This DIY service, repair and maintenance manual by Haynes, covers 1975-1992 VW Rabbit, Cabriolet, Golf, Jetta, Scirocco, and VW Pickup models, with gasoline engines.
Note: this manual DOES NOT include diesel engine information.
Book Excerpt: 1975-1992 VW Rabbit, Cabriolet, Golf, Scirocco, Jetta, Pickup Repair Manual
TIMING BELT AND SPROCKETS | REMOVAL, INSPECTION AND INSTALLATION
ENGINE ELECTRICAL SYSTEMS
NOTE: This procedure applies to both SOHC and DOHC engines.
- Detach the cable from the negative battery terminal.
- On carburetor-equipped vehicles, remove the air cleaner assembly and air ducts (see Chapter 4)(this step is unnecessary on vehicles with fuel injection).
- Remove the air injection pump drivebelt, if equipped (see Chapter 1).
- Loosen the upper and lower alternator mounting bolts and remove the alternator drivebelt (see Chapter 1).
- Remove the water pump pulley (see Chapter 3).
- Remove the nuts and bolts and detach the timing belt cover (see illustration).
- Loosen the tensioner locknut. To remove tension from the belt, turn the tensioner counterclockwise with a wrench (see illustration). Slide the timing belt off the sprockets.
SPROCKET REMOVAL AND INSTALLATION
(Refer to illustration 6.13)
- The camshaft, intermediate shaft and crankshaft sprockets are aligned with each shaft by a Woodruff key and retained by a center bolt and washer. The following procedure applies to all three sprockets.
- If the factory special tool is available, immobilize the sprocket and loosen the center bolt with a socket and ratchet or breaker bar.
If you don't have the special tool, you can prevent the sprocket from turning by inserting a large drift punch through a hole in the sprocket (see illustration).
- Pull off the sprocket. Don't lose the Woodruff key.
- To install a sprocket, place the Woodruff key in the slot, align the slot in the sprocket bore with the key, push the sprocket onto the shaft, install the bolt and washer and tighten the bolt to the torque listed in this Chapter's Specifications.
CHECKING THE CHARGING SYSTEM
- If a malfunction occurs in the charging circuit, don't automatically assume the alternator is causing the problem. First check the following items:
- Check the drivebelt tension and condition (Chapter 1). Replace it if it's worn or deteriorated.
- Make sure the alternator mounting and adjustment bolts are tight.
- Inspect the alternator wiring harness and the connectors at the alternator and voltage regulator. They must be in good condition and tight.
- Check the fusible link (if equipped) located between the starter solenoid and the alternator. If it's burned, determine the cause, repair the circuit and replace the link (the vehicle won't start and/or the accessories won't work if the fusible link blows). Sometimes a fusible link may look good, but still be bad. If in doubt, remove it and check it for continuity.
- Start the engine and check the alternator for abnormal noises (a shrieking or squealing sound indicates a bad bearing).
- Check the specific gravity of the battery electrolyte. If it's low, charge the battery (doesn't apply to maintenance free batteries).
- Make sure the battery is fully charged (one bad cell in a battery can cause overcharging by the alternator).
- Disconnect the battery cables (negative first, then positive). Inspect the battery posts and the cable clamps for corrosion. Clean them thoroughly if necessary (see Chapter 1). Reconnect the cable to the positive terminal.
Subject: 1975, 1976, 1977, 1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992 VW Rabbit, Cabriolet, Golf, Scirocco, Jetta, Pickup service, maintenance, repair. ISBN-10: 1563920611 | ISBN-13: 9781563920615 | Haynes 96016