Haynes VW Rabbit 1974 thru 1992 Automotive Repair Manual 1563920611, 9781563920615

Citation preview

GOLF, JETTA, SCIROCCO, PICK-Ul?

1975 thru 1992 Ail

\

gasoline engine models

Automotive Repair Manual

Digitized by the Internet Archive in

2014

https://archive.org/details/vwautomotiverepaOOIegg_0

vw Automotive Repair

Manual by AK Legg, Larry Warren, Robert Maddox and John H Haynes Member of

the Guild of Motoring Writers

Models covered: Volkswagen Rabbit, Golf, Jetta, Scirocco and Pick-up models with a gasoline engine

All

1975 through 1992

Haynes Publishing Group Sparkford Nr Yeovil

Somerset BA22 7JJ England

Haynes North America, 861 Lawrence Drive Newbury Park California

91320 USA

Inc

Acknowledgements

We

are grateful for the help and cooperation of Volkswagen of Inc., for assistance with technical information, certain illustrations and vehicle photos. The Champion Spark Plug Company supplied the illustrations of various spark plug conditions.

America,

©

Haynes Publishing Group 1990, 1991, 1993 With permission from J.H. Haynes & Co, Ltd.

A book

in

Printed

the

in

Haynes Automotive Repair Manual Series

the

USA

reserved. No part of this book may be reproduced or transmitted In any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright

All rights

holder.

ISBN

1

56392 061

Library of

1

Congress Catalog Card Number 93-77334 made

While every attempt

Is

manual is correct, no

liability

lishers for loss,

to ensure that the information In this can be accepted by the authors or pubdamage or Injury caused by any errors in, or omis-

sions from, the Information given.

Contents IntroHiiptnrv

MUUUl Hub

n^np^ g

IlldllUcll

IntrnHi irtinn tn thp \/nlk5^\

To check voltage supply and the ground for the ignition control unit, unplug the electrical connector from the ignition control unit and check for voltage between terminals 2 (-) and 4 10.5

VISE

{+)

Use a pjn punch

9.5

5-7

systems

to drive out the roll pin that

- when you turn on the

ignition, there should be voltage present (CIS, CIS-E and Digifant II systems)

secures the

drive gear to the shaft

Using a pin punch, drive out the

5

roll

pin securing the

gear

to the shaft

(see illustration).

Remove the gear and withdraw the distributor shaft from the housing. Remove the nylon spacer (if used) from the distributor shaft. Clean all the parts and inspect them for wear and damage (especially

6 ,

7 8

the shaft, the shaft bushings

in

the housing, the base plate and the points

and cam).

Check the disthbutor cap and rotor as described in Chapter 1 Check the fit of the distributor shaft in the housing. If there's excessive side movement, try to obtain replacement bushings or a new housing. Make sure the base plate turns freely. 1 1 Reassembly is the reverse of disassembly, with the following notes: 9 1

10.8 To check the voltage supply and the ground for the Hall sender, unplug the electrical connector from the Hall sender at the distributor and check for voltage between the outer terminals of the connector - when

0

Lubricate the distributor shaft with a

a)

use too much

light film of

engine

oil.

you turn on the

Don't

(CIS,

oil.

should be voltage present CIS-E and Digifant II systems)

ignition, there

When

b)

installing the distributor shaft, make sure the nylon spacer used) contacts the housing bushing. Use a new roll pin when installing the drive gear on the distributor

3

shaft.

voltmeter or low-current

(if

c)

d)

Install

new

points as described

in

Chapter

is

1

Check the operation of the vacuum and centrifugal advance mech-

e)

To perform the following

tests, you'll

need

to

use a high-impedance

LED test light. The sequence of the following tests

need to stick with the sequence as component.

important. You'll

late the faulty

it's

presented to

iso-

anisms.

Cliecl
-

(D

CD

I-

c D.

in

u)

|— Stoplight switch

I

light

42

43

44

47

45 46

R adiator

Stop '

fan"

-Interior

light—

48

— Clock

49 50

52

51

Cigarette "

lighter

53

54

55 56

57

58

59

60

61

62

i

|

'

Wiring diagram for 1979 Rabbit Deluxe

-Emergency flasher

[—Turn

signals-j

1

< a.

X8

LOAD REDUCTION

>-

3

RELAY XII

*i9

16 Y/BK

CO

[]S. []s

[1S.[]S,[]S3[]S.

3

ffce

16

16

Y

W/BK

16

W

20

16 16

W

BL/W

20

16

Y

R

20

20

CYC

GWG

20

20

20 GY|G

16

BK/Y GY/G

R

GWBK

GVBK

20 GY/R

20

GVR

St.

