ACCELERATOR PEDAL CABLE
| WARNING | Accelerator cable is easily kinked, so handle with care. If accelerator cable is kinked, replace cable. |
Automatic Transmission
Turn ignition off. Remove clip from outer throttle cable notched sleeve. Fully depress throttle to Wide Open Throttle (WOT). Move throttle cable outer sleeve in or out of grommet as necessary until WOT is reached. (Scheme 1)and (Scheme 2). On A/T transmission vehicles, ensure kick-down switch audibly clicks. On all vehicles, reinstall clip onto first completely exposed notch closest to grommet.
Manual Transmission
Turn ignition off. Remove clip from outer throttle cable notched sleeve. Fully depress throttle to Wide Open Throttle (WOT). Move throttle cable outer sleeve in or out of grommet as necessary until WOT is reached. Reinstall clip onto first completely exposed notch closest to grommet. (Scheme 1)
Scheme 1
Scheme 2
THROTTLE VALVE CONTROL MODULE
The Throttle Valve Control (TVC) module includes, throttle drive, angle sensor for throttle drive, Throttle Position (TP) sensor and Closed Throttle Position (CTP) switch. TVC module is mounted on throttle valve assembly and not adjustable. Individual components cannot be replaced or adjusted. If adjustment is necessary, Volkswagen Audi Group (VAG) 1551 scan tool is necessary to perform a "basic setting".
IDLE SPEED & MIXTURE
Note. Idle speed and mixture is electronically controlled by Powertrain Control Module (PCM) and cannot be adjusted.
IGNITION TIMING
Note. Ignition timing is electronically controlled by Powertrain Control Module (PCM) and cannot be adjusted.
VALVE CLEARANCE
| WARNING | After lifters are reinstalled (whether new or used), DO NOT start engine for 30 minutes, as valves may hit pistons. Lifters must be allowed to bleed down before starting engine. Turn crankshaft 2 full revolutions by hand before starting engine to ensure valves do not hit pistons. |
Note. All models use hydraulic valve lifters. No adjustment is necessary.
1.8L
- Irregular valve noise is normal when starting engine. If valve noise is encountered, run engine until normal operating temperature is reached. Increase engine speed to approximately 2500 RPM for 2 minutes. If necessary, test drive vehicle. If irregular valve noise disappears, then returns, replace oil retaining valve. Oil retaining valve is located in oil filter bracket. (Scheme 3) If after replacing oil retaining valve, lifters are still noisy, go to next step.
- To check a suspect valve lifter, remove valve cover and turn crankshaft clockwise until cam lobe of suspect valve lifter is pointing upwards. Using a plastic or wooden dowel, push valve lifter down. DO NOT pry on lifter. Attempt to insert a.008" (.20 mm) feeler gauge between camshaft and lifter. If feeler gauge fits between camshaft and lifter, replace lifter. If feeler gauge does not fit between camshaft and lifter, lifter is okay.
Scheme 3
2.8L
Note. Replace hydraulic valve lifters in complete sets.
- Irregular valve noise is normal when starting engine. If valve noise is encountered, run engine until normal operating temperature is reached. Increase engine speed to approximately 2500 RPM for 2 minutes. If necessary, test drive vehicle. If lifters are still noisy, go to next step.
- Remove valve cover for suspect lifter. Turn crankshaft clockwise until cam lobe of suspect valve lifter is pointing upwards. Using a plastic or wooden dowel, push valve lifter down. DO NOT pry on lifter. Attempt to insert a.008" (.20 mm) feeler gauge between camshaft and lifter. If feeler gauge fits between camshaft and lifter, replace lifter. If feeler gauge does not fit between camshaft and lifter, lifter is okay.
- If irregular valve noise occurs repeatedly on short trips and disappears after extended driving, replace oil check valves. (Scheme 4) To replace oil check valves, remove intake manifold. Remove cover under intake manifold. Replace 2 oil check valves.
