Volkswagen Front-Wheel Drive Repair Manual 1974-1989 by Chilton

• VW Golf
• VW Jetta
• VW Rabbit
• VW Scirocco
• VW Pick-up

OIL PAN | REMOVAL AND INSTALLATION
(Refer to illustrations 12.4a and 12.4b)

NOTE: The following procedure is based on the assumption the engine is in the vehicle. If you're working on an engine that's out of the vehicle, mounted on a stand, it's not necessary to use sealant to hold the gasket in place on the engine block. Just turn the engine upside-down.

1. Warm up the engine, and then drain the oil and replace the oil filter (see Chapter 1).



2. Detach the cable from the negative battery terminal.



3. Raise the vehicle and support it securely on jackstands.



4. Remove the bolts securing the oil pan to the engine block (see illustrations).



5. Tap on the pan with a soft-face hammer to break the basket seal, and then detach the oil pan from the engine.



6. Using a gasket scraper, remove all traces of old gasket and/or sealant from the engine block and oil pan. Clean the mating surfaces with lacquer thinner or acetone. Make sure the threaded bolt holes in the block are clean.



7. Clean the oil pan with solvent and dry it thoroughly. Check the gasket flanges for distortion, particularly around the bolt holes. If necessary, place the pan on a block of wood and use a hammer to flatten and restore the gasket surfaces.



8. Attach the new gasket to the engine block with a few dabs of sealant to hold it in place.



9. Apply a 1/8-inch wide bead of RTV sealant to the oil pan gasket surfaces. Continue the bead across the end seals. Make sure the sealant is applied to the inside of the bolt holes.



10. Carefully place the oil pan in position.



11. Install the bolts and tighten them in 1/4-turn increments to the torque listed in this Chapter's Specifications. Start with the bolts closest to the center of the pan and work out in a spiral pattern. Don't overtighten them or leakage may occur.



12. Add oil, run the engine and check for oil leaks.

CLUTCH CABLE | REMOVAL, INSTALLATION AND ADJUSTMENT
(Refer to illustrations 5.2, 5.2, 5.5a and 5.5b)

1. Raise the front of the vehicle and support it securely on jackstands. Apply the parking brake and block the rear wheels so the vehicle can't roll off the stands.


NON-SELF ADJUSTING CLUTCH CABLE


2. Loosen the locknut and back off the adjuster until the cable is loose (see illustration).



3. Lift up the transaxle operating lever to release the cable tension, and then remove the clutch cable clip, pad and retainer and disengage the cable end from the lever (see illustration).


SELF-ADJUSTING CLUTCH CABLE


4. Depress the clutch several times. Compress the self adjuster spring located under the rubber boot at the cable bracket to provide enough slack in the cable so an assistant can detach the cable from the transaxle operating lever.

• Tune-up and routine maintenance
• Engine
• General engine overhaul procedures
• Cooling, heating and air-conditioning systems
• Fuel and exhaust systems
• Engine electrical systems
• Emissions control systems
• Manual transaxle
• Automatic transaxle
• Clutch and drivetrain
• Brakes
• Suspension and steering systems
• Body
• Chassis electrical system
• Wiring diagrams