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

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1•2 Servicing specifications Lubricants, fluids and capacities Refer to the end of “Weekly checks” Engine Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C101/C160 Valve clearances 1.05 and 1.3 litre engines - pre August 1985: Warm: Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 to 0.20 mm Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 to 0.30 mm Cold: Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 to 0.15 mm Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 to 0.25 mm Hydraulic tappet free travel 1.05 and 1.3 litre - post August 1985, 1.6 and 1.8 litre (Maximum travel) . . 0.1 mm Cooling system Antifreeze mixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 % antifreeze (by volume) with water Air conditioning system Compressor drivebelt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 to 10.0 mm deflection on longest run Fuel system Air filter element types Carburettor engines: 1.05 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W101 1.3 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W102 1.6 and 1.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion U508 Fuel-injected engines: K-Jetronic on 16 valve engine: 1.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion U502 All other systems: 1.8 litre Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion U506 1.8 litre Jetta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion U502 1.8 litre GTi ( engine code RP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion U572 Fuel filter element types Carburettor engines (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion L104 Fuel-injected engines: K-Jetronic on 16 valve engine: 1.8 litre Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion L203 1.8 litre Jetta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion L206 All other systems: 1.8 litre GTi ( engine code RP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion L206 All other models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion L204* * New copper washers must be used and these are not supplied with the filter Idle speed 1.05 litre carburettor engines: Pierburg/Solex 31 PIC-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 to 1000 rpm Pierburg/Solex 1B3 and Weber 32 TLA . . . . . . . . . . . . . . . . . . . . . . . 750 to 850 rpm 1.3 litre carburettor engines: Pierburg/Solex 2E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 to 850 rpm 1.6 litre carburettor engines: Pierburg/Solex 2E2 - engine code EZ . . . . . . . . . . . . . . . . . . . . . . . . 900 to 1000 rpm Pierburg/Solex 2E2 - engine code RF . . . . . . . . . . . . . . . . . . . . . . . . 700 to 800 rpm 1.8 litre carburettor engines: Pierburg/Solex 2E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 to 1000 rpm K-Jetronic fuel-injected engine: 8 valve: Pre Sept. 1984 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 to 1000 rpm From Sept. 1984 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 to 1000 rpm Air conditioned models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 850 to 1000 rpm 16 valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 to 1000 rpm Mono Jetronic fuel-injected engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 to 950 rpm (not adjustable) Digijet fuel-injected engine: Up to July 1989 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 to 850 rpm July 1989 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 880 to 980 rpm Digifant fuel-injected engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 to 850 rpm 1081 VW Golf & Jetta

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) . . . . . . . . . . . . . . . . . 1.5 to 2.5 1.6 litre carburettor engines: Pierburg/Solex 2E2 - engine code EZ . . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 1.5 Pierburg/Solex 2E2 - engine code RF . . . . . . . . . . . . . . . . . . . . . . . . 1.0 to 1.5 1.8 litre carburettor engines (Pierburg/Solex 2E2) . . . . . . . . . . . . . . . . . 0.5 to 1.5 K-Jetronic fuel-injected engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 1.5 Mono Jetronic fuel-injected engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 to 1.2 Digijet fuel-injected engine: Up to July 1989 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 to 1.1 July 1989 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 to 1.5 Digifant fuel-injected engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 1.5 Servicing specifications 1•3 Ignition system Firing order (all engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact breaker system 1-3-4-2 (No. 1 cylinder at crankshaft pulley end) Spark plugs*: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type Electrode gap 1.05, 1.3, 1.6 and 1.8 litre (pre July 1985) . . . . . . . . . . . . . . . . . . . . . . Champion N7YCC or N7YC 0.8 mm or 0.7 mm * Spark plug types and electrode gaps are recommended by Champion Spark Plug. If other types are used, refer to their manufacturer’s recommendations HT lead type: 1.05 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion LS-05 boxed set 1.3, 1.6 and 1.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Distributor: Champion LS-07 boxed set Contact breaker gap (initial setting only) . . . . . . . . . . . . . . . . . . . . . . Dwell angle (1.05, 1.3 and 1.6 litre): 0.4 mm Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 to 50° (50 to 56%) Wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition timing (at idle): 42 to 58° (47 to 64%) 1.05 and 1.3 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 to 6° BTDC 1.6 and 1.8 litre (carburettor engine) . . . . . . . . . . . . . . . . . . . . . . . . . . 17 to 19° BTDC 1.8 litre (fuel injection engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transistorised system 5 to 7° BTDC Spark plugs*: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pre Sept. 1985: Type Electrode gap 1.05, 1.3, 1.6, 1.8 litre (pre July 1985) . . . . . . . . . . . . . . . . . . . . . . . from Sept. 1985: Champion N7YCC or N7YC 0.8 mm or 0.7 mm 1.3 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 litre: Champion N7BYC or N7YCC 0.8 mm Coil with green sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion N9BYC4 or N9YCC 1.0 mm Coil with grey sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 litre: Champion N9YCC 0.8 mm Except 16V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion N7BYC or N7YCC 0.8 mm 16V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C6BYC or C6YCC 0.8 mm * Spark plug types and electrode gaps are recommended by Champion Spark Plug. If other types are used, refer to their manufacturer’s recommendations HT lead type: 1.05 litre. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion LS-05 boxed set 1.3, 1.6 and 1.8 litre. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Distributor: Dwell angle (1.05,1.3 and 1.6 litre): Champion LS-07 boxed set Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 to 50° (50 to 56%) Wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition timing: 42 to 58° (47 to 64%) 1.3 litre (code NZ) - TCI-H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 to 6° BTDC at 750 to 850 rpm, with vacuum hose disconnected 1.6 litre (code RF) - TCI-H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 litre: 17 to 19° BTDC at 700 to 800 rpm, with vacuum hose disconnected Code PB and PF - Digifant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 to 7° BTDC at 2000 to 2500 rpm, with temperature sender disconnected Code GU and RH - TCI-H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 to 19° BTDC at 675 to 825 rpm, with vacuum hose connected Code RP - TCI-H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fully electronic system All Specifications as for Transistorised System except for: Ignition timing: 5 to 7° BTDC at 950 rpm, with vacuum hose disconnected 1.8 litre 16 valve engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 to 7° BTDC at 950 to 1050 rpm, with vacuum hose connected 1081 VW Golf & Jetta 1

Page 1: Chapter 1 Routine maintenance and s

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

Page 29 and 30: 9 Cylinder head - removal 3 1 If th

Page 31 and 32: 11 Cylinder head - dismantling and

Page 33 and 34: 14.13a Withdrawing crankshaft rear

Page 35 and 36: 21 Crankshaft and bearings - examin

Page 37 and 38: 29.2 Fitting centre main bearing sh

Page 39 and 40: 35.9 Camshaft sprocket (later type)

Page 41 and 42: Chapter 2 Part B: Engine repair pro

Page 43 and 44: 4.5 Two lengths of metal used to lo

Page 45 and 46: 9 Oil pump - refitting 3 Refitting

Page 47 and 48: guide the cylinder head into positi

Page 49 and 50: 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

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 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 and 106: 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

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 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

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


Page 243 and 244: 1081 VW Golf & Jetta Diagram 20 Ele









Page 261 and 262: 1081 VW Golf & Jetta Diagram 57 Glo




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