Chapter 2 Part C: 201 Engine repair procedures - 1.6 and 1.8 litre 8 valve Contents ‘Camshaft - rexqval, examination and reiting CCeanksitatt ane bearings examination and renovation CCronksialt and main beatings - reiting Crankshaft and tain beatings - removal Cinco locklcrankcase - examination and rendvation Gnd head - dismantling and verhats Gyinder head - reiting finder head - removal Engine -adjstments alter major ocho Engine -retiting Engine - remo Engine ancl Engine arcilry compnents refaing Engine dismenting = gers inearnotion Engi reassembly - generalinferration Engine/gearte - separation and recor [Examinition and rertvation» ganera Fhwhee/aiveplate - examination and renovation (Genet informtion 10 3 Hyrautc bucket tappets - checting fae wavel rom August 1285) 38 Degrees of difficulty trmecite shaft - examination and renewation mechte shalt ret Ingctmee sha - removal [Major oporations enly possible ater removal of engine fm vehicle [Majer operations posite wuth ongsi in weicl Method ot engine renioval Oil cooker ~remeval ane refitting Oilfiter = renewal Giltiter mounting © removal al etn (i sump - examination and renovation Oil seals - renewal Pistons and ecrnesting fouls ~exa Pistons and connscting tous reiting Bistons and connecting ros - removal Surrp and ol pump -rernoval ane reiting Tieng hel an sprocket in ord eanwation ‘ining bet an! sprockats Tieng bel and sprocke Valve clearances - checking and achustment (pre August 1885), Easy, suftable tor Fartyeasy,suiabe 2, | Fairy dimeurr, Sy | Ditnourr, sutaibie tor | Very dime, & rovice whe forbeginer wih | suiebisforcompoter 3: | experienced OY SY] sutsofor expat bry expatonce S| soreenpaience Brine oder a poesia Specifications General Tpe Feu wots cooled, overhead camshat vere ‘Wier eat comerter e rinen abs comer a Correa ou St aman Tac Win caste sonar RIL RD. Pr Freng order Displacement 16 ttre Ve itre Ber: 16 ire La ire Sitoke: 16 kre 1 lire Compression ato olive lve Carle RP Aother codes 1-3-4-2 Wo T at camshaft spracket end) 1.0mm e1.omm Varin 66.4 rm 90101 0101 10.9t01 1081 VW Golf & Jetta 2c2C+2 Engine repair procedures - 1.6 and 1.8 litre 8 valve Compression pressure: "ite New Ninianirs Maximum permissile ference between any two cylincers alive: Hew inion = of iaimum petmisinleciference between any te cyber: Crankshaft Main jour Standard dameter Undersizes crankpt Standard diameter Joumalundersizes. 2... : : Endtioat: Maximum Minimum 200200 Main baring maxima sunning coarancs Connecting rods Big-ones Maximum running clearance Maximum encflost Pistons Clearance in bore: Maximum Minion Diameter Stand Oversize Ist oversize « and oversine \Yeeor limi. [10 mn ror base? right angles te pin Piston rings Maximurn clearance in groove End gap: ‘Compression rings fees . Ci scraper ting “pers Aas 2 part : 3 pert Maxie ere gop Gudgeon pin Fin piston intermediate shaft Maximum enalfioat Cylinder head Maximum allowable face distortion Miriam height Camshaft Run-out atcentre bearing . Endfioat sess. fo : Valves Seat angie Head diemetes: Tre: Codes PB, PF * other cartes Exhaust S10 12 bar 7.5bar subar rot 12 bor 75 bor 20 bar s4omm 58.78, 53.50 and 53.25 mm 47.90 mm, 47.55, 47.30 and 42.05 mm 0.25 mmo 0.07 rm O47 ra 2.012 men osm ‘0.07 mm 03mm 80:8 me 81.23 men, 81.40 me 8.04 mm 9.15 mm 0.300 0.45 mam 0.25 to 040mm 02510045 awn 9.25100 50.mn 10mm Push ft ar 60°C 025 10m, 1 mm 1326 mm ‘801 mm 915mm 45 40.0 mm 30mm 330mm WAT VW Goll R JettaEngine repair procedures - 1.6 and 1.8 litre 8 valve 2C+3 Steen diameter ‘Cades EZ. EV, GU 98,70 mea ‘Al other codes shomm ‘exhoust ‘Codes EZ EV.GU...... : 6.50 mm Contes PEPE RP S07 9995 mm ‘Atother codes 0.20 mn * auton: Cheek wth narutacurer on wolvedmenions before renting Valve guides Maxi value ork stem fish sith gue) Init mes Exhaust awn rer Hydraulic tappets Maxionsn bec wave. . secceeeeees O21 um Valve timing Nilvalve clearance at 1.0 mm valve it “5 re (code EZ shim bucket tappets) ere 21" ABDC a aeDe YP eTOC ele ese EZ yee tapi Ragust 806 ch a Init opens ve serve Ite close cissiainvoseainenvisnairaninnnin IAB Exist opens 2 BBDC fxheust closes EOI sere “sits (code EZ - hydra tappits » Match 1986 oie int opens woe Inet ese : ea ainiwsinnss BRAGS Exhaust opens 28: ABDC Exhaust slses = Sinaancacsss EBT 1.6 its fend RF} Inet opens we Inet closes * 22° ABDC Exhvust opens oe ADC Exhaust closes Sungeess BIDS “alfa CU shim cht opt Inlet opens . rere Ine loses rete IUNINID arrappe Exhaust opens : SOS ape eppe Exhaust closes 2 aIbe "tr nde GU itp ag 68 orc is init opens Sete tne lose Sihiitievinest@soisetenscasents: ABDC Exhot opens oe So ave gepe Exhaust closes «0. LOL. SETS 1.8 tre feode GU - rycen taps - Marc 1388 on ink opens e pte lel loses cesorevaaccusconcccvonrvorecvaveuverwncateess | MAtABDG Exhaust ope SE 44 BRD Exlenst closes : : e'etc 11.8 litre (code EV} inet opens 2 pIOG Inet eens = SII last abo Exo opens 4s BDC Exhaust cones : e'pTDC 1.8 litre (codes PB, PF}: ink opens. . atbe Int eoses syiseaseviaisvsrevevevervors TIT) ast ABbo Extent opens 37 abe Exhaust loses a DL ate 1081 VW Gol & Jetta2C+4 Engine repair procedures - 1.6 and 1.8 litre 8 valve Valve timing (continued) Nil valve clearance at 1.0 mm valve Kft “live code BH Inet ers P BTDO Init closes : So MPABDE Exhoust opens 44 Beoc Exhaust closes ee eroc 1 8 te (ode RP ~ pre July 198 It oats . Paroe Ine clases 3a ABE Exhaust opens = 40: BBDC Exhaust cbse TOC "eve on RP Agus 1968 oi Init opens. . . coe BIDE Init clases 3 AaDE Exhaust opens ene : ad Ertoust even Verne Valve clearances Ware INE eeesranatits carRREntes VAL Gam Exhaust 2! vo SEIDEN. p4otogom oi Tf wee : 01510025 mm Fnhotst 913510045 mn Lubrication system ype : {Wet sump, pressure fac fl lw ter Lubnecantfyperspeciteatoncapacsty Refer to ‘Lubncants fits and eapacries Fiter ype Champion C1O11C169 Pump ype So. Tatin gear Given by intermediate shoft together with distributor Pressure (2000 pin with ot temperoture 80°C) SOE 2 harminimanr Torque wrench settings vm wort Engne to gearbox: mio : 4 33 mre 35 5s Exhaust manifold nats coe 2 6 Exhaust pipe to mani 62... a6 10 7 Fiywheelciveploe bots 20 6 Clutch pressure platetwasher bolts Wenew) «> eaewcvarea HOt ” Sump bots 20 6 Sump dh plug a me 30 2 Main bearing capes > sreenamni 65 48 CGonnsacting ro igen cap rats Stage 1 eaerauroevianatensatett seen a Sage DATES urthor tighten 14 tan (00°) Gil flnip BBS yenraceosnnesneeerarxcessaanan excrete 10 7 Oilpressure suite 020022 SITINIET crane: ® Gitfte lange bos 2% B Front seal Henge bolts a = Smal. es 2 % ange cy 7 Intermediate shat tlange bots 2... coe ry 16 rah bata cap ats fn Suen)... a 20 6 Camsheft sprocket bolt. z ® 89 Vahe cover nts. 10 7 fet tensioner pailey 45 a Crankshaft sprocket bok filed) 200 148 Imomedae shat pocket bok sso esccton niacin, 8D 50 V-belt puley « ‘ es 0s 2 6 Timing cover oa Scanmeeeeemrencen 10 7 Rear cover lower bits > eraaencrsT soa 30 2 Rear cover (op bot mo . 10 7 Goctant pump bats 2 6 Fut pump bats 2 % Distrbuter clamp bait. on 5 1% WAT VW Goll R JettaEngine repair procedures - 1.6 and 1.8 litre 8 valve 2C+5 Cyiner hend bolts fengine cold) Rater to 3 ay Me ayanio . by a. 8 5 9) * Viner checking the connecting 1-0 fstration 525. Alo 40 sa and 40th ie Past A ofthis Chapter. 2s for 1.05 and 7.3 Bre engines Fa 45 35, 45 50 © 70 20 1 a 2 B 2 a4 82 sa ankshatt journal rata clearance using Pastoage. tighten only to 30m (22 tA 1. General intormation Tho 1.6 and 1.8 fue B-valve engines are of four-cylinder, in-kne, overhead. camshalt esigh, meuinted transversely et tha front of the vehicle, The transmission is attached to the fyurieel end of the engere, "The crankshaft is of fhe nmin bearing type, Its endtioat beng conuciled by a shouldered centre bearing or by half thrustwashers. locate each side ofthe centre beating, The ecarrshat is driven by a toothed belt hich is tensioned by a tensioner on an frocentic bearing. On engines manufacticed bbotore August 1008, the vnives are operate! by burke! fype com flyers in rect eomtact wth tho eamstalt. From Augsst 198, ll fengines sre Thied with a redesigned cykinder head incorporating hydraulic bucket tappers in place of the previous shim bucket tappats, Camshaf. beoring No, 4 is deleted on a single camshaft engines. In order to identity the ype of tappets fied. a sticker is normaly ‘aixod to the valve cover indicating that valve Clearance adjustment is neither necessary nor possible ‘An nctimediate shat (dewan bythe tothe turing belt) dives the cisibutor anc ol pump. anedon carburettor equipped engines, the fuel pump The oll pump is of win gear type, deiven fhom the immediate shalt and ineaeperates pressure tall valves. The aluminium cylinder head is ot convertion design wah the inlet and exhaust Iavifokls mountaxd on the rear side (as vitae wth the engine in the valve), The crankcase ventilation system comprises a hose rom the fytee! ene ofthe ake cover ta the sic ofthe a carer ‘On fue injection equipped engines, there is ‘a hose tothe ai init manifold and a hose to the air cleaner from a three-way connecter on, the valve cover. 