1.

8L 4-CYL
Article Text
1985 Volkswagen Golf
For This file passed thru Volkswagen Technical Site - http://volkswagen.msk.ru
Friday, April 23, 2004 12:46AM

ARTICLE BEGINNING

1985 ENGINES
Volkswagen 1.8L In-Line 4-Cylinder

Cabriolet, Golf, GLI, GTI, Jetta, Quantum

* 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 CODING

ENGINE IDENTIFICATION

Stamped engine identification number is on machined pad at

left side of engine block near ignition distributor. Letter prefix is
engine identification code.

ENGINE IDENTIFICATION CODES TABLE

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Application Engine Code

1.8L In-Line 4-Cylinder

Cabriolet & Scirocco ........................... JH
Golf & Jetta ................................... GX
GLI & GTI ...................................... HT
Quantum ........................................ JN
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ENGINE, MANIFOLDS & CYLINDER HEAD

ENGINE

Removal (Longitudinally Mounted)

NOTE: When removing longitudinally mounted engines, separate

engine from transmission before lifting it from engine
compartment.

1) Disconnect battery ground strap. Open radiator cap and

set heater control to "WARM" position. Disconnect power steering
pump from engine and place to side with hoses attached. Drain coolant
by disconnecting and removing all hoses at engine end of hose.
Leaving fuel lines connected, remove cold start valve, warm-up
regulator, fuel injectors and airflow sensor assembly as necessary.
Plug injector sockets and cap injectors. Secure all fuel components
to right inner fender wall.
2) Disconnect all wiring from radiator fan motor, thermo
time switch and any components attached to engine. Remove radiator
assembly with shroud and fan attached. Disconnect accelerator and
clutch cables as necessary. Remove upper nut from left engine mount.
Remove front engine mount. On models without A/C, proceed to step 4).
3) On models with A/C, remove A/C drive belt by loosening
nuts on outer portion of crankshaft pulley. Remove 2 upper and 3
lower compressor mounting bracket bolts. Place compressor and bracket
to side with hoses and wiring attached. Remove horn bracket, throttle
valve housing and auxiliary air regulator as necessary. Remove
condenser and place to side with hoses attached.
4) Disconnect exhaust pipe at manifold. Remove starter
motor. Remove all nuts from right engine mount. Remove bellhousing
dust plate. On models with A/T, disconnect torque converter from
drive plate by removing 3 bolts through starter opening. Hold
transmission up from underneath with Transmission Support Bar (VW
785/1B). Tighten hanger bar plate against transmission with slight
tension.
5) Attach lifting device to engine. Lift engine slowly until
all engine mounts are clear. Remove right engine mount. Readjust
hanger bar plate against transmission. Remove remaining upper bolts
holding engine to transmission. Separate engine from transmission.
Lift engine, turning it so that body is cleared.

NOTE: Lift engine carefully to avoid damage to transmission

mainshaft, clutch and body. On models with A/T, secure
torque converter to transmission so that it cannot fall out.

Installation (Longitudinally Mounted)

1) To install engine, reverse removal procedure. Use
molybdenum disulfide grease on clutch release bearing and
transmission mainshaft. DO NOT lubricate release bearing guide
sleeve. Place intermediate plate on locating dowels at rear of block,
using grease to hold plate in place.
2) Carefully guide engine into vehicle and attach to
transmission, while keeping weight off engine mounts. Tighten lower
bolts that attach engine to transmission. Remove transmission support
bar and lower engine into position on mounts. Replace all
self-locking nuts on engine mounts. Install and tighten remaining
bolts holding transmission to engine.
3) Recharge A/C system. Final tightening of engine mounts
and subframe bolts is done after engine is installed and running at
idle speed. Adjust throttle and clutch cables. Adjust A/C belt
tension with shims between pulley halves. Fill cooling system and
ensure that radiator cooling fan cycles.
Removal (Transversely Mounted)

NOTE: When removing transversely mounted engines, lift engine and

transmission from engine compartment as unit.

1) Remove battery from vehicle. Disconnect drive axles from

transmission flanges. Secure inner axle ends to body with wire.
Remove springs holding together swivel joint of exhaust system. On
models with power steering, remove pump and fluid reservoir with
hoses attached. Secure pump and reservoir to cross member with wire.
2) Remove radiator grille. On models with A/C, remove front
trim panel and lower apron. Disconnect wiring at compressor and
radiator fan shroud. Remove compressor and alternator drive belts.
Disconnect condenser from crossmember and radiator, leaving hoses and
ducting attached.
3) Disconnect vacuum hoses from idle boost valve. Remove air
filter housing and airflow sensor assembly and place on radiator,
leaving all fuel lines attached. Remove compressor from engine with
hoses attached. Secure compressor and condenser out of way with wire.

NOTE: When moving A/C parts that have hoses connected, use care to
avoid kinking or squashing lines.

