|
Affected Model Order Affected
Model Years Number Component Subject
Vanagon 1986 87-N02 Climate Don't Blow Your Top -
Control High Pressure Discharge Hose/
Remove Damper
Vanagon 1986-87 87-N04 Fuel Vanagon Surging/Stalling -
System Adjusting Throttle Switches
1.9 liter 1982-85 87-N05 Engine Easy Does It - Cross-over
Vanagon Water Pipe
Vanagon ALL 87-N06 General Vanagon "Dust Buster" air
filter - Heavy Duty Air Filte
Vanagon 1987 87-N08 Fuel Basic Digifant Assumptions -
System Digifant Management System
Vanagon 1986-88 88-N07 Cooling Coolant Loop - Transmission
System Removal
Vanagon 1988 88-N08 Fuel "Terminal Illness" (Idle
System Stabilizer System Changes)
Vanagon ALL 88-N09 Fuel Throttle Switch Adjustment Ti
Vanagon ALL 10-87-02 Engine Remanufactured Engine
Identification
Vanagon ALL 15-90-T01 Engine Cylinder Head Re-Seal
Water-Boxer (1.9L and 2.1L)
Vanagon 1983-85 17-87-04 Engine Oil Leak from Rear - Oil pump
gaskets
Vanagon ALL 17-87-05 Engine Oil cooler seal leaks in
waterboxer extreme cold
Water-cooled 1983-85 19-87-02 Engine Coolant leaking and/or noise
Vanagon from rear water pump
Water-cooled 1983-85 19-87-03 Engine Carpet wet by rear seat -
Vanagon Heat Exchanger T-piece leakin
All w/ ALL 20-20-90 Fuel Improved Fuel Additive
Gasoline T01 System ZVW 239 003
Engines
Vanagon ALL 20-90-01 Fuel P.I. 2082 - Accelerator Cable
System Change
All w/ ALL 20-90-02 Fuel Gasoline Containing Detergent
Fuel System
Injection
Vanagon 1983-90 24-24-90 Fuel Rough Idle, Engine Stalls -
T01 System Tow In
Vanagon From 24-89-04 Fuel Digifant I: Fuel Injection
1986 System System Cleaning and Intake
on Valve Decarbonization
Vanagon ALL 24-90-03 Fuel Throttle Body - Replacement
w/ Digijet System
Injection
Vanagon 1986-91 24-92-01 Engine Intermittent Misfire
w/Digifant < See also TB 24-92-02 >
Injection
Vanagon 1983-91 24-92-02 Engine Driveability Complaints
Water-Boxer < Supercedes TB 24-92-01 >
Vanagon 1986-91 24-92-01 Electrical Vanagon Intermittent
w/ Digifant System Misfire
Injection
ALL ALL 27-87-03 Engine Cruise Control does not work
Models Years Vacuum loss
Water-cooled Thru 27-87-04 Electric Alternator Mounting Bolt
Vanagon Model loose/broken
Diesel, Year
Vanagon 1985
All Models All 28-87-04 Ignition Rough idle or misfiring
Years System during partial load
Vanagon From 28-90-01 Ignition Vehicle Does Not Start,
1986 System Ignition Miss
Vanagon ALL 30-89-01 Manual Clutch Disc - Installing
w/ Manual Trans.
Transmission
Vanagon ALL 34-89-02 Manual Position of Boot on Shift
w/ 091/1 Trans. Rod Bushing
Transmission
Vanagon ALL 34-89-03 Manual Revised Shift Lever Bearing
w/ Manual Trans.
Transmission
Vanagon ALL 40-88-01 Suspension Upper Control Arm Bushings,
Wheels Checking
Vanagon ALL 42-87-01 Suspension Knocking noise from rear -
Wheels CV Joint
Vangaon ALL 42-89-01 Suspension Coil Spring, Installation
Syncro Wheels Position
Vanagon 1983-85 55-87-01 Body Push Button Operation
Exterior Difficult - Rear Lid Latch
Vanagon 1987 63-87-01 Body Front Bumper/Spoiler -
Wolfsburg Exterior Removing/Installing
Vanagon From 64-86-06 Body Power Operated Window Motor -
3/86 on Exterior Removing/Installing
Vanagon From 66-87-01 Body Outside Mirrors (Electric) -
1986 on Exterior Increasing Mirror Glass
Adjustment Range
Vanagon ALL 66-87-03 Body Outside Mirrors, Electric
Exterior Mirror Assembly - Removing/
Intalling
Vanagon 1984-85 68-84-01 Body Rear Bench Seat Belts
Wolfsburg Interior
Vanagon 1980-89 68-91-02 Seat Belts Automatic Rear 3-Point
Camper/Multivan Seat Belt, Retrofit
Installation
Vanagon 1980-89 68-91-04 Seat Belts Automatic 3-Point Left Center
w/center Seat Belt, Retrofit
seat except Installation
Camper/Multivan
Vanagon 1983-85 70-87-02 Body Front Carpet Seam Gap
Interior
Vanagon From 76-89-01 Body Refrigerator Air Supply
Camper 1980 Interior Modification (Dometic 182
on Models)
Water-cooled 1983-85 80-87-01 Climate Carpet Wet by Rear Seat -
Vanagon Control Heat Exchanger Bleeder Screw
Broken
Vanagon ALL 87-84-06 Climate A/C Evaporator Blower Motor -
w/ A/C Control Installation of Reinforcement
Plate
Vanagon 1984-85 87-85-01 Climate Factory Installed Air
Control Conditioner - Replacement of
A/C Refrigerant Hose Mounting
Clamps
Water-Cooled From 87-87-02 Climate Water out of A/C Vents -
Vanagon 1986 on Control A/C on
Vanagon From 87-87-04 Climate Remove Noise Damper from A/C
w/ A/C 1986 Control Refrigerant High Pressure Hose
on
Vanagon 1986-89 87-89-01 Climate Evaporator Housing - Change
w/ A/C Control
Vanagon ALL 87-90-01 Climate A/C Evaporator -
Van Camper Control Water Leaking
Waterboxer
Vanagon ALL 90-86-02 Electrical Non-Interchangeable
System Cigarette Lighter
Vanagon ALL 90-90-01 Electrical Speedometer Noises (Except
Except System Syncro)
Syncro
Vanagon ALL 90-90-02 Electrical Instrument Indicator Lights
System Malfunction
Vanagon ALL 97-87-05 Electrical Engine Cranks Too Slowly or
Water-Cooled System Won't Crank - Battery Cable
Vanagon ALL 97-87-07 Electrical Engine Stalls and Misses
Water-Cooled System Intermittently / Fuel
Injection Wiring Harness
ALL ALL 90-92-03 Electrical Coolant Indicator LED is
Water-Cooled System Flashing at Normal
Temperatures
ALL ALL 90-87-03 Electrical Coolant Temperature Gauge
Water-Cooled System Light flashes intermittently
/ continuously
Technical Information
Group: 28
Number: 90-01
Date: March 31, 1990
Subject: Vehicle does not start, ignition miss
Model(s): Vanagon, from 1986 Model Year
If the engine does not start or in case of ignition related engine miss,
check the ignition coil for bitumen leakage. Bitumen leakage may be
caused by overheating of the ignition coil which may occur when the
engine runs for a prolonged period of time at idle.
