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

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10•12 Suspension and steering 16.1 Manual steering gear adjustment screw (arrowed) 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. This is necessary to avoid damaging the rack and pinion. 16 With the steering gear removed, clean it externally then release the clips and slide the bellows outwards along the tie-rods away from the inner joints. 17 Support the steering gear in a soft jaw vice with the steering rack in the jaws. Do not clamp the rack into a vice not fitted with protective jaws. 18 Each tie-rod and outer balljoint can be removed in a similar manner to that described for the manual steering gear unit. Refitting 19 Refit the steering tie-rods to the rack and adjust the fitted lengths, as given. Tighten the tie-rods to the specified torque when the settings are correct. 20 Refit the steering gear and tie-rods. 21 On completion, check front wheel alignment. 16.8 Power steering gear adjustment – use VW tool 16 Steering gear - adjustment Manual 3 1 If there is any undue slackness in the steering gear which results in noise or rattles, then the steering gear should be adjusted as follows (see illustration). 2 Raise and support the vehicle at the front end on axle stands (see “Jacking and vehicle support”). 3 With the wheels in the straight-ahead position, tighten the self-locking adjustment screw by approximately 20°. 4 Lower the vehicle to the ground then road test the vehicle. If the steering fails to self-centre after cornering, loosen the adjustment screw a fraction at a time until it does. 5 If, when the correct self-centring point is reached, there is still excessive wear in the steering, retighten the adjuster nut a fraction to take up the play. 6 If the above adjustment procedure does not provide satisfactory steering adjustment, then it is probable that the steering gear is worn beyond an acceptable level and it must be removed and overhauled. Power-assisted 7 Remove the steering gear unit. 8 Loosen the adjuster screw locknut then turn the adjustment screw in to the point where the rack can just be moved by hand without binding or sticking (see illustration). Retighten the locknut. 9 Refit the steering gear to the vehicle. 17 Steering gear unit - removal and refitting 4 Modification - power steering gear pinion: From May 1985, the pinch-bolt clamping the intermediate shaft to the steering gear pinion is located approximately 1.0 mm nearer the centre line of the pinion. To identify the modified pinion, a flat is cut opposite the pinch-bolt location. When renewing either of the components separately, it may be necessary to increase the depth of the pinch-bolt recess in the pinion by 1.0 mm so that the two components match. Do not alter the hole in the intermediate shaft (see illustration). Removal 1 Apply the handbrake, jack up the front of the vehicle and support it on axle stands (see “Jacking and vehicle support”). Remove the roadwheels. 2 Disconnect the inner ends of the tie-rods. 3 On power steering models, detach the fluid suction hose at the pump unit end by 1081 VW Golf & Jetta 17.0 Power steering gear pinion modification a Dimension reduced from 12.1 mm to 11.0 mm A Notch depth increased B Flat for identification loosening the hose clip, withdrawing the hose from the pump and draining the fluid into a suitable container (see illustration). 4 Disconnect the steering tie-rod outer balljoints. 5 Where applicable, disconnect the gearshift securing bracket from the steering gear. 6 Undo and remove the steering gear pinion-to-lower column joint clamp bolt (see illustration). Prise free the joint shaft bellows and pull the bellows up the shaft for access to the clamp bolt. 7 Undo and remove the steering gear unit retaining clamp nuts and withdraw the clamps. Note that the retaining bolts remain in the subframe (see illustration). If necessary the bolts can be removed by driving them out downwards using a soft metal drift. 8 On power steering models, disconnect the pressure and return flow fluid hoses at the union connections to the steering gear unit. 9 To enable the steering unit to be withdrawn, it may be necessary to detach and withdraw 17.6 Steering gear pinion-to-lower column joint
1081 VW Golf & Jetta Suspension and steering 10•13 17.3 Power steering gear components 17.7 Manual steering gear components 10
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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
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26 The engine/gearbox unit is now r
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9.6 Intermediate sprocket timing ma
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and tappet is required. Label the c
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13.1 Sump, oil pump and oil filter
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17 Oil filter - renewal Refer to Ch
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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
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Chapter 3 Cooling, heating and air
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1 Radiator 2 Fan ring 3 Expansion t
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2.2 Removing expansion tank cap 2.4
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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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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
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18.3a Unscrew the bolts . . . 18.3b
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Chapter 4 Part B: Fuel and exhaust
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Fuel supply The fuel pump operates
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4 Switch off all electrical consume
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12.5 Cold acceleration enrichment s
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17 Pressure relief valve - removal,
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Fuel and exhaust systems - K-Jetron
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Chapter 4 Part C: Fuel and exhaust
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1 To ignition control unit 2 Intake
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6.3 Throttle valve switch adjustmen
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Chapter 4 Part D: Fuel and exhaust
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1.0b Mono-Jetronic system inlet man
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distance of 4.0 mm by the operating
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Chapter 4 Part E: Fuel and exhaust
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3.4 CO analyser and connecting pipe
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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 and 162: 6.2 Signal check method from Hall s
Page 163 and 164: Chapter 5 Part D: Starting and char
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: 14.4 Steering tie-rod bellows and r
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
Page 223 and 224: 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
Page 229 and 230: 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
Page 235 and 236: 1081 VW Golf & Jetta Diagram 3 Ligh
Page 237 and 238: 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 12 Diagram 16
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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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