2. Major operations possible ‘ash engine in velcle The tollaving operations can be cariod out that having to remove the engine fam the vehicle {2 Removaland seracing af te cyber feed. camshaft and timing belt 1) Rone ofthe crankshot ear ow seal fatter removal ofthe transmission, hireplato or clutch 2° appaicabe) £) Removal of tho sup ard od pump Gh Remon of the pstorsiconnecting od asso fatter remneval ofthe eyfeder tread an sap) 9} Ronen ofthe erarkshatt rental seat mermectane shat iron el saa! and canst Fon cs se? 1) Rene! ofthe engine mourtings 3. Major operations only possible after removal of ‘engine from vehicle The tollowing operations can only be coariod out after removal ofthe engine trom the voit: 2) Ronewat of crankshatt mata bearings 1) Removal and reiting of the crankshaft ©) Removal anc veliting ofthe imermmebate shaft 4 Method of engine removal 1 The engine. together with the geotbex, must be fit from the engine compartir then the engine separated fram fre gearbox nthe bench. Too poople wile needed 2'Ahkat of 150 kg capacity wil benacded to Ii the engine approximately 1 mete. the hist is not portabie and the engi is Hed, ther sufciee foom rst Be Ie behind the vec w push Rock out of the voy so that the engine may be lowered. Blocks wil be Insedel to spe the engine aller remenal 3 Ideally re vehicle souls be over a ptt this i not possible then the body must be Supported on axle stands (Gee Jecko and onl support) so ta the tert hauls may be tuined to unde the drivestt nuts, The Tofchand shaft fs aesessile om above but the right-hand shalt must be undone Ieom undereath Removal othe gears Erkage tan only be dre rom underesth ss co teshaust downpipe to-manfod detect 4 Tho exhaust downpipe 1o-marifoi ange Eonmectinnf secured by opel spn cps rather than bots or studs and mats, When 1081 VW Gol & Jetta disconnecting and reconnecting the jomt. it wl be necessary to use YW toal no. 30N5A, Without this toch detachment ard certainly reconnection of the jint and clips i vinwally Imposuibl, 20 make arrangements to Bort fr fue the toa in advance. 55 The only other special tots required wil be 2 set of splined key wrenches which il Be needed te remove and rei dhe socket-head boltstised te secure corinin dems suchas the cylinder heat bots, 6 Diaining of ofl and coolant is best done say Wom ths working area if possible. Ts ‘saws the mess mada by spied oll f the plane where you mast wok. 7 Akhough not ksted as an optional fing er UK mois, ei air conditioning system may have been fitted. Where this isthe ease, the following precautions must be taken when hondling retngerant lines or system ‘components 1} Donat sts or bend Restle hase Hines faa radiom of less than 107 men ) Flaubie hose fines must be correctly located, mast nos chote agains: acjacent orapenents ana emust be kept wel clear ofthe exhaust porifold and downpipe ©) Allretal tating fines must be Rep fae of Kinks are! ees be haved wh care oh Beant discomnsct ay ofthe a conditioning supply ines 16} Barnat weld or apply heat inthe vicinty of the a coneiiening fines oF equiomer® it any part ie systema o he detached thea f must fret be depressurised by your YW desler or a competere ne contening systems engineer. ine only excepdon the removal and Hing oF the compressa sivabok which can be aciiaved ithe some mannet a3 forthe aternator aivebo 0 5. Engine -removat Carburettor equipped 1 Disconnect the batery negative led 2 Remowe the bonnet. 3 Dyan the egg codon 4 Postion a suitable container beneath the engine, unde sup da plug ond dai tng od see Chater On commlsion dean the dain phi ancl Reneve the Ong,2C+6 Engine repair procedures - 1.6 and 1.8 litre 8 valve 5.8a Oil pressure switch location inrear of ‘oyinder heat 5 Remove the radiator, together sith the ‘eooling fan, On models manuiactuted after 1908, remove the front panel before removing the tacitoe 6 Remove the at clone unit then disconnect the throttle cabin al the carburetor. Postion the cable out ofthe way 7 Where power steeting is ited. remove the hydraulic pump drivebelt. Unboit the pump, bolt tensioner and fai reservoir and te ter tone sie ofthe engine compartment B Disconneet the following wing Connections, identifying each lead as itis tiesached a sword contusion an reassembly: 4) Atermator Koad 1) Ol pressure switch leads) at eyinder head (600 Mustrations) are oi fie: bracxet 2) Ieee anit prebeoter thermo: switch ‘cod 3 Choke cover thermo switch lead where epptcabie} 6 Ignition HT and LT feods 1) Choke cover load separate conmecter 9) Coolant teperature sender nit ad 1) Earth strap goarbex (see llustration) land muti:tunction switch to goarbex 1) Starter motar leas 8 Disconnect the fuel supply hose from the uel pump ane te fuel return hose (othe tel tank), Phig tha hosas to prevent fel leakage 40 Disconmicet the coolant ana heater hoses From the engine. '5.8b Oil pressure switch location in fiter| ‘mounting '5.24 Engine rear bearer 11. On manual gearbox models, disconnect the clutch eats 12 Disconnect the following tems from around the carowettor, entity the connections. where oncessary 0. avoid ‘confusion on reassembly: a} Thermotime valve 1 klesovernun cut-of voir ©) Inet manifold peohoter separator connecter 4 Pat tio channel hoster separate ‘connector 13 Disconnect the speedometer enble from the tanemston ¥4 Disconnect and remove the vacuum reserver. 5.28 Hycro-type front engine mounting Refer to Specifications for fastener terqua wrench setings b, eand WAT VW Goll R Jetta a = '5.25a Engino/gearbox unt front mounting 15 Disconnact the brake vacuum servo hhoses ard the vacuum hoses from the inlet rondo 416 Undo and remove the gearbox mounting bok 17 Raise ond suppor the vehicle on axle stands (see “Jacking and vehicle support), alioning sufficient clearance (work lunderneich 18 Disconnect the manusl gearbox linkage. 19 Or automatic isnsmission models, seloct P (Park) then cisconnest the throttle anc Selector cables from the transmission, 20 Disconnect the driveshafts tom the {eatbo« and tis thera up out of the way. 21 To dieconnect the exhaust manifokl {downpipe connoction, VW tool no. 30494 wal be required, Although & may be poseble ta prise the clips (ree to separate this joint. the too! will definitely be required to retit the springs. 22 The vehicle can now be lowered, the remaining removal operations. being trom above 22 Aitoch 2 suitable sling ane! hoist to the fenginelgent box unt and take its veka, 2A Disconnect the rear engine bearer by lundang the thee bros (see dkasteation, 28. Thn engine:gearbox unit fron manning must now be detached by unscrewing anc removing the single throug-bok. It may be focsary ta furthor HR kao” wit the unit te allow the srrough-bol to be withdrawn (see istration). Noto that irom December 1934, the front mounting is changed from the bonded rubber type to a “hydro” type wil ‘damping scton (see iustraton).Engine repair procedures - 1.6 and 1.8 litre 8 valve 2C+7 26 The engine/gearbox writ fs now ready for Titing ot but fest make a final check that all cables, wing and hoses are clear, 27 Have an assistant at hand to help guide the une car of the surraunding compares Inthe engine compartment as iis ited out it wl have to be twisted fghtly os ite ar of the vehicle, lower ic 19 Fuel injection equipped 20. On fuel injection equipped enges, the removal procedure closely foams that ven for carburettor equipped engines. However, clstegard those heme concerning éetachment buettor and associated tems, The injection weuspmment ites will reed to be disconnected irstend, Reter ta Chapter ‘oe ter das: 29 Disconnect the wies from the watrn-up rave gyn conneeto (see austration 30 Disconnect tha wiring to the cold start valve blue connect 31 Disconnect the wiring to the aunty si wake 432 Disconnect the thottle cable atthe fast idle cam and bracket but do nat remove the securing clip (see illustration). 