! 12

p.

[iool

L

bk/yI

DIM/ FLSH

SW 54oA

J'

^58b

'"5 LIGHT

IXINST

PNL

SWITCH

LITES GY/BL

SW/ DIMMER

20

GY

ETib

Lie

TU

PLT

SIDE

LITES

MKR

PKG

LITE LF

LITE .1 t

/ \

3

HIGH

i BEAM (X)IND

^

($)($)

LITE

SIDE

SIDE I

W

20 T

20 MKR 4_GY

PKG

TAIL LITE

-GY_

LITE

9 LITE

RF

MKR

^LITE

RF

I

0

SIDE

MKR

TAIL LITE

LITE

-R

-RR

(i

LR

NOTE:

63

64

65

66

Headlights

67

—

All

68

wire size* American Wire

69

70

71

72

Light switch

-

Gauge

20 BR

73

7il 74

1

I

Wiring diagram for 1979 Rabbit Deluxe

7S 75

7A 76

77 7 7

70 78

79

BO 80

81

License plate/Tail/Sidemarlter lights

82

81 83

L

12-42

RADIO

-Fresh air fan —\

—

Oefogger

Wiring diagram for 1979 Rabbit Deluxe

Key

for wiring

Current track

Description Alternator

3

Alternator charging light

24 53

Ashtray

light

Auxiliary air regulator

6

Back-up Back-up

35-36 34

lights

switch Ballast resistance wire Battery light

Cigarette lighter Cigarette lighter light

Clock Cold start valve Control pressure regulator Coolant temperature light Coolant temperature switch 32 Door switch (right) Door switch/buzzer (left) EGR elapsed mileage switch (inoperative

EGR

in

Fresh

air

14 5

29

44 45-46 29-30

Canada)

flasher relay flasher switch

flasher indicator light

fan

fan speed control resistors Fresh air fan switch

Fresh Fuel

air

gauge

Fuel level sensor Fuel pump Fuel

pump

light

Ignition coil

Ignition distributor

Instrument panel lights Instrument panel light switch/dimmer Intermittent wiper relay

License plate lights Light switch

Load reduction relay

light

switch

1

15-19 12-13 56-58 72

23 23 24-28 27

light, left

77

light, right

80 42 42 87 89 88-89

Radiator fan Radiator fan thermal switch

Rear Rear Rear Seat

window defogger window defogger indicator window defogger switch

light

belt/starter lock-out

relay

Seat belt switch, left Seat belt switch, right Seat belt warning light Shift console light (auto.trans) Side marker lights, rear Spark plug suppressors

29 78-83

Stop-light switch

Tachometer

23

Tail light, left

79 82

Starter

Stop-lights

Tail light, right

1

1

I

front c

—

T H G

K

— — — — — — -

90-93 94-98 Current track

1 1

-

m

-

p

T2a

— -

T2b

-

T2c T2d T2e

-

1

T1e T fT 1

1

1

1

1

T1 1

1

1

1

n

l-»

1

T1 Tij

1

1

1

1

1

77

left

Behind instrument panel Behind instrument panel Behind instrument panel Behind instrument panel Behind instrument panel Behind instrument panel Behind instrument panel In luggage compartment.

1

1

1

1

In

In

-

T4 T14

-

5

1

5

82

luggage compartment.

87

rear

Behind instrument panel In engine compartment,

C\ "7

front left

59,77

In

y

/

engine compartment.

Behind Behind Behind Behind Behind

instrument instrument instrument instrument instrument

right of steering

T3

1

47 85 27

79

rear

front right

T2f

80 yy 2y

luggage compartment.

left

T2g

6-7 2

engine compartment.

In

front right 1

1

panel panel panel panel

61,80 84,86 16 16 15

panel.

column

49

Behind instrument panel. right of steering

column

engine compartment On rear of instrument panel In

48,52 61,64,66,80 20,21,23,24,25 29,47,56,67

Ground connectors

® ® @ (Q)

@

-

From battery

-

From

-

On

steering

column support

-

On

steering

column support

-

In

15-20 16 16 25

12-13 12-13 8-10 40-41 38-39

Sparkplugs

1

31

Oil

Parking Parking

63-64 68-69 54 67 36 37

70-71

pressure switch pressure warning light

light

3

20 99

Wire connectors T — Cable adaptor, engine compartment Tila — In engine compartment Tib - In engine compartment.

left

43-44 93 74-75 70-73

Interior lights

temperature gauge Parking brake indicator Parking brake indicator

59-62 53 25 25 73

right rear

1

Ignition/starter switch

Oil

Current track 14-15

Voltage regulator Voltage stabilizer Windshield washer pump Windshield wiper motor Windshield wiper switch

