Contents LIVING WITH YOUR VW POLO Introduction Page 0.4 Safety first! Page 0.5 Roadside repairs Introduction Page 0.6 If your car won’t start Page 0.6 Jump starting Page 0.7 Wheel changing Page 0.8 Identifying leaks Page 0.9 Towing Page 0.9 Weekly checks Introduction Page 0.10 Underbonnet check points Page 0.10 Engine oil level Page 0.11 Coolant level Page 0.11 Brake fluid level Page 0.12 Screen washer fluid level Page 0.12 Wiper blades Page 0.13 Battery Page 0.
Contents REPAIRS & OVERHAUL Engine and associated systems Petrol engine in-car repair procedures Page 2A.1 Engine removal and overhaul procedures Page 2B.1 Cooling, heating and ventilation systems Page 3.1 Fuel/exhaust systems - single-point petrol injection models Page 4A.1 Fuel/exhaust systems - multi-point petrol injection models Page 4B.1 Exhaust and emission control systems Page 4C.1 Engine electrical - starting and charging systems Page 5A.1 Engine electrical - Ignition system Page 5B.
0.4 Introduction The updated VW Polo range was introduced in November of 1990, with a choice of 1.05 litre (1043 cc) or 1.3 litre (1272 cc) petrol engines, with either single-point or multi-point fuel injection. During Spring 1991, the G40 model was launched, equipped with a supercharged version of the 1.3 litre engine. Three body shells are available - a three-door hatchback, a two-door saloon and a threedoor Coupe.
Safety first! 0.5 Working on your car can be dangerous. This page shows just some of the potential risks and hazards, with the aim of creating a safety-conscious attitude. General hazards Scalding Don’t remove the radiator or expansion tank cap while the engine is hot. . Engine oil, automatic transmission fluid or power steering fluid may also be dangerously hot if the engine has recently been running. l Burning Beware of burns from the exhaust system and from any part of the engine.
0.6 Roadside repairs The following pages are intended to help in dealing with common roadside emergencies and breakdowns. You will find more detailed fault finding information at the back of the manual, and repair information in the main chapters. If your car won’t start and the starter motor doesn’t turn If your car won’t start even though the starter motor turns as normal 0 Open the bonnet and make sure that the battery terminals are clean and tight.
Roadside repairs 0.7 Jump starting When jump-starting a car using a booster battery, observe the following precautions: 3 Make sure that the booster battery is the same voltage as the discharged one in the vehicle. 1 Before connecting the booster battery, make sure that the ignition is switched off. 4 If the battery is being jump-started from the battery in another vehicle, the two vehicles MUST NOT TOUCH each other. 2 Ensure that all electrical equipment (lights, heater, wipers, etc) is switched off.
0.8 Roadside repairs Wheel changing Some of the details shown here will vary according to model. For instance, the location of the spare wheel and jack is not the same on all cars. However, the basic principles apply to all vehicles. A ! Warning: Do not change a wheel in a situation where you risk being hit by other traffic. On busy roads, try to stop in a lay-by or a gateway.Be wary of passing traffic while changing the wheel - it is easy to become distracted by the job in hand.
Roadside repairs 0.9 Identifying leaks Puddles on the garage floor or drive, or obvious wetness under the bonnet or underneath the car, suggest a leak that needs investigating. It can sometimes be difficult to decide where the leak is coming from, especially if the engine bay is very dirty already. Leaking oil or fluid can also be blown rearwards by the passage of air under the car, giving a false impression of where the problem lies. A ! Warning: Most automotive oils and fluids are poisonous.
0.10 Weekly checks Introduction q There are some very simple checks which need only take a few minutes to carry out, but which could save you a lot of inconvenience and expense. Keeping an eye on tyre condition and pressures, will not only help to stop them wearing out prematurely, but could also save your life.
Weekly checks 0.11 Engine oil level Before you start V Make sure that your car is on level ground. V Check the oil level before the car is driven, or at least 5 minutes after the engine has been switched off. 2 1 The dipstick top is often brightly coloured for easy identification (see “Underbonnet check points” on page 0.10 for exact location). Withdraw the dipstick from its tube. Using a clean rag, remove all oil from the dipstick.
0.12 Weekly checks Brake fluid level Warning: 0 Brake fluid can harm your eyes and damage pain ted surfaces, so use extreme caution when handling and pouring it. 0 Do not use fluid that has been standing open for some time, as it absorbs moisture from the air, which can cause a dangerous loss of braking effectiveness. 1 The “MAX” and “MIN” marks are shown on the front of the reservoir. The fluid level must be kept between the marks at all times.
Weekly checks 0.13 Wiper blades 1 Check the condition of the wiper blades; if they are cracked or show any signs of deterioration, or if the glass swept area is smeared, renew them. Wiper blades should be renewed annually. 2 To remove a windscreen wiper blade, pull the arm fully away from the screen until it locks. Swivel the blade through 90” and slide it downwards . . . 3 The battery is located in the plenum chamber at the rear right-hand side of the engine compartment.
0.14 Weekly checks Tyre condition and pressure It is very important that tyres are in good condition, and at the correct pressure - having a tyre failure at any speed is highly dangerous. Tyre wear is influenced by driving style - harsh braking and acceleration, or fast cornering, will all produce more rapid tyre wear. As a general rule, the front tyres wear out faster than the rears. Interchanging the tyres from front to rear (“rotating” the tyres) may result in more even wear.
Weekly checks 0.15 Bulbs and fuses 0 Check all external lights and the horn. Refer to the appropriate Sections of Chapter 12 for details if any of the circuits are found to be inoperative. (/Visually check all accessible wiring connectors, harnesses and retaining clips for security, and for signs of chafing or damage. 1 If a single indicator light, stop-light or headlight has failed, it is likely that a bulb has blown and will need to be replaced. Refer to Chapter 12 for details.
0.16 Lubricants, fluids and tyre pressures Lubricants and fluids Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual transmission . . . . . . . . . . . . . . . . . . . . . . . . Braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 1 Routine maintenance and servicing Contents Air filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Auxiliary drivebelt check and renewal . . . . . . . . . . . . . . . . . . . . . . . 15 Brake fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Brake system and fluid leakage check . . . . . . . . . . . . . . . . . . . . . . . . 7 Clutch play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Servicing specifications Lubricants and fluids - Refer to end of “weekly checks” Capacities Engine oil All except G40 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G40models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling system .......................................... 3.5 litres 3.25 litres 5.6 litres (approx) Transmission 4speed models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance schedule 1.3 The maintenance intervals in this manual are provided with the assumption that you, not the dealer, will be carrying out the work. These are the minimum maintenance intervals recommended by us for vehicles driven daily. If you wish to keep your vehicle in peak performance and resale value of your vehicle. condition at all times, you may wish to When the vehicle is new, it should be perform some of these procedures more serviced by a factory-authorised dealer often.
1.4 Maintenance & servicing Underbonnet view of a 1.
Maintenance & servicing 1.5 Rear underbody view 1 2 3 4 5 6 7 8 Exhaust tailbox Rear shock absorber Rear axle beam Rear brake pressurrewe regulating valve Handbrake cable Fuel filter Line fuel pump Accumulator Maintenance procedures General information This Chapter is designed to help the home mechanic maintain his/her vehicle for safety, economy, long life and peak performance. The Chapter contains a master maintenance schedule, followed by Sections dealing specifically with each task in the schedule.
1.6 Maintenance procedures The following series of operations are those which are most often required to improve the performance of a generally poor-running engine: Primary operations a) Clean, inspect and test the battery (refer to “Weekly checks”). b) Check all the engine-related fluids (refer to “Weekly checks”). cl Check the condition and tension of the auxiliary drivebelt (Section 15). d) Renew the spark plugs (Section 7.6).
10 000 mile/12 month service 1.7 collect in the sump. Continue adding oil a small quantity at a time until the level is just above the lower mark on the dipstick. Adding approximately 1.0 litres will raise the level from the lower mark to the upper mark on the dipstick. Refit the filler cap. 14 Start the engine and run it for a few minutes; check for leaks around the oil filter seal and the sump drain plug.
