Volkswagen Golf/Jetta 2 manual

Servicing specifications
Routine maintenance and servicing / Servicing specifications


Lubricants, fluids and capacities Refer to the end of Weekly checks Engine
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C101/C160 Valve clearances
1.05 and 1.3 litre engines - pre August 1985: Warm:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 to 0.20 mm Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 to 0.30 mm Cold:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 to 0.15 mm Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 to 0.25 mm Hydraulic tappet free travel 1.05 and 1.3 litre - post August 1985, 1.6 and 1.8 litre (Maximum travel) . . 0.1 mm
Cooling system
Antifreeze mixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 % antifreeze (by volume) with water Air conditioning system
Compressor drivebelt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 to 10.0 mm deflection on longest run Fuel system
Air filter element types Carburettor engines:
1.05 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W101 1.3 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W102 1.6 and 1.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion U508 Fuel-injected engines:
K-Jetronic on 16 valve engine: 1.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion U502 All other systems:
1.8 litre Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion U506 1.8 litre Jetta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion U502 1.8 litre GTi ( engine code RP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion U572
Fuel filter element types Carburettor engines (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion L104 Fuel-injected engines:
K-Jetronic on 16 valve engine: 1.8 litre Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion L203 1.8 litre Jetta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion L206 All other systems:
1.8 litre GTi ( engine code RP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion L206
All other models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion L204* * New copper washers must be used and these are not supplied with the filter Idle speed
1.05 litre carburettor engines: Pierburg/Solex 31 PIC-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 to 1000 rpm Pierburg/Solex 1B3 and Weber 32 TLA . . . . . . . . . . . . . . . . . . . . . . . 750 to 850 rpm
1.3 litre carburettor engines: Pierburg/Solex 2E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 to 850 rpm 1.6 litre carburettor engines: Pierburg/Solex 2E2 - engine code EZ . . . . . . . . . . . . . . . . . . . . . . . . 900 to 1000 rpm
Pierburg/Solex 2E2 - engine code RF . . . . . . . . . . . . . . . . . . . . . . . . 700 to 800 rpm
1.8 litre carburettor engines: Pierburg/Solex 2E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 to 1000 rpm K-Jetronic fuel-injected engine: 8 valve:
Pre Sept. 1984 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 to 1000 rpm From Sept. 1984 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 to 1000 rpm Air conditioned models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 850 to 1000 rpm 16 valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 to 1000 rpm Mono Jetronic fuel-injected engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 to 950 rpm (not adjustable) Digijet fuel-injected engine: Up to July 1989 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 to 850 rpm July 1989 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 880 to 980 rpm Digifant fuel-injected engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 to 850 rpm CO content (%)
1.05 litre carburettor engines: Pierburg/Solex 31 PIC-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 1.5 Pierburg/Solex 1B3 and Weber 32 TLA . . . . . . . . . . . . . . . . . . . . . . . 1.5 to 2.5
1.3 litre carburettor engines (Pierburg/Solex 2E3) . . . . . . . . . . . . . . . . . 1.5 to 2.5
1.6 litre carburettor engines: Pierburg/Solex 2E2 - engine code EZ . . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 1.5
Pierburg/Solex 2E2 - engine code RF . . . . . . . . . . . . . . . . . . . . . . . . 1.0 to 1.5
1.8 litre carburettor engines (Pierburg/Solex 2E2) . . . . . . . . . . . . . . . . . 0.5 to 1.5
K-Jetronic fuel-injected engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 1.5 Mono Jetronic fuel-injected engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 to 1.2
Digijet fuel-injected engine: Up to July 1989 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 to 1.1 July 1989 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 to 1.5 Digifant fuel-injected engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 1.5 Ignition system
Firing order (all engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2 (No. 1 cylinder at crankshaft pulley end) Contact breaker system
Spark plugs*: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type Electrode gap 1.05, 1.3, 1.6 and 1.8 litre (pre July 1985) . . . . . . . . . . . . . . . . . . . . . . Champion N7YCC or N7YC 0.8 mm or 0.7 mm * Spark plug types and electrode gaps are recommended by Champion Spark Plug. If other types are used, refer to their manufacturers recommendations
HT lead type:
1.05 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion LS-05 boxed set 1.3, 1.6 and 1.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion LS-07 boxed set Distributor:
Contact breaker gap (initial setting only) . . . . . . . . . . . . . . . . . . . . . . 0.4 mm
