Volkswagen Golf (1997) manual

VW Golf & Jetta Service and Repair Manual Models covered VW Golf & Jetta Mk 2 models with petrol engines, including fuel injection, catalytic converter, Formel E, 16-valve and special/limited edition models 1043 cc, 1272 cc, 1595 cc & 1781 cc Covers mechanical features of Van. Does not cover Convertible, Rallye, Caddy, diesel engine, 4 [...]

LIVING WITH YOUR VOLKSW AGEN GOLF OR JETT A Introduction Page 0•4 Safety First! Page 0•5 Roadside Repairs Introduction Page 0•6 If your car won’t start Page 0•6 Jump starting Page 0•7 Wheel changing Page 0•8 Identifying leaks Page 0•9 Towing Page 0•9 W eekly Checks Introduction Page 0•10 Underbonnet check points Page 0•10 Engi[...]

REP AIRS & OVERHAUL Engine and Associated Systems Engine repair procedures - 1.05 and 1.3 litre - pre August 1985 Page 2A•1 Engine repair procedures - 1.05 and 1.3 litre - post August 1985 Page 2B•1 Engine repair procedures - 1.6 and 1.8 litre 8 valve Page 2C•1 Engine repair procedures - 1.8 litre 16 valve Page 2D•1 Cooling, heating and[...]

The Mk. II Volkswagen Golf and Jetta range of models was introduced in March 1984, revised body and trim features being the main visual difference to the earlier range of models. The engine/transmission is mounted transversely at the front of the vehicle, drive being to the front wheels. Detailed improvements have been made throughout the years of [...]

Safety first! 0•5 W orking on your car can be dangerous. This page shows just some of the potential risks and hazards, with the aim of cr eating a safety-conscious attitude. General hazar ds Scalding • Don’t r emove the radiator or expansion tank cap while the engine is hot. • Engine oil, automatic transmission fluid or power steering fluid[...]

0•6 Roadside r epairs The following pages are intended to help in dealing with common roadside emergencies and breakdowns. You will find more detailed fault finding information at the back of the manual, and repair information in the main chapters. If your car won’ t start and the starter motor doesn’ t tur n M If it’s a model with automati[...]

Roadside r epairs 0•7 When jump-starting a car using a booster battery , observe the following precautions: 4 Before connecting the booster battery , make sure that the ignition is switched of f. 4 Ensure that all electrical equipment (lights, heater , wipers, etc) is switched of f. 4 Make sure that the booster battery is the same voltage as the [...]

0•8 Roadside r epairs The spare wheels and tools are stored in the luggage compartment. Release the retaining strap and lift out the jack and tools from the centre of the wheel. Finally ... M Remove the wheel chocks. M Stow the jack and tools in the correct locations in the car. M Check the tyre pressure on the wheel just fitted. If it is low, or[...]

Roadside r epairs 0•9 When all else fails, you may find yourself having to get a tow home – or of course you may be helping somebody else. Long-distance recovery should only be done by a garage or breakdown service. For shorter distances, DIY towing using another car is easy enough, but observe the following points: M Use a proper tow-rope – [...]

0•10 W eekly checks There are some very simple checks which need only take a few minutes to carry out, but which could save you a lot of inconvenience and expense. These "Weekly checks" require no great skill or special tools, and the small amount of time they take to perform could prove to be very well spent, for example; M Keeping an [...]

W eekly checks 0•11 Engine oil level Before you start 4 Make sure that your car is on level ground. 4 Check the oil level before the car is driven, or at least 5 minutes after the engine has been switched off. The correct oil Modern engines place great demands on their oil. It is very important that the correct oil for your car is used (See “Lu[...]

0•12 W eekly checks Brake fluid level Warning: l Brake fluid can harm your eyes and damage painted surfaces, so use extreme caution when handling and pouring it. l Do not use fluid that has been standing open for some time, as it absorbs moisture from the air, which can cause a dangerous loss of braking effectiveness. Safety First! l If the reser[...]

W eekly checks 0•13 Screenwash additives not only keep the winscreen clean during foul weather, they also prevent the washer system freezing in cold weather - which is when you are likely to need it most. Don’t top up using plain water as the screenwash will become too diluted, and will freeze during cold weather. On no account use coolant anti[...]

0•14 W eekly checks T yr e condition and pr essur e It is very important that tyres are in good condition, and at the correct pressure - having a tyre failure at any speed is highly dangerous. Tyre wear is influenced by driving style - harsh braking and acceleration, or fast cornering, will all produce more rapid tyre wear. As a general rule, the[...]

W eekly checks 0•15 Battery Caution: Before carrying out any work on the vehicle battery, read the precautions given in "Safety first" at the start of this manual. 4 Make sure that the battery tray is in good condition, and that the clamp is tight. Corrosion on the tray, retaining clamp and the battery itself can be removed with a solut[...]

0•16 Lubricants and fluids Lubricants and fluids Component or system Lubricant or fluid Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multigrade engine oil to viscosity SAE 15W/50 or 20W/50 Duckhams QXR, QS, Hypergrade Plus or Hypergrade Cooling system . . . . . . . . . . . . . . . . . . . . . . Ethylene-glycol based antifree[...]

Capacities and tyr e pr essur es 0•17 Component or system Capacity Engine: 1.05 & 1.3 litre: rocker-finger type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 litres with filter change 2.5 litres without filter change hydraulic tappet type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 lit[...]

0•18 Notes[...]

1081 VW Golf & Jetta 1 Chapter 1 Routine maintenance and servicing Air cleaner element renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Air conditioning system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Alternator, power steering pump and air conditioner compressor drivebelt(s) check . . . . . [...]

1081 VW Golf & Jetta 2B Chapter 2 Part B: Engine r epair pr ocedur es - 1.05 and 1.3 litr e post August 1985 The following information is a revision of, or supplementary to, that contained in Part A of this Chapter General Code: 1.05 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HZ 1.3 litre[...]

Lubrication system Pump gear teeth backlash: New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm Wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm Pump gear teeth axial play (wear limit) . . . . . . . . . . . . . . . . . . . . [...]

4 Camshaft - removal 3 1 Unscrew the nuts and bolts from the valve cover and remove the cover together with the gasket and reinforcement strips. 2 Turn the engine until the indentation in the camshaft sprocket appears in the TDC hole in the timing cover and the notch in the crankshaft pulley is aligned with the TDC pointer on the front of the oil p[...]

18 With the seals removed, the lower spring seats can also be lifted out for cleaning. Press the new seals onto the ends of the valve guides. 6 Timing belt and sprockets - removal 3 As from August 1986, the crankshaft sprocket incorporates a lug for engagement with the groove in the crankshaft, replacing the Woodruff key arrangement described in Pa[...]

9 Oil pump - refitting 3 Refitting is a reversal of removal, but bear in mind the following points: a) Use new gaskets on all components. b) Lubricate all new parts liberally with clean engine oil. c) If the small plug in the front cover is at all damaged, renew it. d) Fit a new crankshaft oil seal to the cover. The oil seal can be prised out and a[...]

3 If they have been removed, refit the oil pressure switches, using new copper sealing washers (see illustration) . 4 Refit the thermostat housing, using a new O- ring (see illustration) . 5 Refit the coolant hoses, ensuring that they are connected up in the correct position (see illustration) . 6 Lubricate the fuel pump plunger with clean engine o[...]

guide the cylinder head into position but this can be done using suitable sized rods inserted in two cylinder head bolt holes. 15 Install the cylinder head bolts. Refer to Part A of this Chapter for the tightening sequence but use the torque figures and stages given in the Specifications of this Chapter. 16 It is not necessary to retighten the bolt[...]

7 Press the tappet down using a wooden or plastic wedge (see illustration) . 8 If free travel of the tappet exceeds that specified, the tappet must be renewed. 13 Engine - adjustments after major overhaul 2 If the valve tappets have been renewed, it is essential that no attempt to restart the engine is made for a minimum period of 30 minutes after [...]

1081 VW Golf & Jeta 2A Chapter 2 Part A: Engine r epair pr ocedur es - 1.05 and 1.3 litr e pr e August 1985 General Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four-cylinder in-line, water cooled, overhead camshaft Code: 1.05 litre . . . . . . . . . . . . . . . . . . . . . . . . .[...]

Crankshaft Main journal: Standard diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.0 mm Undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.75, 53.50 and 53.25 mm Crankpin: Standard diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

1.3 litre: Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3° BTDC Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38° ABDC Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41° BBDC Exhaust[...]

block, connected to the air cleaner by a rubber hose. Vacuum from the air cleaner provides a partial vacuum in the crankcase and the piston blow-by gases are drawn through the oil separator and into the engine combustion chambers. 2 Major operations possible with engine in vehicle The following operations can be carried out without having to remove[...]

difficulty is experienced, it may be necessary to heat up the coupling with a blowlamp whilst observing the necessary fire precautions. Note that once removed this screw should be renewed. 19 Note its orientation then withdraw the shift rod coupling. 20 Unbolt the exhaust steady bracket from the downpipe and clutch housing/starter motor. 21 Detach [...]

3 Because the rear bearing of the starter armature is in the bellhousing, it is necessary to remove the starter before separating the engine and gearbox. If not already removed when unbolting the starter motor, also detach the exhaust pipe support bracket (see illustration) . 4 Detach the coolant pipe at its flange on the rear side of the coolant p[...]

9 Cylinder head - removal 3 1 If the engine is still in the vehicle, first carry out the following operations: a) Disconnect the battery negative lead b) Remove the air cleaner and fuel pump c) Drain the cooling system and remove the top hose and thermostat d) Remove the distributor and spark plugs e) Remove the inlet and exhaust manifolds. If nece[...]

10 Camshaft - removal 3 1 If the engine is still in the vehicle, first carry out the following operations: a) Disconnect the battery negative lead b) Remove the air cleaner and fuel pump c) Remove the distributor and spark plugs 2 If the cylinder head is still fitted to the engine, first carry out the procedure described in paragraphs 3 to 6 inclus[...]

11 Cylinder head - dismantling and overhaul 3 Dismantling 1 Remove the cylinder head and camshaft, as described in the previous Sections. 2 Using a valve spring compressor, compress each valve spring in turn until the split collets can be removed. Release the compressor and remove the retainers and springs (see illustrations) . If the retainers are[...]

13 If possible, compare the length of the valve springs with new ones and renew them as a set if any are shorter. 14 If the engine is still in the vehicle, clean the piston crowns and cylinder bore upper edges but make sure that no carbon drops between the pistons and bores. To do this, locate two of the pistons at the top of their bores and seal o[...]

14 Support the housing and drive out the oil seal (see illustration) . 15 Clean the recess in the housing. 16 Smear a little clean engine oil on the lip and outer edge of the new seal then tap it into the housing using a block of wood (see illustration) . 17 Clean the mating faces then refit the housing, together with a new gasket, and tighten the [...]

