VolkswagenメーカーTransporter 1600 (1977)の使用説明書/サービス説明書
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Owner s Worksho p Manua l.
V W Transporte r 160 0 Owner s Worksho p Manua l b y J H Hayne s Membe r o f the.Guil d o f Motorin g Writer s an d D H Stea d Model s covered : Al l Volkswage n Transporte r 160 0 model s wit h 158 4 c c (96.
Acknowledgement s Thank s ar e du e t o th e V W organisatio n fo r th e suppl y o f technica l informatio n an d certai n illustrations . Castro l Limite d provide d lubricatio n detail s an d th e Champio n Sparkin g Plu g Compan y supplie d th e illustration s showin g th e variou s spar k Abou t thi s manua l plu g conditions .
Content s Acknowledgement s Abou t thi s manua l Introductio n Tool s an d workin g facilitie s Recommende d lubricant s an d fluid s Vehicl e identificatio n an d spar e part s Routin e maintenanc e .
Tool s an d workin g facilitie s Introduction A selectio n o f goo d tool s i s a fundamenta l requiremen t fo r anyon e contemplatin g th e maintenanc e an d repai r o f a moto r vehicle .
produce d b y th e vehicl e manufacture r specificall y to r it s deale r network . Yo u wil l fin d occasiona l reference s t o thes e manufac - turers ' specia l tool s i n th e tex t o f thi s manual . Generally , a n alternativ e metho d o f doin g th e jo b withou t th e vehicl e manu - facturers ' specia l too l i s given .
Recommende d lubricant s an d fluid s Componen t o r syste m Lubrican t typ e o r specificatio n Castro l produc t Engin e (1 ) Transmissio n (2 ) Transmissio n wit h limite d sli p differentia l (2 ).
Vehicl e identificatio n an d spar e part s Althoug h man y individua l parts , an d i n som e cases , su b assemblie s suc h a s distributors , fi t a variet y o f V W model s i t i s dangerou s t o assum e tha t jus t becaus e the y loo k th e sam e tha t the y ar e th e same .
Routin e maintenanc e For modifications, see Supplement at end of manual Introductio n Becaus e o f th e inheren t toughnes s an d reputatio n fo r reliabilit y an d lon g lif e ther e i s a tendenc y fo r owne r s t o b e a bi t sketch y o n V W maintenanc e - particularl y wit h vehicle s no t i n th e firs t flus h o f youth .
Th e windscree n washe r reservoi r i s mounte d o n th e vertica l pane l i n th e fron t o f th e ca b jus t belo w th e brak e flui d reservoir . Engin e oi l dipstick . t o th e fron t pane l o f th e ca b jus t belo w th e hydrauli c flui d reservoir .
Routin e maintenanc e 1 1 1 i n th e centr e o f th e botto m o f th e crankcase . Befor e starting , yo u mus t obtai n tw o ne w gasket s fo r it , an d i t i s als o desirabl e t o ge t si x ne w coppe r washer s fo r th e stu d nuts . Firs t drai n th e oi l b y removin g th e centr e plu g an d the n remov e th e cove r plate .
Genera l descriptio n an d typ e identificatio n .. . .. . .. . 1 Repai r an d maintenanc e procedure s - dismantlin g .. . .. . 2 Engin e remova l - preparatio n .. . .. . .. . .. . .. . 3 Engin e - remova l .. . .. . .. . .. . .. . .. . 4 Engin e dismantlin g - genera l .
Chapte r 1/Engin e 1 3.
1 Genera l descriptio n an d typ e identificatio n Th e 160 0 versio n o f th e establishe d 'Beetle ' engin e wa s introduce d int o th e transporte r rang e i n 1967 . Th e basi c con - figuratio n o f th e 'Beetle ' engin e i s unchange d - th e coolin g syste m incorporatin g th e superimpose d typ e o f fa n an d housing .
1 Crankcase - right half 2 Generator pedestal 3 Gasket 4 Camshaft bearing - shell - rear 5 Oil selec tor pipe FIG.1. 1 ENGIN E STATI C PART S • EXPLODE D VIE W 6 Camshaft bearing shell- front gasket.
1 6 Chapte r 1/Engin e cylinde r design . Th e shor t crankshaf t run s i n aluminiu m allo y shel l bearing s locate d betwee n th e tw o halve s o f a magnesiu m allo y crankcas e whic h joi n vertically . Th e camshaf t run s centrall y belo w th e crankshaf t an d i s gea r drive n fro m th e rea r en d o f th e crankshaft .
4. 1 Ope n th e engin e cove r an d hav e a goo d loo k round . 4. 6 Removin g th e cros s pane l (earl y models T 4.1 2 Suppor t th e gearbo x wit h a piec e o f rop e o r cha. n Not e t h woode n packin g piece . 4.1 6 V,e w o f th e bumpe r wit h bumpe r an d c r 4.
1 8 Chapte r 1 /Engin e plu g i t wit h a penci l o r punch . Fue l i s gravit y fed . 9 Pul l of f th e heate r pip e connection hoses . 1 0 Disconnec t th e heate r fla p cables .
4.1 4 Remov e th e engin e securin g nut s 4.1 7 Removin g on e o f th e lowe r engin e mountin g bolt s - d o no t forge t th e othe r on e 6. 1 Removin g engin e rea r suppor t bea m 8. 1 Und o stubbor n oi l pressur e regulato r 8. 4 Th e relie f valv e sprin g i s longe r tha n 8.
2 0 Chapte r 1 /Engin e pulle y whe n undoin g o r tightenin g th e bol t pus h a suitabl e articl e throug h on e o f th e hole s i n th e pulle y an d ja m i t agains t th e crankcas e flange .
7 Crankshaft 2 Crankshaft gear 3 Woodruff key 4 Spacer 5 Distributor drive 6 Securing ring 7 Distributor drive FIG.1. 2 ENGIN E RUNNIN G PART S - EXPLODE D VIE W shaft 8 Spring 9 Washer 10 Oil baffle .
2 2 Chapte r 1/Engin e o f sever e burnin g a t th e sealin g are a i n th e hea d the n th e cylinde r ca n b e lightl y groun d i n wit h carborundu m paste .
2 3 FIG.1. 3 LUBRICATIO N SYSTE M - DIAGRAMMATI C DRAWIN G FIG.1. 4 MEASURIN G OI L PUM P GEA R EN D CLEARANC E (Se c 10 ) FIG.1. 5 CRANKSHAF T PULLE Y WHEE L - CROS S SECTIO N (Se c 9 ) 1 Pulley 2 Oi.
2 4 Chapte r 1/Engin e i f yo u ar e goin g t o d o s o anywa y i t wil l b e simple r t o tak e th e connectin g rod s of f th e crankshaf t afterwards .
FIG.1. 6 CAMSHAF T AN D VALVES - EXPLODE D VIE W (Se c 15 ) 1 Camshaft and gear assembly 2 Pushrod 3 Tappet 4 Pushrod tube 5 Pushrod tube seal 6 Rocker shaft 7 Shaft support bracket 8 Thrust washer 9 .
2 6 Chapte r 1 /Engin e poin t o f th e too l use d mus t no t b e allowe d t o di g int o th e crankcase . 3 Whe n th e oi l sea l i s remove d a numbe r o f shim s whic h fi t betwee n th e flywhee l hu b an d th e flang e o n th e fron t mai n bearin g wil l b e observed .
2 7 FIG.1. 9 ENGIN E - CROS S SECTIO N VIEW S 1 Fan housing 2 Coil 3 Oil cover 4 Inlet manifold 5 Fuel pump 6 Distributor 7 Oil pressure switch 8 Valve 9 Cylinder 10 Piston 11 Oil pressure relief valv.
2 8 Chapte r 1 /Engin e 2 0 Crankcas e - examinatio n an d renovatio n Th e crankcas e shoul d b e fre e fro m crack s o r an y othe r for m o f damag e an d th e tw o matin g edge s mus t b e quit e fre e fro m dents , scratche s an d burr s whic h coul d i n an y wa y affec t thei r precis e alignmen t whe n bot h ar e clampe d together .
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3 0 Chapte r 1 /Engin e shell s t o a n un-regroun d crankshaf t thi s i s possible . I f ver y noticeabl e however , i t indicate s tha t th e journa l i s ou t o f round . I f rod s o n a regroun d crankshaf t ar e slightl y tigh t th e engin e wil l nee d running-in .
23.3 a Th e connectin g ro d an d ca p hav e matchin g number s 23.3 b an d a forg e mar k whic h mus t 23.3 c Fi t th e bearin g shel l int o th e cap . b e uppermos t o n installation . 23.3 d Pu t th e ro d int o positio n o n th e 23.3 e an d matc h u p th e cap .
3 2 Chapte r 1/Engin e 1 9 Tighte n th e larg e nut s progressivel y t o a torqu e o f 2 0 f t lb s an d the n t o 2 5 f t lbs . Finall y tighte n th e smalle r nut s t o 1 4 f t lb s (photo) . 2 0 No w rotat e th e crankshaf t - i t shoul d revolv e smoothl y withou t an y stiffness .
