VOLKSWAGEN VANAGON Official Factory Repair Manual 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991 Including Diesel, Syncro and Camper e lam LD) ) A SZ [B] BentieyPubtishersVolkswagen Vanagon Official Factory Repair Manual 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991 Including Diesel, Syncro and CamperSelected Books and Electronic Editions From Bentley Publishers Volkswagen alll fr the Beetle: The Stor) ofthe atthe forthe Giant VW Factory and the Car that Becamean Ieon Around the Globe Karl Lutogson ISBN 08376-0071-5 Volkswagen Model Documentation Joachin Kc ISBN 0-8376-0078-2 Votkswagen Sport Tuning, orSireet and Competition Per Schmader ISBN OSS7EULGL. Golf, GTI, Jetta: 1999-2004, Jetta Wagon 2001-2004 Official Factory Repair Manual ‘on CD-ROM Volksen of America YSBN 0-8976-10818 \VWoa lit No. a2 VAs4 VO25 CD Jetta, Golf, GTI Service Manual: 1999-2003, ISL Tutbs, LAL TDI Diesel, 20L Gasoline, 23 VRE, Bentey Phblishers ISBN 0-8376-0823-4 Volkswagen Part No. LPV 800 119 Passat, Passat Wagon; 1998-2004 Official Factory Repaic Manual on CD-ROM. Votksgen of Ameren ISEN 0-8976-1084.2 ‘VW Lit No Wiz VBB4 V025CD Passa: 1898-200 Service Manual Bently Publishers \SBNO-S376-8969-2 Volksen Part No, LPV 00209 [New Beetle: 1998-2004, New Beetle Convertible 2005-2004 Oficial Factory Repair Mangal on CD-ROM Vossen of America ISDN O-S376-1080-, Vos Lit No: W2 VNB4 025 CD [New Beetle Service Manual 1998-2002 ASL turbo, 1.9L TDI diesel, 284, gasoline Beniley Pabshers SDN 08376-03854 Volkswagen Part No, LPV 900302 Golf, GTI, Jetta: 1993-1999, Cabrio: 1995- 2002 Official Factory Repair Manual on cp-RoM Votksoagen of America ISBN 0-8376-1079- Vos Lit No. W2 VAH VO25CD Jelta, Goll, GTI: 1993-1999 Cabrio. 1995- 2002 Service Manual Bentley Publishers ISBN 0-8376-0366-8 Vollswagen Part No, LPV 800 116, Egiovan: 1982-2003 Official Factory Repair ‘Masia on CD-ROM. Voiksnagen of Amerie ISBN O-8376-1083-4 Wwe Lit No. WA2 VTE W025 CD Earovan Official Factory Repair Maal: 1992-1999 Volkswagen of America ISBN 0-8976.0235-8 Volkswagen Part No. LPV' 800 149 Passat Passat Wagon 1951997 Official Factory Repair Manwal on CD-ROM. Voikswnger of Ameri ISBNVO-8376-1082-6 Yo Gt: Wa2 VBas 025 CD Passat Official Factory Repaie Man 19051997 Volkswagen of Ameria ISBN 0-8876-03803 \olKswagen Part No, LPV 800207 Fox Service Manual 1987-1993 Bentley Publishers ISBN 0-8376.0363-3 ‘Voksen Part Na, LPV 800 504 ah GTUGolt/etta Service Manval: 1985-1992 ‘Gasoline, Diesel, and Tutbo Diese, including 16V Bentley Publishers ISBN 08376-03120 Volkswagen Part No, LPV 800 112, ‘Corrado Official Factory Repair Manval: 1990-1995 Volkswogen of America ISBN 0-8376-0387-0 ‘volkswagen Part No, PV 800 300 ‘Passat Service Manual: 199041999 ‘ieylinder gasoline models, including GLand Wagon ovdley Publisers YSN 0-8376-03784 ‘Volkswagen Part No, LEV 800 205 ‘Cabriolet and Scirocco Service Manual 1985-1993, including 16V. Bentley Publishers ISBN 08376 0362-5 ‘lkswagen Part No, LEV 800 113, ‘Vanagon Official Factory Repais Manual 1980-1991 including Diesel, Syncro, and Camper Vollstonge of Amerie ISBN 0-8376-0336-6 Yolkewagen Part No. LPV 800 148, Rabbit, Scirocco, Jetta Service Manual: 1980-1984 Gasoline Models, Including Uickup Truck, Convertible, and GTT ently Pushes SNC 08976-01835 Volkswagen Part No. LPV 800 104 Rabbit, Jetta Service Manual 1977-1986 Diesel Models, Including Pickup Truck tna Turbo Diesel only Publishers ISBN O-8376-0184-3 Volkswagen Part No, LPV 800 122 Super Beetle, Beetle and Karmann Ghia Officiat Service Manual Type I: 1970-1979 Volkswagen of America ISBN 08376-10960 Volkswagen Part No, LPV' 97 109 Station Wagon/Bus Offical Service Mandal Type 2: 1968-1979 Volksoage of Amerce ISBN 08376-00984 Volkswagen Part No, LPV'997 258 Fastback and Squareback Official Service ‘Manual Type 31968-1973 Vatksge of Arron SBN 0-8376-0087-X ‘Volkswagen Part Na, LPV 997 383 Type 3 Workshop Manval: 1961-1967 Volksen of Aner ISBN 0-8376-1192-X Volkswagen Pat No. LPV 800 139 Beetle and Karmanss Ghia Offical Service Manual Type 11966-1969 Vollsengen of Amerct ISBN 0-8976-04168 Volkswagen Part No. LPY 997 167 Transporter WorksHop Manval: 1963-1967, Type? all models Volksigen of Amercr ISDN 0-8576-0991-9 Volkswagen Part No. LPV 500 135 Transporter Workshop Manual: 1950-1962, Type all models Valkstsngen of Americ ISBN 0-8976-0382-X Volkswagen Part 30. LPY 800 138 1200 Workshop Manual: 1981-1965, Type, ‘and 15, Beetle, Beetle Convertible, Karmann Ghia Coupe, and Karmann Ghia Convertible Votksoage of Ameren ISBN 0-8376-0390.0 Volkswagen Part No. LPV 800 121, Workshop Manual: Types 11,14, and 15, (Beetle €¢ Karmann Ghia): 1939-1960 Volkswagen of America SBN 0-8376-0302.7 ‘lswagen Part No, LPV 800137 Workshop Manual: Types 18,44, and 15 (Beetle de Karmann Chia): 1952-1957 Volksoagen of Amerca ISBN 0-8376-0380-7 Volkswagen PartNo LPV 800 136 Audi Audi: A History of Progress Chronicle ot audi AC Aude AG ISBN 0 83761036-2 ‘Audi AG Etecticl Wiring Manual 198. 2000 Boney Pushers SBN SS76-C166 3 Aa Lit No. EWM AG982000 ‘Avi Ad Service Mana 19962001, 1.8L Turbo, 28 including Avantand quatro ery Paso 3ON OS 7ON7S ‘AS it No WABAUANSS2001RN ‘Audi A4/S4, 19962001 Offical Factory Repair Manual on CD-ROM ‘Au of Ameren SBN 08376-10729 ‘uci Lit No; We ABBA VO2SCD ‘Audi TT Coupe: 2000-200, Roadster: 2001- 2001 Onticial Factory Repair Manual on cb'kom ‘Redo Amerie ISBND 3760745 ‘Ruch Lit'Noc WS2ATI8025CD ‘suai 90 19981995 Oficial Factory Repaic Manual on CD-ROM Andiof Ameren SBN 08076-0882. ‘hud Lit No: WA ABSO VO25CD ‘Au 100,200 Oficial Factory Repair Manas 1989-1991, including 100 Quateo, 201 Quatro, Wagon, Turbo and 20aive ‘Aut of Aneta BON SSRTE INTE 2 ‘nua Pact No: LPV 80070 ‘Audi 0005, 5000CS Oficial Factory Repair Manual 193-198, Gasoline, Turbo, and ‘Turbo Dice including Wagon and Qua idof Amertr SBN 0 876-0376 ‘hut PartNo tPV 80058 Engineering Bosch Fuel Injection and Engine Management sO. Dob SAE son esses Maximum Boost Desigaing esting and Installing Turbocharger Systeme Corky Bal ISBN 08376-0160-6 ea seins AUTOMOTIVE REFERENCE Bentley Publishers has published service ‘mantalsand automobie books since 1950, Please write Beetley Publishers at YPM Massachusetts Avenue, Cambridge MA (21% esitourweb site at www BerloyPublishers.com orca 1-800-123-4595 fora fee copy of on complete catalog,Volkswagen Vanagon Official Factory Repair Manual 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991 Including Diesel, Syncro and Camper [B] BentteyPubtishersB re Techical Contet nfrmaton BENTLEY. PUBLISHERS” | Automotive Reference” ‘We value your teedoack. Technical comments and suggestions aro elplua us. Please post your comments to Sey Paster vn of Reet Betty, ‘ur technical decussion forums. atlas ere i www-Bent leyPublishers..com/tech baoaaa.tinetgr?surat70 te ditrerces From time to time, updates may be made to this manual ‘isting of updates can be found on the web a: BentleyPublishers www. Bent leyPublishers .com/updates WARNING—important Salety Notice Do not use this manual unless you are familar wth basic aulomotive cepair procedures and safe workshop practices. This manual illustrates the workshop procedures required for most service work; isnot a substitute for full and up-to-date information from the: vehicle manufacturer o for proper training as an automotive technician, Note that its nck possible for us to anticipate al of the ways Cr conditions under which vehicles may be serviced or to provide cautions as to all af the possibie hazards that may result “The vehicle manufacturer will continue to issue service information updates and paris retrofits after the edaral dosing of this manual. Some of these updates and revofts will apply fo procedures and specificaions in this manual, We regret thal we cannot ‘Supply updates to purchasers of this manual We have endeavored to ensure the accuracy ofthe information in this manual, Please Note, however, that considering he vast |quanty and the complexity of the serve information involved, we cannot warrant the accuracy or completeness of the information Contained inthis manual FOR THESE REASONS, NEITHER THE PUBLISHER NOM THE AUTHOR MAKES ANY WARRANTIES, EXPRESS OR IMPLIED, THAT THE INFORMATION IN THIS BOOK IS FREE OF ERRORS OR OMISSIONS AND WE EXPRESSLY DISCLAIM THE IMPLIED WARRANTIES OF MERCHANTABILITY AND OF FITNESS FOR & PARTICULAR PURPOSE, EVEN IF THE PUBLISHER OR AUTHOR HAVE BEEN ADVISED (OF A PARTICULAR PURPOSE, AND EVEN IF A PARTICULAR PURPOSE IS INDICATED INTHE MANUAL. THE PUBLISHER AND AUTHOR {ALSO DISCLAIM ALL LIABILITY FOR DIRECT, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH RESULT FROM ANY | USE OF THE EXAMPLES, INSTRUCTIONS OR OTHER INFORMATION IN THIS BOOK. INNO EVENT SHALL OUR WABILITY WHETHER IN TORT, CONTRACT OR OTHERWISE EXCEED THE COST OF THIS MANUAL. Your common sens® and good judgment are crucial 10 sale and successful service wotk. Read procedures through before stating them. Think about whether the condition of your car, your level of mechanical ski, or your level or reading comprehension might result in or conto in some way to an accurrenee which might cause you injury, damage your car, or result in an unsafe repat. you have doubts for these or other reasons aout your ably fo perform safe repair work on your car, have the work done at an authorized Volkswagen dealer or other qualified shop. Part numbers listed in this manual are for identification purposes cnly, not for ordering. Always check with your authorized Volkswagen dealer to vey