1978 Westfalia Repair Manual

42
:a- Repair Manual Type 2 6 l- rfl z Campmobile Repair Troubleshooting

Transcript of 1978 Westfalia Repair Manual

Page 1: 1978 Westfalia Repair Manual

:a-

Repair ManualType 2 6

l-

rflz

CampmobileRepair

Troubleshooting

Page 2: 1978 Westfalia Repair Manual

This publication contains the essential removal, installation, and adjustmentprocedures for 1976, 1977 and 1978 factory-equipped Campmobile vehiclessold in the USA and Canada.

CAUTION

It is assumed that the reader is lamiliar with basic automotive repairprocedures.

Special tools required in performing certain service operations are identiliedin the manual and recommended lor use.

Use of tools or procedures other lhan those recommended in this repairmanual may be detrimental to the vehicle's safe operation as well as the safetyol the person servicing the vehicle.

Part numbers listed in this manual are lor relerence only. Always check withyour authorized dealer to verily part numbers.

w 42-028-965-1

First Edition,4/78

Manufactured in the United States of America

@ 1978 VOLKSWAGENWERK AKTI ENG ESELLSCHAFT

All r ights reserved. Al l information contained in this publ icat ion is based on thelatest product information available at the time of printing. The right is reservedto make changes at any t ime without not ice. No part of this publ icat ion may bereproduced, stored in retrieval system, or transmitted, in any form or by any means,electronic, mechanical , photocopying, recording, or otherwise, without the pr iorwri t ten permission of the publ isher. This includes text, f igures and tables.

"'-----i'

Page 3: 1978 Westfalia Repair Manual

Contents

Ceil ing cabinet and closetLeft inside trim panelLouvered windows

Repair Luggage rackPop-up roofRear seat and storage lockerRef rigerator cabinetSink and gas range cabinet

Page

76.275.976.875.2,75.775.2,75.377.276.776.4

Troubleshooting

Current f low diagram (CANADA) 97.12(usA) 97.4

Cut-off relay f or auxiliary battery (USA) 97.11Ef ectrical system, general layout 97.2Ref rigerator does not cool (CANADA) 97.14

(usA) 97.6

lndexCeil ing cabinet 76.2Circuit breaker 97.3Closet 76.3Controlpanel 97.3Current f low diagram

(cANADA) 97.12(usA) 97.4

Cut-off relay for auxi l iary battery 97.11

Ef ectrical system, general layout 97.2

Left side trim panel 75.9Louvered window 76.8Luggage rack 75.2,75.7

Pop-up roof 75.2,75.3canvas 75.2,75.4seal 75.2,75.5

Rear seat and storage locker 77.2Rectifier 97.3Refrigeratorcabinet 76.7

Sink and gas range cabinet 76.4

Sink water pump 97.3

Troubleshootingcut-of f relay for auxiliary battery (USA) 97.1 1ref rigerator does not cool

(cANADA) 97.14(usA) 97.6

ref rigerator does not cool on 110 volt A.C.(CANADA) 97.14(usA) 97.8

ref rigerator does not cool on 12 volt D.C.(cANADA) 97.14(usA) 97.10

Page 4: 1978 Westfalia Repair Manual
Page 5: 1978 Westfalia Repair Manual

75

Interior PanelsRoof

751

Page 6: 1978 Westfalia Repair Manual

75 Interior Panels, Roof

Sealremoving / instal l ing page 75.5

-Foof

reptacing page75.4removing page75.4instal l ing page 75.5

fiff;i::3r3ii3i

:

Luggage rack

fiffnffii:3:i3l KF

7 5.2 iff :!:?:l;anvas/sea'

Page 7: 1978 Westfalia Repair Manual

Interior Panels, Roof 75

Pop-up roof, removing

Work sequence

- release latch (A)at lock (B)- push up roof at handle (C)and crossbar (D)

unt i l strut supports (E) at f ront are lockedin oosi t ion

- pul l of f double bed snaps (arrows) at f rame andremove mattress

j60 rdt

- remove circl ip (A)f rom bolt (B)- push bolt (B)out of bracket (C)- let strut supports (B)rest between both bolts in

brackets (C)

Note

Fol lowing procedures require 2 mechanics toavoid damage to vehicle paint

- remove 3 bolts (arrows) on each side ofrear l inkages and t ie them together

- let pop-up roof rest at rear of vehicle roof- l i f t pop-up roof of f vehicle

(third mechanic required)

Note

Do not damage paint with f ront support strutswhen removing roof

>;-.:, ' i , : l t.