24.4 a Compar e ne w tappe t flang e thick - nesse s wit h th e ol d 24.4 b Pu t th e tappet s int o th e crankcas e 24.4 c Chec k th e ca m lob e clearance s 24. 5 N o 1 mai n bearin g i s flanged . Th e dowe l pe g hol e goe s toward s th e fly - whee l 24.
25. 4 Positio n th e pisto n ove r th e connec - tin g ro d smal l en d 25.5 a Th e maker s pu t a n arro w o n th e pisto n crow n pointin g toward s th e fly - wheel . Note th e arro w pointin g upward s an d th e pisto n N o 1 scratche d o n th e crow n a s wel l 25.
27.3 a Insertin g a n exhaus t valv e int o th e hea d 27.3 b Fittin g th e sprin g an d retaine r 27.4 a Th e sprin g compresso r need s elon - gate d end s 27.4 b o r us e a piec e o f tub e wit h a hol e i n i t 27.6 a Us e greas e t o hol d th e collet s o n replacemen t 27.
3 6 Chapte r 1/Engin e valv e ste m an d the n th e sprin g an d sprin g collar . Not e tha t th e clos e coil s o f th e sprin g g o agains t th e hea d (photo) . 4 Nex t arrang e th e valv e sprin g compresso r wit h th e space r tub e fitte d i f require d an d carefull y compres s th e sprin g (photos) .
29.2 a Fi t ne w rocke r shaf t mountin g stu d 29.2 b Replac e th e rocke r shaf t assembly.. . 29. 3 makin g sur e th e pushrod s ar e seal s seate d correctl y 30. 2 Crankshaf t en d floa t shim s bein g assemble d 30. 3 Replacin g th e oi l sea l 31.
3 8 Chapte r 1 /Engin e T o d o thi s a dia l gaug e micromete r i s use d agains t th e fac e o f th e flywheel . Th e crankshaf t i s the n move d i n an d ou t an d th e floa t measured . Th e thicknes s o f th e thir d shi m i s th e measure d floa t les s 0.
32.5 c Th e oi l pum p complet e goe s o n 33.2 a Oi l coole r seal s o n th e mountin g las t bracket 33.2 b Fittin g th e oi l coole r t o th e bracke t 33.2 c Th e smal l seale r plat e goe s o n th e 33.3 a Oi l coole r seal s o n th e crankcas e bracke t stud s 33.
4 0 Chapte r 1/Engin e housing . Als o ensur e tha t th e accelerato r cabl e i s i n a positio n wher e i t wil l no t ge t trappe d o r kinked . 4 Wit h th e rea r o f th e vehicl e raise d mov e th e engin e int o positio n underneat h s o tha t i t ca n b e lifted .
Chapte r 1 /Engin e 4 1 3 7 Faul t findin g Whe n investigatin g startin g an d uneve n runnin g fault s d o no t b e tempte d int o sna p diagnosis . Star t fro m th e beginnin g o f th e chec k procedur e an d follo w i t through . I t wil l tak e les s tim e i n th e lon g run .
Chapte r 2 Cooling , heatin g an d exhaus t system s For extra information, see Supplement at end of manual Content s Genera l descriptio n Remova l o f component s - genera l Fa n bel t - adjustment , remova l an d replacemen t Fa n an d dynam o - remova l an d replacemen t .
2 6 2 5 2 7 2 4 2 3 2 2 2 1 2 0 1 9 1 8 1 7 1 2 1 3 1 6 1 5 1 4 1 0 1 1 8 9 1 0 7 6 5 4 3 1 3 2 3 3 3 0 3 6 3 7 3 5 3 4 4 1 k FIG.2. 1 FAN , FA N HOUSIN G AN D THERMOSTA T 17 Outer fan cover 18 Reinfo.
4 4 FIG.2. 2 SPLI T PULLE Y FO R FA N BEL T SHOWIN G SPACER S WHIC H MA Y B E MOVE D T O ADJUS T BEL T TENSIO N FIG.2. 3 FA N ASSEMBL Y - CROS S SECTIO N / Spacer washers 7 Fan 2 Fan hub 8 Fan cover, inner 3 Woodruff key 9 Flange 4 Retaining nut 10 Fan cover, outer 5 Generator shaft a = 2 mm (0.
3. 2 Positionin g pulle y spacer s 3. 3 Checkin g fa n bel t tensio n 3. 4 Fittin g th e oute r hal f o f th e fa n pulle y 4. 3 Disconnectin g th e dynam o lead s 4. 1 O a Fittin g th e fa n oute r cove r t o th e dynam o 4.10 b an d th e stiffenin g plate .
4 6 Chapte r 2/Cooling , heatin g an d exhaus t system s tensio n pulley . Th e pulle y o n th e generato r i s spli t int o tw o an d th e ga p betwee n th e tw o halve s govern s th e effectiv e diameter . Th e ga p i s regulate d b y space r ring s (photo) .
4.10 c Fi t th e inne r cove r plat e 4. 1 O d Not e th e space r o n th e dynam o shaf t 4. 1 O e Fi t th e fa n hu b an d shim s 4. 1 O f ... . followe d b y th e fan .
4 8 Chapte r 2/Cooling , heatin g an d exhaus t system s (th e whol e manifol d o n earlie r models) , shoul d firs t b e posi - tioned . I t canno t b e manoeuvre d betwee n th e housin g an d th e generato r pedesta l afterwards . 1 2 Continu e wit h reassembl y b y carefull y lowerin g th e fa n housin g ove r th e oi l cooler .
5.7 a Removin g th e lowe r hal f o f th e oi l coole r duc t 5.7 b Liftin g th e duc t fro m th e vertica l plat e 5. 8 Lookin g a t th e undersid e o f th e fa n housin g showin g th e ther - mostaticall y controlle d ai r baffl e plate s 5.1 2 Guidin g th e thermosta t ro d throug h th e cylinder s 5.
5.16 a Replac e th e connectin g ro d fo r th e fa n housin g baffl e plate s 5.16 b Securin g th e specia l clip s 5.16 c an d retur n sprin g 6. 4 Unclampin g th e hea t exchange r contro l cable s 6. 6 Undoin g th e hea t exchange r sleev e cli p 6.
7. 2 Slacke n th e thermosta t bellow s mountin g scre w 8. 4 Th e heate r contro l leve r showin g plasti c plu g 9.7 a Th e lowe r stu d als o carrie s th e war m ai r intak e pip e bracket 9.
5 2 Chapte r 2/Cooling , heatin g an d exhaus t system s th e ca b o r let s i t continu e t o th e tw o inne r slot s a t th e bas e o f th e windscreen . Th e heate r outpu t i s therefor e controlle d b y us e o f th e tw o lever s an d th e ho t ai r directio n ca n b e balance d betwee n floo r an d screen .
1 Tail pipe 2 Retaining ring 3 Seal 4 Self-locking nut 5 Clamp 6 Clamp bolt 7 Silencer 8 Seal 9 Air inlet hose 10 Hose clip FJG.2. 5 EXHAUS T SYSTE M AN D MOUNTING S (fo r Dampe r pipe , tai l pip e an d fitting s se e Fig.
5 4 Chapte r 2/Cooling , heatin g an d exhaus t system s 1 1 Faultfindin g I t i s difficul t t o detec t heatin g system s fault s i n a rea r engine d ai r coole d ca r becaus e th e tell-tal e hea d o f stea m i s no t ther e t o sho w an d n o temperatur e gauge s ar e used .
4 3 6 7 Heat exchanger 2 Combustion chamber 3 Electric motor 4 Blower, fresh air 5 Casing 6 Regulator (pressure) 7 Solenoid valve 8 Fuel pump 9 Fuel jet 10 Combustion air blower 11 Spark plug (2 pole).
56 " FIG.2. 8 SUPPLEMENTAR Y HEATE R - WIRIN G DIAGRAM S (above , t o Augus t 196 9 - below , fro m Augus t 196 9 t o 1973 ) 7 2 3 4 5 7 10 Electric motor Spark plug Breaker contact Safety switch Temperature regulating switch Glow plug Thermo switch 11 Overheating switch 17 Ignition coil 15 Fuel pump 17 Warning light 18 Fuse box 19 Fuse.
Chapte r 3 Fue l syste m an d carburatio n For modifications, and information applicable to later models, see Supplement at end of manual Content s Genera l descriptio n an d exhaus t emissio n contro l .. . .. . 1 Ai r cleane r .. . .. . .. . .. . ..
5 8 Chapte r 3/Fue l syste m an d carburatio n fu l t o humans . A s th e expor t o f VW' s t o th e State s i s a ver y significan t percentag e o f thei r tota l output , an d man y see m t o ge t t o th e Wes t Coast , i t i s natura l tha t V W activit y i n th e emissio n contro l fiel d ha s bee n intensive .
