DOWNLOAD! (8 MB) 1984 - 1992 Volkswagen VW Golf & Jetta MK2 Petrol Engines 1043 cc 1272 cc 1595 cc 1781 cc Service Repair Manual / Workshop Manual - (PDF Format) !!
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Download Service Repair Manual for 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.
These manuals will come in PDF format, so it's EXTREMELY easy to move around with you from computer to computer. Many mechanics purchase electronics manuals like this and use a laptop near them while doing maintenance! If you don't have a laptop, no problem! Just print out the pages of the manual that you need and you've got a hard copy in front of you while doing your work! Simply throw it away when your finished! It's much easier and quicker than having to deal with a book!
DETAILED TABLE OF CONTENTS:
======================
LIVING WITH YOUR VOLKSWAGEN GOLF OR JETTA
Introduction Page 04
Safety First! Page 05
Roadside Repairs
Introduction Page 06
If your car wont start Page 06
Jump starting Page 07
Wheel changing Page 08
Identifying leaks Page 09
Towing Page 09
Weekly Checks
Introduction Page 010
Underbonnet check points Page 010
Engine oil level Page 011
Coolant level Page 011
Brake fluid level Page 012
Power steering fluid level Page 012
Screen/headlamp washer fluid level Page 013
Wiper blades Page 013
Tyre condition and pressure Page 014
Battery Page 015
Electrical systems Page 015
Lubricants and fluids Page 016
Capacities and tyre pressures Page 017
MAINTENANCE
Routine Maintenance and Servicing
Servicing specifications Page 12
Maintenance schedule:
Vehicles manufactured before August 1985 Page 15
Vehicles manufactured after August 1985 Page 16
Maintenance - component location Page 17
Maintenance procedures Page 110
REPAIRS & OVERHAUL
Engine and Associated Systems
Engine repair procedures - 1.05 and 1.3 litre - pre August 1985 Page 2A1
Engine repair procedures - 1.05 and 1.3 litre - post August 1985 Page 2B1
Engine repair procedures - 1.6 and 1.8 litre 8 valve Page 2C1
Engine repair procedures - 1.8 litre 16 valve Page 2D1
Cooling, heating and air conditioning systems Page 31
Fuel and exhaust systems - carburettor models Page 4A1
Fuel and exhaust systems - K-Jetronic fuel injection - 8 valve engines Page 4B1
Fuel and exhaust systems - K-Jetronic fuel injection - 16 valve engines Page 4C1
Fuel and exhaust systems - Mono Jetronic fuel injection Page 4D1
Fuel and exhaust systems - Digijet fuel injection Page 4E1
Fuel and exhaust systems - Digifant fuel injection Page 4F1
Ignition system - contact breaker type Page 5A1
Ignition system - transistorised type Page 5B1
Ignition system - fully electronic type Page 5C1
Starting and charging systems Page 5D1
Transmission
Clutch Page 61
Manual gearbox Page 7A1
Automatic transmission Page 7B1
Driveshafts Page 81
Brakes and Suspension
Braking system Page 91
Suspension and steering Page 101
Body Equipment
Bodywork and fittings Page 111
Body electrical systems Page 121
Wiring Diagrams Page 1217
REFERENCE
Dimensions and Weights Page REF1
Conversion Factors Page REF2
Buying Spare Parts and Vehicle Identification Page REF3
General Repair Procedures Page REF4
Jacking and Vehicle Support Page REF5
Tools and Working Facilities Page REF6
MOT test checks Page REF8
Fault Finding Page REF12
Glossary of Technical Terms Page REF20
Index Page REF25
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.
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.
INFORMATION YOU CAN COUNT ON !!
