Volkswagen WATER-COOLED VANAGON 1983 Guide

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§
1
Introductow
Service
*4
Information
1
l
water-cooled
VANAGON
MAINTENANCE
AND
ADJUSTMENTS;
*

Introduction
This
booklet
is
partof
a
two
booklet
set
of
Introductory
Service
Information
for
the
1983
Water-cooled
Vanagon.
Book
1󰾵Introductory
Service
Information
WSP󰾵521󰾵112-00.
This
book
contains
information
on
technical
changes
and
theory
of
operation
for
each
product
change.
This
book
contains
information
on
the
engine,
fuel
injection,
as
well
as
other
changes.
Book
2󰾵Vanagon
Maintenance
and
Adjustments
WSP󰾵521-113-00.
The
maintenance
and
adjustments
book
contains
repair
information
for
Repair
Groups
10
through
34
as
well
as
the
complete
wiring
diagram.
All
of
the
information
contained
in
these
booklets
is
based
on
the
latest
product
information
at
the
time
of
printing.
Please
consult
the
Product
Circular
booklets
and
Microfiche
information
for
the
latest
repair
information.

Service
Policy
for
Vanagon
4
speed
Transmission
The
new
4
speed
manual
transmission
in
the
water-cooled
Vanagon
is
not
repairable
at
this
time.
Repairs
are
limited
to
outside
checks
and
adjustments
such
as
the
shift
linkage.
If
a
problem
develops
which
requires
repair
of
the
transmission
other
than
outside
adjustments,
the
transmission
should
be
replaced.
Exchange
units
are
available
through
the
parts
department.
Group
101315
17
19
20
24
26
28
34
Appendix
Appendix
Appendix
Appendix
Index
Subject Page
Engine󰾵Assembly
..
..
...
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.
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.
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.
..
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..r
.
.
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4
Engine-Crankshaft,Crankcase
....
......
....
.
....
..
.
..
...
.
..
.
..
..
.
.
.......
.....
...
..
..
...
.
.
8
Engine-CylinderHead,Va|ve
Drive
...
.....
....
.
...
..
.
..
.........
.....
..
..
...
....
.........
...
24
Engine󰾵Lubrication System . .... .... .. . ... .... . .. ...... ..... . ... .... ... . .... .... ... .. .. ... 31
Engine󰾵Cooling System . . .... .. ..... ...... ... . ... .. . ... .. . ..... .. . .. ....... .... ... .. .. ... 34
Fuel
Supply
.....
.
..
.......
.....
.
....
......
.......
..
..
..
..
.
.
.
...
..
.
.
.
......
..
..
.
.......
..
42
Fuel |njection,AFC System .. ........... ....... ... . ... .. . .. ..... . ... ..... .....r. .. .. ... ... .. 52
Exhaust
System󰾵Emission
Controls
......
...
.
...
...
.
...
.....
.
..
......
.
..
...
..
.
...
..
.
..
...
..
70
Ignition
System
.
.
........
..
.
.....
.......
...
..
.
....
.
...
.......
...
.
..
......
..
.
.
..
...
.
..
..
..
72
Manual
Transmission󰾵Controls,Assembly
.
.
.....
.
.
.......
.......
....
.
..
..
..
..
.....
...
.
..
....
82
SpecialTools .... . ....... .. . ...... ... . ... ... ...... . ... ....... ... . .. .... .󰾹 . ...... ... . . ... .. 87
New
Vehicle
Delivery
Inspection
.
.
...
.......
..
..
..
...
.
...
........
..
.
..
.
..
.
..
...
.
..
...
.
.
...
..
88
Lubrication,
Emission
and
Vehicle
Maintenance
.
.
.
..
.......
.......
....
.
..
...
.
..
.....
... ..
..
..
89
Wiring
Diagrams
.
.....
.
....
....
.
...
.
..
.
....
.....
...
.
...
..
.
.....
.....
...
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..
94

10
Engine-Assembly
Engine, removing
Work sequence
󰾵
disconnect
ground
cable
from
battery
󰾵 remove air cleaner with air flow sensor and air
intake
duct
󰾵 disconnect wire 1 at alternator
󰾵 disconnect following:
- plugs 2 at injectors
0 plug 3 at throttle valve switch
I plug 4 at auxiliary air regulator
󰾵 disconnect hoses 5 and 6 at charcoal filter
valve
󰾵 disconnect and plug fuel hoses 1 and 2
󰾵 remove accelerator cable from throttle valve
lever
Automatic Transmission
󰾵
remove
circlip
and
spring3
from
accelerator rod
4
Engine,
removing
󰾵
disconnect
following:
- plugs 1 at injectors
0 plug 2 at oxygen sensor
-
plug
3
and
4
at
ignition
distributor
0
plug
5
atoll
pressure
switch
- plug 6 at temperature sensor
a
plug
7
at
temperature
sender
-
plug
at
coolant
level
warning
switch
(not
shown󰾵located
in
coolant
expansion
tank)
󰾵 remove ground connectors 8
󰾵 block coolant hoses with clamps a
0 a = univeral clamp󰾵local supply
󰾵 block coolant hoses with clamps a
0
a
=
universal
clamp󰾵local
supply
󰾵 open coolant expansion tank cap
Engine-Assembly
10
󰾵 remove drain plugs 1 at cylinder heads and
drain coolant
󰾵 remove plates 1 on left and right sides
󰾵 remove bolts 2, do not remove plate 3
󰾵 disconnect brake booster line 1
󰾵 disconnect coolant hoses 2, 3 and 4
󰾵 remove coolant expansion tank 5
󰾵 remove engine/transmission bolt/nut 6 on left
and right sides
Automatic Transmission
󰾵
remove
three
bolts
which
attach
torque
converter to drive plate through hole on
top oftrans. housing (arrow)
󰾹 1 , _
󰾵 attach VW 785/1 B so that distance
between
support
pad
and
transmission
housing is about 120 mm (4 3/4 in.)
󰾵 support engine with US 612/5 and floor
crane
󰾵 disconnect wiring 1 at starter
Automatic Transmission
Engine, removing 5
󰾵 remove accelerator rod2

