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