part numbers and availabilty before beginning service wark that may require new parts. Belore attempting any work on your Volkswagen, read the warnings and cautions on pags'x and x and any warning or caution thal accompanies a procedure in the service manual. Review the wamings and cautions on pages ix and x each time you prepare ‘o:work on your Volkswagen. ‘Special to's required to perform certain service operations are identiied in the manual and are recommended for use, Use tf tools cther than those recorertended in this service manual may be devimental o the cars safe operation as well as the safety of the ‘person servicing the car. Coples of this marual may be purchased from authorized Volkswagen dealers, most automotive accessories and parts dealer specializing in Volkswagens, trom selected booksellers, or directly trom the publisher by mail s The publisher encourages comments from the reader of this manual. These communications have been and will be carefully Considered in the preparation ofthis and other manuals. Please write to Robert Bertley Inc. at the adress listed on the top this page Library of Congress Catalog Card No. 91-74020 ISBN 0-8576-0336-6 \VWo Part No. LPV 800 148 WC Inc. Part No. MAN 101 251F Bentley Stock No. VV3t 1009080705050 1514191211 ‘The paper used inthis publication is acid free and meets the requirements of the National Standard for Information Science: Permanence of Paper for Printed Liorary Materials. (>) © Copyrignt 1991 Volkswagen United States, Inc. Eaitoral closing July 15, 1991 of All rights reserved. All information contained in this manual is based on the information available to tne publisher atthe time of editorial casing. The right is reserved to make changes at any time without notice. No part of this publication may be reproduced, slored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, oF otherwise, without the prior written consent of the publisher. This includes text, figures, and tables. All rights reserved unde Berne and Par-American Copyright conventions. Manufactured in the United States of AmericaForeword vit Wamings and Cations je ‘yp0 Mosel dentcaton age 2 Ui Engine No. Foe 2 General ‘Taras No autora eve 4 Lita car ith oor iach page 6 “owing or eae S Repair Groups Engne—Assembly 0 ‘ramcantiGranicase 8 Shaner Heace ave Bie 8 tester Systm 3 . Cooing Syste % Fut Suny B Engine toys Sas Si 8 Fuster Are Sytem a Furl Wecton —Watorcoows a Esraus Sytemmesen Coir i Etctcal~oatory Stara, Anema a ignion Stem Es Cuten contot 0 Sorave Converter 2 Clutch Tia ennai Aariy ® issi ose, Gear, Sate os Transmission Automatic Ransmission Contos, Asse a7 Gece, Gear, Shas a biterentit = i Front Whee! Suspension—Shafts and Axle 40 Suspension Fea wheel Suspersion—Shafs ana Ate 2 ‘else! Alger a Brakes hes’ Mechanca Gongenens & i thawte Component, Regios Soci o Steering Steering i 8 Soay Drnoneane Es Hoodstuse a 8 Sea Hoa a a Sg a ‘Sunroof = 60 Este = rea Same Vd Regios : e Body Sp eee % co et Sy Heater Ten itror : % 355) Sai potion i Saba ole an: st 8 ‘Gaines, Weer Tank Rigen me Seas bods ° Hostenwnaion @ tester Beste connn CS! & man nado 0 , Minch ie i shar @ Electrical UphteExoror o wes Hs - Vice Cae 1 Appendix Dertyourset Senice > “ectel Oa & Mannan Tabi aForeword Service to Volkswagen owners is @ top priority of Volkswagen organization and has ‘always included the continuing development and introduction of new and expanded servic 2s. In ine wit this purpose, Volkswagen United States, Inc. has introduced this Volkswagen Official Factory Repair Manual. ‘This Vanagon manual covers the model years 1980 through 1991 including Air-cooled ‘and Water-cooled Gasoline Engines, Diesel Engina, Synero and Camper. This manual was specifically written to cover US, and Canada models only. For the Volkswagen owner with basic mechanical skills and for independent garage this manual gives all the specifications and procedures that were available in an authorized Volkswagen service department as this manual went to press. In adltion, the Volkswagen ‘owner who has no intention of working on his or her vehicle may find that reading and own- ing this manual will make it posswle tobe better informed and to discuss repairs more intel- ligently with a professional automotive technician ‘This manual has been prepared from the repair information thatthe Volkswagen orga- nization provides to its own factorytrained technicians and has been developed primariy With the professiona! automotive technician in mind, The aim throughout has been clarity and completeness with step-by-step procedures and accurate specifications. ‘The Volkswagen owner intending to do maintenance and repair should have a set of ‘metric wrenches and sockets, a torque wrench, screwckivers, and feslar gauges, since these basic hand too's will be used for a majority of the repairs described in this manual Usually, the text will note when a repair requires special tools, ‘This manual is organized so that, whenever possible, when a change has been made within a model year, the vehicle identification number (VIN} of the first vehicle with this change is given. The lgits you need to know for this parts and service information are taken from the seventeen digit VIN number. If, for example the VIN is WWWZZZ24Z8H000001, you will need only nine ofthe last eleven cigits ofthis number—or, more specifically, the dig- ts 24 B 000001. Your Volkswagen's VIN is found on the left dooriamb ana on a plate mount-ed on the driver's side of the instrument panel padding where the number can be seen through the windshield. The VIN assigned to Vanagon model for the years 1960 through 11991 which are covered by this manual are: 1980: -25.A.000001 to 25_A 999099 1981: ___26.B 000001 to 25_B_999999 1082: '25.C_000001 to 25.0 939999 1983: '25.D_000001 to 25_D_s99999 198: 25 E 000001 to ~25_£ 999999 1985: “24 F_000001 to 24 F_gagg9 “25_F 000001 to 25 F_99a909 1986: 246000001 to “24 G_999999 725.6 om001 to 25_G_999909 1987: 24 H_000001 to —24_H 999099 '25_H_ 000001 to 25 H_999999 1988: —24-4.000001 to 24_J 999099 -25.J.000001 to —25_J 999999 1289: (24 K_000001 to ______24 «999909 225k 000001 to ~25_K_ 992909 1990; "24 000001 to 24 | 999999 251000001 to © ______25 L_999999 1991: '24.N_000001 to 24 _M_999999 25000001 to 25 M_999999 We have endeavored to ensure the highest degree of accuraey possibile. When the vast array of data presented inthis manual is taken into accotat, however, no cai to infal tbilty can be made, We therefore cannot be respensible forthe result of any efrors that may have crept into the text. The Publisher encourages comments from the readers of this man- ual in regard to any erfors and, also, suggestions for improvement in the preservation of the technical material, These communications have been and will be carefully considered.in the preparation ofthis and other manuais, Please write to Robert Bentley, Inc., Cambridge, Mas- sachusetts 02138 Volkswagen offers extensive warranties, especially on components ofthe fuel delivery and emission control systems. Therefore, before deciding to repair a Volkswagen that may sill be covered whalty or in part by any warranties issued by Volkswagen United Statas, inc, consult your autharized Volkswagen dealer. You may find that he can make the repair either free or at minimumcost. Regardless ofits age, or whether itis under warranty, your Volkswa- {gen is both an easy vehicle ta service and an easy vehicle to get serviced. So it st any time a repairis neaded that you feel is%00 dificult o do yourself, a trained Voliswagen technician is ready to do the job for you. Robert BentleyPlease read these warnings and cautions before proceeding with maintenance and repair work. WARNING— © Some repairs may be beyond your capability. I you lack the skis, tools and equipment, or a suitable workplace for any proce- dure described inthis manual, we suggest you leave such repairs ton authorized Volkswagen dealer service department, or other qualified shop. © Volkswagen is constantly improving its cars. Sometimes these ‘changes, both in parts and specifications, are made applicable fo ‘earlier models. Therefore, belore starting any major jobs or repars to companents on which passenger safety may depend, consult Yyour authorized Volkswagen dealer about Technical Buléins that may have been issue since the editorial closing ofthis manual ‘© Donot re-use any fasteners that are worn or deformed in normal use. Many fasteners are designed to be used only once and become unreliable and may fail when used a second time. This includes, but is not limited to, nuts, bolts, washers, se-locking ‘us or bots, circips and cotter pins. Aivays replace these fasten: ers with new parts (© Nover work under a ited car unless its solidly supported on stands designed for the purpose. Do not support a ear on cindar blocks, hollow ties or other props that may crumble under contin~ uous load. Never work under a car that is supported solely by & Jack. Never work under the car while the engine is running. © tyou are going to work under @ car on the ground, make sure that the ground islavel. Block the wheels to keep the car from rol ing. Disconnect the baltery negative (-) terminal (Ground strap) to prevent others from starting the car while you are under i. © Never run the engine unless the work area is wall ventilated Carbon monoxide kis «© Finger rings, bracelets and other jewelry should be removed so, that they carwiot cause electrical shorts, get caught in running machinery, or be