4) Open coolant reservoir cap and drain coolant by removing

all coolant hoses. Disconnect wiring from radiator fan motor, thermo
time switch and headlights. Disconnect hood release cable from latch
and apron. Remove radiator assembly with fan motor and shroud.
Disconnect all wiring from electrical components that are attached to
engine.
5) On vehicles with M/T, disconnect wiring from transmission
switches, upshift indicator vacuum switch and starter. Disconnect
clutch and speedometer cables from transmission. Plug speedometer
cable opening. Disconnect gearshift rods from shifter bellcrank and
remove bellcrank bracket. On vehicles with A/T, disconnect battery
cable from starter and CIS-E wiring harness. Disconnect accelerator
and selector lever cables from levers and mounts with selector lever
in "PARK".
6) On all models, disconnect accelerator cable at throttle
valve linkage and mounting bracket. DO NOT disconnect throttle
linkage. Remove cold start valve, warm-up valve and all injectors
from engine, leaving all fuel lines connected. Plug injector socket
openings and cap injector tips. Disconnect all vacuum, vent and
preheat hoses.
7) Attach engine lifting device to 2 lifting eyes located at
each end of cylinder head. Apply slight tension to lifting device
with hoist. Remove rear engine mount. Disconnect transmission mount.
Remove through bolt from front mount. Lift engine/transmission
assembly slowly while turning unit slightly to clear front mount.

Installation (Transversely Mounted)

1) To install, reverse removal procedure. Observe all
tightening specifications. Make sure engine/transmission assembly
clears drive axles during lowering process. Connect rear engine
mount, transmission mount and front mount in sequence. ALL engine
supports must be aligned with mount bushings before any mount bolts
are tightened.
2) Connect and adjust accelerator cable, shift linkage,
clutch linkage and headlight alignment as necessary. Make sure that
all electrical components are reconnected correctly and wiring
harnesses are properly routed. Check and adjust exhaust system
alignment if necessary. Fill cooling system and make sure that
cooling fan cycles properly.

CYLINDER HEAD & MANIFOLDS

Removal
1) Disconnect battery ground strap. Detach and remove air
intake boot. If equipped, remove cold start valve, fuel injectors and
control pressure regulator with lines connected. Plug injector seats
and cap nozzles on fuel injectors and cold start valve.
2) Drain coolant from engine and disconnect any coolant
hoses attached to cylinder head. Label and disconnect all vacuum, air
and ventilation hoses attached to cylinder head and intake manifold.
3) Label and disconnect all electrical and ignition wiring
attached to cylinder head and intake manifold. Disconnect wire
attached to oxygen sensor in exhaust manifold. Remove all drive
belts. Remove alternator bracket from cylinder head. Remove upper
timing belt cover. Remove cam cover.
4) Remove water pump pulley. Disconnect exhaust pipe from
manifold. Disconnect throttle cable. If equipped, remove cruise
control servo and linkage. Position No. 1 piston on TDC after
compression stroke. Ensure that flywheel timing mark is on 0ø (TDC).
5) Loosen timing belt tensioner. Remove timing belt from
camshaft sprocket. Loosen head bolts in reverse order of tightening
sequence. See Fig. 1. Remove cylinder head with manifolds attached.

CAUTION: If any head bolt(s) require replacement, new polygon head

bolts must be replaced in COMPLETE sets only. Polygon head
bolts do NOT require retorque subsequent to repairs.

Installation
1) Clean all gasket mating surfaces. Use straightedge to
check cylinder head surface for warping. Cylinder head must be
resurfaced if distortion exceeds .004" (.10 mm).
2) Minimum thickness of cylinder head after surfacing is
5.22" (132.6 mm). This dimension is measured from head gasket surface
of cylinder head to machined surface of head where camshaft cover
gasket sits.
3) Make sure cylinder head bolt holes in block are clean and
dry. Place dry cylinder head gasket on cylinder block with word
"OBEN" ("TOP") facing upward. Use no sealant on head gasket.

CAUTION: To avoid valve/piston contact damage during installation of

head, turn crankshaft counterclockwise about 90ø from TDC.

4) Install cylinder head with manifolds. Install head bolts

Nos. 8 and 10 to align cylinder head. Install remaining head bolts.
Polygon stretch head bolts must be sequentially tightened in 3 stages
with engine cold. Tighten head bolts in proper sequence. See Fig. 1.
5) First tightening step is to 29 ft. lbs. (40 N.m). Second
step is to 43 ft. lbs. (58 N.m). Third step is to turn bolts 180ø
(1/2 turn) further in 1 continuous movement or 2 separate 90ø (1/4
turn) movements. Install remaining components in reverse order of
removal. Ensure valve timing is correct. Install timing belt and
adjust tension.

Fig. 1: Cylinder Head Bolt Tightening Sequence

Tighten polygon stretch bolts in 3 stages.

CAMSHAFT

TIMING BELT COVER

Removal & Installation

Outer cover consists of upper and lower parts. Inner
(against block) timing belt cover is one piece. Remove all drive
belts. Remove crankshaft and water pump pulleys. Remove outer covers.
Install in reverse order of removal.

TIMING BELT

CAUTION: Never use camshaft sprocket attaching bolt to turn engine

as timing belt could be stretched.

Removal
1) Remove all drive belts, crankshaft pulley and vibration
damper. Remove upper and lower timing belt outer covers. Remove
camshaft cover from cylinder head. Turn crankshaft to position No. 1
piston at TDC compression. Make sure that distributor housing and
flywheel timing marks are correct. See Fig. 2.
2) Loosen timing belt tensioner to relieve tension on
timing belt. Slide timing belt off sprockets. Do not allow camshaft,
crankshaft or intermediate sprockets to turn when removing timing
belt.
Fig. 2: Distributor & Flywheel TDC Alignment Points

Installation & Valve Timing

1) Set crankshaft at point just before TDC compression for
No. 1 cylinder. Place timing belt on crankshaft and intermediate
shaft sprockets. Install crankshaft pulley and tighten all 4 bolts.
Align mark on crankshaft pulley with mark on intermediate shaft
sprocket at No. 1 TDC. See Fig. 3.

