Haynes VW Golf and Jetta Owners Workshop Manual 0856967165, 9780856967160

Citation preview

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EDINBURGH CITY LIBRARIES

6

Reference Department q THIS BOOK MUST NOT BE REMOVED UNDER ANY PRETEXT FROM THE REFERENCE DEPARTMENT. INFRINGEMENT OF THIS RULE RENDERS THE OFFENDER LIABLE TO PROSECUTION.

Before leaving the Library readers must return the books to one of the attendants at the issue desk, or they will be held responsible for them.

Readers are required to take care of the books, Writing or drawing with pen or pencil on any part of a book, or turning down the leaves, or cutting or mutilating them, will be treated as serious damage. q CONVERSATION IN THE REFERENCE DEPARTMENT IS ANNOYING TO STUDENTS, AND IS NOT PERMITIED. Class. ae Lo; Yr

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Owners Workshop Manual A K Legg T Eng(CEl),AMIMI Models

covered

All VW

Golf and Jetta models with 1093 cc or 1272 cc engine

ISBN

O 85696 716 5

© Haynes Publishing Group

1982

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.

Printed in England

HAYNES PUBLISHING GROUP SPARKFORD YEOVIL SOMERSET distributed in the USA by

HAYNES PUBLICATIONS 861 LAWRENCE DRIVE NEWBURY PARK CALIFORNIA 91320 USA

INC.

BA22 7JJ ENGLAND

ABCDE cMno

fe &) o

Ge

Acknowledgements Thanks

are

due to Volkswagenwerk

Aktiengesellschaft

for the

supply of technical information. The Champion Sparking Plug Company supplied the illustrations showing the various spark plug conditions. The bodywork repair photographs used in this manual were provided by Holt Lloyd Limited who supply the ‘Turtle Wax’, ‘Dupli-

About

Color Holts’, and other Holts range products. Castrol Limited kindly supplied the lubrication data, and Sykes-Pickavant Ltd provided some of the workshop tools. Special thanks are due to all those people at Sparkford

who

helped in the production of this manual.

this manual

[ts aim 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 step-by-step sequence so that even a novice can do the work.

/ts arrangement The manual is divided into eleven Chapters, logical sub-division of the vehicle. The Chapters are Sections, numbered with single figures, eg 5; and paragraphs (or sub-sections), with decimal numbers the Section they are in, eg 5.1, 5.2, 5.3 etc.

each covering a each divided into the Sections into following on from

It is freely illustrated, especially in those parts where there is a detailed sequence of operations to be carried out. There are two forms of illustration: figures and photographs. The figures are numbered in sequence with decimal numbers, according to their position in the

Chapter — eg Fig. 6.4 is the fourth drawing/illustration in Chapter 6. Photographs carry the same number (either individually or in related groups) as the Section or sub-section to which they relate. There is an alphabetical index at the back of the manual as well as a contents list at the front. Each Chapter is also preceded by its own individual contents list. é

References to the ‘left’ or ‘right’ of the vehitle are in the sense of a person in the driver's seat facing forwards. Unless otherwise stated, nuts and bolts are removed by turning anti-clockwise, and tightened by turning clockwise. Vehicle manufacturers continually make changes to specifications and recommendations, and these, when notified, are incorporated into our manuals at the earliest opportunity. Whilst every care is taken to ensure that the information in this manual is correct, 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.

Introduction Golf abbot andbaited Jetta "ot ste lala to the bt daa EE! oo NS The VW Golf was first introduced in October 1974 as a hatchback available with a 1100 or 1500 cc engine. The 1300 cc engine replaced the 1500 cc version in October 1979. The Golf has proved itself to be a popular econnomical car, and well over three million cars have been manufactured. The Jetta was introduced in March 1980 and is essentially a Golf

with a boot compartment, although there are other minor differences. Both Golf and Jetta have well designed bodies, and as proof of their confidence the manufacturer now give a six year warranty against rust, with unlimited mileage.

Mechanically the engine and gearbox are mounted transversely at the front of the car, and drive is through the front wheels.

Contents Page

Acknowledgements

2

About this manual

2

Introduction to the Golf and Jetta

2

General dimensions, weights and capacities

6

Buying spare parts and vehicle identification numbers

7

Jacking and towing

10

Recommended

11

lubricants and fluids

Safety first!

12

Routine

13

maintenance

Fault diagnosis

15

Chapter

18

1 Engine

Chapter 2 Cooling system

-

Chapter 3 Fuel and exhaust systems

39

;

Chapter 4 Ignition system

45

i

61

Chapter 5 Clutch

Chapter..6

68

Transmission

.

93

Chapter 7 Driveshafts

Chapter 8 Braking system

PcK

ay

Chapter 9 Electrical system Chapter 10 Chapter

11

73

xk

& wien Be

97 117

Suspension .and steering

213

Bodywork and fittings

231

Conversion factors

252

Index

253

VW Golf three-door hatchback

VW Golf five-door hatchback

VW Jetta saloon

VW Jetta saloon in Formula E trim

General dimensions, weights and capacities Dimensions

Golf

OVO sel lalerveg thers: cansevtscascvcs ecvsscteartaresscerere Nepoomar teatteers eteeestice dec srdaoranetens

150.2

OWTaT FALE OTe INteeyn

F

p

ett ee

———

(continue models Golf 1975 for diagram Wiring 9.30 Fig.

