Main Page
From VW T25(T3)-Tech
Welcome to a VW-Tech, the wiki technical archive of the Club 80-90 website.
IMPORTANT
Please stick to the following 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. 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 technical forum.
Club 80-90 Wiki en Français
Notices and Bugs
PLEASE READ THE Disclaimer:
- Club 80-90 members are the only ones with editing rights at the moment, we have not been able to automatically grant 80-90 logons with wiki editing rights these need to be manually added Please PM Mocki for access. 'Please login with your forum username and password'
- Red links are pages that do not yet have information added to them (or whose pages have become orphaned, due to typos in the internal links)
- 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)
e.g. SPACE Name: Brief summary of what has been added below (and possibly why its important)
- 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.
- click here for a 'sandbox' if you want to experiment with wikis before making modifiacations to this one.
New or Prospective Owner?
* Warnings - Must Read *
- Fire warning - Fuel lines, tank, carb etc.
- Fire warning - Aircooled - Carb fuel leaks
- Gearbox /Transaxle /Diff oil levels
- Parts quality - Keep old (removed) parts
Guides
- What are they like to drive?
- The Buyers Guide by Simon Brickyard and others
- Syncro (4 wheel drive) Buyers guide
Tips and tricks
- New owners' questions (FAQ)
- Spares and tools to carry
- Don't panic!
- Flat 4 engines primer
- Importing
- VOSA MOT advisories online, check what might need fixing soon on your prospective purchase
- Gearchange reluctance
- Improving difficult/sloppy gearchange
For Maintenance Bulletins look in Misc Tips and Tips
Engines
Petrol engines (Watercooled)
- Fire warning - Fuel lines, tank, carb etc.
- Not starting - Diagnostic flow chart
- Engine removal and refitting
- Spark plug types
- 1.9 specific
- 2.1 specific
- General Ignition Info/Debugging
- Parts, Pictures, Diagrams and lists etc.
Petrol Engines (Aircooled)
- Schematic parts layout
- Engine removal
- Crankshaft oil-seal (photo article, start-to-finish)
- Differences between engines
- Aircooled running temperature
- Aircooled tinware
- Performance enhancement
- Thermostat
- Solid lifters
- Pushrod & tube seal replacement
- Oil pressures
- A/C Petrol engines - Aircooled Cyl. Head
- A/C Petrol engines - Aircooled Ignition Systems
- A/C Petrol engines - Carburrettors and fuel system
- Hazards
- Fuel leaks
- A/C Petrol engines - Modifications
Petrol specific engine Faults/repairs/maintenance
- Diagnosing faults (petrols)
- Cylinder nos. and firing order
- Oil change
- Engine codes
- Cylinder head leak
- Losing water
- Low oil pressure
- Snapped cylinder head bolt
- Starter motor bush removal
- Overheating
- Emulsified oil (mayonnaise)
- Oil leaks
- Compression testing
- Hydraulic lifters explained
Diesel engines
- Fire warning
- Intro, types and condition diagnosis
- Engine codes
- Engine removal and refitting
- Diesel Engines - Turbo
- Sump and oil pump
- Diesel Engines - Servicing
- Diesel Engines - Parts, pictures, diagrams and lists
- Instruments -
- Links to threads on the 1Y 1.9d (N/A) which is a popular conversion from the 1.6d and 1.7d
All engine faults/repairs/maintenance
- Stripped spark plug thread
- Oil filters recomended
- Replace throttle cable
- Replace starter motor
- Reluctant starting (starter motor)
- Reluctant starting (battery alternator)
- Reconditioned engines
- Dashboard water level and temperature warnings and causes
- Dashboard oil pressure warnings and causes
- Performance/Longevity
- Air-cooled white smoke
- Sump plug problems
Exhausts
Fuel System
Diesel
Petrol
- Carburrettor
Common
Alternative fuels
- Biodiesel Cooking Oil etc
Coolant and Heating
Cooling System
- Flashing red light on dash
- Anti-freeze - Brands, specs, dilutions and capacities
- Front pipe leaks
- Main pipe leaks
- Overheating causes and fixes
- Drain
- Refilling and bleeding system
- New radiator
- Running temperatures
- Replacing original front-to-rear metal pipes
- Replacing water pump, thermostat and adjoining metal pipes
- Temp gauge and sender malfunctions
- Testing radiator fan
- Oil cooling
Heating System
Gearbox Clutch CVJs Driveshafts (not Syncro front)
Automatic specific
Manual specific
- Clutch - pictures
- Clutch slave cylinder replacement
- Clutch slave-cylinder and pipework
- Clutch not disengaging
- Removing the clutch
- Re-installing clutch
- Gear change reluctance
- Improving sloppy g/c & g/c part nos.