Fig. 3: Aligning Intermediate Shaft & Crankshaft

Rotate intermediate shaft and crankshaft to align marks.

2) Position camshaft so mark on back of sprocket is in line

with upper edge of timing belt rear cover. See Fig. 4. Both lobes for
No. 1 cylinder should point upward at 45ø from camshaft follower so
both valves are closed. Install timing belt on camshaft sprocket.

Fig. 4: Setting Camshaft Timing Mark

Align sprocket notch or dot with edge of belt rear cover.

3) Adjust timing belt tension by turning tensioner adjusting

hex clockwise against belt. Make sure shaft timing marks have not
moved. Tighten tensioner lock nut and check tension of timing belt at
point midway between camshaft sprocket and intermediate sprocket. See
Fig. 5.
4) Belt has correct tension when it can be twisted 90ø with
thumb and finger pressure. Rotate engine by hand through 2
revolutions in clockwise direction. Check all timing marks. If belt
tension and valve timing are correct, install remaining components.

Fig. 5: Adjusting Timing Belt Tension

Correctly adjusted belt will twist 90ø with finger pressure.

CAMSHAFT OIL SEAL

Removal
1) Remove upper timing belt cover. Position No. 1 piston on
TDC of compression stroke. Loosen tensioner pulley to relieve tension
on timing belt. Remove camshaft sprocket and Woodruff key from
camshaft. Reinstall sprocket mounting bolt with washer. Use Seal
Extractor (2085) to remove oil seal.
2) Extend inner portion of seal extractor 2 turns. Lock
inner portion in place with set screw. Lubricate threaded end of
extractor. Push end of extractor into seal as far as possible. Loosen
set screw and turn inner part of puller against camshaft until seal
is pulled out.

Installation
1) Install protective sleeve of Seal Installer (10-203) over
camshaft. Coat seal lips with oil. Push seal over sleeve and into
position.
2) Using seal installer, press seal into bearing cap recess
until flush. Install remaining components in reverse order of
removal. Check that valve timing and belt tension are correct before
starting engine.

CAMSHAFT

Removal
1) Remove upper timing belt cover. Remove camshaft cover.
Turn crankshaft to TDC on cylinder No. 1 on compression stroke.
Loosen timing belt tensioner to relieve tension on timing belt.
Remove timing belt from camshaft sprocket. Remove camshaft sprocket
and Woodruff key.
2) If necessary, mark positions of camshaft bearing caps
with No. 1 at front and No. 4 at rear of cylinder head. Remove
bearing caps No. 1 and No. 3. Slowly loosen nuts on bearing caps No.
2 and No. 4. Nuts must be removed alternately and diagonally. Remove
bearing caps and lift out camshaft.

Identification
Stamped number "026" or letter "A" is found between intake
and exhaust lobes of No. 1 cylinder on camshaft. On camshafts with
"A" stamp, stamped number "026" may be found between lobes of No. 3
cylinder. Base circle of camshaft, measured between intake lobes of
No. 2 and No. 3 cylinders, is 1.34" (34.0 mm).

Installation
1) Before installing camshaft, lubricate camshaft journals
and bearing surfaces in cylinder head and caps. Install camshaft.
Make sure that oil spray jet orifice is at 90ø to camshaft. Install
caps No. 2 and No. 4. Make sure caps are not misaligned. See Fig. 6.
2) Tighten caps evenly in alternate and diagonal pattern.
Install caps No. 1 and No. 3. Tighten all cap nuts evenly to 14 ft.
lbs. (20 N.m). Install remaining components in reverse order of
removal. Make sure valve timing and belt tension are correct before
starting engine.

Fig. 6: Checking Camshaft Bearing Cap Alignment

Tighten bearing cap nuts to 14 ft. lbs. (20 N.m).

WEAR MEASUREMENTS

CAUTION: Hydraulic valve lifters are always stored with contact face
down. This applies to new lifters or to lifters removed for
engine repairs. Lifters will take about 30 minutes to leak
down after installation. Do NOT start engine during
leak-down period as internal engine damage will occur.

End Play
1) Remove camshaft and valve lifters. Keep lifters in order
for reassembly. Place lifters on clean surface with contact faces
down. Remove sprocket and oil seal from camshaft. Reinstall camshaft
without lifters or seal as any tension on camshaft will make
measurement inaccurate. Use only caps No. 1 and No. 5.
2) Attach dial indicator with tip on end of camshaft at 90ø
to end face of camshaft. Push camshaft rearward and zero dial
indicator. Push camshaft forward to record maximum movement. If end
play exceeds .006" (.15 mm), check camshaft thrust flange and bearing
cap for wear. Replace worn components.

Radial Play
1) Remove camshaft and valve lifters. Keep lifters in order
for reassembly. Place lifters on clean surface with contact faces
down. Remove sprocket and oil seal from camshaft. Clean bearing caps,
bearing seats and camshaft journals.
2) Place camshaft on cylinder head. Make sure that no lobes
touch valves or valve spring retainers. Place Plastigage on camshaft
journals parallel to length of camshaft. Install bearing caps in
correct position and tighten cap nuts. DO NOT rotate camshaft with
Plastigage installed.
3) Remove bearing caps and measure radial play. Wear limit
for camshaft radial play is .004" (.10 mm). If wear limit is
exceeded, repeat measurement with new camshaft installed. If wear
limit is still exceeded with new camshaft in place, cylinder head
must be replaced.

