1993-97 ENGINE COOLING Cooling System Removal
1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
1993-97 ENGINE COOLING
Cooling System Removal & Installation - EuroVan, 2.4L Diesel (AAB & ACV Engine Codes)
ENGINE IDENTIFICATION
The VIN number ("Code letters" and "Serial number") can be found next to injection pump on left side of
cylinder block. See Fig. 1 . Additionally there is a sticker on the upper toothed belt guard with "Engine
code" and "Serial number". The engine code is also included on the vehicle data plate. See Fig. 2 .
Fig. 1: Identifying 2.4L Diesel (Engine Codes AAB & ACV)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
NOTE:
On some models, vehicle data plate may be attached to trim cover under
lower left side of instrument panel.
The engine number consists of up to nine characters (alphanumeric). The first part (maximal 3 characters)
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© 2004 Mitchell Repair Information Company, LLC.
1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
makes up the "engine code", and the second part (6 characters), the "serial number". If more than 999,999
engines with the same engine code are produced, the first of the six characters is replaced with a letter.
Fig. 2: Locating Vehicle Data Plate
Courtesy of VOLKSWAGEN UNITED STATES, INC.
BLEEDING COOLING SYSTEM
DRAINING
1. Remove cap from coolant expansion tank. See Fig. 4 .
2. Remove lower sound dampening pan. See SOUND DAMPENING PAN .
3. Drain coolant either via drain plug and coolant hose or via thermostat connection. See Fig. 3 .
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 3: Draining Cooling System (2.4L Diesel)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
FILLING
CAUTION:
If radiator, heat exchanger, cylinder head or cylinder head gasket is
replaced, DO NOT reuse old coolant.
NOTE:
The cooling system is filled year-round with a mixture of water and antifreeze plus G11 corrosion protection damage agent. G11 and coolant
additives will prevent frost and corrosion damage, the formation of chalk and
in addition, they raise the coolants' boiling point. For these reasons, the
cooling system must be filled year round with anti-freeze and G11. Due to the
higher boiling point, the mixture is also an aide to operational efficiency
where engines operate at high loads, particularly in tropical climates. For
more information, see COOLING SYSTEM SPECIFICATIONS .
1. Open bleeder screw in coolant hose to heater core.
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
2. Press down on top of radiator hose.
3. Slowly fill with coolant up to MAX mark on expansion tank. See Fig. 4 .
Fig. 4: Identifying Expansion Tank MIN & MAX Marks
Courtesy of VOLKSWAGEN UNITED STATES, INC.
4. Close bleeder screw in coolant hose to heater core.
5. Start engine and run approximately 1500 RPM for 2 minutes maximum. At same time fill coolant up
to over-flow hole on expansion tank.
6. Install expansion tank cap.
7. Run engine until radiator fan comes on at least once.
8.
NOTE:
When engine is at normal operating temperature, coolant level must be
on MAX. When cold, between MIN and MAX marks.
Check coolant level and top-off if necessary.
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
DRIVE BELTS
2.4L DIESEL (UP TO JANUARY, 1995)
The 2.4L diesel engine (up to 1/95) uses of V belts to drive the accessaries. For drive belt routing, see Fig.
5.
Removal & Installation (Generator V Belt)
1. Remove lower sound dampening pan. See SOUND DAMPENING PAN .
2. Loosen all securing bolts for tensioning bracket (A) and generator at least one turn. Note it must be
possible to move the generator easily by hand. See Fig. 7 .
3. Replace drive belt.
4. Tension general V belt by turning the tensioning nut (B) with torque wrench. See Fig. 7 . Tighten to
the appropriate specification using special tool. See Fig. 8 .
New Belt
Tighten to 71 INCH lbs. (8 N.m)
Used Belt
Tighten to 35 INCH lbs. (4 N.m)
5. Tighten tensioning nut securing nut to 22 ft. lbs. (30 N.m).
6. Tighten generator mounting securing bolt to 26 ft. lbs. (35 N.m). Tighten tensioning bracket to
cylinder head/lifting eye to 18 ft. lbs. (25 N.m).
