1 2 3 4 5 2C Manuals... · 1 General information The 1.6 and 1.8 litre 8-valve engines are of four-cylinder, in-line, overhead camshaft design, mounted transversely at the front of

1081 VW Golf & Jetta

2C

Chapter 2 Part C:Engine repair procedures - 1.6 and 1.8 litre 8 valve

GeneralType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four-cylinder in-line, water cooled, overhead camshaftCode:

1.6 litre:Without catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EZWith catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RF

1.8 litre:Jetronic - fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EVCarburettor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GUGTi - January 1987 on:

Without catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PB, GUWith catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RH, RP, PF

Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2 (No 1 at camshaft sprocket end)Displacement:

1.6 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1595 cc1.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1781 cc

Bore:1.6 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.0 mm1.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.0 mm

Stroke:1.6 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.4 mm1.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.4 mm

Compression ratio:1.6 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.0 to 11.8 litre

Code RP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.0 to 1All other codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0 to 1

Camshaft - removal, examination and refitting . . . . . . . . . . . . . . . . . 10Crankshaft and bearings - examination and renovation . . . . . . . . . . 22Crankshaft and main bearings - refitting . . . . . . . . . . . . . . . . . . . . . . 30Crankshaft and main bearings - removal . . . . . . . . . . . . . . . . . . . . . 15Cylinder block/crankcase - examination and renovation . . . . . . . . . 23Cylinder head - dismantling and overhaul . . . . . . . . . . . . . . . . . . . . . 12Cylinder head - refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Cylinder head - removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Engine - adjustments after major overhaul . . . . . . . . . . . . . . . . . . . . 39Engine - refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Engine - removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Engine ancillary components - removal . . . . . . . . . . . . . . . . . . . . . . 8Engine ancillary components refitting . . . . . . . . . . . . . . . . . . . . . . . . 36Engine dismantling - general information . . . . . . . . . . . . . . . . . . . . . 7Engine reassembly - general information . . . . . . . . . . . . . . . . . . . . . 29Engine/gearbox - separation and reconnection . . . . . . . . . . . . . . . . 6Examination and renovation - general information . . . . . . . . . . . . . . 21Flywheel/driveplate - examination and renovation . . . . . . . . . . . . . . 27General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Hydraulic bucket tappets - checking free travel (from August 1985) . . 38

Intermediate shaft - examination and renovation . . . . . . . . . . . . . . . 26Intermediate shaft - refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Intermediate shaft - removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Major operations only possible after removal of engine from vehicle . . 3Major operations possible with engine in vehicle . . . . . . . . . . . . . . . 2Method of engine removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Oil cooler - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Oil filter - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Oil filter mounting - removal and refitting . . . . . . . . . . . . . . . . . . . . . 19Oil pump - examination and renovation . . . . . . . . . . . . . . . . . . . . . . 25Oil seals - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Pistons and connecting rods - examination and renovation . . . . . . . 24Pistons and connecting rods - refitting . . . . . . . . . . . . . . . . . . . . . . . 32Pistons and connecting rods - removal . . . . . . . . . . . . . . . . . . . . . . . 14Sump and oil pump - removal and refitting . . . . . . . . . . . . . . . . . . . . 13Timing belt and sprockets - examination and renovation . . . . . . . . . 28Timing belt and sprockets - refitting . . . . . . . . . . . . . . . . . . . . . . . . . 35Timing belt and sprockets - removal . . . . . . . . . . . . . . . . . . . . . . . . . 9Valve clearances - checking and adjustment (pre August 1985) . . . 33

2C•1

Specifications

Contents

Easy, suitable fornovice with littleexperience

Fairly easy, suitablefor beginner withsome experience

Fairly difficult,suitable for competentDIY mechanic

Difficult, suitable forexperienced DIYmechanic

Very difficult,suitable for expert DIYor professional

Degrees of difficulty

54321

Compression pressure:1.6 litre:

New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 to 12 barMinimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 barMaximum permissible difference between any two cylinders . . . . 3.0 bar

1.8 litre:New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 to 13 barMinimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 barMaximum permissible difference between any two cylinders . . . . 3.0 bar

CrankshaftMain journal:

Standard diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.0 mmUndersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.75, 53.50 and 53.25 mm

Crankpin:Standard diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.80 mmJournal undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.55, 47.30 and 47.05 mm

Endfloat:Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mmMinimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.07 mm

Main bearing maximum running clearance . . . . . . . . . . . . . . . . . . . . . . 0.17 mm

Connecting rodsBig-end:

Maximum running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012 mmMaximum endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.37 mm

PistonsClearance in bore:

Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.07 mmMinimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm

Diameter:Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80.98 mmOversize:

1st oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.23 mm2nd oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.48 mm

Wear limit (10 mm from base/ right angles to pin) . . . . . . . . . . . . . . . . . 0.04 mm

Piston ringsMaximum clearance in groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mmEnd gap:

Compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 to 0.45 mmOil scraper ring:

1 part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 to 0.40 mm2 part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 to 0.45 mm3 part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 to 0.50 mm

Maximum end gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm

Gudgeon pinFit in piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Push fit at 60°C

Intermediate shaftMaximum endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm

Cylinder headMaximum allowable face distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 mmMinimum height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132.6 mm

CamshaftRun-out at centre bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.01 mmEndfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm

ValvesSeat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°Head diameter:

Inlet:Codes PB, PF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.0 mmAll other codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.0 mm

Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.0 mm

2C•2 Engine repair procedures - 1.6 and 1.8 litre 8 valve


Stem diameter:Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.97 mmExhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.95 mm

Standard overall length*:Inlet:

Codes EZ, EV, GU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98.70 mmAll other codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.0 mm

Exhaust:Codes EZ, EV, GU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98.50 mmCodes PB, PF, RP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.95 mmAll other codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.80 mm

* Caution: Check with manufacturer on valve dimensions before renewing

Valve guidesMaximum valve rock (stem flush with guide):

Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mmExhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 mm

Hydraulic tappetsMaximum free travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 mm

Valve timingNil valve clearance at 1.0 mm valve lift1.6 litre (code EZ - shim bucket tappets):

Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5° BTDCInlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21° ABDCExhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41° BBDCExhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3° BTDC

1.6 litre (code EZ - hydraulic tappets - August 1985 to March 1986):Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3° BTDCInlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19° ABDCExhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27° BBDCExhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5° BTDC

1.6 litre (code EZ - hydraulic tappets - March 1986 on):Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TDCInlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22° ABDCExhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28° BBDCExhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6° BTDC

1.6 litre (code RF):Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TDCInlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22° ABDCExhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28° BBDCExhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6° BTDC

1.8 litre (code GU - shim bucket tappets)Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1° BTDCInlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37° ABDCExhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42° BBDCExhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2° ATDC

1.8 litre (code GU - hydraulic tappets - August 1985 to March 1986Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3° BTDCInlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33° ABDCExhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41° BBDCExhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5° BTDC

1.8 litre (code GU - hydraulic tappets - March 1986 on):Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2° BTDCInlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34° ABDCExhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44° BBDCExhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8° BTDC

1.8 litre (code EV):Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2° BTDCInlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° ABDCExhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° BBDCExhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8° BTDC

1.8 litre (codes PB, PF):Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3° ATDCInlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43° ABDCExhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37° BBDCExhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3° ATDC

