Haynes VW Scirocco Owners Workshop Manual 1850105138, 9781850105138

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Haynes Publishing Group Sparkford Nr Yeovil Somerset BA22 7JJ England

Haynes Publications, Inc

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cc

aaa

C0000 00061.

noes

“Wiig

861 Lawrence Drive Newbury Park

California 91320 USA

air. sac

Restoring and Preserving our

|

Motoring Heritage

i

Few people ¢can have had the luck to realise their dreams to quites It the same extent and in such a remarkable fashion as John Haynes," Founder and Chairman of the Haynes Publishing Group. Since 1965 his unique approach to workshop manual publishing has*:

proved so successful that millions of Haynes Manuals are now sold

every year throughout the world, covering literally thousands of olla makes and models of cars, vans and motorcycles.

= ==.

A continuing passion for cars and motoring led to the founding in 1 ast

of a Charitable Trust dedicated to the restoration and preservation\ of) our motoring heritage. To inaugurate the new Museum, John Hayness donated virtually his entire private collection of 52 cars. |

Now with an unrivalled international collection of over 210 veteran,,j vintage and classic cars and motorcycles, the Haynes Motor Museum in) : Somerset is well on the way to becoming one of the most interesting)} Motor Museums in the world.

A 70 seat video cinema, a cafe and an extensive motoring bookshop,), together with a specially constructed one kilometre motor circuit, make a? visit to the Haynes Motor Museum a truly unforgettable experience. Every vehicle in the museum is preserved in as near as possible mint! condition and each car is run every six months on the motor circuit.

Acknowledgements Thanks are due to the Champion Sparking Plug Company Limited who supplied the illustrations showing spark plug conditions, to Holt Lloyd Limited who supplied the illustrations showing bodywork repair, and to Duckhams Oils who provided lubrication data. Thanks are also due to Sykes-Pickavant, who supplied some of the workshop tools and all those people at Sparkford who helped in the production of this Manual.

© Haynes Publishing Group 1991 A book in the Haynes Owners Workshop Printed Somerset

by J. H.

Haynes

& Co.

Ltd.

Manual

Sparkford,

Enjoy the picnic area set amongst the rolling Somerset hills. Peer#

through the William Morris workshop windows at cars being restored, ,

and browse through the extensive displays of fascinating motoring) memorabilia. From the 1903 Oldsmobile through such classics as an MG Midget to) the mighty 'E' Type Jaguar, Lamborghini, Ferrari Berlinetta Boxer, and} Graham Hill's Lola Cosworth, there is something for everyone, young and old alike, at this Somerset Museum.

Series Nr Yeovil,

BA22 7JJ, England

All rights 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 holder.

ISBN 1 85010 513 8 British Library Cataloguing in Publication Data Coomber, lan. 7943VW Scirocco ‘82 to ‘90 owners workshop manual 2nd ed. 1. Cars. Maintenance & repair |. Title Il. VW owners workshop manual Ill. Series

629.28722 ISBN 1-85010-513-8 Whilst every care is taken to ensure that the information in this manual is correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

Haynes Motor Museum Situated mid-way between London and Museum is located just off the A303 at the Haynes Manual) and is open to the round, except Christmas Day and Boxing

Penzance, the Haynes Motor Sparkford, Somerset (home of public 7 days a week all year | Day.

Contents Page

Acknowledgements

2

About this manual

5

Introduction to the Volkswagen Scirocco

5

General dimensions, weights and capacities

6

Jacking and towing

7

ee ee eee ee ee ee

eee

Sener

Buying spare parts and vehicle identification numbers

Se

eS

ee

ee

ee

ee

eee

ee

8

ee

ae eee

General repair procedures

lL eee

;

9

Tools and working facilities

10

Safety first!

;

Routine maintenance Recommended

:

lubricants and fluids

5 id

13 17

Conversion factors

18

Fault diagnosis

19

Chapter 1 Engine

22

Chapter 2 Cooling system

54

Chapter 3 Fuel and exhaust systems (also see Chapter

Chapter 4 Ignition system (a/so see Chapter

12, page 322)

61

12, page 322)

113

Chapter 5 Clutch Chapter 6 Manual

125 gearbox and automatic transmission

Chapter 7 Driveshafts (a/so see Chapter

(a/so see Chapter

12, page 322)

174

Chapter 9 Suspension and steering (also see Chapter

Chapter 10 Bodywork and fittings (a/so see Chapter Chapter 11 Electrical system (a/so see Chaptér

Index

133 167

Chapter 8 Braking system

Chapter 12 Supplement:

