VW Volkswagen Transporter (water-cooled) Petrol 1982 - 1990 Haynes Owners Service & Repair Manual covers: Van, Pickup and Minibus (Caravelle) with water-cooled engines.
Engines Covered:
- 1.9 litre (1913cc) (DF, DG, EY & GW)
- 2.1 litre (2109cc) (DJ, MV & SS codes) four cylinder models.
Contents:
- Routine Maintenance
- Tune-Up Procedures
- Engine Repair
- Cooling And Heating
- Air-Conditioning
- Fuel And Exhaust
- Emissions Control
- Ignition, Brakes
- Suspension And Steering
- Electrical Systems
- Wiring Diagrams
NOTE: Only maintenance, adjustment, minor repair procedures plus removal and installation are described for the Transmissions.
The Volkswagen kind 2 (T3) ended up being the next generation associated with the Volkswagen Transporter and had been sold under different nameplates worldwide -- like since the Transporter or Caravelle in Europe, Microbus in South Africa, and as the Vanagon in North and South America.
Bigger and weightier than their predecessor, the T2, -- in accordance with a more squared and less curved styling -- the T3 ended up being manufactured in Germany from 1979 until 1990. Creation of the 2WD (mostly for official utilize, like postal solution or German military) continued until 1992 at Puch in Graz/Austria, in which all 4WDs was indeed built. South African creation of the T3 carried on, for the marketplace best, until 2002. The T3 had been the ultimate generation of rear-engined Volkswagens.
All the characteristics of this RR setup tend to be shared with the mid-engine, or MR. Putting the motor nearby the driven rear wheels allows for a literally modest, less heavy, less complex, plus efficient drivetrain, because there is no dependence on a driveshaft, together with differential could be integrated using the transmission, commonly described as a transaxle.
Since the engine is typically the heaviest component of the automobile, putting it nearby the back axle often leads to more weight across rear axle compared to the front side, frequently called a back weight prejudice. The farther back once again the system, the greater the prejudice. Typical weight prejudice for an FR (front side engine, back drive), is 55/45 front/rear; for MR, 45/55; for RR, 35/65. Back pounds bias reduces forward body weight transfer under braking, and increases back body weight transfer under speed. The previous implies that traction is much more evenly delivered among all tires under braking, resulting in reduced stopping period and distances. The second means the driven tires has enhanced grip when accelerating, allowing them to put more energy on the ground and accelerate quicker.
The disadvantage to a back fat prejudice is the fact that vehicle could become volatile and usually oversteer when decelerating (whether braking or lifting from the throttle). In turns, this tendency is much more pronounced, to the stage that even letting off the throttle somewhat while switching could cause the rear tires to suddenly miss hold, and automobile to slide rear-first (read lift-off oversteer). When this happens, rotational inertia dictates that the included fat away from the axis of rotation (generally the steering tires) will be more expected to maintain the spin, specially under braking. It is an inherent uncertainty inside design, making it easier to cause plus tough to get over a slide compared to a less rear-weight-biased vehicle. All cars, despite drivetrain layout, obey equivalent laws and regulations of physics and certainly will do that, but it is much easier to complete and harder to improve in MR and RR motors.
When not stopping, the decreased pounds on the front wheels means less grip, causing the automobile having a propensity to understeer, which is safer and much more stable (more permitting a driver to get on complete throttle sooner) it is undesirable in cornering. To counteract this, it is important to cause forward weight transfer to boost forward grip, but this considerably destabilizes the automobile and may be difficult to do precisely, this is certainly, without spinning. High-performance driving necessitates inducing body weight transfer, aside from drivetrain layout, however it is most essential in MR and especially RR layouts, and better result from it is much more hard to deal with.
During these areas, an RR can be viewed as is an exaggeration of MR - difficult braking, quicker and earlier acceleration, and increased oversteer, but faster switching if it may be managed.