Engine repair procedures - 1.6 and 1.8 litre 8 valve 2C•3

2C


Valve timing (continued)

Nil valve clearance at 1.0 mm valve lift1.8 litre (code RH):

Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2° BTDCInlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34° ABDCExhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44° BBDCExhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8° BTDC

1.8 litre (code RP - pre July 1988):Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2° ATDCInlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38° ABDCExhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40° BBDCExhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4° BTDC

1.8 litre (code RP - August 1988 on):Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5° BTDCInlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41° ABDCExhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37° BBDCExhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1° BTDC

Valve clearancesWarm:

Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 to 0.30 mmExhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 to 0.50 m

Cold:Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 to 0.25 mmExhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 to 0.45 mm

LubricationSystem type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wet sump, pressure feed, full flow filterLubricant type/specification/capacity . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to “Lubricants, fluids and capacities”Filter type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C101/C160 Pump type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Twin gear, driven by intermediate shaft together with distributorPressure (2000 rpm with oil temperature 80°C) . . . . . . . . . . . . . . . . . . . 2.0 bar minimum

Torque wrench settings Nm lbf ftEngine to gearbox:

M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 33M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 55

Exhaust manifold nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18Exhaust pipe to manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7Flywheel/driveplate bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15Clutch pressure plate/washer bolts (renew) . . . . . . . . . . . . . . . . . . . . . . 100 74Sump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15Sump drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22Main bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 48Connecting rod big-end cap nuts:

Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22Stage 2* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Further tighten 1/4 turn (90°)

Oil pump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7Oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18Oil filter flange bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18Front seal flange bolts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Small . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15Large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7

Intermediate shaft flange bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18Camshaft bearing cap nuts (in sequence) . . . . . . . . . . . . . . . . . . . . . . . 20 15Camshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 59Valve cover nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7Belt tensioner pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 33Crankshaft sprocket bolt (oiled) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 148Intermediate shaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 59V-belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15Timing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7Rear cover lower bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22Rear cover top bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7Coolant pump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15Fuel pump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15Distributor clamp bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18



1 General information

The 1.6 and 1.8 litre 8-valve engines are offour-cylinder, in-line, overhead camshaftdesign, mounted transversely at the front ofthe vehicle. The transmission is attached tothe flywheel end of the engine.

The crankshaft is of five main bearing type,its endfloat being controlled by a shoulderedcentre bearing or by half thrustwasherslocated each side of the centre bearing.

The camshaft is driven by a toothed beltwhich is tensioned by a tensioner on aneccentric bearing. On engines manufacturedbefore August 1985, the valves are operatedby bucket type cam followers in direct contactwith the camshaft. From August 1985, allengines are fitted with a redesigned cylinderhead incorporating hydraulic bucket tappetsin place of the previous shim bucket tappets.Camshaft bearing No. 4 is deleted on allsingle camshaft engines. In order to identifythe type of tappets fitted, a sticker is normallyaffixed to the valve cover indicating that valveclearance adjustment is neither necessary norpossible.

An intermediate shaft (driven by the toothedtiming belt) drives the distributor and oil pumpand on carburettor equipped engines, the fuelpump.

The oil pump is of twin gear type, drivenfrom the immediate shaft and incorporates apressure relief valve.

The aluminium cylinder head is ofconventional design with the inlet and exhaustmanifolds mounted on the rear side (asviewed with the engine in the vehicle).

The crankcase ventilation systemcomprises a hose from the flywheel end of thevalve cover to the side of the air cleaner.

On fuel injection equipped engines, there isa hose to the air inlet manifold and a hose tothe air cleaner from a three-way connector onthe valve cover.

2 Major operations possiblewith engine in vehicle

The following operations can be carried outwithout having to remove the engine from thevehicle:

a) Removal and servicing of the cylinderhead, camshaft and timing belt

b) Renewal of the crankshaft rear oil seal(after removal of the transmission,driveplate or clutch as applicable)

c) Removal of the sump and oil pumpd) Removal of the piston/connecting rod

assemblies (after removal of the cylinderhead and sump)

e) Renewal of the crankshaft front oil seal,intermediate shaft front oil seal andcamshaft front oil seal

f) Renewal of the engine mountings

3 Major operations onlypossible after removal ofengine from vehicle

The following operations can only becarried out after removal of the engine fromthe vehicle:a) Renewal of crankshaft main bearingsb) Removal and refitting of the crankshaftc) Removal and refitting of the intermediate

shaft

4 Method of engine removal

1 The engine, together with the gearbox,must be lifted from the engine compartment,then the engine separated from the gearboxon the bench. Two people will be needed.2 A hoist of 150 kg capacity will be needed tolift the engine approximately 1 metre. If thehoist is not portable and the engine is lifted,then sufficient room must be left behind thevehicle to push it back out of the way so thatthe engine may be lowered. Blocks will beneeded to support the engine after removal .3 Ideally, the vehicle should be over a pit. Ifthis is not possible then the body must besupported on axle stands (see “Jacking andvehicle support”) so that the front wheels maybe turned to undo the driveshaft nuts. Theleft-hand shaft is accessible from above butthe right-hand shaft must be undone fromunderneath. Removal of the gearshift linkagecan only be done from underneath, as canexhaust downpipe-to-manifold detachment.4 The exhaust downpipe-to-manifold flangeconnection is secured by special spring clipsrather than bolts or studs and nuts. When

disconnecting and reconnecting the joint, itwill be necessary to use VW tool no. 3049A.Without this tool, detachment and certainlyreconnection of the joint and clips is virtuallyimpossible, so make arrangements to borrowor hire the tool in advance.5 The only other special tools required will bea set of splined key wrenches which will beneeded to remove and refit the socket-headbolts used to secure certain items such as thecylinder head bolts.6 Draining of oil and coolant is best doneaway from the working area if possible. Thissaves the mess made by spilled oil in theplace where you must work.7 Although not listed as an optional fitting onUK models, an air conditioning system mayhave been fitted. Where this is the case, thefollowing precautions must be taken whenhandling refrigerant lines or systemcomponents:a) Do not stress or bend flexible hose lines

to a radius of less than 101 mmb) Flexible hose lines must be correctly

located, must not chafe against adjacentcomponents and must be kept well clearof the exhaust manifold and downpipe

c) All metal tubing lines must be kept free ofkinks and must be handled with care

d) Do not disconnect any of the airconditioning supply lines

e) Do not weld or apply heat in the vicinity ofthe air conditioning lines or equipment

f) If any part of the system is to be detachedthen it must first be depressurised by yourVW dealer or a competent air conditioningsystems engineer. The only exception isthe removal and fitting of the compressordrivebelt which can be achieved in thesame manner as for the alternatordrivebelt

5 Engine - removal 4Carburettor equipped1 Disconnect the battery negative lead.2 Remove the bonnet.3 Drain the engine coolant.4 Position a suitable container beneath theengine, undo the sump drain plug and drain theengine oil - see Chapter 1. On completion cleanthe drain plug and refit it. Renew the O-ring.


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Cylinder head bolts (engine cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . As for 1.05 and 1.3 litre enginesRefer to illustration 5.25b. Also 40.1a and 40.1b in Part A of this Chapter.

a) M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18a) M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 33b) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 26c) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 33d) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 37e) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 44f) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 52g) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 59

* When checking the connecting rod-to-crankshaft journal radial clearance using Plastigage, tighten only to 30Nm (22 lbf ft).