Replace the standard grey labeled ignition coil with green labeled coil
Part No. 211 905 115 D. The green labeled coil was installed into
production as of 1/89. VIN: 25HG 06 5838.
*****************************************************************
* CAUTION *
* Part numbers are for reference only. Always check with your *
* Parts Department for latest information. *
****************************************************************
Technical Bulletin
Group: 24
Number: 92-01
Date: February 29, 1992
Subject: Vanagon Intermittent Misfire
Model(s): All Vanagon Digifant Fuel Injection Engines
CONDITION
After driving for 1/2 to 2 hours at a constant speed, vehicle
experiences lack of power, cuts-out or stalls, often accompanied by
bucking or jerking of the vehicle.
In ALL cases, the vehicle will restart immediately. This symptom may
not re-occur for several weeks/months. Inspection by the dealer results
in nothing conclusive.
Some air-flow meters may experience a vibration resonance of the
metering potentiometer wiper during extended constant driving. This
resonance causes the air-flow meter to supply an intermittent signal
to the Digifant ECU. The ECU will then default to a "no-load" condition
and reduce the injection time.
SERVICE
Harness, Part No. 025 906 302, is available to resolve this condition.
* remove electrical connector from air flow sensor (see Figure 24-174)
* install converter assembly, Part No. 025 906 302, between harness and
air flow sensor
NOTE
If customer complaints persist after performing the above repair,
contact your Zone Product Support Specialist (TSM in Canada).
*****************************************************************
* CAUTION *
* Part numbers are for reference only. Always check with your *
* Parts Department for latest information. *
****************************************************************
........................... end ......................................
harness costs about $100! very simple to install. takes about three
minutes maximum. the new harness fits between the old harness and the
silver air-flow meter box attached to the air cleaner box. remove the
silver clip, wiggle out the big wiring connector (from the side of the
air-flow meter), connect the proper end of the new harness to the big
big wiring connector you just wiggled out, put the new clip into the
new connection; then take the other end of the new harness and plug it
into the air-flow meter connection. put the silver clip back. and you
are done.
Technical Bulletin
Group: 24
Number: 92-02
Date: April 30, 1992
Subject: Vanagon Driveability Complaints
Model(s): All Water Cooled Engine Vanagons
SUPERCEDES TECHNICAL BULLETIN 24-92-01 (February 29, 1992)
CONDITION
After driving for an extended period of time at a constant speed, the
vehicle may, on occasion, experience a deterioration of performance
which may be accompanied by a hestiation or surging.
In many cases, after turning off the engine and subsequent re-start or
without having taken any action, the symptoms disappear. These symptoms
may not recur for several weeks or months.
SERVICE
To resolve this condition, wire harness Part No. 025 906 302, should be
installed. This harness provides improved signal voltage stablization.
* remove electrical connector from air flow sensor
* install wire harness, Part No. 025 906 302, between main harness
connetion and air flow sensor connection.
*****************************************************************
* CAUTION *
* Part numbers are for reference only. Always check with your *
* Parts Department for latest information. *
****************************************************************
NOTE
When troubleshooting this system and performing continuity checks, the
following should be noted. Due to active components in the wire
harness, Part No. 025 906 302, there is not continuity between pin two
of the connectors. The following chart on page 2 lists the resistence
of each circuit.
---------------------------------------------
Terminal Approximate
Number Resistance
---------------------------------------------
1 Zero Ohms
2 Greater than 1 Meg. Ohms
3 Zero Ohms
4 Zero Ohms
5 Zero Ohms
NOTE
If customer complaints persist after performing the above repair,
contact your Zone Product Support Specialist for assistance.
........................... end ......................................
harness costs about $100! very simple to install. takes about three
minutes maximum. the new harness fits between the old harness and the
silver air-flow meter box attached to the air cleaner box. remove the
silver clip, wiggle out the big wiring connector (from the side of the
air-flow meter), connect the proper end of the new harness to the big
big wiring connector you just wiggled out, put the new clip into the
new connection; then take the other end of the new harness and plug it
into the air-flow meter connection. put the silver clip back. and you
are done.
Technical Bulletin
Group: 24
Number: 24-90 T01
Date: May 31, 1990
Subject: Rough Idle, Engine Stalls - Tow in
Model(s): 1983-1990 Model Years
The clamp for the air intake boot to air flow meter/throttle body may
yield tension and could cause a vacuum leak. This may create a lean
running condition resulting in the engine to idle rough and in
severe cases stall while idling.