INTERMEDIATE SHAFT
 END PLAY

Using dial indicator, measure intermediate shaft end play.

Maximum end play is .010" (.25 mm). Remove distributor prior to
removing intermediate shaft.

OIL SEAL

If oil seal replacement is necessary, remove oil seal flange

and press out seal. Lubricate new seal lips with oil. Install oil
seal flange with oil return hole at bottom edge. Use Seal Installer
(10-203) to press seal into place.

VALVES

VALVE ARRANGEMENT

E-I-E-I-I-E-I-E (Front-to-rear).

VALVE GUIDE SERVICING

Inspection
1) Make sure valve guides are clean and clear of debris.
Attach dial indicator and Adapter Fixture (VW 387 or US 4420A) to
mounting surface of cylinder head. Insert new valve into valve guide.
Use correct valves in respective guides. End of valve stem must be
flush with upper end of valve guide.
2) Tip of dial indicator must rest against side of valve
head. Rock valve back and forth against tip of dial indicator.
Maximum reading on dial indicator is .039" (1.0 mm) for intake valves
and .051" (1.3 mm) for exhaust valves. Only replace guides in heads
that have valve seats that can be resurfaced.

Removal
Use press and Valve Guide Drift (10-206) to remove valve
guides. Press valve guides out of head from combustion chamber side.

Installation
Coat new guide with oil. Press guide into cold cylinder head
from camshaft side of head, using valve guide drift. Do not use more
than 1 ton of pressure after guide shoulder touches head as shoulder
may break off. Ream guide with Hand Reamer (10-215) and cutting oil.

VALVE & VALVE SEAT SERVICING

NOTE: Manufacturer states that exhaust valves must NOT be refaced

with machinery and that exhaust valves should be lapped in
ONLY by hand.

1) If valves are to be reused, measure valves for minimum

dimensions. Minimum intake valve stem diameter is .314" (7.97 mm).
Minimum exhaust valve stem diameter is .313" (7.95 mm). Minimum
overall length of valve (from face to tip of stem) is 3.58" (90.9 mm)
for intake valves and 3.57" (90.7 mm) for exhaust valves.
2) In HT and MG engines, minimum face diameter of intake
valves is 1.56" (40.00 mm). In all other engines, minimum face
diameter of intake valves is 1.50" (38.0 mm). Minimum face diameter
of exhaust valves is 1.30" (33.0 mm) for all engines.
3) Both intake and exhaust valve seats are cut at 45ø angle.
Using 30ø cutter, narrow intake seat to .079" (2.00 mm) and exhaust
seat to .094" (2.39 mm). In HT and MG engines, intake valve seat
diameter limit is 1.543" (39.2 mm). In all other engines, intake
valve seat diameter limit is 1.464" (37.19 mm). Exhaust valve seat
diameter limit is 1.275" (32.39 mm) in all engines.
 4) To establish limit for cutting valve seats (dimension
"y"), measure distance "X" between end of valve stem and upper edge
of cylinder head (where camshaft cover gasket rests). See Fig. 7.
Insert valve into guide and hold tightly against seat.
5) Measure distance "X". Subtract minimum dimension "X" from
measured distance "X". Result is maximum cut allowed (dimension "y")
for refacing valve seats. In all engines, minimum dimension "X" is
1.33" (33.8 mm) for intake valves and 1.34" (34.1 mm) for exhaust
valves.
6) If minimum dimension "X" is greater than measured
distance "X", cylinder head MUST be replaced. If minimum dimension is
not observed, hydraulic valve lifters may not function properly.

NOTE: Be sure to remove all traces of grinding compound from

valves and guides after valves have been lapped into seats.

Fig. 7: Measuring Refacing Limit Of Valve Seat

Minimum dimension "X" is 1.33" (33.8 mm) for intake and 1.34" (34.1
mm) for exhaust.

VALVE STEM OIL SEALS

NOTE: Valve stem oil seals may be replaced with cylinder head
installed on vehicle.

Removal
1) Remove camshaft and valve lifters. Keep lifters in order
for reassembly. Place hydraulic lifters on clean surface with contact
faces down. Remove spark plug and place piston of cylinder being
serviced at bottom of stroke (BDC). Install air hose and Adapter (VW
653/3) in spark plug hole and apply air pressure.

CAUTION: Engine may rotate due to air pressure if piston is not at

 true BDC. Keep hands clear of belts and pulleys.

2) Do not remove air pressure until valve spring components

have been reassembled. Compress valve springs with Valve Spring
Compressor (VW 541). Remove keepers, dual valve springs and both
spring seats. Remove seal from valve stem.

Installation
Slide plastic protective sleeve onto valve stem. Failure to
use sleeve may result in edge of valve stem tip cutting lip of seal.
Excessive oil consumption and smoking will occur if seal is damaged.
Lubricate new seal and push into place with Seal Installer (10-204).
Install remaining components in reverse order of removal. Make sure
valve timing is correct.

CAUTION: Hydraulic valve lifters are always stored with contact face
down. This applies to new lifters or to lifters removed for
engine repairs. Lifters will take about 30 minutes to leak
down after installation. Do NOT start engine during
leak-down period as internal engine damage will occur.