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 5: Drive Belt Routing (2.4L Diesel - Up To Jan. 1995)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 6: Identifying Drive Belt Pulleys, Brackets & Fasteners (2.4L Diesel)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 7: Identifying Generator Securing Nut
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 8: Ring Insert (1410/2) Required For V Belt Installation
Courtesy of VOLKSWAGEN UNITED STATES, INC.
2.4L DIESEL (FROM FEBRUARY, 1995)
The 2.4L diesel engine (2/95 and up) uses a single serpentine belt. For drive belt routing, refer to Fig. 11 and
Fig. 12 . Serpentine belt may also be referred to as a serpentine belt.
NOTE:
If reusing the serpentine belt, mark the direction of rotation. When installing
the belt make sure it is correctly seated in the pulley.
Removal & Installation
1. Lift tensioning roller with Lever Tool (3299) and remove serpentine belt from the generator pulley.
See Fig. 9 . On A/C equipped engines, grasp the serpentine belt with both hands and slowly pull it
over power steering pump. See Fig. 14 . On all engines, remove belt.
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 9: Lifting Serpentine Belt Tensioning Roller Using Lever Tool (3299)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
2. Before installing the serpentine belt, make sure that all sub-assemblies (generator, power steering
pump) are tight. Place serpentine belt on belt pulley with vibration damper. Lift tensioning roller with
Lever Tool (3299). Install belt. Slowly release Lever Tool (3299) to re-apply tension to belt. For
vehicles with air conditioning, please note the following procedure to install belt:
z First place the serpentine belt on tensioning roller (1), then on generator (2), idler roller (3),
vibration damper (4), idler roller (5) and as far as possible on air conditioner compressor (6).
See Fig. 13 .
z Grasp the serpentine belt with both hands and slowly pull it over power steering pump. See Fig.
14 .
z Turn engine over by hand in engine direction of rotation and make sure serpentine belt seats
correctly in the running grooves in the belt pulley.
3. For all models, start engine and check belt running.
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 10: Special Tool Required For Serpentine Belt Installation
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 11: Serpentine Drive Belt Routing (2.4L Diesel, With A/C)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 12: Serpentine Drive Belt Routing (2.4L Diesel, Without A/C)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 13: Removing Serpentine Belt (2.4L Diesel, With A/C)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 14: Installing Serpentine Belt Onto Power Steering Drive Pulley (2.4L Diesel, With A/C)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
REMOVAL & INSTALLATION
NOTE:
The trim frame may also be referred to as lock carrier.
FRONT BUMPER
Removal & Installation (Up To December, 1995)
1. Pull drive pins out and pull bumper parallel out of guides. See Fig. 15 .
2. To install, reverse removal procedure. Slide bumper parallel onto guides. Secure by driving in pins.
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 15: Exploded View Of Bumper Assembly (Up To December, 1995)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
Removal & Installation (From January, 1996 - Long Front End)
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
1.
2.
3.
4.
5.
Remove radiator grille with trim frame. See RADIATOR GRILL & TRIM FRAME .
Remove Torx screws (2 and 3). See Fig. 16 .
Disconnect right then left side of bumper beam. See Fig. 16 .
To remove bumper beam, pull beam straight out of guide bracket.
To install, reverse removal procedure.
Fig. 16: Exploded View Of Front Bumper (From January, 1996 - Long Front End)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Removal & Installation (From January, 1996 - Short Front End)
1. To remove bumper cover, pry out caps (9). See Fig. 17 .Remove combination hex screw and washer
assemblies (10). Remove Torx screws (8).
2. To remove bumper beam, pull beam straight out of guide bracket. See Fig. 17 .
3. To install, reverse removal procedure.
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 17: Exploded View Of Front Bumper (From January, 1996 - Short Front End)
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© 2004 Mitchell Repair Information Company, LLC.
1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Courtesy of VOLKSWAGEN UNITED STATES, INC.
RADIATOR & RADIATOR FAN
NOTE:
The trim frame may also be referred to as lock carrier.
Special Tools
For radiator fan removal, required special tools.
z
z
z
z
Anti-Freeze Tester
Drip Tray (VAG 1306)
Spring-Type Clip Pliers (VAG 1921)
Torque Wrench (VAG 1331)
Removal & Installation
Remove lower sound dampening pan. See SOUND DAMPENING PAN . Drain coolant. See DRAINING
under BLEEDING COOLING SYSTEM.
