Volkswagen Passat 1995 Operating instructions

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2.0 Liter 4-Cyl. 2V Engine Mechanical, Engine Code(s): ABA m.y. 1995
00 - General, Technical data
Technical data
Engine numbers, location
Engine technical data
10 - Engine - Assembly
Engine, removing and installing
Removing
Installing
Tightening torques
Engine and transmission, aligning
Rubber bushings for engine mount, replacing
Vehicles with A/C, additional information on removing and installing
13 - Engine - Crankshaft, Cylinder block
Engine disassembling and assembling
Ribbed drive belt, removing and installing
Toothed drive belt, removing and installing
Sealing flange and flywheel or drive plate, removing and installing
Crankshaft oil seal (pulley end), replacing
Drive plate, removing and installing
Crankshaft, removing and installing
Crankshaft dimensions
Pistons and connecting rods, disassembling and assembling
Piston and cylinder dimensions
15 - Engine - Cylinder head, Valvetrain
Cylinder head removal and installation
Cylinder head, installing
Compression pressure, checking
Cylinder head, disassembling and assembling
Valve seats, refacing
Camshaft oil seal, removing and installing
Camshaft, removing and installing
Hydraulic valve lifters, checking
Valve guide wear, checking
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Valve guides, removing and replacing
Valve stem seals, replacing
17 - Engine - Lubrication
Lubrication system, general information
Lubrication system, components
Oil pressure and oil pressure switches, checking
19 - Engine - Cooling system
Cooling system
General information
Cooling system components, body side
Cooling system components, engine side
Coolant pump, disassembling and assembling
Cooling system, draining and filling
Radiator and coolant fan, removing and installing
20 - Fuel Supply
Fuel supply system
General information
Fuel filter and fuel tank with attaching parts, removing and installing
Safety precautions
Rules of cleanliness
Accelerator pedal cable, adjusting
Fuel pump module, removing and installing
Fuel pump, checking
Fuel pump delivery rate, checking
Evaporative Emissions (EVAP) system
Components, removing and installing
Fuel tank breather, checking
26 - Exhaust system, Emission controls
Exhaust system removal and installation
Exhaust manifold, front exhaust pipe and Three Way Catalytic Converter (TWC),
removing and installing
Muffler assembly and mounts
Exhaust Gas Recirculation (EGR) system
Exhaust Gas Recirculation (EGR) valve and EGR temperature sensor, checking
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Secondary Air Injection (AIR) system
Function
Secondary Air Injection (AIR) system components, removing and installing
Combi-valve and check valve, checking
Secondary Air Injection (AIR) pump motor, checking
Secondary Air Injection (AIR) solenoid valve, checking
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00-1
Technical data
Engine numbers, location
The engine numbers ("engine code"
and "serial number") are die-stamped in
the front of the cylinder block above the
crankcase breather.
In addition, there is a label with the
"engine code" and "serial number" on
the drive belt cover.
The engine code is also included on the
vehicle data plate.
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00-2
Engine technical data
Engine code ABA ABA
Manufactured from:
to:
03.95
07.95
08.95
Displacement liters 2.0 2.0
Output kW at RPM
HP at RPM
85 at 5400
115 at 5400
85 at 5400
115 at 5400
Torque Nm at RPM
Ft. lb at RPM
165 at 3200
122 at 3200
165 at 3200
122 at 3200
Bore mm 82.5 82.5
Stroke mm 92.8 92.8
Compression ratio 9.4:1 9.4:1
RON minimum 91 lead free 91 lead free
Fuel injection Motronic
multiport fuel injection
Motronic
multiport fuel injection
Ignition Motronic Motronic
Knock control Yes Yes
On Board Diagnostic system OBD OBD II
Oxygen sensor control 1 Oxygen Sensor 2 Oxygen Sensors
Three way catalytic converter Yes Yes
Exhaust gas recirculation (EGR) Yes No
Secondary Air Injection system Yes Yes
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10-1
Engine, removing and
installing
Special tools, testers and auxiliary items
Engine sling 2024 A
G 000 100 grease
Torque wrench VAG 1331: 5-50 Nm (4-
37 ft lb)
Torque wrench VAG 1332: 40-200 Nm
(30-148 ft lb)
Cable ties
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10-2
Removing
The engine is removed by moving it toward the
front together with the transmission.
CAUTION!
Determine correct radio anti-theft coding
before disconnecting the battery.
Ignition switched off.
- Disconnect battery negative cable (ground
strap).
Note:
All tie wraps that are loosened or cut during
engine removal must be replaced when the
engine is installed.
- Remove air cleaner housing with intake air
ducts.
- Loosen power steering reservoir hose clamp.
- Disconnect power steering pressure line clamps
from subframe and transmission.
- Remove power steering pump with bracket and
lay it to the side; power steering hoses remain
connected.
Repair Manual, Suspension, Wheels, Brakes,
Steering, Repair Group 48.
