Vanagon F4-1915cc 1.9L (Water Cooled) (1983)
-
remove coolant overflow bottle bracket
-
center punch and drill 6.3 mm (0.25 in) hole at location a (Fig.1)
a = ^ 136 mm (5.34 in) from left edge of exhaust heat shield
^
8 mm (0.31 in) in front of embossed rib
-
using overflow bottle bracket as a guide, mark and drill holes b and c
-
using 6 mm flat washers, shim coolant overflow bottle bracket 4 mm (0.15 in) above heat shield
-
attach overflow
-
attach coolant overflow bracket to heat shield using M6 x 30 mm bolts, nuts and lock washers
^
torque fasteners to 8-12 N-m ( 6-9 ft.lbs.)
-
loosen lower coolant hose at engine block to relieve
tension (Fig. 2, A)
-
install coolant overflow bottle in bracket
-
tighten lower coolant hose clamp
Coolant hose modification
Work sequence
-
drain coolant system at cylinder head (saving coolant)
-
remove coolant hose splice (Fig. 2, arrow)
-
remove lower coolant hose from overflow bottle
-
loop A/C drive belt over lower coolant hose and slide out of way
-
install a no. 12 refrigerant hose splice of 90 mm (3.54 in) length. (Everco Industries part no. A8204 or equivalent)
-
install hose splice equally into hose ends leaving 40 mm (1.57 in) of splice exposed between ends of hoses
-
install lower coolant hose on overflow bottle
-
tighten original hose clamps
-
refill and bleed coolant system