====================================================================
RELATED KEYWORDS:
==============
Volkswagen Golf,
VW Golf,
VW jetta,
Volkswagen Jetta ,
1043 cc,
1272 cc,
1595 cc,
1781 cc,
1984 Volkswagen Jetta service repair manual,
1985 Volkswagen Jetta service repair manual,
1986 Volkswagen Jetta service repair manual,
1987 Volkswagen Golf service repair manual,
1988 Volkswagen Jetta service repair manual,
1989 Volkswagen Golf service repair manual,
1990 Volkswagen Jetta service repair manual,
1991 Volkswagen Golf service repair manual,
1992 Volkswagen Jetta service repair manual ,
volkswagen golf service repair manual,
volkswagen jetta service repair manual,
vw golf service repair manual,
vw jetta service repair manual,
repair, service, workshop, Service Manual, Repair Manual, Instant Download, Carb, Intake, Heads, Camshaft, Cam, Valve train, Block, Pistons, Rings, Rods, Crankshaft, Crank, Oil Pump, Pan, Ignition, Fasteners, Gaskets, Bearings, Damper, Machining, Balancing, Parts, Lifter, Distributor, Spark Plugs, Spark Plug Wires, Oil Change, Transmission Change, Fluid Change, NOS, Motor Mounts, Clips, Heat Exchanger, Plug Wires, Air Seals, Timing, Muffler, Downpipe, Cat, Catalytic Converter, Exhaust, Headers, Heat Wrap, Fuel Pump, Replacement, Pushrod, Pressure Plate, Clutch, Flywheel, Seals, Valves, Valve Stems, Tires, Rotate, Rotate Tires, Alignment, Timing Gear, Crank Pulley, Air Deflector, Air Hose, Clutch Hose, Brake Hose, Brakes, Change Brakes, Brake Pads, Brake Shoes, Rotor, Rotor Replacement, Clutch Lines, Head Gasket, Piston Ring, Main Bearings, Cam Bearings, Timing Chain, Valve Locks, Freeze Plugs, Freon, Radiator, Radiator Fan, Oil Radiator, Oil Cooling, Push Rods, Intake Valves, Exhaust Valves, Valve Guides, Valve Springs, Piston Pin Bushings, Bushings, Ring Set, Axles, Shift Linkage, Short Shifter, Shifter Cable, Engine Harness, Wiring Harness, Wiring Diagrams, Sensors, Oil Sensor, Pressure Sensor, Oil Pressure Sensor, Volt Meter, Air Screw, Body Plug, Banjo Bolt, Body Tappet, Band Nut, Cam Salai, Cam Bolt, Rotor Puller, Wrench, Rotor Bolt, Balance Spring, Cylinder, Gasket, Insulator, Carburetor, Muffler, Exhaust Gasket, Crankcase, Pin, Crank Shaft Seal, Snap Ring, Piston Ring, Piston Pin, Thrust Washer, Clutch Shoe, Clutch Case, Transfercase, Transfer Case, Transfer Plate, Plug Cap, Grommet, Spacer, Recoil Assembly, Ratchet, Carburetor Assembly, Diaphragm, Pump, Spring, Inlet Valve, Welch Plug, Throttle Shaft, Choke Shaft, Choke Valve, Air Filter, Air Filter Replacement, Fan Cover, Filter Cover, Filter Housing, Sleeve, Choke Lever, Switch Assembly, Assembly, Recoil Starter, Starter Replacement, Battery, Battery Replacement, Fuel Pump Replacement, Fuel Pump, Fuel Filter, Fuel Filter Replacement, Fuel Pipe, Puller Assembly, Hinge, Door Hinge, Door Panels, Dashboard, Dash Replacement, Air Bags, CD Player Replacement, Factory Replacement, Glovebox, Center Console, Console Replacement, Interior Lighting, Lights, HID, Projector, Headlight Replacement, Taillight Replacement, Bulb Replacement, Fogs, Foglight, Foglight Replacement, Third Brake Light, Trim, Trim Replacement, Tun Signal, Catalytic Converter, Headers, Manifold, Oxygen Sensor, Air Filter, Cold Air Intake, PCV, AC Condenser, ACC Cabin Filter, Heater System, Cooling System, Coolant Hose, Fan Shroud, Radiator, Fuel Filter, Fuel Injector, Fuel Screen, Ignition Coil, Spark Plug Wires, Alternator, Alternator Pulley, Starter, Clutch Kit, Clutch Slave Cylinder, Clutch Master Cylinder, Flywheel, Axle Assembly, Axle Shafts, CV Boots, Hubs, Bearings, Cylinder Head, Head Gasket, Timing Belt, Valve Cover, Multi Rib Belt, Oil System, Serpentine Belt, AT Filters, Gaskets, Seals, Shifters, Components, Engine Mount, Transmission Mount, Power Programmer, Air Pressure Gauge, Air Pressure, Oil Pressure, Ammeter, Blower Pressure, Gauge, Gaskets, Seals, Grommets, Orings, O-Ring, O-Rings, Chassis Wire Harness, Main Wire Harness, Electrical Pin Connector, Relay, Bosch, K&N, American Condensers, Eastern Catalytic, Bosal Performance, Alker, Silla, Denso, NGK, Hastings, Dayco, Sachs, AC Delco, Dorman, Timken, AEM, Airtex, Apexi, Bando, Beck Amley, Benchmark, Bosal, Champion, ContiTech, CSF, 4-Seasons, Bulbs, Driving Lights, Fog Lights, Interior Lights, Lighting, Tail Lights, Backup Lights, Turn Signal, Side Markers, Brake Discs, Brake Pads, Brake System, Shocks, Struts, Steering System, Suspension, Suspension System, Floor Mat, Cargo Liners, Consoles, Organizers, Leather, Glass, Window, Windshield, Steering Wheel, Shifter, Pedals, Lugs, Lug Nuts, Hub Caps, Wheel Cover, Rotate Tires, Bumper, Front Bumper, Rear Bumper, Fender, Doors, Emblem, Fuel Cap, Fuel Door, Grilles, Front Grille, Hood, Jack, Hoist, Lifting, Stands, Mud Guards, Mud Flaps, Headlight Relay, Starter Relay, Ignition Relay, Valve Stem, Window Regulator, Door Handle, Hood Hinge, Hood Latch, Wiper Blade, Wiper Motor, Washer Pump, Fuel Tank Cap, Courtesy Light, Door Jamb Switch, Door Lock, Fuel Filler Neck, Antenna, Flush, Electrical Wiring, Diagrams, Torque Specs, Torque Values, Tire Replacement, Flat Repair, Timing Belt Replacement, Routine Maintenance
===========================================================
PLEASE NOTE:
=========
1) Looking for someother Service manual, please check:
http://pecno1.tradebit.com/files.php/1003 (for massive collection of service manuals.)
THANK YOU FOR VISITING THIS PAGE. NOW HAVE A NICE DAY!!
These manuals will come in PDF format, so it's EXTREMELY easy to move around with you from computer to computer. Many mechanics purchase electronics manuals like this and use a laptop near them while doing maintenance! If you don't have a laptop, no problem! Just print out the pages of the manual that you need and you've got a hard copy in front of you while doing your work! Simply throw it away when your finished! It's much easier and quicker than having to deal with a book!
DETAILED TABLE OF CONTENTS:
======================
LIVING WITH YOUR VOLKSWAGEN GOLF OR JETTA
Introduction Page 04
Safety First! Page 05
Roadside Repairs
Introduction Page 06
If your car wont start Page 06
Jump starting Page 07
Wheel changing Page 08
Identifying leaks Page 09
Towing Page 09
Weekly Checks
Introduction Page 010
Underbonnet check points Page 010
Engine oil level Page 011
Coolant level Page 011
Brake fluid level Page 012
Power steering fluid level Page 012
Screen/headlamp washer fluid level Page 013
Wiper blades Page 013
Tyre condition and pressure Page 014
Battery Page 015
Electrical systems Page 015
Lubricants and fluids Page 016
Capacities and tyre pressures Page 017
MAINTENANCE
Routine Maintenance and Servicing
Servicing specifications Page 12
Maintenance schedule:
Vehicles manufactured before August 1985 Page 15
Vehicles manufactured after August 1985 Page 16
Maintenance - component location Page 17
Maintenance procedures Page 110
REPAIRS & OVERHAUL
Engine and Associated Systems
Engine repair procedures - 1.05 and 1.3 litre - pre August 1985 Page 2A1
Engine repair procedures - 1.05 and 1.3 litre - post August 1985 Page 2B1
Engine repair procedures - 1.6 and 1.8 litre 8 valve Page 2C1
Engine repair procedures - 1.8 litre 16 valve Page 2D1
Cooling, heating and air conditioning systems Page 31
Fuel and exhaust systems - carburettor models Page 4A1
Fuel and exhaust systems - K-Jetronic fuel injection - 8 valve engines Page 4B1
Fuel and exhaust systems - K-Jetronic fuel injection - 16 valve engines Page 4C1
Fuel and exhaust systems - Mono Jetronic fuel injection Page 4D1
Fuel and exhaust systems - Digijet fuel injection Page 4E1
Fuel and exhaust systems - Digifant fuel injection Page 4F1
Ignition system - contact breaker type Page 5A1
Ignition system - transistorised type Page 5B1
Ignition system - fully electronic type Page 5C1
Starting and charging systems Page 5D1
Transmission
Clutch Page 61
Manual gearbox Page 7A1
Automatic transmission Page 7B1
Driveshafts Page 81
Brakes and Suspension
Braking system Page 91
Suspension and steering Page 101
Body Equipment
Bodywork and fittings Page 111
Body electrical systems Page 121
Wiring Diagrams Page 1217
REFERENCE
Dimensions and Weights Page REF1
Conversion Factors Page REF2
Buying Spare Parts and Vehicle Identification Page REF3
General Repair Procedures Page REF4
Jacking and Vehicle Support Page REF5
Tools and Working Facilities Page REF6
MOT test checks Page REF8
Fault Finding Page REF12
Glossary of Technical Terms Page REF20
Index Page REF25
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.
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.
INFORMATION YOU CAN COUNT ON !!
====================================================================
RELATED KEYWORDS:
==============
Volkswagen Golf,
VW Golf,
VW jetta,
Volkswagen Jetta ,
1043 cc,
1272 cc,
1595 cc,
1781 cc,
1984 Volkswagen Jetta service repair manual,
1985 Volkswagen Jetta service repair manual,
1986 Volkswagen Jetta service repair manual,
1987 Volkswagen Golf service repair manual,
1988 Volkswagen Jetta service repair manual,
1989 Volkswagen Golf service repair manual,
1990 Volkswagen Jetta service repair manual,
1991 Volkswagen Golf service repair manual,
1992 Volkswagen Jetta service repair manual ,
volkswagen golf service repair manual,
volkswagen jetta service repair manual,
vw golf service repair manual,
vw jetta service repair manual,
repair, service, workshop, Service Manual, Repair Manual, Instant Download, Carb, Intake, Heads, Camshaft, Cam, Valve train, Block, Pistons, Rings, Rods, Crankshaft, Crank, Oil Pump, Pan, Ignition, Fasteners, Gaskets, Bearings, Damper, Machining, Balancing, Parts, Lifter, Distributor, Spark Plugs, Spark Plug Wires, Oil Change, Transmission Change, Fluid Change, NOS, Motor Mounts, Clips, Heat Exchanger, Plug Wires, Air Seals, Timing, Muffler, Downpipe, Cat, Catalytic Converter, Exhaust, Headers, Heat Wrap, Fuel Pump, Replacement, Pushrod, Pressure Plate, Clutch, Flywheel, Seals, Valves, Valve Stems, Tires, Rotate, Rotate Tires, Alignment, Timing Gear, Crank Pulley, Air Deflector, Air Hose, Clutch Hose, Brake Hose, Brakes, Change Brakes, Brake Pads, Brake Shoes, Rotor, Rotor Replacement, Clutch Lines, Head Gasket, Piston Ring, Main Bearings, Cam Bearings, Timing Chain, Valve Locks, Freeze Plugs, Freon, Radiator, Radiator Fan, Oil Radiator, Oil Cooling, Push Rods, Intake Valves, Exhaust Valves, Valve Guides, Valve Springs, Piston Pin Bushings, Bushings, Ring Set, Axles, Shift Linkage, Short Shifter, Shifter Cable, Engine Harness, Wiring Harness, Wiring Diagrams, Sensors, Oil Sensor, Pressure Sensor, Oil Pressure Sensor, Volt Meter, Air Screw, Body Plug, Banjo Bolt, Body Tappet, Band Nut, Cam Salai, Cam Bolt, Rotor Puller, Wrench, Rotor Bolt, Balance Spring, Cylinder, Gasket, Insulator, Carburetor, Muffler, Exhaust Gasket, Crankcase, Pin, Crank Shaft Seal, Snap Ring, Piston Ring, Piston Pin, Thrust Washer, Clutch Shoe, Clutch Case, Transfercase, Transfer Case, Transfer Plate, Plug Cap, Grommet, Spacer, Recoil Assembly, Ratchet, Carburetor Assembly, Diaphragm, Pump, Spring, Inlet Valve, Welch Plug, Throttle Shaft, Choke Shaft, Choke Valve, Air Filter, Air Filter Replacement, Fan Cover, Filter Cover, Filter Housing, Sleeve, Choke Lever, Switch Assembly, Assembly, Recoil Starter, Starter Replacement, Battery, Battery Replacement, Fuel Pump Replacement, Fuel Pump, Fuel Filter, Fuel Filter Replacement, Fuel Pipe, Puller Assembly, Hinge, Door Hinge, Door Panels, Dashboard, Dash Replacement, Air Bags, CD Player Replacement, Factory Replacement, Glovebox, Center Console, Console Replacement, Interior Lighting, Lights, HID, Projector, Headlight Replacement, Taillight Replacement, Bulb Replacement, Fogs, Foglight, Foglight Replacement, Third Brake Light, Trim, Trim Replacement, Tun Signal, Catalytic Converter, Headers, Manifold, Oxygen Sensor, Air Filter, Cold Air Intake, PCV, AC Condenser, ACC Cabin Filter, Heater System, Cooling System, Coolant Hose, Fan Shroud, Radiator, Fuel Filter, Fuel Injector, Fuel Screen, Ignition Coil, Spark Plug Wires, Alternator, Alternator Pulley, Starter, Clutch Kit, Clutch Slave Cylinder, Clutch Master Cylinder, Flywheel, Axle Assembly, Axle Shafts, CV Boots, Hubs, Bearings, Cylinder Head, Head Gasket, Timing Belt, Valve Cover, Multi Rib Belt, Oil System, Serpentine Belt, AT Filters, Gaskets, Seals, Shifters, Components, Engine Mount, Transmission Mount, Power Programmer, Air Pressure Gauge, Air Pressure, Oil Pressure, Ammeter, Blower Pressure, Gauge, Gaskets, Seals, Grommets, Orings, O-Ring, O-Rings, Chassis Wire Harness, Main Wire Harness, Electrical Pin Connector, Relay, Bosch, K&N, American Condensers, Eastern Catalytic, Bosal Performance, Alker, Silla, Denso, NGK, Hastings, Dayco, Sachs, AC Delco, Dorman, Timken, AEM, Airtex, Apexi, Bando, Beck Amley, Benchmark, Bosal, Champion, ContiTech, CSF, 4-Seasons, Bulbs, Driving Lights, Fog Lights, Interior Lights, Lighting, Tail Lights, Backup Lights, Turn Signal, Side Markers, Brake Discs, Brake Pads, Brake System, Shocks, Struts, Steering System, Suspension, Suspension System, Floor Mat, Cargo Liners, Consoles, Organizers, Leather, Glass, Window, Windshield, Steering Wheel, Shifter, Pedals, Lugs, Lug Nuts, Hub Caps, Wheel Cover, Rotate Tires, Bumper, Front Bumper, Rear Bumper, Fender, Doors, Emblem, Fuel Cap, Fuel Door, Grilles, Front Grille, Hood, Jack, Hoist, Lifting, Stands, Mud Guards, Mud Flaps, Headlight Relay, Starter Relay, Ignition Relay, Valve Stem, Window Regulator, Door Handle, Hood Hinge, Hood Latch, Wiper Blade, Wiper Motor, Washer Pump, Fuel Tank Cap, Courtesy Light, Door Jamb Switch, Door Lock, Fuel Filler Neck, Antenna, Flush, Electrical Wiring, Diagrams, Torque Specs, Torque Values, Tire Replacement, Flat Repair, Timing Belt Replacement, Routine Maintenance
===========================================================
PLEASE NOTE:
=========
1) Looking for someother Service manual, please check:
http://pecno1.tradebit.com/files.php/1003 (for massive collection of service manuals.)
THANK YOU FOR VISITING THIS PAGE. NOW HAVE A NICE DAY!!
User tags:
volkswagen golf, vw golf, vw jetta, volkswagen jetta, 1043 cc, 1272 cc, 1595 cc, 1781 cc, 1984 volkswagen jetta service repair manual, 1985 volkswagen jetta service repair manual, 1986 volkswagen jetta service repair manual, 1987 volkswagen golf service repair manual, 1988 volkswagen jetta service repair manual, 1989 volkswagen golf service repair manual, 1990 volkswagen jetta service repair manual, 1991 volkswagen golf service repair manual, 1992 volkswagen jetta service repair manual, volkswagen golf service repair manual, volkswagen jetta service repair manual, vw golf service repair manual, vw jetta service repair manual,
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0·4 Introduction 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. 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 VW Golf VW Jetta 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 Sub-editors Editor & Page Make-up Workshop manager Photo Scans Ian Coomber Cristopher Rogers Carole Turk Sophie Yar Steve Churchill Paul Buckland John Martin Paul Tanswell Steve Tanswell Cover illustration & Line Art Roger Healing 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. 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. Safety first! 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. · 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. 0·5 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 4000C. 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. 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. 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. 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. 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. 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 hightorque nuts when the vehicle is on stands. Initial loosening and final tightening should be done with the wheels on the ground. 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 oilsoaked 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. 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. 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. 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. 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. 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. 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 If it's a model with automatic transmission, make sure the selector is in `P' or `N'. Open the bonnet and make sure that the battery terminals are clean and tight. 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 Is there fuel in the tank? 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. A Check that the HT lead connections at the distributor are clean and make sure they are secure by pushing them onto the cap. B Check that the HT lead connections at the spark plugs are secure by pushing them onto the plugs. C Check that the LT lead connections are clean and secure. D Check the security and condition of the battery connections. 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 E Wiring plugs may cause problems if dirty or not connected properly. |
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