33. Remove the cold scart valve but leave the jul ines connected, Psce cu of he way | Dkzerneet the aint pipe st the Hele ducting attaches tothe tote housing 35 Disconnect the vacuum hos Fram the inet mantokd snd vaciaim booster. 136. Leaving the lel lines connected, unde the Fetairing bolts and withdraw the amp zalve ftom the cylinder block. Postion out of the way 37 Detach the injectors from head and plug the holes, Discomect the insctor ne rom the locating Bracket cn the trons housing and fol thom out of the way. [38 Cetach the vacuum hosts to the tote housing or location cp a the '5.29 Wiring connections to be detached - fuel injection models Aterstor 5 amp vais 1. har of pressixe 4 Oitomperonice sercter bulkhead, Fold the haces back cut ofthe way. 39 Discanneet the off temperature switch sender lead (see illustration) 40. When liting out the enginerqeetbox unit, greater care wl ta be taken it vuvring the unit tom the engine Distibutor HT cate ftermuna 4) Coole tomperatre 9 Thaamotime switch 10.0.3 bar ol prose wich 19 Cold stort ve 12 ataicy a ive 2c ‘compartment cue tothe close proximity othe fi ifot marvioid tthe bullvead. The tink alt heed to be pulled lorerds fet then twisted and Hed, '5.32 Fuel injection compononts to be detached 1 Throwle cote 2 Cold sar valve 3 Vacuum hoses 4 Aisinoke pipe 5 bjectors 1081 VW Gol & Jetta 5.39 Oil temperature sander (arrowed)2C+8 Engine repair procedures - 1.6 and 1.8 litre 8 valve 6 Engine/gearbox - ang reconnection HE This procedure is uly described in Chapter 2, Parts of 8, ns applicable, It is only necessaty to feler co those paragraphs ppsttnent Co he particule mathoe! being used The engine musi ba suppories! on blacks. 0° ailercitvely the gestbox can be separated ‘uth the engine stil on the hoiet, 7 Engine dismantling -gerierel infermation Refer to Section 7 in Past Af this Chapter @ Engine ancillary components, removal S 8 With tha engine removes! rom the vahicle and soparated from the transmission, tha ‘extemally mauned avery components can bbe removed prior to engine d'smanting, The ewence need not necessary oe? a) Altecnaton art civebott 1 ret vari ad ea Imani anes tate ‘Giction ce) Eau mantel ) Fucipurmp (0) acm valve attached fh Disinberor £9) 0 ter wih coeler frhere yptonbt) fad her mounting A) Oi pressure ane coolonctempe jet injector), i 1 Coolant pump and ceotant hose ‘connects from cylinder block ant head ew O-rings vt be teas 4) Chath than intermediate psi fmoend gents} 1) Driveplate, noting locaton of spacer andt semis (nstomart barsnissen) 9. Timing belt and sprockets - fomevial N 8 1 if the engine is sil in the vehicle, frst carry ‘out the feiswing poration 2] Bisconioct the battery earth lead 1) Ronen tie ateenatar drveber ©) Unbot ane romave the coalont perm pusley 2 Depending n typa, unde the retaining bolsinuts). release the retaining clips are Ferove Uke upper timing cover (see itlustration). On come engmes it wall be necessary to remove the bung fem the lant ‘TOOTHED BELT COVER, UPPER roses se oenioncr — 0 Se PULLEY OR IBRATION DAMPER, Py 35.8 Tin om ¢ 9.2 Timing belt and caver components aoa vi Goll R Je TOOTHED BELT COVER REAR CRANKSHAFT SROCKETEngine repair procedures - 1.6 and 1.8 litre 8 valve 2C+9 9.8 Intormecate sprocket timing mark (arrowed) aligned with [ | | | | | | | | | | | | | ‘notch in crankshaft pailley face of the cover to allow aecoss to the fen type retaning serew recessed within the Cover. On other engines. the retaring screw can be seen but is koy slot ts deeply recessed laccess to K being made via the hole inthe centro of tye screw surround! 23 Unserew the ns andi Boks fram the valve ‘cower and remove the cover together rath the ‘packet and renlorcement strips, Detach the ‘crankcase emission Rasa from the racket 4 Mark wre relates: positions of the crankshomt pulley and crankshaft sprocket. thon unis the Tour secket-head ote and widow the pale. 5 Unbolt and withdraw the lower timing § Tho engine must now be set for timing Tenia the cake paty- the > timing hel ane (oth fas 2 cenure-punch mark. Turn the fengine unt this mates wath a notch on the \-bet pulley bolted tothe crankshatt sprocket (Gee illustration), To tuin the engine over remove the spitk plugs then fit a suitable spammer onto the evenkshalt sprocket retaining bolt and turn nthe clrettion ot Engine rotation 7 Vuhen these marks match, look at the sprocket on the camshaft. One tooth of this, has acertre-punch mark. This should be keel with the valve cover flange (Gee Hustration) Having turned the engine untl these marks agree. nous look at the cams tor No | finder Incaroct the timing bel, They wil both be the ‘valve closed position (see illustration) Now lock through the hole in which the TOS sensor goes wdtere the ting marks show on the periphery of the Miwhee! and nate the reeding, 8 Before removing the timing drivebet. check its corect tension. held between the frxger ‘and thumb halfway betwocn the intermedioke shalt and the comsnalt it should be just possible to twist it though 90° (ee Hlustration). If fs toa slack, adjust it by slackering the bolt holding the wscertic cam fo the tensioner whee It you are Saisie’ an be adjusted ta the correct’ tension, move Cand examine it fer amar ow i the tine to order anew one if necessry. 8 Loosan the tensioner then witha the timing bel fom the camshatt,iotermediate ane crankshait sprockets 40 Each of the timing bell sprockets is secured by 2 cenual bot and 9.78 No. 1 cylinder cam lobes in valve closed position ‘28 Timing bel tension check mothod 1081 VW Gol & Jetta 9. Camshaft sprocket timing mark (arrowed) with No 1 eylindor ‘aE TOC on compenssion intermediste, camshaft. and crankshaft sprocket the latter in particulat) securing bolls are tightened te @ substantia torque and to sprockets wil tharofora noed 19 be firmly held water undoing the bots. 11 To remove the camshalt sprocket a the bolt wih the sprocket held ionaty by inserting a suitable meta bar trough 3 sprocket hele and resting it on the valve cover face ofthe cyincer head but take care not to damage the face. Remave the bolt and spacer wasner then withdrew the Sprocket, tapping it tree H necessary, Check the fof the Wioadulf Key inthe carmshat. & must be renewed i loosen is groove. Laver out the Woodrulf key and keep it with the sprocket 12 To romave the crankshaft sprocket, hold the crankshaft stationary witha fever jammed In the starter ring goat femove the starter rmiotor a applicable). Do not allove tha crankshaft ko tum othe pistons may touch, the valve heads, Unsere the retaining bo and remove ii, together smth the spsicer washer then lover the sprocket free trom the nikal, Check the ft the Woodkell key (it fitec) in the crankshat, it must be renewed IHoose in te groove. Lever out the Woods key andl Koop i veh he cranial spxocke. 13, The intermedinte shat sprocket is removed in sinvlar manner to tat for the camshaft sprocket 10 Camshaft - removal 3 gxemination and refiting 3 x Removal 1 To remave the camshaft with the engine in tho vehicle, frst carry out the fellowing operations 3} Reoove the ting caver and valve cover, nen cesconnect ta tng Be rem te cumshot sprocket 2c2C+ 10 Engine repair procedures - 1.6 end 1.8 litre 8 valve 402 Cylinder head and camshatt components - fuel injection engine WAT VW Goll R Jetta 1) tthe camshaft ol seats 10 be conowed then the eauishaft ning sprocket must be remover! 