Text preview for : Haynes VW Golf & Jetta Service And Repair Manual.pdf part of Volkswagen Golf & Jetta MK 2 Golf & Jetta MK 2 with petrol engines incl fuel injection, catalytic converter, Formel E, 16.Valve and special, limited models. 1043ccm, 1272ccm, 1595ccm, 1781ccm. (491 pages)
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VW
Golf
&
Jetta
Service and Repair Manual
I M Coomber and Christopher Rogers
Models covered (1081 - 344 - 1AA11) VW Golf & Jetta Mk 2 models with petrol engines, including fuel injection, catalytic converter, Formel E, 16-valve and special/limited edition models 1043 cc, 1272 cc, 1595 cc & 1781 cc
Covers mechanical features of Van. Does not cover Convertible, Rallye, Caddy, diesel engine, 4 -wheel drive, Mk 1 models or new Golf range introduced in February 1992
ABCDE FGHIJ KLMNO PQRST
© Haynes Publishing 1997 1 2 3 A book in the Haynes Service and Repair Manual Series
All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.
ISBN 1 85960 282 7
British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library Printed by J H Haynes & Co. Ltd, Sparkford, Nr Yeovil, Somerset BA22 7JJ, England Haynes Publishing Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes North America, Inc
861 Lawrence Drive Newbury Park California 91320 USA Editions Haynes S.A. 147/149, rue Saint Honoré, 75001 PARIS, France Haynes Publishing Nordiska AB Fyrisborgsgatan 5, 754 50 Uppsala, Sverige
Contents
LIVING WITH YOUR VOLKSWAGEN GOLF OR JETTA
Introduction Page 0·4 Safety First! Page 0·5
Roadside Repairs
Introduction If your car won't start Jump starting Wheel changing Identifying leaks Towing Page Page Page Page Page Page 0·6 0·6 0·7 0·8 0·9 0·9
Weekly Checks
Introduction Underbonnet check points Engine oil level Coolant level Brake fluid level Power steering fluid level Screen/headlamp washer fluid level Wiper blades Tyre condition and pressure Battery Electrical systems Page Page Page Page Page Page Page Page Page Page Page 0·10 0·10 0·11 0·11 0·12 0·12 0·13 0·13 0·14 0·15 0·15
Lubricants and fluids Capacities and tyre pressures
Page Page
0·16 0·17
MAINTENANCE
Routine Maintenance and Servicing
Servicing specifications Maintenance schedule: Vehicles manufactured before August 1985 Vehicles manufactured after August 1985 Maintenance - component location Maintenance procedures Page Page Page Page 1·5 1·6 1·7 1·10 Page 1·2
Contents
REPAIRS & OVERHAUL
Engine and Associated Systems
Engine repair procedures - 1.05 and 1.3 litre - pre August 1985 Engine repair procedures - 1.05 and 1.3 litre - post August 1985 Engine repair procedures - 1.6 and 1.8 litre 8 valve Engine repair procedures - 1.8 litre 16 valve Cooling, heating and air conditioning systems Fuel and exhaust systems - carburettor models Fuel and exhaust systems - K-Jetronic fuel injection - 8 valve engines Fuel and exhaust systems - K-Jetronic fuel injection - 16 valve engines Fuel and exhaust systems - Mono Jetronic fuel injection Fuel and exhaust systems - Digijet fuel injection Fuel and exhaust systems - Digifant fuel injection Ignition system - contact breaker type Ignition system - transistorised type Ignition system - fully electronic type Starting and charging systems Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page 2A·1 2B·1 2C·1 2D·1 3·1 4A·1 4B·1 4C·1 4D·1 4E·1 4F·1 5A·1 5B·1 5C·1 5D·1
Transmission
Clutch Manual gearbox Automatic transmission Driveshafts Page Page Page Page 6·1 7A·1 7B·1 8·1
Brakes and Suspension
Braking system Suspension and steering Page Page 9·1 10·1
Body Equipment
Bodywork and fittings Body electrical systems Page Page 11·1 12·1
Wiring Diagrams
Page 12·17
REFERENCE
Dimensions and Weights Conversion Factors Buying Spare Parts and Vehicle Identification General Repair Procedures Jacking and Vehicle Support Tools and Working Facilities MOT test checks Fault Finding Glossary of Technical Terms Page Page Page Page Page Page Page REF·1 REF·2 REF·3 REF·4 REF·5 REF·6 REF·8
Page REF·12 Page REF·20 Page REF·25
Index
0·4
Introduction
The Mk. II Volkswagen Golf and Jetta range of models was introduced in March 1984, revised body and trim features being the main visual difference to the earlier range of models. The engine/transmission is mounted transversely at the front of the vehicle, drive being to the front wheels. Detailed improvements have been made throughout the years of manufacture to improve power output and economy. These include the introduction of hydraulic
VW Golf
The VW Golf & Jetta Team
Haynes manuals are produced by dedicated and enthusiastic people working in close co-operation. The team responsible for the creation of this book included: Authors Sub-editors Editor & Page Make-up Workshop manager Photo Scans Ian Coomber Cristopher Rogers Carole Turk Sophie Yar Steve Churchill Paul Buckland John Martin Paul Tanswell Steve Tanswell Cover illustration & Line Art Roger Healing
We hope the book will help you to get the maximum enjoyment from your car. By carrying out routine maintenance as described you will ensure your car's reliability and preserve its resale value.
bucket tappets, the Digifant, Digijet and Mono-Jetronic fuel injection systems, the 16-valve engine fitted to the GTi variant, the fully electronic ignition system (FEI), the 085 5-speed gearbox and several other minor modifications and revisions. As with earlier models the new range is proving popular, giving economy, reliability, comfort and, if previous models can be used as a yardstick, long life.
VW Jetta
Your Volkswagen Golf and Jetta Manual
The aim of this Manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done (even should you choose to get it done by a garage), provide information on routine maintenance and servicing, and give a logical course of action and diagnosis when random faults occur. However, it is hoped that you will use the
Manual by tackling the work yourself. On simpler jobs it may even be quicker than booking the car into a garage and going there twice, to leave and collect it. Perhaps most important, a lot of money can be saved by avoiding the costs a garage must charge to cover its labour and overheads. The Manual has drawings and descriptions to show the function of the various components so that their layout can be understood. Then the tasks are described and photographed in a clear step-by-step sequence.
