VW Without Guesswork 10 1972

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Without Gu ork
'I Typesl,2,Jand4
October�Wi
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TECHNICAL DATA FOR WORKSHOP USE
This booklet contains all major measurements and adjustments for Volkswagens
of the Types 1, 2, 3 and 4 imported into the USA and Canada for the model years 1971,
1972 and 1973.
Use this booklet together with the applicable workshop bulletins and workshop manuals.
VOLKSWAGENWERK AG · WOLFSBURG
--
"'("· ,,_, , , "'-""
� .'-
-:
CONTENTS Au+o,at,c trnnsn, · ,,cm •est da•a
• • •
q Marking of gear
.
. ' ',0IS
• '"
00
R <tcs . . . . • 00
•
Eng me Pago • •
rv
'" T1ql tcn,n g torques • • •
T,,c-hn,cal data . v Do,.nle 10,nt shafts
• •
'"
tts
m "
'
,
,
rolerances,
Crnnkcase
b - Crankshaft
wear
bo,es
l,m,ts') and
.
•
sott«1gs
'
e ••
vt
Vil
lo , "'
,Ou ,p, 1�1on
b,1r adJu<;tm,•r1t
•
•
• •
•
• tan
tzt
c - Connecting rods
B,ak"� a11d wheels
• a
'
d - Ca,,-,shaft To,er,n' weer .,m,ts')
e nnd set'.1ngs
e - Lubroca!,on
g
- Flywheel
P,stons'Cylrnders
system
• •
•
•
•
''
.,
II ,
, - !ids'
wr-cci
r
•
cylwd 'r
cyli nders
•
•
•
•
• •
·�
iaa
.,,
'' ' RrakP drums a,scs
• • •
h - Cylrnde, head and v,, vos ' Brak,• 1,�1ng,
• •
,,
D
J • Cooling T,gnten11,g torqJes
• '' " • '''
tze
'"
•
Clutch
T,ghten1ng torques
• •
'"
''
"
11 I
Body
' ..
d,
, Id
• •
·�
Fuel �ystern .,,
T1gnten1ng to1ques . . . . .
DI
• • • • • •
II "
'
Carburetor settings
Fuel pumps
and rcts. Types 1 and 2
''
''
'
Elec!nca!
l\atter.es
sys!em
.,,
Front axle
Gercral data
'
•
D '
Tolerances,
a · Sett,ngs
b - Suspens,on
wear
for
l1r'r'ats')
tors,on
S'.ru:
and
bars
set:,ngs
stab1l1zer
• ,,
''
II "
Aux,liary
General
heater,
d,,n
Types 1, 2, 3 and 4
. • • •
.
'''
c · Axle beam and +o rs,on nrms ' '''

• General data
d - Steerrng ball J01nts, steer,ng knuckle
D
• • ''
e • Steering PPrlorn,anc,, and consu mp'. 1on
• '' • • • •
C�p<lc1t1e>
•••
! · Wheel a•,gnment data tso
• '' '
• •
T,ghlen,ng torques
• • • • • " "
i1
1 D1mens1ons Types 1, 2 3 and 4
• • tsa
"
Rear axle and gearbo•
''
A" cond,t,oner (VPC)
Marking of •ransm,ss,ons Comprcssoc 01: I Pvel

se
El
• • �
Temperature - pressure relatco�s�,p
'
Tolerances wear r,m,ts") and settmgs ' R·12
'"
" a - Gears, drive p,n,o n ss "
Ill Torque spec1<1cat1ons for compressor t
'se
''
b • Dnve shaft
• •
,c IV_ Torq�e sµf'c1f1CJ\J0ns !or flare nut
c - Fmal drive -: •
;o .,
The term Wea' 1,-n,t" means that pa,ts which are near, o, have reached
'''
d • Gearbox and gearsh1H housing
•
d1me�s,ons g,vcn should not bl' ,e,nstatled during repacrs '"•
e • DMa for automa·,c transm,sswn
• •
'' All measurements are ,n mm followed by inches ,n brackets (
I
''
, . ,. � .
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ENGINE
1. T"'hnl"*I 0.0
ombu,non Maximum
Octane l9n111on Idling
Max,mum torque at
En�,,,..
OutpUt I rpm ,n 1000
Bore
t,,-nbe, m '= compreu<an
require
lgmt,on
'"
Copa,:;,ty Strnkt pressmn
�·'
tlffil"!l weight
rvse Coo, Installed rpm ,n 1000
<ett,og
pre,.ure ')
letter
o,, SAe DIN {mkg) SAE {lb It)
ocm (cu ,n J mml,n I mm (m.
cy'Lnd01 !
r•llO ,rnmt RON ,,m
1es1 (bhpl
head ccm kg/cm2 (p<i)
''' '"'
>++) +<+)
>++I "+I ' 80-1001114-142) 50 ;,fter ++I 800-900 +++)
1/1600 Ae from Aug 1970 48/4 0 46/40 10 2/2 O 72 0/2.0 1584 (96 SI 855{396) 69 0 (2.
50 - 52 +++I �
'' '' '"
�
up to July 1972 I
AK +I from At,g 1972
1/1600 75-95(107-135) 50 .11., +-+)

' 800-900 +++I
Aa from Al!!i 1971 48/40 46/4.0 10 2/2.0 72 0/2 0 1584 (
00 61 855(3961 69 0 12.7
f,O - b2
'' 8 0- 1 0 0 { 1 1 4 142) '' 5o alter ++I

�
eoo.soo '"'
2/1600 Ae from Ac,g 1970 50/4 0 60/4.4 10 8/2.8 817130 1584(966) 85513961 69 0 12.7 50 - 52
up t
o July 1971
'' '' '"
2/1700 from A'-'!1 1871 66/4 8 63/4.8 116/32 81 0/3 2
51 - 52 7 0- 9 5 ( 1 00 - 1 3 5 1 5� after'"!
\01!3 aoo-soo
,,,
16781102.5) 90013541 66 0 1 2 6 C-
''
211700 c"'
o •• 1 from Aug 1972 62/40 59/4.2 116/32 83 0/3 2 1678 {102 5) 9Q O 13 541 66.0 {
2 60
51 - 52 '' 70-95(100-1351 5° alter'"! 000-,000 azs
' a
3/1600 u from Aug 1967 54140 65/4.6 11 212.2 87 0/2 8 1584 (96.6) 85 5 ( 3 96 1 69.0 1
2 72
,,, 80-1001114-142)
'' 5o t>eforo •I 800-900 +++)
"' - "' '' '"'

3/1600
4/1700' w
x from Aug
from Aug
1971
1970
54140
80/49
52/40
85/50
112/22
13.5/2 7
77 0/2.2
995/3 5
1 584 1 9 66)
1679 {102.51
85 5 13 961
90 0 1 3 5 4 1
69 0 { 2 7
66 0 ( 2 60
50 - 52
51 - 52
''
7.5-9 5 {107-130)
90- 1 1.01128 - 1 56)

''
00
50 Delore
27° Delore++)
•I
�B 800--800-+-++)
800-900 +++) '"'

''
- - '
'''
up t
o July 1971
,1 0 - 1 1 0 1 1 2 8 - 1 5 6 1 00 27° t>elo,o ++I 800-900 +++)

4/1700 eA from Aug. 1971 80/49 76/4.9 13 5/2 7 95.0/27 1679(1025) 90 0 ( 3 5 4 ) 66 0 (260 51 - 52
,,,
'''
4/1700
''
for C..hlorma only
from Aug. 1972

72150 69/5 0 12.3/2.7 87.0/2.7 1679 (102 5)
'
900 (3 541 66 0 ( 2 60 51 - 52 ''
''
7 0 - 1 1 0 ( 1 00 - 1 3 5
"'
27� beforo ++)
t}
i I I
800-900 -+-++)
" Jc
"I M1n>m<Jm compreS<JOl1 (wear IEmtl) see pall" 14
+I At ,dlmg speed lthrottlo eol,e do>OO. vacuum ho .., off) ••1 At ,dlmg speed (Throttle valve cl<>SW, vocuum hoses on)
•I From Augufl 1972 for code letter Ae
+;) a
t 3500 rpm (,ocuum hose, off) •••1 VehtclH w•th Automanc St1Ck Shtft I
#)
_, For Autorna!K: Tr0t")<m.,11on only
Up t
o July 1971 50/4 O {60/4 4). 10 8/2 8 (81 7 (3 0) +< •r Engme with cocle leller AE up l
o July 1971 7 5
Autom�t,c Transmn>Eon 900 - 1 000 rpm
•••• ) From August 1972 10° after TDC
'
v,--: '"'','-�' ' ' ' '
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II. Tolerances, wear llm,ts and settings
-
Tyr,<! 1 2,3/lf)()(J
Des,gmt,on Typo,211700
Wear Remark,
Newp,,i\
Now part ' Wear 1,m,t
I 1rn t
,
'
'
Crankcase bores
' '
Borns foe mam bwrrng, '
' a) Bear,r,gs 1 z a diameter 65.00-6& 02 12 5500---2 55fl8) '

' 65 03 12 5601 70 00-70 02 (2 7559-2 /567) i 7003 12 7570)
bl Beafl"'l 4 d,ometer 50 00-50 03 (1 9685-1 9696) SOM {1 9700) 11 9700)
so 00 so ro 11 0085-1 \1696) SOM
Bore to, o,1..,1/ilywh.,..l ond drnrnete, 9000-9005
' (3 5433-3 54521 - - 95 00 95 05 13 7401-3 7420) - -
'
a Bore for 011 se.,1/fan end
d,amete,
' -
- '
'
I
- - f,7 00 62 ()5 12 '409-2 4428) - -
Bores tor comshah bearings
diameter 27 50-27 52
'
11 002-1 083) - - ? I 50-27 52 11 0825-1 08331 - -
s Boce lor 0,1 pump hou"ng d1;wioter - - - 12 7559-2 75701 - -
7000-7003
e Bore, lor corn follower,
d1ome1er 1 9 00 - 1 9 0 2 1 7 48 0 - 7 4 8 8 ) rs os 24 00-24 02 ( 9448- 9456) I 94671
I 75001
b. Cronkshaft
'' oe
I
3 undor,1Zes of O 25 mm 1 010 ,n ) each
Crankshaft
' a) Mam 1oumal1 1 z a drarnetor 54 97-54 99 12 1640-2 1648) - - b4 S7-59 99 {2 3600-2 3617) - -
b) Main JOurrml 4
d13meter 39 98-40 00 {1 5739-157481 - - -
as 98-40 00 11 5739-1 5748) '
'
c) Connecting rod Journal,
d,amot•r 54 98-5500 (2 1644-2 16531 - - -
- 54 98-55 00 12 1644-2 16531
Crankshah a
t No 2 and 4 mam J()Urr>al, '
'
' !No. 1 and 3 )0Umal1 or, V block,) runoul
- - 0 os I 001 2) o cz I 00081
a Crank<haft
unbalance
-
.
max. 12 cmg - - =, 12 cmg - - -
Ma,r, bear1r,g 1ournal
out af round
'
-
- o os I 00121 - - ' uoa 100121
5 · Connecting rod JOUm•I '
out of round - - I
o oa I 00121 - '
'
'
o oa (00121
0
t
--
'
Type, 1, 2, 311600
Types 211 700, 4
Oe<,gnM1on
Weor Remarks
New patt New p0<t
Wear 1,m1t
iHTHl
s Crankshalt/m3m Journal, ltoktn� hou� ng prelm,d mto acc0<mtl
al Bearmg, 1 and 3
radial pl•v 00<!-0 10 ( 0016- 0041 0 ta I 007)
u rn, 0 to I 002- 0041
o,, 'I When repairm!j
bl Steel beaflng :> rad,�I play 0 03-0 09 I 001- 003!
cl Bearmg 4 0 "
I 0007!
oca 0 00
radial play oos o to I 002- 004) 0 rs I 0075)' ()()5-0 10

0 ''
r 0 ts
c,ankshalt/ma,n ,oum..r 1 '
er><I play 007-013 I 0027 ooe: 0 rs '0001 O o,
a Cannect,ng rod 1ourr111l/connect1ng rod radtal p•av 0 02-0 07 { 0003- 0027) t ooer 0 02-0 07
0 ''
'
0 ''
end pl•y 0 ''

0 10-040 I 004- 0161 0 ro I 0271 O 10-0 40 '
0 ''
0 ,o
c · Connecton� rod,
We,ght �1tlerenae between connect>ng rod, ,n ono engme

max 5 grams =, 10gr�m,'J max 6 gram, ma� 10!j(am,')
' We,i,:,t of replacement connoct,ng rods
- We,!,i,t (wh,rnJ t>rown/wh ,te

580---588 worn,
Wo1\f,t (black) grey/black
- 746- 752 gram,
592-600 \1"3ffiS
'
P1,t0<1 p•n
'
- 775 groms -
d1omoter 21 9%-22 00 I 8658- 86611
a
' P,<ton pin i:>ush - 23 996-24 00
''' I 9445- 9448) -
d1omet<r 22009-22017 I 8664- 86611
P«ton p1n/t>u,h
- 2401�-24024 I 9454- 94571 -
,oc1,.1 pl�y 001-002 {.0004-.00001 ( 0016) 001-003 I 0004- 00121 O oa
' 0 "'
d. Camshaft
Beanng, 1 a dco=ter 24 99-25 00 ( 9937., 9842) -

' 24 99-25 00 -
center beanng (bearir,gs 1 and 3 an
Measurer:! at '
' V blocks!
rvoout 0.02 I 00081
0 "'
(0016) O oz O o,
Cam,;h�ft/camshaft bea, l"'J< ltakmg hou11ng
' preload into accoontl ,ad,al play 0 02-0 05 I 0006- 0021 I 00471 002-005
Thrust beanng 0 ''
en<J play 004-013 I 0016- 00511 0 ''
I 00621 D 04-0 13 0 10
Camshaft !;jear 0 ''
• bock lash 0.00--0 05 ( 0-0.021 - 0 00-006 -
a
a
Type, 1 2, 311600
Tyr,< 2 1700,4
Des,gnatton Wea, Remark,
New port Wear l,m,t
"""' 1mr.lln1on
1,m1t
5 C,m follower d,ametor 18 00-1896 IO 74/1 O 1463)

)3% 2398 10 9432-0 9440) 23 93 (09421) ') Note t�e match,ng cok,, c<><J,ng w,thrn the 1n<l1v1dual '"" !j<Oup,
O Borelcom tollowe, radial ploy 0 02-0 06 10 D008-0 0024)
002 0 06 10 OOO!i-0 0024) 0 tz 1000411 Tho colors 01 � hlue, pmk, green
J Pui/1 rod rurH'.)(Jt mas O 3 10 1 21 10 121
" 0 3
� Lubntatoon ,vstem
1 0111.>ressure llor SA� 30 only) >ton orl tempeiatu,e
ol 70"' C 1158� Fl and 2500 rpm approx 3 k!j/C<"f'

2 1
4 2 p;,) 2 kg cm> 128 p$a) ,,
I 2 kg c,-.-,
'.l 128 ps,)
,,pp ox 3 kg.'cm2 [42 pi,)
2 Spr,ny to, preswre rehef YaNe
Length loadocl 44 1 mm 11 73 ,n I load 56-73kg 1 1 2 3 - 1 6 0 l b,; r

3 Spring l
or 011 p, ..,urn rohef valve
longth lood<d 39 0 mm (1 54 rn I k>ad

(15-191b>)
4 Spnng tor 011 pn,,suro control ,olye "8 8 8
Longth loaded 20 2 mm IO 795 on I load 31-38kg (68"·84ib,J

5 Spring for ml p<essuro oontrnl volvo
L"'19th loadOO, 26 0 mm 11 02 rn) lo;,cl

1 l-20k9 137 441bsl
6 0,1 pre=,• sw,tch open at pre,,ure 0 15-0 45 kg/cm> (2 1-6 4 psi) 0 15 O 45 kgtcm>
f Flywheel
1 Flywheel {measured at contr< of friction surface) later•I runout max 030 (012) ,nox 04 0 (
0 161
utmalance max 20 cmg .o cmg

2 Shou,00' for o,I ,eal outr.,de d1• 14 9- 75 1 (2 948-2 956)
699-70 1 (2 7519--2 7598)
J Dn,e plate unbalance rnax 5 cmg
max 5 cmg
g - P,ston, and oylmden
2 o,e•,izesof O 5 mm { 020 ,n ) e•ch
1 Cylinder, wt of rou<><ier/p,stor1 . clearar,cc 'J 004-0 06 {00016-00231 10 008) O M-0 06 10 0016 -0 0023) o zc 1
0 0081
3 a) Uppe, prston r,r,g ,ille cloorarice 007-010 W 0027-.0039) 10 00<\7) 0 06-0 09 (0 0023-0 00351 (0 0047)
bl Lower p•stoo nng so<ie clearance 005-007 {0.002 - 0027) 0 ''
10 004) OM 001 {00016 00027) O to 10 004)
u
''
-
•
!
•
Types 1, 2, 3 I 1600
Types 2 1 1 7 00 . 4
'
Wear Rem1rk,
Dc<tgnaloon Wear hmll
New port Newport
1,m,1
-+
{.0011-00191 0.10 0 to
., when repa.,,ng
"de clo.,•nc• 0 03-005 I 00<1
O 02-0 05 ( 0008- 0019) I OO<I
0,1 ocraper r,ny
'
s •I Upper pi,ton nng
b) Lower P"ton ring .

. .
.
•
•
.
•
•
·�
�,
�,
0 30-"0 45
0.30-0 45
0 25-0 40
( 012-.018)
{012-018)
j 010-016)
000
000
0 ss
( 035)
{.035)
{.037) '
ll 35---0 55
O J0---0 3
O 25-0 40
5
{014-.0211
(012-0141
{.010-0161
o ao
o so
{ 035)
I 035)
.. ,
Typ, 1 - from August 1971
•• • 1 P,n"" weight
s 0,1,cr op�r ring . 0 as I 037)

Type 2 I 1700
P,ston we,ght .. .
t . .
398-410g,om,
.
.. " . .
wOF!jht (brown) 496 - 504 gram,
- we,ght !brown) . . .
406-418 g,am,
.
' . 456 - 464 gram,
< weight !grey) . . . .
.
402-412grann\ "") . .
- we,ght (brown) . . 504-512gram,
. . -,ght lgr"Y)
410-420grorr1' ••1
.
. .
•
+ weight (groyl . . . . . . 464 - 472 grom,
m•x 5 gram,
rn,, JO gram,•
m,, 10g'"m' ")
e Weight d,!lerence b<>tween p,<lon> ,none engme nox. 4 9''"'"
Type 4
. wo,!jht {brown) 472 - 488 grams
h .Cyl1nde< hoad and val=
. we,!jht (grey) 480 - 496 gram•
Cylir>der ..,ot,r,g depth 1n cyhnder he,w:l
1345-1355 I 628- 5321 54-6 5 (.21-.25) . •
inside d,. 1800-1802 17086- 7088) ( 7000)
20 00-20 02 1.7874- 7882) ao oe I 78901 Type4
' •I Rocker arm . .
dtameter 1799-17.97 ( 7081- 70731 ''"'

17 95 ( 7065)
1995-19.97 I 7854- 7861) 1993 I 78461 (from November 1971)
b) Rocker sh•ft .
. weight (brown) 480 - 488 gram,

Valvo ,pnr,g,
.
,o� 63 2-61.2 kg {1172-134.Slbl . .
498 - 506 grams
' Length loodod 31 0 mm 11.221 .
. .
.
,
o� 765-845kg (168-1861b)
L eng t h lo ad od 2 9 0 m m l 1 1 4 1 w•>Qht {gr,,y) 488 - 496 gram,
•
J . Val,o w�ts 506-5149,ams
.
width 1.4-2.5 ( OS- 101 1 8-2 2 (07-081 .
.
•I ,mak•
.
1 4-2.5 10.5- 10) ( 078- 0981 .. Becau"' oft� d,florent p«too we,ghn
width 2 0-25
exh•ust
. necessary 10 chock the we,W,tdur,r,g repalf
,eat ar,gle ac- . ,1.,
"' ,nuko .
,,.
''" . .
. ,eat "'1gk as-
"' exh.ust .
. .
,, rs-
" outer correction •r>gle . .
,;• .
';•
,,. .
inner correction •"91e . .
"
''
''
T y p o , 1 , 2 , 3 / 1 60 0 Typ�s 2 I 1700,4
Rema,ks
DHognot,on w,. Wear
New port Naw port
l1m,1 1,m,t
Valve 9u1d�•
103150-03157) e oe
S (l()-8 02 a oe Me•ou•od wnh thronlo .alve open, •ng1n1: warm. all spark
' intake
ms,de d11 800-802 .'
F 98 (0 3534 0 35381 10 35661 plug, out, g<iOO g•uge •ng,ne turn<!d w,th nartor
exh11Ust •
,ns,de d,a 800-802 (0 3150-0 3157) eoe '00
d11mNor 7 95-7 94 103125-03129) z so
I 94 '"
' ss . .' For Type 2 land Type 4 EB! ongmos only
s V•lv& stem mtoke •
d1ame1er 791-792 {03113-031171 SJl-892 '03507-03511) ''' (034911
exh11Ust
001 oi round o ct (0 004) '"

G 01 '''
'39 1 as 3 11 539-1 546)
d,amet&r 35.6 11 40)
Vol•• head intake •
J?l-330 11 286-1 2991
' exhaurt d,omernr
ae ' 11 26)
Val,e 111.ude/,ol,e ,tem.