17 Pistons and connecting rods - removal 3 1 Remove the cylinder head. 2 Remove the sump. 3 Unbolt and remove the pick-up tube and strainer from the oil pump and cylinder block. Remove the flange gasket. 4 Using a feeler blade, check that the connecting rod big-end endfloat on each crankpin is within the specified limits (see illustration) . If not[...]

21 Crankshaft and bearings - examination and renovation 5 1 Examine the bearing surfaces of the crankshaft for scratches or scoring. Using a micrometer, check each journal and crankpin for ovality. Where this is found to be in excess of 0.17 mm, the crankshaft will have to be reground and undersize bearings fitted. 2 Crankshaft regrinding should be[...]

4 Clean the components in paraffin and wipe dry, then examine them for wear and damage. If evident, renew the oil pump complete but if in good order, reassemble the pump in reverse order and tighten the screws and plug. 25 Flywheel - examination and renovation 4 1 A damaged flywheel must be renewed. 2 Inspect the starter ring teeth. If these are ch[...]

29 Crankshaft and main bearings - refitting 3 1 Clean the backs of the bearing shells and the bearing recesses in the cylinder block and main bearing caps. 2 Press the main bearing shells into the cylinder block and caps and oil them liberally (see illustration) . 3 Where thrustwashers are being refitted (instead of a shouldered type No 3 main bear[...]

5 Locate a new gasket on the flange face then fit the pick-up tube and strainer. Insert the bolts and tighten them to the specified torque. 6 Refit the sump, timing belt and sprocket. 32 Sump - refitting 3 1 If applicable (ie. the engine has been dismantled), refit the crankshaft rear oil seal and housing. 2 Clean the mating faces of the sump and c[...]

8 Adjust the valve clearances. 9 Turn the camshaft so that the indentation in the sprocket is pointing downwards and in line with the pointer on the timing cover plate (see illustration) . 10 Turn the crankshaft a quarter of a turn clockwise so that the notch in the crankshaft pulley is aligned with the TDC pointer on the front of the oil pump. 11 [...]

37 Timing belt and sprockets - refitting 3 1 Fit the Woodruff key in the crankshaft and tap the sprocket into position . 2 Insert the bolt and tighten it to the specified torque while holding the crankshaft stationary with a lever in the starter ring gear. 3 Fit the Woodruff key to the camshaft then fit the sprocket followed by the spacer and bolt.[...]

1•2 Servicing specifications 1081 VW Golf & Jetta Lubricants, fluids and capacities Refer to the end of “Weekly checks” Engine Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C101/C160 Valve clearances 1.05 and 1.3 litre engines - pre August 1985: Warm: Inlet . . . . [...]

CO content (%) 1.05 litre carburettor engines: Pierburg/Solex 31 PIC-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 1.5 Pierburg/Solex 1B3 and Weber 32 TLA . . . . . . . . . . . . . . . . . . . . . . . 1.5 to 2.5 1.3 litre carburettor engines (Pierburg/Solex 2E3) . . . . . . . . . . . . . . . . . 1.5 to 2.5 1.6 litre[...]

Charging system Alternator drivebelt tension Initial adjustment for new drivebelt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 mm deflection under finger pressure at point midway between alternator and crankshaft pulleys Adjustment after 500 miles (750 km) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 mm deflection unde[...]

The maintenance intervals in this Manual are provided with the assumption that you will be carrying out the work yourself. These are the minimum maintenance intervals recommended by the manufacturer for vehicles driven daily. If you wish to keep your vehicle in peak condition at all times, you may wish to perform some of these procedures more often[...]

1•6 Maintenance schedule 1081 VW Golf & Jetta Every 250 miles (400 km) or weekly m m See “ Weekly checks ” Every 10 000 miles (15 000 km) - if completing mor e than 10 000 miles (15 000 km) per annum m m Renew engine oil and filter (Section 18) m m Check brake pad linings (Section 26) Every 1000 miles (1500 km) or monthly m m Check lock, [...]

Maintenance - component location 1•7 1 1081 VW Golf & Jetta Underbonnet view – 1.3 litr e model (air cleaner r emoved) 1 Engine oil dipstick 2 Fuel line filter 3 Brake master cylinder reservoir 4 Carburettor 5 Ignition coil 6 Cooling system expansion tank 7 Windscreen/headlight washer reservoir 8 Ignition distributor 9 Battery 10 Cooling fa[...]

1•8 Maintenance - component location 1081 VW Golf & Jetta Fr ont underbody view - 1.3 litre model 1 Alternator 2 Oil filter 3 Driveshaft 4 Front mounting 5 Cooling system bottom hose 6 Gearbox 7 Track control arm 8 Tie-rod 9 Exhaust 10 Engine sump Fr ont underbody view - fuel injected model 1 Driveshaft 2 Front mounting 3 Starter motor 4 Gear[...]

Maintenance - component location 1•9 1 1081 VW Golf & Jetta Rear underbody view - 1.3 litr e model 1 Exhaust 2 Fuel tank 3 Rear shock absorber lower mounting 4 Axle beam 5 Handbrake cable (right- hand) 6 Handbrake cable (left-hand) 7 Rear drum brake Rear underbody view - fuel injected model 1 Exhaust 2 Fuel tank 3 Rear shock absorber lower mo[...]

1 Introduction This Chapter is designed to help the home mechanic maintain his/her vehicle for safety, economy, long life and peak performance. The Chapter contains a master maintenance schedule, followed by Sections dealing specifically with each task in the schedule. Visual checks, adjustments, component renewal and other helpful items are includ[...]

6 Fluid leakage and engine electrical system check 1 1 Open the bonnet and inspect the engine joint faces, gaskets and seals for any signs of coolant or oil leaks. Pay particular attention to the areas around the rocker cover, cylinder head, oil filter and sump joint faces. Bear in mind that over a period of time some very slight seepage from these[...]

11 Contact breaker point check 2 1 Disconnect the LT lead from the terminal block on the screening ring, then the earth strap spade connector on the distributor body (see illustration) . 2 Release the two retaining clips and withdraw the distributor cap, complete with screen ring, from the distributor (see illustration) . 3 Pull off the rotor arm a[...]

9 The engine will turn over more easily if the spark plugs are removed. Do not rotate the engine by turning the camshaft sprocket as this will stretch the timing belt. Use the alternator drivebelt (V-belt) or jack up one front wheel and with the engine in gear rotate the roadwheel. Do not turn the engine with any of the shims removed, otherwise the[...]

14 Antifreeze concentration check 2 Warning: Wait until the engine is cold before checking antifreeze. Do not allow antifreeze to come in contact with your skin or painted surfaces of the vehicle. Rinse off spills immediately with plenty of water. Never leave antifreeze lying around in an open container or in a puddle in the driveway or on the gara[...]

13 Wipe clean the distributor cap and make sure that the carbon brush moves freely against the tension of the spring. Clean the metal segments in the distributor cap but do not scrape away any metal, otherwise the HT spark at the spark plugs will be reduced. Also clean the HT leads and coil tower. 14 Refit the distributor cap and interference scree[...]

15 Connect a tachometer in accordance with the manufacturer’s instructions. 16 Start the engine and run it at idling speed. 17 Point the timing light at the timing mark and pointer which should appear to be stationary and aligned. If adjustment is necessary (ie. the marks are not aligned), loosen the clamp retaining bolt and turn the distributor [...]

the oil filter, as described below, while the oil is draining. 4 After all the oil has drained, wipe off the drain plug with a clean rag and on 1.6 and 1.8 litre models, renew the O-ring. Clean the area around the drain plug opening and refit the plug. Tighten the plug to the specified torque setting. 5 Depending on engine type, refer to the follow[...]

4 Wipe clean the area around the filler/level plug, then unscrew the plug and clean it. Discard the sealing washer (see illustration) . 5 The oil level should reach the lower edge of the filler/level hole. A certain amount of oil will have gathered behind the plug and will trickle out when it is removed - this does not necessarily indicate that the[...]

25 Fuel and brake line, hose and union check 1 Warning: Do not drive the vehicle until necessary repair work has been carried out on damaged fuel and brake lines. 1 It is essential for this check to raise the vehicle sufficiently enough to allow a complete uninterrupted view of its underside. 2 Working methodically from one end of the vehicle to th[...]

gripping the track rod. If the wheel is now rocked, movement will be felt at the inner joint if wear has taken place. 4 With the vehicle standing on its wheels, have an assistant turn the steering wheel back and forth about an eighth of a turn each way. There should be very little, if any, lost movement between the steering wheel and the roadwheels[...]

8 Withdraw the element from the housing. 9 Wipe clean the inside of the cover. 10 Fit the new element and secure the cover by pressing the clips home. 33 Fuel filter renewal 2 Carburettor models 1 To remove the in-line filter, remove its pipe retaining clips, disconnect the pipes and extract the filter (see illustration) . If necessary, replace the[...]

1081 VW Golf & Jetta 3 Chapter 3 Cooling, heating and air conditioning systems Cooling system Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurised with pump driven by timing or V-belt. Front mounted radiator with internal or external expansion tank. Electric cooling fan Radiato[...]

Torque wrench settings Nm lbf ft All models Temperature sender unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7 Cooling fan thermo-switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

Air conditioning system The air conditioning unit works on exactly the same principle as a domestic refrigerator, having a compressor, a condenser and an evaporator. The condenser is attached to the vehicle radiator system. The compressor, belt- driven from the crankshaft pulley, is installed on a bracket on the engine. The evaporator is installed [...]

Air conditioning refrigerant Although the refrigerant is not itself toxic, in the presence of a naked flame (or a lighted cigarette) it forms a highly toxic gas. Liquid refrigerant spilled on the skin will cause frostbite. If refrigerant enters the eyes, rinse them with a dilute solution of boric acid and seek medical advice immediately. In view of[...]

hose and allow the water to circulate through the radiator until it runs clear from the bottom outlet. If, after a reasonable period the water still does not run clear, the radiator can be flushed with a good proprietary cleaning agent. 7 Disconnect the heater hose from the cylinder head outlet and insert a garden hose in the heater hose. With the [...]

10 Clean the radiator matrix of flies and small leaves with a soft brush or by hosing. At the same time check for signs of damage and coolant leakage. 11 It is not possible to repair this type of radiator without special equipment . 12 Renew any hoses or clips that are damaged. Refitting 13 Refitting is a reversal of removal. If necessary, renew th[...]

Refitting 8 Refitting is a reversal of removal. Fit a new sealing ring and tighten the cover bolts to the specified torque. The breather hole in the thermostat should face upwards. 9 On completion, refill the cooling system. 1.6 and 1.8 litre engines Removal 10 The thermostat is located in the bottom of the coolant pump behind the inlet elbow. To r[...]

the joint. Clean off the old gasket. 18 Remove the thermostat. 19 The impeller housing and impeller complete with bearings are serviced as one part. If coolant is leaking through the bearing, or the impeller is damaged, the complete assembly must be renewed. 20 Fit a new gasket using jointing compound, then fit the two pump halves together and tigh[...]

necessary to remove the lower parcel tray on the passenger side and also the insulation sheet (see illustrations) . 7 It is best to renew the heater cables completely if the inner cable snaps. In this way the exact length required is obtained. It is a good idea to fit new cable clamps also, as the old ones seem to distort when removed. Refitting 8 [...]

