Motor Volkswagen Golf

1.7L 4-CYL & 1.8L 4-CYL

1984 Engines - 1.7L & 1.8L 4-Cylinder

ENGINE IDENTIFICATION

ENGINE IDENTIFICATION

Engine identification number is stamped on machine pad at left side of engine block near ignition distributor.

ENGINE IDENTIFICATION CODES

VALVE CLEARANCE ADJUSTMENT

MEASURING VALVE CLEARANCE

1. Remove valve cover. Turn crankshaft clockwise until both cam lobes point upward for cylinder to be adjusted. After valves are adjusted, continue in firing order sequence 1-3-4-2.

NOTE: For repair procedures not covered in this article, see ENGINE OVERHAUL - GENERAL INFORMATION article in GENERAL INFORMATION section.

Application Engine Code

Jetta, Rabbit & Scirocco

1.7L 4-Cylinder

Carbureted JF

CIS EN

1.8L 4-Cylinder CIS. JH

NOTE: Cold valve clearances are given for initial settings after engine work has been performed. Recheck valve clearance and make final adjustment with engine coolant temperature about 95°F (35°C).

1984 Volkswagen Rabbit

1.7L 4-CYL & 1.8L 4-CYL 1984 Engines - 1.7L & 1.8L 4-Cylinder



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sábado, 02 de agosto de 2014 08:07:50 a.m. © 2011 Mitchell Repair Information Company, LLC.

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sábado, 02 de agosto de 2014 08:07:54 a.m. Page 1 © 2011 Mitchell Repair Information Company, LLC.

Fig. 1: Assembled View of Valve and Camshaft

2. Using feeler gauge, measure valve clearance between cam and follower. If clearance is not as specified, change adjusting disc to adjust valve clearance. See VALVE CLEARANCE SPECIFICATIONS table.

VALVE CLEARANCE SPECIFICATIONS

Application In. (mm)



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ADJUSTING VALVE CLEARANCE

1. To remove adjusting disc, cam follower must be depressed using Valve Spring Compressor (VW 546). Turn cam followers so that grooves are accessible for Disc Removing Pliers (US 4476). Depress cam follower with compressor. Use disc removing pliers to replace adjusting disc.

2. Thickness of adjusting disc is marked on bottom of disc. If measured valve clearance is larger than specifications, use thicker disc. If clearance is less than specification, use thinner disc. Adjusting discs are available in .002" (.05 mm) increments from .118" (3.0 mm) to 1.67" (4.25 mm).

3. To install discs, depress cam followers and slip discs into place. Ensure side of disc with thickness marking is installed down, away from lobe. Repeat procedure until all valves are properly adjusted.

ENGINE, MANIFOLDS, & CYLINDER HEAD

ENGINE R & I

REMOVAL

1. Disconnect battery cables at battery. Loosen fuel filler cap to relieve tank pressure. Remove air intake duct between throttle valve and fuel distributor. Drain engine coolant by removing hose from thermostat flange.

2. Disconnect wiring to radiator fan motor and thermo time switch. Remove radiator assembly with fan motor and shroud. On vehicles with air conditioning, remove air conditioner compressor and bracket to side of engine compartment.

3. On all models, disconnect and position aside all wiring and vacuum lines to engine and fuel injection components. Remove pre-heat duct. Remove injectors with fuel lines connected and place to side. Have container ready to catch leaking fuel in case system is

Intake

Hot .008-.012 (.20-.30)

Cold .006-.010 (.15-.25)

Exhaust

Hot .016-.020 (.40-.50)

Cold .014-.018 (.35-.45)

NOTE: When cylinder head repair has been performed, valve clearance must be checked and adjusted after 1000 miles of usage.



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still under pressure.

4. Remove fuel lines for cold start valve and warm-up regulator. Disconnect remaining fuel, coolant, and emission control lines and position out of way. Disconnect and remove accelerator linkage from engine.

5. Disconnect speedometer cable and ground cable from transmission. Remove selector cable from bracket on A/T models. Detach clutch cable from the clutch operating lever on M/T models. On all models, remove upper starter motor bolt.