10 Engine-Assembly 󰾹 Engine-Assembly
Engine, installing
Proceed in reverse order of removing and note
following:
-󰾵 check clutch release bearing for wear and
replace if necessary
󰾵 lubricate clutch release bearing and main
shaft splines lightly with MoS: grease
(do not lubricate guide sleeve for release
bearing)
󰾵 replace all self-locking nuts on engine mounts
󰾵 check and adjust, if necessary, accelerator
cable/throttle controls, see Repair Group 20
󰾹4󰾵 20 Nm (14 it lb)
¢ s
Tightening
torques:
,󰾺
(5󰾹
-
engine
to
transmission
30
Nm
(22
ft
lb)
t
󰾺
'
Engme
suPpon
- engine carrierto body 25 NM (18 ft lb)
0 transmission mounts 30 Nm (22ft lb)
0 torque converter to a
drive
plate
,
20
Nm
(14ft
lb)
Arrow
points
iii
driving direction
Engine
carrier
󰾺 _
,.
note
installation
position,
arrow
points
in
driving
a
direction
x
󰾺
󰾹
󰾵 lower engine/transmission assembly until
transmission rests on VW 785/1 B
󰾵 when lowering, adjust angle of inclination on
floor crane head and keep wiring harness
aside so that it can pass oil filler tube
󰾵 remove nuts 2 of lower engine mounting bolts
󰾵 remove engine from transmission and lower it
out of vehicle
󰾵 mount engine on repair stand with engine
holder VW 307a
6
Engine,
removing/installing
1
Engine
carrier/support
7

13 Engine-Crankshaft, Crankcase
Note
Arrows
on
carrier
must
point
to
front
of
vehicle
when
reinstalling.
Remove
carrier
as
complete
assembly
20 Nm (14 ft lb)
«0󰾵󰾵 20 Nm (14 ft lb)
Engine
carrier/support
see page 7
Cover
plate,
rear
Catalytic Converter
Exhaust
pipe,
left
Muffler
20. Nm (14 ft lb)
󰾹metal surface faces cyl. head
8 Engine, disassembling/assembling
Engine-Crankshaft, Crankcase
Note
Tighten
all
hoses
with
hose
clamps
7 Nm (61 in. lb)
Intake
manifold
with
throttle
valve
housing
remove
as
complete
assembly
Water pump
remove
and
install
as
complete
assembly
20
Nm
(14
ft
lb)
20 Nm (14 ft lb)
20
Nm
(14ft
lb)
Gasket
cars
with
air
conditioner
and
power
steering
only.
When
removing,
hold
with
tool
3102
Triple V-belt pulley
Bolt
350 Mm (253 ft lb)
Bolt
V-belt
Single
V-belt
pulley
60
Nm
(43
ft
lb)
adjust
tension
so
belt
tpulley
supplied
as
spare
hold
flywheel
or
torque
deflects
under
thumb
part
has
only
TDC
mark
0
converter
drive
plate
pressure
10󰾵15
mm
0
cutting
timing
mark:
through
hole
in
crankcase
(3/8-9/16
in.)
50
after
TDC
=
7.5
mm
when
lqosening
or
(0.294
in.)
to
left
of
TDC
mark
tlghtenlng
Engine,
disassembling/assembling
9

13 Engine󰾵Crankshaft, Crankcase
CAUTION
When assembling crankcase
halves, see Fig. 4
Ignition
distributor
installing
Fig.
3
ignition distributor drive
shaft
removing Fig. 1
installing Fig. 28
Nm (69 in. lb)
Crankcase halves
assembling Fig. 4
20 Nm (14 ft lb)
coat both sides of washer
with
D
3
sealing
compound
TDC
sender
installing
Fig.
10
always
replace
Mt)
Thrust
washers󰾵<9
install and position
. .
35
Nm
(25
ft
lb)
wrth
screwdriver
,,
coat
both
sides
of
washer
with DS sealing compound
Rubber ring
always replace
identification:
thin
green ring
Metal ring
always
replace
35 Nm (25 ft lb)
coat surface with D 3
sealing
compound
.
.
m9
Oil seal
removing
Fig.
5
installing
Fig.
6
Oil
filter
Hydraulic
valve
lifter
Pushrod
tube
note
instructions
on
do
not
interchange
seam
faces
up.
filter
or
box.
positions.
Always
replace
pushrod
Remove
with
US
4462
Store
vertical,
base
tube
seals.
downward
Tube
can
be
replaced
with
repairing,
see
Repair
cyl.
head
installed,
see
Group 15 Repair Group 15
Preloading
and
repairing,
see
Repair
Group
15
1 0 Engine, disassembling/assembling
󰾹3.__4
󰾽Hf-
Engine-Crankshaft,
Crankcase
f 90 Nm (65 ft lb)
Clutch
disc
intall
with
US
219
Torque
converter
drive
plate
removing
Fig.
9
20 Nm (14 ft lb)
O-ring
Dowel
pin
Oil seal'
pry out carefully with
screwdriver
Spacer
installing
Fig.
7
3
Pressure
plate
󰾺
mark
position
before
:-
removing
Felt
ring
Flywhed
a,
removing/installing
Fig.
8
Need|e
bearing
adjusting
Crankshaft
(Manual
Trans.
only)
end
play
F'Q-
11
lubricate
with
MOS:
grease
Cylinder
head
Shims
drain
coolant
at
drain
plug
installing
and
repairing,
see
Repair
Group 15
used
to
adjust
crankshaft
end
la
,see
Fl
.11
py
g
35
Nm
(25
ft
lb)
drain
coolant
before
loosening.
Coat
surface
with
D
3
sealing
compound
tightening
sequence,
see
Repair
Group
15
Rocker
shaft
slot
points
upward
Gasket
always
replace
Sealing
ring/
25 Nm (18 ft lb)
always replace
Cylinder
head
cover
gasket
check
for
damage
and
replace
if
necessary
Coolant drain plug