6 Undo the retaining nuts and withdraw the outlet distributor from the air box, disconnecting the distributor from the left and right- hand air ducts as it is withdrawn. Remove the gasket (see illustration) . 7 Disconnect the control cables at the air box end. 8 Loosen the dash securing screws enough to enable the air box to be withdrawn and remove[...]

11 Air conditioning system compressor - removal and refitting 2 Warning: The air conditioning system must be depressurised and drained by a VW dealer or refrigeration specialist. Do not attempt this yourself. 1 Removal and refitting of the air conditioner compressor is straight-forward. However, under no circumstances should the refrigerant circuit[...]

3• 12 1081 VW Golf & Jetta Notes[...]

1081 VW Golf & Jetta 2D Chapter 2 Part D: Engine r epair pr ocedur es 1.8 litr e 16 valve The following information is a revision of, or supplementary to, that given for the 1.8 litre engine in Part C of this Chapter General Code: GTi 16V with catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KR Compression ratio . .[...]

2D•2 Engine repair pr ocedures 1.8 litr e 16 valve 1081 VW Golf & Jetta 1.0 The 1.8 litre, 16 valve, fuel injection engine 1 Inlet manifold upper section 2 Gasket 3 Valve cover 4 Gasket 5 Cylinder head assembly with camshafts 6 Cylinder head gasket 7 Cylinder block assembly 8 Gasket 9 Sump 10 Oil filter head 11 Oil cooler 12 Oil filter[...]

1 General information The 1.8 litre, 16-valve engine fitted to GTi models from October 1986, incorporates double overhead camshafts, one operating the exhaust valves and the other the inlet valves. There are four valves per cylinder which operate simultaneously in pairs and provide the engine with a much improved breathing capability over the 8-val[...]

12 If necessary, remove the hydraulic bucket tappets. Check the camshafts and drive chain for wear. Refitting 13 Lubricate all bucket tappets and camshaft journals with clean engine oil, then insert the tappets in their original bores. 14 Locate the drive chain on the camshaft sprockets so that the timing marks are aligned as shown in illustration [...]

1081 VW Golf & Jetta 2C Chapter 2 Part C: Engine r epair pr ocedures - 1.6 and 1.8 litr e 8 valve General Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four-cylinder in-line, water cooled, overhead camshaft Code: 1.6 litre: Without catalytic converter . . . . . . . . . . . . . . . .[...]

Compression pressure: 1.6 litre: New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 to 12 bar Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 bar Maximum permissible difference between any two cylinders . . . . 3.0 bar 1.8 litre: New . . . . .[...]

Stem diameter: Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.97 mm Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.95 mm Standard overall length*: Inlet: Codes EZ, EV, GU . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

Valve timing (continued) Nil valve clearance at 1.0 mm valve lift 1.8 litre (code RH): Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2° BTDC Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34° ABDC Exhaust opens . . . . . . . . . . . . .[...]

1 General information The 1.6 and 1.8 litre 8-valve engines are of four- cylinder, in-line, overhead camshaft design, mounted transversely at the front of the vehicle. The transmission is attached to the flywheel end of the engine. The crankshaft is of five main bearing type, its endfloat being controlled by a shouldered centre bearing or by half t[...]

5 Remove the radiator, together with the cooling fan. On models manufactured after 1986, remove the front panel before removing the radiator. 6 Remove the air cleaner unit then disconnect the throttle cable at the carburettor. Position the cable out of the way. 7 Where power steering is fitted, remove the hydraulic pump drivebelt. Unbolt the pump, [...]

26 The engine/gearbox unit is now ready for lifting out but first make a final check that all cables, wiring and hoses are clear. 27 Have an assistant at hand to help guide the unit clear of the surrounding components in the engine compartment as it is lifted out. The unit will have to be twisted slightly as it is raised. Once clear of the vehicle,[...]

6 Engine/gearbox - separation and reconnection 3 This procedure is fully described in Chapter 7, Parts A or B, as applicable. It is only necessary to refer to those paragraphs pertinent to the particular method being used. The engine must be supported on blocks, or alternatively the gearbox can be separated with the engine still on the hoist. 7 Eng[...]

face of the cover to allow access to the Allen type retaining screw recessed within the cover. On other engines, the retaining screw can be seen but its key slot is deeply recessed (access to it being made via the hole in the centre of the screw surround). 3 Unscrew the nuts and bolts from the valve cover and remove the cover together with the gask[...]

b) If the camshaft oil seal is to be renewed then the camshaft timing sprocket must be removed 2 Remove the camshaft bearing caps (see illustrations) , making a careful note of their fitted positions for reference when refitting . The caps are numbered (see illustration) but mark the side nearest the front of the cylinder head. No. 1 cap is the one[...]

and tappet is required. Label the containers 1 to 8, as follows: Containers 1 and 2 will be No 1 cylinder exhaust and inlet respectively Containers 3 and 4 will be No 2 cylinder exhaust and inlet respectively Containers 5 and 6 will be No 3 cylinder inlet and exhaust respectively Containers 7 and 8 will be No 4 cylinder inlet and exhaust respective[...]

4 The valve springs must be renewed if they are damaged, distorted, or known to have covered a high mileage. If in doubt as to their condition, have your VW dealer check them for compression efficiency using a calibrated valve spring compressor. 5 The valves should be cleaned and checked for signs of wear or burring. Where this has occurred, the in[...]

complete with the oil pick-up pipe and strainer. Refitting 4 To refit the pump, ensure that the mating faces are clean, locate it in position and fit and tighten the securing bolts to the specified torque. 5 Locate the new sump gasket but do not apply an adhesive sealant. Refit the sump and tighten the retaining bolts evenly to the specified torque[...]

seen that the caps are numbered 1 to 5 and that the number is on the side of the engine opposite the oil pump position. Identify these numbers. If they are obscured, then mark the caps in the same way as the connecting rod caps. Before removing the caps, push the crankshaft to the rear and check the endfloat using a feeler blade between the thrustw[...]

17 Oil filter - renewal 1 Refer to Chapter 1, Section 18 18 Oil cooler - removal and refitting 2 1 On fuel injection models, an oil cooler is fitted between the oil filter cartridge and mounting bracket. The cooler must be renewed if the engine oil has been contaminated with metal particles, such as might be the case following total or partial engi[...]

23 Cylinder block/crankcase - examination and renovation 5 Refer to Section 22 in Part A of this Chapter. 24 Pistons and connecting rods - examination and renovation 4 Refer to Section 23 in Part A of this Chapter. 25 Oil pump - examination and renovation 3 1 With the oil pump on the bench, prise off the cap with a screwdriver and clean the straine[...]

4 On automatic transmission models, check the driveplate as described for the flywheel. It will also be necessary to mark a new driveplate for ignition timing. 28 Timing belt and sprockets - examination and renovation 1 Refer to Section 26 in Part A of this Chapter. The information given also applies to the intermediate shaft sprocket. 29 Engine re[...]

10 Lubricate the front of the crankshaft and fit the front oil seal and flange with a new gasket. Tighten the bolts to the correct torque. 31 Intermediate shaft - refitting 3 Lubricate the intermediate shaft with clean engine oil then install it in the block. Fit the O-ring and flange, together with the oil seal, then tighten the bolts. Note that t[...]

between the camshaft and intermediate shaft sprockets. Tighten the eccentric adjuster nut to the specified torque - see illustration 9.8. 8 Unbolt and remove the crankshaft V -belt pulley. 9 Fit the lower timing cover then refit the crankshaft V-belt pulley and tighten its retaining bolts to the specified torque. 10 Locate the new valve cover gaske[...]

2C•20 1081 VW Golf & Jetta Notes[...]

37 Timing belt renewal 3 Refer to the appropriate Part of Chapter 2 for the particular engine type concerned. 36 Brake fluid renewal 3 1 The procedure is similar to that described for bleeding of the hydraulic system in Chapter 9, except that the brake fluid reservoir should be emptied before starting by syphoning, using a clean poultry baster or s[...]

1081 VW Golf & Jetta 4A Chapter 4 Part A: Fuel and exhaust systems - carbur ettor models Air cleaner Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic air temperature control Element type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

Carburettor - 1.05 litre (continued) Pierburg/Solex 1B3 Venturi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 mm Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Air correction jet . . . . . . . . . . . . . . . . . . . . . . . [...]

Carburettor-1.6 litre Pierburg/Solex 2E2 - engine code EZ Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Twin progressive choke, downdraught with automatic choke Stage I Stage II Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.0 m[...]

Torque wrench settings (continued) Nm lbf ft 1.6 and 1.8 litre Carburettor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5 Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15 Inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . . [...]

Fuel and exhaust systems - carburettor models 4A• 5 4A 1081 VW Golf & Jetta 3.6 Air cleaner components – 1.6 and 1.8 litre 1 Warm air deflector plate 2 Gasket 3 Spring washer 4 Nut 5 Air hose 6 Bracket 7 Washer 8 Nut 9 Bonded rubber mounting 10 Clip 11 Air Hose 12 Clip 13 Spacer tube 14 Air cleaner 15 Clip 16 Stud 17 Washer 18 Self-locking [...]

5 If the control unit does not operate correctly then renew it, together with the temperature sensor (see illustration) . 6 Refit the vacuum unit and inlet pipe. 5 Fuel pump - testing, removal and refitting 3 Testing 1 Pump location is dependent on engine type and is as follows: a) 1.05 and 1.3 litre engines - The pump is located on the right-hand [...]

6 Fuel reservoir - removal and refitting 2 1 The fuel reservoir is located between the fuel pump and the carburettor (see illustration) . The reservoir has three hose connections which are marked as follows: a) From the pump - arrow marked b) To the carburettor - not marked c) To the fuel return line - marked R 2 To remove the reservoir, disconnect[...]

8 Fuel gauge sender unit - removal and refitting 2 Warning: The fuel gauge sender unit must always be removed in a well ventilated area. Removal 1 Disconnect the battery negative lead. 2 Lift the luggage compartment floor covering and remove the circular sender unit cover. 3 Disconnect the wiring connector from the top of the unit then detach the f[...]

retaining clip and then disconnect the cable from the carburettor. 17 At the transmission end, prise free the securing clip and detach the cable from the operating lever and the cable support bracket. Refitting 18 Refitting of both cables is a reversal of the removal procedure. Adjustment 19 This procedure is described in Chapter 7B. 11 Accelerator[...]

