TME9-803.pdf

WAR DEPARTMENT TECHNICGL MANUAL

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Suecd. Late

TM E9-803

GERMAN

VOLKSWAGEN

REGRADED UNCLASSIFIED BY

^AUTovTY OF DOD DIR. 5200. 1 R

BY I _____ ON

Z O-

WAR DEPARTMENT

6 JUNE 1944

_ DISSEMINATION OF RESTRICTED MATTER-.

The information contained in restricted documents and the essential char-

acteristics of restricted materiel may be given to any person known to be in

the service of the United States and to persons of undoubted loyalty and

discretion who are cooperating in Government work, but will not be com-

municated to the public or to the press except by authorized military public

relations agencies. (See also paragraph 23, AR 380-5, 15 March 1944.)

WAR DEPARTMENT

Washington 25, D. C., 6 June 1944

TM E9-803, German Volkswagen, is published for the information

and guidance of all concerned.

FA.G. 300.7 (15 Mar 44)

]

LO.O.M. 461/Raritan Ars. (7 Jun 44)-R

BY ORDER OF THE SECRETARY OF WAR:

G. C. MARSHALL,

Chief of Staff.

OFFICIAL:

J. A. ULIO,

Major General,

The Adjutant General.

DISTRIBUTION: As prescribed in par. 9.a., FM 21-6: X.

(For explanation of symbol, see FM 21-6.)

TM E9-803

CONTENTS

PART ONE-INTRODUCTION

Paragraphs

Pages

SECTION

I. General ....................................

1- 2

II. Description and data..............

3- 5

2- 6

III. Tools, parts, and accessories..

6- 7

PART TWO-OPERATING INSTRUCTIONS

SECTION IV. Controls and instruments........

8- 9

8- 11

V. Operation under ordinary

conditions ..........................

10- 12

12- 13

VI. Operation under unusual

conditions ............................

13- 17

13- 18

PART THREE-MAINTENANCE INSTRUCTIONS

SECTION VII. Lubrication ............................

18- 19

19- 23

VIII. First echelon preventive

maintenance services..........

20- 24

23- 32

IX. Second echelon preventive

maintenance ........................

25 32- 47

X. Trouble shooting....................

26- 43

48- 60

XI. Engine description and main-

tenance in vehicle................

44- 49

60- 68

XII. Engine, removal and instal-

lation ..................................

50- 52

69- 72

XIII. Clutch ....................................

53- 57

72- 75

XIV. Engine lubrication system .....

58- 62

76- 81

XV. Fuel and air intake and

exhaust systems..................

63- 69

81- 87

XVr. Cooling system .......................

70- 71

87- 88

XVII. Ignition system .......................

72- 76

88- 91-

XVIII. Starting and generating

system ................................

77- 80

91- 94

XIX. Battery and lighting systems

81- 88

94- 99

TM -E9-803

CONTENTS-Contd.

Paragraphs Pages

SECTION XX. Transmission and differential 89- 90 99-102

XXI. Rear axle ................................ 91- 93 103-105

XXII. Front axle ............................. 94-100 106-111

XXIII. Service and parking brakes .... 101-103 111-117

XXIV. Steering system ...................... 104-107 117-120

XXV. Tires, tubes, and wheels ........ 108-110 121-123

XXVI. Shock absorbers ...................... 111-113 123-124

XXVII. Instrument panel and

instruments ........................ 114-115 125

XXVIII. Body and frame...................... 116-125 125-127

APPENDIX

SECTION XXIX. Shipment and temporary

storage ................................ 126-128 128-132

XXX References .............................. 129-131 133-134

INDEX .................................................... ...........................

135-140

TM E9-803

1-2

PART ONE-INTRODUCTION

Section I

GENERAL

1. SCOPE.

a. These instructions are published for the information and

guidance of the personnel to whom this equipment is assigned. They

contain information on the operation and maintenance of the German

Volkswagen as well as descriptions of the major units and their func-

tions in relation to the other components of the vehicle.

b. This manual has the following arrangement.

(1) Part One, Introduction, contains description and data.

(2) Part Two, Operating Instructions, contains instructions for

the operation of the vehicle, with description and location of the con-

trols and instruments.

(3) Part Three, Maintenance Instructions, contains information

needed for the performance of the scheduled lubrication and pre-

ventive maintenance services, and instructions for maintenance opera-

tions which can ordinarily be performed by using organizations (first

and second echelons).

(4) The Appendix contains instructions for shipment and limited

storage, and a list of references which may provide helpful informa-

tion concerning operation or maintenance.

c. The operations described in this manual are based on the

availability of necessary parts, accessories, and tools. Conditions will

arise in which the items referred to in the manual are not available

since they cannot be requisitioned through usual channels. In these

cases,individual initiative must be resorted to when repairs are required.

2. RECORDS.

a. Forms and records which may be provided for use in per-

forming prescribed operations are listed below with brief explanations

of each. In case of Volkswagen, use of these forms will be governed

by tactical situation and extent to which vehicle is employed.

(1) STANDARD FORM No. 26, DRIVER'S REPORT-ACCIDENT,

MOTOR TRANSPORTATION. One copy of this form should be kept

with the vehicle at all times. In case of an accident resulting in

injury or property damage, it should be filled out by the driver on the

spot, or as promptly as practical thereafter.

(2) WAR DEPARTMENT FORM No. 48, DRIVER'S TRIP TICKET

AND PREVENTIVE MAINTENANCE SERVICE RECORD. This form, prop-

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