1.8 Every 12 months - regardless of mileage 8.3a Check the exhaust pipe connections (arrowed) for evidence of leaks, severe corrosion and damage what you are really looking for is any indication of a serious leak (see Haynes Hint). Should a leak be found, renew the offending gasket or oil seal by referring to the appropriate Chapters in this manual. 2 Also check the security and condition of all the engine-related pipes and hoses.
Every 12 months - regardless of mileage 1.9 9.4 Check for wear in the hub bearings by grasping the wheel and trying to rock it 10.1 Check the condition of the driveshaft gaiters 4 Grasp the roadwheel at the 12 o’clock and 6 o’clock positions, and try to rock it (see illustration). Very slight free play may be felt, but if the movement is appreciable, further investigation is necessary to determine the source. Continue rocking the wheel while an assistant depresses the footbrake.
1.10 Every 12 months - regardless of mileage 13.1 Dashboard mounted diagnostic connector (arrowed) 7 Listen for any unusual noises from the engine, clutch and gearbox/transmission. 8 Make sure that the engine runs smoothly when idling, and that there is no hesitation when accelerating. 9 Check that, where applicable, the clutch action is smooth and progressive, that the drive is taken up smoothly, and that the pedal travel is not excessive. Also listen for any noises when the clutch pedal is depressed.
20 000 mile service 1.11 19 Fit the new belt to the crankshaft and alternator pulleys, then refer to the relevant sub-Section and adjust the belt tension. G40 models with single or twin auxiliary V-belts 15.6 Checking the auxiliary drive belt tension assess the amount of deflection that can be caused (see illustration). Compare this measurement with that listed in the Specifications. If necessary, refer to the relevant subSection and correctly tension the belt.
1.12 20 000 mile service 16.3 It is advisable to remove any debris from the spark plug recesses using a clean brush before removing the plugs, to prevent it from dropping into the cylinders 16.4a Unscrew the plugs using a spark plug spanner, or a spark plug socket and extension bar 16.4b Removing a spark plug 16.9 Adjusting the spark plug electrode gap 4 Unscrew the plugs using a spark plug spanner, suitable box spanner or a deep socket and extension bar.
20 000 mile service 1.13 17.2a Lifting out the air cleaner element multi-point fuel-injected models 2 Lift out the air filter element (see illustrations). 3 Brush out any debris that may have collected inside the air cleaner. 4 Lay the new air filter element in position in the lower half of the air cleaner housing, ensuring that the rubberised edges are securely seated in the recess at the outer edge. 5 Refit the air cleaner top cover and snap the retaining clips into position.
1.14 Every 2 years - regardless of mileage surfaces of the vehicle. Rinse off spills immediately with plenty of water. Never leave antifreeze lying around in an open container, or in a puddle in the driveway or on the garage floor. Children and pets are attracted by its sweet smell, but antifreeze can be fatal if ingested.
Chapter 2 Part A: Engine in-car repair procedures Contents Auxiliary drivebelt - removal and refitting . . . . . . . . . . .see Chapter 1 Camshaft - removal and refitting . . . . . . . . . . . . . . . . .see Chapter 2B Camshaft cover gasket - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Camshaft oil seal - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Camshaft timing belt - removal, inspection and refitting . . . . . . . . . . .
2A.2 Engine in-car repair procedures Torque wrench settings Nm Cylinder head bolts (engine cold): Stage1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stage2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stage 3 (angle tighten) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine in-car repair procedures 2A.3 in the form of a small cut-out , however if the terminal is not marked, follow the HT lead from the No 1 cylinder spark plug back to the distributor cap (No 1 cylinder is at the timing belt end of the engine) and using chalk or a pen (not a pencil, as the graphite will conduct electricity), place a mark on the distributor body directly under the terminal.
2A.4 Engine in-car repair procedures manufacturer. Note the lower compression ratio of the supercharged G40 model (engine code PY). 9 If the pressure in any cylinder is low, carry out the following test to isolate the cause. Introduce a teaspoonful of clean oil into that cylinder through its spark plug hole, and repeat the test. 10 If the addition of oil temporarily improves the compression pressure, this indicates that bore or piston wear is responsible for the pressure loss.
Engine in-car repair procedures 2A.5 key is not used, ensure that the lug in the sprocket hub engages with the recess in the end of the camshaft. 8 Insert the camshaft sprocket bolt and tighten it to the specified torque - hold the sprocket still using the method described in the Removal Section. 9 Working from Section 2, check that the engine is still set to TDC on cylinder No 1, then refit and tension the timing belt, as described in Section 4.
2A.6 Engine in-car repair procedures ignition system by 12 Restore the reconnecting the distributor multiway wiring plug. 1 Disconnect the battery negative cable and position from the terminal. 2 Refer to Chapter 1 and remove the auxiliary drivebelt( 3 With reference to Sections 2 and 4 of this Chapter, remove the auxiliary belt pulley and timing belt cover, then set the engine to TDC on cylinder No 1 and remove the timing belt and camshaft sprocket.
Engine in-car repair procedures 2A.7 2 Refer to Chapter 11 and remove the bonnet from its hinges - this will give extra working space and clearance when lifting off the head. 3 Disconnect the battery negative cable and position it away from the terminal. Note: If the vehicle has a security coded radio, check that you have a copy of the code number before disconnecting the battery cable; refer to Chapter 12 for de tails. 4 With reference to Chapter 1, carry out the following : a) Drain the engine oil.
2A.8 Engine in-car repair procedures 9.3Oa Lay a new head gasket on the cylinder block, engaging it with the locating dowels 9.30b The gasket part number should face upwards 31 With the help of an assistant, place the cylinder head and manifolds centrally on the cylinder block, ensuring that the locating dowels engage with the recesses in the cylinder head. Check that the head gasket is correctly seated before allowing the full weight of the cylinder head to rest upon it.
Engine in-car repair procedures 2A.9 11.6a Coat the threads of the flywheel bolts with locking fluid . . . Refitting 6 Follow the removal procedure in reverse, noting the following points (see illustrations): a) Use the marks made during removal to align the flywheel with the crankshaft. b) Use new shouldered bolts when refitting the flywheel. Tighten them diagonally and progressively to specified torque.
2A.10 Engine in-car repair procedures Refitting 4 Remove any remains of the old gasket from the sump and cylinder block - ensure that both mating surface are spotlessly clean. If the gasket has been leaking, check the mating surface of the sump for warpage that may have been caused by over-tightening of the bolts. Renew the sump if it is damaged - do not attempt to repair it. 5 Apply a coating of suitable sealant to the sump and crankcase mating surfaces.
2B.1 Chapter 2 Part B: Engine removal and overhaul procedures Contents Crankshaft - refitting and running clearance check . . . . . . . . . . . . . .10 Crankshaft - removal and inspection . . . . . . . . . . . . . . . . . . . . . . . . .6 Cylinder block/crankcase - cleaning and inspection . . . . . . . . . . . . . .7 Cylinder head - dismantling, cleaning, inspection and assembly . . . .4 Engine overhaul - preliminary information . . . . . . . . . . . . . . . . . . . . . .
2B.2 Engine removal and overhaul procedures Valves Valve head diameter: Inlet AAU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All other engine codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve stem diameter: Inlet: UptoJuly1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FromAugust ...........
Engine removal and overhaul procedures 2B.3 personal injury and/or damage to components by continuing alone. By planning ahead and taking your time, a job of this nature, although major, can be completed successfully and without incident. 10 On all models described in this manual, the engine and transmission are removed through the top of the engine bay - access and clearance are improved by removing the bonnet from the vehicle.
2B.4 Engine removal and overhaul procedures 2.24 Separating the engine and transmission vehicle specification. Note that some of these fixings also serve as mountings for the rear engine mounting. 24 Starting at the bottom, remove all the screws and nuts then carefully draw the transmission away from the engine, resting it securely on wooden blocks (see illustration). Collect the locating dowels if they are loose enough to be extracted.
Engine removal and overhaul procedures 2B.5 4.2 Remove the thermostat housing together with its O-ring (arrowed) Note: New and reconditioned cylinder heads will be available from the original manufacturer, and from engine overhaul specialists. It should be noted that some specialist tools are required for the dismantling and inspection procedures, and new components may not be readily available.
2B.6 Engine removal and overhaul procedures 4.22a Minimum cylinder head height (a) distorted out of specification, it may be possible to repair it by smoothing down any high-spots on the surface with fine abrasive paper. 22 Minimum cylinder head heights (measured between the cylinder head gasket surface and the cylinder head cover gasket surface), where quoted by the manufacturer, are listed in Specifications.
