VW Vanagon Technical Service Bulletins

Technical Service Bulletins zijn berichten van de fabrikant aan de dealers waarin ze uitleggen hoe je bepaalde problemen kunt/moet aanpakken. Je moet het niet verwarren met een terugroep actie.

Deze acties zijn vaak nodig om een risico weg te halen. Dit zijn meer nieuwsberichten met voortschrijdend inzicht om bepaalde zaken op te lossen. Hier een overzicht van deze bulletins van een Amerikaanse bron.

En hieronder een lijst met beschrijvingen er bij.

========================================================================
Import Service, Jan '89, Vol 2, No1
vanagon A/C hose damper

"1986 Vanagons up to VIN 25HH003407 had a damper/restrictor installed
in the high side hose coming from the air compressor.  Occasionally,
these dampers would cause compressor head pressures high enough to
actually blow the compressor head seal.  The tube in question is
about 17 inches long.  Make sure you remove all of it and discard it
if you find it still in place, especially when replacing a compressor
seal that was blown by excessive head pressure."

From: "Dan Houg" 
========================================================================
from Technical Newsletter, 88-N04
........................................................................
Volkswagen Technical Newsletter
88-N04

High Pressure, Low Performance

A Volkswagen that stalls when the engine is cold or after driving a few
hundred feet could be suffering from an air/fuel imbalance.  It could also
have a bad oil pump.  That's right, oil pump!  If the same engine has zero
compression, the chances are even greater than the oil pump is to blame.

If the oil pressure relief valve sticks, oil pressure could rise to over
200 psi when you accelerate to drive off.  With pressure that high, the
hydraulic valve lifters will overextend themselves, causing the valves to
hang open.  After the engine warms up, the car will probably run great the
rest of the day.  So check the oil pressure when you've tried everything
else to solve a stalling problem ... believe it or not!
=======================================================================
from Service Bulletins, Model Year 1990
........................................................................
Technical Information
Group:    20
Number:   90-01
Date:     March 31, 1990
Subject:  P.I. 2082 - Accelerator cable change
Model(s): Vanagon, all Model Years

A modified accelerator cable has been introduced in production, as of
VIN: 25 JH 062 158.  The modified cable is available through the Parts
Deivision.  Although the part number remains the same, the improved
cable can be identified by a white plastic sheath enclosing the length
of the braided cable.  This sheath protects the braided cable from
outside elements.

When repairs are necessary to the accelerator, ensure the following:
*  The boots that cover the ends of the cable housing are installed
   and not damaged.  Replace if necessary.
*  Check the hose that joins the housings.  If not intact, replace it
   and install hose clamps on both ends.
*  Install improved accelerator cable.
................................ end ..................................
part numbers for reference:                           check with the
Accelerator cable:  manual trans - 251-721-555 Q      Parts Dept. to
                    auto trans   - 251-721-555 E      make sure these
Rubber boot (rear/engine):         251-723-580        are correct.
Rubber boot (front/pedal):         251-723-580
........................................................................
Technical Information
Group:    28
Number:   90-01
Date:     March 31, 1990
Subject:  Vehicle does not start, ignition miss
Model(s): Vanagon, from 1986 Model Year

If the engine does not start or in case of ignition related engine miss,
check the ignition coil for bitumen leakage.  Bitumen leakage may be
caused by overheating of the ignition coil which may occur when the
engine runs for a prolonged period of time at idle.

Replace the standard grey labeled ignition coil with green labeled coil
Part No. 211 905 115 D.  The green labeled coil was installed into
production as of 1/89.  VIN: 25HG 06 5838.
*****************************************************************
* CAUTION                                                       *
* Part numbers are for reference only.  Always check with your  *
* Parts Department for latest information.                      *
****************************************************************
========================================================================
from Service Bulletins, Model Year 1992
........................................................................
Technical Bulletin
Group:    24
Number:   92-01
Date:     February 29, 1992
Subject:  Vanagon Intermittent Misfire
Model(s): All Vanagon Digifant Fuel Injection Engines

CONDITION
After driving for 1/2 to 2 hours at a constant speed, vehicle
experiences lack of power, cuts-out or stalls, often accompanied by
bucking or jerking of the vehicle.
In ALL cases, the vehicle will restart immediately.  This symptom may
not re-occur for several weeks/months.  Inspection by the dealer results
in nothing conclusive.

Some air-flow meters may experience a vibration resonance of the
metering potentiometer wiper during extended constant driving.  This
resonance causes the air-flow meter to supply an intermittent signal
to the Digifant ECU.  The ECU will then default to a "no-load" condition
and reduce the injection time.

SERVICE
Harness, Part No. 025 906 302, is available to resolve this condition.
* remove electrical connector from air flow sensor (see Figure 24-174)
* install converter assembly, Part No. 025 906 302, between harness and
  air flow sensor

NOTE
If customer complaints persist after performing the above repair,
contact your Zone Product Support Specialist (TSM in Canada).
*****************************************************************
* CAUTION                                                       *
* Part numbers are for reference only.  Always check with your  *
* Parts Department for latest information.                      *
****************************************************************
........................... end ......................................
harness costs about $100! very simple to install. takes about three
minutes maximum. the new harness fits between the old harness and the
silver air-flow meter box attached to the air cleaner box. remove the
silver clip, wiggle out the big wiring connector (from the side of the
air-flow meter), connect the proper end of the new harness to the big
big wiring connector you just wiggled out, put the new clip into the
new connection; then take the other end of the new harness and plug it
into the air-flow meter connection. put the silver clip back. and you
are done.
=======================================================================
from Service Bulletins, Model Year 1992
......................................................................
Technical Bulletin
Group:    24
Number:   92-02
Date:     April 30, 1992
Subject:  Vanagon Driveability Complaints
Model(s): All Water Cooled Engine Vanagons
SUPERCEDES TECHNICAL BULLETIN 24-92-01 (February 29, 1992)

CONDITION
After driving for an extended period of time at a constant speed, the
vehicle may, on occasion, experience a deterioration of performance
which may be accompanied by a hestiation or surging.

In many cases, after turning off the engine and subsequent re-start or
without having taken any action, the symptoms disappear.  These symptoms
may not recur for several weeks or months.

SERVICE
To resolve this condition, wire harness Part No. 025 906 302, should be
installed.  This harness provides improved signal voltage stablization.
* remove electrical connector from air flow sensor
* install wire harness, Part No. 025 906 302, between main harness
  connetion and air flow sensor connection.
*****************************************************************
* CAUTION                                                       *
* Part numbers are for reference only.  Always check with your  *
* Parts Department for latest information.                      *
****************************************************************

NOTE
When troubleshooting this system and performing continuity checks, the
following should be noted.  Due to active components in the wire
harness, Part No. 025 906 302, there is not continuity between pin two
of the connectors.  The following chart on page 2 lists the resistence
of each circuit.
  ---------------------------------------------
  Terminal      Approximate
  Number        Resistance
  ---------------------------------------------
    1           Zero Ohms
    2           Greater than 1 Meg. Ohms
    3           Zero Ohms
    4           Zero Ohms
    5           Zero Ohms

NOTE
If customer complaints persist after performing the above repair,
contact your Zone Product Support Specialist for assistance.