- remove screws (arrows) at channel

Pop.uproof 75.3

Page 8: 1978 Westfalia Repair Manual

75 Interior Panels, Roof

Pop-up roof, installing

Work sequence

Note

To hold strut supports in posi t ion temporar i lystaple roof canvas to wooden f rame on left andr ight s ides

- l i f t pop-up roof canvas onto vehic le roof(3 mechanics required)

- let strut supports rest between both bol ts offront brackets

- mount rear l inkages to vehic le roof wi th 3 bol tsand t ighten them loosely

- instal l bol ts in strut support brackets andsecure wi th new circ l ips

- reinstal l channel of pop-up roof canvas andt ighten screws f rom center to s ides

- c lose pop-up roof not ing fo l lowing:o lower pop-up roof so that at f ront approx.

200 mm (8 in.)stays open. push roof on both s ides to f ront. push center part of roof to f ront a lso and

let latch engage in lock

- check al ignment of pop-up roof to luggage rackand seating of seal (arrows)

- i f necessary real ign roof by moving rearl inkages A in elongated holes and t ighten bol ts B

Pop-up roof canvas, replacing

Note

When canvas must be replaced cut i t a longvehic le roof. This ensures easv removal of screwsin channel

Pop-up roof canvas, removing

Work sequence

- remove pop-up roof and canvas as described onpage 75.3

- place pop-up roof upside down on two benches

- remove one screw of handle (A) and turn around- remove reinforcement (B)-3 bol ts- remove strut support (C) brackets-2 bol ts on

each side- remove lock (D)-4 bolts

- remove plast ic str ip held wi th staples towooden frame (arrows)

- pul l out staples holding canvas to wooden frame

75.4Pop-up rool canvas

Page 9: 1978 Westfalia Repair Manual

Interior Panels, Roof 75

Pop-up roof canvas, installing

Work sequence

- f i t canvas to al l four corners of wooden f ramewith staoles

- at tach canvas to f ront , rear and side sect ions ofwooden f rame with staples going f rom centerof sect ions to corners

- cut 4 plast ic str ips approx.200 mm (8 in.)shorter than each side of roof

- warm up plast ic str ips in warm water- staple plast ic str ips (stretching them to length

required) to wooden f rame

Note

Always start at corners

- reinstal l pop-up roof and canvas as descr ibedon page 75.4

Pop-up roof seal, removing

- open roof and pul l of f seal

Pop-up roof seal, installing

Work sequence

- instal l seal wi th cross sect ion A-A on rear andlef t and r ight s ides

- instal lseal wi th cross sect ion B-B on front

. seal for f ront (cross sect ion B-B)A - inserted steel c lampsB - rubber part of seal

seal f or s ides and rear (cross-sect ion A-A)

A - inserted steel c lamosB - rubber oart of seal

Note

Correct tension of inserted steel c lamos can berestored by squeezing seal together

l6d-o60 I

Pop-up roof seal 75.5

Page 10: 1978 Westfalia Repair Manual

75 Interior Panels, Roof

- coat seal with talcum powder- slide seal over edges of roof starting at both

f ront corners (arrows)

- to make sure seal with inserted clamps isseated properly on roof press it onto edges withplast ic wedge (A)

75.6 Pop.up roor seal

Page 11: 1978 Westfalia Repair Manual

Interior Panels, Roof 75

Work sequence

- remove beading (A) part ia l ly af ter removing2 Phi l l ips screws

- remove inter ior l ight (B) and insulate hot wire- remove al lT Phi l l ips screws on rear part of

f ront headl iner (arrows)- remove 2 Phi l l ips screws on f ront part of

f ront headliner (arrows)

- part ia l ly pul l down front headl inerand insulat ion- remove nuts (arrows)

Lussagerack 75.7

Page 12: 1978 Westfalia Repair Manual

75 lnterior Panels, Roof

t#

- remove all (four) sheet metal screws (arrows)- l i f t luggage rack off vehicle roof

