2.1L Rod Bearing Failures
Model : Volkswagen, Vanagon Category : Engine
... nuts to loosen or the rod or bolt to break, leading to catastrophic breakdown, which ever comes first. And, indeed, the parts of the rod big end I recovered were ''blued'' from extreme heat! These rods are worked hard, and the big end tends to go oval as they get up in miles. This leads to the viscious cycle of increased rod bearing wear causing lower oil pressure - which leads to ... (more)
Posted : 29 May 2005  
 
VW Bus, How to Add a Rear Seatbelt
Model : Volkswagen, Vanagon Category : Interior - Seats
... for the baby's revers seats it is better than without the upper belt. For the next step of seats for childrens older than a year, the larger seat will be fitted well. too. I keep both, shoulder belts for the youngster's seat, and the single belt for adults. You will need some parts to mount the belt. There is a complete set, as Joel wrote, but I got the whole set as single parts at a local VW ... (more)
Posted : 29 May 2005  
 
091-1 Transmission Problems
Model : Volkswagen, Vanagon Category : Driveterrain - Transmission
... the 2 lower cutouts. This is what eventually happens to the cracked hub. The hub fractures, and now the operating sleeve cannot move easily over the outer surface of the hub. The driver may experience a variety of symtoms such as difficulty shifting in or out of 3rd or 4th gear; being unable to engage 3rd or 4th gear, while 1st and 2nd work fine; or being stuck in either 3rd or 4th gear, ... (more)
Posted : 29 May 2005  
 
CV Joint Servicing
Model : Volkswagen, Vanagon Category : Misc
... and the ball bearings can be separated. While the location of the balls relative to the inner race is not incredibly important, you should not to mix components from one joint with another. The easiest way to avoid this problem is to only service on joint at a time. Once completely apart, wipe off as much of the old grease as possible with a rag or paper towels. Thoroughly clean the joint in ... (more)
Posted : 29 May 2005  
 
Vanagon Upper Balljoint Replacement
Model : Volkswagen, Vanagon Category : Suspension
... of the joint. With the lower nut removed, drive the ball joint separator tool between the upper control arm and the steering knuckle. The "pickle fork" destroys the rubber boot on the joint, but does a good job of popping the joint loose. As the tool is driven into the joint, the tool's taper will force the joint up and out of the steering knuckle. Don't be timid with the hammer - you ... (more)
Posted : 29 May 2005  
 
Vanagon Front Wheel Bearing Servicing
Model : Volkswagen, Vanagon Category : Wheels and Tires - Wheel Bearings
... in the bearings for any signs of pitting, scoring or discoloration. In addition to inspecting the bearings, take a close look at the bearing races. The bearing races are hardened steel carriers that are pressed into the relatively soft cast iron of the rotor, as seen here to the right. They are examined for signs of wear just like the bearings. If there are any serious wear marks on either ... (more)
Posted : 29 May 2005  
 
Steel Brake Line Repair
Model : Volkswagen, Vanagon Category : Brakes
... needed on a Volkswagen is known as a "bubble flare". Most American and some other imports use a "double flare" on the end. They are not interchangeable! If you install the wrong type, the brake fluid may leak out, causing you to loose that wonderful stopping ability. Looking at the photo on the left, the bubble flare is on the top, and the double flare (with the purple ... (more)
Posted : 29 May 2005  
 
New Front Shocks
Model : Volkswagen, Vanagon Category : Suspension - Shocks/struts
... to remove the nut with no damage to any of the threads. Once the lower bolt is removed, the shock literally falls out of the van. I played with the shocks for a few minutes once they were out, extending and compressing them by hand. They offered almost no resistance in either direction and I could hear the air gurgling inside of them. They were obviously worn out. Not only that, they were just ... (more)
Posted : 29 May 2005  
 
Alternator Alternatives
Model : Volkswagen, Vanagon Category : Electrical - Alternator
... in the junkyard is a bit rare around here. But the wreckers have plenty of late model Golfs and Jettas, and the 90 Amp alternators from them will fit the Vanagon just dandy! This is also a great method of upgrading from the 65 Amp alternator found in some earlier water-cooled Vanagons. Note: Click on thumbnails for expanded images! From these pictures, you can see that the Vanagon ... (more)
Posted : 29 May 2005  
 
1.9L Water Pump Replacement
Model : Volkswagen, Vanagon Category : Engine - Cooling System
... Step 4, you deserve a break, so here's an easy one. The thermostat housing is connected to the driver's side cylinder head by a short hose. Loosen the clamps on the hose. You will be removing the water pump and thermoststat housing as a single unit. Now is also a good time to remove the hose that goes from the expansion tank to the top of the water pump. Use a regular pair of pliers to ... (more)
Posted : 29 May 2005  
 
Clutch Job
Model : Volkswagen, Vanagon Category : Driveterrain
... $30. Step 11 - Remove oil seal and pilot bearing: I have a seal puller tool that works really well for prying out oil seals. You can also use a regular screwdriver to do the same thing. You want the tip of the puller/screwdriver just barely under the inside lip of the seal when you pry it out. This will help prevent engine case from getting scratched. When the seal comes out, make sure you ... (more)
Posted : 29 May 2005  
 
Quick and easy rear bumper DIY... for Passat
Model : Volkswagen, Passat Category : Exterior - Rear Bumper
... side) with a pencil. --Do this carefully and in small increments if necessary to prevent a return trip to the skate shop! Cut along the line you've made, leaving a small bit (a few mm) for error. Use big, sharp scissors. It's much easier to cut this way. Lay it back on the bumper to assess the contour. Once you are happy with the look (don't stick on yet!), get the other, uncut piece of tape. ... (more)
Posted : 17 November 2004 Author : Mark Merrill
 