Acknowledgements
Thanks are due to Champion Spark Plug who supplied the illustrations showing spark plug conditions, to Duckhams Oils, who provided lubrication data and also to Sykes-Pickavant Limited, who supplied some of the workshop tools, and to all those people at Sparkford who helped in the production of this Manual. We take great pride in the accuracy of information given in this Manual, but vehicle manufacturers make alterations and design changes during the production run of a particular vehicle of which they do not inform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from the information given.
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 orpower steering fluid may also be dangerously hot if the engine has recently been running.
Burning
· Beware of burns from the exhaust system and from any part of the engine. Brake discs and drums can also be extremely hot immediately after use.
Crushing
· When working under or neara raised vehicle, always supplement the jack with axle stands, or use drive-on ramps. Never venture under a car which is only supported by a jack.
· Take care if loosening or tightening hightorque nuts when the vehicle is on stands. Initial loosening and final tightening should be done with the wheels on the ground.
Fire
. · Fuel is highly flammable; fuel vapour isexplosive. . · Don't let fuel spill onto a hot engine. . · Do not smoke or allow naked lights(including pilot lights) anywhere near a vehicle being worked on. Also beware of creating sparks (electrically or by use of tools). . · Fuel vapour is heavier than air, so don't work on the fuel system with the vehicle over an inspection pit. . · Another cause of fire is an electrical overload or short-circuit. Take care when repairing or modifying the vehicle wiring.
.
· Keep a fire extinguisher handy, of a type suitable for use on fuel and electrical fires.
Electric shock
· Ignition HTvoltage can be dangerous, especially to people with heart problems or a pacemaker. Don't work on or near the ignition system with the engine running or the ignition switched on.
· Mains voltage is also dangerous. Make sure that any mains-operated equipment is correctly earthed. Mains power points should be protected by a residual current device (RCD) circuit breaker.
Fume or gas intoxication
. · Exhaust fumes are poisonous; they often contain carbon monoxide, which is rapidly fatal if inhaled. Never run the engine in a confined space such as a garage with the doors shut. . · Fuel vapour is alsopoisonous, as are the vapours from some cleaning solvents and paint thinners.
Poisonous or irritant substances
. · Avoid skin contact with battery acid and with any fuel, fluid or lubricant, especially antifreeze, brake hydraulic fluid and Diesel fuel. Don't syphon them by mouth. If such a substance is swallowed or gets into the eyes, seek medical advice. . · Prolonged contact with used engine oil can cause skin cancer. Wear gloves or use a barrier cream if necessary. Change out of oilsoaked clothes and do not keep oily rags in your pocket. . · Air conditioning refrigerant forms a poisonous gas if exposed to a naked flame (including a cigarette). It can also cause skin burns on contact.
Asbestos
· Asbestos dust can cause cancer if inhaledor swallowed. Asbestos may be found in gaskets and in brake and clutch linings. When dealing with such components it is safest to assume that they contain asbestos.
Special hazards
Hydrofluoric acid
. · This extremely corrosive acid is formed when certain types of synthetic rubber, found in some O-rings, oil seals, fuel hoses etc, are exposed to temperatures above 400 C. The rubber changes into a charred or sticky substance containing the acid. Once formed, the acid remains dangerous for years. If it gets onto the skin, it may be necessary to amputate the limb concerned. . · When dealing with a vehicle which hassuffered a fire, or with components salvaged from such a vehicle, wear protective
0
gloves and discard them after use.
The battery
. · Batteries contain sulphuric acid, whichattacks clothing, eyes and skin. Take care when topping-up or carrying the battery. . · The hydrogen gas given off by the battery is highly explosive. Never cause a spark or allow a naked light nearby. Be careful when connecting and disconnecting battery chargers or jump leads.
Air bags
· Air bags can cause injury if they go off accidentally. Take care when removing the steering wheel and/or facia. Special storage instructions may apply.
Diesel injection equipment
· Diesel injection pumps supply fuel at veryhigh pressure. Take care when working on the fuel injectors and fuel pipes. Warning: Never expose the hands, face or any other part of the body to injector spray; the fuel can penetrate the skin with potentially fatal results.
0·6 Roadside repair
s
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 it's a model with automatic transmission, make sure the selector is in `P' or `N'. Open the bonnet
and make sure that the battery terminals are clean and tight. Switch on the headlights and try to start the engine. If the headlights go very dim when you're trying to start, the battery is probably flat. Get out of trouble by jump starting (see next page) using a friend's car.
If your car won't start even though the starter motor turns as normal
Is there fuel in the tank? Is there moisture on electrical components under the bonnet? Switch off the ignition, then wipe off any obvious dampness with a dry cloth. Spray a water-repellent aerosol product (WD-40 or equivalent) on ignition and fuel system electrical connectors like those shown in the photos. Pay special attention to the ignition coil wiring connector and HT leads.
Check that the HT lead connections at Check that the HT lead connections at Check that the LT lead connections are by pushing cap.
A
the distributor are clean and make sure
B
the spark plugs are secure
C
clean and secure. they are secure by pushing them onto them onto the plugs. the
Check the security and condition of the
D
battery connections.
Check that electrical connections are secure (with the ignition switched off) and spray them Wiring plugs may cause problems if dirty with a water dispersant spray like WD40 if you suspect a problem due to damp
E
or not connected properly.
Roadside repairs 0·7
0·8 Roadside repair
s
Wheel changing
Some of the details shown here will vary Warning: Do not change a wheel in a situation where you risk being hit by according to model. For instance, the location
another vehicle. On busy roads, try to stop in a lay-by or a gateway. Be wary of of the spare wheel and jack is not the same on
passing traffic while changing the wheel - it is easy to become distracted by all cars. However, the basic principles apply
the job in hand. to all vehicles.
Preparation
When a puncture occurs, stop as soon as If you have one, use a warning triangle to Chock the wheel diagonally opposite the it is safe to do so. alert other drivers of your presence. one being removed a couple of large Park on firm level ground, if possible, Apply the handbrake and engage first or stones will do for this. and well out of the way of other traffic. reverse gear (or Park on models with If the ground is soft, use a flat piece of Use hazard warning lights if necessary. automatic transmission. wood to spread the load under the jack.
Changing the wheel
The spare wheels and tools are stored in Unscrew the retaining nut and lift the Remove the wheel trim/hub cap from the the luggage compartment. Release the
1
2
wheel out of the vehicle.
