https://club8090.co.uk/w/api.php?action=feedcontributions&user=HarryMann&feedformat=atomVW T25(T3)-Tech - User contributions [en]2024-03-28T12:55:36ZUser contributionsMediaWiki 1.36.1https://club8090.co.uk/w/index.php?title=Coolant_and_Heating_Oil_cooling&diff=13399Coolant and Heating Oil cooling2021-09-17T15:04:43Z<p>HarryMann: Created page with "Oil coolers This topic mainly applies to diesel engined T25s specifically TD diesels (indirect injection not direct tDI diesels)"</p>
<hr />
<div>Oil coolers<br />
<br />
This topic mainly applies to diesel engined T25s specifically TD diesels (indirect injection not direct tDI diesels)</div>HarryMannhttps://club8090.co.uk/w/index.php?title=Parts_-_Part_Nos&diff=13223Parts - Part Nos2016-05-23T09:09:43Z<p>HarryMann: </p>
<hr />
<div> '''HarryMann:''' (AAZ/1Y diesel engine parts)<br />
<br />
'''Stretch bolts (Only the head bolts are obtainable from GSF)'''<br />
<br />
<br />
Head bolts (40 N-m + 60 N-m + 90 degrees + 90 degrees; follow correct tightening sequence on gasket package)<br />
<br />
068 103 384 A (M12 x 115mm)<br />
<br />
<br />
B/end (rod) bolts (30 N-m + 90 degrees)<br />
<br />
028 105 425 G (42mm) (8) <br />
<br />
028 105 425 C (45mm) (8)<br />
<br />
028 105 425 N (waisetd) (8) <br />
<br />
028 105 425 K (fully threaded) (8)<br />
<br />
NB. These all take a 10mm bi-hex socket<br />
<br />
<br />
Main cap bolts (65 N-m + 90 degrees)<br />
<br />
N 102 638 01 M10x65 (10)<br />
<br />
N 901 300 01 AM10x80 (10) Late<br />
<br />
<br />
Pulley Bolt (90 N-m + 90 degrees)<br />
<br />
N 905 771 01 M14x1.5x47 (1)<br />
<br />
'''NB.''' This must be of the new style and if not retrofitted should be (i.e. This is an AAZ problem area!)<br />
[[Parts - Crankshaft|Crankshaft Pulley Bolt - Service Bulletin]]<br />
<br />
<br />
'''Bearing Shells (Std. sizes)'''<br />
<br />
Mains<br />
<br />
026 198 491<br />
<br />
Thrusts<br />
<br />
026 198 421 <br />
<br />
<br />
Big-ends<br />
<br />
028 105 701 J<br />
<br />
<br />
<br />
'''Seals and Gaskets''' <br />
(all obtainable from GSF, very expensive from VW)<br />
<br />
Pulley end crank seal<br />
<br />
026 103 085 F<br />
<br />
026 103 161 B (Gasket)<br />
<br />
<br />
Flywheel end crank seal<br />
<br />
068 103 171 F<br />
<br />
026 103 181 B (Gasket)<br />
<br />
<br />
Int. shaft seal (oil pump drive)<br />
<br />
026 103 085 F (same as pulley end seal)<br />
<br />
<br />
'''Oil Pumps'''<br />
<br />
For 80-90 Transporter Diesel <br />
<br />
GSF Part No. 15307 [Shadek] (comes with the longer, angled pickup; 36mm high capacity gears)<br />
<br />
For std. upright VW diesels <br />
<br />
GSF Part No. 15329 [Shadek] (comes with plastic surge baffle attachment; 36mm high capacity gears)<br />
<br />
'''Sump screws:''' (for use with integrated style windage-tray / sump gasket <br />
<br />
N 101 725 01 (M6 x 22 x SPZ1) Sump screws (20 off)<br />
<br />
NB. Read up on integrated baffle plate/gasket /splash tray (from other upright VW diesels) here:<br />
<br />
[http://wiki.club8090.co.uk/index.php/Diesel_engines_-_Sump/Oil_Pump Link back to Wiki on diesel sumps]</div>HarryMannhttps://club8090.co.uk/w/index.php?title=Parts_-_Part_Nos&diff=13222Parts - Part Nos2016-05-23T09:08:50Z<p>HarryMann: </p>
<hr />
<div> '''HarryMann:''' (AAZ/1Y diesel engine parts)<br />
<br />
'''Stretch bolts (Only the head bolts are obtainable from GSF)'''<br />
<br />
<br />
Head bolts (40 N-m + 60 N-m + 90 degrees + 90 degrees; follow correct tightening sequence on gasket package)<br />
<br />
068 103 384 A (M12 x 115mm)<br />
<br />
<br />
B/end (rod) bolts (30 N-m + 90 degrees)<br />
<br />
028 105 425 G (42mm) (8) <br />
<br />
028 105 425 C (45mm) (8)<br />
<br />
028 105 425 N (waisetd) (8) <br />
<br />
028 105 425 K (fully threaded) (8)<br />
<br />
<br />
Main cap bolts (65 N-m + 90 degrees)<br />
<br />
N 102 638 01 M10x65 (10)<br />
<br />
N 901 300 01 AM10x80 (10) Late<br />
<br />
<br />
Pulley Bolt (90 N-m + 90 degrees)<br />
<br />
N 905 771 01 M14x1.5x47 (1)<br />
<br />
'''NB.''' This must be of the new style and if not retrofitted should be (i.e. This is an AAZ problem area!)<br />
[[Parts - Crankshaft|Crankshaft Pulley Bolt - Service Bulletin]]<br />
<br />
<br />
'''Bearing Shells (Std. sizes)'''<br />
<br />
Mains<br />
<br />
026 198 491<br />
<br />
Thrusts<br />
<br />
026 198 421 <br />
<br />
<br />
Big-ends<br />
<br />
028 105 701 J<br />
<br />
<br />
<br />
'''Seals and Gaskets''' <br />
(all obtainable from GSF, very expensive from VW)<br />
<br />
Pulley end crank seal<br />
<br />
026 103 085 F<br />
<br />
026 103 161 B (Gasket)<br />
<br />
<br />
Flywheel end crank seal<br />
<br />
068 103 171 F<br />
<br />
026 103 181 B (Gasket)<br />
<br />
<br />
Int. shaft seal (oil pump drive)<br />
<br />
026 103 085 F (same as pulley end seal)<br />
<br />
<br />
'''Oil Pumps'''<br />
<br />
For 80-90 Transporter Diesel <br />
<br />
GSF Part No. 15307 [Shadek] (comes with the longer, angled pickup; 36mm high capacity gears)<br />
<br />
For std. upright VW diesels <br />
<br />
GSF Part No. 15329 [Shadek] (comes with plastic surge baffle attachment; 36mm high capacity gears)<br />
<br />
'''Sump screws:''' (for use with integrated style windage-tray / sump gasket <br />
<br />
N 101 725 01 (M6 x 22 x SPZ1) Sump screws (20 off)<br />
<br />
NB. Read up on integrated baffle plate/gasket /splash tray (from other upright VW diesels) here:<br />
<br />
[http://wiki.club8090.co.uk/index.php/Diesel_engines_-_Sump/Oil_Pump Link back to Wiki on diesel sumps]</div>HarryMannhttps://club8090.co.uk/w/index.php?title=General_Fastener_Materials&diff=12479General Fastener Materials2014-07-20T15:55:31Z<p>HarryMann: </p>
<hr />
<div>=Fastener and Fixing Materials=<br />
Extracted from [http://www.fastfixdirect.co.uk/code/fastener_materials_and_coatings_information.asp Fastfix Direct Tools Fasteners and Fixings]<br />
<br />
==General==<br />
<br />
Fasteners and fixings such as hexagon nuts, hexagon bolts, coach bolts, blind rivets, solid rivets, woodscrews, machine screw, nails etc, are manufactured in a wide range of materials from common steel to titanium, plastic and other exotic materials. Many materials are further separated into different grades to describe specific alloy mixtures, hardening processes, etc. In addition, some materials are available with a variety of coatings or plating to enhance the corrosion resistance, or appearance of the fastener.<br />
<br />
Fastener material can be important when choosing a fastener due to differences between materials in strength, brittleness, corrosion resistance, galvanic corrosion properties, and of course cost.<br />
<br />
''When replacing fasteners, it is generally best to match what you are replacing.'' Replacing a bolt with a stronger one is not always safe. Harder bolts tend to be more brittle and may fail in specific applications. Also some equipment is designed so that the bolts will fail before more expensive or critical items are damaged. In some environments such as salt water galvanic corrosion must also be considered if changing fastener materials.<br />
<br />
==Materials==<br />
<br />
===Stainless Steel (from a marine fastener perspective)===<br />
Stainless steel is an alloy of low carbon steel and chromium for enhanced corrosion characteristics. Stainless steel is highly corrosion resistant for the price and because the anti-corrosive properties are inherent to the metal, it will not loose this resistance if scratched during installation or use.<br />
<br />
''It is a common misconception that stainless steel is stronger than regular steel.'' In fact, due to the low carbon content, stainless steel cannot be hardened or toughenede in the same way. Therefore when compared with regular steel they can be stronger than mild steel fastener but many are weaker than most hardened steel fasteners.<br />
<br />
Stainless steel is also much less magnetic than regular steel fasteners though some grades will be slightly magnetic.<br />
<br />
Good corrosion resistance is a feature of all stainless steels. Low alloy grades can resist corrosion in normal conditions. Higher alloys resist corrosion by most acids, alkaline solutions and chloride environments.<br />
<br />
The corrosion resistance of stainless steels is due to their chromium content. In general, stainless steels contain a minimum of around 10.5% chromium. The chromium in the alloy forms a self-healing protective clear oxide layer that forms spontaneously in air. The self healing nature of the oxide layer means the corrosion resistance remains intact regardless of fabrication methods. Even if the material surface is cut or damaged, it will self heal and corrosion resistance will be maintained. The most commonly used grades are A2 stainless steel and A4 stainless steel, these are the two types offered by Fast Fix Direct Ltd.<br />
<br />
A1 = a free-cutting quality, having a superior machine ability due to a higher phosphorus and sulphure percentage. As a consequence, however, the general corrosion resistance is decreased. This “automatic lathe” stainless steel is seldom used for mass production fasteners.<br />
<br />
A2 = the most commonly used stainless steel grade - also called 18/8 (18% Cr, 8% Ni) - with outstanding corrosion resistance under normal atmospheric conditions, in wet surroundings, oxidizing and organic acids, many alkali and salt solutions. A2-0 bolts are nearly as strong as 8.8 heat treated fasteners.<br />
<br />
A4 = the most corrosion resistant steel grade - also called “acid proof” - with an increased nickel percentage and addition of molybdenum. Better resistance to aggressive, corrosive environments such as sea climate (chlorides), industrial atmosphere (sulphure dioxide), oxidizing acids and there where pitting may occur.<br />
<br />
Stainless Steel fasteners are the work horse for modern boatbuilding or exterior woodworking applications. They are perfect for marine use due to great corrosion resistance provide while remaining affordable. Hardened steel screws are more common in the woodworking environment but cannot be used in a corrosive environment. Stainless steel is available in a wide range of engineered grades, each with its own designation number and specific properties. Only a few grades of Stainless Steel are suitable for fasteners, those that can be cold headed easily and have adequate torsional and shear strengths. The 300 series stainless steels are the most popular.<br />
<br />
The most commonly used grade is A2 (304), however A4 (316) is a major step up and recommended for use in highly corrosive environments, such as in contact with salt water. A4 (316) series stainless, also known as marine quality or food grade stainless steel, contains molybdenum, which significantly increases corrosion resistance and strength.<br />
<br />
Use Stainless Steel screws cautiously below the waterline. Stainless Steel Screws cannot be in an anaerobic environment. If the screw is immersed in "still water" with no oxygen the corrosion-resistant film, chromium oxide, will not be allowed to form. Without the chromium oxide film the screw will suffer from galvanic corrosion and eventual failure.<br />
<br />
When using stainless steel nuts and bolts especially in larger in size always remember to lubricate with an ant seize compound. This will prevent the nut from binding on the thread (known as galling or cold-welding).<br />
<br />
[http://www.volksbolts.com/faq/basics.htm A good link for markings and comparative strengths of stainless and carbon steel bolts]<br />
<br />
===Steel (carbon steel)===<br />
Steel is the most common fastener material. Steel fasteners are available plain as well as with various surface treatments such as zinc plating, galvanization, and chrome plating.<br />
<br />
Steel fasteners are commonly available in 4 grades. Many other grades exist but are used far less often. The most common grades in the Din standard are mild steel 4.6 to 5.6 grade, this equates to testing 460 to 560 NM tensile strength per square mm.<br />
<br />
Grade 8.8 which is the metric standard high tensile bolt strength at 880 NM per square mm. The next grade being 10.9 which is often found in automotive applications where high loads are expected and 12.9 grade is the UK standard for socket headed cap screws.<br />
<br />
==Coatings==<br />
<br />
===Zinc Plating===<br />
Many steel fasteners are electro-plated with zinc for better corrosion resistance. Fasteners that have been zinc plated have a shiny silver or golden appearance referred to as clear or yellow zinc respectively. They are fairly corrosion resistant but will rust if the coating is destroyed or if exposed to a marine environment.<br />
<br />
===Hot Dip Galvanizing===<br />
Galvanizing is another coating involving the application of a layer of zinc. Hot dipped galvanizing puts the thickest possible coating on the metal resulting in superior corrosion resistance. Due to the thickness of the coating hot dipped galvanized bolts are not compatible with other nuts. Galvanized nuts are tapped slightly larger than other nuts to accommodate this coating.<br />
Hot dipped galvanized fasteners are frequently seen in coastal environments and in pressure treated lumber where the chemicals in the lumber may corrode other fasteners.<br />
<br />
===Chrome===<br />
Chrome is used in plating fasteners for its appearance. It provides similar corrosion resistance to zinc plating. The main drawback of chrome is the extremely high cost. If more corrosion resistance is required stainless steel may be chrome plated, preventing any corrosion should the chrome be penetrated.<br />
<br />
===Cadmium===<br />
Cadmium was a traditional corrosion prevention plating treatment, though concerns and costs over environmental ccleanup by plating companies have reduced its prevalence. However, it is usual to chromate treat or 'passivate' the finish which in simple terms, completes the surface to neutralise and fill microscopic holes. This results in the well known shiny yellowish or satin brown/green effect (the latter on military steel hardware)<br />
Cadmium plating is mainly used to provide a barrier between dissimilar metals in contact, to prevent, or reduce the rate and effect of electrolytic or galvanic corrosion. As cadmium is soft and doesn't embrittle when plated it is ideal for threaded fasteners. It is usually passivated to further enhance the finish and maybe because cadmium is posionous.<br />
==Links==<br />
<br />
[http://www.volksbolts.com/faq/basics.htm Volksbolt links on ratings strengths markings esp. stainless]</div>HarryMannhttps://club8090.co.uk/w/index.php?title=General_Fastener_Materials&diff=12478General Fastener Materials2014-07-20T15:54:15Z<p>HarryMann: /* Stainless Steel (from a marine fastener perspective) */</p>
<hr />
<div>=Fastener and Fixing Materials=<br />
Extracted from [http://www.fastfixdirect.co.uk/code/fastener_materials_and_coatings_information.asp Fastfix Direct Tools Fasteners and Fixings]<br />
<br />
==General==<br />
<br />
Fasteners and fixings such as hexagon nuts, hexagon bolts, coach bolts, blind rivets, solid rivets, woodscrews, machine screw, nails etc, are manufactured in a wide range of materials from common steel to titanium, plastic and other exotic materials. Many materials are further separated into different grades to describe specific alloy mixtures, hardening processes, etc. In addition, some materials are available with a variety of coatings or plating to enhance the corrosion resistance, or appearance of the fastener.<br />
<br />
Fastener material can be important when choosing a fastener due to differences between materials in strength, brittleness, corrosion resistance, galvanic corrosion properties, and of course cost.<br />
<br />
''When replacing fasteners, it is generally best to match what you are replacing.'' Replacing a bolt with a stronger one is not always safe. Harder bolts tend to be more brittle and may fail in specific applications. Also some equipment is designed so that the bolts will fail before more expensive or critical items are damaged. In some environments such as salt water galvanic corrosion must also be considered if changing fastener materials.<br />
<br />
==Materials==<br />
<br />
===Stainless Steel (from a marine fastener perspective)===<br />
Stainless steel is an alloy of low carbon steel and chromium for enhanced corrosion characteristics. Stainless steel is highly corrosion resistant for the price and because the anti-corrosive properties are inherent to the metal, it will not loose this resistance if scratched during installation or use.<br />
<br />
''It is a common misconception that stainless steel is stronger than regular steel.'' In fact, due to the low carbon content, stainless steel cannot be hardened or toughenede in the same way. Therefore when compared with regular steel they can be stronger than mild steel fastener but many are weaker than most hardened steel fasteners.<br />
<br />
Stainless steel is also much less magnetic than regular steel fasteners though some grades will be slightly magnetic.<br />
<br />
Good corrosion resistance is a feature of all stainless steels. Low alloy grades can resist corrosion in normal conditions. Higher alloys resist corrosion by most acids, alkaline solutions and chloride environments.<br />
<br />
The corrosion resistance of stainless steels is due to their chromium content. In general, stainless steels contain a minimum of around 10.5% chromium. The chromium in the alloy forms a self-healing protective clear oxide layer that forms spontaneously in air. The self healing nature of the oxide layer means the corrosion resistance remains intact regardless of fabrication methods. Even if the material surface is cut or damaged, it will self heal and corrosion resistance will be maintained. The most commonly used grades are A2 stainless steel and A4 stainless steel, these are the two types offered by Fast Fix Direct Ltd.<br />
<br />
A1 = a free-cutting quality, having a superior machine ability due to a higher phosphorus and sulphure percentage. As a consequence, however, the general corrosion resistance is decreased. This “automatic lathe” stainless steel is seldom used for mass production fasteners.<br />
<br />
A2 = the most commonly used stainless steel grade - also called 18/8 (18% Cr, 8% Ni) - with outstanding corrosion resistance under normal atmospheric conditions, in wet surroundings, oxidizing and organic acids, many alkali and salt solutions. A2-0 bolts are nearly as strong as 8.8 heat treated fasteners.<br />
<br />
A4 = the most corrosion resistant steel grade - also called “acid proof” - with an increased nickel percentage and addition of molybdenum. Better resistance to aggressive, corrosive environments such as sea climate (chlorides), industrial atmosphere (sulphure dioxide), oxidizing acids and there where pitting may occur.<br />
<br />
Stainless Steel fasteners are the work horse for modern boatbuilding or exterior woodworking applications. They are perfect for marine use due to great corrosion resistance provide while remaining affordable. Hardened steel screws are more common in the woodworking environment but cannot be used in a corrosive environment. Stainless steel is available in a wide range of engineered grades, each with its own designation number and specific properties. Only a few grades of Stainless Steel are suitable for fasteners, those that can be cold headed easily and have adequate torsional and shear strengths. The 300 series stainless steels are the most popular.<br />
<br />
The most commonly used grade is A2 (304), however A4 (316) is a major step up and recommended for use in highly corrosive environments, such as in contact with salt water. A4 (316) series stainless, also known as marine quality or food grade stainless steel, contains molybdenum, which significantly increases corrosion resistance and strength.<br />
<br />
Use Stainless Steel screws cautiously below the waterline. Stainless Steel Screws cannot be in an anaerobic environment. If the screw is immersed in "still water" with no oxygen the corrosion-resistant film, chromium oxide, will not be allowed to form. Without the chromium oxide film the screw will suffer from galvanic corrosion and eventual failure.<br />
<br />
When using stainless steel nuts and bolts especially in larger in size always remember to lubricate with an ant seize compound. This will prevent the nut from binding on the thread (known as galling or cold-welding).<br />
<br />
[http://www.volksbolts.com/faq/basics.htm A good link for markings and comparative strengths of stainless and carbon steel bolts]<br />
<br />
===Steel (carbon steel)===<br />
Steel is the most common fastener material. Steel fasteners are available plain as well as with various surface treatments such as zinc plating, galvanization, and chrome plating.<br />
<br />
Steel fasteners are commonly available in 4 grades. Many other grades exist but are used far less often. The most common grades in the Din standard are mild steel 4.6 to 5.6 grade, this equates to testing 460 to 560 NM tensile strength per square mm.<br />
<br />
Grade 8.8 which is the metric standard high tensile bolt strength at 880 NM per square mm. The next grade being 10.9 which is often found in automotive applications where high loads are expected and 12.9 grade is the UK standard for socket headed cap screws.<br />
<br />
==Coatings==<br />
<br />
===Zinc Plating===<br />
Many steel fasteners are electro-plated with zinc for better corrosion resistance. Fasteners that have been zinc plated have a shiny silver or golden appearance referred to as clear or yellow zinc respectively. They are fairly corrosion resistant but will rust if the coating is destroyed or if exposed to a marine environment.<br />
<br />
===Hot Dip Galvanizing===<br />
Galvanizing is another coating involving the application of a layer of zinc. Hot dipped galvanizing puts the thickest possible coating on the metal resulting in superior corrosion resistance. Due to the thickness of the coating hot dipped galvanized bolts are not compatible with other nuts. Galvanized nuts are tapped slightly larger than other nuts to accommodate this coating.<br />
Hot dipped galvanized fasteners are frequently seen in coastal environments and in pressure treated lumber where the chemicals in the lumber may corrode other fasteners.<br />
<br />
===Chrome===<br />
Chrome is used in plating fasteners for its appearance. It provides similar corrosion resistance to zinc plating. The main drawback of chrome is the extremely high cost. If more corrosion resistance is required stainless steel may be chrome plated, preventing any corrosion should the chrome be penetrated.<br />
<br />
==Cadmium== <br />
Cadmium was a traditional corrosion prevention plating treatment, though concerns and costs over environmental ccleanup by plating companies have reduced its prevalence. However, it is usual to chromate treat or 'passivate' the finish which in simple terms, completes the surface to neutralise and fill microscopic holes. This results in the well known shiny yellowish or satin brown/green effect (the latter on military steel hardware)<br />
Cadmium plating is mainly used to provide a barrier between dissimilar metals in contact, to prevent, or reduce the rate and effect of electrolytic or galvanic corrosion. As cadmium is soft and doesn't embrittle when plated it is ideal for threaded fasteners. It is usually passivated to further enhance the finish and maybe because cadmium is posionous.</div>HarryMannhttps://club8090.co.uk/w/index.php?title=General_Fastener_Materials&diff=12477General Fastener Materials2014-07-20T15:52:49Z<p>HarryMann: /* Cadmium */</p>
<hr />
<div>=Fastener and Fixing Materials=<br />
Extracted from [http://www.fastfixdirect.co.uk/code/fastener_materials_and_coatings_information.asp Fastfix Direct Tools Fasteners and Fixings]<br />
<br />
==General==<br />
<br />
Fasteners and fixings such as hexagon nuts, hexagon bolts, coach bolts, blind rivets, solid rivets, woodscrews, machine screw, nails etc, are manufactured in a wide range of materials from common steel to titanium, plastic and other exotic materials. Many materials are further separated into different grades to describe specific alloy mixtures, hardening processes, etc. In addition, some materials are available with a variety of coatings or plating to enhance the corrosion resistance, or appearance of the fastener.<br />
<br />
Fastener material can be important when choosing a fastener due to differences between materials in strength, brittleness, corrosion resistance, galvanic corrosion properties, and of course cost.<br />
<br />
''When replacing fasteners, it is generally best to match what you are replacing.'' Replacing a bolt with a stronger one is not always safe. Harder bolts tend to be more brittle and may fail in specific applications. Also some equipment is designed so that the bolts will fail before more expensive or critical items are damaged. In some environments such as salt water galvanic corrosion must also be considered if changing fastener materials.<br />
<br />
==Materials==<br />
<br />
===Stainless Steel (from a marine fastener perspective)===<br />
Stainless steel is an alloy of low carbon steel and chromium for enhanced corrosion characteristics. Stainless steel is highly corrosion resistant for the price and because the anti-corrosive properties are inherent to the metal, it will not loose this resistance if scratched during installation or use.<br />
<br />
''It is a common misconception that stainless steel is stronger than regular steel.'' In fact, due to the low carbon content, stainless steel cannot be hardened or toughenede in the same way. Therefore when compared with regular steel they can be stronger than mild steel fastener but many are weaker than most hardened steel fasteners.<br />
<br />
Stainless steel is also much less magnetic than regular steel fasteners though some grades will be slightly magnetic.<br />
<br />
Good corrosion resistance is a feature of all stainless steels. Low alloy grades can resist corrosion in normal conditions. Higher alloys resist corrosion by most acids, alkaline solutions and chloride environments.<br />
<br />
The corrosion resistance of stainless steels is due to their chromium content. In general, stainless steels contain a minimum of around 10.5% chromium. The chromium in the alloy forms a self-healing protective clear oxide layer that forms spontaneously in air. The self healing nature of the oxide layer means the corrosion resistance remains intact regardless of fabrication methods. Even if the material surface is cut or damaged, it will self heal and corrosion resistance will be maintained. The most commonly used grades are A2 stainless steel and A4 stainless steel, these are the two types offered by Fast Fix Direct Ltd.<br />
<br />
A1 = a free-cutting quality, having a superior machine ability due to a higher phosphorus and sulphure percentage. As a consequence, however, the general corrosion resistance is decreased. This “automatic lathe” stainless steel is seldom used for mass production fasteners.<br />
<br />
A2 = the most commonly used stainless steel grade - also called 18/8 (18% Cr, 8% Ni) - with outstanding corrosion resistance under normal atmospheric conditions, in wet surroundings, oxidizing and organic acids, many alkali and salt solutions. A2-0 bolts are nearly as strong as 8.8 heat treated fasteners.<br />
<br />
A4 = the most corrosion resistant steel grade - also called “acid proof” - with an increased nickel percentage and addition of molybdenum. Better resistance to aggressive, corrosive environments such as sea climate (chlorides), industrial atmosphere (sulphure dioxide), oxidizing acids and there where pitting may occur.<br />
<br />
Stainless Steel fasteners are the work horse for modern boatbuilding or exterior woodworking applications. They are perfect for marine use due to great corrosion resistance provide while remaining affordable. Hardened steel screws are more common in the woodworking environment but cannot be used in a corrosive environment. Stainless steel is available in a wide range of engineered grades, each with its own designation number and specific properties. Only a few grades of Stainless Steel are suitable for fasteners, those that can be cold headed easily and have adequate torsional and shear strengths. The 300 series stainless steels are the most popular.<br />
<br />
The most commonly used grade is A2 (304), however A4 (316) is a major step up and recommended for use in highly corrosive environments, such as in contact with salt water. A4 (316) series stainless, also known as marine quality or food grade stainless steel, contains molybdenum, which significantly increases corrosion resistance and strength.<br />
<br />
Use Stainless Steel screws cautiously below the waterline. Stainless Steel Screws cannot be in an anaerobic environment. If the screw is immersed in "still water" with no oxygen the corrosion-resistant film, chromium oxide, will not be allowed to form. Without the chromium oxide film the screw will suffer from galvanic corrosion and eventual failure.<br />
<br />
When using stainless steel nuts and bolts especially in larger in size always remember to lubricate with an ant seize compound. This will prevent the nut from binding on the thread (known as galling or cold-welding).<br />
<br />
===Steel (carbon steel)===<br />
Steel is the most common fastener material. Steel fasteners are available plain as well as with various surface treatments such as zinc plating, galvanization, and chrome plating.<br />
<br />
Steel fasteners are commonly available in 4 grades. Many other grades exist but are used far less often. The most common grades in the Din standard are mild steel 4.6 to 5.6 grade, this equates to testing 460 to 560 NM tensile strength per square mm.<br />
<br />
Grade 8.8 which is the metric standard high tensile bolt strength at 880 NM per square mm. The next grade being 10.9 which is often found in automotive applications where high loads are expected and 12.9 grade is the UK standard for socket headed cap screws.<br />
<br />
==Coatings==<br />
<br />
===Zinc Plating===<br />
Many steel fasteners are electro-plated with zinc for better corrosion resistance. Fasteners that have been zinc plated have a shiny silver or golden appearance referred to as clear or yellow zinc respectively. They are fairly corrosion resistant but will rust if the coating is destroyed or if exposed to a marine environment.<br />
<br />
===Hot Dip Galvanizing===<br />
Galvanizing is another coating involving the application of a layer of zinc. Hot dipped galvanizing puts the thickest possible coating on the metal resulting in superior corrosion resistance. Due to the thickness of the coating hot dipped galvanized bolts are not compatible with other nuts. Galvanized nuts are tapped slightly larger than other nuts to accommodate this coating.<br />
Hot dipped galvanized fasteners are frequently seen in coastal environments and in pressure treated lumber where the chemicals in the lumber may corrode other fasteners.<br />
<br />
===Chrome===<br />
Chrome is used in plating fasteners for its appearance. It provides similar corrosion resistance to zinc plating. The main drawback of chrome is the extremely high cost. If more corrosion resistance is required stainless steel may be chrome plated, preventing any corrosion should the chrome be penetrated.<br />
<br />
==Cadmium== <br />
Cadmium was a traditional corrosion prevention plating treatment, though concerns and costs over environmental ccleanup by plating companies have reduced its prevalence. However, it is usual to chromate treat or 'passivate' the finish which in simple terms, completes the surface to neutralise and fill microscopic holes. This results in the well known shiny yellowish or satin brown/green effect (the latter on military steel hardware)<br />
Cadmium plating is mainly used to provide a barrier between dissimilar metals in contact, to prevent, or reduce the rate and effect of electrolytic or galvanic corrosion. As cadmium is soft and doesn't embrittle when plated it is ideal for threaded fasteners. It is usually passivated to further enhance the finish and maybe because cadmium is posionous.</div>HarryMannhttps://club8090.co.uk/w/index.php?title=General_Fastener_Materials&diff=12476General Fastener Materials2014-07-20T15:51:47Z<p>HarryMann: /* Stainless Steel */</p>
<hr />
<div>=Fastener and Fixing Materials=<br />
Extracted from [http://www.fastfixdirect.co.uk/code/fastener_materials_and_coatings_information.asp Fastfix Direct Tools Fasteners and Fixings]<br />
<br />
==General==<br />
<br />
Fasteners and fixings such as hexagon nuts, hexagon bolts, coach bolts, blind rivets, solid rivets, woodscrews, machine screw, nails etc, are manufactured in a wide range of materials from common steel to titanium, plastic and other exotic materials. Many materials are further separated into different grades to describe specific alloy mixtures, hardening processes, etc. In addition, some materials are available with a variety of coatings or plating to enhance the corrosion resistance, or appearance of the fastener.<br />
<br />
Fastener material can be important when choosing a fastener due to differences between materials in strength, brittleness, corrosion resistance, galvanic corrosion properties, and of course cost.<br />
<br />
''When replacing fasteners, it is generally best to match what you are replacing.'' Replacing a bolt with a stronger one is not always safe. Harder bolts tend to be more brittle and may fail in specific applications. Also some equipment is designed so that the bolts will fail before more expensive or critical items are damaged. In some environments such as salt water galvanic corrosion must also be considered if changing fastener materials.<br />
<br />
==Materials==<br />
<br />
===Stainless Steel (from a marine fastener perspective)===<br />
Stainless steel is an alloy of low carbon steel and chromium for enhanced corrosion characteristics. Stainless steel is highly corrosion resistant for the price and because the anti-corrosive properties are inherent to the metal, it will not loose this resistance if scratched during installation or use.<br />
<br />
''It is a common misconception that stainless steel is stronger than regular steel.'' In fact, due to the low carbon content, stainless steel cannot be hardened or toughenede in the same way. Therefore when compared with regular steel they can be stronger than mild steel fastener but many are weaker than most hardened steel fasteners.<br />
<br />
Stainless steel is also much less magnetic than regular steel fasteners though some grades will be slightly magnetic.<br />
<br />
Good corrosion resistance is a feature of all stainless steels. Low alloy grades can resist corrosion in normal conditions. Higher alloys resist corrosion by most acids, alkaline solutions and chloride environments.<br />
<br />
The corrosion resistance of stainless steels is due to their chromium content. In general, stainless steels contain a minimum of around 10.5% chromium. The chromium in the alloy forms a self-healing protective clear oxide layer that forms spontaneously in air. The self healing nature of the oxide layer means the corrosion resistance remains intact regardless of fabrication methods. Even if the material surface is cut or damaged, it will self heal and corrosion resistance will be maintained. The most commonly used grades are A2 stainless steel and A4 stainless steel, these are the two types offered by Fast Fix Direct Ltd.<br />
<br />
A1 = a free-cutting quality, having a superior machine ability due to a higher phosphorus and sulphure percentage. As a consequence, however, the general corrosion resistance is decreased. This “automatic lathe” stainless steel is seldom used for mass production fasteners.<br />
<br />
A2 = the most commonly used stainless steel grade - also called 18/8 (18% Cr, 8% Ni) - with outstanding corrosion resistance under normal atmospheric conditions, in wet surroundings, oxidizing and organic acids, many alkali and salt solutions. A2-0 bolts are nearly as strong as 8.8 heat treated fasteners.<br />
<br />
A4 = the most corrosion resistant steel grade - also called “acid proof” - with an increased nickel percentage and addition of molybdenum. Better resistance to aggressive, corrosive environments such as sea climate (chlorides), industrial atmosphere (sulphure dioxide), oxidizing acids and there where pitting may occur.<br />
<br />
Stainless Steel fasteners are the work horse for modern boatbuilding or exterior woodworking applications. They are perfect for marine use due to great corrosion resistance provide while remaining affordable. Hardened steel screws are more common in the woodworking environment but cannot be used in a corrosive environment. Stainless steel is available in a wide range of engineered grades, each with its own designation number and specific properties. Only a few grades of Stainless Steel are suitable for fasteners, those that can be cold headed easily and have adequate torsional and shear strengths. The 300 series stainless steels are the most popular.<br />
<br />
The most commonly used grade is A2 (304), however A4 (316) is a major step up and recommended for use in highly corrosive environments, such as in contact with salt water. A4 (316) series stainless, also known as marine quality or food grade stainless steel, contains molybdenum, which significantly increases corrosion resistance and strength.<br />
<br />
Use Stainless Steel screws cautiously below the waterline. Stainless Steel Screws cannot be in an anaerobic environment. If the screw is immersed in "still water" with no oxygen the corrosion-resistant film, chromium oxide, will not be allowed to form. Without the chromium oxide film the screw will suffer from galvanic corrosion and eventual failure.<br />
<br />
When using stainless steel nuts and bolts especially in larger in size always remember to lubricate with an ant seize compound. This will prevent the nut from binding on the thread (known as galling or cold-welding).<br />
<br />
===Steel (carbon steel)===<br />
Steel is the most common fastener material. Steel fasteners are available plain as well as with various surface treatments such as zinc plating, galvanization, and chrome plating.<br />
<br />
Steel fasteners are commonly available in 4 grades. Many other grades exist but are used far less often. The most common grades in the Din standard are mild steel 4.6 to 5.6 grade, this equates to testing 460 to 560 NM tensile strength per square mm.<br />
<br />
Grade 8.8 which is the metric standard high tensile bolt strength at 880 NM per square mm. The next grade being 10.9 which is often found in automotive applications where high loads are expected and 12.9 grade is the UK standard for socket headed cap screws.<br />
<br />
==Coatings==<br />
<br />
===Zinc Plating===<br />