........................... end ......................................
harness costs about $100! very simple to install. takes about three
minutes maximum. the new harness fits between the old harness and the
silver air-flow meter box attached to the air cleaner box. remove the
silver clip, wiggle out the big wiring connector (from the side of the
air-flow meter), connect the proper end of the new harness to the big
big wiring connector you just wiggled out, put the new clip into the
new connection; then take the other end of the new harness and plug it
into the air-flow meter connection. put the silver clip back. and you
are done.
=======================================================================
IMPORT SERVICE MAGAZINE
July '93  Vol. 6 No. 8
Subject: more 'Ghost harness' info

After driving for an extended period of time at a constant speed,
some water cooled Vanagon engines may loose performance or hesitate
and surge.  In many cases, the symptoms will disappear after turning
off the engine and restarting.  After that, the symptoms may not
reoccur for several weeks or months.

A new wiring harness (P/N 025 906 302) is available to correct this
problem.  The new harness provides better signal voltage
stabilization than the old harness it is designed to replace.

To install the new harness, remove the air flow sensor harness
connector.  Install the new harness between the main harness
connector  and the air flow sensor connector.

There are active components in the new wiring harness.  For this
reason, there is no continuity between terminal number 2 at one
of the harness connectors and terminal 2 in the harness connector at
the other end of the new harness.  This is normal and should not be
considered a fault.

All other connector terminals should have 0 ohms resistance from one
harness connector to its mate in the connector at the other end of
the harness.  Keep this in mind when troubleshooting this system and
performing continuity checks.

From: "Dan Houg" 
========================================================================
from Service Bulletins, Model Year 1990
........................................................................
Technical Bulletin
Group:    24
Number:   24-90 T01
Date:     May 31, 1990
Subject:  Rough Idle, Engine Stalls - Tow in
Model(s): 1983-1990 Model Years

The clamp for the air intake boot to air flow meter/throttle body may
yield tension and could cause a vacuum leak.  This may create a lean
running condition resulting in the engine to idle rough and in
severe cases stall while idling.

Installation of Boot Clamp Part Number 191 129 647  will correct this
condition.
========================================================================
from Service Bulletins, Model Year 1987
........................................................................
VW Technical Information
Group 42, Number 87-01
Date: August 5, 1987
Model(s): Vanagon, all model years
Subject: Knocking Noise from rear - CV Joint

A noisy CV joint could be caused by hardened and dried lubricant.
*  Disassemble and inspect all joints, repack serviceable joints
   using new high temperature grease Part Number G 000 603.
*  Replace worn CV joints using Kit Number 251 598 101.  This joint
   has a larger diameter ball bearing (from 19.05mm to 20.0mm) for
   longer wear.  Pack the replacement joint using the new high
   temperature grease supplied with the kit.

Production Change:
CV joints with increased bearing diameter installed as of Dec. 1984,
VIN 25 FH 055 865

New high temperture grease in use as of Oct. 1986, VIN 25 HH 037 577
========================================================================
from Service Bulletins, Model Year 1987
........................................................................
VW Technical Information
Group 80, Number 87-01
Date: July 31, 1987
Model(s): Water-cooled Vanagons, 1983-1985
Subject: Carpet wet by rear seat - heat exchanger bleeder screw broken

The plastic bleeder screw for the rear heat exchanger may be broken due
to seal swelling.
* Replace with an improved metal bleeder screw, Part number N 902 061 01.
  and new gasket, Part number 861 819 037.

Production Change:
Metal bleeder screw installed as of:
December 1984, VIN: 25 FM 050 887
------------------------------------

as of 1995.04.04, this part number N 902 061 01 was invalid. the newer
part number for the Bleeder Screw, as seen on the 1993 Microfiche for
Vanagons 1983-1985 and Vanagons 1986-1991 is  861-819-039. the gasket
number is still the same. BUT the new Bleeder Screw seems to be plastic
again, not metal.
in fact, two reliable parts people have said that there were never any
"metal" bleeder screws ... only plastic. so apparently this tech info
is wrong. but a new bleeder screw might solve the leaking.
.........................................................................
VW Technical Information
Group 19, Number 87-03
Date: December 21, 1987
Model(s):  Vanagon, Water-cooled, model years 1983-1985
Subject: Carpet wet by rear seat - heat exchanger T-piece leaking

A coolant leak in the rear heat exchanger area may be due to poor hose
fit at the metal T-piece which connects the fee hose to the main coolant
hose. An imporved, white plastic T-piece with slightly larger diameter
is available to correct this condition:
* Replace metal T-piece with white plastic version,
  Part number 253-265-543A
* Remove flow restrictor from inlet fitting of heater valve.

Production Change:
Improved T-piece installed as of Nov. 1984, VIN 25 FH 037 898.
=======================================================================
from Service Bulletins, Model Year 1987
.......................................................................
Technical Information
Group:    17
Number:   87-05
Date:     October 29, 1987
Subject:  Oil Cooler seal leaks in extreme cold
Model(s): Vanagon waterboxer, all Model Years

Extreme cold weather can harden and split the seal between the engine
block and the oil cooler thus creating an oil leak:
*  An improved cold-restistant seal was installed in production as of
   02/87.
*  The new seal can be identified by its silver-grey appearance and is
   available through your parts department, Part No. N 901 814.02.
=======================================================================
from Service Bulletins, Model Year 1985
.......................................................................
Technical Information
Group 87, Number 89-01, August 31, 1989
Model(s): Vanagon with A/C, model years 1986-1989
Subject:  Evaporator Housing - change

Starting April 1988, a running change was made to the evaporator housing
and introduced into production.

To prevent cracking, the body attachment points have been relocated.

Evaporator housings are now available through the parts depot and come
as a multiple supersession with the following items:
  1 evaporator housing (color coded)
  2 mounting brackets
  2 shims (color coded)
  6 rivets
  6 body plugs (color coded)
  6 bolts

INSTALLING
- disconnect battery
- remove front A/C control assembly and center vents
- remove both rear side covers at C-pillars
- remove both outside vent covers
- remove relay assembly from left C-pillar adn all tie wraps holding
    A/C lines
- remove evaporator housing fasteners and lower housing

NOTE
Discharging the A/C system is NOT required due to the length of the
evaporator hoses.  A cherry picker with a protective cover helps in
lowering the evaporator housing.

