Volkswagen 1995 Volkswagen Golf III GL Service Manual Download | Manualshive

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1995 Volkswagen Golf III GL

2.0L 4-CYL

1

января

2005

г

. 1:19:02

Page 49 © 2004 Mitchell Repair Information Company, LLC.

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Summary of Contents for 1995 Volkswagen Golf III GL

Page 1: ...le engine identification number is located on left side of cylinder block near transmission ENGINE CODES NOTE For engine repair procedures not covered in this article see ENGINE OVERHAUL PROCEDURES GE...

Page 2: ...MOVAL INSTALLATION CAUTION Radio cassette or radio CD player is equipped with an anti theft protection circuit Whenever battery is disconnected radio will go into anti theft mode When battery is recon...

Page 3: ...3 screws from under front of bumper cover Remove 16 screws under hood attaching fenders and bumper cover to vehicle With a helper remove front fenders and bumper cover as an assembly 2 Disconnect hoo...

Page 4: ...1995 Volkswagen Golf III GL 2 0L 4 CYL 1 2005 1 18 59 Page 4 2004 Mitchell Repair Information Company LLC...

Page 5: ...Fig 2 Removing Front Fenders Bumper Cover Courtesy of VOLKSWAGEN UNITED STATES INC 1995 Volkswagen Golf III GL 2 0L 4 CYL 1 2005 1 18 59 Page 5 2004 Mitchell Repair Information Company LLC...

Page 6: ...ed Set radiator condenser assembly in front of engine mount See Fig 6 Remove A C compressor with hoses attached and set aside with radiator condenser assembly DO NOT stress refrigerant hoses 3 On all...

Page 7: ...nnect 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 Carefully raise engine and transaxle out o...

Page 8: ...Fig 5 Placing Lock Carrier In Service Position Courtesy of VOLKSWAGEN UNITED STATES INC 1995 Volkswagen Golf III GL 2 0L 4 CYL 1 2005 1 18 59 Page 8 2004 Mitchell Repair Information Company LLC...

Page 9: ...g fan on right side of vehicle if equipped Remove power steering hose brackets Remove power steering pump with hoses attached and set aside 4 On vehicles equipped with A C it is not necessary to disch...

Page 10: ...ransaxle to allow position to shift as necessary Evenly tighten mount bolts in reverse order of loosening Fill fluids to proper level Adjust clutch pedal if equipped Tighten all bolts and nuts to spec...

Page 11: ...pliers Remove spacer sleeves and pull off bonded rubber bushings see Fig 8 Install new bonded rubber bushings and insert spacer sleeves as far as possible 3 Install washers 1 over Peening Punch 3302 a...

Page 12: ...Fig 8 Removing Engine Mount Rubber Bushings Courtesy of AUDI OF AMERICA INC 1995 Volkswagen Golf III GL 2 0L 4 CYL 1 2005 1 18 59 Page 12 2004 Mitchell Repair Information Company LLC...

Page 13: ...Fig 9 Installing Engine Mount Rubber Bushing Washers Courtesy of AUDI OF AMERICA INC 1995 Volkswagen Golf III GL 2 0L 4 CYL 1 2005 1 18 59 Page 13 2004 Mitchell Repair Information Company LLC...

Page 14: ...Fig 10 Front Engine Transmission Mount Courtesy of AUDI OF AMERICA INC 1995 Volkswagen Golf III GL 2 0L 4 CYL 1 2005 1 18 59 Page 14 2004 Mitchell Repair Information Company LLC...

Page 15: ...Fig 11 Right Rear Engine Transmission Mount Courtesy of AUDI OF AMERICA INC 1995 Volkswagen Golf III GL 2 0L 4 CYL 1 2005 1 18 59 Page 15 2004 Mitchell Repair Information Company LLC...

Page 16: ...Fig 12 Right Engine Transmission Mount Cabrio Only Courtesy of AUDI OF AMERICA INC 1995 Volkswagen Golf III GL 2 0L 4 CYL 1 2005 1 19 00 Page 16 2004 Mitchell Repair Information Company LLC...

Page 17: ...emove crankcase breather pressure regulating valve Remove upper part of intake manifold Remove cylinder head cover rocker arm cover Remove timing belt See TIMING BELT Disconnect exhaust pipe from exha...

Page 18: ...or warpage Maximum warpage is 004 100 mm Check minimum cylinder head height and replace cylinder head if necessary See CYLINDER HEAD table under ENGINE SPECIFICATIONS Installation Except Beetle 1 Inst...

Page 19: ...Courtesy of VOLKSWAGEN UNITED STATES INC FRONT COVER OIL SEAL Removal Installation Except Beetle 1 Remove timing belt See TIMING BELT Using Crankshaft Holder 3099 remove timing belt drive pulley Rotat...

Page 20: ...so that it can be reinstalled the same way See Fig 15 and Fig 16 Lift belt tensioner with 3299 accessory belt installation tool to relieve belt tension and remove belt from generator pulley Remove V b...

