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Volkswagen Vanagon CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Volkswagen REPAIR SHOPS DON'T WANT YOU TO KNOW
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Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about Volkswagen Vanagon car and truck
repair procedures including Volkswagen engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c
system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix
your Volkswagen Vanagon automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR Volkswagen Vanagon AUTOMOBILES
Air Conditioner and Heater Service Includes module configuration procedures, general service, maintenance, automatic temperature control, compressor services, electric cooling fans, vacuum diagrams, specifications, and manual air conditioning and heater diagnostics and replacement procedures for domestic and imported Volkswagen Vanagon cars and light trucks from 1990+
Imported Cars & Light Trucks & Vans -> 1991-92 -> Evacuating System
Vehicle: 1991 Volkswagen Vanagon 2.1 H4 GAS
The system must be completely discharged before evacuation. After discharging the system, keep low pressure gauge hose connected to low pressure test fitting and both manifold gauge valves closed.
- Connect high pressure gauge hose to vacuum pump, Fig. .
- Connect center manifold gauge hose to refrigerant source with tapping valve closed.
- Open high and low side gauge valves with vacuum pump operating.
- Continue to operate pump for approximately 15-20 minutes after low side gauge reaches 29 or more inches of vacuum. If the system has been left open for an...
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BRAKE SERVICE PROCEDURES FOR Volkswagen Vanagon AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported Volkswagen Vanagon cars and light trucks from 1990+.
HYDRAULIC BRAKE SYSTEM -> ADJUSTMENTS -> BRAKE PRESSURE REGULATOR -> Cabriolet -> Corrado, Fox & Passat -> MODELS LESS ANTI-LOCK BRAKES -> Vanagon
Vehicle: 1990 Volkswagen Vanagon Campmobile 2.1 H4 GAS
BRAKE PRESSURE REGULATOR
MODELS LESS ANTI-LOCK BRAKES
Cabriolet
Brake pressure regulator is mounted on body, and operated by a spring attached to the rear axle.
- Remove bleeder screw on right front caliper and connect gauge US 1016 or equivalent.
- Remove bleeder screw on left rear wheel cylinder/caliper and connect gauge US 1016 or equivalent.
- Bleed both hoses and gauges with bleeding screws on gauges, then depress brake pedal firmly several times.
- Depress brake pedal until gauge of right front caliper reads 797 psi. Gauge of left rear wheel cylinder/caliper must read 565-623 psi.
- Increase p...
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FUEL FILTER REPLACEMENT PROCEDURES FOR Volkswagen Vanagon AUTOMOBILES
Fuel filter replacement procedures with corresponding images for most domestic and imported Volkswagen Vanagon cars and light trucks sold in the U.S. for 1980+.
Volkswagen -> Fuel Filter Replacement -> Gasoline Engines -> Models w/Fitting Or Union Bolt Connection -> Models w/Fuel Hose Connection
Vehicle: 1991 Volkswagen Vanagon Campmobile 2.1 H4 GAS
Models w/Fuel Hose Connection
Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.
After the battery has been disconnected and reconnected, some abnormal driveabilty symptoms may occur. The vehicle may need to be driven while the vehicle relearns its adaptive strategy.
- Obtain the vehicle owners radio theft protection code prior to disconnecting the battery ground cable.
- Disconnect the battery ground cable.
- On models equipped with underbody moun...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR Volkswagen Vanagon AUTOMOBILES
Includes CV axle, universal joint, and driveline replacement, for domestic and imported Volkswagen Vanagon cars and light trucks from 1990+.
DRIVESHAFT, Replace -> Automatic Transmissions -> Manual Transmissions
Vehicle: 1991 Volkswagen Vanagon 2.1 H4 GAS
Manual Transmissions
- Install support tool No. 3250 or equivalent to upper control arm.
- With car on ground, loosen axle shaft bolts, then remove bolt securing wheel bearing housing to lower ball joint.
