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
2C•20 Notes 1081 VW Golf & Jetta
Chapter 2 Part D: Engine repair procedures 1.8 litre 16 valve The following information is a revision of, or supplementary to, that given for the 1.8 litre engine in Part C of this Chapter Contents Camshafts - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cylinder head - dismantling and overhaul . . . . . . . . . . . . . . . . . . . . . 4 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Degrees of difficulty Easy, suitable for novice with little experience 1 Specifications Fairly easy, suitable for beginner with some experience General Code: GTi 16V with catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KR Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10:1 Cylinder head Minimum height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118.1 mm - measured through cylinder head bolt hole Valves Head diameter: Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.0 mm Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.0 mm Stem diameter: Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.97 mm Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.94 mm Overall length: Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.5 mm Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98.2 mm Valve timing 2 Fairly difficult, suitable for competent DIY mechanic Nil valve clearance at 1.0 mm valve lift Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3° ATDC Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35° ABDC Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43° BBDC Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3° BTDC Torque wrench settings Nm Ibf ft Vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15 Intermediate shaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 48 Valve cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7 Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 19 Camshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 48 Camshaft bearing caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 11 Oil temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7 Oil pump cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7 Oil pump mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15 Oil jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7 Crankshaft sprocket bolt (oiled) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 133 1081 VW Golf & Jetta 2D•1 Pistons and connecting rods - removal and refitting . . . . . . . . . . . . 5 Timing belt and sprockets - removal and refitting . . . . . . . . . . . . . . . 2 3 Difficult, suitable for experienced DIY mechanic 4 Very difficult, suitable for expert DIY or professional 5 2D
- 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: etween the camshaft and intermediat
- 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,
Chapter 2 Part D:<br />
Engine repair procedures 1.8 litre 16 valve<br />
The following information is a revision of, or supplementary to, that given for the 1.8 litre engine in Part C of this Chapter<br />
Contents<br />
Camshafts - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 3<br />
Cylinder head - dismantling and overhaul . . . . . . . . . . . . . . . . . . . . . 4<br />
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1<br />
Degrees of difficulty<br />
Easy, suitable for<br />
novice with little<br />
experience<br />
1<br />
Specifications<br />
Fairly easy, suitable<br />
for beginner with<br />
some experience<br />
General<br />
Code:<br />
GTi 16V with catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KR<br />
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10:1<br />
Cylinder head<br />
Minimum height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118.1 mm - measured through cylinder head bolt hole<br />
Valves<br />
Head diameter:<br />
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.0 mm<br />
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.0 mm<br />
Stem diameter:<br />
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.97 mm<br />
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.94 mm<br />
Overall length:<br />
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.5 mm<br />
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98.2 mm<br />
Valve timing<br />
2<br />
Fairly difficult,<br />
suitable for <strong>com</strong>petent<br />
DIY mechanic<br />
Nil valve clearance at 1.0 mm valve lift<br />
Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3° ATDC<br />
Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35° ABDC<br />
Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43° BBDC<br />
Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3° BTDC<br />
Torque wrench settings Nm Ibf ft<br />
Vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15<br />
Intermediate shaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 48<br />
Valve cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7<br />
Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 19<br />
Camshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 48<br />
Camshaft bearing caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 11<br />
Oil temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7<br />
Oil pump cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7<br />
Oil pump mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15<br />
Oil jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7<br />
Crankshaft sprocket bolt (oiled) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 133<br />
1081 <strong>VW</strong> <strong>Golf</strong> & <strong>Jetta</strong><br />
2D•1<br />
Pistons and connecting rods - removal and refitting . . . . . . . . . . . . 5<br />
Timing belt and sprockets - removal and refitting . . . . . . . . . . . . . . . 2<br />
3<br />
Difficult, suitable for<br />
experienced DIY<br />
mechanic<br />
4<br />
Very difficult,<br />
suitable for expert DIY<br />
or professional<br />
5<br />
2D
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