Engine removal and overhaul procedures 2B.7 Reassembly 4.40 Measure the diameters of the valve stems at several points along their lengths using a micrometer 41 Check the overall length of each valve and compare the measurements with the figure in the Specifications. 42 The valve heads should not be cracked, badly pitted or charred. Note that light pitting of the valve head can be rectified by lappingin the valves during reassembly, as described later in this Section.
2B.8 Engine removal and overhaul procedures into position using a long reach socket 4.59 Spring seat being fitted over the tops of the valve springs 4.61 Refitting the hydraulic tappets stepped s u r f a c e o f t h e s e a t (see illustrations). Note: Depending on age and specification, engines may have either concentric double valve springs, or single valve springs with no lower spring seat.
Engine removal and overhaul procedures 2B.9 4.70 Refitting the oil pressure switch 4.71 Refitting the camshaft sprocket and bolt 67 Tighten all bearing caps to the second stage torque, then fit the bolts to bearing cap No 5 and tighten them to the specified torque. 68 With reference to Chapter 2A lubricate the lip of a new camshaft oil seal with clean engine oil and locate it over the end of the camshaft.
2B.10 Engine removal and overhaul procedures 5.18 Checking the piston ring side clearance 5.20a Big end bearing cap and connecting rod markings A identification (cylinder number) markings B Orientation recesses 5.20b Orientation arrow on piston crown (highlighted) 11 Use a section of old piston ring to scrape the carbon deposits out of the ring grooves, taking care not to score or gouge the edges of the groove. 12 Carefully scrape away all traces of carbon from the top of the piston.
Engine removal and overhaul procedures 2B.11 6.4 Checking the crankshaft endfloat using a DTI gauge 6.5 Checking the crankshaft endfloat using a feeler blade the advice of an engineering workshop or your VW dealer. 15 Measure the crankshaft runout by setting up a DTI gauge on the centre main bearing and rotating the shaft in V - blocks. The maximum deflection of the gauge will indicate the runout.
2B.12 Engine removal and overhaul procedures 7.6 Clear out threaded holes using the correct size of tap 5 If the castings are not very dirty, you can do an adequate cleaning job with hot, soapy water and a stiff brush. Take plenty of time, and do a thorough job. Regardless of the cleaning method used, be sure to clean all oil holes and galleries very thoroughly, and to dry all components well. Protect the cylinder bores as described above, to prevent rusting.
8.8 Typical shell bearing failures 20 Apply a light coating of engine oil to the mating surfaces and cylinder bores to prevent rust forming. Store the block in a plastic bag until reassembly. Inspection 1 Even though the main and big-end bearings should be renewed during the engine overhaul, the old bearings should be retained for close examination, as they may reveal valuable information about the condition of the engine.
2B.14 Engine removal and overhaul procedures 10.3 Fitting the centre main bearing upper shell 10.7 Lay a piece of Plastigage on each journal, in line with its axis 10.11 Measure the width of the crushed Plastigage using the gauge provided inner surfaces with a clean rag - they must be kept spotlessly clean. 3 Clean the rear surface of the new bearing shells with a rag and lay them on the bearing saddles.
Engine removal and overhaul procedures 2B. 15 10.18 Tightening the main bearing bolts 11.5 Measuring the piston ring end gap using a feeler blade saddles and caps must be adjacent to each other. Insert the bearing cap bolts and hand tighten them only. 18 Working from the centre bearing cap outwards, tighten the retaining bolts to their specified torques.
2B.16 Engine removal and overhaul procedures 12.16 Using a piston ring compressor to install the piston assemblies Piston and connecting rod assemblies - final refitting 1 0 Note that the following procedure assumes that the crankshaft main bearing caps are in place (see Section 10). 1 1 Ensure that the bearing shells are correctly fitted, as described at the beginning of this Section. If new shells are being fitted, ensure that all traces of the protective grease are cleaned off using paraffin.
Chapter 3 Cooling, heating and ventilation systems Contents Coolant pump - removal, inspection and refitting . . . . . . . . . . . . . . . Coolant renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter Cooling system electrical switches - testing, removal and refitting .. Cooling system hoses - disconnection and renewal . . . . . . . . . . . . . Electric cooling fan - testing, removal and refitting . . . . . . . . . . . . . . .7 1 .6 .2 .5 General information and precautions .
3.2 Cooling, heating and ventilation systems 1 General information and precautions General information 1 The cooling system is of pressurised type, including a pump, an aluminium crossflow radiator, e l e c t r i c c o o l i n g f a n , a n d a thermostat. The system functions as follows. Cold coolant is pumped around the cylinder block, head passages, expansion tank, inlet manifold and heater matrix by the coolant pump.
Cooling, heating and ventilation systems 3.3 3.5a Removing the radiator upper mounting screws inspection 8 If the radiator has been removed due to suspected blockage, reverse flush it as described in Chapter 1. Clean dirt and debris from the radiator fins, using an air line (in which case, wear eye protection) or a soft brush. Be careful, as the fins are easily damaged, and are sharp.
3.4 Cooling, heating and ventilation systems 8 Remove the nuts and lift the cooling fan and motor from the cowling (see illustration). 9 If necessary the fan can be separated from the motor by prising off the clamp washer. Assemble the components in reverse order using a new clamp washer. Coolant temperature gauge sensor Testing 7 Refitting is a reversal of removal, but fit a new washer and tighten the switch to the specified torque setting.
Cooling, heating and ventilation systems 3.5 briefly, as the recirculated air inside the vehicle will soon deteriorate. 6 Certain models may be fitted with heated front seats. The heat is produced by electrically-heated mats in the seat and backrest cushions. The temperature is regulated automatically by a thermostat, and cannot be adjusted. 9 Heater/ventilation components 7.6a Removing the water pump 7.
3.6 Cooling, heating and ventilation systems 9.7 The flow direction arrow on the upper heater outlet - beneath the outlet with temperature valve fitted 9.10 Series resistor and motor connections 9.13a Matrix retaining screw locations in the heater body 9.13b Removing the heater matrix 9.13c Heater matrix and temperature control valve necessary adjust the control cables as described in the following paragraphs. round - the direction of flow is indicated on the outlet elbow (see illustration).
Chapter 4 Part A: Fuel system: single-point injection models Contents Accelerator cable - removal, refitting and adjustment . . . . . . . . . . . . .4 Air cleaner and inlet system - removal and refitting . . . . . . . . . . . . . . .2 Air cleaner filter element - renewal . . . . . . . . . . . . . . . . . .see Chapter 1 Fuel filter - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Fuel injection system - depressurisation . . . . . . . . . . . . . . . . . . . . . . .
4A.2 Fuel system: single-point injection models 1 General information and precautions General information 1 The Bosch Mono-Motronic system is a selfcontained engine management system, which controls both the fuel injection and ignition. This Chapter deals with the fuel injection system components only - refer to Chapter 5A for details of the ignition system components.
Fuel system: single-point injection models 4A.3 8 9 illustration 2.3) and remove the temperature regulator from the air cleaner housing. Recover the gasket. Refitting 4 Refit the regulator by following the removal procedure in reverse. Use a new gasket. Removal 1 Remove the throttle body air box/air cleaner as described in Section 2. 2 At the throttle body, disconnect the accelerator cable inner from the throttle valve spindle plate (see illustration).
4A.4 Fuel system: single-point injection models 5.12 Exploded view of the throttle body upper section and fuel injector 1 Injector retaining screw 2 Protective cap 3 Injector retaining cap with integral inlet air temperature sensor 4 O-ring 5 injector 6 Fuel pressure regulator 7 Throttle body casting 8 Gasket 9 Fuel supply hose 10 Banjo bolt 11 Sealing washers 5.
Fuel system: single-point injection models 4A.5 5.40 Location of engine management system ECU and relays 1 Bosch Mono-Motronic ECU 2 Multiway harness connector 3 Mounting bracket Electronic Control Unit (ECU) Removal Caution: Electronic Control Units (ECUs) contain components that are sensitive to the levels of static electricity generated during normal activity.