r,___~____________',
13 Engine-Crankshaft, Crankcase
Fig. 1 Ignition distributordrive shaft, removing
󰾵
use
puller
as
shown
Fig. 2 Ignition distributor drive shaft, installing
󰾵 set crankshaft to TDC on cyl. No. 1
󰾵 install drive shaft so thatoffset slot
faces bolt (arrow)
󰾵 small segment faces water pump
Fig. 3 Ignition distributor, installing
󰾵 set cylinder No. 1 to TDC
󰾵turn rotor until mark on rotor is in line
with mark on distributor housing
(cyl. No. 1)
Ignition distributor drive shaft
1 2 Crankcase halves
. Crankshaft oil seal
Crankcase halves, assembling
󰾵 first tighten M 8 nut (arrow)
󰾵 then tighten all M 10 nuts
󰾵 tighten remaining M 8 nuts
/ _
Fig. 5 Crankshaft oil seal, removing
-󰾵 pry out
Fig. 6 Crankshaft oil seal, installing
Single pulley
󰾵 coat seal lips with oil and install seal
with 3088 and pulley bolt (without
washer)
󰾵
then
tighten
bolt
with
washer
until
stop
Triple pulley
󰾵
coat
seal
lips
with
oil
and
install
with
3088 and pulley bolt without washer
and tighten bolt until stop
Engine-Crankshaft,
Crankcase
Fig.
7
Crankshaft
oil
seal
(flywheel
side),
Hg"
10
TDC
sender󰾺
"15󰾾"an
installing
󰾵
use
piston
pin
and
plastic
hammer
to
drive
TDC
sender
in
until
stop
󰾵
coat
seal
lips
With
Oil
and
put
on
_
do
not
damage
inner
ring
1
guide A
󰾵
screw
base
B
into
crankshaft
and
press
in
guide
A
with
seal
until
seated
;
13.197
",,._
km
.,
s
..
..
Fig.
11
Crankshaft
and
play,
checkingladjusting
󰾵
check
crankshaft
and
play
0
new:
0.07󰾵0.13
mm
(0003󰾵0005
in.)
0
wear
limit:
0.15
mm
(0.006
in.)
󰾵
if
out
of
specification
proceed
as
\
fol
lows:
'
󰾵
install
flywheel
with
2
shims
but
without
O-ring
and
crankshaft
oil
seal
󰾵
mount
dial
indicator
with
bracket
on
crankcase
,
󰾵
move
crankshaft
in
and
out
and
ii
, '
measure
movement
(crankshaft
end
play)
󰾵
determine
thickness
of
3rd
shim
Fig.
8
Flywheel,
removing
󰾵
lock
flywheel
with
tool
Example
A!
-
~
dial
indicator
reading
0.44
mm
(0.017
in.)
Fig.
9
Torque
converter
drive
plate,
removing
specified
end
play
.󰾵
0.10
mm
(0.004in.)
_
lock
plate
with
VW
802
thickness
of
3rd
shim
0.34
mm
(0.013
in.)
󰾵
to
remove,
screw
in
bolt
1
_
go
to
next
page
(M18
x
1.5
x
60).
Thread
length
of
bolt
must
be
at
least
45
mm
(1.77
in.)
13'6L6
Crankshaft
oil
seal
Torque
converter
driveplate
1
3
Crankshaft
end
play

13
Engine-Crankshaft,
Crankcase
Engine-Crankshaft,
Crankcase
Note
No󰾹e
Thickness of shim is etched on shim. Remove deposits (scale) from
Always
recheck
with
micrometer
i
cylinders/crankcase
and
cylinders/cylinder
head
CAUTION
Always install three shims to obtain
correct crankshaftend play
Piston pin
removing Fig. 3
installing
Fig.
11
to
Fig.
13
󰾵 remove flywheel
󰾵
install
O-ring,
crankshaft
oil
seal
and
felt
ring
󰾵 install all three shims
󰾵 install flywheel
󰾵 tighten bolts to 110 Nm (80 ft lb)
󰾵󰾵 recheck crankshaft end play
5󰾽
Rubber
sealing
ring,
inner
always replace
identification:
thick/black
Circlips
removing/installing Fig. 2
Rubber
sealing
ring,
outer
always replace
identification: thin/green
Piston
l
max.
weight
difference
I between pistons 10 grams
marking Fig. 1
classification Fig. 4
recess depth Fig. 5
checking dia. Fig. 9
installin Fi . 11 to Fi .13
gg
9
Cylinder
sleeve
mark
before
removing
Fig.
1
checking
cylinder
bore
Fig.
10
assembling
Fig.
11
to
Fig.
13
cylinder
bore/piston
dia,
see
Piston
rings
page
18
offset gap between rings 180°
as shown with oil scraper ring
gap
facing
up.
-13_178
Installation
position
in
piston
-
Fig. 6
1
4
eng
gap
Fig.
7
1
5
Crankshaft
end
play
we
Clearance
Cheekmg
F'g'
8
Piston/Cylinder

