N - Remove/Install/Overhaul Article Text

N - REMOVE/INSTALL/OVERHAUL
Article Text
1989 Volkswagen Golf
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Monday, August 23, 1999 11:58PM
ARTICLE BEGINNING
1989 ENGINE PERFORMANCE

Volkswagen Removal, Overhaul & Installation
Cabriolet, Fox, Golf, Golf GT, Jetta, Vanagon
INTRODUCTION
Removal, overhaul and installation procedures (when given by

manufacturer) are covered in this article. If component removal and
installation is primarily an unbolt on procedure, a simple tightening
specification may be all that is furnished.
AIRFLOW SENSOR PLATE
REMOVAL & INSTALLATION
1) Remove air filter and unscrew stop bracket. Using heat

gun, heat locking compound on fastening bolt. Remove bolt slowly. Do
not damage threads. Clean locking compound from bolt hole threads.
2) Install airflow sensor plate. Ensure 5 dimple marks are
up. Lightly tighten self-locking screw. Ensure sensor plate is
centered and rest position is correct. To complete installation,
reverse removal procedure.
AIRFLOW SENSOR POTENTIOMETER
Remove differential pressure regulator. Remove insulating

compound covering mounting screws. Remove potentiometer. Do not touch
or damage slide contact and conductor. To install, reverse removal
procedure. Adjust potentiometer. See ON-VEHICLE ADJUSTMENTS article in
this section.
IGNITION DISTRIBUTOR
REMOVAL
1.8L
1) Turn engine crankshaft to TDC. Marking on vibration
dampener pulley must align with drive belt guard pointer. Marking on
cam shaft gear sprocket must align with cylinder head cover.
2) Remove distributor cap and mark position of rotor. Rotor
should be pointing to No. 1 cylinder in distributor firing sequence.
Mark position of distributor housing for reference to timing currently
set. Remove distributor hold-down and bolt. Remove distributor
assembly, noting position of rotor when distributor shaft gear is
disengaged from driving gear.
Article Text (p. 2)
2.1L
Turn engine crankshaft to TDC. Remove distributor cap. Rotor
should point to No. 1 cylinder mark on edge of distributor housing.
Index mark the current position of distributor housing to the
crankcase. Remove distributor hold-down and bolt. Remove distributor
assembly.
INSTALLATION
1.8L
1) Align oil pump drive pinion lug parallel to crankshaft.
Set rotor so that it is pointing toward mark made when distributor was
disengaged from drive gear.
2) Install distributor. Rotor should now point to mark made
for No. 1 cylinder in distributor firing sequence. Align mark for
distributor housing and install distributor hold-down and bolt.
Tighten hold-down bolt 18 ft. lbs. (24 N.m). Install distributor cap.
2.1L
Align rotor of distributor to No. 1 cylinder mark on edge of
distributor housing. Install distributor and align housing to index
mark made on crankcase. Install distributor hold-down and bolt.
Tighten hold-down bolt 18 ft. lbs. (24 N.m). Install distributor cap.
FUEL DISTRIBUTOR (1.8L ONLY)
CAUTION: Fuel system pressure must be relieved before removing or

disconnecting any fuel lines. Wipe up all gasoline BEFORE
continuing service.
REMOVAL
1) Disconnect battery and remove air cleaner. Disconnect all

fuel and injector lines from fuel distributor. Plug fuel supply and
return lines. Catch any spilled fuel.
2) Disconnect wiring from differential pressure regulator.
Remove screws holding fuel distributor to airflow sensor housing.
Remove fuel distributor by turning back and forth while lifting up.
OVERHAUL
Air Sensor Plate (Rest Position)

Upper edge of sensor plate must be below lower edge of sensor
cone .070-080" (1.80-2.10 mm). See Fig. 1. If rest position is
incorrect, raise sensor plate. Open or close wire clip to change
position of sensor plate. DO NOT bend leaf spring.
Article Text (p. 3)
Fig. 1: Sensor Plate Rest Position

Courtesy of Volkswagen United States, Inc.
Centering Sensor Plate & Lever

1) Check sensor plate for centered position in airflow sensor
housing. See Fig. 2. If plate binds on housing or is off-center,
remove 6 mm bolt holding plate to lever. Coat bolt with locking
compound and install finger tight.
2) Use Centering Gauge (US 1109) or .004" (.10 mm) feeler
gauges to set plate an equal distance from sensor housing. If plate
cannot be centered, remove airflow sensor housing.
3) Turn housing upside-down and remove bolt clamping
counterweight to sensor lever. Coat bolt with locking compound and
install finger tight. Center sensor plate lever in housing and tighten
clamping bolt. Complete centering of plate.
Fig. 2: Adjusting Sensor Plate Lever On Airflow Sensor Housing

Sensor Plate Free Plate

1) Free play is measured between control piston and adjusting
lever. To ensure that Differential Pressure Regulator (DPR) current is
4-16 mA, position of sensor plate lever must be correct. Measure free
Article Text (p. 4)
play on side of sensor cone closest to fuel distributor. See Fig. 3.