2 Remave the camshaft bearing caps (see jstrations). making careful noe of helt positions for reference whien refitting The caps ate numberce! (see ilstration) but mark the sice nearest the font of the cylinder fread. No, 1 cap =the ane with 2 small il eal 3 Remove cap nos. 6, 1 and in that order. Now unde the nuts holding 2 and 4 in a agonal pattern, The camshait will MC the caps up as the pressure ef the valve springs is exerted. When they are fre, It Une e2ps off along with the camshatt. The ol seal on the Tront cnd of the eamskatt wil come with & Depending on toppet type, proceed as Foliows: ‘Shim bucket tappets 4 The tppet buckets are now expose! and h may belted out (29@ Mustration). Tako © ‘ane cn ha, prising the tle dic en ing a small screvaiver either the disc away. On its reverse, each disc fs engraved with a size feg. 3.75) This wits thickness murboe. Note the number and then clean the cise nnd ret, number Sue down, There are eight of these end they rust not he mixed up. On assembly, each ise must go back into the bore from whence camo. This problem exists ales for the volves, 20 a contafer for eactvahe assembly 10.2e Camshaft bearing cap number {arrowed} 10.4 Tappet bucket and shimEngine repair procedures - 1.6 and 1.8 litre 8 valve 2C- 11 sev tappet is rcpited Label the containers 1 18, as fallen: Containers 1 anes 2 wile No eye ‘exhaust and inlet respectively Contanars 3 an 4 willbe No 2 eyinder ‘exis? ond ile respecte Containers 5 arch ut be No 3 cy Inet 2a exhaust respectively Containers 7 onet® vail bo NO 4 cy Inlet and exhaust respectively 6 Note tha thickness of al tappet clearance dises trom Nos. 1 to 8 for use ctiring reassembly, Hydraulic bucket tappets 6 Lift cut the tappets ane by one. ensuring that they are kapt in thet coreoet order and ‘an be ecarred To thet orignal bares 7 Blace them. cam contact surface down, on {clean sheet of papar as they are removed. 8 Inspect the tappors fee wear tinciated by ridging on the clean surtacel, piting and txacks. 8 Tappets connor be repaired! and if wor, rust be onewed. Examination 40 Reler to Section 27 in Part A of this Chapter wit nating that on exchange fenginas or eylinder heads, the camshalt Is cupplind wth bearing shell erkeae! of rirning rectly in the head and bearing caps Exchange units supplied by WWE may have an Undersized camshaft with corresponding bearing shells, Where this 1s the case, the camshaft val have a yellow point spot on ‘avd journal clameter ill be 25.78 min. unmarked camshatt supplied sth bearing shells vol be of standard wien vita journal ‘ameter of 26 00 min, Refitting 11 Refer to Section 12. incor 11 Cylinder head - removal = All engines 1 Irthe eytraer head is boing removed with the engine out of the vehicle, proceed from paragrapi 17. I the cyinder head is being Femoved vith the engine in the vehicle, itis best removed with the inlet andl exhaust rmanifoils. The manifolds ean then be detached after removal of the cylinder head but note that special tool i= exqpuired to release (and subsequently reconnect) the ‘exhaust downpipe to: mando ange rotairing cps, A spied key will alco Be requitod to unde and tghten the eylinder head bolts. 2 Diccortwct the battery anh lad. Drain the baling system, then disconect the cooling ‘avd heater hoses ram the cylinder hese 3 Oiscomect tho thermoswatch and oil pressure lead connections 410m carburetor modal, remove the ai Cleaner uri 5 Disconnect the lear fom he eye head attachnant beaches and remove the cbivedeh 8° removing the marifolls with the cylinder head discoonect th enum hose rom the ince morifol) and the acorkrator eae are Choke cable 'tappiicabh) trom the Soret T Disconnect the HT leads from the spark pugs Fuel injection equipped engines 2 Detach the injactor tines trom the cylinder ead and locaton elpe and tld uhh back outos te ay 8 Dieconnee the inst duck at the Hebe hose connec fo te vot valve housing. 40 Detach the vacuum hoses to te thre Salve Fain ae at the tee way eon etor onthe bulioad side ofthe cylinder head Fotl back ae! socire the fost out ofthe way TH Disconnact the auniiry air vale load trom the nese ol the int mantel and the anti vv ovate Ho hase tothe ite vole bean 12 Disconnect the serua yest hose em the green connector om the lei hae on the ete ben BE Iai concltioning is Hitec, detach the hases trom the airy ar valve ond tbe onmections 1 Detach the MEI hose atthe caro hose valve connectcn 4. ach te wiring connector rom te ool tet ve. All engines 18 Remove the timing cover and vahe cover then disconnect the timing bek Hom the camshaft sprocket, 417 Remove te carmshalt. 18 Romove the cylinder head bolts. Those fre recesced in the wel of the cylinder head find ate socksthead bolts, They mast be Femeived using the covtect splined to 39 The cylinder fmad bolls most be Lnserona! tia progqessive manewr aad nthe reverse sequence to that shasm for lightereng. 20 Wien allen bolts have been removed. et the hae! foo the eyfncer block Ie may need alitia tapping to loaser i but do not ty to Pris t lone by hammering in week, Lilt of the gasket and, if the engi 1% not bog dismantled, clean the piston crowns and block face. Note that the cylinder head bolts must not be reused, a rear set will eed to be obtained when ordering the cylinder head sgaskat set, 12 Cylinder head - dismantling ani! overhaul 8 1 Using a wire brush, seraper ancl stool wool, clean “all carbon from. the combustion chambers, valve faces and exhaust pons, Remove the spark plugs for cleaning 2 The valves are rat easy to get out unless & ‘ultable yave spring compressor is avaiable. Because the collets and spring caps are set so lar down in the head. a long claw is necessary on the compressor and it must be Split cuicionty to enable the costs to be removed and insored, If such a tool is not 19 hand then hind a piece of stel tube of about 25 mn inse ameter which wi ft over the valve stem and press dawn the spring cover {s0¢ istration}. The Ieneth wil depend on the size of the compressor so. Mt compressor over the Head fully extended, ‘measure the distance between the claw ard the valve spring seat and cul the tube to a suitable length 3 The newt step is to cut two windows of Suitable size (opprox. 28 mm long and 16 mm rie in opposite sos ofthe tube, The tbe rmmy than be used with the compressor to fetract tha collet from eich valve stam fy turn. Place the valve. springs. colfsts and Seats with the lappet in the sppropate receptacle. keeping them sivelly tagether for feliting In the valve guide from which they rete taker (see thu stration) if your fingors are too big, puta blob of grease on the ‘collet and pick it up with a small screwdriver, the insort it into the slot on the vaive ster. 12.2 improvised tool used to remove and oft collets to valve stems 1081 VW Gol & Jetta 12.3 Valve springs. cap and collets 2c2C+12 Engine repair procedures - 1.6 end 1.8 litre 8 vaive 12.12a Inserting a valve into the cylinder ‘hoad 4 The valve springs rst be renewed # they ‘are damaged. distertad, oF known To have ‘covered « high mileage. Hin dou. 35 to the concition, have your ¥#l dealer check them for compression efficiency using # caltated sale spring compressor. 85 The valves should be cleaned and checked for signs of reat or barring. Where this has fsccirred, the inlet valve may be reggound on fe machine at a dealer, Exhaust vaives must pot be regrourd on the machine but ground i> by hand On engines fitted with Ryeraulie tappats, valves should nat be re-cut a= this vail adversely affect the operation of the tappets, 6 WWew in the valve quides may be detected by fitting a new valve in the guide ond checking the amount thatthe rim of the vale wil move sideways whan the tp of the valve stem is flush wih the top of the valve guide, Tho valve rock mnie are gwan in the Specifications. New valve guides must be fitoe and reorned by your YW donor. 