13
Engine-Crankshaft,
Crankcase
_
Engine-Crankshaft,
Crankcase
Fig-
1
PiStonlcy'inder
Sleeve󰾺
marking
1
Fig.
6
Piston
rings,
installation
position
i
-
°
arrow
90󰾾󰾽?
to
󾪣yWhee'
I
0
TOP
mark
on
piston
rings
must
face
to
󰾵
before
removmg.
mark
matching
top
of
piston
Fig.
8
Piston
ring
side
clearance,
checking
numbers on pistons and cylinder 3 = upper ring .1 '
f sleeves _ b = lower ring clearance 1 wear limit
󰾺
cyl'󰾾der
boss
1
faces
'nward
c=oi|
scraper
ring
upper
ring
=
0.05󰾵0.08
mm
0.12
mm
.
(0002󰾵0003
in.)
(02005
in.)
Fig.
4
Piston
classifications
󰾹
mwer
ring
_
0
04
0
07
mm
0::10
mm
A=arrow
(stamped
on)
must
point
1
(0002󰾵0003
in.)
(0.004
in.)
toward
flywheel
when
piston
is
O"
scraper_
o
02
0
05
mm
o10
mm
installed
.
-
'
_
'
.
'
.
B
=
paint
dot
(blue)
indicates
matching
I󰾺an
(0.001
-0.002
m.)
(0.004
in.)
size
C=weight
group
(+or󰾵)
stamped
on
󰾵weight
=448-456
grams
+ weight =457󰾵464 grams
D=piston
size
in
millimeters
(see
table
on page 18)
Fig. 2 Circlips, removing/installing
on V-belt side:
󰾵 with piston at TDC, pull out cylinder
sleeve
with
3092
until
piston
pin
circlip visible
_3 - 631
at
flywheelend:
i
Fig.
7
Piston
ring
end
gap,
checking
󰾵 with first cylinder sleeve removed 󰾵 push ring in squarely from lower
cylinder
opening
about
4󰾵5
mm
Fig.
9
Piston,
checking
diameter/wear
(3,16
in')
,
󰾵
measure
at
bottom
of
skirt
approx.
󰾵
measure
gap
wrth
feeler
gauge
15
mm
(9/16
in)
from
edge
. ..
(diameter
stamped
in
top
of
piston)
,ring
end
gap
wear
limit
upper
ring
=
0.30󰾵0.45
mm
0.90
mm
(0012󰾵0018
in.)
(0.035
in.)
lower
ring
=
0.30󰾵0.50
mm
0.90
mm
(0012󰾵0020
in.)
(0.035
in.)
oil
scraper:
0.25󰾵0.40
mm
0.95
mm
ring
(0010-0016
in.)
(0.037
in.)
Fig.
3
Piston
pins,
removing
Fig.
5
Piston
recess
depth
󰾵
remove
pins
as
shown
-
measurement
a
=
11.65
mm
(0.458
in.)
󰾹
Piston/cylinder
sleeve
3
1
6
Piston
pins/circlips
Piston
rings
1
7
󰾹. Piston classifications Piston

13
Engine-Crankshaft,
Crankcase
Engine-Crankshaft,
Crankcase
󰾵
replace
rubber
sealing
rings
for
CAUTION
cylinder sleeves:
0
cylinder
head
end
=thin
ring
(green)
When
assembling
crankcase
halves,
0
crankcase
end
=thick
ring
(black)
observe
tightening
sequence
and
l
tightening
torque
(see
page
12,
Fig.
4)
󰾵
install
piston
into
cylinder
sleeve
(flywheel
Side
first)
Oil
pickup
line
with
-
arrow
on
piston
points
toward
filter
screen
Crankcase
flywheel
Cleaning
Fig-
4
clean
and
blow
through
all
0
gap
of
oil
scraper
ring
must
be
to
replacing
Fig-
5
oil
channels
with
top
compressed
air.
I
iston
rin
a
s
offset
b
180°
see
00"󰾽
pining
surfaces
With
gage
15)
ggp y
(
Dowel
D3
sealing
compound
Main
bearing
No.2
.
.
. .
.
'
.
.
lubricate
before
installing
󰾵
Insert
Circllp
for
piston
pin
on
fly-
check
for
tight
fit
crankshaft
wheel
Side
of
piston
In
case
Note
installation
position
󰾹
I,
when
removing
and
install
in
same
position
as
removed
Camshaft
end
cap
coat
with
sealing
compound
when
installing.
Watch
installation
position
Fig.
10Cylinder
sleeve,
checking
for
wear
󰾵
measure
10󰾵16
mm
(3/8󰾵5/8
in.)
from
top
0
piston
to
sleeve
clearance
is
sleeve
diamater
minus
piston
diameter
new
=0.03-0.06
mm
(0.001
-0.002
in.)
wear
limit
:02
mm
(0.008
in.)
Main
bearing
No.
1
lubricate
before
installing
crankshaft.
Hole
for
dowel
offset
toward
flywheel
Fig.
12
Piston
and
cylinder
sleeve,
installing
󰾵
note
markin
s
on
connectin
rod
Cylindersleeve
bore/Piston
diameter
support
3098
g
0
R
=right
side
of
engine
size
color
°_V󰾽"d°'
"Eamhing
pm󰾾
0
L:
left
side
of
engine
d'ameter
d'ameter
󰾵
push
connecting
rod
support
onto
standard
blue
94005󰾵94016
mm
93.98
mm
Center
stud
SO
finger
of
tool
supports
connecting
rod;
then
secure
it
with
rubber
band
1
to
prevent
it
from
slipping
󰾹
<7
󰾵
align
connecting
rod
such
that
piston
'
pin
canbe
installed
through
hole
in
housing
󰾺
-
crankshaft
must
be
at
TDC
0
lug
on
rod
faces
up
Camshaft bearing
lubricate
before
installing.
Tabs
must
engage
in
󰾹
recess
Crankshaft
1
disassembling/assembling,
c
h
H
see
a
e21
ams
a
-13󰾵179
,
p
g
runout,
checking
Fig.
1
l
end
play,
checking
Fig.
2
Fig.
11
Piston
and
cylinder
sleeve,
installing
󰾹
"󰾹Stang
Hg
3
Note
Remove
deposits
(scale)
around
cylinders/
crankcase
and
cylinders/cylinder
head
Fig.
13Piston
and
cylinder
sleeve,
installing
󰾵󰾵
install
piston
pin
with
3091
and
insert
Crankcase
t
1
8
circlip
Crankshaft
1
9
:
PistonICylinder
sleeve
Camshaft