148

Key to additional wiring diagram for tachometer, rear window wash/wipe system and dual brake circuit warning lamp (from August 1974) . Designation

D

—

E34

—

F

—

F1 FQ

— —

G5

—

K7

—

in current track

To ignition/starter switch, terminal 15 Rear window wiper and washer pump switch Brake light switch To oil pressure switch Handbrake warning lamp switch Tachometer

7 2,34 SAOnn 12 13 7

Dual circuit brake system

and handbrake warning lamp To brake light, left To ignition coil, terminal 1 Fuse in fuse box Single fuse for rear window wiper Flat connector, single, behind instrument panel

12,13,14 8 6

M9 N

— —

S6

—

S30

—

T1a

—

T1b

—

Connector, single, behind instrument panel

T2a

—

T2b

—

T3a

—

T10

—

Flat connector, two point, in luggage boot lid Connector, two point, in luggage boot left Connector, three point, behind instrument panel Multi-point connector, instrument panel insert

V12

—

Rear window wiper

eZ.

V1i3.

—

Rear window washerpump

5

Colour code

,

ro sw li bl we br

— — — — — —

red black lilac blue white brown

gn gr ge

— — —

green grey yellow

9 2

149

30 15

3) 4

[s.

G7 Ww ro

Soo gn

gn

ro/ge

bl/ br F

81a

|82a

gn/ro ro/sw

h

fT

Tso

gr/gn

in

gn/sw

{

N

Ta gn

gn/ro

gn/sw

N

: T20

gn/sw

br

“

] \

N y

G:

Vis

Vi2

ge

31

1

T10/3

53

53

53a

0.5

1,0

0.5

T10/6

iS

br

1

23

9 10

N

12

13 14

brake circuit warning lamp eter, rear window wash/wipe system, and dual Fig. 9.31 Additional wiring diagram for tachom (from August 1974)

150

Key to additional wiring diagram for headlight washer system with intermittent wiper operation (from August 1974 to chassis no 1753149911) Designation E1 — to lighting switch, terminal 56 E22 — Wiper switch for intermittent operation J — todip relay and headlight flasher, terminal 56 J31 — Relay for intermittent

washer/wipe facility J39

—

S11 T1a

— —

T2a

—

Vv V5 V11

— — —

©

Headlight washer system relay Fuse in fuse box Single connector near fuse box Connector, 2 pin near headlight washer pump Windscreen wiper motor Windscreen washer pump Headlight washer pump Earthing point, instrument panel Colour code ro — red ws — white Sw — black gn — green bl — blue br — brown

ge

—

yellow

in current track 11

5-9 12

3.4 espace 2

1-3 10 13

151 30

3]

Ske ne

—o

r

Sn

)i

1,0gn/ge

1,0gn

1,0gn/ro

(Laeoz 7 poz

0,5 br/bl

2,5 ws/sw

1,0gn/ro

WG

0,5gn /ro 60ro O,5ws /sw

Ei

Es

156

53

53b

53a

:

‘30

-

53e

iO os, ee

€

=e 1,0br

0,5br

no wiper operation (from August 1974 to chassis headlight washer syst em with intermittent Fig. 9.32 Additional wiring diagram for 1753149911)

152

Key to additional wiring diagram for windscreen wiper intermittent operation

(gradually from chassis

no 1753149912) Designation

in current track

E22 —Windscreen wiper switch for intermittent operation

J31

69778,9

—Wash/wipe intermittent

1,0sw/gn

1,Ognge

1,0gn/ge_

1Ogn/sw

'1,0gn

1,0gn/ro

relay S11 —Fuse in f b Y ns BE

0,5 br/bl

1,0sw/gr

1,0gn/ro

4,5,6

2

wiper motor V5

iL PS

—Windscreen

washer pump

10

Note: In the case of combined intermittent operation and headlight washer system, the current flow diagram Fig. 9.32 — current tracks 8-13 — is still applicable to the headlight washer system. Colour code

V

:

|

2

—blue —brown —black -—red

gr ge

-—grey —yellow

gn

-—green

Vs

1,0br

]

bl br sw ro

3

4

5

6

7

1,0br

8

9

10

Fig. 9.33 Additional wiring diagram for windscreen wiper intermittent operation (gradually from chassis no 17531 49912)

153

Key to additional wiring diagram for trailer towing (from August 1974)

Designation ES — to emergency light switch i — to brake light switch F4 — toreversing light switch

J20

—

Turn signal/emergency light

K5 K18 M1 M2

— — — —

relay for trailer towing to turn signal warning lamp to trailer warning lamp Parking light, left Tail light, right

M4

—

Taillight, left

M5 — M6 — M7 — M8 — M9 — M10 — M16 — M17 — SZ 1 rh;

Turn signal, front left Turn signal, rear left Turn signal, front right Turn signal, rear right Brake light, left Brake light, right Reversing light, left Reversing light, right ; Fuses in fuse holder

T1a

—

T1b

—

—

Flat connector, single luggage compartment left Flat connector, single luggage compartment right Trailer socket

—

to number plate light

—

Earth point, dash

Xx

in rear

in rear

Colour code bl — blue br — brown sw — black ro — red

gr

—

grey

ws

—

white

ge

—

yellow

gn

-—

green

in current track

Al Wl Geli pa 2 4

16,17,19 18 24 8 20

154 30

3}

FIS

sw/ro

ro/sw

sw/ws

gr/sw

ge/ws

ws

sw/ws/gn bl/ro

aFI6 FCI8

gr/ro

PDS

sw/ lu 0,5 bl/ge

sw/gn

wed

sw/gn

Q

Fs | Ms

H

1,0

Mi

la

oe

E3

E32.

4E3 KS

Es

MNTic

AT

0,5 gr/sw

sw

Ea

[Te 0,5 gr/roft

1,0 sw/gn

1,0 sw/ro

“Mis IMs x

58

1,0

0,5 gr/ro

"oO.s dea

Rie

eijesk

OS

31

BLL

54g

rr

1,0 sw/ro

i

S8R

7\54

ORF

IM &)

yo4 | YAs8

Mio

&)

IM2

(x)

yal

8

&)

br

0,5 br

(10)

7 BS,"

1223.9

450

50.7,

Sy

OT

ES

16

17

18

19

FBI?

