1997-2006 Volkswagen Golf 4 Mk4 Service & Repair Manual

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 © Haynes Publishing 1997 A book in the Haynes Service and Repair Manual Series All rights reserved. No part of this book may be reproduced or 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) ABCDE FGHIJ KLMNO PQRST 1 2 3 AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

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 AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

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 Transmission Clutch Page 6•1 Manual gearbox Page 7A•1 Automatic transmission Page 7B•1 Driveshafts Page 8•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 REFERENCE Dimensions and Weights Page REF•1 Conversion Factors Page REF•2 Buying Spare Parts and Vehicle Identification Page REF•3 General Repair Procedures Page REF•4 Jacking and Vehicle Support Page REF•5 Tools and Working Facilities Page REF•6 MOT test checks Page REF•8 Fault Finding Page REF•12 Glossary of Technical Terms Page REF•20 Index Page REF•25 Contents AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

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. These include the introduction of hydraulic bucket tappets, the Digifant, Digijet and Mono-Jetronic fuel injection systems, the 16-valve engine fitted to the GTi variant, the fully electronic ignition system (FEI), the 085 5-speed gearbox and several other minor modifications and revisions. As with earlier models the new range is proving popular, giving economy, reliability, comfort and, if previous models can be used as a yardstick, long life. 0•4 Introduction Your Volkswagen Golf and Jetta Manual The aim of this Manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done (even should you choose to get it done by a garage), provide information on routine maintenance and servicing, and give a logical course of action and diagnosis when random faults occur. However, it is hoped that you will use the Manual by tackling the work 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 most important, a lot of money can be saved by avoiding the costs a garage must charge to cover its labour and overheads. The Manual has drawings and descriptions to show the function of the various components so that their layout can be understood. Then the tasks are described and photographed in a clear step-by-step sequence. Acknowledgements Thanks are due to Champion Spark Plug who supplied the illustrations showing spark plug conditions, to Duckhams Oils, who 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 take great pride in the accuracy of information given in this Manual, but vehicle manufacturers make alterations and design changes during the production run of a particular vehicle of which 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. The VW Golf & Jetta Team Haynes manuals are produced by dedicated and enthusiastic people working in close co-operation. The team responsible for the creation of this book included: Authors Ian Coomber Cristopher Rogers Sub-editors Carole Turk Sophie Yar Editor & Page Make-up Steve Churchill Workshop manager Paul Buckland Photo Scans John Martin Paul Tanswell Steve Tanswell Cover illustration & Line Art Roger Healing We hope the book will help you to get the maximum enjoyment from your car. By carrying out routine maintenance as described you will ensure your car’s reliability and preserve its resale value. VW Golf VW Jetta AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

