Volkswagen 1995 Volkswagen Golf III GL, 1995 Golf III GL Service Manual

1995-98 ENGINES

Volkswagen - 2.0L 4-Cylinder

ENGINE IDENTIFICATION

On all models except Beetle, engine identification number is stamped on a machined pad on left side of engine block, above crankcase breather. See

Fig. 1

. On Beetle, 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 - GENERAL INFORMATION article in the GENERAL INFORMATION section.

Application Code

2.0L Except Beetle ABA

2.0L Beetle AEG

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.

REMOVAL & 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 reconnected, radio will display CODE, and will be inoperative until proper code number is entered. Obtain security code before disconnecting battery.

1995 Volkswagen Golf III GL

2.0L 4-CYL

FUEL PRESSURE RELEASE

Remove fuel pump relay (located in fuse/relay panel). Crank engine for 5 seconds. Turn ignition switch off. Reinstall fuel pump relay.

RADIATOR

Removal & Installation (Jetta)

1. Disconnect and remove battery. Drain engine coolant by disconnecting coolant hose from thermostat housing. Disconnect radiator hoses. Disconnect fan harness connectors. Remove headlights. Remove radiator mounting bolts.

2. On vehicles equipped with A/C, remove air cleaner. Remove A/C line retaining clamps. DO NOT disconnect hoses. Separate condenser from radiator and move radiator forward.

3. On all vehicles, remove radiator. To install, reverse removal procedure. Fill cooling system. Adjust headlights.

Removal & Installation (Beetle)

1. Remove center undercar tray. Drain coolant from radiator. Remove front inner fenders. Remove fender bolts from inside of fender. See

Fig. 2

. Remove lower fender bolts. Remove screws from rear of fender. Remove 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 hood latch cable. Remove upper bumper bolt on each side and install Special Tools (3411). See

Fig. 3

. Remove upper panel bolts and remaining bumper bolts. Slide entire lock carrier

assembly out on special tools.

3. Disconnect radiator hoses. Disconnect radiator mounted switch harness connectors. Remove radiator mounting bolts. See

Fig. 4

. On vehicles equipped with A/C, remove A/C line retaining clamps. DO NOT disconnect hoses. Fasten condenser to lock carrier before removing radiator. On all vehicles, remove radiator. To install, reverse removal procedure. Fill cooling system. Adjust headlights.

NOTE: For reassembly reference, label all electrical connectors,vacuum hoses and

fuel lines before removal. Place mating marks on other major assemblies before removal.

NOTE: Obtain radio anti-theft code before disconnecting battery.

1995 Volkswagen Golf III GL

2.0L 4-CYL

1995 Volkswagen Golf III GL

2.0L 4-CYL

Fig. 2: Removing Front Fenders & Bumper Cover Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Removal (Except Beetle)

1. Disconnect and remove battery. Drain engine coolant by disconnecting coolant hose from thermostat housing. Disconnect radiator hoses. Remove front bumper/grille assembly (lock carrier). See

Fig. 5

2. On vehicles equipped with A/C, it is not necessary to discharge A/C system. Remove receiver-dryer mounting bolts. DO NOT disconnect hoses from receiver-dryer. Remove accessory drive belt. Remove radiator with fan and condenser attached. 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 vehicles, remove intake air duct. Disconnect all electrical connectors, cables and hoses that interfere with engine removal. Disconnect power steering pump with bracket and set aside. DO NOT disconnect power steering hoses. Remove axle shafts from transaxle. See AXLE SHAFTS - FRONT article in DRIVE AXLES. Leave fuel lines connected and remove cold start injector and warm-up re

ulator.

NOTE: Engine is removed from vehicle with transaxle attached. Obtain radio anti-

theft code before disconnecting battery.

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. Carefully raise engine and transaxle out of vehicle. Separate transaxle from engine.

1995 Volkswagen Golf III GL

2.0L 4-CYL

Fig. 5: Placing Lock Carrier In Service Position Courtesy of VOLKSWAGEN UNITED STATES, INC.

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. Disconnect fuel supply and return hoses from fuel rail.

2. Remove air cleaner. Disconnect shift linkage from transmission. On M/T models, remove slave cylinder. On all models, remove engine undercover. Drain engine coolant from radiator. Drain engine coolant from engine by disconnecting coolant hose from oil cooler.

3. Remove accessory drive belt. Remove cooling 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 discharge A/C system. Remove refrigerant hose brackets. Remove A/C compressor with hoses attached. Secure A/C compressor aside to prevent stressing hoses.

5. Disconnect any hoses interfering with engine/transmission removal. Remove secondary air injection pump. Disconnect any electrical connectors necessary for engine/transmission removal. Remove torque rod from transmission.

6. Remove axle shafts from transmission. See AXLE SHAFTS - FRONT article in DRIVE AXLES. Remove exhaust pipe from exhaust manifold. Remove coolant hose bracket under engine block.

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. To adjust, loosen through-bolt on engine mount. Loosen transaxle mount bolts. Loosen front engine mount and bracket.

