Table of Contents:

Engine	Wheels
Body	Front suspension
Coachbuilts	Rear suspension
Seams	Front brakes
Gutters	Rear brakes
Windows	Brake Pressure Regulator
Front wheel arches	Gearbox
Rear wheel arches	Differential
Fuel tank	Rear Axle
Doors	Electrics
Rear Doors	Engine
Sliding door	Buying spares
Running gear

Engine

Petrol:

2.0 L I4 (1975-1982)
2.4 L I6 (1983-1996)

Diesel:

2.7 L Perkins I4 (1976-1977)
2.4 L D24 I6 (1978-1996)
2.4 L D24T turbo I6 (1983-1992)
2.4 L D24TIC turbo I6 (1993-1996)

Guide to engine codes here on Wikipedia.

Manuals:

4 cylinder petrol.pdf
4 cylinder diesel.pdf
6 cylinder petrol.pdf
6 cylinder diesel.pdf

In a recent poll on the VOLT Facebook group the ACL engine appears to be the most commonly fitted:

When buying second hand (i.e. every time!):

Check under the footwell carpet for rot, and in the dash pod for corrosion on the electrics in there, may be an idea to check all lights and indicators are switching on OK and fuel+heat gauges register if the electrics have moisture in them these may be faulty. LT’s are notorious for water ingress into the cab which can gather under the floor mat seemingly appearing from nowhere. Many state leaks around the indicators as the cause, but the lower corners of the windscreen hold water which can leech under the rubber seal, as it ages, and begins its’ journey into the cab. The left hand corner is the directly above the fusebox and gives most concern in right hand drive countries. This is not unusual but can of course lead to rust if not addressed, so… watch for if there has been water ingress is has it started to rot either the interior, beds and units etc. Also check around the handbrake where a rubber grommet is often missing allowing spray to come up around the handbrake into the cab. Seams all around the van are prone to rust due to poor drainage when blocked, an original design flaw.

^∧∧∧Back to top

Body

It’s unlikely you’ll find a mk 1 (pre-’96) LT without body work issues. However panels are still available to order so don’t let rust or even welding put you off buying, restoring and keeping. Sills were an LT weak point as are front foot wells and rear wheel arches, and rear corners.

^∧∧∧Back to top

Coachbuilts

The big thing in these big things is damp, usually from the joints in the surface skin. If you are looking at a coachbuilt buy a damp meter, from under 10GBP, and check as many areas you can as close to the outer skin as you can. The time of year will have a bearing upon the results. The area around the shower, if fitted, should also be checked. This advice applies to any coachbuilt camper, but it seems that the Karmann coachbuilts on the LT are particularly prone to water ingress at the front and sides of the bed over the cab.

Reading Value Action

0 – 15% No Cause for concern

15-20% Require further investigation Consideration should be given to re-checking the area in three months with the average of all readings taken.

20-30% Remedial work required, there may be early signs of water ingress or evidence of moisture. Resealing and internal work may be required; again, consideration should be given to re-checking the area in three months.

30% Structural damage is occurring, deterioration inevitable. a full strip down of the affected area is required.

Be aware though, that if the vehicle has been stored under a cover and not aired recently, the readings may not be accurate.

^∧∧∧Back to top

Seams

As you are probably aware, LT’s tend to rust a little around the body seams, due to modern manufacturing techniques, body tolerances and panel fit have come along way since the “bay window” van (’68-’79) but once muck is in there you are going to have great difficulty getting it out, so be warned. Walk away from a van with rot around the seams unless you are confident you can get rid of it. Most vans are now getting to that age where a little crispiness around the edges is inevitable, also check that all the seams that are meant to be there actually are! A lot of repairers either weld the seams up or fill over them, it WILL be hiding something! Take a magnet with you, if it does not stick, there is no steel.

^∧∧∧Back to top

Gutters

With the size of the LT it is quite difficult to wash the roof and gutters so they are often overlooked and hence get blocked which holds water against the panels which eventually leads to corrosion. Some camper conversions featured the addition of high top roofs which involved additional sealant in the gutters. If water is allowed to get under this sealant it can cause a real problem not only in the gutters but down behind them and under the sealant if not addressed. Roof racks also scratch the paint around this vulnerable area and impede the free flow of water away, so when you are going to inspect a van, take something to stand on and take a good look at the state of the guttering (or cantrail to give it its correct name). It is a good idea to give the gutters a good clean out once in a while with some cutting compound or T-cut and give them a thin layer of protective wax such as Finigans Waxoyle. 