Many steel fasteners are electro-plated with zinc for better corrosion resistance. Fasteners that have been zinc plated have a shiny silver or golden appearance referred to as clear or yellow zinc respectively. They are fairly corrosion resistant but will rust if the coating is destroyed or if exposed to a marine environment.<br />
<br />
===Hot Dip Galvanizing===<br />
Galvanizing is another coating involving the application of a layer of zinc. Hot dipped galvanizing puts the thickest possible coating on the metal resulting in superior corrosion resistance. Due to the thickness of the coating hot dipped galvanized bolts are not compatible with other nuts. Galvanized nuts are tapped slightly larger than other nuts to accommodate this coating.<br />
Hot dipped galvanized fasteners are frequently seen in coastal environments and in pressure treated lumber where the chemicals in the lumber may corrode other fasteners.<br />
<br />
===Chrome===<br />
Chrome is used in plating fasteners for its appearance. It provides similar corrosion resistance to zinc plating. The main drawback of chrome is the extremely high cost. If more corrosion resistance is required stainless steel may be chrome plated, preventing any corrosion should the chrome be penetrated.<br />
<br />
==Cadmium== <br />
Cadmium was a traditional corrosion prevention plating treatment, though concerns and costs over environmental ccleanup by plating companies have reduced its prevalence. However, it is usual to chromate treat or 'passivate' the finish which in simple terms, completes the surface to neutralise and fill microscopic holes. This results in the well known shiny yellowish or satin brown/green effect (the latter on military steel hardware)<br />
Cadmium plating is mainly used to provide a barrier between dissimilar metals in contact, to prevent, or reduce the rate and effect of electrolytic or galvanic corrosion. AS cadmium is soft and doesn't embrittle when plated it is ideal for threaded fasteners.</div>HarryMannhttps://club8090.co.uk/w/index.php?title=General_Fastener_Materials&diff=12475General Fastener Materials2014-07-20T15:51:13Z<p>HarryMann: /* Stainless Steel */</p>
<hr />
<div>=Fastener and Fixing Materials=<br />
Extracted from [http://www.fastfixdirect.co.uk/code/fastener_materials_and_coatings_information.asp Fastfix Direct Tools Fasteners and Fixings]<br />
<br />
==General==<br />
<br />
Fasteners and fixings such as hexagon nuts, hexagon bolts, coach bolts, blind rivets, solid rivets, woodscrews, machine screw, nails etc, are manufactured in a wide range of materials from common steel to titanium, plastic and other exotic materials. Many materials are further separated into different grades to describe specific alloy mixtures, hardening processes, etc. In addition, some materials are available with a variety of coatings or plating to enhance the corrosion resistance, or appearance of the fastener.<br />
<br />
Fastener material can be important when choosing a fastener due to differences between materials in strength, brittleness, corrosion resistance, galvanic corrosion properties, and of course cost.<br />
<br />
''When replacing fasteners, it is generally best to match what you are replacing.'' Replacing a bolt with a stronger one is not always safe. Harder bolts tend to be more brittle and may fail in specific applications. Also some equipment is designed so that the bolts will fail before more expensive or critical items are damaged. In some environments such as salt water galvanic corrosion must also be considered if changing fastener materials.<br />
<br />
==Materials==<br />
<br />
===Stainless Steel===<br />
Stainless steel is an alloy of low carbon steel and chromium for enhanced corrosion characteristics. Stainless steel is highly corrosion resistant for the price and because the anti-corrosive properties are inherent to the metal, it will not loose this resistance if scratched during installation or use.<br />
<br />
''It is a common misconception that stainless steel is stronger than regular steel.'' In fact, due to the low carbon content, stainless steel cannot be hardened or toughenede in the same way. Therefore when compared with regular steel they can be stronger than mild steel fastener but many are weaker than most hardened steel fasteners.<br />
<br />
Stainless steel is also much less magnetic than regular steel fasteners though some grades will be slightly magnetic.<br />
<br />
Good corrosion resistance is a feature of all stainless steels. Low alloy grades can resist corrosion in normal conditions. Higher alloys resist corrosion by most acids, alkaline solutions and chloride environments.<br />
<br />
The corrosion resistance of stainless steels is due to their chromium content. In general, stainless steels contain a minimum of around 10.5% chromium. The chromium in the alloy forms a self-healing protective clear oxide layer that forms spontaneously in air. The self healing nature of the oxide layer means the corrosion resistance remains intact regardless of fabrication methods. Even if the material surface is cut or damaged, it will self heal and corrosion resistance will be maintained. The most commonly used grades are A2 stainless steel and A4 stainless steel, these are the two types offered by Fast Fix Direct Ltd.<br />
<br />
A1 = a free-cutting quality, having a superior machine ability due to a higher phosphorus and sulphure percentage. As a consequence, however, the general corrosion resistance is decreased. This “automatic lathe” stainless steel is seldom used for mass production fasteners.<br />
<br />
A2 = the most commonly used stainless steel grade - also called 18/8 (18% Cr, 8% Ni) - with outstanding corrosion resistance under normal atmospheric conditions, in wet surroundings, oxidizing and organic acids, many alkali and salt solutions. A2-0 bolts are nearly as strong as 8.8 heat treated fasteners.<br />
<br />
A4 = the most corrosion resistant steel grade - also called “acid proof” - with an increased nickel percentage and addition of molybdenum. Better resistance to aggressive, corrosive environments such as sea climate (chlorides), industrial atmosphere (sulphure dioxide), oxidizing acids and there where pitting may occur.<br />
<br />
Stainless Steel fasteners are the work horse for modern boatbuilding or exterior woodworking applications. They are perfect for marine use due to great corrosion resistance provide while remaining affordable. Hardened steel screws are more common in the woodworking environment but cannot be used in a corrosive environment. Stainless steel is available in a wide range of engineered grades, each with its own designation number and specific properties. Only a few grades of Stainless Steel are suitable for fasteners, those that can be cold headed easily and have adequate torsional and shear strengths. The 300 series stainless steels are the most popular.<br />
<br />
The most commonly used grade is A2 (304), however A4 (316) is a major step up and recommended for use in highly corrosive environments, such as in contact with salt water. A4 (316) series stainless, also known as marine quality or food grade stainless steel, contains molybdenum, which significantly increases corrosion resistance and strength.<br />
<br />
Use Stainless Steel screws cautiously below the waterline. Stainless Steel Screws cannot be in an anaerobic environment. If the screw is immersed in "still water" with no oxygen the corrosion-resistant film, chromium oxide, will not be allowed to form. Without the chromium oxide film the screw will suffer from galvanic corrosion and eventual failure.<br />
<br />
When using stainless steel nuts and bolts especially in larger in size always remember to lubricate with an ant seize compound. This will prevent the nut from binding on the thread (known as galling or cold-welding).<br />
<br />
===Steel (carbon steel)===<br />
Steel is the most common fastener material. Steel fasteners are available plain as well as with various surface treatments such as zinc plating, galvanization, and chrome plating.<br />
<br />
Steel fasteners are commonly available in 4 grades. Many other grades exist but are used far less often. The most common grades in the Din standard are mild steel 4.6 to 5.6 grade, this equates to testing 460 to 560 NM tensile strength per square mm.<br />
<br />
Grade 8.8 which is the metric standard high tensile bolt strength at 880 NM per square mm. The next grade being 10.9 which is often found in automotive applications where high loads are expected and 12.9 grade is the UK standard for socket headed cap screws.<br />
<br />
==Coatings==<br />
<br />
===Zinc Plating===<br />
Many steel fasteners are electro-plated with zinc for better corrosion resistance. Fasteners that have been zinc plated have a shiny silver or golden appearance referred to as clear or yellow zinc respectively. They are fairly corrosion resistant but will rust if the coating is destroyed or if exposed to a marine environment.<br />
<br />
===Hot Dip Galvanizing===<br />
Galvanizing is another coating involving the application of a layer of zinc. Hot dipped galvanizing puts the thickest possible coating on the metal resulting in superior corrosion resistance. Due to the thickness of the coating hot dipped galvanized bolts are not compatible with other nuts. Galvanized nuts are tapped slightly larger than other nuts to accommodate this coating.<br />
Hot dipped galvanized fasteners are frequently seen in coastal environments and in pressure treated lumber where the chemicals in the lumber may corrode other fasteners.<br />
<br />
===Chrome===<br />
Chrome is used in plating fasteners for its appearance. It provides similar corrosion resistance to zinc plating. The main drawback of chrome is the extremely high cost. If more corrosion resistance is required stainless steel may be chrome plated, preventing any corrosion should the chrome be penetrated.<br />
<br />
==Cadmium== <br />
Cadmium was a traditional corrosion prevention plating treatment, though concerns and costs over environmental ccleanup by plating companies have reduced its prevalence. However, it is usual to chromate treat or 'passivate' the finish which in simple terms, completes the surface to neutralise and fill microscopic holes. This results in the well known shiny yellowish or satin brown/green effect (the latter on military steel hardware)<br />
Cadmium plating is mainly used to provide a barrier between dissimilar metals in contact, to prevent, or reduce the rate and effect of electrolytic or galvanic corrosion. AS cadmium is soft and doesn't embrittle when plated it is ideal for threaded fasteners.</div>HarryMannhttps://club8090.co.uk/w/index.php?title=Main_Page&diff=12024Main Page2014-01-13T21:54:38Z<p>HarryMann: /* Common gearbox i.e. automatic and manual */</p>
<hr />
<div>'''Welcome to a VW-Tech, the wiki technical archive of the Club 80-90 website.'''<br />
<br />
<br />
<br />
<br />
== NEW USERS START HERE, READ THE DISCLAIMER==<br />
<br />
'''PLEASE READ THE''' [[Disclaimer|'''Disclaimer:''']]<br />
<br />
'''Club 80-90 Wiki History''' <br />
<br />
Started in around 2005 after we moved from an older bulletin board that had been outgrown by the size of the club. A group of long standing club members decided to retain some of the helpful information on the technical pages that would otherwise get lost as the forum was pruned from time to time. Some of the information is basic vehicle mechanics for those that are just starting out. Some is advanced that you will need an extensive toolset to achieve. Some of it you could find in a Hayne's or Bentley manual and sometimes there are fixes that have not been documented and issues that VW had no repair as these vehicles have long since lasted beyond the working life that VW intended them to achieve. This is a collection of postings on 80-90 over the years and has grown to quite a size, some by professional mechanics and some by novices and all levels of knowledge in between. Ultimately it is to be used along side other forums and manuals to give you another viewpoint on how to solve or fix a problem, but usually with a real persons perspective and photographs to help out. It is not meant to be gospel and it is a living work in progress, articles and advice may change as knowledge grows over time. It may be contradictory in parts as different people have different ideas on the best way to perform a procedure. You may need to use some gut instinct and common sense to tell you which way to proceed, there may be a way to do something which hasn't been thought of, or they may be incorrect information which is out of date. The two main wiki editors are HarryMann and Hacksawbob (usernames on Club 80-90) Send a private message to them if you spot something that needs changing. If you have something to add write it up in the Club 80-90 Technical section in the appropriate section and PM an editor to make them aware of it.<br />
<br />
------<br />
<br />
Please stick to the following [[naming convention|naming convention]]. Feel free to add information to the pages you create but please don't alter the section headings as this will have a knock on effect on the naming scheme. It will help subsequent people to add information and will avoid accidental page overwriting or duplication. Please PM Hacksawbob or HarryMann if you have any questions or suggestions. <br />
I appreciate that there will be some overlap between sections, and equally a topic that could appear in several sections, enter your information in the section that you think is most appropriate, it can then be linked to from other pages. Don't enter into discussion on the WIKI, that is for the forum, try and keep the information here as definative an concise as possible. '''''The WIKI is for answers not questions.''''' If you need clarification then try and contact the poster directly or start a new thread on the [http://www.club80-90.co.uk/forum/viewforum.php?f=2| technical forum.]<br />
<br />
==Club 80-90 Wiki en Français==<br />
[[French language pages|French Language pages]]<br />
<br />
==Notices and Bugs==<br />
'''PLEASE READ THE''' [[Disclaimer|'''Disclaimer:''']]<br />
<br />
*Some club 80-90 members are the only ones with editing rights. Please PM HarryMann if you are a seasoned Wiki editor with valuable T3/T25 content to add. Particularly we are looking for those with experience of the early aircooleds, esepcially the carburrettion, ignition and tuning aspects. <br />
<br />
*Red links are pages that do not yet have information added to them (or whose pages have become orphaned, either due to typos in the internal links, or other reasons)<br />
<br />
*Please - Add your name at the beginning of the section you are adding! A good way is to format it as below, including a brief summary - adding a single space at the beginning turns it into a caption (repetitive saves seem to destroy that though) <br />
<br />
e.g. '''Name: ''' Brief summary of what has been added below (and possibly why its important)<br />
<br />
*Please reference your source if what you are posting is not your own. Ask permission first if there is copyright on it, and if it is from another website please put the link to the original URL.<br />
<br />
*[http://meta.wikimedia.org/w/wiki.phtml?title=Meta:Sandbox&action=edit click here for a 'sandbox'] if you want to experiment with wikis before making modifiacations to this one. <br />
<br />
*[http://meta.wikimedia.org/wiki/Help:Editing here is some help on basic Wiki editing]<br />
<br />
----<br />
<br />
= New or Prospective Owner? =<br />
<br />
==* Warnings - Must Read *==<br />
*[[petrol engines Fire warning|Fire warning - Fuel lines, tank, carb etc.]]<br />
*[[Petrol engines aircooled - Fuel Leaks|Fire warning - Aircooled - Carb fuel leaks]]<br />
*[[Gearbox Clutch CVs - Warnings| Gearbox /Transaxle /Diff oil levels]]<br />
*[[Petrol engines Diagnosing faults|Parts quality - Keep old (removed) parts]]<br />
<br />
==Guides==<br />
*[[New/Prospective Owners What are they like to drive? | What are they like? How to drive?]]<br />
*[[Misc tips and tricks buyers guide | The Buyers Guide by Simon Brickyard and others]]<br />
*[[Syncro - Testing|Syncro (4 wheel drive) Buyers guide]]<br />
*[[A newbies buying experience|A newbies buying experience]]<br />
<br />
==Tips and tricks and basic servicing==<br />
*[[Misc tips and tricks New owners questions| New owners' questions (FAQ)]]<br />
*[[Misc tips and tricks spares to carry| Spares and tools to carry]]<br />
*[[New/Prospective Owners| Don't panic!]]<br />
*[[New/Prospective Owners Flat 4 engines primer| Flat 4 engines primer]]<br />
*[[New/Prospective Owners Importing|Importing]]<br />
*[http://www.motinfo.gov.uk/internet/jsp/ECHID-Internet-History-Request.jsp VOSA MOT advisories online, check what might need fixing soon on your prospective purchase]<br />
*[[Gearbox Clutch CVs CV joints gear change reluctance|Gearchange reluctance]]<br />
*[[Gearbox Clutch CVs Sloppy gear change improving|Improving difficult/sloppy gearchange]]<br />
*[[Petrol engines oil change|Petrol engines - Oil & oil changes]]<br />
*[[New/Prospective Owners All engines servicing overview|All engines servicing overview]]<br />
For Maintenance Bulletins look in Misc Tips and Tips<br />
<br />
----<br />
<br />
=Engines=<br />
== Petrol engines (Watercooled)==<br />
[[Image:1.9-DG-watercooled-top1-(with-LPG-system).jpg|thumb|1.9L DG engine (with LPG system)]]<br />
*[[petrol engines Fire warning|Fire warning - Fuel lines, tank, carb etc.]]<br />
*[[petrol engines Not starting diagnostic flow chart|Not starting - Diagnostic flow chart]]<br />
*[[petrol engines engine removal and refitting|Engine removal and refitting]]<br />
*[[petrol engines spark plug types|Spark plug types]]<br />
<br />
*1.9 specific<br />
**[[petrol engines 1.9 Timing|1.9 timing]]<br />
**[[petrol engines - Pierburg Choke|Pierburg Choke Mechanism]]<br />
<br />
*2.1 specific<br />
**[[petrol engines 2.1 Timing|2.1 timing]]<br />
**[[petrol engines intermittent 2.1 | Petrol engines intermittent 2.1 (incl. Vanagon syndrome)]]<br />
**[[petrol engines 2.1 MV|2.1 MV specific]]<br />
**[[petrol engines Bad idling 2.1|Bad idling (2.1 DJ)]]<br />
**[[petrol engines 2.1 ISCU|2.1 ISCU]]<br />
**[[Petrol engines 2.1 Throwing a rod|2.1 Throwing a rod]]<br />
**[[Petrol engines Oil pressure survey|Oil pressure survey]]<br />
**[[Petrol engines Cam follower removal head in place|Cam follower removal head in place]]<br />
**[[Petrol engines 2.1 Other jobs while out|Removing 2.1 - Other jobs whilst out]]<br />
<br />
*General Ignition Info/Debugging<br />
**[[Petrol engines Ignition firing order|Firing order]]<br />
**[[Petrol engines Ignition advance curves|Ignition advance curves]]<br />
**[[Petrol engines Vac advance/retard problems|Vac advance/retard problems]]<br />
<br />
*Parts, Pictures, Diagrams and lists etc.<br />
**[[Petrol engines Parts - Inlet Manifold (1.9)|Inlet Manifold (1.9)]]<br />
**[[Petrol engines Parts - Oil breather hose(1.9)|Oil breather hose(1.9)]]<br />
**[[Petrol engines Parts - petrol Cooling system diagram|petrol Cooling system diagram]]<br />
**[[Petrol engines Parts - wbx exhaust stud depth|wbx exhaust stud depth]]<br />
<br />
==Petrol Engines (Aircooled)==<br />
[[Image:CU-engine-top-1.JPG|thumb|A CU aircooled engine]]<br />
*[[petrol engines aircooled Schematic|Schematic parts layout]]<br />
*[[petrol engines aircooled engine removal|Engine removal]]<br />
*[[petrol engines aircooled - Crankshaft oil seal|Crankshaft oil-seal (photo article, start-to-finish)]]<br />
*[[petrol engines aircooled Differences|Differences between engines]]<br />
<br />
*[[petrol engines aircooled running temperature|Aircooled running temperature]]<br />
*[[petrol engines aircooled performance enhancement|Performance enhancement]]<br />
*[[petrol engines aircooled thermostat|Thermostat]]<br />
*[[petrol engines aircooled solid lifters|Solid lifters]]<br />
*[[petrol engines aircooled push rod & seal replacement|Pushrod & tube seal replacement]]<br />
*[[petrol engines aircooled Oil pressures|Oil pressures]]<br />
<br />
*A/C Petrol engines - Aircooled Cyl. Head<br />
**[[petrol engines aircooled Refitting cylinder heads|Refitting cylinder heads]]<br />
**[[petrol engines aircooled Valves|Re-cutting seats and lapping valves]]<br />
**[[petrol engines aircooled Cylinder Head Damage|Cylinder head damage]]<br />
<br />
*A/C Petrol engines - Aircooled Ignition Systems<br />
**[[petrol engines aircooled Ignition 01|Ignition timing esp. Vac adv/ret hoses]]<br />
**[[petrol engines aircooled Ignition 02|Distributors, timing and setting up]]<br />
**[http://www.youtube.com/watch?v=xm4OmiVH2J0&feature=related Historic a/c Ignition timing videos Part 1]<br />
**[http://www.youtube.com/watch?v=cIrA4iWkhbE&feature=related Historic a/c Ignition timing videos Part 2]<br />
**[[petrol engines aircooled spark plugs|Spark plugs and HT leads]]<br />
<br />
*A/C Petrol engines - Carburrettors and fuel system<br />
**[[Carburrettors - faults and faultfinding]]<br />
**[[Fuel pump - aircooleds|Fuel pump problems]]<br />
**[[Inlet manifolds - aircooleds|Inlet manifolds]]<br />
**[http://www.youtube.com/watch?v=XOxxS1EMphU&feature=related Historic a/c carb tuning videos (PICT 28 ~34) Part 1]<br />
**[http://www.youtube.com/watch?v=KWdZSr7x81w&feature=related Historic a/c carb tuning videos (PICT 28 ~34) Part 2]<br />
<br />
<br />
*A/C Petrol engines - Cooling and heating systems<br />
**[[petrol engines aircooled tinware|Aircooled tinware]]<br />
**[[petrol engines aircooled Cooling and heating 01|Cooling and heating parts]]<br />
**[[petrol engines aircooled Cooling and heating 01|Cooling and heating description]]<br />
<br />
**Hazards<br />
**[[petrol engines aircooled - Fuel Leaks|Fuel leaks]]<br />
<br />
*A/C Petrol engines - Modifications <br />
**[[petrol engines aircooled Modifications|A/C Modifications, carbs, distributors, tuning, compatability issues]]<br />
<br />
==Petrol specific engine Faults/repairs/maintenance==<br />
* [[petrol engines Diagnosing faults|Diagnosing faults (petrols)]]<br />
* [[petrol engines cylinder head spark plug numbers|Cylinder nos. and firing order ]]<br />
* [[petrol engines oil change|Oil change]]<br />
* [[petrol engines engine codes| Engine codes]]<br />
* [[petrol engines cylinder head leak|Cylinder head leak]]<br />
* [[petrol engines losing water|Losing water]]<br />
* [[petrol engines low oil pressure|Low oil pressure]]<br />
* [[Techniques - Removing seized/broken studs/bolts/nuts|Snapped cylinder head bolt]]<br />
* [[petrol engines starter bush removal|Starter motor bush removal]]<br />
* [[petrol engines Overheating|Overheating]]<br />
* [[petrol engines oil emulsifying|Emulsified oil (mayonnaise)]]<br />
* [[petrol engines Oil leaks|Oil leaks]]<br />
* [[Techniques - Compression testing|Compression testing]]<br />
* [[Hydraulic lifters explained ]]<br />
* [[petrol engines non-start|Won't start (fuel)]]<br />
*[[petrol engines spigot-shaft bearing|Replacing spigot-shaft bearing]]<br />
[http://forum.club8090.co.uk/viewtopic.php?t=107122 ]<br />
<br />
== Diesel engines ==<br />
[[Image:Diesel engine1copy-1.jpg|thumb|JX turbo Diesel Engine]]<br />
*[[Diesel engines Fire warning|Fire warning]]<br />
*[[Diesel engines Diagnosis| Types, condition diagnosis, Service Bulletins etc]]<br />
*[[Diesel engines engine codes|Engine codes]]<br />
*[[Diesel engines engine removal and refitting|Engine removal and refitting]]<br />
* Diesel Engines - Turbo<br />
** [[Turbo - Re-indexing|Re-indexing]]<br />
** [[Turbo - Setting-up the Wastegate|Setting-up the wastegate]]<br />
** [[Turbo - Re-installing|Re-installing]]<br />
** [[Turbo - Oil feeds|Oil feeds]]<br />
** [[Turbo - Manifolds|Manifolds/Heat Shields]]<br />
** [[Turbo - Refurbing|Refurbing]]<br />
*[[Diesel engines - Sump/Oil Pump|Sump and oil pump]]<br />
<br />
* Diesel Engines - Servicing<br />
**[[Diesel Engines Auxiliary drive belts|Auxiliary drive belts]]<br />
**[[Diesel Engines Timing Belt_01|Lining-up camshaft and crankshaft]]<br />
**[[Diesel Engines Timing belt|Timing belt/removing camshaft sprocket]]<br />
**[[Diesel Engines Cyl Head re-fitting|Cylinder head re-fitting]]<br />
**[[Diesel Engines Cold-Starting|Cold starting]]<br />
**[[Diesel Engines Inj. pumps - AAZ pump adjustments|AAZ pump adjustments]]<br />
**[[Diesel Engines 1.6 NA CS ring gaps|1.6 NA (CS) ring gaps]]<br />
<br />
**[[Techniques - Compression testing|Compression testing]]<br />
**[[Parts - Part Nos|Rebuild Part Nos and some torques]]<br />
<br />
*Diesel Engines - Parts, pictures, diagrams and lists<br />
** [[Parts - CS Inlet Manifold|CS Inlet Manifold]]<br />
** [[Parts - Engine Damage|Diesel Engine damage]]<br />
** [[Parts - Shadek Oil pump|Shadek oil pump]]<br />
** [[Parts - Part Nos|Rebuild Part Nos and some torques]]<br />
** [[Parts - Cooling system|Cooling system]]<br />
** [[Parts - Crankshaft|Crankshaft and timing pulley]]<br />
** [[Parts - Block and pistons|Block and pistons]]<br />
** [[Parts - Intercooler|Intercooler]]<br />
<br />
<br />
** [[Parts - Rebuild|Rebuilding parts]]<br />
** [[Parts - Gloplug spanner|Glo-plug ratchet spanner]]<br />
** [[Parts - Head gasket protrusion|Head gasket protrusion]]<br />
** [[Parts - Cyl head instr senders - rear|Cyl head instr senders - rear]]<br />
** [[Parts - Cyl head instr senders - side|Cyl head instr senders - side]]<br />
** [[Parts - JX turbo mounting position|JX turbo mounting position]]<br />
<br />
**Diesel Engines - Modified parts<br />
***[[Parts - Modifications - T3 turbo|T3 turbo install]]<br />
***[[Parts - Modifications - Standard Engine Mounts|Standard engine mounts]]<br />
***[[Parts - Modifications - Engine Mounts|Modified engine mounts]]<br />
***[[Parts - Modifications - Silencer custom heat-shield|Silencer - custom heat-shield]]<br />
***[[Parts - Modifications - AAZ Non-JX Mods 01|AAZ turbo clearance mods]]<br />
***[[Parts - Modifications - Oil cooling|Oil cooling and oil coolers]]<br />
***[[Parts - Modifications - Injection pumps|Injection Pumps - Modifying]]<br />
<br />
<br />
*Instruments - <br />
**[[Diesel Engines Instruments|Diesel Engines Instruments]]<br />
<br />
*Links to threads on the 1Y 1.9d (N/A) which is a popular conversion from the 1.6d and 1.7d<br />
**[[List of Links from Ringo|List of links from Ringo]]<br />
<br />
==All engine faults/repairs/maintenance==<br />
<br />
*[[All engine faults/repairs/maintenance Stripped sparkplug thread|Stripped spark plug thread]]<br />
*[[All engine faults/repairs/maintenance Oils recommended|Engine oils - recommended]]<br />
*[[All engine faults/repairs/maintenance Oil filters recomended|Oil filters - recommended]]<br />
*[[All engine faults/repairs/maintenance Replace throttle cable|Replace throttle cable]]<br />
*[[All engine faults/repairs/maintenance Replace starter motor|Replace starter motor]]<br />
*[[All engine faults/repairs/maintenance reluctant starting|Reluctant starting (starter motor)]]<br />
*[[All engine faults/repairs/maintenance reluctant starting (battery alternator)|Reluctant starting (battery alternator)]]<br />
*[[All engine faults/repairs/maintenance reluctant starting Earths|Reluctant starting earths]]<br />
*[[All engine faults/repairs/maintenance reconditioned engines|Reconditioned engines]]<br />
*[[All engine faults/repairs/maintenance Dashboard water level and temperature warnings and causes|Dashboard water level and temperature warnings and causes]]<br />
*[[All engine faults/repairs/maintenance Dashboard oil pressure warnings and causes|Dashboard oil pressure warnings and causes (DOPWS)]]<br />
*[[All engine faults/repairs/maintenance Performance/Longevity|Performance/Longevity]]<br />
*[[All engine faults/repairs/maintenance Air-cooled white smoke|Air-cooled white smoke]]<br />
*[[All engine faults/repairs/maintenance Sump plug problems|Sump plug problems]]<br />
*[[All engine faults/repairs/maintenance Dipstick lengths|Dipstick lengths]]<br />
*[[All engine faults/repairs/maintenance Engine bay seal|Engine bay seal]]<br />
----<br />
<br />
==Exhausts==<br />
<br />
*[[Exhausts Systems Petrol|Petrol Exhausts - Early/Late]]<br />
*[[Exhausts Suppliers|Exhaust system suppliers - Part Nos & Stainless Alternatives]]<br />
*[[Exhausts Custom|Custom exhausts]]<br />
*[[Exhausts Rust|Exhaust rust repairs]]<br />
*[[Exhausts Heat Pipe|DG Exhaust Heat transfer pipe]]<br />
<br />
=Fuel System=<br />
==Diesel==<br />
*[[Diesel - Injectors|Diesel Injectors]]<br />
*[[Diesel - Glow plugs replacing|Glow plugs - replacing]]<br />
*[[Diesel - Injection pumps|Injection pumps]]<br />
*[[Diesel - Fuel system Tips and Tricks|Fuel system Tips and Tricks]]<br />
*[[Diesel - Adding bulb pump primer and transparent fuel lines| Adding bulb pump primer and transparent fuel lines]]<br />
<br />
==Petrol==<br />
<br />
*Common<br />
**[[Petrol engines Fire warning|#Fire warnings# - fuel lines, tank and filler]]<br />
**[[Petrol engines aircooled - Fuel Leaks|#Fuel leaks# - Aircooled]]<br />
<br />
*Injection<br />
**[[Fuel system - Digijet - Brief overview|Brief overview of Digijet injection system]]<br />
<br />
*Carburrettor <br />
**[[Fuel system - 1.9 Fuel hoses|Replacing 1.9 DG Fuel hoses]]<br />
**[[Fuel system - Pierburg |Pierburg carbs]]<br />
**[[Fuel system - 1.9 WBX stops intermittently|1.9 WBX stops intermittently]]<br />
**[[Fuel system - Carburettor removal|Carburettor removal]]<br />
**[[Fuel system - Carburettor Pierburg alternatives|Carburettor Pierburg alternatives]]<br />
**[[Fuel system - Carburettor Air leaks|Carb or manifold air-leaks]]<br />
**[[Fuel system - Carburettor Autochoke|Carb Autochoke setting]]<br />
**[http://archive.club8090.co.uk/viewtopic.php?f=2&t=36598& Intermitten but very annoying problem (blocked jet?)]<br />
**[[Fuel system - Carburettor Clearing blocked jets|Clearing blocked jets]]<br />
<br />
==Common==<br />
*[[Fuel system - Accelerator cable replacement|Acelerator cable replacement]]<br />
*[[Fuel System tank removal |Tank removal]]<br />
*[[Fuel system breather tanks|Breather tanks]]<br />
*[[Fuel economy unofficial|Fuel economy]]<br />
<br />
*[[Fuel System Filler Problems|Filler/filling problems]]<br />
<br />
== Alternative fuels ==<br />
*LPG<br />
**[[Alternative Fuels type of system|Type of system]]<br />
**[[Alternative Fuels spark plugs|Spark plugs]]<br />
**[[Alternative Fuels cheap filling stations|Cheap filling stations]]<br />
**[[Alternative Fuels engine tuning|Engine tuning]]<br />
**[[Alternative Fuels Fuel economy|Fuel economy]]<br />
<br />
*Biodiesel Cooking Oil etc<br />
**[[Alternative Fuels Biodiesel explained|Biodiesel explained]]<br />
**[[Alternative Fuels Cooking Oil feedback|Cooking oil feedback]]<br />
<br />
<br />
----<br />
<br />
=Coolant and Heating=<br />
==Cooling System==<br />
<br />
* [[Coolant and Heating flashing red light on dash|Flashing red light on dash]]<br />
* [[Coolant and Heating recommended brands|Anti-freeze - Brands, specs, dilutions and capacities]]<br />
* [[Coolant and Heating front pipe leaks|Front pipe leaks]]<br />
* [[Coolant and Heating main pipe leaks |Main pipe leaks]]<br />
* [[Coolant and Heating overheating causes and fixes|Overheating causes and fixes]]<br />
* [[Coolant and Heating draining|Drain]]<br />
* [[Coolant and Heating bleeding system|Refilling and bleeding system]]<br />
* [[Coolant and Heating New radiator|New radiator]]<br />
* [[Coolant and Heating running temperatures|Running temperatures]]<br />
* [[Coolant and Heating System overhaul 1|Replacing original front-to-rear metal pipes]]<br />
* [[Coolant and Heating System overhaul 2|Replacing water pump, thermostat and adjoining metal pipes]]<br />
* [[Coolant and Heating Instrumentation malfunction|Temp gauge and sender malfunctions]]<br />
* [[Coolant and Heating Testing radiator fan |Testing radiator fan]]<br />
* [[Coolant and Heating Oil cooling|Oil cooling]]<br />
* [[Coolant and Heating Header tank top and up tank|Header tank and top up tank]]<br />
<br />
==Heating System==<br />
* [[Coolant and Heating heater blower replacement|<br />
Hot & Cold Air Blower - Diagnosis, Removal, Replacement And Modifications]]<br />
* [[Coolant and Heating - Air-cooled heating system|Air-cooled heating system]]<br />
* [[Coolant and Heating - Heater hoses|Heater hoses]]<br />
<br />
*[http://www.type2.com/library/heat/heat-soundproof.html Excellent article on improving VW a/c insulation & heating system]<br />
<br />
----<br />
<br />
= Gearbox Clutch CVJs Driveshafts (not Syncro front)=<br />
==Automatic specific==<br />
<br />
*[[Gearbox Clutch CVs Automatic General Info|Automatics - General Information]]<br />
*[[Gearbox Clutch CVs Automatic Gearbox Oil|Gearbox oil checking/changing]]<br />
*[[Gearbox Clutch CVs Automatic Gearbox Parts|Automatic gearbox - Parts and finding them]]<br />
<br />
==Manual gearbox specific==<br />
*[[Gearbox Clutch CVs - Warnings|Gearbox ##Warnings##]]<br />
<br />
*[[Gearbox Clutch CVs Clutch Pictures|Clutch - pictures]]<br />
*[[Gearbox Clutch CVs clutch slave replacement|Clutch slave cylinder replacement]]<br />
*[[Gearbox Cutch CVs - Clutch slave-cylinder|Clutch slave-cylinder and pipework]]<br />
*[[Gearbox Clutch CVs Clutch pedal not disengaging|Clutch not disengaging]]<br />
*[[Gearbox Clutch CVs - Removing the clutch|Removing the clutch]]<br />
*[[Gearbox Clutch CVs - Re-installing clutch|Re-installing clutch]]<br />
<br />
*[[Gearbox Clutch CVs - Renovating 5 speed change mechanism Pt1|Renovating 5 speed change mechanism Pt1]]<br />
*[[Gearbox Clutch CVs - Renovating 5 speed change mechanism Pt2|Renovating 5 speed change mechanism Pt2]]<br />
*[[Gearbox Clutch CVs - Renovating 5 speed change mechanism - adjustments|Renovating 5 speed change mechanism - adjustments]]<br />
*[[Gearbox Clutch CVs - Gear change reluctance|Gear change reluctance]]<br />
*[[Gearbox Clutch CVs Sloppy gear change improving|Improving sloppy g/c & g/c part nos.]]<br />
*[[Gearbox Clutch CVs Gear selection process|Gear selection process]]<br />
*[[Gearbox Clutch CVs Fitting Repair Kit_01|Gearlever pivot repair kit - fitting]]<br />
*[[Gearbox Clutch CVs - Gearchange images|Gearchange selection rod pictures and drawings]]<br />
<br />
*[[Gearbox Clutch CVs - Short shifter|Short shifter gearchange kit]]<br />
*[[Gearbox Clutch CVs - Transaxle Code|Transaxle Code]]<br />
*[[Gearbox Clutch CVs - Diesel Uprated Clutch|Diesel Uprated Clutch]]<br />
*[[Gearbox Clutch CVs - Diesel clutch change|Diesel clutch installation considerations]]<br />
*[[Gearbox Clutch CVs - Gearbox type swap|Gearbox type swap (425 & 524)]]<br />
*[[Gearbox Clutch CVs - Diesel Clutch Slave Bracket|Diesel Clutch Slave Bracket - Breakage]]<br />
*[[Gearbox Clutch CVs CV joints drain plug| Drain plug removal, emptying and filling ]]<br />
*[[Gearbox Clutch CVs CV joints Gearbox oil|Gearbox oil]]<br />
*[[Gearbox Clutch CVs - Gearbox corrosion prevention]]<br />
*[http://forum.80-90.co.uk/viewtopic.php?t=30903 80-90 thread on clutch slave cylinder pipes]<br />
<br />
==Common gearbox i.e. automatic and manual==<br />
*[[Gearbox Clutch CVs CV joints diagnosing|Diagnosing]]<br />
*[[Gearbox Clutch CVs Output shaft oil leak repair|Output shaft oil leaks repair]]<br />
*[http://www.rjes.com/html/gearbox_types.html Link to RJES gearbox code chart]<br />
<br />
==CV's and Driveshafts==<br />
<br />
*[[Gearbox Clutch CVs CV joints repair|CV joints repair]]<br />
*[[Gearbox Clutch CVs Driveshaft/CVJ condition check|Driveshaft/CVJ condition check]]<br />
<br />
<br />
----<br />
<br />
= VW Electrics (not camper interior specific)=<br />
<br />
*Electrical System<br />
** [[VW Electrics fuse box|Main fuse box]]<br />
** [[Vw Electrics rear lighting wire colours|Rear lighting wire colours]]<br />
** [[VW Electrics Haynes wiring diagrams|Haynes wiring diagrams]]<br />
** [[VW Electrics Starter motor|Starter motor]]<br />
** [[VW Electrics Diesel battery to starter cable|Diesel battery to starter cable]]<br />
** [[VW Electrics Electric wing mirrors|Electric wing mirrors]]<br />
** [[VW Electrics Wiring heated LT Mirrors|Wiring heated LT Mirrors]]<br />
** [[VW Electrics Brake warning light|Brake warning light]]<br />
** [[VW Electrics Windscreen Wipers|Windscreen wiper functions]]<br />
** [[VW Electrics Standard Headlights|Standard Headlights]]<br />
** [[VW Electrics Alternators|Alternators/Generators]]<br />
** [[VW Electrics Non working temperature and/or fuel gauges |Non working temperature and/or fuel gauges]]<br />
** [[VW Electrics rewiring Dashboard multipin connector|Rewiring Dashboard multipin connector]]<br />
** [[VW Electrics Dashboard multipin connector pinout |Dashboard multipin connector pinout]]<br />
** [[VW Electrics Changing Ignition Barrel|Changing Ignition Barrel]]<br />
** [[VW Electrics Changing Ignition Switch|Changing Ignition Switch]]<br />
<br />
*Troubleshooting<br />
** [[VW Electrics bad earths|Bad earths]]<br />
** [[VW Electrics alternator checking|Alternator checking]]<br />
** [[VW Electrics tracing battery discharging cause|Tracing battery discharging cause]]<br />
** [http://assets.fluke.com/appnotes/automotive/beatbook.pdf Some electrical testing procedures from Fluke]<br />
<br />
*Upgrades and Modifications<br />
** [[VW Electrics Fitting intermittent wipers|Intermittent wipers]]<br />
** [[VW Electrics Upgrading headlights|Upgrading headlights]]<br />
** [[VW Electrics Round Headlights To Square|Round Headlights To Square]]<br />
** [[VW Electrics Headlight warning buzzer|Headlight warning buzzer]]<br />
** [[VW Electrics Rear fog lights|Rear fog lights]]<br />
** [[VW Electrics front fog lights|Front fog lights]]<br />
** [[VW Electrics Heater control Illumination|Heater control illumination]]<br />
** [[VW Electrics dash lights upgrade|Dash lights upgrade]]<br />
** [[VW Electrics Alternator sizes|Alternator size formula & tutorial]]<br />
** [[VW Electrics LED Number plate light|LED Number plate light]]<br />
** [[VW Electrics 12 volt live feed only when engine running|12 volt live feed only when engine running]]<br />
** [[VW Electrics Stereo feed from both batteries|Stereo feed from both batteries]]<br />
** [[VW Electrics Adding an independent or new horn|Adding an independent or new horn]]<br />
<br />
<br />
*Pictures, Diagrams, Lists<br />
**[[Petrol engine wiring|Petrol Engine Wiring]]<br />
**[[Diesel engine wiring|Diesel Engine Wiring]]<br />
** [[VW Electrics Alternator 90 Amp Wiring|90 Amp Alternator Wiring]]<br />
<br />
----<br />
<br />
= Steering and Suspension =<br />
* [[Steering and Suspension alternative steering wheels| Alternative steering wheels]]<br />
* [[Steering and Suspension Alignment| Steering geometry/alignment]]<br />
* [[Steering and Suspension Wheel Bearings| Wheel bearings]]<br />
* [[Steering and Suspension springs | Springs]]<br />
* [[Steering and Suspension Anti-roll bar| Anti-roll bar]]<br />
* [[Steering and Suspension Replacing wishbone bushes | Replacing wishbone bushes]]<br />
* [[Steering and Suspension Seized top shock nut| Seized top shock nut]]<br />
* [[Steering and Suspension Replacing wheel studs | Replacing wheel studs]]<br />
* [[Steering and suspension Lowering|Lowering]]<br />
* [[Steering and suspension Radius-rod and bushes|Radius-rod and bushes]]<br />