3
wheel (some trims have retaining screws retaining
strap and lift out the jack and which must be undone first). Slacken tools from the centre of the wheel. each wheel bolt by half a turn.
Locate the jack below the reinforced Unscrew the wheel bolts and remove the Once the car is on the ground, tighten the the sill and on firm ground. Turn
4
point on
5
wheel. Fit the spare wheel and screw in
6
wheel bolts securely in a diagonal pattern the jack
handle to raise the car until the the wheel bolts. Lightly tighten them using the wheelbrace. At the earliest wheel is clear of the ground. using the wheelbrace, then lower the car to possible opportunity, have the wheel bolts the ground. slackened and then tightened to the correct torque wrench setting.
Finally...
Remove the wheel chocks. Stow the jack and tools in the correct locations in the car. Check the tyre pressure on the wheel just fitted. If it is low, or if you don't have a pressure gauge with you, drive slowly to the nearest garage and inflate the tyre to the right pressure. Have the damaged tyre or wheel repaired as soon as possible.
Roadside repairs 0·9
Engine oil may leak from the drain plug...
...or from the base of the oil filter.
Gearbox oil can leak from the seals at the inboard ends of the driveshafts.
Antifreeze
Brake fluid
Power steering fluid
Leaking antifreeze often leaves a crystalline A leak occurring at a wheel is almost Power steering fluid may leak from the pipe deposit like this. certainly brake fluid. connectors on the steering rack.
When all else fails, you may find yourself having to get a tow home or of course you may be helping somebody else. Long-distance recovery should only be done by a garage or breakdown service. For shorter distances, DIY towing using another car is easy enough, but observe the following points: Use a proper tow-rope they are not expensive. The vehicle being towed must display an `ON TOW' sign in its rear window. Always turn the ignition key to the `on' position when the vehicle is being towed, so that the steering lock is released, and that the direction indicator and brake lights will work. Only attach the tow-rope to the towing eyes provided. Before being towed, release the handbrake and select neutral on the transmission. Note that greater-than-usual pedal pressure will be required to operate the brakes, since the vacuum servo unit is only operational with the engine running. On models with power steering, greater-than-usual steering effort will also be required.
Towing
The driver of the car being towed must keep the tow-rope taut at all times to avoid snatching. Make sure that both drivers know the route before setting off. Only drive at moderate speeds and keep the distance towed to a minimum. Drive smoothly and allow plenty of time for slowing down at junctions. On models with automatic transmission, special precautions apply. If in doubt, do not tow, or transmission damage may result.
0·10 Weekly check
s
Introduction
There are some very simple checks which Keeping an eye on tyre condition and need only take a few minutes to carry out, but pressures, will not only help to stop them which could save you a lot of inconvenience wearing out prematurely, but could also save and expense. your life. These "Weekly checks" require no great skill Many breakdowns are caused by electrical or special tools, and the small amount of time problems. Battery-related faults are particularly they take to perform could prove to be very common, and a quick check on a regular basis well spent, for example; will often prevent the majority of these.
Underbonnet check points
If your car develops a brake fluid leak, the first time you might know about it is when your brakes don't work properly. Checking the level regularly will give advance warning of this kind of problem. If the oil or coolant levels run low, the cost of repairing any engine damage will be far greater than fixing the leak, for example.
All models
(typical)
A Engine oil level dipstick B Engine oil filler cap C Coolant expansion tank D Brake fluid reservoir E Power steering fluid reservoir F Screen washer fluid reservoir
G Battery
Weekly checks 0·11
location). Withdraw the dipstick. then withdraw it again. The correct oil Modern engines place great demands on their oil. It is very important that the correct oil for your car is used (See "Lubricants, fluids and capacities").
Car Care
If you have to add oil frequently, you should check whether you have any oil leaks. Place some clean paper under the car overnight, and check for stains in the morning. If there are no leaks, the engine may be burning oil (see "Fault Finding").
Always maintain the level between the
Note the oil level on the end of the Oil is added through the filler cap.
3
upper and lower dipstick marks (see photo 3).
dipstick, which should be between the
4
Unscrew the cap and top-up the
If the level is too low severe
level; a
upper ("MAX") mark and lower ("MIN") funnel may help to reduce spillage. Add
engine damage
may occur. Oil seal failure may result if the
mark. Approximately 1.0 litre of oil will raise the oil slowly, checking the level on the dipstick level from the lower mark to the upper often. Don't overfill (see "Car Care" left). engine is overfilled by adding too much oil.
mark.
the
Coolant level
Warning: DO NOT attempt to
remove the expansion tank
Car Care
With a sealed-type cooling system, adding It is important that antifreeze is used in the
risk of scalding. Do not leave
pressure cap when the engine
is hot, as there is a very great
coolant should not be necessary on a regular cooling system all year round, not just during topping-up is required, it is the winter months. Don't top-up with water
open containers of coolant
basis. If frequent
likely there is a leak. Check the radiator, all
alone, as the antifreeze will become too
about, as it is poisonous.
hoses and joint faces for signs of staining or diluted.
wetness, and rectify as necessary.
The coolant level varies with the If topping up is necessary, wait until the Add the recommended mixture of water temperature of the engine. When the
1
2
engine is cold. Slowly unscrew the
3
and antifreeze through the expansion
engine is cold, the coolant level should expansion tank cap, to release any tank filler neck, until the coolant is up to be between the MAX and MIN marks on the pressure present in the cooling system, and the MAX level mark. Refit the cap, turning it side of the expansion tank. When the engine remove it. clockwise as far as it will go until it is secure. is hot, the level may rise slightly.
0·12 Weekly check
s
1
dangerous loss of braking
2
indicated on the front of the reservoir.
The "MAX" and "MIN" marks are If topping-up is necessary, first wipe clean the area around the filler cap to
effectiveness. The fluid level must be kept between the prevent dirt entering the hydraulic
investigated immediately.
Unscrew the reservoir cap and carefully Carefully add fluid, taking care not to spill
3
lift it out of position, taking care not to Use
If a leak is suspected, the car should not be system has been
4
it onto the surrounding components.
driven until the braking checked. Never take any risks where brakes
damage the level switch float. Inspect the only the specified fluid; mixing different system the cap and wipe off any spilt fluid.
reservoir, if the fluid is dirty the hydraulic types can cause damage to the system. After should be drained and refilled (see topping-up to the correct level, securely refitare concerned.
Chapter 1).
