VW VANAGON 2.

1 ENGINE SPECIFICATIONS:
CYLINDER BLOCK SPECIFICATIONS (Water-Cooled 2.1l): Application In. (mm)

Displacement 128 Cu. In. (2.1L) Bore 3.701" (94.0 mm) Stroke 2.99" (76.0 mm) Compression Ratio 9.0:1 Cylinder Bore Diameter 3.701-3.702 (94.00-94.03) Cylinder Bore Maximum Taper .002 (.06) Cylinder Bore Maximum Out-Of-Round .002 (.06) Pistons - Diameter 3.700 (93.98) Pistons - Standard Clearance .001-.002 (.02-.05) Pistons - Maximum Clearance .008 (.20) Piston Ring #1 End Gap - Standard .012-.018 (.30-.45) Piston Ring #1 End Gap - Maximum .035 (.95) Piston Ring #1 Sided Clearance - Standard .002-.003 (.05-.08) Piston Ring #1 Sided Clearance - Maximum .005 (.12) Piston Ring #2 End Gap - Standard .012-.020 (.30-.50) Piston Ring #2 End Gap - Maximum .040 (1.0) Piston Ring #2 Sided Clearance - Standard .002-.003 (.04-.07) Piston Ring #2 Sided Clearance - Maximum .004 (.10) Piston Ring #3 (Oil) End Gap - Standard .010-.016 (.25-.40) Piston Ring #3 (Oil) End Gap - Maximum .035 (.95) Piston Ring #3 (Oil) Sided Clearance - Standard .001-.002 (.02-.05) Piston Ring #3 (Oil) Sided Clearance - Maximum .004 (.10) Cylinder Bore *Standard Diameter 3.701-3.702 (94.00-94.03) *Maximum Taper .002 (.06) *Maximum Out-Of-Round .002 (.06) End Play: *Standard .003-.005 (.07-.13) *Service Limit .006 (.15) ______________________________________________ CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS SPECIFICATIONS: Application In. (mm)

Main Bearings Diameter - Blue Dot: *Journal No. 1 2.3614-2.3618 (59.980-59.990) *Journals No. 2 & 3 2.1645-2.1649 (54.980-54.990) *Journal No. 4 1.5741-1.5748 (39.983-40.000) Main Bearings Diameter - Red Dot: *Journal No. 1 2.3610-2.3613 (59.971-59.979) *Journals No. 2 & 3 2.1642-2.1645 (54.971-54.979) *Journal No. 4 1.5741-1.5748 (39.983-40.000) *Journal Out-Of-Round .001 (.03) *Journal Taper .001 (.03) Connecting Rod Bearings: *Journal Diameter 2.1647-2.1651 (54.984-54.996) *Journal Out-Of-Round .001 (.03) *Journal Taper .001 (.03) Camshaft End Play .006 (.16) Camshaft Runout .0015 (.04) Camshaft Backlash .000-.002 (.00-.05) ______________________________________________ CYLINDER HEAD SPECIFICATIONS: Application Specification (mm)

Intake Valve Seat Angle 45 Intake Valve Seat Width .055-.098" (1.40-2.50 mm) Intake Valve Head Diameter 1.575" (40.00 mm) Intake Valve Length 4.823" (122.50 mm) Intake Valve Minimum Margin .020" (.50 mm) Intake Valve Stem Diameter .314" (7.97 mm)

Intake Valve Guide I.D. .315" (8.00 mm) Intake Valve Guide Oil Clearance .047" (1.20 mm) Exhaust Valve Seat Angle 45 Exhaust Valve Seat Width .055-.098" (1.40-2.50 mm) Exhaust Valve Head Diameter 1.340" (34.00 mm) Exhaust Valve Length 4.823" (122.50 mm) Exhaust Valve Minimum Margin Hand lap valve only Exhaust Valve Stem Diameter .3508-.3512" (8.91-8.92 mm) Exhaust Valve Guide I.D. .315" (8.00 mm) Exhaust Valve Guide Oil Clearance .047" (1.20 mm) Push Rod Tube Length 7.6" (194 mm) ______________________________________________ ENGINE AND POWER TRAIN TORQUE SPECIFICATIONS: Application Ft. Lbs. (N.m)