Installation of Boot Clamp Part Number 191 129 647 will correct this
condition.
VW Technical Information
Group: 42
Number: 87-01
Date: August 5, 1987
Subject: Knocking Noise from rear - CV Joint
Model(s): Vanagon, all model years
A noisy CV joint could be caused by hardened and dried lubricant.
* Disassemble and inspect all joints, repack serviceable joints
using new high temperature grease Part Number G 000 603.
* Replace worn CV joints using Kit Number 251 598 101. This joint
has a larger diameter ball bearing (from 19.05mm to 20.0mm) for
longer wear. Pack the replacement joint using the new high
temperature grease supplied with the kit.
Production Change:
CV joints with increased bearing diameter installed as of Dec. 1984,
VIN 25 FH 055 865
New high temperture grease in use as of Oct. 1986, VIN 25 HH 037 577
VW Technical Information
Group: 80
Number: 87-01
Date: July 31, 1987
Model(s): Water-cooled Vanagons, 1983-1985
Subject: Carpet wet by rear seat - heat exchanger bleeder screw broken
The plastic bleeder screw for the rear heat exchanger may be broken due
to seal swelling.
* Replace with an improved metal bleeder screw, Part number N 902 061 01.
and new gasket, Part number 861 819 037.
Production Change:
Metal bleeder screw installed as of:
December 1984, VIN: 25 FM 050 887
VW Technical Information
Group: 19
Number: 87-03
Date: December 21, 1987
Model(s): Vanagon, Water-cooled, model years 1983-1985
Subject: Carpet wet by rear seat - heat exchanger T-piece leaking
A coolant leak in the rear heat exchanger area may be due to poor hose
fit at the metal T-piece which connects the fee hose to the main coolant
hose. An imporved, white plastic T-piece with slightly larger diameter
is available to correct this condition:
* Replace metal T-piece with white plastic version,
Part number 253-265-543A
* Remove flow restrictor from inlet fitting of heater valve.
Production Change:
Improved T-piece installed as of Nov. 1984, VIN 25 FH 037 898.
Technical Information
Group: 17
Number: 87-05
Date: October 29, 1987
Subject: Oil Cooler seal leaks in extreme cold
Model(s): Vanagon waterboxer, all Model Years
Extreme cold weather can harden and split the seal between the engine
block and the oil cooler thus creating an oil leak:
* An improved cold-restistant seal was installed in production as of
02/87.
* The new seal can be identified by its silver-grey appearance and is
available through your parts department, Part No. N 901 814.02.
Technical Information
Group: 87
Number: 89-01
Date: August 31, 1989
Model(s): Vanagon with A/C, model years 1986-1989
Subject: Evaporator Housing - change
Starting April 1988, a running change was made to the evaporator housing
and introduced into production.
To prevent cracking, the body attachment points have been relocated.
Evaporator housings are now available through the parts depot and come
as a multiple supersession with the following items:
1 evaporator housing (color coded)
2 mounting brackets
2 shims (color coded)
6 rivets
6 body plugs (color coded)
6 bolts
INSTALLING
- disconnect battery
- remove front A/C control assembly and center vents
- remove both rear side covers at C-pillars
- remove both outside vent covers
- remove relay assembly from left C-pillar adn all tie wraps holding
A/C lines
- remove evaporator housing fasteners and lower housing
NOTE
Discharging the A/C system is NOT required due to the length of the
evaporator hoses. A cherry picker with a protective cover helps in
lowering the evaporator housing.
- bolt brackets to new evaporator housing and lift into postion
- with the evaporator firmly positioned against the roof, work through
the speaker holes, mark location of new bracket attachment points
approximately 40 mm (1.575 in.) above the original holes
- lower evaporator housing, center punch and drill holes to accomodate
rivets
NOTE
Rivets can be installed using Kent-Moore tool #M-39010
- install original covers on bolt heads
- install remaining components
Labor Operation Number: 8760-31-0
Suggested Repair Time: 280 t.u.
Technical Information
Group: 87
Number: 90-01
Date: March 31, 1990
Subject: A/C Evaporator - water leaking
Model(s): Vanagon/Vanagon Camper Waterboxer, all Model Years
Water may come out of A/C vents if the evaporator drain tray does not
drain properly. This may be caused by:
* A missing or clogged drain valve. A drain valve must be installed
on the drain hose to prevent water from being drawn back into the
evaporator housing via vacuum created by the blower motors.
1. For 1/2" o/d hose, use drain valve Part No. 253 260 180
2. For 3/8" o/d hose, use drain valve Part No. 431 260 155
Clogged drain valves should be cleaned of all foreign matter
and must be reinstalled.
A water drain valve has been installed in production as of 5/88.
VIN 25JH 09 3520
25JG 09 5871
* Make sure drain hoses are properly routed without kinks or
positioned with an upward bend.
On Vanagon and Camper models check that the drain hose is not
kinked at the "D" pillar.
On Campers also check that the hoses are not kinked as they pass
through the cabinets.
* An oversized fiber hose can cause the front of the drain pan to rise
forcing the water to move to the rear of the pan.
* Loose drain hoses at drain pan or elbow (on earlier Waterboxer
Campers) connections. If leaks occur at a connection and the hose is
not damaged, install a clamp to seal the hose.
* Warped drain pans. When replacing the drain pan remove the parts
labels to avoid later drainage problems.
* In extreme cases, with a high blower speed, water may circulate into
a gap where the drain pan and evaporator converge. Seal gap with
duct tape (A/C wrap).