- Gearlever pivot repair kit - fitting
- Gearchange - Pictures and drawings
Common
CV's and Driveshafts
VW Electrics (not camper interior specific)
- Electrical System
- Troubleshooting
- Upgrades and Modifications
- Pictures, Diagrams, Lists
Some electrical testing procedures from Fluke
- Petrol engine wiring
- Diesel engine wiring
Steering and Suspension
- Alternative steering wheels
- Steering geometry/alignment
- Wheel bearings
- Springs
- Anti-roll bar
- Replacing wishbone bushes
- Seized top shock nut
- Replacing wheel studs
- Lowering
- Radius-rod and bushes
Wheels and Tyres (not Syncro)
- Tyres
- Alternative wheels
- Steering/Wheel alignment
- VW Centre-caps for Merc alloys
- Torques for wheel nuts or bolts
- Wheel offset (ET) explained
Brakes
- Brake pipe parts
- Rear Backplate
- Pulsing brake pedal
- Rear brake servicing
- Bleeding brake system
- Bleeding nipples
Body Work, Chassis and Glass
Painting your van
Doors
Leaks
Insulation
Parts
Rust
General Information
Specific areas (details, photos, articles, etc)
- Kitchen/fridge body side panel
- Snorkel box
- Rear cross-member and repair
- Front bumper valance
- Cab steps
- Inner Sills
- Floor - sliding door side
- Front jacking points
- Rear wing bodypanels
- Offside (kitchen) outer sill & panel
- Window frame rust repair
- Seriously rusty van repairs - shows many areas exposed - excellent photo journal
Other relevant information
Body Accessories Exterior
- Square headlights alternative
- Wing mirrors
- Doka tarps, tonneaus, covers
- Removing decals and stickers
- Gutter trim
- Wheel centre Caps
- Intermittant wipers
- Left hand drive headlights and the MOT
- Indicator screws
- Regulations
- Fitting a spoiler
Interior (non camping)
Seatbelts
Seats
Headlining/ interior panels
Cab Door Armrests
Dashboard
Tailgate
Multimedia
Other
Camping Interior
Cupboards, beds, roofs, windows etc
Electrical
- Conversion specs and brochures
- Fitting a split charger
- Facts about auxiliary batteries
- Leisure batteries FAQ (inluding those that fit)
- Zig units
- Wiring radio to leisure battery
- Lighting
Heating
Refrigeration
Cooking
Flooring
Gas
Campers
Exterior
Conversions
- Camper conversions(link to media library)
- Camper Interior website, a photo feast... Take a look!