crushed by heavy parts. ‘© Tio long hair bohind your head. Do not wear a nackte, @ scart. loose clothing, ora necklace when you work near machine tools of running engines. It your hair, clothing, oF jewelry were to get caught in the machinery, severe injury could result {© Do not attempt fo work on your arf you do nat feel wel. You increase the danger of injury to yourself and others if you are tired, upset or have taken medication or any other substance that may k20p you from being fully alert. ¢@ thuminate your work area adequately but safely. Use a portable ‘safety igh! for working inside or under the car. Make sure the Bulb is endesed by a wire cage. The! lament ofan accidentally bro- ken bulb can igrte spied fuel oro (© Catch draining fuel, oes brake fuid in suitable containers. Do ‘ol use food or beverage containers thal might mislead someone into drinking from them. Store flammable uid away from fire haz- ards. Wipe up spils at once, but donot store the oly rags, which can ignite and bum spontaneously. ‘© Aiways observe good workshop practioas. Wear goggles when you operate machine tools or work with baitery acid. Gloves or ‘other protective clothing should be worn whenever the job requires ‘working with harmful substances, (Friction materials such as brake or clutch discs may contain asbestos fibers, Do not create dust by grinding, sanding, or by Cleaning wth compresses air. Avoid breathing asbestos fibers and ‘asbestos dust. Breathing asbesins can cause serious diseases, ‘such as asbestosis or cancer, and may resin death © Disconnect the battery negative (-) terminal (Ground strap) ‘whenever you work on the ful system or the elactrical system. Do nt smoke or work near heaters or other fire hazards. Keep an ‘approved fre extinguisher handy. ‘© Batteries give off explosive hydrogen gas during charging. Keep sparks, ignted matches and opan llama away from the top fof the battery I hydrogen gas escaping trom the cap vents is ignited, it wil ignite gas trapped in the cells and cause the battery oexpiode, ‘© Connect snd disconnect battery cables, jumper cables ora bat- tery charger only with the ignition switched off, to prevent sparks. ono! disconnect the battery while the engine is running {© Do not quick-charge the battery (for boost stating) for longer than one minute. Wai a! least one minute before boosting the bat tery @ second time, ‘© Donot allow battery charging voltage to exceed 16.5voll. ithe battery bagins producing gas or boiling violently, reduce the charg: ing rate, Boosting a sulfated battery at a high charging rate can ‘cause an explosion {© The air-conaltoning systom is filed with chemica! refrigerant, which is hazardous. The AC system should be serviced only by trained technicians using approved refrigerant recovery/recycting ‘equipment, trained in related safety precautions, and familar with, regulations governing the discharging and dispesal of automotive comical refngerants, ‘© Do not expose any part of the AVC system to high temperatures such as open flame. Excessive hea wil increase system pressure ‘and may cause the system to burs © Some aérasol tie intlatars are highly flammable. Be extremely, cautious when repairing a tre that may have boen inflated using ‘an aerosol tire inflatr. Keep sparks, open flame or other souroas, ‘of igniton away from the tire repair area. Inflate and deflate the tire atleast four times before breaking the bead from the rim. Com: pletely remove the tre from the rim betore attempting any repair, ‘© Some cars covered by this manual are equipped witha supple ‘mental restraint system (SRS), thal automatically deploys an airbag in the event of frontal impact. The airbag is inflated by an ‘exlesive device. Handled improperty or without adequate safe- (uards, it can be accidently activated and cause serious injury, ‘© Greases, ubricants and other automotive chemicals contain toxic substances, many of which are absorbed direct through the skin. Read manufacture’ instructions and wamings carefully Use hand and eye protection. Avoid direct skin contact. continued on next pagePlease read these warnings and cautions before proceeding with maintenance and repair work. ‘cAUTION— © I you lack the skis, tools and equipment, or a suitable work- ‘shop for any procedure descrited in this manual, wo suggest you leave such repairs to an authorized Volkswagen doalor or other qualified shop. ‘© Vokswagen offers extensive warranties, especialy on compo: nents of uo! delivery and emission contol systems. Therefore, betore deciding to repair a Volkswagen that may stil be covered ‘wholly or in part by any warranties issued by Volkswagen United States, Inc, consult your authorized Volkswagen dealer. You may {ind that he ean make the repat tor free, or at minimal cost. «© Volkswagon part numbers listed inthis manual are for identiica- tion purposes only, nol for ordering, Always check with your authorized Volkswagen dealer to verily part numbers and avail ablity batore beginning service work thal may require new pars (© Belo starting job, make certain that you have all he neces- sary tools and parts on hand. Read all the instructions thoroughly, 4 not attempt shortcuts, Use tools appropriate to the work and Use only replacement parts meeting Volkswagen specications, Makeshi tool, parts and procedures will not make good repairs © Use pneumatic and electric tools only o loasen threaded parts ‘and fasteners. Nover use these tools to tighten fasteners, espo- cially on light alloy parts. Always use a torque wrench to tighten fasteners fo the lightening torque specification listed. ‘© Be mindful of the environment and eoology. Before you dain the crankcase, ind out the proper way to dispose of the oi. Do not pour oil onto the ground, down @ drain, or into stream, pond of lake, Consult local ordinances that govern the disposal of wastes. ‘© On cars equipped with anti-theft radios, make sure you know the correct radio activation code before disconnecting the battery ‘oF removing the rao. I the wrong code is entered into the rad when powor is restored, that radio may lock up and be rendered inoperable, even if the correct code is then entered. ‘© Connect and disconnect a battey charger only with the battery charger switched of 1 Do not quick-charge the battery (for boost starting) for longer than one minute, Waitt least one minuto before boosting the bat- tery a second time. €@ Seated or ‘maintenance ree" batteries should bo siow-charged, only, at an amperage cate that is approximately 10% of the bat- tery’s ampere-hour (AN) rating ‘© Donot allow battery charging voltage to exceed 16.5 vols. the battery begins producing gas or boiling violently, reduce the charg ing ale. Boosting a sulfated battery at a high charging rate can cause an explosion.Index warwna — * Automosve service and repairs sarous ‘business. You mustbe aon, use conmon ‘sense, and exercise good judgement! fo Drevent personal nry and compete the ven ala * Before begining any work an your Vokswagen, thoroughly read all the CCautons and Warnings isted near the ont ofthis manual Aways raad the complete procedure bbolore you begin the work. Pay special attention to any Cautens and Warnings ‘mat accompany that procedure, cr hor information ona specif enc Air Conditioner ‘Adapter valve VAG 1637 installing 87.18 —Air distribution system ‘components 87.9 —Component locations 87.2 ‘Compressor (Sanden $0510) replacing 87.16 Evaporator removinginstaling 87.14 — Evaporator housing disassembling/assembling €7.12 removing 87.10 Expansion valve removing/installing 87.14 Fuses, locations 87.4 —Refrigerant system ‘capacity 87.7 cautions and warnings 87.7 controls 87.6 discharging 87.8 —Rolays, locations 87.5 Alignment See Wheels Alternator —Alternator/Regulator necking 27.18 Heater blower fan removing/replacing 27.22 — Indicator light, troubleshooting 27.23 Mount, adjusting 27.22 —Removing/installing 27.15 Repairing 45A, 65A 27.16 904 27.17 System layout 27.19 —Vebett adjusting 27.21 replacing 27.21 —Voltage regulator 27.20 Battery Charging 27.5 —Checking 27.4 Battery (Cont'd) Electrolyte level 27.4 thes caps 27.7 Location(s) 27.8 Nomenclature 27.2 —Salety precautions 27.4 — Troubleshooting 27.10 Body —Acid rain, removing spots 50.6 — Adhesives materials 50.5 —Body Dimensions door 50.4 floor 50.2 windshield 50.4 —Painting pop-up rootiluggage carrier 50.5 —Plasties, ideniying 50.5, repairing 50.5 Brakes—Hydraulic Components, Regulator, Booster —Brake booster assembly 47.10 ‘chocking 47.10 —Brake caliper Girling (1980-1985) assembly 47.5 Girling Teves (1980-1985) disassembiinglassembling 47.6 GirlingTeves (trom 1986) assembly 47.7a Teves (1980-1985) assembly 47.4 Teves (1980-1985), noise dampening plates 47.7 —Brake fluid, changing with US 1116 47.8 without US 1116 47.8 —Brake hydraulic systom general repair notes 47.8 Brake master cylinder assembly 47.2 Brake prossure regulator checking 47.88 —Brake system, bleeding with US 1116 47.8 without US 1176 47.8a Cheek valve checking 47.10 —Rear wheel cylinder assembly 47.8 Brakes—Mechanical Components —Brake pedallinkage assembly 46.10 —Front brake assembly (1980-1985) 46.2 assembly (Irom 1986 my.) 46.5 pads (1980-1985) emovinglinstaling 46.3, ppads (rom 1986 my.) remevinglnstaling 46.53 —Parking brake assombly 46.11 —Rear brake assombly 46.6 shoes, adjusting 46.9 shoes, removingiinstaling 46.7 Bumpers —Front bumperispoller 63.2 ~ Roar bumper 63:3, Camper Equipment —Calling cabinet with A/G, installing 76.9 with A/C, comoving 76.7 without