2.1 a Ai r cleane r remove d fro m vehicl e (kee p i t thi s wa y up ) 2. 1 b Th e to p hal f o f th e ai r cleane r withdraw n fo r servicin g FIG . 3.
6 0 Fi g 3.2.A . CARBURETTO R SOLE X 3 0 PICT/ 2 7 Screw 2 Lockwasher 3 Upper body 4 Needle valve 5 Seal 6 Screw 7 Retaining ring 8 Spacer 9 Insert with spring and heater element 10 Cap 11 Screw 12 Co.
6 1 Fig . 3.2B . SOLE X 3 0 PIC T - 3 CARBURETTO R (Sec . 4 ) / Top cover screw 2 Spring washer 3 Top cover 4 Needle valve washer 5 Needle valve 6 Gasket 7 Float pin retainer 8 Float 9 Air corrector j.
6 2 Chapte r 3/Fue l syste m an d carburatio n mixtur e t o ai d startin g a col d engine . A t idlin g speed s th e throttl e fla p i s shu t s o tha t n o ai r an d fue l ca n ge t t o th e engin e i n th e regula r way .
4. 3 Liftin g th e carburetto r of f th e manifol d 4. 4 Lowe r hal f o f carburetto r showin g gaske t • r 4. 6 Uppe r hal f o f carburettor . Not e needl e valv e an d stranqle r fla p 'B ' 4. 9 Electr o magneti c fue l cu t of f valv e unscrewe d fro m carburet - to r bod y 4.
6 4 Fig.3.2.C . SOLE X 31/3 4 PIC T 3 CARBURETTO R - EXPLODE D VIE W Difference between the two types is in pilot jet position — angled on the 31 PICT 3 (Sec 3) 1 Cover screw 2 Spring washer 3 Top c.
6 5 FIG.3. 3 CARBURETTO R ADJUSTMEN T POINT S • NO T FIG.3. 4 CARBURETTO R ADJUSTMEN T POINT S - MODIFIE D MODIFIE D FO R EXHAUS T EMISSIO N CONTRO L REQUIRE - FO R EXHAUS T EMISSIO N CONTRO L (Se c.
6 6 Chapte r 3/Fue l syste m an d carburatio n fiv e carburettor s an d non e o r on e o f tw o type s o f throttl e valv e positioner . * Befor e attemptin g an y adjustmen t mak e sur e yo u kno w whic h on e yo u ar e dealin g with .
6 7 FIG.3. 6 FUE L PUM P (EARL Y TYPE ) COMPONENT S (Se c 8 ) 1 Cover screw 2 Washer 3 Cover 4 Gasket 5 Filter screen 6 Body screw 7 Washer 8 Pump body,upper 9 Diaphragm assembly 10 Pump body,lower 18.
6 8 Chapte r 3/Fue l syste m an d carburatio n late r version s thi s cut-of f valv e wa s incorporate d int o th e bod y o f th e pump . 2 T o clea n th e filte r scree n remov e th e to p cove r securin g scre w an d carefull y lif t of f th e cove r an d gaske t (photo) .
6. 2 Removin g th e fue l pum p cove r (late r types ) t o clea n th e filte r 7. 2 Removin g th e fue l pum p 7.3 a Th e fue l pum p actuatin g ro d 7.3 b Th e fue l pum p intermediat e flang e 7. 6 Fue l pum p an d externa l cu t of f valv e connection s 'A ' fro m th e fue l tan k an d 'B ' t o th e carburetto r 9.
7 0 Chapte r 3/Fue l syste m an d carburatio n cylinde r an d th e pi n take n ou t o f th e cylinde r s o a s t o releas e th e floa t inside . 1 0 Fue l tan k - ventilatio n an d activate d carbo n .
12.4 a Inle t manifol d aluminiu m gaske t 12.4 b Inle t manifol d centr e sectio n bein g positione d 12.4 c Th e section s o f th e inle t manifol d ar e joine d b y rubbe r boot s an d clips .
7 2 FIG . 3.7 . SCHEMATI C DRAWIN G O F FUE L TAN K VENTILA - TIO N WIT H ACTIVATE D CARBO N FILTE R UNI T (Sec . 10 ) / Expansion chamberdncorporated in fuel tank design) 2 Breather line 3 Pressure line from fan housing 4 Suction line from air cleaner 5 Crankcase breather hose 1 2 / Pull rod 2 Pull rod diaphragm 3 Vacuum hose to carburettor FIG.
Chapte r 3/Fue l syste m an d carburatio n 7 3 1 3 Faul t diagnosi s I n additio n t o th e mor e basi c fault s whic h ma y occu r i n an y vehicl e fue l syste m ther e ar e som e peculiaritie s a s.
Chapte r 4 Ignitio n syste m For information applicable to later models, see Supplement at end of manual Content s Genera l descriptio n .. . .. . .. . .. . .. . .. . 1 Contac t point s - adjustment , remova l an d replacemen t .. . 2 Distributo r - remova l an d replacemen t .
7 6 FIG.4. 2 DISTRIBUTO R WIT H CENTRIFUGA L AN D VACUU M ADVANC E EXPLODE D VIE W - (Se c 5 ) FIG.4. 2 DISTRIBUTO R WIT H CENTRIFUGA L AN D VACUU M ADVANC E EXPLODE D VIE W - (Se c 5 1 1 2 3 4 5 6 7 .
Chapte r 4/lgnitio n syste m 7 7 2 Contac t point s - adjustment , remova l an d replacemen t 1 Volkswage n servic e procedure s chec k th e contac t point s b y measurin g th e ca m dwel l wit h specia l equipment . Al l els e bein g equa l th e correc t ca m dwel l give s a point s ga p o f .
2.1 a Removin g th e distributo r ca p 2.1 b an d roto r 2. 3 Contac t point s read y fo r ga p chec k 2. 4 Checkin g th e point s ga p wit h a feele r blad e an d undoin g th e clam p scre w t o enabl e th e fixe d poin t t o b e move d 1 2. 5 Disconnectin g th e point s lea d 2.
Chapte r 4/lgnitio n syste m 7 9 a s describe d earlier . 4 Th e nex t jo b i s t o remov e th e drivin g colla r fro m th e botto m o f th e shaf t bu t befor e doin g thi s i t i s importan t t o not e whic h wa y i t i s fitted .
6. 5 Fittin g th e distributo r driv e shaf t thrus t washe r ove r a suitabl e 6.8 a Replacin g th e distributo r driv e shaft . Not e th e fue l pum p guid e ro d driv e ca m o n th e shaf t FIG.4. 3 DISTRIBUTO R DRIV E SHAF T (Se c 6 ) 7 Spacer spring 2 Fuel pump drive cam 3 Thrust washer 6.
Chapte r 4/lgnitio n syste m 8 1 spee d wil l alte r s o i f i t fall s outsid e th e specifie d limit s adjus t th e by-pas s ai r scre w o n th e carburetto r unti l i t i s onc e mor e correct . The n chec k wit h th e stroboscop e again . 1 4 Whe n th e mar k line s u p wit h th e crankcas e joint , clam p u p th e distributor .
8 2 Chapte r 4/lgnitio n syste m circumstanc e wher e th e ignitio n i s bein g checke d fo r correc t operation . D o no t by-pas s an y par t o f thi s procedur e unles s th e faul t i s particularl y obviou s an d rectificatio n solve s th e problem .
Chapte r 5 Clutc h an d operatin g mechanis m Content s Genera l descriptio n .. . .. . .. . .. . .. . .. . 1 Clutc h cabl e - removal , replacemen t an d adjustmen t .. . 2 Clutc h assembl y - removal , inspectio n an d replacemen t .. . 3 Clutc h releas e operatin g mechanism - inspectio n an d repai r 4 Faul t diagnosi s .
2. 2 Clutc h cabl e adjustin g win g nu t 2. 5 Mak e sur e th e rubbe r dir t excludin g cap s ar e refitte d 3. 9 Replacin g th e drive n plat e an d cove r assembl y 3.
8 5 FIG.5. 1 EARL Y CLUTC H UNI T - COI L SPRIN G TYP E FIG.5. 2 LATE R CLUTC H UNI T - TYPICA L DIAPHRAG M SPRIN G TYP E / Cover securing screw 2 Lock washer 3 Release ring 4 Adjusting nut 5 Pressure.
8 6 FIG.5. 3 COMPARISO N O F EARL Y TYP E (LEFT ) AN D LATE R VERSIO N (RIGHT ) O F TH E DIAPHRAG M SPRIN G CLUTC H COVE R FIG.5. 4 CLUTC H OPERATIN G CABL E OUTE R SLEEV E A Adjustment washer locatio.
Chapte r 5/Clutc h an d operatin g mechanis m 8 7 relieved . Lif t of f th e cove r an d clutc h drive n plate . 4 Th e clutc h drive n plat e shoul d b e inspecte d fo r wea r an d fo r contaminatio n b y oil . Wea r i s gauge d b y th e dept h o f th e rive t head s belo w th e surfac e o f th e frictio n material .