Connecting Rod Nuts 33 ( 45) Coolant Drain Plug 37 ( 50) Crankcase Half 8-mm Nuts 15 ( 20) Crankcase Half 10-mm Nuts 22 ( 30) Crankshaft Pulley Bolt 258 (350) Flywheel Or Drive Plate-To-Crankshaft 80 (110) Oil Drain Plug 20 ( 25) Oil Pump Cover Nuts 20 ( 25) Pressure Plate-To-Flywheel 15 ( 20) Torque Converter-To-Drive Plate 22 ( 30) Water Pump-To-Crankcase 15 ( 20) Cylinder Head-To-Crankcase Nuts: *Step 1 7.5 (10) *Step 2 30 (40) *Step 3 37 (50) Rocker Shaft-To-Cylinder Head Nuts 20 (25) Exhaust Flange-To-Cylinder Head Nut 15 (20) Engine-To-Transaxle Nut/Bolt 22 (30) Engine Carrier to Body 19 (25) End Housing Bolt Power Steering Pump Bolt Pressure-Flow Limiting Valve Cap Pressure Line Fitting Return Line Fitting - On Pump Return Line Fitting - On Valve Housing Steering Gear Retaining Bolt Subframe Bolt - Long Subframe Bolt - Short Tie Rod-to-Steering Arm Valve Housing Bolt Axle Shaft-To-Transaxle Bolt Axle Shaft-To-Flange Bolts Drain Plug Engine-To-Transaxle Nut/Bolt Flywheel-To-Crankshaft Bolt Pressure Plate-To-Flywheel Bolt Torque Converter-To-Drive Plate Bolts Transaxle-To-Engine Bolts Transmission Mount 37 ( 50) 18 ( 25) 42 ( 57) 29 ( 39) 29 ( 39) 22 ( 30) 22 ( 30) 96 (130) 59 ( 80) 32 ( 44) 15 ( 20) 33 ( 45) 33 ( 45) 15 ( 20) 22 ( 30) 80 (110) 18 ( 25) 22 ( 30) 41 ( 55) 22 ( 30)

______________________________________________ IGNITION SPECIFICATIONS: IGNITION TIMING TABLE (Degrees BTDC @ RPM): Application Checking 2.1 Liter 4-8 @ 800-900 Adjusting 5-7 @ 800-900

SPARK PLUG WIRE RESISTANCE:

Application Coil Wire With Connectors Spark Plug Wire/Connector Spark Plug Connector Suppressor (1) 1986-1991 W/DIGIFANT:

Ohms 1200-2800 4600-7400 4000-6000 600-1400

Ignition Timing - Check Value 3 - 7 BTDC Ignition Timing - Adjusting Value 5 1 BTDC (use conditions 1 - 9) Timing mark location Crankshaft Pulley Idle Speed 880 50 RPM (use conditions 1 - 8) CO Content 0.7 0.4 Vol % (use conditions 1 - 8) Advance 35 5 at 3000 RPM RMP Limit 5600 RPM Spark Plugs: *W7CCO - Bosch *14 L-7 CU - Beru *N 288 - Champion Spark Plug Gap 0.7 0.1 mm (0.028 0.004 in.) Spark Plug Tightening Torque 14 ft lb (20 Nm) Firing Order 1-4-3-2 Ignition Testing Conditions (for Digifant): 1) Minimum engine oil temperature - 176 F (80 C) 2) Electrical consumers off. 3) Crankcase breather hose removed and closed tightly. 4) Throttle valve switch turned off 5) Idle stabilizer OK 6) Ignition timing OK 7) Connector for idle stabilizer control valve disconnected 8) Oxygen sensor disconnected 9) Temperature sensor disconnected and RPM increased to 2000-2500 ______________________________________________ FUEL DELIVERY: PRESSURE TEST: With engine idling, minimum pressure should be 29 psi (2 kg/cm2). Remove vacuum hose from fuel pressure regulator. Fuel pressure should increase to 36 psi (2.5 kg/cm2). Turn engine off. After 10 minutes, residual pressure should be 29-36 psi (2-2.5 kg/cm2). MAIN FUEL PUMP VOLUME CHECK: Minimum allowable volume is 1.0 pint (0.5 liter) in 30 seconds. ______________________________________________ SENSOR SPECIFICATIONS: AIRFLOW SENSOR POTENTIOMETER: Resistance between terminals No. 14 and 17 Sensor At Rest Less Than 1000 Resistance between terminals No. 17 and 18 Sensor At Rest More Than 4000 Ohms COOLANT TEMPERATURE SENSOR: Application Temperature F (C) 122 (50) 176 (80) 212 (100) Ohms 800-1000 250-350 100-200

