Rebuild Aircooled VW Engines HP255 by Tom WilsonGet other VW repair manuals hereA guide to engine rebuilding includes discussions of removal parts indentification cylinder head reconditioning and engine assembly Integracar tries to make available a diverse array of workshop guides. But owners manuals can be created for assorted countries and the motor cars engineered for those nations. That means not all service manuals may be acceptable for your particular car. If you have queries whether a particular repair manual is relevant for your automobile kindly contact us hereRebuild Aircooled VW Engines HP255 by Tom Wilson
Volkswagen (VW) Vanagon 1980 – 1983 Haynes Owners Service Repair Manual covers 1980-1983 Volkswagen (VW) Vanagon with 2.0 litre air-cooled flat-four engines.Note: this manual DOES NOT cover water-cooled or diesel engine models.Contents: Introduction: Vehicle Identification Numbers. Buying Parts. Safety. Maintenance Techniques. Chemical And Lubricants And More. Tune-Up And Routine Maintenance General Engine Overhaul Procedures Cooling Heating And Air-Conditioning Systems Fuel And Exhaust Systems Engine Electrical Systems Emissions Control Systems Transmission Driveline Brakes Suspension And Steering Systems Body Chassis Electrical System Wiring Diagrams
Get Other VW Transporter Repair Manuals click here 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.
Volkswagen VW Transporter 1982 – 1989 Owners Workshop Manual Covers The following Engine Reference Letters: Carburetor 1.9 Litre – DF DG or EY. Injected 1.9 Litre – GW. 2.1 Litre Without Catalytic Converter – DJ. 2.1 Litre with Catalytic Converter – MV.Covers the Water Cooled Rear-Engined Petrol models only with Manual Gearbox from 1982 – 1989. Kombi. Stationwagon. Bus. Camper. Caravelle. Pick-Up 1.9 Litre and 2.1 Litre Carburettor Fuel Injected Water Cooled Engines.Contents:: Engines Ignition System Lubrication System Cooling System Carburettor Fuel System Fuel Injection System Exhaust System Clutch Manual Transmission Automatic Transmission Rear Drive Shafts Rear Axle Transmission Front Suspension Mechanical Power Assisted Steering Brake System Electric
How to Convert Volkswagen Bus or Van to Camper by Lindsay PorterGet other VW repair manuals hereThis volume contains detailed step-by-step instructions for converting a VW Transporter van or bus to a Camper. It gives advice on how to choose the best van for your needs and prepare it – how to plan the layout and choose fittings how to fit an elevating roof how to cut panels and fit utilities. Integracar tries to have a sizeable array of owners guides. However owners manuals can sometimes be manufactured for very different nations and the motor vehicles designed for those nations. For this reason not all workshop manuals may be applicable for your individual car. If you have important questions whether or not a selected maintenance manual is best suited for your car do not hesitate to make contact with us hereHow to Convert Volkswagen Bus or Van to Camper by Lindsay Porter
How to Rebuild Your Volkswagen Air-Cooled Engine 1961 onwards
Volkswagen Vanagon Transporter Air cooled 4 cyl 1980-1983
Volkswagen VW Transporter Commercial Type 2 T3 Caravelle Vanagon 1982 – 1990
Volkswagen VW Transporter T3 Petrol 1982-1989 Service Repair Manual Brooklands Books Ltd UK
How to Convert Volkswagen Bus or Van to Camper
The Volkswagen Type 2 (T3) is the third generation of the Volkswagen Transporter and ended up being marketed under numerous nameplates global — like as 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, — sufficient reason for a more squared and less curved styling — the T3 ended up being stated in Germany from 1979 until 1990. Creation of the 2WD (mainly for official use, like postal service or German army) continuing until 1992 at Puch in Graz/Austria, where all 4WDs had been built. South African creation of the T3 continued, for that markets best, until 2002. The T3 ended up being the ultimate generation of rear-engined Volkswagens.
Using internal-combustion engine and transaxle installed very low into the back, the T3 had much larger disk brakes right in front, and drums when you look at the backside. Axle pounds is quite almost equal upon the front and straight back ends for the car. Unlike the T2 before it, the T3 was available with amenities such power steering, air-conditioning, energy home hair, electrically monitored and heated mirrors, lighted vanity mirrors, and a light above the glove field (the majority of that have been essentially standard products in later systems).
