Volkswagen Polo (1991) Bedienungsanleitung

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Contents LIVING WITH YOUR VW POLO Introduction Page 0.4 Safety first! Page 0.5 Roadside repairs Introduction Page 0.6 If your car won’t start Page 0.6 Jump starting Page 0.7 Wheel changing Identifying leaks Towing Page 0.8 Page 0.9 Page 0.9 Weekly checks Introduction Page 0.10 Underbonnet check points Engine oil level Page 0.10 Page 0.11 Coolant [...]

Contents REPAIRS & OVERHAUL Engine and associated systems Petrol engine in-car repair procedures Page 2A.1 Engine removal and overhaul procedures Cooling, heating and ventilation systems Fuel/exhaust systems - single-point petrol injection models Fuel/exhaust systems - multi-point petrol injection models Page 2B.1 Page 3.1 Page 4A.1 Page 4B.1 E[...]

0.4 Introduction The updated VW Polo range was introduced in November of A wide range of standard and optional equipment is available within 1990, with a choice of 1.05 litre (1043 cc) or 1.3 litre (1272 cc) petrol the Polo range to suit most tastes, including a sliding sunroof, tinted engines, with either single-point or multi-point fuel injection[...]

Safety first! 0.5 W orking on your car can be dangerous. This page shows just some of the potential risks and hazards, with the aim of creating a safety-conscious attitude. General hazards l Mains voltage is also dangerous. Make sure that any mains-operated equipment is correctly earthed. Mains power points should be protected by a residual current[...]

0.6 Roadside repairs The following pages are intended to help in dealing with common roadside emergencies and breakdowns. You will find more detailed fault finding information at the back of the manual, and repair information in the main chapters. If your car won’t start If your car won’t start and the starter motor even though the starter does[...]

Roadside repairs 0.7 When jump-starting a car using a 3 Make sure that the booster battery is booster battery, observe the following the same voltage as the discharged precautions: one in the vehicle. 1 Before connecting the booster battery, make sure that the ignition is switched off. 4 If the battery is being jump-started from the battery in anot[...]

0.8 Roadside repairs Wheel changing Some of the details shown here will vary according to model. For instance, the location of the spare wheel and jack is not the same on all cars. However, the basic principles apply to all vehicles. Preparation 0 When a puncture occurs, stop as soon as it is safe to do so. 0 Park on firm level ground, if possible,[...]

Roadside repairs 0.9 Puddles on the garage floor or drive, or obvious wetness under the bonnet or underneath the car, suggest a leak that needs investigating. It can sometimes be difficult to decide where the leak is coming from, especially if the engine bay is very dirty already. Leaking oil or fluid can also be blown rearwards by the passage of a[...]

0.10 Weekly checks Introduction There are some very simple checks which need only take a few minutes to carry out, but which could save you a lot of inconvenience and expense. These “Weekly checks” require no great skill or special tools, and the small amount of time they take to perform could prove to be very well spent, for example; q Keeping[...]

Engine oil level Before you start V Make sure that your car is on level ground. V Check the oil level before the car is driven, or at least 5 minutes after the engine has been switched off. The correct oil Modern engines place great demands on their oil. It is very important that the correct oil for your car is used (See “Lubricants, fluids and t[...]

0.12 Weekly checks Brake fluid level Warning: 0 Brake fluid can harm your eyes and damage pain ted surfaces, so use extreme caution when handling and pouring it. 0 Do not use fluid that has been standing open for some time, as it absorbs moisture from the air, which can cause a dangerous loss of braking effectiveness. Safety First! 0 If the reservo[...]

Weekly checks 0.13 Wiper blades 1 Check the condition of the wiper blades; To remove a windscreen wiper blade, pull . . . then remove the blade from the arm. if they are cracked or show any signs of 2 the arm fully away from the screen until it 3 deterioration, or if the glass swept area is locks. Swivel the blade through 90” and smeared, renew t[...]

0.14 Weekly checks Tyre condition and pressure It is very important that tyres are in good condition, and at the correct pressure - having a tyre failure at any speed is highly dangerous. Tyre wear is influenced by driving style - harsh braking and acceleration, or fast cornering, will all produce more rapid tyre wear. As a general rule, the front [...]

Weekly checks 0.15 Bulbs and fuses 0 Check all external lights and the horn. Refer to the appropriate Sections of Chapter 12 for details if any of the circuits are found to be inoperative. (/Visually check all accessible wiring connectors, harnesses and retaining clips for security, and for signs of chafing or damage. 1 If a single indicator light,[...]

0.16 Lubricants, fluids and tyre pressures Lubricants and fluids Engine ................................... Multigrade engine oil, viscosity SAE 10W/40 to 2OW/50, to WV specification 501 01 Cooling system ............................ Ethylene glycol based antifreeze Manual transmission ........................ Gear oil, viscosity SAE 80 or 75W-90 B[...]

Chapter 1 Routine maintenance and servicing Contents Air filter renewal ................................ Auxiliary drivebelt check and renewal ............... Brake fluid renewal .............................. Brake system and fluid leakage check ............... Clutch play .................................... Coolant renewal ......................[...]

1.2 Servicing specifications Lubricants and fluids - Refer to end of “weekly checks” Capacities Engine oil All except G40 models ...................................... G40models .............................................. Cooling system .......................................... Transmission 4speed models ....................................[...]

Maintenance schedule 1.3 The maintenance intervals in this manual If you wish to keep your vehicle in peak performance and resale value of your vehicle. are provided with the assumption that you, condition at all times, you may wish to When the vehicle is new, it should be not the dealer, will be carrying out the work. perform some of these procedu[...]

1.4 Maintenance & servicing Underbonnet view of a 1.3 litre model 1 Battery 2 Brake fluid reservoir 3 Brake servo 4 Throttle body 5 Fuel injectors 6 Spark plugs 7 Oil filler cap 8 Air cleaner/air flow meter assembly 9 Timing belt cover 10 Ignition distributor 11 Coo/ant expansion tank 12 Front suspension strut top mounting 13 Ignition coil 14 E[...]

Maintenance & servicing 1.5 Rear underbody view 1 2 3 4 5 6 7 8 Exhaust tailbox Rear shock absorber Rear axle beam Rear brake pressurre regulating valve Handbrake cable Fuel filter Line fuel pump Accumulator we Maintenance procedures General information This Chapter is designed to help the home mechanic maintain his/her vehicle for safety, econ[...]

1.6 Maintenance procedures The following series of operations are those which are most often required to improve the performance of a generally poor-running engine: Primary operations a) Clean, inspect and test the battery (refer to “Weekly checks”). b) Check all the engine-related fluids (refer to “Weekly checks”). cl Check the condition a[...]

10 000 mile/12 month service 1.7 collect in the sump. Continue adding oil a small quantity at a time until the level is just above the lower mark on the dipstick. Adding approximately 1.0 litres will raise the level from the lower mark to the upper mark on the dipstick. Refit the filler cap. 14 Start the engine and run it for a few minutes; check f[...]

