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  4. 1995 Volkswagen Golf III GL
  5. Engine Specifications

Volkswagen 1995 Volkswagen Golf III GL Engine Specifications

Manual is about: Volkswagen ENGINE IDENTIFICATION

Summary of 1995 Volkswagen Golf III GL

  • Page 1

    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 b...

  • Page 2

    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...

  • Page 3

    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 ho...

  • 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

    Fig. 2: removing front fenders & bumper cover courtesy of volkswagen united states, inc. 1995 volkswagen golf iii gl 2.0l 4-cyl 1 января 2005 г. 1:18:59 page 5 © 2004 mitchell repair information company, llc..

  • Page 6

    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. Di...

  • Page 7

    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 en...

  • 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 января 2005 г. 1:18:59 page 8 © 2004 mitchell repair information company, llc..

  • Page 9

    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 as...

  • Page 10

    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 beet...

  • Page 11

    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 ...

  • 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 января 2005 г. 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 января 2005 г. 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 января 2005 г. 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 января 2005 г. 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 января 2005 г. 1:19:00 page 16 © 2004 mitchell repair information company, llc..

  • Page 17

    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 elec...

  • Page 18

    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 fr...

  • Page 19

    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. Install...

  • Page 20

    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. 2. Lubricate ...

  • 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

    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. 1995 volkswagen golf iii gl 2.0l 4-cyl 1 января 2005 г. 1:19:00 p...

  • 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

    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. 1995 volkswagen golf iii gl 2.0l 4-cyl 1 января 2005 г. 1:19:00 page 24 © 2004 mitchell repair infor...

  • Page 25

    Fig. 19: removing timing belt (except beetle) courtesy of volkswagen united states, inc. Installation 1. Move camshaft slightly off its timing mark. Place crankshaft at tdc by aligning flywheel (m/t) or drive plate (a/t) tdc marks. Remove distributor cap. Rotate intermediate shaft until rotor is poi...

  • 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

    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. 1995 volkswagen golf iii gl 2.0l 4-cyl 1 января 2005 г. 1:19:00 page 27 © 2004 mitchell repair information company, ll...

  • Page 28

    Fig. 22: checking timing belt tension (except beetle) courtesy of volkswagen united states, inc. Removal (thermo tensioner roller; 1997& up, engine code "aba") 1. Remove timing belt. See removal (engine code aba) under timing belt. 2. Mark the running direction on the timing belt. Remove fastener fo...

  • Page 29

    Fig. 23: identifying timing belt & related components (thermo tensioner roller) courtesy of volkswagen united states, inc. Installation (thermo tensioner roller) assemble new thermo tension roller and install on engine block. See fig. 24 . Tighten bolt/washer assembly (2) to specified torque, 62-97 ...

  • Page 30

    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. See fig. 21 . 2. Turn tension roller to the right using two-pin spanner -b- (h...

  • 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 января 2005 г. 1:19:00 page 31 © 2004 mitchell repair information company, llc..

  • Page 32

    Fig. 25: installing & adjusting thermo tensioner roller courtesy of volkswagen united states, inc. Removal (engine code aeg) 1. Remove engine cover and undercover on right side. Remove accessory drive belt and tensioner. Set piston no. 1 to tdc. Remove coolant expansion tank and place to side. (hose...

  • Page 33

    Remove front engine mount bracket. If timing belt is to be reused, mark direction of rotation on belt. 3. Loosen timing belt tensioner nut. Remove timing belt. See fig. 26 . Rotate crankshaft counterclockwise slightly to ensure pistons are not at tdc. Fig. 26: exploded view of timing belt components...

  • Page 34

    1. Ensure pistons are not at tdc. Align camshaft timing marks. See fig. 28 . Align crankshaft timing marks. See fig. 29 . Install timing belt on timing belt drive pulley and water pump pulley. See fig. 26 . Install engine mount bracket. 2. Install center and lower timing belt covers. Install cranksh...

