Aba Aeg 2 0 PDF

2.
0L 4-CYLINDER
Article Text
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ARTICLE BEGINNING
1999-2000 ENGINES
Volkswagen 2.0L 4-Cylinder
Beetle, Cabrio, Golf, GTI, Jetta
* PLEASE READ THIS FIRST *
NOTE: For engine repair procedures not covered in this article,

see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article
in the GENERAL INFORMATION section.
ENGINE IDENTIFICATION
On models Cabrio, Golf, GTI and Jetta, engine identification

number is stamped on a machined pad on left side of engine block,
above crankcase breather. See Fig. 1 or 2. On Beetle, Golf and Jetta,
engine identification number is located on left side of cylinder
block, near transmission.
ENGINE CODES
Application Engine Code
2.0L Cabrio, Golf, GTI & Jetta ................................ ABA

2.0L Beetle, Golf, Jetta ...................................... AEG
Fig. 1: Locating Engine Identification Code (2.0L (ABA))

Courtesy of Volkswagen United States, Inc.
Fig. 2: Locating Engine Identification Code (2.0L (AEG))

ADJUSTMENTS
VALVE CLEARANCE
Engine is equipped with hydraulic lifters. Adjustment is not

necessary. Valve noise during startup is considered normal.
TROUBLE SHOOTING
NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article in the

GENERAL TROUBLE SHOOTING section.
REMOVAL & INSTALLATION
* PLEASE READ THIS FIRST *
NOTE: When battery is disconnected, vehicle computer and memory

systems may lose memory data. Driveability problems may exist
until computer systems have completed a relearn cycle.
NOTE: For reassembly reference, label all electrical connectors,

vacuum hoses and fuel lines before removal. Place mating
marks on other major assemblies before removal.
WARNING: 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.
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
NOTE: Obtain radio anti-theft code before disconnecting battery.
Removal & Installation (Cabrio, Golf, GTI, Jetta & Passat -

ABA Engine)
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. 3. 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. 4. 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. 5.
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.
Fig. 3: Removing Front Fenders & Bumper Cover

Fig. 4: Sliding Out Lock Carrier

Fig. 5: Exploded View Of Lock Carrier
ENGINE
NOTE: Engine is removed from vehicle with transaxle attached.
Removal (Cabrio, Golf, GTI & Jetta - ABA Engine)

1) Disconnect and remove battery. Drain engine coolant by
disconnecting coolant hose from thermostat housing. Remove intake air
duct. Disconnect all electrical connectors, cables and hoses that
interfere with engine removal.
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. Remove A/C
compressor with hoses attached and set aside with radiator/condenser
assembly. DO NOT stress refrigerant hoses.
3) On all models, remove front bumper/grille assembly.
Disconnect power steering pump with bracket and set aside. DO NOT
disconnect power steering hoses. Remove axle shafts from transaxle.
See FWD AXLE SHAFTS article in DRIVE AXLES. Leave fuel lines connected
and remove cold start injector and warm-up regulator.
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.
Removal (Beetle, Golf & Jetta - AEG Engine)

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 FWD AXLE SHAFTS
article in DRIVE AXLES. Remove exhaust pipe from exhaust manifold.
Remove coolant hose bracket under engine block. 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 (Cabrio, Golf, GTI & Jetta - ABA Engine)

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, Golf & Jetta - AEG Engine)

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. 6.
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.
Fig. 6: Aligning Engine/Transmission Assembly (Beetle, Golf &

Jetta - AEG Engine)
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.

Valve damage may result.
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. 7. Replace cylinder head bolts after loosening or removing.
NOTE: Cracks between valve seats or between valve seat and spark
plug threads are considered acceptable by manufacturer. The
maximum allowable size for cracks is .02" (.5 mm) wide or
less for ABA engine or .01" (.3 mm) or less for AEG engine.

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. 7. 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.
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
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 block. 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. 7. 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.