The fluid reservoir is mounted next to the If topping-up is necessary, first wipe the After filling the reservoir to the proper battery in the engine compartment.
1
2
area around the filler cap with a clean rag
3
level, make sure that the cap is refitted
"MAX" and "MIN" level marks are before removing the cap. When adding securely to avoid leaks and the entry of indicated on the side of the reservoir. The fluid fluid, pour it carefully into the reservoir to foreign matter into the reservoir. level should be maintained between these avoid spillage. Be sure to use only the marks at all times. specified fluid.
Weekly checks 0·13
Screen/headlamp washer fluid level
Screenwash additives not only keep the weather - which is when you are likely to need it freeze during cold weather. On no account use winscreen clean during foul weather, they also most. Don't top up using plain water as the coolant antifreeze in the washer system prevent the washer system freezing in cold screenwash will become too diluted, and will this could discolour or damage paintwork.
The reservoir for the windscreen and headlamp washer systems is located on the left-hand side of the engine compartment, forward of the suspension turret. The rear screen washer system reservoir is located on the right-hand side rear corner of the luggage compartment. Later systems have a single reservoir located in the engine compartment.
When topping-up the reservoir(s) a screenwash additive should be added in the quantities recommended on the bottle.
1
2
Check the operation of both screen and headlamp washers. Adjust
3
the nozzles using
a pin if necessary, aiming the spray to a point slightly above the centre of the swept area. a = 345 mm b = 420 mm c = 320 mm d = 300 mm
Wiper blades
Check the condition of the wiper blades; To remove a windscreen wiper blade, pull
1
if they are cracked or show any signs of
2
the arm fully away from the screen until it
deterioration, or if the glass swept area is locks. Swivel the blade through 90°, smeared, renew them. Wiper blades should press the locking tab with your fingers and be renewed annually. slide the blade out of the arm's hooked end.
Don't forget to check the tailgate wiper blade as well. To remove the blade, depress the retaining tab and slide the blade out of the hooked end of the arm.
0·14 Weekly check
s
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. However, if this is completely effective, you may have the expense of replacing all four tyres at once! Remove any nails or stones embedded in the tread before they penetrate the tyre to cause deflation. If removal of a nail does reveal that
Tread Depth - visual check
The original tyres have tread wear safety bands (B), which will appear when the tread depth reaches approximately 1.6 mm. The band positions are indicated by a triangular mark on the tyre sidewall (A). New tyres should be balanced when they are fitted, but it may become necessary to re-balance them as they wear, or if the balance weights fitted to the wheel rim should fall off. Unbalanced tyres will wear more quickly, as will the steering and suspension components. Wheel imbalance is normally signified by vibration, particularly at a certain speed (typically around 50 mph). If this vibration is felt only through the steering, then it is likely that just the front wheels need balancing. If, however, the vibration is felt through the whole car, the rear wheels could be out of balance. Wheel balancing should be carried out by a tyre dealer or garage.
Tyre Pressure Check
3
Check the tyre pressures regularly with the tyres cold. Do not adjust the tyre pressures immediately after the vehicle has been used, or an inaccurate setting will result.
Uneven Wear
the tyre has been punctured, refit the nail so that its point of penetration is marked. Then immediately change the wheel, and have the tyre repaired by a tyre dealer. Regularly check the tyres for damage in the form of cuts or bulges, especially in the sidewalls. Periodically remove the wheels, and clean any dirt or mud from the inside and outside surfaces. Examine the wheel rims for signs of rusting, corrosion or other damage. Light alloy wheels are easily damaged by "kerbing" whilst parking; steel wheels may also become dented or buckled. A new wheel is very often the only way to overcome severe damage.
Tread Depth - manual check
2
Alternatively, tread wear can be monitored with a simple, inexpensive device known as a tread depth indicator gauge.
Tyre tread wear patterns
Underinflation (wear on both sides) Under-inflation will cause overheating of the tyre, because the tyre will flex too much, and the tread will not sit correctly on the road surface. This will cause a loss of grip and excessive wear, not to mention the danger of sudden tyre failure due to heat build-up. Check and adjust pressures Incorrect wheel camber (wear on one side) Repair or renew suspension parts Hard cornering Reduce speed!
Shoulder Wear
Centre Wear
Overinflation Over-inflation will cause rapid wear of the centre part of the tyre tread, coupled with reduced grip, harsher ride, and the danger of shock damage occurring in the tyre casing. Check and adjust pressures If you sometimes have to inflate your car's tyres to the higher pressures specified for maximum load or sustained high speed, don't forget to reduce the pressures to normal afterwards. Front tyres may wear unevenly as a result of wheel misalignment. Most tyre dealers and garages can check and adjust the wheel alignment (or "tracking") for a modest charge. Incorrect camber or castor Repair or renew suspension parts Malfunctioning suspension Repair or renew suspension parts Unbalanced wheel Balance tyres Incorrect toe setting Adjust front wheel alignment Note: The feathered edge of the tread which typifies toe wear is best checked by feel.
Weekly checks 0·15
Battery
Caution: Before carrying out any work on the vehicle battery, read the precautions given in "Safety first" at the start of this manual. Make sure that the battery tray is in good condition, and that the clamp is tight. Corrosion on the tray, retaining clamp and the battery itself can be removed with a solution of water and baking soda. Thoroughly rinse all cleaned areas with water. Any metal parts damaged by corrosion should be covered
with a zinc-based primer, then painted.
The battery is located on the left-hand Check the tightness of battery clamps (A) Periodically (approximately every three
months), check the charge condition of the
1
side of the engine compartment. The
2
to ensure good electrical
battery as described in Chapter
connections.
5A.
exterior of the battery should be You should not be able to move them.
inspected periodically for damage such as a Also check each cable (B) for cracks and If the battery is flat, and you need to jump
cracked case or cover.
frayed conductors. start your vehicle, see Roadside Repairs.
If a single indicator light, stop-light or If more than one indicator light or tail light To replace a blown fuse, simply pull it out headlight has failed, it is likely that a bulb
1
2
has failed it is likely that either a fuse has
3
and fit a new fuse of the correct rating
has blown and will need to be replaced. blown or that there is a fault in the circuit (see Chapter 12). If the fuse blows again, Refer to Chapter 12 for details. If both stop-(see Chapter 12). The fuses are located under it is important that you find out why - a lights have failed, it is possible that the switch the facia panel, on the right-hand side, behind complete checking procedure is given in has failed. a removable cover. Chapter 12.
