Volkswagen Cabriolet, Scirocco Service Manual: 1985-1993

Volkswagen repair manual index:

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A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

A

Accelerator cable 5-16
automatic transmission 9-10
After-run
see Radiator cooling fan Airbag 10-38
Cautions and Warnings 10-38, 10-39
replacement, reasons for 10-39
steering column assembly with 10-39
wiring diagrams 13-29
Air conditioning 12-39, 13-25
Cautions and Warnings 12-39, 12-40
controls
vacuum system, checking 12-14
general description 12-4
inspection and testing 12-40
safety features 12-40
specifications 12-40
system description 12-40
wiring diagrams 13-29
Air filter
see Filters Air flow sensor
see Fuel injection Alignment, engine/transaxle
see Engine
Alignment, wheel
see Wheel alignment Alternator
see Charging system Antenna 12-9
Anti-freeze
see Coolant
ATF pump, general description 9-5
Automatic transmission
see Transmission, automatic Automatic transmission fluid (ATF)
checking and filling 2-19
draining and replacing 2-20
strainer, cleaning 2-20 Axle
see Suspension, rear Automatic shift lock
wiring diagrams 13-29

B

Back-up lights
see Lights
Ball joints 10-20
also see Suspension, front
Battery
charging 2-14, 13-9 checking and cleaning 2-13
general description 13-4, 1-11
rating equivalents, DIN and SAE 2-14 replacing 2-14
specific gravity of electrolyte 13-9
troubleshooting 13-6
testing 13-8
hydrometer test 13-8
load voltage test 13-9
open-circuit voltage test 13-9
wiring diagrams 13-29
Beginner, general advice for
Cautions and Warnings ix, x, 1-12
also see individual systems/components how to use this manual 1-11
planning ahead 1-14
safety 1-12
troubleshooting 1-11
Belts
see Seat belts or V-belts
Bi-pressure pump
see Central locking
Bleeding, brake
see Brakes
Blower, heater
see Fresh air blower
Body
assembly materials 12-38 doors 12-17
assembly 12-18
handles and locks 12-19
general description 1-4, 12-4
grille, removing 12-26
instruments
see Instrument cluster lubrication 2-22
maintenance 12-4
parts, front, removing 12-26
rear lid 12-30
trim 12-26
removing and installing 12-27
troubleshooting 12-4
Bolt torque, general description 1-14
Brake fluid 2-9,11-7
checking, replacing 2-18, 11-9
Brake lights see Lights
Brakes 2-17
also see Brakes, disc
and Brakes, drum
applications and identification 11-5
bleeding 11-8
diagnostic tests 11-7
fluid
see Brake fluid
flushing, brake system 11-9 hoses and lines, inspecting 2-18
general description 1-10, 11-4
maintenance 11-5
Brakes (continued)
master cylinder
general description 11-4
removing and installing 11-9
noise 11-7
pressure specifications 11-11
proportioning valves general description 11-5
pressure testing 11-11 technical data 11-23
tightening torques 11-23 troubleshooting 11-5
vacuum booster
general description 11-4
removing and installing 11-10
Brakes, disc, front 11-11
calipers 11-14
general description 1-10, 11-4 pads
removing and installing 11-11
wear, checking 2-18, 11-11
reconditioning 11-11
rotors, removing, reconditioning, installing 11-14
Brakes, disc, rear 11-19
calipers 11-22
general description 1-10, 11-4 pads
removing and installing 11-20
wear, checking 2-18, 11-19
reconditioning 11-19
rotors, removing, reconditioning, installing 11-21
Brakes, drum 11-14
reconditioning 11-16
specifications 11-18
wear, checking 2-18, 11-16
wheel cylinder, inspecting and replacing 11-18
Brushes, alternator
see Charging system
Bumpers 12-26, 28