Page 21: ...1995 Volkswagen Golf III GL 2 0L 4 CYL 1 2005 1 19 00 Page 21 2004 Mitchell Repair Information Company LLC...

Page 22: ...ut 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 1995 Volkswagen Golf III GL 2 0L 4 CYL 1 2005...

Page 23: ...1995 Volkswagen Golf III GL 2 0L 4 CYL 1 2005 1 19 00 Page 23 2004 Mitchell Repair Information Company LLC...

Page 24: ...g Marks Except Beetle Courtesy of VOLKSWAGEN UNITED STATES INC Fig 18 Aligning Camshaft Timing Marks Courtesy of VOLKSWAGEN UNITED STATES INC 1995 Volkswagen Golf III GL 2 0L 4 CYL 1 2005 1 19 00 Page...

Page 25: ...nstall drive belt tensioner Rotate tensioner clockwise to tension timing belt Tighten tensioner mounting bolt to specification See TORQUE SPECIFICATIONS 3 Rotate engine 2 times and check belt tension...

Page 26: ...1995 Volkswagen Golf III GL 2 0L 4 CYL 1 2005 1 19 00 Page 26 2004 Mitchell Repair Information Company LLC...

Page 27: ...Timing Marks Courtesy of VOLKSWAGEN UNITED STATES INC Fig 21 Aligning Camshaft Timing Marks Courtesy of VOLKSWAGEN UNITED STATES INC 1995 Volkswagen Golf III GL 2 0L 4 CYL 1 2005 1 19 00 Page 27 2004...

Page 28: ...2 Mark the running direction on the timing belt Remove fastener for timing belt thermo tension roller Remove belt and roller Remove timing belt thermo tensioner See Fig 23 CAUTION To prevent valves fr...

Page 29: ...bolt washer assembly 2 to specified torque 62 97 INCH lbs 7 11 N m Tighten Collar screw and 6 mm fastening nut to specified torque 11 15 Ft lbs 15 20 N m See TORQUE SPECIFICATIONS THERMO TENSIONER 19...

Page 30: ...iston 2 lifts up approx 0 040 in 1 0 mm See Fig 24 3 Tighten mounting bolt 3 by hand Rotate engine 2 revolutions in running direction Counter hold thermo tension roller with two pin spanner and tighte...

Page 31: ...Fig 24 Identifying Thermo Tensioner Roller Assembly Courtesy of VOLKSWAGEN UNITED STATES INC 1995 Volkswagen Golf III GL 2 0L 4 CYL 1 2005 1 19 00 Page 31 2004 Mitchell Repair Information Company LLC...

Page 32: ...stall 10 222A Support with Legs 10 222A 8 and remove front engine mount 2 Remove crankshaft pulley Remove center and lower timing belt covers Raise engine slightly CAUTION To prevent valves from conta...

Page 33: ...nterclockwise slightly to ensure pistons are not at TDC Fig 26 Exploded View Of Timing Belt Components Beetle AEG Engine Courtesy of VOLKSWAGEN UNITED STATES INC Installation NOTE To check timing belt...

Page 34: ...securing nut to 20 Nm 15 ft lb See Fig 30 4 Turn crankshaft two turns in engine direction of rotation until the engine is again at TDC cyl No 1 When doing this it is important that the last 45 1 8 tur...

Page 35: ...Fig 27 Checking Timing Belt Tension Beetle Courtesy of VOLKSWAGEN UNITED STATES INC 1995 Volkswagen Golf III GL 2 0L 4 CYL 1 2005 1 19 01 Page 35 2004 Mitchell Repair Information Company LLC...

Page 36: ...1995 Volkswagen Golf III GL 2 0L 4 CYL 1 2005 1 19 01 Page 36 2004 Mitchell Repair Information Company LLC...

Page 37: ...Aligning Crankshaft Camshaft Timing Marks Beetle AEG Engine Courtesy of VOLKSWAGEN UNITED STATES INC 1995 Volkswagen Golf III GL 2 0L 4 CYL 1 2005 1 19 01 Page 37 2004 Mitchell Repair Information Comp...

Page 38: ...1995 Volkswagen Golf III GL 2 0L 4 CYL 1 2005 1 19 01 Page 38 2004 Mitchell Repair Information Company LLC...

Page 39: ...dicator 2 must move use mirror Turn crankshaft two rotations in direction of engine direction until engine is again at TDC cyl 1 When doing this it is important that last 45 1 8 turn turn is performed...

Page 40: ...all models except Beetle use Camshaft Holder 3036 to hold camshaft sprocket Remove camshaft sprocket Remove Woodruff key 2 Install camshaft sprocket bolt and washer until washer is tight against cams...

Page 41: ...d last bearing caps installed Installation 1 Place camshaft in cylinder head Ensure lobes for No 1 cylinder are pointed upward See Fig 32 Install camshaft bearing caps Camshaft bearing caps are offset...

