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Welcome to a VW-Tech, the wiki technical archive of the Club 80-90 website.
NEW USERS START HERE, READ THE DISCLAIMER
PLEASE READ THE Disclaimer:
Club 80-90 Wiki History
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proceed, there may be a way to do something which hasn't been thought of, or they may be incorrect information which is out of date.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.
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:
- 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.
- 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)
- 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. 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? How to drive?
- The Buyers Guide by Simon Brickyard and others
- Syncro (4 wheel drive) Buyers guide
- A newbies buying experience
Tips and tricks and basic servicing
- 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
- Petrol engines - Oil & oil changes
- All engines servicing overview
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
- 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
- A/C Petrol engines - Cooling and heating systems
- 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
- Won't start (fuel)
- Replacing spigot-shaft bearing
Diesel engines
- Fire warning
- Types, condition diagnosis, Service Bulletins etc
- 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
- Engine oils - recommended
- Oil filters - recommended
- Replace throttle cable
- Replace starter motor
- Reluctant starting (starter motor)
- Reluctant starting (battery alternator)
- Reluctant starting earths
- Reconditioned engines
- Dashboard water level and temperature warnings and causes
- Dashboard oil pressure warnings and causes (DOPWS)
- Performance/Longevity
- Air-cooled white smoke
- Sump plug problems
- Dipstick lengths
- Engine bay seal
Exhausts
- Petrol Exhausts - Early/Late
- Exhaust system suppliers - Part Nos & Stainless Alternatives
- Custom exhausts
- Exhaust rust repairs
- DG Exhaust Heat transfer pipe
Fuel System
Diesel
- Diesel Injectors
- Glow plugs - replacing
- Injection pumps
- Fuel system Tips and Tricks
- Adding bulb pump primer and transparent fuel lines
Petrol
- Carburrettor
Common
- Acelerator cable replacement
- Tank removal
- Tank Cleaning
- Breather tanks
- Fuel economy
- Filler/filling problems
- Filler/filler cap
Alternative fuels
- Biodiesel Cooking Oil etc
Coolant and Heating
Cooling System
- Flashing red low/overheating coolant 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 - 2.1
- Replacing water pump, thermostat and adjoining metal pipes - 1.9DG
- Temp gauge and sender malfunctions
- Testing radiator fan
- Oil cooling
- Header tank and top up tank
Heating System
- Hot & Cold Air Blower - Diagnosis, Removal, Replacement And Modifications
- Dash blower PWM upgrade
- Air-cooled heating system
- Heater hoses
Gearbox Clutch CVJs Driveshafts (not Syncro front)
Automatic specific
- Automatics - General Information
- Gearbox oil checking/changing
- Automatic gearbox - Parts and finding them
Manual gearbox specific
- Clutch - pictures including release bearing
- Clutch slave cylinder replacement
- Clutch slave-cylinder and pipework
- Clutch not disengaging
- Removing the clutch
- Re-installing clutch
- Renovating 4 speed change mechanism Pt1
- Renovating 4 speed change mechanism Pt2
- Renovating 4 speed change mechanism Pt3
- Adjusting 4 speed change mechanism
- Renovating 5 speed change mechanism Pt1
- Renovating 5 speed change mechanism Pt2
- Renovating 5 speed change mechanism - adjustments
- Gear change reluctance
- Improving sloppy g/c & g/c part nos.
- Gear selection process
- Gearlever pivot repair kit - fitting
- Gearchange selection rod pictures and drawings
- Short shifter gearchange kit
- Transaxle Code
- Diesel Uprated Clutch
- Diesel clutch installation considerations
- Gearbox type swap (425 & 524)
- Diesel Clutch Slave Bracket - Breakage
- Drain plug removal, emptying and filling
- Gearbox oil
- Gearbox Clutch CVs - Gearbox corrosion prevention
- 80-90 thread on clutch slave cylinder pipes
Common gearbox i.e. automatic and manual
CV's and Driveshafts
VW Electrics (not camper interior specific)
- Electrical System
- Main fuse box
- Replacing - starter - battery - alternator cable
- Upgrading power connection to dash
- Rear lighting wire colours
- Haynes wiring diagrams
- Starter motor
- Diesel battery to starter cable
- Electric wing mirrors
- Wiring heated LT Mirrors
- Brake warning light
- Windscreen wiper functions
- Round Headlight Upgrade
- Square Headlights
- Headlight Adjustment
- Alternators/Generators
- Ignition Coil
- Non working temperature and/or fuel gauges
- Rewiring Dashboard multipin connector
- Dashboard multipin connector pinout
- Repairing Dashboard multipin connector
- Changing Ignition Barrel
- Changing Ignition Switch
- Simple Guide to Electronic components
- Troubleshooting
- Upgrades and Modifications
- Intermittent wipers
- Upgrading headlights
- Round Headlights To Square
- Headlight warning buzzer
- Rear fog lights
- Front fog lights
- Heater control illumination
- Dash Fan Control Upgrade)
- Dash lights upgrade
- Alternator size formula & tutorial
- LED Number plate light
- 12 volt live feed only when engine running
- Stereo feed from both batteries
- Adding an independent or new horn
- Smooth 12v/5v supply
- Pictures, Diagrams, Lists
Steering and Suspension
- Alternative steering wheels
- Steering geometry/alignment
- Wheel bearings
- Springs
- Anti-roll bar
- Replacing control arm bushes
- Replacing wishbone bushes
- Seized top shock nut
- Replacing wheel studs
- Lowering
- Radius-rod and bushes
- Power steering
- power steering Universal Joint Replacement
- Steering shaft joints
- Replacing shock absorbers (with Sachs HD)
- replace steering rack boot
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
- Speedometer Cable
Brakes
- front caliper replacement
- Brake pipe parts
- Rear Backplate
- Pulsing brake pedal
- Rear brake servicing
- Bleeding brake system
- Bleeding nipples
- Front handbrake cable
- Rear handbrake cables
- poor brake performance diagnostics
Body Work, Chassis and Glass
Painting your van
Windscreen
http://campervanculture.com/2011/05/fitting-vw-t25-vanagon-t3-windscreen/
Doors
Leaks
Insulation
Parts
Rust
General Information
Specific areas (details, photos, articles, etc)
- Kitchen/fridge body side panel
- Snorkel box
- Rear chassis
- Rear cross-member and repair
- Front bumper valance
- Front panel lower
- Cab steps
- Inner Sills
- Floor - sliding door side
- Front jacking points
- Behind VW underseal
- Seat-belt anchor plates (front)
- 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
- Rules on number plates
Interior (non camping)
Seatbelts
Seats
Headlining/ interior panels
Cab Door Armrests
Dashboard
Tailgate
Multimedia
Other
Campers
Camping Interior Cupboards, beds, etc
- Self build/repair/install, several pages here!