- Drain engine coolant Page 19-9
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10-3
- Remove lock carrier (upper radiator support)
with attached parts.
Repair Manual Body Exterior, Interior, Repair
Group 50
- Remove coolant fan and fan shroud.
Vehicles with A/C:
- Refer to additional information and removal
instructions Page 10-14 .
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10-4
Vehicles with manual transmission:
- Remove clutch slave cylinder.
Repair Manual, 5 Spd. Manual Transmission
02A, Repair Group 30
- Disconnect gear shift mechanism from
transmission.
Repair Manual, 5 Spd. Manual Transmission
02A, Repair Group 34
CAUTION!
Always use cotter pins on hooks and pins.
-
Install engine sling 2024 A and lift slightly wit
shop crane:
Drive belt side:
2nd hole up from hook in cross bar posit
1-
Flywheel side:
2nd hole up from hook in cross bar posit
7-
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10-5
Vehicles with automatic
transmission
CAUTION!
Always use cotter pins on hooks and
pins.
Note:
- Install engine sling 2024 A and lift
slightly with shop crane:
Drive belt side:
4th hole up from hook in cross
bar position -1-
Flywheel side:
2nd hole up from hook in cross
bar position -6-
The end of the cross bar marked
with installation positions 1 through
4 points toward drive belt.
Hole numbers in the hook members
are counted from the hook end.
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10-6
All vehicles:
CAUTION!
Lift unit out carefully to avoid
damage to body.
For engine repairs, mount engine in
engine stand with VW 540 holding
fixture.
- Disconnect subframe and, on one
side, pry bracket from rubber
subframe mounting.
- Separate power steering pressure
lines from disconnected subframe.
- Lift engine together with transmission
out toward the front.
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10-7
Installing
Install in reverse order of removal, but note the
following:
-
Check clutch release bearing for wear, repla
necessary.
-
Lightly lubricate clutch release bearing, clutc
release guide sleeve and transmission input
shaft splines with G 000 100 grease.
- Check whether guide sleeves for centering
engine and transmission are in cylinder block
not, install.
-
During installation of engine and transmissio
sure to maintain clearance for drive axle sha
Tightening torques Page 10-9
Repair Manual, 5 Spd. Manual Transmission
02A, Repair Group 30
Repair Manual, 5 Spd. Manual Transmission
02A, Repair Group 34
Repair Manual, Suspension, Wheels, Brake
-
When installing engine mounts, be sure that
recesses on right rear engine mount bracket
front engine mount engage in guide pins of
bonded rubber mounts (arrows).
-
Relieve tension on engine mounts by shakin
engine.
- Install clutch slave cylinder.
- Install gear shift mechanism.
- Install power steering pump.
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Steering, Repair Group 48.
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10-8
- Install lock carrier with attached parts.
Repair Manual Body Exterior, Interior,
Repair Group 50
Engines with ribbed drive belt without
tensioner:
- Install ribbed drive belt Page 13-11 .
All engines:
- Fill engine cooling system coolant Page
19-9
- Adjust accelerator pedal cable Page 20-
10
- Check electrical connections and routing.
Repair Manual, Electrical Equipment,
Repair Group 97
- Check ignition timing and adjust if
necessary.
Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel
Injection & Ignition, Engine Code(s): ABA
m.y. 1995, Repair Group 28
Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel
Injection & Ignition, Engine Code(s): ABA
m.y. 1996-1997, Repair Group 28
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- Carry out idle check.
Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel
Injection & Ignition, Engine Code(s): ABA
m.y. 1995, Repair Group 24
Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel
Injection & Ignition, Engine Code(s): ABA
m.y. 1996-1997, Repair Group 24
- Adjust headlights and adjust if necessary.
Repair Manual, Maintenance
- If necessary, adjust gear shift linkage
cables:
Repair Manual, 5 Spd. Manual
Transmission 02A, Repair Group 34
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10-9
Tightening torques
Fastener/Connection Tightening
torque
Engine to
transmission
M10 60 Nm (44 ft lb)
M12 80 Nm (59 ft lb)
Flywheel cover plate M7 10 Nm (07 ft lb)
Axle shafts to drive flanges 45 Nm (33 ft lb)
Exhaust pipe to manifold 40 Nm (30 ft lb)
Engine mount to body 50 Nm (37 ft lb)
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10-10
Engine and transmission mount
tightening torques
Bolt threads lubricated
Front engine mount
A - 55 Nm (41 ft lb)
B - 55 Nm (41 ft lb)
C - 50 Nm (37 ft lb)
Rear right engine mount
A - 25 Nm (18 ft lb)
B - 50 Nm (37 ft lb)
C - 25 Nm (18 ft lb)
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10-11
Rear left engine mount for manual
transmission
A - 60 Nm (44 ft lb)
B - 25 Nm (18 ft lb)
C - 30 Nm (22 ft lb)
Rear left engine mount for automatic
transmission
A - 60 Nm (44 ft lb)
B - 25 Nm (18 ft lb)
C - 30 Nm (22 ft lb)
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