- bolt brackets to new evaporator housing and lift into postion
- with the evaporator firmly positioned against the roof, work through
  the speaker holes, mark location of new bracket attachment points
  approximately 40 mm (1.575 in.) above the original holes
- lower evaporator housing, center punch and drill holes to accomodate
  rivets

NOTE
Rivets can be installed using Kent-Moore tool #M-39010

- install original covers on bolt heads
- install remaining components

Labor Operation Number:  8760-31-0
Suggested Repair Time:   280 t.u.
=======================================================================
from Service Bulletins, Model Year 1990
.......................................................................
Technical Information
Group:    87
Number:   90-01
Date:     March 31, 1990
Subject:  A/C Evaporator - water leaking
Model(s): Vanagon/Vanagon Camper Waterboxer, all Model Years

Water may come out of A/C vents if the evaporator drain tray does not
drain properly.  This may be caused by:
*  A missing or clogged drain valve.  A drain valve must be installed
   on the drain hose to prevent water from being drawn back into the
   evaporator housing via vacuum created by the blower motors.
   1.  For 1/2" o/d hose, use drain valve Part No. 253 260 180
   2.  For 3/8" o/d hose, use drain valve Part No. 431 260 155

   Clogged drain valves should be cleaned of all foreign matter
   and must be reinstalled.

   A water drain valve has been installed in production as of 5/88.
   VIN 25JH 09 3520
       25JG 09 5871

*  Make sure drain hoses are properly routed without kinks or
   positioned with an upward bend.

   On Vanagon and Camper models check that the drain hose is not
   kinked at the "D" pillar.

   On Campers also check that the hoses are not kinked as they pass
   through the cabinets.

*  An oversized fiber hose can cause the front of the drain pan to rise
   forcing the water to move to the rear of the pan.

*  Loose drain hoses at drain pan or elbow (on earlier Waterboxer
   Campers) connections.  If leaks occur at a connection and the hose is
   not damaged, install a clamp to seal the hose.

*  Warped drain pans.  When replacing the drain pan remove the parts
   labels to avoid later drainage problems.

*  In extreme cases, with a high blower speed, water may circulate into
   a gap where the drain pan and evaporator converge.  Seal gap with
   duct tape (A/C wrap).

******************************************************************
*  CAUTION                                                       *
*  Part numbers are for reference only.  Always check with your  *
*  Parts Department for latest information.                      *
******************************************************************
=======================================================================
from Service Bulletins, Model Year 1990
.......................................................................
Technical Bulletin
Group:    90
Number:   90-01
Date:     Nov 30, 1990
Subject:  Speedometer Noisy
Model(s): Vanagon, except Syncro

Condition:
Noise in the magnet shaft bearing of the speedometer.

Production:
Speedometers with a spring loaded magnet shaft bearing are in
production as of:
   4.90   VIN  25 LH 071 889

Service Solution:
Replace speedometer (No change in part number).  Parts Division supply
only new version speedometers, which can be identified by the graphite
(dark gray) speedometer bushing. (Previously black)

Replacing speedometer cable:

As of VIN  25 HH 040 185, the protective sleeve is lengthened,
eliminating the fastening marking.

Note
To ensure correct installation, be sure to measure and mark the distance
"a" from end of cable to position the securing clip.

Distance between end of cable to the mark is 740 mm. (29 in.)

              1           2                       3

                     __________    _____________||_||_____
        :=|=========|_________/  /______________||_||_____
        ^                                       || ||
        |                                       (_O_)
        |                                         ^
        |                                         |
        ||

                                                  90-789
======================================================================
from Service Bulletins, Model Year 1990
......................................................................
Technical Bulletin
Group:     90
Number:    90-02
Date:      Nov 30, 1990
Subject:   Instrument Indicator Lights Malfunction
Model(s):  Vanagon

Condition:
  Instrument cluster warning lights are inoperative at times due to poor
  contact in the 14 pin instrument plug.  The following warning lights
  may be involved:
    Oil pressure, alternator, turn signal, high beam, or coolant
    temperature.

Service Solution:
  Check compact plug for proper contact adn seating.  Replace spring
  terminals when necessary.
=======================================================================
Technical Bulletin
Group:    90
Number:   92-03
Date:     February 29, 1992
Subject:  Coolant Indicator LED is Flashing at Normal Temperatures
Model(s): All Models

CONDITION
Coolant overheat / low coolant level indicator LED is flashing at
normal coolant temperatures.
SERVICE
Check the coolant indicator LED according to the list below.
The following applies IN ADDITION to tests listed in the Service
Microfiche.          .

* refer to appropriate wiring diagram
* disconnect coolant level sensor electrical connector
* check coolant level in coolant reservoir
   *** MUST be between MIN and MAX marks
* set digital multimeter, Fluke 83 (US 1119) to ohms function
* check resistance of level sensor with digital multimeter Fluke 83
  (US 1119)
  *** must be between 31K Ohm and 65K Ohm with correct COOLANT LEVEL
      AND COOLANT CONCENTRATION.

NOTE
If coolant resistance is NOT within the above specifications, the
coolant MUST be drained and replaced with NEW coolant mixture of
50 percent water and 50 percent phosphate free coolant antifreeze,
Part No. ZVW 237 104.  (In Canada, use Part No. G 001 100).  The
mixing should be performed before filling vehicle cooling system.

*****************************************************************
* CAUTION                                                       *
* Coolant concentrations of 60 percent or higher will cause the *
* overtemp / low coolant LED to activate.                       *
****************************************************************

*****************************************************************
* CAUTION                                                       *
* Coolant antifreeze MUST NOT be reused.  Properly dispose of   *
* used coolant.                                                 *
****************************************************************

* reconnect sensor connector
* check coolant level control unit using wiring diagram

NOTE
The control unit is located on top of the fuse/relay panel on vehicles
up to 1989 model year and thereafter it is integrated into the multi-
processor of the instrument cluster circuit board.

* if wiring, coolant level sensor and coolant concentration are OK,
  replace coolant level control unit or instrument cluster circuit
  board
* refer to appropriate Service Microfiche Group 90 - Coolant
  Temperature Gauge, checking and troubleshooting
* confirm proper operation of temperature gauge and blinking LED per
  Service Microfiche Group 90

*****************************************************************
* CAUTION                                                       *
* Part Numbers are for reference only.  Always check with your  *
* Parts Department for latest parts information.                *
****************************************************************
========================================================================
Technical Information
Group:    90
Number:   87-03
Date:     July 31, 1987
Subject:  Coolant Temperature Gauge Light flashes
          intermittently / continuously
Model(s): All Models, all Model Years

Flashing coolant temperature light may be caused by:
- Low coolant level.
- Coolant level indicator.
- Electrical connections on gauge.

