Page 3 2.0 Liter 4-Cyl. 2V Engine Mechanical, Engine Code(s): ABA m.y. 1995 00 - General, Technical data Technical data Engine numbers, location Engine technical data 10 - Engine - Assembly Engine, removing and installing Removing Installing Tightening torques Engine and transmission, aligning Rubber bushings for engine mount, replacing Vehicles with A/C, additional information on removing and installing 13 - Engine - Crankshaft, Cylinder block...
Page 4 Valve guides, removing and replacing Valve stem seals, replacing 17 - Engine - Lubrication Lubrication system, general information Lubrication system, components Oil pressure and oil pressure switches, checking 19 - Engine - Cooling system Cooling system General information Cooling system components, body side Cooling system components, engine side Coolant pump, disassembling and assembling Cooling system, draining and filling...
Page 5 Secondary Air Injection (AIR) system Function Secondary Air Injection (AIR) system components, removing and installing Combi-valve and check valve, checking Secondary Air Injection (AIR) pump motor, checking Secondary Air Injection (AIR) solenoid valve, checking...
Page 6 Technical data Page 1 of 2 00-1 Technical data Engine numbers, location The engine numbers ("engine code" and "serial number") are die-stamped in the front of the cylinder block above the crankcase breather. In addition, there is a label with the "engine code"...
Page 7 Technical data Page 2 of 2 00-2 Engine technical data Engine code Manufactured from: 03.95 08.95 07.95 Displacement liters Output kW at RPM 85 at 5400 85 at 5400 HP at RPM 115 at 5400 115 at 5400 Torque Nm at RPM 165 at 3200 165 at 3200 Ft.
Page 8 Engine, removing and installing Page 1 of 16 10-1 Engine, removing and installing Special tools, testers and auxiliary items Engine sling 2024 A G 000 100 grease Torque wrench VAG 1331: 5-50 Nm (4- 37 ft lb) Torque wrench VAG 1332: 40-200 Nm (30-148 ft lb) Cable ties http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 9 Engine, removing and installing Page 2 of 16 10-2 Removing The engine is removed by moving it toward the front together with the transmission. CAUTION! Determine correct radio anti-theft coding before disconnecting the battery. Ignition switched off. - Disconnect battery negative cable (ground strap).
Page 10 Engine, removing and installing Page 3 of 16 10-3 - Remove lock carrier (upper radiator support) with attached parts. Repair Manual Body Exterior, Interior, Repair Group 50 - Remove coolant fan and fan shroud. Vehicles with A/C: - Refer to additional information and removal instructions Page 10-14 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 11 Engine, removing and installing Page 4 of 16 10-4 Vehicles with manual transmission: - Remove clutch slave cylinder. Repair Manual, 5 Spd. Manual Transmission 02A, Repair Group 30 - Disconnect gear shift mechanism from transmission. Repair Manual, 5 Spd. Manual Transmission 02A, Repair Group 34 - Install engine sling 2024 A and lift slightly wit shop crane:...
Page 12 Engine, removing and installing Page 5 of 16 10-5 Vehicles with automatic transmission - Install engine sling 2024 A and lift slightly with shop crane: Drive belt side: 4th hole up from hook in cross bar position -1- Flywheel side: 2nd hole up from hook in cross bar position -6- CAUTION!
Page 13 Engine, removing and installing Page 6 of 16 10-6 All vehicles: - Disconnect subframe and, on one side, pry bracket from rubber subframe mounting. - Separate power steering pressure lines from disconnected subframe. - Lift engine together with transmission out toward the front. CAUTION! Lift unit out carefully to avoid damage to body.
Page 14 Engine, removing and installing Page 7 of 16 10-7 Installing Install in reverse order of removal, but note the following: - Check clutch release bearing for wear, repla necessary. - Lightly lubricate clutch release bearing, clutc release guide sleeve and transmission input shaft splines with G 000 100 grease.
Page 15 Engine, removing and installing Page 8 of 16 Steering, Repair Group 48. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 16 Engine, removing and installing Page 9 of 16 10-8 - Install lock carrier with attached parts. Repair Manual Body Exterior, Interior, Repair Group 50 Engines with ribbed drive belt without tensioner: - Install ribbed drive belt Page 13-11 All engines: - Fill engine cooling system coolant Page 19-9...
Page 17 Engine, removing and installing Page 10 of 16 - Carry out idle check. Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s): ABA m.y. 1995, Repair Group 24 Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s): ABA m.y.
Page 18 Engine, removing and installing Page 11 of 16 10-9 Tightening torques Fastener/Connection Tightening torque Engine to M10 60 Nm (44 ft lb) transmission M12 80 Nm (59 ft lb) Flywheel cover plate M7 10 Nm (07 ft lb) Axle shafts to drive flanges 45 Nm (33 ft lb) Exhaust pipe to manifold 40 Nm (30 ft lb)
Page 19 Engine, removing and installing Page 12 of 16 10-10 Engine and transmission mount tightening torques Bolt threads lubricated Front engine mount A - 55 Nm (41 ft lb) B - 55 Nm (41 ft lb) C - 50 Nm (37 ft lb) Rear right engine mount A - 25 Nm (18 ft lb) B - 50 Nm (37 ft lb)
Page 20 Engine, removing and installing Page 13 of 16 10-11 Rear left engine mount for manual transmission A - 60 Nm (44 ft lb) B - 25 Nm (18 ft lb) C - 30 Nm (22 ft lb) Rear left engine mount for automatic transmission A - 60 Nm (44 ft lb) B - 25 Nm (18 ft lb)
Page 21 Engine, removing and installing Page 14 of 16 10-12 Engine and transmission, aligning Aligning is only necessary when the engine and transmission have been removed and additionally the sub-frame and engine carrier bonded rubber mounts have been loosened. - Loosen bonded rubber mount -A- (engine mount) on sub-frame and console.
Page 22 Engine, removing and installing Page 15 of 16 10-13 Rubber bushings for engine mount, replacing - Install engine holding fixture 10-222A with supports 10-222A/1. - Connect engine sling in hook eye on cylinde head (left side) and tighten to lift engine sligh - Remove engine mount.
Page 23 Engine, removing and installing Page 16 of 16 10-14 Vehicles with A/C, additional information on removing and installing CAUTION! DO NOT open A/C refrigerant circuit. DO N release A/C refrigerant into the atmosphe Refrigerant lines bend easily. Only trained technicians using the proper equipment should replace the A/C refrigerant.
Page 24 Engine disassembling and assembling Page 1 of 23 13-1 Engine disassembling assembling CAUTION! If large amounts of metal shavings or small metal particles are found in the engine oil, caused by wear of the crankshaft main and connecting rod bearings, thoroughly clean the oil passages to remove...
Page 25 Engine disassembling and assembling Page 2 of 23 13-2 Part I 1 - Tensioner 2 - 25 Nm (18 ft lb) 3 - Tensioner lever 4 - Dust sleeve 5 - 10 Nm (7 ft 6 - Drive belt guard, lower 7 - Drive belt guard,...
Page 26 Engine disassembling and assembling Page 3 of 23 13-3 11 - Drive belt guard 12 - Drive belt guard, rear Drive belt sprocket, intermediate shaft 14 - 80 Nm (59 ft lb) loosen tighten holding fixture 3036 15 - Drive belt sprocket, crankshaft 16 - 90 Nm (66...