1. Remove radiator grill. See RADIATOR GRILL .
2. Remove coolant hoses off radiator using Hose Clip Pliers (VAG 1921).
3. Disconnect connectors off Engine Coolant Temperature (ECT) thermal switch and coolant fan on
radiator.
4. On engine code ACV with charge air cooler, remove charge air cooler bracket. See Fig. 26 . Remove
charge air cooler with air hoses.
5. On all engines, remove radiator grille. See RADIATOR GRILL & TRIM FRAME .
6. Disconnect power steering hydraulic line from radiator(if equipped). For vehicle with A/C, go to step
7 . For vehicles without A/C, go to step 8 .
7.
WARNING: DO NOT open A/C refrigerant circuit.
CAUTION:
To prevent damage to the condenser, refrigerant lines, pipes, and
hoses; ensure that none of them are stretched, kinked, or bent.
On vehicles with A/C:
z Remove A/C fluid reservoir and allow to hang free.
z Remove clamps from refrigerant lines.
z Unfasten A/C compressor and condenser and secure to body such that refrigerant lines are not
stressed.
z Go to next step.
8. On all vehicles, unclip radiator securing rubber from lock carrier. Remove lock carrier.
9. Lift out radiator with fans and fan shroud assembly. See Fig. 18 and Fig. 19 .
10. To install, reverse removal procedures. See TORQUE SPECIFICATIONS . Fill and bleed air from
cooling system. Check headlight alignment, if necessary.
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
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© 2004 Mitchell Repair Information Company, LLC.
1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 18: Identifying Radiator & Cooling Fan Assembly Up To December, 1995)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 19: Identifying Radiator & Cooling Fan Assembly (2.5L - January, 1996 & Up)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
RADIATOR GRILL & TRIM FRAME
NOTE:
The trim frame may also be referred to as lock carrier.
Removal & Installation (Up To December, 1995)
1. Remove mounting screws on left and right sides at upper grill corners. See Fig. 20 .
2. Tip radiator grill forward and unhook from mounting holes at bottom, remove grill. See Fig. 21 .
3. To install, reverse removal procedure.
Fig. 20: Identifying Mounting Screws (Up To December, 1995)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 21: Removing & Installing Radiator Grill (Up To December, 1995)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 22: Identifying Radiator Grill Assembly Components (Up To December, 1995)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
Removal & Installation (Without Trim Frame - From January, 1996)
NOTE:
Each step in procedure is represented by a number in Fig. 23 . Remove
coolant hoses off radiator using hose clip pliers (VAG 1921). Disconnect
power steering hydraulic line(s) from radiator.
1. Upper radiator grill (1) grill is clipped together with trim frame.
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
2.
3.
4.
5.
6.
7.
8.
Remove screw/washer assemblies (2). Pull upper radiator grill upward with trim frame.
Upper Trim frame (3). Remove with upper radiator grill.
Bonded rubber bushing (4).
Screw/washer assembly (5).
Unlocking lever (6). It is necessary to unlock the corners.
Lower trim frame (7). Remove together with bottom radiator grill.
Lower radiator grill (8). Lower radiator grill is clipped and screwed together with trim frame. Remove
turn signal lights and loosen side latches with unlatching levers (6). Take out combination screw and
washer assemblies (5). Pull radiator grill with trim frame up and out. To install, reverse removal
procedure.
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 23: Removal & Installation Radiator Grill (From January, 1996)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
Removal & Installation (With Trim Frame - From January, 1996)
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
NOTE:
In order to fold down the radiator, grill with trim frame must be removed.
Remove coolant hoses off radiator using hose clip pliers (VAG 1921).
Disconnect power steering hydraulic line(s) from radiator.
1. Remove combination screws 2. See Fig. 24 .
2. Remove (pull out) spray nozzle (5), (if equipped) on left and right side. Hook special (tool 3370) (6)
on trim frame below headlight. Pull radiator grill with trim frame (1) off "T" bolt on left and right
side. See Fig. 24 .