* Check coolant level, top up if necessary.
* Check coolant level sensor for continuity.
* Check for loose connection of wiring at terminal 14 connectors of
  instrument cluster, nuts of temperature gauge, ground connection
  to body and engine ground.  Repair if necessary.

If temperature gauge light still flashes:
* Replace low coolant level control unit
=======================================================================
from Service Bulletins, Model Year 1990
......................................................................
Technical Information
Group:    24
Number:   90-03
Date:     March 31, 1990
Subject:  Throttle Body - replacement
Model(s): Vanagon, all w/ Digijet Injection

Replacement throttle body, Part No. 025 133 061B, has been updated with
the current throttle switch and lacks one vacuum line for the
distributor.

When installing this current replacement throttle body, the following
mechanical and electrical modifications must be completed.

Work Sequence
Mechanical:
* cut hose "A" (from throttle body to fuel pressure regulator) 150mm
  from   intake air distributor port
* install vacuum "T", Part No. 025 201 943, at location "B" (cut in
  hose "A")
* install vacuum hose "C" (from "T" to distributor)
  (Part No. N 020 353 5, approx. 70mm) between vacuum tee "B" and
  distributor vacuum advance unit

Electrical:
* remove the jumper wire for both switches and install supplied
connectors.

Check for vacuum leaks, check and reset basic engine specifications.
=======================================================================
from Service Bulletins, Model Year 1989
.......................................................................
Technical Bulletin
Group:    30
Number:   89-01
Date:     February 28, 1989
Subject:  Clutch Disc, installing
Model(s): Vanagon, all with Manual Transmission

The clutch disc hub and matching splines of the mainshaft are not to
be lubricated with MOS2 grease as described in the repair manual.

Instead, lubricate with grean P/N:  G 000 100.

* splines must be cleaned of all dirt and corrosion before lubricating.

* use only a thin coat of grease.

* clutch disc must move easily on shaft.
=======================================================================
from Service Bulletins, Model Year 1989
.......................................................................
Technical Bulletin
Group:    34
Number:   89-03
Date:     February 28, 1989
Subject:  Revised shift lever bearing
Model(s): Vanagon, all with Manual Transmission

* Beginning with 06/88 production, the centering holes (arrow) in the
shift lever bearing have been deleted.

Revised shift lever bearing, adjusting:

* loosen nuts (not shown).
* turn shift lever bearing to right or left until mounting studs
  contact ends of slots in bearing (arrows)
* tighten nuts to 10 Nm (7 ft lb)

Further adjustment of the gearshift lever is to be conducted as
described in the repair manual.

Note
The revised shift lever bearing can be installed in vehicles beginning
with 10/82 production.
=======================================================================
Product Circular
Group:    90
Number:   86-02
Date:     July 11, 1986
Subject:  Non-interchangeable cigarette lighters
          Part Identifier:  9062
Model(s): Vanagon

Two different cigarette lighters are used in Volkswagen vehicles and
they are NOT interchangeable.  If installed in the wrong vehicle, it
is possible that the lighter will not release properly, thus causing
a possible safety hazard.

Fig. 1                          Fig. 2
Part number  175.919.307B      Part number  171 919 305
                                        or  191 919 305
Application: Rabbit - all      Application: Cabriolet - all
             Pickup - all                   Jetta - all
             Golf - all                     Quantum - all
             GTI - all                      Scirocco - all
                                            Vanagon - all
=======================================================================
from Service Bulletins, Model Year 1987
.......................................................................
Technical Information
Group:    97
Number:   87-05
Date:     July 31, 1987
Subject:  Engine cranks too slowly or won't crank - battery cable
Model(s): Water-cooled Vanagon, all Model Years

A slow or non-cranking engine condition could be caused by high
resistance between the starter motor and battery:

*  Check that the battery is fully charged.
*  Check the ground connections and battery terminals for tightness
   and corrosion.  Clean and tighten as necessary.

If the conditon still exists:
*  Install a new starter cable or larger diameter,
   Part Number  251 971 228G.
*  Install an extra ground strap from the transmission to the body.
.......................................................................
Technical Bulletin
Group:    27
Number:   87-04
Date:     August 06, 1987
Subject:  Alternator mounting bolt loose/broken
Model(s): Water-Cooled Vanagon Diesel, Vanagon through model year 1985

To prevent the alternator bolt from becoming loose and breaking, the
torque specification has been increased.

The increased torque specification requires use of a new bolt on 1.9L
water cooled engines.

To repair a loose/broken bolt:
1.9L Gas Engine
* Install new bolt, Part Number  N 014 400 4.
  Torque to 25Nm (18 ft. lb.).

Diesel Engine
* Replace bolt only if damaged, Part Number is unchanged.
  Torque to 28-33Nm (21-24 ft. lb.).
========================================================================
from Service Bulletins, Model Year 1987
........................................................................
Technical Bulletin
Group:    17
Number:   87-04
Date:     September 30, 1987
Subject:  Oil leak from rear - oil pump gaskets
Model(s): Vanagon, 1983-1985
Supercedes 87-01, July 15, 1987.

Oil seepage from the oil pump on 1.9L water-cooled engines is caused
by gaskets which are not fully compressed.

* Replace the oil pump gasket with Part Number 025 115 111 (quantity
of 2).  These gaskets are interchangeable.
========================================================================
from Service Bulletins, Model Year 1987
.......................................................................
Tech News 87-N02
Issue 2, February 1987
Cold Feet, Hot Tip

A slight "internal" compression leak into the coolant system of a water-
cooled Vanagon is not always easily diagnosed.  But what your customer
tells your Service Advisor may be very helpful to pinpoint such a
problem:
*  Temperature gauge needle moves into the red
*  Very little or no heat output
*  Coolant refill tank overflows
*  Air in the coolant system
If one or a combination of these symptoms apply, be suspicious of a
compression leak between cylinder sleeve and cylinder head.  Either
the metal sealing ring (1) or the 'O' ring (2), or both may be damaged.
.......................................................................
(1) is the outer most sealing ring; next to the cylinder head.
(2) is the inner most sealing ring; next to the cylinder sleeve.
=======================================================================
Import Service, Feb 91, Vol 4, No 2
Subject: Wasserboxer torque spec update

"The cylinder head nut torque specification listed in our November
1990 "Wasserboxer" article [the one on the net] has been updated.  VW
recently increased the recommended head nut tightening torque for all
water cooled Vanagon engines to 50 Nm, up from the original
specification of 35 Nm.

The tightening procedure described in the article must still be
followed, substituting 50 Nm for the final torque.  We apologize for
any problems this specification change may have caused."