The automatic ended up being a standard hydraulic three-speed product, the exact same 090/010 device as used in Audis associated with the period. These featured a cast aluminium alloy situation the transmission area, and a cast iron circumstances the final drive area.
The 091 manual transmission is a four-speed unit, featuring a lightweight aluminium alloy case; from 1983 a 5-speed transmission had been readily available as an option on specific brands; a 5-speed is fitted as standard on diesels and Syncro four-wheel drive products.
The automatic properties a 1.0 proportion top equipment, whilst handbook features a 0.85 top equipment.
The oil filler pipe the system is situated behind the flip-down license dish home, as it is the oil dipstick and power steering fluid reservoir (whenever installed). Most vans had a twist-on/off gas limit close to the exterior just under and behind the passenger side-door. A locking limit was optional. The spare tyre is based on a tray under the extremely front side regarding the van (as the engine is in the straight back), just beneath the radiator.
Following T2, the kind 2, T3 – Transporter 2 Generation 3 (and known as the T3’s) – initially featured air-cooled and consequently water-cooled motors. Variations produced in Southern Africa from 1990 until 2002 featured an Audi five-cylinder system.
Volkswagen sold the Westfalia camper variation through the T3 manufacturing, with functions like an appear roofing, refrigerator, sink, and stove.
1991 Volkswagen Transporter (Typ 245) 2-door utility
Instances built between 1980 and 1985 featured circular headlights and chrome-plated metal bumpers with plastic end-caps. Air-cooled brands (1980 to mid-1983) lack the low barbecue grill above the radiator associated with water-cooled brands, except on products with factory air cooling. 1986 model year automobiles gotten revisions like a tachometer, even more textile alternatives, redesigned ac, larger water-cooled motor with a more higher level motor control system, and redesigned transmissions including an optional Syncro four-wheel drive. Outside changes feature rectangular headlights (on chosen products) and different paint alternatives. Alloy wheels, bigger and squarer plastic bumpers with trim across the rocker panels had been optional, and standard gear on Wolfsburg version vans. For 1990 and 1991 model years, a “Carat” trim amount was offered including all available alternatives (except Westfalia transformation and 4WD).
All 1980 many 1981 designs had eight welded-in steel slats covering the system ventilation passages behind the rear windows. Later versions have black synthetic 16-slat covers that slotted in at the very top and screwed down at the end.
During the 1980s, the U.S. military and atmosphere power in Germany utilized T3’s as administrative (non-tactical) automobiles. In armed forces make use of the vehicle’s nomenclature is “lighter vehicle, Commercial”.
Porsche has established a variation labeled as B32 in a small edition. The van, based on the luxurious Carat model, is loaded with the 231 PS (170 kW) 3.2 liter Carrera engine and ended up being originally developed to support Porsche’s assessment strategies in Algeria. Ten of the had been built, with sold by Porsche to unique subscribers. Porsche on their own furthermore used the Porsche-engined bus to transport workforce quickly. Top rate is around 135 miles per hour (217 km/h), although Porsche only stated 116 miles per hour (187 km/h) to make sure that the numbers could possibly be replicated with nine men within the car and with the air cooling on complete blast.
Oettinger is rolling out a six-cylinder version called WBX6. The engine hails from the “Wasserboxer” system and has most common areas with-it. The introduction of the system ended up being originally developed to Oettinger by VW. Oettinger purchased the legal rights whenever VW didn’t utilize it.
Due to the system position, a T3 features almost equal 50/50 body weight circulation fore-and-aft. The first air-cooled machines had been notably high priced to create along with some reliability problems. Volkswagen originally meant to exchange them with the tennis’s inline-four engine nevertheless cost of re engineering both vehicles and system made them choose upgrading the flat-four alternatively. An overhead-cam design had been mooted but denied as readiness to rev was regarded as being of less benefit than low-end flexibility and low priced. The new 1.9 “Wasserboxer” (for water-cooled boxer) has also been initially considered for use in certain other Volkswagens like the Gol, which however relied in the older air-cooled flat-four during those times.
The U.S variation 1.9 liter 1984 and also the later 1985 and up water-cooled gas engines experienced big and continued difficulties with cylinder mind exterior erosion and coolant leaks. 2.1lr engines suffered exactly the same, mostly because of not having the antifreeze changed often sufficient.