^∧∧∧Back to top

Windows

Sounds silly doesn’t it?, well I’ll explain… it is not actually the windows, rather its frame or surround, windscreen surrounds are prone to corrosion in the bottom corners normally noticed by a small pool of water in the foot wells after rain, although you can’t go pulling someone’s windscreen out when you are thinking of buying it you can probably get away with lifting the corner of the rubber with a small screw driver and having a little sneaky peaky underneath for brown crispy bits, or alternatively you can have a look at the underside from under the dashboard (so remember your torch!). It’s not just the screen you have to watch out for, its converted panel vans, these are the vehicles that left the factory as a delivery van and have had windows “cut” into them. When the hole is cut for the window, the bare metal isn’t often primed or painted so the first time it rains the water runs behind the seal and sits there rotting the metal so watch out for bubbles around these windows.

Factory fitted windows should give you no problems. Some of these parts are still available from VW but alternative sources of similar parts can be used.

^∧∧∧Back to top

Front wheel arches

They are a bit of a water trap and hold mud (therefore water) against the interior of the arch. Regular washing is the answer here but if it has already taken hold then watch out for M.O.T failures as the top of the wheelarch lies within the prescribed 30 cm of a seat belt mounting. So check under the matting around the seat belt mounts. Also watch out for the cab step as the rubber anti slip thing holds water underneath it also leading to rot.

^∧∧∧Back to top

Rear wheel arches

Without mudflaps to protect the chassis behind the wheels road crud will collect in the holes, ledges and gaps in the chassis and the sills. The chassis tends to come off relatively unharmed, but the thinner metalwork can disappear. Most rear panels are available, and even some floor panels and chassis members are still available from VWClassic.

^∧∧∧Back to top

Fuel tank

Feel free to add content here.

^∧∧∧Back to top

Doors

Not many problems here, just the window winder knobs fall off just like the rest of the VW’s of the same era. The use of later MK III polo style winders usually works. Window winder mechanisms wear, easy to repair. Doors are interchangeable between years. Window wipers are shared with T3s and so are easily found and replaced. The same problem of water ingress and therefore rust in between the doorskins will ensue.

^∧∧∧Back to top

Rear Doors

Not many problems here either, doors are interchangeable. Water can enter through the numberplate light and numberplate mounting holes. It sits in between the skins and corrodes its’ own drain. The door handles and locks do not get used as often as a slider and so can become stiff.

^∧∧∧Back to top

Sliding door

(Side loading door). These rot a little along the bottom edge, also watch out for worn door runner bearings resulting in a less than smooth operation of the door.Some sliding door parts are shared with the Bays and T3s which are therefore more easily available.

^∧∧∧Back to top

Running gear

Wheels

A very contentious issue this one.

Firstly, the specifications

• LT28 and LT31 are 5×160 6J14H2 ET51 with M14x1.5 bolts/nuts which have a 60 degree taper
• LT35-LT55 are 6×205 5J14H2 ET120 with M18x1.5 nuts.

5×160/6×205 indicates the number of fixings, 5 or 6, and the pitch circle diameter (PCD) this is the diameter of the circle on which the fixings are centred.

6J/5J. The number indicates the width of the wheel in inches and the letter, the bead profile of the rim.

H2 indicates the double hump profile of the wheel.

ET51/ET120 indicates the offset from the vertical centre of the wheel to the mounting surface.

Although American, this page is useful.http://www.carbibles.com/tyre_bible_pg4.html

Secondly, the contentious part.

LTs are commercial vehicles. The boffins at VW designed the wheels, hubs and fixings, to take the stresses and strains of a fully loaded LT bouncing around on them.

Other manufacturers wheels do ‘fit’ in that they have the same 5×160/6×205 fixings. Wheels can be fitted, through the use of adaptors or redrilling, which have different fixings.