******************************************************************
* CAUTION *
* Part numbers are for reference only. Always check with your *
* Parts Department for latest information. *
******************************************************************
Technical Bulletin
Group: 90
Number: 90-01
Date: Nov 30, 1990
Subject: Speedometer Noisy
Model(s): Vanagon, except Syncro
Condition:
Noise in the magnet shaft bearing of the speedometer.
Production:
Speedometers with a spring loaded magnet shaft bearing are in
production as of:
4.90 VIN 25 LH 071 889
Service Solution:
Replace speedometer (No change in part number). Parts Division supply
only new version speedometers, which can be identified by the graphite
(dark gray) speedometer bushing. (Previously black)
Replacing speedometer cable:
As of VIN 25 HH 040 185, the protective sleeve is lengthened,
eliminating the fastening marking.
Note
To ensure correct installation, be sure to measure and mark the distance
"a" from end of cable to position the securing clip.
Distance between end of cable to the mark is 740 mm. (29 in.)
1 2 3
__________ _____________||_||_____
:=|=========|_________/ /______________||_||_____
^ || ||
| (_O_)
| ^
| |
|<----------------- a ------------------->|
90-789
Technical Bulletin
Group: 90
Number: 90-02
Date: Nov 30, 1990
Subject: Instrument Indicator Lights Malfunction
Model(s): Vanagon
Condition:
Instrument cluster warning lights are inoperative at times due to poor
contact in the 14 pin instrument plug. The following warning lights
may be involved:
Oil pressure, alternator, turn signal, high beam, or coolant
temperature.
Service Solution:
Check compact plug for proper contact adn seating. Replace spring
terminals when necessary.
Technical Bulletin
Group: 90
Number: 92-03
Date: February 29, 1992
Subject: Coolant Indicator LED is Flashing at Normal Temperatures
Model(s): All Models
CONDITION
Coolant overheat / low coolant level indicator LED is flashing at
normal coolant temperatures.
SERVICE
Check the coolant indicator LED according to the list below.
The following applies IN ADDITION to tests listed in the Service
Microfiche. .
* refer to appropriate wiring diagram
* disconnect coolant level sensor electrical connector
* check coolant level in coolant reservoir
*** MUST be between MIN and MAX marks
* set digital multimeter, Fluke 83 (US 1119) to ohms function
* check resistance of level sensor with digital multimeter Fluke 83
(US 1119)
*** must be between 31K Ohm and 65K Ohm with correct COOLANT LEVEL
AND COOLANT CONCENTRATION.
NOTE
If coolant resistance is NOT within the above specifications, the
coolant MUST be drained and replaced with NEW coolant mixture of
50 percent water and 50 percent phosphate free coolant antifreeze,
Part No. ZVW 237 104. (In Canada, use Part No. G 001 100). The
mixing should be performed before filling vehicle cooling system.
*****************************************************************
* CAUTION *
* Coolant concentrations of 60 percent or higher will cause the *
* overtemp / low coolant LED to activate. *
****************************************************************
*****************************************************************
* CAUTION *
* Coolant antifreeze MUST NOT be reused. Properly dispose of *
* used coolant. *
****************************************************************
* reconnect sensor connector
* check coolant level control unit using wiring diagram
NOTE
The control unit is located on top of the fuse/relay panel on vehicles
up to 1989 model year and thereafter it is integrated into the multi-
processor of the instrument cluster circuit board.
* if wiring, coolant level sensor and coolant concentration are OK,
replace coolant level control unit or instrument cluster circuit
board
* refer to appropriate Service Microfiche Group 90 - Coolant
Temperature Gauge, checking and troubleshooting
* confirm proper operation of temperature gauge and blinking LED per
Service Microfiche Group 90
*****************************************************************
* CAUTION *
* Part Numbers are for reference only. Always check with your *
* Parts Department for latest parts information. *
****************************************************************
Technical Information
Group: 90
Number: 87-03
Date: July 31, 1987
Subject: Coolant Temperature Gauge Light flashes
intermittently / continuously
Model(s): All Models, all Model Years
Flashing coolant temperature light may be caused by:
- Low coolant level.
- Coolant level indicator.
- Electrical connections on gauge.
* Check coolant level, top up if necessary.
* Check coolant level sensor for continuity.
* Check for loose connection of wiring at terminal 14 connectors of
instrument cluster, nuts of temperature gauge, ground connection
to body and engine ground. Repair if necessary.
If temperature gauge light still flashes:
* Replace low coolant level control unit
Technical Information
Group: 24
Number: 90-03
Date: March 31, 1990
Subject: Throttle Body - replacement
Model(s): Vanagon, all w/ Digijet Injection
Replacement throttle body, Part No. 025 133 061B, has been updated with
the current throttle switch and lacks one vacuum line for the
distributor.
When installing this current replacement throttle body, the following
mechanical and electrical modifications must be completed.
Work Sequence
Mechanical:
* cut hose "A" (from throttle body to fuel pressure regulator) 150mm
from intake air distributor port
* install vacuum "T", Part No. 025 201 943, at location "B" (cut in
hose "A")
* install vacuum hose "C" (from "T" to distributor)
(Part No. N 020 353 5, approx. 70mm) between vacuum tee "B" and
distributor vacuum advance unit
Electrical:
* remove the jumper wire for both switches and install supplied
connectors.
Check for vacuum leaks, check and reset basic engine specifications.
Technical Bulletin
Group: 30
Number: 89-01
Date: February 28, 1989
Subject: Clutch Disc, installing
Model(s): Vanagon, all with Manual Transmission
The clutch disc hub and matching splines of the mainshaft are not to
be lubricated with MOS2 grease as described in the repair manual.
Instead, lubricate with grean P/N: G 000 100.
* splines must be cleaned of all dirt and corrosion before lubricating.
* use only a thin coat of grease.
* clutch disc must move easily on shaft.