VC, removing/instaling 76.6 Clothes closet instalng 76.11, 76.14 removing 76.9, 76.11 —Cunains: removing/installing 76.3 Curtain rail wresh air duct installing 76.6 removing 76.5 Propane tank removingiinstaling 76.23, —Refrigerator ‘lt supply modification 76.25 Instaling 76.25 omoving 76.24 —Sink cabinet Installing 76.23, removing 76.15 Storage chest wiwater tank instaling 76.17, removing 76.15 —Storage shell removinglintaliing 76.2 wicurtain rod removinglinstaling 76.4 —Water faucet wipump switch removinglinstalling 76.20 —Watertevel sensor removinglinstaling 76.20 —Water pumpikitchon removing/instaliing 76.18 clutch — Bearing shaft bushing Syncro 80.9 —Brake/Giutch uid reservoir 30.3, Clutch assembly diesel 30.5 gasoline 90.4 ‘Synero 90.10 Controls 30.2 ‘Synero 90.8 Diaphragm spring 30.6 ‘Synero 90.11 Hydraulic system 30.2 ‘Syncro 90.8 —Pressure plate 30.6 air-cooled modification 30.6 Synero 30.11 —Release bearing 90.7a air-cooled only 30.7, —Release shaft bushing 30.3 Synero 30.9 Roll pin 90.3 xiIndex Cooling System—Air-cooled AFC — Cooling air control fap gusting 19.3, Cooling fan removing 19.3 Fan housing assembly 19.2 removing 19.3 —Snap-lock wiring connectors instaling 19.19 Thermostat checking 19.3 —Vebelt assembly 19.2 tension, adjusting 19.9 Cooking System—Diesel —Aniifreeze hydrometer ‘checking 19.7 Coolant assembly 19.4 draining/fling 19.6 mixtuee ratio 19.5, pipes, replacing 19.7 Snaprlock wiring connectors instaling 19.19 Pressure cap, checking 19.7 Cooling System—Water-cooled —Antilreeze hydrometer checking 19.17 Coolant assombly 19.8, 19.11, 19.14 drainingfiling 19.15 ‘expansion tank, checking 19.18 hhose layout 19.10 leak checks 19.17 mixture ratio 19.18 refill tank 19.9, 19.13, Hose spring clamps removing/nstaling 19.16 Hot footwell kit, instaling 19.20, —Radiator assembly 19.12 therma-switeh 19.12 Cruise Controt — System, repairing 27.25 Troubleshooting 27.29 Current Flow Diagrams ‘See Electrical Wiring Differential—Automatic Trans. — Adjusting ring 38.51 —Assombly 99.56 —Cover plate 39.51 — Differential bearing outer race 99.53 —Drive flange oil seal 39.53 Final dive assembly 39.50 —Govemor oll seal 93.52 —Pinion bearing ‘nner race 39.54 ‘outer race 39.53. ~Pinion oll seals 39.52 Ring gear 39.56 Ditferential—automatic Trans. (cont'd) Ring gear/pinion adjusting 39.57 backlash 39.61 —Torgue converter ol seal 39.51 Differentiat—Manual Trans. 031, 081/1, 4 Speed 094 5-Speed (except aW0) — Assembly 39.2 — Bearings 39.5, — Housing 39.3, Pinion, adjusting 39.10 — Pinioa’Side goars 99.6 —Ring gear 99.3 adjusting 9.12 backiash 39.13 — Ring/Pinion gears adjusting 39.7 —Shim 8939.11 Ditferontiat—Manual Trans. (094 5-Speed with 4WD = Differential with lock assembly 39.20 bearing outer race 99.24 bearings 39.21 housing 39.21 pinion shafts 99.22 ring gear 89.20 —Diflerential without lock assembly 39.15, bearing outer race 99.19 bearings 39.16 housing 39.16 pinion shafts 99.17 fing gear 39.15, ~Driveshalt flange ol seal 39.44 removingfnstalling 39.43 —Front final drive 39.30 adjusting rings 39.92, axle flange 39.32 circlip 39.93 housing 39.94 mounting 39,32 technical data 39.42 Front pinion 39.99 bearing 39.40 grooved nut 39.40 turing torque 99.41 Locking pin 39.28 Pinion/Side gears 99.25 —Removing 39.33 Ring geaniPinion aghusting 39.26, Do-it-yourself Service (Appendi Changing a wheel A21 Emergency starting A25 —Fusos A22 Headlight adjustment A25, Do-it-yourself Service (Appendix) (cont'd) — Jack and tools A20 —Replacing bulbs 23 —Spare wheel A20 Doors—Front — Adjusting 57.5 Assembly 57.2 Glass 57.4 — Guide channel 57.5 Handles 57.3 —Lock/Lock rod $7.3 LosvBroken keys ‘code location 57.8 —Power door locks 57.6 —Whisting noises: eliminating 87.10 Window regulator 57.4 Doors—Rear Center hinge adjusting 58.9 assembly 58.8 Femovinginstalling 58.9 — Sliding door 1980-1984 bowden cables, adjusting 68.7 door cover 58.3 door handle inner/outer 58.3, door lock buller 58.3 lock, front 68.2 lock, ear 58.6 lock plate, remote control 58.6 lubricating 58.7 removinginstaling 58.4 striker pate, adjusting 58.5 Sliding door, from 1985 ‘assembly 58.10 ‘central lock 58.20 ‘door cover 58.11 handle 58.22 hinge link, adjusting 58.16 hinge link, assembly 58.21 modifications 58.11 remote control lock 58.18 removiaginstaling 58.12 roller guides, adjusting 58.14 striker pin, adjusting 58.15, Electrical Witing—Air-cooled AFC = 1980, 1951 cautions and warnings 97.2 fresh air fan 97.23 fuse/relay panel 97.10 heater booster 97.24 main wiring ciagram 97.12 rear window wiper 97.26 seat belt interiock system 97.27 — 1982, 1983, cautions and warnings 97.2 ‘resh air fan 97.28 fuse/relay panel 97.10 heater booster 97.24Index WARNING — * Automotve sanioe and roparissoraus business. You mus be lor use common sense, and exercise good judgement fo prevent personal nix and come the ‘work saa * Before beginning any work on your Volkswagen, thoroughly read all the Cautions and Warnings sted near the front of his manu * Always rad the complete procedure olore you begin the work. Pay spacial attenton to ary Cautions and Warnings ‘hat accompany tha procedure, or other information ona specific topic. Electrical Wiring—Alr-cooled AFC (cont'd) 1982, 1988 (cont'd) main wiring alagram 97-18 rear window wiper 97.26 ‘seat bot interlock system (1982 only) 97.27, Electrical Wiring—Camper — Auxiliary battery 1986-1989 (rman. trans.) 97.34 (also see 97.53) — Battery level indicator lights 97.90 —Camper elecitical equipment 11980-1985 97.52 from 1986 97.33, —Water pump 97.91 —Water tank level indicator lights 97.90, Electrical Wiring—Diesel —1982 auxiliary heater BAS (Canada only) 97.47 cautions and wamings 97.2 fuselrelay panel 97.10 heater booster 97.49 ‘main witing diagram 97.96 current track index 97.96 rear window wiper 97.26 1983 auxiliary heater BAG (Canada only) 97.47 cautions and warnings 97.2 fuselrelay panel 97.10 healer booster 97.49 ‘main witing diagram 97.41 ‘current track index 97.41 rear window wiper 97.26 Electrical Witing—General —Battery/Ground cables 97.94 isconnecting/cannecting 97.6 Cautions and Wamings 97.2 — Dashboard wiring harness 97.7 —Engine’eody ‘ground connections 97.6 Electrical Wiring—General (contd) —FuseiRelay panel, removing 1980-1985 97.10 from 1986 my. 97.108 —How to read wing diagrams 97.4 Main wiring hamess 97.8 Starter cable routing 97.9 — Symbols used in wiring diagrams 97.5, Troubleshooting 97.3 —Working on the electical system 97.9 Electrical Wiring—Water-cooled ‘Ar conditioning, 1984, 1985 97.137 1986-1988 97.139, trom 1989 97.142 —Aulomatic transmission 1986-1989 97.146 from 1990 97.219 —Auxilary battery 1986-1989 auto. trans, 97.221 from 1990 97.224 ‘See also 97.29 —Auxiiary heater BAS {rom 1987 Canada only 97.148, —Auxilary heater BBW46 {Syncro) 4986-1988 Canada 97.181 from 1989 Canada 97.155 —Central locking system 1986 97.165 4987-1989 97.162 from 1990 87.226 —Crankcase ventilation heat element 1985 97.165 1986 97.168, Cruise control ‘auto. trans. 1986 97.168. 1987-1989 97.176 from 1990 97.229 — Cruise control man. tans. 1986 97.174 1987-1989 97.171 {rom 1990 97.232 Daytime running ights (Canada) 0 Dec. 1989 97.204 ‘rom Dec. 1989 to May 1990 97.298 from May 1990 97.241 Differential lock 41986-1989 Syncro 97.178 —Heated driver's seat 1986 97.179 4987-1989 Canada 97.181 from 1990 Canada 97.244 —Main wiring cbagram 1983, 1984 97.54 1985.97.60 1986 up to VIN G 055 689 97.67 Electrical Wiring—Water-cooled (cont) —Main wiring diagram (cont'd) from VIN G 055 690 97.85, 1987 97.102 1988, 1989 97.119, from 1980 97.201 Power mirrors 1986 up to VIN G 105 000 97.183, 1986 from VIN G 105 001 97.185 from 1987 97.185 —Power windows. 11986 97.187 {rom 1987 97.188 —Radio 1986 97.191 Rear footwell heater blower 11983-1985 97.194 - Stereo radio 1987-1989 97.195 —Stereo radio with ampitied speakers from 1988 97.197 Stereo radio with 4 speakers from 1990 97.246 —450-Walt radiator cooling fan 1986-1989 97.200 Emission Controls — Air-cooled AFC Cali, 1981 26.4 Cali except 1981 26.8 Catalytic converter checking 26.11 EGR vaive 26.5, USA (except Cali) ‘and Canada 26.2 — Diesel 26.6 —Water.cooled Digitant assembly 26.9 (Oxygen sensor ‘water-cooled Digjet 26.8 Engine—Air-cooled AFC — Assembling crankcase 13.6, 13.14 ‘sheet metal 13.2 —Camshatt 13.14 Carton deposits, reducing 15.25 —CarrierSuppon 13.5 ‘Compression pressure checking 15.2 valves 2a —Connecting rod 13.16 Crankshaft assembly 19.16 ciclips 13.16 fend play 13.10 oll seals 13.9 pilot bearing 18.17 Cylinder 13.11 Cylinder head 15.2 —Disassembling crankcase 13.6 sheet metal 13.2 xiiiIndex Engine—Air-cooled AFC (cont) — Distributor five gear 13.16 tiveshatt 13.8 instaling 13.8 —Flywhee! 