C

Calipers
see Brakes, disc
Cam followers, mechanical adjusting 2-13, 3-14
adjusting discs, sizes 3-15
general description 3-4, 5
maintenance interval 2-5
Cam followers, hydraulic
checking 3-18
general description 3-4, 5
identifying 3-17
installing 3-21, 22
Camber adjustment 10-9
also see Wheel alignment Camshaft
see Engine Caster
see Wheel alignment
Catalytic converter
also see Exhaust system checking 6-10
general description 6-4
Cautions and Warnings ix, x, 1-12
also see individual systems/components
Central locking system 12-20, 13-25
activators 2-21 , 22
bi-pressure pump 12-22
troubleshooting 12-21
wiring diagrams 13-29
Centrifugal advance
see Ignition timing
Charcoal canister
see Evaporative emission controls
Charging system 13-4, 10
alternator
noise 13-12
removing and installing 13-12
brushes 13-13
testing 13-10, 11
general description 1-11, 13-4
troubleshooting 13-6, 10
voltage regulator, removing and
installing 13-12, 13
wiring diagrams 13-29
Child restraint tethering
see Seat belts CIS, CIS-E
see Fuel injection, CIS or Fuel
injection, CIS-E Cleanliness, advice about 1-14 Clutch
adjustment 2-17
general description 1-7, 8-4
maintenance 8-5
removing and installing 8-13
technical data 8-44
troubleshooting 8-5
Clutch cable 8-10
Coil
see Ignition system Cold-start valve
see Fuel injection Compression, testing 2-13, 3-9, 10
Connecting rods
general description 3-4
specifications 3-31, 37
Constant velocity joints 2-19, 10-12
disassembling and inspecting 10-16
removing and installing 10-13
Continuous injection system
see Fuel injection, CIS
Continuous injection system-electronic
see Fuel injection, CIS-E Convertible top 12-35
adjustments 12-36, 37
power top and hydraulic system 12-42
emergency operation 12-43
hydraulic components, removing
and installing 12-42, 44
oil, hydraulic, checking/filling 12-43
system, bleeding 12-43
Coolant, engine (anti-freeze) 2-9
anti-freeze water proportions 4-7
checking level 2-15 draining and filling 4-7
specification 2-8
system capacity 2-8
Coolant pump
general description 4-4
inspecting and replacing 4-9
Coolant temperature warning what to do 1-26
Cooling system 2-15, 4-4
also see Coolant and Radiator cooling
fan
expansion tank, pressure testing 4-5
general description 1-6, 4-4
hoses 4-6
inspecting 2-16
pressure testing 4-5 pump
see Coolant pump specifications 2-8, 4-11
system service 4-6 technical data 4-11
thermostat 4-8 thermoswitch, testing 4-10
tightening torques 4-11
troubleshooting 4-4
diagnostic tests 4-5
warning
what to do 1-26
Crankshaft
see Engine
Cruise control 13-26 troubleshooting 13-27
Current flow (wiring) diagrams 13-29
how to read 13-5
CV joints
see Constant velocity joints Cylinder block
bore specifications 3-30, 37
disassembly, assembly and
reconditioning 3-29
oil seals 3-28
Cylinder head 3-10
cover and gasket 3-11
disassembly, assembly and
reconditioning 3-20, 21
general descriptions 3-4, 5
removing and installing 3-19
technical data 3-38

D

Defogger, rear window 13-25
wiring diagrams 13-29
Differential
see Final drive
Differential pressure regulator
see Fuel injection, CIS-E Digifant
see Fuel system, Digifant Disc brakes
see Brakes, disc Distributor, fuel
see Fuel injection Distributor, ignition
see Ignition system Distributor cap
see Ignition system Doors
see Body Drive axles
general description 1-8, 10-12
removing and installing 10-13
Drive flange oil seals 9-16
Drivetraln fundamentals)-7
Dual-diagonal system
see Brakes Duty cycle
also see individual systems/components
meter description 1-22
Dwell meter
description 1-22
Dynamic oil pressure warning system control unit, removing/installing 13-18
description 3-34
system, testing 3-35
wiring diagrams 13-29

