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Golf GTI - Technical Stuff

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Technical Stuff

Please read these translations from the Haynes Manual before proceeding ;)

Front Suspension Diagram Front Strut Diagram Rear Suspension Diagram Instrument Panel   Sunroof   Rear Brake Drums   Rear Brake Shoes   Front Brakes  

Some links to great GUIDE threads on the Mk1 Golf Owners Club forums
Cam & Ignition Timing
Change water pump & thermostat
Reuildi front end
Change gear oil

My notes & stuff on oil pressure system


Electrical::Relays::Layout
VW Golf Mk1 Relay positions

		1 (free)
		2 Inlet manifold heating (Carb) / Fuel pump (Inj) / Glow plugs (Deisel)
		3 Seat belt warning system
		4 Gear change up display (Formel E, GTi)
		5 A/C
		6 Twin horn
		7 Fog lights
		8 X relay
		9 (free)
		10 Wash-wipe interval
		11 Rear windscreen wash/wipe
		12 Hazard warning lights
		13 Seat belt warning system
		14 Seat belt warning system
		15 Headlight dim-dip
		16 Cold start valve
		17 (free)
		18 Coolant temp gauge (Inj, Diesel)
		

Further details on all the connectors on the rear of the (Series 2) fuse/relay board
Rear view of fuse board showing plug locations

A Blue 28 pin Instrument cluster wiring harness
B Red 28 pin Instrument cluster wiring harness (position 5 open)
C Yellow 22 pin Engine compartment/engine management, left side (position 10 open)
D White 29 pin Engine compartment/wiper motor wiring harness, right side (position 6. 10, 14, 18, 27, 28 open)
E Black 18 pin Rear wiring harness (position 17 open)
G n/a 1 pin 10 individual circuits
H Brown 6 pin Air conditioning/coolant fan relay wiring harness
K Neutral 5 pin Seat belt warning system/coolant level wiring harness
L Grey 4 pin Horn wiring harness
L Black 4 pin Headlight/dimmer switch wiring harness
M Black 2 pin Steering column switch wiring harness
M Black 2 pin Headlight/dimmer switch wiring harness
N Red 1 pin Separately fused circuits (glow plug wiring harness)
P Red 7 pin 7 single point connectors for terminal 30 circuit
R Green 2 pin Open/ECM power supply relay



A Blue 28 pin Instrument cluster wiring harness

		1 - gry/blu- light switch pin 58b (dash light dimmer)
		2 - grn - wiper stalk pin 53
		3 - blu/yel- dash plug pin T7b/7 (upshift control light)
		4 - blu/blk- dash plug pin T7c/4 (oil pressure control unit, 0.3 bar feed)
		5 - grn/yel- wiper stalk pin 53b
		6 - grn/blk- wiper stalk pin 53e
		7 - blk/grn- hazard switch pin R & indicator switch pin R
		8 - blk - ignition switch pin 15
		9 - wht/blk- light switch pin 56
		10- blk/grn/wht- hazard switch pin 49a & indicator switch pin 49a
		11- blue/brn- spare plug behind fusebox? (indicator relay pin 2)
		12- brn/blk- wiper stalk pin J
		13- blk/blu- hazard switch pin 15
		14- grn/wht- wiper stalk pin L
		15- grn - fusebox pin B/1
		16- blu - dash plug pin T7a/5 (alternator warning light)
		17- blu/red- dash plug pin T7/7 (indicator warning light)
		18- wht - hazard switch pin 49
		19- grn/red- wiper stalk pin T
		20- blk/wht- hazard switch pin L & indicator switch pin L
		21- yel - indicator stalk pin 56b (headlight flasher/main beam switch)
		22- blk/yel- rear window heater switch pin + and heated seat switches pin 15
		23- blk/red- glovebox light and fresh air blower switch pin + or A/C switch pin +
		24- gry/grn- light switch pin 58 (dash light dimmer)
		25- blk/yel- fusebox pin L/1
		28- blu/wht- dash plug pin T7/? (high beam warning light)
		