7.Do ot spend 90 tong arincing in the valves, I the valve seat and valve are not Satisfactory after 1 minanies then you vil probably sf more harm than goed! by going fn Maka sure both surfacas aro clan, smear ‘grading parte antothe wate evenly and sir, 2B suetion up, swork the vale with on Dscilating motion fing the val away from ta seat bccastonally to stop fdging. Clean the sent andl vnlve oquent'y ane enmry on fe valve than wipe al i the pasa, 8 The surface of the head must be checked wih a stlaigh-edge and feelar blade, Place 12:12b Locating valve springs ancl cap. the stiaight-edge along the cane of the machined lace af the head. Make sura there fare no ridges at the extreme ents ard mrieasute the clearaace wih feelers between ‘each combustion chornber head. This i the een where the neeraest part of the eynder ‘read gasket comes ane! where the gaskets rast bey to fa Ifthe straightedge istry in place ard faers in excaes of 1 men can he put between the head and the siraight-adge, then the head shoukd be taker 1to.a dealer for servicing oF rephcertest 9H the cylinder head shows signs of ‘racking. have it inspected by your WW dealer ta assess ts coneltion lor reuse 10. VW recommend that the valve siem olf seals should always be rencived to prevent possibie high al consumption. Pung off the ‘ld seals simple with piers. With a packet of ‘ew ol seals is a smal plastic sieeve. Ths is fined over the vale stem and lubricated, The seal should then be pushed over the plastic ‘cove unfl sete of the gue, This shoul be done wth VW too! 10 204 which ts spugly ‘ound the outside ofthe seal and pushes itn squarely the seals assembled wahout the plastic sleeve, it wil be damaged and oll consumption wll beeome excessive 11 Before rerssembling the eylinder head, ‘check the condition ofthe cars 42 When all components have been ‘examined, then assembly of the head may ‘commence. Ineatt the valve in tho eorract ‘guide, ft the inner seat, valve springs and ‘outer cap, assemble ‘the velve sping, ‘compressar sel possibly the smal fuse and ‘comptess ihe valve spring until the colleis WAT VW Goll R Jetta 12.lee ... and valve collets may be assembled to the valve stern (see iMustrations) 13 Assemble the second collet ane hokling thom caratuly topethar in place, eace off the compressor unt the spring seats the cclets home. Remove the compressor. put a rag ‘vet the valve stem and tap the stem with 3 Iharnmer. Ths is to ensure thar the eats ate sented comectly I thay are they vill nt come fut, Repeat unt all eight valves are m position inthe cylinder head 114 Rail the tappets in the bores trom whieh UHey came, lubricating thei Mberally with clean engine ol (see illustration). Lubricate the camstaft Beare surfacns with all and i the camshalt, positioned se that No 7 cylinder ‘came point upwards. 15 Fit a new oF seal at the sprocket end. lubricate the bearings, set the shaft in postion ‘and install baaring caps Nos 2 and 4 tightening the ras in a diagonal pattem unit the shaft is iv place (see illustration). Nowe install the ether bearing caps. making sure they are the fight way round (marks towards the drive pulley} and tighten the caps down, using @ diagonal patosn ta the specified torque, Install a few rubber seal at the ‘opposite end to the spracket 16. On engines equipped with shim bucket Lappots, adjust tho valve clearances 13. Sump and oil pump - removal i ani refitting . 8 Modification: From August 1985, 9 farger sump i Fitted hereby increasing engine oi! capacity 1 renewing the sump, entire that ‘one of kiemncal capacty i ced Removal 1A te egies isin the wie then cain engine oil Note that the sump plug fas ar Ouing ishich must be renowed (see fustration) 2 Undo the sump retaining boks and remove the sump from the lower face of the srankcase, Remove the sump gasket which must also be renewed 3 To remove tho oll pump. undo the two retaining bolts and lower the pump unit.Engine repair procedures - 1.6 and 1.8 litre 8 valve 2C- 13 Gears. Oil pump cover with pressure relief valve o-ring Intake pipe — Sump gasket 04 crain plug So-ring ~~ O-ring — PP 4 Oe Ol pressure aq ‘switeh Temperature sender Dipstick o-ring it titer bracket it seat oi cooler ‘sump complete with the oll pick-up pipe ond Refitting 4 To refit te pump, ensure thatthe mating faces ae lean. cate itm poshion and and tighten the securing bolts to the specified torque. 5 Locate the new sump gasket but do not 2pply an adhesive sealant, Relit the sump and tighten the retaining boite evenly to the speritied torque 6 Retit the oll drain plug with O-ring ane Lighten itt the specie trou 14 Pistons and connecting rods “removal HE 1 Resrove the cylin hea. 2 Revove the sump. 3 Unscrew the twa of pump rotaining bots then laer end remove the pump, complete with oll pick-up pipe from the crankcase. Place ton one side lor cleaning wad inspection, 4 The picton and connecting sod removal procese nove fedloer fat giv fr the sma tengie vorors in Part At this Chopter. 1081 VW Gol & Jetta 415 Crankshaft and main bearings - rarnoval 1 Disconnect the pistons and connecting Fads from the crankshaft, Nowe that, aknough to engine has to be removed to remove the ranishifl, the cylinder head, pistons and 2A ting rods can be lel in postion the flywtiee end, uno and remove the bolts securing the oil seal flange to the crankcase (s2e illustration). Withdraw the flange. seal and gasket. 3 Examine the main bearing cops, it ail be 2c2C+ 14 Engine repair procedures - 1.6 and 1.8 litre 8 valve Main BEARING CAP cuunen cc, SEARO ance BEARING SEAL seauns Foaee ‘ é ‘anus wasier =e 8 MI BEARING SHELL crANasnart seen that the caps are numbered 110 5 and that the number is on the side of the engine ‘opposite the oil pump positon. Wentiy these umber they are obscured, ther mark the caps inthe sare way as the connecting rod caps, Before removing the caps, push the Cranksholt to the tear and check the endfioat Using a feeler blade between the thrustwasher Hianges on No & main bearing and the crankshait wed (See iustration) must rat exceed the speciied maximum. 4 Remove the bearing cap retaining bolts, remove the bearing ceps and hit out the thrustwashers from each side of the centre main bearing 5 Lift out the crankshaft and ther remove the top hall bearing shells. If the main bearings ‘ore not being renee, make sure the sbells fate identified so that they go back kno the: Same beating cap the same way round 416 Intermediate shaft - removal g 1.The intermediate shaft can only bo thaw rom the crankcase wih the engine ‘emoved from the vei 2 Remove the ining belt ¥5.2 Checking crankshaft endfloat st ‘No. 3 main bearing 16.8a Intermodiate shaft retaining flange bolts (arrowed) WAT VW Goll R Jetta 18.2 Cranicehaft and cylinder block components 3 Remove the fuel pump en carburettor models and Ue inition dist iautor 4 Before removing the intermediate shalt, ‘@vack that the endflaat does not exceed the rnisirunn spectiee ares 5 Undo the two seaing flange retaining bots then withdraw the intermediate shart, complete with sealing flange (see iystrations). 6 Withdraw the sealing flange from the Inermediate shatt, The ofl seal within the flange and the O-ring must be renewed on reaseembly. i i 16.5 Withdrawing intermediate shaftEngine repair procedures - 1.6 and 1.8 litre 8 valve 2C+ 15 17 Oil filter - renewal Refer to Chapter 1. Section 18 18 Oil cooler - removal and refiting 1 On tuel injection models. an of cooler is Fated teawenn the oi liter cartidge anc mounting bracket, The coolet mist be renewed if the engine of has been Contaminated with metal particles, such se might be the case following total or partial frvgne seizure, Renee it anynay # IS Hkely to contain any other harmful contaminant 2 To remove the cooler, first remove the of Finer carte 3 Drain the cooling systern and disconnact the coolant hoses frm the cooler, 4 Romove the coolet retaining tut and the cooler. The O-ring between the cooler and ‘mounting must be renewed. 5 Rofiting Is a ceversol of the removal Procedure. Wipe clean the sealing faces ofthe Soler and mounting and smear the O-ring wth claan engine of On completion, top-up the engine oil and coolant levels. Sart the engine and check for any signs of aks, 19 Oil filter mounting - removal ‘and! refitting x 11 Remove the il ter and on fuel injection reels, the oil eonke 2 Disconnect the oil pressure switch lend Lndo the oil ter mounting securing bots and vethane the mounting and gasket 2 The oll pressure evaich can be unscrewed Item the top face of the mounting i recuited Fenke the sith Orig, 4 Roliting fs reversal of the removal Proctahve, Ren the mounting gaske, Note: The following procedures wore a corned cxt with the engine the vehicle Crankshaft seals Flywheel/driveplate end 1 On manual georbox modets, remove the dutch and pressure plate, On automat nsinission models, remove the tuanseission then unboit the driveplate from the crankshaft, nating the location of the spacer ard shit) 20 Oil seals -renewal 2 Carctully prise out the oil seal with a Serewdever of sion ite and wipe clone the recess (see illustration) {Fill the space between the lps of the nev seal with muli-purpose ytease, then deve i squarely into the housing using @ black of wood er suitable metal tubing. IF Atal possible, use VW fitting sleeve Ne, 2009 to ‘avoid damage tothe cil sea ip. 4 Refit the eiveplote or hutch, Timing belt end 5 Remove the alternator, together with its thee, 6 Remove the timing belt cover and timing bet ensuring that tho timing marks. are correctly aligned 7 Unsciew the bolt rom the Wont ot the Crankshaft vithdraw the pulley and sprocket fand remove the Woe key Cn mantal gearbox models, i the be citicult 1 foosen, have an assistant engage top gear and. apply the brakes, On automatic transmission models, romove the starter model and restrain the driveplate ring gear ‘oth a suitable lever, B Prise out the oll seal or extract k wth WW tocl No. 2085, then wipe clean the recess (oo istration). 