12, page 322)

12, page 322)

12, page 322)

12, page 322

Revisions and information

on later models

191

216 245

wd

332

MWA

0990119§ 15

About

this manual

/ts aim The aim of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done (even should you choose to get it done by a garage), provide information on routine maintenance and servicing, and give a logical course of action and diagnosis when random faults occur. However, it is hoped that you will use the manual by tackling the work yourself. On simpler jobs it may even be quicker than booking the car into a garage and going there twice, to leave and collect it. Perhaps most important, a lot of money can be saved by avoiding the costs a garage must charge to cover its labour and overheads. The manual has drawings and descriptions to show the function of the various components so that their layout can be understood. Then the tasks are described and photographed in a step-by-step sequence so that even a novice can do the work.

[ts arrangement The manual is divided into eleven Chapters, each covering a logical sub-division of the vehicle. The Chapters are each divided into Sections, numbered with single figures, eg 5; and the Sections into paragraphs. (or sub-sections), with decimal numbers following on from the Section they are in, eg 5.1, 5.2, 5.3 etc. It is freely illustrated, especially in those parts where there is a detailed sequence of operations to be carried out. There are two forms

of illustration: figures and photographs. The figures are numbered in sequence with decimal numbers, according to their position in the Chapter — eg Fig. 6.4 is the fourth drawing/illustration in Chapter 6. Photographs carry the same number (either individually or in related groups) as the Section or sub-section to which they relate. There is an alphabetical index at the back of the manual as well as a contents list at the front. Each Chapter is also preceded by its own individual contents list. References to the ‘left’ or ‘right’ of the vehicle are in the sense of a person in the driver's seat facing forwards. Unless otherwise stated, nuts and bolts are removed by turning anti-clockwise, and tightened by turning clockwise. Vehicle manufacturers continually make changes to specifications and recommendations, and these, when notified, are incorporated into our manuals at the earliest opportunity. This manual is not a direct reproduction of the vehicle manufacturers’ data, and its publication should not be taken as implying any technical approval by the vehicle manufacturers or importers. Whilst every care is taken to ensure that the information in this manual is correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

Introduction to the Volkswagen The new Volkswagen Scirocco range of models was introduced in February of 1982, a revised body and trim features being the main visual dfference to the earlier range of models. The engine and transmission are mounted transversely at the front, and drive is through the front wheels. Detailed improvements have

been

made

to

the

Scirocco mechanics

economy. As with earlier models,

to

the new

improve

range

the

power

is proving

output

and

popular, giving

economy, reliability, comfort and, if previous models can be used as a yardstick, long life.

General dimensions, weights and capacities Dimensions OVeErailematli,

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Se

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Le

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S

BN —— 4 SX |

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—)

starter bush

Saye Ss

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:

Plug Dowel

sleeve

Sleeve

Drive

flange

oil seal

Oe

Bearing

housing

Input shaft Sileeal

Fig. 6.22 The bearing housing and associated components (Sec 9)

150

Chapter 6 Manual gearbox and automatic transmission

in Y, ai

Oil

filler

plug

By

SAS SSS SASNS

rs

w BW

ZmlZ

|J__sth speed gear

|

NYLLZL. 25x

Gearbox

housing

Fig. 6.23 Sectional view showing the additional bearing and its location on the output shaft on 1.8 fuel injection variants (Sec 9)

Fig. 6.25 Synchro-ring wear (Sec 10) a = more than 0.5 mm

(0.02 in)

the housing is supported when fitting the new seals. Smear the new seal lips with a multi-purpose grease.

Fig. 6.24 Output shaft needle bearing fitted depth — 1.8 fuel injection variants (Sec 9) 4

The oil seals should always be renewed.

Before removing the old

ones, note their orientation and fitting depths. Drive or carefully lever

out the old seals. Ensure that the housings are clean before pressing or driving the new seals into position. Also ensure that the underside of

5 The input and output shaft needle bearing units can be removed for renewal using a suitable withdrawal puller. Take care not to damage the housing. Ensure that the housing is clean before fitting the new bearing. Drive or press it into position using a‘suitable tube drift. 6 The end cover retaining the clutch release components is separate

from the main

casings and

is dealt with in Chapter

5. On 1.8 fuel

injection variants, the end cover also incorporates an additional needle

bearing for the output shaft. This bearing is secured in position by a self-tapping special screw and the fitting depth of the bearing is

Chapter 6 Manual

gearbox and automatic transmission

a a a critical. If renewing this bearing, remove the retaining screw then withdraw the bearing as previously described in paragraph 5. When fitting the new bearing drive or press it into position so that the fitted depth is as shown (Figs. 6.23 and 6.24). Position the drift on the

lettered end of the bearing when fitting it.