4. 6 Vie w o f th e bearin g attachmen t clip s 4.8 a Fittin g th e clutc h releas e shaf t bus h 4.8 b followe d b y th e shaf t 4.8 c an d bearin g sleev e an d seals . 4.8 d Mak e sur e th e bus h an d sea l d o no t com e ou t o n th e insid e lik e thi s 4.
Chapte r 5/Clutc h an d operatin g mechanis m 8 9 5 Faul t diagnosi s Symptom s Reason/ s Remed y Judde r whe n takin g u p driv e Clutc h spi n (failur e t o disengage ) s o tha t gear s canno t b e .
FIG.5. 6 CLUTC H RELEAS E MECHANIS M - COMPONENT S 7 2 3 4 5 Clutch housing Bush - starter pinion Bush - operating shaft Oil return sleeve Oil seal • drive shaft 6 7 8 9 10 Clutch operating shaft Re.
Chapte r 6 Transmissio n an d fina l driv e For modifications, and information applicable to later models, see Supplement at end of manual Content s Genera l descriptio n .. . .. . .. . .. . .. . .. . 1 Transmissio n - remova l an d replacemen t .. . .
FIG.6. 1 FINA L DRIV E AN D DIFFERENTIA L (T O AUGUS T 1968 ) (Se c 3 ) 7 Differential 4 Oil seal 2 Side covers 5 '0' ring 3 Outer race taper 6 Shim roller bearings 7 Shim 8 Cap nut 9 Spring.
FIG.6. 2 FINA L DRIV E AN D DIFFERENTIA L (FRO M AUGUS T 1968 ) (Se c 3 ) 1 Differential 2 Adjusting ring 3 Outer race, taper roller bearings 4 Oil seal 5 'O' Rir.
FI G 6.3 . GEARBO X AN D GEA R TRAI N (Se c 3 ) Mote : thi s drawin g i s correc t fo r gearboxe s u p t o Augus t 196 8 afte r whic h th e pinio n shaf t fastening s (8 ) wer e change d an d a pinio n retainin g nu t replace d them . Se e tex t Sectio n 3.
Chapte r 6/Transmissio n an d fina l driv e 9 5 ver y ba d stat e the n th e cos t o f th e componen t part s ma y wel l excee d th e cos t o f a ne w replacemen t unit . Thirdly , remembe r tha t a basi c knowledg e o f gearbo x constructio n an d functio n i s a bar e necessit y befor e tacklin g thi s one .
1. 1 Th e transmissio n fro m belo w showin g 2. 6 Und o th e squar e heade d scre w layou t an d support s 2.7 a Und o th e tw o nut s holdin g th e gear - bo x a t th e fron t mountin g 2.7 b Remov e th e eart h stra p 2.8 a Remov e th e uni t t o th e re a 2.
Chapte r 6/TransmissiO n an d fina l driv e 9 7 1 8 Th e pinio n shaf t i s a ver y tigh t fi t i n th e bal l bearin g i n th e casing . Havin g remove d th e circli p an d dishe d washe r fro m th e.
.
Chapte r 6/Transmissio n an d fina l driv e 9 9 plasti c plug s fro m th e drilling s opposite . Befor e doin g thi s mak e sur e yo u obtai n som e ne w plug s t o driv e i n whe n reassembling . Chec k th e sprin g fre e lengt h whic h shoul d b e 2 5 m m ( 1 inch) .
5.B 1 Th e pinio n shaf t assembl y 5.B 4 Fittin g firs t gea r o n th e pinio n 5.B 5 Fittin g 1st/2n d gea r clutc h shaf t hu b 5.B 8 Fittin g 2n d gea r an d baul k rin g 5.B 9 Fittin g 3r d gea r an d rolle r bearin g 5.B1 0 Fi t 3r d gea r retainin g cli p 5.
Chapte r 6/Transmissio n an d fina l driv e 10 1 5 E Gea r carrie r - fittin g shaft s an d selecto r fork s 1 I t i s assume d tha t th e selecto r rail s ar e i n orde r (se e Sectio n 4 , paragrap h 7 ) an d th e fork s ar e a correc t fi t i n th e hu b sleev e groove s (Sectio n 4 , paragrap h 6) .
5E.2 A Replacin g th e shaft s i n th e bear - 5E.2 B Th e shaft s i n positio n ing s 5E.4 A Fi t th e dishe d washer s an d circli p 5b.4 B Driv e hom e th e circli p ont o th e pinio n shaf t 5E. 5 Assembl e th e selecto r fork s t o th e correc t rail s 5E.
5F.4 a Lowe r th e carrie r an d th e shaft s int o th e casin g 5F.6 b followe d b y th e circli p 5F.4 b I t ma y b e necessar y t o juggl e th e gea r wit h a screwdrive r t o ge t revers e gea r ont o it s shaf t 5F.6 a Replac e th e pinio n shim s 5F.
5H. 2 Rene w th e 'O ' ring s o n th e bearin g 5H. 4 Pu t th e differentia l assembl y int o c° ve r th e casin g 5H.5 a Replac e th e shim s .. . 5H.5 b ... . an d th e sid e bearing s 5H.5 c chec k th e mark s mad e whe n dis - mantlin g 5H.
FIG.6. 5 GEA R CARRIE R AN D SELECTO R LEVER S - COMPONENT S (Se c 5G ) 1 Gear carrier 2 Bearing drive shaft 3 Needle bearing - pinion shaft 4 Support - shift lever 5 Screw 6 Bracket - relay shaft 7 Relay shaft 8 Reverse lever 9 Support 10 Union nut 11 Clamp sleeve 12 Selector rail.
10 6 FIG.6. 6 DIFFERENTIA L ASSEMBL Y (Se c 8 ) 1 Taper roller side bearing 2 Crown wheel (ring gear) 3 Differential housing 4 Shaft retaining pin 5 Thrust washer 6 Differential gear and drive shaft 7.
Chapte r 6/Transmissio n an d fina l driv e 10 7 6 Synchromes h hu b assemblie s - dismantling , inspectio n an d reassembl y 1 Unles s th e transmissio n i s th e victi m o f neglec t o r misuse , o r ha s covere d ver y hig h mileages , th e synchr o hu b assemblie s d o no t normall y nee d replacement .
5H.1 3 a Fi t a ne w gaske t , 5H.13 b ... . an d replac e th e clutc h housin g 6.3 b Th e indente d spline s i n th e sleev e mus t lin e u p wit h th e slidin g key s 7. 6 Drivin g a ne w sea l int o positio n 1 Housing bolt 2 Cover 3 Shaft - short 4 Friction cone FIG.
Chapte r 6/Transmissio n an d fina l driv e 10 9 Whe n th e leve r i s i n 2n d gea r gea r positio n i t shoul d b e exactl y vertica l wit h th e cranke d uppe r sectio n incline d a t abou t 30 ° t o th e rear . Sideway s movemen t measure d a t th e leve r knob , wit h a gea r engage d shoul d no t excee d 3 5 mm .
FIG.6. 9 GEA R CHANG E / Knob 2 Gear lever 3 Bellows 4 Moun ting bracket bolt 5 Spring washer 6 Washer 7 Bracket 8 Spring 9 Stop plate 10 Guide sleeve 11 Shift rod front 12 Muff coupling LEVE R AN D R.
Chapte r 7 Whee l shafts , driv e shaft s an d universa l joint s Content s Genera l descriptio n .. . .. . .. . .. . 1 Driv e shaft s - remova l an d replacemen t .. . .. . .. . 2 Constan t velocit y universa l joint s - removal , repai r an d replacemen t .
2. 1 Undoin g driv e shaf t ca p screw , oute r end . Not e spli t rubbe r boo t 2.3 a Removin g th e shaf t fro m th e gea r bo x 2.3 b Removin g th e shaf t fro m th e whee l hu b 3.1 a Fittin g a ne w boot . Firs t th e inne r circlip. . 3.1 b ...the n th e boot.
3. 1 d eas e th e boo t ove r th e C. V join t an d tighte n u p 3.5 a Pris e ou t th e en d ca p 3.5 b .. . remov e th e circli p 3.5 c remov e th e C. V join t fro m th e shaf t 3.5 d Discar d th e concav e washer , i f on e i s fitted , behin d th e join t 3.
3.7 b Damag e (arrowed ) o n th e join t oute r rin g 3.7 c Damag e (arrowed ) o n th e join t hu b 3. 8 Constan t velocit y join t - placin g th e hu b sectio n i n th e cag e 3.
Chapte r 7/Whee l shafts , driv e shaft s an d universa l joint s 11 5 ma y hav e gon e un-notice d fo r a lon g perio d an d le t i n wate r an d dirt , i t ma y nee d carefu l examinatio n t o decid e whethe r renewa l i s needed . Th e track s i n whic h th e ball s ru n shoul d no t b e groove d o r damage d a t th e edge s i n an y way .
3.1 2 Placin g th e join t o n th e shaf t 3.13 a Placin g th e circli p ove r th e en d o t th e shaf t 3.1 3 b Drivin g th e circli p hom e 3.14 a Repac k th e C.