1) 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. 7. Install NEW head gasket on cylinder block with part number
facing up. Install cylinder head. Install 8 remaining cylinder head
bolts finger tight.
3) Using Guide Pin Extractor (3450/3), remove guide pins.
Install remaining cylinder head bolts finger tight. Tighten cylinder
head bolts in sequence to specification. See Fig. 6. See
TORQUE SPECIFICATIONS.
4) 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.
Fig. 7: Cylinder Head Bolt Tightening Sequence

FRONT COVER OIL SEAL

Removal & Installation (Cabrio, Golf, GTI & Jetta - ABA

Engine)
1) Remove timing belt. See TIMING BELT. Using Crankshaft
Holder (3099), remove timing belt drive pulley. Rotate inner part of
Oil Seal Extractor (2085) outward 2 turns and tighten set screw.
2) Use bolt from Seal Installer (3083) as guide in center of
oil seal extractor. Insert bolt through oil seal extractor and thread
bolt all the way into crankshaft. Lubricate threaded area of extractor
and push in as far as possible. Loosen set screw and turn inner part
of extractor until oil seal is removed.
3) Lubricate lip of new seal. Place guide sleeve from Seal
Installer (3083) onto crankshaft. Push oil seal over guide sleeve.
Press seal completely into position. To complete installation, reverse
removal procedure.
Removal & Installation (Beetle, Golf & Jetta - AEG Engine)

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 threaded area of Seal Extractor (3203). Thread
seal extractor into seal as far as possible. Loosen set screw and turn
inner part of extractor until oil seal is removed.
3) Lubricate lip of new seal. Place guide sleeve from Seal
Installer (2080-A) onto crankshaft. Push oil seal over guide sleeve.
Using Seal Installer (3266), press seal completely into position. To
complete installation, reverse removal procedure.
TIMING BELT


1) Remove accessory drive belt. See Fig. 8. Remove drive belt
tensioner pulley and lever. Remove upper timing belt cover. Remove
crankshaft pulley and idler pulley. Remove water pump pulley.
2) Remove lower belt cover. If timing belt is to be reused,
mark direction of rotation on belt. Rotate crankshaft clockwise until
No. 1 piston is at TDC of compression stroke and TDC mark on flywheel
and bellhousing are aligned.
3) Ensure camshaft pulley "O.T." alignment mark is aligned
with mark on drive belt guard. Loosen timing belt tensioner. Remove
timing belt.


1) Remove engine cover and undercover on right side. Remove
accessory drive belt and tensioner. Set piston No. 1 to TDC. Remove
upper timing belt cover. Support engine and remove front engine mount.
2) Remove crankshaft pulley. Remove center and lower timing
belt covers. Raise engine slightly. 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. 8. Rotate crankshaft counterclockwise slightly to ensure pistons
are not at TDC.
Fig. 8: Removing Timing Belt (Cabrio, Golf, GTI & Jetta - ABA Engine)

1) 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 pointed at No. 1 cylinder mark. See
Fig. 9. Align mark on camshaft sprocket with mark on belt guard. See
Fig. 10.
Fig. 9: Aligning Crankshaft & Distributor Timing Marks (Cabrio,

Golf, GTI & Jetta - ABA Engine)
Fig. 10: Aligning Camshaft Timing Marks

2) Install timing belt around crankshaft, intermediate shaft

and camshaft sprockets. Install 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. It must be
possible to twist timing belt 90 degrees with thumb and forefinger
half-way between camshaft and intermediate shaft sprockets. See
Fig. 11. Adjust tension as necessary. To complete installation,
reverse removal procedure.

1) Ensure pistons are NOT at TDC. Align camshaft timing
marks. See Fig. 10. Install timing belt on timing belt drive pulley
and water pump pulley. Install engine mount bracket.
2) Install center and lower timing belt covers. Install
crankshaft pulley. Set piston No. 1 to TDC. Install engine mount.
Ensure camshaft timing mark is still aligned. Install timing belt on
camshaft sprocket and tensioner.
3) Manufacturer recommends tensioning timing belt with engine
warm. Using Wrench (T-10020), rotate tensioner counterclockwise until
arrow mark on tensioner aligns with notch. See Fig. 12.
4) Rotate crankshaft clockwise 2 revolutions. Ensure timing
marks are still aligned. Ensure tensioner marks align. To complete
installation, reverse removal procedure. Tighten all fasteners to
specification. See TORQUE SPECIFICATIONS.
Fig. 11: Checking Timing Belt Tension (Cabrio, Golf, GTI & Jetta
- ABA Engine)
Fig. 12: Checking Timing Belt Tension (Beetle, Golf & Jetta - AEG
Engine)
CAMSHAFT OIL SEAL