B Red 28 pin Instrument cluster wiring harness (position 5 open)
		1 - grn - fusebox pin A/15 and dual circuit & handbrake warning light
		2 - grn/wht- fog light switch pin 83b (fuse #17)
		3 - vio/blk- dash plug pin T7b/6 (fuel gauge)
		7 - yel/red- dash plug pin T7a/5 (coolant temp gauge)
		8 - red/blk- ignition switch pin 50
		9 - blk/gry- wiper stalk pin 53a
		10- blk/yel- light switch pin X
		11- gry/red- cig lighter
		\- red - radio power plug pin 7
		12- red - digital clock/MFA
		13- red/yel- indicator stalk pin 30 (headlight flasher/main beam switch)
		15- yel - dash plug pin T7a/4 (oil pressure control unit, 1.8 bar feed)
		16- wht/yel- fog light switch pin 83a
		18- blk/grn- upshift/fuel consumpton indicator solonoid shut-off
		19- red/blk- dash plug pin T7b/4 (rev counter)
		20- grn/yel- fog light switch pin 83
		21- wht/grn- rear window heater switch pin 86
		22- wht - indicator stalk pin 56a (headlight flasher/main beam switch)
		23- red - light switch pin 30
		25- brn/blk- fusebox pin L/2
		26- gry/red- light switch pin 58R
		27- gry/blk- light switch pin 58L
		28- red/wht- hazard switch pin 30
		

C Yellow 22 pin Engine compartment/engine management, left side (position 10 open)
		1 - red/blk- brake light switch
		2 - blu - alternator pin D+
		3 - red/yel- brake light switch
		4 - grn/blk- left parking light bulb
		5 - yel/wht- left headlight bulb pin 58b
		6 - yel - right headlight bulb pin 58b
		7 - red - radiator fan thermal switch & radiator fan after-run relay pin 30
		8 - blk/grn- right front indicator & repeater
		9 - grn/red- windscreen washer pump pin +
		12- blu/brn- brake fluid level warning switch
		13- blk/yel- dual tone horns
		14- grn/red- right parking light bulb
		15- brn/blk- dual tone horns
		16- wht - right headlight bulb pin 58a
		17- wht/blk- left headlight bulb pin 58a
		18- red/blk- thermo switch for cold start valve (K-Jet f/inj) or digifant ECU pin 1
		19- blk/wht- left front indicator & repeater
		20- blk - radiator fan run-on control unit pin 2/15
		\- blk - reverse light switch (MK1 models)
		21 - blk/blu - reverse light switch (MK1 models)
		22- wht/yel- foglights
		

D White 29 pin Engine compartment/wiper motor wiring harness, right side (position 6. 10, 14, 18, 27, 28 open)

		1 - blu/blk- oil pressure switch (0.3 bar)
		2 - blk - thermal switch for inlet manifold heater (carb models) or fusebox pin R/1 (digifant f/inj) or idle & WOT switches
		\- blk/wht- idle overrun cut-off valve (carb models)
		\- blk - knock sensor control unit pin 5
		3 - wht/grn- fuel gauge sender or transmission switch/upshift indicator
		7 - blk/yel- low coolant level switch unit pin 6/15, idle boost control unit pin 2/15 (K-Jet f/inj)
		8 - wht/red- vacuum switch/upshift indicator
		9 - grn/yel- windscreen wiper motor pin 53b
		12- grn - windscreen wiper motor pin 53
		13- vio/blk- thermal switch for carb heater, inlet manifold heater, auto choke & bypass cut-off valve (carb models)
		\- red/yel- electronic ignition control unit pin 10 (16v) or digifant ECU pin 3 (digifant f/inj)
		\- red/yel- knock sensor control unit pin 10 (16v)
		15- wht/vio- resistance wire -> ignition coil pin 15
		16- blk/red- reverse light switch (M/T) or starter/inhibitor & reverse light switch pin 15 (A/T) (MK2 models)
		17- grn/blk- windscreen wiper motor pin 53e
		19- blu/blk- reverse light switch or starter/inhibitor & reverse light switch pin R & diode (A/T) (MK2 models)
		20- blk/gry- windscreen wiper motor pin 53a
		21- yel - oil pressure switch (1.8 bar)
		22- br - windscreen wiper motor pin 31, and spare connector behind fusebox or to earth 'claw' near fusebox
		23- blk - ignition coil pin 15
		24- red/blk- starter pin 50 (M/T) or starter/inhibitor & reverse light switch pin 50 (A/T)
		26- red/blk- ignition coil pin 1 & idle control unit pin 1 (K-Jet f/inj), overrun cut-off valve (K-Jet f/inj)
		29- yel/red- coolant temp sender
		\- yel/blk- low coolant level switch unit pin B/G
		

