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

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2D•2 Engine repair procedures 1.8 litre 16 valve 1081 VW Golf & Jetta 1.0 The 1.8 litre, 16 valve, fuel injection engine 1 Inlet manifold upper section 2 Gasket 3 Valve cover 4 Gasket 5 Cylinder head assembly with camshafts 6 Cylinder head gasket 7 Cylinder block assembly 8 Gasket 9 Sump 10 Oil filter head 11 Oil cooler 12 Oil filter
1 General information The 1.8 litre, 16-valve engine fitted to GTi models from October 1986, incorporates double overhead camshafts, one operating the exhaust valves and the other the inlet valves. There are four valves per cylinder which operate simultaneously in pairs and provide the engine with a much improved breathing capability over the 8-valve version, thus resulting in greater power output. A single camshaft sprocket is attached to the exhaust camshaft and a chain and sprocket at the opposite end of the cylinder head is used to drive the inlet camshaft (see illustration). Most overhaul procedures for the 16-valve engine are basically the same as those described for the 8-valve engine in Part C of this Chapter. The following Sections describe procedures which differ. 2 Timing belt and sprockets - removal and refitting 3 Besides the timing mark on the camshaft sprocket referred to in Part C of this Chapter, Section 9, an additional timing mark is provided on the outside of the camshaft sprocket which aligns with a mark on the valve cover (see illustration). This means that if the timing belt alone is being renewed, it is not necessary to remove the valve cover in order to check the alignment marks. When fitting the timing belt, it is recommended that VW tool 210 is used to set the tension accurately as this is more critical with the DOHC arrangement (see illustration). Using this tool, the tension should be set to record a reading of between 13 and 14 on the scale. The tool can be obtained from a VW dealer. A Camshaft sprocket outer marks B Camshaft sprocket inner marks C Crankshaft vibration damper marks 3 Camshafts - removal and refitting 3 Removal 3.4 TDC timing marks in alignment on camshaft drive chain sprockets 2.1 Valve timing marks 1 Remove the camshaft sprocket cover. 2 Unbolt and remove the upper section of inlet manifold. 3 Unbolt and remove the valve cover after disconnecting the HT leads from the spark plugs. Remove the main gasket and the 1081 VW Golf & Jetta Engine repair procedures 1.8 litre 16 valve 2D•3 2.2 Adjusting timing belt tension using VW tool 210 central gasket from around the spark plug locations. 4 Align the timing marks with reference to Part C of this Chapter, then check also that the marks on the chain sprockets are aligned (see illustration). 5 Remove the timing belt and camshaft sprocket with reference to Part C of this Chapter. 6 Note the fitted positions of the camshaft bearing caps, if necessary marking them to ensure correct refitting (see illustration). 7 Progressively unscrew the nuts and bolts from the end caps and bearing cap Nos. 1 and 3 on the exhaust camshaft. 8 Progressively unscrew the bolts from bearing cap Nos. 2 and 4. The exhaust valve springs will force the exhaust camshaft up as the bolts are loosened. Remove the bearing caps keeping them identified for position. 9 Working on the inlet camshaft, progressively unscrew the nuts and bolts from the end cap and bearing cap Nos. 5 and 7. 10 Progressively unscrew the bolts from bearing cap Nos. 6 and 8, then remove all the caps keeping them identified for position. 11 Lift both camshafts from the cylinder head then release them from the drive chain. 3.6 Camshaft bearing cap identification Inset shows recessed corner position (arrowed) 2D
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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
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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
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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 and 68: etween the camshaft and intermediat
Page 69: Chapter 2 Part D: Engine repair pro
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
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
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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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