VALVE SPRINGS

Dual valve springs may be replaced with cylinder head

installed on vehicle. To replace valve springs, use removal and
installation procedure explained in VALVE STEM OIL SEALS. Both inner
and outer valve springs must be replaced together if either is bad.

HYDRAULIC VALVE LIFTERS

Inspection
1) Hydraulic valve lifters are neither repairable nor
adjustable. Any worn, damaged or noisy lifter must be replaced as
complete assembly. Some occasional valve/lifter noise is normal
immediately after starting engine.
2) Run engine until radiator cooling fan has cycled at least
once. Hold engine at steady 2500 RPM for 2 minutes. Allow engine
speed to return to idle. If lifter is still noisy, replace it.
3) Remove camshaft cover. Turn engine by crankshaft bolt
until both camshaft lobes of cylinder to be checked point upward.
Push down on lifters with wooden stick. If lifter can be compressed
more than .004" (.1 mm), it must be replaced.
4) If hydraulic valve lifters are removed for engine
repairs, keep them in correct order for reassembly. Store lifters on
clean surface with contact surface facing down (upside down compared
to installed position).

CAUTION: Hydraulic valve lifters are always stored with contact face
down. This applies to new lifters or to lifters removed for
engine repairs. Lifters will take about 30 minutes to leak
down after installation. Do NOT start engine during
leak-down period as internal engine damage will occur.

PISTONS, PINS & RINGS

OIL PAN

Removal
Drain engine oil. Attach lifting device or Support Bar
(10-222) to engine. Raise engine slightly to support engine weight.
If equipped, remove cover plate under engine. Remove both front bolts
of subframe. Pull front end of subframe down to clear oil pan. Unbolt
and remove oil pan.
 Installation
Install oil pan with new gasket. Do NOT use any adhesive on
gasket. Install oil pan bolts and tighten in diagonal pattern.
Install subframe and cover plate, if equipped. Remove support bar
from engine.

PISTON & ROD ASSEMBLY

NOTE: All connecting rods must be in same weight class. Connecting

rods of same weight class are only available in sets of 4.

Removal
1) Remove cylinder head, oil pan and oil pump. Place piston
to be removed at bottom of cylinder and cover with cloth to collect
metal cuttings. Using ridge reamer, remove ridge or deposit from
upper end of cylinder bore.
2) Before removing piston and rod from engine, mark piston,
rod and rod cap as to cylinder and position. This will ensure that
reassembly position is correct. Remove rod cap and carefully push
piston and rod out top of cylinder. Loosely install rod cap on rod so
rod caps and rods do not become interchanged.

Installation
1) Cover rod bolts with hose or tape to avoid damaging rod
journals on crankshaft. Coat cylinder bore, piston and rings with
engine oil. Ensure ring gaps are spaced 120ø apart and install ring
compressor on piston.
2) Make sure that ring position does not change. Install
piston and rod in correct bore, with arrow on piston head pointing
toward front of engine. Forged casting marks on rod and cap must face
toward intermediate shaft.

FITTING PISTONS

Identification
Recess depth on face of piston varies depending upon engine
application. On HT and MG engines, recess depth is .173" (4.4 mm). On
all other engines, recess depth is .319" (8.1 mm).

Sizing
1) Take 3 cylinder bore measurements with inside micrometer
or cylinder bore gauge. Take 1 set of measurements at 90ø to
crankshaft centerline. Take second set of measurements in line with
crankshaft centerline. Measuring points should be at point 3/8" from
top of bore, at middle of bore and at point 3/8" from bottom of bore.

NOTE: Do not measure cylinder bore when block is on engine stand

as block could be distorted. Resulting measurements would be
inaccurate.

2) Difference between sets of measurements at same point is

cylinder out-of-round. Maximum cylinder out-of-round is .0016" (.04
mm). If cylinder bore measurements vary from top to bottom, taper of
bore may be excessive. If out-of-round or taper is excessive, block
must be honed or bored to next oversize. Maximum deviation allowed
from nominal dimensions, as shown in PISTON & CYLINDER DIMENSIONS
table, is .003" (.08 mm).
3) If cylinder bore is within limit for out-of-round,
measure piston diameter at 90ø to piston pin bore, about 9/16" (15
mm) from bottom of piston skirt. Compare this measurement with
measurement of corresponding cylinder bore. If taper is such that
piston skirt clearance is excessive, block must be honed or bored to
next oversize.
4) Clearance between piston and cylinder wall should be
.001" (.03 mm) for new parts. Wear limit for clearance between piston
and cylinder wall is .003" (.08 mm). Install oversize pistons if wear
limit is exceeded. Pistons are available in oversizes of 81.23 mm and
81.48 mm. Pistons have 4-digit number marked on face, which gives
diameter in millimeters.