6. Disconnect starter wires and back-up light switch. Raise vehicle. Remove exhaust flex-pipe nuts. On M/T models, remove shifter relay lever from shift linkage at relay shaft. On all models, remove the starter. Disconnect drive axles from transmission flanges.

7. Remove horn and place out of the way. Remove engine front mount. Remove axle nuts. Disconnect lower ball joints from strut assemblies. Remove drive axles while pulling wheel and strut assembly away from vehicle.

8. Reconnect ball joints. Remove complete rear engine mount. Remove right front wheel. Attach lifting device to engine and raise slightly. On M/T models, remove relay shaft and gearshift lever rod, and selector rod.

9. On all models, remove bolts holding side mounts to body and lower engine/transmission assembly to the dolly. Raise vehicle to clear engine and remove assembly from beneath vehicle.

INSTALLATION

1. Reverse removal procedures using caution to observe all tightening specifications. Engine/transmission assembly must be aligned as follows: move assembly side to side until rear mount is straight (front-to-rear). Move assembly forward and back until left and right mounts are centered in brackets.

2. Tighten right mount, left mount, and rear mount bolts. Center rubber cone of front mount by moving cup. Tighten cup-to-body bolts. Check and adjust shift linkage on M/T models. See TRANSMISSION SERVICING article.

3. Check and adjust exhaust system alignment if necessary. Fill cooling system and make sure that cooling fan cycles properly.

CAUTION: DO NOT allow weight of vehicle to rest on wheels unless outer CV joint axle stub is installed with nut tightened. (Bolt, nut, and large washers may also be used to hold hub bearing together.) Damage to hub bearings will occur if stub axle and nut are not in place.



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CYLINDER HEAD & MANIFOLDS R & I

REMOVAL

1. Disconnect intake air boot at throttle valve housing. Remove radiator cap. Remove thermostat and housing at water pump. Drain cooling system.

2. Remove camshaft drive belt. Remove injectors from intake manifold, leaving hoses attached. Disconnect all hoses, cables and wires attached to throttle valve housing and intake air distributor. Disconnect exhaust pipe.

3. Remove any screws, bolts or clips attaching air conditioning components to cylinder head (if equipped). Remove upper alternator mounting bolt and adjusting bracket. Disconnect all remaining coolant hoses. Disconnect temperature gauge wire.

4. Remove spark plug wires and spark plugs. Remove wire from oil pressure sending unit. Remove valve cover. Remove head bolts in reverse order of installation. Remove cylinder head.

INSTALLATION

To install, reverse removal procedure. Make sure head gasket is positioned with "OBEN" mark facing up. Tighten 12-point head bolts in 3 stages using correct sequence. See Fig. 2 . First step is to 29 ft. lbs (40 N.m). Second step is to 43 ft. lbs. (60 N.m). Third step is 180° (1/2 turn) further in 1 movement. (Two 90° movements are acceptable).

Fig. 2: Cylinder Head Tightening Sequence

NOTE: Loosen in reverse order.



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CAMSHAFT

TIMING BELT R & I

REMOVAL

Remove alternator belt, water pump pulley, and upper and lower drive belt covers. If equipped, remove air conditioning compressor drive belt. Loosen belt tensioner, and work belt off sprockets toward front of engine.

Fig. 3: Intermediate Shaft Alignment

NOTE: Sprockets DO NOT have to be removed to replace camshaft drive belt.



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INSTALLATION

1. Rotate camshaft sprocket until timing mark on camshaft sprocket is lined up with top surface of valve cover mounting flange on spark plug side of head. Rotate crankshaft and intermediate shaft until timing mark on intermediate shaft sprocket aligns with "V" notch on crankshaft pulley.

2. Use care not to move any sprocket. Fit belt on bottom sprocket first and then at top. There should be no slack between sprockets. Tighten tensioner so belt can just be twisted 90° halfway between camshaft and intermediate sprockets. Tighten adjuster lock nut and reverse removal procedure for remaining components.

