VW Golf & Jetta Service And Repair Manual - Dyn

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VW Golf & JettaService and Repair ManualI M Coomber and Christopher RogersModels 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 cc(1081 - 344 - 1AA11)Covers mechanical features of Van. Does not cover Convertible, Rallye, Caddy, diesel engine, 4 -wheel drive, Mk 1 modelsor new Golf range introduced in February 1992 Haynes Publishing 1997ABCDEFGHIJKLMNOPQRST123A 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 holder.Printed by J H Haynes & Co. Ltd, Sparkford, Nr Yeovil, SomersetBA22 7JJ, EnglandHaynes PublishingSparkford Nr YeovilSomerset BA22 7JJ EnglandHaynes North America, Inc861 Lawrence DriveNewbury ParkCalifornia 91320 USAISBN 1 85960 282 7Editions Haynes S.A.147/149, rue Saint Honoré, 75001 PARIS, FranceBritish Library Cataloguing in Publication DataA catalogue record for this book is available from the British LibraryHaynes Publishing Nordiska ABFyrisborgsgatan 5, 754 50 Uppsala, Sverige

ContentsLIVING WITH YOUR VOLKSWAGEN GOLF OR JETTAIntroductionPage0 4Safety First!Page0 5IntroductionPage0 6If your car won’t startPage0 6Jump startingPage0 7Wheel changingPage0 8Identifying leaksPage0 9TowingPage0 9Roadside RepairsWeekly ChecksIntroductionPage 0 10Underbonnet check pointsPage 0 10Engine oil levelPage 0 11Coolant levelPage 0 11Brake fluid levelPage 0 12Power steering fluid levelPage 0 12Screen/headlamp washer fluid levelPage 0 13Wiper bladesPage 0 13Tyre condition and pressurePage 0 14BatteryPage 0 15Electrical systemsPage 0 15Lubricants and fluidsPage 0 16Capacities and tyre pressuresPage 0 17MAINTENANCERoutine Maintenance and ServicingServicing specificationsPage1 2Vehicles manufactured before August 1985Page1 5Vehicles manufactured after August 1985Page1 6Maintenance - component locationPage1 7Maintenance proceduresPage 1 10Maintenance schedule:

ContentsREPAIRS & OVERHAULEngine and Associated SystemsEngine repair procedures - 1.05 and 1.3 litre - pre August 1985Page 2A 1Engine repair procedures - 1.05 and 1.3 litre - post August 1985Page 2B 1Engine repair procedures - 1.6 and 1.8 litre 8 valvePage 2C 1Engine repair procedures - 1.8 litre 16 valvePage 2D 1Cooling, heating and air conditioning systemsPageFuel and exhaust systems - carburettor modelsPage 4A 1Fuel and exhaust systems - K-Jetronic fuel injection - 8 valve enginesPage 4B 1Fuel and exhaust systems - K-Jetronic fuel injection - 16 valve enginesPage 4C 1Fuel and exhaust systems - Mono Jetronic fuel injectionPage 4D 1Fuel and exhaust systems - Digijet fuel injectionPage 4E 1Fuel and exhaust systems - Digifant fuel injectionPage 4F 1Ignition system - contact breaker typePage 5A 1Ignition system - transistorised typePage 5B 1Ignition system - fully electronic typePage 5C 1Starting and charging systemsPage 5D 13 1Brakes and SuspensionBraking systemPage9 1Suspension and steeringPage 10 1Body EquipmentBodywork and fittingsPage 11 1Body electrical systemsPage 12 1Wiring DiagramsPage 12 17

0 4IntroductionThe Mk. 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 models.The 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 revisions.As with earlier models the new range is proving popular, givingeconomy, reliability, comfort and, if previous models can be used as ayardstick, long life.VW GolfVW JettaThe VW Golf & Jetta TeamHaynes manuals are produced by dedicated andenthusiastic people working in close co-operation. 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 value.Your Volkswagen Golf andJetta ManualThe aim of this Manual is to help you get the best value from yourvehicle. 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 occur.However, 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 overheads.The Manual has drawings and descriptions to show the function ofthe various components so that their layout can be understood. Thenthe tasks are described and photographed in a clear step-by-stepsequence.AcknowledgementsThanks 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 Manual.We 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 given.