Safety first! 0•5 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. Brake discs and drums can also be extremely hot immediately after use. Crushing • When working under or near a raised vehicle, always supplement the jack with axle stands, or use drive-on ramps. Never venture under a car which is only supported by a jack. • Take care if loosening or tightening high- torque nuts when the vehicle is on stands. Initial loosening and final tightening should be done with the wheels on the ground. Fire • Fuel is highly flammable; fuel vapour is explosive. • Don’t let fuel spill onto a hot engine. • Do not smoke or allow naked lights (including pilot lights) anywhere near a vehicle being worked on. Also beware of creating sparks (electrically or by use of tools). • Fuel vapour is heavier than air, so don’t work on the fuel system with the vehicle over an inspection pit. • Another cause of fire is an electrical overload or short-circuit. Take care when repairing or modifying the vehicle wiring. • Keep a fire extinguisher handy, of a type suitable for use on fuel and electrical fires. Electric shock • Ignition HT voltage can be dangerous, especially to people with heart problems or a pacemaker. Don’t work on or near the ignition system with the engine running or the ignition switched on. • Mains voltage is also dangerous. Make sure that any mains-operated equipment is correctly earthed. Mains power points should be protected by a residual current device (RCD) circuit breaker. Fume or gas intoxication • Exhaust fumes are poisonous; they often contain carbon monoxide, which is rapidly fatal if inhaled. Never run the engine in a confined space such as a garage with the doors shut. • Fuel vapour is also poisonous, as are the vapours from some cleaning solvents and paint thinners. Poisonous or irritant substances • Avoid skin contact with battery acid and with any fuel, fluid or lubricant, especially antifreeze, brake hydraulic fluid and Diesel fuel. Don’t syphon them by mouth. If such a substance is swallowed or gets into the eyes, seek medical advice. • Prolonged contact with used engine oil can cause skin cancer. Wear gloves or use a barrier cream if necessary. Change out of oil- soaked clothes and do not keep oily rags in your pocket. • Air conditioning refrigerant forms a poisonous gas if exposed to a naked flame (including a cigarette). It can also cause skin burns on contact. Asbestos • Asbestos dust can cause cancer if inhaled or swallowed. Asbestos may be found in gaskets and in brake and clutch linings. When dealing with such components it is safest to assume that they contain asbestos. Special hazards Hydrofluoric acid • This extremely corrosive acid is formed when certain types of synthetic rubber, found in some O-rings, oil seals, fuel hoses etc, are exposed to temperatures above 400 0 C. The rubber changes into a charred or sticky substance containing the acid. Once formed, the acid remains dangerous for years. If it gets onto the skin, it may be necessary to amputate the limb concerned. • When dealing with a vehicle which has suffered a fire, or with components salvaged from such a vehicle, wear protective gloves and discard them after use. The battery • Batteries contain sulphuric acid, which attacks clothing, eyes and skin. Take care when topping-up or carrying the battery. • The hydrogen gas given off by the battery is highly explosive. Never cause a spark or allow a naked light nearby. Be careful when connecting and disconnecting battery chargers or jump leads. Air bags • Air bags can cause injury if they go off accidentally. Take care when removing the steering wheel and/or facia. Special storage instructions may apply. Diesel injection equipment • Diesel injection pumps supply fuel at very high pressure. Take care when working on the fuel injectors and fuel pipes. Warning: Never expose the hands, face or any other part of the body to injector spray; the fuel can penetrate the skin with potentially fatal results. Remember... DO • Do use eye protection when using power tools, and when working under the vehicle. • Do wear gloves or use barrier cream to protect your hands when necessary. • Do get someone to check periodically that all is well when working alone on the vehicle. • Do keep loose clothing and long hair well out of the way of moving mechanical parts. • Do remove rings, wristwatch etc, before working on the vehicle – especially the electrical system. • Do ensure that any lifting or jacking equipment has a safe working load rating adequate for the job. A few tips DON’T • Don’t attempt to lift a heavy component which may be beyond your capability – get assistance. • Don’t rush to finish a job, or take unverified short cuts. • Don’t use ill-fitting tools which may slip and cause injury. • Don’t leave tools or parts lying around where someone can trip over them. Mop up oil and fuel spills at once. • Don’t allow children or pets to play in or near a vehicle being worked on. AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

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 M If it’s a model with automatic transmission, make sure the selector is in ‘P’ or ‘N’. M Open the bonnet and make sure that the battery terminals are clean and tight. M Switch on the headlights and try to start the engine. If the headlights go very dim when you’re trying to start, the battery is probably flat. Get out of trouble by jump starting (see next page) using a friend’s car. If your car won’t start even though the starter motor turns as normal M Is there fuel in the tank? M Is there moisture on electrical components under the bonnet? Switch off the ignition, then wipe off any obvious dampness with a dry cloth. Spray a water-repellent aerosol product (WD-40 or equivalent) on ignition and fuel system electrical connectors like those shown in the photos. Pay special attention to the ignition coil wiring connector and HT leads. Check that the HT lead connections at the distributor are clean and make sure they are secure by pushing them onto the cap. A Check that the HT lead connections at the spark plugs are secure by pushing them onto the plugs. B Check that the LT lead connections are clean and secure. C Check the security and condition of the battery connections. D Wiring plugs may cause problems if dirty or not connected properly. E Check that electrical connections are secure (with the ignition switched off) and spray them with a water dispersant spray like WD40 if you suspect a problem due to damp AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

Roadside repairs 0•7 When jump-starting a car using a booster battery, observe the following precautions: 4 Before connecting the booster battery, make sure that the ignition is switched off. 4 Ensure that all electrical equipment (lights, heater, wipers, etc) is switched off. 4 Make sure that the booster battery is the same voltage as the discharged one in the vehicle. 4 If the battery is being jump-started from the battery in another vehicle, the two vehcles MUST NOT TOUCH each other. 4 Make sure that the transmission is in neutral (or PARK, in the case of automatic transmission). 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: 1 The battery has been drained by repeated attempts to start, or by leaving the lights on. 2 The charging system is not working properly (alternator drivebelt slack or broken, alternator wiring fault or alternator itself faulty). 3 The battery itself is at fault (electrolyte low, or battery worn out). Connect one end of the red jump lead to the positive (+) terminal of the flat battery Connect the other end of the red lead to the positive (+) terminal of the booster battery. Connect one end of the black jump lead to the negative (-) terminal of the booster battery Connect the other end of the black jump lead to a bolt or bracket on the engine block, well away from the battery, on the vehicle to be started. 1 2 3 4 Make sure that the jump leads will not come into contact with the fan, drive- belts or other moving parts of the engine. 5 Start the engine using the booster battery, then with the engine running at idle speed, disconnect the jump leads in the reverse order of connection. 6 Jump starting AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