E

Electrical system
also see individual systems/components general description 1-10, 11, 13-4
terminal and circuit identification 13-6
troubleshooting 13-5
wiring diagrams 13-29
how to read 13-5
Electrical testing
fundamentals 1-15
making an LED test light 1-16
Electronic ignition
see Ignition system
Electronic timing advance
see Ignition timing Emergencies
car will not start 1-25
changing a tire 1-24
coolant temperature warning 1-26
dim lights 1-26
jump-starting 1-25
oil pressure warning 1-26
overheating 1-26
towing 1-27
Emergency flashers/turn signals 13-23
Emission controls
also see Catalytic converter and
Oxygen sensor evaporative, fuel system
see Evaporative emission controls general description 5-14, 6-4
system identification 6-4
technical data 6-15
Engine
also see individual systems/components camshaft(s) 3-22
oil seal 3-13
removing and installing 3-16, 21, 22
specifications 3-38
camshaft drive belt 3-11 codes, identification 3-5
compression, testing 2-13, 3-9, 10
component descriptions 3-4
coolant
see Coolant crankshaft
clearance specifications 3-32
disassembly, assembly, and
reconditioning 3-31
general description 3-4
journal diameter specifications 3-31
oil seal, front, replacing 3-28
oil seal, rear 3-32
crankshaft
technical data 3-37
tightening torques 3-32, 37
engine/transaxle assembly,
aligning 3-27
fluid leaks 3-7
general description 1-4, 3-4
identification codes 3-5
installing 3-27
low power 3-8
noise 3-7
oil consumption 3-8
oil spray nozzles 3-36
removing 3-25 smoking 3-8
specifications 3-5, 3-36
technical data 3-36 tightening torques 3-36
transaxle, separating 3-26
troubleshooting 3-6
Engine codes 3-5
Evaporative emission controls 5-14
leak testing 5-16
Evaporator
see Air conditioning
Exhaust system
catalytic converter, checking 6-10
front pipe spring clamps, removing/
installing 6-8
general description 1-6, 6-4
identification 6-4
removing/installing 6-8, 9
technical data 6-15
tightening torques 6-15
troubleshooting 6-4
Expansion tank
see Cooling system
Exterior finish, care of 2-22

