Volkswagen Engines - 4-Cylinder
Volkswagen Engines - 4-Cylinder
Volkswagen Engines - 4-Cylinder
ENGINE CODING
ENGINE IDENTIFICATION
Engine code number is stamped on crankcase below breather, near coil. First two digits of cast number are engine code.
ENGINE IDENTIFICATION
ENGINE
Removal
1. Disconnect battery. Remove air cleaner with air flow sensor and air intake duct. Remove rubber boot to heater booster. Disconnect
electrical wiring from the following components: alternator, distributor and oil pressure sending unit. Disconnect plug at control unit.
Pull oil dipstick. Disconnect vacuum hose from brake booster. Disconnect all remaining vacuum hoses and electrical wiring leads
running between engine and engine compartment.
2. Remove nuts of upper engine mounting bolts and disconnect accelerator cable. On automatic transaxle models, remove plug on top
of transaxle housing, pull ATF dipstick and remove ATF filler tube grommet. Remove three 8 mm bolts of torque converter through
hole on top off transaxle housing.
NOTE: To gain access to bolts of torque converter, engine must be rotated until each bolt appears in hole on top of
transmission housing. Use adapter (3052) to turn engine crankshaft.
3. On all models, remove heater flap housing bolt; clamp fuel line and detach. Also clamp fuel line from pressure regulator and detach.
Disconnect wiring from starter. On manual transaxle models, loosen transaxle mount bolt at front of transaxle. On automatic
transaxle models, loosen accelerator cable at selector lever and detach. Loosen transaxle mount bolt at front of transaxle.
4. On all models, place a support (VW785/1) under transaxle. Place a floor jack under engine. Raise jack until engine is just supported.
Remove nuts from lower engine mounting bolts. Remove bolts from engine carrier. Lower engine/transaxle assembly until transaxle
rests on support (VW785/1). Slide engine assembly slightly to rear until it clears input shaft. Remove engine from transaxle and
lower engine with floor jack.
Installation
To install, reverse removal procedure and note the following: Replace all self-locking nuts. On manual transaxle models, check clutch
release bearing for wear; lubricate splines on main drive shaft, contact points of clutch release bearing and clutch release lever. Adjust
accelerator cable at full throttle position. On automatic transaxle models, adjust accelerator cable.
INTAKE MANIFOLD
Removal
1. Fuel injection manifold can be removed with engine in vehicle. Remove air cleaner, hoses, and pressure switch.
2. Disconnect wires on fuel injectors and remove two screws. Pull injectors off with plate and retainer. Make sure locating bushings are
removed from manifold. Disconnect hoses on injectors and remove.
3. Remove intake manifold cover plate. Remove nuts and washers securing manifold to cylinder heads. Lift up on manifold and pull
from tubes on air distributor.
Installation
To install manifold, reverse removal procedure and note the following: Use new gaskets and tighten intake manifold mounting nuts
uniformly. Make sure gray protective cap on injector is to rear and cap is to front.
CYLINDER HEAD
NOTE: Engine must be removed from vehicle and manifolds removed, before removing cylinder heads. If cylinders are not to be
removed, use retaining device to keep cylinders from pulling free.
Removal
1. Remove rocker arm cover and gasket. Remove rocker arm shaft retaining nuts, loosening gradually one at a time to relieve spring
tension evenly. Remove rocker arm assemblies.
2. Remove push rods, keeping in order for reassembly. Loosen cylinder head nuts gradually working in sequence from outside toward
center.
Installation
1. Place new metal gasket rings in peripheries of combustion chambers and install head over cylinder studs. Tighten nuts lightly by
hand and then to specifications in 2 steps following sequence shown in Fig. 1.
2. Install push rod through top of cylinder head with black sealing ring at bottom and white ring at top. Install remaining components in
reverse order of removal. Ensure push rod tube retaining wire bears against end of tubes and engage slots in rocker arm supports
before installing cylinder head cover.
VALVES
VALVE ARRANGEMENT
E-I-I-E (both banks)
CAUTION: DO NOT use a hammer and drift to replace guides due to the danger of damage to the cylinder head.
