Page 2 - DRAINING; Remove cap from coolant expansion tank. See; SOUND DAMPENING PAN
makes up the "engine code", and the second part (6 characters), the "serial number". If more than 999,999 engines with the same engine code are produced, the first of the six characters is replaced with a letter. Fig. 2: Locating Vehicle Data Plate Courtesy of VOLKSWAGEN UNITED STATE...
Page 3 - Courtesy of VOLKSWAGEN UNITED STATES, INC.; FILLING; Open bleeder screw in coolant hose to heater core.; 996 Volkswagen EuroVan CV
Fig. 3: Draining Cooling System (2.4L Diesel) Courtesy of VOLKSWAGEN UNITED STATES, INC. FILLING 1. Open bleeder screw in coolant hose to heater core. CAUTION: If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, DO NOT reuse old coolant. NOTE: The cooling system is filled...
Page 4 - Slowly fill with coolant up to MAX mark on expansion tank. See; Close bleeder screw in coolant hose to heater core.
2. Press down on top of radiator hose. 3. Slowly fill with coolant up to MAX mark on expansion tank. See Fig. 4 . Fig. 4: Identifying Expansion Tank MIN & MAX Marks Courtesy of VOLKSWAGEN UNITED STATES, INC. 4. Close bleeder screw in coolant hose to heater core. 5. Start engine and run approxima...
Page 5 - DRIVE BELTS; Remove lower sound dampening pan. See; possible to move the generator easily by hand. See; New Belt
DRIVE BELTS 2.4L DIESEL (UP TO JANUARY, 1995) The 2.4L diesel engine (up to 1/95) uses of V belts to drive the accessaries. For drive belt routing, see Fig. 5 . Removal & Installation (Generator V Belt) 1. Remove lower sound dampening pan. See SOUND DAMPENING PAN . 2. Loosen all securing bolts f...
Page 9 - and; See
Fig. 8: Ring Insert (1410/2) Required For V Belt Installation Courtesy of VOLKSWAGEN UNITED STATES, INC. 2.4L DIESEL (FROM FEBRUARY, 1995) The 2.4L diesel engine (2/95 and up) uses a single serpentine belt. For drive belt routing, refer to Fig. 11 and Fig. 12 . Serpentine belt may also be referred t...
Page 15 - FRONT BUMPER; Pull drive pins out and pull bumper parallel out of guides. See; The trim frame may also be referred to as lock carrier.
Fig. 14: Installing Serpentine Belt Onto Power Steering Drive Pulley (2.4L Diesel, With A/C) Courtesy of VOLKSWAGEN UNITED STATES, INC. REMOVAL & INSTALLATION FRONT BUMPER Removal & Installation (Up To December, 1995) 1. Pull drive pins out and pull bumper parallel out of guides. See Fig. 15...
Page 17 - Remove radiator grille with trim frame. See; RADIATOR GRILL & TRIM FRAME; Disconnect right then left side of bumper beam. See
1. Remove radiator grille with trim frame. See RADIATOR GRILL & TRIM FRAME . 2. Remove Torx screws (2 and 3). See Fig. 16 . 3. Disconnect right then left side of bumper beam. See Fig. 16 . 4. To remove bumper beam, pull beam straight out of guide bracket. 5. To install, reverse removal procedure...
Page 20 - RADIATOR & RADIATOR FAN
Courtesy of VOLKSWAGEN UNITED STATES, INC. RADIATOR & RADIATOR FAN Special Tools For radiator fan removal, required special tools. z Anti-Freeze Tester z Drip Tray (VAG 1306) z Spring-Type Clip Pliers (VAG 1921) z Torque Wrench (VAG 1331) Removal & Installation Remove lower sound dampening p...
Page 30 - SERPENTINE BELT TENSIONER
Fig. 24: Removing & Installing Radiator Grill With Trim Frame (From January, 1996) Courtesy of VOLKSWAGEN UNITED STATES, INC. SERPENTINE BELT TENSIONER 1996 Volkswagen EuroVan CV COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL 4 января 2005 г . 0:54:41 Page 30 © 2004 Mitchell Repair Infor...
Page 33 - drive shaft at transmission flange.
Courtesy of VOLKSWAGEN UNITED STATES, INC. 3. On all engines, remove left and right securing bolts and fold lock carrier and radiator out forward. See Fig. 26 . Remove power steering line retainers from tensioner bracket and engine mounting. Fig. 26: Identifying Lock Carrier Securing Bolt (Engine Co...