F

Fan
see Radiator cooling fan
Fastener torque, general description 1-14
Fault diagnosis, on-board
see Fuel system, Digifant
Filters air
Digifant 5-56
general description 5-4
service 2-11 fuel
main fuel filter 2-12
mini fuel filter 2-13 oil 2-10
Final drive
automatic transmission
lubricant, checking and filling 2-21
general description 1-8
automatic transaxle 9-6
manual transmission 8-4
manual transmission
bearing preload, adjusting 8-42
bearings and races 8-41
differential gears 8-40
disassembly and assembly 8-38
external adjustments 8-15
technical data 8-44
tightening torques 8-43
removing and installing 38
ring gear 8-38
Firing order
see Ignition system
Fluid leaks 3-7
Fluid specifications 2-4, 2-7
Flywheel 3-33
Fresh airblower 12-11, 13-24
electrical 13-24
Front pipe
see Exhaust system
Front suspension
see Suspension, front
Fuel consumption, excessive 3-8
Fuel distributor
see Fuel injection
Fuel filters
see Filters
Fuel gauge
see Instrument cluster
Fuel gauge sending unit, removing and
installing 5-10
Fuel injection
Cabriolet 1985-1989
see Fuel injection, CIS Cabriolet from 1990
see Fuel system, Digifant Scirocco 1985-1989
see Fuel injection, CIS Scirocco 16V
see Fuel injection, CIS-E
Fuel injection, CIS 5-19
air flow sensor 5-20
applications-identifying features 5-4
auxiliary air regulator 5-27
CO content, adjusting 5-30
specifications 5-31, 73
cold-start valve 5-23
control pressure regulator, testing arid
replacing 5-25
description, general 1-6, 5-4
fuel distributor 5-21 fuel metering functions
air flow measurement and fuel
metering 5-20
fuel metering functions
cold running enrichment 5-25, 6-13
cold-start enrichment 5-23
hot-start pulse enrichment 5-25
fuel pressure, testing 5-28
specifications 5-28, 73
fuel pressure relief valve 5-13
hot-start pulse relay 5-25
idle speed 5-26
specifications 5-30, 31, 73
idle speed boost valve(s) 5-28
injectors, fuel
cleaning 5-19
fuel delivery rate, checking 5-18
quick-checking 5-17
removing and installing 5-17
mixture adjustment 5-30
residual fuel pressure, testing 5-30
system diagram 5-19
technical data 5-73
throttle valve basic adjustment 5-20
troubleshooting 5-5
wiring diagrams 13-29
Fuel injection, CIS-E 5-31
air flow sensor 5-34
cold-start valve 5-38, 39
control current, measuring 5-38
CO adjustment (differential pressure
regulator current) 5-37, 48
description, general 1-6, 5-4
diaphragm pressure regulator 5-14
differential pressure regulator 5-37
electrical tests 5-42
control unit inputs 5-44
precautions ix, x, 5-45
table 5-45, 46
fuel distributor 5-35, 36
fuel metering functions
after-start and cold running
enrichment 5-42
air flow measurement and fuel
metering 5-32
cold acceleration enrichment 5-43
cold-start enrichment 5-38
deceleration fuel shutoff 5-44
full-throttle enrichment 5-44
fuel pressure, testing 5-47
specifications 5-46, 73
identifying features 5-4
idle air stabilizer valve 5-41
idle speed 5-40
specifications 5-48, 49, 73
injectors, fuel
cleaning 5-19
fuel delivery rate, checking 5-18
quick-checking 5-17
removing and installing 5-17
mixture adjustment (differential
pressure regulator current) 5-37, 48
residual fuel pressure, testing 5-48
system diagram 5-32
system fuel pressure, testing 5-47
technical data 5-73
thermo-time switch 5-23, 24
throttle switches 5-33
throttle valve basic adjustment 5-32
troubleshooting 5-5, 7
wiring diagrams 13-29
Fuel injectors
see Fuel injection
Fuel pressure tests and specifications
see Fuel injection Fuel pumps 5-11
check valve, replacing (CIS) 5-13
electrical tests 5-12
fuel delivery rate, checking
CIS, CIS-E 5-11
Digifant 5-12
fuses and relays 5-8
general description 5-4
operating for test 5-9
replacing 5-13
transfer pump 5-9
wiring diagrams 13-29
Fuel system, Digifant
California 1990
see Fuel system, Digifant II California from 1991
see Fuel system, Digifant I (California) Canada
see Fuel system, Digifant II US except California
see Fuel system, Digifant II
Fuel system, Digifant 15-65
basic adjustments 5-67
control unit, resetting Digifant 15-66
coolant temperature sensor 5-56
description, general 1-6, 5-4
electrical tests 5-70
fault diagnosis, OBD 5-65
fuel metering functions
cold-start and cold running
enrichment 5-67
air flow measurement 5-54, 67
fuel pressure, testing 5-61, 70
specifications 5-62, 73
fuel pressure regulator 5-61
fuel rail 5-60
idle speed 5-67, 68
injectors, fuel 5-69
resistance 5-69
intake air pre-heat system 5-55
residual pressure, testing 5-62
system diagram 5-50
system pressure, testing 5-62
technical data 5-73
throttle valve 5-54, 67
throttle valve potentiometer 5-67
troubleshooting 5-50
wiring diagrams 13-29
Fuel system, Digifant 11 5-50
basic adjustments 5-57
CO adjustment 5-57, 58
coolant temperature sensor 5-56
description, general 1-6, 5-4
electrical tests 5-63
fuel metering functions
cold-start and cold running
enrichment 5-55
air flow measurement 5-54
fuel pressure, testing 5-61
specifications 5-62, 73
fuel pressure regulator 5-61
fuel rail 5-60
full-throttle switch 5-55
idle speed
checking 5-57
idle air bypass (idle speed
adjustment) 5-58
stabilization 5-59
idle switch 5-55 injectors, fuel 5-60
resistance 5-61
intake air pre-heat system 5-55
mixture adjustment 5-57
residual pressure, testing 5-62
system diagram 5-50
system pressure, testing 5-62
technical data 5-73
throttle valve 5-54
troubleshooting 5-50
wiring diagrams 13-29
Fuel tank pump
see Fuel pump (transfer pump) venting
see Evaporative emission controls
Fuses
general description 13-4
panel location 13-28
ratings 13-28
wiring diagrams 13-29