From: "Dan Houg" 
=======================================================================
from Service Bulletins, Model Year 1987
.......................................................................
Tech News 87-N04
Issue 4, April 1987
Vanagon Surging/Stalling

A customer complaint of surging/stalling on 1986 and '87 Vanagons could
be the result of a misadjusted idle/full throttle switch.

The digifant system uses a single throttle switch to signal the E.C.U.
when the throttle plate is in the fully closed (idle) or fully open
(full load) position.

Correct adjustment of the throttle switch is very important.  If switch
is misadjusted, the engine may surge at idle or cut out at steady
driving or light acceleration.

Here are some key points to remember:
*  Set or check the switch adjustment only after the engine reaches
   operating temperature.
*  When setting or checking your adjustment allow the throttle to return
   "normally".  Do not "snap" the throttle causing it to slam shut ...
   this could adversely affect the switch adjustment.  See the Vanagon
   Repair Microfiche for complete throttle switch adjustment details.
=======================================================================
from Service Bulletins, Model Year 1987
.......................................................................
Tech News 87-N05
Issue 5, May 1987
Easy Does It

When removing the cross-over water pipe on a 1982 through 1985 model 1.9
liter Vanagon waterboxer engine ... you have to use care.

The cross-over pipe is secured to a welded stud on the intake manifold
(arrow) that could break or crack.


If this happens, a vacuum leak could develop that would be hard to
detect. Such a vacuum leak could cause poor performance under all
running conditions due to leaning out of the mixture ... and would
occur even when all other systems are go.
=======================================================================
from Service Bulletins, Model Year 1987
.......................................................................
Tech News 87-N06
Issue 6, August 1987
Vanagon "Dust Buster" Air Filter

Vanagon owners who operate their vehicles in high dust concentration
areas have some relief in store ... from our parts store, that is.
A specially designed air filter, Part No. 025 129 620 B, standard
equipment on Vanagon Syncro models, is what these owners need.
Special "dust buster" style air filters are also available for other
Volkswagen models that operate in the dust.  So if you encounter an air
cleaner that looks like a "dust bowl" ... you know what to recommend.
=======================================================================
from Service Bulletins, Model Year 1987
.......................................................................
Tech News 87-N08
Issue 8, August 1987
Basic Digifant Assumptions

The Digifant engine management system found on late model Vanagons
operates on the assumption that basic engine TIMING, IDLE SPEED,
THROTTLE SWITCH AND CO%, are correctly set or adjusted.

If not, the system will try to compensate for anyu deviation and end up
"fighting" with itself to make the engine run.  That's why it is
critical that these basic engine settings are checked prior to any work
you perform on the Digifant system.  Equally critical is the need to
use Adapter VW 1473 with your VAG 1367 and US 1119 milliamp meter with
VW 1315A/2 adapter as well as your CO Meter to verify that idle RPM/
stabilizer milliamp and CO% readings are right.

These settings, as well as everything you ever wanted to know about
Digifant, are found in the newly released Vanagon Fuel System Pro-
Training booklet ... available at your dealership now.

For troubleshooting wiring problems, always use the latest wiring
diagram which appears on a circular.
=======================================================================
from Service Bulletins, Model Year 1988
.......................................................................
Tech News 88-N07
Volume 2, Issue 7, August 1988
Coolant Loop

If you have to remove the transmission only on a 2.1 liter Vanagon, be
very careful to check the "Coolant Loop" around the engine compartment.
You can easily break this loop!  Keep an eye on the hose between the
engine and the loop.  Make sure that the loop does not start to pull
tight as teh back of the engine comes down or it will probably break.
If this hose seems too short, take it off the loop or loosen the loop
from the edge of the engine compartment.
=======================================================================
Import Service, March '90  Vol3, No 3
Vanagon coolant leakage

"A damaged plastic coolant return flange located at the rear of the
right cylinder head can cause coolant leakage on 86-88 models.  The
plastic flange is close to the engine's drive belts and can be
damaged by a loose or broken belt.  Engine orverheating can also warp
the sealing surface of the flange, causing coolant leakage and more
overheating.

To correct (or avoid) these problems, replace the damaged plastic
flange with a metal coolant return flange, P/N 025 121 160 D, and
gasket P/N N 901 685 01."

From: "Dan Houg" 
=======================================================================
from Service Bulletins, Model Year 1990
.......................................................................
Technical Bulletin
Group:    20
Number:   20-90 T01
Date:     May 31, 1990
Subject:  Improved fuel additive  ZVW 239 003
Model(s): All Gasoline Engine Vehicles

Research by Volkswagen AG and other manufacturers has shown that the
performance of todays gasoline engines is directly influenced by the
type and quality of fuel used.

Fuel without the proper additives can cause deposits to collect on
fuel injectors, intake ports and valves.

This build-up of deposits can cause the following conditions:
     * unstable idle                    * power loss
     * surging                          * engine run-on
     * misfiring                        * pinging/knocking

Extent of deposit build-up varies depending on type of fuel used,
operating condition, etc.  Refer to current Technical Information
Circulars for description of deposit grading system.

PREVENTION
Prevent deposit build-up through the use of gasolines with injector
and intake valve deposit control additives.
Consult the suppliers and service stations in your area about fuel
grades and additives that prevents or removes these two deposits. 

In areas where gasoline containing deposit control additives are
unavailable, light deposits can be controlled as follows:

* add one 6.5 oz. bottle of Autobahn Gasoline Additive,
  P/N:  ZVW 239 003.

Note:  Fill fuel tank completely.  Do not refill until fuel gauge
       reads 1/4 tank or less.

REMOVAL
Moderate to heavy deposits can also be removed with Autobahn Gasoline
Additive, P/N:  ZVW 239 003.
When used as follows this additive has shown to be effective.

* Check fuel injector spray pattern.  Purge injection system with G-16
  cleaner.  Refer to current Technical Information Circulars for
  injection purge instructions.

* Check that fuel and ignition systems are within specifications.

* Add three (3) 6.5 oz bottles of Autobahn Gasoline Additive,
  P/N: ZVW 239 003 for each of three (3) consecutive fill-ups or
  1000 miles.

Heavy deposit concentration may require 2 or 3 cycles of the above
treatment.

Note:  Fill fuel tank completely.  Do not refill until fuel gauge
       reads 1/4 tank or less.

* Deposit removal with Autobahn Gasoline Additive, P/N: ZVW 239 003
  is more efficient with engine at operating temperature and at
  moderate speed, short distance driving conditions.

* Because of possible contamination of the oil,  the filter and oil
  must be changed at the conclusion of each removal cycle.
=======================================================================
Technical Information
Group:    20
Number:   90-02
Date:     March 31, 1990
Subject:  Gasoline containg detergents
Model(s): All Vehicles with fuel injection

Volkswagen United States, Inc. recommends the use of gasolines which
contain detergents to keep intake valves and fuel injectors free of
deposits.