Refitting 10 Refitting is a reversal of the removal procedure. Ensure that the inlet manifold, intermediate flange and carburettor mating faces are clean and use new gaskets. 11 On completion, top-up the cooling system, restart the engine and check for fuel and coolant leaks. 12 Adjust the carburettor as necessary. 14 Carburettor - overhaul 4 1 A c[...]

Fuel and exhaust systems - carburettor models 4A• 11 4A 1081 VW Golf & Jetta 14.4a Pierburg/Solex PIC carburettor components[...]

4A•12 Fuel and exhaust systems - carburettor models 1081 VW Golf & Jetta 14.4d Pierburg/Solex 2E2 carburettor components 14.4b Pierburg/Solex 1B3 carburettor top cover components 1 Idle speed boost two-way valve 2 To idle adjustment screws 3 To vacuum line and brake servo 4 Idling fuel/air jet 5 Auxiliary fuel/air jet 6 Choke valve 7 Screw 8 [...]

Fuel and exhaust systems - carburettor models 4A• 13 4A 1081 VW Golf & Jetta 14.4e Pierburg/Solex 2E3 carburettor components 14.4f Weber 32 TLA carburettor top cover components 1 Screw 2 Air correction jet 3 Auxiliary fuel jet (if applicable) 4 Idling fuel jet 5 Emulsion tube 6 Choke valve and lever 7 Washer 8 Gauze filter 9 Plugs 10 Needle v[...]

15 Carburettor (1.05 litre engine) - adjustments 4 Note: Accurate adjustment of the carburettor is only possible if adjustment of the ignition timing, dwell angle and spark plug gaps is correct. Incorrect valve clearances can also effect carburettor adjustment Pierburg/Solex 31 PIC7 Bypass air cut-off valve 1 To check the bypass air cut-off valve w[...]

10 Start the engine and let it idle. Check that the engine speed and CO content are as specified. If not, turn the two screws located above the cut-off solenoid alternately as necessary (see illustration) . 11 If an exhaust gas analyser is not immediately available, an approximate mixture setting can be made by turning the mixture screw to give the[...]

33 If difficulty is experienced in making the adjustment, check the pump seal and make sure that the return check valve and injection tube are clear. Idle cut-off solenoid 34 When the ignition is switched on, the solenoid should be heard to click, indicating that the idle circuit has been opened. 35 If the solenoid is removed for testing, the plung[...]

Accelerator pump capacity 55 This can be checked by following the procedure given for the Pierburg 2E3 carburettor, with the following differences. 56 Open the throttle valve quickly when operating the pump (ie. one second per stroke, with pauses of three seconds between strokes). 57 The amount of fuel injected can be altered, but only very slightl[...]

Throttle valve 6 The basic Stage ll throttle valve adjustment is made during manufacture and should not require further adjustment. If, for any reason, the limiting screw has been removed or its setting altered, readjust it as follows. 7 Open the throttle valve and hold it in position by inserting a wooden rod or similar implement between the valve[...]

Accelerator pump 9 To make this check, the carburettor must be removed and you will need a vacuum pump and an M8 x 20 mm bolt. 10 Detach the vacuum hoses from the three/four point unit then connect up the vacuum pump to the three/four point unit at “A” (see illustration) . Plug connection B (and C on four point unit). Apply vacuum with the pump[...]

28 Stop the engine by disconnecting the coil terminal 15, and check that the diaphragm rod remains in the overrun/cut-off position for a minimum of five seconds. 29 Reconnect the coil wiring, control valve plug and hose where applicable. Refit the air cleaner. Stage ll vacuum control unit 30 This device is fitted to 1.6 litre manual gearbox models [...]

2 To check the heater element, the engine should be cold. Disconnect the wire from the element at its in-line connector, then attach an ohmmeter between the wire connector from the element and earth. This should record 0.25 to 0.50 ohm. 3 To remove the element, disconnect the wire then unscrew the bolts and withdraw the unit. Remove the sealing rin[...]

locations, then carefully withdraw the manifold from the cylinder head. 7 Remove the gasket and clean the mating faces of the manifold and cylinder head. 8 Refitting is a reversal of the removal procedure. Use a new manifold gasket and tighten the securing nuts and bolts to the specified torque setting. Exhaust manifold 9 Undo the retaining nut(s) [...]

Fuel and exhaust systems - carburettor models 4A• 23 4A 1081 VW Golf & Jetta 20.4b Exhaust system and associated components – 1.6 and 1.8 litre Connecting piece and clamp setting dimensions a = 5.0 mm b = 12.0 mm c Marking (S for manual gearbox or A for automatic transmission) 20.4a Exhaust system and associated components – 1.5 and 1.3 l[...]

4A•24 1081 VW Golf & Jetta Notes[...]

1081 VW Golf & Jetta 4C Chapter 4 Part C: Fuel and exhaust systems - K-Jetr onic fuel injection - 16 valve engines The following information is a revision of, or supplementary to, that contained in Part B of this Chapter Air cleaner Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auto[...]

1 Union bolt 2 O-rings 3 Bolt 4 Union bolt 5 Union bolt 6 Fuel metering distributor 7 Adjusting shim 8 O-rings 9 Pressure regulator and relief valve 10 Fuel supply and return 11 Spring 12 Control plunger 13 Plug 14 Mixture (CO content) adjustment screw 15 Airflow 16 Union nut 17 Injector 18 O-rings 19 Injector insert 20 Gasket 21 Cold start valve 2[...]

Fuel and exhaust systems - K-Jetronic fuel injection - 16 valve engines 4C• 3 4C 1081 VW Golf & Jetta 1.0b K-Jetronic system inlet manifold and associated components – 16v engine 1 To ignition control unit 2 Intake elbow 3 Screw 4 Gaskets 5 Throttle valve housing 6 O-ring 7 Idle speed adjustment screw 8 Throttle valve switch 9 Connector 10 [...]

8 Check that the mixture (CO reading) is as specified. Temporarily block off the exhaust tailpipe not fitted with the analyser probe while making the check. If necessary, turn the mixture screw as required after removing its cap. A special key is necessary in order to turn the screw but a suitable tool may be used as an alternative. Note that the s[...]

7 Inlet manifold - removal and refitting 3 The inlet manifold is in two sections. When refitting the upper section, fully tighten the nuts securing it to the lower section first before attaching it to the rear support bracket. 8 Exhaust system - inspection, removal and refitting 3 The exhaust system incorporates four silencers together with twin do[...]

4C•6 1081 VW Golf & Jetta Notes[...]

1081 VW Golf & Jetta 4B Chapter 4 Part B: Fuel and exhaust systems - K-Jetr onic fuel injection - 8 valve engines Air cleaner Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic air temperature control Element type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

Torque wrench settings Nm lbf ft Injector insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15 Injector line to injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18 Injector line to fuel metering distributor . . . . . . . . . . . . . . . . . . . . . . . . . 10 7[...]

Fuel supply The fuel pump operates continuously while the engine is running, excess fuel being returned to the fuel tank. The pump is operated when the ignition switch is in the START position. Once the starter is released, a switch which is connected to the air plate, prevents the pump from operating unless the engine is running. The fuel line to [...]

f) DO NOT use fuel or engine oil additives as these may contain substances harmful to the catalytic converter. g) DO NOT continue to use the vehicle if the engine burns oil to the extent of leaving a visible trail of blue smoke. The unburned carbon deposits will clog the converter passages and reduce its efficiency. In severe cases, the element wil[...]

4 Switch off all electrical consumers, then pinch the air hose again and adjust idle speed to that specified. When the correct idle speed is reached, unclamp the hose. The idle speed should then increase up to about 1050 rpm at which point the valve will close and the speed drop to the specified idle speed setting. Valve 2 - checking 5 Run the engi[...]

9 Cold start valve and thermotime switch - testing 2 Cold start valve 1 The thermotime switch energises the cold start valve for a short time on starting. The time for which the valve is switched on depends upon the engine temperature. 2 This check must only be carried out when the coolant temperature is below 30°C. 3 Pull the connector off the co[...]

6 If a fault is evident, check the wiring connections, the throttle valve switch and the diaphragm pressure switch. 7 The diaphragm pressure switch can be checked using an ohmmeter. Detach the wiring connector from the end of the diaphragm pressure switch, then start the engine and allow it to idle. Using the ohmmeter, check the resistance reading [...]

4 If the sensor plate can be moved downwards easily but has a strong resistance to upward movement, the control plunger is sticking. Remove the fuel distributor and clean the control plunger in fuel. If this does not cure the problem, a new fuel distributor must be fitted . 5 Release the pressure on the fuel distributor and then check the rest posi[...]

17 Pressure relief valve - removal, servicing and refitting 2 1 Release the pressure in the fuel system. 2 Unscrew the non -return valve plug and remove the plug and sealing washer. 3 Take out the O-ring, plunger and O-ring, in that order (see illustration) . 4 When refitting the assembly, use new O- rings and ensure that all the shims which were r[...]

20 Fuel filter - removal and refitting 2 Refer to Chapter 1, Section 33 21 Fuel accumulator - removal and refitting 2 Removal 1 The fuel accumulator is mounted on the outboard side of the fuel pump reservoir on the underside of the vehicle at the rear, just forward of the fuel tank (see illustration) . 2 Disconnect the battery earth lead. 3 Raise t[...]

Fuel and exhaust systems - K-Jetronic fuel injection - 8 valve engines 4B• 11 4B 1081 VW Golf & Jetta 23.0b Air cleaner, inlet manifold and associated components – pre September 1984 23.0a Inlet manifold and injection components (except engine codes PB and PF) – from September 1984 1 Two-way valve (II) 2 Two-way valve (I) 3 T-piece 4 Scre[...]

10 Disconnect the cam cover-to-inlet manifold breather hose. 11 Undo and remove the inlet manifold retaining bolts then carefully lift the manifold, together with the throttle housing, away from the cylinder head. Disconnect any wiring or hose connections still attached as it is withdrawn. 12 The throttle housing can be unbolted from the manifold a[...]

1081 VW Golf & Jetta 4C Chapter 4 Part C: Fuel and exhaust systems - K-Jetr onic fuel injection - 16 valve engines The following information is a revision of, or supplementary to, that contained in Part B of this Chapter Air cleaner Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auto[...]

1 Union bolt 2 O-rings 3 Bolt 4 Union bolt 5 Union bolt 6 Fuel metering distributor 7 Adjusting shim 8 O-rings 9 Pressure regulator and relief valve 10 Fuel supply and return 11 Spring 12 Control plunger 13 Plug 14 Mixture (CO content) adjustment screw 15 Airflow 16 Union nut 17 Injector 18 O-rings 19 Injector insert 20 Gasket 21 Cold start valve 2[...]

Fuel and exhaust systems - K-Jetronic fuel injection - 16 valve engines 4C• 3 4C 1081 VW Golf & Jetta 1.0b K-Jetronic system inlet manifold and associated components – 16v engine 1 To ignition control unit 2 Intake elbow 3 Screw 4 Gaskets 5 Throttle valve housing 6 O-ring 7 Idle speed adjustment screw 8 Throttle valve switch 9 Connector 10 [...]