G

Gas tank flap activator
see Central locking Gaskets 1-14
Gasoline additive 2-9
Gauges
see Instrument cluster
Gear oil
see Lubricant specifications
Gear selector
see Transmission, automatic
Gear shift
see Shift mechanism
Gravity vent valve
see Evaporative emission controls
Grease 2-9
also see Lubricant specifications
Grille, removing
see Body

H

Hall-sender
see Ignition system Headlights 12-23,13-23
aiming 12-25
Headliner (Scirocco) 12-17
Heated seats 12-16,13-25
wiring diagrams 13-29 Heater
also see Air conditioning
general description 12-4, 13-4
with air conditioning 12-12
vacuum system, checking 12-14
without air conditioning 12-10
Heater core 12-11, 12-12
Heater fan
see Fresh air blower Hood lock 12-29
Horns 13-22 troubleshooting 13-23
Hoses
see Cooling system
How to use this manual 1-11
Hydraulic lifters
see Cam followers Hydrometer
see Battery, testing

I

Identification codes
automatic transmission 9-6
engine 3-5
manual transmission 8-5
Idle speed
see Fuel injection
Ignition control unit
response to Hall sender signal 7-11
testing 7-9
voltage supply and ground to 7-10
voltage to coil 7-10
Ignition/steering lock cylinder, replacing 10-32
Ignition switch 13-24
Ignition system 1-5
applications 7-4
coil
resistance specifications 7-9
testing 7-8 diagram 7-12, 13
distributor
disassembly and assembly 7-17, 20
removing and installing 7-19
distributor cap and rotor 2-12, 7-19
firing order 7-18
general description 1-5, 7-4, 13-4
Hall-sender, testing 7-9, 10
quick-check 7-7
identification 7-4
knock sensor
general description 7-4
removing and installing 7-16
tightening torque 7-18
rotor 2-12
removing and installing 7-19
technical data 7-21
test equipment 7-6
troubleshooting 7-5
visual inspection 7-8
wiring diagrams 13-29
Ignition timing
basic, checking/adjusting 7-14
control, knock
see Ignition system
electronic advance (CIS-E) 7-15
mechanical advance
centrifugal 7-15
vacuum 7-16
Instrument cluster
general description 12-4, 13-4
removing and installing 12-4
troubleshooting 13-15, 16
voltage stabilizer, testing and
replacing 13-16 wiring diagrams 13-29
Instrument panel
general description 12-4
removing and installing 12-6
Injection, fuel
see Fuel injection Injectors, fuel
see Fuel injection
Intake air temperature sensor
see Fuel system, Digifant Interior
care of 2-23
general description 12-4
instruments
see Instrument cluster light bulbs, replacing 12-9
trim 12-18
Intermediate shaft
also see Engine
general description 3-4
oil seal, replacing 3-29

J

Jack stands 1-20
Jump-starting 1-25

K

Kickdown
see Transmission, automatic Knock sensor

L

Leak-down test 3-10 LEDs, instrument cluster
testing arid replacing 13-16
LED test light
see Tools Lifters
see Cam followers
Lifting the cars-13 License plate lights 13-23
Light emitting diodes (LEDs) and
indicator bulbs
testing and replacing 13-16
Lights
exterior 12-25, 13-4, 13-23
exterior
headlights 12-23
troubleshooting 1-26, 13-23
interior
see Interior and Instrument cluster wirinig diagrams 13-29
Locks
see Body
Low oil pressure warning system
see Dynamic oil pressure warning
system
Lubricant specifications 2-4
engine oil 2-7, 8
Lubrication system 3-34
general descriptio 1-6, 3-4
specifications 2-7, 3-38

