Carrier 2.4L User Manual

1993-97 ENGINE COOLING Cooling System Removal & Installation - EuroVan, 2.4L Diesel (AAB & ACV Engine Codes) ENGINE IDENTIFICATION The VIN num

Fig. 9: Lifting Serpentine Belt Tensioning Roller Using Lever Tool (3299) Courtesy of VOLKSWAGEN UNITED STATES, INC. 2. Before installing the serpenti

Fig. 10: Special Tool Required For Serpentine Belt Installation Courtesy of VOLKSWAGEN UNITED STATES, INC. 1996 Volkswagen EuroVan CV COOLING SYSTEM

Fig. 11: Serpentine Drive Belt Routing (2.4L Diesel, With A/C) Courtesy of VOLKSWAGEN UNITED STATES, INC. 1996 Volkswagen EuroVan CV COOLING SYSTEM R

Fig. 12: Serpentine Drive Belt Routing (2.4L Diesel, Without A/C) Courtesy of VOLKSWAGEN UNITED STATES, INC. 1996 Volkswagen EuroVan CV COOLING SYSTE

Fig. 13: Removing Serpentine Belt (2.4L Diesel, With A/C) Courtesy of VOLKSWAGEN UNITED STATES, INC. 1996 Volkswagen EuroVan CV COOLING SYSTEM REMOVA

Fig. 14: Installing Serpentine Belt Onto Power Steering Drive Pulley (2.4L Diesel, With A/C) Courtesy of VOLKSWAGEN UNITED STATES, INC. REMOVAL &

Fig. 15: Exploded View Of Bumper Assembly (Up To December, 1995) Courtesy of VOLKSWAGEN UNITED STATES, INC. Removal & Installation (From January,

1. Remove radiator grille with trim frame. See RADIATOR GRILL & TRIM FRAME . 2. Remove Torx screws (2 and 3). See Fig. 16 . 3. Disconnect right

Removal & Installation (From January, 1996 - Short Front End) 1. To remove bumper cover, pry out caps (9). See Fig. 17 .Remove combination hex scr

Fig. 17: Exploded View Of Front Bumper (From January, 1996 - Short Front End) 1996 Volkswagen EuroVan CV COOLING SYSTEM REMOVAL & INSTALLTION -

makes up the "engine code", and the second part (6 characters), the "serial number". If more than 999,999 engines with the same en

Courtesy of VOLKSWAGEN UNITED STATES, INC. RADIATOR & RADIATOR FAN Special Tools For radiator fan removal, required special tools. zAnti-Freeze T

1996 Volkswagen EuroVan CV COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL 4 января 2005 г. 0:54:40 Page 21 © 2004 Mitchell Repair Informat

Fig. 18: Identifying Radiator & Cooling Fan Assembly Up To December, 1995) Courtesy of VOLKSWAGEN UNITED STATES, INC. 1996 Volkswagen EuroVan CV

1996 Volkswagen EuroVan CV COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL 4 января 2005 г. 0:54:41 Page 23 © 2004 Mitchell Repair Informat

Fig. 19: Identifying Radiator & Cooling Fan Assembly (2.5L - January, 1996 & Up) Courtesy of VOLKSWAGEN UNITED STATES, INC. RADIATOR GRILL &am

Fig. 21: Removing & Installing Radiator Grill (Up To December, 1995) Courtesy of VOLKSWAGEN UNITED STATES, INC. 1996 Volkswagen EuroVan CV COOLIN

Fig. 22: Identifying Radiator Grill Assembly Components (Up To December, 1995) Courtesy of VOLKSWAGEN UNITED STATES, INC. Removal & Installation (

2. Remove screw/washer assemblies (2). Pull upper radiator grill upward with trim frame. 3. Upper Trim frame (3). Remove with upper radiator grill.