20) 21 227239247

Fig. 9.34 Additional wiring diagram for trailer towing (from August 1974)

155

30—® 15—4

—e—eo— —

|

+—

31

|

ie

| 4

|

LI3

A

G1

apag

LBD

Ja

a

ie

“¥G6

*

U4”

u4\7

H

eee

|

Sis

bw

AB

See

|

|

i

ns

a

|

|

Lap

ae,

eo et

ee at

AB

p85 Bes a J26

|

Ver

A8

\/86

A3

Key to additional wiring diagram for radiator fan circuit (1975 models)

Si

| I

Negative control Negative control with fuse in fuse holder

Hl

Th

IV V F18 J26 >

Th

7

T2

15ro/br

ie

V7

T2

ik

abig?

T2

T2

Fis

15ro/br

V7

V7

E

Fis 1.5br

: Fis

1,5ro/br

1,5ro/br

1,5ro

|

15ro

15ro

15ro

Fis 1,5br

an

1,5br

1,5br

(

[

I

Ww

radiator fan circuit (1975 models) Fig. 9.35 Additional wiring diagram for

Positive control with separate fuse Positive control Relay control

Thermoswitch for radiator fan Radiator fan relay Fuse in fuse holder (16A) Separate fuse for fan Radiator fan Colour code ro — red br — brown

156

ral] —e

KIo ra @KeJsyo

Fo

N

NI

(0;S: 1S

S|

q

sw/we welgn

td

26

8625 24

23 22

D2

Os a57

bl blsw

pe 10' 20 WP ’e® 2

7

6

Fig. 9.36 Wiring diagram for 1976 Golf Land LS models

wnre4a 5

J 15

Al2 Cy we/'\i

on I| , =H Bs

z]

i

157 88

87

$—


Sos

3

a

he

=

S ry

Somme2

4 |} | ad

-

1

oiQ

ax

H eee

=

=

a

==

Dp

3

0

&

fe

ae — Se

2

a

a

a

a

z

2 a

e

=

re

3

2 8

Pe

ee

2

=

&

cS

id

=

2

(continued) models GL and LS L, Golf 1979 for diagram Wiring 9.49 Fig.

186

Key to wiring diagram for 1979 Golf and Golf S models in current track 4 5,6 & 3

Designation Battery

Starter Alternator Voltage regulator

Heated rear window switch Windscreen wiper switch

Ignition/starter switch Turn signal switch Emergency light switch Brake light switch Oil pressure switch Temperature warning switch

Door contact switch, front left Radiator fan thermoswitch Relief relay for X contact Main beam warning lamp Heated rear window warning lamp Headlight, left Headlight, right Instrument panel insert light Connection for fog lights (when service installing, wire according to additional current flow diagram, plug connection in engine compartment) Side light, left Taillight, right Side light, right Tail light, left Fresh air blower series resistance Connection for radio (behind instrument panel insert)

41 32 21

22 23 lis} St 29

Fuel gauge sender Fuel gauge Horn button Horn Emergency light relay Voltage stabilizer Alternator warning lamp Oil pressure warning lamp Turn signal warning lamp Emergency light warning lamp Coolant temperature warning lamp

15 19 18 20 43 16

Turn signal, front left

45

Turn signal, rear left Turn signal, front right Turn signal, rear right

46 47 48

$10-S15

Brake light, left

35

Tig

Brake light, right Connection for reversing light, left Connection for reversing light, right Coil Automatic choke Bypass air cut-off valve Series resistance wire for coil Heater resistance (part throttle port heater models only) fe) = Distributor P = Plug connectors Q = Plugs : — Fuses in fuse box S6,S8,S 9 Tia —- Connector, single, in engine compartment Tib — Connector, single, in engine compartment Tic —- Connector, single, in engine compartment Tid —- Connector, single, on brake light switch Tle —- Connector, single, on brake light switch Connector, single, near carburettor Connector, single behind instrument panel for clock, GL model only) Connector, single, on brake light switch Connector, single, near carburettor Connector, 2 point, near relay plate

36 28 29

i 25 26

7 — certain

24 24 8,9 8,9 front left front right front left

in current track

Designation Lighting switch EJ Headlight dip/flasher switch Fresh air blower switch

\ — Fuses in fuse box

Connector, single, behind instrument panel Connector, single, behind instrument panel Connector, single, in luggage boot left Connector, single, behind instrument panel (connection for control wire for rear window wash/ wipe system) Connector, 2 point, behind instrument panel Connector, 2 point, behind instrument panel Connector, 3 point, behind instrument panel Connector, 4 point, behind instrument panel Connector, 14 point, on instrument panel insert Windscreen wiper motor Fresh air blower Windscreen washer pump Radiator fan Interior light Number plate light Heated rear window Earthing point, steering column strut

(connection

Connector, 2 point, near relay plate Connector, 4 point, behind instrument panel Connector, 14 point, on instrument panel insert

Earthing point, on the interior light Earthing point, centre of rear roof crossmember Earthing point, engine compartment front left Earthing point, engine compartment front right

Earthing point, rear apron left Earthing point, rear apron right

Earthing strap — battery/body/assembly mountings Colour code

Earthing strap — alternator/engine block Earthing point, steering column strut

blue

Earthing point, luggage boot floor rear Earthing point, engine compartment front left Earthing point, engine compartment front right

Earthing wire, steering QO@@OOEOOO

column

.

gn

—

green

ro

brown

gr

—

grey

Sw

yellow

li

—

lilac

187

models Sand Golf 1979 for diagram Wiring 9.50 Fig.

i awa

ALI 3

Yur Yiu

ip We

188

7 ©M

U

sw/gn

47 48

sw/gn we 46

a

TY

Ke

a

1

a

«wy soe se

a

ea

a

43

ee 1

(0

br

43 44

42 I

Ms

sw)

=

|

g ?

et | | |

2 9

2 =° MERC

° eel

Fe

2

na

= ——

2

a

a

Las

ey

sey

ee

SB

(—}

=

= —-——

|

°

5

a

2

ra) o

2 ro) tle

|

oO 5) a

z

7 == —

2

a

|

{>

na

i

SS

.