') 40 {0018) (0 0461
,oc, 0 23-0 27 (0 009-0 0101 (0031) ' ao
' ,ntake ond exhau<t •
''
a Valve clearaooo lcokl)
15
-·�
, I (0 0061
(0 006)
mtoke
,
l 15 (0 006)
0 ''
sett1r,g (0 0061
exhoun
0 '' 2
c, 0- 1 1 Okg/cm 1128 156p,q 7 0 �g/cm' 1100 p"l
9 . Comp,ess,on preuuro 80-10k9/cm> 1114-142 P"l 7 kg/cm21100 P<>)
• 0 9 5 kg/cm' ' 'I ( 10J- 135 I'") 60k9!cm' (85p,F)
•) Typ<n 1 ond 3 - from Aug. 1971 7 5 -9 5 kg/em' (107-135p") 6 kg!cm'l85 p'1)
max 2 kg'c"'' 128 ps,)

Pressure d,fforer,co b<ltween cyhnders ma,,: 2kgfcm0 (28 p11)
! · Cooling
c, 70° C 1149-158',1
opemng tomperMu,e 65-70"C (149-158° Fl
Thennostat
' . Fan�lt pulley out of balance max 5cmg '"" 5 cmg
2
''
''
Type, 1, 2, 3/1600
Type, 211700,4
Wear
De,..gnat ,on
New part Wear l,m,t
New part
! l1m1t
') Type 3 from Augu,1 1971

Clutci>
• 380 - 440 kg 1838 - 970 lb• I
380-420 k.g ') !838-925 lb,I' I 1838-970 lb,)
Toul µras,u,e 440 kg
'
'
' ' ma, 15cmg
Complete clutch out ol balance 15 cmg
'
a P,eswro pl.,ta runout 0 10mm I 0 004 r n l
(0020,nl
•
Clutch plate later.I ''-'""'"' m•• 05 mm 05mm 10020,n)
10-20 mm (04-08 Ln) .,,m 104-08m)

e Pray at clutch µe<lal r ?O
,e
''
w
Ill Tightening torques Types 1, 2 and 3
��-�
lb ft
3-3 5 'I 22- 25 ' I -I F1eploce co�toct, .rfoces oileJ

cc,n11Kt1r1g "xi nut MS x 1
Com,ecu,,g roo,
- a "I
I I
C,-nkco,e h,l,es nut MS '' T1qhtenrng cyl1ndo• head nuts
se•img nut M 12 x I S '5

3 ' S 20 K "
ra
Craflkcase hal,..., ?3 •• )
,,1 M 10 35 S 20 KV ''
3 2 ") 1 T1\flt<n nuts l,ihtly l,r,t
Cyl1nde, head
10 2- 2 5 1, 1, 2 Then llgh'en 10 1mkg 17 lb ltl
M8
nocker ,hoft to cyl,n<ler twod
O,I pomp to c,ankcase

"" MS '' 10
,,
rn the orde, si,ov.•n
"'' M 14 x 1 5 9 S 20 K
'' '' 3 finally t1�0t<•r1 to the"
O,I <lratn plug pl�y
,,1 MO s ''
o, s q,Bre<I wrr1,,c
0,1 ,tra1rwr to crankc ••e

1 1 SS SS ,o
,,1 M 2 x 5
Generator pulley 's
g,;,xl n1Jt M 2 8 x 1 5
45S�OKN " ssa ''
flywheel to cronks11oft
'' ' .. )
F1eµlac,•
M 8 x 1 5 SS IS
Clutch to flywb""I
�"
'!)ark plu9
M 1 4 x 1 2 5 '' '_,
''
Spark plugs
nut M 10 e '' ''

tn91r,e to tcan,m,s,ion
boll
MS ' ''
10
Coo,,e;ter t
o drive plate
''
''
Type, 1 �oo 211600 only
I nc,( M 12 x 1 5 9 S 20 K
Spec,•I nut far fan
'' ''
pulley
M 2 0 x 1 5
9 S XI K ''
' .s '' 29- 36
I
Crank,h•ft
�"
I Type 211600
IS
bolt MO
Er191c,e carrier 10 c ankca"' ' s
M 10 "' �
TyJ)<'311600
' ,o
bolt
MS
-
fr,g1no c•rr<e, (
0 crankcase ' 0 ,_,
'
M 10 00
' Spec•al ba,t far fan and
')S?OK 13- 1 5 \M- t08

M 2 0 x 1 5
I bo, t
cra�kshaft pulley
' Type, 2 and 311600 only

25 ''') 18'")
sell lochn� r�,: MS
En9,,.,. c�mer to be<fy
I ''
- 10
I ,s
Tightening torques Types 2/1700,4
ThrCMJ
Locatoon Remarks
m<a lb ft
Roploce, contact surface, mlOO

c,mnecting rod,
conr>ec!1n9 rod rtU! M
41 c, 4 a 3 3 'l 24 ·1 .'
'' t
,o Trghten r,ua ,l,ghtly •nd then tum to Sf>l'(:1f1od torque m
Cr�nkca'"' hal,a,
oo, M a a .. '
'' '' the lollowir1g sequence

seal,r,g oo! M10x1,25 35 S 20 KV
Crankcase halv�,
'' ''
oo< M <O 35S20KV 3 2 ") 23 "I
Cyl1r>d<r head
oo< M t ,c tt
RockN >haft to cyl1r>der head ' s
M 12 x 1 5 9 S 20 K
0•1 <ira,n plu�
'' '"
011 str&Hlef t
o crnnkca<e
' "'
..,.1,ng n<Jl M e 9 S 20 K s
' '
rocket head ,crew M 12 x 1 5 ro s
Dflve plate to cranksh•h re '
'' ''
Hub to cranksh.>ft
wit locl:mg 1:>olt M e SAE 1022
socket head screw M e ,o

'' ''
Fan to hub
spark plug M14x125 '" a.s ,s

''
Spark plug,
Er;g1oe earner or brackets to crank ca.., self lockmg nut M s SAE 1022 ,o
011 pump to crankca.., M a a ,o ''
'"
sell lock,ng bolt M 1 2 x 1 5 10 19 tt 0
''
so
Flywheel t
o cronksh•it 22 Cr 4
ooO M 8 x 20 eo as ,s
Clutch to flywheel
''
''
Fuel System
I Carburetor soll•O!i• ond )''" '
' , , , , , , 2 1 6 00 Type 211700 T , o c ? ' l 7 00 � , , n t·•�sm Type 2, 1700 aut= tran,m

Tyl)€ 111600 Type 111600 {M 91 fype 111500 IM
Veh-:le
(up t
o July 19721 llro,p Auq 19721 {from Aug 19/21
-
a 34 PICl a 34 PICT a a 34 POSIT- 2 a
Carbureto, type 34 PICT a 34 PICT 3 1 ,, Cl 34 POSIT 34 PDSI r 34 POSIT - 3 34PDSIT- 2 34 POSIT
Part No
1 1 3 1 29 0 29 8 113129031K 113129029T 113129031 129031 DG lelt let, ' r>Jht left right
1 4 1 1 29 0 3 1 '"''
1 4 1 1 29 0 2 9 T 141129 031 G 141 1290'29 T
' 021 129 021 L 021 1L9 028 L oat 129027P 021 129 0 28? 021 129 027 M 02\ 129 028 \
�
,, (�)J 001
AH 00000 1 C 8 000 00 1 CD 000001
AE COO 001 AH 000001 AH 000 001
from Er,grne No
AK00 0 00 1
''
AK 00000 1
' ,,
Ver1tun mm dtametN '' '' ''

'' '' '' ' ' ?5 137 5 x 130 x 132 5
Mom JOI
'"
x12751�130 x1275/x130 x1275'x12
155/050 ,se
' '"' ' '' -
'
752/701
Atr corre<.bon Jet 75 Z • ') 75ZIBOZ 75Z/80Z
'''
,,,
.•oJlb75)
-
Pilot JOt ' 00
c ee '' ,,o
' 1 ' G tao
'''
1�7 5
P1iol )<'t a,r bleed mm d»me,er 147 5 147 5 147 6
1'�14251 ''' '
- -
Aux,l1ary fuel Jet az s az s ,, '' '' ''

- -
'' ' mo 00
'''
00 0 ' 0 '
Aux,l1ary a" I"' 00 ''
-
'
' 1 2 I 1 2 t 2 11 2
Ael 1el d<11i1r,g mm - 1 2 I 1 2
- -
''
100 I 100
I
Power luel JN 1 00 / 1 00 1 00 / 1 00 1 0 0 / 1 00
''
' '
,
, ' z
Float need lo salsa mm diameter
' s ' s ' s ,, ',
o ' ''
} OS OS o, ''
o, ' 0
Wosher ur>de, llo•t needle sol,� mm
t 0 ''
'
'
as ' ' ''
'
Float wmght gram,
'' 1�51015 0 4 5 " 0 1 ''
0 7 �0 1
' '
Pump tnJe<:tLon quant,ty cm3/,troke ''
1 3 - 1 a
''
1 3 - 1 6 1 3 - 1 6
''
' 0 '
"' '
''
oa oa oa
'
Throttle ,alee gap mm
'
- ' '' - -
'
' ') For Cai1lorn,� only

' ") Karmann Ghta Model, eo z
'
'
'
'
' ''
' ''
mr
>
z
H, Fuol J>Ump
' M,mmum <1<1tvory

from Eng,,.. M�x,mum
'
,,� P•rt No copac,ty R•mark,
' So delivery p,e,.ure
'�
Ae I 400cm3/m1n
AH 000001 !13127025CID)
.'
••
' 13-5 P"I
A,
O 35 kg/cm2
a ''}
co 000001 02 1 1 2 7 02 5 A 400cm3/m,n ,aoo
(5p sil
''
FRONT AXLE
I. Toloronoe, """' 1,m1t, and oettm •

----------�-------------------------
a Front tors"'n bar ,e\tings
Susp�nsoon strut,
-�-----··· �------------<-� --------

Introduced Number D ,mete, Le'1\lth
Typ� 1 / Sedan D,men.,on, Type 4
Model Posit,on
from Chassis No of le .....es mm<,n) mm (1n I
mm ! i"'
n. I mm (m) mm Im I
'
---------+-- --
up 10 Juli 1972 from Aug 1972
954 {37 5581 . ')
1 1 6 (}()(] 001
''
,o '"'
bottom >,> ""I -'
").
- - - +-----
a', od< to s e
as
''
0 top ,' effective coil, e
2 1 0 2 C()() 00 1 %0 138 582) 6. 00 ' 1°
a bottom mm 1,n I ttc 1
4 131 {5 08) '
'"
--- mm{,n) 10 4� 104101
'''
12 35 {0.4801
... )
an 0 coo 001 14 9 (0 586.) 859 1338181 390 10 mm (tn ) aze aee 115 161 441 5 {173811
J,<0rlwr p1Ston d,amernr mm (,n I "'

11 25)'
,, 11 259) (1 2591
,, , -1,mrt,er maximum ,troko mm (m)

'' 16 881 17 081
'' 17 081
'I Tor""" bars are preloaded, 1vh1te p.,,nt ,pc.tor, er>d mu,t he on lelt "" ''' '"'
�!abrl,ze< !Type 3)
Wl1e11 1n,tallmg a new ,priny noli, cokn code Spr "�' are a,arl•blo ,n 3 groups
Both Sj:><Jng, on one axle mu,t be ,.;mo cul or co tie

319 000 001 13 7 (0539)
31 36
l
--- -- - ----- -- ' hont >nd '""' ,Prrr,g, are d1llecont
137(0539) -- Vary,r>:J w,re diameter 10 3 mm 10 404 ,n I to 12 25 mm 10 431 ,n I largest diameter 1n the cente,
368 149 834
'"
Autom•t,c
- - ---- ---
l Now a•>d p,e,100, ,µ• ,rig, tllu>t not be p,rred Wh,� spnngs are roploced <luring rop.,1r<, note tM d,ffarence,
,n tr.e <1,me11s,o,,.
''
•
•
--
Type 1 /Sedan 111 Type 2 l ypo 3
De,1gnat.on
New pan Wear l1m1! New part Wen, 1,m 'Jew part Wear hm,t Remark,
'
( I
.
A�t., b<,am and 1<> s,on arm•
' Tors><m arm h•ae1ng, 1n a�le beam •
• 1 when t.,1,r,g w, ,11 VW ?S;i d the mon,J•el r,ust c0<1tact the measurn,g su rfaee
•
' a) S.at to, upi,.,, n�le b<ar<ng diameter 45 97-45 99 . 5697-5699 - J,«7-4Jgg -
{1809-1 6101 12 242-2 2431 •,o 1 7311
Ne<edle b1,ar,n� d,a,.,ete, . 56 96-56 99 - 0 -
'' 0
11811) (2 ?42-2 243) '•
•
1221
Thrust ''rig• diameter - - �711-5719
•
- ,. •
• -
12250-2251)
11 ')81)
rl,ameter 46 17-46 19 - 57 17-57 19 . 41 17 44 19 -

°""""" 11 817-1818) 12 250-2 251) 1 739)
Needle b,,ar,r(l d,ame!e< - -

• •
,
._ """ -
'
'''
11 819)
I
•
, 400)
Thru,t ''ng• d,omoter - - - - ,1 3� -
'460)
•
b) Seat tor 10>10, noe'.Jle brorir>\j d..metor 49 97-49 99 - 5697-�699 - 4g99 -

' J JI
{1 967-1 96135) 12 242-2 2431 • 067-1 968)
Needle hearing diameter eo O - 56 98-56 S9 - -

' '0
11 g53J •
(2 242-2 243) ' j Jb8&)
O,er�,e d,ameter 50 17-50 19 . 57 17 57 19 . "'J 17-50 19 -

•
(1 975-1 9761 {2 250-2 25!) 975 1 S76J

Needle beanng diameter so, - 57 17- 57 19
I
- ',() 2 -
{1 9763) 12 250-2 2511 96631

Bush,r,g for
' a) Tors,ona<tT1, UPI>"' 37 20-37 25 37 38 43 2-43 27 43 40 ,-, 15-3520 32 38

11463-1465)' ( 1 47) {1 700-1 7021 11 70) rn, 1 3851 11 27)
•
bl Tors,on arrr, lower 37 20-37 25 az ae 43 2-43 27 4340 J:17-3322 33,38
11463-1 465] 11 47l 11 /00-17021 11 70) •

aos 1 307)
( 1 66)
a Tor,,on arm ., •
twr,t - -
.' -
'"
'"
Type2 Type3 Type4
T y pe 1 } 5ed on 1 1 1 T y !)<' 1 l � Oll 1 1 3
Remark,
Now part New part I Wwr l1m,t New part Wea, l1m1t New port Wear l1m,1
New part
d · Ball joint,;, ,
t ...rmg knuckles
1 Stoonnq boll 101nt, plaay 2.5 ') ") When check•ng with leve,
' 0 ' 0
(.041 VW281a.
Boll Jomt,, uppe< ""I play ma, OS 2 o-i o, 2.0 • 1 2 5")

' 0 '")Type2only
I ) 12)
After fnt,r,g new 1om11,
Ball Jomu, lower "'I ploy max. O 5 1 0 ")

'"" Js,X O 3 2 0 ·1 m,, OS 2 0 -r
peen to 6-9 ton• wnh
I o,1
VW471threet1me•
2 Steo«n<J h>uckle/.tub axto o 15 '""I 0 15 • • •J

••• I Mea,url!<! with
d1,tort!On I 006)
VW258k/p
Steoring kr,uckle/col•pi,r f!ong� I Q {J5 ''') I
±005 •• 'I
do>torl,on I 002!
3 Wheel bearmg inner. 1n<>de d,a ?9 00-29 01 29 00-29 01 ! >, 75-3177 1 2,! 00-29 01 29 00-29 01
{11417-114201 ?499-1250711
outs,de drl, 50 29-50 32 , 5029-503?! )

Q 13-5916 so 29-50 32 60 29-50 32
' 119799-1981� ,) 3279-2.329() I

''
17 46-17 48 ' ,>05-1907 17 46-17 48 1746-1748

4 Whool h<10nng outer, 1n51de di•. 1746-1748
( 6873-- 6880) ,'499- 75071
39 B!l-39 90 39 88-39 00 t,24-4526 i 39 88-39 90 39 S!l-39 90
{ 1.570-1.5708) 7810-178HII I
b Seat for mner wtwel b<J.Ormg stub •xle 28 98-29 00 28 98- 29 00 , 73 31 75 I 28 ,!8-2900 28 98-29 00
(1.1403-1.1417) )491-124991 j
brnk• drum 50 25-50 28 50 25 -50 28 " < 09 - 5 9 1 2 , 50 25-50 :>8 50 25- 50 28
{1.9783-1.9795 ,,: ",163-? 3275)
,o
''
r
I
Tvp• 1 /Sodon 111 Typ� 1 /Sed.,, 113 Type 2 +) Type 3 Tvpe4
De<1gnat,on ' Remark,

N-part Wea, ltmh: N""' part w... lim ' New port W'1>.r l.rmt New port '
We»r l,m,t Now part Woot i.m,t
'
I
'
' '
I
Seat t
or outer wheel beanng ,;tub oxl� 1745-1746 1745-1746 1gOJ-19.05 1745--1746 17 45-17 46
. .
·1 !f axle" no,.y, adJust
'
'
{ 6869-68731 I !491- 74991 t

o lower i,m,t
brake drum 39 84-39.87 39.64-39 87 0 20-45 23 39 B4-39 87 39.84-39 87

'
••1 Model 14 14 14
'
(1 5684--1 5696) 11 7794-1 78061 '
t Whwl beanrig play 003-012·1 ••" I After cO\ledr,g

. . . . . . 003-0 12 .) 03--0 12 ') 0 03-0 12 ") 003-012"1
(001-0041 3000 m,1e,
'
e · Steermg 8-10cmkg
Ste.,.mg wh""I turn• from lock to lock ' 17-8.7 m lb)

2 1/2
'
2 314 2 3/4 2 3/4
',n
2 . Stoer,ng 9'l•r rano '
. . . 19.4 ts 0 19.4 zz.aa

a Overall rat,o . . . .
•
14 34 "*l '' '
16.5 19 35
I
+I "P 10 July 1972 .
Worm tuml"lf torque {for ax,ol ad1ustment) ''' ''' ' from A� 1972 -
' w,thout o,I "'31 . . . 1 5-2 5 cmkg 2.0-3.0 cmkg 1 S·-2 5 cmkg 1 S cmkg
' O"SOcmkg Worm ond Roller
'
(1.3-22m.lbl 1 7-4.4 ,
n lbl pe •teennQ gear
ty
'
with seal 20-JOcmkg

. . . . . 2 0-3 0 cmk!i" ! 2 0-2 Scmkg lno repa,r poss,D!e)
(1.7-26m. lbl
T,rj,tenw� torque for peg <ecuring nut

- - b cmkg - -
' 229m.lb)
e Peg turning torque . . . .
- - J-3 0 cmkg -
'
-
t Total turning torque .
'
'
. 9·- 12 cmkg '

5-9 cmkg '1 cmkg •••) 9-12 cmkg up to 8 cmkg
(Steer,r,g 91'1'' o, ..mblod) 17 8-10 6 ,nJbl 144-78,n '
220mlb) (7 B-10 6 m.lb) (7.0 ,n lbl
"' i
,,
''
f · Wheel alignment data
With 14 m. wh....is, an angle of 10" equal, a toe moo,,Jrem"'1t of . 1 1 mm {0043 ,n I

•
15 ,
n . . . 1 :2 m m { 0 04 7 , n l Remarks
• . • . .
+ ,n lront of a track moas1.1romar,t m..n, too-,n, -· mmm, toe-oot
T<:$t cond,t•m•
I n,trument ar.d wheel mocror,; properly set
Vciw;le empty
CorrO!Ct tire pressures (for pe,m1ss1ble total we1ghtl
S<ap<,ns,on free of ten.,on
Vehicle •hgned correctly.
Dos,gnat1on Voluo
TYJ>0 1 /Sedan 111
1 - Total t
oe anglo w,th wheel• not pressed . . . . . . . . . . . +30"±15"
Total toe angle w,th whools pressed 5'±15'

. .
• • • . . . . . .
•
'
a P, ....,,. apphed t
o wheels . . . . . . . . . . 10±2kg{22±41b
• •
4 · Max,mum permoss1ble d,lferenco botween rNd,ng, wrth wheel, pr

essed and not pre..ed .
,, .
e Front wheel camber ,n s1ra,ght-E1eod po.,11on ' . . . . . . . . .