Gasolines without detergents tend to clog fuel injectors and leave
residue on intake valves which can cause unstable idle, surging,
misfiring of sparkplugs, stlling and rough engine performance in
vehicles with fuel injection systems.

Because many of our customers may not know whether or not a particular
brand of gasoline contains these detergents, we have examined
advertising literature published by gasoline refiners and other publicly
available literature discussing gasoline ingredients.

We cannot independently confirm the accuracy of gasoline advertising
claims.  The brands of gasolines listed below are claimed by their
manufacturers to contain detergent packages designed to keep intake
valves and fuel injectors clean.  There may be other manufacturers that
offer similar detergent packages.

Please pass this information on to customers who have experienced
driveability problems that may be caused by carbon deposits on intake
valves or fuel injectors.

   Amoco:                  All grades
   Arco:                   All grades
   Chevron:                All grades
   Citgo:                  Some grades in early 1990
   Conoco:                 Some grades in early 1990
   Diamond Shamrock:       Premium grade only
   Exxon:                  All grades
   Fina:                   All grades in early 1990
   Hess:                   All grades in early 1990
   Marathon:               All grades
   Mobil:                  All grades
   Phillips 66:            All grades in early 1990
   Shell:                  All grades
   Sunoco:                 Premium grade only
   Texaco:                 All grades
   Unocal:                 All grades
   Hess:                   All grades in early 1990
   Hess:                   All grades in early 1990
=======================================================================
from Service Bulletins, Model Year 1990
.......................................................................
Technical Bulletin
Group:    00
Number:   90-01
Date:     August 31, 1990
Subject:  Lubricant Capacities/Lubricant Type
Model(s): Air-cooled, Water-cooled -- All 1975-1990

Vehicle:     Vanagon
Model Year:  1980-up
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Engine Oil:
             Air-Cooled:    3.0 liter (3.2 quart)
                            3.5 liter (3.7 quart)/Filter

             Water-Cooled:  3.8 liter (4.2 quart)
             Thru 1986 MY   4.2 liter (4.7 quart)/Filter
             From 1987 MY   4.3 liter (4.8 quart)/Filter

             Diesel:        3.5 liter (3.7 quart)
                            3.8 liter (4.2 quart)/Filter

Use 'API SERVICE SF' for Gasoline engines.
Use 'API SERVICE CC or CD' for Diesel engines.
Note:  Refer to Owner's Manual for oil grade/climate requirements
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Manual Transmission:
             Air-Cooled:    4 speed: 2.9 liter (3.2 quart)
                                     SAE 80/80W/90,
                                     MIL-L-2105, API/GL-4

             Water-Cooled:  4 speed: 2.5 liter (2.8 quart)
                                     SAE 80/80W/90,
                                     MIL-L-2105, API/GL-4

             Diesel:        4 speed: 2.5 liter (2.8 quart)
                            5 speed: 3.4 liter (3.8 quart)
                                     SAE 80/80W/90,
                                     MIL-L-2105, API/GL-4
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Automatic Transmission:
             All Models:    Dry Fill:  6.0 liter (6.3 quart)
                                       ATF Dexron/Dexron II
                            Refill:    3.0 liter (3.2 quart)
                                       ATF Dexron/Dexron II

Automatic Differential:
             All Models:    1.2 liter (1.3 quart)
                            SAE 90W, MIL-L-2105 B, API/GL-5
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Cooling System:
             Waterboxer &   Thru 1986 MY  15.2 liter (16.9 quart)
             Diesel

             Waterboxer     From 1987 MY  16.7 liter (18.6 quart)

Use only Phosphate Free Coolant  ZVW 237 104 (G11)  or equivalent
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Power Steering:
             All Models:    1.2 liter (1.3 quart)
                            ATF Dexron II
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Windshield Washer Solvent:
             All Models:    Front:  3.9 liter (4.3 quart)
                                    9.0 liter (9.5 quart)
                                        w/ headlite washers
                            Rear:   1.0 liter (1.1 quart)

Recommended Solvent:        Concentrated  ZVW 177 901/903
                            Pre-mix       ZVW 177 902 or Equivalent
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Air Conditioning:
             Air-Cooled &
             Water-Cooled:  Refrigerant (R-12) - 1190 + 85 grams
                                                 (42.0 + 3.0 oz.)
                            Refrigerant Oil    - 135 cc (4.75 oz.)
             Diesel,
             From 1986 MY:  Refrigerant (R-12) - 1438 grams (50.75 oz)
                            Refrigerant Oil    - 237 cc (8.0 oz.)

U.S.A. Only:  Use any domestic available refrigerant oil
Canada Only:  Use Suniso 5GS refrigerant oil, available
              through VWC, Part No. X 091050
**********************************************************************
* CAUTION:  Part numbers are for reference only.  Always check with  *
*           your Volkswagen Parts Department for latest information. *
**********************************************************************
=======================================================================
from Service Bulletins, Model Year 1988
.......................................................................
Technical Information
Group:    40
Number:   88-01
Date:     May 31, 1988
Subject:  Upper control arm bushings, checking
Model(s): Vangon, all model years

An insufficient seal at the outer ends of the upper control arm bushings
can cause premature wear to the bushings.  Visually inspect the bushings
as follows to determine if replacement is necessary.

NOTE
When checking the bushings, both front wheels must be on the ground.

* Bolt head or nut/washer must be postioned in center of bonded rubber
  bushing.
* If bolt head or nut/washer comes in contact with supporting ring
  (arrow), wear limit has been reached and bushing must be replaced.



this same information is also shown on page 40.5a of the July 15, 1991
edition of the Bentley Vanagon Manual.
=======================================================================
from Service Bulletins, Model Year 1991
.......................................................................
Technical Information
Group:    68
Number:   91-02
Date:     April 30, 1991
Subject:  Automatic Rear 3-Point Seat Belts, Retrofit Installation
Model(s): Vanagon, 1980-1989 Model Years
          Vanagon Camper/Multivan (right rear only),
            1980-1989 Model Years

AUTOMATIC REAR 3-POINT SEAT BELTS, RETROFIT INSTALLATION
**********************************************************************
* CAUTION                                                            *
* Part numbers are for reference only.  Always check with your Parts *
* Department for latest information.                                 *
**********************************************************************
PARTS REQUIRED
Part Number          Description                      Quantity
------------    -----------------------------------   --------
253 857 815D    Rear 3-point seat belt (left side)       1
253 857 816D    Rear 3-point seat belt (right side)      1