Removal
1) Remove upper timing belt cover. Place crankshaft at TDC
with No. 1 cylinder on compression stroke. Remove timing belt from
camshaft sprocket. Remove camshaft sprocket bolt. On ABA Engine, use
Counter Support (3415), to hold camshaft sprocket. On AEG Engine, 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 camshaft. Rotate inner part of Oil Seal Extractor (2085)
outward 2 turns and tighten set screw. See Fig. 13. Lubricate threaded
area of extractor and push in as far as possible. Loosen set screw and
turn inner part of extractor until oil seal is removed.
Fig. 13: Removing Camshaft Oil Seal

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
remove camshaft pulley, See step 1) under CAMSHAFT OIL SEAL
in REMOVAL & INSTALLATION. Remove valve cover. Loosen and remove
camshaft bearing caps No. 1, 3 and 5 evenly. See Fig. 14. Loosen
camshaft bearing caps No. 2 and 4 evenly, in a crisscross pattern.
Remove camshaft bearing caps. Lift camshaft from cylinder head.
Inspection
Check camshaft bearing oil clearance. See CAMSHAFT table
under ENGINE SPECIFICATIONS. If oil clearance is not within
specification, install new camshaft and recheck clearance. If
clearance still exceeds specification, replace cylinder head. Check
camshaft end play with cam followers removed and first and last
bearing caps installed.
CAUTION: If 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.
Installation
1) Place camshaft in cylinder head. Ensure lobes for No. 1
cylinder are pointed upward. See Fig. 14. Install camshaft bearing
caps. Camshaft bearing caps are offset from center. Ensure camshaft
bearing caps are installed correctly.
2) Tighten camshaft bearing caps No. 2 and 4 evenly in a
crisscross pattern to specification. See TORQUE SPECIFICATIONS.
Tighten camshaft bearing caps No. 1, 3 and 5 evenly to specification.
3) To complete installation, reverse removal procedure. If
cam followers are charged with oil, allow 30 minutes for followers to
bleed down before starting engine.
Fig. 14: Identifying Cylinder Head Components

INTERMEDIATE SHAFT
NOTE: It may be necessary to remove engine in order to remove

intermediate shaft. Procedure for ABA Engine is not available
from manufacturer.

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 seal flange. Remove intermediate shaft. Replace seal (if
necessary). See Fig. 17. To install, reverse removal procedure.
REAR CRANKSHAFT OIL SEAL
NOTE: Rear crankshaft oil seal and retaining flange must be

replaced as an assembly.

Remove flywheel/flexplate and discard bolts. For A/T, see
appropriate REMOVAL & INSTALLATION article in TRANSMISSION SERVICING.
For M/T, see appropriate article in CLUTCHES. See Fig. 17. Remove
retaining flange and seal assembly. Replace flange and seal assembly
as a unit. To complete installation, reverse removal procedure.
Install NEW flywheel/flex plate bolts.
WATER PUMP
CAUTION: Coolant/water mixture should be used at all times. Use only

ethylene glycol based (phosphate-free) coolant.
Removal & Installation (Cabrio, Golf, GTI & Jetta -

ABA Engine)
1) Disconnect negative battery cable. Turn heater control to
HOT position. Drain cooling system. Remove accessories and brackets
(as necessary).
2) Label and remove coolant hoses from water pump. Remove
water pump pulley. Remove bolts and remove water pump assembly. To
install, reverse removal procedure. Tighten bolts to specification.
See TORQUE SPECIFICATIONS.
Removal & Installation (Beetle, Golf & Jetta - AEG Engine)

1) Drain engine coolant. Remove accessory drive belt and
tensioner. Remove timing belt upper and center covers. See TIMING BELT
. Remove timing belt from water pump sprocket only.
2) Remove timing belt inner guard. Cover timing belt with
shop towel. Remove water pump mounting bolts. Remove water pump. DO
NOT allow coolant to spill on timing belt.
3) To install, reverse removal procedure. Use NEW "O" ring.
To install timing belt, see TIMING BELT. Tighten all fasteners to
specification. See TORQUE SPECIFICATIONS. Fill engine with coolant.
OIL PAN
1) Remove lower insulation tray. Drain engine oil. Remove oil

