568 1560 10.9 350Ambula nce 4570 1845 2245 - 200 1160 950 2455 1568 1560 10.9 350Pick-up 4570 1870 1995 2265 200 1160 950 2455 1568 1560 10.9 350Pick-up with large platform 4570 2000 1995 2265 200 1160 950 2455 1568 1560 10.9 350Double C ab 4570 1870 1995 2265 200 1160 950 2455 1568 1560 10.9 350

" at permissible G V W with 185 R 14 C tyresW hen negotiating steep ramps , driving overpoor surfaces, curbs etc., particularly with vehicles with a spoiler, gas containers and heatermounted underneath the floor, care must betaken not to "bottom" and thus cause damageto these fittings.


T E C H N I C A L D A T A

C A PA C I T I E S

F u e l tank .. ap prox . 60 litres (13 galls)F u e l tanksy ncr o .. . appro x. 70 litres (15.3 galls)Wi n d s c r e e n wa sh er .. appro x. 3.5 litresWith headlightwasher approx. 6.5 litresR e a r windowwasher approx 1 0 litre

Petrol engines

C o o l i n g sys tem(with heater) app rox . 17.5 litresEngine oil -with filter ch an ge .. . app rox. 4.5 litresEngine oil -without filter cha nge ap prox. 4.0 litres



washer approx. 1.0 litre

Difference betweenMax. -Min . marks on dipstick . . 1 . 0 litre

Diesel engines

C o o l i n g sys tem(with heater) app rox. 16 litresEngine oil -with filter cha nge . . . . approx. 4.5 litresEngine oil -without filter cha nge . appro x. 4.0 litres

Difference betweenMax. -Min . markson dip stic k app rox . 1.0 litre




The identification plate is on right handdoor pillar between the hinges.

Vehicles for export to certain countrieshave no identification plate.

The chassis num ber is stampe d undervehicle on front cross member

1 7 - 1 8 2

The vehicle data sticker is located oncross me mbe r on left under dash. Thesticker contains the following data:

1. Production control number2. Chassis number3. Model code number4. Model explanation5. Engine and gea rbox cod e letters6. Paint num ber/interior tr im co de7 Optional extra numb er

The vehicle d ata 2 - 7 is also given in theService Schedule.





A L P H A B E T I C A L IN D

Page

Additional heat exchang er 42Adjusting jets 74Anti-freeze 71Ashtray 51ATF 67, 69Automa tic gea rbox 26

Page

compartment 88Clock 34Cold starting aid 30C oola nt additive 71C oola nt level 71C oolant temperature gauge 35Cooling system 71

Page

Emission control sys tem 83Engine- data 108- number 125-oi l 68- oil ca pacity 123

oil consumption 56 108



Auxiliary heater 43, 46Battery 78Blower switch 40, 42Brake fluid 76Brake servo 75Brake system 75Brake warning light 38Bulb changing 96

Care of car 85Canopy 20Capacities 123C avity prese rvation 88C entre sea t 14C entral locking 5Cetane number 64Changing bulbs 96C hanging wheels 93Chassis number 124C hild-proof lock 6

C igare tte lighter 51Cleaning and preserving engine

Cooling system 71Cover, engine 7C urtains 52

Defrosting windows 41Diesel fuel 64Differential locks 22Difficult conditions 84Digital clock 34Dimensions 121Dip switch 38Do-it-yourself 102Doors 6Driving abroad 84Driving econo mica lly 55Driving environment - cons cious ... 55Driving sa fely 54Dropsides 20

Electric window lifters 8Electric seat adjustment 17

Emergency light system 36E mergency starting 102

- oil consumption 56, 108- oil level 68- starting/stopping 29Engine compa rtment fiap 7

F illing tank 65F irst Aid Kit 91F og lights 36Fuel 63- additives 64- consumption 110- gauge 35- saving 55Fuses 94

Gear lever 21Gear oil 69Glow plugs 28, 30

Handbrake 20Headlights 36, 96

He adlights flashe r 38Head restraints 12


ALPHABETICAL INDEX

Page

Heating 40High beam 33Horn 3

Identification data 124Identification plate 124Instrument lighting 36

Page

Octane number 63Oil additives 67Oil consumption 56, 108Oil dipstick 68Oils 67

Package - emission control 107

Page

Seat belts 10Seats 13Seat heating 14Selector lever 26Side lights 36Sliding door 6Sliding roof 48



g gInstrument panel 2Instruments 34Interior light 49

Jack 91Jacking points 91Jets adjusting 74

Keys 4

Lead free petrol 63Lifting vehicle 90Lighting 36Lighting switch 36Limited slip differential 22Load surface 19Locks 6Lubricants 67Luggage compar tment 19

Mirrors 9

Number plate lighting 99

gParking lights 38Payload 118Performance 113Power assisted steering 70

Radiator fan 73Radio 3, 101Rear fog light 36Rear lights 98Rear seat 14

Rear window heated 36Rear wiper and washer 39Reclining seat 18Rev counter 34Reverse gear 21Reversing lights 21Revolving seats 14Roof load 75Roof rack 19Running in 58

Safety switch 45

gSliding windows 8Snow chains 82Socket 51Spare wheel 92Spark plugs 115Speedometer 34Starting engine 29Steering lock/ignit ion switch 28Sun roof 48Switches 3

Syncro- differential locks 22- driving with 4 wheel drive 58- selctable 4 wheel drive 25- snow chains 82- technical description 104- technical data 108- towing 103

Table 52Tailgate 7Taillights 98


A L P H A B E T I C A L IND

Page

Tank ca pac ity 123Technical data 108Technical description 104Tools 91Towing 103Tow starting 27, 29

Page

Wheel changing 93Windscreen washer system — 39, 74Windsc reen wipers 89Winter driving- battery 78- ca re of vehicle 85- cooling system 73



Trailer towing 57Trailer weights 120Trip reco rder 34Turn signals 98Turn signal lever 38Tyres- inflation pressures 116- running in 79

Undercoating 88

Vee belts 115Vehicle care — 85Vehicle data sticke r 124Ventilation 40Ve nt wings 8Viscosity grades 67

Wa rning lamps 32Warning triangle 91Wa ter auxiliary heater 46

Weights 117Wheels 79, 116

cooling system 73- Diese l 64- eng ine oil 67- snow chains 82- tyres 82- windcre en wipers 74Winter tyres 82




The factory is work ing co ntinuously on the develop men t of al l models. We trust , there-fore, that you will appreciate that we must reserve the right to alter, without notice,any part of the vehicle or equipment. No legal commitment is thus implied by thedata, illustrations or descriptions in this manual.© 1985 Volkswagen werk AGMay not be reproduced or translated in whole or in part without the written consent ofVolkswagenwerk AGAll rights reserved. Specifications subject to alteration without notice.

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july 1985 vw t25 instruction manual westfaliat3wm

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