D - ADJUSTMENTS

Article Text
1989 Volkswagen Golf
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Monday, August 23, 1999 11:45PM

ARTICLE BEGINNING

1989 ENGINE PERFORMANCE

Volkswagen On-Vehicle Adjustments

Volkswagen; Cabriolet, Fox, Golf,

Golf GT, Jetta & Vanagon

ENGINE COMPRESSION

ENGINE COMPRESSION TEST

Check compression with engine warm, all spark plugs removed

and throttle wide open. Ground coil wire from center of distributor
cap to engine block. Disconnect one end of duct between airflow sensor
and throttle body to disable fuel injection system. Crank engine
through at least 6 compression strokes per cylinder to determine
engine compression.

ENGINE COMPRESSION TEST

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Model Standard Minimum
psi (kg/cmý) psi (kg/cmý)

Cabriolet ......... 131-174 (9.0-12.0) ........ 109 (7.7)

Fox ............... 131-174 (9.0-12.0) ........ 102 (7.0)
Golf & Jetta ...... 131-174 (9.0-12.0) ........ 102 (7.0)
Golf GT ........... 145-189 (10.2-13.2) ....... 109 (7.7)
GTI ............... 131-174 (9.0-12.0) ........ 109 (7.7)
Vanagon ............ 87-131 (6.1-9.2) ......... 73 (5.2)
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VALVE CLEARANCE

NOTE: All models use hydraulic lifters. No adjustments are

required.

IGNITION TIMING

NOTE: Basic timing readings are only valid when engine idle speed
and the idle mixture are within specifications.

CHECKING & ADJUSTING

All (Except Vanagon)

1) Warm engine to normal operating temperature (cooling fan
should cycle at least once). Remove the 27 mm plastic plug from timing
check hole on transaxle bellhousing (if equipped).
2) With ignition off, connect a tachometer and timing light
to vehicle. Start engine and briefly raise engine speed above 3000 RPM
a few times, then allow engine to idle normally. With distributor
 D - ADJUSTMENTS
Article Text (p. 2)
1989 Volkswagen Golf
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Monday, August 23, 1999 11:45PM

vacuum hoses connected, timing mark on flywheel should appear adjacent

to pointer in hole.
3) If an adjustment is needed, turn ignition off and loosen
distributor hold-down bolt just enough to move distributor by hand.
Start engine and allow to idle. Turn distributor until timing mark is
aligned with pointer in bellhousing. Stop engine and tighten hold down
bolt to 18 ft. lbs. (24 Nm.). Readjust if necessary and install
plastic plug if removed.

Fig. 1: Ignition Timing Mark All (Except Vanagon)

Courtesy of Volkswagen United States, Inc.

Vanagon
1) Warm engine to normal operating temperature. Stop engine
and connect a tachometer and timing light to engine. Start engine and
raise engine speed to a minimum of 2100 RPM at least 4 times, allowing
throttle to close each time (this procedure must be repeated each time
timing is checked).
2) Disconnect coolant temperature sensor connector before
checking ignition timing. See Fig. 2. Increase engine speed to
specification when checking ignition timing. Notch on V-belt pulley
must align with parting line on crankcase.
3) If an adjustment is needed, turn ignition off and loosen
distributor hold-down bolt just enough to move distributor by hand.
Start and allow engine to idle. Turn distributor until timing mark
notch on V-belt pulley is aligned with parting line on crankcase.

IGNITION TIMING TABLE (Degrees BTDC @ RPM)

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Application Checking Adjusting

1.8L ........ 4-8 @ 2250-2350 ... 5-7 @ 2250-2350

2.1L ........ 4-8 @ 2250-2350 ... 5-7 @ 2250-2350
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 D - ADJUSTMENTS
Article Text (p. 3)
1989 Volkswagen Golf
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Monday, August 23, 1999 11:45PM

Fig. 2: Coolant Temperature Sensor (Vanagon)

Courtesy of Volkswagen United States, Inc.

IDLE SPEED & MIXTURE

NOTE: Mixture adjustment is NOT a part of normal tune-up procedure

and should not be performed unless mixture control unit is
replaced or vehicle fails emissions testing.

COLD (FAST) IDLE

Fast idle RPM is not adjustable.