VALVE SPRINGS
NOTE: Valve spring may be removed with cylinder head installed. Apply constant air pressure (minimum 85 psi) to cylinder
through spark plug hole to hold valve in place while compressing spring.
Removal
Remove cylinder head cover and rocker arm shaft. Install suitable valve spring compressor tool (VW311s with cylinder head removed,
VW653/2 with cylinder head installed). Compress spring retainer and spring and remove valve keepers. Release compressor and remove
spring retainer and spring.
Fig. 2: Using Special Tool VW311s to Remove Valve Spring
Installation
Install valve, valve spring, and valve spring retainer. Compress spring and install valve keepers.
NOTE: Install spring with closely spaced coils against cylinder head.
Removal
Disengage wire valve cover clip. Remove valve cover. Remove 4 rocker shaft retaining nuts. Each side has two separate shafts. Make sure
mounting nuts are gradually and evenly loosened until spring tension is relieved.
Inspection
Check rocker arms and shafts for wear. If inside diameter of rocker arm is worn more than 0.789" (20.0 mm), replace rocker arm. If
diameter of rocker shaft is worn to less than 0.783" (19.9 mm), replace rocker shaft.
Installation
To install, reverse removal procedure and note: Make sure push rod tube retaining wire is reinstalled. Adjust valve clearance.
NOTE: Valve lifters may be removed and installed without removing or disassembling engine.
Removal
Valve covers, rocker arms, push rods and push rod covers must be off of engine. Remove lifters by withdrawing with a magnetic tool. Mark
all lifters for installation in original position.
Installation
Ensure that lifters are filled with oil and reverse removal procedure. Back off adjusting screws in rocker arms until threaded part is flush
with bottom of rocker arm. Proceed as in Valve Clearance Adjustment .
CYLINDERS
Removal
Remove engine and remove cylinder head.
Remove deflector plates from bottom of cylinders and pull cylinders from pistons.
Installation
1. Check seating surfaces of cylinders on both ends. Make sure seating areas are perfectly clean and true before installing cylinders.
Stagger ring gaps 120° apart so that oil ring gap faces upward when cylinder is installed.
2. Apply oil to cylinder, piston rings and piston pin. Compress rings with suitable ring compressor (US 1008A). Install new sealing
gasket on crankcase side and slide cylinder over piston.
3. Make sure studs do not contact cooling fins when cylinder is completely seated against crankcase. Install cylinder deflector plates
and remaining components in reverse of removal.
FITTING PISTONS
1. With piston and cylinder removed, measure clearance between piston and cylinder. Check piston size at bottom of skirt and 90° to
piston pin. Check cylinder size at several points throughout cylinder, using largest reading to determine clearance.
2. If clearance exceeds 0.008" (0.20 mm) replace piston and cylinder as a set. New piston must be of the same weight grade as
original or within 10 g of original piston weight. Piston size, weight and installation position are marked on top of piston. Pistons and
cylinders are available in 0.020" (0.5 mm) and 0.040 (1.0 mm) oversizes. See Fig. 6.
Fig. 6: Top View of Piston with Detail of Piston Markings
NOTE: Piston alone may be replaced with one of matching size. Only pistons of same size and weight grade should be
installed in same engine.
3. New piston rings are size graded to match piston/cylinder sets. Measure ring gap with ring installed approximately 3/16" in cylinder.
If ring end gap exceeds 0.035" (0.90 mm) for compression rings or 0.037" (0.95 mm) for oil scraper, replace.
4. Install rings on piston and measure ring side clearance using feeler gauge. If clearance exceeds 0.005" (0.12 mm) on upper and
middle rings or 0.004" (0.10 mm) on oil scraper ring, piston must be replaced.
PISTON PINS
Removal
Remove cylinders and mark pistons before removing for proper installation. Using suitable pliers (VW122b), remove piston pin circlips and
push piston pin out of piston.
