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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volkswagen Transporter, Caravelle (1990 release)

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Volkswagen Transporter / Caravelle
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Volkswagen
Transporter / Caravelle
Instructions
Engine
General Data Engine
Removing and installing engine
Removing radiator
Removal and installation of a mudguard of the engine
Toothed belt
Cylinder Head
Removing and installing the camshaft
Hydraulic bucket tappets
Replacing valve stem seals
Valve
Compression Test
Belt
Troubleshooting Engine
Ignition system
Lubrication system
Engine cooling system
The power supply system of the engine
Fuel injection
Exhaust system
Coupling
Transmission
Suspension
A steering
Brakes
Wheels and tires
Body
Electrical
 


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Removing and installing engine



4-cylinder petrol engine

The engine is removed downwards without a gearbox. To remove the engine requires a jack for an engine or production machine jack.

To set the machine to the backup machine needed a jack and four backup.

Depending on the year of construction and equipping of wires, vacuum hoses or coolant hoses can have a different arrangement. It is therefore recommended before removing mark their piping tape. All rented or cut the connections after the installation of the engine shall be placed on the same spot.

Withdrawal

PERFORMANCE ORDER
1. To disconnect a wire of "weight" (-) from the battery.

A warning

Before disconnecting the wire of "weight" the battery, make sure that the ignition is switched off!

Do not forget that if you disable the "masses" are erased from memory the code anti-theft device and fixed radio settings!


2. Set the machine on a backup (see. Subsection 1.18).
3. Fold the radiator. To do this, unscrew the bolts (1) on the left and the right.
4. Fold the radiator support and lock forward.
5. Remove the bottom mudguard of a motor compartment.
6. Disconnect the system exhaust system between the exhaust manifold and the front exhaust pipe (cm. Subsection 2.19.1).
7. Drain the coolant (see. Subsection 2.16.3).
8. Disconnect from the engine upper radiator hose to the fitting lower coolant hose on oil cooler hose to the thermostat housing bottom coolant pipe coolant water pump are two hose expansion tank and heat exchanger on the coolant pipe, pre-clenching tongs clamps and sliding them back.
9. Remove the pins (indicated by arrows) of the spacer clips on the right and left and remove the spacer clips of the radiator bracket.
10. Remove the radiator (see. Subsection 2.16.2.1).
11. Disconnect all wiring from the engine:
- Plug a potentiometer;
- Plug the throttle potentiometer;
- Plug the multi-compound injection valves;
- Plug valve of stabilization of idling;
- Plug Hall sensor on the ignition distributor;
- Plug connection for lambda probe, below the car, on the bracket mounted units to the right;
- Plug the pressure sensor in the steering amplifier (if available);
- Two pay-offs plug coolant temperature;
- Connectors oil pressure sensor on top of the oil cooler and the left end side of the cylinder head;
- A wire of "weight" from the cylinder head cover;
- To disconnect the generator thick wire (B), and a thin blue line (P).
12. Remove the wiring harness with the engine, marking the former position of cable clamps markers. Clips open or cut.
13. Remove the ignition distributor cap, remove all the spark plug wires and the whole set aside.
14. Remove the wire drive with the throttle and stop (see. Subsection 2.17.5).
15. Remove the air hose at the joints between the air filter and throttle body, unscrew and remove the valve of stabilization of idling with the bracket, remove the crankcase ventilation hose, remove the hose stabilization of idling with the air filter housing and remove the air hose with the valve of stabilization idling.
16. Remove all vacuum hoses from the engine:
- On the throttle heating air receiver;
- Magnetic valve of a tank with the activated coal;
- The control unit Digifant;
- The return valve for brake booster.
17. Remove the fuel line (black), going to a cold start valve and the distributor, and by-pass line (blue) from the fuel rail, loosening the clamps. Before removal put a rag to collect leaking fuel. Plug the fuel suitable stoppers. Hoses can be plugged, for example, clean screws of suitable diameter.
18. Remove from the openings on the gearbox rubber stopper (arrow) and secure the lever of the clutch assembly pin or screw M8h22 mm.
19. On machines with power steering unscrew the pump together with bracket and hang on a wire to the body. Hoses can be worn.

A warning

The hoses can not kink. If you will open the hydraulic lines, after the assembly is necessary to vent the air from the system.


For cars with air conditioning
20. Loosen and remove the V-belt compressor (see. Subsection 2.12.1).
21. Unscrew the compressor with the bracket and hang together with pipelines in the direction of the body.

A warning

The refrigerant circuit can not be opened. Refrigerant in contact with skin can cause frostbite.


22. Screw the cylinder block under the front of the oil filter bracket (arrow) jig VW 3230. Bolts tighten to 20 Nm.
23. Unscrew all screws on the bottom of the engine to the transmission.
24. Remove the rear engine mount.
25. Put a mounting tool VW-3230 jack for the engine and gearbox VAG-1383A and lift the engine and transmission as long as the motor bearings are not unloaded. If you do not have a jack VAG-1383A and assembly tool VW-3230, you can use the factory machine jack with a wooden lining.
26. To unscrew bolts of the right support of the engine central.
27. Remove the right engine support.
28. Unscrew all screws on top of the engine to the gearbox and the engine separated from gearbox.
29. Using the jack carefully lower the engine.