2) Crank starter motor for 10 seconds to develop fuel
pressure. Lift sensor plate slightly until resistance is felt. Minimum
clearance is any noticeable free play. Maximum clearance is .078" (1.
99 mm) up to sensor cone.
3) If free play clearance is incorrect, remove fuel
distributor. Check basic adjustment of sensor plate lever. Install
fuel distributor and repeat free play clearance check. If still
incorrect, adjust sensor plate clearance with control piston stop
screw.
Fig. 3: Sensor Plate Free Play

Sensor Plate Lever Adjustment

Article Text (p. 5)
1) Check basic adjustment of sensor plate lever. With fuel

distributor removed from airflow sensor housing, measure distance
between roller on sensor plate lever and contact points of fuel
distributor on top of airflow sensor housing.
2) Use a depth gauge or vernier caliper for measuring
distance. See Fig. 2. Distance should be .74-.75" (18.9-19.1 mm). If
distance is out of specified range, correct it by adjusting mixture
screw.
INSTALLATION
1) Lightly lubricate new sealing "O" ring and mount on fuel

distributor. Install fuel distributor. Connect all fuel lines except
those to fuel injectors. Check sensor plate adjusting lever and fuel
distributor control piston for smooth operation.
2) Remove fuel pump relay and bridge fuel pump circuit. Use
Jumper Switch (US 4480/3) in place of fuel pump relay. When pressure
has built up, turn off fuel pump. Move sensor plate from rest position
to end of travel.
3) Uniform resistance should be felt during entire movement.
No resistance should be felt during entire movement. No resistance
should be felt on quick return to rest position. Connect injector
lines. Install fuel pump relay. Start engine and check for leaks.
INJECTORS
CAUTION: Fuel system pressure must be relieved before removing

injectors. Wipe up all gasoline BEFORE continuing service.
REMOVAL
1.8L
Remove injectors from inserts in head with fuel lines
attached. Using 13 mm hex head socket, remove inserts from head. Use 2
wrenches to remove injectors from lines.
2.1L
Disconnect negative battery cable. Disconnect electrical
connectors at injectors. Loosen and remove both hoses on each end of
fuel rail. Note direction of electrical connector on injectors. Remove
hold-down bolt and pull out two fuel injectors together with fuel
rail. Remove injectors from fuel rail when servicing.
INSTALLATION
1.8L
To install, reverse removal procedures. Use 2 wrenches when
tightening injector lines to injectors. Use new "O" rings lightly
lubricated. On models with 2-piece inserts, replace insert sealing
washer (against head) and use sealing compound on upper insert
threaded portion.
Article Text (p. 6)
2.1L
To install injectors, reverse removal procedures. Use new "O"
rings when installing injectors. Replace hose clamps if necessary.
OXYGEN SENSOR
All Models
O2 sensor is mounted in the exhaust pipe in front of
catalytic converter. It is equipped with a permanent pigtail which
must be protected from damage when the sensor is removed. Ensure
sensor is free of contaminants, avoid using cleaning solvents of any
type. Sensor may be difficult to remove when engine temperature is
less than 120øF (48øC). Always use anti-seize compound on threads
prior to installation. Tighten sensor to 30 ft. lbs. (41 N.m).
THROTTLE VALVE HOUSING (TVH)
1) Disconnect accelerator cable from linkage. Disconnect

return spring on TVH. Remove cruise control connecting rod on TVH (if
equipped). Pull off vacuum hoses. Remove TVH mounting nuts.
2) Disconnect throttle valve switch. Remove 2 nuts holding
TVH to metallic front vibration mounts. Disconnect fuel return hose
from pressure regulator. Lift sensor housing upward and remove TVH.
Remove gasket.
3) To install, reverse removal procedure. Ensure all surfaces
are clean and mate correctly. Use new gaskets when assembling. Adjust
accelerator linkage and idle speed.
END OF ARTICLE

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N - REMOVE/INSTALL/OVERHAUL

1989 ENGINE PERFORMANCE

Cabriolet, Fox, Golf, Golf GT, Jetta, Vanagon

Removal, overhaul and installation procedures (when given by

AIRFLOW SENSOR PLATE

REMOVAL & INSTALLATION

1) Remove air filter and unscrew stop bracket. Using heat

AIRFLOW SENSOR POTENTIOMETER

REMOVAL & INSTALLATION

Remove differential pressure regulator. Remove insulating

FUEL DISTRIBUTOR (1.8L ONLY)

CAUTION: Fuel system pressure must be relieved before removing or

1) Disconnect battery and remove air cleaner. Disconnect all

Air Sensor Plate (Rest Position)

Fig. 1: Sensor Plate Rest Position

Centering Sensor Plate & Lever

Fig. 2: Adjusting Sensor Plate Lever On Airflow Sensor Housing

Sensor Plate Free Plate

play on side of sensor cone closest to fuel distributor. See Fig. 3.

Fig. 3: Sensor Plate Free Play

Sensor Plate Lever Adjustment

1) Check basic adjustment of sensor plate lever. With fuel

1) Lightly lubricate new sealing "O" ring and mount on fuel

CAUTION: Fuel system pressure must be relieved before removing

REMOVAL & INSTALLATION

THROTTLE VALVE HOUSING (TVH)

REMOVAL & INSTALLATION

1) Disconnect accelerator cable from linkage. Disconnect

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