5 Remove the radiator, together with thecooling fan. On models manufactured after1986, remove the front panel before removingthe radiator.6 Remove the air cleaner unit then disconnectthe throttle cable at the carburettor. Positionthe cable out of the way.7 Where power steering is fitted, remove thehydraulic pump drivebelt. Unbolt the pump,belt tensioner and fluid reservoir and tie themto one side of the engine compartment.8 Disconnect the following wiringconnections, identifying each lead as it isdetached to avoid confusion on reassembly:a) Alternator leadb) Oil pressure switch lead(s) at cylinder head

(see illustrations) and oil filter bracketc) Inlet manifold preheater thermo-switch

leadd) Choke cover thermo-switch lead (where

applicable)e) Ignition HT and LT leadsf) Choke cover lead separate connectorg) Coolant temperature sender unit leadh) Earth strap to gearbox (see illustration)

and multi-function switch to gearboxi) Starter motor leads

9 Disconnect the fuel supply hose from thefuel pump and the fuel return hose (to the fueltank). Plug the hoses to prevent fuel leakage.10 Disconnect the coolant and heater hosesfrom the engine.

11 On manual gearbox models, disconnectthe clutch cable.12 Disconnect the following items fromaround the carburettor. Identify theconnections where necessary to avoidconfusion on reassembly:a) Thermotime valveb) Idle/overrun cut-off valvec) Inlet manifold preheater separator

connectord) Part throttle channel heater separate

connector13 Disconnect the speedometer cable fromthe transmission. 14 Disconnect and remove the vacuumreservoir.

15 Disconnect the brake vacuum servohoses and the vacuum hoses from the inletmanifold.16 Undo and remove the gearbox mountingbolt.17 Raise and support the vehicle on axlestands (see “Jacking and vehicle support”),allowing sufficient clearance to workunderneath.18 Disconnect the manual gearbox linkage.19 On automatic transmission models, selectP (Park) then disconnect the throttle andselector cables from the transmission.20 Disconnect the driveshafts from thegearbox and tie them up out of the way.21 To disconnect the exhaust manifold todownpipe connection, VW tool no. 3049A willbe required. Although it may be possible toprise the clips free to separate this joint, thetool will definitely be required to refit thesprings.22 The vehicle can now be lowered, theremaining removal operations being fromabove.23 Attach a suitable sling and hoist to theengine/gearbox unit and take its weight.24 Disconnect the rear engine bearer byundoing the three bolts (see illustration).25 The engine/gearbox unit front mountingmust now be detached by unscrewing andremoving the single through-bolt. It may benecessary to further lift, lower or twist the unitto allow the through-bolt to be withdrawn (seeillustration). Note that from December 1984,the front mounting is changed from thebonded rubber type to a ‘hydro’ type withdamping action (see illustration).


5.8a Oil pressure switch location in rear ofcylinder head

5.8b Oil pressure switch location in filtermounting

5.8c Earth strap to gearbox

5.24 Engine rear bearer 5.25a Engine/gearbox unit front mounting

5.25b Hydro-type front engine mountingRefer to Specifications for fastener torque wrench settings b, e and f


26 The engine/gearbox unit is now ready forlifting out but first make a final check that allcables, wiring and hoses are clear.27 Have an assistant at hand to help guidethe unit clear of the surrounding componentsin the engine compartment as it is lifted out.The unit will have to be twisted slightly as it israised. Once clear of the vehicle, lower it tothe work surface.

Fuel injection equipped28 On fuel injection equipped engines, theremoval procedure closely follows that givenfor carburettor equipped engines. However,disregard those items concerning detachmentof the carburettor and associated items. Thefollowing injection equipment items will needto be disconnected instead. Refer to Chapter4 for further details:29 Disconnect the wires from the warm-upvalve (green connector) (see illustration). 30 Disconnect the wiring to the cold startvalve (blue connector).31 Disconnect the wiring to the auxiliary airvalve.32 Disconnect the throttle cable at the fastidle cam and bracket but do not remove thesecuring clip (see illustration).33 Remove the cold start valve but leave thefuel lines connected. Place out of the way.34 Disconnect the air inlet pipe at the flexibleducting attached to the throttle housing.35 Disconnect the vacuum hoses from theinlet manifold and vacuum booster.36 Leaving the fuel lines connected, undo theretaining bolts and withdraw the warm-upvalve from the cylinder block. Position out ofthe way.37 Detach the injectors from the cylinderhead and plug the holes. Disconnect theinjector lines from the locating bracket on thethrottle housing and fold them out of the way.38 Detach the vacuum hoses to the throttlehousing T-piece connector location clip at the

bulkhead. Fold the hoses back out of the way.39 Disconnect the oil temperature switchsender lead (see illustration).40 When lifting out the engine/gearbox unit,greater care will have to be taken inmanoeuvring the unit from the engine

compartment due to the close proximity of theair inlet manifold to the bulkhead. The unit willneed to be pulled forwards first then twistedand lifted.


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5.29 Wiring connections to be detached - fuel injection models

1 Alternator2 Warm-up valve3 1.8 bar oil pressure

switch4 Oil temperature sender

5 Distributor HT cable(terminal 4)

6 Hall sender (distributor)7 Vacuum switch8 Coolant temperature

sender

9 Thermotime switch10 0.3 bar oil pressure

switch11 Cold start valve12 Auxiliary air valve

5.32 Fuel injection components to be detached

1 Throttle cable2 Cold start valve

3 Vacuum hoses4 Air intake pipe

5 Injectors

5.39 Oil temperature sender (arrowed)

6 Engine/gearbox - separationand reconnection 3

This procedure is fully described in Chapter7, Parts A or B, as applicable. It is onlynecessary to refer to those paragraphspertinent to the particular method being used.The engine must be supported on blocks, oralternatively the gearbox can be separatedwith the engine still on the hoist.

7 Engine dismantling - generalinformation

Refer to Section 7 in Part A of this Chapter.

8 Engine ancillary components- removal 3

With the engine removed from the vehicleand separated from the transmission, theexternally mounted ancillary components canbe removed prior to engine dismantling. Theremoval sequence need not necessarily followthe order given:a) Alternator and drivebeltb) Inlet manifold and carburettor or inlet

manifold and throttle housing (fuelinjection)

c) Exhaust manifoldd) Fuel pumpe) Warm-up valve (fuel injection), if still

attachedf) Distributorg) Oil filter with cooler (where applicable)

and filter mountingh) Oil pressure and coolant temperature and

sensor switches

I) Coolant pump and coolant hoseconnectors from cylinder block and head.New O-rings will be required

j) Clutch then intermediate plate (manualgearbox)

k) Driveplate, noting location of spacer andshim(s) (automatic transmission)

9 Timing belt and sprockets -removal 3

1 If the engine is still in the vehicle, first carryout the following operations:a) Disconnect the battery earth leadb) Remove the alternator drivebelt c) Unbolt and remove the coolant pump

pulley2 Depending on type, undo the retainingbolt(s)/nut(s), release the retaining clips andremove the upper timing cover (seeillustration). On some engines it will benecessary to remove the bung from the front



