Service

Golf 1992 , Vento 1992 ➤

4-Cyl. injection engine, Mechanics (1.4 and 1.6 l
engine)
Engine ID ABD ABU AEA AEE AEX APQ

Edition 12.1994

Service Department. Technical Information

 Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine)

Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, Valve gear
17 - Lubrication
19 - Cooling system
20 - Fuel supply system
26 - Exhaust system

Technical information should always be available to the foremen and mechanics, because their careful
and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In
addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course,
be observed.
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.3 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.2 Notes on removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.3 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.4 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.5 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.6 Renewing engine carrier rubber mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.2 Removing and installing ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
1.3 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
1.4 Checking semi-automatic toothed belt tensioning roller . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
2 Dismantling and assembling cylinder block, crankshaft and flywheel . . . . . . . . . . . . . . . . . .30
2.1 Dismantling and assembling cylinder block, crankshaft and flywheel . . . . . . . . . . . . . . . . . .30
2.2 Renewing crankshaft oil seal - pulley end - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
2.3 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
3 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
3.1 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
3.2 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

15 - Cylinder head, Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
1.1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
1.3 Checking compressions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
2 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
2.1 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
2.2 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
2.3 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
2.4 Checking hydraulic bucket tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
2.5 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
2.6 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
2.7 Renewing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
2.8 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
1.1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
1.2 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
1.3 Removing and installing Duo-centric oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
1.4 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Contents i
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

1.1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

1.2 Parts of cooling system body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
1.3 Parts of cooling system - engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
1.4 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
1.1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
1.2 Removing and installing fuel tank with its attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
1.3 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . .114
1.4 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
1.5 Adjusting throttle cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
1.6 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
1.7 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
1.8 Removing and installing parts of the activated charcoal filter system . . . . . . . . . . . . . . . . . .122
1.9 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126

1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
1.1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126

ii Contents
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

00 - Technical data

1 - Technical data
1.1 - Technical data

1.2 - Engine number

-> The engine number ("Code letters" and "Serial number") can be found on the front of the cylinder block at
the gearbox end below the thermostat housing.
Additionally there is a sticker on the toothed belt guard with "Engine code" and "Serial number".
The engine code is also included on the vehicle data plate.

1.3 - Engine data

Engine code ABD ABU AEA AEE

Manufactured 10.91...07.95 08.92...09.94 10.94...07.95 08.95 ▸
Stroke cm3 1391 1598 1598 1598
Output kW at rpm 44(401))/5200 55/5200 55/5200 55/4800
Torque Nm at rpm 107(1031))/ 126/2600 128/2800...3400 135/2800...3600
2400...28002)

Engine code ABD ABU AEA AEE

Bore ø mm 75 76.5 76.5 76.5
Stroke mm 78.74) 86.9 86.9 86.9
Compression ratio 9.5 9.3 9.8 9.8
RON min. 91 unleaded3) 91 unleaded 95 unleaded5) 95 unleaded5)
Injection, ignition Mono Motronic Mono Motronic Mono Motronic 1AV
1.2.3R 1.2.3 1.3
Knock control - - x x
Self-diagnosis x x x x
Lambda control x x x x
Volkswagen Technical Site: [Link] [Link]

1.1 - Technical data 1

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

Engine code ABD ABU AEA AEE

Catalyst x/- x x x
Charging - - - -

1) Austria: Reduction in output due to plate in front silencer.

2) ▸ 07.92 max. torque at 2800...3200 rpm.

3) Engines without catalyst can also be run on leaded fuel.

4) ▸ 07.92: 79.14 mm

5) In exceptional circumstances min. 91 RON, however with reduced performance

Engine code AEX, APQ

Manufactured 08.95 ▸
Stroke cm3 1390
Output kW at rpm 44(401))/4700
Torque Nm at rpm 116/2800...3200
(116/30001))
Bore ø mm 76.5
Stroke mm 75.6
Compression ratio 10.2
RON min. 95 unleaded2)
Injection, ignition Motronic MP 9.0
Knock control x
Self-diagnosis x
Lambda control x
Catalyst x
Charging -

1) Austria: Reduction in output due to plate in catalyst.

2) In exceptional circumstances min. 91 RON, however with reduced performance

2 00 - Technical data
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

10 - Removing and installing engine

1 - Removing and installing engine

1.1 - Removing and installing engine

Special tools, testers and auxiliary items

◆ Drip tray V.A.G 1306

◆ Pliers V.A.G 1921 for spring type clips
◆ Lifting tackle 2024 A
◆ Workshop crane V.A.G 1202 A
◆ Grease G 000 100
◆ V.A.G 1331 Torque wrench (5...50 Nm)
◆ V.A.G 1332 Torque wrench (40...200 Nm)
◆ Cable tie

If the engine is to be dismantled:

◆ Engine bracket VW 540

1.2 - Notes on removing

- First check whether a coded radio is fitted. If this is the case obtain the anti-theft coding.
- The engine is removed upwards together with the gearbox.
- With the ignition switched off disconnect the battery earth strap.

Note:
All cable ties that have been released or cut-open when removing the engine are to be reinstated at the same
location when reinstalling engine.
- Drain coolant => Page 106 .
- Disconnect clutch cable:

=> 4-Speed manual gearbox 084 or 5-Speed manual gearbox 085; Repair group 30; Servicing clutch mecha‐
nism; Removing and installing clutch cable. Servicing clutch mechanism Removing and installing clutch cable.

Vehicles with power assisted steering:

- Remove power assisted steering vane pump and secure to engine carrier with wire; hoses remain connec‐
ted:

1.1 - Removing and installing engine 3

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
=> Running gear; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic lines; Removing and
installing power steering vane pump. Assembly overview: vane pump, reservoir, hydraulic lines Removing and
installing power steering vane pump.

- -> Attach lifting tackle 2024 A as follows and lift slightly with workshop crane:

Pulley end:
2nd hole in hook at position 1

Flywheel end:
2nd hole in hook at position 6

Warning!
The hooks and locating pins must be secured with locking pins.

Notes:

◆ The positions marked 1...4 on the bar must be towards the pulley end.
◆ The holes in the hook rails are counted up from the hook.

- Remove front console and lift assembly out upwards.

Note:

When the assembly is lifted off, it must be carefully guided to prevent damage to the bodywork.

When working on the engine, it should be secured to the engine stand using the engine bracket VW 540.

1.3 - Notes on installing

Installation is carried out in the reverse sequence, when doing this note the following:

- Check clutch release bearing for wear, renew if necessary.

- Lightly grease clutch release bearing, release bearing guide sleeve and splines on input shaft with G 000
100.
- Check whether the dowel sleeves for centralising engine/gearbox are in the cylinder block, install if neces‐
sary.
- When lowering the assembly, ensure that clearance exists between assembly and drive shafts.

- -> When installing the engine mounting ensure that the rib on the rear right console also the recess on the
front console locates on the lugs of the bonded rubber mounting -arrows-.
- Align engine mountings stress-free by rocking.
- Renew pointed bolt for securing shift finger (clean threads in shift finger).

Vehicles with power assisted steering:

4 10 - Removing and installing engine

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
- Install power assisted steering vane pump:

=> Running gear; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic lines; Removing and
installing power steering vane pump. Assembly overview: vane pump, reservoir, hydraulic lines Removing and
installing power steering vane pump.
- Installing clutch cable:

=> 4-Speed manual gearbox 084 or 5-Speed manual gearbox 085; Repair group 30; Servicing clutch mecha‐
nism; Removing and installing clutch cable. Servicing clutch mechanism Removing and installing clutch cable.
- Fill with coolant => Page 106
- Adjust throttle cable => Page 115
- Electrical connections and routing:

=> Current flow diagrams, Electrical fault finding and Fitting locations
- Check and if necessary adjust ignition timing:

=> Repair group 28; Injection and ignition system; Checking and adjusting ignition timing. Injection and ignition
system Checking and adjusting ignition timing.
Vehicles 10.94 ▸
- Match engine electronics control unit to immobilizer:

=> Repair group 24; Injection and ignition system; Matching engine electronics control unit to immobilizer.
Injection and ignition system Matching engine electronics control unit to immobilizer.

1.4 - Tightening torques

Bolted connection Tightening torque

Engine to gearbox M10 45 Nm
M12 80 Nm
Starter to gearbox 20 Nm
Drive shafts to flanged shafts 45 Nm
Exhaust pipe to manifold 40 Nm
Shift finger to selector rod 25 Nm

1.5 - Assembly mountings

Tightening torques
(Bolts oiled)

1.3 - Notes on installing 5

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
-> Front assembly mounting

A = 50 Nm
B = 45 Nm
C = 50 Nm

-> Rear right assembly mounting

A = 25 Nm
B = 50 Nm
C = 25 Nm

-> Rear left engine mounting

A = 50 Nm
C = 25 Nm
D = 60 Nm

1.6 - Renewing engine carrier rubber mounting

Special tools, testers and auxiliary items

◆ Engine support bracket 10-222A with legs 10-222A/1

◆ Peening tool 3302
◆ Press tool VW 432

6 10 - Removing and installing engine

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
Work sequence

- Fit engine support bracket 10-222A with legs 10-222A/1.

- Locate support bracket in lifting eye on left of cylinder head and take-up weight of engine.
- Remove engine carrier.
- -> Lever off washers from the spacer sleeves with pliers (replace any washers which are damaged e.g. bent
washers).
- Pull out spacer sleeves and detach rubber mounting.
- Fit new rubber mounting and insert spacer sleeves as far as possible.

- -> Fit washers -1- over peening tool 3302 onto the rubber mounting -2-.
- Fit press sleeve of peening tool 3302 and using a press, press the washers onto the spacer sleeves and
peen. Use VW 432 as packing.
- Remove any resulting protrusion/burr on the peening.

1.6 - Renewing engine carrier rubber mounting 7

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

13 - Crankshaft group

1 - Dismantling and assembling engine

1.1 - Dismantling and assembling engine

Engine codes ABD, ABU

Engine code AEA, AEE, AEX, APQ

=> Page 17

I =>Page 9

II =>Page 12

III =>Page 14

8 13 - Crankshaft group
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

Part I

1 Toothed belt guard - upper part

2 Toothed belt
◆ Mark D.O.R. before removing
◆ Check for wear
◆ Do not kink
◆ Removing, installing and tensioning
=> Page 26
3 80 Nm
4 Camshaft sprocket
◆ Note position when installing toothed belt
=> Page 26
5 Bracket
◆ Engine code letters ABD
◆ For fuel pipes
6 10 Nm
◆ Install with D6
7 Rear toothed belt guard

1.1 - Dismantling and assembling engine 9

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

8 10 Nm
9 Coolant pump
◆ To tension toothed belt loosen slightly and turn with screwdriver => Page 26
10 O-ring
◆ Renew if damaged
11 Bolt M6: 10 Nm
Bolt M8: 20 Nm
◆ Install with D6
12 Crankshaft toothed belt sprocket
13 Toothed belt guard - lower part
14 Belt pulley
◆ When installing note fixing arrangement
◆ Note position when installing toothed belt
=> Page 26

10 13 - Crankshaft group
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

15 Ribbed belt
◆ Mark direction of rotation before removing
◆ Removing and installing
=> Page 25
16 20 Nm
17 90 Nm + 1/3 turn (120 °) further
◆ Renew
◆ Oil threads
◆ The turning further can be done in several stages
◆ The turning further angle can be checked with a commercial protractor e.g. Hazet 6690

1.1 - Dismantling and assembling engine 11

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

Part II

1 10 Nm
2 Sealing washer
◆ Renew
3 Cylinder head cover
4 Cap
◆ Renew seal if damaged
5 Oil deflector
6 Cylinder head cover gasket
◆ Renew if damaged
◆ Before fitting gasket coat transition between bearing cap/cylinder head with D 454 300 A3
7 Cylinder head bolt
◆ Note installation instructions and sequence when loosening and tightening
=> Page 51

12 13 - Crankshaft group
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

8 Cylinder head
◆ Removing and installing
=> Page 51
◆ If replaced renew the complete
coolant
9 Cylinder head gasket
◆ Renew
◆ If replaced renew the complete
coolant

1.1 - Dismantling and assembling engine 13

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

Part III

Note:

Servicing the clutch:

=> 4-Speed manual gearbox 084; Repair group 30; Servicing clutch Servicing clutch

=> 5-Speed manual gearbox 085; Repair group 30; Servicing clutch Servicing clutch