4A.6 Fuel system: single-point injection models 6.5 Slacken the hose clips and disconnect the fuel lines from either side of the filter Lift pump and fuel gauge sender assembly Removal 3 It is advisable to carry out this operation when the fuel tank is almost empty. 4 Refer to Section 9 and depressurise the fuel system. 5 Ensure that the vehicle is parked on a level surface, then disconnect the battery negative cable and position it away from the terminal.
Fuel system: single-point injection models 4A.7 7.16 Line fuel pump and accumulator unit 1 Line fuel pump 2 Accumulator the rear of the vehicle. Access is from the underside of the vehicle (see illustration). 17 Refer to Section 9 and depressurise the fuel system. 18 Park the vehicle on a level surface, apply the handbrake, select first gear (manual transmission) and chock the front roadwheels. Raise the rear of the vehicle and support it securely on axle stands (see “Jacking and vehicle support”).
4A.8 Fuel system: single-point injection models the engine breather hoses are clear and undamaged, referring to Chapter 1, Chapter 2 and Chapter 5B for further information. 2 If these checks fail to reveal the cause of the problem the vehicle should be taken to a suitably equipped VW dealer for testing. A diagnostic connector is incorporated in the engine management system wiring harness, into which a dedicated electronic test equipment can be plugged.
Chapter 4 Part B: Fuel system: multi-point injection models Contents Accelerator cable - removal, refitting and adjustment . . . . . . . . . . . . .4 Air cleaner and intake system - removal and refitting . . . . . . . . . . . . .2 Air cleaner filter element - renewal . . . . . . . . . . . . . . . . . see Chapter 1 Fuel filter - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Fuel injection system - depressurisation . . . . . . . . . . . . . . . . . . . . . .
4B.2 Fuel system: multi-point injection models 1 General information and precautions Genera/ information 1 The Digifant system is a completely self-contained engine management system, which controls both the fuel injection and ignition. This Chapter deals with the fuel injection system components only - refer to Chapter 5A for details of the ignition system components.
Fuel system: multi-point injection models 4B.3 2.2 Detach the cold inlet air ducting from the cowling above the radiator 2.3 Detach the warm inlet air ducting from the shield on the exhaust manifold 2.4 Remove the four air cleaner retaining nuts (arrowed) shield on the exhaust manifold (see illustration) 4 Remove the four retaining nuts, then lift the air cleaner out of the engine bay and recover the rubber mountings (see illustration).
4B.4 Fuel system: multi-point injection models 4.6 Prise the cable grommet (arrowed) from the bulkhead 5.4 Remove the air flow meter retaining screws (at-rowed) 5.7 Unplug the wiring harness from the potentiometer at the connector (arrowed) 5.11 The inlet air temperature sensor (arrowed) is an integral part of the air flow meter 5.
Fuel system: multi-point injection models 4B.5 necessary. It is therefore recommended that this operation is entrusted to a automotive electrical specialist. Throtte body Removal 23 Refer to Section 4 and detach the accelerator cable from the throttle valve lever. 24 Slacken the clips and detach the inlet air ducting from the top of the throttle body inlet. Remove the bolts, lift off the throttle body inlet elbow and recover the seal (see illustrations).
4B.6 Fuel system: multi-point injection models 5.36a Slacken and withdraw the fuel rail retaining screws (art-owed) . . . 5.36b . . . then carefully lift the fuel rail away from the inlet manifold, together with the injectors 5.37a Unclip both halves of the plastic shielding from the injector body 5.37b Remove the insulating shroud 5.37c Unplug the wiring harness connector 5.37d Extract the retaining clip 5.37e Prise out the injector 5.
Fuel system: multi-point injection models 4B.7 5.45 Remove the retaining screws (arrowed) and lift off the regulator body 44 Disconnect the vacuum hose from the port on the top of the fuel pressure regulator. 45 Slacken the clip and disconnect the fuel supply hose from the end of the fuel rail. This will allow the majority of fuel in the regulator to drain out. Be prepared for an amount of fuel loss - position a small container and some old rags underneath the fuel regulator housing.
4B.8 Fuel system: multi-point injection models 10.3a Idle speed adjustment screw location 10 Fuel injection system adjustment - general information 1 If a fault appears in the fuel injection system first ensure that all the system wiring connectors are securely connected and free of corrosion.
Chapter 4 Part C: Emission control and exhaust systems Contents Catalytic converter - general information and precautions . . . . . . . . .6 Crankcase emission system - general information . . . . . . . . . . . . . . .3 Evaporative loss emission control system general information and component renewal . . . . . . . . . . . . . . . . . .2 Exhaust manifold - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .4 Exhaust system - general information and component renewal . . . .
4C.2 Emission control and exhaust systems Exhaust systems 9 The exhaust system comprises the exhaust manifold, a number of silencer units (depending on model and specification), a catalytic converter (where fitted), a number of mounting brackets and a series of connecting pipes. General information 1 The evaporative loss emission control system consists of the purge valve, the activated charcoal filter canister and a series of connecting vacuum hoses.
Emission control and exhaust systems 4C.3 The catalytic converter is a reliable and simple device which needs no maintenance in itself, but there are some facts of which an owner should be aware if the converter is to function properly for its full service life. a) DO NOT use leaded petrol in a car with a catalytic converter - the lead will coat the precious metals reagents, reducing their converting efficiency and will eventually destroy the converter.
Chapter 5 Part A: Starting and charging systems Contents Alternator - brush holder/regulator module renewal . . . . . . . . . . . . . . 5 Alternator - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Alternator/charging system - testing in vehicle . . . . . . . . . . . . . . . . . .4 Auxiliary drivebelt - removal, refitting and adjustment . . .see Chapter 1 Battery - condition check . . . . . . . . . . . . . . . . . . . . . . . . .
5A.2 Starting and charging systems the battery disconnected, capacitive discharge could occur if a component’s live terminal is earthed trough a metal object This could cause a shock or nasty bum. Do not reverse the battev connections. Components such as the alternator, electronic control units, or any other components having semiconductor circuitry could & irreparably damaged.
Starting and charging systems 5A.3 5.4a Location of the brush holder/ voltage regulator module 5.4b Lifting the brush holder/voltage regulator module away from the alternator 5.5 Measure the free length of the brush contacts 5.6 Inspect the surfaces of the slip rings (arrowed), at the end of the alternator shaft charger current below 25 amps. Using this method, the battery should be usable within three hours, giving a voltage reading of 12.
5A.4 Starting and charging systems 6.3a Auxiliary belt tensioner nut and lockscrew (arrowed) 7 Starting system - testing Note: Refer to the precautions given in ‘Safety first!’ and in Section 1 of this Chapter before starting work. Take great care to avoid causing short circuits by accidentally touching the bodywork or other components with ‘live’ wiring. 1 If the starter motor fails to operate when the key is turned to the correct position, the following possible causes may be to blame.
Chapter 5 Part B: Ignition systems Contents Distributor - removal, inspection and refitting . . . . . . . . . . . . . . . . . . 4 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 HT Coil - testing, removal and refitting . . . . . , . . . . . . . . . . . . . . . . . 3 Ignition system - testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ignition system - check . , . . . . . . . . . . . . . . . . . . . . . . ......... .
5B.2 Ignition systems 1 The Bosch Mono-Motronic and Digifant systems are self-contained engine management systems, which control both the fuel injection and ignition. This Chapter deals with the ignition system components only refer to Chapter 4A or B for details of the fuel injection system components.
Ignition systems 5B.3 9 Disconnect the LT cable from the ignition coil at the multiway connector (refer to illustration 3.8). 10 Slacken and withdraw the mounting screws, remove the brackets and detach the earthing strap (where applicable). Remove the ignition coil from the engine bay. Refitting 11 Refitting is a reversal of removal. 3.3 Ignition coil primary and secondary winding terminals A Primary winding terminals B Secondary winding terminals 3.
5B.4 Ignition systems 4.7a Carefully prise off the rotor arm . . . 4.7b . . . then lift off the moisture shield 4.8a Slacken and remove the clamp bolts . . . 4.8b . . .t h e n withdraw the distributor body from the cylinder head . . . 4.8c Recover the seals 7 Carefully prise off the rotor arm, then lift off the moisture shield (see illustrations). 8 Mark the relationship between the distributor body and the drive gear case flange by scribing arrows on each.