13
Engine-Crankshaft,
Crankcase
l
Engine-Crankshaft,
Crankcase
󰾵 turn crankshaft backward
' camshaft must not lift out of
beanngs
o if camshaft lifts out of bearings,
install camshaft with smaller timing
gear
Connecting
rod
bearing
note
position
when
removing
and
install
in
same
position
from
which
>
removed
Crankshaft
clean and blow drillings
out
with
compressed
air,
protect from rust when
storing
clamping
in
vice
Fig.
1
dimensions: see table
Note
Main bearing No. 3
oil before installing
hole for dowel faces
crankshaft web
To obtain specified backlash, camshafts with
various size timing gears are available.
Markings are on inner face of timing gear
Main bearing No. 4
oil
before
installing
groove toward oil thrust
ring
I
Example
below
Fig.
1
Camshaft
runout,
checking
H
_0_1",
u
+01",
M
+02",
indicates
in
Crankshaft
pilot
bearing
-
wear
limit
0.04
mm
(0.0015
in.)
1/100
mm
how
much
pitch
radius
manual
trans.
only
differs
from
standard
pitch
radius
"0󰾾 Spacer
removing Fig. to
installing Fig. 11
CAUTION
Mark 0 on outer face of camshaft timing
gear is timing mark and must not be
confused with markings on inner face.
Crankshaft timing gear is available in one
size only
Oil thrust ring
\
45
Nm
(33
ft
lb)
always
replace
lubricate contact surface
when installing
Crankshaft timing gear
press off/install together
with distributor drive gear
removing Fig. 4
installing Fig. 5
.
Circlip
removing
Fig.
2
installing
Fig.
3
'
US
1027,
󰾺
󰾺
Fig.
2
Camshaft
end
play,
checking
- wear limit 0.16 mm (0.006 in.)
0 if out of specification, replace
camshaft bearings
Distributor drive gear
press
offlinstall
together
i
with
crankshaft
timing
gear
l
removing
Fig.
4
Connecting
rod
installing
Fig_
5
note
position
when
.
--
.-
.
removing
and
install
in
~
"
󰾹
same
position
from
which
.
a
r
..
I
removed
Fig.
4
Oil
pickup
line
with
filter
screen,
i
replace
in
Sets
Of
four
only
󰾹
max.
weight
difference
10
grams
installing Fig. 6 to Fig. 8
󰾵
clean
oil
channels
by
blowingthrough
checking
side
clearance
. .
Fig.
9
With
compressed
air
(arrow)
cleaning
-
Bearing
No.
1
BearingNo.
2
BearingNo.
3
Bearing
No.4
Connecting
rod
l
>
Crankshaft
journal
sizes
(mm)
l
l
󰾽9'
3
camSha󾪣i
i"s󰾹a'"󰾽9
Standard
59980-59990
54.971
-54.990
54980-54990
39984-4000
54983-54996
size
(marked:
blue
dot)
(marked:
blue
dot)
󰾵 mark on camshaft gear tooth must be
between marks on crankshaft gear
teeth (arrow)
󰾵 check backlash of timing gears
0 0.0-0.05 mm (0󰾵0.002 in.)
0 backlash must be hardly noticeable
59.971 -59.979 54.971󰾵54.979
(marked: red dot) (marked: red dot)
Fig. 5 Oil suction line with filter screen,
20
Camshaft
rePIaCing
Crankshaft
Oil
pickup
line
Connecting
rod

13 Engine-Crankshaft, Crankcase
Fig. 1 Crankshaft, clamping in vise
Fig. 4 Distributor drive gear/crankshaft timing
gear, removing
-1A3-11V1M
Fig.
5
Distributor
drive
gear/crankshaft
timing
gear, installing
󰾵
heat
gears
to
approx.
80°C
(175°F)
before installing
Fig.
2
Circlip,
removing
Fig. 3 Circlip, installing
Fig.
6
Connecting
rod,
installing
󰾵
numbers
(arrow)
on
rod
andcap
must
match and beon same side
Crankshaft/Circlip
2 Crankshaft timing gear
Connecting rod
Engine-Crankshaft, Crankcase
r
I
on
1,.
Fig.
7
Connecting
rod,
installing
_
Fig.
10
Crankshaft
pilot
bearing,
removing
󰾵
lightly
tap
both
sides
of
connecting
rod
wtth
hammer
to
elImInate
slight
A
=
US
8028
pinching
of
bearing
shells
when
B
=
US
1039
&US
10539/3]
installing
connecting
rod
.
󰾵
lubricate
with
M082
grease
when
installing
0
forged
mark
on
rods
(arrows)
must
face
°
markings
0󰾽
bearing
0399
must
up
when
rods
are
installed
face
outward
Fig.
8
Connecting
rods,
installation
position
Fig. 9 Connecting rod, checking side clearance
-
wear
limit
0.7
mm
(0.028
in.)
Connecting
rod
Crankshaft
pilot
bearing

