Volkswagen Front Wheel Drive 1974-1989 Repair Guide

Fuel Distributor

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REMOVAL & INSTALLATION



See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Clean any dirt away from the fuel fittings.
  6.  
  7. Mark the fuel lines in the top of the distributor so that you will be able to put them back in their correct positions.
  8.  
  9. Remove the fittings and disconnect the fuel lines from the fuel distributor. Have a rag ready to catch the fuel that escapes.
  10.  



Click image to see an enlarged view

Fig. Fig. 1: The fuel distributor is mounted on top of the airflow sensor

  1. Remove the screws to lift the distributor from the airflow sensor housing.
  2.  

When removing the fuel distributor on CIS engines, be sure the control plunger does not fall out from underneath.

To install:
  1. On CIS-E engines, check the stop screw adjustment if a new fuel distributor is being installed.
  2.  
  3. Install the fuel distributor on the airflow sensor housing with a new O-ring. If the control plunger has been removed, moisten it with gasoline before installing. The small shoulder on the plunger is inserted first. Tighten the screws until snug.
  4.  
  5. Use new sealing washers and connect the fuel lines to the distributor. Torque the smaller fittings to 7 ft. lbs. (10 Nm). and the larger fittings to 15 ft. lbs. (20 Nm).
  6.  
  7. Connect the battery cable.
  8.  

ADJUSTMENT



See Figure 2

These adjustments are only necessary on CIS-E engines.

  1. Use a depth caliper to measure the distance from the shoulder of the gland nut to the stop screw. Distance (a) should be about 0.024 inches (0.6mm).
  2.  
  3. Turn the stop screw in or out as required. Turning the screw in 1 / 4 turn will increase the installed free-play by 0.050 inches. (1.3mm).
  4.  



Click image to see an enlarged view

Fig. Fig. 2: Control plunger stop screw adjustment

  1. Install the fuel distributor.
  2.  
  3. Remove the air inlet boot from the sensor plate and operate the starter for about 10 seconds to build fuel system pressure. The engine will not start.
  4.  
  5. Measure the distance from the top of the airflow sensor housing to the sensor plate at the point nearest the fuel distributor.
  6.  
  7. Use a magnet on the sensor plate bolt to lift the plate until resistance is felt. There should be a minimum of at least some free-play movement to a maximum of 0.074 in. (2mm).
  8.  
  9. If the free-play is not as specified, remove the fuel distributor and check the sensor plate lever basic adjustment. This can be measured with a depth caliper between the fuel distributor contact surface and the roller on the sensor lever. On 4-cylinder models, the specification is approximately 0.748 in. (19mm), on 5-cylinder models it is approximately 0.827 in. (21mm). If adjustment is necessary, remove the mixture adjusting screw plug and adjust as follows:
    1. Center-punch the mixture adjusting screw plug.
    2.  
    3. Drill a 3 / 32 in. (2.5mm) hole approximately 5 / 32 in. (4mm) deep in the center of the plug. It is helpful to apply a small amount of grease to the drill bit to catch the metal shavings.
    4.  
    5. Thread a 1 / 8 in. (3mm) sheet metal screw into the hole.
    6.  
    7. Remove the plug using a pair of pliers.
    8.  
    9. Insert tool P377 or a 3mm Allen wrench into the hole, then adjust the sensor plate lever basic setting until it is within specification. Drive a new mixture adjusting screw plug into the hole.
    10.  

  10.  
  11. If the sensor plate basic adjustment was correct, adjust the free-play with the stop screw on the bottom of the fuel distributor. Turn it clockwise to increase free-play or counterclockwise to decrease free-play. A 1 / 4 turn will change free-play by about 0.050 in. (1.3mm).
  12.  

 
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