Ignition systems 5B.5 Continue until the timing setting is correct, then tighten the distributor bolts to the specified torque. Removal Note: This sensor is fitted to the G40 model (engine code PY) only. Removal 5.5b Ignition timing marks - G40 models to Section 4 and slacken the distributor retaining bolts. Note: Mark the relationship between the distributor body and the cylinder head with a dab of paint, before adjustment is attempted.
6.1 Chapter 6 Clutch Contents Clutch cable - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Clutch components - removal, inspection and refitting . . . . . . . . . . . .4 Clutch pedal - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . .3 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Release bearing and shaft - removal, inspection and refitting . . . . . .
6.2 Clutch Refitting 5 Refitting is a reversal of removal, but note the following points: a) Make sure the flats on the cable are located correctly on the steering gear housing. b) Grease the cable attachment point on the pedal, but do not grease the cable before fitting it to the steering gear housing, as there is a danger of grease blocking the breather vent.
Clutch 6.3 6 Pull the release shaft from the inner bearing then withdraw the shaft and arm from the housing. Inspection Four speed transmission Removal 1 With the transmission removed, unhook the return spring from the release arm (see illustration). 2 Turn the release arm to move the release bearing up the guide sleeve, then disengage the two spring clips from the release fork and withdraw the bearing (see illustration).
6.4 Clutch Five-speed transmission Removal 10 Remove the transmission as described in Chapter 7. Removal and checking procedures for the release bearing are the same as for the four-speed transmission, as described in the previous sub-Section. 11 Extract the circlips securing the release lever to the release shaft, then withdraw the shaft from its bushes and the release lever (see illustration). Note that there is a master spline on the shaft and lever allowing fitment in only one position.
Chapter 7 Manual transmission Contents Drive flange oil seals - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Gearchange mechanism - removal, refitting and adjustment . . . . . . .4 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Reversing lamp switch - testing, removal and refitting . . . . . . . . . . . .5 Speedometer drive - removal and refitting . . . . . . . . . . . . . . . . . . . . . .6 Transmission - removal and refitting . .
7.2 Manual transmission case and planetary gears, thus driving the sun gears and driveshafts. The rotation of the planetary gears on their shaft allows the inner roadwheel to rotate at a slower speed than the outer roadwheel during cornering. 5 Transmission fluid drain and filler plugs are provided, and a magnetic swarf collector is located in the bottom of the transmission casing.
Manual transmission 7.3 removal, refitting and adjustment Removal 2.15 Removing the rear engine mounting and bracket 2.16a Disconnecting the shift rod coupling 2.16b Removing the shift rod coupling 2.16c Shift rod adapter and bush 16 Remove the screw from the shift rod coupling and ease the coupling from the rod.
7.4 Manual transmission 5.8a Disconnect the wiring . . . 5.8b . . . and remove the reversing light switch (4 speed transmission shown) 6.2 Speedometer drive cable locknut (arrowed) at the differential casing 5 If the switch appears to be constantly open or short circuit, or is intermittent in its operation, it should be renewed. housing, at the rear of the transmission casing. 2 Unscrew the locknut and withdraw the end of the drive cable (see illustration). Where fitted, recover the washer.
Chapter 8 Driveshafts Contents Driveshaft - checking and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Driveshaft gaiter check . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1 Driveshaft - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .. . . .2 Driveshaft rubber gaiters - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . .3 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 Driveshafts 1 .1 Exploded view of the right-hand driveshaft 1 Circlip 2 Inner cons tan t velocity joint 3 Dished washer 4 Protective cap 5 Rubber gaiter 6 Balance weight 7 Shaft 8 Dished washer 9 Circlip 10 Clip 11 Rubber gaiter 12 Hose clip 13 Outer constant velocity joint Removal Drive is transmitted from the differential to the front wheels by means of two driveshafts of unequal length (see illustration).
Driveshafts 8.3 3.2 Cross-section diagram of the driveshaft outer joint Driveshaft Rubber gaiter Clip Bearing race 5 Splined shaft 6 Distance washer 7 Dished washer Inner rubber gaiter 1 Remove the driveshaft from the car as described in Section 2 and secure it in a vice equipped with soft jaws. 2 Loosen the clips and release the large diameter end from the joint (see illustration). If necessary cut the clips free. 3 Using a soft faced mallet drive the outer joint from the driveshaft.
8.4 Driveshafts 4.8 Removing the outer joint hub from the cage 4.16 Removing the inner joint hub and cage 4.17a Inner joint hub, cage and housing 7 Turn the cage until the rectangular apertures are aligned with the housing then withdraw the cage and hub (see illustration). 8 Turn the hub and insert one of the segments into one of the rectangular apertures, then swivel the hub from the cage (see illustration).
Chapter 9 Braking system Contents Brake disc - inspection, removal and refitting . . . . . . . . . . . . . . . . . . .6 Brake fluid level check . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1 Brake fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1 Brake pedal - removal, overhaul and refitting . . . . . . . . . . . . . . . . . .1 1 Brake system and fluid leakage check . . . . . . . . . . . . . .
9.2 Braking system 1 General information The braking system is of servo-assisted hydraulic, dual circuit type with discs at the front and self-adjusting drum brakes at the rear. The hydraulic circuit is split diagonally so that with the failure of one circuit, one front and rear brake remain operative. A load sensitive pressure regulator is incorporated in the rear hydraulic circuits on some models to prevent the rear wheels locking in advance of the front wheels during heavy application of the brakes.
Braking system 9.3 4.4a Undo the caliper mounting bolts using an Allen key Bleeding - using a pressurebleeding kit 24 These kits are usually operated by pressurised air contained in a spare tyre. However, note that it will probably be necessary to reduce the pressure to a lower level than normal; refer to the instructions supplied with the kit.
9.4 Braking system A 4.10a Fit the anti-rattle springs to the carrier bracket, making sure they are correctly located . . . 4.10b . . . and install the brake pads with their friction material facing the disc caliper to hang unsupported on the flexible brake hose. 5 Withdraw the two brake pads from the carrier bracket and recover the anti-rattle springs, noting their correct fitted locations (see illustration). Note that the springs are different and are not interchangeable.
Braking system 9.5 5.8a Unhook the shoes from the lower pivot point using an adjustable spanner . . . 5.8b . . . and remove the lower return spring 5.9a Note the elastic band (arrowed) used to retain pistons 9 Ease the upper end of both shoes out from their wheel cylinder locations, taking care not to damage the wheel cylinder seals, and disconnect the handbrake cable from the trailing shoe. The brake shoe assembly can then be manoeuvred out of position and away from the backplate.
9.6 Braking system 6.3 Measuring brake disc thickness with a micrometer 6.7 Undo the retaining screw and remove the front brake disc 7.2 Lever out and remove the cap from the centre of the brake drum 23 Tap the shoes to centralise them with the backplate, then refit the shoe retainer pins and springs, and secure them in position with the spring cups. 24 Refit the brake drum as described in Section 7. 25 Repeat the above procedure on the remaining rear brake.
Braking system 9.7 7.4a . . . then unscrew the retaining nut. . . 7.4b . . . remove the toothed washer. . . 7.4c . . . and withdraw the outer bearing 4 Unscrew and remove the rear hub nut, then slide off the toothed washer and remove the outer bearing from the centre of the drum (see illustrations). 5 It should now be possible to withdraw the brake drum assembly from the stub axle by hand (see illustration).
9.8 Braking system Removal 1 Apply the handbrake, then jack up the front of the vehicle and support it on axle stands (see “Jacking and vehicle support”). Remove the appropriate roadwheel. 2 Minimise fluid loss by first removing the master cylinder reservoir cap, and then tightening it down onto a piece of polythene, to obtain an airtight seal. Alternatively, use a brake hose clamp, a G-clamp or a similar tool to clamp the flexible hose.
Braking system 9.9 19 Ensure that the brake shoes are correctly located in the cylinder pistons, then refit the brake shoe upper return spring, using a screwdriver to stretch the spring into position. 20 Refit the brake drum (see Section 7). 21 Bleed the brake hydraulic system as described in Section 2. Providing suitable precautions were taken to minimise loss of fluid, it should only be necessary to bleed the relevant rear brake. Overhaul 5 If the master cylinder is faulty, it must be renewed.