Page 27 Engine disassembling and assembling Page 4 of 23 shoulder Turning additional -turn (90 ) can be done in stages 17 - Pulley coolant pump Version with ribbed belt http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 28 Engine disassembling and assembling Page 5 of 23 13-4 18 - Ribbed drive belt Before removing, mark direction rotation Removing installing Page 13-11 19 - Vibration damper, crankshaft Also serves as pulley for ribbed drive belt Assembly only possible in one position (holes offset)
Page 29 Engine disassembling and assembling Page 6 of 23 Steering, Repair Group 48 21 - Pulley coolant pump Version for V-belt 22 - Pulley crankshaft http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 30 Engine disassembling and assembling Page 7 of 23 13-5 Part II 1 - Positive Crankcase Ventilation (PCV) valve 2 - 20 Nm (15 ft lb) 3 - Intake manifold, upper 4 - Gasket Always replace 5 - Cap Replace gasket if damaged 6 - 10 Nm (7 ft 7 - Reinforcing...
Page 31 Engine disassembling and assembling Page 8 of 23 13-6 11 - Cylinder head cover gasket Replace damaged 12 - Cylinder head Removing installing Page 15-6 When replaced, always replace engine coolant 13 - Cylinder head gasket Always replace Always replace engine coolant 14 - Lifting eye...
Page 32 Engine disassembling and assembling Page 9 of 23 16 - Grommet 17 - Hose connection From crankcase breather Page 13-8 item 13 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 33 Engine disassembling and assembling Page 10 of 23 13-7 Part III 1 - Cylinder block Removing installing sealing flange flywheel or drive plate Page 13- Removing installing crankshaft Page 13-27 Disassembling assembling pistons and connecting rods Page 13-31 2 - Woodruff Check for tight fit 3 - O-ring...
Page 34 Engine disassembling and assembling Page 11 of 23 6 - Knock sensor Checking Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s): ABA m.y. 1995, Repair Group 01 Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s): ABA m.y.
Page 35 Engine disassembling and assembling Page 12 of 23 13-8 7 - 20 Nm (15 ft lb) Incorrect tightening torque influence knock sensor function 8 - Ignition distributor Installing Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s): ABA m.y.
Page 36 Engine disassembling and assembling Page 13 of 23 14 - Oil cooler Coat flange contact area, outside sealing ring, with sealer AMV 188 100 02 Ensure clearance to surrounding components Replace if oil has been contaminated Caution!, Page 13-1 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 37 Engine disassembling and assembling Page 14 of 23 13-9 15 - Oil filter Loosen with strap wrench Tighten by hand Follow installation instructions on oil filter 16 - 10 Nm (7.5 ft lb) 17 - Engine speed (RPM) sensor Checking Repair Manual, 2.0 Liter 4-Cyl.
Page 38 Engine disassembling and assembling Page 15 of 23 (90 ) Always replace 20 - 30 Nm (22 ft lb) 21 - Tensioner 22 - Bracket 23 - Seal Always replace http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 39 Engine disassembling and assembling Page 16 of 23 13-10 24 - Tensioner lever 25 - Hammer- head screw 26 - Coolant pump Disassembling assembling Page 19-7 27 - Oil pan 28 - 20 Nm (15 ft lb) Loosen or tighten bolts on flywheel side...
Page 40 Engine disassembling and assembling Page 17 of 23 13-11 Ribbed drive belt, removing and installing Note: Before removing the ribbed belt, mark its running direction so that it can be reinstalled same way. When installing, be sure belt is correctly sea in pulleys.
Page 41 Engine disassembling and assembling Page 18 of 23 13-12 Installing - Install ribbed belt on crankshaft vibration damper. - Install V-belt for power steering pump. Repair Manual, Suspension, Wheels, Brake Steering, Repair Group 48 Vehicles without A/C: - Lift belt tensioner with ribbed belt installation 3299 and install ribbed belt.
Page 42 Engine disassembling and assembling Page 19 of 23 13-13 Toothed drive belt, removing and installing (Adjusting valve timing) See Caution! and notes Page 13-14 Special tools, testers and auxiliary items Ribbed belt installation tool 3299 Pin wrench Matra V159 Torque wrench VAG 1331 (5-50 Nm) Removing - Remove ribbed drive belt Page 13-11...
Page 43 Engine disassembling and assembling Page 20 of 23 13-14 Installing Note: For repairs that require the toothed belt to be removed, carry out the toothed belt adjustment as follows. - Align marking on camshaft sprocket with marking on drive belt guard. CAUTION! Before turning the camshaft, make sure that the pistons are NOT at Top...
Page 44 Engine disassembling and assembling Page 21 of 23 13-15 Engine installed: - Align flywheel -A- or drive plate -B- marks as shown (arrows) to set crankshaft to Cyl. 1 TDC. Engine removed: - Turn crankshaft vibration damper to align notch with timing mark (arrow) and set crankshaft to Cyl.
Page 45 Engine disassembling and assembling Page 22 of 23 13-16 - Turn intermediate shaft drive belt sprocket with toothed belt (in direction indicated by arrows) until distributor rotor aligns with Cyl. 1 marking on distributor housing. Drive belt slips over teeth of crankshaft drive belt sprocket.
Page 46 Engine disassembling and assembling Page 23 of 23 13-17 - Increase tension on toothed belt by turning tensioner pulley with pin wrench (e.g. Matra V159) in direction of arrow. It must be just possible to twist the belt by 90 with the thumb and forefinger half-way between the camshaft and intermediate shaft sprockets.
Page 47 Sealing flange and flywheel or drive plate, removing and installing Page 1 of 11 13-18 Sealing flange and flywheel or drive plate, removing installing Note: For clutch repairs Repair Manual, 5 Spd. Manual Transmission 02A, Repair Group 30 1 - Oil seal Install with 10- Lightly...
Page 48 Sealing flange and flywheel or drive plate, removing and installing Page 2 of 11 5 - Gasket Always replace 6 - Cylinder block Removing installing crankshaft Page 13-27 Disassembling assembling pistons and connecting rods Page 13-31 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 49 Sealing flange and flywheel or drive plate, removing and installing Page 3 of 11 13-19 7 - 60 Nm (44 ft lb) plus additional -turn (90 ) Always replace 8 - Flywheel or drive plate Drive plate, removing installing Page 13-24 remove install...
Page 50 Sealing flange and flywheel or drive plate, removing and installing Page 4 of 11 with oil seal Replace only as complete assembly Lightly lubricate sealing 12 - Oil seal Replacing Page 13-21 Intermediate shaft First remove ignition distributor Axial clearance max.
Page 51 Sealing flange and flywheel or drive plate, removing and installing Page 5 of 11 13-20 14 - O-ring Replace damaged Intermediate shaft sealing flange http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 52 Sealing flange and flywheel or drive plate, removing and installing Page 6 of 11 13-21 Crankshaft oil seal (pulley end), replacing Special tools, testers and auxiliary items Counter-hold tool 3099 Oil seal extractor 2085 Oil seal fitting tool 3083 Removing - Remove ribbed drive belt Page 13-11 - Remove toothed camshaft drive belt...
Page 53 Sealing flange and flywheel or drive plate, removing and installing Page 7 of 11 13-22 - Lubricate threaded head of seal puller 2085, place in position and screw into seal as far as possible by applying pressure in direction of arrow.
Page 54 Sealing flange and flywheel or drive plate, removing and installing Page 8 of 11 13-23 - Press seal in to stop with 3083. - Install drive belt and adjust tension Page 13-13 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 55 Sealing flange and flywheel or drive plate, removing and installing Page 9 of 11 13-24 Drive plate, removing and installing Special tools, testers and auxiliary items Holding tool VW 558 M8x45 hex bolt and two M10 hex nuts Depth gauge Loosening and tightening drive plate - Fasten holding tool VW 558 to driveplate with hex bolt M8x45.
Page 56 Sealing flange and flywheel or drive plate, removing and installing Page 10 of 11 13-25 Installing - Install driveplate using washer with cut-outs -1-. - Install new bolts -3- and tighten to 30 Nm (22 ft lb). - Check clearance between drive plate and cylinder block at three points and calculate average value.