Safety first!Working on your car can be dangerous.This page shows just some of the potentialrisks and hazards, with the aim of creating asafety-conscious attitude.General hazardsScalding Don’t remove the radiator or expansiontank cap while the engine is hot. Engine oil, automatic transmission fluid orpower steering fluid may also be dangerouslyhot if the engine has recently been running.Burning Beware of burns from the exhaust systemand from any part of the engine. Brake discsand drums can also be extremely hotimmediately after use.Crushing When working under or neara raised vehicle,alwayssupplement thejack with axlestands, or usedrive-onramps.Neverventureunder a car whichis only supported by a jack. Take care if loosening or tightening hightorque nuts when the vehicle is on stands.Initial loosening and final tightening shouldbe done with the wheels on the ground. Mains voltage is also dangerous. Makesure that any mains-operated equipment iscorrectly earthed. Mains power points shouldbe protected by a residual current device(RCD) circuit breaker.Fume or gas intoxication Exhaust fumes arepoisonous; they oftencontain carbonmonoxide, which israpidly fatal if inhaled.Never run theengine in aconfined spacesuch as a garagewith the doors shut. Fuel vapour is alsopoisonous, as are the vapours from somecleaning solvents and paint thinners.Poisonous or irritant substances Avoid skin contact with battery acid andwith any fuel, fluid or lubricant, especiallyantifreeze, brake hydraulic fluid and Dieselfuel. Don’t syphon them by mouth. If such asubstance is swallowed or gets into the eyes,seek medical advice. Prolonged contact with used engine oil cancause skin cancer. Wear gloves or use abarrier cream if necessary. Change out of oilsoaked clothes and do not keep oily rags inyour pocket. Air conditioning refrigerant forms apoisonous gas if exposed to a naked flame(including a cigarette). It can also cause skinburns on contact.FireAsbestos 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. Also beware ofcreating sparks(electrically or by use of tools). Fuel vapour is heavier than air, so don’twork on the fuel system with the vehicle overan inspection pit. Another cause of fire is an electricaloverload or short-circuit. Take care whenrepairing or modifying the vehicle wiring. Keep a fire extinguisher handy, of a typesuitable for use on fuel and electrical fires. Asbestos dust can cause cancer if inhaledor swallowed. Asbestos may be found ingaskets and in brake and clutch linings.When dealing with such components it issafest to assume that they contain asbestos.Electric shock Ignition HTvoltage can bedangerous,especially topeople with heartproblems or apacemaker. Don’twork on or near theignition system withthe engine running orthe ignition switched on.0 5Special hazardsHydrofluoric acid This extremely corrosive acid is formedwhen certain types of synthetic rubber, foundin some O-rings, oil seals, fuel hoses etc, areexposed to temperatures above 4000C. Therubber changes into a charred or stickysubstance containing the acid. Once formed,the acid remains dangerous for years. If itgets onto the skin, it may be necessary toamputate the limb concerned. When dealing with a vehicle which hassuffered a fire, or with components salvagedfrom such a vehicle, wear protective glovesand discard them after use.The battery Batteries contain sulphuric acid, whichattacks clothing, eyes and skin. Take carewhen topping-up or carrying the battery. The hydrogen gas given off by the batteryis highly explosive. Never cause a spark orallow a naked light nearby. Be careful whenconnecting and disconnecting batterychargers or jump leads.Air bags Air bags can cause injury if they go offaccidentally. Take care when removing thesteering wheel and/or facia. Special storageinstructions may apply.Diesel injection equipment Diesel injection pumps supply fuel at veryhigh pressure. Take care when working onthe fuel injectors and fuel pipes.Warning: Never expose the hands,face or any other part of the bodyto injector spray; the fuel canpenetrate the skin with potentially fatalresults.Remember.A few tipsDODON’T Do use eye protection when using powertools, and when working under the vehicle. Don’t attempt to lift a heavy componentwhich may be beyond your capability – getassistance. Do wear gloves or use barrier cream toprotect your hands when necessary. Do get someone to check periodicallythat all is well when working alone on thevehicle. Do keep loose clothing and long hair wellout of the way of moving mechanical parts. Do remove rings, wristwatch etc, beforeworking on the vehicle – especially theelectrical system. Do ensure that any lifting or jackingequipment has a safe working load ratingadequate for the job. Don’t rush to finish a job, or takeunverified short cuts. Don’t use ill-fitting tools which may slipand cause injury. Don’t leave tools or parts lying aroundwhere someone can trip over them. Mopup oil and fuel spills at once. Don’t allow children or pets to play in ornear a vehicle being worked on.

0 6Roadside repairsThe following pages are intended to help in dealing withcommon roadside emergencies and breakdowns. You will findmore detailed fault finding information at the back of themanual, and repair information in the main chapters.If your car won’t startand the starter motordoesn’t turnIf your car won’t starteven though the startermotor turns as normalM If it’s a model with automatic transmission, make sure theselector is in ‘P’ or ‘N’.M Open the bonnet and make sure that the battery terminalsare clean and tight.M Switch on the headlights and try to start the engine. If theheadlights go very dim when you’re trying to start, thebattery is probably flat. Get out of trouble by jump starting(see next page) using a friend’s car.M Is there fuel in the tank?M Is there moisture on electrical components under thebonnet? Switch off the ignition, then wipe off any obviousdampness with a dry cloth. Spray a water-repellent aerosolproduct (WD-40 or equivalent) on ignition and fuel systemelectrical connectors like those shown in the photos.Pay special attention to the ignition coil wiring connectorand HT leads.ACheck that the HT lead connections atthe distributor are clean and make surethey are secure by pushing them ontothe cap.BCheck that the HT lead connections atthe spark plugs are secure by pushingthem onto the plugs.Check that electrical connections are secure (with the ignition switched off) and spray themwith a water dispersant spray like WD40 if you suspect a problem due to dampCCheck that the LT lead connections areclean and secure.DCheck the security and condition of thebattery connections.EWiring plugs may cause problems if dirtyor not connected properly.

Roadside repairsJump starting will get you outof trouble, but you must correctwhatever made the battery goflat in the first place. There arethree possibilities:The battery has been drained byrepeated attempts to start, or byleaving the lights on.1The charging system is not workingproperly (alternator drivebelt slackor broken, alternator wiring fault oralternator itself faulty).2310 7Jump startingWhen jump-starting a car using abooster battery, observe the followingprecautions:4 Make sure that the booster battery is4 Before connecting the booster4 If the battery is being jump-startedthe same voltage as the dischargedone in the vehicle.from the battery in another vehicle,the two vehcles MUST NOT TOUCHeac

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 -wheel drive, Mk 1 models or new Golf range introduced in .

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