1 Cylinder block
◆ Dismantling and assembling cylinder block, crankshaft and flywheel
=> Page 30
◆ Dismantling and assembling pistons and conrods
=> Page 38
2 Oil filter
◆ Loosen with strap wrench
◆ Tighten by hand
◆ Note instructions on filter when installing

14 13 - Crankshaft group
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

3 Gasket
◆ Not on engines with liquid gasket
◆ Renew
◆ Before fitting gasket coat sump flange/cylinder block flange with "D2"
4 Sump
◆ Removing and installing engines with liquid gasket
=> Page 83
5 15 Nm
◆ Loosen and tighten the bolts flywheel end only with:
Socket head bolts:
3249
Hexagon head bolts: 3185
6 Sealing ring
◆ Renew
7 Oil drain plug, 30 Nm

1.1 - Dismantling and assembling engine 15

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

8 45 Nm
◆ Tightening sequence:
Upper right bolt first, then lower right bolt, and bolts on left last (as seen from direction of travel)
9 Bracket
◆ For vane pump and alternator
10 Tensioning element
11 20 Nm
12 Washer
13 Tensioning roller

16 13 - Crankshaft group
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

Engine code AEA, AEE, AEX, APQ

I =>Page 18

II =>Page 21

III =>Page 23

1.1 - Dismantling and assembling engine 17

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

Part I

1 Toothed belt guard - upper part

2 Toothed belt
◆ Mark D.O.R. before removing
◆ Check for wear
◆ Do not kink
◆ Removing, installing and tensioning
=> Page 26
3 20 Nm + 1/4 turn (90 °) further
◆ Renew
4 Camshaft sprocket
◆ Note position when installing toothed belt
=> Page 26
5 10 Nm
◆ Install with D6
6 Rear toothed belt guard
7 10 Nm

18 13 - Crankshaft group
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

8 O-ring
◆ Renew
9 Coolant pump
10 20 Nm
11 Tensioner
◆ Checking => Page 29
◆ Tensioning toothed belts
=> Page 26
12 20 Nm
13 Crankshaft toothed belt sprocket
◆ Note position when installing toothed belt
=> Page 26
14 Belt pulley
◆ When installing note fixing arrangement
15 20 Nm

1.1 - Dismantling and assembling engine 19

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

16 Ribbed belt
◆ Mark direction of rotation before removing
◆ Removing and installing
=> Page 25
17 Hexagon bolt: 90 Nm + 1/3 turn
(120 °) further
Multi-point screw: 90 Nm + 1/4 turn (90 °) further
◆ Renew
◆ Oil threads
◆ The turning further can be done in several stages
◆ The turning further angle can be checked with a commercial protractor e.g. Hazet 6690
18 Toothed belt guard - lower part

20 13 - Crankshaft group
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

Part II

1 10 Nm
◆ Renew
2 Sealing washer
◆ Renew
3 Cylinder head cover
4 Cap
◆ Renew seal if damaged
5 Cylinder head cover gasket
◆ Renew if damaged
◆ Before fitting gasket coat transition between bearing cap/cylinder head with D 454 300 A3
6 Cylinder head bolt
◆ Renew
◆ Note installation instructions and sequence when loosening and tightening
=> Page 51

1.1 - Dismantling and assembling engine 21

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

7 Cylinder head
◆ Removing and installing
=> Page 51
◆ If replaced renew the complete
coolant
8 Cylinder head gasket
◆ Renew
◆ Metal gasket
◆ If replaced renew the complete
coolant

22 13 - Crankshaft group
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

Part III

Note:

Servicing the clutch:

=> 5-Speed manual gearbox 020; Repair group 30; Servicing clutch Servicing clutch

1 Cylinder block
◆ Dismantling and assembling cylinder block, crankshaft and flywheel
=> Page 30
◆ Dismantling and assembling pistons and conrods
=> Page 38
2 45 Nm
◆ Tightening sequence:
Upper right bolt first, then lower right bolt, and bolts on left last (as seen from direction of travel)

1.1 - Dismantling and assembling engine 23

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

3 Oil filter
◆ Loosen with strap wrench
◆ Tighten by hand
◆ Note instructions on filter when installing
4 20 Nm + 1/4 turn (90 °) further
◆ Renew
5 Gasket
◆ Not on engines with liquid gasket
◆ Metal gasket
◆ Renew
◆ Before fitting gasket coat sump flange/cylinder block flange with "D2"
6 15 Nm
◆ Loosen and tighten the flywheel end bolts only with socket insert 3249
7 Sump
◆ Aluminium sump

24 13 - Crankshaft group
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

8 Sealing ring
◆ Renew
9 Oil drain plug, 20 Nm
10 Bracket
◆ For vane pump and alternator
11 45 Nm
12 Washer
13 Tensioning roller
14 Tensioning element

1.2 - Removing and installing ribbed belt

Note:

Before removing the ribbed belt mark the direction of rotation. When installing the belt ensure it is correctly
seated in the pulley.

1.1 - Dismantling and assembling engine 25

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
Vehicles without power assisted steering

Special tools, testers and auxiliary items

◆ Tensioning lever 3297

Work sequence

- Loosen alternator securing bolts.

- -> Install tensioning lever 3297, secure with spring clip and swivel alternator down (to turn 3297 use e.g.
torque wrench).
- Remove/fit ribbed belt
- After fitting ribbed belt with alternator loose, rotate engine several times (approx. 10 revolutions of engine
by operating starter briefly.
- First tighten lower and then upper alternator bolts to
25 Nm.

Vehicles with power assisted steering

- Remove ribbed belt cover.

- -> Using a spanner on the securing bolt swivel tensioning roller in direction of arrow.
- Remove/fit ribbed belt.

1.3 - Removing and installing toothed belt

(Adjusting valve timing)

Special tools, testers and auxiliary items

◆ V.A.G 1331 Torque wrench (5...50 Nm)

26 13 - Crankshaft group
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
Removing

- Remove ribbed belt => Page 25 .

- Remove vibration damper and toothed belt guard upper and lower parts.
- Mark D.O.R. of toothed belt.
- Loosen coolant pump/tensioning roller and remove toothed belt.

Installing

Prerequisites

• Engine cold
• Pistons not positioned at TDC

Work sequence

Engine codes ABD, ABU

Engine code AEA, AEE, AEX, APQ => Page 28

- Place toothed belt on crankshaft sprocket. For used belts note direction of rotation.
- Install toothed belt guard lower part.

Note:

If a piston is at TDC the valves could strike the piston when turning the camshaft.

- -> Set camshaft sprocket to mark -arrow A-.

- Install belt pulley (note fixing arrangement).
- Set crankshaft to TDC No. 1 cylinder. Notch on the belt pulley must align with "0" mark on lower part of
toothed belt guard -arrow B-.
- Fit toothed belt on camshaft and coolant pump sprockets.

- -> Tension toothed belt by turning coolant pump.

1.3 - Removing and installing toothed belt 27

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

- -> Check toothed belt tension. At the point indicated it must just be possible to turn the toothed belt through
90 ° with the thumb and forefinger.
- Tighten coolant pump securing bolts to
10 Nm.
- Rotate crankshaft two full turns and check adjustment.
- Install toothed belt guard upper part.
- Install ribbed belt => Page 25 .
- Install ribbed belt cover.
- Check ignition timing, adjust if necessary:

=> Repair group 28; Injection and ignition system; Checking and adjusting ignition timing. Injection and ignition
system Checking and adjusting ignition timing.
Engine code AEA, AEE, AEX, APQ

Note:
If a piston is at TDC the valves could strike the piston when turning the camshaft.
- -> Set camshaft sprocket to mark -arrow A-.
- Set crankshaft to TDC No. 1 cylinder. The ground or offset tooth on the crankshaft toothed belt pulley must
align with the marking on the seal flange -arrow B-.
- Fit toothed belt. For used belts note direction of rotation.

28 13 - Crankshaft group
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
- -> Install tensioning roller and tighten securing nut hand-tight. The slot in the base plate -1- must engage
over securing bolt -2- .
- Tension toothed belt by turning the tensioning roller in direction of arrow until the indicator -3- aligns with
the groove in the base plate -arrow-.
- Tighten clamping nut on tensioning roller.
Tightening torque: 20 Nm
- Turn crankshaft two complete turns in engine direction of rotation, set again to to TDC and check adjustment.
- Install toothed belt guard upper and lower parts.
- Install belt pulley (note fixing arrangement).
- Install ribbed belt => Page 25 .
- Install ribbed belt cover.
- Check ignition timing, adjust if necessary:

=> Repair group 28; Injection and ignition system; Checking and adjusting ignition timing. Injection and ignition
system Checking and adjusting ignition timing.

1.4 - Checking semi-automatic toothed belt tensioning roller

Test conditions

• Toothed belt installed and tensioned

Test sequence

- Turn crankshaft two complete turns in engine direction of rotation and set to TDC.
- -> Tension toothed belt with firm thumb pressure.
The marks on the tensioning roller -arrow- must move apart.
- Release thumb pressure on toothed belt. The tensioning roller must move back to its initial position.

1.3 - Removing and installing toothed belt 29

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

2 - Dismantling and assembling cylinder block, crankshaft and flywheel

2.1 - Dismantling and assembling cylinder block, crankshaft and flywheel

Volkswagen Technical Site: [Link] [Link]

1 Bearing shells 1, 2, 4 and 5

◆ Do not interchange used bearing shells (mark)
2 65 Nm
◆ Different types
=> Fig. 1
◆ All bolts installed must always be of the same type
3 Bearing cap
◆ Bearing cap 1: Pulley end
◆ Bearing cap 3 with recesses for thrust washers
◆ Bearing shell retaining lugs (cylinder block/bearing cap) must be on the same side

30 13 - Crankshaft group
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

4 Bearing shell 3
5 Thrust washer
◆ For bearing cap 3
◆ Note fixing arrangement
6 Crankshaft
◆ Axial clearance new: 0.07...0.18 mm
Wear limit: 0.20 mm
◆ Check radial clearance with Plastigage
New: 0.03...0.08 mm
Wear limit: 0.17 mm
◆ Do not rotate the crankshaft when checking the radial clearance
◆ Crankshaft dimensions
=> Page 37
7 10 Nm
◆ 8 Nm for vehicles with Duo-centric oil pump
8 60 Nm + 1/4 turn (90 °) further
◆ Renew

2.1 - Dismantling and assembling cylinder block, crankshaft and flywheel 31

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

9 Flywheel/pressure plate
◆ To remove and install flywheel counter-hold with 10-201
◆ To remove and install pressure plate counter-hold with VW 558
10 Sealing flange with oil seal
◆ Only renew complete
◆ For spare part sealing flange, do not additionally oil sealing lip
◆ The sealing flange replacement part does not have an integral gasket and must be installed with a normal
gasket.
◆ Fit spare part sealing flange with supplied sleeve
11 Gasket
◆ Renew
12 Thrust washer
◆ For cylinder block, bearing 3

32 13 - Crankshaft group
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

13 Sealing flange/Duo-centric oil pump

◆ Removing and installing Duo-centric oil pump => Page 85
14 Oil seal
◆ Renewing => Page 34
15 Sealing bush
◆ Only oil pump driven by chain
◆ Renew if damaged
◆ Insert in sealing flange first
◆ Oil to install
16 Chain sprocket
◆ For oil pump drive
17 Oil pump
◆ Removing and installing
=> Page 73
◆ Removing and installing for vehicles with Duo-centric oil pump => Page 85

2.1 - Dismantling and assembling cylinder block, crankshaft and flywheel 33

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

-> Fig. 1 Identifying characteristics for crankshaft bearing cap securing bolts

- Version A, full-length thread

- Version B, thread not full-length

Note:
All bolts installed in an engine must always be of the same type.

2.2 - Renewing crankshaft oil seal - pulley end -

Vehicles with oil pump driven by chain and vehicles with Duo-centric oil pump => Page 36

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

◆ Engine support bracket 10-222A with legs 10-222A/1

◆ 3415 or 3099 Counter-hold tool
◆ 2085 Oil seal extractor
◆ 3083 Oil seal fitting tool
◆ V.A.G 1331 (5...50 Nm) Torque wrench
◆ V.A.G 1332 (40...200 Nm) Torque wrench

Removing

- Remove toothed belt => Page 26 .