3. To install, replace damaged clips 4 before installing radiator with trim frame. Take note to clip
radiator grill with trim frame on left and right side at the same time. Continue by reversing removal
procedure.
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 24: Removing & Installing Radiator Grill With Trim Frame (From January, 1996)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
SERPENTINE BELT TENSIONER
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
NOTE:
Only for vehicles with tensioning roller. Remove tensioners and bracket only
if necessary to remove timing belt covers.
Removing & Installing
NOTE:
When lowering engine, make sure that front exhaust pipe does not lay on
steering gear. When pushing the engine forward make sure that the pipes
and hoses are not stretched or damaged.
1. Remove lower sound dampening pan. See SOUND DAMPENING PAN . Remove radiator grill. See
RADIATOR GRILL .
2. On ACV engine code only, remove charge air cooler. See Fig. 25 .
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 25: Exploded View Of Charge Air Cooler (Engine Code ACV)
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Courtesy of VOLKSWAGEN UNITED STATES, INC.
3. On all engines, remove left and right securing bolts and fold lock carrier and radiator out forward. See
Fig. 26 . Remove power steering line retainers from tensioner bracket and engine mounting.
Fig. 26: Identifying Lock Carrier Securing Bolt (Engine Code ACV)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
4. Remove serpentine belt using Lever Tool (3299). See DRIVE BELT ROUTING . Unbolt right-hand
drive shaft at transmission flange.
5. Bolt Engine Stand (3227) onto cylinder block and tighten bolts to 15 ft. lbs. (20 N.m). Slightly raise
engine and transmission using engine and transmission jack. See Fig. 27 .
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COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 27: Installing Engine Support Stand (3227) & Engine/Transmission Jack (VAG 1383 A)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
6. On manual transmission, remove front transmission mounts on subframe. See Fig. 28 -Fig. 30 .
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COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 28: Identifying Front Transmission Mount (AAB, Man. Trans. - Up To July, 1992)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 29: Identifying Front Transmission Mount (AAB, Man. Trans. - From August, 1992)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
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COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 30: Identifying Front Transmission Mount (ACV, Man. Trans.)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
7.
NOTE:
When lowering engine make sure that front exhaust line does not lie on
steering gear. When pushing engine forward make sure that cables,
lines and hoses are not overstretched.
On all engines, remove right-hand engine mount center bolt(s). Lower engine using (VAG 1383 A)
engine and transmission jack as far as possible, push forward and prevent from swinging back by
mounting with wooden wedge. See Fig. 31 .
Fig. 31: Showing Placement Of Wooden Wedge To Support Engine
Courtesy of VOLKSWAGEN UNITED STATES, INC.
8. Remove serpentine belt relay (idler) roller. Remove serpentine belt tensioning roller. Remove
tensioner retainer and engine support assembly complete. See Fig. 32 . To install components, reverse
sequence of removal. Torque fasteners to specifications. See TORQUE SPECIFICATIONS .
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COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 32: Identifying Serpentine Belt Tensioning Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.
SOUND DAMPENING PAN
Removal & Installation
1. Unscrew two hex nuts and six combination hex bolts. See Fig. 33 .
2. Unhook locking lever.
3.
NOTE:
On vehicles with automatic transmission or air conditioner, dampening
material must be removed according to perforation. See Fig. 34 .
Swing down dampening pan and unhook at brackets.
4. To install, reverse removal procedures. See TORQUE SPECIFICATIONS .
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 33: Removing & Installing Sound Dampening Pan
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 34: Removing & Installing Sound Dampening Material
Courtesy of VOLKSWAGEN UNITED STATES, INC.
THERMOSTAT
Removal & Installation
1. The thermostat housing is located on the left, front side of the cylinder block (behind water pump
housing). Remove lower sound dampening pan. See SOUND DAMPENING PAN .
2. Drain coolant. See DRAINING under BLEEDING COOLING SYSTEM.
3. Remove thermostat housing, replace thermostat and gasket.
4. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE
SPECIFICATIONS .
5. Fill and bleed cooling system. See FILLING under BLEEDING COOLING SYSTEM. Inspect
system for leaks.
TIMING BELT
Special Tools
For timing belt service required special tools, see Fig. 35 and Fig. 36 .