1.8 Every 12 months - regardless of mileage what you are really looking for is any indication of a serious leak (see Haynes Hint). Should a leak be found, renew the offending gasket or oil seal by referring to the appropriate Chapters in this manual. 2 Also check the security and condition of all the engine-related pipes and hoses. Ensure that all [...]

Every 12 months - regardless of mileage 1.9 9.4 Check for wear in the hub bearings by grasping the wheel and trying to rock it 4 Grasp the roadwheel at the 12 o’clock and 6 o’clock positions, and try to rock it (see illustration). Very slight free play may be felt, but if the movement is appreciable, further investigation is necessary to determ[...]

1.10 Every 12 months - regardless of mileage 13.1 Dashboard mounted diagnostic connector (arrowed) 7 Listen for any unusual noises from the engine, clutch and gearbox/transmission. 8 Make sure that the engine runs smoothly when idling, and that there is no hesitation when accelerating. 9 Check that, where applicable, the clutch action is smooth and[...]

20 000 mile service 1.11 15.6 Checking the auxiliary drive belt tension assess the amount of deflection that can be caused (see illustration). Compare this measurement with that listed in the Specifica- tions. If necessary, refer to the relevant sub- Section and correctly tension the belt. Tensioning All models except G40 7 Slacken the alternator m[...]

1.12 20 000 mile service 16.3 It is advisable to remove any debris from the spark plug recesses using a clean brush before removing the plugs, to prevent it from dropping into the cylinders 16.4a Unscrew the plugs using a spark plug spanner, or a spark plug socket and extension bar 16.4b Removing a spark plug 4 Unscrew the plugs using a spark plug [...]

20 000 mile service 1.13 17.2a Lifting out the air cleaner element - multi-point fuel-injected models 2 Lift out the air filter element (see illustrations). 3 Brush out any debris that may have collected inside the air cleaner. 4 Lay the new air filter element in position in the lower half of the air cleaner housing, ensuring that the rubberised ed[...]

1.14 Every 2 years - regardless of mileage surfaces of the vehicle. Rinse off spills immediately with plenty of water. Never leave antifreeze lying around in an open container, or in a puddle in the driveway or on the garage floor. Children and pets are attracted by its sweet smell, but antifreeze can be fatal if ingested. 1 With the engine complet[...]

Chapter 2 Part A: Engine in-car repair procedures Contents Auxiliary drivebelt - removal and refitting .......... .see Chapter 1 Camshaft - removal and refitting ................ .see Chapter 2B Camshaft cover gasket - renewal ............................ .6 Camshaft oil seal - renewal ................................ .7 Camshaft timing belt - remo[...]

2A.2 Engine in-car repair procedures Torque wrench settings Nm Ibf ft Cylinder head bolts (engine cold): Stage1 ................................................ 40 30 Stage2 ................................................ 60 44 Stage 3 (angle tighten) .................................... + one half-turn (180”), OR + two quarter-turns (2x90°) Ma[...]

Engine in-car repair procedures 2A.3 in the form of a small cut-out , however if the terminal is not marked, follow the HT lead from the No 1 cylinder spark plug back to the distributor cap (No 1 cylinder is at the timing belt end of the engine) and using chalk or a pen (not a pencil, as the graphite will conduct electricity), place a mark on the d[...]

2A.4 Engine in-car repair procedures manufacturer. Note the lower compression ratio of the supercharged G40 model (engine code PY). 9 If the pressure in any cylinder is low, carry out the following test to isolate the cause. Introduce a teaspoonful of clean oil into that cylinder through its spark plug hole, and repeat the test. 10 If the addition [...]

Engine in-car repair procedures 2A.5 To make a camshaft sprocket holding tool, obtain two lengths of steel strip about 6 mm thick by 30 mm wide or similar, one 600 mm long, the other 2OO mm long (all dimensions approximate). Bolt the two strips together to form a forked end, leaving the bolt slack so that the shorter strip can pivot free/y. At the [...]

2A.6 Engine in-car repair procedures 12 Restore the ignition system by reconnecting the distributor multiway wiring plug. 1 Disconnect the battery negative cable and position from the terminal. 2 Refer to Chapter 1 and remove the auxiliary drivebelt( 3 With reference to Sections 2 and 4 of this Chapter, remove the auxiliary belt pulley and timing b[...]

Engine in-car repair procedures 2A.7 2 Refer to Chapter 11 and remove the bonnet from its hinges - this will give extra working space and clearance when lifting off the head. 3 Disconnect the battery negative cable and position it away from the terminal. Note: If the vehicle has a security coded radio, check that you have a copy of the code number [...]

2A.8 Engine in-car repair procedures 9.3Oa Lay a new head gasket on the cylinder block, engaging it with the locating dowels 31 With the help of an assistant, place the cylinder head and manifolds centrally on the cylinder block, ensuring that the locating dowels engage with the recesses in the cylinder head. Check that the head gasket is correctly[...]

Engine in-car repair procedures 2A.9 11.6a Coat the threads of the flywheel bolts with locking fluid . . . Refitting 6 Follow the removal procedure in reverse, noting the following points (see illustrations): a) Use the marks made during removal to align the flywheel with the crankshaft. b) Use new shouldered bolts when refitting the flywheel. Tigh[...]

2A.10 Engine in-car repair procedures Refitting 4 Remove any remains of the old gasket from the sump and cylinder block - ensure that both mating surface are spotlessly clean. If the gasket has been leaking, check the mating surface of the sump for warpage that may have been caused by over-tightening of the bolts. Renew the sump if it is damaged - [...]

2B.1 Chapter 2 Part B: Engine removal and overhaul procedures Contents Crankshaft - refitting and running clearance check . . . . . . . . . . . . . .10 Crankshaft - removal and inspection . . . . . . . . . . . . . . . . . . . . . . . Engine and transmission removal - preparation and precautions . . . .1 . .6 Cylinder block/crankcase - cleaning and [...]

2B.2 Engine removal and overhaul procedures Valves Valve head diameter: Inlet AAU ................................................ 32.0 mm All other engine codes .................................. 36.0 mm Exhaust ............................................... 29.0 mm Valve stem diameter: Inlet: UptoJuly1992 ....................................... [...]

Engine removal and overhaul procedures 2B.3 personal injury and/or damage to components by continuing alone. By planning ahead and taking your time, a job of this nature, although major, can be completed successfully and without incident. 10 On all models described in this manual, the engine and transmission are removed through the top of the engin[...]

2B.4 Engine removal and overhaul procedures 2.24 Separating the engine and transmission vehicle specification. Note that some of these fixings also serve as mountings for the rear engine mounting. 24 Starting at the bottom, remove all the screws and nuts then carefully draw the transmission away from the engine, resting it securely on wooden blocks[...]

Engine removal and overhaul procedures 2B.5 4.2 Remove the thermostat housing together with its O-ring (arrowed) Note: New and reconditioned cylinder heads will be available from the original manufacturer, and from engine overhaul specialists. It should be noted that some specialist tools are required for the dismantling and inspection procedures, [...]