40 4)

o j .

is]

3]

30

29 28 27 26

Fig. 9.50 Wiring diagram for 1979 Golf and Smodels (continued)

189

ie)

ozaW

88

48

¥8

es

78

”

e

i

amid

am

| a6

.

;

am a6

|

26/01

oO

op6

a6

=™s/6

&

5/36

it]

09

6S 8S

es

(penunuos) sjapow g OH pue HOH GLEL 405 wesBeip Buin OG'6 “614

S8

ET

ek = ET

ZT

=f

ul

|

|

98

18 /ms

=

& o ZF) mY > ER = gem a ere eres pei)omar

68

| | 83

so ca}|

sak

zo,

190

|

5

bg eae

“2

Ga

pe br

|

|

G7

emer

DI?

iP DIO

|

Key to additional wiring diagram for front and rear fog lights

(from August 1978)

ee r

D22

an

|

Designation

EI

—

E4

—

ES E23

— —

lke) K1 K17

— — —

=A

.

.

F

To lighting switch, terminal 58

in peter

1

To headlight dip/flasher switch, terminal 56a To fresh air blower switch Front and rear fog light switch Fog light relay Tomain beam warninglamp Front and rear fog light warning lamp

8 6

—~

To headlight, left

9

2 L20

— —

To headlight, right Rear fog light

11 z

L22 L23.

— —

Front left fog light Front right fog light

5 7

ie ess2

1

— Fuses in fuse box

S28

—

T1a

—

Separate fuse for fog lights

T1b.

—

T1c

—

T1d

—

Tle

—

Connector, single, behind

x

—

To number plate

©

—

Earthing point, steering

©)

—

Earthing point, engine compartment front left

—

Earthing point, engine compartment front right Earthing point, rear apron, left

(8 Amp)

\Ssw/ae

1-3 3-5 10

5

Connector, single, in luggage boot Connector, single, underneath windscreen washer container Connector, single, in engine compartment front left Connector, single, in engine

compartment right instrument panel

S28 Nae

Towne

column strut

Ti

Te

Pe

ee

s Tc 10sw/li

1,5ge

:

:

22

10br

L2s

1,5br

1.5br

(io) |(18) 2

,5ge

;

L20

]

Tha

(is) 3

4

5

—

bl br ge

Colour

— — —

code

gn gr li ro

— — — —

sw

—

black

ws

-—

white

blue brown yellow

green grey lilac red

(16) 6

7

Fig. 9.51 Additional wiring diagram for front and rear fog lights (from August 1978)

3

track

191

Key to additional wiring diagram for headlight washer system with intermittent wiper operation (from August 1978) in current track Designation To lighting switch 10 E1 Windscreen wiper switch for E22 intermittent operation 5- 8 Intermittent wash/wipe relay 3— 7 Headlight washer system relay Fuse in fuse box Connector, single, behind instrument panel Connector, 2 point, near headlight washer pump Connector, 2 point, near windscreen washer pump

11-13 6

Connector, 2 point, in engine compartment Windscreen wiper motor Windscreen washer pump Headlight washer pump

Earthing point, steering column strut Earthing point in engine compartment, front, left Colour code bl br

— —

blue brown

ge

—

yellow

gn

—

green

gr ro sw ws

— — — —

grey red black white

1-3 | 13

192

:

31

)!

|,M26

M21

[sn | yes

Woo

Yow

¥os

yoo

Yew

Yes

t “ye2I

WEI8

yes

ROY?

y

Ow,

yoiz

yoiz7—

i

Or,

Glo

FG2

wy

YH

0,5gn/ro

1,0gn/sw

10gn/ge

10sw/gr

lOgnyge

10gn/sw

10gn

1,0gn/ro

Tin

0.5gn /ro

1.5ws/sw

1,0gn/ro

0,5 br/sw

1,0gn

10sw/gr

O.Sws/sw

60r0

Toa

E, 1.09nAws

53

J

E22

_4h ave had T

”

T

sl

1

x 21705

31

T2b

5

1,0br

]

0,5br

2

3

10br

0.5br

4

Fig. 9.52 Additional wiring diagram for headlight washer system with intermittent wiper operation (from August 1978)

193

15 3

ig | +

. ih }

‘4

a

(n

aris

[ re

ro

15.

