VW Golf & Jetta Service and Repair Manual I M Coomber and Christopher Rogers Models covered (1081 - 344 - 1AA11) VW Golf & Jetta Mk 2 models with petrol engines, including fuel injection, catalytic converter, Formel E, 16-valve and special/limited edition models 1043 cc, 1272 cc, 1595 cc & 1781 cc Covers mechanical features of Van. Does not cover Convertible, Rallye, Caddy, diesel engine, 4 -wheel drive, Mk 1 models or new Golf range introduced in February 1992 Printed by J H Haynes & Co. Ltd, Sparkford, Nr Yeovil, Somerset ABCDE FGHIJ BA22 7JJ, England KLMNO PQRST © Haynes Publishing 1997 1 2 3 Haynes Publishing Sparkford Nr Yeovil A book in the Haynes Service and Repair Manual Series Somerset BA22 7JJ England All rights reserved. No part of this book may be reproduced or Haynes North America, Inc transmitted in any form or by any means, electronic or 861 Lawrence Drive mechanical, including photocopying, recording or by any Newbury Park information storage or retrieval system, without permission in California 91320 USA writing from the copyright holder. Editions Haynes S.A. ISBN 1 85960 282 7 147/149, rue Saint Honoré, 75001 PARIS, France British Library Cataloguing in Publication Data Haynes Publishing Nordiska AB A catalogue record for this book is available from the British Library Fyrisborgsgatan 5, 754 50 Uppsala, Sverige Contents LIVING WITH YOUR VOLKSWAGEN GOLF OR JETTA Introduction Page 0•4 Safety First! Page 0•5 Roadside Repairs Introduction Page 0•6 If your car won’t start Page 0•6 Jump starting Page 0•7 Wheel changing Page 0•8 Identifying leaks Page 0•9 Towing Page 0•9 Weekly Checks Introduction Page 0•10 Underbonnet check points Page 0•10 Engine oil level Page 0•11 Coolant level Page 0•11 Brake fluid level Page 0•12 Power steering fluid level Page 0•12 Screen/headlamp washer fluid level Page 0•13 Wiper blades Page 0•13 Tyre condition and pressure Page 0•14 Battery Page 0•15 Electrical systems Page 0•15 Lubricants and fluids Page 0•16 Capacities and tyre pressures Page 0•17 MAINTENANCE Routine Maintenance and Servicing Servicing specifications Page 1•2 Maintenance schedule: Vehicles manufactured before August 1985 Page 1•5 Vehicles manufactured after August 1985 Page 1•6 Maintenance - component location Page 1•7 Maintenance procedures Page 1•10 Contents REPAIRS & OVERHAUL Engine and Associated Systems Engine repair procedures - 1.05 and 1.3 litre - pre August 1985 Page 2A•1 Engine repair procedures - 1.05 and 1.3 litre - post August 1985 Page 2B•1 Engine repair procedures - 1.6 and 1.8 litre 8 valve Page 2C•1 Engine repair procedures - 1.8 litre 16 valve Page 2D•1 Cooling, heating and air conditioning systems Page 3•1 Fuel and exhaust systems - carburettor models Page 4A•1 Fuel and exhaust systems - K-Jetronic fuel injection - 8 valve engines Page 4B•1 Fuel and exhaust systems - K-Jetronic fuel injection - 16 valve engines Page 4C•1 Fuel and exhaust systems - Mono Jetronic fuel injection Page 4D•1 Fuel and exhaust systems - Digijet fuel injection Page 4E•1 Fuel and exhaust systems - Digifant fuel injection Page 4F•1 Ignition system - contact breaker type Page 5A•1 Ignition system - transistorised type Page 5B•1 Ignition system - fully electronic type Page 5C•1 Starting and charging systems Page 5D•1 Brakes and Suspension Braking system Page 9•1 Suspension and steering Page 10•1 Body Equipment Bodywork and fittings Page 11•1 Body electrical systems Page 12•1 Wiring Diagrams Page 12•17 0•4 Introduction The Mk. II Volkswagen Golf and Jetta range of models was bucket tappets, the Digifant, Digijet and Mono-Jetronic fuel injection introduced in March 1984, revised body and trim features being the systems, the 16-valve engine fitted to the GTi variant, the fully main visual difference to the earlier range of models. electronic ignition system (FEI), the 085 5-speed gearbox and several The engine/transmission is mounted transversely at the front of the other minor modifications and revisions. vehicle, drive being to the front wheels. Detailed improvements have As with earlier models the new range is proving popular, giving been made throughout the years of manufacture to improve power economy, reliability, comfort and, if previous models can be used as a output and economy. These include the introduction of hydraulic yardstick, long life. VW Golf VW Jetta Your Volkswagen Golf and The VW Golf & Jetta Team Jetta Manual The aim of this Manual is to help you get the best value from your Haynes manuals are produced by dedicated and vehicle. It can do so in several ways. It can help you decide what work enthusiastic people working in close co-operation. The must be done (even should you choose to get it done by a garage), team responsible for the creation of this book included: provide information on