2B.6 Engine removal and overhaul procedures 4.22a Minimum cylinder head height (a) distorted out of specification, it may be possible to repair it by smoothing down any high-spots on the surface with fine abrasive paper. 22 Minimum cylinder head heights (measured between the cylinder head gasket surface and the cylinder head cover gasket surface), [...]

Engine removal and overhaul procedures 2B.7 4.40 Measure the diameters of the valve stems at several points along their lengths using a micrometer 41 Check the overall length of each valve and compare the measurements with the figure in the Specifications. 42 The valve heads should not be cracked, badly pitted or charred. Note that light pitting of[...]

2B.8 Engine removal and overhaul procedures into position using a long reach socket 4.59 Spring seat being fitted over the tops of the valve springs 4.61 Refitting the hydraulic tappets stepped surface of the seat (see illustrations). Note: Depending on age and specification, engines may have either concentric double valve springs, or single valve [...]

Engine removal and overhaul procedures 2B.9 4.70 Refitting the oil pressure switch 67 Tighten all bearing caps to the second stage torque, then fit the bolts to bearing cap No 5 and tighten them to the specified torque. 68 With reference to Chapter 2A lubricate the lip of a new camshaft oil seal with clean engine oil and locate it over the end of t[...]

2B.10 Engine removal and overhaul procedures 5.18 Checking the piston ring side clearance 11 Use a section of old piston ring to scrape the carbon deposits out of the ring grooves, taking care not to score or gouge the edges of the groove. 12 Carefully scrape away all traces of carbon from the top of the piston. A hand-held wire brush (or a piece o[...]

Engine removal and overhaul procedures 2B.11 6.4 Checking the crankshaft endfloat using a DTI gauge 6.5 Checking the crankshaft endfloat using a feeler blade 6.6 Main bearing cap identification markings gauge. Push the crankshaft fully the other way, and record the endfloat indicated on the dial (see illustration). Compare the result with the figur[...]

2B.12 Engine removal and overhaul procedures 7.6 Clear out threaded holes using the correct size of tap 5 If the castings are not very dirty, you can do an adequate cleaning job with hot, soapy water and a stiff brush. Take plenty of time, and do a thorough job. Regardless of the cleaning method used, be sure to clean all oil holes and galleries ve[...]

8.8 Typical shell bearing failures 20 Apply a light coating of engine oil to the mating surfaces and cylinder bores to prevent rust forming. Store the block in a plastic bag until reassembly. Inspection 1 Even though the main and big-end bearings should be renewed during the engine overhaul, the old bearings should be retained for close examination[...]

2B.14 Engine removal and overhaul procedures 10.3 Fitting the centre main bearing upper shell inner surfaces with a clean rag - they must be kept spotlessly clean. 3 Clean the rear surface of the new bearing shells with a rag and lay them on the bearing saddles. Ensure that the orientation lugs on the shells engage with the recesses in the saddles [...]

Engine removal and overhaul procedures 2B. 15 10.18 Tightening the main bearing bolts 11.5 Measuring the piston ring end gap using a feeler blade saddles and caps must be adjacent to each other. Insert the bearing cap bolts and hand tighten them only. 18 Working from the centre bearing cap outwards, tighten the retaining bolts to their specified to[...]

2B.16 Engine removal and overhaul procedures 12.16 Using a piston ring compressor to install the piston assemblies Piston and connecting rod assemblies - final refitting 10 Note that the following procedure assumes that the crankshaft main bearing caps are in place (see Section 10). 11 Ensure that the bearing shells are correctly fitted, as describ[...]

Chapter 3 Cooling, heating and ventilation systems Contents Coolant pump - removal, inspection and refitting ............... .7 General information and precautions ......................... .1 Coolant renewal ............................... .See Chapter 1 Cooling system electrical switches - testing, removal and refitting Heater/ventilation compone[...]

3.2 Cooling, heating and ventilation systems 1 General information and precautions General information 1 The cooling system is of pressurised type, including a pump, an aluminium crossflow radiator, electric cooling fan, and a thermostat. The system functions as follows. Cold coolant is pumped around the cylinder block, head passages, expansion tan[...]

Cooling, heating and ventilation systems 3.3 3.5a Removing the radiator upper mounting screws inspection 8 If the radiator has been removed due to suspected blockage, reverse flush it as described in Chapter 1. Clean dirt and debris from the radiator fins, using an air line (in which case, wear eye protection) or a soft brush. Be careful, as the fi[...]

3.4 Cooling, heating and ventilation systems 8 Remove the nuts and lift the cooling fan and motor from the cowling (see illustration). 9 If necessary the fan can be separated from the motor by prising off the clamp washer. Assemble the components in reverse order using a new clamp washer. Refitting 10 Refitting is a reversal of removal. Electric co[...]

Cooling, heating and ventilation systems 3.5 7.6a Removing the water pump Refitting 8 Refitting is a reversal of removal, but fit a new sealing ring and refer to Chapter 2 when fitting the camshaft sprocket and tensioning the timing belt. If a reconditioned coolant pump is being fitted, check if the number “5” is stamped on the mounting flange [...]

3.6 Cooling, heating and ventilation systems 9.7 The flow direction arrow on the upper heater outlet - beneath the outlet with temperature valve fitted round - the direction of flow is indicated on the outlet elbow (see illustration). Heater blower motor Note: The blower motor is fixed in the heater unit housing and cannot be obtained as a separate[...]

Chapter 4 Part A: Fuel system: single-point injection models Contents Accelerator cable - removal, refitting and adjustment ............ .4 Fuel pumps and gauge sender unit - removal and refitting ........ .7 Air cleaner and inlet system - removal and refitting .............. .2 Fuel tank - removal and refitting ............................. .8 Air[...]

4A.2 Fuel system: single-point injection models 1 General information and precautions General information 1 The Bosch Mono-Motronic system is a self- contained engine management system, which controls both the fuel injection and ignition. This Chapter deals with the fuel injection system components only - refer to Chapter 5A for details of the igni[...]

Fuel system: single-point injection models 4A.3 2.3 Air cleaner assembly - 8 9 models with single-point fuel injection 1 To throttle body vacuum tapping 2 Air cleaner housing 3 Retaining ring 4 Retaining nut 5 Inlet air temperature regulator valve 6 Gasket 7 Spring clip 8 Intake air temperature regulating flap 9 Warm air ducting 1 0 Cold air ductin[...]

4A.4 Fuel system: single-point injection models 5.12 Exploded view of the throttle body upper section and fuel injector 1 Injector retaining screw 2 Protective cap 3 Injector retaining cap with integral inlet air temperature sensor 4 O-ring 5 injector 6 Fuel pressure regulator 7 Throttle body casting 8 Gasket 9 Fuel supply hose 10 Banjo bolt 11 Sea[...]

