Instruction/ maintenance manual of the product Golf (1997) Volkswagen
Go to page of 309
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.
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 Whee.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 .
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 .
0•18 Notes.
1081 VW Golf & Jetta 1 Chapter 1 Routine maintenance and servicing Air cleaner element renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Air conditioning system 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 . . . .
Lubrication system Pump gear teeth backlash: New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm 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.
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 198.
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.
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) .
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.
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.
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.
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 . .
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.
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.
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) .
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.
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.
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) .
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.
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 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) .
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.
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.
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) .
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.
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.
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.
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.
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) .
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) .
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.
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) .
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 reservoi.
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.
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.
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.
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.
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) .
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.
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.
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.
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 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.
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.
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.
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.
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) .
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.
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.
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.
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.
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 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.
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.
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.
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.
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.
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 .
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 Cylind.
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.
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.
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.
Compression pressure: 1.6 litre: New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 to 12 bar Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 bar Maximum permissible difference between any two cylinders .
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 . . . . . . . . . . . . . . . . . . . . .
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.
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.
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.
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.
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).
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.
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 resp.
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.
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.
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.
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.
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.
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.
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.
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.
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 .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carburettor-1.6 litre Pierburg/Solex 2E2 - engine code EZ Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Twin progressive choke, downdraught with automatic choke Stage I Stage II Venturi diameter .
Torque wrench settings (continued) Nm lbf ft 1.6 and 1.8 litre Carburettor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5 Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 .
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.
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 f.
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.
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.
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.
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 bo.
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 cor.
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.
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) .
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.
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).
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.
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) .
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.
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.
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.
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•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 . . . . .
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 plun.
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.
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.
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.
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 .
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.
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.
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.
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.
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.
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 .
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) .
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) .
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.
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.
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 . . . . .
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 plun.
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.
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.
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.
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 . . . . . . . . . . .
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) .
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.
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.
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.
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 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.
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.
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.
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.
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 . . . . . . . . . . . . . .
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.
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.
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.
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.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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.
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.
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).
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 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.
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.
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) .
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) .
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.
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.
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 . . . . . . . . . . . . . . . . . . . .
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.
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.
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 . . . . . . . . . .
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.
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 .
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.
1081 VW Golf & Jetta 9 Chapter 9 Braking system Brake system Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic, dual circuit, split diagonally, pressure regulator on some models.
Rear disc brakes Disc thickness: New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0 mm Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.
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.
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) .
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.
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) .
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.
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.
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.
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.
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.
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 ”).
1081 VW Golf & Jetta 11 Chapter 11 Bodywork and fittings Torque wrench settings Nm lbf ft Bumper bracket bolts: Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 61 Rear . . . . . . . . . .
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.
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.
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.
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.
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.
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) .
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 .
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) .
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.
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.
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.
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.
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.
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.
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.
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.
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.
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).
Roadwheels Golf base, C, CL and C Formel E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5J x 13 Golf GL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1 ⁄ 2 J x 13 Golf GTI . . . .
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 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.
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.
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.
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.
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 t.
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.
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.
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.
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.
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.
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.
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) .
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.
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) .
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.
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.
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 .
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.
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.
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.
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) .
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.
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.
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 (i.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 Go.
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.
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 .
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 mod.
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.
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.
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, lo.
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.
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.
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.
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.
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.
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.
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.
.
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.
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 mode.
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.
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 . . . . . . . . . .
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.
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.
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.
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.
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.
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) .
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 .
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) .
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.
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.
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.
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.
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.
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.
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.
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.
An important point after buying a device Volkswagen Golf (1997) (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Volkswagen Golf (1997) yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Volkswagen Golf (1997) - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Volkswagen Golf (1997) you will learn all the available features of the product, as well as information on its operation. The information that you get Volkswagen Golf (1997) will certainly help you make a decision on the purchase.
If you already are a holder of Volkswagen Golf (1997), but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Volkswagen Golf (1997).
However, one of the most important roles played by the user manual is to help in solving problems with Volkswagen Golf (1997). Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Volkswagen Golf (1997) along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
