Routine Maintenance — 2.4l models (VW Lt 28)

For weekly maintenance see. in the relevant section at the beginning of this Guide (see photos).

Figure 1. Fill the engine with engine oil.

Figure 2. Install the cap on the valve cover.

Figure 3. Fill the cooling system with fluid.

Figure 4. Windshield washer reservoir (under the dashboard).

• Check and adjust the clutch if necessary;
• Check and adjust valve clearances;
• Inspect the engine for leaks;
• Change engine oil and oil filter;
• Check and adjust idle speed;
• Tighten the cylinder head bolts.

Every 16,000 km or once every 12 months (whichever comes first)

• Check the operation of the exterior lights, direction indicators and horn.
• Check the operation of the windshield wiper and washer (including headlight washers, if equipped).
• Check and adjust the clutch.
• Check the electrolyte level in the battery and add distilled water if necessary.
• Inspect the engine for leaks.
• Check the concentration of antifreeze in the cooling system and add more if necessary.
• Check the condition and, if necessary, adjust the tension of the generator drive belt (and the power steering pump belt, if equipped).
• Replace spark plugs.
• Check steering adjustment and wheel alignment.
• Inspect the steering gear for leaks.
• Clean and lubricate door hinges, locks and sliding door mechanism.
• Change engine oil and oil filter.
• Inspect the exhaust system for leaks.
• Check the tie rod ends for play and secure fastening. Inspect the anthers.
• Inspect the steering knuckle boots for damage.
• Inspect the gearbox, final drive and all joints for wear and damage. Check the condition of the rubber boots.
• Check the operation of the breathing valve on the rear axle pipe.
• Lubricate the front axle (LT 40, 45 and 50).
• Check the thickness of the brake pads and linings.
• Inspect tires for tread depth, wear and damage.
• Check the brake fluid level.
• Check the tightness of the wheel bolts/nuts.
• Replace the breaker contacts.
• Check and adjust the headlights.
• Take a test drive and check the operation of all vehicle systems.
• Check the oil level in the gearbox and final drive (see photos).

Every 32,000 km or once every 2 years (and whichever comes first)

• Replace brake fluid.
• Check and adjust valve clearances, replace the valve cover gasket.
• Replace the air filter, clean the air cleaner housing.
• Replace the fuel filter.
• Inspect the bottom and, if necessary, treat it with an anti-corrosion coating.
• Check the operation of the power steering and the level of hydraulic fluid in the reservoir.

Figure 5. LT 28 models (with a 2.4 L engine) (bottom view): 1 - Push bars; 2 - Thrust; 3 - Steering knuckle; 4 - Pendulum lever; 5 - Lower ball joint; 6 - Lower shock absorber mount; 7 - Lower wishbone; 8 - Brake caliper; 9 - Bridge beam; 10 - Oil pan; 11 - Drain plug of the pan; 12 - Clutch housing; 13 - Gearbox; 14 - Gearbox drain plug; 15 - Gearbox filler plug (not visible in the photo); 16 - Gear shift rod; 17 - Speedometer cable; 18 - Exhaust pipe support bracket; 19 - Starter; 20 - Handbrake drive mechanism; 21 - Steering knuckle; 22 - Generator; 23 - Crankshaft pulley; 24 - Cooling fan; 25 - Fan shroud; 26 - Accelerator pedal cable; 27 - Steering rod (from the steering gear box); 28 - Cooling system drain plug.

Figure 6. Engine compartment of LT 28 models (with a 2.4 L engine): 1 - Expansion tank of the cooling system; 2 - Gas pedal cable; 3 - Hot air supply manifold tube; 4 - Carburetor; 5 - Carburetor air intake channel; 6 - Valve cover breather tube; 7 - Engine breather control valve; 8 - Engine oil filler plug; 9 - Valve cover; 10 - Intake manifold; 11 - Exhaust manifold; 12 - Distributor; 13 - Ignition coil (from the bottom side); 14 - Left engine mount; 15 - Engine oil dipstick; 16 - Ignition wires; 17 - Thermostat housing (cooling system); 18 - Engine air intake filter housing.

Figure 7. Rear axle of LT 28 models with 2.4L engine (bottom view): 1 - Cardan shaft; 2 - Cardan joint; 3 - Differential/rear axle; 4 - Rear shock absorber; 5 - Handbrake cable; 6 - Rear crankcase drain plug; 7 - Rear brake drum; 8 - Spring; 9 - Fuel tank; 10 - Auxiliary rubber spring; 11 - Exhaust system muffler of the bridge.