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Service

Maintenance Golf 1984 ➤ Jetta 1984 ➤

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Service Department. Technical Information

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Edition 08.2003

Service Maintenance

Heading 1. Engine list 2. Oil change service 3. Inspection service 4. General 5. Descriptions of work

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6. Legally required extra work according to country

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Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2010 Volkswagen AG, Wolfsburg

00453715220

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

Contents

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5.10 5.11 5.12 5.13 5.14 5.15 5.16 5.17 5.18 5.19 5.20 5.21 5.22 5.23 5.24 5.25 5.26 5.27 5.28 5.29 5.30 5.31 5.32 5.33 5.34 5.35 6 6.1

Engine list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Oil change service . . . . . . . . . . . . . . . . . . .w.ag. e.n.A.G.. V . o. l.ks.w.a.ge. n. A. G. d. o.e.s . . . . . . . . . . . . . . . . . . 11 n lks Oil change service every 7,500 km . b.y.V.o . . . . . . . . . . . . . . . . . . . . . .ot. g.ua. . . . . . . . . . . . . . 11 d r e is . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a.n.te. . . . . . . . . . . 11 Oil change service every 15,000 hkm or eo t u r Inspection service . . . . . . . .ss.a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a.c . . . . . . . . 13 Inspection service every 12 months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Inspection service every 30,000 km . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Type plate, vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Engine code and engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Lifting vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Tow starting and towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Descriptions of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Self-diagnosis: Read fault memories of all systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Service interval display: Reset (digital driver information centre - DIGIFIZ) . . . . . . . . . . . . 27 Door arrester and securing pins: Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Sunroof: Check function, clean and grease guide rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Windscreen wash/wipe system and headlight washer system: Check function . . . . . . . . . . 29 Check tyres: Condition, wear pattern, inflation pressures, tread depth . . . . . . . . . . . . . . . . 34 Oil level: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Engine oil: Drain or extract and top up; Renew oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Engine and components in engine compartment (from above and below): Perform visual check for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 V-belt: Check condition and tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Poly V-belts: Check condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Manual gearbox/final drive: Check oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Automatic gearbox: Check final drive oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Automatic gearbox: Check ATF level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Changing ATF (automatic gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Brake system: Perform visual check for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . 48 Front and rear brake pads/linings: Check thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Underbody protection: Perform visual check for damage . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Track rod ends: Check play, security and boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Swivel joints: Perform visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Cooling system: Check frost protection and coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Camshaft drive toothed belt: Check condition and tension (diesel engine) . . . . . . . . . . . . 53 Valve clearance: Check (engine code GT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Contact breaker points: Renew (engine code GT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Fuel filter: Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Fuel filter: Drain water (diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Power assisted steering: Check fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Change brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Brake fluid level (dependent upon lining/pad wear): Check . . . . . . . . . . . . . . . . . . . . . . . . 61 Battery: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Clutch play: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Engine basic setting: Perform settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Idling speed: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Headlight settings: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Road test: Carry out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Legally required extra work according to country . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 ility ab y li an pt ce

1 2 2.1 2.2 3 3.1 3.2 4 4.1 4.2 4.3 4.4 5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9

Contents

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Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

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EZ5)

Petrol engine

06.91 4

08.85 07.87 4

08.85 06.91 4

1.6 55/50001)

1.8 82/5500

1.6 55/50001)

125/2500

157/3100

125/2500

81.0

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77.4 9.0

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En‐ gines → Manufac‐ from tured to Number of cylin‐ ders Capacity l Output kW at rpm Torque Nm at rpm Bore ∅ mm Stroke mm Compression ra‐ tio Hydraulic valve clearance com‐ pensation Injection Ignition RON min. Self-diagnosis Catalytic convert‐ er Lambda regula‐ tion Exhaust gas re‐ circulation Turbocharged Engine basic set‐ ting after 1, 2, 4, 6, 8 years etc. Exhaust emis‐ sions test every 12 months Exhaust emis‐ sions test after 3, 5, 7 years etc.

ABN

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Engine code

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Engine list

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yes

2E2 TIS-H 91 unleaded no no/yes2)

K Jetronic TIS-H 98 unleaded4) no no/yes2)

2E2 TIS-H 91 unleaded no no/yes2)

no/yes2)

no no/yes3)

yes/no3)

no/yes3)

1) Austria engine 51 kW at 5000 rpm. 2) Retrofitting is possible 3) For retrofitted regulated catalytic converter. 4) Ignition timing change is necessary when super unleaded (RON 95) is used. 5) For Austria engines are additionally marked with code letters EZA concerning engine number.

1. Engine list

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 GT

Petrol engine

08.85 10.91 4 1.8 66/5200 145/3300 81.0 86.4 10.0 yes

08.85 07.86 4 1.8 66/5250 137/3000 81.0 86.4 9.0 yes

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91 unleaded no no/yes8) no/yes8) no no no/yes9)

yes/no9)

no/yes9)

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98 unleaded7) no no/yes8) no/yes8) no no no/yes9)

7) Ignition timing change is necessary when super unleaded (RON 95) is used.

10) Identification: K Jetronic with warm-up regulator, KE Jetronic without warmup regulator.

GZ Engines → from to

Manufac‐ tured Number of cylinders Capacity l Output kW at rpm Torque Nm at rpm Bore ∅ mm Stroke mm Compression ratio

2 1. Engine list

Petrol engine 08.85 07.88 4 1.8 82/5500 157/3100 81.0 86.4 10.0

Petrol engine 08.85 07.88 4 1.6 55/5000 125/2500 81.0 77.4 9.0

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Engine code

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9) For retrofitted regulated catalytic converter.

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8) Retrofitting is possible.

Petrol engine 08.85 07.87 4 1.8 66/5200 145/3300 81.0 86.4 10.0

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6) Unleaded fuel is permitted.

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Engines → Petrol en‐ gine Manufac‐ from 08.85 tured to 07.86 Number of cylinders 4 Capacity l 1.3 Output kW at rpm 43/5400 Torque Nm at rpm 93/3300 Bore ∅ mm 75.0 Stroke mm 72.0 Compression ratio 8.2 Hydraulic valve clearance no compensation Injection 34 PIC Ignition Breakertriggered RON min. 916) Self-diagnosis no Catalytic converter no Lambda regulation no Exhaust gas recirculation no Turbocharged no Engine basic setting after no 1, 2, 4, 6, 8 years etc. Exhaust emissions test yes every 12 months Exhaust emissions test af‐ no ter 3, 5, 7 years etc.

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Engine code

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 Engine code

Hydraulic valve clearance yes yes compensation Injection K Jetronic Keihin Ignition TIS-H TIS-H 11) RON min. 98 unleaded 9112) swagen AG AG. Volkno Self-diagnosis no does agen ksw not l o V g y Catalytic converter no no ua db ran ise t r e eo Lambda regulation tho no no ra au c s s Exhaust gas recirculation no yes Turbocharged no no Engine basic setting after 1, 2, no no 4, 6, 8 years etc. Exhaust emissions test every yes yes 12 months Exhaust emissions test after 3, no no 5, 7 years etc.

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11) Ignition timing change is necessary when super unleaded (RON 95) is used. 12) Unleaded fuel is permitted.

Petrol engine 08.85 10.91 4 1.05 37/5900 74/3600 75.0 59.0 9.5 yes

Petrol engine 10.85 07.90 4 1.8 102/6100 168/4600 81.0 86.4 10.0 yes

Petrol engine 08.85 12.88 4 1.3 40/5200 96/3400 75.0 72.0 9.5 yes

Weber 32 TLA/1B3 TIS-H 91 no no no no no no

K Jetronic VEZ 98 unleaded13) no no no no no no

2E3 TIS-H 91 unleaded13) no no no no no no

yes

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Manufac‐ tured Number of cylinders Capacity l Output kW at rpm Torque Nm at rpm Bore ∅ mm Stroke mm Compression ratio Hydraulic valve clearance com‐ pensation Injection Ignition RON min. Self-diagnosis Catalytic converter Lambda regulation Exhaust gas recirculation Turbocharged Engine basic setting after 1, 2, 4, 6, 8 years etc. Exhaust emissions test every 12 months Exhaust emissions test after 3, 5, 7 years etc.

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Engine code

Keihin TIS-H 9811) 12) no no no yes no no

1. Engine list

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Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

13) Leaded fuel also permitted.

Engine code Engines →

Petrol engine

Petrol engine 02.87

Petrol engine

Manufac‐ from tured to Number of cylinders Capacity l Output kW at rpm

07.85 12.87 4 1.3 37/5200

Torque

94/3300

Nm at rpm

Bore ∅ mm Stroke mm Compression ratio Hydraulic valve clearance compensation Injection Ignition RON min.

75.0 72.0 9.5 yes

159/4000 81.0 86.4 10.0 yes

Digijet Digifant TIS-H Digifant 91 un‐ 98 unleaded15) 16) leaded no no no k s l w o agen AG V no no/yes17) n AG.yes does wage s k n l ot g 17) Vo no yes no/yes ua by ran ed s i r no no no tee o ho ut ra a c no no ss no no yes no/yes18)

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2E3 TIS-H 91 unleaded14)

yes

yes/no18)

yes

no/yes18)

15) Unleaded at least RON 95 can also be used but with reduced output. 16) For vehicles without catalytic converter leaded fuel also permitted. 17) Retrofitting is possible.

02.87 06.90 4 1.8 79/5400 157/3800 81.0 86.4

04.90 07.91 4 1.8 118/5600 225/4000 81.0 86.4

04.86 10.91 4 1.8 95/5800 168/4250 81.0 86.4

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4 1. Engine list

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Manufac‐ tured Number of cylinders Capacity Output Torque Bore Stroke

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Engine code

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18) For retrofitted regulated catalytic converter.

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14) Leaded fuel also permitted.

4 1.3 40/520 0 99/320 0 75.0 72.0 9.5 yes

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Self-diagnosis Catalytic converter Lambda regulation Exhaust gas recirculation Turbocharged Engine basic setting after 1, 2, 4, 6, 8 years etc. Exhaust emissions test every 12 months Exhaust emissions test after 3, 5, 7 years etc.

02.87 10.91 4 1.8 82/5400

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 Engine code

Compression ratio Hydraulic valve clearance compen‐ sation Injection Ignition RON min.

10.0 yes

8.0 yes

10.0 yes

Digifant Digifant 98 unleaded19)

Digifant Digifant 95 unleaded22)

no yes no/yes20) no no no/yes21)

no no/yes23) yes no G 60 charger no/yes24)

KE Jetronic VEZ 95 unlea‐ ded25) no yes yes no no yes

yes/no21)

yes/no24)

no/yes21)

no/yes24)

yes

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23) Not standard equipment in all countries. 24) For regulated catalytic converter. 25) Unleaded at least RON 91 can also be used but with reduced output.

Engine code

PN Petrol engine 02.87 4

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1.6 51/5200 118/2700 AG.

77.4 8.0 yes

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En‐ gines → Manufac‐ from tured to Number of cylin‐ ders Capacity l Output kW at rpm Torque Nm at rpm Bore ∅ mm Stroke mm Compression ratio Hydraulic valve clearance com‐ pensation

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22) With catalytic converter unleaded fuel, without catalytic converter unleaded or leaded, recommended: Fuel with RON 98

Petrol engine

08.85 07.88 4

04.86 10.91 4

1.8 79/5250

1.6 53/5200

154/3250

120/2700

81.0

86.4 10.0 yes

77.4 9.0 yes

1. Engine list

Prote cted by

c o p yri gh t . C op yi

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 Engine code Injection Ignition RON min. Self-diagnosis Catalytic converter Lambda regulation Exhaust gas recir‐ culation Turbocharged Engine basic set‐ ting after 1, 2, 4, 6, 8 years etc. Exhaust emis‐ sions test every 12 months Exhaust emis‐ sions test after 3, 5, 7 years etc.

2EE TIS-H 91 unleaded yes yes yes no

KE Jetronic VEZ 91 unleaded no no/yes26) no/yes26) no

2E2 TIS-H 91 unleaded no yes no no

no yes

no no/yes27)

no no

yes/no27)

yes

no/yes27)

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Petrol engine

Petrol en‐ gine

08.86 02.87 4

09.86 07.90 4

08.87

1.8 62/5000

1.8 66/5250

154/3500

142/3000

81.0

86.4 10.0 yes

86.4 9.0 yes

K Jetronic

2E2

Ignition RON

VEZ 91 unleaded

TIS-H 95 unleaded

no yes

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6 1. Engine list

c o p yri gh t . C op yi

Self-diagnosis Catalytic converter

86.4 10.0 yes

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min.

1.8 79/5500

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En‐ gines → Manufac‐ from tured to Number of cylin‐ ders Capacity l Output kW at rpm Torque Nm at rpm Bore ∅ mm Stroke mm Compression ratio Hydraulic valve clearance com‐ pensation Injection

Mono Jet‐ ronic TIS-H 91 unlea‐ ded yes yes

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Engine code

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27) For retrofitted regulated catalytic converter.

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26) Retrofitting is possible.

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Petrol engine

no yes no yes

Petrol engine

10.87 10.91 4 1.8 77/5400

02.89 12.89 4 1.8 118/5600

Petrol en‐ gine 08.88 07.91 4 1.8 72/5400

148/3800 81.0 86.4 10.0 yes

225/4000 80.6 86.4 8.0 yes

143/3000 81.0 86.4 10.0 yes

Digifant Digifant 91 unleaded

Digifant Digifant 95 unleaded30)

no no/yes28) no/yes28) no no no/yes29)

no yes yes no G 60 charger yes

Digifant Digifant 91 unlea‐ ded no yes yes no no yes

yes/no29)

no/yes29)

yes

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Torque Nm at rpm Bore ∅ mm Stroke mm Compression ratio Hydraulic valve clearance com‐ pensation Injection Ignition RON min.

yes no

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l kW at rpm

no no no no

from to

no no

Engines →

Manufac‐ tured Number of cylinders Capacity Output

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Lambda regulation Exhaust gas recir‐ culation Turbocharged Engine basic set‐ ting after 1, 2, 4, 6, 8 years etc. Exhaust emis‐ sions test every 12 months Exhaust emis‐ sions test after 3, 5, 7 years etc.

Engine code

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Engine code

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31)

1. Engine list

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

28) Not standard equipment in all countries.

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara dbe used but with reduced output. e 30) Unleaded at least RON 91 can also nte is r o eo h ut up to chassis number 1 GZK 216 175. ra 31) 66 kW at 5200 rpm for vehicles a c s s

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Number of cylinders Capacity l Output kW at rpm Torque Nm at rpm Bore ∅ mm Stroke mm Compression ratio Hydraulic valve clearance compensa‐ tion Injection Ignition RON min. Self-diagnosis Catalytic converter Lambda regulation Exhaust gas recirculation Turbocharged Engine basic setting after 1, 2, 4, 6, 8 years etc. Exhaust emissions test every 12 months Exhaust emissions test after 3, 5, 7 years etc.

2E3 TIS-H 91 unleaded32) no no no no no no AG.

Manufactured

Petrol engine 03.87 12.87 4 1.3 44/5200 96/3400 75.0 72.0 9.5 yes

Petrol engine 01.89 4 1.3 40/5200 96/3400 75.0 72.0 9.5 yes

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Engine code

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29) For regulated catalytic converter.

2E3 TIS-H 91 unleaded33) no no no no no no

yes

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32) Leaded fuel also permitted. 33) Without catalytic converter: 98 unleaded or leaded.

Engine code En‐ gines → Manufac‐ from tured to Number of cylin‐ ders Capacity l Output kW at rpm Torque Nm at rpm Bore ∅ mm

8 1. Engine list

JP34)

Diesel engine

Diesel en‐ gine

08.85 10.91 4

01.89 10.91 4

1.6 40/480035)

1.6 51/4500

1.6 40/4500

100/2500

133/2500

100/2500

76.5

Diesel 45 no no no no no no

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yes

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23.0 yes

86.4 23.0 yes

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Stroke Compression ratio Hydraulic valve clearance compen‐ sation Injection CN min. Self-diagnosis Catalytic converter Exhaust gas recir‐ culation Turbocharged Engine basic set‐ ting after 1, 2, 4, 6, 8 years etc. Exhaust emissions test every 12 months Exhaust emissions test after 3, 5, 7 years etc.

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Engine code

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

Diesel 45 no no no

yes no

no no

yes

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34) For Austria engines are additionally marked with code letters JPA concerning engine number. 35) Austria engine 37 kW at 4800 rpm.

Engine code Manufactured

Engines → from to

Number of cylinders Capacity l Output kW at rpm Torque Nm at rpm Bore ∅ mm Stroke mm Compression ratio Hydraulic valve clearance compensation Injection CN min. Self-diagnosis Catalytic converter Exhaust gas recirculation Turbocharged Engine basic setting after 1, 2, 4, 6, 8 years etc. Exhaust emissions test every 12 months Exhaust emissions test after 3, 5, 7 years etc.

Diesel engine 04.89 02.90 4 1.6 59/4500 155/2600...3000 76.5 86.4 23.0 yes Diesel 45 no no no yes no

Diesel engine 08.89 10.91 4 1.6 59/4500 155/2600...3000 76.5 86.4 23.0 yes Diesel 45 no no no yes no

Diesel engine 10.89

no yes

4 1.6 44/4500 110/2400 76.5 86.4 23.0 yes Diesel 45 no yes no yes no

1. Engine list

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10 1. Engine list

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Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

Golf 1984 ➤ , Jetta 1984 ➤

Oil change service

2.1

Oil change service every 7,500 km pe rm itte d

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♦ When faults requiring repair measures are found during an oil change service, inform the customer. ♦ Ask customer whether new wiper blades should be fitted and if he or she wishes to have Windscreen Clear -G 052 164- in the washer system.

– Fuel filter: Drain water – Engine oil: Drain or extract, renew oil filter – Front and rear brake pads/linings: Check thickness – Engine oil: Replenish – Service sticker: Enter date of next service (including change of brake fluid) on sticker and secure sticker to driver side door pillar (B-pillar)

⇒ page 57 ⇒ page 38 ⇒ page 48

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2.2

⇒ page 38

do c um en

Vehicles with diesel engine driving more than 7,500 km per year:

rrectness of i t to the co nform spec a t i h re o n in wit thi s

♦ The sequence of the individual service tasks has been tested and optimised. Therefore, it should be followed to avoid un‐ necessary interruptions in the work.

Oil change service every 15,000 km

♦ The sequence of the individual service tasks has been tested and optimised. Therefore, it should be followed to avoid un‐ necessary interruptions in the work. ♦ When faults requiring repair measures are found during an oil change service, inform the customer. ♦ Ask customer whether new wiper blades should be fitted and if he or she wishes to have Windscreen Clear -G 052 164- in the washer system. Vehicles with petrol engine driving more than 15,000 km per year:

Page

– Engine oil: Drain or extract, renew oil fil‐ ter – Front and rear brake pads/linings: Check thickness – Spark plugs: Renew, spark plug desig‐ nation see ⇒ Data sheets for exhaust emission test

⇒ page 38

(Vehicles with engine code GT) – Valve clearance: Check and renew cyl‐ inder head cover gasket

⇒ page 48

⇒ page 54

(Vehicles with engine code GT) – Contact breaker points: Renew

⇒ page 55

(Vehicles with engine code GT) – Engine oil: Replenish

⇒ page 38

2. Oil change service

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 Vehicles with petrol engine driving more than 15,000 km per year:

Page

– Service interval display: Reset

⇒ page 27

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12 2. Oil change service

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(Golf with DIGIFIZ) – Service sticker: Enter date of next serv‐ ice (including change of brake fluid) on sticker and secure sticker to driver side door pillar (B-pillar)

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

Inspection service

3.1

Inspection service every 12 months

♦ Ask customer whether new wiper blades should be fitted and if he or she wishes to have Windscreen Clear -G 052 164- in the washer system. ♦ Check if storage life date of first aid box has been exceeded. ♦ The sequence of the individual service tasks has been tested and optimised. Therefore, it should be followed to avoid un‐ necessary interruptions in the work. ♦ The sequence of task descriptions corresponds to the se‐ quence of inspection service work, which is the most com‐ monly performed service. ♦ If faults requiring repair measures are found during an inspec‐ tion service, inform the customer. Work to be com‐ pleted

Page

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es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

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Electrics – Front lights - Check function: Side lights, dipped beam, main beam, fog lights, AG. Volkswagen AG d turn signals, hazard warning lights agen oes ksw not l o V Brake lights (including 3rd brake gu light), tail lights, – Rear lights - Check function: by ar d e s reversing lights, rearorifog light, number plate light, turn signals,anhazard warning tee h or ut compartment lights lights, luggage/load a a c ss – Interior and glove compartment lighting, cigarette lighter, warning lamps and horn: Check function – Self-diagnosis: Read fault memories of all systems – Service interval display: Reset

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(Vehicles with digital driver information centre - DIGIFIZ) Vehicle exterior – Door arrester and securing pins: Grease – Windscreen wash/wipe system and headlight washer system: Check function and settings – Windscreen wiper blades: Check for damage; check park position; only if wiper blades “judder” : Check setting angle Tyres – Spare wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm – Front left wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm – Rear left wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm – Rear right wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm – Front right wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm Vehicle from below – Engine oil: Drain or extract; renew oil filter – Engine and components in engine compartment (from below): Visual check for leaks and damage – Gearbox, final drive and drive shaft bellows: Visual check for leaks and damage

⇒ page 24 ⇒ page 27

⇒ page 28 ⇒ page 29 ⇒ page 31

⇒ page 34 ⇒ page 34 ⇒ page 34 ⇒ page 34 ⇒ page 34

⇒ page 38 ⇒ page 41

3. Inspection service

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Prote cted by c o p yri gh t. C op yi

Page

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Work to be com‐ pleted

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– Brake system: Perform visual check for leaks and damage – Front and rear brake pads/linings: Check thickness – Exhaust system: Visual check for leaks, security and damage – Track rod ends: Check play, security and boots – Swivel joints: Visual check of swivel joint boots for leaks and damage Engine compartment – Engine oil: Replenish – Engine and components in engine compartment (from above): Visual check for leaks and damage – Windscreen wash/wipe system: Replenish with Windscreen Clear -G 052 164– Cooling system: Check frost protection and coolant level

⇒ page 48 ⇒ page 48 ⇒ page 50 ⇒ page 50 ⇒ page 38 ⇒ page 41 ⇒ page 29 ⇒ page 50

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Specification -25 °C (in countries with arctic climate -35 °C) actual value(measured value): ____ °C – Spark plugs: Renew - spark plug designation ⇒ Data sheets for exhaust emis‐ sion test Prote cted by c o p yri gh t. C op yi

(Vehicles with engine code GT) – Valve clearance: Check and renew cylinder head cover gasket

⇒ page 54

(Vehicles with engine code GT) – Contact breaker points: Renew

⇒ page 55

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(Vehicles with engine code GT) – Air cleaner: Clean housing and renew filter element Every 2 years for vehicles driving less than 30,000 km in 2 years (vehicles with 51 kW turbo diesel, vehicles with air cleaner secured to engine and vehicles up to 07.88 with air cleaner secured to body) – Fuel filter: Drain water

⇒ page 57

(Diesel engine) – Automatic gearbox: Check ATF level – Change brake fluid / additional work as a separate charge!