Luggage rack, installing

Work sequence

- place rubber washers (A) on holes- l i f t luggage rack on roof and al ign holes- insert sheet metal screws and loosely t ighten

in brackets (B)

- instal l washers and nuts f rom inside of vehic leand loosely t ighten

- f inal ly t ighten al l sheet metal screws and nuts- reinstal l insulat ion, f ront headl iner, beading

and inter ior l ight

75.8 Lussage rack

Page 13: 1978 Westfalia Repair Manual

lnterior Panels, Roof 75

Left inside trim panel, removing

$r '

Work sequence

Note

Removal is only possible af ter ref r igerator cabinetand sink/gas range cabinet are removed

- loosen cable c lamp- disconnect wir ing f rom plug (A)- remove Phi l l ips screws (arrows) and pul l out

control panel (B)

IF

WARNING

Before start ing to perform fol lowing repairoperat ions disconnect extension cord andremove ground strap on both batter ies

r-

t r im oanel out of channel

Left inside tr im panel , instal l ing

- install in reverse order

r-

Left inside tr im panel 75.9

Page 14: 1978 Westfalia Repair Manual
Page 15: 1978 Westfalia Repair Manual

76

CabinetsWater TankWindows

76.1

Page 16: 1978 Westfalia Repair Manual

76 Cabinets, Water Tank, Windows

Ceiling cabinet, removing

- open cabinet l id- on lef t s ide remove four nuts (arrows)

and oush bol ts into c loset

- on r ight s ide remove Phi l l ips screws (arrows)- l i f t cabinet out (2 mechanics needed)

Cei l ing cabinet, instal l ing- instal l in reverse order start ino wi th 2 bol ts

in top of cabinet

76.2 ceirins cabinet

Page 17: 1978 Westfalia Repair Manual

Cabinets, Water Tank, Windows 76

Closet, removing

Work sequence

Note

Removal only possible af ter cei l ing cabinetis removed

- remove engine compartment insulat ion- remove Phi l l ips screws (arrows) also hold

ref rigerator cabinet frame

- remove Phil l ips screws (arrows) at brackets atengine compartment top

- remove Phi l l ips screws (arrows) at bracket onroof frame

- t i l t c loset and remove

Closet, installing- instal l in reverse order

croset 76.3

Page 18: 1978 Westfalia Repair Manual

76 Cabinets, Water Tank, Windows

76.4 Sink and sas ranse cabinet

Page 19: 1978 Westfalia Repair Manual

Cabinets, Water Tank, Windows 76

Sink and gas range cabinet, removing

Work sequence

- remove from underneath vehic le:A = bracket for s ink drainB = covef plate wi th sealC = cov€I plate for water tank drain hose

- remove lock bolt (A) for spare tire storagecompartment door from bracket (C)

- remove door (B) f rom hinges

- remove bolts (arrows) behind driver's seatpart i t ion

- remove bol ts (arrows) inside of cabinet

Sink and gas range cabinet 76.5

Page 20: 1978 Westfalia Repair Manual

76 Cabinets, Water Tank, Windows

- remove shelf retainers (B)- remove shelves (A)- ( leave shel f supports (C) instal led)

- remove cover plate for s ink drain plate (A)- remove cabinet doors and drawers

- remove fuse in in- l ine fuse holder for waterpump, disconnect hot wire (A) and groundwire (B) f rom f use box, gas range connect ion(C)and ci ty water hook-up (D)(E = s ink drain pipe)

Note

Do not damage wire (arrow) to fuse box

Sink and gas range cabinet, installing- instal l in reverse order

CAUTION

Water and gas range connect ions mustnot leak

- remove sink and gas range cabinet

76.6Sink and gas range cabinet

Page 21: 1978 Westfalia Repair Manual

Cabinets, Water Tank, Windows 76

Ref rigerator cabinet, removing

Work sequence

Note

Removal only possible af ter s ink andgas range cabinet is removed

;.