9.2 Timing belt and cover components

face of the cover to allow access to the Allentype retaining screw recessed within thecover. On other engines, the retaining screwcan be seen but its key slot is deeplyrecessed (access to it being made via the holein the centre of the screw surround).3 Unscrew the nuts and bolts from the valvecover and remove the cover together with thegasket and reinforcement strips. Detach thecrankcase emission hose(s) from the rockercover.4 Mark the relative positions of the crankshaftpulley and crankshaft sprocket, then undo thefour socket-head bolts and withdraw thepulley.5 Unbolt and withdraw the lower timingcover.6 The engine must now be set for timing.Temporarily refit the crankshaft pulley. On theintermediate sprocket for the timing belt onetooth has a centre-punch mark. Turn theengine until this mates with a notch on theV-belt pulley bolted to the crankshaft sprocket(see illustration). To turn the engine over,remove the spark plugs then fit a suitablespanner onto the crankshaft sprocketretaining bolt and turn it in the direction ofengine rotation.7 When these marks match, look at thesprocket on the camshaft. One tooth of thishas a centre-punch mark. This should be level

with the valve cover flange (see illustration).Having turned the engine until these marksagree, now look at the cams for No 1 cylinder(nearest the timing belt). They will both be inthe ‘valve closed’ position (see illustration).Now look through the hole in which the TDCsensor goes where the timing marks show onthe periphery of the flywheel and note thereading.8 Before removing the timing drivebelt, checkits correct tension. If held between the fingerand thumb halfway between the intermediateshaft and the camshaft it should be justpossible to twist it through 90° (seeillustration). If it is too slack, adjust it byslackening the bolt holding the eccentric camon the tensioner wheel. If you are satisfied itcan be adjusted to the correct tension,remove it and examine it for wear. Now is thetime to order a new one if necessary.9 Loosen the tensioner then withdraw thetiming belt from the camshaft, intermediateand crankshaft sprockets.10 Each of the timing belt sprockets issecured by a central bolt and washer. The

intermediate, camshaft and crankshaftsprocket (the latter in particular) securingbolts are tightened to a substantial torque andthe sprockets will therefore need to be firmlyheld when undoing the bolts.11 To remove the camshaft sprocket,unscrew the bolt with the sprocket heldstationary by inserting a suitable metal barthrough a sprocket hole and resting it on thevalve cover face of the cylinder head, but takecare not to damage the face. Remove the boltand spacer washer then withdraw thesprocket, tapping it free if necessary. Checkthe fit of the Woodruff key in the camshaft, itmust be renewed if loose in its groove. Leverout the Woodruff key and keep it with thesprocket.12 To remove the crankshaft sprocket, holdthe crankshaft stationary with a lever jammedin the starter ring gear (remove the startermotor as applicable). Do not allow thecrankshaft to turn or the pistons may touchthe valve heads. Unscrew the retaining boltand remove it, together with the spacerwasher, then lever the sprocket free from thecrankshaft. Check the fit of the Woodruff key(if fitted) in the crankshaft, it must be renewedif loose in its groove. Lever out the Woodruffkey and keep it with the crankshaft sprocket.13 The intermediate shaft sprocket isremoved in a similar manner to that for thecamshaft sprocket.

10 Camshaft - removal,examination and refitting 3

Removal1 To remove the camshaft with the engine inthe vehicle, first carry out the followingoperations:a) Remove the timing cover and valve cover,

then disconnect the timing belt from thecamshaft sprocket


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9.7b No. 1 cylinder cam lobes in valveclosed position

9.8 Timing belt tension check method


9.6 Intermediate sprocket timing mark (arrowed) aligned withnotch in crankshaft pulley

9.7a Camshaft sprocket timing mark (arrowed) with No 1 cylinderat TDC on compression

b) If the camshaft oil seal is to be renewedthen the camshaft timing sprocket mustbe removed

2 Remove the camshaft bearing caps (seeillustrations), making a careful note of theirfitted positions for reference when refitting .The caps are numbered (see illustration) butmark the side nearest the front of the cylinderhead. No. 1 cap is the one with a small oil sealon it.3 Remove cap nos. 5, 1 and 3 in that order.Now undo the nuts holding 2 and 4 in adiagonal pattern. The camshaft will lift thecaps up as the pressure of the valve springs isexerted. When they are free, lift the caps offalong with the camshaft. The oil seal on thefront end of the camshaft will come with it.Depending on tappet type, proceed asfollows:

Shim bucket tappets4 The tappet buckets are now exposed andmay be lifted out (see illustration). Take eachone out in turn, prising the little disc out of thebucket by inserting a small screwdriver eitherside and lifting the disc away. On its reverse,each disc is engraved with a size (eg. 3.75).This is its thickness number. Note the numberand then clean the disc and refit it, numberside down. There are eight of these and theymust not be mixed up. On assembly, eachdisc must go back into the bore from whenceit came. This problem exists also for thevalves, so a container for each valve assembly



10.2a Cylinder head and camshaft components - carburettor engine

10.2b Cylinder head and camshaft components - fuel injection engine10.4 Tappet bucket and shim

10.2c Camshaft bearing cap number(arrowed)

and tappet is required. Label the containers 1to 8, as follows:

Containers 1 and 2 will be No 1 cylinderexhaust and inlet respectivelyContainers 3 and 4 will be No 2 cylinderexhaust and inlet respectively Containers 5 and 6 will be No 3 cylinderinlet and exhaust respectivelyContainers 7 and 8 will be No 4 cylinderinlet and exhaust respectively

5 Note the thickness of all tappet clearancediscs from Nos. 1 to 8 for use duringreassembly.

Hydraulic bucket tappets6 Lift out the tappets one by one, ensuringthat they are kept in their correct order andcan be returned to their original bores.7 Place them, cam contact surface down, ona clean sheet of paper as they are removed.8 Inspect the tappets for wear (indicated byridging on the clean surface), pitting andcracks.9 Tappets cannot be repaired and if worn,must be renewed.

Examination10 Refer to Section 27 in Part A of thisChapter whilst noting that on exchangeengines or cylinder heads, the camshaft issupplied with bearing shells instead of runningdirectly in the head and bearing caps.Exchange units supplied by VW may have anundersized camshaft with correspondingbearing shells. Where this is the case, thecamshaft will have a yellow paint spot on itand the journal diameter will be 25.75 mm. Anunmarked camshaft supplied with bearingshells will be of standard size with a journaldiameter of 26.00 mm.

Refitting11 Refer to Section 12.

11 Cylinder head - removal 3All engines1 If the cylinder head is being removed withthe engine out of the vehicle, proceed fromparagraph 17. If the cylinder head is beingremoved with the engine in the vehicle, it isbest removed with the inlet and exhaustmanifolds. The manifolds can then bedetached after removal of the cylinder headbut note that a special tool is required torelease (and subsequently reconnect) theexhaust downpipe-to-manifold flange retainingclips. A splined key will also be required toundo and tighten the cylinder head bolts.2 Disconnect the battery earth lead. Drain thecooling system, then disconnect the coolingand heater hoses from the cylinder head.3 Disconnect the thermoswitch and oilpressure lead connections.

4 On carburettor models, remove the aircleaner unit.5 Disconnect the alternator from the cylinderhead attachment brackets and remove thedrivebelt.6 If removing the manifolds with the cylinderhead, disconnect the vacuum hose from theinlet manifold and the accelerator cable (andchoke cable if applicable) from thecarburettor.7 Disconnect the HT leads from the sparkplugs.