⇒ page 45 ⇒ page 58

(every 2 years) – Brake fluid level (dependent upon lining/pad wear): Check – Battery: Check – Exhaust emission test: Perform test / additional work as a separate charge! – Engine basic setting: Perform settings

⇒ page 61 ⇒ page 62 ⇒ page 109 ⇒ page 70

(12 and 24 months after initial registration and then every 12 months after last emissions test for vehicles with petrol engine and regulated catalytic converter engines without automatic idling speed regulation and CO control) – Idling speed: Check

⇒ page 104

(12 and 24 months after initial registration and then every 12 months after last emissions test for vehicles with diesel engine) Final checks – Tyre inflation pressure of all 4 wheels and spare wheel: Check – Headlight settings: Check – Service sticker: Enter date of next service (including change of brake fluid) on sticker and secure sticker to driver side door pillar (B-pillar)

14 3. Inspection service

⇒ page 34 ⇒ page 105

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 Work to be com‐ pleted

Page

– Road test: Carry out

3.2

⇒ page 108

Inspection service every 30,000 km

♦ Ask customer if new wiper blades should be fitted and if he or she wishes to have Windscreen Clear -G 052 164- (cleanser and anti-freeze) in the washer system. ♦ Check if storage life date of first aid box has been exceeded. ♦ The sequence of the individual service tasks has been tested and optimised. Therefore, it should be followed to avoid un‐ necessary interruptions in the work. ♦ The sequence of task descriptions corresponds to the se‐ quence of inspection service work, which is the most com‐ monly performed service. ♦ If faults requiring repair measures are found during an inspec‐ tion service, inform the customer. Work to be completed

Page

Electrics – Front lights - Check function: Side lights, dipped beam, main beam, fog lights, turn signals, hazard warning lights – Rear lights - check function: Brake lights (including 3rd brake light), tail lights, reversing lights, rear fog light, number plate light, turn signals, hazard warn‐ ing lights, luggage/load compartment lights – Interior and glove compartment lighting, cigarette lighter, warning lamps and horn: Check function AG. Volkswagen AG d agen oes – Self-diagnosis: Read fault kswmemories of all systems not l o gu yV b ara d – Service interval display: Reset e n is tee or ac

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Vehicle exterior – Door arrester and securing pins: Grease – Sunroof: Check function, clean guide rails and lubricate with special grease -G 000 450 02– Windscreen wash/wipe system and headlight washer system: Check function and settings – Windscreen wiper blades: Check for damage; Check park position Tyres – Spare wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm – Front left wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm – Rear left wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm – Rear right wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm – Front right wheel: Check condition and wear pattern of tyre; enter tread depth: _______ mm Vehicle from below – Engine oil: Drain or extract; renew oil filter

⇒ page 24 ⇒ page 27

⇒ page 28 ⇒ page 28 ⇒ page 29 ⇒ page 31 ⇒ page 34 ⇒ page 34 ⇒ page 34 ⇒ page 34 ⇒ page 34

⇒ page 38

3. Inspection service

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Prote cted by c o py rig ht . C op yi

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 Work to be completed

Page

– Engine and components in engine compartment (from below): Visual check for leaks and damage – V-belt: Check condition and tension – Poly V-belts: Check condition

⇒ page 41 ⇒ page 42 ⇒ page 44

(every 60,000 km) – Gearbox, final drive and drive shaft bellows: Visual check for leaks and dam‐ age – Manual gearbox/final drive: Check oil level

⇒ page 44

(Vehicles from model year 1988) – Automatic gearbox: Check final drive oil level – Automatic gearbox: Change ATF

⇒ page 45 ⇒ page 45

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⇒ page 50 ⇒ page 50 ⇒ page 38 ⇒ page 41 ⇒ page 29 ⇒ page 50

rrectness o f i t to the co n f orm spec atio h re n wit

Specification -25 °C (in countries with arctic climate -35 °C) actual value(meas‐ ured value): ____ °C – Spark plugs: Renew, spark plug designation see ⇒ Data sheets for exhaust emission test

⇒ page 48 ⇒ page 48 ⇒ page 49

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(every 60,000 km) – Brake system: Perform visual check for leaks and damage – Front and rear brake pads/linings: Check thickness – Underbody protection: Perform visual check for damage – Exhaust system: Visual check for leaks, security and damage – Track rod ends: Check play, security and boots – Swivel joints: Visual check of swivel joint boots for leaks and damage Engine compartment – Engine oil: Replenish agen AG Visual check Volkswabove): – Engine and components in engine compartment AG.(from does agen ksw not for leaks and damage l o V gu y b ara ed – Windscreen wash/wipe system:risReplenish with Windscreen Clear -G 052 nte o eo h 164ut ra a c s s protection and coolant level – Cooling system: Check frost

(Every 60,000 km: G 60 engines) – Camshaft drive toothed belt: Check condition and tension

⇒ page 53

(Diesel engine) – Valve clearance: Check and renew cylinder head cover gasket

⇒ page 54

(Vehicles with engine code GT) – Contact breaker points: Renew

⇒ page 55

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Every 2 years for vehicles driving less than 30,000 km in 2 years (vehicles with 51 kW turbo diesel, vehicles with air cleaner secured to engine and vehicles up to 07.88 with air cleaner secured to body) – Fuel filter: Renew agen lksw Vo by

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16 3. Inspection service

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(Carburettor and diesel engine) – Automatic gearbox: Check ATF level

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(Vehicles with engine code GT) – Air cleaner: Clean housing and renew filter element

⇒ page 56 ⇒ page 45

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 Work to be completed

Page

– Power assisted steering: Check fluid level

⇒ page 58

(every 30,000 km: Vehicles up to 07.91) (every 60,000 km: Vehicles from 07.91) – Change brake fluid / additional work as a separate charge!

⇒ page 58

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– Clutch play: Check

⇒ page 61 ⇒ page 62 ⇒ page 69 ⇒ page 109 ⇒ page 70

(12 and 24 months after initial registration and then every 12 months after last emissions test for vehicles with petrol engine and regulated catalytic converter - engines without automatic idling speed regulation and CO control) – Idling speed: Check

⇒ page 104

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(not for self-adjustment) – Exhaust emission test: Perform test / additional work as a separate charge! – Engine basic setting: Perform settings

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⇒ page 34 ⇒ page 105

⇒ page 108

3. Inspection service

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Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

General

4.1

Type plate, vehicle identification number

A - Type plate It is located in the engine compartment on right side panel or on plenum chamber on the right. B - Vehicle identification number Stamped on the rear engine compartment bulkhead.

4.1.1

Interpretation of vehicle identification number:

WVW

ZZZ

000 001

Fill Mo Pr er del od ch ye uc‐ tee ara ar tio or acte 19 n c rs 90 lo‐ cat ion

Serial number

1936) 1637) 1G38)

36) Golf up to and including model year 1988 37) Jetta up to and including model year 1988 38) Golf and Jetta from model year 1989

4.2

Engine code and engine number

1.05 l and 1.3 l petrol engine (vehicles up to 05.89):

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18 4. General

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Engine number is stamped in engine block on front right side (from driver perspective) next to exhaust manifold.

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Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 1.05 l and 1.3 l petrol engine (vehicles up to 06.89): The engine number is stamped in engine block on the left below distributor. The engine number is additionally found on a bar code sticker on the camshaft toothed belt cover.

1.5 l /1.6 l and 1.8 l petrol engine: Identification at front on cylinder block

4-valve engines:

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Between injection pump and vacuum pump on cylinder block. Note

♦ The “engine codes” are found on the vehicle data sticker,

which is applied on the cross panel at rear left in the luggage compartment.

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♦ “Engine code and engine number” are found on a sticker on

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1.5 l / 1.6 l diesel engine

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The engine number is located above the crankcase breather at front on cylinder block.

4. General

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

4.3

Lifting vehicle WARNING . Volkswag

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Please note the following:

4.3.1

Trolley jack:

To prevent damage always use a suitable rubber or wooden block. On no account should vehicle be lifted at the engine sump, gear‐ box or on front or rear axle as this may cause serious damage.

4.3.2

Lifting platform:

Note

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♦ The vehicle may only be lifted at points indicated in order to

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♦ Vehicles with side member trim must not be lifted at the side

member trim. To prevent damage, therefore note the following when lifting the vehicle:

♦ 1. e.g. lifting platforms with adjustable lifting arms -

V.A.G 1615- : The vehicle may only be lifted at the mounting points designed for use with lifting platform.

♦ 2. Reception lifting platforms with fluid pads -V.A.G 1440- : The

longitudinal members of lifting platforms must be placed so far below the vehicle that the fluid pads do not contact the side member trim. It is absolutely necessary to drive the vehicle centrally on the working platform , because the mounting ad‐ justment area is limited. For this purpose the alignment sup‐ ports prescribed for this lifting platform are very useful. Therefore check that the alignment supports on the lifting plat‐ form are fitted according to the installation instructions.

♦ 3. Other lifting platforms with rigid, large area mountings may

only be used, when rubber blocks are placed additionally on the mounting plates and the mounting points designed for the vehicle can be reached.

4.3.3

Lifting points for lifting platform and trol‐ ley jack

All vehicles, except Golf Country

20 4. General

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Before driving on to a lifting platform ensure there is sufficient clearance between low lying vehicle components and lifting plat‐ form.

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♦ If work is to be performed under vehicle, it must be sup‐ ported by suitable stands.

ran tee or ac ility ab y li an pt ce

r ♦ Never start engine and ho engage a gear with vehicle lifted ut a as long as even sone driven wheel has contact with the s floor! Disregarding these warnings risks the danger of an accident!

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 Front: On mounting block welded on floor pan.

Rear: On longitudinal member between side member and rear axle mounting. olkswagen AG en AG. V Do not jam handbrake cables!

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4.4

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Rear

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4.3.4

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On vehicles with fuel injection engine ensure that the fuel pump at the rear right trolley jack mounting is not damaged.

Tow starting and towing

Towing eyes are fitted at front and rear below the bumpers.

4. General

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 Note ♦ Tow-ropes or bars should be attached at above mentioned

points only.

♦ The tow-rope should be slightly elastic to reduce the risk of

damage to both vehicles. It is advisable to use ropes only of synthetic fibre or similarly elastic material. However, it is safer to use a tow bar.

♦ Avoid excessive towing effort and do not jerk. During towing

operations on unsurfaced roads there is always a danger that the attachment points will be overstressed and damaged.

♦ Before trying to start engine by towing, the battery from an‐

other vehicle should be used for starting if possible.

When the vehicle has to be tow started or towed, the following must be noted: ♦ Regulations concerning towing must be observed. ♦ Both drivers must be familiar with special considerations when towing. Inexperienced drivers should not attempt to tow start or tow. ♦ When using a tow rope, the driver of the towing vehicle must engage the clutch very gently when moving off and lkswagen AG G. Vochanging nA does wage gear. no olks V by

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♦ The emergency lights of both vehicles must be switched on unless local regulations differ.

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♦ The ignition must be switched on so that the steering wheel is free and the turn signals, horn and if necessary the windscreen wiper and washer can be used. ♦ Because on vehicles without ABS the brake servo only func‐ tions when the engine is running, considerably more pressure is required on the brake pedal when the engine is not running. ♦ On vehicles with power assisted steering more force is re‐ quired to turn steering wheel when engine is not running. ♦ When there is no lubricant in a manual gearbox or automatic gearbox, the vehicle may only be towed with driving wheels lifted. When tow starting vehicles with manual gearbox always note the following: – Before tow starting engage “2nd” or “3rd” gear. r fo ng

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22 4. General

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– As soon as engine starts, depress clutch and move gear stick into neutral to avoid running into the towing vehicle.

do c um en

– Switch on ignition.

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

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n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a s s Note

engine) the engine must not be started by towing the vehicle over a longer distance than 50 m (when catalytic converter is at operating temperature) otherwise fuel may pass into the catalytic converter and may burn. This can lead to overheat the catalytic converter.

♦ For technical reasons, it is not possible to tow start a vehicle

with an automatic gearbox.

When towing a vehicle with automatic gearbox additionally note the following: ♦ Selector lever at “N” . ♦ Do not tow vehicle faster than 50 km/h (30 mph).

in t his d o cu m en

r te o iva r rp fo ng

♦ Do not tow further than 50 km.

rrectness o f i t to the co n f orm spec atio h re n wit

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♦ On vehicles with an exhaust catalytic converter (only petrol

♦ If towed over greater distances, the vehicle must be suspen‐ ded at the front.

Reason: When the engine is not turning, the gearbox oil pump it is not working and the gearbox is not adequately lubricated for high speeds or long distances. ht rig py Co t.

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If towed by a breakdown vehicle, the towed vehicle must be sus‐ pended at the front. AG.

Prote cted by

Reason: If vehicle is towed with rear suspended, the drive shafts turn backwards. The planetary gears in the automatic gearbox then turn at such high speeds that the gearbox will be severely damaged in a short time.

4.4.1

Valid for the Golf syncro:

♦ The vehicle can be towed in the same way as a Golf with twowheel drive. ♦ Using a breakdown vehicle the vehicle may be towed suspen‐ ded at front or rear. If the vehicle has to be towed with the rear wheels lifted and the rear wheels cannot turn freely, ensure that the freewheel in the rear axle has not been bridged beforehand by driving vehicle in reverse. To reintroduce the freewheel action the gear lever must be selected briefly to “1st” gear with ignition switched on and then back into neutral.

4. General

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

Descriptions of work

5.1

Self-diagnosis: Read fault memories of all systems

♦ Fault reader -V.A.G 1551-

Identification characteristic for EDL: 5 pin connector below the brake fluid reservoir.

5.1.2

Connecting fault reader -V.A.G 1551-

– Pull on handbrake. – Automatic gearbox: Selector lever in position “P” or “N” . – Manual gearbox: Gear lever in neutral. – Connect fault reader -V.A.G 1551- to diagnosis connections near gear selector lever using diagnosis lead -V.A.G 1551/1with ignition switched off as follows:

24 5. Descriptions of work

AG.

Vehicles with ABS or ABS and EDL from model year 1990:

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Prote cted by c o p yri gh t. C op yi

5.1.1

do c um en

r te o iva r rp fo g n

♦ Diagnosis lead -V.A.G 1550/1-

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♦ Diagnosis lead -V.A.G 1551/1- or

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♦ ll

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Special tools and workshop equipment required

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

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– First connect black fault reader connector for voltage supply to black diagnostic connector -A- in vehicle.

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Note

Only vehicles with ABS:

rrectness o f i t to the co n f orm spec atio h re n wit

5.1.3

Do not connect white connector if there is no indication on display! In this case check voltage supply of fault reader -V.A.G 1551(repair measure).

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AG.

Prote cted by

c o p yri gh t. C op yi

5.1.4

in t his d o cu m en

r te o iva r rp fo ng

– Only connect white connector to blue or grey diagnosis con‐ nection -B- when “V.A.G SELF-DIAGNOSIS” is indicated on display.

Vehicles with ABS and EDL:

Note

Do not connect white or blue connector if there is no indication on display! In this case check connector (black connector) for self diagnosis. – Only connect white connector to white diagnosis connection -B- , blue connector to blue or grey diagnosis connection -Cwhen “V.A.G SELF-DIAGNOSIS” is indicated on display.

5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

5.1.5

Reading fault memory:

5.1.6

Procedure

– Switch off ignition. – Switch on printer with Print button (warning lamp in button lights up). – Press button 2 to select “Flash code output” mode. – Press → button until “Permanent earth to initiating wire (Kwire)” is indicated on display. – Switch on ignition.

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AG. Volkswagen AG d agen oes ksw not l o V gu ara – Press → button.ed by nte is r o eo h ut or flash codes of control unit are indicated on ra The faults stored a s display one safter the other and printed out. If no fault is stored, c pe rm itte d

“Flash code: 4444 No fault detected” is displayed. – Press → button.

5.1.7

Reading fault memory of engine elec‐ tronics (engine codes PN, RP):

The diagnostic connectors for self-diagnosis/engine are located below the selector mechanism cover or in engine compartment. Diagnostic connector below selector mechanism cover: r te o iva r rp fo ng

– Connect fault reader -V.A.G 1551- to diagnosis connections using diagnosis lead -V.A.G 1551/1- with ignition switched off as follows: – First connect black connector to black diagnosis connection. ht rig py Co t.

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Note

Do not connect white connector if there is no indication on display! In this case check voltage supply of fault reader -V.A.G 1551(repair measure). AG.

– Connect white connector to brown diagnosis connection only when “V.A.G SELF-DIAGNOSIS” is indicated on display.

26 5. Descriptions of work

in t his d o cu m en

es, in part or in w l purpos hole ercia , is n m ot com

If faults are stored, repairs are necessary. Fault print-out must accompany vehicle to repair.

rrectness o f i t to the co n f orm spec atio h re n wit

After the last fault or after “Flash code 4444 No fault detected” is indicated, “Flash code: 0000 End output” is displayed.

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 Diagnostic connector in engine compartment: – Connect fault reader -V.A.G 1551- to diagnosis connections using diagnosis lead -V.A.G 1550/1- with ignition switched off as follows: – First connect black terminal of diagnosis lead to battery -—- . – Connect red terminal to battery -+- . – Connect flat connector -1- (yellow) of diagnosis lead to diag‐ nosis connection in engine compartment only when “V.A.G SELF-DIAGNOSIS” is indicated on display. Note

Do not connect diagnosis lead to terminal “1” .

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– Press Print button.

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– Operate fault reader -V.A.G 1551- with regard to display.

rrectness o f i t to the co n f orm spec atio h re n wit

– Press → button.

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– Press button 2 to select “Flash code output” mode. If no fault is stored “Flash code: 4444” appears, the display con‐ tinues automatically to “Flash code 0000 - End output” . – Switch off ignition.

If faults are stored, repairs are necessary. Fault print-out must accompany vehicle to repair. The Fault reader -V.A.G 1551- must remain connected for ex‐ haust emissions test or engine basic setting.

If a service is due, also after starting the engine, the respective service type is displayed for approx. 5 seconds, for example: ♦ Inspection service every 12 months -B- or

AG.

♦ Inspection service every 30,000 km -C-

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♦ Engine oil change -A- or

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Service interval display: Reset (digital driver information centre - DIGIFIZ)

in t his d o cu m en

5.2

The display “INSP” flashes when every service type is displayed. If the oil service is due only a few months before the inspection service, we recommend the customer to perform the inspection service. Therefore “IN:01” or “IN:02” is indicated on display. After a service has been performed, service types which appear in the display before that one, must also be called-up individually and reset: If, for example, the inspection service “IN 02” has been performed “OIL, IN 01” and “IN 02” must be reset. Reset the display as follows:

5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 – With ignition switched off press and hold hour button -h- of clock. – Switch on ignition and release press button. The display “INSP” flashes. – Press hour button several times until the lettering of service performed flashes on display. olkswagen AG en AG. V ag ksw

Vol more than 2 – Then press the minute button (min) of clockbyfor d e been reset. “15 seconds. The service already displayedrishas tho display. 000” , “12” and “OIL” appears on service u a

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Note

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– Switch off ignition.

does not gu ara nte eo ra c

♦ The values in service display remain valid when the battery is

disconnected.

♦ If after repairs on dash panel insert a different mileage is dis‐

played than before repairs, inspection service is to be per‐ formed according to the service schedule but not according to service display. The service display is reactivated only after inspection “IN:2” has been performed and the service display has been reset.

5.3

Door arrester and securing pins: Grease

Carry out the following procedure:

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Prote cted by

– Check function of sunroof. – Clean guide rail -arrows- and lubricate with special grease -G 000 450 02- .

28 5. Descriptions of work

AG.

Carry out the following procedure:

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Sunroof: Check function, clean and grease guide rails

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5.4

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– Grease door arrester in side area -arrow A- and securing pins -arrow B- with lock cylinder lubricant spray -G 052 778 A2- .

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

5.5

Windscreen wash/wipe system and headlight washer system: Check func‐ tion

Special tools and workshop equipment required

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

Check windscreen wash/wipe system frost protection concentration, replenish if necessary

Checking anti-freeze concentration: Read precise value for the following tests at bright/dark boundary. Using a pipette, place a drop of water on the glass to improve the readability of the bright/dark boundary. The bright/dark boundary can be clearly recognised on the “WATERLINE” . – Check concentration of anti-freeze additive using refractome‐ ter -T10007- (refer to operating instructions). ht rig py Co t.

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The scale -1- of the refractometer -T10007- is calibrated for Gen‐ uine Volkswagen Windscreen Clear -G 052 164- .

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5.5.1

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♦ Refractometer -T10007-

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The scale -2- is designed for commercially available windscreen cleanser as well as a mixture of commercially available wind‐ screen cleanser and Windscreen Clear -G 052 164- . agen lksw Vo by

AG.

Prote cted by

5.5.2

Mixture ratio:

Frost protection to

Windscreen Clear G 052 164-

Water

-17/-18 °C -22/-23 °C -37/-38 °C

1 part 1 part 1 part

3 parts 2 parts 1 part

Topping up with fluid: The windscreen wash/wipe system fluid reservoir must be filled up fully. Starting immediately, use only “Genuine Volkswagen Wind‐ screen Clear” all-year-round when replenishing windscreen wash/wipe system.

5. Descriptions of work

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AG. Volkswagen AG d agen oes ksw not l o V, Jetta 1984 ➤ Golf 1984 ➤ gu y b ara d nte ise Maintenance Edition 08.2003 r o eo h t u ra a c s s

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Note

♦ Genuine Volkswagen Windscreen Clear -G 052 164- protects

♦ Use Genuine Volkswagen Windscreen Clear -G 052 164- in

the warmer periods of the year also. The powerful cleanser removes wax and oil residue from the glass.

♦ Frost protection must be guaranteed to approx. -15 °C (ap‐

prox. -35 °C in countries with an arctic climate) in the washer system.

5.5.3

Windscreen wipe/wash system: Check jet setting, adjust jets if necessary

Special tools and workshop equipment required

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♦ Window washer jet adjusting tool -3125 A- or

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♦ Window washer jet adjusting tool -T10127-

Note ♦ Under no circumstances a needle or similar instrument should

be used, because the water channels in the spray jet will be damaged!

♦ The windscreen wash/wipe system fluid reservoir must be fil‐

led up fully.

– Check spray jet setting, if necessary adjust using window washer jet adjusting tool -V.A.G 3125 A- or window washer jet adjusting tool -T10127- . Windscreen jet setting markings:

30 5. Descriptions of work

rrectness of i t to the co nform spec at i h re o n wit in t his

the spray jets, fluid reservoir and connecting hoses from freez‐ ing.

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 Vehicles with single-jet spray jets -a- 345 mm -b- 300 mm

-c-d-

320 mm 420 mm

Tolerance: ± 20 mm

Rear window jet setting figures:

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320 mm

rrectness o f i t to the co n f orm spec atio h re n wit

Tolerance: ± 20 mm

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440 mm 210 mm 490 mm

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Vehicles with twin-jet spray jets

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s 360 mm

Spray jet in centre of wiped area Note

If stream of water is uneven or cannot be adjusted to specified dimensions, renew jet (repair measure).

Special tools and workshop equipment required ht rig py Co t.

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AG.

Prote cted by

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♦ Adjusting tool -3019 A-

in t his d o cu m en

Windscreen wipe/wash system: Check jet setting, adjust jets if necessary r te o iva r rp fo ng

5.5.4

– Check jet settings, if necessary adjust with setting device -3019 A- .

5.5.5

Windscreen wiper blades: Check park position, if wiper blades judder: Check setting angle

Special tools and workshop equipment required

5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

Windscreen: -a- 60 mm -b- 60 mm

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♦ Torque wrench -V.A.G 1331-

Prote cted by

5.5.6

Wiper blades: Check setting angle, ad‐ just if necessary

Note

Check setting angle only if wiper blades judder or make noises. Special tools and workshop equipment required

32 5. Descriptions of work

AG.

Wiper arm torque setting: 20 Nm

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c o p yri gh t. C op yi

-a- 15 mm

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Rear window:

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r te o iva r rp fo ng

Wiper arm torque setting: 20 Nm

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 ♦ Wiper arm setting device -3358 A-

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

♦ 24 mm AF combination spanner -VAS 5397Carry out the following procedure: – Bring wiper arm to park position. – Remove wiper blade.

– Insert wiper arm -2- into wiper arm setting device -3358 A- and secure with locking screw -3- .

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Adjust setting angle to specification, if required, as follows:

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AG.

5. Descriptions of work

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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♦ Torque wrench -V.A.G 1331- and

Prote cted by c o p yri gh t. C op yi

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 – Fit combination spanner, AF 24 -VAS 5397- -1- on the wiper arm setting device -3358 A- and adjust wiper arm -2- to spec‐ ification -arrows- . – Loosen wiper arm -2- from wiper arm setting device -3358 Aand again secure with locking screw -3- . – Check setting value according to table. Repeat adjustment and check sequence until specifications are achieved. AG. Volkswagen n wage

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olksand fit wiper blade. – Remove setting device yV b ed

rissetting: 20 Nm Wiper arm torque tho au

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ss – Check if wiper system operates without juddering.

Driver side Front passenger side Rear window wiper Tolerance

5.6

LHD vehicles - 2° 0°

RHD vehicles + 2° 0°

0° ± 2°

Check tyres: Condition, wear pattern, in‐ flation pressures, tread depth

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Note

For safety reasons, only tyres of same type and tread pattern should be fitted on a vehicle! agen lksw Vo by

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Inspection service:

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AG.

Prote cted by

5.6.1

– Check tyres for cupping, one-sided wear, porous side walls, cuts and punctures. The customer must be informed of any faults found.

5.6.2

Checking tyre wear pattern

The wear pattern on the front tyres will indicate, for example, if toe and camber settings should be checked: ♦ Feathering on tread indicates incorrect toe setting. ♦ One-sided tread wear is caused mainly by incorrect camber. When wear of this nature is noticed determine cause by carrying out alignment checks (repair measure).

5.6.3

Tyre tread depth (including spare wheel): Check

– Check tyre tread depth Minimum tread depth: 1.6 mm

34 5. Descriptions of work

rrectness of i t to the co nform spec at i h re o n wit in t his

Setting angle (specification) for

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For checking and adjusting the setting angle the following speci‐ fications are valid:

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 Note ♦ This figure may vary according to legislation in individual coun‐

tries.

G. Volkswagen AG d oes not o Vindicators gu worn down level with the 1.6 mm high tread wear y b ara d nte positioned at intervals around the tyre. ise r o eo h t u ra a If the tread depth is approaching the minimum allowed depth, c s s

A agen ♦ The minimum tread depth is reached when the tyres have lksw

5.6.4

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inform the customer.

Tyre pressures (including spare): Check, correct if necessary

Special tools and workshop equipment required

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Prote cted by

wheel disc need not be removed. The valve can be reached through the opening.

AG.

♦ Temporary spare wheels with a rectangular opening in the

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Note

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♦ Tyre inflator -VAS 5216-

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urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

♦

♦ Observe the tyre pressures in the table are valid for cold sum‐

mer tyres or all-season tyres. Do not reduce increased pres‐ sures of warm tyres.

♦ Important information concerning winter tyres recommended

by Volkswagen can be found in ⇒ Fault finding - Wheels, tyres; Chapter 2 .

♦ Tyre pressures for the relevant model (summer tyres or all-

season tyres) can also be found on a sticker attached to the inside of fuel tank flap.

♦ When using winter tyres the relevant tyre pressure must be

increased to 0.2 bar.