10

1,0

sw

swio

ro/sw

e

+

—

—

ibes i DI8 02)

ro/ge

0,5

0.5

bl/br

bl/br

“"G9

WG3

C12

0.5

0,5

05

0,5

bl/sw

bl4w

sw

blAw

Key to additional wiring diagram for dual circuit and handbrake warning lamp (from August 1978) Designation

in current track

D

—

Ignition/starter switch

he

F FQ J6 K3 K7

— — — — —

4,5 6 2 6

M9 M10 S6 Tid

— — -— —

Tle

—

Brake light switch Handbrake warning lamp switch To voltage stabilizer To oil pressure warning lamp Dual circuit and handbrake warning lamp Brake light, left Brake light, right Fuse in fuse box Connector, single on brake light switch Connector, single

Tip

—

3

—

6,7,8 4 3 5

on brake light switch

a4,

JD

Sigg

—

Connector, single on brake light switch Connector, 3 point, on brake light switch Earthing point, steering column strut

te 0.5 sw

0.5 br

Colour code ro — red sw — black

05 gt/gn

ge | Je

Ti

—

yellow

bl

_

—

blue

br

—

brown

gr gn

=" —

Giey, green

1,0 ro/ge 1.0

! sw/ro

Mio

820

Af

Mo

Fo

Fi

ye

E

=:

i

© @ 1

2

3

4

5

6

7

1978) Fig. 9.53 Additional wiring diagram for dual circuit and handbrake warning lamp (from August

194

Key to wiring diagram for 1980

Golf S,

L amd

LS models

Note: for 1.3 litre engines also refer to Fig. 9.49 Designation

in current track

A B Cc

— — —

Battery Starter Alternator

4 5-7 3

C1 D E2 E3 [F

— —

Voltage regulator Ignition/starter switch Turn signal switch Emergency light switch Brake light switch

3 1-14 3,40

Oil pressure switch Contact for choke control

23 25

Fi F12

F14 F52 G G1 H H1 J2 J6 K2 K3 K5 K6 K15 K28 K43 M5

— — — — — — — — — — — — — — — — — — — — —

Sa

Temperature control switch (too hot)* 21 Temperature control switch (too cold)* Ze Fuel gauge sender 24 Fuel gauge 18 Horn button 30 Horn 29 Emergency light relay Voltage stabilizer 18 Alternator warning lamp 16 Oil pressure warning lamp 19 Turn signal warning lamp 17 Emergency flasher warning lamp 41 Choke warning lamp 25 Coolant temperature warning lamp (too hot)* 21 Coolant temperature warning lamp (too cold)* 21 Turn signal front left 42 M6 -— Turn signal rear left 43 M7 — Turn signal front right 44 M8 — Turn signal rear right 45 MQ — Brake light left 34 M10 — Brake light right 35 M16 — Reversing light left 28 M17 — Reversing light right 29 N — Ignition coil 8 N3 — Bypass air cut-off valve 2: N6 -— Series resistance for coil 8 N52 — Heater element (part throttle drilling heating — carburettor) 26 O — Distributor P — Plug connector 8-10 Q — Plugs 8-10 S6,S8,S9 -— Fuses in fuse box 5fa — Connector single, in engine compartment front left T1a — Connector single, behind dash (connection for clock) T1b — Connector single, near relay plate Tic — Connector single, near carburettor T1d — Connector single, near carburettor Tie — Connector single, on brake light switch T2 — Connector two pin, near relay plate T2a — Connector two pin, in engine compartment front Tb T2c

— —

Connector two pin, near choke control Connector two pin, behind dash

T2d — T3a_— T4a —

Connector two pin, on brake light switch Connector three pin, engine compartment front right Connector four pin, engine compartment front left

T4b T14/

Connector four pin, behind dash Connector fourteen pin, on dash insert

— —

Earthing strap, battery body — engine mounting

Earthing wire, alternator to engine Earthing point, steering column support

Earthing point, boot floor rear (heel plate) Earthing point in insulating sleeve of front loom Earthing wire, steering gear *Certain

models only

Designation Light switch Headlight dip and flasher switch Fresh air blower switch Heated rear window switch Windscreen wiper switch Door switch, front left Door switch, front right Thermoswitch for radiator fan Relief relay for X contact High beam warning lamp Rear window warning lamp Twin filament bulb for headlight, left Twin filament bulb for headlight, right Dash insert light Connection for fog lights (when service installing, wire as in additional wiring

in current track

diagram, connection in engine compartment) Side light left Tail light right Side light right Tail light left Series resistance for fresh air blower Connection for radio (behind dash) \ — Fuses in fuse box

$10-S15 Tig Tih TIi

Connector single, behind dash Connector single, in boot rear left Connector single, behind dash (connection switch wire for rear window

wiper

and washer) Connector single, behind dash Connector two pin, behind dash Connector two pin, behind dash Connector three pin, behind dash Conenctor four pin, in engine compartment front left Connector four pin, behind dash Connector fourteen pin on dash insert Windscreen wiper motor Fresh air blower Windscreen wiper pump Radiator fan Interior light Number plate light Heated rear window Earthing point, steering column

support

Earthing point, roof'crossmember

rear centre

Earthing point, in front loom Earthing point, rear apron left Earthing point, rear apron right

Colour code red black lilac

,

bl we br

— — —

blue white brown

gn gr ge

— — —

green grey yellow

195

| a “

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to =

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Wiring 9.54 Fig. diagram Golf LS 1980 for Land S, models

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(continued) models LS and Lfor S, Golf, 1980 diagram Wiring 9.54 Fig.

a

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198

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Key to wiring diagram for 1980 Jetta and Jetta L models Note: Use in conjunction with Fig. 9.54 Designation D from ignition switch (terminal E3 to emergency light switch

in current track

15)

(terminal 58b) Switch for reversing lights Fuel gauge Sender for temperature gauge Temperature gauge Voltage stabilizer High beam warning lamp Alternator warning lamp Oil pressure warning lamp

Turn signal warning lamp Coolant temperatre warning lamp Dash insert light Tail light, right Tail light, left Turn signal, rear left Turn signal, rear right Brake light, left Brake light, right Reversing light, left Reversing light, right to bypass air cut-off valve Connector, single, behind dash Connector, single, behind dash Connector, single, on left in boot Connector, 2 pin, behind dash Connector,

14 pins, on dash insert

from interior-light (terminal 30) Number Clock

plate light

Relay plate/fuse box Earth point, steering column support Earth points, on left in boot Earth points, on left of rear apron

Earth points, on right of rear panel

Colour code ro sw li bl ws br gn

— —

gr

—

grey

ge

—

yellow

— — — — —

red black lilac blue white brown green

1 16,17 11 11

200

Key to wiring diagram for 1980 Golf GLS models Note: use in conjunction with Fig. 9.57 Designation E1 — Lighting switch H4 -— Headlight dip/flasher switch

Designation

in current track

A B

— —

Battery Starter

4 5,6

G Ci D E2 E3.

