Volkswagen Golf 2 - Repair, Service Manual and Electrical Wiring Diagrams

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VOLKSWAGEN GOLF 2 - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual / Repair Manual and Wiring Diagrams, for vehicles Volkswagen Golf 2.
 

CONTENTS:

Fundamentals
- Introduction
- General Description
- Body
- 1.2 Engine
- Engine Systems
- Ignition System
- Fuel System
- Cooling System
- Lubrication System
- Exhaust System
- 1.3 Drivetrain
- Clutch or Torque Converter
- Transmission
- Final Drive
- Drive Axles
- 1.4 Suspension and Steering
- 1.5 Brakes
- Anti-lock Braking System (ABS)
- 1.6 Electrical System
- Battery
- Alternator
- Wiring Harness and Circuits
- 2. How To Use This Manual
- 2.1 Fundamentals
- 2.2 Lubrication and Maintenance
- 2.3 Repair Sections
- General Description
- Maintenance
- Troubleshooting
- 2.4 Using the Search Tab
- 2.5 Notes, Cautions, and Warnings
- 3. Getting Started
- 3.1 Safety
- Lifting The Car
- 3.2 General Advice For The Beginner
- Planning Ahead
- Cleanliness
- Tightening Bolts
- Bolt Torque
- Gaskets
- Seals
- Wire Repairs
- Cleaning
- Electrical Testing
- Making An LED Test Light
- Disconnecting Wiring Harness Connectors
- 3.3 Buying Parts
- Genuine Volkswagen Parts
- Volkswagen Remanufactured Parts
- Non-returnable Parts
- What Information You Need To Know
- 4. Tools
- Basic Tool Requirements
- Jack Stands
- Oil Change Equipment
- Torque Wrench
- Timing Light
- Tachometer
- Duty Cycle Meter or Dwell Meter
- Feeler Gauges
- Micrometers
- Test Light
- Volt-Ohm Meter or Multimeter
- Jumper Wires
- Volkswagen Special Tools
- 5. Troubleshooting Fundamentals
- 5.1 Starting
- 5.2 Running
- 5.3 Driving
- 6. Emergencies
- 6.1 Changing a Tire
- 6.2 Car Will Not Start
- 6.3 Jump-Starting
- 6.4 Coolant Temperature Warning Light - Overheating
- 6.5 Oil Pressure Warning Light
- 6.6 Dim Lights
- 6.7 Towing
- 6.8 Spare Parts Kit

Lubrication and Maintenance
- Introduction
- General Description
- Scheduled Maintenance
- 1.2 Fluid and Lubricant Specifications
- 1.3 Engine Oil Change
- 1.4 Tune-up
- 1.5 Engine Compartment Maintenance
- 1.6 Under-car Maintenance
- 1.7 Body and Interior Maintenance
- 1.8 Cleaning and Preserving
- 2. Scheduled Maintenance
- 3. Fluid and Lubricant Specifications
- Engine Oil
- Gear Oil - Manual Transmission and Final Drive
- Brake Fluid
- Engine Coolant (Anti-freeze)
- Power Steering Fluid
- Gasoline Additive
- Greases
- 4. Engine Oil Change
- 4.1 Changing Engine Oil and Filter
- 5. Tune-up
- 5.1 Air Filter
- 5.2 Spark Plugs
- 5.3 Distributor Cap, Rotor, and Spark Plug Wires
- 5.4 Fuel Filters
- Main Fuel Filter (gasoline)
- Mini Fuel Filter
- Diesel Fuel Filter
- 5.5 EGR System
- 5.6 Idle Speed
- 5.7 Compression Test
- 5.8 Diesel Fuel Water Separator
- Draining Water From Diesel Fuel Filter
- 5.9 Valve Adjustment (diesel and turbo diesel only)
- 6. Engine Compartment Maintenance
- 6.1 Battery
- Checking and Cleaning Battery
- Replacing Battery
- Charging Battery
- 6.2 V-Belts
- Inspecting and Adjusting
- Replacing V-Belts
- 6.3 Cooling System
- Checking Coolant Level
- Inspecting Hoses
- 6.4 Power Steering
- 6.5 Oxygen Sensor (gasoline engines only)
- Replacing Oxygen Sensor
- Resetting OXS Warning Light Counter
- 6.6 Clutch Adjustment
- 7. Under-Car Maintenance
- 7.1 Tires and Wheels
- Tire Inflation Pressure
- Tire Rotation
- Wheel Alignment
- 7.2 Brakes
- Checking Brake Fluid Level
- Inspecting Brake Hoses and Lines
- Checking Disc Brake Pad Wear
- Checking Rear Drum Brake Lining Wear
- Replacing Brake Fluid
- 7.3 Exhaust System
- 7.4 Constant Velocity Joints
- 7.5 Manual Transaxle Service
- Checking and Filling Transaxle Lubricant
- 7.6 Automatic Transaxle Service
- Checking and Filling ATF
- Draining and Replacing ATF, and Cleaning ATF Strainer
- Checking and Filling Final Drive Lubricant
- Checking Kickdown Operation
- 7.7 Front Suspension and Steering
- 8. Body and Interior Maintenance
- 8.1 Windshield Wiper Blades
- 8.2 Body Lubrication
- 8.3 Seat Belts
- 9. Cleaning and Preserving
- 9.1 Care of Exterior Finish
- Washing
- Waxing
- Polishing
- Washing Chassis
- Special Cleaning
- 9.2 Care of Interior
- Leatherette Upholstery and Trim