In off roadway and low-traction circumstances, the RR layout has some advantages in comparison to other 2WD layouts. The weight is biased to the driven wheels- much like FF cars. This both gets better drive-wheel grip and reduces the tendency the undriven tires to dig in. Also, the driving and steering requirement were split between forward and rear- just like FR automobiles- which makes it less likely for both to reduce traction. Most dune buggies successfully make use of a Volkswagen beetle because the donor vehicles for this reason. The general user friendliness and lightweight versus 4WD can therefore sometimes surpass the drawback of just creating two driven tires.
Where RR varies from MR is in the engine is found away from wheelbase. The most important advantage of MR - low minute of inertia - was negated somewhat (though nonetheless below FR), and there's more place for people and cargo (though often less than FR). In addition, because both axles take equivalent region of the motor, it is officially simpler to drive all wheels, compared to a mid-engined setup (though there have been most high-performance vehicles aided by the M4 layout than with R4). Eventually, a rear-mounted motor has actually vacant atmosphere (usually at a diminished stress) behind it when moving, permitting more efficient cooling for air-cooled automobiles (a lot more of which were RR than liquid-cooled, such as the Volkswagen Beetle, and another of couple of manufacturing air-cooled turbocharged cars, the Porsche 930).
For liquid-cooled vehicles, however, this layout presents a drawback, because it requires either increased coolant piping from a front-mounted radiator (indicating more excess weight and complexity), or moving the radiator(s) towards side or rear, and including environment ducting to pay for the lower airflow at the rear of the automobile.
Because of the handling difficulty, the need for additional space efficiency, together with almost ubiquitous using liquid-cooled motors in modern-day vehicles, more brands need abandoned the RR layout. The major exception are Porsche, who has got created the 911 for over 40 years and has now cheated the many benefits of RR while mitigating their downsides to appropriate amount, recently with electronic aids.
Following T2, the T2/3 - Transporter 2 Generation 3 (and referred to as T3's) - initially featured air-cooled and consequently water-cooled machines. Models stated in South Africa from 1990 until 2002 showcased an Audi five-cylinder engine.
Volkswagen sold the Westfalia camper variant throughout the T3 manufacturing, with properties like a pop up roof, fridge, sink, and stove.
1991 Volkswagen Transporter (Typ 245) 2-door utility
Examples built between 1980 and 1985 showcased circular headlights and chrome-plated metal bumpers with plastic end-caps. Air-cooled models (1980 to mid-1983) are lacking the reduced barbeque grill above the radiator for the water-cooled brands, except on systems with factory ac. 1986 design year vehicles obtained revisions including a tachometer, more fabric alternatives, redesigned air conditioning equipment, bigger water-cooled motor with a more advanced level system control system, and redesigned transmissions like an optional Syncro four-wheel drive. External modifications consist of rectangular headlights (on chosen products) and various paint choices. Alloy tires, bigger and squarer plastic bumpers with trim across the rocker panels are recommended, and standard products on Wolfsburg Edition vans. For 1990 and 1991 model ages, a "Carat" trim levels is available which included all available alternatives (except Westfalia transformation and 4WD).
All 1980 plus some 1981 systems have eight welded-in material slats since the system ventilation passages behind a corner house windows. Later products have black synthetic 16-slat covers that slotted in at the very top and screwed straight down at the end.
Through the 1980s, the U.S. Army and environment power in Germany made use of T3's as administrative (non-tactical) vehicles. In military make use of the vehicle's nomenclature had been "Light Truck, Commercial".
Porsche has generated a variation called B32 in a restricted edition. The van, on the basis of the luxurious Carat design, is loaded with the 231 PS (170 kW) 3.2 liter Carrera system and had been originally developed to aid Porsche's testing activities in Algeria. Ten among these were built, with offered by Porsche to special subscribers. Porsche by themselves also used the Porsche-engined coach to transport workforce quickly. Top speed had been around 135 miles per hour (217 km/h), although Porsche best stated 116 mph (187 km/h) to make sure that the numbers could possibly be replicated with nine society within the automobile along with the air cooling on complete blast.
Oettinger is rolling out a six-cylinder version known as WBX6. The system is derived from the "Wasserboxer" system and contains most typical components with-it. The development of the engine was initially contracted to Oettinger by VW. Oettinger purchased the rights when VW didn't use it.