Page 38 - tensioner retainer and engine support assembly complete. See; TORQUE SPECIFICATIONS
Fig. 30: Identifying Front Transmission Mount (ACV, Man. Trans.) Courtesy of VOLKSWAGEN UNITED STATES, INC. 7. On all engines, remove right-hand engine mount center bolt(s). Lower engine using (VAG 1383 A) engine and transmission jack as far as possible, push forward and prevent from swinging back b...
Page 39 - Unscrew two hex nuts and six combination hex bolts. See
Fig. 32: Identifying Serpentine Belt Tensioning Components Courtesy of VOLKSWAGEN UNITED STATES, INC. SOUND DAMPENING PAN Removal & Installation 1. Unscrew two hex nuts and six combination hex bolts. See Fig. 33 . 2. Unhook locking lever. 3. Swing down dampening pan and unhook at brackets. 4. To...
Page 41 - THERMOSTAT; under BLEEDING COOLING SYSTEM.; TIMING BELT; For timing belt service required special tools, see
Fig. 34: Removing & Installing Sound Dampening Material Courtesy of VOLKSWAGEN UNITED STATES, INC. THERMOSTAT Removal & Installation 1. The thermostat housing is located on the left, front side of the cylinder block (behind water pump housing). Remove lower sound dampening pan. See SOUND DAM...
Page 45 - .Fold lock carrier with radiator out forward. See
Fig. 36: Timing Belt Required Special Tools (2 Of 2) Courtesy of VOLKSWAGEN UNITED STATES, INC. Removal (Vehicles Up To January, 1995) 1. Remove sound dampening pan. See SOUND DAMPENING PAN . 2. Remove the front grille. See RADIATOR GRILL .Fold lock carrier with radiator out forward. See Fig. 20 . 3...
Page 49 - belt pulley securing bolts. Remove vibration damper.
Fig. 40: Setting Crankshaft To TDC Cylinder No. 1. Courtesy of VOLKSWAGEN UNITED STATES, INC. 6. Remove vibration damper center bolt. Remove the 4 x M8 crankshaft vibration damper and timing belt pulley securing bolts. Remove vibration damper. 7. Release timing belt tension by loosening coolant (wat...
Page 52 - Install cylinder head cover and timing belt cover.; DRIVE BELT
Fig. 43: Adjusting Timing Belt Using Tool (VW210) Courtesy of VOLKSWAGEN UNITED STATES, INC. 7. Tighten lower timing belt cover. Ensure crankshaft is still positioned at TDC No. 1 cylinder, correct if necessary. 8. Tighten camshaft sprocket securing bolt using Counter-Hold Tool (3036). Observe steel...
Page 53 - For ACV engine code only, remove charge air cooler bracket. See
1. Remove serpentine belt. See DRIVE BELTS . 2. Remove radiator grille. See RADIATOR GRILL & TRIM FRAME . 3. For ACV engine code only, remove charge air cooler bracket. See Fig. 26 . Remove left and right hand securing bolts. Fold lock carrier and radiator out forward. 4. Remove both timing belt...
Page 56 - Manufacturer recommends using NEW center bolt, if removed.
6. On all engines, remove vibration damper bolt. See Fig. 39 . Remove lower timing belt guard. 7. If reusing old timing belt, mark belt with arrow indicating original direction of rotation.Move tensioning roller and remove timing belt. See Fig. 46 . Installation (Vehicles From February, 1995) 1. Che...
Page 57 - tensioning roller securing bolt hand tight.
Fig. 47: Installing Timing Belt Tensioning Roller (From February, 1995) Courtesy of VOLKSWAGEN UNITED STATES, INC. 6. Install timing belt for camshaft drive. Note observe marked direction of rotation for used belt.Tighten tensioning roller securing bolt hand tight. 7. To tighten the toothed belt tur...
Page 58 - Tighten tensioning roller to specification. See; with NEW center bolt. See
Fig. 48: Tensioning Timing Belt (From February, 1995) Courtesy of VOLKSWAGEN UNITED STATES, INC. 8. Ensure crankshaft is still on TDC of No. 1 cylinder. Correct, if necessary. 9. Tighten tensioning roller to specification. See TORQUE SPECIFICATIONS . 10. Tighten camshaft sprocket securing bolt using...
Page 59 - WATER PUMP; COOLING SYSTEM SPECIFICATIONS
12. Tighten the 4 M8 crankshaft vibration damper and toothed belt pulley securing bolts. See TORQUE SPECIFICATIONS . 13. Turn crankshaft two rotations in engine direction of rotation until crankshaft is set to TDC No. 1 cylinder again. Again check the position of the tensioning roller indicator. If ...