Installation
1. Check fit of pin in piston. At room temperature piston pin should be light push fit. If pin is too loose, both pin and piston must be
replaced.
2. Install one circlip in piston on side facing flywheel. Position piston on connecting rod and push piston pin through piston. Replace
remaining circlip. Replace remaining components in reverse of removal.
CRANKCASE
Crankcase must be taken apart to replace connecting rods, connecting rod bearings and main bearings. It is also necessary to
disassemble crankcase to remove crankshaft, camshaft, and camshaft bearings.
Disassembly
1. Remove engine from vehicle and remove cylinder heads, cylinders, and pistons. Remove flywheel or drive plate, and crankshaft
pulley. Remove distributor, distributor drive shaft and fuel pump.
2. Remove oil cooler, oil filter and bracket, and oil pump assembly. See OIL PUMP REMOVAL. Remove rear engine carrier
crossmember, bonded rubber mountings, and fan hub. Remove oil pan and oil filler pipe mounting bracket bolt.
3. Remove six 10 mm main bearing nuts and bolts and five 8 mm nuts and bolts from crankcase flange. Using spring clips, clamp
tappets in right half of crankcase and lift off right hand crankcase half.
CAUTION: Never insert tools between crankcase flanges to separate halves. If stuck together, use rubber hammer to loosen
right hand half from left.
Reassembly
1. Thoroughly clean and inspect both crankcase halves. Remove old sealing compound from mating surfaces and from all bolts, studs
and washers. Blow out oil passages with compressed air. Check studs for tightness and check oil suction pipe for tightness.
2. Install crankshaft with connecting rods, in left side crankcase half, making sure dowel pins are properly seated in bearings. Install
camshaft. See CAMSHAFT INSTALLATION. Install camshaft plug using liquid sealer all around plug. Spread liquid sealer over
mating surfaces of crankcase halves.
3. Using spring clips, clamp tappets in right hand half of crankcase to join crankcase halves. Coat main bearing bolt heads (10 mm)
with sealer and install in crankcase.
NOTE: Install plastic dampers (part No. 021 101 107) on shank of main bearing bolts whether or not originally equipped.
4. Coat the sealing nuts for main bearing bolts with sealer and install nuts with sealing rings outward. Tighten main bearing nuts and
bolts and hand turn crankshaft to check for free movement. Coat bolt heads and nuts of 8 mm bolts with sealer, then install and
tighten.
5. Check crankshaft end play. See Thrust Bearing Alignment. Install new crankshaft oil seals. See FRONT CRANKSHAFT OIL SEAL
REPLACEMENT and Rear Crankshaft Oil Seal Replacement. Install remaining components in reverse of removal procedure.
NOTE: Lightly tap both sides of connecting rod with hammer to eliminate slight pinching of bearing shells when installing
connecting rod.
7. Check connecting rod side play with feeler gauge. If side play exceeds 0.0275" (0.70 mm), replace connecting rod. Install crankshaft
and connecting rod assembly as previously outlined. Check crankshaft end play. See Thrust Bearing Alignment .
1. Install flywheel with 2 shims, but do not install "O" ring and crankshaft oil seal. Attach dial indicator to crankcase and measure back
and forth movement of crankshaft.
2. Calculate necessary thickness of third shim. Install third shim and recheck end play. Thickness of shim is etched on face of shim,
always use three shims to obtain correct end play.
.24 mm .0095"
.30 mm .0118"
.32 mm .0126"
.34 mm .0134"
.36 mm .0142"
.38 mm .0150"
3. With correct shim thickness determined, install crankshaft oil seal. See Front Crankshaft Oil Seal . Install flywheel, tighten bolts as
required, and recheck crankshaft end play.
CAMSHAFT
CAMSHAFT INSTALLATION
1. With camshaft removed, check riveting of camshaft gear to camshaft. Check camshaft for maximum runout of 0.0015" (0.040 mm).
If beyond limit, replace camshaft.
2. Check gear backlash with camshaft and crankshaft installed in crankcase half. Correct backlash is 0.002" (0.05 mm). Gears have
correct fit when crankshaft is rotated backwards and camshaft does not try to lift out of bearings.