Fig. 4: Camshaft Timing Marks (All But 16 Valve)

NOTE: Rotate intermediate shaft and crankshaft to align marks.



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Fig. 5: Crankshaft Timing Marks On Vibration Damper (16 Valve)

CAMSHAFT R & I

REMOVAL

1. Remove camshaft cover. Loosen and remove bearing caps in following sequence: 5, 1, and 3. Then loosen bearing caps 2 and 4 diagonally. Bearing caps are numbered front to rear.

2. Check camshaft end play. Remove camshaft and cam followers, keeping followers in order for reassembly. Install camshaft using only bearing caps 1 and 5. Fit dial indicator so tip of gauge touches front of camshaft. Pry camshaft back and forth. Reading should not exceed .006" (.15 mm). If end play is beyond limits, replace either camshaft or cylinder



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head.

3. Check camshaft runout. Mount camshaft in lathe or "V" blocks. Set dial indicator so pin is against center journal of camshaft. Turn camshaft and record runout range. Runout must not exceed .0004" (.010 mm). Replace camshaft if runout is excessive.

4. Inspect camshaft lobes for wear. Worn lobes usually indicate lack of lubrication. Check engine oiling passages to make sure they are not restricted. If worn, replace camshafts and adjusting discs.

5. Inspect cam followers for signs of seizure or lack of lubrication. If any aluminum particles from head are found on cam followers, replace followers. Cylinder head must be replaced if any follower bores are worn or excessively rough.

INSTALLATION

1. Lightly lube cam follower bores, then fit followers in their original bores. Install adjusting discs. Place camshaft on cylinder head. Loosely attach No. 2 and No. 4 bearing caps.

2. Gradually tighten caps. Fit No. 5 and No. 3 bearing caps. Install new oil seal in front of camshaft. Install No. 1 bearing cap. Make sure all caps are torqued to proper specifications.

VALVE TIMING

1. With timing belt removed as previously described, rotate crankshaft and intermediate shaft until index mark (punch mark) on intermediate shaft is positioned in "V" notch on crankshaft pulley. See Fig. 3 .

2. This is TDC for No. 1 cylinder. Turn camshaft until timing mark on rear of camshaft sprocket is in line with top of valve cover gasket. See Fig. 6 . Both lobes for No. 1 cylinder should be pointing upward. Replace timing belt and adjust tension. Recheck timing marks.



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Fig. 6: Camshaft Sprocket Positioning

VALVES

VALVE SPRINGS R & I

REMOVAL (HEAD INSTALLED)

With camshaft and tappets removed, turn crankshaft until piston of cylinder being worked on is

NOTE: Align dot on sprocket with cylinder head flange.

NOTE: Although normal maintenance on valve system is performed with head removed, it is possible to replace stem seals, keepers, retainers or broken springs with cylinder head installed.



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at BDC. Apply line pressure of at least 85 psi through spark plug hole adapter to keep valves seated. Compress spring with Spring Compressor (VW 541) and remove valve keepers. Remove and replace damaged or worn parts.

REMOVAL (HEAD REMOVED)

With camshaft and tappets removed, use compressor (VW 541) to depress retainer and remove keepers. Take out retainer and springs.

INSTALLATION

Before installation, check springs on spring tester and inspect for cracks or distortion. To install, reverse removal procedure. When installing springs, make sure closely spaced coils of outer springs are against spring seats.

VALVE STEM OIL SEALS

With tappet, adjuster pad, keepers, springs, and spring seats removed, extract valve stem oil seal. When installing new seal, position protective plastic sleeve on valve stem. Lubricate seal, and use Seal Installer (10-204) to push seal onto valve guide.

VALVE ARRANGEMENT

E-I-E-I-I-E-I-E (Starting at gear end).

PISTONS, PINS, & RINGS

OIL PAN R & I

REMOVAL & INSTALLATION

1. Drain oil, remove bolts and remove oil pan. Remove nuts holding engine mounts on subframe and bolts holding subframe to body. Pull subframe downward to separate engine mounts and body.