13.9 — Gasoline aditive 15.25 —Hydrauie valve liters 15.6 —Instaling 10.5, —Lubscation assembly 17.2 ‘i cooler 17.2 oil pressure switch 17.2 oll pump 17.2 Piston rings 13.11 —Pistons 13.11 —Removing 10.2 Rocker arm shalt 15.3, —Torque converter drive plate 13.9 —Valves assembly 15.2 dimensions 15.3 guides 15.4 hydraulic ilters 15.6 seats 15.4 springs 15.2 Engine—Diese! Camshaft assembly 15.10 end play 15.15 oll seal 15.15 radial clearance, checking 15.158 run-out 18.15 Camshaft drive belt 13.18 — Compression pressure checking 15.16 values 2a Connecting rod 13.27 bearing clearance 13.30 bolts 13.30 side clearance 13.30 —Crankshalt 13.22 boaring caps 19.22 rive belt cover 19.21a ond play 13.24 journal sizes 13.28 main bearing clearance 19.25, oil seal drive belt side 13.26 flywheel side 13.25 sprocket bolt 13.21 Cylinder block 13.27 bore dimensions 13.30 clearance 13.30 Cylinder head assembly 15.8 botts 15.9 distortion 15.11 gasket 15.9 Cylinder head gasket 13.19, 13.31 —Fiywheol 13.28 Installing 10.7 — Intermediate plate 13.23 Engine—Diesel (cont'd) Intermediate shatt oll seal 13.22 Lubrication system assembly 17.4 cil cooler 17.4 oil fiter 17.4 il pan 17.4 «il prossure switch 17.4, 17.6 cil pump 17.4 —Pilot bearing 13.22 —Piston 13.27 clearance 13.29 diameter 13.29 height 13.31 identication 13.31 marking 19.28 pin 13.28 fing end gap 1829 ring side clearance 19.29 fings 18.27 —Removing 10.6 —Valve assembly 15.10 Engine—Water-cooled — Assembling’ Disassembling 13.32 —Camshat 13.50 — Carbon deposits, reducing 15.31 Cartier Support 13.974 — Compression pressure checking 15.20 values 2a —Crankzhaft assembly 13.52 circlips 13.54 rive gear 13.54 end play 13.40 oilseals 13.39 pilot bearing 19.56 replacing (1.9L) 13.87 Cylinder 13.43 — Cylinder head assembly 15.17 installing 18.23 sealing 15.23, 15.26 Distributor drive gear 19.38 driveshaft 13.38 instaling 18.98 Engine block assembly 18.22 — Fiywhoo! 13.40 Gasoline adcitive 15.31 —Instaling 10.10 ~ Lubrication system assembly 17.7 crankcase breather, heating pipe 17.9 oilpressure switch 17.9 olipump 17.9 — Piston pin hole burs removing 13.47 — Pistons 13.43, Gassifications 13.44 pin 13.44 rings 18.45 Engine—Water-cooled (con's) —Pushrod tubes replacing 15.25 —Removing 10.8 — Torque converter drive plate 13.40 —Vbelt pulley 13.94, 13.42 —Valves assembly 15.17 dimensions 15.18 guides 15.20 hydraute liters 18.29 seats, refacing 15.18 springs 15.18) Exhaust System Air-cooled AFC Cali. 1981 26.4 Call. except 1981 26.3 USA (except Cali) ‘and Canada 26.5 —Calaiytic converter checking 26.11 Diesel 26.6 —Onygen sensor water-cooled Digjot 26.8 —Water-cooled Digitant 28.9 Digit 26.7 Fuel Injection—Air-cooted AFC —AFC system check 24.15 —Airfter housing 24.8 —Ausiliary air regulator 24.8 —Cold-start valve 24.5 —Control unitWiring hamess 24.12 —Deceleration valve 24.7 — Double relay 24.13 —Full throttle enrichment switch 24.13, —lIdle speediC0 24.10 — Injector resistance 24.6 — Injector spray pattern! leak checking 24.7 — Intake air sensor housing 24.8 — Intake aishemp. sensors 24.9 — Oxygen sensortWiring 24.16 — Pressure regulator 24.5 —Spood limit switch 24.14 —System components 24.2 Call. 24.4 USA (except Cali) and Canada 24.3, —Temperature sensor 126.13 —Thermortime switch 24.6 —Voliage supply/ series resistance 24.6 Fuel Injection—Diesel Cold start cable 23.5, —Engine speed 23.5 Fuel cut-off solenoid 23.5, —Fuol delivery valvernousing 23.7 xivIndex warnina — ‘Automotve sarice and eparissereus business. Younus be ale, use common sense, and exercise good jxdgement fo prevent personal nix and complete te work say + Before beginning any wore on your Volkswagen, thoroughly read all the CCautons and Warnings listed near the ont of his mara * Aways read the complete procedure bolore you bagin the work Pay special attention fo any Cauts and Warnings ‘ha accompany tha procedure, or other infermation ona spect topic. Fuol Injection—iese! (cont'd) —Fus! fiter water indicator kt installing 23.10 Fuse! injectors 23.8 —Injection pump 23.6 —Injection pumpvalve timing 23.3, — Injection system 23.2 Injection timing 23.4 Fuol Injection—Water-cooled Digitant —Daceleration tue! shutoff 24.60 Electrical testing 24.61 —Fue| injection system ‘components 24.48 repairing 24.46 Fuel injectors, checking 24.56 —Full throttle enrichment ‘checking 24.60 —lIdle speed/CO content ‘checking/adjusting 24.50 Ide stablizer checking 24.53 Intake air sensor ‘checking 24.57 Oxygen sensor ‘checking 24.54 —Pressure regulator checking 24.55 —Satety precautions 24.42 —Technical data 24.43 —Throttle valve basic adjustment 24.37 Throttle valve switeh 24.58 Fue! Injection—Water-cooled Digijet Air filter housing 24.27 Auxiliary air regulator 24.27 Control univWire hamess 24.31 checking 24.95 —Data/Speciications 24.18 — Double relay 24.32 — Fue! injoctors 24.25 troubleshooting 24.38 Fuel Injection—Water-cooled Digit (cont'd) — Full throtle enrichment switch 24.34 checking/adjusting 24.29 —Idle speed’co checkingladjusting 24.29 — Intake ait sensor 24.28 housing 24.27 Pressure regulator 24.25 — System check 24.20 ‘System components 24.22 ‘early version 24.24 late version 24.24a — Temperature sensor | 24.28 — Temperature sensor ll 24.32 —Throltle valvetdeceleration/ idle switch 24.33 Fuel Supply—Air-cooled AFC Accelerator linkagercable auto. trans, 20.8 man. trans, 20.6 —Fuel fiter 20.4 —Fuel gauge sending unit 20.4 —Fuel pump 20.7 —Fuel system 20.2 leak checking 20.5, Fuel tank 20.4 Fuel Supply—Diesel ‘Acoaloratorlinkaga/cable 20.14 —Fuel gauge sending unit 20.13 Fuol system 20.10 leak checking 20.13, Fug! tank 20.12 Fuel Supply—Water-cooled Digitant — Accelerator linkage/cable adjusting 20.82 auto. trans 20.31 ‘mar. cans. 20.20 —Charcoal filter 20.33 —Fuel gauge sending unit 20.28 —Fuel pump 20.29 —Fuel system 20.26 leak checking 20.21 Fuel tank 20.28 Fuel Supply—Water-cooled Digijet — Accelerator linkagelcable auto. tans. 20.23, rman. trans. 20.22 ‘Charcoal filter valve 20.20 — Fuel fiter 20.18 -Fuel gauge sending unit 20.18 —Fuel pump 20.19 = Fuol system 20.16 —Fuol tank 20.18 Leak checking 20.21 Glass, Window Regulators —Giuing rubber window seals from 1986 rear lid window 64.5 side window 64.4 sliding door window 64.5 windshield 64.3 —Power window motor from 1986 MY installing 64,7 removing 64. 6 Sliding window roplesing quides 64.2 Heater—Auxiliary BBW 46 Combustion air blower adjusting 82.92 remavinginstalling 82.92 —Components 82.20 — Electrical wiring 82.24 —Engine coolant system draininglrefiling 82.95 —Felt pad removinglinstaling 82.29 Flame head removinginstaling 82.33 Flame switch checking 82.30 removingiinstalling 82.30 —Fuse $24 removingiinstaling 82.33 —Glow plug, checking 82.30 Heater core removinglinstaling 82.33 Metering prop flow rate checking 82.95 Operating 82.25 Recirculation pump romoving/installing 82.32 —Series resistor removingiinstaliing 82.92 Temperature sensor checking 82.31 removingiinstaling 82.31 —Watestiow 82.22 Heater Booster—Alr-cocled AFC —Air circulation blower 82.7 Assembly 82.3 —Combustion air bower 82.3 ‘Control flaps 82.8 —Detroster/Footwell laps 82.7 —Flame switch 82.8 Fuel pump 82.6 — Glow/Spark plug 82.3 Heater booster/components 82.2 —Healer lever switch 82.8 Ignition coil 82.6 —Overheat switch 82.7 — Safety switch 827 —Temperature regulating switch 82.5, —Temperature sensor 82.6 —Troubleshooting 82.10 xvIndex Heater Booster—Water-cooled —Aircirculation blower 82.17 Combustion air blower 82.14 —Control valve 82.17 — Flame switch 82.15 —Fue! pump 82.17 —Glow/Spark plug 82.14 —new style 82.14 —Heater booster/Components 82.12 —Heater housing 82.14 —lgnition col! 82.17 —Overheat switch 82.15 — System companents 82.12 — Temperature regulating switch 82.16 ‘emperature sensor 82.16 Troubleshooting 82.18 Heater/Ventilation —Controls/Assembly arcooled with fresh air fan 80.8 without fresh air fan 80.5 water-cooled 80.12 Flap housing air-cooled with fresh alt fan 80.10 water-cooled 80.14 —Heater, additional under fear bench seat 80.16 —Heater control flap cable 80.4 —Heater/Fresh air box housing spitting 80.15 —Froar air duct 80,3, — System components air-cooled 80.2 water-cooled 80.11 Hoodsitids —Rear doorflock cylinder 55.2 Rear lid spring 55.4 —Rubber door stop 55.3 — Striker plate 55.3 Identification—Numbers/Codes Automatic trans. 4 Engine 2 —Front final drive Synero ab “Manual trans. 3 —TypelModel/Assemblies 2 VIN (Vehicle Idonttication Number) 2 and Foreword Ignition Distributor and Settings — Air-cooled AFC ‘CANIUSA, (except Cali) 8 Cali. —Water-cooled Digit 10 —Digifant 14 Ignition System—Air-cooted AFC = California 28.8, dlistioutor 28.19 distrbutor dive 28.20 Hall control unt/generator 29.14 Hall ignition, woubleshooting 28.17 xvi Ignition System—Alr-cooled AFC (cont) —California (con's) idle stabilizer 28.16 igniion/distributor settings 28.9 ignition timing 28.11 rotor 28.10 ‘vacuum advancefretard 28.13 vacuum unit 28.12 wiresfeol, checking 28.10 USA (except Call) and Canada 28.2 distributor 28.6 distributor drive 28.4 ignition/dstributor settings 28.3, ignition timing 28.5 rotor 28.4, ‘vacuum unitladvance 28.7 wires/coll, checking 28.4 Ignition System—Diesel Glow plug light troubleshooting 28.27 —Auick glow troubleshooting 28.24 Ignition System—Water-cooled Digitant —Distributor, installing 28.44 Hall sender, checking 28.43, ition and injection system repairing 28.39 — Ignition distrbutor 28.40 — Ignition settings 28.41 —lgntion switching function checking 28.44 — Ignition timing 28.42 Ignition System—Water-cooled Digiiet —Centritugal advance 28.94 — Distributor diveshatt 28.32 Hall control unit 28.36 —Hall generator 28.37 ~ Idle stabiizer 28.38 —Ignition cable connectors new style 28.308 —lgnition coil 28.32 —lgnition gistrioutor! Hall generator 28.29 Ignition aistbutorisettings 28.29 —Ignition wires/connectors 28.31 —Fotor 28.31 — Suppressor connectors 28.32 —Trigger whee! 28.38 ~ Vacuum advancelretard 28.35 Vacuum unit 28.35 Instruments, Radio 1980-1984 —Cigarette lighter, replacing 90.31 —Fusl gauge ‘checking 80.5, 90.9 troubleshooting 90.13 Instruments, Radio 1980-1984 (cont'd) —Fuel gauge sender removinginstalling 90.11 — Instrument cluster assombling/disassembling 90.2, 90.5 removingfnstalling 90.10 —Light emiting diodes (LED) checking 90.5 Identiying 90.4, 90.8 —Mult-point connector identilying 90.4, 90.8 Speedometer calibration 90.30 — Speedometer cable removingfnstating 90.10 Voltage stabilizer 90.4, 90.8 Instruments, Radio From 1985 — Cigarette lighter, replacing 90.31 —Coolant temperature gauge locating 90.14 troubleshooting 90.21 —Dynamic oil pressure system assembly 90.22 removinglinstaling 90.23, troubleshooting 90.24 —Fuel gauge, locating 90.14 troubleshooting 90,20, Instrument cluster assembling/disassembling 90.14 removingfinstaliing 90.10 —Light emitting diodes (LED) checking 90.18 identitying 90.18 —Multi-point connector identiying 20.18, — Speedometer calibration 90:30 — Speedometer cable installing from VIN 25 H 040 185, except Syncro 90.17 removing/nstaling 90.17 —Voltage stabilizer, checking 90.18 Instruments, Radio From 1990 — Heidelberg VI fixed coded radio coding a new or remanufactured radio 90.32 reactivating radio after reconnecting power 90.33 unlocking an electronically controlled radio 90.34 Lifting Vehicle — Holst Foor jack 5 Lights —Bulb holder 94.6Index waRNine — * Autorotve sence and reparis serious business. Younus bo ale, use common sense, and exercise good judgement prevent personal injury and conplete the ‘nor saly * Before beginning any work on your Volkswagen, thoroughly read all the CCautons and Warnings listed near the Font of this manual, * Alnays read the complete procedure botore you begin the work. Pay special attanon to any Cautions and Warnings that accompany hat procedure, or other Iiformaion on specif topic Lights (cont'd) —Headtight 94.4 ‘aerodynamic 94.58 adjusting 94.5, mounting frame 94.5, removing 94.5 —gnition key, deburring 94.9 — Intermittent windshield wipor 94.4 Steering column covers 94.3, lock 94.3 lock cylinder 94.4 switches 94.2 —Tail ight 94.6 —Tum signal switch 94.3 Lubrication System—Air-cooled AFC ‘Assembly 17.2 —Oil cooler 17.2 Oil pressure switeh 17.2 03 pump 17.2 Lubrication System—Diesel Assembly 17.4 Oil cooler 17.4 =Oilfiter 17.4 Oil pan 17.4 Oil pressure switch 17.4 Oil pump 17.4 Lubrication System—Water-cooled —Assembly 17.7 —Healing pipe, crankcase breather 17.9 —Oil pressure switch 17.9 Oil pump 17.9 Maintenance Schedules —Lubrication, Emissions and Vehicle Maintenance Schedules (Appendix) al-cooted, water-cooled ‘and ciese! models 1982-1985 A2B ‘water-cooled models from 1986 A32 Mirrors — Outside, electric adjustment range, increasing 66.3 assembly 66.4 lass, removing/instalting 66.2 Radio See Instruments, Raclio Refrigerator —See Camper Equipment Root —Front headliner, installing 75.74 removing 75.7 Luggage rack, removing 75.8 —Pop-up 100}, installing 75.3, removing 75.4 —Pop-up roof seal, installing 75.6a removing 75.6 Roof vent, installing 75.7 removing 75.6 Seat belts —Aulomatic 3-point seat belts ‘otrofit installation 68.5 Automatic zear 3-point seat belts roroft installation 68.7, Automatic 3-point let center seat belt, retrofit installation 68.10 Mluminated vanity mirrors replacing bulbs 68.13 —Seat bells, inspection 68.2 wobbing defects 68.4 —Template measurements 68.6 Seats — Armrest, romovinglinstalling 72.4 ‘Armrest, adjustable ‘assombly 72.5 removing/instaling 72.6 —Front seat, removing/instaling 72.2 —Front seat backrest romoving/instaliing 72.2 —Healed seats component locations 74.2 heat elements 74.21 —Rear seat with storage locker removingfinstaling 77.2 —Roof beds, boards removing/instaling 77.3 Steering —Power steering checking for leaks 48.7 pressurefiow limiting valve 48.11 ‘suspension changes 48.6 system layout 48.6 technical data 48.6 —Power stosring pump removingiinstaling 48.9 repairing 48.10 Steering (cont'd) —Power steering pump pressure checking 48.7 —Power steering system filingtbleeding 48.7 — Steering column switches 48.2 Steering drive/gear 48.4 — Steering lock assembly 48.3 Steering wheeVcolumn 48.2 Tie rods 48.4 removing 48.5 Troubleshooting 48.12 Sunroot —Panel adjusting 60.3 ‘guide plate acfusting 60.4 height alignment front 60.3, rear 60.4 parallel adjustment 60.4 removingiinstalling 60.2 —Trim panel removing/intaling 60.3, —Water drains, cleaning 60.6 rear drain hose, replacing 60.6 ‘Suspension—Front —Assombly early version 40.2 late version 40.7, —Ball joints assembly 40.10 lower 40.12 —Coit spring removinglinstaling 40.3, Lower control arm bushing, early version 40.6 ‘bushing, later version 40.8 femovinglinstaling 40:3, —Shock absorber removinglinstaling 40.4 Steering arm, checking 40.32 — Steering knuckle ‘assembly 40,12 checking for wear 40.12 modiiestion, grease seal 40.13, moaifieation, brake disc interference 40.14 —Subtrame wax preservation 40.14 —Upper control arm bushing 40.5 lower 40.6 removing 40.5 wax preservation 40.14 —Whee! bearing adjusting 40.11 assombly 40.10 ‘Suspension—Front, Syncro —Axle shall, assembly 40.29 length 40.30 removinginstaling 40.28 xviiIndex ‘Suspension—Front, Synero (cont) Bal joints pressing 40.25 Col spring removingiinstalling 40,20 —Components assembly 40.15 —CV joint, inner assembly 40.29 disassembling/assembling 40.93 pressing 40.31 —CV joint, outer assembly 40.29 disassembling/assembling 40.92 removing 40.31 —Guards, drive shatviengine removinginstalling 40,28 —Lower control arm bushings 40.19 Shock absorber removing/installing 40.20 —Subtrame, components 40.26 installing 40.28 removing 40.27 — Upper control arm bushings 40.19 removingiinstalling 40.18 —Wheel bearing pressing 40.24 —Wheel bearing housing assembly 40.23, removinglinstaing 40.17 —Wheel hub assembly 40.23, pressing 40.24 Suspension—Rear ‘Axle shail assembly 42.4, 42.7 removinglinstaling 42.4 Constant velocity joint assembly 42.7 disassombling/assembling 42.8 removinglinstaling 42.8 Rear axle assombly 42.4 —Rear whee! suspension assombly 42.2 —Shock absorber bushing/sieeve 42.3 —Traling arm bushing 42.3, —Wheol bearings, innorfouter grease seals 42.5 Femovingiinstalling 42.5, —Wheel studs Femoving/instaling 42.6, Tarpaulin Canada 61.2 Technical Data —Capacities Appendix 27 Cylinder Location Appendix 27 fant General 12 Engine Appendix 27 —Vehicle identification Appendix 26 Tires Rotating 44.18 Torque Converter Bushing 32.3, —Code lotler 4, 32.2 Draining 32.2 — Installing 32.3 Oil seal 32.3 Towing Procedure 6,7 Transmission 4-speed 091 — Adjusting rings 35.3, ‘Assembly 35.2 Clutch housing! mechanism 35.12 —Ditlerential 35.4 —Drive flange 35.3, 35.4 oll seal 24.18, 36.15 —Goar carrier/Gearshilt housing 35.6, 25.18, —Gear carrier housing assembly 35.8, 35.16 —Gears 1st gear needle bearing 96.27 ‘rd gear end play 35.29 —Goarshift lever 34.3, — Gearshift nkage 34.2 assembly 34.3 adjusting 94.4 bearing plate 34.4 —Instaling 34.15 —Interlock/detent plungers 85.17, Lover bearing plate 34.4 —Main shalt assembly 35.9, 35.20 ball bearing 35.23, oil seal 95.13 Pinion neodle bearing 95.23, 35.29 —Pinion shaft assembly 35.9, 35.24 Roar main shaft 35.5, — Release shall bushing 35.13 Removing 34.14 — Retaining ring 35.7 Reverse gear 35.14 cond play 35.17 shaft ctcip 96.15 —Racker lever shaft 95.19 Selector shaft 35.19 —Shift forks 35.10 Shift od 34.3 —Starter bushing 35.13, —Synchronizers tsV/2nd gear 35.26, 35.28, Srd/4th goar 35.21 circlips Srd/ath gear 35.21, 35.26 ring identification 95.30 Tapered roller bearing 35.26 Transmission housing 35.14 ‘Transmission 4-speed 091/1 —Aajusting rings 35.92 installing 95.35, rmarkinglromoving 95.34 Transmission 4-speed 091/1 (contd) —Assombly 35.92, 95.38 ‘mounting in repair stand 35.04 —Clutch housing assembly 35.42 —Ditferential 35.35 —Drive flange 35.32 circlip,instaing 35.35, instaling 35.95, oil seal 24.18 removing 35.34 Gear carrier 35.44 assembling 35.40 assembly 35.36, cover 35.44 instaling 35.39 removing 35.38 —Gears ‘sv2nd, removing 35.36 34d, ond play 35.59 3rd, installing 35.59 3rd, removing 35.58 —Goar ratios 34.9, 35.60 —Goarshit lever 34.6 bearing 34.6 Gearshift linkage 94.6 assembly 34.6 adjusting 248 bearings 34.6, — Installing 34.7 Lever bearing plate 34.6 —Lubricant specifications 34.9, 35.60 Main shaft 95.49 assembly 35.48 ball bearing 35.51 lock ring 35.52 needle bearing 35.51 oil seal 35.43 rear, removingjinstalling 35.35 Pinion shalt 98.55 assembly 35.54 needle bearings 35.57 roller bearings 35.56 Removing 34.16 —Retaining ring 35.97 installing 35.40 removing 35.38 —Solector shatt ‘modifications 35.60 parts for 35.600 Shift forksisynchronizers ‘modifications 95.60 parts for 35.60d Shift rod bushing 95.46 Shi rod mounting 34.72 —Shift shaft oll seal 35.46 Starter bushing 35.43 —Synchronizers. 