5.6.5

Tyre pressure table for summer tyres or all-season tyres

Tyre pressures in bar (for all tyre sizes fitted in the factory): Half load front Vehicles with petrol engine:

rear

Full load front rear

37 to 47 kW 5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

rear

155 R 13 175/70 R 13 185/60 R 14 185/55 R 15 195/50 R 15 51, 53 and 55 kW 175/70 R 13 185/60 R 14 185/55 R 15 195/50 R 15 62 and 66 kW 175/70 R 13 185/60 R 14 185/55 R 15 195/50 R 15 79 and 82 kW 175/70 R 13 185/60 R 14 185/55 R 15 195/50 R 15 95 and 102 kW 185/60 R 14 185/55 R 15 195/50 R 15 118 kW 185/55 R 15 195/50 R 15

1.8

2.0

2.4

1.8

2.0

2.4

1.8

2.0

2.4

1.8

2.0

2.4

1.8

2.0

2.4

2.0

1.8

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s 2.0s 2.4

2.0

1.8

2.0

1.8

2.0

1.8

2.0

1.8

2.0

1.8

2.0

1.8

2.0

1.8

2.0

1.8

2.0

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2.4

2.2

2.4

2.2

2.4

2.2

2.4

2.2

2.4

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2.0

2.6

1.8

2.4

2.6

2.0

1.8

2.4

2.6

2.0

1.8

2.4

2.6

2.2

2.0

2.5

2.7

2.2

2.0

2.5

2.7

2.2

2.0

2.5

2.7

2.6

2.4

2.8

3.0

2.6

2.4

2.8

3.0

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2.4

AG.

2.0

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2.4

rrectness of i t to the co nform spec at i h re o n wit in t his

2.0

2.4

Prote cted by

c o p yri gh t. C op yi

36 5. Descriptions of work

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front Vehicles with petrol engine:

Full load front rear

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Half load

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 Half load rear

n AG. Volkswagen AG do es n ot g ua ran tee or ac

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AG.

37 to 44 kW 155 R 13 175/70 R 13 185/60 R 14 185/55 R 15 195/50 R 15 51 and 59 kW 175/70 R 13 185/60 R 14

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Half load front rear Vehicles with diesel engine:

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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wage 66 and olks V 72 kW by ed synchro ris o th 175/70 2.1 2.1 ss au 2.3 2.7 R 13 185/60 2.1 2.1 2.3 2.7 R 14 185/55 2.1 2.1 2.3 2.7 R 15 195/50 2.1 2.1 2.3 2.7 R 15 118 kW synchro 185/55 2.6 2.6 2.8 3.2 R 15 195/50 2.6 2.6 2.8 3.2 R 15 Golf Country 195/60 2.1 2.1 2.3 2.7 R 15 Rallye Golf 205/50 2.2 2.2 2.4 2.8 R 15 Emer‐ 4.2 gency spare wheel: Stand‐ Keep to the highest pressure required for the vehicle. ard wheel:

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front Vehicles with petrol engine:

Full load front rear

2.0

1.8

2.2

2.4

2.0

1.8

2.2

2.4

2.0

1.8

2.2

2.4

2.0

1.8

2.2

2.4

2.0

1.8

2.2

2.4

2.0

1.8

2.2

2.4

2.0

1.8

2.2

2.4

5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 Half load front rear Vehicles with diesel engine:

Full load front rear

185/55 2.0 1.8 2.2 2.4 R 15 195/50 2.0 1.8 2.2 2.4 R 15 Emer‐ 4.2 gency spare wheel: Stand‐ Keep to the highest pressure required for the vehicle. ard wheel:

5.7

Oil level: Check

Allow engine to stand for a few minutes (at least 3 minutes) so that the oil can flow back into the oil sump. – Pull out dipstick and wipe with a clean cloth and then push dipstick in again to limit stop. Note

Observe disposal regulations! – Pull dipstick out again and read oil level: Area -aArea -bArea -c-

Oil must be topped-up. After replenishing it is sufficient when the oil level is somewhere in area -b- . Oil need not be topped-up. Oil must not be replenished.

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is above area -c- .

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Engine oil: Drain or extract and top up; Renew oil filter

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5.8

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Special tools and workshop equipment required

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AG.

Prote cted by

c o p yri gh t . C op yi

38 5. Descriptions of work

do c um en

r te o iva r rp fo g n

♦ Oil extractor -V.A.G 1307 A- or

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 ♦ Oil extractor -V.A.G 1358 A-

G. Volkswagen AG d oes not gu ara nte eo ra c

Note

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urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

o yV db e ris tho au

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A agen 1331♦ Torque wrench -V.A.G lksw

♦ When the engine oil is drained and not extracted with oil ex‐

tractor -V.A.G 1307 A- or extractor -V.A.G 1358 A- , replace drain plug seal.

♦ Observe disposal regulations!

Oil drain plug torque settings: 30 Nm

Renew oil filter AG.

Note

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5.8.1

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Capacities with filter change: ⇒ Data sheets for exhaust emission test

Observe disposal regulations! – Loosen oil filter with tensioning strap (e.g. Hazet -2171-1- ) and remove oil filter. – Clean engine sealing surface. – Lightly oil rubber seal. – Screw on new filter and tighten hand-tight.

5.8.2

Engine oil: Replenish

Capacities with filter change: ⇒ Data sheets for exhaust emission test Use only the following approved engine oils ( ⇒ page 41 ) for reasons of their positive oil properties:

5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ agen AG. Volkswagen AG do es n w ot g olks Maintenance - Edition 08.2003 yV u

Oil specifications for petrol engines s s

ara nte e

B - Multi-grade oils, specification VW 501 01

rrectness of i t to the co nform spec at i h re o n wit in t his

- Multi-grade oils, specification API-SF39) or SG 39) 39) These oils may only be used when no authorised engine oil is available.

5.8.4

Diesel engine specifications

A - High-lubricity multi-grade oil, specification VW 500 00 B - Multi-grade oil, specification VW 505 00 (suitable, without res‐ ervations, for all diesel engines) - Multi-grade oil, specification API-CD Continuation for all engines

Prote cted by c o py rig ht . C op yi

Turbo engines: After changing engine oil and oil filter, check fol‐ lowing after first engine start:

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– The engine must only run at idling speed as long as the oil pressure warning lamp lights up in dash panel. Do not rev up! If the engine is revved up the turbocharger can be damaged or fail completely. AG.

– The full oil pressure is not attained until the warning lamp has gone out, only then can the engine be revved up. – After replenishing with oil, wait at least 3 minutes and then check oil level. – Pull out dipstick and wipe with a clean cloth and then push dipstick in again to limit stop. Note

Observe disposal regulations! – Pull dipstick out and read off oil level: Area -aArea -bArea -c-

Oil must be topped-up. After replenishing it is sufficient when the oil level is somewhere in area -b- . Oil need not be topped-up. Oil must not be replenished.

Note

A danger exists of damaging the catalytic converter when oil level is above area -c- .

40 5. Descriptions of work

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- Multi-grade oils, specification VW 501 01

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A - High-lubricity multi-grade oil, specification VW 500 00 or VW 502 00

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5.8.3

b ed ris o th au

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

5.8.5

Oil properties

5.8.6

Multi-grade oils conforming to VW standard 501 01 and 505 00 are oils with the following properties:

♦ All-year-round use in mild climates. ♦ Excellent cleansing abilities. ♦ Reliable lubricating abilities during all engine temperature and load conditions. . Volkswagen AG

AG ♦ High resistance to ageing. agen ksw

♦ All-year-round use at practically all ambient temperatures. ♦ Best possible cold starting abilities even at very low tempera‐ tures.

5.8.8

High-lubricity multi-grade oil conforming to VW standard 502 00:

Note

r fo ng

This petrol engine suitable oil corresponds to VW standards 501 00, 505 00 as well as 500 00 and has the following additional advantages: It is especially suitable for use under difficult oper‐ ating conditions, such as extremely difficult road conditions, or when predominantly towing a trailer, or high percentage of driving is in mountainous conditions and when driving in hot climatic zones.

♦ Single grade oils are not suitable for all-year-round use be‐

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cause of the single viscosity range. Therefore these oils should only be used in extreme climatic zones.

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

♦ Lower frictional loss in the engine.

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High-lubricity multi-grade oil conforming to VW standard 500 00 have the follow‐ ing additional properties:

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5.8.7

by ed ris o th au ss

Vol

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♦ When using SAE 5 W-30 multi grade oils, high engine speeds AG.

and continually heavy loading must be avoided. This restric‐ tion is not valid for high-lubricity multi-grade oils.

5.9

Engine and components in engine com‐ partment (from above and below): Per‐ form visual check for leaks and damage

Perform visual check as follows: – Check engine and components in engine compartment for leaks and damage. – Check hoses, lines and connections of ♦ Fuel system ♦ Cooling and heating system ♦ and brake system for leaks, abrasions, porosity and brittleness.

5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 Note ♦ Ensure that all faults detected are rectified within repair meas‐

ures.

♦ If fluid loss is greater than can be expected through normal

use, determine source and rectify (repair measure).

5.10

V-belt: Check condition and tension

5.10.1

Checking V-belt condition

– Check for: ♦ Substructure cracks (cracks, core ruptures, cross sectional breaks) ♦ Layer separation (top layer, cord strands) ♦ Base break-up ♦ Fraying of cord strands ♦ Flank wear (material wear, frayed flanks, brittle flanks -glassy flanks-, surface cracks) ♦ Traces of oil and grease Note

If faults are found, it is absolutely necessary to renew the V-belt. This will avoid possible breakdowns or operating problems. The replacement of a V-belt is a repair measure.

5.10.2

n AG. Volkswagen AG do Checking V-belt tension, es n wage tensioning V s k l ot g o yV ua belt if necessary b ra ed is or

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V-belt for alternator without tensioning device:

Special tools and workshop equipment required

Checking: approx. 5 mm deflection with thumb. agen lksw Vo by

AG.

Prote cted by

c o p yri gh t . C op yi

42 5. Descriptions of work

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♦ Torque wrench -V.A.G 1331-

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5.10.3

nte eo ra c ility ab y li an pt ce

th central point between the two pul‐ The V-belts are checked atauthe s leys that are the greatestsdistance apart from one another by using strong thumb pressure.

5.10.4

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Adjusting: un le

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– Swing alternator and tension V-belt to specification. es, in part or in w l purpos hole ercia , is n m ot com

V-belt for alternator with tensioning de‐ vice:

Special tools and workshop equipment required

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AG.

c o p yri gh t . C op yi

♦ Ring spanner insert -V.A.G 1410/2-

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♦ Torque wrench -V.A.G 1410-

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– Tighten securing bolt to 30 Nm.

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– Unbolt securing bolts for alternator support and for alternator to mounting at least one turn.

5.10.5

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

Prote cted by

Checking: approx. 5 mm deflection with thumb.

5.10.6

Adjusting:

The torque wrench -V.A.G 1410- in conjunction with the ring spanner insert -V.A.G 1410/2- -A- is especially suited for the following operation. – Unbolt all securing bolts for tensioning arm -A- and alternator and tensioning nut clamping bolt -B- at least one turn. – Tension V-belt to 4 Nm by turning tensioning nut using torque wrench -V.A.G 1410- and tighten tensioning nut clamping bolt -B- to 25 Nm. – Tighten alternator mounting securing bolts to 35 Nm and ten‐ sioning arm to lifting eye to 20 Nm.

5. Descriptions of work

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V-belt for power assisted steering vane pump:

Checking: approx. 5 mm deflection with thumb.

5.10.8

Adjusting:

– Unbolt securing bolts/nuts -1- and -2- at least one turn (bolt -2- is not visible and is located inside console). – Turn bolt -3- of tensioning device respectively; specification: approx. 5 mm deflection.

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Check poly V-belt condition AG.

– Check for:

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5.11.1

Poly V-belts: Check condition

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5.11

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– Tighten securing bolts/nuts.

♦ Substructure cracks (cracks, core ruptures, cross sectional breaks) ♦ Layer separation (top layer, cord strands) ♦ Base break-up ♦ Fraying of cord strands ♦ Flank wear (material wear, frayed flanks, brittle flanks -glassy flanks-, surface cracks) ♦ Traces of oil and grease Note ♦ It is essential to renew poly V-belt if faults are found. This will

avoid possible breakdowns or operating problems. The re‐ placement of a poly V-belt is a repair measure.

♦ It is not necessary to check and adjust the poly V-belt tension,

because a proper belt tension is guaranteed by a spring loa‐ ded tensioner -arrow- .

5.12

Manual gearbox/final drive: Check oil level Note

For vehicles with 5-speed manual gearbox 020, build date up to 07.09.1987, it is not possible to check the oil level because the oil level hole is too low. Valid for all other gearboxes:

44 5. Descriptions of work

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

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5.10.7

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d Golf 1984 ➤ , Jetta 1984 ➤ e nte is r o eo h Maintenance - Edition 08.2003 ut ra a c s s

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 – Remove oil filler plug. – Checking oil level: Oil level to lower edge of filler plug drilling. – If necessary replenish gearbox oil “Specification G 50 SAE 75W90 (synthetic oil)” . – Check oil level (oil level to lower edge of filler plug drilling). – Screw in oil filler plug.

5.13

Automatic gearbox: Check final drive oil level Note

Observe disposal regulations! – Unbolt final drive oil filler plug -arrow- . – Checking oil level: Oil level to lower edge of filler plug drilling. – Top up with gear oil if necessary.

AG. Volkswagen AG d agen oes

SAE 75 W 90 (synthetic)Volksw

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5.14

Automatic gearbox: Check ATF level

Special tools and workshop equipment required

Prote cted by

•

Vehicles on level surface

•

Handbrake pulled on

•

Selector lever at “P”

•

Engine running at idling speed

AG.

Test conditions:

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♦ Probe -V.A.G 1358 A2-

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♦ Oil extractor -V.A.G 1358 A- and

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♦

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♦

y db ise l -G 052 145 A1Container sizeor0.5 h ut sa Container ssize 1.0 l -G 052 145 A2-

5. Descriptions of work

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Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

Note

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pe rm itte d

– Check ATF level with dipstick. Cold ATF must be filled to at least -20 °C- marking, otherwise replenish ATF.

♦ Use non-fluffy cloth to wipe off dipstick.

♦ Only “ATF” with the designation “DEXTRON” may be replen‐

ished and lubricant additives are not permitted!

– Check ATF level with dipstick at a temperature of 50 ... 70 °C. The ATF level must be between the -min- . and -max- . marking of the dipstick. – If ATF level is too low, replenish “ATF” via a funnel. r te o iva r rp fo ng

– Check ATF level again (at 50 ... 70 °C)

5.15

Changing ATF (automatic gearbox)

Special tools and workshop equipment required ♦ Oil extractor -V.A.G 1358 A- and

♦ Probe -V.A.G 1358 A2♦ Torque wrench -V.A.G 1331-

Carry out the following procedure:

46 5. Descriptions of work

AG.

– With engine running and vehicle stationary select all selector lever positions once.

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Prote cted by c o p yri gh t. C op yi

Observe disposal regulations!

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Note

in t his d o cu m en

– If ATF level is too high, extract “ATF” with probe -V.A.G 1358 A2- and oil extractor -V.A.G 1358 A- .

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 – Extract “ATF” with probe -V.A.G 1358 A2- and oil extractor V.A.G 1358 A- . Quantity to be changed approx. 3.0 l Note ♦ Observe disposal regulations! ♦ The engine must not be started and the vehicle must not be

towed without “ATF” .

– Remove ATF filler pipe from oil sump. – Remove oil sump and ATF strainer.

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– Clean oil sump and ATF strainer.

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

pe rm itte d

During subsequent installation ensure absolute cleanliness! – Install ATF strainer. Securing bolt tightening torque: 4 Nm

rrectness of i t to the co nform spec a t i h re o n in wit thi s

– Install ATF filler pipe.

es, in part or in w l purpos hole ercia , is n m ot com

– Install oil sump with new gasket. Securing bolt tightening tor‐ que: 20 Nm. – First fill with 2.5 l ATF via a funnel and extension hose. Note

♦ Use non-fluffy cloth to wipe off dipstick. ♦ Only “ATF” with the designation “DEXTRON” may be replen‐

ished and lubricant additives are not permitted!

•

Handbrake pulled on

•

Selector lever at “P”

•

Engine running at idling speed

r te o iva r rp fo g n

AG.

Vehicles on level surface

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•

Prote cted by c o p yri gh t. C op yi

Test conditions:

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– Check ATF level with dipstick.

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– With engine running and vehicle stationary select all selector lever positions once.

– Cold “ATF” must be filled to at least the 20 °C marking, other‐ wise replenish “ATF” . – Check ATF level with dipstick at a temperature of 50 ... 70 °C. The ATF level must be between the min. and max. markings on the dipstick. – If ATF level is too low, replenish “ATF” via a funnel. – If ATF level is too high, extract “ATF” with probe -V.A.G 1358 A2- and oil extractor -V.A.G 1358 A- . – With engine running and vehicle stationary select all selector lever positions once. – Check ATF level again (at 50 ... 70 °C)

5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

5.16

Brake system: Perform visual check for leaks and damage

– Check brake master cylinder, brake servo (for anti-locking brake system: hydraulic unit), brake pressure regulator, brake calipers for leaks and damage. – Ensure that brake hoses are not twisted. – Ensure that brake hoses do not touch any vehicle components when steering is at full lock. – Check brake hoses for porosity or brittleness, brake hoses and brake lines for wear due to rubbing. – Check brake connections and fastenings for correct seating, leaks and corrosion. WARNING

Faults found must be rectified (repair measure).

5.17

Front and rear brake pads/linings: Check thickness

5.17.1

Front brake pads:

Special tools and workshop equipment required

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

Carry out the following procedure:

rrectness of i t to the co nform spec at i h re o n wit in t his

♦ Electric hand torch

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♦ Torque wrench -V.A.G 1332-

– For better evaluation of remaining pad thickness remove one wheel. When doing this mark position of wheel in relation to brake disc and after the check install in same position. Note

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AG.

Prote cted by

c o p yri gh t . C op yi

48 5. Descriptions of work

do c um en

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Experience has shown that brake pad wear on passenger side is slightly greater than on the driver side, therefore it is better to re‐ move the front wheel on passenger side.

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 – Measure inner and outer pad thickness a - Pad thickness without backplate Wear limit: 2 mm At a pad thickness of 2 mm (without backplate), the brake pads have reached their wear limit and must be renewed (repair meas‐ ure). – Fit wheel and tighten wheel securing bolts to 110 Nm.

5.17.2

Rear brake pads:

Special tools and workshop equipment required ♦ Electric hand torch and mirror Carry out the following procedure: – Determine thickness of outer pad by checking visually (illumi‐ nate area behind hole in wheel using a torch). – Determine thickness of inner pad by checking visually (using a torch and mirror). a - Pad thickness without backplate Wear limit: 2 mm

olkswagen AG en AG. V does not gu ara nte eo ra c

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5.17.3

t au ss

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ag At a pad thickness of 2 mm (without backplate), the kswbrake pads Vol y b have reached their wear limit and must be renewed (repair meas‐ ed ris ure). ho

Rear drum brake pads:

rrectness o f i t to the co n f orm spec atio h re n wit

es, in part or in w l purpos hole ercia , is n m ot com

– Check brake pad thickness through inspection holes in brake backplates -arrow- . - Wear limit: 2.5 mm (pad thickness only) Note

Check pads for brake fluid or grease contamination.

During visual check, also check floor pan, wheel housings and sills.

AG.

Prote cted by

Faults found must be rectified (repair measure). This inhibits cor‐ rosion and rusting through.

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c o p yri gh t. C op yi

Note

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Underbody protection: Perform visual check for damage

in t his d o cu m en

5.18

5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

5.19

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

Track rod ends: Check play, security and boots

rrectness o f i t to the co n f orm spec atio h re n wit

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pe rm itte d

– Check mountings. – Check boots are not damaged and are seated correctly.

5.20

Swivel joints: Perform visual check r te o iva r rp fo ng

Carry out the following procedure: – Check swivel joint boots -arrow- for leaks and damage.

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AG.

Prote cted by c o p yri gh t. C op yi

Cooling system: Check frost protection and coolant level

For all engines only fill with frost and corrosion protection additive G 12 Plus according to TL VW 774 F (lilac). G 12 Plus (lilac) can be mixed with the coolant additive G 12 (red) and also with G 11 (green)! Note ♦ G 12 Plus is suitable as a filled-for-life filling for cast iron and

all-aluminium engines and gives optimum protection against frost, corrosion damage, scaling and over-heating.

♦ G 12 Plus raises the boiling point to 135 °C and ensures better

heat dissipation.

♦ The coolant concentration must be at least 40% (frost protec‐

tion to -25 °C) and should never exceed 60% (frost protection to -40 °C). Otherwise both frost protection and cooling effect will be reduced.

♦ Protection against frost must be assured to about -25 °C (in

arctic climatic countries to about -35 °C).

50 5. Descriptions of work

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5.21

in t his d o cu m en

es, in part or in w l purpos hole ercia , is n m ot com

– With vehicle raised (wheels hanging free), check play by mov‐ ing track rods -arrow- and wheels. Play: Zero play

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Carry out the following procedure:

5.21.1

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

Checking frost protection, replenishing coolant additive if necessary

♦ Refractometer -T10007-

Note

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urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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Special tools and workshop equipment required un le

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

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Read precise value for the following tests at bright/dark boundary. Using a pipette, place a drop of water on the glass to improve the readability of the bright/dark boundary. The bright/dark boundary can be clearly recognised on the “WATERLINE” . agen lksw Vo by

Prote cted by c o py rig ht . C op yi

– Check concentration of coolant additive using refractometer T10007- (refer to operating instructions). AG.

The scale -1- of the refractometer is calibrated for coolant addi‐ tives -G 12 Plus and -G 11-. The scale -2- is calibrated for coolant additive -G 13- (VW L80). Note ♦ Protection against frost must be assured to about -25 °C (in

arctic climatic countries to about -35 °C).

♦ If for climatic reasons a greater frost protection is required, the

amount of G 12 can be increased, but only up to 60 % (frost protection to about -40 °C), as otherwise frost protection is re‐ duced again and cooling effectiveness is also reduced.

– If frost protection is insufficient, drain off required quantity shown in frost protection table ( ⇒ page 51 ) and add coolant additive G 12 Plus (lilac). Note

Observe disposal regulations!

5.21.2

Frost protection table

Frost protection to °C Actual value

Specified val‐ ue

-25 -35

Quantity to drain in litres expansion tank without with 2.0 3.0

3.5 4.0 5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

un le

Frost protection to °C

without

with

-5

-25 -35 -25 -35 -25 -35 -25 -35 -35 -35 -40

2.0 3.0 1.5 2.5 1.0 2.0 0.5 1.5 1.0 0.5 0.5

3.0 3.5 2.0 3.0 1.5 2.0 1.0 1.5 1.0 0.5 0.5

-10 -15 -20 -25 -30 -35

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

Specified val‐ ue

– After road test check coolant additive concentration. r fo ng

Checking coolant level, replenishing coolant if necessary Prote cted by

– If coolant is too low, add required amount according to mixture ratio.

5.21.4

Mixture ratio:

Frost protection to -25 °C -35 °C -40 °C

Coolant additive G 12 Plus approx. 40 % approx. 50 % approx. 60 %

Water approx. 60 % approx. 50 % approx. 40 %

Note ♦ G 12 Plus (lilac) and coolant additives "according to TL VW

774 F" prevent frost and corrosion damage, scaling and also raise the boiling point of coolant. For this reason the system must be filled all year round with frost and corrosion protection additives.

♦ The coolant concentration must not be reduced by adding wa‐

ter even in warmer seasons and in warmer countries. The coolant additive ratio must be at least 40 %.

♦ Because of its high boiling point, the coolant improves engine

reliability under heavy loads, particularly in countries with trop‐ ical climates.

52 5. Descriptions of work

AG.

The oil level must be between the min. and max. markings.

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c o p yri gh t . C op yi

– Check coolant level on expansion tank with engine cold.

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5.21.3

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Actual value

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Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

Camshaft drive toothed belt: Checkencon‐ AG. Volkswagen AG d ag oes ksw not l o dition and tension (diesel engine) V gu y b

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Checking toothed belt condition pe rm itte d

– Check for:

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5.22.1

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5.22

rrectness o f i t to the co n f orm spec atio h re n wit

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♦ Cracks, cross sectional breaks

♦ Layer separation (toothed belt body, draw strands) ♦ Toothed belt body break-up ♦ Fraying of cord strands

♦ Surface cracks (synthetic coating) ♦ Traces of oil and grease Note

r te o iva r rp fo ng

Checking toothed belt tension, tension toothed belt if necessary AG.

Prote cted by

♦ Torque wrench -V.A.G 1331-

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c o p yri gh t. C op yi

Special tools and workshop equipment required

ht rig py Co t.

5.22.2

in t his d o cu m en

If faults are found always renew toothed belt. This will avoid pos‐ sible breakdowns or operating problems. The replacement of a toothed belt is a repair measure.

♦ V and toothed belt tester -VW 210-

5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

rrectness o f i t to the co n f orm spec atio h re n wit

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pe rm itte d

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♦ Pin wrench Matra -V 159-

Carry out the following procedure: – Remove upper toothed belt cover. – Measure toothed belt tension between camshaft sprocket and injection pump sprocket using tester V and toothed belt tester -VW 210- . Specification: Scale value 12 ... 13. r te o iva r rp fo ng

– Loosen tensioning roller securing nut.