* [[Steering and suspension power steering|Power steering]]<br />
* [[Steering and suspension power steering Universal Joint Replacement|power steering Universal Joint Replacement]]<br />
* [[Steering and suspension Steering shaft joints|Steering shaft joints]]<br />
* [[Steering and suspension Replacing shock absorbers|Replacing shock absorbers (with Sachs HD)]]<br />
* [[Steering and suspension replace steering rack boot|replace steering rack boot]]<br />
----<br />
<br />
= Wheels and Tyres (not Syncro)=<br />
<br />
<br />
*[[Wheels and tyres - Tyres|Tyres]]<br />
*[[Wheels and tyres - Alternative wheels|Alternative wheels]]<br />
*[[Wheels and Tyres Steering/Wheel Alignment|Steering/Wheel alignment]]<br />
*[[Wheels and Tyres - VW Centre-caps for Merc alloys|VW Centre-caps for Merc alloys]]<br />
*[[Wheels and Tyres - Nut/Bolt Torques|Torques for wheel nuts or bolts]]<br />
*[[Wheels and tyres Wheel offset (ET)|Wheel offset (ET) explained ]]<br />
*[[Wheels and tyres - Speedometer Cable|Speedometer Cable]]<br />
----<br />
<br />
=Brakes=<br />
*[[Brakes front caliper replacement|front caliper replacement]]<br />
*[[Brakes brake pipe parts| Brake pipe parts]]<br />
*[[Brakes Rear Backplate| Rear Backplate]]<br />
*[[Brakes Pulsing brake pedal| Pulsing brake pedal]]<br />
*[[Brakes Rear brake servicing| Rear brake servicing]]<br />
*[[Brakes Bleeding brake system| Bleeding brake system]]<br />
*[[Brakes Bleeding nipples| Bleeding nipples]]<br />
*[[Brakes Front handbrake cable| Front handbrake cable]]<br />
*[[Brakes Rear handbrake cables| Rear handbrake cables]]<br />
*[[Brakes poor brake performance diagnostics| poor brake performance diagnostics]]<br />
----<br />
<br />
= Body Work, Chassis and Glass =<br />
<br />
==Painting your van==<br />
**[[Bodywork and Glass Painting |Painting - General]]<br />
**[[Bodywork and Glass Roller painting |Rollering Rustoleum - Paint your van for £50]]<br />
**[[Bodywork and Glass Window removal and refitting|Window removal and refitting]]<br />
<br />
==Windscreen==<br />
**[[Bodywork and Glass Windscreen Removing|Removing windscreen]]<br />
**[[Bodywork and Glass Windscreen re-fitting|Windscreen re-fitting]]<br />
**[[Bodywork and Glass Leaking windscreen|Leaking windscreen]]<br />
http://campervanculture.com/2011/05/fitting-vw-t25-vanagon-t3-windscreen/<br />
<br />
==Doors==<br />
**[[Bodywork and Glass Doors locks|Door locks and keys]]<br />
**[[Bodywork and Glass Sliding Door and Parts|Sliding Door and parts]]<br />
**[[Bodywork and Glass Door seals|Door seals]]<br />
**[[Bodywork and Glass Guide to fitting Cab Door seals|Guide to fitting Cab Door seals]]<br />
**[[Bodywork and Glass Window scrapers |Window scrapers]]<br />
<br />
==Leaks==<br />
**[[Bodywork and Glass Leaking windscreen|Leaking windscreen]]<br />
**[[Bodywork and Glass Footwell leaks| Foot-well leaks]]<br />
**[[T25 Media Library dripping air vent| Dripping air vent syndrome]]<br />
<br />
==Insulation==<br />
**[[Bodywork and Glass Insulation|Insulation]]<br />
<br />
==Parts==<br />
**[[Bodywork and Glass Parts|Pictures of parts]]<br />
**[[Bodywork and Glass Parts DIY|Pictures of DIY parts]]<br />
<br />
==Rust==<br />
<br />
===General Information===<br />
<br />
**[[Bodywork and Glass - Rust|Rust and some treatments]]<br />
**[[Areas that rust - General|General list of areas that rust]]<br />
**[[Bodywork and Glass - Rust - Elecrolytic de-rusting|Electrolytic de-rusting of parts]]<br />
**[[Techniques - Digicam inspection|Internal section inspection method e.g. for rust]]<br />
<br />
===Specific areas (details, photos, articles, etc)===<br />
<br />
**[[Areas that rust - Kitchen panel|Kitchen/fridge body side panel]] <br />
**[[Areas that rust - Snorkel box|Snorkel box]]<br />
**[[Areas that rust - Rear chassis|Rear chassis]]<br />
**[[Areas that rust - Rear cross-member|Rear cross-member and repair]]<br />
**[[Areas that rust - Front bumper valance|Front bumper valance]]<br />
**[[Areas that rust - Front panel lower|Front panel lower]]<br />
**[[Areas that rust - Cab step|Cab steps]]<br />
**[[Areas that rust - Inner Sills|Inner Sills]]<br />
**[[Areas that rust - Floor sliding door side|Floor - sliding door side]]<br />
**[[Areas that rust - Front jacking points|Front jacking points]]<br />
**[[Areas that rust - Behind VW underseal|Behind VW underseal]]<br />
**[[Areas that rust - Front seat-belt anchors|Seat-belt anchor plates (front)]]<br />
**[[Areas that rust - Bodypanels rear|Rear wing bodypanels]]<br />
**[[Areas that rust - Offside outer sill|Offside (kitchen) outer sill & panel]]<br />
**[[Areas that rust - Window frames|Window frame rust repair]]<br />
**[http://forum.club8090.co.uk/viewtopic.php?f=11&t=32407 Seriously rusty van repairs - shows many areas exposed - excellent photo journal]<br />
<br />
===Other relevant information===<br />
<br />
**[[Bodywork and Glass - Storage|Storage and over-wintering]]<br />
**[[Techniques - Welding|Techniques - Welding]]<br />
**[[General Homemade Chassis cleaning tools|Chassis Cleaning Tools]]<br />
<br />
----<br />
<br />
= Body Accessories Exterior =<br />
*[[Body accessories square headlights| Square headlights alternative]]<br />
* [[Body accessories exterior Wing mirrors|Wing mirrors]]<br />
* [[Body accessories exterior Doka tarps|Doka tarps, tonneaus, covers]]<br />
* [[Body accessories exterior Removing decals and stickers|Removing decals and stickers]]<br />
* [[Body accessories exterior gutter trim |Gutter trim]]<br />
* [[Body Accessories Exterior - Wheel Centre caps|Wheel centre Caps]]<br />
* [[Body accessories intermittant wipers|Intermittant wipers]]<br />
* [[Body Accessories Exterior Left hand drive headlights and the MOT|Left hand drive headlights and the MOT]] <br />
* [[Body Accessories Exterior indicator screws|Indicator screws]]<br />
* [[Body Accessories Exterior Regulations|Regulations]]<br />
* [http://homepage.ntlworld.com/georgina_shaun/T3_website/spoiler_fitting.html Fitting a spoiler]<br />
<br />
----<br />
<br />
=Interior (non camping)=<br />
==Seatbelts==<br />
*[[Interior non camping fitting rear 3 point belts|Fitting rear 3 point belts]]<br />
*[[Interior non camping seatbelt legality|Seatbelt legality]]<br />
<br />
==Seats==<br />
<br />
*[[Interior non camping Caravelle seat arms|Caravelle seat arms]]<br />
*[[Interior non camping alternative front seats|Alternative front seats]]<br />
*[[Interior non camping Headrest fitting to rear seats|Headrests - Fitting to rear seats]]<br />
*[[Interior non camping Headrest removing|Headrests - Removing]]<br />
<br />
==Headlining/ interior panels==<br />
*[[Interior non camping interior panels|Interior panels]]<br />
*[[Interior non camping Headlining replacing|Headlining replacing]]<br />
<br />
==Cab Door Armrests==<br />
*[[Interior non camping Cab Door Armrests|Cab Door Armrests]]<br />
<br />
==Dashboard==<br />
*[[Interior non camping Dashboard removal| Dashboard removal]]<br />
*[[Interior non camping Dash tidy bracket| Dash tidy bracket]]<br />
<br />
==Tailgate==<br />
*[[Interior non camping Tailgate strut lock| Tailgate strut lock (when bike rack fitted)]]<br />
*[[Interior non camping Tailgate Interior latch opening| Tailgate - Interior latch opening]]<br />
<br />
==Multimedia==<br />
*[[Interior non camping stereo fitting| Stereo fitting]]<br />
<br />
==Other==<br />
<br />
<br />
= Campers =<br />
<br />
==Camping Interior Cupboards, beds, etc==<br />
<br />
<br />
* [[Camping Interior safety| Safety]]<br />
<br />
* [[Camping Interior self build|Self build/repair/install, several pages here!]]<br />
* [[Camping Interior Cab bunk|Cab bunk]]<br />
* [[Camping Interior rear hatch ventilation|Rear hatch ventilation]]<br />
* [[Camping Interior Removing units|Removing units]]<br />
* [[Camping Interior Useful Westfalia specific sites|Useful Westfalia specific sites]]<br />
<br />
==Electrical==<br />
* [[Camping Interior - Electrical Safety|Electrical Standards & Safety]]<br />
* [[Camping Interior Westfalia leisure battery charging|Westfalia leisure battery charging]]<br />
* Conversion specific electrical wiring diagrams<br />
**[[Camping Interior Conversion specific electrical wiring diagrams Holdsworth Villa| Holdsworth Villa]]<br />
* [[Camping Interior Fitting a split charger|Fitting a split charger]]<br />
**[[Camping Interior Heavy duty charging|Heavy duty charging]]<br />
* [[Camping Interior Hookup Schemes|Mains Hookup - Schemes and Safety]]<br />
* [[Camping interior Solar power charging systems|Solar power charging systems]]<br />
* [[Camping interior Facts about Auxiliary batteries|Facts about auxiliary batteries]] <br />
* [[Camping Interior Leisure batteries that fit|Leisure batteries FAQ (inluding those that fit) ]]<br />
* [[Camping Interior Leisure battery removal from under swivel seat|Leisure battery removal from under swivel seat]]<br />
* [[Camping Interior Zig Units|Zig units]]<br />
* [[Camping Interior Wiring radio to leisure battery|Wiring radio to leisure battery]]<br />
* [[Camping Interior lighting|Lighting]]<br />
<br />
* [[Camping Interior Inverter efficiency |Inverter efficiency]]<br />
* [[Camping Interior Towing connections|Towing connections]]<br />
<br />
==Heating==<br />
*[[Camping Interior Eberspacher|Eberspacher]]<br />
*[[Camping Interior Propex|Propex]]<br />
*[[Camping Interior Webasto|Webasto]]<br />
*[[Camping Interior Other camping heating|Other camping heating]]<br />
*[[Camping Interior Insulation|Insulation]]<br />
<br />
==Refrigeration==<br />
* [[Camping Interior fridge settings/lighting|Fridge settings/lighting]]<br />
* [[Camping Interior fridge safety/fridge safety|Fridge safety]]<br />
* [[Camping Interior fridge Manuals/fridge Manuals|Fridge Manuals]]<br />
* [[Camping Interior fridge removal|Fridge removal]]<br />
* [[Camping interior fridge servicing/Maintenance|Fridge servicing & maintenance]]<br />
<br />
==Cooking==<br />
* [[Camping Interior Cooking|Cooking suggestions and recipes]]<br />
* [[Camping Interior Gas|Calor Gas facts]]<br />
<br />
==Flooring==<br />
* [[Camping Interior Flooring (Vinyl)|Vinyl Flooring]]<br />
<br />
==Gas==<br />
* [[Camping Interior Gas|Gas information]]<br />
----<br />
<br />
==Camping Exterior Campers exterior ,roofs, windows, skylights, awnings etc==<br />
* [[Camping Exterior Westfalia|Westfalia]]<br />
* [[Camping Exterior Fitting devon roof|Fitting Devon roof]]<br />
* [[Camping Exterior Fitting pop-top|Fitting a pop-top]]<br />
* [[Camping Exterior Electric Hookup|Electric hookup]]<br />
* [[Camping Exterior |Awnings review]]<br />
* [[Camping Exterior stop the drip |Stop the drip]]<br />
* [[Camping Exterior Hightop side windows |Hightop side windows]]<br />
<br />
<br />
* [[Body work and glass - Storage|Storage and over-wintering]]<br />
<br />
==Conversions==<br />
<br />
*[[T25 Media Library camper Conversions| Camper conversions(link to media library)]]<br />
*[http://www.camperinterior.co.uk/index.html Camper Interior website, a photo feast... Take a look!]<br />
*[[Danbury - Instruction Manual for Volkswagen Transporter (1981)|Danbury Instruction Manual for Volkswagen Transporter (1981)]]<br />
*[http://www.80-90.co.uk/techhelp/pdfs/Westy.PDF Westy camper plans in pdf format (German) - Thanks to Aberdeenbus]<br />
<br />
==Karmann Coachbuilts==<br />
<br />
[http://www.vwcampervanblog.com/the-rare-volkswagen-karmann-coachbuilt-camper-van/ The rare Karmann coachbuilt camper van]<br />
<br />
[http://www.karmann-coachbuilts.com/ Volkswagen Karmann Coachbuilts Club]<br />
<br />
==Campsites==<br />
* [[Camping Exterior recommended sites|Recommended sites]]<br />
* [[Camping Exterior sites to avoid|Sites to avoid]]<br />
* [[Camping Exterior overnight parkups|Overnight parkups]]<br />
<br />
==Touring/Camping outside UK==<br />
*[[Touring abroad country specific legal requirements|Touring abroad country specific legal requirements]]<br />
*[[Touring - Sweden|Sweden]]<br />
*[[Ferry services - Spain|Ferry services]]<br />
----<br />
<br />
= Syncro =<br />
*[[Syncro links page| Syncro links page]]<br />
<br />
<br />
<br />
<br />
----<br />
<br />
=T25 Alternative Engine =<br />
*[[Alternative engine 1.9TD|1.9 TD]]<br />
*[[Alternative engine 1.9 Tdi|1.9 Tdi]]<br />
*[[Alternative engine Subaru|Subaru]]<br />
*[[Alternative engine Golf GTI|Golf GTI]]<br />
*[[Alternative engine other|Other]]<br />
<br />
<br />
----<br />
<br />
=General - Techniques, Tools and Tips=<br />
==Useful Data==<br />
<br />
*[[General Fasteners|Fasteners and fastener types]]<br />
<br />
*[[General Fastener Materials|Fastener materials & selection]]<br />
*[[General Torques|Torques]]<br />
*[[General ISO Metric threads| ISO Metric threads, spanner and tapping drill sizes]]<br />
<br />
*[[general list of nut sizes and torques|List of nut sizes and torques]]<br />
*[[General VIN codes - decyphering|VIN codes - decyphering]]<br />
*[[General Oils - Data|Oils - Data]]<br />
*[[General Tyre pressure calc|Tyre pressures - Generic formula]]<br />
<br />
* [http://www.boltscience.com/pages/convert.htm Torque converter]<br />
* [http://www.green-oval.com/data/zeus.pdf Zeus tables in pdf format (16.3 Mb)]<br />
<br />
* [http://www.shender4.com/thread_chart.htm Std. Imperial thread data (US source)]<br />
<br />
==Tools/Sundries/Safety equipment==<br />
<br />
===Tools===<br />
*[[General Rear Brake Adjuster Tool|Brake adjuster tool for rear brakes]]<br />
*[[General Tools for the T25 Home Mechanic |Tools for the T25 Home Mechanic]]<br />
*[[General Thread Taps and Dies|Thread Tap and Die Set]]<br />
*[[General Screw/bolt punch|Screw/Bolt/Nut punch (drift)]]<br />
*[[General Impact Screwdriver|Impact Screwdriver]]<br />
*[[General Screw extractors|Screw extractors (easiouts)]]<br />
*[[General EMPI Rear hub nut spanner|EMPI Rear hub nut spanner]]<br />
*[[General Engineering Scrapers|Engineering scrapers]]<br />
*[[General Oil-seal extractor|Oil-seal extractor]]<br />
*[[General Bench Vise|Bench vise]]<br />
*[[General Thread File|Thread File]]<br />
*[[General Thread Chaser|Thread Chaser]]<br />
*[[General Battery Impact driver|Battery Impact driver]]<br />
*[[General air compressors |Air compressors]]<br />
*[[General Rivnuts|Rivnuts]]<br />
*[[General Welding equipment|Welding equipment]]<br />
*[[General Spot Blaster|Hobby spot-blaster]]<br />
*[[General Glow-plug spanner|Diesel glow-plug removal spanner]]<br />
*[[General Shelter-tent workshop|Shelter-tent workshop]]<br />
*[[General QMAX hole punch|QMAX hole punch]]<br />
*[[General Pipe spanners|Pipe spanners/hydraulics ring spanners/split jaw spanners]]<br />
*[[General Underseal chisel|Underseal chisel]]<br />
*[[General Cleco pins|Cleco (Avdel)locating pins]]<br />
*[[General Stainless Wire Brush|Stainless Wire Brushes]]<br />
*[[General Chain wrench|Chain-wrench/Strap wrench/Pipe wrench]]<br />
*[[General Belt finger sander|Belt (finger) sander {powerfile)]]<br />
*[[General HD vacuum cleaner|HD (or industrial) workshop vacuum cleaner]]<br />
*[[General Joggler|Sheet-metal joggler tool]]<br />
*[[General Battery Chargers|Battery chargers]]<br />
<br />
===Home made tools===<br />
*[[General Homemade gearbox removal clamp|Homemade gearbox removal clamp]]<br />
*[[General Homemade brake bleed pressure device|Brake bleed pressure device]]<br />
*[[General Homemade working light|Cheap working light for inaccessible areas]]<br />
*[[General Homemade Chassis cleaning tools|Chassis cleaning tools]]<br />
*[[General Homemade Welding clamp deep - Improvised|Improvised deep-reach welding clamp]]<br />
*[[General Homemade Welding clamp deep - Home-made|Home-made deep-reach G-clamp]]<br />
*[[General Homemade Soda Blaster attachment for carb cleaning - Home-made|Soda Blaster attachment for carb cleaning]]<br />
*[[General Homemade Emergency Welders|Emergency Welders]]<br />
<br />
===Sundries===<br />
*[[General Duralac anti-corrosion compound|Duralac anti-corrosion assembly compound]]<br />
*[[General Assembly Lube|Assembly lube]]<br />
*[[General LFS|Laminate fibre sheet (LFS) e.g. Tufnol]]<br />
*[[General J-B Weld|J-B Weld epoxy repair]]<br />
*[[General Cold Front|Cold Front (welding)]]<br />
*[[General High Temperature finishes|High-temp paints]]<br />
*[[General Anti-corrosion paint|Weld-thru Zinc spray]]<br />
*[[General Rust-busters|Rust-busters and penetrating oils]]<br />
*[[General EZGrip|EZ-Grip fastener head friction drops]]<br />
*[[General Dinitrol Rust-off|Dinitrol (RC900) Rust-off primer (optional Chassis Black overcoating)]]<br />
*[[General Rustoleum paint|Rustoleum Combi-colour paint]]<br />
<br />
===Safety equipment and H&S usage cautions===<br />
<br />
Safety, Safely & Sagely.<br />
<br />
*[[General Face mask|Goggles & full-face masks (grinding)]]<br />
*[[General Welding masks|Goggles & full-face masks (welding)]]<br />
*[[General Angle Grinder Safety|Angle Grinder - Cautions]]<br />
*[[General Hi-lift Jack Safety|Hi-lift jacks - Safety]]<br />
*[[General - H&S Drilling|Drilling - Safety]]<br />
<br />
==Techniques==<br />
*[[Techniques - Removing seized/broken studs/bolts/nuts|Removing seized/broken studs/bolts/nuts]]<br />
*[[Techniques - Removing rusty screws|Removing rusty screws]]<br />
*[[Techniques - Loosening rear hub nut|Loosening (46mm) rear-hub castle-nut]]<br />
*[[Techniques - Annealing dural sheet/plate|Annealing dural sheet]]<br />
*[[Techniques - Cleaning/Trueing mating faces|Cleaning/Trueing mating faces]]<br />
*[[Techniques - Removing spigot shaft bearing|Removing spigot shaft bearing]]<br />
*[[Techniques - Welding|Welding and brazing]]<br />
*[[Techniques - Bleeding brakes/clutches|Bleeding hydraulic brakes and clutches]]<br />
*[[Techniques - Soldering wires|Soldering wires]] <br />
*[[Techniques - Compression testing|Compression testing]]<br />
*[[Techniques - Removing rust|Removing rust using vinegar (from small components)]]<br />
*[[Techniques - Digicam inspection|Handy method for inspecting inside sills/sections etc]] <br />
<br />
*[http://assets.fluke.com/appnotes/automotive/beatbook.pdf Some electrical testing procedures from Fluke]<br />
*[http://www.ratwell.com/technical/HydraulicLifters.html Hydraulic lifters]<br />
*[[Bodywork and Glass - Rust - Elecrolytic de-rusting]]<br />
*[[General Joggler| Joggling (stepping) panels for seam joins]]<br />
<br />
*[[Techniques - Sheet steel fabrication|Sheet steel fabrication]]<br />
<br />
*[[Techniques - CB radio installation and aerial tuning|CB radio installations and aerial tuning]]<br />
<br />
==Technical Information - non vehicle specific ==<br />
<br />
===Electrical===<br />
<br />
===Mechanical===<br />
<br />
===Other===<br />
<br />
==Featured Parts==<br />
<br />
*[[Parts - Bodywork - Seatbelt anchor plates|Seatbelt anchor nut plates]]<br />
<br />
*[[Parts - Turbo pipework - Murray aviation hose clamp|Murray aviation hose clamp]]<br />
<br />
= Insurance =<br />
*[[Insurance insurance companies Dealing with claims | Dealing with claims ]]<br />
*[[Insurance insurance companies feedback| Insurance companies feedback]]<br />
*[[TEMPLATE copy and paste this for your entry]] <br />
*[[Insurance Camper|Camper]]<br />
*[[Insurance Caravelle|Caravelle]]<br />
*[[Insurance Panel|Panel]]<br />
*[[Insurance DOKA|DOKA]]<br />
*[[Insurance SIKA|SIKA]]<br />
*[[Insurance Non Stock engine and modified|Non stock engine and modified]]<br />
*[[Insurance LPG|LPG]]<br />
*[[Insurance Postcode rating|Postocde rating]]<br />
----<br />
<br />
= Breakdown =<br />
<br />
*[[breakdown ADAC|ADAC (Deutsche AA)]]<br />
*[[breakdown Adrian Flux|Adrian Flux]]<br />
*[[breakdown AA|AA]]<br />
*[[breakdown Freeway (Via Glynwood insurance)|Freeway (Via Glynwood insurance)]]<br />
*[[breakdown CIS|CIS (Co-Op Insurance Services)]]<br />
----<br />
<br />
=T25 Media Library=<br />
*Images<br />
**[[T25 Media Library Classic Photos|Classic Photos]]<br />
**[[T25 Media Library camper Conversions| Camper conversions]]<br />
<br />
*Pictures of hard to get to places and bits you don't normally see (also see Rust and Interiors)<br />
**[[T25 Media Library Interior stripped| Interior parts]]<br />
**[[T25 Media Library Exterior Stripped| Exterior Parts]]<br />
**[[T25 Media Library parts|Parts]]<br />
<br />
*Sounds and video<br />
**[http://meta.wikimedia.org/wiki/Multimedia/Help:Listening_to_sounds Explanation of Ogg sound format]<br />
**[[T25 Media Library Engine| Engine]]<br />
**[[T25 Media Library Suspension| Suspension]]<br />
**[[T25 Media Library dripping air vent| Dripping air vent syndrome]]<br />
----<br />
<br />
=T25 Camper Manuals, VW manuals, Specifications, Literature, Magazine Articles,=<br />
*[http://www.vanagonauts.com/2.1L-Vanagon-Specs234.htm List of torques and specifications, fluids etc ]<br />
*[http://web.mac.com/gbotter/Club_del_Maggiolino_di_Treviso/VW_Camper_T3_A.html Lots of original brochures on an Italian website]<br />
*[[Scanned T25 Literature camper manuals|Camper manuals /Autosleeper Trident/ Autohomes]]<br />
*[[Scanned T25 Literature weight measurments| Specifications/towing/weights/dimensions]]<br />
*[[Scanned T25 Literature VW manuals| VW manuals]]<br />
*[[Scanned T25 Literature VW manuals Technical books| Technical books Haynes etc]]<br />
*[[Scanned T25 Literature brouchers|Brochures]]<br />
*[[Scanned T25 Literature magazine articles|Magazine articles]] <br />
*[http://www.thewoodcrafter.net/proj/prpics/p93/p93.pdf Wooden toy template, can be modified to look more T25]<br />
*[[Scanned T25 Literature Origami|Origami]]<br />
*[[Scanned T25 Literature Manuals|Where to get manuals]]<br />
<br />
*[http://www.vw-mplate.com/mcode.php M-Code M-Plate decipher website]<br />
<br />
----<br />
<br />
=Links & Addresses (Parts, sundries & other useful websites) =<br />
<br />
==Parts & sundry Suppliers/Traders==<br />
*[[Internet Links New Parts suppliers|Parts and sundry supplies]]<br />
*[[Internet Links 2nd Hand Parts suppliers and breakers|2nd hand parts suppliers and breakers]]<br />
*[[Internet Links Mechanics|Mechanics and camper converters]]<br />
*[[Internet Links Carriers/delivery services |Carriers/delivery services]]<br />
*[[Internet Links Electronic and Electrical Services|Electronic (ECU) and Electrical Services]]<br />
*[http://www.dubdoctors.com/ http://www.dubdoctors.com/]<br />
<br />
===Suppliers feedback gleaned from the forum===<br />
<br />
*[[Elite VW]]<br />
<br />
=Internet links - Other relevant websites=<br />
<br />
<br />
<br />
*[[Internet Links non vw related helpful site links| Non VW related helpful site links]]<br />
<br />
*[http://www.transportoffice.gov.uk/crt/doitonline/bl/mottestingmanualsandguides/mottestingmanualsandguides.htm | MOT testers manual in depth, you can download the manual opens as a PDF]<br />
*[http://www.motuk.co.uk/images/Special%20Notice%2009-11.pdf | MOT changes for 2012 opens as a PDF]<br />
*[http://www.bradtech.ltd.uk/ |Thetford portaloo spares]<br />
*[http://s136500617.websitehome.co.uk/gipsy/ Karmann Coachbuilts Website]<br />
*[http://www.jigrah.co.uk/mhpark/Default.htm Hightop-friendly carparks]<br />
*[[Internet Links other T25 and vanagon resources|Other useful T25 and vanagon tech resources]]<br />
*[[Internet Links other VW websites|Other VW websites]]<br />
*[[Internet Links Club suppliers|Club suppliers]]<br />
<br />
*[[Westy jokers]]<br />
*[http://www.type2.com/library/heat/heat-soundproof.html Heat Rust and Noise in VWs (That famous Bulley-Hewlett article)]<br />
*[[Dometic Refrigerators]] <br />
*[http://www.motinfo.gov.uk/internet/jsp/ECHID-Internet-History-Request.jsp MOT advisories online]<br />
*[[Internet Links Stolen Vehicle registers|Stolen Vehicle registers]]<br />
*[http://www.camperinterior.co.uk/index.html Camper Interior website, a photo feast... Take a look!]<br />
*[http://www.opsi.gov.uk/acts/acts1994/ukpga_19940033_en_8#pt5-pb1 Criminal justice act Part V relating to trespass powers to remove, may have a relevance to overnight camping]<br />
*[http://s136500617.websitehome.co.uk/herman/ Herman the German (Westfalia Joker) - lots here incl. interior shots and brochure pics] site not active march20111<br />
*[http://www.vwpix.org/eng/ VWPix, Boltze & Co's VW brochure site]<br />
*[http://sbmcc.co.uk/forum/ SBMCC (Self-build Motor Caravanners Club]<br />
<br />
*[http://www.vw-mplate.com/mcode.php?lang=EN M-Code decoder website(Bottom right, 1979~1991 T3)]<br />
<br />
=Misc tips, tricks and info...(including posting pictures)=<br />
==Computer==<br />
[http://www.geology.enr.state.nc.us/gis/latlon.html Latitude and longtitude format converter]<br />
<br />
[http://homepage.ntlworld.com/robertj.green/T25/Knowledge%20base/GSF-POI/ GSF POI for Tom Tom sat nav]<br />
<br />
*[[Misc tips and tricks 80-90 forum uploading pictures| 80-90 forum uploading pictures]]<br />
*[[Misc tips and tricks 80-90 forum clean url linking| 80-90 forum clean url linking]]<br />
*[[Misc tips and tricks 80-90 Google Eath| Google Earth]] <br />
*[[Misc tips and tricks GSF locations csv|GSF locations csv]]<br />
*[[Misc tips and tricks - How to resize images| How to resize images.]]<br />
*[[Misc tips and tricks installing Firefox|Installing Firefox]]<br />
*[[Misc tips and tricks - Joining the Waze Group|Joining the 80-90 Waze Nav App Group]]<br />
<br />
*[[Misc tips and tricks - Windows PC - Fixing problems|Windows PC - Fixing Problems]]<br />
<br />
==Parts Acquisition==<br />
<br />
*[[Parts Acquisition - Main Dealer|Buying VW parts (UK, Germany and SA]]<br />
*[[Parts Acquisition - Non-Main Dealer|Buying parts from other suppliers - Warning]]<br />
*[[Parts - Non-VW Parts|Non VW parts]]<br />
<br />
==Maintenance Bulletins==<br />
<br />
*[[Fuel System Filler Problems|Filler/filling problems]]<br />
*[[Body work and glass - Storage|Storage and over-wintering]]<br />
*[http://www.type2.com/library/heat/heat-soundproof.html Heat Rust and Noise in VWs (That famous Bulley-Hewlett article)]<br />
<br />
==Fuel Economy==<br />
*[[Fuel economy unofficial|Fuel economy]]<br />
<br />
<br />
==Performance; Power; Dyno results==<br />
*[[Performance - Dyno results|Dynamometer test results]]<br />
----<br />
<br />
=Prices=<br />
[[prices campervans|campervan prices]]<br />
<br />
=Garages, Workshops and services=<br />
==T25==<br />
[[Garages T25 Specific|T25 specific garages]]<br />
==General==<br />
[[Garages General Recommended|Recommended general garages]]<br />
<br />
[[Garages recomended Non UK|Garages recomended Non UK]]<br />
<br />
==Services==<br />
[[Services Recommended|Recommended Services]]<br />
<br />
=Health & Safety=<br />
==Common workshop dangers==<br />
<br />
*[[H&S Dangerous Gases|Highly Dangerous Gases from common workshop sundries]]<br />
<br />
*Safety equipment and H&S usage cautions (From Tools, Techniques & Sundries)<br />
<br />
**[[General Face mask|Goggles & full-face masks (grinding)]]<br />
**[[General Welding masks|Goggles & full-face masks (welding)]]<br />
**[[General Angle Grinder Safety|Angle Grinder - Cautions]]<br />
**[[General - H&S Drilling|Drilling - Safety]]<br />
**[[General Battery charging Hydrogen gas explosion warnings]] <br />
*Safety - Driving -Roadside repairs - Off-road etc<br />
**[[General Hi-lift Jack Safety|Hi-lift jacks - Safety]]</div>HarryMannhttps://club8090.co.uk/w/index.php?title=Main_Page&diff=12023Main Page2014-01-13T21:53:18Z<p>HarryMann: /* Common geqrbox ie automatic and manual */</p>
<hr />
<div>'''Welcome to a VW-Tech, the wiki technical archive of the Club 80-90 website.'''<br />
<br />
<br />
<br />
<br />
== NEW USERS START HERE, READ THE DISCLAIMER==<br />
<br />
'''PLEASE READ THE''' [[Disclaimer|'''Disclaimer:''']]<br />
<br />
'''Club 80-90 Wiki History''' <br />
<br />
Started in around 2005 after we moved from an older bulletin board that had been outgrown by the size of the club. A group of long standing club members decided to retain some of the helpful information on the technical pages that would otherwise get lost as the forum was pruned from time to time. Some of the information is basic vehicle mechanics for those that are just starting out. Some is advanced that you will need an extensive toolset to achieve. Some of it you could find in a Hayne's or Bentley manual and sometimes there are fixes that have not been documented and issues that VW had no repair as these vehicles have long since lasted beyond the working life that VW intended them to achieve. This is a collection of postings on 80-90 over the years and has grown to quite a size, some by professional mechanics and some by novices and all levels of knowledge in between. Ultimately it is to be used along side other forums and manuals to give you another viewpoint on how to solve or fix a problem, but usually with a real persons perspective and photographs to help out. It is not meant to be gospel and it is a living work in progress, articles and advice may change as knowledge grows over time. It may be contradictory in parts as different people have different ideas on the best way to perform a procedure. You may need to use some gut instinct and common sense to tell you which way to proceed, there may be a way to do something which hasn't been thought of, or they may be incorrect information which is out of date. The two main wiki editors are HarryMann and Hacksawbob (usernames on Club 80-90) Send a private message to them if you spot something that needs changing. If you have something to add write it up in the Club 80-90 Technical section in the appropriate section and PM an editor to make them aware of it.<br />
<br />
------<br />
<br />
Please stick to the following [[naming convention|naming convention]]. Feel free to add information to the pages you create but please don't alter the section headings as this will have a knock on effect on the naming scheme. It will help subsequent people to add information and will avoid accidental page overwriting or duplication. Please PM Hacksawbob or HarryMann if you have any questions or suggestions. <br />
I appreciate that there will be some overlap between sections, and equally a topic that could appear in several sections, enter your information in the section that you think is most appropriate, it can then be linked to from other pages. Don't enter into discussion on the WIKI, that is for the forum, try and keep the information here as definative an concise as possible. '''''The WIKI is for answers not questions.''''' If you need clarification then try and contact the poster directly or start a new thread on the [http://www.club80-90.co.uk/forum/viewforum.php?f=2| technical forum.]<br />
<br />
==Club 80-90 Wiki en Français==<br />
[[French language pages|French Language pages]]<br />
<br />
==Notices and Bugs==<br />
'''PLEASE READ THE''' [[Disclaimer|'''Disclaimer:''']]<br />
<br />
*Some club 80-90 members are the only ones with editing rights. Please PM HarryMann if you are a seasoned Wiki editor with valuable T3/T25 content to add. Particularly we are looking for those with experience of the early aircooleds, esepcially the carburrettion, ignition and tuning aspects. <br />
<br />
*Red links are pages that do not yet have information added to them (or whose pages have become orphaned, either due to typos in the internal links, or other reasons)<br />
<br />
*Please - Add your name at the beginning of the section you are adding! A good way is to format it as below, including a brief summary - adding a single space at the beginning turns it into a caption (repetitive saves seem to destroy that though) <br />
<br />
e.g. '''Name: ''' Brief summary of what has been added below (and possibly why its important)<br />
<br />
*Please reference your source if what you are posting is not your own. Ask permission first if there is copyright on it, and if it is from another website please put the link to the original URL.<br />
<br />
*[http://meta.wikimedia.org/w/wiki.phtml?title=Meta:Sandbox&action=edit click here for a 'sandbox'] if you want to experiment with wikis before making modifiacations to this one. <br />
<br />
*[http://meta.wikimedia.org/wiki/Help:Editing here is some help on basic Wiki editing]<br />
<br />
----<br />
<br />
= New or Prospective Owner? =<br />
<br />
==* Warnings - Must Read *==<br />
*[[petrol engines Fire warning|Fire warning - Fuel lines, tank, carb etc.]]<br />
*[[Petrol engines aircooled - Fuel Leaks|Fire warning - Aircooled - Carb fuel leaks]]<br />
*[[Gearbox Clutch CVs - Warnings| Gearbox /Transaxle /Diff oil levels]]<br />
*[[Petrol engines Diagnosing faults|Parts quality - Keep old (removed) parts]]<br />
<br />
==Guides==<br />
*[[New/Prospective Owners What are they like to drive? | What are they like? How to drive?]]<br />
*[[Misc tips and tricks buyers guide | The Buyers Guide by Simon Brickyard and others]]<br />
*[[Syncro - Testing|Syncro (4 wheel drive) Buyers guide]]<br />
*[[A newbies buying experience|A newbies buying experience]]<br />
<br />
==Tips and tricks and basic servicing==<br />
*[[Misc tips and tricks New owners questions| New owners' questions (FAQ)]]<br />
*[[Misc tips and tricks spares to carry| Spares and tools to carry]]<br />
*[[New/Prospective Owners| Don't panic!]]<br />
*[[New/Prospective Owners Flat 4 engines primer| Flat 4 engines primer]]<br />
*[[New/Prospective Owners Importing|Importing]]<br />
*[http://www.motinfo.gov.uk/internet/jsp/ECHID-Internet-History-Request.jsp VOSA MOT advisories online, check what might need fixing soon on your prospective purchase]<br />
*[[Gearbox Clutch CVs CV joints gear change reluctance|Gearchange reluctance]]<br />
*[[Gearbox Clutch CVs Sloppy gear change improving|Improving difficult/sloppy gearchange]]<br />
*[[Petrol engines oil change|Petrol engines - Oil & oil changes]]<br />
*[[New/Prospective Owners All engines servicing overview|All engines servicing overview]]<br />
For Maintenance Bulletins look in Misc Tips and Tips<br />
<br />
----<br />
<br />
=Engines=<br />
== Petrol engines (Watercooled)==<br />
[[Image:1.9-DG-watercooled-top1-(with-LPG-system).jpg|thumb|1.9L DG engine (with LPG system)]]<br />
*[[petrol engines Fire warning|Fire warning - Fuel lines, tank, carb etc.]]<br />
*[[petrol engines Not starting diagnostic flow chart|Not starting - Diagnostic flow chart]]<br />
*[[petrol engines engine removal and refitting|Engine removal and refitting]]<br />
*[[petrol engines spark plug types|Spark plug types]]<br />
<br />
*1.9 specific<br />
**[[petrol engines 1.9 Timing|1.9 timing]]<br />
**[[petrol engines - Pierburg Choke|Pierburg Choke Mechanism]]<br />
<br />
*2.1 specific<br />
**[[petrol engines 2.1 Timing|2.1 timing]]<br />
**[[petrol engines intermittent 2.1 | Petrol engines intermittent 2.1 (incl. Vanagon syndrome)]]<br />
**[[petrol engines 2.1 MV|2.1 MV specific]]<br />
**[[petrol engines Bad idling 2.1|Bad idling (2.1 DJ)]]<br />
**[[petrol engines 2.1 ISCU|2.1 ISCU]]<br />
**[[Petrol engines 2.1 Throwing a rod|2.1 Throwing a rod]]<br />
**[[Petrol engines Oil pressure survey|Oil pressure survey]]<br />
**[[Petrol engines Cam follower removal head in place|Cam follower removal head in place]]<br />
**[[Petrol engines 2.1 Other jobs while out|Removing 2.1 - Other jobs whilst out]]<br />
<br />
*General Ignition Info/Debugging<br />
**[[Petrol engines Ignition firing order|Firing order]]<br />
**[[Petrol engines Ignition advance curves|Ignition advance curves]]<br />
**[[Petrol engines Vac advance/retard problems|Vac advance/retard problems]]<br />
<br />
*Parts, Pictures, Diagrams and lists etc.<br />
**[[Petrol engines Parts - Inlet Manifold (1.9)|Inlet Manifold (1.9)]]<br />
**[[Petrol engines Parts - Oil breather hose(1.9)|Oil breather hose(1.9)]]<br />
**[[Petrol engines Parts - petrol Cooling system diagram|petrol Cooling system diagram]]<br />
**[[Petrol engines Parts - wbx exhaust stud depth|wbx exhaust stud depth]]<br />
<br />
==Petrol Engines (Aircooled)==<br />
[[Image:CU-engine-top-1.JPG|thumb|A CU aircooled engine]]<br />
*[[petrol engines aircooled Schematic|Schematic parts layout]]<br />
*[[petrol engines aircooled engine removal|Engine removal]]<br />
*[[petrol engines aircooled - Crankshaft oil seal|Crankshaft oil-seal (photo article, start-to-finish)]]<br />
*[[petrol engines aircooled Differences|Differences between engines]]<br />
<br />
*[[petrol engines aircooled running temperature|Aircooled running temperature]]<br />
*[[petrol engines aircooled performance enhancement|Performance enhancement]]<br />
*[[petrol engines aircooled thermostat|Thermostat]]<br />
*[[petrol engines aircooled solid lifters|Solid lifters]]<br />
*[[petrol engines aircooled push rod & seal replacement|Pushrod & tube seal replacement]]<br />
*[[petrol engines aircooled Oil pressures|Oil pressures]]<br />
<br />
*A/C Petrol engines - Aircooled Cyl. Head<br />
**[[petrol engines aircooled Refitting cylinder heads|Refitting cylinder heads]]<br />
**[[petrol engines aircooled Valves|Re-cutting seats and lapping valves]]<br />
**[[petrol engines aircooled Cylinder Head Damage|Cylinder head damage]]<br />
<br />
*A/C Petrol engines - Aircooled Ignition Systems<br />
**[[petrol engines aircooled Ignition 01|Ignition timing esp. Vac adv/ret hoses]]<br />
**[[petrol engines aircooled Ignition 02|Distributors, timing and setting up]]<br />
**[http://www.youtube.com/watch?v=xm4OmiVH2J0&feature=related Historic a/c Ignition timing videos Part 1]<br />
**[http://www.youtube.com/watch?v=cIrA4iWkhbE&feature=related Historic a/c Ignition timing videos Part 2]<br />
**[[petrol engines aircooled spark plugs|Spark plugs and HT leads]]<br />
<br />
*A/C Petrol engines - Carburrettors and fuel system<br />
**[[Carburrettors - faults and faultfinding]]<br />
**[[Fuel pump - aircooleds|Fuel pump problems]]<br />
**[[Inlet manifolds - aircooleds|Inlet manifolds]]<br />
**[http://www.youtube.com/watch?v=XOxxS1EMphU&feature=related Historic a/c carb tuning videos (PICT 28 ~34) Part 1]<br />
**[http://www.youtube.com/watch?v=KWdZSr7x81w&feature=related Historic a/c carb tuning videos (PICT 28 ~34) Part 2]<br />
<br />
<br />
*A/C Petrol engines - Cooling and heating systems<br />
**[[petrol engines aircooled tinware|Aircooled tinware]]<br />
**[[petrol engines aircooled Cooling and heating 01|Cooling and heating parts]]<br />
**[[petrol engines aircooled Cooling and heating 01|Cooling and heating description]]<br />
<br />
**Hazards<br />
**[[petrol engines aircooled - Fuel Leaks|Fuel leaks]]<br />
<br />
*A/C Petrol engines - Modifications <br />
**[[petrol engines aircooled Modifications|A/C Modifications, carbs, distributors, tuning, compatability issues]]<br />
<br />
==Petrol specific engine Faults/repairs/maintenance==<br />
* [[petrol engines Diagnosing faults|Diagnosing faults (petrols)]]<br />
* [[petrol engines cylinder head spark plug numbers|Cylinder nos. and firing order ]]<br />
* [[petrol engines oil change|Oil change]]<br />
* [[petrol engines engine codes| Engine codes]]<br />
* [[petrol engines cylinder head leak|Cylinder head leak]]<br />
* [[petrol engines losing water|Losing water]]<br />
* [[petrol engines low oil pressure|Low oil pressure]]<br />
* [[Techniques - Removing seized/broken studs/bolts/nuts|Snapped cylinder head bolt]]<br />
* [[petrol engines starter bush removal|Starter motor bush removal]]<br />
* [[petrol engines Overheating|Overheating]]<br />