Resistance between terminals No. 6 and 10

CYLINDER HEAD TEMPERATURE SENSOR: Application Temperature F (C) 68 (20) 176 (80) Ohms 2100-2900 270-390

Resistance between terminal No. 13 and ground

INTAKE AIR TEMPERATURE SENSOR: Application Temperature F (C) 68 (20) Ohms 2300-2700

Resistance between terminals No. 6 and 14

______________________________________________ AUTOMATIC TRANSMISSION SPECIFICATIONS: Recommended Transmission Fluid: Dexron or Dexron-II ATF. Recommended Final Drive Fluid: G50 or SAE 75W90. Fluid Capacity Qts. (L) Transmission Refill 3.2 (3.0) Transmission Dry Fill 6.4 (6.0) Final Drive 1.4 (1.3) Draining & Refilling: -Remove transmission protection plate (if necessary). -Remove rear pan bolts. -Loosen front pan bolts. -Carefully lower pan to drain as much fluid as possible. -Remove oil pan. -Pour out remaining fluid. -Remove filter. -Clean oil pan in solvent. -Dry pan. -Install new filter. Tighten filter retaining screws to 27 INCH lbs. (3 N.m). -Install oil pan with new gasket. Tighten oil pan bolts to 15 ft. lbs. (20 N.m). -Install protection plate if it was removed. Tighten bolts to 18 ft. lbs. (25 N.m). -Add 3.2 qts. (3.0L) transmission fluid. Check fluid level. Add if necessary. ______________________________________________ FRONT SUSPENSION TORQUE SPECIFICATIONS: 2WD: Application Ft. Lbs. (N.m)

Ball Joint Self-Locking Nut 80 (108) Brake Caliper Bolt 118 (160) Caliper Pin Bolt 26 ( 35) Lower Control Arm Pivot 66 ( 89) Shock Absorber Mounting Bolt - Lower 110 (150) Shock Absorber Mounting Bolt - Upper 22 ( 30) Strut Rod-To-Chassis Nut 74 (100) Strut Rod-To-Control Arm Nut 133 (180) Tie Rod-To-Steering Knuckle Nut 22 ( 30) Upper Ball Joint-To-Control Arm Nut 43 ( 58) Upper Control Arm Pivot Shaft 54 ( 73) Wheel Lug Bolt 133 (180) Caliper Mounting Bolts 26 ( 35) Pad Carrier Mounting Bolt 200 (271) Rear Axle Nut 369 (500) Rear Backing Plate-To-Flange Bolt 47 ( 64) Rear Brake Shoe Support Bolt 48 ( 65) Wheel Lug Nut 123 (167) Wheel Cylinder Bolt 17 ( 20) SYNCRO:

Application

Ft. Lbs. (N.m) 236 (320) 81 (110) 177 (240) 14 ( 19) 66 ( 89) 110 (149) 22 ( 30) 22 ( 30) 18 ( 24) 125 (169) 51 ( 69) 33 ( 45) 22 ( 30) 44 ( 60) 54 ( 73) 123 (167) 177 (240) 14 ( 19)