For Lt28/31/35e LT fits (naturally), some Transit wheels fit (after modification), Tata wheels fit (with no modification), Defender wheels fit (with special screws)

This page has useful information. http://www.carlsalter.com/wheel_fitments_by_pcd.html

ANY changes to wheels MUST be passed on the your insurance company.

^∧∧∧Back to top

Front suspension

LT28 and LT 31 have coil springs, and all others, LT35-50 use a leaf-sprung beam, including 4×4. Shock absorbers on coil-sprung vehicles should be checked for leaks, but replacements are readily available. Always replace in pairs.

^∧∧∧Back to top

Rear suspension

Leaves are supposed to look sad, ie higher in the middle.

^∧∧∧Back to top

Front brakes

Feel free to add content here.

^∧∧∧Back to top

Rear brakes

The automatic adjusters never seem to work as they should, one of the tags on the back plates corrode and fall off and that’s about it, nothing is hard to replace, cables are straight forward to do, unless they have affixed themselves to the flimsy backplates. Rear brake adjuster bars wear which don’t allow the rear brakes to adjust as they should, this can be rectified by clever filing of the bar.

^∧∧∧Back to top

Brake Pressure Regulator

This is the valve above the rear axle which distributes braking force so when empty there is less braking force at the rear wheels, therefore preventing locking up. When loaded, the variable nature of the valve automatically adjusts the braking force so the rear wheels can help more. Before you consider removing it, because it is leaking, that scenario is covered in the MOT test by ‘Evidence that a load sensing valve has been removed or disconnected from a vehicle where it is known to have been fitted as standard ’

They have not been available from VW for a long time, however all is not lost. DAF/Ford/Scania 1518097 is the same part, if you can find one.

The only new parts found so far, 13th February 2016, here.

Parts and breakdown, and of course one of our German friends can rebuild them.
http://www.lt1-forum.de/dokuwiki/doku.php?id=start:reparaturtips:bremskraftregler_instandsetzen
http://www.lt1-forum.de/dokuwiki/doku.php?id=start:reparaturtips:bremskraftregler_wabco_hinterachse

http://www.lt-forum.de/dokuwiki/doku.php?id=start:reparaturtips:bremskraftregler_reparieren
http://www.lt-forum.de/dokuwiki/doku.php?id=start:reparaturtips:bremskraftregler_instandsetzen

Volition82 on Brickyard has replaced his with a modern one and a little bit of mathematics.
http://www.brick-yard.co.uk/forum/rear-brake-pressure-regulator-booster_topic81142_page1.html

^∧∧∧Back to top

Gearbox

4 and 5 speed manual gearboxes were available. Regular oil changes are a good idea. An leak oil out of the bell housing, the seal is cheap but you have to take the gearbox out. Don’t be put off by a 4 speed box   Gearboxes are broadly indestructible, but do not attempt bumpstarting in reverse, it will probably end badly. The earlier LTs had a four-speed gearbox. It can be swapped for the later fiver-speed but it is only the gap between gears which changes, and not the top gear. First gear is also slightly lower in the five-speed.

^∧∧∧Back to top

Differential

Not much to say, except they are not all the same. There are fast and slow ones, 3.79:1 to 6.43:1. Originally matched to specific engines with specific torque curves, nowadays anything goes.
http://www.lt1-forum.de/dokuwiki/doku.php?id=start:wichtige_daten:hinterachse

^∧∧∧Back to top

Rear Axle

From new VW gave the option for different speed ratios on the rear axle so many have reported different top speeds. The German LT Freunde wiki has information on the codes and the ratios: http://www.lt-forum.de/dokuwiki/doku.php?id=start%3Awichtige_daten%3Ahinterachse If you’ve got the highest speed rear axle it should go well over 90 (for a short time!) and cruise happily at 75 ish…

^∧∧∧Back to top

Electrics

They don’t seem that bad It is just when someone has been messing with them!, Have a poke under the dash and look for scotch locks (or bodge locks as I like to call them) they are those little blue connectors that you squeeze together with pliers, they are OK but…… The printed circuit on the back of the instrument cluster is prone to burning out where it goes around corners and the connector that connects it to the loom often corrodes and causes trouble it is not a risk you want to take so make sure all the warning lights and the dash illumination works, if the fuel gauge and temperature gauges do not work this is probably a diode on the foil, easily repaired,doesn’t work it could be a few things and could lead to fuel tank removal so check it!  The youngest wiring is twenty years old now, 2015, and the oldest forty, so oxidisation will have happened within the looms.