* [[petrol engines oil emulsifying|Emulsified oil (mayonnaise)]]<br />
* [[petrol engines Oil leaks|Oil leaks]]<br />
* [[Techniques - Compression testing|Compression testing]]<br />
* [[Hydraulic lifters explained ]]<br />
* [[petrol engines non-start|Won't start (fuel)]]<br />
*[[petrol engines spigot-shaft bearing|Replacing spigot-shaft bearing]]<br />
[http://forum.club8090.co.uk/viewtopic.php?t=107122 ]<br />
<br />
== Diesel engines ==<br />
[[Image:Diesel engine1copy-1.jpg|thumb|JX turbo Diesel Engine]]<br />
*[[Diesel engines Fire warning|Fire warning]]<br />
*[[Diesel engines Diagnosis| Types, condition diagnosis, Service Bulletins etc]]<br />
*[[Diesel engines engine codes|Engine codes]]<br />
*[[Diesel engines engine removal and refitting|Engine removal and refitting]]<br />
* Diesel Engines - Turbo<br />
** [[Turbo - Re-indexing|Re-indexing]]<br />
** [[Turbo - Setting-up the Wastegate|Setting-up the wastegate]]<br />
** [[Turbo - Re-installing|Re-installing]]<br />
** [[Turbo - Oil feeds|Oil feeds]]<br />
** [[Turbo - Manifolds|Manifolds/Heat Shields]]<br />
** [[Turbo - Refurbing|Refurbing]]<br />
*[[Diesel engines - Sump/Oil Pump|Sump and oil pump]]<br />
<br />
* Diesel Engines - Servicing<br />
**[[Diesel Engines Auxiliary drive belts|Auxiliary drive belts]]<br />
**[[Diesel Engines Timing Belt_01|Lining-up camshaft and crankshaft]]<br />
**[[Diesel Engines Timing belt|Timing belt/removing camshaft sprocket]]<br />
**[[Diesel Engines Cyl Head re-fitting|Cylinder head re-fitting]]<br />
**[[Diesel Engines Cold-Starting|Cold starting]]<br />
**[[Diesel Engines Inj. pumps - AAZ pump adjustments|AAZ pump adjustments]]<br />
**[[Diesel Engines 1.6 NA CS ring gaps|1.6 NA (CS) ring gaps]]<br />
<br />
**[[Techniques - Compression testing|Compression testing]]<br />
**[[Parts - Part Nos|Rebuild Part Nos and some torques]]<br />
<br />
*Diesel Engines - Parts, pictures, diagrams and lists<br />
** [[Parts - CS Inlet Manifold|CS Inlet Manifold]]<br />
** [[Parts - Engine Damage|Diesel Engine damage]]<br />
** [[Parts - Shadek Oil pump|Shadek oil pump]]<br />
** [[Parts - Part Nos|Rebuild Part Nos and some torques]]<br />
** [[Parts - Cooling system|Cooling system]]<br />
** [[Parts - Crankshaft|Crankshaft and timing pulley]]<br />
** [[Parts - Block and pistons|Block and pistons]]<br />
** [[Parts - Intercooler|Intercooler]]<br />
<br />
<br />
** [[Parts - Rebuild|Rebuilding parts]]<br />
** [[Parts - Gloplug spanner|Glo-plug ratchet spanner]]<br />
** [[Parts - Head gasket protrusion|Head gasket protrusion]]<br />
** [[Parts - Cyl head instr senders - rear|Cyl head instr senders - rear]]<br />
** [[Parts - Cyl head instr senders - side|Cyl head instr senders - side]]<br />
** [[Parts - JX turbo mounting position|JX turbo mounting position]]<br />
<br />
**Diesel Engines - Modified parts<br />
***[[Parts - Modifications - T3 turbo|T3 turbo install]]<br />
***[[Parts - Modifications - Standard Engine Mounts|Standard engine mounts]]<br />
***[[Parts - Modifications - Engine Mounts|Modified engine mounts]]<br />
***[[Parts - Modifications - Silencer custom heat-shield|Silencer - custom heat-shield]]<br />
***[[Parts - Modifications - AAZ Non-JX Mods 01|AAZ turbo clearance mods]]<br />
***[[Parts - Modifications - Oil cooling|Oil cooling and oil coolers]]<br />
***[[Parts - Modifications - Injection pumps|Injection Pumps - Modifying]]<br />
<br />
<br />
*Instruments - <br />
**[[Diesel Engines Instruments|Diesel Engines Instruments]]<br />
<br />
*Links to threads on the 1Y 1.9d (N/A) which is a popular conversion from the 1.6d and 1.7d<br />
**[[List of Links from Ringo|List of links from Ringo]]<br />
<br />
==All engine faults/repairs/maintenance==<br />
<br />
*[[All engine faults/repairs/maintenance Stripped sparkplug thread|Stripped spark plug thread]]<br />
*[[All engine faults/repairs/maintenance Oils recommended|Engine oils - recommended]]<br />
*[[All engine faults/repairs/maintenance Oil filters recomended|Oil filters - recommended]]<br />
*[[All engine faults/repairs/maintenance Replace throttle cable|Replace throttle cable]]<br />
*[[All engine faults/repairs/maintenance Replace starter motor|Replace starter motor]]<br />
*[[All engine faults/repairs/maintenance reluctant starting|Reluctant starting (starter motor)]]<br />
*[[All engine faults/repairs/maintenance reluctant starting (battery alternator)|Reluctant starting (battery alternator)]]<br />
*[[All engine faults/repairs/maintenance reluctant starting Earths|Reluctant starting earths]]<br />
*[[All engine faults/repairs/maintenance reconditioned engines|Reconditioned engines]]<br />
*[[All engine faults/repairs/maintenance Dashboard water level and temperature warnings and causes|Dashboard water level and temperature warnings and causes]]<br />
*[[All engine faults/repairs/maintenance Dashboard oil pressure warnings and causes|Dashboard oil pressure warnings and causes (DOPWS)]]<br />
*[[All engine faults/repairs/maintenance Performance/Longevity|Performance/Longevity]]<br />
*[[All engine faults/repairs/maintenance Air-cooled white smoke|Air-cooled white smoke]]<br />
*[[All engine faults/repairs/maintenance Sump plug problems|Sump plug problems]]<br />
*[[All engine faults/repairs/maintenance Dipstick lengths|Dipstick lengths]]<br />
*[[All engine faults/repairs/maintenance Engine bay seal|Engine bay seal]]<br />
----<br />
<br />
==Exhausts==<br />
<br />
*[[Exhausts Systems Petrol|Petrol Exhausts - Early/Late]]<br />
*[[Exhausts Suppliers|Exhaust system suppliers - Part Nos & Stainless Alternatives]]<br />
*[[Exhausts Custom|Custom exhausts]]<br />
*[[Exhausts Rust|Exhaust rust repairs]]<br />
*[[Exhausts Heat Pipe|DG Exhaust Heat transfer pipe]]<br />
<br />
=Fuel System=<br />
==Diesel==<br />
*[[Diesel - Injectors|Diesel Injectors]]<br />
*[[Diesel - Glow plugs replacing|Glow plugs - replacing]]<br />
*[[Diesel - Injection pumps|Injection pumps]]<br />
*[[Diesel - Fuel system Tips and Tricks|Fuel system Tips and Tricks]]<br />
*[[Diesel - Adding bulb pump primer and transparent fuel lines| Adding bulb pump primer and transparent fuel lines]]<br />
<br />
==Petrol==<br />
<br />
*Common<br />
**[[Petrol engines Fire warning|#Fire warnings# - fuel lines, tank and filler]]<br />
**[[Petrol engines aircooled - Fuel Leaks|#Fuel leaks# - Aircooled]]<br />
<br />
*Injection<br />
**[[Fuel system - Digijet - Brief overview|Brief overview of Digijet injection system]]<br />
<br />
*Carburrettor <br />
**[[Fuel system - 1.9 Fuel hoses|Replacing 1.9 DG Fuel hoses]]<br />
**[[Fuel system - Pierburg |Pierburg carbs]]<br />
**[[Fuel system - 1.9 WBX stops intermittently|1.9 WBX stops intermittently]]<br />
**[[Fuel system - Carburettor removal|Carburettor removal]]<br />
**[[Fuel system - Carburettor Pierburg alternatives|Carburettor Pierburg alternatives]]<br />
**[[Fuel system - Carburettor Air leaks|Carb or manifold air-leaks]]<br />
**[[Fuel system - Carburettor Autochoke|Carb Autochoke setting]]<br />
**[http://archive.club8090.co.uk/viewtopic.php?f=2&t=36598& Intermitten but very annoying problem (blocked jet?)]<br />
**[[Fuel system - Carburettor Clearing blocked jets|Clearing blocked jets]]<br />
<br />
==Common==<br />
*[[Fuel system - Accelerator cable replacement|Acelerator cable replacement]]<br />
*[[Fuel System tank removal |Tank removal]]<br />
*[[Fuel system breather tanks|Breather tanks]]<br />
*[[Fuel economy unofficial|Fuel economy]]<br />
<br />
*[[Fuel System Filler Problems|Filler/filling problems]]<br />
<br />
== Alternative fuels ==<br />
*LPG<br />
**[[Alternative Fuels type of system|Type of system]]<br />
**[[Alternative Fuels spark plugs|Spark plugs]]<br />
**[[Alternative Fuels cheap filling stations|Cheap filling stations]]<br />
**[[Alternative Fuels engine tuning|Engine tuning]]<br />
**[[Alternative Fuels Fuel economy|Fuel economy]]<br />
<br />
*Biodiesel Cooking Oil etc<br />
**[[Alternative Fuels Biodiesel explained|Biodiesel explained]]<br />
**[[Alternative Fuels Cooking Oil feedback|Cooking oil feedback]]<br />
<br />
<br />
----<br />
<br />
=Coolant and Heating=<br />
==Cooling System==<br />
<br />
* [[Coolant and Heating flashing red light on dash|Flashing red light on dash]]<br />
* [[Coolant and Heating recommended brands|Anti-freeze - Brands, specs, dilutions and capacities]]<br />
* [[Coolant and Heating front pipe leaks|Front pipe leaks]]<br />
* [[Coolant and Heating main pipe leaks |Main pipe leaks]]<br />
* [[Coolant and Heating overheating causes and fixes|Overheating causes and fixes]]<br />
* [[Coolant and Heating draining|Drain]]<br />
* [[Coolant and Heating bleeding system|Refilling and bleeding system]]<br />
* [[Coolant and Heating New radiator|New radiator]]<br />
* [[Coolant and Heating running temperatures|Running temperatures]]<br />
* [[Coolant and Heating System overhaul 1|Replacing original front-to-rear metal pipes]]<br />
* [[Coolant and Heating System overhaul 2|Replacing water pump, thermostat and adjoining metal pipes]]<br />
* [[Coolant and Heating Instrumentation malfunction|Temp gauge and sender malfunctions]]<br />
* [[Coolant and Heating Testing radiator fan |Testing radiator fan]]<br />
* [[Coolant and Heating Oil cooling|Oil cooling]]<br />
* [[Coolant and Heating Header tank top and up tank|Header tank and top up tank]]<br />
<br />
==Heating System==<br />
* [[Coolant and Heating heater blower replacement|<br />
Hot & Cold Air Blower - Diagnosis, Removal, Replacement And Modifications]]<br />
* [[Coolant and Heating - Air-cooled heating system|Air-cooled heating system]]<br />
* [[Coolant and Heating - Heater hoses|Heater hoses]]<br />
<br />
*[http://www.type2.com/library/heat/heat-soundproof.html Excellent article on improving VW a/c insulation & heating system]<br />
<br />
----<br />
<br />
= Gearbox Clutch CVJs Driveshafts (not Syncro front)=<br />
==Automatic specific==<br />
<br />
*[[Gearbox Clutch CVs Automatic General Info|Automatics - General Information]]<br />
*[[Gearbox Clutch CVs Automatic Gearbox Oil|Gearbox oil checking/changing]]<br />
*[[Gearbox Clutch CVs Automatic Gearbox Parts|Automatic gearbox - Parts and finding them]]<br />
<br />
==Manual gearbox specific==<br />
*[[Gearbox Clutch CVs - Warnings|Gearbox ##Warnings##]]<br />
<br />
*[[Gearbox Clutch CVs Clutch Pictures|Clutch - pictures]]<br />
*[[Gearbox Clutch CVs clutch slave replacement|Clutch slave cylinder replacement]]<br />
*[[Gearbox Cutch CVs - Clutch slave-cylinder|Clutch slave-cylinder and pipework]]<br />
*[[Gearbox Clutch CVs Clutch pedal not disengaging|Clutch not disengaging]]<br />
*[[Gearbox Clutch CVs - Removing the clutch|Removing the clutch]]<br />
*[[Gearbox Clutch CVs - Re-installing clutch|Re-installing clutch]]<br />
<br />
*[[Gearbox Clutch CVs - Renovating 5 speed change mechanism Pt1|Renovating 5 speed change mechanism Pt1]]<br />
*[[Gearbox Clutch CVs - Renovating 5 speed change mechanism Pt2|Renovating 5 speed change mechanism Pt2]]<br />
*[[Gearbox Clutch CVs - Renovating 5 speed change mechanism - adjustments|Renovating 5 speed change mechanism - adjustments]]<br />
*[[Gearbox Clutch CVs - Gear change reluctance|Gear change reluctance]]<br />
*[[Gearbox Clutch CVs Sloppy gear change improving|Improving sloppy g/c & g/c part nos.]]<br />
*[[Gearbox Clutch CVs Gear selection process|Gear selection process]]<br />
*[[Gearbox Clutch CVs Fitting Repair Kit_01|Gearlever pivot repair kit - fitting]]<br />
*[[Gearbox Clutch CVs - Gearchange images|Gearchange selection rod pictures and drawings]]<br />
<br />
*[[Gearbox Clutch CVs - Short shifter|Short shifter gearchange kit]]<br />
*[[Gearbox Clutch CVs - Transaxle Code|Transaxle Code]]<br />
*[[Gearbox Clutch CVs - Diesel Uprated Clutch|Diesel Uprated Clutch]]<br />
*[[Gearbox Clutch CVs - Diesel clutch change|Diesel clutch installation considerations]]<br />
*[[Gearbox Clutch CVs - Gearbox type swap|Gearbox type swap (425 & 524)]]<br />
*[[Gearbox Clutch CVs - Diesel Clutch Slave Bracket|Diesel Clutch Slave Bracket - Breakage]]<br />
*[[Gearbox Clutch CVs CV joints drain plug| Drain plug removal, emptying and filling ]]<br />
*[[Gearbox Clutch CVs CV joints Gearbox oil|Gearbox oil]]<br />
*[[Gearbox Clutch CVs - Gearbox corrosion prevention]]<br />
*[http://forum.80-90.co.uk/viewtopic.php?t=30903 80-90 thread on clutch slave cylinder pipes]<br />
<br />
==Common gearbox i.e. automatic and manual==<br />
*[[Gearbox Clutch CVs CV joints diagnosing|Diagnosing]]<br />
*[[Gearbox Clutch CVs Output shaft oil leak repair|Output shaft oil leaks repair]]<br />
<br />
==CV's and Driveshafts==<br />
<br />
*[[Gearbox Clutch CVs CV joints repair|CV joints repair]]<br />
*[[Gearbox Clutch CVs Driveshaft/CVJ condition check|Driveshaft/CVJ condition check]]<br />
<br />
<br />
----<br />
<br />
= VW Electrics (not camper interior specific)=<br />
<br />
*Electrical System<br />
** [[VW Electrics fuse box|Main fuse box]]<br />
** [[Vw Electrics rear lighting wire colours|Rear lighting wire colours]]<br />
** [[VW Electrics Haynes wiring diagrams|Haynes wiring diagrams]]<br />
** [[VW Electrics Starter motor|Starter motor]]<br />
** [[VW Electrics Diesel battery to starter cable|Diesel battery to starter cable]]<br />
** [[VW Electrics Electric wing mirrors|Electric wing mirrors]]<br />
** [[VW Electrics Wiring heated LT Mirrors|Wiring heated LT Mirrors]]<br />
** [[VW Electrics Brake warning light|Brake warning light]]<br />
** [[VW Electrics Windscreen Wipers|Windscreen wiper functions]]<br />
** [[VW Electrics Standard Headlights|Standard Headlights]]<br />
** [[VW Electrics Alternators|Alternators/Generators]]<br />
** [[VW Electrics Non working temperature and/or fuel gauges |Non working temperature and/or fuel gauges]]<br />
** [[VW Electrics rewiring Dashboard multipin connector|Rewiring Dashboard multipin connector]]<br />
** [[VW Electrics Dashboard multipin connector pinout |Dashboard multipin connector pinout]]<br />
** [[VW Electrics Changing Ignition Barrel|Changing Ignition Barrel]]<br />
** [[VW Electrics Changing Ignition Switch|Changing Ignition Switch]]<br />
<br />
*Troubleshooting<br />
** [[VW Electrics bad earths|Bad earths]]<br />
** [[VW Electrics alternator checking|Alternator checking]]<br />
** [[VW Electrics tracing battery discharging cause|Tracing battery discharging cause]]<br />
** [http://assets.fluke.com/appnotes/automotive/beatbook.pdf Some electrical testing procedures from Fluke]<br />
<br />
*Upgrades and Modifications<br />
** [[VW Electrics Fitting intermittent wipers|Intermittent wipers]]<br />
** [[VW Electrics Upgrading headlights|Upgrading headlights]]<br />
** [[VW Electrics Round Headlights To Square|Round Headlights To Square]]<br />
** [[VW Electrics Headlight warning buzzer|Headlight warning buzzer]]<br />
** [[VW Electrics Rear fog lights|Rear fog lights]]<br />
** [[VW Electrics front fog lights|Front fog lights]]<br />
** [[VW Electrics Heater control Illumination|Heater control illumination]]<br />
** [[VW Electrics dash lights upgrade|Dash lights upgrade]]<br />
** [[VW Electrics Alternator sizes|Alternator size formula & tutorial]]<br />
** [[VW Electrics LED Number plate light|LED Number plate light]]<br />
** [[VW Electrics 12 volt live feed only when engine running|12 volt live feed only when engine running]]<br />
** [[VW Electrics Stereo feed from both batteries|Stereo feed from both batteries]]<br />
** [[VW Electrics Adding an independent or new horn|Adding an independent or new horn]]<br />
<br />
<br />
*Pictures, Diagrams, Lists<br />
**[[Petrol engine wiring|Petrol Engine Wiring]]<br />
**[[Diesel engine wiring|Diesel Engine Wiring]]<br />
** [[VW Electrics Alternator 90 Amp Wiring|90 Amp Alternator Wiring]]<br />
<br />
----<br />
<br />
= Steering and Suspension =<br />
* [[Steering and Suspension alternative steering wheels| Alternative steering wheels]]<br />
* [[Steering and Suspension Alignment| Steering geometry/alignment]]<br />
* [[Steering and Suspension Wheel Bearings| Wheel bearings]]<br />
* [[Steering and Suspension springs | Springs]]<br />
* [[Steering and Suspension Anti-roll bar| Anti-roll bar]]<br />
* [[Steering and Suspension Replacing wishbone bushes | Replacing wishbone bushes]]<br />
* [[Steering and Suspension Seized top shock nut| Seized top shock nut]]<br />
* [[Steering and Suspension Replacing wheel studs | Replacing wheel studs]]<br />
* [[Steering and suspension Lowering|Lowering]]<br />
* [[Steering and suspension Radius-rod and bushes|Radius-rod and bushes]]<br />
* [[Steering and suspension power steering|Power steering]]<br />
* [[Steering and suspension power steering Universal Joint Replacement|power steering Universal Joint Replacement]]<br />
* [[Steering and suspension Steering shaft joints|Steering shaft joints]]<br />
* [[Steering and suspension Replacing shock absorbers|Replacing shock absorbers (with Sachs HD)]]<br />
* [[Steering and suspension replace steering rack boot|replace steering rack boot]]<br />
----<br />
<br />
= Wheels and Tyres (not Syncro)=<br />
<br />
<br />
*[[Wheels and tyres - Tyres|Tyres]]<br />
*[[Wheels and tyres - Alternative wheels|Alternative wheels]]<br />
*[[Wheels and Tyres Steering/Wheel Alignment|Steering/Wheel alignment]]<br />
*[[Wheels and Tyres - VW Centre-caps for Merc alloys|VW Centre-caps for Merc alloys]]<br />
*[[Wheels and Tyres - Nut/Bolt Torques|Torques for wheel nuts or bolts]]<br />
*[[Wheels and tyres Wheel offset (ET)|Wheel offset (ET) explained ]]<br />
*[[Wheels and tyres - Speedometer Cable|Speedometer Cable]]<br />
----<br />
<br />
=Brakes=<br />
*[[Brakes front caliper replacement|front caliper replacement]]<br />
*[[Brakes brake pipe parts| Brake pipe parts]]<br />
*[[Brakes Rear Backplate| Rear Backplate]]<br />
*[[Brakes Pulsing brake pedal| Pulsing brake pedal]]<br />
*[[Brakes Rear brake servicing| Rear brake servicing]]<br />
*[[Brakes Bleeding brake system| Bleeding brake system]]<br />
*[[Brakes Bleeding nipples| Bleeding nipples]]<br />
*[[Brakes Front handbrake cable| Front handbrake cable]]<br />
*[[Brakes Rear handbrake cables| Rear handbrake cables]]<br />
*[[Brakes poor brake performance diagnostics| poor brake performance diagnostics]]<br />
----<br />
<br />
= Body Work, Chassis and Glass =<br />
<br />
==Painting your van==<br />
**[[Bodywork and Glass Painting |Painting - General]]<br />
**[[Bodywork and Glass Roller painting |Rollering Rustoleum - Paint your van for £50]]<br />
**[[Bodywork and Glass Window removal and refitting|Window removal and refitting]]<br />
<br />
==Windscreen==<br />
**[[Bodywork and Glass Windscreen Removing|Removing windscreen]]<br />
**[[Bodywork and Glass Windscreen re-fitting|Windscreen re-fitting]]<br />
**[[Bodywork and Glass Leaking windscreen|Leaking windscreen]]<br />
http://campervanculture.com/2011/05/fitting-vw-t25-vanagon-t3-windscreen/<br />
<br />
==Doors==<br />
**[[Bodywork and Glass Doors locks|Door locks and keys]]<br />
**[[Bodywork and Glass Sliding Door and Parts|Sliding Door and parts]]<br />
**[[Bodywork and Glass Door seals|Door seals]]<br />
**[[Bodywork and Glass Guide to fitting Cab Door seals|Guide to fitting Cab Door seals]]<br />
**[[Bodywork and Glass Window scrapers |Window scrapers]]<br />
<br />
==Leaks==<br />
**[[Bodywork and Glass Leaking windscreen|Leaking windscreen]]<br />
**[[Bodywork and Glass Footwell leaks| Foot-well leaks]]<br />
**[[T25 Media Library dripping air vent| Dripping air vent syndrome]]<br />
<br />
==Insulation==<br />
**[[Bodywork and Glass Insulation|Insulation]]<br />
<br />
==Parts==<br />
**[[Bodywork and Glass Parts|Pictures of parts]]<br />
**[[Bodywork and Glass Parts DIY|Pictures of DIY parts]]<br />
<br />
==Rust==<br />
<br />
===General Information===<br />
<br />
**[[Bodywork and Glass - Rust|Rust and some treatments]]<br />
**[[Areas that rust - General|General list of areas that rust]]<br />
**[[Bodywork and Glass - Rust - Elecrolytic de-rusting|Electrolytic de-rusting of parts]]<br />
**[[Techniques - Digicam inspection|Internal section inspection method e.g. for rust]]<br />
<br />
===Specific areas (details, photos, articles, etc)===<br />
<br />
**[[Areas that rust - Kitchen panel|Kitchen/fridge body side panel]] <br />
**[[Areas that rust - Snorkel box|Snorkel box]]<br />
**[[Areas that rust - Rear chassis|Rear chassis]]<br />
**[[Areas that rust - Rear cross-member|Rear cross-member and repair]]<br />
**[[Areas that rust - Front bumper valance|Front bumper valance]]<br />
**[[Areas that rust - Front panel lower|Front panel lower]]<br />
**[[Areas that rust - Cab step|Cab steps]]<br />
**[[Areas that rust - Inner Sills|Inner Sills]]<br />
**[[Areas that rust - Floor sliding door side|Floor - sliding door side]]<br />
**[[Areas that rust - Front jacking points|Front jacking points]]<br />
**[[Areas that rust - Behind VW underseal|Behind VW underseal]]<br />
**[[Areas that rust - Front seat-belt anchors|Seat-belt anchor plates (front)]]<br />
**[[Areas that rust - Bodypanels rear|Rear wing bodypanels]]<br />
**[[Areas that rust - Offside outer sill|Offside (kitchen) outer sill & panel]]<br />
**[[Areas that rust - Window frames|Window frame rust repair]]<br />
**[http://forum.club8090.co.uk/viewtopic.php?f=11&t=32407 Seriously rusty van repairs - shows many areas exposed - excellent photo journal]<br />
<br />
===Other relevant information===<br />
<br />
**[[Bodywork and Glass - Storage|Storage and over-wintering]]<br />
**[[Techniques - Welding|Techniques - Welding]]<br />
**[[General Homemade Chassis cleaning tools|Chassis Cleaning Tools]]<br />
<br />
----<br />
<br />
= Body Accessories Exterior =<br />
*[[Body accessories square headlights| Square headlights alternative]]<br />
* [[Body accessories exterior Wing mirrors|Wing mirrors]]<br />
* [[Body accessories exterior Doka tarps|Doka tarps, tonneaus, covers]]<br />
* [[Body accessories exterior Removing decals and stickers|Removing decals and stickers]]<br />
* [[Body accessories exterior gutter trim |Gutter trim]]<br />
* [[Body Accessories Exterior - Wheel Centre caps|Wheel centre Caps]]<br />
* [[Body accessories intermittant wipers|Intermittant wipers]]<br />
* [[Body Accessories Exterior Left hand drive headlights and the MOT|Left hand drive headlights and the MOT]] <br />
* [[Body Accessories Exterior indicator screws|Indicator screws]]<br />
* [[Body Accessories Exterior Regulations|Regulations]]<br />
* [http://homepage.ntlworld.com/georgina_shaun/T3_website/spoiler_fitting.html Fitting a spoiler]<br />
<br />
----<br />
<br />
=Interior (non camping)=<br />
==Seatbelts==<br />
*[[Interior non camping fitting rear 3 point belts|Fitting rear 3 point belts]]<br />
*[[Interior non camping seatbelt legality|Seatbelt legality]]<br />
<br />
==Seats==<br />
<br />
*[[Interior non camping Caravelle seat arms|Caravelle seat arms]]<br />
*[[Interior non camping alternative front seats|Alternative front seats]]<br />
*[[Interior non camping Headrest fitting to rear seats|Headrests - Fitting to rear seats]]<br />
*[[Interior non camping Headrest removing|Headrests - Removing]]<br />
<br />
==Headlining/ interior panels==<br />
*[[Interior non camping interior panels|Interior panels]]<br />
*[[Interior non camping Headlining replacing|Headlining replacing]]<br />
<br />
==Cab Door Armrests==<br />
*[[Interior non camping Cab Door Armrests|Cab Door Armrests]]<br />
<br />
==Dashboard==<br />
*[[Interior non camping Dashboard removal| Dashboard removal]]<br />
*[[Interior non camping Dash tidy bracket| Dash tidy bracket]]<br />
<br />
==Tailgate==<br />
*[[Interior non camping Tailgate strut lock| Tailgate strut lock (when bike rack fitted)]]<br />
*[[Interior non camping Tailgate Interior latch opening| Tailgate - Interior latch opening]]<br />
<br />
==Multimedia==<br />
*[[Interior non camping stereo fitting| Stereo fitting]]<br />
<br />
==Other==<br />
<br />
<br />
= Campers =<br />
<br />
==Camping Interior Cupboards, beds, etc==<br />
<br />
<br />
* [[Camping Interior safety| Safety]]<br />
<br />
* [[Camping Interior self build|Self build/repair/install, several pages here!]]<br />
* [[Camping Interior Cab bunk|Cab bunk]]<br />
* [[Camping Interior rear hatch ventilation|Rear hatch ventilation]]<br />
* [[Camping Interior Removing units|Removing units]]<br />
* [[Camping Interior Useful Westfalia specific sites|Useful Westfalia specific sites]]<br />
<br />
==Electrical==<br />
* [[Camping Interior - Electrical Safety|Electrical Standards & Safety]]<br />
* [[Camping Interior Westfalia leisure battery charging|Westfalia leisure battery charging]]<br />
* Conversion specific electrical wiring diagrams<br />
**[[Camping Interior Conversion specific electrical wiring diagrams Holdsworth Villa| Holdsworth Villa]]<br />
* [[Camping Interior Fitting a split charger|Fitting a split charger]]<br />
**[[Camping Interior Heavy duty charging|Heavy duty charging]]<br />
* [[Camping Interior Hookup Schemes|Mains Hookup - Schemes and Safety]]<br />
* [[Camping interior Solar power charging systems|Solar power charging systems]]<br />
* [[Camping interior Facts about Auxiliary batteries|Facts about auxiliary batteries]] <br />
* [[Camping Interior Leisure batteries that fit|Leisure batteries FAQ (inluding those that fit) ]]<br />
* [[Camping Interior Leisure battery removal from under swivel seat|Leisure battery removal from under swivel seat]]<br />
* [[Camping Interior Zig Units|Zig units]]<br />
* [[Camping Interior Wiring radio to leisure battery|Wiring radio to leisure battery]]<br />
* [[Camping Interior lighting|Lighting]]<br />
<br />
* [[Camping Interior Inverter efficiency |Inverter efficiency]]<br />
* [[Camping Interior Towing connections|Towing connections]]<br />
<br />
==Heating==<br />
*[[Camping Interior Eberspacher|Eberspacher]]<br />
*[[Camping Interior Propex|Propex]]<br />
*[[Camping Interior Webasto|Webasto]]<br />
*[[Camping Interior Other camping heating|Other camping heating]]<br />
*[[Camping Interior Insulation|Insulation]]<br />
<br />
==Refrigeration==<br />
* [[Camping Interior fridge settings/lighting|Fridge settings/lighting]]<br />
* [[Camping Interior fridge safety/fridge safety|Fridge safety]]<br />
* [[Camping Interior fridge Manuals/fridge Manuals|Fridge Manuals]]<br />
* [[Camping Interior fridge removal|Fridge removal]]<br />
* [[Camping interior fridge servicing/Maintenance|Fridge servicing & maintenance]]<br />
<br />
==Cooking==<br />
* [[Camping Interior Cooking|Cooking suggestions and recipes]]<br />
* [[Camping Interior Gas|Calor Gas facts]]<br />
<br />
==Flooring==<br />
* [[Camping Interior Flooring (Vinyl)|Vinyl Flooring]]<br />
<br />
==Gas==<br />
* [[Camping Interior Gas|Gas information]]<br />
----<br />
<br />
==Camping Exterior Campers exterior ,roofs, windows, skylights, awnings etc==<br />
* [[Camping Exterior Westfalia|Westfalia]]<br />
* [[Camping Exterior Fitting devon roof|Fitting Devon roof]]<br />
* [[Camping Exterior Fitting pop-top|Fitting a pop-top]]<br />
* [[Camping Exterior Electric Hookup|Electric hookup]]<br />
* [[Camping Exterior |Awnings review]]<br />
* [[Camping Exterior stop the drip |Stop the drip]]<br />
* [[Camping Exterior Hightop side windows |Hightop side windows]]<br />
<br />
<br />
* [[Body work and glass - Storage|Storage and over-wintering]]<br />
<br />
==Conversions==<br />
<br />
*[[T25 Media Library camper Conversions| Camper conversions(link to media library)]]<br />
*[http://www.camperinterior.co.uk/index.html Camper Interior website, a photo feast... Take a look!]<br />
*[[Danbury - Instruction Manual for Volkswagen Transporter (1981)|Danbury Instruction Manual for Volkswagen Transporter (1981)]]<br />
*[http://www.80-90.co.uk/techhelp/pdfs/Westy.PDF Westy camper plans in pdf format (German) - Thanks to Aberdeenbus]<br />
<br />
==Karmann Coachbuilts==<br />
<br />
[http://www.vwcampervanblog.com/the-rare-volkswagen-karmann-coachbuilt-camper-van/ The rare Karmann coachbuilt camper van]<br />
<br />
[http://www.karmann-coachbuilts.com/ Volkswagen Karmann Coachbuilts Club]<br />
<br />
==Campsites==<br />
* [[Camping Exterior recommended sites|Recommended sites]]<br />
* [[Camping Exterior sites to avoid|Sites to avoid]]<br />
* [[Camping Exterior overnight parkups|Overnight parkups]]<br />
<br />
==Touring/Camping outside UK==<br />
*[[Touring abroad country specific legal requirements|Touring abroad country specific legal requirements]]<br />
*[[Touring - Sweden|Sweden]]<br />
*[[Ferry services - Spain|Ferry services]]<br />
----<br />
<br />
= Syncro =<br />
*[[Syncro links page| Syncro links page]]<br />
<br />
<br />
<br />
<br />
----<br />
<br />
=T25 Alternative Engine =<br />
*[[Alternative engine 1.9TD|1.9 TD]]<br />
*[[Alternative engine 1.9 Tdi|1.9 Tdi]]<br />
*[[Alternative engine Subaru|Subaru]]<br />
*[[Alternative engine Golf GTI|Golf GTI]]<br />
*[[Alternative engine other|Other]]<br />
<br />
<br />
----<br />
<br />
=General - Techniques, Tools and Tips=<br />
==Useful Data==<br />
<br />
*[[General Fasteners|Fasteners and fastener types]]<br />
<br />
*[[General Fastener Materials|Fastener materials & selection]]<br />
*[[General Torques|Torques]]<br />
*[[General ISO Metric threads| ISO Metric threads, spanner and tapping drill sizes]]<br />
<br />
*[[general list of nut sizes and torques|List of nut sizes and torques]]<br />
*[[General VIN codes - decyphering|VIN codes - decyphering]]<br />
*[[General Oils - Data|Oils - Data]]<br />
*[[General Tyre pressure calc|Tyre pressures - Generic formula]]<br />
<br />
* [http://www.boltscience.com/pages/convert.htm Torque converter]<br />
* [http://www.green-oval.com/data/zeus.pdf Zeus tables in pdf format (16.3 Mb)]<br />
<br />
* [http://www.shender4.com/thread_chart.htm Std. Imperial thread data (US source)]<br />
<br />
==Tools/Sundries/Safety equipment==<br />
<br />
===Tools===<br />
*[[General Rear Brake Adjuster Tool|Brake adjuster tool for rear brakes]]<br />
*[[General Tools for the T25 Home Mechanic |Tools for the T25 Home Mechanic]]<br />
*[[General Thread Taps and Dies|Thread Tap and Die Set]]<br />
*[[General Screw/bolt punch|Screw/Bolt/Nut punch (drift)]]<br />
*[[General Impact Screwdriver|Impact Screwdriver]]<br />
*[[General Screw extractors|Screw extractors (easiouts)]]<br />
*[[General EMPI Rear hub nut spanner|EMPI Rear hub nut spanner]]<br />
*[[General Engineering Scrapers|Engineering scrapers]]<br />
*[[General Oil-seal extractor|Oil-seal extractor]]<br />
*[[General Bench Vise|Bench vise]]<br />
*[[General Thread File|Thread File]]<br />
*[[General Thread Chaser|Thread Chaser]]<br />
*[[General Battery Impact driver|Battery Impact driver]]<br />
*[[General air compressors |Air compressors]]<br />
*[[General Rivnuts|Rivnuts]]<br />
*[[General Welding equipment|Welding equipment]]<br />
*[[General Spot Blaster|Hobby spot-blaster]]<br />
*[[General Glow-plug spanner|Diesel glow-plug removal spanner]]<br />
*[[General Shelter-tent workshop|Shelter-tent workshop]]<br />
*[[General QMAX hole punch|QMAX hole punch]]<br />
*[[General Pipe spanners|Pipe spanners/hydraulics ring spanners/split jaw spanners]]<br />
*[[General Underseal chisel|Underseal chisel]]<br />
*[[General Cleco pins|Cleco (Avdel)locating pins]]<br />
*[[General Stainless Wire Brush|Stainless Wire Brushes]]<br />
*[[General Chain wrench|Chain-wrench/Strap wrench/Pipe wrench]]<br />
*[[General Belt finger sander|Belt (finger) sander {powerfile)]]<br />
*[[General HD vacuum cleaner|HD (or industrial) workshop vacuum cleaner]]<br />
*[[General Joggler|Sheet-metal joggler tool]]<br />
*[[General Battery Chargers|Battery chargers]]<br />
<br />
===Home made tools===<br />
*[[General Homemade gearbox removal clamp|Homemade gearbox removal clamp]]<br />
*[[General Homemade brake bleed pressure device|Brake bleed pressure device]]<br />
*[[General Homemade working light|Cheap working light for inaccessible areas]]<br />
*[[General Homemade Chassis cleaning tools|Chassis cleaning tools]]<br />
*[[General Homemade Welding clamp deep - Improvised|Improvised deep-reach welding clamp]]<br />
*[[General Homemade Welding clamp deep - Home-made|Home-made deep-reach G-clamp]]<br />
*[[General Homemade Soda Blaster attachment for carb cleaning - Home-made|Soda Blaster attachment for carb cleaning]]<br />
*[[General Homemade Emergency Welders|Emergency Welders]]<br />
<br />
===Sundries===<br />
*[[General Duralac anti-corrosion compound|Duralac anti-corrosion assembly compound]]<br />
*[[General Assembly Lube|Assembly lube]]<br />
*[[General LFS|Laminate fibre sheet (LFS) e.g. Tufnol]]<br />
*[[General J-B Weld|J-B Weld epoxy repair]]<br />
*[[General Cold Front|Cold Front (welding)]]<br />
*[[General High Temperature finishes|High-temp paints]]<br />
*[[General Anti-corrosion paint|Weld-thru Zinc spray]]<br />
*[[General Rust-busters|Rust-busters and penetrating oils]]<br />
*[[General EZGrip|EZ-Grip fastener head friction drops]]<br />
*[[General Dinitrol Rust-off|Dinitrol (RC900) Rust-off primer (optional Chassis Black overcoating)]]<br />
*[[General Rustoleum paint|Rustoleum Combi-colour paint]]<br />
<br />
===Safety equipment and H&S usage cautions===<br />
<br />
Safety, Safely & Sagely.<br />
<br />
*[[General Face mask|Goggles & full-face masks (grinding)]]<br />
*[[General Welding masks|Goggles & full-face masks (welding)]]<br />
*[[General Angle Grinder Safety|Angle Grinder - Cautions]]<br />
*[[General Hi-lift Jack Safety|Hi-lift jacks - Safety]]<br />
*[[General - H&S Drilling|Drilling - Safety]]<br />
<br />
==Techniques==<br />
*[[Techniques - Removing seized/broken studs/bolts/nuts|Removing seized/broken studs/bolts/nuts]]<br />
*[[Techniques - Removing rusty screws|Removing rusty screws]]<br />
*[[Techniques - Loosening rear hub nut|Loosening (46mm) rear-hub castle-nut]]<br />
*[[Techniques - Annealing dural sheet/plate|Annealing dural sheet]]<br />
*[[Techniques - Cleaning/Trueing mating faces|Cleaning/Trueing mating faces]]<br />
*[[Techniques - Removing spigot shaft bearing|Removing spigot shaft bearing]]<br />
*[[Techniques - Welding|Welding and brazing]]<br />
*[[Techniques - Bleeding brakes/clutches|Bleeding hydraulic brakes and clutches]]<br />
*[[Techniques - Soldering wires|Soldering wires]] <br />
*[[Techniques - Compression testing|Compression testing]]<br />
*[[Techniques - Removing rust|Removing rust using vinegar (from small components)]]<br />
*[[Techniques - Digicam inspection|Handy method for inspecting inside sills/sections etc]] <br />
<br />
*[http://assets.fluke.com/appnotes/automotive/beatbook.pdf Some electrical testing procedures from Fluke]<br />
*[http://www.ratwell.com/technical/HydraulicLifters.html Hydraulic lifters]<br />
*[[Bodywork and Glass - Rust - Elecrolytic de-rusting]]<br />
*[[General Joggler| Joggling (stepping) panels for seam joins]]<br />
<br />
*[[Techniques - Sheet steel fabrication|Sheet steel fabrication]]<br />
<br />
*[[Techniques - CB radio installation and aerial tuning|CB radio installations and aerial tuning]]<br />
<br />
==Technical Information - non vehicle specific ==<br />
<br />
===Electrical===<br />
<br />
===Mechanical===<br />
<br />
===Other===<br />
<br />
==Featured Parts==<br />
<br />
*[[Parts - Bodywork - Seatbelt anchor plates|Seatbelt anchor nut plates]]<br />
<br />
*[[Parts - Turbo pipework - Murray aviation hose clamp|Murray aviation hose clamp]]<br />
<br />
= Insurance =<br />
*[[Insurance insurance companies Dealing with claims | Dealing with claims ]]<br />
*[[Insurance insurance companies feedback| Insurance companies feedback]]<br />
*[[TEMPLATE copy and paste this for your entry]] <br />
*[[Insurance Camper|Camper]]<br />
*[[Insurance Caravelle|Caravelle]]<br />
*[[Insurance Panel|Panel]]<br />
*[[Insurance DOKA|DOKA]]<br />
*[[Insurance SIKA|SIKA]]<br />
*[[Insurance Non Stock engine and modified|Non stock engine and modified]]<br />
*[[Insurance LPG|LPG]]<br />
*[[Insurance Postcode rating|Postocde rating]]<br />
----<br />
<br />
= Breakdown =<br />
<br />
*[[breakdown ADAC|ADAC (Deutsche AA)]]<br />
*[[breakdown Adrian Flux|Adrian Flux]]<br />
*[[breakdown AA|AA]]<br />
*[[breakdown Freeway (Via Glynwood insurance)|Freeway (Via Glynwood insurance)]]<br />
*[[breakdown CIS|CIS (Co-Op Insurance Services)]]<br />
----<br />
<br />
=T25 Media Library=<br />
*Images<br />
**[[T25 Media Library Classic Photos|Classic Photos]]<br />
**[[T25 Media Library camper Conversions| Camper conversions]]<br />
<br />
*Pictures of hard to get to places and bits you don't normally see (also see Rust and Interiors)<br />
**[[T25 Media Library Interior stripped| Interior parts]]<br />
**[[T25 Media Library Exterior Stripped| Exterior Parts]]<br />
**[[T25 Media Library parts|Parts]]<br />
<br />
*Sounds and video<br />
**[http://meta.wikimedia.org/wiki/Multimedia/Help:Listening_to_sounds Explanation of Ogg sound format]<br />
**[[T25 Media Library Engine| Engine]]<br />
**[[T25 Media Library Suspension| Suspension]]<br />
**[[T25 Media Library dripping air vent| Dripping air vent syndrome]]<br />
----<br />
<br />
=T25 Camper Manuals, VW manuals, Specifications, Literature, Magazine Articles,=<br />
*[http://www.vanagonauts.com/2.1L-Vanagon-Specs234.htm List of torques and specifications, fluids etc ]<br />
*[http://web.mac.com/gbotter/Club_del_Maggiolino_di_Treviso/VW_Camper_T3_A.html Lots of original brochures on an Italian website]<br />
*[[Scanned T25 Literature camper manuals|Camper manuals /Autosleeper Trident/ Autohomes]]<br />
*[[Scanned T25 Literature weight measurments| Specifications/towing/weights/dimensions]]<br />
*[[Scanned T25 Literature VW manuals| VW manuals]]<br />
*[[Scanned T25 Literature VW manuals Technical books| Technical books Haynes etc]]<br />
*[[Scanned T25 Literature brouchers|Brochures]]<br />
*[[Scanned T25 Literature magazine articles|Magazine articles]] <br />
*[http://www.thewoodcrafter.net/proj/prpics/p93/p93.pdf Wooden toy template, can be modified to look more T25]<br />
*[[Scanned T25 Literature Origami|Origami]]<br />
*[[Scanned T25 Literature Manuals|Where to get manuals]]<br />
<br />
*[http://www.vw-mplate.com/mcode.php M-Code M-Plate decipher website]<br />
<br />
----<br />
<br />
=Links & Addresses (Parts, sundries & other useful websites) =<br />
<br />
==Parts & sundry Suppliers/Traders==<br />
*[[Internet Links New Parts suppliers|Parts and sundry supplies]]<br />
*[[Internet Links 2nd Hand Parts suppliers and breakers|2nd hand parts suppliers and breakers]]<br />
*[[Internet Links Mechanics|Mechanics and camper converters]]<br />
*[[Internet Links Carriers/delivery services |Carriers/delivery services]]<br />
*[[Internet Links Electronic and Electrical Services|Electronic (ECU) and Electrical Services]]<br />
*[http://www.dubdoctors.com/ http://www.dubdoctors.com/]<br />
<br />
===Suppliers feedback gleaned from the forum===<br />
<br />
*[[Elite VW]]<br />
<br />
=Internet links - Other relevant websites=<br />
<br />
<br />
<br />
*[[Internet Links non vw related helpful site links| Non VW related helpful site links]]<br />
<br />
*[http://www.transportoffice.gov.uk/crt/doitonline/bl/mottestingmanualsandguides/mottestingmanualsandguides.htm | MOT testers manual in depth, you can download the manual opens as a PDF]<br />
*[http://www.motuk.co.uk/images/Special%20Notice%2009-11.pdf | MOT changes for 2012 opens as a PDF]<br />