0·16 Lubricants and fluid
s
Lubricants and fluids
Component or system Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
Lubricant or fluid
Multigrade engine oil to viscosity SAE 15W/50 or 20W/50 Duckhams QXR, QS, Hypergrade Plus or Hypergrade
Cooling system . . . . . . . . . . . . . . . . . . . . .
. Ethylene-glycol based antifreeze with corrosion inhibitors. Duckhams Antifreeze & Summer Coolant. Mixture 50% by volume Gear oil, viscosity SAE 80 Duckhams Hypoid 80 or Hypoid 75W/90S Dexron type ATF Duckhams Uni-Matic
Manual gearbox . . . . . . . . . . . . . . . . . . . . . Automatic transmission . . . . . . . . . . . . .
.
Final drive:
Manual gearbox . . . . . . . . . . . . . . . . . . . . . . Gear oil, viscosity SAE 80 Duckhams Hypoid 80 or Hypoid 75W/90S Automatic transmission . .
. . . . . . . . . . . . . . Gear oil, viscosity SAE 90EP Duckhams Hypoid 90S or Hypoid 75W/90S
Brake hydraulic system . . . . . . . . . . . . . .
Hydraulic fluid to FMVSS 11 6 DOT 4 Duckhams Universal Brake and Clutch Fluid
Power steering system:
pre-April 1989 . . . . . . . . . . . . . . . . . . . . . . . Dexron type ATF Duckhams Uni-Matic post-April 1989 . . . . . . . . . . . . . . . . . . . . . . VW oil G 002 000 No Duckhams equivalent
Choosing your engine oil
Oils perform vital tasks in all engines. The higher the engine's performance, the greater the demand on lubricants to minimise wear as well as optimise power and economy. Duckhams tailors lubricants to the highest technical standards, meeting and exceeding the demands of all modern engines.
HOW ENGINE OIL WORKS · Beating friction
Without oil, the surfaces inside your engine which rub together will heat, fuse and quickly cause engine seizure. Oil, and its special additives, forms a molecular barrier between moving parts, to stop wear and minimise heat build-up.
· Cooling hot spots
Oil cools parts that the engine's water-based coolant cannot reach, bathing the combustion chamber and pistons, where temperatures may exceed 1000°C. The oil assists in transferring the heat to the engine cooling system. Heat in the oil is also lost by air flow over the sump, and via any auxiliary oil cooler.
· Cleaning the inner engine
Oil washes away combustion by-products (mainly carbon) on pistons and cylinders, transporting them to the oil filter, and holding the smallest particles in suspension until they are flushed out by an oil change. Duckhams oils undergo extensive tests in the laboratory, and on the road.
Note: It is antisocial and illegal to dump oil down the drain. To find the location of your local oil recycling bank, call this number free.
Capacities and tyre pressures 0·17
Capacities
Component or system Engine:
1.05 & 1.3 litre: rocker-finger type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 litres with filter change 2.5 litres without filter change 3.5 litres with filter change 3.0 litres without filter change 1.6 & 1.8 litre: pre-August 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 litres with filter change 3.0 litres without filter change 4.0 litres with filter change 3.5 litres without filter change 6.3 litres
Capacity
hydraulic tappet type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
post-August 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
Manual gearbox:
084 type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 085 type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 020 4-speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 020 5-speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 litres 3.1 litres 1.5 litres 2.0 litres 6.0 litres from dry 3.0 litres service drain & fill
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
Final drive:
Manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Included in gearbox capacity
Automatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.75 litre 55.0 litres
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
Tyre pressures (tyres cold)
Front 1.05 & 1.3 litre models:
Half load . . . . . . . . . . . . . . . . . . . . . . . . . . Full load . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 bar (26 lbf/in2) 1.8 bar (26 lbf/in2) 1.8 bar (26 lbf/in2) 2.4 bar (35 lbf/in2)
Rear
1.6 & 1.8 litre models:
Half load . . . . . . . . . . . . . . . . . . . . . . . . . . Full load . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 bar (29 lbf/in2) 2.0 bar (29 lbf/in2) 1.8 bar (26 lbf/in2) 2.4 bar (35 lbf/in2)
Notes
0·18
Chapter Routine maintenance and
1 servicing
Contents
Air cleaner element renewal . . . . . Air conditioning system check . . . . Alternator, power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 . . . . . . . . . . . . . . . . . . . . . . . . . 8 pump and air conditioner compressor 13 14 35 23 7 5 36 26 21 16 11 24 18 19 6 25
drivebelt(s) check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Antifreeze concentration check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic transmission and final drive fluid renewal . . . . . . . . . . . . Automatic transmission fluid level check . . . . . . . . . . . . . . . . . . . . . Battery electrolyte level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake pad and rear shoe lining check . . . . . . . . . . . . . . . . . . . . . . . . Clutch operation check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact breaker point renewal and adjustment . . . . . . . . . . . . . . . . Contact breaker point check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CV joint and boot check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine oil and filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fluid leakage and engine electrical system check . . . . . . . . . . . . . . Fuel and brake line, hose and union check . . . . . . . . . . . . . . . . . . . .
Degrees of difficulty
Fuel filter renewal . . . . . . . . . . . . . . . . Fuel system control linkage check . . . . . . Gearbox oil level check . . . . . . . . . . . . Headlight beam alignment check . . . . . . . Hinge and catch lubrication . . . . . . . . . . Ignition timing check . . . . . . . . . . . . . . Intensive maintenance . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . Light, direction indicator and horn check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 9 22 27 30 17 2 1 10
Lock, hinge and latch mechanism check . . . . . . . Seat belt check . . . . . . . . . . . . . . . . . . . . . . Slow running adjustment . . . . . . . . . . . . . . . . . Spark plug renewal . . . . . . . . . . . . . . . . . . . . Steering gear check . . . . . . . . . . . . . . . . . . . . Sunroof guide rails cleaning and lubrication . . . . . . Suspension check . . . . . . . . . . . . . . . . . . . . . Timing belt renewal . . . . . . . . . . . . . . . . . . . . Valve clearance check . . . . . . . . . . . . . . . . . . Vehicle underbody check . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . .
3 4 20 15 28 34 29 37 12 31
Easy, suitable for Fairly easy, suitable Fairly difficult, Difficult, suitable for Very difficu lt, novice with little for beginner with suitable for competent experienc ed DIY suitable for expert DIY
1
4
2
3
experience some experience DIY mechanic mechanic or professional
1·2
Servicing specifications
Refer to the end of "Weekly checks" Champion C101/C160
Lubricants, fluids and capacities Engine
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve clearances 1.05 and 1.3 litre engines - pre August 1985: Warm: Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cold: Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic tappet free travel 1.05 and 1.3 litre - post August 1985, 1.6 and 1.8 litre (Maximum travel) . .
0.15 to 0.20 mm 0.25 to 0.30 mm 0.10 to 0.15 mm 0.20 to 0.25 mm 0.1 mm
Cooling system
Antifreeze mixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 % antifreeze (by volume) with water
Air conditioning system
Compressor drivebelt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 to 10.0 mm deflection on longest run
Fuel system
Air filter element types Carburettor engines: 1.05 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 and 1.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel-injected engines: K-Jetronic on 16 valve engine: 1.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All other systems: 1.8 litre Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 litre Jetta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 litre GTi ( engine code RP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel filter element types Carburettor engines (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Fuel-injected engines: K-Jetronic on 16 valve engine: 1.8 litre Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 litre Jetta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion L203 Champion L206 Champion U502 Champion U506 Champion U502 Champion U572 Champion W101 Champion W102 Champion U508
Champion L104
All other systems: 1.8 litre GTi ( engine code RP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . All other models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion L206 Champion L204*
.* New copper washers must be used and these are not supplied with the filter .* Spark plug types and electrode gaps are recommended by Champion Spark Plug. If other types are used, refer to their manufacturer's
Idle speed 1.05 litre carburettor engines: Pierburg/Solex 31 PIC-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pierburg/Solex 1B3 and Weber 32 TLA . . . . . . . . . . . . . . . . . . . . . . . 1.3 litre carburettor engines: Pierburg/Solex 2E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 litre carburettor engines: Pierburg/Solex 2E2 - engine code EZ . . . . . . . . . . . . . . . . . . . . . . . . Pierburg/Solex 2E2 - engine code RF . . . . . . . . . . . . . . . . . . . . . . . . 1.8 litre carburettor engines: Pierburg/Solex 2E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-Jetronic fuel-injected engine: 8 valve: Pre Sept. 1984 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . From Sept. 1984 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air conditioned models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mono Jetronic fuel-injected engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digijet fuel-injected engine: Up to July 1989 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . July 1989 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digifant fuel-injected engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 to 850 rpm 880 to 980 rpm 750 to 850 rpm 900 to 1000 rpm 800 to 1000 rpm 850 to 1000 rpm 900 to 1000 rpm 750 to 950 rpm (not adjustable)
900 to 1000 rpm 750 to 850 rpm 750 to 850 rpm 900 to 1000 rpm 700 to 800 rpm 900 to 1000 rpm
Servicing specifications 1·3
CO content (%) 1.05 litre carburettor engines: Pierburg/Solex 31 PIC-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pierburg/Solex 1B3 and Weber 32 TLA ..................... .. 1.3 litre carburettor engines (Pierburg/Solex ............... 2E3) .. 1.6 litre carburettor engines: ....................... . Pierburg/Solex 2E2 - engine code RF ....................... . 1.8 litre carburettor engines (Pierburg/Solex ............... 2E2) .. K-Jetronic fuel-injected engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mono Jetronic fuel-injected ........................... engine . Digijet fuel-injected engine: Up to July 1989 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pierburg/Solex 2E2 - engine code EZ
0.5 to 1.5 1.5 to 2.5 1.5 to 2.5
0.5 to 1.5 1.0 to 1.5 0.5 to 1.5 0.5 to 1.5 0.2 to 1.2
0.3 to 1.1
July 1989 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digifant fuel-injected engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.3 to 1.5 0.5 to 1.5
Ignition system
Firing order (all ................................... engines) .. Contact breaker system Spark ............................................ plugs*: . 1.05, 1.3, 1.6 and 1.8 litre (pre July 1985) . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2 (No. 1 cylinder at crankshaft pulley end)
Type Champion N7YCC or N7YC
Electrode gap 0.8 mm or 0.7 mm
recommendations HT lead type: 1.05 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3, 1.6 and 1.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Distributor: Contact breaker gap (initial setting only) . . . . . . . . . . . . . . . . . . . . . . Dwell angle (1.05, 1.3 and 1.6 litre): Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition timing (at idle): 1. 1.05 and 1.3 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. 1.6 and 1.8 litre (carburettor engine) . . . . . . . . . . . . . . . . . . . . . . . . . . 3. 1.8 litre (fuel injection engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transistorised system Spark plugs*: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pre Sept. 1985: 1.05, 1.3, 1.6, 1.8 litre (pre July 1985) . . . . . . . . . . . . . . . . . . . . . . . from Sept. 1985: 1. 1.3 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. 1.6 litre:Coil with green sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coil with grey sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. 1.8 litre:Except 16V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16V . . . . ...........................................
Champion LS-05 boxed set Champion LS-07 boxed set 0.4 mm 44 to 50° (50 to 56%) 42 to 58° (47 to 64%) 4 to 6° BTDC 17 to 19° BTDC 5 to 7° BTDC Type Champion N7YCC or N7YC Champion N7BYC or N7YCC Champion N9BYC4 or N9YCC Champion N9YCC Champion N7BYC or N7YCC Electrode gap 0.8 mm or 0.7 mm 0.8 mm 1.0 mm 0.8 mm 0.8 mm
1
Champion C6BYC or C6YCC
0.8 mm
* Spark plug types and electrode gaps are recommended by Champion Spark Plug. If other types are used, refer to their manufacturer's recommendations HT lead type: 1.05 litre. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3, 1.6 and 1.8 litre. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Distributor: Dwell angle (1.05,1.3 and 1.6 litre): Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition timing: 1. 1.3 litre (code NZ) - TCI-H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. 1.6 litre (code RF) - TCI-H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. 1.8 litre:Code PB and PF - Digifant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Code GU and RH - TCI-H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Code RP - TCI-H . . . . . . . . ............................... Fully electronic system All Specifications as for Transistorised System except for: Ignition timing: 1.8 litre 16 valve engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion LS-05 boxed set Champion LS-07 boxed set 44 to 50° (50 to 56%) 42 to 58° (47 to 64%) 4 to 6° BTDC at 750 to 850 rpm, with vacuum hose disconnected 17 to 19° BTDC at 700 to 800 rpm, with vacuum hose disconnected 5 to 7° BTDC at 2000 to 2500 rpm, with temperature sender disconnected 17 to 19° BTDC at 675 to 825 rpm, with vacuum hose connected 5 to 7° BTDC at 950 rpm, with vacuum hose disconnected
5 to 7° BTDC at 950 to 1050 rpm, with vacuum hose connected
1·4
Servicing specifications
2.0 mm deflection under finger pressure at point midway between alternator and crankshaft pulleys 5.0 mm deflection under finger pressure at same point 8 to 10 Nm (6 to 7 Ibf ft) torque loading on adjuster bolt 15 to 20 mm
Charging system
Alternator drivebelt tension Initial adjustment for new drivebelt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment after 500 miles (750 km) . . . . . . . . . . . . . . . . . . . . . . . . . . . Models after early 1985 fitted with rack type adjustment link . . . . . . . .
