Repair manual

ManualsBrandsVolkswagen ManualsAuto Parts1995 Volkswagen Golf III GL

VW Golf & Jetta

Service and Repair Manual

Models covered

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

I M Coomber and Christopher Rogers

A book in the Haynes Service and Repair Manual Series

transmitted in any form or by any means, electronic or

mechanical, including photocopying, recording or by any

information storage or retrieval system, without permission in

writing from the copyright holder.

ISBN 1 85960 282 7

British Library Cataloguing in Publication Data

A catalogue record for this book is available from the British Library

Printed by J H Haynes & Co. Ltd, Sparkford, Nr Yeovil, Somerset

BA22 7JJ, England

Haynes Publishing

Sparkford Nr Yeovil

Somerset BA22 7JJ England

Haynes North America, Inc

861 Lawrence Drive

Newbury Park

California 91320 USA

Editions Haynes S.A.

147/149, rue Saint Honoré, 75001 PARIS, France

Haynes Publishing Nordiska AB

Fyrisborgsgatan 5, 754 50 Uppsala, Sverige

(1081 - 344 - 1AA11)

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1 2 3

Summary of content (18 pages)

PAGE 1
VW Golf & Jetta Service and Repair Manual I M Coomber and Christopher Rogers Models covered 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 (1081 - 344 - 1AA11) Covers mechanical features of Van.
PAGE 2
Contents LIVING WITH YOUR VOLKSWAGEN GOLF OR JETTA Introduction Page 0•4 Safety First! Page 0•5 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 Roadside Repairs 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
PAGE 3
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.
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0•4 Introduction The Mk. II Volkswagen Golf and Jetta range of models was introduced in March 1984, revised body and trim features being the main visual difference to the earlier range of models. The engine/transmission is mounted transversely at the front of the vehicle, drive being to the front wheels. Detailed improvements have been made throughout the years of manufacture to improve power output and economy.
PAGE 5
Safety first! Working on your car can be dangerous. This page shows just some of the potential risks and hazards, with the aim of creating a safety-conscious attitude. General hazards Scalding • Don’t remove the radiator or expansion tank cap while the engine is hot. • Engine oil, automatic transmission fluid or power steering fluid may also be dangerously hot if the engine has recently been running. Burning • Beware of burns from the exhaust system and from any part of the engine.
PAGE 6
0•6 Roadside repairs The following pages are intended to help in dealing with common roadside emergencies and breakdowns. You will find more detailed fault finding information at the back of the manual, and repair information in the main chapters. If your car won’t start and the starter motor doesn’t turn If your car won’t start even though the starter motor turns as normal M If it’s a model with automatic transmission, make sure the selector is in ‘P’ or ‘N’.
PAGE 7
Roadside repairs Jump starting will get you out of trouble, but you must correct whatever made the battery go flat in the first place. There are three possibilities: The battery has been drained by repeated attempts to start, or by leaving the lights on. 1 The charging system is not working properly (alternator drivebelt slack or broken, alternator wiring fault or alternator itself faulty).
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0•8 Roadside repairs Wheel changing Some of the details shown here will vary according to model. For instance, the location of the spare wheel and jack is not the same on all cars. However, the basic principles apply to all vehicles. Warning: Do not change a wheel in a situation where you risk being hit by another vehicle. On busy roads, try to stop in a lay-by or a gateway. Be wary of passing traffic while changing the wheel - it is easy to become distracted by the job in hand.
PAGE 9
Roadside repairs 0•9 Identifying leaks Puddles on the garage floor or drive, or obvious wetness under the bonnet or underneath the car, suggest a leak that needs investigating. It can sometimes be difficult to decide where the leak is coming from, especially if the engine bay is very dirty already. Leaking oil or fluid can also be blown rearwards by the passage of air under the car, giving a false impression of where the problem lies. Warning: Most automotive oils and fluids are poisonous.
PAGE 10
0•10 Weekly checks Introduction There are some very simple checks which need only take a few minutes to carry out, but which could save you a lot of inconvenience and expense. M Keeping an eye on tyre condition and pressures, will not only help to stop them wearing out prematurely, but could also save your life.
PAGE 11
Weekly checks 0•11 Engine oil level Before you start 4 Make sure that your car is on level ground. 4 Check the oil level before the car is driven, or at least 5 minutes after the engine has been switched off.
PAGE 12
0•12 Weekly checks Brake fluid level Warning: l Brake fluid can harm your eyes and damage painted surfaces, so use extreme caution when handling and pouring it. l Do not use fluid that has been standing open for some time, as it absorbs moisture from the air, which can cause a dangerous loss of braking effectiveness. 1 The “MAX” and “MIN” marks are indicated on the front of the reservoir. The fluid level must be kept between the marks at all times.
PAGE 13
Weekly checks 0•13 Screen/headlamp washer fluid level Screenwash additives not only keep the winscreen clean during foul weather, they also prevent the washer system freezing in cold weather - which is when you are likely to need it most. Don’t top up using plain water as the screenwash will become too diluted, and will 1 The reservoir for the windscreen and headlamp washer systems is located on the left-hand side of the engine compartment, forward of the suspension turret.
PAGE 14
0•14 Weekly checks Tyre condition and pressure New tyres should be balanced when they are fitted, but it may become necessary to rebalance them as they wear, or if the balance weights fitted to the wheel rim should fall off. Unbalanced tyres will wear more quickly, as will the steering and suspension components. Wheel imbalance is normally signified by vibration, particularly at a certain speed (typically around 50 mph).
PAGE 15
Weekly checks 0•15 Battery Caution: Before carrying out any work on the vehicle battery, read the precautions given in "Safety first" at the start of this manual. 4 Make sure that the battery tray is in good condition, and that the clamp is tight. Corrosion on the tray, retaining clamp and the battery itself can be removed with a solution of water and baking soda. Thoroughly rinse all cleaned areas with water. Any metal parts damaged by corrosion should be covered with a zinc-based primer, then painted.
PAGE 16
0•16 Lubricants and fluids Lubricants and fluids Component or system Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricant or fluid Cooling system . . . . . . . . . . . . . . . . . . . . . . Ethylene-glycol based antifreeze with corrosion inhibitors. Duckhams Antifreeze & Summer Coolant. Mixture 50% by volume Manual gearbox . . . . . . . . . . . . . . . . . . . . . Gear oil, viscosity SAE 80 Duckhams Hypoid 80 or Hypoid 75W/90S Automatic transmission . . . . . . . . . . . . .
PAGE 17
Capacities and tyre pressures Capacities Component or system Engine: Capacity 1.05 & 1.3 litre: rocker-finger type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hydraulic tappet type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 & 1.8 litre: pre-August 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . post-August 1985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling system . . . . . . . . . . . . . . .
PAGE 18
0•18 Notes