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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 this page and 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. Please PM hacksawbob on the club 80-90 forums 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/Prospective Owners
- What are they like to drive?
- The Buyers Guide by Simon Brickyard and others
- Syncro (4 wheel drive) Buyers guide
- New owners' questions
- 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
For Maintenance Bulletins look in Misc Tips and Tips
Engines
Petrol engines
- 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.
Aircooled
- electric fuel pumps
- Aircooled running temperature
- Aircooled tinware
- Performance enhancement
- Thermostat
- solid lifters
- petrol engines aircooled push rod & seal replacement
- Differences between engines
- Oil pressures
- engine removal
- Petrol engines - Aircooled Cyl. Head
- Petrol engines - Aircooled Ignition
- spark plugs
- Petrol engines - Aircooled Carburrettors
Petrol specific engine Faults/repairs/maintenance
- 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
- 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
- Diesel Engines - Modified parts
- 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
- Injectors
- Glow plug replacing
- Injection pumps
Petrol
- Carburrettor
Common
Alternative fuels
- Biodiesel Cooking Oil etc
Coolant and Heating
Coolant
- Flashing red light on dash
- Recommended brands
- 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
Heating
Gearbox Clutch CVJs Driveshafts (not Syncro front)
Automatic specific
Manual specific
- clutch slave replacement
- Gear change reluctance
- Clutch pedal not disengaging
- Improving sloppy g/c & g/c part nos.
- Gearlever pivot repair kit - fitting
- Gearchange - Pictures and drawings
- Removing the clutch
- Re-installing clutch
- Short shifter gearchange kit
- Transaxle Code
- Diesel Uprated Clutch
- Gearbox type swap (425 & 524)
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)
- Recommended tyres
- Alternative wheels
- Tyre size calculator
- Steering/Wheel alignment
- VW Centre-caps for Merc alloys
- Torques for wheel nuts or bolts
- Tyre pressures
- 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
- Rust
- Areas that rust
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
Interior (non camping)
Seatbelts
Seats
Headlining/ interior panels
Cab Door Armrests
Dashboard
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
- Rock and roll bed hinges
- Inverter efficiency
- Towing connections
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
Campsites
Touring/Camping outside UK
Syncro
T25 Alternative Engine
General - Techniques, Tools and Tips
Useful Data
- Types of screw fixings
- Torques
- ISO Metric threads, spanner and tapping drill sizes
- List of nut sizes and torques
- VIN codes - decyphering
- Oils - Data
Tools/Sundries/Techniques
Tools
- Tools for the T25 Home Mechanic
- Thread Tap and Die Set
- Bolt/Nut punch (drift)
- 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
Home made tools
- Homemade gearbox removal clamp
- Brake bleed pressure device
- Cheap working light for inaccessible areas
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
Techniques
- Removing seized/broken studs/bolts/nuts
- Annealing dural sheet
- Cleaning/Trueing mating faces
- Removing spigot shaft bearing
- Welding
- Bleeding hydraulic brakes and clutches
- Removing rusty screws
- Soldering wires
- Compression testing
- Some electrical testing procedures from Fluke
- Hydraulic lifters
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
T25 Media Library
- Images
- Please of your pictures of hard to get to places and bits you dont normally see
- 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
- Origami
- Where to get manuals
Internet Links and Contacts
Parts 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
- Hightop-friendly carparks
- Other T25 and vanagon resources
- Other VW websites
- Club supplier contacts
- Non VW related helpful site links
- Westy jokers
- 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
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
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