Technical Bulletin
Group: 34
Number: 89-03
Date: February 28, 1989
Subject: Revised shift lever bearing
Model(s): Vanagon, all with Manual Transmission
* Beginning with 06/88 production, the centering holes (arrow) in the
shift lever bearing have been deleted.
Revised shift lever bearing, adjusting:
* loosen nuts (not shown).
* turn shift lever bearing to right or left until mounting studs
contact ends of slots in bearing (arrows)
* tighten nuts to 10 Nm (7 ft lb)
Further adjustment of the gearshift lever is to be conducted as
described in the repair manual.
Note
The revised shift lever bearing can be installed in vehicles beginning
with 10/82 production.
Product Circular
Group: 90
Number: 86-02
Date: July 11, 1986
Subject: Non-interchangeable cigarette lighters
Part Identifier: 9062
Model(s): Vanagon
Two different cigarette lighters are used in Volkswagen vehicles and
they are NOT interchangeable. If installed in the wrong vehicle, it
is possible that the lighter will not release properly, thus causing
a possible safety hazard.
Fig. 1 Fig. 2
Part number 175.919.307B Part number 171 919 305
or 191 919 305
Application: Rabbit - all Application: Cabriolet - all
Pickup - all Jetta - all
Golf - all Quantum - all
GTI - all Scirocco - all
Vanagon - all
Technical Information
Group: 97
Number: 87-05
Date: July 31, 1987
Subject: Engine cranks too slowly or won't crank - battery cable
Model(s): Water-cooled Vanagon, all Model Years
A slow or non-cranking engine condition could be caused by high
resistance between the starter motor and battery:
* Check that the battery is fully charged.
* Check the ground connections and battery terminals for tightness
and corrosion. Clean and tighten as necessary.
If the conditon still exists:
* Install a new starter cable or larger diameter,
Part Number 251 971 228G.
* Install an extra ground strap from the transmission to the body.
Technical Bulletin
Group: 27
Number: 87-04
Date: August 06, 1987
Subject: Alternator mounting bolt loose/broken
Model(s): Water-Cooled Vanagon Diesel, Vanagon through model year 1985
To prevent the alternator bolt from becoming loose and breaking, the
torque specification has been increased.
The increased torque specification requires use of a new bolt on 1.9L
water cooled engines.
To repair a loose/broken bolt:
1.9L Gas Engine
* Install new bolt, Part Number N 014 400 4.
Torque to 25Nm (18 ft. lb.).
Diesel Engine
* Replace bolt only if damaged, Part Number is unchanged.
Torque to 28-33Nm (21-24 ft. lb.).
Technical Bulletin
Group: 17
Number: 87-04
Date: September 30, 1987
Subject: Oil leak from rear - oil pump gaskets
Model(s): Vanagon, 1983-1985
Supercedes 87-01, July 15, 1987.
Oil seepage from the oil pump on 1.9L water-cooled engines is caused
by gaskets which are not fully compressed.
* Replace the oil pump gasket with Part Number 025 115 111 (quantity
of 2). These gaskets are interchangeable.
Tech News 87-N02
Issue 2, February 1987
Cold Feet, Hot Tip
A slight "internal" compression leak into the coolant system of a water-
cooled Vanagon is not always easily diagnosed. But what your customer
tells your Service Advisor may be very helpful to pinpoint such a
problem:
* Temperature gauge needle moves into the red
* Very little or no heat output
* Coolant refill tank overflows
* Air in the coolant system
If one or a combination of these symptoms apply, be suspicious of a
compression leak between cylinder sleeve and cylinder head. Either
the metal sealing ring (1) or the 'O' ring (2), or both may be damaged.
(1) is the outer most sealing ring; next to the cylinder head.
(2) is the inner most sealing ring; next to the cylinder sleeve.
Tech News 87-N04
Issue 4, April 1987
Vanagon Surging/Stalling
A customer complaint of surging/stalling on 1986 and '87 Vanagons could
be the result of a misadjusted idle/full throttle switch.
The digifant system uses a single throttle switch to signal the E.C.U.
when the throttle plate is in the fully closed (idle) or fully open
(full load) position.
Correct adjustment of the throttle switch is very important. If switch
is misadjusted, the engine may surge at idle or cut out at steady
driving or light acceleration.
Here are some key points to remember:
* Set or check the switch adjustment only after the engine reaches
operating temperature.
* When setting or checking your adjustment allow the throttle to return
"normally". Do not "snap" the throttle causing it to slam shut ...
this could adversely affect the switch adjustment. See the Vanagon
Repair Microfiche for complete throttle switch adjustment details.
Tech News 87-N05
Issue 5, May 1987
Easy Does It
When removing the cross-over water pipe on a 1982 through 1985 model 1.9
liter Vanagon waterboxer engine ... you have to use care.
The cross-over pipe is secured to a welded stud on the intake manifold
(arrow) that could break or crack.
< picture showing engine from rear of car >
If this happens, a vacuum leak could develop that would be hard to
detect. Such a vacuum leak could cause poor performance under all
running conditions due to leaning out of the mixture ... and would
occur even when all other systems are go.
Tech News 87-N06
Issue 6, August 1987
Vanagon "Dust Buster" Air Filter
Vanagon owners who operate their vehicles in high dust concentration
areas have some relief in store ... from our parts store, that is.
A specially designed air filter, Part No. 025 129 620 B, standard
equipment on Vanagon Syncro models, is what these owners need.
Special "dust buster" style air filters are also available for other
Volkswagen models that operate in the dust. So if you encounter an air
cleaner that looks like a "dust bowl" ... you know what to recommend.
Tech News 87-N08
Issue 8, August 1987
Basic Digifant Assumptions
The Digifant engine management system found on late model Vanagons
operates on the assumption that basic engine TIMING, IDLE SPEED,
THROTTLE SWITCH AND CO%, are correctly set or adjusted.