E Black 18 pin Rear wiring harness (position 17 open)

		1 - gry/grn- number plate lights
		2 - grn/blk- rear wiper motor pin 53
		3 - red - interior light & boot light
		5 - vio/blk- fuel pump or fuel gauge sender pin G
		6 - blk/wht- left rear indicator
		7 - grn/red- windscreen washer pump pin 31 (rear pump on earlier models)
		\- brn/blu- windscreen washer pump
		8 - blk/gry- rear wiper motor pin 53a
		9 - grn/blk- left rear light
		10- grn/wht- rear foglight
		11- blk/grn- rear right indicator
		12- blk - reverse lights pin RF
		13- grn - handbrake warning switch
		14- red/wht- warm up regulator, aux air regulator & control pressure regulator (K-Jet f/inj)
		\- red/yel- main & transfer fuel pumps
		15- wht-wht/grn- rear window heater and heated mirror glass
		16- blk/red- brake lights pin 54
		18- grn/red- rear light bulb
		

G n/a 1 pin 10 individual circuits
		1 - blk/yel- Electric mirror adjustment switch pin 5 & electric window relay pin 6/86
		2 - blk - heated washer jets, spare plug behind fusebox & idle stabilser valve pin 2/15
		3 - blk/yel- heated seat control units pin 17/15
		9 - gry/grn- headlight washer relay pin 5/56
		10- grn/red- headlight washer relay pin 4/5
		

H Brown 6 pin Air conditioning/coolant fan relay wiring harness

		1 - red/wht- radiator fan thermoswitch & A/C refrig. high pressure switch
		2 - red/blk- A/C switch
		3 - red - Battery +ve
		4 - grn/yel- A/C thermostat
		5 - yel/red- fresh air fan switch pin 4
		6 - blk - fresh air fan
		

K Neutral 5 pin Seat belt warning system/coolant level wiring harness 5 - brn/red- ignition switch pin S or SU (difficult to make out!)
L Grey 4 pin Horn wiring harness / Black 4 pin Headlight/dimmer switch wiring harness
		1 - blk/yel- fusebox pin A/25
		2 - brn/blk- fusebox pin B/25
		3 - brn - earth location 16 or 81
		4 - brn/blu- horn switch
		

M Black 2 pin Headlight/dimmer switch wiring harness / Black 2 pin Steering column switch wiring harness
N Red 1 pin Separately fused circuits (glow plug wiring harness)
		N - red/wht- inlet manifold heater
		\- red/blk- f/injection relay pin 86 (K-Jet f/inj)
		

P Red 7 pin 7 single point connectors for terminal 30 circuit
		- red - battery +, ignition switch pin 30, electric window relay pin 87, headlight washer relay pin B/30 & f/injection relay pin 30 (K-Jet f/inj)
		

R Green 2 pin Open/ECM power supply relay
		1 - blk - fusebox pin D/2 (digifant f/inj)
		2 - blk/yel- digifant ECU pin 14 & fuel injectors (digifant f/inj) 
		