Clutch
Free play at clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Braking system
Pad thickness Front disc brakes: New - excluding backplate: 1.05 and 1.3 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 and 1.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 litre with ventilated discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum - including backplate: All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear disc brakes: New - including backplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum - including backplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shoe lining thickness Rear drum brakes: Minimum - including shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum - excluding shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 mm 2.5 mm 10.0 mm deflection under firm finger pressure at point midway between pump and crankshaft pulleys 12.0 mm 14.0 mm 10.0 mm 7.0 mm 12.0 mm 7.0 mm
Steering
Power steering pump drivebelt tension . . . . . . . . . . . . . . . . . . . . . . . . .
Tyre pressures Torque wrench settings
Engine Sump drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition system Contact breaker system: Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Distributor clamp bolt: 1.05 and 1.3 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 and 1.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transistorised and fully electronic systems: Spark plugs: 1.05 and 1.3 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 and 1.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging system Alternator mounting/pivot bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator adjuster link bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual gearbox Oil filler plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic transmission Oil pan bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil strainer (filter) cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Power steering pump/swivel bracket bolts . . . . . . . . . . . . . . . . . . . . . . Power steering pump tensioner/bracket . . . . . . . . . . . . . . . . . . . . . . . . Roadwheels Roadwheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Body fittings Seat belt anchor bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refer to the end of "Weekly checks" Nm lbf ft
30 22 10 7
20 15 10 7 25 18
25 18 20 15 45 33 25 18
25 18 25 18
20 15 32
20 15 20 15
110 81
40 30
Maintenance schedule 1·5
The maintenance intervals in this Manual are provided with the assumption that you will be carrying out the work yourself. These are the minimum maintenance intervals recommended by the manufacturer for vehicles driven daily. If you wish to keep your vehicle in peak condition at all times, you may wish to perform some of these procedures more often. We encourage frequent maintenance, because it enhances the efficiency, performance and resale value of your vehicle. If the vehicle is driven in dusty areas, used to tow a trailer, or driven frequently at slow speeds (idling in traffic) or on short journeys, then more frequent maintenance intervals are recommended. When the vehicle is new, it should be serviced by a factory-authorised dealer service department, in order to preserve the factory warranty.
1·6
Maintenance schedule
Maintenance - component location 1·7
Underbonnet view 1.3 litre model (air cleaner removed)
1 Engine oil dipstick 2 Fuel line filter 3 Brake master cylinder reservoir 4 Carburettor 5 Ignition coil 6 Cooling system expansion tank 7 Windscreen/headlight washer reservoir 8 Ignition distributor 9 Battery 10 Cooling fan 11 Engine oil filler cap
Underbonnet view fuel injection model
1 Engine oil dipstick 2 Compressor (air conditioning) 3 Fuel distributor 4 Alternator 5 Engine oil filler cap 6 Brake master cylinder reservoir 7 Throttle housing 8 Ignition coil 9 Cooling system expansion tank 10 Windscreen/headlamp washer reservoir 11 Battery 12 Clutch cable 13 Cooling fan 14 Ignition distributor
1·8
Maintenance - component location
Front underbody view - 1.3 litre model
1 Alternator 2 Oil filter 3 Driveshaft 4 Front mounting 5 Cooling system bottom hose 6 Gearbox 7 Track control arm 8 Tie-rod 9 Exhaust 10 Engine sump
Front underbody view - fuel injected model
1 Driveshaft 2 Front mounting 3 Starter motor 4 Gearbox 5 Track control arm 6 Tie-rod 7 Anti-roll bar 8 Exhaust system 9 Engine sump
Maintenance - component location 1·9
Rear underbody view - 1.3 litre model
1 Exhaust 2 Fuel tank 3 Rear shock absorber lower mounting 4 Axle beam 5 Handbrake cable (right hand) 6 Handbrake cable (left-hand) 7 Rear drum brake
Rear underbody view - fuel injected model
1 2 3 4 5 6 7
Exhaust Fuel tank Rear shock absorber lower mounting Axle beam Fuel pump and associated fittings Brake pressure regulator Rear disc brake
1·10
Maintenance procedures
1 Introduction
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. Visual checks, adjustments, component renewal and other helpful items are included. Refer to the accompanying illustrations of the engine compartment and the underside of the vehicle for the locations of the various components. Servicing your vehicle in accordance with the mileage/time maintenance schedule and the following Sections will provide a planned maintenance programme, which should result in a long and reliable service life. This is a comprehensive plan, so maintaining some items but not others at the specified service intervals, will not produce the same results. As you service your vehicle, you will discover that many of the procedures can and should - be grouped together, because of the particular procedure being performed, or because of the close proximity of two otherwise-unrelated components to one another. For example, if the vehicle is raised for any reason, the exhaust can be inspected at the same time as the suspension and steering components. The first step in this maintenance programme is to prepare yourself before the actual work begins. Read through all the Sections relevant to the work to be carried out, then make a list and gather together all the parts and tools required. If a problem is encountered, seek advice from a parts specialist, or a dealer service department.