  • 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 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

    Fig. 28: aligning crankshaft & camshaft timing marks (beetle - aeg engine) courtesy of volkswagen united states, inc. 1995 volkswagen golf iii gl 2.0l 4-cyl 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

    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. Testing (semi-automatic toothed belt tensioning roller; engine code "aeg") 1. Place camshaft...

  • Page 40

    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 . Camshaft oil seal removal...

  • Page 41

    Installation coat new seal lips lightly with engine oil. Using installer (10-203), install seal until flush. To complete installation, reverse removal procedure. Camshaft removal see step 1) under camshaft oil seal removal to remove camshaft pulley. Remove valve cover. Loosen and remove camshaft bea...

  • Page 42

    Fig. 32: identifying cylinder head components courtesy of volkswagen united states, inc. 1995 volkswagen golf iii gl 2.0l 4-cyl 1 января 2005 г. 1:19:01 page 42 © 2004 mitchell repair information company, llc..

  • Page 43

    Intermediate shaft removal & installation 1. Remove timing belt. See timing belt . Mark distributor assembly for installation reference and remove distributor assembly. 2. Ensure intermediate shaft end play does not exceed .010" (.25 mm). Remove intermediate shaft sprocket. Remove intermediate shaft...

  • Page 44

    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 cylinder head clean all gasket mating surfaces. Check cylinder head for warpage. See cylinder head table under engine specifications...

  • Page 45

    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 3. The difference is maximum ref...

  • Page 46

    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. Cylinder block assembly piston & rod assembly 1. Ensure piston, connecting rod and rod cap...

  • Page 47

    Fig. 34: assembling piston & rod 1995 volkswagen golf iii gl 2.0l 4-cyl 1 января 2005 г. 1:19:01 page 47 © 2004 mitchell repair information company, llc..

  • Page 48

    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). Ensure rod is properly positioned with piston. See fig....

  • 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

    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 s...

  • Page 51

    Torque specifications torque specifications backlash new .002 (.05) service limit .008 (.20) axial play limit .006 (.15) beetle (aeg) (1) (1) information is not available from manufacturer. Application ft. Lbs. (n.M) a/c bracket-to-engine bolt except beetle 22 (30) beetle 33 (45) axle shaft-to-trans...

  • Page 52

    Except beetle 18 (25) beetle 11 (15) engine mounts beetle front engine mount-to-body long bolts (1) step 1 30 (40) step 2 additional 90 degrees short bolt 18 (25) front engine mount-to-engine bracket (1) step 1 44 (60) step 2 additional 90 degrees cabrio, golf, gti & jetta (3) passat front mount-to-...

  • Page 53

    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 (1) step 1 44 (60) step 2 additional 90 degrees intake manifold lower 18 (25) upper 15 (...

  • Page 54

    Torque specifications (thermo tensioner 1997 & up) engine specifications general specifications general specifications crankshaft, main & connecting rod bearings crankshaft, main & connecting rod bearings (aba engine) valve cover retaining nut 89 (10) water pump-to-housing (except beetle) 89 (10) (1...

  • Page 55

    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) journal out-of-rou...

  • Page 56

    Crankshaft, main & connecting rod bearings (aeg engine) (1) information is not available from manufacturer. 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) maximum 2.1266 (54.017) minimum 2...

  • Page 57

    Connecting rods connecting rods pistons, pins & rings pistons, pins & rings 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 (1) journal taper (1) oil clearance standard .0004-.0024 (.010-.060) ...

  • Page 58

    Cylinder block cylinder block valves & valve springs valves & valve springs 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...

  • Page 59

    Cylinder head cylinder head camshaft camshaft exhaust valves face angle 45° head diameter 1.289-1.301" (32.75-33.05 mm) length 3.588" (91.15 mm) minimum margin (1) stem diameter .272" (6.92 mm) valve stem installed height (minimum) 1.34 (34.1) (1) do not machine valves; hand lap only. Application sp...

  • Page 60

    Oil clearance (maximum) .004 (.10) 1995 volkswagen golf iii gl 2.0l 4-cyl 1 января 2005 г. 1:19:02 page 60 © 2004 mitchell repair information company, llc..