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COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
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COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 35: Timing Belt Required Special Tools (1 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
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COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 36: Timing Belt Required Special Tools (2 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
Removal (Vehicles Up To January, 1995)
NOTE:
Engines up to January, 1995 have elongated holes in water pump for
tensioning timing belt.
1. Remove sound dampening pan. See SOUND DAMPENING PAN .
2. Remove the front grille. See RADIATOR GRILL .Fold lock carrier with radiator out forward. See
Fig. 20 .
3. Removing generator V See 2.4L DIESEL (UP TO 1/95) under DRIVE BELT ROUTING. Fold
generator up fully and secure.
Fig. 37: Identifying 2.4L Diesel Timing Belt Components (Up To January, 1995)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
4. Removing V belt for power steering pump. See 2.4L DIESEL (UP TO 1/95) under DRIVE BELT
ROUTING.
5. Remove cylinder head cover and timing belt cover for both timing belts. Insert Counter-Hold Tool
(T10025) and loosen vibration damper/timing belt pulley by loosening center bolt. See Fig. 38 and
Fig. 39 . Turn crankshaft to TDC No. 1 cylinder. See Fig. 40 .
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© 2004 Mitchell Repair Information Company, LLC.
1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
4 января 2005 г. 0:54:43
Page 47
© 2004 Mitchell Repair Information Company, LLC.
1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 38: Identifying Cylinder Head Cover & Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.
Fig. 39: Removing/Installing Vibration Dampener Puller Center Bolt
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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© 2004 Mitchell Repair Information Company, LLC.
1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 40: Setting Crankshaft To TDC Cylinder No. 1.
Courtesy of VOLKSWAGEN UNITED STATES, INC.
6. Remove vibration damper center bolt. Remove the 4 x M8 crankshaft vibration damper and timing
belt pulley securing bolts. Remove vibration damper.
7. Release timing belt tension by loosening coolant (water) pump.
8.
NOTE:
If reusing old timing belt, mark original direction of rotation on belt.
Remove lower timing belt cover. Take off timing belt.
Installation (Vehicles Up To January, 1995)
1. Check whether TDC mark on flywheel and reference mark are aligned.
2. Lock camshaft with Setting Bar Tool (2065 A). See Fig. 41 .
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© 2004 Mitchell Repair Information Company, LLC.
1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 41: Locking Camshaft Into Position Using Setting Bar Tool (2065)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
3. Center setting bar as follows:
z Turn camshaft so that one end of setting bar contacts the cylinder head. Using feeler gauge
establish the gap at the other end of the setting bar.
z Place a feeler gauge corresponding to half the gap between setting bar and cylinder head. Turn
camshaft until the setting bar contacts the feeler gauge.
z Place a 2nd feeler gauge, of same thickness, at the other end between setting bar and cylinder
head.
4. Loosen camshaft sprocket securing bolt a 1/2 turn. Release camshaft sprocket from camshaft taper by
tapping with a hammer (using a drift through rear timing belt cover opening). See Fig. 42 .
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© 2004 Mitchell Repair Information Company, LLC.
1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 42: Releasing Camshaft Sprocket From Camshaft Tapered End
Courtesy of VOLKSWAGEN UNITED STATES, INC.
5. Install timing belt for camshaft drive. Note observe marked direction of rotation for used belt.Install
lower timing belt cover and also install M8 securing bolt for coolant pump.
6. Adjust timing belt tension by turning coolant pump with Test Unit (VW 210). See Fig. 43 . Scale
value: 12-13. Make measurement between coolant pump and camshaft sprocket. Tighten coolant
(water) pump securing bolts to 15 ft. lbs. (20 N.m).
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© 2004 Mitchell Repair Information Company, LLC.
1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 43: Adjusting Timing Belt Using Tool (VW210)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
7. Tighten lower timing belt cover. Ensure crankshaft is still positioned at TDC No. 1 cylinder, correct if
necessary.
8. Tighten camshaft sprocket securing bolt using Counter-Hold Tool (3036). Observe steel type marking
on bolt head:
Bolts Marked "8.8"
Tighten to 63 ft. lbs. (85 N.m)
9.
10.
11.
12.
13.
14.