41st/2nd gear 35.58, ralath gear 35.50 Technical data 34.1 — Transmission housing 95.45 assembling 35.39 disassembling 35.38Index WARNING — * Aufomotve sorvoe and eparissenous business. You must be alo useconmon | ‘sense, and exercise good judgement fo. | rovant personal nury and complete the work slo. * Bolore beginning any work on your Volkswagen. thoreughiy read all the (Cautions ang Warnings Usted near the front of ts anual. + ays road the compote procedure belore you begin the work. Pay special attention fo ary Cautions and Warnings ‘that accompany that procedure, or other Information on a specie topic. ‘Transmission 5-speed 094 —Adjusting rings 35.62 instaling 35.65 marking/removing 95.64 Assembly 35.62, 35.66 ‘mounting in repair stand 35.64 —Clutch housing assembly 35.74 —Ditferential 35.65 —Drive flange 35.62 installing 35.65 oil seal 34.18 removing 35.64 —Gear cartier 35.76 assembling 35.70 assembly 35,66 cover 36.76 cover 35.76 installing 35.69 removing 35.68 —Gears 1st, shim 95.72 2nd, removing 35.88 3rd/ath, removing 35.88 4th, end play 35.91 ‘4th, instaling 35.31 —Goarshift lever 34.10 bearing 34.10 —Gearshit, adjusting 84.12 assembly 34,10 — Installing 34,16 —Lever beating plate 34.10 Main shatt 95.1 assembly 95,80 ball bearing 35.83, lock ring 98.84 needle bearings 35.83, oll seal 96.75 rear, removing/nstalling 35.652 —Moaifications to trans, ‘manufactured prior to Deo. 15, 1982.35.65 —Pinion shaft 35.87 assembly 35,86 neat bearings 35.89 roller bearings 35.88 ‘Transmission 5-speed 094 (cont'd) —Romouing 34.16 Retaining ring 95.67 Installing 35.70 removing 35.68 —Shift rod bushing 35.78 Shift shaft ol seal 35.78 Starter bushing 35.75, = Synchronizer rings checking 35,90 identifcation 35.92 —Synchronizers 2nd/3rd gear 36.90 ‘tivSih gear 35.82 assombling 36.90 checking 325.62 installing 35.99 removing 35,82, 95.88 ‘Technical data 34.1b — Transmission housing 35.77 assombling 35.69 disassembling 35.68 ‘Transmission S-speed 094 4WD Adjusting rings instaling 25.96 marking/temaving 35.95 —AssembiingDisassembling 95.99 Assembly 35,94, 35.98, 35.105 —Axle flange installing 35.96 removing 35.95 Bearing instalng/ehecking 95.123 removing 35.122 Inner race, removing 35.122 Clutch housing 35.111 — Differential lock components 34:24 —Differential lock control repairing 24.26 —Differentia lock servo 34.25, 35.96 —Drive flange seal, installing 36.115 —Drive pinion 35,121 —Driveshatt ange, removing 35.104 Flange nut Jooseningfightening 35.104 Flange seal, instaling 35.104 — Gear carrier 35.107, 35.116 disassembing/assembiing 35.108 —Goars ‘st, 2nd and 3rd, removing 95.122 Gearshift linkage assembly 34.20 adjusting 94.21 Housing 95.113 Installing $4.23 — Intermediate housing removing 85.106 —Low gear idler, removing 35.106 —Low gear shim, measuring 35.101 —Lower gear bearing romoving/installing 35.126 —Main shat 95.117 bearing, retmoving/instaling 35.119 Transmission 5-speed 094 4WD (cont'd) —Main shatt seal emovingfinstalling 35.12 —Needle bearing inner race looseninghightening 35.123 outer race, instaling 35.126 outer race, removing 35.125 removingfinstaling 35.115 Output housing 35.103 —Output shatt bearing removinglinstalling 35.114 —Rear driveshaft, measuring 35.97 —Removing 34.22 — Reverse gear idler removingiinstaling 35.108 —Shift rod bushing romovingfinstalling 35.115 —Shift shatt seal removingjinstalling 35.114 Starter bushing romoving/installing 35.112 Synchronizer rings Identification 35.127 —Technical data 34.19 —1oV2nd gear synchronizer checkinginstaling 95.124 8rd gear, instaling 35.125 —Srd/ath gear synchronizer 35.118 instaling 35.119 Transmission, Automatic — Accelerator cablevlinkage (090 except code letters NH 37.12 code letters NH only 37.14 —Apply shell 38.10 ATE checkingriling 37.9 dipstick changes 97.9 troubleshooting 37.9 —DirectReverso/Forward clutches instaling 38.11 —Final drive il seal 37.10 —Fonward clutch 38.8, 38.17 Governor cisassemblinglassembiing (090 code letters NG 38.22 removingiinstaliing (090 except code letters NG 98.23 — Governor drive gear 38.14 Installing (090 except code letters NH 37.5 (090 code letters NH only 37.6 —Kickdown lever mosifcatioa (090 code letters NH. NK 28.99 —Manual vaive 38.35 Modifications 37.19 —Oil pump 38.8, 38.22 — Operating rod 38.35 Operation 37.17, 37.19 —Parking lock 38 3: xixIndex Transmission, Automatic (cont'd) —Parking lock modification (090 code letters NH, NK‘ 98.39 —Prassure test procedure $7.18 — Pump shaft 38.3 Removing (090 except code letters NH 37.4 (090 code letters NH only $7.6 —Reverse planetary goar sot 38.12 Reverse planetary ring gear 38.14 —Selector lever assombly 37.2 Selector lever cable 37.3 —Separation plate 1090 code letters NG 38.26, (090 code letier NG from trans. no. 17 07 0 38,28 (090 code letters NH, NK 38,37 — Shift points 37.19 —Spacer springs and rollers 38.15 ~Spring table (090 code letters NH, NK Upto trans, no. 16 07 038.30, (090 code letters NG. {rom trans. no. 17 07 0.98.92 —Technical data code letters NG, NH 97.18 code letlers NK'37.15 Transfer plate 090 code letters NG 38.26 090 code letters NG. from trans. no. 17 07 0 98.28 090 code letters NH, NK 28.97 —Transmission assembly 38.7 (090 modifications cade letters NH, NK 38.37 —Transmission/Final drive assembly 38.2 end play 38.5 separating 38.3 —Transmmission housing studs 38.4 —Turbine shalt 38.3 —vave body removing/instaling 38.25 (090 code letters NG 38.26 (090 code letters NG from trans. no. 17 07 038.29 code letters NG upto trans. no. 16 07 0 —tst/reverse beake piston 38.10 ‘2nd gear brake band 38.12 —2nd gear brake band piston 98.10 disassembling/assembling 38.24 Trim—Interior —Colfee cup bracket, repairing 70.9 Front door trim panel ‘assembly 70.2 moisture barrier 70.2 —Headining removinglinstaling 70.8 ‘Trim—interior (cont'd) Instrument panel removing 70.5 replacing 70.6 —Siiding door trim panel ‘assembly 70.3 removing 70.4 ‘Vehicle Car Air cloanar A10 —Battory Ata —Brako fluid A13 Cleaning products A3 —Cooling system A11 Corrosion protection AS —Engine compartment AG —Engine oil A7 —Engine oi filter AB Exterior A3 —Fus| filter (diese!) A10 —Fuol supply At — Interior 4 —Lubricants A 7 —Maintenance AS —Power steering A10 — Replacing wiper blades A16 Tres Wheels A17 Vitel at2 \Vehicte Identification Number (VIN) VIN 2, foreword Wheels —Alignment front 443. rear 44.4 specifications 44.2 Alignment Syncro determining tront toe 44.34 specifications 44.5 Windshield Wiper Washer Assembly 92.2 —Rear window washer/wiper 92.5 washer pump 92.7 Spray jots 92.4 —Troubieshooting 92.8 —Windshiold washer 92.4 Wiper arms/motor 92.3 —Wiper blade rubber insert 92.3 Wiring Diagrams — See Electrical Wiring XxxGeneral Index Identification (Numbers/Godes) — Automatic trensirission 4 — Compression pressure values 22 — Engine 2 — Front final drive Syncro 3b — Manual transmission 3, 8 — TypelModeVAssemblies 2 — VIN (Vehicle Identification Number) 2 Lifting Vehicle — HoistFloor jack 5 Towing — Procedure 6, 7 ignition distributor and set = Ai-cooled AFC CanUSA, not Cal. 8 California 9 |— Water-cooled Digit 10 — Digitant 11 Technical data — Digitant 12General Type/model: Type: 25 Model: VANAGON/VANAGON SYNCRO- Assemblies Code letters: BHP (SAE) RPM Engine (air-cooled) 2.0 Liter (AFC) ov 70 4200 Manual Transmission - 4 speed (091) 0K = = Autornatic Transmission (080) NG = = Engine (Diesel) 1.6 Liter os 50 4200 Manual Transmission - 4 speed (091) DMZ = = Manual Transmission - 5 speed (094) Dx = = Engine (water-cooled) 1.9 Lier (Digiet) DH 20 4800 Manual Transmission - 4 speed (091/1) DUIABD = = ‘Automatic Transmission (090) NH = = Engine (water-cooled) 2.1 Liter (Digitant) wv 90 4800 ‘Manual Transmission - 4 speed (091/1) ‘ABDIACW = = ‘Automatic Transmission (090) NK = — ‘Manual Transmission - Syncro 5-speed (094-4WD) (with differential lock) ‘AANIAVN - - (without ciferential lock) AAKIAVY = = ‘CAUTION 'SYNCRO TRANSMISSIONS When checking engine performance, only use dynamometer designed to brake all our wheels at the same time. Vehicle Identification Vehicle identification number (VIN) ‘on dashboard on driver's side (arrow) ‘Type/Model/ Assemblies identification Vehicle identification number (VIN) Engine number Engine number (Gasoline) + stamped on crankcase below breather (arrow) +n engine block (arrow) between injection pump ‘and vacuum pumpBeginning May 1987, engine codes are now either a ‘wo letter combination or a combination of ene Compression pressure values General AB number and one leter Engine codes cv | on,mv | cs Engine code continues to precede the engine number. [Compression pressure | 6-9 | 10-13 | 36 values bar (psi) _|(@7 ~ 191) |(145 - 190) [4999 ‘CAUTION 3 e/a Wear limit bar (psi) Engines with identical code DO NOT @_|_ 9) _ |r necessarily have identical specifications Maximum permissible 3 e citference between all « wo {four cylinders bar (psi) new (water-cooled shown) Engine code From May 1987 ‘Compression pressure values 2aTHIS PAGE INTENTIONALLY LEFT BLANKGeneral Manual Transmission Type 091 Code letters and date of manufacture Example DK 0 08g I 1 I code letters day month year(79) of manufacture “ [_4speed |General Manual Transmission Type 094 Manual transmission code letters 5-speedGeneral Front Final Drive [34-1687] syncro b y Front tna dvecosetetersGeneral ‘Automatic Transmission Type 090 Code letters and date of manufacture Example NG. 1% 08g j I t ! code letters day month year(79) of manufacture Converter code letter + letter D or 3! arrow ) OW] cies sete Valve body code letters * on boss (arrow) Transfer plate identification + part number (arrow) A sorte vansnssioncose ersao General Lifting vehicle with hoist/Hoor jack ‘CAUTION Before driving onto lift, check for clearance between lifting arms and tires to avoid cutting sidewalls, Extend arms and check to see if arms are long enough to contact lifting points. Lift only at points shown Front at crossmember next to jacking port Roar at rear crossmember When lifting vehicle with floor jack, use same lifting points as with hoist ‘CAUTION Do not lift vehicle by engine, transmission fr front suspension. Daing so may result in ‘damage to componentsGeneral Emergency Towing Note Al towing procedures are based on use of typical sling-type tow truck equipment. If other types ot towing equipment are used, these procedures may not apply ‘whenever possible, tow with rear wheels off ‘ground ‘if car with automatic transmission must be towed with front wheels lited because of extensive damage, dollies should be used under rear wheels if towing speed will exceed 30 mph or distance over 30 miles. Exceeding these limits will damage transmission Front hook-up—From 1986 