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HOMESERVICE MANUALSVOLKSWAGEN1982RABBIT SREPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE PERFORMANCEFUEL DELIVERYBOSCH CIS (LAMBDA) SYSTEMTESTINGAIR/FUEL MIXTURE CONTROL (AIR-FLOW SENSOR)
1982 Volkswagen Rabbit S

Air/Fuel Mixture Control (Air-Flow Sensor)

1982 Volkswagen Rabbit SSECTION Air/Fuel Mixture Control (Air-Flow Sensor)
  1. Remove rubber bellows to expose air-flow sensor plate. Disconnect electrical connectors on auxiliary air valve and control pressure regulator, then operate fuel pump for ten seconds to build up control pressure.
    Fig 1: Removing Fuel Distributor Control Plunger
    G09315280Courtesy of AUDI OF AMERICA, LLC

    Use care not to drop control plunger when removing fuel distributor. 

    Fig 2: Cold Engine Control Pressure Test Graphs
    G09315281Courtesy of AUDI OF AMERICA, LLC
  2. Using extreme care not to damage sensor plate, lift sensor plate slowly with magnet or pliers. Constant resistance due to control plunger pressure should be felt throughout range of lift. Release plate slowly, lever and control piston should follow. See Figure.
  3. Lift plate, then return it rapidly to lower position. The piston moves more slowly and should be heard hitting the lever. If not, control piston is sticking.
  4. Remove 3 screws from fuel distributor and lift off of air flow sensor housing. Be careful not to drop control plunger. See Fig 1.
  5. Clean plunger in solvent. Remove any deposits with finger nail; DO NOT use tools. Slide plunger in and out while turning it. If any sticking or binding is felt, replace fuel distributor.
  6. Reinstall fuel distributor. Check air flow sensor plate alignment. Plate should be even with bottom rim or 0.02" (0.5 mm) lower. If not, bend spring clip to correct, or reposition stop pin (tap lightly with punch). See Figure.
  7. Plate should be centered in housing. If not, loosen center screw and align plate with 0.004" (.1 mm) feeler gauge at four points around rim. Apply Loctite to screw and install and tighten.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.