Volkswagen 1995 Golf III GL Service Manual
  1. Manuals
  2. Brands
  3. Volkswagen Manuals
  4. Automobile
  5. 1995 Volkswagen Golf III GL
  6. Service manual
Volkswagen 1995 Golf III GL Service Manual

Volkswagen 1995 Golf III GL Service Manual

2.0l 4-cyl
Hide thumbs
Table of Contents

Advertisement

Quick Links

ENGINE IDENTIFICATION

NOTE:
For engine repair procedures not covered in this article, see ENGINE
OVERHAUL PROCEDURES - GENERAL INFORMATION article in the
GENERAL INFORMATION section.
On all models except Beetle, engine identification number is stamped on a machined pad on left side of
engine block, above crankcase breather. See
left side of cylinder block, near transmission.
ENGINE CODES
Application
2.0L Except Beetle
2.0L Beetle
1 января 2005 г. 1:18:58
1995 Volkswagen Golf III GL
2.0L 4-CYL
1995-98 ENGINES
Volkswagen - 2.0L 4-Cylinder
Fig. 1
. On Beetle, engine identification number is located on
Page 1
© 2004 Mitchell Repair Information Company, LLC.
Code
ABA
AEG

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 1995 Volkswagen Golf III GL and is the answer not in the manual?