pan and bell housing bolts. Remove oil pan using rubber hammer if
necessary. Remove sealant from cylinder block and oil pan. Ensure
surfaces are free from grease and oil.
2) To install, apply 2-3 mm thick silicone bead around
sealing surface of oil pan. Immediately install oil pan and lightly
tighten oil pan bolts. Ensure oil pan is flush with cylinder block.
Tighten bolts to specification. See TORQUE SPECIFICATIONS. Allow
sealer to dry for 30 minutes before installing engine oil.
OVERHAUL
CYLINDER HEAD
NOTE: Cracks between valve seats or between valve seat and spark
plug threads are considered acceptable by manufacturer. The
maximum allowable size for cracks is .02" (.5 mm) wide or
less for ABA engine or .01" (.3 mm) or less for AEG engine.
Cylinder Head
Clean all gasket mating surfaces. Check cylinder head for
warpage. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.
Valve Stem Oil Seals
Valve stem oil seals may be replaced with cylinder head
installed. On ABA engine, install seals using Valve Seal Driver (10-
204). On AEG engine, install valve seals using Valve Seal Driver
(3129).
Valve Springs
On AEG engine, remove valve spring using Lever (VW541-1A) and
Press Piece (VW 541/5). On ABA engine, information is not available
from manufacturer.
Valve Guides
1) Using dial indicator, check valve stem-to-guide clearance.
See CYLINDER HEAD table under ENGINE SPECIFICATIONS. To replace valve
guide, press guide out from camshaft side. Replacement 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 in cold cylinder head as far as
guide will go from camshaft side. DO NOT exceed one ton pressure.
Using Valve Guide Reamer (3120), ream guides to proper stem-to-guide
clearance. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.
Valve Seats
1) Check valve seats before any other cylinder head service.
Insert valve and hold firmly against valve seat. Measure distance
between valve stem tip and valve cover surface. See Fig. 15.
Fig. 15: Measuring Valve Installed Height

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. (mm)
Intake Valve ........................................ 1.331 (33.80)

Exhaust Valve ....................................... 1.343 (34.10)
3) The difference is maximum refacing allowable for valve and

seat. If valve installed height is less than specification, 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
specification, replace valves. DO NOT reface valves with machine. Lap
valves by hand only. Replace as necessary. See VALVES & VALVE SPRINGS
table under ENGINE SPECIFICATIONS.
VALVE TRAIN
Lifters (Cam Followers)

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) on ABA engines, and .007" (.20 mm) on AEG
engines, replace lifters. Lifters must be replaced as a set.
CAUTION: If lifters are charged with oil, allow 30 minutes for

followers to bleed down before starting engine. Pistons may
strike valves, resulting in bent valves.
CYLINDER BLOCK ASSEMBLY
Piston & Rod Assembly

1) Ensure piston, connecting rod and rod caps are marked with
matching cylinder number prior to removal. Ensure engine front arrow
is marked on top of piston and front mark exists on rod and cap. See
Fig. 16. Pistons and rods are to be replaced in sets of 4. Rod cap
bolts and nuts must be replaced after removing or loosening.
Fig. 16: Assembling Piston & Rod

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 140F (60C).
Ensure rod is properly positioned with piston. See Fig. 16.
Fitting Pistons
Measure clearances with cylinder block supported on work
bench. Check clearance of piston-to-cylinder bore. Piston diameter is
stamped on top of piston in millimeters.
PISTON-TO-CYLINDER BORE DIMENSIONS
Piston Diameter (1) - Cylinder Bore

Size In. (mm) - In. (mm)
AEG Engine
Standard .......... 3.246 (82.465) .............. 3.248 (82.51)
1st Oversize ...... 3.266 (82.965) .............. 3.268 (83.01)
ABA Engine
Standard ........... 3.247 (82.49) .............. 3.248 (82.51)
1st Oversize ....... 3.257 (82.74) .............. 3.258 (82.76)
2nd Oversize ....... 3.267 (82.99) .............. 3.268 (83.01)
(1) - New pistons have graphite coating that wears away. For
used piston, subtract .0007" (.020 mm) for AEG engine, or .0006"
(.015 mm) for ABA engine, from piston diameter.
Piston Rings
Measure ring end gap. Measure ring side clearance with
piston. If not within specification, replace as necessary. See
PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS. Install rings
on piston with TOP mark facing upward. Recessed edge on outside of
center ring must face piston pin (down). Position ring gaps on piston
at 120-degree intervals. See Fig. 16.
Rod Bearings
Mark rod caps for reinstallation. Use Plastigage 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 necessary. See
appropriate CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under
ENGINE SPECIFICATIONS. Lubricate bolt threads when installing
connecting rod caps. Tighten evenly to specification in several steps.
See TORQUE SPECIFICATIONS.
Crankshaft & Main Bearings