A warning

Lower the engine with great prudence to avoid damage, as well as transmission and body.


Setting

PERFORMANCE ORDER
1. Check the engine mounts, fuel, oil pipelines and water hoses for wear and cuts, and replace if necessary.
2. Check the thickness and condition of the friction linings clutch disc. If heavy wear and high mileage clutch replaced completely. If you press the clutch release bearing publishes noise, replace the bearing.
3. Check the wear on the clutch release bearing and replace if necessary (see. Section 3.2).
4. Clean the clutch and drive shaft splines, spread a thin layer of grease MoS 2 or VAG-Fett G000100.

A warning

The guide bushing off not lubricated.


5. Check the cylinder block guides for centering engine and gearbox, if necessary, install it.
6. Push in the guides intermediate plate and coat in some places fat grease, glued to the cylinder block.
7. Carefully insert the motor into the engine compartment. Lifting done with great caution to avoid damage to the drive shaft, the clutch or the body.
8. Screw the new self-locking nuts of the engine mounts. The nuts are not tightened.
9. Attach the engine to the gearbox, rotating the drive shaft of the box so that he went into the clutch and flywheel. You can also rotate the crankshaft at central bolt.
10. Tighten the bolts connecting the engine to the gearbox the following torque:
- Bolts M8 - 20 Nm;
- Bolts M10 - 60 Nm;
- Bolts M12 - 80 Nm.
11. Tighten the flywheel housing to 20 Nm.
12. seeling without straining the engine set. Finally tighten the engine support the following torque:
- Support of the engine on the carrier beam M10 - 65 Nm;
- Engine support right at the cylinder 50 Nm 90 ?� (1/4 turn) further;
- Support of the engine at the rear of the cylinder M8 - 20 Nm;
- Support of the engine at the rear of the cylinder M10 - 45 Nm;
- Engine support rear gearboxes M8 - 20 Nm.
13. Unscrew the assembly tool VW-3230 from the cylinder.
14. Fit the fuel line (black) on the union, and a bypass line (blue) to the fuel distributor, fix collars. Do not confuse the piping supply and return fuel.
15. If removed, the screw refrigeration compressor and pump power steering. Tightening torque, power steering pump - 20 Nm. Push and pull the V-belt (see. Subsection 2.12.1).
16. Remove from the transmission housing mounting studs or screw M8h22. Close the hole with a rubber stopper and check the correct position of the push rod lever clutch.
17. Secure the collector voltage without front exhaust pipe.
18. Install the coolant tube between the thermostat and water pump, coolant hose from the heat exchanger.
19. Install the heat sink (see. Subsection 2.16.2.1).
20. Connect all coolant hoses, clamps fix:
- The upper radiator hose to the fitting of a cooling liquid;
- The lower hose on the oil cooler;
- Hose to the thermostat housing coolant; Two hose expansion tank and heat exchanger on the coolant pipe.
21. push the harness through the engine intake manifold.
22. firmly connected, according to the notation of duct tape, electric wires following tips:
- Plug a potentiometer;
- Plug the throttle potentiometer;
- Multi-compound injection valves;
- Plug valve of stabilization of idling;
- Plug valve cold start;
- Plug Hall sensor on the ignition distributor;
- Plug connection for lambda probe under the machine on the bracket mounted units, to the right;
- Plug the pressure sensor on the body of the power steering, if any;
- Two plugs of both coolant temperature sensor;
- Plug the oil pressure sensor on top of the oil cooler and the left end side of the cylinder head;
- Earth wire cylinder head cover;
- Thick wire (B), and a thin blue line (P) of the generator, to impose a gray protective cap.
23. Secure the electrical wiring in their original locations cable clamps.
24. Establish the bottom mudguard of a motor compartment (see. Section 2.4).
25. Lower the car.
26. To establish a cover of the distributor of ignition and to put all the wires to the spark plugs.
27. Install the air hose with the valve of stabilization of idling between the air filter and throttle body. Put on hoses and clamps secure.
28. Screw the valve of stabilization of idling with the bracket to the intake manifold.
29. Set the throttle cable to the fence and adjust (see Fig. Subsection 2.17.5).
30. Connect all the vacuum hoses to the engine:
- Hose heating receiving air throttle;
- A hose of solenoid valve of a tank with the activated carbon on the throttle;
- Hose Digifant control unit to throttle the screen;
- A hose on the brake booster check valve.
31. Check the oil level in the engine and the transmission, top up if necessary.
32. Check the coolant concentration, top up if necessary (see. Subsection 2.16.3).
33. Connect a wire of "weight" (-) to the battery. Enter anti-theft code, program the radio stations and set the clock.

A warning

A battery connected only with the ignition off, otherwise fail control unit fuel injection system.


34. Warm up the engine to operating temperature, check again the oil level and coolant leaks.
35. Check the ignition timing (see. Subsection 2.14.6).
36. Check the idle speed and CO content (see. Subsection 2.18.1).
37. Check the adjustment of the headlamp (see. Subsection 10.19.4).




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Removing radiator

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