11 7 / Split pin 2 Nut 3 Brake drum and hub 4 Back plate assembly 5 Bolt FIG.7. 1 REA R WHEE L SHAF T AN D BEARING S (T O AUGUS T 1970 ) 6 Spring washer 7 Bolt 8 Lock washer 9 Dowel pin 10 Bearing hou.
Chapte r 8 Brakin g syste m For information applicable to later models, see Supplement at end of manual Content s Genera l descriptio n .. . .. . .. . .. . .. . .. . 1 Brak e adjustmen t (includin g th e han d brake ) .. . .. . 2 Fron t drum s an d brak e shoe s - inspectio n an d renewa l .
Chapte r 8/Brakin g syste m Serv o Boostin g facto r Torqu e wrenc h setting s Tande m maste r cylinder/suppor t screw s .. . Fron t whee l cylinde r an d backplat e o n steerin g knuckl e Dis c calipe r o n steerin g knuckl e .. . Rea r axl e shaf t (fo r brak e drum ) .
2. 7 Th e handbrak e adjuste r # & unde r th e rubbe r gromme t (earl y models ) 3. 2 Fron t dru m brak e B FIG . 8. 1 BRAK E ADJUSTMEN T - MOVEMEN T O F ADJUSTE R WHEEL S T O PU T SHOE S NEARE R THE DRUM S (Sec . 2 ) A Front drum LEFT B Front drum RIGHT viewed from drum side viewed from drum side C Rear drums viewed from either side FI G 8.
9 1 5 FIG . 8. 3 FRON T WHEE L DRU M BRAK E ASSEMBL Y (SEC . 3 ) / C washer (for speedo cable only) 2 Dust cover 3 Bearing clamp nut 4 Thrust washer 5 Wheel bearing 6 Brake drum 7 Brake shoe 8 Return .
I FIG . 8. 4 REA R WHEE L BRAK E ASSEMBL Y (DETACHABL E DRUMS ) 7 2 3 4 5 6 Split pin Nut Socket head screw Brake drum Wheel hub Slotted cup washer 7 8 9 10 11 12 Spring Steady pin Return spring Brake.
Chapte r 8/Brakin g syste m 12 3 plat e an d se e tha t th e othe r sho e i s move d b y th e hydrauli c pisto n whe n th e brak e peda l i s depressed . D o no t le t th e pisto n com e righ t ou t o r th e syste m wil l nee d bleedin g afte r reassem - blin g it .
4.8 a Fittin g th e stead y pin , sprin g an d washe r whils t assemblin g th e righ t rea r brak e sho e assembl y 4.8 b Hookin g th e handbrak e cabl e t o th e leve r o n a righ t rea r brak e assembl y FIG . 8. 5 REA R WHEE L BRAK E ASSEMBL Y (ON E PIEC E HU B AN D BRAK E DRUM ) (SEC .
Chapte r 8/Brakin g syste m 12 5 6 I f th e pad s ar e t o b e use d agai n mar k wher e the y cam e fro m beforehan d s o the y ma y b e pu t bac k i n th e sam e position . Driv e ou t th e retainin g pin s fro m th e outsid e wit h a lon g nose d punch .
12 6 FIG . 8. 6 FRON T WHEE L HYDRAULI C BRAK E CYLINDE R (SEC . 6 ) 1 Boot 2 Piston 3 Cup 4 Housing 5 Bleed valve 6 Dust cap 7 Adjusting nut 8 Adjusting screw FIG . 8. 7 REA R WHEE L HYDRAULI C BRAK E CYLINDE R (SEC . 6 ) 1 Boot 2 Piston 3 Seal 4 Circlip 5 Housing 6 Bleed valve 7 Dust cap FIG .
Chapte r 8/Brakin g syste m 12 7 •1 1 Fi t th e ne w oute r seal . 1 2 Repea t th e proces s fo r th e othe r piston . 1 3 Refi t th e calipe r t o th e knuckle , tightenin g th e securin g bolt s t o 7 2 I b ft/1 0 mkg .
8. 4 Mountin g bol t an d union , maste r cylinde r 8. 6 Fillin g th e maste r cylinde r flui d reservoi r FIG . 8. 9 HYDRAULI C MASTE R CYLINDE R (SINGL E CIRCUIT ) CROS S SECTIO N (SEC .
12 9 FIG . 8.1 0 TANDE M MASTE R BRAK E CYLINDE R (SEC . 10 ) Top : Cros s Sectio n 1 Rear brake circuit piston 4 Port 2 Primary cup 5 Primary cup 3 Port I Rear brake circuit TJ Front brake circuit Ce.
13 0 FIG . 8.1 1 MASTE R CYLINDE R PRESSUR E DIFFERENTIA L INDICATO R PISTO N AN D WARNIN G LAM P SWITCH ; CROS S SECTIO N (SEC . 10 ) / Plug 2 Sealing washer 3 Spring 4 Connecting port 5 Piston 6 Seal cups 7 Warning lamp plunger switch / Primary piston 2 Secondary piston 3 Spring between pistons A From master cylinder FIG .
Chapte r 8/Brakin g syste m 13 1 9 Som e cylinder s incorporat e a pressur e differentia l warnin g system . Thi s consist s o f a singl e pisto n hel d centrall y i n balanc e b y th e equa l pressur e o f th e tw o circuits .
12. 5 Flexibl e hos e mountin g bracke t an d cli p 13. 4 Blee d nippl e ca p removed , righ t han d fron t whee l 1 0 FIG . 8.1 3 BRAK E PEDA L CLUSTE R - EARL Y VERSION S R.
13 3 FI G 8.1 4 TYPICA L BRAK E PRESSUR E REGULATO R (Sec . 11 ) FIG . 8.1 5 BRAK E (AN D CLUTCH ) PEDA L CLUSTE R - LAT E VERSION S R.H.D . (SEC . 14 ) 7 Split pin 2 Washer 3 Clevis pin 4 Push rod 5 .
13 4 1 2 3 4 5 6 Roll pin Handle Ratchet bar stop Cover Screw Lock washer 7 Trim plate 8 Guide sleeve 9 Spring 10 Split pin 11 Washer 12 Pin FIG . 8.1 6 HANDBRAK E LEVE R ASSEMBL Y (SEC .
Chapte r 8/Brakin g syste m 13 5 th e prope r fluid , a clea n receptacl e an d a tub e whic h wil l fi t ove r th e blee d nippl e securel y an d whic h i s convenientl y lon g enough . A usefu l devic e i s th e tub e whic h i s fitte d wit h a non-retur n valve .
13 6 732454 1 6 3 FIG . 8.1 7 MODIFICATIO N T O TANDE M BRAK E MASTE R CYLINDE R FO R SERV O ASSISTE D SYSTE M (SEC . 16 ) 15. 5 Vie w o f th e handbrak e cabl e fro m belo w 7 Seal 2 Circlip 3 Washer 5 Washer 7 Rear brake piston 1 Retaining ring 2 Circlip FIG .
Chapte r 8/Brakin g syste m 13 7 1 7 Faul t diagnosi s an d remedie s Befor e diagnosin g fault s i n th e brak e syste m chec k tha t an y irregularitie s ar e no t cause d by : 1 Uneve n an d incorr.
Chapte r 9 Electrica l syste m For modifications, and information applicable to later models, see Supplement at end of manual Content s Genera l descriptio n .. . .. . .. . .. . .. . .. . 1 Batter y - remova l an d replacemen t .. . .. . 2 Batter y - maintenanc e an d inspectio n .
Chapte r 9/Electrica l syste m 13 9 Fuse s N o o f fuse s No 1 N o 2 N o 3 N o 4 N o 5 N o 6 N o 7 N o 8 N o 9 No1 0 No1 1 No1 2 Identification ; Re d 1 6 amp . Whit e 8 am p 196 7 1968-8 9 197 0 1971-7 2 8 1 0 1 2 1 2 Lef t headlamp . Lo w Brak e light s Interio r ligh t Parkin g light s bea m Hor n .
14 0 2. 1 Disconnec t th e batter y FIG . 9. 1 DYNAM O COMPONENT S (TYPICA L LAYOUT ) (SEC . 12 ) / Through bolt 2 Lock washer 3 Spacer ring 4 Screw 5 Lock washer 6 Commutator end plate 7 Brush spring.
Chapte r 9/Electrica l syste m 14 1 2 A s wel l a s keepin g th e terminal s clea n an d covere d wit h petroleu m jelly , th e to p o f th e batter y an d especiall y th e to p o f th e cells , shoul d b e kep t clea n an d dry .
14 2 FIG . 9. 2 DYNAM O AN D REGULATO R TEST S A Voltmete r connectio n fo r n o loa d regulate d voltag e chec k B Voltmete r connectio n fo r n o loa d unregulate d voltag e chec k C Ammete r connec.