Fuel system: single-point injection models 4A.5 5.40 Location of engine management system ECU and relays 1 Bosch Mono-Motronic ECU 2 Multiway harness connector 3 Mounting bracket 4 Fuel injection pump relay 5 Inlet manifold pre-heater relay Electronic Control Unit (ECU) Removal Caution: Electronic Control Units (ECUs) contain components that are se[...]

4A.6 Fuel system: single-point injection models 6.5 Slacken the hose clips and disconnect the fuel lines from either side of the filter Lift pump and fuel gauge sender assembly Removal 3 It is advisable to carry out this operation when the fuel tank is almost empty. 4 Refer to Section 9 and depressurise the fuel system. 5 Ensure that the vehicle is[...]

Fuel system: single-point injection models 4A.7 7.16 Line fuel pump and accumulator unit 1 Line fuel pump 2 Accumulator the rear of the vehicle. Access is from the underside of the vehicle (see illustration). 17 Refer to Section 9 and depressurise the fuel system. 18 Park the vehicle on a level surface, apply the handbrake, select first gear (manua[...]

4A.8 Fuel system: single-point injection models the engine breather hoses are clear and undamaged, referring to Chapter 1, Chapter 2 and Chapter 5B for further information. 2 If these checks fail to reveal the cause of the problem the vehicle should be taken to a suitably equipped VW dealer for testing. A diagnostic connector is incorporated in the[...]

Chapter 4 Part B: Fuel system: multi-point injection models Contents Accelerator cable - removal, refitting and adjustment ............ .4 Air cleaner and intake system - removal and refitting ............ .2 Air cleaner filter element - renewal ................. see Chapter 1 Fuel filter - renewal ....................................... .6 Fuel in[...]

4B.2 Fuel system: multi-point injection models 1 General information and precautions Genera/ information 1 The Digifant system is a completely self-contained engine management system, which controls both the fuel injection and ignition. This Chapter deals with the fuel injection system components only - refer to Chapter 5A for details of the igniti[...]

Fuel system: multi-point injection models 4B.3 2.2 Detach the cold inlet air ducting from the cowling above the radiator shield on the exhaust manifold (see illustration) 4 Remove the four retaining nuts, then lift the air cleaner out of the engine bay and recover the rubber mountings (see illustration). To improve access, detach the charcoal canis[...]

4B.4 Fuel system: multi-point injection models 4.6 Prise the cable grommet from the bulkhead (arrowed) 5.4 Remove the air flow meter retaining screws (at-rowed) 5.7 Unplug the wiring harness from the potentiometer at the connector (arrowed) through into the engine bay, prise the grommet from the bulkhead (see illustration). 7 Release the cable from[...]

Fuel system: multi-point injection models 4B.5 necessary. It is therefore recommended that this operation is entrusted to a automotive electrical specialist. Throtte body Removal 23 Refer to Section 4 and detach the accelerator cable from the throttle valve lever. 24 Slacken the clips and detach the inlet air ducting from the top of the throttle bo[...]

4B.6 Fuel system: multi-point injection models 5.36a Slacken and withdraw the fuel rail retaining screws (art-owed) . . . 5.36b . . . then carefully lift the fuel rail away from the inlet manifold, together with the injectors 5.37a Unclip both halves of the plastic shielding from the injector body 5.37b Remove the insulating shroud 5.37c Unplug the[...]

Fuel system: multi-point injection models 4B.7 5.45 Remove the retaining screws (arrowed) and lift off the regulator body 44 Disconnect the vacuum hose from the port on the top of the fuel pressure regulator. 45 Slacken the clip and disconnect the fuel supply hose from the end of the fuel rail. This will allow the majority of fuel in the regulator [...]

4B.8 Fuel system: multi-point injection models 10.3a Idle speed adjustment screw 10.3b Exhaust CO adjustment screw location location 10 Fuel injection system adjustment - general information 1 If a fault appears in the fuel injection system first ensure that all the system wiring connectors are securely connected and free of corrosion. Then ensure [...]

Chapter 4 Part C: Emission control and exhaust systems Contents Catalytic converter - general information and precautions ........ .6 Exhaust manifold - removal and refitting ...................... .4 Crankcase emission system - general information .............. .3 Exhaust system - general information and component renewal .... 5 Evaporative loss [...]

4C.2 Emission control and exhaust systems Exhaust systems 9 The exhaust system comprises the exhaust manifold, a number of silencer units (depending on model and specification), a catalytic converter (where fitted), a number of mounting brackets and a series of connecting pipes. General information 1 The evaporative loss emission control system con[...]

Emission control and exhaust systems 4C.3 The catalytic converter is a reliable and simple device which needs no maintenance in itself, but there are some facts of which an owner should be aware if the converter is to function properly for its full service life. a) DO NOT use leaded petrol in a car with a catalytic converter - the lead will coat th[...]

Chapter 5 Part A: Starting and charging systems Contents Alternator - brush holder/regulator module renewal .............. 5 Battery - testing and charging .............................. .3 Alternator - removal and refitting ............................ .6 Electrical fault finding - general information ........ .see Chapter 12 Alternator/charging s[...]

5A.2 Starting and charging systems the battery disconnected, capacitive discharge could occur if a component’s live terminal is earthed trough a metal object This could cause a shock or nasty bum. Do not reverse the battev connections. Components such as the alternator, electronic control units, or any other components having semiconductor circui[...]

Starting and charging systems 5A.3 5.4a Location of the brush holder/ voltage regulator module 5.4b Lifting the brush holder/voltage regulator module away from the alternator 5.5 Measure the free length of the brush contacts charger current below 25 amps. Using this method, the battery should be usable within three hours, giving a voltage reading o[...]

5A.4 Starting and charging systems 6.3a Auxiliary belt tensioner nut and 6.3b Loosening the tensioner strut lockscrew (arrowed) pivot bolt 7 Starting system - testing Note: Refer to the precautions given in ‘Safety first!’ and in Section 1 of this Chapter before starting work. Take great care to avoid causing short circuits by accidentally touc[...]

Chapter 5 Part B: Ignition systems Contents Distributor - removal, inspection and refitting . . . . . . . . . General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HT Coil - testing, removal and refitting . . . . . , . . . . . . . . Ignition system - testing . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition system[...]

5B.2 Ignition systems 1 The Bosch Mono-Motronic and Digifant systems are self-contained engine management systems, which control both the fuel injection and ignition. This Chapter deals with the ignition system components only - refer to Chapter 4A or B for details of the fuel injection system components. 2 The ignition system comprises four spark [...]

Ignition systems 5B.3 3.3 Ignition coil primary and secondary winding terminals A Primary winding terminals B Secondary winding terminals check and renew them if there is any doubt about their condition. 14 If no HT voltage is present, check the ignition coil; its secondary windings may be breaking down under load. Testing 1 The resistance of the c[...]

5B.4 Ignition systems 4.7a Carefully prise off the rotor arm . . . 7 Carefully prise off the rotor arm, then lift off the moisture shield (see illustrations). 8 Mark the relationship between the distributor body and the drive gear case flange by scribing arrows on each. Slacken and remove the clamp bolts, then withdraw the distributor body from the[...]