NOTE
Check with your Parts Department for additional installation parts.
Not all parts listed may be applicable to all vehicles.
*  remove rear seat bottom
*  remove existing 2-point left/right side lap belt
*  remove rear floor carpet
*  remove right rear luggage area trim panel
*  mark and cut rear luggage area trim panel using dimensions as shown
   on Page 3
*  locate, by feel, threaded hole under D-pillar trim (arrow)
   
*  cut hole in trim to expose threaded bolt hole
*  using bolts (2), mount retractor assembly (1), to side panel (3)
   -> 40 Nm (30 ft lb)
   
*  install belt through cut hole in trim panel
*  mount upper belt guide onto D-pillar
   -> 40 NM (30 ft lb)
   
*  install belt anchor (arrow) to original lap belt anchor point
   -> 40 Nm (30 ft lb)
*  reinstall right rear luggage area trim panel
*  repeat procedure for left side belt assembly, noting to reverse
   dimensions accordingly
*  reinstall all other components in reverse order
*  check rear 3-point belts for proper function
---------------------------------------------------
Automatic rear 3-point |       |         |         |
seat belts, retrofit   |       |         |         |
installation           | Diag. |         | Quality |
(one side only)        | Check | Repair  | Check   |
---------------------------------------------------
Labor Op. 6876312      |  --   | 120 T.U.| --      |
---------------------------------------------------


DIAGRAM
  (8-1/4in)        \
           /                     ______ ________ \
          /                     38mm    | hole |      (15-7/8in)     \
         /                       ______ |______|                      \
        /                                                              |
       /                             ||                      |
      /                              | (5-7/8in)|                      |
     /                               |----------|--                    |
    /                                |          | 32mm (1-1/4in) ______|
   /---------------------------------|          |---------------|
   ||

........................................ end ...........................
 that is, the dimensions of the hole are 71mm x 38mm (2-13/16in x
 1-1/2in). but the front edge of the hole is 203mm (8in) below the top
 edge of of the luggage area trim panel, while the rear edge of the hole
 is 210 mm (8-1/4in) from that same edge. the hole is slightly tilted.

 the notch is cut in the bottom to accomodate those three bolts that
 hold the retractor assembly to the metal of the body.

also notice that this does NOT say anything about those 1986-1989
vanagons with air conditioning. the upper belt guide attachment point
will be behind the air conditioning housing that runs vertically over
the D-pillar. so you would have to cut a hold in the plastic a/c
housing to pass the belt through. (it helps to look at a 1990 or 1991
model, to see how the factory installation looks). in order to prevent
damage to the belt, the little plastic edging (that covers the edges
of the hole in the a/c housing) will have to be installed.
=======================================================================
from Service Bulletins, Model Year 1991
.......................................................................
Technical Information
Group:    68
Number:   91-04
Date:     April 30, 1991
Subject:  Automatic 3-Point Left Center Seat Belt, Retrofit Installation
Model(s): All Vanagon w/ center seat, EXCEPT Camper/Multivan
          1980-1989 Model Years

AUTOMATIC 3-POINT LEFT CENTER SEAT BELT, RETROFIT INSTALLATION
**********************************************************************
* CAUTION                                                            *
* Part numbers are for reference only.  Always check with your Parts *
* Department for latest information.                                 *
**********************************************************************
PARTS REQUIRED
Part Number          Description                      Quantity
------------    -----------------------------------   --------
253 857 811D    3-point seat belt (left side)            1

NOTE
Check with your Parts Department for additional installation parts.
*  remove rear seat back
*  remove rear seat bottom
*  remove original left center belt
*  remove rear left side panel trim
   
*  measure location of belt retractor, belt guide, and mounting holes,
   using dimensions on page 3
*  cut panel as required
*  reinstall trim panel
*  install seat belt retractor on outside of panel, as shown
   -> 40 Nm (30 ft lb)
   -> hand tighten forward bolt only
*  locate, by feel, threaded hole in C-pillar (arrow) for belt guide
   D-ring
   
*  cut C-Pillar trim from threaded hole, install belt guide D-ring
   -> 40 Nm (30 ft lb)
*  install anchor of 3-point belt into forward mounting hole of
   retractor bracket (arrow A)
   -> 40 Nm (30 ft lb)
   
*  align bracket for betls, reinstall rear seat bottom and belts
*  reinstall rear seatback
*  install new buckle for 3-point belt
*  check seat belt for proper function
---------------------------------------------------
Automatic left center  |       |         |         |
3-point seat belt,     |       |         |         |
retrofit installation  | Diag. |         | Quality |
(left side only)       | Check | Repair  | Check   |
---------------------------------------------------
Labor Op. 6876311      |  --   | 150 T.U.| --      |
---------------------------------------------------


DIAGRAM
          Top                                Front of Vehicle -->

                Rear Left side trim panel
  -------------------------------------------------
                                                  |
                                                  |
                                                  |
                                                  |
                       _________ _________________|__________
                      |  67mm   |                 |    38mm
                      |(2-5/8in)|                 |  (1-1/2in)
\                     |_________|_________________|_____:________
 \                                                |            .
  \                  < 102mm >                   |            .
  >\ 31mm< hole (4in) | . ---\-- () 22mm __________ _______._ | 442mm . \ . | | . | (17-3/8in) . \ . | 118mm | 327mm | . . \ | (4-5/8in)| (12-7/8in) | . . \ _._|__________|._ . | . . \ . . . | . . \ . . . ()--------.--(hole 22mm) . \ 245mm 216mm . > 31mm|<   .     (7/8in)
298mm       \  (9-5/8in)  (8-1/2in)    .          |    .       .
(11-3/4in)   \    .             .      .          |  203mm     .
 .            \   .             .      .          | (8-1/8in)  .
 .             \  .             .      .          |    .       .
 .____________  \_._____________.______.__________| ___._______._

........................................ end ...........................
 that is, the dimension of the bottom hole is 118mm x 102mm (4-5/8in x
 4in). but the front edge of the hole is 216mm (8-1/2in) above the
 bottom edge of the trim panel, while the rear edge of the hole is
 245mm (9-5/8in) from that same edge.  that is, the hole is slightly
 tilted. the upper hole is 67mm x 38mm (2-5/8in x 1-1/2in) and appears
 also to be slightly tilted. the upper hole has its bottom front edge
 442mm (17-3/8in) from the bottom edge of the trim panel.

notice that the instructions do NOT say anything about those two 22mm
(7/8in) holes. both are 31mm (1-1/4in) from the closest edge of the trim
panel. the lower of the two is 203mm (8-1/8in) from the bottom edge,
while the upper of the two holes is 298mm (11-3/4in) above that same
bottom edge.

i have no idea what those holes are supposed to be used for.
========================================================================
Technical Information
Group:    28
Number:   87-04
Date:     July 15, 1987
Subject:  Rough idle or misfiring during partial load
Model(s): All Models, all Model Years

A rough idle or misfire during partial load could be caused by ignition
sparks jumping from the plug wire connector to the noise suppresion
shield, or the cylinder head.