5.23

Valve clearance: Check (engine code GT)

Special tools and workshop equipment required ♦ -FühlerblattlehreEngine warm (cylinder head hand-warm)

Inlet valve Exhaust valve

Test value (mm)

Adjustment value (mm)

0.15 ... 0.20 0.25 ... 0.30

0.15 0.25

Engine cold (room temperature)

Inlet valve

54 5. Descriptions of work

Test value (mm)

Adjustment value (mm)

0.10 ... 0.15

0.10

AG.

– Install toothed belt cover.

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– Tighten tensioning roller securing nut to 45 Nm.

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– Turn tensioning roller clockwise using pin wrench Matra -V 159- -arrow- , until the specification is achieved.

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If actual value is outside tolerance then tension toothed belt as follows:

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

Exhaust valve

Test value (mm)

Adjustment value (mm)

0.20 ... 0.25

0.20

Carry out the following procedure: – Turn crankshaft so that the pair of cams of the cylinder to be adjusted evenly faces upwards. – Check valve clearance between camshaft and rocker finger. -A- Exhaust valve -E- Inlet valve – If the test values are outside tolerance, adjust valve clearance by turning the ball head screw to relevant specification. – Renew cylinder head cover gasket.

Contact breaker points: Renew (engine code GT)

♦ Ignition tester -V.A.G 1767-

5.24.1

Renewing: ht rig py Co t.

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– Grease mounting of breaker lever -A- , cam running surface and plastic cam follower -B- with multi-purpose grease (grease sachet).

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urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

Special tools and workshop equipment required

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5.24

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– Remove grease when it comes into contact with surface. agen lksw Vo by

AG.

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Note

♦ When installing contact breaker points always ensure that the

journal on contact breaker point engages in determined hole of base plate.

♦ Ensure that the contact surfaces of contact breaker points and

lever align, if necessary realign.

– Oil lubricating felt of distributor shaft (if fitted).

5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

5.24.2

Adjusting:

Note

First adjust dwell angle and then ignition timing. When dwell angle is changed, also ignition timing is changed.

Checking and adjusting dwell angle

5.24.4

Checking: pe rm itte d

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5.24.3

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Note

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When checking and adjusting the dwell angle, the bearing cap for the ignition distributor must be fitted firmly. Always check dwell angle when the engine is running. Observe specification (wear limit)! ⇒ Data sheets for exhaust emission test

5.24.5

Adjusting:

– Change contact gap at starter motor speed until the correct dwell angle is shown. Observe specification (wear limit)! ⇒ Data sheets for exhaust emission test r te o iva r rp fo ng

– Check dwell angle when the engine is running.

AG.

Prote cted by

5.25

Fuel filter: Renew

5.25.1

Carburettor engine (filter in engine com‐ partment)

Note installation position! Note

Flow direction is marked by arrows (do not interchange connec‐ tions). – Check fuel system for leaks (visual check).

56 5. Descriptions of work

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After adjusting the dwell angle readjust ignition timing.

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Note

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– Tighten clamping bolt and check if dwell angle has changed.

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

5.25.2

Diesel engine

Note ♦ Please ensure that no diesel fuel contacts coolant hoses. If

necessary clean hose immediately.

♦ Observe disposal regulations!

5.25.3

Filter without fuel preheating:

– Pull hose off fuel tank to filter -A- . – Pull hose off filter to injection pump -B- . gen AG does not gu ara nte eo ra c

Filter with fuel preheating:

rrectness o f i t to the co n f orm spec atio h re n wit

5.25.4

– Pull off retaining clip -5- . – Remove control valve with fuel lines connected. – Fit new O ring. – Install control valve with fuel lines connected. – Fit retaining clip -5- .

Flow direction is marked by -arrows- (do not interchange connec‐ tions). agen lksw Vo by

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– Check fuel system for leaks (visual check).

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Note

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– Push fuel hoses over hose connections -1- and -2- and secure hoses with hose clips.

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– Push fuel hoses over hose connections -A- and -B- and secure hoses with hose clips. Volkswa

– Operate throttle repeatedly and when engine is at idling speed fuel must flow bubble-free through the transparent line. AG.

Prote cted by

5.26

Fuel filter: Drain water (diesel engine) Note

♦ Please ensure that no diesel fuel contacts coolant hoses. If

necessary clean hose immediately.

♦ Observe disposal regulations!

5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

5.26.1

Filter without fuel preheating:

– Loosen bleed screw -arrow A- . – Loosen drain screw -arrow B- and drain approx. 100 cm3 fluid. – Tighten drain screw and bleed screw.

5.26.2

Filter with fuel preheating:

– Pull off retaining clip -5- and take off regulating valve -B- with fuel lines connected. – Drain approx. 100 cm3 fluid at drain screw (filter lower part). – Install control valve and fit retaining clip. – Tighten water drain screw.

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s Check fuel ssystem for leaks (visual check).

Carry out the following procedure: – Check oil level with engine running and front wheels at straight-ahead position. – If necessary replenish with the following oil: power assisted steering - oil -G 002 000Note r te o iva r rp fo ng

♦ If oil level is above MAX. marking, the oil must be extracted. ♦ If oil level is below MIN. marking, then the hydraulic system

must be checked for leaks (repair measure). It is not sufficient merely to top up with oil. If the hydraulic system is not leaking, replenish power assisted steering oil -G 002 000- . Prote cted by

Special tools and workshop equipment required

AG.

58 5. Descriptions of work

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Change brake fluid

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5.28

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Power assisted steering: Check fluid level

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5.27

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– Operate throttle several times. Then fuel must flow bubble-free through the transparent line when engine is at idling speed.

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–

With and without preheating:

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5.26.3

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 ♦ Brake filling and bleeding unit -VAS 5234-

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

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♦ Adapter -VAS 5234/1- or

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♦ Brake filling and bleeding unit -V.A.G 1869- or

♦ Brake filling and bleeding unit with upgrade kit -V.A.G 1869/4♦ Brake pedal depressor -V.A.G 1869/2ht rig py Co t.

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5.28.1

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♦ Adapter -V.A.G 1869/1-

Vehicles without anti-locking brake sys‐ tem:

Use only new brake fluid -B 000 7000 A- (corresponds to US standard FMVSS 116 DOT 4)

5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 WARNING

♦ Brake fluid must under no circumstances come into con‐ tact with fluids containing mineral oils (oil, petrol, cleaning solutions). Mineral oils will damage seals and sleeves of brake system. ♦ Brake fluid is poisonous. In addition, due to its corrosive nature, it must not come into contact with paint. ♦ Brake fluid is hygroscopic, i.e. it attracts moisture from the surrounding air and therefore must always be stored in airtight containers. ♦ Wash away spilt brake fluid using plenty of water. ♦ Observe disposal regulations! Carry out the following procedure: Observe ⇒ operating instructions for brake filling and bleeding unit -VAS 5234- or for brake filling and bleeding unit -V.A.G 1869- . – Unbolt cap from brake fluid reservoir. – Extract as much brake fluid as possible from brake fluid res‐ ervoir using suction hose of brake filling and bleeding unit VAS 5234- or of brake filling and bleeding unit -V.A.G 1869(with upgrade kit). – Extract as much brake fluid as possible using a suction bottle with built-in strainer from brake filling and bleeding unit -V.A.G . Volkswagen AG 1869- (without upgrade kit). gen AG does swa

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WARNING

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Ensure that no brake fluid runs through the strainer after extrac‐ tion (the brake fluid level in the reservoir must not be lower than the lower edge of the strainer).

Do not reuse extracted (used) brake fluid. – Place brake pedal depressor -V.A.G 1869/2- between driver seat and brake pedal and tension it. – Screw adapter -VAS 5234/1- or adapter -V.A.G 1869/1 A- onto brake fluid reservoir.

r te o iva r rp fo ng

– Remove caps from bleed screws of wheel brake cylinders and brake calipers.

Prote cted by

60 5. Descriptions of work

AG.

Repeat procedure on other side of vehicle at rear.

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40) Start at rear right of left-hand drive vehicles and at rear left of right-hand drive vehicles.

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– Push collector bottle bleed hose onto rear bleed screw 40) , open bleed screw and allow appropriate quantity of brake fluid to flow out (see table on ⇒ page 61 ). Close bleed screw.

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– Connect filling hose of brake filling and bleeding unit -VAS 5234- or of brake filling and bleeding unit -V.A.G 1869- to adapter.

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 – Push collector bottle bleed hose onto front bleed screw 41) , open bleed screw and let appropriate quantity of brake fluid run out (see following table). Close bleed screw. 41) Start at front right of left-hand drive vehicles and at front left of right-hand drive vehicles.

Repeat procedure on other side of vehicle at front.

5.28.2

Table - Sequence and quantity of brake fluid

Sequence: Brake calipers (LHD vehicles) Rear right Rear left Front right Front left Total quantity

Brake fluid quantity which must flow out of brake calipers: 0.4...0.5 litre 0.4...0.5 litre 0.4...0.5 litre 0.4...0.5 litre olkswagen AG 2. Vlitres gen AG d

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by – Fit caps on bleed screws ed of brake calipers.

–

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(⇒ operating instructions ).

– Remove filler hose from adapter. es, in part or in w l purpos hole ercia , is n m ot com

– Check brake fluid level and correct if necessary. – Screw on cap of brake fluid reservoir. – Remove brake pedal depressor -V.A.G 1869/2- . – Check pressure and free travel of brake pedal. Free play: max. 1 / of pedal travel. 3

5.28.3

Vehicles with anti-locking brake system:

Front axle

– Switch off ignition and depress brake pedal approx. 20 times to reduce the reservoir pressure. Prote cted by c o py rig ht . C op yi

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Brake fluid level (dependent upon lining/ pad wear): Check AG.

5.29

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– Extract as much brake fluid as possible from brake fluid res‐ ervoir with a suction bottle.

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Quantity to change: 2.5 l (larger quantity is dependent on the size of container).

rrectness of i t to the co nform spec a t i h re o n in wit thi s

– Unbolt adapter -VAS 5234/1- or adapter -V.A.G 1869/1 Afrom brake fluid reservoir.

Only use new brake fluid -B 000 700 A- . (corresponds to US standard FMVSS 116 DOT 4)

5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 WARNING

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte s i r The max. marking must not be exceeded, because brake fluid o eo h ut ra a flows out of reservoir. c s s pe rm itte d

es, in part or in w l purpos hole ercia , is n m ot com

– The fluid level must always be judged in conjunction with lin‐ ing/pad wear. When vehicle is in use, fluid level tends to drop slightly due to lining/pad wear and automatic adjustment. – When fluid level is at min. marking or just above, fluid should not be replenished if brake pads are almost at wear limit. – If brake pads are new or well above wear limit then fluid level must be between min. and max. marking.

Battery: Check Prote cted by c o p yri gh t. C op yi

♦ Battery tester with printer -VAS 5097 A- or

62 5. Descriptions of work

AG.

♦ Battery tester -VAS 5096-

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♦ Battery tester with printer -VAS 5097- or

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Special tools and workshop equipment required

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5.30

r te o iva r rp fo g n

– If fluid level is below min. marking, the brake system should be checked before fluid is added (repair measure).

rrectness of i t to the co nform spec a t i h re o n in wit thi s

For the brake system with “ABS” the pressure accumulator of the hydraulic brake servo is also supplied from the brake fluid reser‐ voir. The fluid level must only be checked, after the electric hydraulic pump has built-up the operating pressure with ignition switched on. This can take up to one minute. If the operating pressure is reduced, the fluid level may slightly be above the max. marking.

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Note

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

♦ Commercially available hydrometer

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AG.

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5.30.1

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♦ Torque wrench -V.A.G 1331-

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♦ Battery filler bottle -VAS 5045-

Inspection service (batteries with “magic eye” )

Perform a visual check ⇒ page 64 and a battery check with the “magic eye” ⇒ page 64 .

5.30.2

Inspection service (batteries without “magic eye” )

Perform a visual check ⇒ page 64 and an electrolyte level check ⇒ page 67 . If distilled water is topped up, perform an additional battery load test ⇒ page 65 .

5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

5.30.3

Performing visual check (all batteries)

Carry out the following procedure: – Check battery casing for damage. Battery acid can leak out if housing is damaged. – Check battery terminals (battery cable connections) for dam‐ age. If battery terminals are damaged, contact with wiring connections cannot be guaranteed. This may lead to a cable fire resulting in electrical system malfunction. – Check battery is located securely, tighten clamp securing bolt -1- to 22 Nm if necessary. If the battery is not properly secured, there is a danger of the fol‐ lowing: ♦ Shortened service life caused by vibration damage (danger of explosion). ♦ Improper securing of battery can damage battery plates. ♦ Damage to battery casing by clamping bracket (possible leak‐ age of acid with high consequential costs). ♦ Poor crash safety.

5.30.4

Checking battery / batteries lkswagmagic owith en AG en AG. V does wagcell s k not l eye and covered-over sealing plugs o V gu y b ed

ris magic eye and without cell seal‐ Checking battery / batteries with tho u ing plugs ⇒ page 69 sa

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– Before performing a visual check, tap magic eye lightly and carefully with the handle of a screwdriver. Tapping will cause air bubbles, which can hamper the display, to dissipate. Consequently, the colour display of the “magic eye” will be more accurate. Note

♦ The magic eye can be located at various positions on the bat‐

tery.

♦ Three display colours are possible: Green → the battery is charged sufficiently.

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Transparent or yellow → critical electrolyte level has been reached, it is essential that distilled water be added ⇒ page 66 . Following this, perform battery load test ⇒ page 65 . AG.

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Note

If the battery is more than 5 years old and the magic eye is a light or yellowish colour, the battery should be renewed following cus‐ tomer approval.

64 5. Descriptions of work

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Black → no charge or charge is insufficient (repair measure).

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The magic eye -arrow- provides information concerning the level of the electrolyte and the battery charge.

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Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

5.30.5

Battery load test

Note ♦ The following description is calibrated for the battery tester

with printer -VAS 5097 A- . When performing the battery load test with a different battery tester ⇒ Operating instructions for respective battery tester .

♦ When using the battery tester with printer -VAS 5097 A- or the

battery tester with printer -VAS 5097- it is not necessary to remove the battery. Nor does the battery need to be discon‐ nected.

– Switch off ignition. – Connect tester cable clamps to battery terminal ⇒ Operating instructions for respective battery tester The clamps must have a good contact with the battery terminals.

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– The load current varies and must be set on the tester accord‐ ing to the battery capacity. ⇒ Operating instructions for re‐ spective battery tester

5. Descriptions of work

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Prote cted by c o p yri gh t. C op yi

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 – Perform battery load test according to ⇒ operating instructions AG. Volkswagen AG d for respective battery tester and compare test agen oes wprintout s k not l Vo -arrow- with following table. gu by a ed ris ho t au 1 - Measuring range set on tester ss

ran tee or ac

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3 - Test result

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4 - Battery voltage while load test is running 5 - Vehicle data and date (to be completed by person performing test) Battery tester print-out Battery very good Battery good Battery sufficient Battery poor Battery very poor Not testable

Inspection service Battery OK Battery OK Charge battery42) Charge battery42) Charge battery42) Charge battery42)

42) If after recharging battery, the display shows “battery sufficient, battery poor, battery very poor or cannot be tested” , replace battery in agreement with the customer. Prote cted by

If the battery is OK, the voltage does not drop below the minimum voltage. If the battery is defective or has a weak charge, the battery voltage quickly drops below the specified minimum voltage. After the test has been completed, this low voltage value remains over a long period, and the voltage increases again only slowly.

5.30.6

Topping up with distilled water (batteries with magic eye)

To prevent electrolyte contamination, which leads to increased self-discharge, use only distilled water “when replenishing the electrolyte” . Carry out the following procedure: – Pull off foil covering the sealing plug. – Remove battery sealing plug.

66 5. Descriptions of work

AG.

The high load on the battery (a high current flows) during this test causes the battery voltage to drop.

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Explanation of battery load test:

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After battery is recharged, perform a battery load test again.

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2 - Diagram (arrow indicates battery state)

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Note

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– Replenish with distilled water to max. mark -arrow- using bat‐ tery filler bottle -VAS 5045- .

♦ The construction of filler support of battery filler bottle -

VAS 5045- prevents an overfilling of the battery cells and therefore prevents electrolyte leaking out. When the max. level is reached the flow of distilled water into the cells is interrupted.

♦ When the electrolyte level is too low (below the min. marking)

♦ If the electrolyte level is too high (above the max. marking) the

AG.

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Checking electrolyte level (batteries without magic eye)

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5.30.7

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– Fit battery sealing plugs.

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leaking electrolyte (sulphuric acid/water mixture) will cause damage outside the battery, i.e. to components in engine com‐ partment.

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the cell plates dry and there is a loss of battery capacity (loss of power). If the cell plates are not enclosed by electrolyte (sulphuric acid), corrosion will occur on the plates, plate bridges and cell connector. The function of the battery cannot be guaranteed if corrosion occurs. The battery will become unusable.

Markings on battery housing -arrowNote

The correct battery electrolyte level is an important factor in en‐ suring a long service life for the battery.

5.30.8

Electrolyte level too low

Note

When the electrolyte level is too low (below the min. marking) the cell plates dry and there is a loss of battery capacity (loss of pow‐ er). If the cell plates are not enclosed by electrolyte (sulphuric acid), corrosion will occur on the plates, plate bridges and cell connector. The function of the battery cannot be guaranteed if corrosion occurs. The battery will become unusable. To prevent electrolyte contamination, which leads to increased self-discharge, use only distilled water “when replenishing the electrolyte” . – Remove battery sealing plug. – Replenish with distilled water to max. mark using battery filler bottle -VAS 5045- .

5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 Note

The construction of filler support of battery filler bottle -VAS 5045prevents an overfilling of the battery cells and therefore prevents electrolyte leaking out. When the max. level is reached the flow of distilled water into the cells is interrupted. – Fit battery sealing plugs.

5.30.9

Electrolyte level too high

Note

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– Remove battery sealing plug.

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If the electrolyte level is too high (above the max. marking) the. Volkswagen AG d gen AG oes swa leaking electrolyte (sulphuric acid/water mixture) will dam‐ kcause not l o gu yV ara age outside the battery, i.e. to components in eengine compart‐ db nte s i r ment. o e h t

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If the electrolyte level is too high (overfilled), e.g. lies above inner electrolyte level marking (synthetic material) or above the exterior marking: – Draw off electrolyte with a hydrometer until the electrolyte level reaches the synthetic material web -1- or the max. marking. Note

Observe disposal regulations!

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68 5. Descriptions of work

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– Fit battery sealing plugs.

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

5.30.10

Checking battery / batteries with magic eye and without cell sealing plugs

You can identify these batteries by the “magic eye” -1- and a cover -2- (as shown in the illustration). Note

The “magic eye” can be located at various positions on the bat‐ tery. AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo The cover serves only for filling during production. The cover h t u ra a c must not be removed under any circumstances, because this s s

WARNING

The magic eye provides information concerning the electrolyte level and the charge state of battery. – Before performing a visual check, tap magic eye lightly and carefully with the handle of a screwdriver. Tapping will cause air bubbles, which can hamper the display, to dissipate. Consequently, the colour display of the “magic eye” will be more accurate. Three display colours are possible: – Green → the battery is charged sufficiently. – Black → no charge or insufficient charge. The battery must be charged (repair measure). – Colourless or yellow → the battery must be renewed.

5.31.1

Checking

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Clutch play: Check ht rig py Co t.

5.31

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will lead to battery damage. The battery will become unusable.

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– Check free travel of brake pedal (play 15 ... 20 mm). Prote cted by

Adjusting

AG.

5.31.2

Adjust clutch play at adjustment nut -arrow- : – Depress clutch pedal several times. Check play. – Lubricate threaded part of clutch cable with multi-purpose grease . Manual gearbox 020

5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 Manual gearbox 084

5.32

Engine basic setting: Perform settings

5.32.1

Procedure according to engine codes:

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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⇒ page 82 ⇒ page 85 ⇒ page 88 ⇒ page 91 ⇒ page 96 ⇒ page 100

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

Engine codes: ABN, EZ, GU

Special tools and workshop equipment required

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AG.

70 5. Descriptions of work

Prote cted by c o py rig ht . C op yi

♦ Ignition tester -V.A.G 1367-

ht rig py Co t.

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♦ Ignition tester -V.A.G 1767- or

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

5.32.2

⇒ page 70 ⇒ page 73 ⇒ page 75 ⇒ page 78

ility ab y li an pt ce

ABN, EZ, GU EV GX (K Jetronic) GX (KE Jetron‐ ic) NZ PB, PF, 1P PG, 1H PL PN RD

rrectness of i t to the co nform spec a t i h re o n in wit thi s

un le

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

ility ab y li an pt ce

♦ Trigger clamp -V.A.G 1367/8-

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ra ir se Golf 1984 ➤ n,teJetta 1984 ➤ o eo h t u r a 08.2003 a Maintenance Edition c ss

do c um en

ht rig py Co t.

r te o iva r rp fo g n

♦ 4 component exhaust emission tester -V.A.G 1787- or

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AG.

Prote cted by

c o p yri gh t . C op yi

♦ 4 component exhaust emission tester -V.A.G 1788- and ♦ Hose adapter -V.A.G 1363/3Note ♦ For all relevant engine basic setting test prerequisites and da‐

ta: ⇒ Data sheets for exhaust emission test

♦ To prevent injuries to personnel and/or damage to ignition and

injection system, the ignition system wiring (including high voltage wiring) should be connected and disconnected only with ignition switched off.

5.32.3

Performing visual check of components influencing emissions

⇒ Data sheets for exhaust emission test – Perform visual check for: ♦ Installation ♦ Completeness ♦ Leakage ♦ Damage Note

Faults found are to be rectified.

5.32.4

Connecting test units

– Pull on handbrake. 5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 AG. Volkswagen AG d agen o

es n w – Automatic gearbox:VSelector lever in position “P” or ot g“N” . olks by ed

ua ran tee

ris Gear lever in neutral. – Manual gearbox: ho

t au

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or ac

es, in part or in w l purpos hole ercia , is n m ot com

For vehicles without CO sampling pipe connect CO tester to ex‐ haust tail pipe.

5.32.5

Test sequence

– Start engine and run at idling speed.

Note

The ignition timing is displayed directly on ignition tester with “TDC sender” .

ht rig py Co t.

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– When checking or adjusting ensure the diaphragm rod -A- is at idling position and the adjustment screw -B- (for cold idling speed) contacts the diaphragm rod. AG.

– Check idling speed and CO content (at idling), if necessary adjust by alternately turning the idling speed regulating valve -A- and CO adjustment screw -B- .

-A- Idling speed regulating valve

72 5. Descriptions of work

do c um en

r te o iva r rp fo g n

– Check ignition timing, if necessary adjust by turning distributor.

rrectness of i t to the co nform spec a t i h re o n in wit thi s

– Connect 4 component exhaust emission tester -V.A.G 1787or 4 component exhaust emission tester -V.A.G 1788- to CO sampling pipe using hose adapter -V.A.G 1363/3- .

ility ab y li an pt ce

s – Connect signition tester -V.A.G 1367- with trigger clamp V.A.G 1367/8- or ignition tester -V.A.G 1767- with ignition switched off.

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 -B- CO adjustment screw – If CO adjustment to the relevant test value is not possible, perform repair measures! – Seal CO adjustment screw with new anti-tamper plug. After completing basic engine setting note the following: ♦ Operate assemblies e.g. power-assisted steering, automatic gearbox, air conditioning system and check that the engine operates smoothly under these load conditions. ♦ Reconnect all hoses and connections that have been discon‐ nected or separated for checking and adjusting purposes.

5.32.6

Engine code: EV

Special tools and workshop equipment required ♦ Ignition tester -V.A.G 1767- or

♦ Ignition tester -V.A.G 1367-

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

♦ 4-component exhaust emission tester -V.A.G 1788-

ht rig py Co t.

r fo ng

♦ 4 component exhaust emission tester -V.A.G 1787- or

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

ility ab y li an pt ce

un le

♦ Trigger clamp -V.A.G 1367/8-

agen lksw Vo by

5. Descriptions of work

AG.

Prote cted by

c o p yri gh t . C op yi

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 Note ♦ For all relevant engine basic setting test prerequisites and da‐

ta: ⇒ Data sheets for exhaust emission test

♦ To prevent injuries to personnel and/or damage to ignition and

injection system, the ignition system wiring (including high voltage wiring) should be connected and disconnected only with ignition switched off. swagen AG. Volkswagen AG does

not gu ara nte eo ra c

pe rm itte d

⇒ Data sheets for exhaust emission test es, in part or in w l purpos hole ercia , is n m ot com

– Perform visual check for:

rrectness of i t to the co nform spec a t i h re o n in wit thi s

♦ Installation

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Performing visual check of components influencing emissions un le

5.32.7

k Vol by d e ris tho u a ss

♦ Completeness ♦ Leakage ♦ Damage Note

Faults found are to be rectified.

Connecting test units

– Pull on handbrake. – Automatic gearbox: Selector lever in position “P” or “N” . c o p yri gh t. C op yi

– Connect ignition tester -V.A.G 1367- with trigger clamp V.A.G 1367/8- or ignition tester -V.A.G 1767- with ignition switched off.

ht rig py Co t.