*[http://www.bradtech.ltd.uk/ |Thetford portaloo spares]<br />
*[http://s136500617.websitehome.co.uk/gipsy/ Karmann Coachbuilts Website]<br />
*[http://www.jigrah.co.uk/mhpark/Default.htm Hightop-friendly carparks]<br />
*[[Internet Links other T25 and vanagon resources|Other useful T25 and vanagon tech resources]]<br />
*[[Internet Links other VW websites|Other VW websites]]<br />
*[[Internet Links Club suppliers|Club suppliers]]<br />
<br />
*[[Westy jokers]]<br />
*[http://www.type2.com/library/heat/heat-soundproof.html Heat Rust and Noise in VWs (That famous Bulley-Hewlett article)]<br />
*[[Dometic Refrigerators]] <br />
*[http://www.motinfo.gov.uk/internet/jsp/ECHID-Internet-History-Request.jsp MOT advisories online]<br />
*[[Internet Links Stolen Vehicle registers|Stolen Vehicle registers]]<br />
*[http://www.camperinterior.co.uk/index.html Camper Interior website, a photo feast... Take a look!]<br />
*[http://www.opsi.gov.uk/acts/acts1994/ukpga_19940033_en_8#pt5-pb1 Criminal justice act Part V relating to trespass powers to remove, may have a relevance to overnight camping]<br />
*[http://s136500617.websitehome.co.uk/herman/ Herman the German (Westfalia Joker) - lots here incl. interior shots and brochure pics] site not active march20111<br />
*[http://www.vwpix.org/eng/ VWPix, Boltze & Co's VW brochure site]<br />
*[http://sbmcc.co.uk/forum/ SBMCC (Self-build Motor Caravanners Club]<br />
<br />
*[http://www.vw-mplate.com/mcode.php?lang=EN M-Code decoder website(Bottom right, 1979~1991 T3)]<br />
<br />
=Misc tips, tricks and info...(including posting pictures)=<br />
==Computer==<br />
[http://www.geology.enr.state.nc.us/gis/latlon.html Latitude and longtitude format converter]<br />
<br />
[http://homepage.ntlworld.com/robertj.green/T25/Knowledge%20base/GSF-POI/ GSF POI for Tom Tom sat nav]<br />
<br />
*[[Misc tips and tricks 80-90 forum uploading pictures| 80-90 forum uploading pictures]]<br />
*[[Misc tips and tricks 80-90 forum clean url linking| 80-90 forum clean url linking]]<br />
*[[Misc tips and tricks 80-90 Google Eath| Google Earth]] <br />
*[[Misc tips and tricks GSF locations csv|GSF locations csv]]<br />
*[[Misc tips and tricks - How to resize images| How to resize images.]]<br />
*[[Misc tips and tricks installing Firefox|Installing Firefox]]<br />
*[[Misc tips and tricks - Joining the Waze Group|Joining the 80-90 Waze Nav App Group]]<br />
<br />
*[[Misc tips and tricks - Windows PC - Fixing problems|Windows PC - Fixing Problems]]<br />
<br />
==Parts Acquisition==<br />
<br />
*[[Parts Acquisition - Main Dealer|Buying VW parts (UK, Germany and SA]]<br />
*[[Parts Acquisition - Non-Main Dealer|Buying parts from other suppliers - Warning]]<br />
*[[Parts - Non-VW Parts|Non VW parts]]<br />
<br />
==Maintenance Bulletins==<br />
<br />
*[[Fuel System Filler Problems|Filler/filling problems]]<br />
*[[Body work and glass - Storage|Storage and over-wintering]]<br />
*[http://www.type2.com/library/heat/heat-soundproof.html Heat Rust and Noise in VWs (That famous Bulley-Hewlett article)]<br />
<br />
==Fuel Economy==<br />
*[[Fuel economy unofficial|Fuel economy]]<br />
<br />
<br />
==Performance; Power; Dyno results==<br />
*[[Performance - Dyno results|Dynamometer test results]]<br />
----<br />
<br />
=Prices=<br />
[[prices campervans|campervan prices]]<br />
<br />
=Garages, Workshops and services=<br />
==T25==<br />
[[Garages T25 Specific|T25 specific garages]]<br />
==General==<br />
[[Garages General Recommended|Recommended general garages]]<br />
<br />
[[Garages recomended Non UK|Garages recomended Non UK]]<br />
<br />
==Services==<br />
[[Services Recommended|Recommended Services]]<br />
<br />
=Health & Safety=<br />
==Common workshop dangers==<br />
<br />
*[[H&S Dangerous Gases|Highly Dangerous Gases from common workshop sundries]]<br />
<br />
*Safety equipment and H&S usage cautions (From Tools, Techniques & Sundries)<br />
<br />
**[[General Face mask|Goggles & full-face masks (grinding)]]<br />
**[[General Welding masks|Goggles & full-face masks (welding)]]<br />
**[[General Angle Grinder Safety|Angle Grinder - Cautions]]<br />
**[[General - H&S Drilling|Drilling - Safety]]<br />
**[[General Battery charging Hydrogen gas explosion warnings]] <br />
*Safety - Driving -Roadside repairs - Off-road etc<br />
**[[General Hi-lift Jack Safety|Hi-lift jacks - Safety]]</div>HarryMannhttps://club8090.co.uk/w/index.php?title=File:Fastener_Types_Bob_04.jpg&diff=11983File:Fastener Types Bob 04.jpg2013-10-19T14:16:47Z<p>HarryMann: uploaded a new version of "File:Fastener Types Bob 04.jpg"</p>
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<div></div>HarryMannhttps://club8090.co.uk/w/index.php?title=General_Fasteners&diff=11982General Fasteners2013-10-19T14:16:31Z<p>HarryMann: </p>
<hr />
<div>*[http://en.wikipedia.org/wiki/Screw Types of screw fixings (Wikipedia.org page)]<br><br />
<br />
[[File:Fastener_Types_Bob_01.jpg]]<br />
<br />
[[File:Fastener_Types_Bob_02.jpg]]<br />
<br />
[[File:Fastener_Types_Bob_03.jpg]]<br />
<br />
[[File:Fastener_Types_Bob_04.jpg]]<br />
<br />
[[File:Fastener_Types_Bob_05.jpg]]</div>HarryMannhttps://club8090.co.uk/w/index.php?title=File:Fastener_Types_Bob_05.jpg&diff=11981File:Fastener Types Bob 05.jpg2013-10-19T14:15:26Z<p>HarryMann: uploaded a new version of "File:Fastener Types Bob 05.jpg"</p>
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<div></div>HarryMannhttps://club8090.co.uk/w/index.php?title=File:Fastener_Types_Bob_05.jpg&diff=11980File:Fastener Types Bob 05.jpg2013-10-19T14:10:59Z<p>HarryMann: </p>
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<div></div>HarryMannhttps://club8090.co.uk/w/index.php?title=File:Fastener_Types_Bob_04.jpg&diff=11979File:Fastener Types Bob 04.jpg2013-10-19T14:10:43Z<p>HarryMann: </p>
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<div></div>HarryMannhttps://club8090.co.uk/w/index.php?title=File:Fastener_Types_Bob_03.jpg&diff=11978File:Fastener Types Bob 03.jpg2013-10-19T14:10:23Z<p>HarryMann: </p>
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<div></div>HarryMannhttps://club8090.co.uk/w/index.php?title=File:Fastener_Types_Bob_02.jpg&diff=11977File:Fastener Types Bob 02.jpg2013-10-19T14:10:01Z<p>HarryMann: </p>
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<div></div>HarryMannhttps://club8090.co.uk/w/index.php?title=General_Fasteners&diff=11976General Fasteners2013-10-19T14:09:50Z<p>HarryMann: </p>
<hr />
<div>*[http://en.wikipedia.org/wiki/Screw Types of screw fixings (Wikipedia.org page)]<br><br />
<br />
[[File:Fastener_Types_Bob_01.jpg]]<br />
<br />
[[File:Fastener_Types_Bob_02.jpg]]<br />
<br />
[[File:Fastener_Types_Bob_03.jpg]]<br />
<br />
[[File:Fastener_Types_Bob_04.jpg]]<br />
<br />
[[File:Fastener_Types_Bob_05.jpg]]<br />
<br />
[[File:Fastener_Types_Bob_06.jpg]]</div>HarryMannhttps://club8090.co.uk/w/index.php?title=General_Fasteners&diff=11975General Fasteners2013-10-19T14:09:03Z<p>HarryMann: </p>
<hr />
<div>*[http://en.wikipedia.org/wiki/Screw Types of screw fixings (Wikipedia.org page)]<br><br />
<br />
[[File:Fastener_Types_Bob_01.jpg]]<br />
[[File:Fastener_Types_Bob_02.jpg]]<br />
[[File:Fastener_Types_Bob_03.jpg]]<br />
[[File:Fastener_Types_Bob_04.jpg]]<br />
[[File:Fastener_Types_Bob_05.jpg]]<br />
[[File:Fastener_Types_Bob_06.jpg]]</div>HarryMannhttps://club8090.co.uk/w/index.php?title=File:Fastener_Types_Bob_01.jpg&diff=11974File:Fastener Types Bob 01.jpg2013-10-19T14:03:40Z<p>HarryMann: </p>
<hr />
<div></div>HarryMannhttps://club8090.co.uk/w/index.php?title=General_Fasteners&diff=11973General Fasteners2013-10-19T14:03:17Z<p>HarryMann: </p>
<hr />
<div>*[http://en.wikipedia.org/wiki/Screw Types of screw fixings]<br />
<br />
[[File:Fastener_Types_Bob_01.jpg]]</div>HarryMannhttps://club8090.co.uk/w/index.php?title=General_Fasteners&diff=11972General Fasteners2013-10-19T14:01:18Z<p>HarryMann: Created page with ' *[http://en.wikipedia.org/wiki/Screw Types of screw fixings]'</p>
<hr />
<div><br />
*[http://en.wikipedia.org/wiki/Screw Types of screw fixings]</div>HarryMannhttps://club8090.co.uk/w/index.php?title=Main_Page&diff=11971Main Page2013-10-19T14:00:52Z<p>HarryMann: /* Useful Data */</p>
<hr />
<div>'''Welcome to a VW-Tech, the wiki technical archive of the Club 80-90 website.'''<br />
<br />
<br />
<br />
<br />
== NEW USERS START HERE, READ THE DISCLAIMER==<br />
<br />
'''PLEASE READ THE''' [[Disclaimer|'''Disclaimer:''']]<br />
<br />
'''Club 80-90 Wiki History''' <br />
<br />
Started in around 2005 after we moved from an older bulletin board that had been outgrown by the size of the club. A group of long standing club members decided to retain some of the helpful information on the technical pages that would otherwise get lost as the forum was pruned from time to time. Some of the information is basic vehicle mechanics for those that are just starting out. Some is advanced that you will need an extensive toolset to achieve. Some of it you could find in a Hayne's or Bentley manual and sometimes there are fixes that have not been documented and issues that VW had no repair as these vehicles have long since lasted beyond the working life that VW intended them to achieve. This is a collection of postings on 80-90 over the years and has grown to quite a size, some by professional mechanics and some by novices and all levels of knowledge in between. Ultimately it is to be used along side other forums and manuals to give you another viewpoint on how to solve or fix a problem, but usually with a real persons perspective and photographs to help out. It is not meant to be gospel and it is a living work in progress, articles and advice may change as knowledge grows over time. It may be contradictory in parts as different people have different ideas on the best way to perform a procedure. You may need to use some gut instinct and common sense to tell you which way to proceed, there may be a way to do something which hasn't been thought of, or they may be incorrect information which is out of date. The two main wiki editors are HarryMann and Hacksawbob (usernames on Club 80-90) Send a private message to them if you spot something that needs changing. If you have something to add write it up in the Club 80-90 Technical section in the appropriate section and PM an editor to make them aware of it.<br />
<br />
------<br />
<br />
Please stick to the following [[naming convention|naming convention]]. Feel free to add information to the pages you create but please don't alter the section headings as this will have a knock on effect on the naming scheme. It will help subsequent people to add information and will avoid accidental page overwriting or duplication. Please PM Hacksawbob or HarryMann if you have any questions or suggestions. <br />
I appreciate that there will be some overlap between sections, and equally a topic that could appear in several sections, enter your information in the section that you think is most appropriate, it can then be linked to from other pages. Don't enter into discussion on the WIKI, that is for the forum, try and keep the information here as definative an concise as possible. '''''The WIKI is for answers not questions.''''' If you need clarification then try and contact the poster directly or start a new thread on the [http://www.club80-90.co.uk/forum/viewforum.php?f=2| technical forum.]<br />
<br />
==Club 80-90 Wiki en Français==<br />
[[French language pages|French Language pages]]<br />
<br />
==Notices and Bugs==<br />
'''PLEASE READ THE''' [[Disclaimer|'''Disclaimer:''']]<br />
<br />
*Some club 80-90 members are the only ones with editing rights. Please PM HarryMann if you are a seasoned Wiki editor with valuable T3/T25 content to add. Particularly we are looking for those with experience of the early aircooleds, esepcially the carburrettion, ignition and tuning aspects. <br />
<br />
*Red links are pages that do not yet have information added to them (or whose pages have become orphaned, either due to typos in the internal links, or other reasons)<br />
<br />
*Please - Add your name at the beginning of the section you are adding! A good way is to format it as below, including a brief summary - adding a single space at the beginning turns it into a caption (repetitive saves seem to destroy that though) <br />
<br />
e.g. '''Name: ''' Brief summary of what has been added below (and possibly why its important)<br />
<br />
*Please reference your source if what you are posting is not your own. Ask permission first if there is copyright on it, and if it is from another website please put the link to the original URL.<br />
<br />
*[http://meta.wikimedia.org/w/wiki.phtml?title=Meta:Sandbox&action=edit click here for a 'sandbox'] if you want to experiment with wikis before making modifiacations to this one. <br />
<br />
*[http://meta.wikimedia.org/wiki/Help:Editing here is some help on basic Wiki editing]<br />
<br />
----<br />
<br />
= New or Prospective Owner? =<br />
<br />
==* Warnings - Must Read *==<br />
*[[petrol engines Fire warning|Fire warning - Fuel lines, tank, carb etc.]]<br />
*[[Petrol engines aircooled - Fuel Leaks|Fire warning - Aircooled - Carb fuel leaks]]<br />
*[[Gearbox Clutch CVs - Warnings| Gearbox /Transaxle /Diff oil levels]]<br />
*[[Petrol engines Diagnosing faults|Parts quality - Keep old (removed) parts]]<br />
<br />
==Guides==<br />
*[[New/Prospective Owners What are they like to drive? | What are they like? How to drive?]]<br />
*[[Misc tips and tricks buyers guide | The Buyers Guide by Simon Brickyard and others]]<br />
*[[Syncro - Testing|Syncro (4 wheel drive) Buyers guide]]<br />
*[[A newbies buying experience|A newbies buying experience]]<br />
<br />
==Tips and tricks and basic servicing==<br />
*[[Misc tips and tricks New owners questions| New owners' questions (FAQ)]]<br />
*[[Misc tips and tricks spares to carry| Spares and tools to carry]]<br />
*[[New/Prospective Owners| Don't panic!]]<br />
*[[New/Prospective Owners Flat 4 engines primer| Flat 4 engines primer]]<br />
*[[New/Prospective Owners Importing|Importing]]<br />
*[http://www.motinfo.gov.uk/internet/jsp/ECHID-Internet-History-Request.jsp VOSA MOT advisories online, check what might need fixing soon on your prospective purchase]<br />
*[[Gearbox Clutch CVs CV joints gear change reluctance|Gearchange reluctance]]<br />
*[[Gearbox Clutch CVs Sloppy gear change improving|Improving difficult/sloppy gearchange]]<br />
*[[Petrol engines oil change|Petrol engines - Oil & oil changes]]<br />
*[[New/Prospective Owners All engines servicing overview|All engines servicing overview]]<br />
For Maintenance Bulletins look in Misc Tips and Tips<br />
<br />
----<br />
<br />
=Engines=<br />
== Petrol engines (Watercooled)==<br />
[[Image:1.9-DG-watercooled-top1-(with-LPG-system).jpg|thumb|1.9L DG engine (with LPG system)]]<br />
*[[petrol engines Fire warning|Fire warning - Fuel lines, tank, carb etc.]]<br />
*[[petrol engines Not starting diagnostic flow chart|Not starting - Diagnostic flow chart]]<br />
*[[petrol engines engine removal and refitting|Engine removal and refitting]]<br />
*[[petrol engines spark plug types|Spark plug types]]<br />
<br />
*1.9 specific<br />
**[[petrol engines 1.9 Timing|1.9 timing]]<br />
**[[petrol engines - Pierburg Choke|Pierburg Choke Mechanism]]<br />
<br />
*2.1 specific<br />
**[[petrol engines 2.1 Timing|2.1 timing]]<br />
**[[petrol engines intermittent 2.1 | Petrol engines intermittent 2.1 (incl. Vanagon syndrome)]]<br />
**[[petrol engines 2.1 MV|2.1 MV specific]]<br />
**[[petrol engines Bad idling 2.1|Bad idling (2.1 DJ)]]<br />
**[[petrol engines 2.1 ISCU|2.1 ISCU]]<br />
**[[Petrol engines 2.1 Throwing a rod|2.1 Throwing a rod]]<br />
**[[Petrol engines Oil pressure survey|Oil pressure survey]]<br />
**[[Petrol engines Cam follower removal head in place|Cam follower removal head in place]]<br />
**[[Petrol engines 2.1 Other jobs while out|Removing 2.1 - Other jobs whilst out]]<br />
<br />
*General Ignition Info/Debugging<br />
**[[Petrol engines Ignition firing order|Firing order]]<br />
**[[Petrol engines Ignition advance curves|Ignition advance curves]]<br />
**[[Petrol engines Vac advance/retard problems|Vac advance/retard problems]]<br />
<br />
*Parts, Pictures, Diagrams and lists etc.<br />
**[[Petrol engines Parts - Inlet Manifold (1.9)|Inlet Manifold (1.9)]]<br />
**[[Petrol engines Parts - Oil breather hose(1.9)|Oil breather hose(1.9)]]<br />
**[[Petrol engines Parts - petrol Cooling system diagram|petrol Cooling system diagram]]<br />
**[[Petrol engines Parts - wbx exhaust stud depth|wbx exhaust stud depth]]<br />
<br />
==Petrol Engines (Aircooled)==<br />
[[Image:CU-engine-top-1.JPG|thumb|A CU aircooled engine]]<br />
*[[petrol engines aircooled Schematic|Schematic parts layout]]<br />
*[[petrol engines aircooled engine removal|Engine removal]]<br />
*[[petrol engines aircooled - Crankshaft oil seal|Crankshaft oil-seal (photo article, start-to-finish)]]<br />
*[[petrol engines aircooled Differences|Differences between engines]]<br />
<br />
*[[petrol engines aircooled running temperature|Aircooled running temperature]]<br />
*[[petrol engines aircooled performance enhancement|Performance enhancement]]<br />
*[[petrol engines aircooled thermostat|Thermostat]]<br />
*[[petrol engines aircooled solid lifters|Solid lifters]]<br />
*[[petrol engines aircooled push rod & seal replacement|Pushrod & tube seal replacement]]<br />
*[[petrol engines aircooled Oil pressures|Oil pressures]]<br />
<br />
*A/C Petrol engines - Aircooled Cyl. Head<br />
**[[petrol engines aircooled Refitting cylinder heads|Refitting cylinder heads]]<br />
**[[petrol engines aircooled Valves|Re-cutting seats and lapping valves]]<br />
**[[petrol engines aircooled Cylinder Head Damage|Cylinder head damage]]<br />
<br />
*A/C Petrol engines - Aircooled Ignition Systems<br />
**[[petrol engines aircooled Ignition 01|Ignition timing esp. Vac adv/ret hoses]]<br />
**[[petrol engines aircooled Ignition 02|Distributors, timing and setting up]]<br />
**[http://www.youtube.com/watch?v=xm4OmiVH2J0&feature=related Historic a/c Ignition timing videos Part 1]<br />
**[http://www.youtube.com/watch?v=cIrA4iWkhbE&feature=related Historic a/c Ignition timing videos Part 2]<br />
**[[petrol engines aircooled spark plugs|Spark plugs and HT leads]]<br />
<br />
*A/C Petrol engines - Carburrettors and fuel system<br />
**[[Carburrettors - faults and faultfinding]]<br />
**[[Fuel pump - aircooleds|Fuel pump problems]]<br />
**[[Inlet manifolds - aircooleds|Inlet manifolds]]<br />
**[http://www.youtube.com/watch?v=XOxxS1EMphU&feature=related Historic a/c carb tuning videos (PICT 28 ~34) Part 1]<br />
**[http://www.youtube.com/watch?v=KWdZSr7x81w&feature=related Historic a/c carb tuning videos (PICT 28 ~34) Part 2]<br />
<br />
<br />
*A/C Petrol engines - Cooling and heating systems<br />
**[[petrol engines aircooled tinware|Aircooled tinware]]<br />
**[[petrol engines aircooled Cooling and heating 01|Cooling and heating parts]]<br />
**[[petrol engines aircooled Cooling and heating 01|Cooling and heating description]]<br />
<br />
**Hazards<br />
**[[petrol engines aircooled - Fuel Leaks|Fuel leaks]]<br />
<br />
*A/C Petrol engines - Modifications <br />
**[[petrol engines aircooled Modifications|A/C Modifications, carbs, distributors, tuning, compatability issues]]<br />
<br />
==Petrol specific engine Faults/repairs/maintenance==<br />
* [[petrol engines Diagnosing faults|Diagnosing faults (petrols)]]<br />
* [[petrol engines cylinder head spark plug numbers|Cylinder nos. and firing order ]]<br />
* [[petrol engines oil change|Oil change]]<br />
* [[petrol engines engine codes| Engine codes]]<br />
* [[petrol engines cylinder head leak|Cylinder head leak]]<br />
* [[petrol engines losing water|Losing water]]<br />
* [[petrol engines low oil pressure|Low oil pressure]]<br />
* [[Techniques - Removing seized/broken studs/bolts/nuts|Snapped cylinder head bolt]]<br />
* [[petrol engines starter bush removal|Starter motor bush removal]]<br />
* [[petrol engines Overheating|Overheating]]<br />
* [[petrol engines oil emulsifying|Emulsified oil (mayonnaise)]]<br />
* [[petrol engines Oil leaks|Oil leaks]]<br />
* [[Techniques - Compression testing|Compression testing]]<br />
* [[Hydraulic lifters explained ]]<br />
* [[petrol engines non-start|Won't start (fuel)]]<br />
*[[petrol engines spigot-shaft bearing|Replacing spigot-shaft bearing]]<br />
[http://forum.club8090.co.uk/viewtopic.php?t=107122 ]<br />
<br />
== Diesel engines ==<br />
[[Image:Diesel engine1copy-1.jpg|thumb|JX turbo Diesel Engine]]<br />
*[[Diesel engines Fire warning|Fire warning]]<br />
*[[Diesel engines Diagnosis| Types, condition diagnosis, Service Bulletins etc]]<br />
*[[Diesel engines engine codes|Engine codes]]<br />
*[[Diesel engines engine removal and refitting|Engine removal and refitting]]<br />
* Diesel Engines - Turbo<br />
** [[Turbo - Re-indexing|Re-indexing]]<br />
** [[Turbo - Setting-up the Wastegate|Setting-up the wastegate]]<br />
** [[Turbo - Re-installing|Re-installing]]<br />
** [[Turbo - Oil feeds|Oil feeds]]<br />
** [[Turbo - Manifolds|Manifolds/Heat Shields]]<br />
** [[Turbo - Refurbing|Refurbing]]<br />
*[[Diesel engines - Sump/Oil Pump|Sump and oil pump]]<br />
<br />
* Diesel Engines - Servicing<br />
**[[Diesel Engines Auxiliary drive belts|Auxiliary drive belts]]<br />
**[[Diesel Engines Timing Belt_01|Lining-up camshaft and crankshaft]]<br />
**[[Diesel Engines Timing belt|Timing belt/removing camshaft sprocket]]<br />
**[[Diesel Engines Cyl Head re-fitting|Cylinder head re-fitting]]<br />
**[[Diesel Engines Cold-Starting|Cold starting]]<br />
**[[Diesel Engines Inj. pumps - AAZ pump adjustments|AAZ pump adjustments]]<br />
**[[Diesel Engines 1.6 NA CS ring gaps|1.6 NA (CS) ring gaps]]<br />
<br />
**[[Techniques - Compression testing|Compression testing]]<br />
**[[Parts - Part Nos|Rebuild Part Nos and some torques]]<br />
<br />
*Diesel Engines - Parts, pictures, diagrams and lists<br />
** [[Parts - CS Inlet Manifold|CS Inlet Manifold]]<br />
** [[Parts - Engine Damage|Diesel Engine damage]]<br />
** [[Parts - Shadek Oil pump|Shadek oil pump]]<br />
** [[Parts - Part Nos|Rebuild Part Nos and some torques]]<br />
** [[Parts - Cooling system|Cooling system]]<br />
** [[Parts - Crankshaft|Crankshaft and timing pulley]]<br />
** [[Parts - Block and pistons|Block and pistons]]<br />
** [[Parts - Intercooler|Intercooler]]<br />
<br />
<br />
** [[Parts - Rebuild|Rebuilding parts]]<br />
** [[Parts - Gloplug spanner|Glo-plug ratchet spanner]]<br />
** [[Parts - Head gasket protrusion|Head gasket protrusion]]<br />
** [[Parts - Cyl head instr senders - rear|Cyl head instr senders - rear]]<br />
** [[Parts - Cyl head instr senders - side|Cyl head instr senders - side]]<br />
** [[Parts - JX turbo mounting position|JX turbo mounting position]]<br />
<br />
**Diesel Engines - Modified parts<br />
***[[Parts - Modifications - T3 turbo|T3 turbo install]]<br />
***[[Parts - Modifications - Standard Engine Mounts|Standard engine mounts]]<br />
***[[Parts - Modifications - Engine Mounts|Modified engine mounts]]<br />
***[[Parts - Modifications - Silencer custom heat-shield|Silencer - custom heat-shield]]<br />
***[[Parts - Modifications - AAZ Non-JX Mods 01|AAZ turbo clearance mods]]<br />
***[[Parts - Modifications - Oil cooling|Oil cooling and oil coolers]]<br />
***[[Parts - Modifications - Injection pumps|Injection Pumps - Modifying]]<br />
<br />
<br />
*Instruments - <br />
**[[Diesel Engines Instruments|Diesel Engines Instruments]]<br />
<br />
*Links to threads on the 1Y 1.9d (N/A) which is a popular conversion from the 1.6d and 1.7d<br />
**[[List of Links from Ringo|List of links from Ringo]]<br />
<br />
==All engine faults/repairs/maintenance==<br />
<br />
*[[All engine faults/repairs/maintenance Stripped sparkplug thread|Stripped spark plug thread]]<br />
*[[All engine faults/repairs/maintenance Oils recommended|Engine oils - recommended]]<br />
*[[All engine faults/repairs/maintenance Oil filters recomended|Oil filters - recommended]]<br />
*[[All engine faults/repairs/maintenance Replace throttle cable|Replace throttle cable]]<br />
*[[All engine faults/repairs/maintenance Replace starter motor|Replace starter motor]]<br />
*[[All engine faults/repairs/maintenance reluctant starting|Reluctant starting (starter motor)]]<br />
*[[All engine faults/repairs/maintenance reluctant starting (battery alternator)|Reluctant starting (battery alternator)]]<br />
*[[All engine faults/repairs/maintenance reluctant starting Earths|Reluctant starting earths]]<br />
*[[All engine faults/repairs/maintenance reconditioned engines|Reconditioned engines]]<br />
*[[All engine faults/repairs/maintenance Dashboard water level and temperature warnings and causes|Dashboard water level and temperature warnings and causes]]<br />
*[[All engine faults/repairs/maintenance Dashboard oil pressure warnings and causes|Dashboard oil pressure warnings and causes (DOPWS)]]<br />
*[[All engine faults/repairs/maintenance Performance/Longevity|Performance/Longevity]]<br />
*[[All engine faults/repairs/maintenance Air-cooled white smoke|Air-cooled white smoke]]<br />
*[[All engine faults/repairs/maintenance Sump plug problems|Sump plug problems]]<br />
*[[All engine faults/repairs/maintenance Dipstick lengths|Dipstick lengths]]<br />
*[[All engine faults/repairs/maintenance Engine bay seal|Engine bay seal]]<br />
----<br />
<br />
==Exhausts==<br />
<br />
*[[Exhausts Systems Petrol|Petrol Exhausts - Early/Late]]<br />
*[[Exhausts Suppliers|Exhaust system suppliers - Part Nos & Stainless Alternatives]]<br />
*[[Exhausts Custom|Custom exhausts]]<br />
*[[Exhausts Rust|Exhaust rust repairs]]<br />
*[[Exhausts Heat Pipe|DG Exhaust Heat transfer pipe]]<br />
<br />
=Fuel System=<br />
==Diesel==<br />
*[[Diesel - Injectors|Diesel Injectors]]<br />
*[[Diesel - Glow plugs replacing|Glow plugs - replacing]]<br />
*[[Diesel - Injection pumps|Injection pumps]]<br />
*[[Diesel - Fuel system Tips and Tricks|Fuel system Tips and Tricks]]<br />
*[[Diesel - Adding bulb pump primer and transparent fuel lines| Adding bulb pump primer and transparent fuel lines]]<br />
<br />
==Petrol==<br />
<br />
*Common<br />
**[[Petrol engines Fire warning|#Fire warnings# - fuel lines, tank and filler]]<br />
**[[Petrol engines aircooled - Fuel Leaks|#Fuel leaks# - Aircooled]]<br />
<br />
*Injection<br />
**[[Fuel system - Digijet - Brief overview|Brief overview of Digijet injection system]]<br />
<br />
*Carburrettor <br />
**[[Fuel system - 1.9 Fuel hoses|Replacing 1.9 DG Fuel hoses]]<br />
**[[Fuel system - Pierburg |Pierburg carbs]]<br />
**[[Fuel system - 1.9 WBX stops intermittently|1.9 WBX stops intermittently]]<br />
**[[Fuel system - Carburettor removal|Carburettor removal]]<br />
**[[Fuel system - Carburettor Pierburg alternatives|Carburettor Pierburg alternatives]]<br />
**[[Fuel system - Carburettor Air leaks|Carb or manifold air-leaks]]<br />
**[[Fuel system - Carburettor Autochoke|Carb Autochoke setting]]<br />
**[http://archive.club8090.co.uk/viewtopic.php?f=2&t=36598& Intermitten but very annoying problem (blocked jet?)]<br />
**[[Fuel system - Carburettor Clearing blocked jets|Clearing blocked jets]]<br />
<br />
==Common==<br />
*[[Fuel system - Accelerator cable replacement|Acelerator cable replacement]]<br />
*[[Fuel System tank removal |Tank removal]]<br />
*[[Fuel system breather tanks|Breather tanks]]<br />
*[[Fuel economy unofficial|Fuel economy]]<br />
<br />
*[[Fuel System Filler Problems|Filler/filling problems]]<br />
<br />
== Alternative fuels ==<br />
*LPG<br />
**[[Alternative Fuels type of system|Type of system]]<br />
**[[Alternative Fuels spark plugs|Spark plugs]]<br />
**[[Alternative Fuels cheap filling stations|Cheap filling stations]]<br />
**[[Alternative Fuels engine tuning|Engine tuning]]<br />
**[[Alternative Fuels Fuel economy|Fuel economy]]<br />
<br />
*Biodiesel Cooking Oil etc<br />
**[[Alternative Fuels Biodiesel explained|Biodiesel explained]]<br />
**[[Alternative Fuels Cooking Oil feedback|Cooking oil feedback]]<br />
<br />
<br />
----<br />
<br />
=Coolant and Heating=<br />
==Cooling System==<br />
<br />
* [[Coolant and Heating flashing red light on dash|Flashing red light on dash]]<br />
* [[Coolant and Heating recommended brands|Anti-freeze - Brands, specs, dilutions and capacities]]<br />
* [[Coolant and Heating front pipe leaks|Front pipe leaks]]<br />
* [[Coolant and Heating main pipe leaks |Main pipe leaks]]<br />
* [[Coolant and Heating overheating causes and fixes|Overheating causes and fixes]]<br />
* [[Coolant and Heating draining|Drain]]<br />
* [[Coolant and Heating bleeding system|Refilling and bleeding system]]<br />
* [[Coolant and Heating New radiator|New radiator]]<br />
* [[Coolant and Heating running temperatures|Running temperatures]]<br />
* [[Coolant and Heating System overhaul 1|Replacing original front-to-rear metal pipes]]<br />
* [[Coolant and Heating System overhaul 2|Replacing water pump, thermostat and adjoining metal pipes]]<br />
* [[Coolant and Heating Instrumentation malfunction|Temp gauge and sender malfunctions]]<br />
* [[Coolant and Heating Testing radiator fan |Testing radiator fan]]<br />
* [[Coolant and Heating Oil cooling|Oil cooling]]<br />
* [[Coolant and Heating Header tank top and up tank|Header tank and top up tank]]<br />
<br />
==Heating System==<br />
* [[Coolant and Heating heater blower replacement|<br />
Hot & Cold Air Blower - Diagnosis, Removal, Replacement And Modifications]]<br />
* [[Coolant and Heating - Air-cooled heating system|Air-cooled heating system]]<br />
* [[Coolant and Heating - Heater hoses|Heater hoses]]<br />
<br />
*[http://www.type2.com/library/heat/heat-soundproof.html Excellent article on improving VW a/c insulation & heating system]<br />
<br />
----<br />
<br />
= Gearbox Clutch CVJs Driveshafts (not Syncro front)=<br />
==Automatic specific==<br />
<br />
*[[Gearbox Clutch CVs Automatic General Info|Automatics - General Information]]<br />
*[[Gearbox Clutch CVs Automatic Gearbox Oil|Gearbox oil checking/changing]]<br />
*[[Gearbox Clutch CVs Automatic Gearbox Parts|Automatic gearbox - Parts and finding them]]<br />
<br />
==Manual gearbox specific==<br />
*[[Gearbox Clutch CVs - Warnings|Gearbox ##Warnings##]]<br />
<br />
*[[Gearbox Clutch CVs Clutch Pictures|Clutch - pictures]]<br />
*[[Gearbox Clutch CVs clutch slave replacement|Clutch slave cylinder replacement]]<br />
*[[Gearbox Cutch CVs - Clutch slave-cylinder|Clutch slave-cylinder and pipework]]<br />
*[[Gearbox Clutch CVs Clutch pedal not disengaging|Clutch not disengaging]]<br />
*[[Gearbox Clutch CVs - Removing the clutch|Removing the clutch]]<br />
*[[Gearbox Clutch CVs - Re-installing clutch|Re-installing clutch]]<br />
<br />
*[[Gearbox Clutch CVs - Renovating 5 speed change mechanism Pt1|Renovating 5 speed change mechanism Pt1]]<br />
*[[Gearbox Clutch CVs - Renovating 5 speed change mechanism Pt2|Renovating 5 speed change mechanism Pt2]]<br />
*[[Gearbox Clutch CVs - Renovating 5 speed change mechanism - adjustments|Renovating 5 speed change mechanism - adjustments]]<br />
*[[Gearbox Clutch CVs - Gear change reluctance|Gear change reluctance]]<br />
*[[Gearbox Clutch CVs Sloppy gear change improving|Improving sloppy g/c & g/c part nos.]]<br />
*[[Gearbox Clutch CVs Gear selection process|Gear selection process]]<br />
*[[Gearbox Clutch CVs Fitting Repair Kit_01|Gearlever pivot repair kit - fitting]]<br />
*[[Gearbox Clutch CVs - Gearchange images|Gearchange selection rod pictures and drawings]]<br />
<br />
*[[Gearbox Clutch CVs - Short shifter|Short shifter gearchange kit]]<br />
*[[Gearbox Clutch CVs - Transaxle Code|Transaxle Code]]<br />
*[[Gearbox Clutch CVs - Diesel Uprated Clutch|Diesel Uprated Clutch]]<br />
*[[Gearbox Clutch CVs - Diesel clutch change|Diesel clutch installation considerations]]<br />
*[[Gearbox Clutch CVs - Gearbox type swap|Gearbox type swap (425 & 524)]]<br />
*[[Gearbox Clutch CVs - Diesel Clutch Slave Bracket|Diesel Clutch Slave Bracket - Breakage]]<br />
*[[Gearbox Clutch CVs CV joints drain plug| Drain plug removal, emptying and filling ]]<br />
*[[Gearbox Clutch CVs CV joints Gearbox oil|Gearbox oil]]<br />
*[[Gearbox Clutch CVs - Gearbox corrosion prevention]]<br />
*[http://forum.80-90.co.uk/viewtopic.php?t=30903 80-90 thread on clutch slave cylinder pipes]<br />
<br />
==Common geqrbox ie automatic and manual==<br />
*[[Gearbox Clutch CVs CV joints diagnosing|Diagnosing]]<br />
*[[Gearbox Clutch CVs Output shaft oil leak repair|Output shaft oil leaks repair]]<br />
<br />
==CV's and Driveshafts==<br />
<br />
*[[Gearbox Clutch CVs CV joints repair|CV joints repair]]<br />
*[[Gearbox Clutch CVs Driveshaft/CVJ condition check|Driveshaft/CVJ condition check]]<br />
<br />
<br />
----<br />
<br />
= VW Electrics (not camper interior specific)=<br />
<br />
*Electrical System<br />
** [[VW Electrics fuse box|Main fuse box]]<br />
** [[Vw Electrics rear lighting wire colours|Rear lighting wire colours]]<br />
** [[VW Electrics Haynes wiring diagrams|Haynes wiring diagrams]]<br />
** [[VW Electrics Starter motor|Starter motor]]<br />
** [[VW Electrics Diesel battery to starter cable|Diesel battery to starter cable]]<br />
** [[VW Electrics Electric wing mirrors|Electric wing mirrors]]<br />
** [[VW Electrics Wiring heated LT Mirrors|Wiring heated LT Mirrors]]<br />
** [[VW Electrics Brake warning light|Brake warning light]]<br />
** [[VW Electrics Windscreen Wipers|Windscreen wiper functions]]<br />
** [[VW Electrics Standard Headlights|Standard Headlights]]<br />
** [[VW Electrics Alternators|Alternators/Generators]]<br />
** [[VW Electrics Non working temperature and/or fuel gauges |Non working temperature and/or fuel gauges]]<br />
** [[VW Electrics rewiring Dashboard multipin connector|Rewiring Dashboard multipin connector]]<br />
** [[VW Electrics Dashboard multipin connector pinout |Dashboard multipin connector pinout]]<br />
** [[VW Electrics Changing Ignition Barrel|Changing Ignition Barrel]]<br />
** [[VW Electrics Changing Ignition Switch|Changing Ignition Switch]]<br />
<br />
*Troubleshooting<br />
** [[VW Electrics bad earths|Bad earths]]<br />
** [[VW Electrics alternator checking|Alternator checking]]<br />
** [[VW Electrics tracing battery discharging cause|Tracing battery discharging cause]]<br />
** [http://assets.fluke.com/appnotes/automotive/beatbook.pdf Some electrical testing procedures from Fluke]<br />
<br />
*Upgrades and Modifications<br />
** [[VW Electrics Fitting intermittent wipers|Intermittent wipers]]<br />
** [[VW Electrics Upgrading headlights|Upgrading headlights]]<br />
** [[VW Electrics Round Headlights To Square|Round Headlights To Square]]<br />
** [[VW Electrics Headlight warning buzzer|Headlight warning buzzer]]<br />
** [[VW Electrics Rear fog lights|Rear fog lights]]<br />
** [[VW Electrics front fog lights|Front fog lights]]<br />
** [[VW Electrics Heater control Illumination|Heater control illumination]]<br />
** [[VW Electrics dash lights upgrade|Dash lights upgrade]]<br />
** [[VW Electrics Alternator sizes|Alternator size formula & tutorial]]<br />
** [[VW Electrics LED Number plate light|LED Number plate light]]<br />
** [[VW Electrics 12 volt live feed only when engine running|12 volt live feed only when engine running]]<br />
** [[VW Electrics Stereo feed from both batteries|Stereo feed from both batteries]]<br />
** [[VW Electrics Adding an independent or new horn|Adding an independent or new horn]]<br />
<br />
<br />
*Pictures, Diagrams, Lists<br />
**[[Petrol engine wiring|Petrol Engine Wiring]]<br />
**[[Diesel engine wiring|Diesel Engine Wiring]]<br />
** [[VW Electrics Alternator 90 Amp Wiring|90 Amp Alternator Wiring]]<br />
<br />
----<br />
<br />
= Steering and Suspension =<br />
* [[Steering and Suspension alternative steering wheels| Alternative steering wheels]]<br />
* [[Steering and Suspension Alignment| Steering geometry/alignment]]<br />
* [[Steering and Suspension Wheel Bearings| Wheel bearings]]<br />
* [[Steering and Suspension springs | Springs]]<br />
* [[Steering and Suspension Anti-roll bar| Anti-roll bar]]<br />
* [[Steering and Suspension Replacing wishbone bushes | Replacing wishbone bushes]]<br />
* [[Steering and Suspension Seized top shock nut| Seized top shock nut]]<br />
* [[Steering and Suspension Replacing wheel studs | Replacing wheel studs]]<br />
* [[Steering and suspension Lowering|Lowering]]<br />
* [[Steering and suspension Radius-rod and bushes|Radius-rod and bushes]]<br />
* [[Steering and suspension power steering|Power steering]]<br />
* [[Steering and suspension Steering shaft joints|Steering shaft joints]]<br />
* [[Steering and suspension Replacing shock absorbers|Replacing shock absorbers (with Sachs HD)]]<br />
* [[Steering and suspension replace steering rack boot|replace steering rack boot]]<br />
----<br />
<br />
= Wheels and Tyres (not Syncro)=<br />
<br />
<br />
*[[Wheels and tyres - Tyres|Tyres]]<br />
*[[Wheels and tyres - Alternative wheels|Alternative wheels]]<br />
*[[Wheels and Tyres Steering/Wheel Alignment|Steering/Wheel alignment]]<br />
*[[Wheels and Tyres - VW Centre-caps for Merc alloys|VW Centre-caps for Merc alloys]]<br />
*[[Wheels and Tyres - Nut/Bolt Torques|Torques for wheel nuts or bolts]]<br />
*[[Wheels and tyres Wheel offset (ET)|Wheel offset (ET) explained ]]<br />
*[[Wheels and tyres - Speedometer Cable|Speedometer Cable]]<br />
----<br />
<br />
=Brakes=<br />
*[[Brakes front caliper replacement|front caliper replacement]]<br />
*[[Brakes brake pipe parts| Brake pipe parts]]<br />
*[[Brakes Rear Backplate| Rear Backplate]]<br />
*[[Brakes Pulsing brake pedal| Pulsing brake pedal]]<br />
*[[Brakes Rear brake servicing| Rear brake servicing]]<br />
*[[Brakes Bleeding brake system| Bleeding brake system]]<br />
*[[Brakes Bleeding nipples| Bleeding nipples]]<br />
*[[Brakes Front handbrake cable| Front handbrake cable]]<br />
*[[Brakes Rear handbrake cables| Rear handbrake cables]]<br />
*[[Brakes poor brake performance diagnostics| poor brake performance diagnostics]]<br />
----<br />
<br />
= Body Work, Chassis and Glass =<br />
<br />
==Painting your van==<br />
**[[Bodywork and Glass Painting |Painting - General]]<br />
**[[Bodywork and Glass Roller painting |Rollering Rustoleum - Paint your van for £50]]<br />
**[[Bodywork and Glass Window removal and refitting|Window removal and refitting]]<br />
<br />
==Windscreen==<br />
**[[Bodywork and Glass Windscreen Removing|Removing windscreen]]<br />
**[[Bodywork and Glass Windscreen re-fitting|Windscreen re-fitting]]<br />
**[[Bodywork and Glass Leaking windscreen|Leaking windscreen]]<br />
http://campervanculture.com/2011/05/fitting-vw-t25-vanagon-t3-windscreen/<br />
<br />
==Doors==<br />
**[[Bodywork and Glass Doors locks|Door locks and keys]]<br />
**[[Bodywork and Glass Sliding Door and Parts|Sliding Door and parts]]<br />
**[[Bodywork and Glass Door seals|Door seals]]<br />
**[[Bodywork and Glass Guide to fitting Cab Door seals|Guide to fitting Cab Door seals]]<br />
**[[Bodywork and Glass Window scrapers |Window scrapers]]<br />
<br />
==Leaks==<br />
