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VW Golf & Jetta Service and Repair Manual

VW Golf & JettaService and Repair ManualModels coveredVW 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 ccCovers mechanical features of Van. Does not cover Convertible, Rallye, Caddy, diesel engine, 4 -wheel drive, Mk 1 models or new Golf range introduced in February 1992I M Coomber and Christopher Rogers Haynes Publishing 1997A book in the Haynes Service and Repair Manual SeriesAll rights reserved. No part of this book may be reproduced ortransmitted in any form or by any means, electronic ormechanical, including photocopying, recording or by anyinformation storage or retrieval system , without permission inwriting from the copyright 1 85960 282 7 British Library Cataloguing in Publication DataA catalogue record for this book is available from the British LibraryPrinted by J H Haynes & Co.

Engine repair procedures - 1.05 and 1.3 litre - post August 1985 Page 2B•1 Engine repair procedures ... Braking system Page 9•1 Suspension and steering Page 10•1 Body Equipment Bodywork and fittings Page 11•1 Body electrical systems Page 12•1 Wiring Diagrams Page 12•17

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Transcription of VW Golf & Jetta Service and Repair Manual

1 VW Golf & JettaService and Repair ManualModels coveredVW 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 ccCovers mechanical features of Van. Does not cover Convertible, Rallye, Caddy, diesel engine, 4 -wheel drive, Mk 1 models or new Golf range introduced in February 1992I M Coomber and Christopher Rogers Haynes Publishing 1997A book in the Haynes Service and Repair Manual SeriesAll rights reserved. No part of this book may be reproduced ortransmitted in any form or by any means, electronic ormechanical, including photocopying, recording or by anyinformation storage or retrieval system , without permission inwriting from the copyright 1 85960 282 7 British Library Cataloguing in Publication DataA catalogue record for this book is available from the British LibraryPrinted by J H Haynes & Co.

2 Ltd, Sparkford, Nr Yeovil, SomersetBA22 7JJ, EnglandHaynes PublishingSparkford Nr YeovilSomerset BA22 7JJ EnglandHaynes North America, Inc861 Lawrence DriveNewbury ParkCalifornia 91320 USAE ditions Haynes , rue Saint Honor , 75001 PARIS, FranceHaynes Publishing Nordiska ABFyrisborgsgatan 5, 754 50 Uppsala, Sverige(1081 - 344 - 1AA11)ABCDEFGHIJKLMNOPQRST1 2 3 LIVING WITH YOUR VOLKSWAGEN GOLF OR JETTAI ntroductionPage0 4 Safety First!Page0 5 Roadside RepairsIntroduction Page0 6If your car won t startPage0 6 Jump startingPage0 7 Wheel changingPage0 8 Identifying leaksPage0 9 TowingPage0 9 Weekly ChecksIntroductionPage0 10 Underbonnet check pointsPage0 10 Engine oil levelPage0 11 Coolant levelPage0 11 Brake fluid levelPage0 12 Power steering fluid levelPage0 12 Screen/headlamp washer fluid levelPage0 13 Wiper bladesPage0 13 Tyre condition and pressurePage0 14 BatteryPage0 15 Electrical systemsPage0 15 Lubricants and fluidsPage0 16 Capacities and tyre pressuresPage0 17 MAINTENANCER outine Maintenance and ServicingServicing specificationsPage1 2 Maintenance schedule.

3 Vehicles manufactured before August 1985 Page1 5 Vehicles manufactured after August 1985 Page1 6 Maintenance - component locationPage1 7 Maintenance proceduresPage1 10 Contents REPAIRS & OVERHAULE ngine and Associated SystemsEngine Repair procedures - and litre - pre August 1985 Page 2A 1 Engine Repair procedures - and litre - post August 1985 Page 2B 1 Engine Repair procedures - and litre 8 valve Page 2C 1 Engine Repair procedures - litre 16 valve Page 2D 1 Cooling.

