1986 Volkswagen Vanagon Repair Manual

The 1986 Volkswagen Vanagon is a versatile rear-engine van featuring air-cooled or water-cooled engines (depending on model), rear-wheel drive, manual or automatic transmission options, and spacious interior with camping configurations available. This comprehensive repair manual covers maintenance procedures, troubleshooting, specifications, and step-by-step repair instructions for all major systems including engine, transmission, electrical, brakes, suspension, and body components.

Vehicle Specifications

Technical specifications for 1986 Volkswagen Vanagon models including engine options, dimensions, and capacities.

Maintenance Schedule

Recommended maintenance intervals for optimal performance and longevity.

1. Oil Change: Every 3,000 miles or 3 months
2. Spark Plugs: Every 10,000 miles
3. Air Filter: Every 15,000 miles
4. Fuel Filter: Every 20,000 miles
5. Brake Fluid: Every 24 months
6. Coolant (water-cooled): Every 24 months
7. Timing Belt: Every 60,000 miles

WARNING! Always disconnect battery before performing electrical work. Use jack stands when lifting vehicle.

Engine Repair

Step-by-step procedures for engine maintenance and repair.

1. Compression Testing: Remove spark plugs, test each cylinder
2. Valve Adjustment: Set clearance to 0.006" (cold)
3. Carburetor Adjustment: Set idle speed and mixture
4. Ignition Timing: Set to 7.5° BTDC at idle
5. Oil Change Procedure: Drain, replace filter, refill with 4.2 quarts

CAUTION! Engine components can be hot. Allow engine to cool before working.

Transmission Service

• Manual Transmission Fluid: SAE 80W-90 GL-4, 2.6 quarts
• Automatic Transmission Fluid: Dexron II, 3.0 quarts
• Shift Linkage Adjustment: Proper alignment for smooth shifting
• Clutch Replacement: 8-10 hour procedure
• Transmission Removal: Support engine, disconnect driveshaft

Electrical System

Wiring diagrams and electrical component service procedures.

Battery: 12V, negative ground. Alternator: 55-65 amp output. Starter: Direct drive type.

Fuse Panel: Located under dashboard. Main fuses: 8A, 16A, 25A. Wiring: Color-coded per German standards. Troubleshooting: Use multimeter for voltage and continuity tests. Common Issues: Ground connections, corroded terminals, aging wiring insulation.

Brake System

Disc brakes front, drum brakes rear with dual-circuit hydraulic system.

1. Brake Pad Replacement: Remove caliper, compress piston
2. Brake Drum Service: Adjust shoes, check for leaks
3. Bleeding Procedure: Start with wheel farthest from master cylinder
4. Master Cylinder: Bench bleed before installation

Tip: Always replace brake fluid when servicing hydraulic components.

Suspension & Steering

Front: Independent with torsion bars. Rear: Independent with torsion bars.

1. Front Suspension: Check ball joints, tie rod ends, bushings
2. Rear Suspension: Inspect trailing arm bushings, CV joints
3. Steering Gear: Recirculating ball type, adjustment possible
4. Wheel Alignment: Toe-in 0° to 1/8", camber -30' to +30'
5. Shock Absorbers: Replace in pairs, check mounts

WARNING! Always torque suspension bolts to specification. Improper torque can cause failure.

Cooling System

Water-cooled models only: Radiator, thermostat, water pump service.

Fuel System

Carbureted fuel system with mechanical fuel pump.

CAUTION! Gasoline is flammable. No smoking or open flames during fuel system work.

Body & Interior

Body panel alignment, door adjustment, window mechanisms, and interior trim.

Troubleshooting Guide

Special Tools: Required for certain procedures: valve adjustment tool, torsion bar tool, CV joint puller.

Parts Sources: Volkswagen dealerships, specialty suppliers, online retailers