- remove bol t (arrow) located in storage lockerunder rear seat bench

- disconnect electr ical connect ion and l i f t outref r igerator cabinet

Refrigerator cabinet, installing- instal l in reverse order

Note

Connect electr ical wi res

- remove Phi l l ips screws (arrows) holding frame

Refrigerator cabinet 76.7

Page 22: 1978 Westfalia Repair Manual

76 Cabinets, Water Tank, Windows

Louvered windows, removing

Work sequence

Note

Removal is only possible after refrigerator cabinet

- remove curtain rod cover (arrow)

- remove 2 Phi l l ips screws holding curtain rodand bend rod (A) down careful ly

- remove knur led knob of window opener and16 Phi l l ips screws (arrows)

- careful ly press louvered window to outside ofpanel opening

cover ts removeo

76.9Louvered windows

Page 23: 1978 Westfalia Repair Manual

Cabinets, Water Tank, Windows 76

Louvered window, installing

Work sequence

- instal l louvered window in panel openingwith two upper corners f i rst

- check proper seat ing of rubber seal ing. Rect i fyf i t of rubber l ip i f necessary

- instal l 16 Phi l l ips screws and knur led knob ofwindow opener

- instal l curtain rod- instal l curtain rod cover

Louvered window 76'9

Page 24: 1978 Westfalia Repair Manual
Page 25: 1978 Westfalia Repair Manual

SeatsTableBeds

77

771

Page 26: 1978 Westfalia Repair Manual

77 Seats, Tables, Beds

Rear seat and storage locker, removing

Work sequence

Note

Removal is only possible after s ink/gas rangecabinet and ref r igerator cabinet are removed

eg-,gugl- pul l seat bel ts into storage locker- remove Phi l l ips screw (arrow) on lef t and r ight

s ides at brackets

WARNING

Before start ing to perform fol lowing repairoperat ions disconnect extension cord andremove ground strap on both batter ies

- remove 2 sel f - locking nuts (A), nut f rom anchorbol t (B) and bol t f rom f loor (C)

Wfl *@ " tu.* *m4*W WwW{ W

77.2Rear seat and storage locker

Page 27: 1978 Westfalia Repair Manual

Seats, Tables, Beds 77

- remove Phi l l ips screws (arrows) and then coverfor rect i f ier

- remove bol t and washer (A) and disconneclground cable (B)

remove electr ical receptacle (A), detach f romhousing (B)and pul l to inside of vehic le

- loosen cable c lamp at lef t wheel housing andplace electr ical receptacle and housing onbottom of storage locker

- open cover of rect i f ier and disconnect wir ing (A)at connector (B)

- l i f t rear seat out of vehic le wi th a helper

Note

Make sure wooden wedge remains underanchor bol t

Rear seat and storage locker, installing- instal l in reverse order

Note

When instal l ing reinforcement plate wi th 2 studs (A)in r ight wheel housing, make sure rubber seal ing(B) is at tached. Use new sel f - locking nuts

II

I

. .q*; -t'.::';)F

' " . . " - . f t -. : ' : - \ ' , t -. ; *r i l, S.-- i-

--*r+.r*lgr-ffi* 'FFg

Rear seat and storage locker 77.3

Page 28: 1978 Westfalia Repair Manual
Page 29: 1978 Westfalia Repair Manual

Wiring

97

971

Page 30: 1978 Westfalia Repair Manual

97 wirins

Ref r igerator thermoslal

cut .of f re lay

Auxi l iary bal lery

Sink waier pump Fig.

Fuse for auxi l iary bat lery

Recl i l ier connect ions and

circui t breaker Fig. 3

Inside auxi l iary out lets ancic i rcui t breaker box(110 vol t A.C.) Fig. 2

WARNING

Never remove/ instal l external e lectr icalreceptacle, inside auxi l iary out lets,c i rcui t breaker or rect i f ier i f vehic le ishooked-up to 1 '10 vol t A.C.