Ignition systems 5B.5 5.5b Ignition timing marks - G40 models to Section 4 and slacken the distributor retaining bolts. Note: Mark the relationship between the distributor body and the cylinder head with a dab of paint, before adjustment is attempted. This gives a reference point that can be reverted to if the timing setting is lost. 7 Turn the dis[...]

6.1 Chapter 6 Clutch Contents Clutch cable - renewal .................................... .2 General information ...................................... .1 Clutch components - removal, inspection and refitting ........... .4 Release bearing and shaft - removal, inspection and refitting ...... 5 Clutch pedal - removal and refitting ..................[...]

6.2 Clutch Refitting 5 Refitting is a reversal of removal, but note the following points: a) Make sure the flats on the cable are located correctly on the steering gear housing. b) Grease the cable attachment point on the pedal, but do not grease the cable before fitting it to the steering gear housing, as there is a danger of grease blocking the b[...]

Clutch 6.3 Four speed transmission Removal 1 With the transmission removed, unhook the return spring from the release arm (see illustration). 2 Turn the release arm to move the release bearing up the guide sleeve, then disengage the two spring clips from the release fork and withdraw the bearing (see illustration). 3 Note how the springs and clips [...]

6.4 Clutch Five-speed transmission Removal 10 Remove the transmission as described in Chapter 7. Removal and checking procedures for the release bearing are the same as for the four-speed transmission, as described in the previous sub-Section. 11 Extract the circlips securing the release lever to the release shaft, then withdraw the shaft from its [...]

Chapter 7 Manual transmission Contents Drive flange oil seals - renewal ............................. .3 Reversing lamp switch - testing, removal and refitting ........... .5 Gearchange mechanism - removal, refitting and adjustment ...... .4 ..................... .6 General description Speedometer drive - removal and refitting .....................[...]

7.2 Manual transmission case and planetary gears, thus driving the sun gears and driveshafts. The rotation of the planetary gears on their shaft allows the inner roadwheel to rotate at a slower speed than the outer roadwheel during cornering. 5 Transmission fluid drain and filler plugs are provided, and a magnetic swarf collector is located in the [...]

Manual transmission 7.3 2.15 Removing the rear engine mounting and bracket 2.16a Disconnecting the shift rod coupling 2.16b Removing the shift rod coupling 2.16c Shift rod adapter and bush 16 Remove the screw from the shift rod coupling and ease the coupling from the rod. The screw threads are coated with a liquid locking agent and if difficulty is[...]

7.4 Manual transmission 5.8a Disconnect the wiring . . . Testing 1 Ensure the ignition switch is ‘OFF’. 2 Unplug the wiring harness from the reversing lamp switch at the connector. The switch is threaded into the transmission casing, at the front of the unit on 085 5 speed transmissions, and at the rear of the unit on 084 4 speed transmissions.[...]

Chapter 8 Driveshafts Contents Driveshaft - checking and cleaning .......................... .4 Driveshaft rubber gaiters - renewal .......................... .3 Driveshaft gaiter check ......................... See Chapter 1 General information ...................................... .1 Driveshaft - removal and refitting . . . . . . . . . . . . . .[...]

8.2 Driveshafts 1 .1 Exploded view of the right-hand driveshaft 1 Circlip 2 Inner cons tan t velocity joint 3 Dished washer 4 Protective cap 5 Rubber gaiter 6 Balance weight 7 Shaft 8 Dished washer 9 Circlip 10 Clip 11 Rubber gaiter 12 Hose clip 13 Outer constant velocity joint Drive is transmitted from the differential to the front wheels by means[...]

Driveshafts 8.3 3.2 Cross-section diagram of the driveshaft outer joint Driveshaft Rubber gaiter Clip Bearing race 5 Splined shaft 6 Distance washer 7 Dished washer Outer rubber gaiter 1 Remove the driveshaft from the car as described in Section 2 and secure it in a vice equipped with soft jaws. 2 Loosen the clips and release the large diameter end[...]

8.4 Driveshafts 4.8 Removing the outer joint hub from the cage 7 Turn the cage until the rectangular apertures are aligned with the housing then withdraw the cage and hub (see illustration). 8 Turn the hub and insert one of the segments into one of the rectangular apertures, then swivel the hub from the cage (see illustration). 9 Note that the join[...]

Chapter 9 Braking system Contents Brake disc - inspection, removal and refitting .................. .6 Brake fluid level check .......................... Brake fluid renewal .See Chapter 1 ............................ .See Chapter 1 Brake pedal - removal, overhaul and refitting ................. .1 1 Brake system and fluid leakage check ...........[...]

9.2 Braking system 1 General information The braking system is of servo-assisted hydraulic, dual circuit type with discs at the front and self-adjusting drum brakes at the rear. The hydraulic circuit is split diagonally so that with the failure of one circuit, one front and rear brake remain operative. A load sensitive pressure regulator is incorpo[...]

Braking system 9.3 4.4a Undo the caliper mounting bolts using an Allen key Bleeding - using a pressure- bleeding kit 24 These kits are usually operated by pressurised air contained in a spare tyre. However, note that it will probably be necessary to reduce the pressure to a lower level than normal; refer to the instructions supplied with the kit. 2[...]

9.4 Braking system 4.10a Fit the anti-rattle springs to the carrier bracket, making sure they are correctly located . . . caliper to hang unsupported on the flexible brake hose. 5 Withdraw the two brake pads from the carrier bracket and recover the anti-rattle springs, noting their correct fitted locations (see illustration). Note that the springs [...]

Braking system 9.5 5.8a Unhook the shoes from the lower pivot point using an adjustable spanner . . . 9 Ease the upper end of both shoes out from their wheel cylinder locations, taking care not to damage the wheel cylinder seals, and disconnect the handbrake cable from the trailing shoe. The brake shoe assembly can then be manoeuvred out of positio[...]

9.6 Braking system 6.3 Measuring brake disc thickness with a micrometer 23 Tap the shoes to centralise them with the backplate, then refit the shoe retainer pins and springs, and secure them in position with the spring cups. 24 Refit the brake drum as described in Section 7. 25 Repeat the above procedure on the remaining rear brake. 26 Once both se[...]

Braking system 9.7 7.4a . . . then unscrew the retaining nut. . . 7.4b . . . remove the toothed washer. . . 7.4c . . . and withdraw the outer bearing 4 Unscrew and remove the rear hub nut, then slide off the toothed washer and remove the outer bearing from the centre of the drum (see illustrations). 5 It should now be possible to withdraw the brake[...]

9.8 Braking system Removal 1 Apply the handbrake, then jack up the front of the vehicle and support it on axle stands (see “Jacking and vehicle support”). Remove the appropriate roadwheel. 2 Minimise fluid loss by first removing the master cylinder reservoir cap, and then tightening it down onto a piece of polythene, to obtain an airtight seal.[...]