— — — — -—

Alternator Voltage regulator Ignition/starter switch Turn signal switch Emergency light switch

3 é} 11-15 39 37-42

E9 E15

— —

Fresh air blower switch Heated rear window switch

E20

—

Instrument lighting contro! switch (certain models only)

E22

—

Instrument

E19

—

Parking light switch (in turn signal switch)

12-13

F

—

Brake light switch

34

F1

—

Oil pressure switch

23

F4 F26

— —

Reversing light switch Thermoswitch for automatic choke*

30 28

F2 Fee! F5 F18

— — — —

Door contact Door contact Luggage boot Thermoswitch

J31

—

Wash/wipe intermittent relay

F35 G

—-— —

Thermoswitch for intake manifold preheating* Fuel gauge sender

27 25

J59 K1

— —

G1

—

Fuel gauge

16

G2 G3

-— —-

Coolant temperature sender (certain models only) Temperature gauge (certain models only)

24 17

K10 1 L2

— — —

G5

—

Tachometer (where fitted)

19

H H1 J2 J6 J81 K2 K3

— — — — —— —

Horn button Horn Emergency light relay Voltage stabilizer Intake manifold preheating relay* Alternator warning lamp Oil pressure warning lamp

33 32 38,39 16 26,27 20 22

L8 L10 L15

L16 L22

— — — — —-—

K5 K6

— —

Turn signal warning lamp Emergency light warning lamp

21 41

L28 M1 M2 M3 M4

-— — — — —

N23 R

——

Relief relay for X contact High beam warning lamp Heated rear window warning lamp Headlight bulb, left Headlight bulb, right Clock light Instrument panel insert light Ashtray light (certain models only) Fresh air controls light (certain models only) Connection for fog lights (for service installation, wire up according to additional diagram, connector in engine compartment) Cigarette lighter light Side light bulb, left Tail light bulb, right Side light bulb, right Tail light bulb, left Series resistance for fresh air blower

K28 M5

‘

wiper switch

switch, left switch right lighting switch (certain models only) for radiator fan

-—

Coolant temperature warning lamp

M6 M7 M8 M9 M10 M16 M17

-— -— — -— -— — — —

Turn signal, front left Turn signal, rear left Turn signal, front right Turn signal, rear right Brake light, left Brake light, right Reversing light, left Reversing light, right

18 43 44 45 46 36 37 31 32

S$1-S5 S7t $10-S15

\ — Fuses in fuse box

Tle Tif

— —

Connector, Connector,

N N1

— —

Coil Automatic

8 28

T1g

—

Connector, single, behind instrument panel

29 8 26 9 9-10 9-10

Tih T2a T2c T3b T4a T14

— — = — — —

Connector, Connector, Connector, Connector, Connector, Connector,

N3 — N6 — N51 — O — P — Q — S6,S8,S9

1 T1la Tib Tic Tid 2 T2a_ T2b T3a T4a T4b T14/

choke Bypass cut-off valve Series resistance wire for coil Heat resistance for intake manifold preheating* Distributor Spark plug connector Spark plugs — Fuses in fuse box

—

Connector,

— — — -— — — — — — — —

connection) Connector, single in engine compartment, front left Connector, single, near carburettor Connector, single, near carburettor Connector, single, on brake light switch Connector, 2 point, near relay plate Connector, 2 point, behind instrument panel Connector, 2 point, behind instrument panel Connector, 3 point, in engine compartment front right Connector, 4 point, in engine compartment front left Connector, 4 point, behind instrument panel Connector,14 point, on instrument panel insert

single,

behind

instrument

panel

(clock

Connection

control

in current track 50-55 63,64 79,80 91,92

for radio (behind instrument panel insert)

single, in luggage boot left single, behind instrument panel (connection

wire for rear window

wash/wipe

system)

single, in luggage boot ieft 2 point, behind instrument pane! 2 point, behind instrument pane! 3 point, behind instrument panel 4 point, behind instrument panel 14 point, on instrument panel insert

U1 Vv V2 V5 V7 Ww

— — — — ~~ =— —

Cigarette lighter (certain models only) Windscreen wiper motor (certain models oiity) Fresh air blower Windscreen washer pump Radiator fan Interior light

W3

—

Luggage boot light (certain models only)

x Y,

— —

Z1

—

Number plate light Clock (certain models tachometer fitted) Heated rear window

only—clock in console if

Earthing point, steering column support Earthing point, rear central roof crossmember

Earthing strap, battery-body-subframe assembly

Earthing point, in insulating sleeve of front wiring loom

Earthing wire, alternator — engine block

Earthing point, on rear apron

left

Earthing point, steering column support

Earthing point, on rear apron

right

Earthing point, luggage boot floor (heel plate) Earthing point, in insulating sleeve of front wiring loom Earthing wire, steering gear Earthing point in engine compartment cover

*Certain models only — see Fig. 9.54

on cylinder head

Colour code blue

gn

—

green

ro

—

red

brown

gr

—

grey

yellow

li

—

lilac

sw we

— -

black white

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(continued) models GLS Golf 1980 for diagram Wiring 9.56 Fig.