Page 42: ...Fig 32 Identifying Cylinder Head Components Courtesy of VOLKSWAGEN UNITED STATES INC 1995 Volkswagen Golf III GL 2 0L 4 CYL 1 2005 1 19 01 Page 42 2004 Mitchell Repair Information Company LLC...

Page 43: ...pump pulley Remove bolts and remove water pump assembly To install reverse removal procedure Tighten bolts to specification See TORQUE SPECIFICATIONS Removal Installation Beetle 1 Drain engine coolant...

Page 44: ...placement valve guides have shoulder on camshaft end Press replacement guides out from combustion chamber side 2 Lubricate new valve guides with oil Using Valve Guide Installer 3121 press valve guide...

Page 45: ...fication replace cylinder head assembly If valve installed height is too low or too high cam followers will not work correctly Valves Measure valve stem diameter and valve margin If not within specifi...

Page 46: ...ylinder number prior to removal Ensure engine front arrow is marked on top of piston and front mark exists on rod and cap See Fig 34 Pistons and rods are to be replaced in sets of 4 Rod cap bolts and...

Page 47: ...Fig 34 Assembling Piston Rod 1995 Volkswagen Golf III GL 2 0L 4 CYL 1 2005 1 19 01 Page 47 2004 Mitchell Repair Information Company LLC...

Page 48: ...e to measure bearing oil clearance Tighten connecting rod nuts to 22 ft lbs 30 N m when measuring oil clearance DO NOT turn additional 90 degrees Measure connecting rod side play Replace or machine as...

Page 49: ...1995 Volkswagen Golf III GL 2 0L 4 CYL 1 2005 1 19 02 Page 49 2004 Mitchell Repair Information Company LLC...

Page 50: ...Check oil pressure with engine at normal operating temperature Minimum oil pressure at idle is 29 psi 2 0 kg cm 2 FD Minimum oil pressure at 2000 RPM is 43 psi 3 0 kg cm 2 FD OIL PUMP Removal Install...

Page 51: ...Beetle 59 80 Beetle 74 100 Connecting Rod Bearing Cap Nut 1 Step 1 22 30 Step 2 Additional 90 Degrees Crankshaft Main Bearing Cap Bolt 1 Step 1 48 65 Step 2 Additional 90 Degrees Crankshaft Timing Spr...

Page 52: ...8 25 Right Rear Mount To Engine Bracket 18 25 Right Rear Mount To Bracket 37 50 Transmission Mount To Body Cabrio Golf GTI Jetta 3 Transmission Mount To Body Except Cabrio Golf GTI Jetta Long Bolts 1...

Page 53: ...le 11 15 Oil Pump Sprocket Beetle 15 20 Oil Pump Chain Tensioner Bolt Beetle 11 15 Oil Pan Drain Plug 22 30 Pressure Plate To Flywheel Bolt 1 Step 1 22 30 Step Additional 90 Degrees Starter Mount Bolt...

Page 54: ...10 N m Application Ft Lbs N m Collar Screw Bolt 11 15 15 20 Torx R Bolt 18 25 INCH Lbs N m Bolt Washer Assembly 2 62 97 7 11 Nut 62 97 7 11 Application Specification Displacement 121 Cu In 2 0L Bore 3...

Page 55: ...Connecting Rod Bearings Journal Diameter Standard Nominal 1 8819 47 800 Maximum 1 8828 47 823 Minimum 1 8803 47 760 1st Undersize Nominal 1 8720 47 550 Maximum 1 8729 47 572 Minimum 1 8704 47 508 2nd...

Page 56: ...inal 2 1063 53 500 Maximum 2 1070 53 517 Minimum 2 1048 53 463 3rd Undersize Nominal 2 0965 53 250 Maximum 2 0971 53 267 Minimum 2 0950 53 213 Journal Out Of Round 1 Journal Taper 1 Oil Clearance Stan...

Page 57: ...t available from manufacturer Application In mm Bore Diameters 1 Center To Center Length 1 Side Play Standard 0020 0122 05 31 Service Limit 015 37 1 Information is not available from manufacturer Appl...

Page 58: ...1 Measurement includes graphite coating For new pistons subtract 0 0006 0 015 mm from piston diameter 2 Information is not available from manufacturer Application In mm Cylinder Bore Standard Diamete...

Page 59: ...2 00 mm Exhaust Valve Seat Angle 45 Seat Width 094 2 40 mm Valve Guides Intake Valve Valve Guide Installed Height 1 Valve Stem To Guide Oil Clearance 2 040 1 00 mm Exhaust Valve Valve Guide Installed...

Page 60: ...Oil Clearance Maximum 004 10 1995 Volkswagen Golf III GL 2 0L 4 CYL 1 2005 1 19 02 Page 60 2004 Mitchell Repair Information Company LLC...

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