9 Fil the space botween the lips of the new seal with mult-purpoxe grease, then deve it squarely inte the housing using a block af Wood oF suitable metal tubing, Hable ure YW titing leeve No, 3083 10 The remaining refiting procedure is a reversal of removal, Ensure mechs ate aligned belore 1 bait anc tensioning it Camshaft front seal 11. Remove the alkamator together with its driveoeh ‘12 Remove the timing bet cover and timing belt ensuring that the timing marks are correctly algae 13 Hold the camshaft sprocket stationary vith 2 screwdrwer merce through one off hiss, then unsere te bolt ant remove the washer, sprocket and Wood key 14 Prise out the off seal er altematively 20.8 VW tool 2085 for removing erankshait cil seal timing belt ene) anc ‘oamshatt oil seal 1081 VW Gol & Jetta 20.2 Flywheel end crankshaft oi seat ‘components weplate 4 Sealing eng (ot ‘ete Yo al models extract i with YW tool No. 2 lean the recess 18. Filthe epace between the fips.of the seal with mui purpase grease. then eve it squarely into tho eVincer hoad using block Gf wood or suable metal tubing, It avalble ‘se VW fing sieave No. 10-203. 18 The remaining reiting procedure is 9 reversal of Femoval. Ensbre that the Ling marks are aligned before reiting the timing bolt ond tensioning it Intermediate shaft seat 17 Remove the alternator together with its vebet, 1B Remove the timing tet cower andl timing belt ensuring that the timing marks are conoctly aired 1B Hold the itesmediote shatt sprocket sinvonary wih a serencete inserts trough fone of its holes, then unsczrur the bolt and emove the washer. sprocket and Waodrutl key. 20: Renew the ol sea 21 The remaining reliting proceduro is a reversal of removal, Ensure that the Lining ‘marks are aligned before reiting the timing balt and tensioning it 085, then wipe 21 Examination and renovation = general information Ree to Section 20 in Part Act this lee 22 Crankshaft and bearings - examination and renovation, 8 Refer to Section 27 in Part Al this Chapt2C+ 16 Engine repair procedures - 1.6 end 1.8 litre 8 valve 25.2 Examine face of oll pump cover for eis s = g Refer to Section 22 i Pat ofthis Chopte. 23 Cylinder block/crankcase - ‘examination’ and renovation 24 Pistons and connecting rods. + examination snd renovation g PRetor to Saction 23 in Part ofthis Chop. 25 Oil pump - exerrination and. renovation: = ss 1 With the oil pump on the bench, prise off the cap with a screwdriver and clean the strainer gauze m fuel Refit the gauge and presson the cap. 2 Remove the two small hots and take the over wey fron the bexly. Examine the lace Of the cover (506 illustration) As con in te 26.3 Checking oil pump gear backlash Mustation te: gears hove matked the cover, Ite dept of this marking is sigrficant, then ‘the face of the cover must be machined tlat grin, 13 Remave the gears and wash them with the body in clean paraltin, Dry and reassemble the gears, lubvicating thom with clean engino ail, Measure the backloah between the gears vith a Ieeler blade {see istration). This ‘hould be 0.05 to 0.20 mm, 4 Now place a straight edge over the pump body along the lite joining the eenkre of the tivo goars and messure vith a feear blade the axial clearance between the gears and the ‘straigh-oxge (see illustration) This must rot ‘exceed 018 ri 5 Wallis well, check thatthe shafts met slack in beorings and teassembde the pump for fiting tothe eng, 6 I there is ary doubt about the pump, is Fecommended that a raplacement be: fobiainad Once waar stars ina pimp it progresses rapidly. in vinw of the engin ‘damage that may foloxe a oss of ol pressure, Skimping the oil pump repair ma fake. ‘economy, 273 FlywheeU/crveplate ignition timing rharks Engine cove £2 2.6-ywheet a 37.0 mm 18" BTOC Engine coue £2 1 S-dkveplote a~ 42.0 men 18° TOC Engine cove EV (1.8) fywheet: a WAT VW Goll R Jetta 25.4 Checking oil pump gear enefloat g S g 1 Check the tet the intermediate shaft in is bearing, there ts excessive play, the shart rust be comparee with a new one. the shalt is in goexl orcer but the bearings i the block {are wer then soak oxport adhe 2 Check the surlace of te cam which dives the fuel pump (where applicable). tse Fidging is present a new shal fs incicated 3 Cheek the (eth ofthe distibutor event for scuifing or chipping. Check the cone tion ‘ofthe uring belt sprocket. 4 It unlikely that damage to the shaft hi happened but il thas, seek advice fram a sealer 55 Thera is an oil seal in the flange far the Intormednte shalt, This may nocd renewal i there ae sigs ol leakage, To do this, rors the tming belt sprocket and withdraw the: Hang ten the shit. The ol seal may naw be prised out and a new one pressed in. Alves Mm a new O-ring on the tiange before assembling itto the eyinder black 26 Intermediate shaft - examination ard renovation 21 Flywheelriveplate- ‘ Donors area s g 1 apache ster Hg tenth hse ae hipped or worn then canes the starter rng, This means heating the rng unti it may be witha from the flywheel or sternal, ‘pling A ner one must then be shrunken if you know heww ta do this ana youcan get a new ring then the job can be done but tis beyond ine capacity of mest owners 2 Serious scoring on the flywheel clutch fecing requires a new flywheel. Do not attempt to clean the sconng of with a seraper fr emery, Tha face must be macht 3 Ihe necessery to Mt a new flywheel, the ignition timing mark must be made by the ‘owner. The new fysehwe! has only the TOC mark as an 9 on the outer face, Punch oF scribe the appropriate timing mark for your adel to the felt of the TOC marie at the appropriate Gistance (see illustration).Engine repair procedures - 1.6 and 1.8 litre 8 valve 2C+ 17 '30.3a Fitting flanged type centre main bearing into crankease 30.3b Fitting aternative type centre main bearing into crankcase... 30.34 Fitting flanged type centre main beang to cap 4 On automatic transmission madels. check the driveplate as described forthe Miya, i will also be necessary to marke 3 new ‘tiseplate for ignition ting 28 Timing belt and sprockets ‘examination and renovation xy Refer 10 Section 26 in Patt A of this CChapet. The informetion given also appses to the intermediate shaft speachet. 29 Engine reassembly - yencial infermation| Role to Section 20 in Pott Aol tis Chapter 30 Crankshaft and main bearings - refitting & Noto: iis eficul to roree the crankshaft chock that the bearing shells are seated properly ane thatthe bearing cops 18 ovrect ay round Rotation wil eniy bile if something is iicemect and the fa mast be ound Dit on the back oF heawing shel is metias the cause of a ght rman bearing Til a new crankshall 15 being filed 16 sutematic transmission models, the need= Toler bearing supplied anc ftted by the ranutactarer UA reed te be removed fam fe 30.2e Fitting centre bearing and separate ‘tirustwashers t9 cap) ‘aperture in the rasr end of the exankshat. I may sready have been remaved by the supplies, but check anys, 2 Clean the crankcase recesses and besig Caps thoroughly ancl ft vie bearing shes so that che tang en the bearing engages in the recess in the crarkcase or bearing cap. Ensure that the shes fited to the crankcase have ail groaves ard holes and that these alan vith te dillngs in the bearing housings When fting the bearing shells to the cops, note that beating Hos. 1. 2 and § sre plaet hells whist Ne, 4 has an ail groove. 2 The bearing shulls of the certee bearing Wo. 3} may either be llanged t© oct a Uhnistwashere, or may have separate thrustiashers, These should be fitted il groove ounards, Fit the basting shells so that the ends of the baaring ce Hush with the joint face (see Mlustrtions). 