'
0° 30' ± 20'
M.!X1mum perm""ble d,fference betw..,n ,id ..

' '
. . . . . . . . . . .
'
ao-
s Toe •"Ille 01 20° lock t

o left and nght {wheel, r>Ot pressed) t
o left - 1 ° 2 0 ' :! 3 0 '
to r,ght -2° 10':!30'
7 - Offset botween ,rub axles . . . . . . . . . . . . . . . .

" mox8mm{0314,
8 -Caster angle of• wheel . . . . . . . . .
' ' ' ' " "
' ' ' 3 ° 20 ' t 1 °
9 - Corfffpand> to th• combo, d1fforence of a wheel on a 20° k,,::k t
o left •nd right . . . . . . . . . . 2° 15' :!40°
'
'' ''
r
Des,gna11on v.1,..
Remork,
Type 1/Sadan 113
Totol toe angle ol front wheel,, not pressed + 30' t

' Toti I too ar,gle of front wheels, p,e•
• ed 10'± 'I AdJ
USt as cto .. o, pos11ble to 1 °
''
';·
a
' Pre,<ure •wl1od to wheel•
' ' ' 10 � kg 122 ±4 lb<
Max,mum J}1!rm,n,ble d1llerence �twetm total toa angle with wheel, pre,sed •nd r,ot pro,sod ze-
'
s Front wheel comber w,th wheel< ,tro,ght •mead '} '
' 1•1+20·
-40'
s Maximum perm,1<.tile d1fferer.ce between ,<des ao-
Toe-OlJt •ngle •t 20° lock to left and "ght (not p�s....:11 :!:30
a - '' 11mm{0433,
' Stub •�le oll,et ma�
a Caster 1ngle ol • wheel

'
2° ± 35'
m Correspond, t
o the comber d,lferonce of a whoo I on• lock from 20° left to 20°, >ght 1°20':!:25'
'
R&ar ••de
Rear wheel cambor w,th spr,ng plate< properly >e

t l•lter U 1.,.,1 300 m,lesl
' al Veh,cles With doobl•·1omt roar ax!< all mC>deh -1°20'±40'

'
b) Veh.cle, with ,w,r,g oxle
Modol 111
pe,m.,S1b!e mm,mum camoe,

_,.±
1° 1°
Model, 14, 15 t 1°
perm.,.,ble m,mmum c•ml:>or . ''

-1° 30'
Maximum perm,.,1ble doflerenco 1:>etween ,Ide,

'
'
models w,t� doublo-Jo1nt oxlo ss-
"'
model< with ,w,ng •xle ao-
I
Roar whool toe ""!l� wnh correct comber "'
' '
1 ' ' •II models w,tt, double·Jomt •xi• oo � 'S'
model< w,th ,w.,19 axle

_,. ±1 O'
a Max,mum perm 1u,blo dev10!10<1 ,

n w�I ahg=ont "'
' '
m,, 'O'
''
''
o,•• gn•tton Remarks
V•lue
Typo2
Total toe angle With wheel, oot pr=d . . +15'±15'
'
Total toe angle w,th wheel, pru«d . ()" ± 1 0 '
.
'
a Pressurn appl<e<J to wheel, . . 15±3�g{J3±5 I
•
Maxomum p,,,m.,s,i>le difference between re.ld1ng, w,th wheel, presoed •r>d
' ,, .
oot r<"™'d .
•
5 · Front wh� camber ,n rtro,ght •head poS1lion . . . . +40'±20'
Max,mum po,m,,.1ble d,llorenco t>etween S1do, . .

•
ao-
Toe out ar'lglo at o 20° lock t
o Iott and r,ght (wt,.,.i, r,ot pre..e<J) . . . 30' ± 30'
' - '"
OH<et between stub axles . . max8mm(0314,
•
'
s Carter •ngl� of o wheel . . . . . . . . 3"±40'
equals the camber d•flerence of• wheel on• 20" lock to loft •rxl right 2° ± 25'
,,
'"
Des!ll"11l>On Value
Remar�,
'
0 Roor wheel camber w,tt, Sj)l'ln<J plate, properly ><at
laher at 1...,.1 300 m1leol

,,
all modolo - 5 1)' • 3 0
Maximum r,,,m,..,i}le d•fforence between "des SO'
R�ar wheel toe anglo w'1h CO<fOCl camber
''
oil models +10't20'
Ma�1mum perm,u1ble ctev,at,on ,n whoel alignment
" all model, 'O'
'
,,'
'
,,
;i
,
,'
'
'
i
,I
d
::
'
i
''
'
:I ''
Rema,k,
Type 3
1 Total t0< angle w<th wheel, not pressed + 40 i 15
2 Total toe angle wrth wheel• pressed + 30' ! 15'
3 Pressure appl<ed to wheel<

10�2kg(22�41
4 Maximum perm,s"bl� d,tterence between read ,rig, w,th whools pre"ed and not prcsse<:I ,o
5 Front wheal camber ,n straight ahead position
1° 20' �20'
M•x•mum perm,s.,ble difference b<en,..,en s>de,;
6 Toe-out angle •t • 20° lock to k>lt •r><I nght (wheel, not pressed)
to lelt -40 '30
to r,ght -10 t30·
7 Offset between stub axlo,

max 8mm(O 3141
8 Ca,t,,,- angle ol • wheel

4° �40
equals the camber d1fte,-once ol a wheel on • 20" lock to left ar>d r,ght ?
0
40'175
'
,i
n
'
''
''
l l
,,
i
,l_
I
i "
• DeS>gnat,on Volue
I,
' '
s lh,ar wheel camt>er with spnng plate. properly set
Iafter at least 300 miles) all model, - 1 ° 20' t40'

'
,
;
Mox,mum perm,1<1ble d,llerencc Mtwoen ,!dos all model,
10 Rear wheel toe angle with correct cambor Modal 31 -5!15'
MOOol 36 0° t !5
11 Maximum perm,.s,ble d"'1,1t>0n ,n wh""I alagnment max 10
'
'' ''
Remarks
Varue
ype4
1 Total toe ar,gle w,th wh�I, r.ot pre,sed +20·+15 ') Mea.urn only w,th test •F>PI '"""e VW 361 (three p,ece) 1n pos,t,or1
' 0' + 1 5 ' Pointer of VW 361/1 on center of cast,ng rib

;
,L 2 Total toe ac,gle w<th wM<I, pressed
3 Preswre appl,ed to whwls 10 ..!'. 2 kg 122 + 4 lb,) '') T�ke into account late<al angle of seh1<;ie
4 Maximum perm""ble d,fference between ,eadmgs
with wh,..,I, p,e,...d or,d no

t presSW zs-
5 To• out •nglo on 20° lock to l•lt and >'\]ht (w™'ol, r.ot p,e,.odl 1"20''40
6 Camber w>th wheols ,tr•'.lhl aheod 10 10' •25'

Ma, ,mum permi,.,bl� d,fleret>CS t>etwe,,n S<des SO'
7 Caste< ac,gle 1 ° 45 ' ± 3 5 '
equol, the camber d,11,,.-ec.:;e ot • wheel on a
20" kJcl: to left and r,ght 1 ° 1 0 ' :!: 25
8 Stub ••le offset rnox 11 mm (0 43 '"
9 Total rMr wheoi toe angle') +10i15
10 Camber ot rear whoel, - 1 ° ± 3 0 ' •• I
Permis,,ble d1tference 1:>€tweer1 ,ide, SO'
11 Maximum pe, m ""ble de,iat KJ 1

1 ,
r. whoo I a l1gr1men\
'O'
12 Drive>11,t1sett1rq; 110,ni
25mm
Ollset bHwttn veh ,cle cef\ter ,'ld eng1ne,1•an,m1Ss>0n un ,t center 110,ol
25mm
Center of ldt me•sunc,g ho'e to center of ri1it me,,su,,ng hole 1126+1 mm '4 43 '00�
Center at lett measuric,g r.010 to center o' nt, on transm,man 58 8 ± 0 5 m m ,231•002rn)
Comer of "'iht rneosur1c,g �'" lO center cf 11 b on trar»m1S<ton 5 38 l 0 o m m •21 ;
'' ''
11. · T,ghtemng torques:
Location Th,ead lb f! Remarks
• - Front •�le - Typo 1r.i.d"" 111 ') T,ghten nut wh,le turhmg wheel. Then �k off :,ut unt,1 the
'
v
,
,' front axl• to frame M 12 x 1 5
00" sc ,pec,l,ed "''•I play of O 03 - 0 12 mm (
0 001 - 0 005 m I
'' '' ''

Shock ob,orber t
o """ plate M t0 e "obtoined IBrack•t VW 769 with dtal gouge)
""' "'
' 0
• o lower tor"on arm

Shock ab,orber t ru, M <O e 3 0-3 5 ''
22-25 o lower l1m1t
II tront asle ter>d, to bo noESy, k""P ploy t
• "'
{ M 1 2 x 1 5 5 O· 7 O 36-50 o OJ- O 06 mm (0001 - 0002 ,
n I
i Steenng boll 1omts '• ") ..,11 lock,r>g nut as a
orM10x1 4 0-5 0 29-36
• \\11,en pl�y "correct, t,gl\ten socket h<ia.d ,<:row to tho
Wl1eel bearn;ll cl•mp nut S<><:ket h<,ad scr•w M, to s 1 0-mox 1 3 •1 7-mo, correct torque
'"'
".'
T,e rods ,lottod nut M 12 x 1 5 3 0 "I 22")
Stewrng damper to t1• rod

... )
Hif lockf"9 f>ll1 M10"1
'' ''
a ,a '') T�m on to cotter p,n l><>le.
' "' ''
Steer.no damper to •�le tube 00" M <O as 4 0-4 5 29-32
s,,ucrew lor tor,rnn bar M14x1,5 '' 4 0-5 0 29-36

• '') Alway, u,e new 5<'11 lockmg nut> oher rerno...ol
'"'"''"w
Lockr,ut for >t>lscrtw lock.-.ut M 14, 1 5 4 0-5 0 29-36
"'
'' ''
I
J ,.,
' ' '

' '
Oual•ty Ten,1ie
De•• gnat,on Throi,d lb ft Remark,
cla,s
·-
b Frontaxlo�Typei/s..don11l
.,
za Turn on to cotter p<n hole
Track control arm !o frame head M 1 0 x l ' ,,
""' ''
Track control arm to t>all Jo,nt M 12 x l 5 ,
, u
zs
T11jhten nut while tucn1r,g whe.l Tr>en back off nut until the ,pecrli«!
,lotted nut ' 3 o ') n '·,
Sto!i,li,...- to track control arm M 12 x 1 5
'' ax,•I ploy of O 03 - 0 1/ 1nm 10 001 - 0 005 •n ) "obtame<l lBrocket
'
Stab,l<>er clamp to frame head
WI 769 with 6ial q•ugel II front axle terd, to be r,o,sy, keep play to
Suut moont1ng to shock absorber

"'
M 14 x 1 5 '' ' "
71-8 5
''
so lowec l,rnit O 03 - 0 06 mm (0 001 - 0 002 ,n I Whon play a<correct
Sturrng h;uckle axle t>all 1omt M <O

' as '' tighten ,ockct h�od screw to the correct torque
'' ' '

to <1rut
Strut !o body MS e
' 0
M <O to a ''
' Bocking plate to >teonf'lll knucklo
'
10.9 I 0-max
' " 1 3")
''
7-max 9")
Scrow ,n clamp <rut iOCket heod sc,ew M>
,, ldlor ym brackot to body oo« M <0 SS

'" ''
ldlet .,m to brackot M 1 4 x 1 5 e
' ""' ' " ''
J
' Ad1u,t1ng bolt 1n idler arm bracket MS e
""' ' " ''
"
'
'
'
''
,
,
1'
!
I
'
J
-----'----·'--·---
''
'
'
'
Ou,l,ty Ten.,re
Locats,n De,,gnat,on Thread
,,oo cl•s, m<s lb ft Rf>ll'lorks
C•nter t,e rod to drop arm and idler arm ,lotted nut M 12 x 1 5 - 3 0 -r 22 •1 •) Turn on to cotter prn hole
Stde TIO rod• to center 1,e rod •rwJ ,lonod nut M 12, 1 5 - s
'
3 o 'I 22 ' I
l!I
steermg knud;le
Clamps on tie ,ods �, M 8 x 1 - a

Locknut on tie rod �, M 14 x 1 5 s
' '
"
St-mg damper t
o framo head oo, M to ''
- to s '' ''
St-,r,g dampe, 10 drnp arm oo, M ro
- ''
1 (}-4 5 ''
29-32
''
'
'' ''
Gua'aty l
b ft
Loc;•l1on Des,gnat,on Thread
!Tade
Front axle - Type 2 '

'I T,ghten nut wh,le tu,mng whwl Then back off nut unt,I tho ,pec,fttd
' 9 J-12 5 65-00
Front •• le/lr•mo bolts ("d• memt>er I M 1 2 , 1 5 rz s
tz ' ox,ol play of O 03 - 0 1:Z mm (0 001 - 0 005 ,n ) "obto,ned (Bracket VW 769
""' ,c
Shock ab<Ofb<r uppor moummg
Shoe� obsorber lower mountm�

�· M 1 2 x 1 5
M to SS
'' '"
2 5-3 5 ''
18-25
w,th d•al gauge) II front axle ter>d, 10 be no,sy keep play to lower hm,t
0 03 - 0 06 mm 10 001 - 0 002 ,n I Vt/hen play co,rect, 119'>1en =Ket head

""'
I
S
,,
B•I I )')mts to ,teen t1ll knuckle ' ' ' ) ,elf lock,r,g nut M1Bx15 SS e
,crew t
o tM oorroct torque.
1 0 -m� 2 0·1 ''
11-max 14 ·1
,ockot ;crew ro s
Wh"� bearrr,g clamp nut h<ad
1 "I Turn on to con er pm holo
3 0 • ·1 22 • • 1
{M12x15
,c
T,�md, ar>d draghnk •••1 Alw�y• use new ,ell lock,ng r<Jts oft or remO\lal
slott•d oot 2 G •• ) 18 "· 1
M 10 x 1 ,c
l,0-45 29-32
Steor.ng damper lox lo tube 00"
M10x40 ,c
29-32
Steer.ng dampe< l,w,.-.. l�er 00"
M10x72 ,c 4 0-4 5
Set>erew for ton,on bar> <ttscrow M 14 x 1 5 CK 45 KV

' ' za
'
'
'" zs
' Lockr>ut 10< selicrew lockoot M14x1,5 SC
;
/
'"
.J 5-5 0 25 - 36
"
'
Stal><llle< to tor,,on a<m
�· {M 10
SC
to x
, ;
'
"' ''
i
' '
' '
'
'
r
,
'
:1
'
'
''
'
1 ,
,
;;
l
'
,
,
i '' )
' ,
,
Loconon Ten><le
Oes,gnot,on Thread l
b ft Remarks
class
' '
'
'"' d • Front lll<lo - Type 3 'I Tighten nut wh,lc turn mg wheel Then back off nut un11l 1he spec,fted •�1al
I '
'
.
, r
pl'1y of O 03 •• 0 12 mm I 001 - 005 ,n I "obtained I Brocket VW 769 Wtth dtal
From axle moont1ng
gauge)
upper •nd lower 0011 M 10
'
'
' ' ' o be f>O"Y, keop ploy to lower hmtt O 03 - 0.06 mm
If front ax le tends t
,Ii j b center 0011 M 10 ,c
'' '' ''
' 0
002 ,n) Wh<an ploy" corr�ct, tighten ,ocket heod ocrew t
o the correct
Setscrew for ton,on bor, reuc,,,,,., M14x1.5 ''
s
'' { 001 -
'0 torquo
Set.crew for ,tab,l'lor ..,,.crew M 1 4 x 1 5 '' e 1 5-5 5 ''
32-�0
., I
Turn on to cotter pin hol•
Locknut for ..!>Crew locl:oot x 1 5
M 14 '' a 0
•• • 1 T,ghten clamp OOlt t
o 4 mkg 129 lb It) ftr,t, then t•ghtan adJustmg bolt t
o 1 mkg
Torston bar to axle l:>e•m M 10 ''
ac ''
zs
' 0 17 lb HI and lock f
t
Clamp bolt to, stab,h,er ""'
0011 M 10 ''
ro s as
ro '
Ad)Urtmg bolt for stobtlizor 0011 M a ac I
'
)
'
••• ) 7 •• ')
Shock absorbe< to oxle beam roll M 12 x 1 5 tu s; ''

ro s 3 ,J-3 5 22-25
Shock obiorl:>er t
o tors,on arm 001 M 10 ac a 1 0-3 5 22-25
St.,.rmg «rm <

m steering b'O.Jckle roll M 10 x 1 ro a r; :, ,o
Upper •ru:l lower ball io•nts

{M20x 1 5 0 , '''
s I ' 0 00
'"' M 1 8 x 1 5
''
Clomp bol" for upper ar,d lower boll roll M10x40 10 S
io,nu ''' '' ''

Wheel l:>earmgciomp nut oocket head screw
,.
M ro « to a 1 1 -mox
' a- 7-max
T,e-n>ds
'
M 1 2 x 1 5 ac 10
. 0") 22 ")
slott«l mt
{ M 10 x 1 SS a l � ") 18 • • 1
Steering d•mper t
o axlo roll M 10 1 D-4 5 29-32
Steeri1>9 domper t
o drop arm M 10 ''
ac ''
a "
'"' ;
''
I
s,
ff\tl \
/ 11 ,
i !' i
f ,
i
, '
I '
' ' j
) '
,
Ou�hty
11" Locanon De,;ignat1on Romar�,
Th,e"'°
.�. '"''""
c '"
n,'.g lb lt
• · Front axle - tyl>" 4

