VW MKII A2 MK2 Golf Jetta Fox Service Manual - VAGLinks.com
VW MKII A2 MK2 Golf Jetta Fox Service Manual - VAGLinks.com VW MKII A2 MK2 Golf Jetta Fox Service Manual - VAGLinks.com
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 . . . . . . .
CO content (%)<br />
1.05 litre carburettor engines:<br />
Pierburg/Solex 31 PIC-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 1.5<br />
Pierburg/Solex 1B3 and Weber 32 TLA . . . . . . . . . . . . . . . . . . . . . . . 1.5 to 2.5<br />
1.3 litre carburettor engines (Pierburg/Solex 2E3) . . . . . . . . . . . . . . . . . 1.5 to 2.5<br />
1.6 litre carburettor engines:<br />
Pierburg/Solex 2E2 - engine code EZ . . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 1.5<br />
Pierburg/Solex 2E2 - engine code RF . . . . . . . . . . . . . . . . . . . . . . . . 1.0 to 1.5<br />
1.8 litre carburettor engines (Pierburg/Solex 2E2) . . . . . . . . . . . . . . . . . 0.5 to 1.5<br />
K-Jetronic fuel-injected engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 1.5<br />
Mono Jetronic fuel-injected engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 to 1.2<br />
Digijet fuel-injected engine:<br />
Up to July 1989 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 to 1.1<br />
July 1989 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 to 1.5<br />
Digifant fuel-injected engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 1.5<br />
Servicing specifications 1•3<br />
Ignition system<br />
Firing order (all engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .<br />
Contact breaker system<br />
1-3-4-2 (No. 1 cylinder at crankshaft pulley end)<br />
Spark plugs*: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type Electrode gap<br />
1.05, 1.3, 1.6 and 1.8 litre (pre July 1985) . . . . . . . . . . . . . . . . . . . . . . Champion N7YCC or N7YC 0.8 mm or 0.7 mm<br />
* Spark plug types and electrode gaps are re<strong>com</strong>mended by Champion Spark Plug. If other types are used, refer to their manufacturer’s<br />
re<strong>com</strong>mendations<br />
HT lead type:<br />
1.05 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion LS-05 boxed set<br />
1.3, 1.6 and 1.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .<br />
Distributor:<br />
Champion LS-07 boxed set<br />
Contact breaker gap (initial setting only) . . . . . . . . . . . . . . . . . . . . . .<br />
Dwell angle (1.05, 1.3 and 1.6 litre):<br />
0.4 mm<br />
Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 to 50° (50 to 56%)<br />
Wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .<br />
Ignition timing (at idle):<br />
42 to 58° (47 to 64%)<br />
1.05 and 1.3 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 to 6° BTDC<br />
1.6 and 1.8 litre (carburettor engine) . . . . . . . . . . . . . . . . . . . . . . . . . . 17 to 19° BTDC<br />
1.8 litre (fuel injection engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .<br />
Transistorised system<br />
5 to 7° BTDC<br />
Spark plugs*: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .<br />
pre Sept. 1985:<br />
Type Electrode gap<br />
1.05, 1.3, 1.6, 1.8 litre (pre July 1985) . . . . . . . . . . . . . . . . . . . . . . .<br />
from Sept. 1985:<br />
Champion N7YCC or N7YC 0.8 mm or 0.7 mm<br />
1.3 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .<br />
1.6 litre:<br />
Champion N7BYC or N7YCC 0.8 mm<br />
Coil with green sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion N9BYC4 or N9YCC 1.0 mm<br />
Coil with grey sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .<br />
1.8 litre:<br />
Champion N9YCC 0.8 mm<br />
Except 16V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion N7BYC or N7YCC 0.8 mm<br />
16V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C6BYC or C6YCC 0.8 mm<br />
* Spark plug types and electrode gaps are re<strong>com</strong>mended by Champion Spark Plug. If other types are used, refer to their manufacturer’s<br />
re<strong>com</strong>mendations<br />
HT lead type:<br />
1.05 litre. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion LS-05 boxed set<br />
1.3, 1.6 and 1.8 litre. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .<br />
Distributor:<br />
Dwell angle (1.05,1.3 and 1.6 litre):<br />
Champion LS-07 boxed set<br />
Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 to 50° (50 to 56%)<br />
Wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .<br />
Ignition timing:<br />
42 to 58° (47 to 64%)<br />
1.3 litre (code NZ) - TCI-H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 to 6° BTDC at 750 to 850 rpm, with vacuum hose disconnected<br />
1.6 litre (code RF) - TCI-H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .<br />
1.8 litre:<br />
17 to 19° BTDC at 700 to 800 rpm, with vacuum hose disconnected<br />
Code PB and PF - Digifant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 to 7° BTDC at 2000 to 2500 rpm, with temperature sender disconnected<br />
Code GU and RH - TCI-H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 to 19° BTDC at 675 to 825 rpm, with vacuum hose connected<br />
Code RP - TCI-H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .<br />
Fully electronic system<br />
All Specifications as for Transistorised System except for:<br />
Ignition timing:<br />
5 to 7° BTDC at 950 rpm, with vacuum hose disconnected<br />
1.8 litre 16 valve engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 to 7° BTDC at 950 to 1050 rpm, with vacuum hose connected<br />
1081 <strong>VW</strong> <strong>Golf</strong> & <strong>Jetta</strong><br />
1