Page 57 Sealing flange and flywheel or drive plate, removing and installing Page 11 of 11 13-26 If clearance dimension is NOT as specified: - Remove drive plate and install shim - - Install and tighten bolts -3- in three stages. Stage I: 30 Nm (22 ft lb) Stage II: 60 Nm (44 ft lb) Stage III: additional -turn (90 )
Page 58 Crankshaft, removing and installing Page 1 of 6 13-27 Crankshaft, removing installing 1 - Main bearing shells 1, 2, 4 and 5 Without groove: for main bearing caps 1, 2 and 5 With oil groove: for main bearing cap 4 and cylinder block Do not...
Page 59 Crankshaft, removing and installing Page 2 of 6 only, NOT additional turn (90 ) 3 - Main bearing caps Main bearing cap 1: pulley Main bearing cap 3 has recesses for thrust washers - Holding tabs on bearing shells in cylinder block and main...
Page 60 Crankshaft, removing and installing Page 3 of 6 13-28 4 - Main bearing shell 3 Without groove: for main bearing With oil groove: cylinder block 5 - Thrust washer For main bearing cap 3 Note installation position 6 - Sensor gear For RPM sensor...
Page 61 Crankshaft, removing and installing Page 4 of 6 13-29 8 - Crankshaft Dimensions Page 13-30 Axial clearance: New: 0.07-0.17 (0.0028- 0.0067 in.) Wear limit: 0.25 mm (0.00984 in.) Radial clearance: Measure Plastigage New: 0.02-0.06 (0.0008- 0.0024 in.) Wear limit: 0.17 mm (0.0067 in.) CAUTION!
Page 62 Crankshaft, removing and installing Page 5 of 6 washer cylinder block bearing 3 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 63 Crankshaft, removing and installing Page 6 of 6 13-30 Crankshaft dimensions Reconditioning dimension Crankshaft journal Connecting rod journal diameter - mm (in.) diameter - mm (in.) maximum -0.022 (0.00087) -0.022 (0.00087) Basic dimension (nominal) -54.00 (2.1260) -47.80 (1.8819) minimum -0.042 (0.00165) -0.042 (0.00165) maximum -0.022 (0.00087)
Page 64 Pistons and connecting rods, disassembling and assembling Page 1 of 12 13-31 Pistons and connecting rods, disassembling assembling 1 - Piston ring Offset gaps by Remove and install with piston ring pliers "TOP" marking faces toward piston crown Checking ring Fig.
Page 65 Pistons and connecting rods, disassembling and assembling Page 2 of 12 compressor Dimensions Fig. 4 3 - Connecting rod With oil supply hole for piston pin lubrication Replace only as complete Installation position: marking -A- points toward pulley end Make matching marks -B- for cylinder...
Page 66 Pistons and connecting rods, disassembling and assembling Page 3 of 12 13-32 4 - Connecting bearing Note installation position 5 - 30 Nm (22 ft lb) plus additional -turn (90 ) threads contact surface Measuring radial clearance: tighten to 30 Nm (22 ft lb) only, additional -turn...
Page 67 Pistons and connecting rods, disassembling and assembling Page 4 of 12 Opening pressure: 2.5-3.2 bar (36- 46 psi) applicable from 04.95 7 - Oil spray piston cooling applicable from 04.95 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 68 Pistons and connecting rods, disassembling and assembling Page 5 of 12 13-33 8 - Bearing shell Note installation position Shells with oil hole installed in connecting rod - 3 -, face toward piston pin Do not interchange worn bearing shells Check to make sure...
Page 69 Pistons and connecting rods, disassembling and assembling Page 6 of 12 with Plastigage New: 0.01-0.06 (0.0004- 0.0024) Wear limit: 0.12 mm (0.0047) CAUTION! DO NOT turn crankshaft while measuring radial clearance. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 70 Pistons and connecting rods, disassembling and assembling Page 7 of 12 13-34 9 - Cylinder block Checking cylinder bore diameter Fig. 5 Piston and cylinder dimensions Page 13-39 10 - Connecting rod bolt 11 - Circlip 12 - Piston pin If difficult remove, warm...
Page 71 Pistons and connecting rods, disassembling and assembling Page 8 of 12 13-35 Special tools, testers and auxiliary items Feeler gauges Internal dial gauge 50-100 mm Micrometer 75-100 mm Fig. 1 Checking piston ring gap - Squarely insert piston ring into cylinder from above, to approx.
Page 72 Pistons and connecting rods, disassembling and assembling Page 9 of 12 13-36 Fig. 2 Checking piston ring/groove clearance - Clean ring groove before measuring. Piston ring Side clearance - mm (in.) Wear limit Compression 0.02-0.05 0.15 ring (0.0008- (0.0059) 0.0020) Oil scraper 0.02-0.05 0.15...
Page 73 Pistons and connecting rods, disassembling and assembling Page 10 of 12 13-37 Fig. 4 Piston dimensions Engine code up to from 04.95 04.95 Dimension - 19.1 20.1 (in.) (0.752) (0.791) Dimension - (in.) (0.279) (0.279) Recess 66.5 65.0 diameter -c- (in.) (2.618) (2.559)
Page 74 Pistons and connecting rods, disassembling and assembling Page 11 of 12 13-38 Fig. 5 Cylinder bore, checking - Use 50-100 mm internal micrometer. - Measure in direction -A- perpendicular to crankshaft, and direction -B- parallel to crankshaft. - Measure in three places as shown. 1 - 10 mm (0.39 in.) from top 2 - Center 3 - 10 mm (0.39 in.) from bottom...
Page 75 Pistons and connecting rods, disassembling and assembling Page 12 of 12 13-39 Piston and cylinder dimensions Piston and cylinder dimensions up to04.95 Reconditioning Piston Cylinder dimension diameter bore mm (in.) diameter - mm (in.) Basic dimension 82.485 82.51 (3.24744) (3.2484) 1st oversize 82.735 82.76...
Page 76 Cylinder head removal and installation Page 1 of 9 15-1 Cylinder head removal installation Checking compression pressures Page 15-8 Note: When installing a reconditioned cylinder head, oil the contact surfaces between valve lifters and cam lobes after installing the head. Remove plastic washers that...
Page 77 Cylinder head removal and installation Page 2 of 9 15-2 1 - Positive Crankcase Ventilation (PCV) valve 2 - Grommet 3 - 20 Nm (15 ft lb) 4 - Intake manifold, upper 5 - Gasket Always replace 6 - Cap Replace gasket if damaged...
Page 78 Cylinder head removal and installation Page 3 of 9 15-3 11 - Cylinder head bolt Always replace Loosening tightening sequence Page 15-6 12 - Gasket Always replace 13 - Cylinder head Installing Page 15-6 Check distortion Fig. 1 When replacing, always replace engine...
Page 79 Cylinder head removal and installation Page 4 of 9 15 - Camshaft sprocket Note position when installing drive belt Page 13-13 16 - Hook eye http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 80 Cylinder head removal and installation Page 5 of 9 15-4 17 - Drive belt guard, rear 18 - Toothed drive belt Check for wear Do not kink Removing installing Page 13-13 19 - Belt tensioner 20 - 45 Nm (33 ft lb) 21 - Drive belt guard,...
Page 81 Cylinder head removal and installation Page 6 of 9 15-5 Fig. 1 Checking cylinder head for distortion Max. permissible distortion: 0.1 mm (0.004 in.) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 82 Cylinder head removal and installation Page 7 of 9 15-6 Cylinder head, installing Special tools, testers and auxiliary items Torque wrench VAG 1332 (40-200 Guide pin 3070 Requirements Engine cold Pistons NOT at Top Dead Center (TDC) Installing - To align cylinder head, install guide pins from tool 3070 into holes for cylinder head bolts 8 and 10 (arrows).