-
' •1 Tighten nut whde \urnlflll wheel Then back off nut um,! the >!)<Clflod •x.al play
of o 03 _ o 12 mm 10 00 1 0 005 in ) " obtained (Brocket VW 769 w<1h d,ol 9""9" I

' From axle""""' t
o body 00" M 1 2 x 1 5
so 55-6 5 40-�7
T,acK contml arm to front axle carr,er M 12 x 1 5 '' e e
58-65
If front axle ter>ds to boa no••y, keep pl>y to low..- l1m,t O 03 - 0 06 mm
""'
,,
Rad,u! rnd to front ••le carr,er ooO M 1 2 x 1 5 ''
10 ,
' o
10 001 o 002 1r, I When play "corroc! Hghten ,oc�et head ,crew lo tho correct
" StaDlli,er t
o track coritrol arm '0 n
0-0 58-65
�1 M 10 torque
00 3-3 5 22-25
StaDlli,er t
o bod
y �1 M 10 ''
eo 4-4 5
• ·1 Turn on t
o u,lte, pin Ml•
Sto•ring knuckle •nd ball ,0"11 to strut
,,
00" M 10
4-4 5 '' -3''
29 2
•i
' Strut bear, nq to nrut • • s!Sf lockm� nut M 14 x 1 5 ''
OS '' 50-61
•• 'I Alway, u,e new ,ell lock11\\l rots ottor rem Olla I
Stmt to track control arm •• 'J ,ell lockong nut M 14 x 1 0

Str"t to body ••• )
OS
' ' ''
4-4 5 29 -32
,elf lock,ng nut M e OS
"
s 1,
ldlor a,m bn,cket to body 10 ,
00" M 10
'
'0'
'
z
ldlor orm to brocket '" 'I self t M 12 x 1 5
''
lock,r>Q nu
OS
0
'
1 Loc� od1u,ttn9 ,crew
M ''
'
-·
e
'
a 1,
Taper rtng on t,e-rod
-1 M 1 4 x 1 5 '' a 2-2 5 14-18
'
'
Clomp on tie rod
M '' a 1 5-2 11 -14
""'
1 ' S,de 11e-rod to"""'"' He ,
od and ,1eor1ng knuckl� ,lotted nut ''' 5
M 12 x t ''
eo
' a 3 "I 22 "J
arm Klier m
1 T,o-rod to drDI) otld ar
slotted 001 M 12 x 1 e
3 ., I
a 22 ' ")
Steering domper to front axl• carrier
00" M ro "' 4-4 5 29-32

' Stoe,,ng dompe, to 1,.,.rod
00" M to '' '' 4-4 5 29-32
'
l Splash sh••ld to ,teon"!l k nuc�le
00'1 M ''
so
e
''
SS t
;' Wh""I beann9 clamp nut sock•t head >Crow
10 ' 10 s
1
1 -mox 7- max
,
,
"' 1 3 •1 e 'I
'
'
1
' '
' SS
!
i :
!
r:
, 'I
; i
i ji
'
1 1'
, 1
',' '
, ' Ou•l,ty Ten,,le
Locot,on De,,gn•t1on Thread m•s Remark,
'
'
'
'
gracfo class '"
"
,,
I
'
'
'
1< Steenng gea,. Type• 1 and 3

•
2 5-3 0 18 · 22
Stt,ermg gear t
o •�I• · Type 1 M 10 ,c 00
.,, f
Steenr,g gear to axle - Type 3
""" M 10 ,s 00
2 5-3 0 18 · 22
Lock=t for roller shaft ad1u<1,ng screw luck nut M 10 x 1 SS

' """
'e
I Steenr,g gear co,er M 8 x 1 2 5 ?O - 2 5 1
'4
' - 18
'
' oc
' Drop arm 10 roller >halt M 1 2 x 1 5
,o so
""" 00
S1ecr,r,g wheel """ M 18 x t 5 so
Lockt-.ut for ,teOrlfl!l worm adJustmcm ,crew -·
locknut M35x15
''
9 S''
20 K
50 -6 0
20 - 2 5
'
3'
6 - 43
14 - 18
I St«lrmg coop I ,
ng to ueermg worm MO to « to a
' F I d,sc ,,,
"""
ta
m }" to coup mg
MO 0 ' ;
"
,
,
' '
Se-11-<;arcelmg rir,g on stwr,r,g wheel f1ll"ter head screw AM 3 5 oc OS OS
''
' '
'
' '
' locknut tor tapered nt19 to He rod lockr,ut M 14 x 1 5 ''
e
'
Tte rod retam1ng clamp M S ' t '' '' ''
I ',
Stoenng column moontmg plate t
o mstrum•nt panel
""' '' ' ' "
M S ''
' ' s
, ,
,
,
Bracket for <!Ccentnc nng on rteenr,g column tube '"'
bolt MO ''
''
's
"
I ' "
, ' Typo 1/Sodon 113 addmonal part, ''
' ' Un,venal J<,,nt shaft to stoenf1!l geor ar>d column <ell lock,ng r>.Jt MS ,s
, ' 10
Drop arm to ,teenng goa, roller <haft M 1 0 x 1 5 Cc < 10 0 ''
! Steem'l\l gear t
o body ""
bolt M ro '' ,o ''
,, ,,
''
Locknut lo, sp1r>dle W1u,11ng bolt locknut M41x15 9 S 20 K ''
' 2 0 - 2 5 14 - 18
, Steering gear cooer M8x125 oc
Locknut tor steen"ll adjusting bolt """
locknut M 10 x 1
,, ,,
10
Column tube to HIS!rnment panol ooO MS 1 5 - 2 0 1 1 - 14

I
Swnch to collnl'ln tub,, ,ocket i,eOO ..::rew MO 0 5 - 1 0 36 - 7
' '
I ,
' '
I , 00 01
I 1
,
"!j
'
' '
• '
'
,
; j,
,
, I'
' '
i1' I
Location Ten«le
lb f
t Remark,
grade class
' '
''
'
• •
•• •
b - Steenng ij<ar - Type 2 (upto July 1972)
'1
"
• Steering gear to ,.de momt>er oo, M 1 0 , 40 SC 3 5-5 0 ,s
I Drop arm to .shalt
M20,15
no
''
58 - 60
'"' ' c,
Sw,ng l<ve, to shaft
• bolt ''
' ' M 12 x 1 5
'
•
Steerrng wh"'I to column ,,, '' '' ''
M 16 x 1 5 2 5-3 0 18 - 22
Flange to steer, ng worm ,,, ''

'' MS
a
Coupling dr,c to flan!I" slotted nut '' '' ''
MS
s
' '' ' s
'
'
Steern>g column cop to floor pl�� l,ll"ter Mead <erew
MS SS
"
•
'
'
St«rmg gear c•.e cos er oo, '' '' ''
MS s, ,s
1 '
1 r
' Steeron.g gear end co,er ''
bolt ''
MS
te
'• •
'
•
'
i"
- St1'enng gear - Type 2 (from Augu.i 1sn1 '' "
j
' '
�·
Drop arm to shaft
ue rm
M ''
R,i
'·'
:I
'
,
I '
i
i .
'
'
, .
;
'
' "
J }
s,
I ,
' '
!i .
'
•
'"
•
.
•
TenS<le
•
' m<, Remark<
Location D"'19Mt><>n Thread c1 ••• '
" ft
•
c · Steenng gear - Type 4
•
I Steer mg case upper and lower part,
Locknut for worm ,pmdle

oo,
locknut
M8x125
M35x15
to a 2-2 5
,.,
14-18
36---43
l!I
Locknut for sector sh•ft locknut 2-2.5 14-18
M 1 0 x 1 5
S1oer,"!J box to body

'
10.9 29-32
M to
•
Drop arm t
o sector sholt
•
""'
<pec1•I nut M 2 0 x 1 5
''
9 - 1 1 65-80
•
Couplmg to worm sp,ndle oo, MO
'rc s 2-2.5 14-18
•
•
Stc,,nng coupling to column rocket head screw MO 08 a
• •
'
Twoaarm flar,ge to d,.,,
,, ''
' rocket head screw MO
•• Column ,w11ch t
o bracket/pedal cluster rocket head screw MO
,., '
05-1 3
''5-7
x • oo, 00
•
Column tube "-'Dport, rng ta bracket MO
•
i
Steor1r,g wheel to column
'
4.5-5 5 '
32-39
• M 18 x 1 5
""' '
Steer,r,g column SWftch t
o column tube . rock te head screw Ma '.0
•
'' us
'
Caoce! l ,
r,g m t
ca o steering wheol 1
1,1 •
•wr head screw M 3 5
•
• ''
' ''
I
•
•
,
· •
j
TRANSMISSION ANO REAR AXLE
l. Mark,ng of tran,m.,.,on,
Mark,r,g
Tran,missrnn coo.
M Mo R•mark, ol solv•
··� letter
as,;eml:tly
Trnn,m"'""' No
Remark,
··�
•
1,1500 St•ndard Double J01m •xle from August 1968 on the 111
' '' T ,r,< nt tr•nsm,,.,on Monu•I tron,m,,.,on
Sta.-.Jard Double JOmt »<le '•

from August 1972 Automatoc St1c� Sh1!1
•
' ''
MS Automat"' Stock Sh,tt
a • AutomatLc trao,m,.s,0t1
Ill
SA 0 123 698
'
2/1600 Standard Double 10,nt axl� CA 0216409
'
2/1700 Star>dard Do<Jble jOFnt axle c, !from August 1971
'
a M 249 Automatic Tr>nsm10«on MA 0000 from September 1972
•
3/1600 t Standard Double Jorn\ ax l
o oc 0 231 79{)
I
a • M 249 AutomatK: tr•n""'"""" a 0 1 1 7 822
'
''
• St..-.1ard Double 10,r11 "'<le from Aug<J<t 1970
'
''
from May Hl72
''
a M 249 Autom•t>e 1,..,..,.,,,.,00 cc 0 up t
o July 1971
a M,� Automot>e tron,mr,,ion 0 from Augu,t 1971
''
•
•
•
.z
.'
'• .
•
1 ,
"
''
'
/ l'
-J'i '
' I. Toleron,,,,., Wfla
r hm,ts and ..,rt,ngs
,P
' '
Manual tron.m,,>1on
Automat.: S!1ck Shilt
Typo, 1, 2 and J
' De�gnot,on Remark,
; '
New part Wea< 1,mn New part Wear l,m,t
mm Im I ,mm{,n) mml,nl mm l1n I
'I
Try t
o keep to lower hmit {O 10 mm/0 004 m )
• . Gear,, d"�' p>mon
I
J 10-025 ·1 - - -
; 1st gear erd play
III
' ' '
''} Bea<mgs u..d more thon 30 m,le,
,lOQ4-0010)
z 3rd 90or
0 to o za - 0 to 0 25 ') -
end µlay
' ' ''
' '
- •• ·1 wid�,
a 4th gear -
, 10 o zs - 0 10-0 25 Operot,r,g ole,we with ,lot
end play
0 5-0 85 mm (0 019-0033 m )
Synchrome,11 un,t,
• '
J clea,ance "a" belw""n coup Im� te<>th •r>d syrn;hroni,e, rmg 1 12 !)ears clearance
1-1 8 o so 1 1- 1 8 oso
I
,, 043-0 070) {0024) 1
0 043 0 0701 10 0241 I
' 0 000 ; ; , a 000

3 1
4 �.." clearance ; ' I
1J 039 0 070) {0024) (0 043-0 0701 {00241
0 C 10-030"'') - o 10-oJo ••• I -

Sh,tt fork/ope•at,r,g sleeve, fur 1 12 and 3 /
4 gea" end play
'
1 004-0 0121 (0004-00121
Pre load oi p1oton tapered roller bearir,g
" Tum,ng torque 21 cmkg

'
- 21cmkg -
' "=
' Hl3mlbl "
1 5 2 - 1 8 3 , n l !) j ' '
I
u , 00 • • 1
' 'I cmkg - 3- 7 cmkg
I -
"
,26-61,n 1 2 6 - fi l m l o )
'"'
:
'
! "
;
, j
se es
,
[ ,
:
Manual tranom, ..,on
Automat,e St,ck Shilt
Types 1, 2 and 3
Remarks
New part We,,; l1m1t New p,,rt Weor hm,t
mm (,n I mml,nl mm {<n I mm Im)
' '
b · Drove sllatt
7 Dnve sh•ft, front Isurface for 3rd ge,,r ne•dle l:>eannq)

runaut mox O 02
'
c · F,na! dnvo 10 0008)
' ' 8 Play at d<llerontrol ge,,r, With dill hou,in<J bolted together 114-020
,
o 0055-0 0061
0 03-0 OB 0 tz
10001-0003) 10 0051
Ploy between d1ff hou>tog and cov« /georshaft
rad,al
' '
f)QJ.006
0 ''
0 001 • 0 0021 10 005)
9 Roar •xle shaft,
• Flar,ge/d,ffcront,al Qear> {measured aero .. the
convex lace<)
'
clearance 003-010 o zo
iO 001-0 004) 10 008)
b M..,,u,c,d at t:,..rir,g ,eot ,haft between centou

'
ma, 0 05
10 002)
''
''
! '
Maooal tran,m,ss,oo
Automatfc Suck Shott
Tyl)E!s1,2•nd3
Remarks
New part I Wear l,m,l New port Wear limit
mm (m) ,mm(ml mm (1nl mm (1n I
.s
r
d • G.,..,box and 11""nh•ft ho<as,ng
'I Bearing, u<ed more than 30 mde,
10 ?reload ol Imai drive cov�r, on tapered roller bear mg,
•
Tummgtorque ,ow 18-22cmk�
! • 1J 35 cm�g
1l6-30m lb)
(158-193,n lb)
u..,d 'J
3 7 cmkg 3- 7 cmkg
1)6-6 l 1n lbl ( 2 6 6 1 1 n l b l
11 Plasoc pack,t,g/transmas,on case/ •xle tut>e/ tµbe retame,

•
•
G 00-020
• ' ,
� 000 -0 0081
/' Shift rad shtft prewire
6 5 K�
• 0 20 kg
''
! , i
o 44 lbl 114 lb)
Geo;sh,lt t>ous,ng bcnhmgs 15 25

• • 1n,.:Je diameter 1',05-1503 15 2& rs os 15 03
'
·
,
· '' 10 6001
1)592-05911 10 6001 10592-05911
Inner shift 1.,e, . 14 75
.
• •
dtameter 1500-1496 14 15 1500-1496
• ''
-
, 590-0 5881 10 580) 10 590- 0 588) (0 5801
r
,
St•rter boshrng 1255-1257 12 65

• d,ameter ·2 55-12 57 12 65
J
'""d<,
'" 10497)
J 493-0 494) 10 4971 (0 493-0 4941
'
Startor shaft/bush,ng .. o zs
• , '19- o 14
r o zs 0 09-0 1�
• !
• '" 10 0101
• 1<'0035-00051 (0010) 10 0035 0 005)
• !
, ,,
DrlV• shafts
measured between center, runout r 5 {0020) 05{00201
'
•
,,
•
• ''
MaNJ<O tr0<1,rT1'S!IOO
Ma.,.,,1 ,r,n,r1l1!"on
Typ•4
Type4
D"''-"'"°" D<,,gn,1.,,,,
New p•rt Wear l1ma
New put Wear l1m1t
mm \,n I mm i,n J
mm Im) m rn l 1 n l
.
-· ·-
F•nol """"' Typo 4

G�or ,.t ladJU<tln�) Tyl"' 4
I Tum1n� torcyJ< for taperod rolle, t>e,rin� / dri,o pi�1on
t Asi,I ploy new t>e,ring T,mk�n 18- 22 omkg -

C 00 o re
•
IO 003- 0 0061 116-19 IOI
z
i
n
Syrichromesh urnt,
,,, 16-20 cmk�
Cl•or•= t:..1,...,n cuupl1r,g tooth I
1 1 t. - 1 7 • n IOI I
,v,x,hronizer rlCJ!l 1•11lnJ'
IO 047 0 0771 (
0 01
q 1
lbo•rinll' u=J mme th,n 30 mtlO!I 13-6,n IOI
a Cleoronco be,ween Oll<l'""''l ,1.,,. ,h,lt te<< O 7-T O

' I z Tu,n,riy torqu• for d,ff«•nt"I t,.,.,,nl)l
100:n-OOJSI o 04 7J
18-22 cmk� -
new bt•""H'
Ax,ol c-,a,once of the '°"""r,h,h
• 0 01 u as 116-19,n lbl
10 002 0 0131 ,_, .

all U!<ld i)e>f<)}\l< cm):.g
s Countor>haft run out
0 or - 11><.,.1n9, u;w rno,• th...-. 3(l m<le<) 13-6 1n lb)
I 10 COl3i
a Ax"I cle¥,nce °" d,tfe«nti,I upa,eci ,c>II" be•"fl<J> 0-0 14 -
I
e Sh,ft lock. I Shilt rnd ,tuft P'°'""" 6 S kB 5 b kg 10-0 ll051
114 tb<I 112 lh!)