4 Oil tho bearings and journals then locata 1081 VW Gol & Jetta 30.31 Ensure that ends of boaring are flush with joint face the cranks inthe crakons "Fa the rin bonnng exp Coa cere main bearing trustwesters Hf applicable in thet Conoet pasion (ao dstation) 6 Fath boksto te beta aps an hte the bots of the cerre cap to the species torqin then check tho the crankshaft tas tre 7 Working out from the conte ight tho remaining bearing eapsin tn. checking that tho. erankehalt rots. teay afer “each taring has bac ten 8 Check tht the entootc the crakchal tain spec ons by Fring octet blader Setween the cranksnsh and tre cente Besrng thn faeehseer fie ewerng te crankanatfret none cretion ane then inthe sir 8 Lubricate the rear ofthe crankshat and sing ea ask stall hetero a Tange. Tava hese bots Goo station) ae 30.9 Fiting crankshaft rear ol seal and flange 2c2C+ 18 Engine repair procedures - 1.6 end 1.8 litre 8 vaive 40 Lubvicote the front of the erarkshatt and Fic the front oll seal andl flange with » new gasket. Tighten the bolts to the correct torque, 31 Intermediate shaft reiting Lubricate the intermediate shaft vith clean engine ol then install an te block, Fic the O-ring and Mange, together wih the cil seal then ughten the bolts. Hote that tw fhale st be at the Kottom cl the flange. 32 Pistons and connecting rods srefting s EY Proceed as desc in Sacton 20, Pan & ofthis Chapter. When refitting Une ‘Gn completion, check the endiloct of each connecting rod in @ simiar manner to that deseribed fer checking the ctankshatt ents ragraphs 2 to 7 inclusive, bigeend nuts, al the 33 Valve clearances - checking and adjustment pre August 1988) 1 Ita now oF roconeltioned cylinder head, comple with camshat, is being fied, tat the Yale Ciarance’ wl have ben preset 2 Valve clearances can be checked and adjusted with the cylinder head removed (prior to rafting after overhaul) 6r in the rormal manner described in Section 12 of Ghaptes 1 2 There are two specitied valve clearance seitings. these being for @ cold feyliner head remaid owar gine vil gi ronson, 41 valve adjustment is made wih the engine fold, then it must be checker! again wih the engine at normal operating temperature (le coolant above 35°C). 1 te cylinder head has been cverhauled, then it should be checked ‘agai, fot alter 690 rales (900 ki) 34 Cylinder head - refitting Note: Naw cyinder nead rctaning bees must oused on reiting 11 Clear the top face of the block. Clean and inspect the botes and lubricate them wih clean engine oil Turn the exankshalt so that the pistons ace inthe mi-eyindes postion 2 The engine number is’ stamped cn an inclined suraco between No 3.and Ho. 4 cylinders on the side above the distributer 34.2 Cylinder head gasket located on ‘block Using this as a datur, install a rew eylnder head gasket so thatthe word OBEN’ on the ‘gasket is over this datum poe and on the top Side of the gasket (see illustration) 3 Lower the cylinder had into position, locating onto the centring pins where fied (Gee istration). I the cylinder block does rot have coniring pins, rata ett new No, 8 ‘and No, 10 csfindar head bolts, Do not use jointing compound. Check that the gastet is Seating corectly and ft the remainder of the new bolts. Folovting the sequence shown, tightan the bos until the head! is fmly held Using a torque wrench, righten the botts stages to the speitied torque following the same sequence (see illustration), 4 The eylinder head vill not need further ightoring, 23 Timing belt and sprockets - retting 1 Fit the Wocdrutt key into its groove in the intermediate shalt then relt the sprocket to the front of the shoft. Locate the spacer ‘washer onto the bolt then fan tighten the bolt to the specified torque wrench sexing, Hold the sprocket stationary whan tightening by inserting a serewdnver though one of is holes and jamming it agzevst the eylincer block 2 Locate the Woodiulf key {i appkcable} to the groove at the front of the crankshaft then 34.3a Lowering cylinder head onto block refit the timing bet sprocket ont the shat Lubricate the retaining bok with of, locate the spacer svashes onto the bolt then fic and Lighien it to the specified toxque wrench ‘sting. When tightening the bot prevent he Cranks from turning by using te sare fresh as that for Is removal 3 Louate the Woodeuft key inte ts geoowe on the front of the camshaft then refit the ccamshalt sprocket. Refit the rotaining bolt together with the spacer washer and tight to the specitiad varque wrench sating. He the sprocket stationary when tightening by insering a screacdrver through one of as. holes and jamming t against the eytinder black or head 4 If removed. rai the tining bett rear cover. Apply locang compound tothe stud thread S Locate the craneshalt pulley onto the ‘sprocket faligring the marks made previously) Using on boi to secure temporary 6 Turn the camehat sprocket so that the lobes of Ne. 1 cylinder cams are pointing lpivards and the mark on the camshaft Sprocket is aligned with the valve cover - see stration 9.78, 7 Rotate the crankshatt sprocket and the imermediate shaft sprecket until the dot on theintermeciate sprocket and the mark on the V-belt pulley coincide, Install the timing b Iensioner loosely nnd then the timing belt Maing sure the marks ate stil im place, put a Spanner on the adjuster and tighten the belt Li it wil ist anly 90 degrees when held wen the finger ard Tunis halfweiy {3b Cylinder head bok tightening sequence WAT VW Goll R JettaEngine repair procedures - 1.6 and 1.8 litre 8 valve 2C+ 19 between the canshoft and intermediate shaft Sprockets, Tighten the receniric acister nat tothe specifi torque seo ikrstration 8.8, @ Unbolt and remove the crankshalt V-belt pale pu the lower timing cover then refit the crarkshat V-belt pully sane tighten. its retaining bok tothe specified torque 10 Locate the now valve cover gasket on the yllide Head, the seal tothe No. 1 camshaft beating cap and the half round grommet into ity focation at the rear ened of the cyinder head, 111 Fie valvo cover inte postion, locate the Feinfercement stips then rat and tighter the retaining nuts evenly to the speciied torque: 12 Refi the upper timing bel come 36 Engine ancillary components reiting & 1 On automatic trensmission models, refit the tiveplate together with any shims orginally cated betyieen the erarkshaft and tho plate Ficthe wesher on the transmission sie of the ‘itwepiate, ensuing thatthe chamlerad side ff the wachar faces towards the civeplste Use new bolts and tighten them to the spocified torque setting then sing vernior Calipers, chesk the distance between the tiiveplaie ancl the eylinder block as shown (Gee illustration) at thine postions It the Hlearanee ts not between 40.8 and 32,1 nam, remove te driveplate, fit shims of suitable thickness between the deveplate and the crankshaft then refit the erivepiate assembly faze recheck the clearance, I the engine is 3 new of reconditioned short block replace mer, check thatthe bore inthe rear end does. ot contain 2 needle ralier bearing, IK does, then remave the bearing as this for manwal ‘geatbox morte oniy 2 On manvel gearbox models. refit the clutch together wth te imermedate plate 13 Refi the inet anc extmust manifolds 4 Refi the cool pump ard al hoses to the rayne $5 Rel the aerrator al ckivebel 6 Roit ths ol prossute switch to the cylinder head or fiter mcurting 3 applicable. using a ‘en wosher of Ging, Tighten tothe spec ied torque. 7 Fit the oi filer mounting to the eyinder block, togethor with a new gasket and tighton the Boks. On models tted wih an cil cooler, ralit the supply and return hases to thei 8 Fi theo fter 9 Roftthe dstrkater. 10 On carbureitor models, ret the tual pump, 11 On tel injection models werinup valve (tthe hoses ciscannected 42. Rot the coolant tempera senler tune ‘ad the thermatime switch with new Orgs, 15. Rol the spark plugs, not alteady done. 44 Refit the gearboxftansmission to the engine. 