Note

l l lustrat ions show USA version equipment

External e lectr ical receptaclefor 1 10 vol t A.C.connect ions: Fig. 1

Control boardremoving/ instal l ing Fig. 4

Fluorescenl lamp(12 vol l D.C.)

swi lch

Fig. 1 External electrical receptacle, connections

1 -electr ical receptacle2-black colored wire3-white colored wire4-non- insulated copper wire (ground)

Wire to vehic leand al lernator

97.2 Etectricat system, senerat layout

Page 31: 1978 Westfalia Repair Manual

wirins 97

Fig.2 Circui t breaker and auxi l iary out lets

' ,]1.29e:

1 -housing2-circui t breaker (1 ' l 0 vol t / 1 5 amp)3-sockets ( '110 vol t A.C.)4-wire f rom external receotacleS-wire to rect i f ier6-9round wire-must make good contact

i_rur

rexFig.4 Control panel , removing/ instal l ing

CAUTION

Remove only wi th external receptacledisconnected and in l ine fuse on auxi l iarvbatterv removed

lz7:Tazf

Fig.5 Sink water pump, removing/ instal t ing

- remove f use in f use box- remove cover plate in s ink cabinet- d isconnect wires at connector (4)- loosen clamp (3)- remove water pump ( '1)wi th f use

housing (2)

Fig.3 Rect i f ier(converts 1 10 vol t A.C. to 12 vol t D.C.)

1 -housing2-f use on D.C. s ide-25 amps3-wire f rom external receotacle v ia

circui t breaker4-hot wire-12 vol t D.C.5-ground wire-12 vol t D.C.

Circuit breakerRect i f ierControl panelSink water pump 97.3

Page 32: 1978 Westfalia Repair Manual

97 wirins

Current f low wiringdiagram color code

Black - BK Green-GBrown - BR Blue - BLRed -R Violet-VOrange-O Gray -GYYel low -Y White-W

1'E,fl

B'

l l0,5

c

I8K

l,+il

5678

97.4 currenrfrowdiasram USA vgrsion

Page 33: 1978 Westfalia Repair Manual

wiring 97

Description

A - to standard battery41 - auxiliary batteryB -to water pump inline fuse (8 amp) next to fuse boxB1 - to fuse 59 in fuse boxC - to alternator, terminal 61 (D + )E1 - battery charging timerE2 -switch BATTERY/CITY POWERE3 - ref rigerator switchE4 - switch for testing battery conditionE5 - water pump switchE6 - f lourescent lamp switchF - ref rigerator thermostatG - battery (charge) condition indicatorJ - battery cut-off relayK - ref r igerator warning l ightN - rect i f ier l l0vol t A.C. l12vol t D.C.51 - c ircu i t breaker (1 10 vol t / 15 amp) with 2 out lets52 - fuse-12vol l l25 amp-in rect i f ier53 - fuse-12 volt /15 amp-for refr igerator54 - fuse-12 volt /16 amp-forauxi l iary batteryS5 - fuse-12 volt /16 amp-forwater pumpf 2 - wire connector, double; in rectif ierT2a - wire connector, double; next to refrigerator thermostatT2b - wire connector, double; next to water pump switchT2c - wire connector, double; next to water pumpT3 - wire connector, 3-point; on ref rigerator thermostatT4 - wire connector, 4-point; on control panelU - external receptacle (ci ty power) 1 10 vol t A.C.u1 -U2 - auxi l iary out lets 110 volt A.C.V - water pump with fuse 12 volt /2 ampW - f lourescent lamp 12 volt D.C.Z - resistor for ref rigerator (12 volt D.C.)

Currenttrack

I8

1113108557

111447

9,106

1,22258

11

1,2

1,211

12,133

USA vgrsion currenr row diasram 97.5

Page 34: 1978 Westfalia Repair Manual

97 wirins

Refrigerator does not coolCheck these f i rst :o extension cord to external receptacle

(broken wire or bad connect ions)r c i rcui t breaker. fuses in system

(see current f low diagram on page 97.4)

Sr circuit breaker, checking

- connect a table lamp (1 10 vol t A.C.) to out letson kickboard

- check that c i rcui t breaker is in normal posi t ion. i f table lamp l ights up circui t breaker is OK. i f table lamp does not l ight up, c i rcui t breaker

is defect ive-reolace

Sz fuse in rectif ier, checking

. j ' ;1

rJ1-: i .

| 27-308 '

- connect one lead of test l ight to wire connectorterminal 1

- connect other lead of test l ight to wire connectorterminal 2o i f test l ight l ights up f use is OK

- remove test l ight lead f rom terminal 2 andconnect to f use holder terminal 3. i f test l ight l ights up f use is defect ive

Note

l f auxi l iary battery is recharged with rect i f ier , i t ispossible that fuse in rect i f ier b lows. In such casecharge auxi l iary battery wi th stat ionary charger

Ss fuse for ref rigerator, checking( located on control panel)

- check for blown fuse

So fuse for auxiliary battery, checking( located next to auxi l iary battery in enginecompartment)

- check for blown f use

l f a l l f uses are checked and found OK, proceedas fol lows:

. switch for BATTERY/CITY POWER switched toCITY POWER

. circui t breaker in ON posi t iono extension cord plugged in external receptacle

2.

