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

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2C•12 Engine repair procedures - 1.6 and 1.8 litre 8 valve 12.12a Inserting a valve into the cylinder head 4 The valve springs must be renewed if they are damaged, distorted, or known to have covered a high mileage. If in doubt as to their condition, have your VW dealer check them for compression efficiency using a calibrated valve spring compressor. 5 The valves should be cleaned and checked for signs of wear or burring. Where this has occurred, the inlet valve may be reground on a machine at a dealer. Exhaust valves must not be reground on the machine but ground in by hand. On engines fitted with hydraulic tappets, valves should not be re-cut as this will adversely affect the operation of the tappets. 6 Wear in the valve guides may be detected by fitting a new valve in the guide and checking the amount that the rim of the valve will move sideways when the top of the valve stem is flush with the top of the valve guide. The valve rock limits are given in the Specifications. New valve guides must be fitted and reamed by your VW dealer. 7 Do not spend too long grinding in the valves. If the valve seat and valve are not satisfactory after 15 minutes then you will probably do more harm than good by going on. Make sure both surfaces are clean, smear grinding paste onto the valve evenly and using a suction cup, work the valve with an oscillating motion lifting the valve away from the seat occasionally to stop ridging. Clean the seat and valve frequently and carry on until there is an even grey band on both seat and valve then wipe off all the paste. 8 The surface of the head must be checked with a straight-edge and feeler blade. Place the straight-edge along the centre of the machined face of the head. Make sure there are no ridges at the extreme ends and measure the clearance with feelers between each combustion chamber head. This is the area where the narrowest part of the cylinder head gasket comes and where the gasket is most likely to fail. If the straight-edge is firmly in place and feelers in excess of 0.1 mm can be put between the head and the straight-edge, then the head should be taken to a dealer for servicing or replacement. 9 If the cylinder head shows signs of cracking, have it inspected by your VW dealer to assess its condition for reuse. 10 VW recommend that the valve stem oil seals should always be renewed to prevent possible high oil consumption. Pulling off the old seal is simple with pliers. With a packet of new oil seals is a small plastic sleeve. This is fitted over the valve stem and lubricated. The seal should then be pushed over the plastic sleeve until it seats on the guide. This should be done with VW tool 10 204 which fits snugly round the outside of the seal and pushes it on squarely. If the seal is assembled without the plastic sleeve, it will be damaged and oil consumption will become excessive. 11 Before reassembling the cylinder head, check the condition of the camshaft. 12 When all components have been examined, then assembly of the head may commence. Insert the valve in the correct guide, fit the inner seat, valve springs and outer cap, assemble the valve spring compressor and possibly the small tube and compress the valve spring until the collets 12.14 Fit the tappet buckets 12.15 Fit the bearing caps 12.12b Locating valve springs and cap . . . 12.12c . . . and valve collets 1081 VW Golf & Jetta may be assembled to the valve stem (see illustrations). 13 Assemble the second collet and holding them carefully together in place, ease off the compressor until the spring seats the collets home. Remove the compressor, put a rag over the valve stem and tap the stem with a hammer. This is to ensure that the collets are seated correctly. If they are they will not come out. Repeat until all eight valves are in position in the cylinder head. 14 Refit the tappets in the bores from which they came, lubricating them liberally with clean engine oil (see illustration). Lubricate the camshaft bearing surfaces with oil and fit the camshaft, positioned so that No 1 cylinder cams point upwards. 15 Fit a new oil seal at the sprocket end, lubricate the bearings, set the shaft in position and install bearing caps Nos 2 and 4, tightening the nuts in a diagonal pattern until the shaft is in place (see illustration). Now install the other bearing caps, making sure they are the right way round (marks towards the drive pulley) and tighten the caps down using a diagonal pattern to the specified torque. Install a new rubber seal at the opposite end to the sprocket. 16 On engines equipped with shim bucket tappets, adjust the valve clearances. 13 Sump and oil pump - removal and refitting 3 Modification: From August 1985, a larger sump is fitted thereby increasing engine oil capacity. If renewing the sump, ensure that one of identical capacity is fitted Removal 1 If the engine is in the vehicle then drain the engine oil. Note that the sump plug has an O-ring which must be renewed (see illustration). 2 Undo the sump retaining bolts and remove the sump from the lower face of the crankcase. Remove the sump gasket which must also be renewed. 3 To remove the oil pump, undo the two retaining bolts and lower the pump unit,
13.1 Sump, oil pump and oil filter components - fuel injection engine complete with the oil pick-up pipe and strainer. Refitting 4 To refit the pump, ensure that the mating faces are clean, locate it in position and fit and tighten the securing bolts to the specified torque. 5 Locate the new sump gasket but do not apply an adhesive sealant. Refit the sump and tighten the retaining bolts evenly to the specified torque. 6 Refit the oil drain plug with O-ring and tighten it to the specified torque. Engine repair procedures - 1.6 and 1.8 litre 8 valve 2C•13 14 Pistons and connecting rods - removal 3 1 Remove the cylinder head. 2 Remove the sump. 3 Unscrew the two oil pump retaining bolts then lower and remove the pump, complete with oil pick-up pipe from the crankcase. Place it on one side for cleaning and inspection. 4 The piston and connecting rod removal procedure now follows that given for the smaller engine variants in Part A of this Chapter. 1081 VW Golf & Jetta 15 Crankshaft and main bearings - removal 3 1 Disconnect the pistons and connecting rods from the crankshaft. Note that, although the engine has to be removed to remove the crankshaft, the cylinder head, pistons and connecting rods can be left in position. 2 At the flywheel end, undo and remove the six bolts securing the oil seal flange to the crankcase (see illustration). Withdraw the flange, seal and gasket. 3 Examine the main bearing caps. It will be 2C
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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
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 tappet is required. Label the c
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
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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
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3 Use an Allen key and unscrew the
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3.18 Rear brake caliper components
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4.15 . . . followed by the outer wa
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13 Refit the hydraulic pipe and tig
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19 This method is particularly effe
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Chapter 10 Suspension and steering
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1081 VW Golf & Jetta 1.1 Front susp
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3.2 Front suspension camber adjustm
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8.4 Removing rear suspension strut
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11.3b Removing steering wheel centr
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14.4 Steering tie-rod bellows and r
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1081 VW Golf & Jetta Suspension and
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Removal 2 To remove the pump unit,
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Chapter 11 Bodywork and fittings Co
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Repair of rust holes or gashes in b
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hand. A largish screwdriver will ju
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14 Door trim panel - removal and re
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15.3 Removing interior door handle
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22.4 Front bumper bracket securing
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6 Renew any retaining screw locatio
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28.9 Sunroof adjustment dimensions
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31.8 Front seat guide fixing - from
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Chapter 12 Body electrical systems
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k) Never use an ohmmeter of the typ
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6 Headlamp range control - removal
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4 If the indicators do not function
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17.2a Instrument panel unit compone
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Component testing Voltage stabilise
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3 Ease the wiper arm from the spind
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29 Windscreen wiper linkage - remov
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1081 VW Golf & Jetta Wiring diagram
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1081 VW Golf & Jetta Wiring diagram
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Relays (typical) 1 Vacant 2 Intake
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1081 VW Golf & Jetta Diagram 3 Ligh
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1081 VW Golf & Jetta Diagram 7 Brak
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1081 VW Golf & Jetta 12 Diagram 12
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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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