- Then remove crankshaft toothed belt sprocket. To do this secure counter-hold tool 3415 or 3099 to toothed
belt sprocket.
- To guide oil seal extractor screw crankshaft sprocket securing bolt into crankshaft onto stop.
- Unscrew inner part of the oil seal extractor 2085 two turns (approx. 3 mm) out of the outer part and lock with
knurled screw.

- -> Lubricate threaded head of oil seal extractor, place it in position and exerting firm pressure screw it as
far as possible into oil seal.

34 13 - Crankshaft group
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
- Loosen knurled screw and turn inner part against crankshaft until the oil seal is pulled out.

Installing

- Lightly oil sealing lip of oil seal.

- Fit guide sleeve from 3083 onto crankshaft journal.
- Slide oil seal over guide sleeve.

- -> Press oil seal in flush with press sleeve from 3083.
- Install toothed belt => Page 26

2.2 - Renewing crankshaft oil seal - pulley end - 35

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

Vehicles with Duo-centric oil pump

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

◆ 3240 Oil seal extractor

◆ T10022 Sleeve
◆ T10022/1 Press piece
◆ T10022/2 Spindle
◆ 3099 Counter-hold tool

Removing

- First remove toothed belt

=> Page 26 .
- Then remove crankshaft toothed belt sprocket. To do this secure counter-hold tool to toothed belt sprocket.
- To guide oil seal extractor screw crankshaft sprocket securing bolt into crankshaft onto stop.
- Unscrew inner part of oil seal extractor 3240 two turns (approx. 3 mm) out of the outer part and lock with
knurled screw.

36 13 - Crankshaft group
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

- -> Lubricate threaded head of oil seal extractor, place it in position and exerting firm pressure screw it as
far as possible into oil seal.
- Loosen knurled screw and turn inner part against crankshaft until the oil seal is pulled out.

Installing
- Lightly oil sealing lip of oil seal.
- -> Fit sleeve T10022 onto crankshaft journal and turn spindle T10022/2 in onto stop.
- Slide oil seal over sleeve T10022.

- -> Press in oil seal onto stop with press piece T10022/1.
- Install toothed belt => Page 26
- Then install crankshaft toothed belt sprocket. To do this secure counter-hold tool 3099 to toothed belt
sprocket.

2.3 - Crankshaft dimensions

Honing dimension in mm Crankshaft main bearing journal ø Conrod journal ø

Engine code letters
ABD ABU, AEA, AEE, AEX, APQ
Basic dimension 0.022 -0.020 -0.022
54.00 42.00 47.80
-0.037 -0.035 -0.037

2.2 - Renewing crankshaft oil seal - pulley end - 37

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

Honing dimension in mm Crankshaft main bearing journal ø Conrod journal ø

Engine code letters
ABD ABU, AEA, AEE, AEX, APQ
1st undersize -0.022. -0.020 -0.022
53.75 41.75 47.55
-0.037 -0.035 -0.037
2nd undersize -0.022 -0.020 -0.022
53.50 41.50 47.30
-0.037 -0.035 -0.037
3rd undersize -0.022 -0.020 -0.022
53.25 41.25 47.05
-0.037 -0.035 -0.037

3 - Dismantling and assembling pistons and conrods

3.1 - Dismantling and assembling pistons and conrods

1 Piston ring
◆ Offset gaps by 120 °
◆ Remove and install with piston ring pliers
◆ "TOP" faces towards piston crown
◆ Checking ring gap=> Fig. 1

38 13 - Crankshaft group
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
◆ Checking ring to groove clearance
=> Fig. 2
2 Piston
◆ Checking => Fig. 3
◆ Mark installation position and cylinder number
◆ Arrow on piston crown points to pulley end
◆ Install using piston ring clamp
◆ Characteristics=> Fig. 4
3 Piston pin
◆ If difficult to remove, heat piston to 60 °C
◆ Remove and install with 10-14

4 Circlip
5 Conrod
◆ Only renew as a set
◆ Mark cylinder number -A-
◆ Installation position:
Marking -B- faces towards pulley end
◆ Guided axially via piston
6 Bearing shell
◆ Insert bearing shells centrally
◆ Do not interchange used bearing shells
◆ Measure pretension
=> Fig. 6
◆ Check radial clearance with Plastigage:

3.1 - Dismantling and assembling pistons and conrods 39

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
New: 0.020...0.061 mm
Wear limit: 0.091 mm
Do not rotate crankshaft when checking radial clearance

7 Cylinder block
◆ Checking cylinder bores
=>Fig. 5
◆ Piston and cylinder dimensions
=>Page 44
8 Conrod bearing cap
◆ Note installation position
◆ The caps only fit in one position and only on the appropriate con-rod, this is due to the breaking procedure
(cracking) separating the cap from the con-rod
9 Conrod bolt
M8: 30 Nm + 1/4 turn (90 °) further
M7: 20 Nm + 1/4 turn (90 °) further
◆ Renew
◆ Oil threads and contact surface
◆ To measure radial clearance tighten to 20 or 30 Nm but not further

40 13 - Crankshaft group
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

-> Fig. 1 Checking piston ring gap

- Push ring squarely from above down to approx. 15 mm from bottom end of cylinder.

Piston ring New Wear limit

Dimensions in mm
1. Compression ring 0.20...0.50 1.0
2. Compression ring 0.40...0.60 1.0
ABD 0.40...0.70
ABU, AEA, AEE, AEX, APQ
Oil scraper ring 0.25...0.50 1.0
1 part 0.40...1.40 ---1)
3 part

1) No wear limit details

3.1 - Dismantling and assembling pistons and conrods 41

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
-> Fig. 2 Checking ring to groove clearance

Clean groove before check.

Piston ring New Wear limit

Dimensions in mm
1. Compression ring 0.04...0.08 0.15
2. Compression ring 0.04...0.08 0.15
Oil scraper ring 0.04...0.08 0.15
1 part
3 part Not measurable

-> Fig. 3 Checking piston

Special tools, testers and auxiliary items

◆ Micrometer 75...100 mm

- Approx. 10 mm from lower edge and offset 90 ° to piston pin axis. Deviations from nominal dimensions
max. 0.04 mm

-> Fig. 4 Piston characteristics

Engine code ABD1) ABU AEAAEE AEX

APQ
Dimension "a" mm 25.8 23.5 22.4 19.8
▸07.92 26.0
08.92▸
Dimension "b" mm 15.2 8.7 7.8 5.9
Recess ø "c" max. mm 58 64 69 60

42 13 - Crankshaft group
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

Engine code ABD1) ABU AEAAEE AEX

APQ
Piston pin ø "d" mm 17 17 17 17

1) Ensure correct type; differing crankshaft throws (see parts list)!

-> Fig. 5 Checking cylinder bores

Special tools, testers and auxiliary items

◆ Internal dial gauge 50...100 mm

- Take measurements at 3 positions in both lateral -A- and longitudinal -B- directions, as illustrated. Deviation
from nominal dimension
max. 0.08 mm

Note:

Measuring the cylinder bores must not be done when the cylinder block is mounted on a repair stand with
adapter bracket VW 540, as incorrect measurements would then be possible.

3.1 - Dismantling and assembling pistons and conrods 43

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
-> Fig. 6 Measuring bearing shell pretension

Special tools, testers and auxiliary items

◆ Vernier caliper

The bearing shell pretension is calculated as follows:

Bearing shell dimension -a-

- Conrod diameter -b-
= Pretension

Minimum dimension:

◆ Engine code ABD: 0.5 mm

◆ Engine code ABU, AEA, AEE, AEX, APQ:
1.5 mm

If the pretension is not achieved:

- Renew bearing shells.

3.2 - Piston and cylinder dimensions

Engine code letters ABD

Honing Piston-ø Cylinder bore-ø

dimension
Basic dimen. mm 74.985 75.01
1st oversize mm 75.235 75.26
2nd oversize mm 75.485 75.51
2nd oversize mm 75.735 75.76

Engine code letters ABU, AEA, AEE, AEX, APQ

Honing Piston-ø Cylinder bore-ø

dimension
Basic dimen. mm 76.470 76.51
1st oversize mm 76.720 76.76
2nd oversize mm 76.970 77.01
2nd oversize mm 77.220 77.26

1) Engine code ABU: Pistons are coated at the area of the measuring point (coating thickness approx.
0.015 mm). Dimensions given are for an uncoated piston.

44 13 - Crankshaft group
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

15 - Cylinder head, Valve gear

1 - Removing and installing cylinder head

1.1 - Removing and installing cylinder head

Checking compressions=> Page 52

Notes:

◆ When installing an exchange cylinder head with fitted camshaft, the contact surfaces between the bucket
tappets and the cam must be oiled before installing the cylinder head cover.
◆ The plastic packing pieces for protecting the open valves must not be removed until immediately before
fitting cylinder head.
◆ If the cylinder head is replaced, all the coolant in the system must also be renewed.

1.1 - Removing and installing cylinder head 45

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
Engine codes ABD, ABU
Engine code AEA, AEE, AEX, APQ
=> Page 48
1 Toothed belt guard - upper part
2 Toothed belt
◆ Check for wear
◆ Do not kink
◆ Removing and installing
=> Page 26
3 80 Nm
4 Camshaft sprocket
◆ Note position when installing the toothed belt
=> Page 26
5 10 Nm
◆ Install with D6
6 Rear toothed belt guard
7 10 Nm

8 Sealing washer
◆ Renew

46 15 - Cylinder head, Valve gear

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

9 Cap
◆ Renew seal if damaged
10 Cylinder head cover
11 Oil deflector
12 Cylinder head cover gasket
◆ Renew if damaged
◆ Before fitting gasket coat transition between bearing cap/cylinder head with D 454 300 A3
13 Cylinder head bolt
◆ Sequence when loosening and tightening => Installing cylinder head Page 51

14 Cylinder head
◆ Check for distortion => Fig. 1
◆ Installing => Page 51
◆ After replacing renew the complete coolant
15 Cylinder head gasket
◆ Renew
◆ After replacing renew the complete coolant
16 Bolt M6: 10 Nm
Bolt M8: 20 Nm

1.1 - Removing and installing cylinder head 47

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
◆ Install with D6

Engine code AEA, AEE, AEX, APQ

1 Toothed belt guard - upper part

2 Toothed belt
◆ Check for wear
◆ Do not kink
◆ Removing and installing
=> Page 26
3 20 Nm + 1/4 turn (90 °) further
◆ Renew
4 Camshaft sprocket
◆ Note position when installing the toothed belt
=> Page 26
5 10 Nm
◆ Install with D6
6 Rear toothed belt guard
7 10 Nm

48 15 - Cylinder head, Valve gear

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
◆ Renew cylinder head cover bolts

8 Sealing washer
◆ Renew
9 Cap
◆ Renew seal if damaged
10 Cylinder head cover
11 Cylinder head cover gasket
◆ Renew if damaged
◆ Before fitting gasket coat transition between bearing cap/cylinder head with D 454 300 A3
12 Cylinder head bolt
◆ Renew
◆ Knurled bolt head
◆ Sequence when loosening and tightening => Installing cylinder head Page 51
13 Cylinder head
◆ Check for distortion => Fig. 1
◆ Installing => Page 51
◆ After replacing renew the complete coolant

1.1 - Removing and installing cylinder head 49

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

14 Cylinder head gasket

◆ Renew
◆ Metal gasket
◆ After replacing renew the complete coolant
15 Tensioner
◆ Tensioning toothed belts
=> Page 26
16 20 Nm
17 Belt pulley
◆ When installing note fixing arrangement
◆ Note position when installing toothed belt
=> Page 26
18 20 Nm
19 Ribbed belt
◆ Mark direction of rotation before removing
◆ Removing and installing
=> Page 25
20 Toothed belt guard - lower part

50 15 - Cylinder head, Valve gear

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

-> Fig. 1 Checking cylinder head for distortion

Max. permissible distortion: 0.05 mm

1.2 - Removing and installing cylinder head

Special tools, testers and auxiliary items

◆ Guide pin 3070

◆ V.A.G 1332 Torque wrench (40...200 Nm)

Prerequisites

• Engine cold
• Pistons not positioned at TDC

Work sequence

Notes:
◆ Only remove the new cylinder head gasket from its packing immediately before installing.
◆ Handle the new gasket with extreme care. Damaging will lead to leaks.

Removing

- -> Maintain sequence when loosening and tightening cylinder head bolts.