T1

5-10

Fuses SI -SI 5, on fuse/relay panel (under dash) S20 (on fuel pump relay) Headlights Headlight dimmer/flasher switch

Oil

29 51-53 49-56 55 86 84 84-86 20 33 7

relay

Heater lever light High beam indicator Horn Horn button

Description Thermal time switch Turn signal lights Turn signal switch Turn signal indicator light Trunk signal indicator light Trunk light

1

Canada)

light (inoperative in

Emergency Emergency Emergency

1

1

4 48 52 47

12

diagrams on pages 12-44 through 12-48

to

body

alternator to engine

luggage compartment, rear

On dome

light

Middle body member, rear

© @ 0 @ @

-

In

engine compartment, front

-

In

engine compartment, front right

-

On

steering

-

On

tail

light cover, left

-

On

tail

light cover, right

column

left

Wiring diagram for 1979 Scirocco models

12-45

r

15

16

17 18

19

20

21

22

Ignition/Safety/Gauges

Wiring diagram for

1

979 Scirocco models

12-46

2

3

38

39

40

42

41

|— Stoplight switch

I

"light

43

44

*

fan

47

45 46

Ra diator

Stop

-Interior light

48

— — Clock—

49 50

52

51

Cigarette

Wiring diagram for

1

ighter

53

54

55 56

57

58

59

60

61

62

i

|

'

-Emergency flasher

979 Scirocco models

1— Turn

signals-]

12-47

Z xs

LOAD REDUCTION

>

RELAY

3

Kll

P4

[IS'

20

20

crc

CVG

s

16

16

Y/BK

T

W/BK

20

16

W

Bl/W

16 16

W

T

16

S

-

< (A

Fresh

— Defogger

air fan -|

Wiring diagram for

1

979 Scirocco models

11

Key

i

diagrams on pages 12-50 through 12-54

for wiring

Current track

Description

Current track

Description

Alternator Alternator charging light

3

Turn signal switch Turn Qinnal inHir^itnr

Ashtray

24 53

light

Auxiliary air regulator

6

Back-up Back-up

35-36 34

lights

switch Ballast resistance wire light

1

4 48 52 14

Battery Cigarette lighter Cigarette lighter light Cold start valve Control pressure regulator

5

29 32 44 45-46 29-30

Coolant temperature light Coolant temperature switch Door switch (right) Door switch/buzzer (left) EGR elapsed mileage switch (inoperative

EGR

in

Canada)

light (inoperative in

Emergency Emergency Emergency

Canada)

flasher relay

flasher switch flasher indicator light

Fresh air fan Fresh air fan speed control resistors Fresh air fan switch Fuel gauge Fuel level sensor Fuel

Fuel

pump pump

front

Tic

-

Tid Tie

Tik

-

Til

-

7

Tim -

63-66 68-69

Headlights Headlight dimmer/flasher switch Heater lever light High beam indicator light

Horn Horn button

54 67 36 37

Ignition coil

1

Ignition/starter switch

15-19 12-13 56-58

Ignition distributor

mstrument panel

lights

Instrument panel

light

switch/dimmer

Tig Tlh Tli Tij

License plate lights Light switch Load reduction relay Oil pressure switch Oil pressure warning light Parking brake indicator light

Starter

Stop-lights Stop-light switch Tail light, left

Tail light, right

Thermal time switch Turn signal lights

77

left

Behind instrument panel Behind instrument panel Behind fuse/relay panel Behind instrument panel Behind instrument panel Behind instrument panel Behind instrument panel In luggage compartment. In

-

T2b

-

T2c

-

T2e

— -

-

rear

front

z.\

T2g

light

23 24-28 27 77 80 42 42 100 87 89 88-89 1 5-20 25 29 76-81 78-83 12-13 12-13 8-10 40-41 38-39 79 82 14-15 59-62

87 97 59,77

left

r

61 ,80

lyii

Behind instrument panel RphinH in

>-

5 UJ a:

s.

UJ

C3-

[]s.

s.[]

CT 06

0^5

18

BU/BR

R/Y

WEW

'G9

TI

ft

20

1RW

W

R

s

16

18

16

BK tC\3

18

18

BK

BI^G

18

BltW

18

18

BICW

Blt/W

18

18 BK.'0

BKX;

lie.

