1991 Volkswagen Golf Service and Repair Manual

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Factory-Grade Data

1991 Volkswagen Golf service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you diagnose issues correctly, follow proven repair steps, and use wiring diagrams and system sections to track faults faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Electrical diagnostics with wiring diagrams
  • Coverage across major systems: engine, transmission/driveline, brakes, steering, suspension, HVAC, and more

Trims covered

  • GTI 16-Valve Hatchback 2-Door
  • Basico Hatchback 4-Door
  • GTI 8-Valve Hatchback 2-Door
  • GL Hatchback 4-Door
  • GTI Hatchback 4-Door
  • Basico Hatchback 2-Door
  • GL Hatchback 2-Door
  • Eclipse Hatchback 4-Door
  • Base Hatchback 2-Door

Engines covered

  • 2.0L 1984CC 121Cu. In. l4 GAS DOHC Naturally Aspirated
  • 1.8L 1781CC l4 GAS SOHC Naturally Aspirated
  • 1.6L 1588CC 97Cu. In. l4 DIESEL SOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

1991 Volkswagen Golf Recalls & Complaints

NHTSA #93V12900002/08/1993Component: SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, A

AN ENGINE PREHEATING TUBE MAY NOT BE PROPERLY SUPPORTED DUE TO A MISSING SUPPORT BRACKET, CAUSING THE PREHEATING TUBE TO CHAFE AGAINST THE RIGHT FRONT METAL BRAKE LINE. THIS CAN DAMAGE THE HYDRAULIC L

Consequence

DIMINISHED BRAKING CAN RESULT IN INCREASED STOPPINGDISTANCES AND A POSSIBLE ACCIDENT.

Remedy

DEALERS WILL INSTALL A PREHEATING TUBE SUPPORT BRACKET TO ENSURE PROPER POSITIONING RELATIVE TO THE

NHTSA #06E01800001/03/2006Component: SERVICE BRAKES, HYDRAULIC

CERTAIN HYDRAULIC BRAKE HOSES, P/N 171.611.107B, SOLD AS REPLACEMENT EQUIPMENT FOR 1975-1985 VOLKSWAGEN (VW) RABBIT; 1985-1992 VW GOLF; AND 1980-1992 VW JETTA PASSENGER VEHICLES. POSSIBLE BRAKE HOSE

Consequence

BRAKE HOSE RUPTURE COULD RESULT IN LOSS OF BRAKING ABILITY, POSSIBLY RESULTING IN A VEHICLE CRASH.

Remedy

FOREIGN PARTS DISTRIBUTORS WILL NOTIFY OWNERS AND REPLACE THE BRAKE HOSES WITH COMPLIANT BRAKE HOSES

TSB #10213836

Airbag Issues.

TSB #10159010

The part number listed in the document is to be returned if it meets the criteria provided.

TSB #10157383

VAS 6154 Replacement Part Setup Guide

TSB #10155644

This special notice is to inform dealers to return all part numbers listed in the document and order the superseded part numbers going forward.

TSB #10128105

This document contains the VW Elsa Newsletter that contains a general overview of wiring diagrams updates, technical bulletins, pending service solutions, tech tips, campaigns, updates, and suggestions.

TSB #10128104

This document contains the VW Elsa Newsletter that contains a general overview of wiring diagrams updates, ElsaPro infomedia icons grayed out, workshop equipment tool storage application, technical bulletins, pending service solutions, tech

TSB #10128055

This communication is to update our ProFi dealers of the current status of the latest inbound and outbound ProFi requests.

TSB #10126785

Update model year applicability to include 2017.

Showing the 8 most recent of 14 technical service bulletins on file with NHTSA.

19950512Component: ELECTRICAL SYSTEM:IGNITIONCrash reported1 injured

DRIVING VEHICLE AT SPEED 40 MPH, HAD COMPLETE LOSS OF POWER, IMPACT 3:00 POSITION. TT

20000903Component: VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:HEATER CORE1 injured

TOP SECTION OF HEATER CORE CRACKED OPEN WHILE ENGINE AT IDLE SPEED ALLOWING VERY HOT COOLANT TO ENTER THE COCKPIT DRIVER AND PASS. SIDE AT THE FOOT LEVEL. AFTER EMAILING OTHER VW OWNERS GOLF, JETTA,

20000903Component: VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:HEATER CORE1 injured

TOP SECTION OF HEATER CORE CRACKED OPEN WHILE ENGINE AT IDLE SPEED ALLOWING VERY HOT COOLANT TO ENTER THE COCKPIT DRIVER AND PASS. SIDE AT THE FOOT LEVEL. AFTER EMAILING OTHER VW OWNERS GOLF, JETTA,

20020331Component: VEHICLE SPEED CONTROL

WHILE DRIVING IN EXTREMELY COLD WEATHER THE ACCELERATOR STUCK OPEN. ( IN RESEARCHING ON THE INTERNET I FOUND VOLKSWAGEN RECALLED CARS IN CANADA FOR THIS PROBLEM. RECALL TR (CANADA ONLY). ) THIS HAP

20000208Component: FUEL SYSTEM, GASOLINE:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS

CONSUMER RECEIVED RECALL CAMPAIGN SK IN NOVEMBER 1999 DATED AUGUST 1993, HOWEVER NOT ABLE TO RECEIVE REPAIR DUE TO LACK OF KITS AVAILABLE FOR REPAIR. (92V-058) *MJS

Showing the 5 most serious of 11 complaints filed with NHTSA.

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