Questions and answers

Related Manuals for Volkswagen 1995 Volkswagen Golf III GL

Summary of Contents for Volkswagen 1995 Volkswagen Golf III GL

  • Page 1 1995 Volkswagen Golf III GL 2.0L 4-CYL 1995-98 ENGINES Volkswagen - 2.0L 4-Cylinder ENGINE IDENTIFICATION NOTE: For engine repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL INFORMATION section. On all models except Beetle, engine identification number is stamped on a machined pad on left side of engine block, above crankcase breather.
  • Page 2 1995 Volkswagen Golf III GL 2.0L 4-CYL Fig. 1: Locating Engine Identification Number (Except Beetle) Courtesy of VOLKSWAGEN UNITED STATES, INC. ADJUSTMENTS VALVE CLEARANCE Engine is equipped with hydraulic lifters. Adjustment is not necessary. Valve noise during startup is considered normal.
  • Page 3 1995 Volkswagen Golf III GL 2.0L 4-CYL NOTE: For reassembly reference, label all electrical connectors,vacuum hoses and fuel lines before removal. Place mating marks on other major assemblies before removal. FUEL PRESSURE RELEASE Remove fuel pump relay (located in fuse/relay panel). Crank engine for 5 seconds. Turn ignition switch off.
  • Page 4 1995 Volkswagen Golf III GL 2.0L 4-CYL 1 января 2005 г. 1:18:59 Page 4 © 2004 Mitchell Repair Information Company, LLC.
  • Page 5 1995 Volkswagen Golf III GL 2.0L 4-CYL Fig. 2: Removing Front Fenders & Bumper Cover Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 января 2005 г. 1:18:59 Page 5 © 2004 Mitchell Repair Information Company, LLC.
  • Page 6 1995 Volkswagen Golf III GL 2.0L 4-CYL Fig. 3: Sliding Out Lock Carrier Courtesy of VOLKSWAGEN UNITED STATES, INC. Fig. 4: Exploded View Of Lock Carrier Courtesy of VOLKSWAGEN UNITED STATES, INC. ENGINE NOTE: Engine is removed from vehicle with transaxle attached. Obtain radio anti- theft code before disconnecting battery.
  • Page 7 1995 Volkswagen Golf III GL 2.0L 4-CYL 4. Remove fuel injectors. Remove rear engine mount. Remove complete transaxle mount. Disconnect exhaust pipe from exhaust manifold. On M/T models, disconnect clutch cable. Attach Engine Sling (2024A) to engine. On A/T models, remove crankshaft pulley and water pump pulley. Install engine sling on engine lift hooks.
  • Page 8 1995 Volkswagen Golf III GL 2.0L 4-CYL Fig. 5: Placing Lock Carrier In Service Position Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 января 2005 г. 1:18:59 Page 8 © 2004 Mitchell Repair Information Company, LLC.
  • Page 9 1995 Volkswagen Golf III GL 2.0L 4-CYL Fig. 6: Removing A/C Condenser With Hoses Attached Courtesy of VOLKSWAGEN UNITED STATES, INC. Removal (Beetle) 1. Disconnect and remove battery. Relieve fuel pressure. See FUEL PRESSURE RELEASE . Remove engine cover. Remove power steering reservoir from battery tray with hoses attached and secure aside.
  • Page 10 1995 Volkswagen Golf III GL 2.0L 4-CYL Support engine/transmission assembly with suitable jack. 7. Remove engine mount-to-engine bolts. Remove transmission mount-to-transmission bolts. Carefully lower engine/transmission assembly. Ensure power steering hoses clear transmission. Separate transmission from engine. Installation (Except Beetle) 1. To install, reverse removal procedure. Engine alignment adjustment is necessary whenever engine is removed or mounts are loosened.
  • Page 11 1995 Volkswagen Golf III GL 2.0L 4-CYL Fig. 7: Aligning Engine/Transmission Assembly (Beetle) Courtesy of VOLKSWAGEN UNITED STATES, INC. ENGINE MOUNT RUBBER BUSHING NOTE: To see exploded views of component locations, see Fig. 10 -Fig. 13 . Removal & Installation (Cabrio, Golf, GTI & Jetta) 1.
  • Page 12 1995 Volkswagen Golf III GL 2.0L 4-CYL Fig. 8: Removing Engine Mount Rubber Bushings Courtesy of AUDI OF AMERICA, INC. 1 января 2005 г. 1:18:59 Page 12 © 2004 Mitchell Repair Information Company, LLC.
  • Page 13 1995 Volkswagen Golf III GL 2.0L 4-CYL Fig. 9: Installing Engine Mount Rubber Bushing Washers Courtesy of AUDI OF AMERICA, INC. 1 января 2005 г. 1:18:59 Page 13 © 2004 Mitchell Repair Information Company, LLC.
  • Page 14 1995 Volkswagen Golf III GL 2.0L 4-CYL Fig. 10: Front Engine/Transmission Mount Courtesy of AUDI OF AMERICA, INC. 1 января 2005 г. 1:18:59 Page 14 © 2004 Mitchell Repair Information Company, LLC.
