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

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4A•4 Fuel and exhaust systems - carburettor models Torque wrench settings (continued) 1.6 and 1.8 litre Nm lbf ft Carburettor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5 Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15 Inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18 Inlet manifold preheater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7 Fuel tank strap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18 Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust pipe clip: 25 18 8 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18 10 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 30 1 General information and precautions General information The fuel system comprises a rear-mounted fuel tank, a mechanical diaphragm fuel pump and a downdraught carburettor. The pump on 1.05 and 1.3 litre models is operated by means of a plunger activated by the camshaft, whilst on 1.6 and 1.8 litre models, it is operated directly by an eccentric on the intermediate shaft. The air cleaner unit contains a renewable paper element and incorporates an automatic temperature control. A conventional exhaust system is used on all models, being fitted in sections for ease of replacement. Precautions Fuel warning Many of the procedures in this Chapter require the removal of fuel lines and connections which may result in some fuel spillage. Before carrying out any operation on the fuel system refer to the precautions given in Safety first! at the beginning of this Manual and follow them implicitly. Petrol is a highly dangerous and volatile liquid and the precautions necessary when handling it cannot be overstressed. Tamperproof adjustment screws Certain adjustment points in the fuel system are protected by “tamperproof” caps, plugs or seals. The purpose of such tamperproofing is 3.2 Removing air cleaner body retaining ring - 1.3 litre to discourage, and to detect, adjustment by unqualified operators. In some EEC countries (though not in the UK), it is an offence to drive a vehicle with missing or broken tamperproof seals. Before disturbing a seal, satisfy yourself that you will not be breaking any anti-pollution regulations by doing so. Fit a new seal when adjustment is complete, if this is required by law. Do not break tamperproof seals on a vehicle which is still under warranty. Unleaded petrol - usage For full information on the use of unleaded petrol, consult your VW dealer who will be able to inform you if your vehicle is capable of running on unleaded fuel and, where possible, of the necessary adjustments required. The use of unleaded fuel in a vehicle not designed, or suitably adjusted, to run on unleaded fuel will lead to serious damage of the valve seats. 2 Air cleaner element - renewal Refer to Chapter 1, Section 32 1 3 Air cleaner unit - removal and refitting 2 1.05 and 1.3 litre engines 1 Remove the element. 2 Unscrew the nut(s) securing the air cleaner body and remove the adapter or retaining ring (see illustration). 3.3a Disconnecting temperature sensor hose . . . 1081 VW Golf & Jetta 3 Note the location of all hoses and tubes then disconnect them. Withdraw the air cleaner body from the carburettor and remove the sealing ring (see illustrations). 4 Refit in the reverse order of removal, ensuring that all hose connections are securely made. 1.6 and 1.8 litre engines 5 Remove the element. 6 Unclip and detach the air hose at the side of the cleaner body (see illustration). 7 Undo the retaining nut at the top and lift the cleaner unit clear, disconnecting the remaining hoses. 8 Refit in the reverse order of removal. Fit a new sealing washer if the old one has perished or distorted. 4 Automatic air cleaner temperature control - testing 2 1 Unclip and remove the vacuum unit and inlet pipe but leave the vacuum pipe connected (see illustration). 2 Suspend a thermometer in the flow of air through the inlet duct then start the engine. Between -20°C and + 20°C, the control flap in the unit should be a maximum of 2/3rds open to admit hot air from the exhaust manifold. Above 20°C, the control flap must close the hot air supply (see illustration). 3 The control flap movement can be checked by sucking on the vacuum inlet. 4 With the engine running and inlet air temperature above 20°C, disconnect the vacuum hose from the vacuum unit. The control flap should fully open within a maximum of 20 seconds. 3.3b . . . and crankcase emission hose - 1.3 litre
3.6 Air cleaner components – 1.6 and 1.8 litre 1 Warm air deflector plate 2 Gasket 3 Spring washer 4 Nut 5 Air hose 6 Bracket 7 Washer 8 Nut 9 Bonded rubber mounting 10 Clip 11 Air Hose 12 Clip 13 Spacer tube 14 Air cleaner 15 Clip 16 Stud 17 Washer 18 Self-locking nut 19 Filter element 20 Sealing washer 21 Spring 22 Lockplate 23 Retaining clip 24 Dual thermostat 25 Union 26 Air hose 27 Clip 4.1 Air cleaner vacuum unit Fuel and exhaust systems - carburettor models 4A•5 1081 VW Golf & Jetta 4.2 Air cleaner load and temperature control diagram – 1.05 and 1.3 litre A Temperature regulator C Vacuum unit B Intake pipe with thermostat 4A
Page 1 and 2:
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
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25.3a Bend each brake hose to check
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32.4b . . . loosen front mounting n
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Chapter 2 Part A: Engine repair pro
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1.3 litre: Inlet opens . . . . . .
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difficulty is experienced, it may b
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9 Cylinder head - removal 3 1 If th
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11 Cylinder head - dismantling and
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14.13a Withdrawing crankshaft rear
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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 and 86: Chapter 4 Part A: Fuel and exhaust
Page 87: Carburettor-1.6 litre Pierburg/Sole
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
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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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