2. Drain oil, remove mounting bolts and remove oil pan. To install, reverse removal procedure. Make sure gasket surfaces are clean before installing new gaskets.

PISTON & ROD ASSEMBLY R & I

REMOVAL

NOTE: Piston and rod assemblies can be removed with engine in vehicle.



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1. Mark cylinder number on crown of each piston. If necessary, mark arrows pointing toward front of block on piston crowns. Remove rod cap bolts and push piston out top of cylinder. Use wooden hammer handle for this operation.

2. If a ridge at top of cylinder prevents piston removal, use a ridge reamer to cut down the ridge. DO NOT force piston out of cylinder. Mark connecting rods and bearing caps for proper reinstallation.

INSTALLATION

1. Turn crankshaft so No. 1 journal is at BDC. Install piston connecting rod assembly until ring compressor contacts block. Use a wood hammer handle to push piston into cylinder. Install No. 4 piston and rod assembly.

2. Ensure tabs on bearing halves engage notch in rod and cap. Install and tighten caps on rods 1 and 4. Turn crankshaft 180° and install No. 2 and 3 rod assemblies and rod caps.

PISTON PINS R & I

REMOVAL

Remove pin circlips. Press out pin and remove piston from rod. For installation purposes, note direction piston is fitted to rod.

INSTALLATION

1. Check pin fit in each piston. Piston pin must be thumb-push fit in piston. If correct fit is not obtained, replace both pin and piston.

2. Check pin fit in connecting rod. Wear limit is .0016" (.040 mm). Re-bush connecting rod and hone bushing to obtain correct clearance.

FITTING PISTONS

1. Measure cylinder at 3 points: 3/8" (10 mm) from top and bottom, and at center of bore. Take measurements in line with, and at 90° to thrust face. Maximum cylinder taper or out-of-round is .0016" (.040 mm) beyond standard dimensions. If excessive, cylinder re-boring and oversize pistons are necessary.

NOTE: If pin is too tight, heat piston to approximately 140°F (60°C) in an oil bath.



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Fig. 7: Codes Stamped on Piston Head

Fig. 8: Piston Ring Installation Word "TOP" must face piston crown.



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2. Measure pistons at .63" (16.0 mm) from bottom of piston skirt (measuring 90° to pin bore). Combining this measurement with measurement of corresponding cylinder bore, note piston-to-cylinder clearance. If this exceeds .0028" (.070 mm), oversize pistons must be installed.

3. Place rings squarely in cylinder bore about .6" (15 mm) down from top edge and measure end gap. Install rings on piston and measure side clearance. Position ring gaps 120° offset to each other (start with oil ring gap directly to the rear). Ensure stamp mark "TOP" on rings is facing upward.

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS

MAIN & CONNECTING ROD BEARINGS

1. Push crankshaft toward one end and measure crankshaft end play at No. 3 (thrust) bearing. Main bearing caps are stamped "1" to "5" (front to rear), and must be returned to original positions upon reassembly. Measure end play (side play) of connecting rods.

2. Remove all bearing caps and check bearing clearance using Plastigage. Measure crankshaft journals with a micrometer to determine journal out-of-round and taper. The maximum allowable wear is .0012" (.030 mm).

3. Install main bearing inserts with oil groove in the engine block, making sure anti-rotation tabs engage in saddle notches. Lubricate new bearings, place crankshaft in block, and install lower main shells and caps in proper order.

REAR MAIN BEARING OIL SEAL R & I

NOTE: When checking clearance of connecting rod bearings on 1.8L engines, only tighten bolts to 25 ft. lbs. (35 N.m).

NOTE: Rear main bearing oil seal may be replaced with engine in vehicle. Transmission and flywheel must be removed.



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Fig. 9: Using Special Tool to Install Rear Main Oil Seal

REMOVAL

Insert a large screwdriver between crankshaft flywheel flange and inside lip of oil seal. Pry out old seal.