Installing

- Place a clean cloth in cylinders so that no dirt or emery cloth particles can get in between cylinder wall and
piston.
- Also prevent dirt and emery cloth particles from getting into the coolant.

1.1 - Removing and installing cylinder head 51

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
- Carefully clean cylinder head and cylinder block sealing surfaces. Thereby ensuring that no scoring or
scratches are formed (when using abrasive paper the grade must not be less than 100).

- Carefully remove metal particles, emery remains and cloths.

- -> To centralize screw guide pins from 3070 into holes for rear, outer cylinder head bolts -arrows-.
- Fit cylinder head gasket. Lettering (Part No.) must be readable.
- Fit cylinder head, screw in 8 remaining cylinder head bolts and tighten by hand.
- Remove guide pins with removal tool from 3070 and install cylinder head bolts.

- -> Tighten cylinder head in four stages in sequence shown as follows:

- Pretighten all bolts to 40 Nm.
- Then tighten all bolts to 60 Nm.
- Then tighten all bolts a 1/4 turn (90 °) further using a rigid wrench.
- Then tighten all bolts again a 1/4 turn (90 °) further.

The rest of the assembly is basically a reverse of the dismantling sequence.

Installing toothed belt and adjusting timing => Page 26 .
Filling with new coolant => Page 106 .

1.3 - Checking compressions

Special tools, testers and auxiliary items

◆ Compression tester V.A.G 1381 or V.A.G 1763

Test conditions
• Engine oil temperature min. 30 °C.

Work sequence
- Pull plug off Hall sender (distributor).
- Fully open throttle valve.

52 15 - Cylinder head, Valve gear

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
- Check compressions with compression tester V.A.G 1381 or V.A.G 1763.

Note:

Using the compression tester => Operating instructions.

- Operate starter until tester shows no further pressure increase.

Compression pressure:

New: 10...15 bar

Wear limit: 7 bar

Permissible difference between all cylinders: 3 bar

2 - Servicing valve gear

2.1 - Servicing valve gear

1.3 - Checking compressions 53

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
Note:
Cylinder heads which have cracks between the valve seats or between valve seat inserts and the spark plug
thread can be used further without reducing service life, provided the cracks do not exceed a maximum of 0.5
mm in width, or when no more than the first turns of the spark plug thread are cracked.
1 10 Nm
2 6 Nm + 1/4 turn (90 °) further
3 Bearing cap
◆ Installation sequence
=> Page 64 , removing and installing camshaft
◆ Coat bearing cap 1 and 5 seating areas lightly with sealant AMV 174 004 01

4 Camshaft
◆ Checking axial clearance => Fig. 2
◆ Removing and installing
=> Page 64
◆ Checking radial clearance with plastigage
Wear limit: 0.1 mm
◆ Run-out: max. 0.01 mm
◆ Identification and valve timing
▸09.94 => Page 58 , Fig. 4
5 Bucket tappet
◆ Do not interchange
◆ With hydraulic valve clearance compensation

54 15 - Cylinder head, Valve gear

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
◆ Checking => Page 63
◆ Store with cam lobe contact surface downwards
◆ Before installing check camshaft axial clearance => Fig. 2
◆ Oil contact surface
6 Cotters

7 Upper valve spring plate

8 Valve spring(s)
◆ Engine code letters ABD, AEA, AEE, AEX, APQ: single spring
◆ Removing and installing:
Cylinder head
removed: with 2037
installed: => Page 67 , renewing valve stem seals
9 Service part - valve guide
◆ With collar
10 Valve stem seal
◆ Renewing=> Page 67
11 Valve guide
◆ Checking => Page 66
◆ Renewing => Page 66
12 Oil seal
◆ Lightly oil sealing lip of oil seal

2.1 - Servicing valve gear 55

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
◆ Renewing=> Page 62

13 Cylinder head
◆ Reworking valve seats
=> Page 60
◆ Reworking sealing surface
=> Fig. 1
14 Valves
◆ Do not rework only grinding-in is permitted
◆ Valve dimensions => Fig. 5
15 20 Nm
16 Bracket
◆ For H.T. cable guide
17 Lifting eye

56 15 - Cylinder head, Valve gear

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

-> Fig. 1 Reworking cylinder head sealing surface

Cylinder head reworking dimension:

a = At least 135.6 mm
Note:
When the sealing surface has been reworked, the valves must be set deeper by the same amount (rework
valve seat inserts), otherwise valves will contact pistons. Ensure when doing this that the permissible minimum
dimension is maintained => Page 60 .

-> Fig. 2 Checking camshaft axial clearance

Special tools, testers and auxiliary items

◆ Universal dial gauge bracket VW 387
◆ Dial gauge

Check with bucket tappets removed and No. 3 bearing cap fitted.
Wear limit: max. 0.15 mm

2.1 - Servicing valve gear 57

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
-> Fig.3 Camshaft identification, valve timing ▸09.94

Identification

Engine code letters ABD ABU

Between inlet and exhaust cams No. 1 cyl‐ 030 032
inder or No. 3 cylinder AH

Valve timing at 1 mm valve lift

Engine code letters ABD ABU

Inlet opens ATDC 5° 6°
Inlet closes ABDC 29 ° 37 °
Exhaust opens BBDC 33 ° 39 °
Exhaust closes BTDC 9° 4°

-> Fig. 4 Camshaft identification, valve timing 10.94 ▸

Identification

Engine code ABD AEA AEE AEE AEX

up to from APQ
12.95 01.96
Between inlet and exhaust cams No.1 cylinder -arrow- 032 Q 032 N 032 P 032 S 030AM
or
032 P
Identification 1 and 5 1 1 1 1 and 2
or
1 and 3

Valve timing at 1 mm valve lift

Engine code ABD AEA AEE AEE AEX

up to from APQ
12.95 01.96
Inlet opens ATDC 3° 8° 8° 7° 10 °
Inlet closes after BDC 27 ° 32 ° 32 ° 32 ° 27 °
Exhaust opens BBDC 31 ° 27 ° 27 ° 32 ° 27 °

Volkswagen Technical Site: [Link] [Link]

58 15 - Cylinder head, Valve gear

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

Engine code ABD AEA AEE AEE AEX

up to from APQ
12.95 01.96
Exhaust closes BTDC 7° 3° 3° 9° 10 °

-> Fig. 5 Valve dimensions

Note:

Valves must not be reworked. Only lapping-in is permitted.

Engine code ABD

Dimension Inlet valve Exhaust valve

øa mm 36.0 29.0
øb mm ▸ 07.92: 7.965 ▸ 07.92: 7.945 08.92 ▸:
08.92 ▸: 6.97 6.95
c mm 99.3 99.1
α <° 45 45

Engine code ABU

Dimension Inlet valve Exhaust valve

øa mm 34.6 29.0
øb mm 6.963 6.943
c mm 94.8 95.0
α <° 45 45

Engine code AEA, AEE, AEX, APQ

Dimension Inlet valve Exhaust valve

øa mm 35.6 29.0
øb mm 6.963 6.943
c mm 94.8 95.0
α <° 45 45

2.1 - Servicing valve gear 59

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

2.2 - Reworking valve seats

Special tools, testers and auxiliary items

◆ Depth gauge
◆ Valve seat refacing tool

Notes:
◆ When repairing engines with leaking valves, it is not sufficient to replace or renew valve seats and valves.
It is also necessary to check the valve guides for wear. This particularly important on high mileage engines
=> Page 66 .
◆ The valve seats should only be reworked just enough to produce a perfect seating pattern. The maximum
permissible reworking dimension must be calculated before work is carried out. If the reworking dimension
is exceeded, the function of the hydraulic tappets can no longer be guaranteed and therefore the cylinder
head should be renewed.

The max. permissible reworking dimension is calculated as follows:

- Insert valve and press firmly against seat.

Note:
If the valve is to be renewed as part of a repair, use a new valve for the calculation.

- -> Measure distance -a- between end of valve stem and upper edge of cylinder head.
- Calculate max. permissible reworking dimension from measured distance and minimum dimension.

Minimum dimension:
Inlet valve 35.8 mm
Exhaust valve 36.1 mm
Measured distance minus minimum dimension
= max. permissible reworking dimension.
Example:
- Measured distance 36.5 mm
Minimum dimension 35.8 mm
= max. perm. rework dimension* 0.7 mm
*) The max. permissible reworking dimension is shown on illustrations for reworking valve seats as
dimension "b".

60 15 - Cylinder head, Valve gear

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
Engine code ABD

-> Reworking inlet valve seat

a = ø34.8 mm
b = Max. permissible reworking dimension*
c = Max. 2.0 mm
Z = Cylinder head lower edge
α = 45 ° valve seat angle
β = 30 °upper correction angle
γ = 60 °lower correction angle

-> Reworking exhaust valve seat

a = ø27.8 mm
b = Max. permissible reworking dimension*
c = Max. 2.0 mm
Z = Cylinder head lower edge
α = 45 °valve seat angle
β = 30 °upper correction angle

Engine code letters ABU, AEA, AEE, AEX, APQ

-> Reworking inlet valve seat

a ABU = 33.4 mm ø
b AEA, AEE, AEX = 34.4 mm ø
c = Max. permissible reworking dimension*
Z = Max. 2.0 mm
α = Cylinder head lower edge
β = 45 °valve seat angle
γ = 30 °upper correction angle
= 60 °lower correction angle

2.2 - Reworking valve seats 61

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
Note:
Valve seat rings having restrictor may only be reworked so far that the restrictor is not damaged.

-> Reworking exhaust valve seat

a = ø27.8 mm
b = Max. permissible reworking dimension*
c = max. 2.0 mm
Z = Cylinder head lower edge
α = 45 °valve seat angle
β = 30 °upper correction angle
γ = 60 °lower correction angle

2.3 - Removing and installing camshaft oil seal

Special tools, testers and auxiliary items

◆ Counter-hold tool 3036
◆ Oil seal extractor 2085
◆ Guide sleeve from puller 3083
◆ Oil seal fitting tool 10-203
◆ V.A.G 1332 Torque wrench (40...200 Nm)

Removing
Engine codes ABD, ABU
- Remove toothed belt guard - upper part.
- Loosen camshaft sprocket (counter-hold with 3036).
- Loosen coolant pump and remove toothed belt.
- Pull off camshaft sprocket.
- Unbolt rear toothed belt guard from cylinder head.
- Remove upper coolant pump bolt and pull rear toothed belt guard forwards.
- Unscrew inner part of oil seal extractor 2085 two turns (approx. 3 mm) out of the outer part and lock in
position with knurled screw.

62 15 - Cylinder head, Valve gear

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
- -> Lubricate threaded head of oil seal extractor, place it in position and exerting firm pressure screw it as
far as possible into oil seal.
- Loosen knurled screw and turn inner part of extractor against camshaft until oil seal has been extracted.

Engine code AEA, AEE, AEX, APQ

- Remove ribbed belt => Page 25 .
- Remove vibration damper and toothed belt guard upper and lower parts.
- Loosen camshaft sprocket (counter-hold with 3036).
- Release tensioner and take off toothed belt.
- Pull off camshaft sprocket.
- Unbolt rear toothed belt guard from cylinder head.
- Remove upper coolant pump bolt and pull rear toothed belt guard forwards.
- Unscrew inner part of oil seal extractor 2085 two turns (approx. 3 mm) out of the outer part and lock in
position with knurled screw.

- -> Lubricate threaded head of oil seal extractor, place it in position and exerting firm pressure screw it as
far as possible into oil seal.
- Loosen knurled screw and turn inner part of extractor against camshaft until oil seal has been extracted.

Installing
- Lightly oil sealing lip of oil seal.
- Start oil seal with guide sleeve from 3083.

- Remove guide sleeve.

- -> Press oil seal in onto stop with press sleeve from 10-203 and bolt 10-203/1. Place two washers between
press sleeve and hexagon head bolt.
- Install toothed belt => Page 26

2.4 - Checking hydraulic bucket tappets

Special tools, testers and auxiliary items

◆ Feeler gauge

2.3 - Removing and installing camshaft oil seal 63

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
◆ Wood or plastic wedge

Notes:

◆ Renew defective tappet complete (cannot be adjusted or repaired).

◆ Irregular valve noises when starting engine are normal.

Test sequence

- Start engine and run until the radiator fan has switched on once.
- Increase engine speed to about 2500 rpm for approx. 2 minutes.

If the hydraulic tappets are still noisy, locate defective tappets as follows:

- Remove cylinder head cover.