Fig. 23: Removal & Installation Radiator Grill (From January, 1996) Courtesy of VOLKSWAGEN UNITED STATES, INC. Removal & Installation (With Tr

1. Remove combination screws 2. See Fig. 24 . 2. Remove (pull out) spray nozzle (5), (if equipped) on left and right side. Hook special (tool 3370) (

Fig. 3: Draining Cooling System (2.4L Diesel) Courtesy of VOLKSWAGEN UNITED STATES, INC. FILLING 1. Open bleeder screw in coolant hose to heater core.

Fig. 24: Removing & Installing Radiator Grill With Trim Frame (From January, 1996) Courtesy of VOLKSWAGEN UNITED STATES, INC. SERPENTINE BELT TENS

Removing & Installing 1. Remove lower sound dampening pan. See SOUND DAMPENING PAN . Remove radiator grill. See RADIATOR GRILL . 2. On ACV engine

Fig. 25: Exploded View Of Charge Air Cooler (Engine Code ACV) 1996 Volkswagen EuroVan CV COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL 4 ян

Courtesy of VOLKSWAGEN UNITED STATES, INC. 3. On all engines, remove left and right securing bolts and fold lock carrier and radiator out forward. See

Fig. 27: Installing Engine Support Stand (3227) & Engine/Transmission Jack (VAG 1383 A) Courtesy of VOLKSWAGEN UNITED STATES, INC. 6. On manual tr

Fig. 28: Identifying Front Transmission Mount (AAB, Man. Trans. - Up To July, 1992) Courtesy of VOLKSWAGEN UNITED STATES, INC. 1996 Volkswagen EuroVan

Fig. 29: Identifying Front Transmission Mount (AAB, Man. Trans. - From August, 1992) Courtesy of VOLKSWAGEN UNITED STATES, INC. 1996 Volkswagen EuroVa

1996 Volkswagen EuroVan CV COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL 4 января 2005 г. 0:54:42 Page 37 © 2004 Mitchell Repair Informat

Fig. 30: Identifying Front Transmission Mount (ACV, Man. Trans.) Courtesy of VOLKSWAGEN UNITED STATES, INC. 7. On all engines, remove right-hand engi

Fig. 32: Identifying Serpentine Belt Tensioning Components Courtesy of VOLKSWAGEN UNITED STATES, INC. SOUND DAMPENING PAN Removal & Installation 1

2. Press down on top of radiator hose. 3. Slowly fill with coolant up to MAX mark on expansion tank. See Fig. 4 . Fig. 4: Identifying Expansion Tank

Fig. 33: Removing & Installing Sound Dampening Pan Courtesy of VOLKSWAGEN UNITED STATES, INC. 1996 Volkswagen EuroVan CV COOLING SYSTEM REMOVAL &

Fig. 34: Removing & Installing Sound Dampening Material Courtesy of VOLKSWAGEN UNITED STATES, INC. THERMOSTAT Removal & Installation 1. The th

1996 Volkswagen EuroVan CV COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL 4 января 2005 г. 0:54:42 Page 42 © 2004 Mitchell Repair Informat

Fig. 35: Timing Belt Required Special Tools (1 Of 2) Courtesy of VOLKSWAGEN UNITED STATES, INC. 1996 Volkswagen EuroVan CV COOLING SYSTEM REMOVAL &am

1996 Volkswagen EuroVan CV COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL 4 января 2005 г. 0:54:42 Page 44 © 2004 Mitchell Repair Informat

Fig. 36: Timing Belt Required Special Tools (2 Of 2) Courtesy of VOLKSWAGEN UNITED STATES, INC. Removal (Vehicles Up To January, 1995) 1. Remove sound

4. Removing V belt for power steering pump. See 2.4L DIESEL (UP TO 1/95) under DRIVE BELT ROUTING. 5. Remove cylinder head cover and timing belt cove

1996 Volkswagen EuroVan CV COOLING SYSTEM REMOVAL & INSTALLTION - 2.4L DIESEL 4 января 2005 г. 0:54:43 Page 47 © 2004 Mitchell Repair Informat