8 Check that the mixture (CO reading) is as specified. Temporarily block off the exhaust tailpipe not fitted with the analyser probe while making the check. If necessary, turn the mixture screw as required after removing its cap. A special key is necessary in order to turn the screw but a suitable tool may be used as an alternative. Note that the s[...]

7 Inlet manifold - removal and refitting 3 The inlet manifold is in two sections. When refitting the upper section, fully tighten the nuts securing it to the lower section first before attaching it to the rear support bracket. 8 Exhaust system - inspection, removal and refitting 3 The exhaust system incorporates four silencers together with twin do[...]

4C•6 1081 VW Golf & Jetta Notes[...]

1081 VW Golf & Jetta 4D Chapter 4 Part D: Fuel and exhaust systems - Mono Jetr onic fuel injection The following information is a revision of, or supplementary to, that contained in Part B of this Chapter Injection system Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mono Jetronic, [...]

1 General information and precautions General information The Mono-Jetronic central fuel injection system is fitted to the 1.8 litre (code RP) engine. It is a simplified method of fuel injection (see illustrations) . Fuel is injected into the inlet manifold by a single solenoid valve (fuel injector) mounted centrally in the top of the injector unit[...]

passage closed off. At temperatures above 45° C, the regulator should be closed and the warm air passage sealed off. 5 Idle speed and mixture (CO content) - testing 4 1 The prerequisites for this test are that the ignition timing must be correct and the engine must be at its normal operating temperature. During the test, all electrical circuits in[...]

2 With the engine running at idle speed, look into the top of the injector unit and check the fuel spray pattern which should be visible on the throttle valve. 3 Increase the engine speed to 3000 rpm then snap shut the throttle and check that the fuel spray from the injector is momentarily interrupted. Turn the ignition off and then check that no m[...]

distance of 4.0 mm by the operating lever (see illustration) . If adjustment is required, loosen off the adjuster locknut then rotate the damper screw to the point where the lever is just in contact with the plunger. Now turn the damper four and a half turns towards the lever, then retighten the locknut. 10 Fuel pump - testing , removal and refitti[...]

4D•6 1081 VW Golf & Jetta Notes[...]

1081 VW Golf & Jetta 4E Chapter 4 Part E: Fuel and exhaust systems - Digijet fuel injection Injection system Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digijet Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 litre (cod[...]

1 General information and precautions General information The Digijet fuel injection system is fitted to the 1.3 litre (code NZ) engine (see illustrations) . The system is regulated in accordance with instructions received from a control unit, located in the bulkhead plenum chamber on the left-hand side. This unit was modified in July of 1989 and c[...]

3 Idle speed and mixture - adjustment 4 1 The idle speed can only be accurately checked using a suitable tachometer and an exhaust CO analyser. VW recommend that the inlet air temperature sender in the airflow meter must ideally be set to 1.8 K ohms to provide a neutral air inlet temperature. As this requires the use of specialised VW equipment, an[...]

3 Insert a feeler blade of 0.3 mm thickness between the lever and the stop screw to ensure the correct clearance (see illustration) . If adjustment is required, loosen off the throttle valve switch screws then move the switch in the required direction to the point where the zero ohms reading is shown. Retighten the screws. Fully open the throttle v[...]

feed line attachment to the gravity valve from the charcoal filter. g) The fuel pump and its location is identical to that described in Part F of this Chapter. 10 Evaporative fuel control system 2 1 The function of this system is to aid evaporative fuel control by collecting and recirculating the fuel vapours in the fuel tank to prevent them from e[...]

4E•6 1081 VW Golf & Jetta Notes[...]

1081 VW Golf & Jetta 4F Chapter 4 Part F: Fuel and exhaust systems - Digifant fuel injection The following information is a revision of, or supplementary to, that contained in Part B of this Chapter Injection system Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digifant Application [...]

2 Idle speed and mixture (CO content) - adjustment 4 1 Run the engine until the oil temperature is at least 80°C. This should correspond to normal operating temperature. 2 Switch off all electrical components, including the air conditioning, where fitted. Note that the radiator fan must be stationary during adjustment. 3 For accurate adjustment, t[...]

5 Fully open the throttle and align a datum with 0° on the card. Close the throttle by approximately 20°, then slowly open it until switch 2 points close. This should occur at 10° ± 2° before full throttle. If necessary, adjust the position of switch 2. Note that the throttle valve lever roller must contact the sloping part of switch 2. 6 Thro[...]

9 Airflow meter - testing 2 1 Disconnect the wiring plug from the airflow meter (see illustration) . 2 Connect an ohmmeter between terminals 1 and 4 and check that the resistance of the inlet air temperature sender is as shown (see illustration) according to the ambient air temperature. 3 Connect the ohmmeter between terminals 3 and 4 and check tha[...]

Fuel and exhaust systems - Digifant fuel injection 4F•5 4F 1081 VW Golf & Jetta 9.1 Airflow meter components 1 Air cleaner element 2 Cover 3 Bolt 4 Seal 5 Airflow meter 6 Connector 7 Tamperproof plug 8 Mixture (CO content) adjustment screw 9 O-ring 10 Clip 11 Air inlet hose 12 Plate 13 Seal 14 Retaining ring 15 Air cleaner body 16 Rubber wash[...]

4F•6 1081 VW Golf & Jetta Notes[...]

1081 VW Golf & Jetta 5A Chapter 5 Part A: Ignition system - contact br eaker type General System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 12 volt battery and coil with contact breaker points Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

Torque wrench settings Nm lbf ft Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15 Distributor clamp bolt: 1.05 and 1.3 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7 1.6 and 1.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

Ignition system - contact breaker type 5A•3 5A 1081 VW Golf & Jetta 1.1c Contact breaker ignition system components - 1.6 litre engine 1.1b Contact breaker ignition system components - Ducellier distributor, 1.05 and 1.3 litre engines[...]

Ignition advance is controlled both mechanically and by a vacuum-operated system. The mechanical governor mechanism comprises two weights, which move out from the distributor shaft as the engine speed rises due to centrifugal force. As they move outwards, they rotate the cam relative to the distributor shaft and so advance the spark. The weights ar[...]

7 Distributor - removal, overhaul and refitting 4 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 [...]

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 distributo[...]

1081 VW Golf & Jetta 5B Chapter 5 Part B: Ignition system - transistorised type General System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Transistorised. 12 volt battery and coil Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4[...]

1 General information and precautions General information TCI-H system The transistorised (TIC-H) ignition system functions in a similar manner to that described in Part A of this Chapter for the contact breaker system, with the following exceptions. An electronic sender unit replaces the contact points and condenser in the distributor and a remote[...]

Ignition system - transistorised type 5B•3 5B 1081 VW Golf & Jetta 1.1b Transistorised ignition system components – 1.6 litre engine The system for 1.8 litre engines is similar 1.5 Digifant ignition system components 1 TCI-H switch unit 2 Connector 3 Plate 4 Nut 5 Connector 6 Digifant control unit 7 Temperature sender 8 Knock sensor 9 Bolt [...]

3 HT leads, distributor cap and rotor arm - inspection and renewal 2 Refer to Section 3 in Part A of this Chapter 4 Switch unit - testing 2 1 When making this test, the coil must be in good condition. 2 Remove the plastic cover on the right-hand side of the plenum chamber for access to the switch unit (see illustrations) . 3 Disconnect the multi-pl[...]

4 Unscrew and remove the TDC sensor or blanking plug from the top of the gearbox (see illustration) then turn the engine over until the TDC “O” mark is aligned with the timing pointer (see illustration) . If not already marked, scribe an alignment mark on the distributor body in line with the tip of the rotor arm (see illustration) . Also mark [...]

Refitting 12 Before fitting the distributor, set No. 1 piston to TDC. When correctly set, the flywheel mark or the crankshaft pulley vibration damper mark should align with the matching mark on the casing or belt cover. The mark on the camshaft sprocket must align with the joint of the camshaft cover. 13 Using a screwdriver, turn the slot in the en[...]

10 Check that the rotor arm is not damaged. Use an ohmmeter to measure the resistance between the brass contact in the centre of the rotor arm and the brass contact at the edge of the arm. The measured value of resistance should be between 600 and 1400 ohm. 11 Suck on the pipe connection to the vacuum diaphragm and check that the operating rod of t[...]

5B•8 1081 VW Golf & Jetta Notes[...]

1081 VW Golf & Jetta 5C Chapter 5 Part C: Ignition system - fully electr onic type The following information is a revision of, or supplementary to, that contained in Part B of this Chapter General System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fully Electronic Ignition (FEI) Ignition timi[...]

2 Spark plugs - renewal 2 Refer to Chapter 1, Section 15 3 HT leads, distributor cap and rotor arm - inspection and renewal 2 Refer to Section 3 in Part A of this Chapter 4 Switch unit - testing 2 1 The switch unit is located in the left -hand side of the plenum chamber beneath a plastic cover. The ignition coil should be in good condition before m[...]

attach the diode test light to its centre and outer (brown/white) terminals (see illustration) . Operate the starter motor and check that the LED is seen to flicker. If it does not, the Hall sender unit is at fault and must be renewed. 7 Distributor - removal and refitting 3 Refer to Section 6 in Part B of this Chapter for the TCI-H system but igno[...]

5C•4 1081 VW Golf & Jetta Notes[...]

1081 VW Golf & Jetta 5D Chapter 5 Part D: Starting and char ging systems System Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt, negative earth Battery Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Ah or 45 Ah M[...]

1 General information and precautions General information The starting and charging system is of a 12 volt negative earth type. The battery is charged by a belt-driven alternator which incorporates a voltage regulator. The starter motor is of pre-engaged type, incorporating a solenoid which moves the drive pinion into engagement with the flywheel/d[...]

Refitting 5 Refitting is a reversal of removal. Note the following: a) Ensure that the leads are fitted to their correct terminals b) Do not overtighten the lead clamp nuts or battery retaining clamp bolt c) Smear a little petroleum jelly on the terminals and clamps 5 Alternator drivebelt - inspection and adjustment 2 Refer to Chapter 1, Section 13[...]

9 Starting motor - testing 2 Note: The following test was carried out with the starter motor in the vehicle 1 If the starter motor fails to operate, first check the condition of the battery by switching on the headlamps. If they glow brightly, then gradually dim after a few seconds, the battery is in an uncharged condition. 2 If the battery is in g[...]

1081 VW Golf & Jetta 9 Chapter 9 Braking system Brake system Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic, dual circuit, split diagonally, pressure regulator on some models. Disc front brakes. Drum or disc rear brakes. Cable-operated handbrake on rear wheels. Front brakes[...]

