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

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2C•2 Engine repair procedures - 1.6 and 1.8 litre 8 valve Compression pressure: 1.6 litre: New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 to 12 bar Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 bar Maximum permissible difference between any two cylinders . . . . 3.0 bar 1.8 litre: New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 to 13 bar Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 bar Maximum permissible difference between any two cylinders . . . . 3.0 bar Crankshaft Main journal: Standard diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.0 mm Undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.75, 53.50 and 53.25 mm Crankpin: Standard diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.80 mm Journal undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.55, 47.30 and 47.05 mm Endfloat: Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.07 mm Main bearing maximum running clearance . . . . . . . . . . . . . . . . . . . . . . 0.17 mm Connecting rods Big-end: Maximum running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012 mm Maximum endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.37 mm Pistons Clearance in bore: Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.07 mm Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm Diameter: Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80.98 mm Oversize: 1st oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.23 mm 2nd oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.48 mm Wear limit (10 mm from base/ right angles to pin) . . . . . . . . . . . . . . . . . 0.04 mm Piston rings Maximum clearance in groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm End gap: Compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 to 0.45 mm Oil scraper ring: 1 part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 to 0.40 mm 2 part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 to 0.45 mm 3 part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 to 0.50 mm Maximum end gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm Gudgeon pin Fit in piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Push fit at 60°C Intermediate shaft Maximum endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm Cylinder head Maximum allowable face distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 mm Minimum height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132.6 mm Camshaft Run-out at centre bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.01 mm Endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm Valves Seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Head diameter: Inlet: Codes PB, PF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.0 mm All other codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.0 mm Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.0 mm 1081 VW Golf & Jetta
Stem diameter: Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.97 mm Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.95 mm Standard overall length*: Inlet: Codes EZ, EV, GU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98.70 mm All other codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.0 mm Exhaust: Codes EZ, EV, GU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98.50 mm Codes PB, PF, RP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.95 mm All other codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.80 mm * Caution: Check with manufacturer on valve dimensions before renewing Valve guides Maximum valve rock (stem flush with guide): Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 mm Hydraulic tappets Maximum free travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 mm Valve timing Nil valve clearance at 1.0 mm valve lift 1.6 litre (code EZ - shim bucket tappets): Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5° BTDC Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21° ABDC Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41° BBDC Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3° BTDC 1.6 litre (code EZ - hydraulic tappets - August 1985 to March 1986): Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3° BTDC Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19° ABDC Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27° BBDC Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5° BTDC 1.6 litre (code EZ - hydraulic tappets - March 1986 on): Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TDC Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22° ABDC Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28° BBDC Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6° BTDC 1.6 litre (code RF): Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TDC Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22° ABDC Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28° BBDC Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6° BTDC 1.8 litre (code GU - shim bucket tappets) Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1° BTDC Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37° ABDC Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42° BBDC Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2° ATDC 1.8 litre (code GU - hydraulic tappets - August 1985 to March 1986 Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3° BTDC Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33° ABDC Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41° BBDC Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5° BTDC 1.8 litre (code GU - hydraulic tappets - March 1986 on): Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2° BTDC Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34° ABDC Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44° BBDC Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8° BTDC 1.8 litre (code EV): Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2° BTDC Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° ABDC Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° BBDC Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8° BTDC 1.8 litre (codes PB, PF): Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3° ATDC Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43° ABDC Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37° BBDC Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3° ATDC Engine repair procedures - 1.6 and 1.8 litre 8 valve 2C•3 1081 VW Golf & Jetta 2C
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
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: Chapter 2 Part C: Engine repair pro
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 97 and 98: 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 107 and 108:
Fuel and exhaust systems - carburet
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 241 and 242:
Page 243 and 244:
1081 VW Golf & Jetta Diagram 20 Ele
Page 245 and 246:
Page 247 and 248:
Page 249 and 250:
Page 251 and 252:
Page 253 and 254:
Page 255 and 256:
Page 257 and 258:
Page 259 and 260:
Page 261 and 262:
1081 VW Golf & Jetta Diagram 57 Glo
Page 263 and 264:
Page 265 and 266:
Page 267 and 268:
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