RAD FAN

Wiring Color Code -BK -BR -CL

Black

Blown Clear

u R/BK

-R -V -G

RADIATORr FAN L

Light Green

-LT.G

THERMAL R

Blue

-BL

Violet

-V

STOP

STOP

Gray

-Gv

LITE

LITE

White

-W

•L

•R

Red Yellow

Green

NOTE:

All

TURN

SWITCH

wire tizei American Wire

,SIGS

I LF

LR

18 BR

18

an

1^ 39

40

4>

I— Stoplight switch

I

"light

42

44

43

47

45 46

Ra diator

Stop '

RR

A

fi

Gauge DM K

38

FR

A

fan~

Interior

Wiring diagram for

1

light—

|

48

49 50

— Clock— — J

ijghter

51

52

53

54

55 56

57

Emergency flasher

58

59

|j® 60

1— Turn

61

62

signals-]

980 Rabbit Deluxe and Pick-up Truck LX models

A

Wiring diagram for

1

980 Rabbit Deluxe and Pick-up Truck LX models

1

Key

for wiring

diagrams on pages 12-62 through 12-67

Description

Current track

Description

Current track

Alternator Alternator charging light Air conditioner control lever light

2-3

Stop-light, right

31

Stop-light,

60

Stop-light, right

Ashtray

61

Stop-light switch

94 68 67 64 26 13-14

light

Auxiliary air regulator

Back-up Back-up Back-up

light, left

40

light, right

41

light

39

switch

Ballast resistor

9

Ballast resistor, fresh air fan

112 4

Battery Cigarette lighter Cigarette lighter light Clock Clock illumination light Cold start valve

63 62 57 58 5

1

Coolant over-temperature indicator 29 Coolant temperature indicator Coolant temperature sensor Cut-out relay (load reduction) Door switch (right) Door switch/buzzer (left) EGR elapsed mileage indicator

EGR

Emergency Emergency Emergency Fog

27 36 81-82 55 53-54

34-35 33

indicator light

pump

Electric fuel

light

Fresh Fresh

flasher relay

flasher switch

connector fan

air

fan switch

gauge gauge sender

Fuel

pump

S31

fuel

101 1 1 3

112-113 25 38 18-20

unit

relay

Fuses S 1 -S

1

5,

pump

on fuse/relay panel fuse on fuel/pump

Headlight, high

light

beam beam

Headlight, high Headlight, low left Headlight, low right

left

101

right

97-99 98-100 95-96

Headlight dimmer switch High beam indicator light Horn, double tone Horn button Horn relay, double tone

41-42 44 43-44

Ignition coil

9

Ignition distributor

8-12 21-24 81-83

103

Ignition/starter switch

Instrument panel lights Instrument panel light switch/dimfner Interior lighting

86 56

License plate lights Light switch

88-89 83-86

Luggage compartment Oil

Oil

87 37

light

pressure switch pressure warning light

59

45 65-66 48 47 90 93 104

Parking light, left Parking light, right Radiator fan Radiator fan thermoswitch

window defogger window defogger indicator window defogger switch belt buzzer switch, left

warning light belt warning relay marker light, rear Sparkplugs Spark plug connector belt

Starter Stop-light,

left

25

Warm

16

air

regulator

Windshield washer motor/pump Windshield washer/wiper intermittent

72

73 74 75 32 78 3

1

1

1

107-108

relay

Windshield wiper intermittent selector switch Windshield wiper motor

108-1 10

106-107

Wire connectors -

T Tia

Tib Tic Tid Tie Tif

Tig Tlh Tij

Tik

-

Til Ti m

Tin Tlo Tip Tir

TIs Tit

Tlu T2a T2b T2c T2d T2e T2f

T2g T2h T3a T3b T4 T14

-

-

^ -

-

Cable adaptor behind instrument panel Single, behind instrument panel Single, behind instrument panel Single,.

engine compartment,

left

headlight

Single, near relay panel Single, behind instrument panel Single, behind instrument panel Single, behind instrument panel Single, luggage

compartment, rear left Single, behind instrument panel Single, left engine compartment, near main brake cylinder Single, behind instrument panel Single, luggage compartment, rear left Single, behind instrument panel Single, behind instrument panel Single, behind instrument panel Single, behind instrument panel Single, near left stop-light Single, near right stop-light Single, behind instrument panel Double, engine compartment, near double horn Double, behind instrument panel Double, near main brake cylinder Double, engine compartment, near right headlight Double, engine compartment fixed to coolant hose Double, behind instrument panel Double, under drivers seat Double, behind instrument panel Three-point, engine compartment, near left headlight Three-point, behind instrument panel Four-point, behind instrument panel Fourteen-point, instrument panel

30 46

temperature indicator Oil temperature indicator light Oil temperature sensor Parking brake switch Parking brake indicator light Parking brake light switch Oil