Engine
- Introduction
- General Description
1.1 Engine Components
- Crankshaft and Bearings
- Connecting Rods and Pistons
- Cylinder Head
- Valve Train
- Intermediate Shaft
- Lubrication System
- 1.2 16-valve Engines
- Cylinder Block
- Pistons
- Cylinder Head
- Valve Train
- Intermediate Shaft
- 1.3 Diesel and Turbo Diesel Engines
- Cylinder Head and Valve Train
- Connecting Rods and Pistons
- Valve Train
- 1.4 Engine Identification Codes and Specifications
- Finding Engine Letter Codes
- 2. Maintenance
- 3. Troubleshooting
- 3.1 Basic Troubleshooting Principles
- Noise
- Fluid Leaks
- Smoking
- Excessive Oil Consumption
- Poor Fuel Consumption and Low Power
- Engine Not Running
- 3.2 Diagnostic Testing
- Compression Test
- Wet Compression Test (gasoline engines only)
- Leak-down Test
- 4. Cylinder Head
- 4.1 Cylinder Head Cover and Gasket
- 4.2 Camshaft Drive Belt (except diesel engines)
- 4.3 Camshaft Oil Seal
- 4.4 Valve Adjustment(1985 and early 1986 diesel and turbo diesel only)
- 4.5 Removing and Installing Camshaft
- 4.6 Hydraulic Cam Followers
- Checking Hydraulic Cam Followers
- 4.7 Valve Stem Oil Seals
- 4.8 Removing and Installing Cylinder Head
- 4.9 Disassembly, Assembly, and Reconditioning
- Cylinder Head Assembly (16-valve engines)
- Cylinder Head Assembly (gasoline engines except 16-valve)
- Cylinder Head Assembly (diesel and turbo diesel engines)
- Camshaft and Cam Followers
- Valves and Valve Springs
- Valve Guides
- Valve Seats
- 5. Removing and Installing Engine and Transaxle
- Removing
- Separating Engine and Transaxle
- Installing
- Aligning Engine and Transaxle Assembly
- 6. Cylinder Block and Pistons
- 6.1 Cylinder Block Oil Seals
- Replacing Front Crankshaft Oil Seal
- Replacing Intermediate Shaft Oil Seal
- 6.2 Disassembly, Assembly, and Reconditioning
- Pistons and Connecting Rods
- Piston Rings
- Diesel and Turbo Diesel Piston Height
- Crankshaft and Intermediate Shaft
- Flywheel or Drive Plate
- 7. Lubrication System
- 7.1 Dynamic Oil Pressure Warning System
- Checking Low Oil Pressure Warning System
- Checking Dynamic Oil Pressure Warning System (high rpm)
- Testing Oil Pressure Switches
- 7.2 Oil Pump
- Oil Spray Nozzles
- 7.3 Oil Cooler
- 8. Engine Technical Data
- Tightening Torques
- II. Crankshaft, Intermediate Shaft, and Bearing Specifications
- III. Piston, Piston Ring, and Cylinder Specifications
- IV. Camshaft, Valve, and Cylinder Head Specifications
- V. Lubrication System Specifications

Cooling System
- Introduction
- General Description
- Coolant Pump and Thermostat
- Radiator
- Radiator Cooling Fan
- 2. Maintenance
- 3. Troubleshooting
- 3.1 Basic Troubleshooting Principles
- 3.2 Diagnostic Tests
- Pressure Testing Cooling System and Expansion Tank Cap
- Temperature Gauge and Sending Unit Quick-Check
- 4. Cooling System Service
- 4.1 Coolant and Cooling System Hoses
- Draining and Filling Coolant
- 4.2 Thermostat
- Removing and Installing Thermostat
- Testing Thermostat
- 4.3 Coolant Pump
- Inspecting and Replacing Coolant Pump
- 4.4 Radiator Cooling Fan
- Testing Cooling Fan and Radiator Thermoswitch
- Radiator Cooling Fan After-Run System
- Removing and Installing Radiator Cooling Fan
- 4.5 Radiator
- Removing and Installing Radiator
- 5. Cooling System Technical Data
- Tightening Torques
- II. Cooling System Specifications