PISTON & CYLINDER DIMENSIONS TABLE

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Size Piston Diameter Cylinder Bore

Standard ..................... 80.98 mm ................. 81.01 mm

1st Over ..................... 81.23 mm ................. 81.26 mm
2nd Over ..................... 81.48 mm ................. 81.51 mm
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FITTING RINGS

1) Place piston rings squarely into cylinder bore about .59"

(15 mm) from bottom of bore. Using feeler gauge, measure ring end
gap. End gap should be .012-.018" (.30-.45 mm) for new compression
rings. End gap should be .010-.016" (.25-.40 mm) for new oil scraper
rings. Maximum end gap is .04" (1.0 mm) on all rings.
2) With rings installed on piston, use a feeler gauge to
measure ring side clearance. Take measurement around entire
circumference of piston, between top of ring and ring land. New parts
should have side clearance of .0008-.002" (.02-.05 mm). Wear limit
for side clearance is .006" (.15 mm).
3) Install rings on piston with "TOP" mark facing upward.
Recessed edge on outside of center ring must face piston pin (down).
Ring end gaps should be spaced 120ø apart when piston is installed.

PISTON PIN REPLACEMENT

Removal
Remove circlip from pin bore groove. Use Piston Pin Drift
(VW 222a or VW 207c) to remove and install piston pins. If pins are
very tight, warm pistons to 140ø F (60ø C).

Installation
Assemble connecting rod to piston. Arrow on piston head and
forged casting beads on connecting rod must face toward front of
engine when assembly is installed. Use piston pin drift to install
piston pin. Pin, piston and rod bushing should have interference fit.
Install circlip into pin bore groove.

CRANKSHAFT & ROD BEARINGS

MAIN BEARINGS

1) Five main bearings are numbered front to rear. Main

bearing caps must NEVER be interchanged. Always measure main bearing
clearances 1 at a time.
2) Use Plastigage method for measuring bearing clearances.
Clean any oil film from bearing shells and crankshaft journals before
measuring clearance. Main bearing clearance with new parts should be
.001-.003" (.03-.08 mm). Wear limit for main bearing clearance is
.007" (.17 mm).
3) When replacing bearings, install bearing halves with
lubrication grooves into cylinder block. Plain bearing halves are
installed in main bearing caps. Make sure locating tangs butt against
each other when installed. Lubricate crankshaft journal and bearings
prior to installing bearings.

CONNECTING ROD BEARINGS

 1) Always measure connecting rod bearing clearances 1 at a
time. Use Plastigage method for measuring bearing clearances. Clean
oil film from bearing shells and crankshaft journals before measuring
clearance.
2) Connecting rod bearing clearance should be .0011-.0034"
(.028-.088 mm) with new parts. Wear limit for connecting rod bearing
clearance is .005" (.12 mm). Using feeler gauge, measure clearance
between side of connecting rod and face of crankshaft counterweight.
Wear limit for connecting rod side clearance is .015" (.37 mm).
3) Install connecting rod stretch bolts. Install bearings
and rod cap. Make sure that bearing tangs are correctly located so
that they butt against each other. Lubricate contact surface of rod
nuts and tighten evenly to 22 ft. lbs. (30 N.m). Tighten both nuts
additional 90ø (1/4 turn).

CRANKSHAFT END PLAY

Use a feeler gauge to check crankshaft end play. Insert

feeler gauge between No. 3 main bearing (thrust bearing) and
crankshaft thrust face. With new parts, end play should be .003-.007"
(.07-.17 mm). Wear limit for end play is .010" (.25 mm). Original
thrust bearing uses plain shell with 4 separate washers while
replacement thrust bearings have attached collar.

CRANKSHAFT REAR OIL SEAL

Removal
If engine is in vehicle, remove transmission. Remove
flywheel/flex plate, noting position of shim if used. Use Flywheel
Lock (10-201) to hold flywheel/flex plate when loosening and
tightening bolts. Carefully pry oil seal from seal flange.

Installation
1) Coat new seal lips with oil. Place Centering Sleeve
(2003/2A) on crankshaft and start seal into place. Using Seal
Installer (2003/1), press in seal until seated.
2) On models with flex plate (A/T), measure distance from
back of block to face of flex plate (converter side) with
intermediate plate removed. Distance must be 1.20-1.26" (30.5-32.1
mm), measured from lower left corner of block (high point). If
distance is too small, install shim between end of crankshaft and
flex plate.
3) Install intermediate plate, making sure it is located on
dowel sleeves. Chamfered side of washer faces flex plate during
installation. On all models, bolts with NO shoulder are tightened to
55 ft. lbs. (75 N.m). Bolts with shoulder should be replaced with new
bolts and tightened to 74 ft. lbs. (100 N.m). Install remaining
components.

CRANKSHAFT FRONT OIL SEAL

Removal
1) Remove all drive belts. Remove upper timing belt cover.
Set No. 1 piston on TDC after compression stroke. Remove crankshaft
pulley. Install Locking Retainer (3099) and loosen bolt that holds
timing belt sprocket to crankshaft. Remove water pump pulley.
2) Remove lower timing belt cover. Loosen timing belt
tensioner. Remove timing belt and drive sprocket. Install Allen head
bolt from Seal Installer (3083) in end of crankshaft. Remove seal
using Seal Extractor (2085) guided by bolt from installer.

Installation
1) Slide sleeve from Seal Installer (3083) onto crankshaft.
Slide new seal over sleeve after dipping seal in fresh engine oil.
Place thrust sleeve from installer over guide sleeve.
2) Press seal into place with thrust sleeve and Allen head
bolt until seal is fully seated. Install crankshaft timing belt
sprocket, making sure keyed lug on sprocket is fitted to machined
groove in crankshaft. Use locking retainer to hold crankshaft.
3) Use oil to coat threads of bolt which secures timing belt
sprocket to crankshaft. Install bolt and tighten to 148 ft. lbs. (200
N.m). Install remaining components. Make sure valve timing and timing
belt tension are correct.