70 71

69 68 67 66 65

64

204

4

Key to wiring diagram for 1980 Jetta S, LS, GL and GLS models Note: use in conjunction with Fig. 9.56 Designation

in current track

D

—

from ignition/starter switch (terminal 15)

E1

—

from lighting switch

G1 G3 J6 K1 K2 K3 K5 K28

— — — — — — — —

L10 T1m

— —

T1n

— —

—

— — — — — |

(terminal 58b)

2

Fuel gauge Coolant temperature gauge Voltage stabilizer Main beam warning lamp Alternator warning lamp Oil pressure warning lamp Turn signal warning lamp Coolant temperature warning lamp Instrument panel insert light Connector, single, behind instrument panel Connector, single, in luggage boot left Connector, 2-point, behind instrument panel Connector, 14-point, on instrument panel insert From interior lights (terminal 30) Glovebox light Number plate lights

2 3 2 6 8 9 1

Clock Relay plate with fuse box Earthing point, steering column support

—

Greie 2.8 — {se

1

Earthing point, steering column support Earthing point, in luggage boot left Colour code ro — red sw — black li — lilac bl

—

blue

ws br gn gr ge

-— — — — —

white brown green grey yellow

5 12713

11 14 SG) 11

205

E12

D8

D 15

D22

D2

018

«=04

af er) \\

‘o >

=

87 lo ¢

JR2

4

ibees

es[cers |

Ch

iatd|or

mAag

a

§

“4 hitedot

o

Oh T44/44

1445

O

N44/33

O

TA

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TA4/7 O

28 [ K4

Tse O

ATH

©

2L

x

2)

NTH 3Of 44/4

THs O

Tin

Le)

9

ie)

t

T2

© Tim

D

F43

a

W

a} =

DS

O

O

(he. Ete Q & ke K3 [Ks

©

Fig. 9.57 Wiring diagram for 1980 Jetta S, LS, GL and GLS

models

8.)

O

206

Key to wiring diagram for 1981 Golf/Jetta L, S, LS, GL and GLS models Note: This diagram must be used in conjunction with Fig. 9.54 Designation Lighting switch

Headlight dip/flasher switch Fresh air blower switch Heated rear window switch Instrument lighting brightness control

(only Land GL models) Windscreen wiper switch (only L and GL models with intermittent

facility) Door contact switch front left Door contact switch front right (only Land GL models) Not applicable Thermoswitch for radiator fan Intermittent wash/wipe relay (only L and GL models) Relief relay (for X contact) Heated rear window warning lamp Headlight left Headlight right Digital clock light**

Lighting switch light (only L and GL models) Dash insert light Fresh air controls light (only L

and GL models) Connection for fog lights

Cigarette lighter light (only GL models) Parking light left Tail light right**** Parking light right

Tail light left****

Ballast resistance for fresh air blower Connection for radio (behind dash

insert)***

—. Fuses in fuse box/relay plate

Connection single, in boot rear left Connection single, behind dash (connection control wire for rear wiper and washer system)

in current track 53-58 73,74 87,88 91,92

58

84,85 64 63 66 89 83,84 50,51 2 76,78 Uti) 56

50 S703 59 80 60

Designation

in current track

Connection single, behind dash Connection single, in boot rear left Connection single, behind dash

Connection single, in engine compartment left Connection two-point, behind dash Connection two-point, behind dash Connection two-point, behind dash

Connection two-point, in engine compartment front left Connection two-point, behind dash Connection three-point, behind dash Connection four-point, in engine compartment near right headlight Connection fourteen-point on dash insert Cigarette lighter (only GL models) Windscreen wiper motor Fresh air blower Windscreen washer pump Radiator fan Interior light front Not applicable

Glove box light (only Jetta vehicles-GL models) Number plate light Digital clock (optional extra for Jetta vehicles and certain Golf models

together with tachometer)** Heated rear window

61 82,82 88 86 89 65 66 81 67,68 62 90

Earth point, on relay plate/fuse box bracket Earth point, in insulating sleeve of front loom

Earth point, bound with insulating tape in dash loom Earth point, cross panel rear left

Earth point, roof crossmember ©C@Q@@O* rear centre

** only certain Golf models *** from October 1980, radio fused via fuse S6 **** twin filament lamp not on Jetta

207

Key to wiring diagram for 1981

Designation

Golf/Jetta L, S, LS, GL and GLS models (continued)

in current track

Battery

Designation

N52

Starter Alternator Voltage regulator

—

Heater element (part throttle

drilling heating—carburettor)*

Ignition/starter switch

Distributor Plug connector Plugs

Turn signal switch Emergency light switch

Fuses in fuse box/relay plate

Parking light switch (only GL models) Brake light switch Oil pressure switch Reversing light switch Thermo switch for choke (certain models only)* Thermo switch for intake manifold preheating (certain models only) Fuel gauge sender Fuel gauge

Connector single, in engine compartment front left Connector single, near carburettor Connector single, near carburettor Connector single, on brake light switch Connector single, in engine compartment near right headlight Connector single, near carburettor Connector two-point, behind dash Connector two-point, behind dash Connector two-point, near relay plate Connector two-point, on brake light switch Connector two-point, in engine compartment near left headlight Connector two-point, in engine compartment near right headlight Connector three-point, behind dash Connector four-point, in engine compartment near right headlight Connector fourteen-point, on dash insert

Coolant temperature gauge sender

Coolant temperature gauge Tachometer (option for Jetta vehicles

and certain Golf models)** Horn button Horn (double horn) Emergency light relay Voltage stabilizer

42

Relay for intake manifold preheating

28

(certain models only)* High beam warning lamp Alternator warning lamp Oil pressure warning lamp Turn signal warning lamp Emergency light system warning lamp Coolant temperature warning lamp Turn signal front left Turn signal rear left Turn signal front right Turn signal rear right Brake light left**** Brake light right**** Reversing light left Reversing light right Ignition coil Automatic choke (certain models only)* 29