Fuel injection equipped engines8 Detach the injector lines from the cylinderhead and location clips and fold them backout of the way.9 Disconnect the inlet duct at the flexiblehose connection to the throttle valve housing.10 Detach the vacuum hoses to the throttlevalve housing and at the three-way connectoron the bulkhead side of the cylinder head.Fold back and secure the hoses out of theway.11 Disconnect the auxiliary air valve leadfrom the underside of the inlet manifold andthe auxiliary air valve hose to the flexible hoseon the throttle valve housing.12 Disconnect the servo vacuum hose fromthe green connector on the flexible hose onthe throttle housing.13 If air conditioning is fitted, detach thehoses from the auxiliary air valve and tubeconnections.14 Detach the MFI hose at the servo hosevalve connection. 15 Detach the wiring connector from the coldstart valve.

All engines16 Remove the timing cover and valve cover,then disconnect the timing belt from thecamshaft sprocket.17 Remove the camshaft.18 Remove the cylinder head bolts. Theseare recessed in the well of the cylinder headand are socket-head bolts. They must beremoved using the correct splined tool.19 The cylinder head bolts must beunscrewed in a progressive manner and in thereverse sequence to that shown fortightening.

20 When all ten bolts have been removed, liftthe head from the cylinder block. It may needa little tapping to loosen it but do not try toprise it loose by hammering in wedges. Lift offthe gasket and, if the engine is not beingdismantled, clean the piston crowns andblock face. Note that the cylinder head boltsmust not be re-used, a new set will need to beobtained when ordering the cylinder headgasket set.

12 Cylinder head - dismantlingand overhaul 3

1 Using a wire brush, scraper and steel wool,clean all carbon from the combustionchambers, valve faces and exhaust ports.Remove the spark plugs for cleaning.2 The valves are not easy to get out unless asuitable valve spring compressor is available.Because the collets and spring caps are setso far down in the head, a long claw isnecessary on the compressor and it must besplit sufficiently to enable the collets to beremoved and inserted. If such a tool is not tohand then find a piece of steel tube of about25 mm inside diameter which will fit over thevalve stem and press down the spring cover(see illustration). The length will depend onthe size of the compressor so fit thecompressor over the head fully extended,measure the distance between the claw andthe valve spring seat and cut the tube to asuitable length.3 The next step is to cut two windows ofsuitable size (approx. 25 mm long and 16 mmwide) in opposite sides of the tube. The tubemay then be used with the compressor toextract the collets from each valve stem inturn. Place the valve, springs, collets andseats with the tappet in the appropriatereceptacle, keeping them strictly together forrefitting in the valve guide from which theywere taken (see illustration).


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12.2 Improvised tool used to remove andrefit collets to valve stems

12.3 Valve springs, cap and collets


If your fingers are too big,put a blob of grease on thecollet and pick it up with asmall screwdriver, then

insert it into the slot on the valve stem.

4 The valve springs must be renewed if theyare damaged, distorted, or known to havecovered a high mileage. If in doubt as to theircondition, have your VW dealer check themfor compression efficiency using a calibratedvalve spring compressor.5 The valves should be cleaned and checkedfor signs of wear or burring. Where this hasoccurred, the inlet valve may be reground ona machine at a dealer. Exhaust valves mustnot be reground on the machine but ground inby hand. On engines fitted with hydraulictappets, valves should not be re-cut as thiswill adversely affect the operation of thetappets.6 Wear in the valve guides may be detectedby fitting a new valve in the guide andchecking the amount that the rim of the valvewill move sideways when the top of the valvestem is flush with the top of the valve guide.The valve rock limits are given in theSpecifications. New valve guides must befitted and reamed by your VW dealer.7 Do not spend too long grinding in thevalves. If the valve seat and valve are notsatisfactory after 15 minutes then you willprobably do more harm than good by goingon. Make sure both surfaces are clean, smeargrinding paste onto the valve evenly and usinga suction cup, work the valve with anoscillating motion lifting the valve away fromthe seat occasionally to stop ridging. Cleanthe seat and valve frequently and carry onuntil there is an even grey band on both seatand valve then wipe off all the paste.8 The surface of the head must be checkedwith a straight-edge and feeler blade. Place

the straight-edge along the centre of themachined face of the head. Make sure thereare no ridges at the extreme ends andmeasure the clearance with feelers betweeneach combustion chamber head. This is thearea where the narrowest part of the cylinderhead gasket comes and where the gasket ismost likely to fail. If the straight-edge is firmlyin place and feelers in excess of 0.1 mm canbe put between the head and thestraight-edge, then the head should be takento a dealer for servicing or replacement.9 If the cylinder head shows signs ofcracking, have it inspected by your VW dealerto assess its condition for reuse.10 VW recommend that the valve stem oilseals should always be renewed to preventpossible high oil consumption. Pulling off theold seal is simple with pliers. With a packet ofnew oil seals is a small plastic sleeve. This isfitted over the valve stem and lubricated. Theseal should then be pushed over the plasticsleeve until it seats on the guide. This shouldbe done with VW tool 10 204 which fits snuglyround the outside of the seal and pushes it onsquarely. If the seal is assembled without theplastic sleeve, it will be damaged and oilconsumption will become excessive.11 Before reassembling the cylinder head,check the condition of the camshaft.12 When all components have beenexamined, then assembly of the head maycommence. Insert the valve in the correctguide, fit the inner seat, valve springs andouter cap, assemble the valve springcompressor and possibly the small tube andcompress the valve spring until the collets

may be assembled to the valve stem (seeillustrations). 13 Assemble the second collet and holdingthem carefully together in place, ease off thecompressor until the spring seats the colletshome. Remove the compressor, put a ragover the valve stem and tap the stem with ahammer. This is to ensure that the collets areseated correctly. If they are they will not comeout. Repeat until all eight valves are in positionin the cylinder head.14 Refit the tappets in the bores from whichthey came, lubricating them liberally withclean engine oil (see illustration). Lubricatethe camshaft bearing surfaces with oil and fitthe camshaft, positioned so that No 1 cylindercams point upwards.15 Fit a new oil seal at the sprocket end,lubricate the bearings, set the shaft in positionand install bearing caps Nos 2 and 4,tightening the nuts in a diagonal pattern untilthe shaft is in place (see illustration). Nowinstall the other bearing caps, making surethey are the right way round (marks towardsthe drive pulley) and tighten the caps downusing a diagonal pattern to the specifiedtorque. Install a new rubber seal at theopposite end to the sprocket.16 On engines equipped with shim buckettappets, adjust the valve clearances.

13 Sump and oil pump - removaland refitting 3

Modification: From August 1985, a largersump is fitted thereby increasing engine oilcapacity. If renewing the sump, ensure thatone of identical capacity is fitted

Removal1 If the engine is in the vehicle then drain theengine oil. Note that the sump plug has anO-ring which must be renewed (seeillustration).2 Undo the sump retaining bolts and removethe sump from the lower face of thecrankcase. Remove the sump gasket whichmust also be renewed.3 To remove the oil pump, undo the tworetaining bolts and lower the pump unit,


12.12a Inserting a valve into the cylinderhead

12.12b Locating valve springs and cap . . . 12.12c . . . and valve collets

12.14 Fit the tappet buckets 12.15 Fit the bearing caps


complete with the oil pick-up pipe andstrainer.

