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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.
..
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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