VW Golf, Jetta, Cabriolet Repair Manual 1990-1998

This Chilton repair manual covers 1990-1998 VW Cabrio, Cabriolet, Fox, Golf, GTI and Jetta, all U.S. and Canadian models. A comprehensive how-to service guide for the DIY VW owner.
Book Excerpt: 1990-1998 VW Golf, Jetta, Cabriolet Repair Manual DIESEL ENGINE

TIMING BELT TENSIONER AND SPROCKETS | REMOVAL AND INSTALLATION

1. Before starting work, disable the fuel system by disconnecting the wiring from the fuel cut-off solenoid (see Chapter 4D). Prevent any vehicle movement by applying the parking brake and blocking the rear wheels.
2. To gain access to the components detailed in this Section, refer to Section 6 and remove the auxiliary drive belt(s). TIMING BELT TENSIONER | REMOVAL
   (Refer to illustrations 5.4 and 5.5)
3. With reference to the relevant paragraphs of Sections 2 and 4, set the engine TDC on No. 1 cylinder, and then remove the upper and lower sections of the timing belt outer cover.
4. Loosen the retaining nut at the hub of the tensioner pulley and allow the assembly to rotate counterclockwise, relieving the tension on the timing belt. Remove the nut and recover the washer (see illustration).
5. Slide the tensioner off its mounting stud (see illustration).
6. Wipe the tensioner clean, but do not use solvents that may contaminate the bearings. Spring the tensioner pulley on its hub by hand. Stiff movement or excessive free play is an indication of severe wear; the tensioner is not a serviceable component, and should be replaced.
INSTALLATION
7. Slide the tensioner pulley over the mounting stud.
8. Install the tensioner washer and retaining nut - do not fully tighten the nut at this stage.
9. With reference to Section 4, install and tension the timing belt.
10. Restore the fuel system by reconnecting the fuel cut-off solenoid wiring.
11. Refer to Section 4 and install the timing belt covers.

IGNITION SYSTEM | GASOLINE-ENGINE MODELS

IGNITION SYSTEM SENSORS | REMOVAL AND INSTALLATION

1. Many of the engine management system sensors provide signals for both the fuel injection and ignition systems. Those which are specific to the ignition system are detailed in this Section.
2. Those sensors that are common to both systems are detailed in Chapter 4A or B as applicable. These include the coolant temperature sensor, the inlet air sensor, the air flow/mass meter, the engine speed/TDC sensor, the throttle potentiometer, the idle switch and the intake manifold depression sensor.
KNOCK SENSOR (2.0L ENGINES ONLY)
(Refer to illustration 6.6) REMOVAL
3. Disconnect the battery negative cable and position it away from the terminal.
CAUTION! If the stereo in your vehicle is equipped with an anti-theft system, make sure you have the correct activation code before disconnecting the battery.
4. The knock sensor is located on the front of the cylinder block, below spark plug No 2.
5. Unplug the electrical connector from the sensor.
6. Loosen and withdraw the mounting bolt and lift off the sensor (see illustration).

Subject: 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998 Volkswagen Golf, Jetta, Cabriolet service, maintenance, repair. ISBN-10: 0801991226 | ISBN-13: 9780801991226 | Chilton 70402