9.10 Braking system 9 Unscrew the nuts and remove the washers securing the servo unit to the bulkhead. Where applicable, note the location of the retaining plate on the upper stud. Remove the assembly from the engine compartment. 1O Slacken and remove the two nuts and washers securing the master cylinder to the vacuum servo unit, then withdraw the master cylinder and recover the rubber O-ring. new fluid, and bleed the complete hydraulic system as described in Section 2.
Braking system 9.11 Refitting 5 Refitting is a reversal of the removal procedure, but finally adjust the handbrake as described in Section 14. I Front cable Removal 1 Chock the front wheels then jack up the rear of the car and support on axle stands (see “Jacking and vehicle support”). Release the handbrake. 2 If fitted, remove the plastic cover from the handbrake lever (see illustration). Where necessary remove the rear section of the centre console with reference to Chapter 11.
9.12 Braking system withdraw the lines so that they are just clear of the regulator. Tape the ends of the brake lines to prevent entry of dust and dirt. 6 Unscrew the mounting bolts and withdraw the regulator from under the car. Refitting 7 Before refitting the regulator check that the brake line apertures and sealing surfaces are clean. 8 Locate the regulator on the underbody, insert the bolts and tighten securely.
Chapter 10 Suspension and steering Contents Front anti-roll bar - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .7 Front coil spring - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .3 Front shock absorber - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Front suspension strut - removal and refitting . . . . . . . . . . . . . . . . . . .2 Front track control arm and balljoint - removal and refitting . . . . . . . .
10.2 Suspension and steering Wheels Type Size ................................................. ................................................. Pressed steel disc or alloy 45J x 13 or 55J x 13 Tyres Pressures - see end of “Weekly checks”. Sizes:* Roadwheels: 135 R 13,145 R 13 or 155/70 R 13 45Jx13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165/65 R 13 or 175/60 R 13 5.5Jx13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suspension and steering 10.3 2.10a Removing the front suspension strut top cap 2.10b View of the front suspension strut upper mounting from below 4 Remove the brake disc with reference to Chapter 9, then unbolt the splash plate from the strut. 5 Unscrew the nut securing the steering tierod end to the strut, then use a balljoint separator to release the tie-rod. 6 Remove the anti-roll bar as described in Section 7.
10.4 Suspension and steering Note: VW tool 40-201 B is necessary in order to unscrew the screw cap from the top of the strut. 1 A faulty shock absorber will normally make a knocking noise as the car is driven over rough surfaces. 2 To remove the shock absorber first remove the front coil spring as described in Section 3. 3 Using VW tool 40-201 B unscrew the screw cap from the top of the strut and remove the piston rod guide and seal. If necessary first mount the strut in a vice.
Suspension and ‘steering 10.5 8.2 Remove the cap from the top of the rear suspension strut Remove the rear wheel. 8.5a Rear suspension strut lower mounting bolt 8.5b View of the rear suspension strut upper mounting from below 2 Working inside the rear of the car, remove the parcel tray then remove the cap from the top of the strut by twisting it anti-clockwise (see illustration). 3 Support the trailing arm with a trolley jack.
10.6 Suspension and steering the readings at a minimum of three points and if the difference between the maximum and minimum readings exceeds 0.25 mm, renew the stub axle. Refitting 4 Refitting is a reversal of removal, but make sure that all mating faces are clean and tighten the bolts to the specified torque. Refer to Section 10 as necessary and adjust the wheel bearings. 9.
Suspension and steering 10.7 and the axle beam pivot bolts to the specified torques until the full weight of the car is on the roadwheels. Bleed the brake hydraulic system as described in Chapter 9. 10.11 Grease the lips of the seal, and press it into the rear of the hub 10.16 Checking the rear wheel bearing adjustment with a screwdriver (see text) 11 Smear the lips of the new seal with a little grease.
10.8 Suspension and steering 13.3a Unscrew the nut. . . 13.3b . . . and remove the washer 14.3b . . . and withdraw the lower shroud . . . 14.3c . . . and upper shroud Refitting 4 Refitting in a reversal of removal, but make sure that the turn signal lever is in its neutral position, otherwise damage may occur to the cancelling arm.
Suspension and steering I0.9 15.1 Draw the splined adapter off the steering column using a puller 15.7 Use the steering wheel nut to press the adapter onto the inner column 16.2 Removing the splined adapter and spring from the top of the inner column 16.6 Unscrewing the steering lock clamp bolt 16.8a Undo the retaining screw . . . 16.8b . . . and remove the ignition switch from the steering column lock assembly 4 Withdraw the inner column from the outer column and remove the support ring.
10.10 Suspension and steering 17.10a Steering gear location (engine removed from car) disengage it from the steering gear (see illustration). 6 Set the front wheels in the straight-ahead position then unscrew the clamp bolt securing the inner column to the steering gear pinion. Where applicable, remove the trim panel for access to the clamp bolt. 7 Prise the inner column up from the pinion as far as it will go. Do not bend the clamp open.
Suspension and steering 10.11 axis is defined as an imaginary line drawn through the axis of the suspension strut, extended where necessary to contact the ground. 2 C a m b e r is the angle between each roadwheel and a vertical line drawn through its centre and tyre contact patch, when viewed from the front or rear of the car. Positive camber is when the roadwheels are tilted outwards from the vertical at the top; negative camber is when they are tilted inwards.
Chapter 11 Bodywork and fittings Contents Body exterior fittings - removal and refitting . . . . . . . . . . . . . . . . . . .23 Bonnet lock - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . 11 Bonnet release cable - removal and refitting . . . . . . . . . . . . . . . . . . .10 Bonnet - removal, refitting and adjustment . . . . . . . . . . . . . . . . . . . . .9 Boot lid lock components (Saloon models) - removal and refitting . .
11.2 Bodywork and fittings 1 General information The bodyshell is made of pressed-steel sections, and is available in three-door Hatchback, three-door Coupe and two-door Saloon versions. Most components are welded together, but some use is made of structural adhesives; the front wings are bolted on. The bonnet, door, and some other vulnerable panels are made of zinc-coated metal, and are further protected by being coated with an anti-chip primer before being sprayed.
Bodywork and fittings 11.3 Should the dent be in a section of the bodywork which has a double skin, or some other factor making it inaccessible from behind, a different technique is called for. Drill several small holes through the metal inside the area - particularly in the deeper section. Then screw long self-tapping screws into the holes, just sufficiently for them to gain a good purchase in the metal. Now the dent can be pulled out by pulling on the protruding heads of the screws with a pair of pliers.
11.4 Bodywork and fittings and fuse a plastic filler rod into the groove. Any excess plastic is then removed, and the area rubbed down to a smooth finish. It is important that a filler rod of the correct plastic is used, as body components can be made of a variety of different types (eg polycarbonate, ABS, polypropylene). Damage of a less serious nature (abrasions, minor cracks etc) can be repaired by the DIY owner using a two-part epoxy filler repair material which can be used directly from the tube.
Bodywork and fittings 11.5 Saloon models 3 Remove the number plate lights from the rear bumper as described in Chapter 12. 4 Unscrew the mounting bolts securing the rear bumper to the underbody bracket. If necessary, access can be improved by raising the rear of the car and supporting on axle stands (see “Jacking and vehicle support”). 5 Pull the rear bumper rearwards and disengage it from the side guide plates. Refitting 6 Refitting is a reversal of removal.
11.6 Bodywork and fittings 13.1 Removing the locking knob 13.2 Slide the inner handle surround to the rear to remove it 13.3a Removing the exterior mirror control knob. . . 13.3b . . . and boot 13.4a Prise out the trim cover. . . 13.4b . . . unscrew the mounting screws. . . 13.4c . . . and release the door pull from the trim 13.5a Prise off the cover . . . 13.5b . . . remove the screw. . . 13.5c . . . and withdraw the window regulator handle from the splines 13.
Bodywork and fittings 11.7 13.8 Releasing the inner trim panel from the weatherseal 13.9 Removing the window regulator handle packing 13.10 Peeling the protective sheet from the door 14.1 Screw securing the exterior handle to the rear edge of the door 14.2 Removing the plastic strip insert from the exterior door handle 14.3a Remove the screw. . . 14.3b . . . then release the exterior handle from the door 14.5 Packing around the inner door handle panel taking care not to damage the trim.