  • Page 15 1995 Volkswagen Golf III GL 2.0L 4-CYL Fig. 11: Right Rear Engine/Transmission Mount Courtesy of AUDI OF AMERICA, INC. 1 января 2005 г. 1:18:59 Page 15 © 2004 Mitchell Repair Information Company, LLC.
  • Page 16 1995 Volkswagen Golf III GL 2.0L 4-CYL Fig. 12: Right Engine/Transmission Mount (Cabrio Only) Courtesy of AUDI OF AMERICA, INC. 1 января 2005 г. 1:19:00 Page 16 © 2004 Mitchell Repair Information Company, LLC.
  • Page 17 1995 Volkswagen Golf III GL 2.0L 4-CYL Fig. 13: Left Rear Engine/Transmission Mount Courtesy of AUDI OF AMERICA, INC. INTAKE MANIFOLD (UPPER & LOWER) Removal and installation procedures are not available from manufacturer. See TORQUE SPECIFICATIONS . CYLINDER HEAD CAUTION: DO NOT turn crankshaft or camshaft with timing belt removed.
  • Page 18 1995 Volkswagen Golf III GL 2.0L 4-CYL valve seats or between valve seat and spark plug threads are considered acceptable by manufacturer. Removal (Beetle) 1. Allow engine to cool. Disconnect negative battery cable. Remove engine cover. Release fuel pressure. See FUEL PRESSURE RELEASE . Drain engine coolant from radiator. Drain engine coolant from cylinder block by disconnecting coolant hose from oil cooler.
  • Page 19 1995 Volkswagen Golf III GL 2.0L 4-CYL 1. Ensure cylinder head bolt holes are clean and free of oil or coolant. Position piston No. 1 to TDC. Rotate crankshaft counterclockwise slightly. 2. Install Guide Pins (3450/2A) into bolt holes No. 7 and 9. See Fig. 14 . Install NEW head gasket on cylinder block with part number facing up.
  • Page 20 1995 Volkswagen Golf III GL 2.0L 4-CYL procedure. Removal & Installation (Beetle) 1. Remove timing belt. See TIMING BELT . Using Crankshaft Holder (3415), remove timing belt drive pulley. Install timing belt drive pulley bolt finger tight. Rotate inner part of Oil Seal Extractor (3203) outward 9 turns and tighten set screw.
  • Page 21 1995 Volkswagen Golf III GL 2.0L 4-CYL 1 января 2005 г. 1:19:00 Page 21 © 2004 Mitchell Repair Information Company, LLC.
  • Page 22 1995 Volkswagen Golf III GL 2.0L 4-CYL Fig. 15: Removing & Installing Ribbed (Accessory) Drive Belts (Without A/C) Courtesy of VOLKSWAGEN UNITED STATES, INC. Fig. 16: Removing & Installing Ribbed (Accessory) Drive Belts (With A/C) Courtesy of VOLKSWAGEN UNITED STATES, INC.
  • Page 23 1995 Volkswagen Golf III GL 2.0L 4-CYL 1 января 2005 г. 1:19:00 Page 23 © 2004 Mitchell Repair Information Company, LLC.
  • Page 24 1995 Volkswagen Golf III GL 2.0L 4-CYL Fig. 17: Aligning Crankshaft And Distributor Timing Marks (Except Beetle) Courtesy of VOLKSWAGEN UNITED STATES, INC. Fig. 18: Aligning Camshaft Timing Marks Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 января 2005 г. 1:19:00 Page 24 ©...
  • Page 25 1995 Volkswagen Golf III GL 2.0L 4-CYL Fig. 19: Removing Timing Belt (Except Beetle) Courtesy of VOLKSWAGEN UNITED STATES, INC. Installation NOTE: Disregard marking on intermediate shaft drive belt sprocket. 1. Move camshaft slightly off its timing mark. Place crankshaft at TDC by aligning flywheel (M/T) or drive plate (A/T) TDC marks.
  • Page 26 1995 Volkswagen Golf III GL 2.0L 4-CYL 1 января 2005 г. 1:19:00 Page 26 © 2004 Mitchell Repair Information Company, LLC.
  • Page 27 1995 Volkswagen Golf III GL 2.0L 4-CYL Fig. 20: Aligning Crankshaft & Distributor Timing Marks Courtesy of VOLKSWAGEN UNITED STATES, INC. Fig. 21: Aligning Camshaft Timing Marks Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 января 2005 г. 1:19:00 Page 27...
  • Page 28 1995 Volkswagen Golf III GL 2.0L 4-CYL Fig. 22: Checking Timing Belt Tension (Except Beetle) Courtesy of VOLKSWAGEN UNITED STATES, INC. Removal (Thermo Tensioner Roller; 1997& Up, Engine Code "ABA") CAUTION: To prevent valves from contacting piston, DO NOT rotate camshaft or crankshaft with timing belt removed.
  • Page 29 1995 Volkswagen Golf III GL 2.0L 4-CYL Fig. 23: Identifying Timing Belt & Related Components (Thermo Tensioner Roller) Courtesy of VOLKSWAGEN UNITED STATES, INC. Installation (Thermo Tensioner Roller) CAUTION: DO NOT turn the camshaft while any piston is at TDC position. There is risk of damage to valves and piston crowns.