Rod,al pl,y ,t d1ffe,ent••I hoo"n� o, co•,e, I!!"•' sh,ft 0 03-0 D5 C 00
•
10 001-0 0021 (0 0031
s aock,.,h 015-025 .
(meas�,ed .n the p<\ch 01,cle di,meterl 10006-00101
,,
'"
New port Wear lmi
Do,ignatwn Remark,
mm {1n I mm Im.)
o · Data for llUt om atoe transm,..,on . , Ad1u<t band, w,th transrrnu,on hori,ontal and tighten ad1u,t«>1 screws to 1 mkg 17 0 lb It) ftrst to "'ttlo tho bands
1 Ad1ustmg pl n
a etary goar end play .. ,
Use only l1r>ed plate, with annular groove and 6 1-5 85 mm 1
0 240-0 230 ,n I th>ek pressure plate Note thtcknes, of
045--1 05
O 018-0 042)
{
2 AdJus l
mg brake ban ds
corcl1p
• 2nd geu
' .. ) Use only hoed plote, with waffle ,urfaco 6 3-6 15 mm (0 248--0 240 on) thick pres!i\Jro plate and ctrcl,p 1 7 mm
T,ghten screw to en back o ff 1 314 t

o 2 t
urn, •i {O 067 m I thtck
1th •
0 5 m k g { 3 5 ft
b 1,tgear
"' •I
Uw only hned plate, w,th waffl� surfoco and 6 3--6 15 mm 10 248 -0 240 1n) th,ck pres,uro plate AdJUil to correct
T,g h
ten "''""' 4 - 3 1 /2 tum, •)
10, then b•ck off 3 1( 0 5 m k g ( 3 5 ft play 1 7-2 2 mm (0 067-0 007 ,n I
3 C u l t hc es '"
•· Forward clu t h ••1
c
End play -r- 08-1 2
O 032-0 048)
{
b Direct •nd revo,,. clutcli lw<th 2 l irled l

p ate>) •" 'I
c,rc11p
th1ckne" 1 7 (00671
c • Dorek t and r
everse cl utc h lw,th 3 ln
i ed l
p ate,) +I
A�••I ploy
1 7-2 2
110 067-0 0871
4 Pre load of p,mon beari<'!JS {tum1"Y torque)
••• 14-20 cmku
{12-18 1n. lb)

•
8eann!jS u,;od mo'" t n mile• •
ha 30
2 cmkg
12 m lb)
5 T ot .i �load ltum ng 1 to rquel
1
P mon and 1
d tte r ent,a l
18-24cmkg
(16-22 ,n lb)
8oanngs u,od more t han 30 m

,les
3-5cmkg
(2-5,n lbl
'' ''
f - Automatic transmi$$iOn test data
Stall IONju" ,p� for •II Type, '"nd Models 1900-2000 rpm
Pre..,..re tllblo
S.lector
..,. Preuure
Typo 2 Typo3 Type 4
Rem>rk,
po,'11on kg/cm2 {ps,J kg/cm2 (ps,) kg/cm2 lp>rl
Pnmary throttle p,o,..,,o 145 51 32{455)

30{421'1 1,,crNse •dl1n9 ,peod to ") From AllQuot 1971
' 3 2 145.5)
'' 1000 rpm
__!!'a,n P"""" 6 5 (92) 82-85(116-1201 v ocuum ho.. off
84-871119-1241
-- -
Primary throttlo p
-re ••Ure 0 35-0 45 {5-8) -
0.35-0 45 (5-61-- -o 35-0 4515=6) 1,,c,;;.;·idhng .....,d t
o
1000""'
Mam reuure 3 3-3 5 {47-501 33-3.5(47-50) 3.1-33(44-471 Vacuum hooe on
- - --
M,m pi"e,..,,e - 10-11{142-156) - -
6 7
--:... 7. 7 {95- 110)· 85-75(92
- -- -
'
0 -P,n"nuV ihrOttie Presoure - ----
2 2-31131-44] 3 O (40---421 3 0::-3 2 14�451 ""' ",11lltorqu• ipoid
'' ("ull throttle)

M'"an p,o,ouro 6.5 192)
- - - 80--84(114-120) 82-86{116-122) VaculliTI hoso on
-- ---
M•m pri$$11,.- J... _ 18-i3 1256-327) ,s -
- -- 20(213 2841 15-20 1213::.284)
- -- --- - -
'
0 M,,n preSSUre 6.5 (92) '
s r-e 3187-00f
-
5 9 - 6 1 ( 84
-
, , full throttle and" • road
871
WM'(! of ovor 18 mph
G,..- ol11ft opeo(h mph
Full throttlo Kw:kdown

Geor
Type 2 Ty� 3 lupto 7 72) Type 3 !from 8 72) Type2 Type 3 (up t
o 7 721 • Type 3 !from 8 72) Type4
Type 4
18 - 25 17 - 18 17 - 19 c7 - 33 30- 39 31 - 40 30 - 40
17 - 20
'_,'
' -
,_, 41 -46 45 -49 43 - 50 48 - 55 47 - 51 55- 59 54 - 59 56 - 65
,_, 2'9 - 25
16 - 14 " - "
37 - 30 33 - 25 48 -44 55 - 52 55 -50 00 - S,
15- 13 15 - 11 14 - 11 !O - 24 34- 27 35 -27 36 - 27
-'-
,, -
''
g • Marlling of 90ar teU
2 . MafXlal transmo,O!on Type 2
1 . Manual 1r.1nsm, ..,on Types 1 and land Automat,c St,ck Shift
�
I I
-- R -------;
' '
I
-F�---1
"
- '
r=t- '
''"
,o
11
11 II
0
a
'
'
'
'
'
-r '
·'=--
••
'
-
• '
"
'" "
L
' '
I Example M•nuol tranorn,,.,on w,th clooble JOmt axle)
1 "G 833" moan, Gleason goar set w,th • rabo of 8 33
2 Motch,ng numt>tr (369) of gear set "I

'K843 rrt€0<11Khngelnt>e•g��ars1"w.ma,a d 43
3 De»atlon "r" baoed on lhe master gauge of tile spec1ol mach,ne u""1 m productH>n '
Matching numt>er {312) ol gear set 'I
The dev,atmn "g,ven ,n O 01 mm w,th same sign For example "25" mean, that
tho
' De,iat1on ' r ' based on t™! maste, gwye ol t�e " '< ,,I n>,ch1m, osed ,n prodt;tt1on 'I
r•+025mm•I
'
Ro L•r.gth of master gauge used ,n ,pec,al mochrr1e '10 63 1nm '
I
Ro Longth of master 9""11" uwd •n 51)<!<:<II moch,.,., "Ro� 58 70 mm"
d Actu•I moa,u,ement between ring II'" cented•ne ar><I er,J to ,:r ve prn•on at po nt cf qu,ete,, runnmg
R Actual meuun,ment between r,ng gear centerl,,.. and eOO ol dnve p1n,on a
t pomt of qu,otost runnmg
Ve Hypo!d off,., 10 mm
") From January 1972 not marked 1n prodoct,on Therefore 6'!tormme "actual" mea<ummnts before ropa,r
'I from March 1972 not markod 1n production Thorolore deterP>•n� >elu•I" measurements befor� repa" I
''
4 Automat,e transm, ..,oo Type, 2, 3 ond 4
a Manual transm.,,,on Typo 4
- -
"
•
-
--+, ·-
Q I
. ' i
jh
t
'
I
, , ' ' '

"G 933 meons Giea,on gear set w,th • ratio of 9 33
' Match,nu numbe< of �r .., 1369)
'
a Dev,.,hon ",' ba.W on the mast!lf ga<Jlle of the ,pec,.1 moclime u-1 m product,on
'G 1141" means Glea,on gear set w,1h • ratio of 11 41
The d,,.,. 1at1on" gr,en m O 01 mm Wtlh the $Orne "9" For exampl• "26" mean, that
' Ma1ch1ng No olgeor >et 13691
,�+026mm
'
a Dev •• t,on 'r bawl on the mastN g•ug• of the ,pecral machme u,od ,n product>on
Lefl!lth of ma;t0< ga<Jge used m spec,al mochme "Ro" � 40 55 mm
So Length of the gouge u«d m the ,poc,al machme' R o • 41 2 mm'
Actuol measurement between rmg \l('Of centerlme and end of dnve pm,on ot qu,etett runnrng pomt
Actual m•a,urement between ring gear center I""' ;r,d the end of the dri-. p,n,a,n at the
Hypo1d oll<et � 42 5 mm
' quoetest runmng po,nt
Vo Hypot<:I off,ot r 44 mm
''
Adjuotmg f,n1I drrve
1 . Manual tranom,ss,on with swm� axle
[)e,"J"at'°n D,menSlon
'"'
s,."
- ,,,
Mean bockla>rt 020 mm
Mooruring rmg -
,,
�&..L Ll Axial rnosemer,t o• rrng gea, to gi.e
,pecil,od mNn backlash 001 mm

,, ./4
s, Sh mot rn·g gea, enrl
- -, lmd th,cknes,
- - ,, Shim at oppo.,te enrl lmd thickness

"
O,flerence t>erween ,e,o semng ot
I i
'
rnac.d, el pin ion actual d 1mer1,•on w<thout stia111, O 1 0.-0 50 mm
I I
Preln,O on one b!,arrn� 007 mm
El ' - '
' '
De. at,on " 1ear ,et

'
G 35!!/K 835 G 3381K 833 005-065 mm
s, Actual d, mens,:in ,,>easuring
I I -
man,lrel setl1r,g pm
F mdm9 th1ekne'5 ol
Sh,m S3 Sh,m S2
S 2 • J · L - S 1 + 2 p
I
Sh,m, S, to, dfl<< pinion
' Sh,m, s, at r,ng gear er>1J,,ng bctw�n ball l>ooring•
'
s L lengtt, of <l1fferential rK:N.Js,ng s, · M C\ + ..,:j s , h re•d 1ng, O 01 mm
L'.I s, Axial n,o,emeM of r,ng gear t

o grve
spec.1l1od mean backlast' 001 mm
,, S� mat ring qear «Kl f1r,d lh,cSn<<,
,, Sham at oppo,,le end f,r,d th,ckness
D it•eref>Ce between ,ero u,ttlnq af measuring mandrel
' and actual �m1on d1meri,,or1 v,nhout �,m, 010-050mm
Dev1at1on !or gear ,et G 833 / K 833 0 05-·0 65 mm
'
Corcoctlo� facto, lex (lear ,et G 833
' 00
" Correction factor to, gear <et K 833
' to
R1r;g gear lift Imm full mes!1 posrt,on
" for G 833 �ea< ,.1 0 20mm
Rn,g gear lift from full mesh po,r\,::m
le,, K 833 gear wt 0 20mm
,, Length o! settrng pin 58 70 mm
Fmd,ng ttnckneu
SIHm $ Fmdmg ..c:::::::J.S1

3
L'.'.J�, w ISvomean x w) - h
''
Explanauon of s,gns
3 • Automatic Stick Shift
s,, De,,.�.otlon D1men�o�
,,
- Svo rnear1 Avero9(' o< 9"¥rr,il backlaSP ,ea11I movo<nem of ring ge.r to gi,e
'1>"'-1h"6 mear1 bac�la,I\ 001mm
s, Ser..,,. ,n {lep!l1 ut ,l{IJu,t,r,g ""9 a,
rrr,g ge," eCKI -
s, Screw r1 dc�ltn of "'Justnq ""'lo t
<>pp(Jsi!e er>d -
Difle<ence hetween me""'""ll mand,el

'
•00 ,,.,tt,ng D n
010-050mm
Deveat,on far go¥ >el G 835 K 835 005-065mm

•
w Ga,rnct;cm factor for qear ,et G 835

' 00
Go!1ect1on facto, la< g,;:,•r "°' K 835
' '0
Ring gear lrft <rom full me�� ,)(Js,tron
" for G 835 !1""' ,et 02 0m m
A1n!,l 9<'•r lift from •url mesh post"'n
for K 835 gear >et O 22 mm
s, Le"rgth ot set1,n9 pin 58 70 mm
l ''
'
Fmdrnll thiekne"
Sh,m sj
I L'.Js, • (Svomea� x wl - h
''
4. Manual transm,ss,oo Type 2 £xplanatton of "9"'
Sign DesignaHon D1men�on
Seo mNn A,ernge of'"""'"' backlosri rneoswement, O 01 mm
Ll s, Axial movement of rio;J qear to ;1ve
average backlash 001 mm
MS Measur1r,g sri,m VW 3811 l O (two olfl 1 30 mm

--- .
s M<isemont ot tap,erod ro,ler b,anr,g outer ,..., O o, rnrn
Correct>On Iactor for ,nd 1v1dual gear "'1 -

w
Arn',/ ge..- Hft from no ploy me;h po"t1on with
" p1n1on of ,ncli,1dual gear ,,et 0 01 mm
Devtat!on from "Ro", ,nar�e<;e tietw.,.,,, sen, 1� pin ...,cJ mandrel Mea,ured m mm

•
(0 85-1 30 mm po;s1ble)
--- Fmdmg tt,,ckness 5h,m thwkne,s S1 oommol
Sh,ms S0 *) ond S, nom,nal
L ,
, ,
_ "
_ '
_"'_
_''
_ "
__' '
_ '
_ ' I · ') I S, nom,nal � M 5 - .,1s,
O.tormmm11
,,
51 • !Svo mean x w) - h
S; r,omm,1l•MS � Lls, -S
') From Chass,, No 218 000 001 to cm,.,, No 218 202 751 !he sh1<'1 is o� the Tin<) qear ,-Oe
••1 From Chass,, No 219 000001 th,, sl,,m » on the tran,rn,ssion ,idc The final dr,,e
"a<l1usted with �dJU<tln� rings a, on Type 1 Automatic St1d, Shift
''
E,planat,on of ,,gn,
0,mem,on
5 Manual tran,m""0" Type 4 Sign
s,o mean A>erag< of 1e,eral Dacklash mea.urement, 001 mm
Axial mo,ement o( r,ng gear to g«e
a,eraqo backlash 001 mm
Screw m depth of :•d1urnoJ r,r,g at nng goo, eOO
Screw ,n dep!h ot adJU<t<ng r<rl\J al opposite end
D1fferonce between mearnrir,g mandrel and
,etr.r,g p,n 070-120mm
Deviatioo !or gea< ,et G 114 1 0 10-0 55

'
w Corroct<on t.cto, for gear set G 1 1 4 1 ' ,o
R1t'9 gear lift from full mesh po,1t1on
" fo,gea,,etG 1141 026 mm
Length of set!ll>g pm 61 2 mm
F1ndor,g thocknns
sh,m S 3
'
' _j'
l
Fmdm�
� s t
''
''
----�-"' -----------
Explanot>0n of 01gns
-
6 Automa:t,c tronsm, ..,on Types 2, 3 aM 4
On Type 2 tho d1flerent1•I

( and dr,ve p1n1on are located ,n the fmol dnve hoo,ing The ad1u1tm<nt of the drive De;,gnat1on D,men,ion
Sign
pm1c,n •nd rir,g gear " �as,cally the '""" as on th< Type, 3 •nd 4 The ,h,m s,, " po11t1� behmd the tapered
roller b<,;,nng ,noor rac,, I
s, Screw rn clepth ol •d1u1tlf>;J ring at ring year end
,, s, Screw 1n depth of ad1usht,g nng •I c,p(X>s<te �nd
s, Sh 1m between taper roller l>eaflr>g ,000 drl'e 01n1on
So
' Loogth of maste,- QauQe used rn <rectal test machine 4055 mm
0 Locat,on of p1mon rn relation to centorl1r>e of Tl"'J year
M qu ,ates! runn 1r,g (X>lnt {nom1n,1 d,menoon) R � R o t r
D�v1at1on from "Ao", marked Ofl gear«!

' -j I
'
015-025mm
-- 'l s,o Backlash
,, Hypo1d othet
42 5 mm
ratio · 3 67
c saa G<o, '"
' G - Glea>M No of teeth 3319
"''
Hall d,ometer of mar>drel
D /2 • 1 0 00 m m
'"
e, Length of setting pm
Eo•5055mm
WI 380/3 Eo • Ao• 0/2 mm
011ference t..!!ween mandrel

•
meastJred 1n mm
..-.;:f ,et11ng pm
'
'
Fondin11 ttuekneu Sh , m s , � e r
I I
SS
I
--- ---
--------------------- _
, '
111. Ratios
Ty!)<'s 1 and 3 Tyr,< 2 Type 4 Type, 2, 3 arid 4
M,r,uol tr,nsm """" Man<Jal tr•n<rni>sion M,nuol tr,n,mos"on !.t.utomot,c Sttck Sh,ft Automat,c ttan,:m,.,ion Romack,
No of tee!I, ratw So ol teeth rat,o So of teeth r•tio No of teeth ratro

'""
ht !J""' 38/10 a so 38/10 a eo 31'18x31114 a ar zoe z ss o Cho,.,, No.
") Up t 112 2 961 362 60 53 10 88)
2r>d 9"•' 35/17 z os 3511 7 , 00 31/18 x 27/22 1.26 ""I TypeluptoChH1'SNo 1 1 2 2 5 69 36 2 ·

3rd gear 29/23
' zs 29/23
' ze
31118 x 22127 '" oea ' '' 20/14 x 43/17 13.61)
' 0
4th gear 54/58 ·1 o 93 "I 23/28 direct ' '' Type3uptoChass,sNo 3122087704.
0 '' ' 00
Ro,er .. 20/14 x 40/15 ··1 3 80 "') 20/14 x 40/15 ' " ' I 3 80 • ") 31/18 x 35/14 3.07 20/14 x 4311 7 (3 61)
Torque"''"""'" max '' •••1 Up to Cha,.,, No 211 2 276 560 20/14 x 43/17 :
11'
'' '' (3.611

,
,
: ' 1I
i '
J
, I
Ma.nual tran,m ,.,,on Automat,c

Automatic transm """" +I Type 1 from August 1972 8 31 (3 875)
Frnoldnse Type, 1 and 3 Model 14 Type 2 Type 4 St,:k Shaft Type 3 Type4
No of teeth ra1Lo So of teeth rono No of teeth

,, of teeth rat10 So ot teeth No of 1..1h
++IType4sedanfromMoy1972 1141(373)
So of teeth ratio
'""" '"''° '"''°
l<lmgolnl>erg a 5 375
'' a er
a 33 • I 4 125 a 3 875 43 >+I e
'' " ''
Gleason , ,
.
•
a er a at
'- " " ''
00
''
IV. Tightening torque,
Oual,!y T�ns,le
Locat,on Des>gnat1on Thread lb ft Remark,
.�. class
•
•. Transm,ssion •nd fmal dnve '
") tighten t
o 22.0 mkg (160 lb ft), loosen. tighten hnally to 22 0 mkg (160 lb ft)
Tvll<!< 1 and 3
"'
EngIr>e/transm t"'on M 1 0 x 1 5 ,., I
""' "'
Be,nng rtrt,mer 00" M 10 x 1 5 to e; ''
as
p,mon retaining nut M 80 x 1 CQ 35 ''
G..r,lhous,ng /22.0 ") 160 • I . !
••
•
Gear carrier/�us,ng M 8 x 1 25 , 2.0 ,iI
""' '' •
•
•
F,nal dr<va covers M 8 x 1 25
(3.0
''
""' ''
Tran,m,ssK>nlbor>ded rubber moum,ng M 8 x 1 25
, 2.0
'' 1
1
�·
Sh ,ft hous,nglgear car,ior M '' '' •
tr
�· ''' i
T,pered roller bearmgldn,e pm,on rouOO nut M35x15 ''
C 35 N
•
A ,ng gear /d,lfernnnol housong 00" M 1 0 x 1 5 ro « ''' •
•
•
Selector ,haft/fork M 8 x 1 25 C 45 KN ''
00"
Support/reverse lever M 1 0 x 1 5 ac ''

'"'
Bush ,ng/clutch operating shaft fock bolt M s, t
'' �!
0,1 lillor hole plug M24x15 "'
MbK6
'
•
M24x1.5 MbK6
011 droin �le magr>ellC plug ''
''
I
•
sa
.l
Ouo11ty
Remarks
Loe:,t,on De<>gnat,on Thread
i,ade
zsa
Rear wh""I ,haft ,lotte<te "'"

,;ocket head screw M 8x125 tc x
,,
''
Control arm/l11!od bolt ,;ocket h�i>d ,c,ew M M x 1 5 c as
,s
Spnng plate b.ushm9fcover M 10 x 1 5
Tr,msm,s,.on c;,rr1(,r/lr•m•
"'"
!rtted b'olt M 18 x 1 5 ''
SC ·�
Fron\ mount1r,glfrnmals.ub lr�me -, M 10 x 1 5

re ' ''
,a
Er,gm• carrier self·lock,ng r>ut M 8 x 1 2 5
Shock aboorber/control arm -, M 12x 1.5 '' SC
Shock abso,ber/fram• M 17 x I 5 ''

SC
SC
'"'
Beanng cov..-lwhe�I bearon<J M 10 x 1 5 ec ''
"""
u»
too
Ouahty Ten,,le
Location Designation Thread mso I
I} ft 11emark,
,aoo class
b • Automatic Stoel,; Shift 'I Tighten to22 mkg 1160 lb ft), IDDsen, !'!Jhton tonally to 22 mk� (160 lb It)
Clutch housing
temperature ,w,tch M 1 4 x 1 5 GO ZuA 14 Whon """!l VW 183 C' wrer,ch, set torque wrench to 18 mkg (130 II} It)
Transm,s"oo ca,e seloctor sw,tch M 1 4 x 1 5 GD ZuA 14

,.,
'' ''
Gwrsh1lt hou,mg r,eutral safety ""'tch M 1 4 x 1 5 GD ZuA 14 ''
Converterldri,e plate
,ocket head ,crew M 8 x 1 25 SC c
' ''
2.5 ''
Geor,/tronsmi,;s,on case , 60
'' •J ••I
reta1n1ng n<J! M 8 0 >< 1 Cp 35
' 22 • 1 ··1
•
Lock plate/reta1n1n9 ring
tapp,ng screw LO r
Cp 5 K
Gea< can,erltransm 111,on case oo, ''
M 8 x 1 25 ,c
•
, 2.0
Lock pta1e/ad1ust1ng rmg f,11,<ter head serew M 7 x 1 25 <s 1.0 ''