Page 83 Cylinder head removal and installation Page 8 of 9 15-7 - Tighten cylinder head bolts in sequence shown, following same sequence for each of four stages. Note: To loosen cylinder head bolts, follow the same sequence in reverse order. - First tighten with torque wrench. Stage I 40 Nm (30 ft lb) Stage II...
Page 84 Cylinder head removal and installation Page 9 of 9 15-8 Compression pressure, checking Special tools, testers and auxiliary items Compression tester US 1120 Test conditions Engine oil temperature min. 30 C (86 F) - Disconnect harness connector for engine speed (RPM) sensor G28.
Page 85 Cylinder head, disassembling and assembling Page 1 of 24 15-9 Cylinder head disassembling assembling Note: Cylinder heads with cracks between the valve seats or between a valve seat and the spark plug threads can be used without decreasing the service life.
Page 86 Cylinder head, disassembling and assembling Page 2 of 24 15-10 3 - Camshaft Axial play, checking Fig. 1 Removing installing Page 15-22 Check radial clearance with Plastigage Wear limit: 0.1 (0.004 in.) Runout: max. 0.01 mm (0.0004 in.) Identification and valve timing specifications Fig.
Page 87 Cylinder head, disassembling and assembling Page 3 of 24 Check for tight 5 - 80 Nm (60 ft lb) holding tool 3036 to loosen tighten 6 - Cylinder head Replacement cylinder heads with camshaft bearing shells Fig. See Note Page 15-9 Valve seats,...
Page 88 Cylinder head, disassembling and assembling Page 4 of 24 15-11 8 - Cylinder head refacing dimension Minimum height -a- = 132.6 (5.220 in.) 9 - Valves DO NOT reface by cutting or grinding, only hand- lapping is permitted Valve dimensions Fig.
Page 89 Cylinder head, disassembling and assembling Page 5 of 24 install with 3047A 12 - Valve spring Removing installing with cylinder head removed: use valve spring compressor 2037 Removing installing with cylinder head installed Page 15-29 13 - Valve spring seat, upper http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 90 Cylinder head, disassembling and assembling Page 6 of 24 15-12 14 - Valve keepers 15 - Hydraulic valve lifters Do not interchange Checking Page 15-25 When removed, store with camshaft contact surface pointing downward Before installing check camshaft axial play Fig.
Page 91 Cylinder head, disassembling and assembling Page 7 of 24 15-13 Special tools, testers and auxiliary items Dial indicator Holder VW 387 Fig. 1 Checking camshaft axial play Measure with valve lifters removed, and first and last bearing caps installed Wear limit: max. 0.15 mm (0.0059 in.) Fig.
Page 92 Cylinder head, disassembling and assembling Page 8 of 24 15-14 Fig. 3 Camshaft for reconditioned cylinder head with camshaft bearing shells Reconditioned cylinder heads or replacement engines are sometimes supplied with camshaft bearing shells. Standard camshaft: Dimension -a- = 26.00 mm (1.024 in.) Undersize camshaft: Dimension -a- = 25.75 mm (1.014...
Page 93 Cylinder head, disassembling and assembling Page 9 of 24 15-15 Fig. 4 Valve dimensions CAUTION! DO NOT recondition valves by cutting or grinding; only lapping is permitted. Dimension Intake Exhaust valve valve Head diameter 39.5 32.9 a - mm 0.15 0.15 Stem diameter 6.92...
Page 94 Cylinder head, disassembling and assembling Page 10 of 24 15-16 Fig. 5 Camshaft identification and valve timing Identification Cam lobe base circle: -a- = 34 mm Identification number and letter markings are stamped between intake and exhaust cam lobes for cylinders 1 and 3.
Page 95 Cylinder head, disassembling and assembling Page 11 of 24 15-17 Valve seats, refacing CAUTION! When refacing valve seats, remove only enough material to produce the correct se contact pattern. The maximum permissib refacing dimension for the cylinder head must be calculated before refacing. If the maximum permissible head refacing dimension is exceeded, the hydraulic lifte will not function properly and the cylinder...
Page 96 Cylinder head, disassembling and assembling Page 12 of 24 15-18 The measured distance minus the specified minimum dimension is the maximum permissible refacing dimension, the maximum amount of material that can be removed when refacing the valve seats. Minimum cylinder head dimensions For intake valves: 33.8 mm (1.331 in.) For exhaust valves: 34.1 mm (1.343 in.) Example:...
Page 97 Cylinder head, disassembling and assembling Page 13 of 24 15-19 Intake valve seat refacing dimensions a - 39.2 mm (1.543 in.) b - maximum permissible refacing dimension c - approx. 2.0 mm (0.079 in.) Z - cylinder head lower edge 45 = valve seat angle 30 = valve seat upper correction angle...
Page 98 Cylinder head, disassembling and assembling Page 14 of 24 15-20 Camshaft oil seal, removing and installing Special tools, testers and auxiliary items Holder tool 3036 Oil seal extractor 2085 Oil seal installation tool 10-203 Removing - Remove upper drive belt guard. - Loosen camshaft sprocket (hold with 3036).
Page 99 Cylinder head, disassembling and assembling Page 15 of 24 15-21 - Turn inner part of seal puller 2085 out two tu (approx. 3 mm) from the outer part and lock w knurled screw. - Lubricate threaded part of seal puller, install and, while applying pressure, screw into sea far as possible.
Page 100 Cylinder head, disassembling and assembling Page 16 of 24 15-22 Camshaft, removing and installing Special tools, testers and auxiliary items Holder tool 3036 Torque wrench VAG 1331 (5-50 Torque wrench VAG 1576 (75-400 Removing - Remove upper drive belt guard. - Loosen camshaft sprocket (hold with 3036).
Page 101 Cylinder head, disassembling and assembling Page 17 of 24 15-23 - Remove camshaft bearing caps 1, 3 and 5. - Gradually loosen camshaft bearing caps 2 a 4, alternating in diagonal pattern to loosen nu evenly. - Remove camshaft bearing caps 2 and 4. - Remove camshaft.
Page 102 Cylinder head, disassembling and assembling Page 18 of 24 15-24 - Insert Woodruff key in camshaft. - Install camshaft drive belt sprocket. Use holding tool 3036 Tightening torque: 80 Nm (59 ft lb) - Install toothed drive belt and adjust tension Page 13-13 CAUTION! After installing new hydraulic valve lifters, DO...
Page 103 Cylinder head, disassembling and assembling Page 19 of 24 15-25 Hydraulic valve lifters, checking Special tools, testers and auxiliary items Feeler gauges Wood or plastic wedge Note: Replace hydraulic valve lifters only as complete units (they can not be adjusted or repaired). Some irregular valvetrain noise during start up is normal.
Page 104 Cylinder head, disassembling and assembling Page 20 of 24 15-26 If there is less than 0.1 mm (0.004 in.) play, or no play, check as follows: - Press down with suitable non- marring tool (e.g. wood or plastic). If the lifter can be pushed down more than 0.1 mm (0.004 in.) before valve starts to open: - Replace valve lifter.
Page 105 Cylinder head, disassembling and assembling Page 21 of 24 15-27 Valve guide wear, checking Special tools, testers and auxiliary items Dial indicator Holder VW 387 New intake and exhaust valves (2) Checking - Place new valve in guide. Valve stem end must be flush with guide CAUTION! Intake guides and exhaust guides have different diameters.
Page 106 Cylinder head, disassembling and assembling Page 22 of 24 15-28 Valve guides, removing and replacing Special tools, testers and auxiliary items Drift 3121 7 mm reamer 3120 and cutting fluid Replacing - Clean and check cylinder head. Cylinder heads with valve seats that can no longer be refaced, or which have already been machined to the minimum dimension, should not have the valve guides replaced.