Braking system 9.9 19 Ensure that the brake shoes are correctly located in the cylinder pistons, then refit the brake shoe upper return spring, using a screwdriver to stretch the spring into position. 20 Refit the brake drum (see Section 7). 21 Bleed the brake hydraulic system as described in Section 2. Providing suitable precautions were taken to [...]

9.10 Braking system 9 Unscrew the nuts and remove the washers securing the servo unit to the bulkhead. Where applicable, note the location of the retaining plate on the upper stud. Remove the assembly from the engine compartment. 1O Slacken and remove the two nuts and washers securing the master cylinder to the vacuum servo unit, then withdraw the [...]

Braking system 9.11 Refitting 5 Refitting is a reversal of the removal procedure, but finally adjust the handbrake as described in Section 14. I Front cable Removal 16.10 Re lease the retaining clips (arrowed) 1 Chock the front wheels then jack up the and detach the handbrake cable from the rear of the car and support on axle stands trailing arm (s[...]

9.12 Braking system withdraw the lines so that they are just clear of the regulator. Tape the ends of the brake lines to prevent entry of dust and dirt. 6 Unscrew the mounting bolts and withdraw the regulator from under the car. Refitting 7 Before refitting the regulator check that the brake line apertures and sealing surfaces are clean. 8 Locate t[...]

Chapter 10 Suspension and steering Contents Front anti-roll bar - removal and refitting ...................... .7 Front coil spring - removal and refitting ....................... .3 Front shock absorber - renewal ............................. .4 Front suspension strut - removal and refitting .................. .2 Front track control arm and balljo[...]

10.2 Suspension and steering Wheels Type ................................................. Pressed steel disc or alloy Size ................................................. 45J x 13 or 55J x 13 Tyres Pressures - see end of “Weekly checks”. Sizes:* Roadwheels: 45Jx13 ............................................. 135 R 13,145 R 13 or 155/70 R 13[...]

Suspension and steering 10.3 2.10a Removing the front suspension strut top cap 2.10b View of the front suspension strut upper mounting from below 4 Remove the brake disc with reference to Chapter 9, then unbolt the splash plate from the strut. 5 Unscrew the nut securing the steering tie- rod end to the strut, then use a balljoint separator to relea[...]

10.4 Suspension and steering Note: VW tool 40-201 B is necessary in order to unscrew the screw cap from the top of the strut. 1 A faulty shock absorber will normally make a knocking noise as the car is driven over rough surfaces. 2 To remove the shock absorber first remove the front coil spring as described in Section 3. 3 Using VW tool 40-201 B un[...]

Suspension and ‘steering 10.5 8.2 Remove the cap from the top of the rear suspension strut 8.5a Rear suspension strut lower mounting bolt 2 Working inside the rear of the car, remove 6 Remove the upper spring seat, coil spring, the parcel tray then remove the cap from the lower buffer, washer, bump stop and bellows top of the strut by twisting it[...]

10.6 Suspension and steering 9.3 Checking the rear wheel stub axle for distortion Refitting 8 Refitting is a reversal of removal, but make sure that the coil spring is correctly located in the seats. Delay tightening the lower mounting bolt until the full weight of the car is on the roadwheels. Removal 1 Remove the rear brake shoes and wheel cylind[...]

Suspension and steering 10.7 10.11 Grease the lips of the seal, and press it into the rear of the hub 11 Smear the lips of the new seal with a little grease. Using a block of wood drive the seal squarely into the drum/hub with the lips facing inwards (see illustration). 12 Refit the drum and locate the outer bearing on the stub axle. 13 Fit the thr[...]

10.8 Suspension and steering 13.3a Unscrew the nut. . . 13.3b . . . and remove the washer 14.3b . . . and withdraw the lower shroud . . . Refitting 4 Refitting in a reversal of removal, but make sure that the turn signal lever is in its neutral position, otherwise damage may occur to the cancelling arm. Make sure that the 3 mm thick washer is fitte[...]

Suspension and steering I0.9 15.1 Draw the splined adapter off the 15.7 Use the steering wheel nut to press steering column using a puller the adapter onto the inner column 16.6 Unscrewing the steering lock clamp bolt 4 Withdraw the inner column from the outer column and remove the support ring. 5 Clean the components and examine them for wear and [...]

10.10 Suspension and steering 17.10a Steering gear location (engine removed from car) disengage it from the steering gear (see illustration). 6 Set the front wheels in the straight-ahead position then unscrew the clamp bolt securing the inner column to the steering gear pinion. Where applicable, remove the trim panel for access to the clamp bolt. 7[...]

Suspension and steering 10.11 axis is defined as an imaginary line drawn through the axis of the suspension strut, extended where necessary to contact the ground. 2 Camber is the angle between each roadwheel and a vertical line drawn through its centre and tyre contact patch, when viewed from the front or rear of the car. Positive camber is when th[...]

Chapter 11 Bodywork and fittings Contents Body exterior fittings - removal and refitting .................. .23 Bonnet lock - removal and refitting ......................... 11 Bonnet release cable - removal and refitting .................. .10 Bonnet - removal, refitting and adjustment .................... .9 Boot lid lock components (Saloon model[...]

11.2 Bodywork and fittings 1 General information The bodyshell is made of pressed-steel sections, and is available in three-door Hatchback, three-door Coupe and two-door Saloon versions. Most components are welded together, but some use is made of structural adhesives; the front wings are bolted on. The bonnet, door, and some other vulnerable panel[...]

Bodywork and fittings 11.3 Should the dent be in a section of the bodywork which has a double skin, or some other factor making it inaccessible from behind, a different technique is called for. Drill several small holes through the metal inside the area - particularly in the deeper section. Then screw long self-tapping screws into the holes, just s[...]

11.4 Bodywork and fittings and fuse a plastic filler rod into the groove. Any excess plastic is then removed, and the area rubbed down to a smooth finish. It is important that a filler rod of the correct plastic is used, as body components can be made of a variety of different types (eg polycarbonate, ABS, polypropylene). Damage of a less serious n[...]

Bodywork and fittings 11.5 Saloon models 3 Remove the number plate lights from the rear bumper as described in Chapter 12. 4 Unscrew the mounting bolts securing the rear bumper to the underbody bracket. If necessary, access can be improved by raising the rear of the car and supporting on axle stands (see “Jacking and vehicle support”). 5 Pull t[...]

11.6 Bodywork and fittings 13.1 Removing the locking knob 13.2 Slide the inner handle surround to the rear to remove it 13.3a Removing the exterior mirror control knob. . . 13.3b . . . and boot 13.4a Prise out the trim cover. . . 13.4b . . . unscrew the mounting screws. . . 13.4c . . . and release the door pull from the trim Removal 1 If required, [...]

Bodywork and fittings 11.7 13.8 Releasing the inner trim panel from the weatherseal 14.1 Screw securing the exterior handle to the rear edge of the door panel taking care not to damage the trim. Remove the panel and release it from the upper inner door weatherseal (see illustration). 9 Remove the window regulator handle packing (see illustration). [...]