If not, the system will try to compensate for anyu deviation and end up
"fighting" with itself to make the engine run. That's why it is
critical that these basic engine settings are checked prior to any work
you perform on the Digifant system. Equally critical is the need to
use Adapter VW 1473 with your VAG 1367 and US 1119 milliamp meter with
VW 1315A/2 adapter as well as your CO Meter to verify that idle RPM/
stabilizer milliamp and CO% readings are right.
These settings, as well as everything you ever wanted to know about
Digifant, are found in the newly released Vanagon Fuel System Pro-
Training booklet ... available at your dealership now.
For troubleshooting wiring problems, always use the latest wiring
diagram which appears on a circular.
Tech News 88-N07
Volume 2, Issue 7, August 1988
Coolant Loop
If you have to remove the transmission only on a 2.1 liter Vanagon, be
very careful to check the "Coolant Loop" around the engine compartment.
You can easily break this loop! Keep an eye on the hose between the
engine and the loop. Make sure that the loop does not start to pull
tight as teh back of the engine comes down or it will probably break.
If this hose seems too short, take it off the loop or loosen the loop
from the edge of the engine compartment.
Technical Bulletin
Group: 20
Number: 20-90 T01
Date: May 31, 1990
Subject: Improved fuel additive ZVW 239 003
Model(s): All Gasoline Engine Vehicles
Research by Volkswagen AG and other manufacturers has shown that the
performance of todays gasoline engines is directly influenced by the
type and quality of fuel used.
Fuel without the proper additives can cause deposits to collect on
fuel injectors, intake ports and valves.
This build-up of deposits can cause the following conditions:
* unstable idle * power loss
* surging * engine run-on
* misfiring * pinging/knocking
Extent of deposit build-up varies depending on type of fuel used,
operating condition, etc. Refer to current Technical Information
Circulars for description of deposit grading system.
PREVENTION
Prevent deposit build-up through the use of gasolines with injector
and intake valve deposit control additives.
Consult the suppliers and service stations in your area about fuel
grades and additives that prevents or removes these two deposits. < sic >
In areas where gasoline containing deposit control additives are
unavailable, light deposits can be controlled as follows:
* add one 6.5 oz. bottle of Autobahn Gasoline Additive,
P/N: ZVW 239 003.
Note: Fill fuel tank completely. Do not refill until fuel gauge
reads 1/4 tank or less.
REMOVAL
Moderate to heavy deposits can also be removed with Autobahn Gasoline
Additive, P/N: ZVW 239 003.
When used as follows this additive has shown to be effective.
* Check fuel injector spray pattern. Purge injection system with G-16
cleaner. Refer to current Technical Information Circulars for
injection purge instructions.
* Check that fuel and ignition systems are within specifications.
* Add three (3) 6.5 oz bottles of Autobahn Gasoline Additive,
P/N: ZVW 239 003 for each of three (3) consecutive fill-ups or
1000 miles.
Heavy deposit concentration may require 2 or 3 cycles of the above
treatment.
Note: Fill fuel tank completely. Do not refill until fuel gauge
reads 1/4 tank or less.
* Deposit removal with Autobahn Gasoline Additive, P/N: ZVW 239 003
is more efficient with engine at operating temperature and at
moderate speed, short distance driving conditions.
* Because of possible contamination of the oil, the filter and oil
must be changed at the conclusion of each removal cycle.
Technical Information
Group: 20
Number: 90-02
Date: March 31, 1990
Subject: Gasoline containg detergents
Model(s): All Vehicles with fuel injection
Volkswagen United States, Inc. recommends the use of gasolines which
contain detergents to keep intake valves and fuel injectors free of
deposits.
Gasolines without detergents tend to clog fuel injectors and leave
residue on intake valves which can cause unstable idle, surging,
misfiring of sparkplugs, stlling and rough engine performance in
vehicles with fuel injection systems.
Because many of our customers may not know whether or not a particular
brand of gasoline contains these detergents, we have examined
advertising literature published by gasoline refiners and other publicly
available literature discussing gasoline ingredients.
We cannot independently confirm the accuracy of gasoline advertising
claims. The brands of gasolines listed below are claimed by their
manufacturers to contain detergent packages designed to keep intake
valves and fuel injectors clean. There may be other manufacturers that
offer similar detergent packages.
Please pass this information on to customers who have experienced
driveability problems that may be caused by carbon deposits on intake
valves or fuel injectors.
Amoco: All grades
Arco: All grades
Chevron: All grades
Citgo: Some grades in early 1990
Conoco: Some grades in early 1990
Diamond Shamrock: Premium grade only
Exxon: All grades
Fina: All grades in early 1990
Hess: All grades in early 1990
Marathon: All grades
Mobil: All grades
Phillips 66: All grades in early 1990
Shell: All grades
Sunoco: Premium grade only
Texaco: All grades
Unocal: All grades
Technical Bulletin
Group: 00
Number: 90-01
Date: August 31, 1990
Subject: Lubricant Capacities/Lubricant Type
Model(s): Air-cooled, Water-cooled -- All 1975-1990
Vehicle: Vanagon
Model Year: 1980-up
Engine Oil:
Air-Cooled: 3.0 liter (3.2 quart)
3.5 liter (3.7 quart)/Filter
Water-Cooled: 3.8 liter (4.2 quart)
Thru 1986 MY 4.2 liter (4.7 quart)/Filter
From 1987 MY 4.3 liter (4.8 quart)/Filter
Diesel: 3.5 liter (3.7 quart)
3.8 liter (4.2 quart)/Filter
Use 'API SERVICE SF' for Gasoline engines.
Use 'API SERVICE CC or CD' for Diesel engines.