- Rotate crankshaft clockwise, until cam of the tappet to be checked is pointing upwards.
- Determine play between cam and bucket tappet.

- -> Push bucket tappet down lightly with a wooden or plastic wedge. If when the bucket tappet is pushed
down a 0.2 mm thick feeler gauge can be pushed between the camshaft and bucket tappet, the bucket
tappet is to be replaced.

Note:

After installing new tappets the engine must not be started for approx. 30 minutes. Hydraulic compensation
elements must settle (otherwise valves will strike pistons).

2.5 - Removing and installing camshaft

Special tools, testers and auxiliary items

◆ Counter-hold tool 3036

◆ V.A.G 1331 Torque wrench (5...50 Nm)
◆ V.A.G 1332 Torque wrench (40...200 Nm)
◆ Sealing compound AMV 174 004 01

Removing

Engine codes ABD, ABU

- Remove toothed belt guard upper part and cylinder head cover.
- Loosen camshaft sprocket (counter-hold with 3036).
- Loosen coolant pump and remove toothed belt.
- Pull off camshaft sprocket.
- Unbolt rear toothed belt guard from cylinder head.
- Remove distributor.

64 15 - Cylinder head, Valve gear

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

- -> First remove bearing caps 5, 1 and 3.

- Slacken off bearing caps 2 and 4 alternately and diagonally.

Engine code AEA, AEE, AEX, APQ

- Remove ribbed belt => Page 25 .

- Remove vibration damper and toothed belt guard upper and lower parts.
- Loosen camshaft sprocket (counter-hold with 3036).
- Release tensioner and take off toothed belt.
- Pull off camshaft sprocket.
- Unbolt rear toothed belt guard from cylinder head.
- Remove cylinder head cover.
- Remove distributor.

- -> First remove bearing caps 5, 1 and 3.

- Slacken off bearing caps 2 and 4 alternately and diagonally.

Installing

• The pistons must not be positioned at TDC.

Note:

Note fitting position of bearing cap: Wider cast lug -arrow A- to intake side and the bearing cap number -arrow
B- readable from the exhaust side.

- Oil camshaft running surfaces.

- Tighten bearing caps 2 and 4 alternately and
diagonally to
6 Nm.
- Coat bearing cap 1 and 5 contact surfaces lightly with sealant AMV 174 004 01.
- Install bearing caps 3, 1 and 5 and tighten to
6 Nm.
When doing this insert distributor for centralizing bearing cap 5.
- Turn all nuts by 1/4 turn (90 °) further.
- Insert bolts for bearing cap 5 and tighten to

2.5 - Removing and installing camshaft 65

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
10 Nm.

The rest of the assembly is basically a reverse of the dismantling sequence.

Installing toothed belt and adjusting timing => Page 26 .
Note:
When new tappets have been installed the engine must not be started for about 30 minutes. Hydraulic com‐
pensation elements must settle (otherwise valves will strike pistons).

2.6 - Checking valve guides

Special tools, testers and auxiliary items

◆ VW 387 Universal dial gauge bracket
◆ Dial gauge

Test sequence

- -> Insert new valve into guide until end of valve stem is flush with end of guide. Due to the slight difference
in stem dimensions, ensure that only an inlet valve is used in the inlet guide and an exhaust valve in the
exhaust guide.
- Determine rock.
Wear limit:
Inlet valve guide = 1.0 mm
Exhaust valve guide = 1.3 mm

2.7 - Renewing valve guides

Special tools, testers and auxiliary items

Valve stem ø 8 mm:
◆ Drift 3121
◆ Hand reamer 3120 and cutting fluid

Valve stem ø 7 mm:

◆ Drift 3121
◆ Hand reamer 3120 and cutting fluid

Removing
- First check whether the valve seat insert rings and if necessary the cylinder head sealing surface can be
reworked. If this is not the case then the valve guide should not be replaced.

66 15 - Cylinder head, Valve gear

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
- Press worn valve guides out with
Valve stem ø 8 mm: 10-206
Valve stem ø 7 mm: 3121
from the camshaft side (valve guides with collar -service version- from the combustion chamber side).

Installing

- Coat new guides with oil and press in with 10-206/3121 from the camshaft side with head cold until shoulder
makes contact.

Note:

When the shoulder on guide makes contact, the pressure must not exceed 10 kN (approx. 1.0 t) otherwise
shoulder may break off.

- Ream guides out with hand reamer

Valve stem ø 8 mm: 10-215
Valve stem ø 7 mm: 3120
using plenty of cutting fluid.
- Rework valve seats => Page 60 .

2.8 - Renewing valve stem seals

(with cylinder head fitted)

Special tools, testers and auxiliary items

◆ Puller 3047A
◆ Assembly tool 2036
◆ Pressure hose VW 653/3
◆ Lever VW 541/1A with press piece VW 541/5

Valve stem ø 8 mm:

◆ Fitting tool 3129

Valve stem ø 7 mm:

◆ Fitting tool 3129

Removing

- Remove camshaft => Page 64 .

- Remove bucket tappets (do not interchange) and store with the contact surface downwards.
- Remove spark plugs.
- Set piston of appropriate cylinder to "bottom dead centre".

2.7 - Renewing valve guides 67

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
- -> Fit assembly tool 2063 and adjust to height of studs.
- Screw compressed air hose VW 653/3 into spark plug thread and apply a continuous pressure of
min. 6 bar.
- Remove valve springs with lever VW 541/1A and press piece VW 541/5.

Note:

Tight cotters can be loosened by tapping lightly on the lever.

- Pull off valve stem seals with 3047A.

Installing

- -> To prevent damage to the new valve stem seals, place plastic sleeve -A- on valve shaft.
- Oil valve stem seal -B-, place it in tool
Valve shaft ø 8 mm: 10-204
Valve stem ø 7 mm: 3129
and push carefully onto the valve guide.

68 15 - Cylinder head, Valve gear

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

17 - Lubrication

1 - Removing and installing parts of the lubrication system

1.1 - Removing and installing parts of the lubrication system
Note:
The oil level must not be above the max. mark - danger of damaging catalyst!
Checking oil pressure => Page 88
Oil system capacity1):
◆ Without oil filter: 3.0 ltr.
◆ With oil filter 056 115 561G (approx. 120 mm long): 3.5 ltr.
◆ With oil filter 030 115 561E (approx. 80 mm long): 3.4 ltr.

1) Up-to-date figures:
=> Exhaust emissions test binder
Engine oil specifications:
Use engine oil to VW standard 500 00 or 501 01. Only in exceptional cases: Multi-grade oils corresponding to
API-SF or SG.

1.1 - Removing and installing parts of the lubrication system 69

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
Vehicles with oil pump driven by chain
Vehicles with Duo-centric oil pump => Page 78
1 Cap
◆ Renew seal if damaged
2 0.3 or 0.25 bar oil pressure switch (F22), 25 Nm
◆ 0.3 bar switch: brown
◆ 0.25 bar switch: blue
◆ Wiring: blue/black
◆ Checking => Page 88
◆ If sealing ring is leaking nip open and replace.
3 10 Nm
4 Guide tube
5 Guide
◆ Pull off to extract oil

6 Dipstick
◆ The oil level must not be above the max. mark!
◆ Area above shaded zone up to max. mark: Do not top up with engine oil!
◆ Oil level in shaded zone: Engine oil can be topped up
◆ Area min. mark up to shaded zone: Top-up with max. 0.5 ltr. of engine oil!
7 1.4 or 0.9 bar oil pressure switch (F1), 25 Nm
◆ 1.4 bar switch: black
◆ 0.9 bar switch: grey

70 17 - Lubrication
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
◆ Wiring: yellow
◆ Checking => Page 88
◆ If sealing ring is leaking nip open and replace.
8 Camshaft sprocket

9 Oil filter
◆ Loosen with strap wrench
◆ Tighten by hand
◆ Observe installation instructions on oil filter
10 Chain sprocket
11 Tensioner
◆ Engine code AEA, AEE, AEX, APQ only
◆ Tensioning toothed belts
=> Page 26
12 20 Nm
13 Toothed belt
◆ Mark D.O.R. before removing
◆ Check for wear
◆ Do not kink
◆ Removing, installing and tensioning
=> Page 26
14 Toothed belt guard - upper part

1.1 - Removing and installing parts of the lubrication system 71

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

15 Toothed belt guard - lower part

16 20 Nm
17 Hexagon bolt: 90 Nm + 1/3 turn
(120 °) further
Multi-point screw: 90 Nm + 1/4 turn (90 °) further
◆ Renew
◆ Oil threads
◆ The turning further can be done in several stages
◆ The turning further angle can be measured with a commercial protractor e.g. Hazet 6690
18 Belt pulley
◆ When installing note fixing arrangement
19 Crankshaft toothed belt sprocket
20 Oil seal
◆ Renewing => Page 34
21 Sealing flange

72 17 - Lubrication
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

22 Gasket
◆ Renew
23 Sealing bush
◆ Renew if damaged
◆ Insert in sealing flange first
◆ Coat with oil when installing
24 Chain
◆ Tensioning => Fig. 3
Engine code ABU 02.93...09.93:
◆ Removing and installing chain guide rail => Fig. 4
25 Oil pump
◆ Checking backlash
=> Fig. 1
◆ Checking axial clearance
=> Fig. 2
26 Oil pump cover with pressure relief valve
◆ Opening pressure: 4.0...5.0 bar
◆ Clean strainer if soiled

1.1 - Removing and installing parts of the lubrication system 73

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

27 Seal
◆ Renew
28 Oil drain plug
◆ Metal sump: 30 Nm
◆ Aluminium sump: 20 Nm
29 Sump
◆ Engine code ABD, ABU: Steel sump
◆ Engine code AEA, AEE, AEX, APQ: Aluminium sump
◆ Clean sealing surface before installing
◆ Removing and installing engines with liquid gasket
=> Page 83
30 15 Nm
◆ Loosen and tighten the bolts flywheel end only with:
Socket head bolts:
3249
Hexagon head bolts: 3185

74 17 - Lubrication
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

31 Gasket
◆ Not on engines with liquid gasket
◆ Renew
◆ Before fitting coat sump/cylinder block flanges with "D2"
Engine code AEA:
◆ Metal gasket
32 Bracket
33 O-ring
◆ Renew
34 Oil separator
35 To cylinder head cover
36 To air cleaner or air intake elbow

1.1 - Removing and installing parts of the lubrication system 75

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

-> Fig. 1 Checking oil pump backlash

New: 0.05 mm

Wear limit: 0.20 mm

-> Fig. 2 Checking oil pump axial clearance

Wear limit: 0.15 mm

-> Fig. 3 Tensioning drive chain

Note:

On engines with guide rail, this must be removed when checking or adjusting chain tension.

76 17 - Lubrication
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
Tension chain by moving oil pump. Check tension with light thumb pressure.

Engine codes ABD ▸ 12.93, ABU ▸ 01.93 (without guide rail):

Deflection a = 2.0...3.0 mm

Engine codes ABD 01.94 ▸, ABU 02.93 ▸ (with and without guide rail), AEA, AEE, AEX, APQ:

Deflection
Test figure: a = 4.0...5.0 mm
Setting figure: a = 3.5...4.5 mm

-> Fig. 4 Removing and installing guide rail

1- Camshaft chain sprocket

2- Oil pump
3- 20 Nm
4- Guide rail
5- 10 Nm
6- Drive chain

1.1 - Removing and installing parts of the lubrication system 77

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

Volkswagen Technical Site: [Link] [Link]

Vehicles with Duo-centric oil pump

1 Cap
◆ Renew seal if damaged
2 1.4 bar oil pressure switch (F1), 25 Nm
◆ Black
◆ Checking => Page 88
3 10 Nm
4 Guide tube
5 Guide
◆ Pull off to extract oil
6 Dipstick
◆ The oil level must not be above the max. mark!
◆ Area above shaded zone up to max. mark: Do not top up with engine oil!
◆ Oil level in shaded zone: Engine oil can be topped up
◆ Area min. mark up to shaded zone: Top-up with max. 0.5 ltr. of engine oil!