**[[Bodywork and Glass Leaking windscreen|Leaking windscreen]]<br />
**[[Bodywork and Glass Footwell leaks| Foot-well leaks]]<br />
**[[T25 Media Library dripping air vent| Dripping air vent syndrome]]<br />
<br />
==Insulation==<br />
**[[Bodywork and Glass Insulation|Insulation]]<br />
<br />
==Parts==<br />
**[[Bodywork and Glass Parts|Pictures of parts]]<br />
**[[Bodywork and Glass Parts DIY|Pictures of DIY parts]]<br />
<br />
==Rust==<br />
<br />
===General Information===<br />
<br />
**[[Bodywork and Glass - Rust|Rust and some treatments]]<br />
**[[Areas that rust - General|General list of areas that rust]]<br />
**[[Bodywork and Glass - Rust - Elecrolytic de-rusting|Electrolytic de-rusting of parts]]<br />
**[[Techniques - Digicam inspection|Internal section inspection method e.g. for rust]]<br />
<br />
===Specific areas (details, photos, articles, etc)===<br />
<br />
**[[Areas that rust - Kitchen panel|Kitchen/fridge body side panel]] <br />
**[[Areas that rust - Snorkel box|Snorkel box]]<br />
**[[Areas that rust - Rear chassis|Rear chassis]]<br />
**[[Areas that rust - Rear cross-member|Rear cross-member and repair]]<br />
**[[Areas that rust - Front bumper valance|Front bumper valance]]<br />
**[[Areas that rust - Front panel lower|Front panel lower]]<br />
**[[Areas that rust - Cab step|Cab steps]]<br />
**[[Areas that rust - Inner Sills|Inner Sills]]<br />
**[[Areas that rust - Floor sliding door side|Floor - sliding door side]]<br />
**[[Areas that rust - Front jacking points|Front jacking points]]<br />
**[[Areas that rust - Behind VW underseal|Behind VW underseal]]<br />
**[[Areas that rust - Front seat-belt anchors|Seat-belt anchor plates (front)]]<br />
**[[Areas that rust - Bodypanels rear|Rear wing bodypanels]]<br />
**[[Areas that rust - Offside outer sill|Offside (kitchen) outer sill & panel]]<br />
**[[Areas that rust - Window frames|Window frame rust repair]]<br />
**[http://forum.club8090.co.uk/viewtopic.php?f=11&t=32407 Seriously rusty van repairs - shows many areas exposed - excellent photo journal]<br />
<br />
===Other relevant information===<br />
<br />
**[[Bodywork and Glass - Storage|Storage and over-wintering]]<br />
**[[Techniques - Welding|Techniques - Welding]]<br />
**[[General Homemade Chassis cleaning tools|Chassis Cleaning Tools]]<br />
<br />
----<br />
<br />
= Body Accessories Exterior =<br />
*[[Body accessories square headlights| Square headlights alternative]]<br />
* [[Body accessories exterior Wing mirrors|Wing mirrors]]<br />
* [[Body accessories exterior Doka tarps|Doka tarps, tonneaus, covers]]<br />
* [[Body accessories exterior Removing decals and stickers|Removing decals and stickers]]<br />
* [[Body accessories exterior gutter trim |Gutter trim]]<br />
* [[Body Accessories Exterior - Wheel Centre caps|Wheel centre Caps]]<br />
* [[Body accessories intermittant wipers|Intermittant wipers]]<br />
* [[Body Accessories Exterior Left hand drive headlights and the MOT|Left hand drive headlights and the MOT]] <br />
* [[Body Accessories Exterior indicator screws|Indicator screws]]<br />
* [[Body Accessories Exterior Regulations|Regulations]]<br />
* [http://homepage.ntlworld.com/georgina_shaun/T3_website/spoiler_fitting.html Fitting a spoiler]<br />
<br />
----<br />
<br />
=Interior (non camping)=<br />
==Seatbelts==<br />
*[[Interior non camping fitting rear 3 point belts|Fitting rear 3 point belts]]<br />
*[[Interior non camping seatbelt legality|Seatbelt legality]]<br />
<br />
==Seats==<br />
<br />
*[[Interior non camping Caravelle seat arms|Caravelle seat arms]]<br />
*[[Interior non camping alternative front seats|Alternative front seats]]<br />
*[[Interior non camping Headrest fitting to rear seats|Headrests - Fitting to rear seats]]<br />
*[[Interior non camping Headrest removing|Headrests - Removing]]<br />
<br />
==Headlining/ interior panels==<br />
*[[Interior non camping interior panels|Interior panels]]<br />
*[[Interior non camping Headlining replacing|Headlining replacing]]<br />
<br />
==Cab Door Armrests==<br />
*[[Interior non camping Cab Door Armrests|Cab Door Armrests]]<br />
<br />
==Dashboard==<br />
*[[Interior non camping Dashboard removal| Dashboard removal]]<br />
*[[Interior non camping Dash tidy bracket| Dash tidy bracket]]<br />
<br />
==Tailgate==<br />
*[[Interior non camping Tailgate strut lock| Tailgate strut lock (when bike rack fitted)]]<br />
*[[Interior non camping Tailgate Interior latch opening| Tailgate - Interior latch opening]]<br />
<br />
==Multimedia==<br />
*[[Interior non camping stereo fitting| Stereo fitting]]<br />
<br />
==Other==<br />
<br />
<br />
= Campers =<br />
<br />
==Camping Interior Cupboards, beds, etc==<br />
<br />
<br />
* [[Camping Interior safety| Safety]]<br />
<br />
* [[Camping Interior self build|Self build/repair/install, several pages here!]]<br />
* [[Camping Interior Cab bunk|Cab bunk]]<br />
* [[Camping Interior rear hatch ventilation|Rear hatch ventilation]]<br />
* [[Camping Interior Removing units|Removing units]]<br />
* [[Camping Interior Useful Westfalia specific sites|Useful Westfalia specific sites]]<br />
<br />
==Electrical==<br />
* [[Camping Interior - Electrical Safety|Electrical Standards & Safety]]<br />
* [[Camping Interior Westfalia leisure battery charging|Westfalia leisure battery charging]]<br />
* Conversion specific electrical wiring diagrams<br />
**[[Camping Interior Conversion specific electrical wiring diagrams Holdsworth Villa| Holdsworth Villa]]<br />
* [[Camping Interior Fitting a split charger|Fitting a split charger]]<br />
**[[Camping Interior Heavy duty charging|Heavy duty charging]]<br />
* [[Camping Interior Hookup Schemes|Mains Hookup - Schemes and Safety]]<br />
* [[Camping interior Solar power charging systems|Solar power charging systems]]<br />
* [[Camping interior Facts about Auxiliary batteries|Facts about auxiliary batteries]] <br />
* [[Camping Interior Leisure batteries that fit|Leisure batteries FAQ (inluding those that fit) ]]<br />
* [[Camping Interior Leisure battery removal from under swivel seat|Leisure battery removal from under swivel seat]]<br />
* [[Camping Interior Zig Units|Zig units]]<br />
* [[Camping Interior Wiring radio to leisure battery|Wiring radio to leisure battery]]<br />
* [[Camping Interior lighting|Lighting]]<br />
<br />
* [[Camping Interior Inverter efficiency |Inverter efficiency]]<br />
* [[Camping Interior Towing connections|Towing connections]]<br />
<br />
==Heating==<br />
*[[Camping Interior Eberspacher|Eberspacher]]<br />
*[[Camping Interior Propex|Propex]]<br />
*[[Camping Interior Webasto|Webasto]]<br />
*[[Camping Interior Other camping heating|Other camping heating]]<br />
*[[Camping Interior Insulation|Insulation]]<br />
<br />
==Refrigeration==<br />
* [[Camping Interior fridge settings/lighting|Fridge settings/lighting]]<br />
* [[Camping Interior fridge safety/fridge safety|Fridge safety]]<br />
* [[Camping Interior fridge Manuals/fridge Manuals|Fridge Manuals]]<br />
* [[Camping Interior fridge removal|Fridge removal]]<br />
* [[Camping interior fridge servicing/Maintenance|Fridge servicing & maintenance]]<br />
<br />
==Cooking==<br />
* [[Camping Interior Cooking|Cooking suggestions and recipes]]<br />
* [[Camping Interior Gas|Calor Gas facts]]<br />
<br />
==Flooring==<br />
* [[Camping Interior Flooring (Vinyl)|Vinyl Flooring]]<br />
<br />
==Gas==<br />
* [[Camping Interior Gas|Gas information]]<br />
----<br />
<br />
==Camping Exterior Campers exterior ,roofs, windows, skylights, awnings etc==<br />
* [[Camping Exterior Westfalia|Westfalia]]<br />
* [[Camping Exterior Fitting devon roof|Fitting Devon roof]]<br />
* [[Camping Exterior Fitting pop-top|Fitting a pop-top]]<br />
* [[Camping Exterior Electric Hookup|Electric hookup]]<br />
* [[Camping Exterior |Awnings review]]<br />
* [[Camping Exterior stop the drip |Stop the drip]]<br />
* [[Camping Exterior Hightop side windows |Hightop side windows]]<br />
<br />
<br />
* [[Body work and glass - Storage|Storage and over-wintering]]<br />
<br />
==Conversions==<br />
<br />
*[[T25 Media Library camper Conversions| Camper conversions(link to media library)]]<br />
*[http://www.camperinterior.co.uk/index.html Camper Interior website, a photo feast... Take a look!]<br />
*[[Danbury - Instruction Manual for Volkswagen Transporter (1981)|Danbury Instruction Manual for Volkswagen Transporter (1981)]]<br />
*[http://www.80-90.co.uk/techhelp/pdfs/Westy.PDF Westy camper plans in pdf format (German) - Thanks to Aberdeenbus]<br />
<br />
==Karmann Coachbuilts==<br />
<br />
[http://www.vwcampervanblog.com/the-rare-volkswagen-karmann-coachbuilt-camper-van/ The rare Karmann coachbuilt camper van]<br />
<br />
[http://www.karmann-coachbuilts.com/ Volkswagen Karmann Coachbuilts Club]<br />
<br />
==Campsites==<br />
* [[Camping Exterior recommended sites|Recommended sites]]<br />
* [[Camping Exterior sites to avoid|Sites to avoid]]<br />
* [[Camping Exterior overnight parkups|Overnight parkups]]<br />
<br />
==Touring/Camping outside UK==<br />
*[[Touring abroad country specific legal requirements|Touring abroad country specific legal requirements]]<br />
*[[Touring - Sweden|Sweden]]<br />
*[[Ferry services - Spain|Ferry services]]<br />
----<br />
<br />
= Syncro =<br />
*[[Syncro links page| Syncro links page]]<br />
<br />
<br />
<br />
<br />
----<br />
<br />
=T25 Alternative Engine =<br />
*[[Alternative engine 1.9TD|1.9 TD]]<br />
*[[Alternative engine 1.9 Tdi|1.9 Tdi]]<br />
*[[Alternative engine Subaru|Subaru]]<br />
*[[Alternative engine Golf GTI|Golf GTI]]<br />
*[[Alternative engine other|Other]]<br />
<br />
<br />
----<br />
<br />
=General - Techniques, Tools and Tips=<br />
==Useful Data==<br />
<br />
*[[General Fasteners|Fasteners and fastener types]]<br />
<br />
*[[General Fastener Materials|Fastener materials & selection]]<br />
*[[General Torques|Torques]]<br />
*[[General ISO Metric threads| ISO Metric threads, spanner and tapping drill sizes]]<br />
<br />
*[[general list of nut sizes and torques|List of nut sizes and torques]]<br />
*[[General VIN codes - decyphering|VIN codes - decyphering]]<br />
*[[General Oils - Data|Oils - Data]]<br />
*[[General Tyre pressure calc|Tyre pressures - Generic formula]]<br />
<br />
* [http://www.boltscience.com/pages/convert.htm Torque converter]<br />
* [http://www.green-oval.com/data/zeus.pdf Zeus tables in pdf format (16.3 Mb)]<br />
<br />
* [http://www.shender4.com/thread_chart.htm Std. Imperial thread data (US source)]<br />
<br />
==Tools/Sundries/Safety equipment==<br />
<br />
===Tools===<br />
*[[General Rear Brake Adjuster Tool|Brake adjuster tool for rear brakes]]<br />
*[[General Tools for the T25 Home Mechanic |Tools for the T25 Home Mechanic]]<br />
*[[General Thread Taps and Dies|Thread Tap and Die Set]]<br />
*[[General Screw/bolt punch|Screw/Bolt/Nut punch (drift)]]<br />
*[[General Impact Screwdriver|Impact Screwdriver]]<br />
*[[General Screw extractors|Screw extractors (easiouts)]]<br />
*[[General EMPI Rear hub nut spanner|EMPI Rear hub nut spanner]]<br />
*[[General Engineering Scrapers|Engineering scrapers]]<br />
*[[General Oil-seal extractor|Oil-seal extractor]]<br />
*[[General Bench Vise|Bench vise]]<br />
*[[General Thread File|Thread File]]<br />
*[[General Thread Chaser|Thread Chaser]]<br />
*[[General Battery Impact driver|Battery Impact driver]]<br />
*[[General air compressors |Air compressors]]<br />
*[[General Rivnuts|Rivnuts]]<br />
*[[General Welding equipment|Welding equipment]]<br />
*[[General Spot Blaster|Hobby spot-blaster]]<br />
*[[General Glow-plug spanner|Diesel glow-plug removal spanner]]<br />
*[[General Shelter-tent workshop|Shelter-tent workshop]]<br />
*[[General QMAX hole punch|QMAX hole punch]]<br />
*[[General Pipe spanners|Pipe spanners/hydraulics ring spanners/split jaw spanners]]<br />
*[[General Underseal chisel|Underseal chisel]]<br />
*[[General Cleco pins|Cleco (Avdel)locating pins]]<br />
*[[General Stainless Wire Brush|Stainless Wire Brushes]]<br />
*[[General Chain wrench|Chain-wrench/Strap wrench/Pipe wrench]]<br />
*[[General Belt finger sander|Belt (finger) sander {powerfile)]]<br />
*[[General HD vacuum cleaner|HD (or industrial) workshop vacuum cleaner]]<br />
*[[General Joggler|Sheet-metal joggler tool]]<br />
*[[General Battery Chargers|Battery chargers]]<br />
<br />
===Home made tools===<br />
*[[General Homemade gearbox removal clamp|Homemade gearbox removal clamp]]<br />
*[[General Homemade brake bleed pressure device|Brake bleed pressure device]]<br />
*[[General Homemade working light|Cheap working light for inaccessible areas]]<br />
*[[General Homemade Chassis cleaning tools|Chassis cleaning tools]]<br />
*[[General Homemade Welding clamp deep - Improvised|Improvised deep-reach welding clamp]]<br />
*[[General Homemade Welding clamp deep - Home-made|Home-made deep-reach G-clamp]]<br />
*[[General Homemade Soda Blaster attachment for carb cleaning - Home-made|Soda Blaster attachment for carb cleaning]]<br />
*[[General Homemade Emergency Welders|Emergency Welders]]<br />
<br />
===Sundries===<br />
*[[General Duralac anti-corrosion compound|Duralac anti-corrosion assembly compound]]<br />
*[[General Assembly Lube|Assembly lube]]<br />
*[[General LFS|Laminate fibre sheet (LFS) e.g. Tufnol]]<br />
*[[General J-B Weld|J-B Weld epoxy repair]]<br />
*[[General Cold Front|Cold Front (welding)]]<br />
*[[General High Temperature finishes|High-temp paints]]<br />
*[[General Anti-corrosion paint|Weld-thru Zinc spray]]<br />
*[[General Rust-busters|Rust-busters and penetrating oils]]<br />
*[[General EZGrip|EZ-Grip fastener head friction drops]]<br />
*[[General Dinitrol Rust-off|Dinitrol (RC900) Rust-off primer (optional Chassis Black overcoating)]]<br />
*[[General Rustoleum paint|Rustoleum Combi-colour paint]]<br />
<br />
===Safety equipment and H&S usage cautions===<br />
<br />
Safety, Safely & Sagely.<br />
<br />
*[[General Face mask|Goggles & full-face masks (grinding)]]<br />
*[[General Welding masks|Goggles & full-face masks (welding)]]<br />
*[[General Angle Grinder Safety|Angle Grinder - Cautions]]<br />
*[[General Hi-lift Jack Safety|Hi-lift jacks - Safety]]<br />
*[[General - H&S Drilling|Drilling - Safety]]<br />
<br />
==Techniques==<br />
*[[Techniques - Removing seized/broken studs/bolts/nuts|Removing seized/broken studs/bolts/nuts]]<br />
*[[Techniques - Removing rusty screws|Removing rusty screws]]<br />
*[[Techniques - Loosening rear hub nut|Loosening (46mm) rear-hub castle-nut]]<br />
*[[Techniques - Annealing dural sheet/plate|Annealing dural sheet]]<br />
*[[Techniques - Cleaning/Trueing mating faces|Cleaning/Trueing mating faces]]<br />
*[[Techniques - Removing spigot shaft bearing|Removing spigot shaft bearing]]<br />
*[[Techniques - Welding|Welding and brazing]]<br />
*[[Techniques - Bleeding brakes/clutches|Bleeding hydraulic brakes and clutches]]<br />
*[[Techniques - Soldering wires|Soldering wires]] <br />
*[[Techniques - Compression testing|Compression testing]]<br />
*[[Techniques - Removing rust|Removing rust using vinegar (from small components)]]<br />
*[[Techniques - Digicam inspection|Handy method for inspecting inside sills/sections etc]] <br />
<br />
*[http://assets.fluke.com/appnotes/automotive/beatbook.pdf Some electrical testing procedures from Fluke]<br />
*[http://www.ratwell.com/technical/HydraulicLifters.html Hydraulic lifters]<br />
*[[Bodywork and Glass - Rust - Elecrolytic de-rusting]]<br />
*[[General Joggler| Joggling (stepping) panels for seam joins]]<br />
<br />
*[[Techniques - Sheet steel fabrication|Sheet steel fabrication]]<br />
<br />
*[[Techniques - CB radio installation and aerial tuning|CB radio installations and aerial tuning]]<br />
<br />
==Technical Information - non vehicle specific ==<br />
<br />
===Electrical===<br />
<br />
===Mechanical===<br />
<br />
===Other===<br />
<br />
==Featured Parts==<br />
<br />
*[[Parts - Bodywork - Seatbelt anchor plates|Seatbelt anchor nut plates]]<br />
<br />
*[[Parts - Turbo pipework - Murray aviation hose clamp|Murray aviation hose clamp]]<br />
<br />
= Insurance =<br />
*[[Insurance insurance companies Dealing with claims | Dealing with claims ]]<br />
*[[Insurance insurance companies feedback| Insurance companies feedback]]<br />
*[[TEMPLATE copy and paste this for your entry]] <br />
*[[Insurance Camper|Camper]]<br />
*[[Insurance Caravelle|Caravelle]]<br />
*[[Insurance Panel|Panel]]<br />
*[[Insurance DOKA|DOKA]]<br />
*[[Insurance SIKA|SIKA]]<br />
*[[Insurance Non Stock engine and modified|Non stock engine and modified]]<br />
*[[Insurance LPG|LPG]]<br />
*[[Insurance Postcode rating|Postocde rating]]<br />
----<br />
<br />
= Breakdown =<br />
<br />
*[[breakdown ADAC|ADAC (Deutsche AA)]]<br />
*[[breakdown Adrian Flux|Adrian Flux]]<br />
*[[breakdown AA|AA]]<br />
*[[breakdown Freeway (Via Glynwood insurance)|Freeway (Via Glynwood insurance)]]<br />
*[[breakdown CIS|CIS (Co-Op Insurance Services)]]<br />
----<br />
<br />
=T25 Media Library=<br />
*Images<br />
**[[T25 Media Library Classic Photos|Classic Photos]]<br />
**[[T25 Media Library camper Conversions| Camper conversions]]<br />
<br />
*Pictures of hard to get to places and bits you don't normally see (also see Rust and Interiors)<br />
**[[T25 Media Library Interior stripped| Interior parts]]<br />
**[[T25 Media Library Exterior Stripped| Exterior Parts]]<br />
**[[T25 Media Library parts|Parts]]<br />
<br />
*Sounds and video<br />
**[http://meta.wikimedia.org/wiki/Multimedia/Help:Listening_to_sounds Explanation of Ogg sound format]<br />
**[[T25 Media Library Engine| Engine]]<br />
**[[T25 Media Library Suspension| Suspension]]<br />
**[[T25 Media Library dripping air vent| Dripping air vent syndrome]]<br />
----<br />
<br />
=T25 Camper Manuals, VW manuals, Specifications, Literature, Magazine Articles,=<br />
*[http://www.vanagonauts.com/2.1L-Vanagon-Specs234.htm List of torques and specifications, fluids etc ]<br />
*[http://web.mac.com/gbotter/Club_del_Maggiolino_di_Treviso/VW_Camper_T3_A.html Lots of original brochures on an Italian website]<br />
*[[Scanned T25 Literature camper manuals|Camper manuals /Autosleeper Trident/ Autohomes]]<br />
*[[Scanned T25 Literature weight measurments| Specifications/towing/weights/dimensions]]<br />
*[[Scanned T25 Literature VW manuals| VW manuals]]<br />
*[[Scanned T25 Literature VW manuals Technical books| Technical books Haynes etc]]<br />
*[[Scanned T25 Literature brouchers|Brochures]]<br />
*[[Scanned T25 Literature magazine articles|Magazine articles]] <br />
*[http://www.thewoodcrafter.net/proj/prpics/p93/p93.pdf Wooden toy template, can be modified to look more T25]<br />
*[[Scanned T25 Literature Origami|Origami]]<br />
*[[Scanned T25 Literature Manuals|Where to get manuals]]<br />
<br />
*[http://www.vw-mplate.com/mcode.php M-Code M-Plate decipher website]<br />
<br />
----<br />
<br />
=Links & Addresses (Parts, sundries & other useful websites) =<br />
<br />
==Parts & sundry Suppliers/Traders==<br />
*[[Internet Links New Parts suppliers|Parts and sundry supplies]]<br />
*[[Internet Links 2nd Hand Parts suppliers and breakers|2nd hand parts suppliers and breakers]]<br />
*[[Internet Links Mechanics|Mechanics and camper converters]]<br />
*[[Internet Links Carriers/delivery services |Carriers/delivery services]]<br />
*[[Internet Links Electronic and Electrical Services|Electronic (ECU) and Electrical Services]]<br />
*[http://www.dubdoctors.com/ http://www.dubdoctors.com/]<br />
<br />
===Suppliers feedback gleaned from the forum===<br />
<br />
*[[Elite VW]]<br />
<br />
=Internet links - Other relevant websites=<br />
<br />
<br />
<br />
*[[Internet Links non vw related helpful site links| Non VW related helpful site links]]<br />
<br />
*[http://www.transportoffice.gov.uk/crt/doitonline/bl/mottestingmanualsandguides/mottestingmanualsandguides.htm | MOT testers manual in depth, you can download the manual opens as a PDF]<br />
*[http://www.motuk.co.uk/images/Special%20Notice%2009-11.pdf | MOT changes for 2012 opens as a PDF]<br />
*[http://www.bradtech.ltd.uk/ |Thetford portaloo spares]<br />
*[http://s136500617.websitehome.co.uk/gipsy/ Karmann Coachbuilts Website]<br />
*[http://www.jigrah.co.uk/mhpark/Default.htm Hightop-friendly carparks]<br />
*[[Internet Links other T25 and vanagon resources|Other useful T25 and vanagon tech resources]]<br />
*[[Internet Links other VW websites|Other VW websites]]<br />
*[[Internet Links Club suppliers|Club suppliers]]<br />
<br />
*[[Westy jokers]]<br />
*[http://www.type2.com/library/heat/heat-soundproof.html Heat Rust and Noise in VWs (That famous Bulley-Hewlett article)]<br />
*[[Dometic Refrigerators]] <br />
*[http://www.motinfo.gov.uk/internet/jsp/ECHID-Internet-History-Request.jsp MOT advisories online]<br />
*[[Internet Links Stolen Vehicle registers|Stolen Vehicle registers]]<br />
*[http://www.camperinterior.co.uk/index.html Camper Interior website, a photo feast... Take a look!]<br />
*[http://www.opsi.gov.uk/acts/acts1994/ukpga_19940033_en_8#pt5-pb1 Criminal justice act Part V relating to trespass powers to remove, may have a relevance to overnight camping]<br />
*[http://s136500617.websitehome.co.uk/herman/ Herman the German (Westfalia Joker) - lots here incl. interior shots and brochure pics] site not active march20111<br />
*[http://www.vwpix.org/eng/ VWPix, Boltze & Co's VW brochure site]<br />
*[http://sbmcc.co.uk/forum/ SBMCC (Self-build Motor Caravanners Club]<br />
<br />
*[http://www.vw-mplate.com/mcode.php?lang=EN M-Code decoder website(Bottom right, 1979~1991 T3)]<br />
<br />
=Misc tips, tricks and info...(including posting pictures)=<br />
==Computer==<br />
[http://www.geology.enr.state.nc.us/gis/latlon.html Latitude and longtitude format converter]<br />
<br />
[http://homepage.ntlworld.com/robertj.green/T25/Knowledge%20base/GSF-POI/ GSF POI for Tom Tom sat nav]<br />
<br />
*[[Misc tips and tricks 80-90 forum uploading pictures| 80-90 forum uploading pictures]]<br />
*[[Misc tips and tricks 80-90 forum clean url linking| 80-90 forum clean url linking]]<br />
*[[Misc tips and tricks 80-90 Google Eath| Google Earth]] <br />
*[[Misc tips and tricks GSF locations csv|GSF locations csv]]<br />
*[[Misc tips and tricks - How to resize images| How to resize images.]]<br />
*[[Misc tips and tricks installing Firefox|Installing Firefox]]<br />
*[[Misc tips and tricks - Joining the Waze Group|Joining the 80-90 Waze Nav App Group]]<br />
<br />
*[[Misc tips and tricks - Windows PC - Fixing problems|Windows PC - Fixing Problems]]<br />
<br />
==Parts Acquisition==<br />
<br />
*[[Parts Acquisition - Main Dealer|Buying VW parts (UK, Germany and SA]]<br />
*[[Parts Acquisition - Non-Main Dealer|Buying parts from other suppliers - Warning]]<br />
*[[Parts - Non-VW Parts|Non VW parts]]<br />
<br />
==Maintenance Bulletins==<br />
<br />
*[[Fuel System Filler Problems|Filler/filling problems]]<br />
*[[Body work and glass - Storage|Storage and over-wintering]]<br />
*[http://www.type2.com/library/heat/heat-soundproof.html Heat Rust and Noise in VWs (That famous Bulley-Hewlett article)]<br />
<br />
==Fuel Economy==<br />
*[[Fuel economy unofficial|Fuel economy]]<br />
<br />
<br />
==Performance; Power; Dyno results==<br />
*[[Performance - Dyno results|Dynamometer test results]]<br />
----<br />
<br />
=Prices=<br />
[[prices campervans|campervan prices]]<br />
<br />
=Garages, Workshops and services=<br />
==T25==<br />
[[Garages T25 Specific|T25 specific garages]]<br />
==General==<br />
[[Garages General Recommended|Recommended general garages]]<br />
<br />
[[Garages recomended Non UK|Garages recomended Non UK]]<br />
<br />
==Services==<br />
[[Services Recommended|Recommended Services]]<br />
<br />
=Health & Safety=<br />
==Common workshop dangers==<br />
<br />
*[[H&S Dangerous Gases|Highly Dangerous Gases from common workshop sundries]]<br />
<br />
*Safety equipment and H&S usage cautions (From Tools, Techniques & Sundries)<br />
<br />
**[[General Face mask|Goggles & full-face masks (grinding)]]<br />
**[[General Welding masks|Goggles & full-face masks (welding)]]<br />
**[[General Angle Grinder Safety|Angle Grinder - Cautions]]<br />
**[[General - H&S Drilling|Drilling - Safety]]<br />
**[[General Battery charging Hydrogen gas explosion warnings]] <br />
*Safety - Driving -Roadside repairs - Off-road etc<br />
**[[General Hi-lift Jack Safety|Hi-lift jacks - Safety]]</div>HarryMannhttps://club8090.co.uk/w/index.php?title=Steering_and_suspension_Steering_shaft_joints&diff=11970Steering and suspension Steering shaft joints2013-10-16T16:31:33Z<p>HarryMann: /* Steering Column shaft coupling (inside vehicle) */</p>
<hr />
<div>==Steering Column shaft coupling (inside vehicle)==<br />
'''Fullsonian:''' I'm trying to find a replacememt steering coupling for the one at the bottom of the steering shaft in the vehicle cab. <br />
The one that has the two pins passing through, it wears out and makes the steering rattle like hell <br />
Can't find them on brickwerks, anybody know anywhere that does them?<br />
<br />
'''Toolsntat:''' On mine I have 2 rubber grommets that those 2 pins go into and not bare metal. Are your grommets missing? <br />
<br />
'''Fullsonian:''' Thanks for that. The grommets are there but have gone oval. Like I said it knocks like hell over bumps! Going to strip it tomorrow and have a good look...<br />
<br />
'''vern41130:''' Mine has a jubilee clip round it, was wondering why and I'm guessing I've found out!<br />
<br />
Probably not the greatest solution ? Isnt this the bit that's supposed to come apart in a crash to stop you getting a steering wheel to the face <br />
<br />
<br />
'''lhd:''' They make a massive difference when renewed. <br />
<br />
'''cruz:''' This has just reminded me to change my grommet bushes too as my steering has been sloppy in the middle for years.<br />
Obsolete at VW and classic parts. <br />
<br />
They are now only available from Justkampers part number J10271 <br />
<br />
First is the new grommet/bush (2 per van) and coupling (3 per van); Second is where they fit on the van; Third is the old knackered coupling I removed <br />
<br />
[[File:Steering_Couplings_01.jpg]]<br />
<br />
[[File:Steering_Couplings_02.jpg]]<br />
<br />
[[File:Steering_Couplings_031.jpg]]<br />
<br />
One of the runner plate UJ couplings, fits the column approx at the floor aperture position (big rubber boot)<br />
<br />
Two others connect the relay shaft from the relay box to the steering rack.<br />
<br />
NB. Some differences underneath on power-steering models<br />
<br />
'''Cruz:''' Just letting people know that the steering bushes mentioned above are NLA from VW as of the beginning of 2010<br />
<br />
JK to the rescue for £2.30 each (08/2010) [http://www.justkampers.com/shop/steering-column-bush-j10271.html Steering column bushes available from JK]<br />
<br />
<br />
'''toolsntat:''' Just a timely reminder that I had rattly steering for a while, until one day it went clunk and then floppy @@<br />
<br />
It was because one of the bolts on the first flexi-joint had worked loose and then dropped out as we were going along the A14 (a leisure battery terminal bolt saved the day ).<br />
<br />
==Steering Column shaft rubber UJ Couplings (outside vehicle)==<br />
<br />
<br />
These noise isolation UJ's are flat rubber disc/plate type, with 4 push-fit steel bushes taking short M8 nuts and bolts.<br />
<br />
The one at the steering rack end of the return shaft seems to go first, seen many on Syncros that are perished badly, once we saw a Syncro lose or break a bolt.<br />
<br />
At the steering box end, one joint might require removing the splined fitting, if so, scribe the two, so that steering is dead-ahead centre-aligned when refitted!<br />
<br />
<br />
<br />
==Latest Update ==<br />
<br />
'''Cruz:'''<br />
<br />
Steering Column Bushes and Steering Coupling<br />
<br />
Over time the rubber tophat steering column bushes (the area where the column splits in an accident) become oval giving excess play in the steering without anything happening at the wheels. Not good in winds.<br />
<br />
[http://www.youtube.com/watch?v=a37rRKQo0fk Here is a sad video I made ]<br />
<br />
Also the safety coupling at the base of the steering column can also degrade (there is one under the van too) and you can end up with no steering. See mine in the picture below!!<br />
<br />
[http://www.justkampers.com/shop/steering-column-bush-j10271.html Steering column bushes available from JK]<br />
<br />
[http://www.brickwerks.co.uk/index.php/t3-parts/t3-steering/rubber-steering-coupling-t3-iltis.html ..and Couplings from Brickwerks]<br />
<br />
I have attached some images<br />
<br />
First is the new bushes (2 per van) and coupling<br />
<br />
Second is where they fit on the van<br />
<br />
Third is the old knackered coupling I removed<br />
<br />
It's pretty straight forward thing to fix. Just make sure you mark the positions on the spline when dismantling the column so you get it back in the same place.</div>HarryMannhttps://club8090.co.uk/w/index.php?title=Steering_and_suspension_Steering_shaft_joints&diff=11969Steering and suspension Steering shaft joints2013-10-16T16:30:34Z<p>HarryMann: /* Steering Column shaft coupling (inside vehicle) */</p>
<hr />
<div>==Steering Column shaft coupling (inside vehicle)==<br />
'''Fullsonian:''' I'm trying to find a replacememt steering coupling for the one at the bottom of the steering shaft in the vehicle cab. <br />
The one that has the two pins passing through, it wears out and makes the steering rattle like hell <br />
Can't find them on brickwerks, anybody know anywhere that does them?<br />
<br />
'''Toolsntat:''' On mine I have 2 rubber grommets that those 2 pins go into and not bare metal. Are your grommets missing? <br />
<br />
'''Fullsonian:''' Thanks for that. The grommets are there but have gone oval. Like I said it knocks like hell over bumps! Going to strip it tomorrow and have a good look...<br />
<br />
'''vern41130:''' Mine has a jubilee clip round it, was wondering why and I'm guessing I've found out!<br />
<br />
Probably not the greatest solution ? Isnt this the bit that's supposed to come apart in a crash to stop you getting a steering wheel to the face <br />
<br />
<br />
'''lhd:''' They make a massive difference when renewed. <br />
<br />
'''cruz:''' This has just reminded me to change my grommet bushes too as my steering has been sloppy in the middle for years.<br />
Obsolete at VW and classic parts. <br />
<br />
They are now only available from Justkampers part number J10271 <br />
<br />
First is the new grommet/bush (2 per van) and coupling (3 per van); Second is where they fit on the van; Third is the old knackered coupling I removed <br />
<br />
[[File:Steering_Couplings_01.jpg]]<br />
<br />
[[File:Steering_Couplings_02.jpg]]<br />
<br />
[[File:Steering_Couplings_031.jpg]]<br />
<br />
One of the runner plate UJ couplings, fits the column approx at the floor aperture position (big rubber boot)<br />
<br />
Two others connect the relay shaft from the relay box to the steering rack.<br />
<br />
NB. Some differences underneath on power-steering models<br />
<br />
'''Cruz:''' Just letting people know that the steering bushes mentioned above are NLA from VW as of the beginning of 2010<br />
<br />
JK to the rescue for £2.30 each (08/2010) [http://www.justkampers.com/shop/type_25/type-25-original-vehicle-parts/steering/mechanical-components/steering-column-bush-j10271-803419775b.html Top hat rubber steering column grommets from JK]<br />
<br />
<br />
'''toolsntat:''' Just a timely reminder that I had rattly steering for a while, until one day it went clunk and then floppy @@<br />
<br />
It was because one of the bolts on the first flexi-joint had worked loose and then dropped out as we were going along the A14 (a leisure battery terminal bolt saved the day ).<br />
<br />
==Steering Column shaft rubber UJ Couplings (outside vehicle)==<br />
<br />
<br />
These noise isolation UJ's are flat rubber disc/plate type, with 4 push-fit steel bushes taking short M8 nuts and bolts.<br />
<br />
The one at the steering rack end of the return shaft seems to go first, seen many on Syncros that are perished badly, once we saw a Syncro lose or break a bolt.<br />
<br />
At the steering box end, one joint might require removing the splined fitting, if so, scribe the two, so that steering is dead-ahead centre-aligned when refitted!<br />
<br />
<br />
<br />
==Latest Update ==<br />
<br />
'''Cruz:'''<br />
<br />
Steering Column Bushes and Steering Coupling<br />
<br />
Over time the rubber tophat steering column bushes (the area where the column splits in an accident) become oval giving excess play in the steering without anything happening at the wheels. Not good in winds.<br />
<br />
[http://www.youtube.com/watch?v=a37rRKQo0fk Here is a sad video I made ]<br />
<br />
Also the safety coupling at the base of the steering column can also degrade (there is one under the van too) and you can end up with no steering. See mine in the picture below!!<br />
<br />
[http://www.justkampers.com/shop/steering-column-bush-j10271.html Steering column bushes available from JK]<br />
<br />
[http://www.brickwerks.co.uk/index.php/t3-parts/t3-steering/rubber-steering-coupling-t3-iltis.html ..and Couplings from Brickwerks]<br />
<br />
I have attached some images<br />
<br />
First is the new bushes (2 per van) and coupling<br />
<br />
Second is where they fit on the van<br />
<br />
Third is the old knackered coupling I removed<br />
<br />
It's pretty straight forward thing to fix. Just make sure you mark the positions on the spline when dismantling the column so you get it back in the same place.</div>HarryMannhttps://club8090.co.uk/w/index.php?title=Steering_and_suspension_Steering_shaft_joints&diff=11968Steering and suspension Steering shaft joints2013-10-16T16:27:51Z<p>HarryMann: /* Latest Update */</p>
<hr />
<div>==Steering Column shaft coupling (inside vehicle)==<br />
'''Fullsonian:''' I'm trying to find a replacememt steering coupling for the one at the bottom of the steering shaft in the vehicle cab. <br />
The one that has the two pins passing through, it wears out and makes the steering rattle like hell <br />
Can't find them on brickwerks, anybody know anywhere that does them?<br />
<br />
'''Toolsntat:''' On mine I have 2 rubber grommets that those 2 pins go into and not bare metal. Are your grommets missing? <br />
<br />
'''Fullsonian:''' Thanks for that. The grommets are there but have gone oval. Like I said it knocks like hell over bumps! Going to strip it tomorrow and have a good look...<br />
<br />
'''vern41130:''' Mine has a jubilee clip round it, was wondering why and I'm guessing I've found out!<br />
<br />
Probably not the greatest solution ? Isnt this the bit that's supposed to come apart in a crash to stop you getting a steering wheel to the face <br />
<br />
<br />
'''lhd:''' They make a massive difference when renewed. <br />
<br />
'''cruz:''' This has just reminded me to change my grommet bushes too as my steering has been sloppy in the middle for years.<br />
Obsolete at VW and classic parts. <br />
<br />
They are now only available from Justkampers part number J10271 [http://www.justkampers.com/shop/type_25/type-25-original-vehicle-parts/steering/mechanical-components/steering-column-bush-j10271-803419775b.html Justkampers Part Number J10271]<br />
<br />
First is the new grommet/bush (2 per van) and coupling (3 per van); Second is where they fit on the van; Third is the old knackered coupling I removed <br />
<br />
[[File:Steering_Couplings_01.jpg]]<br />
<br />
[[File:Steering_Couplings_02.jpg]]<br />
<br />
[[File:Steering_Couplings_031.jpg]]<br />
<br />
One of the runner plate UJ couplings, fits the column approx at the floor aperture position (Big rubber boot)<br />
<br />
Two others connect the realy shaft from the real;y box to the steering rack <br />
<br />
NB. Some differences underneath on power-steering models<br />
<br />
'''Cruz:''' Just letting people know that the steering bushes mentioned above are NLA from VW as of the beginning of 2010<br />
<br />
JK to the rescue for £2.30 each (08/2010) [http://www.justkampers.com/shop/type_25/type-25-original-vehicle-parts/steering/mechanical-components/steering-column-bush-j10271-803419775b.html Top hat rubber steering column grommets from JK]<br />
<br />
<br />
'''toolsntat:''' Just a timely reminder that I had rattly steering for a while, until one day it went clunk and then floppy @@<br />
<br />
It was because one of the bolts on the first flexi-joint had worked loose and then dropped out as we were going along the A14 (a leisure battery terminal bolt saved the day ).<br />
<br />
==Steering Column shaft rubber UJ Couplings (outside vehicle)==<br />
<br />
<br />
These noise isolation UJ's are flat rubber disc/plate type, with 4 push-fit steel bushes taking short M8 nuts and bolts.<br />
<br />
The one at the steering rack end of the return shaft seems to go first, seen many on Syncros that are perished badly, once we saw a Syncro lose or break a bolt.<br />
<br />
At the steering box end, one joint might require removing the splined fitting, if so, scribe the two, so that steering is dead-ahead centre-aligned when refitted!<br />
<br />
<br />
<br />
==Latest Update ==<br />
<br />
'''Cruz:'''<br />
<br />
Steering Column Bushes and Steering Coupling<br />
<br />
Over time the rubber tophat steering column bushes (the area where the column splits in an accident) become oval giving excess play in the steering without anything happening at the wheels. Not good in winds.<br />
<br />
[http://www.youtube.com/watch?v=a37rRKQo0fk Here is a sad video I made ]<br />
<br />
Also the safety coupling at the base of the steering column can also degrade (there is one under the van too) and you can end up with no steering. See mine in the picture below!!<br />
<br />
[http://www.justkampers.com/shop/steering-column-bush-j10271.html Steering column bushes available from JK]<br />
<br />
[http://www.brickwerks.co.uk/index.php/t3-parts/t3-steering/rubber-steering-coupling-t3-iltis.html ..and Couplings from Brickwerks]<br />
<br />
I have attached some images<br />
<br />
First is the new bushes (2 per van) and coupling<br />
<br />
Second is where they fit on the van<br />
<br />
Third is the old knackered coupling I removed<br />
<br />
It's pretty straight forward thing to fix. Just make sure you mark the positions on the spline when dismantling the column so you get it back in the same place.</div>HarryMannhttps://club8090.co.uk/w/index.php?title=Steering_and_suspension_Steering_shaft_joints&diff=11967Steering and suspension Steering shaft joints2013-10-16T16:26:53Z<p>HarryMann: /* Latest Update */</p>
<hr />
<div>==Steering Column shaft coupling (inside vehicle)==<br />
'''Fullsonian:''' I'm trying to find a replacememt steering coupling for the one at the bottom of the steering shaft in the vehicle cab. <br />
The one that has the two pins passing through, it wears out and makes the steering rattle like hell <br />
Can't find them on brickwerks, anybody know anywhere that does them?<br />
<br />