Note: Refer to Owner's Manual for oil grade/climate requirements
Manual Transmission:
Air-Cooled: 4 speed: 2.9 liter (3.2 quart)
SAE 80/80W/90,
MIL-L-2105, API/GL-4
Water-Cooled: 4 speed: 2.5 liter (2.8 quart)
SAE 80/80W/90,
MIL-L-2105, API/GL-4
Diesel: 4 speed: 2.5 liter (2.8 quart)
5 speed: 3.4 liter (3.8 quart)
SAE 80/80W/90,
MIL-L-2105, API/GL-4
Automatic Transmission:
All Models: Dry Fill: 6.0 liter (6.3 quart)
ATF Dexron/Dexron II
Refill: 3.0 liter (3.2 quart)
ATF Dexron/Dexron II
Automatic Differential:
All Models: 1.2 liter (1.3 quart)
SAE 90W, MIL-L-2105 B, API/GL-5
Cooling System:
Waterboxer & Thru 1986 MY 15.2 liter (16.9 quart)
Diesel
Waterboxer From 1987 MY 16.7 liter (18.6 quart)
Use only Phosphate Free Coolant ZVW 237 104 (G11) or equivalent
Power Steering:
All Models: 1.2 liter (1.3 quart)
ATF Dexron II
Windshield Washer Solvent:
All Models: Front: 3.9 liter (4.3 quart)
9.0 liter (9.5 quart)
w/ headlite washers
Rear: 1.0 liter (1.1 quart)
Recommended Solvent: Concentrated ZVW 177 901/903
Pre-mix ZVW 177 902 or Equivalent
Air Conditioning:
Air-Cooled &
Water-Cooled: Refrigerant (R-12) - 1190 + 85 grams
(42.0 + 3.0 oz.)
Refrigerant Oil - 135 cc (4.75 oz.)
Diesel,
From 1986 MY: Refrigerant (R-12) - 1438 grams (50.75 oz)
Refrigerant Oil - 237 cc (8.0 oz.)
U.S.A. Only: Use any domestic available refrigerant oil
Canada Only: Use Suniso 5GS refrigerant oil, available
through VWC, Part No. X 091050
**********************************************************************
* CAUTION: Part numbers are for reference only. Always check with *
* your Volkswagen Parts Department for latest information. *
**********************************************************************
Technical Information
Group: 40
Number: 88-01
Date: May 31, 1988
Subject: Upper control arm bushings, checking
Model(s): Vangon, all model years
An insufficient seal at the outer ends of the upper control arm bushings
can cause premature wear to the bushings. Visually inspect the bushings
as follows to determine if replacement is necessary.
NOTE
When checking the bushings, both front wheels must be on the ground.
* Bolt head or nut/washer must be postioned in center of bonded rubber
bushing.
* If bolt head or nut/washer comes in contact with supporting ring
(arrow), wear limit has been reached and bushing must be replaced.
< picture shows the hex-head bolt of the upper control arm, which
passes through the bushings. the 'arrow' seems to be pointing to the
'eccentric washer' which is shown in the Bentley book on page 40.2. >
this same information is also shown on page 40.5a of the July 15, 1991
edition of the Bentley Vanagon Manual.
Technical Information
Group: 68
Number: 91-02
Date: April 30, 1991
Subject: Automatic Rear 3-Point Seat Belts, Retrofit Installation
Model(s): Vanagon, 1980-1989 Model Years
Vanagon Camper/Multivan (right rear only),
1980-1989 Model Years
AUTOMATIC REAR 3-POINT SEAT BELTS, RETROFIT INSTALLATION
**********************************************************************
* CAUTION *
* Part numbers are for reference only. Always check with your Parts *
* Department for latest information. *
**********************************************************************
PARTS REQUIRED
Part Number Description Quantity
253 857 815D Rear 3-point seat belt (left side) 1
253 857 816D Rear 3-point seat belt (right side) 1
NOTE
Check with your Parts Department for additional installation parts.
Not all parts listed may be applicable to all vehicles.
* remove rear seat bottom
* remove existing 2-point left/right side lap belt
* remove rear floor carpet
* remove right rear luggage area trim panel
* mark and cut rear luggage area trim panel using dimensions as shown
on Page 3
* locate, by feel, threaded hole under D-pillar trim (arrow)
< arrow seems to indicate a point on the D-pillar about six inches
above the lower trim panels, and about 1-2 inches from the forward
(front) edge of the D-pillar >
* cut hole in trim to expose threaded bolt hole
* using bolts (2), mount retractor assembly (1), to side panel (3)
-> 40 Nm (30 ft lb)
< behind the luggage area trim panel, it shows three bolt holes along
the bottom edge of the metal of the body. the retractor assembly
fits BEHIND the metal, and the bolts pass THROUGH the metal into the
retractor assembly >
* install belt through cut hole in trim panel
* mount upper belt guide onto D-pillar
-> 40 NM (30 ft lb)
< the bolt for the upper belt guide goes into the hole you felt for
behind the trim of the D-pillar>
* install belt anchor (arrow) to original lap belt anchor point
-> 40 Nm (30 ft lb)
* reinstall right rear luggage area trim panel
* repeat procedure for left side belt assembly, noting to reverse
dimensions accordingly
* reinstall all other components in reverse order
* check rear 3-point belts for proper function
---------------------------------------------------
Automatic rear 3-point | | | |
seat belts, retrofit | | | |
installation | Diag. | | Quality |
(one side only) | Check | Repair | Check |
---------------------------------------------------
Labor Op. 6876312 | -- | 120 T.U.| -- |
---------------------------------------------------
< which seems to say that the vw dealer will charge you two hours labor
plus parts >
DIAGRAM
<-Front of vehicle Top
Luggage area trim panel
/-------------------------------------------------\
/ 203mm 210mm \
/ (8in) < 71mm > (8-1/4in) \
/ ______ ________<-------- 403mm --> \
/ 38mm | hole | (15-7/8in) \
/ ______ |______| \
/ |
/ |<-149mm-->| |
/ | (5-7/8in)| |
/ |----------|-- |
/ | | 32mm (1-1/4in) ______|
/---------------------------------| |---------------|
|<------- 569mm (22-3/8in)------->|
........................................ end ...........................