^∧∧∧Back to top

Engines

There are a few different engines to choose from, to be brutally honest none of the engines are brilliant, the later ACL and 1E would be preferred, it is just which one do you go for. ALL of the petrol engine available for use in the UK are capable of running on unleaded fuel with little or no alterations. LPG conversions help with fuel consumption.

For engine transplants see this forum thread: http://vwlt.co.uk/forum/discussion/5/engine-transplants

The following tables were taken from http://www.lt1-forum.de/dokuwiki/doku.php?id=start:wichtige_daten:daten_motoren

Petrol
Designation	CH	CL	DL	HS	1E
Cylinders	4	4	6	6	6
Capacity cm3	1960	1984	2383	2383	2383
Installation	Long, vertical	Long, vertical	Long, sloping	Long, sloping	Long, sloping
Built from	1 Aug 75	1 May 76	1 Jan 83	1 Apr 83	1 Oct 88
Built to	1 Dec 82	1 Dec 82	Production ends 95	1 Jul 86	Production ends 95
Power (kW)	55	52	66	61	69
Power (PS)	75	71	90	83	94
@rpm	4300	4300	4500	4500	4200
Torque (Nm)	150	132	168	160	167
@rpm	2400	2400	2800	2800	2400
NA Diesel
Designation	CG	CP	DW	1S	ACT
Cylinders	4	6	6	6	6
Capacity cm3	2710	2383	2383	2383	2383
Installation	Long, vertical	Long, vertical	Long, sloping	Long, sloping	Long, sloping
Built from	Jan 76	Nov 78	01/12/82	Aug 89	Aug 92
Built to	01/03/79	Nov 82	Jul 91	Jul 92	Production ends 95
Power (kW)	48	55	55	51	51
Power (PS)	65	75	75	69	69
@rpm	3600	4300	4300	3400	3700-3800
Torque (Nm)	152	140	140	145	140
@rpm	2300	2500	2500	1600-1800	1800-3000
Turbodiesel
Designation	DV	1G	ACL
Cylinders	6	6	6
Capacity cm3	2383	2383	2383
Installation	Long, sloping	Long, sloping	Long, sloping
Built from	Jan 83	01/08/1989*	Aug 92
Built to	Jul 91	Jul 92	Production ends 95
Power (kW)	75	68	70
Power (PS)	102	92	95
@rpm	4300	3500	3500
Torque (Nm)	195	195	205
@rpm	2500-2600	1800-3100	2200-3200
		*Export 88

^∧∧∧Back to top

Buying spares

Is the part you need available from VW?

For this exercise we will try to find an inner rear chassis member for a 1989 LT28.

Firstly, you need the part number. If you can see it marked on the part you have, that will make life easier, if not then one of these two online VAG catalogues will help.

EKTA There are various emulations of the VW part number database online some of which work better than others. Try OEMEPC or VW.7ZAP (http://www.oemepc.com/vw/main_group/markt/RDW/modell/LT/year/1989/hauptgruppen/1234567890/drive_standart/6/lang/e or https://volkswagen.7zap.com/en/rdw/) for after market part numbers.

Secondly, availability can be ascertained by using the part number in VW Classics’ stock monitoring system, which is also free.

 

Make a note of, or copy, the part number ready for insertion into the VW Heritagesearch dialogue, in this case 281803713C. The next stage is to access VW ClassicParts via VW Heritage

 

 

This part is in stock, and is priced at £120.25, today January 30th 2016.

Now you know it is in Germany, a phone call or email to Brickwerks(https://www.brickwerks.co.uk/) or VW Heritage will get your part winging its’ way to you in a couple of weeks.

Naturally, there are many third party manufacturers for items such as shock absorbers, ignition coils etc, but the part number will help you find the correct part more easily.