Earth strap from battery via body to gearbox

Earth wire alternator - engine block , Earth point on relay plate bracket Earth wire steering box Earth point in insulating sleeve of front loom

Earth point bound @@OO O @ tape in dash loom

*See Fig. 9.54 current tracks 25 to 27 **Certain Golf models only ****Twin filament lamp not on Jetta

Bypass air cut-off valve* Ballast resistance for coil Heater element for intake manifold

preheating (certain models only)*

with insulating

27 Colour code blue white brown

Caen gr = ge -

green grey yellow

208

35

34

33 32

—

eee

foo’

|

|

=~

=

$ =

2

12

a

ce @

c

ee (*)

ae

gg

5 Saas

%

mes

| |

4

|| |

5

ti4/4 14/3,

Fig. 9.58 Wiring diagram 1981 for Golf/Jetta S, L, GL LS, GLS and models

Wud V/112

209

Se

sz

ee

ee

pe

pr

pe

er

$e

69 68 67

66

65 64

63

62

61 60

59

58 57

56

55 525354 51

49 48

47 46

43 45 44

42

4)

40 39

9.58 Fig. Golf/Jetta GLS (continued) Wiring and GL LS, S, models 1981 for diagram L, 38 37°

35

34

33 32

210

e®

a!

2

= SLL

OLS 2

a

Pe

A273

——p. io

t+

5

5o

a

2 ee

TS

ST OFa

can

nis> "

=

— 2 a Se

Za

2

91

u

=

$

&

‘

i =

eee

2 eee

es 2

@

90

N

4s —

2 =

| 2

=

92

=a al

+

3 SS

a arse Ue

z =

SS

> ee

=

ae2 ss Oe

0)

87 88 89 86

85

84

83

82

81

ny SY fay (> A 80 6)

9.58 Fig. Wiring diagram for Golf/Jetta 1981 L, S, GL LS, GLS and (continued models

69 70 72 71 “7&4 73! 75 68

211

Key to additional wiring diagram for fog lights (from August

1980) Designation

E1 E23 25 K17 L20 L22 L23

M4 S12

— from lighting switch (terminal 58) — Fog light and rear fog light switch — Fog light relay — Fog light warning lamp (yellow) — Rear fog light — Fog light left — Fog light right — Tail light left

in current track 7 3-7 1-3 6 5 2 1

—

Fuse in fuse box/relay plate

7 4

S28

—

Separate fuse for fog lights on fog light relay (8A)

1

T1a T1b T1c

— — —

Connector single, behind dash Connector single, behind dash Connector single, in engine

T1d

—

Tle

—

compartment left

©GO @ **

— —

Connector single, in engine compartment front left Connector single, in engine compartment front right to number plate light Relay plate with fuse box

—

Earth point on rel ay plate bracket

—

Earth point in compartment Earth point in compartment Earth point in

—

engine front left engine front right boot rear left

Colour code brown br =

ge

=

yellow

ws ro sw gr gn

— -

white red

black

= =

grey green

Fig. 9.59 Additional wiring diagram for fog lights (from August 1980)

4 4

212

| SAO (eae KLA

-

rs >

{#) Fe M > Neo

$

¥

ae

t :

Za

Ssh

& .

2 5

:

g x

EC.u

Kye

KA

2

:

Key to additional wiring diagram for gearchange and consumption indicators (Formula E models from February

1981)

Designation — to ignition/starter switch D — to switch for fresh air blower E9 AL W

eth

in current track 3 i

F12

—

Contact for choke warning

F62

—

Vacuum switch for

6

F68

—

Gear switch for gearchange

G51

—

and consumption indicator Gearchange and consumption indicator

J98

—

K15

—

Control unit for gearchange indicator Warning lamp (yellow) for

K48

—

Warning lamp for gearchange

N N60

— —

indicator to ignition coil Solenoid valve for gearchange

3 5

and consumption indicator

1

S10 ia! ii

— — —

T2a

—

Ze

—

©)

—

©)

—

(@

—

gearchange indicator

(de) e ~ s G

w

x

iN 8

2 ext

J 98

8

choke

©)

—

2

2 2-8

;

5

Fuse in fuse box Connector single, behind dash Connector two-point, behind dash Connector two-point, behind dash Relay plate with fuse box

Earth point in engine compartment on gearbox Earth point on relay plate bracket Earth point near carburettor /

Earth point bound with insulating tape in dash loom Colour code sw — black br — brown ge — yellow gr — grey gn — green ro — red ws — white bl — blue

Fig. 9.60 Additional wiring diagram for gearchange and consumption indicators (Formula E models from February 1981)

Chapter p

10 Suspens Litye) ion

and steering steeri

Contents Fault diagnosis — suspension and Steering ........cccccseseeessssscsssssseeeees Front and rear coil springs — inspection and renewal ..........cceeee Front shock absorbers — inspection and renewal .........cccsccceseeeeeeees Front suspension strut — removal and refitting .........ccccccccsseeeeseens Front suspension wishbone — removal, overhaul and refitting ...... Front wheel bearing housing — removal and refitting ........c.:cc0 FRONT IWMEE! DE ANINGS:— FEMEWall ca ccrccccccccesesscacdersscesroveaocegeravesereeneenrooeoe ISRETEVES eA CLESCID CIGDIa)chess SoM acne ce ccsesnsuncncvsscccatesctatesevanesesacton sooesiaves Rear anti-roll bar — removal and refitting ..........:ccccsccscscessescssesseseeeeees Meat aAxlen— FemmOVall amd) refitUliG\q.b.s0.