Main bearing caps are marked with matching journal for
installation in original position. See Fig. 17. Use Plastigage to
measure oil clearance. Tighten main bearing cap bolts to 48 ft. lbs.
(65 N.m) when measuring oil clearance. DO NOT turn additional 90
degrees. Measure crankshaft end play. See THRUST BEARING.
Fig. 17: Crankshaft Assembly
Thrust Bearing
Insert feeler gauge between No. 3 main bearing and crankshaft
thrust face to measure end play. See Fig. 17. Replace thrust bearing
as necessary. See appropriate CRANKSHAFT, MAIN & CONNECTING ROD
BEARINGS table under ENGINE SPECIFICATIONS.
Cylinder Block
Measure cylinder block while supported on work bench. Check
cylinder bore for wear, out-of-round and taper. Check cylinder block
for warpage. See CYLINDER BLOCK table under ENGINE SPECIFICATIONS.
ENGINE OILING
ENGINE LUBRICATION SYSTEM

Crankcase Capacity
See CRANKCASE CAPACITY table.
CRANKCASE CAPACITY
Application Qts. (L)
Without Filter Replacement .............................. 3.7 (3.5)

With Filter Replacement ................................. 4.2 (4.0)
Oil Pressure
Check oil pressure with engine at normal operating
temperature. Minimum oil pressure at idle is 29 psi (2.0 kg/cm).
Minimum oil pressure at 2000 RPM is 43 psi (3.0 kg/cm).
OIL PUMP
NOTE: Oil pump removal and installation procedure for Beetle, Golf
and Jetta is not available from manufacturer.

Remove oil pan. Remove oil pump attaching bolts and remove
oil pump assembly. To install, reverse removal procedure.
Inspection
Check oil pump backlash and oil pump axial play. If not
within specification, replace oil pump assembly. See
OIL PUMP SPECIFICATIONS table.
OIL PUMP SPECIFICATIONS
ABA Engine
Backlash
New ................................................ .002 (.05)
Service Limit ...................................... .008 (.20)
Axial Play Limit ..................................... .006 (.15)
AEG Engine .................................................... (1)
(1) - Information is not available from manufacturer.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
A/C Bracket-To-Engine Bolt