Refitting4 To refit the pump, ensure that the matingfaces are clean, locate it in position and fit andtighten the securing bolts to the specifiedtorque.5 Locate the new sump gasket but do notapply an adhesive sealant. Refit the sump andtighten the retaining bolts evenly to thespecified torque.6 Refit the oil drain plug with O-ring andtighten it to the specified torque.

14 Pistons and connecting rods- removal 3

1 Remove the cylinder head.2 Remove the sump. 3 Unscrew the two oil pump retaining boltsthen lower and remove the pump, completewith oil pick-up pipe from the crankcase.Place it on one side for cleaning andinspection. 4 The piston and connecting rod removalprocedure now follows that given for the smallerengine variants in Part A of this Chapter.

15 Crankshaft and mainbearings - removal 3

1 Disconnect the pistons and connectingrods from the crankshaft. Note that, althoughthe engine has to be removed to remove thecrankshaft, the cylinder head, pistons andconnecting rods can be left in position.2 At the flywheel end, undo and remove thesix bolts securing the oil seal flange to thecrankcase (see illustration). Withdraw theflange, seal and gasket.3 Examine the main bearing caps. It will be


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13.1 Sump, oil pump and oil filtercomponents - fuel injection engine

seen that the caps are numbered 1 to 5 andthat the number is on the side of the engineopposite the oil pump position. Identify thesenumbers. If they are obscured, then mark thecaps in the same way as the connecting rodcaps. Before removing the caps, push thecrankshaft to the rear and check the endfloatusing a feeler blade between the thrustwasherflanges on No 3 main bearing and thecrankshaft web (see illustration). It must notexceed the specified maximum.4 Remove the bearing cap retaining bolts,remove the bearing caps and lift out thethrustwashers from each side of the centremain bearing.

5 Lift out the crankshaft and then remove thetop half bearing shells. If the main bearingsare not being renewed, make sure the shellsare identified so that they go back into thesame bearing cap the same way round

16 Intermediate shaft - removal 31 The intermediate shaft can only bewithdrawn from the crankcase with the engineremoved from the vehicle. 2 Remove the timing belt.

3 Remove the fuel pump on carburettormodels and the ignition distributor.4 Before removing the intermediate shaft,check that the endfloat does not exceed themaximum specified amount. 5 Undo the two sealing flange retaining boltsthen withdraw the intermediate shaft,complete with sealing flange (seeillustrations).6 Withdraw the sealing flange from theintermediate shaft. The oil seal within theflange and the O-ring must be renewed onreassembly.


15.3 Checking crankshaft endfloat at No. 3 main bearing

16.5b Withdrawing intermediate shaft16.5a Intermediate shaft retaining flangebolts (arrowed)


15.2 Crankshaft and cylinder block components

17 Oil filter - renewal 1Refer to Chapter 1, Section 18

18 Oil cooler - removal andrefitting 2

1 On fuel injection models, an oil cooler isfitted between the oil filter cartridge andmounting bracket. The cooler must berenewed if the engine oil has beencontaminated with metal particles, such asmight be the case following total or partialengine seizure. Renew it anyway if it is likelyto contain any other harmful contaminant.2 To remove the cooler, first remove the oilfilter cartridge.3 Drain the cooling system and disconnectthe coolant hoses from the cooler.4 Remove the cooler retaining nut and thecooler. The O-ring between the cooler andmounting must be renewed.5 Refitting is a reversal of the removalprocedure. Wipe clean the sealing faces of thecooler and mounting and smear the O-ringwith clean engine oil.6 On completion, top-up the engine oil andcoolant levels. Start the engine and check forany signs of leaks.

19 Oil filter mounting - removaland refitting 2

1 Remove the oil filter and on fuel injectionmodels, the oil cooler.2 Disconnect the oil pressure switch lead,undo the oil filter mounting securing bolts andwithdraw the mounting and gasket.3 The oil pressure switch can be unscrewedfrom the top face of the mounting if required.Renew the switch O-ring.4 Refitting is a reversal of the removalprocedure. Renew the mounting gasket.

20 Oil seals - renewal 4Note: The following procedures were allcarried out with the engine in the vehicle

Crankshaft seals

Flywheel/driveplate end1 On manual gearbox models, remove theclutch and pressure plate. On automatictransmission models, remove thetransmission then unbolt the driveplate fromthe crankshaft, noting the location of thespacer and shim(s).

2 Carefully prise out the oil seal with ascrewdriver or strong wire and wipe clean therecess (see illustration).3 Fill the space between the lips of the newseal with multi-purpose grease, then drive itsquarely into the housing using a block ofwood or suitable metal tubing. If at allpossible, use VW fitting sleeve No. 2003 toavoid damage to the oil seal lip.4 Refit the driveplate or clutch.

Timing belt end5 Remove the alternator, together with itsdrivebelt.6 Remove the timing belt cover and timingbelt, ensuring that the timing marks arecorrectly aligned.7 Unscrew the bolt from the front of thecrankshaft, withdraw the pulley and sprocketand remove the Woodruff key. On manualgearbox models, if the belt is difficult toloosen, have an assistant engage top gearand apply the brakes. On automatictransmission models, remove the startermodel and restrain the driveplate ring gearwith a suitable lever.8 Prise out the oil seal or extract it with VWtool No. 2085, then wipe clean the recess(see illustration).9 Fill the space between the lips of the newseal with multi-purpose grease, then drive itsquarely into the housing using a block ofwood or suitable metal tubing. If available useVW fitting sleeve No. 3083.10 The remaining refitting procedure is areversal of removal. Ensure that the timingmarks are aligned before refitting the timingbelt and tensioning it.

Camshaft front seal11 Remove the alternator together with itsdrivebelt.12 Remove the timing belt cover and timingbelt, ensuring that the timing marks arecorrectly aligned.13 Hold the camshaft sprocket stationarywith a screwdriver inserted through one of itsholes, then unscrew the bolt and remove thewasher, sprocket and Woodruff key.14 Prise out the oil seal or alternatively,

extract it with VW tool No. 2085, then wipeclean the recess.15 Fill the space between the lips of the newseal with multi-purpose grease, then drive itsquarely into the cylinder head using a blockof wood or suitable metal tubing. If available,use VW fitting sleeve No. 10-203.16 The remaining refitting procedure is areversal of removal. Ensure that the timingmarks are aligned before refitting the timingbelt and tensioning it.

Intermediate shaft seal17 Remove the alternator together with itsdrivebelt.18 Remove the timing belt cover and timingbelt, ensuring that the timing marks arecorrectly aligned.19 Hold the intermediate shaft sprocketstationary with a screwdriver inserted throughone of its holes, then unscrew the bolt andremove the washer, sprocket and Woodruffkey.20 Renew the oil seal.21 The remaining refitting procedure is areversal of removal. Ensure that the timingmarks are aligned before refitting the timingbelt and tensioning it.