15 Engine-Cylinder Head, Valve Drive
Note
Cylinder heads with cracks between valve seats
or
between
a
valve
seat
and
spark
plug
thread
can
be
used
again
withoutreducing
service
life
provided
that
cracks
are
small
and
not
more
than
0.5 mm (0.019 in.) wide orthat only first coil of
plug
thread
is
cracked
Valves
valve
dimensions
Fig.
2
intake valve refacing Fig. 3
Valve guides
checking page 27
Compression
checking page 27
24
Cylinder
head
Note
Cylinder head canbe removed and
installed with engine installed
Cylinder head
valve seat refacing page 25
Valve springs
removing/installing Fig. 1
Engine-Cylinder
Head,
Valve
Drive
15
us
0
i
us
102011
d
-----
󰾵»
I
Fig.
3
Intake
valves,
refacing
L
-
valve
margin
d
must
not
be
less
than
0.5
mm
(0.020
in.)
Fig.
1
Valve
springs,
removing/installing
_
Valve seats, refacmg
Work
sequence
Fig.
2
Valve,
dimensions
Intake valve
a
=40.0
mm
(1.575
in.)
diameter
b_󰾵.7.96-7.97
mm
(0.313󰾵0.314
in.)
die.
C:
122.5
mm
(4.823
in.)
length
󰾽=45󰾾
Exhaust
valve
a
:34
mm
(1.339
in.)
diameter
b
=8.91󰾵8.92
mrn
(03508-3512
in.)
dia.
CAUTION
c
=122.5
mm
(4.823
in.)
length
04: 45 °
Damaged
or
burnt
seats
can
be
refaced
it:
-
permissible
width
of
seat
A
is
maintained
-
15°
chamfer
Bdoes
not
exceed
outer
diameter
of
valve
seat
insert
in
cylinder
CAUTION
Do
not
rework
exhaust
valves
by
machine,
lap
by
hand
only
m󰾽
5
󾪣?
󰾵
seat
Width
a
=1.4󰾵2.5
mm
(0.055-0.098
in.)
Valveslspn'ngsldimensionslrefacing

15
Engine-Cylinder
Head,
Valve
Drive
󰾵
reface
valve
seats
to
45°
angle
0 stop cutting as soon as complete seat is
cleaned
󰾵 reface surface to 75° angle
0
slightly
chamfer
lower
edge
of
valve
seat
26
Valve
seats,
relacing
15~431
󰾵 reface surface to 15° angle
-
chamfer
upper
edge
of
valve
seat
until
correct seat width is obtained
Note
When
new
valves
are
installed
in
properly
reworked
seats,
it
may
not
be
necessary
to
lap
in
valves
CAUTION
After
lapping
valve,
remove
all
traces
of
grinding paste
Engine-Cylinder
Head,
Valve
Drive
Valve
guides,
checking
Note
When
repairing
engines
with
leaking
valves
it
is
not
sufficient
to
rework
or
replace
valve
seats
and valves.
It
is
also
necessary
to
check
valve
guides
for
wear.
This
is
particularly
important
on
engines
which
have
considerable
mileage.
󰾵 remove carbon
-󰾵 insert new valve into valve guide
- valve stem must be flush with valve
guide end
󰾵
rock
valve
back
and
forth
against
dial
indicator (arrow)
󰾹 max. 1.2 mm (0.047 in.)
Compression,
checking
0
engine
oil
temperature
minimum
30°C
(86°F)
0
throttle
valve
open
fully
(accelerator
pedal
in
full throttle position)
󰾵
remove
all
spark
plugs
󰾵
disconnect
coil
wire
at
ignition
distributor
and
connect
to
ground
with
clamp
115' 󰾹2󰾹󰾽
󰾵
check
compression
with
tool
US
1120
󰾵
operate
starter
until
tester
no
longer
indicates
a
rise
in
pressure
0
compression
pressure:
10󰾵13
bar
(145-189
psi)
0
minimum:
8
bar
(116
psi)
0
maximum
pressure
difference
between
highest
and
lowest
cylinders:
3
bar
(44
psi)
Valve
guides
Compression,
checking