Petrol/gasoline
There have been four general petrol system variations between 1979 and 1991, with several sub-models. All are overhead-valve push-rod horizontally opposed four-cylinder motors. Offered system alternatives differed between regions. Aftermarket VW professional Oettinger in addition provided 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 fuel injected (Bosch L-Jetronic) flat-four into the 1980 to 1983 versions
Water-cooled (1983 onwards)
1.9 litre machines:
1.9 L (1,913 cc) (83 bhp) (Serial # DH) water-cooled (or “Wasserboxer”) motor used for the 1983 to 1985 designs, that used a fuel injection system referred to as “Digijet” (Digital Jet-tronic)
1.9 L (1,913 cc) (59 bhp) (Serial # DF) 8.6:1 compression proportion, 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 electronic gasoline shot
2.1 Litre machines:
2.1 L (2,109 cc) (95 bhp) (Serial # MV) Wasserboxer, utilized through to the end of Vanagon importation in to the US in 1991. This motor put a far more higher level motor administration system referred to as Bosch “Digifant I” which today digitally was able ignition time and 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 shot, just marketed in countries in europe maybe not needing catalytic converter.
The Wasserboxer showcased an aluminum instance, cylinder heads, and pistons, and a forged metallic crankshaft. The Wasserboxer, as with all VW boxer engines have a gear-driven camshaft. It also featured Heron, or “bowl-in-piston” kind burning chambers where in fact the combustion takes place inside the piston dish region, and not only when you look at the cylinder head as is the instance with flat top pistons..
The change to water-cooled boxer machines ended up being made mid-year in 1983. T2 transporters or ‘bay window’ vans, stated in Brazil until 2013, were switched to in-line 4 cylinder water-cooled machines and a front attached 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 used in the VW Oettinger WBX6 was created by VW along with Oettinger to be used in T3. When VW abandoned the task, Oettinger took the design, processed they and put they in the marketplace. Therefore the six-cylinder shares numerous parts with the four-cylinder Wasserboxer.
Diesel machines
As opposed to the conventional flat-four gas machines, all diesel system options were of an L4 inline configuration.
1.6 L (1,588 cc) (52 bhp) (Serial # CS) Naturally aspirated Diesel I4, available in the US on 1982/3 brands only.
1.6 L (1,588 cc) (70 bhp) (Serial # JX) Turbocharged I4.
1.7 L (1,715 cc) (54 bhp) (Serial # KY) organic aspirated I4.
United States design variants
1988 California-spec VW Vanagon Wolfsburg Version
United States Vanagon design variations included the Vanagon, featuring plastic seating and a spartan inside; the Vanagon L with recommended cloth seats, more upscale interior panels, and an optional dashboard blower; the Vanagon GL with increased products, together with Westfalia pop-top camper Vanagons, which emerged in 2 models. A Camper variation with built-in cooking area, detailed with refrigerator (which went on Propane, 110V or 12V), a two burner stove, and metal sink with onboard water-supply. A fold down rear bench seat transformed into a bed together with pop-top included a fold out sleep; these products could sleep four grownups. A ‘Weekender ‘ variation which lacked the refrigerator, propane kitchen stove, and sink for the complete ‘camper’ models offered an optional removable closet with a 12 volt cooler and self-contained sink. In 1984, the Wolfsburg version was configured with a rear bench chair and two forward-facing center chairs. Beneath the bench seat, which folded down seriously to create full size sleep, was a storage area and a rear heater.
Wolfsburg version “Weekender” brands featured two rear-facing chairs behind the front chairs rather than a center workbench chair and a dining table which could fold up through the sidewall — or fold straight down if not in use. “Multivan” versions featured Wolfsburg Edition trim and an inside with rear-facing seating. Wolfsburg version and camper van motors had been outfitted for Volkswagen because of the Westfalia factory.
Syncro brands had been manufactured in restricted data from 1985 through 1992, aided by the four-wheel drive program added by Steyr-Daimler-Puch Works in Graz, Austria, with a short wheelbase and 48/52 front/rear fat distribution.
Design many years 1980 to 1985 have circular sealed beam headlights. Subsequent designs for North American and European markets had round sealed beam headlights or smaller square headlights, using biggest lighting outboard and high beams inboard. Later on products from South Africa returned to round headlight housings for the primary headlights and high-beams.