11.8 Bodywork and fittings 14.7a Unscrew the mounting screws . . . 14.7b . . . and withdraw the lock from the door 15.3b Bolts securing the lifting plate to the window channel 7 Unscrew the two screws securing the door lock to the rear edge of the door, then withdraw the lock while guiding the locking control rod and main control rods from the door[...]

Bodywork and fittings 11.9 16.5 Tailgate hinge 4 Tie a piece of string to each end of the wiring then, noting the correct routing of the wiring harness, release the harness rubber grommets from the tailgate and withdraw the wiring. When the end of the wiring appears, untie the string and leave it in position in the tailgate; it can then be used on [...]

11.10 Bodywork and fittings bolts and withdraw the boot lid. Recover the spacer where fitted. 3 The boot lock and striker are each secured by two cross-head screws, but when removing the lock it will be necessary to unhook the connecting rod. Refitting 4 Refitting is a reversal of removal, but make sure that the boot lid is central within the apert[...]

Bodywork and fittings 11.11 24.1 a Remove the screw from the front of the seat. . . 24.1b . . . then release the spring tensioned pin 24.2a Remove the screw . . . 24.2b . . . and withdraw the inner runner cover Refitting 3 On refitting wheel arch liners and under- panels, renew any retaining clips that may have been broken on removal, and ensure th[...]

1 1 .1 2 Bodywork and fittings 25.2 Pull back the cover from the front seat belt lower mounting 25.4 Unhooking the spring from the front seat belt lower mounting 25.7 Removing the plastic cover from the front seat belt upper mounting 25.8 Pull away the weatherstrip before removing the rear trim panel 4 Unhook the spring and gently allow the tension[...]

Bodywork and fittings 11.13 26.11 Glovebox hinge pins however that they can break quite easily so replacements should be available. The best way of releasing such clips without the correct type of tool, is to use a large flat-bladed screwdriver. Note in many cases that the adjacent sealing strip must be prised back to release a panel. 4 When removi[...]

11.14 Bodywork and fittings 28.3c Disconnecting the diagnostic socket wiring plugs 9 Disconnect the wiring from the switches and the cigarette lighter, noting the location of each wire (see Haynes Hint). 10 Disconnect the loudspeaker wiring from the left-hand side of the facia. 28.3d Shelf/trim panel front pin and rubber grommet 11 Unscrew the faci[...]

12.1 Chapter 12 Body electrical system Contents Battery - removal and refitting .................... .See Chapter 5 Loudspeakers - removal and refitting ........................ .17 Battery check and maintenance ............. .See “Weekly checks” Radio aerial - removal and refitting ......................... .18 Bulbs (exterior lights) renewal [...]

12.2 Body electrical system relays). Visually inspect the condition of all fuses, wires and connections in a problem circuit before testing the components. Use the wiring diagrams to determine which terminal connections will need to be checked in order to pinpoint the trouble spot. 4 The basic tools required for electrical fault- finding include a [...]

Body electrical system 12.3 3.7a Relays located beneath the left-hand side of the facia panel Relays 7 The main relays are near the fusebox in the left-hand side of the plenum chamber/ bulkhead. Other relays are beneath the left- hand side of the facia panel and behind the ECU on the bulkhead (see illustrations). 8 If a circuit or system controlled[...]

12.4 Body electrical system 4.8 With the switch removed from the facia, the wiring plug can be disconnected 4.10 Prising off the heater control panel cover 4.11a Removing the ashtray insert mounting screws 4.11b Disconnecting the wiring plug from the rear of the cigarette lighter 4.12a Slide out the bulbholder. . . 4.12b . . . lever the tab . . . 4[...]

Body electrical system 12.5 5.3 Disconnecting the wiring plug from the rear of the headlamp bulb 5.5a Release the clips . . . 5.5b . . . and remove the bulb from the rear of the headlight unit 5.10 Removing the front sidelight bulbholder 5.14a Disconnect the wiring . . . 5.14c . . . and remove the front direction indicator bulb rear of the light un[...]

12.6 Body electrical system 5.24a Squeeze together the plastic tabs . . . 5.24b . . . and remove the rear light cluster bulbholder 5.25 Removing a bulb from the rear light cluster bulbholder 5.27a Remove the screws. . . 5.27b . . . and remove the rear number plate light lens 5.28 Rear number plate light bulb removal with the front tag in the small [...]

Body electrical system 12.7 6.6 Removing a bulbholder from the rear of the instrument panel Instrument panel illumination/warning lights 5 Remove the instrument panel (Section 8). 6 Twist the relevant bulbholder anti- clockwise and withdraw it from the rear of the panel (see illustration). 7 All bulbs are integral with their holders. Be very carefu[...]

12.8 Body electrical system 8.3a Removing the instrument panel 8.3b The special tools are used to hold in with the special tools the side clips 8.4 Disconnecting the wiring plug from the rear of the instrument panel 18 Withdraw the light unit and disconnect it from the wiring connector. 19 Refitting is a reversal of removal. Note: Two special U-sha[...]

Body electrical system 12.9 12.2a Pull off the weatherstrip . . . 12.2b . . . and remove the plastic cover from over the windscreen wiper motor 12.3 2 Wiper blade 3 Pull rods 4 Wiper bearing 5 Windscreen wiper frame 6 Parking position 7 Wiper motor the spindle, aligning the wiper blade with the tape fitted on removal. Refit and tighten the spindle [...]

12.10 Body electrical system 13.3a Disconnect the wiring plug . . . 13.3b . . . unscrew the mounting bracket bolts . . . 13.3c . . . and withdraw the motor assembly from the tailgate 3 Disconnect the wiring plug, then unscrew the mounting bracket bolts and withdraw the motor assembly (see illustrations). Note the location of any spacers and recover[...]

Body electrical system 12.11 16.3a Fitting the special 16.3b Disconnecting the wiring plug radio removal tools from the radio 2 Disconnect the battery negative lead. Note: Make sure you know the anti-theft code for the radio/cassette so that you can re-activate it on refitting. 3 Insert the tools into the two holes on each side of the unit and push[...]

Solenoid actuator Item no. Wire - permanent positive supply (double line) Wire - permanent direct earth (thick line) E6 E7 E8 E9 El0 E11 El2 El3 El4 Near fuse relay box Behind dashboard, left Luggage compartment, left In wiring loom for instruments In dashboard loom In front right wiring loom In Digifant wiring loom In boot lid In front left wiring[...]

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Reference REF.1 Dimensions and weights ................... REF.1 Radio/cassette unit anti-theft system ......... REF.5 Conversion factors ....................... REF.2 Tools and working facilities ................. REF.6 Buying spare parts ....................... .REF.3 MOT test checks ........................ .REF.8 Vehicle identification ........[...]

Length (distance) Inches (in) x 25.4 = Millimetres (mm) Feet (ft) x 0.305 = Metres (m) Miles x 1.609 = Kilometres (km) Volume (capacity) Cubic inches (cu in; in³) Imperial pints (Imp pt) Imperial quarts (Imp qt) Imperial quarts (Imp qt) US quarts (US qt) Imperial gallons (Imp gal) Imperial gallons (Imp gal) US gallons (US gal) Mass (weight) x 16.3[...]