78 17 - Lubrication
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

7 Camshaft sprocket
◆ Note position when installing toothed belt
=> Page 26
8 Oil filter
◆ Loosen with strap wrench
◆ Tighten by hand
◆ Observe installation instructions on oil filter
9 Gasket
◆ Renew
◆ Must be located on dowel sleeves
10 Tensioner
◆ Tensioning toothed belts
=> Page 26
11 20 Nm
12 Toothed belt
◆ Mark D.O.R. before removing
◆ Check for wear
◆ Do not kink
◆ Removing, installing and tensioning
=> Page 26
13 Toothed belt guard - upper part
14 Toothed belt guard - lower part

1.1 - Removing and installing parts of the lubrication system 79

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

15 20 Nm
16 90 Nm + 1/4 turn (90 °) further
◆ Renew
◆ Oil threads
◆ The turning further can be done in several stages
◆ The turning further angle can be measured with a commercial protractor e.g. Hazet 6690
17 Belt pulley
◆ When installing note fixing arrangement
18 Crankshaft toothed belt sprocket
◆ Note position when installing toothed belt
=> Page 26
19 8 Nm

80 17 - Lubrication
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

20 Oil seal
◆ Renewing => Page 34
21 Oil pump
◆ Only renew complete
◆ When installing note follower on crankshaft
=> Page 85 , item 24
◆ Must be located on dowel sleeves
◆ Removing and installing
=> Page 85
22 Gasket
23 Suction pipe
◆ Clean strainer if soiled
24 Follower
◆ Coat with oil before installing oil pump
25 Seal
◆ Renew

1.1 - Removing and installing parts of the lubrication system 81

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

26 Oil drain plug

◆ Metal sump: 30 Nm
◆ Aluminium sump: 20 Nm
27 Sump
◆ Removing and installing engines with liquid gasket
=> Page 83
◆ Clean sealing surface before installing
◆ Install with silicone sealant
D 176 404 A2
=> Page 83
28 Socket head combi-bolt
◆ Metal sump: 15 Nm
◆ Aluminium sump to aluminium block: 13 Nm
◆ On aluminium block: Renew bolts (coated with sealant)
29 O-ring
◆ Renew
30 Oil separator
31 To cylinder head cover
32 To air cleaner or air intake elbow

82 17 - Lubrication
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

1.2 - Removing and installing oil sump

Work sequence for engine with sump sealed with liquid gasket.

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

◆ Socket 3249
◆ Hand drill with plastic brush
◆ Flat scraper

Engine codes AEE, AEX:

◆ Silicone sealant D176404 A2

Work sequence

- Drain engine oil.

- Unbolt right-hand drive shaft at gearbox.

=> Running gear; Servicing front suspension (base running gear); Removing and installing wheel bearing,
suspension strut and drive shaft (base running gear)

- Remove ribbed belt guard.

- Unbolt sump sealed with liquid gasket.
- Remove sump, it may be necessary to release sump by tapping lightly with a rubber head hammer.
- Remove sealant residue on cylinder block with a flat scraper.

- -> Remove sealant residue on the sump with a rotating brush, e.g. a hand drill with a plastic brush (wear
eye protection).

Engine codes ABD, AEA:

- Install sump with a former type solid gasket.

- Tighten sump bolts to
15 Nm.

Engine codes AEE, AEX, APQ:

(Aluminium sump)

- Clean sealing surface, must be free of oil and grease.

Notes:

◆ Note the use by date of the sealant.

◆ Sump must be installed within 5 minutes of applying silicone sealing compound.

1.2 - Removing and installing oil sump 83

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

- -> Cut off tube nozzle at forward marking (nozzle approx. 3 mm ø).
- Apply silicone sealing compound, as shown, to clean sump sealing surface. Sealing compound bead must
be.
- 2...3 mm thick
- and run on inside of bolt holes -arrows-.

Note:

The sealing compound bead must not be thicker, otherwise excessive sealing compound will enter the sump
and may block the oil suction pipe strainer.

- Install sump immediately and tighten all sump bolts lightly.

- Tighten sump bolts to
15 Nm.

Note:

After installing sump the sealant must be allowed to dry for approx. 30 minutes before engine oil is replenished.

84 17 - Lubrication
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

1.3 - Removing and installing Duo-centric oil pump

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

◆ T10022 Sleeve
◆ 3083 Oil seal fitting tool
◆ V.A.G 1331 Torque wrench (5...50 Nm)
◆ V.A.G 1332 Torque wrench (40...200 Nm)
◆ 3099 Counter-hold tool

Removing

- Remove toothed belt => Page 26 , Removing, installing and tensioning toothed belt.
- Position crankshaft at TDC No. 1 cylinder:

The chamfered tooth of toothed belt sprocket must align with the marking (2V) on the oil pump.

1.3 - Removing and installing Duo-centric oil pump 85

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

- -> Turn crankshaft/toothed belt sprocket three teeth anti-clockwise away from TDC:

The third tooth -arrow- to the right of the tooth ground down -A- on the toothed belt sprocket must align with
TDC mark on the oil pump housing.

- Loosen securing bolt from crankshaft toothed belt sprocket. To do this secure toothed belt sprocket using
counter-hold tool 3099.

Note:

This procedure moves the crankshaft to the correct installation position for the oil pump. One of the polygon
cams on the crankshaft is uppermost.

- Remove crankshaft toothed belt sprocket and toothed belt tensioning roller. To do this secure toothed belt
sprocket using counter-hold tool 3099.
- Remove sump => Page 83 .
- Remove suction pipe => Page 81 , item 23 .
- Remove oil pump.
- Remove gasket.
- Remove sealant remnants on cylinder block with a flat scraper.
- Clean sealing surfaces, they must be oil and grease free.

Installing

Conditions

• -> One of the polygon cams -arrow- on the crankshaft is uppermost.

86 17 - Lubrication
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

Work sequence

- -> Fit sleeve T10022 and hexagon socket head bolt from 3083 onto crankshaft and tighten hand tight.
- Fit new gasket onto guide pins -A-.

- -> Position one of the oil pump inner rotor markings arrow -A- on installation position mark arrow -B- on oil
pump housing cover.
- Coat the four crankshaft polygon cams with oil.
- Lightly oil sealing lip of oil pump oil seal.
- Guide oil pump carefully onto crankshaft polygon cams.
- Align inner rotor to crankshaft polygon cams by turning slightly if necessary.
- Then slide oil pump carefully onto guide pins.
- Tighten oil pump => Page 78 , item 19 .
- Remove sleeve T10022.
- Install suction pipe => Page 81 , item 23 .
- Install oil sump => Page 83 .
- Install toothed belt sprocket and tensioning roller, install and tension toothed belt => Page 26 , Removing,
installing and tensioning toothed belt.

1.3 - Removing and installing Duo-centric oil pump 87

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

1.4 - Checking oil pressure and oil pressure switch

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

◆ V.A.G 1342 Oil pressure tester

◆ V.A.G 1527 B Diode test lamp
◆ V.A.G 1594 A Adapter set

88 17 - Lubrication
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
Vehicles ▸ 08.97
Engine code ABD, ABU, AEA

Note:
Functional check and servicing the optical and acoustic oil pressure warning:
=> Current flow diagrams, Electrical fault finding and Fitting locations
Test sequence
- -> Remove 0.9 or 1.4 bar oil pressure switch (black or grey insulation) and screw into the tester.
- Screw tester into the cylinder head in place of the oil pressure switch.
- Connect brown wire of tester to earth (-).

- Connect diode test lamp V.A.G 1527 with adapter cables from V.A.G 1594 to battery positive (+) and to 0.25
or 0.3 bar oil pressure switch (F22, blue or brown insulation) -B-. LED must light up.
- Start engine and slowly raise rpm. At
0.25 bar switch: 0.15...0.35 bar
0.3 bar switch: 0.15...0.45 bar
the LED must go out, otherwise renew oil pressure switch.
- Connect diode test lamp to 0.9 or 1.4 bar oil pressure switch (F1) -A-. At
0.9 bar switch: 0.7...1.1 bar
1.4 bar switch: 1.2...1.6 bar
the LED must light up, otherwise renew oil pressure switch.
- Increase engine speed further.
At 2000 rpm and an oil temperature of 80 °C the oil pressure should be at least 2.0 bar.

Engine codes AEE, AEX, APQ:

Test sequence

1.4 - Checking oil pressure and oil pressure switch 89

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
- -> Remove oil pressure switch (F22) and screw into tester.
- Screw tester into the cylinder head in place of the oil pressure switch.
- Connect brown wire of tester to earth (-).
- Connect diode test lamp V.A.G 1527 using aux. cables from V.A.G 1594 to battery positive (+) and oil
pressure switch. LED must light up.
- Start engine and increase speed slowly.
At
0.15...0.35 bar
the LED must go out, otherwise renew oil pressure switch.
- Increase engine speed further.
At 2000 rpm and an oil temperature of 80 °C the oil pressure should be at least 2.0 bar.

Vehicles 09.97 ▸

Note:

Functional check and servicing the optical and acoustic oil pressure warning:

=> Current flow diagrams, Electrical fault finding and Fitting locations

- -> Remove 1.4 bar oil pressure switch (F1) (black insulation) and screw into test unit.
- Screw tester into the cylinder head in place of the oil pressure switch.
- Connect brown wire of tester to earth (-).
- Connect diode test lamp V.A.G 1527 B using aux. cables from V.A.G 1594 A to battery positive (+) and oil
pressure switch. LED must not light up.
- If the LED lights up, renew 1.4 bar oil pressure switch (F1) .

If the LED does not light up:

- Start engine and run at idling speed

at
1.2...1.6 bar
the LED must light up, otherwise renew 1.4 bar oil pressure switch (F1).
- Increase engine speed further.
At 2000 rpm and an oil temperature of 80 °C the oil pressure should be at least 2.0 bar.

90 17 - Lubrication
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

19 - Cooling system

1 - Removing and installing parts of cooling system

1.1 - Removing and installing parts of cooling system

Notes:

◆ When the engine is warm the cooling system is under pressure. If necessary release pressure before com‐
mencing repair work.
◆ Hoses are secured with spring-type clips. In cases of repair only use spring-type clips.
◆ V.A.G 1921 pliers are recommended when installing spring-type clips.

Draining and filling with coolant=> Page 106

Coolant mixture ratios => Page 106 , draining and filling with coolant

Carry out cooling system leakage check with V.A.G 1274 and 1274/3.

1.1 - Removing and installing parts of cooling system 91

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

1.2 - Parts of cooling system body side

Volkswagen Technical Site: [Link] [Link]

1 Thermo switch (F18), 35 Nm

◆ For electric fan
◆ Switching temperatures:
Stage 1
on: 92...97 °C
off: 84...91 °C
Stage 2
on: 99...105 °C
off: 91...98 °C
2 Connector
3 Radiator
◆ To remove
- Unclip radiator grille
- Remove strut from lock carrier
- Remove left headlight
◆ After replacing renew entire coolant

92 19 - Cooling system
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

4 Guide ring
◆ Note fitting position
◆ Secured on lock carrier - 6 - with clips
5 Radiator fan
6 Lock carrier
7 10 Nm
8 Upper coolant hose
◆ To thermostat housing
◆ AEE, AEX, APQ:
=> Page 101 , item 19
◆ ABD, ABU: =>Page 96 , Item 11
◆ AEA: =>Page 98 , Item 16
9 Lower coolant hose
◆ To connecting pipe
◆ ABD, ABU: =>Page 96 , Item 13
◆ AEA: =>Page 98 , Item 17
◆ AEE, AEX, APQ:
=> Page 99 , item 3

1.2 - Parts of cooling system body side 93

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

10 Cover
11 Expansion tank
12 To
◆ ABD, ABU: Coolant pipe
=>Page 96 , Item 10
◆ AEA: thermostat housing =>Page 97 , Item 6
◆ AEE, AEX, APQ: thermostat housing
=> Page 100 , item 9
13 Cap
◆ Check with V.A.G 1274 and 1274/4
◆ Test pressure 1.4...1.6 bar
14 To thermostat housing
◆ ABD, ABU =>Page 95 , Item 5
◆ AEA: =>Page 97 , Item 5
◆ AEE, AEX:
=> Page 100 , item 7

94 19 - Cooling system
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

1.3 - Parts of cooling system - engine side

Thermostat side

Engine codes ABD, ABU

1 O ring
◆ Renew
2 Coolant temperature sender (G62)
◆ With coolant temperature gauge sender (G2)
3 Retaining clip
4 20 Nm
5 To expansion tank
◆ =>Page 94 , Item 14
6 Coolant pipe
7 To heat exchanger
8 Hexagon bolt, 10 Nm or self-tapping screw