14 3 FIG . 9. 3 STARTE R MOTO R COMPONENT S (BOSCH ) 1 Nut 2 Lock washer 3 Screw 4 Rubber seal 5 Disc 6 Solenoid switch 7 Stop ring 8 Circlip 9 Screw 10 Washer 11 End cap 12 C washer 13 Shim 14 Sealin.
14 4 FIG . 9. 4 STARTE R MOTO R COMPONENT S V.W . 1 Nut and lock washer 2 Connecting strip 3 Nut and lock washer 4 Solenoid housing and winding 5 Insulating disc 6 Moulded seal 7 Insulating plate 8 Ca.
Chapte r 9/Electrica l syste m 14 5 th e voltag e shoul d b e approximatel y 1 2 volts . A t twic e thi s spee d th e voltag e shoul d increas e t o 3 6 volts . Chec k quickl y an d switc h of f withi n a fe w seconds . I f th e voltag e i s ni l o r lo w the n th e generato r i s faulty .
10. 2 Terminal s D+an d D F o n th e generato r 11. 1 Th e regulato r i s behin d th e ai r cleane r i n th e engin e compartmen t 12.2 a Removin g th e apertur e cove r fro m th e dynam o 12.2 b Hookin g u p sprin g t o pul l th e brus h fro m th e holde r 1 2.
13. 2 Removin g th e starte r to p bolt . Not e th e bol t hea d an d ter - mina l (arrowed ) fo r th e mai n cabl e connectio n 13. 3 D o no t confus e th e tw o nut s o n th e solenoi d 14.2 a Undoin g th e connectin g stra p termina l nu t 14.2 b Removin g th e solenoi d retainin g screw s 14.
14.6 a Remov e th e U cli p fro m th e en d o f th e shaf t 14.6 b an d th e shi m washer s 14.7 a Remov e th e throug h bolt s 14.7 b Tak e of f th e en d cove i 14.
Chapte r 9/Electrica l syste m 14 9 holder s an d pus h the m t o on e sid e s o tha t th e pressur e i s relieved . Th e yok e complet e wit h th e brus h holde r mountin g plat e ma y the n b e draw n ,of f th e armature . Watc h ou t fo r th e washer s o n th e en d o f th e shaf t (photo) .
FIG . 9. 5 WINDSCREE N WIPE R SPINDL E AN D BEARIN G ASSEMBL Y 7 Cap nut (early models had clamp nuts) 2 Lock washer 3 Wiper arm 4 Bearing cover 5 Circlip 6 Nut 7 Washer 8 Seal 9 Shaft bearing 10 Spring washer 11 Brass nut 12 Spring washer 13 Wiper shaft 15.
Chapte r 9/Electrica l syste m 15 1 o f th e remova l procedure . Whe n refittin g th e uni t t o th e ca r mak e sur e th e spindle s ar e a t righ t angle s t o th e windscreen . Th e mountin g hol e i n th e fram e i s slotte d t o permi t adjustment .
23. 1 Th e sto p ligh t switc h i s connecte d t o th e fou r wa y distribu - to r jus t ove r th e maste r cylinde r 24. 2 Pris e ou t th e ca p fro m th e centr e o f th e steerin g whee l 24. 5 A s a las t resor t tr y movin g th e adjustin g scre w 25.
15 3 FIG . 9. 6 BRAK E LIGHT/BRAK E PRESSUR E WARNIN G SWITCHES . CIRCUI T DIAGRA M (SEC . 23 ) a. b. current feed to brake lights 1 Rim securing screw 2 Rubber washer 3 Rim FIG .
15 4 FIG . 9. 8 HEADLAM P BEA M AIMIN G DIMENSION S SEALE D BEA M UNITS . RIGH T SID E DI P A Distanc e betwee n lam p centre s (108 0 mm/42. 5 ins ) B Heigh t o f lam p centr e abov e groun d (measur e o n vehicle ) D 2. 0 ins/5 0 m m H Lam p horizonta l centr e lin e V Lam p vertica l centr e line s FIG .
Chapte r 9/Electrica l syste m 15 5 plu g i s connecte d th e correc t wa y roun d — gre y wir e positive . 3 Al l doubl e filamen t bulb s fi t onl y on e wa y roun d becaus e th e wattag e o f eac h filamen t i s differen t - th e flashe r filamen t bein g brighter .
26. 2 Eas e th e pane l forwar d an d disconnec t th e speed o cabl e 26. 3 Th e connection s a t th e rea r o f th e pane l 28.1 a Und o th e screw s holdin g th e switc h t o th e colum n (Not e steerin g whee l ha s bee n remove d t o giv e a bette r photo ) 28.
Chapte r 9/Electrica l syste m 15 7 secon d perio d an d measure s to e an d cambe r an d print s ou t th e answe r i n degree s an d minutes . Th e ignitio n an d chargin g system s ar e measure d b y th e resistance s o f th e variou s circuits . I t i s importan t tha t al l connection s ar e clea n an d tha t cabl e size s ar e standard .
15 8 WIRIN G DIAGRA M 196 8 T O 196 9 EXCEP T NORT H AMERICA N MODEL S A B C C 1 D L U E 1 E 2 E 6 E 9 F F 1 G H H 1 J J 1 J 3 K 1 K 2 K 3 K 4 K 5 L 1 L 2 L 6 L 7 L 8 M 1 M 2 M 3 M 4 M 5 M 6 M 7 M 8 N.
15 9 WIRIN G DIAGRA M 196 8 T O 196 9 NORT H AMERICA N MODEL S A B C C 1 D E F G H H 1 J J 1 J 2 J 3 J 4 J 5 J 6 J 7 J 9 K 1 K 2 K 3 K 4 K 5 K 6 K 7 K 8 K 9 L 1 L 2 M l M 2 N 0 0 1 0 2 P 1 P 2 P 3 P 4.
WIRIN G DIAGRA M 197 2 ONWARD S EXCEP T NORT H AMERICA N MODEL S O A B C C 1 D E E 1 E 2 E 3 E 6 F F 1 F 2 F 3 F 4 G G 1 H H 1 J J 2 K K 1 Batter y Starte r Generato r Regulato r Ignition/starte r loc.
WIRIN G DIAGRA M 197 2 ONWARD S EXCEP T NORT H AMERICA N MODEL S O ).
WIRIN G DIAGRA M 197 2 ONWARD S NORT H AMERICA N MODEL S A Batter y B Starte r C Generato r C 1 Regulato r D Ignition/starte r switc h E Windshiel d wipe r moto r E 1 Lightin g switc h E 2 Tur n signa.
M WIRIN G DIAGRA M 197 2 ONWARD S NORT H AMERICA N MODEL S s.
H 105*1 FIG . 9.1 2 INSTRUMEN T CONSOL E (CLOC K NO T SHOWN ) Turn signal warning lights Generator warning light High beam warning light Parking light warning light Oil pressure warning light 6 Instru.
Chapte r 1 0 Suspension , damper s an d steerin g For information applicable to later models, see Supplement at end of manual Contint s Specification ! Wheelbei B 2,40 0 m m (94. 5 in ) Trac k Front - dru m brake s 138 4 m m (54. S In ) Fron t - dis c brake s 138 6 m m (54.
7 3 FIG.10. 1 FRON T AXL E ASSEMBL Y (Se c 1 an d 17 ) 7 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Caliper bolt Shouldered bolt Spring washer Caliper Hub cap Bearing nut clamp screw Bearing clamp nut Thrust w.
Chapte r 10/Suspension , damper s an d steerin g Steerin g geometr y To e i n *fron t whee l unpresse d .. . .. . .. . .. . 1571. 6 m m •fron t whee l 1 5 K g pressur e .. . .. . .. . 570. 6 m m rea r whee l t5'±10 ' *Not e to e i n variation s o f 1 571.
1.1 a Vie w o f th e steerin g knuckle s an d bal l joint s (whee l an d dru m remove d t o giv e cleare r photo ) 1.1 b Genera l vie w o f th e fron t suspensio n an d steerin g linkag e fro m beneat h I • 2.1 a Greas e poin t i n th e centr e o f th e axl e bea m an d 2.
Chapte r 10/Suspension , damper s an d steerin g 16 9 Prio r t o 197 2 th e steerin g gea r wa s o f th e wor m an d pe g typ e bu t i n 197 2 thi s change d t o wor m an d roller . A t th e sam e tim e th e steerin g rati o wa s increase d makin g th e steerin g lighte r tha n before .
3.7 a Bearin g packe d wit h greas e 3.7 b fi t th e oute r bearin g 3.7 c followe d b y th e thrus t washe r 3.7 d replac e th e clam p nu t t 3. 8 an d tighte n th e socke t hea d ser e 4.
Chapte r 10/Suspension , damper s an d steerin g ar m the y shoul d b e renewe d b y a specialis t wit h th e correc t tools . I f yo u hav e alread y carrie d th e dismantlin g o f th e fron t axl e .
17 2 1 8 1 Frame 2 Diagonal arm 3 Bearing housing 4 Spring plate 5 Torsion bar 6 Inner and outer bushes FIG.10. 3 REA R SUSPENSIO N ASSEMBL Y (Se c 9 ) 7 Cover for spring plate bearing 13 Bolt 8 Bolt .