Dwell angle (1.05, 1.3 and 1.6 litre): Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 to 50 (50 to 56%) Wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 to 58 (47 to 64%) Ignition timing (at idle): 1.05 and 1.3 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 to 6 BTDC 1.6 and 1.8 litre (carburettor engine) . . . . . . . . . . . . . . . . . . . . . . . . . . 17 to 19 BTDC 1.8 litre (fuel injection engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 to 7 BTDC Transistorised system
Spark plugs*: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type Electrode gap pre Sept. 1985:
1.05, 1.3, 1.6, 1.8 litre (pre July 1985) . . . . . . . . . . . . . . . . . . . . . . . Champion N7YCC or N7YC 0.8 mm or 0.7 mm from Sept. 1985:
1.3 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion N7BYC or N7YCC 0.8 mm 1.6 litre:
Coil with green sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion N9BYC4 or N9YCC 1.0 mm Coil with grey sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion N9YCC 0.8 mm 1.8 litre:
Except 16V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion N7BYC or N7YCC 0.8 mm 16V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C6BYC or C6YCC 0.8 mm * Spark plug types and electrode gaps are recommended by Champion Spark Plug. If other types are used, refer to their manufacturers recommendations
HT lead type:
1.05 litre. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion LS-05 boxed set 1.3, 1.6 and 1.8 litre. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion LS-07 boxed set Distributor:
Dwell angle (1.05,1.3 and 1.6 litre): Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 to 50 (50 to 56%) Wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 to 58 (47 to 64%) Ignition timing:
1.3 litre (code NZ) - TCI-H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 to 6 BTDC at 750 to 850 rpm, with vacuum hose disconnected 1.6 litre (code RF) - TCI-H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 to 19 BTDC at 700 to 800 rpm, with vacuum hose disconnected 1.8 litre:
Code PB and PF - Digifant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 to 7 BTDC at 2000 to 2500 rpm, with temperature sender disconnected Code GU and RH - TCI-H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 to 19 BTDC at 675 to 825 rpm, with vacuum hose connected Code RP - TCI-H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 to 7 BTDC at 950 rpm, with vacuum hose disconnected Fully electronic system
All Specifications as for Transistorised System except for: Ignition timing:
1.8 litre 16 valve engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 to 7 BTDC at 950 to 1050 rpm, with vacuum hose connected Charging system
Alternator drivebelt tension Initial adjustment for new drivebelt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 mm deflection under finger pressure at point midway between alternator and crankshaft pulleys Adjustment after 500 miles (750 km) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 mm deflection under finger pressure at same point Models after early 1985 fitted with rack type adjustment link . . . . . . . . 8 to 10 Nm (6 to 7 Ibf ft) torque loading on adjuster bolt Clutch
Free play at clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 to 20 mm Braking system
Pad thickness
Front disc brakes:
New - excluding backplate: 1.05 and 1.3 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.0 mm
1.6 and 1.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.0 mm 1.8 litre with ventilated discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0 mm
Minimum - including backplate: All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 mm Rear disc brakes:
New - including backplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.0 mm
Minimum - including backplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 mm
Shoe lining thickness
Rear drum brakes:
Minimum - including shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 mm
Minimum - excluding shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 mm
Steering
Power steering pump drivebelt tension . . . . . . . . . . . . . . . . . . . . . . . . . 10.0 mm deflection under firm finger pressure at point midway between pump and crankshaft pulleys Tyre pressures Refer to the end of Weekly checks Torque wrench settings Nm lbf ft Engine
Sump drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22 Valve cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7 Ignition system
Contact breaker system:
Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15 Distributor clamp bolt:
1.05 and 1.3 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7
1.6 and 1.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Transistorised and fully electronic systems: Spark plugs:
1.05 and 1.3 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
1.6 and 1.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15
Charging system
Alternator mounting/pivot bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 33
Alternator adjuster link bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Manual gearbox
Oil filler plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18 Oil drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18 Automatic transmission
Oil pan bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15 Oil strainer (filter) cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2
Steering
Power steering pump/swivel bracket bolts . . . . . . . . . . . . . . . . . . . . . . 20 15
Power steering pump tensioner/bracket . . . . . . . . . . . . . . . . . . . . . . . . 20 15
Roadwheels
Roadwheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 81 Body fittings
Seat belt anchor bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 30


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