ENGINE OILING

ENGINE OILING SYSTEM

Oiling system is pressure feed system. A gear-type oil pump

lifts oil from oil pan and pressure feeds it to crankshaft journals,
camshaft bearings and intermediate shaft. Other parts of system
receive oil lubrication by drainage or splash method.

CRANKCASE CAPACITY

Capacity is 3.7 quarts (3.5L) without filter replacement;

4.3 quarts (4.0L) with filter replacement.

NORMAL OIL PRESSURE

Minimum oil pressure is 29 psi (2.0 kg/cmý) at 2000 RPM,

with oil temperature of 176ø F (80ø C). Specification is for 20W/20
type engine oil.

OIL PUMP

Removal & Disassembly

Remove oil pan. Remove oil pump attaching bolts and lower
pump away from engine. Remove pump pick-up bolts. Separate pickup
from pump body. Remove strainer cover from pick-up tube and clean
strainer.

Inspection
1) With oil pump gears installed in pump housing, insert
feeler gauge between drive gear and driven gear teeth (where teeth
mesh). Measure pump gear backlash. Maximum backlash is .002-.008"
(.05-.20 mm).
2) Place straightedge over pump housing. Insert feeler gauge
between pump gears and straightedge. Maximum end play of gears is
.006" (.15 mm).

Reassembly & Installation

Assemble pump in reverse order of disassembly. Prime oil
pump prior to installing. Install pump in reverse order of removal
procedures. Make sure engine has oil pressure after starting.

ENGINE COOLING

CAUTION: Coolant/water mixture should be used at all times. Only

ethylene glycol based (phosphate-free) antifreeze may be
used, as it protects aluminum/iron engines from corrosion.

WATER PUMP

Removal & Disassembly

1) Set heater control on dash to warm (partially opens
heater control valve). Remove cap from expansion tank. Disconnect
wiring and remove thermo-time switch from coolant flange on left side
of head. Drain coolant. Remove alternator and drive belt.
2) Remove coolant hoses at pump housing. Remove water pump
pulley. Remove bolts holing pump housing against engine block. Remove
pump assembly. Unbolt and separate impeller portion from pump housing.

Reassembly & Installation

1) To reassemble, reverse disassembly procedure. Use new
gasket between pump and housing. When installing pump assembly, use
new "O" ring between pump housing and engine block. Open heater
control valve fully. Add coolant to expansion tank until coolant
comes out of thermo time switch opening on coolant flange.
2) Reinstall thermo time switch and connect wiring. Fill
expansion tank 3/4" above full mark. Start and run engine until
radiator cooling fans cycles on and off. Check coolant level. Fill
expansion tank if necessary. Make sure coolant circulates (thermostat
opens).

NOTE: For information on cooling system capacities and other

cooling system components, see appropriate article in ENGINE
COOLING SYSTEMS section.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS TABLE

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Application Ft. Lbs. (N.m)

Camshaft Bearing Cap Nut ......................... 14 (20)

Camshaft Sprocket Bolt ........................... 58 (80)
Connecting Rod Cap Nut ....................... (1) 22 (30)
Crankshaft Pulley Nut ............................ 14 (20)
Crankshaft Sprocket Bolt ....................... 148 (200)
CV Joint-to-Flange ............................... 33 (45)
Cylinder Head Bolt (Engine Cold)
Step 1 ......................................... 29 (40)
Step 2 ......................................... 43 (60)
Step 3 ............................ Plus 180ø (1/2 Turn)
Engine-to-Transmission Bolt
M10 ............................................ 33 (45)
M12 ............................................ 54 (75)
Engine/Transmission-to-Body
Longitudinally Mounted Unit
Front Mount-to-Body ........................... 18 (25)
Side Mounts-to-Subframe ....................... 25 (35)
Transversely Mounted Unit
Front Mount-to-Body Bolt
Front ....................................... 51 (70)
Rear ........................................ 25 (35)
Front Mount-to-Trans. Bolt .................... 33 (45)
Front Mount Through Bolt ...................... 36 (50)
Rear Mount-to-Bushing Bolt .................... 18 (25)
Rear Mount-to-Engine Bolt ..................... 18 (25)
Rear Mount Through Bolt ....................... 58 (80)
Trans. Mount-to-Bushing Bolt .................. 43 (60)
Trans. Mount Bushing-to-Body .................. 18 (25)

Exhaust Pipe-to-Manifold Nut ..................... 25 (35)

Flywheel-to-Crankshaft Bolt (2)
Without Shoulder ............................... 55 (75)
With Shoulder (3) ............................. 74 (100)
Intermediate Shaft Sprocket Bolt ................. 58 (80)
Main Bearing Cap Bolts ........................... 47 (65)
Manifold Fasteners (M8) .......................... 18 (25)
Power Steering Pump-to-Bracket Nut ............... 14 (20)
Timing Belt Tensioner Nut ........................ 33 (45)

Torque Converter-to-Drive Plate Bolt

Longitudinally Mounted ......................... 14 (20)
Transversely Mounted ........................... 22 (30)

(1) - Plus 90ø (1/4 turn) after reaching

specified torque.
(2) - Use locking compound.
(3) - Always use new bolts.
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ENGINE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

GENERAL SPECIFICATIONS TABLE

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Application In. (mm)