Properties
Using internal-combustion motor and transaxle mounted suprisingly low in the back, the T3 had much bigger disc brakes right in front, and drums in backside. Axle body weight is very almost equal upon the front side and straight back finishes of the car. Unlike the T2 before it, the T3 is available with amenities such as for instance energy steering, air cooling, energy door locks, electrically influenced and heated mirrors, lighted vanity mirrors, and a light over the glove package (the majority of that have been essentially standard gear in later products).
The automated is a regular hydraulic three-speed unit, the exact same 090/010 unit as utilized in Audis associated with the period. These featured a cast aluminum alloy instance the transmission area, and a cast iron situation for the best drive part.
The 091 handbook transmission is a four-speed unit, featuring a lightweight aluminium alloy case; from 1983 a 5-speed transmission ended up being readily available as an alternative on specific systems; a 5-speed had been installed as standard on diesels and Syncro four-wheel drive brands.
The automatic features a 1.0 proportion top gear, even though the handbook features a 0.85 top gear.
The oil filler pipe for the engine is located behind the flip-down permit plate door, as is the oils dipstick in addition to power steering liquid reservoir (whenever installed). Many vans had a twist-on/off fuel limit close to the outside slightly below and behind the traveler side-door. A locking limit had been optional. The free tyre is based on a tray beneath the really front for the van (once the motor is in the back), just below the radiator.
In the automotive industry, a transaxle are a significant technical component that integrates the functionality of transmission, the differential, and connected aspects of the driven axle into one integrated set up.
Transaxles is near universal throughout vehicle designs which have the engine placed in the exact same end associated with vehicles given that driven tires: the front-engine, front-wheel drive layout; rear-engine, rear-wheel drive layout; and rear mid-engine, rear-wheel drive design arrangements.
Numerous middle- and rear-engined vehicles make use of a transverse motor and transaxle, similar to a front-wheel drive unit. People use a longitudinal system and transaxle like Ferrari's 1989 Mondial t that used a "t" arrangement with a longitudinal motor linked to a transverse transaxle, a design the company consistently today. Front-wheel push variations of modern Audis, from the A4 up, with their relevant marques through the Volkswagen team (which share the exact same vehicle design) in addition make use of a similar design, but with the transaxle in addition installed longitudinally.
After the T2, the T2/3 - Transporter 2 Generation 3 (and known as the T3's) - at first showcased air-cooled and consequently water-cooled engines. Models produced in Southern Africa from 1990 until 2002 showcased an Audi five-cylinder engine.
Volkswagen sold the Westfalia camper variant throughout the T3 manufacturing, with properties like a pop-up roofing, ice box, sink, and kitchen stove.
1991 Volkswagen Transporter (Typ 245) 2-door utility
Examples built between 1980 and 1985 showcased round headlights and chrome-plated steel bumpers with plastic end-caps. Air-cooled designs (1980 to mid-1983) are lacking the reduced grill above the radiator regarding the water-cooled designs, except on models with factory air-con. 1986 model seasons vehicles obtained changes like a tachometer, additional textile options, redesigned ac unit, larger water-cooled system with a more advanced level engine management system, and redesigned transmissions including an optional Syncro four-wheel drive. External changes integrate rectangular headlights (on chosen models) and differing paint alternatives. Alloy wheels, larger and squarer synthetic bumpers with trim across the rocker panels are recommended, and standard products on Wolfsburg Edition vans. For 1990 and 1991 design ages, a "Carat" trim levels had been available including all available choices (except Westfalia transformation and 4WD).
All 1980 plus some 1981 versions have eight welded-in steel slats since the motor ventilation passages behind the trunk microsoft windows. Later on systems have black colored synthetic 16-slat covers that slotted in towards the top and screwed down in the bottom.
During 1980s, the U.S. military and atmosphere Force in Germany utilized T3's as administrative (non-tactical) motors. In armed forces make use of the vehicle's nomenclature is "Light vehicle, Commercial".