21 Examination and renovation- general information


22 Crankshaft and bearings -examination and renovation 5



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20.2 Flywheel end crankshaft oil sealcomponents

1 Intermediate plate2 Bolt3 Oil seal

4 Sealing ring (notfitted to all models)

20.8 VW tool 2085 for removing crankshaftoil seal (timing belt end) and

camshaft oil seal


23 Cylinder block/crankcase -examination and renovation 5


24 Pistons and connecting rods- examination and renovation 4


25 Oil pump - examination andrenovation 3

1 With the oil pump on the bench, prise offthe cap with a screwdriver and clean thestrainer gauze in fuel. Refit the gauge andpress on the cap.2 Remove the two small bolts and take thecover away from the body. Examine the faceof the cover (see illustration). As seen in the

illustration, the gears have marked the cover.If the depth of this marking is significant, thenthe face of the cover must be machined flatagain.3 Remove the gears and wash them with thebody in clean paraffin. Dry and reassemblethe gears, lubricating them with clean engineoil. Measure the backlash between the gearswith a feeler blade (see illustration). Thisshould be 0.05 to 0.20 mm.4 Now place a straight-edge over the pumpbody along the line joining the centre of thetwo gears and measure with a feeler blade theaxial clearance between the gears and thestraight-edge (see illustration). This must notexceed 0.15 mm.5 If all is well, check that the shaft is not slackin its bearings and reassemble the pump forfitting to the engine.6 If there is any doubt about the pump, it isrecommended that a replacement beobtained. Once wear starts in a pump itprogresses rapidly. In view of the enginedamage that may follow a loss of oil pressure,skimping the oil pump repair is a falseeconomy.

26 Intermediate shaft -examination and renovation 5

1 Check the fit of the intermediate shaft in itsbearing. If there is excessive play, the shaftmust be compared with a new one. If the shaftis in good order but the bearings in the blockare worn, then seek expert advice.2 Check the surface of the cam which drivesthe fuel pump (where applicable). If seriousridging is present, a new shaft is indicated.3 Check the teeth of the distributor drivegearfor scuffing or chipping. Check the conditionof the timing belt sprocket.4 It is unlikely that damage to the shaft hashappened but if it has, seek advice from a VWdealer.5 There is an oil seal in the flange for theintermediate shaft. This may need renewal ifthere are signs of leakage. To do this, removethe timing belt sprocket and withdraw theflange from the shaft. The oil seal may now beprised out and a new one pressed in. Alwaysfit a new O-ring on the flange beforeassembling it to the cylinder block.

27 Flywheel/driveplate -examination and renovation 4

1 Inspect the starter ring teeth. If these arechipped or worn then renew the starter ring.This means heating the ring until it may bewithdrawn from the flywheel, or alternatively,splitting it. A new one must then be shrunk on.If you know how to do this and you can get anew ring then the job can be done but it isbeyond the capacity of most owners.2 Serious scoring on the flywheel clutchfacing requires a new flywheel. Do notattempt to clean the scoring off with a scraperor emery. The face must be machined.3 If it is necessary to fit a new flywheel, theignition timing mark must be made by theowner. The new flywheel has only the TDCmark as an O on the outer face. Punch orscribe the appropriate timing mark for yourmodel to the left of the TDC mark at theappropriate distance (see illustration).


25.2 Examine face of oil pump cover forscoring

25.3 Checking oil pump gear backlash 25.4 Checking oil pump gear endfloat


27.3 Flywheel/driveplate ignition timing marks

Engine code EZ (1.6)-flywheel a = 37.0 mm 18° BTDCEngine code EZ (1.6)-driveplate: a = 42.0 mm 18° BTDCEngine code EV (1.8) - flywheel: a = 12.5 mm 6° BTDCEngine code GU (1.8) - flywheel a = 37.0 mm 18° BTDCEngine code GU (1.8) - driveplate: a = 42.0 mm 18° BTDC

4 On automatic transmission models, checkthe driveplate as described for the flywheel. Itwill also be necessary to mark a newdriveplate for ignition timing.

28 Timing belt and sprockets -examination and renovation 1

Refer to Section 26 in Part A of thisChapter. The information given also applies tothe intermediate shaft sprocket.

29 Engine reassembly - generalinformation


30 Crankshaft and mainbearings - refitting 3

Note: If it is difficult to rotate the crankshaft,check that the bearing shells are seatedproperly and that the bearing cap is in thecorrect way round. Rotation will only be difficultif something is incorrect and the fault must befound. Dirt on the back of a bearing shell issometimes the cause of a tight main bearing.1 If a new crankshaft is being fitted toautomatic transmission models, the needleroller bearing supplied and fitted by themanufacturer will need to be removed from its

aperture in the rear end of the crankshaft. Itmay already have been removed by thesupplier, but check anyway.2 Clean the crankcase recesses and bearingcaps thoroughly and fit the bearing shells sothat the tang on the bearing engages in therecess in the crankcase or bearing cap.Ensure that the shells fitted to the crankcasehave oil grooves and holes and that thesealign with the drillings in the bearing housings.When fitting the bearing shells to the caps,note that bearing Nos. 1, 2 and 5 are plainshells whilst No. 4 has an oil groove.3 The bearing shells of the centre bearing(No. 3) may either be flanged to act asthrustwashers, or may have separatethrustwashers. These should be fitted oilgroove outwards. Fit the bearing shells so thatthe ends of the bearing are flush with the jointface (see illustrations).4 Oil the bearings and journals then locate

the crankshaft in the crankcase.5 Fit the main bearing caps (with centre mainbearing thrustwashers if applicable) in theircorrect positions (see illustration).6 Fit the bolts to the bearing caps and tightenthe bolts of the centre cap to the specifiedtorque, then check that the crankshaft rotatesfreely. 7 Working out from the centre, tighten theremaining bearing caps in turn, checking thatthe crankshaft rotates freely after eachbearing has been tightened.8 Check that the endfloat of the crankshaft iswithin specifications by inserting feeler bladesbetween the crankshaft and the centrebearing thrust face/washer while levering thecrankshaft first in one direction and then in theother.9 Lubricate the rear of the crankshaft andusing a new gasket, install the rear oil seal andflange. Tighten the six bolts (see illustration).


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30.3a Fitting flanged type centre mainbearing into crankcase

30.3b Fitting alternative type centre mainbearing into crankcase . . .

30.3c . . . together with thrustwashers

30.5 Fitting main bearing caps 30.9 Fitting crankshaft rear oil seal andflange

30.3d Fitting flanged type centre mainbearing to cap

30.3e Fitting centre bearing and separatethrustwashers to cap

30.3f Ensure that ends of bearing are flushwith joint face


10 Lubricate the front of the crankshaft andfit the front oil seal and flange with a newgasket. Tighten the bolts to the correcttorque.

31 Intermediate shaft - refitting 3Lubricate the intermediate shaft with clean

engine oil then install it in the block.Fit the O-ring and flange, together with the

oil seal, then tighten the bolts. Note that theoil hole must be at the bottom of the flange.

32 Pistons and connecting rods- refitting 3

Proceed as described in Section 30, Part Aof this Chapter, paragraphs 2 to 7 inclusive.When refitting the big-end nuts, oil thethreads.

On completion, check the endfloat of eachconnecting rod in a similar manner to thatdescribed for checking the crankshaftendfloat.

33 Valve clearances - checkingand adjustment (pre August1985)

31 If a new or reconditioned cylinder head,complete with camshaft, is being fitted, thenthe valve clearances will have been preset.2 Valve clearances can be checked andadjusted with the cylinder head removed(prior to refitting after overhaul) or in thenormal manner described in Section 12 ofChapter 1.3 There are two specified valve clearancesettings, these being for a cold (cylinder headremoved) or warm (engine in vehicle) enginecondition.4 If valve adjustment is made with the enginecold, then it must be checked again with theengine at normal operating temperature (ie.coolant above 35°C). If the cylinder head hasbeen overhauled, then it should be checkedagain, hot, after 600 miles (900 km).