M

Main bearings
see Engine Main fuel pump
see Fuel pumps Maintenance 2-3
maintenance schedules 2-5
Manual transmission
see Transmission, manual Master cylinder
see Brakes MFI
see Instrument cluster Micrometers 1-22
Mirrors, side 12-22, 23
electric/heated 13-25
Misfire
see Ignition (troubleshooting)
Multi-function indicator(MFI)
see Instrument cluster

N

No-start
see Fuel injection (troubleshooting)
Noise, engine 3-7

O

Oil
see Lubricant specifications
Oil change
equipment 1-21
general description 2-4
interval 2-5
procedure 2-10
specifications 2-10
Oil consumption, excessive 3-8
Oil cooler 3-36
Oil filter, changing 2-10
Oil pressure
also see Lubrication system and
Dynamic oil pressure warning
system
switches, testing 3-35
Oil pressure warning
what to do 1-26
Oil pump 3-35
On-board diagnosis (OBD)
see Fuel system, Digifant
Overheating
what to do 1-26
OXS warning light/mileage counter 2-16
Oxygen sensor
CIS
checking 6-11, 13
control unit, checking/replacing 6-12
duty cycle, measuring 6-11
frequency valve, checking 6-11
general description 6-4
quick-checking 6-11
replacing 2-16, 6-13
technical data 6-15
testing 6-11, 6-13
thermoswitch, checking 6-11
CIS-E
checking/replacing 6-15
control unit, checking 2-16, 6-14
technical data 6-15
testing 6-14
Digifant 6-15
replacing 2-16, 6-16
technical data 6-16

P

Parking brake
disc brakes 11-21
adjusting 11-21
cable, replacing 11-22
drum brakes 11-18
adjusting 11-18
cables, replacing 11-19
general description 11-5
Parking lights
see Lights
Parts, buying 1-17
genuine Volkswagen parts 1-17
information you need to know 1-18
non-returnable 1-17
remanufactured 1-17
Piston rings
end gap 3-31
side clearance 3-31
specifications 3-37
Pistons and connecting rods disassembly, assembly and reconditioning 3-29
general description 3-4
specifications 3-37
Planetary gear system, general descrip
tion 9-5
Potentiometer
see Fuel injection, CIS-E (cold acceleration enrichment) or Fuel system, Digifant (throttle valve potentiometer)
Power-assisted steering 10-36, 2-16
Power door locks
see Central locking system
Power options and accessories 13-25
also see individual options/accessories wiring diagrams 13-29
Power steering
fluid, draining and filling 10-36
pressure testing 10-36
pump 10-37 Power top (Cabriolet)
see Convertible top Power windows 13-26
window regulator (Cabriolet) 12-41
wiring diagrams 13-29
Proportioning valves
see Brakes
Pulling symptoms, isolating 10-7

R

Radiator
general description 4-4
removing and installing 4-11
Radiator cooling fan 4-9
after-run system 4-10
general description 4-4
removing and installing 4-10
thermoswitch, testing 4-10
Radio 12-9
wiring diagrams 13-29
Rear crankshaft oil seal
see Engine
Rear disc brakes
see Brakes, disc, rear Rear drum brakes
see Brakes, drum Rear suspension
see Suspension and Suspension, rear
Rear window defogger-13-25
wiring diagrams 13-29
Refrigerant, air conditioning
see Air conditioning
Regulator, voltage
see Charging system Relays
general description 13-4
locations 13-28, 29
Residual fuel pressure
see Fuel injection
Rotor, brake
see Brakes, disc, front or Brakes, disc, rear
Rotor, distributor
see Ignition
RPM -dependent timing advance
see Ignition timing

