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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4
Engine-Crankshaft,Crankcase
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8
Engine-CylinderHead,Va|ve
Drive
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24
Engine󰾵Lubrication System . .... .... .. . ... .... . .. ...... ..... . ... .... ... . .... .... ... .. .. ... 31
Engine󰾵Cooling System . . .... .. ..... ...... ... . ... .. . ... .. . ..... .. . .. ....... .... ... .. .. ... 34
Fuel
Supply
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42
Fuel |njection,AFC System .. ........... ....... ... . ... .. . .. ..... . ... ..... .....r. .. .. ... ... .. 52
Exhaust
System󰾵Emission
Controls
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70
Ignition
System
.
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72
Manual
Transmission󰾵Controls,Assembly
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82
SpecialTools .... . ....... .. . ...... ... . ... ... ...... . ... ....... ... . .. .... .󰾹 . ...... ... . . ... .. 87
New
Vehicle
Delivery
Inspection
.
.
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88
Lubrication,
Emission
and
Vehicle
Maintenance
.
.
.
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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