– Manual gearbox: Gear lever in neutral. agen lksw Vo by

AG.

Prote cted by

– Connect 4 component exhaust emission tester -V.A.G 1787or 4 component exhaust emission tester -V.A.G 1788- to tail pipe (seal 2nd tail pipe).

5.32.9

Test sequence

– Start engine and run at idling speed. – Pull vacuum hose off ignition distributor and seal. – Check ignition timing, if necessary adjust by turning distributor.

74 5. Descriptions of work

do c um en

r te o iva r rp fo g n

5.32.8

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

pe rm itte d

un le

“TDC sender” .

ility ab y li an pt ce

♦

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d Note e nte is r o eo h ut ra a c s The ignition timing is displayed directly on signition tester with

♦ With strobe lamp the strobe must be directed at ignition timing es, in part or in w l purpos hole ercia , is n m ot com

marks.

RON 95 is used.

rrectness o f i t to the co n f orm spec atio h re n wit

♦ The ignition timing mark is not valid when super unleaded – Connect vacuum hose to ignition distributor. – Check idling speed and CO content (at idling speed), if nec‐ essary correct by turning the adjustment screws alternately. A - Idling speed adjustment screw B - CO adjustment screw

♦ When adjusting, do not push down the adjustment wrench.

Prote cted by c o py rig ht . C op yi

♦ Do not operate throttle when adjustment wrench is inserted.

AG.

and operate throttle before the duty cycle is read.

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♦ Remove adjustment wrench after every adjusting procedure

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Note

in t his d o cu m en

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– If CO adjustment to the relevant test value is not possible, perform repair measures!

♦ After completing basic engine setting note the following: ♦ Operate assemblies e.g. power-assisted steering, automatic

gearbox, air conditioning system and check that the engine operates smoothly under these load conditions.

♦ Reconnect all hoses and connections that have been discon‐

nected or separated for checking and adjusting purposes.

5.32.10

Engine code: GX (K Jetronic)

Special tools and workshop equipment required ♦ Ignition tester -V.A.G 1767- or

♦ Ignition tester -V.A.G 1367-

5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

ility ab y li an pt ce

AG.

♦ Hose adapter -V.A.G 1363/3- and

agen lksw Vo by

Prote cted by c o py rig ht . C op yi

♦ 4 component exhaust emission tester -V.A.G 1788- and ♦ Test lead -V.A.G 1367/5Note

♦ For all relevant engine basic setting test prerequisites and da‐

ta: ⇒ Data sheets for exhaust emission test

♦ To prevent injuries to personnel and/or damage to ignition and

injection system, the ignition system wiring (including high voltage wiring) should be connected and disconnected only with ignition switched off.

5.32.11

Performing visual check of components influencing emissions

⇒ Data sheets for exhaust emission test – Perform visual check for: ♦ Installation ♦ Completeness ♦ Leakage ♦ Damage Note

Faults found are to be rectified.

76 5. Descriptions of work

ht rig py Co t.

r fo ng

♦ 4 component exhaust emission tester -V.A.G 1787- or

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

un le

♦

AG. Volkswagen AG d agen oes ksw not l o gu Trigger clamp -V.A.G 1367/8yV b ara d e nte is r o eo h ut ra a c s s

5.32.12

Golf 1984 ➤ , Jetta 1984 ➤ n AG. Volkswagen AG do es n wage s k l ot g o Maintenance - Edition 08.2003 V y ua db ran ir se tee ho or ut ac a ss

Connecting test units un le

pe rm itte d

ility ab y li an pt ce

– Pull on handbrake.

– Automatic gearbox: Selector lever in position “P” or “N” . es, in part or in w l purpos hole ercia , is n m ot com

– Connect ignition tester -V.A.G 1367- with trigger clamp V.A.G 1367/8- or ignition tester -V.A.G 1767- with ignition switched off.

– Clamp idling speed boost valve hose -1- together ensuring that there are no leaks. – Pull hose -2- off intake manifold and hose -3- off air cleaner. c o p yri gh t . C op yi

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AG.

Prote cted by

5.32.13

ht rig py Co t.

– Attach angled piece -4- so that the free connection with the restricted hole is inserted into the air intake duct.

do c um en

r te o iva r rp fo g n

– Connect 4 component exhaust emission tester -V.A.G 1787or -V.A.G 1788- to CO sampling pipe using hose adapter V.A.G 1363/3- .

rrectness of i t to the co nform spec a t i h re o n in wit thi s

– Manual gearbox: Gear lever in neutral.

Test sequence

– Start engine and run at idling speed. – Pull vacuum hose off ignition distributor. – Check ignition timing, if necessary adjust by turning distributor. Note ♦ The ignition timing is displayed directly on ignition tester with

“TDC sender” .

♦ With strobe lamp the strobe must be directed at ignition timing

marks.

– Connect vacuum hose to ignition distributor.

5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 – Check idling speed, if necessary correct at adjustment screw -5- .

– To check the duty cycle connect ignition tester -V.A.G 1367to connector -1- (blue/white wire) and press <% button. Only use test lead -V.A.G 1367/5- for connector -1- with round con‐ nector sleeve. n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o The terminal for ignition lead cylinder 1 must not be connected. h t or u ac a ss

Note

pe rm itte d

un le

ility ab y li an pt ce

– Check duty cycle for duty cycle valve and CO content.

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

Note

If the CO content is more than 1.2 Vol. % at a duty cycle of 20 ... 70 %, this is not caused by an incorrect CO adjustment (repair measure). If the duty cycle is less than 20 % or more than 70 %, adjust duty cycle with CO adjustment wrench. – Adjusst duty cycle with CO adjustment wrench -6- . Note

♦ Do not operate throttle when adjustment wrench is inserted.

♦ After completing basic engine setting note the following:

♦ Reconnect all hoses and connections that have been discon‐

nected or separated for checking and adjusting purposes.

5.32.14

Engine code: GX (KE Jetronic)

Special tools and workshop equipment required

78 5. Descriptions of work

Prote cted by

gearbox, air conditioning system and check that the engine operates smoothly under these load conditions.

AG.

♦ Operate assemblies e.g. power-assisted steering, automatic

agen lksw Vo by

c o p yri gh t . C op yi

and operate throttle before the duty cycle is read.

ht rig py Co t.

♦ Remove adjustment wrench after every adjusting procedure

do c um en

r te o iva r rp fo g n

♦ When adjusting, do not push down the adjustment wrench.

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

rrectness of i t to the co nform spec a t i h re o n in wit thi s do c um en

r te o iva r rp fo g n

♦ Trigger clamp -V.A.G 1367/8-

ht rig py Co t.

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

ility ab y li an pt ce

un le

♦ Ignition tester -V.A.G 1767-

c o p yri gh t. C op yi

♦ 4 component exhaust emission tester -V.A.G 1787- or agen lksw Vo by

AG.

Prote cted by

♦ 4-component exhaust emission tester -V.A.G 1788-

5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

pe rm itte d

ility ab y li an pt ce

un le

♦ Ignition tester -V.A.G 1367-

rrectness o f i t to the co n f orm spec atio h re n wit

es, in part or in w l purpos hole ercia , is n m ot com

♦ Hose adapter -V.A.G 1363/3♦ Hand multimeter -V.A.G 1526- or ♦ Hand multimeter -V.A.G 1315 A- and ♦ Test lead -1315 A/1Note

♦ For all relevant engine basic setting test prerequisites and da‐

ta: ⇒ Data sheets for exhaust emission test

♦ To prevent injuries to personnel and/or damage to ignition and r te o iva r rp fo ng

Prote cted by c o py rig ht . C op yi

⇒ Data sheets for exhaust emission test ♦ Installation ♦ Completeness ♦ Leakage ♦ Damage Note

Faults found are to be rectified.

5.32.16

Connecting test units

– Pull on handbrake. – Automatic gearbox: Selector lever in position “P” or “N” . – Manual gearbox: Gear lever in neutral.

80 5. Descriptions of work

AG.

– Perform visual check for:

agen lksw Vo by

Performing visual check of components influencing emissions

ht rig py Co t.

5.32.15

in t his d o cu m en

injection system, the ignition system wiring (including high voltage wiring) should be connected and disconnected only with ignition switched off.

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 – Connect ignition tester -V.A.G 1367- with trigger clamp V.A.G 1367/8- or ignition tester -V.A.G 1767- with ignition switched off. – Connect 4 component exhaust emission tester -V.A.G 1787or 4 component exhaust emission tester -V.A.G 1788- to CO sampling pipe using hose adapter -V.A.G 1363/3- . Connect Hand multimeter -V.A.G 1315 A- or Hand multimeter V.A.G 1526- to measure control current: – Hand multimeter -V.A.G 1315 A- : Press mA button and con‐ nect unit lines using test lead -1315 A/1- to pressure regulator -1- . – Hand multimeter -V.A.G 1526- : Set unit switch to 200 mA and switch on unit. Connect unit to pressure regulator -1- using test lead -V.A.G 1315 A/1- .

–

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte Clamp idling speed boost valve hose -1- together is ensuring that r o eo h there are no leaks. ut ra a c s s

Do not seal connection at intake manifold. – Vehicles with activated charcoal filter: Attach angled piece -4- so that the free connection with the restricted hole is in‐ serted into the air intake duct.

5.32.17

Test sequence

– Pull vacuum hose off ignition distributor. – Start engine and run at idling speed.

– Check ignition timing, if necessary adjust by turning distributor.

r fo ng

♦ The ignition timing is displayed directly on ignition tester with

♦ With strobe lamp the strobe must be directed at ignition timing AG.

marks.

agen lksw Vo by

Prote cted by c o py rig ht . C op yi

“TDC sender” .

ht rig py Co t.

Note

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

un le

ility ab y li an pt ce

– Pull hose -2- off intake manifold and hose -3- off air cleaner.

5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 – Check idling speed, if necessary correct at adjustment screw -5- . – Check control current and CO content, if necessary adjust with adjustment wrench -6- . Note

If the CO content (control value) is more than 1.2 Vol. % at a control current of 4 ... 16 mA, this is not caused by an incorrect CO adjustment (repair measure). olkswagen AG en AG. V

does not gu ara nte eo ra c ility ab y li an pt ce

pe rm itte d

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–

wag olks yV b If the CO content is OK when control current iis edoutside toler‐ rs ance, adjust control current to adjustment uvalue at CO adjust‐ tho a ment screw -6- . ss

Note

rrectness o f i t to the co n f orm spec atio h re n wit

es, in part or in w l purpos hole ercia , is n m ot com

♦ When adjusting, do not push down the adjustment wrench. ♦ Do not operate throttle when adjustment wrench is inserted. ♦ Remove adjustment wrench after every adjusting procedure

and operate throttle before the duty cycle is read.

♦ After completing basic engine setting note the following: ♦ Operate assemblies e.g. power-assisted steering, automatic

gearbox, air conditioning system and check that the engine operates smoothly under these load conditions.

♦ Reconnect all hoses and connections that have been discon‐

Engine code: NZ

Special tools and workshop equipment required

agen lksw Vo by

AG.

82 5. Descriptions of work

Prote cted by c o py rig ht . C op yi

♦ Ignition tester -V.A.G 1367-

ht rig py Co t.

♦ Ignition tester -V.A.G 1767- or

in t his d o cu m en

5.32.18

r te o iva r rp fo ng

nected or separated for checking and adjusting purposes.

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 ♦ Trigger clamp -V.A.G 1367/8-

AG. Volkswagen AG d agen oes

y db ise r tho au s s

not gu ara nte eo ra c

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

ility ab y li an pt ce

un le

ksw 1787- or ♦ 4 component exhaust emission tester -V.A.G Vol

♦ 4 component exhaust emission tester -V.A.G 1788-

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t. C op yi

♦ Hose adapter -V.A.G 1363/3-

do c um en

r te o iva r rp fo g n

♦ Digital potentiometer -V.A.G 1630-

♦ Adapter for air flow meter -V.A.G 1721Note ♦ For all relevant engine basic setting test prerequisites and da‐

ta: ⇒ Data sheets for exhaust emission test

♦ ♦ To prevent injuries to personnel and/or damage to ignition and

injection system, the ignition system wiring (including high voltage wiring) should be connected and disconnected only with ignition switched off.

5.32.19

Performing visual check of components influencing emissions

⇒ Data sheets for exhaust emission test 5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 – Perform visual check for: ♦ Installation ♦ Completeness ♦ Leakage ♦ Damage

un le

Connecting test units

– Pull on handbrake.

– Automatic gearbox: Selector lever in position “P” or “N” . – Manual gearbox: Gear lever in neutral.

– Connect ignition tester -V.A.G 1367- with trigger clamp V.A.G 1367/8- or ignition tester -V.A.G 1767- with ignition switched off. – Connect 4 component exhaust emission tester -V.A.G 1787or 4 component exhaust emission tester -V.A.G 1788- to CO sampling pipe using hose adapter -V.A.G 1363/3- .

r fo ng

5.32.21

Test sequence

– Pull vacuum hose off ignition distributor.

84 5. Descriptions of work

AG.

– Adjust digital potentiometer -V.A.G 1630- side A to 1.8 kΩ∼ and connect to air flow meter and wiring harness using adapter for air flow meter -V.A.G 1721- .

agen lksw Vo by

Prote cted by c o py rig ht . C op yi

– Pull connector off air flow meter potentiometer (00552-2323) -G19- .

ht rig py Co t.

For idling speed adjustment the intake air temperature sender (in air flow meter) has to be renewed by a 1.8 kΩ resistance. When connecting the testers for ignition timing and CO content the dig‐ ital potentiometer -V.A.G 1630- must additionally be connected as follows:

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

5.32.20

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

Faults found are to be rectified.

ility ab y li an pt ce

Note

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 – Separate Lambda probe connector -1- with ignition switched off. – Start engine and run at idling speed. AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

♦ The ignition timing is displayed directly on ignition tester with

“TDC sender” .

♦ With strobe lamp the strobe must be directed at ignition timing

marks.

– Connect vacuum hose to ignition distributor.

r te o iva r rp fo ng

– Check idling speed and CO content (at idling speed), if nec‐ essary correct by turning the adjustment screws alternately. A - Idling speed adjustment screw ht rig py Co t.

B - CO adjustment screw

rrectness o f i t to the co n f orm spec atio h re n wit

Note

in t his d o cu m en

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

ility ab y li an pt ce

un le

– Check ignition timing, if necessary adjust by turning distributor.

c o p yri gh t. C op yi

– Connect Lambda probe (00525-2342) -G39- connector. agen lksw Vo by

AG.

– Check CO content.

Prote cted by

– Control unit with copper-brown sticker: Run engine at idling speed for approx. 2 minutes. The CO content must increase to approx. 1.5 Vol. %. – Correct speed after the CO content has been regulated by the Lambda regulation. – Seal CO adjustment screw with new anti-tamper plug. After completing basic engine setting note the following: ♦ Operate assemblies e.g. power-assisted steering, automatic gearbox, air conditioning system and check that the engine operates smoothly under these load conditions. ♦ Reconnect all hoses and connections that have been discon‐ nected or separated for checking and adjusting purposes.

5.32.22

Engine codes: PB, PF, 1P

Special tools and workshop equipment required

5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 ♦ Ignition tester -V.A.G 1767- or

♦ Ignition tester -V.A.G 1367-

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

♦ 4 component exhaust emission tester -V.A.G 1787- or

ta: ⇒ Data sheets for exhaust emission test

♦ To prevent injuries to personnel and/or damage to ignition and

injection system, the ignition system wiring (including high voltage wiring) should be connected and disconnected only with ignition switched off.

5.32.23

Performing visual check of components influencing emissions

⇒ Data sheets for exhaust emission test – Perform visual check for:

86 5. Descriptions of work

AG.

♦ For all relevant engine basic setting test prerequisites and da‐

agen lksw Vo by

Prote cted by c o py rig ht . C op yi

Note

ht rig py Co t.

♦ Hose adapter -V.A.G 1363/3-

r fo ng

♦ 4 component exhaust emission tester -V.A.G 1788-

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

ility ab y li an pt ce

un le

♦ Trigger clamp -V.A.G 1367/8-

♦

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h Installationaut ra c s s pe rm itte d

un le

ility ab y li an pt ce

♦ Completeness ♦ Leakage

Faults found are to be rectified.

Connecting test units

– Pull on handbrake. – Automatic gearbox: Selector lever in position “P” or “N” . – Manual gearbox: Gear lever in neutral.

Engine codes PF and 1P:

ht rig py Co t.

r te o iva r rp fo ng

– Connect ignition tester -V.A.G 1367- with trigger clamp V.A.G 1367/8- or ignition tester -V.A.G 1767- with ignition switched off.

in t his d o cu m en

es, in part or in w l purpos hole ercia , is n m ot com

Note

rrectness o f i t to the co n f orm spec atio h re n wit

♦ Damage

5.32.24

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

c o p yri gh t. C op yi

– Connect 4 component exhaust emission tester -V.A.G 1787or 4 component exhaust emission tester -V.A.G 1788- to CO sampling pipe using hose adapter -V.A.G 1363/3- . agen lksw Vo by

AG.

Prote cted by

Engine code PB:

– Connect 4 component exhaust emission tester -V.A.G 1787or 4 component exhaust emission tester -V.A.G 1788- to tail pipe (seal 2nd tail pipe). – Pull crankcase breather hose off pressure regulating valve -arrow 1- and seal hose.

5.32.25

Test sequence

– Start engine and run at idling speed. – Pull connector off temperature sensor -G18- (blue). – Check ignition timing, if necessary adjust by turning distributor.

5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 Note ♦ The ignition timing is displayed directly on ignition tester with

“TDC sender” .

♦ With strobe lamp the strobe must be directed at ignition timing

marks.

– Operate throttle 3 times (throttle burst above 3000 rpm), run engine at idling speed and check idling speed.

– Check idling speed and CO content (at idling speed), if nec‐ essary correct by turning the adjustment screws alternately. 1 - Idling speed adjustment screw 2 - CO adjustment screw – Engine code PB: If it is not possible to adjust the CO content lkswagen o to the relevant test value, perform repair measures! yV db e ris

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– Push connector onto temperature sensor -G18- , operate tho au throttle 3 times, run engine at idling speed. s s

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– Seal CO adjustment screw with new anti-tamper plug. After completing basic engine setting note the following:

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

♦ Operate assemblies e.g. power-assisted steering, automatic gearbox, air conditioning system and check that the engine operates smoothly under these load conditions. ♦ Reconnect all hoses and connections that have been discon‐ nected or separated for checking and adjusting purposes.

5.32.26

Engine code: PG, 1H

Special tools and workshop equipment required

r te o iva r rp fo g n

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AG.

Prote cted by c o p yri gh t. C op yi

88 5. Descriptions of work

do c um en

♦ Ignition tester -V.A.G 1367-

ht rig py Co t.

♦ Ignition tester -V.A.G 1767- or

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 ♦ Trigger clamp -V.A.G 1367/8-

♦ 4 component exhaust emission tester -V.A.G 1787- or

♦ Hose adapter -V.A.G 1363/3♦ Adapter set -V.A.G 1594Note

♦ For all relevant engine basic setting test prerequisites and da‐

ta: ⇒ Data sheets for exhaust emission test

♦ To prevent injuries to personnel and/or damage to ignition and

injection system, the ignition system wiring (including high voltage wiring) should be connected and disconnected only with ignition switched off.

5.32.27

Performing visual check of components influencing emissions

AG.

Prote cted by

♦ Leakage

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♦ Completeness

c o p yri gh t . C op yi

♦ Installation

ht rig py Co t.

– Perform visual check for:

r fo ng

⇒ Data sheets for exhaust emission test

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

♦ Voltage divider -V.A.G 1473-

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♦

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r 4 component exhaust emission testertho-V.A.G 1788or u ac a ss Adapter cable -V.A.G 1367/9-

♦ Damage

5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ . Volkswagen AG gen AG does Maintenanceo-lkEdition 08.2003 swa no

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5.32.28

Connecting test units

– Pull on handbrake. – Automatic gearbox: Selector lever in position “P” or “N” . – Manual gearbox: Gear lever in neutral. – Connect ignition tester -V.A.G 1367- with trigger clamp V.A.G 1367/8- or ignition tester -V.A.G 1767- with ignition switched off. Engine code PG: For vehicles with charge air cooler above gear‐ box, a TDC sender is installed as standard. To connect ignition tester to TDC sender use adapter cable -V.A.G 1367/9- . To connect the tester to terminal 1 of ignition coil use voltage di‐ vider -V.A.G 1473- and test leads from adapter set -V.A.G 1594- . r fo ng

AG.

Prote cted by

– Start engine and run at idling speed.

agen lksw Vo by

c o p yri gh t. C op yi

Test sequence

ht rig py Co t.

5.32.29

do c um en

– Connect 4 component exhaust emission tester -V.A.G 1787or 4 component exhaust emission tester -V.A.G 1788- to CO sampling pipe using hose adapter -V.A.G 1363/3- .

– Pull crankcase breather hose -arrow- off pressure regulating valve and place so that only fresh air is drawn in.

– Pull connector off temperature sensor -G18- (blue) -arrow- . – Check ignition timing, if necessary adjust by turning distributor.

90 5. Descriptions of work

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

Faults found are to be rectified.

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 Note ♦ The ignition timing is displayed directly on ignition tester with

“TDC sender” .

♦

rrectness of i t to the co nform spec at i h re o n wit in t his

– Check idling speed and CO content (at idling speed) and if necessary correct by turning the adjustment screw alternately. 1 - Idling speed adjustment screw 2 - CO adjustment screw – Push connector onto temperature sensor -G18- coolant tem‐ perature sender (blue), operate throttle 3 times and run engine at idling speed. – Seal CO adjustment screw with new anti-tamper plug. After completing basic engine setting note the following: ♦ Operate assemblies e.g. power-assisted steering, automatic gearbox, air conditioning system and check that the engine operates smoothly under these load conditions. r fo ng

Engine code: PL

AG.

Special tools and workshop equipment required

agen lksw Vo by

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5.32.30

ht rig py Co t.

♦ Reconnect all hoses and connections that have been discon‐ nected or separated for checking and adjusting purposes.

do c um en

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

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– Operate throttle 3 times (throttle burst above 3000 rpm) and run engine at idling speed.

ility ab y li an pt ce

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♦ Ignition tester -V.A.G 1767- or

♦ Ignition tester -V.A.G 1367-

5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 ♦ Trigger clamp -V.A.G 1367/8-

ility ab y li an pt ce

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

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♦

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h 4 component exhaust emission ut tester -V.A.G 1787- or ra a c s s

♦ 4 component exhaust emission tester -V.A.G 1788-

ht rig py Co t.

agen lksw Vo by

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Prote cted by c o p yri gh t. C op yi

92 5. Descriptions of work

do c um en

r te o iva r rp fo g n

♦ Hand multimeter -V.A.G 1526 A-

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

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♦ Additional test lead -V.A.G 1315 A/1-

♦ Hose adapter -V.A.G 1363/3Note

♦ For all relevant engine basic setting test prerequisites and da‐

ta: ⇒ Data sheets for exhaust emission test

♦ To prevent injuries to personnel and/or damage to ignition and

injection system, the ignition system wiring (including high voltage wiring) should be connected and disconnected only with ignition switched off.

5.32.31

Performing visual check of components influencing emissions

⇒ Data sheets for exhaust emission test

♦ Completeness

Prote cted by

♦ Damage

AG.

♦ Leakage

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c o p yri gh t. C op yi

♦ Installation

ht rig py Co t.

r fo ng

– Perform visual check for:

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

♦ Test lead -V.A.G 1367/5-

Note

Faults found are to be rectified.

5.32.32

Connecting test units

– Pull on handbrake. – Automatic gearbox: Selector lever in position “P” or “N” . – Manual gearbox: Gear lever in neutral.

5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

–

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switched off.

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AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h Connect ignition tester -V.A.G 1367- with trigger clamp t u ra a c V.A.G 1367/8- or ignition tester -V.A.G 1767- withssignition

– Connect Hand multimeter -V.A.G 1526 A- to pressure regula‐ tor -1- using test lead -V.A.G 1315 A/1- .

Prote cted by

94 5. Descriptions of work

AG.

– Attach angled piece in intake air duct so that only fresh air can be drawn in through restricted hole -arrow- .

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c o p yri gh t. C op yi

Vehicles from 10.86 with activated charcoal filter system:

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– Pull crankcase breather hoses -1- and -2- off breather housing -3- , separate and place so that only fresh air is drawn in. Con‐ nection with calibrated drilling -4- must remain in hose -2- .

in t his d o cu m en

r te o iva r rp fo ng

rrectness o f i t to the co n f orm spec atio h re n wit

es, in part or in w l purpos hole ercia , is n m ot com

– Connect 4 component exhaust emission tester -V.A.G 1787or 4 component exhaust emission tester -V.A.G 1788- to CO sampling pipe using hose adapter -V.A.G 1363/3- .

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

5.32.33

Test sequence

– Start engine and run at idling speed. agen – Check ignition timing, if necessary adjust by turning distributor. lksw

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Note

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“TDC sender” .

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♦ The ignition timing is displayed directly on ignition tester with

rrectness o f i t to the co n f orm spec atio h re n wit

marks.

es, in part or in w l purpos hole ercia , is n m ot com

♦ With strobe lamp the strobe must be directed at ignition timing – Check idling speed and control current (at idling speed) and if necessary correct by turning the adjustment screw alternately.