' tt,\1,; ":ffi

si'j:;i!.!T jit,;:;

97.6 rroubreshootinsrefriserator USA version

Page 35: 1978 Westfalia Repair Manual

wirins 97

ref rigerator switch defective

-remove control panel

Note

Do not disconnect 4-point connector

- connect test l ight to blue and white wire

refrigerator warningl ight l ights up

refrigerator warningl ight does notl ight up

replace refr igeratorswitch

wiring to ref rigerator broken

- connect test l ight to blue and white wire of2-point wire connector on ref r igerator

Note

Do not disconnect wire connector

test l ight l ights up test l ight does notl ight up

reoair broken wire

wir ing of ref r igerator thermostat or resistorbroken

- d isconnect 2-point wire connector- connect ohmmeter as shown- turn thermostat fu l ly to r ight

wir ing not brokenohmmeter reads0-2.5 Ohms

wir ing brokenohmmeter reads

oo Ohms

go to next pagerefrigerant f lowdefect ive, replaceref rigerator

USA versionTroubleshooting ref rigerator 97.7

Page 36: 1978 Westfalia Repair Manual

97 wirins

loose or discolored wir ing on 3-pointconnector for ref r igerator thermostat

- remove ref r igerator and check wireconnect ions for t ightness anddiscolorat ion

wir ing OK

clean and ret ightenwir ing connect ions

refr igerant f lowdefect ive, replaceref rigerator

Refrigeratordoes not coolon 110 voltA.C. powerCheck these f i rst :. ref r igerator cools on 12 vol t D.C. power. BATTERY/CITY POWER switch is switched to

CITY POWERo circui t breaker is in ON oosi t iono extension cord is plugged in external receptacle I-

4r mr:l

f use (25 amp) in rect i f ier b lown

- connect test l ight to terminals 4 and 5 ofwire connector

test l ight does notl ight up

test l ight l ights up,f use OK

go to page 97.9

wire (2.5 mm'z)to 4-point connector oncontrol panel broken

- remove control panel- connect test l ight to red and white wire

test l ight l ights up test l ight does notl ight up

switch defect ive,replace

repair broken wire

97.8 rroubteshootinsrefriserator USA verSiOn

Page 37: 1978 Westfalia Repair Manual

97Wiring

fuse (25 amp) blown

connect test l ight to terminal 4 in wireconnector and f use (whi te arrow)

test l ight l ights up test l ight does notl ight up

f use (25 amp)blown, replace

rect i f ier defect ive

- connect table lamp (110 vol t ) to auxi l iaryout let at k ick board

table lamp l ights up table lamp does notl ight up

wire f rom externalreceptacle torect i f ier broken,reparr

WARNING

Unplug external receptacle before repair ingbroken wire

Continued f rom page 97.8

m*

USA versionTroubleshooti ng ref rigerator 97.9

Page 38: 1978 Westfalia Repair Manual

97 wirins

Refrigerator does not cool on12 volt D.C. powerCheck these f i rst :r ref r igerator cools on 110 vol t A.C. powero in l ine f use (16 amp) next to auxi l iary battery in

engine compartment is OK

standard battery discharged

r check acid levelr check speci f ic gravi ty. charge battery

Battery can be charged with:

1-rect i f ier in vehic le2-stat ionary battery charger3-al ternator wi th vehic le engine running

Note

Discharged battery wi l l not only be caused byoperat ing ref r igerator too long on battery but alsoby defect ive cut-of f re lay for auxi l iary battery

auxi I iary battery d ischarged

- BATTERY/CITY POWER switch (1) inoosi t ion BATTERY

- ref r igerator switch (2) in posi t ion ON- ref r igerator thermostat turned ful ly to r ight