ABA Engine .............................................. 22 (30)
AEG Engine .............................................. 33 (45)
Axle Shaft-To-Transaxle Drive Flange Bolt
ABA Engine .............................................. 33 (45)
AEG Engine .............................................. 30 (40)
Camshaft Bearing Cap Bolt ................................. 15 (20)
Camshaft Drive Gear Bolt
ABA Engine .............................................. 59 (80)
AEG Engine ............................................. 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)
Crankshaft Timing Sprocket Bolt (1)
Step 1 .................................................. 66 (90)
Cylinder Head Bolt (1)
Step 1 .................................................. 30 (40)
Step 2 (ABA Engine) ................................. (2) 44 (60)
Driveplate (A/T) (1)
Step 1 .................................................. 22 (30)
Step 2 .................................................. 44 (60)
EGR Tube Nuts ............................................. 22 (30)
Engine Front Cover
ABA Engine .............................................. 18 (25)
AEG Engine .............................................. 11 (15)
Engine Mounts
ABA Engine
Front Mount-To-Bracket ................................ 41 (55)
Front Mount-To-Transmission Bracket ................... 41 (55)
Left Rear Mount-To-Bracket ............................ 44 (60)
Left Rear Mount-To-Body ............................... 22 (30)
Left Rear Mount Bracket-To-Transmission ............... 18 (25)
Right Rear Mount-To-Body .............................. 18 (25)
Right Rear Mount-To-Engine Bracket .................... 18 (25)
Right Rear Mount-To-Bracket ........................... 37 (50)
AEG Engine
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
Transmission Mount-To-Body
Long Bolts (1)
Step 1 ............................................ 30 (40)
Step 2 .............................. Additional 90 Degrees
Short Bolt .......................................... 18 (25)
Transmission Mount-To-Transmission (1)
Step 1 .............................................. 44 (60)
Torque Rod-To-Transmission (1)
Step 1 .............................................. 30 (40)
Torque Rod-To-Body (1)
Step 1 .............................................. 15 (20)
Engine Mount Carrier-To-Frame Bolt ........................ 37 (50)
Engine-To-Transaxle 10-mm Bolt
ABA Engine .............................................. 44 (60)
AEG Engine .............................................. 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)
Intake Manifold
Lower ................................................... 18 (25)
Upper ................................................... 15 (20)
Intermediate Shaft Sprocket Bolt .......................... 59 (80)
Knock Sensor ........................................ 15-18 (20-25)
Oil Pan Bolt
ABA Engine .............................................. 15 (20)
AEG Engine .............................................. 11 (15)
Oil Pump Cover (ABA Engine)
Long Bolt ............................................... 15 (20)
Short Bolt .................................................. (3)
Oil Pump Bolts (AEG Engine) ............................... 11 (15)
Oil Pump Sprocket (AEG Engine) ............................ 15 (20)
Oil Pump Chain Tensioner Bolt (AEG Engine) ................ 11 (15)
Oil Pan Drain Plug ........................................ 22 (30)
Pressure Plate-To-Flywheel Bolt (1)
Step 1 .................................................. 22 (30)
Starter Mount Bolt ........................................ 40 (60)
Timing Belt Tensioner Nut
ABA Engine .............................................. 33 (45)
AEG Engine .............................................. 15 (20)
Torque Converter-To-Drive Plate Bolt
ABA Engine .............................................. 22 (30)
AEG Engine .............................................. 44 (60)
Water Pump Housing-To-Engine Bolt
ABA Engine (1)
Step 1 ................................................ 15 (20)
Step 2 .................................. Additional 90 Degrees
AEG Engine .............................................. 11 (15)
Water Pump Pulley Bolt (ABA Engine) ....................... 18 (25)
INCH Lbs. (N.m)
Piston Oil Jet Nozzle ..................................... 89 (10)

Transaxle/Engine Cover Plate Bolt ......................... 89 (10)
Valve Cover Retaining Nut ................................. 89 (10)
Water Pump-To-Housing (ABA Engine) ........................ 89 (10)
(1) - Use NEW bolts.

(2) - On AEG Engine, perform steps 1, 3 and 4.
(3) - Tighten bolt to 89 INCH lbs. (10 N.m).
ENGINE SPECIFICATIONS
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Specification
Displacement ................................... 121 Cu. In. (2.0L)

Bore .............................................. 3.25" (82.5 mm)
Stroke ............................................ 3.65" (92.8 mm)
Compression Ratio
ABA Engine ................................................ 9.0:1
AEG Engine ............................................... 10.0:1
Fuel System .................................... CIS-E Motronic SFI
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS (ABA ENGINE)

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS (ABA ENGINE)
Crankshaft End Play

Standard .................................... .003-.007 (.07-.17)
Service Limit ........................................ .010 (.25)
Main Bearings
Journal Diameter
Standard (Nominal) ............................ 2.1260 (54.000)
Maximum ..................................... 2.1269 (54.023)
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-Round ........................................ (1)
Journal Taper ............................................... (1)
Oil Clearance
Standard ................................ .0008-.0024 (.02-.06)
Service Limit ...................................... .007 (.17)
Connecting Rod Bearings
Journal Diameter
Maximum ..................................... 1.8828 (47.823)
Minimum ..................................... 1.8803 (47.760)
Maximum ..................................... 1.8729 (47.572)
Minimum ..................................... 1.8704 (47.508)
Maximum ..................................... 1.8631 (47.323)
Minimum ..................................... 1.8610 (47.270)
Maximum ..................................... 1.8533 (47.074)
Minimum ..................................... 1.8510 (47.015)
Journal Taper ............................................... (1)
Oil Clearance
Standard .................................. .002-.012 (.05-.31)
Service Limit ...................................... .015 (.37)
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS (AEG ENGINE)
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS (AEG ENGINE)
Crankshaft End Play