2. Lightly rock engine and transaxle 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 specification. See

TORQUE SPECIFICATIONS

Installation (Beetle)

1. To install, reverse removal procedure. Ensure engine/transmission assembly are aligned. Engine/transmission are aligned when there is .39" (10.0 mm) distance between top engine mount and engine mount bracket. See

Fig. 7

2. On A/T models, use NEW lock washer on shift cable. On all models, adjust all cables as necessary. Fill fluids to proper level. Tighten all fasteners to specification. See

TORQUE SPECIFICATIONS

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

Removal & Installation (Cabrio, Golf, GTI & Jetta)

1. Support engine from above, using engine support bracket, or the like. Connect engine sling in hook eye on cylinder head (left side) and tighten to lift engine slightly. Remove engine mount.

2. Pry washers off spacer sleeves with 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) and onto bonded rubber bushing (2), see

Fig. 9

. Install

pressure sleeve peening punch and press on.

4. Crimp washers on spacer sleeves using press. Use Arbor (VW432) as support. If necessary, remove

urrs caused by crimping.

NOTE: To see exploded views of component locations, see Fig. 10 -Fig. 13 .

1995 Volkswagen Golf III GL

2.0L 4-CYL

Fig. 8: Removing Engine Mount Rubber Bushings Courtes

of AUDI OF AMERICA, INC.

1995 Volkswagen Golf III GL

2.0L 4-CYL

Fig. 9: Installing Engine Mount Rubber Bushing Washers Courtesy of AUDI OF AMERICA, INC.

1995 Volkswagen Golf III GL

2.0L 4-CYL

Fig. 10: Front Engine/Transmission Mount Courtesy of AUDI OF AMERICA, INC.

1995 Volkswagen Golf III GL

2.0L 4-CYL

Fig. 11: Right Rear Engine/Transmission Mount Courtesy of AUDI OF AMERICA, INC.

1995 Volkswagen Golf III GL

2.0L 4-CYL

Fig. 12: Right Engine/Transmission Mount (Cabrio Only) Courtesy of AUDI OF AMERICA, INC.

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

Removal (Except Beetle)

1. Allow engine to cool. Label and disconnect electrical connectors and vacuum hoses. Disconnect throttle, cruise and kickdown cables. Leave fuel lines connected and remove cold start injector and warm-up regulator.

2. Remove fuel injectors. Remove 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 exhaust manifold.

3. Ensure pistons are NOT at TDC. Remove timing belt inner cover. Remove cylinder head bolts in reverse sequence of installation. See

Fig. 14

. Replace cylinder head bolts after loosening or

removing.

CAUTION: DO NOT turn crankshaft or camshaft with timing belt removed. Valve damage

may result.

NOTE: Cracks .02" (.5 mm) wide or less (.01" (.3 mm) or less on Beetle) between

1995 Volkswagen Golf III GL

2.0L 4-CYL

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.

2. Disconnect fuel hoses from fuel rail. Remove air cleaner. Disconnect throttle cable from Throttle Valve Control Module (TVCM). Disconnect hoses and electrical connector from TVCM. Remove upper intake manifold-to-lower intake manifold front bolts.

3. Disconnect hoses from intake manifold, secondary air injection valve and fuel pressure regulator (as necessary). Remove warm air deflector bolts. Disconnect hoses from fuel pressure regulator. Disconnect electrical connectors from fuel injectors and camshaft position sensor.

4. Remove hoses from secondary air injection pump. Disconnect spark plug wires from spark plugs. Remove accessory drive belt and tensioner. Remove upper timing belt cover. Ensure pistons are NOT at TDC. Remove timing belt tensioner. Remove timing belt from camshaft pulley. See

TIMING

BELT

5. Disconnect exhaust pipe from exhaust manifold. Remove valve cover. Loosen cylinder head bolts in reverse order of tightening sequence. See

Fig. 14

. Remove cylinder head.

Inspection (All Models)

Thoroughly clean all gasket mating surfaces. Check cylinder head for 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. Install Guide Pins (3070) into bolt holes No. 8 and 10. Install NEW head gasket on cylinder block with part number facing up. DO NOT use any type of sealant. Ensure pistons are NOT at TDC.

2. Carefully position cylinder head on cylinder. Install 8 remaining head bolts finger tight. Remove guide pins with extractor (3070). Install remaining head bolts finger tight.

3. Tighten cylinder head bolts in sequence to specification. See

Fig. 14

. See

TORQUE

SPECIFICATIONS

. To complete installation, reverse removal procedure. Tighten all fasteners to

specification. See

TORQUE SPECIFICATIONS

. Fill radiator with NEW coolant. Fill all fluids to

proper level.

Installation (Beetle)

valve seats or between valve seat and spark plug threads are considered acceptable by manufacturer.

NOTE: DO NOT reuse antifreeze after replacing cylinder block, cylinder head, head

gasket, radiator and/or heater core.

CAUTION: If camshaft or cam followers are changed, and cam followers are charged

with oil, allow 30 minutes for followers to bleed down before starting engine. Pistons may strike valves, resulting in bent valves.

CAUTION: Ensure cylinder head bolt holes are clean and free of oil or coolant.

Hydrostatic lock may occur when tightening cylinder head bolts

1995 Volkswagen Golf III GL

2.0L 4-CYL

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Volkswagen 1995 Volkswagen Golf III GL, 1995 Golf III GL Service Manual

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