Rear disc brakes Disc thickness: New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0 mm Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 mm Disc maximum run-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

3 Use an Allen key and unscrew the upper and lower caliper securing bolts (see illustration) . Withdraw the caliper and tie it up out of the way. Do not allow the weight of the caliper to stretch or distort the brake hose (see illustration) . 4 Withdraw each pad by sliding it sideways from the wheel bearing housing. Note that the pads differ, the p[...]

If both bolts were removed, carefully lift off and support the caliper. 18 If the pads are to be re-used, mark them for identification to ensure that they are refitted to their original location. Their positions must not be changed (see illustration) . 19 Brush all dust and dirt from the caliper, piston, disc and pads whilst taking care not to inha[...]

13 Tighten the brake hose union so that the hose is not twisted or in a position where it will chafe against surrounding components. 14 Remove the hose clamp or polythene sheet from the reservoir. Top-up the brake fluid and bleed the brakes. Rear calipers 15 Chock the front wheels, jack up the rear of the vehicle and support it on axle stands (see [...]

27 Locate the Allen key or angled circlip pliers into the piston and pressing firmly down, screw the piston fully home into the cylinder so that the outer seal lip of the protective cap springs into the location groove in the piston (see illustration) . 28 Caliper reassembly is now complete but before refitting it to the vehicle, it must be topped [...]

15 Undo the hub nut and then withdraw the thrustwasher and outer taper bearing race (see illustration) . 16 Withdraw the disc from the stub axle. 17 Unless a disc is being renewed after a low mileage due to damage or other defect, both discs must be renewed at the same time. 18 Refer to the following Section for hub bearing replacement. 19 Lubricat[...]

12 Grip the strut in a vice and release the shoe, then remove the wedge and spring. The backplate and stub axle may be removed if necessary, by unscrewing the four bolts after removing the wheel cylinder. Note the location of the handbrake cable bracket. If the wheel cylinder is being left in position, retain the pistons with an elastic band. Check[...]

13 Refit the hydraulic pipe and tighten the union. Remove the hose clamp or polythene sheet. 14 Refit the brake shoes. 15 Top-up the brake fluid reservoir and bleed the valves. 8 Rear brake drum - examination and renovation 2 1 Whenever the brake drums are removed, they should be checked for wear and damage. Light scoring of the friction surface is[...]

Refitting 12 Refitting the master cylinder is a reversal of the removal procedure. Fit a new mounting seal between the cylinder and servo unit. 13 On completion, bleed the brake hydraulic system. 10 Brake pressure regulator - testing, removal and refitting 5 1 The regulator is located on the under-body, in front of the left-hand rear wheel (see ill[...]

19 This method is particularly effective when bleeding “difficult” systems or when bleeding the entire system at routine fluid renewal. All methods 20 If the entire system is being bled, the procedures described above should now be repeated at each wheel. The correct sequence is as follows. Do not forget to recheck the fluid level in the master[...]

Refitting 5 Refitting is a reversal of removal. Lubricate the pivot pin and on completion, adjust the handbrake cables. 14 Handbrake cables - removal, refitting and adjustment 3 Removal 1 Chock the front wheels, then jack up the rear of the vehicle and support it on axle stands (see “ Jacking and vehicle support ”). Release the handbrake. 2 Rem[...]

1081 VW Golf & Jetta 11 Chapter 11 Bodywork and fittings Torque wrench settings Nm lbf ft Bumper bracket bolts: Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 61 Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 52 Tailgate [...]

If the vehicle is very dirty, especially underneath or in the engine compartment, it is tempting to use one of the pressure washers or steam cleaners available on garage forecourts. Whilst these are quick and effective, especially for the removal of the accumulation of oily grime which sometimes is allowed to become thick in certain areas, their us[...]

Repair of rust holes or gashes in bodywork Remove all paint from the affected area and from an inch or so of the surrounding sound bodywork, using an abrasive pad or a wire brush on a power drill. If these are not available a few sheets of abrasive paper will do the job most effectively. With the paint removed you will be able to judge the severity[...]

used. At one time the use of a universal paint was not possible owing to the complex range of plastics encountered in body component applications. Standard paints, generally speaking, will not bond satisfactorily to plastic or rubber, but a proprietary paint to match any plastic or rubber finish can be obtained from dealers. However, it is now poss[...]

hand. A largish screwdriver will just reach the lock release when inserted through the grille centre badge. By pushing the screwdriver or carefully using the badge as a pivot, the bonnet can be unlocked. 8 Radiator grille - removal and refitting 1 1 Raise and support the bonnet. 2 Undo and remove the two grille retaining screws on the top front edg[...]

retaining lugs each side of the lock cylinder together then pull free the grip (see illustration) . 4 Fit the key to the lock cylinder, prise free the retaining clip and withdraw the lock cylinder by pulling on the key. 5 To remove the cylinder housing, prise free the retaining ring and withdraw the housing from the grip. 6 Refitting is a reversal [...]

14 Door trim panel - removal and refitting 2 Removal 1 Unscrew and remove the door locking knob (see illustration) . 2 Remove the inner handle surround by sliding it to the rear (see illustration) . 3 Prise the cover from the door pull with a small screwdriver, remove the cross-head screws and withdraw the door pull (see illustrations) . 4 Note the[...]

11•8 Bodywork and fittings 1081 VW Golf & Jetta 15.2a Front door components - pre 1988 15.2b Front door components – from 1988 a = 310 mm 1 Exterior handle 2 Locking rod 3 Door lock 4 Locking pin 5 Seal 6 Internal remote control 7 Pull rod 8 Window regulator 9 Window glass[...]

15 Door handles - removal and refitting 2 Interior 1 Remove the door trim panel. 2 Pull the foam seal away then prise the retainer from the bottom of the handle (see illustrations) . 3 Press the finger plate forwards out of the door and unhook it from the rod (see illustration) . 4 Refitting is a reversal of removal. Exterior 5 Remove the door trim[...]

19 Central locking system - component removal and refitting 2 1 The central locking system fitted to some models comprises the following (see illustration) : a) Pressure/vacuum pump b) Control element - on driver’s door c) Shift elements - on remaining doors and fuel tank flap d) Interconnecting tubing. 2 To remove the pressure/vacuum pump, relea[...]

21 Windows - removal and refitting 5 Doors 1 Remove the window regulator. 2 With the window fully lowered, unclip the inner and outer mouldings from the window aperture. 3 Remove the bolt and screw and pull out the front window channel abutting the corner window. 4 Withdraw the corner window and seal. 5 Lift the glass from the door. 6 Refitting is [...]

1988-on 11 From 1988, the exterior mirrors are mounted in the triangular area in front of the window glass (see illustration) . 12 The removal and refitting procedures are basically the same as for earlier models. 13 The mirror glass is clipped in position and may be removed by carefully levering out the bottom edge, then the top edge, using a plas[...]

6 Renew any retaining screw location rivets which are damaged. 7 Refit in the reverse order of removal. 26 Front wing - removal and refitting 3 1 A damaged front wing may be renewed complete. First, remove the front bumper. 2 Remove the screws and withdraw the liner from inside the wing. 3 Where applicable, disconnect/remove the wing- mounted radio[...]

Care must be taken to protect the paintwork. 9 Clean off any adhesive and polish using white spirit and a suitable silicone remover. 10 Before fitting the new strip into position, check that the contact area on the body is dry and heat it to a temperature of 35°C. Peel back the foil from the new strip and carefully locate it into position by press[...]

Refitting 7 To refit the sunroof, locate it in the aperture and fit the front guides. 8 With the sunroof closed and correctly aligned, fit the rear guides and leaf springs. Adjustment 9 For correct adjustment, the front edge of the sunroof must be level with, or a maximum of 1.0 mm below, the roof panel. The rear edge must be level with, or a maxim[...]

4 Remove the centre console. 5 Pull free the heater/fresh air control knobs then carefully unclip the control panel trim and detach the electrical connectors. 6 Remove the radio/cassette unit or cubby hole, the instrument panel cluster and the loudspeaker and grille. 7 Remove the air vent pivot grilles by carefully levering them free. Undo the scre[...]

8 Remove the cross-head screw (3) and pull the cap (4) from the seat guide (see illustration) . 9 Slide the seat fully forward and then unscrew the cap nut. Extract the circlip and fillister head screw. 10 Release the locking bar and slide the seat rearwards out of the guide rails. 11 Refitting is a reversal of removal. 32 Rear seat - removal and r[...]

3 These adjustable seat belts can be fitted to any model having a chassis number later than 16/19 G 054 900, but a new B pillar trim must also be fitted. 4 Never modify a seat belt or alter its attachment point to the body. 34 Dust and pollen filter - renewal 2 This filter is fitted (or can be fitted) to all models covered by this Manual. The filte[...]

1081 VW Golf & Jetta 10 Chapter 10 Suspension and steering Front suspension Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Independent with spring struts, lower track control arms and anti-roll bar (some models). Telescopic shock absorbers incorporated in struts Rear suspension Type [...]

Roadwheels Golf base, C, CL and C Formel E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5J x 13 Golf GL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1 ⁄ 2 J x 13 Golf GTI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 ⁄ [...]

Suspension and steering 10•3 10 1081 VW Golf & Jetta 1.2 Rear suspension components 1.1 Front suspension components[...]

2 Front suspension strut - removal, overhaul and refitting 3 Removal 1 Apply the handbrake then jack up and support the front of the vehicle on axle stands (see “ Jacking and vehicle support ”). Remove the roadwheel on the side concerned. 2 Position a jack under the outer end of the track control arm for support. 3 In the engine compartment, pr[...]

3 Front suspension - camber adjustment 4 Early models 1 On early models, front suspension camber adjustment is possible by loosening the two bolts securing the strut to the wheel bearing housing, then turning the eccentric top bolt as required. The position of the eccentric bolt must be accurately marked before removing it, otherwise the camber adj[...]

6 Undo the two suspension arm -to-wheel bearing retaining bolt nuts and remove them, together with their special washers. These nuts must be renewed when refitting. Withdraw the bolts and separate the wheel bearing housing from the suspension strut. 7 If the wheel bearing housing is to be renewed, remove the wheel bearing then fit the bearing and h[...]

14 Delay tightening the pivot bolts until the weight of the vehicle is on the suspension. 15 Have the front wheel camber angle checked and if necessary, adjusted by a VW dealer. 8 Rear suspension strut and coil spring - removal and refitting 4 Removal 1 Detach the trim panel from the top of the rear suspension strut within the luggage compartment. [...]

9 Rear axle beam - removal and refitting 4 Note: If the axle beam is suspected of being distorted, then it should be checked in position by a VW garage using optical alignment equipment Modification: On 1988 models, the rear suspension mounting bracket bolts incorporate a modified shoulder. Their tightening torque is reduced to that specified. Remo[...]

Refitting 5 Refitting is a reversal of removal. Ensure that the turn signal lever is in its neutral position, otherwise damage may occur in the cancelling arm. The cancelling ring tongue points to the left. Tighten the retaining nut to the specified torque. 6 On completion, reconnect the battery and check that the horn and column switches operate s[...]

