1991 Volkswagen Vanagon Service and Repair Manual

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Factory-Grade Data

1991 Volkswagen Vanagon service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you diagnose issues correctly, follow proven repair steps, and use wiring diagrams and system sections to track faults faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Electrical diagnostics with wiring diagrams
  • Coverage across major systems: engine, transmission/driveline, brakes, steering, suspension, HVAC, and more

Trims covered

  • Syncro Standard Passenger Van 3-Door
  • GL Standard Passenger Van 3-Door
  • Base Standard Passenger Van 3-Door
  • Carat Standard Passenger Van 3-Door
  • Campmobile Van Camper 3-Door

Engines covered

  • 2.1L 2109CC H4 GAS OHV Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

1991 Volkswagen Vanagon Recalls & Complaints

NHTSA #93V17500029/10/1993Component: EQUIPMENT:APPLIANCE:AIR CONDITIONER

THE PLASTIC MATERIAL OF THE CENTER AIR FLOW DUCT, WHICH IS FASTENED BY TWO MOUNTING SCREWS TO THE CEILING OF THE PASSENGER COMPARTMENT, CAN CRACK AND EVENTUALLY BREAK.

Consequence

IF THE PLASTIC BREAKS WHERE IT IS HELD AT THE TWOMOUNTING SCREWS, THE CENTER AIR FLOW DUCT CAN SEPAR

Remedy

DEALERS WILL INSTALL A REINFORCEMENT PLATE AT THE CONNECTIONS OF BOTH THE CENTER AND REAR AIR FLOW D

TSB #10026848

VOLKSWAGEN: EXHAUST HEAT SHIELD, REPLACEMENT GUIDELINES. HEAT SHIELDS ARE TO BE INSPECTED AFTER COMPLETION O ANY TYPE OF REPAIR TO THE UNDERBODY (EXHAUST SYSTEM TRANSMISSION, ETC.), AND IF DAMAGED, REPLACED. *PE

TSB #621613

SUBJECT REGARDING LATCH SYSTEM LOWER ANCHORS AND TETHERS FOR CHILDREN, INSTALLING / RETROFITTING. *TT

19971015Component: ENGINE AND ENGINE COOLING:ENGINE:GASOLINEFire reported

ENGINE FIRE TOTALLY DESTROYED VEHICLE. *AK

19970918Component: ELECTRICAL SYSTEM:WIRING:INTERIOR/UNDER DASHFire reported

VEHICLE FIRE, ORIGINATING UNDER THE DASH. VEHICLE WAS TOTALED. *AK

20131115Component: TIRES

TL* THE CONTACT OWNS A 1988 VOLKSWAGEN VANAGON (N/A) EQUIPPED WITH KUMHO RADIAL 857 TIRES, SIZE: 185/75R14C. THE CONTACT STATED THAT WHILE DRIVING 60 MPH, THE REAR PASSENGER TIRE TREAD BECAME DETACHED

20121001Component: TIRES

MY HANKOOK RA08 195R14C TIRE SIDE WALL BLEW OUT AS I WAS TRAVELING SOUTH BOUND ON I-110 AT APPROX. 65 MPH. THERE WAS NO INDICATION THAT THE EVENT WAS TO HAPPEN AS THE TIRE DID NOT SEEM DEFLATED WHEN I

20120709Component: EQUIPMENT:APPLIANCE:AIR CONDITIONER

TL* THE CONTACT OWNS A 1991 VOLKSWAGEN VANAGON. THE VEHICLE WAS INCLUDED IN NHTSA CAMPAIGN ID NUMBER: 93V175000 (EQUIPMENT:ELECTRICAL:AIR CONDITIONER) AND WAS REPAIRED. AFTER THE REPAIR THE CONTACT WA

Showing the 5 most serious of 9 complaints filed with NHTSA.

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