my. + selector lever must be in “N" position when ‘moving car with automatic transmission with rear remove front license platerbracket if interfere wheels on groune with front hook-up WARNING Always secure front wheels with an external steering whee! lock when towing with rear vwhee's off ground, Never use ignition steering lock to secure front wheels. Nover allow passengers to ride in towed vohicie —altach T-hooks (above) to tle down slots in tong members (as shown) = position four foot long 44+ wooden crossbeam under bumper (as shown) double wrap chains on tow bar attach safety chains on axle platform CAUTION Front hook-up — all models thru 1885 Do not attach hooks or chains around brake attach grab hooks under lower control arms lines outboard of shock absorber mounts (as shown) —place 4x4 wonden crossbeam under spare tre —ralse vehicle to allow four inches clearance — place tow bar under 4x4 botween tires and road — double wrap chains on tow bar attach salty cain ower contol arms (as Towing speed/distance Front tow ~ all models EXCEPT Syncro. Automatic transmission 30 mph (48 kmh) for up to G0 miles (48 km) Manual transmission {50 mph (80 km) for up to 50 miles (80 km) Vanagon 6 sovina aGeneral Rear hook-up — alr cooled gasoline models only attach grab hooks to tailing arms — place 4x4 under engine carrier to space tow bar ‘away from heat exchangers attach safety chains to traling arms Rear hook-up — water-cooled/diesel models ‘The Vanagon cannot be towed with conventional ‘ling-type towing equipment to avoid damage to valance panes Vanagon Syncro Frontirear hook-up ‘The Vanagon Syncro cannot be towed with ‘conventional sling-type towing equipment nor with wheel lift equipment or wheel dollies to avoid ‘damage 10 the all-wheel drive system. use flat-bed tow truck only. Flat Towing Vehicles with automatic transmission may be towed forward (in diving direction) at speeds up to 30 mph for maximum of 30 miles CAUTION. Towing vehicles at more than 30 mph andlor {or distance greater than 30 miles with rear wheels on ground will damage automatic transmission due to lack of fubrication If towing speed will be greater than 80 mph or distance greater than 30 miles, temporary rmoaifications to vehicle are required as follows: Work sequence ~ remove drive shaft assemblies — seal drive shaft flanges against water and dirt —wrap drive shafts and stare in vehicle Manual transmission (including Syncro) ‘There are no restrictions on speed or distance when towing manual transmission cars behind cther vehicles As Rear towing — alt Syncro-front/rear towing | sowing 7General Engine code letters Distributor (Part No) ov 022 905 2058 Janition timing Timing mark location: crankshaft pulley 75° BTDC. Idle speed manual | 800-950 rom automatic {850-1000 rpm | Vacuum hose disconnects i Dwell angle new points, 48-50" wear limit 42-58" Centrifugal advance (cranksnatt degrees) start 1000-1200 rpm 9-14" at 1600 rpm — end 21-25¢ at 3400 rom Vacuum advance start 107-147 mbar (80-110 mm Hg) | ¢ 266 mbar (200 mm Hg) en em | ~ | Spark plugs Bosen W145 M2. W 8.CO ' Beru 145/473 i Champion | _N2s8 Spark plug tightening torque | 50 nm 22 tei) Spark piug gap |__0.6-0.7 mm (0.023-0.028 in.) Firing order 2 Air-cooled AFC CAN/USA, not Calif.General Engine code letters Distributor (Part No.) cv (039 905 205C Ignition timing 5" ATDC Timing mark location: crankshaft pulley Idle adjustment ‘Vacuum hoses connected ldle stabilizer plugs removed and connected together Dwell angle setting Centrifugal advance (crankshaft degrees) 50-960 rpm| not adjustable stant 1050-1200 rpm 9-19" at 1600 com | end 21-25% at 3400 em Vacuum advance | start 0-160 mbar (70-120 mm Ho) one 3240-260 moar (180-210 mm Ho) oa" i Vacuum retard | start 90-160 mbar (70-120 mm 49) | 4 200-260 mbar (150-210 mm Hg) ent 11-13" Spa plugs Bosen W 145 M2, W8 CO eru asinaist Champion N20 Spark plug gap 0.6-0.7 mm (0.023-0.028 in) Spark plug tightening torque Firing order 30 Nm (22 ft 1b) ‘Transistorized igri system cautions Do not connect any condenserisuppressor or test light to ferminal 1. Do not connect test instruments with a 12 volt supply on terminal 15 of ignition coil, D0 not crank engine detore high tension wire of distributor eap (terminal 4) is connected to ground with jumper wire (example: compression check etc), Do not replace installed coil— 211 905 115 C—with conventional type. Oo not leave battery connected when electric welding ‘on car, Do not start engine after heating up 10 more than 80°C (176°F), example: paint drying booth. Do not wash engine when it is running. Do ot use battery booster longer than 15 sec. nor ‘exceed 16.5 volts with booster. Allow 1 minute pause between boosting attempts, Do not discon: ect battery while engine is running, Disconnect plug 10 ignition control unit when car has to be ‘owed. Ato Air-cooled AFC California _| and settings lgnition distributor 9General Engine code letters DH Distributor (Part No.) 026 905 205 D Ignition timing 51° ATOC Timing mark location: crankshaft pulley Idle speed Vacuum hoses connected Idle stabilizer contro! unit electrical plugs disconnected from unit, and connected together Centrifugal advance (crankshaft degrees) start 1050-1150 pm 16-20" at 2400 rom end 21-25" at 3800 rpm ‘Vacuum advance start 190-230 mbar (14.0-17.0 em Hg) ena 360 mbar (27.0 om Hg) 1246 | Vacuum retara / start 100-220 mbar (7.5-16.5 em Ha) end 260-360 mbar (19.5-27.0 om Hg) 9-11" Spark plugs Bosch w7co Beru wire Champion N 286 Spark plug gap 0.7 0.1 mm (0.028 + 0.004 in.) Spark plug tightening torque 20 Nm (14 ft Ib) Firing order 43-2 VO sesionsisuor and ceings Water-cooledGeneral Introduation ‘October 1985 Engine code wv Part no. Ignition distbutor (026 905 205 M Digifant contol ‘925 906 0220 old unit" 025 906 022022 new Tgnition timing (Checking valve 7 bolore TOC. ‘Adjusting valve = 1° belore TOC Timing mark location REM Ignition adjustment™* timing map -- APM Approx. 3000 Degrees Ee PM limit Switch-off RPM of RPM ‘5600 emovinglinstalling Fig.2 tinder Repair Group 15 Drive belt guide 40Nem (71118) Ye cooler o 25 Nm (8110) ow titer Olt panigasket removingtinstaling, Repair Group 17 ° ° 45 Nm (93 tb) 10 Nem (7 tt 1b) Diesel] sgn csnsenbiagrssonting 1B» 1913 Engine-Crankshaft, Crankcase Drive belt, removing Work sequence —femove bolt cover and valve cover Fig. 2 Fuel injection pipes, removinglinstalting —remove with toot 3035 tighten to 25 Nm (18 ft 1b) & Fig. 3 Injection pump sprocket, removing —loosen sprocket retaining nut slightly carefully apply tension with puller hit puller spindle head (arrow) with light hammer taps until sprocket loosens from injection pump shaft smove puller and nut remove sprocket by hand —turn engine to TDC arrow on cylinder No. 1 and. fix camshaft in position with tool 20858 align tool as follows: * turn camshaft until one end of too! touches cylinder head ‘+ measure gap at other end of too! with feeler gauge + take half of measurement and insert feeler of this thickness between too! and cylinder head * turn camshaft so that tool rests on feeler ‘insert second feeler of same thickness be- tween other end of tool and cylinder head Fuel injection pipes Injection pump sprocket Drive belt sel 13.2 DsEngine-Crankshaft, Crankcase 13 —lock injection pump sprocket in position with pin 2084 check that marks on sprocket, bracket and pump body are aligned (engine at TOC) loosen tensioner remove V-belt pulley from crankshatt —remove drive belt Drive belt, installing Work sequence check that TDC mark on clutch pressure plate is aligned with reference mark loosen camshaft sprocket bolt 1/2 turn and loosen gear from camshaft by tapping with rubber hammer —install drive belt and remove pin 2084 from injection pump sprocket —tension belt by turning tensioner to right ‘check that on VW 210, scale reads 12-13 ‘check belt tension between camshaft sprocket and injection pump sprocket tighten camshatt sprocket bolt to 45 Nm (33 ft Ib) remove tool from camshaft —turn crankshaft 2 tums in direction of engine rotation (clockwise) —strike belt once with rubber hammer between ‘camshatt sprocket and injection pump sprocket check belt tension again check injection pump timing, see Repair Group 23, Drive belt sprocket bolt, tightening 12 mm bott 014 Version 1150 Nem (10816) with locking compound 4 mm bolt New Version| 200 Nm (148 ft Ib) lubricate threads before installing Shown above are the two versions of drive belt sprocket used on Diesel Vanagon. Ensure that the Correct tightening torque specification is used when repairing these engines. Ds Diese! | Drive beit Bie eneesaroe 13.2113 Engine-Crankshaft, Crankcase Fully closed drive belt cover Boginning in February 1984, the Diesel engine has been produced with a fully closed drive belt cover. Additional new parts include & revised injection pump mounting bracket and intermediate shaft pulley. The pulley now mounts closer to the engine block. Note Only the new version pulleys will be supplied as service parts, When installing the new version pulley in earlior engines (without fully closed belt cover) itis 6 mm hole necessary 10 provide at least 0.5 mm (0.020 in.) clearance between pulley and injection pump 10 Nm (7 $28} mounting bracket (arrows). Rework pump bracket \ as necessary. Rear belt cover £ removing: remove camsnalt spracket (tap sprocket off taper with punch and ‘ammo through 6 mm hole), tensioner {and injection pump. Loosen pump mounting bracket Upper belt cover Lower bett cover 10 Nm (7 ft 1b) we 13.21 siverntconr [Diesel