0•8 Roadside repairs The spare wheels and tools are stored in the luggage compartment. Release the retaining strap and lift out the jack and tools from the centre of the wheel. Finally... M Remove the wheel chocks. M Stow the jack and tools in the correct locations in the car. M Check the tyre pressure on the wheel just fitted. If it is low, or if you don’t have a pressure gauge with you, drive slowly to the nearest garage and inflate the tyre to the right pressure. M Have the damaged tyre or wheel repaired as soon as possible. Locate the jack below the reinforced point on the sill and on firm ground. Turn the jack handle to raise the car until the wheel is clear of the ground. Unscrew the wheel bolts and remove the wheel. Fit the spare wheel and screw in the wheel bolts. Lightly tighten them using the wheelbrace, then lower the car to the ground. Once the car is on the ground, tighten the wheel bolts securely in a diagonal pattern using the wheelbrace. At the earliest possible opportunity, have the wheel bolts slackened and then tightened to the correct torque wrench setting. Remove the wheel trim/hub cap from the wheel (some trims have retaining screws which must be undone first). Slacken each wheel bolt by half a turn. Unscrew the retaining nut and lift the wheel out of the vehicle. 1 2 3 4 5 6 Preparation M When a puncture occurs, stop as soon as it is safe to do so. M Park on firm level ground, if possible, and well out of the way of other traffic. M Use hazard warning lights if necessary. M If you have one, use a warning triangle to alert other drivers of your presence. M Apply the handbrake and engage first or reverse gear (or Park on models with automatic transmission. M Chock the wheel diagonally opposite the one being removed – a couple of large stones will do for this. M If the ground is soft, use a flat piece of wood to spread the load under the jack. Changing the wheel 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. AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

Roadside repairs 0•9 When all else fails, you may find yourself having to get a tow home – or of course you may be helping somebody else. Long-distance recovery should only be done by a garage or breakdown service. For shorter distances, DIY towing using another car is easy enough, but observe the following points: M Use a proper tow-rope – they are not expensive. The vehicle being towed must display an ‘ON TOW’ sign in its rear window. M Always turn the ignition key to the ‘on’ position when the vehicle is being towed, so that the steering lock is released, and that the direction indicator and brake lights will work. M Only attach the tow-rope to the towing eyes provided. M Before being towed, release the handbrake and select neutral on the transmission. M Note that greater-than-usual pedal pressure will be required to operate the brakes, since the vacuum servo unit is only operational with the engine running. M On models with power steering, greater- than-usual steering effort will also be required. M The driver of the car being towed must keep the tow-rope taut at all times to avoid snatching. M Make sure that both drivers know the route before setting off. M Only drive at moderate speeds and keep the distance towed to a minimum. Drive smoothly and allow plenty of time for slowing down at junctions. M On models with automatic transmission, special precautions apply. If in doubt, do not tow, or transmission damage may result. Towing 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. Wash them off skin, and change out of contaminated clothing, without delay. Identifying leaks The smell of a fluid leaking from the car may provide a clue to what’s leaking. Some fluids are distinctively coloured. It may help to clean the car carefully and to park it over some clean paper overnight as an aid to locating the source of the leak. Remember that some leaks may only occur while the engine is running. Sump oil Gearbox oil Brake fluid Power steering fluid Oil from filter Antifreeze Engine oil may leak from the drain plug... ...or from the base of the oil filter. Leaking antifreeze often leaves a crystalline deposit like this. Gearbox oil can leak from the seals at the inboard ends of the driveshafts. A leak occurring at a wheel is almost certainly brake fluid. Power steering fluid may leak from the pipe connectors on the steering rack. AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

0•10 Weekly checks 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. These "Weekly checks" require no great skill or special tools, and the small amount of time they take to perform could prove to be very well spent, for example; 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. M Many breakdowns are caused by electrical problems. Battery-related faults are particularly common, and a quick check on a regular basis will often prevent the majority of these. M If your car develops a brake fluid leak, the first time you might know about it is when your brakes don't work properly. Checking the level regularly will give advance warning of this kind of problem. M If the oil or coolant levels run low, the cost of repairing any engine damage will be far greater than fixing the leak, for example. Introduction § All models (typical) A Engine oil level dipstick B Engine oil filler cap C Coolant expansion tank D Brake fluid reservoir E Power steering fluid reservoir F Screen washer fluid reservoir G Battery Underbonnet check points AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

1997-2006 Volkswagen Golf 4 Mk4 Service & Repair Manual

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