INSTALLATION

Install Seal Guide Sleeve (2003/2A or equivalent) over crankshaft flange. Start new seal over guide sleeve, and into recess in seal carrier. Remove guide sleeve and bolt Seal Press Plate (2003/1) to flywheel mounting flange. Tighten bolts evenly to bring seal flush with carrier.

FRONT MAIN BEARING AND INTERMEDIATE SHAFT OIL SEAL R & I



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REMOVAL

Remove camshaft belt. Remove crankshaft sprocket. Pry seal from seal carrier, being careful not to damage carrier. Use Seal Remover (10-219) to remove seal.

INSTALLATION

Use Seal Installer (10-203), to press in new seal until flush with seal carrier. Remove installer and use aluminum part of tool to press seal in until recessed .08" (2.0 mm) in seal carrier.

ENGINE OILING

ENGINE OILING SYSTEM

Oiling system is a pressure feed type. Gear-type oil pump lifts oil from pan and pressure feeds it to crankshaft journals, camshaft bearings, and intermediate shaft. Remainder of engine receives splash lubrication or is covered by oil mist.

CRANKCASE CAPACITY

Capacity is 4.2 quarts (4.7 quarts with filter change).

OIL FILTER

Replaceable spin-on type.

NORMAL OIL PRESSURE

Minimum of 28 psi (1.97 kg/cm2 ) with engine at normal operating temperature.

OIL PUMP R & I

REMOVAL

Remove oil pan. Remove pump mounting bolts. Remove oil pump, leaving pick-up tube attached. Separate pick-up tube from pump.

INSPECTION

NOTE: Procedure is same for intermediate shaft oil seal except that intermediate shaft sprocket must be removed. Only press new seal in until flush with seal carrier.



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Check oil pump gear backlash. Clearance should be between .002-.008" (.05-.20 mm). If specification is exceeded, replace gears or pump. Measure oil pump gear end play. If end play exceeds .006" (.15 mm), replace the pump.

INSTALLATION

To install, reverse removal procedure. Make sure all mating surfaces are clean before installing gaskets. Oil pump drive shaft must align with distributor drive gear.

ENGINE COOLING

WATER PUMP R & I

The front portion of water pump (shaft, seals, bearing, and housing) can be replaced separately. To do this, camshaft drive belt and sprockets must be removed. To avoid removing drive belt, remove water pump as an assembly.

REMOVAL

Drain coolant with engine cool. Remove alternator belt and alternator. Disconnect hoses from water pump and remove bolt holding camshaft drive belt cover to water pump. Remove water pump bolts and pump assembly.

INSTALLATION

To install, reverse removal procedure and make sure to use new "O" ring in recess in pump mounting flange. DO NOT use sealer between water pump mounting flange and engine block.

VALVE GUIDE SERVICING

1. Clean valve guides before making measurements. To measure guide, attach dial indicator with bracket to mounting surface of cylinder head. Insert a new valve until end of stem is flush with end of valve guide.

2. Rock valve head against dial indicator tip and check amount of rock recorded. Maximum allowable rock is .039" (1.0 mm) for intake valves and .051" (1.30 mm) for exhaust valves.

3. Use press and Adaptor (10-206) to remove and install valve guides. To remove guides, press out from camshaft side of head.

4. Coat new valve guides with engine oil. Press new guides into cold head from camshaft side. Make sure shoulder of guide meets firmly with top of cylinder head. Ream guides to uniform inside diameter.



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TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

ENGINE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

GENERAL SPECIFICATIONS

NOTE: DO NOT use more than 1 ton pressure once guide shoulder is seated or shoulder may break.

Application Ft. Lbs. (N.m)

Timing Belt Tensioner Lock Nut 33 (45)

Intermediate Sprocket Bolt (1) 59 (80)

Crankshaft Sprocket Bolt 59 (80)

Water Pump Pulley Bolts 15 (20)

Crankshaft Pulley Bolts 15 (20)

Drive Plate-to-Crankshaft Bolts

Without Shoulder 55 (75)

With Shoulder 72 (100)

Connecting Rod Cap Bolts

1.7L 33 (45)

1.8L (2) (3)

22 (30)

Main Bearing Cap Bolts 48 (65)

Cylinder Head Bolts See Text

Ball Joint Nuts 36 (49)

Stub Axle Nuts 173 (235)

Manifold-to-Cylinder Head Bolts 18 (25)

Water Pump Bolts 15 (20)

(1) Use Loctite.