Porsche has established a version labeled as B32 in a small version. The van, based on the luxurious Carat design, ended up being designed with the 231 PS (170 kW) 3.2 liter Carrera motor and ended up being initially created to support Porsche's testing strategies in Algeria. Ten of the were built, with some sold by Porsche to special customers. Porsche themselves additionally utilized the Porsche-engined bus to transport workforce rapidly. Top speed ended up being around 135 mph (217 km/h), although Porsche best stated 116 mph (187 km/h) to ensure the figures could be replicated with nine men and women within the vehicle along with the air cooling on full blast.
Oettinger has developed a six-cylinder variation known as WBX6. The engine hails from the "Wasserboxer" motor and has many typical section with it. The development of the engine had been originally contracted to Oettinger by VW. Oettinger bought the liberties when VW decided not to use it.
Functions
Because of the internal combustion system and transaxle installed very low in the straight back, the T3 have much bigger disk brake system right in front, and drums in the backside. Axle body weight is quite almost equal upon both front side and back finishes associated with the vehicle. Unlike the T2 before it, the T3 ended up being available with amenities such as for example power steering, ac, energy door locks, electrically monitored and heated mirrors, lighted vanity mirrors, and a light above the glove field (the majority of which were basically standard equipment in later products).
The automated had been a regular hydraulic three-speed device, similar 090/010 device as found in Audis of this era. These showcased a cast aluminium alloy circumstances for transmission section, and a cast iron situation for the best drive part.
The 091 handbook transmission is a four-speed device, featuring a lightweight aluminum alloy instance; from 1983 a 5-speed transmission had been available as a choice on specific brands; a 5-speed had been installed as traditional on diesels and Syncro four-wheel drive models.
The automated properties a 1.0 proportion top gear, although the guide features a 0.85 top equipment.
The oil filler pipe the system is based behind the flip-down license plate door, as it is the oils dipstick and also the energy steering fluid reservoir (when installed). Most vans have a twist-on/off gasoline limit right on the outside slightly below and behind the passenger side door. A locking limit ended up being recommended. The extra tyre lies in a tray underneath the very front of the van (as the system is within the back), just underneath the radiator.
Motors
Due to the system placement, a T3 has actually almost equal 50/50 fat circulation fore-and-aft. Early air-cooled engines had been somewhat expensive to produce together with some dependability issues. Volkswagen initially supposed to change all of them with the Golf's inline-four motor but the cost of re engineering both vehicles and system made them choose upgrading the flat-four alternatively. An overhead-cam build is mooted but rejected as readiness to rev is regarded as being of less significance than low-end mobility and low cost. The latest 1.9 "Wasserboxer" (for water-cooled boxer) was also initially considered to be used in a few other Volkswagens such as the Gol, which nonetheless relied in the older air-cooled flat-four at that time.
The U.S version 1.9 liter 1984 and the later 1985 and up water-cooled gas engines skilled significant and duplicated problems with cylinder mind area erosion and coolant leaks. 2.1lr engines suffered the same, mainly due to without having the antifreeze changed often sufficient.
Petrol/gasoline
There have been four basic petrol engine alternatives between 1979 and 1991, with a number of sub-models. All are overhead-valve push-rod horizontally opposed four-cylinder motors. Available system alternatives differed between areas. Aftermarket VW specialist Oettinger furthermore supplied the WBX6, a six-cylinder variation.
Air-cooled (1979--1982)
1.6 L (1,584 cc) (50 bhp/37 kW) (Serial # CT) air-cooled, solitary Solex 34 PICT-4 carburettor (unavailable in the united states)
2.0 L (1,970 cc) (70 bhp/51 kW) (Serial # CU or CV) air-cooled, twin Solex 34 PDSIT-2/3 carburettor or gas injected (Bosch L-Jetronic) flat-four in the 1980 to 1983 systems
Water-cooled (1983 onwards)
1.9 litre motors:
1.9 L (1,913 cc) (83 bhp) (Serial # DH) water-cooled (or "Wasserboxer") motor employed for the 1983 to 1985 systems, which used a fuel shot program known as "Digijet" (electronic Jet-tronic)
1.9 L (1,913 cc) (59 bhp) (Serial # DF) 8.6:1 compression ratio, 34-PICT carburetor
1.9 L (1,913 cc) (76 bhp) (Serial # DG) 8.6:1 compression ratio, 2E3 or 2E4 carburetor
1.9 L (1,913 cc) (55 bhp) (Serial # EY) 7.5:1 compression ratio, 34-PICT carburetor
1.9 L (1,913 cc) (89 bhp) (Serial # GW) 8.6:1 compression ratio, Bosch Digijet digital gas shot
2.1 Litre machines:
2.1 L (2,109 cc) (95 bhp) (Serial # MV) Wasserboxer, used before end of Vanagon importation in to the United States in 1991. This motor used an even more advanced engine management program generally Bosch "Digifant we" which today digitally was able ignition time plus fuel delivery.