Bolts Marked "10.9"
Tighten to 74 ft. lbs. (100 N.m)
Take Setting Bar Tool (2065 A) off camshaft. See Fig. 41 .
Insert Counter-Hold Tool (T10025) and tighten crankshaft vibration damper and timing belt pulley
center bolt. See Fig. 39 .
Tighten the 4 x M8 crankshaft vibration damper and timing belt pulley securing bolts to 15 ft. lbs. (20
N.m).
Install cylinder head cover and timing belt cover.
Install power steering pump V belt and adjust. Install generator V belt and adjust. See DRIVE BELT
ROUTING .
Install lower sound dampening pan. Install radiator with lock carrier.
Removal (Vehicles From February, 1995)
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© 2004 Mitchell Repair Information Company, LLC.
1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
1. Remove serpentine belt. See DRIVE BELTS .
2. Remove radiator grille. See RADIATOR GRILL & TRIM FRAME .
3. For ACV engine code only, remove charge air cooler bracket. See Fig. 26 . Remove left and right
hand securing bolts. Fold lock carrier and radiator out forward.
4. Remove both timing belt guard and valve cover. See Fig. 38 .
5. Turn crankshaft to TDC No. 1 cylinder. See Fig. 44 . For AAB and ACV (non-synchro) engine codes,
marks on injection pump sprocket and console (C) and on flywheel and clutch bell housing (A) or
drive plate and clutch bell housing (B) must align. For ACV (synchro) engine code, marks on
injection pump sprocket and console (C) and on flywheel and clutch bell housing (A) or drive plate,
and clutch bell housing (B) must align. See Fig. 45 .
Fig. 44: Setting Engine To TDC (AAB & ACV Non-Synchro Engine Codes)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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© 2004 Mitchell Repair Information Company, LLC.
1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 45: Setting Engine To TDC (ACV Synchro Engine Code)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
4 января 2005 г. 0:54:43
Page 54
© 2004 Mitchell Repair Information Company, LLC.
1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 46: Identifying 2.4L Diesel Timing Belt Components (From February, 1995)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
NOTE:
This condition only occurs every 2nd engine rotation at TDC position.
4 января 2005 г. 0:54:43
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© 2004 Mitchell Repair Information Company, LLC.
1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
6.
CAUTION:
Manufacturer recommends using NEW center bolt, if removed.
On all engines, remove vibration damper bolt. See Fig. 39 . Remove lower timing belt guard.
7. If reusing old timing belt, mark belt with arrow indicating original direction of rotation.Move
tensioning roller and remove timing belt. See Fig. 46 .
Installation (Vehicles From February, 1995)
1. Check whether TDC mark on flywheel and reference mark are aligned.
2. Lock camshaft with Setting Bar Tool (2065 A). See Fig. 41 .
3. Center setting bar as follows:
z Turn camshaft so that one end of setting bar contacts the cylinder head. Using feeler gauge
establish the gap at the other end of the setting bar.
z Place a feeler gauge corresponding to half the gap between setting bar and cylinder head. Turn
camshaft until the setting bar contacts the feeler gauge.
z Place a 2nd feeler gauge, of same thickness, at the other end between setting bar and cylinder
head.
4. Loosen camshaft sprocket securing bolt a 1/2 turn. Release camshaft sprocket from camshaft taper by
tapping with a hammer (using a drift through rear timing belt cover opening). See Fig. 42 .
5. Install tensioning roller (1) so that retaining lug locates on the retaining pin (2) on the lower part of
the toothed belt guard. See Fig. 47 .
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© 2004 Mitchell Repair Information Company, LLC.
1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 47: Installing Timing Belt Tensioning Roller (From February, 1995)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
6. Install timing belt for camshaft drive. Note observe marked direction of rotation for used belt.Tighten
tensioning roller securing bolt hand tight.
7. To tighten the toothed belt turn the tensioning roller clockwise with Ring Wrench (3355) until the
right edge of indicator (A) aligns with right edge of indicator (B). See Fig. 48 . The right edge of
indicator (A) must not be rotated past the right edge of indicator (B), otherwise the tensioning roller
can be damaged. If it does happen that it is turned too far, the tensioning roller must be fully released
and then retightened. You must not turn the eccentric back by purely the amount it has been turned
too far. Tighten tensioning roller securing bolt to 15 ft. lbs. (20 N.m).