Overhaul 9 Check the various components for excessive wear. If the column has been damaged in any way then it must be renewed as a unit. If renewing the earlier type column as a unit, then the later telescopic type column unit may be fitted, in which case a new lower mounting must also be fitted as the earlier type is not compatible with the later [...]

4 Release the retaining clips and withdraw the bellows from the steering gear and tie-rod (see illustration) . 5 Refit in the reverse order of removal. Smear the inner bore of the bellows with lubricant prior to fitting to ease its assembly. Renew the balljoint locknuts. 6 On completion, check front wheel alignment. 15 Tie- rods and balljoints - re[...]

13 Reconnect the outer balljoints to the wheel bearing housing and tighten the locknuts to the specified torque wrench settings. Always fit new locknuts if refitting the old balljoints/tie-rod. 14 On completion, check front wheel alignment. Power steering Removal 15 Remove the steering gear unit together with the tie-rods from the vehicle. This is [...]

Suspension and steering 10•13 10 1081 VW Golf & Jetta 17.3 Power steering gear components 17.7 Manual steering gear components[...]

the steering column a sufficient amount to enable the pinion shaft to disengage from the lower column joint. Before disengaging the pinion from the lower column joint, it is advisable to make an index mark between the two to ensure correct alignment when refitting. 10 On power steering models, support the weight of the engine/gearbox unit by using [...]

Removal 2 To remove the pump unit, first drain the system fluid. 3 Disconnect the pressure hose from the pump unit (see illustration) . 4 Loosen the pump unit retaining bolts and pivot the pump so that the drivebelt can be disconnected from the pulley. 5 Support the pump, withdraw the retaining bolts and withdraw the pump unit. Refitting 6 Refittin[...]

10•16 1081 VW Golf & Jetta Notes[...]

1081 VW Golf & Jetta 12 Chapter 12 Body electrical systems System Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt, negative earth Fuses - pre August 1989 Fuse Component Rating (amps) 1 Radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

1 General information and precautions General information The electrical system is of a 12-volt negative earth type and comprises a battery, an alternator with integral voltage regulator, a starter motor and related electrical accessories, components and wiring. Further details of the various systems are given in the relevant Sections of this Chapt[...]

k) Never use an ohmmeter of the type incorporating a hand cranked generator for circuit or continuity testing. l) When carrying out welding operations on the vehicle using electric welding equipment, disconnect the battery and alternator. m) When fitting electrical accessories it is important that they are connected correctly, otherwise serious dam[...]

2 The fuses are numbered consecutively for identification. Always renew a fuse with one of identical rating and never renew it more than once without finding out the source of the problem (see illustration) . 3 All relays are of the plug -in type and are numbered for identification, though not consecutively (see illustration) . 4 Relays cannot be r[...]

6 Headlamp range control - removal and refitting 2 1 Where fitted, this system is designed to provide the driver with in-car headlamp adjustment to counteract the effects of heavy loading at the rear. The system operates on dipped headlamps only and the light units are raised or lowered by means of an electrically- operated motor mounted at the rea[...]

Rear lights 8 Open the tailgate or bootlid, as applicable. Compress the bulb carrier securing tabs to release the bulb carrier and withdraw it for bulb inspection/renewal (see illustration) . 9 Depress and twist the relevant bulb to remove it. Number plate light 10 Remove the cross-head screws and withdraw the lens and cover (see illustration) . 11[...]

4 If the indicators do not function correctly, a series of tests may be done to find which part of the circuit is at fault. 5 The most common fault is in the flasher lamps, defective bulbs and dirty or corroded contacts or mountings. Check these first, then test the emergency switch. Remove it from the circuit and check its operation. 6 If the swit[...]

3 On other switch types such as the heated rear seat switch, simply lever the switch free from the bottom edge (see illustration) . 4 With the switch withdrawn, detach the wiring connector. Where applicable, warning light bulb holders can be withdrawn from the switch and the bulb removed. 5 Refitting is a reversal of the removal procedure. Check th[...]

Body electrical systems 12•9 12 1081 VW Golf & Jetta 17.2a Instrument panel unit components – type A 1 Voltage stabiliser 2 Bulb 3 Connecting housing (black) 4 LED’s 5 Diode holder 6 Switch unit (printed) 7 Speedometer 8 Gearchange and consumption indicator 9 Dash insert 10 Switch rod for memory 11 Coolant temperature gauge 12 Fuel gauge [...]

LED indicators 6 The warning lamp LED indicators in the lamp housing are positioned as shown (see illustration) . When renewing the LEDs, each diode can be pulled free from the retainer plate. Note that one of the connector prongs is wider. This is the negative connection and it is important that it is correctly refitted. If necessary, the diode ho[...]

Component testing Voltage stabiliser 11 To test the voltage stabiliser, connect a voltmeter between the terminals shown (see illustration) with a 12 volt supply to the remaining terminal. A constant voltage of 10 volts must be registered. If the voltage is above 10.5 volts or below 9.5 volts renew the voltage stabiliser. Fuel gauge 12 The accuracy [...]

21 Cigarette lighter - removal and refitting 1 1 Disconnect the battery negative lead. 2 Remove the lower facia panel then reach up and disconnect the wiring from the cigarette lighter. 3 Remove the retaining ring and withdraw the cigarette lighter from the facia. 4 Refitting is a reversal of removal. 22 Speedometer cable - removal and refitting 2 [...]

3 Ease the wiper arm from the spindle, taking care not to damage the paintwork (see illustration) . 4 Refitting is a reversal of removal. 5 In the parked position, the end of the wiper arm (ie. middle of the blade), should be positioned as shown (see illustration) . 6 On the rear window, the dimension should be measured at the points shown (see ill[...]

12•14 Body electrical systems 1081 VW Golf & Jetta 29.2b Rear window wiper components 29.2a Windscreen wiper components[...]

29 Windscreen wiper linkage - removal and refitting 2 1 Disconnect the battery negative lead. 2 Remove the wiper arms, then unscrew the bearing nuts and remove the spacers (see illustrations) . 3 Pull the weatherstrips from the front of the plenum chamber and remove the plastic cover. 4 Disconnect the wiring multi-plug. 5 Unscrew the frame mounting[...]

32 Loudspeakers - removal and refitting 1 1 Disconnect the battery earth lead. Facia-mounted speakers 2 Carefully prise free the small square plastic cap covering the screw head in the speaker grille then undo and remove the screw. Lift the speaker grille clear. 3 Undo the two screws securing the speaker unit and lift the speaker out far enough to [...]

Wiring diagrams 12•17 12 1081 VW Golf & Jetta[...]

12•18 Wiring diagrams 1081 VW Golf & Jetta[...]

Wiring diagrams 12•19 12 1081 VW Golf & Jetta[...]

12•20 Wiring diagrams 1081 VW Golf & Jetta[...]

Wiring diagrams 12•21 12 1081 VW Golf & Jetta Wiring relays and connections – all models Relays (typical) 1 Vacant 2 Intake manifold preheating relay (carburettor models) or fuel pump relay (injection models) 3 Seat belt warning system relay 4 Gearshift indicator control unit 5 Air conditioner relay 6 Dual tone horn relay 7 Relay for foglig[...]

12•22 Wiring diagrams 1081 VW Golf & Jetta Diagram 2 Interior light, boot light, radio and cigarette lighter - 1.05, 1.3 and 1.6 models, pre July 1987 Diagram 1 Starter, alternator, battery and ignition system - 1.05, 1.3 and 1.6 models, pre July 1987[...]

Wiring diagrams 12•23 12 1081 VW Golf & Jetta Diagram 4 Headlights, tail lights and dip/flasher headlight switch - 1.05, 1.3 and 1.6 models, pre July 1987 Diagram 3 Lighting switch, instrument and dash insert lights - 1.05, 1.3 and 1.5 models, pre July 1987[...]

12•24 Wiring diagrams 1081 VW Golf & Jetta Diagram 6 Indicators and hazard warning lights - 1.05, 1.3 and 1.6 models, pre July 1987 Diagram 5 Foglights, rear foglights and heated rear window - 1.05, 1.3 and 1.6 models, pre July 1987[...]

Wiring diagrams 12•25 12 1081 VW Golf & Jetta Diagram 8 Dual tone horn, handbrake and brake fluid level warning - 1.05, 1.3 and 1.6 models, pre July 1987 Diagram 7 Brake lights, fresh air blower, reversing lights and radiator fan - 1.05, 1.3 and 1.6 models, pre July 1987[...]

Diagram 11 Intake manifold preheater and automatic choke - 1.3 models, pre July 1986 12•26 Wiring diagrams 1081 VW Golf & Jetta Diagram 10 Rear wiper and washer - 1.05, 1.3 and 1.6 models, pre December 1985 Diagram 9 Windscreen wiper and washer - 1.05, 1.3 and 1.6 models. Golf, pre December 1985. Jetta pre July 1987[...]

Wiring diagrams 12•27 12 1081 VW Golf & Jetta Diagram 13 Lighting switch, instrument and dash lights - 1.8 models, pre July 1987 Diagram 12 Starter, alternator, battery and ignition system - 1.8 models with carburettor[...]

12•28 Wiring diagrams 1081 VW Golf & Jetta Diagram 15 Rear foglight and heated rear window - 1.8 models, pre July 1987 Diagram 14 Headlights, tail lights and dip flasher switch - 1.8 models, pre July 1987[...]

Wiring diagrams 12•29 12 1081 VW Golf & Jetta Diagram 17 Brake lights, fresh air blower, reversing lights and radiator fan - 1.8 models, pre July 1987 Diagram 16 Indicators and hazard warning lights - 1.8 models, pre July 1987[...]

12•30 Wiring diagrams 1081 VW Golf & Jetta Diagram 19 Windscreen wiper and washer - 1.8 models, pre July 1987 Diagram 18 Dual tone horn, handbrake and brake fluid warning - 1.8 models, pre July 1987[...]

Wiring diagrams 12•31 12 1081 VW Golf & Jetta Diagram 21 Electric windows - 1.8 models with carburettor, pre July 1987 Diagram 20 Electrically-controlled heated outside mirror and rear wiper and washer - 1.8 models, pre December 1985[...]

12•32 Wiring diagrams 1081 VW Golf & Jetta Diagram 23 Starter, alternator, battery, ignition system and increased idling speed - 1.8 models with fuel injection, from August 1984 to July 1987 Diagram 22 Starter, alternator, battery and ignition system - 1.8 models with fuel injection, pre July 1984[...]

Wiring diagrams 12•33 12 1081 VW Golf & Jetta Diagram 25 250W radiator fan - 1.6 and 1.8 models Diagram 26 Automatic transmission - 1.6 models Diagram 24 Headlight washer - all models[...]