- Raise and support vehicle.
- Remove bolt for shock absorber/stabilizer link rod.
- Remove axle shaft from drive flange of transmission.
- Compress shock absorber completely, then remove axle shaft.
- Reverse procedure to install, noting the following:
- Torque wheel lug nuts to 133 ft. lbs.
A...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR Volkswagen Vanagon AUTOMOBILES
Includes starter and alternator replacement procedures for domestic and imported Volkswagen Vanagon cars and light trucks from 1990+.
Alternator, Replace
Vehicle: 1990 Volkswagen Vanagon Syncro 2.1 H4 GAS
- Disconnect battery ground cable at battery.
- Relieve tension on drive belt and remove drive belt.
- Remove electrical connections from alternator.
- Re...
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MAINTENANCE LAMP RESET PROCEDURES FOR Volkswagen Vanagon AUTOMOBILES
Maintenance lamp reset procedures with corresponding images for most domestic and imported Volkswagen Vanagon cars and light trucks sold in the U.S. from 1990+.
Volkswagen -> Malfunction Indicator Lamp -> -> Digifant & Digifant II -> Digifant I -> OBD ll
Vehicle: 1990 Volkswagen Vanagon Syncro 2.1 H4 GAS
OBD ll
If faults are recognized and verified by the engine control module, they will be indicated by switching on the MIL. Perform the functional inspection as follows: Turn the ignition switch to the ON position. The MIL must light up if the MIL does not light with the ignition switch on, inspect the bulb and/or locate and eliminate short or open in wiring circuit from the engine control module to MIL using a proper wiring diagram. If no fault can be detected in the wiring the ECM may be faulty. If the MIL lights with the ignition switch on, start engine and run at idle speed the MIL must go o...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR Volkswagen Vanagon AUTOMOBILES
Includes radiator, cooling and heater hose replacement procedures for domestic and imported Volkswagen Vanagon cars and light trucks from 1990+
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 1991 Volkswagen Vanagon Campmobile 2.1 H4 GAS
Lower
- Drain coolant into a suitable container.
- Reposition hose clamp at radiator and remove hose.
- Reposition hose clamp at thermostat housing and remove hose.
- Remove hose from vehicle.
- Reverse procedu...
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COMPONENT LOCATION DIAGRAMS FOR Volkswagen Vanagon AUTOMOBILES
Component location diagrams for most Volkswagen Vanagon cars and light trucks sold in the U.S. from 1990+.
 A/C & Cooling System Component Locations Diagram for 1989 Volkswagen Vanagon Syncro 2.1 H4 GASComponents on diagram: |
 Fuse/Relay Panel Diagram for 1989 Volkswagen Vanagon Syncro 2.1 H4 GASComponents on diagram: |
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WIRING DIAGRAMS FOR Volkswagen Vanagon AUTOMOBILES
OEM drawn wiring diagrams for most Volkswagen Vanagon cars and light trucks sold in the U.S.
 1990 Volkswagen Vanagon Campmobile 2.1 H4 GAS Wiring DiagramComponents on diagram: |
 1991 Volkswagen Vanagon 2.1 H4 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR Volkswagen Vanagon AUTOMOBILES
OEM TSB listings for most Volkswagen Vanagon cars and light trucks sold in the U.S. from 1985+.
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Document: WARRANTY - POLICIES & PROCEDURES MANUAL UPDATE Vehicle: 1988 Volkswagen Vanagon Campmobile 2.1 H4 GAS Auto Systems: |
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Document: TOOLS - HUNTER VAG1944B, VAS6292 ALIGNER SPECIFICATION UPDATE Vehicle: 1986 Volkswagen Vanagon Campmobile 2.1 H4 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR Volkswagen Vanagon AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most Volkswagen Vanagon cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most Volkswagen Vanagon cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most Volkswagen Vanagon cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most Volkswagen Vanagon cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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