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this manual will help you understand, care
for and repair your Volkswagen Multivan.
This repair manual will help you to perform
all the main maintenance and repair work
correctly and efficiently. It should be
consulted regularly by workshop personnel as
an addition to the practical and theoretical
knowledge obtained in Training School
courses. It is a contribution towards
achieving even higher Service quality.
Proper service and repair is
important to the safe, reliable operation of
all motor vehicles or driving axles whether
they be front or rear. The service
procedures recommended and described in this
service manual are effective methods for
performing service operations. Some of these
service operations require the use of tools
specially designed for the purpose. The
special tool should be used when and as
recommended.
CAUTION: EXTREME CARE SHOULD BE EXERCISED
WHEN WORKING ON COMPO-NENTS UTILIZING SNAP
RINGS OR SPRING LOADED RETENTION DEVICES.
FOR PERSONAL SAFETY, IT IS RECOMMENDED THAT
INDUSTRIAL STRENGTH SAFETY GOGGLES OR
GLASSES BE WORN WHENEVER REPAIR WORK IS
BEING DONE ON ANY VEHICLE OR VEHICLE
COMPONENTS.
It is impossible to know, evaluate and
advise the service trade of all conceivable
ways in which service might be done or of
the possible hazardous consequences of each
way. Accordingly, anyone who uses a service
procedure or tool which is not recommended
must first satisfy himself thoroughly that
neither his safety or vehicle safety will be
jeopardized by the service methods he
selects.
Precautions It is necessary to take extra
care when working on the electrical system
to avoid damage to semi-conductor devices (diodes
and transistors) and to avoid the risk of
personal injury. In addition to the
precautions given in the “Safety first!”
Section at the beginning of this manual,
take note of the following points when
working on the system. a) Before
disconnecting any wiring or removing
components, always ensure that the ignition
is switched off. b) Disconnect the battery
leads before using a mains charger. c) Do
not reverse the battery connections.
Components such as the alternator or any
other having semi-conductor circuitry could
be irreparably damaged. d) If the engine is
being started using jump leads and a slave
battery, connect the batteries positive to
positive and negative to negative. This also
applies when connecting a battery charger.
e) Never disconnect the battery terminals or
alternator multi-plug connector when the
engine is running. f) The battery leads and
alternator multiplug must be disconnected
before carrying out any electric welding on
the vehicle. g) Never use an ohmmeter of the
type incorporating a hand cranked generator
for circuit or continuity testing. h) When
carrying out welding operations on the
vehicle using electric welding equipment,
disconnect the battery and alternator. i)
When fitting electrical accessories it is
important that they are connected correctly,
otherwise serious damage may result to the
components concerned.
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