Page 107 Cylinder head, disassembling and assembling Page 23 of 24 15-29 Valve stem seals, replacing With cylinder head installed Special tools, testers and auxiliary items Slide hammer 3047A Adjustable rod 2036 Pressure hose VW 653/3 Valve spring compressor VW 541/1A with VW 541/5 Seal driver 3129 Replacing...
Page 108 Cylinder head, disassembling and assembling Page 24 of 24 15-30 - Install 2036 and adjust bar to cylinder stud height. - Install pressure hose VW 653/3 in spark plug hole and apply steady pressure. At least 6 bar (87 psi) - Compress valve springs with VW 541/1A and VW 541/5, and remove.
Page 109 Lubrication system, general information Page 1 of 12 17-1 Lubrication system, general information CAUTION! If large amounts of metal shavings or small metal particles are found in the engine oil, caused by wear of crankshaft and connecting rod bearings, thoroughly clean the oil passages to remove contaminants and help prevent later damage.
Page 110 Lubrication system, general information Page 2 of 12 17-2 Lubrication system, components 1 - Gasket Replace damaged 2 - Cap 3 - Oil dipstick The oil level must not be above the max. mark! Oil above shaded zone: DO NOT top up with engine oil!
Page 111 Lubrication system, general information Page 3 of 12 4 - Dipstick tube Pull out when draining 5 - 0.3 bar oil pressure switch - F22- 25 Nm (18 ft lb) Wire color: Blue/black Checking Page 17-7 leaking, cut seal replace. Engines up to 04.95...
Page 112 Lubrication system, general information Page 4 of 12 17-3 6 - Oil pressure switch - 1.8 bar (26 psi) 25 Nm (18 ft lb) Color: White Wire color: Yellow Checking Page 17-7 leaking, cut seal replace. 7 - Check valve 5 Nm (44 in lb) 8 - Plug...
Page 113 Lubrication system, general information Page 5 of 12 contact surfaces with AMV 188 100 (outside seal) Ensure clearance to surrounding components Caution! Page 17-1 13 - 25 Nm (18 ft lb) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 114 Lubrication system, general information Page 6 of 12 17-4 14 - Oil filter Loosen with filter wrench Tighten by hand Note installation instructions on oil filter 15 - Oil pump gears Gear backlash, checking Fig. 1 Checking axial clearance Fig. 2 16 - Oil pump cover with pressure...
Page 115 Lubrication system, general information Page 7 of 12 19 - Oil drain plug 30 Nm (22 ft lb) Replace if leaking. See Parts Catalog for correct application. In some cases, seal and drain plug are combined; do not interchange with separate seal and drain plug.
Page 116 Lubrication system, general information Page 8 of 12 17-5 21 - Oil pan Clean mating surface before assembly 22 - Suction line Clean screen if dirty 23 - Baffle plate remove, remove oil pump cover or suction line 24 - Gasket Always replace Baffle...
Page 117 Lubrication system, general information Page 9 of 12 from 04.95 26 - Oil spray nozzle piston cooling applicable from 04.95 27 - Gasket Always replace http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 118 Lubrication system, general information Page 10 of 12 17-6 Fig. 1 Checking oil pump backlash New: 0.05 mm (0.002 in.) Wear limit: 0.20 mm (0.008 in.) Fig. 2 Checking oil pump axial clearance Wear limit: 0.15 mm (0.006 in.) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 119 Lubrication system, general information Page 11 of 12 17-7 Oil pressure and oil pressure switches, checking For functional testing and repair of the optical (warning light) and acoustic (warning buzzer) oil pressure warning systems: Electrical Wiring Diagrams, Troubleshooting & Component Locations Special tools, testers and auxiliary items...
Page 120 Lubrication system, general information Page 12 of 12 17-8 - Connect VAG 1527B voltage tester between battery positive (B+) and 0.3 bar oil pressure switch -A-, using adapter cables from VW 15 connector test kit. LED must light up - Start engine and increase RPM slowly. The LED must go out: Engines up to 04.95: 0.15-0.45 bar (2.1-6.5 psi)
Page 121 Cooling system Page 1 of 20 19-1 Cooling system General information WARNING! When the engine is hot, the cooling system is under pressure. If it is necessary to open the cooling system, do so slowly to relieve pressure gradually before starting repairs. Note: Hose connections are secured with spring-type or screw-type clamps.
Page 122 Cooling system Page 2 of 20 19-2 Cooling system components, body side 1 - Mounting 2 - 10 Nm (7 ft 3 - Radiator Removing installing Page 19-12 After replacing, always replace coolant 4 - Coolant hose, upper connector pipe Page 19- , item 1 5 - Coolant...
Page 123 Cooling system Page 3 of 20 Only with optional equipment 7 - Guide ring Note installation position Attached to fan shroud - 10 - with clips http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 124 Cooling system Page 4 of 20 19-3 8 - Coolant fan -V7- Removing installing Page 19-12 9 - Auxiliary Only with optional equipment Removing installing Page 19-12 10 - Fan shroud Note installation position 11 - Connector 12 - Cover 13 - Expansion tank 14 - To coolant...
Page 125 Cooling system Page 5 of 20 transmission http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 126 Cooling system Page 6 of 20 19-4 16 - To cylinder head Page 19-5 item 8 17 - To upper coolant hose Page 19-5 item 2 18 - Cap Check with VAG 1274 and 1274/4 Test pressure: 1.3-1.5 bar (19- 22 psi) 19 - Coolant Control...
Page 127 Cooling system Page 7 of 20 ON: 92 - 97 C (198 - 207 F) OFF: 84 -91 (183 - 196 F) Switching temperatures: 2nd stage: ON: 99 - 105 C (210- 221 F) OFF: 91 -98 (196 - 208 F) 20 - Rubber bushing http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 128 Cooling system Page 8 of 20 19-5 Cooling system components, engine side 1 - To top of radiator Page 19-2 item 4 2 - To expansion tank Page 19-5 item 17 3 - Engine Coolant Temperature (ECT) sensor - G62- With sensor G2 for...
Page 129 Cooling system Page 9 of 20 expansion tank Page 19-4 item 16 9 - To heater core 10 - To ATF cooler Vehicles with auto. trans. 11 - 10 Nm (7 ft 12 - Bracket http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 130 Cooling system Page 10 of 20 19-6 13 - From heater core 14 - From expansion tank or ATF cooler Page 19-3 item 14 15 - Coolant line 16 - Oil cooler Removing installing Page 17-3 item 12 17 - To bottom of radiator Page 19-2...
Page 131 Cooling system Page 11 of 20 Ribbed drive belt, removing installing Page 13-11 V-belt tension, adjusting: Repair Manual, Suspension, Wheels, Brakes, Steering, Repair Group 48 22 - Coolant pump Disassembling assembling Page 19-7 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 132 Cooling system Page 12 of 20 19-7 Coolant pump, disassembling assembling 1 - 25 Nm (15 ft lb) 2 - Coolant pump pulley ribbed drive belt 3 - Coolant pump Make sure that shaft rotates smoothly 4 - Gasket Always replace 5 - Coolant thermostat...
Page 133 Cooling system Page 13 of 20 Opening stroke: 7 mm (0.28 in.) minimum 6 - Connector pipe http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 134 Cooling system Page 14 of 20 19-8 7 - O-ring Always replace 8 - Clip 9 - 10 Nm (7 ft 10 - Flange 11 - Coolant pump pulley For V- belt Remove install with VAG 1590 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 135 Dispose of properly. Filling Note: The cooling system of all Volkswagen vehicles is filled at the factory with a mixture of water and anti-freeze solution (G11) containing corrosion inhibitors designed for year round use. Phosphate-free antifreeze prevents...