Standard .................................... .003-.009 (.07-.23)
Service Limit ........................................ .012 (.30)
Main Bearings
Journal Diameter (Beetle)
Maximum ..................................... 2.1266 (54.017)
Minimum ..................................... 2.1245 (53.963)
Maximum ..................................... 2.1168 (53.767)
Minimum ..................................... 2.1147 (53.713)
Maximum ..................................... 2.1070 (53.517)
Minimum ..................................... 2.1048 (53.463)
Maximum ..................................... 2.0971 (53.267)
Minimum ..................................... 2.0950 (53.213)
Journal Diameter (Golf & Jetta)
Standard
Maximum ..................................... 2.1253 (53.983)
Minimum ..................................... 2.1245 (53.963)
1st Undersize
Maximum ..................................... 2.1154 (53.733)
Minimum ..................................... 2.1146 (53.713)
2nd Undersize
Maximum ..................................... 2.1056 (53.483)
Minimum ..................................... 2.1048 (53.463)
3rd Undersize
Maximum ..................................... 2.0957 (53.233)
Minimum ..................................... 2.0949 (53.213)
Journal Taper ............................................... (1)
Oil Clearance
Standard .............................. .0004-.0016 (.010-.040)
Service Limit .................................... .0059 (.150)
Connecting Rod Bearings
Journal Diameter (Beetle)
Maximum ..................................... 1.8828 (47.823)
Minimum ..................................... 1.8803 (47.760)
Maximum ..................................... 1.8729 (47.572)
Minimum ..................................... 1.8704 (47.508)
Maximum ..................................... 1.8631 (47.323)
Minimum ..................................... 1.8610 (47.270)
Maximum ..................................... 1.8533 (47.074)
Minimum ..................................... 1.8510 (47.015)
Journal Diameter (Golf & Jetta)
Standard
Maximum ..................................... 1.8810 (47.778)
Minimum ..................................... 1.8802 (47.758)
1st Undersize
Maximum ..................................... 1.8711 (47.528)
Minimum ..................................... 1.8703 (47.508)
2nd Undersize
Maximum ..................................... 1.8613 (47.278)
Minimum ..................................... 1.8605 (47.258)
3rd Undersize
Maximum ..................................... 1.8514 (47.028)
Minimum ..................................... 1.8507 (47.008)
Journal Taper ............................................... (1)
Oil Clearance
Standard .............................. .0004-.0024 (.010-.060)
Service Limit .................................... .0047 (.120)
CONNECTING RODS
CONNECTING RODS
Bore Diameters ................................................ (1)

Center-To-Center Length ....................................... (1)
Side Play
Standard .................................. .0020-.0122 (.05-.31)
Service Limit ........................................ .015 (.37)
PISTONS, PINS & RINGS
PISTONS, PINS & RINGS
Pistons
Clearance .......................................... .0016 (.040)
Standard Diameter (1) ............................. 3.247 (82.49)
1st Oversize (1) .................................. 3.257 (82.74)
2nd Oversize (1) .................................. 3.267 (82.99)
Pins
Diameter .................................................... (2)
Piston Fit .................................................. (2)
Rod Fit ..................................................... (2)
Rings
No. 1 & 2
End Gap
Standard ................................ .007-.016 (.20-.40)
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)
Side Clearance (AEG Engine)
Standard ................................ .002-.004 (.06-.09)
Service Limit .................................... .008 (.20)
No. 3 (Oil)
End Gap
Standard ................................ .010-.020 (.25-.51)
Service Limit (ABA Engine) ...................... .039 (1.00)
Service Limit (AEG Engine) ....................... .031 (.80)
Side Clearance
Standard ................................ .001-.002 (.02-.05)
Service Limit .................................... .006 (.15)
(1) - Measurement includes graphite coating. For new pistons,

subtract 0.0006" (0.015 mm) from piston diameter.
CYLINDER BLOCK
CYLINDER BLOCK
Cylinder Bore
Standard Diameter ................................. 3.248 (82.51)
1st Oversize ...................................... 3.258 (82.76)
2nd Oversize ...................................... 3.268 (83.01)
Maximum Taper ...................................... .0016 (.040)
Maximum Out-of-Round ................................. .001 (.03)
VALVES & VALVE SPRINGS
VALVES & VALVE SPRINGS
Intake Valves
Face Angle .................................................. 45
Head Diameter ..................... 1.549-1.561" (39.35-39.65 mm)
Length ........................................ 3.616" (91.85 mm)
Minimum Margin .............................................. (1)
Stem Diameter ................................... .272" (6.92 mm)
Valve Stem Installed Height
(Minimum) ....................................... 1.33" (33.8 mm)
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 mm)
(1) - DO NOT machine valves; hand lap only.
CYLINDER HEAD
CYLINDER HEAD
Cylinder Head Height (Minimum) .................. 5.220" (132.6 mm)