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Prote cted by c o py rig ht . C op yi

– If the CO content is OK when control current is outside toler‐ ance, adjust control current to adjustment value at CO adjust‐ ment screw.

ht rig py Co t.

Control current (CO) adjustment screw -arrow-

in t his d o cu m en

r te o iva r rp fo ng

Idling speed adjustment screw -arrow-

Note ♦ When adjusting, do not push down the adjustment wrench. ♦ Do not operate throttle when adjustment wrench is inserted. ♦ Remove adjustment wrench after every adjusting procedure

and operate throttle before the duty cycle is read.

– Connect test lead terminal 1 of ignition tester to duty cycle test connection -white/blue lead- (for double round connector sleeve housing with test lead -V.A.G 1367/5- ). – Check with ignition tester -V.A.G 1367- : Do not connect test lead cylinder 1! Switch on dwell angle measuring range <% . – Check with ignition tester -V.A.G 1767- : Switch on duty cycle measuring range. – Check duty cycle and CO content. If the specifications are not achieved - Repair measure.

5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 – Seal end of connecting piece -4- of crankcase breather hose -2- with finger. The CO content must increase briefly and drop again. After completing basic engine setting note the following: ♦ Operate assemblies e.g. power-assisted steering, automatic gearbox, air conditioning system and check that the engine operates smoothly under these load conditions. ♦ Reconnect all hoses and connections that have been discon‐ nected or separated for checking and adjusting purposes.

5.32.34

Engine code: PN

Special tools and workshop equipment required ♦ Ignition tester -V.A.G 1767- or

♦

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rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

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♦

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara Ignition tester -V.A.G 1367d e nte is r o eo h ra Trigger clamp -V.A.Gaut1367/8c s s

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96 5. Descriptions of work

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♦ Adapter set -V.A.G 1594-

ht rig py Co t.

♦ 4 component exhaust emission tester -V.A.G 1788-

do c um en

r te o iva r rp fo g n

♦ 4 component exhaust emission tester -V.A.G 1787- or

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 ♦ Diode test lamp -V.A.G 1527♦ Hose adapter -V.A.G 1363/3Note ♦ For all relevant engine basic setting test prerequisites and da‐

ta: ⇒ Data sheets for exhaust emission test

♦ To prevent injuries to personnel and/or damage to ignition and

injection system, the ignition system wiring (including high voltage wiring) should be connected and disconnected only with ignition switched off. AG. Volkswagen AG d agen o

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5.32.35

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♦ Completeness ♦ Leakage ♦ Damage Note

rrectness of i t to the co nform spec a t i h re o n in wit thi s

♦ Installation

es, in part or in w l purpos hole ercia , is n m ot com

– Perform visual check for:

pe rm itte d

⇒ Data sheets for exhaust emission test

Faults found are to be rectified.

Connecting test units

– Pull on handbrake.

– Automatic gearbox: Selector lever in position “P” or “N” .

AG.

– Connect 4 component exhaust emission tester -V.A.G 1787or 4 component exhaust emission tester -V.A.G 1788- to CO sampling pipe using hose adapter -V.A.G 1363/3- .

agen lksw Vo by

Prote cted by c o p yri gh t. C op yi

– Connect ignition tester -V.A.G 1367- with trigger clamp V.A.G 1367/8- or ignition tester -V.A.G 1767- with ignition switched off.

ht rig py Co t.

– Manual gearbox: Gear lever in neutral.

do c um en

r te o iva r rp fo g n

5.32.36

Note

When inserting the TDC sender observe “white marking” of TDC sender mounting.

5.32.37

Test sequence

– Start engine and run at idling speed. – Check ignition timing, if necessary adjust by turning distributor.

5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 Note ♦ The ignition timing is displayed directly on ignition tester with

“TDC sender” .

♦ With strobe lamp the strobe must be directed at ignition timing

marks.

– Only check idling speed (not adjustable). If the specification for idling speed is not achieved, determine cause according to workshop manual (repair measure). Check CO content (vehicles with activated charcoal filter system): – Switch off ignition and let switched off at least 20 seconds. – Connect diode test lamp -V.A.G 1527- between test connector -1- (single connector to blue lead) and battery -(+)- (diode sticking) using test lead from adapter set -V.A.G 1594- . – Connect test lead -2- from adapter set -V.A.G 1594Volkswagen AG G. test Ato does agen connector lead -1- diode test lamp -V.A.G 1527ksw -arrow- and not l o V gu y b earth -(-)- (diode lights up). ara d e un le pe rm itte d

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Note

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♦ Connector -1- must not be connected without test lamp -(+)- . es, in part or in w l purpos hole ercia , is n m ot com

♦ Do not use a “regular” test lamp with bulb. The high connected

rrectness o f i t to the co n f orm spec atio h re n wit

load of this test lamp can lead to destroy electronic compo‐ nents.

– Start engine and run at idling speed. – After engine has been running for at least 4 seconds remove test lead -2- (separate earth connection). Note

♦ If the engine speed is increased above 4000 rpm, the display

is erased by the control unit, if necessary initiate display again. r te o iva r rp fo ng

mixture is OK (CO content is in specified range of Lambda regulation). At the same time the CO content must be 0.2...1.0 Vol. %, if necessary check Lambda regulation or probe43) . c o p yri gh t. C op yi

too rich (CO basic setting too high, not within specified range). Prote cted by

♦ If the diode flashes (25 times per second) the Lambda probe

is not at operating temperature, the probe is defective or there is an open circuit in the Lambda probe (connector sep‐ arated).

43)

43) Lambda probe can be sooted due to malfunctions, if necessary carry out a 20 minute overland drive trying to remove soot.

Check CO content (vehicles without activated charcoal filter sys‐ tem):

98 5. Descriptions of work

AG.

lean (CO basic setting too low, not within specified range, di‐ ode is defective or eliminate wiring open circuit).

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♦ If the diode does not light up, the idling speed mixture is too

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♦ If the diode lights up continuously, the idling speed mixture is

in t his d o cu m en

♦ If the diode flashes (1.5 times per second) the idling speed

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 – Connect diode test lamp -V.A.G 1527- between test connector -1- (single connector to blue lead) and battery using test lead from adapter set -V.A.G 1594- . Note ♦ Connector -1- must not be connected without test lamp -(+)n AG..Volkswagen AG do age

es n ot g ua ran tee or ac

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is load of this test lamp can lead to destroy helectronic compo‐ or ut nents. a s

es, in part or in w l purpos hole ercia , is n m ot com

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Note

pe rm itte d

– Start engine and run at idling speed.

♦ If the diode flashes (1.5 times per second) the idling speed

mixture is OK (CO content is in specified range of Lambda regulation). At the same time the CO content must be 0.2...1.0 Vol. %, if necessary check Lambda regulation or probe44) .

♦ If the diode lights up continuously, the idling speed mixture is

too rich (CO basic setting too high, not within specified range).

♦ If the diode does not light up, the idling speed mixture is too

lean (CO basic setting too low, not within specified range, di‐ ode is defective or eliminate wiring open circuit).

♦ If the diode flashes (25 times per second) the Lambda probe r te o iva r rp fo g n

AG.

– Separate Lambda probe wire -1- (connector on green or black wire to control unit may not come into contact with earth).

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Prote cted by c o py rig ht . C op yi

Adjust CO content (vehicles with and without activated charcoal filter system):

ht rig py Co t.

44) Lambda probe can be sooted due to malfunctions, if necessary carry out a 20 minute overland drive trying to remove soot.

do c um en

is not at operating temperature, the probe is defective or there is an open circuit in the Lambda probe wire (connector separated).

44)

Diode must flicker (25 times per second), control unit has switch‐ ed to electronic control (emergency) and Lambda regulation is switched off.

5. Descriptions of work

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 – Adjust CO content at adjustment screw -A- . Note ♦ The function of Lambda regulation is OK when the fault mem‐

ory is read and no fault is shown in Lambda regulation.

♦

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♦

n AG. Volkswagen AG do es n wage s k l After completing basic engine setting note the following: ot g o yV ua b ran ed s i tee r Operate assemblies e.g. power-assisted steering, automatic o h t or u that the engine gearbox, air conditioning system and check ac a s s operates smoothly under these load conditions.

nected or separated for checking and adjusting purposes.

5.32.38

Engine code: RD

Special tools and workshop equipment required

Prote cted by

100 5. Descriptions of work

AG.

♦ 4 component exhaust emission tester -V.A.G 1787- or

agen lksw Vo by

♦ Trigger clamp -V.A.G 1367/8-

c o p yri gh t . C op yi

♦ Ignition tester -V.A.G 1367-

ht rig py Co t.

r fo ng

♦ Ignition tester -V.A.G 1767- or

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

♦ Reconnect all hoses and connections that have been discon‐

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 ♦ 4 component exhaust emission tester -V.A.G 1788♦ Hand multimeter -V.A.G 1526 A-

ility ab y li an pt ce

rrectness o f i t to the co n f orm spec atio h re n wit

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

un le

♦

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or Additional test lead -V.A.G 1315 u A/1ac a ss

♦ Test lead -V.A.G 1367/5♦ Hose adapter -V.A.G 1363/3-

r te o iva r rp fo ng

♦ For all relevant engine basic setting test prerequisites and da‐

ta: ⇒ Data sheets for exhaust emission test

AG.

Prote cted by

5.32.39

agen lksw Vo by

c o p yri gh t . C op yi

injection system, the ignition system wiring (including high voltage wiring) should be connected and disconnected only with ignition switched off.

ht rig py Co t.

♦ To prevent injuries to personnel and/or damage to ignition and

in t his d o cu m en

Note

Performing visual check of components influencing emissions

⇒ Data sheets for exhaust emission test – Perform visual check for: ♦ Installation 5. Descriptions of work

101

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 ♦ Completeness ♦ Leakage ♦ Damage Note

Faults found are to be rectified.

5.32.40 –

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–

n AG. Volkswagen AG do es n wage s k l ot g o Pull on handbrake. yV ua b ran ed s i tee r Automatic gearbox: Selectortholever in position “P” or “N” . or u ac a ss Manual gearbox: Gear lever in neutral. un le

–

Connecting test units

– Check duty cycle using ignition tester -V.A.G 1367- : Press < % button and connect lead -1- to connector -5- .

agen lksw Vo by

c o p yri gh t . C op yi

To connect, use test lead -V.A.G 1367/5- if a round connector sleeve housing is fitted instead of connector -5- . AG.

Prote cted by

Note

The terminal for ignition lead cylinder 1 must not be connected. Connect Hand multimeter -V.A.G 1526 A- to measure control cur‐ rent: – Hand multimeter -V.A.G 1526 A- : Set unit switch to 200 mA and switch on unit. Connect unit to pressure regulator -1- using test lead -V.A.G 1315 A/1- .

102 5. Descriptions of work

ht rig py Co t.

r fo ng

– Connect 4 component exhaust emission tester -V.A.G 1787or 4 component exhaust emission tester -V.A.G 1788- to CO sampling pipe using hose adapter -V.A.G 1363/3- .

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

– Connect ignition tester -V.A.G 1367- with trigger clamp V.A.G 1367/8- or ignition tester -V.A.G 1767- with ignition switched off.

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 – Pull off crankcase breather hoses and place so that only fresh air can be drawn in: – Pull hose -2- off intake manifold and hose -3- off air cleaner. Do not seal connection at intake manifold. Vehicles with activated charcoal filter: n AG. Volkswagen A

pe rm itte d

Test sequence

– Check ignition timing, if necessary adjust by turning distributor. Note

♦ The ignition timing is displayed directly on ignition tester with

“TDC sender” .

♦ With strobe lamp the strobe must be directed at ignition timing

– Check duty cycle (idling speed) using ignition tester V.A.G 1367- <% button, if necessary correct at adjustment screws -5- .

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t. C op yi

Note

ht rig py Co t.

r te o iva r rp fo ng

marks.

rrectness o f i t to the co n f orm spec atio h re n wit

– Start engine and run at idling speed.

in t his d o cu m en

es, in part or in w l purpos hole ercia , is n m ot com

5.32.41

an tee or ac

e ris tho u a ss

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G do age es n the – Attach angled piece -4- soothat lksw the free connection with ot g Vinto y ua restricted hole is inserted the air intake duct. db r

If duty cycle cannot be adjusted at idling speed adjustment screw - repair measure. – Check control current and CO content, if necessary adjust with adjustment wrench -6- . Note

If the CO content is more than 1.2 Vol. % at a control current of 4 ... 16 mA, this is not caused by an incorrect CO adjustment (repair measure).

5. Descriptions of work

103

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 – If the CO content is OK when control current is outside toler‐ ance, adjust control current at CO adjustment screw -6- . Note ♦ When adjusting, do not push down the adjustment wrench. ♦ Do not operate throttle when adjustment wrench is inserted. ♦ Remove adjustment wrench after every adjusting procedure

and operate throttle before the duty cycle is read.

♦ After completing basic engine setting note the following: ♦ Operate assemblies e.g. power-assisted steering, automatic

gearbox, air conditioning system and check that the engine operates smoothly under these load conditions.

♦ Reconnect all hoses and connections that have been discon‐

nected or separated for checking and adjusting purposes.

5.33

Idling speed: Check

Special tools and workshop equipment required

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

Note

rrectness of i t to the co nform spec at i h re o n wit in t his

♦ Ignition tester -V.A.G 1367-

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

ility ab y li an pt ce

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♦ Ignition tester -V.A.G 1767- or

Checking and adjustment conditions and specifications ⇒ Data sheets for exhaust emission test – Connect ignition tester -V.A.G 1367- or ignition tester V.A.G 1767- . – Injection pump without idling speed boost (engine codes JP and JR up to approx. 08.85): Check idling speed and if nec‐ essary adjust by turning the idling speed adjustment screw -arrow- . r fo ng

ht rig py Co t.

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AG.

Prote cted by

c o p yri gh t . C op yi

104 5. Descriptions of work

do c um en

– Lock adjustment screw.

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 – Injection pump with idling speed boost (engine codes JP and JR from approx. 09.85, ME, RA, SB and 1V): Check idling speed and if necessary adjust by turning the idling speed ad‐ justment screw -arrow- .

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h equipment required Special tools and workshop ut ra a c s s

5.34

Headlight settings: Check

rrectness of i t to the co nform spec a t i h re o n in wit thi s

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♦ Headlight adjustment unit -VAS 5046- or

♦ Headlight setting unit -VAS 5047-

Checking and adjusting prerequisites: Prote cted by c o py rig ht . C op yi

♦ Lenses must not be damaged or dirty.

AG.

♦ Vehicle must be loaded.

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♦ Reflectors OK.

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♦ Tyre pressures OK.

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The following test and adjustment instructions are applicable in all countries. However, national guidelines and regulations of the respective country are to be followed.

Loading: With one person or 75 kg on the driver seat and the vehicle otherwise unloaded (unladen weight). The unladen weight is weight of vehicle ready for operation with filled fuel tank (at least 90 %) including weight of all equipment usually carried (e.g. spare wheel, tools, jack, fire extinguisher etc.). If the fuel tank is not at least 90% full, then load as follows: – Read off level of fuel in fuel tank on fuel gauge. Determine additional weight from following table and place weight in lug‐ gage compartment.

5. Descriptions of work

105

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

5.34.1

Fuel gauge table Fuel gauge

Additional weight in kg

1/4 1/2 3/4 Full

45 30 n AG. Volkswagen AG do 15 es n wage s k l ot g o yV 0 ua b d r

Example:

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rrectness of i t to the co nform spec a t i h re o n in wit thi s

Note

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When the fuel tank is half full an additional weight of 30 kg must be placed in the luggage compartment.

an tee or ac ility ab y li an pt ce

e ris tho u a ss

The additional weight is best produced using fuel canisters filled with water (a 5 litre fuel canister filled with water weighs approx. 5 kg). The vehicle must be rolled several metres or bounce front and rear springs fully several times so that springs settle correctly. ♦ Vehicle and headlight adjuster must be on a level surface ⇒ Operating instructions for respective headlight adjuster ♦ Vehicle and headlight adjuster must be aligned. Inclination:

♦ Headlights and main beam 12 cm c o p yri gh t . C op yi

On vehicles with headlight range control a sticker with inclination information in “%” is attached to lock carrier. Headlights must be adjusted according to this information. Percentage information on sticker is based on a projection distance of 10 metres. For exam‐ ple: inclination of 1.2 % converts to approx. 12 cm.

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AG.

Prote cted by

♦ On vehicles with headlight range control the thumb wheel on the dash panel must be in basic setting (-).

5.34.2

Checking headlight setting (using new test screen without 15° setting line)

Headlights: – Check whether the switched on dipped beam contacts the horizontal light-dark border of the setting line -1- . – Check, whether the breaking point -2- between the horizontal part of the light/dark border on the left and the rising part on the right lies on the vertical line of the central point -3- . The bright core of the light beam must be on the right of the vertical line.

106 5. Descriptions of work

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♦ Fog lights 20 cm

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♦ Inclination must be set.

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 Note ♦ To make it easier to determine the breaking point -2- , cover AG. Volkswagen

AG do en and uncover left half of headlight (from driver perspective) es n a wag ot g olks V y few times. Then check dipped beam again. ua b d r e ris

ho of dipped beam the centre point of the ♦ After correct adjustment ut

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♦ For the previous test screen with -15° setting line- , adjust as

rrectness o f i t to the co n f orm spec atio h re n wit

Fog lights:

– Check whether the upper light-dark border touches the setting line and runs horizontally over the entire width of the test screen. Other auxiliary lights:

Adjusting headlights

Round headlight, right (Golf):

Prote cted by c o py rig ht . C op yi

A - Height adjustment

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B - Lateral adjustment

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5.34.3

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Additionally retrofitted lights of other systems must be checked/ set according to valid guidelines.

in t his d o cu m en

es, in part or in w l purpos hole ercia , is n m ot com

for new test screen. To avoid incorrect settings, ignore the -15 ° setting line- .

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a on the centre mark -3- . main beam mustsslie

an tee or ac

AG.

On the left-hand headlight both adjuster knobs are a mirror image. – To lower headlight insert cross head screwdriver into the opening -A- and turn clockwise.

Right rectangular headlight (Jetta) On the left-hand headlight both adjuster knobs are a mirror image. A - Height adjustment B - Lateral adjustment – To lower headlight insert cross head screwdriver into the opening -A- and turn clockwise.

5. Descriptions of work

107

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 Right rectangular DE headlight (Rallye Golf) Adjust headlights by turning knurled nuts in engine compartment. A - Height adjustment B - Lateral adjustment On the left-hand headlight both adjuster knobs are a mirror image. Fog lights: – Adjust by turning one bolt only (height adjustment). A lateral adjustment is not possible.

5.35

Road test: Carry out

Which of the following can be checked depends on vehicle equip‐ ment and local conditions (urban/country). Check the following during a road test: – Engine: Output, misfiring, idling speed, acceleration. – Clutch: Pulling away, pedal pressure, odours. – Gear selection: Ease of operation, stick position. – Automatic gearbox: Selector lever position, shift lock / ignition key removal lock, shift behaviour, dash panel insert display. – Foot brake and handbrake: Function, free travel and effec‐ tiveness, pulling to one side, juddering, squeal. – ABS function: A “pulsing” at the brake pedal must be felt when performing ABS controlled braking. – Steering: Function, steering free play, steering wheel centred when vehicle is travelling straight ahead. – Radio/radio navigation system: Function, reception, GALA, in‐ terference noise AG. Volkswagen A gen swa

G do es n ot g ua ran tee or ac

k Vol (MFI): Functions – Multi-function indicator by d se

ri – Air conditioning tho system: Function au

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– Imbalance: Wheels, drive shafts, propshafts

rrectness o f i t to the co n f orm spec atio h re n wit

es, in part or in w l purpos hole ercia , is n m ot com

– Wheel bearings: Noises

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ss – Vehicle: Pulling to one side when travelling straight-ahead (level road)

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AG.

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c o p yri gh t. C op yi

108 5. Descriptions of work

in t his d o cu m en

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– Engine: Hot starting behaviour

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

Legally required extra work accord‐ AG. Volkswagen AG d agen oes ing oto country no lksw t gu ara nte eo ra c

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6.1

Emissions test

6.1.1

Emissions test intervals:

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es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

The following description is only valid for countries where no spe‐ cific exhaust emission regulations have to be adhered to.

♦ Every 12 months for vehicles without catalytic converter or without regulated catalytic converter (engine codes ABN, EV, EZ, GT, GU, GX, GZ, HM, HV, HZ, KR, MH, NU, PB, PF, PG, RD, RF, RG, RH, RV, 2C, 2G) ♦ 3 years after initial registration and then every 2 years after last exhaust emissions test for vehicles with regulated catalytic converter (engine codes ABN, EV, EZ, GU, GX, NZ, PF, PG, PL, PN, RD, RP, RV, 1H, 1P)

r fo ng

Procedure according to engine codes:

c o p yri gh t . C op yi

Vehicles with regulated catalytic converter: AG.

Prote cted by

⇒ page 110 ⇒ page 112 ⇒ page 115 ⇒ page 118 ⇒ page 121 ⇒ page 124 ⇒ page 127 ⇒ page 130 ⇒ page 132 ⇒ page 135

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ABN, EZ, GU EV GX NZ PB, PF, 1P PG, 1H PL PN RD RP

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6.1.2

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♦ 3 years after initial registration and then every 2 years after last exhaust emissions test for vehicles with diesel engine (engine codes JP, JR, ME, RA, SB, 1V).

Vehicles without catalytic converter or without regulated catalytic converter: ABN, EZ, GU, ⇒ page 110 RF, RH EV, GZ, RG ⇒ page 112 GT ⇒ page 137 GX ⇒ page 115 HM, HV ⇒ page 140 HZ (1B3 carbu‐ ⇒ page 142 rettor) HZ (Weber 32 ⇒ page 145 TLA carburettor) KR ⇒ page 148 MH, NU, 2C, 2G ⇒ page 150 PB, PF, RV ⇒ page 121 PG ⇒ page 124 6. Legally required extra work according to country

109

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 RD

⇒ page 132

Vehicles with diesel engine: JP, JR, ME, RA, SB, 1V

6.1.3

⇒ page 153

Engine codes: ABN, EZ, GU, RF, RH

Special tools and workshop equipment required ♦ Ignition tester -V.A.G 1767- or

♦ Ignition tester -V.A.G 1367-

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

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♦ Trigger clamp -V.A.G 1367/8-

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

♦ 4 component exhaust emission tester -V.A.G 1787- or

ht rig py Co t.

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AG.

Prote cted by

c o p yri gh t. C op yi

110 6. Legally required extra work according to country

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♦ 4 component exhaust emission tester -V.A.G 1788-

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 Note

injection system, the ignition system wiring (including high voltage wiring) should be connected and disconnected only with ignition switched off. un le

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♦

rrectness of i t to the co nform spec at i h re o n wit in t his

6.1.4

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

♦

n AG. Volkswagen AG do es n wage s k l ot g Vo y ua b For all relevant engine basic setting testeprerequisites and da‐ d ran s i tee r test ta: ⇒ Data sheets for exhaust emission o h t or u ac a ss To prevent injuries to personnel and/or damage to ignition and

Performing visual check of components influencing emissions

⇒ Data sheets for exhaust emission test

♦ Damage

Faults found are to be rectified.

Connecting test units

Prote cted by

– Pull on handbrake.

AG.

6.1.5

– Automatic gearbox: Selector lever in position “P” or “N” .

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Note

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♦ Leakage

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♦ Completeness

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♦ Installation

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– Perform visual check for

– Manual gearbox: Gear lever in neutral. – Connect ignition tester -V.A.G 1367- with trigger clamp V.A.G 1367/8- or ignition tester -V.A.G 1767- with ignition switched off. – Connect 4 component exhaust emission tester -V.A.G 1787or 4 component exhaust emission tester -V.A.G 1788- to tail pipe.

6.1.6

Test sequence

– Start engine and run at idling speed. – Check ignition timing, if necessary adjust by turning distributor. Note

The ignition timing is displayed directly on ignition tester with TDC sender.

6. Legally required extra work according to country

111

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 – When checking or adjusting ensure the diaphragm rod -A- is at idling position and the adjustment screw -B- (for cold idling speed) contacts the diaphragm rod. – Check idling speed and CO content (at idling speed and for vehicles with catalytic converter at increased idling speed), if necessary adjust by alternately turning the idling speed regu‐ lating valve -A- and CO adjustment screw -B- .

B - CO adjustment screw

– If it is not possible for vehicles with catalytic converter to adjust the CO content to the relevant test value, perform repair meas‐ ures! A - Idling speed regulating valve – Seal CO adjustment screw with new anti-tamper plug. olksw

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nected or separated for checking and adjusting purposes. es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

♦

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♦ Operate assemblies e.g. power-assisted steering, automatic

6.1.7

rrectness of i t to the co nform spec at i h re o n wit in t his

gearbox, air conditioning system and check that the engine operates smoothly under these load conditions.

Engine codes: EV, GZ, RG

Special tools and workshop equipment required

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AG.

Prote cted by

c o p yri gh t . C op yi

112 6. Legally required extra work according to country

ht rig py Co t.