OS
Goar,!, ,It hou,mg/trari,m ,..,on """"
M ,c r. 1.5 '
Con,erter hoosmg/tronsm""°" ca,e '"

oo, M '
8' t
x 1 25 cc "
> 2.0
"
Cove</transm"""" ca.. 1tllrSter head ,e,ew M 7 , 1 25 CG : 1.0 ''
Bon.dOO rut,i:>e, mountrnll/ '

oo, M
converter t>ousing 8 x 1 25 CG
T,an,rni,s>On mountmg/
''
oo, M
bonded rut>b"1' mount 1
r,g 8 x 1 25 so
Selector shaft/fork M 8 x 1 25 C 45 KN ''
,e
"'" ,,
Bearing lock bolt M 8 x 1 25
"'"
roor.J r,ut
Pm.on M 3 5 x 1 5 Cp 35 '
R,nggear M 1 0 x 1 5 to s; ' 4,5 '''
Georsh1ft hous,r,glbondro
'"" ''
oo, ,,
rut,00, mounting M 1 0 x 1 5 ec
roa
'''
Loc,,t,on Ouahty Tensile
o.,1gnat<0n Thread rn,a
.�. class
lb ft Remark,
One way clutch ,upport

') After mstalhng • new gasket, tighten•• cleta1led m Work,hop Maooal H
tub<,/converter oocket he,id ,crew M
Clutch/clutch earner plate oocket head screw M "' ' '

to''
x "
0,11eed lmo/tranm,,s,.on �nron "'

M 12 x '
1 5 SS 20 K 'a J 5 "
011 return hne/tronsm"'"'" union M 14 x 1 5 g s 20 K

,
',
'
011 S<Jct,on line/tank un,oo M 14 x l 5 9 S 20 K III
O•mp bolt/clutch lovor
M 8 x 1 25
''
SG
Joint to flange "'"
socket head ,crew M 8 x 1 25 to x
,., ''
''
c · Automauc tr&nsm1Ss10n
ATF pump to transm,ss,on case

M OG
Tran,ter plate on valve body "'"
<lotted icrew "' '8
M 5x0 ac '"
Val,e body to tran,rms;,on case w,
M SC ''
Pan to tran,m,s,.,n case " '
'
M 8 x 1 25 OG '"
7 0 •I
ATF strnmor to valve body "'"
<lotted icrow M SG
Manual .alve IO\le<kable l..,.et
M
"'
8 ,
'
1 25
C.ble lover to transm1s,>0n caoe

�·
reta1n1ng xrew M '"
' '
,,
''
Operat1 t>"J 10\ler on transm"'"'" cax threaded pin "' '5
M 1 0 x 1 "'
Cable bcacket o� tran,rrnss>0n ca.e w, M 8 x 1 25 "C G
" ''
"0
Filler tube on tran,m,s,,on caso w, M ac ,o
0 ' '
"" tos
Oual1ty Tens,le
Locot>0n Dos1gnat,on Thread
,.,, cla,., m>o
Rem...-k,
""
Plug for p,en,re comu,cttor>/ ,, T,ghten to 1 mkg 17 lb hi. loosen, t,ghten to O 5 mkg {3 5 lb ft) and IOOSl!I'
tran,m1..,1on case sock•! or ti.�

,,.,
M 10 x 1 "''""' 1 3/4 to 2 tum, from th" POOIUOn
t
Vacuum un,t/transm,..,on case .. ,
M 14 x 1 5 ,., Tighten to 1 mkg {7 lb hi, loo<en, tighten to O 5 mkg 13 5 lb ft) and loo,on
AdJu<tmg =•w for front brake b�nd M12x175 ''

screw 3 114 to 3 1 /2 turns from th" pos,t<on
3 5 +I
Ad1uslrn9 ,crew for re...- broke batld

M 1 2 x 1 7 5
3.5 •• I
Lock nut t
or batld adJUS!lr>g <crew M 1 2 x 1 7 5
""' ;,20
Air deflector on final dTFve ho,,s,ng M 10 x 1 5 "'
so ''
,o
'"" ' 0
D,llerennal earner on l,nal dr "" hou,mg
�· M
s' '
00
so
'"
Side covef/l1nol drive housmg
M SC 00
""' s' '
StMter/fmal drive hous,ng
Beam..., cap/d1flerent,al earner

�· M 10 x 1 5
M 10, 1 5 "' '"

Ring (J<M/d1fierent1al hot,s,r,g
'"" re '
''
M to « 00
Trar1smiss>0n case/Imai drove hous,r,g '""
M "' '
8 x 1 25 oc ,o '"
'"'
Converter to drove plate 8 , 1 25
M BC ,o ''
Drive shaft/flange "'"

'°cke1 head <crew M 8, 1 25 ,., ''
ro '
'"
,o,
I
'
Loconon Oual,ty Ten ..le

De •• gn•tion Th re.rd
7ade Clas, Remarks

mkg
""
d · Tran,m,n,on and f,nal dn>&
Typ..2 ") T,9'1ten to22 O mkg {160 lb hi, loosen, tighten finally to 220 mkg 1160 lb ltl
Gears I h<>us.ng
reta,mnq r,ut M Box 1 Cp 35
Round f\U! / pinion
160 ')
roor>d nut M35x15 Cp 35
m
Umon nut I sleeve
un,on nut M 14 x 1 5
S 20 r
'''
Bracket I'"""''" sh,ftor ,halt on
''
gear earner
M 8 x 1 5 ,,
Support I rocker Ieve, on gear carrier "'''
"'"
M 8 x 1 5
,,,
'' ''
Selector >haft I fork
M 8 x 1 25 ''
C 45 KN
,,, ''
Lockl"'J ,crew with dog point "'" M 8 x 1 25 ,s
''
Clamp >le""e on gear carrier "'"' ',S
cl�mp sle�e M 14 x 1 5 45S20K
"
Sh,ft houS1ng to gear rnrr,er
M ec '' ''
Nuts tor geor earner, tr�nsmo,,ion
""' r ' '
' s
and clutch hoosmg
"
R ,ng gear to d,lfetent!l!I f>ou<in�
�· M 8 x 1 25 ec
,,o
Lock plate I adJustrng rmg "'"

M
'' '
to x
so
''
ph1ll1p, head screw M
'
so
''t
' 0
""
r
'
Locat>on Q"al1ty 'ren>ilr

o.,,gnat,on Thread ,, fi
Romark•
r,ode class
J,ag::,rial arm to reor wheel
bearong hou,ir,g
'I At lea<t 32 - 35 mkg {230 - 253 lb It) with re,nlo,ced <loe,e
M 14 x 1 5 ro «
D,aoonal arm to frame
""' M 12 x 1 5 oc ''
Shock absorber to frame and rear
""' ea
wheel be1mng t>ou>1ng
M 12 x 1 5 oc
Dr.vo >halt I flange
""'
socket head ,crow,
M 0 to r; ,,
''
Cover I ,prmg pl>te bush,ng
M to
oc
Back,r,g plate to hou<ir,g
""' M s ,c ''
"°" M to ,,
Rear wheel hub t
o roar wheel shalt
slotted nut ''
M30x15 C 4 5 KN ''
253 ·1
'
<
'p
» '
"
' '
'
" '
'
uo
Oual,ty
Locanon De,,gnation Thread m<a
,oo, ." Remark>
Tt11n1m,nion Ty"" 4
•
Tran,m,,.ton case to Imai drl'lo cop nut M 8x1,25 ac
Shilt hou""II to transmi,,ion ca<e M Bx 1 25 SC
''
,o ''
""'
Co'°' plate t
o transm """" case Ph,ll1p, screw ''
M 7x1,25 SS
' o
Co.er plate to transm """" case Ph,11'!'• lock scr= '

M 7x 1,25 SS
' 0
'
Dnve shaft to dnve gear M !1"1,25 ,o
Kr>urlod cap on tran,m1ssH}fl ca>e
-·
Ph1ll1p, !Crew M 7x1 25
"' as
SS
''
t
' '
Sh,lt fork to '111ft rod <quare r>ei'MJ screw M 8x1 25 C35 K ,o
Cover detent plungers Ph1ll1ps screw ''
M 7x1,25 SC
' 0
8earFng pin, selector sh•lt l>eartnQ pin '
M14xl,5 cc 22
' s
End plate m•mshalt carrier M10x1,5 SC ,s "
""'
Lock plate, ad1ust1r,g r,ng Ph1ll1ps screw
''
M 7x1,25 SS
' 0
Rmg (lear, d1lforont1•I hoo"r,g M s et • s '
··= ,,
Switch, backup light sw,tch M 18x1,5
''' ''
ta
O,I hlle, hole
''
plug M24x1,5 Mb K 6 ,o
O,I drain hole ''

plu� M 2 4 x 1 5 M b K 6 ,o
''
,,,
"'
Quality Ten,.le
Locat,on De<tgna11on Thread Remarks
grade
cla" ••• lb It
Rear a,cle Typt 4
'
Rear ax lo earner to body M <O ,c
Aetammg plate to lx>dy """ M 8 x 1 25
,,
''
,.
Shock ab,ocb<r to body ""'

sell lockor"l(l "ut M <O ''
Bor,ded rubber moont1r,g t
o roar axle
''
Ill
r;:orr,er M <O
Er,grne carr10< to mwnt1ng """
wit loc�,ng nut M a ,s
'' ''
ReM l>onded rubber mount mg t
o body self·locbr'J nut M a ,s
''
Shock abso<ber to wishbone M 1 2 x 1 5
''
.,
Bracket to rear axle came< """ M 12, 1 5 ''

W11hbone to bracket ""' x 1 5 ''
M 12
''
Rear wheel beanng ret�rner ""' M 10 x 1 5
''
to x .,
''
Wheel ,halt and flao;w
"""
stretch l:>olt M 14 x 15 65-80
Or,vo ,haft I flar,ge oocket heod ,crew M 8 x 1 25 ''
tz'
Bonded rubb�r mountrr,g to gear<hrlt
''
hou"ng M a ,.
""' ''
"'
V. Double jo,m lfl•ftl
a · om. sbllfts
CO<!<, number Lenqth,mm {,nch)

Tron ..
,,� m1«1on On er>d Shalt Shott Shaft assembly

Part No
Remark<
,,� ol <haft assembly

D,m�nuon "b" D,m,,n«on "•" Shaft lw1!hout /{lmh)
mm(,nl mm {,n I
415 5 eoe a 1 1 3 50 1 2 1 1
' ' ' ( 1 6 357) 115 955)
� 1 • Manual tronsm,s"or,
'. Tron<m«<ion type,
sos a
' 415 5 1 1 3 50 1 2 1 1
2 • Automat<e Stick Shift
El
'
' ' {16 357) 115 955)
3 � Autom•t,c tran•m"«on
2 1 1 50 1 2 1 1
'
' '''
(18 7391
a 211 501 211 8 'I l�ft
' ' '''

{17 9921
a sos 2 1 1 50 1 2 1 2 8 . ) n gh t
' (19 881)
- ----
415 5 sos a 1 1 3 50 1 2 1 1
' '
' 116 3571 115955)
a 2 left 2 left 389 5 379 3 311 501 211 ielt

{15 333) (14 931)
a 3 nght 3 nght 439 5 427 3 3 1 1 50 1 2 1 2 , i gh t
{17 302) 1168211
»as asa 4 1 1 50 1 2 1 1
•
'
' ' 117 1251 117 047)
a s o, --- 0 - -- -- -- -
' 117 125)

'''
116.810)
b �---
--- -
') Drive shafts f
or *<ltom tr>r><mi<.,on hav• • ridge on the m!ddle ol the shalt
"'
b - Constant Yllocity joints
Ball
,,� Port No
o,ameter "a" Wodth -t,-
diameter
Greaw
Oesigr,at1on
New part Wear
mm lin.) mm l•n )
mm 1,n ) hmtt
per ){lint
mm {,n I
05mm(0019)
1 1 3 5 0 1 33 1 91 - 0 1 32 to 3 rs es
'
(3.582 - O 003) l1 259 - 0.0111 10 624)
max. 20 cmkg
- • -,
up t
o C'l!Oss1> No.
2102 300 000

2 1 1 50 1 3 3 1 A
1
) 1 00 - 0.2
{3 937 - 0 007)
32 t 0.3
11259-00111
17.46
{0.887)
117 4 1n lb)
I III
z
2
from Chas.,1< No. 2 1 1 50 1 33 1 8 to a oe 90 g<ams of
I
1 100-0.2 32 3 t
2 1 1 2 000 00 1 (3 937 - 0 007) 1259-00111 mult, purpose

107491
!lfOase With
MoSl add!t,,,.
113 501 331 91 - 0.1 32 t 0.3 15.88

a •
13 582 - O 0031 (1259-0011) {O 6241
1 1 3 50 1 33 1 A 1 00 - 0 1 34 ± 0 3 17 46
' {3.937 - 0 003) (1338±0011) 10 6871
1
1 Groove tor metal cap on fl•nge end
2
1 Annular groo,,. on outside diameter mull be towards fla11ge
,,, tta
VI. Toroion Bar Ad1ustrnen1,,,s,,,",�e!'c'
':'e':'C"C'c'°,-o:,"c'c..---,--,---,-----
Tronsmiss,oo lnstalle<l Ton.,n 00<
Model
,.ng,h d,,m<tO< S•ttm� D,mens,on,
Type from Chas,a No to
mml,n) mm[,nl
Sedan upto July 1972 Sedan from Augu,11972
t 1 1 7 000 00 1 •
552 121 7321 21 10 826) 20" + 50 ·-
' " r a
with double-101nt axle s '
"'
676 126 614) 22 {O 866) 20° 30' + 50
' .'
11�-00)�� ' '
•• ·1 ' '
' '"
1350mm 153.n) 139 0 mm (5471,n)
318 000 001 I 23° + 50
15 1 mm (0594,n)
'" ' 15 4 mm 1 0 605 , n I 16 4 mm (0644
m
,
n I
a a 24°+50
'"
je t
368 000 005
382 0 mm 1150,nl 3800 mm 1 1 4 960 , n l 3620 mm 11424,n)
676 126 614 ) 23 5 10 925) 21° 30' 5'
' . ' t
'
..
21 23,26 218 000 002 610 124 015) 28 1 (1 104) 21°10�5�
' -- ..
-
218 000 002
610 124 015 26211070) 23° t 00
--- . I
' ''
21, 23 ' + 3 ')
1 2 1 2 2 000 00 1 610 124 015 1 2 8 9 1 1 1 3 7 ) 20° • 50
2 1 2 2 000 00 1 610 124 01 5 I 26 g 23° , �fl

11 059)
'' ' ' '
TransmisS1on types Manual tran,m>,,ion
' Automatic s,.,k Sh,ft

Remark,
'
a Automa,., "'"""""on
MOOel 23 {Campmc,l:,11•1 only .,

.' front aod res< sprmgs ..-
e different
Wh•n 1nstallm9 new spring,"°'" color code, Spnngs are av•1lobl• ,� 3 g,oup,
. ''
Both ,pnngs on one a�I• must b< th• some
Sedan w>th 2 or J po,n! mork,
Wagonw,th 1 , 2 o r 3 p • m t ma , k s
• ··i
Comcal Top • 1 3 3 m m l 5 2 36 1 n ) d t om e t e ,
Bottoo, • 138mm (5432 ,n )d1'"'1eter
'''
'''
SRAKES AND WHEELS
I. To!erance,, wear hm,t, and setting,
Tvn• 1
Tyf><'/ Type 3 Type 4
D•• ,gn•tion ''= ,,w Fram ,_ ,_

Chass" No
Wear
Cha,,,, No
,- Wea, w•• ''= Wear Remark•
Ch""" No.
,.,
�·
part l1m1t l1m1t limn
part I ,m,t
M�,te, cyltnder
•
.. , .,
T•rid em maoter cyl 1r,<Jer • 1 Model 111 from
' Chass,,No 1 1 7 000 00 1 :

Front wh••I c,rcu11 ,tr<*• 1 1 1 2 0 00 0 0 1 17 5 10 6891
2 1 1 2 00 0 00 1 19 0 f
O 748) 15.010 590)
150{05901 4 1 8 000 00 1
front wheel c1rcu,t ,troke
Rearwhoel circuit stroke
11�10453)
130(05121 15 0{0 5901 150!0590)
155mm!0.610m)
re
ar wheel c,;i,u,t ,troke
o,ame,er 1 1 7 000 00 1 1 9 5 { 0 7 50 )
211 2 000 001 238110936] 41 8000001 19.05{0 7501
12.Smm 10491 ,n I
1905{0750)
.. ,
Model 14 from
Wheel cyhride, aia ..<SNo 147000001
" front wheel c,rcun strok,

Wheel cyl1tl(le,-
' 1" mm 1
0 551 ITT I
fro11t d1am<tor 1 1 1 2 000 00 1 2381!09361 •• • 1
reM wheel c,rcuot stro!<.
14mm(0551,n)
d111rnetor 118 000 001 17 46(0 687)

2 1 8 000 00 1 22 210 8741 418 000 001 22 210 874)
•• • 1 Model 111 from
'""' 22.210 874)
ChoS<ISNO 1 1 7 000 00 1
2 1 2 2 000 00 1 23 8 1 ( 0 9 36)
Cyl,ride, ,n caJ,p•r d,ame,er 222mml0874,n)
1 4 7 000 00 1 4 00 11 575) 2 1 1 2 0 00 00 1 54 0 (2 126) 42 0{1 6541 41 8 000 00 1 42 {X 54)
1.6
'
taa
'''
,,_ Typ< 1
,,_ TYi>< 2
Ty,,. 3 Typ, 4
�- w,.
�-
froo,
0..'!I ""'""
Ch'"" No
•••
i,m,i °'""' No
"''
v,,,
-
"" """'
a,,,,,. No
-
p,n
w,.
l1rr.ot
R,m.,>,
Bt>k• dN rt1>/t.<>k1
• do"°'
r,, drnm '"'"'"" drn,,,,.,n f

o, O 5
.'
s B0 o1<.,o,.J,,,. 1
0 0201 o,-,.,,. r,n,og," l O 1
0 D,t(]I
.'
front "',.,1, dItm< t
e r 1 1 1 2 000 00 1
l48 l•02 •• ) 249 5 2 1 1 1 000 00 1 ""°" th,"'"" d,,,.,,.,oo for ,11 &um,
418000001
19 ,!)8.() 008)
.. ,
1
9 8<31
Moo,1 ll I 231 + 0.
2 (
9 05
9 • O 0081
,,,;,de d,....,.rn, 230•0 1 231 5 :>52 -o s ... ,
Model!ll 40 0 1 1 511
"' 19055<0008) 1
9 1
14) I� 92•!0 0081
2431•02 249 5 2481<02 249 5
. ,
,, 1
9 768+0 ooet 198231 1
9 768+0 008) (9 8231
"''""'""' "'''"'"' """ c,,, ..,

hont.,.,, ""
w,H th"'""" .,
p1 •••
f,om AUi>"' 1971 Th,dno"

1
0 ,s,, •• .. '
(
0 1571 101571 11 o..c 1 ro 433 .o 0041
oct ot ro,;00 0 10!000,,)
•• 0 1 0 1 0 004 )
••• 0 10 (
0 0041 Th,ckoo" ofter m,ehm,.,.
-, ••• 0 1 0 ( 0 00 4 1
""
_,
O I G I 0 004 ) max 0 10 10 coo
0 1 0 1 0 00 • 1
"" '"0
"'"'
0 1 0 ( 0 004 1
(03931
0?5 iO 0101 ors 10010,
"" ""
"'" w.,,
D
""'"' ,uooct
02510010) 025 1
0 0,01 1...,,, 9 5 10374)
me•.u,<d ,t !r,ct,on OJI I..:;< •••
••• 0 15 rn 006\ 0 10 iO 00-01
""
,..:1,.i '"'""''
,, "" ••• 0 20 1
0 OC!a)
••• a20 1
0 oo.s
1
•++) 4>to�1, 1972 1 0 0 1 0 393 1
s th,c�n.>< 9 �-q 4S no
·�
B"k<! d,,c
945 +•I ., 110-01
10 374-0 37:1) f
O 315)
''
! 0 5 1 1 - 0 00 1 )
9 510 374)
10 374-0 372) 10 315) 10 433-0 004)

