Jetta IV, Golf IV Triple Gauge Panel Installation Instructions
Tools Recommended: Radio Removal Keys
1. Prior to installing gauge panel, have all wires and tubing run to gauges and tested. It is recommended that all wires be left long to free workspace behind the panel.
2. Remove radio using radio removal keys. Snap keys in. Pull up and out. With radio hanging out, cover climate controls with a soft cloth to avoid scratches. Push in tabs on side of radio to remove keys.
Read the rest of this entry »

• 0 Comments

The 1.8T BCS (Boost Control System) is designed to work with all throttle-by-wire Audi and Volkswagen 1.8T engines. Compatible models include the A4, Beetle, Passat, Jetta, Golf and GTI. The BCS provides user adjustability of maximum boost. At the minimum setting, the boost is held to the stock level of 6 PSI and the car will drive exactly like a stock car. As the boost setting is increased, the allowable boost is increased in precise increments. At the maximum setting, the boost is allowed to reach 14.5 PSI. This boost increases horsepower by 30 hp and the low-end torque is increased by 45 ft-lbs. The BCS includes a ten segment, three color LED boost gauge that reads in 1.5 PSI increments from 1 to 14.5 PSI. The display is electronically filtered to provide a smooth reading.
Read the rest of this entry »

• 0 Comments

This Volkswagen Golf and Jetta Braking System Manual contains the Brake calipers - removal, overhaul and refitting Brake discs - examination, removal and refitting Brake pads- inspection and renewal Brake pressure regulator - testing, removal and refitting Footbrake pedal - removal and refitting General information and precautions Handbrake cables - removal, refitting and adjustment Handbrake lever - removal and refitting Hydraulic pipes and hoses - renewal Hydraulic system - bleeding Master cylinder - removal and refitting Rear brake cylinder - removal, overhaul and refitting Rear brake drum - examination and renovation Rear brake shoes - inspection and renewal Rear hub bearings - renewal Vacuum servo unit - removal and refitting Vacuum servo unit - testing Degrees of difficulty Easy, suitable for novice with little experience
Read the rest of this entry »

• 0 Comments

Accelerator and throttle cables - removal, refitting and adjustment . 10 Accelerator pedal - removal and refitting Air cleaner element - renewal Air cleaner unit - removal and refitting Automatic air cleaner temperature control - testing Carburettor (1.05 litre engine) - adjustments Carburettor (1.3 litre engine) - adjustments Carburettor (1.6 & 1.8 litre engines) - adjustments Carburettor - overhaul Carburettor - removal and refitting Choke cable (1.05 litre engine) - removal, refitting and adjustment . 12 Exhaust system - inspection, removal and refitting Fuel filler gravity valve - removal, testing and refitting Fuel gauge sender unit - removal and refitting Fuel pump - testing, removal and refitting Fuel reservoir - removal and refitting Fuel tank - removal and refitting General information and precautions Inlet and exhaust manifolds - removal and refitting Inlet manifold preheating - testing Specifications Air cleaner Type Element type Element application: 1.05 litre 1.3 litre 1.6 litre 1.8 litre Automatic air temperature control Renewable paper Champion Wl01 Champion W102 Champion U508 Champion U508 Fuel pump Type: 1.05 and 1.3 litre 1.6 and 1.8 litre Mechanical, diaphragm, operated by plunger from camshaft Mechanical, diaphragm, operated by eccentric on intermediate shaft 4A Fuel filter Type Champion L104 Carburettor - 1.05 litre Pierburg/Solex 31 PIC-7 Type Venturi Main jet Air correction jet with emulsion tube Idling fuel jet Idling air jet uxiliary fuel jet Auxiliary air jet Enrichment (primary/secondary) Injection capacity (cc/stroke) Float needle valve Float needle valve washer thickness Fast idle speed Choke valve gap Throttle valve gap smooth running detent Idle speed CO content % Downdraught with manual or automatic choke 23 mm X117.5 115 Z 45 135 32.5 130 70/70 1.00 ± 0.15 1.5 2.0 mm 2600 ± 100 rpm 1.8 ± 0.2 mm 2.5 ± 0.3 mm 950 ± 50 rpm 1.0 ± 0.5 1081 VW Golf & Jetta 4A•2
Read the rest of this entry »