3. If camshaft rises out of bearings, teeth on camshaft gear have the wrong pitch radius for crankshaft gear. Camshafts with gears that
have various pitch radii are available. Pitch radius is stamped on inner face of timing gear.
4. Install camshaft with "O" stamped in tooth on outside of camshaft gear between 2 teeth with punch marks on crankshaft gear.
Assemble crankcase halves as previously outlined. See Fig. 11.
VALVE TIMING
Install camshaft with "O" stamped in tooth on outside of camshaft gear between 2 teeth with punch marks on crankshaft gear. See Fig. 11.
ENGINE OILING
Oil Capacity
3.2 qts. Add 0.5 qt. with filter change.
Oil Pressure
29 psi (2.04 kg/cm2 ) at 2000 RPM with engine at 176°F (80°C).
Oil Filter
Full-flow, throw-away type oil filter.
OIL COOLER
To remove oil cooler, remove cooling air fan housing, three 6 mm nuts with washers attaching oil cooler to rear of crankcase, and bolts
attaching oil cooler support strap. Remove support strap and oil cooler as unit. Always use new rubber seals when installing oil cooler.
OIL PUMP
Removal
Remove engine. Remove 4 nuts holding oil pump housing. Using 2 levers, pry oil pump out of crankcase. Oil pump insert can be removed
with puller (VW803). See Fig. 15 .
Inspection
Check housing for excessive wear, mainly in gear seating portions. Measure gear backlash for wear. Backlash must not exceed 0.008"
(0.20 mm). Replace bearing plate if scored.
Installation
Hand turn oil pump drive shaft until fully engaged in camshaft. Rotate crankshaft two revolutions. Pump plate should now be aligned with
camshaft. Refit new gasket and reverse removal procedure for remaining components.
ENGINE COOLING
Thermostat
At 185-194°F (85-90°C), thermostat length should be at least 1 13/16" (46 mm) measured from shoulders on bellows shaft.
COOLING SYSTEM
Engine is cooled by a radial blower mounted to rear end of crankshaft. Blower draws air through opening in blower shroud at rear of
engine. Blower shroud is two-piece unit, mounted around blower and attached to crankcase. As air is drawn in, it is directed over finned
cylinders and cylinder heads by deflector plates. As engine warms up, thermostat opens flaps completely to allow total flow of air.
TIGHTENING SPECIFICATIONS
Fan-to-Hub 14 (19)
Engine-to-Transmission 22 (30)
Flywheel-to-Crankshaft 80 (110)
ENGINE SPECIFICATIONS
GENERAL SPECIFICATIONS
Engine & Head Face Seat Seat Width Stem Stem Valve Lift
Valve Diam. In. Angle Angle In. (mm) Diameter In. Clearance In. In. (mm)
(mm) (mm) (mm)
1970 cc
Int. 1.547 29.5 30° .070-.086 .313 (7.95) .018 (.46) .....
(39.3) (1.80-2.20)
Exh. 1.299 45° 45° .070-.098 .351 (8.92) .014 (.35) .....
(33.0) (2.00-2.50)
VALVE SPRINGS
Engine Free Length In. (mm) PRESSURE Lbs. @ In. (kg @ mm)
CAMSHAFT
Engine Journal Diam. In. (mm) Clearance In. (mm) Lobe Lift In. (mm)
Clearance In. Piston Fit In. Rod Fit In. (mm) Rings End Gap In. Side Clearance In.
(mm) (mm) (mm) (mm)
1
Push fit with light thumb pressure at room temperature.
1970 cc
2 2.3609- .0012-.0035
2.3617 (.030-.089)
Engine MAIN BEARINGS CONNECTING ROD BEARINGS
(59.967-
59.987)
3 2.3609- .0016-.0039
2.3617 (.041-.099)
(59.967-
59.987)
4 1.5739- .0020.0039
1.5748 (.051-.099)
(39.977-
40.025)
1
Limit.028" (.7 mm).