- check charge of bat tery wi th switch (3)in oosi t ion BATTERY

needle of instrument (4) is in:

green scale I yel low scale

chargebattery

971 0 rroubreshoor.ns rerriserator USA version

Page 39: 1978 Westfalia Repair Manual

wirins 97

Gut-off relay for auxiliary battery,checking(see also current f low diagram, page 97.4)

- remove ground strap of auxi l iary battery- remove fuse (16 amp) of in l ine fuse holder- remove red wire f rom terminal 87 of relay- check wires

o to al ternator terminal 61 (D + )r to standard battery

cut-of f re lay for auxi l iary battery defect ive

- br idge terminal 87 of re lay and groundwith test l ight

- sta ' r t engine. wi th engine at id le, test l ight must

l ight up

test l ight l ights up test l ight does notl ight up

cut-off relay OK

cut-of f re lay for auxi l iary battery defect ive

- stop engine- br idge terminal 86 (black wire)and

terminal 30 (red wire) of cut-of f re lay wi thtest l ight

relay clicks and testl ight does notl ight up

relay does not c l ick

points in relaydefect ive, replace

coi l in relaydefect ive, replace

USA VgfSiOn rroubteshootinscut-off rerayrorauxiriarybatrery 97.11

Page 40: 1978 Westfalia Repair Manual

97 wirins

Il l

AvYt l

cIBK

1,.TT

Assfl

"i

Current f low wir ingdiagram color code

Black - BK Green-GBrown - BR Blue - BLRed -R Violet-VOrange-O Gray -GYYel low -Y White-W

97.12 currenrrowdiasram CANADA version

Page 41: 1978 Westfalia Repair Manual

wirins 97

CurrenttrackDescription

A - to standard batteryA1 - auxiliary batteryB - to fuse panel, terminal 30 (incoming side)81 - to fuse panel, fuse 9C - to alternator, terminal 61 (D + )E - switch BATTERY/CITY POWERE5 - water pump switchE6 - f lourescent lamp switchF - refrigerator thermostat (1 10 volt only)J - battery cut-off relay54 - fuse-12 volt /16 amp-forauxi l iary battery56 - f use- 12volt/2 amp-for water pumpT2 - wire connector, double; next to ref rigerator switchT2b - wire connector, double; next to water pump switchT2c - wire connector, double; next to water pumpT3 - wire connector, 3-point; next to refrigerator thermostatU - auxi l iary out lets 110 volt A.C.V - water pumpW - flourescent lamp 12 volt D.G.Z - resistor for ref rigerator 110 volt A.C.21 - resistor for refrigerator 12 volt D.C.

O - ground connect ion(green/yellow wire must make good contact)

87

101292-5

101328,97

10

1-3101134

CANADA version currenrrowdiasram 97.1 3

Page 42: 1978 Westfalia Repair Manual

97 wirins

Refrigerator does not cool

- pul l out p lug at 110 vol t A.C. receptacles- remove ref rigerator- remove BATTERY/CITY POWER switch- check for loose or discolored wire connect ions

o i f wires and connect ions are OK, ref r igerantf low is defect ive-replace refr igeratorand switch

. repair loose or discolored wire connect ionsand let ref r igerator operate on '1 10 and 12 vol tpower. l f ref r igerator st i l l does not cool ,replace refrigerator

Ref rigerator cools on 12 volt D.C.power only

check these f i rst :

o plug at 110 vol t external receptacle pul led. in l ine fuse 12 vol t /16 amp forauxi l iary battery

(next to battery in engine compartment)

Ref rigerator does not cool on 110 voltA.G. power- pul l out p lug at 110 vol t A.C. receptacle- check extension cord and auxi l iary out lets on

kick board for broken wire, wires for loose anddiscolored connect ions

- i f no faul ts are found check as descr ibed above"ref r igerator does not cool"

auxi I iary battery d ischarged

- br idge white and black wire of double wireconnector on ref r igerator wi th test l ight

test l ight does notl ight up

test l ight l ights up

check as descr ibed Power suPP|Yabove "ref rigerator defective, checkdoes not cool" cut-off relay for

auxi l iary battery.Charge auxi l iarybattery

97.14 rroubreshoorins rerriseraror CANADA version