'''Toolsntat:''' On mine I have 2 rubber grommets that those 2 pins go into and not bare metal. Are your grommets missing? <br />
<br />
'''Fullsonian:''' Thanks for that. The grommets are there but have gone oval. Like I said it knocks like hell over bumps! Going to strip it tomorrow and have a good look...<br />
<br />
'''vern41130:''' Mine has a jubilee clip round it, was wondering why and I'm guessing I've found out!<br />
<br />
Probably not the greatest solution ? Isnt this the bit that's supposed to come apart in a crash to stop you getting a steering wheel to the face <br />
<br />
<br />
'''lhd:''' They make a massive difference when renewed. <br />
<br />
'''cruz:''' This has just reminded me to change my grommet bushes too as my steering has been sloppy in the middle for years.<br />
Obsolete at VW and classic parts. <br />
<br />
They are now only available from Justkampers part number J10271 [http://www.justkampers.com/shop/type_25/type-25-original-vehicle-parts/steering/mechanical-components/steering-column-bush-j10271-803419775b.html Justkampers Part Number J10271]<br />
<br />
First is the new grommet/bush (2 per van) and coupling (3 per van); Second is where they fit on the van; Third is the old knackered coupling I removed <br />
<br />
[[File:Steering_Couplings_01.jpg]]<br />
<br />
[[File:Steering_Couplings_02.jpg]]<br />
<br />
[[File:Steering_Couplings_031.jpg]]<br />
<br />
One of the runner plate UJ couplings, fits the column approx at the floor aperture position (Big rubber boot)<br />
<br />
Two others connect the realy shaft from the real;y box to the steering rack <br />
<br />
NB. Some differences underneath on power-steering models<br />
<br />
'''Cruz:''' Just letting people know that the steering bushes mentioned above are NLA from VW as of the beginning of 2010<br />
<br />
JK to the rescue for £2.30 each (08/2010) [http://www.justkampers.com/shop/type_25/type-25-original-vehicle-parts/steering/mechanical-components/steering-column-bush-j10271-803419775b.html Top hat rubber steering column grommets from JK]<br />
<br />
<br />
'''toolsntat:''' Just a timely reminder that I had rattly steering for a while, until one day it went clunk and then floppy @@<br />
<br />
It was because one of the bolts on the first flexi-joint had worked loose and then dropped out as we were going along the A14 (a leisure battery terminal bolt saved the day ).<br />
<br />
==Steering Column shaft rubber UJ Couplings (outside vehicle)==<br />
<br />
<br />
These noise isolation UJ's are flat rubber disc/plate type, with 4 push-fit steel bushes taking short M8 nuts and bolts.<br />
<br />
The one at the steering rack end of the return shaft seems to go first, seen many on Syncros that are perished badly, once we saw a Syncro lose or break a bolt.<br />
<br />
At the steering box end, one joint might require removing the splined fitting, if so, scribe the two, so that steering is dead-ahead centre-aligned when refitted!<br />
<br />
<br />
<br />
==Latest Update ==<br />
<br />
'''Cruz:'''<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
Steering Column Bushes and Steering Coupling<br />
<br />
Over time the rubber tophat steering column bushes (the area where the column splits in an accident) become oval giving excess play in the steering without anything happening at the wheels. Not good in winds.<br />
<br />
[http://www.youtube.com/watch?v=a37rRKQo0fk Here is a sad video I made ]<br />
<br />
Also the safety coupling at the base of the steering column can also degrade (there is one under the van too) and you can end up with no steering. See mine in the picture below!!<br />
<br />
[http://www.justkampers.com/shop/steering-column-bush-j10271.html Steering column bushes available from JK]<br />
<br />
[http://www.brickwerks.co.uk/index.php/t3-parts/t3-steering/rubber-steering-coupling-t3-iltis.html ..and Couplings from Brickwerks]<br />
<br />
I have attached some images<br />
<br />
First is the new bushes (2 per van) and coupling<br />
<br />
Second is where they fit on the van<br />
<br />
Third is the old knackered coupling I removed<br />
<br />
It's pretty straight forward thing to fix. Just make sure you mark the positions on the spline when dismantling the column so you get it back in the same place.</div>HarryMannhttps://club8090.co.uk/w/index.php?title=Steering_and_suspension_Steering_shaft_joints&diff=11966Steering and suspension Steering shaft joints2013-10-16T16:21:35Z<p>HarryMann: /* Latest Update */</p>
<hr />
<div>==Steering Column shaft coupling (inside vehicle)==<br />
'''Fullsonian:''' I'm trying to find a replacememt steering coupling for the one at the bottom of the steering shaft in the vehicle cab. <br />
The one that has the two pins passing through, it wears out and makes the steering rattle like hell <br />
Can't find them on brickwerks, anybody know anywhere that does them?<br />
<br />
'''Toolsntat:''' On mine I have 2 rubber grommets that those 2 pins go into and not bare metal. Are your grommets missing? <br />
<br />
'''Fullsonian:''' Thanks for that. The grommets are there but have gone oval. Like I said it knocks like hell over bumps! Going to strip it tomorrow and have a good look...<br />
<br />
'''vern41130:''' Mine has a jubilee clip round it, was wondering why and I'm guessing I've found out!<br />
<br />
Probably not the greatest solution ? Isnt this the bit that's supposed to come apart in a crash to stop you getting a steering wheel to the face <br />
<br />
<br />
'''lhd:''' They make a massive difference when renewed. <br />
<br />
'''cruz:''' This has just reminded me to change my grommet bushes too as my steering has been sloppy in the middle for years.<br />
Obsolete at VW and classic parts. <br />
<br />
They are now only available from Justkampers part number J10271 [http://www.justkampers.com/shop/type_25/type-25-original-vehicle-parts/steering/mechanical-components/steering-column-bush-j10271-803419775b.html Justkampers Part Number J10271]<br />
<br />
First is the new grommet/bush (2 per van) and coupling (3 per van); Second is where they fit on the van; Third is the old knackered coupling I removed <br />
<br />
[[File:Steering_Couplings_01.jpg]]<br />
<br />
[[File:Steering_Couplings_02.jpg]]<br />
<br />
[[File:Steering_Couplings_031.jpg]]<br />
<br />
One of the runner plate UJ couplings, fits the column approx at the floor aperture position (Big rubber boot)<br />
<br />
Two others connect the realy shaft from the real;y box to the steering rack <br />
<br />
NB. Some differences underneath on power-steering models<br />
<br />
'''Cruz:''' Just letting people know that the steering bushes mentioned above are NLA from VW as of the beginning of 2010<br />
<br />
JK to the rescue for £2.30 each (08/2010) [http://www.justkampers.com/shop/type_25/type-25-original-vehicle-parts/steering/mechanical-components/steering-column-bush-j10271-803419775b.html Top hat rubber steering column grommets from JK]<br />
<br />
<br />
'''toolsntat:''' Just a timely reminder that I had rattly steering for a while, until one day it went clunk and then floppy @@<br />
<br />
It was because one of the bolts on the first flexi-joint had worked loose and then dropped out as we were going along the A14 (a leisure battery terminal bolt saved the day ).<br />
<br />
==Steering Column shaft rubber UJ Couplings (outside vehicle)==<br />
<br />
<br />
These noise isolation UJ's are flat rubber disc/plate type, with 4 push-fit steel bushes taking short M8 nuts and bolts.<br />
<br />
The one at the steering rack end of the return shaft seems to go first, seen many on Syncros that are perished badly, once we saw a Syncro lose or break a bolt.<br />
<br />
At the steering box end, one joint might require removing the splined fitting, if so, scribe the two, so that steering is dead-ahead centre-aligned when refitted!<br />
<br />
<br />
<br />
==Latest Update ==<br />
<br />
'''Cruz:'''<br />
<br />
[http://www.youtube.com/watch?v=a37rRKQo0fk Here is a sad video I made ]<br />
<br />
[http://www.justkampers.com/shop/steering-column-bush-j10271.html Steering column bushes available from JK]<br />
<br />
[http://www.brickwerks.co.uk/index.php/t3-parts/t3-steering/rubber-steering-coupling-t3-iltis.html And Coupling from Brickwerks]</div>HarryMannhttps://club8090.co.uk/w/index.php?title=File:Itchyfeet_ssb_06.jpg&diff=11965File:Itchyfeet ssb 06.jpg2013-10-14T18:20:01Z<p>HarryMann: </p>
<hr />
<div></div>HarryMannhttps://club8090.co.uk/w/index.php?title=File:Itchyfeet_ssb_05.jpg&diff=11964File:Itchyfeet ssb 05.jpg2013-10-14T18:19:38Z<p>HarryMann: uploaded a new version of "File:Itchyfeet ssb 05.jpg"</p>
<hr />
<div></div>HarryMannhttps://club8090.co.uk/w/index.php?title=File:Itchyfeet_ssb_04.jpg&diff=11963File:Itchyfeet ssb 04.jpg2013-10-14T18:19:08Z<p>HarryMann: uploaded a new version of "File:Itchyfeet ssb 04.jpg"</p>
<hr />
<div></div>HarryMannhttps://club8090.co.uk/w/index.php?title=Petrol_engines_spigot-shaft_bearing&diff=11962Petrol engines spigot-shaft bearing2013-10-14T18:18:35Z<p>HarryMann: /* How to replace a spigot shaft bearing - itchyfeet */</p>
<hr />
<div>== Introduction==<br />
<br />
The spigot shaft bearing is the common name for a (usually needle) bearing (or plain bush ) in the clutch end of the crankshaft that helps to align and support the 'spigot' or gearbox input shaft (sometimes called the 1st motion shaft)<br />
<br />
VW T25(UK)/T3 (Euro) utilise needle rollers beearings as their input shafts project a considerable distance from the first(closest) of the their gearbox support bearings. <br />
<br />
A characteristic of a worn spigot shaft bearing is a rattling from that bellhousing area when the engine is idling in neutral and the clutch engaged... depressing the clucth pedal removes drive to the input shaft and rattling/knocking may cease, a fairly accepted diagnosis.<br />
<br />
Also note that on WBX's there is a felt washer in a recess in the flywheel that might best be changed too, and that you will need the correct needle brg for your engine/gearbox combination<br />
<br />
[HM]<br />
<br />
==Alt Engines and (missing) spigot shaft bearings ==<br />
<br />
'''NB.''' When replacing your T25 engine with another Alt Eng. such as a VW in-line 4 (Golf 1800 etc)<br />
it is wise to check whether it actually has a spigot-shaft bearing in the crankshaft recess.<br />
<br />
Many other engines do not (or have a plain bush) as their 1st motion shaft /input shaft are short and fully cantilevered from the gearbox bearings.<br><br />
This requires one to be fitted to suit the T25 g.box spigot.<br />
<br />
This also applies to Alt Diesel engines.<br />
<br />
The result of overlooking this can do a lot of damage to the input side of the gearbox, such as the oil seal, bearing and oil thrower, and annoys the bejesus out of Aidan to boot :)<br />
<br />
[HM]<br />
<br />
==How to replace a spigot shaft bearing - Aidan==<br />
<br />
<br />
'''Aidan:''' So faced with flywheel<br />
<br />
[[File:spigshftbrg_01.jpg]]<br />
<br />
you need to undo the 5 bolts holding it on - it helps to have an impact gun, but failing that a 2 foot bar and another long bar or a flywheel locking tool to hold the flywheel whilst you undo them 10mm Hex<br />
<br />
leaves you with<br><br />
[[File:spigshftbrg_02.jpg]]<br />
<br />
then armed with your puller or slide hammer<br />
<br><br />
[[File:spigshftbrg_03.jpg]]<br />
<br />
fit into bearing and tighten then fit slide hammer<br />
<br />
<br><br />
[[File:spigshftbrg_04.jpg]]<br />
<br />
and start to pull it<br><br />
[[File:spigshftbrg_05.jpg]]<br />
<br />
till it comes out :ok <br />
<br />
<br />
[[File:spigshftbrg_06.jpg]]<br />
<br />
leaving an empty space in the flywheel with a stop behind<br />
<br><br />
[[File:spigshftbrg_07.jpg]]<br />
<br />
this shows the diesel spigot bearing on the left and petrol on right, the flat face with the writing on faces the gearbox the curved end faces the engine when fitted<br />
<br><br />
[[File:spigshftbrg_08.jpg]]<br />
<br />
as you can see the receiving hole in the crank is 21mm<br />
<br><br />
[[File:spigshftbrg_09.jpg]]<br />
<br />
as is the bearing shell outer diameter<br />
<br><br />
[[File:spigshftbrg_10.jpg]]<br />
<br />
and the inner dimension is 15mm ish - to match the spigot end of the input shaft which will be just under 15mm (like 14.97mm)<br />
<br />
<br><br />
[[File:spigshftbrg_11.jpg]]<br />
<br />
and the felt washer on the petrol engine fits in the recess on the back of the flywheel and the sealing o ring sits in the groove, just visible in the picture<br />
<br><br />
[[File:spigshftbrg_12.jpg]]<br />
<br />
Replace the 'O' ring, the washer and the spigot bearing and reassemble - flywheel bolts need to be tight but VW tightening spec is scary tight as previously noted - 60Nm (44ftlb) plus an added 90degrees - you probably won't get them that tight so use a very little threadlock<br />
<br />
Lube the new bearing with high temp grease :ok<br />
<br />
==How to replace a spigot shaft bearing - itchyfeet==<br />
<br />
OK so I did this today with the Rawlbolt method, tip courtesy of Ian Hulley, probably wasn't broken but as the box was being replaced with an Aidan Talbot rebuild and as it probably has 100K miles on it I though it was time it was done. <br />
<br />
[[File:itchyfeet_ssb_01.jpg]]<br />
<br />
Flywheel needs removing as the bearing won't fit through the hole, for a WBX you need new bolts and an o ring ( oiled with a little fresh oil) and a felt ring. ( Parts all available from Brickwerks)<br />
I replaced the oil seal at the end of last year when the engine was out but this would be another thing I would recommend doing while the flywheel was off.<br />
<br />
<br />
then fit an M8 Rawlbolt through the bearing, and expand it, you don't want it too far in just past the bearing, I added a nut to stop it coming out.<br />
<br />
[[File:itchyfeet_ssb_02.jpg]]<br />
<br />
<br />
Then drill a 20mm hole in a block of wood large enough for the rawlbolt body to slide through, add a large washer and tighten.<br />
<br />
[[File:itchyfeet_ssb_03.jpg]]<br />
<br />
[[File:itchyfeet_ssb_04.jpg]]<br />
<br />
New bearing was tapped in with a wooden drift.<br />
<br />
[[File:itchyfeet_ssb_05.jpg]]<br />
<br />
As the gearbox nearly fell on me when removing it with a trolley jack I added some eyelets under the decking (I used existing holes but worth drilling some I think) and used ratchet straps to refit the gearbox.<br />
<br />
[[File:itchyfeet_ssb_06.jpg]]<br />
<br />
== Links==<br />
Here is a link to a forum thread on this, the 2nd of each pair of links hopefully still working once the topic has been moved to the 80-90 Tech Archive in due course (don't ask!)<br />
<br />
'''itchyfeet:''' thread <br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=120014 Current forum]<br><br />
[http://archive.club8090.co.uk/viewtopic.php?f=37&t=120014 Future Archive]<br />
<br />
'''nickthefish:''' thread <br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=83151 Current forum]<br><br />
[http://archive.club8090.co.uk/viewtopic.php?f=37&t=83151 Current forum]<br />
<br />
<br />
'''jaylo264:''' thread <br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=107122 Current forum]<br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=107122 Current forum]<br />
<br />
<br />
<br />
[http://wiki.club8090.co.uk/index.php/Parts_-_Crankshaft From the diesel spigot-bearing topic]<br />
<br />
<br />
Yes, I'm confused now too, other than that the flywheel has to come off to do petrol spigot bearings and not for diesels @@<br />
<br />
[HM]<br />
<br />
==Other==<br />
<br />
More about spigotty things..</div>HarryMannhttps://club8090.co.uk/w/index.php?title=File:Itchyfeet_ssb_05.jpg&diff=11961File:Itchyfeet ssb 05.jpg2013-10-14T18:15:18Z<p>HarryMann: </p>
<hr />
<div></div>HarryMannhttps://club8090.co.uk/w/index.php?title=File:Itchyfeet_ssb_04.jpg&diff=11960File:Itchyfeet ssb 04.jpg2013-10-14T18:14:55Z<p>HarryMann: </p>
<hr />
<div></div>HarryMannhttps://club8090.co.uk/w/index.php?title=File:Itchyfeet_ssb_03.jpg&diff=11959File:Itchyfeet ssb 03.jpg2013-10-14T18:13:09Z<p>HarryMann: </p>
<hr />
<div></div>HarryMannhttps://club8090.co.uk/w/index.php?title=File:Itchyfeet_ssb_02.jpg&diff=11958File:Itchyfeet ssb 02.jpg2013-10-14T18:12:08Z<p>HarryMann: </p>
<hr />
<div></div>HarryMannhttps://club8090.co.uk/w/index.php?title=File:Itchyfeet_ssb_01.jpg&diff=11957File:Itchyfeet ssb 01.jpg2013-10-14T18:11:28Z<p>HarryMann: </p>
<hr />
<div></div>HarryMannhttps://club8090.co.uk/w/index.php?title=Petrol_engines_spigot-shaft_bearing&diff=11956Petrol engines spigot-shaft bearing2013-10-14T18:11:14Z<p>HarryMann: </p>
<hr />
<div>== Introduction==<br />
<br />
The spigot shaft bearing is the common name for a (usually needle) bearing (or plain bush ) in the clutch end of the crankshaft that helps to align and support the 'spigot' or gearbox input shaft (sometimes called the 1st motion shaft)<br />
<br />
VW T25(UK)/T3 (Euro) utilise needle rollers beearings as their input shafts project a considerable distance from the first(closest) of the their gearbox support bearings. <br />
<br />
A characteristic of a worn spigot shaft bearing is a rattling from that bellhousing area when the engine is idling in neutral and the clutch engaged... depressing the clucth pedal removes drive to the input shaft and rattling/knocking may cease, a fairly accepted diagnosis.<br />
<br />
Also note that on WBX's there is a felt washer in a recess in the flywheel that might best be changed too, and that you will need the correct needle brg for your engine/gearbox combination<br />
<br />
[HM]<br />
<br />
==Alt Engines and (missing) spigot shaft bearings ==<br />
<br />
'''NB.''' When replacing your T25 engine with another Alt Eng. such as a VW in-line 4 (Golf 1800 etc)<br />
it is wise to check whether it actually has a spigot-shaft bearing in the crankshaft recess.<br />
<br />
Many other engines do not (or have a plain bush) as their 1st motion shaft /input shaft are short and fully cantilevered from the gearbox bearings.<br><br />
This requires one to be fitted to suit the T25 g.box spigot.<br />
<br />
This also applies to Alt Diesel engines.<br />
<br />
The result of overlooking this can do a lot of damage to the input side of the gearbox, such as the oil seal, bearing and oil thrower, and annoys the bejesus out of Aidan to boot :)<br />
<br />
[HM]<br />
<br />
==How to replace a spigot shaft bearing - Aidan==<br />
<br />
<br />
'''Aidan:''' So faced with flywheel<br />
<br />
[[File:spigshftbrg_01.jpg]]<br />
<br />
you need to undo the 5 bolts holding it on - it helps to have an impact gun, but failing that a 2 foot bar and another long bar or a flywheel locking tool to hold the flywheel whilst you undo them 10mm Hex<br />
<br />
leaves you with<br><br />
[[File:spigshftbrg_02.jpg]]<br />
<br />
then armed with your puller or slide hammer<br />
<br><br />
[[File:spigshftbrg_03.jpg]]<br />
<br />
fit into bearing and tighten then fit slide hammer<br />
<br />
<br><br />
[[File:spigshftbrg_04.jpg]]<br />
<br />
and start to pull it<br><br />
[[File:spigshftbrg_05.jpg]]<br />
<br />
till it comes out :ok <br />
<br />
<br />
[[File:spigshftbrg_06.jpg]]<br />
<br />
leaving an empty space in the flywheel with a stop behind<br />
<br><br />
[[File:spigshftbrg_07.jpg]]<br />
<br />
this shows the diesel spigot bearing on the left and petrol on right, the flat face with the writing on faces the gearbox the curved end faces the engine when fitted<br />
<br><br />
[[File:spigshftbrg_08.jpg]]<br />
<br />
as you can see the receiving hole in the crank is 21mm<br />
<br><br />
[[File:spigshftbrg_09.jpg]]<br />
<br />
as is the bearing shell outer diameter<br />
<br><br />
[[File:spigshftbrg_10.jpg]]<br />
<br />
and the inner dimension is 15mm ish - to match the spigot end of the input shaft which will be just under 15mm (like 14.97mm)<br />
<br />
<br><br />
[[File:spigshftbrg_11.jpg]]<br />
<br />
and the felt washer on the petrol engine fits in the recess on the back of the flywheel and the sealing o ring sits in the groove, just visible in the picture<br />
<br><br />
[[File:spigshftbrg_12.jpg]]<br />
<br />
Replace the 'O' ring, the washer and the spigot bearing and reassemble - flywheel bolts need to be tight but VW tightening spec is scary tight as previously noted - 60Nm (44ftlb) plus an added 90degrees - you probably won't get them that tight so use a very little threadlock<br />
<br />
Lube the new bearing with high temp grease :ok<br />
<br />
==How to replace a spigot shaft bearing - itchyfeet==<br />
<br />
OK so I did this today with the Rawlbolt method, tip courtesy of Ian Hulley, probably wasn't broken but as the box was being replaced with an Aidan Talbot rebuild and as it probably has 100K miles on it I though it was time it was done. <br />
<br />
[[File:itchyfeet_ssb_01.jpg]]<br />
<br />
Flywheel needs removing as the bearing won't fit through the hole, for a WBX you need new bolts and an o ring ( oiled with a little fresh oil) and a felt ring. ( Parts all available from Brickwerks)<br />
I replaced the oil seal at the end of last year when the engine was out but this would be another thing I would recommend doing while the flywheel was off.<br />
<br />
<br />
then fit an M8 Rawlbolt through the bearing, and expand it, you don't want it too far in just past the bearing, I added a nut to stop it coming out.<br />
<br />
[[File:itchyfeet_ssb_02.jpg]]<br />
<br />
<br />
Then drill a 20mm hole in a block of wood large enough for the rawlbolt body to slide through, add a large washer and tighten.<br />
<br />
[[File:itchyfeet_ssb_03.jpg]]<br />
<br />
[[File:itchyfeet_ssb_04.jpg]]<br />
<br />
New bearing was tapped in with a wooden drift.<br />
<br />
[[File:itchyfeet_ssb_05.jpg]]<br />
<br />
As the gearbox nearly fell on me when removing it with a trolley jack I added some eyelets under the decking (I used existing holes but worth drilling some I think) and used ratchet straps to refit the gearbox.<br />
<br />
[[File:itchyfeet_ssb_06.jpg]]<br />
<br />
<br />
<br />
== Links==<br />
Here is a link to a forum thread on this, the 2nd of each pair of links hopefully still working once the topic has been moved to the 80-90 Tech Archive in due course (don't ask!)<br />
<br />
'''itchyfeet:''' thread <br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=120014 Current forum]<br><br />
[http://archive.club8090.co.uk/viewtopic.php?f=37&t=120014 Future Archive]<br />
<br />
'''nickthefish:''' thread <br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=83151 Current forum]<br><br />
[http://archive.club8090.co.uk/viewtopic.php?f=37&t=83151 Current forum]<br />
<br />
<br />
'''jaylo264:''' thread <br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=107122 Current forum]<br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=107122 Current forum]<br />
<br />
<br />
<br />
[http://wiki.club8090.co.uk/index.php/Parts_-_Crankshaft From the diesel spigot-bearing topic]<br />
<br />
<br />
Yes, I'm confused now too, other than that the flywheel has to come off to do petrol spigot bearings and not for diesels @@<br />
<br />
[HM]<br />
<br />
==Other==<br />
<br />
More about spigotty things..</div>HarryMannhttps://club8090.co.uk/w/index.php?title=Petrol_engines_spigot-shaft_bearing&diff=11955Petrol engines spigot-shaft bearing2013-10-14T18:01:55Z<p>HarryMann: /* Introduction */</p>
<hr />
<div>== Introduction==<br />
<br />
The spigot shaft bearing is the common name for a (usually needle) bearing (or plain bush ) in the clutch end of the crankshaft that helps to align and support the 'spigot' or gearbox input shaft (sometimes called the 1st motion shaft)<br />
<br />
VW T25(UK)/T3 (Euro) utilise needle rollers beearings as their input shafts project a considerable distance from the first(closest) of the their gearbox support bearings. <br />
<br />
A characteristic of a worn spigot shaft bearing is a rattling from that bellhousing area when the engine is idling in neutral and the clutch engaged... depressing the clucth pedal removes drive to the input shaft and rattling/knocking may cease, a fairly accepted diagnosis.<br />
<br />
Also note that on WBX's there is a felt washer in a recess in the flywheel that might best be changed too, and that you will need the correct needle brg for your engine/gearbox combination<br />
<br />
[HM]<br />
<br />
==Alt Engines and (missing) spigot shaft bearings ==<br />
<br />
'''NB.''' When replacing your T25 engine with another Alt Eng. such as a VW in-line 4 (Golf 1800 etc)<br />
it is wise to check whether it actually has a spigot-shaft bearing in the crankshaft recess.<br />
<br />
Many other engines do not (or have a plain bush) as their 1st motion shaft /input shaft are short and fully cantilevered from the gearbox bearings.<br><br />
This requires one to be fitted to suit the T25 g.box spigot.<br />
<br />
This also applies to Alt Diesel engines.<br />
<br />
The result of overlooking this can do a lot of damage to the input side of the gearbox, such as the oil seal, bearing and oil thrower, and annoys the bejesus out of Aidan to boot :)<br />
<br />
[HM]<br />
<br />
==How to replace a spigot shaft bearing==<br />
<br />
<br />
'''Aidan:''' So faced with flywheel<br />
<br />
[[File:spigshftbrg_01.jpg]]<br />
<br />
you need to undo the 5 bolts holding it on - it helps to have an impact gun, but failing that a 2 foot bar and another long bar or a flywheel locking tool to hold the flywheel whilst you undo them 10mm Hex<br />
<br />
leaves you with<br><br />
[[File:spigshftbrg_02.jpg]]<br />
<br />
then armed with your puller or slide hammer<br />
<br><br />
[[File:spigshftbrg_03.jpg]]<br />
<br />
fit into bearing and tighten then fit slide hammer<br />
<br />
<br><br />
[[File:spigshftbrg_04.jpg]]<br />
<br />
and start to pull it<br><br />
[[File:spigshftbrg_05.jpg]]<br />
<br />
till it comes out :ok <br />
<br />
<br />
[[File:spigshftbrg_06.jpg]]<br />
<br />
leaving an empty space in the flywheel with a stop behind<br />
<br><br />
[[File:spigshftbrg_07.jpg]]<br />
<br />
this shows the diesel spigot bearing on the left and petrol on right, the flat face with the writing on faces the gearbox the curved end faces the engine when fitted<br />
<br><br />
[[File:spigshftbrg_08.jpg]]<br />
<br />
as you can see the receiving hole in the crank is 21mm<br />
<br><br />
[[File:spigshftbrg_09.jpg]]<br />
<br />
as is the bearing shell outer diameter<br />
<br><br />
[[File:spigshftbrg_10.jpg]]<br />
<br />
and the inner dimension is 15mm ish - to match the spigot end of the input shaft which will be just under 15mm (like 14.97mm)<br />
<br />
<br><br />
[[File:spigshftbrg_11.jpg]]<br />
<br />
and the felt washer on the petrol engine fits in the recess on the back of the flywheel and the sealing o ring sits in the groove, just visible in the picture<br />
<br><br />
[[File:spigshftbrg_12.jpg]]<br />
<br />
Replace the 'O' ring, the washer and the spigot bearing and reassemble - flywheel bolts need to be tight but VW tightening spec is scary tight as previously noted - 60Nm (44ftlb) plus an added 90degrees - you probably won't get them that tight so use a very little threadlock<br />
<br />
Lube the new bearing with high temp grease :ok<br />
<br />
== Links==<br />
Here is a link to a forum thread on this, the 2nd of each pair of links hopefully still working once the topic has been moved to the 80-90 Tech Archive in due course (don't ask!)<br />
<br />
'''itchyfeet:''' thread <br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=120014 Current forum]<br><br />
[http://archive.club8090.co.uk/viewtopic.php?f=37&t=120014 Future Archive]<br />
<br />
'''nickthefish:''' thread <br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=83151 Current forum]<br><br />
[http://archive.club8090.co.uk/viewtopic.php?f=37&t=83151 Current forum]<br />
<br />
<br />
'''jaylo264:''' thread <br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=107122 Current forum]<br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=107122 Current forum]<br />
<br />
<br />
<br />
[http://wiki.club8090.co.uk/index.php/Parts_-_Crankshaft From the diesel spigot-bearing topic]<br />
<br />
<br />
Yes, I'm confused now too, other than that the flywheel has to come off to do petrol spigot bearings and not for diesels @@<br />
<br />
[HM]<br />
<br />
==Other==<br />
<br />
More about spigotty things..</div>HarryMannhttps://club8090.co.uk/w/index.php?title=Petrol_engines_spigot-shaft_bearing&diff=11954Petrol engines spigot-shaft bearing2013-10-14T18:00:29Z<p>HarryMann: /* Links */</p>
<hr />
<div>== Introduction==<br />
<br />
The spigot shaft bearing is the common name for a (usually needle) bearing (or plain bush ) in the clutch end of the crankshaft that helps to align and support the 'spigot' or gearbox input shaft (sometimes called the 1st motion shaft)<br />
<br />
VW T25(UK)/T3 (Euro) utilise needle rollers beearings as their input shafts project a considerable distance from the first(closest) of the their gearbox support bearings. <br />
<br />
A characteristic of a worn spigot shaft bearing is a rattling from that bellhousing area when the engine is idling in neutral and the clutch engaged... depressing the clucth pedal removes drive to the input shaft and rattling/knocking may cease, a fairly accepted diagnosis.<br />
<br />
[HM]<br />
<br />
==Alt Engines and (missing) spigot shaft bearings ==<br />
<br />
'''NB.''' When replacing your T25 engine with another Alt Eng. such as a VW in-line 4 (Golf 1800 etc)<br />
it is wise to check whether it actually has a spigot-shaft bearing in the crankshaft recess.<br />
<br />
Many other engines do not (or have a plain bush) as their 1st motion shaft /input shaft are short and fully cantilevered from the gearbox bearings.<br><br />
This requires one to be fitted to suit the T25 g.box spigot.<br />
<br />
This also applies to Alt Diesel engines.<br />
<br />
The result of overlooking this can do a lot of damage to the input side of the gearbox, such as the oil seal, bearing and oil thrower, and annoys the bejesus out of Aidan to boot :)<br />
<br />
[HM]<br />
<br />
==How to replace a spigot shaft bearing==<br />
<br />
<br />
'''Aidan:''' So faced with flywheel<br />
<br />
[[File:spigshftbrg_01.jpg]]<br />
<br />
you need to undo the 5 bolts holding it on - it helps to have an impact gun, but failing that a 2 foot bar and another long bar or a flywheel locking tool to hold the flywheel whilst you undo them 10mm Hex<br />
<br />
leaves you with<br><br />
[[File:spigshftbrg_02.jpg]]<br />
<br />
then armed with your puller or slide hammer<br />
<br><br />
[[File:spigshftbrg_03.jpg]]<br />
<br />
fit into bearing and tighten then fit slide hammer<br />
<br />
<br><br />
[[File:spigshftbrg_04.jpg]]<br />
<br />
and start to pull it<br><br />
[[File:spigshftbrg_05.jpg]]<br />
<br />
till it comes out :ok <br />
<br />
<br />
[[File:spigshftbrg_06.jpg]]<br />
<br />
leaving an empty space in the flywheel with a stop behind<br />
<br><br />
[[File:spigshftbrg_07.jpg]]<br />
<br />
this shows the diesel spigot bearing on the left and petrol on right, the flat face with the writing on faces the gearbox the curved end faces the engine when fitted<br />
<br><br />
[[File:spigshftbrg_08.jpg]]<br />
<br />
as you can see the receiving hole in the crank is 21mm<br />
<br><br />
[[File:spigshftbrg_09.jpg]]<br />
<br />
as is the bearing shell outer diameter<br />
<br><br />
[[File:spigshftbrg_10.jpg]]<br />
<br />
and the inner dimension is 15mm ish - to match the spigot end of the input shaft which will be just under 15mm (like 14.97mm)<br />
<br />
<br><br />
[[File:spigshftbrg_11.jpg]]<br />
<br />
and the felt washer on the petrol engine fits in the recess on the back of the flywheel and the sealing o ring sits in the groove, just visible in the picture<br />
<br><br />
[[File:spigshftbrg_12.jpg]]<br />
<br />
Replace the 'O' ring, the washer and the spigot bearing and reassemble - flywheel bolts need to be tight but VW tightening spec is scary tight as previously noted - 60Nm (44ftlb) plus an added 90degrees - you probably won't get them that tight so use a very little threadlock<br />
<br />
Lube the new bearing with high temp grease :ok<br />
<br />
== Links==<br />
Here is a link to a forum thread on this, the 2nd of each pair of links hopefully still working once the topic has been moved to the 80-90 Tech Archive in due course (don't ask!)<br />
<br />
'''itchyfeet:''' thread <br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=120014 Current forum]<br><br />
[http://archive.club8090.co.uk/viewtopic.php?f=37&t=120014 Future Archive]<br />
<br />
'''nickthefish:''' thread <br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=83151 Current forum]<br><br />
[http://archive.club8090.co.uk/viewtopic.php?f=37&t=83151 Current forum]<br />
<br />
<br />
'''jaylo264:''' thread <br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=107122 Current forum]<br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=107122 Current forum]<br />
<br />
<br />
<br />
[http://wiki.club8090.co.uk/index.php/Parts_-_Crankshaft From the diesel spigot-bearing topic]<br />
<br />
<br />
Yes, I'm confused now too, other than that the flywheel has to come off to do petrol spigot bearings and not for diesels @@<br />
<br />
[HM]<br />
<br />
==Other==<br />
<br />
More about spigotty things..</div>HarryMannhttps://club8090.co.uk/w/index.php?title=Petrol_engines_spigot-shaft_bearing&diff=11953Petrol engines spigot-shaft bearing2013-10-14T17:59:36Z<p>HarryMann: /* Links */</p>
<hr />
<div>== Introduction==<br />
<br />
The spigot shaft bearing is the common name for a (usually needle) bearing (or plain bush ) in the clutch end of the crankshaft that helps to align and support the 'spigot' or gearbox input shaft (sometimes called the 1st motion shaft)<br />
<br />
VW T25(UK)/T3 (Euro) utilise needle rollers beearings as their input shafts project a considerable distance from the first(closest) of the their gearbox support bearings. <br />
<br />
A characteristic of a worn spigot shaft bearing is a rattling from that bellhousing area when the engine is idling in neutral and the clutch engaged... depressing the clucth pedal removes drive to the input shaft and rattling/knocking may cease, a fairly accepted diagnosis.<br />
<br />
[HM]<br />
<br />
==Alt Engines and (missing) spigot shaft bearings ==<br />
<br />
'''NB.''' When replacing your T25 engine with another Alt Eng. such as a VW in-line 4 (Golf 1800 etc)<br />
it is wise to check whether it actually has a spigot-shaft bearing in the crankshaft recess.<br />
<br />
Many other engines do not (or have a plain bush) as their 1st motion shaft /input shaft are short and fully cantilevered from the gearbox bearings.<br><br />
This requires one to be fitted to suit the T25 g.box spigot.<br />
<br />
This also applies to Alt Diesel engines.<br />
<br />
The result of overlooking this can do a lot of damage to the input side of the gearbox, such as the oil seal, bearing and oil thrower, and annoys the bejesus out of Aidan to boot :)<br />
<br />
[HM]<br />
<br />
==How to replace a spigot shaft bearing==<br />
<br />
<br />
'''Aidan:''' So faced with flywheel<br />
<br />
[[File:spigshftbrg_01.jpg]]<br />
<br />
you need to undo the 5 bolts holding it on - it helps to have an impact gun, but failing that a 2 foot bar and another long bar or a flywheel locking tool to hold the flywheel whilst you undo them 10mm Hex<br />
<br />
leaves you with<br><br />
[[File:spigshftbrg_02.jpg]]<br />
<br />
then armed with your puller or slide hammer<br />
<br><br />
[[File:spigshftbrg_03.jpg]]<br />
<br />
fit into bearing and tighten then fit slide hammer<br />
<br />
<br><br />
[[File:spigshftbrg_04.jpg]]<br />
<br />
and start to pull it<br><br />
[[File:spigshftbrg_05.jpg]]<br />
<br />
till it comes out :ok <br />
<br />
<br />
[[File:spigshftbrg_06.jpg]]<br />
<br />
leaving an empty space in the flywheel with a stop behind<br />
<br><br />
[[File:spigshftbrg_07.jpg]]<br />
<br />
this shows the diesel spigot bearing on the left and petrol on right, the flat face with the writing on faces the gearbox the curved end faces the engine when fitted<br />
<br><br />
[[File:spigshftbrg_08.jpg]]<br />
<br />
as you can see the receiving hole in the crank is 21mm<br />
<br><br />
[[File:spigshftbrg_09.jpg]]<br />
<br />
as is the bearing shell outer diameter<br />
<br><br />
[[File:spigshftbrg_10.jpg]]<br />
<br />
and the inner dimension is 15mm ish - to match the spigot end of the input shaft which will be just under 15mm (like 14.97mm)<br />
<br />
<br><br />
[[File:spigshftbrg_11.jpg]]<br />
<br />
and the felt washer on the petrol engine fits in the recess on the back of the flywheel and the sealing o ring sits in the groove, just visible in the picture<br />
<br><br />
[[File:spigshftbrg_12.jpg]]<br />
<br />
Replace the 'O' ring, the washer and the spigot bearing and reassemble - flywheel bolts need to be tight but VW tightening spec is scary tight as previously noted - 60Nm (44ftlb) plus an added 90degrees - you probably won't get them that tight so use a very little threadlock<br />
<br />
Lube the new bearing with high temp grease :ok<br />
<br />
== Links==<br />
Here is a link to a forum thread on this, the 2nd of each pair of links hopefully still working once the topic has been moved to the 80-90 Tech Archive in due course (don't ask!)<br />
<br />
'''itchyfeet:''' thread <br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=120014 Current forum]<br><br />
[http://archive.club8090.co.uk/viewtopic.php?f=37&t=120014 Future Archive]<br />
<br />
'''nickthefish:''' thread <br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=83151 Current forum]<br><br />
[http://archive.club8090.co.uk/viewtopic.php?f=37&t=83151 Current forum]<br />
<br />
<br />
'''jaylo264:''' thread <br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=107122 Current forum]<br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=107122 Current forum]<br />
<br />
<br />
<br />
[http://wiki.club8090.co.uk/index.php/Parts_-_Crankshaft From the diesel spigot-bearing topic]<br />
<br />
[HM]<br />
<br />
==Other==<br />
<br />
More about spigotty things..</div>HarryMannhttps://club8090.co.uk/w/index.php?title=Petrol_engines_spigot-shaft_bearing&diff=11952Petrol engines spigot-shaft bearing2013-10-14T17:56:28Z<p>HarryMann: /* Other */</p>
<hr />
<div>== Introduction==<br />
<br />
The spigot shaft bearing is the common name for a (usually needle) bearing (or plain bush ) in the clutch end of the crankshaft that helps to align and support the 'spigot' or gearbox input shaft (sometimes called the 1st motion shaft)<br />
<br />
VW T25(UK)/T3 (Euro) utilise needle rollers beearings as their input shafts project a considerable distance from the first(closest) of the their gearbox support bearings. <br />
<br />
A characteristic of a worn spigot shaft bearing is a rattling from that bellhousing area when the engine is idling in neutral and the clutch engaged... depressing the clucth pedal removes drive to the input shaft and rattling/knocking may cease, a fairly accepted diagnosis.<br />