34 Cylinder head - refitting 3Note: New cylinder head retaining bolts mustbe used on refitting1 Clean the top face of the block. Clean andinspect the bores and lubricate them withclean engine oil. Turn the crankshaft so thatthe pistons are in the mid-cylinder position.2 The engine number is stamped on aninclined surface between No. 3 and No. 4cylinders on the side above the distributor.

Using this as a datum, install a new cylinderhead gasket so that the word ‘OBEN’ on thegasket is over this datum point and on the topside of the gasket (see illustration).3 Lower the cylinder head into position,locating onto the centring pins where fitted(see illustration). If the cylinder block doesnot have centring pins, initially refit new No. 8and No. 10 cylinder head bolts. Do not usejointing compound. Check that the gasket isseating correctly and fit the remainder of thenew bolts. Following the sequence shown,tighten the bolts until the head is firmly held.Using a torque wrench, tighten the bolts instages to the specified torque following thesame sequence (see illustration).4 The cylinder head will not need furthertightening.

35 Timing belt and sprockets -refitting 3

1 Fit the Woodruff key into its groove in theintermediate shaft then refit the sprocket tothe front of the shaft. Locate the spacerwasher onto the bolt then fit and tighten thebolt to the specified torque wrench setting.Hold the sprocket stationary when tighteningby inserting a screwdriver through one of itsholes and jamming it against the cylinderblock.2 Locate the Woodruff key (if applicable) tothe groove at the front of the crankshaft then

refit the timing belt sprocket onto the shaft.Lubricate the retaining bolt with oil, locate thespacer washer onto the bolt then fit andtighten it to the specified torque wrenchsetting. When tightening the bolt, prevent thecrankshaft from turning by using the samemethod as that for its removal.3 Locate the Woodruff key into its groove onthe front of the camshaft then refit thecamshaft sprocket. Refit the retaining bolttogether with the spacer washer and tightento the specified torque wrench setting. Holdthe sprocket stationary when tightening byinserting a screwdriver through one of itsholes and jamming it against the cylinderblock or head.4 If removed, refit the timing belt rear cover.Apply locking compound to the stud thread.5 Locate the crankshaft pulley onto thesprocket (aligning the marks made previously)using one bolt to secure it temporarily.6 Turn the camshaft sprocket so that thelobes of No. 1 cylinder cams are pointingupwards and the mark on the camshaftsprocket is aligned with the valve cover - seeillustration 9.7a.7 Rotate the crankshaft sprocket and theintermediate shaft sprocket until the dot onthe intermediate sprocket and the mark on theV-belt pulley coincide. Install the timing belttensioner loosely and then the timing belt.Making sure the marks are still in place, put aspanner on the adjuster and tighten the beltuntil it will twist only 90 degrees when heldbetween the finger and thumb halfway


34.2 Cylinder head gasket located onblock

34.3a Lowering cylinder head onto block

34.3b Cylinder head bolt tightening sequence


between the camshaft and intermediate shaftsprockets. Tighten the eccentric adjuster nutto the specified torque - see illustration 9.8.8 Unbolt and remove the crankshaft V-beltpulley.9 Fit the lower timing cover then refit thecrankshaft V-belt pulley and tighten itsretaining bolts to the specified torque.10 Locate the new valve cover gasket on thecylinder head, the seal to the No. 1 camshaftbearing cap and the half round grommet intoits location at the rear end of the cylinderhead.11 Fit the valve cover into position, locate thereinforcement strips then refit and tighten theretaining nuts evenly to the specified torque. 12 Refit the upper timing belt cover.

36 Engine ancillary components- refitting 3

1 On automatic transmission models, refit thedriveplate together with any shims originallylocated between the crankshaft and the plate.Fit the washer on the transmission side of thedriveplate, ensuring that the chamfered sideof the washer faces towards the driveplate.Use new bolts and tighten them to thespecified torque setting then using verniercalipers, check the distance between thedriveplate and the cylinder block as shown(see illustration) at three positions. If theclearance is not between 30.5 and 32.1 mm,remove the driveplate, fit shims of suitablethickness between the driveplate and thecrankshaft, then refit the driveplate assemblyand recheck the clearance. If the engine is anew or reconditioned short block replace-ment, check that the bore in the rear end doesnot contain a needle roller bearing. If it does,then remove the bearing as this is for manualgearbox models only.2 On manual gearbox models, refit the clutchtogether with the intermediate plate.3 Refit the inlet and exhaust manifolds.4 Refit the coolant pump and all hoses to theengine.5 Refit the alternator and drivebelt.6 Refit the oil pressure switch to the cylinderhead or filter mounting as applicable, using anew washer or O-ring. Tighten to the specifiedtorque.7 Fit the oil filter mounting to the cylinderblock, together with a new gasket and tightenthe bolts. On models fitted with an oil cooler,refit the supply and return hoses to theircorrect unions.8 Fit the oil filter.9 Refit the distributor. 10 On carburettor models, refit the fuelpump.11 On fuel injection models, refit thewarm-up valve (if the hoses weredisconnected) .12 Refit the coolant temperature sender unitand the thermotime switch with new O-rings.

13 Refit the spark plugs, if not already done.14 Refit the gearbox/transmission to theengine.

37 Engine - refitting 4To refit the engine/transmission, reverse the

removal procedures but note the following:a) When lowering the unit into the engine

compartment, align the driveshafts withthe flanges prior to attaching therespective mountings

b) Assemble the engine mountings looselyinitially and tighten them only after theunit is central without straining themountings

c) Adjust the clutch cable (manual gearbox)d) Adjust the throttle and selector cables

(automatic transmission)e) Reconnect and adjust the gear selector

linkages (manual gearbox)f) Adjust the throttle and choke cablesg) Refill the cooling systemh) Refill the engine with the correct grade

and quantity of oili) Where necessary, retension the power

steering pump drivebelt and replenish thesystem fluid

38 Hydraulic bucket tappets -checking free travel (fromAugust 1985)

21 Start the engine and run it until the radiatorcooling fan has switched on once.2 Increase engine speed to about 2500 rpmfor about two minutes.

3 Irregular noises are normal when startingbut should become quiet after a few minutesrunning.4 If the valves are still noisy, carry out thefollowing check to identify worn tappets.5 Stop the engine and remove the valve coverfrom the cylinder head.6 Turn the crankshaft clockwise by using awrench on the crankshaft pulley securing bolt,until the cam of the tappet to be checked isfacing upward and is not exerting anypressure on the tappet.7 Press the tappet down using a wooden orplastic wedge.8 If free travel of the tappet exceeds thatspecified, the tappet must be renewed.

39 Engine - adjustments aftermajor overhaul 2

Refer to Section 41 in Part A of this Chapter.If new hydraulic bucket tappets have been

fitted, it is essential that no attempt to restartthe engine is made for a minimum period of30 minutes after installation. Failure toobserve this precaution may result in enginedamage caused by the valves contacting thepistons.


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36.1 Checking driveplate-to-cylinder block dimension (A) using vernier calipers


2C•20


Notes

Documents

1 2 3 4 5 2C Manuals... · 1 General information The 1.6 and 1.8 litre 8-valve engines are of four-cylinder, in-line, overhead camshaft design, mounted transversely at the front of