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

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4A•2 Fuel and exhaust systems - carburettor models Carburettor - 1.05 litre (continued) Pierburg/Solex 1B3 Venturi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 mm Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Air correction jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.5 Idling fuel/air jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50/130 Pump injection tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.5/150 Needle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Accelerator pump capacity (cc/stroke) . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 ± 0.15 Choke valve gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 ± 0.2 mm Fast idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000 ± 100 rpm Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 ± 50 rpm CO content % . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weber 32 TLA 2.0 ± 0.5 Venturi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main jet: 22 mm Code 030 129 016 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Code 030 129 016 D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air correction jet: 102 Code 030 129 016 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Code 030 129 016 D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F96 Idling fuel jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Idling air jet: 47 Code 030 129 016 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Code 030 129 016D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Auxiliary fuel jet (code 030 129 016D) . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Auxiliary air jet (code 030 129 016D) . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 Pump injection tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35/0.35 Needle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.75 Needle valve washer thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0.75 mm Accelerator pump capacity (cc/stroke) . . . . . . . . . . . . . . . . . . . . . . . . . . Choke valve gap (pull-down): 1.05 ± 0.15 Without vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 ± 0.2 mm With 300 mbar vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Choke valve gap (wide open kick): 2.0 ± 0.2 mm Code 030 129 016 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 ± 0.5 mm Code 030 129 01 6D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 ± 0.5 mm Float level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.0 ± 1.0 mm Fast idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000 ± 100 rpm Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 ± 50 rpm CO content % . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 ± 0.5 Carburettor - 1.3 litre Pierburg/Solex 2E3 Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Twin progressive choke, downdraught with automatic choke Stage I Stage II Venturi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 23 Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X95 X110 Air correction jet with emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 130 Idling fuel/air jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45/130 - Full throttle enrichment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 95 Pump injection tube diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm - Choke cover code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 Injection capacity (cc/stroke) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 ± 0.15 Locking lever clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 ± 0.15 mm Full throttle enrichment - height above atomiser . . . . . . . . . . . . . . . . . . 12.0 mm Choke valve gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 ± 0.1 mm Fast idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000 ± 100 rpm Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 ± 50 rpm C0 content % . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 ± 0.5 1081 VW Golf & Jetta
Carburettor-1.6 litre Pierburg/Solex 2E2 - engine code EZ Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Twin progressive choke, downdraught with automatic choke Stage I Stage II Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.0 mm 26.0 mm Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X110 X127 Air correction jet with emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75/1.05 mm 1.05 mm Idle fuel/air jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.5 - Full throttle enrichment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 0.7 Pump injection tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 - Injection capacity (cc/stroke) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 ± 0.15 Choke valve gap with primary throttle open 45° . . . . . . . . . . . . . . . . . . 6.3 ± 0.3 mm Fast idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 ± 200 rpm Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Increased idle speed: 950 ± 50 rpm Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 rpm Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 950 ± 50 rpm CO content % . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 ± 0.5 Pierburg/Solex 2E2 - engine code RF Stage I Stage II Venturi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.0 mm 26.0 mm Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102.5 127.5 Air correction jet with emulsion tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 105 Idle fuel/air jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.5 - Fuel throttle enrichment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 0.7 Accelerator pump injection tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Choke valve gap: 0.5 - Manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 ± 0.15 mm 5.0 ± 0.15 mm Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 ± 0.15 mm 5.3 ± 0.15 mm Accelerator pump capacity (cc/stroke) . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 ± 0.15 Fast idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 ± 200 rpm Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 ± 50 rpm CO content % . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 to 1.5 Carburettor - 1.8 litre Fuel and exhaust systems - carburettor models 4A•3 Pierburg/Solex 2E2 Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Twin progressive choke, downdraught with automatic choke Stage I Stage II Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.0 mm 26.0 mm Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X105 X120 Air correction jet with emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 mm 100 mm Idle fuel/air jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.5 - Full throttle enrichment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump injection tube: - 0.9 Carburettor part number type 027 129 015 . . . . . . . . . . . . . . . . . . . . 0.35 - Carburettor part number type 027 129 015 Q . . . . . . . . . . . . . . . . . . 0.5 - Injection capacity (cc/stroke) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 ± 0.15 Choke valve gap (measured at lower edge) . . . . . . . . . . . . . . . . . . . . . . 2.3 ± 0.15 mm 4.7 ± 0.15 mm Fast idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 ± 200 rpm Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Increased idle speed: 950 ± 50 rpm Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 rpm Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 950 ± 50 rpm CO content % . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 ± 0.5 Torque wrench settings 1.05 and 1.3 litre Nm lbf ft Carburettor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7 Intermediate flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7 Inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18 Inlet manifold preheater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7 Fuel tank strap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18 Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18 Exhaust manifold to downpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18 Exhaust pipe clamp bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18 1081 VW Golf & Jetta 4A
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 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 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: Chapter 4 Part A: Fuel and exhaust
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
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
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1081 VW Golf & Jetta Diagram 57 Glo
Page 263 and 264:
Page 265 and 266:
Page 267 and 268:
show all

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