* Remove and inspect the plug connector for white spots or burn marks.

* On those vehicles equipped with a suppressor shield on the
  distributor cap, it is necessary to remove the shield and check for
  white spots or burn marks on the distributor cap.

if white spots or burn marks are present, replace the damaged
components.
======================================================================== 135
1968-1979 Buses
  Removing and Installing Fuel Tank Sender Unit
  (from Repair Manual Type 2, Second Edition, VW AG)

The sender unit can be removed without taking out the engine, bulkhead
and fuel tank. This is done by cutting a hole in the floor plate which
is then closed afterwards with a plate available as a spare part.

The following parts are required:
   1 ea.  Cover plate (oval) for floor plate.
          
   1 ea.  gasket for cover plate
          
   4 ea.  screws B 4.2x9.5, DIN 7981, galvanized
          
   -      VW Universal Adhesive


**********************************************
*               WARNING                      *
*  DO NOT USE any of the following tools     *
*  to cut the hole or clean edges:           *
*  Gas Torch,  Grinding Disc, Parting Disc.  *
**********************************************

- Disconnect the battery ground cable.

- Remove the spare tire and spare tire cover.

- Measure the center point of the hole:
   - from the left (driver) interior side panel, next to the
       spare tire hole:
       a = 807mm (31.77 in.)
   - from the rearmost edge of the rear hatch opening (the metal 'rim',
       that is next to the rubber gasket for the rear hatch):
       b = 893mm (35.15 in.)
   - See Fig. 1

- Cut hole and remove burrs.
  - radius of hole is:
       r = 40mm (1.57 in.)
  - width of cut is:
       w = 70mm (2.75 in.)
  - See Fig. 2

- Cut into the rib at front and rear edge of hole about 15mm (0.59 in.)
  and hammer rib flat.  Support metal from underneath with a strong
  lever.

- Check that the plate and seat fit properly.  To ensure that the
  plate seals properly, the hole should be lifted slightly around the
  edge.

- Place the cover over the hole, mark off the screw hole positions on
  the floor plate and drill 3mm (1/8 in.) diameter holes for the four
  screws.

- Renew fuel guage sender unit.

- Connect up the battery ground strap and check operation of the
  sender unit.

- Stick seal to plate and secure plate with four taping screws.

Fig. 1 ----------------------------------------------------------------
                     (rear of bus)

                           latch
        ====================----====================
                     :                              |  a = 807mm
                     :                       |-----||      31.77 in.
                     :                       |     ||
                     :                       |spare||  b = 893mm
                     :                       |tire ||      35.15 in.
                     b                       |hole ||
                     :                       |     ||
                     :                       |     ||
                     :                       |     ||
                     :                       |     ||
                     :                       |-----||
                     :                              |
                     x |
 forward edge  > . . . . . . . . . . . . . . . . . .
 of engine ledge
 (dropoff to floor of bus)
Fig. 2 ----------------------------------------------------------------
                     (rear of bus)
 raised ribs-> ||     ||     ||     ||     ||    a = 807mm (31.77 in.)
 on engine     ||     ||     ||     ||     ||    r = 40mm (1.57 in.)
 ledge         ||     ||     ||     ||     ||    w = 70mm (2.75 in.)
               ||     || :  /---- › ||     ||                    |
               ||     || w (-r-x<--)------------a--------------->|
               ||     || :  ›-----/ ||     ||
 forward edge  > . . .|| . . ||. . .|| . . ||. . . .
 of engine ledge
 (dropoff to floor of bus)

description of hole: at the measured point x (a from the side, and
b from the rear edge), draw a circle of radius r.  on the front-rear
axis of the circle, truncate the circle to 35mm in front of x and
35mm to the rear of x (so the hole will look like a flattened circle).
the forward edge of the hole will almost be at the dropoff ledge from
the engine compartment to the floor of the middle of the bus.
-----------------------------------------------------------------------
one of the raised ribs on the engine compartment will be just right
(passenger side) of the point x. this is the one that will have to be
cut and flattened.

the picture shows a flat wrecking bar type instrument being held under
the cut rib, while the rib is being flattend with a small tack hammer.
-----------------------------------------------------------------------
the next picture shows the edges of the hole having been curled upward
just a bit (with pliers, i assume. or with one of those 'lip' maker
tools that body shops used to use).
-----------------------------------------------------------------------
comments: even though the cover plate is listed as 'no longer available',
i suppose you could make your own plate. it would just need to have a small
downward lip around the outer edge ... to secure and seal the gasket in
place. the four screw holes were basically laid out 2 per side of the hole,
like so:         /--------›
               /  o      o  ›
              (       x      )   where x is the center-point of the hole
               ›  o      o  /
                 ›--------/
=========================================================================
Import Service, Dec '90, Vol 3, No 12
Subject: VW rotor govenor

"A faulty distributor rotor may cause the engine to cut out on some
69 to 71 VW Type 1, 2, and 4 vehicles.  the rotor has a built in
centrifugal govenor cutout that prevents the engine from
over-revving.  Low speed cutout may be caused by a weak govenor
spring.  the rotor can be replaced with a conventional non-governor
rotor, but the engine may be damaged by over-revving."

From: "Dan Houg" 
Import Service, March 1995 Vol 8, No 3
Reader 'tech tip' submission

"If you have low cranking compression but little cylinder leakdown on
an air-cooled VW engine equipped with hydraulic valves, try
readjusting the valves.  If this does not correct the problem, I have
seen several cases where the hydraulic lifters were bad enough to
hold the valves open slightly at all times.

The defective hydraulic lifters can be replaced without removing the
engine or cylinder heads, which will save your customer quite a bit
of money.

Dan Rickert
Almanor Import Repair
Clear Creek, California"
From: "Dan Houg" 
=========================================================================
Import Service, March 1995 Vol 8 No 3
Reader 'tech tip' submission:

"If you have done some brake work on a VW Vanagon that requires you
to bleed the system, you will find the master cylinder behind the
instrument cluster.  Because of this fact, it is hard to get a power
brake bleeder attached to the cylinder.

I have found that a screw on radiator cap fitting from a cooling
system pressure testing outfit will fit the threads on the brake
master cylinder reservoir.  Use the cap fitting to pressurize the
brake system, then proceed to bleed the brakes solo.

Al Tuck
Repair Dynamics
Steamboat, Colorado"
Dan's Note:
Great idea here folks!  BUT make sure the cap you use is new or
ABSOLUTELY dry as any residual moisture left from its cooling system
application will be forced into the brake system.  I have a 'spare'
bad cap that will work for this so i'll have to give it a try
sometime.
From: "Dan Houg"