37. Engine - reiting Torefit the enginetransrnsicn, reverse the remeval procedures bu nate the flloveing 2) When lowerig the unit int the engine coimpunerert, align the driveshafts with the flanges porto attaching the _ especie mountings 1} Assemble th orgie mountings loosely femey anc tighten ther only after the Unit isconra without aang the ‘mourings ©} Adjust the clutch cable fnanust gearbox) 3) Adjust the teats wd saactor cubes fautomatic vonsirssion) 2) Reconnect and aciust the gear selector Inkages daria! gearba3) 2. Aajuist the throttle and choke cables Rofl the costing systom Ay Ret he enone un te comect radio and quancty of os! 1) Wibere necessary retension the poswer Steering purna orwvebelt arc replenish the systenn td 38 Hydraulic bucket tappets- Nectng ree tave em ‘August 1985) y 4 Star the engine and un tu the rcator oolng lan hs sched once 2 ncreane engine speed to abouk 2500 rpm for aot tao te 4 Irregular noises are normel when starting bat shoul! become quiet alter» few minutes ening, 41 the valves are still noisy, emery ou che: following chock to identity worn tapas. 5 Stop the engine and remove the valve cover from the cylin hen 6 Turn the crankshalt clockwise by ‘wrench on te crankshat pulley secuting bot UUnt| the am of the tapper tb be checked facing upward and is not exerting any reso on the tappet 7 Press the tappet dean using a wooden or plastic wedge. 2B If ee travel of the tappet exceeds that Spactied the tappet must be renewed, 39 Engine adjusimonts after major overigul & Refer to Secton 1 in Par Act this Chapter. I new tyratie bucket tappets hae been fotos ts essen that ne aterm to ester the engine mace fore minerum patio of 30 minutes. aor instalation. Failure to baer ths precaution may result in engine Gamage caused by the valves contacting tre pistons “36.1 Checking driveplate-to-cylinder block dimension (A) using vernier calipers 1081 VW Gol & Jetta 2c2C: 20 Notes aoa20-1 Chapter 2 Part D: Engine repair procedures 1.8 litre 16 valve The following information is a revision of, or supplementary to, that given for the 1.8 litre engine in Part C of this Chapter Contents Camshafts «removal and refiting Pistons and connecting rods «removal and refiting 5 Cynder head = dismantling ane veratd 4 Timing bek and sprocksts removal and reiting 2 Gere formation 3 Degrees of difficulty Easy, sumatie‘er Fariyeasy suche | Fanyameur, 2 | Dou sunbetor | Verycmcum, novice wihlve | tarbeginmerwih S| suitable forcompetet QS | experienced OY SS] suitable for expert DIY experienoe Qi) someerperice XQ] orvmechanie SS] mechanic SQ] o Hoessiona Specifications General an waa Cylinder head Nini bight 118.1 nm - measured tough ender hand bolt hake Valves: Head ameter me 2 20mm fone : zionm stam ore inet 627mm Exact Seem Overal lnat ink Etat Valve timing Nilvalve clearance at 1.0mm valve Bt Inlet opens Inlet closes Exhaust opens Exhaust closes Torque wrench settings wore 18 “6 ‘0 8 shaft beating caps n (i termperatine sender 7 Ol pump cover 7 Oi pup mounting boks | is Bape 7 Cranial sprocket bolt fied 133 1081 VW Golf & Jetta20+ 2 Engine repair procedures 1.8 litre 16 valve WAT VW Goll R JettaEngine repair procedures 1.8 litre 16 valve 20-3 1 General information The 7.8 Inve, 16-valve engine fitted to GTi models fom October 1996. incorporate ‘double overhead camshatts, ane opetating the exhaust valves and the other the inlet There are four valves per cylinder te simuiltaneoutsly Fr p's and provide the engine with a much improved bresthing capability over the Bovake version ths resulting in greater power output. A ‘ingle carnshaft spracket is attached to the exhaust camshait and a chain and sprocket 3t the opposite ond ofthe cylinder hoad is used to de the inlet camshat (S00 tlustration) Most averhaul procedures for the 16-valve fengine ato basically the came 8s those ‘doseribed Tor th Beaive origin in Part C of this Chapter. The tolisung Sections desert Procedires which citer, 2. Timing belt and sprockets renmoval and refting Besides the timing mark on the camshaft sprocke! ler to in Part Co thi Chapter Sectian 9, an additional timing mark is fovided on the outside of the camshalt Sprocket which aligns with a mark on the (sive cover (see ikistration). This means tat if the timing belt alone i baing rencwed i's ot necessary ta remove the valve Cover in fader to check the alignment marks When fitting the tii bel. kis recommenced that VW toot 710 fs used to Set the tension securately as this i more clea with the DCHC. arrangement (eee illustration), Using this tool, the tension should be 2et to reverd a reading of between and 1 en the The tec! eat be ‘obtained trom a WW dealer. 2A Valve timing marks shale sprocket outer marks Camshaft spracket exe marks (© Crankshatt vilwation dampar masks 3 Camshafts - removal and refitting HE Removal 1 Rervave the camshalt sprocket cover 2 Unbolt and remove the uppet section af Inlet mario 2 Unbolt and remove the valve caver after disconnecting the HT lea spark plugs. Remove the main gasket and the 22 Adjusting timing bel tension using ‘VW toot 210 central gasket trom around the spark plug locations, 4 Align the timing marks wth reference to Part G of this Copier, then check also that the marks on the chain sprockets are aligned {see ilustration) 5 Remove the timing belt and camehatt Sprocket with reference to Part C of this, Chapter 6 Note the fitted positions of the camshaft beating caps, itneorssary marking them 10 fence cotrect rlting (soe istration). 7 Progressiva unscrew the nuts and bots fcom the end caps ate! bearing eap Nos, 1 nd 3 onthe exhst canst 2 Progressively unscrew the boks from bearing cap Nes. 2 and 4, The exhoust vale springs wil force the exhaust camshalt up 2s the bolts are loosened. Remove the besting, caps keeping them identi tor postion 9 Working on the inlet camshall, peo ‘ressivoly unsere the nuts and bests rom the end cap and bearing cap Nos. 5 and 7. 10 Progessively unscrew the bolts Kom bearing cap Nos. 6 and 8. then remave all the caps keaping thom ideniied for postion, 11 Lift both camshaits trom the éytinder heat then release them from the chive chain 3:4 TOG timing marks in alignment on camshaft drive chain sprockets 1087 VW Golf & Jetta 3.6 Camshaft bearing cap identification Inset shows recessed conner postion forowed) 2D20+ 4 Engine repair procedures 1.8 litre 16 valve 12 HW necessary, remove the hydraulic bucket Lappets. Check the camshafts and eve chain fon west Refitting 14 Lubsicate all bucket tappets and earmshatt Journals wth clean engine oi then insert the tappetsinthelr anginal bores 44 Locate the dive chain on the eamshatt prockets so thatthe timing marks are aligned 235 shown in illustration 3.4, then lower the ‘camshalts ito postion on the cyineer ted. Recheck the timing mork alignment. 45 Fa anew oil seal to the Iront end ot the exhaust canrhalt, 46 When refining the bearing cape, make sure that they are located the comect way round, The numbers: must be readable from the inlet manifold side of the head. The recessed comers of the caps must also face the net marstold side of the head, 7 Refit bearing cop) Nos. 6 ond, then progressively tighten the Boks tothe specified forque. 48 Refit the infor camshaft end caps and bearing c=p Nos. § ar 7, then progresswvely tighten the nuts and bolts to the specified torque 19 Refit bearing cup Mos. 2 and 4, then progressively tighten the bolts to the specified torque 20 Refit the exhaust eamshalt end eaype anc bearing cap Nos. 1 and 3. then progressively Tighten the nuts and bolis ta the specified 21 alt tha camshatt sprocket and timing bok wih reference to Part © of this Chapter and Section 2 22 Check thet al tining marks, including the tive choin sprocket rnatks, are alge’ 23 Refit the vaive cover together with neve gaskets and reconnect the spark plug HT Toads 24 Refit he ilet maniold upper Seetion and the cammshalt sprocket caver 4 Cylinder head - cismanting ane) overhaul g Eahaust vales on the 16 vale angen are {ea wih Sodiy to provide improved heat ddssipation, Speck precautions. ore neeassary when disposing of this ype of vate, particularly where recycling of scrap Inetal concord To render each vaWe safe, It should bo wriped ery then eut trough the stem vith a hacksaw” Throw the este ito 9 ilk ot twoter Keeping well nag fom Intl the Chemical rencton has subse WAT VW Goll R Jetta 5. Pistons and c¢ Hethovel and relltog “The big-end caps on 16 volve engines sre fies sith ol js tahich drt a scam of el to the underside of the pistons, mainly for contig parpowes (ae Musteation), “Th jets ane scr a the caps by small screws which must be coated with theo locking tid belore meeting them are Ughtentng to the spectied torque 51 Big-ond cop components 1 Ofer 4 ep 2 Screw 5 Mins 2 Bowring shel