Exhaust System and Emission Controls
- Introduction
- General Description
- Exhaust System
- Turbocharger
- 1.2 Emission Controls
- Catalytic Converter
- Oxygen Sensor System
- EGR System
- 1.3 Exhaust System and Emission Control Identification
- 2. Maintenance
- 3. Troubleshooting
- 3.1 Basic Troubleshooting Principles
- 4. Exhaust System
- 4.1 Removing and Installing Exhaust System
- Removing Exhaust System
- Removing and Installing Front Pipe Spring Clamps
- Installing Exhaust System
- 4.2 Catalytic Converter
- Removing and Installing Catalytic Converter
- Checking Catalytic Converter
- Replacing Catalytic Converter Heat Shield
- 5. Oxygen Sensor System
- 5.1 Testing Oxygen Sensor System (CIS)
- Measuring Frequency Valve Duty Cycle
- Quick-Checking Oxygen Sensor System
- Checking Thermoswitch
- Checking Frequency Valve
- Checking Oxygen Sensor System Control Unit
- Checking Oxygen Sensor
- Replacing Oxygen Sensor
- Troubleshooting Oxygen Sensor Circuits
- 5.2 Testing Oxygen Sensor System (CIS-Electronic)
- Testing Oxygen Sensor
- Checking Control Unit Response
- Replacing Oxygen Sensor
- 5.3 Testing Oxygen Sensor System (Digifant II and Digifant I)
- Testing Oxygen Sensor Function
- Replacing Oxygen Sensor
- 5.4 Testing Oxygen Sensor System (CIS-E Motronic)
- Checking Oxygen Sensor and Control Unit Response
- Replacing Oxygen Sensor
- 6. Exhaust Gas Recirculation System
- Testing EGR System (Canada models only)
- Testing EGR System (California models only)
- 7. Turbocharger (turbo diesel and ECO diesel only)
- 7.1 Removing and Installing Turbocharger
- 7.2 Testing Turbocharger Wastegate and Blow-Off Valve
- 8. Exhaust System and Emission Control Technical Data
- Tightening Torques (engine codes: RD, PF, PL, 9A)
- II. Tightening Torques (engine codes: GX, HT, RV, MZ)
- III. Tightening Torques (engine codes: ME, MF, 1V)
- IV. Turbocharger Technical Data (engine code: MF, 1V)
- V. Oxygen Sensor System Technical Data (CIS)
- VI. Oxygen Sensor System Technical Data (CIS-E)
- VII. Oxygen Sensor System Technical Data (CIS-E Motronic)