- Cab bunk
- Rear hatch ventilation
- Removing units
- Useful Westfalia specific sites
Electrical
- Electrical Standards & Safety
- Westfalia leisure battery charging
- Conversion specific electrical wiring diagrams
- Fitting a split charger
- Installing a TV
- Mains Hookup - Schemes and Safety
- Solar power charging systems
- Solar panel fitted to a tintop
- Facts about auxiliary batteries
- Leisure batteries FAQ (inluding those that fit)
- Leisure battery removal from under swivel seat
- Zig units
- Wiring radio to leisure battery
- Lighting
Heating
Refrigeration
Cooking
Flooring
Gas
Camping Exterior Campers exterior ,roofs, windows, skylights, awnings etc
- Westfalia
- Fitting Devon roof
- Fitting a pop-top
- Electric hookup
- Awnings review
- Stop the drip
- Hightop side windows
Conversions
- Camper conversions(link to media library)
- Camper Interior website, a photo feast... Take a look!
- Danbury Instruction Manual for Volkswagen Transporter (1981)
- Westy camper plans in pdf format (German) - Thanks to Aberdeenbus
Karmann Coachbuilts
The rare Karmann coachbuilt camper van
Volkswagen Karmann Coachbuilts Club
Campsites
Touring/Camping outside UK
Syncro
T25 Alternative Engine
General - Techniques, Tools and Tips
Useful Data
Tools/Sundries/Safety equipment
Tools
- Torque Wrench
- Brake adjuster tool for rear brakes
- Tools for the T25 Home Mechanic
- Thread Tap and Die Set
- Screw/Bolt/Nut punch (drift)
- Impact Screwdriver
- 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
- Diesel glow-plug removal spanner
- Shelter-tent workshop
- QMAX hole punch
- Pipe spanners/hydraulics ring spanners/split jaw spanners
- Underseal chisel
- Cleco (Avdel)locating pins
- Stainless Wire Brushes
- Chain-wrench/Strap wrench/Pipe wrench
- Belt (finger) sander {powerfile)
- HD (or industrial) workshop vacuum cleaner
- Sheet-metal joggler tool
- Battery chargers
Home made tools
- Homemade gearbox removal clamp
- Brake bleed pressure device
- Cheap working light for inaccessible areas
- Chassis cleaning tools
- Improvised deep-reach welding clamp
- Home-made deep-reach G-clamp
- Soda Blaster attachment for carb cleaning
- Emergency Welders
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
- Dinitrol (RC900) Rust-off primer (optional Chassis Black overcoating)
- Rustoleum Combi-colour paint
Safety equipment and H&S usage cautions
Safety, Safely & Sagely.
- 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 using vinegar (from small components)
- Handy method for inspecting inside sills/sections etc
- Some electrical testing procedures from Fluke
- Hydraulic lifters
- Bodywork and Glass - Rust - Elecrolytic de-rusting
- Joggling (stepping) panels for seam joins
Technical Information - non vehicle specific
Electrical
Mechanical
Other
Featured Parts
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
- Postocde rating
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,
- List of torques and specifications, fluids etc
- Lots of original brochures on an Italian website
- Camper manuals /Autosleeper Trident/ Autohomes
- Specifications/towing/weights/dimensions
- VW manuals
- Technical books Haynes etc
- 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
- | MOT testers manual in depth, you can download the manual opens as a PDF
- | MOT changes for 2012 opens as a PDF
- |Thetford portaloo spares
- Karmann Coachbuilts Website
- Hightop-friendly carparks
- Other useful T25 and vanagon tech resources
- Other VW websites
- Club suppliers
- Westy jokers
- Heat Rust and Noise in VWs (That famous Bulley-Hewlett article)
- Dometic Refrigerators
- MOT advisories online
- 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 site not active march20111
- VWPix, Boltze & Co's VW brochure site
- SBMCC (Self-build Motor Caravanners Club
Misc tips, tricks and info...(including posting pictures)
Computer
Latitude and longtitude format converter
- 80-90 forum uploading pictures
- 80-90 forum clean url linking
- Google Earth
- GSF locations csv
- How to resize images.
- Installing Firefox
- Joining the 80-90 Waze Nav App Group
Parts Acquisition
Maintenance Bulletins
- Filler/filling problems
- Storage and over-wintering
- Heat Rust and Noise in VWs (That famous Bulley-Hewlett article)
Fuel Economy
Performance; Power; Dyno results
Prices
Garages, Workshops and services
T25
General
Services
Health & Safety
Common workshop dangers
- Safety equipment and H&S usage cautions (From Tools, Techniques & Sundries)
- Safety - Driving -Roadside repairs - Off-road etc