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

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5C•4 Notes 1081 VW Golf & Jetta
Chapter 5 Part D: Starting and charging systems Contents Alternator - brush and voltage regulator renewal . . . . . . . . . . . . . . . 8 Alternator - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Alternator - testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Alternator drivebelt - inspection and adjustment . . . . . . . . . . . . . . . 5 Battery - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Battery - maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Degrees of difficulty Easy, suitable for novice with little experience 1 Specifications Fairly easy, suitable for beginner with some experience System Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt, negative earth 2 Fairly difficult, suitable for competent DIY mechanic Battery Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Ah or 45 Ah Minimum voltage (under load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator 9.6 volts at 110 amps Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch or Motorola Maximum output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55, 65 or 90 amp Minimum allowable brush length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 mm Rotor winding resistance (ohms): Bosch Motorola 55 amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 to 3.2 3.1 to 3.3 65 amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 to 3.1 3.9 to 4.1 90 amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter motor 3.0 to 4.0 - Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Application/VW part No: Pre-engaged 1.05 and 1.3 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 036 911 023 G 1.3 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 litre: 036 911 023 H Manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 055 911 023 G Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 055 911 023 A 1.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 027 911 023 Torque wrench settings Starter motor Nm Ibf ft 1.05 and 1.3 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15 1.6 and 1.8 litre (manual gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 44 1.6 litre (automatic transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator 20 15 Pulley nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 30 Mounting (to engine) bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 33 Mounting/alternator pivot bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 33 Adjuster strap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18 1081 VW Golf & Jetta 5D•1 Battery - charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General information and precautions . . . . . . . . . . . . . . . . . . . . . . . . 1 Starting motor - brush renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Starting motor - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 10 Starting motor - testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3 Difficult, suitable for experienced DIY mechanic 4 Very difficult, suitable for expert DIY or professional 5 5D
Page 1 and 2:
Chapter 1 Routine maintenance and s
Page 3 and 4:
CO content (%) 1.05 litre carburett
Page 5 and 6:
The maintenance intervals in this M
Page 7 and 8:
Maintenance - component location 1
Page 9 and 10:
Maintenance - component location 1
Page 11 and 12:
6 Fluid leakage and engine electric
Page 13 and 14:
9 The engine will turn over more ea
Page 15 and 16:
13 Wipe clean the distributor cap a
Page 17 and 18:
18.13 Using a chain wrench to unscr
Page 19 and 20:
25.3a Bend each brake hose to check
Page 21 and 22:
32.4b . . . loosen front mounting n
Page 23 and 24:
Chapter 2 Part A: Engine repair pro
Page 25 and 26:
1.3 litre: Inlet opens . . . . . .
Page 27 and 28:
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
Page 39 and 40:
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
Page 51 and 52:
Stem diameter: Inlet . . . . . . .
Page 53 and 54:
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
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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
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etween the camshaft and intermediat
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Chapter 2 Part D: Engine repair pro
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1 General information The 1.8 litre
Page 73 and 74:
Chapter 3 Cooling, heating and air
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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
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8.3a Pulling free heater/ventilatio
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11 Air conditioning system compress
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Chapter 4 Part A: Fuel and exhaust
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Carburettor-1.6 litre Pierburg/Sole
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3.6 Air cleaner components - 1.6 an
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6.1 Fuel reservoir location - 1.3 l
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etaining clip and then disconnect t
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Fuel and exhaust systems - carburet
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Page 99 and 100:
15.10 Idle speed (A) and mixture (B
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15.53 Checking choke valve gap (wid
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17.10 Accelerator pump check prepar
Page 105 and 106:
18.3a Unscrew the bolts . . . 18.3b
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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
Page 157 and 158: 7.5 Vacuum unit removal 7.7 Hall se
Page 159 and 160: Chapter 5 Part C: Ignition system -
Page 161: 6.2 Signal check method from Hall s
Page 165 and 166: 4.3 Battery retaining clamp and bol
Page 167 and 168: Chapter 9 Braking system Contents B
Page 169 and 170: 3 Use an Allen key and unscrew the
Page 171 and 172: 3.18 Rear brake caliper components
Page 173 and 174: 4.15 . . . followed by the outer wa
Page 175 and 176: 13 Refit the hydraulic pipe and tig
Page 177 and 178: 19 This method is particularly effe
Page 179 and 180: Chapter 10 Suspension and steering
Page 181 and 182: 1081 VW Golf & Jetta 1.1 Front susp
Page 183 and 184: 3.2 Front suspension camber adjustm
Page 185 and 186: 8.4 Removing rear suspension strut
Page 187 and 188: 11.3b Removing steering wheel centr
Page 189 and 190: 14.4 Steering tie-rod bellows and r
Page 191 and 192: 1081 VW Golf & Jetta Suspension and
Page 193 and 194: Removal 2 To remove the pump unit,
Page 195 and 196: Chapter 11 Bodywork and fittings Co
Page 197 and 198: Repair of rust holes or gashes in b
Page 199 and 200: hand. A largish screwdriver will ju
Page 201 and 202: 14 Door trim panel - removal and re
Page 203 and 204: 15.3 Removing interior door handle
Page 205 and 206: 22.4 Front bumper bracket securing
Page 207 and 208: 6 Renew any retaining screw locatio
Page 209 and 210: 28.9 Sunroof adjustment dimensions
Page 211 and 212: 31.8 Front seat guide fixing - from
Page 213 and 214:
Chapter 12 Body electrical systems
Page 215 and 216:
k) Never use an ohmmeter of the typ
Page 217 and 218:
6 Headlamp range control - removal
Page 219 and 220:
4 If the indicators do not function
Page 221 and 222:
17.2a Instrument panel unit compone
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Component testing Voltage stabilise
Page 225 and 226:
3 Ease the wiper arm from the spind
Page 227 and 228:
29 Windscreen wiper linkage - remov
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1081 VW Golf & Jetta Wiring diagram
Page 231 and 232:
1081 VW Golf & Jetta Wiring diagram
Page 233 and 234:
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
Page 239 and 240:
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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Page 267 and 268:
show all

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

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