VW MKII A2 MK2 Golf Jetta Fox Service Manual - VAGLinks.com

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4A•22 Fuel and exhaust systems - carburettor models 19.5 Inlet manifold support stay - 1.3 litre 19.6 Inlet manifold-to-cylinder head securing nuts and bolts locations, then carefully withdraw the manifold from the cylinder head. 7 Remove the gasket and clean the mating faces of the manifold and cylinder head. 8 Refitting is a reversal of the removal procedure. Use a new manifold gasket and tighten the securing nuts and bolts to the specified torque setting. Exhaust manifold 9 Undo the retaining nut(s) and withdraw the warm air deflector plate from the exhaust manifold (see illustration). 10 On 1.05 and 1.3 litre engines, unbolt and detach the exhaust downpipe from the manifold joint (see illustration). 11 On 1.6 and 1.8 litre engines, refer to Section 20, paragraph 2. 12 Unscrew and remove the remaining manifold retaining bolts/nuts, then carefully withdraw the manifold from the cylinder head. Remove the gasket. 13 Clean the mating faces of the manifold and cylinder head. Also the exhaust downpipe flange connections. 14 Refit in the reverse order of removal. Use a new gasket and tighten the securing nuts/bolts evenly to the specified torque wrench setting. 15 When reconnecting the downpipe to the manifold, smear a little exhaust jointing paste onto the flange prior to connection. This will ensure a good seal at the joint. Note position of earth lead spade connector (arrowed) - 1.3 litre 20 Exhaust system - inspection, removal and refitting 3 Inspection 1 Refer to Chapter 1, Section 19 Removal 19.10 Exhaust downpipe-to-manifold flange connection - 1.3 litre 2 On 1.6 and 1.8 litre engines, it should be noted that if the exhaust system is to be separated at the manifold/downpipe connection, then VW tool No. 3049A will be necessary to release and subsequently refit the joint retaining clips (see illustration). Without this tool, it is virtually impossible to separate and reassemble the joint without distorting the retaining clips. In view of this, removal and refitting of the system will necessitate detachment of the manifold and front pipe section, or manifold and system complete, and then taking the assembly to your VW dealer to separate/reassemble the front joint. If the complete system is in need of replacement, it is probably best entrusted to your VW dealer. 3 On 1.05 and 1.3 litre engines, when removing any part of the exhaust system it is usually easier to undo the manifold-to-front pipe joint and remove the complete system from the vehicle, then separate the various 1081 VW Golf & Jetta 20.2 VW tool 3049A used to release and fit exhaust downpipes to manifold clips - 1.6 and 1.8 litre 19.9 Warm air deflector plate - 1.3 litre pieces of the system, or cut out the defective part with a hacksaw. 4 Before doing any dismantling work on the exhaust system, wait until the system is cool and then saturate all bolts and joints with a proprietary anti-corrosion fluid (see illustrations). It may be found easier to cut through heavily corroded bolts with a hacksaw, rather than try to unscrew them. Refitting 5 Refit the system a section at a time starting at the front. If the manifold has been removed its gasket must be renewed. New nuts and bolts should be used throughout the system. 6 Before assembly, smear all joints with a proprietary exhaust sealing compound. This makes it easier to align the pieces and also ensures that the joints will be gas tight. Leave all bolts loose. 7 Run the engine until the exhaust system is at normal temperature and then, with the engine running at idling speed, tighten all the mounting bolts and clips, starting at the manifold and working towards the rear silencer. Take care to avoid touching any part of the system with bare hands because of the danger of painful burns. 8 With all bolts and clips tightened, it is important to ensure that there is no strain on any part of the system.
Fuel and exhaust systems - carburettor models 4A•23 20.4a Exhaust system and associated components – 1.5 and 1.3 litre Connecting piece and clamp setting dimensions a = 5.0 mm b = 12.0 mm c Marking (S) 20.4b Exhaust system and associated components – 1.6 and 1.8 litre 1081 VW Golf & Jetta 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) 4A
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Chapter 1 Routine maintenance and s
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CO content (%) 1.05 litre carburett
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The maintenance intervals in this M
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Maintenance - component location 1
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Maintenance - component location 1
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6 Fluid leakage and engine electric
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9 The engine will turn over more ea
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13 Wipe clean the distributor cap a
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18.13 Using a chain wrench to unscr
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25.3a Bend each brake hose to check
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32.4b . . . loosen front mounting n
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Chapter 2 Part A: Engine repair pro
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1.3 litre: Inlet opens . . . . . .
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difficulty is experienced, it may b
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9 Cylinder head - removal 3 1 If th
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11 Cylinder head - dismantling and
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14.13a Withdrawing crankshaft rear
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21 Crankshaft and bearings - examin
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29.2 Fitting centre main bearing sh
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35.9 Camshaft sprocket (later type)
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Chapter 2 Part B: Engine repair pro
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4.5 Two lengths of metal used to lo
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9 Oil pump - refitting 3 Refitting
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guide the cylinder head into positi
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Chapter 2 Part C: Engine repair pro
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Stem diameter: Inlet . . . . . . .