♦ Ignition tester -V.A.G 1367-

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♦ Ignition tester -V.A.G 1767- or

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 ♦ Trigger clamp -V.A.G 1367/8-

♦ 4 component exhaust emission tester -V.A.G 1787- or

♦ 4 component exhaust emission tester -V.A.G 1788Note ♦ For all relevant engine basic setting test prerequisites and da‐

ta: ⇒ Data sheets for exhaust emission test

♦ To prevent injuries to personnel and/or damage to ignition and

Performing visual check of components influencing emissions

⇒ Data sheets for exhaust emission test

rrectness of i t to the co nform spec at i h re o n wit in t his

– Perform visual check for ♦ Installation ♦ Completeness ♦ Leakage ♦ Damage Note

Faults found are to be rectified.

6.1.9

Connecting test units

r fo ng

– Pull on handbrake. – Automatic gearbox: Selector lever in position “P” or “N” .

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es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

tee or ac

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6.1.8

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AG. Volkswagen G d injection system, the ignition high agensystem wiring A(including oes ksw connected and disconnected not l o voltage wiring) should be only V g y ua d b off. r with ignition switched an e is

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6. Legally required extra work according to country

113

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AG.

Prote cted by c o py rig ht . C op yi

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 – Manual gearbox: Gear lever in neutral. – Connect ignition tester -V.A.G 1367- with trigger clamp V.A.G 1367/8- or ignition tester -V.A.G 1767- with ignition switched off. – Connect 4 component exhaust emission tester -V.A.G 1787or 4 component exhaust emission tester -V.A.G 1788- to tail pipe (seal 2nd tail pipe). . Volkswage

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Engine code RG:

– Start engine and run at idling speed.

c o p yri gh t. C op yi

– Check ignition timing, if necessary adjust by turning distributor. Prote cted by

“TDC sender” .

♦ With strobe lamp the strobe must be directed at ignition timing

marks.

♦ For engine code EV the ignition timing mark is not valid when

super unleaded RON 95 is used.

– Connect vacuum hose to ignition distributor.

114 6. Legally required extra work according to country

AG.

♦ The ignition timing is displayed directly on ignition tester with

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Note

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– Pull vacuum hose off ignition distributor and seal.

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Test sequence

rrectness of i t to the co nform spec a t i h re o n in wit thi s

6.1.10

es, in part or in w l purpos hole ercia , is n m ot com

– Clamp hose -1- of idling speed boost two-way valves together, ensuring that there are no leaks.

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 – Check idling speed and CO content (at idling speed and for vehicles with catalytic converter at increased idling speed), if necessary correct by turning the adjustment screws alternate‐ ly. A - Idling speed adjustment screw B - CO adjustment screw – If it is not possible for vehicles with catalytic converter to adjust the CO content to the relevant test value, perform repair meas‐ ures! Note ♦ When adjusting, do not push down the adjustment wrench. ♦ Do not operate throttle when adjustment wrench is inserted. ♦ Remove adjustment wrench after every adjusting procedure

and operate throttle before the duty cycle is read.

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise discon‐ r Reconnect all hoses and connections that havethbeen o eo u ra nected or separated for checking and adjusting a purposes. c s s

Note

♦

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♦ Operate assemblies e.g. power-assisted steering, automatic

Engine code: GX

rrectness of i t to the co nform spec at i h re o n wit in t his

6.1.11

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

gearbox, air conditioning system and check that the engine operates smoothly under these load conditions.

Special tools and workshop equipment required

r fo ng

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AG.

Prote cted by

c o p yri gh t. C op yi

♦ Trigger clamp -V.A.G 1367/8-

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♦ Ignition tester -V.A.G 1367-

ht rig py Co t.

♦ Ignition tester -V.A.G 1767- or

6. Legally required extra work according to country

115

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 ♦ 4 component exhaust emission tester -V.A.G 1787- or

♦ 4 component exhaust emission tester -V.A.G 1788Note ♦ For all relevant engine basic setting test prerequisites and da‐

ta: ⇒ Data sheets for exhaust emission test

♦ To prevent injuries to personnel and/or damage to ignition and

injection system, the ignition system wiring (including high voltage wiring) should be connected and disconnected only with ignition switched off.

6.1.12

Performing visual check of components AG. Volkswagen AG d agen oes influencing emissions ksw not l o V

⇒ Data sheets for exhaust emission test

♦ Completeness ♦ Damage Note

Faults found are to be rectified.

6.1.13

rrectness of i t to the co nform spec at i h re o n wit in t his

♦ Leakage

un le es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

♦ Installation

gu ara nte eo ra c ility ab y li an pt ce

– Perform visual check for

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Connecting test units

– Pull on handbrake.

– Automatic gearbox: Selector lever in position “P” or “N” .

ht rig py Co t.

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AG.

Prote cted by c o p yri gh t. C op yi

116 6. Legally required extra work according to country

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– Manual gearbox: Gear lever in neutral.

– Pull hose -2- off intake manifold and hose -3- off air cleaner. Do not seal connection at intake manifold (KE Jetronic). – Attach angled piece -4- so that the free connection with the restricted hole is inserted into the air intake duct (KE Jetronic with activated charcoal filter and K Jetronic generally).

6.1.14

Test sequence

– Start engine and run at idling speed. – Pull vacuum hose off ignition distributor.

Prote cted by c o p yri gh t. C op yi

Note

ht rig py Co t.

r fo ng

– Check ignition timing, if necessary adjust by turning distributor.

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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– Clamp idling speed boost valve hose -1- together ensuring that there are no leaks.

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AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

♦ The ignition timing is displayed directly on ignition tester with agen lksw Vo by

AG.

“TDC sender” .

♦ With strobe lamp the strobe must be directed at ignition timing

marks.

– Connect vacuum hose to ignition distributor.

6. Legally required extra work according to country

117

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 – Check idling speed and CO content (at idling speed and for vehicles with catalytic converter at increased idling speed), if necessary correct by turning the adjustment screws alternate‐ ly. 5 - Idling speed adjustment screw 6 - CO adjustment screw – If it is not possible for vehicles with catalytic converter to adjust the CO content to the relevant test value, perform repair meas‐ ures! Note ♦ When adjusting, do not push down the adjustment wrench. ♦ Do not operate throttle when adjustment wrench is inserted. ♦ Remove adjustment wrench after every adjusting procedure

and operate throttle before the duty cycle is read. Note

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

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♦ Reconnect all hoses and connections that have been discon‐ pe rm itte d

nected or separated for checking and adjusting purposes.

♦ Operate assemblies e.g. power-assisted steering, automatic

rrectness of i t to the co nform spec a t i h re o n in wit thi s

6.1.15

es, in part or in w l purpos hole ercia , is n m ot com

gearbox, air conditioning system and check that the engine operates smoothly under these load conditions.

Engine code: NZ

Special tools and workshop equipment required

AG.

118 6. Legally required extra work according to country

agen lksw Vo by

Prote cted by c o py rig ht . C op yi

♦ Trigger clamp -V.A.G 1367/8-

ht rig py Co t.

♦ Ignition tester -V.A.G 1367-

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♦ Ignition tester -V.A.G 1767- or

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 ♦ 4 component exhaust emission tester -V.A.G 1787- or

♦ 4 component exhaust emission tester -V.A.G 1788-

pe rm itte d

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

es, in part or in w l purpos hole ercia , is n m ot com

Note

♦ For all relevant engine basic setting test prerequisites and da‐

ta: ⇒ Data sheets for exhaust emission test

♦ To prevent injuries to personnel and/or damage to ignition and

injection system, the ignition system wiring (including high voltage wiring) should be connected and disconnected only with ignition switched off.

r te o iva r rp fo ng

Performing visual check of components influencing emissions

⇒ Data sheets for exhaust emission test

♦ Leakage

AG.

♦ Completeness

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♦ Installation

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– Perform visual check for

in t his d o cu m en

6.1.16

rrectness o f i t to the co n f orm spec atio h re n wit

♦ Adapter for air flow meter -V.A.G 1721-

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♦ Digital potentiometer -V.A.G 1630- and

♦ Damage Note

Faults found are to be rectified.

6.1.17

Connecting test units

– Pull on handbrake. 6. Legally required extra work according to country

119

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 – Automatic gearbox: Selector lever in position “P” or “N” . – Manual gearbox: Gear lever in neutral. – Connect ignition tester -V.A.G 1367- with trigger clamp V.A.G 1367/8- or ignition tester -V.A.G 1767- with ignition switched off. n AG. Volkswagen AG do es n ot g ua ran tee h t or u ac a For idling speed adjustment the intake ss air temperature sender (in wage – Connect 4 component exhaust emission tester -V.A.G 1787olks V y or 4 component exhaust emission tester d-V.A.G 1788- to tail b ise pipe. or

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

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air flow meter) has to be renewed by a 1.8 kΩ resistance. When connecting the testers for ignition timing and CO content the dig‐ ital potentiometer -V.A.G 1630- must additionally be connected as follows: – Pull connector off air flow meter potentiometer (00552-2323) -G19- . – Adjust digital potentiometer -V.A.G 1630- -side A- to 1.8 kΩ and connect to air flow meter and wiring harness using adapter -V.A.G 1721- .

– Start engine and run at idling speed. – Check ignition timing, if necessary adjust by turning distributor. Note ♦ The ignition timing is displayed directly on ignition tester with

“TDC sender” .

♦ With strobe lamp the strobe must be directed at ignition timing

marks.

– Connect vacuum hose to ignition distributor.

120 6. Legally required extra work according to country

AG.

Test sequence

agen lksw Vo by

Prote cted by c o p yri gh t. C op yi

6.1.18

ht rig py Co t.

– Separate 3 or 4 pin connector for Lambda probe -1- with igni‐ tion switched off.

do c um en

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– Pull vacuum hose off ignition distributor and seal.

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 – Check idling speed and CO content (at idling speed and at increased idling speed), if necessary correct by turning the adjustment screws alternately. A - Idling speed adjustment screw B - CO adjustment screw – Connect Lambda probe (00525-2342) -G39- connector. – Check CO content. – If it is not possible to adjust the CO content to the relevant test value, perform repair measure! – Seal CO adjustment screw with new anti-tamper plug. Note ♦ Reconnect all hoses and connections that have been discon‐

nected or separated for checking and adjusting purposes.

♦ Operate assemblies e.g. power-assisted steering, automatic

gearbox, air conditioning system and check that the engine operates smoothly under these load conditions.

6.1.19

Engine codes: PB, PF, RV, 1P G. Volkswage nA wage

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ks Special tools and yworkshop equipment requireds not gu Vol b ed

ara nte e

a ss

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es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

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ris ♦ Ignition ttester -V.A.G 1767- or ho u

♦ Ignition tester -V.A.G 1367-

in t his d o cu m en

ht rig py Co t.

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♦ Trigger clamp -V.A.G 1367/8-

6. Legally required extra work according to country

121

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AG.

Prote cted by

c o p yri gh t . C op yi

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

♦ 4 component exhaust emission tester -V.A.G 1788Note

♦ For all relevant engine basic setting test prerequisites and da‐

ta: ⇒ Data sheets for exhaust emission test

♦ To prevent injuries to personnel and/or damage to ignition and

Prote cted by

– Perform visual check for ♦ Installation ♦ Completeness ♦ Leakage ♦ Damage Note

Faults found are to be rectified.

6.1.21

Connecting test units

– Pull on handbrake. – Automatic gearbox: Selector lever in position “P” or “N” . – Manual gearbox: Gear lever in neutral.

122 6. Legally required extra work according to country

AG.

c o p yri gh t. C op yi

⇒ Data sheets for exhaust emission test

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Performing visual check of components influencing emissions

ht rig py Co t.

6.1.20

r fo ng

injection system, the ignition system wiring (including high voltage wiring) should be connected and disconnected only with ignition switched off.

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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♦ 4 component exhaust emission tester -V.A.G 1787- or

– Pull crankcase breather hose off pressure regulating valve -arrow 1- and seal hose.

Test sequence

pe rm itte d

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6.1.22

– Start engine and run at idling speed.

es, in part or in w l purpos hole ercia , is n m ot com

r te o iva r rp fo g n

– Check ignition timing, if necessary adjust by turning distributor.

Note

rrectness of i t to the co nform spec a t i h re o n in wit thi s

– Pull connector off temperature sensor -G18- (blue).

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do c um en

♦ The ignition timing is displayed directly on ignition tester with ht rig py Co t.

“TDC sender” . c o p yri gh t . C op yi

♦ With strobe lamp the strobe must be directed at ignition timing agen lksw Vo by

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marks.

– Operate throttle 3 times (throttle burst above 3000 rpm), run engine at idling speed and check idling speed.

6. Legally required extra work according to country

123

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo th uspeed ra Check idling speed and CO content (at idling and for a c s s idling speed), if vehicles with catalytic converter at increased

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

ility ab y li an pt ce

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–

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

necessary correct by turning the adjustment screws alternate‐ ly.

1 - Idling speed adjustment screw

rrectness of i t to the co nform spec at i h re o n wit in t his

2 - CO adjustment screw

– If it is not possible for vehicles with catalytic converter to adjust the CO content to the relevant test value, perform repair meas‐ ures! – Push connector onto temperature sensor -G18- , operate throttle 3 times, run engine at idling speed. – Seal CO adjustment screw with new anti-tamper plug. Note

♦ Reconnect all hoses and connections that have been discon‐

nected or separated for checking and adjusting purposes. r fo ng

♦ Ignition tester -V.A.G 1767- or

♦ Ignition tester -V.A.G 1367♦ Trigger clamp -V.A.G 1367/8-

124 6. Legally required extra work according to country

AG.

Special tools and workshop equipment required

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Engine code: PG, 1H

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6.1.23

ht rig py Co t.

gearbox, air conditioning system and check that the engine operates smoothly under these load conditions.

do c um en

♦ Operate assemblies e.g. power-assisted steering, automatic

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 ♦ 4 component exhaust emission tester -V.A.G 1787- or

♦ 4 component exhaust emission tester -V.A.G 1788♦ Adapter cable -V.A.G 1367/9Note ♦ For all relevant engine basic setting test prerequisites and da‐

ta: ⇒ Data sheets for exhaust emission test

♦ To prevent injuries to personnel and/or damage to ignition and

injection system, the ignition system wiring (including high voltage wiring) should be connected and disconnected only with ignition switched off.

6.1.24

Performing visual check of components influencing emissions

⇒ Data sheets for exhaust emission test – Perform visual check for ♦ Installation ♦ Completeness ♦ Leakage un le pe rm itte d

ility ab y li an pt ce

♦ Damage

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

Note

Faults found are to be rectified.

6.1.25

Connecting test units

– Pull on handbrake.

– Automatic gearbox: Selector lever in position “P” or “N” .

do c um en

ht rig py Co t.

r te o iva r rp fo g n

– Manual gearbox: Gear lever in neutral.

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AG.

6. Legally required extra work according to country

125

Prote cted by c o py rig ht . C op yi

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

ility ab y li an pt ce

Note

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

un le

–

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d e nte Connect ignition tester -V.A.G 1367- with trigger clamp - horis eo t u ra V.A.G 1367/8- or ignition tester -V.A.G 1767- with ignition a c s s switched off.

For vehicles (engine code PG) with charge air cooler above gear‐ box, a TDC sender is installed as standard. To connect ignition tester to TDC sender use adapter cable -V.A.G 1367/9- . – Connect 4 component exhaust emission tester -V.A.G 1787or 4 component exhaust emission tester -V.A.G 1788- to tail pipe.

6.1.26

Test sequence

– Start engine and run at idling speed.

“TDC sender” .

♦ With strobe lamp the strobe must be directed at ignition timing

marks.

– Operate throttle 3 times (throttle burst above 3000 rpm) and run engine at idling speed.

126 6. Legally required extra work according to country

Prote cted by

♦ The ignition timing is displayed directly on ignition tester with

AG.

Note

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c o p yri gh t. C op yi

– Check ignition timing at 2000 ... 2500 rpm, if necessary adjust by turning the distributor.

ht rig py Co t.

– Pull connector off temperature sensor -G18- (blue) -arrow- .

do c um en

r fo ng

– Pull crankcase breather hose -arrow- off pressure regulating valve and place so that only fresh air is drawn in.

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 AG. Volkswagen AG d agen o

un le

pe rm itte d

1 - Idling speed adjustment screw 2 - CO adjustment screw

– Seal CO adjustment screw with new anti-tamper plug. Note

♦ Reconnect all hoses and connections that have been discon‐

nected or separated for checking and adjusting purposes.

♦ Operate assemblies e.g. power-assisted steering, automatic

Engine code: PL

AG.

♦ Ignition tester -V.A.G 1767- or

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Prote cted by c o py rig ht . C op yi

Special tools and workshop equipment required

ht rig py Co t.

6.1.27

r te o iva r rp fo ng

gearbox, air conditioning system and check that the engine operates smoothly under these load conditions.

in t his d o cu m en

es, in part or in w l purpos hole ercia , is n m ot com

– Push connector onto temperature sensor -G18- , operate throttle 3 times, run engine at idling speed.

rrectness o f i t to the co n f orm spec atio h re n wit

– If it is not possible for vehicles with catalytic converter to adjust the CO content to the relevant test value, perform repair meas‐ ures!

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es n ksw – Check idling speed and CO (at idling speed and ofor olcontent tg yV b d vehicles with catalyticsconverter at increased idling speed), uifaran e i tee r necessary correct by ho turning the adjustment screws alternate‐ or ut ac a ly. ss

♦ Ignition tester -V.A.G 1367♦ Trigger clamp -V.A.G 1367/8-

6. Legally required extra work according to country

127

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 ♦ 4 component exhaust emission tester -V.A.G 1787- or

♦ 4 component exhaust emission tester -V.A.G 1788olksw AG. V agen ksw l o yV db ise r tho au

Note

agen AG does not gu ara nte eo ra c

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pe rm itte d

ta: ⇒ Data sheets for exhaust emission test

♦ To prevent injuries to personnel and/or damage to ignition and es, in part or in w l purpos hole ercia , is n m ot com

6.1.28

Performing visual check of components influencing emissions

⇒ Data sheets for exhaust emission test – Perform visual check for ♦ Installation ♦ Completeness ♦ Damage

Connecting test units

AG.

6.1.29

agen lksw Vo by

Prote cted by c o p yri gh t. C op yi

Faults found are to be rectified.

– Pull on handbrake. – Automatic gearbox: Selector lever in position “P” or “N” . – Manual gearbox: Gear lever in neutral.

128 6. Legally required extra work according to country

ht rig py Co t.

Note

do c um en

r te o iva r rp fo g n

♦ Leakage

rrectness of i t to the co nform spec a t i h re o n in wit thi s

injection system, the ignition system wiring (including high voltage wiring) should be connected and disconnected only with ignition switched off.

ility ab y li an pt ce

s ♦ For all relevant sengine basic setting test prerequisites and da‐

– Pull crankcase breather hoses -1- and -2- off breather housing -3- , separate and place so that only fresh air is drawn in. Con‐ nection with calibrated drilling -4- must remain in hose -2- . Vehicles from 10.86 with activated charcoal filter system:

pe rm itte d

es, in part or in w l purpos hole ercia , is n m ot com

Test sequence

rrectness of i t to the co nform spec a t i h re o n in wit thi s

6.1.30

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– Attach angled piece in intake air duct so that only fresh air can AG. Volkswagen AG d be drawn in through restricted hole -arrow- . agen o

– Start engine and run at idling speed. – Check ignition timing, if necessary adjust by turning distributor. Note

♦ The ignition timing is displayed directly on ignition tester with

“TDC sender” .

♦ With strobe lamp the strobe must be directed at ignition timing

marks.

r te o iva r rp fo g n

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

Idling speed adjustment screw -arrow-

do c um en

– Check idling speed and CO content (at idling speed and at increased idling speed), if necessary correct by turning the adjustment screws alternately.

6. Legally required extra work according to country

129

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 CO adjustment screw -arrow– If it is not possible to adjust the CO content to the relevant test value, perform repair measure! Note

♦ ♦

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara When adjusting, do not push down the adjustment wrench. d e nte is r o eo h ut Do not operate throttle when adjustment wrench is inserted. ra a c s s un le

ility ab y li an pt ce

♦ Remove adjustment wrench after every adjusting procedure

rrectness of i t to the co nform spec at i h re o n wit in t his

Note

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

and operate throttle before the duty cycle is read.

♦ Reconnect all hoses and connections that have been discon‐

nected or separated for checking and adjusting purposes.

♦ Operate assemblies e.g. power-assisted steering, automatic

gearbox, air conditioning system and check that the engine operates smoothly under these load conditions.

6.1.31

Engine code: PN

Special tools and workshop equipment required

AG.

130 6. Legally required extra work according to country

agen lksw Vo by

Prote cted by c o py rig ht . C op yi

♦ Trigger clamp -V.A.G 1367/8-

ht rig py Co t.

♦ Ignition tester -V.A.G 1367-

do c um en

r fo ng

♦ Ignition tester -V.A.G 1767- or

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 ♦ 4 component exhaust emission tester -V.A.G 1787- or

♦ 4 component exhaust emission tester -V.A.G 1788Note

ility ab y li an pt ce

injection system, the ignition system wiring (including high voltage wiring) should be connected and disconnected only with ignition switched off.

rrectness of i t to the co nform spec a t i h re o n in wit thi s

6.1.32

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

♦

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♦

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran For all relevant engine basic settingisetest prerequisites and da‐ tee r o ta: ⇒ Data sheets for exhaust emission test h t or u ac a s s To prevent injuries to personnel and/or damage to ignition and

Performing visual check of components influencing emissions

⇒ Data sheets for exhaust emission test – Perform visual check for

Faults found are to be rectified.

Connecting test units

Prote cted by

– Pull on handbrake.

AG.

6.1.33

do c um en

Note

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♦ Damage

c o p yri gh t . C op yi

♦ Leakage

r te o iva r rp fo g n

♦ Completeness

ht rig py Co t.

♦ Installation

– Automatic gearbox: Selector lever in position “P” or “N” . – Manual gearbox: Gear lever in neutral.

6. Legally required extra work according to country

131

When inserting the TDC sender observe white marking of TDC sender mounting.

6.1.34

Test sequence

– Start engine and run at idling speed. – Check ignition timing, if necessary adjust by turning distributor. Note ♦ The ignition timing is displayed directly on ignition tester with

“TDC sender” .

♦ With strobe lamp the strobe must be directed at ignition timing

marks.

– Only check idling speed (not adjustable). If the specification n AG. Volkswagen AG do es n wage for idling speed is not achieved, determine cause to ksaccording l ot g o V ua by workshop manual (repair measure). d ra e un le

ility ab y li an pt ce

speed, if necessary adjust at adjustment screw -A- . pe rm itte d

–

nte eo ra c

ris ho ut a ss at increased idling Check CO content at idling speed and

rrectness o f i t to the co n f orm spec atio h re n wit

Note

es, in part or in w l purpos hole ercia , is n m ot com

– If it is not possible to adjust the CO content to the relevant test value, perform repair measure!

♦ Operate assemblies e.g. power-assisted steering, automatic

gearbox, air conditioning system and check that the engine operates smoothly under these load conditions.

♦ Reconnect all hoses and connections that have been discon‐

nected or separated for checking and adjusting purposes.

6.1.35

Engine code: RD r te o iva r rp fo ng

ht rig py Co t.

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AG.

Prote cted by c o p yri gh t. C op yi

132 6. Legally required extra work according to country

in t his d o cu m en

Special tools and workshop equipment required

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 ♦ Ignition tester -V.A.G 1767- or

ility ab y li an pt ce

ht rig py Co t.

r fo ng

♦ 4 component exhaust emission tester -V.A.G 1787- or

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

♦

un le

♦

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte s i r Ignition tester -V.A.G 1367o eo h ut ra a c s s Trigger clamp -V.A.G 1367/8-

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

♦ 4 component exhaust emission tester -V.A.G 1788Note ♦ For all relevant engine basic setting test prerequisites and da‐

ta: ⇒ Data sheets for exhaust emission test

♦ To prevent injuries to personnel and/or damage to ignition and

injection system, the ignition system wiring (including high voltage wiring) should be connected and disconnected only with ignition switched off.

6.1.36

Performing visual check of components influencing emissions

⇒ Data sheets for exhaust emission test – Perform visual check for ♦ Installation 6. Legally required extra work according to country

133

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 ♦ Completeness ♦ Leakage ♦ Damage Note

Faults found are to be rectified.

6.1.37

Connecting test units

– Pull off crankcase breather hoses and place so that only fresh air can be drawn in: Intake manifold hose -2-

un le

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AG. Volkswagen AG d agen oes ksw not l o V Air cleaner hose -3gu by ara d e nte is r o Do not seal connection at intake manifold. eo h ut ra a c s s Vehicles with activated charcoal filter:

Test sequence

– Start engine and run at idling speed. – Check ignition timing, if necessary adjust by turning distributor. Note

♦ The ignition timing is displayed directly on ignition tester with

“TDC sender” .

♦ With strobe lamp the strobe must be directed at ignition timing r fo ng

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AG.

Prote cted by c o p yri gh t. C op yi

134 6. Legally required extra work according to country

ht rig py Co t.

marks.

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

6.1.38

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

– Attach angled piece -4- so that the free connection with the restricted hole is inserted into the air intake duct.

. Volkswagen AG gen AG does not gu ara nte eo ra c

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

Note

t au ss

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a – If it is not possible for vehicles with catalytic converter to adjust ksw Vol by the CO content to the relevant test value, perform repair meas‐ d e ris ures! ho

♦ When adjusting, do not push down the adjustment wrench.

rrectness of i t to the co nform spec at i h re o n wit in t his

♦ Do not operate throttle when adjustment wrench is inserted. ♦ Remove adjustment wrench after every adjusting procedure

and operate throttle before the duty cycle is read. Note

♦ Reconnect all hoses and connections that have been discon‐

nected or separated for checking and adjusting purposes.

