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

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12•8 Body electrical systems 13.2 Facia switch removal 13.3 Prise free switch from bottom edge 14.2 Tailgate actuated luggage compartment light switch 3 On other switch types such as the heated rear seat switch, simply lever the switch free from the bottom edge (see illustration). 4 With the switch withdrawn, detach the wiring connector. Where applicable, warning light bulb holders can be withdrawn from the switch and the bulb removed. 5 Refitting is a reversal of the removal procedure. Check the switch for satisfactory operation on completion. 14 Courtesy and luggage compartment light switches - removal and refitting 1 1 Disconnect the battery negative lead. 2 Open the door, boot lid or tailgate (as applicable) and unscrew the cross-head screw from the switch (see illustration). 3 Withdraw the switch and disconnect the wiring. Tie a loose knot in the wire to prevent it from dropping into the door pillar (see illustration). 4 Check the switch seal for condition and renew it, if necessary. 5 Refitting is a reversal of removal. 15 Oil pressure warning switches - testing 2 1 Some models are equipped with an optical and acoustic oil pressure warning system. This system incorporates two oil pressure switches, a 0.3 bar switch with brown insulation on the cylinder head and a 1.8 bar switch with white insulation on the oil filter head. 2 On starting the engine, as soon as the oil pressure rises above 0.3 bar, the oil pressure warning light will go out. At engine speeds above 2000 rpm, the high pressure switch comes into operation and should the oil pressure drop below 1.8 bar, the oil warning light will come on and the buzzer will sound. 3 Testing each switch should be done by substitution. Little can be done by way of maintenance and your VW dealer should be consulted if the system malfunctions. 16 Instrument panel cluster - removal and refitting 2 1 Disconnect the battery earth lead. 2 Remove the facia panel. 3 Remove the instrument panel retaining screws (one each side at the top) (see illustration). 4 Prise the panel away, tilting from the top edge. Reach behind the panel and disconnect the speedometer cable (see illustration) and, where applicable, the vacuum hose from the vacuum sender. Detach the wiring multi-connectors from the rear lower edge then lift the instrument panel out whilst taking care not to damage the printed circuit on its rear face. 5 The individual circuits of the printed circuit foil can be checked for continuity using an ohmmeter. For circuit identification, refer to the appropriate wiring diagram. 6 Refitting is a reversal of the removal sequence. Ensure that all connections are securely made and check instruments for satisfactory operation on completion. 17 Instrument panel - dismantling, testing and reassembly 2 Dismantling 1 Remove the instrument panel cluster. 2 Remove the relevant instrument (see illustrations) whilst taking particular care not to damage the printed circuit foil. Gearchange/consumption indicator 3 If renewing the gearchange/consumption indicator, avoid touching the back of the gauge. Removal necessitates detaching the printed circuit and the vacuum sender unit then undoing the three securing screws (see illustration). Renew the diode (LED) or consumption indicator unit, as necessary. Clock - normal type 4 When renewing the normal type clock (which incorporates the fuel gauge), it is important to ensure that the correct printed circuit connections are made when refitting (see illustration). Clock - digital type 5 The digital type clock is secured by two retaining screws. When removing the clock, take care not to allow the adjuster pins for the hours and minutes to fall out. 14.3 Door courtesy light switch removal 16.3 Instrument panel screw removal 16.4 Disconnect speedometer cable 1081 VW Golf & Jetta
17.2a Instrument panel unit components – type A 1 Voltage stabiliser 2 Bulb 3 Connecting housing (black) 4 LED’s 5 Diode holder 6 Switch unit (printed) 7 Speedometer 8 Gearchange and consumption indicator 9 Dash insert 10 Switch rod for memory 11 Coolant temperature gauge 12 Fuel gauge 13 Rev counter 14 High beam warning lamp 15 Multi-function indicator (printed circuit) 16 Connector housing (white) 17 Printed circuit 18 Vacuum sender 19 Vacuum sender 20 Speed sender 1081 VW Golf & Jetta Body electrical systems 12•9 17.2b Instrument panel unit components – type B 1 With rev counter and digital clock 2 With normal type clock 12
Page 1 and 2:
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
Page 17 and 18:
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
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Chapter 4 Part F: Fuel and exhaust
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A Front crankcase ventilation valve
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12.1 Fuel pump and filter component
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Chapter 5 Part A: Ignition system -
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1.1b Contact breaker ignition syste
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7.4 Crankshaft pulley mark (A) timi
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Chapter 5 Part B: Ignition system -
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Ignition system - transistorised ty
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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
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: 4 If the indicators do not function
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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