O,,c th"'""'"''"" tL-<"•"il
!47000001 m"' 8 5 r
o 3351 1liO<l?J
'' '"" 10 0 10 :¥13) �5103741
!0315) "''" 8 5 1
0 335) �'
''
Moch,r,, d,mon<,oo pe< uk 05100201 1
0 3151
max 0 5 1
0 0.'01
"" 05 1
0 0201
-·
m,, O5 !
O 0201
002 1
0 0001!1 OO?IO�J
r""'"'" tole'>"« ••
O"c ruooot 0 2 1
0 oce:
""
O I 100041 e carc coce 0 02 100008)
"" "'" "" "" 02(00081

"'" 0 2 1 0 008 1
B,oko hnmo> 1 1 1 2 000 00 1
""
'
Bra<• '"''"'l'
'
rro,11 w,lth 450···111
,.,:J,h I la 000 001 40011571

"' 1 : 11 1 , 000 00 1 5501? 165)
"' th,okn.,, • 0-3 8 4501177) 418000001 45011771
.
'"'" "" ''"'
'
''
1
0 160 O IWI ''
1 0 1 00 1
''
10 ?35-0 ))�, 4 0-3 8 4 0-3 8
., ., '
1
0 160-0 150) ''
iO 1001 I
O 160---0 Hi})
''
10 100)
loY"'"'i
,,
1
0 177 O I 701 ''
1 0 1 00 , 4 5---4 J 4 5-4 3
e Froc,,oo 1
>od for 147 000 001 ro o I< 0 ••• I 10177-0170) ''
1
0 1001 1
0 177 -0 170) 10 100)
' ' to c ;o 1• o •ttl

d"< ;,,,,, •I
th�'""" 1
0 393> ''
1
0 079) 105�11
" 0 393)
1 {0079 (0��1) '"
10.079)
"' "'
II. Tightenir>g torques
Oual ,, Torque
,,�
Rom ark,
LC'Co'tion Oe,;gmt1on Th road
m>o lb It t z a
·�· '
B"ralte moswr eyhndM ., ID< oil lino com><ct,ons
Stop bolt 1n hou"ng MO sr
, 0.5-1 0 36-7 • • •
00" Type 3 lrom August 1971
' ">
ReS1dual �res,ure valve on hou�ng M 12 x 1 ,o • •
'' , 7 5 mkg 154 ib ft)
Brake l,;iht switch valve on housir,g M 10 x 1
'
• • ... )
Type 2 from August 1972
Brake ma,ter cyl1r1der on frame MS ,c '' ''
• •
00" • BoltM 14 x 1 5 16 mkg ( 1 1 6 lb hi
Tandem broke master cyl>nd.,.. on support 00"
M 1 0 x 1 5
''
4-4 5 29-33
'' •
Brake line on ma,tec cylinder") '' 11- 15
• •
union nut M 10 x 1 1 5-2 0
• •
Push rod (rc,d on cl..,i,) 11--15
M 9 x 1 00 1 5-2 0 •
""'
Tandem br,ke master cyl 1ndor on b,ake s,r,o
Front l'>TI""I i>rakes

""'
MO 00
=·
''
mox 9 4
•
Ill
Back mg plate on steering knuckle
00"
M >O so •
Whe� cylinder and back1r,g plate on stee<mg knuckle
00"
M >O 5 5-6 '' •
Splash shield on stcormg knuckle M; '
t
' '' • •
00"
' c ' o •
Spl•ih shield on ,teenr,g knuckle MS t
00"
' c ' o
Wheel cylmd"1" on back,r,g plate MO
00" •
C•bp,,r housmg '' •
,ocket hood screw ''
2 0-2 5 14�
'' 18
•
Cal.per on stO{lflr>g kt\lJckla
00" M
"'>O to > 4 "I •
Cal<per on steonr.g knuckle M 1 2 x 1 5 to K ,.s
,,
'' '
'
00" '
Caltper on ,toem'II �nuckle
00" M 12 x 1 5 1O K 1 0 0 • •• 1 • • • '
Bk•der valve 1n wh""I cyl1nclerlcal1per M 61 M 7 9 S M n Pb 2 m�x O 5 ''
m,,
'
' ' '
''
B'8ke has• on wheel cyl1nde,1c•l1per <
M >O 9 S 70 > 1 5-2 0 11 • 15 • '
Socket head screw for clamp nut 7 m,x 9
1o K O m,x
socket head screw M' '
,ocket head ocrew M, 1c
1 K '1 5 ma,
,,
'' 1 1 max 15 •
''' '''
Tc,rque
Oua1,·\
Locatoon o.,.,gn.,tion Thread ··� Rern&<ks
II'"''" m<a lb It a
' ' '
Rear wheel brakes ") Wl1eel nuu
Wheel cylinder on bocking plate M, ,c ,_, 14-22

00" ' '
M ro
,, ' 12-14mkg {87-101 lb It I
BeMmQ cover on wheal beoring h""""9 00" to ' ,_, '' ' ' '
Backing pfate on wheel bearinQ housmy M' ,c 14-22
Backing plate on whwl boa<1ng hou,ing

00"
M to ,c
,_, 22-29 '
000
'
Brake drum/rear wheel hub on rear wheal shaft slottod nut M24/M30 c 45 rr.
'' ' ' '
'''
Wheel,
Wheal on lxake drum M 14 � 1 5 12-13 87-94

00"
e<,f on lxoke drum
\\lh M 1 4 x 1 5 13 ·1 ' ' '
00" '
"
Broke pre..ure regulator
Regulator on luggage compartm€nt Hoo, ,c ,o

""' M' ,o '
Plug on body plug ''
'
Ad1ust1ng ><:r{!'W nut m< M tu "
2 6-3 5 18-25
t '
Spr1r.q "°"""<l on bodv ,ock�t head ''"""'
MO ac
' 0 '
Regulator on ,,�e membe,
00"
MS ' s
Brake se,vo
"
Brake servo on tront •�I• w, M, mo, ma� 9 4
Pedal cluoter
'' ' '
Pedal cluster on frame M to ac 4-4 5 29-33
00" ' '
Pedal stop plate on lrame 2-2 5 14-18
MO
00"
,_, ' '
8rnke pedol/p,n
oo" M 12 � 1 5 '' ,.,
22-29
'
Br�k• pedal/push cod MS a,
00" ''
,a '
Clutch podal/p,n w, M to ''
'' '
Support/clutch pedol on frame bolt Ma '' '
''
'' ''
tzs
'''
•
•
Ill. Tire Data
,,� Type 1 Type 2 Type 3 Type 4
113, 15 21,22,23,26 21 23
,,, L 1,23
,,
"""' '" '' •
-
.
'' '' '' '' ''
T!fo (tut..Jess) 6 00-154PR "') 15 4 P R •• 6 00-154PR '") 7 00 - 1 4 8 P R
' 00 185SA14 18'1 R 14C 600-15L4PA 6 00-15L6PR 165 SR 15 ') 155SR 15 165SR15
Fhm x wheel ,i,e 41/2Jx15'") 41/2Jx15"*1 41/2Jx15 5 1 r.l J x T 4 • 41/2Jx15 4 1 f2 J x 1 5

'
lnflotoon preuures
front roar front rear front front front rear front
(po,) front front front froot rear front front rear front
"" "" '
"" ""' "" "" '""
'
,, ,, ,,
• up to two occupant< - - - - - - - ' - - - -
fully loaded
'' ,, '' '' ''
- -
'' '' '' '' ''
,,
- - - - - - - ,a - - - -
' '' '' '' '' '' •'
•
,
'' " '' ''
c • w,th half payload - - - - - se ao ao ,, ,,
'
ao - - - - - -
wnh lull payload - - - - - -

'',
, ao
''
so
'
'
I
'' - -
'' - -
'' '' - -
''
' '' '" '
• '' '' '' '' '' '' '' ''
'
•
'
'
Rad,al run-out
For prol0J190(l h,9h speed Under no circumstonce "the
'
I fo, Canada only
.. ,
UptoMa,ch1972
tr.-.el the pre,.urns oo tire pressure t he maxi
o exeod t
Wheel for all types Models 1 1 1 , 1 1 3 , 151 Model 14
mox,mum 1 5 mm IO 060 m.) veh,clos wflh boa, ply 1,rn,
mflot1on preuure muked on d]; Tire 5 60 - 15 Tore 560S-15
Lateral rur.out
shook! bo tncrea,.d by 3 p11
Whoel 11,e 4J X 15
rao ,,,
•
0 ,,, ,,,, 0
• • .' • • ',-��-
�-------------------------------------------· """ """ .. ""-
BODY
1. T1ghi.n111g torques
Torque
Ten,,le l
b ft Romar ks
Locot<on Threod
class
') The bolts for the sub frame mutt be t<ghte™>d ,nth• order as 5hown her•
• - Body {Tyl>"' 1 and 3)
W�n m,t•lhng body

11 - 14
body l:>olts 00" MS
•
11 - 14
M ro ''
body bolts 00"
''
When check,r,g
7 - 11
body bolt< 00"
MS
7 - 11
body bolts M tc
''
00"
M
"' SS
to
''
II
Fram• heod to body jooly TvP<> 1 /Model 113) 00"
A c D to
b - Body (adtht,ona1 for Ty.,. 3 only)

30 - 32
Sub fr•me to frame (Al M to
00"
''
Sub frame to frame IS I 00"
•• "'
'' '
Body to sub frame lt,ght•nod from klgogge
-
so
comportment M to .
I
00"
' '
Rear engine >Uf>POrl
'"
IOI MS "
s's
- 's
' -
00"
"
M to
Body t
o from oxle ,upporl 00" ''
"' ' '
taa
taa
ELECTRICAL SYSTEM
Batt .....
5� ofter TDC ++I

I. aam,oe, (Stalldonl oqu,pmentl I. G&noral d;no
at ,dlmg ,pood
Type 1 Type 2 Type 3 Type4

Types 1 or>d 2 I 1600 Type3 Type 211700 TYI"' 4
12 V/45 Ah 12 V/45 Ah 12 V/45Ah 12 V/45 Ah
,,
IS!riU<llor
Normal rrop1cal IQn!llon t1m1fl<l 1n degree< 5° ofter TDC ") at ()<> " " l a t 27° before roc'":
State of charge Spec1hc ;!:iett1ng marks 1dl1ng speed !dl,ng ,p,eod at 3500 eng,ne rpm
SPl!<•l1c
gr•,ity gra,ity
ootch ,n crar>kshaft f1 notch

le 1n pulley/ r
ed ootch in fan
Discharged
' tz pulley/crankcase 101nt tongue of sett,ng gauge pulley/fan h<Ju"ng
' 00
Half charged t zo , IS
Fully ctiarged 1 285 I za

ntac! breaker gap dwell an�e 44 - 50°
Chedt,ng battery
Levo I of acrd over !he plate, and oepa<atou S mm 13116 in I Champ,cn L 88 A

po;k >"ug, Bosch W 175 T 2
Bo.ch W 145T 1
II
Make/Des,gnatoon •••1 Beru 175/14/3
11 ac,d level rn.r:!1cotor, ore fitted, top acid up ,u Seri, 145/14
l,:vol shown
O7 mm I o,,,"-''"-''----------------S
Load test
Deta•ls ol d"tnbutor 1nterchangab,l1ty ore give,, ,n the W0<�shr,p M>nual, volume K

B•ttery 12 Volt 6 Volt
Load current 110 amp, Remarks
Mm1murn voltag<' nsv I Vacuum hose, on +-

) From August 1971 5" before TDC
5-lO<ecs ,••1 Vacuum hoses off ++) From Augu,t 1972 With m•nual transm1ss10n
Load nod
*') The types goven or plugs w,th the ,.me value, from other manufacturers 10° af1er TDC
'" '''
OeS19nation Type 1 Typ• 2/1600 Type 3 Tyf>0>2/1700 1 Remarks
Gener.itor
' Drive rat,o - generator shalt/crank shalt

' a a
-
' Mox,mum output .

'
30Amp
' s
'
38'Amp ' 30 Amp -
'
a Voltage regulator {for test data,
,oeWorkshop Monu•II
< • AlterMtor
1 · Dr,ve rat,o - alternator <hafllcr,mksholt - - - 1 2 26
a Maa1mumoutput - - - 55 Amp
a Stator w,ndmg res,star>eo . - - 0 13-0013"
4 · Exc,tor wmd,r,g re>1stance - - - 4 0 :!: 0 4 n
s M1mmum brush length . . . . - - - 14mm 10551
a Bru>h pres<ure - - - 300- 400 gram °'

{106-1410,,
M,n,mum d,amete, of slip rmg, - - - 31 5 mm
' (1240,n)
e Slip ring out of round . . . - - - m>,. 0 03 mm
(0 001 "
' l
a Rotoc out of round . . . - - - m a x 0 05 m m
D
10 002 on )
d . Volt>ge rO!Julator
1 · Rogul•tong voltage under load . 125-145 125-14.5 125-145 13.8-149Volts
load current . 25 Amp 25 Amp 25 Amp 25-30 Amp
' "' 2000--2500 a

t 2000-2500 at 2000-2500 at 2000
,,m ,om
'>"'11 {er,g,ne)
·�
{ger,erator) (
go nerato rI (generator!
''' '''
0e<IQrlall00 Type 1 Typ,, 2/1600 Type 3 Tyl)<' 4 Remark,
Typ,, 2/1700
Starter 12Volt07hp'I 12 Volt O 7 h p ' " ) 12Volt,07hp''I 12 Volt,0 7 hp • •1 Autom•t>C St1ck Shilt 08 hp
• . ., .
;
, "utomat,c transmr,:;1on 08 hp
Test dala {<ea Work>hop Manual I
a
' End play 311911 023 B,C/0 0 1 - 03 o, 0 1 - 03 o,
0 ' 0 '
0 0 12) O 004
{ - 0 012) t
o ooe
0 012, 10004 - 0 0 1 ?
m ""'
003911 023 Al Automat<c 0 is - 0" 0 1 - 0 15
0 ' 0 '
O 00
{ 4 - 0 0061 10 004 - 0 0061 10 004 - 0 000
a P.,,m,,s,ble commula!Cr runout
311911023 8/CIO 0 0 3 ( 0 00 1 ) 0 0 3 ( 0 00 1 1 0 03 10 001) 0 0 3 ( 0 00 1 1
003911023 A 0 05 10 002) o 05 10 0021 0 05 {O 002) o 05 10 0021
Mrn1mum commutator diam,t"1'

•
311911023B1C/D 3 4 5 1 1 3 58 ) 3 4 5 1 1 3 58 ) 345(1358) 34 5 1 1 3 58 )
003911023A 33511319) 335 [1 3191 335(1319) 335{1319)
111911023A 3 3 0 { 1 2 99 ) 330(1299) 330(12991 3 3 0 { 1 29 9 1
s Bi ush pre,Stire approx 1200 gram, 1200gr,m, 12009,...,,, 1200 gram,
D
M23od 1423ozl 1423ozl 142 3 od
I . Soleno•d
Pull in 0011 current (Bosch) 35 Am p 35 Amp 35 Amp 35 Amp
' Pull m coil cu,renl IVW) 30 Amp 30 Amp 30 Amp 30Amp
11 Amp 1 1 Amp
a
' Holdmg coil current (Bosch) 11 Amp 11 Amp
12 Amp 12 Amp 12 Amp 12 Amp

Hold,ng coil current (VW) .
•
taa
'''
Type 211600
Typo 1 Type 3 Ty,>e 4
Typ,,2/1700
"I Moo•I 36 46 2 5-3 0 kg/cm2 (35-42 psi)

1 - Windstnold wop,er mot<>r
1 Current •I low ;peed . opprox 2 5Amp 2 5Amp 2 5 Amp 2� Amp *•) Mod•I 36, 46 4 0 k!j{cm2 157 p«)
at high ,;,,,
ed oppro� 3 5 Amp. 3 5Amp 3 5 A mp 35 Amp
lJ!)toJuly1971 OB
2 • Mmimum comrnutotor d,omete, 215(846) 2 1 5 { 34 6 )
3 RE,al runout 00310001) 003!0001) 00 O 001)

3 { O IJJ IO 001) UptoJulyl\171 084
4 • Armatu..., ond ploy 0 2 - 0 3 1 0 008 0 0 1 1 1 0 2 - 0 3 ( 0 000 0 0 1 2 ) 0 2 · 0 3 ! 0 005 0 0 1 2 0 2 - 0 3 { 0 008 0 0 1 1 1
5 • W,per <h,ttib<onng erd play 04{0016) 04(0016) 0410016) 0410016)
h Frein"" fan mol<lr
1 Cur ..nt at low ,;,,,e<J (3500 rpm) 1n<tall«l I 3 O Amp 3 5Amp 20Amp
•
t h,gh 'P'!ed 15500 rpm I 1n<t>lled 6 0 Amp 3
'"0 """
Amp 60Amp 30Amp
j • Hoodl•mp
1 · Maximum ,oltoge drop ,n l1ght1'1!i w"1n9 0 6 Vol! 0 6 Volt 0 6 Volt 0 6 Volt
k · W,ndsh..,ld wMher
1 · Wo<OO, contame, M,x pre»u,o 3 0 kg/om2 142 P"I
Cut-<ifl .-i,,e 1 5-2 O kg/cm2 15-20k�lcm2 ') 15-20�gicm< ·1
l21-28p,i) {21-28p,,) 121-28 p<I)
3 O kq/cm2 30kg/cm2•·1 3 0 kg/cm2 •• I
142 P"I (42 p,i) (42 p11)
I Si,oodomo"'r
Rot<o of dl$!00Ct/,o,olut>om 0 62 • ") o s:i ••• I 082 " " ' ) 0 82 +)
m Htatod roar w,rdow 60-70Watti 60-70Wstt, 60-70 Watt, 80 Watt>
n Fu .. b<»< 10/12 potnt 12 point 12 po,nt 12 point
''" '''
Auxtllary heaters
Type 2/1600
Type, 1 and J Type 4

De,cript,on Type 2/1700 Remarks
''.
''' ''.
Gonerol data
1 • Heater 001,J\Jt max 2000 Kcal/h 18000 STU/hi 4000 Kcal/h (10000 BTU/h) max 4000Kc�l/h (16000BTUlhJ
2 , Fuel conwmpt,on 0 3 1 - 0 3 7 1 /h I065-07BU.S pt'I 029-150US pt/hi 0 2 - 0 6 1 /h 1042-128US pt/hi
1054·-0651mppt'11 {117 1 25 Imp pt/hi 1039 -1 16 lrnp pt/hi

3 Fuel pump deli.ety capac,ty at 200 stroke, 59-71cm3 118-125cm3
4 · Power con$Umpbon a
t ,tart1fl\l 200 Watt 200 Watt
at nco-mol pperotion 36 Watt 130 Wort
5 Temperature 1,m,tatoon 160-2()()0 C 1266-320" Fl
6 Temperature range upper 1300 C (2£60 Fl opprnx 1150_133oc(239-271°FI
ecc c {122ofl approx 30°- 4o"C I 86 -1040 Fl
7 Overl,eatmg ...,<!ch re�on"'

"""time 1 1 0 - 1 50 ,ec 170-200""" opprox 1 80 ""
120-180,ec
8 S.iety swEtch '""'"'"" t,me 150-230 "'
�
9 lgrntlon coil soltage 5000 Volts
10 Heate, pl'-"J electrode gap I010m) 2 5mrn {010m.)
11 · Flame detector switch
Switch hooOlng to heat •�changer d"t011c,, Smm 10314 '" I 10314,nl Smm (0314 ,n I
Run on t,me 110-150,ec 90-150,ec

•
12 Combustloo air tan
lgrntlon contact breaker gap
Fl>el pump coo tact break.er gw

•
•
04mm
04mm
(0016,nl
I0016m)
D
Blower fan/motor ,upport hoosmg clearance 1 Omm 1 0 04 0 m )
•
Fan rpm .;t nom,nal voltage 6400-7100
''' '''
General data
I. P rform1nce •Old consumptK>n Type 1 from Aug 1972