1.3 - Parts of cooling system - engine side 95

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

9 From heat exchanger

10 From expansion tank
◆ =>Page 94 , Item 12
11 To top of radiator
◆ =>Page 93 , Item 8
12 Coolant thermostat
◆ Installation position => Fig. 1
◆ Checking: heat-up thermostat in water
◆ Opening commences approx. 84 °C
◆ Ends approx. 98 °C
◆ Opening lift min. 7 mm
13 From bottom of radiator
◆ =>Page 93 , Item 9
14 Bracket
15 Thermostat housing

96 19 - Cooling system
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

Engine code AEA

1 Self-tapping bolt
2 Connection
3 O-ring
◆ Renew
4 Coolant thermostat
◆ Installation position => Fig. 2
◆ Checking: heat-up thermostat in water
◆ Opening commences approx. 84 °C
◆ Ends approx. 98 °C
◆ Opening lift min. 7 mm
5 To expansion tank
◆ =>Page 94 , Item 14
6 From expansion tank
◆ =>Page 94 , Item 12

1.3 - Parts of cooling system - engine side 97

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

7 To heat exchanger
8 From heat exchanger
9 Seal
◆ Renew
10 Coolant pipe
11 Retaining clip
12 Thermostat housing
13 10 Nm
14 Coolant temperature sender (G62)
◆ With coolant temperature gauge sender (G2)
15 Sealing plug
16 To top of radiator
◆ =>Page 93 , Item 8
17 From bottom of radiator
◆ =>Page 93 , Item 9

98 19 - Cooling system
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

Engine code AEE, AEX, APQ

1 Retainer
◆ For central connector
2 Self-tapping bolt
3 From bottom of radiator
◆ =>Page 93 , Item 8
4 Connection
5 O-ring
◆ Renew
6 Coolant thermostat
◆ Checking operation: heat-up thermostat in water the thermo element pin must move out
◆ Temperature check: Opening starts (approx. 84 °C) and ends (approx. 98 °C) cannot be checked.

1.3 - Parts of cooling system - engine side 99

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

7 To expansion tank
◆ =>Page 94 , Item 14
8 To heat exchanger
9 From expansion tank
◆ =>Page 94 , Item 12
10 Retaining clip
11 From heat exchanger
12 Coolant pump housing on cylinder block
13 Seal
◆ Renew
14 Coolant pipe
15 Thermostat housing
16 10 Nm

100 19 - Cooling system

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

17 Coolant temperature sender (G62)

◆ With coolant temperature gauge sender (G2)
18 Sealing plug
19 To top of radiator
◆ =>Page 93 , Item 8

1.3 - Parts of cooling system - engine side 101

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

Coolant pump side

Engine codes ABD, ABU

1 10 Nm
2 Rear toothed belt guard
3 10 Nm
◆ Install with D6
4 Camshaft sprocket
◆ Note position when installing the toothed belt
=> Page 26
5 80 Nm
6 Toothed belt
◆ Check for wear
◆ Do not kink
◆ Removing and installing
=> Page 26
7 Toothed belt guard - upper part

102 19 - Cooling system

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

8 Bolt M6: 10 Nm
Bolt M8: 20 Nm
◆ Install with D6
9 Coolant pump
◆ Check for ease of movement
◆ If damaged or leaking renew complete
◆ Ensure correct type (teeth on sprocket)
◆ To tension toothed belt loosen slightly and turn with screwdriver => Page 26
10 O-ring
◆ If leaking and damaged renew
◆ Use oversize seal ø5 mm on reconditioned coolant pumps with "5" stamped in securing flange area

1.3 - Parts of cooling system - engine side 103

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

Engine code AEE, AEX, APQ

1 O-Ring
◆ If leaking and damaged renew
2 Coolant pump
◆ Check for ease of movement
◆ If damaged or leaking renew complete
3 Rear toothed belt guard
4 Camshaft sprocket
◆ Note position when installing the toothed belt
=> Page 26
5 20 Nm + 1/4 turn (90 °) further
◆ Renew
6 10 Nm
◆ Install with D6

104 19 - Cooling system

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

7 Toothed belt
◆ Check for wear
◆ Do not kink
◆ Tensioning toothed belts
=> Page 26
8 Toothed belt guard - upper part
9 10 Nm
10 Toothed belt guard - lower part
11 20 Nm
12 Tensioner
◆ Tensioning toothed belts
=> Page 26

1.3 - Parts of cooling system - engine side 105

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

-> Fig.1 Thermostat installation position

Engine codes ABD, ABU

The thermostat bridge support -1- must align with the threaded holes in the housing.

-> Fig.2 Thermostat installation position

Engine code AEA

The thermostat bridge support must lie in the cut-out of the housing connection piece.

1.4 - Draining and filling cooling system

Special tools, testers and auxiliary items

◆ Drip tray V.A.G 1306

◆ Pliers V.A.G 1921 for spring type clips
◆ Anti-freeze tester

Draining

- Remove cap from coolant expansion tank.

- Drain coolant from bottom radiator hose.

Note:

Observe disposal regulations!

106 19 - Cooling system

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
Filling

Notes:

◆ Only use coolant additive G 12 in accordance with TL VW 774 F.

Distinguishing feature: coloured violet
◆ G 12 violet (in accordance with TL VW 774 F) can be mixed with the previous coolant additives G 11 and
G 12 red!

◆ G 12 and coolant additives marked "In accordance with TL VW 774 F" prevent frost and corrosion damage,
scaling and also raise boiling point of coolant. For this reason the system must be filled all year round with
frost and corrosion protection additives.
◆ Because of its high boiling point, the coolant improves engine reliability under heavy loads, particularly in
countries with tropical climates.
◆ Protection against frost must be assured to about -25 °C (in arctic climatic countries to about -35 °C).
◆ The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer
countries. The anti-freeze ratio must be at least 40 %.
◆ If for climatic reasons a greater frost protection is required, the amount of G 12 can be increased, but only
up to 60 % (frost protection to about -40 °C), as otherwise frost protection is reduced again and cooling
effectiveness is also reduced.
◆ If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reuse old coolant.

Recommended mixture ratios:

Frost pro- tection Anti-freeze amount G 121) Water1)

to
-25 °C 40 % 2.25 l 3.35 l
-35 °C 50 % 2.8 l 2.8 l

1) The quantity of coolant can vary depending upon the vehicle equipment.

With cooling system charging unit VAS 6096

- Fill coolant circuit using cooling system charging unit VAS 6096.

=> Operating instructions for cooling system charging unit VAS 6096

Not using cooling system charging unit VAS 6096

- -> Slowly fill with coolant up to max. mark on expansion tank (filling time approx. 5 minutes).

With and without cooling system charging unit VAS 6096

- Fit expansion tank cap.

- Run engine until radiator fan cuts-in.
- Check coolant level and replenish as necessary. When the engine is at normal operating temperature, the
coolant level must be on the max. mark, when the engine is cold, between the min. and max. marks.

1.4 - Draining and filling cooling system 107

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

20 - Fuel supply system

1 - Removing and installing parts of fuel supply system

1.1 - Removing and installing parts of fuel supply system

Notes:

◆ Always replace clamp-type clips with spring or screw-type clips.

◆ Fuel hoses in engine compartment must only be secured with spring-type clips. The use of clamp or screw-
type clips is not permissible.
◆ V.A.G 1921 pliers are recommended when installing spring-type clips.

Observe safety precautions=> Page 114 .

Observe rules for cleanliness => Page 115 .

Adjusting throttle cable => Page 115

108 20 - Fuel supply system

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

1.2 - Removing and installing fuel tank with its attachments

Note:

Please ensure after all repairs to the fuel supply unit and the fuel gauge sender, the corrugated hoses/hoses
between delivery unit and fuel tank flange do not make contact with the fuel tank, otherwise pump noises will
be transmitted.

1 Cap
2 Retaining ring
3 Rubber cup
4 O-ring
◆ Renew if damaged

1.2 - Removing and installing fuel tank with its attachments 109
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

5 Gravity valve
◆ To remove, release locking lug and unclip valve upwards out of filler neck
◆ Check valve for through-flow
valve vertical: open,
valve tilted 45 °: closed
6 Vent pipe
◆ To activated charcoal filter
=>Page 123 , Item 6
◆ On vehicles without activated charcoal filter system to rubber cup -Item 3 -
7 Earth connection
8 Vent valve
◆ Checking =>Fig. 2
◆ To remove pull locking latch lightly to inside -arrow- and pull valve out

110 20 - Fuel supply system

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

9 Return hose/line
◆ Blue or with blue marking
◆ From injection unit or from fuel manifold

=> Repair group 24; Mixture preparation, injection Mixture preparation, injection

10 Union nut, 75 Nm
◆ Remove and install with 3217
11 Hose guide
12 Flange
◆ Note fitting position on fuel tank => Fig. 1
13 Supply hose/corrugated pipe
◆ When the flange is installed it must not contact the fuel tank, otherwise pump noises will be transmitted
14 Sealing ring
◆ Coat with fuel when installing
◆ Renew if damaged

1.2 - Removing and installing fuel tank with its attachments 111
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

15 Return hose/corrugated hose

◆ When the flange is installed it must not contact the fuel tank, otherwise pump noises will be transmitted
16 Fuel delivery unit
◆ Removing and installing
=> Page 115
◆ Checking fuel pump
=> Page 116
17 Fuel gauge sender
◆ Adjusting adjustable type:

=> Current flow diagrams, Electrical fault finding and Fitting locations

18 Strainer
19 Securing strap
◆ Note differing length
20 Bracket
◆ For securing straps
21 25 Nm

112 20 - Fuel supply system

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

Volkswagen Technical Site: [Link] [Link]

22 Fuel tank
◆ Support with engine and gearbox jack V.A.G 1383 A when removing
23 Supply pipe
◆ White arrow
◆ To injection unit or to fuel manifold

=> Repair group 24; Mixture preparation, injection Mixture preparation, injection

24 Fuel filter
◆ Fitting position: Arrow points in direction of flow
25 Retaining clip
26 20 Nm
27 Bracket
◆ For fuel filter
28 Rubber buffer
29 Spring clip
30 Spacer bush
31 10 Nm

1.2 - Removing and installing fuel tank with its attachments 113
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

-> Fig. 1 Installation position of fuel delivery unit flange

Marking on the flange must align with marking on the fuel tank.

-> Fig. 2 Checking vent valve

Lever in rest position: Closed

Lever pushed in direction of arrow: Open

1.3 - Safety precautions when working on the fuel supply system

Warning!
Fuel supply lines are under pressure! Before removing from hose connection wrap a cloth around the connec‐
tion. Then release pressure by carefully pulling hose off connection.

When removing and installing the fuel gauge sender or fuel pump (fuel delivery unit) from a full or partly full fuel
tank the following must be observed:

◆ Before commencing work, switch on exhaust extraction system and place an extraction hose close to the
sender opening in the fuel tank to extract escaping fuel fumes.
If no exhaust extraction system is available, a radial fan (as long as motor is not in air flow) with a displace‐
ment greater than 15 m3/h can be used.
◆ Prevent skin contact with fuel! Wear fuel-resistant gloves!

114 20 - Fuel supply system

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

1.4 - Rules for cleanliness

When working on the fuel supply/injection system, pay careful attention to the following "5 rules":
◆ Thoroughly clean all unions and the adjacent areas before disconnecting.
◆ Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!
◆ Carefully cover opened components or seal, if the repair cannot be carried out immediately.
◆ Only install clean components:
Only unpack replacement parts immediately prior to installation.
Do not use parts that have been stored loose (e.g. in tool boxes etc.).
◆ When the system is open:
Do not work with compressed air if this can be avoided.
Do not move vehicle unless absolutely necessary.

1.5 - Adjusting throttle cable

- -> Adjust throttle cable by moving the retainer at the support bracket so that the full throttle position is just
attained at the throttle valve lever.

1.6 - Removing and installing fuel delivery unit

Note:
Check whether a coded radio is installed as during the forthcoming work sequences the battery earth strap
must be disconnected. Obtain radio code first if necessary.
Special tools, testers and auxiliary items
◆ Union nut spanner 3217

Removing
- Observe safety precautions => Page 114
- With ignition switched off disconnect battery earth strap.
- Remove cover in luggage boot floor.

1.4 - Rules for cleanliness 115

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
- -> Pull connector and supply and return pipes off flange.
- Remove union nut with 3217.
- Pull flange and seal out of the opening in fuel tank.
- Release delivery unit by turning to left out of bayonet connection and remove.