4 Heating and air conditioning systems Page 3 1 Fuel and exhaust systems - carburettor models Page 4A 1 Fuel and exhaust systems - K-Jetronic fuel injection - 8 valve engines Page 4B 1 Fuel and exhaust systems - K-Jetronic fuel injection - 16 valve engines Page 4C 1 Fuel and exhaust systems - Mono Jetronic fuel injection Page 4D 1 Fuel and exhaust systems - Digijet fuel injection Page 4E 1 Fuel and exhaust systems - Digifant fuel injection Page 4F 1 Ignition system - contact breaker type Page 5A 1 Ignition system - transistorised type Page 5B 1 Ignition system - fully electronic type Page 5C 1 Starting and

5 Charging systems Page 5D 1 Brakes and SuspensionBraking system Page 9 1 Suspension and steering Page 10 1 Body EquipmentBodywork and fittings Page 11 1 Body electrical systems Page 12 1 Wiring Diagrams Page 12 17 ContentsThe Mk.

6 II Volkswagen Golf and Jetta range of models wasintroduced in March 1984, revised body and trim features being themain visual difference to the earlier range of engine/transmission is mounted transversely at the front of thevehicle, drive being to the front wheels. Detailed improvements havebeen made throughout the years of manufacture to improve poweroutput and economy. These include the introduction of hydraulicbucket tappets, the Digifant, Digijet and Mono-Jetronic fuel injectionsystems, the 16-valve engine fitted to the GTi variant, the fullyelectronic ignition system (FEI), the 085 5-speed gearbox and severalother minor modifications and with earlier models the new range is proving popular, givingeconomy, reliability, comfort and, if previous models can be used as ayardstick, long 4 IntroductionYour Volkswagen Golf andJetta ManualThe aim of this Manual is to help you get the best value from yourvehicle.

7 It can do so in several ways. It can help you decide what workmust be done (even should you choose to get it done by a garage),provide information on routine maintenance and servicing, and give alogical course of action and diagnosis when random faults , it is hoped that you will use the Manual by tackling the workyourself. On simpler jobs it may even be quicker than booking the carinto a garage and going there twice, to leave and collect it. Perhapsmost important, a lot of money can be saved by avoiding the costs agarage must charge to cover its labour and Manual has drawings and descriptions to show the function ofthe various components so that their layout can be understood.

8 Thenthe tasks are described and photographed in a clear are due to Champion Spark Plug who supplied theillustrations showing spark plug conditions, to Duckhams Oils, whoprovided lubrication data and also to Sykes-Pickavant Limited, whosupplied some of the workshop tools, and to all those people atSparkford who helped in the production of this take great pride in the accuracy of information given in thisManual, but vehicle manufacturers make alterations and designchanges during the production run of a particular vehicle of whichthey do not inform us. No liability can be accepted by the authorsor publishers for loss, damage or injury caused by any errors in, oromissions from the information VWGolf & Jetta TeamHaynes manuals are produced by dedicated andenthusiastic people working in close co-operation.

9 Theteam responsible for the creation of this book included: AuthorsIan CoomberCristopher RogersSub-editorsCarole TurkSophie YarEditor & Page Make-upSteve ChurchillWorkshop managerPaul BucklandPhoto ScansJohn MartinPaul TanswellSteve TanswellCover illustration & Line ArtRoger HealingWe hope the book will help you to get the maximumenjoyment from your car. By carrying out routinemaintenance as described you will ensure your car sreliability and preserve its resale GolfVW JettaSafety first!0 5 Working on your car can be page shows just some of the potentialrisks and hazards, with the aim of creating asafety-conscious hazardsScalding Don t remove the radiator or expansiontank cap while the engine is hot.

10 Engine oil, automatic transmission fluid orpower steering fluid may also be dangerouslyhot if the engine has recently been Beware of burns from the exhaust systemand from any part of the engine. Brake discsand drums can also be extremely hotimmediately after When working under or neara raised vehicle,alwayssupplement thejack with axlestands, or a car whichis only supported by a jack. Take care if loosening or tightening high-torque nuts when the vehicle is on loosening and final tightening shouldbe done with the wheels on the Fuel is highly flammable; fuel vapour isexplosive. Don t let fuel spill onto a hot engine. Do not smoke or allow naked lights(including pilot lights) anywhere near avehicle being worked on.


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