S

Safety 1-12
Cautions and Warnings ix, x, 1-12
also see individual systems/components Scheduled maintenance 2-4
Seals 1-14
also see individual systems/components Seat belts
child restraint tethering 12-15
cleaning 2-22
general description 12-4
inspecting 12-14
removing and installing 12-14
Seats
front 12-15
general description 12-4
heated 12-16, 13-25
wiring diagrams 13-29
rear 12-16
Selector lever
see Automatic transmission
Self-diagnosis
see Fuel system, Digifant
Shift mechanism
adjusting 8-8
description, illustration 8-7
removing and installing 8-9
Shock absorbers
see Suspension
Shoulder belts
see Seat belts
Side marker lights
see Lights
Smoking (engine) troubleshooting 3-8
Solenoid switch
removing and installing 13-13
Spark plugs
replacement interval 2-5
specifications 2-12
Spark plug wires
firing order 7-19
removing and installing 7-19
testing 7-8
Special tools, Volkswagen
see Tools
Speedometer cable and drive gear, re
moving and installing 12-9
Springs, rear
see Suspension, rear
Stabilizer bar
see Suspension
Stall speed
see Transmission, automatic
Stalling
see Fuel injection (troubleshooting)
Starter
bushing, replacing (man. trans.) 13-14
general description 13-4
removing and installing 13-13
troubleshooting 13-6, 13-13
wiring diagrams 13-29
Steering 10-29
Cautions and Warnings, airbag 10-38
column 10-3
with airbag 10-39
general description 1-8, 10-5
inspection and testing 10-7
power-assisted
see Power steering
pulling symptoms, isolating 10-7
technical data 10-41
tie rods 10-32
replacing and adjusting 10-33
tightening torques 10-42
troubleshooting 10-5, 6
wheel. removing/installing 10-30
Steering column switches
see Switches
Steering rack and gearbox 10-32
adjusting 10-34
removing and installing 10-35
Struts
see Suspension, front Stub axle
see Suspension, rear Sun roof
adjusting 12-34
cables, removing and installing 12-33
guides, removing and installing 12-33
removing and installing 12-31
trim, removing and installing 12-33
wiring diagrams 13-29
Suspension
also see Suspension, front
and Suspension, rear general description 1-8, 10-4
inspection and testing 10-7
maintenance 2-21
technical data 10-41
tightening torques 10-42
troubleshooting 10-5
Suspension, front
also see Suspension bearings 10-21
wheel bearing housings, removing
and installing 10-21 control arms 10-18
removing and installing 10-19
shock absorbers, checking 10-11
struts 10-11
disassembly and assembly 10-12
removing and installing 10-11
tightening torques 10-42
Suspension, rear
also see Suspension axle beam 10-27
bushings, replacing 10-28
removing/installing as a unit 10-27
shock absorbers and springs,
removing and installing 10-24
stabilizer bar, removing/installing 10-28
stub axle, checking 10-28
tightening torques 10-42
wheel bearings 10-25
adjusting 10-27
Switches, steering column 13-24
also see specific function -
Headlights, Wipers, etc. wiring diagrams 13-29
Synchronizers
see Transmission, manual