Page 136 Cooling system Page 16 of 20 19-10 Recommended mixture ratios: Protection Anti-freeze Water percentage Vehicles with automatic transmission 3.7 liters -25 C (- liters 13 F) (3.9 qt.) (2.6 qt.) 3.1 liters -35 C (- liters 31 F) (3.3 qt.) (3.3 qt.) Vehicles with manual transmission...
Page 137 Cooling system Page 17 of 20 19-11 - Slowly fill coolant up to "MAX" mark on expansion tank. Filling time: approx. 5 minutes - Close expansion tank (install cap). - Let engine run until coolant fan comes on. - Check coolant level and top off if necessary.
Page 138 Cooling system Page 18 of 20 19-12 Radiator and coolant fan, removing and installing Special tools, testers and auxiliary items Pliers VAG 1921 for spring-type clips Removing - Drain coolant Page 19-9 - Disconnect coolant hoses from radiator. - Disconnect harness connectors from coolant fan thermal switch F18 and coolant fan.
Page 139 Cooling system Page 19 of 20 19-13 Installing Install in the reverse order of removal, noting the following: Cooling system, filling Page 19-9 Electrical connections and routing: Repair Manual, Electrical Equipment, Repair Group 97 Headlight adjustment: Repair Manual, Electrical Equipment, Repair Group 94 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 140 Cooling system Page 20 of 20 19-14 Additional information for vehicles with A/C WARNING! The A/C refrigerant is toxic. The A/C circuit must only be opened by specially trained technicians using the proper tools and equipment. CAUTION! Disconnect brackets and support points only.
Page 141 Fuel supply system Page 1 of 24 20-1 Fuel supply system General information Observe safety rules Page 20-7 Observe rules for cleanliness Page 20-9 Accelerator pedal cable Page 20-10 Note: Hose connections are secured with either screw, clamp, or spring-type hose clips. Always replace clamp-type with screw or spring-type clips.
Page 142 Fuel supply system Page 2 of 24 20-2 Fuel filter and fuel tank with attaching parts, removing and installing CAUTION! After repairs to fuel pump or fuel level sensor are complete, be sure fuel supply or return hoses do not make contact with the fuel tank (pump noises may be...
Page 143 Fuel supply system Page 3 of 24 20-3 8 - Reservoir Type shown: Wagon Basic expansion tank in Sedan 9 - Vent hose Filler vent 10 - Vent hose Fuel tank vent, for Wagon only 11 - Return hose Color: Blue From fuel rail...
Page 144 Fuel supply system Page 4 of 24 Remove install with 3217 13 - Flange Note installed position on fuel tank Page 20- Fig. 1 14 - Supply hose 15 - Sealing ring Lubricate with gasoline assemble Replace damaged http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 145 Fuel supply system Page 5 of 24 20-4 16 - Return hose 17 - Fuel level sensor -G- 18 - Fuel Pump (FP) -G6- Removing installing Page 20-12 Checking Page 20-14 19 - Mounting strap Note different lengths 20 - Bracket mounting straps 21 - 25 Nm (18...
Page 146 Fuel supply system Page 6 of 24 Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s): ABA m.y. 1995, Repair Group 24 Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s): ABA m.y. 1996-1997, Repair Group 24 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 147 Fuel supply system Page 7 of 24 20-5 24 - Fuel filter Installation position: Arrow on filter points in direction of flow 25 - Retaining clip 26 - 10 Nm (7 ft 27 - Breather hose Evaporative Emissions (EVAP) canister Page 20- , item 7 28 - Gravity...
Page 148 Fuel supply system Page 8 of 24 closed http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 149 Fuel supply system Page 9 of 24 20-6 Fig. 1 Installation position fuel pump module flange Mark on flange must align with mark on fuel tank Fig. 2 Checking vent valve Lever in rest position: valve closed Lever pressed in direction of arrow: valve open http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW...
Page 150 Fuel supply system Page 10 of 24 20-7 Safety precautions WARNING! When removing and installing the fuel pump or fuel level sensor from a filled or partially filled fuel tank: Fuel supply lines are under pressure! Before removing, wrap a cloth around the connection.
Page 151 Fuel supply system Page 11 of 24 Disconnect harness connectors from all fuel injectors. After the work is completed, erase Diagnostic Trouble Code (DTC) memory. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 152 Fuel supply system Page 12 of 24 20-8 CAUTION! BEFORE disconnecting the battery: Stop the engine. Be sure the ignition is switched OFF (also applies when connecting the battery). Failure to do so may damage the Engine Control Module (ECM). Be sure of the proper radio code (for vehicles equipped with coded anti-theft radio).
Page 153 Fuel supply system Page 13 of 24 20-9 Rules of cleanliness CAUTION! Whenever carrying out work on the fuel supply and fuel injection systems, carefully observe the following five rules of cleanliness. 1 - Thoroughly clean fuel system line and hose connections and the surrounding area before disconnecting.
Page 154 Fuel supply system Page 14 of 24 20-10 Accelerator pedal cable, adjusting Vehicles with manual transmission - Adjust accelerator pedal cable by moving retainer (arrow) on support bracket until throttle valve just reaches wide open throttle position when accelerator pedal is fully depressed.
Page 155 Fuel supply system Page 15 of 24 20-11 - Adjust accelerator pedal cable by moving retainer (arrow) on support bracket until throttle valve just reaches wide open throttle position when accelerator pedal is fully depressed. - Release accelerator pedal. - Connect multimeter to kickdown switch F8 using adapter cables from VW 1594 test kit.
Page 156 Fuel supply system Page 16 of 24 20-12 Fuel pump module, removing and installing Special tools, testers and auxiliary items Ring nut spanner 3217 Removing - Observe safety precautions Page 20-7 CAUTION! Determine correct radio anti-theft coding before disconnecting the battery. - With ignition switched off, disconnect battery negative cable (ground strap).
Page 157 Fuel supply system Page 17 of 24 20-13 - Loosen fuel pump module from bayonet connection by turning to the left and remove. CAUTION! If the fuel pump module is still filled with fue empty before replacing. Installing Install fuel pump module in reverse order of removal.
Page 158 Fuel supply system Page 18 of 24 20-14 Fuel pump, checking Special tools, testers and auxiliary items Remote control VAG 1348/3A with VAG 1348/3-2 adapter cable Voltage tester VAG 1527B Connector test kit VW 1594 Ring nut spanner 3217 Pressure tester VAG 1318 Adapter 1318/1 Adapter 1318/10 Adapter 1318/11...
Page 159 Fuel supply system Page 19 of 24 20-15 Test sequence - Switch ignition on. Fuel pump must be heard to run briefly If the fuel pump does not run: - Switch ignition off. - Remove fuel pump relay J17 from relay panel, position -12-.
Page 160 Fuel supply system Page 20 of 24 20-16 If fuel pump does not run: - Remove luggage compartment floor covering - Disconnect harness connector from fuel tank flange. - Connect VAG 1527B voltage tester to the ou terminals of the connector using adapter cab from VW 1594 test kit.
Page 161 Fuel supply system Page 21 of 24 20-17 Fuel pump delivery rate, checking Test conditions Voltage supply OK. Remote control VAG 1348/3A connected. Test sequence - Remove fuel tank filler cap. WARNING! Fuel supply lines are under pressure! Before removing, wrap a cloth around the connection.
Page 162 Fuel supply system Page 22 of 24 20-18 - Operate VAG 1348/3A remote control and slowly close shutoff valve, until pressure gau shows 1.2 bar (17 psi). Do not change positio of shut-off valve. - Empty measuring container. - Connect multimeter to vehicle battery using adapter cables from VW 1594 test kit, then measure and record voltage.
Page 163 Fuel supply system Page 23 of 24 20-19 If the minimum delivery rate is not reached: - Check the fuel lines and hoses for possible restrictions (kinks) or blockages. - Disconnect supply hose -1- from inlet to fuel filter. - Connect VAG 1318 pressure gauge to hose 1318/10 adapter.
