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Condition Value
expand_moreAir intake system
expand_moreInduction-pipe flap control unit
expand_moreIntake manifold
M6 7.38 lbf⋅ft
M8 14.75 lbf⋅ft
All other modifications 18.44 lbf⋅ft
expand_moreAuxiliary assemblies
Auxiliary drive belt deflection pulley 14.75 lbf⋅ft
expand_moreAuxiliary drive belt tensioner
1.8 with gasoline straight-4 1.8 L 66 HP engine (1990.12–1992.7) 25.81 lbf⋅ft
1.9 D with diesel straight-4 1.9 L 59 HP engine (1990.9–1995.12) 22.13 lbf⋅ft
expand_more2.0 with gasoline straight-4 2.0 L 83 HP engine (1990.9–2003.4)
With 120-A generator 18.44 lbf⋅ft
With fan belt 25.81 lbf⋅ft
expand_moreAll other modifications
M6 7.38 lbf⋅ft
M8 14.75 lbf⋅ft
expand_moreAuxiliary drive belt tensioner
expand_more2.0 with gasoline straight-4 2.0 L 83 HP engine (1990.9–2003.4)
With 120-A generator 18.44 lbf⋅ft
All other modifications 14.75 lbf⋅ft
expand_moreAir-conditioning compressor
expand_more2.0 with gasoline straight-4 2.0 L 83 HP engine (1990.9–2003.4)
M8 14.75 lbf⋅ft
M10 33.19 lbf⋅ft
expand_moreAll other modifications
M8 14.75 lbf⋅ft
M10 29.5 lbf⋅ft
expand_moreAir-conditioning compressor bracket
2.4 D with diesel straight-5 2.4 L 76 HP engine (1990.9–1998.4) 29.5 lbf⋅ft
expand_moreAll other modifications
M8 14.75 lbf⋅ft
M10 29.5 lbf⋅ft
Air-conditioning compressor pressure line 5.16 lbf⋅ft
expand_moreAlternator
1.8 with gasoline straight-4 1.8 L 66 HP engine (1990.12–1992.7) 25.81 lbf⋅ft
expand_more1.9 D with diesel straight-4 1.9 L 59 HP engine (1990.9–1995.12)
M8 18.44 lbf⋅ft
M10 36.88 lbf⋅ft
expand_more2.0 with gasoline straight-4 2.0 L 83 HP engine (1990.9–2003.4)
With fan belt 25.81 lbf⋅ft
With ribbed V-belt 18.44 lbf⋅ft
expand_moreAll other modifications
With air-conditioning 18.44 lbf⋅ft
Without air-conditioning system 29.5 lbf⋅ft
expand_moreAlternator pulley
expand_moreGenerator bracket
1.8 with gasoline straight-4 1.8 L 66 HP engine (1990.12–1992.7) 22.13 lbf⋅ft
expand_more1.9 D with diesel straight-4 1.9 L 59 HP engine (1990.9–1995.12)
expand_moreWith fan belt
M8 × 65 screws 14.75 lbf⋅ft
M8 × 70 screws 18.44 lbf⋅ft
With ribbed V-belt 18.44 lbf⋅ft
expand_more2.0 with gasoline straight-4 2.0 L 83 HP engine (1990.9–2003.4)
With air-conditioning 24.34 lbf⋅ft
Nuts must be replaced.
Without air-conditioning 22.13 lbf⋅ft
All other modifications 29.5 lbf⋅ft
expand_morePower steering pump bracket
2.4 D with diesel straight-5 2.4 L 76 HP engine (1990.9–1998.4) 29.5 lbf⋅ft
All other modifications 14.75 lbf⋅ft
expand_moreServo pump pulley
All Volkswagen diesel straight-4 1.9 Liters 1X engines 7.38 lbf⋅ft
All other modifications 14.75 lbf⋅ft
expand_moreServo steering pump
All other modifications 14.75 lbf⋅ft
Vacuum pump 14.75 lbf⋅ft
expand_moreCarburetion
Injection pump drive wheel 73.76 lbf⋅ft
Exhaust gas return valve 11.06 lbf⋅ft
expand_moreExhaust recirculation pipe
Nuts 18.44 lbf⋅ft
Sealing rings must be replaced.
Screws 11.06 lbf⋅ft
Sealing rings must be replaced.
expand_moreFuel-distributing pipe
Injection hoses 18.44 lbf⋅ft
expand_moreInjection nozzle (injector)
All other modifications 51.63 lbf⋅ft
expand_moreInjection pump
2.4 D with diesel straight-5 2.4 L 76 HP engine (1990.9–1998.4) 22.13 lbf⋅ft
All other modifications 18.44 lbf⋅ft
expand_moreInjection pump pulley
One-part injection pump pulley 33.19 lbf⋅ft
Two-part injection pump pulley 18.44 lbf⋅ft