T

Tachometer, external 1-22
Tailgate (rear lid)
see Body Taillights
see Lights
Temperature gauge and sending unit,
quick-check 4-6
Terminal and circuit identification 13-6
Test light
see Tools
Thermostat
see Cooling System Throttle cable
see Accelerator cable Throttle switches
see Fuel injection Throttle valve
see Fuel injection Tie rods
see Steering
Tightening torque, general description 1-14
Timing, camshaft and valve
see Engine Timing advance
see Ignition timing Timing belt
see Engine, camshaft drive belt
Timing light 1-21
Tires 10-8
changing 1-24
inflation pressure 2-17
rotation 2-17
wear, checking 10-7 Toe
see Wheel alignment
Tools
basic requirements 1-19
duty cycle meter 1-22
dwell meter 1-22
feeler gauges 1-22
jack stands 1-20
jumper wires 1-23
micrometers 1-22
oil change equipment 1-21
spare parts kit 1-27
tachometer, external 1-22
test light 1-22
LED test light, making 1-16
timing light 1-21
torque wrench 1-21
Volkswagen special tools 1-23
volt-ohm meter or multimeter 1-22
Torque converter
see Transmission, automatic
Torque wrench
see Tools
Towing 1-27
Transaxle, automatic
also see Transmission, automatic and
Final drive
assembly 9-13
oil seals 9-15
removing and installing 9-13
Transaxle, manual
also see Transmission, manual and
Final drive leaks
see Transaxle vent
lubricant, checking and filling 2-19
oil seals 8-16
removing and installing 8-20
Transaxle vent 8-19
Transistorized coil ignition
see Ignition system
Transmission
general description 1-8, 8-4
service 2-19
Transmission, automatic
accelerator cable 9-10
adjusting 9-12
ATF pump 9-5
brake band, adjusting 9-12
control cables, removing/installing 9-10
drive flange oil seals 9-16
final drive
see Final drive general description 9-4
hydraulic controls 9-6
identification codes and
specifications 9-6
kickdown, checking 2-21
maintenance 9-7
pressure testing 9-9
second gear brake band, adjusting 9-12
selector lever
cable 9-10
adjusting 9-12
shift points 2-21 specifications 9-7
stall speed 9-9
technical data 9-17
tightening torques 9-17
torque converter
general description 1-7, 9-5
oil seal 9-15
troubleshooting 9-7, 9
Transmission, manual circlips
third gear 8-29
diagnostic tests 8-7
disassembly and assembly 8-22
fifth gear, removing/installing 8-24
gear ratios 8-5, 43
gear train
bearings and races 8-34
disassembly and assembly 8-30
general description 8-4
identification codes 8-5
leaks
see Transaxle vent
main shaft, removing/installing 8-24
pinion shaft
removing/installing 8-24
shims, adjusting 8-36, 37
turning torque specifications 8-38
Transmission, manual (continued) shifter
see Shift mechanism specifications 8-5, 43
synchronizers 8-32
tightening torques 8-43
troubleshooting 8-5
Troubleshooting
also see individual systems/components
fundamentals 1-11, 24
Trunk lid (rear lid)
see Body
Tune-up 2-4
Turn signals/emergency flashers 13-23
front 12-25
switch 13-24
wiring diagrams 13-29

U

Upshift indicator, testing 13-17

V

V-belts 2-14, 15
Vacuum booster
see Brakes Vacuum-dependent timing advance
see Ignition timing Valve adjustment
see Cam followers, mechanical Valve body
see Automatic transmission Valve cover
see Cylinder head
Valve clearance specifications 3-23
(1985=1987, engine code JH) 3-15
Valve guides 3-23
Valve lifters
see Cam followers Valves 3-22
specifications 3-38
Valve springs 3-22
Valve seats 3-24
dimensions
(JH engines) 3-24
(PL (16-valve) engines) 3-24
minimum dimensions for calculating
valve seat refacing dimensions 3-24
Valve stem oil seals 3-18
Valve train 3-4
16-valve engine 3-5
Vehicle identification number (VIN) 1-1
also see Foreword (vii) Vibration 10-8
VIN
see Vehicle identification number Volkswagen special tools 1-23
Voltage regulator
see Charging system Voltage stabilizer
see Instrument cluster

W

Warning lights
troubleshooting 13-11
what to do 1-26
Warnings ix, x, 1-12
also see individual systems/components
Water pump
see Coolant pump Weather-stripping 12-19
Wheel alignment 2-17, 10-8
camber adjustment 10-9 description 10-8
specifications 10-10
toe adjustment 10-10
Wheel bearings
see Suspension, front
and Suspension, rear
Wheels 2-17, 10-8
Windows 12-18
adjustments 12-37
power 13-26
window regulator (Cabriolet) 12-41
wiring diagrams 13-29
Windshield wipers and washers blades 2-21
general description 13-4
intermittent relay, testing 13-20
switch
continuity tests 13-20
testing 13-19
system troubleshooting 13-19
wiper motor, rear 13-19
removing and installing 13-22
wiper motor and linkage, windshield
removing and installing 13-20
testing 13-19
voltage tests 13-19
wiring diagrams 13-29
Wiring harness
disconnecting connectors 1-17
general description 1-11, 13-4
repairing 1-15
wiring diagrams 13-29