Volkswagen Golf/Jetta 2 manual

Distributor - removal, overhaul and refitting
Ignition system - contact breaker type / Distributor - removal, overhaul and refitting


Removal
1 Disconnect the battery earth lead, then remove the distributor cap and screening ring.

2 Disconnect the vacuum hose.

1.05 and 1.3 litre engines 3 The distributor driveshaft is located in the end of the camshaft by an offset centre key and therefore the procedures described in paragraphs 4 and 5 are only necessary for checking purposes, such as when fitting a new distributor.

4 Turn the engine with a spanner on the crankshaft pulley bolt until the rotor arm points to the No. 1 spark plug lead position.

On some models, a TDC groove is provided on the distributor body rim and the rotor arm must align with this. The mark on the crankshaft pulley should be aligned with the TDC pointer with No. 1 piston (timing belt end) at TDC compression (see illustration).

7.4 Crankshaft pulley mark (A) timing mark (B) and TDC mark (C) with timing
7.4 Crankshaft pulley mark (A) timing mark (B) and TDC mark (C) with timing cover removed - 1.3 litre engine

5 Mark the distributor flange and cylinder head in relation to each other, then unscrew the bolts and withdraw the distributor (see illustration).

7.5 Removing the distributor
7.5 Removing the distributor

1.6 and 1.8 litre engines 6 Unscrew and remove the TDC sensor or blanking plug from the top of the gearbox then turn the engine over so that the TDC УOФ mark on the flywheel or driveplate is visible and aligned with the timing pointer. The crankshaft pulley timing notch should be aligned with the TDC arrow mark on the timing case (see illustration). The rotor arm should be pointing to the timing mark on the top rim of the distributor body (see illustration).

7.6a TDC timing marks - 1.6 and 1.8 litre engines
7.6a TDC timing marks - 1.6 and 1.8 litre engines

A Flywheel/driveplate B Crankshaft pulley

7.6b Rotor arm aligned with TDC mark on distributor body
7.6b Rotor arm aligned with TDC mark on distributor body

7 Mark the distributor body in line with the tip of the rotor arm and also mark the distributor body and cylinder block in relation to each other, then unscrew the clamp bolt and withdraw the clamp, followed by the distributor, from the cylinder block. Note by how much the rotor turns clockwise. Remove the distributor body sealing washer which must be renewed.

Overhaul
8 Overhauling of the distributor is similar for all models. The accompanying illustrations show the distributor fitted to 1.05 and 1.3 litre engines.

9 Remove the contact breaker points.

10 On the Bosch distributor, mark the position of the guide pin then remove the bearing plate retaining ring (see illustrations).

7.10a Correct fitted position of bearing plate retaining ring
7.10a Correct fitted position of bearing plate retaining ring

7.10b Removing bearing plate retaining ring
7.10b Removing bearing plate retaining ring

11 Before removing the vacuum unit on the Ducellier distributor, mark the adjustment segment position so that it can be correctly repositioned when reassembling.

12 Extract the circlip securing the vacuum unit arm to the contact breaker plate.

13 Remove the retaining screws, then unhook the arm and withdraw the vacuum unit. Note that the screws may also secure a suppression choke unit to the distributor body.

14 Remove the side screws, noting the location of the earth lead terminal, then remove the contact breaker plate by turning it anti-clockwise to align the lugs with the cut-outs (if applicable).

15 Wipe clean all electrical components.

Clean the distributor body assembly with paraffin then wipe dry.

16 Check all components for wear and damage.

17 Reassembly is a reversal of the dismantling procedure.

18 On the Ducellier distributor, realign the vacuum unit adjuster segment with the mark made when removing it.

19 On the Bosch distributor, locate the retaining ring guide pin as previously marked.

20 Lubricate the centrifugal mechanism and the contact breaker plate with a little multi-purpose grease then adjust the contact breaker points.

Refitting
1.05 and 1.3 litre engines 21 To refit the distributor, reverse the removal procedure and align the timing marks made during removal before tightening the clamp bolts.

1.6 and 1.8 litre engines 22 To refit the distributor, first check that the oil pump drive spigot is correctly positioned with the spigot parallel to the crankshaft. This is visible through the distributor aperture (see illustration). Check that the TDC УOФ mark is still aligned. Set the rotor arm to the position noted, align the distributor body and cylinder block marks and insert the distributor. As the gears mesh, the rotor will turn anti-clockwise and point to the previously made mark. Refit the clamp and tighten the bolt. Reconnect the vacuum hose, and low tension lead or multi-plug (as applicable). Refit the TDC sensor or blanking plug.

7.22 Oil pump drive spigot position prior to refitting distributor
7.22 Oil pump drive spigot position prior to refitting distributor

All models
23 Refit the distributor cap, then reconnect the battery negative terminal .

24 Check and if necessary, adjust the ignition timing.


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