Maximum Warpage ................................... .004" (.100 mm)
Valve Seats
Intake Valve
Seat Angle ................................................ 45
Seat Width .................................... .079" (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 Height .............................. (1)
Valve Stem-to-Guide
Oil Clearance ........................... (2) .051" (1.30 mm)
(1) - Valve guide shoulder flush with cylinder head.

(2) - New valve installed in cylinder head. Dial indicator used
to measure valve wobble in guide.
CAMSHAFT
CAMSHAFT
Journal Diameter
Standard .......................................... 1.024 (26.00)
Undersize ......................................... 1.014 (25.75)
End Play .............................................. .006 (.150)
Runout ............................................... .0004 (.010)
Oil Clearance (Maximum) ................................ .004 (.10)
END OF ARTICLE

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2.

Beetle, Cabrio, Golf, GTI, Jetta

* PLEASE READ THIS FIRST *

NOTE: For engine repair procedures not covered in this article,

On models Cabrio, Golf, GTI and Jetta, engine identification

Application Engine Code

2.0L Cabrio, Golf, GTI & Jetta ................................ ABA

Fig. 1: Locating Engine Identification Code (2.0L (ABA))

Fig. 2: Locating Engine Identification Code (2.0L (AEG))

Engine is equipped with hydraulic lifters. Adjustment is not

NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article in the

REMOVAL & INSTALLATION

* PLEASE READ THIS FIRST *

NOTE: When battery is disconnected, vehicle computer and memory

NOTE: For reassembly reference, label all electrical connectors,

WARNING: Radio/cassette or radio/CD player is equipped with an

FUEL PRESSURE RELEASE

Remove fuel pump relay (located in fuse/relay panel). Crank

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

Removal & Installation (Cabrio, Golf, GTI, Jetta & Passat -

Removal & Installation (Beetle)

Fig. 3: Removing Front Fenders & Bumper Cover

Fig. 4: Sliding Out Lock Carrier

NOTE: Engine is removed from vehicle with transaxle attached.

Removal (Cabrio, Golf, GTI & Jetta - ABA Engine)

Removal (Beetle, Golf & Jetta - AEG Engine)

Installation (Cabrio, Golf, GTI & Jetta - ABA Engine)

Installation (Beetle, Golf & Jetta - AEG Engine)

Fig. 6: Aligning Engine/Transmission Assembly (Beetle, Golf &

INTAKE MANIFOLD (UPPER & LOWER)

Removal and installation procedures are not available from

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

Removal (Beetle, Golf & Jetta - AEG Engine)

Inspection (All Models)

NOTE: DO NOT reuse antifreeze after replacing cylinder block,

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

Installation (Cabrio, Golf, GTI & Jetta - ABA Engine)

Installation (Beetle, Golf & Jetta - AEG Engine)

Fig. 7: Cylinder Head Bolt Tightening Sequence

FRONT COVER OIL SEAL

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

Removal & Installation (Cabrio, Golf, GTI & Jetta - ABA

Removal & Installation (Beetle, Golf & Jetta - AEG Engine)

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

Removal (Cabrio, Golf, GTI & Jetta - ABA Engine)

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

Removal (Beetle, Golf & Jetta - AEG Engine)

Installation (Cabrio, Golf, GTI & Jetta - ABA Engine)

Fig. 9: Aligning Crankshaft & Distributor Timing Marks (Cabrio,

Fig. 10: Aligning Camshaft Timing Marks

2) Install timing belt around crankshaft, intermediate shaft

Installation (Beetle, Golf & Jetta - AEG Engine)

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

Fig. 13: Removing Camshaft Oil Seal

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

Fig. 14: Identifying Cylinder Head Components

NOTE: It may be necessary to remove engine in order to remove

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

Removal & Installation