All Volkswagen diesel straight-5 2.4 Liters AAB engines 36.88 lbf⋅ft
All other modifications 66.38 lbf⋅ft
expand_moreInjection pump lockup screws
With spacer 8.85 lbf⋅ft
Otherwise 22.13 lbf⋅ft
expand_moreCharging
Turbo charger 33.19 lbf⋅ft
Nuts and screws must be replaced.
expand_moreTurbocharger oil feed line
At the turbocharger 18.44 lbf⋅ft
Sealing rings must be replaced.
On the engine block 22.13 lbf⋅ft
Sealing rings must be replaced.
expand_moreTurbocharger oil return line
At the turbocharger 22.13 lbf⋅ft
Sealing rings must be replaced.
On the engine block 29.5 lbf⋅ft
expand_moreCooling system
expand_moreCoolant drain plug
expand_moreCoolant pump
1.9 D with diesel straight-4 1.9 L 59 HP engine (1990.9–1995.12) 7.38 lbf⋅ft
All other modifications 14.75 lbf⋅ft
expand_moreCoolant pump pulley
Collar screws 18.44 lbf⋅ft
Otherwise 14.75 lbf⋅ft
All other modifications 14.75 lbf⋅ft
expand_moreFan wheel
expand_moreRadiator mounting
expand_moreCylinder head
expand_moreCamshaft bearing
All other modifications 14.75 lbf⋅ft
First tighten bearing covers 2 and 5 alternately and in steps
expand_moreCylinder head screws
expand_moreAll other modifications
Figure 1. Cylinder head, Cylinder head screws, All other modifications.
Figure 1. Cylinder head, Cylinder head screws, All other modifications.
First stage 29.5 lbf⋅ft
Screws must be replaced. See figure 1.
Second stage 44.25 lbf⋅ft
Third stage 90°
Fourth stage 90°
expand_moreCylinder head screws shank length (new)
1.8 with gasoline straight-4 1.8 L 66 HP engine (1990.12–1992.7) 3.86 in
All other modifications 4.53 in
Valve cover 7.38 lbf⋅ft
expand_moreEngine block
expand_moreConnecting rod bearing
First stage 22.13 lbf⋅ft
Screws must be replaced.
Second stage 90°
expand_moreCrankshaft central screws
expand_more1.8 with gasoline straight-4 1.8 L 66 HP engine (1990.12–1992.7)
First stage 66.38 lbf⋅ft
Screws must be replaced. Lightly oil the screws.
Second stage 90°
expand_more1.9 D with diesel straight-4 1.9 L 59 HP engine (1990.9–1995.12)
First stage 66.38 lbf⋅ft
Screws must be replaced. Lightly oil the screws.
Second stage 90°
expand_more2.0 with gasoline straight-4 2.0 L 83 HP engine (1990.9–2003.4)
First stage 66.38 lbf⋅ft
Screws must be replaced. Lightly oil the screws.
Second stage 90°
expand_moreAll other modifications
65 mm screws 339.28 lbf⋅ft
expand_more110 mm screws
First stage 118.01 lbf⋅ft
Second stage 180°
expand_moreCrankshaft pulley
1.8 with gasoline straight-4 1.8 L 66 HP engine (1990.12–1992.7) 14.75 lbf⋅ft
1.9 D with diesel straight-4 1.9 L 59 HP engine (1990.9–1995.12) 18.44 lbf⋅ft
expand_more2.0 with gasoline straight-4 2.0 L 83 HP engine (1990.9–2003.4)
Collar screws 18.44 lbf⋅ft
Otherwise 14.75 lbf⋅ft
expand_more2.4 D with diesel straight-5 2.4 L 76 HP engine (1990.9–1998.4)
Vehicles manufactured before 01.1995 14.75 lbf⋅ft
expand_moreAll other modifications
First stage 14.75 lbf⋅ft
Second stage 90°
expand_moreDrive plate
First stage 44.25 lbf⋅ft
Screws must be replaced.
Second stage 90°
expand_moreFlywheel
First stage 44.25 lbf⋅ft
Screws must be replaced.
Second stage 90°
Flywheel cover 7.38 lbf⋅ft
expand_moreMain bearing
First stage 47.94 lbf⋅ft
Replace screws.
Second stage 90°
expand_moreWith continuous thread
First stage 47.94 lbf⋅ft
Second stage 90°
Otherwise 47.94 lbf⋅ft
All other modifications 47.94 lbf⋅ft
expand_moreVibration damper