Electrical::Relays::Part Numbers


part numberendfunction (notes)pin identification
811 905 343 idle speed boost1, 15, 31, 87
813 906 054 hot start pulse... (5A)31, 31b, 50
433 906 059 jetronic FPR (16A fuse)1, 15, 30, 31, 87
443 906 059 jetronic FPR (big blades, 5 cyl)1, 15, 30, 31, 87
321 906 059 jetronic FPR (big blades, 4 cyl)1, 15, 30, 31, 87
321 906 059 E2jetronic FPR (big blades, 5 cyl)1, 15, 30, 31, 87
321 906 059 F63jetronic FPR (big blades, 5 cyl)1, 15, 30, 31, 87
443 907 385 jetronic FPR (big blades, 5 cyl)1, 15, 30, 31, 87
443 907 385 C jetronic FPR (big blades, 4 cyl)1, 15, 30, 31, 87
443 907 393Kidle stabilisation (VDO sticker)1, 15, 31, k, Ls, st 1, st 2, T
447 919 080 dash light booster (double space)31, 58, 58d1, 58d2, 58d3, P1, P2, P3
433 919 082 oil pressure warning15, 31, 61, OsLa, W/1
443 919 082240oil pressure warning15, 31, 61, OsLa, W/1
171 919 0915upshift/economy1/W, 15, 31, G, L, U/S
171 919 091 A6upshift/economy1/W, 15, 31, G, L, U/S
171 919 4334"warning time relay"15, 31, 85, 86, G, L
171 919 437 A "warning time relay" (double space)15, 31, 50, 85, 86, C, G, L
810 919 439 seat belt warning (buzzer)15, 31, 85, 86, G, L
810 919 439 A225seat belt warning (buzzer)15, 31, 58, 85, 86, G, L, R, TK
443 919 469 headlight check unit56bL, 56bL1, 56bR, 56bR1, K
443 919 469 A headlight check unit56bL, 56bL1, 56bR, 56bR1, K
443 919 469 B281headlight check unit31, 56bL, 56bL1, 56bR, 56bR1, K
443 919 533 heated seats15, 31, 86, P, T
433 919 577 retardation (orange)15, U, K
443 919 578 (D) A/C15, 30, 31, 87, HL, HLS, U
443 919 578 A A/C15, 30, 31, 87, 87a, HL, HLS, U
443 927 82676ABS relay (10A fuse)15, 30, 31, 87, S1, S2, T
411 941 583 B Sunroof relay30, 56, 56a, 56b, S
447 947 115 C Interior light delay control (blue)15a, 30a, 30az, 31, 31L, 31z, T
443 947 553232SPST? (solid state?)30a, 85, 86, 87
431 951 253 SPST NO (25A, grey)30, 85, 86, 87
431 951 253 A (40A)30, 86, 87, T
141 951 253 B53SPST NO (40A, dark grey)30, 85, 86, 87
431 951 253 B SPST NO (40A, blue)30, 85, 86, 87
443 951 253 B SPDT w/breaker? (tall size)30, 85, 86, 87, 87b
431 951 253 C DPST NO (2 X 10A, white)30, 85, 86, 87, 87b
431 951 253 D SPDT (20/30A, brown or metal)30, 85, 86, 87, 87a
431 951 253 F SPST NC (20A, red)30, 85, 86, 87a
443 951 253 F211jetronic FPR (big blades, code socket)30, 85, 86, 87, 87a, L, T
431 951 253 G SPST NO, with diode (40A, purple)30, 85, 86, 87
431 951 253 H SPST NO (40A, orange or black)30, 85, 86, 87
443 951 253 J213SPST NO (70A, big blades, grey)30, 85, 86, 87
443 951 253 K214SPST NO (40A, grey)30, 85, 86, 87
443 951 253 L215KE3 jetronic FPR (code socket)30, 85, 86, 87, 87a, T, L
431 951 254208SPST NO (70A, big blades, orange)30, 85, 86, 87
443 951 257261express window one way (double space)15, 30, 31, 61, 85, 86, 87, 87a, 87b
TKI=TKII=TKIII
111 953 227 D21turn signal unit31, 49, 49a
171 955 52920rear window wipe/wash15, 31, 53, L
191 955 52972r/w/ wipe/wash - intermittent15, 31, 53, L
3B0 955 531197interval wipers - programmable
two identical relays
compatible with 431 955 531
15, 31, 53m, 53s, I, T
357 955 5319915, 31, 53m, 53s, I, T
431 955 531229interval wipers15, 31, 31b, 53c, 53e, I
431 955 531271interval wipers (white, type 89)15, 31, 31b, 53c, 53e, I
443 955 532 A236after run radiator fan15, 30, 31, 87, St1, T
443 955 532 C272after run radiator fan15, 30, 31, 87, St1, T
443 955 535275headlight washer30, 31, 56, P, S
171 959 143 A DPST NO (2 X 25A, metal)30, 85, 86, 87, A, B
443 959 251261express window one way (double space)15, 30, 31, 61, 85, 86, 87, 87a, 87b
TKI=TKII=TKIII=KR
443 959 257 A280express window one way (double space)15, 30, 30A, 31, 85, 86, 87, 87a, 87b, SK
TKI=TKII=TKIII=KR
441 959 257 B329express window one way (double space)15, 30, 30A, 31, 85, 86, 87, 87a, 87b, SK
TKI=TKII=TKIII=KR
441 959 257 D329express window two way (double space)15, 30, 30A, 31, 85, 86, 87, 87a, 87b, SK
TKI=TKII=TKIII=KR
443 963 141 SPST NO fused (10A, grey)30, 85, 86, 87
part numberendfunction (notes)pin identification