IDLE SPEED & MIXTURE ADJUSTMENT

Vanagon
1) Warm engine to normal operating temperature. Engine oil
temperature must be at least 176øF (80øC). Connect an inductive
tachometer or Tester (VW 1367) to alternator, Test Lead (VW1473) to
ignition coil, and timing light lead to No. 1 spark plug wire.
2) Start and run engine at idle. Disconnect electrical
connector at coolant temperature sensor. See Fig. 2. Raise engine
speed to specification and check and/or adjust ignition timing.
3) Ensure all electrical accessories are off. Disconnect and
plug crankcase breather hose. Ensure throttle valve switch is
operating properly and throttle screw stop is properly adjusted.
Switch must be closed with engine at idle.
4) Ensure that idle stabilizer valve hums/vibrates when
ignition is turned on. Ensure test equipment is properly connected.
See. Fig. 3. Using Adapter (Sun 120.239), connect CO tester at probe
receptacle on left exhaust pipe.
5) With ignition off, disconnect idle stabilizer valve and
oxygen sensor. Check idle speed. If necessary, turn idle speed screw
until idle speed is correct. See Fig. 4. Check CO reading. If CO
reading is within specifications, remove intake air sensor. Center
punch plug in CO adjusting hole.
6) Using a 3/32" drill bit, drill hole 5/32" deep in center
of plug. Remove any metal shavings. Screw in a sheet metal screw and
remove plug using pliers to pry plug out.
 D - ADJUSTMENTS
Article Text (p. 4)
1989 Volkswagen Golf
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Monday, August 23, 1999 11:45PM

7) Start engine. Set idle speed and CO reading by alternately

turning mixture and idle speed adjustment screws. Reconnect oxygen
sensor connector and idle stabilizer control valve. Let engine idle
for 2 minutes.
8) Check CO content. If incorrect, repeat adjusting
procedure. If correct, remove and plug hose at pressure regulator. CO
reading should increase briefly and then drop in value.
9) If CO reading changes as specified, turn engine off and
drive in new adjusting hole plug flush with air intake sensor. Remove
all test equipment and reconnect all hoses and wiring.

All Others
1) Warm engine at normal operating temperature. Radiator fan
must come on at least once and engine oil temperature must be at least
176øF (80øC). Turn off all electrical equipment, including A/C and
radiator fan.

Fig. 3: Tester (VW 1367) & Test Lead (VW 1473) (Vanagon)
Courtesy of Volkswagen United States, Inc.

Fig. 4: Idle Mixture Screw & Idle Adjustment Screw (Vanagon)

Courtesy of Volkswagen United States, Inc.
 D - ADJUSTMENTS
Article Text (p. 5)
1989 Volkswagen Golf
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Monday, August 23, 1999 11:45PM

2) Disconnect all fuel pressure test equipment (if

installed). If injection lines have been removed or replaced, run
engine several times to 3000 RPM for about 2 minutes.
3) Ensure idle switch is properly adjusted. Pull crankcase
breather hoses off valve cover and air filter and vent to atmosphere.
On Fox, remove suction hose from carbon canister.
4) On all other models, disconnect "T" fitting from carbon
canister at air intake boot. Turn "T" fitting 90 degrees and insert
blank side with .059" (1.5 mm) restrictor into hole in intake air
boot. If vehicle is not equipped with this type of connector, use Plug
(026 133 382D) with .059" (1.5 mm) orifice.
5) On all models, connect an inductive tachometer or Tester
(VW 1367) and Test Lead (VW 1473). See Fig. 3. Remove CO probe
receptacle cap and connect CO meter. Ensure fit is snug to prevent
exhaust leaks. Connect Digital Multimeter (US 1119) with Adapter (VW
1315 A/1) to differential pressure regulator. See Fig. 5.
6) Connect adapter between connector and regulator. Connect
multimeter to adapter and turn switch to "DCA 200 milliamps" range.
7) Check and/or adjust engine idle speed. Check ignition
timing and adjust as required. Read and compare current (4-16
milliamps) and CO values to specifications. Turn engine off.
8) If CO reading is more than 1.2% at current reading of 4-16
milliamps, check for exhaust system leaks, ignition timing, injector
inserts for leaks, and fuel distributor for uneven fuel distribution.
If required, seal injector inserts with sealing compound and tighten
to 15 ft. lbs. (20 N.m.).
9) If current reading is less than 4 milliamps or more than
16 milliamps, adjustment must be made with CO adjustment screw as
follows: remove boot from mixture control unit. Center punch hole in
CO adjusting hole and drill a 3/32" hole to a depth of 5/32". DO NOT
drill completely through as adjustment screw will be damaged.

Fig. 5: Digital Multimeter Hook-up

Courtesy of Volkswagen United States, Inc.

10) Install a 1/8" sheet metal screw and remove plug using
pliers. Start engine and run at idle. Adjust current reading to 10
milliamps by turning CO adjustment screw with Wrench (P 377). Turn
 D - ADJUSTMENTS
Article Text (p. 6)
1989 Volkswagen Golf
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Monday, August 23, 1999 11:45PM

screw clockwise to lower reading, counterclockwise to raise reading.

