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2.1L Vanagon Specs




from VW Doka
reply-to VW Doka
to vanagon@gerry.vanagon.com
date Wed, Sep 2, 2009 at 4:20 PM
subject Vanagon Specifications Sheet
mailed-by gerry.vanagon.com

hide details 4:20 PM (18 minutes ago)

I was poking around my old files and found this list of specifications
for Vanagons (mostly 2.1 liter). If I remeber correctly, most of this
information came from Mitchell and Alldata sources. But it should be
"mostly" correct.

Just thought I'd share with the list.

If the formatting is all screwed up in your mail reader, just shoot me
an email and I'll send the original file.

Cheers,

Jeff

2.1 ENGINE SPECIFICATIONS
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
ENGINE SPECIFICATIONS (Water-Cooled 2.1l)
Application Specification (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 BLOCK SPECIFICATIONS
Application Specification (mm)
-------------------------------------------------
Cylinder Bore
- Standard Diameter 3.701-3.702 (94.00-94.03)
- Maximum Taper .002 (.06)
- Maximum Out-Of-Round .002 (.06)

END PLAY SPECIFICATIONS
Application Specification (mm)
-----------------------------------
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 SPECIFICATIONS
Application Specification (mm)
---------------------------------------
End Play .006 (.16)
Camshaft Runout .0015 (.04)
Camshaft Backlash .000-.002 (.00-.05)

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)

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)



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

SPARK PLUG WIRE RESISTANCE
Application Ohms
---------------------------------------
Coil Wire With Connectors 1200-2800
Spark Plug Wire/Connector 4600-7400
Spark Plug Connector 4000-6000
Suppressor (1) 600-1400


1986-1991 W/DIGIFANT
---------------------------------------------------------------------------
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/cmý).
Remove vacuum hose from fuel pressure regulator. Fuel pressure should
increase to 36 psi (2.5 kg/cmý). Turn engine off. After 10 minutes,
residual pressure should be 29-36 psi (2-2.5 kg/cmý).

MAIN FUEL PUMP VOLUME CHECK
-----------------------------------------------------------
Minimum allowable volume is 1.0 pint (0.5 liter) in 30 seconds.


SENSOR SPECIFICATIONS
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
AIRFLOW SENSOR POTENTIOMETER
Application Condition Ohms
-----------------------------------------------------------
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

COOLANT TEMPERATURE SENSOR
Application Temperature °F (°C) Ohms
---------------------------------------------------------
Resistance between 122 (50) 800-1000
terminals No. 6 and 10 176 (80) 250-350
212 (100) 100-200

CYLINDER HEAD TEMPERATURE SENSOR
Application Temperature °F (°C) Ohms
-------------------------------------------------------------
Resistance between 68 (20) 2100-2900
terminal No. 13 and ground 176 (80) 270-390

INTAKE AIR TEMPERATURE SENSOR
Application Temperature °F (°C) Ohms
-------------------------------------------------------------
Resistance between 68 (20) 2300-2700
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 with compressed air.

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.


TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
--------------------------------------------------
Axle Shaft-To-Transaxle Bolt 33 ( 45)
Axle Shaft-To-Flange Bolts 33 ( 45)
Drain Plug 15 ( 20)
Engine-To-Transaxle Nut/Bolt 22 ( 30)
Flywheel-To-Crankshaft Bolt 80 (110)
Pressure Plate-To-Flywheel Bolt 18 ( 25)
Torque Converter-To-Drive Plate Bolts 22 ( 30)
Transaxle-To-Engine Bolts 41 ( 55)
Transmission Mount 22 ( 30)


BRAKE SPECIFICATIONS
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Brake Line Bleeding Sequence
----------------------------
Right Rear -Left Rear -Right Front -Left Front

Wear limit of pads is .28" (7.0 mm),


TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
---------------------------------------------
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
Brake Caliper-To-Housing Bolt 177 (240)
Brake Rotor-To-Hub Assembly Bolt 14 ( 19)



FRONT SUSPENSION SPECIFICATIONS
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
TORQUE SPECIFICATIONS
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)


TORQUE SPECIFICATIONS - SYNCRO
Application Ft. Lbs. (N.m)
-------------------------------------------------
Axle Shaft Nut 236 (320)
Ball Joint Self-Locking Nut 81 (110)
Brake Caliper-To-Housing Bolt 177 (240)
Brake Rotor-To-Hub Assembly Bolt 14 ( 19)
Lower Control Arm Pivot Bolt 66 ( 89)
Shock Absorber Bottom Bolt 110 (149)
Shock Absorber Top Nut 22 ( 30)
Stabilizer Link-To-Strut Rod 22 ( 30)
Stabilizer Mount-To-Frame 18 ( 24)
Strut Rod-To-Chassis Nut 125 (169)
Strut Rod-To-Lower Control Arm Nut 51 ( 69)
Subframe-To-Body Bolt 33 ( 45)
Tie Rod End-to-Bearing Housing Nut 22 ( 30)
Upper Ball Joint-To-Control Arm Bolt 44 ( 60)
Upper Control Arm Pivot Bolt 54 ( 73)
Wheel Lug Nut 123 (167)



REAR SUSPENSION SPECIFICATIONS
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
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
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
CAPACITY
- Fluid capacity is approximately 1 qt. (.95L).

FLUID TYPE
- Recommended fluid type is V.W. Hydraulic Oil (G 002 000).

HYDRAULIC SYSTEM PRESSURE
- Pressure should be 1670-1750 psi (117-123 kg/cmý).

TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
------------------------------------------------
End Housing Bolt 37 ( 50)
Power Steering Pump Bolt 18 ( 25)
Pressure-Flow Limiting Valve Cap 42 ( 57)
Pressure Line Fitting 29 ( 39)
Return Line Fitting - On Pump 29 ( 39)
Return Line Fitting - On Valve Housing 22 ( 30)
Steering Gear Retaining Bolt 22 ( 30)
Subframe Bolt - Long 96 (130)
Subframe Bolt - Short 59 ( 80)
Tie Rod-to-Steering Arm 32 ( 44)
Valve Housing Bolt 15 ( 20)


WHEEL ALIGNMENT SPECIFICATIONS
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Application Preferred Range
----------------------------------------
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/cmý)
Low Side
26-40 psi (1-2 kg/cmý)


FUSES
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Fuse # Amperage Identification
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








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