Front Suspension Diagram

VW Golf Mk1 Front suspension diagram

Front Strut Diagram

VW Golf Mk1 Front strut diagram

Rear Suspension Diagram

VW Golf Mk1 rear suspension diagram

Instrument Panel

REMOVAL & INSTALLATION

Rabbit, Golf, Jetta, Scirocco

  • Disconnect the negative battery cable.
  • If applicable, remove the gear shift boot and the center console.
  • Remove the steering wheel.
  • Remove the trim panels from below the dashboard.
  • Remove the steering column support bracket and lower the column.
  • Pull the knobs off the heater controls and remove the control assembly and the radio.
  • Remove the headlight switch and switch blanks to gain access to the screws. Remove the instrument cluster and trim panel around the cluster.
  • Remove the glove compartment.
  • At the firewall, remove the plastic tray and remove the nuts holding the top of the dashboard.
  • Remove the main fuse panel and disconnect the plugs at the back. Disconnect the ground wires.
  • Disconnect any remaining wiring from the dashboard and remove the last screws securing the dash. Remove the dashboard.

To install:

  • Fit the dashboard into place and start all screws, then tighten them.
  • Install the fuse panel and connect the wiring.
  • Secure the steering column into place.
  • Install the switches and instrument cluster.
  • Install the heater controls and radio.
  • Install the console and connect all wiring.
  • Install the steering wheel and all other remaining components.
  • Connect the negative battery cable.
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Sunroof

  • Open the sunroof halfway, then remove the steel clips at the front edge using a plastic wedge tool.
  • Close the sunroof and push the interior panel back all the way.
  • Remove both front guides from the outer panel.
  • Slide the springs at the rear guide in towards the center.
  • Unfasten the screws, then remove the rear support plates in towards the center. Lift the sunroof cover out.
  • Installation is the reverse of removal. ;)
VW Golf Sunroof Diagram

Brake Drums

REMOVAL & INSTALLATION
  • Disconnect the negative battery cable.
  • Raise and safely support the vehicle, then remove the rear wheels.
  • Insert a small prytool through a wheel bolt hole and push up on the adjusting wedge to slacken the rear brake adjustment.
  • Remove the grease cap, cotter pin, locking ring, axle nut and thrust washer. Carefully remove the bearing and put all these parts where they will stay clean.
  • Carefully remove the drum.
To install:
  • Before installing, if any brake dust has fallen onto the axle, wipe off all the grease and apply a coat of new high temperature bearing grease. Install the parts in the reverse order of removal.
  • NOTE: When tightening the axle nut, the thrust washer must still be movable with a small screwdriver. Spin the drum and check that the thrust washer can still be moved.
  • When installing the locking ring, keep trying different positions of the ring on the nut until the cotter pin goes into the hole. Don't turn the nut to align the locking ring with the hole in the axle. Use a new cotter pin.
  • Connect the battery cable.
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Rear Brake Shoes