Page 164 Fuel supply system Page 24 of 24 20-20 If the correct delivery rate has been reached, b you still suspect a fuel supply system malfuncti (e.g. intermittent failure of fuel supply system): - Carry out a current draw test of the fuel pum follows: - Reconnect all disconnected fuel hoses/line - Connect a multimeter (Fluke 83 or equivale...
Page 165 Evaporative Emissions (EVAP) system Page 1 of 7 20-21 Evaporative Emissions (EVAP) system Components, removing and installing 1 - Connector 2 - EVAP canister purge regulator valve -N80- Valve opens approx. 5 seconds after ignition is switched With engine warm, valve is activated Motronic...
Page 166 Evaporative Emissions (EVAP) system Page 2 of 7 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s): ABA m.y. 1996-1997, Repair Group 01 Engines up to 07.95 Color: blue Engines from 08.95 Color: black 3 - Bracket On air cleaner housing, lower...
Page 167 Evaporative Emissions (EVAP) system Page 3 of 7 20-22 5 - Throttle valve 6 - Breather hose From gravity valve page 20- 7 - EVAP canister Right front wheel housing Removing: press safety clasp in direction of (arrow) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 168 Evaporative Emissions (EVAP) system Page 4 of 7 20-23 Fuel tank breather, checking Special tools, testers and auxiliary items Hand vacuum pump US 8026 Test conditions Ignition switched off Test sequence - Remove air cleaner: Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection &...
Page 169 Evaporative Emissions (EVAP) system Page 5 of 7 from EVAP canister -4- and plug port on canister. - Operate hand vacuum pump US 8026 several times. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 170 Evaporative Emissions (EVAP) system Page 6 of 7 20-24 Vacuum must not build-up If vacuum builds-up: - Check breather connection -5- on EVAP can -4- for contamination, clean if necessary. - Remove plug from EVAP canister port. - Check EVAP canister purge regulator valve N80- -6- for continuity, and replace if necess (Applies to vehicles up to 07.95 blue valve o If vacuum does not build-up:...
Page 171 Evaporative Emissions (EVAP) system Page 7 of 7 20-25 - Operate hand vacuum pump US 8026 several times. Vacuum must not build-up Note: If the fuel level in the tank is low, hand vacuum pump may need to be operated at least 20-30 times.
Page 172 Exhaust system removal and installation Page 1 of 16 26-1 Exhaust system removal and installation Exhaust manifold, front exhaust pipe and Three Way Catalytic Converter (TWC) Page 26-2 Muffler assembly and mounts Page 26-7 Exhaust Gas Recirculation (EGR) system Page 26-10 Checking Secondary Air Injection (AIR) system Page 26-16 CAUTION!
Page 173 Exhaust system removal and installation Page 2 of 16 26-2 Exhaust manifold, front exhaust pipe and Three Way Catalytic Converter (TWC), removing and installing Vehicles up to 07.95 1 - Bracket For heat deflector 2 - 25 Nm (18 ft lb) 3 - Heat deflector 4 - 35 Nm (26...
Page 174 Exhaust system removal and installation Page 3 of 16 9 - EGR tube http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 175 Exhaust system removal and installation Page 4 of 16 26-3 10 - Heated Oxygen Sensor (HO2S) 50 Nm (37 ft lb) Lube threads with "G5": "G5" must not get into or near sensor slots Remove install with 3337 Checking Repair Manual, 2.0 Liter 4-Cyl.
Page 176 Exhaust system removal and installation Page 5 of 16 sequence Page 26-6 Fig. 1 14 - Heat shield 15 - 10 Nm (7 ft 16 - Front exhaust pipe 17 - Gasket Always replace 18 - Exhaust manifold 19 - 35 Nm (26 ft lb) Fitting Page 26-...
Page 177 Exhaust system removal and installation Page 6 of 16 26-4 Vehicles from 08.95 1 - Bracket For heat deflector 2 - 25 Nm (18 ft lb) 3 - Heat deflector 4 - Heated Oxygen Sensor (HO2S) 2 50 Nm (37 ft lb) Installation location: after three...
Page 178 Exhaust system removal and installation Page 7 of 16 Fuel Injection & Ignition, Engine Code(s): ABA m.y. 1995, Repair Group 24 Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s): ABA m.y. 1996-1997, Repair Group 24 5 - Three Way Catalytic Converter (TWC)
Page 179 Exhaust system removal and installation Page 8 of 16 26-5 7 - Heated Oxygen Sensor (HO2S) 1 50 Nm (37 ft lb) Installation location: before three way catalytic converter Lube threads with "G5": "G5" must not get into or near sensor slots Remove...
Page 180 Exhaust system removal and installation Page 9 of 16 Repair Group 24 8 - 40 Nm (30 ft lb) Tightening sequence Fig. 1 9 - Heat shield 10 - 10 Nm (7 ft 11 - Front exhaust pipe 12 - Gasket Always replace 13 - Exhaust...
Page 181 Exhaust system removal and installation Page 10 of 16 26-6 Fig. 1 Exhaust pipe/manifold tightening sequence http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 182 Exhaust system removal and installation Page 11 of 16 26-7 Muffler assembly and mounts Note: The exhaust system must be aligned lengthwise so that the dimensions -a-, - b- and -c- are maintained. 1 - From TWC 2 - 40 Nm (30 ft lb) 3 - Double clamp...
Page 183 Exhaust system removal and installation Page 12 of 16 marking = dimension a, - 14 - http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 184 Exhaust system removal and installation Page 13 of 16 26-8 11 - Cutting point For repair to individual exhaust components When replacing center muffler Marked by three impressions circumference of connecting pipe through connecting pipe with hack saw (e.g. VAG 1523) at right angle, at...
Page 185 Exhaust system removal and installation Page 14 of 16 circumference of connecting pipe production, center and rear muffler installed as one part. For repairs, center and rear mufflers and a connecting pipe with two clamps supplied individually. through connecting pipe with hack saw (e.g.
Page 186 Exhaust system removal and installation Page 15 of 16 26-9 13 - Dimension Approx. 10 mm (0.39 in.) 14 - Dimension Approx. 5 mm (0.20 in.) 15 - Marking Marked three times on pipe circumference 16 - Marking Marked three times on pipe circumference Manual...
Page 187 Exhaust system removal and installation Page 16 of 16 mufflers and a connecting pipe with two clamps supplied individually. 18 - Center muffler http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 188 Exhaust Gas Recirculation (EGR) system Page 1 of 7 26-10 Exhaust Gas Recirculation (EGR) system Vehicles up to 07.95 only Note: The function of the EGR system is monitored by the On Board Diagnostic system of the Motronic Engine Control Module (ECM) J220.
Page 189 Exhaust Gas Recirculation (EGR) system Page 2 of 7 26-11 9 - 30 Nm (22 ft lb) 10 - To exhaust manifold 11 - To intake manifold, upper 12 - To air cleaner housing, upper 13 - Air Cleaner (ACL) Dirty air cleaner element can...
Page 190 Exhaust Gas Recirculation (EGR) system Page 3 of 7 26-12 Exhaust Gas Recirculation (EGR) valve and EGR temperature sensor, checking Vehicles up to 07.95 only Checking activation of the EGR valve N18: Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s): ABA m.y. 1995, Repair Group 01 Special tools, testers and auxiliary items VAG 1551 Scan Tool (ST) with VAG...
Page 191 Exhaust Gas Recirculation (EGR) system Page 4 of 7 Measuring Value Block" function 08; Display Group 002 Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s): ABA m.y. 1995, Repair Group 01 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 192 Exhaust Gas Recirculation (EGR) system Page 5 of 7 26-13 Test sequence VAG 1551 in "Read Measuring Value Block" function 08 Engine idling Indicated on display: (1, 2, 3 and 4 Read measuring value block 2 Display fields) 1 2 3 4 - Disconnect EGR valve vacuum hose from EGR vacuum regulator solenoid valve -1-.
