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Engines
1980s
Germany

History

VW Volkswagen Water-boxer engine

 
VW Volkswagen wasserboxer engine
Overview
Manufacturer Volkswagen Group
Production August 1982–July 1992
Combustion chamber
Configuration flat-4 petrol engine
Displacement 1,914 cc (116.8 cu in), 2,109 cc (128.7 cu in)
Cylinder bore 94.0 mm (3.70 in)
Cylinder block alloy Cast aluminium alloy
Cylinder head alloy Cast aluminium alloy
Valvetrain pushrod OHV
Combustion
Fuel system Carburetor
Fuel type Petrol/gasoline
Oil system Wet sump
Cooling system Water-cooled
Chronology
Predecessor Volkswagen air-cooled engine

 

The Volkswagen Water-Boxer (wasserboxer) engine is a four cylinder horizontally opposed pushrod overhead-valve (OHV) petrol engine developed by Volkswagen. The engine is water-cooled, and takes its name from the German: "wasserboxer" ("Water-boxer"); with "boxer" being another term for horizontally opposed engines. It was available in two displacements - either a 1.9-litre or a 2.1-litre the 2.1-litre being a longer stroke version of the 1.9-litre, both variants sharing the same cylinder bore.This engine was unique to the Volkswagen Type 2 (T3) (Transporter T3 / Caravelle / Vanagon / T25), having never been used in any other vehicle. Volkswagen contracted Oettinger to develop a six-cylinder version of this engine. Volkswagen decided not to use it, but Oettinger sold a Volkswagen Type 2 (T3) equipped with this engine.

Design detail

The wasserboxer featured a cast aluminium alloy cylinder block, cylinder heads, and pistons; and a die-forged steel flatplane crankshaft with three main bearings.

The wasserboxer, as with all Volkswagen boxer engines, directly drives the three-bearing camshaft via a small steel gear on the crankshaft, and a large aluminium one on the camshaft, so there is no timing belt or timing chain. The entire mechanism is internal to the engine, so there should be no concerns regarding wear or replacements, as long as the engine oil is changed regularly. The overhead poppet valves each feature two concentric valve springs, and are operated by pushrods, with adjustable rocker arms to facilitate valve clearance adjustment.

It also featured a "Heron cylinder head", or "bowl-in-piston" type combustion chambers - where the combustion takes place within the piston area, and not in a recess machined in the cylinder head.

The cylinder banks contain cast iron cylinder liners inserted into the crankcase surrounded by a water jacket, with a "rubber lip" style head gasket, which is a very different design as compared to most engines. The top of the cylinder liners is pressed into a recessed cut-out in the cylinder heads, that are sealed with compressible metal rings, to prevent leakage.

Some wasserboxers were plagued by water jacket gasket failures (often erroneously referred to as head gaskets) due to several design issues. Engine failure was also a result of poorly placed sensors, corrosion in the cooling system, and many areas subjected to leaks.

The switch to water-cooling for the boxer engines was made mid-year in 1982, because Volkswagen could no longer make the air-cooled engines meet emissions standards. (The previous generation Volkswagen Type 2 (T2), currently produced in Brazil, was changed to water-cooled engines since 23 December 2005 in response to Brazil's emission laws; the power plant used in the previous-generation T2 is an Audi-sourced inline four.) Water-cooled T2 models can be distinguished by a second radiator grille.

Variants

engine ID code compr. ratio DIN-rated max. motive power fuel system years notes
1.9-litre engines — 1,914 cc (116.8 cu in)
DF 8.6:1 44 kW (60 PS; 59 bhp) 34 PICT-5 carburetor 08/82–07/92  
DG 8.6:1 57 kW (77 PS; 76 bhp) 2E3 or 2E4 carburetor 08/82–07/92  
DH   60 kW (82 PS; 80 bhp) Digijet (Digital-Jetronic) fuel injection, vane-type air flow meter 01/83–07/85  
EY 7.5:1 55 bhp (41 kW; 56 PS) 34 PICT-5 carburetor    
GW 8.6:1 66 kW (90 PS; 89 bhp) Digijet (Digital-Jetronic) fuel injection, vane-type air flow meter 08/83–07/85  
SP   54 kW (73 PS; 72 bhp) 2E3 or 2E4 carburetor 08/86–07/89 Switzerland only
2.1-litre engines — 2,109 cc (128.7 cu in)
DJ 10:1 82 kW (111 PS; 110 bhp) Digijet (Digital-Jetronic) fuel injection, vane-type air flow meter 08/84–07/92 sold in European countries not requiring catalytic converter
MV   70 kW (95 PS; 94 bhp) Digifant II fuel injection, vane-type air flow meter 08/85–07/92 also used until the end of Vanagon importation into the US in 1991
SR   64 kW (87 PS; 86 bhp) Digifant II fuel injection, vane-type air flow meter 08/86–07/92 Switzerland only
SS 9:1 68 kW (92 PS; 91 bhp) Digifant II fuel injection, vane-type air flow meter 08/89–07/92  

VW-wasserboxer-engine (water boxer)

VW-wasserboxer-engine (water boxer)

Technical

  • VW wasserboxer engine Technical details and specifications

    Volkswagen Transporter 1.9 L Engine code: DF

    No. of cylinders 4/OHV
    Capacity 1913 cc
    Compression ratio 8.6:1
    Firing order 1-4-3-2
    Suitable for unleaded petrol Yes
    Fuel system Make Solex Type 34 PICT
    Diagnostic socket No
    Ignition coil Make Bosch Type 0 221 122 022
    Distributor Make Bosch Type 0 231 023 013
    Oil pressure 2.0 bar @ 2000 rpm
    Thermostat opens 85°C
    Starter motor Make Bosch Type 0 001 211 253
    Minimum starting voltage 10V
    Maximum cranking amps 170-208 A
    Alternator Make Bosch Type 0 120 489 986
    Regulated voltage 13.7-14.5V

    © Motor car History
     

Service

  • VW wasserboxer engine Service Guide

    Volkswagen Transporter 1.9 L Engine code: DF
     
    Spark plugs Electrode gap 0.7-0.8 mm
    Spark plugs Tighten 20 Nm
    Spark plugs Original equipment Bosch W7DTC/W7DCO
    Spark plugs Champion N7BYC
    Spark plugs NGK BP6ET
    Valve clearance -INLET Hydraulic
    Valve clearance -EXHAUST Hydraulic
    Drive belt size - alternator 9.5x1165mm
    Drive belt tension - alternator 15 mm
    Engine oil grade - normal/moderate climate 15W/40 SAE or 15W/50 SAE
    Engine oil grade - cold climate 5W/30 SAE
    Engine oil grade - hot climate 20W/50 SAE
    Engine oil change 4.5 litres
    Oil Sump drain bolt Tighten 25 Nm
    Manual gearbox oil grade 80W/90 SAE
    Manual gearbox oil 3.0 litres
    Automatic transmission fluid Type Dexron
    Automatic transmission oil 3.0 litres
    Differential oil grade rear 90W SAE
    Cooling system 10.0 litres

    © Motor car History

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