11.8 Bodywork and fittings 14.7a Unscrew the mounting screws . . . 14.7b . . . and withdraw the lock from the door 15.3a Bolts securing the window regulator to the door 15.3b Bolts securing the lifting plate to the window channel 15.4 Removing the window regulator through the door aperture 15.
Bodywork and fittings 11.9 16.5 Tailgate hinge 16.6 Prise out the spring clips before removing the support struts from their balljoint mountings 17.1 Using an Allen key to unscrew the tailgate lock retaining screws 4 Tie a piece of string to each end of the wiring then, noting the correct routing of the wiring harness, release the harness rubber grommets from the tailgate and withdraw the wiring.
11.10 Bodywork and fittings bolts and withdraw the boot lid. Recover the spacer where fitted. 3 The boot lock and striker are each secured by two cross-head screws, but when removing the lock it will be necessary to unhook the connecting rod. Refitting 4 Refitting is a reversal of removal, but make sure that the boot lid is central within the aperture and adjust its position on the hinge bolts. If necessary, adjust the bootlid rubber buffers by screwing them in or out.
Bodywork and fittings 11.11 24.1 a Remove the screw from the front of the seat. . . 24.1b . . . then release the spring tensioned pin 24.2a Remove the screw . . . 24.2b . . . and withdraw the inner runner cover 24.8 Squab securing screws (split rear seat) 24.9 Split rear seat central mounting bracket bolt 24.11 Spring clip on the centre pivot bracket 24.
1 1 .1 2 Bodywork and fittings 25.2 Pull back the cover from the front seat belt lower mounting 25.4 Unhooking the spring from the front seat belt lower mounting 25.7 Removing the plastic cover from the front seat belt upper mounting 25.8 Pull away the weatherstrip before removing the rear trim panel 25.9 Front seat belt inertia reel mounting bolt 25.12 Rear seat belt outer mounting 4 Unhook the spring and gently allow the tension to be released by allowing the spring to unwind (see illustration).
Bodywork and fittings 11.13 26.11 Glovebox hinge pins 27.2 Unclipping the rubber boot from the centre console 27.3 Centre console front mounting screw however that they can break quite easily so replacements should be available. The best way of releasing such clips without the correct type of tool, is to use a large flat-bladed screwdriver. Note in many cases that the adjacent sealing strip must be prised back to release a panel.
11.14 Bodywork and fittings 28.3c Disconnecting the diagnostic socket wiring plugs 28.3d Shelf/trim panel front pin and rubber grommet 28.13 Facia panel mounting screw next to the steering column 9 Disconnect the wiring from the switches and the cigarette lighter, noting the location of each wire (see Haynes Hint). 11 Unscrew the facia panel lower mounting screws. 12 With the glovebox open, unscrew the mounting screw from inside the glovebox compartment.
12.1 Chapter 12 Body electrical system Contents Battery - removal and refitting . . . . . . . . . . . . . . . . . . . . .See Chapter 5 Battery check and maintenance . . . . . . . . . . . . . .See “Weekly checks” Bulbs (exterior lights) renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Bulbs (interior lights) renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Electrical fault-finding - general information . . . . . . . . . . . . . . . . . . . . .
12.2 Body electrical system relays). Visually inspect the condition of all fuses, wires and connections in a problem circuit before testing the components. Use the wiring diagrams to determine which terminal connections will need to be checked in order to pinpoint the trouble spot.
Body electrical system 12.3 3 Undo the retaining screws and remove the steering column upper and lower shrouds. 4 Slacken and remove the three retaining screws then disconnect the wiring connectors and remove both switch assemblies from the steering column (see illustrations). 5 Separate the direction indicator switch from the windscreen wiper switch if necessary (see illustration). 6 Refitting is a reversal of removal; refer to Chapter 10 when refitting the steering wheel. Facia-mounted switches 3.
12.4 Body electrical system 4.8 With the switch removed from the facia, the wiring plug can be disconnected 4.10 Prising off the heater control panel cover 4.11a Removing the ashtray insert mounting screws 4.11b Disconnecting the wiring plug from the rear of the cigarette lighter 4.12a Slide out the bulbholder. . . 4.12b . . . lever the tab . . . General 1 Whenever a bulb is renewed, note the following points. 4.12c . . . withdraw the body. . . 4.12d . . .
Body electrical system 12.5 5.3 Disconnecting the wiring plug from the rear of the headlamp bulb 5.5a Release the clips . . . 5.5b . . . and remove the bulb from the rear of the headlight unit 5.10 Removing the front sidelight bulbholder 5.14a Disconnect the wiring . . . 5.14b . . . then remove the bulbholder. . . 14 Reach down behind the front direction indicator light, alternatively remove the indicator light first as described later.
12.6 Body electrical system 5.24a Squeeze together the plastic tabs ... 5.27a Remove the screws. . . with the front tag in the small hole. Press in the light until the rear clip engages. Front foglight 19 Apply the handbrake then jack up the front of the car and support on axle stands (see “Jacking and vehicle support”). 20 Reach up behind the front bumper and disconnect the wiring from the connector plug on the rear cap. 21 Turn the cap anticlockwise and withdraw it from the foglamp.
Body electrical system 12.7 14 Unclip the surround from around the bulb then carefully pull the bulb out of its holder. 15 Refitting is the reverse of removal. Switch illumination bulbs 16 All of the switches are fitted with illuminating bulbs; some are also fitted with a bulb to show when the circuit concerned is operating. These bulbs are an integral part of the switch assembly and cannot be obtained separately. Bulb replacement will therefore require the renewal of the complete switch assembly. 6.
12.8 Body electrical system Note: It is not necessary to remove the instrument panel when removing the speedometer drive cable. Removal 8.3a Removing the instrument panel with the special tools 8.3b The special tools are used to hold in the side clips 1 Open the bonnet and then reach down behind the engine and unscrew the speedometer cable nut from the gearbox. Recover the washer. 2 Where necessary for improved access, remove the air cleaner and ducting as described in Chapter 3.
Body electrical system 12.9 12.2a Pull off the weatherstrip . . . 12.2b . . . and remove the plastic cover from over the windscreen wiper motor N o t e : Make sure the ignition and a l l accessories are s w i t c h e d o f f b e f o r e commencing work. Removal 1 Open the tailgate and carefully prise off the inner trim panel. 2 Remove the wiper arm as described in Section 11, then unscrew the spindle outer nut and remove t h e s p a c e r s (see illustrations). 12.
12.10 Body electrical system 13.3a Disconnect the wiring plug . . . 13.3b . . . unscrew the mounting bracket bolts . . . Washer system reservoir 1 Refer to Section 14. Two pumps are fitted to the reservoir, the larger one being the headlight washer pump. Washer pump 13.3c . . . and withdraw the motor assembly from the tailgate 3 Disconnect the wiring plug, then unscrew the mounting bracket bolts and withdraw the motor assembly (see illustrations).
Body electrical system 12.11 16.3a Fitting the special radio removal tools 2 Disconnect the battery negative lead. Note: Make sure you know the anti-theft code for the radio/cassette so that you can re-activate it on refitting. 3 Insert the tools into the two holes on each side of the unit and push them until they snap into place. The radio/cassette player can then be slid out of the facia and the wiring connectors and aerial disconnected (see illustrations).
Solenoid actuator Item no.
Reference REF.1 Dimensions and weights . . . . . . . . . . . . . . . . . . . Conversion factors . . . . . . . . . . . . . . . . . . . . . . . Buying spare parts . . . . . . . . . . . . . . . . . . . . . . . Vehicle identification . . . . . . . . . . . . . . . . . . . . . . General repair procedures . . . . . . . . . . . . . . . . . Jacking and vehicle support . . . . . . . . . . . . . . . . REF.1 REF.2 .REF.3 REF.3 REF.4 REF.5 Radio/cassette unit anti-theft system . . . . . . . . . REF.
Length (distance) Inches (in) Feet (ft) Miles = Millimetres (mm) x 25.4 x 0.305 = Metres (m) x 1.609 = Kilometres (km) x 0.0394 = Inches (in) x 3.281 = Feet (ft) x 0.621 = Miles Volume (capacity) Cubic inches (cu in; in³) Imperial pints (Imp pt) Imperial quarts (Imp qt) Imperial quarts (Imp qt) US quarts (US qt) Imperial gallons (Imp gal) Imperial gallons (Imp gal) US gallons (US gal) x x x x x x x x 16.387 = Cubic centimetres (cc; cm3) 0.568 = Litres (I) 1.137 = Litres (I) 1.201 = US quarts (US qt) 0.