  • Disconnect the negative battery cable.
  • Raise and safely support the vehicle, then remove the rear wheels.
  • Remove the rear brake drum. (as detailed here)
  • Remove the spring retainers by holding the pin behind the backing plate, while pushing on and turning the retainer 1/4 turn.
Brake Shoes rabbit
  • Clamp the pushrod that holds the shoes apart at the top in a vise and begin removing the springs. Start with the lower return spring, adjusting wedge spring, upper return spring and then the tensioning spring and adjusting wedge.
Brake Shoes rabbit self adjusting type
  • On most vehicles, the parking brake lever must be removed from the old shoes and reused. When new parts are purchased, don't forget the clip that holds the parking brake lever pin in place.
To install:
  • Check the wheel cylinder for leaks. If any defects are found, replace the wheel cylinder.
  • Inspect the springs. If the springs are damaged or show signs of overheating they should be replaced. Indications of overheated springs are discoloration and distortion.
  • Inspect the brake drum and recondition or replace as necessary.
  • Clean the backing plate and lubricate the shoe contact points with a suitable brake lubricant.
  • With the push rod clamped in a vise, attach the front brake shoe and tensioning spring.
  • Insert the adjusting wedge between the front shoe and pushrod so its lug is pointing toward the backing plate.
  • Remove the parking brake lever from the old shoe and attach it onto the new rear brake shoe.
  • Put the rear brake shoe and parking brake lever assembly onto the pushrod and hook up the spring.
  • Connect the parking brake cable to the lever and place the whole assembly onto the backing plate.
  • Install the hold-down springs.
  • Install the upper and lower return springs.
  • Install the adjusting wedge spring.
  • Center the brake shoes on the backing plate, making sure the adjusting wedge is fully released (all the way up) before installing the drum.
  • Install the drum and wheel assembly.
  • Apply the brake pedal a few times to bring the brake shoe into adjustment.
  • If the wheel cylinder was replaced, bleed the system.
  • Connect the battery cable.
  • Road test the vehicle.
  • Smile.
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Front Disc Brakes

Kelsey-Hayes Floating Caliper This unit is a single piston, one piece caliper which floats on two guide pins screwed into the adapter (anchor plate). The adaptor, in turn, is held to the steering knuckle with two bolts. As the brake pads wear, the caliper floats along the adapter and guide pins during braking.
  • Disconnect the negative battery cable.
  • Raise the front of the vehicle and safely support it with jackstands. Remove the wheel.
  • Siphon some brake fluid from the master cylinder reservoir to prevent its overflowing when the piston is retracted into the cylinder bore. Kelysey Hayes floating caliper
  • Disconnect the brake pad warning indicator if so equipped.
  • Using a pair of needlenose pliers or the like, remove the anti-rattle springs.
  • Using an Allen wrench, back out the two guide pins that attach the caliper to the anchor plate.
    NOTE: When replacing pads only, it is not necessary to remove the guide pins completely from the rubber bushings, as they may be difficult to reinstall.
  • Lift off the caliper and position it out of the way with some wire. You need not remove the brake lines.
    WARNING Never allow the caliper to hang by its brake lines.
  • Slide the outer pad out of the anchor plate and then remove the inner pad.
  • Check the rotor as detailed in this section.
  • Check the caliper for fluid leaks or cracked boots.
  • If any damage is found, the caliper will require overhauling or replacement.
To install:
  • Carefully clean the anchor plate with a wire brush or some other abrasive material.
  • Install the new brake pads into position on the anchor plate. The inner pad usually has chamfered edges.
    NOTE: When replacing brake pads, always replace both pads on both sides of the vehicle. Mixed pads may cause uneven braking.
  • Slowly and carefully push the piston into its bore until it is bottomed, then position the caliper onto the anchor plate.
  • Install the guide pins and tighten them to 2530 ft. lbs. (3441 Nm).
    NOTE: The upper guide pin is usually longer than the lower one. Use extreme care so as not to cross-thread the guide pins when tightening!
  • Install the anti-rattle springs between the anchor plate and brake pads ears.
  • The loops on the springs should be positioned inboard.
  • Fill the reservoir with brake fluid and pump the brake pedal several times to set the piston.
  • It should not be necessary to bleed the system. However, if a firm pedal cannot be obtained, the system must be bled.
  • Install the wheel and lower the vehicle.
  • Connect the battery cable.
  • Pray. Back to Top of Page

    Seats

    REMOVAL & INSTALLATION

    Front Seats
    • Slide the seat forward to the stop and remove the track cover beside the tunnel.
    • Remove the acorn nut, washer and bolt at the front of the center seat rail.
    • Pull the seat release handle and push the seat back and out of the tracks. Lift the seat out of the vehicle.
    To install:
    • Slide the seat assembly into the tracks and install the bolt, washer and nut.
    • Install the track cover and check operation.


    Rear Seat
    • On Fox, Golf, Jetta and Quantum models, lift the seat cushion up and pull forward to remove it.
    • On other models, remove the two screws at the front of the seat cushion and pull forward and up.
    • Release the seat backrest and fold forward.
    • Release the locking lug in the mounting and pull the backrest out of the mounting.

    To install:
    • Install the seat and fold back.
    • Install and tighten the retaining bolts.