1.9 D with diesel straight-4 1.9 L 59 HP engine (1990.9–1995.12) 18.44 lbf⋅ft
expand_more2.0 with gasoline straight-4 2.0 L 83 HP engine (1990.9–2003.4)
Collar screws 18.44 lbf⋅ft
Screws 14.75 lbf⋅ft
expand_more2.4 D with diesel straight-5 2.4 L 76 HP engine (1990.9–1998.4)
expand_moreVehicles manufactured before 01.1995
Central screws 339.28 lbf⋅ft
M8 14.75 lbf⋅ft
expand_moreAll other modifications
expand_moreWith ribbed V-belt
First stage 14.75 lbf⋅ft
Second stage 90°
M8 14.75 lbf⋅ft
expand_moreEngine control
expand_moreCamshaft drive belt deflection pulley
All other modifications 7.38 lbf⋅ft
expand_moreCamshaft timing gear
All Volkswagen diesel straight-4 1.9 Liters 1X engines 33.19 lbf⋅ft
All Volkswagen gasoline straight-4 2.0 Liters AAC engines 59 lbf⋅ft
All Volkswagen gasoline straight-4 1.8 Liters PD engines 59 lbf⋅ft
expand_moreAll other modifications
Class 8.8 screws 62.69 lbf⋅ft
Class 10.9 73.76 lbf⋅ft
expand_moreChain tensioner
Injection pump drive belt tensioning roller 11.06 lbf⋅ft
expand_moreTiming case cover
expand_moreToothed belt guard
expand_more2.4 D with diesel straight-5 2.4 L 76 HP engine (1990.9–1998.4)
M6 7.38 lbf⋅ft
M8 14.75 lbf⋅ft
All other modifications 7.38 lbf⋅ft
Toothed belt guard, rear
expand_moreToothed belt guard at the bottom
1.8 with gasoline straight-4 1.8 L 66 HP engine (1990.12–1992.7) 7.38 lbf⋅ft
expand_moreAll other modifications
M6 7.38 lbf⋅ft
M8 14.75 lbf⋅ft
expand_moreToothed belt guard at the top
1.8 with gasoline straight-4 1.8 L 66 HP engine (1990.12–1992.7) 7.38 lbf⋅ft
expand_moreToothed belt tensioning roller
1.8 with gasoline straight-4 1.8 L 66 HP engine (1990.12–1992.7) 33.19 lbf⋅ft
expand_more1.9 D with diesel straight-4 1.9 L 59 HP engine (1990.9–1995.12)
With automatic tensioner 14.75 lbf⋅ft
Otherwise 33.19 lbf⋅ft
2.0 with gasoline straight-4 2.0 L 83 HP engine (1990.9–2003.4) 33.19 lbf⋅ft
2.4 D with diesel straight-5 2.4 L 76 HP engine (1990.9–1998.4) 14.75 lbf⋅ft
expand_moreAll other modifications
Nuts 11.06 lbf⋅ft
Screws 14.75 lbf⋅ft
expand_moreEngine lubrication
expand_moreOil cooler
All other modifications 18.44 lbf⋅ft
expand_moreOil drain plug
All Volkswagen diesel straight-4 1.9 Liters 1X engines 22.13 lbf⋅ft
All Volkswagen gasoline straight-4 2.0 Liters AAC engines 22.13 lbf⋅ft
All Volkswagen gasoline straight-4 1.8 Liters PD engines 22.13 lbf⋅ft
All other modifications 36.88 lbf⋅ft
expand_moreOil filter
expand_moreOil filter housing
expand_moreOil pressure sensor
expand_moreOil pump
All other modifications 14.75 lbf⋅ft
expand_moreOil sump
All Volkswagen diesel straight-4 1.9 Liters 1X engines 14.75 lbf⋅ft
All Volkswagen gasoline straight-4 2.0 Liters AAC engines 14.75 lbf⋅ft
All Volkswagen gasoline straight-4 1.8 Liters PD engines 14.75 lbf⋅ft
expand_moreAll other modifications
M6 7.38 lbf⋅ft
M8 14.75 lbf⋅ft
expand_moreEngine management
expand_moreCamshaft sensor
expand_moreCrankshaft sensor
expand_moreGlow plugs
1.9 D with diesel straight-4 1.9 L 59 HP engine (1990.9–1995.12) 18.44 lbf⋅ft
2.4 D with diesel straight-5 2.4 L 76 HP engine (1990.9–1998.4) 18.44 lbf⋅ft
All other modifications 11.06 lbf⋅ft
Knock sensor 14.75 lbf⋅ft
Lambda sensor 36.88 lbf⋅ft
expand_moreEngine mounting
expand_moreEngine bracket
First stage 36.88 lbf⋅ft
Second stage 90°
First stage 36.88 lbf⋅ft
Second stage 90°
First stage 36.88 lbf⋅ft
Second stage 90°
expand_moreAll other modifications