• 0 Comments

This VolksWagen Golf and Jetta Routine includes the Air cleaner element renewal Air conditioning system check Alternator, power steering pump and air conditioner compressor drivebelt(s) check Antifreeze concentration check Automatic transmission and final drive fluid renewal Automatic transmission fluid level check Battery electrolyte level check Brake check Brake fluid renewal Brake pad and rear shoe lining check Clutch operation check Contact breaker point renewal and adjustment Contact breaker point check CV joint and boot check Engine oil and filter renewal Exhaust system check Fluid leakage and engine electrical system check Fuel and brake line, hose and union check Fuel filter renewal Fuel system control linkage check Gearbox oil level check Headlight beam alignment check Hinge and catch lubrication Ignition timing check Intensive maintenance Introduction Light, direction indicator and horn check Lock, hinge and latch mechanism check Seat belt check Slow running adjustment Spark plug renewal Steering gear check Sunroof guide rails cleaning and lubrication Suspension check Timing belt renewal Valve clearance check Vehicle underbody check Servicing specifications Refer to the end of “Weekly checks” Champion C101/C160 Lubricants, fluids and capacities Engine Oil filter Valve clearances 1.05 and 1.3 litre engines - pre August 1985: Warm: Inlet Exhaust Cold: Inlet Exhaust Hydraulic tappet free travel 1.05 and 1.3 litre - post August 1985, 1.6 and 1.8 litre (Maximum travel) 0.15 to 0.20 mm 0.25 to 0.30 mm 0.10 to 0.15 mm 0.20 to 0.25 mm 0.1 mm 50 % antifreeze (by volume) with water 5.0 to 10.0 mm deflection on longest run Cooling system
Read the rest of this entry »

• 0 Comments

Main wiring diagram, 2.8L Gas Engine, Engine Code AAA Note: For A/C system wiring information for vehicles equipped with the 2.8L Gas Engine, code AAA, see Index for correct Wiring Diagram No. Relay locations Positions of relays and multi-pin connector wiring, see also “Component Locations” sections. Load Reduction Relay Emergency Flasher Relay Wiper / Washer Intermittent Relay Seat Belt Warning System Relay Dual Horn Relay Fuel Pump Relay
Read the rest of this entry »

• 0 Comments

If your car won’t start Jump starting Wheel changing Identifying leaks Towing Weekly Checks Introduction Underbonnet check points Engine oil level Coolant level Brake fluid level Power steering fluid level Screen/headlamp washer fluid level Wiper blades Tyre condition and pressure Battery Electrical systems Lubricants and fluids Capacities and tyre pressures MAINTENANCE Routine Maintenance and Servicing Servicing specifications Maintenance schedule: Vehicles manufactured before August 1985 Vehicles manufactured after August 1985 Maintenance - component location Maintenance procedures Contents REPAIRS & OVERHAUL Engine and Associated Systems Engine repair procedures - 1.05 and 1.3 litre - pre August 1985 Engine repair procedures - 1.05 and 1.3 litre - post August 1985 Engine repair procedures - 1.6 and 1.8 litre 8 valve Engine repair procedures - 1.8 litre 16 valve Cooling, heating and air conditioning systems Fuel and exhaust systems - carburettor models Fuel and exhaust systems - K-Jetronic fuel injection - 8 valve engines Fuel and exhaust systems - K-Jetronic fuel injection - 16 valve engines Fuel and exhaust systems - Mono Jetronic fuel injection Fuel and exhaust systems - Digijet fuel injection Fuel and exhaust systems - Digifant fuel injection Ignition system - contact breaker type Ignition system - transistorised type Ignition system - fully electronic type Starting and charging systems Transmission Clutch Manual gearbox Automatic transmission Driveshafts Brakes and Suspension Braking system Suspension and steering Body Equipment Bodywork and fittings Body electrical systems Wiring Diagrams
Read the rest of this entry »

• 0 Comments

The aim of this VW Golf Jetta Service Repair 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 ust be done (even should you choose to get it done by a garage), provide information on routine maintenance and servicing, and give a ogical course of action and diagnosis when random faults occur. owever, it is hoped that you will use the Manual by tackling the work ourself.
Read the rest of this entry »

• 0 Comments