2 Intensive maintenance
1 If, from the time the vehicle is new, the routine maintenance schedule is followed closely, and frequent checks are made of fluid levels and high-wear items, as suggested throughout this Manual, the engine will be kept in relatively good running condition, and the need for additional work will be minimised. 2 It is possible that there will be times when the engine is running poorly due to the lack of regular maintenance. This is even more likely if a used vehicle, which has not received regular and frequent maintenance checks, is purchased. In such cases, additional work may need to be carried out, outside of the regular maintenance intervals. 3 If engine wear is suspected, a compression test will provide valuable information regarding the overall performance of the main internal components. Such a test can be used as a basis to decide on the extent of the work to be carried out. If, for example, a compression test indicates serious internal engine wear, conventional maintenance as described in this Chapter will not greatly improve the performance of the engine, and may prove a waste of time and money, unless extensive overhaul work is carried out first. 4 The following series of operations are those most often required to improve the performance of a generally poor-running engine:
Primary operations
a) Clean, inspect and test the battery b) Check all the engine-related fluids c) Check the condition and tension of the auxiliary drivebelt d) Renew the spark plugs e) Inspect the distributor cap and HT leads as applicable f) Check the condition of the air cleaner filter element, and renew if necessary g) Renew the fuel filter (if fitted) h) Check the condition of all hoses, and check for fluid leaks i) Check the idle speed and mixture settings -as applicable 5 If the above operations do not prove fully effective, carry out the following secondary operations:
Secondary operations
a) Check the charging system b) Check the ignition system c) Check the fuel system d) Renew the distributor cap and rotor arm as applicable f) Renew the ignition HT leads - as applicable
Every 1000 miles (1500 km) or monthly
3 Lock, mechanism hinge and latch check
1
Check the security and operation of all hinges, latches and locks. Check the condition and operation of the tailgate struts, renewing them if either is leaking or is no longer able to support the tailgate securely when raised.
4 Seat belt check
1
1 Check the webbing of each belt for signs of fraying, cuts or other damage, pulling the belt out to its full extent to check its entire length. Check the operation of the buckles by fitting the belt tongue plate and pulling hard to ensure that it remains locked, then check the retractor mechanism (inertia reel only) by pulling out the belt to the halfway point and jerking hard. The mechanism must lock immediately to prevent any further unreeling but must allow free movement during normal driving. 2 Ensure that all belt mounting bolts are securely tightened. Note that the bolts are shouldered so that the belt anchor points are free to rotate. 3 If there is any sign of damage, or any doubt about a belt's condition, it must be renewed. If the vehicle has been involved
in a collision any belts in use at the time must be renewed as a matter of course and all other belts should be checked carefully. 4 Use only warm water and non-detergent soap to clean the belts. Never use any
5.4 Check brake fluid level warning device chemical cleaners, strong detergents, dyes or bleaches. Keep the belts fully extended until they have dried naturally; do not apply heat to dry them.
5 Brake check
1 Make sure that the vehicle does not pull to one side when braking and that the wheels do not lock prematurely when braking hard. 2 Check that there is no vibration through the steering when braking. 3 Check that the handbrake operates correctly without excessive movement of the lever and that it holds the vehicle stationary on a slope. 4 Check the brake warning device for correct operation by switching the ignition on and releasing the handbrake. Now press the contact on the reservoir filler cap down and get an assistant to check that the handbrake and dual circuit warning lamp light up (see illustration).
Every 1000 miles or monthly 1·11
6 Fluid leakage and engine electrical system check
1
1 Open the bonnet and inspect the engine joint faces, gaskets and seals for any signs of coolant or oil leaks. Pay particular attention to the areas around the rocker cover, cylinder head, oil filter and sump joint faces. Bear in mind that over a period of time some very slight seepage from these areas is to be expected but what you are really looking for is any indication of a serious leak. Should a leak be found, renew the offending gasket or oil seal. 2 Carefully check the condition and security of all under bonnet coolant, fuel, power steering and brake pipes and hoses. Renew any hose which is cracked, swollen or deteriorated. Cracks will show up better if the hose is squeezed. Pay close attention to the hose clips that secure the hoses to the system components. Hose clips can pinch and puncture hoses, resulting in leaks. If wire type hose clips are used, it may be a good idea to replace them with screw-type clips (see Haynes Hint).
3 Check the condition of all exposed wiring harnesses. Ensure that all cable-ties are in place and in good condition. Ties which are broken or missing can lead to chafing of the wiring which could cause serious problems in the future. 4 Wipe away any dirt which has accumulated on the outside of the alternator and check that its cable connector is pushed firmly onto its terminals. 5 Clean the ignition system HT and LT leads by wiping along their length with a fuelmoistened cloth. Inspect each lead for damage and renew if defective in any way. Ensure that all lead connections are secure and where applicable, protected (see illustration). 6 Check that all HT and LT leads are correctly routed and clear of moving or hot engine components. 7 Any corroded HT or LT lead connection
6.5 Ensure all HT lead connections are secure must be cleaned. A smear of petroleum jelly (not grease) applied to the cleaned connection will help to prevent further corrosion. 8 Check the transmission for obvious oil leaks and investigate and rectify any problems found. 9 Where accessible, inspect the fuel filler neck for punctures, cracks and other damage. Sometimes a rubber filler neck or connecting hose will leak due to loose retaining clamps or deteriorated rubber.
7 Battery electrolyte level check
2
1 A "maintenance-free" (sealed for life) battery is standard equipment on all vehicles covered by this Manual. Although this type of battery has many advantages over the older refillable type and should never require the addition of distilled water, it should still be routinely checked. The electrolyte level can be seen through the battery's translucent case and must be between the MINIMUM and MAXIMUM level marks. Although it should not alter in normal use, if the level has lowered (for example, due to electrolyte having boiled away as a result of overcharging) it is permissible to gently prise up the cell cover(s) and to top-up the level. 2 If a conventional battery has been fitted as a replacement, the electrolyte level of each cell should be checked and, if necessary, topped up until the separators are just
7.3a Remove battery filler caps . . . covered. On some batteries the case is translucent and incorporates MINIMUM and MAXIMUM level marks. The check should be made more often if the vehicle is operated in high ambient temperature conditions. 3 Top-up the electrolyte level using distilled or deionised water (see illustrations).
8 Air check
conditioning
system
During winter months, operate the air conditioner for a few minutes each week to keep the system in good order. Check that the condenser is free of dirt and insects. If necessary, clean it either by rinsing with a cold water hose or by blowing it clean with an air hose. Use a soft bristle brush to assist removal of dirt jammed in the condenser fins.
1
9 Fuel system control linkage check
1
direction indicator and check
Check all parts of the fuel system control linkage for free movement throughout its complete operating range. Clean all linkage joints and then lubricate with a light machine oil.
10 horn
Light,
Check