- Danbury Instruction Manual for Volkswagen Transporter (1981)
- Herman the German (Westfalia Joker) - lots here incl. interior shots and brochure pics
- Westy camper plans in pdf format (German) - Thanks to Aberdeenbus
Karmann Coachbuilts
Campsites
Touring/Camping outside UK
Syncro
T25 Alternative Engine
General - Techniques, Tools and Tips
Useful Data
- Types of screw fixings
- Fastener materials & selection
- Torques
- ISO Metric threads, spanner and tapping drill sizes
- List of nut sizes and torques
- VIN codes - decyphering
- Oils - Data
- Tyre pressures - Generic formula
Tools/Sundries/Techniques
Tools
- Tools for the T25 Home Mechanic
- Thread Tap and Die Set
- Screw/Bolt/Nut punch (drift)
- Screw extractors (easiouts)
- EMPI Rear hub nut spanner
- Engineering scrapers
- Oil-seal extractor
- Bench vise
- Thread File
- Thread Chaser
- Battery Impact driver
- Air compressors
- Rivnuts
- Welding equipment
- Hobby spot-blaster
- Glow-plug spanner
- Shelter-tent workshop
- QMAX hole punch
- Pipe spanners/hydraulics ring spanners/split jaw spanners
Home made tools
- Homemade gearbox removal clamp
- Brake bleed pressure device
- Cheap working light for inaccessible areas
- Chassis cleaning tools
Sundries
- Duralac anti-corrosion assembly compound
- Assembly lube
- Laminate fibre sheet (LFS) e.g. Tufnol
- J-B Weld epoxy repair
- Cold Front (welding)
- High-temp paints
- Weld-thru Zinc spray
- Rust-busters and penetrating oils
- EZ-Grip fastener head friction drops
Safety equipment and H&S usage cautions
- Goggles & full-face masks (grinding)
- Goggles & full-face masks (welding)
- Angle Grinder - Cautions
- Hi-lift jacks - Safety
- Drilling - Safety
Techniques
- Removing seized/broken studs/bolts/nuts
- Removing rusty screws
- Loosening (46mm) rear-hub castle-nut
- Annealing dural sheet
- Cleaning/Trueing mating faces
- Removing spigot shaft bearing
- Welding and brazing
- Bleeding hydraulic brakes and clutches
- Soldering wires
- Compression testing
- Removing rust (from components)
Insurance
- Dealing with claims
- Insurance companies feedback
- TEMPLATE copy and paste this for your entry
- Camper
- Caravelle
- Panel
- DOKA
- SIKA
- Non stock engine and modified
- LPG
Breakdown
T25 Media Library
- Images
- Pictures of hard to get to places and bits you don't normally see (also see Rust and Interiors)
- Sounds and video
T25 Camper Manuals, VW manuals, Specifications, Literature, Magazine Articles,
- Almost every brochure and manual
- Camper manuals /Autosleeper Trident/ Autohomes
- Specifications/towing/weights
- VW manuals
- Brochures
- Magazine articles
- Wooden toy template, can be modified to look more T25
- Origami
- Where to get manuals
Links & Addresses (Parts, sundries & other useful websites)
Parts & sundry Suppliers/Traders
- Parts and sundry supplies
- 2nd hand parts suppliers and breakers
- Mechanics and camper converters
- Carriers/delivery services
- Electronic (ECU) and Electrical Services
- http://www.dubdoctors.com/
Suppliers feedback gleaned from the forum
Internet links - Other relevant websites
- Karmann Coachbuilts Website
- Hightop-friendly carparks
- Other useful T25 and vanagon tech resources
- Other VW websites
- Club supplier contacts
- Westy jokers
- Heat Rust and Noise in VWs (That famous Bulley-Hewlett article)
- Dometic Refrigerators
- MOT advisories online
- Internet Links Stolen Vehicle registers
- Camper Interior website, a photo feast... Take a look!
- Criminal justice act Part V relating to trespass powers to remove, may have a relevance to overnight camping
- Herman the German (Westfalia Joker) - lots here incl. interior shots and brochure pics
- VWPix, Boltze & Co's VW brochure site
Misc tips, tricks and info...(including posting pictures)
Computer
Latitude and longtitude format converter GSF POI for Tom Tom sat nav
- 80-90 forum uploading pictures
- 80-90 forum clean url linking
- Google Earth
- GSF locations csv
- How to resize images.
- Installing Firefox
Parts Acquisition
Maintenance Bulletins
- Filler/filling problems
- Storage and over-wintering
- Heat Rust and Noise in VWs (That famous Bulley-Hewlett article)
.jpg){kind=link}