<br />
[HM]<br />
<br />
==Alt Engines and (missing) spigot shaft bearings ==<br />
<br />
'''NB.''' When replacing your T25 engine with another Alt Eng. such as a VW in-line 4 (Golf 1800 etc)<br />
it is wise to check whether it actually has a spigot-shaft bearing in the crankshaft recess.<br />
<br />
Many other engines do not (or have a plain bush) as their 1st motion shaft /input shaft are short and fully cantilevered from the gearbox bearings.<br><br />
This requires one to be fitted to suit the T25 g.box spigot.<br />
<br />
This also applies to Alt Diesel engines.<br />
<br />
The result of overlooking this can do a lot of damage to the input side of the gearbox, such as the oil seal, bearing and oil thrower, and annoys the bejesus out of Aidan to boot :)<br />
<br />
[HM]<br />
<br />
==How to replace a spigot shaft bearing==<br />
<br />
<br />
'''Aidan:''' So faced with flywheel<br />
<br />
[[File:spigshftbrg_01.jpg]]<br />
<br />
you need to undo the 5 bolts holding it on - it helps to have an impact gun, but failing that a 2 foot bar and another long bar or a flywheel locking tool to hold the flywheel whilst you undo them 10mm Hex<br />
<br />
leaves you with<br><br />
[[File:spigshftbrg_02.jpg]]<br />
<br />
then armed with your puller or slide hammer<br />
<br><br />
[[File:spigshftbrg_03.jpg]]<br />
<br />
fit into bearing and tighten then fit slide hammer<br />
<br />
<br><br />
[[File:spigshftbrg_04.jpg]]<br />
<br />
and start to pull it<br><br />
[[File:spigshftbrg_05.jpg]]<br />
<br />
till it comes out :ok <br />
<br />
<br />
[[File:spigshftbrg_06.jpg]]<br />
<br />
leaving an empty space in the flywheel with a stop behind<br />
<br><br />
[[File:spigshftbrg_07.jpg]]<br />
<br />
this shows the diesel spigot bearing on the left and petrol on right, the flat face with the writing on faces the gearbox the curved end faces the engine when fitted<br />
<br><br />
[[File:spigshftbrg_08.jpg]]<br />
<br />
as you can see the receiving hole in the crank is 21mm<br />
<br><br />
[[File:spigshftbrg_09.jpg]]<br />
<br />
as is the bearing shell outer diameter<br />
<br><br />
[[File:spigshftbrg_10.jpg]]<br />
<br />
and the inner dimension is 15mm ish - to match the spigot end of the input shaft which will be just under 15mm (like 14.97mm)<br />
<br />
<br><br />
[[File:spigshftbrg_11.jpg]]<br />
<br />
and the felt washer on the petrol engine fits in the recess on the back of the flywheel and the sealing o ring sits in the groove, just visible in the picture<br />
<br><br />
[[File:spigshftbrg_12.jpg]]<br />
<br />
Replace the 'O' ring, the washer and the spigot bearing and reassemble - flywheel bolts need to be tight but VW tightening spec is scary tight as previously noted - 60Nm (44ftlb) plus an added 90degrees - you probably won't get them that tight so use a very little threadlock<br />
<br />
Lube the new bearing with high temp grease :ok<br />
<br />
== Links==<br />
Here is a link to a forum thread on this, the 2nd of each pair of links hopefully still working once the topic has been moved to the 80-90 Tech Archive in due course (don't ask!)<br />
<br />
'''itchyfeet:''' thread <br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=120014 Current forum]<br><br />
[http://archive.club8090.co.uk/viewtopic.php?f=37&t=120014 Future Archive]<br />
<br />
'''nickthefish:''' thread <br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=83151 Current forum]<br><br />
[http://archive.club8090.co.uk/viewtopic.php?f=37&t=83151 Current forum]<br />
<br />
<br />
[http://wiki.club8090.co.uk/index.php/Parts_-_Crankshaft From the diesel spigot-bearing topic]<br />
<br />
[HM]<br />
<br />
==Other==<br />
<br />
More about spigotty things..</div>HarryMannhttps://club8090.co.uk/w/index.php?title=Petrol_engines_spigot-shaft_bearing&diff=11951Petrol engines spigot-shaft bearing2013-10-14T17:56:10Z<p>HarryMann: /* Links */</p>
<hr />
<div>== Introduction==<br />
<br />
The spigot shaft bearing is the common name for a (usually needle) bearing (or plain bush ) in the clutch end of the crankshaft that helps to align and support the 'spigot' or gearbox input shaft (sometimes called the 1st motion shaft)<br />
<br />
VW T25(UK)/T3 (Euro) utilise needle rollers beearings as their input shafts project a considerable distance from the first(closest) of the their gearbox support bearings. <br />
<br />
A characteristic of a worn spigot shaft bearing is a rattling from that bellhousing area when the engine is idling in neutral and the clutch engaged... depressing the clucth pedal removes drive to the input shaft and rattling/knocking may cease, a fairly accepted diagnosis.<br />
<br />
[HM]<br />
<br />
==Alt Engines and (missing) spigot shaft bearings ==<br />
<br />
'''NB.''' When replacing your T25 engine with another Alt Eng. such as a VW in-line 4 (Golf 1800 etc)<br />
it is wise to check whether it actually has a spigot-shaft bearing in the crankshaft recess.<br />
<br />
Many other engines do not (or have a plain bush) as their 1st motion shaft /input shaft are short and fully cantilevered from the gearbox bearings.<br><br />
This requires one to be fitted to suit the T25 g.box spigot.<br />
<br />
This also applies to Alt Diesel engines.<br />
<br />
The result of overlooking this can do a lot of damage to the input side of the gearbox, such as the oil seal, bearing and oil thrower, and annoys the bejesus out of Aidan to boot :)<br />
<br />
[HM]<br />
<br />
==How to replace a spigot shaft bearing==<br />
<br />
<br />
'''Aidan:''' So faced with flywheel<br />
<br />
[[File:spigshftbrg_01.jpg]]<br />
<br />
you need to undo the 5 bolts holding it on - it helps to have an impact gun, but failing that a 2 foot bar and another long bar or a flywheel locking tool to hold the flywheel whilst you undo them 10mm Hex<br />
<br />
leaves you with<br><br />
[[File:spigshftbrg_02.jpg]]<br />
<br />
then armed with your puller or slide hammer<br />
<br><br />
[[File:spigshftbrg_03.jpg]]<br />
<br />
fit into bearing and tighten then fit slide hammer<br />
<br />
<br><br />
[[File:spigshftbrg_04.jpg]]<br />
<br />
and start to pull it<br><br />
[[File:spigshftbrg_05.jpg]]<br />
<br />
till it comes out :ok <br />
<br />
<br />
[[File:spigshftbrg_06.jpg]]<br />
<br />
leaving an empty space in the flywheel with a stop behind<br />
<br><br />
[[File:spigshftbrg_07.jpg]]<br />
<br />
this shows the diesel spigot bearing on the left and petrol on right, the flat face with the writing on faces the gearbox the curved end faces the engine when fitted<br />
<br><br />
[[File:spigshftbrg_08.jpg]]<br />
<br />
as you can see the receiving hole in the crank is 21mm<br />
<br><br />
[[File:spigshftbrg_09.jpg]]<br />
<br />
as is the bearing shell outer diameter<br />
<br><br />
[[File:spigshftbrg_10.jpg]]<br />
<br />
and the inner dimension is 15mm ish - to match the spigot end of the input shaft which will be just under 15mm (like 14.97mm)<br />
<br />
<br><br />
[[File:spigshftbrg_11.jpg]]<br />
<br />
and the felt washer on the petrol engine fits in the recess on the back of the flywheel and the sealing o ring sits in the groove, just visible in the picture<br />
<br><br />
[[File:spigshftbrg_12.jpg]]<br />
<br />
Replace the 'O' ring, the washer and the spigot bearing and reassemble - flywheel bolts need to be tight but VW tightening spec is scary tight as previously noted - 60Nm (44ftlb) plus an added 90degrees - you probably won't get them that tight so use a very little threadlock<br />
<br />
Lube the new bearing with high temp grease :ok<br />
<br />
== Links==<br />
Here is a link to a forum thread on this, the 2nd of each pair of links hopefully still working once the topic has been moved to the 80-90 Tech Archive in due course (don't ask!)<br />
<br />
'''itchyfeet:''' thread <br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=120014 Current forum]<br><br />
[http://archive.club8090.co.uk/viewtopic.php?f=37&t=120014 Future Archive]<br />
<br />
'''nickthefish:''' thread <br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=83151 Current forum]<br><br />
[http://archive.club8090.co.uk/viewtopic.php?f=37&t=83151 Current forum]<br />
<br />
<br />
[http://wiki.club8090.co.uk/index.php/Parts_-_Crankshaft From the diesel spigot-bearing topic]<br />
<br />
[HM]<br />
<br />
==Other==</div>HarryMannhttps://club8090.co.uk/w/index.php?title=Petrol_engines_spigot-shaft_bearing&diff=11950Petrol engines spigot-shaft bearing2013-10-14T17:55:56Z<p>HarryMann: /* Links */</p>
<hr />
<div>== Introduction==<br />
<br />
The spigot shaft bearing is the common name for a (usually needle) bearing (or plain bush ) in the clutch end of the crankshaft that helps to align and support the 'spigot' or gearbox input shaft (sometimes called the 1st motion shaft)<br />
<br />
VW T25(UK)/T3 (Euro) utilise needle rollers beearings as their input shafts project a considerable distance from the first(closest) of the their gearbox support bearings. <br />
<br />
A characteristic of a worn spigot shaft bearing is a rattling from that bellhousing area when the engine is idling in neutral and the clutch engaged... depressing the clucth pedal removes drive to the input shaft and rattling/knocking may cease, a fairly accepted diagnosis.<br />
<br />
[HM]<br />
<br />
==Alt Engines and (missing) spigot shaft bearings ==<br />
<br />
'''NB.''' When replacing your T25 engine with another Alt Eng. such as a VW in-line 4 (Golf 1800 etc)<br />
it is wise to check whether it actually has a spigot-shaft bearing in the crankshaft recess.<br />
<br />
Many other engines do not (or have a plain bush) as their 1st motion shaft /input shaft are short and fully cantilevered from the gearbox bearings.<br><br />
This requires one to be fitted to suit the T25 g.box spigot.<br />
<br />
This also applies to Alt Diesel engines.<br />
<br />
The result of overlooking this can do a lot of damage to the input side of the gearbox, such as the oil seal, bearing and oil thrower, and annoys the bejesus out of Aidan to boot :)<br />
<br />
[HM]<br />
<br />
==How to replace a spigot shaft bearing==<br />
<br />
<br />
'''Aidan:''' So faced with flywheel<br />
<br />
[[File:spigshftbrg_01.jpg]]<br />
<br />
you need to undo the 5 bolts holding it on - it helps to have an impact gun, but failing that a 2 foot bar and another long bar or a flywheel locking tool to hold the flywheel whilst you undo them 10mm Hex<br />
<br />
leaves you with<br><br />
[[File:spigshftbrg_02.jpg]]<br />
<br />
then armed with your puller or slide hammer<br />
<br><br />
[[File:spigshftbrg_03.jpg]]<br />
<br />
fit into bearing and tighten then fit slide hammer<br />
<br />
<br><br />
[[File:spigshftbrg_04.jpg]]<br />
<br />
and start to pull it<br><br />
[[File:spigshftbrg_05.jpg]]<br />
<br />
till it comes out :ok <br />
<br />
<br />
[[File:spigshftbrg_06.jpg]]<br />
<br />
leaving an empty space in the flywheel with a stop behind<br />
<br><br />
[[File:spigshftbrg_07.jpg]]<br />
<br />
this shows the diesel spigot bearing on the left and petrol on right, the flat face with the writing on faces the gearbox the curved end faces the engine when fitted<br />
<br><br />
[[File:spigshftbrg_08.jpg]]<br />
<br />
as you can see the receiving hole in the crank is 21mm<br />
<br><br />
[[File:spigshftbrg_09.jpg]]<br />
<br />
as is the bearing shell outer diameter<br />
<br><br />
[[File:spigshftbrg_10.jpg]]<br />
<br />
and the inner dimension is 15mm ish - to match the spigot end of the input shaft which will be just under 15mm (like 14.97mm)<br />
<br />
<br><br />
[[File:spigshftbrg_11.jpg]]<br />
<br />
and the felt washer on the petrol engine fits in the recess on the back of the flywheel and the sealing o ring sits in the groove, just visible in the picture<br />
<br><br />
[[File:spigshftbrg_12.jpg]]<br />
<br />
Replace the 'O' ring, the washer and the spigot bearing and reassemble - flywheel bolts need to be tight but VW tightening spec is scary tight as previously noted - 60Nm (44ftlb) plus an added 90degrees - you probably won't get them that tight so use a very little threadlock<br />
<br />
Lube the new bearing with high temp grease :ok<br />
<br />
== Links==<br />
Here is a link to a forum thread on this, the 2nd of each pair of links hopefully still working once the topic has been moved to the 80-90 Tech Archive in due course (don't ask!)<br />
<br />
'''itchyfeet:''' thread <br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=120014 Current forum]<br><br />
[http://archive.club8090.co.uk/viewtopic.php?f=37&t=120014 Future Archive]<br />
<br />
'''nickthefish:''' thread <br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=83151 Current forum]<br><br />
[http://archive.club8090.co.uk/viewtopic.php?f=37&t=83151 Current forum]<br />
<br />
<br />
[http://wiki.club8090.co.uk/index.php/Parts_-_Crankshaft From the diesel spigot-bearing topic]<br />
<br />
==Other==</div>HarryMannhttps://club8090.co.uk/w/index.php?title=Petrol_engines_spigot-shaft_bearing&diff=11949Petrol engines spigot-shaft bearing2013-10-14T17:55:07Z<p>HarryMann: /* Links */</p>
<hr />
<div>== Introduction==<br />
<br />
The spigot shaft bearing is the common name for a (usually needle) bearing (or plain bush ) in the clutch end of the crankshaft that helps to align and support the 'spigot' or gearbox input shaft (sometimes called the 1st motion shaft)<br />
<br />
VW T25(UK)/T3 (Euro) utilise needle rollers beearings as their input shafts project a considerable distance from the first(closest) of the their gearbox support bearings. <br />
<br />
A characteristic of a worn spigot shaft bearing is a rattling from that bellhousing area when the engine is idling in neutral and the clutch engaged... depressing the clucth pedal removes drive to the input shaft and rattling/knocking may cease, a fairly accepted diagnosis.<br />
<br />
[HM]<br />
<br />
==Alt Engines and (missing) spigot shaft bearings ==<br />
<br />
'''NB.''' When replacing your T25 engine with another Alt Eng. such as a VW in-line 4 (Golf 1800 etc)<br />
it is wise to check whether it actually has a spigot-shaft bearing in the crankshaft recess.<br />
<br />
Many other engines do not (or have a plain bush) as their 1st motion shaft /input shaft are short and fully cantilevered from the gearbox bearings.<br><br />
This requires one to be fitted to suit the T25 g.box spigot.<br />
<br />
This also applies to Alt Diesel engines.<br />
<br />
The result of overlooking this can do a lot of damage to the input side of the gearbox, such as the oil seal, bearing and oil thrower, and annoys the bejesus out of Aidan to boot :)<br />
<br />
[HM]<br />
<br />
==How to replace a spigot shaft bearing==<br />
<br />
<br />
'''Aidan:''' So faced with flywheel<br />
<br />
[[File:spigshftbrg_01.jpg]]<br />
<br />
you need to undo the 5 bolts holding it on - it helps to have an impact gun, but failing that a 2 foot bar and another long bar or a flywheel locking tool to hold the flywheel whilst you undo them 10mm Hex<br />
<br />
leaves you with<br><br />
[[File:spigshftbrg_02.jpg]]<br />
<br />
then armed with your puller or slide hammer<br />
<br><br />
[[File:spigshftbrg_03.jpg]]<br />
<br />
fit into bearing and tighten then fit slide hammer<br />
<br />
<br><br />
[[File:spigshftbrg_04.jpg]]<br />
<br />
and start to pull it<br><br />
[[File:spigshftbrg_05.jpg]]<br />
<br />
till it comes out :ok <br />
<br />
<br />
[[File:spigshftbrg_06.jpg]]<br />
<br />
leaving an empty space in the flywheel with a stop behind<br />
<br><br />
[[File:spigshftbrg_07.jpg]]<br />
<br />
this shows the diesel spigot bearing on the left and petrol on right, the flat face with the writing on faces the gearbox the curved end faces the engine when fitted<br />
<br><br />
[[File:spigshftbrg_08.jpg]]<br />
<br />
as you can see the receiving hole in the crank is 21mm<br />
<br><br />
[[File:spigshftbrg_09.jpg]]<br />
<br />
as is the bearing shell outer diameter<br />
<br><br />
[[File:spigshftbrg_10.jpg]]<br />
<br />
and the inner dimension is 15mm ish - to match the spigot end of the input shaft which will be just under 15mm (like 14.97mm)<br />
<br />
<br><br />
[[File:spigshftbrg_11.jpg]]<br />
<br />
and the felt washer on the petrol engine fits in the recess on the back of the flywheel and the sealing o ring sits in the groove, just visible in the picture<br />
<br><br />
[[File:spigshftbrg_12.jpg]]<br />
<br />
Replace the 'O' ring, the washer and the spigot bearing and reassemble - flywheel bolts need to be tight but VW tightening spec is scary tight as previously noted - 60Nm (44ftlb) plus an added 90degrees - you probably won't get them that tight so use a very little threadlock<br />
<br />
Lube the new bearing with high temp grease :ok<br />
<br />
== Links==<br />
Here is a link to a forum thread on this, the 2nd link hopefully still pointing one the topic has been moved to the 80-90 Tech Archive in due course.<br />
<br />
'''itchyfeet:''' thread <br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=120014 Current forum]<br><br />
[http://archive.club8090.co.uk/viewtopic.php?f=37&t=120014 Future Archive]<br />
<br />
'''nickthefish:''' thread <br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=83151 Current forum]<br><br />
[http://archive.club8090.co.uk/viewtopic.php?f=37&t=83151 Current forum]<br />
<br />
<br />
[http://wiki.club8090.co.uk/index.php/Parts_-_Crankshaft From the diesel spigot-bearing topic]<br />
<br />
==Other==</div>HarryMannhttps://club8090.co.uk/w/index.php?title=Petrol_engines_spigot-shaft_bearing&diff=11948Petrol engines spigot-shaft bearing2013-10-14T17:54:39Z<p>HarryMann: /* Links */</p>
<hr />
<div>== Introduction==<br />
<br />
The spigot shaft bearing is the common name for a (usually needle) bearing (or plain bush ) in the clutch end of the crankshaft that helps to align and support the 'spigot' or gearbox input shaft (sometimes called the 1st motion shaft)<br />
<br />
VW T25(UK)/T3 (Euro) utilise needle rollers beearings as their input shafts project a considerable distance from the first(closest) of the their gearbox support bearings. <br />
<br />
A characteristic of a worn spigot shaft bearing is a rattling from that bellhousing area when the engine is idling in neutral and the clutch engaged... depressing the clucth pedal removes drive to the input shaft and rattling/knocking may cease, a fairly accepted diagnosis.<br />
<br />
[HM]<br />
<br />
==Alt Engines and (missing) spigot shaft bearings ==<br />
<br />
'''NB.''' When replacing your T25 engine with another Alt Eng. such as a VW in-line 4 (Golf 1800 etc)<br />
it is wise to check whether it actually has a spigot-shaft bearing in the crankshaft recess.<br />
<br />
Many other engines do not (or have a plain bush) as their 1st motion shaft /input shaft are short and fully cantilevered from the gearbox bearings.<br><br />
This requires one to be fitted to suit the T25 g.box spigot.<br />
<br />
This also applies to Alt Diesel engines.<br />
<br />
The result of overlooking this can do a lot of damage to the input side of the gearbox, such as the oil seal, bearing and oil thrower, and annoys the bejesus out of Aidan to boot :)<br />
<br />
[HM]<br />
<br />
==How to replace a spigot shaft bearing==<br />
<br />
<br />
'''Aidan:''' So faced with flywheel<br />
<br />
[[File:spigshftbrg_01.jpg]]<br />
<br />
you need to undo the 5 bolts holding it on - it helps to have an impact gun, but failing that a 2 foot bar and another long bar or a flywheel locking tool to hold the flywheel whilst you undo them 10mm Hex<br />
<br />
leaves you with<br><br />
[[File:spigshftbrg_02.jpg]]<br />
<br />
then armed with your puller or slide hammer<br />
<br><br />
[[File:spigshftbrg_03.jpg]]<br />
<br />
fit into bearing and tighten then fit slide hammer<br />
<br />
<br><br />
[[File:spigshftbrg_04.jpg]]<br />
<br />
and start to pull it<br><br />
[[File:spigshftbrg_05.jpg]]<br />
<br />
till it comes out :ok <br />
<br />
<br />
[[File:spigshftbrg_06.jpg]]<br />
<br />
leaving an empty space in the flywheel with a stop behind<br />
<br><br />
[[File:spigshftbrg_07.jpg]]<br />
<br />
this shows the diesel spigot bearing on the left and petrol on right, the flat face with the writing on faces the gearbox the curved end faces the engine when fitted<br />
<br><br />
[[File:spigshftbrg_08.jpg]]<br />
<br />
as you can see the receiving hole in the crank is 21mm<br />
<br><br />
[[File:spigshftbrg_09.jpg]]<br />
<br />
as is the bearing shell outer diameter<br />
<br><br />
[[File:spigshftbrg_10.jpg]]<br />
<br />
and the inner dimension is 15mm ish - to match the spigot end of the input shaft which will be just under 15mm (like 14.97mm)<br />
<br />
<br><br />
[[File:spigshftbrg_11.jpg]]<br />
<br />
and the felt washer on the petrol engine fits in the recess on the back of the flywheel and the sealing o ring sits in the groove, just visible in the picture<br />
<br><br />
[[File:spigshftbrg_12.jpg]]<br />
<br />
Replace the 'O' ring, the washer and the spigot bearing and reassemble - flywheel bolts need to be tight but VW tightening spec is scary tight as previously noted - 60Nm (44ftlb) plus an added 90degrees - you probably won't get them that tight so use a very little threadlock<br />
<br />
Lube the new bearing with high temp grease :ok<br />
<br />
== Links==<br />
Here is a link to a forum thread on this, the 2nd link hopefully still pointing one the topic has been moved to the 80-90 Tech Archive in due course.<br />
<br />
'''itchyfeet:''' thread <br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=120014 Current forum]<br><br />
[http://archive.club8090.co.uk/viewtopic.php?f=37&t=120014 Future Archive]<br />
<br />
'''nickthefish:''' thread <br><br />
<br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=83151 Current forum]<br />
[http://archive.club8090.co.uk/viewtopic.php?f=37&t=83151 Current forum]<br />
<br />
<br />
[http://wiki.club8090.co.uk/index.php/Parts_-_Crankshaft From the diesel spigot-bearing topic]<br />
<br />
==Other==</div>HarryMannhttps://club8090.co.uk/w/index.php?title=Petrol_engines_spigot-shaft_bearing&diff=11947Petrol engines spigot-shaft bearing2013-10-14T17:48:26Z<p>HarryMann: /* Alt Engines and (missing) spigot shaft bearings */</p>
<hr />
<div>== Introduction==<br />
<br />
The spigot shaft bearing is the common name for a (usually needle) bearing (or plain bush ) in the clutch end of the crankshaft that helps to align and support the 'spigot' or gearbox input shaft (sometimes called the 1st motion shaft)<br />
<br />
VW T25(UK)/T3 (Euro) utilise needle rollers beearings as their input shafts project a considerable distance from the first(closest) of the their gearbox support bearings. <br />
<br />
A characteristic of a worn spigot shaft bearing is a rattling from that bellhousing area when the engine is idling in neutral and the clutch engaged... depressing the clucth pedal removes drive to the input shaft and rattling/knocking may cease, a fairly accepted diagnosis.<br />
<br />
[HM]<br />
<br />
==Alt Engines and (missing) spigot shaft bearings ==<br />
<br />
'''NB.''' When replacing your T25 engine with another Alt Eng. such as a VW in-line 4 (Golf 1800 etc)<br />
it is wise to check whether it actually has a spigot-shaft bearing in the crankshaft recess.<br />
<br />
Many other engines do not (or have a plain bush) as their 1st motion shaft /input shaft are short and fully cantilevered from the gearbox bearings.<br><br />
This requires one to be fitted to suit the T25 g.box spigot.<br />
<br />
This also applies to Alt Diesel engines.<br />
<br />
The result of overlooking this can do a lot of damage to the input side of the gearbox, such as the oil seal, bearing and oil thrower, and annoys the bejesus out of Aidan to boot :)<br />
<br />
[HM]<br />
<br />
==How to replace a spigot shaft bearing==<br />
<br />
<br />
'''Aidan:''' So faced with flywheel<br />
<br />
[[File:spigshftbrg_01.jpg]]<br />
<br />
you need to undo the 5 bolts holding it on - it helps to have an impact gun, but failing that a 2 foot bar and another long bar or a flywheel locking tool to hold the flywheel whilst you undo them 10mm Hex<br />
<br />
leaves you with<br><br />
[[File:spigshftbrg_02.jpg]]<br />
<br />
then armed with your puller or slide hammer<br />
<br><br />
[[File:spigshftbrg_03.jpg]]<br />
<br />
fit into bearing and tighten then fit slide hammer<br />
<br />
<br><br />
[[File:spigshftbrg_04.jpg]]<br />
<br />
and start to pull it<br><br />
[[File:spigshftbrg_05.jpg]]<br />
<br />
till it comes out :ok <br />
<br />
<br />
[[File:spigshftbrg_06.jpg]]<br />
<br />
leaving an empty space in the flywheel with a stop behind<br />
<br><br />
[[File:spigshftbrg_07.jpg]]<br />
<br />
this shows the diesel spigot bearing on the left and petrol on right, the flat face with the writing on faces the gearbox the curved end faces the engine when fitted<br />
<br><br />
[[File:spigshftbrg_08.jpg]]<br />
<br />
as you can see the receiving hole in the crank is 21mm<br />
<br><br />
[[File:spigshftbrg_09.jpg]]<br />
<br />
as is the bearing shell outer diameter<br />
<br><br />
[[File:spigshftbrg_10.jpg]]<br />
<br />
and the inner dimension is 15mm ish - to match the spigot end of the input shaft which will be just under 15mm (like 14.97mm)<br />
<br />
<br><br />
[[File:spigshftbrg_11.jpg]]<br />
<br />
and the felt washer on the petrol engine fits in the recess on the back of the flywheel and the sealing o ring sits in the groove, just visible in the picture<br />
<br><br />
[[File:spigshftbrg_12.jpg]]<br />
<br />
Replace the 'O' ring, the washer and the spigot bearing and reassemble - flywheel bolts need to be tight but VW tightening spec is scary tight as previously noted - 60Nm (44ftlb) plus an added 90degrees - you probably won't get them that tight so use a very little threadlock<br />
<br />
Lube the new bearing with high temp grease :ok<br />
<br />
== Links==<br />
Here is a link to a forum thread on this, the 2nd link hopefully still pointing one the topic has been moved to the 80-90 Tech Archive in due course.<br />
<br />
'''itchyfeet:''' <br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=120014 Current forum]<br><br />
[http://archive.club8090.co.uk/viewtopic.php?f=37&t=120014 Future Archive]<br />
<br />
<br />
[http://wiki.club8090.co.uk/index.php/Parts_-_Crankshaft From the diesel spigot-bearing topic]<br />
<br />
==Other==</div>HarryMannhttps://club8090.co.uk/w/index.php?title=Petrol_engines_spigot-shaft_bearing&diff=11946Petrol engines spigot-shaft bearing2013-10-14T17:48:12Z<p>HarryMann: /* Introduction */</p>
<hr />
<div>== Introduction==<br />
<br />
The spigot shaft bearing is the common name for a (usually needle) bearing (or plain bush ) in the clutch end of the crankshaft that helps to align and support the 'spigot' or gearbox input shaft (sometimes called the 1st motion shaft)<br />
<br />
VW T25(UK)/T3 (Euro) utilise needle rollers beearings as their input shafts project a considerable distance from the first(closest) of the their gearbox support bearings. <br />
<br />
A characteristic of a worn spigot shaft bearing is a rattling from that bellhousing area when the engine is idling in neutral and the clutch engaged... depressing the clucth pedal removes drive to the input shaft and rattling/knocking may cease, a fairly accepted diagnosis.<br />
<br />
[HM]<br />
<br />
==Alt Engines and (missing) spigot shaft bearings ==<br />
<br />
'''NB.''' When replacing your T25 engine with another Alt Eng. such as a VW in-line 4 (Golf 1800 etc)<br />
it is wise to check whether it actually has a spigot-shaft bearing in the crankshaft recess.<br />
<br />
Many other engines do not (or have a plain bush) as their 1st motion shaft /input shaft are short and fully cantilevered from the gearbox bearings.<br><br />
This requires one to be fitted to suit the T25 g.box spigot.<br />
<br />
This also applies to Alt Diesel engines.<br />
<br />
The result of overlooking this can do a lot of damage to the input side of the gearbox, such as the oil seal, bearing and oil thrower, and annoys the bejesus out of Aidan to boot :)<br />
<br />
==How to replace a spigot shaft bearing==<br />
<br />
<br />
'''Aidan:''' So faced with flywheel<br />
<br />
[[File:spigshftbrg_01.jpg]]<br />
<br />
you need to undo the 5 bolts holding it on - it helps to have an impact gun, but failing that a 2 foot bar and another long bar or a flywheel locking tool to hold the flywheel whilst you undo them 10mm Hex<br />
<br />
leaves you with<br><br />
[[File:spigshftbrg_02.jpg]]<br />
<br />
then armed with your puller or slide hammer<br />
<br><br />
[[File:spigshftbrg_03.jpg]]<br />
<br />
fit into bearing and tighten then fit slide hammer<br />
<br />
<br><br />
[[File:spigshftbrg_04.jpg]]<br />
<br />
and start to pull it<br><br />
[[File:spigshftbrg_05.jpg]]<br />
<br />
till it comes out :ok <br />
<br />
<br />
[[File:spigshftbrg_06.jpg]]<br />
<br />
leaving an empty space in the flywheel with a stop behind<br />
<br><br />
[[File:spigshftbrg_07.jpg]]<br />
<br />
this shows the diesel spigot bearing on the left and petrol on right, the flat face with the writing on faces the gearbox the curved end faces the engine when fitted<br />
<br><br />
[[File:spigshftbrg_08.jpg]]<br />
<br />
as you can see the receiving hole in the crank is 21mm<br />
<br><br />
[[File:spigshftbrg_09.jpg]]<br />
<br />
as is the bearing shell outer diameter<br />
<br><br />
[[File:spigshftbrg_10.jpg]]<br />
<br />
and the inner dimension is 15mm ish - to match the spigot end of the input shaft which will be just under 15mm (like 14.97mm)<br />
<br />
<br><br />
[[File:spigshftbrg_11.jpg]]<br />
<br />
and the felt washer on the petrol engine fits in the recess on the back of the flywheel and the sealing o ring sits in the groove, just visible in the picture<br />
<br><br />
[[File:spigshftbrg_12.jpg]]<br />
<br />
Replace the 'O' ring, the washer and the spigot bearing and reassemble - flywheel bolts need to be tight but VW tightening spec is scary tight as previously noted - 60Nm (44ftlb) plus an added 90degrees - you probably won't get them that tight so use a very little threadlock<br />
<br />
Lube the new bearing with high temp grease :ok<br />
<br />
== Links==<br />
Here is a link to a forum thread on this, the 2nd link hopefully still pointing one the topic has been moved to the 80-90 Tech Archive in due course.<br />
<br />
'''itchyfeet:''' <br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=120014 Current forum]<br><br />
[http://archive.club8090.co.uk/viewtopic.php?f=37&t=120014 Future Archive]<br />
<br />
<br />
[http://wiki.club8090.co.uk/index.php/Parts_-_Crankshaft From the diesel spigot-bearing topic]<br />
<br />
==Other==</div>HarryMannhttps://club8090.co.uk/w/index.php?title=Petrol_engines_spigot-shaft_bearing&diff=11945Petrol engines spigot-shaft bearing2013-10-14T17:47:39Z<p>HarryMann: /* Alt Engines and spigot shaft bearings */</p>
<hr />
<div>== Introduction==<br />
<br />
The spigot shaft bearing is the common name for a (usually needle) bearing (or plain bush ) in the clutch end of the crankshaft that helps to align and support the 'spigot' or gearbox input shaft (sometimes called the 1st motion shaft)<br />
<br />
VW T25(UK)/T3 (Euro) utilise needle rollers beearings as their input shafts project a considerable distance from the first(closest) of the their gearbox support bearings. <br />
<br />
A characteristic of a worn spigot shaft bearing is a rattling from that bellhousing area when the engine is idling in neutral and the clutch engaged... depressing the clucth pedal removes drive to the input shaft and rattling/knocking may cease, a fairly accepted diagnosis.<br />
<br />
==Alt Engines and (missing) spigot shaft bearings ==<br />
<br />
'''NB.''' When replacing your T25 engine with another Alt Eng. such as a VW in-line 4 (Golf 1800 etc)<br />
it is wise to check whether it actually has a spigot-shaft bearing in the crankshaft recess.<br />
<br />
Many other engines do not (or have a plain bush) as their 1st motion shaft /input shaft are short and fully cantilevered from the gearbox bearings.<br><br />
This requires one to be fitted to suit the T25 g.box spigot.<br />
<br />
This also applies to Alt Diesel engines.<br />
<br />
The result of overlooking this can do a lot of damage to the input side of the gearbox, such as the oil seal, bearing and oil thrower, and annoys the bejesus out of Aidan to boot :)<br />
<br />
==How to replace a spigot shaft bearing==<br />
<br />
<br />
'''Aidan:''' So faced with flywheel<br />
<br />
[[File:spigshftbrg_01.jpg]]<br />
<br />
you need to undo the 5 bolts holding it on - it helps to have an impact gun, but failing that a 2 foot bar and another long bar or a flywheel locking tool to hold the flywheel whilst you undo them 10mm Hex<br />
<br />
leaves you with<br><br />
[[File:spigshftbrg_02.jpg]]<br />
<br />
then armed with your puller or slide hammer<br />
<br><br />
[[File:spigshftbrg_03.jpg]]<br />
<br />
fit into bearing and tighten then fit slide hammer<br />
<br />
<br><br />
[[File:spigshftbrg_04.jpg]]<br />
<br />
and start to pull it<br><br />
[[File:spigshftbrg_05.jpg]]<br />
<br />
till it comes out :ok <br />
<br />
<br />
[[File:spigshftbrg_06.jpg]]<br />
<br />
leaving an empty space in the flywheel with a stop behind<br />
<br><br />
[[File:spigshftbrg_07.jpg]]<br />
<br />
this shows the diesel spigot bearing on the left and petrol on right, the flat face with the writing on faces the gearbox the curved end faces the engine when fitted<br />
<br><br />
[[File:spigshftbrg_08.jpg]]<br />
<br />
as you can see the receiving hole in the crank is 21mm<br />
<br><br />
[[File:spigshftbrg_09.jpg]]<br />
<br />
as is the bearing shell outer diameter<br />
<br><br />
[[File:spigshftbrg_10.jpg]]<br />
<br />
and the inner dimension is 15mm ish - to match the spigot end of the input shaft which will be just under 15mm (like 14.97mm)<br />
<br />
<br><br />
[[File:spigshftbrg_11.jpg]]<br />
<br />
and the felt washer on the petrol engine fits in the recess on the back of the flywheel and the sealing o ring sits in the groove, just visible in the picture<br />
<br><br />
[[File:spigshftbrg_12.jpg]]<br />
<br />
Replace the 'O' ring, the washer and the spigot bearing and reassemble - flywheel bolts need to be tight but VW tightening spec is scary tight as previously noted - 60Nm (44ftlb) plus an added 90degrees - you probably won't get them that tight so use a very little threadlock<br />
<br />
Lube the new bearing with high temp grease :ok<br />
<br />
== Links==<br />
Here is a link to a forum thread on this, the 2nd link hopefully still pointing one the topic has been moved to the 80-90 Tech Archive in due course.<br />
<br />
'''itchyfeet:''' <br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=120014 Current forum]<br><br />
[http://archive.club8090.co.uk/viewtopic.php?f=37&t=120014 Future Archive]<br />
<br />
<br />
[http://wiki.club8090.co.uk/index.php/Parts_-_Crankshaft From the diesel spigot-bearing topic]<br />
<br />
==Other==</div>HarryMannhttps://club8090.co.uk/w/index.php?title=Petrol_engines_spigot-shaft_bearing&diff=11944Petrol engines spigot-shaft bearing2013-10-14T17:46:07Z<p>HarryMann: /* Alt Engines and spigot shaft bearings = */</p>
<hr />
<div>== Introduction==<br />
<br />
The spigot shaft bearing is the common name for a (usually needle) bearing (or plain bush ) in the clutch end of the crankshaft that helps to align and support the 'spigot' or gearbox input shaft (sometimes called the 1st motion shaft)<br />
<br />
VW T25(UK)/T3 (Euro) utilise needle rollers beearings as their input shafts project a considerable distance from the first(closest) of the their gearbox support bearings. <br />
<br />
A characteristic of a worn spigot shaft bearing is a rattling from that bellhousing area when the engine is idling in neutral and the clutch engaged... depressing the clucth pedal removes drive to the input shaft and rattling/knocking may cease, a fairly accepted diagnosis.<br />
<br />
==Alt Engines and spigot shaft bearings ==<br />
<br />
'''NB.''' When replacing your T25 engine with another Alt Eng. such as a VW in-line 4 (Golf 1800 etc)<br />
it is wise to check whether it actually has a spigot-shaft bearing in the crankshaft recess.<br />
<br />
Many other engines do not (or have a plain bush) as their 1st motion shaft /input shaft are short and fully cantilevered from the gearbox bearings.<br><br />
This requires one to be fitted to suit the T25 g.box spigot.<br />
<br />
This also applies to Alt Diesel engines.<br />
<br />
==How to replace a spigot shaft bearing==<br />
<br />
<br />
'''Aidan:''' So faced with flywheel<br />
<br />
[[File:spigshftbrg_01.jpg]]<br />
<br />
you need to undo the 5 bolts holding it on - it helps to have an impact gun, but failing that a 2 foot bar and another long bar or a flywheel locking tool to hold the flywheel whilst you undo them 10mm Hex<br />
<br />
leaves you with<br><br />
[[File:spigshftbrg_02.jpg]]<br />
<br />
then armed with your puller or slide hammer<br />
<br><br />
[[File:spigshftbrg_03.jpg]]<br />
<br />
fit into bearing and tighten then fit slide hammer<br />
<br />
<br><br />
[[File:spigshftbrg_04.jpg]]<br />
<br />
and start to pull it<br><br />
[[File:spigshftbrg_05.jpg]]<br />
<br />
till it comes out :ok <br />
<br />
<br />
[[File:spigshftbrg_06.jpg]]<br />
<br />
leaving an empty space in the flywheel with a stop behind<br />
<br><br />
[[File:spigshftbrg_07.jpg]]<br />
<br />
this shows the diesel spigot bearing on the left and petrol on right, the flat face with the writing on faces the gearbox the curved end faces the engine when fitted<br />
<br><br />
[[File:spigshftbrg_08.jpg]]<br />
<br />
as you can see the receiving hole in the crank is 21mm<br />
<br><br />
[[File:spigshftbrg_09.jpg]]<br />
<br />
as is the bearing shell outer diameter<br />
<br><br />
[[File:spigshftbrg_10.jpg]]<br />
<br />
and the inner dimension is 15mm ish - to match the spigot end of the input shaft which will be just under 15mm (like 14.97mm)<br />
<br />
<br><br />
[[File:spigshftbrg_11.jpg]]<br />
<br />
and the felt washer on the petrol engine fits in the recess on the back of the flywheel and the sealing o ring sits in the groove, just visible in the picture<br />
<br><br />
[[File:spigshftbrg_12.jpg]]<br />
<br />
Replace the 'O' ring, the washer and the spigot bearing and reassemble - flywheel bolts need to be tight but VW tightening spec is scary tight as previously noted - 60Nm (44ftlb) plus an added 90degrees - you probably won't get them that tight so use a very little threadlock<br />
<br />
Lube the new bearing with high temp grease :ok<br />
<br />
== Links==<br />
Here is a link to a forum thread on this, the 2nd link hopefully still pointing one the topic has been moved to the 80-90 Tech Archive in due course.<br />
<br />
'''itchyfeet:''' <br><br />
[http://forum.club8090.co.uk/viewtopic.php?f=37&t=120014 Current forum]<br><br />
[http://archive.club8090.co.uk/viewtopic.php?f=37&t=120014 Future Archive]<br />
<br />
<br />
[http://wiki.club8090.co.uk/index.php/Parts_-_Crankshaft From the diesel spigot-bearing topic]<br />
<br />
==Other==</div>HarryMann