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1 General information The 1.6 and 1
Page 55 and 56: 26 The engine/gearbox unit is now r
Page 57 and 58: 9.6 Intermediate sprocket timing ma
Page 59 and 60: and tappet is required. Label the c
Page 61 and 62: 13.1 Sump, oil pump and oil filter
Page 63 and 64: 17 Oil filter - renewal Refer to Ch
Page 65 and 66: 30.3a Fitting flanged type centre m
Page 67 and 68: etween the camshaft and intermediat
Page 69 and 70: Chapter 2 Part D: Engine repair pro
Page 71 and 72: 1 General information The 1.8 litre
Page 73 and 74: Chapter 3 Cooling, heating and air
Page 75 and 76: 1 Radiator 2 Fan ring 3 Expansion t
Page 77 and 78: 2.2 Removing expansion tank cap 2.4
Page 79 and 80: Refitting 8 Refitting is a reversal
Page 81 and 82: 8.3a Pulling free heater/ventilatio
Page 83 and 84: 11 Air conditioning system compress
Page 85 and 86: Chapter 4 Part A: Fuel and exhaust
Page 87 and 88: Carburettor-1.6 litre Pierburg/Sole
Page 89 and 90: 3.6 Air cleaner components - 1.6 an
Page 91 and 92: 6.1 Fuel reservoir location - 1.3 l
Page 93 and 94: etaining clip and then disconnect t
Page 95 and 96: Fuel and exhaust systems - carburet
Page 97 and 98: Fuel and exhaust systems - carburet
Page 99 and 100: 15.10 Idle speed (A) and mixture (B
Page 101 and 102: 15.53 Checking choke valve gap (wid
Page 103 and 104: 17.10 Accelerator pump check prepar
Page 105: 18.3a Unscrew the bolts . . . 18.3b
Page 109 and 110: Chapter 4 Part B: Fuel and exhaust
Page 111 and 112: Fuel supply The fuel pump operates
Page 113 and 114: 4 Switch off all electrical consume
Page 115 and 116: 12.5 Cold acceleration enrichment s
Page 117 and 118: 17 Pressure relief valve - removal,
Page 119 and 120: Fuel and exhaust systems - K-Jetron
Page 121 and 122: Chapter 4 Part C: Fuel and exhaust
Page 123 and 124: 1 To ignition control unit 2 Intake
Page 125 and 126: 6.3 Throttle valve switch adjustmen
Page 127 and 128: Chapter 4 Part D: Fuel and exhaust
Page 129 and 130: 1.0b Mono-Jetronic system inlet man
Page 131 and 132: distance of 4.0 mm by the operating
Page 133 and 134: Chapter 4 Part E: Fuel and exhaust
Page 135 and 136: 3.4 CO analyser and connecting pipe
Page 137 and 138: feed line attachment to the gravity
Page 139 and 140: Chapter 4 Part F: Fuel and exhaust
Page 141 and 142: A Front crankcase ventilation valve
Page 143 and 144: 12.1 Fuel pump and filter component
Page 145 and 146: Chapter 5 Part A: Ignition system -
Page 147 and 148: 1.1b Contact breaker ignition syste
Page 149 and 150: 7.4 Crankshaft pulley mark (A) timi
Page 151 and 152: Chapter 5 Part B: Ignition system -
Page 153 and 154: Ignition system - transistorised ty
Page 155 and 156: 6.4a TDC blanking plug - manual gea
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7.5 Vacuum unit removal 7.7 Hall se
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Chapter 5 Part C: Ignition system -
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6.2 Signal check method from Hall s
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Chapter 5 Part D: Starting and char
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4.3 Battery retaining clamp and bol
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Chapter 9 Braking system Contents B
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3 Use an Allen key and unscrew the
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3.18 Rear brake caliper components
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4.15 . . . followed by the outer wa
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13 Refit the hydraulic pipe and tig
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19 This method is particularly effe
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Chapter 10 Suspension and steering
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1081 VW Golf & Jetta 1.1 Front susp
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3.2 Front suspension camber adjustm
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8.4 Removing rear suspension strut
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11.3b Removing steering wheel centr
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14.4 Steering tie-rod bellows and r
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1081 VW Golf & Jetta Suspension and
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Removal 2 To remove the pump unit,
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Chapter 11 Bodywork and fittings Co
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Repair of rust holes or gashes in b
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hand. A largish screwdriver will ju
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14 Door trim panel - removal and re
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15.3 Removing interior door handle
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22.4 Front bumper bracket securing
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6 Renew any retaining screw locatio
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28.9 Sunroof adjustment dimensions
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31.8 Front seat guide fixing - from
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Chapter 12 Body electrical systems
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k) Never use an ohmmeter of the typ
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6 Headlamp range control - removal
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4 If the indicators do not function
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17.2a Instrument panel unit compone
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Component testing Voltage stabilise
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3 Ease the wiper arm from the spind
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29 Windscreen wiper linkage - remov
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1081 VW Golf & Jetta Wiring diagram
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1081 VW Golf & Jetta Wiring diagram
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Relays (typical) 1 Vacant 2 Intake
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1081 VW Golf & Jetta Diagram 3 Ligh
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1081 VW Golf & Jetta Diagram 7 Brak
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1081 VW Golf & Jetta 12 Diagram 12
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1081 VW Golf & Jetta Diagram 20 Ele
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1081 VW Golf & Jetta Diagram 57 Glo
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