12•34 Wiring diagrams 1081 VW Golf & Jetta Diagram 28 Starter, alternator and battery - 1.8 16v models Diagram 27 Starter, alternator, battery and ignition system - 1.3 models, from August 1985[...]

Wiring diagrams 12•35 12 1081 VW Golf & Jetta Diagram 30 Low coolant level warning - 1.8 16v models Diagram 29 Ignition system - 1.8 16v models[...]

12•36 Wiring diagrams 1081 VW Golf & Jetta Diagram 32 Starter, alternator, battery and ignition system - 1.6 models from August 1985 to July 1987 Diagram 31 Fuel supply - 1.8 16v models[...]

Wiring diagrams 12•37 12 1081 VW Golf & Jetta Diagram 34 Windscreen wiper - all Golf models from January 1986 to July 1987 Diagram 33 Radiator fan run-on - 1.6 and 1.8 models from March 1986 to July 1987[...]

12•38 Wiring diagrams 1081 VW Golf & Jetta Diagram 36 Starter, alternator, battery and ignition system - 1.6 models, from August 1987 Diagram 35 Windscreen washer, rear wiper and washer - all Golf models from January 1986 to July 1987[...]

Wiring diagrams 12•39 12 1081 VW Golf & Jetta Diagram 38 Interior lights, boot light and radio - all models, from August 1987 Diagram 37 Inlet manifold preheating and automatic choke - 1.6 models, from August 1987[...]

12•40 Wiring diagrams 1081 VW Golf & Jetta Diagram 40 Headlights, tail lights, dip/flasher headlight switch, brake light switch and reversing light switch - all models, from August 1987 Diagram 39 Light switch and number plate lights - all models, from August 1987[...]

Wiring diagrams 12•41 12 1081 VW Golf & Jetta Diagram 42 Foglights, rear foglights and heated rear window - all models, from August 1987 Diagram 41 Indicators and hazard warning lights - all models, from August 1987[...]

12•42 Wiring diagrams 1081 VW Golf & Jetta Diagram 44 Windscreen wiper and washers (with heated jets) - all models, from August 1987 Diagram 43 Handbrake and brake fluid level warning, fresh air blower, glovebox light and horn - all models, from August 1987[...]

Wiring diagrams 12•43 12 1081 VW Golf & Jetta Diagram 46 Electric windows - 1.6 models, from August 1987 Diagram 45 Rear window wiper and radiator fan run-on - 1.6 and 1.8 carburettor models, from August 1987[...]

12•44 Wiring diagrams 1081 VW Golf & Jetta Diagram 48 Rear window wiper and radiator fan - 1.05, 1.3 and 1.8 fuel injection models, from August 1987 Diagram 47 Handbrake, brake fluid warning, low coolant level indicator and dual tone horn - all models from 1987[...]

Wiring diagrams 12•45 12 1081 VW Golf & Jetta Diagram 50 Alternator, battery, starter motor and ignition switch - 1.6 and 1.8 carburettor models, from January 1989 Diagram 49 Automatic transmission - 1.6 models, from January 1989[...]

12•46 Wiring diagrams 1081 VW Golf & Jetta Diagram 52 Automatic choke and inlet manifold preheating - 1.6 and 1.8 carburettor models, from January 1989 Diagram 51 Radiator fan and fresh air blower - 1.6 and 1.8 carburettor models, from January 1989[...]

Wiring diagrams 12•47 12 1081 VW Golf & Jetta Diagram 54 Instrument panel and oil pressure warning system - 1.6 and 1.8 carburettor models, from January 1989 Diagram 53 Ignition system and overrun cut-off - 1.6 and 1.8 carburettor models, from January 1989[...]

12•48 Wiring diagrams 1081 VW Golf & Jetta Diagram 56 Handbrake ‘on’ and brake fluid level warning - 1.6 and 1.8 carburettor models, from January 1989 Diagram 55 Instrument panel (tachometer clock, fuel and temperature gauges) - 1.6 and 1.8 carburettor models, from January 1989[...]

Wiring diagrams 12•49 12 1081 VW Golf & Jetta Diagram 58 Interior light, boot light and number plate light - 1.6 and 1.8 carburettor models, from January 1989 Diagram 57 Glovebox light, cigarette lighter, radio connection and cassette storage light - 1.6 and 1.8 carburettor models, from January 1989[...]

12•50 Wiring diagrams 1081 VW Golf & Jetta Diagram 60 Direction indicators, hazard warning lights and parking light switch - 1.6 and 1.8 carburettor models, from January 1989 Diagram 59 Headlights, sidelights and headlight dip/flash switch - 1.6 and 1.8 carburettor models, from January 1989[...]

Wiring diagrams 12•51 12 1081 VW Golf & Jetta Diagram 62 Lighting switch and brake lights - 1.6 and 1.8 carburettor models, from January 1989 Diagram 61 Direction indicators and tail lights - 1.6 and 1.8 carburettor models, from January 1989[...]

[...]

Wiring diagrams 12•53 12 1081 VW Golf & Jetta Diagram 66 Central locking system - all models from January 1989 Diagram 65 Windscreen washers and wipers - 1.6 and 1.8 carburettor models, from January 1989[...]

12•54 Wiring diagrams 1081 VW Golf & Jetta Diagram 68 Dim-dip lights (headlight bulbs) - all models from January 1989 Diagram 67 Dim-dip lights (lighting switch and series resistance) - all models from January 1989[...]

Wiring diagrams 12•55 12 1081 VW Golf & Jetta Diagram 70 Digijet control unit and injectors - 1.3 (code NZ) models Diagram 69 Digijet control unit and sensors - 1.3 (code NZ) models[...]

12•56 Wiring diagrams 1081 VW Golf & Jetta Diagram 72 Digifant ignition system - later 1.8 models Diagram 71 Digifant fuel system - later 1.8 models[...]

1081 VW Golf & Jetta 11 Chapter 11 Bodywork and fittings Torque wrench settings Nm lbf ft Bumper bracket bolts: Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 61 Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 52 Tailgate [...]

If the vehicle is very dirty, especially underneath or in the engine compartment, it is tempting to use one of the pressure washers or steam cleaners available on garage forecourts. Whilst these are quick and effective, especially for the removal of the accumulation of oily grime which sometimes is allowed to become thick in certain areas, their us[...]

Repair of rust holes or gashes in bodywork Remove all paint from the affected area and from an inch or so of the surrounding sound bodywork, using an abrasive pad or a wire brush on a power drill. If these are not available a few sheets of abrasive paper will do the job most effectively. With the paint removed you will be able to judge the severity[...]

used. At one time the use of a universal paint was not possible owing to the complex range of plastics encountered in body component applications. Standard paints, generally speaking, will not bond satisfactorily to plastic or rubber, but a proprietary paint to match any plastic or rubber finish can be obtained from dealers. However, it is now poss[...]

hand. A largish screwdriver will just reach the lock release when inserted through the grille centre badge. By pushing the screwdriver or carefully using the badge as a pivot, the bonnet can be unlocked. 8 Radiator grille - removal and refitting 1 1 Raise and support the bonnet. 2 Undo and remove the two grille retaining screws on the top front edg[...]

retaining lugs each side of the lock cylinder together then pull free the grip (see illustration) . 4 Fit the key to the lock cylinder, prise free the retaining clip and withdraw the lock cylinder by pulling on the key. 5 To remove the cylinder housing, prise free the retaining ring and withdraw the housing from the grip. 6 Refitting is a reversal [...]

14 Door trim panel - removal and refitting 2 Removal 1 Unscrew and remove the door locking knob (see illustration) . 2 Remove the inner handle surround by sliding it to the rear (see illustration) . 3 Prise the cover from the door pull with a small screwdriver, remove the cross-head screws and withdraw the door pull (see illustrations) . 4 Note the[...]

11•8 Bodywork and fittings 1081 VW Golf & Jetta 15.2a Front door components - pre 1988 15.2b Front door components – from 1988 a = 310 mm 1 Exterior handle 2 Locking rod 3 Door lock 4 Locking pin 5 Seal 6 Internal remote control 7 Pull rod 8 Window regulator 9 Window glass[...]

15 Door handles - removal and refitting 2 Interior 1 Remove the door trim panel. 2 Pull the foam seal away then prise the retainer from the bottom of the handle (see illustrations) . 3 Press the finger plate forwards out of the door and unhook it from the rod (see illustration) . 4 Refitting is a reversal of removal. Exterior 5 Remove the door trim[...]

19 Central locking system - component removal and refitting 2 1 The central locking system fitted to some models comprises the following (see illustration) : a) Pressure/vacuum pump b) Control element - on driver’s door c) Shift elements - on remaining doors and fuel tank flap d) Interconnecting tubing. 2 To remove the pressure/vacuum pump, relea[...]

21 Windows - removal and refitting 5 Doors 1 Remove the window regulator. 2 With the window fully lowered, unclip the inner and outer mouldings from the window aperture. 3 Remove the bolt and screw and pull out the front window channel abutting the corner window. 4 Withdraw the corner window and seal. 5 Lift the glass from the door. 6 Refitting is [...]

1988-on 11 From 1988, the exterior mirrors are mounted in the triangular area in front of the window glass (see illustration) . 12 The removal and refitting procedures are basically the same as for earlier models. 13 The mirror glass is clipped in position and may be removed by carefully levering out the bottom edge, then the top edge, using a plas[...]

6 Renew any retaining screw location rivets which are damaged. 7 Refit in the reverse order of removal. 26 Front wing - removal and refitting 3 1 A damaged front wing may be renewed complete. First, remove the front bumper. 2 Remove the screws and withdraw the liner from inside the wing. 3 Where applicable, disconnect/remove the wing- mounted radio[...]

Care must be taken to protect the paintwork. 9 Clean off any adhesive and polish using white spirit and a suitable silicone remover. 10 Before fitting the new strip into position, check that the contact area on the body is dry and heat it to a temperature of 35°C. Peel back the foil from the new strip and carefully locate it into position by press[...]

Refitting 7 To refit the sunroof, locate it in the aperture and fit the front guides. 8 With the sunroof closed and correctly aligned, fit the rear guides and leaf springs. Adjustment 9 For correct adjustment, the front edge of the sunroof must be level with, or a maximum of 1.0 mm below, the roof panel. The rear edge must be level with, or a maxim[...]

4 Remove the centre console. 5 Pull free the heater/fresh air control knobs then carefully unclip the control panel trim and detach the electrical connectors. 6 Remove the radio/cassette unit or cubby hole, the instrument panel cluster and the loudspeaker and grille. 7 Remove the air vent pivot grilles by carefully levering them free. Undo the scre[...]

8 Remove the cross-head screw (3) and pull the cap (4) from the seat guide (see illustration) . 9 Slide the seat fully forward and then unscrew the cap nut. Extract the circlip and fillister head screw. 10 Release the locking bar and slide the seat rearwards out of the guide rails. 11 Refitting is a reversal of removal. 32 Rear seat - removal and r[...]