routine maintenance and servicing, and give a logical course of action and diagnosis when random faults occur. Authors Ian Coomber However, it is hoped that you will use the Manual by tackling the work Cristopher Rogers yourself. On simpler jobs it may even be quicker than booking the car into a garage and going there twice, to leave and collect it. Perhaps Sub-editors Carole Turk most important, a lot of money can be saved by avoiding the costs a Sophie Yar garage must charge to cover its labour and overheads. Editor & Page Make-up Steve Churchill The Manual has drawings and descriptions to show the function of the various components so that their layout can be understood. Then Workshop manager Paul Buckland the tasks are described and photographed in a clear step-by-step Photo Scans John Martin sequence. Paul Tanswell Acknowledgements Steve Tanswell Thanks are due to Champion Spark Plug who supplied the illustrations showing spark plug conditions, to Duckhams Oils, who Cover illustration & Line Art Roger Healing provided lubrication data and also to Sykes-Pickavant Limited, who supplied some of the workshop tools, and to all those people at Sparkford who helped in the production of this Manual. We hope the book will help you to get the maximum We take great pride in the accuracy of information given in this enjoyment from your car. By carrying out routine Manual, but vehicle manufacturers make alterations and design maintenance as described you will ensure your car’s changes during the production run of a particular vehicle of which reliability and preserve its resale value. they do not inform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from the information given. Safety first! 0•5 Working on your car can be dangerous. • Mains voltage is also dangerous. Make This page shows just some of the potential sure that any mains-operated equipment is Special hazards risks and hazards, with the aim of creating a correctly earthed. Mains power points should Hydrofluoric acid safety-conscious attitude. be protected by a residual current device (RCD) circuit breaker. • This extremely corrosive acid is formed General hazards when certain types of synthetic rubber, found Fume or gas intoxication in some O-rings, oil seals, fuel hoses etc, are 0 Scalding • Exhaust fumes are exposed to temperatures above 400 C. The • Don’t remove the radiator or expansion poisonous; they often rubber changes into a charred or sticky tank cap while the engine is hot. contain carbon substance containing the acid. Once formed, • Engine oil, automatic transmission fluid or monoxide, which is the acid remains dangerous for years. If it power steering fluid may also be dangerously rapidly fatal if inhaled. gets onto the skin, it may be necessary to hot if the engine has recently been running. Never run the amputate the limb concerned. engine in a • When dealing with a vehicle which has Burning confined space suffered a fire, or with components salvaged • Beware of burns from the exhaust system such as a garage from such a vehicle, wear protective gloves and from any part of the engine. Brake discs with the doors shut. and discard them after use. and drums can also be extremely hot • Fuel vapour is also The battery immediately after use. poisonous, as are the vapours from some cleaning solvents and paint thinners. • Batteries contain sulphuric acid, which Crushing attacks clothing, eyes and skin. Take care • When working under or near Poisonous or irritant substances when topping-up or carrying the battery. a raised vehicle, • Avoid skin contact with battery acid and • The hydrogen gas given off by the battery always with any fuel, fluid or lubricant, especially is highly explosive. Never cause a spark or supplement the antifreeze, brake hydraulic fluid and Diesel allow a naked light nearby. Be careful when jack with axle fuel. Don’t syphon them by mouth. If such a connecting and disconnecting battery stands, or use substance is swallowed or gets into the eyes, chargers or jump leads. drive-on seek medical advice. Air bags ramps. • Prolonged contact with used engine oil can Never cause skin cancer. Wear gloves or use a • Air bags can cause injury if they go off venture barrier cream if necessary. Change out of oil- accidentally. Take care when removing the under a car which soaked clothes and do not keep oily rags in steering wheel and/or facia. Special storage is only supported by a jack. your pocket. instructions may apply. • Take care if loosening or tightening high- • Air conditioning refrigerant forms a Diesel injection equipment torque nuts when the vehicle is on stands. poisonous gas if exposed to a naked flame • Diesel injection pumps supply fuel at very Initial loosening and final tightening should (including a cigarette).