Fig. 38: Identifying Cylinder Head Cover & Components Courtesy of VOLKSWAGEN UNITED STATES, INC. Fig. 39: Removing/Installing Vibration Dampener P

Fig. 40: Setting Crankshaft To TDC Cylinder No. 1. Courtesy of VOLKSWAGEN UNITED STATES, INC. 6. Remove vibration damper center bolt. Remove the 4 x M

DRIVE BELTS 2.4L DIESEL (UP TO JANUARY, 1995) The 2.4L diesel engine (up to 1/95) uses of V belts to drive the accessaries. For drive belt routing, se

Fig. 41: Locking Camshaft Into Position Using Setting Bar Tool (2065) Courtesy of VOLKSWAGEN UNITED STATES, INC. 3. Center setting bar as follows: zTu

Fig. 42: Releasing Camshaft Sprocket From Camshaft Tapered End Courtesy of VOLKSWAGEN UNITED STATES, INC. 5. Install timing belt for camshaft drive. N

Fig. 43: Adjusting Timing Belt Using Tool (VW210) Courtesy of VOLKSWAGEN UNITED STATES, INC. 7. Tighten lower timing belt cover. Ensure crankshaft is

1. Remove serpentine belt. See DRIVE BELTS . 2. Remove radiator grille. See RADIATOR GRILL & TRIM FRAME . 3. For ACV engine code only, remove ch

Fig. 45: Setting Engine To TDC (ACV Synchro Engine Code) Courtesy of VOLKSWAGEN UNITED STATES, INC. 1996 Volkswagen EuroVan CV COOLING SYSTEM REMOVAL

Fig. 46: Identifying 2.4L Diesel Timing Belt Components (From February, 1995) Courtesy of VOLKSWAGEN UNITED STATES, INC. NOTE: This condition only occ

6. On all engines, remove vibration damper bolt. See Fig. 39 . Remove lower timing belt guard. 7. If reusing old timing belt, mark belt with arrow i

Fig. 47: Installing Timing Belt Tensioning Roller (From February, 1995) Courtesy of VOLKSWAGEN UNITED STATES, INC. 6. Install timing belt for camshaft

Fig. 48: Tensioning Timing Belt (From February, 1995) Courtesy of VOLKSWAGEN UNITED STATES, INC. 8. Ensure crankshaft is still on TDC of No. 1 cylinde

12. Tighten the 4 M8 crankshaft vibration damper and toothed belt pulley securing bolts. See TORQUE SPECIFICATIONS . 13. Turn crankshaft two rotation

Fig. 5: Drive Belt Routing (2.4L Diesel - Up To Jan. 1995) Courtesy of VOLKSWAGEN UNITED STATES, INC. 1996 Volkswagen EuroVan CV COOLING SYSTEM REMOV

Coolant Recommendations When refilling the coolant system only use G 12 VW engine coolant. The frost and corrosion protection additive G 11 must only

TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Component Ft. Lbs. (N.m) Axle Shaft-To-Transmission Flange Bolts (1)59 (80) Camshaft Sprocket Bolt Bolt H

(2)Coat threads and bolt head contact surface with sealing paste AMV 188 001 02, or equivalent.(3)Clean all grease and oil from bolt threads.(4)For to

Fig. 6: Identifying Drive Belt Pulleys, Brackets & Fasteners (2.4L Diesel) Courtesy of VOLKSWAGEN UNITED STATES, INC. 1996 Volkswagen EuroVan CV

Fig. 7: Identifying Generator Securing Nut Courtesy of VOLKSWAGEN UNITED STATES, INC. 1996 Volkswagen EuroVan CV COOLING SYSTEM REMOVAL & INSTALL

Fig. 8: Ring Insert (1410/2) Required For V Belt Installation Courtesy of VOLKSWAGEN UNITED STATES, INC. 2.4L DIESEL (FROM FEBRUARY, 1995) The 2.4L di