Vanagon F4-1915cc 1.9L (Water Cooled) (1983)
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Technical Service Bulletin # 151590T01
Date: 900531
Cylinder Head - Reseal Procedure
Subject:
Cylinder Head Reseal
Model(s): 1.9L and 2.1L Vanagon Waterboxer
Group:
15
Number:
15-90 T01
Date:
May 31, 1990
The following procedure is to be applied when replacing cylinder head gaskets on the Vanagon waterboxer engine. Removal of both cylinder heads can
be performed with the engine in the vehicle.
This procedure is essentially a major engine repair where cleanliness and accuracy is a necessity.
ALWAYS REPLACE GASKETS, "O" RINGS, SEALS
AND LUBRICANTS.
DO NOT RE-USE.
Procedure:
1.
Disconnect battery
2.
Remove rear carpet, mattress (where applicable) and engine cover.
3.
Remove air cleaner assembly.
4.
Remove air conditioning compressor from bracket and place on ledge next to engine. It is not necessary to drain Freon.
5.
Remove left and right fuel rails, injectors, ground wires and manifolds.
WARNING
Fire hazard do not smoke or have anything in
area that can ignite fuel.
6.
Remove left and right splash shields, push rod tube shields, and disconnect oxygen sensor wire.
7.
Drain all coolant, oil and remove oil filter.
Do not reinstall oil drain plug at this time.
To drain coolant from engine remove drain plugs between cylinders.
Remove spare tire cover under front of vehicle and disconnect coolant hoses from radiator. Reconnect coolant hoses to radiator and close spare
tire cover.
Remove coolant pump.
9.
Remove exhaust system, including cross-over pipes, muffler with converter and exhaust heat-shield.
10.
Remove crankshaft pulley.
Depending on the model year use retaining tool 3149 for 1986 and above or tool 3120 for pre-1986 vehicles. Refer to Vanagon workshop microfiche
Group 13, pages 13.35 for 1986 and above or 13.42 for pre-1986 vehicles.
11.
Remove power steering pump.
12.
Remove coolant cross-over pipes at front and rear of cylinder head.
13.
Remove valve covers, rocker arms, push rods and oil filler pipe.
NOTE:
Mark push rods to be certain they are re-installed in the same position.
14.
Remove cylinder head cap nuts. Remove push rod tubes and both cylinder heads.
In cases where the cylinder sleeves are stuck to the head, lightly tap the sleeve with a small solid rubber mallet.