The T3 was replaced because of the T4 (Eurovan) in america marketplace in 1993 (1992 spotted no Volkswagen bus brought in into the U.S. markets, save customized campers sold by organizations other than VW). Top-of-the-line Wolfsburg Edition Westfalia Campers, which have all alternatives, are near the top of the cost range. Aside from the camper models, a Carat trim degree is readily available for 1990 and 1991 model many years. This design included all solutions when it comes to Transporter configuration. Some products had optional aluminum alloy tires.
South African designs
Production of the T3 continuing in Southern Africa until June 2002, whenever, as a result of the economies of scale, Volkswagen SA are obliged to cease manufacturing after parts provide started initially to be a problem. The South African T3s post 1991 had a face-lift which included customized front door sheet material, larger part windows behind the B pillars and various back grilles inside D pillars. The bodyshell was a real RHD build lacking the unused door track address regarding offside and LHD wiper arm mount guidelines as available on previous versions (that have been originally designed as an adaptation of a LHD Twin-sliding home bodyshell). On brands with 5-cylinder engines the boot flooring grew up to accommodate the taller motor and contains little storing areas either side of the engine hatch. Inner modifications consist of a completely cushioned dashboard featuring an inferior glove field and updated vacuum-powered ventilation settings operated by round knobs in place of slip levers, the fuse package was also relocated off to the right hand side of the steering column. At the front for the car twin-headlamps in both circular and rectangular designs were fitted alongside a full width reduced grille integrating the indicator lenses, which were changed from emerald to smoked contacts from 1999 onwards, this grille and headlight fusion wasn’t discover elsewhere on the planet. These later South African T3s became called gigantic screen T3s because of their bigger side house windows.
The 2.1 Wasserboxer engines were replaced with five-cylinder Audi machines inside “Microbus” and “Caravelle”, while a VW 1.8 inline-four cylinder system is found in the “Kombi” and “Van” systems. The 5-cylinder T3’s came out at first with a 2.5 litre gas inserted engine in 1991, but this is changed in 1995 with a 2.6 litre with a better gas shot system, 5-speed transmission and two types of 15″ alloy tires as traditional (Rhein or Starburst) alongside bigger ventilated front disc brakes. A slightly lower spec 2.3 five cylinder fuel-injected design is introduced combined with the 2.6 but had been built with a 4-speed transmission and changed wrap-around steel bumpers. Near the end of manufacturing, a high associated with range Caravelle 2.6i known as the “Exclusiv” incorporated two rear-facing chairs in the place of the centre bench chair, a fridge and a folding dining table at the back of the car and Carat 2 alloy tires. A Microbus 2.6i with similar services, however with Rhein alloy tires had been known as the “Activ”. The past T3 from the manufacturing line in Uitenhage on Friday June 16, 2002 ended up being a gold-coloured Microbus 2.6i which Volkswagen SA retained for their AutoPavilion, Place of Cars and Legends, which very first exposed their doors in 2004. The car was later on written down in a transporter roll-over accident in November 2006, after returning from a display in Cape city.
Five-cylinder Audi Machines made use of
2.3i (AFU) 90 kW
2.5i (AAY) 100 kW
2.6i (ADV) 100 kW
More or less 45 WBX6 motors had been imported to Southern Africa.
Eighty-nine Big Window T3’s came out into the Syncro version from 1991 to 1992.
Most modern internal combustion motors is cooled by a closed-circuit holding fluid coolant through networks when you look at the system block and cylinder head, where in actuality the coolant absorbs heat, to a temperatures exchanger or radiator in which the coolant releases heat to the atmosphere (or natural liquid, regarding marine engines). Thus, as they aren’t finally cooled because of the fluid, due to the liquid-coolant circuit they truly are referred to as water-cooled. In contrast, temperatures created by an air-cooled motor is introduced directly into air. (Direct Cooled motor) Typically this can be facilitated with material fins covering the outside the Cylinder Head and cylinders which boost the area that air can operate on. Atmosphere might force-fed with the use of a fan and shroud to accomplish efficient air conditioning with a high volumes of atmosphere or just by natural air flow with well-designed and angled fins.
Throughout combustion machines, an excellent portion of the temperatures generated (around 44per cent) escapes through the exhaust, maybe not through either a liquid coolant system nor through the steel fins of an air-cooled system (12percent). About 8percent associated with temperature power discovers their means into the oil, which although mostly meant for lubrication, in addition is important in heat dissipation via a cooler.
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Volkswagen Transporter – Wikipedia, the free encyclopedia
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Volkswagen Type 2 (T3) – Wikipedia, the free encyclopedia
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