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© 2004 Mitchell Repair Information Company, LLC.
1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Fig. 48: Tensioning Timing Belt (From February, 1995)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
8. Ensure crankshaft is still on TDC of No. 1 cylinder. Correct, if necessary.
9. Tighten tensioning roller to specification. See TORQUE SPECIFICATIONS .
10. Tighten camshaft sprocket securing bolt using Counter-Hold Tool (3036). Observe steel type marking
on bolt head:
Bolts Marked "8.8"
Tighten to 63 ft. lbs. (85 N.m)
Bolts Marked "10.9"
Tighten to 74 ft. lbs. (100 N.m)
11. Remove Setting Bar (2065A) from camshaft. Install lower timing belt guard. Install vibration damper
with NEW center bolt. See Fig. 39 . Tighten to specification. See TORQUE SPECIFICATIONS .
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© 2004 Mitchell Repair Information Company, LLC.
1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
12. Tighten the 4 M8 crankshaft vibration damper and toothed belt pulley securing bolts. See TORQUE
SPECIFICATIONS .
13. Turn crankshaft two rotations in engine direction of rotation until crankshaft is set to TDC No. 1
cylinder again. Again check the position of the tensioning roller indicator. If the right edges of
indicator (A) and (B) do not align, the tensioning procedure must be repeated. See Fig. 48 .
14. Install timing belt covers. Install cylinder head cover.Install serpentine belt. See DRIVE BELTS .
15. Install radiator grille. See RADIATOR GRILL & TRIM FRAME .
WATER PUMP
NOTE:
Water pump is driven the engine timing belt. The water pump may also be
referred to as coolant pump.
Removal
1.
2.
3.
4.
5.
Remove lower sound dampening pan. See SOUND DAMPENING PAN .
Drain coolant. See DRAINING under BLEEDING COOLING SYSTEM.
Remove radiator grill. See RADIATOR GRILL .
Remove timing belt. See TIMING BELT .
Remove water pump.
Installation
CAUTION:
If installing re-manufactured water pump, check "O" ring size. Some pumps
must be installed with a 5-mm "O" ring. These pumps are identified by a "5"
stamped on mounting flange.
1. Install water pump with new "O" ring. Tighten water pump bolts to specification. See TORQUE
SPECIFICATIONS .
2. To install remaining components, reverse removal procedure. Fill and bleed cooling system. See
FILLING under BLEEDING COOLING SYSTEM. Inspect system for leaks.
COOLING SYSTEM SPECIFICATIONS
COOLING SYSTEM SPECIFICATIONS
COOLING SYSTEM SPECIFICATIONS
Application
Volume
Specification
9.5 Qts. (9.0 L)
(1)
Cooling Fan Thermal Switch (2)
First Stage
On
Off
Second Stage
On
Off
4 января 2005 г. 0:54:44
183-192°F (84-89°C)
168-181°F (76-83°C)
194-203°F (90-95°C)
180-192°F (82-89°C)
Page 59
© 2004 Mitchell Repair Information Company, LLC.
1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
Run After Cooling Fan Thermal Switch (3)
On
Off
219°F (104°C)
217°F (103°C)
Thermostat (4)
Starts To Open
Fully Open
Opening Stroke
Reservoir (Expansion Tank) Cap Opening Pressure
189°F (87°C)
216°F (102°C)
.28" (7mm)
19-22 psi (1.3-1.5 Bar)
(1)
Total coolant quantity may vary depending on vehicle equipment. Open bleeder
screw in coolant hose to heater core when filling cooling system.
(2) Coolant fan thermal switch is located in the right side of the radiator.
(3)
Run after cooling fan thermal switch is located on the left side of the cylinder
head, between the injectors.
(4) Thermostat is located on left side of engine block, under lower radiator hose
connection housing.
Coolant Recommendations
When refilling the coolant system only use G 12 VW engine coolant. The frost and corrosion protection
additive G 11 must only be used for topping off purposes, when the cooling system is still filled with G 11
(green in color). On no account must G 12 be mixed with other coolant additives!