Rear Rear Rear Seat Seat Seat Side

*

Turn signal light, front left Turn signal light, rear left Turn signal light, front right Turn signal light, rear right Turn signal indicator light Turn signal switch Voltage regulator Voltage regulator

-

105 102

relay

Glove compartment

9

80 77-79 76-81

flasher light

Fuel

Fuel

1

air

Tachometer Thermal time switch

7

1

left

104 69 light

Ground connectors

® ®

7

70 52

49 50-52 92-95 10-12 10-12 5_5 91

@ @

-

Battery to body

-

Alternator to engine

-

Fuse/relay panel

-

Steering column support

-

Rear baggage compartment

-

Rear roof middle support

-

From

-

Steering column

-

Tail light cover, left

-

Tail light cover, right

isolated tubing, front harness

12-62

2

3

— Charging

4

1

S

Starting

6

7

1

9

e

10

Ignition

Wiring diagram for

1

II

13

—

1

13

14

Cold Start

980/81 Scirocco and

17

16

IS

1

—

I

IB

19

Fuel

20

22

21

1

.

23

Ign. /Starter

980 Jetta models (except

24

Sw

California)

25

26 1

27

28

Gauges/

29

|

•1

2 >-

3 CO

3 f!c>

|TC12

ffFlJ

At5

MAI?

BFie

|AI1

I

I

I

04

20

20

rfc9

20

U/W H/K

30

31

32

-Indicator Lights

33

34

35

36

37

38

— Sending Units—

[-

39

—

40

41

42

Bacl(-up Lighits/Horn-

43

44

4S

-Oil

46

Temp

Indicator

Wiring diagram for 1980/81 Scirocco and 1980 Jetta models (except California)

—

_l

12-64

<


CY/«

IK^

20

IKA;

I' INT LITE

St.,

AC 20

IK/G

DOOR M/w SW 20

i°

20

CLOCK

«/w ;ui/M LITE

20

CNTRL

cyti

LEVER

ii

1

20

LITE -

3 CO

3

97

98

99

100

101

102

103

104

UHeadlite Dimmer/Headlites—L Rad. Fan

L '

'

Wiring diagram for

—

1

107

Glove CompI Lite

109

no

Windshield Wiper/Washer

^

980/81 Scirocco and

108

1

980 Jetta models (except

—

111

112

n3

—[-Fresh Air Fan-|

California)

12- 67

_J1

LU

z


CO

D

18

20

18

16

'6

16

16

.16

16

20

16

Or/«

«/Y

T

W

T/M

T

W/*K

W

•l/w

R/BK

18

G

T

18 18 G/v BK/CY

181C G/BK

O/"

20

BM3T G/Y

G

BB/BK

18

18

16

C/B

G/fi

W/ll

"

J

...t

COOl TEMP

V

BLWR

16

16

i;

s

16

^'

^^^^ 3.1,

AIR

WIND I

WIPCR

SNSR

SW

11

'6 RESIST-

Si i

If

20

20

HOIT

I

-I

r4H SIDE

Th»-bm

UTf 6 M*KR -R

l/TES

H

HOLT

\lND

R

\llTe

I

RAO FAN

Ml

WIND WIPER

T WIND

TfRSH

A WIPER

^ AIR

1

8

PUMP

FAN

MTR

20

97

—

98

99

Tall Lights

100

101

102

103

Headlights

104

106

Radiator Fan

107

108

109

111

Windshield Wiper/Washer

112

113

tU

115

Fresh Air Fan

Wiring diagram for 1980 Rabbit Convertible (except California) and 1980 Canadian Rabbit Deluxe models

12-68

Key

for wiring

diagrams on pages 12-69 through 12-74

^1 irron't'

Altprnatnr Altprn^tor pK^^rninn linht

Ashtray

light

Aiiyili^rv AAU A IllOiy

Jiir Clll

Bark-un

linht*?

r(^niilptrir iC^UlaLk/l

I—*

1

1

V_/

1

1

1

v_/

1

1

1

1

1

1

rhprk rplav i^ioy \^

Riilh Lj L-/

1

1

(N

1

r^inprpttP linhtpr f^inJirpttp linhtpr linht

Clock f^nlH Qtart

tm

\/?iI\/p

nn n rocci ro rtin tnr V^UIILIUI (Jit^ooUIC IC;LJUICllUI 1

i

1

1

1

1

1

1

1

1

1

1

1

1

1

1

4

Load reduction relay

36 39 84 54 68 29

Oil

pressure switch pressure warning light

Oil

Oxvnpn «;pn