At the cylinder head 14.75 lbf⋅ft
On the engine block 29.5 lbf⋅ft
expand_moreEngine mounting
expand_more1.8 with gasoline straight-4 1.8 L 66 HP engine (1990.12–1992.7)
On chassis 14.75 lbf⋅ft
On engine bracket 47.94 lbf⋅ft
expand_moreAll other modifications
Central screws 47.94 lbf⋅ft
Nuts 40.57 lbf⋅ft
expand_moreExhaust system
expand_moreCatalytic converter
All other modifications 18.44 lbf⋅ft
expand_moreCatalytic converter bracket
All other modifications 14.75 lbf⋅ft
expand_moreExhaust manifold
1.8 with gasoline straight-4 1.8 L 66 HP engine (1990.12–1992.7) 16.96 lbf⋅ft
Nuts must be replaced.
expand_more2.0 with gasoline straight-4 2.0 L 83 HP engine (1990.9–2003.4)
M6 7.38 lbf⋅ft
M8 18.44 lbf⋅ft
M10 29.5 lbf⋅ft
expand_more2.5 with gasoline straight-5 2.5 L 109 HP engine (1990.11–2003.4)
expand_moreVehicles manufactured before 04.1999
M6 7.38 lbf⋅ft
M8 18.44 lbf⋅ft
M10 29.5 lbf⋅ft
All other modifications 18.44 lbf⋅ft
Nuts must be replaced.
expand_moreExhaust manifold heat shields
expand_moreExhaust pipe
expand_more2.0 with gasoline straight-4 2.0 L 83 HP engine (1990.9–2003.4)
M6 7.38 lbf⋅ft
M8 18.44 lbf⋅ft
M10 29.5 lbf⋅ft
expand_moreAll other modifications
expand_moreVehicles manufactured before 04.1999
M6 7.38 lbf⋅ft
M8 18.44 lbf⋅ft
M10 29.5 lbf⋅ft
expand_moreExhaust pipe bracket
expand_moreAll other modifications
M6 7.38 lbf⋅ft
M8 18.44 lbf⋅ft
M10 29.5 lbf⋅ft
Exhaust pipe rear 29.5 lbf⋅ft
expand_moreExhaust system middle heat protection plate
expand_moreFuel supply
expand_moreFuel filter bracket
2.0 with gasoline straight-4 2.0 L 83 HP engine (1990.9–2003.4) 7.38 lbf⋅ft
expand_moreIgnition system
expand_moreSpark plugs
1.8 with gasoline straight-4 1.8 L 66 HP engine (1990.12–1992.7) 18.44 lbf⋅ft
All other modifications 22.13 lbf⋅ft
expand_moreStart system
expand_moreStarter
M8 14.75 lbf⋅ft
M10 44.25 lbf⋅ft
M12 59 lbf⋅ft

Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 1991 Volkswagen Transporter Van user's manual. Keep in mind that all information here is provided “as is” without any warranty of any kind.

Before doing any DIY service please check your insurance policy and Volkswagen warranty policy for your region. In some regions DIY service may invalidate your warranty.

Conquer your fears and never give up!

DIY car service is not as difficult as it looks like and it might save you thousands of dollars per year. It might be even fun and a good thing to do with your kids on a weekend to teach them how basic machinery works. It's really hard to screw something up and damage your car permanently if you use right tools, follow Volkswagen Transporter Van service manual and use right parts and fluids in prescribed amounts. Even modern cars stuffed with electronics can be serviced in your garage or even in your driveway. Changing engine oil, brake fluid, ATF, replacing brake pads, and etc. It's all may be done by yourself in a mater of a couple of hours.

Doing basic service for your 1991 Volkswagen Transporter Van you're not only saving money, but also also improving your technical skills and learning something new.

1991 Volkswagen Transporter Van generations

In 1991 Volkswagen offered 2 generations of the Transporter Van. Engine fastener tightening specifications may vary in different generations. Be sure that you are looking at the rigt modification.

Units:
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