 

Thanks go out to Hannibal for kicking this hopefully useful guide off…

Bodywork	Steering
Engine	Service history
Gearbox and Diff.	Other things…
Interior
Water Heater	Vents & windows
Space Heater	Seating
Fridge	Lighting / Plug sockets
Gas hob	The Table’s
Shower /Toilet	Waste tank
Cab area
Dash
Engine cover
Extras

What to look out for …

Bodywork

Rust, like all old vehicles theres going to be some rust some where.
Area’s to look at ..

• Around the windscreen , seals leak causing rust not only to the outer panel but to the inner one , sometimes simply by pressing the outer panel you can hear the inner one falling apart.
• Also the area around the outer areas of the windscreen where the pillar meets the cross panel.
• The area behind the bumper , anyone who has owned a T3/25 will know this well.
• The panel where the fridge vents are.
• All seams
• Gutter area’s.
• Inner wings , mud and salt collects here and will attract the legendary tin-worm.
• Inner steps , both front and the slider one.
• Cab floors. Now if the windscreen or indicators are leaking then water will collect under the sound proofing and slowly eat away the metal.

^∧∧∧Back to top

Engine

Ok some say it has to be TD, but I have a 2.4D and its ok ,slow on long hills but its OK. Been all over Europe and the UK in her so yeah its OK.
Like all diesels check for smoke from cold. But remember its a big old lump so if its still coughing and farting after say 5 minutes then time to look deeper.
Rough starting , glow plugs ? Air in the system ? Glow plug relay ? Glow plug fuse/s ( there are 2) , old fuel , air filter old and clogged , fuel filters old and clogged/ full of water.
Other things to look out for , inter cooler leaks , turbo not doing it thing , power steering pipes leaking , coolant pipes leaking.
Most of the above can be sorted out fairly easy. Pipes can be made up at say PerTek , and parts can be sourced ebay etc.
^∧∧∧Back to top

Gearbox and Diff.

If they are wining or if the gear can not be selectored then maybe think ££££ or walk away.
^∧∧∧Back to top

Steering

All parts are available from German Ebay , much cheaper than in the UK.
Ok if its not PAS then don’t think all is lost , just learn to drive it.
^∧∧∧Back to top

Service history

Look for receipts for the belts being done in the last 5 years . Not a big or expensive job but it is something to help bring the price down if buying.
Other stuff like oil , filter etc depends on the owner ,I do all my own but save receipts when I remember.
^∧∧∧Back to top

Other things ..

• Towbar is a bonus.
• Roof box is a bonus
• Make sure the roof bars are OK but expect maybe a bend or lose bolts.
• Bike rack is a bonus.
• Kayak rack is a BONUS.
• Tyre / wheel size , read up about this. A few members are fitting Ford Transit (16?s)  (more here)
• Now Mr VW updated the LT and gave her a face lift again the choice is yours.
• Head Lights , I have both LHD and RHD sets so best of both worlds and it takes 5 minutes to change them.

Remember read other forums , Brickyard is a good start (here’s a thread Tim started when he bought his, and here’s Chappy’s legendary Winter Fettling thread), theres loads out there , and a daft question will always be answered , cause we have all been there.

For sourcing secondhand Florida & SVen Hedin parts start with sourcing the part number from the online EKTA site here: oemepc.com (link to 1989 Florida page)
^∧∧∧Back to top

Interior

Water , make sure all the taps work , both hot and cold and in the shower. The original ones will be getting old and loads have been replaced.
^∧∧∧Back to top

Water Heater

Make sure the boiler works ,again take your time read more on Brickyard about this (Chappy Thread) . Now the boiler only works on gas so make sure its turned on and getting the supply. There are two valves on the LPG tank and 4 in the rear cupboard next to the fridge. Make sure you understand how this work. OK back to the boiler , some will work only when the van is nice and level , others work at more acute angles. Sometimes the boiler may take a few starts to fire up.
The water tank is under the rear seat , check that for leaks , make sure the sender is working as is the pump. The filler is out side on the rear panel , make sure you have the key for the cap.
^∧∧∧Back to top