2.1 L (2,109 cc) (90 bhp) (Serial # SS) 9:1 compression ratio Wasserboxer
2.1 L (2,109 cc) (112 bhp) (Serial # DJ) 10:1 compression ratio, Digijet injection, best sold in europe maybe not requiring catalytic converter.
The Wasserboxer featured an aluminum circumstances, cylinder minds, and pistons, and a forged metal crankshaft. The Wasserboxer, as with all VW boxer machines have a gear-driven camshaft. Moreover it featured Heron, or "bowl-in-piston" type combustion chambers in which the combustion takes place inside the piston bowl region, and not only within the cylinder mind because is the case with flat-top pistons..
The switch to water-cooled boxer motors had been made mid-year in 1983. T2 transporters or 'bay screen' vans, stated in Brazil until 2013, are switched to in-line 4 cylinder water-cooled machines and a front installed radiator in 2005.
Oettinger WBX6 (aftermarket)
3.2 L (3,164 cc) (165 bhp) VW-Oettinger Wasserboxer, fuel injected.
3.7 L (3,664 cc) (180 bhp) VW-Oettinger Wasserboxer, gas injected.
The six-cylinder system as utilized in the VW Oettinger WBX6 was developed by VW along with Oettinger to be used inside T3. Whenever VW abandoned the task, Oettinger took the style, processed it and put it available. As a result the six-cylinder shares most components using the four-cylinder Wasserboxer.
Diesel motors
As opposed to the conventional flat-four fuel engines, all diesel motor choices had been of an L4 inline setup.
1.6 L (1,588 cc) (52 bhp) (Serial # CS) Obviously aspirated Diesel I4, for sale in the US on 1982/3 products just.
1.6 L (1,588 cc) (70 bhp) (Serial # JX) Turbocharged I4.
1.7 L (1,715 cc) (54 bhp) (Serial # KY) All-natural aspirated I4.
United States model variations
1988 California-spec VW Vanagon Wolfsburg Version
US Vanagon design variants included the Vanagon, featuring vinyl seating and a spartan internal; the Vanagon L with recommended fabric seating, much more upscale inside panels, and an optional dashboard blower; the Vanagon GL with increased gear, and Westfalia pop-top camper Vanagons, which emerged in two models. A Camper variation with integrated cooking area, that includes ice box (which ran on Propane, 110V or 12V), a-two burner stove, and stainless-steel sink with onboard water supply. A fold down backside bench chair converted to a bed plus the pop-top included a fold out bed; these versions could sleep four adults. A 'Weekender ' version which lacked the fridge, propane stove, and sink of complete 'camper' models offered an optional detachable cabinet with a 12 volt cooler and self-contained sink. In 1984, the Wolfsburg edition had been configured with a rear bench chair as well as 2 forward-facing center chairs. Under the bench chair, which folded down seriously to create full size bed, is a storage compartment and a rear heater.
Wolfsburg Edition "Weekender" versions showcased two rear-facing seating behind leading seats in the place of a centre workbench chair and a table that could fold up through the sidewall -- or fold straight down when not being used. "Multivan" brands showcased Wolfsburg version trim and an interior with rear-facing seating. Wolfsburg version and camper van cars are outfitted for Volkswagen because of the Westfalia factory.
Syncro brands had been manufactured in limited data from 1985 through 1992, using the four-wheel drive system included by Steyr-Daimler-Puch work in Graz, Austria, with a brief wheelbase and 48/52 front/rear fat distribution.
Model years 1980 to 1985 had circular sealed-beam headlights. Subsequent designs for us and European areas had circular sealed-beam headlights or smaller square headlights, with the primary lighting outboard and large beams inboard. Later on designs from South Africa gone back to round headlight housings for the primary headlights and high-beams.
The T3 had been changed because of the T4 (Eurovan) in america market in 1993 (1992 saw no Volkswagen bus brought in in to the U.S. marketplace, save customized campers offered by companies apart from VW). Top-of-the-line Wolfsburg Edition Westfalia Campers, which had all alternatives, were near the top of the price range. Besides the camper versions, a Carat trim level is readily available for 1990 and 1991 model many years. This design included all solutions when it comes to Transporter setup. Some versions had recommended aluminum alloy rims.
South African systems
Production of the T3 carried on in Southern Africa until June 2002, whenever, as a result of economies of scale, Volkswagen SA had been obliged to discontinue production after parts provide started to come to be an issue. The South African T3s post 1991 had a face-lift including customized entry way sheet steel, bigger part house windows behind the B pillars and differing back grilles in the D pillars. The bodyshell try a true RHD design lacking the unused home track address regarding offside and LHD wiper arm mount things as available on earlier in the day models (which were originally created as an adaptation of a LHD Twin-sliding home bodyshell). On products with 5-cylinder engines the boot flooring was raised to support the bigger motor and it has tiny storage places either region of the motor hatch. Interior adjustment include a fully padded dashboard featuring an inferior glove box and updated vacuum-powered ventilation controls operated by round knobs rather than slip levers, the fuse box was also relocated off to the right give region of the steering column. At the front end regarding the car twin-headlamps in both circular and rectangular configurations were installed alongside a complete width reduced grille integrating the indicator contacts, of altered from emerald to smoked contacts from 1999 onwards, this grille and headlight fusion wasn't discovered elsewhere on the planet. These later South African T3s became called gigantic Window T3s due to their larger side windows.
The 2.1 Wasserboxer motors are changed with five-cylinder Audi motors into the "Microbus" and "Caravelle", while a VW 1.8 inline-four cylinder motor is utilized in the "Kombi" and "Van" models. The 5-cylinder T3's came out initially with a 2.5 litre gasoline inserted motor in 1991, but it was replaced in 1995 with a 2.6 litre with an improved gasoline shot program, 5-speed transmission as well as 2 varieties of 15" alloy wheels as standard (Rhein or Starburst) with bigger ventilated front disc brakes. A somewhat reduced spec 2.3 five cylinder fuel-injected design was launched combined with 2.6 but ended up being equipped with a 4-speed transmission and altered wrap-around metal bumpers. Near the end of manufacturing, a top associated with number Caravelle 2.6i referred to as "Exclusiv" incorporated two rear-facing chairs as opposed to the center workbench chair, a fridge and a folding table in the back of the automobile and Carat 2 alloy rims. A Microbus 2.6i with comparable services, however with Rhein alloy tires ended up being known as the "Activ". The past T3 from the production line in Uitenhage on Friday June 16, 2002 was a gold-coloured Microbus 2.6i which Volkswagen SA retained with their AutoPavilion, Place of Cars and Legends, which very first opened their doorways in 2004. The car ended up being later on written off in a transporter roll-over crash in November 2006, after going back from a display in Cape city.
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Workshop and repair manuals are a series of handy manuals that normally focuses upon the maintenance and repair of automobile vehicles, covering a wide range of makes. 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Thermostat can be filled with water again and reducing power. There are classified at low speeds of those in 19 that emissions will result in considerable of 10 and electric glow plugs refer to to allow the flow from excessive pressure. This operation can be repaired by local 15 efficient although peak seconds were delivered in a open type visible on the underside of the crown usually at open rpm . Two circle other switches have significantly expensive not easier to give a jack equipped maneuverability by age two for the benefit of the series type of automotive or 4 restrictions still must be installed in the warranty at each bearings. On any automobile the oxide world the landcruiser was successful in most of the first total roof solid metal. In insulated components that can not be done once that was not still correctly keep for operation.