  • Page 30 1995 Volkswagen Golf III GL 2.0L 4-CYL 1. Place timing belt on crankshaft gear (note running direction of belt). Ensure crankshaft timing is correct. See Fig. 20 . Align mark on camshaft drive sprocket with mark on cylinder head cover and/or timing belt guard.
  • Page 31 1995 Volkswagen Golf III GL 2.0L 4-CYL Fig. 24: Identifying Thermo Tensioner Roller Assembly Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 января 2005 г. 1:19:00 Page 31 © 2004 Mitchell Repair Information Company, LLC.
  • Page 32 1995 Volkswagen Golf III GL 2.0L 4-CYL Fig. 25: Installing & Adjusting Thermo Tensioner Roller Courtesy of VOLKSWAGEN UNITED STATES, INC. Removal (Engine Code AEG) CAUTION: To prevent valves from contacting piston, DO NOT rotate camshaft or crankshaft with timing belt removed. Valve damage may result.
  • Page 33 1995 Volkswagen Golf III GL 2.0L 4-CYL Remove front engine mount bracket. If timing belt is to be reused, mark direction of rotation on belt. NOTE: To check timing belt tensioner operation. See TESTING (SEMI- AUTOMATIC TOOTHED BELT TENSIONING ROLLER) .
  • Page 34 1995 Volkswagen Golf III GL 2.0L 4-CYL NOTE: To check timing belt tensioner operation. See TESTING (SEMI-AUTOMATIC TOOTHED BELT TENSIONING ROLLER) . 1. Ensure pistons are NOT at TDC. Align camshaft timing marks. See Fig. 28 . Align crankshaft timing marks.
  • Page 35 1995 Volkswagen Golf III GL 2.0L 4-CYL Fig. 27: Checking Timing Belt Tension (Beetle) Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 января 2005 г. 1:19:01 Page 35 © 2004 Mitchell Repair Information Company, LLC.
  • Page 36 1995 Volkswagen Golf III GL 2.0L 4-CYL 1 января 2005 г. 1:19:01 Page 36 © 2004 Mitchell Repair Information Company, LLC.
  • Page 37 1995 Volkswagen Golf III GL 2.0L 4-CYL Fig. 28: Aligning Crankshaft & Camshaft Timing Marks (Beetle - AEG Engine) Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 января 2005 г. 1:19:01 Page 37 © 2004 Mitchell Repair Information Company, LLC.
  • Page 38 1995 Volkswagen Golf III GL 2.0L 4-CYL 1 января 2005 г. 1:19:01 Page 38 © 2004 Mitchell Repair Information Company, LLC.
  • Page 39 1995 Volkswagen Golf III GL 2.0L 4-CYL Fig. 29: Locating TDC Mark on Transaxle (Beetle - AEG Engine) Courtesy of VOLKSWAGEN UNITED STATES, INC. Fig. 30: Checking Timing Belt Tension (Beetle - AEG Engine) Courtesy of VOLKSWAGEN UNITED STATES, INC.
  • Page 40 1995 Volkswagen Golf III GL 2.0L 4-CYL Check camshaft drive belt tension again. Tensioning roller must return to its original position (notch - 1- and indicator -2- align again). See Fig. 30 . To complete installation, reverse removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS .
  • Page 41 1995 Volkswagen Golf III GL 2.0L 4-CYL Installation Coat new seal lips lightly with engine oil. Using Installer (10-203), install seal until flush. To complete installation, reverse removal procedure. CAMSHAFT CAUTION: DO NOT turn crankshaft or camshaft with timing belt removed. Valve damage may result.
  • Page 42 1995 Volkswagen Golf III GL 2.0L 4-CYL Fig. 32: Identifying Cylinder Head Components Courtesy of VOLKSWAGEN UNITED STATES, INC. 1 января 2005 г. 1:19:01 Page 42 © 2004 Mitchell Repair Information Company, LLC.
  • Page 43 1995 Volkswagen Golf III GL 2.0L 4-CYL INTERMEDIATE SHAFT NOTE: It may be necessary to remove engine in order to remove intermediate shaft. Procedure for Beetle is not available from manufacturer. CAUTION: DO NOT turn crankshaft or camshaft with timing belt removed. Valve damage may result.
  • Page 44 1995 Volkswagen Golf III GL 2.0L 4-CYL engine with coolant. OIL PAN Oil pan can be removed and installed with engine in vehicle. No further information is available from manufacturer. OVERHAUL CYLINDER HEAD NOTE: On ABA (except Beetle) engine, cracks .02" (.5 mm) wide or less between valve seats or between valve seat and spark plug threads are considered acceptable by manufacturer.
  • Page 45 1995 Volkswagen Golf III GL 2.0L 4-CYL Fig. 33: Measuring Valve Installed Height Courtesy of VOLKSWAGEN UNITED STATES, INC. 2. This measurement determines installed valve height. Subtract measured distance from minimum specification. See MINIMUM VALVE INSTALLED HEIGHT table. MINIMUM VALVE INSTALLED HEIGHT Application In.