Page 193 Exhaust Gas Recirculation (EGR) system Page 6 of 7 26-14 If the idle gets worse: - Read EGR temperature in display field 4. Temperature must rise steadily without interruption The value 127.4 C will be displayed if there an interruption, or until this temperature is reached.
Page 194 Exhaust Gas Recirculation (EGR) system Page 7 of 7 26-15 - Check wiring between ECM harness connector and 2-pin connector terminal 1 for short circuit to terminal 2 and/or to ground, according to wiring diagram. Terminal 1 and test box socket 33 Specification: (no continuity) - In addition check wiring for short circuit to...
Page 195 Secondary Air Injection (AIR) system Page 1 of 24 26-16 Secondary Air Injection (AIR) system Function Vehiclesup to 07.95 The Secondary Air Injection (AIR) system directs air in behind the exhaust valve for approx. 30 seconds during a cold start (engine coolant temperature 15 to 35 C or 59 to 95 F).
Page 196 Secondary Air Injection (AIR) system Page 2 of 24 1996-1997, Repair Group 01 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 197 Secondary Air Injection (AIR) system Page 3 of 24 26-17 Secondary Air Injection (AIR) system components, removing and installing Vehicles up to 07.95 Note: The complete system is checked by the On Board Diagnostic program. Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection &...
Page 198 Secondary Air Injection (AIR) system Page 4 of 24 1 - Combi- valve Checking Page 26-23 2 - To connection on hose to vacuum brake booster 3 - Vacuum hose 4 - Harness connector 2-pin http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 199 Secondary Air Injection (AIR) system Page 5 of 24 26-18 5 - Secondary Injection (AIR) solenoid valve - N112-** Checking Page 26-29 6 - T- connector 7 - Vacuum hose 8 - Check valve 9 - Pressure hose Connection should be tight and free of leaks...
Page 200 Secondary Air Injection (AIR) system Page 6 of 24 line 15 - To fitting exhaust manifold Page 26-3 item 19 16 - 10 Nm (7 ft http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 201 Secondary Air Injection (AIR) system Page 7 of 24 26-19 17 - Bracket combi- valve 18 - 25 Nm (18 ft lb) 19 - 10 Nm (7 ft 20 - Pressure hose Connection should be tight and free of leaks 21 - Bracket secondary injection...
Page 202: Table Of Contents
Secondary Air Injection (AIR) system Page 8 of 24 V101-** Checking Page 26-24 27 - To Air Cleaner (ACL) 28 - Intake air hose secondary injection pump motor - 26 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 203: Checking
Secondary Air Injection (AIR) system Page 9 of 24 26-20 Vehicles from 08.95 Note: The complete system is checked by the On Board Diagnostic program. Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s): ABA m.y. 1995, Repair Group 01 Repair Manual, 2.0 Liter 4-Cyl.
Page 204 Secondary Air Injection (AIR) system Page 10 of 24 2-pin 5 - Secondary Injection (AIR) solenoid valve - N112- Checking Page 26-23 6 - Pressure hose Connection should be tight and free of leaks http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 205: 14 - To Air
Secondary Air Injection (AIR) system Page 11 of 24 26-21 7 - Bracket secondary injection pump motor - 12 8 - 10 Nm (7 ft 9 - Bracket For A/C hose 10 - 10 Nm (7 ft 11 - 25 Nm (18 ft lb) 12 - Secondary Injection...
Page 206 Secondary Air Injection (AIR) system Page 12 of 24 15 - To fitting exhaust manifold Page 26-5 item 14 16 - 30 Nm (22 ft lb) 17 - Air injection line 18 - 10 Nm (7 ft http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 207 Secondary Air Injection (AIR) system Page 13 of 24 26-22 19 - 10 Nm (7 ft 20 - Bracket combi- valve 21 - 25 Nm (18 ft lb) 22 - Gasket Always replace 23 - Union http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 208 Secondary Air Injection (AIR) system Page 14 of 24 26-23 Combi-valve and check valve, checking Special tools, testers and auxiliary items US 8026 hand vacuum pump Test sequence - Disconnect vacuum hose -1- from secondary air injection solenoid valve -2-. - Connect US 8026 hand vacuum pump to vacuum hose -1-.
Page 209 Secondary Air Injection (AIR) system Page 15 of 24 26-24 Secondary Air Injection (AIR) pump motor, checking Special tools, testers and auxiliary items VAG 1598/18 test box VW 1594 connector test kit VAG 1527B voltage tester Test conditions Fuse -3- on secondary air injection pump relay J299 -4- OK Test sequence Vehicles up to 07.95...
Page 210 Secondary Air Injection (AIR) system Page 16 of 24 26-25 Vehicles up to 07.95 - Switch ignition off. - Connect VAG 1598/18 test box to ECM wiring harness. - Disconnect pressure hose from check valve -1-. - Switch ignition on. - Connect test box sockets 1 and 50 using adapter cables from VW 1594 connector test kit.
Page 211 Secondary Air Injection (AIR) system Page 17 of 24 26-26 If the motor does not run: - Disconnect 2-pin connector from secondary air injection pump motor V101. - Connect VAG 1527B voltage tester to 2-pin connector using adapter cables from VAG 1594 test kit.
Page 212 Secondary Air Injection (AIR) system Page 18 of 24 26-27 Vehicles from 08.95 - Switch ignition off. - Connect VAG 1598/18 test box to ECM wiring harness. - Disconnect pressure hose from combi-valve -1-. - Switch ignition on. - Bridge test box sockets 1 and 06 using adapter cables from VW 1594 connector test kit.
Page 213 Secondary Air Injection (AIR) system Page 19 of 24 26-28 LED must light up If YES (voltage supply OK): - Replace secondary air injection pump motor. If LED does NOT light up: - Check wiring between test box socket 49 and secondary air injection pump relay using wiring diagram.
Page 214 Secondary Air Injection (AIR) system Page 20 of 24 1996-1997, Repair Group 01 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW... 5/12/2004...
Page 215 Secondary Air Injection (AIR) system Page 21 of 24 26-29 Secondary Air Injection (AIR) solenoid valve, checking Vehicles up to 07.95 Special tools, testers and auxiliary items VW 1594 connector test kit VAG 1527 voltage tester Test conditions Engine oil temperature 15-35 C (59-95 F) Secondary air injection pump motor Test sequence...
Page 216 Secondary Air Injection (AIR) system Page 22 of 24 26-30 - Connect VAG 1527B voltage tester to 2-pin connector using adapter cables from VW 159 connector test kit. - Start engine and run at idle. LED must light-up If YES (voltage supply OK): - Replace secondary air injection solenoid valv If LED does not light up: - Reconnect 2-pin connector.
Page 217 Secondary Air Injection (AIR) system Page 23 of 24 26-31 Vehicles from 08.95 Special tools, testers and auxiliary items VW 1594 connector test kit VAG 1527 voltage tester US 8026 Hand vacuum pump Test conditions Vacuum hoses OK Test sequence - Disconnect vacuum hose to secondary air injection solenoid valve at vacuum line to bra servo, item - 2 -...
Page 218 Secondary Air Injection (AIR) system Page 24 of 24 26-32 Vacuum must build up (valve closed) If vacuum builds up: - Disconnect 2-pin connector from solenoid valve. - Connect VAG 1527B voltage tester to 2-pin harness connector using adapter cables from VW 1594 connector test kit.

Volkswagen Passat 1995 Official Factory Repair Manual

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Summary of Contents for Volkswagen Passat 1995

Page 202: Table Of Contents

Page 203: Checking

Page 205: 14 - To Air