F󰾾
'
"
W
'
T
15
Engine-Cylinder
Head,
Valve
Drive
Engine-Cylinder
Head,
Valve
Drive
Note
CAUTION
._
Cylinder
head
can
be
. .
.
_
'
removed
and
installed
If
metal
particles
are
found
in
Oil
pan,
W
,
with
engine
installed
remove,
disassemble,
clean
and
reinstall
all
<
valve
lifters
from
position
removed
s ( l , t
3
s
I
d;
_.
r
a
3󰾺&
j
_.
"
3
.
_
I
m
Guide
pushrod
carefully
into
socket
of
󰾺
-
󰾹<
hydraulic
valve
lifter
O-ring
Fig.
1
Pushrod
tube,
pretensioning
(thin-green)
always replace
lf
rocker
shafts
have
been
removed,
the
following
adjustment
is
necessary
󰾵
pretension
tube
to
correct
length
0
a
=approx.
194
mm
(7.638
in.)
󰾵
when
installing,
seam
faces
upward
and
small
end
to
cylinder
head
󰾵-
always
replace
sealing
rings
Metal
sealing
ring
Work
sequence
always
replace
-
pushrod
tubes
can
be
replaced
with
󰾵󰾵
backout
adjusting
screws
in
rocker
arms
so
engine
installed
that
ball
shaped
end
is
flush
with
surface
of
arm
󰾵
turn
crankshaft
until
cylindertNo.
1
is
at
TDC
(mark
on
rotor
in
line
with
mark
on
distributor
housing)
Pushrod
tube
󰾵
turn
adjusting
screws
in
so
they
just
touch
small
and
faces
head.
valve
stems
'
Pretensioning Fig. 1
replacmg
page
30 -󰾵
turn
adjusting
screws
2
turns
clockwise
and
tighten
locknuts
󰾵
rotate
crankshaft
180°
and
adjust
next
cylinder
󰾵
repeat
until
all
cylinders
are
adjusted
Hydraulic
valve
lifter
Pushrod
' ' '
do
not
interchange.
max.
run-out
0.3
mm
Hydrau'lc
valve
󰾽Hers,
bleedmg
adjusting,
page
29
Ca
m󰾽
(0.012
in.).
-
- -
bleeding,
page
29
35mm
(25
n
M
guide
pushrod
carefully
i
Flg'
2
cylmder
head'
in󾪣allmg
work
sequence
drain
coolant
before
[mo
seat
0󰾹
hydrau'ic
Va'Ve
󰾵
tighten
cylinder
head
at
stud
1
with
removing
nuts;
"󾪣er
󰾹
cap
nut
just
enough
so
that
all
coat
surface
with
remaining
7
cap
nuts
can
be
installed
03
sealing
Compound
Adjusting
screw
1
󰾵
coat
surface
of
cap
nuts
with
D
3
adjusting
hydraulic
valve
1
sealing
compound
and
torque
(1st
lifterS.
page
29
v
stage)
in
sequence
to
10
Nm
(7
ft
lb)
Support
Note
slot faces upward
Be
sure
that
pushrod
tubes
are
properly
seated
󰾵
tighten
cap
nuts
to
final
torque
35
Nm
(25
ft
lb)
Gasket
always replace.
Apply
thin
bead
of
sealing
compound
D
000400
to
gasket
surface
facing
󰾵
befOre
installing,
check
that
valve
lifter
is
bled
Hydraulic
valve
lifters,
adjusting
cylinder
head
Note
I
25
Nm
(18ft
lb)
correctly
Sealing
ring
Cylinder
head
Never
repair
valve
lifters;
if
worn
or
damaged,
-
check
by
applying
firm
thumb
pressure
on
always
replace
before
removing,
drain
coolant.
replace
complete
assembly.
push
rod
socket
in
direction
of
arrow.
Smooth
damaged
painted
surfaces
.
Lifter
ShOUId
󰾽01
move-
.
_
Valve
lifters
can
be
removed
and
replaced
.
.
Coolant
drain
plug
at
gasket
contact
area
with
󾪢ne
Gasket
. .
.
.
If
N0,
bleed
lifter
as
follows:
sandpaper
and
clean
with
servant
always
replace
Without
engine
removal
and
Without
major
before
installing
engine
disassembly.
Installing,
Fi
_
2
Intermittent
valve
noises
are
normal
upon
8
9
starting,
sudden
acceleration,
high
temperatures
L12:
2
Cylindef
head
or
mgh
engme
Speed
Hydraulic
valve
lifters

l
1
:ll
󰾹.
15
Engine-Cylinder
Head,
Valve
Drive
U󰾵 Lock ring
Pushrod socket 󾪣
Ball
check
valVe
g󰾵Check
valve
spring
Check valve
retainer
g Plunger spring
Valve body
Plunger
󰾵 pry out lock ring
󰾵 remove pushrod socket, plunger, ball check
valve with spring, check valve retainer and
plunger spring from body
󰾵 fill valve lifter body with oil up to bleed hole
󰾵 insert plunger spring
󰾵 install plunger with ball check valve, spring
and valve retainer and push downward; at
same time, open ball check valve with scribe
󰾵 insert pushrod in socket and slowly press
together with valve guide or sawed-off
pushrod in vise (bore a must face upward) or
in
press
until
lock
ring
can
be
installed
󰾵 install lock ring
30
Pushrod
tubes
Pushrod tubes, replacing
Note
Pushrod tubes supplied as replacement parts
can be installed as follows with engine installed
Work sequence
󰾵 remove valve cover
󰾵 remove rocker arm shaft and pull pushrod out
󰾵 remove lower cover plate
󰾵 remove defective tube with pliers or
screwdriver
󰾵 squeeze new pushrod tube together and insert
with new sealing rings as shown (arrow)
(tube seam faces upward,sma|l end to head)
󰾵 insert pushrod and install rocker arm shaft
CAUTION
Guide
pushrod
carefully
into
seat
of
hydraulic valve lifter.
If pushrod rests on edge of valve lifter
basic
setting
will
be
incorrect
and
valve
lifter
will
be
damaged
when
engine
is
started
󰾵
adjust
hydraulic
valve
lifters,
see󰾹
page
29
Engine-Lubrication
System
Note
Always
replace
all
gaskets
and
sealing rings
Engine oil filling capacity
with oil filter change󰾵4.5 ltr (4.7 US qt)
without
oil
filter
change󰾵4.0
ltr
(4.2
US
qt)
8 Nm (69 in.lb)
Oil dipstick V.
difference between V .
min.
and
max.
1.0
ltr
(1.0
US
qt)
Oil filler tube
slide out extension
to refill oil
Oil pump housing
check
for
wear
removing
Fig.
1
Oil
pressure
switch
30 Nm (22 ft lb)
checking
Fig.
3
5,
if󰾽)
Oil
drain
plug
4󰾹
25
Nm
(18ft
lb)
Oil filter
loosen with US 4462.
Note instructions
on filter or box
Oil pump gears
checking and play Fig. 2
Oil
pressure
relief
valve
20
Min
(14
ft
lb)
check
for
wear
and
free
movement
Sealing
nut
25
Nm
(18ft
lb)
always
replace.
Seal
faces
inward
Oil pump cover
if scored, replace
Oil pump
Oil
pressure
switch
Oil filter