Chapte r 10/Suspension , damper s an d steerin g 17 3 clockwis e o n th e oute r en d b y 8 spline s (60° ) th e ne t increas e i n th e angl e wil l b e 65 ° 20 ' les s 60 ° whic h i s 5 ° 20 ' an d a s nea r a s on e ca n get .
17 4 nea r suspensio n sprin g plat e angl e bod y lin e angl e FIG.10. 4 REA R SUSPENSION . SPRIN G PLAT E SETTIN G ANGL E CALCULATION - (Se c 10 ) B FI G 10. 5 ADJUSTIN G REA R WHEE L CAMBE R B Y ALTER - IN G THE TORSIO N BA R ANGLE S THROUG H ROTATIO N O F TH E DIAGONA L ARM S (Sec .
17 ! FIG . 10. 7 WOR M AN D PE G STEERIN G GEA R - COMPONENT S (Se c 13 ) Bolt and washer 7 Spring washer Adjusting screw and lock nut 8 Special washer Cover for gear case 9 Taper rollers Nut 10 Lever.
17 6 15. 4 Th e bal l join t betwee n th e dra g lin k an d th e dro p arm ; not e th e numbe r o f thread s visibl e befor e undoin g th e clam p FIG .
Chapte r 10/Suspension , damper s an d steerin g 1 3 Steerin g gea r - overhau l 1 Th e decisio n t o dismantl e an d rebuil d a steerin g gea r assem - bl y wil l depen d t o a larg e exten t o n th e availabilit y o f parts .
17 8 FIG . 10. 9 STEERIN G COLUM N ASSEMBL Y (Se c 14 ) 1 Nut 2 Fillister head screw 3 Lock washer 4 Cancelling ring 5 Steering wheel 6 Cheese head screw 7 Spring washer 8 Plastic clamping ring 9 Cap .
Chapte r 10/Suspension , damper s an d steerin g 17 9 axl e tube ) b y fittin g th e securin g bolt s an d nut s an d tightenin g the m t o th e specifie d torques .
FIG . 10.1 0 STEERIN G LINKAG E AN D BAL L JOINT S (Se c 15 ) / Screw 2 Lock washer 3 Split pin 4 Nut 5 Spring washer 6 Screw 7 Washer 8 Steering damper 9 Sleeve 10 Bush 11 Split pin 12 Nut 13 Left tie rod 14 Right tie rod 15 Nut 16 Spring washer 17 Screw 18 Clip 19 Tie rod ball joint R.
Chapte r 10/Suspension , damper s an d steerin g 18 1 2 1 Faul t diagnosi s Befor e diagnosin g fault s i n th e mechanic s o f th e suspensio n an d steerin g itself , chec k tha t an y irregularitie.
Chapte r 1 1 Bodywor k an d underfram e For modifications, and information applicable to later models, see Supplement at end of manual Content s Genera l descriptio n .. . .. . .. . .. . .. . .. . 1 Maintenanc e - bodywor k .. . .. . .. . .. . .. . 2 Maintenanc e - upholster y an d floo r covering s .
Chapte r 1 1 /Bod y 18 3 th e hea d linin g clea n i n th e sam e wa y a s th e upholstery . Whe n usin g liqui d cleaner s insid e th e ca r d o no t over-we t th e surface s bein g cleaned . Excessiv e dam p coul d ge t int o th e seam s an d padde d interio r causin g stains , offensiv e odour s o r eve n rot .
18 4 FIG.11. 1 FLOO R FRAM E 1 Side member, rear 2 Side member insert, rear 3 Cross tube with flange 4 Outrigger, rear 5 Outrigger, centre 6 Support, rear member 7 Heater tube 8 Side member, front 9 Outrigger, front 10 Side member insert 11 Seat box 12 Stiffener between side member inserts 13 Cross member, front 14 Front cross support FIG.
Chapte r 1 1 /Bod y 18 5 wil l ensur e tha t a ver y smoot h finis h i s imparte d t o th e fille r a t th e fina l stage . A t thi s stag e th e den t shoul d b e surrounde d b y a rin g o f bar e metal , whic h i n tur n shoul d b e encircle d b y th e finel y 'feathered ' edg e o f th e goo d paintwork .
9.4 a Chec k stra p lubricatio n 9.4 b Doo r hing e lubricatio n 10.1 a Remov e th e windo w winde r handl e 10. 1 b Pris e ou t th e doo r latc h finge r plat e 10.
Chapte r 1 1 /Bod y 18 7 vehicl e b y fou r countersun k crosshea d screws . Ther e i s als o a doo r chec k stra p whic h i s hel d b y a pin . Th e pi n ca n b e take n ou t afte r retainin g cli p i s take n of f it s lowe r end . 2 T o slacke n th e hing e screw s a n impac t screwdrive r i s essen - tial .
18 8 FIG . 11. 3 DOO R LATC H STRIKE R PLAT E (Se c 15 ) Slackening of screws enables plate to be moved in any direction FIG.11. 4 CA B DOO R HANDL E AN D LOC K CYLINDE R - EARL Y MODEL S (Se c 16 ) /.
Chapte r 1 1 /Bod y 18 9 1 7 Slidin g doo r mechanis m - descriptio n an d adjustmen t 1 Th e slidin g doo r run s i n thre e channels . A t th e bottom , a rolle r bracke t fitte d a t th e fron t corne r support s weigh t an d guide s th e doo r i n a channe l fitte d alon g th e botto m o f th e doo r opening .
19 0 FIG.11. 6 SLIDIN G DOOR-LOWE R ROLLER S AN D BRACKE T FIG.11. 7 SLIDIN G DOO R - TO P GUID E ROLLE R AN D (Se c 17 ) BRACKE T (Se c 17 ) Arrows indicate movement and shims Arrow indicates roller movement for door position adjustment. Bracket screws are loosened to move roller into channel recess.
FIG.11.1 1 REMOTECONTRO L LATC H (LEFT ) AN D CENTR E LATC H (RIGHT ) SHOWIN G POSITION S O F SETTIN G SCREW S O R PIN S (Se c 17 ) FIG.11.1 3 SLIDIN G DOO R - REMOVIN G TH E DOO R RETAINE R CATC H (Se c 18 ) FIG.11.1 4 SLIDIN G DOO R - CENTR E RUNNE R COVE R COMPONENT S (Se c 18 ) 7 Beading 2 Cover 3 Retaining strip FIG.
19 2 7 Return spring 2 Hinge link 3 M6nut 4 Lock washer 5 Roller bracket 6 Guide block FIG.11.1 6 SLIDIN G DOOR - HING E LIN K ASSEMBL Y COMPONENT S (Se c 18 ) 7 Roller and bearing 8 Phillips screw 9 .
Chapte r 11/Bod y 19 3 4 Chec k th e hekjh t o f th e rea r en d o f th e roof . Thi s i s don e b y swingin g th e lea f spring s ou t t o on e sid e an d the n slackenin g th e hexago n loc k nu t an d screw . Mov e th e lifte r pi n i n th e elongate d hol e t o correc t th e height , (Fig.
Chapte r 1 2 Supplement : Revision s an d informatio n o n late r model s Content s Introductio n .. . .. . .. . .. . .. . .. . .. . 1 Revise d routin e maintenanc e schedule s (196 8 t o 1974 ) .. . 2 Specification s .. . .. . .. . .. . .. . .. . .. .
Chapte r 12/Supplemen t 19 5 3 Specification s Fuel system Carburetto r (Augus t 197 5 on ) Typ e Mai n je t Ai r correctio n je t Pilo t je t Auxiliar y fue l je t Enrichmen t Needl e valv e washe r .
19 6 Chapte r 12/Supplemen t 1 0 1 1 1 2 Fuse identification Supplementar y heate r (Nort h America ) Rea r interio r lam p (u p t o 1974 ) Supplementar y heate r (Nort h America ) Heate d rea r windo.
Chapte r 12/Supplemen t 19 7 4 Engin e Pushrod tubes - renewal with engine in position 1 Damage d o r leakin g pushro d tube s ca n b e renewe d withou t th e necessit y o f removin g th e engine . 2 Refe r t o Chapte r 1 an d remov e th e rocke r cover .
19 8 Chapte r 12/Supplemen t FIG.12. 5 CROS S SECTIONA L VIE W O F MODIFIE D 1ST/2N D SYNCHR O HU B GROOV E (ARROWED ) FIG.12. 6 GEARCHANG E RO D BUS H FITTIN G DIAGRA M a 43.03 in (1093 mm) 9 Hav e th e engin e a t th e norma l operatin g temperatur e an d idlin g speed .
19 J FIG.12. 7 TYP E 09 1 GEARBO X FINA L DRIV E AN D BELLHOUSIN G COMPONENT S / 2 3 4 Clutch bellhousing Input shaft Circlip Reverse gear 5 6 7 8 Differential Gasket Gearcase Adjusting ring 9 10 11 1.