10.3 Checking a synchro-ring for wear

eS

es

ee

151

10 Synchro units (020 4- and 5-speed) — servicing 1 Unless the transmission is the victim of neglect or misuse, or has covered very high mileages, the synchro-hub assemblies do not normally need renewing, if they do, they must be renewed as a complete assembly. It is not practical to fit an inner hub or outer sleeve alone — even if you could buy one. 2 When synchro baulk rings are being renewed, it is advisable to fit new sliding keys and retaining springs in the hubs, as this will ensure that full advantage is taken of the new, unworn cut-outs in the rings. 3 Check the synchro-rings by assembling them on their respective gears and using a feeler gauge to measure the gap between the dogs. If it is less than 0.5 mm (0.02 in), renew the rings (photo). 4 To dismantle the synchro unit, press the hub out of the sleeve and remove the keys and springs. 5 1st/2nd synchro: The ist gear synchro-ring fitted during manufacture differs from other synchro-rings in having a 110° tooth angle (instead of 120° as with other synchros) and every fourth hub tooth is missing (see Fig. 6.26). When refitting this synchro-ring ensure that it is only fitted to 1st gear. When the synchro-ring is renewed, a ring with full teeth will be supplied. 6 When assembling the hub and sleeve, the groove on the end face of the hub must face 1st gear, the assembly position is otherwise unimportant. 7 Assemble the keys and springs in the manner described in paragraph 11. : 8 3rd/4th synchro: When assembling the hub and sleeve the chamfer on the hub inner splines must face towards 3rd gear with the outer groove on the end face towards 4th gear. The assembly position is otherwise unimportant. 9 Assemble the keys and springs in the -manner described in paragraph 11. 10 5th gear synchro: Ensure when fitting that the chamfer on the splines of the synchro sleeve faces towards 5th gear. An exploded view of the 5th gear synchro unit is shown in Fig. 6.29. 11 When assembling the synchro units, fit the springs with the angled ends located in the keys and note that the springs point in opposite directions with the angled ends 120° apart engaged in the hollow key (Figs. 6.30 and 6.31). On the 5th gear synchro-hub unit, the keys must be fitted with their long side downwards (towards the synchro-ring end) and the springs are both fitted from beneath (120° offset). Engage spring with angled end into the hollow key (Fig. 6.32).

Fig. 6.26 1st gear synchronizer ring — early type with teeth missing and 110° tooth angle (Sec 10)

Fig. 6.27 1st/2nd gear synchro-hub-to-sleeve orientation showing groove location (white or black arrow) (Sec 10)

Fig. 6.28 3rd/4th gear synchro-hub-to-sleeve orientation showing groove (white arrow) towards 4th gear, and chamfer

(black arrow) towards

3rd gear (Sec 10)

Chapter 6 Manual

152

gearbox and automatic transmission

Screw

B o—

Dished washer Retaining ring

Operating sleeve

=] _—

Synchronizer hub

SRA

=

|

Fig. 6.30 1st/2nd synchro-hub

Fu

yy)

g

ss

Q

v

Locking

unit showing spring locations

(Sec 10)

key

7

a

Y, e I errr eel Fig. 6.29 5th gear synchro-hub assembly (Sec 10)

ade,

components

Fig. 6.32 Sectional view showing the 5th gear synchro-hub and sleeve orientation (Sec 10) 3

Using a puller, pull the inner races and rollers from each side of the

differential. 4 Wipe clean

nr

al

Fig. 6.31 3rd/4th synchro-hub

unit showing

spring locations

(Sec 10)

ne 11

es.)

Differential J

ant >J A

C

st

(020 4- and

unit

tho (hie

Aiffercntic Gi

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15 br

15 br

ie

® Jo 52

53

54

55

Cigarette lighter

56

57

58

59

60

61

62

63

64

Lighting

Fig. 11.38 Wiring diagram for all models from 1985 (continued)

65

66

67

68

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gn/ge

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104

105

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i oy

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Yes

ow

10

BFE (TEAPEP ABP WEDDED SP SED FL LP LEP EW ia FLT AAT

100

101

102

nn wiper and washer

103

106

107

108

OS

Os

111

112

Coolant shortage indicator Fig. 11.38 Wiring diagram for all models from 1985 (continued)

113

114

115

116

Dual tone horn