CAUTION:
If the fluid in expansion tank is brown, G 12 has been mixed with other
coolant. In this case the coolant must be changed.
CAUTION:
On no account must the coolant additives G 11 and G 12 be mixed. If these
additives are mixed it will cause serious engine damage.
If the cooling system was filled with G 11 anti-freeze (colored green), before filling with new anti-freeze G
12 (colored red), the cooling system must be flushed out. Remove as much of the coolant remains as is
possible from the cooling system. To do this blow compressed air into the coolant expansion tank. Close
cooling system and top off with pure water.
G 12 (G 11) and coolant additives marked "In accordance with TL VW 774 D (C)" prevent frost and
corrosion damage, scaling and also raise boiling point of the coolant. For this reason the system must be
filled all year round with frost and corrosion protection additives. Because of its high boiling point, the
coolant improves engine reliability under heavy loads, particularly in countries with tropical climates.
Protection against frost must be assured to about -25°C (in arctic climatic countries to about -35°C). The
coolant concentration must not be reduced by adding water even in warmer seasons and in warmer
countries. The anti-freeze ratio must be at least 40%. If for climatic reasons a greater frost protection is
required, the amount of G 12 can be increased, but only up to 60% (frost protection to about -40°C),
otherwise frost protection is reduced again and cooling effectiveness is also reduced.
NOTE:
If radiator, heat exchanger, cylinder head or cylinder head gasket has been
replaced, do not reuse old coolant.
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© 2004 Mitchell Repair Information Company, LLC.
1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Component
Ft. Lbs. (N.m)
59 (80)
Bolts (1)
Axle Shaft-To-Transmission Flange
Camshaft Sprocket Bolt
Bolt Head Marked 8.8
Bolt Head Marked 10.9
Center Engine Mounting Bolt (M10 x 60)
Coolant Fan Thermo Switch
Coolant (Water) Pump-To-Cylinder Block
Coolant (Water) Pump Pulley
Crankshaft Timing Sprocket Center Bolt
63 (85)
74 (100)
48 (65)
18 (25)
15 (20)
15 (20)
Up To Jan., 1995 (2)
339 (460)
Crankshaft Timing Sprocket Center Bolt (From Feb., 1995) (3)
Step 1
Step 2
Serpentine Idler Roller-To-Tensioner Bracket Bolt
Serpentine Belt Tensioner Bracket To-Cylinder Block
Serpentine Belt Tensioner Roller-To-Tensioner Lever
Timing Belt Tensioner Roller Nut
From Feb., 1995
Transmission Mount-To-Sub-Frame
AAB Engine Code
ACV Engine Code
118 (160)
Plus 180° Turn
15 (20)
51 (70)
15 (20)
15 (20)
33 (45)
(4)
Vibration Damper -To-Crankshaft Timing Sprocket (4 Bolts)
Up To Jan., 1995
15 (20)
Vibration Damper-To-Crankshaft Timing Sprocket (4 Bolts), From Feb. 1995
Step 1
15 (20)
Step 2
Plus 90° Turn
INCH Lbs. (N.m)
Drain Screw (Coolant)
89 (10)
Radiator Mounting Bolt
89 (10)
Sound Dampening Pan Hex Nut
80 (9)
(5)
Timing Belt Covers (M6 Short)
89 (10)
(5)
Timing Belt Covers (M8 Long)
(5)
Timing Belt Idler Bolt
89 (10)
(5)
Timing Belt Inner Covers
Thermostat Housing
Valve (Cylinder Head) Cover
(1)
177 (20)
89 (10)
89 (10)
Always use hardness grade 12.9 bolts on axle shaft flange.
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© 2004 Mitchell Repair Information Company, LLC.
1996 Volkswagen EuroVan CV
COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL
(2)
Coat threads and bolt head contact surface with sealing paste AMV 188 001 02,
or equivalent.
(3) Clean all grease and oil from bolt threads.
(4)
For torque specification, see Fig. 30 .
(5)
For torque specifications related to timing belt components, also refer to Fig. 37
and Fig. 46 .
4 января 2005 г. 0:54:44
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© 2004 Mitchell Repair Information Company, LLC.
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