♦ Operate assemblies e.g. power-assisted steering, automatic

agen lksw Vo by

AG.

♦ Ignition tester -V.A.G 1767- or

Prote cted by c o p yri gh t. C op yi

Special tools and workshop equipment required

ht rig py Co t.

Engine code: RP

do c um en

6.1.39

r fo ng

gearbox, air conditioning system and check that the engine operates smoothly under these load conditions.

♦ Ignition tester -V.A.G 1367♦ Trigger clamp -V.A.G 1367/8-

6. Legally required extra work according to country

135

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 ♦ 4 component exhaust emission tester -V.A.G 1787- or

♦ 4 component exhaust emission tester -V.A.G 1788Note ♦ For all relevant engine basic setting test prerequisites and da‐

ta: ⇒ Data sheets for exhaust emission test

♦ To prevent injuries to personnel and/or damage to ignition and

injection system, the ignition system wiring (including high voltage wiring) should be connected and disconnected only . Volkswagen AG with ignition switched off. gen AG does swa

not gu ara nte eo ra c

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

⇒ Data sheets for exhaust emission test – Perform visual check for

rrectness of i t to the co nform spec at i h re o n wit in t his

♦ Installation

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Performing visual check of components influencing emissions un le

6.1.40

k Vol by d e ris tho u a ss

♦ Completeness ♦ Leakage ♦ Damage Note

Faults found are to be rectified.

6.1.41

Connecting test units

– Pull on handbrake. r fo ng

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AG.

Prote cted by

c o p yri gh t . C op yi

136 6. Legally required extra work according to country

ht rig py Co t.

– Manual gearbox: Gear lever in neutral.

do c um en

– Automatic gearbox: Selector lever in position “P” or “N” .

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 – Connect ignition tester -V.A.G 1367- with trigger clamp V.A.G 1367/8- or ignition tester -V.A.G 1767- with ignition switched off.

oes not gu ara nte eo ra c

– Pull vacuum hose off ignition distributor and seal. – Start engine and run at idling speed. – Check ignition timing, if necessary adjust by turning distributor. Note

♦ The ignition timing is displayed directly on ignition tester with

“TDC sender” .

♦ With strobe lamp the strobe must be directed at ignition timing

r fo ng

– Connect vacuum hose to ignition distributor. The ignition tim‐ ing must not change, otherwise check vacuum control valve of distributor (repair measure) – Check CO content at idling speed and at increased idling speed (not adjustable).

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Prote cted by c o py rig ht . C op yi

– Check idling speed (not adjustable).

ht rig py Co t.

marks.

do c um en

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t itte iva d pr

Test sequence

rrectness of i t to the co nform spec at i h re o n wit in t his

6.1.42

wa olks yV b ed ris ho t au

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– Connect 4 component exhaust emission tester -V.A.G 1787or 4 component exhaust emission tester -V.A.G 1788- to tail . Volkswagen AG pipe. gen AG d

AG.

If actual figures deviate from test values: Carry out repair meas‐ ures! Note ♦ Reconnect all hoses and connections that have been discon‐

nected or separated for checking and adjusting purposes.

♦ Operate assemblies e.g. power-assisted steering, automatic

gearbox, air conditioning system and check that the engine operates smoothly under these load conditions.

6.1.43

Engine code: GT

Special tools and workshop equipment required

6. Legally required extra work according to country

137

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 ♦ Ignition tester -V.A.G 1767- or

♦ Ignition tester -V.A.G 1367-

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

rrectness o f i t to the co n f orm spec atio h re n wit

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

ility ab y li an pt ce

un le

♦ Trigger clamp -V.A.G 1367/8-

agen lksw Vo by

Prote cted by c o py rig ht . C op yi

Note

ht rig py Co t.

♦ 4 component exhaust emission tester -V.A.G 1788-

♦ For all relevant engine basic setting test prerequisites and da‐ AG.

ta: ⇒ Data sheets for exhaust emission test

♦ To prevent injuries to personnel and/or damage to ignition and

injection system, the ignition system wiring (including high voltage wiring) should be connected and disconnected only with ignition switched off.

6.1.44

Performing visual check of components influencing emissions

⇒ Data sheets for exhaust emission test – Perform visual check for ♦ Installation

138 6. Legally required extra work according to country

in t his d o cu m en

r te o iva r rp fo ng

♦ 4 component exhaust emission tester -V.A.G 1787- or

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 ♦ Completeness ♦ Leakage ♦ Damage Note

AG. Volkswagen AG d agen oes ksw not l o V gu y b rectified. ara d Faults found are isto be e nte r o eo h t u ra a c s s un le

Connecting test units

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6.1.45

pe rm itte d

– Pull on handbrake. – Manual gearbox: Gear lever in neutral. – Connect ignition tester -V.A.G 1367- with trigger clamp V.A.G 1367/8- or ignition tester -V.A.G 1767- with ignition switched off.

Test sequence

– Start engine and run at idling speed. agen lksw Vo by

c o p yri gh t. C op yi

– Check dwell angle, adjust if necessary.

ht rig py Co t.

6.1.46

do c um en

r te o iva r rp fo g n

– Connect 4 component exhaust emission tester -V.A.G 1787or 4 component exhaust emission tester -V.A.G 1788- to tail pipe.

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

– Automatic gearbox: Selector lever in position “P” or “N” .

Prote cted by

– Pull vacuum hose off ignition distributor and seal. AG.

– Check ignition timing, if necessary adjust by turning distributor. Note ♦ The ignition timing is displayed directly on ignition tester with

“TDC sender” .

♦ With strobe lamp the strobe must be directed at ignition timing

marks.

– Connect vacuum hose to ignition distributor.

6. Legally required extra work according to country

139

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 – Check idling speed and CO content (at idling speed), if nec‐ essary correct by turning the adjustment screws alternately. 1 - Idling speed adjustment screw 2 - CO adjustment screw – Seal CO adjustment screw with new anti-tamper plug. Note ♦ Reconnect all hoses and connections that have been discon‐

nected or separated for checking and adjusting purposes.

♦ Operate assemblies e.g. power-assisted steering, automatic

gearbox, air conditioning system and check that the engine operates smoothly under these load conditions.

6.1.47

Engine codes: HM, HV

Special tools and workshop equipment required ♦ Ignition tester -V.A.G 1767- or

ility ab y li an pt ce

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t . C op yi

140 6. Legally required extra work according to country

in t his d o cu m en

r te o iva r rp fo ng

rrectness o f i t to the co n f orm spec atio h re n wit

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

un le

♦

ht rig py Co t.

♦

n AG. Volkswagen AG do es n wage s k l ot g Ignition tester -V.A.G y1367Vo ua b ran ed s i tee r Trigger clamp -V.A.G 1367/8o h t or u ac a ss

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 . Volkswagen AG gen AG does not gu ara nte eo ra c

y db ise r tho au s s

rrectness o f i t to the co n f orm spec atio h re n wit

♦ 4 component exhaust emission tester -V.A.G 1788Note

♦ For all relevant engine basic setting test prerequisites and da‐

ta: ⇒ Data sheets for exhaust emission test r te o iva r rp fo ng

♦ To prevent injuries to personnel and/or damage to ignition and

injection system, the ignition system wiring (including high voltage wiring) should be connected and disconnected only with ignition switched off. c o p yri gh t. C op yi

Performing visual check of components influencing emissions

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⇒ Data sheets for exhaust emission test

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6.1.48

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a 1787- or ♦ 4 component exhaust emission testerVo-V.A.G lksw

– Perform visual check for ♦ Installation ♦ Completeness ♦ Leakage ♦ Damage Note

Faults found are to be rectified.

6.1.49

Connecting test units

– Pull on handbrake. – Automatic gearbox: Selector lever in position “P” or “N” . – Manual gearbox: Gear lever in neutral.

6. Legally required extra work according to country

141

TDC sender mounting:

♦ Engine code HM “white” ♦ Engine code HV “green”

6.1.50

Test sequence

– Pull vacuum hose off ignition distributor. – Start engine and run at idling speed. – Check ignition timing, if necessary adjust by turning distributor. Note ♦ The ignition timing is displayed directly on ignition tester with

“TDC sender” .

♦ With strobe lamp the strobe must be directed at ignition timing AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

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marks.

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B - CO adjustment screw

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A - Idling speed adjustment screw

pe rm itte d

– Check idling speed and CO content (at idling speed), if nec‐ essary correct by turning the adjustment screws alternately.

– Connect vacuum hose to ignition distributor. Note

♦ Operate assemblies e.g. power-assisted steering, automatic

gearbox, air conditioning system and check that the engine operates smoothly under these load conditions.

♦ Reconnect all hoses and connections that have been discon‐

Engine code: HZ (1B3 carburettor)

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142 6. Legally required extra work according to country

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Special tools and workshop equipment required

in t his d o cu m en

6.1.51

r te o iva r rp fo ng

nected or separated for checking and adjusting purposes.

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 ♦ Ignition tester -V.A.G 1767- or

♦ Ignition tester -V.A.G 1367-

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rrectness of i t to the co nform spec at i h re o n wit in t his

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♦ Trigger clamp -V.A.G 1367/8-

♦ 4 component exhaust emission tester -V.A.G 1787- or

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Note

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♦ 4 component exhaust emission tester -V.A.G 1788-

♦ For all relevant engine basic setting test prerequisites and da‐ AG.

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ta: ⇒ Data sheets for exhaust emission test

♦ To prevent injuries to personnel and/or damage to ignition and

injection system, the ignition system wiring (including high voltage wiring) should be connected and disconnected only with ignition switched off.

6.1.52

Performing visual check of components influencing emissions

⇒ Data sheets for exhaust emission test – Perform visual check for ♦ Installation 6. Legally required extra work according to country

143

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 ♦ Completeness ♦ Leakage ♦ Damage Note

Faults found are to be rectified.

6.1.53 –

6.1.54

Test sequence

– Pull vacuum hose off ignition distributor.

r fo ng

– Check ignition timing, if necessary adjust by turning distributor.

“TDC sender” .

♦ With strobe lamp the strobe must be directed at ignition timing

marks.

♦ After connecting the vacuum hose to vacuum unit the ignition

timing jumps to 16 ... 22° before TDC.

– When checking or adjusting, ensure the adjustment screw -B- with air flap open is not on the fast idle cam -A- , if neces‐ sary turn fast idle cam. – Check idling speed and CO content (at idling speed), if nec‐ essary correct by turning the adjustment screws alternately.

144 6. Legally required extra work according to country

AG.

♦ The ignition timing is displayed directly on ignition tester with

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Note

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– Start engine and run at idling speed.

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– Manual gearbox: Gear lever in neutral.

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–

Connecting test units

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

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CO adjustment screw -arrow– Seal CO adjustment screw with new anti-tamper plug.

Note

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– Connect vacuum hose to ignition distributor.

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♦ Operate assemblies e.g. power-assisted steering, automatic c o p yri gh t. C op yi

gearbox, air conditioning system and check that the engine operates smoothly under these load conditions. agen lksw Vo by

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♦ Reconnect all hoses and connections that have been discon‐ AG.

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Idling speed adjustment screw -arrow-

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

nected or separated for checking and adjusting purposes.

6.1.55

Engine code HZ (Weber 32 TLA carbu‐ rettor)

Special tools and workshop equipment required ♦ Ignition tester -V.A.G 1767- or

♦ Ignition tester -V.A.G 1367♦ Trigger clamp -V.A.G 1367/8-

6. Legally required extra work according to country

145

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 ♦ 4 component exhaust emission tester -V.A.G 1787- or

♦ 4 component exhaust emission tester -V.A.G 1788Note ♦ For all relevant engine basic setting test prerequisites and da‐

ta: ⇒ Data sheets for exhaust emission test

♦ To prevent injuries to personnel and/or damage to ignition and

injection system, the ignition system wiring (including high voltage wiring) should be connected and disconnected only with ignition switched off.

6.1.56

Performing visual check of components AG. Volkswagen AG d influencing emissions agen oes n lksw

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♦ Damage Note

Faults found are to be rectified.

6.1.57

Connecting test units

– Pull on handbrake.

– Automatic gearbox: Selector lever in position “P” or “N” .

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c o p yri gh t. C op yi

146 6. Legally required extra work according to country

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r fo ng

– Manual gearbox: Gear lever in neutral.

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

♦ Leakage

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

♦ Completeness

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⇒ Data sheets for exhaust emission test rised b ho ut – Perform visual check for sa

6.1.58

Test sequence

– Pull vacuum hose off ignition distributor. – Start engine and run at idling speed. AG. Volkswagen – Check ignition timing, if necessary adjust bywturning agen distributor. AG doe

Note

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♦ With strobe lamp the strobe must be directed at ignition timing

marks.

♦ After connecting the vacuum hose to vacuum unit the ignition

timing jumps to 16 ... 22° before TDC.

– Check idling speed and CO content (at idling speed), if nec‐ essary correct by turning the adjustment screws alternately.

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c o p yri gh t . C op yi

CO adjustment screw -arrow-

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Idling speed adjustment screw (illustration B -arrow- )

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urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

“TDC sender” .

un le

♦ The ignition timing is displayed directly on ignition tester with

– Seal CO adjustment screw with new anti-tamper plug. Note ♦ Operate assemblies e.g. power-assisted steering, automatic

gearbox, air conditioning system and check that the engine operates smoothly under these load conditions.

♦ Reconnect all hoses and connections that have been discon‐

nected or separated for checking and adjusting purposes.

6. Legally required extra work according to country

147

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

6.1.59

Engine code: KR

Special tools and workshop equipment required ♦ Ignition tester -V.A.G 1767- or

♦ Ignition tester -V.A.G 1367-

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pe rm itte d

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♦ Trigger clamp -V.A.G 1367/8-

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es, in part or in w l purpos hole ercia , is n m ot com

♦ 4 component exhaust emission tester -V.A.G 1787- or

r te o iva r rp fo ng

c o p yri gh t . C op yi

♦ For all relevant engine basic setting test prerequisites and da‐ Prote cted by

injection system, the ignition system wiring (including high voltage wiring) should be connected and disconnected only with ignition switched off.

148 6. Legally required extra work according to country

AG.

♦ To prevent injuries to personnel and/or damage to ignition and

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Note

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♦ 4 component exhaust emission tester -V.A.G 1788-

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Performing visual check of components influencing emissions

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– Perform visual check for ♦ Installation ♦ Completeness ♦ Leakage ♦ Damage Note

Faults found are to be rectified.

Prote cted by c o py rig ht . C op yi

– Pull on handbrake.

r fo ng

Connecting test units

– Automatic gearbox: Selector lever in position “P” or “N” .

AG.

– Connect ignition tester -V.A.G 1367- with trigger clamp V.A.G 1367/8- or ignition tester -V.A.G 1767- with ignition switched off.

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– Manual gearbox: Gear lever in neutral.

do c um en

6.1.61

rrectness of i t to the co nform spec at i h re o n wit in t his

⇒ Data sheets for exhaust emission test

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6.1.60

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara 1984 ➤ d Golf 1984 ➤ , Jetta e nte is r o eo h Maintenance - Edition 08.2003 ut ra a c s s

– Connect 4 component exhaust emission tester -V.A.G 1787or 4 component exhaust emission tester -V.A.G 1788- to tail pipe (seal 2nd tail pipe).

– Pull crankcase breather hoses -1- and -2- off breather housing -3- , separate and place so that only fresh air is drawn in. Con‐ nection with calibrated drilling -4- must remain in hose -2- .

6.1.62

Test sequence

– Start engine and run at idling speed. – Check ignition timing, if necessary adjust by turning distributor.

6. Legally required extra work according to country

149

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 Note ♦ The ignition timing is displayed directly on ignition tester with

“TDC sender” .

♦ With strobe lamp the strobe must be directed at ignition timing

marks.

– Switch off engine.

– Separate connector -1- . – Start engine and run at idling speed.

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–

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o h t and CO content (at idling speed), if nec‐ e or Check idling speed u ac a essary correctssby turning the adjustment screws alternately. pe rm itte d

A - Idling speed adjustment screw

♦ When adjusting, do not push down the adjustment wrench. ♦ Do not operate throttle when adjustment wrench is inserted. ♦ Remove adjustment wrench after every adjusting procedure

and operate throttle before the duty cycle is read. Note r te o iva r rp fo ng

♦ Reconnect all hoses and connections that have been discon‐

nected or separated for checking and adjusting purposes.

♦ Operate assemblies e.g. power-assisted steering, automatic

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Engine codes: MH, NU, 2C, 2G AG.

6.1.63

Special tools and workshop equipment required

150 6. Legally required extra work according to country

ht rig py Co t.

gearbox, air conditioning system and check that the engine operates smoothly under these load conditions.

rrectness o f i t to the co n f orm spec atio h re n wit

Note

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es, in part or in w l purpos hole ercia , is n m ot com

B - CO adjustment screw

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 ♦ Ignition tester -V.A.G 1767- or

♦ Ignition tester -V.A.G 1367-

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♦

AG. Volkswagen AG d agen oes ksw not l o Trigger clamp -V.A.G 1367/8- by V gu ara d e nte is r o eo h ut ra a c s s

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♦ 4 component exhaust emission tester -V.A.G 1788-

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r te o iva r rp fo g n

♦ 4 component exhaust emission tester -V.A.G 1787- or

Note ♦ For all relevant engine basic setting test prerequisites and da‐

ta: ⇒ Data sheets for exhaust emission test

♦ To prevent injuries to personnel and/or damage to ignition and

injection system, the ignition system wiring (including high voltage wiring) should be connected and disconnected only with ignition switched off.

6.1.64

Performing visual check of components influencing emissions

⇒ Data sheets for exhaust emission test – Perform visual check for ♦ Installation 6. Legally required extra work according to country

151

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 ♦ Completeness ♦ Leakage ♦ Damage Note

Faults found are to be rectified.

6.1.65

Connecting test units

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Test sequence pe rm itte d

6.1.66

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AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte The TDC sender must be inserted iseinto hole marked “190” up to r o eo h t and including chassis numberau16/19 GW 087 945. ra c s s

– Start engine and run at idling speed. – Check ignition timing, if necessary adjust by turning distributor. Note

♦ The ignition timing is displayed directly on ignition tester with

“TDC sender” .

♦ With strobe lamp the strobe must be directed at ignition timing

marks.

♦ After connecting the vacuum hose to vacuum unit the ignition

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c o p yri gh t. C op yi

152 6. Legally required extra work according to country

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r te o iva r rp fo ng

timing jumps to 16 ... 22° before TDC.

in t his d o cu m en

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rrectness o f i t to the co n f orm spec atio h re n wit

– Pull vacuum hose off ignition distributor.

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 – Check idling speed and CO content (at idling speed), if nec‐ essary correct by turning the adjustment screws alternately. A - Idling speed adjustment screw B - CO adjustment screw – Seal CO adjustment screw with new anti-tamper plug. Note ♦ Reconnect all hoses and connections that have been discon‐

nected or separated for checking and adjusting purposes.

♦ Operate assemblies e.g. power-assisted steering, automatic

gearbox, air conditioning system and check that the engine operates smoothly under these load conditions.

6.1.67

Engine codes JP, JR, ME, RA, SB, 1V

AG. Volkswagen AG d agen oes

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♦ Combustion tester -V.A.G 1500-

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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♦

by ed Diesel tester -V.A.G 1743- or ris o th au ss

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Note ♦ For all relevant emissions test prerequisites and data: ⇒ Data

sheets for exhaust emission test

♦ The test should if possible be completed in the open following

a road test. If this is not possible for various reasons (weather, excess noise in residential areas), then the test can be carried out in a workshop.

♦ To reduce noise levels, the bonnet should be closed on first

catch during tests.

6. Legally required extra work according to country

153

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

6.1.68

Performing visual check of components influencing emissions

⇒ Data sheets for exhaust emission test – Perform visual check for: ♦ Installation ♦ Completeness ♦ Leakage ♦ Damage Note

Faults found are to be rectified.

6.1.69

Test sequence with Diesel tester -V.A.G 1743- :

(Test sequence with Combustion tester -V.A.G 1500⇒ page 157 ) Note

The combustion tester -V.A.G 1500- can be used alternatively to the Diesel tester -V.A.G 1743- . – Connect diesel tester -V.A.G 1743- according to operating in‐ structions. Description, measuring process, function, setting up and opera‐ tion ⇒ Operating instructions V.A.G 1743 . Carry out the following procedure:

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is Perform exhaust emission test according to instructions on diesel r o eo h ut tester -V.A.G 1743- display. ra a c s s

– Start engine and run at idling speed.

n rpm XXX XXXX

mode k l/m B X.XX

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If the following is indicated on display:

T °C XX

6.1.70

rrectness of i t to the co nform spec at i h re o n wit in t his

Unit ready to carry out measurements.

Checking idling speed:

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154 6. Legally required extra work according to country

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Idling speed not within specified range:

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 – Injection pump without idling speed boost (engine codes JP and JR up to approx. 08.85): Check idling speed and if nec‐ essary adjust by turning the idling speed adjustment screw -arrow- . – Lock adjustment screw.

– Injection pump with idling speed boost (engine codes JP and JR from approx. 09.85, ME, RA, SB and 1V): Check idling speed and if necessary adjust by turning the idling speed ad‐ justment screw -arrow- .

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For all engines:

6.1.71

Perform acceleration test:

rrectness of i t to the co nform spec at i h re o n wit in t his

– Press button for Acceleration test . First, a fresh air comparison is performed. If the following is indicated on display:

n rpm | tB s XXX XXXX -.--

M XX -

6. Legally required extra work according to country

155

The arrow pointing upwards indicates that the unit is waiting for the throttle burst. – Depress accelerator pedal fully and hold for specified time.

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– Check maximum speed (not under load) and if necessary ad‐ just as follows:

do c um en

Gas T °C 0

Current values for temperature and speed are displayed.

k 1/m X.XX

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c o p yri gh t . C op yi

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003 – Loosen lock nut of adjustment screw -arrow- . – Open the throttle and adjust speed with the adjustment screw -arrow- . – Lock adjustment screw. WARNING

If the governed speed (maximum speed) is exceeded, lift off accelerator pedal immediately and adjust governed speed. If the unit detects a valid throttle burst (the speed increases con‐ tinually during measuring period tx), the following is indicated on display: If the following is indicated on display: n rpm | tB s k 1/m Gas T °C XXX XXXX -.--.-1 XX

M -

The display remains “frozen” during the evaluation phase (ap‐ prox. 15 seconds). Volkswag AG. agen

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lksw After the evaluation phase, the changes to: odisplay yV b ed

M -

a ss

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The upwardly pointing arrow indicates that the unit is ready for the next throttle burst.

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Repeat test 4 times.

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ris T °C n rpm | tB s k 1/m oGas h XXX XXXX X.XX X.XX X XX ut

The following is indicated on display after each throttle burst: n rpm | tB s k 1/m Gas T °C XXX XXXX X.XX X.XX X XX

M -

In this way, the unit measures and registers at least four throttle bursts. After the fourth and for each further throttle burst se‐ quence, an average of the last three measurements is performed. The following is indicated on display after each throttle burst: n rpm | tB s k 1/m Gas T °C XXX XXXX X.XX X.XX X XX

M -

Average

tB s k 1/m Band width M X.XX X.XX -

X.XX

After 5 seconds, this display changes to: M -

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|tB s k 1/m Band width X.XX X.XX XX

The display remains until a further throttle burst is performed or another measurement is called up. AG.

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If the opacity figures are equal to or less than the prescribed fig‐ ures, cease measurements. But if the determined opacity figures are over the prescribed fig‐ ures, locate fault during a repair measure ⇒ Fault finding, engine.

156 6. Legally required extra work according to country

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Average

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After 10 seconds, this display changes to:

Golf 1984 ➤ , Jetta 1984 ➤ Maintenance - Edition 08.2003

6.1.72

Test sequence with Combustion tester V.A.G 1500- :

Description, measuring process, tester function, setting up and operation ⇒ Operating instructions combustion tester V.A.G 1500- . – Start engine and run at idling speed.

6.1.73

Connect combustion tester V.A.G 1500- .

During the following tests and adjustments the measuring head is not, as yet, to be placed on the exhaust tail pipe. – Injection pump without idling speed boost (engine codes JP and JR up to approx. 08.85): Check idling speed and if nec‐ essary adjust by turning the idling speed adjustment screw -arrow- . – Lock adjustment screw.

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– Check governed speed (maximum speed) (not under load) AG. Volkswagen AG d and if necessary adjust as follows: agen oes ksw n

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AG.

6. Legally required extra work according to country

157

Prote cted by c o p yri gh t. C op yi

If the governed speed (maximum speed) is exceeded, lift off accelerator pedal immediately and adjust governed speed. – Place measuring head on exhaust tail pipe.

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

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158 6. Legally required extra work according to country

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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– Perform at least 2 x 5 throttle bursts (but max. 5 x 5 throttle bursts). If after 2 x 5 throttle bursts the opacity figures are equal to or less than the prescribed figures then end measurement. But if after 5 x 5 throttle bursts the determined opacity figures are above the prescribed figures then locate fault within repair measures framework ⇒ Fault finding engine