20 0 Chapte r 12/Supplemen t FIG.12. 8 REMOVIN G A N ADJUSTE R RIN G USIN G TH E SPECIA L TOO L FIG.12. 9 REMOVIN G PINIO N DRIVESHAF T RIN G NU T USIN G TH E SPECIA L TOO L nut .
FIG.12.1 0 MAINSHAF T COMPONENT S ; 2 3 4 4th speed gear Baulk ring Needle bearing Circlip 5 6 7 3rd/4th synchro assembly Circlip Baulk ring 8 9 10 11 3rd speed gear Needle bearing Mainshaft Spring 12.
20 2 FIG.12.1 1 COMPONENT S O F TH E PINIO N DRIVESHAF T 1 3 5 6 1 Anti-rotation ring 2 1st gear needle bearing 3 Combined 1st gear needle bearing/locknut 4 Tapered roller bearing Pinion shaft Circlip.
Chapte r 12/Supplemen t 20 3 FIG.12.1 2 REMOVIN G ANTI-ROTATIO N RIN G FRO M 1ST/2N D SYNCHR O HU B betwee n th e baul k rin g an d th e gea r teet h wit h feele r blades . Th e ga p shoul d b e withi n th e followin g limits : 1st/2nd 0.023 and 0.071 in (0.
FIG.12.1 3 COMPONENT S O F TH E GEA R CARRIE R / 2 3 4 5 Intermediate selector lever Ball joint Link Selector lever shaft Coil springs 6 7 8 9 10 Stop Intermediate selector lever bracket 3rd'/4th.
20 5 FIG.12.1 5 SYNCHR O SID E T O SID E SPRIN G LOCATIO N FIG.12.1 4 3RD/4T H SYNCHR O HU B AN D SLEEV E Line on hub must be at bottom (black arrow) when groove on sleeve is uppermost (white arrow) FIG.12.1 6 1ST/2N D SYNCHR O HU B AN D SLEEV E FIG.12.
206 Chapte r 12/Supplemen t (shoulde r toward s 2n d gear) , circlips , space r spring , 4t h gea r (shoulde r toward s spring ) an d th e circlip , bu t not e th e followin g points . 6 9 Befor e pressin g th e 1st/2n d synchr o ont o th e driveshaft , fi t a ne w anti-rotatio n ring .
Chapte r 12/Supplemen t 20 7 9 9 Adjus t th e unio n nu t o n th e revers e rocke r leve r suppor t unti l th e suppor t i s jus t fre e t o slid e i n an d ou t o f it s clam p sleeve . 10 0 Pus h th e revers e (middle ) selecto r shaf t unti l it s circli p contact s th e fac e o f th e gea r carrier .
20 8 Chapte r 12/Supplemen t / Housing 2 Bush FIG . 12.2 4 GEARSHIF T HOUSIN G COMPONENT S 3 Inner selector lever 4 Spacer Seal 12 1 Se t th e left-han d differentia l bearin g adjustin g rin g t o it s originall y marke d positio n (se e paragrap h 54 ) b y screwin g i t i n th e tur n whic h i t wa s backe d off .
Chapte r 12/Supplemen t 20 9 FIG.12.2 5 GIRLIN G TYP E CALIPE R ; 2 3 Disc/hub Caliper body Bleed screw 4 5 6 Anti-rattle spring Pad retaining pin Pin securing clip 7 8 9 Piston seal Piston Dust excluder 10 11 12 Retaining ring Anti-squeal shim Friction pad o f th e calipe r together .
21 0 1 5 2 2 FIG.12.2 6 BRAK E MASTE R CYLINDE R (WITHOU T SERVO ) / 2 3 4 5 6 7 Stop lamp switch Stop lamp switch Sealing plug Master cylinder body Stop bolt Spring Support ring 8 9 10 11 12 13 14 Wa.
21 1 FIG.12.2 7 BRAK E MASTE R CYLINDE R (WIT H SERVO ) / 2 3 4 5 6 7 Plug Stop bolt Stop lamp switch Stop lamp switch Master cylinder body Sealing ring Spring 8 9 10 11 12 13 14 Support ring Cup seal.
21 2 Chapte r 12/Supplemen t FIG.12.2 8 INSTRUMEN T PANE L RETAININ G CLIP S th e pane l an d twis t th e pane l securin g clip s unti l th e pane l ca n b e draw n forwar d fa r enoug h fo r th e speedomete r cabl e t o b e disconnected . 4 Disconnec t th e wirin g havin g firs t identifie d th e wire s an d terminals .
Chapte r 12/Supplemen t 21 3 a - To starter b - Diagnosis leads X - Battery cut-out switch FIG. 12.3 0 ALTERNATO R TES T CIRCUI T A - Ammeter (0 to 50 amps) V - Voltmeter 10 to 18V) R - Load resistance (0.
21 4 Chapte r 12/Supplemen t 2 5 Th e alternato r system s us e a negativ e earth . Car e mus t b e take n no t t o revers e th e batter y connectio n o r damag e t o th e diode s wil l b e extensive . Neve r ru n th e alternato r wit h th e outpu t wir e disconnected .
1 7 FIG.12.3 2 EXPLODE D VIE W O F TH E ALTERNATO R ; 2 3 4 5 Spacer Fan end plate Bearing Bearing retainer Washer 6 7 8 9 Cover plate Regula tor/brush assembly Body Insulating plate 10 11 12 13 14 Di.
216 FIG.12.3 3 WINDSCREE N AN D HEADLAM P WASHE R SYSTE M 1 Washer fluid reservoir 2 Headlamp washer pump 3 Headlamp washer jets 4 Windscreen washer jets 5 Windscreen washer pump FIG.
Chapte r 12/Supplemen t 21 7 FIG.12.3 6 STEERIN G COLUM N LOC K AN D SWITCHE S (197 5 ON ) 1 2 3 4 5 6 Direction indicator switch Wiper switch Column/switch upper trim Cover plate Spacer Switch/lock h.
21 8 Chapte r 12/Supplemen t rolle r shaf t t o preven t the m cuttin g th e lip s o f th e oi l sea l a s i t i s fitted . 9 Appl y greas e t o th e lip s o f th e sea l an d driv e i t int o positio n usin g a piec e o f tubing .
^ .
Conversio n factor s Inche s (in ) X Fee t (ft ) X Mile s X Volume (capacity) Cubi c inche s (c u in ; in 3 ) X Imperia l pint s (Im p pt ) X Imperia l quart s (Im p qt ) X Imperia l quart s (Im p qt .
Safet y first ! Professiona l moto r mechanic s ar e traine d i n saf e workin g proce - dures . Howeve r enthusiasti c yo u ma y b e abou t gettin g o n wit h th e jo b i n hand , d o tak e th e tim e t o ensur e tha t you r safet y i s no t pu t a t risk .
Inde x Ai r cleane r 58,19 7 Ai r contro l flap s - 4 8 Alternato r adjustment - 214 descriptio n an d precautions - 21 3 driveshaft-21 4 overhau l - 214 remova l an d refittin g - 214 testin g i n po.
Inde x headlam p washers - 21 4 ' heate d rea r window-21 2 horn - 15 1 instrumen t pane l - 20 9 lamps - 15 1 regulato r - 14 5 speedomete r driv e cabl e - 21 3 starte r moto r - 14 5 steerin g.
デバイスVolkswagen Transporter 1600 (1977)の購入後に（又は購入する前であっても）重要なポイントは、説明書をよく読むことです。その単純な理由はいくつかあります：
Volkswagen Transporter 1600 (1977)をまだ購入していないなら、この製品の基本情報を理解する良い機会です。まずは上にある説明書の最初のページをご覧ください。そこにはVolkswagen Transporter 1600 (1977)の技術情報の概要が記載されているはずです。デバイスがあなたのニーズを満たすかどうかは、ここで確認しましょう。Volkswagen Transporter 1600 (1977)の取扱説明書の次のページをよく読むことにより、製品の全機能やその取り扱いに関する情報を知ることができます。Volkswagen Transporter 1600 (1977)で得られた情報は、きっとあなたの購入の決断を手助けしてくれることでしょう。
Volkswagen Transporter 1600 (1977)を既にお持ちだが、まだ読んでいない場合は、上記の理由によりそれを行うべきです。そうすることにより機能を適切に使用しているか、又はVolkswagen Transporter 1600 (1977)の不適切な取り扱いによりその寿命を短くする危険を犯していないかどうかを知ることができます。
ですが、ユーザガイドが果たす重要な役割の一つは、Volkswagen Transporter 1600 (1977)に関する問題の解決を支援することです。そこにはほとんどの場合、トラブルシューティング、すなわちVolkswagen Transporter 1600 (1977)デバイスで最もよく起こりうる故障・不良とそれらの対処法についてのアドバイスを見つけることができるはずです。たとえ問題を解決できなかった場合でも、説明書にはカスタマー・サービスセンター又は最寄りのサービスセンターへの問い合わせ先等、次の対処法についての指示があるはずです。