Installing the Mann ProVent CCV Filter in a 2004+ TDI-PD
Model : Volkswagen, Golf Category : Engine - Intake
... condensed oil over a period of, say, 10,000 miles is unknown at this time. In my installation I have attached a section of 1/2" ID hose, capped at the end, to the drain hole, and will attempt to measure the rate of oil accumulation over the next few thousand miles. Here is a view of the Filter inside the Housing: FILTER INSTALLATION My goals for my filter installation were three: 1. The ... (more)
Posted : 17 November 2004 Author : Jeff Daigle
 
Center Console Monitor DIY for Golf III & Jetta III
Model : Volkswagen Category : Interior
... tedious part. I will post up the next part, mounting the lcd frame, either tonight or tommorow. good luck and again, be very very very very very careful when taking the lcd apart. if you've already taken it apart, and haven't broken anything, good job!! Day 2 Part 2 - Mounting The Screen Mounting The Screen alright, so now we've got just the frame of monitor and we can hack that up. its a ... (more)
Posted : 17 November 2004 Author : N/A
 
Short shifter (2.0) for Golf III & Jetta III
Model : Volkswagen Category : Driveterrain - Shifter Linkage
... in its corresponding bushings [img] 2. Remove the shift weight in the order shown 3. Now remove the one 13mm nut and remove the shift plate off the thread 5. You will have to hold the shift plate while unbolting the nut (direction for removal as shown) 5. The opening where the shift plate is held by the nut is rectangular, when the shift plate is removed the thread should be up as far as ... (more)
Posted : 15 November 2004 Author : Rob Saccone (golfgen3)
 
For those wanting to add hoodlifts...
Model : Volkswagen, Passat Category : Exterior - Hood
... I have pointed to each screw (in both cases, the middle screw) that needs to be removed in order to bore out the hold for the mounting stud: Driver's side: Passenger's side: Using the 10mm deep well socket and 1/4 inch ratchet, remove both screws (you should now have a total of 4 leftover parts, whoever said you couldn't reduce weight on a VW and still have performance...) NOTE: I cannot ... (more)
Posted : 15 November 2004 Author : Michael Gray (Blk95VR6)
 
Samco Intake (AWP) DIY for new Beetle
Model : Volkswagen, Beetle Category : Engine - Intake
... performance... I notice very little change. Turbo seem to be pulling faster. Turbo sound is also a little louder (and different tone). Not obvious, but louder if listen and compare. It's been raining for the past few days. Notice more wheel spin than usual. Maybe Samco. Maybe lead foot. Overall I'm very happy with the product. (1) Size Comparison: (2) Opening Comparison: (3) Removal of cowl ... (more)
Posted : 15 November 2004 Author : Lam Nguyen (Lorem)
 
A/C controls bulb replacement DIY ..... easy ish for Jetta III and Golf III
Model : Volkswagen Category : Lights - Interior
... screwdriver - Phillips screwdriver Parts: - bulb ref. 2723 With the flat head screwdriver carefully remove the A/C controls panel Remove the 4 screws that hold the controls Remove the ashtray and remove the 2 screws shown Pull all the assembly from the dash With the flat head press the 2 tabs shown.. And there's the bulb housing Remove the green filter cover, replace the bulb and reassemble. ... (more)
Posted : 15 November 2004 Author : Diego Martin (vr6power !)
 
Dash Kit Installation MK IV Golf/ GTI/ Jetta
Model : Volkswagen, Golf Category : Interior
... very easily. Make sure there is contact on all areas. Now that the pieces are ready to be placed, you have to prime the surfaces to which the adhesive backing will be applied. The kit comes with a primer pen, which is extremely easy to use. Test the pen on some cardboard to ensure an even flow of primer in the pen. Once the pen is ready, prime the surfaces that will be covered. Be careful to ... (more)
Posted : 31 October 2004 Author : N/A
 
Bilstein PSS9 Coilovers suspension Install For the Golf and Jetta IV
Model : Volkswagen, Golf Category : Suspension - Shocks/struts
... and only apply the compound to the area in which to wish to have your set level at (The Drop). Use anti-seize on the rear height adjuster threaded shaft, I coated it completely. 4. Remove the dust covers front the front PSS9 struts and screw on the lock ring and the bottom spring plate (For 45mm lowered, go to the bottom last thread, all the way down). Make sure you have some anti-seize ... (more)
Posted : 30 October 2004 Author : Roger Moore
 
Monsoon Subwoofer Install (for MK IV Golf/ GTI/ Jetta)
Model : Volkswagen, Golf Category : Electrical - Radio
... device there. Next, remove the plastic screw fastener in the rear of the panel. Then pull out on the bottom of the panel and feel the fasteners un-pop, once that is felt then lift up on the panel to unhook it from the window lip. Remove the tweeter speaker wire, remove the panel and set on a padded surface so it will not be damaged, inspect door panel for bad fasteners, I noticed some on mine ... (more)
Posted : 30 October 2004 Author : Roger Moore
 
How to install MK4 Lights (for MK III Golf/Jetta/Vento)
Model : Volkswagen, Golf Category : Lights - Headlights
... sure to sand the area down and then paint it with some anti-rust paint. Getting the wiring harness ready You might want to disconnect the battery before you do this. Cut off the stock wiring harness. Now, if you bought your lights from PG-Performance, the wires come pre-labeled. Just solder the appropriate wires together. Make sure you wrap the wires in some sort of electrical tape or ... (more)
Posted : 30 October 2004 Author : Roger Moore
 
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