Note:

If the delivery unit is still full of fuel, empty it before replacing.

Installing

- Installing the fuel delivery unit is carried out in the reverse order.

Notes:

◆ When inserting the fuel delivery unit ensure that the fuel gauge sender is not bent.
◆ -> When the fuel delivery unit is correctly installed the fuel gauge sender float points
α=5°
to direction of travel A.
◆ Coat flange seal with fuel when fitting.
◆ Fitting position of fuel delivery unit flange => Page 114 , Fig. 1 .

1.7 - Checking fuel pump

Special tools, testers and auxiliary items

◆ Remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2

◆ Adapter set V.A.G 1594
◆ Diode test lamp V.A.G 1527
◆ Multimeter V.A.G 1715
◆ Current flow diagram
◆ Union nut spanner 3217
◆ Pressure tester V.A.G 1318
◆ Adapter 1318/1
◆ Adapter 1318/10
◆ Adapter 1318/11
◆ Adapter 1318/12
◆ Adapter 1318/14
◆ Measuring container

Test conditions

• Battery voltage OK.

• Fuse No. 18 OK.

116 20 - Fuel supply system

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Checking function and voltage supply
Note:
Check whether a coded radio is installed as during the forthcoming work sequences the battery earth strap
must be disconnected. Obtain radio code first if necessary.
- Briefly operate starter. Fuel pumps must be heard to run briefly -approx. 1 second-.

If the fuel pump does not run:

- -> Pull fuel pump relay (J17) out of relay plate with fuse box, relay position 12.

Note:
If the relay cannot be removed from the relay plate without tools then first disconnect battery earth strap.
- Connect remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2 to contact 4 and battery positive
(+).
- Operate remote control.

Fuel pump runs:

- Check activation of fuel pump relay:

Engine codes ABD, ABU, AEX, APQ:

=> Current flow diagrams, Electrical fault finding and Fitting locations, Fuel supply system
Engine code AEA:
=> Mono Motronic injection and ignition system; Repair group 01; Self-diagnosis; Final control diagnosis Self-
diagnosis Final control diagnosis
Engine code AEE:
=> 1AV Injection and ignition system;
=> Repair group 01; Self-diagnosis; Final control diagnosis Self-diagnosis Final control diagnosis
Fuel pump does not run:
- Remove cover in luggage boot floor.
- Pull connector off fuel tank flange.

1.7 - Checking fuel pump 117

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- -> Connect diode test lamp V.A.G 1527 with aux. cables from V.A.G 1594 to the outer contacts of the
connector.
- Operate remote control.
LED must light up

LED does not light up:

- Locate and eliminate open circuit using current flow diagram

LED lights up (voltage supply OK.):

- Unscrew union nut with 3217.

- Check that the electrical wires between flange and fuel pump are connected.

If not open circuit can be found:

- Renew fuel delivery unit.

Checking delivery rate

Test conditions

• Voltage supply OK.

• Remote control V.A.G 1348/3A connected.

Test sequence

- Remove filler cap from fuel tank filler neck.

Warning!
Fuel supply lines are under pressure! Before removing from hose connection wrap a cloth around the connec‐
tion. Then release pressure by carefully pulling hose off connection.

- -> Connect pressure gauge V.A.G 1318 with adapter 1318/10 to the fuel supply pipe -1- .
- Push the hose V.A.G 1318/1 onto the adapter V.A.G 1318/11 on the pressure gauge and hold hose in a
measuring container.
- Open the pressure gauge shut-off tap. The lever then points in the direction of flow -A-.
- Operate remote control V.A.G 1348/3A. Whilst doing this slowly close the cut-off tap, until gauge shows
Engine code ABD, ABU, AEA:1.2 bar
Engine code AEE, AEX, APQ: 3 bar
From now on do not alter the position of the cut-off tap.
- Empty the measuring container.
- Connect multimeter to vehicle battery to measure voltage using auxiliary cables from V.A.G 1594.
- Operate remote control for
30 seconds
and measure battery voltage
- Compare the quantity of fuel delivered with specification.

118 20 - Fuel supply system

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-> Engine code ABD, ABU, AEA

*) Minimum delivery cm3/30 seconds

**) Voltage at fuel pump with engine stopped and pump running (approx. 2 volts less than battery voltage).

Example:

During the test a voltage of 12.5 volts is measured at the battery. As the voltage at the pump is approx. 2 volts
less than the battery voltage then this will equate to a minimum delivery of 500 cm3/30 s.

-> Engine code AEE, AEX, APQ

*) Minimum delivery cm3/30 seconds

**) Voltage at fuel pump with engine stopped and pump running (approx. 2 volts less than battery voltage).

If the minimum delivery rate is not attained:

- Check the fuel pipes for possible restrictions (kinks) or blockages.

1.7 - Checking fuel pump 119

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
- -> Pull the supply hose -1- off inlet to fuel filter.
- Connect the pressure gauge V.A.G 1318 to hose with adapter 1318/10.
- Repeat delivery rate check.

If the minimum delivery rate is now attained:

- Replace the fuel filter.

If the minimum delivery rate is again not attained:

- Remove the fuel delivery unit and check the strainer filter for soiling.

Only when up to now no fault has been detected:

- Replace the fuel delivery unit.

If the delivery rate has been attained but nevertheless you suspect a fuel supply system fault (e.g. intermittent
failure of fuel supply system):

- Check the current draw of the fuel pump as follows:

- Reconnect all disconnected fuel pipes.

- -> Connect the multimeter V.A.G 1715 using the current clamp to the red/yellow wire from wiring loom.
- Start the engine and run at idling speed.
- Measure the current draw of the fuel pump.
Specification: max. 8 amps.

Note:

If the fuel system malfunction is intermittent, you can perform the check during a test drive with the help of a
2nd person.

If the current draw is exceeded:

- Replace the fuel delivery unit.

Checking fuel pump non-return valve

Test conditions

• Remote control V.A.G 1348/3A connected

• Pressure gauge V.A.G 1318 connected

120 20 - Fuel supply system

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
Test sequence

Note:

With this check the fuel supply pipe connections from the fuel delivery unit to the point at which the pressure
gauge V.A.G 1318 is connected will be checked for leaks at the same time.

- Close pressure gauge cut-off tap (lever at right angle to direction of flow).
- Operate remote control at short intervals, until a pressure of
Engine code ABD, ABU, AEA: 2 bar
Engine code AEE, AEX, APQ: 3 bar
has built up.

Warning!
Danger of spray when opening the shut-offtap, hold container over the free connection of the pressure gauge.

- If pressure builds up too high, lower excess pressure by carefully opening the shut-off tap.
- Watch pressure drop. After 10 minutes the pressure must not drop below
Engine code ABD, ABU, AEA: 1.2 bar
Engine code AEE, AEX, APQ: 2 bar.

If the pressure drops further:

- Check pipe connections for leaks.

If no fault is detected in the wiring:

- Replace the fuel delivery unit.

1.7 - Checking fuel pump 121

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

1.8 - Removing and installing parts of the activated charcoal filter system

1 Connector
2 Solenoid valve 1 (N80)
◆ With ignition switched off valve open in direction of arrow
◆ When the engine is warm the valve will be activated from the Mono Motronic control unit (pulsed)
◆ Checking:

=> Repair group 01; Self-diagnosis; Final control diagnosis Self-diagnosis Final control diagnosis

3 Bracket
◆ On right suspension strut turret
◆ 08.92 ▸ integral part of the wheel housing-air cleaner
4 Retaining ring

122 20 - Fuel supply system

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

5 Injection unit
6 Vent pipe
◆ From gravity valve on fuel tank
=> Page 110 , Item 6
7 Activated charcoal filter
◆ Location: in front right wheel housing
◆ To remove push securing strap in direction of arrow

1.9 - Checking fuel tank breather

Special tools, testers and auxiliary items

◆ Hand vacuum pump V.A.G 1390

◆ Vacuum tester V.A.G 1368

Test conditions

• Ignition switched off

1.8 - Removing and installing parts of the activated charcoal filter system 123
 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
Test sequence

Only for wheel housing air cleaner:

- Remove air cleaner.

- -> Pull breather hose -1- off the injection unit -2-.
- Connect hand vacuum pump V.A.G 1390 to hose -1-.
- Pull breather hose -3- from fuel tank off activated charcoal filter -4- and connect to -connection A- of vacuum
tester V.A.G 1368.
- Connect vacuum tester V.A.G 1368 -connection B- to activated charcoal filter.
- Set vacuum tester to position -B-.
- Operate hand vacuum pump V.A.G 1390 several times.
Vacuum must not
build up.

If vacuum builds up:

- Check breather connection -5- on activated charcoal filter -4- for soiling, clean if necessary.

If vacuum does not build up:

- Remove fuel filler cap from filler neck.

- -> Connect hand vacuum pump V.A.G 1390 to vacuum tester V.A.G 1368 -connection B-.
- Set vacuum tester to -A/B- position.
- Operate V.A.G 1390 several times. Vacuum must

124 20 - Fuel supply system

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
not build-up.

If vacuum builds-up:

- Check gravity valve => Page 110 , Item 5

- Check line -1- from fuel tank for blockage.

If vacuum does not build up:

- Refit fuel filler cap.

- Operate hand vacuum pump V.A.G 1390 several times.
Vacuum must not
build up.

Note:

If the fuel level in the tank is low the hand vacuum must be operated at least 20...30 times.

If vacuum builds up:

- Replace fuel tank cap.

1.9 - Checking fuel tank breather 125

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

26 - Exhaust system

1 - Removing and installing parts of exhaust system

1.1 - Removing and installing parts of exhaust system

Notes:

◆ After working on the exhaust system ensure that the system is not under stress, and that it has sufficient
clearance from the bodywork. If necessary, loosen double and single clamps and align silencer and exhaust
pipe so that sufficient clearance is maintained to the bodywork and the support rings are evenly loaded.
◆ Renew self-locking nuts.

Exhaust manifold, front exhaust pipe and catalyst with attachments

1 Warm air collector plate

2 10 Nm

126 26 - Exhaust system

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

3 Exhaust manifold
◆ Service part exhaust manifold without connection for CO measuring pipe
4 Gasket
◆ Renew
5 30 Nm
6 Olive
7 Cap
8 CO take-off pipe
◆ 02.93 ▸ deleted
9 Lambda probe, 55 Nm
◆ Grease only the threads with "G5"; "G5" must not get into the slots on the probe body
◆ Remove and install with 3337
◆ Checking:

=> Repair group 24; Mixture preparation, injection Mixture preparation, injection

10 Front silencer (additional)

◆ Engine code letters ABD without catalyst

1.1 - Removing and installing parts of exhaust system 127

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

11 Catalyst1)
◆ Engine code letters AEX: for Austria with plate for reducing output
12 Sealing ring1)
◆ Renew
◆ Wider side to front exhaust pipe
13 20 Nm
14 M8: 25 Nm
M10: 40 Nm
15 Bracket
16 Front exhaust pipe1)
◆ Engine code ABD 10.94 ▸, AEX, APQ: Single pipe
17 35 Nm

1) 10.94 ▸ the front exhaust pipe is welded to the catalyst. In cases of repair the unit must be removed
complete. The front exhaust pipe and catalyst are still available individually as spare parts.

128 26 - Exhaust system

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

Silencer with mountings

Note:

Align the exhaust system longitudinally so that the dimensions - 8 -, - 9 -, and - 11 - are maintained.

1 40 Nm
2 Double clamp
3 Front silencer
◆ Engine code letters ABD: for Austria with plate for reducing output
4 Clamp
5 Bracket
◆ Note different version => Fig. 1
6 25 Nm
7 Rear silencer
8 Dimension -c- = at least 10 mm

1.1 - Removing and installing parts of exhaust system 129

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994

9 Dimension -b- = approx. 5 mm

10 Marking
11 Dimension-a- = ca. 5 mm
12 Marking
◆ S = Manual gearbox

130 26 - Exhaust system

 Golf 1992 , Vento 1992 ➤
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine) - Edition 12.1994
-> Fig.. 1 Versions of retainer

A - Version ▸ approx. 12.92

B - Version approx. 01.93 ▸

Note:

The -B- version can be installed by sets in earlier vehicles. A mixed installation of earlier/new versions is not
allowed.

1.1 - Removing and installing parts of exhaust system 131