11) Readjust idle speed if required. Turn engine off. Install
new plug in mixture control unit and seat plug flush with unit. Remove
all test equipment and reconnect all hoses and wiring.

NOTE: Do not push down on adjustment screw and do not accelerate

engine with wrench in place. Remove wrench after each
adjustment and accelerate engine briefly before measuring
current reading. Always adjust from a high to a low reading.

IDLE SPEED & CO LEVEL TABLE

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Application Idle RPM CO Level

Cabriolet ......... 850-1000 ............. ...

Fox ............... 800-1000 ........ 0.5-1.5%
Golf .............. 800-1000 ........ 0.3-1.2%
Golf GT ........... 800-900 ......... 0.3-1.2%
GTI ............... 800-1000 ........ 0.3-1.2%
Jetta ............. 800-1000 ........ 0.3-1.2%
Vanagon ........... 830-930 ......... 0.3-1.2%
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DIGIFANT 2 System
1) Remove the cap from the CO tap tube that comes from the
exhaust manifold and connect an exhaust gas analyzer.Disconnect the
coolant temperature sensor harness connector.
2) Raise the oil dipstick slightly to vent the crankcase).
Disconnect and plug the crankcase ventilation hose, or clamp the hose
tightly to close it off. Be careful that the clamp does not damage the
hose.
3) Start the engine. Briefly raise the engine speed to at
least 2100 RPM, and let it return to idle. Repeat this step four times
to cancel the control unit's hot-start fast idle function.
4) Check idle speed and adjust if necessary. With the
crankcase ventilation plugged and the coolant sensor disconnected,
idle speed should be 800 ñ 50 RPM. At idle the CO reading should be
within the specifications given in Fig. 6.

Fig. 6: Idle Mixture CO Tolerance Chart

Courtesy of Volkswagen United States, Inc.
 D - ADJUSTMENTS
Article Text (p. 7)
1989 Volkswagen Golf
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Monday, August 23, 1999 11:45PM

5) To change the idle mixture CO, remove the anti-tampering

plug in the top of the air flow sensor housing. With the plug removed,
adjust the idle mixture using a 5 mm hex wrench. Adjust the CO idle
mixture to the specification on Fig. 7.

Fig. 7: Idle Mixture CO Specification Chart

Courtesy of Volkswagen United States, Inc.

THROTTLE POSITION SENSOR (TPS)

THROTTLE POSITION SENSOR (TPS) ADJUSTMENT

1) Raise sensor plate to lower edge of air flow sensor (fuel

distributor side) using Tool (US 1348-1). Connect test Adapter (VW
1501) to sensor switch terminal and wiring harness connector.
2) Connect digital multimeter to test adapter leads No. 1 and
2 and switch multimeter to volts scale. Turn ignition switch to "ON"
position. Loosen sensor hold-down screws.
3) Adjust sensor position until it reads 0.2-0.3 volts.
 D - ADJUSTMENTS
Article Text (p. 8)
1989 Volkswagen Golf
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Monday, August 23, 1999 11:45PM

Tighten screws. Lift sensor plate up to stop, voltage reading should

be approximately 7 volts. Secure screws with locking paint.

THROTTLE STOP SCREW

NOTE: Stop screw is set by manufacturer and should not be moved.

Throttle Plate Stop Screw

If basic factory setting has been changed, turn throttle stop
screw counterclockwise until there is a gap between stop and screw.
Turn screw in until it just touches stop. Turn screw 1/2 turn (180
degrees) further. Check and adjust idle speed and CO.

IDLE SWITCH

IDLE SWITCH ADJUSTMENT

Idle Switch (Except Fox)

1) Connect Test Harness (VW 1501) between vehicle harness and
throttle switch lead. Turn ignition on. Connect voltmeter between
terminal No. 1 of test harness and ground. If battery voltage is NOT
present, check voltage supply between terminal no. 2 of test harness
and ground.
2) If battery voltage is NOT present, check and repair
wiring. See WIRING DIAGRAMS at end of this article for wiring color
and terminal numbers. If battery voltage is present, open and slowly
close throttle valve.
3) Check switch-on point of idle switch, using feeler gauge
between throttle lever and idle stop. Switch-on point gap should be .
006-.002" (.15-.05 mm) before idle stop. See Fig. 8. If switch-on
point is incorrect, loosen and adjust idle switch position. Idle
switch is located on underside of throttle valve housing, opposite
idle stop.

Fig. 8: Checking Idle Switch Adjustment

Courtesy of Volkswagen United States, Inc.
 D - ADJUSTMENTS
Article Text (p. 9)
1989 Volkswagen Golf
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Monday, August 23, 1999 11:45PM

END OF ARTICLE