Fuel System - Gasoline
- Introduction
- General Description
- Fuel Storage
- Fuel Pump and Fuel Circuit
- Air Filter
- Continuous Injection System (CIS)
- 1.2 Continuous Injection System-Electronic (CIS-E)
- 1.3 CIS-E Motronic Engine Management System
- 1.4 Digifant II Engine Management System
- 1.5 Digifant I Engine Management System
- 1.6 Applications-Identifying Features
- Four-cylinder (8-valve) Engines
- 16-valve Engines
- Identifying The Systems
- 2. Maintenance
- 3. Troubleshooting
- 3.1 Basic Troubleshooting Principles
- 3.2 CIS Troubleshooting
- 3.3 CIS-E and CIS-E Motronic Troubleshooting
- 3.4 CIS-E Motronic Fault Diagnosis
- 3.5 Digifant II and Digifant I Troubleshooting
- 4. Fuel Supply
- 4.1 Fuses and Relays
- Operating Fuel Pump For Test
- 4.2 Transfer Pump
- 4.3 Fuel pump
- Fuel Pump Electrical Tests
- Replacing Fuel Pump
- Replacing Fuel Pump Check Valve (CIS, CIS-E, and CIS-E
- Motronic)
- 4.4 Fuel Pressure Regulator
- CIS Pressure Relief Valve
- CIS-E and CIS-E Motronic Diaphragm Pressure Regulator
- Digifant Fuel Pressure Regulator
- 4.5 Evaporative Emission Controls
- Testing Charcoal Canister Bypass Valve (CIS, CIS-E, Digifant)
- Testing Charcoal Canister Solenoid Valves (CIS-E Motronic)
- 4.6 Accelerator Cable
- 4.7 Fuel Injectors (CIS, CIS-E and CIS-E Motronic)
- Removing and Installing Fuel Injectors
- Quick-checking Injectors
- Testing Injector Fuel Delivery
- Cleaning and Testing Injectors
- 4.8 Fuel Injectors (Digifant II)
- Testing Injectors
- Removing and Installing Injectors
- 5. Continuous Injection System (CIS)
- 5.1 Air Flow Measurement and Fuel Metering
- Throttle Valve Basic Adjustment
- Air Flow Sensor
- Fuel Distributor
- 5.2 Cold Start Enrichment
- 5.3 Cold Running Enrichment
- Testing and Replacing Control Pressure Regulator
- 5.4 Idle Speed
- Idle Air Bypass Adjustment
- Auxiliary Air Regulator
- Idle Speed Boost Valve
- 5.5 Fuel Pressure Tests and Specifications
- System Pressure
- Control Pressure
- Residual Pressure
- 5.6 Idle Specifications (rpm and % CO)
- 6. CIS-Electronic (CIS-E) and CIS-E Motronic
- 6.1 Air Flow Measurement and Fuel Metering
- Throttle Valve Basic Adjustment
- Throttle Switches (HT, RD, PL and 9A engines)
- Air Flow Sensor
- Basic Adjustments
- Fuel Distributor
- Differential Pressure Regulator
- 6.2 Cold Start Enrichment
- 6.3 Idle Speed
- Adjusting Idle Air Bypass (engine code GX only)
- Idle Air Stabilizer Valve (engine codes HT, RD, PL and 9A)
- Adjusting Idle Air Stabilizer Duty Cycle (engine codes HT, RD and
- PL)
- 6.4 Electrical Tests (CIS-E)
- After-start and Cold Running Enrichment
- Cold Acceleration Enrichment
- Full-throttle Enrichment (engine codes HT, RD, and PL only)
- Deceleration Fuel Shutoff (engine codes HT, RD, and PL only)
- Control Unit Inputs
- 6.5 Electrical Tests (CIS-E Motronic)
- After-start, Warm-up and Cold Acceleration Enrichment
- Coolant Temperature Sensor
- Deceleration Fuel Shutoff
- Air Flow Sensor Potentiometer
- Control Unit Inputs
- 6.6 Fuel Pressure Tests and Specifications
- System Pressure
- Differential Pressure
- Residual Pressure
- 6.7 Idle Specifications
- CIS-E
- CIS-E Motronic
- 7. Digifant II Fuel Injection
- 7.1 Air Flow Measurement
- Air Flow Sensor
- Throttle Valve Basic Adjustment
- Throttle Valve Vacuum Hoses
- 7.2 Cold Start and Cold Running Enrichment
- Coolant Temperature Sensor
- Intake Air Preheat System
- 7.3 Idle Speed
- Idle Air Bypass
- Idle Air Stabilizer Valve
- Idle and Full-Throttle Switches
- 7.4 Electrical Tests
- 7.5 Fuel Pressure Tests and Specifications
- System Pressure and Residual Pressure
- Replacing Pressure Regulator
- 7.6 Idle Mixture Specifications (% CO)
- 7.7 Digifant II On-Board Fault Diagnosis (California only)
- 8. Digifant I Fuel Injection (California)
- 8.1 Digifant I On-Board Fault Diagnosis
- 8.2 Resetting Digifant I Control Unit
- 8.3 Air Flow Measurement
- 8.4 Cold Start and Cold Running Enrichment
- 8.5 Idle Speed and Mixture (% CO) Adjustment
- Idle Speed and Mixture Adjustment
- Throttle Valve Potentiometer
- 8.6 Electrical Tests
- Testing Fuel Injectors
- Control Unit Inputs
- 8.7 Fuel Pressure Tests and Specifications
- 9. Fuel System Technical Data
- CIS Fuel Injection Specifications
- II. CIS-E Fuel Injection Specifications
- III. CIS-E Motronic Fuel Injection Specifications
- IV. Digifant II and Digifant I Fuel Injection Specifications