that is, the dimensions of the hole are 71mm x 38mm (2-13/16in x
1-1/2in). but the front edge of the hole is 203mm (8in) below the top
edge of of the luggage area trim panel, while the rear edge of the hole
is 210 mm (8-1/4in) from that same edge. the hole is slightly tilted.
the notch is cut in the bottom to accomodate those three bolts that
hold the retractor assembly to the metal of the body.
also notice that this does NOT say anything about those 1986-1989
vanagons with air conditioning. the upper belt guide attachment point
will be behind the air conditioning housing that runs vertically over
the D-pillar. so you would have to cut a hold in the plastic a/c
housing to pass the belt through. (it helps to look at a 1990 or 1991
model, to see how the factory installation looks). in order to prevent
damage to the belt, the little plastic edging (that covers the edges
of the hole in the a/c housing) will have to be installed.
Technical Information
Group: 68
Number: 91-04
Date: April 30, 1991
Subject: Automatic 3-Point Left Center Seat Belt, Retrofit Installation
Model(s): All Vanagon w/ center seat, EXCEPT Camper/Multivan
1980-1989 Model Years
AUTOMATIC 3-POINT LEFT CENTER SEAT BELT, RETROFIT INSTALLATION
**********************************************************************
* CAUTION *
* Part numbers are for reference only. Always check with your Parts *
* Department for latest information. *
**********************************************************************
PARTS REQUIRED
Part Number Description Quantity
------------ ----------------------------------- --------
253 857 811D 3-point seat belt (left side) 1
NOTE
Check with your Parts Department for additional installation parts.
* remove rear seat back
* remove rear seat bottom
* remove original left center belt
* remove rear left side panel trim
< this is the triangular trim panel just below the forward edge of
the rearmost left side window >
* measure location of belt retractor, belt guide, and mounting holes,
using dimensions on page 3
* cut panel as required
* reinstall trim panel
* install seat belt retractor on outside of panel, as shown
-> 40 Nm (30 ft lb)
-> hand tighten forward bolt only
* locate, by feel, threaded hole in C-pillar (arrow) for belt guide
D-ring
< diagram seems to indicate a point about 5-6 inches from the top
edge of the side windows, in the middle of the C-pillar>
* cut C-Pillar trim from threaded hole, install belt guide D-ring
-> 40 Nm (30 ft lb)
* install anchor of 3-point belt into forward mounting hole of
retractor bracket (arrow A)
-> 40 Nm (30 ft lb)
< diagram shows this to be at the very bottom front edge of the
trim panel, almost at the floor level >
* align bracket for betls, reinstall rear seat bottom and belts
* reinstall rear seatback
* install new buckle for 3-point belt
* check seat belt for proper function
---------------------------------------------------
Automatic left center | | | |
3-point seat belt, | | | |
retrofit installation | Diag. | | Quality |
(left side only) | Check | Repair | Check |
---------------------------------------------------
Labor Op. 6876311 | -- | 150 T.U.| -- |
---------------------------------------------------
< which seems to say that the vw dealer will charge you two and one half
hours labor plus parts.>
DIAGRAM
Top Front of Vehicle -->
Rear Left side trim panel
-------------------------------------------------
|
|
|
|
_________ _________________|__________
| 67mm | | 38mm
|(2-5/8in)| | (1-1/2in)
\ |_________|_________________|_____:________
\ | .
\ < 102mm > | .
>\ 31mm< hole (4in) | .
---\-- () 22mm __________ _______._ | 442mm
. \ . | | . | (17-3/8in)
. \ . | 118mm | 327mm | .
. \ | (4-5/8in)| (12-7/8in) | .
. \ _._|__________|._ . | .
. \ . . . | .
. \ . . . ()--------.--(hole 22mm)
. \ 245mm 216mm . > 31mm|< . (7/8in)
298mm \ (9-5/8in) (8-1/2in) . | . .
(11-3/4in) \ . . . | 203mm .
. \ . . . | (8-1/8in) .
. \ . . . | . .
.____________ \_._____________.______.__________| ___._______._
........................................ end ...........................
that is, the dimension of the bottom hole is 118mm x 102mm (4-5/8in x
4in). but the front edge of the hole is 216mm (8-1/2in) above the
bottom edge of the trim panel, while the rear edge of the hole is
245mm (9-5/8in) from that same edge. that is, the hole is slightly
tilted. the upper hole is 67mm x 38mm (2-5/8in x 1-1/2in) and appears
also to be slightly tilted. the upper hole has its bottom front edge
442mm (17-3/8in) from the bottom edge of the trim panel.
notice that the instructions do NOT say anything about those two 22mm
(7/8in) holes. both are 31mm (1-1/4in) from the closest edge of the trim
panel. the lower of the two is 203mm (8-1/8in) from the bottom edge,
while the upper of the two holes is 298mm (11-3/4in) above that same
bottom edge.
i have no idea what those holes are supposed to be used for.
Technical Information
Group: 28
Number: 87-04
Date: July 15, 1987
Subject: Rough idle or misfiring during partial load
Model(s): All Models, all Model Years
A rough idle or misfire during partial load could be caused by ignition
sparks jumping from the plug wire connector to the noise suppresion
shield, or the cylinder head.
* Remove and inspect the plug connector for white spots or burn marks.
* On those vehicles equipped with a suppressor shield on the
distributor cap, it is necessary to remove the shield and check for
white spots or burn marks on the distributor cap.
if white spots or burn marks are present, replace the damaged
components.
|