Buying spare parts REF.3 Buying spare parts Spare parts are available from many sources, including maker’s appointed garages, accessory shops, and motor factors. To be sure of obtaining the correct parts, it will sometimes be necessary to quote the vehicle identification number. If possible, it can also be useful to take the old parts along for p[...]

REF.4 General repair procedures Whenever servicing, repair or overhaul work is carried out on the car or its components, it is necessary to observe the following procedures and instructions. This will assist in carrying out the operation efficiently and to a professional standard of workmanship. Joint mating faces and gaskets When separating compon[...]

Jacking and vehicle support REF.5 The jack supplied with the vehicle tool kit To raise the front of the vehicle, position the To raise the rear of the vehicle, position the should only be used for changing the jack with an interposed block of wood jack with an interposed block of wood roadwheels - see “Wheel changing” at the underneath. Do not [...]

REF.6 Tools and working facilities introduction A selection of good tools is a fundamental requirement for anyone contemplating the maintenance and repair of a motor vehicle. For the owner who does not possess any, their purchase will prove a considerable expense, offsetting some of the savings made by doing-it-yourself. However, provided that the [...]

Tools and working facilities REF.7 Special tools The tools in this list are those which are not used regularly, are expensive to buy, or which need to be used in accordance with their manufacturers’ instructions. Unless relatively difficult mechanical jobs are undertaken frequently, it will not be economic to buy many of these tools. Where this i[...]

REF.8 MOT test checks This is a guide to getting your vehicle through the MOT test. Obviously it will not be possible to examine the vehicle to the same standard as the professional MOT tester. However, working through the following checks will enable you to identify any problem areas before submitting the vehicle for the test. Where a testable com[...]

MOT test checks REF.9 Seat belts and seats Note: The following checks are applicable to all seat belts, front and rear 0 Examine the webbing of all the belts (including rear belts if fitted) for cuts, serious fraying or deterioration. Fasten and unfasten each belt to check the buckles. If applicable, check the retracting mechanism. Check the securi[...]

REF .10 MOT test checks Exhaust system 0 Start the engine. With your assistant holding a rag over the tailpipe, check the entire system for leaks. Repair or renew leaking sections. 3 Checks carried out WITH THE VEHICLE RAISED AND THE WHEELS FREE TO TURN Jack up the front and rear of the vehicle, and securely support it on axle stands. Position the [...]

MOT test checks Ref.11 0 Examine the handbrake mechanism, checking for frayed or broken cables, excessive corrosion, or wear or insecurity of the linkage. Check that the mechanism works on each relevant wheel, and releases fully, without binding. 0 It is not possible to test brake efficiency without special equipment, but a road test can be carried[...]

REF.12 Fault finding Engine . . . . . . . . . . . . . . . . . . . . .......... 1 Driveshafts ...................,,.,... 6 Engine fails to rotate when attempting to start Engine rotates, but will not start Engine difficult to start when cold Engine difficult to start when hot Starter motor noisy or excessively-rough in engagement Engine starts, but [...]

Fault finding REF.13 headings denoting various components or systems, such as Engine, Cooling system, etc. The Chapter and/or Section which deals with the problem is also shown in brackets. Whatever the fault, certain basic principles apply. These are as follows: Verify the fault. This is simply a matter of being sure that you know what the symptom[...]

REF.14 Fault finding 1 Engine (continued) Engine lacks power 0 Timing belt incorrectly fitted or tensioned (Chapter 2A or 2B). 0 Fuel filter choked (Chapter 1). 0 Fuel pump faulty, or delivery pressure low (Chapter 4A or 4B). 0 Uneven or low cylinder compressions (Chapter 2A or 2B). 0 W orn, faulty or incorrectly-gapped spark plugs (Chapter 1). q V[...]

Fault finding REF .15 3 Fuel and exhaust systems Excessive fuel consumption Excessive noise or fumes from exhaust system q Air filter element dirty or clogged (Chapter 1). 0 Fuel injection system fault (Chapter 4A or 4B). 0 Ignition timing incorrect/ignition system fault (Chapters 1 and 5B). 0 Tyres under-inflated (Weekly checks”). Fuel leakage a[...]

REF.16 Fault finding 6 Driveshafts Clicking or knocking noise on turns Vibration when accelerating or decelerating (at slow speed on full-lock) 0 W orn inner constant velocity joint (Chapter 8). 0 Lack of constant velocity joint lubricant, possibly due to damaged 0 Bent or distorted driveshaft (Chapter 8). gaiter (Chapter 8). 0 W orn outer constant[...]

Fault finding REF.17 8 Suspension and steering (continued) Excessive pitching and/or rolling around corners, or during braking 0 Defective shock absorbers (Chapters 1 and 10). q Broken or weak spring and/or suspension component (Chapters 1 and 10). 0 W orn or damaged anti-roll bar or mountings (Chapter IO). Wandering or general instability 0 Incorr[...]

REF.18 Fault finding 9 Electrical system (continued) Horn inoperative, or unsatisfactory in operation Horn operates all the time 0 Horn push either earthed or stuck down (Chapter 12). 0 Horn cable-to-horn push earthed (Chapter 12). Horn fails to operate 0 Blown fuse (Chapter 12). 0 Cable or cable connections loose, broken or disconnected (Chapter 1[...]

Glossary of technical terms REF.9 A ABS (Anti-lock brake system) A system, usually electronically controlled, that senses incipient wheel lockup during braking and relieves hydraulic pressure at wheels that are about to skid. Air bag An inflatable bag hidden in the steering wheel (driver’s side) or the dash or glovebox (passenger side). In a head[...]

REF.20 Glossary of technical terms Camshaft A rotating shaft on which a series of cam lobes operate the valve mechanisms. The camshaft may be driven by gears, by sprockets and chain or by sprockets and a belt. Canister A container in an evaporative emission control system; contains activated charcoal granules to trap vapours from the fuel system. C[...]

Glossary of technical terms REF.21 E EGR valve A valve used to introduce exhaust gases into the intake air stream. EGR valve Electronic control unit (ECU) A computer which controls (for instance) ignition and fuel injection systems, or an anti-lock braking system. For more information refer to the Haynes Automotive Electrical and Electronic Systems[...]

REF.22 Glossary of technical terms J Jump start Starting the engine of a vehicle with a discharged or weak battery by attaching jump leads from the weak battery to a charged or helper battery. Load Sensing Proportioning Valve (LSPV) A brake hydraulic system control valve that works like a proportioning valve, but also takes into consideration the a[...]

Glossary of technical terms REF.23 automatic transmission, a switch that prevents starting if the vehicle is not in Neutral or Park. Strut See MacPherson strut. Tappet A cylindrical component which transmits motion from the cam to the valve stem, either directly or via a pushrod and rocker arm. Also called a cam follower. Thermostat A heat-controll[...]