Fuel System - Diesel
- Introduction
- General Description
- Fuel Storage and Supply
- Fuel Injection
- Injectors
- Air Cleaner
- Emission Controls
- Applications and Identification Codes
- 2. Maintenance
- 3. Troubleshooting
- 3.1 Basic Troubleshooting Principles
- 3.2 Diagnostic Testing
- Checking Fuel Supply to Injectors
- Idle Speed Drop Test
- 4. Fuel Supply
- 4.1 Fuel Tank Vents
- 4.2 Fuel Gauge Sender
- 5. Fuel Injection
- 5.1 Idle Speed and Maximum RPM Adjustments
- Checking and Adjusting Idle Speed (1985 models without idle
- speed boost)
- Checking and Adjusting Idle Speed (1986 and later models with
- idle speed boost)
- Checking and Adjusting Maximum RPM (All diesel and turbo
- diesel models)
- 5.2 Accelerator Cable
- Replacing Accelerator Cable
- Checking and Adjusting Accelerator Cable
- 5.3 Cold Start System
- Removing, Installing, and Adjusting Cold Start Cable
- 5.4 Camshaft/Injection Pump Drive Belt
- 5.5 Injection Pump
- Altitude and Load Compensation
- Removing and Installing Injection Pump
- Checking and Adjusting Injection Pump Timing
- Inspecting and Replacing Stop Solenoid
- Stop Solenoid Quick-Check
- Injection Pump Valves
- 5.6 Injectors
- Removing and Installing Injectors
- Pressure Testing Injectors
- Inspecting and Repairing Injectors
- 5.7 Turbo Diesel Boost Enrichment
- 6. Technical Data
- Tightening Torques
- II. Diesel Fuel System General Technical Data

Ignition
- Introduction
- General Description
- Electronic Ignition System
- 1.2 Knock Sensor System
- 1.3 Digifant Ignition System
- 1.4 CIS-E Motronic Ignition System
- 1.5 Glow Plug System
- 1.6 System Identification and Applications
- 2. Maintenance
- 3. Troubleshooting
- 3.1 Basic Troubleshooting Principles
- Test Equipment
- Quick-Check of Ignition System
- 3.2 Ignition System Visual Inspection
- 3.3 Testing Coil and Spark Plug Wires
- 3.4 Testing Hall Sender and Ignition Control Unit (all except CIS-E Motronic
- and Digifant I)
- Voltage Supply and Ground to Ignition Control Unit
- Voltage Supply and Ground to Hall Sender
- Hall Sender Switching Function
- Ignition Control Unit Voltage to Coil
- Ignition Control Unit Response to Hall Sender Signal
- 3.5 Testing Hall Sender and Coil Power Stage (CIS-E Motronic only)
- Voltage Supply and Ground to Power Stage
- Voltage Supply and Ground to Hall Sender
- Hall Sender Switching Function
- Motronic Control Unit Response to Hall Sender Signal
- Power Stage Response to Motronic Control Unit Signal
- 3.6 Testing Hall Sender and Coil Power Stage (Digifant I only)
- Power Stage Voltage Supply and Ground
- Hall Sender Voltage Supply and Ground
- Hall Sender Switching Function
- Control Unit Response to Hall Sender Signal
- Power Stage Response to Control Unit Signal
- 4. Transistorized Coil Ignition (TCI-h) System
- 4.1 Ignition Timing
- 4.2 Mechanical Timing Advance (basic TCI-h only, engine codes GX and MZ)
- 4.3 Electronic Timing Advance (TCI-h with knock control, engine codes HT,
- RD, PL, RV, PF, 9A)
- Checking Timing Advance (engine codes HT, RD, PL)
- Checking Digifant II and Digifant I Timing Advance (engine codes
- RV and PF)
- Checking Motronic Timing Advance (engine code 9A)
- 4.4 Knock Sensor System Fault Diagnosis (engine codes HT, RD, PL, 9A)
- CIS-E (engine codes HT, RD, PL)
- CIS-E Motronic (engine code 9A)
- 4.5 Checking and Replacing Knock Sensor
- 4.6 Troubleshooting Knock Sensor System
- 5. Distributor
- 5.1 Removing and Installing Distributor Cap, Rotor, and Spark Plug Wires
- Replacing Spark Plug Wires
- Replacing Distributor Cap and Rotor
- 5.2 Removing and Installing Distributor
- 5.3 Disassembling and Assembling Distributor
- All Engines except 16-valve
- 16-valve Engines
- 6. Diesel Glow Plug System
- 6.1 Testing and Replacing Glow Plugs
- 6.2 Testing and Repairing Glow Plug System Circuits
- Checking Wiring
- Glow Plug System Voltage Checks
- Checking Glow Plug Relay
- 7. Technical Data
- Ignition System Specifications
- II. Knock Sensor Specifications

Manual Transmission and Clutch
- Introduction
- General Description
- Clutch
- 1.2 Transaxle
- Five-Speed Manual Transmission
- Final Drive


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