  • Page 46 1995 Volkswagen Golf III GL 2.0L 4-CYL Test lifters by pushing then downward with a suitable wooden dowel with camshaft lobe pointing up. If lifter can be pushed downward more than .004" (.10 mm), replace lifters. Lifters must be replaced as a set.
  • Page 47 1995 Volkswagen Golf III GL 2.0L 4-CYL Fig. 34: Assembling Piston & Rod 1 января 2005 г. 1:19:01 Page 47 © 2004 Mitchell Repair Information Company, LLC.
  • Page 48 1995 Volkswagen Golf III GL 2.0L 4-CYL Courtesy of VOLKSWAGEN UNITED STATES, INC. 2. Mark piston in relation to pin. Remove circlips from ends of pin bore. Use Piston Pin Replacer/Installer (VW 222A) to remove and install piston pin. If pin is too tight, heat piston to 140°F (60°C).
  • Page 49 1995 Volkswagen Golf III GL 2.0L 4-CYL 1 января 2005 г. 1:19:02 Page 49 © 2004 Mitchell Repair Information Company, LLC.
  • Page 50 1995 Volkswagen Golf III GL 2.0L 4-CYL Fig. 35: Crankshaft Assembly Courtesy of VOLKSWAGEN UNITED STATES, INC. Thrust Bearing Insert feeler gauge between No. 3 main bearing and crankshaft thrust face to measure end play. See Fig. 35 . Replace thrust bearing as necessary. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.
  • Page 51 1995 Volkswagen Golf III GL 2.0L 4-CYL Backlash .002 (.05) Service Limit .008 (.20) Axial Play Limit .006 (.15) Beetle (AEG) Information is not available from manufacturer. TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Bracket-To-Engine Bolt Except Beetle...
  • Page 52 1995 Volkswagen Golf III GL 2.0L 4-CYL Except Beetle 18 (25) Beetle 11 (15) Engine Mounts Beetle Front Engine Mount-To-Body Long Bolts Step 1 30 (40) Step 2 Additional 90 Degrees Short Bolt 18 (25) Front Engine Mount-To-Engine Bracket Step 1...
  • Page 53 1995 Volkswagen Golf III GL 2.0L 4-CYL Beetle 33 (45) Engine-To-Transaxle 12-mm Bolt 59 (80) Exhaust Manifold-To-Cylinder Head Bolt & Nut 18 (25) Exhaust Pipe-To-Manifold Nut 30 (40) Exhaust Pipe-To-Support Bracket Bolt 18 (25) Flywheel-To-Crankshaft Step 1 44 (60) Step 2...
  • Page 54 1995 Volkswagen Golf III GL 2.0L 4-CYL Valve Cover Retaining Nut 89 (10) Water Pump-To-Housing (Except Beetle) 89 (10) Use NEW bolts. On Beetle, perform steps 1, 3 and 4. For engine and transmission mount torque specifications, see Fig. 10 -Fig. 13 .
  • Page 55 1995 Volkswagen Golf III GL 2.0L 4-CYL Minimum 2.1243 (53.957) 1st Undersize Nominal 2.1161 (53.749) Maximum 2.1170 (53.772) Minimum 2.1145 (53.708) 2nd Undersize Nominal 2.1063 (53.500) Maximum 2.1071 (53.520) Minimum 2.1047 (53.459) 3rd Undersize Nominal 2.0965 (53.251) Maximum 2.0973 (53.271) Minimum 2.0949 (53.210)
  • Page 56 1995 Volkswagen Golf III GL 2.0L 4-CYL Information is not available from manufacturer. CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS (AEG ENGINE) Application In. (mm) Crankshaft End Play Standard .003-.009 (.07-.23) Service Limit .012 (.30) Main Bearings Journal Diameter Standard Nominal 2.1260 (54.000)
  • Page 57 1995 Volkswagen Golf III GL 2.0L 4-CYL Maximum 1.8631 (47.323) Minimum 1.8610 (47.270) 3rd Undersize Nominal 1.8524 (47.051) Maximum 1.8533 (47.074) Minimum 1.8510 (47.015) Journal Out-Of-Round Journal Taper Oil Clearance Standard .0004-.0024 (.010-.060) Service Limit .0047 (.120) Information is not available from manufacturer.
  • Page 58 1995 Volkswagen Golf III GL 2.0L 4-CYL Service Limit (ABA Engine) .039 (1.00) Service Limit (AEG Engine) .031 (.80) Side Clearance ABA Engine Standard .001-.002 (.02-.05) Service Limit .006 (.15) AEG Engine Standard .002-.004 (.06-.09) Service Limit .008 (.20) No. 3 (Oil)
  • Page 59 1995 Volkswagen Golf III GL 2.0L 4-CYL Exhaust Valves Face Angle 45° Head Diameter 1.289-1.301" (32.75-33.05 mm) Length 3.588" (91.15 mm) Minimum Margin Stem Diameter .272" (6.92 mm) Valve Stem Installed Height (Minimum) 1.34 (34.1) DO NOT machine valves; hand lap only.
  • Page 60 1995 Volkswagen Golf III GL 2.0L 4-CYL Oil Clearance (Maximum) .004 (.10) 1 января 2005 г. 1:19:02 Page 60 © 2004 Mitchell Repair Information Company, LLC.

Table of Contents

Save PDF