(2) Stretch bolts.

(3) Plus 90° (1/4 Turn).


1.7L



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PSTON/PIN/RING SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

Displacement

Cu. In. 105

Liters 1.7

Fuel System (1) CIS Fuel Inj.

HP @ RPM (2) 74 @ 5000

Torque Ft. @ RPM 90 @ 3000

Compr. Ratio 8.2:1

Bore 3.13 (79.5)

Stroke 3.40 (86.4)

1.8L

Displacement

Cu. In. 109

Liters 1.8

Fuel System CIS Fuel Inj.

HP @ RPM 90 @ 5500

Torque Ft. @ RPM 100 @ 3000

Compr. Ratio 8.5:1

Bore 3.19 (81.0)

Stroke 3.40 (86.4)

(1) Some 1.7L Rabbit models use Carter TYF 1-Bbl. carburetor.

(2) HP @ RPM is 65 @ 5000 on Rabbit models with carburetor.


Piston Clearance (1) .0012 (.03)

Pins

Piston Fit (2)

Rod Fit Push Fit

Rings

Nos. 1 & 2

End Gap (3) .012-.018 (.30-.45)

Side Clearance (4) .0008-.0020 (.02-.05)



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BEARING SPECIFICATIONS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECIFICATIONS

No. 3 (Oil Ring)

End Gap (3) .010-.016 (.25-.40)

Side Clearance (4) .0008-.0020 (.02-.05)

(1) Wear limit .027" (.07 mm).

(2) Light press fit at 140°F (60°C).

(3) Wear limit .039" (1 mm).

(4) Wear limit .006" (.15 mm).


Standard Size

Main Bearings

Journal Diameter (1) 2.124-2.125 (53.96-

53.98)

Clearance (2) .001-.003 (.03-.07)

Connecting Rod Bearings

Journal Diameter (1) (4) 1.880-1.881 (47.76-

47.78)

Clearance (5) .0011-.0034 (.028-

.088)

Side Play .014 (.38)

1st U/Size

Main Bearings Journal Diameter 2.114-2.115 (53.71-53.73)

Connecting Rod Bearings Journal Diameter (4) 1.871-1.872 (47.51-47.53)

2nd U/Size


Connecting Rod Bearings Journal Diameter (4) 1.860-1.861 (47.26-

47.28)

3rd U/Size




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VALVE SPECIFICATIONS

VALVE SPECIFICATIONS

Connecting Rod Bearings Journal Diameter (4) 1.851-1.852 (47.01-

47.03)

Thrust Bearing No. 3

Crankshaft End Play (3) .003-.007 (.07-.17)

(1) Maximum out-of-round for standard or undersize crankshaft journals is .001" (.03 mm).

(2) Wear limit .007" (.17 mm).

(3) Wear limit .010" (.25 mm).

(4) Rod journal diameter on 1.7L is .071" (1.8 mm) smaller.

(5) Wear limit is .005" (.12 mm).


1.7L

Intake

Head Diameter 1.338 (33.9)

Face Angle 45°

Seat Angle 45°

Seat Width .079 (2.01)

Stem Diameter .314 (7.97)

Stem Clearance n/a

Valve Lift n/a

Exhaust


Face Angle 45°

Seat Angle 45°


Stem Diameter .313 (7.95)

Stem Clearance n/a

Valve Lift n/a

1.8L

Intake



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Face Angle 45°

Seat Angle 45°


Stem Diameter .314 Min. (7.97)

Stem Clearance n/a

Valve Lift n/a

Exhaust


Face Angle 45°

Seat Angle 45°


Stem Diameter .313 Min. (7.95)

Stem Clearance n/a

Valve Lift n/a



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