Buying spare parts REF.3 Spare parts are available from many sources, including maker’s appointed garages, accessory shops, and motor factors. To be sure of obtaining the correct parts, it will sometimes be necessary to quote the vehicle identification number. If possible, it can also be useful to take the old parts along for positive identification. Items such as starter motors and alternators may be available under a service exchange scheme any parts returned should always be clean.
REF.4 General repair procedures Whenever servicing, repair or overhaul work is carried out on the car or its components, it is necessary to observe the following procedures and instructions. This will assist in carrying out the operation efficiently and to a professional standard of workmanship. Joint mating faces and gaskets When separating components at their mating faces, never insert screwdrivers or similar implements into the joint between the faces in order to prise them apart.
Jacking and vehicle support REF.5 The jack supplied with the vehicle tool kit should only be used for changing the roadwheels - see “Wheel changing” at the front of this book. When carrying out any other kind of work, raise the vehicle using a hydraulic (or “trolley”) jack, and always supplement the jack with axle stands positioned under the vehicle jacking points.
REF.6 Tools and working facilities introduction A selection of good tools is a fundamental requirement for anyone contemplating the maintenance and repair of a motor vehicle. For the owner who does not possess any, their purchase will prove a considerable expense, offsetting some of the savings made by doing-it-yourself. However, provided that the tools purchased meet the relevant national safety standards and are of good quality, they will last for many years and prove an extremely worthwhile investment.
Tools and working facilities REF.7 Special tools Buying tools Working facilities The tools in this list are those which are not used regularly, are expensive to buy, or which need to be used in accordance with their manufacturers’ instructions. Unless relatively difficult mechanical jobs are undertaken frequently, it will not be economic to buy many of these tools.
REF.8 MOT test checks This is a guide to getting your vehicle through the MOT test. Obviously it will not be possible to examine the vehicle to the same standard as the professional MOT tester. However, working through the following checks will enable you to identify any problem areas before submitting the vehicle for the test. Where a testable component is in borderline condition, the tester has discretion in deciding whether to pass or fail it.
MOT test checks REF.9 Electrical equipment q Switch on the ignition and check the operation of the horn. 0 Check the windscreen washers and wipers, examining the wiper blades; renew damaged or perished blades. Also check the operation of the stop-lights. 0 Inspect both front brake flexible hoses for cracks or deterioration of the rubber. Turn the steering from lock to lock, and ensure that the hoses do not contact the wheel, tyre, or any part of the steering or suspension mechanism.
REF.10 MOT test checks Exhaust system 0 Start the engine. With your assistant holding a rag over the tailpipe, check the entire system for leaks. Repair or renew leaking sections. Front and rear suspension and wheel bearings 0 Starting at the front right-hand side, grasp the roadwheel at the 3 o’clock and 9 o’clock positions and shake it vigorously. Check for free play or insecurity at the wheel bearings, suspension balljoints, or suspension mountings, pivots and attachments.
MOT test checks Ref.11 0 Examine the handbrake mechanism, checking for frayed or broken cables, excessive corrosion, or wear or insecurity of the linkage. Check that the mechanism works on each relevant wheel, and releases fully, without binding. 0 It is not possible to test brake efficiency without special equipment, but a road test can be carried out later to check that the vehicle pulls up in a straight line.
REF.12 Fault finding Engine . . . . . . . . . . . . . . . . . . . . .......... 1 Driveshafts . . . . . . . . . . . . . . . . . . . , , . , . . .
Fault finding REF.13 headings denoting various components or systems, such as Engine, Cooling system, etc. The Chapter and/or Section which deals with the problem is also shown in brackets. Whatever the fault, certain basic principles apply. These are as follows: Verify the fault. This is simply a matter of being sure that you know what the symptoms are before starting work. This is particularly important if you are investigating a fault for someone else, who may not have described it very accurately.
REF.14 Fault finding 1 Engine (continued) Engine lacks power Engine noises 0 0 0 0 0 Pre-ignition (pinking) or knocking during acceleration or under load Timing belt incorrectly fitted or tensioned (Chapter 2A or 2B). Fuel filter choked (Chapter 1). Fuel pump faulty, or delivery pressure low (Chapter 4A or 4B). Uneven or low cylinder compressions (Chapter 2A or 2B). Worn, faulty or incorrectly-gapped spark plugs (Chapter 1).
Fault finding REF.15 3 Fuel and exhaust systems Excessive fuel consumption q Air filter element dirty or clogged (Chapter 1). 0 Fuel injection system fault (Chapter 4A or 4B). 0 Ignition timing incorrect/ignition system fault (Chapters 1 and 5B). 0 Tyres under-inflated (Weekly checks”). Fuel leakage and/or fuel odour 0 Excessive noise or fumes from exhaust system 0 0 0 Leaking exhaust system or manifold joints (Chapters 1 and 4A or 4B).
REF.16 Fault finding 6 Driveshafts Clicking or knocking noise on turns (at slow speed on full-lock) 0 0 Lack of constant velocity joint lubricant, possibly due to damaged gaiter (Chapter 8). Worn outer constant velocity joint (Chapter 8). Vibration when accelerating or decelerating 0 0 Worn inner constant velocity joint (Chapter 8). Bent or distorted driveshaft (Chapter 8).
Fault finding REF.17 8 Suspension and steering (continued) Excessive pitching and/or rolling around corners, or during braking 0 q 0 Defective shock absorbers (Chapters 1 and 10). Broken or weak spring and/or suspension component (Chapters 1 and 10). Worn or damaged anti-roll bar or mountings (Chapter IO). Wandering or general instability Incorrect front wheel alignment (Chapter 10). q Worn steering or suspension joints, bushes or components (Chapters 1 and 10).
REF.18 Fault finding 9 Electrical system (continued) Horn inoperative, or unsatisfactory in operation Horn operates all the time 0 0 Horn push either earthed or stuck down (Chapter 12). Horn cable-to-horn push earthed (Chapter 12). Horn fails to operate 0 Blown fuse (Chapter 12). 0 Cable or cable connections loose, broken or disconnected (Chapter 12). Cl Faulty horn (Chapter 12).
Glossary of technical terms REF.9 A ABS (Anti-lock brake system) A system, usually electronically controlled, that senses incipient wheel lockup during braking and relieves hydraulic pressure at wheels that are about to skid. Air bag An inflatable bag hidden in the steering wheel (driver’s side) or the dash or glovebox (passenger side). In a head-on collision, the bags inflate, preventing the driver and front passenger from being thrown forward into the steering wheel or windscreen.
REF.20 Glossary of technical terms Camshaft A rotating shaft on which a series of cam lobes operate the valve mechanisms. The camshaft may be driven by gears, by sprockets and chain or by sprockets and a belt. Canister A container in an evaporative emission control system; contains activated charcoal granules to trap vapours from the fuel system. Catalytic converter A silencer-like device in the exhaust system which converts certain pollutants in the exhaust gases into less harmful substances.
Glossary of technical terms REF.21 E EGR valve A valve used to introduce exhaust gases into the intake air stream. Feeler blade A thin strip or blade of hardened steel, ground to an exact thickness, used to check or measure clearances between parts. electrode in a spark plug. Also refers to the spacing between the points in a contact breaker assembly in a conventional pointstype ignition, or to the distance between the reluctor or rotor and the pickup coil in an electronic ignition.
REF.22 Glossary of technical terms J Jump start Starting the engine of a vehicle with a discharged or weak battery by attaching jump leads from the weak battery to a charged or helper battery. Load Sensing Proportioning Valve (LSPV) A brake hydraulic system control valve that works like a proportioning valve, but also takes into consideration the amount of weight carried by the rear axle. Locknut A nut used to lock an adjustment nut, or other threaded component, in place.
Glossary of technical terms REF.23 automatic transmission, a s w i t c h t h a t prevents starting if the vehicle is not in Neutral or Park. Strut See MacPherson strut. Tappet A cylindrical component which transmits motion from the cam to the valve stem, either directly or via a pushrod and rocker arm. Also called a cam follower. Thermostat A heat-controlled valve that regulates the flow of coolant between the cylinder block and the radiator, so maintaining optimum engine operating temperature.