• Type 1 from Aug 1971
rvoe 1 up to July 1971 Remarks
,,� 113 M 9
113 M 9 I 14 M 9 tta I
111+113M9 14 M 9
ua
Moo,
u' ''
•
'
"" '' 'I Modol 15
'
,o ea '''0
za
es ''ss ''
at aa
Max1ml><T\ ond cru,,ing speed moo
''
,ooo ,,oo ''
asoo 4375
•om soeo ''

aoso ''
,ooo ''
0000 4130
"'"' '' s
at an "r>\l"'" speed ol
,ooo eooo
Road speed•
«oo «xo sooo aooo aooo aooo ,ooo «oo sooo
,o - ''
at •n er,g1ne ,peed of •am
,o - - - • - • ") Model 15 aa o
ae
1ot gear
moo
'' '' ''
se s
''
�
"' '' •
"' "' "' ee
"' '' e
2nd !l'•r
=" '' ''
so ee
'' '' ''
ao
ts s
3rd II'"' m'"'

mac ''
'' '' '
'' '' ao
''
'' '' ''
4th gear . .
H,11 cl1mb1ng ob>iity on good road, with

'' '' '' '' ''
••• ) MOOel 15
"0
two occupants ae s 3!, 5 l as s
ea c aa s
ze s .
2,
1 I"') "' WO
l st g .., %
as 0 24 0 •
as 0
29 'l •·
) ze s "' '''
zz s 29 o '"\
zo s
'' ro s
'13
''l ''
2nd gear
'''
.
zo s tz s 205 \
' ,, 0 0 l zo s
"
a ''-
3,d gear .
'
%
,., '' s
- - ''a - -
''
4th gear 's ''
'' -
Accelerat,on tLmH lthr()U(Jh the geo.-.1
- - - - - - -
- - -
secords ras
0 - 3 1 m ph ,, ;
ta 0 rs 0 rs 0
,econds
0-50 mph
0-62 mph
.
S<cond,
'" 0
" 0
za o .. '
l'
S.5 ''
te s
''
22 5 rs e
'' 0 '' 0
es s
fuol consumpt10n IDIN 700301 aa z za a 25.5
ao a zs a 00 >
aoe ao s
aa s
m,les pe, Imp gallon
"' a
ze '
"ae' "' "' ' ''' zs a zaa as s
23.5
mil"' per u� ¥lion
0•1 con,umpt10�
''' ''' 1 4-2 B 1 4-2 8 1 4-2 8 1 4-2 8
1.4-28 14-28 1 4-28

1.4-28 1 4-2 8 1 4-2 8 1 7-3 4
Imp pints per 1ooom,1e, 1 4-2 8 1 7-34 1 7-3 4
1 7-3 4
1 7-3 4 1.7-3 4 1.7-3 4
1 7-34 1 7.• 3 4 1 7-3 4 1 7-34
US p,nu per 1000 mile,; •
I
,,,
'''
' •
•
'"'""'""'' '""''-"''"¥1''-'1'4 '
"'"
"
'"
""'
"7
''
"
,
'
'
-;"
,,,
i§t
""'
' "
" "
" '
· ·-·, """'' " " -------�
' ,,
,,
! 11
>
' P•rlormlfflOI ond cona,mption <'.
'
'
,
>,
!
Type 2
Typo, 3
rvoe ,,oo 1700 M 249
,,' Remark,
r reoo
' A
I h
-
21,23 31+36 M 249
21,22.23,26 21,23,26
1
· ' ''
"' ''
""'"' t"
*) Squareba<:k w,th full load 29 %
M,J<1mum or.:I cru,.;ng � '
moo ea 'J84 ''220 ,,�
,,oo '
a'
seo '"
aeao ;r4220 4 ''
at �n or,g,rie spoed of '
�
'
'
,
Road ..-,cl<
coo .
t \ 4000 eoco sooo
t •n engine ,peed of
o ' aooo
-v 18
ht gear ""'
moo "
re"'
s -
�-
'
'
'' aa 0
!
< 34
r ''
200 geor
-
'
''s '' ''

3rd 9""' '
�o '' 52.0 aa -' se
)r' 19
se
''
,;
4th gear
m,<, " is 0
Htll cl,mb1ng ob,l,ty on gc,od roads with " " '

,
} '
'"
two OCCt.Jponts ' '
r:440
'
4-0/36 ')
1'1 ll{'ar
% - - '';
2nd gear - - ''
- ' 23 O -
' '' s
3rd goor
' - - - '
,, 13 0
-
' '
'' 0
"so
'
% - - - -
4th 9""' '
Accelora1,on 1,mu (Th,ough the gears)

' '"
-
socor,c::I< ',- - -
0 - 3 1 m pt, - -
<
' t 1.5
socor>ds
0 - 50 m p h - -
" e
0-62mph =m• - - ''
,, - '
- ''
-
I Fuel consumpt,on {DIN 700301 it,.
m,le< per Imp gallon 21.8 ,31.7 zs '

I
miles per US gall<m ''' 18.2
'' e �·26 4 '''
0,1 consumpt,on
''. '"' ''' '''
-
1.4-2 B 1 4-2 8 .4-28 1 4-28 1 4-2.8
I mp pmts per 1 000 miles '
1 4-2 8
1.7-J 4 1 7-34 1.7-3 4 1.7-3 4 1 7-3 4

US p,nu per 1000 m,les 1 7-3 4
'
-
'''
P$rformlnOI ind conoumpt,on
,,� Type4 Typa4 M 249 Type 4 (C,tt,f. only) Typo 4 M 249 (Cal 1f only I
Remarb
Model
'' '' '' '' '' '' '' ''

Maxrmum and cru,,1r,g speed
�" ''
saoo ''
5130 ',,oo
' '' '' '' ''
aeso
at "'1 engme speed of mm
Road ,peecls ""' """ "''
asoo
,.., aeoo ssoo sooo sooo woo
•tan engine spee<l of
t gear
'�
'
h mo" ''
,,
2nd gear m,o ''
''
''
'' ''
"
"''
ea
M
''
as s
3rd !)ear mo" es sa

'' '' '' '' ''
4th !)ear mpl1
'' '' ''
H,11 cl 1mb1r,g a1J1l 1ty on good roads wtth '' '' '' '' '"'
,,
'
two occupants
% aa aa
1st gear
2nd gear %
'' ''' '' '' ''
3rd g<ar % '' ta' '

'
to
'' s
4th gear ''s 'e

Acceletat1on t1m•s !through the gear<) ' '
0-31mph ,ecor.ds
0 - 5 0 m ph S€Cor.d, ,o
0 - 6 2 m ph ,ocor.d, '' ,, ' ''

zo '
''
20. 1
Fuel conoumpt.on IDIN 70030) '''

mile, per Imp gallon 27.0 zr o
m,le, per US gallon ez
'' e
' '' ' zz a
011 coosumptron ''' '''
1 4-2 8 1 4-2 8 1 4-2 8 1 4-2 8
Imp pint, por 1000 m,le, 1 4-2 8 1 4-2 8
US pint, per 1000 mt le,

1 7 - 4
3 1 7-3 4 1 7-34 1.7-3 .4
1. 7- 34 1 7-3 4 ''
1 7
''
- 3 4
'''
_,, _______ , , ,, ,,,__
----"--" 1;<@&hh< -��--"'-
--- -- - -
I
I. Capac,t,es
-
-
/\" Cleaner Transm11,,on Automat,cSt,ck Shilt Automat,c Tran,rms,,on ''-
) ,&
> Fuel
St"""".l
,,� Moo, Eng,ne (fill t
o and frn•I Transm1u1on Con,ertor and Final
Brake, Remark,
mark) drwe
Converter
fmal dri.a transmosSton dr,,,. �· tank
53USpt
{4 4 Imp
09USpt
IO 8 Imp pt)
63USpt
15 3 Imp ptl
76USpt
{
6 3 Imp pt)
6 3 1JS p t
(5 3 Imp pt)
1
, , 1 60 cc
t,ii{ (5.4floz)
10 6
{8.8
us
Imp
1)11
1
�al)
08
10 7
US pt
Imp. pt)
') Typ• 2/1600 5 3 US pt {4 4 Imp pt)
111114 at chonge, at char,ges trans grease re.er.�

"' 53USpt 53USp1
-
1 3 U S ga l
'
5JUSpt
--
OS U
�-J.
S pt
(4 4 Imp
63USpt
pt!
76USpt
(4 4 Imp
TI'us p;--
ptl
J -
175 cc
-
1 1 1
11
Imp
1 US9al
gal )
OS US pt
14 4 Imp 10 8 Imp pt) (5 3 Imp ptl l631mp pt) 15 3 Imp pt) 15 9 fl ozl (
9 2 Imp !,,11 ) 107 Imp pt)
a
t changes at change, -o, ,_,,,.,,
tran, grease
"' "'' 5JUSpt 53USpt
-
1 3 U S ga l
{441mpptJ 14 .
': m
l y pt) {111mp�•II
-- -- - - -
--
74USpt 09USpt 74USpt 126USpt 30USpt 0.6 us pt 15 8 us 11-11 1 0 us
-'
16 1 Imp 10 8 Imp pt) (6 1 Imp pt) 11101mppt) i251mprt (O.S Imp pt) (1321mpg,II (0 9 Imp
21122! pt) ·1 from At;g 72 at chan<Je• at Chango< ' Hypo,d reserve "'
'
' 23/26 paper �lemen 74USpt 63U5pt
'
tfons o,I l J U S ga l
f,lt•r type {6 1 Imp pt) 15 3 Imp pl) 11 1 Imp

-- -- ·- - ---� ---
53USpt 0.9 US pt 63USpt 126USpt 21USpt - 160 cc 106USpt '" O S US pt
14 4 Imp 10 8 Imp pt) {531mp pt) 11101mppt) 1171mppl ' 154flo,) 18 8 Imp pt) {O 7 Imp pt\
}
'
a 31/36 at clian9"' at cha'1ge, at char>g<, Iran, gr,,ase
53USpt
'"'""�
1 3 U S ga l
" 63USpt 2 1 US p 1
{441mp pt) 15 3 Imp pl] l171mp pt { 1 . 1 1 mp g E 1 1

--- -·
74USpt 0 9 US pt 53USpt 126USpt 21USpt 250cc 132USgal 08USpt
16 1 Imp (
0 8 Imp pt) {4 4 Imp ptl 11101mppt) 1171mp ,,, .(85'1oz) {1101mp gal) (0 7 Imp pt)
42/46 ,,, al c�anges at change, lr>n, greaso ,e..,rve

at chanlje>
\ '
' 42USpt 6 3 US p t 21USpt 1 6 us 11-11.
};
13 5 Imp pt) 15 3 Imp pt) 11 7 Imp "''
,
,
,
,
_
{1 3 Imp. gal )
D
'
\
tso
'"
I
- - -
1 1 1 .Dimensions
T y pe s 1 , 2 , 3 and 4
ua na 21.23,26 21,23,26
De,,gnat,on 31 36 42,46 Remorh
' u up to July 1972 from Aug 1972 ur, to July 1972 m Ac;g. 1972
''
mm {1n ) 2400 (94 51 2400 (94 5) 00 194.5) 2400 194 51 2500 198 41 •1 Up to July 1972
Wheelbase 2420 195 3) 2420 (95 31 2400 (!}4 5)
1310IT'm {516 in I
mm {>n ' 9S (54 9) 1310 (51 61 1376 (54 71
Track, front I 1322 152 0) •1 1304 (51 3) 1375 ( 5 4 1 1 1390(5471 1386 (54 51
1350mm(53210)
mm (,n 15 7 3) 1350(5311 1 3 50 ( 5 2 8 )
I 136315311 ·1 1338 {52 6) 1350(5311 1 3 6 3 1 5 371 1439 (56 6)
"' mm {,n ) 4368 (171 91 4553(1792)
., I
Komb, 1950 {76 71
Loflllth 4030 158 61 414011626) 40601160 6) 4140 (163 0) 4420(1740)
-
Wodth mm {on I 1634 164 31 1585162.3) 1640 164 51 167516591 "''1 I " 'I Up t
o July 1972
1 5 50 ( 6 1 0 1 1585 162 31 1765(694)
1 63 5 m m ( 6 4 4 r n )
Height, empty mm {,n l 1320 {51 91 1500(590) 1470 157 81 1485 (
5!3 51
1500(5901 1500 (59 01 1955 ""1176.9
Ground clearor.co,
loodod mm (on ) 1 50 1 5 9 ) 150(59) 150(59) 17 8) 150159) 135 15.41

150159) 185 (7.3)
,,, ,,, ,,, ,,,

Angle ol approach ,,o
departur<
,,, ,,,
iso
,,, ,,,
'"' ,,, ,,o
'"'
11 25 m 11 2 m 11 4 m
Tummg cl'cl• 10 5m SSm SS m 12 3 m
{34 ft 2 112 ,n I 136ft11m) {31 ft 5 ,n I 131 It 5 ,n.) 140ft 4m) 136ft 10,n) 1371! 4m)
D
''' '''
I
Aor oond,ti<>,... (VPCl
z Comp....,,, <>� 1, ...1 T&mpornuro - p,....u,. rolot1o;uhip R - 12
CompTOIOOr Type --,

pe»1t100 mm mm {1n
Q;I �Ii/ht
I m,, mm l1n I
Rerno,kt
Tomr-,rature
'c •• k�cm2
P,....,ro T<mPof01Uro
•c
•• kg/cm2
Pre>iu,e Temperotu!l!
•c
••
Pressure
-,�
·�='
Tecom ..h 22217/8) 27.0 1 1 1 / 1 6 1
"" "' "'
.
. 4l - ., 11.0') as
28.6 {11(8)
{1 cylmdor) h(}l",zOf\tol 22 217/S)
''' -·
_, '' '' ''' '' '" '''
York ""rt,col 22.2 {7/8) 286(11/8) -� S 3 •1 aa s 00 ss s
--- - '' '" '' ''
ho,izootol 20.6113/16) 302{13/16)
'' ''
{
2 oylmd•r) -� o ze 5 3 •) u
-"
toe t
2.3 ·1 z
''
ss
'' "'
aa e
''
aa
''
too
''
116.9
- '' - '' '' '' .'
o
-"
126 2
- '' • '' ·�
'"
,, '' ''' '' ''
,,,
r 136 0
- '' - '' ''
,,, ,,, '' '' .' ' ••
"'
- za sc to s 146 5
- '' .. ' ' rs
,., '' '' ''

- s ra ss n 11.4 157 1
- '' '' ••
'' '" "'
- ,, c ,., 00 ., tae 167 5
'' " ''' '' '''
s ta tao 13.4 179 0
- '' '' "' '
,' '' �· ''
,
ro '
00 ,, . ,�,
- '' '' '' ''' " '' "'
- s re a tso 16.4 232 0
'' ' ' "' '

,'
, '' '' "' ,,,
- e ,, ' ta a aeo a
'' '' '' '' '' ' ''
') 1n;;hes Of mercury �ocuum
,,,
,� N<>m<n•I Aluminum • Steel
,_,
�.
Tecum ..h
Descr<pt,on Rem..-k, s1 ..1 Steel e.....
m,o or Brus Steel
l
b It
••• tube ""'

Remork,
- {1n ) m,o lib ft)

-� lib•:) m, 11bltl
Cylmder head 2 1-3 2 15-23 2 8-33 20-24 28-33 (20-24) 2.1-2.11

(3/SJ (15-19) 23-29 117-21)
•• •i Tho,o '""l'H' are
bo,ed 0'1 tile fFrtt
,n,ullotoon of•
Front $001 plate 0 7 ---0 9 ,_' 0.8-14 6-10 12 7 {1/21 48-5 5 (35-40) 2.9-3.7 (21-271 39-4 7 128-341 r,ew 11..-ed httm11
I
I t
M se,,
I "broken,
s.....,.,. ,.r.,. 4 1-4 8 30-35 9 Q•

• 9 7
65-70
for'""'" ..id
159 (5/81 (42-47) 3.5-4-3 (25-311
•• 46-54 (33-391
0 7 m k g l 5 1 b lt l
'' to th
e torque
spec,f><:otK>m
0,1 ftll&r pllJ!I 03-08
,_, 25-30 18-22
Clutch pulley bol

t 21-28 15-20 2 1-2 8 15-20
Clutoh hoi<1"'9 COii 0.9-1 4 7-10 e

''
a... ploto 1 9-3 0 14-22 - -
9-17
Rear boor>"IJ "°""' 1 2-2 4 - -
'
"' 157 m

VW Without Guesswork 10 1972

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1972 and 1973.

c · Axle beam and +o rs,on nrms ' '''

Marking of •ransm,ss,ons Comprcssoc 01: I Pvel

AK +I from At,g 1972

1/1600 75-95(107-135) 50 .11., +-+)

'' 8 0- 1 0 0 { 1 1 4 142) '' 5o alter ++I

"' - "' '' '"'

90- 1 1.01128 - 1 56)

800-900 +++) '"'

,1 0 - 1 1 0 1 1 2 8 - 1 5 6 1 00 27° t>elo,o ++I 800-900 +++)

from Aug. 1972

•••• ) From August 1972 10° after TDC

Borns foe mam bwrrng, '

' a) Bear,r,gs 1 z a diameter 65.00-6& 02 12 5500---2 55fl8) '

3 undor,1Zes of O 25 mm 1 010 ,n ) each

s Crankshalt/m3m Journal, ltoktn� hou� ng prelm,d mto acc0<mtl

radial play oos o to I 002- 004) 0 rs I 0075)' ()()5-0 10

end pl•y 0 ''

We,ght �1tlerenae between connect>ng rod, ,n ono engme

- We,!,i,t (wh,rnJ t>rown/wh ,te

Beanng, 1 a dco=ter 24 99-25 00 ( 9937., 9842) -

5 C,m follower d,ametor 18 00-1896 IO 74/1 O 1463)

1 0111.>ressure llor SA� 30 only) >ton orl tempeiatu,e

ol 70"' C 1158� Fl and 2500 rpm approx 3 k!j/C<"f'

Length loadocl 44 1 mm 11 73 ,n I load 56-73kg 1 1 2 3 - 1 6 0 l b,; r

longth lood<d 39 0 mm (1 54 rn I k>ad

Longth loaded 20 2 mm IO 795 on I load 31-38kg (68"·84ib,J

L"'19th loadOO, 26 0 mm 11 02 rn) lo;,cl

utmalance max 20 cmg .o cmg

g - P,ston, and oylmden

2 o,e•,izesof O 5 mm { 020 ,n ) e•ch

1 Cylinder, wt of rou<><i m�x O 01 1

b) Lower P"ton ring .

s 0,1,cr op�r ring . 0 as I 037)

dtameter 1799-17.97 ( 7081- 70731 ''"'

. weight (brown) 480 - 488 gram,

inner correction •"91e . .

001 oi round o ct (0 004) '"

Val,e 111.ude/,ol,e ,tem.

max 2 kg'c"'' 128 ps,)

') Type 3 from Augu,1 1971

10-20 mm (04-08 Ln) .,,m 104-08m)

3-3 5 'I 22- 25 ' I -I F1eploce co�toct, .rfoces oileJ

se•img nut M 12 x I S '5

O,I pomp to c,ankcase

0,1 ,tra1rwr to crankc ••e

nut M 10 e '' ''

')S?OK 13- 1 5 \M- t08

' Type, 2 and 311600 only

Roploce, contact surface, mlOO

'' '' the lollowir1g sequence

socket head screw M e ,o

spark plug M14x125 '" a.s ,s

011 pump to crankca.., M a a ,o ''

I Carburetor soll•O!i• ond )''" '

' , , , , , , 2 1 6 00 Type 211700 T , o c ? ' l 7 00 � , , n t·•�sm Type 2, 1700 aut= tran,m

Ver1tun mm dtametN '' '' ''

Aux,l1ary fuel Jet az s az s ,, '' '' ''

' ') For Cai1lorn,� only

' M,mmum <1<1tvory

I. Toloronoe, """' 1,m1t, and oettm •

-�-----··· �------------<-� --------