17
Engine-Lubrication
System
Notes
Fig.
1
Oil
pump
housing,
removing
Fig.
3
Oil
pressurelswitch,
checking
0
engine
oil
temperature
should
be
80°C
(176°F)
󰾵
remove
oil
pressure
switch
and
install
in
gauge
I I
-
_
󰾵
install
oil
pressure
gauge/adapter
in
Fig.
2
on
pump
end
play,
checking
place
of
oil
pressure
switch
-
max.
0.1
mm
(0.004
in.)
󰾵
connect
wire
1
(blue)
of
gauge
to
oil
1󰾹
pressure
switch
and
wire
of
oil
󰾹
pressure
warning
light
3
as
shown
󰾵
connect
wire
2
(brown)
to
ground
󰾵
turn
ignition
ON
0
oil
pressure
warning
light
must
light
UP
0
if
N0,
switch
is
defective,
replace
switch
󰾵-
start
engine
-
oil
pressure
warning
light
must
go
out
at
an
oil
pressure
of
,
0.15-0.45
bar
(2-6.5
psi)
3
󰾵
increase
engine
speed
-
at
2000
rpm,
pressure
should
be
minimum
2.0
bar
(29
psi)
1
Oil
pump
󰾹1
3
Oil
pump
end
play
󰾹
Oil
pressure/switch

19
Engine-Cooling
System
l
󰾹
Engine-Cooling
System
Cooling
system
Note
draining
Fig.
1
to
Fig.
4
checking
for
leaks
Fig_
9
Always
replace
all
gaskets.
All
parts
of
cooling
system
can
be
i
l
Cooling
hoses
layout
removed
and
installed
with
engine
E
see
a
e
40
.
p
g
Coolant
expansion
tank
cap
Ins'talled
checking
Fig.
10
i
to
radiator
Bleeder
connection
valve
»
~.
,
t»-
open
when
filling
or
.;
..
_󰾹
bleeding
cooling
system
)
see
Fig.
5
Coolant level warning
light switch
lrom
radiator
Spring clamp
removing/installing
Fig.
3
to heater core
from
heater
core
Temperature
gauge
sender
Temperature
sensor
10
Nm
(7
ft
lb)
10 Nm (7 it lb)
checking, see
Repair Group 24
Thermostat
checking
:
heat
thermostat
in
water
opening
begins
:
approx.
85°C
(185°F)
opening
ends
:
approx.
105°C
(221
°F)
Refill tank
stroke
:
min.8
mm
(0.315
in.)
,
󰾹
.
note
min.
and
max.
marks
󰾹0
\
f
filling
system
Fig.
5
to
Fig.8
\
J
20
Nm
(14
ft
lb)
_
l
20
Nm
(14
ft
lb)
7
Nm
(61
in.
lb)
20
Nm
(14
ft
lb)
lo
coolant
expansmn
tank
\
-
\\\a
3
l
20
Nm
(14ft
lb)
ll
,
E"
'
Coolin
s
stern
*
Coollng
system
I
9
y

19
Engine-Cooling
System
Engine-Cooling
System
Note Note
Cooling
system
is
filled
at
factory
with
mixture
Secure
coolant
noses
of
water
and
antifreeze/corrosion
protective
with
hose
clamps
solution.
Coolant
mixture
should
be
used
all
year.
When
replacing
coolant
only
use
ethylene
glycol
based
antifreeze
(phosphate-free).
Thermo-switch
for
fan
onIy
use
G11
coolant
(located
at
bottom
of
radiator)
removing/installing: remove
radiator grille and move left
cardboard
air
deflector
to
l
side
i
'-
51398
||-
stage
Fig.
1
Coolant
system,
draining
(when
removing
cut-in
temperature:
93
°C󰾵98
°C
99°C-105
°C
engine
4'
' 󰾹
Radiator
_
o
_
a
Fi
.
4
Coolants
stem,
drainin
(199
208
F)
(210
221
F)
󰾵
pinch
coolant
hoses
with
hose
clamp
g y
9
remove
spare
wheel
bracket
and
radiator
grille
before
removing
or
lowering
radiator
(A-local
supply)
(arrows)
before
󰾵
open
coolant
expansion
tank
cap
removing
cut-out
temperature:
88-93
󰾽C
91
󰾵97
uC
USO󰾵199°C)
(196󰾵206°F)
󰾵
drain
coolant
at
drain
plugs
1
on
Bleeder
screw
cylmder
heads
open when filling
cooling system,
see Fig. 5
Washer
Radiator
fan
󰾹
canbe
removed
and
.
,,
.
g
i
installed
without
draining
L
.
coolant
after
lowering
(3
radiator
(:3
Fig.
2
Coolant
system,
draining
󰾵
in
case
that
coolant
hoses
1
and
2
for
heat
exchanger
have
to
be
removed,
pinch
hoses
with
hose
clamp
(A-Iocal
SUPP'Y)
Fig.
5
Cooling
system,
filling
󰾵
set
heater
control
to
maximum
heating
󰾵
open
control
valve
for
auxiliary
heater
under
rear
seat
󰾵
remove
radiator
grille
󰾵
raise
vehicle
approx.
40
cm
(153/4
in.)
at
front
under
cross-member
with
floor
jack
and
wooden
support
or
equivalent
󰾵
open
bleeder
screw
(arrow)
on
radiator
Lower bolts
remove bolts on both
sides before lowering
radiator
15
Nm(11ftlb)
Fig.
3
Hose
spring
clamp,
removing/installing
19-254
󰾹
󰾵
use
universal
pliers
or
hose
clamp
pliers
to
remove
or
installclamp
(arrow)
,l
,
l󰾹;
Radiator
assembly
Hose
spring
Clamp
l
Thermo'SWitCh
Cooling
system,
drainlnglfilling