Axle Shaft Nut Ball Joint Self-Locking Nut Brake Caliper-To-Housing Bolt Brake Rotor-To-Hub Assembly Bolt Lower Control Arm Pivot Bolt Shock Absorber Bottom Bolt Shock Absorber Top Nut Stabilizer Link-To-Strut Rod Stabilizer Mount-To-Frame Strut Rod-To-Chassis Nut Strut Rod-To-Lower Control Arm Nut Subframe-To-Body Bolt Tie Rod End-to-Bearing Housing Nut Upper Ball Joint-To-Control Arm Bolt Upper Control Arm Pivot Bolt Wheel Lug Nut Brake Caliper-To-Housing Bolt Brake Rotor-To-Hub Assembly Bolt

______________________________________________ REAR SUSPENSION TORQUE SPECIFICATIONS: Application Ft. Lbs. (N.m)

Axle Nut - 10 Slot 370 (500) Axle Nut - 6 Slot 250 (340) Brake Backing Plate-To-Housing Lower Bolt 48 ( 65) Brake Backing Plate-To-Housing Upper Bolt 15 ( 20) Drive Shaft Bolt 33 ( 45) Housing Assembly-To-Trailing Arm 101 (137) Shock Absorber Retaining Bolt 65 ( 88) Trailing Arm Pivot Bolt 76 (103) Wheel Lug Nut 133 (180) ______________________________________________ POWER STEERING: -Fluid capacity: approximately 1 qt. (.95L). -Recommended fluid type: V.W. Hydraulic Oil (G 002 000). -Hydraulic System Presure: 1670-1750 psi (117-123 kg/cm2). ______________________________________________ WHEEL ALIGNMENT SPECIFICATIONS: 2WD: -Camber: *Front: 0 -1/2 to 1/2 *Rear: -13/16 -1 5/16 to 5/16 -Caster: 7 1/4 7 to 7 1/2 -Toe-In: *Front: 5/16 1/16 to 9/16 *Rear: 0 -5/16 to 5/16 SYNCRO: -Camber: *Front: 5/16 0 to 5/8 *Rear: -1/4 -7/16 to 1/16 -Caster: 4 5/8 4 3/8 to 4 7/8 -Toe-In: *Front: 0 1/4 to -1/4 *Rear: 1/8 -1/8 to 3/8 ______________________________________________

A/C SYSTEM SPECIFICATIONS: -Compressor Type: Sanden 5 or 7-Cylinder -Compressor Belt Deflection: 3/16" (4.8 mm) -System Oil Capacity: 7.0 ozs. -Refrigerant (R-12) Capacity: 50 ozs. -System Operating Pressures: *High Side: 150-210 psi (10.5-19 kg/cm) *Low Side: 26-40 psi (1-2 kg/cm) ______________________________________________ FUSES: 1) 30 Amp (Green) Radiator Fan 2) 10 Amp (Red) Brake Lights 3) 15 Amp (Blue) Interior Lights, Illuminated Mirror, Clock, Cigar Lighter, Radio 4) 15 Amp (Blue) Emergency Flasher System 5) Blank 6) Blank 7) 10 Amp (Red) Left Tail & Side Marker Lights 8) 10 Amp (Red) Right Tail & Side Marker Lights 9) 10 Amp (Red) Right High Beam 10) 10 Amp (Red) Left High Beam 11) 15 Amp (Blue) Windshield Wiper/Washer 12) 20 Amp (Yellow) Cruise Control, A/C, Power Windows, Auxiliary Heater, Electric Mirrors, Auxiliary Heat Exchanger, Rear Wiper 13) 20 Amp (Yellow) Fresh Air Fan, Rear Window Defroster 14) 20 Amp (Yellow) Rear Defogger, Heated Mirror, Lighting Switch Illumination Auxiliary Heat Exchanger (If Equipped) 15) 10 Amp (Red) Back-Up Lights 16) 15 Amp (Blue) Horn 17) 10 Amp (Red) Windshield Wiper Motor 18) 10 Amp (Red) Brake Warning Light, Cruise Control, Heated Driver's Seat 19) 10 Amp (Red) Turn Signals 20) 10 Amp (Red) License Plate Light, Headlight Washer(If Equipped) 21) 10 Amp (Red) Left Low Beam 22) 10 Amp (Red) Right Low Beam