Cabriolet
Displacement
Cubic Inches ..................................... 109
Liters ........................................... 1.8
Fuel System ....................... CIS-E Fuel Injection
HP @ RPM ..................................... 90 @ 5500
Torque Ft. @ RPM ............................ 100 @ 3000
Compression Ratio ................................ 8.5:1
Bore ....................................... 3.19 (81.0)
Stroke ..................................... 3.40 (86.4)
GLT & GTI
Displacement
Cubic Inches ..................................... 109
Liters ........................................... 1.8
Fuel System ....................... CIS-E Fuel Injection
HP @ RPM .................................... 100 @ 5500
Torque Ft. @ RPM ............................ 105 @ 3000
Compression Ratio ............................... 10.0:1
Bore ....................................... 3.19 (81.0)
Stroke ..................................... 3.40 (86.4)
Golf & Jetta
Displacement
Cubic Inches ..................................... 109
Liters ........................................... 1.8
Fuel System ....................... CIS-E Fuel Injection
HP @ RPM ..................................... 85 @ 5250
Torque Ft. @ RPM ............................. 96 @ 3000
Compression Ratio ................................ 9.0:1
Bore ....................................... 3.19 (81.0)
Stroke ..................................... 3.40 (86.4)
Quantum
Displacement
Cubic Inches ..................................... 109
Liters ........................................... 1.8
Fuel System ....................... CIS-E Fuel Injection
HP @ RPM ..................................... 88 @ 5500
Torque Ft. @ RPM ............................ 109 @ 3000
Compression Ratio ................................ 8.5:1
Bore ....................................... 3.19 (81.0)
 Stroke ..................................... 3.40 (86.4)
Scirocco
Displacement
Cubic Inches ..................................... 109
Liters ........................................... 1.8
Fuel System ....................... CIS-E Fuel Injection
HP @ RPM ..................................... 90 @ 5500
Torque Ft. @ RPM ............................ 100 @ 3000
Compression Ratio ................................ 8.5:1
Bore ....................................... 3.19 (81.0)
Stroke ..................................... 3.40 (86.4)
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VALVE SPECIFICATIONS

VALVE SPECIFICATIONS TABLE

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Application In. (mm)

Intake (GX/JN)
Head Diam. ............................... 1.496 (38.00)
Face Angle ......................................... 45ø
Seat Angle ......................................... 45ø
Seat Width ................................. .079 (2.01)
Stem Diameter ......................... .314 Min. (7.97)
Stem Clearance ..................................... ...
Valve Lift ......................................... ...
Intake (HT/JH)
Head Diam. ............................... 1.575 (40.00)
Face Angle ......................................... 45ø
Seat Angle ......................................... 45ø
Seat Width ................................. .079 (2.01)
Stem Diameter ......................... .314 Min. (7.97)
Stem Clearance ..................................... ...
Valve Lift ......................................... ...
Exhaust
Head Diam. ............................... 1.300 (33.00)
Face Angle ......................................... 45ø
Seat Angle ......................................... 45ø
Seat Width ................................. .094 (2.40)
Stem Diameter .......................... .313 Min (7.95)
Stem Clearance ..................................... ...
Valve Lift ......................................... ...
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PISTONS, PINS & RINGS SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS TABLE

ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Application In. (mm)

Pistons
Clearance ............................. (1) .0011 (.028)
Pins
Piston Fit ......................................... (2)
Rod Fit ................................... Interference
Rings
Ring No. ........................................... All
End Gap ...................... (3) .012-.018 (.30-.46)
Side Clearance ........... (4) .0008-.0020 (.020-.050)

(1) - Wear limit is .003" (.07 mm).

(2) - Light press fit at 140øF (60øC).
(3) - Wear limit is .040" (1.02 mm).
(4) - Wear limit is .006" (.15 mm).
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CRANKSHAFT MAIN & CONNECTING

ROD BEARINGS SPECIFICATIONS

CRANKSHAFT MAIN & CONNECTING

ROD BEARINGS SPECIFICATIONS TABLE
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Application In. (mm)

1.8L
Standard Size
Main Bearings
Journal Diam. .......... (1) 2.124-2.125 (53.96-53.98)
Clearance .................... (2) .001-.003 (.03-.07)
Thrust Bearing ................................. No. 3
Crankshaft End Play .......... (3) .003-.007 (.07-.17)
Connecting Rod Bearings
Journal Diam. ............(1) 1.880-1.881 (47.76-47.78)
Clearance ................ (4) .0011-.0034 (.028-.088)
Side Play ............................ .015 Max. (.38)
1st Under Size
Main Bearings
Journal Diam. .............. 2.114-2.115 (53.71-53.73)
Connecting Rod Bearings
Journal Diam. .............. 1.871-1.872 (47.51-47.53)
2nd Under Size
Main Bearings
Journal Diam. .............. 2.104-2.105 (53.46-53.48)
Connecting Rod Bearings
Journal Diam. .............. 1.860-1.861 (47.26-47.28)
3rd Under Size
Main Bearings
Journal Diam. .............. 2.095-2.096 (53.21-53.23)
Connecting Rod Bearings
Journal Diam. .............. 1.851-1.852 (47.01-47.03)

(1) - Out-of-round limit is .001" (.03 mm).

(2) - Wear limit is .007" (.17 mm).
(3) - Wear limit is .010" (.25 mm).
(4) - Wear limit is .005" (.12 mm).
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END OF ARTICLE