Heating

Ebberspacher . Like all ebbers a good supply of electricity is needed , so if the leisure battery is on its way out or lacking charge then it will not start up. Simple trick start the engine , make sure the leisure is getting a good voltage and then fire it up. Again service parts are available but may take some tracking down , check your local Ebberspacher place. Again check that diesel supply is getting to the unit and the pump is well pumping … tick tick tick. Another thing is to check all the vents both inlet and outlet , and the exhaust. Main fuse for the ebber is next to the leisure battery under the rear seat. Again check the rotating thermostat isn’t broken , very hard to find a replacement , but other controllers can be fitted.
^∧∧∧Back to top

Fridge

Its a 3 way , so check it on gas , 12v and 240v .. simple to work on and parts are available. Remember it will take a hour or so to chill down . Check the auto sparker is working , quick test turn the gas off and it should start ticking .
^∧∧∧Back to top

Gas Hob

Again simple , check it has a good clean flame and that the gas turns itself off is the flame goes out , easy repair if the thermocouple if not working.
^∧∧∧Back to top

Shower /Toilet

Check its all ok and working. The toilet is stored in the area to the right and is held in place with a fabric/leather belt.
Now some of us have replaced the toilet with a fix one that you have to empty via a put out. But more on that at another time.
^∧∧∧Back to top

Roof vents

Check for cracks and that the vent goes right up . Again replacements are available via ebay.
Side upper windows , can blow off if not closed , and replacements are very hard to find.
Lower windows , again I think you can get them via Gunzls but £££ .. Replacement seals are also available.
Blinds , very hard to find , as are the fastening. So check that the clips are all good.
Curtains , check the cab one is there. Nothing out of the ordinary , check the state of them.
Cupboards , check the condition of them.
^∧∧∧Back to top

Seating / Beds / pockets

Check the condition of the fabric , foam , zippers etc.
Now the bed is made up of two rock’n’roll ones so check the mechs on them , theres a little catch and spring on the hinge that fails. Again simple things that need checking. The front seat should side easy simply. Check the seat belts while your there.
Again the vans are getting old so the foam may need replacing at some point.

Rubbish bin , again these are replaceable. (ebay)
^∧∧∧Back to top

Lighting / Plug sockets

Old style tubes that are easy to replace with led strip or tube.
240v sockets , again these are easy to replace with UK ones is you fancy. Again check the trip fuse on the rear panel.
^∧∧∧Back to top

The Table’s

Ok there are 2 . a little pop up one , make sure it locks into place.
The big dining table is stored behind the rear seat , check the condition of this and the fittings. TIP , check out the above cab storage for the table , much easier to use and there is no where to put the table when the bed is down ?!!.
^∧∧∧Back to top

Waste tank

Again nothing special , check for leaks and that the drain tap is ok . Tip if your driving along and you get a very strange smell in the cab , like gas or rotten eggs , chances are its your waste tank , bleach or bleach tablets do the trick.
^∧∧∧Back to top

Cab area

Again check the seats , fabric of the seat , arm rests and seat belts.
^∧∧∧Back to top

Dash

Ok again nothing special , check all the switches work as they should , check the blower works and is blowing on all 3 settings . Check the slide controllers.
Now rev counters came on later vans and are like rocking horse shit , but a VDO one will do the job and take the feed off the W terminal on the back of the alternator.
Glove box , theres an under storage pocket that was available as an add on. Again hard to find.
^∧∧∧Back to top

Engine cover

Two types , one with just the hatch for checking the oil , the other has 2 hatches one for checking the coolant.
I also thing (iirc) that the very early vans had a different hatch. But do your research.
^∧∧∧Back to top

Extras

Radios , most will have been replaced so check the wiring etc.
Led bulbs in the lights.

Now swivel bases , I’ve only done my passenger side but again more on that at a later date.

Hope this is of some help , feel free to add to this as its a work in progress…
^∧∧∧Back to top

Facebook is all very well for getting quick responses from whoever is listening at the time you ask, and forums are OK if you’re technical enough to bother with them, but what’s missing is the ability to easily capture and search the knowledge that is shared and stored in these collective hive minds. Here I attempt to do a little bit of that by sieving through and storing as much of the best bits as I can… starting with an open storage of all the VW LT documentation I could lay my hands on. They are split between petrol & diesel where possible, and listed below where they relate to both: