VW GOLF/JETTA/GTI/RABBIT HAYNES RESTORATION MANUAL
Dolls and Bears
VW GOLF/JETTA/GTI/RABBIT HAYNES RESTORATION MANUAL
VW Golf and Jetta Restoration Manual by Lindsay Porter **2000 publication by Haynes North America, hardbound, 8 ¼ x 10 ½, 192 pages, 510 black & white photographs, NOS- shrinkwrapped & in mint condition. ISBN#- 185960448X Covers Golf Marks 1 and 2 (all petrol engine sizes), GTI 1600 and 1800, Jetta and Rabbit (USA), but excludes 4-wheel drive and diesel models. With the aid of more than 1,000 illustrations and text aimed at the DIY enthusiast this book tells you: · What to look for when buying a used vehicle. · How to undertake a mechanical overhaul. · How to restore bodywork and electrics · How to replace a soft-top mechanism (mechanical and powered). · How to fit an uprated engine, modify suspension and brakes. · How to retro-fit power steering, a power soft-top and higher spec trim/grille/spoiler and body kits. · The history and development of this trend-setting vehicle. · Includes names and addresses of suppliers and other useful contacts. Table Of Contents Introduction and Acknowledgements 1. Preparation and Essential Safety! Preparations Essential DOs and DON’Ts Fire Fumes The Battery Mains Electricity Ignition HT Voltage Welding and Bodywork Repairs Compressed Gas Cylinders Dangerous Liquids and Gases Work with Plastics General Safety Notes Finishing Petrol Safety Engine Oils Oil Disposal Workshop Safety – Summary Paint Spraying Fluoroelastomers Raising Your Vehicle – Safely! Using Ramps Using a Trolley Jack More Safety Notes Tools and Equipment 2. Heritage and Buying Origins The New Volkswagen Westmoreland Rabbit Golf Mk 2 ‘Sport’ Golf GTI Developments Jetta Variations Buyin – by Peter Carrick All Shapes and Sizes Everyday Golfs The Legendary Golf GTI Convertibles Four-wheel Drives Commercials Inspecting and Buying Finding One Inspecting First Impressions Doing the Paperwork Bodywork Golf Mk 1 Golf Mk 2 Interior Golf Mk 1 Golf Mk 2 Mechanicals Static Test – Mechanical Components Engine Suspension Road Test Engine Gearbox and Drivetrain Brakes, Suspension and Steering Classic Car Insurance UK Tax Exemption 3. Bodywork Stripdown Introduction to Body Repairs Door Removal Radiator Grille Removal Bonnet (Hood) and Mechanism Removal and Fitting Tailgate (Luggage Bay Lid) Replacement Front and Rear Bumper Removal Front Wing ( Fender) Replacement Door Stripdown Trim Glass and Winder Gear Quarter Light Lock and Latch Mechanism Cabriolet Rear Side Window Renewing a Door Skin Replacing a Sill (Body Rocker) Front Panel Replacement Rear Wheel Arch Repairs Rear Valance Replacement Repair Panels Minor Body Repairs Small Dent Repair Total Respray Spraying with Aerosol Welding Plastic Components Preparing the Shell for Fitting-up Repairing Alloy Wheel Damage 4. Engine and Transmission Engine Removal and Replacement Gearchange Mechanism Overhaul Disconnecting Transmission from Engine Engine Stripdown Cylinder Head Stripdown Cylinder Head Rebuild Cylinder Head and Ancillaries Reassembly Engine Block Reassembly Flywheel, Clutch, Transmission and Starter Motor Engine Bay Fit-out 5. Suspension and Steering Front Suspension Stripdown Front Suspension Rebuild Front Suspension Camber Adjustment Steering Strip and Rebuild Wheel Bearings and Driveshafts Rear Suspension Strip and Rebuild Wheels and Tyres 6. Braking System Removing Pipework Brake Pressure Regulator Engine Bay Components Removing Front Brakes Removing Rear Brakes Handbrake Mechanism Removal Fitting New Brake Pipes Engine Bay Refit Front Brake Build-up Rear Brake Build-up Handbrake Cable Refit Bleeding the Brakes 7. Electrical, Ignition, Fuel and Exhaust Lighting and Wiring Wiper Mechanism Fitting the Alternator Steering Column and Dashboard Switches Ignition Overhaul Mechanical Fuel Pump Fuel Tank Removal and Replacement 8. Interior, Glass and Soft-top Windscreen (Windshield) Removal Glass ‘Bullseye’ Damage Seat Belt Removal Front and Rear Seat Removal Door Mirror Removal Interior Stripout Dashboard Removal and Refit Plastic Instrument Panel Repair Plastic Dashtop Repair Plastic Door Capping Repair Headlining Replacement Interior Refit Soft-top Skin Replacement Seat Cover Replacement Seat Valeting 9. Modifications and Improvements Fitting and Uprated Exhaust Electronic Ignition Fitting an Oil Cooler Manual Choke Conversion Converting Carburettor to Injection Power Steering Conversion Uprating the Suspension Mk 1 Golf Rear Disk Brake Conversion Larger Master Cylinder for Golf Mk 1 More Braking System Improvements Wheels and Tyres Fitting a Body Kit Fitting a Sunroof Power Hood Conversion Retrimming Seats/Leather Trim Fitting a Soundproofing Kit Fitting a Car Alarm Fitting In-Car Entertainment Appendix Specialists and Suppliers Featured in this BookProduction Modifications | ||||||||||||
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